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• Page 2
  2009 Shop Manual ® iS™ 255 † LIMITED iS™ 255…
• Page 3
  Printed in Canada Technical Publications Bombardier Recreational Products Inc. (BRP) Valcourt (Quebec) Canada ®™ Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates. ® ™ iTC™ 4-TEC Sea-Doo ® Learning Key™ Sea-Doo ™ ™ D.E.S.S. O.T.A.S. VTS™ (Variable Trim System) iBR™…
• Page 4
  TABLE OF CONTENTS SAFETY NOTICE ………………… . . IX INTRODUCTION .
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  TABLE OF CONTENTS 02 ENGINE (cont’d) (cont’d) 04 – SUPERCHARGER TROUBLESHOOTING ………………42 PROCEDURES.
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  TABLE OF CONTENTS 02 ENGINE (cont’d) 09 – COOLING SYSTEM ………………. 113 GENERAL .
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  TABLE OF CONTENTS 03 ELECTRONIC MANAGEMENT SYSTEMS (cont’d) 03 – COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE ……….179 GENERAL .
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  TABLE OF CONTENTS 04 FUEL SYSTEM (cont’d) (cont’d) 03 – FUEL TANK AND FUEL PUMP (cont’d) PROCEDURES …………….. . . 271 FUEL LEVEL SENSOR 05 ELECTRICAL SYSTEM 01 –…
• Page 9
  TABLE OF CONTENTS 05 ELECTRICAL SYSTEM (cont’d) (cont’d) 06 – DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) (cont’d) PROCEDURES ………………. 330 D.E.S.S.
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  TABLE OF CONTENTS 06 STEERING AND PROPULSION (cont’d) 03 – JET PUMP ………………… . 407 GENERAL .
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  TABLE OF CONTENTS 07 BODY AND HULL (cont’d) (cont’d) 02 – BODY (cont’d) PROCEDURES …………..476 STORAGE COMPARTMENT COVER .
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  SAFETY NOTICE This manual has been prepared as a guide to CAUTION Indicates a hazard situation correctly service and repair 2009 Sea-Doo ® which, if not avoided, could result in minor or tercraft as describe in the model list in the moderate injury.

• Page 13: Hull Identification Number

  INTRODUCTION INTRODUCTION This shop manual covers the following BRP made 2009 Sea-Doo watercraft models. MODEL COLOR ENGINE MODEL NUMBER GTX Limited iS Topaz mist metallic 1503 HO (255 HP) 189A, 189B Bright yellow 349A, 349B RXT iS 1503 HO (255 HP)

• Page 14: Engine Emissions Information

  EPA Emission Regulations All new 1999 and more recent SEA-DOO wa- tercrafts manufactured by BRP are certified to the EPA as conforming to the requirements of the regulations for the control of air pollution from new watercraft engines.

• Page 15
  INTRODUCTION As many of the procedures in this manual are in- terrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the proce- dure is contained. A number of procedures throughout the book re- quire the use of special tools.
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  INTRODUCTION Typical_iso_2008_en XIII smr2009-011…
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  INTRODUCTION typical_txt_2008_en smr2009-011…

• Page 18: Tightening Torque

  INTRODUCTION TIGHTENING TORQUE 2. Apply the half of the recommended torque value. Tighten fasteners to torque mentioned in ex- NOTICE ploded views and/or text, When they are not Be sure to use proper tightening specified, refer to following table. torque for the proper strength grade. NOTE: When possible, always apply torque on WARNING the nut.

• Page 19
  INTRODUCTION FASTENER INFORMATION 3. Choose proper strength Loctite threadlocker. 4. Fit bolt in the hole. SELF-LOCKING FASTENERS 5. Apply a few drops of threadlocker at proposed PROCEDURE tightened nut engagement area. 6. Position nut and tighten as required. Threadlocker Application for Blind Holes A00A6LA TYPICAL —…
• Page 20
  INTRODUCTION Threadlocker Application for Adjusting 2. Apply LOCTITE PRIMER N (P/N 293 800 041) Screw threads and allow to dry. 3. Put 2 or 3 drops of proper strength Loctite threadlocker on female threads and in hole. NOTE: To avoid a hydro lock situation, do not ap- ply too much Loctite.
• Page 21
  INTRODUCTION 3. Twist bolt when inserting it to improve thread 5. Place gasket on mating surfaces and assemble conformation. immediately. NOTE: NOT intended for engine stud repairs. NOTE: If the cover is bolted to blind holes (above), apply proper strength Loctite in the hole and on Repair of Small Holes/Fine Threads threads.
• Page 22
  INTRODUCTION Threadlocker Application for Case-In Components (Metallic Gaskets) 1. Proper strength Loctite 1. Clean inner housing diameter and outer gasket diameter. 2. Spray housing and gasket with LOCTITE PRIMER N (P/N 293 800 041) 3. Apply a strip of proper strength Loctite on lead- ing edge of outer metallic gasket diameter.
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  smr2009-011…

• Page 24: Maintenance Schedule

  Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) MAINTENANCE SCHEDULE The maintenance schedule should be adjusted according to operating conditions and use. NOTE: The schedule provides an equivalence between number of hours and months/year. Maintenance operations should be carried out following whichever time frame comes due first. IMPORTANT: Watercraft rental operations or intensive use of watercraft, will require greater frequency of inspection and maintenance.

• Page 25
  Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) FIRST 10 HOURS A: Adjust C: Clean 25 HOURS OR 3 MONTHS I: Inspect 50 HOURS or 6 MONTHS L: Lubricate R: Replace 100 HOURS or 1 YEAR 200 HOURS or 2 YEAR O: Operator D: Dealer TO BE PERFORMED BY…
• Page 26
  Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) FIRST 10 HOURS A: Adjust C: Clean 25 HOURS OR 3 MONTHS I: Inspect 50 HOURS or 6 MONTHS L: Lubricate R: Replace 100 HOURS or 1 YEAR 200 HOURS or 2 YEAR O: Operator D: Dealer TO BE PERFORMED BY…

• Page 28: Preseason Preparation

  Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is necessary after the winter months or when a vehicle has not been used during several weeks. Any worn, broken or damaged parts found during the storage procedure should have been replaced. If not, proceed with the replacement.

• Page 30: Storage Procedure

  Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) STORAGE PROCEDURE SERVICE PRODUCTS Description Part Number Page 413 408 600 ……….7 BRP FUEL STABILIZER …………..413 707 000 ……….9 DOW CORNING 111 …………..293 800 070 ……….9 LOCTITE 767 (ANTISEIZE LUBRICANT) ……..293 600 016 ………

• Page 31
  Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) smo2008-001-053_a TYPICAL 1. Flushing adaptor (P/N 295 500 473) 2. Hose 13 mm (1/2 in) 3. Air hose male adapter NOTICE Failure to drain the exhaust mani- fold may cause severe damage to this compo- nents.

• Page 32: Electrical System

  Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURE) ELECTRICAL SYSTEM NOTICE Never cut the locking ties of ignition coil connectors. This would allow mixing the Battery Removal wires between cylinders. For battery removal, cleaning and storage, refer to 3. Clean ignition coil areas to avoid falling dirt into CHARGING SYSTEM subsection.

• Page 34: Special Procedures

  Special precautions should be taken when towing – A water-flooded engine must be properly a Sea-Doo watercraft in water. drained, lubricant replaced (oil change), op- Maximum recommended…

• Page 35
  Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) Supercharger Servicing 8. Put a tape at 400 mm (16 in) from the end of the suction pump tube. If there was water in the oil or in the supercharger inlet hose, it is recommended to take the super- 9.

• Page 36: Capsized Watercraft

  Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) 5290325002 WARNING Certain components in the engine compart- ment may be very hot. Direct contact may re- sult in skin burn. Do not touch any electrical parts or jet pump area when engine is run- ning.

• Page 38: Engine Removal And Installation

  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page 529 035 719 ……..20–21 ALIGNMENT SHAFT ADAPTER ………… 529 035 506 ……….. 21 ALIGNMENT SHAFT SUPPORT ………… 295 000 141 ……..20, 22 ALIGNMENT SHAFT …………..

• Page 39
  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) COOLING SYS- 6. Drain cooling system. Refer to subsection. 7. Cut locking tie securing exhaust water outlet hose and engine blow-by hose. 8. Disconnect the exhaust water outlet hose from the exhaust manifold. 9.
• Page 40
  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) COMMUNICA- 13. Connect B.U.D.S. Refer to TION TOOLS AND B.U.D.S. SOFTWARE subsection. 14. Release fuel pressure using B.U.D.S. 15. Using the FUEL HOSE DISCONNECT TOOL disconnect fuel hose from (P/N 529 036 037) fuel rail.
• Page 41
  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) smr2009-016-014_a smr2009-016-017_a 1. Cut this locking tie 2. MATS sensor 1. Ride plate hoses 3. Vehicle harness 2. Water pump housing 23. At the rear of engine, unplug the magneto 26. Install a suitable lifting device. connector and detach connector housing from ECM support.
• Page 42
  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) smr2009-016-023_a 1. Water outlet hose 2. Exhaust manifold 33. Slightly lift engine to ease the remaining com- smr2009-016-020_a 1. Rear engine support screw on starboard side ponent removal. 2. Water pump housing 34.
• Page 43
  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) Check tightness and condition of engine rubber ENGINE MOUNTS mounts. Refer to in this sub- section. Before completely lowering engine, install ground cable, starter cable and both cooling hoses on ex- haust manifold.
• Page 44
  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) 529036170 ENGINE ALIGNMENT PLATE Trace two thin lines on alignment shaft. One at 739 mm (29-3/32 in) and the other at 742 mm (29-7/32 in). smr2009-016-027_a 1. Engine alignment plate 2. Engine alignment support smr2009-016-200_a 3.
• Page 45
  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) NOTE: Use shim(s) (P/N 270 000 770) for the front engine mount and shim(s) (P/N 270 000 762) for the rear engine mounts. Shims location is between engine mount and engine mount plate.

• Page 46: Engine Mounts

  Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) When alignment and longitudinal position of en- gine are correct, tighten engine mount screws. ENGINE MOUNTS Refer to in this subsection. Recheck engine alignment. ENGINE MOUNTS If engine mounts have been removed, apply LOC- on screw threads TITE 243 (BLUE) (P/N 293 800 060)

• Page 48: Air Intake System

  Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM smr2009-017-001_a smr2009-017…

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  Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) smr2009-017-002_a smr2009-017…

• Page 50: General

  Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) GENERAL Rear Ventilation Box Installation The installation is the reverse of the removal pro- During assembly/installation, use torque values cedure. However, pay attention to the following. and service products as in the exploded views. Before installing the ventilation box, check the Clean threads before applying a threadlocker.

• Page 51: Air Intake Silencer Cover

  Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) Air Intake Duct Installation Tighten clamp to 1.7 N•m (15 lbf•in). Install suspension base. Refer to iS SUSPENSION AIR INTAKE SILENCER BAFFLE for complete procedure. ENGINE REMOVAL AND Install engine. Refer to Air Intake Silencer Baffle Removal INSTALLATION AIR INTAKE SILENCER COVER…

• Page 52: Air Intake Silencer

  Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) smr2009-017-009_a 1. Air intake silencer 2. Inlet hose groove smr2009-017-007_a 1. Rubber latches Install all other removed parts. Remove air intake tube from vehicle. SUPERCHARGER AIR INLET Air Intake Tube Installation HOSE The installation is the reverse of the removal pro- Supercharger Air Inlet Hose Removal cedure.

• Page 54: Intake Manifold

  Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) INTAKE MANIFOLD SERVICE PRODUCTS Description Part Number Page 293 800 060 ……….. 35 LOCTITE 243 (BLUE)…………..smr2009-018-001_a smr2009-018…

• Page 55: General

  Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) GENERAL Cut all locking ties securing the harness to the in- take manifold. During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS LOCTITE…

• Page 56
  Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) smr2009-018-008_a smr2009-018-005_a 1. Engine connector 1. Ignition coil connectors 2. ECM support 2. Fuel injector connectors Unplug the knock sensor (KS), the magneto and Unplug the «B» connector from the ECM by pulling the throttle actuator connectors.
• Page 57
  Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) Unplug the oil pressure switch (OPS). smr2009-018-011_a Lift intake manifold up to pull it out of the mount- 1. Oil pressure switch (OPS) ing brackets. Unscrew ECM retaining screws and remove ECM from its support. smr2009-018-012_a 1.

• Page 58: Flame Arrester

  Section 02 ENGINE Subsection 03 (INTAKE MANIFOLD) smr2009-018-013_a Ensure to properly route and secure wiring har- ness with locking ties. INTAKE MANIFOLD 1. Gaskets Apply on the LOCTITE 243 (BLUE) (P/N 293 800 060) ECM retaining screws and torque them to 9 N•m First, position intake manifold on front mounting (80 lbf•in).

• Page 60: Supercharger

  Section 02 ENGINE Subsection 04 (SUPERCHARGER) SUPERCHARGER SERVICE TOOLS Description Part Number Page 529 035 948 ……..46, 48 4-PIN SOCKET…………….529 035 950 ……….. 48 BEARING SUPPORT/PUSHER …………529 035 839 ……….. 40 CAMSHAFT LOCKING TOOL…………529 036 025 ……….. 41 SUPERCHARGER GEAR HOLDER……….

• Page 61
  Section 02 ENGINE Subsection 04 (SUPERCHARGER) smr2009-020-001_a smr2009-020…

• Page 62: General

  Section 02 ENGINE Subsection 04 (SUPERCHARGER) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded view. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS LOCTITE APPLICATION at the beginning of this manual for complete procedure.

• Page 63: Supercharger Clutch Slipping Moment (On Engine)

  Section 02 ENGINE Subsection 04 (SUPERCHARGER) Remove supercharger and perform the clutch slip- Remove the air inlet hose from supercharger. ping moment test. Inspect bearings and friction clutch. Replace bearings and clutch components as necessary. Separate supercharger housing. NOTE: Since supercharger is disassembled, it is recommended to completely inspect it.

• Page 64: Supercharger Clutch Slipping Moment (Bench Test)

  Section 02 ENGINE Subsection 04 (SUPERCHARGER) SUPERCHARGER CLUTCH SLIPPING MOMENT (BENCH TEST) Mount supercharger on the SUPPORT PLATE (P/N 529 035 947) smr2009-025-007_b 1. Camshaft locking tool Check slipping moment counterclockwise by us- ing a torque wrench with actual torque viewer. A mirror is useful to see the viewer.

• Page 65: Troubleshooting

  Section 02 ENGINE Subsection 04 (SUPERCHARGER) ENGINE LACKS ACCELERATION OR POWER (DOES NOT REACH MAXIMUM RPM) 1. Supercharger inlet is dirty — Check and clean supercharger inlet. — Check engine oil. Siphon excess of oil. 2. Supercharger slipping clutch defective — Check slipping clutch moment.

• Page 66
  Section 02 ENGINE Subsection 04 (SUPERCHARGER) smr2009-020-012_a smr2008-012-011_a 1. Air inlet hose 1. Rubber adapter 2. Hose clamp 2. Exhaust pipe Remove air outlet hose from supercharger. Loosen clamp securing rubber adapter to exhaust pipe. Detach muffler strap. Move muffler back (± 5 cm (2 in)). Remove retaining screws and pull out the super- charger.

• Page 67: Supercharger Disassembly

  Section 02 ENGINE Subsection 04 (SUPERCHARGER) 1. Upper retaining screw Supercharger Disassembly 1. Retaining screws 2. Housing half (intake side) 3. Housing half (engine side) NOTICE Be scrupulous when working on supercharger parts. Supercharger rotation reaches 45 000 RPM. Any modification, im- proper repair, assembly or damage on the parts, may result in damage of the super- charger.

• Page 68
  Section 02 ENGINE Subsection 04 (SUPERCHARGER) smr2009-020-006_a 1. Cap nut (left-handed thread) 4. Remove washer, turbine, O-ring and step collar from supercharger shaft. 1. Nut 2. Retaining key NOTE: There are 40 loose needle bearings under the gear. Do not reuse. 6.
• Page 69
  Section 02 ENGINE Subsection 04 (SUPERCHARGER) NOTE: It may be necessary to heat the housing with a heat gun to release the retaining disc. 1. Supercharger shaft 8. Remove and discard ball bearing from super- charger shaft by using a press and the SUPER- 1.

• Page 70: Supercharger Assembly

  Section 02 ENGINE Subsection 04 (SUPERCHARGER) SPRING WASHER PACKAGE HEIGHT 10.7 mm to 10.9 mm (.4213 in to .4291 in) SERVICE LIMIT 10.2 mm (.4016 in) Supercharger Assembly NOTICE Every time when supercharger shaft has been removed, both ball bearings have to be replaced.

• Page 71
  Section 02 ENGINE Subsection 04 (SUPERCHARGER) 529035947 6. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) retaining disc. If a new retaining disc is used, the threads are coated with a self-locking prod- uct. 7. Install the retaining disc in supercharger hous- ing half by using the 4-PIN SOCKET (P/N 529 035 948)
• Page 72
  Section 02 ENGINE Subsection 04 (SUPERCHARGER) 529035950 smr2006-012-032_a 1. Compressor shaft 2. Ball bearing 3. Supercharger housing half 4. Thrust washer 5. Distance sleeve 1. Support plate 2. Bearing support/pusher 3. Protrusion here NOTICE Before pressing in the supercharger shaft, be sure to properly support the inner race of ball bearing in supercharger housing half with the recommended tool.
• Page 73
  Section 02 ENGINE Subsection 04 (SUPERCHARGER) 13. Install step collar, O-ring, turbine and washer 20. Install the second titanium shim. on supercharger shaft. Apply LOCTITE 243 21. Install the lock washer. on cap nut and tem- (BLUE) (P/N 293 800 060) 22.

• Page 74: Supercharger Installation

  Section 02 ENGINE Subsection 04 (SUPERCHARGER) Supercharger Installation 1. Grease sealing surface between supercharger and PTO housing with SUPER LUBE GREASE (P/N 293 550 030) NOTE: Ensure O-rings are installed. 529035949 27. Tighten the cap nut to 29 N•m (21 lbf•ft). 28.

• Page 75
  Section 02 ENGINE Subsection 04 (SUPERCHARGER) NOTICE Not installing the tool as shown will change the torque applied to the screw. Proper torque and tightening sequence are important. 6. After complete installation of the supercharger, the slipping moment has to be rechecked. SUPERCHARGER CLUTCH SLIPPING Refer to MOMENT (ON ENGINE)

• Page 76: Intercooler

  Section 02 ENGINE Subsection 05 (INTERCOOLER) INTERCOOLER SERVICE TOOLS Description Part Number Page 529 032 500 ……….. 55 LARGE HOSE PINCHER…………..529 021 800 ……….. 55 VACUUM/PRESSURE PUMP …………smr2009-019-001_a smr2009-019…

• Page 77: General

  Section 02 ENGINE Subsection 05 (INTERCOOLER) GENERAL Intercooler Cleaning If temperature in intake manifold is too high or if During assembly/installation, use torque values engine is down in performance, intercooler may and service products as in the exploded view. require to be cleaned. Clean threads before applying a threadlocker.

• Page 78: Intercooler Removal

  Section 02 ENGINE Subsection 05 (INTERCOOLER) smr2009-019-009_a 1. Garden hose installed on water outlet 2. High and regular water flow 529021800 BLEED HOSE FITTING 7. Perform a leak test before installing the inter- cooler in the watercraft. Pressurize the intercooler. PRESSURE TEST Intercooler Leak Test 69 kPa (10 PSI) for 10 minutes min.

• Page 79: Intercooler Attachments

  Section 02 ENGINE Subsection 05 (INTERCOOLER) smr2009-019-005_a FIXED DECK REMOVED FOR CLARITY PURPOSE 1. iS module 2. Retaining latch smr2009-019-003_a Cut locking ties securing wiring harness to iS mod- 1. Intercooler air inlet hose ule support and front attachment. 2. Intercooler air outlet hose Detach both intercooler straps.

• Page 80
  Section 02 ENGINE Subsection 05 (INTERCOOLER) Remove plastic rivets and rubber pad. smr2009-019-050_a THROUGH THE LH REAR OPENING 1. Plastic rivet 2. Rubber pad Remove and discard screw securing the attach- ment to the hull. smr2009-019-051_a THROUGH THE LH REAR OPENING 1.

• Page 82: Exhaust System

  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE TOOLS Description Part Number Page 295 500 473 ……….. 62 FLUSHING CONNECTOR ADAPTER ……….SERVICE PRODUCTS Description Part Number Page 293 800 060 ……….. 67 LOCTITE 243 (BLUE)…………..smr2009-021…

• Page 83
  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) smr2009-021-001 smr2009-021…

• Page 84: General

  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS LOCTITE APPLICATION at the beginning of this manual for complete procedure.

• Page 85: Procedures

  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) help to clean up sand, salt, shells or other particles in water jackets (exhaust system, intercooler and hoses. Exhaust system flushing should be performed when the watercraft is not expected to be used further the same day or when the watercraft is stored for any extended time.

• Page 86
  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) 4. Gently disconnect the hose from blow-by valve. smr2009-016-005_a 1. Exhaust hose clamp 8. Detach retaining strap. smr2009-016-003_a 1. Cut this locking tie 2. Water outlet hose (exhaust system) 3. Blow-by hose 4. Blow-by valve 5.

• Page 87: Exhaust Hoses

  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) smr2008-013-025_a 1. Exhaust manifold mark 2. Exhaust pipe mark Tighten exhaust clamp to 11 N•m (97 lbf•in). smr2008-013-026_a Step 1: Lift adjuster tab Step 2: Move adjuster outward NOTICE Do not use pneumatic or electric tools as seizure may occur.

• Page 88: Exhaust Pipe

  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) Move the coolant expansion tank aside and cut locking tie retaining the starter cable (RED) to ex- haust hose. Remove exhaust hose from resonator. Cut locking tie retaining bailer hose elbow fittings to exhaust hose. Remove front exhaust hose from vehicle.

• Page 89: Exhaust Manifold

  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) smr2008-013-035_a 1. Bulge smr2008-013-037_a 2. Middle of the opening 1. Middle of rubber adapter strip 2. Center of the muffler bulge opening Install the rubber adapter on exhaust pipe. Ensure rubber adapter is properly seats against exhaust Using a caliper, measure the distance between pipe shoulder.

• Page 90: Resonator

  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) 3. Disconnect the exhaust manifold water outlet Apply LOCTITE 243 (BLUE) (P/N 293 800 060) hose. threads of screws. To help holding the manifold while installing screws, first insert the exhaust manifold into the exhaust pipe then, install the upper front screw.

• Page 91
  Section 02 ENGINE Subsection 06 (EXHAUST SYSTEM) Resonator Installation Installation is the reverse of the removal proce- dures. However, pay attention to the following. After installation, ensure there is no water or ex- haust gas leak when the engine is running. Test run the engine while supplying water to the ex- haust system.

• Page 92: Pto Housing And Magneto

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) PTO HOUSING AND MAGNETO SERVICE TOOLS Description Part Number Page 529 036 016 ……..78–79 3-PIN MAGNETO HARNESS ADAPTER……..529 036 117 ……….. 77 BLIND HOLE BEARING PULLER SET……….. 420 877 650 ……….. 78 HANDLE ………………

• Page 93
  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2008-014-007_b smr2009-022…

• Page 94: General

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) GENERAL ENGINE WILL NOT START (ENGINE DOES NOT TURN OVER) NOTE: It is good practice to check for fault codes using the B.U.D.S. software as a first trou- 1. Obstructed starter drive gear assembly MONITORING bleshooting step.

• Page 95
  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) WARNING Always disconnect battery cables exactly in the specified order, BLACK negative cable first. 2. Remove the moving deck and deck extension. BODY Refer to subsection. 3. Drain the engine oil. Refer to LUBRICATION SYSTEM subsection.
• Page 96
  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Slightly lift aft end of engine and insert a safely block under the engine to secure it in this position. Remove LH rear engine support. smr2009-016-015_b 1. Magneto connector 2. ECM 3.
• Page 97
  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) PTO Housing Inspection Inspect PTO housing for cracks or any other dam- ages. Replace if necessary. Inspect the needle bearing in the PTO housing used to support the starter drive assembly shaft. NOTE: Clean all disassembled metal components in a non-ferrous metal cleaner.
• Page 98
  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2005-034-100_a TYPICAL 1. Thrust washer 2. Disc springs 3. Starter drive assembly NOTE: When installing a NEW starter drive as- smr2009-022-001_b sembly, oil the shaft and gear splines with engine 1. Screws M6 x 35 2.

• Page 99: Pto Seal

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) PTO Seal Removal Reinstall LH engine support. Apply LOCTITE 243 on screw threads then (BLUE) (P/N 293 800 060) Place rags under PTO housing to prevent spillage. torque to 24 N•m (18 lbf•ft). If spillage occurs, clean immediately with PULLEY Remove block under engine.

• Page 100: Pto Coupling

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Crimp Oetiker clamp using OETIKER PLIERS (P/N 295 000 070) PTO COUPLING PTO Coupling Removal CYLINDER BLOCK Lock crankshaft. Refer to sub- section for the procedure. Remove PTO seal as described in previous proce- dure.

• Page 101: Stator

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2009-016-015_b 1. Magneto connector 2. ECM 3. Throttle body 529036117 Install the 3-PIN MAGNETO HARNESS ADAPTER Starter Drive Bearing Installation onto the magneto connector. (P/N 529 036 016) Prior to assembly grease starter drive bearing with NOTE: Do not connect the magneto harness ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021) adapter to the vehicle harness connector.

• Page 102
  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) STATOR OUTPUT VOLTAGE TEST TEST ENGINE TERMINAL VOLTAGE (AC) SPEED 1 and 2 4000 RPM 1 and 3 Approx. 50 Vac 2 and 3 If voltage is lower than specification, carry out a STATOR CONTINUITY TEST STATOR INSU- and a…

• Page 103: Stator Installation

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) smr2009-022-101_c STATOR INSULATION TEST smr2009-022-012_a 1. Connect adapter to magneto stator connector 1. Stator screws 2. Leave vehicle harness disconnected 2. Stator Read resistance. Stator Installation STATOR INSULATION TEST For installation, reverse the removal procedure. RESISTANCE @ However, pay attention to the following.

• Page 104: Rotor And Trigger Wheel

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) Recheck reading on reference tooth to ensure gauge has not changed position (gauge should still read zero). NOTE: The maximum allowable difference be- tween teeth is 0.15 mm (.006 in). If the reading exceeds the maximum allowable difference, straighten the tooth or replace the trigger wheel.

• Page 105: Ring Gear

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) TYPICAL 1. Magneto rotor retaining screws 2. Rotor TYPICAL 3. Trigger wheel 1. Rotor retaining screws 4. Ring gear 2. Rotor 3. Trigger wheel Ring Gear Inspection Rotor and Trigger Wheel Installation Inspect ring gear for damages.

• Page 106: Starter Drive

  Section 02 ENGINE Subsection 07 (PTO HOUSING AND MAGNETO) STARTER DRIVE If any part of the assembly shows signs of ab- normal wear, cracks, broken teeth or malfunction Starter Drive Removal (sprag clutch), replace the faulty part. Remove the PTO housing and ring gear as de- Starter Drive Installation scribed in this subsection.

• Page 108: Lubrication System

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page 529 035 652 ……….. 93 ADAPTER HOSE …………….529 036 166 ……..95, 109 ECM ADAPTER TOOL…………..529 035 868 ……… 109 FLUKE 115 MULTIMETER …………529 035 822 ………

• Page 109
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-001_a smr2009-023…
• Page 110
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-002_a smr2009-023…
• Page 111
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT smr2009-023-100_en 1. Oil dipstick 2. Rocker arm (intake) 3. Rocker arm (exhaust) 4. Hydraulic valve lifter 5. Camshaft 6. Piston pin 7. Into PTO cover 8. From oil filter 9. Piston cooling 10.
• Page 112
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT (CONT’D) smr2009-023-101_en 1. To air intake silencer 18. Oil spray nozzle 2. Rocker arm (intake) 19. Drive shaft 3. Rocker arm (exhaust) 20. Crankshaft 4. Rocker arm axle 21. PTO seal 5.

• Page 113: General

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS LOCTITE APPLICATION at the beginning of this manual for complete procedure.

• Page 114: Oil Change

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) lmr2007-053-100_a 1. Full 2. Add 3. Operating range Otherwise, add oil until its level is between marks as required. To add oil, unscrew oil cap. Place a funnel into the smo2009-002-002_a oil filler neck opening and add the recommended 1.

• Page 115: Oil Filter

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTICE Never crank or start engine when suction pump tube is in dipstick hole. Never start engine when there is no oil in engine. NOTE: So that suction pump tube is located at the proper height to siphon oil, it is suggested to put some electrical tape on tube at 475 mm (18-11/16 in) from its end.

• Page 116: Inspection

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Apply engine oil on filter ring, filter cover O-rings and on oil filter screw O-ring. NOTE: In salt water area, it is recommended to coat mating surface of cover with SUPER LUBE GREASE (P/N 293 550 030) Torque oil filter screw to 9 N•m (80 lbf•in).

• Page 117: Troubleshooting

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Reinstall oil pressure switch. 4. Oil pressure regulator valve sticks open, or spring load is too small. Test at the Cylinder Head Location — Clean oil regulator piston and its bore. Replace if necessary.

• Page 118: Procedures

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) PROCEDURES ENGINE RUNNING TEST PROBES RESISTANCE ( ) OIL PRESSURE SWITCH (OPS) Infinitely high (OL) Oil Pressure Switch Operation Engine when pressure reaches connector ground 180 kPa (26.11 PSI) and The oil pressure switch activates if engine oil (pin 1) 220 kPa (32 PSI) pressure…

• Page 119: Pto Oil Strainer

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) PTO OIL STRAINER RESISTANCE CONNECTOR ADAPTER NOTE: The oil strainer does not need to be Close to 0 cleaned at every oil change. Clean it during other Pin 1 Pin E3 (continuity) inspections, especially when the engine is disas- sembled.

• Page 120: Suction Pump Oil Strainer

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1. Oil inlet to the oil pump smr2006-014-022_a 1. Oil strainer PTO Oil Strainer Installation 2. Suction pump cover For installation, reverse the removal procedure. Suction Pump Oil Strainer Cleaning However, pay attention to the following. and Inspection Clean cylinder block to remove all remaining sili- Clean oil strainer with a part cleaner then use an…

• Page 121: Engine Oil Pressure Regulator

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-007_a smr2009-023-009_a 1. Oil inlet TIGHTENING SEQUENCE 2. Oil outlet ENGINE OIL PRESSURE Suction Pump Oil Strainer Installation REGULATOR For installation, reverse the removal procedure. However, pay attention to the following. The oil pressure regulator is located on the bottom of the PTO housing.

• Page 122: Oil Pressure Pump

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Oil Pressure Pump Removal 1. Remove engine oil. See procedure in CHANGE in this subsection. 2. Remove the PTO housing. Refer to HOUSING AND MAGNETO subsection. 3. Remove water pump housing and the impeller. COOLING SYSTEM Refer to subsection.

• Page 123
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1. Pittings on the teeth Using a feeler gauge, measure the clearance be- tween inner and outer rotors. TYPICAL NOTICE Be careful not to damage the surface of the rotary seal bore in PTO housing cover. 8.
• Page 124
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1. PTO housing surface 2. Vernier depth gauge 1. Oil seal Install the new rotary seal by using the WATER PUMP SEAL PUSHER (P/N 529 035 823) 529035823 NOTICE Never use a hammer for the rotary seal or water/oil pump shaft installation.

• Page 125: Oil Suction Pump

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) AIR IN- 3. Remove the air intake silencer. Refer to TAKE SYSTEM subsection. 4. Detach the muffler from the exhaust manifold and move muffler backwards. Refer to HAUST SYSTEM subsection. 5. Remove engine support mount screws. 6.

• Page 126
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1. Pittings on the teeth smr2008-015-006_a TYPICAL Using a feeler gauge, measure the clearance be- 1. Oil pump cover 2. Oil pump screws tween inner and outer rotors. 13. Remove oil pump shaft. 14.

• Page 127: Oil Spray Nozzle (Supercharger)

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-008_a 1. Screws M6 x 25 1. Oil pump housing surface 2. Screws M6 x 45 2. Vernier depth gage Tighten suction pump cover screws as per follow- ing sequence. 1. Oil pump outer rotor surface 2.

• Page 128: Oil Spray Nozzles (Pistons)

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2008-015-007_a smr2008-015-008_a 1. Banjo bolt A. 1 mm (0.039 in) 2. Oil spray nozzle 3. Oil spray nozzle support NOTE: Make sure that the oil spray nozzle is fac- 4. Torx screw ing to the center of the tool. Not following this Oil Spray Nozzle Inspection procedure will lead to an insufficient oiling of the supercharger and a supercharger failure can oc-…

• Page 129: Oil Separator Cover

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Oil Spray Nozzle Installation NOTE: When the scope of repair work obligates you to split the cylinder block, take this opportu- NOTICE At assembly make sure the contact nity to clean the oil spray nozzles. surface of the oil spray nozzle is well fitted onto the cylinder block.

• Page 130
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTE: Make sure not to loose thrust washer when removing it from oil separator cover, oth- erwise thrust washer would fall into the PTO housing. smr2006-014-067_a 1. Camshaft 2. Oil separator cover NOTE: Be careful not to break the holding clips from oil separator cover when its removed from the timing gear.

• Page 131: Blow-By Valve

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) BLOW-BY VALVE Blow-by Valve Description The blow-by valve has two main functions: – It recirculates oil vapors. – It protects the engine in the event the water- craft tip over. To a accomplish the second function, the blow-by valve has a tip over protection switch (TOPS).

• Page 132
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) NOTE: After voltage test, clear the fault codes in the ECM using the B.U.D.S. software. Blow-By Valve TOPS Switch Output Voltage Test Remove the blow-by valve. Back-probe TOPS connector and check voltage using the FLUKE 115 MULTIMETER (P/N 529 035 868) NOTE: To easily probe wire terminals through the…
• Page 133
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) smr2009-023-051 529036166 When installing the TOPS switch, make sure Check continuity of the blow-by valve TOPS printed information is visible. switch circuit as per following table. TOPS SWITCH RESISTANCE CONNECTOR ADAPTER Pin 1 Pin F4 Close to 0 Pin 2…

• Page 134: Oil Cooler

  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) Disconnect the TOPS switch connector of the Blow air through inlet port. Air must flow freely to blow-by valve. the outlet port. Unscrew and remove the blow-by valve. smr2009-023-023_a smr2009-023-014_a Turn valve upside down and blow air again. Air 1.

• Page 135
  Section 02 ENGINE Subsection 08 (LUBRICATION SYSTEM) 1. O-rings Oil Cooler Inspection smr2009-023-025_a 1. Oil cooler If O-rings are brittle, cracked or hard, replace them. Oil Cooler Removal Clean both contact surfaces of oil cooler. ENGINE Remove engine from vehicle. Refer to REMOVAL AND INSTALLATION subsection.

• Page 136: Cooling System

  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page 295 000 070 ……… 120 OETIKER PLIERS…………….529 035 822 ……… 125 OIL SEAL GUIDE…………….529 035 991 ……… 119 TEST CAP ………………529 021 800 ……… 119 VACUUM/PRESSURE PUMP …………

• Page 137
  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) CLOSED LOOP COOLING SYSTEM smr2009-024-100_en smr2009-024…
• Page 138
  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) VEHICLE COMPONENTS smr2009-024-101_a smr2009-024…
• Page 139
  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) ENGINE COMPONENTS smr2009-024-001_a smr2009-024…

• Page 140: General

  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) GENERAL During assembly/installation, use torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS LOCTITE APPLICATION at the beginning of this manual for complete procedure.

• Page 141
  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) NOTICE Cleaning the System Pure antifreeze will freeze at a higher temperature than the optimal water/antifreeze NOTICE Cleaning the cooling system as per mix. A blend of 40% antifreeze with 60% dem- the following procedure is required when en- ineralized water will improve the cooling effi- gine overheats (assuming everything else is ciency.

• Page 142: Inspection

  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) INSPECTION COOLING SYSTEM LEAK TEST WARNING To avoid potential burns, do not remove the expansion tank cap or loosen the ride plate drain plug if the engine is hot. Remove the deck extension. Refer to BODY sub- section.

• Page 143: Troubleshooting

  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) PROCEDURES PRESSURE CAP Pressure Cap Inspection Using a pressure cap tester, check pressure cap efficiency. If the efficiency is feeble, install a new 90 kPa (13 PSI) cap (do not exceed this pressure). CLAMPS Clamp Replacement To cut or secure Oetiker clamps of cooling system…

• Page 144: Water Pump Housing

  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) WATER PUMP HOUSING smr2009-024-105_a 1. Expansion tank hose Disconnect exhaust hose from the resonator. Place hose over muffler. smr2009-024-004_b 1. Water pump housing Water Pump Housing Removal BODY Remove the moving deck. Refer to sub- section.

• Page 145
  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) Check if thermostat is in good condition. Refer to THERMOSTAT in this subsection. Water Pump Housing Leak Test Plug the connections of the oil cooler return hose, coolant tank hose, ride plate return hose and cylin- der head return hose with a rag.

• Page 146: Water Pump Impeller

  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) 1. Screws M6 x 25 2. Screws M6 x 105 1. Impeller NOTICE To prevent leaking, take care that the NOTICE Coolant/oil pump shaft and impeller gaskets are exactly in groove when you rein- have left-hand threads.

• Page 147: Rotary Seal

  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) Thermostat Installation For installation, reverse the removal procedure, paying attention to the following details. WATER PUMP HOUSING Refer to in this subsec- tion. ROTARY SEAL Rotary Seal Inspection Check leak indicator hole for oil or coolant leak. 1.

• Page 148
  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) NOTE: Never use oil in the press fit area of the oil seal and rotary seal. Push water pump shaft oil seal in place by using thumb. Install the NEW rotary seal using a press and the WATER PUMP SEAL PUSHER (P/N 529 035 823) 1.
• Page 149
  Section 02 ENGINE Subsection 09 (COOLING SYSTEM) 1. Oil seal protector 2. Coolant/oil pump shaft Using the WATER PUMP SEAL PUSHER (P/N 529 to support the PTO cover, install the 035 823) coolant/oil pump shaft. 1. Coolant/oil pump shaft with oil seal protector 2.

• Page 150: Cylinder Head

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) CYLINDER HEAD SERVICE TOOLS Description Part Number Page 529 035 839 ……… 138 CAMSHAFT LOCKING TOOL…………529 035 985 ……… 130 DRIVE SHAFT ADAPTER…………… 529 035 661 ……… 130 ENGINE LEAK DOWN TEST KIT ……….. 529 036 087 ………

• Page 151
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) smr2009-025-001_a smr2009-025…

• Page 152: General

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) GENERAL WARNING Be careful to burns when working on a hot NOTE: When diagnosing an engine problem, al- engine. ways perform an engine leak test. This will help ENGINE LEAK TEST pin-point a problem. Refer to in this subsection for procedures.

• Page 153
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Leak Test Procedure NOTE: Cylinder numbers are molded on cylinder head cover. 1. Rotate engine crankshaft counterclockwise un- til the cylinder no. 1 is at Top Dead Center (TDC) compression stroke. 1.1 As the engine crankshaft is turned over, observe the movement of intake rocker arm of the cylinder to be checked.

• Page 154: Troubleshooting

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) OBSERVATION CAUSE Air escaping on intake Leaking intake valve(s) port Air escaping on Leaking exhaust valve(s) exhaust port Air escaping into Excessively worn and/or crankcase broken piston rings Air bubbles out of Leaking cylinder head coolant tank gasket Air/water…

• Page 155: Procedures

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) 4. Rocker arm screw not properly tightened 4. Broken rocker arm(s) — Retighten screws with recommended torquing — Replace defective parts. procedure. PROCEDURES 5. Faulty chain tensioner — Replace chain tensioner. EXHAUST MANIFOLD 6.

• Page 156: Cylinder Head Cover

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Torque screws to 9 N•m (80 lbf•in) as per follow- ing illustrated sequence. smr2008-017-005_a 1. Cylinder head cover screws 5. Remove the cylinder head cover and its gasket. CYLINDER HEAD COVER Cylinder Head Cover Removal 1.

• Page 157: Spark Plug Tubes

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) smr2005-036-001_a TYPICAL 1. Spark plug tube 2. Seal to the cylinder head cover 3. Seal to the cylinder head Spark Plug Tube Installation smr2006-016-026_a For installation, reverse the removal procedure. Pay attention to the following detail. Torque screws to 9 N•m (80 lbf•in).

• Page 158
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) A. Measure rocker arm shaft diameter here ROCKER ARM SHAFT DIAMETER 19.980 mm — 19.993 mm (.7866 in — .7871 in) 1. Rocker arm shaft 2. Rocker arms (exhaust side) 3. Rocker arm (intake side) SERVICE LIMIT 19.965 mm (.786 in) Rocker Arm Inspection…

• Page 159: Camshaft Timing Gear

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) smr2009-025-006_a 1. Position lines 7. Retorque screws to 20 N•m (15 lbf•ft). 3. Apply engine oil on rocker arm shaft. 8. Finish tightening screws turning an additional 4. Position the rocker arm shaft with the notches 90°…

• Page 160
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) CYLINDER Remove the chain tensioner. Refer to BLOCK subsection. Remove the chain guide. Remove the Allen screws securing the camshaft timing gear. Remove the camshaft timing gear. smr2008-017-007_a 1. Chain guide 1. Good (with 1503 aligned) 2.

• Page 161: Camshaft

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Camshaft Removal Remove the CAMSHAFT TIMING GEAR , see pro- cedure in this subsection. ROCKER ARM Remove the , see procedure in this subsection. Remove the camshaft lock to remove the camshaft. 1. Position lines NOTICE Ensure to remove locking tools when finished.

• Page 162: Cylinder Head

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) COOLING SYSTEM Drain coolant, refer to sub- CAMSHAFT BEARING JOURNAL section. 39.892 mm — 39.905 mm (1.5706 in — 1.5711 in) Unscrew blow-by valve from cylinder head. Refer LUBRICATION SYSTEM subsection. SERVICE LIMIT 39.860 mm (1.5693 in) CAMSHAFT BEARING JOURNAL Unplug the camshaft position sensors (CAPS).

• Page 163
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) smr2009-025-010_a 1. Oil orifices Cylinder Head Inspection 1. Cylinder head screws M6 Check for cracks between valve seats or other Remove the cylinder head screws M11 securing damages, if so, replace cylinder head. cylinder head to cylinder block.

• Page 164: Valve Springs

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) NOTICE Each installation of the cylinder head requires a new cylinder head gasket. Us- ing a gasket twice will cause engine damage, even if the engine had not run. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) threads of screws M6.

• Page 165
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) smr2008-017-009_a 1. Valve cotters 2. Valve spring retainer 3. Inner valve spring 4. Outer valve spring Valve Spring Inspection Check valve springs for rust, corrosion or other visible damages. If so, replace faulty valve 1.

• Page 166: Valves

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) NOTE: Valve cotters must be properly engaged in valve stem grooves. 1. Position of the valve spring VALVES Valve Removal Valve Inspection Remove valve spring. Valve Stem Seal Push valve stem then pull valves out of valve Inspection of valve stem seals is not needed guides.

• Page 167
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) Valve Face and Seat 1. Valve seat A. Valve stem diameter 2. Exhaust valve contaminated area 3. Valve face (contact surface to valve seat) VALVE STEM DIAMETER Check valve face and seat for burning or pittings and replace valve or cylinder head if there are 5.946 mm — 5.960 mm signs of damage.
• Page 168
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) A. Valve seat outer diameter INTAKE VALVE SEAT OUTER DIAMETER A. Valve face contact width B. Valve seat contact width Intake 37.35 mm (1.4705 in) Valve Seat Grinding Exhaust 30.3 mm (1.1929 in) NOTE: The valve seats may be reground with a valve seat grinder which centers on the valve 3.

• Page 169: Valve Guides

  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) VALVE GUIDES Valve Guide Replacement NOTICE Do not heat cylinder head for this procedure. NOTICE The sharp edge near the top of the valve guide must be machined away. Other- wise it will foul the valve guide hole in the cylinder head and destroy the cylinder head, as the valve guide is removed.

• Page 170
  Section 02 ENGINE Subsection 10 (CYLINDER HEAD) TYPICAL 1. Punch Check valve guide bore for abreased material. The inlet and exhaust valve guides have the same length and are interchangeable. TYPICAL A. Protrusion NOTE: If valve guide has caused scoring during extraction, replace the cylinder head.

• Page 172: Cylinder Block

  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) CYLINDER BLOCK SERVICE TOOLS Description Part Number Page 529 035 821 ….160, 164, 166, 171 CRANKSHAFT LOCKING TOOL ………… 420 877 650 ……… 169 HANDLE ………………529 035 765 ……… 157 PISTON CIRCLIP INSTALLER…………420 876 502 ………

• Page 173
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) smr2007-018-001_b smr2009-026…
• Page 174
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) smr2009-026-001_a smr2009-026…

• Page 175: General

  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) GENERAL 3. Crankshaft or balancer shaft axial play out of specification When disassembling parts that are duplicated in — Measure crankshaft and balancer shaft axial play. the engine, (e.g.: pistons, connecting rods etc.), — If axial play is out of specification, replace thrust it is strongly recommended to note their position washers.

• Page 176: Chain Tensioner

  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Timing Chain Removal Remove: – Engine oil (refer LUBRICATION SYSTEM sub- section) ENGINE RE- – Engine from vehicle (refer to MOVAL AND INSTALLATION subsection) CYLINDER HEAD – Cylinder head (refer to sub- section) PTO HOUSING AND –…

• Page 177
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1. Piston 1. Connecting rod screws 2. Piston pin 3. Circlip NOTE: Before removing the connecting rod caps, mark them to remember the right position when 6. Detach piston no. 10 from connecting rod no. 5. reassembling.
• Page 178
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) A. Connecting rod big end bearing 1. Bore gauge CONNECTING ROD BIG END DIAMETER 2. Connecting rod SERVICE LIMIT 45.080 mm (1.775 in) CONNECTING ROD SMALL END DIAMETER 23.01 mm — 23.02 mm CONNECTING ROD BIG END (.9059 in — .9063 in) RADIAL PLAY…
• Page 179
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) PISTON PIN DIAMETER 22.996 mm — 23.000 mm (.905 in — .906 in) SERVICE LIMIT 22.990 mm (.905 in) Measure connecting rod small end diameter (re- fer to CONNECTING RODS INSPECTION above) to check connecting rod small end radial play. Piston Inspection Inspect piston for scoring, cracking or other dam- ages.
• Page 180
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) NOTE: Make sure the cylinder bore gauge indica- tor is set exactly at the same position as with the micrometer, otherwise the reading will be false. Position the dial bore gauge 62 mm (2.44 in) above cylinder base, measuring perpendicularly (90°) to piston pin axis.

• Page 181: Piston Rings

  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) NOTICE Failure to strictly follow this proce- dure may cause screw to loosen and lead to engine damage. Knowing that the screws have been stretched from the previous installation, it is very important to use new screws at as- sembly.

• Page 182: Crankshaft

  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1. Rectangular ring 2. Taper-face ring 3. Oil scraper ring NOTICE Ensure that top and second rings are not interchanged. 1. Piston 2. Filler gauge NOTE: Use a ring expander to prevent breakage Ring End Gap during installation.

• Page 183
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Remove: INTAKE MANIFOLD – Intake manifold (refer to subsection) – Spark plugs – Cylinder head cover (refer to CYLINDER HEAD subsection – Crankshaft access plug screw. smr2009-026-004_a 1. Position lines Use a small screwdriver to check if the groove in the crankshaft is aligned with the hole.
• Page 184
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) NOTE: Before removing the connecting rod caps, mark them to remember the right position when reassembling. It is recommended to measure connecting rod big end axial play prior to re- PISTONS AND move connecting rod. Refer to CONNECTING RODS in this subsection for the procedure.
• Page 185
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1. Micrometer 2. Crankshaft area for bearing 1. Crankshaft CRANKSHAFT JOURNAL DIAMETER Crankshaft Inspection 49.991 mm — 50.01 mm Crankshaft Gear Inspection (1.9681 in — 1.9689 in) Replace crankshaft if the gears are worn or other- SERVICE LIMIT 49.95 mm (1.9665 in) wise damaged.
• Page 186
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) CRANKSHAFT PIN RADIAL CLEARANCE SERVICE LIMIT 0.09 mm (.0035 in) Crankshaft Axial Clearance When assembling the cylinder-block, measure the crankshaft axial clearance. 1. Mark on balancer shaft 2. Mark on crankshaft For correct installation of the connecting rods, re- PISTONS AND CONNECTING RODS fer to in this…

• Page 187: Balancer Shaft

  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1. Thrust washer 1. Crankshaft locking tool 2. Sealing surface Install cylinder block lower half. Refer to CYLIN- BALANCER SHAFT DER BLOCK in this subsection. Balancer Shaft Removal Install the crankshaft cover before mounting the engine bracket.

• Page 188
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1. Screws 1. Micrometer 11. Remove cylinder block lower half. 2. Balancer shaft area for bearing 12. Remove thrust washers no. 6. BALANCER SHAFT SEAT DIAMETER 31.984 mm — 32.000 mm (1.2592 in — 1.2598 in) SERVICE LIMIT 31.960 mm (1.2583 in) BALANCER SHAFT SEAT RADIAL CLEARANCE…
• Page 189
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Balancer Shaft Installation For installation, reverse the removal procedure. Pay attention to following details. NOTICE Balancer shaft and crankshaft marks have to be aligned. 1. Thrust washer 2. Sealing surface Install cylinder block lower half. Refer to CYLIN- DER BLOCK in this subsection.

• Page 190: Cylinder Block

  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) 1. Crankshaft locking tool 1. Mark on balancer shaft bearings CYLINDER BLOCK 2. Mark on crankshaft bearings Starter Drive Bearing Cylinder Block Disassembly Check bearing no. 21 of starter drive assembly Remove: no. 22 in cylinder block and replace it if damaged. LUBRICATION SYSTEM –…

• Page 191
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Close puller claws so that they can be inserted Cylinder Out of Round in end bearing. Holding claws, turn puller shaft Measure cylinder diameter in piston axis direction clockwise so that claws open and become firmly from top of cylinder.
• Page 192
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Correctly install bearings. Top crankshaft bearing CRANKSHAFT BEARING INSIDE DIAMETER halves have a bore which has to be placed in the SERVICE LIMIT 50.1 mm (1.9724 in) upper cylinder block. 1. Cylinder block upper half 2.
• Page 193
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Clean oil passages and make sure they are not clogged. Clean all metal components in a solvent. Cylinder block mating surfaces are best cleaned using a combination of the LOCTITE CHISEL (GAS- and a brass brush. KET REMOVER) (P/N 413 708 500) Brush a first pass in one direction then make the fi- nal brushing perpendicularly (90°) to the first pass…
• Page 194
  Section 02 ENGINE Subsection 11 (CYLINDER BLOCK) Install the crankshaft cover before mounting the engine bracket. Apply engine oil on O-ring and press cover in. Crankshaft cover has to be flush with cylinder block surface. 1. O-ring 2. Crankshaft cover Install the CRANKSHAFT LOCKING TOOL (P/N 529 right away to position crankshaft at TDC…

• Page 196: Engine Management System

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) ENGINE MANAGEMENT SYSTEM smr2009-027-002_en smr2009-027…

• Page 197
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) smr2009-027-003_en smr2009-027…

• Page 198: General

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) GENERAL Engine RPM Limiter The ECM will limit the maximum engine speed. SYSTEM DESCRIPTION The ECM monitors engine RPM through the CPS and it changes the fuel injection and ignition as There are 7 main systems in interaction with the necessary.

• Page 199
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) MONITORING SYS- in limp home mode. Refer to TEM AND FAULT CODES subsection for more in- formation. smr2009-027…

• Page 200: Icontrol System

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 02 (iCONTROL SYSTEM) iCONTROL SYSTEM GENERAL iTC (INTELLIGENT THROTTLE CONTROL) The iControl (intelligent Control) system consist of the following systems: The iTC is an electronic throttle control system – Intelligent Throttle Control (iTC) that includes a cableless throttle control located on the RH side of handlebar and an electric throt- –…

• Page 201: Is (Intelligent Suspension)

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 02 (iCONTROL SYSTEM) For a comprehensive and complete description of IBR and VTS this system, refer to subsection in PROPULSION section. iS (INTELLIGENT SUSPENSION) The intelligent suspension is a mechanical system of one spring and one shock absorber installed in the lower fixed deck connecting to the upper mov- ing deck to isolate the riders from the rough water.

• Page 202: Communication Tools And B.u.d.s. Software

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE SERVICE TOOLS Description Part Number Page 710 000 851 ……… 182 MPI-2 DIAGNOSTIC CABLE…………529 036 018 ……… 182 MPI-2 INTERFACE CARD ………….. SERVICE TOOLS –…

• Page 203
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) Message Box: «No Vehicle Detected…» CAN LIGHT If the following message box is displayed in STATUS WHAT TO DO B.U.D.S.: Light is Check connection between MPI-2 and diagnostic connector of vehicle. Light is Check CAN wires/connectors on vehicle.

• Page 204: Procedures

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) Message Box: «Some of the Information NOTE: Never use the D.E.S.S. POST INTERFACE. Normally Displayed…» If the following message box is displayed in B.U.D.S.: smr2009-028-016 1. Click on the OK button in B.U.D.S. 2.

• Page 205
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) ssi2009-002-004_a 1. Diagnostic connector 529036018 Connect the MPI-2 DIAGNOSTIC CABLE (P/N 710 NOTE: An optional to vehicle connector. MALE-FEMALE EXTENSION SE- 000 851) available at electronic retail RIAL CABLE (P/N DB9) outlets can be used between diagnostic cable and MPI-2 interface.

• Page 206: B.u.d.s. Software

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) Reading Data in ECM Read ECM by clicking the Read Data button. vmr2006-012-100_aen mmr2006-079-200 B.U.D.S. is now ready to use. MPI-2 INTERFACE CARD CONNECTED TO USB PORT Electronic Modules («ECU») Update CAUTION If the computer you are using is connected to the power outlet, there is a poten- NOTICE…

• Page 207
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) NOTE: When selecting the update menu in B.U.D.S., a dialog box will appear and the update file description may give some clue to find the vehicle-related information in BOSSWeb. smr2009-028-003 1.
• Page 208
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE) NOTE: If there is still a communication problem, COMMUNICATION PROBLEMS WITH refer to B.U.D.S. in this subsection. After the write operation, remove D.E.S.S. key from watercraft D.E.S.S. post to complete the operation.

• Page 210: Monitoring System And Fault Codes

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) MONITORING SYSTEM AND FAULT CODES GENERAL INFORMATION CENTER MONITORING Information center MONITORING SYSTEM VTS and iS switch A system monitors the electronic components of MODE and SET switch the EMS (engine management system), iBR, in- Cruise switch formation center, iS and other components of the…

• Page 211
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) – Start engine. The following conditions will trigger a limp home mode. – Check if fault code disappeared. The electronic system will react differently de- iBR PROBLEM SYSTEM BEHAVIOR pending on the fault type.
• Page 212
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) PILOT LAMPS MESSAGE DISPLAY DESCRIPTION (ON) MAINTENANCE REMINDER Maintenance required LOW or HIGH BATTERY Low/high battery voltage VOLTAGE Low fuel level, approx. 25% tank capacity, 14 L LOW-FUEL (3.7 U.S.

• Page 213: Fault Codes

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) Beeper Signals BEEPER DESCRIPTION CODES When one of the below conditions occurs, the monitoring system emits the following beep sig- High engine temperature nals. coolant. COOLING SYSTEM Refer BEEPER DESCRIPTION subsection.

• Page 214
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) Fault Code Types There are 4 types of fault codes used on the vehi- cle: – “B” for information center and switches faults (Bxxxx) – “C” for iBR and iS faults (Cxxxx) –…

• Page 215: Specific Fault Codes

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) Fault Code U0129 This will reset the appropriate counter(s) and will also record that the problem has been fixed in the CAN communication error between ECM and iBR related module memory.

• Page 216: Fault Code Table

  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT CODE TABLE FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Left keypad fault The switch may be defective, verify the functionality of the switch or the wires. (switch kept activated B2210 Cluster…

• Page 217
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Damaged sensor, damaged circuit wires, Brake Lever Sensor Check system circuits C03-6pos and damaged connector (BRLS) signals B C01-12pos. C0043 or damaged iBR pins.
• Page 218
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Perform an electrical system shut down and clear fault. Last session Unexpected battery Verify starting and charging system C2122 interrupted power lost circuits.
• Page 219
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Use B.U.D.S. iBR unlock function. System disabled and System is locked. C2151 Refer to the Service Manual for more need activation Need activation details.
• Page 220
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check for 12 volts on sensor connector pin A. Warning only: TOPS Check continuity for circuits B-H1, detected by the system, C2252 TOPS active B-H3.
• Page 221
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check the sensor for approximately 2280 to 2736 ohms at 19 to 21°C (66 to 70°F). Intake manifold Damaged sensor, Check for approximately 2280 to temperature sensor damaged circuit wires,…
• Page 222
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check system circuits B-E1, B-K1, B-K3. Check for 0 volt on sensor connector pin E. TAS (Throttle Damaged sensor, Check for 5 volts on sensor connector damaged circuit wires, Accelerator sensor) 1 pin D.
• Page 223
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check for debris or blockage in cooling system. Check the sensor for approximately 2280 to 2736 ohms at 19 to 21°C (66 to 70°F).
• Page 224
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check for 11.4 to 12.6 ohms between engine connector pin 1 and ECM connector pin A-B3. Damaged injector, Check for 12 volts on pin 2 of injector damaged circuit wires, Injector 1 open circuit connector.
• Page 225
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check for 11.4 to 12.6 ohms between engine connector pin 3 and ECM connector pin A-J1. Damaged injector, Check for 12 volts on pin 2 of injector damaged circuit wires, Injector 3 shorted to connector.
• Page 226
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check for 0.85 to 1.15 ohms between engine connector pin 1 and ECM connector pin A-M2. Damaged coil, damaged Ignition coil 2 open Check for 12 volts on pin 2 of circuit wires, damaged P0352…
• Page 227
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check for 0.85 to 1.15 ohms between engine connector pin 1 and ECM connector pin A-M2. Damaged coil, damaged Ignition Power Stage Check for 12 volts on pin 2 of circuit wires, damaged P0358…
• Page 228
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check for approximately 2280 Damaged sensor, to 2736 ohms at temperature of Exhaust gas damaged circuit wires, 19 to 21°C (66 to 70°F) between P0545 temperature sensor damaged connector or…
• Page 229
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE ECM EEPROM fault — P062F Damaged ECM. Replace ECM. exchange ECM ECM Fast ADC fault P06B6 (knock detection line) Damaged throttle Throttle positions actuator, damaged Check system circuit, perform…
• Page 230
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Damaged throttle Throttle Actuator Check system circuit, perform closed actuator, damaged — Controller Fault — throttle with B.U.D.S. P160E circuit wires, damaged digital position control Replace throttle actuator, replace connector or damaged…
• Page 231
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Damaged throttle Check system circuit, perform closed actuator, damaged Throttle Actuator — throttle with B.U.D.S. P1621 circuit wires, damaged Abortion of adaptation Replace throttle actuator, replace connector or damaged ECM.
• Page 232
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Safety fuel cut off P16C5 activ — Monitoring level 1 Safety fuel cut off P16C6 activ — Monitoring level 2 Damaged throttle Monitoring fault due actuator, damaged…
• Page 233
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Check cooling system for blockage. Exhaust overheat, Check if the exhaust injection High exhaust P2428 damaged sensor or valve is properly calibrated. temperature detected damaged circuit wires.
• Page 234
  Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (MONITORING SYSTEM AND FAULT CODES) FAULT MODULE DESCRIPTION POSSIBLE CAUSE SERVICE ACTION CODE Cluster fault detected by Check CAN circuits wires. Cluster CAN Time out ECM CAN circuit failure, Replace instrument Cluster. U16A1 error-Missing CAN ID Instrument cluster or Refer to the Service Manual for…

• Page 236: Intelligent Throttle Control (Itc)

  Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) INTELLIGENT THROTTLE CONTROL (iTC) SERVICE TOOLS Description Part Number Page 529 036 179 ……… 215 DIAGNOSTIC HARNESS …………… 529 035 868 ……… 215, 217 FLUKE 115 MULTIMETER …………SERVICE PRODUCTS Description Part Number Page…

• Page 237: Procedures

  Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) While the throttle lever might be fully depressed the driver initiates a full turn. When handlebar is and held, the ECM could close the throttle plate, brought back to its center position, the throttle instead of opening it, if the iBR lever were de- reverts to idle.

• Page 238
  Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-042-005_c smr2009-030-033_a 1. 8-pin connector 2. 12-pin connector Test on the 12-pin Connector of Diagnostic Harness Connect the DIAGNOSTIC HARNESS (P/N 529 036 to make an in-line connection between the 179) WIDE OPEN 12-PIN CONNECTOR…

• Page 239: Cruise Switch

  Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-030-100_a smr2009-030-102_a Step 1: Pry out 1. Route harness here Step 2: Pull out sensor When installation is completed, ensure throttle Revert removal procedure for installation. Pay at- lever works properly. tention to the following.

• Page 240
  Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) smr2009-042-002_a 1. Gauge connector smr2009-036-002_b 2. Pull out to unlock connector 1. Read Data 2. Monitoring tab 6. Use the FLUKE 115 MULTIMETER (P/N 529 035 3. Cluster tab 4. Cruise indicator light 868) If the test succeeded, the switch and wiring are 7.
• Page 241
  Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) 12. Reconnect gauge connector. 13. Properly insert cruise switch wiring in slot in switch support before installing MODE/SET and UP/DOWN arrow switches. smr2009-036-003_a GAUGE CONNECTOR PIN-OUT 3. Attach a string approximately 1.2 m (4 ft) to the end of the wires which will be used for draw- ing the new switch wires through the harness protective sheath.

• Page 242: Electronic Fuel Injection (Efi)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) ELECTRONIC FUEL INJECTION (EFI) SERVICE TOOLS Description Part Number Page 529 014 500 ……… 222 DIGITAL INDUCTION TACHOMETER ……….. 529 036 166 ……225, 235, 242, ECM ADAPTER TOOL…………..246–247, 249, 251 529 035 868 ……

• Page 243: System Description

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) WARNING If any gasoline leak and/or odor are present, do not start the engine. Repair the leak. SYSTEM DESCRIPTION The electronic fuel injection system (EFI) on this engine is based on the open-loop Bosch ME-Motronic system.

• Page 244: Adjustment

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Flame Arrester The flame arrester is a tube inside the intake mani- fold. It prevents flames leaving through the intake system if the engine backfires. EFI Sensors The ECM reads the inputs from the sensors, makes computations, uses pre-determined pa- rameters and activates the outputs (injectors, smr2009-030-019_a…

• Page 245: Closed Throttle Reset

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Use a Install the D.E.S.S. key on its post. DIGITAL INDUCTION TACHOMETER (P/N 529 014 500) Briefly press the START button to wake up the ECM. Engine must not crank. In B.U.D.S., click on the Reset button.

• Page 246: Procedures

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) PROCEDURES It is important to ensure that the mechanical in- tegrity of the engine/propulsion system are intact. ENGINE CONTROL MODULE For diagnostics purposes, use B.U.D.S. software. COMMUNICATION TOOLS AND B.U.D.S. (ECM) SOFTWARE subsection.

• Page 247
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) ECM Power Supply Troubleshooting – Relay contacts open and power to the ECM is cut. ECM Power Supply Diagram – Power is cut on all the electrical system except the GPS supply in the information center. When engine is running and the D.E.S.S.
• Page 248
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) POWER DISTRIBU- – Relay and wiring. Refer to TION – ECM power supply wires and ground wires. See below. ECM Power Supply Test Remove cover of fuse box #2 (FB). Refer to POWER DISTRIBUTION subsection.
• Page 249
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) smr2009-030-010_a If measurement is out of specification, check smr2009-016-026_b LH SIDE OF ENGINE ground bus bar in fuse box #2 and continuity 1. Battery ground cable of its wires and connections with the engine 2.
• Page 250
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) NOTICE Always replace ECM by the same Briefly press the START button to wake up the part number or by an approved equivalent. ECM. Engine must not crank. From B.U.D.S., choose ECM, Replace under Reconnect ECM connectors to ECM.
• Page 251
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Click on the Open button. mmr2009-023-080 smr2009-030-006 Click once on the Folder Up button in the Open IMPORTANT: Ensure to use the file that specifi- box. cally matches the vehicle you are servicing. NOTE: The file name structure is as follows: BUDS version_VIN_date read (yyyymmdd)_hour read (hhmmss).mpem…
• Page 252
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Entering the Collected Information Into the Remove the faulty ECM. Install and connect the new ECM. Use the B.U.D.S. software. Refer to COMMUNI- CATION TOOLS AND B.U.D.S. SOFTWARE sub- section. Install the D.E.S.S.

• Page 253: Fuel Rail

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) 3. Customer name Perform the Closed throttle reset. Refer to ADJUSTMENTS Closed Throttle Reset (TPS) in 4. Enter the old ECM serial number in the Part in this subsection. Replacement under History tab. Click on Add Part in History.

• Page 254
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Rail Removal Cut locking ties retaining engine harness to fuel rail. smr2009-030-027_a 1. Fuel rail Unplug all injector connectors. Pull fuel rail out with fuel injectors. Fuel Rail Installation smr2009-030-011_b Reverse the removal procedure.

• Page 255: Fuel Injector

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) FUEL INJECTOR Fuel Injector Operation Test with B.U.D.S. (Dynamic) COMMUNICATION 1. Connect B.U.D.S. Refer to TOOLS AND B.U.D.S. SOFTWARE. 2. Start engine. 3. Using the B.U.D.S. software, shut down each engine cylinder, one at a time.

• Page 256
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) 5. Fuel pressure must be within specification. Re- FUEL TANK AND FUEL PUMP fer to subsec- tion. Re-activate fuel pump as necessary. 6. In B.U.D.S., energize the fuel injector no. 1. smr2009-030-013_a ACTIVATION AND ECM TABS 1.
• Page 257
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Fuel Injector Input Voltage Test Open seat. AIR INTAKE Remove rear ventilation box. Refer to SYSTEM Disconnect fuel injector connectors. NOTE: Push against tab underneath connector as shown to unlock it. smr2009-030-029_a If input voltage is good, carry out the INJECTOR…
• Page 258
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Disconnect the ECM A connector. Install ECM ADAPTER TOOL (P/N 529 036 166) ECM connector. Remove the long bus bar from fuse box #1. smr2009-030-015_j If continuity is good, wiring and connectors are functional.

• Page 259: Throttle Body

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Insert the fuel injector in place on fuel rail. RESISTANCE @ INJECTOR PIN 20°C (68°F) Secure injector to fuel rail with its clip. See above FUEL RAIL Install fuel rail. Refer to in this subsec- tion.

• Page 260
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Throttle-Body Faults and Effects NOTE: Among other things, a weak or broken spring and a sticky throttle plate (carbon build-up, dried salt water etc) are validated by the throttle body diagnostic mode. FAULT EFFECT Limp home mode.
• Page 261
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) NOTICE Only use an appropriate throttle WARNING body cleaner that will not damage O-rings and Keep your fingers out of the throttle plate EFI sensors. area while the ECM turns on. The throttle actuator will cycle.

• Page 262: Tps (Throttle Position Sensor)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Throttle plate must fully open and when released, must return freely to the rest position (slightly opened). Push throttle plate where shown. It must com- pletely close and when released, freely return to the rest position (slightly opened).

• Page 263
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Install the D.E.S.S. key on its post. Briefly press the START button to wake up the ECM. Do not start engine. COMMUNICATION Connect B.U.D.S. Refer to TOOLS AND B.U.D.S. SOFTWARE. In B.U.D.S., select the Monitoring tab then the ECM tab.

• Page 264: Crankshaft Position Sensor (Cps)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-005_a If any resistance value is incorrect, check wire smr2008-023-016_a continuity between ECM and throttle body. If TYPICAL continuity is good, replace throttle body. Install the D.E.S.S. key on its post. If resistance values are correct, try a new ECM.

• Page 265
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) BODY Remove deck extension. Refer to Remove air intake silencer. Refer to AIR INTAKE SYSTEM PTO HOUS- Drain oil from PTO housing. Refer to ING AND MAGNETO NOTE: It is not necessary to drain oil from engine. Disconnect CPS connector.

• Page 266: Camshaft Position Sensor (Caps)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Trigger Wheel Inspection CAPS CONNECTOR MEASUREMENT Refer to PTO HOUSING AND MAGNETO in the VOLTAGE ENGINE section. Battery voltage CAMSHAFT POSITION SENSOR (CAPS) smr2009-030-035_a CAPS DY- If battery voltage is read, proceed with NAMIC TEST further.

• Page 267
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2007-050-004 They can be inserted at the end of the standard probes of the FLUKE 115 MULTIMETER (P/N 529 035 868) smr2009-027-011_f 1. Pull out Use the FLUKE 115 MULTIMETER (P/N 529 035 868) and select Read resistance of the CAPS circuit.

• Page 268: Manifold Air Temperature Sensor (Mats)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) smr2009-030-034_a 1. CAPS connector Unscrew the retaining screw. smr2007-021-009_c 1. Metallic object Pull out CAPS from engine. Install the CAPS. Ensure to reinstall O-ring. If voltage is appropriate, check/repair wiring/con- nector between sensor and ECM.

• Page 269
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) TEMPERATURE RESISTANCE (OHMS) °C °F NOMINAL HIGH — 30 — 22 12600 11800 13400 — 20 11400 11000 11800 — 10 9500 8000 11,000 5900 4900 6900 3800 3100 4500 2500 2200 2800…

• Page 270: Coolant Temperature Sensor (Cts)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) COOLANT TEMPERATURE If resistance tests good, reconnect the CTS con- nector and disconnect the ECM connector A on SENSOR (CTS) the ECM. Using a multimeter and the ECM ADAPTER TOOL , check the circuit resistance as (P/N 529 036 166) per table.

• Page 271: Manifold Absolute Pressure Sensor (Maps)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) AIR INTAKE Remove rear ventilation box. Refer to SYSTEM Remove deck extension. Refer to BODY Disconnect CTS connector and remove CTS. Install the new CTS and torque to 18 N•m (159 lbf•in).

• Page 272: Exhaust Gas Temperature Sensor (Egts)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) Using a multimeter and the ECM ADAPTER TOOL , check the resistance of circuit (P/N 529 036 166) A-B4, A-G4 and A-H2. If wiring harness is good, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this sec- tion.

• Page 273: Knock Sensor (Ks)

  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) KNOCK SENSOR (KS) vmr2008-022-005_a If resistance value is correct, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this sec- tion. If resistance value is incorrect, repair the connec- tor or replace the wiring harness between ECM connector and the EGTS.

• Page 274
  Section 04 FUEL SYSTEM Subsection 02 (ELECTRONIC FUEL INJECTION (EFI)) vmr2008-022-005_a If wiring harness is good, check ECM. Refer to ENGINE CONTROL MODULE (ECM) in this sec- tion. smr2009-030-038_a 1. KS connector Otherwise, repair the connector or replace the wiring harness between ECM connector and Using a multimeter, check the resistance be- knock sensor.

• Page 276: Fuel Tank And Fuel Pump

  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number Page 529 036 179 ……… 271 DIAGNOSTIC HARNESS …………… 529 036 166 ……… 265 ECM ADAPTER TOOL…………..529 035 868 ……… 265, 272 FLUKE 115 MULTIMETER …………

• Page 277
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP smr2009-031-001_a smr2009-031…
• Page 278
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL SYSTEM DIAGNOSTIC FLOW CHART smr2009-031-028_en smr2009-031…

• Page 279: General

  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) GENERAL NOTICE Whenever repairing the fuel system, always check for water infiltration in the fuel WARNING tank. Replace any damaged, leaking or deteri- orated fuel line. Fuel lines remain under pressure at all times. Always proceed with care and use appro- SYSTEM DESCRIPTION priate safety equipment when working on a…

• Page 280
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) When the START button is pressed, the electrical system is powered. The fuel pump will come on for approximately 2 seconds to pressurize the fuel rail in preparation for the engine start. The ECM supplies the ground signal to turn on the fuel pump motor.

• Page 281: Inspection

  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-002_c 1. Outlet valve smr2009-031-008_a If pressure in fuel tank build up and exceed 1. Ventilation box 2.8 kPa — 7.6 kPa (.4 PSI — 1.1 PSI), the outlet valve opens and let excess pressure evacuate outside Visually inspect condition of hoses and clamps.

• Page 282
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-101_a TEST SETUP mmr2009-121-004_a Slowly apply pressurized air. 1. Y-fitting P/N 293 710 059 2. Check valve P/N 275 500 505 NOTE: If pressure rises quickly within a few 3.
• Page 283
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) WARNING If a leak is found, do not start the engine. Wipe off any fuel that leaked and ventilate the hull thoroughly to remove any accu- mulated fuel vapors. Do not use electric powered tools on watercraft unless system has passed the leak test.
• Page 284
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Set the vacuum/pressure pump to vacuum. smr2009-031-012_a 1. Pressure selected smr2009-031-013_a Squeeze the vacuum/pressure pump handle sev- 1. Vacuum selected eral times to pressurize air to the inlet valve. Install a SMALL HOSE PINCHER (P/N 295 000 076) near outlet valve.

• Page 285: Fuel System High Pressure Leak Test

  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) FUEL SYSTEM HIGH PRESSURE LEAK TEST WARNING A high pressure leak test must be carried out before starting the engine anytime a fuel system component has been disconnected for maintenance, or replacement. Visually inspect fuel system to ensure all fuel sys- tem connections are installed.

• Page 286: Procedures

  Inspect all clamps for tightness. Fuel Hose Replacement smr2009-031-019_a When replacing fuel lines on all SEA-DOO wa- FUEL PUMP PRESSURE TEST tercraft models, be sure to use “A1” type hose 1. Valve on gauge approved by BRP for pressurized hoses, and…

• Page 287: Fuel Pump

  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) “B1” type hose approved by BRP for ventilation hoses. These hoses available from BRP meet our system requirements and will ensure continued proper and safe operation. WARNING Use of fuel lines other than those recom- mended by BRP may compromise fuel sys- tem integrity.

• Page 288
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-030-024_a 1. Throttle body 2. Inlet hose 3. Connector Remove D.E.S.S. key from its post to prevent en- gine starting. Press START button. smr2008-022-017_b The fuel pump should run for 2 seconds to build If battery voltage is read, power circuit is good.
• Page 289
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) 529036166 Set multimeter to and test pump circuit as per following table. smr2009-031-021_a PUMP CIRCUIT TEST THROUGH FUEL PUMP RESISTANCE @ TEST PROBES 20°C (68°F) Fuse box #1 connector B Approx.
• Page 290
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) smr2009-031-008_a smr2009-031-022_a 1. Ventilation box 1. Fuel pump module socket 2. Fuel pump retaining nut Disconnect the negative battery terminal, refer to CHARGING SYSTEM subsection. NOTICE While pulling out the fuel pump module, pay attention to the corrugated tubes Disconnect fuel pump electrical connector.

• Page 291: Fuel Filter

  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) WARNING Always wipe off any fuel spillage from the watercraft. When working with fuel or fuel system and its components, always work in a well ventilated area. Fuel Pump Installation Reverse the removal procedure however, pay at- tention to the following.

• Page 292: Fuel Tank

  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Press new filter on by hand. Ensure it is fully NOTE: A fuel tank is comprised of 2 components: seated and locked onto the pump reservoir hous- the tank and the filler neck. The necks are injec- ing.

• Page 293
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Place fuel tank retaining strap ends in anchoring clips. Temporarily use tape to hold straps on the top of fuel tank. smr2009-031-017_b 1. Quick connect fitting (high pressure fuel hose) 2.

• Page 294: Fuel Level Sensor

  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Fuel Level Troubleshooting FUEL LEVEL TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE – Wiring/connectors Fuel gauge always – Fuel level sensor display EMPTY – Float stuck in low position – Water in fuel pump Fuel gauge always connector display FULL…

• Page 295
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Remove diagnostic harness and reconnect con- nector. Fuel Level Sensor Resistance Test at Information Center Disconnect information center (multifunction gauge) connector. Refer to GAUGE subsection. Use the FLUKE 115 MULTIMETER (P/N 529 035 868) and select 529036179 Alternately drain then fill fuel tank and measure…
• Page 296
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Fuel Level Sensor Removal smr2008-022-018_f TYPICAL — FUEL PUMP MODULE smr2008-022-029 1. Fuel pump module connector FUEL LEVEL SENSOR Alternately drain then fill fuel tank and measure Remove fuel pump module from fuel tank, see the sensor resistance between pins C and D of the FUEL PUMP REMOVAL in this subsection.
• Page 297
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Once the pressure regulator is rotate over the locking tab, pull up on it to remove it from the pump reservoir cover. smr2008-022-022_a 1. Pressure regulator 2. Ground wire contact on pressure regulator 3.
• Page 298
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Align the fuel pressure regulator tabs into the pump reservoir cover and turn it counterclock- wise until it locks properly. smr2008-022-026_a 1. Fuel level sensor release tabs 2. Locking pins smr2008-022-025_b PRESSURE REGULATOR INSERTION INTO PUMP RESERVOIR COVER…
• Page 299
  Section 04 FUEL SYSTEM Subsection 03 (FUEL TANK AND FUEL PUMP) Ensure fuel level sensor connector is locked into the module flange connector. smr2008-022-021_a 1. Fuel level sensor connector FUEL LEVEL SENSOR RESISTANCE Carry out a TEST as described in this subsection. FUEL Reinstall the fuel pump module.

• Page 300: Controller Area Network (Can)

  Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) CONTROLLER AREA NETWORK (CAN) SERVICE TOOLS Description Part Number Page 529 036 166 ……… 279 ECM ADAPTER TOOL…………..529 035 868 ……… 279 FLUKE 115 MULTIMETER …………GENERAL SYSTEM DESCRIPTION The CAN (Controller Area Network) protocol is an ISO standard for serial data communication.

• Page 301: Troubleshooting

  Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) TROUBLESHOOTING DIAGNOSTIC TIPS MONITORING Check the fault codes using B.U.D.S. software as a first troubleshooting step. Refer to SYSTEM/FAULT CODES section. CAN Communication Problems The following chart gives some symptoms and behaviors relative to the CAN component in cause. The list is not exhaustive, only the most significant items are given to help troubleshooting.

• Page 302
  Section 05 ELECTRICAL SYSTEM Subsection 01 (CONTROLLER AREA NETWORK (CAN)) CAN Continuity Tests The following gives an example between the CAN LO wire and the ECM. If a communication problem is present, perform the appropriate continuity test relating to the com- NOTE: When working with the ECM, install the ponent reported by B.U.D.S.

• Page 304: Power Distribution

  Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) POWER DISTRIBUTION SERVICE TOOLS Description Part Number Page 529 035 868 ……… 287 FLUKE 115 MULTIMETER …………SERVICE PRODUCTS Description Part Number Page 293 550 004 ……… 286 DIELECTRIC GREASE …………..smr2009-049…

• Page 305
  Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) SIMPLIFIED ELECTRICAL SYSTEM SCHEMATIC smr2009-027-008_en smr2009-049…

• Page 306: General

  Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) GENERAL It is highly recommended to disconnect the bat- tery when replacing any electric or electronic com- ponent. WARNING Always disconnect battery exactly in the specified order, BLACK (-) cable first, RED (+) cable last.

• Page 307: Power Distribution

  Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) Fuse box Cover Installation When installing a fuse box cover, ensure the seal is properly seated. If the seal has been removed, ensure to reinstall it as illustrated. smr2009-016-011_a FRONT OF ENGINE 1.

• Page 308
  Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) smr2009-027-011_a smr2009-027-010_b FUSE BOX 1 — BUS BAR IDENTIFICATION FUSE BOX 2 — BUS BAR IDENTIFICATION 1. Primary switched power 1. 12 Vdc from battery 2. Secondary switched power 2. 12 Vdc from battery 3.

• Page 309: Troubleshooting

  Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) If B.U.D.S. is being used for communicating with Keep in mind that an electrical component may the electronic modules, or if the information cen- require more than one fuse, one low amperage ter must be ON for testing, selecting modes of rated fuse for its control circuit, and another higher operation, changing key settings, or for other…

• Page 310: Procedures

  Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) – Check the ECM fuse in FB2. If no voltage is measured, test the wire jumper between FB1-D6 and FB2-A10. – Check the GAUGE fuse in FB1. Also test for a voltage drop across the power relay If you cannot feel the power relay activating when main contact between the long bus-bar in FB2-B7 pressing the START button, or if you suspect that…

• Page 311
  Section 05 ELECTRICAL SYSTEM Subsection 02 (POWER DISTRIBUTION) smr2007-027-060_a TERMINAL RESISTANCE max. (continuity) smr2009-049…

• Page 312: Ignition System

  Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page 529 036 166 ……… 292 ECM ADAPTER TOOL…………..529 035 868 ……… 291 FLUKE 115 MULTIMETER …………SERVICE PRODUCTS Description Part Number Page 413 707 000 ……… 293 DOW CORNING 111 …………..

• Page 313: Ignition System Testing

  Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) IGNITION SYSTEM TESTING ENGINE WILL NOT START (ENGINE TURNS OVER) NOTE: It is a good practice to check for fault 1. Fouled or defective spark plug codes using B.U.D.S. software as a first trou- COMMUNICATION bleshooting step.

• Page 314
  Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr2008-024-005_b smr2009-032-001_a IGNITION COIL INPUT VOLTAGE TEST IGNITION COIL ACTIVATION 1. Activation tab IGNITION COIL If test succeeded, refer to 2. ECM tab 3. Click on the desired ignition coil POWER CIRCUIT TEST You should hear the spark occurring.
• Page 315
  Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr2009-030-015_h If test succeeded, wiring and connectors are func- tional. smr2007-023-003_d If test failed, repair/replace wiring from fuse box IGNITION COIL CONTROL CIRCUIT TEST terminal to ignition coil. If test failed, repair the connector or replace the Reinstall bus bar and cover.

• Page 316: Ignition Coil Installation

  Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) smr05-015-002_b SECONDARY WINDING RESISTANCE @ CIRCUIT TERMINAL 20°C (68°F) Secondary 1 and spark sbs2009-011-001_a 9.5 — 13.5 k winding plug terminal 1. Apply product here 3. Pull rubber seal back on its seat making sure the If any test failed, replace ignition coil.

• Page 317: Spark Plugs

  Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) Unscrew spark plug then use the ignition coil to take spark plug out of spark plug hole. smr2009-032-004_a 1. Seal properly seated SPARK PLUGS Spark Plug Removal smr2009-032-003_a Open seat. 1. Ignition coil 2.

• Page 318
  Section 05 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) the spark plug at prescribed intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber). Spark Plug Installation Prior to installation, ensure the contact surfaces of the cylinder head and spark plug are free of grime.

• Page 320: Charging System

  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page 295 500 352 ……… 302 ENGINE LEAK TEST KIT…………..SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page ……… 306 ELECTRO SPECIALTIES BATTERY LOAD TESTER……. 380941 ………

• Page 321: Inspection

  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) INSPECTION CHARGING SYSTEM OUTPUT First ensure that battery is in good condition prior to performing the following tests. NOTE: It is good practice to check for fault codes using the B.U.D.S. software as a first MONITORING troubleshooting step.

• Page 322
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) TEST ENGINE CURRENT SPEED Approx. 10 A (while 5500 RPM suspension does not move) NOTE: Initial current reading will be higher than specified due to the battery drain from the engine start. This is an indication that the charging sys- tem is operating normally.

• Page 323: Procedures

  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) VOLTAGE OUTPUT CURRENT TEST REGULATOR/RECTIFIER TEST ENGINE CURRENT (DC) Voltage Regulator Continuity Test SPEED Due to internal circuitry, there is no static test Approx. 10 A (while 5500 RPM available to check continuity. suspension does not move) Voltage Regulator/Rectifier NOTE: Initial current reading will be higher than…

• Page 324: Battery

  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) Voltage Regulator/Rectifier Installation NOTE: “Key Off” or parasitic loads may be loads due to installed accessories. Parasitic loads may Installation is the reverse of removal procedure. also be due to water infiltration in connectors, or However, pay attention to the following.

• Page 325
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) Use the vacuum/pressure pump in the Set vacuum/pressure pump to VACUUM. ENGINE LEAK TEST KIT (P/N 295 500 352) 295500352 smr2009-031-013_a 1. Vacuum selected Set vacuum/pressure pump to PRESSURE. Squeeze the vacuum/pressure pump handle sev- eral times to draw air in through the check valve.

• Page 326: Battery Removal

  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) ssi2009-002-003_a 1. Storage bin 3. Disconnect the diagnostic connector from its smr2006-023-003_a holder. Battery Removal WARNING The BLACK negative battery cable must al- ways be disconnected first and reconnected last. Never charge or boost battery while in- stalled in watercraft.

• Page 327
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) 6. Remove the electrical component support from the battery holder. 6.1 Lift and push the top of electrical compo- nent support forward to unlock it from bat- tery holder. smr2009-033-009_a 1. Disconnect here 9.
• Page 328
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) NOTICE Should any electrolyte spillage oc- cur, immediately wash off area with a solution of baking soda and water, then rinse thor- oughly. Remove retaining screws from battery holder if applicable. smr2009-005-006 Remove battery holder from battery.
• Page 329
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) Battery Voltage Test (No Load) WARNING NOTE: Be aware that the voltage test can indi- Battery electrolyte is caustic. To prevent cate that the battery is in good condition even spillage, ensure battery cell caps are suffi- though the battery does not have enough stored ciently tight to properly seal each cell.

• Page 330: Battery Storage

  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) The battery must always be stored fully charged. ELECTROLYTE OPERATION TO If required, recharge until the recommended spe- TEMPERATURE PERFORM cific gravity obtained prior to storage. °C °F NOTICE .012 Battery electrolyte temperature Add to the must not exceed 50°C (122°F) during charging.

• Page 331
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) WARNING Failure to remove the sealing tube could re- sult in an explosion. 1. Remove caps and fill battery to UPPER LEVEL line with electrolyte (specific gravity: 1.265 at 21°C (70°F)). NOTE: This battery may fill slower than others due to the anti-spill check ball design.
• Page 332
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) For best results, battery should be charged when it is at room temperature. A battery that is cold may not accept current for several hours after charging has begun. Do not charge a frozen battery. If the battery charge is very low, the battery may freeze.
• Page 333
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) NOTE: Some chargers have a polarity protec- 5. Remove the temporary hose used to plug the tion feature which prevents charging unless the battery vent. charger leads are connected to the correct battery 6.
• Page 334
  Section 05 ELECTRICAL SYSTEM Subsection 04 (CHARGING SYSTEM) ssi2009-002-005_a 1. BLACK (-) cable 2. RED (+) cable 10. Apply dielectric grease on battery posts. 11. Verify cable routing and attachments. 12. Insert diagnostic connector in its holder. 13. Install remaining removed components. smr2009-033…

• Page 336: Starting System

  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 179 ……… 315 DIAGNOSTIC HARNESS …………… 529 036 166 ……… 317–319 ECM ADAPTER TOOL…………..529 035 868 ……… 315–318 FLUKE 115 MULTIMETER …………SERVICE PRODUCTS Description Part Number…

• Page 337: Procedures

  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) STARTER TURNS, BUT STARTER DRIVE 3. Discharged battery DOES NOT MESH WITH RING GEAR — Check/recharge. Refer to CHARGING SYSTEM. 1. Worn starter drive gear 4. Defective START/STOP switch — Replace starter drive. Refer to PTO HOUSING — Check.

• Page 338: Engine Start/Stop Switch

  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) NOTE: The solenoid may be the cause of a burnt Measure resistance through switch as per follow- fuse (F4). ing table. If fuse is good, proceed with the STARTER QUICK START/STOP SWITCH OPERATION TEST TEST 8-PIN CONNECTOR…

• Page 339
  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) If test succeeded, problem is in the control circuit START/STOP SWITCH INPUT VOLTAGE TEST START/STOP SWITCH going to ECM. Perform the 8-PIN CONTROL CIRCUIT TEST CONNECTOR SWITCH VOLTAGE Start/Stop Switch Power Circuit Test POSITION DIAGNOSTIC START/STOP…

• Page 340: Starter Solenoid

  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) POWER CIRCUIT TEST CONTROL CIRCUIT TEST 8-PIN 8-PIN CONNECTOR CONNECTOR FUSE BOX 2 RESISTANCE CONNECTOR RESISTANCE OF DIAGNOSTIC OF DIAGNOSTIC HARNESS HARNESS Close to 0 Close to 0 Pin 2 Terminal B2 Pin 1 B-D1 (continuity)

• Page 341
  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) smr2009-034-006_a SOLENOID CON- If test succeeded, carry out a TROL CIRCUIT TEST smr2009-034-002_c 1. Fuse box 2 POWER CIRCUIT TEST If test failed, carry out a as follows. Solenoid Input Voltage Test (at Solenoid Connector) Solenoid Power Circuit Test Disconnect solenoid connector.
• Page 342
  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) SOLENOID CONTROL CIRCUIT TEST SOLENOID CONNECTOR RESISTANCE CONNECTOR Close to 0 Pin B B-L4 (continuity) smr2009-034-008_a If test failed, replace solenoid. If test succeeded, perform the following test. Disconnect battery negative cable. smr2009-034-006_c Test solenoid main contacts as per following table.
• Page 343
  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) Solenoid Dynamic Test SOLENOID DYNAMIC TEST (ENGINE CRANKING) Ensure battery and starter solenoid are properly TEST PROBES VOLTAGE (DC) connected. Solenoid Solenoid 0.2 Vdc max. Set ECM in engine drowned mode: Depress battery post starter post throttle lever and install a rubber band to hold…
• Page 344
  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) smr2009-034-005_a smr2009-034-002_d 1. Cables 1. Fuse box 2 2. Diagnostic connector Solenoid Installation 3. Electrical component support 4. Voltage regulator/rectifier connectors Revert removal operations and pay attention to 5. Starter solenoid connector the following.

• Page 345: Starter

  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) NOTE: It may be necessary to pull retaining tab to BLACK booster cable: ensure proper locking. Connect one clip to the negative (-) battery termi- Wiggle solenoid to ensure it is securely locked. nal in the vehicle.

• Page 346: Starter Installation

  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) Starter Gear Installation Disconnect starter power cable. Remove starter retaining screws. Installation is the reverse of removal procedure. However, pay particular attention to the following. Use a new circlip. Starter Installation Installation is the reverse of the removal proce- dure.

• Page 347
  Section 05 ELECTRICAL SYSTEM Subsection 05 (STARTING SYSTEM) WARNING To prevent electric shock whenever connect- ing the RED power cable to the starter motor, ensure the BLACK (-) battery cable is discon- nected. Apply on ter- DIELECTRIC GREASE (P/N 293 550 004) minal and nut.

• Page 348: Digitally Encoded Security System (D.e.s.s.)

  Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) SERVICE TOOLS Description Part Number Page 529 036 179 ……… 330 DIAGNOSTIC HARNESS …………… 529 036 166 ……… 331 ECM ADAPTER TOOL…………..529 035 868 ……… 330 FLUKE 115 MULTIMETER …………

• Page 349: Procedures

  Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) Start B.U.D.S. and logon. BEEPER SIGNIFICATION IMPORTANT 2 short Indicate a working D.E.S.S. key. beeps Engine starting can take place. Approximately 3 minutes after pressing the START button, the ECM will stop communicating with Indicates a wrong D.E.S.S.

• Page 350
  Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) smr2009-035-003_c After approximately 10 seconds, the following window will pop up confirming the new key has smr2009-035-005_a been saved in the PC computer. 1. Key to be erased Click on Erase Key button at bottom of B.U.D.S. screen.
• Page 351
  Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) If programming is complete, write the changes to After the write operation, remove key from WRITING CHANGES TO ECM the ECM. Refer to D.E.S.S. post. in this subsection. Try the key(s) on the watercraft. Erasing All Keys Setting Maximum Speed for Learning Click on Erase All Keys button at bottom of…
• Page 352
  Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) sdd2009-001-024_e 1. MODE button smo2009-002-114_c NOTE: Pressing the SET button twice will enable the Rental key setting function. 6. Press the UP or DOWN arrow button to tog- gle the key setting between 1 and 5. Refer to MAXIMUM WATERCRAFT SET SPEED TABLE smo2009-002-114_b 5.

• Page 353: Beeper

  Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) MAXIMUM WATERCRAFT SET SPEED TABLE D.E.S.S. KEY APPROX. KEY SETTING TYPE MAX. SPEED 58 km/h (36 MPH) 55 km/h (34 MPH) 50 km/h 529036179 Learning key (31 MPH) NOTE: Plug only the connector that has been dis- 47 km/h connected.

• Page 354
  Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) smr2009-035-001_b D.E.S.S. Key on Post Probe D.E.S.S. post terminals to check continuity as follows. smr2009-042-005_b 8-PIN CONNECTOR RESISTANCE 1. 8-pin connector here D.E.S.S. POST HARNESS @ 20°C (68°F) Set multimeter to Pin 3 Pin 5 Close to 0…
• Page 355
  Section 05 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) 8-PIN CONNECTOR ECM ADAPTER RESISTANCE D.E.S.S. POST VEHICLE TOOL @ 20°C (68°F) HARNESS B-E4 B-B2 Close to 0 B-F2 smr2009-035-009_a Reinstall removed components. If any continuity test failed, check wiring harness between D.E.S.S.

• Page 356: Gauge

  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) GAUGE SERVICE TOOLS Description Part Number Page 529 035 868 ……… 344, 353 FLUKE 115 MULTIMETER …………SERVICE PRODUCTS Description Part Number Page 293 550 004 ……333, 350, 354 DIELECTRIC GREASE …………..GENERAL 2.

• Page 357: Procedures

  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) PROCEDURES tion). This self test function allows the driver time to ensure that all indications are functioning properly. INFORMATION CENTER It also validates the information centers internal Information Center Overview circuits, however, this does not validate proper op- eration of the individual external circuits and sen- The information center (cluster) is a multifunction sors that provide inputs to the information center.

• Page 358
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Gauge Description smo2009-002-119_a 1. Speedometer 2. Tachometer 3. Digital screen 4. Indicator lights 5. Fuel level 6. VTS position 7. iS position 8. Numerical display 9. Multifunction display 10. Depth sounder indicator 11. Water temperature display 12.
• Page 359
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) The numerical and multifunction displays in the PILOT MESSAGE digital screen can be used to display various indi- LAMPS DESCRIPTION DISPLAY cations, or for selecting modes of operation and (ON) changing settings as explained in their respective CRUISE mode or subsections.
• Page 360
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) A single segment of a bar gauge type indicator is pears and a single segment of the bar gauge is turned on to indicate the relative position of the turned on to indicate the position of the suspen- watercraft bow.
• Page 361
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 9) Multifunction Display When the watercraft is being operated, the multi- function displays provides and indication of com- pass direction, scrolling messages from the fault monitoring system, or a scrolling DOCK MODE ON message when the function is active. The display also allows for the selection of vari- ous functions which, permit changing the numeri- cal display indication, system modes of operation,…
• Page 362
  TEM AND FAULT CODES subsection. AUTOMATIC Automatic suspension MESSAGE DISPLAY INFORMATION SUSPENSION acknowledgement WELCOME ABOARD Power up display Manual suspension SEA-DOO MANUAL SUSPENSION acknowledgement NORMAL KEY Normal key detected MODE/SET, UP/DOWN RIGHT KEYPAD ERROR arrow button LEARNING KEY Learning key detected…
• Page 363
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) MESSAGE DISPLAY INFORMATION CALIBRATION Cluster programming CHECKSUM ERROR corrupted MAINTENANCE Watercraft maintenance REQUIRED required SUPERCHARGER Maintenance on MAINTENANCE supercharger required REQUIRED 10) Depth Sounder Indicator GTX Limited iS Model NUMERICAL DISPLAY can be selected to smo2009-002-114_t provide an indication of the lake water depth.
• Page 364
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Setting Language and Units of Measurement Connect vehicle to the latest applicable B.U.D.S. COMMUNICATION TOOLS software, refer to the AND B.U.D.S. SOFTWARE subsection. 1. Press the START/STOP button to energize the electrical system. NOTE: You will need to press the START button every three minutes or the electrical system will shut off.
• Page 365
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Clearing the Maintenance Reminder Information Center Pin-Out Indicators INFORMATION CENTER PIN-OUT When the watercraft, engine or supercharger is FUNCTION due for maintenance, the maintenance reminder indicator light in the speedometer will come on, GPS back-up power and a scrolling MAINTENANCE REQUIRED or CAN HI…
• Page 366
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Double click the iS button to move the suspen- Carry out a continuity check of the CAN bus wires sion to the up position. If the suspension does not from the CAN bus-bars in FB2 to the information WIRING DIA- move to the up position, the problem is related center (pins 2 and 3).
• Page 367
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Information Center Input Voltage Test NO Speed or Compass Indication (at Gauge Connector) If there is no speed or compass indication, look for the GPS indicator icon. If the GPS indicator is 1. Remove the gauge support cover, refer to off, either the GPS cannot uplink with the satel- FORMATION CENTER REMOVAL in this sub-…
• Page 368
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 4. Carry out an input voltage test at the steering connector (vehicle harness side) as per follow- ing table. INFORMATION CENTER INPUT VOLTAGE TEST (STEERING CONNECTOR) INFORMATION CENTER VOLTAGE STEERING CONNECTOR Pin 7 (Violet) Pin 6 (Black) Battery voltage Pin 7 (Violet)
• Page 369
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) smr2009-027-011_g VOLTAGE TEST AT FUSE CONTACTS smr2009-036-006_a BATTERY VOLTAGE TEST 7. Remove the cover from fuse box 2 (FB2). smr2009-027-011_d TYPICAL — CONTACT COORDINATES (FRONT VIEW FB1) If battery voltage is measured at A12 but not at A11 (with fuse installed), replace the fuse.
• Page 370
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Continuity Test of Gauge Power Wire 5. Set multimeter to setting. 1. Remove lanyard. 6. Test the information center power wire continu- ity as per following table. 2. Disconnect gauge connector. CONTINUITY TEST OF GAUGE POWER WIRE NOTICE Pull connector lock out sideways.
• Page 371
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) BODY Remove the RH rear storage bin, refer to subsection. Remove the cover from fuse box 2. smr2009-036-005_a 12 PIN STEERING CONNECTOR PIN-OUT (VEHICLE SIDE) A. Connector alignment keys 2009-027-009_a 1. Fuse box #1 2.
• Page 372
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) smr2009-036-003_a GAUGE CONNECTOR PIN-OUT smr2009-027-010_f TYPICAL — CONTACT COORDINATES (FRONT VIEW FB2) Repair wiring and connectors as required. Information Center Removal 1. Open the front cover. 2. Move the steering to its highest position, refer BODY subsection.
• Page 373
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) Information Center Installation Installation of the information center is the reverse of the removal procedure. However, pay attention to the following. 1. Insert and align the bottom of the gauge into the support first, then push the top into the sup- port and ensure it properly locks into the retain- ing tab.

• Page 374: Mode/Set And Up/Down Arrow Buttons

  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) smr2009-036-011_b smr2009-036-011_c 1. Read Data button 1. Reset Supercharger maintenance button 2. Vehicle page tab 3. Total Hours NOTE: Replacement information centers are de- 4. Supercharger maintenance hours (approximate time left) livered already programmed. 4.

• Page 375
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If the MODE switch is pressed, 2 diodes are by- 2. Press the START/STOP button to energize the passed. The remaining two diodes in the circuit electrical system. drop 1.2 Vdc (at pin B). NOTE: You will need to press the START button If the SET switch is pressed, 1 diode is bypassed.
• Page 376
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If one or all of the indicator lights does not come 4. Test the MODE/SET and UP/DOWN arrow MODE/SET AND UP/DOWN ARROW on, refer to switches as per following tables. SWITCH TEST USING A MULTIMETER MODE/SET SWITCH TEST MODE/SET and UP/DOWN Switch Test SWITCH…

• Page 377: Water Temperature Sensor

  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) If voltages measured on every switch are as spec- 6. Install connector on new switch assembly. ified (or very close to it), the switches and the 7. Insert switch assembly in switch support. wiring harness are good.

• Page 378: Depth Sounder

  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) DEPTH SOUNDER Depth Sounder Removal 1. Open the boarding platform. GTX Limited iS Models Depth Sounder Troubleshooting DEPTH SOUNDER TROUBLESHOOTING POSSIBLE SYMPTOM REMEDY CAUSE Depth sounder Properly connect not connected. depth sounder. Make sure depth sounder is properly installed in…

• Page 379
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 5. Remove the battery (with holder) from the wa- CHARGING SYSTEM tercraft, refer to WARNING Always disconnect the battery cables exactly in the specified order, BLACK (-) battery cable first then the RED (+) cable last. 6.
• Page 380
  Section 05 ELECTRICAL SYSTEM Subsection 07 (GAUGE) 6. Install the diagnostic connector in its holder. 7. Carry out the following procedure: TESTING DEPTH SOUNDER OPERATION Testing Depth Sounder Operation 1. Press START/STOP button. 2. Install the D.E.S.S. key on the D.E.S.S. post. 3.

• Page 382: Steering And O.t.a.s

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) STEERING AND O.T.A.S. SERVICE TOOLS Description Part Number Page 529 035 943 ……… 364 D.E.S.S. POST REMOVER …………529 036 166 ……… 370 ECM ADAPTER TOOL…………..529 035 868 ……… 370 FLUKE 115 MULTIMETER …………

• Page 383
  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-001_a smr2009-037…

• Page 384: General

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) GENERAL ADJUSTMENT During assembly/installation, use torque values STEERING ALIGNMENT and service products as in the exploded view. Raise the iBR gate by activating the iBR override Clean threads before applying a threadlocker. Re- IBR AND VTS function.

• Page 385: Inspection

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-042-007_a 1. Steering column 2. Steering column clamp bolts 3. Steering column clamp 4. Steering cable adjusting nut smr2009-037-034_a After adjustment, torque steering column clamp MONITORING AND IBR TABS 1. O.T.A.S. «LED» bolts to 6 N•m (53 lbf•in).

• Page 386: Handlebar Grip

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-007_a 1. Grip insert smr2009-037-041_a 1. Nozzle NOTE: Verify grip insert for damage. 2. Nozzle arm 3. Hexagonal screw 4. Nozzle link rod Handlebar Grip Installation 5. Socket screw 6. VTS trim ring When installing the grip insert in the handlebar, ensure that it is properly inserted in the slot at the Remove nozzle from watercraft.

• Page 387: Handlebar Switch Cover (Lh Or Rh)

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-009_a 1. Grip insert 2. Grip 3. Flat washer 4. Screw smr2009-037-012_a 5. Cap RH SIDE SHOWN 1. Front tab HANDLEBAR SWITCH COVER (LH Press on the cover to lock it. OR RH) STEERING COVER Handlebar Switch Cover Removal (LH…

• Page 388
  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 3. Unlock steering cover from steering. 3.4 Remove foam inside the steering cover. 3.1 Insert a small tool, such as an Allen key, 3.5 Remove D.E.S.S. post from steering into a steering cover hole. Press the tool cover.

• Page 389: Throttle And Ibr Levers

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) smr2009-037-019_a smr2009-037-031_a 1. Harness slots 1. Retaining screw 2. Washer 5.2 Clip the top of the cover. 3. Bushings 4. Throttle lever 5.3 Stretch the bottom of the steering cover until the cover edge passes over the inner 4.

• Page 390
  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 2. Remove the adjusting nut from steering cable end. 3. At the rear of the vehicle, disconnect ball joint from jet pump nozzle arm. smr2009-037-022_a 1. Steering cable 2. Steering cable nut 6.

• Page 391: Steering Column

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) GAUGE 2. Remove the gauge support. Refer to subsection. 3. Disconnect the four connectors under moving deck. smr2006-031-006_a A. 9 mm ± 1 mm (.354 in ± .039 in) 11.2 Tighten jam nut to 2.5 N•m (22 lbf•in). 11.3 Position the steering cable ball joint to the nozzle as per following illustration.

• Page 392: Steering Column Support

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) 3. On both side of vehicle, remove both pivot bushings (steering column support and steer- ing adjustment handle). smr2009-037-028_a 1. Upper bushing 2. Steering column support 3. Lower bushing smr2009-037-033_a Check wear sleeve behind the steering column 1.

• Page 393: O.t.a.s. Switch

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) O.T.A.S. SWITCH O.T.A.S. Switch Power Wire Continuity Test Check continuity between O.T.A.S. switch 3-pin O.T.A.S. Switch Dynamic Test connector and fuse block (FB1). COMMUNI- Connect B.U.D.S. software. Refer to 3-PIN FUSE BLOCK RESISTANCE CATION TOOLS AND B.U.D.S.

• Page 394: O.t.a.s. Magnets

  Section 06 STEERING AND PROPULSION Subsection 01 (STEERING AND O.T.A.S.) O.T.A.S. MAGNETS MULTIMETER STEERING LEAD RESISTANCE POSITION Magnets Replacement POSITION STEERING COLUMN 1. Remove , see procedure Center position 1935 — 2365 Pin «C» and in this subsection. vehicle ground Fully turned 324 — 396 2.

• Page 396: Service Products

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR AND VTS SERVICE TOOLS Description Part Number Page 529 036 179 ……… 384, 386 DIAGNOSTIC HARNESS …………… 529 035 868 ….384, 389–390, 404 FLUKE 115 MULTIMETER …………SERVICE PRODUCTS Description Part Number Page…

• Page 397
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-100_a smr2009-037…

• Page 398: General

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) GENERAL During assembly/installation, use torque values and service products as indicated in the exploded view. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS LOCTITE APPLICATION at the beginning of this manual for complete procedure.

• Page 399
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) Braking Mode NOTE: The iBR lever must be pulled in at least 25% of its travel (approximately) before the iBR If the watercraft speed is 8 km/h (5 MPH) per hour gate starts to move.
• Page 400
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) NOTICE An object or tool caught in the iBR gate, nozzle or linkages when using the iBR override function may cause damage to these components. Remove any foreign object that may obstruct the iBR gate travel.

• Page 401: System Description (Vts)

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) WARNING When moving the iBR gate using the iBR override function, ensure nobody stands near the rear of the watercraft. Movement of the gate may squeeze fingers. SYSTEM DESCRIPTION (VTS) This watercraft is equipped with a programmable high performance VTS (Variable Trim System).

• Page 402: Maintenance

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-026_a PULL DOWN SLIGHTLY ON iBR GATE sdd2009-001-042_a 3. Using a machinists ruler, measure the distance INFORMATION CENTER — VTS POSITION INDICATOR between the bottom of the guard and the 1.

• Page 403: Friction Sleeve Replacement

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 7. Check iBR gate backlash and gate operation af- ter parts replacement and reassembly. FRICTION SLEEVE REPLACEMENT The 4 friction sleeves on the VTS trim ring should be replaced if they show signs of advanced wear (flat spots), or every 100 hours as per the mainte- nance schedule.

• Page 404: Ibr Gate Locking Sleeve Replacement

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) IBR GATE LOCKING SLEEVE 4. Install new screw(s) with Scotch Grip thread- locker and torque as specified in exploded view. REPLACEMENT NOTE: The iBR locking sleeve (iBR key) should be INSPECTION replaced if it is cracked, broken, show signs of ad- vance wear, is loose fitting in the «U»…

• Page 405: Vts Functional Test

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) Test With Watercraft on a Waterway 4. Pull in and release the iBR lever to engage for- ward thrust, allow to run at idle RPM 1. Start watercraft and allow engine to run at idle RPM.

• Page 406: Procedures

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) – Check the 30 A iBR power fuse in FB2 and the 5 A iBR control fuse in FB1 if the gate did not move using the iBR OVERRIDE function. –…

• Page 407
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) NOTE: Connect only the test harness 12 and 6 pin connectors to both sides of same steering har- ness connectors. smo2009-002-124_a Step 1: Push storage bin latches backwards (one each side) smr2009-042-005_e Step 2: Lift and tilt forward to remove storage bin 1.
• Page 408
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) Continuity Test of BRLS Wiring 6-PIN CONNECTOR iBR LEVER iBR LEVER Harness OF DIAGNOSTIC RELEASED PULLED IN HARNESS 1. Ensure the steering connector (C01-12 POS and C03-6 POS) pins are clean, make good VOLTAGE (Vdc) contact, and properly connected.
• Page 409
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-036-004_c 1. Forward ventilation box 2. 12 pin steering connector to disconnect 3. 6 pin steering connector to disconnect smr2009-038-003_b NOTE: Connecting the DIAGNOSTIC HARNESS Step 1: Disconnect the 12 pin connector to the steering connectors (P/N 529 036 179) (steering side only then vehicle side only) will…

• Page 410: Ibr Actuator

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) CONTINUITY TEST STEERING CONNECTORS TO iBR CONNECTOR 12 PIN 6 PIN 12 PIN RESISTANCE STEERING STEERING Pin 5 Pin 7 (VI/YL) (VI/YL) Pin 9 Pin 4 (BK) (BK) Pin 3 Pin 5 (YL/WH) (YL/WH)

• Page 411
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-029_a 1. iBR position indication 2. Press and hold the VTS UP button on the LH handlebar to position the iBR to the full up po- smr2009-038-028_a sition and look for the iBR Motor Current indi- 1.
• Page 412
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-030_a 1. iBR motor harness connector 2. iBR motor module connector smr2009-038-033_b Step 1: Note iBR current draw 2. Set the FLUKE 115 MULTIMETER (P/N 529 035 Step 2: Note iBR position indication change to Vdc selection.
• Page 413
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR Actuator Input Voltage Test 1. Disconnect the 3 pin and 12 pin connectors from the iBR actuator. sdd2009-001-019_c 1. VTS UP 2. VTS DOWN NOTE: Electrical power will shut off after approx- imately 3 minutes.
• Page 414
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) If battery voltage is not measured, check the fol- iBR ACTUATOR INPUT VOLTAGE TEST lowing: (5 AMP SWITCHED) – 30 A iBR fuse in FB2 iBR CONNECTORS – Battery voltage at fuse contact D11 of FB2 BATTERY READING 12 PIN…
• Page 415
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 2. Open the boarding platform and remove the LH storage bin. 3. Disconnect the two aft electrical connectors from the iBR actuator. The forward electrical connector (iBR motor power) does not need to be removed.

• Page 416: Ibr Gate

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR GATE iBR Gate Removal (with VTS Trim Ring and Steering Nozzle) 1. Move the iBR gate to the forward position (full iBR OVERRIDE up) using the function. Refer SYSTEM DESCRIPTION (iBR) in this subsec- tion.

• Page 417
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR Gate and VTS Trim Ring Disassembly VTS Trim Ring Removal Remove the two hexagonal screws securing the iBR gate to the VTS trim ring. smr2009-038-008_a 1. Trim ring hexagonal screw (LH side) smr2009-038-011_a 1.
• Page 418
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-022_a TYPICAL — WORN AND DEFORMED PLASTIC BUSHING smr2009-038-025_a TYPICAL — WEAR MARK ON VTS RING AND iBR GATE CONTACT POINTS 1. Wear mark on VTS ring 2. Wear mark on iBR gate NOTE: Wear marks on VTS ring and iBR gate con- tact points are normal up to 3.175 mm (.125 in).
• Page 419
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 2. Replace as required. Steering Nozzle Lever Inspection 1. Inspect steering nozzle lever, steering arms, and spacers for cracks, elongated holes, ev- idence of wear, deformation and other dam- ages. 2.
• Page 420
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-011_b 1. Small end of nozzle smr2009-038-015_a 2. Steering lever 1. «U» arm 3. Warning label 2. Hexagonal screw and washer 3. Spacer sleeve 4. Actuator shaft iBR Gate Installation (with VTS Trim Ring and Steering Nozzle) «U»…

• Page 421: Ibr Gate Support Plates

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) iBR GATE SUPPORT PLATES NOTE: Two locking tabs on the inner plate locks it to the outer plate exhaust nozzle. iBR Gate Support Plate Removal 5. Using a small screwdriver or a scriber, lift the NOTE: The following steps must be carried out upper locking tab slightly to help release the when removing the LH or RH support plates.

• Page 422
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-043-006_a TYPICAL 1. Bailer hoses (x2) 2. Intercooler bleed hose 3. Pump water pressure hose smr2009-039-002_a 1. Bailer hoses 6. Remove the FITTING PLATE from the support 3. Loosen the gear clamp and disconnect the wa- plate as described in this subsection (this step ter pressure hose from the jet pump.

• Page 423: Fitting Plate

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 4. Install 5 new hexagonal screws to secure iBR support plates and torque as per exploded view. 5. Install the fitting plate, refer to FITTING PLATE in this subsection. 6. Install remaining parts in reverse order of re- moval.

• Page 424
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-043-005_a TYPICAL 1. Hexagonal screw 2. Metal fitting plate retainer smr2009-039-003_a 1. Water pressure hose 4. Cut the locking ties and disconnect the 2 bailer hoses from the jet pump venturi. 6.
• Page 425
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) Fitting Plate Installation Models With a Metal Retainer on Fitting Plate 1. Ensure the «O» ring seal is properly installed on the fitting plate and in good condition. 2. Insert the fitting plate through the outer iBR support plate.

• Page 426: Vts Control Button

  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 7. Install remaining parts in the reverse order of across the 4 the diodes (pin A to pin C). This 2.4 removal, refer to appropriate procedure in this Vdc at pin B tells the gauge the VTS switch is subsection.

• Page 427
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) 5. Depress and hold the VTS UP arrow button and ensure the iBR gate moves up to the forward position. NOTE: If the VTS button is released before full travel of the iBR gate, movement of the iBR gate will cease.
• Page 428
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) fault may be within the gauge. Replace the gauge VTS BUTTON TEST USING and carry out a new B.U.D.S. to ensure the problem is solved. VTS Control Button Removal NOTE: The VTS and iS control s come as a switch assembly which must be replaced as a unit.
• Page 429
  Section 06 STEERING AND PROPULSION Subsection 02 (iBR AND VTS) smr2009-038-035_b 1. START/STOP switch 2. Wiring routed in slot provided in support 3. VTS/iS switch connector 4. Insert switch assembly in switch support. STEERING AND 5. Install steering cover, refer to O.T.A.S.

• Page 430: Jet Pump

  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) JET PUMP SERVICE TOOLS Description Part Number Page 529 035 820 ..416, 418–419, 421, 424 IMPELLER REMOVER/INSTALLER ……….529 035 956 ..416, 418–419, 421, 424 IMPELLER REMOVER/INSTALLER ……….529 036 168 ……… 420, 422 IMPELLER SHAFT BEARING TOOL ……….

• Page 431
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-039-001_a smr2009-039…

• Page 432: General

  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) GENERAL During assembly/installation, use torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENER LOCTITE APPLICATION at the beginning of this manual for complete procedure.

• Page 433: Leak Test

  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 5290218002 smr2009-006-008_a TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to impeller hub end RADIAL PLAY 0 mm (0 in) Excessive play can come either from worn bearing or damaged jet pump housing bearing surface.

• Page 434: Procedures

  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Sacrificial Anode Removal Unscrew sacrificial anode hexagonal screw and remove anode. smr2009-006-002_a TYPICAL 1. Small leak here is acceptable 6. Disconnect pump and remove pressure cap. 7. Reinstall impeller cover. Refer to IMPELLER smr2006-027-009 COVER…

• Page 435
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Jet Pump Housing Inspection and 3. Loosen gear clamp and remove the hose from Cleaning the water pressure outlet fitting on the jet pump housing. 1. Visually inspect jet pump housing. Pay atten- tion to the stator.
• Page 436
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 2. Install the pump on a spare ride plate, the mounting screws should be tight, but it is not required to torque them. 3. Torque hexagonal screws retaining adapters to the jet pump housing as speci- fied in the exploded view.

• Page 437: Venturi

  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) VENTURI Venturi Removal Jet Pump Housing installed 1. Remove the iBR gate and VTS trim ring as an iBR AND VTS assembly. Refer to subsection. 2. Cut locking ties and remove the 2 bailer hoses from the venturi.

• Page 438
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 5. Remove both O-rings. Check impeller boot and O-rings condition on im- peller. Replace as required. smr2009-006-004_a 1. Impeller boot smr2009-006-003_a 2. Impeller O-ring TYPICAL 3. Pump housing O-ring 1. O-rings Impeller Cover Installation Impeller Cover Inspection 1.

• Page 439: Impeller

  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 3. Install impeller cover by aligning the cover index mark with the pump top fin as shown. sdd2009-001-114_c 1. Align mark with top fin NOTE: Cover can only be installed in one position as screw holes are not located symmetrically.

• Page 440
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 529035820 TOOL FOR 130 AND 155 ENGINES smr2009-006-005_a TYPICAL 1. Flat side 2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT) on threads of impeller shaft. (P/N 293 800 070) 529035956 TOOL FOR 215 AND 255 ENGINES 6.

• Page 441: Wear Ring

  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) WEAR RING Wear Ring Inspection Check wear ring for: – Deep scratches – Irregular surface – Any apparent damage. Check IMPELLER/WEAR RING CLEARANCE , see procedure at the beginning of this subsection. Wear Ring Removal 1.

• Page 442: Impeller Shaft And Bearing

  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 2. Mount in a vise the appropriate impeller re- mover/installer tool according to engine type. MODEL TOOL IMPELLER 130 and 155 engines REMOVER/INSTALLER (P/N 529 035 820) IMPELLER 215 and 255 engines REMOVER/INSTALLER (P/N 529 035 956) 1.

• Page 443
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 8. Use the IMPELLER SHAFT PUSHER (P/N 529 035 to press impeller shaft out of pump hous- 955) ing. NOTE: Bearing will come out with the impeller shaft. smr2009-006-009_a TYPICAL 529035955_a 5.
• Page 444
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-012_a smr2009-006-006_a TYPICAL TYPICAL 1. Impeller shaft and bearing 2. Bearing tool on INNER race 4. Turn pump upside down and retry unscrewing Impeller Shaft Nut Removal if Impeller has impeller shaft nut. Loosened 1.
• Page 445
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-019_a TYPICAL 1. Threads 2. Seal lip contact surface 3. Threads Inspect ball bearing for corrosion. smr2009-006-014_a Impeller Shaft and Bearing Installation TYPICAL 1. Bearing tool 2. Impeller shaft and bearing Bearing Installation 2.
• Page 446
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) TYPICAL TYPICAL 7. Press a NEW double lip seal using the 1. Seal/bearing pusher until SEAL/BEARING PUSHER (P/N 529 035 819) 8. Install spacer and then the other seal (thin). En- seal bottoms.
• Page 447
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-017_a TYPICAL 1. O-rings 12. Before installing any other parts, pressurize jet TYPICAL pump to insure proper seal installation. Refer LEAK TEST in this subsection. 16. Using a 30 mm socket, screw the impeller shaft nut on clockwise.
• Page 448
  Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) IMPELLER 19. Install the impeller cover. Refer to COVER in this subsection. smr2009-039…

• Page 450: Drive Shaft

  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) DRIVE SHAFT SERVICE TOOLS Description Part Number Page 529 035 985 ……… 431, 433 DRIVE SHAFT ADAPTER…………… 529 036 167 ……… 431, 434 DRIVE SHAFT WRENCH …………… SERVICE PRODUCTS Description Part Number Page 293 800 050 ………

• Page 451
  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-040-001_a smr2009-040…

• Page 452: General

  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) GENERAL The jet pump must be removed to replace any component of the drive system. Refer to PUMP for removal procedure. During assembly/installation, use torque values and service products as specified in the exploded view.

• Page 453: Procedures

  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) PROCEDURES DRIVE SHAFT Drive Shaft Removal To prevent oil spillage when pulling out drive shaft, carry out the following: – Start engine. – Bring engine to 4000 RPM for 10 seconds. –…

• Page 454
  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-040-003_a smr2009-007-002_a 1. Sealing ring TYPICAL 1. Drive shaft wrench 12. From rear of watercraft, install the DRIVE on drive SHAFT ADAPTER (P/N 529 035 985) shaft end. smr2009-007-001_a TYPICAL 1. Rubber protector 10.
• Page 455
  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-006_a 1. Splines 2. Threads 3. Taper 4. Rubber sealing lip 5. Rubber coating smr2009-007-003_b TYPICAL — CLOCKWISE TO UNSCREW 4. Measure drive shaft deflection. Excessive de- flection could cause vibration and damage to CAUTION Ensure to unscrew clockwise drive shaft splines, impeller or PTO seal.
• Page 456
  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) 2. Remove the damper at the end of drive shaft and replace it with a NEW one. smr2009-007-010_a LOCTITE 577 APPLICATION A. First 5 threads B. 3 mm (1/8 in) 8. From rear of watercraft, engage drive shaft through the drive shaft boot.
• Page 457
  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-002_a smr2009-007-003_a TYPICAL 1. Drive shaft wrench TYPICAL 1. Drive shaft adapter 15. While a coworker holds the drive shaft wrench NOTE: Make sure all spark plugs are removed in engine compartment, continue turning drive from engine.

• Page 458: Sealing Ring

  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) 23. Run watercraft then ensure there is no oil leak in PTO seal area. 24. Properly reinstall the deck extension, moving deck and ventilation box. Refer to BODY sub- section. SEALING RING Sealing Ring Removal DRIVE SHAFT 1.

• Page 459
  Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) smr2009-007-008_a WRONG 1. Sealing ring incompletely inserted into PTO seal smr2009-040…

• Page 460: Suspension (Is)

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) SUSPENSION (iS) SERVICE TOOLS Description Part Number Page 529 035 868 ….447, 449–450, 452 FLUKE 115 MULTIMETER …………295 000 136 ……… 447 MAGNETO HARNESS 6 PINS…………529 031 800 ……… 459 SUPERTITANIUM DRILL BIT 3/16″……….

• Page 461
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) FRONT smr2009-041-001_a smr2009-041…
• Page 462
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) REAR smr2009-041-002_a smr2009-041…

• Page 463: General

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) GENERAL NOTE: For a complete overview of the vehicle POWER DISTRIBU- electrical system, refer to TION subsection. It is highly recommended to disconnect the bat- tery when replacing any electric or electronic com- ponent.

• Page 464: Troubleshooting

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Circuit Testing The suspension can be set to the AUTO or MAN- UAL mode. Check the related-circuit fuse condition with a In AUTO mode, suspension height is factory fuse tester or ohmmeter (relying solely on a preset and the iS module constantly monitors visual inspection could lead to an incorrect con- the stroke of the suspension and it automatically…

• Page 465
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) SUSPENSION BOTTOMS HARD. 5. Leak on hydraulic circuit. — Repair or replace defective part(s). 1. Spring(s) out of specification or broken. 6. Faulty suspension position sensor. — Replace the defective spring(s). — Test sensor and replace as required.

• Page 466: Diagnostic Flow Charts

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) DIAGNOSTIC FLOW CHARTS smr2009-041-100_en smr2009-041…

• Page 467
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-101_en smr2009-041…

• Page 468: Procedures

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) PROCEDURES SHOCK ABSORBER Shock Absorber Removal BODY 1. Remove the moving deck. Refer to sub- section. 2. Remove tapes securing central bellows to mounting plate. 3. Move down central bellows to reach shock smr2009-041-005_a holder screws.

• Page 469: Springs

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 2. The shock should extend unassisted. Rod must come out at a steady speed. If any problem is detected, replace the shock ab- sorber. Shock Absorber Installation The installation is the reverse of the removal pro- cedure.

• Page 470
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Suspension Position Sensor Input Voltage Test At Sensor Connector SUSPENSION POSITION VOLTAGE 295000136 SENSOR CONNECTOR 5. Using the FLUKE 115 MULTIMETER (P/N 529 035 Pin 1 Pin 2 5 Vdc , check voltage as per the following table. 868) Using the 6-pin Magneto Harness Tool COMMUNICATION…
• Page 471
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 529035868 smr2009-041-011_a SUSPENSION iS MODULE 1. Sensor connector 2. Hydraulic pump reservoir POSITION (6-pin RESISTANCE (% in B.U.D.S.) connector) 4. Remove screws securing the suspension posi- All positions 1803 — 2203 tion sensor.

• Page 472: Is Module

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) NOTE: When reassembling parts, index sensor lever shaft with sensor inner slot. The sensor lever must be positioned to 180° with the sensor electrical connector. smr2009-041-055_a Repeat the test using a test light. TEST LIGHT POSITION RESULT Pin 1 of…

• Page 473
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) iS Module Input Voltage Test Continuity Test of iS Module Battery (Battery Power) Power Wire Using the FLUKE 115 MULTIMETER (P/N 529 035 iS MODULE FUSE BOX , perform the following test. 868) 3-PIN RESISTANCE…

• Page 474: Is Button

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-037_a 1. iS module input voltage connector smr2009-041-034_a 1. Suspension position sensor connector NOTE: The locking tab of input voltage connector 3. Detach the retaining latch. is located underneath. 6. Remove the iS module from vehicle. iS Module Installation The installation is the reverse of the removal pro- cedure.

• Page 475
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) transmit it through the CAN bus. The module will react to the command, carry out the function, and transmit the result back through the CAN bus. The gauge will use the signals from the switches and the transmitted information from the other modules, convert them to an indication, and cancel the command signal it sent out once the…

• Page 476: Hydraulic Pump

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Hydraulic Pump Fluid Level iS SWITCH TEST Verification MULTIMETER SWITCH NOTE: The fluid level will drop slightly during LEAD/GAUGE VOLTAGE POSITION break-in period because the actuator uses a small CONNECTOR amount of fluid to lubricate its moving parts. If a RED lead/Pin 14 Approx.

• Page 477
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Reinstall reservoir plug and tighten it to 1 N•m If the current draw is excessive, replace the hy- (9 lbf•in). draulic pump. Hydraulic Pump Operation Test Hydraulic Pump Removal (as a Unit with Actuator) Connect a jumper from the positive (30 A fused jumper) and negative side of the battery to the hy- To work on many parts of suspension system, the…
• Page 478
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-028_a 1. Actuator holder screws smr2009-041-045_a VIEW FROM THE REAR OF VEHICLE 7. Remove the suspension position sensor to 1. Secure hydraulic hose to hydraulic pump avoid damaging it. 2. Secure hydraulic hose, fuel hose and vehicle wiring harness 8.
• Page 479
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-016_a smr2009-041-019_a 1. Cut this locking tie 1. Socket screw 2. Hydraulic hose 2. Hydraulic hose lock 6. Unscrew the retaining clamp completely and re- 9. Remove hose from pump and plug hose to move it.

• Page 480: Actuator

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 4. Secure hydraulic pump to suspension base. 4.1 Install pump retaining screw and tighten it to 10 N•m (89 lbf•in). 4.2 Install retaining clamp and tighten it to 2 N•m (18 lbf•in). 5.

• Page 481: Lateral Support

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-023_a smr2009-041-052_a 1. Lateral support screw 1. Hose fully inserted in lock slot 2. Position hydraulic hose in lock hook 4. Remove lateral support from lateral bellows. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) Lateral Support Installation threads of lock screw.

• Page 482: Front Suspension Arm

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-026_a smr2009-041-024_a 1. Ring pin 1. Lateral support screw 2. Bellows alignment hole 3. Body hole 2. Decouple lateral support from suspension Install new rivets. If the head of rivet tool can- shaft.

• Page 483: Suspension Base

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 2. Using a marker, trace the shape of suspension base at the bottom of the hull to reposition it at the same place. 3. Remove and discard suspension base screws. smr2009-041-024_a RH SIDE SHOWN 1.

• Page 484: Rear Suspension Arm

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) Suspension Base Installation 4.2 If required, move suspension base until both distances are equal. The installation is the reverse of the removal pro- cedure. However, pay attention to the following. 4.3 Tighten suspension base rear screws to 25 N•m (18 lbf•ft).

• Page 485
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) NOTE: If the upper arm shaft or one of its arm shaft support has been removed or loosened, re- SUSPENSION ARM SHAFTS fer to for proper in- stallation procedure. 2. Tighten screws to 25 N•m (18 lbf•ft). 3.

• Page 486: Suspension Arm Shafts

  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 5.3 Reposition rear suspension arm brackets 6. InstallNEW support screws and tighten them to on fixed deck until positioning of moving 25 N•m (18 lbf•ft). deck is satisfactory. 7. Secure both supports to shaft using NEW 6.

• Page 487
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) smr2009-041-078_a 1. Support pin 2. Holder hole smr2009-041-079_a 1. Bar clamp 2. New socket screws 4. Tighten the LH support screws to 25 N•m (18 lbf•ft). Removal of Rear Suspension Arm 5.
• Page 488
  Section 07 BODY AND HULL Subsection 01 (SUSPENSION (iS)) 5. Remove and discard socket screws securing rear brackets to arm shaft ends. smr2009-041-071_a 1. Bad installation 2. Good installation smr2009-041-069_a 3. Lower the rear suspension arm on fixed deck. 1. Socket screw 2.

• Page 490: Body

  Section 07 BODY AND HULL Subsection 02 (BODY) BODY SERVICE TOOLS Description Part Number Page 529 031 800 ……… 485 SUPERTITANIUM DRILL BIT 3/16″……….SERVICE PRODUCTS Description Part Number Page 413 711 200 ……… 481–482 BRP PLASTIC & VINYL CLEANER ……….293 800 060 ……

• Page 491: Splash Deflector

  Section 07 BODY AND HULL Subsection 02 (BODY) SPLASH DEFLECTOR 2. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) threads of shock absorber body. Splash Deflector Removal 3. Tighten manually the attachment on gas shock. 4. Install the bellows and secure it using a locking tie.

• Page 492: Moving Deck

  Section 07 BODY AND HULL Subsection 02 (BODY) Deck Extension Installation 1. Position the deck extension. 2. Install screws retaining deck extension and air inlet. 3. Tighten these screws to 1.5 N•m (13 lbf•in). NOTICE Do not tighten screws over this recommended torque.

• Page 493
  Section 07 BODY AND HULL Subsection 02 (BODY) Tilting Moving Deck for Servicing 5. Lift the rear suspension arm against seat handle Watercraft and attach it with locking tie or strap. BOARDING PLATFORM 1. Remove the , see pro- cedure in this subsection. smr2009-042-012_a 1.
• Page 494
  Section 07 BODY AND HULL Subsection 02 (BODY) Removing the Moving Deck for Servicing Watercraft 1. Open the front storage cover and remove the front basket. BOARDING PLATFORM 2. Remove the , see pro- cedure in this subsection. smr2009-042-066_a 1. Hoist 2.
• Page 495
  Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-014_a smr2009-042-011_a RH SIDE SHOWN 1. Rear suspension arm 1. Front carpet (discard) 2. Reinstallation marks 2. Protective cap 3. Screws (discard) 8.2 Remove and discard screws securing 6. Lift and attach the rear suspension arm against moving deck to lateral supports.
• Page 496
  Section 07 BODY AND HULL Subsection 02 (BODY) 15. Install lifting straps. 15.1 Using both mooring cleats under steer- ing, install two lifting straps. smr2009-042-005_a 1. Disconnect these connectors 14. Detach steering cable from steering column. 14.1 Remove bolt securing ball joint to steer- ing column.
• Page 497
  Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-074_a smr2009-042-015_a 1. Steering cable RH SIDE SHOWN 2. Steering column 1. Retaining screws (new) 3. Install steering cable clamp and its bolts. Do 6. Remove pieces of wood located under lateral not tighten bolts yet.

• Page 498: Carpets

  Section 07 BODY AND HULL Subsection 02 (BODY) 10. Install two homemade alignment pins on sus- 16. Carefully lower and secure the rear suspen- pension mounting plate. sion arm to the fixed deck. 10.1 Take two M8 x 50 bolts and cut their 16.1 Position the rear suspension arm brack- heads.

• Page 499: Storage Compartment Cover

  Section 07 BODY AND HULL Subsection 02 (BODY) STORAGE COMPARTMENT COVER smr2009-042-029_a 1. Cover hinge key 2. Front body module slot smr2009-042-024_a Storage Compartment Cover 1. Storage compartment cover Installation Storage Compartment Cover Removal The installation is the reverse of the removal pro- cedure.

• Page 500: Mirrors

  Section 07 BODY AND HULL Subsection 02 (BODY) 3. Install the new mirror and tighten wing nut. 3.1 The mirror adjustment correct when the spring length is between 10 mm and 12 mm (13/32 in and 15/32 in). smr2009-042-031_a 1. Lower attachment in its cavity Close cover to lock the bottom of the gas shock.

• Page 501: Glove Box Cover

  Section 07 BODY AND HULL Subsection 02 (BODY) GLOVE BOX COVER FRONT GRILLE smr2009-042-055_a 1. Glove box cover Glove Box Cover Removal smr2009-042-056_a 1. Move steering in its upper position. LOCATED UNDER STORAGE COMPARTMENT COVER 1. Front grille 2. Open glove box cover until cover hinges are aligned with front body module openings.

• Page 502: Body Cover

  Section 07 BODY AND HULL Subsection 02 (BODY) BODY COVER ssi2009-003-004_a LH SIDE SHOWN 1. Remove this plastic push-in clip smr2009-042-057_a 6. Open seat and using a 3/16″ drill bit, drill the 1. Body covers rivets securing the seat trims. Body Cover Removal 1.

• Page 503: Front Body Module

  Section 07 BODY AND HULL Subsection 02 (BODY) – Storage bin – Glove box cover – Body covers and front grille – Steering and steering lock – Speed-Tie unit (if equipped). 2. Remove both screws and washers located be- tween seat and glove box. smr2009-042-059_a RH SIDE SHOWN 1.

• Page 504: Seat

  Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-064_a smr2009-042-027_a 1. Front body module retaining tabs 1. Central arm 2. Retaining bolts 6. Remove front body module. 5. Remove seat from vehicle. Front Body Module Installation Seat Installation The installation is the reverse of the removal pro- The installation is the reverse of the removal pro- cedure.

• Page 505: Seat Latch

  Section 07 BODY AND HULL Subsection 02 (BODY) For dirt build-up, use All cleaning methods must be followed by a thor- BRP PLASTIC & VINYL , Vinyl Finish Vinyl ough rinse with warm water. CLEANER (P/N 413 711 200) Cleaner or an equivalent. Let soak for approxi- Certain household cleaners, powdered abrasives, mately 10 minutes, then gently scrub with a soft steel wool and industrial cleaners can cause dam-…

• Page 506
  Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-048_a smr2009-042-045_a 1. Rear bumper 1. Front bumper 2. Protective cap 2. Protective caps 2. Remove side screws securing rear bumper to 2. Remove side screws securing front bumper to body. body. smr2009-042-049_a smr2009-042-046_a FROM RH SIDE OF VEHICLE…

• Page 507: Speed-Tie Unit

  Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-053_a 1. Protective skin smr2009-042-051_a 1. Trace a line here 4. Insert bumper over body lip. 3. Pull the top of bumper to unclip it from body. 4.1 Insert lower section first. NOTE: A heat gun can be used to soften side 4.2 Insert upper section last.

• Page 508
  Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-003_a 1. Upper trim smr2009-042-034_a 1. Retaining tabs 4. Remove the plastic push-in clip retaining the LH trim. 7. Using a small screwdriver, release both retain- ing hooks securing the cam trim on locking mechanism.
• Page 509
  Section 07 BODY AND HULL Subsection 02 (BODY) smr2009-042-036_a 1. Retaining screws 4. Remove the Speed-Tie unit from vehicle. ssi2009-003-010_a Front Speed-Tie Unit Installation 1. Rear locking tab 1. Ensure both double cage nuts are correctly in- 13. Lightly pull the top of LH trim and remove the serted into Speed-Tie unit cavities.
• Page 510
  Section 07 BODY AND HULL Subsection 02 (BODY) 5. Lift the lever and insert the locking mechanism so that the lever is pointing toward the front of vehicle. ssi2009-003-010_a 1. Rear locking tab 2.3 Lightly pull the top of LH trim and insert ssi2009-003-013_a 1.
• Page 511
  Section 07 BODY AND HULL Subsection 02 (BODY) 9. Install the front trim. 9.1 Insert top tabs and align lower tabs with openings. ssi2009-003-102_a 1. Locking lever 2. Boarding platform slot 4. Position a double cage nut on the locking mech- anism.
• Page 512
  Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-109_a 1. Tabs 2. Alignment pin 12.2 Press trim in place. ssi2009-003-105_a 13. Test Speed-Tie operation. 1. Speed-Tie unit Speed-Tie Unit Cleaning 9. Close boarding platform. A minimum of maintenance is required to keep 10.
• Page 513
  Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-018_a ssi2009-003-021_a 1. Untie this knot 1. Retaining screw 4. Remove the locking mechanism and let the 8. Split the rewind unit and remove damaged rope retracts into housing. rope. 5. Remove the back cover. ssi2009-003-019_a 1.
• Page 514
  Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-025_a ssi2009-003-028_a 1. Inner stopper 1. Cover notch A. 106 mm ± 6 mm (4-1/8 in ± 15/64 in) 13.2 Press in the cover until both parts are 11. On rewind unit base, identify the short tongue. completely pressed together.
• Page 515
  Section 07 BODY AND HULL Subsection 02 (BODY) ssi2009-003-030 ssi2009-003-033_a 15. Lock the end of rope as shown. 18. Unlock the end of the rope and pull it out by the housing opening. NOTE: Be careful not to release the rope and the spring.

• Page 516: Decals

  GELCOAT Film on Back Side) These decals usually contain written information The fixed deck of this Sea-Doo is constructed (e.g.: warning) and are used on gelcoat or metal. of chopped fiberglass, saturated with resin. It is sprayed on the layer of gelcoat along with pieces…

• Page 517
  Section 07 BODY AND HULL Subsection 02 (BODY) Filling the Cavity WARNING The prepared surface must be cleaned with ace- Protect skin, wear gloves when in contact tone on a cloth. Use a gelcoat repair kit. Follow with resin, hardeners and gelcoat. A barrier the mixing instructions in the kit when preparing skin cream may also be used.
• Page 518
  Section 07 BODY AND HULL Subsection 02 (BODY) then additional reinforcement may be necessary. buffing with a white medium compound. Finish COMPOUND This subject will be covered in off using a fine compound. While buffing, pay FRACTURES close attention to avoid overheating the surface. Preparing the Surface Compound Fractures Repair Small Fractures: Open the cracks up with a…
• Page 519
  Section 07 BODY AND HULL Subsection 02 (BODY) pieces evenly. Try to work quickly, you may only have 15 or 20 minutes. You may clean the brush with acetone. Wait until the repair has hardened before moving on to the interior repair. If the size of the opening is too large for the pieces to maintain the proper shape, you will have to use a backing support.

• Page 520: Hull

  Section 07 BODY AND HULL Subsection 03 (HULL) HULL SERVICE PRODUCTS Description Part Number Page 293 110 001 ……502–503, 505 BRP HEAVY DUTY CLEANER …………293 800 086 ……… 508–509 LOCTITE 5150 (SILICONE SEALANT) ……….. 293 800 050 ……… 507 LOCTITE 577 (THREAD SEALANT) ……….

• Page 521
  Section 07 BODY AND HULL Subsection 03 (HULL) smr2009-043-101_a smr2009-042…
• Page 522
  Section 07 BODY AND HULL Subsection 03 (HULL) All Models smr2009-043-100_a smr2009-042…

• Page 523: General

  Section 07 BODY AND HULL Subsection 03 (HULL) GENERAL Verify condition and operation of hinges and latch- ing mechanisms. Replace any damaged compo- nents. During assembly/installation, use torque values and service products as specified in the exploded views. Clean threads before applying a threadlocker. Re- SELF-LOCKING FASTENERS LOCTITE fer to…

• Page 524: Ride Plate

  Section 07 BODY AND HULL Subsection 03 (HULL) RIDE PLATE Ride Plate Removal NOTE: The jet pump support and ride plate must be removed as an assembly. The pump support is fastened to the ride plate and the forward pump support mounting screws cannot be accessed when the ride plate is installed.

• Page 525
  Section 07 BODY AND HULL Subsection 03 (HULL) Ride Plate Installation 1. Install the jet pump support on the ride plate, see procedure in this section. NOTE: The jet pump support must be installed on the ride plate before installation of the ride plate on the watercraft.

• Page 526: Jet Pump Support

  Section 07 BODY AND HULL Subsection 03 (HULL) 9. Reinstall coolant hoses on ride plate fittings, 3. Sealant is applied between the jet pump sup- pay attention to gear clamp positioning. See port and the ride plate. Using a heat gun, heat following illustration.

• Page 527: Thru-Hull Fitting

  Section 07 BODY AND HULL Subsection 03 (HULL) Thru-Hull Fitting Removal Inner Fitting Removal 1. Remove drive shaft, refer to DRIVE SHAFT sub- section. 2. Using a heat gun, heat the glue at the joint be- tween the hull and the inner thru-hull fitting to soften the glue applied.

• Page 528
  Section 07 BODY AND HULL Subsection 03 (HULL) 2. Insert the outer fitting into the hull from the jet pump side of the hull towards the inside. En- sure fitting is pushed in against the hull. 3. Continue with INNER FITTING INSTALLATION procedure.

• Page 529: Sponson

  Section 07 BODY AND HULL Subsection 03 (HULL) The bailer pick ups are connected through a hose system to two syphon tubes mounted in the jet pump venturi that draw the water out of the bilge through the bailer pick ups. The bailers are also connected to the bilge drain plugs in the stern.

• Page 530: Drain Plugs

  Section 07 BODY AND HULL Subsection 03 (HULL) smr2009-043-032_a DRAIN PLUG REMOVAL 1. Drain plug smr05-005-001_A 2. Drain neck 1. Elbow fitting holes 4. Using a ratchet handle and extension of appro- DRAIN PLUGS priate size, unscrew the drain neck from the hull.

• Page 531
  Section 07 BODY AND HULL Subsection 03 (HULL) der the splash deflector indicates the exact loca- tion of the piece to cut out. Carry out the following steps. 1. Remove splash deflector, refer to BODY sub- section. 2. Using a drill bit 6 mm (1/4 in) in size MINIMUM, drill a hole at each of the five corners of the piece to cut out of the fixed deck as per follow- ing illustration.

• Page 532: Stern Eyelets

  Section 07 BODY AND HULL Subsection 03 (HULL) 4. Clean any residue of silicone sealant from the hull. Stern Eyelet Installation 1. Install small washers and nylon washers to stern eyelet and insert it through the hull. 2. Inside hull, apply LOCTITE 5150 (SILICONE all around holes.

• Page 533
  Section 07 BODY AND HULL Subsection 03 (HULL) smr2009-043-025_a smr2009-043-026_b 1. Passe thru insert BLIND HOLE INSERT 1. Excess glue on head 3. Use a six pan socket of appropriate size and a ratchet wrench to unscrew the insert from the hull.

• Page 534: Rxt Is 255/Gtx Limited Is 255

  Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) RXT iS 255/GTX LIMITED iS 255 MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE Engine type ROTAX 1503 4-TEC, 4-stroke, Single Over Head Camshaft (SOHC) Induction Supercharged intercooled Number of cylinders Number of valves 12 valves with hydraulic lifters (no adjustment)

• Page 535
  Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE (cont’d) Upper compression ring, rectangular Piston ring type Lower compression ring, tapered face Oil scraper ring Rectangular 0.30 mm to 0.50 mm (.012 in to .02 in) Taper-face 0.30 mm to 0.50 mm (.012 in to .02 in) Ring end gap…
• Page 536
  Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ENGINE (cont’d) Connecting rod small end radial play Wear limit 0.080 mm (.0031 in) 22.996 mm to 23.000 mm (.9054 in to .9055 in) Piston pin diameter Wear limit 22.990 mm (.9051 in)
• Page 537
  Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 ELECTRICAL SYSTEM #1: Gauge #2: CAPS #3: Depth sounder #4: Starter solenoid #5: iBR control #6: Fuel pump Fuse box #1 #7: Inj/Ign 10 A cyl 1…
• Page 538
  Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 STEERING AND PROPULSION Steering Adjustable tilt Steering nozzle pivoting angle 26° O.T.A.S. (Off-Throttle Assisted Steering) Electronically-controlled. Achieved with the iBR gate and engine speed Type Axial flow single stage Jet pump…
• Page 539
  Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (RXT iS 255/GTX LIMITED iS 255) MODEL RXT iS 255 GTX LIMITED iS 255 iS SUSPENSION (cont’d) Type Radial piston Oil type Automatic transmission fluid (ATF) Dexron III Hydraulic pump Reservoir is full when oil level reaches 130 mm ± 5 mm Oil quantity (5-1/8 in ±…

• Page 540: Wiring Diagram Information

  Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) WIRING DIAGRAM INFORMATION GENERAL WIRING DIAGRAM LOCATION The wiring diagram is in the back cover pocket. WIRING DIAGRAM CODES Wire Color Codes smr05-026-002_a 1. Wire main color TYPICAL 2. Tracer (thin colored line) 1.

• Page 541
  Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) smr2009-045-007_a 1. CAN wire 2. Wire destination FB2: Fuse box #2 C7: Terminal C7 in fuse box #2 On the wiring diagram, corresponding CAN links are identified in fuse box #2 using the following coding.

• Page 542: Connector Information

  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) CONNECTOR INFORMATION SERVICE TOOLS Description Part Number Page 529 035 730 ……… 526 CRIMPING TOOL (HEAVY GAUGE WIRE) ……..529 036 166 ……… 523 ECM ADAPTER TOOL…………..529 036 175 ……… 523 ECM TERMINAL REMOVER 2.25……….

• Page 543
  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) Connector Disassembly 1. Male connector TYPICAL 2. Female connector 1. Deutsch connectors 3. Secondary lock 2. Press release button 4. Sealing cap Engine Connector NOTICE Do not apply dielectric grease on ter- Insert a small flat screwdriver between the sup- minal inside connector.

• Page 544: Ecm Connector (Molex)

  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) 6. After all required terminals have been inserted, the lock must be installed. MALE CONNECTOR 1. Wire identification numbers 1. Male lock NOTE: Before extraction, push wire forward to re- ECM CONNECTOR (MOLEX) lieve pressure on retaining tab.

• Page 545
  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) smr2009-045-013_b smr2009-045-011_a Install connector to ECM. Rotate connector lock until it stops. Rotate connector lock until it snaps locked. smr2009-045-012_a Pull out connector. smr2009-045-011_b 1. Locked here ECM Connector Inspection Before replacing an ECM, always check electrical connections.
• Page 546
  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) ECM Connector Probing The most recommended and safest method to probe ECM connector terminals is to use the . This tool will ADAPTER TOOL (P/N 529 036 166) prevent deforming or enlarging terminals which would lead to bad ECM terminal contact creating intermittent or permanent problems.

• Page 547: Brls, Tas And Starter Solenoid Connectors (Delphi)

  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) smr2009-045-015_a WARNING Before terminal installation, ensure all ter- minals are properly crimped on wires. After smr2009-045-027_a plugging connectors, ensure they are prop- erly fastened. WARNING Before terminal installation, ensure all ter- iBR AND iS POWER minals are properly crimped on wires.

• Page 548: Sps Connectors (Bosch)

  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) WARNING Before terminal installation, ensure all ter- minals are properly crimped on wires. After plugging connectors, ensure they are prop- erly fastened. SPS CONNECTORS (BOSCH) To remove a terminal from connector, use a spe- cial tool such as the AMP TERMINAL EXTRACTOR (P/N 726503-1)

• Page 549: Battery Cable Terminal

  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) smr2009-045-023_a A. 10 mm (3/8 in) 1. Pry out locking cap NOTE: Make sure not to cut wire strands while stripping the wire. Install the appropriate terminal on the wire ac- cording to the requirement. Refer to appropriate PARTS CATALOG smr2009-045-024_a 1.

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  Section 09 WIRING DIAGRAM Subsection 02 (CONNECTOR INFORMATION) Install the protective heat shrink rubber tube on the terminal. Heat the heat shrink rubber tube us- ing the heat gun so that it grasps the wire and the terminal. NOTICE Make sure that the protective heat shrink rubber tube has been properly installed and no part of wire is exposed.
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