2003 sea doo gti le rfi 6104 service repair manual
- 2. 2003 Shop Manual GTI, GTI LE, GTI LE RFI, GTX DI, XP DI, RX DI, LRV DI, GTX 4-TEC SERIES
- 3. Legal deposit: National Library of Quebec 2nd trimester 2003 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. 2003 Technical Publications Bombardier Inc. Valcourt (Quebec) Canada Printed in Canada ®*Registered trademarks of Bombardier Inc. Knight’s Spray-Nine† is a trademark of Korkay System Ltd GTX† is a trademark of Castrol Ltd. Used under license Loctite® is a trademark of Loctite Corporation Snap-on® is a trademark of Snap-on Tools Corporation Gelcote® is a trademark of Gelcote International Limited The following trademarks are the property of Bombardier Inc. or its subsidiaries: SEA-DOO® BOMBARDIER-ROTAX® BOMBARDIER LUBE® BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil BOMBARDIER Formula XP-S DI Synthetic Injection Oil BOMBARDIER-ROTAX Injection Oil Sea-Doo Synthetic Grease Sea-Doo LKTM DESSTM Rotax® O.P.A.S.TM TOPSTM
- 4. SMR2003_001_00_00A2.FM I SECTION SUBSECTION PAGE SAFETY NOTICE.................................................................................................................................. III INTRODUCTION ................................................................................................................................... IV 01 SERVICE TOOLS AND PRODUCTS 01 - Table of contents ...................................................................... 01-01-1 02 - Mandatory service tools............................................................ 01-02-1 03 - Optional service tools................................................................ 01-03-1 04 - Service products ....................................................................... 01-04-1 02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1 02 - Periodic inspection chart........................................................... 02-02-1 03 - Flushing and lubrication............................................................. 02-03-1 04 - Water-flooded engine................................................................ 02-04-1 05 - Storage...................................................................................... 02-05-1 03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1 04 ENGINE (2-stroke) 01 - Table of contents ...................................................................... 04-01-1 02 - Leak test ................................................................................... 04-02-1 03 - Removal and installation ........................................................... 04-03-1 04 - Magneto system....................................................................... 04-04-1 05 - Top end ..................................................................................... 04-05-1 06 - Bottom end ............................................................................... 04-06-1 07 - Rotary valve............................................................................... 04-07-1 08 - Exhaust system......................................................................... 04-08-1 05 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 05-01-1 02 - Leak test ................................................................................... 05-02-1 03 - Intake system............................................................................ 05-03-1 04 - Exhaust system......................................................................... 05-04-1 05 - Removal and installation ........................................................... 05-05-1 06 - PTO housing/magneto .............................................................. 05-06-1 07 - Lubrication system.................................................................... 05-07-1 08 - Cylinder head and valves........................................................... 05-08-1 09 - Engine block.............................................................................. 05-09-1 06 ENGINE MANAGEMENT (RFI) 01 - Table of contents ...................................................................... 06-01-1 02 - Overview................................................................................... 06-02-1 03 - Diagnostic procedures .............................................................. 06-03-1 04 - Component inspection.............................................................. 06-04-1 05 - Troubleshooting summary ........................................................ 06-05-1 06 - Adjustment................................................................................ 06-06-1 07 - Removal and installation ........................................................... 06-07-1 07 ENGINE MANAGEMENT (DI) 01 - Table of contents ...................................................................... 07-01-1 02 - Overview................................................................................... 07-02-1 03 - Component inspection and adjustment .................................... 07-03-1 04 - Diagnostic procedures .............................................................. 07-04-1 08 ENGINE MANAGEMENT (4-TEC) 01 - Table of contents ...................................................................... 08-01-1 02 - Overview................................................................................... 08-02-1 03 - Component inspection and adjustment .................................... 08-03-1 04 - Diagnostic procedures .............................................................. 08-04-1 09 COOLING SYSTEM 01 - Table of contents ...................................................................... 09-01-1 02 - Circuit, components and care ................................................... 09-02-1 TABLE OF CONTENTS
- 5. II SMR2003_001_00_00A2.FM SECTION SUBSECTION PAGE 10 FUEL SYSTEM 01 - Table of contents...................................................................... 10-01-1 02 - Fuel circuit ................................................................................ 10-02-1 03 - Air intake (2-stroke)................................................................... 10-03-1 04 - Carburetor................................................................................. 10-04-1 11 LUBRICATION SYSTEM (2-stroke) 01 - Table of contents...................................................................... 11-01-1 02 - Oil injection system .................................................................. 11-02-1 03 - Oil injection pump..................................................................... 11-03-1 12 ELECTRICAL SYSTEM 01 - Table of contents...................................................................... 12-01-1 02 - Ignition system (carbureted engines) ....................................... 12-02-1 03 - Charging system....................................................................... 12-03-1 04 - Starting system......................................................................... 12-04-1 05 - Instruments and accessories.................................................... 12-05-1 06 - DESS (carbureted and RFI engines).......................................... 12-06-1 13 PROPULSION SYSTEM 01 - Table of contents...................................................................... 13-01-1 02 - Jet pump................................................................................... 13-02-1 03 - Drive system............................................................................. 13-03-1 04 - Reverse system........................................................................ 13-04-1 05 - Variable trim system................................................................. 13-05-1 14 STEERING SYSTEM 01 - Table of contents...................................................................... 14-01-1 02 - Steering system........................................................................ 14-02-1 03 - Alignment ................................................................................. 14-03-1 15 SUSPENSION 01 - Table of contents...................................................................... 15-01-1 02 - Direct action suspension .......................................................... 15-02-1 16 HULL/BODY 01 - Table of contents...................................................................... 16-01-1 02 - Adjustment and repair .............................................................. 16-02-1 17 TECHNICAL DATA 01 - GTI and GTI LE models............................................................. 17-01-1 02 - GTI LE RFI models.................................................................... 17-02-1 03 - GTX DI, RX DI and XP DI models.............................................. 17-03-1 04 - LRV DI models.......................................................................... 17-04-1 05 - GTX 4-TEC models.................................................................... 17-05-1 18 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 18-01-1 TABLE OF CONTENTS
- 6. SMR2003_001_00_00A2.FM III SAFETY NOTICE 0 This manual has been prepared as a guide to correctly service and repair all 2003 SEA-DOO watercraft. See model list below. This edition was primarily published to be used by watercraft mechanical technicians who are already familiar with all service procedures relating to Bombardier made watercraft. Mechanical technicians should attend training courses given by Bombardier Training Dept. Please note that the instructions will apply only if proper hand tools and special service tools are used. This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts Catalog. It is understood that this manual may be translated into another language. In the event of any discrepancy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts. The use of Bombardier parts is most strongly recommended when considering replacement of any com- ponent. Dealer and/or distributor assistance should be sought in case of doubt. The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab, self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols: CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle 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. 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 mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations. ƽ WARNING Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. SAFETY NOTICE
- 7. IV SMR2003_001_00_00A2.FM INTRODUCTION 0 This Shop Manual covers the following BOMBARDIER made SEA-DOO® 2003 watercraft models. HULL IDENTIFICATION NUMBER (H.I.N.) It is located on footboard at the rear of watercraft. 1. Hull Identification Number (H.I.N.) TYPICAL 1. Hull Identification Number (H.I.N.) MODELS ENGINE TYPE MODEL NUMBER XP DI 947 DI 6131 XP DI International 947 DI 6130 GTI (blue) International 717 5568 GTI (ultraviolet) 717 5598 GTI California (ultraviolet) 717 5567 GTI International (ultraviolet) 717 5597 GTI LE (earthen clay) 717 6102 GTI LE International (earthen clay) 717 6101 GTI LE RFI 787 RFI 6104 GTI LE RFI International 787 RFI 6103 GTX DI 947 DI 6119 GTX DI International 947 DI 6118 RX DI 947 DI 6123 RX DI International 947 DI 6122 LRV DI 947 DI 5771 GTX 4-TEC 1503 6112 GTX 4-TEC International 1503 6111 GTX 4-TEC Vans Triple Crown Edition 1503 6126 GTX 4-TEC Vans Triple Crown Edition International 1503 6125 GTX 4-TEC Supercharged (viper red) 1503 6129 GTX 4-TEC Supercharged International (viper red) 1503 6128 GTX 4-TEC Supercharged (yellow) 1503 6106 GTX 4-TEC Supercharged International (yellow) 1503 6105 GTX 4-TEC Supercharged Limited 1503 6108 GTX 4-TEC Supercharged Limited International 1503 6107 F00L2EA 1 F08L0QA 1 INTRODUCTION
- 8. SMR2003_001_00_00A2.FM V All Models The Hull Identification Number is composed of 12 digits: ENGINE IDENTIFICATION NUMBER (E.I.N.) 717 Engines The Engine Identification Number is located on the upper side of the magneto housing. TYPICAL 1. Engine Identification Number (E.I.N.) 787 RFI Engines The Engine Identification Number is located on the upper crankcase on PTO side. 1. Engine Identification Number (E.I.N.) 947 DI Engines The Engine Identification Number is located on the upper crankcase on MAGNETO side. 1. Engine Identification Number (E.I.N.) ARRANGEMENT OF THIS MANUAL The manual is divided into many major sections as you can see in the main table of contents at the beginning of the manual. Several sections are divided in various subsections. There is a table of contents at the beginning of many sections. Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number* F00A0CB Month of production Year of production *A letter may also be used as a digit. Manufacturer 1 F01D01A F01D87A 1 F06D15A 1 INTRODUCTION
- 9. VI SMR2003_001_00_00A2.FM Subsection 04 (MAGNETO SYSTEM) 03-04-1 F01D4WS Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 648 145 N•m (107 lbf•ft) Anti-seize lubricant Page heading indicates section and subsection detailed. Exploded view assits you in identifying parts and related positions. TYPICAL PAGE F01A0CS Illustration number for publishing process. Subsection title indicates beginning of the subsection. Dotted box contains parts of a particular model or an exploded view. Page numbering system: 03: ENGINE section 04: MAGNETO SYSTEM subsection 1: First page of this subsection Italic sub-title above exploded view indicate pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 243 to screw threads. Bold face number indicates special procedure concerning this part. INTRODUCTION
- 10. SMR2003_001_00_00A2.FM VII 1 2 Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS) 06-03-4 Diaphragm XP Model Only CARBURETOR REMOVAL Inspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.). PUMP DIAPHRAGM LEAK TEST TYPICAL To remove carburetors from engine, proceed as fol- lows: 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. NOTE: For fuel line removal, use pliers (P/N 295 000 054). 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. Remove screws no. 6 and lock washers no. 7 retaining carburetors. All Others Models Remove 4 bolts no. 8 and lock washers no. 12 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, other-wise it must be timed. Remove carburetors from intake manifold. Disconnect fuel bypass line between carburetors (twin carburetors). Remove carburetor(s) from rotary valve cover. DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester, perform the fol- lowing 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). Diaphragm must stand pressure for 10 seconds. If pressure drops, replace diaphragm. F01F0XB A 2 1 1 2 TYPICAL PAGE Sub-title with part name(s) from exploded view. “TYPICAL” mention indicates a general view which does not represent full detail. Sub-sub-title in this case indicates that particular procedure for XP is finished, so from this point, all others models are concerned. Title in italic indicates a particular procedure concerning a model. Service tool to be used to perform a certain procedure. Title indicates main procedure to be carried-out. Sub-sub-title in capital indicates a particular testing, adjustment or repair procedure. Illustration always follows text it is pertained to. Numbers in a frame are used to give a sequence to be perfomed. Numbers are used for description of components. Letters are used for any measures. Bold numbers in the text refer to the parts shown in the exploded view at the beginning of the subsection. F01A0BS INTRODUCTION
- 11. VIII SMR2003_001_00_00A2.FM LIST OF ABBREVIATIONS USED IN THIS MANUAL GENERAL INFORMATION The use of RIGHT (starboard) and LEFT (port) indi- cations in the text, always refers to driving position (when sitting on watercraft). Besides, in the marine industry, FRONT is called BOW and REAR is called STERN. 1. Left (port) 2. Right (starboard) The information and component/system descrip- tions contained in this manual are correct at time of writing. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to in- stall 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. 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 watercraft are designed with parts dimensioned mostly in the metric system. Howeversomecomponentsmaybefromtheimpe- rial system.Whenreplacing fasteners, makesureto use only those recommended by Bombardier. DESCRIPTION ADC Analog to Digital Conversion AC Alternate Current APS Air Pressure Sensor ATS Air Temperature Sensor B.U.D.S. Bombardier Utility and Diagnostic Software CDI Capacitor Discharge Ignition CPS Crankshaft Position Sensor CSI Cooling System Indicator DC Direct Current DESS Digitally Encoded Security System DI Direct Injection E.I.N. Engine Identification Number ECM Engine Control Module ECU Electronic Control Unit EPA Environmental Protection Agency (USA) HP Horse Power LED Light Emitting Diode MAG Magneto MPEM Multi-Purpose Electronic Module MPH Mile Per Hour MPI Multi Protocol Interface N.A. Not Applicable OPT Optional P/N Part Number PFD Personal Flotation Device PSI Pound Per Square Inch PTO Power Take Off RAVE Rotax Adjustable Variable Exhaust RFI Rotax Fuel Injection RPM Revolution Per Minute STD Standard TBD To Be Determined TDC Top Dead Center TPS Throttle Position Sensor VDC Volt Direct Current VCK Vehicle Communication Kit VDC Volt Direct Current VTS Variable Trim System WTS Water Temperature Sensor F01L45B 1 2 INTRODUCTION
- 12. SMR2003_001_00_00A2.FM IX As many of the procedures in this manual are in- terrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the proce- dure is contained. A number of procedures throughout the book re- quire the use of special tools. Before undertaking any procedure, be sure that you have on hand all the tools required, or approved equivalents. ENGINE EMISSIONS INFORMATION Manufacturer’s Responsibility Beginning with 1999 model year engines, PWC manufacturers of marine engines must determine the exhaust emission levels for each engine horse- power family and certify these engines with the United States of America Environmental Protec- tion Agency (EPA). An emissions control informa- tion label, showing emission levels and engine specifications, must be placed on each vehicle at the time of manufacture. Dealer Responsibility When performing service on all 1999 and more re- cent Sea-Doo watercrafts that carry an emissions control information label, adjustments must be kept within published factory specifications. Replacement or repair of any emission related com- ponent must be executed in a manner that main- tains emission levels within the prescribed certifi- cation standards. Dealers are not to modify the engine in any man- ner that would alter the horsepower or allow emis- sion levels to exceed their predetermined factory specifications. Exceptions include manufacturer’s prescribed changes, such as altitude adjustments for exam- ple. Owner Responsibility The owner/operator is required to have engine maintenance performed to maintain emission lev- els within prescribed certification standards. The owner/operator is not to, and should not allow anyone to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory spec- ifications. EPA Emission Regulations All new 1999 and more recent Sea-Doo watercrafts manufactured by Bombardier are certified to the EPA as conforming to the requirements of the reg- ulations for the control of air pollution from new wa- tercraft engines. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenev- er practicable, returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emis- sions for marine products. For more detailed informa- tion on this subject, you may contact the following locations: VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460 VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001 EPA INTERNET WEB SITE: http:/www.epa.gov/omswww SELF-LOCKING FASTENERS PROCEDURE The following describes the most common appli- cation procedures when working with self-locking fasteners. Use a metal brush or a screwtap to clean the hole properly then use a solvent (Methyl-Chloride), let act during 30 minutes and wipe off. The solvent utilization is to ensure the adhesive works properly. INTRODUCTION
- 13. X SMR2003_001_00_00A2.FM LOCTITE APPLICATION PROCEDURE The following describes the most common appli- cation procedures when working with Loctite products. NOTE: Always use proper strength Loctite prod- uct as recommended in this Shop Manual. THREADLOCKER Uncovered Holes (bolts and nuts) 1. Apply here 2. Do not apply 1. Clean threads (bolt and nut) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. 3. Choose proper strength Loctite threadlocker. 4. Fit bolt in the hole. 5. Apply a few drops of threadlocker at proposed tightened nut engagement area. 6. Position nut and tighten as required. Blind Holes 1. On threads 2. On threads and at the bottom of hole 1. Clean threads (bolt and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on threads (bolt and nut) and allow to dry for 30 seconds. 3. Choose proper strength Loctite threadlocker. 4. Apply several drops along the threaded hole and at the bottom of the hole. 5. Apply several drops on bolt threads. 6. Tighten as required. Stud in Blind Holes 1. On threads 2. On threads and in the hole 3. Onto nut threads A00A3LA 1 2 A00A3MA 1 2 A00A5RA 2 1 3 INTRODUCTION
- 14. SMR2003_001_00_00A2.FM XI 1. Clean threads (stud and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. 3. Put several drops of proper strength Loctite threadlocker on female threads and in hole. 4. Apply several drops of proper strength Loctite on stud threads. 5. Install stud. 6. Install cover, etc. 7. Apply drops of proper strength Loctite on un- covered threads. 8. Tighten nuts as required. Preassembled Parts 1. Apply here 2. Do not apply 1. Clean bolts and nuts with solvent. 2. Assemble components. 3. Tighten nuts. 4. Apply drops of proper strength Loctite on bolt/nut contact surfaces. 5. Avoid touching metal with tip of flask. NOTE: For preventive maintenance on existing equipment, retighten nuts and apply proper strength Loctite on bolt/nut contact surfaces. Adjusting Screw 1. Apply here 2. Plunger 1. Adjust screw to proper setting. 2. Apply drops of proper strength Loctite thread- locker on screw/body contact surfaces. 3. Avoid touching metal with tip of flask. NOTE: If it is difficult to readjust, heat screw with a soldering iron (232°C (450°F)). STRIPPED THREAD REPAIR Stripped Threads 1. Release agent 2. Stripped threads 3. Form-A-Thread 4. Tape 5. Cleaned bolt 6. Plate 7. New threads 8. Threadlocker A00A3OA 1 2 A00A3PA 1 2 A00A3QA 5 8 6 7 1 2 3 4 INTRODUCTION
- 15. XII SMR2003_001_00_00A2.FM Standard Thread Repair 1. Follow instructions on Loctite FORM-A-THREAD 81668 package. 2. If a plate is used to align bolt: a. Apply release agent on mating surfaces. b. Put waxed paper or similar film on the surfaces. 3. Twist bolt when inserting it to improve thread conformation. NOTE: NOT intended for engine stud repairs. Repair of Small Holes/Fine Threads Option 1: Enlarge damaged hole, then follow Stan- dard Thread Repair procedure. Option 2: Apply FORM-A-THREAD on the screw and insert in damaged hole. Permanent Stud Installation (light duty) 1. Use a stud or thread on desired length. 2. DO NOT apply release agent on stud. 3. Do a Standard Thread Repair. 4. Allow to cure for 30 minutes. 5. Assemble. GASKET COMPOUND All Parts 1. Proper strength Loctite 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518 (P/N 293 800 038) on both sides of gasket 3. Loctite Primer N only 1. Remove old gasket and other contaminants with Loctite Chisel remover (P/N 413 708 500). Use a mechanical mean if necessary. NOTE: Avoid grinding. 2. Clean both mating surfaces with solvent. 3. Spray Loctite Primer N on both mating surfaces and on both sides of gasket. Allow to dry 1 or 2 minutes. 4. Apply GASKET ELIMINATOR 518 (P/N 293 800 038) on both sides of gasket, using a clean ap- plicator. 5. Place gasket on mating surfaces and assemble immediately. NOTE: If the cover is bolted to blind holes (above), apply proper strength Loctite in the hole and on threads. Tighten. If holes are sunken, apply proper strength Loctite on bolt threads. 6. Tighten as usual. MOUNTING ON SHAFT Mounting with a Press 1. Bearing 2. Proper strength Loctite 3. Shaft Standard 1. Clean shaft external part and element internal part. 2. Apply a strip of proper strength Loctite on shaft circumference at insert or engagement point. NOTE: Retaining compound is always forced out when applied on shaft. 3. DO NOT use anti-seize Loctite or any similar product. 4. No curing period is required. A00A3SA 21 1 3 1 A00A3UA 1 2 3 INTRODUCTION
- 16. INTRODUCTION SMR2003_001_00_00A2.FM XIII Mounting in Tandem 1. Apply retaining compound on internal element bore. 2. Continue to assemble as shown above. CASE-IN COMPONENTS Metallic Gaskets 1. Proper strength Loctite 1. Clean inner housing diameter and outer gasket diameter. 2. Spray housing and gasket with Loctite Primer N (P/N 293 800 041). 3. Apply a strip of proper strength Loctite on lead- ing edge of outer metallic gasket diameter. NOTE: Any Loctite product can be used here. A low strength liquid is recommended as normal strength and gap are required. 4. Install according to standard procedure. 5. Wipe off surplus. 6. Allow it to cure for 30 minutes. NOTE: Normally used on worn-out housings to prevent leaking or sliding. It is generally not necessary to remove gasket compound applied on outer gasket diameter. TIGHTENING TORQUES Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table.The table also gives the metric conversion. A00A3VA 1 N•m FASTENER SIZE (8.8) Lbf•in 1 9 2 M4 18 3 27 4 M5 35 5 44 6 53 7 62 8 71 9 80 10 M6 89 11 97 12 106 13 115 14 124 15 133 16 142 17 150 18 159 19 168 N•m FASTENER SIZE (8.8) Lbf•ft 20 15 21 15 22 16 23 M8 17 24 18 25 18 26 19 27 20 28 21 29 21 30 22 31 23 32 24 33 24 34 25 35 26 36 27 37 27
- 17. INTRODUCTION XIV SMR2003_001_00_00A2.FM 38 28 39 29 40 30 41 30 42 31 43 32 44 32 45 33 46 34 47 35 48 M10 35 49 36 50 37 51 38 52 38 53 39 54 40 55 41 56 41 57 42 58 43 59 44 60 44 61 45 62 46 63 46 64 47 65 48 66 49 67 49 68 50 69 51 70 52 71 52 72 53 73 54 74 55 75 55 76 56 77 57 78 58 79 58 80 M12 59 81 60 82 60 N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft 83 61 84 62 85 63 86 63 87 64 88 65 89 66 90 66 91 67 92 68 93 69 94 69 95 70 96 71 97 72 98 72 99 73 100 74 101 74 102 75 103 76 104 77 105 77 106 78 107 79 108 80 109 80 110 81 111 82 112 83 113 83 114 84 115 85 116 86 117 86 118 87 119 88 120 89 121 89 122 90 123 91 124 91 125 92 126 93 127 94
- 18. INTRODUCTION SMR2003_001_00_00A2.FM XV TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS Technical Publications Bombardier Inc. Valcourt (Quebec), Canada N•m FASTENER SIZE (8.8) Lbf•ft 128 94 129 95 130 96 131 97 132 97 133 98 134 99 135 M14 100 136 100 137 101 138 102 139 103 140 103 141 104 142 105 143 105 144 106 145 107 146 108 147 108 148 109 149 110 150 111
- 19. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (TABLE OF CONTENTS) SMR2003-049_01_01ATOC.FM 01-01-1 TABLE OF CONTENTS 0 MANDATORY SERVICE TOOLS ........................................................................................... 01-02-1 ENGINE .............................................................................................................................. 01-02-1 COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-02-5 PROPULSION SYSTEM..................................................................................................... 01-02-7 STEERING SYSTEM .......................................................................................................... 01-02-9 OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1 ENGINE .............................................................................................................................. 01-03-1 COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-03-6 PROPULSION SYSTEM..................................................................................................... 01-03-7 BODY.................................................................................................................................. 01-03-8 WATERCRAFT HANDLING................................................................................................ 01-03-9 SERVICE PRODUCTS ............................................................................................................ 01-04-1
- 20. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) SMR2003-002_01_02A.FM 01-02-1 MANDATORY SERVICE TOOLS 0 ENGINE Degree wheel P/N 529 035 607 A00B334 APPLICATION 717 and 787 RFI engines. Piston circlip installer A) P/N 529 035 562 B) P/N 529 035 563 F06B014 C) P/N 529 035 765 V04B0B4 APPLICATION A) 717 and 787 RFI engines. B) 947 DI engines. C) 4-TEC engines 360 350 340 330 320 310 300 290280270260250 240 2 30 220 210200190180170 160 150 140 130 1201101009080 70 60 50 40 30 20 10 10 20 30 40 50 60 70 8090100110 120 130 1 40 150 160 170180190200 210 220 230 240 250260270280290 300 310 320 330 340 350 360 Sleeve set A) P/N 529 035 542 (20 mm sleeve) B) P/N 529 035 543 (21 mm sleeve) F00B0U4 APPLICATION A) 717 and 787 RFI engines. B) 947 DI engines. Air compressor ring compressor P/N 529 035 713 F12B0L4 APPLICATION 947 DI engines. Carbon dam guide P/N 529 035 715 F12B0M4 APPLICATION 947 DI engines. Carbon dam compressor P/N 529 035 716 F12B0N4 APPLICATION 947 DI engines. Bearing pusher P/N 420 876 501 F00B074 APPLICATION 717 and 787 RFI engines. PTO flywheel remover/installer A) P/N 295 000 001 B) P/N 529 035 820 F01J0T4 APPLICATION A) 717 engines. B) 4-TEC engines. NOTE: This tool is also used for the impeller.
- 21. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) 01-02-2 SMR2003-002_01_02A.FM Starter drive bearing pusher P/N 420 876 502 F06B054 APPLICATION 947 DI engines. Piston pin puller P/N 529 035 503 Expansion sleeve P/N 295 000 117 (787 RFI engines) F00B0T4 APPLICATION All 2-stroke engines. Puller P/N 529 035 547 A00C1A4 Puller plate P/N 520 035 533 A00C1R4 Extension handle P/N 295 000 125 F01D164 Screw M8 x 35 (3) P/N 420 841 591 F00A094 Sleeve (3) P/N 290 847 220 F00A0A4 APPLICATION 717 engines. Puller is also used for PTO fly- wheel on 947 DI engines. Pusher P/N 420 876 605 A00C0Y4 APPLICATION 717 engines. Puller ass’y P/N 290 876 488 1) Screw P/N 290 240 860 2) Hexagonal nut P/N 290 242 210 F01B0I4 APPLICATION 717 and 787 RFI engines. Alignment support plate kit P/N 529 035 506 1) Alignment plates A) P/N 529 035 507 B) P/N 529 035 508 2) Support P/N 529 035 511 3) Screw (2) P/N 207 182 544 4) Lock washer (2) P/N 234 181 601 5) Flat washer (2) P/N 234 081 410 F00B0F4 APPLICATION All models. A) 155.6 mm jet pump. B) 139.5 mm jet pump. Alignment shaft P/N 295 000 141 F00B0G4 APPLICATION All models. 2 1
- 22. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) SMR2003-002_01_02A.FM 01-02-3 Adapter P/N 529 035 590 F00B124 APPLICATION XP DI models. Alignment adaptor P/N 529 035 719 F18B0C4 APPLICATION GTX 4-TEC models. VCK (Vehicle Communication Kit) P/N 529 035 844 F12H0A4 APPLICATION All models. Flywheel extractor P/N 295 000 156 F00B044 APPLICATION 787 RFI engines. Engine leak tester kit P/N 295 500 352 Pump only P/N 529 021 800 F01B2Q5 APPLICATION 717, 787 RFI , 947 DI engines. Supplementary engine leak test kit P/N 295 500 780 1a) 787 RFI Intake plate P/N 296 000 024 1b) 947 DI Intake plate P/N 296 000 025 2) 947 DI Rave plate P/N 296 000 026 3) 947 DI Exhaust plate P/N 296 000 027 APPLICATION 787 RFI and 947 DI engines. NOTE: This kit is supplementary to P/N 295 500 352. Handle P/N 420 877 650 A00C3V4 APPLICATION Use with pushers (P/N 290 876 609 and 290 877 740). Rotary valve shaft pusher P/N 290 876 609 F01B2B4 APPLICATION 787 RFI engines. Use with handle P/N 420 877 650. 21 3
- 23. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) 01-02-4 SMR2003-002_01_02A.FM Oil seal pusher P/N 290 877 740 F01B2C4 APPLICATION 787 RFI engines. Use with handle P/N 420 877 650 Ring gear puller tool P/N 420 976 235 (puller ass’y) P/N 529 035 549 (puller bolt) F01B294 APPLICATION 787 RFI and 947 DI engines. Crankshaft protective cap A) P/N 420 876 557 B) P/N 290 877 414 F00B194 APPLICATION A) 717 and 787 RFI engines. B) 947 DI engines. A B Polygonal wrench P/N 529 035 505 F00B0Y4 APPLICATION Exhaust system of the 947 DI en- gines. Ring gear blocking tool kit A) P/N 529 035 846 B) P/N 529 035 946 F15B014 APPLICATION A) 787 RFI engines. B) 947 DI engines. Intake plug P/N 529 035 708 F12B0O4 APPLICATION 947 DI engines. Crankshaft looking tool P/N 529 035 821 F18B064 APPLICATION 4-TEC engines. NEW Camshaft looking tool P/N 529 035 839 F18B074 APPLICATION 4-TEC engines. Drive shaft adaptor P/N 529 035 892 F00B214 APPLICATION 4-TEC engines. Torx adapter P/N 529 035 938 F00B204 APPLICATION 4-TEC Supercharged engines. NEW NEW
- 24. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) SMR2003-002_01_02A.FM 01-02-5 COOLING/FUEL/OIL SYSTEMS Gear holder P/N 420 277 905 A00C164 APPLICATION 717 engines. Pliers P/N 295 000 070 Oetiker 1099 F01D174 APPLICATION All models. Pliers P/N 295 000 054 Caillau F01B1T4 APPLICATION All models. NOTE: This tool is also used for the propulsion system. Fuel pressure gauge P/N 529 035 591 F02B0B4 APPLICATION 787 RFI and 4-TEC engines. Fuel line disconnect tool P/N 529 035 714 F12B0G4 APPLICATION 947 DI engines. 1. Fuel pressure gauge P/N 529 035 709 2. Fuel pressure gauge T-fitting P/N 529 035 710 3. Fuel pressure gauge pressure relief valve P/N 529 035 711 4. Fuel pressure gauge air com- pressor adapter P/N 529 035 712 F12R014 APPLICATION 947 DI engines. Oil pressure gauge (1 to 8 bars) P/N 529 035 709 V00B064 APPLICATION 4-TEC engines. 1 3 2 4
- 25. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) 01-02-6 SMR2003-002_01_02A.FM Engine oil pressure adapter P/N 529 035 652 V00B074 APPLICATION 4-TEC engines. Oil seal guide P/N 529 035 822 F18B094 APPLICATION 4-TEC engines. Coolant pump seal pusher P/N 529 035 823 F18B084 APPLICATION 4-TEC engines.
- 26. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) SMR2003-002_01_02A.FM 01-02-7 PROPULSION SYSTEM Impeller remover/installer A) P/N 295 000 001 B) P/N 529 035 820 F01J0T4 APPLICATION A) All 2-stroke models. B) 4-TEC engines. NOTE: This tool is also used for the PTO flywheel (on some mod- els). Pliers P/N 295 000 069 Oetiker 1090 F01D184 APPLICATION All models. Impeller shaft holder P/N 295 000 082 F01B0W4 APPLICATION All 2-stroke models. Jet pump bearing remover P/N 295 000 144 F01J114 APPLICATION All 2-stroke models. Bearing/seal installer P/N 295 000 107 F01J4K4 APPLICATION All 2-stroke models Inner seal installer P/N 529 035 609 F08B014 APPLICATION 155.6 mm (6-1/8 in) jet pump. Impeller shaft guide P/N 295 000 002 F01J1O4 APPLICATION All 2-stroke models. Pliers P/N 295 000 054 Caillau F01B1T4 APPLICATION All models. NOTE: This tool is also used for the fuel system. VTS tool P/N 295 000 133 F01B2P4 APPLICATION XP DI models. Drive shaft alignment tool P/N 529 035 590 F08B024 APPLICATION XP DI models.
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- 28. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) 01-02-8 SMR2003-002_01_02A.FM PTO seal support P/N 529 035 842 F18B0F4 APPLICATION GTX 4-TEC models. Drive shaft holder P/N 529 035 871 F18B0G4 APPLICATION GTX 4-TEC models. Drive shaft/floating ring P/N 529 035 841 F18B044 APPLICATION GTX 4-TEC models. Seal/bearing pusher P/N 529 035 818 F18B0D4 APPLICATION GTX 4-TEC models. Shaft pusher P/N 529 035 819 F18B0E4 APPLICATION GTX 4-TEC models. Pressure cap P/N 529 035 843 F18B054 APPLICATION GTX 4-TEC models.
- 29. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) SMR2003-002_01_02A.FM 01-02-9 STEERING SYSTEM O.P.A.S. cylinder nut wrench P/N 529 035 840 F18B0A4 APPLICATION Models equipped with the O.P.A.S. system