1998 Bombardier Seadoo Speedster Sk Jet Boat Service Manual.pdf by www.heydownloads.com

Volume 2 SPEEDSTER/SK

219 100 099 JB99C.FH7 03/07/98 PHOTO X:FINAUX\1999\JET_BOAT\COVER99\LMR\ JBFR99.EPS

1999 Shop Manual VOLUME 2 SPEEDSTER SPEEDSTER SK

Legal deposit: National Library of Quebec 1st trimester 1999 National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1999 Printed in Canada *Registered trademarks of Bombardier Inc.

Loctite® is a trademark of Corporation. Snap-on® is a trademark of Snap-on Tools Corporation. Gelcote® is a trademark of Gelcote International Limited.

TABLE OF CONTENTS

SECTION

SUBSECTION

PAGE

SAFETY NOTICE .................................................................................................................................. WHAT’S NEW .......................................................................................................................................

III IV

INTRODUCTION ...................................................................................................................................

SERVICE TOOLS AND PRODUCTS

01 – Table of Contents ..................................................................... 01-01-1 02 – Service Tools ............................................................................ 01-02-1 03 – Service Products ...................................................................... 01-03-1

MAINTENANCE

01 – Table of Contents ..................................................................... 02 – Periodic Inspection Chart ......................................................... 03 – Flushing and Lubrication........................................................... 04 – Water-Flooded Engine.............................................................. 05 – Storage .....................................................................................

TROUBLESHOOTING

01 – Table of contents...................................................................... 03-01-1 02 – Troubleshooting........................................................................ 03-02-1 03 – Flow Chart ................................................................................ 03-03-1

ENGINE

01 – Table of Contents ..................................................................... 02 – Leak Test ................................................................................. 03 – Removal and Installation .......................................................... 04 – Magneto System...................................................................... 05 – Top End .................................................................................... 06 – Bottom End .............................................................................. 07 – Rotary Valve ............................................................................. 08 – Exhaust System .......................................................................

COOLING SYSTEM

01 – Table of Contents ..................................................................... 05-01-1 02 – Components............................................................................. 05-02-1 03 – Circuit ....................................................................................... 05-03-1

FUEL SYSTEM

01 – Table of Contents ..................................................................... 02 – Fuel Circuit ............................................................................... 03 – Air Intake .................................................................................. 04 – Carburetors...............................................................................

LUBRICATION SYSTEM

01 – Table of Contents ..................................................................... 07-01-1 02 – Oil Injection Reservoir .............................................................. 07-02-1 03 – Oil Injection Pump .................................................................... 07-03-1

ELECTRICAL

01 – Table of Contents ..................................................................... 02 – Overview .................................................................................. 03 – Ignition System ........................................................................ 04 – Spark Plugs............................................................................... 05 – The DESS (Digitally Encoded Security System) ....................... 06 – MPEM (Multi-Purpose Electronic Module)............................... 07 – Charging System ...................................................................... 08 – Starting System........................................................................ 09 – Instruments and Accessories...................................................

02-01-1 02-02-1 02-03-1 02-04-1 02-05-1

04-01-1 04-02-1 04-03-1 04-04-1 04-05-1 04-06-1 04-07-1 04-08-1

06-01-1 06-02-1 06-03-1 06-04-1

08-01-1 08-02-1 08-03-1 08-04-1 08-05-1 08-06-1 08-07-1 08-08-1 08-09-1

TABLE OF CONTENTS

SECTION

SUBSECTION

PAGE

PROPULSION SYSTEM

01 – Table of Contents...................................................................... 02 – Jet Pump................................................................................... 03 – Drive System ............................................................................ 04 – Reverse System........................................................................ 05 – Weedless System.....................................................................

09-01-1 09-02-1 09-03-1 09-04-1 09-05-1

STEERING SYSTEM

01 – Table of Contents...................................................................... 02 – Steering System ....................................................................... 03 – Alignment.................................................................................. 04 – Throttle/Shifter Controller .........................................................

10-01-1 10-02-1 10-03-1 10-04-1

HULL/DECK

01 – Table of Contents...................................................................... 02 – Components ............................................................................. 03 – Repair........................................................................................ 04 – Painting .....................................................................................

11-01-1 11-02-1 11-03-1 11-04-1

TECHNICAL DATA...................................................................................................................... 12-01-1

WIRING DIAGRAMS................................................................................................................... 13-01-1

SAFETY NOTICE

This manual was primarily published to be used by jet boat technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made Sea-Doo jet boat. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into local language upon certain conditions and furthermore agreed that in the event of any discrepancy among the two versions, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at its time of manufacture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing the product. The use of Bombardier parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking disk, lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols:

â&#x2014;&#x2020;

WARNING

Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death.

CAUTION

Denotes an instruction which, if not followed, could severely damage boat components. NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier jet boat and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional technician. It is understood that certain modifications may render use of the boat illegal under existing federal, provincial and state regulations.

III

WHAT’S NEW

This section indicates this year is major changes brought to this shop manual including 717 engine procedures applicable to the new Speedster SK model.

SERVICE TOOLS AND SERVICE PRODUCTS • Revised tool part numbers. Tool are identical to last year, only part numbers have been modified. • The following tools are new: • Radio installation tool (P/N 295 100 106). • Tool board (P/N 295 500 608). • Tie-down (P/N 295 100 088). • Lift kit: –14 foot (P/N 295 000 160). –16 foot (P/N 295 100 085). –18 foot (P/N 295 100 045). • The following products are new: • Loctite Chisel (P/N 413 708 500) replaces Gasket stripper (P/N 295 000 110). • Parts cleaner (P/N 413 711 809) replaces Loctite safety solvent (P/N 293 800 019).

MAINTENANCE • • • •

Revised periodic inspection chart with aluminum anode inspection. Revised flushing procedure. New photographs. New flow chart.

ENGINE • Revised engine cover removal procedure + photographs. • New main battery cut-off switch. • New wire color codes on generating and charging coils.

FUEL SYSTEM • Revised procedure for clamp removal.

LUBRICATION SYSTEM • Oil reservoir removal procedure.

WHAT’S NEW

ELECTRICAL • • • • •

Standardized wire color codes. Main battery cut-off switch on all boats. New aluminium anode system on all boats. Identified ground blocks to ease troubleshoot. Connector location table moved to WIRING DIAGRAM 13-01.

PROPULSION SYSTEM • Revamped weedless rod and cables replacement.

HULL/DECK • • • • •

New paint colors for 1999. New swivel base removal procedure. New ski post removal/disassembly/installation procedure for Speedster SK model. New bow cover removal/installation/alignment procedure for Speedster SK model. Lock pin adjustment and step removal procedures for Speedster SK model.

TECHNICAL DATA • Updated specifications for 1999.

WIRING DIAGRAMS • Updated for 1999.

INTRODUCTION

INTRODUCTION This Shop Manual covers the following BOMBARDIER made SEA-DOOÂ® Jet Boat. MODEL

MODEL NUMBER

Speedster

5678

Speedster SK

5677/5681

0 HULL IDENTIFICATION NUMBER (H.I.N.) The Hull Identification Number (H.I.N.) is located at right hand rear side of hull.

MAXIMUM BOAT CAPACITY The jet boat maximum capacity can be found on RH side of operator position.

30 70 45 90

km/h

MPH Bombardier

F09L03B

TYPICAL 1. Hull Identification Number (H.I.N.)

MADE IN U.S.A., BOMBARDIER CORPORATION OF AMERICA

Refer to the next illustration for a description of the serial number.

U.S. COAST GUARD

MAXIMUM CAPACITIES

7PERSONS OR 565 KG/1245 LBS. 565 KG/1245 LBS. PERSONS, GEAR

THIS BOAT COMPLIES WITH U.S. AND CANADIAN COAST GUARD SAFETY STANDARDS IN EFFECT ON THE DATE OF CERTIFICATION

BOAT DESIGN CATEGORY:

F10L1YA

CEC 1 2 3 4 5 L 4 9 5

Serial number*

TYPICAL

Model year Year of production Month of production

F00A0YA

*A letter may also be used as a digit.

CEC indicates that boats are manufactured in USA.

INTRODUCTION

ENGINE IDENTIFICATION NUMBER (E.I.N.)

ARRANGEMENT OF THIS MANUAL

717 Engine E.I.N. is located on the upper side of the magneto housing.

The manual is divided into 13 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 HULL/DECK 12 TECHNICAL DATA 13 WIRING DIAGRAMS Each section is divided in various subsections, and again, each subsection has one or more division. A table of contents is included at the beginning of most sections.

F01D01A

TYPICAL — 717 ENGINE 1. Engine Identification Number (E.I.N.)

787 Engine E.I.N is located on crankcase PTO side.

F01D87A

TYPICAL — 787 ENGINE 1. Engine Identification Number (E.I.N.)

VII

INTRODUCTION

TYPICAL PAGE Page heading indicates section and subsection detailed. Subsection title indicates beginning of the subsection.

Section 03 ENGINE (MAGNETO SYSTEM)

Subsection 04

Exploded view assists you in identifying parts and related positions.

MAGNETO SYSTEM 717 Engine

Italic sub-title above exploded view indicate pertaining models.

5 N m (44 lbf in)

Drop represents a liquid product to be applied to a surface. In this case Loctite 242 to screw threads.

9 N m 13 (80 lbf in)

Loctite 242

4 7

6 N m (53 lbf in) 5

Bold face number indicates special procedure concerning this part.

Dotted box contains parts of a particular model or an exploded view.

Loctite 242 6 N m (53 lbf in)

Loctite 242 9 6 N m (53 lbf in)

Loctite 242 3 14

Loctite 242

4 Loctite 648 10

15 145 N m (107 lbf ft) Anti-seize lubricant

F01D4WS

Illustration number for publishing process.

03-04-1

Tightening torque nearby fastener. In this case, nut must be torqued to 145 N m (107 lbf ft).

CAUTION

Pay attention to torque specifications. Some of these are in lbf in instead of lbf ft. Use appropriate torque wrench. F04A09S

VIII

2 9 N m (80 lbf in)

Page numbering system: 03: ENGINE section 04: MAGNETO SYSTEM subsection 1: First page of this subsection

INTRODUCTION

TYPICAL PAGE Sub-title indicates a particular procedure for the named part.

Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS)

Title indicates main procedure to be carried-out.

Service tool to be used to perform a certain procedure.

Italic bold face setting indicates a particular procedure concerning a model. Italic bold face setting in this case indicates that particular procedure for Challenger is finished, so from this point, all others models are concerned.

CARBURETOR REMOVAL

DISASSEMBLY AND INSPECTION

To remove carburetors from engine, proceed as follows: Remove air vent tube support. Unlock retaining slides holding air intake silencer base. Remove air intake silencer base from watercraft. Remove screws holding flame arrester base support to cylinder head cover. Unscrew base retaining screws then remove base from carburetors and move to front of watercraft. Turn the valve to OFF position.

Inspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.).

Diaphragm

Sub-sub-title indicates a particular testing, adjustment or repair procedure.

Pump Diaphragm Leak Test Using a suitable pump gauge tester, perform the following test proceeding as follows: - Install pump gauge tester (P/N 295 000 083) on pulse nipple. - Pump tester until it reaches 28 kPa (4 PSI).

NOTE: For fuel line removal, use pliers (P/N 295 000 054).

Illustration always follows text it is pertained to.

Disconnect pulse line from fuel pump. Disconnect fuel fuel supply line from fuel pump. Disconnect fuel return line. Disconnect oil injection pump cable, throttle cable and choke cable. Challenger Model Only Remove screws and lock washers retaining carburetors. Remove carburetors from intake manifold. All Others Models Remove 4 bolts and lock washers from rotary valve cover then move carburetors and rotary valve cover on top of engine. NOTE: When removing rotary valve cover , pay attention that the rotary valve stay in place, otherwise it must be timed. Remove carburetors from intake manifold. Disconnect fuel bypass line between carburetors (twin carburetors). Remove carburetor(s) from rotary valve cover.

F01F0XB

''TYPICAL'' caption indicates a general view which does not represent full detail.

TYPICAL Step 1 : Install pump gauge tester to pulse nipple Step 2 : Pump tester until it reaches the desired pressure 1. Fuel outlet nipple 2. Fuel inlet nipple A. 28 kPa (4 PSI)

Diaphragm no. 3 must stand pressure for 10 seconds. If pressure drops, replace diaphragm.

Numbers in a frame are used to give a sequence to be perfomed for above illustration.

Number: following part name refers to exploded view at beginning of subsection. 06-03-4

Letters are used for any measures for above illustration.

Numbers are used for description of components for above illustration.

F04A08S

INTRODUCTION

LIST OF ABBREVIATIONS USED IN THIS MANUAL

Alternative Current

Ass’y

Assembly

ATDC

After Top Dead Center

BTDC

Before Top Dead Center

CDI

Capacitor Discharge Ignition

CSI

Cooling System Indicator

Direct Current

DC-CDI

Direct-Current Capacitor Discharge Ignition

DESS

Digitally Encoded Security System

E.I.N

Engine Identification Number

H.I.N.

Hull Identification Number

Horsepower

Left Hand side (port)

MAG

Magneto

MPEM

Multi-Purpose Electronic Module

N.A. or N/A

Not Applicable

P/N

Part Number

PTO

Power Take Off

RAVE

Rotax Adjustable Variable Exhaust

RFI

Radio-Frequency Interference

Right Hand side (starboard)

RMS

Root Mean Square

ROM

Read-Only Memory

RPM

Revolution Per Minute

SAE

Society of Automotive Engineering

TDC

Top Dead Center

T.I.G.

Tungsten Inert Gas

TLCS

Total Loss Cooling System

Vac

Volt, Alternative Current

Vdc

Volt, Direct Current

VROI

Variable Rate Oil Injection

GENERAL INFORMATION In marine industry, PORT, STARBOARD, BOW and STERN are used to refer to LEFT, RIGHT, FRONT and REAR respectively. They always refer to the operator’s position sitting in boat. 1

F04L03C

1. 2. 3. 4.

BOW (front) STARBOARD (RH) STERN (rear) PORT (LH)

The information and component/system descriptions contained in this manual are correct at time of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This Shop Manual uses technical terms which may be different from the ones of the Parts Catalogs. When ordering parts always refer to the specific model Parts Catalogs.

INTRODUCTION

ILLUSTRATIONS AND PROCEDURES The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown; however, they represent parts which have the same or a similar function.

CAUTION

These boats are designed with parts dimensioned in both the metric and the imperial systems. When replacing fasteners, make sure to use only those recommended by Bombardier. Mismatched or incorrect fasteners could cause damage to the boat or possible personal injury. As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. Technical Publications Bombardier Inc. Valcourt (Quebec), Canada

Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA)

TECHNICAL DATA ENGINE

0 SPEEDSTER (5678)

Number of engine Engine type

BOMBARDIER-ROTAX 787, water cooled

BOMBARDIER-ROTAX 717, water cooled

Induction type Exhaust type

SPEEDSTER SK (5677/5681)

Rotary valve Type

Water cooled, water injected

Water injection fittings

3.5 mm (.139 in)

Starting system

Electric start Fuel/oil mixture

VROI (Variable Rate Oil Injection)

Oil injection pump

MIKUNI (gear driven)

Lubrication

Bombardier-Rotax injection oil P/N 413 802 900 (12 x 1 L) P/N 413 803 000 (3 x 4 L) P/N 413 803 200 (205 L)

Oil type Number of cylinders Bore

2x2 Standard

82.00 mm (3.228 in)

First oversize

82.25 mm (3.238 in)

Second oversize Stroke Displacement Compression ratio

781.0 Uncorrected Corrected

Engine maximum torque Cylinder head warpage (maximum) Piston ring type and quantity Ring end gap Ring/piston groove clearance Piston/cylinder wall clearance

New Wear limit New Wear limit New Wear limit

cm3

(47.65

68 mm (2.68 in) 718.2 cm³ (43.81 in³)

in3)

11.75: 1

12:1

5.9: 1

6.2:1

2 x 110 N•m (81 lbf•ft) @ 6500 RPM

2 x 91 N•m (67 lbf•ft) @ 6250 RPM

0.05 mm (.002 in) 0.25 - 0.40 mm (.010 - .016 in) 1.00 mm (.039 in) 0.025 - 0.070 mm (.001 - .003 in) 0.20 mm (.008 in) 0.09 - 0.11 mm (.003 - .004 in) 0.20 mm (.008 in) 0.10 mm (.004 in)

Cylinder out of round

0.08 mm (.003 in) New Wear limit

0.39 - 0.74 mm (.015 - .029 in) 1.2 mm (.047 in) 0.08 mm (.003 in) ➀

Crankshaft deflection (center) Rotary valve timing

82.50 mm (3.248 in)

1 semi-trapez — 1 rectangular

Cylinder taper (maximum) Connecting rod big end axial play

N.A. 74 mm (2.91 in)

Opening

147° ± 5° BTDC

Closing

63.5° ± 5° ATDC

Rotary valve duration

158°

Crankcase/rotary valve gap

0.25 - 0.35 mm (.010 - .014 in)

Connecting rod/crankshaft pin radial clearance

New

Connecting rod/piston pin radial clearance

New

Wear limit Wear limit

0.01 - 0.02 mm (.0004 - .0008 in) 0.050 mm (.002 in) 0.003 - 0.012 mm (.00012 - .00047 in) 0.015 mm (.00059 in)

ADDITIONAL INFORMATION: ➀ MAG side: 0.05 mm (.002 in) PTO side: 0.03 mm (.001 in) N.A.: Not Applicable

12-01-1

Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA)

ELECTRICAL Magneto generator output Ignition system type

Spark plug

SPEEDSTER (5678)

SPEEDSTER SK (5677/5681)

2 x 180 W @ 6000 RPM or 5 A @ 2000 RPM

2 x 160 W @ 6000 RPM or 4 A @ 2000 RPM

DC-CDI (Direct Current-Capacitor Discharge Ignition)

CDI (Capacitor Discharge Ignition)

Make and type

NGK BR8ES

Gap

0.55 mm (.021 in)

mm (in)

3.38 (.133)

2.59 (.102)

Degrees

22° @ 3500 RPM ➀

20° ± 1 @ 6000 RPM ➀

N.A.

40 - 76 Ω

Trigger coil

242 Ω

N.A.

Battery charging coil

0.8 Ω

0.05 - 0.6 Ω

0.6 Ω (not measurable)

.34 - .62 Ω (not measurable)

11.4 - 14 kΩ

9 - 15 kΩ

7200 (± 50) RPM

7000 (± 50) RPM

Ignition timing (BTDC) Generating coil

Ignition coil

Primary Secondary

Engine RPM limiter setting

Not supplied ➁

Battery MPEM (Multi-Purpose Electronic Module) supply

Fuse block supply

3 x 20 A

Charging system

2 x 15 A

Blower Fuse

7.5 A

Bilge pump

Lighting system

Gauges

Additional accessories

10 A

Horn fuse

Jack system

10 A

Radio/courtesy lights

10.0 A

N.A.

ADDITIONAL INFORMATION: ➀ With shifter in forward or reverse position. ➁ Recommended: Exide RV24-130, 12 V, 25 A•h (130 minutes reserve) or RV24-160 (160 minutes) or equivalent. Battery posts: On top. Round taper type. Battery maximum allowed size: 285 mm (11-1/4 in) long x 190 mm (7-1/2 in) wide x 238 mm (9-3/8 in) high. N.A.: Not Applicable

;

WARNING

Never use automotive type battery. Its mechanical construction does not allow to meet the shock conditions where boats operate. Only use the type of battery recommended. .

12-01-2

Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA)

CARBURETION

SPEEDSTER (5678)

SPEEDSTER SK (5677/5681)

Mikuni twin diaphragm with acceleration pump

Mikuni single diaphragm with acceleration pump

Model (MAG side) (PTO side)

BN 40i-38-49 BN 40i-38-50

BN 40i-38-28

Quantity

2 per engine

1 per engine

Main jet

MAG: 142.5, PTO: 145

167.5

Pilot jet

67.5

70.0

Type Carburetor

Low-speed screw

1-1/2 turn

1-1/4 turn

High speed screw Adjustment

Idle speed (in water)

1500 RPM

Idle speed (out of water)

3000 RPM

Docking assistance speed (in water) Fuel

Type

2800 RPM

2500 RPM

Regular unleaded gasoline

Octane no.

Fuel return line orifice

87 (R + M)/2 (MAG) 8 mm (.316 in) — (PTO) 6 mm (.237 in)

(PTO) 6 mm (.237 in)

SPEEDSTER (5678)

SPEEDSTER SK (5677/5681)

ADDITIONAL INFORMATION:

COOLING Type

Open circuit — Direct water flow

Thermostat

None

Overheating beeper setting

96 - 99°C (205 - 210°F)

ADDITIONAL INFORMATION:

PROPULSION

Bombardier Formula Pump (big hub)

Number of pump

Jet pump type

Axial flow single stage

Impeller rotation (seen from rear)

Counterclockwise

Transmission

Direct drive

Coupling type

Crowned splines SEA-DOO JET PUMP SYNTHETIC OIL Polyolester 75W90 GL5 ➀ (P/N 293 600 011 - 12 x 6 oz)

Oil type Steering nozzle pivoting angle

26°

Minimum required water level

90 cm (35 in)

Drive shaft deflection (maximum)

0.5 mm (.020 in)

Impeller outside diameter Impeller/wear ring clearance

SPEEDSTER SK (5677/5681)

SPEEDSTER (5678)

Propulsion system

139.5 mm (5.492 in) New Wear limit

Impeller shaft end play (new)

0.18 - 0.44 mm (.007 - .017 in) 1.02 mm (.040 in) 0.12 - 0.54 mm (.005 -.021 in)

Impeller shaft side play

0.05 mm (.002 in)

Impeller pitch/material

Progressive pitch/stainless steel

ADDITIONAL INFORMATION: ➀ Do not mix different brands or oil types.

12-01-3

Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA)

DIMENSIONS

SPEEDSTER (5678)

SPEEDSTER SK (5677/5681)

Dead rise

20Â°

Draft

30.5 cm (12 in)

Overall length

503 cm (164 ft 6 in)

Overall width (beam)

231 cm (91 in)

Overall height

127 cm (50 in)

Dry weight

777 kg (1710 lb)

Load limit (passengers and 10 kg (22 lb) luggage)

5 passengers OR 410 kg (905 lb)

Maximum water skiers on tow

ADDITIONAL INFORMATION:

CAPACITIES

SPEEDSTER (5678)

Fuel tank (including reserve)

151 L (40 U.S. gal)

Fuel tank reserve Impeller shaft reservoir

SPEEDSTER SK (5677/5681)

15 L (4 U.S. gal) Capacity

100 mL (3.4 U.S. oz)

Oil level height

To bottom of cover hole

Oil injection reservoir

9 L (2.4 U.S. gal)

ADDITIONAL INFORMATION:

MATERIAL

SPEEDSTER (5678)

Hull

SPEEDSTER SK (5677/5681)

Composite (fiberglass and wood)

Air intake silencer

Thermoplastic

Flame arrester

Multi-layer wire screen

Exhaust muffler

Aluminum

Fuel tank

Polyethylene

Oil injection reservoir

Polyethylene

Seat

Base: polyethylene, Foam: polyurethane

Ride shoe

Plastic

Jet pump

Plastic

Front storage cover

Polystyrene

ADDITIONAL INFORMATION:

PERFORMANCE

SPEEDSTER (5678)

SPEEDSTER SK (5677/5681)

Estimated pump power

2 x 33.0 kW (44.2 hp)

2 x 25.4 kW (34 hp)

Maximum fuel consumption at wide open throttle

92 L/h (24.4 U.S. gal/h)

63 L/h (16.7 U.S. gal/h)

1 h 25 min

2 h 10 min

15 min

Cruising time at full throttle

Fuel tank without reserve Fuel tank reserve

ADDITIONAL INFORMATION:

12-01-4

Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA)

STANDARD EQUIPMENT

SPEEDSTER (5678)

DESS (Digitally Encoded Security System) Spark plug wrench Fuel tank reserve Electric fuel level gauge Oil injection low level/warning device Overheating warning device and CSI (Cooling System Indicator) Speedometer Tachometer Variable Trim System (VTS) Stern light and navigation lights Courtesy lights Shifter control (forward/neutral/reverse) Electric bilge pump (manual switch + auto) Blower Storage compartment (front/console/rear/deck) Grab handles Extinguisher holder Cup holders Mirrors Retractable ski pole Bow filler cushion Sun deck cushion Rear cover pad Platform pad Radio AM-FM Horn Bimini Top Swivel bucket seats Windshield Rack for ski/knee/wakeboard Lift kit Ski door lock Engine cover lock Storage cover lock Cooler door lock Ski rope locker lock Glove box Low-speed steering control system Depth sounder provision Mooring cover Weedless (system) Ladder Deck carpet ADDITIONAL INFORMATION: N.A.: Not Applicable

SPEEDSTER SK (5677/5681) Standard Standard Standard Standard Standard Standard Standard Standard (2) N.A. Standard

Standard

Optional

Standard Standard Standard Standard std/std/std/std Standard Standard Standard Standard (1) Standard (+ extension) N.A. N.A. Standard Standard Optional Standard Optional Standard Standard (2) N.A. Optional Standard Standard Standard Standard N.A. N.A. Standard Standard Optional Standard Standard Optional

12-01-5

Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA)

SPEEDSTER (5678) SPEEDSTER SK (5677/5681)

TIGHTENING TORQUES Exhaust manifold screw

24 N•m

(17 lbf•ft)

(1)

Magneto flywheel nut (787 engine)

110 N•m

(81 lbf•ft)

(1)

Magneto flywheel nut (717 engine)

145 N•m

(107 lbf•ft)

(1)

Flywheel (PTO side)

105 N•m

(77 lbf•ft)

(5)

9 N•m

(80 lbf•in)

(1)

24 N•m

(17 lbf•ft)

(1)

Crankcase/engine support nuts

25 N•m

(18 lbf•ft)

(1)

Engine support/hull

25 N•m

(18 lbf•ft)

(1)

Cylinder head cover screws

24 N•m

(17 lbf•ft)

(3)

Crankcase/cylinder screws

24 N•m

(17 lbf•ft)

(3)

Tuned pipe nut/manifold stud, screws and nuts

40 N•m

(30 lbf•ft)

(1) and (2)

Tuned pipe fixation screws

25 N•m

(18 lbf•ft)

(1)

Flame arrester screws

10 N•m

(88 lbf•in)

(1)

Carburetor on intake manifold nuts

25 N•m

(18 lbf•ft)

(1)

Impeller shaft

70 N•m

(52 lbf•ft)

(2) (2)

STEERING

PUMP

ENGINE

Crankcase screws

Pump/hull nuts (inside bilge)

31 N•m

(23 lbf•ft)

Pump/hull nuts (outside bilge)

28 N•m

(21 lbf•ft)

Venturi/pump housings screws

21 N•m

(15 lbf•ft)

Nozzle/venturi screws

20 N•m

(15 lbf•ft)

Pump housing cover screws

4 N•m

(35 lbf•in)

(1)

Reverse gate support/venturi screws

21 N•m

(15 lbf•ft)

(1)

Intake grate/hull screws

6 N•m

(53 lbf•in)

(1)

Ride shoe screws/nuts

10 N•m

(88 lbf•in)

(6)

Steering wheel nut

30 N•m

(22 lbf•ft)

Steering support/deck screws

6 N•m

(53 lbf•in)

Steering support/helm screws

4.5 N•m

(40 lbf•in)

Steering cable retaining block bolts

14 N•m

(124 lbf•in)

Steering cable/rotating arm screw and nut

3 N•m

(27 lbf•in)

(1)

Steering cable/nozzle screw and nut

3 N•m

(27 lbf•in)

(4) on bushing

Dashboard screws

ELECTRICAL

PRODUCT TO APPLY

1.5 N•m

(14 lbf•in)

Steering cable/hull nut

8 N•m

(71 lbf•in)

Ignition housing cover screws

8 N•m

(71 lbf•in)

(5)

Starter mountion screws

25 N•m

(16 lbf•ft)

(1)

Starter lock nuts

7 N•m

(62 lbf•in)

Spark plugs

24 N•m

(17 lbf•ft)

Anode

5.7 N•m

(50 lbf•in)

ADDITIONAL INFORMATION: Apply where indicated;

(1) Add Loctite 242 (P/N 293 800 015) (2) Add Loctite 271 (P/N 293 800 005) (3) Add Loctite 518 (P/N 293 800 038) (4) Syhthetic grease (P/N 293 550 010) (5) Anti-seize lubricant (P/N 293 800 023) (6) Adseal 4511 (P/N 293 800 033) N.A.: Not Applicable

; WARNING

Correct torques and use of Loctite® must be strictly followed.

12-01-6

(1) and (6)

(6)

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

SERVICE TOOLS....................................................................................................................

01-02-1

SERVICE PRODUCTS ............................................................................................................

01-03-1

01-01-1

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

SERVICE TOOLS

This is a list of tools to properly service Sea-Doo jet boats. The list includes both the mandatory tools and the optional tools that are ordered separately. Service Products are not part of any kit and must all be ordered separately. If you need to replace or add to your tool inventory these items can be ordered through the regular parts channel. NEW Following mention points out new tool:

WORKSHOP — MANDATORY SERVICE TOOLS Tool board P/N 295 500 608 NEW

F00A0S4

APPLICATION All models.

01-02-1

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

WORKSHOP â&#x20AC;&#x201D; RECOMMENDED SERVICE TOOLS Radio removal tool P/N 295 100 106 NEW

F10P094

APPLICATION Boats equipped with radio. Protective mat P/N 295 000 129

F04L1V4

APPLICATION All models except Explorer.

01-02-2

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

ENGINE â&#x20AC;&#x201D; MANDATORY SERVICE TOOLS Degree wheel P/N 295 000 007 33 50

350 360 10 20 340 10 360 350 3 20 40

0 70

0 14

12 0 13 250 0 24 1 0 2

A01B1P4

APPLICATION 717 and 787 engines.

22 0

180 190 2 170 00 21 160 0 200 190 180 17 22 0 210 0 16 0 15 0

280

290

120

270

110 100 90

90 100 11 0 280 270 26 0

130

Piston circlip

290

250

300

Piston circlip installer P/N 529 035 562

5 2

260

0 23

30 33

A00B334

APPLICATION All models. Rubber pad P/N 295 000 101

MAG side

PTO side

F01D884

1) Puller P/N 420 877 635 2) Protective cap (both ends) P/N 420 876 557 3) Ring (both ends) P/N 420 977 490

F01B0J4

APPLICATION All models. PTO flywheel remover/installer P/N 295 000 001

Pusher P/N 420 876 605

4) Ring halves (PTO) P/N 420 977 475 (2)

A00C0Y4

APPLICATION All engines except 787. Bearing pusher P/N 420 876 501

5) Distance ring (MAG) P/N 420 876 569 F00B074

6) Ring halves (MAG) P/N 420 276 025 (2)

APPLICATION 717 and 787 engines.

7) Screw M8 x 40 P/N 420 840 681 (2) F01J0T4

APPLICATION All engines except 787. NOTE: This tool is also used for the impeller.

8) Screw M8 x 70 P/N 420 841 201 (2) APPLICATION All models.

01-02-3

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

ENGINE (continued) â&#x20AC;&#x201D; MANDATORY SERVICE TOOLS Digital multimeter P/N 529 022 000

Puller P/N 529 035 547

Alignment support plate kit P/N 529 035 506 1) Alignment plates P/N 529 035 507 2) Support P/N 529 035 511

A00C1A4

Puller plate P/N 420 876 080

3) Screw (2) P/N 207 182 544 Lock washer (2) P/N 234 181 601 Flat washer (2) P/N 234 081 410

F01B1O4 A00C1R4

APPLICATION All models.

Extension handle P/N 295 000 125 F00B0F4

Puller P/N 290 876 488

F01D164

Screw M8 x 35 (3) P/N 420 841 591 2

APPLICATION Engine alignment. Alignment shaft P/N 295 000 141

1 F00A094

F01B0I4

APPLICATION All engines. Replacement parts: 1) Hex. screw (M6 x 60) P/N 290 240 860 2) Nut (M6) P/N 232 061 414

Sleeve (3) P/N 290 847 220 F00B0G4

APPLICATION Engine alignment. F00A0A4

APPLICATION All engines except 787.

Ring gear blocking tool P/N 295 000 155

F01B264

APPLICATION 787 engine.

01-02-4

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

ENGINE (continued) â&#x20AC;&#x201D; MANDATORY SERVICE TOOLS Piston pin puller P/N 529 035 503

Flywheel extractor P/N 295 000 156

F00B0T4

APPLICATION All engines. Sleeve set P/N 529 035 542 (20 mm sleeve)

F00B044

APPLICATION 787 engine. Engine leak tester kit P/N 295 500 352

F00B0U4

APPLICATION All models. MPEM programmer P/N 529 035 589

F01B2Q5

APPLICATION All models. Ring gear puller tool P/N 529 035 547 A01B5B4

APPLICATION Boats equipped with the DESS.

F01B294

APPLICATION 787 engine.

01-02-5

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

ENGINE â&#x20AC;&#x201D; RECOMMENDED SERVICE TOOLS Ring compressor P/N 290 876 979 (82 mm)

Stroboscopic timing light P/N 529 031 900

Digital/induction type tachometer P/N 529 014 500

A00B4F4

F01B1G4

APPLICATION All models.

Dial indicator (TDC gauge) P/N 295 000 143

Timing mark pointer P/N 295 000 130

A01B1T4

APPLICATION 717 and 787 engines. Coil centering tool P/N 420 876 922

A00B4E4

A01B1V4

APPLICATION All models.

APPLICATION All engines except 787.

Distance gauge

Cylinder aligning tool P/N 420 876 904

F01B2O4

A) P/N 529 034 800 B) P/N 529 034 900

APPLICATION All engines except 787. Timing mark pointer P/N 295 000 135

A00B084

APPLICATION All engines except 787. F01B0H4

APPLICATION A) 717 engine. B) 787 engine.

F01H544

APPLICATION 787 engine.

01-02-6

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

ENGINE (continued) — RECOMMENDED SERVICE TOOLS Crimping tool P/N 295 100 164

Engine lifting device Not sold by Bombardier Do it yourself Refer to ENGINE REMOVAL AND INSTALLATION section

Slide hammer puller Not sold by Bombardier Snap-on: Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4

F01J0Z4

APPLICATION All models.

F00B0E4

NOTE: This tool is also used to

APPLICATION Contacts in AMP connectors on MPEM.

pull out impeller shaft seal. F01D0A4

Oil seal pusher P/N 290 877 740

APPLICATION All engines except 787.

Safety lanyard switch tool P/N 529 034 600

Feeler gauge 45° Not sold by Bombardier Snap-on FB 300 A F01B244 F01B2C4

APPLICATION Boats equipped with the DESS.

APPLICATION 787 engine. F01B1K4

Ring halves and ring P/N 420 876 330 (halves) (2) P/N 420 977 480 (ring)

APPLICATION All models. Terminal remover Not sold by Bombardier

A) Four-pin magneto harness P/N 295 000 131 B) Six-pin magneto harness P/N 295 000 136

Snap-on TT 600-4

F01B2D4

APPLICATION 787 engine.

F01B1J4

APPLICATION All models.

F01B284

APPLICATION A) 717, 1995 and newer. B) 787 engine.

01-02-7

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

ENGINE (continued) â&#x20AC;&#x201D; RECOMMENDED SERVICE TOOLS Rotary valve shaft pusher P/N 290 876 609

Gear/bearing puller P/N 290 877 665

F01B2B4

APPLICATION 787 engine. Handle P/N 420 877 650

F04B034

APPLICATION 787 engine. Crankshaft protector P/N 420 876 552

F00B034

APPLICATION For use with pullers.

A00C3V4

APPLICATION 787 engine. Exhaust outlet tool P/N 295 000 132

F01B2A4

APPLICATION Exhaust nut on transom.

01-02-8

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

COOLING/FUEL/OIL SYSTEMS â&#x20AC;&#x201D; MANDATORY SERVICE TOOLS Hose pincher P/N 295 000 076

Pliers P/N 295 000 054

Lighted adjustable mirror Not sold by Bombardier

Caillau

Snap-on 50101

F01B1I4 F01B1T4

APPLICATION All models.

A01B2I4

APPLICATION All models.

NOTE: This tool is also used for the propulsion system.

Gear holder P/N 420 277 905

Pump gauge tester (carburetor) P/N 295 000 114

Hose pincher P/N 529 032 500 TYPICAL

2 15 1

25 3

F01B234

APPLICATION All engines.

A00C164

APPLICATION All engines except 787. Pliers P/N 295 000 070 Oetiker 1099

Flexible spout (oil) P/N 414 837 300

F01B0X4

APPLICATION All models. Screwdriver Not sold by Bombardier Snap-on SDD-143

F01D174

F04B044

APPLICATION All models.

APPLICATION All models. F01B1P4

APPLICATION All models.

01-02-9

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

PROPULSION SYSTEM â&#x20AC;&#x201D; MANDATORY SERVICE TOOLS Impeller remover/installer P/N 295 000 001

Bearing/seal installer P/N 295 000 107

Fitting P/N 295 000 086

F01J0T4

APPLICATION All models. NOTE: This tool is also used for the PTO flywheel. Pliers P/N 295 000 069 Oetiker 1090

F01B0Z4 F01J4K4

APPLICATION All models. Impeller shaft guide P/N 295 000 002

F01D184

F01J1O4

APPLICATION All models.

Impeller shaft holder P/N 295 000 082

Pliers P/N 295 000 054

APPLICATION All models. Slide hammer puller Not sold by Bombardier Snap-on: Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4

F01J0Z4

APPLICATION All models.

NOTE: This tool is also used to

Caillau

remove rotary valve shaft bearing. Hacksaw Not sold by Bombardier Snap-on HS3

F01B0W4

F01B1T4

APPLICATION All models.

APPLICATION All models. NOTE: This tool is also used for the fuel system.

01-02-10

F01B1M4

APPLICATION All models.

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

PROPULSION SYSTEM (continued) — MANDATORY SERVICE TOOLS Machinist’s square Not sold by Bombardier

Pump bearing remover P/N 295 000 144

Snap-on PMF 122 F01J114

APPLICATION All models.

F02B064

APPLICATION Explorer.

Impeller housing remover P/N 295 000 113

Fitting remover Not sold by Bombardier Do it yourself Refer to Shop Manual Deep socket 14 mm (9/16 in)

F01L2O4

APPLICATION Models without a jet pump support. F01J2R4

APPLICATION Models without a jet pump support.

01-02-11

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS)

BOAT HANDLING â&#x20AC;&#x201D; RECOMMENDED SERVICE TOOLS Tie-down with ratchet 3.60 m (12 ft) long P/N 295 100 104

F04B054

APPLICATION All models. Tie-down P/N 295 100 088 NEW

F00l0l4

APPLICATION All boats. Lift kit NEW

14 foot: P/N 295 000 160 16 foot: P/N 295 100 085 18 foot: P/N 295 100 045

01-02-12

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

SERVICE PRODUCTS

Loctite is a trademark of LoctiteTM Corporation. Dow Corning® is a trademark of Dow Corning® Corporation. Medium strength threadlocker P/N 293 800 015

High temperature threadlocker P/N 413 711 400

Loctite 242 (blue) (10 mL)

Retaining compound P/N 413 703 100 Loctite® RC/609 (green) (10 mL)

Loctite 648 (green) (10 mL)

LOCTITE®

REMOVABLE

RC/609

THREADLOCKER 242

A00B324

A00B3D4

A00B2S4

APPLICATION Flywheel nut, crankcase studs, etc.

APPLICATION

APPLICATION Used for retaining bushings, bearings in slightly worn housing or on shaft.

High strength threadlocker P/N 293 800 005

For RAVE valve rod distance nut. High temperature retaining compound P/N 293 800 054

Loctite 271 (red) (10 mL)

Loctite 642 (50 mL)

General purpose instant adhesive P/N 293 800 021 Loctite 495

A00B2V4

LOCTITE

SURE S A

LOCTITE® 271 Adhesive Sealant

642

APPLICATION Rubber to metal bonding and most hard plastic.

NET 1.69 FL .OZ. (50 ml)

A00B2U4

APPLICATION Fasteners and studs up to 1 in diameter.

F00B024

01-03-1

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

Loctite Primer P/N 293 800 041

Thread sealant P/N 293 800 050

Loctite Primer N

Gun Kote Not sold by Bombardier

Loctite 577 (250 mL)

Kal-Gard Coating & Mfg. Corp.

APPLICATION Ring gear and magneto flywheel. F00B0W4

All purpose gasket and jointing compound P/N 293 800 001

A00B3N4

Dielectric grease P/N 293 550 004 Dow Corning (150 g)

Hylomar (100 g)

APPLICATION To prepare mating surfaces before applying paste gasket, retaining compound or threadlockers.

F01B164

APPLICATION Paste Gasket P/N 293 800 038 Loctite 518 Gasket Eliminator (50 mL)

A00B3F4

High temperature RTV sealant P/N 413 710 300 Loctite 179 ULTRA COPPER (80 mL)

518

On all electric connections. High tension coil and spark plug connections. Connector housings, etc. Deoxit contact lubricant P/N 293 550 015 DeoxIT D5 (200 mL)

F01B124

APPLICATION - Cylinder sleeve O-ring groove. - Crankcase halves. Pipe sealant with teflon A) P/N 293 800 018 B) P/N 293 800 013 A) Loctite 592 A(50 mL)

B) Loctite 567 (250 mL)

A02B044

A00B2W4

APPLICATION Engine plugs and senders.

01-03-2

Epoxy glue Not sold by Bombardier 3M-05900

F00B0X4

APPLICATION Header pins on MPEM connectors.

Section 01

Grease for bearings P/N 293 550 005

SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

Anti-seize lubricant P/N 293 800 023

(400 g)

Sea-Doo fuel stabilizer P/N 413 408 600

Loctite anti-seize lubricant 12 oz (454 g)

(8 oz)

A00B2L4

NEW

Super Lube grease P/N 293 550 014

FUEL STABILIZER

F01B174

PERMATEX INDUSTRIAL

Super Lube R

BOMBARDIER LUBE P/N 293 600 016

M Syn ulti-Purpose the tic Lubrica nt Wi th Teflon R Ne tW

(12 x 14 oz)

) t. 14.5 Oz. (41 1g

A00B3V4

BOMBARDIER-ROTAX injection oil P/N 413 802 900 (12 x 1 L)

s ray

! Spwn! do NEW side up

BOMBARDIER

LUBE REPLA CES SEA-DOO LUBE

A00B474

ANTICO T RROSIVE LUBRICAN Excellent for salt water and high humidity environments ®

340 g

BOMBARDIER ®

DANGER

Lubricant Not sold by Bombardier G.E. Versilube G341M

Two-stroke

Injection Oil

FLAMMABLE CONTA D. INER MAY EXPLODE IF HEATE DIRECT INHALATION OF SPRAY MAY BE HARMFUL. BOMBARDIER INC.

Sea-Doo Valcourt, / Ski-Doo Division2LO Québec, Canada J0E

1 U.S. quart

F01B0S4

F01B184

Bombardier storage oil P/N 413 711 600 350 g spray can (12 x 350 g) or Esso Beacon 325 A00B1T4

BOMBARDIER-ROTAX injection oil P/N 413 803 000 (3 x 4 L) P/N 413 803 200 (205 L)

Sea-Doo Synthetic grease P/N 293 550 010 (400 g)

SYNTHETIC GREASE ®

F01B154

APPLICATION PTO flywheel.

F01B2H4

A02B054

01-03-3

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

BOMBARDIER-ROTAX Formula XP-S synthetic injection oil P/N 413 711 000 (3 x 4 L) P/N 413 710 700 (205 L)

Right Stuff Gasket P/N 293 800 053

Sea-Doo Cleaner P/N 293 110 001 (400 g) P/N 293 110 002 (4 L)

Permatex® (198 g) (300 mL)

BOMBARDIER

CLEANER 400 g

BOMBARDIER

DANGER ®

DANGER

293 110 002

BOMBARDIER

EXTREMELY FLAMMABLE. HARMFUL OR FATAL IF SWALLOWED. VAPOUR HARMFUL.

Two-stroke FORMULA XP-S

4 U.S. quart

SYNTHETIQUE Injection Oil Two-Stroke Oil

F01B2J4 F01B354

BOMBARDIER-ROTAX Formula XP-S synthetic injection oil P/N 413 710 500 (12 x 1 L)

Gasket/paint remover (P/N 413 708 500) NEW F00B0V4

Loctite® 79040 Chisel 510 g (18 oz)

Clear silicone sealant P/N 293 800 033 Adseal 4511 (clear) BOMBARDIER ®

FORMULA XP-S Synthetic

ADCHEM

Two-Stroke Oil

ADS E AL

SCELLANT ADHÉSIF PREMIÈRE QUALITÉ

F01B1S4

1 liter (1.05 U.S. qt)

F01B2G4

Jet pump synthetic oil P/N 293 600 011 (12 x 6 oz)

Adhesive activator P/N 293 530 036

A00B3L4

(250 mL)

Sea-Doo jet pump synthetic oil

ACTIVEUR D'ADHÉSIF

250 mL POUR L'APPLICATION DE MOULURE PRESSION ET VINYLES SENSIBLES À LA LORSQU'UNE MEILLEURE . ADHÉRENCE EST NÉCESSAIRE

DANGER

JET PUMP SYNTHETIC OIL

AVEC LA PEAU -ÉVITER TOUT CONTACT PROLONGÉ CAS DE CONTACT. LAVER À L'EAU FROIDE EN BIEN AÉRÉ. -UTILISER DANS UN ENDROITFERMÉ. -TENIR LE CONTENANT BIEN DES ENFANTS. -GARDEZ HORS DE LA PORTÉE . -CONTIENT DU TRICHLORETYLÈNE DE CE PRODUIT -AVERTISSEMENT ! L'INHALATION EST NOCIF. N/P 293 530 036

FABRIQUÉ AU

F01B1Z4 F01B0P4

APPLICATION Impeller shaft reservoir.

01-03-4

PREMIUM SEALANT ADHESIVE

APPLICATION Decal replacement.

APPLICATION Clean mating surfaces of cylinders and crankcase. Remove carbon in combustion chambers. NOTE: This product replaces Gasket stripper (P/N 295 000 110).

Section 01

Parts cleaner P/N 413 711 809 (320 g) NEW

SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

Sea-Doo spray paint for gelcoat A) Super white (140 g) P/N 293 500 082 B) Super white (140 g) P/N 293 500 076 C) White (140 g) P/N 293 500 041 D) Dark green (140 g) P/N 293 500 101

Glue for P.V.C. P/N 204 000 044 Vinyl and Plastic Cleaner P/N 413 711 200 Molykote 111 P/N 413 707 000 NEW

VERTICAL FANSPRAY PATTERN

ROTATE VALVE NOZZLE 1/4 TURN TO CHANGE SPRAY PATTERN

HORIZONTAL FANSPRAY PATTERN

Danvern Fanspray® - A Sprayon Exclusive Feature

DOW CORNING ®

PEIN TURE POUR

DA NGE R

GELCOAT

R DANGE

F01B1Q4 A00B4X4

APPLICATION Any greasy surfaces. NOTE: This product replaces Loctite Safety solvent (P/N 413 708 200). Spray paint for metallic parts only A) White (140 g) P/N 293 500 029 B) Purple (140 g) P/N 293 500 020

111

T PAIN

Gelcoat (liquid) A) Super white (1 L) P/N 293 500 075 B) White (1 L) P/N 293 500 033

A00B3W4

APPLICATION - Crankshaft seals. - Rotary valve shaft seals. - Engine top end screws. Threadlocker P/N 293 800 040 NEW

C) Dark green (1 L) P/N 293 500 100

Loctite 425

Loctite Super Bonder P/N 413 705 800 NEW

C) Grey (140 g) P/N 293 500 009

Loctite 414

Sea-Doo paint

F09P084

APPLICATION Small plastic fasteners.

F01B0Q4 F09P074

APPLICATION Seat trim.

01-03-5

Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

PERIODIC INSPECTION CHART ...........................................................................................

02-02-1

FLUSHING AND LUBRICATION ........................................................................................... GENERAL ........................................................................................................................... PROCEDURE ......................................................................................................................

02-03-1 02-03-1 02-03-1

WATER-FLOODED ENGINE .................................................................................................. GENERAL ........................................................................................................................... PROCEDURE ......................................................................................................................

02-04-1 02-04-1 02-04-2

STORAGE...............................................................................................................................

02-05-1

02-01-1

Subsection 02

Section 02 MAINTENANCE (PERIODIC INSPECTION CHART)

PERIODIC INSPECTION CHART

NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency. FREQUENCY DESCRIPTION Lubrication/corrosion protection of metallic components including anode connections Lubrication of locks of storage compartments covers DESS operation/DESS post and safety lanyard cap terminal condition Engine ignition timing Spark plug replacement Throttle/choke cables/accelerator pump mechanism and plunger, inspection/lubrication Steering cables/reverse cables Flame arrester inspection Carburetor adjustment including choke/throttle cable adjustment and linkage RAVE valve Water flow regulator valve Oil injection pump adjustment Fuel filter and oil filter inspection Fuel filter and oil filter replacement Engine head screws, retorque Steering system and low-speed steering control system Throttle/shifter inspection/adjustment Reverse system/reverse cable adjustment Fastener tightening (flame arrester(s), carburetor(s), engine(s), exhaust system(s), etc.) Muffler(s), battery and reservoir fastening devices

Every 100 Every 10 Every 25 Every 50 hours or hours hours hours seasonally ➀

➀ ➀

Fuel/oil lines, inspection, fuel system pressurization Inspect/clean engine drain hose(s) Bilge pump/deck drain hole/scupper valve inspection Battery condition MPEM connector condition Battery and starter cables Monitoring beeper/electrical connections Impeller shaft reservoir oil level/condition Impeller condition and impeller/wear ring and clearance Drive shaft boot/spline condition (both ends)

➀

Replace ➃ ➁ ➁

Drive shaft floating seal circlip position PTO flywheel lubrication Water intake grate and weedless system lubrication/condition Hull/ride shoe condition/deck mounting bolts tightening (if applicable) Cooling system flushing ➂ Aluminum anode Bilge air blower inspection

➁

➀ Every 10 hours in salt water use. ➁ These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in this chart. ➂ Daily flushing when used in salt or foul water use. ➃ Inspect anti-rattle pusher. 02-02-1

Subsection 03

Section 02 MAINTENANCE (FLUSHING AND LUBRICATION)

FLUSHING AND LUBRICATION

GENERAL

Flushing at Pump Location

Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. It will help to clear sand, salt, shells or other particles in water jackets (engine, exhaust manifold, tuned pipe) and/or hoses. Flushing should be performed when the boat is not expected to be used further the same day or when the boat is stored for any extended time.

1. Clean jet pump by spraying water in its inlet and outlet and then spray a soapy solution.

CAUTION

Failure to flush cooling system, when necessary, will severely damage engine and/or exhaust system. Never flush a hot engine. Make sure engine operates during entire procedure.

;

WARNING

Always remove safety lanyard cap from DESS post to prevent accidental engine starting, before cleaning the jet pump area. Engine must not be running for this operation. 2. Open rear storage compartment and remove storage tray. 3. Connect a garden hose directly to the pump support flushing connector, as shown in the next photo. To prevent water leak, ensure the rubber washer is in the boat connector. 2

PROCEDURE For flushing procedure perform following steps 1 and 3. For complete flushing and lubrication procedure perform all four steps. 1. Flushing at pump or at engine compartment location (choose one of both method). 2. Engine lubrication. 3. After flushing procedure. 4. Cylinder wall Lubrication.

;

WARNING

Perform this operation in a well-ventilated area. Do not touch any electrical parts or jet pump area when engine is running.

F09L1RA

TYPICAL 1. Pump support flushing connector 2. Garden hose

NOTE: Perform the operation on both engines.

02-03-1

Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION)

F09L03A

TYPICAL 1. Flushing connector for port engine on pump support 2. Flushing connector for starboard engine on pump support

Flushing at Engine Compartment Location The engine can also be flushed from the flushing connector located on the edge of the engine compartment. See next photos.

F09L1TA

PORT SIDE ENGINE 1. Flushing connector in engine compartment area with its cap

For proper flushing from engine compartment location, it is necessary to prevent water from going out directly by the flushing connector on the pump support. 1. Install a hose pincher (P/N 529 032 500) on the hose between the pump support and the T-fitting as shown.

717 Engine 1

F09L1SA

STARBOARD SIDE ENGINE 1. Flushing connector in engine compartment area with its cap

F04E14A

TYPICAL 1. Hose pincher right after the T-fitting 2. T-fitting

02-03-2

Subsection 03

787 Engine 2

Section 02 MAINTENANCE (FLUSHING AND LUBRICATION)

2. Spray BOMBARDIER LUBE lubricant (P/N 293 600 016) through air intake silencer cover keeping engine at fast idle. NOTE: If the lubrication is done for the storage, use BOMBARDIER STORAGE OIL (P/N 413 711 600) instead.

F09L1UA

TYPICAL 1. T-fitting 2. Hose pincher right after the T-fitting

F00M01A

CAUTION

Do not open water tap yet. 2. Start the engine then immediately open the water tap.

CAUTION

Always start the engine before opening the water tap to prevent engine flooding. Open water tap immediately after engine is started to prevent overheating. 3. Run the engine about 3 minutes at a fast idle around 3500 RPM.

TYPICAL 1. Spray BOMBARDIER LUBE (storage oil when performing storage lubrication)

NOTE: Lubrication of engine should be done at least for one minute. 3. If the lubrication is done for the storage, pinch fuel hose to run engine out of fuel after approximately half a minute of lubrication.

CAUTION

If the lubrication is done for the storage, immediately stop water flow before engine dies when engine begins to run irregularly.

Engine Lubrication

After Flushing Procedure

1. Pull plug from air intake silencer cover.

1. Close the water tap then stop the engine.

CAUTION

Always close the water tap before stopping the engine. 2. Remove garden hose. Ensure the rubber washer remains in the boat hose connector. 3. Remove hose pincher from water outlet hose. F01F25B

1. Air intake silencer cover 2. Pull plug

CAUTION

Serious engine damage can occur if hose pincher is not removed. 02-03-3

Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION)

4. Wipe up any residual water from the engine. 5. Remove spark plug cables and connect them on the appropriate grounding device.

;

WARNING

Always use spark plug cable grounding device when removing spark plugs. 2

Cylinder Wall Lubrication 1. Remove both spark plugs and spray BOMBARDIER LUBE lubricant (P/N 293 600 016) into each cylinder. 2. Crank the engine a few turns to distribute the oil onto cylinder wall. 3. Apply anti-seize lubricant (P/N 293 800 023) on spark plug threads then reinstall them. 4. Properly reconnect spark plug cables to spark plugs. 5. Reinstall plug on air intake silencer cover. NOTE: Engine fogging should be done with BOMBARDIER STORAGE OIL (P/N 413 711 600) whenever the boat is to be stored for a few days or a long period.

CAUTION

Never leave rags or tools in the engine compartment or in the bilge. 6. Reinstall tray and close storage compartment cover. F04H5ZA

TYPICAL 1. Electrical box 2. Connect spark plug cables to grounding device

02-03-4

Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE)

WATER-FLOODED ENGINE GENERAL If engine is water-flooded, it must be serviced within a few hours after the event. Otherwise engine will have to be overhauled.

Snugly install the hose pincher on the hose as shown in the following photos. 1

CAUTION

A water-flooded engine must be properly lubricated, operated then lubricated again, otherwise parts will be seriously damaged.

Towing the Boat in Water The maximum recommended towing speed is 24 km/h (15 MPH). When towing your boat in water, pinch the water supply hose from the jet pump housing to the engine with a hose pincher (not supplied) (P/N 529 032 500) shown in the following illustration. F10E01A

TYPICAL — 717 ENGINE 1. Install hose pincher on this hose

F01B23A

NOTE: If for some reason, you operate the jet boat over 24 km/h (15 MPH) with only one engine running, the non-running engine should have its water supply hose plugged. This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system. Without the engine running there isn’t any exhaust pressure to carry the water out the exhaust outlet.

CAUTION

Failure to do this may result in damage to the engine. If you must tow a stranded boat in water and do not have a hose pincher be sure to stay well below the maximum towing speed of 24 km/h (15 MPH).

F04E0QA

TYPICAL — 787 ENGINE 1. Install hose pincher on this hose

CAUTION

When finished towing the boat you must remove the hose pincher before operating it. Failure to do so will result in damage to the engine.

02-04-1

Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE)

Operating the Boat with Only One Engine If in an emergency situation the jet boat is operated with only one engine, special care must be taken. See above in Towing the Boat in Water for complete procedure.

PROCEDURE Check fuel and oil reservoirs for water contamination. If necessary, siphon and refill with fresh fluids. Drain bilge if water is present. Remove spark plug cables and connect them on the appropriate grounding device.

;

WARNING

Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device. 2

Spray BOMBARDIER LUBE lubricant (P/N 293 600 016) into spark plug holes. Crank engine(s) again.

787 Engine There is an oil passage from the crankcase toward the balance shaft gear and bearing. Therefore, water that enters the engine, can flow through this passage and be trapped in a cavity. Proper draining of this water is required. Refer to STORAGE 02-05 and look for Engine Draining. All Engines Reinstall spark plugs and spark plug cables then safety lanyard cap on DESS post. Start engine(s). It may be necessary to use the choke. If engine(s) do not start, repeat previous steps as necessary.

CAUTION

To avoid starting motor overheating, the cranking period should not exceed 5-10 seconds and a rest period of 30 seconds should be observed between cranking cycles. NOTE: If engine(s) do not start after several attempts, check ignition system for spark occurrence. Refer to IGNITION SYSTEM 08-03. Check crankshaft if needed, it can become misaligned or deflected. Refer to BOTTOM END 04-06. After engine has started, spray BOMBARDIER LUBE lubricant (P/N 293 600 016) through air intake silencer while engine is running.

F04H5ZA

TYPICAL 1. Electrical box 2. Connect spark plug cables to grounding device

Remove spark plugs and dry them with a clean cloth. A contact cleaner spray can be used. It may be preferable to replace spark plugs. Do NOT install spark plugs on engine. Crank engine(s) to drain crankcase.

CAUTION

Be careful when cranking engine(s), water will spray out from spark plug holes. 02-04-2

F00M01A

1. Spray BOMBARDIER LUBE

Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE)

Run engine until it reaches its normal operating temperature.

CAUTION

Water must be supplied to cool engine(s) through the boat flushing connector(s).

02-04-3

Section 02 MAINTENANCE Subsection 05 (STORAGE)

STORAGE

NOTE: Perform the operation on each engine.

Engine Draining Check engine drain tube running from engine manifold fitting to outlet socket. Make sure it contains no sand or other particles and that it is not obstructed, so that water can leave the engine. Clean tube and outlet socket as necessary.

CAUTION

Water in engine drain tube must be free to flow out, otherwise water could be trapped in engine. Should water freeze in engine, severe damage will occur. Check engine drain tube for obstructions.

F09E01A

TYPICAL â&#x20AC;&#x201D; 787 ENGINE 1. Drain tube must be clean

Engine Cavity Draining 787 Engine In the event water entered the engine during the season (water flood), water may have been trapped in the oil cavity of the balance shaft gear and bearing. Draining is required to prevent any potential damage. Proceed as follows.

F04E16A

CAUTION

Failure to properly drain this cavity may result in freezing inside engine leading to damage of cylinder base gasket.

TYPICAL â&#x20AC;&#x201D; 717 ENGINE 1. Drain tube must be clean

02-05-1

Section 02 MAINTENANCE Subsection 05 (STORAGE)

Remove the filler plug of the counterbalance shaft on the engine crankcase.

NOTE: Fuel stabilizer should be added prior engine lubrication to ensure carburetor protection against varnish deposit.

CAUTION

Fuel stabilizer should be added prior to engine lubrication to ensure carburetor protection against varnish deposit.

;

F07D06A

WARNING

Fuel is flammable and explosive under certain conditions. Always work in a well-ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the boat.

1. Remove filler plug

Insert a wire through oil level hole to check oil condition. A whitish oil indicates water contamination and must be replaced. In order to replace the oil, remove the drain plug of the counterbalance shaft located on the PTO side of the lower crankcase.

Cooling System Flushing and Engine Internal Lubrication Cooling system has to be flushed with fresh water to prevent salt, sand or dirt accumulation which will clog water passages. Engine must be lubricated to prevent corrosion on internal parts. For proper procedure, refer to FLUSHING AND LUBRICATION 02-03.

Propulsion System Lubricant in impeller shaft reservoir should be drained. Reservoir should be cleaned and refilled with BOMBARDIER synthetic 75W 90 GL5 polyester oil (P/N 293 600 011). See following table and refer to DRIVE SYSTEM 09-03 for complete detailled procedure. F07D07A

1. Drain plug

Drain completely the crankcase oil of the counterbalance shaft. Reinstall drain plug with Loctite 518 (P/N 293 800 038). Add 30 mL (1 oz) of SAE 30 motor oil. Reinstall filler plug.

Fuel System All Engines Sea-Doo Fuel Stabilizer (P/N 413 408 600) should be added in fuel tank to prevent fuel deterioration and carburetor gumming. Follow manufacturerâ&#x20AC;&#x2122;s instructions for proper use. 02-05-2

MODEL

RESERVOIR CAPACITY

Speedster

100 mL (2.7 U.S. oz)

Speedster SK

100 mL (2.7 U.S. oz)

CAUTION

Use only BOMBARDIER jet pump oil or equivalent synthetic gear oil, otherwise component service life could be reduced. Do not mix oil brands or types.

Section 02 MAINTENANCE Subsection 05 (STORAGE)

Lubricate PTO flywheel at grease fitting with synthetic grease (P/N 293 550 010).

CAUTION

Do not lubricate excessively. Immediately stop when a slight movement is noticed on rubber boot.

Antifreezing Protection In cool regions (where freezing point temperature may be encountered), cooling system must be filled with water and antifreeze solution (40% water, 60% antifreeze).

CAUTION

Antifreeze mix must be fed in cooling system. Otherwise water will freeze in engines/exhaust system causing severe damage. NOTE: When available, it is recommended to use biodegradable antifreeze compatible with internal combustion aluminum engines. This will contribute to protect the environment.

CAUTION

Always use ethylene-glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines. F01I0BA

NOTE: The engine will not have to run during this operation but should have been ran before to exhaust water from cooling system components.

1. Grease PTO flywheel

CAUTION

Never leave any clothing, tool or other objects in engine compartment.

Boat Cleaning

Hose Pinchers Installation Some hoses have to be plugged to prevent draining, before filling cooling system jackets with the antifreeze. Use hose pinchers (P/N 529 032 500).

Clean the bilge with hot water and mild detergent or with bilge cleaner. Rinse thoroughly. Lift front end of boat to completely drain bilge. If any repairs are needed to the body or to the hull, touch up paint and GelcoatÂŽ repair kit are available. Replace damaged labels/decals. Wash the body and the trailer with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull. Apply a nonabrasive wax.

CAUTION

Never clean apparent fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc.

F01B23A

Air will escape from bleed hose on tuned pipe.

Stains may be removed from seats and fiberglass with Knightâ&#x20AC;&#x2122;s Spray-Nine* from Korkay System Ltd or the equivalent. 02-05-3

Section 02 MAINTENANCE Subsection 05 (STORAGE)

717 Engine Install a hose pincher and firmly tighten on: – water injection hose at tuned pipe

F04E17A

TYPICAL 1. Hose pincher right after T-fitting 2. T-fitting 3. Hose pincher on this hose 4. Hose pincher on drain tube

F04E0YA

787 Engine Install a hose pincher and firmly tighten on: – engine drain tube coming from cylinder base before T-fitting – hose right after T-fitting – hose on cylinder head

TYPICAL 1. Hose pincher on injection hose going to tuned pipe

– engine drain tube coming from exhaust manifold before T-fitting – hose right after T-fitting – hose on cylinder head

F04E0TC

TYPICAL 1. Hose pincher right after T-fitting 2. T-fitting 3. Hose pincher on this hose 4. Hose pincher on drain tube

02-05-4

Section 02 MAINTENANCE Subsection 05 (STORAGE)

All Engines NOTE: Hose pinchers must be firmly tightened so that no antifreeze can flow through the blocked hoses. If you hear the liquid flowing in the muffler immediately after starting pouring antifreeze, it indicates that antifreeze is bypassing the engine/ tuned pipe water jackets. To correct this, firmly retighten hose pinchers. Antifreeze Unscrew cap from flushing fitting on the edge of engine compartment and insert a funnel into flushing fitting. Pour about 2 liters (1/2 gal) of antifreeze solution through the funnel. Let the antifreeze enough time to flow. Moving the hose with the T-fitting should accelerate the flow. 1

F04E0TA

TYPICAL â&#x20AC;&#x201D; 787 ENGINE 1. Pour antifreeze until it flows out here

Remove hose pincher from injection hose at tuned pipe and continue to pour approximately 200 mL (7 oz). This will allow antifreeze to flow inside muffler to protect it.

F04E0SA

TYPICAL

Pour antifreeze until you see it flowing out of tuned pipe bleed hose. At this time only, the entire circuit is filled with antifreeze. 1 F04E0WA

1. Remove hose pincher

787 Engine At this time, remove hose pincher hose at engine head and continue to pour approximately 200 mL (7 oz). This will allow antifreeze to flow through water regulator valve toward muffler in order to protect it.

F04E10A

TYPICAL â&#x20AC;&#x201D; 717 ENGINE 1. Pour antifreeze until it flows out here 02-05-5

Section 02 MAINTENANCE Subsection 05 (STORAGE)

Battery For battery removal, cleaning and storage, refer to CHARGING SYSTEM 08-07.

Anticorrosion Treatment Wipe off any residual water in the engine compartment. Spray BOMBARDIER LUBE lubricant (P/N 293 600 016) over all metallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant.

Finalizing Storage F04E0TB

TYPICAL 1. Remove hose pincher

Hose Pinchers Removal

All Engines When finished, remove all remaining hose pinchers. Most of the antifreeze will drain out from flushing fitting and jet pump nozzle when removing hose pinchers. Use a suitable container to recover it. Dispose antifreeze as per your local laws and regulations. NOTE: Although most antifreeze will drain out, it has flowed to mix with water that was possibly trapped in cooling system cavities thus preventing freezing problems. NOTE: For pre-season preparation, drain antifreeze from cooling system prior to launching boat in water as explained above.

02-05-6

The engine storage cover should be left opened during storage (disconnect gas shocks from cover to prevent full opening). Remove storage tray. Place it on deck. This will avoid engine compartment condensation and possible corrosion. If the boat is to be stored outside, cover it with a vented opaque tarpaulin to prevent sun rays and grime from affecting the plastic components or boat finish as well as to prevent dust accumulation. Unscrew the drain plugs for the storage. Lift the boat so that the bow is higher then the stern to allow draining of the bilge. Safely block it in this position.

CAUTION

The boat must never be Ieft in water for storage. Never leave the boat stored in direct sunlight. UV radiation will dull finishes. Make sure to turn OFF bilge pump and blower.

Section 03 TROUBLESHOOTING Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

TROUBLESHOOTING............................................................................................................

03-02-1

FLOW CHART ........................................................................................................................

03-03-1

03-01-1

Section 03 TROUBLESHOOTING Subsection 02 (TROUBLESHOOTING)

TROUBLESHOOTING

The following chart is provided to help in diagnosing the probable source of troubles. It is a guideline only and does not detail all causes for all problems. NOTHING IS WORKING IN THE ELECTRICAL SYSTEM OTHER OBSERVATION

POSSIBLE CAUSE

No beeps are heard when installing • Main battery cut-off switch is safety lanyard on DESS post turned OFF.

REMEDY • Verify and turn ON.

ENGINE WILL NOT START OTHER OBSERVATION Engine does not turn over

Engine turns slowly

POSSIBLE CAUSE

REMEDY

• Safety lanyard cap worn or removed.

• Replace/reinstall.

• DESS operation non functional.

• If 2 short beeps are not heard when installing safety lanyard, refer to section 08-06.

• Start/stop button defective.

• Check, refer to section 08-06.

• Burnt main fuse(s).

• Check wiring then replace fuse.

• Burnt MPEM supply fuse.

• Check wiring then replace fuse.

• MPEM supply fuse keeps on burning.

• Check wiring and MPEM refer to section 08-06. Replace fuse.

• Discharged battery.

• Check/recharge.

• Battery connections.

• Check/clean/tighten.

• Water/fuel hydrolock.

• Check, refer to section 02-04.

• Starter or solenoid.

• Check, refer to section 08-06.

• Seized engine.

• Check/repair as needed.

• Seized jet pump.

• Check, refer to section 09-02.

• Jammed jet pump.

• Check/clean out debris.

• Discharged/weak battery.

• Check/charge/replace.

• Battery connections.

• Check/tighten connections.

• Restriction in jet pump.

• Check/clean pump.

• Seizure in jet pump.

• Inspect, refer to section 09-02.

• Partial engine hydrolock.

• Check, refer to section 02-04.

• Partial engine seizure.

• Check compression, refer to section 04-06.

• Worn starter.

• Check, refer to section 08-06.

• Wear ring of jet pump improperly • Check/replace, refer to section installed. 09-02. 03-02-1

Section 03 TROUBLESHOOTING Subsection 02 (TROUBLESHOOTING)

ENGINE WILL NOT START (CONT’D) OTHER OBSERVATION Engine turns over

POSSIBLE CAUSE

REMEDY

• Fuel tank empty.

• Refill.

• Fuel water-contaminated.

• Renew supply.

• Dirty fuel filter.

• Replace.

• Fouled spark plugs.

• Replace.

• Water in engine.

• Check, refer to section 02-04.

• Misuse of throttle lever(s) (fuel flooded).

• Avoid moving throttle lever(s) several times when engine(s) is (are) not running.

• Misuse of choke (fuel flooded).

• Use only with cold engine.

• Carburation.

• Check, refer to section 06-04.

• Ignition.

• Check, refer to section 04-04 and 08-04.

• Engine flooded.

• Check, refer to section 06-04.

– Needle valve stuck open. • Choke(s) not closing completely.

• Adjust for complete closure.

• Excessive rotary valve clearance. • Check, refer to section 04-07.

No spark at spark plugs

03-02-2

• Internal engine damage.

• Check, refer to section 04-06 and 04-07.

• Sheared flywheel key.

• Check timing mark, refer to section 04-04.

• Incorrect rotary valve timing.

• Check, refer to section 04-07.

• Unproperly grounded MPEM BLACK wire.

• Repair.

• Defective MPEM.

• Check, refer to section 08-04.

• Faulty magneto system.

• Check wiring and ignition system, refer to section 04-04.

Section 03 TROUBLESHOOTING Subsection 02 (TROUBLESHOOTING)

ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION Weak spark

POSSIBLE CAUSE • Fouled, defective, worn spark plugs.

REMEDY • Check/verify heat range/gap/ replace.

• Faulty MPEM or start/stop switch. • Check, refer to section 08-04.

Lean fuel mixture Dry spark plug (except when water fouled)

Rich fuel mixture Fouled spark plug

• Faulty ignition.

• Check, refer to section 04-04.

• Sheared flywheel key.

• Check timing mark, refer to section 04-04.

• Fuel level low.

• Check/refill.

• Stale or water fouled fuel.

• Check/siphon and refill.

• Fuel filter dirty or restricted.

• Check/replace.

• Carburetion dirty or out of adjustment.

• Check/clean/adjust, refer to section 07-03.

• Leaking crankshaft seal(s), rotary valve cover O-ring(s).

• Check/test/replace, refer to engine section 04-02.

• Loose carburetor(s).

• Tighten carburetor(s).

• Partially closed choke.

• Check/adjust choke cable.

• Flame arrester dirty or restricted.

• Check/replace.

• Carburetor adjustment.

• Check/adjust, refer to section 06-04.

• Leaking check valve at injector of • Check, refer to section 06-04. accelerator pump. • Main jet loose.

• Check, refer to section 06-04.

• Rotary valve shaft seal leaking.

• Check/replace, refer to section 06-04.

• Oil pump adjustment.

• Check/adjust, refer to section 07-03.

• Worn needle(s) and seat(s).

• Check, refer to section 06-04.

• Excessive rotary valve clearance. • Check, refer to section 04-07. Difficult to start

• Incorrect rotary valve timing.

• Check/adjust, refer to section 04-07.

• Excessive rotary valve clearance. • Check, refer to section 04-07.

03-02-3

Section 03 TROUBLESHOOTING Subsection 02 (TROUBLESHOOTING)

ENGINE OVERHEATS OTHER OBSERVATION Monitoring beeper continuously sounds

POSSIBLE CAUSE

REMEDY

• Restricted jet pump water intake. • Check/clean. • Cooling system restriction.

• Check/flush, refer to section 02-03.

• Grounded temperature sensor or • Check/repair/replace. sensor wire.

ENGINE CONTINUALLY BACKFIRES OTHER OBSERVATION Weak spark

POSSIBLE CAUSE

REMEDY

• Fouled, defective spark plugs.

• Clean/replace.

• MPEM malfunction.

• Check, refer to section 08-04.

• Incorrect setting.

• Check/reset, refer to section 04-04.

• Flywheel key sheared.

• Check/replace.

Rotary valve

• Timing incorrect.

• Check/reset, refer to section 04-07.

Carburetor

• Carburetion too lean.

• Check/adjust, refer to section 06-04.

Engine

• Intake leak/crankshaft seal failure. • Pressure check engine, refer to section 04-03.

Ignition timing

ENGINE DETONATION OR PINGING OTHER OBSERVATION Ignition

Engine temperature

03-02-4

POSSIBLE CAUSE

REMEDY

• Timing too far advanced.

• Check/reset.

• Spark plug heat range too high.

• Check/change to correct range.

• Engine overheating.

• Check, refer to section 02-04 and 05-02 or to engine overheat.

• Poor quality fuel.

• Use good quality fuel.

Section 03 TROUBLESHOOTING Subsection 02 (TROUBLESHOOTING)

ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION

POSSIBLE CAUSE

REMEDY

• Weak spark.

• Check/replace, refer to section 04-04.

• Carburetion, jetting too rich/lean/ accelerator pump not working properly.

• Check/adjust, refer to section 06-04.

• Throttle does not open fully.

• Check/readjust.

• Low compression.

• Check/repair, refer to section 04-06.

• Exhaust system restriction.

• Check/clean.

• Water in gas or oil.

• Check/siphon/replace.

• Debris in needle valve.

• Check/clean, refer to section 06-04.

• Jet pump related problem.

• Refer to ”POOR START, ACCELERATION OR PERFORMANCE OF BOAT” below.

• Twisted crankshaft.

• Check, refer to section 04-07.

• Cooling system water flow regulator valve.

• Check/adjust, refer to section 05-02.

Engine revs lower than its maximum • RAVE valve does not open. operational RPM

• Check, refer to section 04-06.

Peak performance is delayed until higher RPM range is reached

• Check, refer to section 04-06.

• RAVE valve is stuck open.

03-02-5

Section 03 TROUBLESHOOTING Subsection 02 (TROUBLESHOOTING)

POOR START, ACCELERATION OR PERFORMANCE OF BOAT OTHER OBSERVATION

POSSIBLE CAUSE

REMEDY

Jet pump cavitation: • Poor start/acceleration of boat

• Trailing edge of impeller is damaged.

• Check/replace.

• Poor top performance of boat and/or stator vanes erosion

• Leading edge of impeller is damaged.

• Check/replace.

Jet pump ventilation:

• Jet pump improperly sealed to • Check/reseal. ride shoe; insufficient sealant on the ride shoe or missing neoprene seal (or sealing in this area).

Engine RPM is high and boat is slow • Through-hull seal around drive to accelerate shaft; air comes from inside the boat.

• Check/replace.

OR engine does not react quickly when pushing on throttle lever (assuming that engine is correct)

• Retaining screws of ride shoe or sealing of weedless system cable/housing; air comes from inside the boat.

• Check/reseal.

OR engine does not keep a steady top RPM (assuming that engine is correct)

• Retaining screws of intake grate; • Check/reseal. air comes from inside the boat.

Other problem with jet pump (related to performance): Boat does not reach its top speed

03-02-6

• A wear ring (jet pump) with excessive clearance.

• Check/replace.

• A damaged or worn jet pump.

• Check/replace.

• A damaged impeller.

• Check/replace.

• An impeller with the wrong pitch (too low).

• Check/replace.

• Missing or damaged impeller boot.

• Check/install.

• Weeds or debris in intake grate, jet pump intake or impeller.

• Check/clean.

Section 03 TROUBLESHOOTING Subsection 02 (TROUBLESHOOTING)

ABNORMAL NOISE FROM PROPULSION SYSTEM OTHER OBSERVATION

POSSIBLE CAUSE • Low oil level in jet pump.

• Worn or damaged anti-knoc pusher.

REMEDY • Check/troubleshoot source of leak/refill supply, refer to section 09-02. • Check/replace, refer to section 09-02.

• Drive shaft protector rubbing against drive shaft or impeller boot.

• Check/replace, refer to section 09-03.

• Damaged or bent drive shaft.

• Check/replace, refer to section 09-03.

• Broken motor mounts.

• Check/replace, refer to section 04-05.

03-02-7

Section 03 TROUBLESHOOTING Subsection 03 (FLOW CHART)

FLOW CHART

0 ENGINE DOES NOT START

Fuses

Inspect wires

Check battery

OK Check solenoid Repair

YES

YES Check solenoid

Starter motor cranks

Replace

Code

Repair

Check ground and power supply in the electrical box

Check DESS post

Replace

Repair

Replace

Check start/stop button

Replace

Check MPEM

Replace Check starter

Repair

YES

Enable advanced diagnostic mode

Replace

2 Beeps

Check lanyard

Repair wires

Fuel or mechanical problem

YES

Spark at spark plugs

2 Beeps

YES

Replace spark plugs Repair Spark returns

YES

Check buzzer

NO Motor starts Check coil and high tension cables

Check voltage at the primary wires of the ignition coil

YES

Check lanyard

OK Check ground

Check plug cap

Repair wires Replace MPEM

OK OK = BAD

OK = ADEQUATE

Repair

Replace MPEM

Check trigger

Replace trigger

F00H1BS

03-03-1

Subsection 01

Section 04 ENGINE (TABLE OF CONTENTS)

TABLE OF CONTENTS

LEAK TEST............................................................................................................................. GENERAL ........................................................................................................................... PREPARATION ................................................................................................................... TESTING PROCEDURE ..................................................................................................... ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................

04-02-1 04-02-1 04-02-1 04-02-1 04-02-5

REMOVAL AND INSTALLATION .......................................................................................... GENERAL ........................................................................................................................... REMOVAL FROM JET BOAT ............................................................................................. CLEANING ......................................................................................................................... INSTALLATION..................................................................................................................

04-03-1 04-03-1 04-03-1 04-03-5 04-03-5

MAGNETO SYSTEM ............................................................................................................. GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... ASSEMBLY......................................................................................................................... INSTALLATION ..................................................................................................................

04-04-1 04-04-3 04-04-3 04-04-6 04-04-7 04-04-7 04-04-9

TOP END ................................................................................................................................ 04-05-1 ENGINE DESCRIPTION ..................................................................................................... 04-05-3 GENERAL ........................................................................................................................... 04-05-3 DISASSEMBLY................................................................................................................... 04-05-5 CLEANING ......................................................................................................................... 04-05-8 INSPECTION ...................................................................................................................... 04-05-8 ASSEMBLY......................................................................................................................... 04-05-12 ADJUSTMENT ................................................................................................................... 04-05-19 BOTTOM END........................................................................................................................ 04-06-1 DISASSEMBLY................................................................................................................... 04-06-3 CLEANING ......................................................................................................................... 04-06-7 INSPECTION ...................................................................................................................... 04-06-7 ASSEMBLY......................................................................................................................... 04-06-11 ROTARY VALVE ..................................................................................................................... GENERAL ........................................................................................................................... INSPECTION ON BOAT..................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY.........................................................................................................................

04-07-1 04-07-2 04-07-2 04-07-3 04-07-5 04-07-5 04-07-6 04-01-1

Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS)

EXHAUST SYSTEM ............................................................................................................... TUNED PIPE........................................................................................................................ EXHAUST MANIFOLD ....................................................................................................... MUFFLER ............................................................................................................................ EXPANSION CHAMBER .................................................................................................... EXHAUST OUTLET ............................................................................................................

04-01-2

04-08-1 04-08-3 04-08-5 04-08-6 04-08-7 04-08-10

Section 04 ENGINE Subsection 02 (LEAK TEST)

LEAK TEST

GENERAL

PREPARATION

A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) is available to help diagnose engine problems such as engine seizure, poor performance, oil leakage, etc. Before disassembling any components of the engine, it is important to perform a leakage test to determine which part is defective. It is also very important after servicing the engine, even for a complete engine rebuilt, to perform another leakage test; at this stage, it may avoid further engine problems and minimizing the risk of having to remove and reinstall the engine again. Static bench testing is the most effective way to conduct a leakage test. Inboard testing does not allow complete access to, and observation of all engine surfaces and should be avoided whenever possible. On 717 and 787 engines, cylinders cannot be verified individually due to leakage from one cylinder to another through a common intake manifold. When installing hoses of the Engine Leak Test Kit, use the collars provided in the kit to ensure a proper sealing. When pressurizing the engine, first confirm that the components of the Engine Leak Test Kit are not leaking by spraying a solution of soapy water on all hoses, connections, fittings, plates, etc. If there is a leak, bubbles will indicate leak location. Three areas of the engine will be tested in sequence as per the diagnostic flow chart (see the end of this subsection). 1. Engine Cooling System 2. Bottom End and Top End 3. Rotary Valve Shaft NOTE: If a leak is found, it is important to continue testing as there is the possibility of having more than one leak. Continue pumping to compensate for the air lost to find another leak.

Verify fuel system for leaks.

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WARNING

If any fuel leak is found, do not start the engine. Correct the leak and wipe off any fuel spillage. Do not use electric powered tools unless fuel system has passed pressure test. Turn OFF main battery cut-off switch. Disconnect battery BLACK negative cable.

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WARNING

Always disconnect battery cables in the specified order, BLACK negative cable first. Disconnect battery RED positive cable.

TESTING PROCEDURE Engine Cooling System Remove the tuned pipe. Remove the exhaust manifold gasket and ensure the surface is clean. Disconnect engine cooling hoses. Install the appropriate exhaust manifold plate (no. 1 for the 787 engine and no. 2 for the 717 engine) from the Engine Leak Test Kit. Tighten plate using fasteners provided in the kit. Use hoses provided in the kit and install them on the engine. Install pump using reducer and appropriate tube(s) as necessary.

04-02-1

Section 04 ENGINE Subsection 02 (LEAK TEST)

4 3

F01B2UB

F01B2WA

717 ENGINE — REAR VIEW 1. Engine drain hose blocked with a hose pincher

2 1

F01B2VA

717 ENGINE — FRONT VIEW 1. Loop hose and use clamps 2. Use 2 washers with exhaust manifold stud 3. Hose with adapter and nipple

04-02-2

TYPICAL — 787 ENGINE 1. Loop hose and use clamps 2. Hose with clamps. Plug end with a screw 3. Block engine drain hose with a hose pincher 4. Use 2 washers with exhaust manifold stud

NOTE: Water is not required for testing. Activate pump and pressurize engine cooling system to 5 PSI (34 kPa). Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking and pressure drops, verify all external jointed surfaces, temperature sensor and the O-ring between the spark plug area and the engine cylinder head cover. If none of these components are leaking, there is an internal leak and it can be detected with Bottom End and Top End testing.

Bottom End and Top End Remove the carburetors and gaskets. Make sure the surface of the intake manifold (717 engine) or rotary valve cover (787 engine) are clean. Install the intake plates no. 3 with fasteners from the kit and tighten adequately. On engines with the RAVE system, remove the RAVE valves and gaskets. Install plates no. 4 with fasteners from the kit and tighten adequately.

Section 04 ENGINE Subsection 02 (LEAK TEST)

NOTE: On engines with the RAVE system, boot and O-ring can be checked for leakage with the valve in place. Simply remove the cover to expose the boot. Make sure the spark plugs are installed and tightened. Block pulse hose using a hose pincher. NOTE: Do not block the rotary valve shaft hoses. Install pump to the exhaust plate fitting. 3

2 F01B2ZA

TYPICAL — 717 ENGINE 1. Intake plates 2. Pulse hose blocked with a hose pincher 3. Exhaust plate

CAUTION

Do not exceed this pressure. Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking, verify engine jointed surfaces as per following areas: – spark plugs – cylinder head gasket – cylinder base gasket – crankcase halves – rotary valve cover – engine plugs – exhaust manifold – intake manifold (717 engine) – oil injection pump (717 engine) Check also small oil injection pump lines and fittings; check for air bubbles or oil column going toward pump, which indicate a defective check valve. If the above mentioned components are not leaking, block both oil hoses of the rotary valve shaft using hose pinchers. NOTE: If leakage stops at this point, proceed with rotary valve shaft testing. If there is still some leakage, remove the PTO flywheel and verify crankshaft outer seal. If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft outer seal. Proceed with the rotary valve shaft testing if the crankshaft outer seals are not leaking.

Rotary Valve Shaft

NOTE: It is preferable to drain the injection oil from the rotary valve shaft, but it is not mandatory. Block oil return hose of the rotary valve shaft with a hose pincher.

F01B30A

TYPICAL — 787 ENGINE 1. Intake plates 2. RAVE valve plates 3. Pulse hose blocked with a hose pincher 4. Exhaust plate

Activate pump and pressurize engine to 5 PSI (34 kPa).

04-02-3

Section 04 ENGINE Subsection 02 (LEAK TEST)

F01B31A

TYPICAL — 717 ENGINE 1. Oil return hose blocked with hose pincher

F01B33A

TYPICAL — 717 ENGINE 1. Pump with reducer and nipple

F01B32A

F01B34A

TYPICAL — 787 ENGINE 1. Oil return hose blocked with hose pincher

TYPICAL — 787 ENGINE 1. Pump with reducer and nipple

Install pump with reducer and nipple to the oil supply hose of the rotary valve shaft.

Activate pump and pressurize to 5 PSI (34 kPa). Check plug of the rotary valve shaft in crankcase. Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal. Remove MAG side spark plug. If pressure drops, it indicates a defective MAG side crankshaft inner seal. If the above mentioned components are not leaking and there is a pressure drops, remove the rotary valve cover. Check the seal of the rotary valve shaft. If the rotary valve shaft is not leaking, it could indicates a defective engine casting. Disassemble engine and carefully check for defects in castings. Pay attention to tapped holes which may go through sealed areas of engine and thus lead to leakage.

04-02-4

Section 04 ENGINE Subsection 02 (LEAK TEST)

ENGINE LEAKAGE DIAGNOSTIC FLOW CHART PRESSURIZE ENGINE COOLING SYSTEM

IS SYSTEM LEAKING?

YES

CHECK TESTING KIT

NO REPLACE O-RING OF CYLINDER HEAD AND/OR CYLINDER BASE GASKET

PRESSURIZE ENGINE NO

IS ENGINE LEAKING?

RECHECK ENGINE SEALING

YES CHECK TESTING KIT

CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC.

ANY LEAK FOUND?

YES

REPLACE GASKET OR O-RING, RE-SEAL LEAKING AREA

CHECK SMALL OIL LINES OF INJECTION PUMP AIR BUBBLES FOUND OR OIL MOVING TOWARD PUMP?

YES

REPLACE CHECK VALVE(S) / LINE(S)

BLOCK LARGE HOSES OF ROTARY VALVE GEAR LUBRICATION SYSTEM NO

IS ENGINE STILL LEAKING?

CHECK TESTING KIT

CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES

ARE SEALS LEAKING?

PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE

YES

REPLACE DEFECTIVE SEAL(S)

NO PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE

YES

RECHECK ENGINE SEALING

IS RESERVOIR LEAKING?

UNSEAL PTO CYLINDER AND MAG CYLINDER SEPARATELY BY REMOVING THE APPROPRIATE SPARK PLUG

IS RESERVOIR LEAKING?

YES

REPLACE DEFECTIVE SEAL(S)

YES

REPLACE OIL SEAL OF ROTARY VALVE SHAFT END, OR REPLACE CAP

NO CHECK TESTING KIT

IS RESERVOIR LEAKING?

YES

CHECK FOR LEAKAGE AT ROTARY VALVE SHAFT CRANKCASE PLUG

ANY LEAK FOUND? NO REMOVE ROTARY VALVE COVER, CHECK SEAL OF ROTARY VALVE SHAFT

IS SEAL LEAKING?

YES

REPLACE DEFECTIVE SEAL

CAREFULLY INSPECT ENGINE CASTINGS, PARTICULARLY THE THREADED HOLE AREAS

ANY LEAK FOUND?

YES

REPLACE DEFECTIVE PARTS

ENGINE IS PERFECTLY SEALED INTERNALLY

F00D07S

04-02-5

Subsection 03

Section 04 ENGINE (REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATION

GENERAL

Jet Pump Removal

It is not necessary to remove engine from jet boat for TOP END or PTO FLYWHEEL AND MAGNETO servicing. However, engine removal is necessary to repair BOTTOM END AND ROTARY VALVE. Although basically the same engines are used for port and starboard, there are differences in hardware, such as throttle/choke cable length, fuel/oil lines, electrical wiring etc. Properly identify engines prior to removal.

To withdraw jet pump unit ass’y, refer to JET PUMP 09-02.

Electrical Connections

REMOVAL FROM JET BOAT In order to remove engine from jet boat proceed as follows.

CAUTION

Whenever removing engine from jet boat, engine/jet pump alignment must be performed at installation.

F09H06A

TURN OFF MAIN BATTERY CUT-OFF SWITCH

Rear Storage Compartment Cover Removal NOTE: To ease working in engine compartment, it is suggested to remove rear storage compartment cover from boat. Some models features a removable pin on the hinge but the best way to remove cover is to mark hinge position with a pencil, as shown in the next photo, then unscrew hinge from deck.

Unfasten battery top brace. First, remove BLACK negative cable from battery(ies), then RED positive cable.

◆

WARNING

Always disconnect starter or battery cables exactly in the specified order, BLACK negative cable first. Electrolyte or fuel vapors can be present in the engine compartment and a spark might ignite them and possibly cause personal injuries. It is recommended to disconnect electrical connections prior to disconnecting fuel lines. Disconnect thermosensor wire and spark plug cables. Disconnect magneto wires at connector of engine. Disconnect rectifier/voltage regulator wires.

F00L0KA

TYPICAL — MARK HINGE POSITION 1. Remove these three screws 04-03-1

Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION)

F01D8RA

TYPICAL — 717 ENGINE 1. Unplug connector

F04D0ZA

TYPICAL — 787 ENGINE SHOWN 1. Move carburetors away

Cooling System Disconnect cooling system hoses from engine head.

717 Engine Disconnect bleed hose at T-fitting close to engine. NOTE: The bleed hose of the 787 engine will be disconnected later.

Engine Rubber Mounts

F06D0FA

TYPICAL — 787 ENGINE 1. Unplug connector

Air Intake Silencer

All Engines Remove engine rubber mount screws. NOTE: Be careful when removing engine rubber mount screws, shims could have been installed underneath. Shims control engine/jet pump alignment. Always note position of shims for reinstallation to avoid altering engine alignment.

To remove air intake silencer, refer to AIR INTAKE 06-03.

Carburetors and Fuel Pump Properly identify hoses on fuel pump then disconnect hoses. To remove carburetors, refer to CARBURETORS 06-04. Do not disconnect throttle cable. It will save time for reassembly. Move carburetors away from engine.

04-03-2

1 F01D32A

TYPICAL — 717 ENGINE 1. Shim

Subsection 03

Section 04 ENGINE (REMOVAL AND INSTALLATION)

3 2

F01D8PB

TYPICAL — 787 ENGINE 1. Rear support 2. Rubber mount 3. Shim

Lifting Engine 717 Engine Engine can be easily lifted using the following suggested tools. – Cut porcelain from 2 old spark plugs. – Weld a lock washer approximately 20 mm diameter on each spark plug as shown.

F04D0YA

TYPICAL

All Engines Using a chain block, a hoist or other suitable equipment, slightly lift engine to ease the removal of remaining components.

CAUTION

Take care not to damage oil pump cable or oil injection hoses.

Removal of Remaining Components F01D0AA

To prevent excessive oil spillage, use a hose pincher (P/N 295 000 076).

1. Weld a lock washer here 2. Old spark plug

Remove spark plugs and replace by special tools. Hook a sling into holes of special tools then using a chain block, a hoist or other suitable equipment, slowly lift engine.

295 000 076

787 Engine Engine can be easily lifted by inserting a hook into exhaust manifold eyelet. A01B2JA

TYPICAL

04-03-3

Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION)

Lift engine until oil injection pump supply line, rotary valve oil lines (supply and return) are reachable. Install a hose pincher on each line then disconnect. NOTE: When disconnecting oil tube, a salvaged tube with a plugged end can be used to plug the engine nipple to prevent oil spillage.

Disconnect RED positive cable from starter post and ground cable (where applicable).

F01H1JB

TYPICAL — 717 ENGINE 1. Disconnect RED positive cable

2 1 F01D3ZA

TYPICAL — 717 ENGINE 1. Rotary valve supply line 2. Hose pincher installed

F04D10A

TYPICAL — 787 ENGINE 1. Rotary valve supply line 2. Hose pincher installed 3. Disconnect RED positive cable

F04D11A

TYPICAL — 717 ENGINE 1. Plugged tube installed on nipple

04-03-4

Subsection 03

Section 04 ENGINE (REMOVAL AND INSTALLATION)

CAUTION

Be careful not to scratch body with engine support or to hit any component.

Tuned Pipe To remove tuned pipe/exhaust manifold, refer to EXHAUST SYSTEM 04-08.

CLEANING 1 F04D12A

2 3

TYPICAL — 787 ENGINE 1. Disconnect injection pump cable 2. Oil injection pump supply line 3. Hose pincher installed

Wipe off any spillage in bilge. Clean with a bilge cleaner. Clean external parts of engine.

INSTALLATION Installation of engine in boat is essentially the reverse of removal procedures. However, pay particular attention to the following.

Rubber Mount, Shim and Screw Check tightness and condition of rubber mounts. If rubber mounts have been removed, apply Loctite 242 (P/N 293 800 015) on screw threads. Torque screws to 25 N•m (18 lbf•ft).

CAUTION

Strict adherence to this torque is important to avoid damaging threads of aluminum insert in bilge.

717 Engine 3 F04D13A

TYPICAL — UNDERNEATH VIEW OF 787 ENGINE 1. Disconnect bleed hose 2. Oil injection pump return line 3. Hose pincher installed

Engine Support Properly install support on crankcase so that rounded portion of support matches with MAG side of crankcase. Apply Loctite 242 (P/N 293 800 015) on threads then torque nuts in a criss-cross sequence to 43 N•m (32 lbf•ft).

Carefully lift engine out of boat.

04-03-5

Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION)

Loctite 242

F00D0BA

TYPICAL 1. Torque nut to 43 N•m (32 lbf•ft)

F00B0FB

1. Alignment plate (P/N 529 035 508) 2. Support (P/N 529 035 511)

All Engines

Oil Injection Hoses

Alignment shaft (P/N 295 000 141).

Make sure to reinstall hoses before completely lowering engine in bilge.

Positive Starter Cable Torque nut of positive starter cable to 6 N•m (53 lbf•in). Apply dielectric grease on terminal and nut.

Engine/Jet Pump Alignment Alignment is necessary to eliminate possible vibration and/or damage to components. Check alignment of engine using the following alignment tool. TOOL PREPARATION From alignment support plate kit (P/N 529 035 506). Assemble alignment plate with support, as shown in the next photo. Secure plate using screws and washers. NOTE: Both alignment plates have different holes positioning. In the case that part number is not stamped on alignment plate, use plate whose holes match jet pump studs position.

CAUTION

Ensure that both parts are clean before assembly.

04-03-6

1 F00B0GA

TYPICAL 1. Alignment shaft

ENGINE/JET PUMP ALIGNMENT – Install alignment plate previously assemble (see tool preparation) to jet pump support. – Secure alignment plate using existing jet pump nuts. – Carefully slide shaft through support, as shown in the next photo.

Subsection 03

If the alignment is incorrect, loosen engine support screws to enable to align PTO flywheel with shaft end. NOTE: Use shim(s) (P/N 270 000 024) or (P/N 270 000 025) as necessary between engine support and rubber mounts to correct alignment.

F09J05A

Section 04 ENGINE (REMOVAL AND INSTALLATION)

TYPICAL — STARBOARD SIDE SHOWN 1. Sliding shaft through support 2. Alignment plate properly secured to pump support

– Insert shaft end into PTO flywheel. NOTE: Ensure the protective boot and carbon ring are removed to check engine alignment. If the alignment is correct, the shaft will slide easily without any deflection in PTO flywheel. 1

F00D0CA

TYPICAL 1. Shim

CAUTION

Whenever shims are used to correct alignment, never install more than 1.3 mm (.051 in) shim thickness. If alignment cannot be obtained verify for engine support bending.

Engine Support Screws

F09J06A

TYPICAL 1. Alignment shaft 2. PTO flywheel

Apply Loctite 242 (P/N 293 800 015) on screw threads. Torque engine support screws to 25 N•m (18 lbf•ft) once procedure is complete. NOTE: Whenever alignment tool is not utilized, apply BOMBARDIER LUBE lubricant (P/N 293 600 016) on its shaft and inside the housing to eliminate possible corrosion.

04-03-7

Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION)

Final Inspection Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. After its installation, properly adjust and bleed oil injection pump as specified in OIL INJECTION PUMP 07-03. Properly reconnect hoses on fuel pump. Check hose condition and pressure test fuel system, refer to FUEL CIRCUIT 06-02.

;

WARNING

Whenever doing any type of repair on craft or if any components of the fuel system are disconnected, a pressure test must be done before starting engine. Verify all electrical connections. Run engine and ensure there is no leakage.

CAUTION

Water must be supplied to cool the engine.

04-03-8

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

MAGNETO SYSTEM

717 Engine 7

5 N m (44 lbf in)

9 N m (80 lbf in)

Loctite 242

10 13

Loctite 242 6 N m (53 lbf in)

Loctite 242 14 6 N m (53 lbf in)

6 N m (53 lbf in) 15 Loctite 242 3

4 16

Loctite 242

Loctite 648 5

6 145 N m (107 lbf ft)

2 9 N m (80 lbf in) Anti-seize lubricant

F00D11S

PARTS

04-04-1

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

787 Engine

Loctite 242 10 N m (88 lbf in)

Molykote 111

Loctite 648 10 N m (88 lbf in)

Loctite 648

105 N m (77 lbf ft) Loctite 242

10 N m (88 lbf in)

10 N m (88 lbf in) 9 N m (80 lbf in)

Anti-seize lubricant

1 F01D7TU

04-04-2

PARTS

Synthetic grease

6 N m (53 lbf in)

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

GENERAL The following procedures can be performed without removing engine from jet boat.

REMOVAL

Using a suitable socket, unscrew retaining nut no. 6 COUNTERCLOCKWISE when facing it. NOTE: If socket is found too large to be inserted in puller plate, machine or grind its outside diameter as necessary.

717 Engine

Magneto Housing Cover and Screw

Remove screws no. 2, wire support and spark plug grounding device then withdraw cover no. 1. MAG flywheel no. 4 is locked with puller plate (P/N 420 876 080), sleeves (P/N 290 847 220) and extension handle (P/N 295 000 125). 1 2 F01D4BA

TYPICAL 1. Extension handle locking crankshaft

3 F01D47A

1. 2. 3. 4.

Remove nut and lock washer from magneto flywheel. Magneto flywheel/ring gear assembly is easily freed from crankshaft with puller (P/N 529 035 547).

Screw Extension handle Puller plate Sleeve

Using 3 M8 x 35 screws (P/N 420 841 591), install screws through puller plate and slide sleeves on screws then secure puller plate on magneto flywheel no. 4 so that sleeves are against flywheel. Install extension handle on end of puller plate.

A00C1AA

Fully thread bolt on puller in puller plate. Tighten puller bolt and at the same time, tap on bolt head using a hammer to release magneto flywheel no. 4 from its taper.

F01D48A

TYPICAL 1. Sleeves on opposite side

04-04-3

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

1 2

3 F01D4CA

1. Puller plate 2. Puller 3. Extension handle

Armature Plate Remove 3 retaining screws no. 15 and withdraw armature plate no. 10.

Magneto Housing To remove magneto housing no. 7, starter has to be removed. Refer to ELECTRICAL SYSTEM 0807. Unscrew retaining screws no. 9, then withdraw housing.

F01D4DA

1. Crankcase locating lug 2. Mark armature plate at the end of lug

– At assembly, align armature plate mark (previously punched) with the end of the same locating lug on the new crankcase. 1

Engine Crankcase Replacement Since replacement crankcases do not have timing mark for armature plate location, indexing marks should be made on armature plate and crankcase to ease reassembly and further ignition timing. The following procedure is to find a common reference point on both crankcases (old and new) to position armature plate. Proceed as follows: – Find a crankcase locating lug (the top one in this example). – Place a cold chisel at the end of chosen lug, then punch a mark on armature plate at this point.

F01D4EA

TYPICAL 1. Lug end of crankcase 2. Align mark and lug end here

04-04-4

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

– Find manufacturer’s mark on armature plate. In line with this mark, punch another mark on adjacent crankcase lug.

787 Engine

Magneto Housing Cover Loosen screws no. 2. Remove magneto housing cover no. 1.

Rotor and Ring Gear Remove starter. Refer to STARTING SYSTEM 08-08. Lock ring gear no. 5 using special tool (P/N 295 000 155). 2

1 2 1

F01B26A

F01D4FA

1. Ring gear blocking tool 2. Retaining plate

TYPICAL 1. Manufacturer’s mark on armature plate 2. Punch a mark on crankcase lug aligned with plate mark

The new mark on crankcase will be used for further assembly positioning as a pre-timing position.

F01D85A

1. Ring gear blocking tool with retaining plate

F01D4GA

TYPICAL 1. For further assembly, use these marks

04-04-5

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

If desired, magneto flywheel no. 4 can be removed without the engine ring gear no. 5. Remove the 6 screws no. 11.

DISASSEMBLY 717 Engine

Magneto Flywheel and Ring Gear Lay magneto flywheel no. 4 on a steel plate. Tap lightly on ring gear no. 5 using a hammer to release it from magneto flywheel. 1

F01D7XA

1. Screw

Using a suitable socket, unscrew retaining nut no. 6 of engine ring gear no. 5 COUNTERCLOCKWISE when facing it. Remove special tool locking ring gear. Ring gear is easily freed from crankshaft with puller (P/N 529 035 547) and crankshaft protective cap (P/N 420 876 557). Insert crankshaft protector to outer end of crankshaft and fully thread puller in engine ring gear.

F01D3AA

1. Magneto flywheel

Generating Coil To replace generating coil no. 11: – Heat the armature plate to 93°C (200°F) around the screw holes to break the threadlocker bond.

1 F00D08A

1. Heat the armature plate F01D7YA

1. Puller

Tighten puller screw and at the same time, tap on screw head using a hammer to release engine ring gear from its taper.

04-04-6

CAUTION

Protect harness from flame.

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

– Remove screws. – Uncrimp and unsolder GREY (GREY/GREEN on starboard side) wire from coil.

– Remove screws. – Uncrimp and unsolder both BROWN wires from coil. – Uncrimp and unsolder ground wire (BLACK) from coil core.

A25E0QA

1. Uncrimp and unsolder wire here

A25E0SA

Battery Charging Coil To replace battery charging coil no. 13: – Heat the armature plate to 93°C (200°F) around the screw holes to break the threadlocker bond.

1. Uncrimp and unsolder ground wire (BLACK) 2. Uncrimp and unsolder BROWN wires

CLEANING All Engines Clean all metal components in a solvent.

CAUTION

Clean coils and magnets using only a clean cloth. Clean crankshaft taper and threads. 1

ASSEMBLY 717 Engine

F00D09A

Generating Coil

1. Heat the armature plate

CAUTION

Protect harness from flame.

Strip end of old wire then crimp and solder on new coil no. 11. Apply Loctite 242 (P/N 293 800 015) to screws no. 12 and install the new coil on armature plate.

04-04-7

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

Use magneto coil centering tool (P/N 420 876 922) and install so that it fits around armature plate before tightening screws. 1

Magneto Flywheel and Ring Gear Apply Loctite 648 (P/N 413 711 400) to magneto flywheel no. 4 mating surface. Lay ring gear no. 5 on a steel plate, then heat with a propane torch in order to install it on magneto flywheel. Pay particular attention to position ring gear teeth chamfer side as per following illustration.

F00D0AA

1. Magneto coil centering tool

CAUTION

Before reinstalling the magneto, remove the loose epoxy from harness.

Battery Charging Coil Position new coil no. 13, crimp and solder all wires. Prior to assembly, apply Loctite 242 (P/N 293 800 015). Use magneto coil centering tool (P/N 420 876 922) and install it so that it fits around armature plate before tightening screws no. 14. 1

F00D0AA

1. Magneto coil centering tool (P/N 290 876 922)

04-04-8

F01D3BA

1. Teeth chamfer

NOTE: Ensure that ring gear contacts magneto flywheel flange. Whenever replacing either ring gear or magneto flywheel, Gun Kote (available from Kal-Gard Coating & Mfg. Corp.) must be applied to prevent possible corrosion.

CAUTION

Always assemble magneto flywheel and ring gear prior to applying Gun Kote. If not done correctly, ring gear won’t contact magneto flywheel flange. To apply Gun Kote proceed as follows: 1. Clean thoroughly and degrease replacement part using a non oil base solvent. 2. Apply coating in light thin coats using a spray gun. NOTE: Do not spray Gun Kote into magneto flywheel threaded holes. Bake parts in oven at 175° (350°F) for one hour to cure Gun Kote.

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

CAUTION

Do not eliminate Gun Kote heat curing time because it will lose all its resistance and not give any protection.

CAUTION

At installation of magneto, ring gear teeth chamfer and starter clutch should be facing each other.

787 Engine

F06D0DA

Stator Install the stator no. 12 in magneto housing cover no. 1 and torque screws no. 13 to 10 N•m (88 lbf•in). Reinstall wiring harness bracket no. 16 of stator and torque screws to 4.5 N•m (40 lbf•in). 1

1. Trigger coil

INSTALLATION 717 Engine

Magneto Housing Install gasket no. 8 between magneto housing no. 7 and engine crankcase. Install magneto housing and torque screws no. 9 to 9 N•m (80 lbf•in).

Armature Plate Position the armature plate no. 10 on the crankcase, aligning the marks on both parts. Apply a drop of Loctite 242 (P/N 293 800 015) on threads of screws no. 15 and torque to 6 N•m (53 lbf•in). F06D0CA

1. Stator screws 2. Bracket

Trigger Coil Install the trigger coil no. 14 in magneto housing cover no. 1 and torque screws no. 15 to 10 N•m (88 lbf•in). NOTE: The trigger coil is not adjustable.

Magneto Flywheel Apply Loctite 242 on crankshaft taper. Position Woodruff key no. 16 and magneto flywheel no. 4. Apply Loctite 242 on nut no. 6. Install nut with lock washer and torque to 145 N•m (107 lbf•ft).

CAUTION

Never use any type of impact wrench at magneto installation.

04-04-9

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

Ignition Timing

Rotor and Ring Gear

For ignition timing procedures, refer to IGNITION SYSTEM 08-03.

When reinstalling magneto flywheel no. 4 to ring gear no. 5, apply Loctite 648 (P/N 413 711 400) to mating surfaces. One of the protuberance end of magneto rotor must align with hole of ring gear.

787 Engine

Magneto Housing To install oil seal no. 10 of magneto housing no. 7, use pusher (P/N 290 877 740) and handle (P/N 420 877 650).

F01D83A

1. Protuberance 2. Hole F01B2NA

1. Pusher 2. Handle

Apply Loctite 648 on screws no. 11 and torque to 10 N•m (88 lbf•in). Apply Loctite 242 on crankshaft taper. Apply Loctite 242 on nut no. 6. Install nut with lock washer and torque to 105 N•m (77 lbf•ft).

CAUTION

Never use any type of impact wrench at magneto installation.

All Engines

Magneto Housing Cover

F04D0CA

Install gasket no. 8 between magneto housing and engine crankcase. Install magneto housing and torque screws no. 9 to 9 N•m (80 lbf•in).

04-04-10

Properly install O-ring no. 3 in magneto housing no. 1. Apply anti-seize lubricant (P/N 293 800 023) on screws no. 2, install cover then torque screws no. 2 in a criss-cross sequence to 9 N•m (80 lbf•in).

Section 04 ENGINE Subsection 05 (TOP END)

TOP END

717 Engine Loctite 242 24 N m 11 (17 lbf ft) Molykote 111

Pipe sealant

Loctite 242 24 N m 11 (17 lbf ft)

1 10

Molykote 111

25 10

2 Molykote 111

Molykote 111

9 24 N m (17 lbf ft)

24 N m 9 (17 lbf ft)

Loctite 242

Loctite 242 7 34 rollers 6 5

Loctite 518 12

34 rollers

Molykote 111

F04D0UU

PARTS

04-05-1

Section 04 ENGINE Subsection 05 (TOP END)

787 Engine Loctite 242 Molykote 111

24 N m 11 (17 lbf ft) 1

2 24 16 13

Molykote 111

9 40 N m (30 lbf ft) Loctite 518 7

20 19

34 rollers

Loctite 518

6 5 4 12 4 5

Molykote 111 3

F01D7DV

04-05-2

PARTS

Molykote 111 6

34 rollers

Section 04 ENGINE Subsection 05 (TOP END)

ENGINE DESCRIPTION The 2-stroke ROTAX engine rotates counterclockwise seen from the rear (PTO flywheel). It has a rotary valve to control fuel mixture intake. Lubrication is provided by a variable oil injection pump. It is cooled by water supplied from the jet pump. It has a NIPPONDENSO Capacitor Discharge Ignition System. The fuel is provided by diaphragm MIKUNI carburetor having an integrated fuel pump.

CAUTION

No engine components can be interchanged between engines.

GENERAL When repairing a seized engine, connecting rods should be checked for straightness and crankshaft for deflection/misalignment. Refer to BOTTOM END for procedures.

787 Engine This engine is canted at a 30 degree angle, lowering the center of gravity of the craft. Cylinder exhaust ports are located on the same side of the intake, allowing a high volume tuned pipe design. This engine also features the RAVE system (Rotax Adjustable Variable Exhaust). The RAVE system, working in combination with the high volume tuned pipe, offers a broader power band.

When an engine of this design is run at a medium speed, efficiency falls off quickly. The relatively high exhaust port effectively shortens the useful power stroke, and because the exhaust system is tuned for maximum power, there is a large increase of fresh charge losses. As a result, the torque decreases along with a dramatic increase of the specific fuel consumption. Higher torque along with lower fuel consumption can be obtained at lower engine speeds if the time the exhaust port is open is shortened. BOMBARDIER-ROTAX has patented a remarkably simple system to automatically change the exhaust port height based on pressure in the exhaust system. Located above the exhaust port is a guillotinetype slide valve. This rectangular valve is connected by a shaft to a diaphragm which is working against the return spring. One small passage in the cylinder just outside the exhaust port allows exhaust gas pressure to reach the diaphragm. To the outside of the return spring is a red plastic adjustment knob. Turning the adjustment in or out changes the preload on the return spring which, in turn, will change the RPM at which the RAVE valve opens and closes. 1

5 3 2

RAVE System THEORY For a 2-stroke-cycle engine to have high power capacity at high crankshaft speeds, a high volumetric or breathing efficiency is required and the fresh charge losses must be minimized. The result is achieved by opening the exhaust port early and utilizing the resonant effects of the tuned exhaust system to control fresh charge losses.

A18C01A

TYPICAL 1. Sliding valve 2. Diaphragm 3. Spring 4. Exhaust port 5. Adjustment knob

As the throttle is opened and the engine begins producing more power, the pressure against the diaphragm will overcome the pressure of the return spring and the RAVE valve will open.

04-05-3

Section 04 ENGINE Subsection 05 (TOP END)

F01D7GA

VALVE FULLY OPENED

Item P1 in figure is the force of the return spring against the diaphragm. The exhaust pressure must be high enough to overcome this force before the valve begins opening. Item P2 is the pressure required to completely open the RAVE valve. Between P1 and P2, the usable power curve of the engine is moving from power curve 1 to power curve 2. This transition takes place very rapidly at full throttle and from a practical standpoint can be considered to be instantaneous at item 7. Gradual application of the throttle, however, will result in the RAVE valve opening much later. If the RAVE valve opens too late, the engine will bog or hesitate momentarily as the RPM increases. Full peak performance (item 6) is still available. From a functional point of view, it is better to have the valve open a bit early than a bit late.

POWER

F01D7HA

VALVE FULLY CLOSED

The RAVE valve does not allow an engine to make higher peak horsepower than an engine not so equipped; however, it can make moving the peak horsepower higher practical because of its effect on the rest of the power curve. Item 2 in the following figure is the power curve of an engine with the RAVE valve held fully open through its entire RPM range. Item 6 notes the peak power produced. That peak would not change if the exhaust port timing of a similar engine without a RAVE valve were the same (with all other features equal). Item 1 is the power curve of the engine with the RAVE valve closed through its entire RPM range. The shaded area (item 3) is the improvement in power at lower engine speeds that is gained because of the lower exhaust port. If the port were to remain at this height; however, the power would peak as noted in item 5. Raising the exhaust port at the proper RPM (item 7) will allow the engine peak power to continue to rise (item 6).

04-05-4

A18C02A

RPM

MAINTENANCE There are no wear parts anywhere in the system and there are no adjustments to be periodically checked. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide. Cleaning intervals would depend upon the userâ&#x20AC;&#x2122;s riding style and the quality of the oil used. Using BOMBARDIER-ROTAX injection oil, we would suggest annual cleaning of the valve. If a customer uses a lower quality oil, more frequent cleaning may be required. No special solvents or cleaners are required when cleaning the valve.

Section 04 ENGINE Subsection 05 (TOP END)

BORING PRECAUTION In its stock configuration the RAVE valve guillotine has a minimum of 0.5 mm (.020 in) clearance to the cylinder bore measured at the center line of the cylinder. This is the minimum production clearance. There is only a first oversize piston available for the 787 engine. That piston is 0.25 mm (.010 in) larger in diameter than the stock piston. When the oversize is installed, the guillotine will have a minimum clearance of 0.375 mm (.015 in) with the cylinder bore. This is the minimum operating clearance the guillotine should be used with. Clearance less than 0.375 mm (.015 in) will require reworking of the guillotine to achieve the proper clearance and radius.

DISASSEMBLY

F01D8IA

787 Engine

1. Allen screws

RAVE Valve

Remove bellow no. 17 from valve piston no. 16. Unscrew valve piston no. 16 from sliding valve no. 18. NOTE: Hold the sliding valve to prevent it from turning.

Remove the cover no. 14 of the valve no. 24 by releasing the spring no. 13.

â&#x2014;&#x2020;

WARNING

Firmly hold cover to valve base. The spring inside the valve is applying a pressure against the cover.

2 F01D8MA

1. Unscrew piston 2. Hold sliding valve

All Engines Top end can be serviced while engine is in the boat, proceed as follow.

F01D8HA

1. Spring

Electrical Connections

Loosen Allen screws no. 15 and remove RAVE valve.

Disconnect thermosensor wire and spark plug cables. Disconnect spark plug cables and connect on grounding device.

04-05-5

Section 04 ENGINE Subsection 05 (TOP END)

Exhaust System To withdraw tuned pipe and exhaust manifold, refer to EXHAUST SYSTEM 04-08.

Bring piston to Top Dead Center and install rubber pad (P/N 295 000 101) over crankcase opening. Secure with screws. Lower piston until it sits on pad.

Air Intake Silencer

To remove air intake silencer, refer to AIR INTAKE 06-03.

Cylinder Head Cover and Cylinder Head Remove cylinder head cover no. 1. NOTE: Cylinder head screws secure also cylinder head cover. If shells, sand, salt or any other particles are present in cylinder head, clean with a vacuum cleaner. Remove cylinder head no. 2. If shells, sand, salt water or any other particles are present in cylinder cooling jacket, clean with a vacuum cleaner. Remove cylinders, being careful that connecting rods do not hit crankcase edge.

â&#x2014;&#x2020;

F01B0JA

1. Rubber pad

If other cylinder has been removed, completely cover its opening with a clean rag.

WARNING

If screws need to be heated for removal when engine is in jet boat, fuel system pressurization must be done first. Do not use open flame; use a heat gun. An explosion might occur since vapors can be present in engine compartment. NOTE: Even if only one cylinder needs repair, both cylinders should be lifted to allow 1-piece cylinder base gasket replacement.

F01D43A

1. Openings covered with rag and rubber pad

Piston, Piston Pin, Circlip and Roller Bearing

CAUTION

Never use a magnet to catch rollers of bearing. This magnetizes the rollers that will catch dust. NOTE: These engines feature cageless piston pin bearing.

04-05-6

To remove circlip no. 5, insert a pointed tool in piston notch then pry it out and discard.

â&#x2014;&#x2020;

WARNING

Always wear safety glasses when removing piston circlips.

Section 04 ENGINE Subsection 05 (TOP END)

2 3 4

F00B0JA F01D0PA

1. Piston notch

To extract piston pin no. 4, use piston pin puller (P/N 529 035 503) with a set of sleeves (P/N 529 035 542). 2

1. 2. 3. 4.

Puller Sleeve Shoulder sleeve Extracting nut

NOTE: The tool cutout must be positioned toward the bottom of the piston.

1 F00B0IA

1. Puller 2. Shoulder sleeve 3. Sleeve

– Fully thread on puller handle. – Insert extractor spindle into the piston pin no. 4. – Slide the sleeve and shoulder sleeve onto the spindle. – Screw in extracting nut with the movable extracting ring towards spindle.

F00B0KA

1. Tool cutout toward bottom of piston

– Firmly hold puller and rotate handle to pull piston pin no. 4. – Rotate spindle until the shoulder sleeve is flushed with the piston recess.

04-05-7

Section 04 ENGINE Subsection 05 (TOP END)

F00B0NA

F00B0LA

1. Shoulder sleeve flush with piston recess

1. Needles and thrust washer 2. Sleeve

– Loosen the extracting nut and remove puller. – Remove the shoulder sleeve from piston no. 3.

F00B0MA

1. Remove shoulder sleeve

– Carefully remove the piston. – The needles, thrust washers and the sleeve remain in the connecting rod bore and may be used again.

04-05-8

CLEANING Discard all gaskets and O-rings. Clean all metal components in a solvent. Clean water passages and make sure they are not clogged. Remove carbon deposits from cylinder exhaust port, RAVE valve (787 engine), cylinder head and piston dome. Clean piston ring grooves with a groove cleaner tool, or a piece of broken ring. Piston pin may be cleaned with a fine steel whool.

INSPECTION 787 Engine Check RAVE valve bellow no. 17 for cracks. Check if passages of valve housing no. 21 and cylinder no. 9 are not obstructed.

Section 04 ENGINE Subsection 05 (TOP END)

NOTE: Replacement cylinder sleeves are available if necessary. Also, oversize pistons of 0.25 mm (.010 in) are available for all engines and additional oversize pistons of 0.5 mm (.020 in) are available for 717 engines.

Cylinder Taper Using a cylinder bore gauge, measure cylinder diameter 16 mm (5/8 in) from top of cylinder to just below auxiliary transfer port, facing exhaust port. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced. 1

F01D8JA

1. Passage of valve housing

All Engines Visually inspect all parts for corrosion damage. Inspect piston for damage. Light scratches can be sanded with a fine sand paper. Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper. The inspection of engine top end should include the following measurements.

ENGINE MEASUREMENT

1 A

TOLERANCES (ALL ENGINES) NEW PARTS (min.) (max.)

WEAR LIMIT

Cylinder taper

N.A.

0.1 mm (.004 in)

Cylinder out of round

N.A.

0.08 mm (.003 in)

Piston/cylinder clearance

0.09 mm 0.11 mm (.0037 in) (.0044 in)

Ring/piston groove clearance

0.025 mm 0.07 mm 0.20 mm (.001 in) (.0028 in) (.008 in)

Ring end gap

0.25 mm (.010 in)

0.40 mm (.016 in)

0.2 mm (.008 in)

F01D8AA

1. Measuring perpendicularly (90Â°) to piston pin axis 2. Auxiliary transfer port A. 16 mm (5/8 in)

Cylinder Out of Round Using a cylinder bore gauge, measure cylinder diameter 16 mm (5/8 in) from top of cylinder. Measure diameter in piston pin axis direction then perpendicularly (90Â°) to it. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced.

1.0 mm (.039 in)

04-05-9

Section 04 ENGINE Subsection 05 (TOP END)

Piston/Cylinder Wall Clearance Used and New Piston NOTE: Make sure used piston is not worn. See USED PISTON above. To determine the piston dimension, take the measurement on the piston dome.

F01D8BA

1. Measuring in piston pin axis 2. Measuring perpendicularly (90°) to piston pin axis A. 16 mm (5/8 in)

F00D0EA

1. Piston dome 2. Piston measurement

Used Piston Measurement Using a micrometer, measure piston at 25 mm (1 in) from skirt end perpendicularly (90º) to piston pin.

Adjust and lock a micrometer to the specified value on the piston dome. 1

F00B08A

1. Micrometer set to the piston dimension

F01D0NA

1. Measuring perpendicularly (90°) to piston pin axis A. 25 mm (1 in)

The measured dimension should be the same as the one scribed on piston dome. If not, install a new piston.

04-05-10

PISTON/CYLINDER WALL CLEARANCE MEASUREMENT Used and New Pistons With the micrometer set to the piston dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to zero.

Section 04 ENGINE Subsection 05 (TOP END)

1 2

Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.

Ring/Piston Groove Clearance Using a feeler gauge, check clearance between rectangular ring and groove. If clearance exceeds specified tolerance, replace piston. NOTE: Ring/piston groove clearance can be correctly measured only on rectangular ring which is bottom ring.

F00B09A

1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge

F01D0XA

1. Feeler gauge 2. Rectangular ring (bottom)

1 F00B0AA

1. Indicator set to zero

Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge.

Ring End Gap Position ring halfway between exhaust port and top of cylinder. NOTE: In order to correctly position ring in cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. If gap exceeds specified tolerance, rings should be replaced.

1 A

F01D0KA

1. Measuring perpendicularly (90Â°) to piston pin axis A. 16 mm (5/8 in) 04-05-11

Section 04 ENGINE Subsection 05 (TOP END)

F01D0OA

GASKET THICKNESS

IDENTIFICATION HOLES

0.3 mm (0.012 in)

0.4 mm (0.016 in)

0.5 mm (0.020 in)

0.6 mm (0.024 in)

0.8 mm (0.031 in)

ASSEMBLY Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following.

1. Top of cylinder 2. Ring end gap

Cylinder Base Gasket

787 Engine

NOTE: The general procedure is to install a new gasket of the same thickness. However, if you do not know the gasket thickness that was installed or if a crank repair has involved replacement of connecting rods, refer to the COMBUSTION CHAMBER VOLUME MEASUREMENT to properly determine the required gasket thickness. Five thicknesses of cylinder base gaskets no. 12 are available for a precise adjustment of the squish gap. To determine gasket thickness, refer to the identification holes on the gasket.

RAVE Valve Make sure to insert O-ring no. 19 onto rod of sliding valve no. 18. The TOP position of the sliding valve no. 18 is indicated on one side.

3 F01D8KA

1. Sliding valve 2. O-ring 3. TOP

F01D67A

1. Identification holes

04-05-12

Install a new gasket no. 20. It must be installed at the same time as the sliding valve no. 18. Position the valve housing no. 21 onto the cylinder so that its opening is toward the bottom.

Section 04 ENGINE Subsection 05 (TOP END)

1 AUS

A01C01A

1. Exhaust side

F01D8JB

1. Bottom of valve housing

When the valve is mounted onto the cylinder, move the valve piston no. 16 to ensure the sliding valve no. 18 moves easily and doesn’t stick.

F01D7EA

787 ENGINE SHOWN 1. “AUS”

Carefully cover crankcase opening as for disassembly.

Piston Pin and Roller Bearing

F01D8LA

All Engines

Piston At assembly, place the pistons no. 3 over the connecting rods with the letters “AUS” (over an arrow on the piston dome) facing in direction of the exhaust port. NOTE: On the 787 engine, exhaust ports are located on the same side as the intake.

To install roller bearing no. 6 and piston pin no. 4, use piston pin puller (P/N 529 035 503) with a set of sleeves (P/N 529 035 542) as for disassembly. Replacement bearings are held in place by a locating sleeve outside and 2 plastic cage halves inside. – Push needle bearing together with inner halves out of the locating sleeve into the connecting rod bore. – Insert piston pin no. 4 into piston no. 3 until it comes flush with inward edge of piston hub. NOTE: Make sure thrust washers are present each side of needles. – Install the shoulder sleeve tool on the opposite side of the piston pin.

04-05-13

Section 04 ENGINE Subsection 05 (TOP END)

F00B0OA F01D0QA

1. Piston pin 2. Shoulder sleeve

1. Outer ring removal after inner sleeve insertion into bore

– Insert extractor spindle into the piston pin no. 4, screw on extracting nut. 2

– Make sure thrust washers are present on each side of rollers.

F00B0PA

1. Puller installed on the opposite side of the piston pin 2. Tighten extracting nut

– Rotate handle to pull piston pin carefully into the piston.

F01D0VA

1. Thrust washer each side

– Insert piston pin no. 4 into piston no. 3 until it comes flush with inward edge of piston hub.

PLASTIC MOUNTING DEVICE METHOD As an alternate method when no service tool is available proceed as follows: Replacement roller bearings no. 6 are delivered in a convenient plastic mounting device. For installation, proceed as follows: – Align replacement roller bearing with connecting rod bore. – Carefully push inner plastic sleeve into connecting rod bore; outer plastic ring will release rollers.

F01D0RA

1. Piston pin flush here 2. Thrust washers 04-05-14

Section 04 ENGINE Subsection 05 (TOP END)

– Place piston over connecting rod and align bores, then gently tap piston pin with a fiber hammer to push out inner plastic ring on opposite side. Support piston from opposite side.

F06D18A

1. Circlip opening at 6 o’clock (at bottom)

To easily insert circlip no. 5 into piston no. 3, use circlip installer (P/N 529 035 562).

F01D0SA

– As necessary, pull halves of inner sleeve with long nose pliers.

F06B01A

1. Circlip installer

– Remove sleeve from pusher then insert circlip into its bore. – Reinstall sleeve onto pusher and push until circlip comes in end of tool. F01D0TA

1. Pulling inner sleeve half

Circlip Secure circlip no. 5 with its opening located at the bottom of the piston.

CAUTION

To minimize the stress on the circlips, it is important to install them as described.

F00B0QA

TYPICAL 1. Circlip near end of tool

04-05-15

Section 04 ENGINE Subsection 05 (TOP END)

â&#x20AC;&#x201C; Position end of tool against piston pin no. 4 opening. â&#x20AC;&#x201C; Firmly hold piston against tool and tap tool with a plastic tip hammer to insert circlip into its groove.

Make sure to align ring end gap with piston locating pin. Slide tool over rings. 1

F01D0ZA

1. Ring end gap aligned with piston locating pin

F00B0RA

CAUTION

Install cylinder gasket no. 12 and slide cylinder no. 7 over piston no. 3.

The forearm retaining the piston should absorb the energy to protect the connecting rod. Circlips must not move freely after installation.

Cylinder To easily slide cylinder no. 7 over piston, install ring compressor (P/N 295 000 112) over rings.

F01D10A

A01B1TA

1. Slide this edge

NOTE: Ring compressor will not fit on oversize piston/rings.

04-05-16

When reassembling cylinders to crankcase, it is important to have them properly aligned so that exhaust flanges properly match up with exhaust manifold. Use aligning tool (P/N 420 876 904) or exhaust manifold itself.

Section 04 ENGINE Subsection 05 (TOP END)

717 Engine

F01D44A

787 Engine The exhaust manifold is used to align cylinders.

F00D0FA

TYPICAL 1. Aligning cylinders using exhaust manifold

1. Exhaust flange aligning tool

Screw, Grease and Cylinder 717 Engine Apply Molykote 111 (P/N 413 707 000) below screw head no. 9. Apply Loctite 242 (P/N 293 800 015) on screw threads. Install and torque screws in a crisscross sequence for each cylinder to 24 N•m (17 lbf•ft). 1

F01D45A

1. Aligning cylinders using exhaust manifold

F01D35A

04-05-17

Section 04 ENGINE Subsection 05 (TOP END)

787 Engine Prior installation, apply Molykote 111 (P/N 413 707 000) below screw head and Loctite 518 (P/N 293 800 038) on screw threads. Install M10 x 105 screws on exhaust side and the M10 x 73.5 on opposite side. Torque screws in a criss-cross sequence for each cylinder to 20 N•m (15 lbf•ft). Repeat the procedure, retightening all cylinder screws to 40 N•m (30 lbf•ft). 2

Apply Loctite 518 (P/N 293 800 038) in cylinder sleeve O-ring groove. Install cylinder head.

Cylinder Head Cover and Screw Install cover no. 1 over cylinder head no. 11. Apply Molykote 111 (P/N 413 707 000) below screw head. Apply Loctite 242 (P/N 293 800 015) on screw threads. Torque cylinder head screws to 24 N•m (17 lbf•ft) as per following illustrated sequence.

2 10

F01D7FA

4 F01D46A

All Engines

TORQUING SEQUENCE

Cylinder Head and O-Ring

Finalizing Assembly

Make sure to install O-rings no. 10 around spark plug holes and cylinder head O-ring no. 25 where shown.

Reconnect electric wires/cables. To properly reinstall tuned pipe and exhaust manifold, refer to EXHAUST SYSTEM 04-08. To properly reinstall air intake silencer, refer to AIR INTAKE 06-03.

F01D5AA

1. O-ring

04-05-18

Section 04 ENGINE Subsection 05 (TOP END)

ADJUSTMENT RAVE Valve

787 Engine Turn the red plastic knob no. 22 until it is fully tightened. 1

F01D5VA

1. Combustion chamber

F00D0WA

NOTE: When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposit and cylinder head must be leveled. 1. Remove both spark plugs and bring one piston to Top Dead Center using TDC gauge.

1. Knob fully tightened

This will ensure the correct preload on the return spring no. 23 in order to open and close the RAVE valve at the proper RPM.

Combustion Chamber Volume Measurement NOTE: This procedure is required to determine gasket thickness if you do not know the gasket thickness that was installed, if a crank repair has involved replacement of connecting rods or if you are experiencing repetitive engine seizure. The combustion chamber volume is the region in the cylinder head above the piston at Top Dead Center. It is measured with the cylinder head installed on the engine.

F01D2IA

1. Bring piston to TDC

04-05-19

Section 04 ENGINE Subsection 05 (TOP END)

2. Use a graduated burette (capacity 0-50 cc) and fill with an equal part (50/50) of gasoline and injection oil.

F00B0BA

1. Graduated burette (0-50 cc)

3. Open burette valve to fill its tip. Add liquid in burette until level reaches 0 cc. 4. Inject the burette content through the spark plug hole until liquid touches the top spark plug hole.

NOTE: The liquid level in cylinder must not drop for a few seconds after filling. If so, there is a leak between piston and cylinder. The recorded volume would be false. 5. Let burette stand upward for about 10 minutes, until liquid level is stabilized. 6. Read the burette scale to obtain the quantity of liquid injected in the combustion chamber. Compare the obtained value with the table below. The volume should be in the allowable range. If the volume is not as per specification, change cylinder base gasket thickness as follows. A higher volume dictates a thinner gasket. A lower volume dictates a thicker gasket. NOTE: When the combustion chamber is filled to top of spark plug hole, it includes an amount of 2.25 cc corresponding to the spark plug tip. The following table of combustion chamber volume includes this value. ENGINE

COMBUSTION CHAMBER VOLUME

717

31.2 - 34.0 cc

787

34.7 - 37.9 cc

7. Repeat the procedure for the other cylinder.

F00D0HA

1. Top of spark plug hole

04-05-20

Section 04 ENGINE Subsection 06 (BOTTOM END)

BOTTOM END

717 Engine Loctite 518

Anti-seize lubricant

1 2 2 18 Molykote 111

6 Anti-seize lubricant

Anti-seize lubricant

4 Primer "N" and Loctite 518

Loctite 242

5 3

5 3 Molykote 111

10 24 N m (17 lbf ft) Loctite 518 Molykote 111

F04D1HT

Loctite 12 518 9 24 N m (17 lbf ft)

Loctite 518

Loctite 518 8 40 N m (30 lbf ft) Molykote 111 11 10 N m (88 lbf in)

PARTS

04-06-1

Section 04 ENGINE Subsection 06 (BOTTOM END)

787 Engine 30 mL (1 oz) SAE 30 motor oil Anti-seize lubricant Loctite 518

Molykote 111

19 1

13 2

16 17

14 7 2

Molykote 111 Anti-seize lubricant

5 18

6 Anti-seize lubricant 15

Anti-seize lubricant

Anti-seize lubricant Loctite 242

Molykote 111

Loctite 518 Anti-seize lubricant Loctite 518 40 N m 9 (30 lbf ft)

8 12

Loctite 518

Molykote 111 Molykote 111 F04D1IT

04-06-2

PARTS

24 N m (17 lbf ft)

Loctite 518 40 N m (30 lbf ft) Molykote 111

Loctite 518 24 N m (17 lbf ft) Molykote 111

3 Anti-seize lubricant

Section 04 ENGINE Subsection 06 (BOTTOM END)

DISASSEMBLY

Engine has to be removed from boat to open bottom end.

PTO Flywheel To remove PTO flywheel no. 19, the crankshaft no. 6 must be locked. Refer to MAGNETO SYSTEM 04-04 and follow the procedure to lock the magneto flywheel. NOTE: Do not remove the magneto flywheel. PTO flywheel is loosen using PTO flywheel remover (P/N 295 000 001).

F00D0ZA

TYPICAL 1. Extension handle locking crankshaft

NOTE: When splines of PTO flywheel are worn out and special tool can not be used, proceed with the following alternate method. Use a pipe wrench and install it on PTO flywheel no. 19 as illustrated.

1 F01J0TA

Insert special tool in PTO flywheel splines.

1 F00D10A

TYPICAL 1. Extension handle locking crankshaft

F01D1AA

787 Engine PTO flywheel can be loosen using either PTO flywheel remover as explained above or the one described below (P/N 295 000 156).

TYPICAL 1. PTO flywheel remover (P/N 295 000 001)

Using a suitable wrench or socket with a breaker bar, unscrew PTO flywheel COUNTERCLOCKWISE when facing it and hold extension handle locking the magneto flywheel.

F00B04A

Install special tool.

04-06-3

Section 04 ENGINE Subsection 06 (BOTTOM END)

– rotary valve cover and valve – crankcase retaining screws Put engine on a trestle. Loosen crankcase screws. Put engine back on a support. Insert a pry bar between crankcase lugs to separate halves.

CAUTION

Be careful to precision machined surfaces.

F06I02A

1. PTO flywheel remover

Install the extension handle (P/N 295 000 125) on the PTO flywheel remover. Loosen PTO flywheel COUNTERCLOCKWISE when facing it.

F01D1KA

All Engines

TYPICAL 1. Separate halves by prying at provided lugs

Crankshaft Seal(s) If a crankshaft end seal has to be replaced, bottom end must be opened (except for the MAG side seal on the 787 engine, which is mounted on the magneto housing).

Crankcase Remove the following parts: – engine support (717 engine) – magneto flywheel, refer to MAGNETO SYSTEM 04-04 – starter – ignition housing

1 F01D1LA

TYPICAL 1. Separate halves by prying at provided lugs

Remove crankshaft and counterbalance shaft (787 engine).

Seal and Bearing NOTE: Do not needlessly remove crankshaft bearings. Remove end seals nos. 1 and 4.

F01D4JA

1. Separating ignition housing/armature plate from crankcase 04-06-4

Section 04 ENGINE Subsection 06 (BOTTOM END)

787 Engine To remove end bearings nos. 2 and 3 from crankshaft, use the following tools. NOTE: The outer PTO bearing and crankshaft gear can be removed in one step using another puller. See Crankshaft Gear. 1

F06D1GA

TYPICAL 1. End seal

F01B2MA

To remove end bearings nos. 2 and 3 from crankshaft, use the following tools. Use grease to hold protective cap on crankshaft end.

787 ENGINE 1. Puller (P/N 290 876 298) 2. Protective cap (P/N 290 876 557) 3. Distance ring (P/N 290 876 569) 4. Ring (P/N 290 977 490) 5. Ring halves (P/N 290 977 475) 6. Screw M8 x 40 (P/N 290 840 681) 7. Screw M8 x 70 (P/N 290 841 201)

717 Engine NOTE: To facilitate ring or distance ring installation lubricate their inside diameters.

NOTE: To facilitate ring or distance ring installation lubricate their inside diameters.

All Engines

F01B09A

717 ENGINE 1. Puller (P/N 290 877 635) 2. Protective cap (P/N 420 876 557) 3. Distance ring, MAG side only (P/N 420 876 569) 4. Ring (both side) (P/N 420 977 490) 5. Side ring halves (P/N 420 276 025) 6. PTO side ring halves (P/N 420 977 475) 7. Screw M8 x 40 (P/N 420 840 681) 8. Screw M8 x 70 (P/N 420 841 201)

F01D1OA

1. Removing crankshaft bearing

04-06-5

Section 04 ENGINE Subsection 06 (BOTTOM END)

Or, use a bearing extractor such as Proto no. 4332 and a press to remove 2 bearings at a time (except on PTO side for the 787 engine).

F00D0IA

F01D1PA

1. Press bearings out 2. Bearing extractor

787 Engine

1. Puller 2. Protective cap

Secure puller in a vise and remove gear and bearing.

Crankshaft Gear The crankshaft gear no. 17 and bearing no. 2 can be removed in one step using the following puller.

F00D0JA

F04B03A

1. Puller (P/N 290 877 665)

Install the puller as per following illustration.

04-06-6

NOTE: If the inner PTO bearing needs to be replaced, remove the Woodruff key on the crankshaft.

Section 04 ENGINE Subsection 06 (BOTTOM END)

Counterbalance Shaft Bearings no. 13 can be removed by using the following tools: 1

Use a press to remove the gear no. 16 from the counterbalance shaft.

5 F00B0CA

1. 2. 3. 4. 5.

Puller (P/N 290 876 298) Protective cap (P/N 290 876 557) Ring (P/N 290 977 480) Ring halves (P/N 290 876 330) Screw M8 x 40 (P/N 290 840 681)

F00D0TA

CLEANING

F00D0KA

1. Tool installed

To remove gear no. 16, first trace an index mark on the gear and counterbalance shaft no. 14. NOTE: There is no Woodruff key to position the gear no. 16 on the counterbalance shaft. An index mark must be traced to ease assembly procedure.

All Engines Discard all oil seals, gaskets, O-rings and sealing rings. Clean water and oil passages and make sure they are not clogged. Clean all metal components in a solvent. Remove old Loctite from crankcase mating surfaces with Loctite Chisel (P/N 413 708 500).

CAUTION

Be careful not to spray cleaner on the painted surface of the engine. Never use a sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing.

INSPECTION Assembled Engine The following verifications can be performed with the crankshaft installed in the engine. Crankshaft Alignment at Center Main Journal Since it is an assembled crankshaft it can become misaligned or deflected. Crankshaft can be twisted on center main journal, changing timing of one cylinder in relation with the other. F00D0SA

1. Index mark 04-06-7

Section 04 ENGINE Subsection 06 (BOTTOM END)

– With the other hand, slowly rotate engine by PTO flywheel. 1

F01D1NA

1 2

1. Main journal alignment here

Counterweights can also be twisted on connecting rod journal on any or both cylinder(s). F01D1IA

1. Lay 1 hand over screwdrivers to feel movement 2. Screwdrivers in spark plug holes

F01D1NB

1. Connecting rod journal alignment here

Crankshaft Alignment at Center Main Journal NOTE: The following checks can be performed with engine in boat without overhauling engine. To quickly check, without accuracy, if crankshaft is twisted on center main journal, proceed as follows: – Remove PTO flywheel guard. – Remove spark plugs. – Insert a screwdriver in one spark plug hole. – Insert a longer screwdriver in the other hole. – Lay a forearm over both screwdriver handles to feel piston displacements.

04-06-8

As soon as one piston starts going up, the other must immediately go down. Any interval between strokes indicates a misaligned crankshaft. Or, to accurately check crankshaft alignment, proceed as follows: – Remove ignition housing cover. – Remove MAG flywheel nut and MAG rotor. Refer to MAGNETO SYSTEM 04-04 for procedures. – Install Bombardier degree wheel (P/N 295 000 007) on crankshaft end. Hand-tighten nut only. – Remove both spark plugs. – Install a TDC gauge (P/N 295 000 143) in spark plug hole on MAG side. – Bring MAG piston at Top Dead Center. – As a needle pointer, secure a wire with a cover screw and a washer. – Rotate degree wheel (NOT crankshaft) so that needle pointer reads 360°.

Section 04 ENGINE Subsection 06 (BOTTOM END)

Crankcase Inspect crankcase no. 7 plane surfaces for warpage. Small deformation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper.

Bearing 3 4

Inspect crankshaft bearings nos. 2 and 3. Check for corrosion, scoring, pitting, chipping or other evidence of wear. Make sure plastic cage is not melted. Rotate and make sure they turn smoothly.

Crankshaft

F01D4IA

TYPICAL 1. TDC gauge 2. Degree wheel 3. Hand tighten nut 4. Needle pointer

– Remove TDC gauge and install on PTO side. – Bring PTO piston at Top Dead Center. Interval between cylinders must be exactly 180°; therefore, needle pointer must indicate 180° on degree wheel (360° - 180° = 180°). Any other reading indicates a misaligned crankshaft. Crankshaft Alignment at Connecting Rod Journal Such misalignment may cause a crankshaft hard to be manually turned. Verification can be done by measuring deflection each end of crankshaft. If deflection is found greater than specified tolerance, this indicates worn bearing(s), bent and/or disaligned crankshaft. Proceed with the disassembly of the engine.

NOTE: If crankshaft no. 6 and/or components are found defective, they must be repaired by a specialized shop or replaced. The inspection of engine bottom end should include the following measurements: Connecting Rod Straightness Align a steel ruler on edge of small end connecting rod bore. Check if ruler is perfectly aligned with edge of big end. 1

F01D1QA

1. Ruler must be aligned with edge of connecting rod here 2. Align ruler here

Crankshaft Deflection NOTE: Crankshaft deflection cannot be correctly measured between centers of a lathe.

Disassembled Engine The following verifications can be performed with the engine component removed.

TOLERANCES MEASUREMENT

Connecting rod big end axial play

NEW PARTS (min.)

(max.)

WEAR LIMIT

0.39 mm (.015 in)

.74 mm (.029 in)

1.2 mm (.047 in)

04-06-9

Section 04 ENGINE Subsection 06 (BOTTOM END)

Crankshaft deflection is measured at each end with a dial indicator. First, check deflection with crankshaft in crankcase. If deflection exceeds the specified tolerance, it can be either ball bearings wear or bent/twisted crankshaft at connecting rod journal.

F01D1VA

1. Measuring PTO side deflection on V-shaped blocks

If the deflection exceeds the specified tolerance, crankshaft should be repaired or replaced. Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight.

F01D1SA

TOLERANCES

1. Measuring PTO side deflection in crankcase

MEASUREMENT

NEW PARTS (max.)

Crankshaft deflection center

N.A.

0.08 mm (.0031 in)

MAG side

N.A.

0.05 mm (.002 in)

PTO side

N.A.

0.03 mm (.001 in)

F01D1TA

1. Measuring MAG side deflection in crankcase

Remove crankshaft bearings and check deflection again on V-shaped blocks as illustrated.

1 2 F01D1WA

1. Measuring big end axial play 2. Feeler gauge

F01D1UA

1. Measuring MAG side deflection on V-shaped blocks 04-06-10

WEAR LIMIT

(min.)

Section 04 ENGINE Subsection 06 (BOTTOM END)

ASSEMBLY

Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following.

Bearing and Crankshaft Apply Anti-seize lubricant (P/N 293 800 023) on part of crankshaft where bearing fits. Prior to installation, place bearings nos. 2 and 3 into a container filled with oil, previously heated to 75Â°C (167Â°F). This will expand bearing and ease installation. Or, as an alternative method, apply heat with a propane torch. Lay bearing on a steel plate, then heat plate from back side of plate, not directly on the bearing. Install bearing carefully on crankshaft. To properly position the outer PTO bearing on 717 engine or the outer MAG side bearing on the 787 engine, a distance gauge must be temporarily installed against the inner bearing. Slide the outer bearing until stopped by the distance gauge, then remove it. ENGINE

DISTANCE GAUGE

717

P/N 529 034 800 (PTO)

787

P/N 529 034 900 (MAG)

F01D1YA

TYPICAL 1. Distance gauge 2. PTO side outer bearing

Distance Ring When installing the distance ring no. 7, make sure to position it with its chamfer toward the counterweight of the crankshaft.

787 Engine

Crankshaft Gear Position the long flange of the gear no. 17 toward the counterweight of the crankshaft. Also, make sure to align the gear keyway with the Woodruff key on the crankshaft.

F01B0HA

1. Distance gauge

F00D0LA

1. Woodruff key on the crankshaft

04-06-11

Section 04 ENGINE Subsection 06 (BOTTOM END)

2 F00D0MA

F00D0OA

1. Keyway 2. Long flange toward the crankshaft counterweight

1. Drive pin

Counterbalance Shaft and Gear

Seal At seal nos. 1 and 4 assembly, apply a light coat of Molykote 111 (P/N 413 707 000) on seal lips. Position PTO seal no. 1 against the retaining shim; the gap between the seal and bearing will ensure proper lubrication of the bearing.

Press gear no. 16 onto counterbalance shaft no. 14 taking care to align both marks previously traced.

CAUTION

Counterbalance shaft must be properly assembled, otherwise engine will vibrate and premature wear will occur. Proceed as follows to check if the gear no. 16 is properly positioned on the counterbalance shaft: â&#x20AC;&#x201C; Temporarily install the counterbalance shaft in the crankcase. â&#x20AC;&#x201C; Rotate the counterbalance shaft to align the notch of the gear with the crankcase.

F00D0NA

1. Seal against the retaining shim

All Engines

Drive Pin Make sure drive pins no. 5 of bearings nos. 2 and 3 are properly installed in crankcase recesses at assembly.

F00D0UA

1. Gear notch aligned with the crankcase

04-06-12

Section 04 ENGINE Subsection 06 (BOTTOM END)

– The notch of the couterweight on the opposite end of the counterbalance shaft must also be aligned with the cranckcase. 1

F00D0PA

1. Marks must be aligned F00D0VA

1. Counterweight notch aligned with the crankcase

If notches are not aligned with the crankcase, remove the gear and repeat the procedure until the notches are properly aligned.

Bearing and Counterbalance Shaft Prior to installation, place bearings no. 13 into a container filled with oil, previously heated to 75°C (167°F). This will expand bearings and ease their installation.

Crankshaft and Counterbalance Shaft Install crankshaft no. 6 first in crankcase. After crankshaft installation, install counterbalance shaft no. 14. Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears.

CAUTION

Marks on the crankshaft and counterbalance shaft must be aligned, otherwise engine will vibrate and premature wear will occur.

Turn by hand the crankshaft and counterbalance shaft. Make sure they do not interfere with the crankcase.

Crankcase Crankcase halves are factory matched and therefore, are not interchangeable or available as single halves. Prior to joining crankcase halves, apply a light coat of Loctite 518 (P/N 293 800 038) on mating surfaces. Do not apply in excess as it will spread out inside crankcase. NOTE: On aluminum material it is recommended to use Loctite Primer N (P/N 293 800 041) to reduce curing time and increase gap filling capability. Refer to manufacturer’s instructions.

CAUTION

Rotary valve shaft must be installed in crankcase before closing halves. Before joining crankcase halves, make sure that crankshaft gear is well-engaged with rotary valve shaft gear. Position crankcase halves together and handtighten bolts.

04-06-13

Section 04 ENGINE Subsection 06 (BOTTOM END)

Fitting

All Engines If inlet and outlet oil fittings of rotary valve shaft have been removed from crankcase, reinstall them with their ends pointing toward ignition housing. Apply Loctite 518 (P/N 293 800 038) on threads of fittings.

787 Engine F01D20A

5 13

6 14

Bearing Cover Install the bearing cover no. 15 with its hollow side toward the bearing.

Torque both M10 crankcase screws to 40 N•m (30 lbf•ft).

1 F01D20B

1. Torque to 40 N•m (30 lbf•ft)

Crankcase Screw F00D0QA

1. Hollow side facing bearing

717 Engines

Screw Apply Loctite 518 (P/N 293 800 038) on screw threads and Molykote 111 (P/N 413 707 000) below head screws.

Apply Loctite 518 (P/N 293 800 038) on screw threads and Molykote 111 (P/N 413 707 000) below head screws. Torque crankcase screws nos. 8 and 9 to 12 N•m (9 lbf•ft) as per following sequence. Repeat procedure, retightening all screws to 24 N•m (17 lbf•ft). 11

Crankcase Screw Torque crankcase screws nos. 8, 9 and 10 to 24 N•m (17 lbf•ft) as per following illustrated sequence.

F01D81A

04-06-14

Section 04 ENGINE Subsection 06 (BOTTOM END)

As a final step, torque only M10 screws no. 9 of crankcase to 40 N•m (30 lbf•ft) as per following sequence. 11

Apply Loctite anti-seize lubricant (P/N 293 800 023) to crankshaft threads. Using the same tools as for disassembly procedure, torque PTO flywheel to 110 N•m (81 lbf•ft).

Final Assembly 12

717 Engine If engine support is installed on crankcase before ignition housing, electric starter must be installed before engine support. 1

F01D81B

Crankcase Stud At assembly in crankcase, apply Loctite 271 (P/N 293 800 005) on stud no. 11 threads. Torque to 12 N•m (9 lbf•ft).

PTO Flywheel 787 Engine Install O-ring onto crankshaft.

F01D4KB

1. End towards ignition housing 2. Install starter before engine support

F01D84A

1. O-ring

04-06-15

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

ROTARY VALVE

10 14 8

3 13 1

Molykote 111

1 12 2 20 N m (15 lbf ft)

787 engine

717 engine

2 20 N m (15 lbf ft) F01D7ST

PARTS

04-07-1

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

GENERAL The following verification procedures such as clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without removing engine from boat. Refer to INSPECTION further in this section. However, engine must be removed from boat to work on rotary valve shaft/components. Refer to REMOVAL AND INSTALLATION 04-03 for procedures. Bottom end must be opened to remove rotary valve shaft. Refer to ROTARY VALVE 04-07.

Feeler gauge blade from 0.25 mm (.010 in) to 0.35 mm (.014 in) thickness should fit between rotary valve and cover. Insert feeler gauge blade through cover inlet ports to verify clearance. At least verify clearance at two different places in each port. 1

INSPECTION ON BOAT Remove carburetors. Refer to CARBURETORS 06-04.

Rotary Valve Cover and Screw Unscrew 4 screws no. 2 and withdraw rotary valve cover no. 1 and valve no. 13.

Rotary Valve/Cover Clearance The clearance between the rotary valve and the cover must be 0.30 ± 0.05 mm (.012 ± .002 in). NOTE: If the clearance is below 0.25 mm (.010 in) this could create an overheating situation and if the clearance is over 0.35 mm (.014 in) this could create a hard starting situation. There is two methods to verify rotary valve/cover clearance. One with a 45° feeler gauge, the other one with a solder. 45° FEELER GAUGE METHOD Remove O-ring no. 12 from rotary valve cover. Remove intake manifold from rotary valve cover (except 787 engine). Reinstall cover in place WITHOUT its O-ring and torque screws to 20 N•m (15 lbf•ft).

04-07-2

F01D53A

1. 45 ° feeler gauge

If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface or replace the cover. SOLDER METHOD Remove O-ring no. 12 from rotary valve cover. Use the following type of solder: – rosin core – diameter: 0.8 mm (.032 in) – electronic application (available at electronic stores) Install two solder pieces of 13 mm (1/2 in) long directly on rotary valve, one above and one below rotary valve gear. Apply grease to hold solder in position. Reinstall cover in place WITHOUT its O-ring and torque screws to 20 N•m (15 lbf•ft). Remove cover then clean and measure compressed solder thickness, it must be within the specified tolerance 0.30 ± 0.05 mm (.012 ± .002 in).

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

Reverify the clearance. At assembly the rotary valve timing must remain as per original setting. NOTE: If rotary valve crankcase surface is worn, it is possible to have it reworked at the factory. Contact your dealer or distributor.

Rotary Valve Shaft Gear Backlash 1 F01D3PA

TYPICAL 1. Solder

If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface or replace the cover. MACHINING INFORMATION The amount of material over tolerance must be removed from the rotary valve cover seating surface. Also cut the O-ring groove the same amount to keep the 1.0 ± 0.03 mm (.039 ± .001 in) depth between the bottom of the groove and the seating surface. Remove burrs on the edges of the seating surface and O-ring groove. 1

Remove PTO flywheel guard. Remove spark plugs, rotary valve cover and valve. Manually feel backlash at one position, then turn crankshaft about 1/8 turn and recheck. Continue this way to complete one revolution. Backlash must be even at all positions. Otherwise overhaul engine to find which part is faulty (gear, rotary valve shaft or crankshaft with excessive deflection).

DISASSEMBLY Rotary Valve Cover and Screw Unscrew 4 retaining screws no. 2 and withdraw rotary valve cover no. 1 and valve no. 13. NOTE: It is necessary to withdraw carburetors prior to removing rotary valve cover. Refer to CARBURETORS 06-04 then refer to Carburetor Removal.

Rotary Valve Shaft and Snap Ring To remove rotary valve shaft assembly no. 3 from crankcase, first remove snap ring no. 4 from crankcase. 1

F01D3OA

SAME AMOUNT REMOVED FROM COVER SEATING SURFACE AND O-RING GROOVE BASE 1. Cover seating surface 2. O-ring groove depth must be 1.0 ± 0.03 mm (.039 ± .001 in)

F01D22A

TYPICAL 1. Removing snap ring

04-07-3

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

CAUTION

Bottom end must be opened to remove rotary valve shaft. To remove rotary valve shaft, use puller (P/N 290 876 488). 1

F01D27A

TYPICAL

Circlip and Spring Seat

F01D23C

1. Rotary valve shaft remover

Place puller over rotary valve shaft end and screw on puller bolt into shaft. While retaining bolt with a wrench, turn puller nut CLOCKWISE until shaft comes out.

If it is necessary to disassemble components of rotary valve shaft assembly, use seat no. 6 to compress spring and remove circlips no. 5. 1

F01D25A

1. Compress seat 2. Remove circlips

Snap Ring and Bearing F01D61A

TYPICAL 1. Hold bolt

04-07-4

To remove bearing no. 8 use a bearing extractor such as Snap-on no. CJ-950 as illustrated. Slide off distance sleeve, remove snap ring no. 7 and press shaft out.

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

F01J0ZA

Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing. Slide puller sleeve outwards and tap puller end. Retighten claws as necessary to always maintain them tight against bearing. Continue this way until bearing completely comes out.

F01D4NA

1. Bearing 2. Bearing extractor Snap-on CJ-950

CAUTION

Ensure that rotary valve shaft is perfectly perpendicular with press tip or damage will occur.

Bearing

CAUTION

Do not remove plug against bearing in upper crankcase half.

F01D28A

1. End bearing

CLEANING

1 F01D4OA

Discard all seals and O-rings. Clean all metal components in a solvent. Clean oil passages and make sure they are not clogged. Clean rotary valve shaft and inside of distance sleeve no. 14.

1. Do not remove this plug

End bearing no. 9 can be easily removed using the following suggested tool. Snap-on hammer puller including: Handle CJ93-1, hammer CJ125-6 or claws CJ93-4.

INSPECTION Rotary Valve Cover Inspect rotary valve cover no. 1 for warpage. Small deformation can be corrected by surfacing with fine sand paper on a surface plate. Surface part against oiled sand paper. 04-07-5

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

Bearing

Inspect bearings nos. 8 and 9. Check for scoring, pitting, chipping or other evidence of wear. Make sure plastic cage (on bigger bearing) is not melted. Rotate them and make sure they turn smoothly.

To install end bearings nos. 8 and 9 in crankcase, use the appropriate pusher according to the table.

Gear

ENGINE

PUSHER

717/787

P/N 420 876 501

Visually check gear wear pattern. It should be even on tooth length all around. Otherwise it could indicate a bent shaft, check deflection. Replace gear if damaged. Check for presence of brass filings in gear housing.

Rotary Valve Shaft Deflection

1 F00B07A

Deflection is measured with a dial gauge. Install rotary valve shaft in crankcase half, without its gear. NOTE: End bearing must be in crankcase half. Measure shaft deflection next to gear splines.

1. Pusher (P/N 420 876 501)

Position ball bearing shielded side towards rotary valve.

F01D2DA

TYPICAL 1. Shielded side here (towards gear)

Push bearing until it stops on its seat. 1

F01D2CA

1. Rotary valve shaft 2. End bearing in place

Deflection must not exceed 0.08 mm (.003 in). Replace shaft as necessary.

ASSEMBLY Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following. F01D33A

TYPICAL 1. Bearing 2. Pusher 04-07-6

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

Rotary Valve Shaft and Seal

Rotary Valve Shaft Ass’y and Snap Ring

Apply Molykote 111 (P/N 413 707 000) on seal no. 11 lips. Position seal with shielded portion against shaft splines.

Rotary Valve Shaft, Snap Ring and Bearing Install ball bearing no. 8 as illustrated.

CAUTION

Crankcase halves must be separated and crankshaft must not be present to install rotary valve shaft ass’y in crankcase.

717 Engine To install rotary valve shaft no. 3 in crankcase, use a pusher (P/N 420 876 605). 1

1 2

3 A00C0YA

1. Pusher

Push shaft until its stops on bearing seat. 1

A13C0FB

1. Seal 2. Ball bearing 3. Bearing extractor Snap-on CJ-950

Install shim no. 15, snap ring no. 7, and slide distance sleeve no. 14 on shaft. 1

F01D34A

1. Rotary valve shaft ass’y 2. Push shaft until it stops

F01D2FA

1. 2. 3. 4. 5. 6.

Seal Ball bearing Snap ring Distance sleeve Shim 0.5 mm (.020 in) Rotary valve shaft

04-07-7

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

787 Engine To install rotary valve shaft in crankcase, use a pusher (P/N 290 876 609) and handle (P/N 290 877 650).

All Engines

Snap Ring Position snap ring no. 4 so that its sharp edge faces outwards.

Rotary Valve 2 1

The rotary valve no. 13 controls the opening and closing of the inlet ports. Therefore its efficiency will depend on the precision of its installation. IDENTIFICATION OF THE ROTARY VALVE

F01B2FA

1. Pusher 2. Handle

Push shaft until it stops on bearing seat.

F01D8OA

04-07-8

ENGINE

ROTARY VALVE P/N

VALVE DURATION

717/787

290 924 502

159Â°

There is no identification code on the valves. To find out the duration, place an angle finder on the valve and measure the valve cut-out angle or use the following template.

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

F01D73T

TEMPLATE 1. Actual size of valve (P/N 290 924 502) A. 159Â° (cut-out angle)

Rotary Valve Timing 30 33

40 32

350 360 10 20 340 10 360 350 3 20 40

80 190 2 170 1 00 21 160 0 200 190 180 17 22 0 210 16 0 0 15 0

270

22 0

280

290

250

0 14

260

110 100 90

120

250

130

120

90 100 11 0 280 270 26 0

A00B44A

290

The following tools are required to measure rotary valve opening and closing angles in relation with MAG side piston.

300

295 000 007

Never use the ridge molded in crankcase as a timing mark.

CAUTION

295 000 143

04-07-9

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

Rotary valve must be set so that timing occurs as follows:

TIMING ENGINE TYPE

OPENING BTDC

CLOSING ATDC

717

147 ± 5°

65 ± 5°

787

147 ± 5°

63.5 ± 5°

For the following instructions, use these specifications as example: OPENING: 147° BTDC CLOSING: 65° ATDC Proceed as follows: – Turning crankshaft, bring MAG side piston to Top Dead Center using a TDC gauge.

147°

F01D3DC

OPENING MARK Step 1 : Bottom of MAG inlet port. Align 360 ° line of degree wheel Step 2 : Find 147 ° on degree wheel and mark here

NOTE: Do not rotate the crankshaft. – For closing mark, first align 360° line of degree wheel with TOP of MAG side inlet port. Then, find 65° line on degree wheel and mark crankcase at this point. 1

65° F01D2IA

1. TDC gauge on MAG side. Bring piston to TDC

– For opening mark, first align 360° line of degree wheel with BOTTOM of MAG side inlet port. Then, find 147° line on degree wheel and mark crankcase at this point.

F01D3EB

CLOSING MARK Step 1 : Top of MAG inlet port Align 360 ° line of degree wheel Step 2 : Find 65 ° on degree wheel and mark here

04-07-10

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

– Remove degree wheel. – Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC. NOTE: Rotary valve is asymmetrical. Therefore, try flipping it over, then reinstall on splines to obtain best installation position. Apply BOMBARDIER-ROTAX injection oil (P/N 413 802 900) on rotary valve before reassembling rotary valve cover. – Remove TDC gauge.

Rotary Valve Cover and Screw Install O-ring no. 12 and cover no. 1 then torque screws to 20 N•m (15 lbf•ft) in a criss-cross sequence.

04-07-11

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

EXHAUST SYSTEM

Speedster Model Loctite 242

40 N m (30 lbf ft)

7 9

8 24

Loctite 271

25 N m (18 lbf ft) Loctite 22 242

21 Ultra Copper 4 10 N m (89 lbf in)

25 N m (18 lbf ft)

25 6

Loctite 242

Loctite 242 22

Loctite 242

4 N m 1 (35 lbf in) 2

1 17

17 4 N m (35 lbf in) 15

4 N m (35 lbf in)

F09D0AS

13 3

4 N m (35 lbf in) 5

Adseal 4511 16

Body 18 4 N m (35 lbf in)

Adseal 4511

PARTS

04-08-1

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Speedster SK Model

25 N m (18 lbf ft) 8

Loctite 242 7

22 25

22 25 N m 6 (18 lbf ft)

Loctite 242

4 N m 4 (35 lbf in)

Loctite 242

25 N m (18 lbf ft)

STARBORD

21 3

4 N m 1 (35 lbf in)

40 N m (30 lbf ft) 2

4 N m (35 lbf in)

PORT STARBORD 17

14 Adseal 4511 4 N m (35 lbf in) 13

4 N m (35 lbf in)

F09D0MS

04-08-2

PARTS

Loctite 242

PORT

28 N m (21 lbf ft)

Loctite 242

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

TUNED PIPE

NOTE: Slightly lift tuned pipe to release nut as necessary. Take care not to drop nut and flat washer. Withdraw tuned pipe no. 10 in a forward and rotating movement.

Removal Turn OFF main battery cut-off switch.

Speedster SK Model Disconnect water inlet hose and water injection hose. Disconnect tuned pipe bleed hose. 1

Speedster Model Disconnect water supply hose and water injection hose at tuned pipe head.

F01D3YA

TYPICAL 1. Water supply hose 2. Water injection hose F01D8NA

TYPICAL 1. Bleed hose removed 2. Injection hose removed 3. Inlet hose removed

Cut tie rap retaining together engine and tuned pipe bleed hoses (if applicable). Loosen exhaust hose collar no. 1 at tuned pipe outlet. Disconnect strap no. 17 retaining muffler no. 13. Remove exhaust hose no. 3 from tuned pipe by pulling muffler. Remove clamp no. 4 from tuned pipe. Remove tuned pipe cone no. 12. Remove tuned pipe retaining screw no. 6 from exhaust manifold side. Remove screws no. 7, nut no. 8 and flat washers no. 9 from tuned pipe flange.

Loosen exhaust hose collar no. 1 at tuned pipe cone outlet. Remove clamp no. 4 securing tuned pipe cone to tuned pipe head. Remove screws no. 7 and nut no. 8 with flat washers no. 9 at tuned pipe head flange.

F01D7IA

TYPICAL

04-08-3

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Remove retaining screw no. 23 of tuned pipe head.

Remove tuned pipe cone no. 12 from engine compartment.

Repair All Models This procedure is given to repair tuned pipe cracks using T.I.G. welding process.

F01D76A

TYPICAL 1. Screw

Remove tuned pipe head no. 10. Remove both screws no. 6 retaining tuned pipe cone to engine.

Procedure – Sand the cracked area to obtain bare metal. – Perform a 1.50 mm (1/16 in) depth chamfer over crack. – Use pure argon gas with 5.55 mm (3/32 in) tungsten electrode (puretung “green”, zirtung “brown”) and AC current. – Use a 5.55 mm (3/32 in) aluminum welding rod (no. 4043), to fill crack. – Sand welding slightly to remove material surplus. Test – Use compressed air at 124 kPa (18 PSI) to pressurize tuned pipe. NOTE: Prior to verifying leaks, plug all holes and pressurize tuned pipe while immerging it in water.

CAUTION

Always ensure water passages are not blocked partially or completely while welding tuned pipe.

Installation F01D7KA

TYPICAL

Installation is essentially the reverse of removal procedures. However, pay particular attention to the following.

All Models Ensure rubber bushings no. 22 and sleeve no. 25 are not damaged and are properly installed into tuned pipe support.

CAUTION

Damage to bushings and/or sleeve will eventually cause stress to tuned pipe and may cause cracking. F01D7LA

TYPICAL

04-08-4

Make sure that gasket no. 24 is properly located on exhaust manifold prior to finalizing pipe installation.

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Apply Loctite 242 (P/N 293 800 015) on nut no. 8 and screws nos. 6 and 7. Hand tighten all fasteners before torquing any of them. For torquing specifications, see the main illustrations at the beginning of this subsection.

Speedster Model Make sure to install the sealing ring no. 21 on tuned pipe cone no. 12 if it was removed.

Speedster SK Model Install tuned pipe cone no. 12 with collar no. 21 and clamp no. 4. Position clamp no. 4 as illustrated. Do not tighten clamp yet.

F01D69A

TYPICAL 1. Sealing ring

Apply a thin layer of Ultra Copper (P/N 413 710 300) all around sealing ring.

EXHAUST MANIFOLD F01D41A

Removal

1. Clamp 2. Exhaust collar

With hose removed, align cone outlet with muffler inlet. NOTE: Due to exhaust cone angle, it may have to be rotated to obtain alignment. Push cone no. 12 until it touches tuned pipe, then tighten exhaust clamp no. 4 and torque to 4 Nâ&#x20AC;˘m (35 lbfâ&#x20AC;˘in).

CAUTION

There must be no gap between tuned pipe cone and tuned pipe head.

All Models Turn OFF main battery cut-off switch. Remove air intake silencer and carburetors. Refer to section FUEL SYSTEM 06 for proper procedure. Remove eight screws and washers then withdraw exhaust manifold no. 11.

Installation Installation is essentially the reverse of removal procedures. However, pay particular attention to the following. Make sure gasket(s) no. 24 are properly positioned prior to finalizing manifold installation.

NOTE: Exhaust clamp nuts should be tightened alternately to ensure no leakage and to obtain specified torque.

04-08-5

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Speedster SK Model Apply synthetic grease on (P/N 293 550 010) threads of manifold/engine screws. Install and torque screws to 24 N•m (17 lbf•ft) as per following illustrated sequence.

Torque exhaust manifold screws to 24 N•m (17 lbf•ft) as per following illustrated sequence. Repeat the procedure, retightening screws to 40 N•m (30 lbf•ft).

4 7

7 6

5 8

F01D82A

MUFFLER F01D59A

Removal Speedster Model Apply Loctite 518 (P/N 293 800 038) on two manifold/ engine screws. On the other screws, apply synthetic grease on threads. Install screws. Refer to the following illustration for proper position of screws on the exhaust manifold. 1

F01D82B

1. Screws with Loctite 518 2. Screws with synthetic grease

04-08-6

All Models Loosen muffler hose collar(s) no. 1. Disconnect hose(s) from muffler no. 13. Detach retaining strap no. 17 (717 engine) or no. 2 (787 engine) from muffler. 1

F09D0CA

TYPICAL — SPEEDSTER SK SHOWN 1. Disconnect this hose

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Installation

Reverse removal procedure.

EXPANSION CHAMBER Removal Speedster Model NOTE: Expansion chambers no. 15 can be removed without removing muffler. Turn OFF main battery cut-off switch.

F09D0DA

TYPICAL â&#x20AC;&#x201D; SPEEDSTER SK SHOWN 1. Disconnect this hose 2. Detach this strap

Speedster Model Disconnect both hoses from water flow regulator valve. See next photo.

Starboard Side Remove battery to allow removal of expansion chambers. Refer to STARTING SYSTEM 08-08 for proper procedure. Unplug connector at top of electrical box then put box away from expansion chamber. Disconnect red cables from main battery cut-off switch.

CAUTION

Main battery cut-off switch does not need to be removed. Disconnect and connect cables from inside deck. Disconnect both hoses from expansion chamber, as shown in the next photo. 2

F09D01A

STARBOARD SIDE SHOWN 1. Loosen muffler hose collar 2. Disconnect hose from mufler 3. Detach retaining strap 4. Disconnect both hoses

Pull muffler out of bilge.

F09D02A

1. Expansion chamber 2. Disconnect both hoses

04-08-7

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Loosen hose clamps no. 3 then remove hose no. 5 linking expansion chamber no. 14 to resonator no. 16. 2

Removal Speedster SK Model Starboard Side Cut Locking tie. Detach both straps no. 2. Remove both gear clamps. See next photo. 2

F09D03A

1. Loosen hose clamps 2. Expansion chamber 3. Resonnator

Detach both expansion chamber straps no. 17. Withdraw expansion chambers, as shown in the next photo.

F09D0EA

1. Cut this locking tie 2. Remove these straps 3. Remove these gear clamps

Detach top hose from expansion chamber no. 15, as shown in the next photo. 1

F09D04A

MECHANIC REMOVING BOTTOM EXPANSION CHAMBER

Port Side Follow the same procedure as for starboard side, except battery and main battery cut-off switch cables.

04-08-8

F09D0FA

1. Expansion chamber 2. Top hose

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Detach expansion chamber from bottom hose then pull chamber out of bilge, as shown in the next photo. 1

F09D06A

PORT SIDE POSITIONING

When attaching expansion chambers with straps, ensure they are properly positioned, as shown in the next photos. F09G0GA

PULL OUT EXPANSION CHAMBER 1. Bottom hose

Port Side Follow same procedure as for starboard side.

Inspection All Models Inspect expansion chambers for cracks or damage. If so, replace with new ones.

Installation Installation is essentially the reverse of removal procedures. However, pay particular attention to the following.

F09D09A

STRAPS AND EXPANSION CHAMBERS POSITIONING

Speedster Model Make sure that expansion chambers are properly positioned depending on side. Refer to the following photos.

F09D05A

STARBOARD SIDE POSITIONING 04-08-9

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Speedster SK Model Ensure that gear clamps and straps are properly secured. Reinstall locking tie. See following photo. 2

F04D1EA

F09D0EA

1. Locking tie 2. Straps 3. Gear clamps

TYPICAL â&#x20AC;&#x201D; INSIDE VIEW TO SHOW POSITION OF WRENCH INSERTED FROM THE OUTSIDE 1. Closed wrench holding nut

EXHAUST OUTLET Removal Speedster Model If nobody can help to hold nuts no. 18 from inside of bilge, proceed as follows. Insert a closed wrench from the outside opening of exhaust outlet to the inside of bilge. Position wrench over a nut. While holding wrench, use a ratchet and socket from the outside. Loosen nut. F04D1FA

TYPICAL 1. Hold wrench 2. Loosen nut with a ratchet and a socket

Repeat for each nut being careful not to drop nut inside bilge.

04-08-10

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Speedster SK Model Using exhaust outlet tool (P/N 295 000 132) or pliers as shown in the next photo, loosen exhaust outlet nut no. 14 from outside hull. 1

Installation Speedster Model Apply Adseal 4511 (P/N 293 800 033) sealant all around gasket between hull and gasket lip, as shown in the next photo.

F09L1QA

1. Apply sealant between hull and gasket lip F09D0HA

1. Loosen exhaust nut

Remove gasket no. 5. From inside bilge, loosen gear clamp then detach hose from exhaust outlet no. 16.

Speedster SK Model Install gasket no. 5 on exhaust outlet no. 16. Align nut notch with gasket recess, as shown in the next photo.

F09D0JA

NUT NOTCH ALIGNED WITH GASKET RECESS F09D0IA

1. Hose 2. Gear clamp

Pull out exhaust outlet.

04-08-11

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Apply Adseal 4511 (P/N 293 800 033) all around pipe, as shown in the next photo.

Secure exhaust outlet with plastic nut. Torque nut as specified in exploded view. Finalize installation with Adseal 4511 (P/N 293 800 033) all around nut end, as shown in the next photo.

F09D0KA F09D0LA

APPLY ADSEAL 4511 TYPICAL â&#x20AC;&#x201D; APPLY SEALANT ALL AROUND

From inside bilge, insert exhaust outlet in hull hole.

CAUTION

Ensure that exhaust outlet notches are properly aligned with hole recesses, as shown in the following photo. 1

F09L31A

1. Hole recesses

04-08-12

Section 05 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

COMPONENTS ...................................................................................................................... GENERAL ...........................................................................................................................

05-02-1 05-02-3

CIRCUIT.................................................................................................................................. GENERAL ........................................................................................................................... COOLING SYSTEM ARRANGEMENT ..............................................................................

05-03-1 05-03-1 05-03-2

05-01-1

Section 05 COOLING SYSTEM Subsection 02 (COMPONENTS)

COMPONENTS

Speedster SK Model

Pipe sealant

F09E07S

PARTS

05-02-1

Section 05 COOLING SYSTEM Subsection 02 (COMPONENTS)

Speedster Model Pipe sealant

Hull

1 2

Pipe sealant

Outlet

Pipe sealant 3

Inlet

4 7 8 0.11 N m (1 lbf in)

6 0.6 N m (5 lbf in) 5 N m (44 lbf in)

F09E05T

05-02-2

PARTS

Pipe sealant

Section 05 COOLING SYSTEM Subsection 02 (COMPONENTS)

GENERAL

CAUTION

All hoses and fittings of the cooling system have calibrated inside diameters to ensure proper cooling of the engine. Always replace using appropriate Bombardier part number. 1

Clamp To remove non-reusable Oetiker clamps (where applicable) of cooling system hoses, use screwdriver. 1 2

F01B2KA

1. Cutting clamp 2. Securing clamp

Flushing Connector The flushing connector no. 2 is used to flush cooling system. Refer to FLUSHING AND LUBRICATION 02-02.

Elbow Fitting

F09E11A

1. Lift clamp tab

NOTE: If clamp cannot be removed using screwdriver, cut clamp. To cut or secure non-reusable Oetiker clamps, use pliers (P/N 295 000 070).

Water injection used on exhaust system cools the exhaust gases to obtain maximum performance from the tuned pipe. The elbow fitting no. 1 has a calibrated inside diameter to optimize water flow. The water injection also helps in reducing noise level and cools components of the exhaust system.

CAUTION

The elbow fittings are calibrated for each engine model and cannot be interchanged with one of a different size as severe engine damage could result.

05-02-3

Section 05 COOLING SYSTEM Subsection 02 (COMPONENTS)

The elbow fitting can be identified by using the 2 digits number stamped onto the fitting or by measuring its inside diameter. Refer to the following illustration and chart.

The water flow regulator valve is mounted directly onto the muffler. 2

16 1

3 F00E04A

TYPICAL 1. Outlet diameter 2. Stamped number 3. Inlet diameter

1. Water supply hose of regulator valve 2. Regulated water to injection fitting at tuned pipe head 3. Water injected into the muffler

STAMPED NUMBER ON FITTING

FITTING P/N

293 700 016

5.5 mm (.219 in)

4.6 mm (.181 in)

293 710 048

4.0 mm (.157 in)

3.5 mm (.139 in)

INLET OULET DIAMETER DIAMETER

Water Flow Regulator Valve 787 Engine GENERAL A water flow regulator valve is mounted on muffler so that the engine can produce the maximum horsepower output and yet maintain the necessary diameter of the injection fitting at the tuned pipe head for unobstructed water flow.

05-02-4

F09E02A

NOTE: The water injected into the muffler is not regulated by the valve. A calibrated water injection fitting of 3.5 mm (.138 in) inside diameter limits water flow into the muffler. The water flow regulator valve has a calibrated spring and a tapered needle which regulate the injected water in the tuned pipe.

CAUTION

Do not change the calibration of the spring, otherwise serious engine damage can occur. At low speed, water pressure in the supply hose of the regulator valve is not sufficient to overcome the spring of the regulator valve; more water is being delivered to the injection fitting at the tuned pipe.

Section 05 COOLING SYSTEM Subsection 02 (COMPONENTS)

F01E2BA

F01E2CA

LOW SPEED OPERATION 1. Water entering regulator valve 2. Water exiting regulator valve 3. Water injected in the muffler

HIGH SPEED OPERATION 1. Water entering regulator valve 2. Water exiting regulator valve 3. Water injected in the muffler

F01E1HA

F01E1IA

1. Needle position at low speed

1. Needle position at high speed

At higher speed, water pressure increases in the supply hose of the regulator valve and gradually overcomes the return spring of the regulator valve. Less water is being delivered to the injection fitting at the tuned pipe.

ADJUSTMENT The water flow regulator valve has been calibrated at the factory and should not be modified. NOTE: Water flow regulator valves ordered from the parts channel are also calibrated. If the maximum engine speed cannot be attained or if the engine has poor performance, the water flow regulator valve should be considered in the troubleshooting of the problem.

05-02-5

Section 05 COOLING SYSTEM Subsection 02 (COMPONENTS)

DISASSEMBLY Remove the cover no. 4 of the valve by releasing the spring no. 3.

;

WARNING

Firmly hold cover to valve base. The spring inside the valve is applying a pressure against the cover.

F01E1TA

1. Tapered needle

Remove the tapered needle from valve housing. 1 2

F01E1RA

1. Spring 2. Cover

Remove fitting no. 5 from valve housing. 1 F01E20A

1. Remove tapered needle

Pull the valve no. 7 slightly. Using pliers, release the clamp which retains the bellows no. 8. Remove valve and bellows.

F01E1SA

1. Fitting

Unscrew the tapered needle no. 6. NOTE: Hold the valve to prevent it from turning.

F01E21A

05-02-6

Section 05 COOLING SYSTEM Subsection 02 (COMPONENTS)

Loosen clamp to separate valve from bellows.

F01E24A

1. Clamp

INSPECTION Inspect parts for damage. Verify especially bellows for cracks. ASSEMBLY Assembly is essentially the reverse of disassembly procedures.

05-02-7

Section 05 COOLING SYSTEM Subsection 03 (CIRCUIT)

CIRCUIT GENERAL TECHNICAL DATA

0 When towing your boat, pinch the water supply hose from the impeller housing to the engine with the hose pincher large (P/N 529 032 500) shown in the following illustration.

TYPE: TLCS (Total Loss Cooling System). COOLANT FLOW: Pressure build-up at impeller housing (no water pump). TEMPERATURE CONTROL: Calibrated outlet fittings (no thermostat). SYSTEM BLEEDING: Self-bleed type (hose at uppermost point of circuit and at tuned pipe). SYSTEM DRAINING: Self-drain type (hose at lowest point of circuit). SYSTEM FLUSHING: Flushing connector on jet pump support and in engine compartment area. MONITORING BEEPER: Turns on at 96-99°C (205-210°F).

The cooling system is equipped with flushing connectors for flushing purposes. For flushing operation, a garden hose is to be connected to flush the whole system by backwash. For flushing procedure, refer to FLUSHING AND LUBRICATION 02-03. For winterization of cooling system, refer to STORAGE 02-05.

Towing a Boat in Water Special precautions should be taken when towing a Sea-Doo Jet Boat behind another craft in water. Maximum recommended towing speed is 24 km/h (15 MPH).

F01B23A

NOTE: If for some reason, you operate boat over 24 km/h (15 MPH) with only one engine running, the non-running engine should have its water supply hose plugged. This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system. Without the engine running there isn’t any exhaust pressure to carry the water out the exhaust outlet.

CAUTION

Failure to do this may result in damage to the engine. If you must tow a stranded boat and do not have a hose pincher be sure to stay well below the maximum towing speed of 24 km/h (15 MPH).

05-03-1

Section 05 COOLING SYSTEM Subsection 03 (CIRCUIT)

Snugly install the hose pincher on the hose as shown in the following photo.

F01E1LA

1. Cylinder head cover 2. Fresh water from jet pump 3. Water exiting head assembly to tuned pipe, exhaust manifold and cylinders 4. Water from cylinder water jackets exiting engine

F09E03A

TYPICAL â&#x20AC;&#x201D; STARBOARD SIDE SHOWN 1. Install hose pincher on this hose

CAUTION

When finished towing the boat you must remove the hose pincher before operating it. Failure to do so will result in damage to the engine.

The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation. Water is pre-heated by the exhaust system before entering the cylinder cooling jackets. Water enters cylinder cooling jacket through passages located below exhaust ports from tuned pipe.

COOLING SYSTEM ARRANGEMENT The water supply is taken from a pressurized area in the jet pump between the impeller and venturi. Water enters the cylinder head assembly, cooling the combustion chamber to prevent detonations. Then, water exits cylinder head toward tuned pipe. F01D7HB

1. Water passages

05-03-2

Section 05 COOLING SYSTEM Subsection 03 (CIRCUIT)

No water enters crankcase. When engine is running, water must flow from bleed outlet indicating that water circulates.

CAUTION

When investigating for no water flow in the cooling system, check all elbows and straight fittings as well as all hoses for blockage. For a minimum of back pressure in the exhaust, engine water outlet hose is not connected to the exhaust. It has its own fitting on the jet pump support (the same used for cooling system flushing). 1

F01E26A

TYPICAL â&#x20AC;&#x201D; 717 ENGINE 1. Drain tube

787 Engine Draining of the system is accomplished by a fitting at the bottom of each cylinder. Fittings are linked to a common line. The line is connected to the exhaust outlet at the stern of the craft.

F09L03A

TYPICAL 1. LH engine water outlet (flushing connector) 2. RH engine water outlet (flushing connector)

717 Engine Draining of the system is accomplished by a fitting to the bottom of exhaust manifold. Refer to illustration below. F01E1MA

787 ENGINE 1. Drain tube

For a complete view of cooling system arrangement, refer to the next page.

CAUTION

Never modify cooling system arrangement, otherwise serious engine damage could occur.

05-03-3

Section 05 COOLING SYSTEM Subsection 03 (CIRCUIT)

Speedster SK Cooling System Temperature sensor activates monitoring beeper when temperature exceeds 96-99Â°C (205-210Â°F) Uppermost point of circuit (tuned pipe) allows bleeding

Fresh water enters engine head for additional combustion chamber cooling

Calibrated cylinder head limits water flow

Additional flushing connector (capped)

Engine water hose outlet To pump support flushing connector

Water flows through tuned pipe and manifold water jackets

Water injected directly into exhaust gases for noise reduction and performance improvement

Tuned pipe bleed hose injects water into muffler to cool exhaust components Lowest point of circuit allows draining whenever engine is stopped

F09E06S

05-03-4

PARTS

Pressure zone Cooling System Indicator (CSI): Small stream of water flows out of bleed outlet located behind stern ring

Section 05 COOLING SYSTEM Subsection 03 (CIRCUIT)

787 Engine Cooling System Uppermost point of circuit (tuned pipe) allows bleeding Calibrated cylinder head limits water flow

Temperature sensor activates monitoring beeper when temperature exceeds 96-99Â°C (205-210Â°F)

Fresh waters enters engines head to prevent detonation

Cooling System Indicator (CSI): Small stream of water flows out of bleed oulet located behind stern ring

Water flows through tuned pipe and manifold water jackets

Engine water outlet hose Calibrated outlet fitting limits water flow. ALSO used as flushing connector To pump support flushing connector

Water regulated by the valve is injected directly into exhaust gases for noise reduction and performance improvement

Lowest point of circuit allows draining whenever engine is stopped

Additional flushing connector (capped)

Pressure zone Water flow regulator valve: At low speed, water is injected in tuned pipe Injects water directly (not regulated by the valve) into resonator through a calibrated hole. This cool exhaust components

To pump support

At higher speed, no water is injected in tuned pipe

Calibrated outlet fitting limits water flow F09E04S

TYPICAL

PARTS

05-03-5

Section 06 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

FUEL CIRCUIT........................................................................................................................ GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... FUEL SYSTEM PRESSURIZATION ...................................................................................

06-02-1 06-02-2 06-02-3 06-02-4 06-02-4 06-02-5

AIR INTAKE............................................................................................................................ REMOVAL........................................................................................................................... ASSEMBLY.........................................................................................................................

06-03-1 06-03-2 06-03-2

CARBURETORS ..................................................................................................................... 06-04-1 GENERAL ........................................................................................................................... 06-04-2 REMOVAL........................................................................................................................... 06-04-2 CLEANING ......................................................................................................................... 06-04-3 DISASSEMBLY AND INSPECTION................................................................................... 06-04-3 ASSEMBLY......................................................................................................................... 06-04-5 CARBURETOR INSTALLATION......................................................................................... 06-04-8 THROTTLE CABLE ADJUSTMENTS ................................................................................ 06-04-9 CARBURETOR ADJUSTMENTS ....................................................................................... 06-04-13

06-01-1

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

FUEL CIRCUIT

Right engine 787 engine Loctite 242 Loctite 242 Loctite 242 Left engine

Loctite 242

Loctite 242 Engine

Engine 1

1.5 N m ( 14 lbf in) 8 8 N m (71 lbf in)

Loctite 242 15 N m (133 lbf in)

2 3

5 23 N m (17 lbf ft) 2.8 N m 6 (25 lbf in) 7

2.8 N m (25 lbf in) F09F06T

PARTS

06-02-1

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

GENERAL

;

◆ WARNING

Whenever repairing the fuel system, always verify for water infiltration in reservoir. When replacing fuel lines on SEA-DOO Jet Boats be sure to use “A1” hoses as available from the BOMBARDIER parts department. This will ensure continued proper and safe operation.

;

WARNING

Replace any damaged, leaking or deteriorated fuel lines. To remove non-reusable Oetiker clamps, use screwdriver, as shown in the next photo. 1

WARNING

Use of improper fuel lines could compromise fuel system integrity. To open or secure reusable clamps on fuel lines, use pliers (P/N 295 000 054). To open clamp, place flat side of pliers on clamp embossment, squeeze and twist pliers.

F09E11A

1. Lift clamp tab

NOTE: If clamp cannot be removed using screwdriver, cut clamp. To cut or secure non-reusable Oetiker clamps, use pliers (P/N 295 000 070). F01B1VA

To secure clamp, place notch side of pliers on clamp embossment and squeeze pliers.

F01B2KA

F01B1UA

06-02-2

1. Cutting clamp 2. Securing clamp

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

F01B05A

1. Securing clamp in limited access

REMOVAL

F09F01A

Turn OFF main battery cut-off switch.

;

WARNING

Whenever working in fuel system, always ensure that main battery cut-off switch has been turned off before.

1. Cut locking tie 2. Remove clamps

Disconnect fuel hose ends from filter. Remove filter.

Baffle Pick Up NOTE: The baffle pick up no. 2 has an integrated fuel sensor.

Fuel Filter

Pinch fuel hose on both sides of fuel filter no. 1. Use hose pincher (P/N 295 000 076).

;

WARNING

The engine must not be running and fuel hose must be pinched. Fuel is flammable and explosive under certain conditions. Always work in a well-ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Cut locking tie. Remove both clamps. See next photo.

3 F01F20A

1. Pick up tube 2. Fuel sensor 3. Baffle pick up

06-02-3

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

Ensure that main battery cut-off switch is turned OFF. Empty fuel tank no. 3.

◆

WARNING

Fuel is inflammable and explosive under certain conditions. Always work in a well-ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the boat. Mark all 4 fuel hoses at fuel baffle location. This will ensure proper reinstallation. Remove hoses from baffle pick up. Pick up and disconnect fuel sensor wiring harness. Loosen both lower clamps from baffle pick up adapter and pull out baffle from fuel tank, as shown in the next photo.

INSPECTION Fuel Filter Inspect fuel filter no. 1 condition. Never use compressed air to clean fuel filter. Replace filter if permanently clogged or damaged.

Gear Clamp and Filler Neck Hose Verify fuel filler neck hose no.7 for damage. Always ensure that clamps no.6 are well-positioned and tightened. Torque clamps to 2.8 N•m (25 lbf•in).

Baffle Pick Up Filter Inspect filter no.5 of baffle pick up. Clean or replace as necessary.

ASSEMBLY Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following.

Fuel Filter Fuel filter no. 1 must be installed with pointers aligned with fuel flow, as shown in the next photo. 1

F09F03A F09F02A

1. Wiring harness 2. Loosen both clamps

Remove upper clamp from adapter and slide adapter from baffle.

Fuel Tank Vent Vent line fitting can be reached from engine compartment.

Fuel Tank Fuel tank cannot be removed. 06-02-4

1. Pointers indicating fuel flow 2. To carburetors 3. From fuel tank

Baffle Pick Up and Clamp Slide adapter onto baffle pick up no. 2 until it stops on rib. Install baffle pick up into fuel tank no. 3 and push it until it sits on fuel tank neck. Install all 3 clamps no. 8, as shown in the next photo, and torque to 1.5 N•m (14 lbf•in).

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

Pressure Test

F09F04A

PROPER CLAMP POSITIONING

FUEL SYSTEM PRESSURIZATION

◆

WARNING

Whenever doing any type of repair on jet boat or if any components of the fuel system are disconnected, a pressure test must be done before starting engine and/or releasing jet boat to customer.

CAUTION

Ensure to verify fuel line ends for damage. Always cut damaged end before reinstallation.

Proceed as follows: – Fill up fuel tank. – Ensure to firmly tighten fuel tank cap. Remove vent hose from boat body. – Install an adapter on pump gauge tester to match vent hose (1/4 to 5/8 in). – Connect pump gauge tester (P/N 529 021 800 from kit P/N 295 500 352) to vent hose. – Pressurize fuel system to 34 kPa (5 PSI). – If pressure is not maintained locate leak and repair/replace component leaking. To ease leak search spray a solution of soapy water on components, bubbles will indicate leak location. Ensure the leak does not come from vent hose that could not be sealed completely. NOTE: To minimize time of fuel system pressurization, the fuel tank should be quite full. The system must maintain a pressure of 34 kPa (5 PSI) during 10 minutes. Never pressurize over 34 kPa (5 PSI).

◆

WARNING

If any leak is found, do not start the engine and wipe off any fuel leakage. Failure to correct a leak could lead to an explosion. Do not use electric powered tools on boat unless system has been verified for no leaks. Reconnect vent hose of fuel tank vent on body.

06-02-5

Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE)

AIR INTAKE

0 1

10 N m 2 (88 lbf in)

10 N m (88 lbf in) 10

7 Loctite 518 F10F06S

TYPICAL

PARTS

06-03-1

Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE)

REMOVAL Air Intake Silencer Cover Unlock retaining slides no. 11 holding air intake silencer cover no. 1 and remove cover. 1

F00F03A

TYPICAL 1. Remove support

F01F2OA

TYPICAL 1. Air intake silencer cover 2. Unlock

Air Intake Silencer Base Remove screws no. 2 of plate no. 3. Pull out plate no. 3 and air intake silencer base no. 4. 1

Remove screws no. 10 from flame arrester base no. 7 then withdraw base. NOTE: To ease flame arrester base and support screws removal, heat one screw at a time with a heat gun then remove screw immediately. This procedure will also avoid screws breakage.

;

WARNING

Never use red hot element or open flame to heat the screws. Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area.

ASSEMBLY Assembly is essentially the reverse of removal procedures. However, pay particular attention to the following.

F00F02A

1. Retaining plate 2. Remove screws

CAUTION

Do not modify air intake system, otherwise calibration will be affected.

Flame Arrester Base

Remove flame arrester no. 5. Remove screws no. 8 retaining support no. 6 of flame arrester base no. 7 to the cylinder head cover (717 engine) or to the exhaust manifold (787 engine).

Apply Loctite 518 (P/N 293 800 038) on mating surfaces of flame arrester base no. 7. Apply Loctite 242 (P/N 293 800 015) on screws no. 10 and torque to 10 Nâ&#x20AC;˘m (88 lbfâ&#x20AC;˘in).

06-03-2

Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE)

Flame Arrester Inspect condition of flame arrester no. 5. Replace or clean as necessary.

â&#x2014;&#x2020;

WARNING

Do not operate boat without flame arrester.

787 Engine Position flame arrester with its embossment toward TOP.

F00F04A

Gasket Inspect condition of gasket no. 9. Make sure to properly install gasket.

06-03-3

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

CARBURETORS

13 3 7

Loctite 577

MAG/PTO

11 8 1

14 Loctite 222 2

6 4

Synthetic grease

PTO 17

F09F07T

TYPICAL

PARTS

06-04-1

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

GENERAL Some carburetor components and/or settings can be changed to improve boat performance in high altitude regions between 1500-3000 m (5000-10000 ft). Refer to the service department for the latest specifications.

CAUTION

Such modifications should only be performed by experienced mechanics since they can greatly affect boat performance and can cause severe damage to engine. Use only recommended settings. The following illustration shows which part of the carburetor begins to function at different throttle valve openings.

The carburetors are equipped with a fuel accelerator pump. The fuel accelerator pump is linked to the throttle valve via a linkage. A metering jet in the fuel inlet hose controls fuel supply to the pump. A check valve on the fuel outlet hose prevents air from entering in the system.

REMOVAL Carburetor Turn OFF main battery cut-off switch. Remove air intake silencer. Refer to AIR INTAKE 06-03. NOTE: For fuel line removal, use pliers (P/N 295 000 054). Disconnect pulse line(s) from fuel pump(s).

2 4 5 6

F00F05A

TYPICAL 1. Pulse line

3 F01F13A

VIEW FROM AIR INTAKE OPENING 1. Throttle plate openings 2. Close 3. Wide open 4. Low-speed screw 5. Pilot jet 6. Main jet and high-speed screw

06-04-2

Disconnect fuel supply line(s) from fuel pump(s). Disconnect fuel return line(s). Disconnect oil injection pump cable(s), throttle cable(s) and choke cable(s). Remove screws and lock washers retaining carburetor(s).

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

DISASSEMBLY AND INSPECTION

Inspect parts for corrosion damage (shaft, throttle and choke plates, spring, screw, check valve housing, accelerator pump plunger, cam, roller etc.).

Needle Valve Inspect needle valve no. 1 tip for a grooved condition. If worn, needle and seat must be replaced as a matched set.

Low-Speed Mixture Screw Check screw tip no. 2 for a grooved condition. Replace if necessary. F07F03A

TYPICAL 1. Screw

Remove linkage rod from carburetors. Remove carburetor(s).

CLEANING The entire carburetor should be cleaned with a general solvent and dried with compressed air before disassembly.

Accelerator Pump Verification Disconnect inlet and outlet tubes from accelerator pump no. 13 nipples. Using a suitable pump gauge tester, perform the following test proceeding as follows: – Install pump gauge tester (P/N 295 000 114) on inlet nipple. – Obstruct outlet nipple with a finger and hold while pumping. – Pump tester until it reaches 28 kPa (4 PSI).

CAUTION

Be careful at carburetor cleaning not to remove paint. Paint removal will cause carburetor to rust very rapidly. Repaint if necessary. Carburetor body and jets should be cleaned in a carburetor cleaner following manufacturer’s instruction.

◆

WARNING

Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as they are flammable and explosive.

◆

WARNING

Heavy duty carburetor cleaner may be harmful to the rubber parts, O-ring, etc. Therefore, it is recommended to remove those parts prior to cleaning.

F04F0HA

TYPICAL 1. Pump gauge tester 2. Install on inlet nipple 3. Obstruct outlet nipple

Diaphragm no. 3 must stand pressure for 10 seconds. If pressure drops, replace diaphragm.

Discard O-rings, diaphragms and gaskets. 06-04-3

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

Verify accelerator pump check valves operation as follows: Connect a clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with the mouth. The check valve should release with pressure and hold under vacuum.

◆

WARNING

Diaphragm Fuel Pump Diaphragm Leak Test Using a suitable pump gauge tester, perform the following test proceeding as follows: – Install pump gauge tester (P/N 295 000 114) on pulse nipple. Pump tester until it reaches 28 kPa (4 PSI).

Some fuel may be present in fuel pump. Be careful not to swallow fuel when under vacuum.

F01F0XA

TYPICAL 1. Pump gauge tester 2. Install on pulse nipple

Diaphragm no. 3 must stand pressure for 10 seconds. If pressure drops, replace diaphragm. F04F0IA

Pressure: 28 kPa (4 PSI) for 10 seconds

TYPICAL 1. Apply pressure and vacuum at inlet nipple

Repeat the same procedure at the injector nipple. 1

Pump Body External Fuel Pump Inspect all hoses connected to fuel pump. Disconnect outlet hose from fuel pump. Connect a long test hose to outlet fitting that can be brought outside engine compartment. Use a container to recover fuel that will be pumped out. Wipe any fuel spillage inside engine compartment. Start bilge blower for 5 minutes.

◆ F04F0JA

TYPICAL 1. Apply pressure and vacuum at injector nipple

06-04-4

WARNING

Wiping fuel spillage and ventilation of bilge is very important prior to starting engine. Take care that no fuel spills in engine compartment.

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

Start engine and ensure the fuel pump is properly pumping gas into container. Otherwise, replace fuel pump.

Filter

To verify filter no. 5 condition proceed as follows: Remove pump cover no. 4 and O-ring no. 6. Remove filter from carburetor body then clean filter and blow carefully with compressed air (low pressure). Replace filter if damaged.

F01F0ZA

TYPICAL 1. Metering chamber floor 2. Lever end 3. Flush

To adjust, bend lever very slightly to change its height.

F01F0YA

TYPICAL 1. Filter

ASSEMBLY When assembling pump, ensure to properly position components together. Refer to previous illustrations if necessary.

Choke Plate and Throttle Plate

CAUTION

When adjusting lever, do not pry it. This will apply pressure on needle and damage valve seat/needle. 1

When installing choke plate no. 6 and throttle plate no. 7 onto shaft, close plate so that it centers into carburetor bore. Firmly tighten screws.

CAUTION

Always apply Loctite 242 (P/N 293 800 015) on screw threads prior to installing screws.

Needle Valve Lever

F01F0HA

HIGH LEVER Step 1 : Depress here Step 2 : Push tab down

Inlet Control Lever Rounded end of needle valve lever no. 9 must be flush with surrounding metering chamber floor and not with body assembly. Place the end of a ruler over lever to check adjustment.

06-04-5

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

If release pressure is not within specification, check control lever adjustment. Replace spring as necessary.

CAUTION

Do not stretch or cut spring. F01F34A

LOW LEVER Step 1 : Depress here Step 2 : Pry up here

Pressure Test Proceed as follows: – Install pump gauge tester on carburetor inlet nipple. – Obstruct outlet nipple with a finger. – Pump tester until inlet release pressure is reached (seen by a sudden pressure drop). 3 1

Leak Test Needle valve must stand a pressure of 69 kPa (10 PSI) for 30 seconds. Otherwise, hold carburetor upside down, pour oil over needle valve and apply pressure. Check for bubbles. If they come from seat O-ring, bubbles will exit around seat. Retighten as necessary. If it still leaks remove needle and seat and replace O-ring. If bubbles come from needle, replace needle and seat.

Main Jet and Pilot Jet Pilot jet no. 11 and main jet no. 10 are replaceable. Different jet sizes are available to suit temperature and altitude conditions. Always inspect spark plug tip condition when dealing with pilot jet and main jet. Spark plug tip condition gives a good indication of carburetor mixture setting.

CAUTION

Adjustments vary with temperature and altitude. Always observe spark plug condition for proper jetting.

2 F01F10A

TYPICAL 1. Pump gauge tester 2. Install on inlet nipple 3. Obstruct outlet nipple

Refer to the following table for pop-off pressures. ENGINE TYPE

POP-OFF PRESSURES kPa (PSI)

717 and 787

265 ± 83 (38 ± 12)

NOTE: Pressure test should be performed 3 times to obtain a valid reading.

06-04-6

CAUTION

Such modifications should only be performed by experienced mechanics since they can greatly affect boat performance and can cause severe damage to engine. Use only recommended settings. NOTE: To have access to pilot jet or main jet, check valve no. 12 housing must be removed.

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

O-Ring When installing O-rings nos. 14 and 15 of lowspeed no. 2 and high-speed no. 16 screws, apply some BOMBARDIER LUBE (P/N 293 600 006) to prevent sticking.

2 1

Accelerator Pump 3

Lubricate pump plunger, roller and cam with synthetic grease (P/N 293 550 010) and roller shaft with BOMBARDIER LUBE.

4 2

F01F11A

TYPICAL 1. Pilot jet 2. Gasket 3. Main jet 4. Check valve housing

Check Valve Assembly The check valve no. 12 is needed if a back pressure occurs into carburetor. It will prevent fuel from flowing back into carburetor lower portion. Inspect check valve, it should be free of holes, tears or imperfections. Replace as needed.

F04F0NB

1. Apply synthetic grease 2. Apply BOMBARDIER LUBE on roller shaft

For tubes location, refer to the following illustration.

F01F12A

1. Check valve

NOTE: Prior to check valve assembly installation, remember to set gasket.

Diaphragm and Cover Install diaphragm no. 3 with its integrated O-ring into carburetor groove. Make sure that the tab of cover no. 13 is inserted into carburetor notch.

1 2

F04F0OA

1. Inlet tube here 2. Outlet tube connects here

06-04-7

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

CARBURETOR INSTALLATION At installation, pay attention to the following. Install carburetor(s) with gasket(s) to intake manifold (rotary valve cover for 787 engine). If applicable, synchronize carburetors before installation. Refer to Carburetor Synchronization. Apply Loctite 577 (P/N 293 800 050) on screw threads. Then, install screws with lock washers and torque to 20 N•m (15 lbf•ft). This will prevent screws to jam to ease further removal.

CAUTION

Failure to apply Loctite 577 might lead you to damage carburetor to allow its removal if screws are jammed.

Fuel Lines and Hose Clamps If fuel line ends are damaged, cut damaged end before reinstallation. Properly install clamps.

◆

Loosen jam nuts on carburetor linkage and adjust linkage with adjustment nut. Make sure threads length is the same on each side of linkage and flat surfaces of both ends are parallel with each other.

WARNING

Make sure there is no leak in fuel system. For fuel system pressurization, refer to FUEL CIRCUIT 06-02.

F01F1YA

1. Jam nuts 2. Adjustment nut 3. Flat surfaces

Tighten jam nuts and torque to 3 N•m (27 lbf•in). NOTE: Grease carburetor linkage at both ends with synthetic grease (P/N 293 550 010). Connect linkage between both carburetor levers. Ensure both throttle plates no. 8 are still in closed position. NOTE: The linkage installation is done with the marks located near PTO carburetor throttle lever to ease adjustment when performed in the boat.

Carburetor Synchronization With idle speed screw not touching throttle lever stopper on MAG carburetor, both throttle plates are in closed position.

F01F1ZD

TYPICAL 1. Throttle lever PTO side 2. Marks

F01F1XA

TYPICAL — 787 ENGINE 1. Stopper 2. Idle speed screw

06-04-8

CAUTION

Throttle plates must open simultaneously, otherwise this will cause engine to vibrate and/or backfire.

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

THROTTLE CABLE ADJUSTMENTS

Full Throttle Adjustment for Proper Cable Slack

NOTE: Perform the following adjustments on each engine.

CAUTION

Make sure engine is turned off before adjusting cable(s), except otherwise specified. As a preliminary adjustment, turn idle speed screw until it contacts throttle lever stopper. Then, turn 2 additional turns.

Fully push throttle levers forward. NOTE: Do not activate throttle levers unnecessarily. Carburetors are equipped with fuel accelerator pump. These pumps deliver fuel to the engines each time throttle levers are moved forward. Ensure throttle cables have sufficient slack to allow 0.4 mm (1/64 in) gap between throttle lever and throttle stop, at carburetor.

F01F1XB

1. Idle speed screw

The throttle cable adjustments imply the following steps which must be followed in this order. • Full throttle adjustment for proper cable slack. • Idle speed adjustment. • Full throttle check for maximum RPM with proper cable slack. • Throttle levers synchronization. • Accelerator pump adjustment. • Injection oil pump cable adjustment. • Low-speed steering control system cable adjustment. • Final cable adjustment.

F01G0YC

TYPICAL — 717 ENGINE 1. Adjustment nut 2. Jam nut 3. Throttle lever stopper

CAUTION

Always perform cable adjustments in the specified order, as described in the following instructions. Lubricate cable(s) with BOMBARDIER LUBE lubricant (P/N 293 600 016).

F01F07A

TYPICAL — 787 ENGINE 1. Throttle lever stoppers (behind levers) 2. Adjustment nut

CAUTION

Improper cable adjustment will cause strain on cable(s), linkage or components. 06-04-9

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

If not, readjust cable threaded end at throttle/ shifter controller bracket location, then perform previous throttle cable tension validation.

CAUTION

Use a protective mat in throttle/shifter controller area when withdrawing it for adjustment.

Connect an induction-type tachometer (P/N 529 014 500) on spark plug cable of magneto side to measure engine speed. NOTE: To adjust idle speed, ensure flame arrester and air intake silencer are installed. Start engine and bring to normal operating temperature. Adjust idle speed to 3000 RPM (out of water) by using carburetor idle speed screws.

CAUTION

Water must be supplied to cool engine with a garden hose at flushing connector.

F04L0GB

TYPICAL 1. Cable threaded end at throttle/shifter controller

If throttle lever stop cannot be adjusted at throttle/ shifter controller, readjust throttle cable end on carburetor bracket. Repeat this procedure until gap is 0.4 mm (1/64 in). NOTE: When checking gap, ensure that throttle/ shifter controller is properly positioned into deck cutaway. If throttle lever stop cannot be adjusted with proper free play, replace cable with a new one.

Idle Speed Adjustment Ensure steering wheel is centered. Pull throttle lever back to idle position. NOTE: Turning screw clockwise increases engine idle speed and turning screw counterclockwise decreases engine idle speed. There is only one idle speed screw for both carburetors. It is located on the MAG side carburetor. 06-04-10

F01G0YD

717 ENGINE 1. Idle speed screw

F01F1XA

787 ENGINE 1. Stopper 2. Idle speed screw

Stop engine. If it is not possible to properly adjust idle speed, readjust throttle cable end on carburetor bracket. NOTE: Carburetor lever must rest on idle screw when control lever is at idle position.

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

If carburetor lever does not rest on idle screw with control lever at idle position and when cable threaded end on carburetor bracket is at limit position, readjust cable threaded end on throttle/ shifter controller bracket. If idle speed cannot be properly adjusted. Replace cable with a new one. 2

Full Throttle Check for Maximum RPM with Proper Cable Slack Start engine. Set shifter control lever to forward or reverse position. Push throttle levers forward momentarily to full position and check that engine revving is according to the following specifications:

F04F18A

ENGINE TYPE

RPM

1. Locking nut 2. Loosen until a gap is seen

717

7000 Âą 50

Retighten locking nut.

787

7200 Âą 50

Stop engine. Ensure again that throttle cables have sufficient slack to allow 0.4 mm (1/64 in) gap between throttle lever and throttle stop.

Throttle Levers Synchronization Start engines. Push one throttle lever until engine reaches 3000 RPM (in water). Move the second throttle lever to the same position, engine revving should be between 2800 and 3200 RPM (in water). Stop engines. If engine is not at proper RPM, adjust cable threaded end on throttle/shifter controller bracket.

Accelerator Pump Adjustment Since accelerator pump no. 17 adjustment is affected by throttle cable adjustment, throttle cable adjustment should be done first. Push throttle lever to full throttle. Loosen locking nut then turn screw until there is a small gap between lever tab and pump plunger. Refer to the following photo.

Accelerator Pump Verification With engine stopped, remove intake silencer cover and flame arrester then activate throttle lever to ensure accelerator pump is injecting fuel in carburetor(s). Reinstall removed parts. NOTE: Activate throttle only a few times to prevent engine flooding.

Injection Oil Pump Cable Adjustment Since accelerator pump adjustment is affected by throttle cable adjustment, throttle cable adjustment should be done first. Refer to OIL INJECTION PUMP 07-03.

CAUTION

Improper cable adjustment will cause strain on cable(s), linkage or components.

Low-Speed Steering Control System Cable Adjustment Open front storage cover. Remove basket. Remove existing heat shrink tubing(s). Turn adjuster knob to completely close rotating ends, as shown in the following illustration.

06-04-11

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

Test Boat in Water Boat may be tested in a test basin or on open water.

;

WARNING

If testing on open water, ensure to accelerate slowly, boat may veer suddenly to left or right.

F04K12A

TYPICAL — ROTATING ENDS COMPLETELY CLOSED

Fully turn steering in one direction. Adjust cable housing in bracket so that throttle moves slightly.

With boat in water and helm arm fixed on, set throttle lever to idle speed (1500 RPM (in water)). Fully turn steering left and right, then turn adjuster knob of rotating end so that engine revolution (in water) is as per following table.

ENGINE

RPM

717

2500 ± 100

787

2800 ± 100

1 F04K0SC

TYPICAL 1. Adjust and tighten adjustment screws

Tighten adjustment screws. Turn steering in the other direction and repeat procedure on the other cable. When engine(s) RPM are the same for the two extreme steering positions, proceed with procedure FINAL CABLE ADJUSTMENT as described.

Final Cable Adjustment NOTE: Ensure throttle cable adjustment, injection oil pump cable adjustment and low-speed steering control system cable adjustment have been performed prior to achieving this final adjustment.

06-04-12

F04K0OA

1. To reduce RPM 2. To increase RPM

Seal rotating ends with heat shrink tubing. NOTE: Ensure that right side engine will speed up when steering is turned right. Left side engine will speed up when steering is turned left. If not, reposition cables accordingly, at helm bracket and/or control lever bracket.

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

CARBURETOR ADJUSTMENTS Low-Speed Mixture Screw

Start and warm up engine. NOTE: Turning screw clockwise leans mixture and turning screw counterclockwise enriches mixture. Check that engine idles and runs smoothly. Make sure engine reacts quickly to throttle lever. If necessary, readjust low-speed screw (± 1/4 turn). NOTE: Both low-speed screws must be adjusted exactly the same way. Never adjust screws more than 1/4 turn at a time.

High-Speed Mixture Screw The high-speed mixture screw no. 16 is sealed with a plastic cap that allows an adjustment of 1/4 turn. NOTE: Turning screw counterclockwise enriches mixture and turning screw clockwise leans mixture.

F06F0GA

TYPICAL — 717 ENGINE 1. Low speed screw

CAUTION

When adjusting high-speed mixture screw, always inspect spark plug tip color and readjust screw accordingly. Otherwise, severe engine damage can occur.

F01F07B

TYPICAL — 787 ENGINE 1. PTO low-speed mixture screw 2. MAG low-speed mixture screw (not shown)

CAUTION

Do not attempt to set engine idle speed with low-speed mixture screw. Severe engine damage can occur. Tighten screw no. 2 in until a slight resistance is felt then back off to the specification as per following chart. ENGINE TYPE

LOW SPEED SCREW

717

1.25 turns

787

1.5 turns

F06F0IA

717 ENGINE 1. High-speed mixture screw

06-04-13

Section 06 FUEL SYSTEM Subsection 04 (CARBURETORS)

ROT F01F2QA

TYPICAL â&#x20AC;&#x201D; 787 ENGINE 1. High-speed mixture screws

06-04-14

Section 07 LUBRICATION SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

OIL INJECTION RESERVOIR................................................................................................. GENERAL ........................................................................................................................... OIL RESERVOIR ................................................................................................................. OIL SYSTEM PRESSURIZATION ......................................................................................

07-02-1 07-02-2 07-02-2 07-02-3

OIL INJECTION PUMP .......................................................................................................... REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... ASSEMBLY......................................................................................................................... ADJUSTMENTS ................................................................................................................ CHECKING OPERATION....................................................................................................

07-03-1 07-03-3 07-03-3 07-03-3 07-03-3 07-03-4 07-03-6

07-01-1

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION RESERVOIR)

OIL INJECTION RESERVOIR Dielectric grease

3 8 28 N m (21 lbf ft)

0 6

3 N m 1 (27 lbf in)

6 N m (53 lbf in) 5 3 N m (27 lbf in)

F10G01T

PARTS

07-02-1

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION RESERVOIR)

GENERAL Whenever repairing the oil injection system, always verify for water infiltration in reservoir. Perform also a pressure test of the oil injection system, as described later.

Clamp and Hose Verify oil filler neck hose no. 2 for damage. Always ensure that clamps no. 1 are well-positioned and tightened. See exploded view.

Check Valve White side of the one-way check valve no. 3 is the valve outlet. It allows air to get in reservoir.

Cut locking tie then unplug hose from low-level oil sensor no. 6. Unplug low-level oil sensor connector no. 8. Cut locking tie then detach oil reservoir valve no. 3. Loosen filler neck hose collars no. 1 then detach hose no. 2 from reservoir. Remove all 3 nuts no. 5 (2 top and 1 bottom) retaining oil reservoir to support. Remove reservoir from support. Lean reservoir in bottom of engine compartment. Cut locking ties, as shown in the next photo, then remove oil hoses. 1

Oil Filter

Oil filter no. 4 should be replaced annually.

OIL RESERVOIR Removal Drain oil reservoir no. 7. Install 3 hose pinchers (P/N 295 000 076) on oil lines, as shown in the next photo. 1 F09G05A

TYPICAL â&#x20AC;&#x201D; SPEEDSTER SK SHOWN 1. Cut these locking ties 2. Hose pinchers previously installed

Inspection Visually inspect the inside and outside of the oil reservoir necks for crack(s). If crack(s) are existing, replace reservoir. Check with your finger to feel the inside and outside surfaces of oil reservoir. Flex reservoir necks to ensure there are no hidden cracks. F09G03A

TYPICAL â&#x20AC;&#x201D; SPEEDSTER SK SHOWN 1. Hose pinchers installed 2. Hose pincher not shown

07-02-2

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION RESERVOIR)

OIL SYSTEM PRESSURIZATION

Installation Installation is essentially the reverse of removal procedures. However, pay particular attention to the following. Ensure that oil reservoir valve is properly secured to harness with locking tie, as shown in the next photo. 1

Pressure Test Proceed as follows: – Fill up oil reservoir. – Install hose pinchers to oil supply outlet hoses close to reservoir fitting. – Install a hose pincher to rotary valve shaft oil return hose close to reservoir. – Connect pump gauge tester to check valve of oil injection reservoir vent. 1

F09G04A

1. Oil reservoir valve secured to harness

Fill up oil reservoir and bleed oil lines. Refer to OIL INJECTION PUMP 07-03 for complete detailed procedure.

CAUTION

Whenever oil system components are disconnected or replaced, line bleeding and pressure test must be done before starting engine. Ensure to verify oil line ends for damage. Always cut damaged end before reinstallation.

F01G0IA

TYPICAL 1. Connect pump to check valve

– Pressurize oil system to 21 kPa (3 PSI). If pressure is not maintained, locate leak and repair/ replace component leaking. To ease leak search, spray a solution of soapy water on components, bubbles will indicate leak location. NOTE: The system must maintain a pressure of 21 kPa (3 PSI) for at least 10 minutes. Never pressurize over 21 kPa (3 PSI).

CAUTION

If any leak is found, do not start the engine and wipe off any oil leakage. – Disconnect pump gauge tester and remove hose pinchers.

07-02-3

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

OIL INJECTION PUMP

717 Engine

Loctite 577

6 N m (53 lbf in) 2

1 Loctite 242

Loctite 242 6 N m (53 lbf in)

3 10 N m (89 lbf in)

5 5 N m (44 lbf in)

8 N m (71 lbf in) 8 N m (71 lbf in)

4.5 N m (40 lbf in) Loctite 242 F09G06S

PARTS

07-03-1

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

787 Engine

Loctite 242 25 N m (18 lbf ft) Anti-seize 25 N m (18 lbf ft) Loctite 242

4 Molykote 111

Loctite 242

F09G02S

07-03-2

PARTS

4.5 N m (40 lbf in)

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

REMOVAL

DISASSEMBLY

717 Engine Remove air intake silencer (refer to AIR INTAKE 06-03). Remove rotary valve cover (refer to ROTATY VALVE 04-07). Remove Allen screws no. 3 retaining intake manifold no. 4 to rotary valve cover. Separate intake manifold from rotary valve cover.

NOTE: Some oil pump parts are not available in single parts. A gasket set is available for the pump. If the pump is found defective, it should be replaced by a new one.

Oil Pump Gear

ASSEMBLY

To separate oil pump no. 5 from intake manifold no. 4, remove oil pump gear no. 1 using gear holder (P/N 420 277 905) and unscrew lock nut no. 2.

717 Engine

CLEANING Discard all seals and O-rings. Clean metal components in a solvent.

Oil Injection Pump and Intake Manifold Install oil injection pump no. 5 to intake manifold no. 4. Torque screws to 6 N•m (53 lbf•in).

CAUTION

Whenever oil injection lines are removed, always make the routing as shown.

A00C17B

1. Gear holder

Oil Pump Disconnect oil injection pump cable no. 7. Remove both Allen screws with flat washers retaining oil injection pump no. 5 to intake manifold no. 4. Remove pump. Disconnect oil hoses from fittings of oil injection pump.

787 Engine

Oil Pump Disconnect oil injection pump cable no. 7. Remove both Allen screws no. 3 with flat washers retaining oil injection pump to magneto housing cover. Pull pump. Disconnect oil hoses from fittings of oil injection pump.

F01D4SA

TYPICAL 1. Small oil line

Oil Pump Gear Install gear no. 1 to oil injection pump shaft. Torque lock nut no. 2 to 6 N•m (53 lbf•in). NOTE: Make sure one washer is installed on each side of gear.

07-03-3

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

Intake Manifold Install intake manifold no. 4 to rotary valve cover and torque screws to 10 N•m (89 lbf•in). NOTE: Make sure a new gasket is installed to rotary valve cover.

NOTE: Make sure carburetors are properly synchronized. If necessary, refer to CARBURETORS 06-04. Turn idle speed screw until it contacts stopper. Turn idle speed screw 2 turns. Turn cable adjustment nut to align marks on pump. NOTE: A mirror may be used to facilitate this verification.

1 2

F01D4RC

TYPICAL A. 10 N•m (89 lbf•in)

F01D4RE

787 Engine

Oil Pump Make sure oil pump shaft no. 4 is installed in crankshaft end. Apply Molykote 111 (P/N 413 707 000) on shaft. Install pump. Secure with flat washers no. 2 and screws no. 3. Torque to 6 N•m (53 lbf•in). Install oil injection pump cable.

TYPICAL — 717 ENGINE 1. Jam nut 2. Adjustment nut 3. Aligned marks

ADJUSTMENTS

CAUTION

As oil injection pump adjustment is dependent on throttle cable position, make sure to perform throttle cable adjustment first.

Preliminary Synchronization NOTE: To check synchronization of pump as a routine maintenance, refer to Final Synchronization. Make sure idle speed of engine is properly adjusted. Ensure carburetor butterflies are in closed position.

07-03-4

F07G02B

TYPICAL — 787 ENGINE 1. Aligned marks

NOTE: The adjustment nut and jam nut for the oil injection pump cable are located at the cable support on PTO side carburetor.

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

Bleeding

CAUTION

Oil injection system must be bled and adjustment checked before operating engine.

F01F32G

Ensure oil injection reservoir is sufficiently filled. Install a dry rag below oil injection pump. Loosen bleed screw to allow oil to flow.

1 2

1. Adjustment nut on this side 2. Jam nut

All Engines Start and bring engine to normal operating temperature.

CAUTION

Water must be supplied to cool engine. Adjust idle speed to specification. Refer to CARBURETORS 06-04. Stop engine.

Final Synchronization

TYPICAL â&#x20AC;&#x201D; 717 ENGINE 1. Bleed screw

Eliminate throttle cable free-play by depressing throttle lever until a slight resistance is felt. In this position, marks on pump body and lever must align. NOTE: A mirror may be used to facilitate this verification. If necessary, turn cable adjustment screw to obtain pump mark alignment. Refer to above illustrations. Tighten jam nut and recheck alignment marks. NOTE: Apply Loctite 242 on jam nut.

F01D4SC

CAUTION

Proper oil injection pump adjustment is very important. Any delay in the opening of pump can result in serious engine damage.

F07G02A

TYPICAL â&#x20AC;&#x201D; 787 ENGINE 1. Bleed screw

07-03-5

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

All Engines Keep bleeding until all air has escaped from line. Make sure no air bubbles remain in oil supply line. Tighten bleed screw. Wipe any oil spillage. Check small oil lines between pump and intake manifold. They must be full of oil. If not, run engine at idle speed while manually holding pump lever in fully open position. Do not activate throttle lever.

CAUTION

Water must be supplied to cool engine.

F01G0QA

1. Check valves

CHECKING OPERATION On Boat NOTE: Oil line supply must be full of oil. See bleeding procedure above. Start engine and run at idle while holding the pump lever in fully open position. Oil must advance into small oil lines. NOTE: The engine should have a rich mixture, idling irregularly and emitting smoke at exhaust outlet. If not, remove pump assembly and check the pump gear (717 engine) or shaft (787 engine) for defects, replace as necessary. Test pump as described below: NOTE: Through normal use, oil level must not drop in small tubes. If oil drops, verify check valve operation. Replace as necessary.

Bench Test The oil pump must be removed from boat. Connect a hose filled with injection oil to main line fitting. Insert other hose end in an injection oil container. Using a counterclockwise (reverse position) rotating drill, rotate pump shaft. Oil must drip from fittings in parts of rotary valve cover while holding lever in a fully open position. 2

4 3 F01G02A

F02D05B

TYPICAL â&#x20AC;&#x201D; 717 ENGINE 1. Check valves 07-03-6

TYPICAL 1. Supply oil line to an oil container 2. Hold lever in fully open position 3. Counterclockwise (reverse) rotating drill 4. Oil must drip here

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

For an accurate test, each port should be checked separately to ensure equal delivery on both ports. To obtain a precise result of the oil pump delivery rate, rotate it counterclockwise at 1500 RPM for a total time of 30 seconds. NOTE: To ensure accuracy of test, oil lines should be completely filled before starting test. Compare the results with the chart below. If oil pump is out of specification, replace it. ENGINE

OIL PUMP FLOW RATE AT 1500 RPM (30 SECONDS)

717

1.24 - 1.51 mL (each port)

787

0.71 - 0.87 mL (each port)

NOTE: Test can also be done at 3000 RPM. Double quantities in chart.

07-03-7

Section 08 ELECTRICAL Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS OVERVIEW............................................................................................................................. GENERAL ........................................................................................................................... MAIN BATTERY CUT-OFF SWITCH ................................................................................. SACRIFICIAL ANODE SYSTEM ........................................................................................ 717 ENGINE ....................................................................................................................... MAGNETO SYSTEM ......................................................................................................... IGNITION SYSTEM (SINGLE GENERATOR COIL)........................................................... MPEM (MULTI-PURPOSE ELECTRONIC MODULE) ................................................................ CHARGING SYSTEM......................................................................................................... STARTING SYSTEM .......................................................................................................... GAUGES/ACCESSORIES .................................................................................................. 787 ENGINE ....................................................................................................................... MAGNETO SYSTEM ......................................................................................................... CHARGING SYSTEM......................................................................................................... CHARGING CIRCUIT SCHEMATIC.................................................................................... IGNITION SYSTEM............................................................................................................ STARTING SYSTEM ..........................................................................................................

0 08-02-1 08-02-1 08-02-1 08-02-1 08-02-2 08-02-2 08-02-2 08-02-2 08-02-3 08-02-3 08-02-3 08-02-4 08-02-4 08-02-4 08-02-4 08-02-5 08-02-5

IGNITION SYSTEM................................................................................................................ 08-03-1 IGNITION SYSTEM TESTING PROCEDURE, 717 ENGINE ............................................. 08-03-1 GENERAL ........................................................................................................................... 08-03-1 IGNITION TIMING, 717 ENGINE....................................................................................... 08-03-3 IGNITION TIMING ADJUSTMENT ................................................................................... 08-03-7 IGNITION SYSTEM TESTING PROCEDURE, 787 ENGINE ............................................. 08-03-8 GENERAL ........................................................................................................................... 08-03-8 IGNITION TIMING, 787 ENGINE....................................................................................... 08-03-10 SPARK PLUGS....................................................................................................................... NGK SPARK PLUG SYMBOL EXPLANATION.................................................................. DISASSEMBLY................................................................................................................... HEAT RANGE ..................................................................................................................... FOULING............................................................................................................................ SPARK PLUG ANALYSIS................................................................................................... SPARK PLUG INSTALLATION........................................................................................... SPARK PLUG CHART ........................................................................................................

08-04-1 08-04-1 08-04-2 08-04-2 08-04-2 08-04-2 08-04-3 08-04-3

THE DESS (DIGITALLY ENCODED SECURITY SYSTEM) ................................................... PROGRAMMING OF SAFETY LANYARD(S) .................................................................... FEATURES OF THE DESS ................................................................................................. MONITORING SYSTEM ....................................................................................................

08-05-1 08-05-1 08-05-1 08-05-1

08-01-1

Section 08 ELECTRICAL Subsection 01 (TABLE OF CONTENTS)

MPEM (MULTI-PURPOSE ELECTRONIC MODULE) ............................................................ MPEM OPERATION............................................................................................................ MPEM TESTS ..................................................................................................................... GENERAL............................................................................................................................ WIRE TERMINAL REMOVAL ............................................................................................. AMP CONNECTORS (26 PINS).......................................................................................... IDENTIFICATION OF FUSE BLOCKS ON MPEM.............................................................. IDENTIFICATION OF CONNECTOR PINS ......................................................................... MPEM CIRCUIT VERIFICATION.........................................................................................

08-06-1 08-06-1 08-06-5 08-06-5 08-06-6 08-06-6 08-06-10 08-06-12 08-06-15

CHARGING SYSTEM ............................................................................................................. 08-07-1 TESTING PROCEDURE ...................................................................................................... 08-07-1 STARTING SYSTEM .............................................................................................................. ELECTRIC STARTER........................................................................................................... GENERAL............................................................................................................................ STARTING SYSTEM TROUBLESHOOTING...................................................................... REMOVAL ........................................................................................................................... DISASSEMBLY ................................................................................................................... CLEANING .......................................................................................................................... INSPECTION ....................................................................................................................... ASSEMBLY ......................................................................................................................... STARTER INSTALLATION.................................................................................................. STARTER SPECIFICATION ................................................................................................. BATTERY............................................................................................................................. TROUBLESHOOTING......................................................................................................... SPECIFICATIONS ............................................................................................................... ACTIVATION OF NEW BATTERY ....................................................................................... REMOVAL ........................................................................................................................... CLEANING .......................................................................................................................... INSPECTION ....................................................................................................................... BATTERY TESTING ............................................................................................................ BATTERY STORAGE .......................................................................................................... TIPS FOR CHARGING A USED BATTERY......................................................................... CHARGING 2 OR MORE BATTERIES AT A TIME............................................................. INSTALLATION...................................................................................................................

08-08-1 08-08-1 08-08-2 08-08-3 08-08-4 08-08-4 08-08-4 08-08-5 08-08-5 08-08-7 08-08-8 08-08-9 08-08-9 08-08-9 08-08-9 08-08-9 08-08-10 08-08-10 08-08-10 08-08-11 08-08-11 08-08-12 08-08-12

INSTRUMENTS AND ACCESSORIES................................................................................... 08-09-1 GENERAL............................................................................................................................ 08-09-2 INSPECTION ....................................................................................................................... 08-09-2

08-01-2

Section 08 ELECTRICAL Subsection 02 (OVERVIEW)

OVERVIEW

GENERAL MAIN BATTERY CUT-OFF SWITCH

SACRIFICIAL ANODE SYSTEM 4

3 Grounding blocks

F00H46A

TYPICAL

Switch is located in the engine compartment, close to battery. It is provided to allow a complete cut-out of the electrical system. When in OFF position, all electrical equipments and electronics will not be powered and not working. It must be in the ON position to allow the use of electrical components and to start the engine(s). It is recommended to set in the OFF position whenever performing maintenance in the engine compartment, on the electrical system, for transportation and for short term storage on the trailer.

F00H18A

TYPICAL 1. Aluminum anode 2. Weedless cable 3. Reverse cable 4. Steering cable

This system is an additional protection against corrosion for under water metal parts and electrical system. Principle is very simple. Some metals are less active and some are more active in corrosion process. Anode aluminum alloy is highly active compare with other metals used in boat. For that reason anode will erode away instead of the other expensive components. NOTE: Anode will not provide corrosion protection when boat is removed from water. Refer to INSTRUMENTS AND ACCESSORIES 0809 for anode system inspection.

08-02-1

Section 08 ELECTRICAL Subsection 02 (OVERVIEW)

717 ENGINE The electrical system consist of different subsystems where some are inter related. The magneto is coupled to the engine and produces electrical energy for the ignition system and the charging system. Its outputs are directed toward the ignition coil as well as the charging system and some circuits through the MPEM (MultiPurpose Electronic Module). In the charging system, the battery supplies the MPEM, the starting system and the accessories. The following gives an outline of each components. There are different voltage types (AC (alternative current) and DC (direct current)) and voltage levels (0 to 40 000 Vac, 5 Vdc and 12 Vdc). There is unregulated AC from magneto for the charging system and the ignition system. For the charging system, the AC current is rectified to DC and regulated to 12 Vdc for MPEM, gauges, accessories and electrical system. The MPEM lowers the voltage level to 5 Vdc for its internal circuitry and some external components (neutral switch and low-fuel warning system). For the ignition system, the AC voltage from the magneto is stepped up to 40 000 V. Keep that in mind when dealing with voltages in the electrical system.

IGNITION SYSTEM (single generator coil) IGNITION COIL AND SPARK PLUGS (with integrated ignition module) The ignition coil integrates the electronic circuitry of the CDI (ignition module). The CDI circuitry receives its primary electric current from magneto via 2 wires which charges its capacitor. The CDI circuitry controls the ignition timing and generates the spark occurrence by discharging the current stored in its capacitor to ignition coil. The primary windings of ignition coil (connected to CDI circuitry internally) receives the electrical energy from the CDI circuitry. The ignition coil jumps this voltage to a high level in secondary windings to produce a spark at spark plug.

3 1

MAGNETO SYSTEM It is the primary source of electrical energy. It transforms magnetic field into electric current through generator coil for the ignition system and through another separate 3-pole generator coil for the charging system. 1

F04H6SA

TYPICAL 1. Spark plugs 2. Ignition coil with integrated ignition module 3. Magneto system 4. MPEM (Multi-Purpose Electronic Module)

MPEM (Multi-Purpose Electronic Module) It is powered by the battery. The MPEM is the distribution center for electrical components and it includes an engine RPM limiter.

F04H0UA

TYPICAL 1. Ignition system generator coil 2. Magneto flywheel 3. Charging system generator coil

08-02-2

Section 08 ELECTRICAL Subsection 02 (OVERVIEW)

CHARGING SYSTEM

GAUGES/ACCESSORIES

It receives its primary electric current from magneto via 2 wires which charges the battery. The magneto supplies unregulated AC current to a voltage rectifier/regulator. The half-wave rectifier receives the AC current and changes it to DC current to allow battery charging. This regulated DC current then supplies the MPEM, starting system and the accessories.

The battery supplies the DC current through the MPEM to the gauges and accessories. 2 1

1 3

F09H08A

TYPICAL 1. Battery 2. MPEM (Multi-Purpose Electronic Module) 3. Accessories

F04H0WA

TYPICAL 1. Voltage rectifier/regulator 2. Battery 3. Magneto system

STARTING SYSTEM The battery supplies the DC current to the electric starter via a solenoid to start the engine.

1 3 2 F04H0XA

TYPICAL 1. Battery 2. Solenoid 3. Electric starter

08-02-3

Section 08 ELECTRICAL Subsection 02 (OVERVIEW)

787 ENGINE The electrical system consist of different subsystems where some are inter related. The magneto is coupled to the engine and produces electrical energy for the charging system. Its outputs are directed toward the charging system and some circuits through the MPEM (MultiPurpose Electronic Module). In the charging system, the battery supplies the MPEM, the starting system and the accessories. The following gives an outline of each components. There are different voltage types (AC (alternative current) and DC (direct current)) and voltage levels (0 to 40 000 Vac, 5 Vdc and 12 Vdc). There is unregulated AC from magneto for the charging system. For the charging system, the AC current is rectified to DC and regulated to 12 Vdc for the MPEM, gauges, accessories and electrical system. The MPEM lowers the voltage level to 5 Vdc for its internal circuitry and some external components (neutral switch). For the ignition system, the DC voltage from the battery is stepped up to 40 000 V. Keep that in mind when dealing with voltages in the electrical system.

MAGNETO SYSTEM It is the source of electrical energy to charge the battery and keep it at a full state of charge. It transforms magnetic field into electric current through a 3 phase, â&#x20AC;&#x153;Yâ&#x20AC;? wound stator on 18 poles.

CHARGING SYSTEM It receives its primary electric current from magneto via 3 wires which charges the battery. The magneto supplies unregulated AC current to a voltage rectifier/regulator. 1 2

F04H24A

1. Magneto system 2. Voltage rectifier/regulator 3. Battery

Rectifier/Regulator A dual 1/2 wave series rectifier/regulator receives the AC voltage and rectifies it into DC. The system is regulated to a maximum of 14.5 - 14.8 volts (DC).

Battery The battery is the DC source for the electric starter, Multi-Purpose Electronic Module (MPEM) and all accessories.

CHARGING CIRCUIT SCHEMATIC

DUAL 1/2 WAVE SERIES REGULATOR

F04H23A F01H4VA

08-02-4

BATTERY

CONTROL CIRCUIT

AC 1 (YE)

1. Charging system generator coil 2. Magneto flywheel

POSITIVE (RED)

AC 2 (YE)

GROUND (BLACK)

AC 3 (YE) ALTERNATOR 180 WATT 3-PHASE

Section 08 ELECTRICAL Subsection 02 (OVERVIEW)

IGNITION SYSTEM A Digital DC-CDI (Direct Current-Capacitor Discharge Ignition) system is utilized on the 787 engine. The ignition system is made up of the following components:

1 6 3 4

F09H07A

TYPICAL 1. Battery 2. MPEM module 3. Flywheel/rotor 4. Trigger coil 5. Ignition coil 6. Spark plugs

Multi-Purpose Electronic Module (MPEM) The MPEM has 3 micro-controllers inside of its sealed case. One is basically responsible for the DESS (Digitally Encoded Security System), interpreting information, distribution of information, and as a timed/untimed power source. The 2 others are used to manage the ignition system (one for each engine). A relay is used to prevent discharge of the battery, through the ignition system, when the craft is not running. The relay is in the MPEM. The DC-CDI system within the MPEM receives the input from the trigger coil and signals the ignition coil when to fire. It also has the RPM limiter function built into its circuitry, as well as the ignition timing curve.

Ignition Coil

Magneto Rotor/Trigger Coil The trigger coil is mounted outside the rotor (inside the magneto cover of the engine) and is not adjustable. Itâ&#x20AC;&#x2122;s purpose is to signal the DC-CDI to be conductive at the proper number of degrees before TDC (Top Dead Center). The rotor has two protrusions (180 degrees apart) that, when coupled with the trigger coil, accomplish the signaling.

The ignition coil steps up the voltage input from the DC-CDI system and the end result is firing of the spark plugs. The coil is housed in the electrical box.

STARTING SYSTEM These systems are similar to the 717 engine. Refer to the previous pages.

7 3

4 1 N A00E4JA

1. 2. 3. 4. 5. 6. 7.

1 N S

Coil Magnet Protrusion Magnetic field outside of coil Magnetic field crossing coil Current to CDI module Magneto flywheel

08-02-5

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

IGNITION SYSTEM

IGNITION SYSTEM TESTING PROCEDURE, 717 ENGINE GENERAL NOTE: On occasion a component will statically test good but in fact be defective. In this instance, removing the original part and replacing it with a known good part is the most accurate procedure. The MPEM (Multi-Purpose Electronic Module) is part of the ignition system as well as part of the electrical system. This section gives testing procedure for ignition-related problems. For other type of problems, refer to MPEM section.

CAUTION

Whenever replacing a component of ignition system, check ignition timing. Spark occurrence can be checked with a tester from Superex Canada Ltd P/N 15-785. To perform verifications, a good quality multimeter such as Fluke 73 (P/N 529 022 000) can be used. When dealing with ignition problems, the following items should be checked in this order: 1. Spark occurrence/spark plug condition. 2. Battery condition. 3. MPEM supply fuse condition. 4. Electrical connections. 5. Engine stop/safety lanyard post. 6. MPEM. 7. Magneto output. 8. Ignition coil output. The first 4 items can be checked with common automotive equipment. For item 5 and 6, refer to section 08-06 MPEM. For items 7 and 8, refer to the following procedures.

MPEM (Multi-Purpose Electronic Module) IGNITION AND RPM CONTROL PROBLEMS NOTE: There is one RPM limiter for each engine in the MPEM. A defective RPM limiter may cause the following problems: • no spark • misfiring/black fouled spark plugs • uninterrupted spark when engine stop/safety lanyard is used • incorrectly controlled engine maximum speed of 7000 RPM at forward/reverse and 3500 RPM at neutral • sudden engine stop while riding at maximum RPM To diagnose spark problems that may come from the MPEM, first check that its BLACK wire is perfectly grounded, then if there is no spark, temporarily bypass the RPM limiter by disconnecting the GREY/GREEN for starboard (RH) side and GREY for port (LH) side wire coming from engine magneto system. If everything now works normally, the RPM limiter is defective and the MPEM must be replaced. If engine does not stop when using stop/safety lanyard, ensure that GREY/GREEN and PURPLE/ GREEN wires for starboard (RH) side and GREY and PURPLE wires for port (LH) side are well-connected to MPEM. For additional testing, refer to MPEM 08-06.

Intermittent Ignition Problems In dealing with intermittent problems there is no easy diagnosis. For example, problems that occur only at normal engine operating temperature have to be tested under similar conditions. In most cases of temperature and/or vibration failure, only parts replacement can solve the problem as most of these failures return to normal when engine is not running.

08-03-1

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

Multiple Problems

There is always the possibility of more than one faulty part. If after a component has been replaced, the problem still persists, carefully repeat the complete test procedure to find the other faulty part.

Safety Precautions

â&#x2014;&#x2020;

WARNING

To prevent powerful electric shocks while cranking engine, neither touch any electronic ignition components (ignition coil, high tension wire, wire harness, etc.) nor tester lead clips. Also make sure that tester leads do not touch any metallic object. Ventilate bilge at least 5 minutes prior to performing any test.

Generating Coil Verification STATIC TEST Disconnect magneto wiring harness connector. Install the 4-pin magneto harness adapter (P/N 295 000 131).

F01B28A

TYPICAL

Check resistance with a high-sensitivity ohmmeter. Refer to the following table for values and wire colors. PART NAME

ADAPTER WIRE

RESISTANCE

Generating coil

BLACK with RED/BLACK

40-76 â&#x201E;Ś

08-03-2

F01H5WA

TYPICAL 1. Multimeter 2. Four-pin magneto harness adapter 3. RED/BLACK wire 4. BLACK wire

DYNAMIC TEST 1. Connect spark plug cables to grounding device. 2. Disconnect magneto wiring harness connector. 3. Install the 4-pin magneto harness adapter (P/N 295 000 131). 4. Connect positive test probe of the multimeter to the RED/BLACK wire of the 4-pin magneto harness adapter. 5. Connect negative test probe of the multimeter to BLACK wire of the 4-pin magneto harness adapter. 6. Set multimeter to Vac scale. 7. Crank engine and note result. The obtained value should be between 18 and 25 Vac. If the generating coil is out of specification, replace it. NOTE: If the generating coil tests good, disconnect the primary wires of the ignition coil. Crank engine and check voltage at primary wires. It should be at least 20 Vdc. If there is insufficient or no voltage, either the MPEM or wiring harness is defective.

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

Ignition Coil Verification Before conducting any testing on the ignition coil, make sure there is at least 20 Vdc at the primary wires. If there is insufficient voltage, the ignition problem is occurring before the ignition coil. STATIC TEST NOTE: An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an ohmmeter. Primary Winding Due to the integrated CDI module, it is not possible to take any resistance measurement. Secondary Winding The spark plug caps must be removed from high tension cables, because they are resistor caps. The cap resistance is 10 kΩ. 1

1. With ignition coil removed from craft, disconnect spark plug caps from high tension cables. 2. Hook high tension leads from tester to ignition coil high tension cables. 3. Connect 2 smaller tester leads to primary of ignition coil. 1

ON OFF 12 V 6V

2 F01H55A

TYPICAL 1. Leads to secondary 2. Leads to primary

4. Turn power switch to 12 volts and you should observe spark jumping at a predetermined gap of 7 to 8 mm (.276 to .311 in). If there is no spark, if it is weak or intermittent, the coil is defective and should be replaced.

A00E0QA

1. Resistor cap 2. High-tension cable

IGNITION TIMING, 717 ENGINE

IGNITION COIL PART NAME

WIRE

RESISTANCE

Secondary winding

End of each spark plug cable, spark plug caps removed

8.4 - 15.6 kΩ

NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter. DYNAMIC TEST Use an ignition coil tester, available from aftermarket tool/equipment suppliers.

◆

This section is divided in 2 main parts, the first one using a top dead center (TDC) gauge to verify PTO Flywheel Timing Mark Position. The second one using a stroboscopic timing light to check Ignition Timing. NOTE: It is mandatory to verify the timing mark on the PTO flywheel corresponding to the specific engine. Do not use the factory mark found without verification of its accuracy.

WARNING

Do NOT use coil tester on metal work bench. Follow manufacturer instructions.

08-03-3

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

CAUTION

The relation between the PTO flywheel mark position and crankshaft position may change as the PTO flywheel might tighten/loosen on the crankshaft. As an example, when the engine is accelerated out of water, PTO flywheel may tighten and then loosen when the engine is decelerated. This will result in a false ignition timing reading since the PTO flywheel has moved relatively to crankshaft. It is suggested to strongly accelerate engine in a water basin (or test run) and then slowly decelerate the engine to avoid PTO flywheel loosening. Always verify PTO flywheel mark position before checking ignition timing with an appropriate timing light. If mark does not align with tool, repeat static test to ensure flywheel has not loosen before changing the ignition timing.

F01H5SA

1. Timing mark tool (P/N 295 000 102)

Install and adjust a TDC gauge (P/N 295 000 143) in spark plug hole as follows: 1

Flywheel timing mark position verification is required to: 1. Troubleshoot a missing or broken magneto flywheel Woodruff key. 2. Troubleshoot a magneto flywheel corresponding to a different engine type. 3. Scribe the timing mark on a new service PTO flywheel. 4. Ensure that an accurate mark will be used to check ignition timing.

Verifying PTO Flywheel Timing Mark Position Disconnect MAG side spark plug wire and connect wire to grounding device then remove spark plug. Remove PTO flywheel guard. Install timing mark tool (P/N 295 000 130) on engine using wing nuts previously removed.

08-03-4

F01H5TA

TYPICAL 1. TDC gauge on MAG side

Rotate PTO flywheel counterclockwise (when facing it) until piston is just before top dead center.

70 60

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

F01H5SB

1. Tool slot 2. Flywheel mark

This mark becomes the reference when using stroboscopic timing light.

F01H4LA

TYPICAL 1. Adjust gauge dial at zero

Loosen adapter lock nut then, holding gauge with dial facing toward PTO, screw adapter in spark plug hole. Slide gauge far enough into adapter to obtain a reading then, finger tighten adapter lock nut. Rotate PTO flywheel counterclockwise until piston is at Top Dead Center. Unlock outer ring of dial and turn it until zero (0) on dial aligns with pointer. Lock outer ring in position. From this point, rotate flywheel back 1/4 turn then rotate it counterclockwise to reach 2.59 mm (.102 in). Using timing tool slot as reference mark, scribe in middle of tool slot a mark onto PTO flywheel.

CAUTION

Timing mark position verification cannot be used as a timing procedure, therefore, always check the timing with a stroboscopic timing light at 6000 RPM after the marks have been checked.

Checking Ignition Timing NOTE: To perform this procedure it is recommended to use a stroboscopic timing light rated to work up to 6000 RPM. To check ignition timing, use a timing light (P/N 529 031 900).

A00B4FA

08-03-5

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

NOTE: This timing light is battery powered (2 batteries, type C) and therefore needs no auxiliary power source.

3. Start engine and point timing light straight in line with timing tool slot. Bring engine to 6000 RPM for a brief instant.

CAUTION

Always verify timing marks with TDC gauge before checking the timing. The ignition components are affected by temperature variation, therefore, timing must be checked when engine is cold, after idling for a MAXIMUM of 20 seconds. 1. Connect an induction-type tachometer to spark plug wire. 1 F00H0IA

TYPICAL 1. Timing light straight in line with tool slot

IMPORTANT: Place shifter in forward or reverse position to allow engine reaching 6000 RPM. NOTE: On this NIPPONDENSO system, timing advance decreases as engine speed increases. When marks are aligned at 6000 RPM, spark occurrence is still Before Top Dead Center. 4. Check if PTO flywheel mark (or reference one previously scribed) aligns with timing tool slot. F06H06A

1. Tachometer pickup

2. Connect timing light pickup to MAG side spark plug lead. 1

CAUTION

If engine is to be ran more than a few seconds, connect a garden hose and supply water to the engine to properly cool it. If timing marks align, timing is correct. If mark does not align, recheck PTO flywheel mark before adjusting ignition timing to ensure PTO flywheel has not loosen.

F00H0HA

1. Timing light pick up on MAG side

08-03-6

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

IGNITION TIMING ADJUSTMENT Timing is performed by moving armature plate, clockwise to retard spark occurrence or counterclockwise to advance. 1

F01H5UA

1. Too advanced timing

In this case, turn armature plate clockwise. When PTO flywheel mark is on left side of timing tool slot, it indicates retarded timing.

A25E0RA

TYPICAL 1. To retard 2. To advance

To adjust, loosen 3 armature plate retaining screws and slightly rotate armature plate in proper direction.

1 1 1

F01H5VA

1. Retarded timing A25E0VA

TYPICAL 1. Retaining screw

When PTO flywheel mark is on right side of timing tool slot, it indicates advanced timing.

In this case, turn armature plate counterclockwise. After adjustment, tighten armature plate retaining screws.

CAUTION

Armature plate screws must have Loctite 242 (P/N 293 800 015) applied before tightening. Make sure armature plate screws are well secured. Reinstall removed parts. Recheck ignition timing (make sure engine is cold).

08-03-7

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

IGNITION SYSTEM TESTING PROCEDURE, 787 ENGINE GENERAL NOTE: On occasion a component will statically test good but in fact be defective. In this instance, removing the original part and replacing it with a known good part is the most accurate procedure. The MPEM (Multi-Purpose Electronic Module) is part of the ignition system as well as of the electrical system. This section gives testing procedure for ignition-related problems. For other type of problems, refer to MPEM section.

CAUTION

Whenever replacing a component of ignition system, check ignition timing. Spark occurrence can be checked with a tester from Superex Canada Ltd (P/N 15-785). To perform verifications, a good quality multimeter such as Fluke 73 (P/N 529 022 000) can be used. When dealing with ignition problems, the following items should be checked in this order: 1. Spark occurrence/spark plug condition. 2. Battery condition. 3. MPEM supply fuse condition. 4. Electrical connections. 5. Engine stop/safety lanyard. 6. MPEM. 7. Magneto output. 8. Ignition coil output. The first 4 items can be checked with common automotive equipment. For items 5 and 6, refer to MPEM 08-06. For items 7 and 8, refer to the following procedures.

MPEM (Multi-Purpose Electronic Module) IGNITION AND RPM CONTROL PROBLEMS NOTE: There is one RPM limiter and one ignition system circuitry for each engine in the MPEM. A defective RPM limiter may cause the following problems: • no spark • misfiring/black fouled spark plugs

08-03-8

• uninterrupted spark when engine stop/safety lanyard is used • incorrectly controlled engine maximum speed of 7200 RPM at forward/reverse and 3500 RPM at neutral • sudden engine stop while riding at maximum RPM To diagnose spark problems that may come from the MPEM, first check that its BLACK wire is perfectly grounded, then if there is no spark, temporarily bypass the RPM limiter by disconnecting the GREY/GREEN for starboard (RH) side and GREY for port (LH) side wire coming from engine magneto system. If everything now works normally, the RPM limiter is defective and the MPEM must be replaced. If engine does not stop when using stop/safety lanyard, ensure that GREY/GREEN and PURPLE/ GREEN wires for starboard (RH) side and GREY and PURPLE wires for port (LH) side are well-connected. Check the trigger coil and the ignition coil. If they test good, refer to MPEM 08-06 for additional testing.

Multiple Problems There is always the possibility of more than one faulty part. If after a component has been replaced, the problem still persists, carefully repeat the complete test procedure to find the other faulty part.

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

Safety Precautions

â&#x2014;&#x2020;

WARNING

Trigger Coil STATIC TEST: CONTINUITY Check resistance with a high-sensitivity ohmmeter. 1. Disconnect magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136).

F01B28A

3. Connect one of the multimeter leads to the WHITE wire of the 6-pin magneto harness adapter. 4. Connect the other multimeter lead to the BLACK/ YELLOW wire of the 6-pin magneto harness adapter. 5. Measure resistance; it should be between 190300 ohms.

F01H5YA

TYPICAL 1. Multimeter 2. 6-pin magneto harness adapter 3. WHITE wire 4. BLACK/YELLOW wire

DYNAMIC TEST 1. Disconnect magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Connect one of the multimeter leads to the WHITE wire of the 6-pin magneto harness adapter. 4. Connect the other multimeter lead to the BLACK/ YELLOW wire of the 6-pin magneto harness adapter. 5. Crank engine and note result. The obtained value should be between 0.2 and 0.5 Vac. 6. If the trigger coil is out of specification, replace it.

Ignition Coil Before conducting any testing on the ignition coil, make sure there is at least 20 Vdc at the primary wires. If there is insufficient voltage, the ignition problem is occurring before the ignition coil. STATIC TEST: CONTINUITY NOTE: An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an ohmmeter.

08-03-9

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

Primary Winding 1. Remove the 2 female spade connectors from the primary side of the ignition coil. 2. With the multimeter set on the resistance scale, connect the meter leads to the primary terminals of the coil. 3. Resistance should be approximately .6 Ω. Secondary Winding The spark plug caps must be removed from high tension cables, because they are resistor caps. The cap resistance is 10 kΩ. 1

ON OFF 12 V 6V

2 F01H55A

TYPICAL 1. Leads to secondary 2. Leads to primary

A00E0QA

1. Resistor cap 2. High-tension cable

IGNITION TIMING, 787 ENGINE

IGNITION COIL PART NAME

WIRE

RESISTANCE

End of each Secondary spark plug cable, winding spark plug caps (all other models) removed

8.4 - 15.6 kΩ

NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter. DYNAMIC TEST Use an ignition coil tester, available from aftermarket tool/equipment suppliers.

CAUTION

Do NOT use coil tester on metal work bench. Follow manufacturer instructions. 1. With ignition coil removed from craft, disconnect spark plug caps from high tension cables. 2. Hook high tension leads from tester to ignition coil high tension cables. 3. Connect 2 smaller tester leads to primary of ignition coil.

08-03-10

Overview Normally ignition timing adjustment should not be required. It has been set at factory and it should remain correctly adjusted since every part is fixed and is not adjustable. The only time the ignition timing might have to be changed would be when replacing the crankshaft, the magneto flywheel, the trigger coil or the MPEM. If the ignition timing is found incorrect, you should first check for proper crankshaft alignment. This might be the indication of a twisted crankshaft. With this CDI system, the ignition timing can be checked with the engine either hot or cold. Besides the ignition timing is to be checked at 3500 RPM with the timing light. Within 3000 and 4000 RPM, the spark advance does not change. So when checking timing at 3500 RPM, a change in engine speed within ± 500 RPM will not affect the timing mark when checked with the timing light.

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

Ignition Timing Procedure Before checking ignition timing with a stroboscopic timing light (dynamic test), it is mandatory to scribe a timing mark on the PTO flywheel (static test) corresponding to the specific engine. Also, the timing mark scribed on the PTO flywheel can be used to: 1. Troubleshoot a missing or broken magneto flywheel Woodruff key. 2. Troubleshoot a magneto flywheel corresponding to a different engine type. 3. Scribe the timing mark on a new service PTO flywheel. 4. Ensure that an accurate mark will be used to check ignition timing. NOTE: Do not use the factory mark found on the PTO flywheel to check ignition timing or troubleshoot any problems.

F01H54A

1. Timing mark pointer tool (P/N 295 000 135)

CAUTION

F06H05A

1. Timing mark pointer tool (P/N 295 000 135)

2. Install a TDC gauge in MAG side spark plug hole. 1

STATIC TEST 1. To install the timing mark pointer tool, first remove PTO flywheel guard. Then remove middle screw securing the engine to the rear crossover motor mount. Reinstall screw with timing mark pointer tool attached.

F01H5TA

TYPICAL 1. TDC gauge on MAG side 08-03-11

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

3. Rotate PTO flywheel until piston is at top dead center.

1. Connect an induction-type tachometer (P/N 295 000 100) to spark plug wire.

70 60

F06H06A

1. Tachometer pick-up

2. Check ignition timing using the stroboscopic timing light connected to the MAG side spark plug cable. F01H4LA

TYPICAL 1. Adjust gauge dial at zero

4. From this point, rotate flywheel clockwise (when facing it) until piston is at 3.38 mm (.133 in) before top dead center. 5. Scribe a mark on PTO flywheel aligned with timing mark pointer tool. 6. Remove TDC gauge, reinstall spark plug and connect wire. DYNAMIC TEST To check ignition timing, use a timing light (P/N 529 031 900).

F00H0HA

1. Timing light pick-up

3. Rev the engine to 3500 RPM and point beam of timing light straight in line with timing mark pointer.

CAUTION

If engine is to be ran more than a few seconds, connect a garden hose and supply water to the engine to properly cool it. A00B4FA

08-03-12

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

NOTE: If mark on PTO flywheel is perfectly aligned with timing mark pointer, no adjustment is required. If mark does not align with pointer, recheck PTO flywheel mark before adjusting ignition timing to ensure PTO flywheel has not loosen.

Ignition Timing Adjustment Since the trigger coil on this engine is fixed and not movable to correct the ignition timing, the MPEM programmer (P/N 529 035 589) is now used to set the timing when an adjustment is required. The programmer will act as if you were moving the trigger coil to advance or retard the ignition timing. Through the MPEM programmer, the ignition timing can be advanced up to 3° or retarded up to 4°. If the timing is too retarded, a performance decrease of the engine will be noticed. If the timing is too advanced, serious engine damage will occur.

CAUTION

The Timing Correction Chart The timing marks refer to the physical component position when the spark must occur. The DC-CDI system must be synchronized with these marks. The timing correction does just that. For instance, on a particular engine, the timing correction may need to be advanced to 2° so that the marks align. This is not the real spark advance, just a correction for the tolerances of the mechanical components. A timing light is used to check the marks alignment. If the marks are found aligned, the ignition timing is correct and no further action is required. If the marks are found misaligned, the ignition timing must be corrected. When using the programmer, it will give you the actual correction number that is programmed inside the MPEM. Referring to the chart below, find the corresponding degree and if the correction was made to advance or retard the timing. Knowing that, you select the higher or lower number to advance or retard the actual timing correction by referring to the chart.

If the ignition timing is too advanced, this will cause serious damage to the engine. TIMING CORRECTION CHART

ADVANCED

RETARDED

Number from the programmer (read from MPEM)

Correction of ignition timing in degrees

3°

2°

1°

- 1°

- 2°

- 3°

- 4°

Simply put, you just have to change the number the programmer gave to have the timing marks aligned. If the flywheel mark goes in the bad direction after you tried the next value given by the programmer, try the other value to move the mark in the opposite direction. E.g.: the programmer gave no. 3. You tried no. 4 and the flywheel mark moved in the wrong direction, try no. 2.

08-03-13

Section 08 ELECTRICAL Subsection 03 (IGNITION SYSTEM)

Examples: a. You found the flywheel mark advanced. You must retard the timing. – The programmer gives you number 3. Referring to the chart, number 3 returns 2°. The timing correction is actually set at 2° (advanced) and this is too much. – You estimate the correction should be set to 1° (advanced) to retard flywheel mark so that the timing marks align. Back in the chart, look to find 1° (advanced). This gives number 4. Enter this number with the programmer. – You recheck the marks with the timing light and they are now aligned. The adjustment is finished. b. You found the flywheel mark advanced. You must retard the timing. – The programmer gives you number 3. Referring to the chart, number 3 returns 2°. The timing correction is actually set at 2° (advanced) and this is too much. – You estimate the correction should be set to 1° (advanced) to retard flywheel mark so that the timing marks align. Back in the chart, look to find 1° (advanced). This gives number 4. Enter this number with the programmer. – You recheck the marks with the timing light and found that the flywheel mark is still too advanced. You know now that the correction made previously was not enough and you estimate the correction should be set to 2° (retarded) to retard flywheel mark more. Back in the chart, look to find 2° (retarded). This gives number 6. Enter this number with the programmer. – You recheck the marks with the timing light and they are now aligned. The adjustment is finished. c. You found the flywheel mark retarded. You must advance the timing. – The programmer gives you number 4. Referring to the chart, number 4 returns 1°. The timing correction is actually set at 1° (advanced) and this is too much. – You estimate the correction should be set to 2° (advanced) to advance flywheel mark so that the timing marks align. Back in the chart, look to find 2° (advanced). This gives number 3. Enter this number with the programmer.

08-03-14

– You recheck the marks with the timing light and they are now aligned. The adjustment is finished.

Adjusting the Ignition Timing with the Programmer 1. Connect the communication cable to the MPEM programmer and the other end to the safety lanyard post on the craft. 2. Press the ON/C button on programmer and enter you password. 3. Press 3 to choose Vehicle info in programmer. 4. Press 4 to choose Engine param. 5. Press 2 to choose Timing adjust. 6. The programmer display a number that is actually stored in the MPEM. NOTE: The first number displayed is for the starboard engine (although “starboard” is not displayed). The port engine will follow when finished with the starboard engine. 7. Press ↔ to choose yes for modify then press Enter. 8. Now punch in the number that corresponds to the degree you want for the ignition timing then press Enter. 9. Press Menu to go back one level. 10. Press 8 to choose Save + Quit (even if item no. 8 is not visible on the display, it is active when you select it). 11. Press Enter to confirm yes you want to save modifications to the MPEM. 12. You must see Operation successful. This confirms that the new timing has been stored in the MPEM. 13. Unplug communication cable from safety lanyard post on craft. At this point, you can install the craft safety lanyard and start the engine to check the effect of the correction on the timing marks. If further adjustment is required, repeat the procedure. 14. Press Off to turn off the programmer. NOTE: The MPEM module features a permanent (non-volatile) memory and keeps the ignition timing programmed even when the craft battery is disconnected.

Section 08 ELECTRICAL Subsection 04 (SPARK PLUGS)

SPARK PLUGS

NGK SPARK PLUG SYMBOL EXPLANATION WIDE GAP

SUFFIX

PREFIX

B R 8 E S Thread diameter

A: B: C: D: E: J:

18 mm

12 mm x 19 mm Reach

Construction

Compact Type

Projected Insulator Type

R: U: Z:

Resistor Type

19 mm (3/4")

Special Design

Taper Seat

Single Ground Special Alloy

12.7 mm (1/2")

Dual Ground Special Alloy

11.2 mm (7/16")

Racing Type

21 mm (53/54")

Hot

GV:

Blank 8

18 mm ø 12 mm (31/64")

14 mm ø 9.5 mm (3/8")

Surface Discharge Inductive Suppressor Type

Firing end construction

Reach

12 mm 8 mm

Heat rating numbers

14 mm 10 mm

10: 1.0 mm (.040") 11: 1.1 mm (.044") 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080")

Racing Version of V-Type

Half Heat Range

Standard Center Electrode

Fine Wire Center Electrode

Booster Gap

V-Grooved Center Electrode

Cold

F00H16S

CROSSCUTS AND GAP STYLES OF SPARK PLUGS

A01E1PS

Standard Type

Projected Insulator Type

Taper Seat Type

V-Type

Surface Discharge Type

08-04-1

Section 08 ELECTRICAL Subsection 04 (SPARK PLUGS)

DISASSEMBLY First unscrew the spark plug one turn. Clean the spark plug and cylinder head with pressurized air then completely unscrew.

HEAT RANGE The proper heat range of the spark plugs is determined by the spark plugs ability to dissipate the heat generated by combustion. The longer the heat path between the electrode tip to the plug shell, the hotter the spark plug operating temperature will be and inversely, the shorter the heat path, the colder the operating temperature will be. A “cold” type plug has a relatively short insulator nose and transfers heat very rapidly into the cylinder head. Such a plug is used in heavy duty or continuous high speed operation to avoid overheating. The “hot” type plug has a longer insulator nose and transfers heat more slowly away from its firing end. It runs hotter and burns off combustion deposits which might tend to foul the plug during prolonged idle or low speed operation.

A too “hot” plug will result in overheating preignition, etc. A too “cold” plug will result in fouling (shorting the spark plug) or may create carbon build up which can heat up red-hot and cause pre-ignition or detonation.

FOULING Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible causes are: prolonged idling, or running on a too rich mixture due to a faulty carburetor adjustment or incorrect fuel. The plug face of a fouled spark plug has either a dry coating of soot or an oily, glossy coating given by an excess either of oil or of oil with soot. Such coatings form a conductive connection between the center electrode and ground.

SPARK PLUG ANALYSIS

A00E0AA

1. Overheated (light grey) 2. Normal (brownish) 3. Fouled (black)

The plug face (and piston dome) reveals the condition of the engine, operating condition, method of driving and fuel mixture. For this reason it is advisable to inspect the spark plug at regular intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber) and the piston dome.

A00E09A

1. Cold 2. Hot

CAUTION

Severe engine damage might occur if a wrong heat range plug is used.

08-04-2

Section 08 ELECTRICAL Subsection 04 (SPARK PLUGS)

SPARK PLUG INSTALLATION Prior to installation make sure that contact surfaces of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap according to the following chart. 2. Apply anti-seize lubricant over the spark plug threads to prevent possible seizure. 3. Hand screw spark plug into cylinder head and tighten with a torque wrench and a proper socket. 1

A00E0BA

1. Proper socket 2. Improper socket

SPARK PLUG CHART ENGINE TYPE

SPARK PLUGS

All

NGK BR8ES

TORQUE GAP N•m (lbf•ft) mm (inch) 24 (17)

0.55 (.022)

08-04-3

Subsection 05

Section 08 ELECTRICAL (THE DESS (DIGITALLY ENCODED SECURITY SYSTEM))

THE DESS (DIGITALLY ENCODED SECURITY SYSTEM) PROGRAMMING OF SAFETY LANYARD(S) You must use the MPEM programmer (P/N 529 035 502). Refer to its guide for proper use.

FEATURES OF THE DESS The DESS comprises the MPEM (Multi-Purpose Electronic Module) purposely designed for, a DESS post and a cap that contains both a magnet and a ROM chip. This system allows an anti-start protection against unauthorized use of the boat. The DESS safety lanyard cap specifically contains an electronic circuit that gives it a unique digital serial number so no other lanyard can be used (unless otherwise programmed). Other type of non DESS safety lanyard will not work on a DESS system. At least one safety lanyard must be programmed to operate a boat. At this point, only this lanyard allows starting the engine(s) on this particular boat which has been programmed to recognize only this safety lanyard. This safety lanyard cannot be used on another boat and conversely, the one from another boat cannot be used on your boat unless otherwise programmed as explained below. NOTE: Technically, the boat MPEM is the component that is actually programmed to recognize a safety lanyard. The MPEM stores the digital serial number from the safety lanyard cap in its memory. However, for the sake of clarity, we will refer to â&#x20AC;&#x153;safety lanyard programmingâ&#x20AC;? in the following technical discussions. The DESS brings a great flexibility. You can sell additional lanyard(s) and program it (them) to a boat so that more than one lanyard can be usable on a particular boat. Up to 8 safety lanyards can be programmed to a boat. The same lanyard cannot be programmed twice on a particular boat.

All of these lanyards can be programmed to a boat during the same programming session or thereafter if desired. The safety lanyards cumulate up to 8 in the MPEM memory of the boat. If you add safety lanyard(s) and reach the 9th lanyard you will have the choice to keep the previous 8 lanyards or restart from the 1st and thus erasing all previous lanyards. NOTE: If a customer sells his boat, you can permanently erase all lanyards that were programmed for the boat and program a new one for the new customer (remember at least one lanyard MUST be programmed in the boat MPEM). Or, reprogram only the lanyards that the new customer wants. You can program a lanyard to operate other boats (if equipped with the DESS). The same safety lanyard can be programmed to as many boats as desired. Lanyard(s) programmed for other boats (if equipped with the DESS) can be used on your own boat when programmed for. When buying a new safety lanyard for the DESS from the factory, it can be used on any boat equipped with the DESS. At this point, it is only physically interchangeable and it will not allow engine starting unless programmed for. After it has been programmed to a boat, the lanyard will be the only one that allows engine starting (unless otherwise programmed as explained above). The boat MPEM features a permanent (non-volatile) memory and keeps programmed safety lanyard(s) active even when the boat battery is disconnected. When replacing an MPEM, reprogramming safety lanyard(s) is required.

MONITORING SYSTEM To assist you when using the boat, a system monitors the DESS and sends audible signals through a beeper to warn you of a particular condition. Refer to MPEM 08-06 (Multi-Purpose Electronic Module).

08-05-1

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

MPEM (MULTI-PURPOSE ELECTRONIC MODULE) 0 Electrical circuits on this boat are controlled by the MPEM. If one of these features does not work, refer to MPEM Tests section.

MPEM OPERATION Automatic Power Shut-Down

Gauge Current Supply

The MPEM is equipped with an automatic power shut-down. This feature prevents the battery from losing its charge if the safety lanyard is left on the DESS post when the engines are not running. For one of the following conditions, the MPEM remains in standby mode during the next 10 minutes, waiting for a starting. If any start/stop button is not depressed, then the MPEM will be automatically powered down. • When safety lanyard is removed from DESS post. • When engine are stopped. The standby mode allows instantaneous starting.

The purpose of this function is to allow fuel level reading without the engine running. Gauges are supplied with current for 33 seconds when inserting the safety lanyard on the DESS post or when pressing any start/stop switch without the safety lanyard on the DESS post. When the MPEM automatic power shut-down is activated, gauges are also supplied with current for 33 seconds when moving the shift lever.

Antistart Feature When inserting a safety lanyard on the DESS post, the MPEM comes on and indicates whether it is the right safety lanyard or not with the following audible signals: – 2 short beeps indicate a right safety lanyard is being used and gauges are supplied with current for 33 seconds. The MPEM will thus allow the engines to start. – 1 long beep indicates a wrong safety lanyard is being used or that the antistart feature is defective. Current to gauges is cut after the audible signal is emitted and the engines cannot be started. A wrong safety lanyard is a safety lanyard which is defective or not programmed in the MPEM memory. To better understand the antistart feature, refer to DESS (DIGITALLY ENCODED SECURITY SYSTEM) 08-05. If the MPEM responds differently from what is mentioned above, refer to the troubleshooting section to find out why.

Engine Starting If the MPEM recognizes a valid safety lanyard, it allows both engines to start when the start/stop switches pressed and the shifter is in neutral position. MPEM prevents both engines from starting at the same time. If the safety lanyard is left on the DESS post for more than 10 minutes after stopping both engines (automatic power shut-down), the MPEM may send out 1 long beep when pressing the start/stop switch. The gauges current supply will not be stopped as explained in the Antistart Feature section. A light pressure on the safety lanyard is required to allow the MPEM to read and validate the safety lanyard, the engines can then be started. If button is held, the MPEM automatically stops the starter when the engine speed reaches 1000 RPM.

Neutral Switch The engines cannot be started if the shifter lever is not in neutral. In this case, the MPEM sends out an audible signal of 4 short beeps when pressing any start/stop switch. The MPEM will send out a short beep to confirm when the shifter lever is in neutral.

08-06-1

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

This condition is canceled when any engine is running or after the 10 minutes automatic power shut-down.

RPM Limiter The MPEM allows for a maximum engine RPM of 3500 when the shifter is in neutral position. When the shifter is in forward/reverse gear, the maximum RPM is 7000 RPM for 717 engine and 7200 for 787 engine. There is a RPM limiter for each engine in the MPEM.

Engine Stopping There are 2 ways to stop the engines. Press both start/stop switches or remove the safety lanyard from the DESS post. It is not necessary to hold button to stop engines. In both cases, the gauges current supply is cut about 6 seconds after the engines are completely stopped. This delay allows the tachometer needles to go back to zero (0). If the engines are stopped by removing the safety lanyard, it is possible to restart the engines as explained in the engine starting section. If safety lanyard is inserted again within 6 seconds, the current supply to gauges is cut for a brief moment and comes back on with the audible signal of safety lanyard validation.

Bilge Pump Control Automatic Mode When water level reaches water sensor during at least 10 seconds, the MPEM starts the bilge pump. It will be running during at least 25 seconds. Then, if water level doesn't reach sensor lever anymore, the MPEM will stop bilge pump. The 10 seconds delay prevents an abusive use of the bilge pump. Manual Mode Using the bilge pump manual switch overrides the MPEM automatic mode circuitry.

08-06-2

Low-Fuel Level Warning Device This electronic system operates as follows: When the fuel level in the reservoir is low, the fuel level sensor transmits a signal to the MPEM. The MPEM sends out signals for the beeper and the low fuel level switch pilot lamp. These two signals are synchronized. When the operator acknowledges theses signals, he presses the low fuel level switch. The audible signal ceases and the pilot lamp stops blinking. However, the pilot lamp will stay on until the engines are stopped.

Power Distribution The MPEM distributes power from battery to all accessories. Accessories are protected by 2 fuses blocks integrated in the MPEM. For fuse identification, refer to MPEM TESTS farther in this section and look for Identification of Fuse Blocks on MPEM.

Overheat Sensor When the temperature of any engine reaches a threshold value, the MPEM triggers a continuous beep to indicate overheating.

Diagnostic Mode In order to facilitate the use of the boat, a system controls the digitally encoded security system and sends, through a buzzer, some audible signals informing the operator of a specific situation. The diagnostic mode is divided into 2 parts: the basic mode and the advanced mode. The basic mode is automatically activated when connecting the safety lanyard to the boat DESS post and allows for immediate control. Some codes can only appear when pressing any start/stop switch. Refer to the following charts.

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Basic Diagnostic Mode BASIC DIAGNOSTIC MODE NUMBER OF BEEPS

CAUSE

REMEDY

2 shorts (while installing safety lanyard on boat DESS post)

• Everything is correct with the safety lanyard (good contact and right lanyard cap).

• Engine can be started normally.

1 long (while installing safety lanyard on boat DESS post or when pressing start/stop button in some cases)

• Bad connection between safety lanyard cap and DESS post.

• Lightly press on cap until 2 shorts beeps are heard to indicate the system is ready to allow engine starting.

• Wrong safety lanyard.

• Use the safety lanyard that has been programmed for the boat. If it does not work, check safety lanyard condition with the MPEM programmer. Replace safety lanyard if reported defective. If it still does not work, enable the advanced diagnostic mode to obtain more detail about the failure.

• Dried salt water, dirt or oil in safety lanyard cap.

• Shake/rinse/clean safety lanyard cap to remove dried salt water, dirt or oil.

CAUTION

Never lubricate the DESS post and cap contacts. This would allow bad contacts and lead to a wrong reading of safety lanyard. • Improper operation of MPEM or defective wiring harness.

• Enable advanced diagnostic mode to obtain more detail about the failure.

4 shorts (while pressing start/stop button with safety lanyard already installed)

• Shifter is NOT in neutral.

• Place shifter in neutral. While moving the shifter, 1 short beep indicates you reached the neutral position.

1 short (while moving shifter to neutral)

• Confirmation that shifter is now in neutral.

• Engine is now ready to be started.

8 shorts

• Defective MPEM (memory).

• Replace MPEM.

Continuous

• Engine overheating.

• Check connections and engine overheat sensor. If everything is correct, troubleshoot engine.

NOTE: It is possible to obtain more information about these codes by referring to Advanced Diagnostic Mode on following page.

08-06-3

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Advanced Diagnostic Mode This mode must be manually activated. Proceed as explained below: 1. Remove safety lanyard from boat DESS post and set shifter in NEUTRAL. 2. Press 5 times any boat starting button. • 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3. Install safety lanyard on boat DESS post. 4. Press any boat starting button again. • If everything is correct, engine will start. Otherwise, refer to the following chart. ADVANCED DIAGNOSTIC MODE NUMBER OF BEEPS

CAUSE

REMEDY

No beep

• Engine actually starts.

• Everything is correct.

1 long and 1 short

• No safety lanyard has ever been programmed in boat MPEM.

• Use programmer and program a safety lanyard. This code can occur only when you receive a new MPEM from the factory and no safety lanyard has ever been programmed.

2 shorts

• MPEM cannot read the electronic circuit in safety lanyard or the magnet is defective in safety lanyard.

• Check safety lanyard condition with the MPEM programmer. Replace safety lanyard if reported defective.

• Mixed wires at switch connectors or wrong connections.

• Check DESS post wiring harness.

2 longs

• Wrong safety lanyard or wrong connection of the DESS wires.

3 shorts

• Wiring harness of DESS post is grounded or there is a short circuit.

• Check wiring harness and DESS post.

NOTES: • If you need to listen again the coded beeps, remove safety lanyard and repeat the procedure to activate the diagnostic mode. • If many problems are encountered, the MPEM will send only one error code. When the problem is solved, the MPEM will send a second code and so on until there is no problem.

08-06-4

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

MPEM TESTS GENERAL The following gives general electrical-related problems. For ignition problems, refer to IGNITION SYSTEM 08-03. To ease working, the engine compartment cover may be removed. Always use resistor type spark plugs, original cables and spark plug caps otherwise RFI (Radio Frequency Interference) might affect MPEM operation. It is possible that a component seems to operate in static condition but in fact, it is defective. In this case, the best way to solve this problem is to remove the original part and replace it with one which is in good condition. It is recommended to always disconnect the battery when replacing the MPEM. Turn off the main battery cut-off switch. References for wire and connector numbers and for pin position in connectors mentioned in this section come from wiring diagram. Refer to WIRING DIAGRAMS, section 13.

Wire Green Tracer In the electrical system, the same wire colors are basically used for starboard (RH) and port (LH) sides. To differentiate sides, the starboard (RH) side wires have an additional GREEN tracer on the main wiring harness and on the MPEM. IMPORTANT: When having to solve an electrical problem, the first thing to do is to check battery condition as well as its cables and connections. Never use a battery charger to replace temporarily the battery, as it may cause the MPEM to work erratically or not to work at all. Also ensure the main battery cut-off switch is ON. Check main fuses (close to battery) and MPEM fuses condition and solidity and visually examine harness and connections. Pay particular attention to ensure that pins are not out of their connectors or out of shape. The following troubleshooting procedure covers problems not resulting from one of these causes.

Before replacing a MPEM, always check electrical connections. Make sure that these are very tight and they make good contact and that they are corrosionfree. A “defective module” can be repaired simply by unplugging and replugging the MPEM. The voltage and current might be too weak to go through dirty wire pins. Check carefully if posts show signs of moisture, corrosion or if they look dull. Clean pins properly and then coat them with silicon-based dielectric grease when reassembling them. Pay attention to grounding paths. The electrical system features grounding blocks connected in series to the battery negative post. Also pay attention to lighting paths. There is a similar series arrangement for gauges and switches lighting. See Grounding Blocks and Lighting Blocks Arrangement farther.

How to Measure Continuity of Long Wires In order to measure the continuity of long wires, for example, between the MPEM connectors and the connectors in front storage compartment, ohmmeter wires are not long enough to meet both ends of the wire to be checked. Proceed as follows: Make sure to isolate circuit wires by unplugging connectors. Use a larger gauge wire (14 or 12 so as not to increase resistance of wires to be checked). Connect one end of this wire to wire to be checked using a jumper wire or an adequate pin. Bring other end close to location where ohmmeter reading will be taken. The resistance should not exceed 0.1 Ω.

08-06-5

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

WIRE TERMINAL REMOVAL To remove terminal from Packard connector housing, use Snap-on TT600-4 tool. 1

F01B1JA

;

WARNING

Ensure all terminals are properly crimped on wires and connector housings are properly fastened.

AMP CONNECTORS (26 PINS)

F04H44A

TYPICAL 1. Jumper wire coming from other end of wire to be checked 2. Connect one ohmmeter probe to end of jumper wire 3. Connect other ohmmeter probe to end of wire to be checked

When servicing electrical system, special care must be taken when working with AMP plug connectors in order to prevent any malfunction of the system.

Identification Parts 5

Checking for Shorts Between 2 Wires When checking continuity of a wire in a circuit, wires should be checked for short circuit as follows. Make sure to isolate circuit wires by unplugging connectors. Letâ&#x20AC;&#x2122;s suppose that the circuit to be checked has a RED and a BLACK wire. Using an ohmmeter, measure the resistance between the RED and the BLACK wire. The resistance should be infinite (0 L). Otherwise, there is a short circuit between both wires. We must therefore identify and correct the fault.

9 1 2

F00H0WA

1. 2. 3. 4. 5. 6. 7. 8. 9. 08-06-6

Plug assembly Cover assembly Mating seal Wedge lock Header assembly Seal plug Power wire Signal wire Locking tabs

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Connectors Each connector is identified by a unique number from 1 to 3, number 1 being the right most connector. The number is found on the MPEM close to the connector. 2

2 1

1 F04H6CA

TYPICAL 1. AMP connectors 2. Identification numbers

Each plug assembly is mechanically keyed to mate only with identical mechanical keyed header on the MPEM.

F00H12A

TYPICAL 1. Mechanically keyed

To remove plug connector from the header assembly on the MPEM, press both tabs and pull plug.

Wire Selection and Preparation The size of the wires must be 20 to 16 AWG with a wire insulation diameter having a minimum dimension of 1.7 mm (0.067 in) and a maximum dimension of 2.78 mm (0.106 in). The wire strip length shall be 5.1 mm (13/64 in). NOTE: When stripping wires, ensure conductor is not nicked, scrapped or cut. Wire stripping tool jaws may leave marks on the surface of the wire insulation. If these marks occur at the location of the wire seal, leakage may result. Insulation surface within 25 mm (1 in) from the tip of the contact must be smooth.

08-06-7

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Contact Crimping

All contacts in AMP plug connectors must be crimped using the crimping tool (P/N 295 100 164).

CAUTION

If contacts are not crimped using the proper crimping tool, the wire seal may be damaged.

F00H10A

1. Seal plug 2. Wire seal

F00B0EA

CRIMPING TOOL (P/N 295 100 164)

All circuits are sealed by a diaphragm in the rubber wire seal. When installing wire contacts in plug connector, the diaphragm is pierced as the contact passes through it. If the diaphragm is pierced and the cavity is not used, install a seal plug, large end first, into circuit cavity as far as it will go. NOTE: It is suggested that all unused circuit cavities be sealed with a seal plug, even if they are not pierced.

CAUTION

Do not pierce the diaphragm with a sharp point for electrical troubleshooting. The resulting pin holes in the insulation will allow moisture to penetrate the system and possibly result in system failure.

Contact Removal Signal Contact Insert a screwdriver blade between the mating seal and the wedge lock tab. Release the plug locking tab and at the same time, pry open the wedge lock to the open position.

CAUTION

The wedge lock should never be removed from the housing for insertion or removal of the signal wire contacts.

08-06-8

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

1 2

F00H0OB

1. Wedge lock 2. Locking tab

F00H0QA

1. Rotate wire back and forth 2. Pull wire

Power Contact NOTE: The wedge lock must be removed to extract power contact. Pull both locking tabs and remove wedge lock from plug assembly. 1

F00H0PA

1. Wedge lock in open position

While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.

F00H0RA

1. Pull locking tab (both sides)

Before extraction, push wire forward to relieve pressure on retaining tab. Insert a 4.8 mm (0.189 in) wide screwdriver blade inside the front of the contact cavity.

08-06-9

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

1 F00H11A

TYPICAL 1. Apply a thin coat of DEOXIT D5 contact lubricant

F00H0ZA

Pry back the retaining tab while gently pulling wire back until contact is removed.

Contact Installation For insertion of signal contact, make sure the wedge lock is in the open position. NOTE: For insertion of power contact, the wedge lock may or may not be on the open position. Insert contact into appropriate circuit cavity and push as far as it will go. Pull back on the contact wire to be sure the retention fingers are holding the contact. After all required contacts have been inserted, the wedge lock must be closed to its locked position.

CAUTION

Do not apply lubricant excessively. Care must be taken so that the lubricant will not come in contact with the mating seal; the seal may loose its sealing capacities. Do not apply lubricant on contacts inside plug connector.

IDENTIFICATION OF FUSE BLOCKS ON MPEM Each fuse block is identified by a unique number from 1 to 2, number 1 being the topmost. The number is found on the MPEM close to the fuse block. 2

CAUTION

Never apply dielectric grease on contacts in plug connector. The use of dielectric grease will create hydrolock and poor sealing. Apply a thin coat of DEOXIT D5 contact lubricant (P/N 293 550 015) to the pins of the header on the MPEM only.

F04H6DA

TYPICAL 1. Fuse blocks 2. Identification numbers

08-06-10

Subsection 06

Speedster SK Model

F04H64A

Speedster Model

FUSE IDENTIFICATION IN TOP FUSE BLOCK 1. MPEM supply 2. Gauges supply 3. Bilge pump

F10H03A

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

F10H02A

FUSE IDENTIFICATION IN TOP FUSE BLOCK 1. MPEM supply 2. Gauges supply 3. Ignition system 4. Bilge pump

6 F10H03A

FUSE IDENTIFICATION IN BOTTOM FUSE BLOCK 1. Bilge air blower 2. Additional accessories 3. Navigation light 4. Radio 5. Horn and courtesy lights 6. 12-volt accessory jack

FUSE IDENTIFICATION IN BOTTOM FUSE BLOCK 1. Bilge air blower 2. Horn and courtesy lights 3. Additional accessories 4. 12-volt accessory jack 5. Navigation light 6. Radio

08-06-11

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

IDENTIFICATION OF CONNECTOR PINS

AMP Connector of Fuel Gauge

AMP Connectors of MPEM

F04H6EA

AMP Connector of Radio

F04H6RA

AMP Connectors of Wiring Harness

F10H07A

Deutsch Connectors of Engine and Electrical Box 9

1 F04H6GA

F04H6LA

4-PIN CONNECTOR 1. Wires identification numbers

08-06-12

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

F04H6KA

6-PIN CONNECTOR 1. Wires identification numbers

F10H06A

Carlington Connectors of Accessory Switches

SIDE VIEW SHOWING IDENTIFICATION NUMBERS 1. Wires identification numbers

Packard Connectors at Various Locations (2, 3 and 6-pin connector)

1 1

F10H05A

F04H45A

VIEW OF A 3-POSITION CONNECTOR 1. Connector identification letters

08-06-13

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Grounding Blocks and Lighting Blocks Arrangement The grounds for the accessories are grouped in connectors called grounding blocks. They are distributed at different locations (see chart of Connector Location in WIRING DIAGRAM section). Each block is a 6-pin connector enclosing a strip that makes contact between each wires in the connector. Each block is connected to the sacrificial aluminum anode which protect wiring and metal parts against corrosion. To ease troubleshooting, each block is also numbered.

The gauge lights are powered through the lighting block. The lighting block is powered by an additional block (connected in series) that powers the switch lights. They use the same parts as the grounding blocks. When troubleshooting, visually check condition of strip and terminals for corrosion/oxidation. Test continuity between all wires in connector with an ohmmeter. Each wire brings a printed identification number which corresponds to the number shown on the wiring diagram (ex: W127). When checking a ground for an accessory, it is important to know that the only grounding block that connects to the battery negative post is the no. 1. The others grounding blocks connect in series with each other. For this reason, each grounding block in a series arrangement must be checked individually for continuity and the continuity between each grounding block up to the battery ground must be checked according to the circuit arrangement. The following illustrations show a typical arrangement of grounding lighting blocks through the battery ground. For more information refer to the wiring diagram.

F04H6HA

Grounding block # 5

Grounding block # 4

Grounding block # 7

Grounding block # 2

GROUNDING/LIGHTING BLOCKS

Grounding block # 1

F04H6TA

Battery

TYPICAL â&#x20AC;&#x201D; GROUNDING BLOCKS

F04H6IA

1. Strip that makes contact between wires in connector

08-06-14

Sacrificial Anode

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

NAV/ANC switch

Lighting block

Lighting block To stern light

Bilge pump switch light

Speedometer light

Blower switch light Fuel/oil gauge light Horn switch light Tachometer(s) light

Courtesy light switch light F09H09S

TYPICAL â&#x20AC;&#x201D; LIGHTING BLOCK

NAV/ANC Light, Pump, Blower, Horn, Deck Light and Low-Fuel Warning Switches

MPEM CIRCUIT VERIFICATION NOTE: Some verifications concern accessories which can be optional.

;

WARNING

Fuel or electrolyte vapors might be present in the bilge and a spark would then cause an explosion. Ventilate the bilge to evacuate vapors before performing electrical testing. If a fuel odor persists, pressurize the fuel system and correct the problem before proceeding.

1 F09H0CA

TYPICAL VIEW OF A SWITCH 1. Switch identification numbers

Conventions in this Section The italicized bold references preceded by a C (ex: C-101 ) refer to connector numbers as found on the wiring diagrams. The ones preceded by a W (ex: W-48 ) refer to wire numbers. 08-06-15

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

MPEM Supply

Automatic Power Shut-Down

The MPEM is supplied by three 20 A fuses located close to battery. If no accessory or if MPEM is not working, first check these fuses. Ensure the main battery cut-off switch is turned ON. If main fuses are in good condition, disconnect connector (C-101 and C-102) from MPEM, and measure voltage between the following circuits.

The only defect not bringing the MPEM in standby mode is a start/stop switch failure. The switch remains closed or an electrical circuit failure is identical to a closed switch. In order to check start/stop switch, see Engine Starting section.

MAIN WIRING HARNESS WIRES WIRE COLOR

WIRE CONNECTOR AND POSITION

VOLTAGE

RED

C-101, 24 ➀

C-101, 26

12 Vdc

RED

C-101, 25

C-101, 26

12 Vdc

RED

C-102, 26 ➁

C-101, 26

12 Vdc

➀ Stamped 1 on MPEM ➁ Stamped 2 on MPEM 1

Antistart Operation problems that can be met are: 1. Upon inserting the safety lanyard on the DESS post; – No bip is heard (with or without gauge supply). – Gauge supply flashes and a long bip is heard. 2. The engine starts up when pressing the start/ stop switch while the safety lanyard is not on the DESS post (within 10 minutes after removing the safety lanyard). Check safety lanyard using the MPEM programmer. If the safety lanyard is in good condition, go on to following step. The advanced diagnostic mode can be used to identify more rapidly the cause of the problem. In order to check post operation, disconnect connector on rear of dashboard (C-003). Remove safety lanyard from DESS post. Using an ohmmeter, measure resistance of the following wires. POST WIRES WIRE COLOR PURPLE/WHITE and PURPLE/GREY PURPLE/GREY and PURPLE/BLACK

RESISTANCE

Infinite (0.L)

F09H0DA

TYPICAL — C-101 CONNECTOR 1. Wire position no. 24 2. Wire position no. 26

If voltage is not adequate, bypass connector ground by probing directly to the battery negative post. If voltage comes, check circuits for wire continuity on the connector ground side. Otherwise, check continuity on the supply side. If supply wires test good, the MPEM may be defective.

08-06-16

PURPLE/WHITE and PURPLE/BLACK

20 MΩ min.

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

F04H6MA

TYPICAL 1. Main wiring harness C-102 connector

If there is no supply to gauges and if no bip is heard, check gauge and MPEM supply fuse. See Gauge Current Supply section.

Gauge Current Supply The MPEM supplies current to the gauges and beeper through a supply relay. If no gauge is working, check the gauge current supply fuse on MPEM. If only one gauge is defective, check related section below.

Fuel and Oil Level Gauge

F04H6NA

TYPICAL VIEW — SEE TABLE TO IDENTIFY WIRES TO BE CHECKED 1. DESS post connector

Insert safety lanyard on DESS post and measure resistance of the following wires. POST WIRES WIRE COLOR

RESISTANCE

PURPLE/WHITE and PURPLE/BLACK

1 Ω max.

Check continuity between center post and PURPLE/ GREY wire and continuity between ring terminal and PURPLE/BLACK wire. If the DESS post is in good condition, check circuits for wire continuity. If they test good, the MPEM may be defective.

Gauge Current Supply Disconnect connector (C-017) from gauge. Measure voltage between indicated wires. Press any start/stop switch while the safety lanyard is not on the DESS post in order to supply current to the gauge. Perform the test within 33 seconds. MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR

VOLTAGE

PURPLE/PINK and BLACK

C-017

12 Vdc

08-06-17

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

If the warning system isn’t working properly after you did this bypass test, then check wire from the sender to the MPEM for continuity. If it tests good, check the beeper. If it tests good, disconnect connector (C-048) from switch and measure the voltage at the indicated wires. MAIN WIRING HARNESS WIRES WIRE COLOR

BLUE/RED F09H0EA

C-017 CONNECTOR SHOWN

If voltage is adequate, check sensor. Refer to INSTRUMENTS AND ACCESSORIES 08-09. If sensor test good, the gauge may be defective. If voltage is not adequate, bypass connector ground by probing directly to the battery negative post. If voltage comes, check circuits for wire continuity on the connector ground side. Otherwise, check continuity on the supply side. If supply wires test good, the MPEM may be defective.

Low-Fuel Warning System Release connector of fuel sensor and attach a jumper wire between the battery negative post (ground) and the PINK/WHITE wire of main wiring harness. With the engine running, the warning beeper should sound and the light should flash after a 30 to 60 second delay. When the warning beeper is sounding, depress the fuel warning switch to verify that the override function works (beeper will shut off and warning light will stop blinking and remain on). If the system is working properly now but it doesn’t when reconnected to the sender and there is a low fuel condition then there is a problem with the sender and/or the gauge. This will need to be repaired before proceeding.

08-06-18

CONNECTOR C-048

VOLTAGE

Battery ground post (-)

12 Vdc

If voltage is adequate, check light in switch. If it is working, check PINK/BLACK wire (W-100) going to MPEM for wire continuity. If it tests good, the MPEM may be defective. If voltage is not adequate, check BLUE/RED wire from circuits (W-90 and W-91) going to MPEM for wire continuity. If they test good, the MPEM may be defective. If the override feature of the low fuel warning system isn’t working, disconnect connector (C-048) from switch and measure the voltage at the indicated wires. MAIN WIRING HARNESS WIRES WIRE COLOR

PINK/BLUE

CONNECTOR C-048

Battery ground post (-)

VOLTAGE 5 Vdc

Tachometer Gauge Current Supply Disconnect gauge connector (C-019). Measure voltage between wires as indicated. Press start/stop switch while the safety lanyard is not on DESS post in order to supply gauge. Perform the test within 33 seconds.

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR VOLTAGE

RH side

PURPLE/GREY/GREEN and BLACK

C-019A

12 Vdc

C-019B

12 Vdc

LH side

PURPLE/GREY and BLACK

If voltage is adequate, the tachometer may be defective. If voltage is not adequate, bypass connector ground by probing directly to the battery negative post. If voltage comes, check circuits for wire continuity on the connector ground side. Otherwise, check continuity on the supply side. If supply wires test good, the MPEM may be defective.

Speedometer Gauge Current Supply Disconnect gauge connector (C-022). Measure voltage between indicated wires. Press any start/stop switch while the safety lanyard is not on DESS post in order to supply gauge. Perform the test within 33 seconds. MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR

VOLTAGE

PURPLE/WHITE and BLACK

C-022

12 Vdc

F09H0FA

C-019A CONNECTOR SHOWN â&#x20AC;&#x201D; RH SIDE

If voltage is adequate, check engine signal circuit. If it test good, the tachometer may be defective. If voltage is not adequate, bypass connector ground by probing directly to the battery negative post. If voltage comes, check circuits for wire continuity on the connector ground side. Otherwise, check continuity on the supply side. If supply wires test good, the MPEM may be defective. Engine Signal Check Disconnect connector (C-019) close to tachometer. Measure voltage between wires as indicated. Start engine in order to measure voltage. MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR

VOLTAGE

C-019A

4-6 Vdc

C-019B

4-6 Vdc

RH side

GREY/GREEN and BLACK LH side

GREY and BLACK

F09H0GA

C-022 CONNECTOR SHOWN

If voltage is adequate, check sensor. Refer to INSTRUMENTS AND ACCESSORIES 08-09. If sensor test good, the speedometer may be defective. If voltage is not adequate, bypass connector ground by probing directly to the battery negative post. If voltage comes, check circuits for wire continuity on the connector ground side. Otherwise, check continuity on the supply side. If supply wires test good, the MPEM may be defective.

08-06-19

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Engine Starting NOTE: The cord has to be installed on the DESS post. If nothing happens when pressing the start/stop switch (supposing that the battery and its connections are in good operating condition), check available voltage on switch. Measure voltage between connector circuits (C-006). MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR

If voltage is adequate, check the start/stop switch. If it tests good, unplug connector (C-080) from electrical box. Measure voltage between indicated wires while pressing start/stop button. MAIN WIRING HARNESS WIRES WIRE COLOR

RH side

YELLOW/RED/GREEN and BLACK

VOLTAGE

LH side

YELLOW/RED and BLACK

RH side BLACK and YELLOW/RED/GREEN

C-006

12 Vdc

LH side BLACK and YELLOW/RED

C-006

12 Vdc

CONNECTOR VOLTAGE C-080A

12 Vdc

C-080B

12 Vdc

F09H0IA

C-080B CONNECTOR SHOWN â&#x20AC;&#x201D; LH SIDE

F09H0HA

1. Start/stop switch connector at main wiring harness

If voltage is not adequate, check MPEM supply fuse. If the fuse is good, bypass connector ground by probing directly to the battery negative post. If voltage comes, check circuits for wire continuity on the connector ground side. Otherwise, check continuity on the supply side. If supply wires test good, the MPEM may be defective.

08-06-20

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Neutral Switch Disconnect connector (C-020) from switch. Check neutral switch voltage. Insert a safety lanyard on DESS post and measure voltage between the following wires. Perform the test within 33 seconds. MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR

VOLTAGE

C-020

5 Vdc

WHITE and BLACK

NOTE: Vibrations can cause the neutral switch to become defective. Vibrations close contacts, and this can prevent the engine from operating beyond 3500 RPM.

Speed Limiter If the engine does not reach its limit (7000 RPM for 717 engine and 7200 RPM for 787 engine) in forward/reverse position and 3500 RPM limit in neutral, or if it exceeds this limit (assuming the boat mechanical components are in good working condition), replace the MPEM. If engine is always restricted to 3500 RPM, check neutral switch. Refer to Neutral Switch section.

Engine Stopping Should the engine be impossible to shut off with the start/stop switch, remove safety lanyard from DESS post. If it still doesnâ&#x20AC;&#x2122;t shut off, disconnect the (C-101 and C-102) MPEM connectors. Inspect the start/stop circuit as well as the DESS post circuit. Refer to Engine Starting and Antistart sections.

Beeper

If beeper does not emit diagnostic codes anymore, while the MPEM gauge supply outlet works, check if beeper functions by grounding the overheat sensor wire (ensure to press start/stop switch to activate the circuit. Perform the test within 33 seconds). If beeper is not working, disconnect connector from beeper (C-002) and measure voltage between wires indicated in table while the engine overheat wire is still connected to ground and gauge supply is active. MAIN WIRING HARNESS WIRES

F04H4SA

WIRE COLOR

CONNECTOR

VOLTAGE

PURPLE/RED and PURPLE/BLACK

C-002

12 Vdc

1. Neutral switch connector at main wiring harness

08-06-21

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Disconnect sensor connector (C-026) . Using jumper wires, connect wires of main wiring harness.

F04H4WA

1. Overheat sensor to main wiring harness connector 2. Use a jumper wire to maintain it to ground F04H4ZA

1. Water sensor to main wiring harness connector 2. Jump wires of main wiring harness

The pump should start. Otherwise, check sensor. Measure sensor connector resistance. DEVICE Water sensor

ACTION

RESISTANCE

None

Infinite (0.L)

Connect sensor posts

0.1 â&#x201E;Ś max.

NOTE: The sensor shown on the following illustrations was removed from the bilge for reasons of clarity only. It is not necessary to remove it for checking purposes. F09H0JA

1. Beeper connector at main wiring harness

If voltage is not adequate, check circuits for wire continuity. Ensure beeper operation using external supply wires. If everything tests good, the MPEM may be defective. If voltage is adequate, the overheat sensor is defective.

Automatic Bilge Pump If the automatic bilge pump does not work despite a sufficient amount of water inside the bilge, check if it works in manual mode. If it still does not work, see section on Bilge Pump. Clean the water sensor posts to remove oil and dirt which could interfere with its operation. If automatic bilge pump still does not work, check water sensor. 08-06-22

F04H51A

1. Water sensor 2. Measure connector resistance

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

1 F04H52A

F09H0KA

1. Jumper wire connected to terminals 2. Measure connector resistance

C-051 CONNECTOR SHOWN

If the sensor works properly, check circuits for wire continuity. If everything tests goods, the MPEM may be defective.

Bilge Pump Check bilge pump fuse on MPEM. Disconnect (C-051) connector from pump switch. Measure voltage between indicated wires. NOTE: It is not necessary to press the start/stop switch or to have the safety lanyard on the DESS post. MAIN WIRING HARNESS WIRES WIRE COLOR

BROWN/RED

CONNECTOR C-051

Battery ground post (-)

VOLTAGE 12 Vdc

If voltage is not adequate, check circuits coming from MPEM for wire continuity. If they test good, the MPEM may be defective. If voltage is adequate, check switch, grounds and circuits going to pump for wire continuity. If they test good, the pump may be defective. If bilge pump continuously works, refer to sections concerning bilge pump (manual and automatic mode). If there is no short circuit, between electrical circuit wires, the MPEM can be suspected.

Blower Check blower fuse on MPEM. Disconnect (C-052) connector from blower switch. Measure voltage between indicated wires. NOTE: It is not necessary to press the start/stop switch or to have the safety lanyard on the DESS post. MAIN WIRING HARNESS WIRES WIRE COLOR

BROWN/ YELLOW/RED

CONNECTOR C-052

Battery ground post (-)

VOLTAGE 12 Vdc

08-06-23

Section 08 ELECTRICAL Subsection 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

Bow/Stern Lights and Gauge Lighting Check NAV/ANC light fuse on MPEM. If bow or stern light does not work, place switch to ON and try a bulb known to be in good condition. If the new bulb does not work or gauge lights do not work, disconnect (C-053) connector from NAV/ANC switch. Measure voltage between indicated wires. NOTE: It is not necessary to press the start/stop switch or to have the safety lanyard on the DESS post. MAIN WIRING HARNESS WIRES WIRE COLOR

GREY/RED

CONNECTOR C-053

Battery ground post (-)

VOLTAGE

MAIN WIRING HARNESS WIRES WIRE COLOR

BLUE/RED

CONNECTOR

VOLTAGE

Battery ground post (-)

C-049

12 Vdc

Auxiliary Output Check auxiliary output fuse on MPEM. Disconnect auxiliary output connector (C-014) and check available voltage at main wiring harness connector. MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR

VOLTAGE

PURPLE and BLACK

C-014

12 Vdc

Courtesy Lights Check courtesy light fuse on MPEM. If one light does not work, place switch to ON and try a bulb known to be in good condition. If the new bulb does not work, disconnect (C-049) connector from courtesy switch. Measure voltage between indicated wires. NOTE: It is not necessary to press any start/stop switch or to have the safety lanyard on the DESS post.

08-06-24

F09H0LA

1. Auxiliary output connector at main wiring harness

Subsection 06

Section 08 ELECTRICAL (MPEM (MULTI-PURPOSE ELECTRONIC MODULE))

12-Volt Jack

Horn

Check 12-volt jack fuse on MPEM. Disconnect auxiliary output connector (C-043) and check available voltage at main wiring harness connector.

Check horn fuse on MPEM. Disconnect (C-050) connector from horn switch. Measure voltage between indicated wires. NOTE: It is not necessary to press the start/stop switch or to have the safety lanyard on the DESS post.

MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR

VOLTAGE

ORANGE

C-043

12 Vdc

MAIN WIRING HARNESS WIRES WIRE COLOR

ORANGE

CONNECTOR Battery ground post (-)

C-050

VOLTAGE 12 Vdc

Radio (if so equipped) Disconnect radio connector (C-086). Measure voltage between wires as indicated. F09H0MA

C-043 CONNECTOR SHOWN

MAIN WIRING HARNESS WIRES WIRE COLOR

CONNECTOR

VOLTAGE

ORANGE and BLACK

C-086

12 Vdc

If voltage is adequate, check wires/connector going to the radio. If they test good, the radio may be defective. If voltage is not adequate, bypass connector ground by probing directly to the battery negative post. If voltage comes, check circuits for wire continuity on the connector ground side. Otherwise, check continuity on the supply side. If supply wires test good, the MPEM may be defective.

08-06-25

Section 08 ELECTRICAL Subsection 07 (CHARGING SYSTEM)

CHARGING SYSTEM TESTING PROCEDURE NOTE: First, ensure that battery is in good condition prior to performing the following test using current inductive ammeter such as Snap-on MT 110. If the battery is regularly discharged, check charging system fuse condition on MPEM. The rectifier/regulator could be the culprit of a blown fuse. To check, simply disconnect the rectifier/ regulator from the circuit. If the fuse still burns, check for a defective wire.

CAUTION

Do not use a higher rated fuse as this cause severe damage.

Rectifier/Regulator NOTE: There is one rectifier/regulator for each engine. Perform the tests on each rectifier/regulator. STATIC TEST: CONTINUITY 1. Due to internal circuitry, there is no static test available. DYNAMIC TEST Current Test Proceed as follows: – Start engine. – Lay an inductive ammeter on positive cable of battery. – Bring engine to approximately 5500 RPM. Depending on battery charge, current reading should be approximately 4 amperes for the 717 engine or 5 amperes for the 787 engine. If not, check magneto output prior to concluding that regulator is faulty.

0 Voltage Test Proceed as follows: – Start engine. – Connect a multimeter to battery posts. Set multimeter to Vdc scale. – Bring engine to approximately 5500 RPM. If multimeter reads over 15 volts, regulator is defective. Replace it. NOTE: Whatever the voltmeter type used (peak voltage or RMS), the voltage must not exceed 15 V. A faulty regulator will allow voltage to exceed 15 V as engine speed is increased. NOTE: If it is continually necessary to add distilled water to the battery, this indicates an over voltage situation, requiring replacement of the rectifier/ regulator. If, on the other hand, the battery will not stay charged, the problem can be any of the charging circuit components. If these all check good, you would be accurate in assuming the problem to be in the rectifier/regulator. If there is no charging at the battery with the preceding voltage test, the following test can also be performed. Disconnect the connector housing of the rectifier/ regulator. Using an appropriate terminal remover (Snap-on TT600-4), remove the RED and BLACK wires from the tab housing of the rectifier/regulator. Reconnect the connector housing. Connect the positive probe of a multimeter to the RED wire and the negative probe to the BLACK wire. Set multimeter to Vdc scale. Start and rev engine to 3500 RPM. The obtained value should be between 12 and 25 Vdc. NOTE: If the rectifier/regulator is within the specification, either the MPEM or wiring harness between the rectifier and battery is defective. If the rectifier/regulator is out of specification and the stator test good, the rectifier/regulator is defective.

08-07-1

Section 08 ELECTRICAL Subsection 07 (CHARGING SYSTEM)

Magneto, Charging System Generator Coil 717 Engine STATIC TEST: CONTINUITY Charging system generator coil can be checked with an ohmmeter (preferably a digital one). Unplug magneto connector at engine. Connect the 4-pin magneto test harness (P/N 295 000 131) at the engine. DO NOT connect the other end at the boat harness. Use the following table: MAGNETO PART NAME

WIRE COLOR

Charging system generator coil

BROWN with BROWN of magneto harness

F01H4WB

RESISTANCE (OHM) (Ω) 0.05 - 0.6

NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter. 1. Unplug magneto connector at engine. 2. Connect the 4-pin magneto test harness (P/N 295 000 131) between the unplugged connectors. 3. Connect test probes of the multimeter to the BROWN wires of the 4-pin magneto harness adapter. 4. Set multimeter to Vac scale. 5. Start and rev engine to 3500 RPM. The obtained value should be between 25 and 40 Vac. 6. If the battery charging coil is out of specification, replace it.

BR BR BR BK GY-BK GY

TYPICAL — AC-1 AND AC-2

2. Place either meter test probe into the remaining stator lead (AC-3) and note the resistance (same as step no. 1). If the readings are out of specification, the stator will need to be replaced.

F01H4XB

BR BR BR BK GY-BK GY

TYPICAL — AC-1 AND AC-3

Stator 787 Engine STATIC TEST: CONTINUITY 1. Disconnect the magneto wiring harness connector. Connect the 6-pin magneto test harness (P/N 295 000 136) on the engine connector only. With a good multimeter (preferably a digital one), place the 2 meter test probes onto the stator wire leads AC-1 and AC-2 of the stator. The resistance should be 0.8 Ω.

08-07-2

STATIC TEST: INSULATION With the stator leads disconnected, insert either meter test probe onto AC-1 and ground the other meter test probe to the engine or the stator iron core and note the reading. There should be no continuity (infinity) between the stator insulated coils and ground. If there is a reading, the stator coils and/or the wiring from the coils is grounded and needs to be replaced/repaired respectively.

Section 08 ELECTRICAL Subsection 07 (CHARGING SYSTEM)

YL YL YL BK BK-YL YL-WH F01H4YA

TYPICAL â&#x20AC;&#x201D; AC-1 AND GROUND

DYNAMIC TEST 1. Unplug magneto connector at engine. 2. Connect the 6-pin magneto test harness (P/N 295 000 136) between the unplugged connectors. 3. Connect test probes of the multimeter to two of the YELLOW wires of the 6-pin magneto harness adapter. 4. Set multimeter to Vac scale. 5. Start and rev engine to 3500 RPM. The obtained value should be between 45 and 70 Vac. 6. If the stator is out of specification, replace it.

08-07-3

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

STARTING SYSTEM

ELECTRIC STARTER

15 6 7 8

1 2 5 N m (44 lbf in) 5

22 N m (16 lbf in) 13

3 Loctite 242

Dielectric grease 12 Loctite 242 16 Loctite 271

Ground cable

14 22 N m (16 lbf in)

F09H0NS

TYPICAL

PARTS

08-08-1

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

GENERAL

MPEM Supply Fuse

Causes of troubles are not necessarily related to starter but may be due to a burnt fuse, faulty battery, MPEM, start/stop switch, main battery cutoff switch, safety lanyard post, solenoid, electrical cables or connections. Check these components before removing starter. Consult also the Starting System Troubleshooting table on next page for a general view of possible problems.

Make sure the MPEM supply fuse is in good condition.

â&#x2014;&#x2020;

WARNING

Short circuiting electric starter is always a danger, therefore disconnect the battery ground cable before carrying out any kind of maintenance on starting system. Do not place tools on battery.

Main Battery Cut-Off Switch Ensure that switch is turned ON. When switch is turned OFF, ALL electrical equipments and electronics are not powered and not working.

Battery To check battery condition, refer to CHARGING SYSTEM 08-07.

Engine Start/Stop Switch and Safety Lanyard Post Refer to MPEM 08-06 for procedures.

Solenoid NOTE: Solenoid are located in electrical boxes. Prior to performing the following test, ensure the solenoid receives electric current from the MPEM. Refer to MPEM 08-06. Disconnect large cables from solenoid. Inspect connections and clean as necessary. Solenoid condition can be checked with an ohmmeter. Install test probes on large connectors of solenoid. Measure resistance when current is applied to small connectors; if it is more than a few ohms, replace solenoid.

Electrical Cables or Connections Check all connections, cables and wires. Tighten any loose cables. Replace any chafe wires.

F00H46A

08-08-2

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

STARTING SYSTEM TROUBLESHOOTING SYMPTOM

CAUSE

REMEDY

Starter does not turn.

Main battery cut-off switch is turned OFF.

Verify and turn ON.

Burnt MPEM supply fuse.

Check wiring condition and replace fuse.

Poor contact of battery terminal(s) or ground cable connections.

Clean and tighten terminal(s).

Weak battery.

Recharge battery.

Poor contact or open circuit of: start/stop switch, safety lanyard post or solenoid.

Check and replace defective part. Refer to MPEM 08-06.

Poor contact of battery terminal(s).

Clean and tighten terminal(s).

Poor battery ground cable connection.

Clean and tighten.

Burnt or poor contact of solenoid switch contact disc.

Replace solenoid switch.

Poor contact of brush.

Straighten commutator and brush.

Burnt commutator.

Turn commutator in lathe.

Worn commutator segments.

Undercut mica.

Shorted armature.

Repair or replace armature.

Weak brush spring tension.

Replace brush holder.

Weak magnet.

Replace bushings.

Worn bushings.

Replace bushings.

Weak battery.

Recharge or replace battery.

Worn clutch pinion gear.

Replace clutch.

Defective clutch.

Replace clutch.

Poor movement of clutch on splines.

Clean and correct.

Worn clutch bushing.

Replace clutch.

Worn ring gear.

Recharge ring gear.

Shorted solenoid switch winding.

Replace solenoid switch.

Melted solenoid contacts.

Replace solenoid switch.

Sticking or defective starter clutch.

Lubricate or replace.

Presence of salt water in the electrical box which gives continuity.

Verify electrical box watertightness.

Starter turns; but does not crank the engine.

Starter turns, but overrunning clutch pinion does not mesh with ring gear.

Starter motor keeps running.

08-08-3

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

REMOVAL

Circlip, Pinion Stop Collar and Spring

Turn OFF main battery cut-off switch. Disconnect BLACK cable ground connection from battery.

Tap the pinion stop collar no. 11 using a screwdriver. Remove circlip no. 10. Disassemble pinion stop collar and spring no. 15.

◆

WARNING

Always disconnect ground cable first and reconnect last. Disconnect RED cable connection from battery. Remove the following parts. – cables from starter – screw of starter rear support no. 13 – starter mount screws no. 14

A03E04A

1. Pinion stop collar

DISASSEMBLY

Clutch Ass’y, Housing, O-Ring and Armature

Yoke, Brush Holder, End Frame, Through Bolt and Nut

Turn clutch assembly no. 6 clockwise to remove it from armature assembly no. 9. Pull housing no. 7 from armature. Remove O-ring no. 8 from housing.

Before disassembling, trace index marks on yoke no. 1 and clutch housing no. 7 to ease further assembly. 1

CLEANING

CAUTION

Yoke ass’y and clutch assembly must not be immersed in cleaning solvent.

F01H0PA

TYPICAL 1. Trace indexing marks here

Remove starter support nuts no. 5 then through bolts no. 4. Separate end frame no. 3 from yoke assembly no. 1. Withdraw yoke assembly from armature no. 9. Brush holder no. 2 can be removed from end frame by unscrewing nut retaining terminal. Check that the radial play between the armature shaft and end frame is not greater than 0.20 mm (.008 in). Replace end frame if so.

08-08-4

Discard all O-rings and gasket. Clean brushes and holders with a clean cloth soaked in solvent. Brushes must be dried thoroughly with a clean cloth. Blow brush holders clean using compressed air.

◆

WARNING

Always wear safety glasses when using compressed air. Remove dirt, oil or grease from commutator using a clean cloth soaked in suitable solvent. Dry well using a clean, dry cloth. NOTE: Bushings (717 engine) or bearings (787 engine) must not be cleaned with grease dissolving agents. Clean engine ring gear teeth and clutch assembly.

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

NOTE: Bushings must not be cleaned with grease dissolving agents. Immerse all metal components in cleaning solution. Dry using a clean, dry cloth.

Brush Holder

INSPECTION

Check brush holder no. 2 for insulation using an ohmmeter. Place one test probe on insulated brush holder and the other test probe on brush holder plate. If continuity is found, brush holder has to be repaired or replaced.

Armature

Brush Length

NOTE: An ohmmeter may be used for the following testing procedures, except for the one concerning shorted windings in armature. Check commutator for roughness, burnt or scored surface. If necessary, turn commutator on a lathe, enough to resurface only. Check commutator for mica depth. If depth is less than 0.20 mm (.008 in), undercut mica. Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed.

Measure brush length. If less than 8.5 mm (.335 in), replace it. NOTE: New brush length is 12 mm (.472 in).

2 1

A03E05A

1. New 2. Wear limit, 8.5 mm (.335 in)

F01H0RA

1. Commutator undercut 0.20 mm (.008 in)

Check commutator out of round condition with Vshaped blocks and an indicator. If commutator out of round is more than 0.40 mm (.016 in), commutator should be turned on a lathe. Check commutator outer diameter. If less than 27 mm (1.063 in), replace.

Clutch Assâ&#x20AC;&#x2122;y Pinion of clutch assembly should turn smoothly in clockwise direction, and should not slip in a counterclockwise direction. If defective, replace. Check pinion teeth for wear and damage. If defective, replace. NOTE: Always check engine ring gear teeth for wear and damage. If defective replace ring gear. Refer to MAGNETO SYSTEM 04-04 then refer to Ring Gear.

ASSEMBLY Reverse the order of disassembly to reassemble starter. However, attention should be paid to the following operations. Prior to assembling, coat sliding surfaces on armature shaft splines and clutch assembly with G.E. Versilube G 341 M or ESSO Beacon 325 lubricant or equivalent. Apply motor oil on metal bushings. A03E06A

08-08-5

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

Circlip and Pinion Stop Collar After placing stop collar no. 11 on armature no. 9 shaft, fit circlip no. 10 into armature shaft, then make sure that it is properly secured. Slide stop collar over circlip and secure in place by punching it at 2 or 3 places.

Yoke Assâ&#x20AC;&#x2122;y, End Frame and Through Bolt Open brushes and slide over commutator. Align end frame no. 3 locating notch with yoke no. 1 locating protrusion and properly sit brush holder no. 2 into yoke. 1

4 1 2

A03E0EA

1. 2. 3. 4.

F01H0SA

Armature shaft Circlip Pinion stop collar Punch

1. Locating protrusion is the higher one

Yoke Assâ&#x20AC;&#x2122;y and Housing Align previously traced indexing marks on yoke no. 1 and clutch housing no. 7. 1

F01H0TA

1. Brush holder locating notch

F01H0QA

TYPICAL 1. Align marks

08-08-6

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

To ease end frame no. 3 installation, retain brush holder no. 2 with a small screwdriver while installing end frame.

Screw Torque starter screws to 22 N•m (16 lbf•ft).

Nut Connect the RED battery cable to the starter and torque nut no. 12 to 6 N•m (53 lbf•in). Apply dielectric grease on terminal and nut.

Screw and Teeth Washer Apply Loctite 271 (P/N 293 800 005) on screw no. 16. Connect BLACK cable to starter using flat washer, teeth washer no. 18 and screw no. 16. Torque screws to 22 N•m (16 lbf•ft). Apply dielectric grease on terminal and screw.

◆ 1

F01H0UA

WARNING

Always connect RED positive cable first then BLACK negative cable last. Whenever connecting the RED positive cable to the starter motor make sure the battery cables are disconnected to prevent electric shock.

Step 1 : Retaining brush holder with a screwdriver Step 2 : Align here

Align end frame notch with brush holder notch/ yoke protrusion.

CAUTION

Make sure end frame fits perfectly on yoke. Reinstall starter support on end frame no. 3 then through bolts no. 4. Secure with nuts no. 5. Torque nuts to 5 N•m (44 lbf•in).

STARTER INSTALLATION Installation is essentially the reverse of removal procedure. However, pay particular attention to the following. Make sure that starter and engine mating surfaces are free of debris. Serious trouble may arise if starter is not properly aligned.

F01H1JA

3-4

TYPICAL 1. Torque to 6 N•m (53 lbf•in) 2. Loctite 271 3. Torque to 22 N•m (16 lbf•ft) 4. Dielectric grease

08-08-7

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

STARTER SPECIFICATION Nominal output

0.6 kW

Voltage

12 V

Rated time

30 seconds

Rotation

Counterclockwise (viewed from pinion side)

Weight

Approx. 2 kg (4.4 lb)

Performance specification at 20°C (68°F)

No load

11.5 V

Load

717 engine: 8.5 V 170 A max.

2200 RPM

2 N•m (18 lbf•in)

787 engine: 8.5 V 170 A max.

2200 RPM

2.2 N•m (20 lbf•in)

717 engine: 5V 350 A max.

0 RPM

3 N•m (27 lbf•in)

787 engine: 5V 350 A max.

0 RPM

3.2 N•m (29 lbf•in)

Stall

08-08-8

20 A max.

5500 RPM

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

BATTERY TROUBLESHOOTING SYMPTOM: DISCHARGED OR WEAK BATTERY CAUSE

REMEDY

1. Battery posts and/or cable terminal oxidized.

Clean and coat with dielectric grease.

2. Loose or bad connections.

Check wiring and connector cleanliness, damaged or short circuit.

3. Faulty battery (sulfated, doesn’t keep a full charge, damaged casing, loose rectifier).

Replace.

F04H15A

4. Charging system fuse First check charging burnt or faulty rectifier.* system generator coil. If it is in good condition replace fuse or rectifier. 5. Faulty charging system generator coil.**

Replace.

A. 285 mm (11-1/4 in) B. 190 mm (7-1/2 in) C. 238 mm (9-3/8 in)

ACTIVATION OF NEW BATTERY

◆

WARNING

*To test charging system, refer to CHARGING SYSTEM 08-07 then look for Current Test. **To test charging system generator coil, refer to CHARGING SYSTEM 08-07 then look for Charging System Generator Coil.

Properly follow manufacturer’s instructions for the activation of a new battery.

SPECIFICATIONS

REMOVAL

Exyde RV24-130, 25 A•h (130 minutes reserve) minimum or RV24-160 (160 minutes) or equivalent.

Turn OFF main battery cut-off switch. Unfasten top brace.

◆

WARNING

Never use automotive type battery. Its mechanical construction does not allow to meet the shock conditions where boats operate. Only use the type of battery recommended. The battery has to be purchased locally. Refer to following illustration for MAXIMUM allowed size.

Never charge or boost battery while installed in boat.

◆

WARNING

Battery BLACK negative cable must always be disconnected first and connected last. Never charge or boost battery while installed in boat. Electrolyte or fuel vapors can be present in engine compartment and a spark might ignite them and possibly cause personal injuries. Pivot retaining rods toward front and lay down. Disconnect the BLACK negative cable first. Then disconnect the RED cable last. Withdraw battery from boat.

08-08-9

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

CLEANING

◆

WARNING

A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte. A fully charged battery will have a specific gravity between 1.265 to 1.280.

Electrolyte is poisonous, dangerous and explosive. It contains sulfuric acid and can cause severe burns. Avoid contact with eyes, skin and clothing.

Clean the battery casing, caps, cables and battery posts using a solution of baking soda and water. Remove corrosion from battery cable terminals and battery posts using a firm wire brush. Rinse with clear water and dry well.

INSPECTION

A17E0JA

Visually inspect battery casing for cracks or other possible damage. If casing is damaged, replace battery and thoroughly clean battery rack with water and baking soda.

◆

WARNING

Should the battery casing be damaged, wear a suitable pair of non-absorbent gloves when removing the battery by hand. Inspect battery rack mounting and retaining rods condition. Inspect battery posts for security of mounting. Inspect for cracked or damaged battery caps (if applicable), replace defective caps.

BATTERY TESTING

TYPICAL 1. Specific gravity 1.265

A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte. Most hydrometers give a true reading at 21°C (70°F). In order to obtain correct readings, adjust the initial reading by adding .004 points to the hydrometer readings for each 5.5°C (10°F) above 21°C (70°F) and by subtracting .004 point for every 5.5°C (10°F) below 21°C (70°F). This chart will be useful to find the correct reading. ELECTROLYTE TEMPERATURE °C

°F

OPERATION TO PERFORM

100

There are 2 types of battery tests: unloaded and loaded. An unloaded test is made on a battery without discharging current. It is the simplest and commonly used. A loaded test gives more accuracy of the battery condition.

.004

correct reading

.004

Unload Test

Check charge condition using either a hydrometer or a multimeter. With a multimeter, voltage readings appear instantly to show the state of charge. Always respect polarity. A fully charged battery will have a reading of 12.6 Vdc.

08-08-10

-1

.012 add

.008

.008 subtract

.012

to the reading

from the reading

.016

EXAMPLE NO. 1

EXAMPLE NO. 2

Temperature below 21°C (70°F): Hydrometer reading: 1.250 Electrolyte temperature: - 1°C (30°F) Subtract .016 Sp. Gr. Corrected Sp. Gr. is 1.234

Temperature above 21°C (70°F): Hydrometer reading: 1.235 Electrolyte temperature: 38°C (100°F) Add .012 Sp. Gr. Corrected Sp. Gr. is 1.247

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

Load Test This is the best test of battery condition under a starting load. Use a load testing device that has an adjustable load. Apply a load of 3 times the ampere-hour rating of the battery. At 14 seconds into the test, check battery voltage; if battery is in good condition, it will have at least 10.5 Vdc.

BATTERY STORAGE Turn OFF main battery cut-off switch. Disconnect and remove battery from boat. Check electrolyte level in each cell, add distilled water up to upper level line (if applicable).

CAUTION

Do not overfill.

◆

WARNING

Prior to charging the battery, always remove it from jet boat. For best results, battery should be charged when the electrolyte and the plates are 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. If it is suspected to be frozen, keep it in a heated area for about 2 hours before charging.

◆

WARNING

Do not place battery near open flame.

The battery must always be stored in fully charged condition. If required, charge until specific gravity of 1.265 is obtained.

TIPS FOR CHARGING A USED BATTERY

CAUTION

Battery electrolyte temperature must not exceed 50°C (122°F). The casing should not feel hot. Clean battery terminals and cable connections using a wire brush. Apply a light coat of dielectric grease on terminals. Clean battery casing and caps using a solution of baking soda and water. Rinse battery with clear water and dry well using a clean cloth. Store battery on a wooden shelf in a cool dry place. Such conditions reduce self-discharging and keep fluid evaporation to a minimum. Keep battery away from dew, high moisture and direct sunlight. During the storage period, recheck electrolyte level and specific gravity readings at least every month. If applicable, keep the battery at its upper level line. Keep near full charge as possible (trickle charge).

The time required to charge a battery will vary depending on some factors such as: – Battery temperature: The charging time is increased as the temperature goes down. The current accepted by a cold battery will remain low. As the battery warms up, it will accept a higher rate of charge. – State of charge: Because the electrolyte is nearly pure water in a completely discharged battery, it cannot accept current as well as electrolyte. This is the reason the battery will not accept current when the charging cycle first begins. As the battery remains on the charger, the current from the charger causes the electrolytic acid content to rise which makes the electrolyte a better conductor and then, the battery will accept a higher charging rate. – Type of charger: Battery chargers vary in the amount of voltage and current that they can supply. Therefore, the time required for the battery to begin accepting measurable current will also vary.

08-08-11

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

Charging a Very Flat or Completely Discharged Battery Unless this procedure is properly followed, a good battery may be needlessly replaced. – Measure the voltage at the battery posts with an accurate voltmeter. If it is below 10 volts, the battery will accept current at very low rate, in term of milliamperes, because electrolyte is nearly pure water as explained above. It could be some time before the charging rate increases. Such low current flow may not be detectable on some charger ammeters and the battery will seem not to accept any charge. – Exceptionally for this particular case, set the charger to a high rate. NOTE: Some chargers have a polarity protection feature which prevents charging unless the charger leads are connected to the correct battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly. This will make it appear that the battery will not accept a charge. Follow the charger manufacturer’s instruction on how to bypass or override this circuitry so that the charger will turn on and charge a low-voltage battery. – Since the battery chargers vary in the amount of voltage and current they provide, the time required for the battery to accept measurable charger current might be up to approximately 10 hours or more. – If the charging current is not up to a measurable amount at the end of about 10 hours, the battery should be replaced. – If the charging current is measurable before the end or at the end of about 10 hours, the battery is good and charging should be completed in the normal manner. – It is recommended that any battery recharged by this procedure be load tested prior to returning it to service.

CHARGING 2 OR MORE BATTERIES AT A TIME Connect all positive battery posts together and use a charger with a capacity (rated) equal to number of battery to be charged. 1

A17E0PA

TYPICAL 1. Two batteries connected in parallel

INSTALLATION Install charged battery in battery support so that the positive post is toward stern (rear) and secure with top brace. 3

F09H05A

BATTERY POSITIVE (+) POST TOWARD STERN (REAR) 1. Battery properly secured with top brace 2. RED positive cable (+) with protective boot 3. BLACK negative cables (-)

08-08-12

Section 08 ELECTRICAL Subsection 08 (STARTING SYSTEM)

Properly route cables toward battery posts.

◆

WARNING

Routing will keep battery cables away from tuned pipe. Connect RED positive (+) cable first then connect BLACK negative (-) cables last. Firmly tighten post fasteners. Apply dielectric grease (P/N 293 550 004) on battery posts. Finalize installation with RED positive (+) cable boot.

◆

WARNING

Never secure electrical wires/cables with fuel lines. Keep wires away from any rotating, moving, heating, vibrating or sharp edge. Use proper locking ties.

◆

WARNING

Verify starter cable connections for tightness. Always connect battery cables exactly in specified order, RED positive cable first, then BLACK negative ground cable. Do not charge battery when installed. Turn ON main battery cut-off switch.

08-08-13

Subsection 09

Section 08 ELECTRICAL (INSTRUMENTS AND ACCESSORIES)

INSTRUMENTS AND ACCESSORIES

Loctite 242

Typical connection (simple or multiple ways)

Dielectric grease

F04H6US

PARTS

08-09-1

Section 08 ELECTRICAL Subsection 09 (INSTRUMENTS AND ACCESSORIES)

GENERAL

For electrical system circuit testing procedures, refer to MPEM 08-06. It is possible to activate the fuel gauge/low oil warning light when the engine is not running. Make sure the safety lanyard is removed, then depress the start/stop button. The gauge will be activated during 33 seconds: the delay timer of the MPEM will stay on.

INSPECTION

Fuel Gauge/Low Oil Warning Light The fuel gauge has a pointer which indicates fuel level in the tank. The low oil warning light is part of the gauge. It will light when injection oil level is low.

F01F20A

1. Pick up tube 2. Fuel sensor 3. Baffle pick up

The resistance measured between PINK/BLACK and PINK wires must be in accordance with fuel level (measured from under the flange) as specified in the following chart. FUEL LEVEL AND RESISTANCE FUEL LEVEL

mm full

(in)

299 and more 11.8 and more

RESISTANCE (Ω) 0 ± 2.2

7/8

272 @ 298

10.7 @ 11.7

17.8 ± 2.2

3/4

247 @ 271

9.7 @ 10.6

27.8 ± 2.2

5/8

220 @ 246

8.7 @ 9.6

37.8 ± 2.2

1/2

194 @ 219

7.6 @ 8.6

47.8 ± 2.2

1. Low oil level warning light

3/8

162 @ 193

6.4 @ 7.5

57.8 ± 2.2

Fuel Baffle Pick Up Sensor

1/4

130 @ 161

5.1 @ 6.3

67.8 ± 2.2

The baffle pick up has an integrated fuel sensor. To verify fuel sensor, a resistance test should be performed with an ohmmeter allowing the float to move up through a sequence.

1/8

86 @ 129

3.4 @ 5.0

77.8 ± 2.2

empty

0 @ 85

0 @ 3.3

89.8 ± 2.2

F01G07A

08-09-2

NOTE: For the low-fuel warning system testing, refer to MPEM 08-06.

Subsection 09

Section 08 ELECTRICAL (INSTRUMENTS AND ACCESSORIES)

Low-Level Oil Sensor The sensor sends the signal to the low-oil level light in the fuel gauge. The bottom of the sensor has a small reservoir with 2 small holes underneath to let the oil enter inside and 1 at the top to let the air enter to allow the oil to flow out. When there is enough oil inside the oil tank (and therefore in the sensor reservoir), the sensor detects the liquid and the light DOES NOT turn on. When the oil level goes at a critical LOW level inside the oil tank (and therefore in sensor reservoir), the sensor detects the absence of liquid and the light turns on. To check the oil sensor, unplug its connector and pull sensor out of oil tank. Using an ohmmeter, check the continuity between the LIGHT BLUE and LIGHT BLUE/BLACK terminals. When sensor is out of oil tank and its reservoir is empty, resistance must be infinite (open circuit). Soak sensor in oil so that its reservoir fills up. Resistance must be 1 Ω max. (closed circuit). NOTE: Wait about 15-20 seconds before taking any reading to give the oil enough time to flow out or inside sensor reservoir.

2 F03H0BA

1. Measure resistance here 2. Sensor reservoir

Speed Sensor Verification The speedometer gives a reading through a speed sensor. Speed sensor is installed on ride shoe. It works with the water flow which turns a magnetic paddle wheel that triggers on electronic pick up that in turn sends a speed signal to the speedometer. The paddle wheel is protected by the pick up housing.

SUMMARY TEST CONDITION

READING (Ω)

Sensor OUT of oil

∞ (open circuit)

Sensor soaked IN oil

1 Ω max. (closed circuit)

To reinstall sensor: – Remove rubber seal from sensor. – Install seal in oil tank hole. – Push sensor in seal. – Plug connectors. NOTE: This sensor turns the low-level oil light to ON if the connector has been left unconnected even when there is enough oil in tank. This warns the operator that something is wrong.

F01H3VA

TYPICAL 1. Pick up housing 2. Paddle wheel

To verify speed sensor, use a voltmeter as follows: – With both speed sensor wires properly connected to boat harness WHITE wires, connect the voltmeter (+) probe to the speed sensor PURPLE/YELLOW wire and the (-) probe to the speed sensor BLACK/ORANGE wire. – Slowly turn the paddle wheel. You should read a voltage variation with the voltmeter. If not, replace speed sensor.

08-09-3

Section 08 ELECTRICAL Subsection 09 (INSTRUMENTS AND ACCESSORIES)

Aluminum Sacrificial Anode System 4

3 Grounding blocks

F00H18A

TYPICAL 1. Aluminum anode 2. Weedless cable 3. Reverse cable 4. Steering cable

This system is an additional protection against corrosion for under water metal parts and electrical system, refer to OVERVIEW 08-02.

CAUTION

DO NOT paint aluminum anode as this will prevent it from providing corrosion protection. Anode should be kept clean, using fresh water and a nylon brush if necessary. Change anode when 60% by weight is corroded. Inspect the following items and ensure that screws and nuts are properly tightened: – Anode connection inside engine compartment. – Anode wire conections at throttle/shifter location, on weedless system and on steering cable. – Connection on grounding block no. 1 (all others grounding blocks are connected in serie with block no.1).

08-09-4

Section 09 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

JET PUMP .............................................................................................................................. GENERAL ........................................................................................................................... INSPECTION ON JET BOAT.............................................................................................. REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... PUMP PRESSURIZATION ................................................................................................. INSTALLATION .................................................................................................................. RIDE SHOE REMOVAL AND INSTALLATION.................................................................. REMOVAL .......................................................................................................................... CLEANING ......................................................................................................................... INSTALLATION.................................................................................................................. JET PUMP SUPPORT REMOVAL AND INSTALLATION .................................................

09-02-1 09-02-2 09-02-2 09-02-4 09-02-6 09-02-8 09-02-8 09-02-12 09-02-17 09-02-18 09-02-20 09-02-20 09-02-21 09-02-21 09-02-22

DRIVE SYSTEM ..................................................................................................................... GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... LUBRICATION....................................................................................................................

09-03-1 09-03-2 09-03-2 09-03-3 09-03-4 09-03-7

REVERSE SYSTEM................................................................................................................ INSPECTION ...................................................................................................................... DISASSEMBLY................................................................................................................... ASSEMBLY.........................................................................................................................

09-04-1 09-04-2 09-04-2 09-04-4

WEEDLESS SYSTEM ............................................................................................................ INTAKE GRILL .................................................................................................................... WEEDLESS SYSTEM MECHANISM (Inside RH Front Storage Compartment) ............ WEEDLESS ROD AND CABLES REPLACEMENT ............................................................

09-05-1 09-05-2 09-05-2 09-05-4

09-01-1

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

JET PUMP

Adseal 4511 Right Stuff Gasket Loctite 242 Port side

Loctite 242 12

Adseal 4511 11 Adseal 4511

Starboard 9

Right Stuff Gasket Adseal 4511

10 N m (89 lbf in)

13 17

Right Stuff Gasket

Hull 10 N m (89 lbf in)

Adseal 31 N m Loctite 4511 (23 lbf ft) 518 Loctite 271 6

5 28 N m (21 lbf ft)

19 20 Loctite 271 18

Loctite Primer N and Loctite 518 1 20 N m 7 (15 lbf ft) 3

25 20 21 Loctite Primer N and Loctite 271

23 22

70 N m (52 lbf ft) Loctite Primer N and Pipe Sealant (P/N 293 800 013)

F09J07T

21 N m (15 lbf ft)

Loctite 518

8 Loctite 242

4 N m (35 lbf in) 15

13 N m (115 lbf in)

Jet Pump Synthetic Oil

PARTS

09-02-1

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

GENERAL

INSPECTION ON JET BOAT

Some pump components can be changed to improve boat performance in high altitude regions between 1500 - 3000 m (5000 - 10 000 ft). Refer to the service department for the latest specifications.

To work on boat, securely install it on a stand. Thus, if access is needed to water inlet area, it will be easy to slide underneath boat. A lift kit can be used to install boat on a stand. See table below. Refer to the kit instruction sheets for proper use.

CAUTION

Such modifications should only be performed by experienced mechanics since they can greatly affect vehicle performance.

BOAT MODEL

KIT P/N

16 ft Speedster and Speedster SK

295 100 085

The jet pump housing and venturi are made of plastic.

Impeller Condition

Impeller Identification

Condition of impeller, boot and ring can be quickly checked from underneath of the jet boat. Lower grill and look through water inlet opening.

To identify the impellers no. 17 refer to the following illustration and chart.

1 1

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1. Boot with ring

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1. Stamped part number

BOAT MODEL

Impeller/Wear Ring Clearance

IMPELLER MATERIAL P/N

Speedster SK 204 160 072 Speedster

204 160 048

;

PITCH

Stainless Progressive steel pitch Stainless Progressive steel pitch

WARNING

Always remove safety lanyard from DESS post to prevent unattended engine starting prior to working on the jet pump/ride shoe.

09-02-2

This clearance is critical for jet pump performance. Clearance can be checked from water inlet opening, after lowering inlet grate no. 12 with the weedless lever, or from venturi side, after venturi/ nozzle assembly removal as described in Oil Inspection in this section.

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Remove speedometer sensor (if necessary) from ride shoe. Detach steering link rod from nozzle no. 4. Detach reverse gate link rod from RH reverse gate (required even if you are working on LH side).

F01J0EA

TYPICAL â&#x20AC;&#x201D; MEASURING FROM WATER INLET SIDE 1. Feeler gauge F04J2NA

TYPICAL 1. Detach

Remove reverse gate support (with gate), venturi no. 7 and nozzle assembly from impeller housing no. 6. NOTE: If you are removing parts on LH side, the reverse gate link rod may be kept with the reverse gate. Oil Verification Remove plug from cover. F01J0FA

TYPICAL â&#x20AC;&#x201D; MEASURING FROM VENTURI SIDE 1. Feeler gauge

Using a long feeler gauge 30 cm (12 in) blades, measure clearance between impeller blade tip and wear ring. Measure each blade at its center. Clearance should not exceed 1.02 mm (.040 in). If clearance is greater, disassemble jet pump and inspect impeller and wear ring. Renew worn parts.

Oil Inspection Venturi Removal Detach adjuster of steering cable from nozzle no. 4 (required only if removal is for starboard RH side). Detach ball joint of shifter cable from reverse gate (required only if removal is for starboard RH side).

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1. Remove plug

Check oil level, it should be at bottom of hole threads.

09-02-3

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

If oil level is low, check impeller shaft housing for leaks. A pressure test must be performed. Refer to Pump Pressurization in this section. To check oil condition, insert a wire through opening then withdraw. A whitish oil indicates water contamination. This may involve defective impeller shaft seal and/or O-ring of housing cover. Jet pump unit should be overhauled to replace seal. If everything is correct, apply Loctite Primer N (P/N 293 800 041) then Loctite Pipe Sealant (P/N 293 800 018) on plug and reinstall it on cover. Properly reinstall removed parts.

Remove plug from cover. Pour oil through hole until oil reaches the bottom of hole threads. Use SEA-DOO JET PUMP SYNTHETIC OIL (P/N 293 600 011 — 12 x 6 oz) only. Oil will penetrate slowly in center area of housing, wait a few minutes and readjust oil level.

CAUTION

This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands.

Oil Replacement

Apply Loctite Primer N (P/N 293 800 041) then Loctite Pipe Sealant (P/N 293 800 018) on plug and reinstall it on cover. Properly reinstall removed parts.

Remove parts as described in Oil Inspection. Remove 3 screws retaining cover.

REMOVAL Disconnect adjuster of steering cable from nozzle no. 4 (refer to Oil Level Inspection above for more details).

F02J0TB

TYPICAL 1. Screws

Using a fiber hammer, gently tap cover no. 15 to release it from housing no. 6. Be careful as cover is spring loaded. Thoroughly clean reservoir and inside of cover with a solvent. Check O-ring no. 23 condition. Replace as necessary. Apply a thin layer of Loctite 518 (P/N 293 800 038) on mating surface of cover and reinstall it with its O-ring. Torque screws to 4 N•m (35 lbf•in).

09-02-4

F04K0MA

TYPICAL

Remove ball joint fasteners to release reverse cable from reverse gate.

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Remove 4 retaining screws no. 8 and withdraw venturi.

F04K0KA

TYPICAL

Remove speedometer sensor from ride shoe no. 26 (if necessary).

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1. Remove screws

Remove reverse gate support (with gate) from impeller housing no. 6.

Impeller Housing

F04H2XA

NOTE: At this point, impeller housing no. 6 can be removed as an assembly with nozzle no. 4 and venturi/ reverse gate support no. 7. Refer to Impeller Housing below.

NOTE: In the following procedure, impeller housing no. 6 is removed as an assembly with nozzle and venturi/reverse gate support. Disconnect adjuster of steering cable from nozzle no. 4 (refer to Oil Inspection above for more details). Remove ball joint fasteners to release reverse cable from reverse gate. Remove nuts retaining impeller housing no. 5 to hull.

Nozzle Remove 2 retaining screws no. 1 and withdraw nozzle no. 4 (refer to Oil Inspection above for more details). Push sleeves and bushings no. 3 out of nozzle.

Venturi Remove nozzle no. 4 prior to removing venturi no. 7 (refer to Oil Inspection above for more details). F04J2PA

TYPICAL 1. Remove nuts

09-02-5

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Remove jet pump assembly with a wiggle movement. If pump is hard to remove, use a curved pry bar, apply electrical tape around the curved end in order to protect hull and pry to remove pump.

Cover With pump assembly in horizontal position, remove 3 retaining screws no. 16. Place container under cover no. 15 to catch oil. Using a fiber hammer, gently tap cover to release it from impeller housing. Be careful as cover is spring loaded.

Impeller Insert impeller shaft holder (P/N 295 000 082) on impeller shaft flat end. Using 2 screws previously removed from venturi no. 7, secure shaft holder to housing.

F04P0LA

Pry pump evenly ensuring not to damage the threaded studs.

CAUTION

Some boats may be equipped with shims. Ensure to note location of these shims at removal for reinstallation purposes.

F00J07A

1. Shaft holder

NOTE: If jet pump cannot be removed, the drive shaft may be seized in the impeller splines. Refer to DRIVE SYSTEM 09-03 to remove drive shaft at the same time. If ride shoe needs to be removed, refer to Ride Shoe Removal and Installation at the end of this section.

DISASSEMBLY NOTE: Whenever removing a part, visually check for damage such as: corrosion, crack, split, break, porosity, cavitation, deformation, distortion, heating discoloration, wear pattern, missing plating, missing or broken needle on needle bearing, water damage diagnosed by black-colored spots, etc. Renew any damaged part. As a quick check, manually feel clearance and end play, where applicable, to detect excessive wear.

09-02-6

To ease removal heat impeller no. 17 center with a propane torch to approximately 150Â°C (300Â°F) to break the Loctite bond. Impeller is loosened using impeller remover tool (P/N 295 000 001).

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Install shaft holder in a vice.

NOTE: Wear ring no. 18 can be cut using a jigsaw, a small buffer or a low clearance hacksaw such as Snap-on HS3 or equivalent.

CAUTION

When cutting ring, be careful not to damage impeller housing. 1

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1. Impeller shaft holder secured in a vice

Impeller is loosened using impeller remover tool (P/N 295 000 001). 1

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TYPICAL

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1. Impeller remover tool

Rotate impeller remover tool counterclockwise and unscrew completely impeller.

CAUTION

Never use any impact wrench to loosen impeller. To remove impeller, apply a rotating movement and pull at same time. Slide impeller out of housing and remove tool from impeller.

Wear Ring

F01J0WA

TYPICAL 1. Snap-on HS3

After cutting ring, insert a screwdriver blade between impeller housing and ring outside diameter. Push ring so that it can collapse internally. Pull ring out.

Place impeller housing no. 6 in a vise with soft jaws. It is best to clamp housing using a lower ear. Cut wear ring no. 18 at 2 adjacent places. 09-02-7

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Impeller Shaft

CLEANING

Remove shaft holder tool. Remove impeller shaft no. 25 with thrust washer and thrust bearing.

Properly clean all threads. Remove all O-rings and clean parts in a solvent. Carefully check water passages (Cooling system) and oil passages. Blow low pressure compressed air through them and make sure they are clear.

Seal and Needle Bearing Remove seal no. 19 and bearings no. 20 at the same time using bearing/seal remover tool (P/N 295 000 144).

F01J11A

Insert bearing remover then press tool using a arbor press until seal and bearings are out. However, care should be taken not to damage bearing journals.

F01J13B

1. Water passages 2. Oil passages

Brush and clean impeller shaft threads, impeller and drive shaft splines with Loctite Parts Cleaner (P/N 413 711 809) or equivalent. Free threads and splines from any residue.

CAUTION

Be careful not to damage impeller shaft diameter.

INSPECTION Impeller F00J0MA

1. Bearing/seal remover tool

NOTE: It is always recommended to renew both bearings, even if only one bearing needs to be replaced.

09-02-8

Visually inspect impeller no. 17 splines. Check for wear or deformation. Renew parts if damaged. NOTE: Check also PTO flywheel and drive shaft condition. Refer to DRIVE SYSTEM 09-03. Examine impeller in wear ring for distortion. Check if blade tips are blunted round, chipped or broken. Such impeller is unbalanced and will vibrate and damage wear ring, impeller shaft, shaft seal or bearings. Renew if damaged.

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

With a finger nail, feel contact surface of seal. If any irregular surface is found, renew impeller shaft no. 25. Install bearings then install impeller shaft and rotate it. Make sure it turns smoothly.

F02J0VB

1. Replace if blunted round or damaged

Check impeller for cavitation damage, deep scratches or any other damage.

Radial Play Radial play is critical for jet pump unit life span. Radial play of impeller shaft is checked with shaft in housing, without impeller. Retain housing in a brass jaw vise making sure not to damage housing lug. Set a dial gauge and position its tip onto shaft end, close to end of threads. Move shaft end up and down. Difference between highest and lowest dial gauge reading is radial play. Maximum permissible radial play is 0.05 mm (.002 in).

1 1

F02J0UA

1. Check for cavitation, deep scratches or other damage

Wear Ring Check wear ring no. 18 for deep scratches, irregular surface or any apparent damage. If impeller/wear ring clearance is too large and impeller no. 17 is in good shape, renew wear ring.

F01J18A

MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to threads at shaft end

To check both bearings, proceed the same way with other shaft end. Position gauge tip on diameter, close to flats on shaft.

Impeller Shaft and Needle Bearing Wear Inspect needle bearings no. 20 and their contact surface. Check for scoring, pitting, chipping or other evidence of wear.

09-02-9

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Thrust Washer and Thrust Bearing Visually inspect thrust washer no. 21, thrust bearing no. 22 and their contact surface. Check for scoring, pitting, flaking, discoloration or other evidence of wear.

2 3

F01J19A

MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to flats at shaft end

Excessive play can come either from worn bearings or impeller shaft or damaged impeller housing bearing surfaces. Measuring shaft diameter will determine defective part. Using a micrometer, measure diameter on bearing contact surfaces. Minimum shaft diameter should be 22.24 mm (.876 in). 1

F01J52A

TYPICAL 1. Worn roller (trunnion worn on end of roller) 2. Good roller (cylindrical shape) 3. Look for scoring on retainer

NOTE: When replacing either washer or bearing, it is recommended to renew both.

Cover and Impeller Shaft

F01J1AA

1. Inspect for wear at the bearing pilot 2. Radial bearing raceway

NOTE: If shaft is to be replaced, it is recommended to replace both bearings at the same time. In addition, it is suggested to replace thrust bearing and thrust washer.

09-02-10

End Play End play of impeller shaft no. 25 is checked with shaft in housing, without impeller no. 17 and with housing cover no. 15 installed. Retain housing in a brass jaw vise making sure not to damage housing lug. Set a dial gauge and position its tip on the end of shaft. Move shaft end by pulling and pushing. Difference between highest and lowest dial gauge reading is end play. Maximum permissible end play (new) is 0.12 - 0.54 mm (.005 - .021 in).

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

1 F00J0QA

A. Wear limit 8.0 mm (.315 in) F01J2SA

TYPICAL 1. Tip on shaft end

Excessive play comes from worn protrusion inside housing cover and wear of impeller shaft nose. Using pliers, remove anti-knock pusher no. 27 and spring no. 28 from cover no. 15.

Pusher should be replaced if it is not within specification. Be sure to check end play after installing a new pusher. Inspect impeller shaft nose for wear.

F00J0AA

F00J09A

TYPICAL 1. Pusher

Inspect pusher for any damage or deterioration. Refer to the following illustration to determine the wear limit of the pusher.

1. Impeller shaft nose

Seal Carefully inspect seal no. 19 lips. Make sure that lips are not worn, distorted, cracked or present any other damages. Renew as necessary.

09-02-11

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

ASSEMBLY The jet pump and all its components are the same on port and starboard (LH/RH). However pay attention to the following points.

Wear Ring The wear ring no. 18 features a lip on one edge; position lip outwards of housing. NOTE: To ease insertion into housing, apply a soapy solution (P/N 293 600 016) onto outside circumference of wear ring. To install ring in housing, use a square steel plate approx. 180 x 180 x 6 mm thick (7 x 7 x 1/4 in) and a press. Manually engage ring in housing making sure it is equally inserted all around. Press ring until it seats into bottom of housing.

2 1

F01J5EA

1. Piece of wood 2. Seal lip here 3. Wear ring

Needle Bearing and Seal Bearings no. 20 and seal no. 19 will be properly installed in housing using bearing/seal installer tool (P/N 295 000 107). 1 1

2 F01J5DA

1. Seal lip 2. Press wear ring

If a press is not readily available, a piece of wood, such as a 2 x 4 x 12 in long, can be used. Manually engage ring in housing making sure it is equally inserted all around. Place wood piece over ring. Using a hammer, strike on wood to push ring. Strike one side then rotate wood piece about 90Â° and strike again. Frequently rotate wood piece so that ring slides equally all around until it seats into bottom of housing.

09-02-12

F01J4KA

BEARING/SEAL INSTALLER TOOL 1. Seal end 2. Bearing end

Stamped end of bearings (showing identification marks) must be located toward outside of housing. Properly insert bearing on tool. Using an arbor press only, push tool until tool flange contacts housing. Proceed the same way for both bearings.

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Bearing on impeller side must be 1.5 to 2.5 mm (.060 - .100 in) inside reservoir measured from seal seat. Bearing on venturi side must be 2 to 3 mm (.080 - .120 in) inside reservoir measured from thrust washer seat. Refer to following illustration.

A 1

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1. Stamped end this side

CAUTION

Never hammer the bearing into its housing.

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1. 2. 3. 4. A. B.

Seal seat Stamped end of bearing Thrust washer seat Stamped end of bearing 1.5 - 2.5 mm (.060 - .100 in) 2 - 3 mm (.080 - .120 in)

Seal must be installed so that lips raised edges are toward outside of housing (toward impeller). Apply Loctite 518 (P/N 293 800 038) in seal housing, all around outer diameter and on seal seat. Properly insert seal on tool. NOTE: Be careful when installing seals to pack seal with grease before inserting bearing/seal installer tool. Properly insert tool in seal with a rotating movement.

F00J0BA

1. Press on tool until it stops

CAUTION

This tool has been designed to properly position bearings and seal, thus providing space for lubrication purposes. The tool flanges allow this. If a different pusher type is being used, components must be properly positioned as follows.

F01J1KA

1. Raise edge of seal this side

09-02-13

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

CAUTION

Prevent sealant from contacting any needle of bearing. Push on tool end with a press until tool flange contacts housing.

F00J0DA

1. Thrust washer properly installed in stator seat

Thrust Bearing Apply Sea-Doo jet pump synthetic oil (P/N 293 600 011) on both sides of thrust bearing no. 22. Position thrust bearing on thrust washer no. 21. 1

F00J0BA

1. Press on tool until it stops

Apply synthetic grease (P/N 293 550 010) between seal lips. 1

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1. Thrust bearing on top of thrust washer

F01J1MA

Impeller shaft To prevent seal lip damage when inserting impeller shaft no. 25, use impeller shaft guide (P/N 295 000 002).

1. Loctite 518 all around and behind 2. Raised edge of seal lip this side

Thrust Washer Position impeller housing with the stator vanes on top. Insert thrust washer no. 21 in the stator seat. F01J1OA

09-02-14

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Insert tool onto shaft end then carefully install shaft in impeller housing.

Using 2 screws previously removed from venturi no. 7, secure impeller shaft holder tool to housing. Install shaft holder tool in a vice.

F00J0FA

1. Impeller shaft 2. Impeller shaft guide

NOTE: If jet impeller housing rests against a table, raise it slightly to allow complete shaft insertion with the shaft guide. Remove shaft guide.

Impeller Apply Loctite Primer N (P/N 293 800 041) on impeller shaft threads. Allow to dry for 2 minutes. NOTE: Loctite Primer N is used to reduce Loctite 271 curing time and to activate stainless steel and aluminum surfaces for better bonding action. If applied, complete curing time is 6 hours, if primer is not used, allow 24 hours for curing time. Apply Loctite 271 ( P/N 293 800 005) to shaft threads.

F00J0HA

1. Impeller shaft holder secured in a vice

To ease impeller no. 17 installation, apply liquid soap on wear ring no. 18. Insert impeller into wear ring. Manually rotate impeller and push so that it slides on impeller shaft threads. Carefully engage threads making sure they are well-aligned. Install impeller remover/installer tool into impeller splines and tighten. 1

F00J08A

1. Impeller remover/installer tool

F00J0GA

1. Apply Loctite 271 on threads

CAUTION

Make sure thrust washer and bearing are not wedged in shaft groove. To check, manually pull and push impeller housing, some axial play must be felt. 09-02-15

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Torque impeller to 70 N•m (52 lbf•ft) then remove tools.

CAUTION

Never use any impact wrench to tighten impeller. Apply synthetic grease (P/N 293 550 010) on impeller splines. Insert a new boot no. 13 and ring no. 14 to impeller.

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1. Spring 2. Pusher 3. O-ring with Loctite 518

Install cover to impeller housing making sure to properly position filler plug on top side.

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1. Boot and ring

Cover Install O-ring no. 23 to cover no. 15. Apply Loctite 518 (P/N 293 800 038) on O-ring. Make sure spring no. 28 and anti-knock pusher no. 27 are in place.

F01J5IA

1. Filler plug toward top side of pump housing

Apply Loctite 242 (P/N 293 800 015) on screw threads and evenly tighten cover screws. Torque to 4 N•m (35 lbf•in).

09-02-16

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Oil Fill NOTE: It is highly recommended to perform a leakage test prior to adding the oil. Refer to PUMP PRESSURIZATION in this subsection. Place housing horizontally as in its operating position so that filler plug is located on top. Remove filler plug from cover. Pour SEA-DOO JET PUMP SYNTHETIC OIL (P/N 293 600 011) in reservoir until oil comes level with bottom of hole. Let oil drain into housing and after a few minutes add more oil until it is level with bottom of filler hole.

CAUTION

This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands. NOTE: When filling reservoir, oil must be poured into cover quite slowly to allow complete housing fill.

F00J0JA

F04J2OA

1. Torque screws to 21 N•m (16 lbf•ft)

PUMP PRESSURIZATION Whenever doing any type of repair on the pump, pressure test should be done to check for any leakage. Proceed as follows: – Remove drain plug from housing cover. – Apply Loctite Pipe Sealant (P/N 293 800 018) on threads fitting tool (P/N 295 000 086) then secure on cover. – Connect pump gauge tester (P/N 295 000 083) to fitting. – Pressurize pump to a maximum of 70 kPa (10 PSI).

TYPICAL 1. Pour oil slowly until it is level with bottom of filler hole

Venturi Apply Loctite 518 (P/N 293 800 038) on mating surface. Position venturi no. 7 with bailer passages on top. Install reverse gate support (with gate). Apply Loctite 242 (P/N 293 800 015) on threads of screws no. 8. Install screws no. 8, lock washers and flat washers then torque to 21 N•m (16 lbf•ft).

F00J0LA

– Pump must maintain this pressure for 10 minutes.

09-02-17

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

CAUTION

Repair any leak, failure to correct a leak will lead to premature wear of pump components. NOTE: If there is a pressure drop, spray soapy water around housing cover. If there are no bubbles, impeller shaft, impeller shaft seal, or impeller housing is leaking through porosity and has to be replaced. Jet pump unit has to be disassembled if jet pump has been overhauled, the impeller shaft seal no. 19 may be leaking; add a small quantity of Sea-Doo jet pump synthetic oil to wet the oil seal. Let soak and recheck. – Disconnect pump gauge tester and remove fitting. – Check oil level. Refill as necessary. Apply Loctite Primer N (P/N 293 800 041) then Loctite Pipe Sealant (P/N 293 800 018) on plug threads then secure it on cover.

INSTALLATION NOTE: It is recommended to apply the Right Stuff Gasket at a temperature within 5-27°C (40-80°F).

Miscellaneous Generously apply synthetic grease (P/N 293 550 010) on drive shaft splines. Make sure rubber damper is on drive shaft end. Apply the Right Stuff Gasket (P/N 293 800 053) on pump as shown in the following illustration.

Ensure drive shaft protector tube is properly installed. While holding pump, guide and engage drive shaft splines in impeller. Wiggle pump if necessary. NOTE: As an alternative method if you experience difficulties, you may release the small clamp on PTO flywheel to withdraw drive shaft. Refer to DRIVE SYSTEM 09-03. Insert drive shaft in impeller splines then insert drive shaft (with the pump) in PTO flywheel. Properly reinstall components. If necessary, carefully tap pump end with a rubber hammer until retaining nuts and washers can be installed. Apply Loctite 242 (P/N 293 800 015) on threads and equally tighten nuts in a criss-cross sequence and torque as shown in exploded view.

Nozzle and Bushing Apply BOMBARDIER LUBE (P/N 293 600 016) on bushings no. 3. Insert bushings in nozzle, positioning their flanges from inside of nozzle. Install nozzle no. 4 on venturi no. 7, position its steering arm on RH side. Apply Loctite 242 (P/N 293 800 015) on threads. Install screws then torque to 20 N•m (15 lbf•ft). Reinstall adjuster of steering cable and ball joint of reverse cable. Torque reverse cable bolts to 2.7 N•m (24 lbf•in).

F04J04B

F04J0CB

TYPICAL 1. Apply the Right Stuff Gasket 09-02-18

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

F04J0DA

1. Ball joint parallel with cable lever 2. Latching mechanism

NOTE: Ball joint must be parallel with cable lever. If not, loosen jam nut and adjust ball joint. Torque jam nut to 4.6 N•m (40 lbf•in). Reinstall speedometer sensor (if removed) to ride shoe. Attach speedometer sensor cable to hook on starboard side (right) of pump. Secure using a small locking tie.

Reinstall reverse gate link rod to RH reverse gate. Reinstall steering link rod to nozzle. Check steering alignment. Refer to ALIGNMENT 10-03. Slightly lubricate wear ring with a soapy solution before starting to minimize friction during initial start. Manually rotate the PTO flywheel to ensure impeller rotates freely. If flywheel does not rotate, perform the following procedure. Loosen the 4 nuts retaining impeller housing enough to remove pressure, (approximately 1 turn). Generously apply BOMBARDIER LUBE lubricant (P/N 293 600 016) in impeller housing to minimize friction during initial start. Start engine. Run engine for a few seconds to allow impeller to make its way into the wear ring.

CAUTION

Run engine at idle speed only. If engine is to be ran more than a few seconds, engine must be water cooled with a garden hose through the flushing fitting. Gradually tighten nuts of impeller housing in a criss-cross sequence and torque to 28 N•m (21 lbf•ft). NOTE: Repeat procedure for both impellers if such is the case. Test run boat.

F04L5AA

1. Locking tie

09-02-19

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

RIDE SHOE REMOVAL AND INSTALLATION REMOVAL

CAUTION

Removing ride shoe will possibly damage it. Remove only when it is absolutely necessary. NOTE: If ride shoe is removed for a ventilation problem, ensure it is not a cavitation problem. Also make sure the ventilation does not come from the jet pump sealing, a leakage of the through-hull fitting/drive shaft boot, weedless cable/housing or ride shoe fasteners. Refer to TROUBLESHOOTING 03-01 for more information. To provide access for removing ride shoe, lift bow and partially move boat off back of trailer. Use a lift kit, see table below. Refer to the kit instruction sheets for proper use. BOAT MODEL

KIT P/N

(16 ft) Speedster and Speedster SK

295 100 085

NOTE: The ride shoes and jet pump supports are different on port and starboard (LH/RH).

Tools Required – 2 pry bars, approx. 46 cm (19 in) in length – phillips head screwdriver – hammer – scraper NOTE: Jet pump and intake grill do not need to be removed. Lower intake grill with the weedless system lever. Remove six bolts that are retaining ride shoe to hull. The ride shoe is assembled to the hull with bolts instead of screws. You will need a person to hold the nuts from the bilge while removing the bolts under the hull. The nuts are located each side of the water channel at the back.

F04L4UA

F04L2DB

TYPICAL 1. Trailer supported with jack stands and wheels blocked

;

WARNING

Always remove safety lanyard from DESS post to prevent unattended engine starting, prior to working on the jet pump/ride shoe.

09-02-20

TYPICAL

NOTE: It may be necessary to heat ride shoe in order to remove it. Insert pry bars between hull and ride shoe. Tap ends of pry bars gently and alternately until the sealant bond breaks.

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

F04L4VA

Apply a slight downward pressure on pry bars until sealant releases and ride shoe separates from boat.

CLEANING Scrape all excess of sealant from ride shoe, hull and pump support.

F04L4XA

INSTALLATION NOTE: It is recommended to apply the Right Stuff Gasket at a temperature within 5-27°C (40-80°F). Apply a 6 mm (1/4 in) thick seam of Right Stuff Gasket (P/N 293 800 053) on ride shoe while paying close attention to the routing shown on the following photos.

F04J3WA F04L56A

STARBOARD RIDE SHOE SHOWN

TYPICAL

Clean hull using acetone. Clean plastic ride shoe and pump support using isopropyl alcohol. Let the cleaner evaporate completely. Ensure to eliminate grease, dust and any remaining loose sealant.

09-02-21

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Apply Right Stuff Gasket around screw holes on flat surface of intake grate.

CAUTION

Allow sealant to cure 12 hours when using Right Stuff Gasket before putting boat in water. Test run boat.

JET PUMP SUPPORT REMOVAL AND INSTALLATION Jet Pump Support F04J3XA

STARBOARD RIDE SHOE SHOWN

Install ride shoe on hull.

F04L50A

Install within 3-4 minutes after having applied Right Stuff Gasket. Apply the Right Stuff Gasket around screws and on the taper of the screw head. Torque screws to 10 N•m (88 lbf•in) in a criss-cross sequence while someone is holding the nuts from inside the bilge. Apply Adseal 4511 (P/N 293 800 033) on nuts inside bilge to have a water tight seal. Insert arm up through intake opening from beneath boat and using a finger, spread excess sealant that is lodged between the hull and ride shoe.

09-02-22

Removal NOTE: Ride shoe removal is required. Since the support no. 9 is used to seal the hull and thus easing pump removal, the support should not be removed needlessly. Remove jet pump as explained above. Remove ball joints, boots, nuts, half rings and O-ring from cables. From inside of hull, disconnect water supply hose from its fitting. Remove fasteners retaining support to hull. Using a heat gun, heat support until it can be pulled off. Cleaning Scrape all excess sealant from ride shoe and hull. Clean ride shoe and hull using acetone. Ensure to eliminate grease, dust and any remaining loose sealant. Installation NOTE: It is recommended to apply Right Stuff Gasket (P/N 293 800 053) at a temperature within 5-27°C (40-80°F).

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Apply Right Stuff Gasket onto jet pump support as per the following illustrations.

F10J01A

F10J02A

Properly reinstall remaining parts.

09-02-23

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

DRIVE SYSTEM

0 Loctite 271

1 2

5 11 8 12 7

6 10 Synthetic grease

Right Stuff Gasket

1.8 N m (16 lbf in) 3

Synthetic grease 10 13

F04J47S

PARTS

09-03-1

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

GENERAL Jet pump must be removed to replace any components of the drive system. Refer to JET PUMP 09-02 for jet pump removal procedure.

REMOVAL Remove PTO flywheel guard.

Large Clamp Unfasten large clamp no. 1 of PTO flywheel boot as follows: – Use pliers (P/N 295 000 069). F01J29A

TYPICAL 1. Locking hooks

Small Clamp Unfasten small clamp no. 2 of PTO flywheel boot as follows: Use pliers (P/N 295 000 054).

F01J0GA

– Insert pointed tips of pliers in closing hooks.

F01B1TA

To open clamp, place flat side of plier on clamp embossment, squeeze and twist plier.

F01J2AA

TYPICAL 1. Closing hooks

– Squeeze pliers to draw hooks together and disengage windows from locking hooks.

F02J0PA

09-03-2

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

Floating Ring and Circlip

Protective Boot

Hold floating ring no. 4 and compress boot no. 7; then, pull out circlip no. 5 from drive shaft groove.

Loosen gear clamp no. 6 holding protective boot, then carefully pull hose and carbon ring no. 8 from hull insert.

Carbon Ring Loosen gear clamp no. 12 then pull carbon ring no. 8 from protective boot.

Drive Shaft Protector Tube If it is required to remove the drive shaft protector tube no. 13. First remove locking ring with a flat screwdriver, as shown in the next photo then squeeze retaining tabs of protector to withdraw tube from through-hull (from the pump side). F06I06A

TYPICAL 1. Push floating ring 2. Remove circlip

Slide floating ring forward completely.

F09J0LA

1. Remove this locking ring

INSPECTION Drive Shaft Protector

TYPICAL

Inspect drive shaft protector tube no. 13 condition. Check inside of tube and its retaining tabs. Replace tube as necessary.

Drive Shaft

Pull out drive shaft no. 3. NOTE: If the drive shaft is jammed into PTO flywheel, a hammer puller can be used to withdraw drive shaft.

Inspect condition of drive shaft no. 3 and PTO flywheel no. 9 splines. Inspect condition of groove. With your finger nail, feel machined surface of drive shaft. If any irregular surface is found, renew drive shaft.

F04I02A

09-03-3

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

F01I0FA

1. Surface condition 2. Groove condition 3. Splines condition

Excessive deflection could cause vibration and damage to drive shaft splines, impeller, flywheel or floating ring. Place drive shaft on V-blocks and set-up a dial gauge in center of shaft. Slowly rotate shaft; difference between highest and lowest dial gauge reading is deflection. Refer to the following illustration. Maximum permissible deflection is 0.5 mm (.020 in).

F01I0GA

1. O-rings 2. Floating ring contact surface

ASSEMBLY Assembly is essentially the reverse of disassembly procedure. However, pay particular attention to the following.

Drive Shaft Protector Tube Apply some Right Stuff Gasket (P/N 293 800 053) on drive shaft protector tube no. 13, as shown in the next illustration. This will avoid protector vibrations. A

F01J15A

2 1

MEASURING DRIVE SHAFT DEFLECTION 1. Dial gauge 2. V-blocks

Damper Visually inspect shape of dampers no. 10 for deformation or other damage.

Floating Ring and O-Ring Inspect condition of O-rings no. 11 and floating ring no. 4 contact surface.

09-03-4

F09J0KA

1. Apply Right Stuff Gasket here A. 40 mm (1-9/16 in)

Insert drive shaft protector tube in through-hull fitting and properly clip the tabs on the edge of the fitting then reinstall locking ring. NOTE: When inserting drive shaft protector tube, check that embossment is positioned at bottom, as shown in the next photo.

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

Insert floating ring no. 4 on drive shaft. Engage drive shaft splines in PTO flywheel. NOTE: If shaft is difficult to insert into flywheel boot, a small quantity of grease can be applied INSIDE the boot. Rotate shaft to properly index splines. Make sure boot is well-positioned over shaft end.

Drive Shaft Boot Preload

F09J0MA

1. Embossment positioned at bottom 2. Right Stuff Gasket on opposite side

Damper Install damper no. 10 on drive shaft no. 3. NOTE: Make sure dampers were not left in PTO flywheel or impeller.

This procedure is required to confirm the proper preload of the boot. Improper preload may allow ventilation of propulsion system or water infiltration in the bilge. Ensure floating ring no. 4 is far enough forward in order to release all pressure from carbon ring. Measure protective boot free length. Note the measurement.

Floating Ring and O-Ring Ensure both O-rings no. 11 are properly located inside floating ring no. 4 grooves.

CAUTION

Grease on the carbon seal, floating ring or O-ring may cause O-ring to dislodge from the groove and slide on the drive shaft which may allow water leakage. Always wipe off any grease.

Drive Shaft Insert drive shaft no. 3 in through-hull fitting but temporarily keep a gap between shaft end and PTO flywheel no. 9.

CAUTION

Do not apply grease on drive shaft splines. Lubrication will be done later from the PTO flywheel grease fitting.

1 F00J03A

TYPICAL â&#x20AC;&#x201D; DO NOT READ THE RULER FROM THE PHOTOGRAPH 1. Measuring free length of protective boot A. Measure between carbon ring and through-hull fitting

Push floating ring no. 4 farther than groove on shaft.

CAUTION

Take care not to break the O-rings in the floating ring while inserting the drive shaft. Insert circlip no. 5 in groove of shaft.

09-03-5

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

Reinstall parts and verify compressed length of boot another time. If everything is within the specification, continue with the installation of clamps (see below). Otherwise, call your service representative.

Large Clamp – Secure large clamp no. 1 as follows: – Use pliers (P/N 295 000 069) as for removal. – Manually engage holding hook in large window. This is a pre-clamping position only. 1 F06I06A

1. Push floating ring 2. Install circlip

Measure the compressed length (installed parts) of the protective boot (between carbon ring and through-hull fitting). Note the measurement. Subtract the compressed length from the free length. Free length - Compressed length = Difference A difference of 8 mm (5/16 in) to 16 mm (5/8 in) should be obtained. If the difference is less than 8 mm (5/16 in), a spacer is required (see next paragraph). Otherwise, continue with the installation of clamps (see below). Unlock and pull out drive shaft to install one spacer between protective boot and hull on throughhull fitting.

F01J23A

PRE-CLAMPING POSITION 1. Holding hook 2. Large window

– Insert pointed tips of pliers first in closing hooks.

F01J2BA

TYPICAL 1. Closing hooks F00J04B

TYPICAL 1. Spacer

09-03-6

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

â&#x20AC;&#x201C; Squeeze pliers. When both large and small windows are directly over the 2 locking hooks, press those windows down to engage hooks in windows.

F02J0PB

1. Squeeze pliers F02J0IA

LUBRICATION

1. Press to engage hooks in windows

NOTE: At installation, clamp tail should be in opposite direction of engine rotation. 1

F01J23B

Using a grease gun, carefully lubricate PTO flywheel with synthetic grease (P/N 293 550 010), until boot is just beginning to expand. At this point, immediately stop greasing.

1. Engine rotation (counterclockwise) 2. Tail in opposite direction

Small Clamp To secure small clamp no. 2, place notch side of plier on clamp embossment and squeeze plier.

F01I0BB

09-03-7

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

REVERSE SYSTEM Loctite 242

0 4.5 N m (40 lbf in)

Loctite 242 10 N m (89 lbf in) Loctite 242

7 N m (62 lbf in)

2.7 N m (24 lbf in)

4 Loctite 242

Loctite 242

9 N m (80 lbf in)

6 3

1.7 N m (15 lbf in) 1

F10J05S

TYPICAL

PARTS

09-04-1

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

INSPECTION Check all moving parts and bushings for wear, straightness, corrosion and free movement. Replace parts as required.

DISASSEMBLY Reverse Gate Support For additional information, refer to JET PUMP 0902. Detach steering/shifter cables. Detach steering link rod from nozzle. Detach reverse gate link rod no. 3 from RH reverse gate no. 1 (required even if working on LH side).

1. Remove rearmost nut

F04J1XA F09J08B

1. Detach

Remove reverse gate support no. 2 (with gate), venturi and nozzle assembly from impeller housing. NOTE: When removing parts on LH side, reverse gate link rod may be kept with the reverse gate.

Reverse Gate Link Rod To detach reverse gate link rod no. 3 from LH reverse gate no. 1, remove the rearmost nut and rotate link rod. This gives access to reverse gate retaining screw.

09-04-2

F04J1WA

1. Rotate rod 2. Remove screw

Remove reverse gate to give access to the remaining screw of link rod.

Latching Mechanism Note that the latching mechanism is installed on RH reverse gate. Remove screw no. 4 to detach lever.

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

For installation, install lever no. 5 in a vise and apply some BOMBARDIER LUBE (P/N 293 600 016) in lever hole. Properly position reverse gate and carefully insert roll pin with a hammer.

CAUTION

Failure to properly hold lever in a vise may lead to damages to the reverse gate or the lever.

F04J1YA

TYPICAL

Carefully install reverse gate in a vise with a socket underneath tab holding roll pin.

CAUTION

Failure to properly support tab of roller pin will lead to damages to the reverse gate. Remove lever no. 5 using a small punch by carefully pushing roll pin no. 6 out.

F04J20A

TYPICAL 1. Hold lever in a vise 2. Carefully insert roller pin

If the pawl-stop no. 7 needs to be replaced, drill rivets out with a 4.8 mm (3/16 in) drill bit.

2 1

F04J1ZA

TYPICAL 1. Socket to support tab of roll pin 2. Carefully punch roller pin out

F04J21A

TYPICAL â&#x20AC;&#x201D; USE A 4.8 MM (3/16 IN) DRILL BIT

NOTE: If roll pin cannot be removed this way, a small cutting disk can be used.

09-04-3

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

For installation, position pawl-stop as shown.

Anode Wire When reinstalling reverse link rod, ensure that anode wire is properly installed, as shown in the next photo.

F04J22A

TYPICAL 1. Correct position of pawl-stop

Reverse Gate Deflector If reverse gate deflector has been removed, ensure to reinstall it on the inner side of the reverse gate.

F10J06A

1. Install wire ends here

Reverse Gate Locking System Verification and Adjustment NOTE: Proceed with RH side. Fully pull both throttle levers to idle position then pull shifter in reverse position. Ensure reverse gate ear contacts the stopper.

F04J23A

TYPICAL â&#x20AC;&#x201D; RH REVERSE GATE SHOWN 1. On inner side of reverse gate

ASSEMBLY Prior to assembling moving parts, lubricate with synthetic grease (P/N 293 550 010). Reinstall steering link rod and reverse link rod no. 3 steering and shifter cables. Refer to ALIGNMENT 10-03 then look for Alignment. Ensure that steering cable ball joints are parallel with cable lever.

09-04-4

F04J05A

TYPICAL â&#x20AC;&#x201D; IN REVERSE POSITION 1. Must touch

Fully push shifter in forward position. A latching sound should be heard. Try pulling reverse gate down manually. It must be locked by the latching mechanism.

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

2 F04L7KA

F04J06A

TYPICAL â&#x20AC;&#x201D; IN FORWARD POSITION 1. Must be locked when manually pulling downward 2. Latching mechanism

If either check fail, readjust cable to meet both conditions. Shifter Cable Adjustment Unscrew throttle/shifter controller from boat.

CAUTION

Use a protective mat (P/N 295 000 129) in shifter area when withdrawing it for adjustment.

TYPICAL 1. Adjust reverse gate here

Shifter Cable Replacement Detach cable ball joint from cable lever on reverse gate then unscrew ball joint from cable. From inside of hull, loosen lock nut. From outside of hull, pull cable to allow half rings removal. For the other end of cable, remove throttle/shifter controller from boat and detach cable from mechanism. At assembly, ensure to properly tighten lock nut. Check watertightness. Adjust as explained above.

09-04-5

Section 09 PROPULSION SYSTEM Subsection 05 (WEEDLESS SYSTEM)

WEEDLESS SYSTEM Loctite 242

Loctite 242 6 5

4 3 Synthetic grease

Loctite 242 Anode system

1.5 N m (14 lbf in) Loctite 242 4.5 N m (40 lbf in) 11 10 N m (89 lbf in)

Synthetic grease

10 10 N m (89 lbf in) Adseal 4511

Synthetic grease 10 N m (89 lbf in)

7 1

Adseal 4511

Body

Loctite 242 4.5 N m (40 lbf in) F09J0OS

PARTS

09-05-1

Section 09 PROPULSION SYSTEM Subsection 05 (WEEDLESS SYSTEM)

INTAKE GRILL Removal Lower the grill no. 1 and grab it with a hand to feel the play. If excessive, replace bushings. Detach rod end. Remove retaining screws to withdraw grill.

F09J09A

PULL SPRING OUT

Pull lever out while holding locking block no. 4, as shown in the next photo.

F04J26A

TYPICAL 1. Detach rod end 2. Remove screws

Installation At assembly, ensure to apply the Right Stuff Gasket (P/N 293 800 053) between hull and grill base as well as inside screw holes. Apply Loctite 242 (P/N 293 800 015) on fasteners as shown in exploded view, as described in JET PUMP 09-02. Torque screw to 6 N•m (53 lbf•in).

WEEDLESS SYSTEM MECHANISM (Inside RH Front Storage Compartment) Removal Pull spring no. 3 out to unlock lever no. 2.

09-05-2

F09J0AA

1. Locking block

Section 09 PROPULSION SYSTEM Subsection 05 (WEEDLESS SYSTEM)

Position sliding block no. 5, as shown in the next photo then detach both cable ends from support bracket no. 6. 2

F09J0BA

1. Sliding block 2. Cable ends

Move sliding block backward then halfway forward again, as shown in the next photo. Detach both cable ends from sliding block. See following photo. NOTE: To ease cable ends removal, slightly open sliding block slot using a screwdriver.

F09J0CA

MOVE BACKWARD THEN HALFWAY FORWARD 1. Sliding block 2. Cable ends 3. Sliding block slot

Loosen cable lock nuts then detach cables from support bracket. Detach support bracket from body by removing retaining nuts.

09-05-3

Section 09 PROPULSION SYSTEM Subsection 05 (WEEDLESS SYSTEM)

Inspection Inspect parts for wear, bending or other damage. Replace parts as necessary. Inspect locking block no. 4 for wear/damage where shown.

WEEDLESS ROD AND CABLES REPLACEMENT Rod Removal Lower intake grill no. 1. From underneath hull, detach rod end from grill.

F04J2BA

1. Inspect for wear/damage particularly here

F04J26B

Assembly Assembly is essentially the reverse of disassembly. However, pay attention to the following. Apply synthetic grease to all moving parts. Apply Loctite 242 (P/N 293 800 015) on threads of fasteners as shown in exploded view. Reinstall support bracket with sliding block to body. Reattach all cables to support bracket. Install lever with its open end as shown.

TYPICAL 1. Detach rod end

From inside of bilge, unscrew nut retaining rod to sliding block, as shown in the next photo. 4

F04J2FA

TYPICAL 1. Open end here

Reinstall locking block on lever then secure with spring.

09-05-4

F09J04B

TYPICAL 1. Unscrew this nut 2. Rod 3. Sliding block 4. Support bracket 5. Cables

Section 09 PROPULSION SYSTEM Subsection 05 (WEEDLESS SYSTEM)

Detach anode contact plate no. 9 from cable end, as shown in the next photo.

F09J0RA

F09J0PA

DETACH ANODE CONTACT PLATE

Slide rod down then remove anode contact plate and lock nut, as shown in the next photo. NOTE: Once lock nut has been removed, rod can be pulled out from outside bilge then replaced.

1. V-shape at bottom 2. Grease

Reinstall screw no. 10 then torque to 10 N•m (89 lbf•in). Reinstall first nylon washer, install support bracket, install second nylon washer then secure with elastic nut no. 11. Torque nut to 10 N•m (89 lbf•in).

Rod Adjustment Adjustment at Intake Grill When weedless lever no. 2 is fully pushed in, the water intake grill must be fully lifted. Ensure there is no gap and that intake grill fingers are aligned with the bottom of the ride shoe. At this point, the weedless system lever must be locked when pulling lever WITHOUT TURNING (contrarily to its normal use). This will validate the operation of the locking mechanism.

F09J0QA

1. Remove this lock nut

Rod Installation Apply grease in bushing hole. From outside bilge, position shortest threaded rod end on top then insert rod into hull fitting. From inside bilge, install bushing on rod, as shown in the next photo. Make sure that bushing V-shape is positioned at bottom.

F04J2FA

TYPICAL 1. Pull lever WITHOUT TURNING

09-05-5

Section 09 PROPULSION SYSTEM Subsection 05 (WEEDLESS SYSTEM)

Cable(s) Removal Detach cable from sliding block inside RH front storage compartment. Refer to WEEDLESS SYSTEM MECHANISM (inside RH front storage compartment) above. From inside bilge, loosen nut, as shown in the next photo, retaining support bracket to hull.

F04J2JA

1. Adjust to remove all gap here

If adjustment is required, loosen lock nut, unscrew rod end and turn as necessary. After adjustment, ensure to apply Loctite 242 (P/N 293 800 015) and torque screws to 4.5 N•m (40 lbf•in). Adjustment at Weedless Mechanism Inside Bilge Loosen nuts, as shown in the next photo, to adjust intake grill.

F09J0SA

1. Loosen nut

Detach cables from sliding block then support bracket, as shown in the following photo sequence:

F09J04A

WEEDLESS MECHANISM INSIDE ENGINE COMPARTMENT 1. Loosen lock nuts

Apply Loctite 242 (P/N 293 800 015) on threads then tighten nuts. Validate adjustment as explained above.

09-05-6

F09J0TA

SLIDE CABLE END OUT OF SUPPORT SLOT

Section 09 PROPULSION SYSTEM Subsection 05 (WEEDLESS SYSTEM)

In the case that both cables needs to be removed, repeat above procedure and pay attention to the following for second cable removal.

F09J0UA

REMOVE GROMMETS FROM SUPPORT 1. Remove both grommets for each cable

F09J0XA

SLIDE CABLE END OUT OF SLOT

Cable(s) Installation Tape the rear end of the old cable to the end of the new cable. Pull the old cable from the front to allow the installation of the new one. Installation is essentially the reverse of removal. However, pay attention to the following. Attach cables to support bracket no. 6 and sliding block no. 5 inside bilge. Attach all cables to support bracket and sliding block inside RH front storage compartment. See next illustration for proper cable positioning. F09J0VA

USING LONG NOSE PLIERS, DETACH CABLE END

F09J0WA

PULL CABLE OUT 09-05-7

Section 09 PROPULSION SYSTEM Subsection 05 (WEEDLESS SYSTEM)

F09J0GA

1. Cable adjuster

F09J0FA

CABLES POSITIONING

Remove any play from both upper cables with adjustment screws located inside RH front storage compartment on support bracket. See following photo.

Apply synthetic grease (P/N 293 550 010) to all moving parts. Also apply Loctite 242 (P/N 293 800 015) and torque fasteners as shown in exploded view. Perform rod and cables adjustment as described below. 1

Cables Adjustment Push handle to the closed position. Remove any play from both lower cables with cable adjuster located inside RH front storage compartment. See following photo. F09J0HA

1. Adjustment screw

Check that inlet grate properly operates.

09-05-8

Section 10 STEERING SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

STEERING SYSTEM .............................................................................................................. STEERING SYSTEM INSPECTION ................................................................................... STEERING CABLE REPLACEMENT .................................................................................. LOW-SPEED STEERING CONTROL SYSTEM CABLE REPLACEMENT ......................... STEERING HELM REPLACEMENT ...................................................................................

10-02-1 10-02-2 10-02-2 10-02-3 10-02-4

ALIGNMENT ..........................................................................................................................

10-03-1

THROTTLE/SHIFTER CONTROLLER .................................................................................... REMOVAL........................................................................................................................... INSPECTION ...................................................................................................................... LUBRICATION .................................................................................................................... ADJUSTMENTS ................................................................................................................ ASSEMBLY.........................................................................................................................

10-04-1 10-04-2 10-04-2 10-04-2 10-04-2 10-04-3

10-01-1

Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM)

STEERING SYSTEM

0 12

6 N m (53 lbf in) Loctite 242 10

6 N m (53 lbf in)

2.8 N m (25 lbf in)

12.7 N m (112 lbf in)

8 2.8 N m (25 lbf in)

13 14

30 N m (22 lbf in) 7

Loctite 242 20 N m (15 lbf ft)

9 1.3 N m (12 lbf in)

Loctite 242 2.8 N m (25 lbf in) Loctite 271 6 N m (53 lbf in)

11 4

5 7.8 N m (68 lbf in)

Loctite 242

Synthetic grease

F09K0AS

ADSEAL 4511

1 2.8 N m (25 lbf in)

PARTS

10-02-1

Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM)

STEERING SYSTEM INSPECTION Check operation of steering. It must turn easily and smoothly with a regular resistance from side to side. Rotating resistance must be at a minimum. No friction should be felt. No frictional sound should be heard. Check steering end play. If something is wrong, isolate cable from steering helm to diagnose faulty part. Proceed as follows: – Visually check cable for wear and oxidation at steering helm and at nozzle. Check at end of cable housing. Replace as necessary. – Detach cable end from helm arm.

Turn steering from side to side, if rotation movement is abnormal or if end play is excessive, replace steering helm as an assembly.

◆

WARNING

Disassembly of the steering helm can lead to steering failure. Replace complete assembly. For cable assembly, use supplied hardware only. Do not use substitutes.

STEERING CABLE REPLACEMENT Removal

F09K03A

TYPICAL 1. Remove nut and detach from arm (underneath) 2. Loosen this nut to allow moving cable

F04K0QA

TYPICAL — SINGLE ENGINE HELM REMOVED FOR CLARITY PURPOSE ONLY (REMOVAL IS NOT REQUIRED FOR THE VERIFICATION) 1. Check for wear (particularly brass bushing wear) or oxidation in this area

– Check cable movement. Replace as necessary. 10-02-2

Remove nut no. 1 from adjuster no. 2, then detach adjuster from nozzle. Remove nut no. 3 from cable. From inside of hull, remove silicone around cable. Pull cable out of transom. Remove helm no. 10. This will ease further reassembly of low-speed steering control system cables. Refer to Steering Helm Replacement below. Detach cable ends from pivoting arm no. 14. Rotate steering wheel (or shaft) to release tension on throttle cables. Detach throttle cables from pivoting plates no. 4. Refer to Low-speed Steering Control System Cable Replacement below. Detach cable housing no. 5 from helm arm no. 11. Unscrew adjuster no. 16 from cable while rotating bracket no. 11 of throttle cables to allow removal of steering cable.

F04K0RA

TYPICAL 1. Unscrew adjuster while rotating bracket

Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM)

Remove cable from hull.

Installation Reinstall removed parts and pay attention to the following: Pass cable through transom. Apply ADSEAL 4511 (P/N 293 800 033), as shown in exploded view. Screw external nut no. 3. Position adjuster no. 2 half way on threaded length of cable end. Install adjuster with washer on nozzle, as shown in the next photo.

LOW-SPEED STEERING CONTROL SYSTEM CABLE REPLACEMENT Removal Remove helm no. 10 (refer to Steering Helm Replacement below). This will ease further reassembly of low-speed steering control system cables. Refer to Steering Helm Replacement. Loosen nuts retaining pivoting plates no. 4 together just enough to release cable ends. Loosen lock nuts then detach cables from throttle cables bracket no. 11. Detach throttle cables from throttle/shifter controller and from carburetors.

Installation Reinstall the throttle cables at carburetors and at throttle/shifter controller. Proceed with throttle cables adjustment as specified in CARBURETORS 06-04. Reinstall cables to bracket and in proper holes of pivoting plates. Retighten nut of pivoting plate. 1

F09K04A

ADJUSTER POSITIONED HALFWAY ON THREADED LENGTH 1. Adjuster 2. Washer properly positioned

Secure steering cable to throttle cables bracket no. 11 on helm arm no. 15. Install throttle cable ends to pivoting plates. Refer to Low-speed Steering Control System Cable Replacement below. Reinstall helm. Refer to Steering Helm Replacement. Proceed with steering adjustment. Refer to ALIGNMENT 10-03. From inside of hull, apply ADSEAL 4511 (P/N 293 800 033) on cable and nut area to seal hull. Check cable/hull watertightness.

F04K0SA

TYPICAL 1. Cable end of LH engine at this position 2. Cable end of RH engine at this position 3. Retighten this nut

NOTE: To find which cable matches which engine, pull one cable and ask an helper to look on which engine the throttle cable is activated. Reinstall helm, refer to Steering Helm Replacement below.

10-02-3

Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM)

Proceed with low-speed steering control system cables adjustment as specified in CARBURETORS 06-04.

Once steering wheel is unlocked, remove steering wheel puller, nut with washer and steering wheel.

STEERING HELM REPLACEMENT Removal To release steering cover no. 6, push tabs inside then pull cover, as shown in the next photo.

CAUTION

Do not hammer on the shaft to dislodge the steering wheel.

F09K06A

F09K05A

1. Push tab inside

Loosen lock nut no. 7. Use a 19 mm (3/4 in) socket. Use of puller tool (P/N 295 000 161) is recommended to ease steering wheel removal and to prevent damage.

1. Loosen this nut first 2. Use a 24 mm (15/16 in) socket

Be careful to keep Woodruff key for reinstallation. Remove dashboard no. 8. Disconnect steering cable and low-speed steering control system cables as described above. Remove nut and screw retaining steering brace no. 12 to deck.

F04B0FA

Install steering wheel puller, hold steering wheel firmly and tighten puller screw to detach wheel from the shaft.

F09K07A

1. Remove nut and screw

Remove all 3 screws no. 9 and withdraw steering helm no. 10. Pay attention, spacer(s) may be present. 10-02-4

Section 10 STEERING SYSTEM Subsection 02 (STEERING SYSTEM)

Installation

Reinstall removed parts and pay attention to the following: Prior to installing steering helm to boat, position helm arm as shown.

F09K08A

1. Screw centered in slot

2 1

F04K0TA

TYPICAL 1. Correct position 2. Pivoting arm

Torque screws as indicated in exploded view. Ensure to install Woodruff key. Apply anti-seize lubricant (P/N 293 800 023) on helm shaft. Install steering wheel. Secure steering wheel with nut and torque as indicated in exploded view. Proceed with steering alignment. Refer to ALIGNMENT 10-03.

When installing steering helm to boat, reinstall spacer(s) if some were present then position screws no. 9 as required in slots on steering support no. 13 to keep space between helm/cable and body. Centering screws in slots is a good starting point.

10-02-5

Section 10 STEERING SYSTEM Subsection 03 (ALIGNMENT)

ALIGNMENT

Position steering in straight ahead position.

F04K0WA

F04K01A

TYPICAL

Check jet pump nozzle alignment and steering centering by placing a straight edge across nozzle ends. Straight edge must lean on both edges of each nozzle.

When finished, apply Loctite 242 (P/N 293 800 015) on lock nut threads and retighten it. After the adjustment, ensure to install rod ends so that they are parallel each other and centered.

F04K0UA

TYPICAL 1. Must be leaned on both edges of each nozzle

Loosen lock nut of steering link rod. While holding rod end, turn link rod to adjust.

F09K09A

1. Rod ends parallel and centered each other

If not enough adjustment is available here, adjust cable end on steering helm arm.

CAUTION

Cable end must remain protruding helm pivoting arm.

10-03-1

Section 10 STEERING SYSTEM Subsection 03 (ALIGNMENT)

F04K0QC

TYPICAL â&#x20AC;&#x201D; SINGLE ENGINE SHOWN 1. Adjust here. Cable end must remain protruding

Ensure to apply Loctite on parts as indicated on exploded view.

10-03-2

Subsection 04

Section 10 STEERING SYSTEM (THROTTLE/SHIFTER CONTROLLER)

THROTTLE/SHIFTER CONTROLLER 8 N m (71 lbf in) 4

8 N m (71 lbf in)

Loctite 425

Anti-seize lubricant

Loctite 242

3 4 N m (35 lbf in) Anode System

F10J07T

PARTS

10-04-1

Section 10 STEERING SYSTEM Subsection 04 (THROTTLE/SHIFTER CONTROLLER)

REMOVAL 1

Unscrew retaining screws no. 1 and no. 2.

CAUTION

Use a protective mat (P/N 295 000 129) in shifter area when withdrawing controller.

INSPECTION Check all moving parts for free movement and for excessive play. Pay attention to pivot plates nos. 5 and 6. Check cables for wear and oxidation. Replace parts as required.

Anode System Inspect anode wire condition. Ensure anode wire is properly secured to pivot plates no. 6. Refer to exploded view.

LUBRICATION Lubricate moving parts with synthetic grease (P/N 293 550 010). Where not possible, apply BOMBARDIER LUBE (P/N 293 600 016).

ADJUSTMENTS Throttle and shifter cable adjustment are covered in CARBURETORS 06-04 and REVERSE SYSTEM 09-04.

Lever Friction Adjustment Lever friction can be adjusted to suit operator’s preferences. Throttle levers friction can be synchronized. Turn set screw clockwise to increase friction and counterclockwise to decrease it, as shown in the next illustration.

10-04-2

F04K07A

1. Set screw of port throttle (inner lever) 2. Set screw (1 screw each side for each lever)

To adjust shifter friction, turn set screw that is on the same side as shifter lever. To adjust starboard throttle lever (outer lever), turn set screw on the same side as its lever. To adjust port throttle lever (inner lever), turn set screw on center of pivot point of lever. Ensure that both throttle levers have the same friction. To adjust shifter friction, turn set screw that is on the same side as shifter lever. For throttle, turn set screw on the same side as its lever.

Shifter Lock Adjustment The locking action can be adjusted. The positions Forward/Neutral/Reverse are “notched” by means of a steel ball no. 8 pushed by a spring no. 9 against a notch on shifter plate. Turning the set screw no. 10 clockwise will increase spring pressure and therefore “hardens” shifter lock action. Conversely turning screw counterclockwise “softens” lock action.

Subsection 04

Section 10 STEERING SYSTEM (THROTTLE/SHIFTER CONTROLLER)

The set screw is located on the same side as shifter lever. 1

3 2 F04K05B

1. Shifter lever 2. Shifter plate 3. Set screw (shifter lock)

ASSEMBLY When reinstalling throttle/shifter controller no. 11 to boat, be careful not to bend cables. Ensure everything works properly.

10-04-3

Section 11 HULL/DECK Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

COMPONENTS ...................................................................................................................... DECK MOUNTING BOLTS ................................................................................................ BUMPER REPLACEMENT ................................................................................................. DECAL REPLACEMENT..................................................................................................... REAR STORAGE COMPARTMENT COVER...................................................................... REAR LATCH ADJUSTMENT............................................................................................ BILGE PUMP/COOLING SYSTEM OUTLETS LOCATION................................................ DRAIN TUBES REPLACEMENT ........................................................................................ SEAT AND BACKREST REMOVAL/INSTALLATION......................................................... ARMREST REMOVAL/INSTALLATION ............................................................................. REPLACEMENT OF REAR STORAGE COMPARTMENT COVER LATCH CABLE........... WINDSHIELD ..................................................................................................................... LUBRICATION OF LOCKS ................................................................................................. SKI POST............................................................................................................................ BOW COVER ...................................................................................................................... LOCK PIN ........................................................................................................................... STEP ...................................................................................................................................

11-02-1 11-02-8 11-02-8 11-02-9 11-02-10 11-02-10 11-02-11 11-02-11 11-02-13 11-02-14 11-02-14 11-02-15 11-02-15 11-02-15 11-02-19 11-02-20 11-02-20

REPAIR ................................................................................................................................... GENERAL ........................................................................................................................... AIR BUBBLES .................................................................................................................... BLISTERS ........................................................................................................................... MINOR GELCOAT FRACTURES........................................................................................ COMPOUND FRACTURES ................................................................................................ TOOLS AND MATERIALS LIST......................................................................................... HULL INSERT REPAIR .......................................................................................................

11-03-1 11-03-1 11-03-1 11-03-2 11-03-2 11-03-3 11-03-4 11-03-4

PAINTING ............................................................................................................................... PARTS THAT CAN BE PAINTED........................................................................................ CONCEPT TM PAINTING PROCEDURE .............................................................................. SURFACE PREPARATION.................................................................................................. FULL PANEL AND OVERALL REPAIRS ............................................................................ SPOT/PANEL REPAIRS ...................................................................................................... DELTATM PAINTING PROCEDURE .................................................................................... SURFACE PREPARATION.................................................................................................. DELTATM 2800, COLOR ...................................................................................................... RECOMMENDED SPRAY EQUIPMENT ...................................................................................

11-04-1 11-04-2 11-04-4 11-04-4 11-04-4 11-04-4 11-04-5 11-04-5 11-04-5 11-04-5

11-01-1

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

COMPONENTS

Speedster and Speedster SK Models Loctite 242

Loctite 242

4 Loctite 242

Body F09L32S

TYPICAL

PARTS

11-02-1

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

Speedster and Speedster SK Models Loctite 425 Loctite 425

Adseal 4511 Loctite 414 Dielectric grease

Adseal 4511

Synthetic grease Adseal 4511

F09L33S

TYPICAL

11-02-2

PARTS

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

Speedster and Speedster SK Models Loctite 425

Loctite 242

9 N m (80 lbf in)

Adseal 4511

Body

Adseal 4511

Loctite 271 Loctite 242 14.5 N m (128 lbf in)

Loctite 271 Loctite 242

Adseal 4511

Adseal 4511 3 2

Adseal 4511 Loctite 414

14.5 N m (128 lbf in) Adseal 4511 F09L34S

Loctite 242 Adseal 4511 Loctite 271

TYPICAL

PARTS

11-02-3

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

Speedster and Speedster SK Models Speedster

9 N m (80 lbf in)

Loctite 242

7 6

10 9

Synthetic grease

0.8 N m (7 lbf in) 8

8 N m (71 lbf in)

Loctite 242

Body

Adseal 4511

Body

Loctite 242

8 N m (71 lbf in)

Loctite 242 Adseal 4511 F09L2BT

TYPICAL

11-02-4

PARTS

1.7 N m (15 lbf in)

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

Speedster and Speedster SK Models

Seat base Backrest 50 N m (37 lbf ft)

12 13 14

18 6 N m (53 lbf in)

17 18 18

F09L35S

TYPICAL

PARTS

11-02-5

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

Speedster SK Model

30 Loctite 242 35 Loctite 242 Loctite 242 34 33

5.5 N m (48 lb in) 38

5.5 N m (48 lb in)

4.6 N m (40 lb in) 5.5 N m (48 lb in)

Loctite 242 3.5 N m (31 lb in)

F09L36S

TYPICAL

11-02-6

PARTS

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

Speedster SK Model

29 27

Loctite 271

28 2.5 N m (23 lbf in) Loctite 271

8 N m (71 lbf in)

Loctite 271 20

21 19 N m (14 lbf ft)

19 N m (14 lbf ft) 23

F09L37S

TYPICAL

PARTS

11-02-7

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

DECK MOUNTING BOLTS

Adjustment Bolts

Verify tightness of bolts and retighten as necessary.

Two adjustment bolts are located at rear inside deck storage compartment.

Front Bolt Speedster Model Bolt is located under bow seat. Seat is secured with VELCRO. To detach, pull seat at backrest location.

F09L1WA

RIGHT SIDE SHOWN 1. Adjustment bolt inside deck storage compartment 2. Also verify tightness of mounting bolts

BUMPER REPLACEMENT Bumper and Trim NOTE: Prior to beginning job, place bumper trim in a container of hot water to soften material and ease installation. In cool weather, bumper rail may be warmed too. 1. Remove bumper cover no. 1 at rear of boat. 2. Remove trim no. 2 from bumper rail no. 3. 3. Drill pop rivets to remove bumper rail. 4. Mark hole positions on body. 5. Using a 4.80 mm (3/16 in) drill bit, drill a first hole through bumper rail at any rear end. Use locating mark as a guide and install a rivet.

F09L0GA

PULL BOW SEAT

All Models

F09L1VB

TYPICAL 1. Front bolt at bow

11-02-8

CAUTION

When drilling, be careful not to damage bumper rail, hull and resonators located inside engine compartment. NOTE: Check condition of silicone joint between hull and body. Reseal as necessary with Adseal 4511 sealant (P/N 293 800 033) or equivalent without acetic acid vapors. 6. Position bumper rail properly onto body all around coming back to other rear end and cut excess length if necessary.

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

NOTE: Masking tape may be used to temporarily retain bumper rail ahead of your work. Prior to installing trim in bumper rail for rear corners, apply Adseal 4511 sealant (P/N 293 800 033) inside bumper rail all around boat, as shown. This is required so that trim properly remains attached to rail.

1 2

F04L9OC

1. Bumper rail 2. Adseal 4511 sealant in grooves

7. Install trim using soapy water. Gently tapping trim with a rubber hammer will help to fit trim in rail. 8. Reinstall bumper cover. 9. Check fit between bumper and body. Fill gaps with silicone sealant as necessary.

DECAL REPLACEMENT Removal Using a heat gun, warm up one end of decal for a few seconds until decal can roll off when rubbing decal edge with your finger. Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off. If decal tears while pulling off, it has to be heated for a few seconds longer. If decal tends to stretch while pulling off, stop heating and wait a few seconds to let it cool, then peel it off.

Installation There are 2 types of decals used on jet boat. One has a protective film on back side and the other has a protective film on both sides. They are used on 3 types of materials; plastic, gelcoat and metal. Decals Having a Protective Film on Back Side Only These decals usually contain written information (ex.: warning) and are used on gelcoat or metal. Clean surface with a good solvent such as ACRYLICLEAN DX 330 from PPG or equivalent (refer to manufacturerâ&#x20AC;&#x2122;s instructions). Using a pencil and the new decal as a template, mark the area where decal will be located. Remove half of the decal back protective film and align decal with marks. Start sticking it from center and remove the other half of the film to stick it completely. Carefully squeegee decal beginning at center and working outward using, firm, short, overlapping strokes. Decals Having a Protective Film on Both Sides These decals usually contain graphics and are used on gelcoat or plastic. Installation on Gelcoat Clean surface with a good solvent such as ACRYLICLEAN DX 330 from PPG or equivalent (refer to manufacturerâ&#x20AC;&#x2122;s instructions). For best result apply an activator (P/N 293 530 036) to prepare the surface using a clean cloth. After a few seconds, when the activator evaporates, the surface is ready. Using a pencil and the new decal as a template, mark the area where decal will be located. For better adhesion a dry application is recommended; however, to ease decal installation a mild solution of soapy water can be sprayed over surface where decal will be installed. Remove back protective film from decal and align decal with marks. When well-aligned squeegee decal beginning at center and working outward using, firm, short, overlapping strokes. Remove protective film once decal has adhered to hull.

11-02-9

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

Installation on Plastic Front (front storage cover) Clean surface with isopropyl alcohol. Using a pencil and the decal as a template, mark the area where decal will be located. Apply an activator (P/N 293 530 036) to prepare the surface using a clean cloth. After a few seconds, when the activator evaporates, the surface is ready.

Cover Removal NOTE: To ease working in engine compartment, it is suggested to remove rear storage compartment cover no. 5 from boat Some models features a removable pin on the hinge but the best way to remove cover is to mark hinge position with a pencil, as shown in the next photo, then unscrew hinge from deck.

CAUTION

Do not use soapy water as a cleaner to prepare the surface or to locate decal on cover. Remove back protective film from decal and carefully align decal with marks. Apply pressure to center of decal using a squeegee then slide outward using a firm, short overlapping stroke. Repeat as necessary. Remove protective film from front of decal after application.

REAR STORAGE COMPARTMENT COVER If cover no. 4 does not lift by itself (or with a little help), when latch is released, replace gas shocks no. 5. Each shock should be checked individually by detaching them one at a time. At shock installation, position it so that the piston rod is at bottom.

Shocks Removal Using a flat screwdriver, lift tab as shown in the next photo.

F09L1XA

LIFT TAB

Detach shock end. 11-02-10

F00L0KA

TYPICAL — MARK HINGE POSITION 1. Remove these three screws

REAR LATCH ADJUSTMENT Rear storage compartment cover latch is adjustable. If cover is not tight enough or if it is hard to close, adjust as necessary. 1. Loosen lock nut. See next illustration. 2. Turn locking pin and adjustment nut as required and check cover fit and locking action. 3. When adjustment is satisfactory, temporarily remove lock nut and apply Loctite 242 (P/N 293 800 015)) on lock pin threads. 4. If locking pin does not properly center in latch hole, loosen lock nut until latch may move freely sidewards. 5. Close cover so that locking pin auto centers in latch. Reopen cover and tighten locking nut in this position. 6. Torque nut to 5 N•m (44 lbf•in).

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

DRAIN TUBES REPLACEMENT 1

Bilge Pump Drain • Disconnect drain tube no. 7 from transom fitting no. 6. Note the loop there, you will have to remake it. • Cut locking ties all along drain tube from transom toward bilge pump. • Disconnect drain tube from bilge pump and remove tube. • Cut new tube to proper length. • Reconnect tube at each end and resecure tube with locking ties. • Drill a 0.8 mm (1/32 in) hole where the tube is formed into a loop. This will prevent any type of siphoning that could occur in certain situations. • Ensure tube does not leak in bilge.

F02L25B

TYPICAL — MOUNTED UPSIDE DOWN 1. Locking pin 2. Adjustment nut. Torque to 5 N•m (44 lbf•in) 3. Lock nut

BILGE PUMP/COOLING SYSTEM OUTLETS LOCATION 1

Deck Drain • Disconnect drain tube no. 9 from transom fitting no. 8. • Cut locking ties all along drain tube from transom toward deck storage compartment. • From cup holder opening, disconnect drain tube from deck fitting no. 10. • Cut new tube to proper length. • Reconnect tube at each end and resecure with locking ties. • Ensure tube does not leak in bilge.

Scupper Valve Check that ball is clean and moves freely. 2

Removal Remove all 4 screws retaining existing scupper valve no. 11.

F09L1ZA

1. Engine cooling system outlet/flushing connector 2. Deck drain outlet 3. Bilge pump outlet

11-02-11

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

F04L9WA

TYPICAL — REMOVE ALL 4 SCREWS

Installation Install valve membrane taking care to properly position membrane lip facing ball. Ensure membrane positioning holes are properly aligned with valve knob. See next photo.

CAUTION

Make sure to assemble all the parts exactly in the same position as illustrated. If scupper valve is assemble wrong, water will still seep through.

11-02-12

F04L9VB

1. Ball 2. Membrane lip 3. Membrane positioning hole aligned with valve knob

Carefully clean the inside of the plastic bushing. Install scupper valve assembly onto plastic fitting. Secure using screws. Tighten to 0.8 N•m (7.27 lbf•in).

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

SEAT AND BACKREST REMOVAL/INSTALLATION Rear Seat Both rear seats are secured with velcro and retaining plates. To detach, pull seat at backrest location, as shown in the next photo.

F09L22A

PULL BACKREST

Speedster Model

Bow Seat Seat is secured with velcro and retaining plate. To remove, refer to Rear Seat Removal. F09L20A

Bow Seat Backrest

PULL SEAT

To remove seat, drill both retaining plate rivets, as shown in the next photo. 1

Backrest is secured to deck with retaining brackets. To remove, lift backrest as shown in the next photo. 1

F09L21B

1. Drill these two rivets

Use a 4.75 mm (3/16 in) drill bit. F09L0GB

Rear Seat Backrest

1. Lift backrest

Backrest are secured with velcro and press-buttons. To remove, pull backrest as shown in the next photo, then detach press-buttons.

When reinstalling backrest, firmly slide its slots over the retaining brackets. Ensure backrest is properly locked.

11-02-13

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

All Models

Front Seat/Backrest Seats and backrests are secured with velcro and press-buttons. To remove, pull seat/backrest then detach pressbutton. SWIVEL BASE REMOVAL Remove central shoulder screw no. 12, flat washer no. 13 and waved washer no. 14. Remove seat. Remove the 6 Phillips screws no. 16 retaining the swivel base no. 15.

Apply Loctite 242 (P/N 293 800 015) on Phillips screws. Then torque to 6 N•m (53 lbf•in). Reinstall seat with shoulder screw, flat washer and waved washer. Torque them to 50 N•m (37 lbf•ft). Reinstall seat cushion.

ARMREST REMOVAL/ INSTALLATION Armrest no. 17 are secured to deck with darts no. 18. Carefully pull foam by hand to release darts.

REPLACEMENT OF REAR STORAGE COMPARTMENT COVER LATCH CABLE Remove latch mechanism from body and open it by removing the plate underneath. Detach cable no. 19 end from the rod.

F00L0HA

1. Remove the 6 Phillips screws 2. Through ski locker, hold elastic nuts underneath seat base

Remove swivel base. SWIVEL BASE INSTALLATION Install swivel plate. Take care to place notch into provided hole.

F04L7HA

1. Detach cable end from rod

Tape the end of the new cable to the end of the old cable. Detach front portion of cable in front storage compartment and pull cable toward front thus pulling the new cable at the same time.

CAUTION

Existing cable is attached with locking ties, use extreme caution when pulling to insert new cable. Complete parts assembling in the reverse order of disassembly. F00L0IA

PLACE NOTCH INTO HOLE

11-02-14

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

WINDSHIELD

Refer to the following photo sequence for detailled procedure.

Cleaning First rinse with fresh water to remove dried salt water. Wash with Bombardier cleaner (P/N 293 110 001). Clean only with flannel clothes or Kimtowels® wipers no. 58-380 from Kimberly-Clark.

CAUTION

It is necessary to use flannel cloths or “Kimtowels” wipers on windshield to avoid damaging further surfaces to clean. To remove scratches on windshield: Start with “Slip Streamer Motorcycle Windshield Heavy Duty Scratch, Remover”. Finish with “Slip Streamer Motorcycle Cleaner and Polish”. NOTE: The later product may be used alone if only light scratches are noticeable.

F09L38A

REMOVE PLUNGER

CAUTION

Never clean windshield with strong detergent, degreasing agent, paint thinner, acetone, products containing chlorine, etc.

LUBRICATION OF LOCKS Locks should be lubricated with BOMBARDIER LUBE lubricant (P/N 293 600 016) to keep them working properly. This will help dissolving dried salt water. F09L39A

Speedster SK Model

SKI POST

REMOVE BOTH SKI POST BASE BOLTS 1. Ski post base bolts

Removal From inside engine compartment, remove spring plunger no. 20 and both ski post base bolts no. 21, loosen collar stop screw no. 22, lift ski post assembly and remove base no. 23. Pull out ski post assembly.

11-02-15

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

F09L3AA

LOOSEN COLLAR STOP SCREW 1. Collar stop screw

F09L3CA

LOOSEN BOLT THEN REMOVE BASE 1. Ski post base

F09L3DA

PULL OUT SKI POST ASSEMBLY

Disassembly

F09L3BA

LIFT SKI POST ASSEMBLY

11-02-16

Pull inner post no. 24 out of outer post no. 25, loosen inner post cap no. 26 until it detach from threaded rod no. 27, pull threaded rod out then remove compression boot no. 28. Refer to the following photo sequence for detailed procedure.

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

F09L3EA

PULL INNER POST OUT OF OUTER POST 1. Inner post 2. Outer post

F09L3HA

REMOVE COMPRESSION BOOT 1. Retain this nut 2. Loosen screw here

Inspection Check for any cracks, wear or damage on compression boot. Replace if so.

Assembly

F09L3FA

LOOSEN INNER POST CAP 1. Inner post

Assembly is essentially the reverse of disassembly. However pay attention to the following. Apply Loctite 271 (P/N 293 800 005) on internal threads of coupling nut then torque to 8.0 N•m (71 lbf•in).

CAUTION

Threaded rod and screw should have 9 mm (11/32 in) of thread engaged in coupling nut. When reinstalling threaded rod in inner post, ensure that rod end is properly inserted into rod holder no. 29, as shown in the next photo. F09L3GA

PULL THREADED ROD OUT

11-02-17

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

From outside hull, insert inner post assembly into outer post. Align inner post V-groove with outer post hole, as shown in the next photo. Then install spring plunger. 1

F09L3IA

1. Rod holder 2. Rod end inserted into rod holder

Installation Installation is essentially the reverse of removal procedure. However pay attention to the following. With boat leveled, level outer ski post, as shown in the next photo. Torque ski post base bolts as described in exploded view.

F09L3LA

1. Outer post hole aligned with V-groove

Check post operation. Lock spring plunger using lock nut.

Operation Inner post must move up and down and stop when reaching spring plunger.

F09L3JA

LEVEL SKI POST

11-02-18

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

BOW COVER Removal Detach both shocks no. 31 from bow cover no. 30. Using a flat screwdriver, lift tab as shown in the next photo.

Remove bow cover. NOTE: Note shim(s) no. 34 position (if applicable). At reinstallation shim(s) should be positioned at the same place.

Installation Installation is essentially the same as removal procedure. Torque nuts to 5.5 N•m (48 lbf•in).

Alignment Bow cover must be adjusted so that cover latch no. 35 is aligned with lock pin no. 36. To align cover loosen nuts no. 37, as shown in the next photo.

F09L1XA

TYPICAL — LIFT TAB

Loosen both upper nuts no. 32 from bow cover hinge no. 33. See next photo.

;

WARNING

In order to avoid personal injuries or boat damage, always ask someone to hold bow cover while loosening nuts. 1

F09L3NA

1. Loosen these nuts

F09L3MA

1. Remove these two nuts 2. Bow cover hinge

11-02-19

Section 11 HULL/DECK Subsection 02 (COMPONENTS)

LOCK PIN

STEP 2

To remove step no. 38, loosen nut and remove screw, as shown in the next photo.

F09L3PA

F09L3OA

1. Lock nut 2. Lock pin 3. Adjustment nut

Cover lock pin is adjustable. If cover is not tight enough or if it is hard to close, adjust as necessary. Loosen lock nut. See above photo. Turn locking pin and adjustment nut as required and check cover fit and locking action. Retighten lock nut.

11-02-20

STARBOARD SIDE SHOWN 1. Loosen this nut

Section 11 HULL/DECK Subsection 03 (REPAIR)

REPAIR

GENERAL

1. Preparation of Surface

Gelcoat is the smooth and durable cosmetic finish which coats the fiberglass hull and body of a SeaDoo Jet Boat. It also provides a protective barrier against water and sun. It consists of a mixture of resin, pigment (coloring), fillers, monomers and catalyst which is sprayed into the mold. The body and hull of the Sea-Doo Jet Boat are constructed of chopped fiberglass, saturated with resin. It is sprayed on the layer of gelcoat along with pieces of fiberglass mat, cloth and woven rowing which are added at required areas. This type of construction is very accommodating for high quality repairs. With patience, the proper techniques and materials, a damaged area can be restored to an original finish. The content presented here is not intended to replace the use of a complete fiberglass and gelcoat repair manual. Its main purpose is to help you understand what factors are involved when making a damage assessment or estimate. NOTE: Fiberglass repair kit is available through automotive or marine suppliers. Gelcote® repair kits are available through regular channel.

Remove all of the damaged gelcoat surrounding the air bubble with a putty knife or preferably a carbide grinding tip. Make sure all loose and weak areas are completely removed. Sand a small area of the gelcoat surface with 220-grit sandpaper. If needed, sand the cavity itself. These areas must have a rough surface to allow the gelcoat putty to bond properly.

;

WARNING

Protect skin, wear gloves when in contact with resin, hardeners and gelcoat. A barrier skin cream may also be used. Do not expose area to open flame or lit cigarette. Some of the materials are flammable. Protect eyes, wear safety glasses when grinding, sanding or spraying. Use a dust mask when sanding or grinding. When spraying wear a respirator or paint mask. Always read warning labels on products.

AIR BUBBLES

F09L2ZA

REMOVE DAMAGED GELCOAT

2. Filling the Cavity The prepared surface must be cleaned with acetone on a cloth. Use the Bombardier Gelcote® repair kit (P/N 295 500 100). Follow the mixing instructions in the kit when preparing the gelcoat putty. Carefully mix the required amount while making sure there are no air bubbles in the mixture. With a putty knife fill the repair area, as shown in the next photo, and cover with plastic film. Curing time may depend on temperature, amount of putty and percentage of catalyst. After 2 hours, press lightly on the surface with fingers to test the hardness. When the area becomes hard, remove the plastic film.

Possible Cause – Air pocket trapped between layers of laminate and gelcoat.

11-03-1

Section 11 HULL/DECK Subsection 03 (REPAIR)

CAUTION

Ensure blistered area is completely dry before attempting repairs.

MINOR GELCOAT FRACTURES Possible Causes

F09L30A

DAMAGED AREA FILLED — PLASTIC FILM NOT SHOWN

3. Sanding Begin block sanding the patch with 320-grit sandpaper until you come close to the original surface. Remove dust with a water soaked cloth and continue sanding with a 400-grit wet paper. Finish wet sanding with a 600-grit to remove deeper scratches. If needed you can wet sand with finer grit paper such as 1000-grit.

4. Buffing and Waxing Buff the surface using a heavy duty polisher with a buffing pad. Make sure the pad is free of dirt or you may damage the gelcoat. Carefully begin buffing with a white medium compound RM 856. Finish off using a fine RM 852 compound. While buffing, pay close attention to avoid overheating the surface.

BLISTERS Possible Causes – Inert catalyst. – Improper catalyst/gelcoat ratio. A blister is a visible bump on the Sea-Doo Jet Boat surface that may not necessarily come right through the gelcoat layer. In the case of only a few blisters, you may follow the same repair procedure as for air bubbles. If they are numerous and in close concentration, you may have to spray liquid gelcoat to achieve proper repair. This procedure is covered in the next problem.

11-03-2

– Flexing of fiberglass laminate. – Gelcoat thickness. – Direct result of impact. In case of fractures which have not penetrated past the gelcoat layer, the repair concerns the gelcoat only. If flex cracking or impact are evident, then additional reinforcement may be necessary. This subject will be covered in the next problem.

1. Preparing the Surfaces Small Fractures: Open the cracks up with a sharp triangular can opener or preferably a carbide tipped die grinder. The V groove will provide a good bonding area for the gelcoat. With 220-grit sandpaper, sand the sides of the notched out areas. Numerous Fractures: Using a grinder with a 24-grit disk, remove the gelcoat. Sand the area edge with 220-grit sandpaper.

2. Filling the Repair Area Small Fractures: Refer to the same procedure as in the air bubbles. Numerous Fractures Over Large Surface: Prepare the area for spray application of liquid gelcoat. Wipe down the surface with acetone. Mask the surrounding area to protect the boat from overspray. Mix the needed quantity of gelcoat and catalyst according to supplier’s recommendations. The gelcoat can be thinned with acetone up to 10%. If it needs more consistency you can add cabosil. Make sure that the air supply is free of oil, dirt and water.

Section 11 HULL/DECK Subsection 03 (REPAIR)

Test spray the gelcoat mixture on paper to verify its consistency and pattern. You may have to apply 5 or 6 coats to cover the area properly. Overlap each coat further than the last, leaving at least 30 seconds between passes. Avoid trying to coat the surface with only a few heavy coats, this will not allow the gelcoat to dry properly. Apply a coat of polyvinyl alcohol to seal off the air and protect the gelcoat surface from dust. PVA speeds up the curing process because gelcoat will not cure properly when exposed to air.

Outside Remove the damaged gelcoat and fiberglass with a 24-grit disk using a power sander. Grind outward at least 2 inches from the fracture to allow the patch to bond to strong material. Cut enough pieces of fiberglass mat necessary to build up the area. The pieces should be cut so they overlap each other by at least half an inch. For a smoother finish, the last layer should be fiberglass cloth. If the fracture is small enough all you may have to do is fill the area with an epoxy filler.

3. Sanding Wash the polyvinyl alcohol off with water. Depending on the size of the area repaired, you can either block sand as per previous procedure or you may use an air sander. Sand the surface down with progressively finer grits of sandpaper until the desired finish is achieved.

Inside For the interior repair, you can grind more. This will allow for more fiberglass material which will strengthen the area. If the fracture opening is too large after surface preparation, you may need a backing support to cover the opening. Cut alternating pieces of fiberglass mat and cloth in overlapping sizes.

4. Buffing and Waxing

Patching the Repair Area

Buff the surface using a heavy duty polisher with a buffing pad. Make sure the pad is free of dirt or you may damage the gelcoat. Carefully begin buffing with a white medium compound RM 856. Finish off using a fine RM 852 compound. While buffing, pay close attention to avoid overheating the surface.

COMPOUND FRACTURES Possible Causes â&#x20AC;&#x201C; Thickness of fiberglass laminate. â&#x20AC;&#x201C; Direct result of impact. Compound fractures are those that have gone past the gelcoated surface and in through the layers of fiberglass laminate. Two types of repairs have to be performed. The first is to restore the structural integrity of the damaged area. Fracture types can vary from a simple crack to a large hole. Usually, fiberglass reinforcement becomes necessary, especially if the fracture can be attributed to weakness. The final part of the repair is the gelcoating, which cannot be done until the interior and exterior laminate surfaces have been repaired.

Outside The outside should be done first. Wipe clean the area with acetone on a cloth, then mask off area. For a small crack use an epoxy filler in the same way you would use Bombardierâ&#x20AC;&#x2122;s gelcoat repair putty. When laying up a larger area you will use mat, cloth and fiberglass resin and hardener. Use a clean container to mix the resin, mix only what you will need. Follow the recommended catalyst ratio. Using a clean paintbrush, brush the mixed resin on the surface. Place the smallest piece of mat over the fracture and then wet out the mat. Follow with the remaining pieces of mat and final layer of cloth. While wetting the pieces make sure you work the air bubbles out and saturate all the 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. It is a shaped piece of cardboard that fits flush to the interior surface and has a plastic layer on the repair side. It is held in place by tape or a support.

11-03-3

Section 11 HULL/DECK Subsection 03 (REPAIR)

Inside Wipe down the area with acetone on a cloth. Apply the same procedure as for outside repair when laminating the alternating pieces of fiberglass material. If a backing support was used, remove it before starting the repair. After the area has hardened, remove sharp edges of material from surface. If required paint the surface.

Materials – – – – – –

Sanding Outside This surface will have to be prepared for application of gelcoat. The size of the area will determine the gelcoating procedure to be used. Refer to the repair procedure for minor gelcoat fractures.

Buffing and Waxing Refer to the buffing and waxing for minor gelcoat fractures. If painting the exterior is preferred, refer to Painting subsection 04.

TOOLS AND MATERIALS LIST Tools – – – – – – – – – – – – – – –

safety glasses air mask white cloths sanding block putty knife plastic film stirring stick scissors buffing pad heavy-duty polisher power sander paint brush plastic container (mixing) spray gun plastic squeegee

11-03-4

– – – – – – – – –

fiberglass mat fiberglass cloth polyester resin cardboard masking tape sandpaper (100-grit, 220-grit, 320-grit, 400-grit, 600-grit, 1000-grit) 24-grit sanding disks Bombardier gelcoat putty Bombardier liquid gelcoat acetone cabosil epoxy filler medium compound (white) fine compound (white) wax

HULL INSERT REPAIR For hull insert repair proceed as follows: Cut plastic hull insert flush with hull using a saw.

F01L2UA

1. Hull 2. Plastic hull insert

Mix epoxy glue (3M-05900), follow manufacturer’s instructions.

Section 11 HULL/DECK Subsection 03 (REPAIR)

Apply epoxy glue on replacement insert (P/N 292 000 075) knurled surface and on plastic insert inner bore.

CAUTION

A clearance between plastic insert and aluminum insert could possibly be noticed. If so, ensure to fill gap with epoxy glue to obtain aluminum insert adhesion. 1

2 F01L2VA

1. Knurled surface 2. Inner bore

Install insert into plastic hull insert. NOTE: Align aluminum insert as much as possible with PTO flywheel. 2

F01L2WB

1. Aluminum insert 2. PTO flywheel

NOTE: The epoxy glue curing time is 30 minutes. Do not reinstall drive shaft protector as the replacement insert does not allow its installation.

11-03-5

Section 11 HULL/DECK Subsection 04 (PAINTING)

PAINTING

The following was prepared in conjunction with PPG Industries Inc. It contains a list of SEA-DOO Jet Boat parts with their respective PPG color codes and 2 painting procedures; CONCEPT TM the most commonly used and DELTATM (with low VOC) mainly used in California. PPG Industries Inc. sells paint and related products and these are not available from Bombardier Inc. To find your nearest PPG dealer, dial one of the following numbers. NORTH AMERICA

EUROPE

PACIFIC RIM

CANADA

Phone: Fax:

(905) 855-5670 (905) 823-1894

U.S.A.

Phone: Fax:

(440) 572-6913 (440) 572-6955

DENMARK Phone: SWEDEN Fax:

45 43 43 65 66 45 43 43 81 88

ITALY

FRANCE

Phone: Fax:

33 1 46 98 81 93 33 1 46 98 83 15

PORTUGAL Phone: SPAIN Fax:

34 93 205 3063/3002 34 93 205 3355

GERMANY Phone: Fax:

49 7142 706 162 49 7142 706 202

UNITED KINGDOM

Phone: Fax:

44 121 455 1320 44 121 455 1209

JAPAN

81 3 3280 2851 81 3 3280 2857

KOREA

Phone: Fax:

82 51 620 8521 not available

Phone: Fax:

39 02 4567 9346/9226 39 02 4892 9129

PPG paint for Sea-Doo Jet Boat is not available in spray can. For best result it must be applied by a professional painter. For fast touch up on metallic and gelcoat surfaces, refer to the appropriate Bombardier Sea-Doo Jet Boat Parts Catalog, it contains a few spray can part numbers.

11-04-1

Section 11 HULL/DECK Subsection 04 (PAINTING)

PARTS THAT CAN BE PAINTED 11

10 1 2 3

8 14 4

13 F09L2DS

TYPICAL 1. Body 2. Hull 3. Rear storage cover 4. Engine 5. Tuned pipe 6. Muffler 7. Exhaust manifold

11-04-2

8. 9. 10. 11. 12. 13. 14.

Ignition housing Ignition housing cover Deck storage compartment cover Flame arrester support Flame arrester base Ride shoe Rear storage compartment tray

Section 11 HULL/DECK Subsection 04 (PAINTING)

PART

BOMBARDIER COLOR Nos. FOR SEA-DOO JET BOATS ALL MODELS

1. Body

White — 5801-88-01

2. Hull

White — 5801-88-01 Viper red — B176 Bright yellow — M506

3. Rear storage cover

Viper red — B176 Bright yellow — M506

4. Engine

717/787: Silver reflection — M529

5. Tuned pipe

717/787: Silver reflection — M529

6. Muffler

717/787: Silver reflection — M529

7. Exhaust

717/787: Silver reflection — M529

8. Ignition housing

717/787: Silver reflection — M529

9. Ignition housing cover

717/787: Silver reflection — M529

10. Deck storage compartment cover 11. Flame arrester support

White — 5801-88-01 Stainless steel — Not painted

12. Flame arrester base

Black — 5802-88-04

13. Ride shoe

Black — 5802-88-04

14. Rear storage compartment tray (ABS thermoform)

White — 5801-88-01

NOTE: Due to natural discoloration it may be necessary to completely repaint the part.

11-04-3

Section 11 HULL/DECK Subsection 04 (PAINTING)

CONCEPT TM PAINTING PROCEDURE For additional information refer to PPG P-Bulletin no. 168.

SURFACE PREPARATION Prepare and clean surface consistent with good painting practices. Primer DP Epoxy Primer/DP 401 Catalyst; DX 1791/1792 (Prime before topcoating). Primer Surfacer K36/K201, K200/K201 or DZ KONDAR® Primer Surfacers. NOTE: KONDAR must be sealed before applying CONCEPT TM color. Sealer KTS30 2K Sealer, DP Epoxy Primer reduced as a sealer or DAS 1980 or DAS 1987.

Direct Gloss Color How to Mix Standard Air Dry: Mix CONCEPT TM Color 2:1:1 — 2 parts color with 1 part DT Reducer best suited to shop temperatures and 1 part DU 4 Hardener below 29°C (85°F) or DU 5 Hardener above 29°C (85°F). Standard Force Dry: Mix CONCEPT TM Color 2:1:1 — Application temperatures below 29°C (85°F) use DU 5 Hardener, above 29°C (85°F) use DU 6. Medium Solids (MS) Application: For faster film build, when using solid colors, mix 2 parts CONCEPT TM color with half part DT Reducer and 1 part DU 5 or DU 6 Hardener. Select the DT Reducer appropriate for shop temperature. Pot Life Pot life of ready-to-spray CONCEPT TM color is 6 to 8 hours at 21°C (70°F). Medium solids option is 2 to 4 hours at 21°C (70°F).

11-04-4

FULL PANEL AND OVERALL REPAIRS Application Apply 1 medium wet coat and give 5-10 minutes flash, followed by 2 wet coats with 15 minutes flash time between each coat. Adjust metallic on the last full wet coat. If necessary, apply a mist coat. For medium solids option apply 2 full wet coats. Air Pressure 275-345 kPa (40-50 PSI) at the gun. Dry Time – Dust free: 30 minutes. – Tack free: 2 to 3 hours. – Tape print free: 6 hours. – Dry to handle: 6 to 8 hours at 21°C (70°F). – Force dry: 40 minutes at 60°C (140°F). Faster dry times may be obtained by using 15 mL (1/2 oz) of DXR 81 Accelerator per sprayable quart, however, the pot life is reduced to 2 hours.

SPOT/PANEL REPAIRS Application Spray medium wet coat of color on the repair area and allow 5-10 minutes flash time. Apply 2 additional full coats until hiding is achieved, extending each coat beyond the previous coat. Flash 15 minutes between each coat. For medium solids option apply 2 full wet coats. Blending Add DT 95 Reducer to a second gun cup. Reduce the fluid feed of the gun and lower the air pressure to 207 kPa (30 PSI). Dust the dry edge until a slight wet look appears, then stop. Or mix reduced and catalyzed color with equal parts of reduced and catalyzed CONCEPT TM DCU 2020 Clear.

Section 11 HULL/DECK Subsection 04 (PAINTING)

DELTATM PAINTING PROCEDURE (with low VOC, mainly in California) For additional information refer to PPG P-Bulletin no. 157.

SURFACE PREPARATION Primer: DELTATM PRIME DPU 166.

DELTATM 2800, COLOR How to Mix Mix DELTATM 2800 2:1, 2 parts Colors to 1 DU 6 Catalyst. Application Apply 2 coats of DELTATM Polyurethane Color. Apply the first coat at 1.5 -1.8 wet mils. Allow a minimum of 15 minutes flash time prior to the application of the second coat. Apply a second coat of DELTATM using the same technique as the first application, paying strict attention to gun set up and proper equipment choices.

RECOMMENDED SPRAY EQUIPMENT GUN MANUFACTURER

DEVILBISS

BINKS

GRACO

HVLP

JGA

800N

Can Am Model 900

FF 1.4 mm (0.055 in)

63D 1.5 mm (0.059 in)

02N 1.2 mm (0.047 in)

HT no. 9072 2.5 mm (0.098 in)

797/264

63 PW

02/03

C9062

GUN DISTANCE

25 - 30 cm (10 - 12 in)

FLUID DELIVERY

227 - 340 mL/min (8 - 12 oz/min)

414 - 517 kPa (60 - 75 PSI)

62 kPa (9 PSI)

GUN MODEL FLUID TIP SIZE AIR CAP

AIR PRESSURE (AT-THE-GUN)

Dry Time at 21°C (70°F) – Dust free: 25-35 minutes. – Tack free: 2-1/2 to 3 hours. – Tape/sand: Overnight. Force Dry Allow 20 minutes purge time at 27-32°C (80-90°F) before bake. Bake 75 minutes at 65°C (150°F) or 40 minutes at 82°C (180°F). Allow to cool after force dry, before sanding or taping.

11-04-5

Section 13 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

WIRING DIAGRAMS HOW TO USE THE TABLES WITH THE WIRING DIAGRAMS The following illustration explains the wires and connectors in wiring diagrams.

0 Wire Color It identifies the color of a wire. When a 2-color scheme is used, the first color is the main color while the second color is the tracer color.

Circuit

Wire position in connector Connector identification

This is the electrical circuit that matches the wire, connector, etc. Wire color (french) Wire color (english)

Wire identification

Connector This is the connector to which the wire is connected. Each connector is identified with a ’’C’’ or a ’’S’’ followed by a number (ex: C-002). ’’C’’ stands for connector and ’’S’’ for splice connector.Refer to MPEM 08-06 for connector types and connector pin identification.

Wire Position in Connector This is the wire position in the connector. The number or letter given refers to the physical identification stamped on the connector.

F04H6OA

The following refer to the column titles in the tables.

From and To This column indicates where each wire end is connected.

Wire Identification This is the ’’name’’ of a wire that identifies the various wires. Each wire is identified with a ’’W’’ followed by a number (ex: W1). ’’W’’ stands for wire.

13-01-1

Section 13 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

C002 C003 C004, C005 C006A C006B C014 C017 C019A C019B C020 C022 C023 C024 C025 C026 C027 C028 C029 C030A C030B C031A C031B C038, C039 C040, C041 C042, C043 C044 C045, C046 C048 C049 C050 C051 C052 C053 C055, C056 C057, C058 C070A C070B C080A C080B C085 C095, C096, C098 C097 C098 C101, C102, C103 C150, C151, C152 SP-1 to SP-9 SP-10, SP-11

CONNECTOR LOCATION Inside front storage compartment (beeper) Behind dashboard (DESS post) On bow light Behind dashboard (RH start/stop switch) Behind dashboard (LH start/stop switch) Behind dashboard (auxiliary supply) Inside front storage compartment (fuel/oil gauge 6-pin connector) AMP 6 pins inside front storage compartment (RH tachometer) AMP 6 pins inside front storage compartment (LH tachometer) Close to shifter controller (neutral switch) AMP 6 pins inside front storage compartment (speedometer) On blower (rear RH duct) On stern light On speedometer sensor on transom On water sensor close to bilge pump (rear portion of bilge) On bilge pump (rear portion of bilge) On fuel tank On oil tank On engine (RH overheat sensor) On engine (LH overheat sensor) DEUTSCH 4 pins, on RH engine DEUTSCH 4 pins, on LH engine Behind deck (LH courtesy light) Behind deck (LH speaker) Behind dashboard (12-volt jack) Inside RH front storage compartment (horn) Behind deck (front courtesy light) Behind dashboard (low-fuel switch) Behind dashboard (courtesy light switch) Behind dashboard (horn switch) Behind dashboard (bilge pump switch) Behind dashboard (blower switch) Behind dashboard (NAV/ANC light switch) Behind deck (RH speaker) Behind deck (RH courtesy light) On RH rectifier On LH rectifier DEUTSCH 6 pins, on RH electrical box DEUTSCH 6 pins, on LH electrical box Inside LH front storage compartment (radio) On battery, positive post On battery, negative post On battery, positive post AMP 26 pins on MPEM (numbers 1, 2 and 3 respectively are stamped on the MPEM) Main fuses close to battery Grounding block, attached to main wiring harness inside front storage compartment Lighting block, attached to main wiring harness inside front storage compartment

NOTE: Some connector numbers are deliberately missing in the list. They do not apply. 13-01-2

0 0 0 0

SPEEDSTER R

W11 Gy/Bk

W5 Gy/Bk/G INTERUPTEUR PRINCIPAL

WIRE COLOR CODE TABLE

MAIN DISCONNECT C-031B 6

C-031B 4 C-031B 2

W12 Bk C-031B 5

MAGNETO BABORD

SP-07 A

W7 Gy C-095

C-096

BATTERIE

12V W140 R

W139 R

W138 R

C-070B C

REDRESSEUR BABORD

C-070B A

RECTIFIER PORTSIDE

C-071B A

C-071B B

BATTERY

C-150 B

C-151 B

C-152 B

20A

C-150 A

C-151 A

C-152 A

W121 R

W122 R

W124 R

ANODE

C-201

C-101 25

C-101 24

C-101 6

C-070A A

C-070A B

C-102 26

C-101 1

C-101 2

C-071A A

C-071A B

SP-07 C

BOUGIES BABORD SPARK PLUGS PORTSIDE

W20 Pu

C-101 11

W21 Y/R

C-101 8

W22 Bk

C-101 14

W2 Br

REDRESSEUR TRIBORD RECTIFIER STARBOARD

C-070A C

W15 R

C-031A 2

W3 Br

W14 Bk C-101 5

C-031A 1

W4 Br

W16 Bk SP-07 D

CODE

W151 G C-200

W10 Br

C-070B B

C-031A 3

W8 Br

C-031A 4

MAGNETO TRIBORD MAGNETO STARBOARD

C-098

C-031B 1

W9 Br

C-031A 5

W1 Gy/G

MAGNETO PORTSIDE C-031B 3

C-031A 6

W6 Bk SP-07 B

RPM BABORD

RPM TRIBORD

PORTSIDE RPM

STARBOARD RPM

W13 R

C-101 10

W17 Pu/G

C-101 7

NOIR

BLUE

BLEU

BROWN

BRUN

GREEN

VERT

DARK GREY

GRIS FONCE

Lt Bl

LIGHT BLUE

BLEU PALE

ORANGE

PINK

ROSE

PURPLE

VIOLET

RED

ROUGE

TAN

BEIGE

WHITE

BLANC

YELLOW

JAUNE

W18 Y/R/G

SPARK PLUGS STARBOARD

C-080B 6

C-080B 4

C-080B 5

MPEM

15amp.

W19 Bk/G

C-102 23

W34 Y/R/G

C-103 8

W36 Y/R

ALIMENTATION CIRCUIT D'ALLUMAGE

MPEM POWER SUPPLY

C-080B 3

C-101 15

IGNITION CIRCUIT POWER SUPPLY

C-080A 3

C-006 3

C-080A 5

C-080A 4

C-006 1 INTERRUPTEUR DEMARRAGE/ARRET BABORD

N.O.

UCT

C-080A 6

15amp. INTERRUPTEUR DEMARRAGE/ARRET TRIBORD

N.O.

PORTSIDE START/STOP SWITCH

STARBOARD START/STOP SWITCH

CPU C-006 2

SOLENOIDE DE DEMARRAGE BABORD

BOBINE D'ALLUMAGE BABORD IGNITION COIL PORTSIDE

SOLENOIDE DE DEMARRAGE TRIBORD

W35 Bk

STARTER SOLENOID PORTSIDE

BOBINE D'ALLUMAGE TRIBORD IGNITION COIL STARBOARD

STARTER SOLENOID STARBOARD

SP-08 A

CIRCUIT DE DETECTION D'EAU

W43 Pu/Gy

C-019B 1 TACHYMETRE BABORD

W49 Gy

C-102 2

W103 O

C-102 15

7.5A

W119 O

C-102 25

10A

W90 Bl/R

C-102 17

C-019B 5

7.5A

C-103 12

W100 Pk/Bk

PORTSIDE TACHOMETER

MEM

C-101 23

7.5A

PRISE 12V JACK 12V

10A

W42 Pu/Gy/G

C-102 1

W48 Gy/G

C-102 24

W83 Pu

C-101 19

W50 Pu/Pk

STARTER STARBOARD

C-019A 1

C-103 11

W55 Pk/W C-019A 5

C-101 21

DEMARREUR TRIBORD

C-049 2

W101 Pk/Bl

W91 Bl/R

W120 Bk

SP-08 D

C-086B

C-049 3

C-086A

W150 Bl

W104 O

C-049 7

C-048 7

W99 Bk SP-02 B

C-048 3

W102 Bk

W75 Br/R

W86 W

SP-04 D

C-101 16

W76 Br

W79 Br

C-102 7

C-102 22

W82 Br/W

W81 Br/W

W68 Gy/R

W38 W

INTERRUPTEUR 2R VENTILATEUR

W70 Bk C-051 2 8

INTERRUPTEUR 2R POMPE DE CALE

C-053 7

C-053 2

BILGE PUMP SWITCH

C-052 3

C-052 7

W67 Bk

W64 Br/Y

SP-06 B

INTER. NEUTRE NEUTRAL SWITCH

INTERRUPTEUR NAV/ANC NAV/ANC SWITCH

C-020 2

C-051 7

C-053 3

C-051 3

C-020 1 C-053 6

C-103 1

C-103 16

C-103 9

C-102 9

C-101 22

C-101 26

W31 Pu/W

W32 Pu/Gy

W33 Pu/Bk

W41 Pu/Bk

W40 Pu/R

W123 Bk

SAFETY LANYARD SWITCH C-003 A

ROM

C-003 C

C-003 B

SP-04 A

W71 Gy/Bk

C-044 A SP-11 A

C-085 5

C-085 11

W117 W

C-085 9

W111 W/G

SP-11 C

KLAXON HORN

C-085 3 C-044 B

W108 W/Bk/G

C-041

C-56

C-040

C-55

C-023 A

W87 Bk

HAUT-PARLEUR TRIBORD STARBOARD SPEAKER

W92 Bl C-039 LUMIERE DE COURTOISIE BABORD

PORTSIDE COURTESY LIGHT C-038

W93 Bk SP-03 C

W96 Bl

SP-04 C

VENTILATEUR

BLOWER C-023 B

W65 Bk SP-05 C

C-026 B C-027 B POMPE DE CALE BILGE PUMP C-027 A

W80 Bk SP-03 B

BUZZER C-002 B

C-017 1 C-017 4

INDICATEUR DE VITESSE

C-022 5

C-017 5

W61 W

W62 W/Bk

W59 Bk

C-017 3

W60 Bl

AUXILIAIRE

W69 Bl/R

SP-12 E

CAPTEUR DE PRESENCE D'EAU WATER PROXIMITY SENSOR

C-026 A

SP-12 D

W73 Gy

C-024 A LUMIERE DE POUPE

SP-10 F

C-004 2

BLOC #12

BLOC #10

BLOCK #12

BLOCK #10

STERN LIGHT

SP-12 A

BOW LIGHT C-024 B

W72 Bk SP-03 A

SP-12 C

W57 Bl

OIL SENSOR

SP-08 E

W84 Bk SP-04 B

C-029 B

W52 Lt Bl/Bk C-028 A

C-025 B C-028 C

CAPTEUR DE VITESSE

C-028 B

SP-05 B

CAPTEUR D'ESSENCE FUEL SENSOR

SPEEDO SENSOR

SP-10 B

C-014 B

C-029 A

CAPTEUR D'HUILE

SP-10 D C-025 A

LUMIERE DE PROUE

AUXILIARY

W51 Lt Bl

W56 Bk

SP-06 A

SP-10 C

C-004 1

W74 Bk SP-06 D

SP-06 C

SP-10 A

C-057 LUMIERE DE COURTOISIE TRIBORD STARBOARD COURTESY LIGHT C-058

SP-12 B SP-01 C

W97 Bk SP-03 D

BLOC #5

BLOC #3

BLOC #1

BLOC #2

BLOC #4

BLOC #6

BLOC #8

BLOCK #7

BLOCK #5

BLOCK #3

BLOCK #1

BLOCK #2

BLOCK #4

BLOCK #6

BLOCK #8

SP-07 F

SP-05 D

SP-07 E

SP-05 E

SP-03 E

SP-01 E

SP-01 B

W144 Bk SP-01 F

SP-G F

SP-02 E

SP-02 F

SP-04 F

SP-04 E

SP-06 F

SP-06 E

SP-08 F

W143 Bk a

MISE A TERRE EQUIPOTENTIELLE EQUIPONTENTIAL BUS

W125 Bk

SP-01 D

BLOC #7

W142 Bk

W126 Bk

W147 Bk

W146 Bk

W145 Bk

W152 G

BLOC G BLOCK G SP-G C

SP-G A

Speedster

W53 Pk

W54 Pk/Bk

C-017 2 C-017 6

FUEL/OIL GAUGE

C-022 4

SP-08 C

C-014 A

CADRAN D'HUILE/ESSENCE

C-022 3

SPEEDOMETER

SP-10 E

SP-05 A

C-085 7

RADIO

C-022 2

C-022 8

C-002 A AVERTISSEUR SONORE

W141 Bl

BLOCK #11

W114 W/Bk

C-019A 2

W44 Bk

INTER. CORDON SECURITE

W39 Bk

W78 Bk

BLOC #11 C-085 2

C-103 24

C-102 8

C-051 8

W89 Bk

C-101 17

W77 Bl C-052 2

C-052 8

C-050 7

C-050 3

SP-02 C

SP-11 D

W63 Br/Y/R

BLOWER SWITCH

HORN SWITCH 7

C-101 18

INTERRUPTEUR KLAXON

GAS RESERVE SWITCH 7

C-102 16

W66 Bl

INTERRUPTEUR RESERVE D'ESSENCE

C-050 8

C-050 2

C-048 2 8

COURTESY LIGHT SWITCH

NOTE: RADIO OPTIONEL

C-085 1

W88 Bl C-048 8

INTERRUPTEUR LUMIERE COURTOISIE

SP-02 D

NOTE: RADIO OPTIONAL

W105 O

W85 O

W98 Bl/Pu C-049 8 2

C-086A

TACHYMETRE TRIBORD

W58 Pu/W

C-019A 3 C-102 21

C-103 13

W46 Bk

PORTSIDE SPEAKER

STARBOARD TEMPERATURE SENSOR C-101 20

STARBOARD TACHOMETER

C-042

HAUT-PARLEUR BABORD

C-043

C-019B 3

SP-01 A

SENSEUR DE TEMPERATURE TRIBORD

WATER DETECTION CIRCUIT

PORTSIDE TEMPERATURE SENSOR

STARTER PORTSIDE

W118 Bk

BOITE ELECTRIQUE TRIBORD C-030A 1

SENSEUR DE TEMPERATURE BABORD

DEMARREUR BABORD

W47 Bl

W148 T/G

STARBOARD ELECTRICAL BOX C-030B RO RD

C-019B 2

C-102 10

C-102 11

W149 T BOITE ELECTRIQUE BABORD PORTSIDE ELECTRICAL BOX

SP-G B

W153 G C-202

GOUVERNAIL STEERING

W154 G C-203

RENVERSE REVERSE

W155 G C-204

ANTI-ALGUE WEEDLESS

F09Z02

FRANCAIS

BLACK

BOUGIES TRIBORD

ALIMENTATION MEM

ENGLISH

C-097

W11 Gy/Bk

W5 Gy/Bk/G INTERUPTEUR PRINCIPAL

WIRE COLOR CODE TABLE

MAIN DISCONNECT C-031B 6

C-031B 4 C-031B 2

W12 Bk C-031B 5

MAGNETO BABORD

SP-07 A

W7 Gy C-095

C-096

BATTERIE

12V W140 R

W139 R

W138 R

C-070B C

REDRESSEUR BABORD

C-070B A

RECTIFIER PORTSIDE

C-071B A

C-071B B

BATTERY

C-150 B

C-151 B

C-152 B

20A

C-150 A

C-151 A

C-152 A

W121 R

W122 R

W124 R

ANODE

C-201

C-101 25

C-101 24

C-101 6

C-070A A

C-070A B

C-102 26

C-101 1

C-101 2

C-071A A

C-071A B

SP-07 C

BOUGIES BABORD SPARK PLUGS PORTSIDE

W20 Pu

C-101 11

W21 Y/R

C-101 8

W22 Bk

C-101 14

W2 Br

REDRESSEUR TRIBORD RECTIFIER STARBOARD

C-070A C

W15 R

C-031A 2

W3 Br

W14 Bk C-101 5

C-031A 1

W4 Br

W16 Bk SP-07 D

CODE

W151 G C-200

W10 Br

C-070B B

C-031A 3

W8 Br

C-031A 4

MAGNETO TRIBORD MAGNETO STARBOARD

C-098

C-031B 1

W9 Br

C-031A 5

W1 Gy/G

MAGNETO PORTSIDE C-031B 3

C-031A 6

W6 Bk SP-07 B

RPM BABORD

RPM TRIBORD

PORTSIDE RPM

STARBOARD RPM

W13 R

C-101 10

W17 Pu/G

C-101 7

NOIR

BLUE

BLEU

BROWN

BRUN

GREEN

VERT

DARK GREY

GRIS FONCE

Lt Bl

LIGHT BLUE

BLEU PALE

ORANGE

PINK

ROSE

PURPLE

VIOLET

RED

ROUGE

TAN

BEIGE

WHITE

BLANC

YELLOW

JAUNE

W18 Y/R/G

SPARK PLUGS STARBOARD

C-080B 6

C-080B 4

C-080B 5

MPEM

15amp.

W19 Bk/G

C-102 23

W34 Y/R/G

C-103 8

W36 Y/R

ALIMENTATION CIRCUIT D'ALLUMAGE

MPEM POWER SUPPLY

C-080B 3

C-101 15

IGNITION CIRCUIT POWER SUPPLY

C-080A 3

C-006 3

C-080A 5

C-080A 4

C-006 1 INTERRUPTEUR DEMARRAGE/ARRET BABORD

N.O.

UCT

C-080A 6

15amp. INTERRUPTEUR DEMARRAGE/ARRET TRIBORD

N.O.

PORTSIDE START/STOP SWITCH

STARBOARD START/STOP SWITCH

CPU C-006 2

SOLENOIDE DE DEMARRAGE BABORD

BOBINE D'ALLUMAGE BABORD IGNITION COIL PORTSIDE

SOLENOIDE DE DEMARRAGE TRIBORD

W35 Bk

STARTER SOLENOID PORTSIDE

BOBINE D'ALLUMAGE TRIBORD IGNITION COIL STARBOARD

STARTER SOLENOID STARBOARD

SP-08 A

CIRCUIT DE DETECTION D'EAU

W43 Pu/Gy

C-019B 1 TACHYMETRE BABORD

W49 Gy

C-102 2

W103 O

C-102 15

7.5A

W119 O

C-102 25

10A

W90 Bl/R

C-102 17

C-019B 5

7.5A

C-103 12

W100 Pk/Bk

PORTSIDE TACHOMETER

MEM

C-101 23

7.5A

PRISE 12V JACK 12V

10A

W42 Pu/Gy/G

C-102 1

W48 Gy/G

C-102 24

W83 Pu

C-101 19

W50 Pu/Pk

STARTER STARBOARD

C-019A 1

C-103 11

W55 Pk/W C-019A 5

C-101 21

DEMARREUR TRIBORD

C-049 2

W101 Pk/Bl

W91 Bl/R

W120 Bk

SP-08 D

C-086B

C-049 3

C-086A

W150 Bl

W104 O

C-049 7

C-048 7

W99 Bk SP-02 B

C-048 3

W102 Bk

W75 Br/R

W86 W

SP-04 D

C-101 16

W76 Br

W79 Br

C-102 7

C-102 22

W82 Br/W

W81 Br/W

W68 Gy/R

W38 W

INTERRUPTEUR 2R VENTILATEUR

W70 Bk C-051 2 8

INTERRUPTEUR 2R POMPE DE CALE

C-053 7

C-053 2

BILGE PUMP SWITCH

C-052 3

C-052 7

W67 Bk

W64 Br/Y

SP-06 B

INTER. NEUTRE NEUTRAL SWITCH

INTERRUPTEUR NAV/ANC NAV/ANC SWITCH

C-020 2

C-051 7

C-053 3

C-051 3

C-020 1 C-053 6

C-103 1

C-103 16

C-103 9

C-102 9

C-101 22

C-101 26

W31 Pu/W

W32 Pu/Gy

W33 Pu/Bk

W41 Pu/Bk

W40 Pu/R

W123 Bk

SAFETY LANYARD SWITCH C-003 A

ROM

C-003 C

C-003 B

SP-04 A

W71 Gy/Bk

C-044 A SP-11 A

C-085 5

C-085 11

W117 W

C-085 9

W111 W/G

SP-11 C

KLAXON HORN

C-085 3 C-044 B

W108 W/Bk/G

C-041

C-56

C-040

C-55

C-023 A

W87 Bk

HAUT-PARLEUR TRIBORD STARBOARD SPEAKER

W92 Bl C-039 LUMIERE DE COURTOISIE BABORD

PORTSIDE COURTESY LIGHT C-038

W93 Bk SP-03 C

W96 Bl

SP-04 C

VENTILATEUR

BLOWER C-023 B

W65 Bk SP-05 C

C-026 B C-027 B POMPE DE CALE BILGE PUMP C-027 A

W80 Bk SP-03 B

BUZZER C-002 B

C-017 1 C-017 4

INDICATEUR DE VITESSE

C-022 5

C-017 5

W61 W

W62 W/Bk

W59 Bk

C-017 3

W60 Bl

AUXILIAIRE

W69 Bl/R

SP-12 E

CAPTEUR DE PRESENCE D'EAU WATER PROXIMITY SENSOR

C-026 A

SP-12 D

W73 Gy

C-024 A LUMIERE DE POUPE

SP-10 F

C-004 2

BLOC #12

BLOC #10

BLOCK #12

BLOCK #10

STERN LIGHT

SP-12 A

BOW LIGHT C-024 B

W72 Bk SP-03 A

SP-12 C

W57 Bl

OIL SENSOR

SP-08 E

W84 Bk SP-04 B

C-029 B

W52 Lt Bl/Bk C-028 A

C-025 B C-028 C

CAPTEUR DE VITESSE

C-028 B

SP-05 B

CAPTEUR D'ESSENCE FUEL SENSOR

SPEEDO SENSOR

SP-10 B

C-014 B

C-029 A

CAPTEUR D'HUILE

SP-10 D C-025 A

LUMIERE DE PROUE

AUXILIARY

W51 Lt Bl

W56 Bk

SP-06 A

SP-10 C

C-004 1

W74 Bk SP-06 D

SP-06 C

SP-10 A

C-057 LUMIERE DE COURTOISIE TRIBORD STARBOARD COURTESY LIGHT C-058

SP-12 B SP-01 C

W97 Bk SP-03 D

BLOC #5

BLOC #3

BLOC #1

BLOC #2

BLOC #4

BLOC #6

BLOC #8

BLOCK #7

BLOCK #5

BLOCK #3

BLOCK #1

BLOCK #2

BLOCK #4

BLOCK #6

BLOCK #8

SP-07 F

SP-05 D

SP-07 E

SP-05 E

SP-03 E

SP-01 E

SP-01 B

W144 Bk SP-01 F

SP-G F

SP-02 E

SP-02 F

SP-04 F

SP-04 E

SP-06 F

SP-06 E

SP-08 F

W143 Bk a

MISE A TERRE EQUIPOTENTIELLE EQUIPONTENTIAL BUS

W125 Bk

SP-01 D

BLOC #7

W142 Bk

W126 Bk

W147 Bk

W146 Bk

W145 Bk

W152 G

BLOC G BLOCK G SP-G C

SP-G A

Speedster

W53 Pk

W54 Pk/Bk

C-017 2 C-017 6

FUEL/OIL GAUGE

C-022 4

SP-08 C

C-014 A

CADRAN D'HUILE/ESSENCE

C-022 3

SPEEDOMETER

SP-10 E

SP-05 A

C-085 7

RADIO

C-022 2

C-022 8

C-002 A AVERTISSEUR SONORE

W141 Bl

BLOCK #11

W114 W/Bk

C-019A 2

W44 Bk

INTER. CORDON SECURITE

W39 Bk

W78 Bk

BLOC #11 C-085 2

C-103 24

C-102 8

C-051 8

W89 Bk

C-101 17

W77 Bl C-052 2

C-052 8

C-050 7

C-050 3

SP-02 C

SP-11 D

W63 Br/Y/R

BLOWER SWITCH

HORN SWITCH 7

C-101 18

INTERRUPTEUR KLAXON

GAS RESERVE SWITCH 7

C-102 16

W66 Bl

INTERRUPTEUR RESERVE D'ESSENCE

C-050 8

C-050 2

C-048 2 8

COURTESY LIGHT SWITCH

NOTE: RADIO OPTIONEL

C-085 1

W88 Bl C-048 8

INTERRUPTEUR LUMIERE COURTOISIE

SP-02 D

NOTE: RADIO OPTIONAL

W105 O

W85 O

W98 Bl/Pu C-049 8 2

C-086A

TACHYMETRE TRIBORD

W58 Pu/W

C-019A 3 C-102 21

C-103 13

W46 Bk

PORTSIDE SPEAKER

STARBOARD TEMPERATURE SENSOR C-101 20

STARBOARD TACHOMETER

C-042

HAUT-PARLEUR BABORD

C-043

C-019B 3

SP-01 A

SENSEUR DE TEMPERATURE TRIBORD

WATER DETECTION CIRCUIT

PORTSIDE TEMPERATURE SENSOR

STARTER PORTSIDE

W118 Bk

BOITE ELECTRIQUE TRIBORD C-030A 1

SENSEUR DE TEMPERATURE BABORD

DEMARREUR BABORD

W47 Bl

W148 T/G

STARBOARD ELECTRICAL BOX C-030B RO RD

C-019B 2

C-102 10

C-102 11

W149 T BOITE ELECTRIQUE BABORD PORTSIDE ELECTRICAL BOX

SP-G B

W153 G C-202

GOUVERNAIL STEERING

W154 G C-203

RENVERSE REVERSE

W155 G C-204

ANTI-ALGUE WEEDLESS

F09Z02

FRANCAIS

BLACK

BOUGIES TRIBORD

ALIMENTATION MEM

ENGLISH

C-097

0 0 0 0

SPEEDSTER SK R

INTERUPTEUR PRINCIPAL

WIRE COLOR CODE TABLE

MAIN DISCONNECT C-031B 2

MAGNETO BABORD

W6 Bk

W12 Bk SP-07 B

C-031B 1

C-096

C-098

C-031B 3

W139 R

W138 R

C-150 B

C-151 B

C-152 B

20A

C-150 A

C-151 A

C-152 A

W140 R

12V BATTERY -

C-070B C C-070B B

W121 R

C-070B A

W122 R

W4 Br

ANODE

C-201

W3 Br

C-070A B

W14 Bk C-101 24

C-101 5

C-101 25

C-101 1

C-102 26

RECTIFIER STARBOARD

C-070A A

C-070A D

SP-07 C

W15 R

REDRESSEUR TRIBORD

C-070A C

W124 R

W16 Bk SP-07 D

C-031A 3

W151 G

C-200

W10 Br

MAGNETO TRIBORD MAGNETO STARBOARD

C-031A 4

BATTERIE

W9 Br

C-070B D

C-031A 1

W1 Gy/G

W7 Gy C-095

REDRESSEUR BABORD RECTIFIER PORTSIDE

CODE

SP-07 A

MAGNETO PORTSIDE C-031B 4

C-031A 2

BOUGIES BABORD SPARK PLUGS PORTSIDE

W20 Pu

C-101 11

W21 Y/R

C-101 8

RPM BABORD

RPM TRIBORD

PORTSIDE RPM

STARBOARD RPM

W13 R

ENGLISH

FRANÃ&#x2021;AIS

BLACK

NOIR

BLUE

BLEU

BROWN

BRUN

GREEN

VERT

DARK GREY

GRIS FONCE

Lt Bl

LIGHT BLUE

BLEU PALE

ORANGE

PINK

ROSE

PURPLE

VIOLET

RED

ROUGE

TAN

BEIGE

WHITE

BLANC

YELLOW

JAUNE

BOUGIES TRIBORD

C-101 10

W17 Pu/G

C-101 7

W18 Y/R/G

C-101 15

W19 Bk/G

C-102 23

W34 Y/R/G

C-103 8

W36 Y/R

SPARK PLUGS STARBOARD

MPEM

C-101 14

W22 Bk

ALIMENTATION MEM

C-080B 6

C-080B 5

C-080B 4

ALIMENTATION CIRCUIT D'ALLUMAGE

MPEM POWER SUPPLY

C-080B 3

15amp.

IGNITION CIRCUIT POWER SUPPLY

C-080A 3

C-080A 5

C-080A 4

C-006 1

C-006 3

N.O.

INTERRUPTEUR DEMARRAGE/ARRET BABORD

N.O.

15amp.

INTERRUPTEUR DEMARRAGE/ARRET TRIBORD STARBOARD START/STOP SWITCH

PORTSIDE START/STOP SWITCH

UCT

C-080A 6

CPU BOBINE D'ALLUMAGE BABORD

SOLENOIDE DE DEMARRAGE BABORD

IGNITION COIL PORTSIDE

STARTER SOLENOID PORTSIDE

C-006 2

W35 Bk

SOLENOIDE DE DEMARRAGE TRIBORD

BOBINE D'ALLUMAGE TRIBORD

STARTER SOLENOID STARBOARD

IGNITION COIL STARBOARD

SP-08 A

C-102 11

W149 T BOITE ELECTRIQUE BABORD PORTSIDE ELECTRICAL BOX

C-030B

RO RD

C-019B 1 TACHYMETRE BABORD

W43 Pu/Gy

C-101 23

W49 Gy

C-102 2

W103 O

C-102 15

7.5A

W119 O

C-102 25

10A

W90 Bl/R

C-102 17

W100 Pk/Bk

C-103 12

C-019B 5

PORTSIDE TACHOMETER

MEM

PRISE 12V JACK 12V

C-103 13 C-049 2

C-049 2

W46 Bk

INTERRUPTEUR LUMIERE COURTOISIE

SP-02 D

NOTE: RADIO OPTIONAL

8 2R R

NOTE: RADIO OPTIONEL

C-049 3

C-086B

W104 O

GAS RESERVE SWITCH

HORN SWITCH

C-048 7

W99 Bk SP-02 B

C-050 8 2

INTERRUPTEUR KLAXON

C-049 7

INTERRUPTEUR RESERVE D'ESSENCE

W150 Bl

C-086A

C-085 1

W88 Bl C-050 2

C-048 2

C-048 8

COURTESY LIGHT SWITCH

W105 O

W85 O

W98 Bl/Pu C-049 8 2

C-086A

C-102 21

W101 Pk/Bl

W91 Bl/R

W120 Bk

SP-08 D

W102 Bk

C-101 18

W63 Br/Y/R

W75 Br/R

W66 Bl

C-050 3

INTERRUPTEUR 2R VENTILATEUR

W86 W

SP-04 D

W76 Br

W79 Br

C-102 8

C-102 7

C-102 22

W82 Br/W

W81 Br/W

W68 Gy/R

PORTSIDE SPEAKER

C-103 24

W38 W

W48 Gy/G

C-102 24

W83 Pu

C-101 19

W50 Pu/Pk C-019A 1

W55 Pk/W

8 INTERRUPTEUR POMPE DE CALE

C-053 7

C-053 2

C-052 7

C-052 3

W67 Bk

W64 Br/Y

SP-06 B

C-051 7

INTER. NEUTRE

INTERRUPTEUR NAV/ANC

NEUTRAL SWITCH

NAV/ANC SWITCH 7

C-020 2

C-053 3

C-051 3

C-020 1 C-053 6

C-103 1

C-103 16

C-103 9

C-102 9

C-101 22

C-101 26

W31 Pu/W

W32 Pu/Gy

W33 Pu/Bk

W41 Pu/Bk

W40 Pu/R

W123 Bk

SAFETY LANYARD SWITCH

W117 W

C-085 9

W111 W/G

C-023 A

C-040

C-55

KLAXON

SP-11 B

W108 W/Bk/G C-56

SP-11 C

HORN

C-085 3

C-041

C-019A 2

W45 Bl

STARBOARD TACHOMETER

C-044 B

W87 Bk

HAUT-PARLEUR TRIBORD STARBOARD SPEAKER

W92 Bl C-039 LUMIERE DE COURTOISIE BABORD PORTSIDE COURTESY LIGHT C-038

W93 Bk SP-03 C

W94 Bl C-046 LUMIERE DE COURTOISIE AVANT FRONT COURTESY LIGHT C-045

W95 Bk SP-02 A

W96 Bl

SP-04 C

VENTILATEUR

C-003 A

BLOWER C-023 B

W65 Bk SP-05 C

POMPE DE CALE BILGE PUMP C-027 A

W80 Bk SP-03 B

BUZZER C-002 B

C-003 B

C-003 C

CADRAN D'HUILE/ESSENCE

C-022 3 C-017 5

SPEEDOMETER

C-017 2

C-017 4

INDICATEUR DE VITESSE

C-022 5

W62 W/Bk

W59 Bk

C-017 3

W60 Bl

W53 Pk

W54 Pk/Bk

AUXILIAIRE C-017 6

FUEL/OIL GAUGE

C-022 4

W61 W

W69 Bl/R

SP-12 E SP-12 D

W73 Gy

CAPTEUR DE PRESENCE D'EAU WATER PROXIMITY SENSOR

C-026 A

C-024 A

C-004 2

LUMIERE DE POUPE STERN LIGHT C-024 B

LUMIERE DE PROUE BOW LIGHT C-004 1

W72 Bk SP-03 A

BLOCK #12

BLOCK #10

SP-08 E

C-025 B

SPEEDO SENSOR SP-12 A

SP-12 C

W84 Bk SP-04 B

C-029 B

C-028 B

C-028 A C-028 C

CAPTEUR DE VITESSE

SP-10 B

W57 Bl

OIL SENSOR

W52 Lt Bl/Bk C-025 A

BLOC #10

C-014 B

C-029 A

CAPTEUR D'HUILE

SP-10 D

BLOC #12

AUXILIARY

W51 Lt Bl

W56 Bk

SP-06 A

SP-10 F

SP-08 C

C-014 A

C-017 1

C-022 2

C-022 8

SP-10 E

SP-05 A

C-026 B C-027 B

W44 Bk

W141 Bl

SP-04 A

W71 Gy/Bk

C-044 A

C-002 A AVERTISSEUR SONORE

ROM

W39 Bk

W78 Bk

C-085 7

RADIO

C-085 11

TACHYMETRE TRIBORD

C-019A 5

W58 Pu/W

INTER. CORDON SECURITE

W70 Bk C-051 2

C-051 8

W89 Bk

C-101 16

BILGE PUMP SWITCH

C-050 7

C-101 17

W77 Bl C-052 2

C-052 8

BLOWER SWITCH

C-048 3

C-102 16

8 R

SP-02 C

SP-11 D

SP-11 A

HAUT-PARLEUR BABORD

C-102 1

C-101 21

BLOCK #11

C-085 2

W114 W/Bk

W42 Pu/Gy/G

C-103 11

BLOC #11

C-085 5

STARTER STARBOARD

C-101 20

C-019A 3

C-042

SP-01 A

10A

DEMARREUR TRIBORD

C-043

C-019B 3

W118 Bk

STARBOARD TEMPERATURE SENSOR

7.5A

RO RD

SENSEUR DE TEMPERATURE TRIBORD

WATER DETECTION CIRCUIT

PORTSIDE TEMPERATURE SENSOR

BOITE ELECTRIQUE TRIBORD STARBOARD ELECTRICAL BOX

C-030A 1

CIRCUIT DE DETECTION D'EAU

STARTER PORTSIDE

C-019B 2

W148 T/G

SENSEUR DE TEMPERATURE BABORD

DEMARREUR BABORD

W47 Bl

C-102 10

SP-05 B

CAPTEUR D'ESSENCE FUEL SENSOR

SP-10 C

W74 Bk SP-06 D

SP-06 C

SP-10 A

C-057 LUMIERE DE COURTOISIE TRIBORD

SP-12 B SP-01 C

STARBOARD COURTESY LIGHT C-058

W97 Bk SP-03 D

BLOC #7

BLOC #5

BLOC #3

BLOC #1

BLOC #2

BLOC #4

BLOC #6

BLOC #8

BLOCK #7

BLOCK #5

BLOCK #3

BLOCK #1

BLOCK #2

BLOCK #4

BLOCK #6

BLOCK #8

SP-07 F

SP-07 E

SP-05 D

W142 Bk

SP-05 E

SP-03 E

SP-01 E

SP-01 B

W144 Bk SP-01 F

SP-G F

EQUIPONTENTIAL BUS

SP-02 E

SP-02 F

SP-04 F

SP-04 E

SP-06 F

SP-06 E

C-097

SP-08 F

W143 Bk a

MISE A TERRE EQUIPOTENTIELLE

W125 Bk

SP-01 D

W126 Bk

W147 Bk

W146 Bk

W145 Bk

W152 G

BLOC G BLOCK G

SP-G A

SP-G C

SP-G B

Speedster SK

W153 G C-202 GOUVERNAIL STEERING

W154 G C-203 RENVERSE REVERSE

W155 G C-204 ANTI-ALGUE WEEDLESS

F09Z03

INTERUPTEUR PRINCIPAL

WIRE COLOR CODE TABLE

MAIN DISCONNECT C-031B 2

MAGNETO BABORD

W6 Bk

W12 Bk SP-07 B

C-031B 1

C-096

C-098

C-031B 3

W139 R

W138 R

C-150 B

C-151 B

C-152 B

20A

C-150 A

C-151 A

C-152 A

W140 R

12V BATTERY -

C-070B C C-070B B

W121 R

C-070B A

W122 R

W4 Br

ANODE

C-201

W3 Br

C-070A B

W14 Bk C-101 24

C-101 5

C-101 25

C-101 1

C-102 26

RECTIFIER STARBOARD

C-070A A

C-070A D

SP-07 C

W15 R

REDRESSEUR TRIBORD

C-070A C

W124 R

W16 Bk SP-07 D

C-031A 3

W151 G

C-200

W10 Br

MAGNETO TRIBORD MAGNETO STARBOARD

C-031A 4

BATTERIE

W9 Br

C-070B D

C-031A 1

W1 Gy/G

W7 Gy C-095

REDRESSEUR BABORD RECTIFIER PORTSIDE

CODE

SP-07 A

MAGNETO PORTSIDE C-031B 4

C-031A 2

BOUGIES BABORD SPARK PLUGS PORTSIDE

W20 Pu

C-101 11

W21 Y/R

C-101 8

RPM BABORD

RPM TRIBORD

PORTSIDE RPM

STARBOARD RPM

W13 R

ENGLISH

FRANÃ&#x2021;AIS

BLACK

NOIR

BLUE

BLEU

BROWN

BRUN

GREEN

VERT

DARK GREY

GRIS FONCE

Lt Bl

LIGHT BLUE

BLEU PALE

ORANGE

PINK

ROSE

PURPLE

VIOLET

RED

ROUGE

TAN

BEIGE

WHITE

BLANC

YELLOW

JAUNE

BOUGIES TRIBORD

C-101 10

W17 Pu/G

C-101 7

W18 Y/R/G

C-101 15

W19 Bk/G

C-102 23

W34 Y/R/G

C-103 8

W36 Y/R

SPARK PLUGS STARBOARD

MPEM

C-101 14

W22 Bk

ALIMENTATION MEM

C-080B 6

C-080B 5

C-080B 4

ALIMENTATION CIRCUIT D'ALLUMAGE

MPEM POWER SUPPLY

C-080B 3

15amp.

IGNITION CIRCUIT POWER SUPPLY

C-080A 3

C-080A 5

C-080A 4

C-006 1

C-006 3

N.O.

INTERRUPTEUR DEMARRAGE/ARRET BABORD

N.O.

15amp.

INTERRUPTEUR DEMARRAGE/ARRET TRIBORD STARBOARD START/STOP SWITCH

PORTSIDE START/STOP SWITCH

UCT

C-080A 6

CPU BOBINE D'ALLUMAGE BABORD

SOLENOIDE DE DEMARRAGE BABORD

IGNITION COIL PORTSIDE

STARTER SOLENOID PORTSIDE

C-006 2

W35 Bk

SOLENOIDE DE DEMARRAGE TRIBORD

BOBINE D'ALLUMAGE TRIBORD

STARTER SOLENOID STARBOARD

IGNITION COIL STARBOARD

SP-08 A

C-102 11

W149 T BOITE ELECTRIQUE BABORD PORTSIDE ELECTRICAL BOX

C-030B

RO RD

C-019B 1 TACHYMETRE BABORD

W43 Pu/Gy

C-101 23

W49 Gy

C-102 2

W103 O

C-102 15

7.5A

W119 O

C-102 25

10A

W90 Bl/R

C-102 17

W100 Pk/Bk

C-103 12

C-019B 5

PORTSIDE TACHOMETER

MEM

PRISE 12V JACK 12V

C-103 13 C-049 2

C-049 2

W46 Bk

INTERRUPTEUR LUMIERE COURTOISIE

SP-02 D

NOTE: RADIO OPTIONAL

8 2R R

NOTE: RADIO OPTIONEL

C-049 3

C-086B

W104 O

GAS RESERVE SWITCH

HORN SWITCH

C-048 7

W99 Bk SP-02 B

C-050 8 2

INTERRUPTEUR KLAXON

C-049 7

INTERRUPTEUR RESERVE D'ESSENCE

W150 Bl

C-086A

C-085 1

W88 Bl C-050 2

C-048 2

C-048 8

COURTESY LIGHT SWITCH

W105 O

W85 O

W98 Bl/Pu C-049 8 2

C-086A

C-102 21

W101 Pk/Bl

W91 Bl/R

W120 Bk

SP-08 D

W102 Bk

C-101 18

W63 Br/Y/R

W75 Br/R

W66 Bl

C-050 3

INTERRUPTEUR 2R VENTILATEUR

W86 W

SP-04 D

W76 Br

W79 Br

C-102 8

C-102 7

C-102 22

W82 Br/W

W81 Br/W

W68 Gy/R

PORTSIDE SPEAKER

C-103 24

W38 W

W48 Gy/G

C-102 24

W83 Pu

C-101 19

W50 Pu/Pk C-019A 1

W55 Pk/W

8 INTERRUPTEUR POMPE DE CALE

C-053 7

C-053 2

C-052 7

C-052 3

W67 Bk

W64 Br/Y

SP-06 B

C-051 7

INTER. NEUTRE

INTERRUPTEUR NAV/ANC

NEUTRAL SWITCH

NAV/ANC SWITCH 7

C-020 2

C-053 3

C-051 3

C-020 1 C-053 6

C-103 1

C-103 16

C-103 9

C-102 9

C-101 22

C-101 26

W31 Pu/W

W32 Pu/Gy

W33 Pu/Bk

W41 Pu/Bk

W40 Pu/R

W123 Bk

SAFETY LANYARD SWITCH

W117 W

C-085 9

W111 W/G

C-023 A

C-040

C-55

KLAXON

SP-11 B

W108 W/Bk/G C-56

SP-11 C

HORN

C-085 3

C-041

C-019A 2

W45 Bl

STARBOARD TACHOMETER

C-044 B

W87 Bk

HAUT-PARLEUR TRIBORD STARBOARD SPEAKER

W92 Bl C-039 LUMIERE DE COURTOISIE BABORD PORTSIDE COURTESY LIGHT C-038

W93 Bk SP-03 C

W94 Bl C-046 LUMIERE DE COURTOISIE AVANT FRONT COURTESY LIGHT C-045

W95 Bk SP-02 A

W96 Bl

SP-04 C

VENTILATEUR

C-003 A

BLOWER C-023 B

W65 Bk SP-05 C

POMPE DE CALE BILGE PUMP C-027 A

W80 Bk SP-03 B

BUZZER C-002 B

C-003 B

C-003 C

CADRAN D'HUILE/ESSENCE

C-022 3 C-017 5

SPEEDOMETER

C-017 2

C-017 4

INDICATEUR DE VITESSE

C-022 5

W62 W/Bk

W59 Bk

C-017 3

W60 Bl

W53 Pk

W54 Pk/Bk

AUXILIAIRE C-017 6

FUEL/OIL GAUGE

C-022 4

W61 W

W69 Bl/R

SP-12 E SP-12 D

W73 Gy

CAPTEUR DE PRESENCE D'EAU WATER PROXIMITY SENSOR

C-026 A

C-024 A

C-004 2

LUMIERE DE POUPE STERN LIGHT C-024 B

LUMIERE DE PROUE BOW LIGHT C-004 1

W72 Bk SP-03 A

BLOCK #12

BLOCK #10

SP-08 E

C-025 B

SPEEDO SENSOR SP-12 A

SP-12 C

W84 Bk SP-04 B

C-029 B

C-028 B

C-028 A C-028 C

CAPTEUR DE VITESSE

SP-10 B

W57 Bl

OIL SENSOR

W52 Lt Bl/Bk C-025 A

BLOC #10

C-014 B

C-029 A

CAPTEUR D'HUILE

SP-10 D

BLOC #12

AUXILIARY

W51 Lt Bl

W56 Bk

SP-06 A

SP-10 F

SP-08 C

C-014 A

C-017 1

C-022 2

C-022 8

SP-10 E

SP-05 A

C-026 B C-027 B

W44 Bk

W141 Bl

SP-04 A

W71 Gy/Bk

C-044 A

C-002 A AVERTISSEUR SONORE

ROM

W39 Bk

W78 Bk

C-085 7

RADIO

C-085 11

TACHYMETRE TRIBORD

C-019A 5

W58 Pu/W

INTER. CORDON SECURITE

W70 Bk C-051 2

C-051 8

W89 Bk

C-101 16

BILGE PUMP SWITCH

C-050 7

C-101 17

W77 Bl C-052 2

C-052 8

BLOWER SWITCH

C-048 3

C-102 16

8 R

SP-02 C

SP-11 D

SP-11 A

HAUT-PARLEUR BABORD

C-102 1

C-101 21

BLOCK #11

C-085 2

W114 W/Bk

W42 Pu/Gy/G

C-103 11

BLOC #11

C-085 5

STARTER STARBOARD

C-101 20

C-019A 3

C-042

SP-01 A

10A

DEMARREUR TRIBORD

C-043

C-019B 3

W118 Bk

STARBOARD TEMPERATURE SENSOR

7.5A

RO RD

SENSEUR DE TEMPERATURE TRIBORD

WATER DETECTION CIRCUIT

PORTSIDE TEMPERATURE SENSOR

BOITE ELECTRIQUE TRIBORD STARBOARD ELECTRICAL BOX

C-030A 1

CIRCUIT DE DETECTION D'EAU

STARTER PORTSIDE

C-019B 2

W148 T/G

SENSEUR DE TEMPERATURE BABORD

DEMARREUR BABORD

W47 Bl

C-102 10

SP-05 B

CAPTEUR D'ESSENCE FUEL SENSOR

SP-10 C

W74 Bk SP-06 D

SP-06 C

SP-10 A

C-057 LUMIERE DE COURTOISIE TRIBORD

SP-12 B SP-01 C

STARBOARD COURTESY LIGHT C-058

W97 Bk SP-03 D

BLOC #7

BLOC #5

BLOC #3

BLOC #1

BLOC #2

BLOC #4

BLOC #6

BLOC #8

BLOCK #7

BLOCK #5

BLOCK #3

BLOCK #1

BLOCK #2

BLOCK #4

BLOCK #6

BLOCK #8

SP-07 F

SP-07 E

SP-05 D

W142 Bk

SP-05 E

SP-03 E

SP-01 E

SP-01 B

W144 Bk SP-01 F

SP-G F

EQUIPONTENTIAL BUS

SP-02 E

SP-02 F

SP-04 F

SP-04 E

SP-06 F

SP-06 E

C-097

SP-08 F

W143 Bk a

MISE A TERRE EQUIPOTENTIELLE

W125 Bk

SP-01 D

W126 Bk

W147 Bk

W146 Bk

W145 Bk

W152 G

BLOC G BLOCK G

SP-G A

SP-G C

SP-G B

Speedster SK

W153 G C-202 GOUVERNAIL STEERING

W154 G C-203 RENVERSE REVERSE

W155 G C-204 ANTI-ALGUE WEEDLESS

F09Z03