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SeaDoo GTI LE RFI Manuals
Manuals and User Guides for SeaDoo GTI LE RFI. We have
2
SeaDoo GTI LE RFI manuals available for free PDF download: Shop Manual, Manual
SeaDoo GTI LE RFI Shop Manual (801 pages)
Brand:
SeaDoo
| Category:
Boat
| Size: 61.74 MB
Table of Contents
Table of Contents
4
Safety Notice
15
Introduction
16
Hull Identification Number (H.I.n.)
16
Engine Identification Number (E.I.n.)
17
Arrangement of this Manual
18
List of Abbreviations Used in this Manual
21
General Information
21
Illustrations and Procedures
22
Engine Emissions Information
22
Self-Locking Fasteners Procedure
23
Loctite Application Procedure
23
Threadlocker
23
Stripped Thread Repair
24
Gasket Compound
25
Mounting on Shaft
25
Case-In Components
26
Tightening Torques
27
Service Tools and Products
28
Mandatory Service Tools
28
Engine
28
Cooling/Fuel/Oil Systems
32
Propulsion System
33
Steering System
35
Optional Service Tools
36
Engine
36
Cooling/Fuel/Oil Systems
41
Propulsion System
41
Body
42
Watercraft Handling
42
Service Products
43
Maintenance
47
Periodic Inspection Chart
47
Flushing and Lubrication
53
General
53
Procedure
53
Anticorrosion Treatment
58
Water-Flooded Engine
59
General
59
Procedure
59
Storage
65
Engine Draining
65
Propulsion System
66
Fuel System
67
Engine Oil Change and Filter
67
Cooling System Flushing and Engine Internal Lubrication
67
Engine Lubrication
67
Battery
68
Watercraft Cleaning
68
Additional Recommended Protection
68
Anticorrosion Treatment
74
Checklist
74
Troubleshooting
75
Troubleshooting Chart
75
Engine will Not Start
75
Engine Hard to Start
78
Engine Starts but Runs Only at Idle Speed
78
Engine Misfires, Runs Irregularly
79
Engine Continually Backfires
81
Engine Detonation or Pinging
81
Engine Lacks Acceleration or Power
82
Engine Stops Running
83
Engine Cannot Reach Maximum Rpm
83
Engine Runs too Fast (Vehicle Cannot Reach Its Top Speed)
84
Engine Overheats
84
System Faults (Gtx 4-Tec Models)
85
Engine Smoke in the Exhaust (4-Tec Series)
85
Low or no Engine Oil Pressure (4-Tec Series)
86
Engine Oil Contamination (Milky) (4-Tec Series)
86
Unusual Engine Noise And/Or Vibration (4-Tec Series)
87
Abnormal Noise from Propulsion System
87
Engine (2-Stroke)
88
Leak Test
88
General
88
Preparation
88
Testing Procedure
88
Engine Leakage Diagnostic Flow Chart
94
Removal and Installation
96
General
96
Engine Removal
96
Cleaning
101
Installation
101
Magneto System
107
Disassembly
110
Cleaning
117
Assembly
117
Top End
122
General
125
Disassembly
127
Cleaning
134
Inspection
135
Used Piston Measurement
136
Assembly
139
Adjustment
148
Bottom End
151
Disassembly
154
Cleaning
161
Inspection
162
Assembly
166
Rotary Valve
175
General
176
Inspection on Watercraft
176
Disassembly
177
Cleaning
179
Inspection
179
Assembly
180
Rotary Valve Timing
184
Exhaust System
186
Removal
189
Tuned Pipe Repair
195
Installation
195
Engine (4-Tec)
202
Leak Test
202
Leak Test Procedure
202
Preparation
202
Procedure
203
Installation
204
Leak Test Procedure for Intercooler
205
Intake System
206
Inspection
210
Removal
212
Disassembly
219
Assembly
222
Installation
226
Exhaust System
229
Exhaust Pipe
230
Exhaust Manifold
233
Muffler
234
Resonator
234
Exhaust Outlet
235
Removal and Installation
236
General
236
Engine Removal
236
Cleaning
240
Installation
240
Pto Housing/Magneto
243
General
244
Pto Housing
244
Pto Seal
247
Coupling
247
Stator
248
Rotor and Encoder Wheel
249
Ring Gear
249
Starter Drive Ass'y
250
Oil Spray Nozzle
251
Lubrication System
253
General
255
Oil Level Verification
255
Engine Oil Pressure Test
256
Oil Filter
258
Oil Strainers
259
Engine Oil Pressure Regulator
262
Oil Pressure Pump
263
Oil Suction Pump
266
Oil Cooler
269
Oil Separator
270
Cylinder Head and Valves
272
General
273
Spark Plug
273
Valve Cover
273
Rocker Arm
274
Camshaft Timing Gear
277
Timing Chain
279
Cylinder Head
279
Camshaft
280
Valve Spring
282
Valve
283
Engine Block
289
General
291
Crankshaft Locking
291
Crankshaft
291
Timing Chain
295
Chain Tensioner
296
Balancer Shaft
296
Engine Block
299
Piston/Connecting Rod
304
Piston Rings
310
Engine Management (Rfi)
312
Overview
312
Air Induction
313
Fuel Delivery
313
Fuel Pump
313
Fuel Pressure Regulator
313
Fuel Filters
313
Fuel Pump Module
314
Fuel Injectors
314
Electronic Management
314
Electronic Control Unit (Ecu)
314
Mpem (Multi-Purpose Electronic Module)
315
Diagnostic Procedures
317
Introduction
317
Self-Diagnostic Mode
317
Advanced Diagnostic
317
Fault Code Tables
319
Output Signal Faults
320
Component Inspection
321
General
321
Air Induction System
323
Throttle Body
323
Fuel Delivery
323
Fuel Filter
323
Fuel Pump
323
Regulator
323
Fuel Injector
324
Leak Test (Supply and Ventilation Circuits)
325
High Pressure Test (Fuel Pump Circuit)
325
Electronic Management
326
Throttle Position Sensor (Tps)
326
Crankshaft Position Sensor (Cps)
327
Air Temperature Sensor (Ats)
328
Water Temperature Sensor (Wts)
328
Air Pressure Sensor (Aps)
329
Rave Solenoid
330
Rfi Sensors Resistance Values
331
Troubleshooting Summary
332
Engine Does Not Start
332
Flooded Engine Feature
332
Spark Plug Inspection
332
Ecu Fault Codes
332
Engine Starts but Runs Poorly
332
Engine Runs Only on One Cylinder
332
Engine Cannot Reach Maximum Revolutions
333
Adjustment
334
Throttle Cable Adjustment
334
Throttle Position Sensor (Tps)
334
Closed Tps
334
Idle Speed
334
Removal and Installation
335
Mpem/Ecu
335
Throttle Position Sensor (Tps)
335
Air Temperature Sensor (Ats)
335
Air Pressure Sensor (Aps)
335
Water Temperature Sensor (Wts)
335
Crankshaft Position Sensor (Cps)
335
Fuel Pump Assembly
335
Regulator
336
Fuel Filter
336
Fuel Injectors
336
Engine Management (DI)
338
Overview
338
Operating Principle
338
Air Induction
338
Air Compressor System
338
Fuel Delivery System
338
Basic Operation
338
Air/Fuel Rail Assembly
339
Fuel Pump Module
339
Electronic Management
340
Mpem (Multi-Purpose Electronic Module)
340
Mpem - Engine Management Functions
343
Ignition System
345
Component Inspection and Adjustment
346
General
346
Fuel System
346
Electrical System
347
Amp Connector Pin-Out
348
Quick Fuel Pressure Test
348
Air Induction System
350
Throttle Body
350
Air Compressor
353
Pressure Test
353
Repair
354
Fuel Delivery
357
Fuel Pressure Regulator
357
Fuel Injector
359
Air/Fuel Rail
360
Direct Injector
361
Fuel Pump
363
Fuel Filters
365
Electronic Management
368
Mpem Replacement
368
Throttle Position Sensor (Tps)
369
Crankshaft Position Sensor (Cps)
371
Manifold Air Temperature Sensor (Mats)
373
Water Temperature Sensor (Wts)
373
Manifold Air Pressure Sensor (Maps)
374
Exhaust Gas Temperature Sensor (Egts)
375
Knock Sensor (Ks)
375
Rave Solenoid
376
Ignition Coil
377
Ignition Timing
379
Spark Plugs
383
Cranking System
384
DI System Test Summary
384
Diagnostic Procedures
387
General
387
Fault Detection and Compensatory Actions
389
Component Failure Warning System
389
Vck (Vehicle Communication Kit)
391
DI System Fault Codes
392
Engine Management (4-Tec)
400
Overview
400
Complete Electrical System Overview
400
Magneto System and Power Supply
402
Operating Principle of Engine Management
402
Air Induction
402
Fuel Delivery System
403
Basic Operation
403
Fuel Pump Module
405
Electronic Management
405
Ems (Engine Management System)
405
Ems - General Functions
406
Ems - Engine Management Functions
408
Mpem - Multi-Purpose Electronic Module
411
Component Inspection and Adjustment
412
General
412
Fuel System
412
Electrical System
413
Engine Connector Pin-Out
414
Connectors on Engine
415
Air Induction System
416
Throttle Body
416
Fuel Delivery
420
Fuel Pump
421
Fuel Filter
423
Fuel Rail
423
Fuel Injector
424
Electronic Management
426
Ecm and Mpem Replacement
426
Engine Wiring Harness
428
Throttle Position Sensor (Tps)
430
Idle Bypass Valve
432
Crankshaft Position Sensor (Cps)
433
Camshaft Position Sensor (Caps)
434
Manifold Air Temperature Sensor (Mats)
435
Coolant Temperature Sensor (Cts)
436
Manifold Air Pressure Sensor (Maps)
437
Exhaust Gas Temperature Sensor (Egts)
438
Knock Sensor (Ks)
438
Oil Pressure Sensor (Ops)
440
Oil Separator Pressure Sensor (Osps)
440
Tops Valve (Blow-By)
442
Ignition Coils
445
Ignition Timing
446
Engine Start/Stop Switch Verification
446
Safety Lanyard Switch Verification
446
Spark Plugs
447
Cranking System
447
Diagnostic Procedures
448
General
448
Self-Diagnostic Mode
450
Vck (Vehicle Communication Kit)
452
4-Tec System Fault Codes
453
4-Tec System Fault Codes Chart
456
Burnt Fuse and Related Fault Code
474
Cooling System
475
Circuit, Components and Care
475
Circuit
481
Components
484
Care
488
Circuit
496
Cooling System Leak Test
496
Inspection
498
Draining the System
498
Cleaning
498
Coolant Replacement
499
Coolant Pump Housing
500
Thermostat
501
Coolant Pump Impeller
502
Rotary Seal
502
Care
504
Fuel System
507
Fuel Circuit
507
General
513
Removal
514
Inspection
516
Assembly
517
Fuel System Pressurization
517
Air Intake (2-Stroke)
519
General
521
Removal
521
Assembly
522
Removal
524
Assembly
525
Carburetor
526
General
527
Removal
527
Cleaning
527
Disassembly and Inspection
528
Assembly
530
Installation
532
Adjustments
532
Lubrication System (2-Stroke)
535
Oil Injection System
535
General
537
Oil System Pressurization
537
Oil Injection Pump
538
Oil Pump Identification
541
Removal
541
Disassembly
541
Cleaning
541
Assembly
541
Adjustment
543
Checking Operation
546
Electrical System
547
Ignition System
547
General
547
Multi-Purpose Electronic Module (Mpem)
548
Ignition Timing
548
Procedure
556
Spark Plugs
559
Spark Plug Chart
560
Charging System
562
General
562
Testing Procedure
565
Battery
569
Battery Storage
571
Cable Terminal Installation
575
Starting System
577
General
580
Starting System Troubleshooting
581
Starter Removal
582
Starter Disassembly
582
Cleaning
586
Parts Inspection
586
Starter Assembly
587
Starter Installation
589
Starter Specification
591
Instruments and Accessories
592
General
592
Power Supply Cut-Off Relay Verification
592
Multi-Purpose Electronic Module (Mpem)
592
Information Center
593
Addition of Electrical Accessories
601
Inspection
601
Dess (Carbureted and Rfi Engines)
610
General
610
Dess Key Programming
612
Propulsion
615
Jet Pump
615
General
616
Jet Pump Inspection on Watercraft
616
Removal
618
Disassembly
620
Cleaning
622
Parts Inspection
623
Assembly
625
Pump Pressurization
633
Installation
633
General
637
Jet Pump Inspection on Watercraft
637
Removal
638
Pump Assembly
638
Reverse Gate
639
Disassembly
641
Cleaning
644
Parts Inspection
644
Assembly
646
Pump Pressurization
649
Installation
650
Drive System
653
General
656
Removal
656
Inspection
663
Assembly
665
Installation
666
Lubrication
673
Reverse System
675
Disassembly
676
Shift Lever
677
Inspection
678
Assembly
678
Adjustment
678
Variable Trim System
679
General
681
Removal
681
Disassembly
681
Inspection
682
Assembly
682
Installation
683
Adjustment
683
Steering System
685
1 Steeringsystem
687
Disassembly
687
Assembly
692
Disassembly
697
Assembly
700
Off-Power Assisted Steering System (O.p.a.s.)
702
General
703
Side Vane
703
Cylinder Support
704
Tie Rod
705
Sealed Tube
706
Filter
706
Valve
707
Water Hose
707
Cross Support Plate
708
Alignment
709
Suspension
711
Direct Action Suspension
711
Removal
712
Inspection
713
Assembly
714
Hull/Body
715
Adjustment and Repair
715
General
733
Glove Box
733
Engine Cover
735
Seat Adjustment
736
Storage Compartment Inner Shell
737
Storage Cover Shock
744
Storage Compartment Cover Adjustment
745
Access Panel Adjustment
746
Mirror
746
Info Center (Lcd Gauge)
747
Deflector And/Or Upper Grid
747
Finition Plate
748
Inlet Grate
748
Riding Plate
749
Jet Pump Support
750
Drain Plug Installation
751
Seat Removal
752
Seat Cover Replacement
753
Bumper Replacement
753
Wake Pylon
754
Sponson Replacement
756
Engine Compartment Cover Removal
756
Decals Replacement
757
Hull and Body Repair
758
Tools and Materials List
760
Thru-Hull Fitting Installation
761
Technical Data
762
Gti and Gti Le Models
762
Gti Rfi and Gti Le Rfi Models
765
Xp DI Model
768
Rxp 4-Tec Models
772
Gtx 4-Tec Models
778
Wiring Diagram
784
Wiring Diagrams
784
Wire Color Codes
784
Wire Digit Codes
784
Deutsch Connectors
784
Packard Connector
787
Amp Plug Connector
787
Identification of Connector Pins
790
Ecm Connectors
791
Main Fuse Holder Joint Connector
794
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SeaDoo GTI LE RFI Manual (391 pages)
Brand:
SeaDoo
| Category:
Boat
| Size: 41.46 MB
Table of Contents
Table of Contents
4
Safety Notice
11
Introduction
12
General Information
12
Arrangement of this Manual, Illustrations and Procedures
13
List of Abbreviations Used in this Manual
16
Engine Emissions Information
16
Self-Locking Fasteners Procedure
17
Loctite ® Application Procedure
17
Tightening Torques
20
Maintenance
22
Maintenance Chart
22
Preseason Preparation
26
Storage Procedures
28
Fuel System
28
Oil Injection System
28
Propulsion System
29
Engine and Exhaust System
29
Electrical System
38
Hull/Body
38
Checklist
39
Special Procedures
40
Towing the Watercraft in Water
40
Submerged Watercraft
41
Water-Flooded Engine
41
Capsized Engine
43
Fuel-Flooded Engine
43
Troubleshooting
45
Troubleshooting Chart
45
Engine will Not Start
45
Engine Hard to Start
48
Engine Starts but Runs Only at Idle Speed
48
Engine Starts but Runs Only on One Cylinder (Rfi Models)
48
Engine Runs on both Cylinders at Idle after Engine Is Warm-Up (Rfi Models)
49
Engine Misfires, Runs Irregularly
49
Engine Continually Backfires
51
Engine Detonation or Pinging
51
Engine Lacks Acceleration or Power
52
Engine Stops Running
53
Engine Cannot Reach Maximum Rpm
53
Engine Overheats
54
Vehicle Cannot Reach Its Top Speed
54
O.t.a.s. System Faults
54
Abnormal Noise from Propulsion System
55
Steering Pole Is Heavier than Usual (3D Series)
55
Steering Pole Is Stiffer than Usual (3D Series)
55
Engine System
56
Air Intake System
56
General
59
Removal
59
Assembly
59
Exhaust System
61
Gti Series
62
General
64
Removal
64
Repair
66
Installation
66
3D Series
69
General
70
Removal
70
Repair
73
Installation
73
Removal and Installation
76
General
76
Procedures
76
Engine Removal
76
Cleaning
81
Installation
81
Alignment Shaft
83
Plate
84
PTO Flywheel Adapter
85
Lubrication System
88
Oil Injection System
88
Part Number
88
Service Products
88
Small Hose Pincher
88
General
91
Oil System Pressurization
91
Oil Injection Pump
93
Loctite 243 (Blue)
93
Assembly
96
Cleaning
96
Disassembly
96
Oil Pump Identification
96
Removal
96
Adjustment
97
Checking Operation
99
Fuel System
101
Carburetor
101
General
103
Removal
103
Cleaning
103
Inspection
104
Assembly
106
Installation
108
Adjustments
109
Fuel Tank and Fuel Pump
111
General
115
Testing Procedures
116
Removal
118
Inspection
121
Installation
123
Engine Management (Rfi)
124
Overview
124
Engine Management System (Ems)
124
General
125
Operating Principle
125
Air Induction
125
Fuel System
125
Electrical System
127
Engine Management
130
Electronic Fuel Injection
130
Ignition Timing
130
Rave Valve Activation
130
Other Engine Management Functions
131
Engine Management System Flow Chart
131
Diagnostic Procedures
132
General
132
Engine Management System Fault Codes
132
Vck (Vehicle Communication Kit)
137
Component Adjustment, Inspection and Replacement
139
General
139
Adjustment
143
Idle Speed
143
Throttle Cable
143
Throttle Position Sensor (Tps)
145
Testing Procedures
145
Fuel Pump
145
Fuel Injector
146
Throttle Position Sensor (Tps)
149
Throttle Body
150
Crankshaft Position Sensor (Cps)
150
Air Temperature Sensor (Ats)
151
Water Temperature Sensor (Wts)
151
Air Pressure Sensor (Aps)
152
Rave Solenoid
153
Parts Replacement
154
Ecm and VCM
154
Throttle Position Sensor (Tps)
155
Air Temperature Sensor (Ats)
156
Air Pressure Sensor (Aps)
156
Water Temperature Sensor (Wts)
156
Crankshaft Position Sensor (Cps)
156
Fuel Injectors
156
Electrical System
158
Ignition System
158
717 Engine
158
General
158
Adjustment
159
Ignition Timing
159
Testing Procedures
163
Spark Plugs
163
Generating Coil
163
Multi-Purpose Electronic Module (Mpem)
164
Ignition Coil
164
787 Rfi Engine
166
General
167
Adjustment
168
Ignition Timing
168
Testing Procedures
172
Ignition Coil
172
Vehicle Control Module (VCM)
173
Engine Control Module (Ecm)
174
Spark Plugs
174
Charging System
178
717 Engine
178
General
178
Testing Procedures
180
Battery
180
Rectifier/Regulator
180
Battery Charging Coil
180
787 Rfi Engine
182
General
183
Testing Procedures
184
Battery
184
Rectifier/Regulator
184
Stator
185
Battery
188
Starting System
193
Electric Starter Exploded View
194
Starting System Electrical Diagram
196
Starting System Troubleshooting Chart
197
General
198
Testing Procedures
198
Removal
202
Disassembly
202
Cleaning
202
Inspection
202
Assembly
203
Installation
205
Starter Specification
206
Instruments and Accessories
207
General
207
Fuses
207
Multi-Purpose Electronic Module (Mpem)
208
Information Center
210
Testing Procedures
212
Power Supply Cut-Off Relay
212
Information Center
213
Indicator Light Cluster
218
Fuel Gauge/Low Oil Warning Light
219
Fuel Level Sender
219
Oil Sensor
221
Speedometer
222
Speed Sensor
222
Electric Bilge Pump
222
Digitally Encoded Security System (Dess)
224
General
224
Self-Diagnostic Mode
225
Dess Key Programming
226
Cooling System
230
Components and Circuit
230
Circuit
237
Components
239
Propulsion
244
Jet Pump
244
General
246
Jet Pump Inspection on Watercraft
246
Removal
248
Disassembly
248
Cleaning
250
Parts Inspection
251
Assembly
253
Pump Pressurization
259
Installation
260
Drive System
262
Gti Series
263
General
264
Removal
266
Inspection
266
Installation
268
Lubrication
268
3D Series
269
General
270
Removal
270
Inspection
271
Assembly
273
Installation
275
Lubrication
277
Reverse System
278
Disassembly
280
Inspection
282
Assembly
282
Adjustment
283
Variable Trim System
284
Removal
286
Disassembly
286
Inspection
286
Assembly
287
Installation
287
Steering System
288
1 Steeringsystem
289
Gti Series
289
Disassembly
290
Assembly
293
Steering Alignment
295
3D Series
297
Inspection
299
Disassembly
299
Assembly
307
Steering Alignment
313
Off-Power Assisted Steering (Opas)
315
General
317
Procedures
317
Off-Throttle Assisted Steering (O.t.a.s.)
321
General
321
Testing Procedures
321
Adjustment
322
11 Hull/Body
325
Gti Series
325
General
330
Procedures
330
Glove Box
330
Seat
331
Storage Compartment Inner Shell
331
Storage Cover Shock
332
Storage Compartment Cover
333
Mirror
333
Inlet Grate
334
Riding Plate
334
Jet Pump Support
335
Drain Plug
336
Seat Cover
336
Bumper
336
Sponson
337
Sponson Adaptor
337
Bailer Pick-Ups
337
Thru-Hull Fitting
338
Decals Replacement
339
Hull and Body Repair
340
Tools and Materials List
342
3D Series
343
General
349
Procedures
349
Moto Seat (if so Equipped)
349
Kart Seat (if so Equipped)
351
Bilge Vent Tubes
351
Rear Access Cover
352
Engine Cover Inner Shell
352
Inlet Grate
352
Riding Plate
353
Jet Pump Support
353
Drain Plug
354
Bumper
355
Sponson
355
Bailer Pick-Ups
356
Thru-Hull Fitting
356
Decals Replacement
357
Hull and Body Repair
358
Tools and Materials List
361
Technical Specifications
362
Gti Models
362
Gti Rfi and Gti Rfi Le Models
364
3D Rfi Model
366
Electrical Connectors and Wiring Diagrams
369
Electrical Connectors
369
Deutsch Connectors
369
Packard Connector
370
Amp Connector
371
Ecm Connectors
374
VCM Connectors
378
Battery and Starter Cable Connectors
380
Wiring Diagrams
382
Wire Color Codes
382
Wire Digit Codes
382
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