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2005 Sea-Doo Engine Service Manual (1) 15

The document contains technical specifications and instructions for installing and removing various engine components. It includes torque specifications and types of lubricants to use for reassembly. The sections cover the intake manifold, supercharger, cylinder block, cylinder head, lubrication system, PTO housing and magneto for both naturally aspirated and supercharged 1,503cc 4-TEC engines. Installation instructions include applying threadlocker, using specific torques and lubricating components with oil or grease prior to reassembly.

Uploaded by

Michael Young
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
489 views

2005 Sea-Doo Engine Service Manual (1) 15

The document contains technical specifications and instructions for installing and removing various engine components. It includes torque specifications and types of lubricants to use for reassembly. The sections cover the intake manifold, supercharger, cylinder block, cylinder head, lubrication system, PTO housing and magneto for both naturally aspirated and supercharged 1,503cc 4-TEC engines. Installation instructions include applying threadlocker, using specific torques and lubricating components with oil or grease prior to reassembly.

Uploaded by

Michael Young
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Section 01 ENGINES (1503 4-TEC)

Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)

Naturally Aspirated Engine Intake Manifold and Throttle Body

10 Nm
(89 lbfin)
Loctite 243
6 Nm
(53 lbfin)

Oil

10 Nm
(89 lbfin)

Loctite 243

10 Nm
(89 lbfin)
Loctite 243
6 Nm
(53 lbfin)

18 Nm
(159 lbfin)

Oil
Loctite 243

10 Nm
(89 lbfin)

smr2005-033-200_aen

TYPICAL

SMR2005-033

Section 01 ENGINES (1503 4-TEC)


Subsection 07 (CYLINDER BLOCK)

Engine
oil

10
8

Engine
oil

260 Nm
(191 lbfft)
Loctite
anti-seize

Engine
oil

Engine
oil

Engine
oil
Engine
oil
4

23
Engine
oil
4

12
Engine
oil

Engine
oil

45 Nm
11 (33 lbfft) + 90

13
Engine
oil
6
Engine
oil

5
Engine
oil

15

Engine
oil

Engine
oil

Engine
oil

14

15
R1503motr02S

SMR2005-037

91

Section 01 ENGINES (1503 4-TEC)


Subsection 06 (CYLINDER HEAD)

3
10 Nm
(89 lbfin)

1
Engine oil

4
5

10
Grease Klueber
Isoflex Topas NB52 11

14

10

Engine
oil

Loctite
243

6 Nm
(53 lbfin)

7
18 Nm
(159 lbfin)

24
25
22

12

20 Nm (14.5 lbfft) + 90

10 Nm
(89 lbfin)

21

16

10 Nm 15
(89 lbfin)

28

23
13

Loctite
243
10 Nm
(89 lbfin)

Loctite
243
20

Engine
oil

Loctite 243

17

6 Nm
(53 lbfin)
18 Nm
(159 lbfin)
Engine oil

10 Nm
(89 lbfin)

40 Nm (29.5 lbfft)
+ 120 + 90

18

Engine oil

19

26
27

Loctite 243
10 Nm (89 lbfin)

smr2005-036-003_aen

70

smr2005-036

Section 01 ENGINES (1503 4-TEC)


Subsection 04 (LUBRICATION SYSTEM)

Supercharged Intercooled Engine

Oil
18 Nm
(159 lbfin)
Loctite 243
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
Loctite 243
34
18 Nm
(159 lbfin)

8
5-25 Nm
(44-221 lbfin)
Loctite 243

35
Oil
27

38

37

Oil
28

36

9
29

30

10
14

Loctite 243
10 Nm
(89 lbfin)

12

13
11

Loctite
243
10 Nm
(89 lbfin)

R1503motr369S

44

SMR2005-035

Section 01 ENGINES (1503 4-TEC)


Subsection 04 (LUBRICATION SYSTEM)

Naturally Aspirated and Supercharged Engines

Oil

18 Nm
(159 lbfin)
Loctite 243
10 Nm
(89 lbfin)

10 Nm
(89 lbfin)

8
18 Nm
(159 lbfin)

34

Loctite 243
7
Oil

35

5-25 Nm
(44-221 lbfin)
9

14

37

36

38
Oil

27

Loctite 243

28
29 30

Loctite 243

Loctite 243

10
10 Nm
(89 lbfin)

12
13
11

smr2005-035-001_aen

SMR2005-035

43

Section 01 ENGINES (1503 4-TEC)


Subsection 04 (LUBRICATION SYSTEM)

All Engines

Loctite 243
10 Nm
(89 lbfin)

1
Loctite 243
10 Nm
(89 lbfin)

2
4

Oil

Multi-purpose
grease

Oil

4-TEC
Supercharged
only

24 Nm
(18 lbfft)
Loctite 243
10 Nm
(89 lbfin)

20

19
3 Nm
(27 lbfin)
Left handed
threads

25 26
Loctite 243
10 Nm
(89 lbfin)
Oil

Loctite
5910

18
17

16
23

Loctite 243
12 Nm
(106 lbfin)

24

15

22
Oil

Loctite 243
10 Nm
(89 lbfin)
21

R1503motr368S

42

SMR2005-035

Section 01 ENGINES (1503 4-TEC)


Subsection 03 (PTO HOUSING AND MAGNETO)

Loctite 243
10 Nm
(89 lbfin)

Oil

11

4-TEC
Supercharged
only
Loctite 243
10 Nm
(89 lbfin)

Oil
3 Nm
(26 lbfin)
Left handed thread

23

Loctite 243
10 Nm
(89 lbfin)

22

10

10 Nm
(89 lbfin)

17

15

14
7

Oil
18

Loctite 243
10 Nm
(89 lbfin)

13

16
Loctite
5910
Loctite
243 19

Oil
Loctite 243
12 Nm
(106 lbfin)

Oil

Oil

20
21

Oil

Loctite 243
10 Nm
(89 lbfin)

12
Loctite
anti-seize

R1503motr366S

30

smr2005-032

Section 01 ENGINES (1503 4-TEC)


Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)

Supercharged Engines Supercharger

30 Nm
(22 lbfft)
Loctite 243

Loctite 5910

Loctite 243
Oil
30 Nm
(22 lbfft)
Loctite 243
30 Nm
(22 lbfft)

10 Nm
(89 lbfin)

Klueber isoflex

Loctite 243
Anti-seize
lubricant
Oil

30 Nm
(22 lbfft)

R1503motr357S

SMR2005-033

Section 01 ENGINES (1503 4-TEC)


Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)

Supercharged Intercooled Engine Intake Manifold and Throttle Body

Oil

Loctite 243
6 Nm
(53 lbfin)
Loctite
243
Oil

10 Nm
(89 lbfin)

Oil
Loctite
243

Loctite 243
10 Nm
(89 lbfin)
Loctite 243
6 Nm
(53 lbfin)

18 Nm
(159 lbfin)

smr2005-033-008_aen

SMR2005-033

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