SeaDoo GTX Series 2022 Shop Manual
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SeaDoo GTX Series 2022 Shop Manual

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2022
Shop Manual
GTX
†
Series, RXT™ Series
WAKE™ Pro
Fish Pro Sport, Fish Pro Trophy

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  • Page 1 2022 Shop Manual † Series, RXT™ Series WAKE™ Pro Fish Pro Sport, Fish Pro Trophy...
  • Page 2 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. 2022 Bombardier Recreational Products Inc. © Printed in Canada Technical Publications Bombardier Recreational Products Inc. Valcourt QC Canada ®...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ..................... . . VII IMPORTANT SAFETY PRECAUTIONS .
  • Page 4 TABLE OF CONTENTS 02 ENGINE (cont’d) (cont’d) 04 – COOLING SYSTEM - VEHICLE INSPECTION....................53 .
  • Page 5 TABLE OF CONTENTS 04 FUEL SYSTEM (cont’d) (cont’d) 02 – FUEL TANK AND FUEL PUMP PROCEDURES....................93 .
  • Page 6 TABLE OF CONTENTS 05 ELECTRICAL SYSTEM (cont’d) (cont’d) 06 – INFORMATION CENTER TROUBLESHOOTING ..................140 .
  • Page 7 TABLE OF CONTENTS 06 STEERING AND PROPULSION (cont’d) 03 – JET PUMP ..................... . 183 GENERAL .
  • Page 8 TABLE OF CONTENTS 07 BODY AND HULL (cont’d) (cont’d) 02 – HULL (cont’d) PROCEDURES ................... 245 DRAIN PLUGS .

  • Page 9: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to cor- NOTE: Indicates supplementary information re- rectly service and repair GTX, RXT, Fish PRO and quired to fully complete an instruction. Wake PRO Sea-Doo ® watercraft. Although the mere reading of such information This edition was primarily published to be used does not eliminate the hazard, your understanding by technicians who are already familiar with all...
  • Page 10 SAFETY NOTICE equipment and taking all necessary safety precau- tions. Please be especially careful of the follow- ing: – Read and understand all instructions before you begin a procedure or repair. – Ensure you have the proper tools, any neces- sary replacement parts and the skills to perform the tasks safely and completely.

  • Page 11: Introduction

    INTRODUCTION INTRODUCTION ENGINE IDENTIFICATION The information and component/system descrip- tions contained in this manual are correct at time NUMBER (EIN) of writing. BRP however, maintains a policy of The Engine Identification Number is located on continuous improvement of its products without front end of the engine.

  • Page 12: Manual Information

    INTRODUCTION The owner/operator is not to, and should not al- low anyone else to modify the engine in any man- ner that would alter the horsepower or allow emis- sions levels to exceed their predetermined factory specifications. Emission Regulations The vehicle you are servicing may have been certified to applicable emission regulations in your country or state.
  • Page 13 INTRODUCTION 219100893-005-003_a 1. Left (port) 2. Right (starboard) Other common terms used in the marine indus- try are the BOW (front of the watercraft), and the STERN (rear of the watercraft). This manual uses technical terms which may be PARTS CATALOGS different from the ones in the MANUAL LAYOUT This manual is divided into many major sections as...
  • Page 14 INTRODUCTION TYPICAL PAGE Page heading Section 06 ENGINE indicates section Subsection 01 (MAGNETO) and subsection. MAGNETO Subsection title Indicates applicable Models models. Drop represents a Loctite 243 service product Exploded view assists to be applied. Model you in identifying parts and their related Dotted box contains positions.
  • Page 15 INTRODUCTION TYPICAL PAGE Section 03 ENGINE Section 03 ENGINE Subsection 09 (MAGNETO SYSTEM) Subsection 09 (MAGNETO SYSTEM) Tittle in bold indicates category GENERAL GENERAL of information to be carried out. NOTE: The following procedures can be done NOTE: The following procedures can be done without removing the engine.
  • Page 16 INTRODUCTION TIGHTENING TORQUE Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When a torque is not specified, the torque normally recommended for a specific fastener should be used. Refer to the following table. WARNING Torque wrench tightening specifications must be strictly adhered to.

  • Page 17: Fastener Information

    INTRODUCTION FASTENER INFORMATION Threadlocker Application for Uncovered Holes (Bolts and Nuts) NOTICE Most fasteners are metric. Mis- matched or incorrect fasteners could cause damage to the vehicle. SELF-LOCKING FASTENER PROCEDURE A00A3LA 1. Apply here 2. Do not apply 1. Clean threads (bolt and nut) with solvent. TYPICAL —...
  • Page 18 INTRODUCTION Threadlocker Application for 5. Apply several drops on bolt threads. Pre-Assembled Parts 6. Tighten as required. Threadlocker Application for Stud Installation in Blind Holes lmr2007-040-005_a A00A3OA 1. On stud threads 2. On threads and in the hole 1. Apply here 3.
  • Page 19 INTRODUCTION Gasket Compound Application NOTE: If it is difficult to readjust, heat screw with a soldering iron (232°C (450°F)). Application for Stripped Thread Repair A00A3QA 1. Release agent 2. Stripped threads 3. Form-A-Thread lmr2007-040-006_a 4. Tapes 5. Cleaned bolt 1. Proper strength Loctite 6.
  • Page 20 INTRODUCTION 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.
  • Page 21 SERVICE TOOLS INDEX ALIGNMENT SHAFT ADAPTER DRIVE SHAFT C-CLIP REMOVER FLUKE 115 MULTIMETER (P/N 529 036 521) (P/N 529 036 026) (P/N 529 035 868) Page: 20 Page: 202 ALIGNMENT SHAFT SUPPORT (P/N 529 035 506) ECM ADAPTER TOOL (P/N 529 036 166) Page: 86, 94, 98–99, 129, 139 Page: 20 FLUSHING CONNECTOR ADAPTER...
  • Page 22 SERVICE TOOLS INDEX FUEL TANK TEST CAP LARGE HOSE PINCHER PRESSURE GAUGE (P/N 529 036 242) (P/N 529 032 500) (P/N 529 036 395) Page: 14, 57 MPI-2 INTERFACE CARD Page: 91 (P/N 529 036 018) IBR NUT SOCKET (P/N 529 036 379) Page: 92 PTO SUPPORT TOOL (P/N 529 035 842)
  • Page 23 SERVICE TOOLS INDEX TEST CAP (P/N 529 035 991) Page: 53 VACUUM/PRESSURE PUMP (P/N 529 021 800) Page: 53, 57, 91, 186...

  • Page 25: Maintenance

    Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) MAINTENANCE SCHEDULE Maintenance is very important for keeping your vehicle in safe operating condition. Proper maintenance is the owner’s responsibility. A warranty claim may be denied if, among other things, the owner or operator caused the problem through improper maintenance or use. Perform periodic checks and follow the maintenance schedule.
  • Page 26 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE SCHEDULE) EVERY YEAR AT PRESEASON OR 100 HOURS OF OPERATION (WHICHEVER COMES FIRST) Visually inspect connection between throttle body and intake manifold Inspect the air intake for damage on hoses and clamps. Inspect electrical connections and fastening (ignition system, starting system, fuel injectors, fuse box etc.) Visually inspect area around carbon ring and drive shaft rubber bellow for the following signs of failure: black carbon dust and water sprays (more frequently when using PWC in dirty water) Visually inspect impeller and bellow...

  • Page 27: Storage Procedure

    Section 01 MAINTENANCE Subsection 02 (STORAGE PROCEDURE) STORAGE PROCEDURE SERVICE PRODUCTS Description Part Number Page 219 700 304 ..........9 ANTICORROSION SPRAY ............. 779183 ..........7 FUEL STABILIZER (EUR) ............... 779171 ..........7 FUEL STABILIZER ................. 779224 ......... 7, 9 LUBRICANT AND ANTI-CORROSIVE (EUR) .........

  • Page 28: Water-Flooded Engine

    Section 01 MAINTENANCE Subsection 02 (STORAGE PROCEDURE) 219100893-007-002_a 1. Air inlet hose 2. Air outlet hose 4. Loosen the clamp retaining the intercooler inlet 219100893-007-001_a hose. 1. Flushing connector 5. Remove the intercooler inlet hose from the in- The following hose can be fabricated to ease tercooler.

  • Page 29: Electrical System

    Section 01 MAINTENANCE Subsection 02 (STORAGE PROCEDURE) Lubricating the Internal Parts of the Applying an Anticorrosion Treatment Engine Wipe off any residual water in the engine compart- ment. Engine must be lubricated to prevent corrosion on internal parts. Spray anti-corrosive lubricant or an equivalent product over all metallic components only in en- Lubrication of the engine is recommended at the gine compartment while minimizing overspray.

  • Page 31: Preseason Preparation

    Section 01 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is necessary after the winter months or when a watercraft has not been used during 4 months. Any worn, broken or damaged parts found must be replaced. MAINTENANCE SCHEDULE Using the , perform EVERY 100 HOURS OR 1 YEAR...

  • Page 33: Special Procedures

    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE TOOLS Description Part Number Page 529 032 500 ........... 14 LARGE HOSE PINCHER..............529 035 880 ........... 14 SUCTION PUMP ................GENERAL Lubricating the Engine WATER-FLOODED ENGINE Refer to in this sub- Refer to the following special procedures accord- section.
  • Page 34 Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) 2. Remove the air intake silencer and check for water in the supercharger inlet hose. Remove hose to empty it. 3. Remove the water from blow-by valve hose. 4. If water is suspected in the intake manifold, remove the intake manifold and drain it.

  • Page 35: Drowned Mode

    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) To activate DROWNED MODE, proceed as per fol- WARNING lowing steps. Certain components in the engine compart- 1. Install the tether cord cap on the engine cut out ment may be very hot. Direct contact may re- switch.

  • Page 37: Engine Removal And Installation

    Section 02 ENGINE Subsection 01 (ENGINE REMOVAL AND INSTALLATION) REFER TO ENGINE REMOVAL AND INSTALLATION 219101047-002...

  • Page 38: Air Intake System

    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM 155 Engines 1.7 ± 0.2 N•m (15 ± 1 lbf•in) 4 ± 1 N•m (35 ± 4 lbf•in) 219100893-011-301_a 219100893-011...
  • Page 39 Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) 230 and 300 Engines 4 ± 1 N•m 1.7 ± 0.2 N•m (35 ± 4 lbf•in) (15 ± 1 lbf•in) 4 ± 1 N•m (35 ± 4 lbf•in) 219100893-011-302_a 219100893-011...

  • Page 40: Procedures

    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) PROCEDURES AIR INTAKE SILENCER Air Intake Silencer Location Air intake silencer is located above the fuel tank. Removing the Air Intake Silencer 1. Remove the seats. 2. Detach rear retaining straps retaining air intake silencer.
  • Page 41 Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) 9. From the front storage compartment, cut lock- ing ties securing the wiring harness and the fuel hose to air intake silencer. smr2017-305-004_a Release all retaining tabs. Separate upper and lower sections. 219100893-011-308_a TYPICAL 1.

  • Page 42: Air Intake Tube

    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE TUBE Removing the Air Intake Tube Supercharged Engine 1. Remove seats. 2. Remove the engine access cover. Refer to BODY 3. Loosen clamps retaining the air intake tube. smr2016-011-006_a 1. Baffle tab into air intake silencer slot 2.

  • Page 44: Exhaust System

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE TOOLS Description Part Number Page 295 500 473 ........... 36 FLUSHING CONNECTOR ADAPTER ..........SERVICE PRODUCTS Description Part Number Page 293 800 060 ........... 37 LOCTITE 243 (BLUE)..............293 800 038 ........... 35 LOCTITE 518 .................
  • Page 45 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) 11 ± 1 N•m (97 ± 9 lbf•in) See tightening Loctite 567 sequence (pipe sealant) 16 ± 1 N•m (142 ± 9 lbf•in) Loctite 243 9 ± 1 N•m (80 ± 9 lbf•in) 9.5 ±...
  • Page 46 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) = Component must be replaced when removed. 219100893-012-002_a 219100893-012...
  • Page 47 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) Models without intercooler 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 219100893-012-101_a 219100893-012...
  • Page 48 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) Models with intercooler 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ±...

  • Page 49: General

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) GENERAL SYSTEM DESCRIPTION The exhaust system is cooled by water provided by a pressurized area in the jet pump (open loop system). smr2008-013-009_a 1. Water packet holes Water is evacuated through the exhaust outlet in transom area.
  • Page 50 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) Testing the EGTS Resistance 1. Remove the parts required to access the EGTS. 2. Disconnect the connector from the EGTS. 3. Measure the resistance of the sensor. EGTS RESISTANCE TEST EGTS PIN MEASUREMENT Refer to EGTS RESISTANCE...

  • Page 51: Flushing The Exhaust System

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) Connect a garden hose to the connector located at the rear of watercraft (on the port side of the stern). Do not open water tap at this time. smr2008-013-041_a 1. Apply Loctite 518 in this area 4.

  • Page 52: Procedures

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) NOTICE The engine must not run more than 30 seconds without water supply. Stopping en- gine might be necessary. Ensure water flows out of jet pump while flushing. NOTICE Never run engine longer than 2 min- utes.

  • Page 53: Muffler

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) Muffler Access Remove or open seat. Remove the engine service cover. smr2016-012-008_c Step 1: Install first Step 2: Install last Tighten screws to specification as per following illustrated sequence. TIGHTENING TORQUE Repeat the procedure twice. Exhaust manifold 9 N•m ±...
  • Page 54 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) NOTICE Do not use pneumatic or electrical – Cracked tools as seizure may occur. – Otherwise damaged. Replace any defective part. 6. Unplug the exhaust gas temperature sensor (EGTS). Installing the Muffler With a new muffler, install the EGTS sensor. Re- fer to this subsection.

  • Page 55: Exhaust Hoses

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) EXHAUST HOSES 219100893-012-308_a 1. Exhaust manifold rib wall facing the engine 2. Exhaust pipe mark smr2016-012-002_a A. 15 mm (19/32 in) 1. Muffler 2. Front exhaust hose 3. Resonator Tighten exhaust clamp to specification. 4.

  • Page 56: Exhaust Pipe

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) Removing the Exhaust Pipe Remove MUFFLER , see procedure in this subsec- tion. Disconnect water inlet hose from exhaust pipe fit- ting. 219100893-012-316_a 1. Rear exhaust hose 2. Hose clamp 3. RH fixing plate When reinstalling rear exhaust hose, tighten clamps to specification.

  • Page 57: Resonator

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) smr2008-013-038_a 1. Exhaust pipe shoulder 2. Rubber adapter Center the rubber adapter strip of the rubber smr2016-012-020_a SECTION VIEW adapter between both exhaust pipe marks. 1. 57 mm ± 2 mm (2-1/4 in ± 5/64 in) Tighten retaining clamps.
  • Page 58 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) smr2016-012-014_a Inspecting the Resonator Inspect parts condition paying attention for defor- 219100893-012-314_a mation, cracks or other damage. Check hoses. Remove strap holding resonator. Replace any defective part. Installing the Resonator Installation is the reverse of the removal proce- dures.

  • Page 60: Cooling System - Vehicle

    Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) COOLING SYSTEM - VEHICLE SERVICE TOOLS Description Part Number Page 295 000 070 ........... 54 OETIKER PLIER ................529 035 991 ........... 53 TEST CAP ..................529 021 800 ........... 53 VACUUM/PRESSURE PUMP ............
  • Page 61 Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) Cooling System (closed loop) 219100893-013-100_a 1. Coolant temperature sensor (CTS) activates when monitoring 6. Oil cooler beeper turns on at 110°C (230°F) 7. Coolant flows to oil cooler 2. Water pump cover / thermostat housing - Thermostat opens at 8.
  • Page 62 Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) Cooling System (open loop) 219100893-013-102_a 1. Water enters system 5. Water exits the intercooler 2. Water enters the exhaust manifold 6. Water exits system 3. Water exits the exhaust manifold 7. Bleed hose from intercooler 4.
  • Page 63 Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) Cooling System Components (closed loop) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 3.5 ± 0.5 N•m (31 ± 4 lbf•in) 4 ± 1 N•m (35 ±...
  • Page 64 Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) Cooling System Components (open loop, 155 models) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) = Component must be replaced when removed. 219100893-013-103_a 219100963-007...
  • Page 65 Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) Cooling System Components (open loop, 230 and 300 models) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ± 0.2 N•m (15 ± 2 lbf•in) 1.7 ±...

  • Page 66: General

    Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) GENERAL Technical Specifications TYPE Closed loop cooling system. SYSTEM DESCRIPTION COOLANT FLOW Flow from water pump. A closed loop cooling system is utilized on all BRP watercraft engines, which offers an efficient TEMPERATURE Thermostat.
  • Page 67 Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) NOTICE To prevent rust formation or freezing Reinstall cap on coolant tank. condition in cold areas, always replenish the Install watercraft in a test basin or ride on a water system with 50% antifreeze and 50% distilled plane.

  • Page 68: Inspection

    Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) When engine has completely cooled down, recheck coolant level in the coolant tank and top up if necessary. INSPECTION COOLING SYSTEM LEAK TEST WARNING To avoid potential burns, do not remove the coolant tank cap if the engine is hot.

  • Page 69: Troubleshooting

    Section 02 ENGINE Subsection 04 (COOLING SYSTEM - VEHICLE) NOTE: In general leaking coolant indicates a dam- 7. Exhaust system clogged aged rotary seal. Leaking oil indicates a damaged - Flush exhaust system. oil seal. If either seal is leaking, both seals must 8.

  • Page 70: Intercooler

    Section 02 ENGINE Subsection 05 (INTERCOOLER) INTERCOOLER SERVICE TOOLS Description Part Number Page 529 032 500 ........... 57 LARGE HOSE PINCHER..............529 021 800 ........... 57 VACUUM/PRESSURE PUMP ............230 and 300 engines 4 ± 1 N•m (35 ± 4 lbf•in) 4 ±...

  • Page 71: Maintenance

    Section 02 ENGINE Subsection 05 (INTERCOOLER) MAINTENANCE INTERCOOLER FLUSHING Flushing the intercooler with fresh water is essen- tial to neutralize corroding effects of salt or other chemical products present in water. It will help to clean up sand, salt, shells or other particles in in- tercooler.
  • Page 72 Section 02 ENGINE Subsection 05 (INTERCOOLER) Intercooler Leak Test Block intercooler water outlet hose. REQUIRED TOOL LARGE HOSE PINCHER (P/N 529 032 500) 219100893-014-001_a 300 ENGINE INTERCOOLER 1. Intercooler water outlet fitting 2. Intercooler water inlet fitting 3. Intercooler bleeding hose fitting 219100893-014-003_a MANY PARTS REMOVED FOR CLARITY PURPOSE 1.
  • Page 73 Section 02 ENGINE Subsection 05 (INTERCOOLER) 219100893-014-004_a 219100893-014-006_a PARTS REMOVED FOR CLARITY 1. Intercooler bleed hose 2. Intercooler outlet hose 3. Intercooler inlet hose Removing the Intercooler 6. Untie intercooler straps. BODY 1. Remove seats. Refer to subsection. BODY 2. Remove engine service cover. Refer to subsection.

  • Page 74: Replacing Intercooler Attachments

    Section 02 ENGINE Subsection 05 (INTERCOOLER) TIGHTENING TORQUE Intercooler air hoses 4 N•m ± 1 N•m clamp (35 lbf•in ± 9 lbf•in) Intercooler water hoses 1.7 N•m ± .2 N•m clamp (15 lbf•in ± 2 lbf•in) Intercooler bleed hose 1.7 N•m ± .2 N•m clamp (15 lbf•in ±...

  • Page 76: Electronic Management Systems

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) ENGINE MANAGEMENT SYSTEM 1503 NA (155) 219100893-015-015_a 219100963-009...
  • Page 77 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) 1503 HO ACE (230) IGN-3 IGN-3 IGN-2 IGN-2 INJ-3 INJ-3 IGN-1 IGN-1 INJ-2 INJ-2 ECMA E CMA INJ-1 INJ-1 MAPTS M APTS CAPS CAPS smr2017-313_199_a 219100963-009...
  • Page 78 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) 1630 ACE (300) IGN-3 IGN-3 IGN-2 IGN-2 INJ-3 INJ-3 IGN-1 IGN-1 ECMA E CMA INJ-2 INJ-2 INJ-1 INJ-1 MAPTS MAPTS CAPS CAPS smr2017-011-099_a 219100963-009...

  • Page 79: General

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) GENERAL Engine Control Module (ECM) SYSTEM DESCRIPTION An engine management system (EMS) is used to ensure a high power output with cleaner combus- tion. There are 6 main systems that interact with the engine management system: 1.
  • Page 80 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 (ENGINE MANAGEMENT SYSTEM) Limp Home Mode The ECM may automatically set the engine in LIMP HOME MODE using default parameters when certain major faults are detected. For more information, refer to DIAGNOSTIC AND FAULT CODES Diagnostic Mode The ECM features a self-diagnostic mode that is...

  • Page 82: Icontrol System

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 02 (iCONTROL SYSTEM) iCONTROL SYSTEM GENERAL The iControl (intelligent Control) system may con- sist of the following systems: – Intelligent Throttle Control (iTC) – Intelligent Brake and Reverse (iBR). The information center (gauge) and handlebar switches are used to navigate through and select several functions, modes of operation and change certain settings and system parameters using the...

  • Page 84: Controller Area Network (Can)

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (CONTROLLER AREA NETWORK (CAN)) CONTROLLER AREA NETWORK (CAN) GENERAL SYSTEM DESCRIPTION The CAN (Controller Area Network) protocol is an ISO standard for serial data communication. The CAN bus is the nervous system of the iControl system and the engine management system (EMS). It links the electronic modules (ECMs) together so that they communicate to interact as required.

  • Page 85: Troubleshooting

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 03 (CONTROLLER AREA NETWORK (CAN)) TROUBLESHOOTING DIAGNOSTIC TIPS Check the fault codes using the BRP diagnostic software (BUDS2) as a first troubleshooting step. Make sure the modules are powered before testing CAN. CAN Communication Problems The following chart gives some symptoms and behaviors relative to the CAN component in cause.

  • Page 86: Communication Tools

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (COMMUNICATION TOOLS) COMMUNICATION TOOLS SERVICE TOOLS Description Part Number Page 710 000 851 ........... 71 DIAGNOSTIC CABLE ..............529 036 018 ........... 71 MPI-2 INTERFACE CARD .............. 529 036 353 ........... 71 MPI-3 INTERFACE CARD .............. GENERAL DIAGNOSTIC CONNECTOR LOCATION...
  • Page 87 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 04 (COMMUNICATION TOOLS) COMMUNICATION PROBLEM (CAN) STATUS WHAT TO DO – BUDS2 does not communicate with the vehicle. – Check connections from computer to vehicle. Light is – Check if BUDS2. is started. vdd2006-001-151_b –...

  • Page 88: Diagnostic And Fault Codes

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 05 (DIAGNOSTIC AND FAULT CODES) DIAGNOSTIC AND FAULT CODES GENERAL INFORMATION CENTER MONITORING MODE and SET switch MONITORING SYSTEM Cruise switch This system monitors the electronic components of the EMS (engine management system), iBR, information center and other components of the electrical system to detect if they are faulty or de- Fuel level sensor...
  • Page 89 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 05 (DIAGNOSTIC AND FAULT CODES) This mode allows the rider to return home which When this mode is active, LIMP HOME MODE would otherwise not be possible. will be displayed in the information center. Indicator Lights and Message Display Information The fault indicators and messages displayed in the information center will inform you of a particular con- dition or if an anomaly occurs.
  • Page 90 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 05 (DIAGNOSTIC AND FAULT CODES) FAULT MESSAGES LIMP HOME MODE Major fault detected, engine power limited FUEL SENSOR DEFECTIVE Fuel level sensor fault WATER TEMP SENSOR DEFECTIVE Problem in iBR, not sending water temperature info CALIBRATION CHECKSUM ERROR Information center programming corrupted MAINTENANCE REQUIRED...
  • Page 91 Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 05 (DIAGNOSTIC AND FAULT CODES) Beeper Signals When one of the below conditions occurs, the monitoring system emits the following beep signals. BEEPER CODES DESCRIPTION Bad D.E.S.S. system connection. Reinstall tether cord correctly over engine cut-off switch. Wrong D.E.S.S.

  • Page 92: Fault Codes

    Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 05 (DIAGNOSTIC AND FAULT CODES) FAULT CODES A fault code is an indication that a glitch or mal- function is detected by the monitoring system of the vehicle. When there is a problem, the ECM can provide fault codes to ease troubleshooting.

  • Page 94: Fuel System

    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) INTELLIGENT THROTTLE CONTROL (iTC) SERVICE TOOLS Description Part Number Page 529 036 384 ........... 85 DIAGNOSTIC HARNESS ............... 529 035 868 ........... 86 FLUKE 115 MULTIMETER ............GENERAL The throttle lever operates the throttle accelera- tor sensor (TAS).

  • Page 95: Sport Mode

    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) Slow Speed Mode When throttle is applied, the engine will progres- sively accelerate to an operating range whereby The Intelligent Throttle Control also allows for a full power eventually becomes available. If the en- Slow Speed Mode where the driver can adjust and gine is throttled down sufficiently and for a long set idle speed.

  • Page 96: Operating Modes

    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) OPERATING MODES LIMITED GTX 155, 230, WAKE FISH OPERATING MODE AVAILABLE RXT-X GTX 230 LIMITED Touring mode Sport mode ECO mode Speed limiter mode Slow speed mode Ski mode Learning key mode X = Indicates a standard feature - = See a Sea-Doo dealer for availability.

  • Page 97: Speed Limiter Mode

    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) Once the maximum speed is set, the operator can vary the watercraft speed from idle speed up to the set speed using the throttle lever. The set iVTS speed will not be exceeded even if the throttle lever is fully depressed.

  • Page 98: Ski Mode

    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) the throttle lever will deactivate slow speed mode Changing Set Slow Speed and normal control of the watercraft will be re- To increase or decrease the set slow speed, turned to the operator. press the UP/DOWN button on the RH handlebar once, or repeatedly.

  • Page 99: Procedures

    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) PROCEDURES TARGET SPEED Function The TARGET SPEED function limits the maximum THROTTLE ACCELERATOR towing speed. SENSOR (TAS) Once the RAMP has been selected, an average PWC target speed for that RAMP will be visible in General the numerical display.

  • Page 100: Mode/Speed Control Switch

    Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) MODE/SPEED CONTROL SWITCH 2. Connect the diagnostic harness to make an in-line connection between the disconnected Mode/Speed Control Switch Overview connectors. REQUIRED TOOL DIAGNOSTIC HARNESS (P/N 529 036 384) 3. Install the tether cord on the engine cut-off switch.
  • Page 101 Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) NOTE: The above stated voltages vary slightly de- pending on the actual voltage applied to the circuit and the current flow through the diodes. When using a Fluke 115 multimeter for testing in diode test mode, the voltage and current applied by the multimeter are lower than in circuit.
  • Page 102 Section 04 FUEL SYSTEM Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC)) If voltages measured on every switch are as listed in the previous tables (or very close to it), the switches and the wiring harness are good. The fault may be within the gauge, or in the circuit or component the function applies to.

  • Page 104: Fuel Tank And Fuel Pump

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number Page 529 036 384 ........... 98 DIAGNOSTIC HARNESS ............... 529 036 166 ........... 94 ECM ADAPTER TOOL..............529 035 868 ....... 94, 98–99 FLUKE 115 MULTIMETER ............

  • Page 105: General

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) GENERAL SYSTEM DESCRIPTION The fuel system is comprised of: WARNING – A fuel tank Fuel lines remain under pressure at all times. – A vented fuel tank cap Always proceed with care and use appro- –...

  • Page 106: Inspection

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) When the ECM receives a signal to shut down REQUIRED TOOL the engine (START/STOP switch, engine cut-off switch, or T.O.P.S. switch) it removes the fuel VACUUM/PRESSURE PUMP pump ground signal. (P/N 529 021 800) Fuel Level Indication An electric float type fuel level sensor is mounted...

  • Page 107: Testing Fuel Pump Pressure

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) WARNING FUEL TANK LEAK TEST Cover the fuel line connection with an ab- TIME WITHOUT PRESSURE sorbent shop rag. Wipe off any fuel spillage PRESSURE DROP inside the bilge. 10 minutes 21 kPa (3 PSI) If the pressure drops, locate fuel leak(s), repair/re-...

  • Page 108: Procedures

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) Test when Engine Is Stopped ELECTRONIC fuel injectors for leaks, refer to the FUEL INJECTION (EFI) subsection. If injectors 1. Remove tether cord from the engine cut-off are not leaking, then replace fuel pump. switch to prevent engine starting.

  • Page 109: Fuel Pump

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) 2. Disconnect fuel pump harness connector. Re- WARNING REMOVING THE FUEL PUMP fer to – Never use a hose pincher on high pressure 3. Use the FLUKE 115 MULTIMETER (P/N 529 035 hoses.
  • Page 110 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) PUMP CIRCUIT TEST THROUGH FUEL PUMP RESISTANCE @ TEST PROBES 20°C (68°F) Fuse box ECM connector B Approx. 12 terminal B2 pin B-M1 219100893-021-002_b 219100893-021-001_a 5. If test succeeded, the fuel pump, its fuse and its wiring harness are good.
  • Page 111 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) WARNING The upper filter and fuel pump reservoir on the fuel pump module contain fuel which will drain out when fuel pump module is not in an upright position. 7.

  • Page 112: Fuel Filter

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) TESTING 5. Test the fuel tank for leaks. Refer to FUEL TANK FOR LEAKS FUEL FILTER Inspecting the Fuel Filter Inspect fuel filter. If dirty, partially clogged or dam- aged, replace it.
  • Page 113 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) The information center interprets this signal and turns on the appropriate number of segments of a bar type fuel level indication in the lower RH side of the digital screen in the information center. Troubleshooting the Fuel Level Sensor FUEL LEVEL TROUBLESHOOTING SYMPTOM...
  • Page 114 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) FUEL FUEL If voltage is out of specifications, test the If readings are out of specifications, test the LEVEL SENSOR RESISTANCE AT INFORMATION LEVEL SENSOR RESISTANCE AT FUEL PUMP CENTER as described in this subsection.
  • Page 115 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) 3. Disconnect the fuel level sensor connector from the fuel pump module upper flange. smr2012-027-011_d FUEL LEVEL SENSOR RESISTANCE TEST smr2008-022-021_a If readings are out of specifications, replace sen- 1.
  • Page 116 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) smr2008 022-023_a smr2008-022-028_a 1. Pressure regulator 1. Do not remove pressure regulator cover at locking tabs 2. Pressure regulator locking tab 2. Pressure regulator cover 3. Pressure regulator housing 7.
  • Page 117 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) Installing the Fuel Level Sensor Installation is the reverse of the removal proce- dure however, pay attention to the following. 1. Ensure fuel level sensor locking pins are prop- erly engaged into the fuel pump reservoir.

  • Page 118: Fuel Tank

    Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) 6. Reinstall the fuel pump module. Refer to 10. Install filler hose and torque retaining clamps. STALLING THE FUEL PUMP in this subsection. FUEL TANK Inspecting the Fuel Tank BODY 1.
  • Page 119 Section 04 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) smr2016-028-003_a 5. Secure retaining strap ends on top of fuel tank. smr2012-027-012_c 6. Properly secure wire harness, cables and hose 1. Filler hose as prior to removal using appropriate locking 2.

  • Page 120: Electrical System

    Section 05 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) POWER DISTRIBUTION AND GROUNDS GENERAL Fuse Identification POWER DISTRIBUTION DIAGRAM WIRING DIAGRAM Refer to the appropriate NOTE: Refer to WIRING DIAGRAM INFORMA- TION for how to properly interpret the WIRING DIAGRAM FUSE BOX 219100893-022-005_a...

  • Page 121: Relay

    Section 05 ELECTRICAL SYSTEM Subsection 01 (POWER DISTRIBUTION AND GROUNDS) RELAY DESCRIPTION Relay Pin Identification Through relay: – Fuel pump FUSE BOX The relay is in the fuse box. Refer to 15 A – Fuel injectors RELAY PIN IDENTIFICATION – Ignition coils FUNCTION FUSE BOX PIN CONDITION...

  • Page 122: Wiring Harness And Connectors

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS AND CONNECTORS SERVICE TOOLS Description Part Number Page 529 036 384 ......... 117 DIAGNOSTIC HARNESS ............... 529 036 166 ......... 114 ECM ADAPTER TOOL..............529 036 175 ......... 115 ECM TERMINAL REMOVER 2.25..........
  • Page 123 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) 219100893-023-100_a 219100963-012...
  • Page 124 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) 219100893-023-101_a 219100963-012...
  • Page 125 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Sound System and USB Option 219100893-023-102_a 219100963-012...

  • Page 126: General

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) GENERAL ACRONYM DESCRIPTION ACRONYM DESCRIPTION Accessory GND3 Engine Ground BAT+ Battery + GND4 Battery Ground BAT- Battery - Harness Inter Connector to Engine Brake and Reverse Lever BRLS HIC1 Harness Inter Connector to Steering 1 Sensor CAPS Camshaft Position Sensor...

  • Page 127: Diagnostic Connector, Lts (Deutsch)

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) DIAGNOSTIC CONNECTOR, LTS (DEUTSCH) Disassembling and reassembling the Connector V01G0PA F00H1CA TYPICAL - MALE CONNECTOR 1. Male lock TYPICAL - DEUTSCH CONNECTOR 1. Male connector 2. Female connector NOTE: Before pin extraction, push wire forward 3.

  • Page 128: Ecm Connector (Molex)

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) 3. Pull back on the terminal wire to ensure the re- tention fingers are holding the terminal. 4. After all required terminals have been inserted, the lock must be installed. smr2009-045-011_a LOCKING TAB TO PRESS AND HOLD 3.
  • Page 129 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) smr2009-045-013_b smr2009-045-011_a CONNECTOR LOCKING CAM IN RELEASE POSITION LOCKING TAB FULLY OUT 2. Insert connector on ECM. Inspecting the Connector 3. As you push the connector onto the ECM, ro- Before replacing an ECM, always check electrical tate the connector locking cam until it snaps connections.
  • Page 130 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) 2. Probe wire terminals of the circuit to be tested directly in the adapter holes. smr2009-045-025_a vmr2008-139-016_a 3. Insert tool to unlock terminal. TYPICAL 1. ECM connector 2. ECM adapter NOTICE Never probe directly on the ECM harness connector.

  • Page 131: Ds, Sts, Fp, Tas, Brls, Fb, Dcc, Msl, Msr,Connectors (Delphi/Packard)

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) NOTICE NOTICE Before installing wire terminals in Before installing terminals in the the connector, ensure all terminals are prop- connectors, ensure all terminals are properly erly crimped on wires. After installation of crimped on the wires.

  • Page 132: Acc, Hic, Hic1,Hic2, Usb Ic,(Molex)

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) smr2014-045-003_a 1. Red secondary lock (shown out) smr2009-045-028_a 2. Latch lever NOTICE Before installing terminals in the Probing the Connector connectors, ensure all terminals are properly 1. Disconnect the steering connector in the vehi- crimped on the wires.
  • Page 133 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) smr2014-045-002_a 1. Pin locator 2. Insert long nose pliers here 3. Holes for inserting terminal extractor tool smr2014-030-012_b 1. Socket locator 2. Insert the extractor tool in the small hole adja- 2.

  • Page 134: Voltage Regulator/Rectifier Connector (Furukawa)

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) VOLTAGE REGULATOR/RECTIFIER CONNECTOR (FURUKAWA) Removing the Terminal 1. Remove the secondary lock (plastic insert). smr2014-045-004_a TYPICAL - PIN INSERTION 1. Notch 2. Stepped portion towards notch 4. Push the pin in until the pin lock engages the pin.

  • Page 135: Battery Cables

    Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) A32E2RA INSTALLATION OF TERMINAL Follow the instructions provided with the crimping tool to select the proper position of the tool. NOTE: Different wires require different crimping pliers settings, so make sure to follow the instruc- tion supplied with the tool.
  • Page 136 Section 05 ELECTRICAL SYSTEM Subsection 02 (WIRING HARNESS AND CONNECTORS) Install the protective heat shrink rubber tube on the terminal. Heat the heat shrink rubber tube us- ing the heat gun so that it grasps the wire and the terminal. NOTICE Make sure that the protective heat shrink rubber tube has been properly installed...

  • Page 138: Charging System

    Section 05 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL Battery SYSTEM DESCRIPTION The purpose of the charging system is to maintain the battery at a full state of charge and to provide the electrical system with the required electrical power for normal vehicle operation.

  • Page 139: Troubleshooting

    Section 05 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) NOTE: Initial current reading will be higher than OUTPUT VOLTAGE TEST USING A MULTIMETER specified due to the battery drain from the engine TEST ENGINE SPEED VOLTAGE (DC) start. This is an indication that the charging sys- tem is operating normally.

  • Page 140: Procedures

    Section 05 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Removing the Voltage 3. Defective charging system wiring or connec- Regulator/Rectifier tions. - Check for damaged wiring. 1. Disconnect both connectors from the voltage - Check for damaged or loose connections. regulator/rectifier. REPETITIVE BLOWN F6 FUSE 1.

  • Page 141: Battery

    Section 05 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) BATTERY Cleaning the Battery Clean the battery casing, caps, cables and battery posts using a solution of baking soda and water. NOTICE Do not allow cleaning solution to en- ter battery. Remove corrosion from battery cable terminals and battery posts using a firm wire brush.
  • Page 142 Section 05 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) If the battery has just received a charge, wait 1-2 WARNING hours before taking a voltage reading. Never charge battery while installed in water- Set multimeter to Vdc and measure voltage at bat- craft.
  • Page 143 Section 05 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) NOTE: Some chargers have a polarity protec- tion 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.

  • Page 144: Starting System

    Section 05 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 384 ......... 129 DIAGNOSTIC HARNESS ............... 529 036 166 ......... 129 ECM ADAPTER TOOL..............529 035 868 ......... 129 FLUKE 115 MULTIMETER ............GENERAL REQUIRED TOOLS ECM ADAPTER TOOL (P/N 529...

  • Page 145: Diagnostic Guidelines

    Section 05 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) DIAGNOSTIC GUIDELINES ENGINE CRANKS SLOWLY 1. Loose, corroded or dirty battery cable connec- NOTHING HAPPENS WHEN START/STOP tions BUTTON PRESSED - Check/clean/tighten. 1. Battery not connected 2. Discharged/weak battery - Connect battery. - Recharge and test.

  • Page 146: Starter Solenoid

    Section 05 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Disconnect connector "B" from the ECM, refer to CONTINUITY TEST OF START/STOP WIRING HARNESS AND CONNECTOR subsec- SWITCH CIRCUIT tion. DIAGNOSTIC SWITCH Install ECM adapter tool on ECM harness connec- HARNESS RESISTANCE POSITION tor "B".
  • Page 147 Section 05 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Testing Solenoid Coil Resistance 1. Set multimeter to . 2. Disconnect solenoid connector. 3. Measure solenoid coil resistance as per follow- ing table. SOLENOID COIL RESISTANCE TEST SOLENOID CONNECTOR RESISTANCE Pin A Pin B 4.5 to 5.5 If test fails, replace solenoid.
  • Page 148 Section 05 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) NOTICE Always disconnect the BLACK (-) SOLENOID DYNAMIC TEST (ENGINE CRANKING) battery cable first and reconnect last. TEST PROBES VOLTAGE (DC) Disconnect solenoid connector. Solenoid Battery ground Battery voltage starter post smr2009-034-010_b 1.

  • Page 149: Starter

    Section 05 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 219100893-025-005_a Installing the Solenoid The installation is the reverse of the removal pro- cedure. STARTER PTO HOUSING, For starter information refer to MAGNETO AND STARTER subsection. 219100963-014...

  • Page 150: Radio Frequency Digitally Encoded Security System (Rf D.e.s.s.)

    Section 05 ELECTRICAL SYSTEM Subsection 05 (RADIO FREQUENCY DIGITALLY ENCODED SECU- RITY SYSTEM (RF D.E.S.S.)) RADIO FREQUENCY DIGITALLY ENCODED SECURITY SYSTEM (RF D.E.S.S.) GENERAL SYSTEM DESCRIPTION The following components are specially designed for this system: ECM, D.E.S.S. key (inside tether cord cap) and engine cut-off switch.

  • Page 151: Troubleshooting

    Section 05 ELECTRICAL SYSTEM Subsection 05 (RADIO FREQUENCY DIGITALLY ENCODED SECU- RITY SYSTEM (RF D.E.S.S.)) TROUBLESHOOTING 5. No voltage at RFID-D connector - Refer to WIRING DIAGRAM and / or IGNITION SYSTEM and troubleshoot D.E.S.S. / Engine Cut- DIAGNOSTIC GUIDELINES Off Switch The following is provided to help in diagnosing the INVALID KEY...
  • Page 152 Section 05 ELECTRICAL SYSTEM Subsection 05 (RADIO FREQUENCY DIGITALLY ENCODED SECU- RITY SYSTEM (RF D.E.S.S.)) IGNITION SYSTEM 5. Ensure that anti-theft system is activated. If Refer to subsection for test- not, activate it before trying to add a key. ing procedures. 6.

  • Page 154: Information Center

    Section 05 ELECTRICAL SYSTEM Subsection 06 (INFORMATION CENTER) INFORMATION CENTER SERVICE TOOLS Description Part Number Page 529 035 868 ......... 139 FLUKE 115 MULTIMETER ............GENERAL WIRING DIAGRAM INFORMATION Refer to sub- section for diagnostic tips on troubleshooting Most of the electrical tests require the following electrical problems.

  • Page 155: Troubleshooting

    Section 05 ELECTRICAL SYSTEM Subsection 06 (INFORMATION CENTER) MESSAGE DISPLAY INFORMATION Problem with water temperature sensor, not sending WATER TEMP SENSOR DEFECTIVE water temperature info. IBR MODULE ERROR iBR system malfunction Watercraft maintenance required MAINTENANCE REQUIRED When a digital warning appears, it will show the warning for 6 seconds and then the warning will disap- pear for 15 minutes.
  • Page 156 Section 05 ELECTRICAL SYSTEM Subsection 06 (INFORMATION CENTER) MULTIFUNCTION GAUGE CAN WIRE TEST CL_A SPECIFICATION CONNECTOR Pin 1 Pin 13 (CAN HI) Close to 0.4 Pin 14 (CAN Pin 2 Close to 0.4 If the CAN wire verification test fails, check the related circuit.
  • Page 157 Section 05 ELECTRICAL SYSTEM Subsection 06 (INFORMATION CENTER) MULTIFUNCTION GAUGE USB POWER MULTIFUNCTION GAUGE USB CIRCUIT TEST VOLTAGE TEST AT GAUGE CL_B SPECIFICATION GAUGE CONNECTOR CONNECTOR BATTERY SPECIFICATION PINOUT B Pin 20 Pin 1 (5V) Negative (-) Pin 20 Close to 5 V Pin 9 Pin 2 (Data -) post...
  • Page 158 Section 05 ELECTRICAL SYSTEM Subsection 06 (INFORMATION CENTER) Setting Language and Units of Measurement 1. Connect the vehicle to the BRP diagnostic soft- COMMUNICATION ware (BUDS2), refer to the TOOLS subsection. 2. Press the START/STOP button to energize the electrical system. 3.

  • Page 160: Accessories

    Section 05 ELECTRICAL SYSTEM Subsection 07 (ACCESSORIES) ACCESSORIES GENERAL PROCEDURES WIRING DIAGRAM Refer to subsection for diag- REMOVING AND INSTALLING nostic tips on troubleshooting electrical problems. THE SOUND SYSTEM NOTE: The accessory circuit stays ON for a period of up to 60 minutes after the engine is turned OFF BODY Refer to subsection.

  • Page 161: Fish Finder Sonar

    Section 05 ELECTRICAL SYSTEM Subsection 07 (ACCESSORIES) INPUT VOLTAGE TEST AT SOUND SYSTEM CONNECTOR PROBE VOLTAGE Pin 1 (Hot at Pin 3 all times) (Permanent Battery voltage Pin 2 (Hot with ground) main relay on) Repair wiring and connectors as required. FISH FINDER SONAR 219100963-016-002 The sonar is connected on the accessory circuit...
  • Page 162 Section 05 ELECTRICAL SYSTEM Subsection 07 (ACCESSORIES) 219100963-016-002 SONAR CONNECTOR PIN-OUT INPUT VOLTAGE TEST AT VEHICLE CONNECTOR PROBE VOLTAGE Pin 3 Pin 2 (Hot with (Permanent Battery voltage main relay on) ground) 219100963-016-003 VEHICLE CONNECTOR PIN-OUT Repair wiring and/or connectors as required. For further information, troubleshooting and diag- nostic, refer to the sonar manufacturer.

  • Page 164: Steering And Propulsion

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) STEERING SERVICE PRODUCTS Description Part Number Page 293 800 060 ......... 153 LOCTITE 243 (BLUE)..............779231 ......... 157 SYNTHETIC GREASE (EUR) ............779162 ......... 157 SYNTHETIC GREASE ..............STEERING COLUMN 1 ± 0.2 N•m (9 ±...
  • Page 165 Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) STEERING COLUMN SUPPORT AND CABLE 7 ± 1 N•m (62 ± 9 lbf•in) 7 ± 1 N•m (62 ± 9 lbf•in) 2.5 ± 0.3 N•m (22 ± 3 lbf•in) 8 ± 1 N•m (71 ±...

  • Page 166: Adjustment

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) ADJUSTMENT ADJUSTING THE ALIGNMENT OF THE STEERING Remove the top cover. 219100893-028-001_a 1. Top cover 2. Top cover retaining crews 1. Slide the cable lock toward the front of water- craft. 219100893-028-002_a 2.
  • Page 167 Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) WATERCRAFT BEHAVIOR WHAT TO DO Turn steering cable adjustment nut as shown Pulls on left side Turn steering cable adjustment nut as shown Pulls on right side 3. Slide back the cable lock in place. 219100963-017...

  • Page 168: Procedures

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 219100893-028-004_a 1. Handlebar grip 2. Handlebar grip screw 3. Handlebar grip cap Installing the Handlebar Grip Install handlebar grip on handlebar matching it to the notch in the handlebar. Apply blue Loctite on screw threads (or use new 219100893-028-002_b self-locking screws).

  • Page 169: Steering Cover

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) On all models 2. Remove steering pad by pulling the bottom first and then the top. 219100893-028-302_a Installing the Handlebar Switch Cover 219100893-028-005_a (LH or RH) TYPICAL Installation is the reverse of the removal proce- 3.
  • Page 170 Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 219100893-028-008_a 219100893-028-028_a 1. Retaining tab VIEWED FROM UNDERNEATH 1. Rear cavity 219100893-028-303_a Installing the Steering Cover 1. Make sure all harnesses are routed properly into their positioning slots and are away from 219100893-028-007_a the outer edges.

  • Page 171: Replacing The Engine Cut-Off Switch

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 219100893-028-029_a 219100893-028-010_a 1. Harness slots Push cut-off switch out of the steering column. 2. Locking tie Install the engine cut-off switch by aligning the 2. Clip the top of the cover. alignment pin into the notch of steering column. 3.

  • Page 172: Steering Cable

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 2. Remove the screw and washer securing throt- 6.2 Insert sensor lever end into throttle lever tle lever. fork. 3. Remove throttle lever. 6.3 Position the return tab against the handle- bar. 6.4 Secure the lever with washer and screw.
  • Page 173 Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 1.4 Slide out the cable from the steering arm. Access can be improved by lifting the steering lever. 219100893-028-309_a 219100893-028-016_a 2. At rear of the watercraft, disconnect ball joint 1.2 Remove the steering column upper steer- from jet pump nozzle arm.
  • Page 174 Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 219100893-028-019_a 219100893-028-021_a 1. Steering cable 2. Jam nut 3. Ball joint 4. Remove half-rings retaining screws. 219100893-028-022_a 1. Steering cable 2. Half ring 3. O ring 6. Remove the adjusting nut from the new steer- 219100893-028-020_a ing cable.
  • Page 175 Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 11.2 Tighten the half-rings retaining screws to The installation of the steering cable to the steer- specification. ing column is the reverse of the removal proce- dure. However, pay attention to the following. TIGHTENING TORQUE TIGHTENING TORQUE Half-rings retaining...

  • Page 176: Steering Column

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 219100893-028-304_a VIEWD FROM UNDERSIDE 3. Adjust steering cable as described in STEER- ING ALIGNMENT in this subsection. 219100893-028-025_a STEERING COLUMN 1. Steering column screws Removing the Steering Column 5. Pull steering column out of its support. 1.

  • Page 177: Steering Column Support

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) Ensure the steering system is working properly by turning side to side. Reinstall all removed parts using appropriate pro- cedure. STEERING COLUMN SUPPORT Removing the Steering Column Support 1. Remove steering column, refer to REMOVING THE STEERING COLUMN in this subsection.

  • Page 178: Steering Tilt Release Handle

    Section 06 STEERING AND PROPULSION Subsection 01 (STEERING) 3. Remove steering column support and steering adjustment handle from vehicle. Installing the Steering Column Support The installation is the reverse of the removal pro- cedure. STEERING TILT RELEASE HANDLE Replacing the Steering Tilt Release Handle Use the same procedure as for STEERING COL-...

  • Page 180: Ibr, Reverse And Vts

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) iBR, REVERSE AND VTS SERVICE TOOLS Description Part Number Page 529 036 384 ......... 181 DIAGNOSTIC HARNESS ............... 529 036 379 ......... 176 IBR NUT SOCKET................SERVICE PRODUCTS Description Part Number Page 293 800 005 .........
  • Page 181 Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) VTS TRIM RING AND NOZZLE 27 ± 1 N•m 5 ± 1 N•m (20 ± 1 lbf•ft) (44 ± 9 lbf•in) Loctite 271 Loctite 271 5 ± 1 N•m (44 ±...
  • Page 182 Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) iBR GATE 7 ± 1 N•m (62 ± 9 lbf•in) Loctite 5900 Loctite 271 27 ± 1 N•m (20 ± 1 lbf•ft) 7 ± 1 N•m (62 ± 9 lbf•in) 6 ±...

  • Page 183: General

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) GENERAL During assembly/installation, use torque values and service products as indicated in the exploded view. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS LOCTITE APPLICATION at the beginning of this manual for complete procedure.
  • Page 184 Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) 219100893-029-005_b 219100893-029-003_a REVERSE 219100893-029-004_a FORWARD 219100893-029-007_a iBR ACTUATOR AIR CHAMBER MOVEMENT NOTE: The iBR gate will move when commanded by the iBR lever only if the engine is running. For maintenance purposes, the iBR OVERRIDE func- tion available through the gauge can be used to electrically move the gate to the desired position.
  • Page 185 Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) Every time the iBR gate moves when commanded When the iBR lever is pulled in to engage the re- by the iBR lever, engine RPM is momentarily re- verse, the following occurs: duced to idle speed as the gate moves.

  • Page 186: System Description (Vts)

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) SYSTEM DESCRIPTION (VTS) Using the VTS Button (LH Side of Handlebar) The VTS system is actually part of the iBR system. Press the UP or DOWN arrow button to change It provides watercraft pitch trim adjustments by the VTS setting.

  • Page 187: Adjustment

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) In BUDS2, go to: – Flash page – iBR button VALID FIRMWARE Select the update file in the UPDATES window and click when prompted. 219100963-011-002 The message LAUNCH ON will be displayed. sbs2017-005-003a The following message will confirm that the up- date has been donne successfully.

  • Page 188: Ibr Auto Calibration

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) INSPECTION The iBR system is self monitoring. If a fault oc- curs in the iBR system, it will raise a fault code and communicate it to the information center through the CAN bus.

  • Page 189: Procedures

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) NOTICE Do not install an exhaust ventilation 4. Release the iBR lever completely. Reverse hose in the iBR gate area or damage may oc- thrust should cease and the watercraft should cur when the iBR gate moves downward dur- continue to drift rearward on momentum.

  • Page 190: Ibr Actuator

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) 219100893-029-014_a IBR ACTUATOR CONNECTOR 219100893-029-012_a STEERING CONNECTOR LOCATION iBR ACTUATOR Specifications IBR ACTUATOR CONNECTOR SIGNAL Battery voltage iBR-1 (Hot at all times) Battery voltage iBR-2 (Hot with main relay on) iBR-8 Ground iBR ACTUATOR CURRENT DRAW...
  • Page 191 Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) Testing iBR Actuator Motor Current 1. Connect the vehicle to the BRP diagnostic soft- ware (BUDS2). 2. In BUDS2, go to: – Measurements page – iBR button 3. Note the Gate Position (°) indication. 4.
  • Page 192 Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) smr2016-036-013_a 5. If the same actuator is reinstalled, clean all residues of sealing compound near the threaded area. 219100893-029-008_a 6. Apply Loctite 5900 on actuator, between actu- 1. Actuator retaining screw ator housing and threads, as shown in the ex- 9.

  • Page 193: Ibr Reverse Gate

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) iBR REVERSE GATE TIGHTENING TORQUE 7 N•m ± 1 N•m iBR reverse gate screw (62 lbf•in ± 9 lbf•in) 27 N•m ± 1 N•m (20 lbf•ft ± 1 lbf•ft) iDF connecting arm screw LOCTITE 271 (RED)
  • Page 194 Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) 3. Remove connecting arm pin and screw. smr2016-036-045 3. Position the bellows over the connecting arm. smr2016-036-045 4. Remove connecting arm. Installing the Connecting Arm Use iBR override function to move iBR actuator to the full down setting.

  • Page 195: Actuator Output Shaft

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) VTS TRIM RING smr2016-036-048_a 5. Reinstall other removed parts. Refer to appro- priate subsections for procedures. NOTICE Allow 24 hours for thread locker on retaining screws to cure. IBR AUTO-CALIBRATION Perform procedure.

  • Page 196: Brake And Reverse Lever Switch (Brls)

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) BRAKE AND REVERSE LEVER Removing the BRLS SWITCH (BRLS) Testing and Specifications BRLS PINOUT SIGNAL BRLS-A 5 VDC BRLS-B BRLS-C View signal % in BUDS2 BRLS-D 5VDC BRLS-E BRLS-F View signal % in BUDS2 NOTE: When moving BRLS lever, the BRLS per- centage should increase or decrease in a steady...

  • Page 197: Testing Can Communication

    Section 06 STEERING AND PROPULSION Subsection 02 (iBR, REVERSE AND VTS) TESTING CAN COMMUNICATION CAN WIRE RESISTANCE TEST ACTUATOR SPECIFIED CONNECTOR CONNECTOR RESISTANCE iBR-3 COM-1 iBR-4 COM-2 smr2014-119-011_a PROCEDURES Refer to in this subsection for wiring diagram and pinouts. Refer to CONTROLLER AREA NETWORK (CAN) subsection for additional information.

  • Page 198: Jet Pump

    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) JET PUMP SERVICE TOOLS Description Part Number Page 529 035 956 ......193–194, 199 IMPELLER REMOVER/INSTALLER ..........529 036 168 ......... 196–197 IMPELLER SHAFT BEARING TOOL ..........529 035 955 ......... 195, 197 IMPELLER SHAFT PUSHER............
  • Page 199 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 25 ± 1 N•m (18 ± 1 lbf•ft) Loctite 518 9 ± 1 N•m (80 ± 9 lbf•in) Loctite 438 Triple guard grease Loctite 767 (antiseize 12 ± 1 N•m lubricant) (106 ±...

  • Page 200: General

    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) GENERAL Using a feeler gauge, measure clearance between impeller blade tip and wear ring. Measure each blade at its center. JET PUMP MAIN COMPONENTS smr2006-027-008 MAXIMUM WEAR MODEL CLEARANCE All models 0.35 mm (.014 in) 219100893-030-003_a 1.

  • Page 201: Leak Test

    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Excessive play can come either from worn bearing or damaged jet pump housing bearing surface. LEAK TEST Whenever performing any type of repair on the jet pump, a leak test should be carry out. Proceed as follows: 1.

  • Page 202: Idf Arm

    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Removing the Sacrificial Anode Remove and discard screw and anode. 219100963-019-200 3. Rotate the iDF arm then using a screwdriver or any suitable tool, carefully pry out the iDF arm from the rotary valve. smr2016-037-003_a 219100963-019-201 Installing the iDF Arm...
  • Page 203 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 3. Remove and discard the nuts that retain the jet pump to the pump support. smr2016-037-005_a 4. Pull back jet pump housing to remove it from the pump support. It may be necessary to wig- gle it slightly as you pull back on the pump.
  • Page 204 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Installing the Jet Pump Housing REQUIRED TOOL The installation is the reverse of the removal pro- cedure. However, pay attention to the following. PUMP PLATE (P/N 529 036 224) Clean impeller splines and drive shaft splines with Clutch and pulley flange cleaner or equivalent.

  • Page 205: Impeller Cover

    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Install new nuts and tighten as per table and the illustrated sequence. TIGHTENING TORQUE 27 N•m ± 1 N•m Jet pump nuts (20 lbf•ft ± 1 lbf•ft) smr2016-037-008_a 1. Slide adapter onto pump 2.
  • Page 206 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 3. Using a fiber hammer, gently tap impeller cover to help release it from the jet pump housing. 4. Use a flat screwdriver in the slots provided as pry points to remove it from the jet pump hous- ing.

  • Page 207: Impeller

    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) IMPELLER SERVICE PRODUCT Removing the Impeller JET PUMP BEARING GREASE (P/N 293 550 032) NOTE: If impeller shaft is to be disassembled, 2. Install O-rings in their respective groove and loosen the impeller shaft nut prior to removing make sure they are properly lubricated.
  • Page 208 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) REQUIRED TOOL IMPELLER REMOVER/INSTALLER (P/N 529 035 956) NOTICE Never use an impact wrench to loosen impeller. smr2009-006-002_b TYPICAL 1. Antiseize lubricant 3. Apply Lubricant and anti-corrosive on the wear ring surface. SERVICE PRODUCTS LUBRICANT AND Scandinavia...

  • Page 209: Wear Ring

    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Removing the Wear Ring 1. Remove jet pump housing. Refer to JET PUMP HOUSING in this subsection. IMPELLER 2. Remove impeller, refer to in this subsection. 3. On models equipped with the 300 engine, re- move screws securing the wear ring.

  • Page 210: Impeller Shaft, Bearing And Seals

    Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) Installing the Wear Ring SERVICE PRODUCTS Like the removing procedure, two methods can LOCTITE 243 (BLUE) (P/N 293 800 060) be used to install the wear ring, use the most ap- propriate as your situation.
  • Page 211 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-011 smr2016-037-017_a TYPICAL 1. Circlip Removing the Bearing 2. Using an appropriate tool, press seals out of the 1. Remove the bearing retaining nut. housing. 2. Use the Impeller shaft bearing tool to press Inspecting the Impeller Shaft and its bearing off impeller shaft.
  • Page 212 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 2. Use the Impeller shaft pusher tool to protect the impeller shaft threads. REQUIRED TOOL IMPELLER SHAFT PUSHER (P/N 529 035 955) NOTE: The bearing can be installed in either direc- tion.
  • Page 213 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) 219100959-021-001 F18J12A 1. Grease in seals cavities TYPICAL 7. Apply 11 g (.4 oz) of grease inside NEW double lip seal and in the seal lips. F18J13A 1. Seal lip facing up 219100959-021-002 PUT GREASE IN ALL SEAL CAVITIES.
  • Page 214 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) smr2009-006-016_a F18J0PB 1. Seal lip facing up 1. Impeller remover/installer tool 10. Install circlip. 15. Install jet pump housing over tool. smr2006-027-007_c TYPICAL 1. Circlip 11. Turn pump upside down. F18J0QA 12.
  • Page 215 Section 06 STEERING AND PROPULSION Subsection 03 (JET PUMP) SERVICE PRODUCT JET PUMP BEARING GREASE (P/N 293 550 032) smr2009-006-018 219100959-021-006 1. Grease around nut 19. Install the two O-rings in pump housing and make sure they are properly lubricated. smr2009-006-017_a TYPICAL 1.

  • Page 216: Drive Shaft

    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) DRIVE SHAFT SERVICE TOOLS Description Part Number Page 529 036 026 ......... 202 DRIVE SHAFT C-CLIP REMOVER ..........529 036 116 ......... 202 FLOATING RING TOOL (TYPE II) ..........529 035 842 ......... 203, 206 PTO SUPPORT TOOL ..............

  • Page 217: Procedures

    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) PROCEDURES DRIVE SHAFT Drive Shaft Access Remove the seat and engine service cover. Refer BODY subsection. Removing the Drive Shaft Procedures NOTE: Ensure jet pump is installed before begin- ning this procedure. 1.

  • Page 218: Pto Support Tool

    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) F18I0OA TYPICAL 1. Largest opening on PTO seal side smr2011-036-031_a TYPICAL 1. Telltale groove 2. Lubricate this area A. 18 mm (11/16 in) smr2011-036-030_a 9. Remove the floating ring tool. TYPICAL 1.
  • Page 219 Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) F18C02A TYPICAL 1. Largest opening here 2. Floating ring F18I04A 3. PTO seal support tool 4. Remove circlip 1. Insert in groove of PTO seal assembly NOTICE 14. Remove the floating ring tool. Strictly follow this procedure other- wise damage to component might occur.
  • Page 220 Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) Inspect condition of drive shaft splines. If splines Floating Ring are damaged, replace drive shaft and check Inspect condition of O-rings and contact surface splines of impeller and PTO housing. of floating ring. With your finger nail, feel machined surface of Replace as required.

  • Page 221: P80 Grip-It

    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) REQUIRED TOOL PTO SUPPORT TOOL (P/N 529 035 842) Apply a thin coat of lubricant on the floating ring O-rings. Do not get lubricant on floating ring con- tact surface. SERVICE PRODUCT P80 GRIP-IT (P/N 296 000 406) F18I0EA CORRECT POSITION...

  • Page 222: Drive Shaft Bellows

    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) F18I02A TYPICAL Maintain PTO seal assembly in the proper position F18I0JA and tap shaft end until it bottoms against engine. IMPROPER INSTALLATION At this time, the telltale groove MUST NOT be vis- 1.

  • Page 223: Carbon Ring

    Section 06 STEERING AND PROPULSION Subsection 04 (DRIVE SHAFT) Loosen gear clamp holding bellows, then carefully pull bellows and carbon ring from hull insert. 219100893-031-002_a TYPICAL 1. Loosen this clamp 2. Drive shaft bellows Installing the Drive Shaft Bellows The installation is the reverse of the removal pro- cedure.

  • Page 224: Body And Hull

    Section 07 BODY AND HULL Subsection 01 (BODY) BODY SERVICE PRODUCTS Description Part Number Page 413 705 800 ......... 219 LOCTITE 414 ................. 293 800 066 ......... 236 LOCTITE 5900 ................779231 ......... 233–234 SYNTHETIC GREASE (EUR) ............779162 ......... 233–234 SYNTHETIC GREASE ..............
  • Page 225 Section 07 BODY AND HULL Subsection 01 (BODY) BODY 2.75 ± 0.25 N•m 2.75 ± 0.25 N•m (24 ± 2 lbf•in) (24 ± 2 lbf•in) 11.5 ± 1.5 N•m (102 ± 13 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 3.25 ±...
  • Page 226 Section 07 BODY AND HULL Subsection 01 (BODY) STORAGE COMPARTMENT AND VENTILATION See tightening sequence 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 5.5 ± 0.5 N•m (49 ± 4 lbf•in) 5.5 ± 0.5 N•m 4.5 ± 0.5 N•m (49 ± 4 lbf•in) (40 ±...
  • Page 227 Section 07 BODY AND HULL Subsection 01 (BODY) FRONT COVER 5.5 ± 0.5 N•m (49 ± 4 lbf•in) 5.5 ± 0.5 N•m (49 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 219100893-032-105_a 219100963-021...
  • Page 228 Section 07 BODY AND HULL Subsection 01 (BODY) FISH FINDER SONAR (FISH PRO MODEL) 5.5 ± 0.5 N•m (49 ± 4 lbf•in) 5.5 ± 0.5 N•m (49 ± 4 lbf•in) 3.5 ± 0.5 N•m (31 ± 4 lbf•in) 219100963-021-100 219100963-021...
  • Page 229 Section 07 BODY AND HULL Subsection 01 (BODY) SEAT 219100893-032-106_a 219100963-021...
  • Page 230 Section 07 BODY AND HULL Subsection 01 (BODY) WAKEBOARD RACK AND WAKE PYLON (WAKE PRO MODEL) 5 ± 0.5 N•m (44 ± 4 lbf•in) (silicon sealant) 2.5 ± 0.5 N•m (22 ± 4 lbf•in) = Component must be replaced when removed. 219100893-032-104_a 219100963-021...
  • Page 231 Section 07 BODY AND HULL Subsection 01 (BODY) REAR EXTENSION (FISH PRO MODEL) 8 ± 1 N•m (71 ± 9 lbf•in) See tightening sequence 17.5 ± 1 N•m (155 ± 9 lbf•in) 8 ± 1 N•m (71 ± 9 lbf•in) 8 ±...

  • Page 232: Procedures

    Section 07 BODY AND HULL Subsection 01 (BODY) PROCEDURES GELCOAT, DECALS AND CARPETS CLEANING For information and repair, refer to AND REPAIR subsection. HOOD 219100893-032-003_a 3. Remove hood by pulling it up and with a for- ward motion. Installing Hood The installation is the reverse of the removal pro- cedure, however pay attention to the following.

  • Page 233: Storage Compartment Cover

    Section 07 BODY AND HULL Subsection 01 (BODY) TIGHTENING TORQUE 3.25 N•m ± 0.75 N•m Screw (29 lbf•in ± 7 lbf•in) STORAGE COMPARTMENT COVER 219100693-021-102a 1. Retainer 2. Front attaching point 3. The hood’s rear tabs must be properly inserted under the attachment points.

  • Page 234: Glove Box Cover

    Section 07 BODY AND HULL Subsection 01 (BODY) TIGHTENING TORQUE 5.5 N•m ± 0.5 N•m Hinge screws (49 lbf•in ± 4 lbf•in) Adjust the alignment of the steering, refer to STEERING section. GLOVE BOX COVER 219100893-032-702_a 4. Remove top cover. 5.

  • Page 235: Fish Finder Sonar Support

    Section 07 BODY AND HULL Subsection 01 (BODY) 3. Remove mirror covers and fish finder sonar support (if equipped), see procedure in this subsection. 4. Remove outer skin. 219100963-021-001 Step 1: Lift tab to remove sonar Step 2: Unscrew knob to remove support plate Remove the mounting screw and pull mirror cover toward the front.

  • Page 236: Seat

    Section 07 BODY AND HULL Subsection 01 (BODY) SEAT Cleaning the Seat CLEANING AND REPAIR For information, refer to subsection. Removing the Seat To remove the seat, push on the two release but- tons and lift the back end of the seat. 219100963-021-005 Ensure the mounting tabs are properly located.

  • Page 237: Mirrors

    Section 07 BODY AND HULL Subsection 01 (BODY) CAUTION Ensure the latch is properly locked onto the pin. MIRRORS Replacing the Mirror 1. Lift handlebar. 2. Open storage compartment. 3. Remove mirror cover 219001878-021_a 1. Seat retainer Insert the forward part of the rear seat into the retainers.

  • Page 238: Bumpers

    Section 07 BODY AND HULL Subsection 01 (BODY) 7. Install mirror using adhesive tape at the back of 2. Remove front bumper from vehicle. mirror. Rear Bumper 8. Install mirror trim by reversing the removal pro- All models excluding Fish PRO. cedure.
  • Page 239 Section 07 BODY AND HULL Subsection 01 (BODY) 219100893-032-712_a Installing the Bumper Front and Rear Bumper The installation is the reverse of the removal pro- cedure. 219100893-032-008_a 4. Remove rear bumper from vehicle. Side Bumpers 1. Insert bumper over body lip. Side Bumpers 1.1 Insert lower section first.

  • Page 240: Lateral Cosmetics

    Section 07 BODY AND HULL Subsection 01 (BODY) LATERAL COSMETICS 219100893-032-713_a 219100893-032-714_a 1. Front Cosmetic 1. Plastic rivet 2. Center Cosmetic 2. Screw Removing the Center Cosmetic 219100893-032-715_a Installing the Center Cosmetic 219100893-032-722_a The installation is the reverse of the removal pro- Remove seats.

  • Page 241: Lateral Grille Assembly

    Section 07 BODY AND HULL Subsection 01 (BODY) LATERAL GRILLE ASSEMBLY Removing the Front Cosmetic 219100893-032-725_a Removing the Lateral Grille 219100893-032-721_a Remove center cosmetic, see procedure in this subsection. Remove center cosmetic. Remove screws. Remove lateral grille, see procedure in this sub- section.

  • Page 242: Front Grille Assembly

    Section 07 BODY AND HULL Subsection 01 (BODY) FRONT GRILLE ASSEMBLY TIGHTENING TORQUE 3.25 N•m ± 0.75 N•m Grille retaining screw (29 lbf•in ± 7 lbf•in) CLEAT 219100893-032-716_a Removing the Front Grille Assembly 1. Remove hood. 219100893-032-730_a 2. Remove screws and retaining tabs. Removing the Cleat LH side shown, the procedure is the same for both sides.

  • Page 243: Engine Service Cover

    Section 07 BODY AND HULL Subsection 01 (BODY) 219100893-032-732_a Remove cleat. NOTE: There are nuts and washers inside the hull. Be careful not to lose them in the hull. Storage compartment can be removed fo easy 219100893-032-720_a access. 3. Remove screws. Installing the Cleat The installation is the reverse of the removal pro- cedure.

  • Page 244: Sound System

    Section 07 BODY AND HULL Subsection 01 (BODY) SOUND SYSTEM 219100893-032-728_a Insert a long screwdriver or 1/4 in. extension in hole to release tab. 219100893-032-727_a Removing the Sound System LH side shown, the procedure is the same for both sides. Remove: –...

  • Page 245: Ventilation

    Section 07 BODY AND HULL Subsection 01 (BODY) Remove retaining screws and disconnect electri- cal connector. 219100963-021-013 VIEWED FROM UNDERNEATH 1. Hole 2. Tab to be released. Slide speaker unit out toward the rear. Installing the Sound System The installation is the reverse of the removal pro- cedure.
  • Page 246 Section 07 BODY AND HULL Subsection 01 (BODY) NOTICE Make sure anchorage hooks are properly installed. 219100893-032-200 219100893-032-735_a 2. Position the inner rib of the compartment cover Slightly pull storage compartment out. evenly front and back on the seal. Cut locking ties retaining the ventilation hoses to 2.1 Move the storage compartment front to the bin.

  • Page 247: Wake Pylon (Wake Pro)

    Section 07 BODY AND HULL Subsection 01 (BODY) WAKE PYLON (WAKE PRO) Removing the Wake Pylon Remove the seat. Unlock the LinQ attachment. 219100893-032-202 STORAGE COMPARTMENT COVER RIB 3. Make sure ventilation adaptor is properly in- stalled on anchorage hooks. NOTICE Make sure both ventilation tubes are positioned underneath the storage com-...
  • Page 248 Section 07 BODY AND HULL Subsection 01 (BODY) Remove locking strap and the inner lock. Handle Extend handle approximately 75 mm to 90 mm (3 in to 3-1/2 in). 219001878-045_a Disassembling the Wake Pylon Extend the handle completely. smr2008-035-016_a Turn the wake pylon upside down. A.

  • Page 249: Rear Extension (Fish Pro)

    Section 07 BODY AND HULL Subsection 01 (BODY) Position a ball on each ends of spring. Install a feeler gauge over each balls. Tighten the locking tie in order to retain feeler gauges and balls. smr2008-035-021_a 1. Retaining pin 2. Locking strap Using a suitable tool, position the locking strap in its groove.
  • Page 250 Section 07 BODY AND HULL Subsection 01 (BODY) 219100963-021-008 219100963-021-011 Remove the following fasteners. 219100963-021-012 1. Extention body 2. Extension float 219100963-021-010 3. Extension hull Installing the Fish PRO Extension The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Refer to the exploded view for tightening torques.
  • Page 251 Section 07 BODY AND HULL Subsection 01 (BODY) 219100963-021-017 Apply loctite on the following screws. SERVICE PRODUCT LOCTITE 5900 (P/N 293 800 066) 219100963-021-019 219100963-021-018 219100963-021...

  • Page 252: Hull

    Section 07 BODY AND HULL Subsection 02 (HULL) HULL SERVICE PRODUCTS Description Part Number Page 293 110 001 ......... 241–243 BRP HEAVY DUTY CLEANER ............296 000 309 ......... 244, 246 CLEAR SILICONE SEALANT ............293 800 005 ......... 239–240 LOCTITE 271 (RED)...............
  • Page 253 Section 07 BODY AND HULL Subsection 02 (HULL) 25 ± 1 N•m (18 ± 1 lbf•ft) 27 ± 1 N•m 9 ± 1 N•m (20 ± 1 lbf•ft) (80 ± 9 lbf•in) 27 ± 1 N•m (20 ± 1 lbf•ft) 11 ±...

  • Page 254: Procedures

    Section 07 BODY AND HULL Subsection 02 (HULL) PROCEDURES HULL CLEANING AND REPAIR For hull repair, refer to subsection. INLET GRATE Removing the Inlet Grate Remove counter nut on front screw on the inside of the hull. Remove inlet grate retaining screws using an im- 219100893-033-019_a pact tool.

  • Page 255: Ride Plate

    Section 07 BODY AND HULL Subsection 02 (HULL) 8. Disconnect coolant hoses from the ride plate. TIGHTENING TORQUE 9. Remove coolant hose fittings from the ride First step Hand tighten INLET plate. GRATE 27 N•m ± 1 N•m Second step SCREWS NOTICE If possible, remove the hose fittings...

  • Page 256: Jet Pump Support

    Section 07 BODY AND HULL Subsection 02 (HULL) 219100893-033-004_a SEALANT APPLICATION smr2009-043-036_a TYPICAL 4. Secure ride plate with retaining screws. 1. Hydraulic bottle jack 2. Steel plates NOTE: Measure distance between pivot arms on ride plate and jet pump support to ensure ride 13.
  • Page 257 Section 07 BODY AND HULL Subsection 02 (HULL) Cleaning the Jet Pump Support 2. Disconnect hoses from jet pump support. 1. Scrape off all excess sealant from jet pump sup- port, ride plate, and hull. 2. Inspect pump support for cracks or other dam- age.

  • Page 258: Thru-Hull Fitting

    Section 07 BODY AND HULL Subsection 02 (HULL) 219100893-033-008_a 219100893-033-006_a SEALANT APPLICATION JET PUMP SUPPORT TIGHTENING SEQUENCE 3. Insert the studs in the jet pump support square 9. Remove excess sealant. holes. 10. Reinstall other removed parts. Refer to appro- 4.

  • Page 259: Rear Sponsons

    Section 07 BODY AND HULL Subsection 02 (HULL) 2. Apply CLEAR SILICONE SEALANT (P/N 296 000 on back side of sponson spacers. 309) 219100893-033-020_a 219100893-033-016_a SEALANT APPLICATION 1. Apply silicone sealant here 3. Tighten thru-hull fitting screws to the specified 3.

  • Page 260: Bailers

    Section 07 BODY AND HULL Subsection 02 (HULL) BAILERS Two bailers (one each side), serve to drain the bilge of the watercraft when it is in operation. The bailers are connected to syphon tubes mounted in the jet pump venturi that use the jet pump thrust to create a vacuum.

  • Page 261: Bow Eyelet

    Section 07 BODY AND HULL Subsection 02 (HULL) BOW EYELET Installing the Bow Eyelet Removing the Bow Eyelet BODY 1. Remove the storage bin, refer to subsec- tion. 2. Remove nuts and washers securing the bow eyelet. Discard nuts. 219100893-033-012_a TYPICAL –...
  • Page 262 Section 07 BODY AND HULL Subsection 02 (HULL) 3. Install eyelet and other parts using new elastic stop nuts as per following illustration. 219100893-033-014_a 1. Stern eyelet 2. Small washer 3. Loctite 5150 (silicone sealant) here 4. Rubber washer 5. Large washer 6.

  • Page 264: Technical Specifications

    Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (VEHICLES) VEHICLES COOLING SYSTEM Type Closed loop cooling system Ethylene-glycol / distilled water mix (50%/50%) Use BRP extended life pre-mixed Coolant coolant or a low silicate coolant specially formulated for internal combustion aluminum engines Cooling system capacity 5.8 L (6.13 qt (U.S.
  • Page 265 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (VEHICLES) ELECTRICAL SYSTEM #1: Not Used #2: Fuel inj., Ing. Coils and Fuel Pump 15 A #3: Bilge pump (if equipped) #4: NOT USED #5: NOT USED #6: Charge 30 A #7: Cluster Fuse box #8: Depth sounder (if equipped) #9:iBR 30 A...
  • Page 266 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (VEHICLES) PROPULSION Coupling type Crowned splines, direct drive Drive shaft Deflection (max.) 0.5 mm (.02 in) 90 cm (3 ft) underneath the lowest Minimum required water level for propulsion system rear portion of hull IBR AND VTS Intelligent Brake and Reverse activated by a LH lever.
  • Page 267 Section 08 TECHNICAL SPECIFICATIONS Subsection 01 (VEHICLES) DIMENSIONS 125.5 cm (49.4 in) Overall width RXT-X 300 115 cm (45.3 in) Overall height All other models 114 cm (44.9 in) MATERIALS Impeller material Stainless steel Impeller housing/stator Aluminum/aluminum Hull CM-TEC process, composite Inlet grate Aluminum Steering cover...

  • Page 268: Wiring Diagram

    Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) WIRING DIAGRAM INFORMATION GENERAL Terminal Identification on Connector On the wiring diagram, a letter or a digit is used to WIRING DIAGRAM LOCATION identify the terminal position in a connector. The wiring diagrams are in the back cover pocket. WIRING DIAGRAM CODES Wire Color Codes smr2015-009-002_a...
  • Page 269 Section 09 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM INFORMATION) smr2015-009-003_a TYPICAL 1. Connector location 2. Wire pin location in connector Connectors Linked by a Dashed Line Connectors may be divided into segments linked by dashed lines, however, some segments of the smr2012-047-004_a same connector may be found elsewhere on the TYPICAL...

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