2005 Seadoo 3D 2-Strokes Service & Repair Manual

2005 Vehicle Shop Manual 2-Stroke Models

Legal deposit: National Library of Quebec National Library of Canada 2005 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) © Bombardier Recreational Products Inc. (BRP) 2005 Technical Publications Bombardier Recreational Products Inc. (BRP) Valcourt (Québec) Canada Printed in Canada ®TM and BRP logo are trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates. * Trademark of Bombardier Inc. used under license. SEA-DOO ® BOMBARDIER-ROTAX ® BOMBARDIER LUBE ® Sea-Doo ® Learning Key TM DESS TM Rotax ® O.P.A.S. TM TOPS TM This document contains the trademarks of the following companies: Knight’s Spray-Nine † is a trademark of Korkay System Ltd Loctite ® is a trademark of Loctite Corporation Snap-on ® is a trademark of Snap-on Tools Corporation Gelcote ® is a trademark of Gelcote International Limited Molykote © is a trademark of Dow Corning Corporation AMP © is a trademark of Tyco Electronics Corporation

TABLE OF CONTENTS SAFETY NOTICE .................................................................................. VIII INTRODUCTION ................................................................................... IX GENERAL INFORMATION......................................................................................... IX ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES ............................. X LIST OF ABBREVIATIONS USED IN THIS MANUAL ......................................................... XIII ENGINE EMISSIONS INFORMATION .......................................................................... XIII SELF-LOCKING FASTENERS PROCEDURE ................................................................... XIV LOCTITE ® APPLICATION PROCEDURE ........................................................................ XIV TIGHTENING TORQUES ........................................................................................ XVII 01 MAINTENANCE 01 – MAINTENANCE CHART ....................................................................................... 1 02 – PRESEASON PREPARATION ................................................................................. 5 03 – STORAGE PROCEDURES ..................................................................................... 7 FUEL SYSTEM......................................................................................................... 7 OIL INJECTION SYSTEM ............................................................................................. 7 PROPULSION SYSTEM............................................................................................... 8 ENGINE AND EXHAUST SYSTEM ................................................................................... 8 ELECTRICAL SYSTEM ............................................................................................... 17 HULL/BODY .......................................................................................................... 17 CHECKLIST ........................................................................................................... 18 04 – SPECIAL PROCEDURES ..................................................................................... 19 TOWING THE WATERCRAFT IN WATER........................................................................... 19 SUBMERGED WATERCRAFT ....................................................................................... 20 WATER-FLOODED ENGINE ......................................................................................... 20 CAPSIZED ENGINE .................................................................................................. 22 FUEL-FLOODED ENGINE ........................................................................................... 22 02 TROUBLESHOOTING 01 – TROUBLESHOOTING CHART .............................................................................. 25 ENGINE WILL NOT START .......................................................................................... 25 ENGINE HARD TO START ........................................................................................... 28 ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED .............................................................. 28 ENGINE STARTS BUT RUNS ONLY ON ONE CYLINDER (RFI MODELS) ....................................... 28 ENGINE RUNS ON BOTH CYLINDERS AT IDLE AFTER ENGINE IS WARM-UP (RFI MODELS) .............. 29 ENGINE MISFIRES, RUNS IRREGULARLY......................................................................... 29 ENGINE CONTINUALLY BACKFIRES ............................................................................... 31 ENGINE DETONATION OR PINGING ............................................................................... 31 ENGINE LACKS ACCELERATION OR POWER .................................................................... 32 ENGINE STOPS RUNNING .......................................................................................... 33 ENGINE CANNOT REACH MAXIMUM RPM ...................................................................... 33 ENGINE OVERHEATS ................................................................................................ 34 VEHICLE CANNOT REACH ITS TOP SPEED ....................................................................... 34 O.T.A.S. SYSTEM FAULTS ........................................................................................... 34 ABNORMAL NOISE FROM PROPULSION SYSTEM.............................................................. 35 STEERING POLE IS HEAVIER THAN USUAL (3D SERIES) ....................................................... 35 STEERING POLE IS STIFFER THAN USUAL (3D SERIES) ........................................................ 35 03 ENGINE SYSTEM 01 – AIR INTAKE SYSTEM ........................................................................................ 37 GENERAL ............................................................................................................. 40 I

TABLE OF CONTENTS REMOVAL ............................................................................................................ 40 ASSEMBLY ........................................................................................................... 40 02 – EXHAUST SYSTEM.......................................................................................... 43 GTI SERIES .................................................................................................... 44 GENERAL ............................................................................................................. 46 REMOVAL ............................................................................................................ 46 REPAIR ................................................................................................................ 48 INSTALLATION ....................................................................................................... 48 3D SERIES ..................................................................................................... 51 GENERAL ............................................................................................................. 52 REMOVAL ............................................................................................................ 52 REPAIR ................................................................................................................ 55 INSTALLATION ....................................................................................................... 55 03 – REMOVAL AND INSTALLATION........................................................................... 59 GENERAL ...................................................................................................... 59 PROCEDURES ................................................................................................ 59 ENGINE REMOVAL .................................................................................................. 59 CLEANING ............................................................................................................ 64 INSTALLATION ....................................................................................................... 64 04 LUBRICATION SYSTEM 01 – OIL INJECTION SYSTEM ................................................................................... 71 GENERAL ............................................................................................................. 74 OIL SYSTEM PRESSURIZATION .................................................................................... 74 02 – OIL INJECTION PUMP....................................................................................... 77 OIL PUMP IDENTIFICATION ........................................................................................ 80 REMOVAL ............................................................................................................ 80 DISASSEMBLY ....................................................................................................... 80 CLEANING ............................................................................................................ 80 ASSEMBLY ........................................................................................................... 80 ADJUSTMENT ........................................................................................................ 81 CHECKING OPERATION ............................................................................................. 83 05 FUEL SYSTEM 01 – CARBURETOR ................................................................................................ 85 GENERAL ............................................................................................................. 87 REMOVAL ............................................................................................................ 87 CLEANING ............................................................................................................ 87 INSPECTION.......................................................................................................... 88 ASSEMBLY ........................................................................................................... 90 INSTALLATION ....................................................................................................... 92 ADJUSTMENTS ...................................................................................................... 93 02 – FUEL TANK AND FUEL PUMP ............................................................................. 95 GENERAL ............................................................................................................. 99 TESTING PROCEDURES .......................................................................................... 100 REMOVAL .......................................................................................................... 102 INSPECTION........................................................................................................ 105 INSTALLATION ..................................................................................................... 107 06 ENGINE MANAGEMENT (RFI) 01 – OVERVIEW ................................................................................................... 109 ENGINE MANAGEMENT SYSTEM (EMS)........................................................................ 109 II

TABLE OF CONTENTS GENERAL ..................................................................................................... 110 OPERATING PRINCIPLE .................................................................................... 110 AIR INDUCTION .................................................................................................... 110 FUEL SYSTEM...................................................................................................... 110 ELECTRICAL SYSTEM ............................................................................................. 112 ENGINE MANAGEMENT .................................................................................. 115 ELECTRONIC FUEL INJECTION .................................................................................. 115 IGNITION TIMING .................................................................................................. 115 RAVE VALVE ACTIVATION ......................................................................................... 115 OTHER ENGINE MANAGEMENT FUNCTIONS.................................................................. 116 ENGINE MANAGEMENT SYSTEM FLOW CHART .............................................................. 116 02 – DIAGNOSTIC PROCEDURES ............................................................................. 117 GENERAL ........................................................................................................... 117 ENGINE MANAGEMENT SYSTEM FAULT CODES.............................................................. 117 VCK (VEHICLE COMMUNICATION KIT) .......................................................................... 122 03 – COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT ................................ 125 GENERAL ..................................................................................................... 125 ADJUSTMENT ............................................................................................... 129 IDLE SPEED ........................................................................................................ 129 THROTTLE CABLE ................................................................................................. 129 THROTTLE POSITION SENSOR (TPS)............................................................................ 131 TESTING PROCEDURES ................................................................................... 131 FUEL PUMP ........................................................................................................ 131 FUEL INJECTOR ................................................................................................... 132 THROTTLE POSITION SENSOR (TPS)............................................................................ 135 THROTTLE BODY .................................................................................................. 136 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 136 AIR TEMPERATURE SENSOR (ATS) .............................................................................. 137 WATER TEMPERATURE SENSOR (WTS) ........................................................................ 137 AIR PRESSURE SENSOR (APS) ................................................................................... 138 RAVE SOLENOID................................................................................................... 139 PARTS REPLACEMENT..................................................................................... 140 ECM AND VCM .................................................................................................... 140 THROTTLE POSITION SENSOR (TPS)............................................................................ 141 AIR TEMPERATURE SENSOR (ATS) .............................................................................. 142 AIR PRESSURE SENSOR (APS) ................................................................................... 142 WATER TEMPERATURE SENSOR (WTS) ........................................................................ 142 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 142 FUEL INJECTORS .................................................................................................. 142 07 ELECTRICAL SYSTEM 01 – IGNITION SYSTEM ......................................................................................... 145 717 ENGINE .................................................................................................. 145 GENERAL ..................................................................................................... 145 ADJUSTMENT ............................................................................................... 146 IGNITION TIMING .................................................................................................. 146 TESTING PROCEDURES ................................................................................... 150 SPARK PLUGS ...................................................................................................... 150 GENERATING COIL ................................................................................................ 150 MULTI-PURPOSE ELECTRONIC MODULE (MPEM) ............................................................ 151 IGNITION COIL ..................................................................................................... 151 787 RFI ENGINE ............................................................................................. 153 III

TABLE OF CONTENTS GENERAL ..................................................................................................... 154 ADJUSTMENT ............................................................................................... 155 IGNITION TIMING ................................................................................................. 155 TESTING PROCEDURES ................................................................................... 159 IGNITION COIL ..................................................................................................... 159 VEHICLE CONTROL MODULE (VCM) ............................................................................ 160 ENGINE CONTROL MODULE (ECM) ............................................................................. 161 SPARK PLUGS ...................................................................................................... 161 02 – CHARGING SYSTEM ....................................................................................... 165 717 ENGINE .................................................................................................. 165 GENERAL ..................................................................................................... 165 TESTING PROCEDURES ................................................................................... 167 BATTERY ............................................................................................................ 167 RECTIFIER/REGULATOR .......................................................................................... 167 BATTERY CHARGING COIL ....................................................................................... 167 787 RFI ENGINE ............................................................................................. 169 GENERAL ..................................................................................................... 170 TESTING PROCEDURES ................................................................................... 171 BATTERY ............................................................................................................ 171 RECTIFIER/REGULATOR .......................................................................................... 171 STATOR ............................................................................................................. 172 BATTERY ............................................................................................................ 175 03 – STARTING SYSTEM ........................................................................................ 181 ELECTRIC STARTER EXPLODED VIEW .......................................................................... 182 STARTING SYSTEM ELECTRICAL DIAGRAM ................................................................... 184 STARTING SYSTEM TROUBLESHOOTING CHART ............................................................. 185 GENERAL ........................................................................................................... 186 TESTING PROCEDURES .......................................................................................... 186 REMOVAL .......................................................................................................... 190 DISASSEMBLY ..................................................................................................... 190 CLEANING .......................................................................................................... 190 INSPECTION........................................................................................................ 190 ASSEMBLY ......................................................................................................... 191 INSTALLATION ..................................................................................................... 193 STARTER SPECIFICATION ........................................................................................ 194 04 – INSTRUMENTS AND ACCESSORIES .................................................................... 195 GENERAL ..................................................................................................... 195 FUSES............................................................................................................... 195 MULTI-PURPOSE ELECTRONIC MODULE (MPEM) ............................................................ 196 INFORMATION CENTER .......................................................................................... 198 TESTING PROCEDURES ................................................................................... 200 POWER SUPPLY CUT-OFF RELAY ............................................................................... 200 INFORMATION CENTER .......................................................................................... 201 INDICATOR LIGHT CLUSTER ..................................................................................... 206 FUEL GAUGE/LOW OIL WARNING LIGHT ...................................................................... 207 FUEL LEVEL SENDER ............................................................................................. 207 OIL SENSOR........................................................................................................ 209 SPEEDOMETER .................................................................................................... 210 SPEED SENSOR.................................................................................................... 210 ELECTRIC BILGE PUMP ........................................................................................... 210 05 – DIGITALLY ENCODED SECURITY SYSTEM (DESS) ................................................... 213 GENERAL ........................................................................................................... 213 IV

TABLE OF CONTENTS SELF-DIAGNOSTIC MODE ........................................................................................ 214 DESS KEY PROGRAMMING ...................................................................................... 215 08 COOLING SYSTEM 01 – COMPONENTS AND CIRCUIT ............................................................................ 219 CIRCUIT ............................................................................................................. 226 COMPONENTS ..................................................................................................... 228 09 PROPULSION 01 – JET PUMP .................................................................................................... 233 GENERAL ........................................................................................................... 235 JET PUMP INSPECTION ON WATERCRAFT..................................................................... 235 REMOVAL .......................................................................................................... 237 DISASSEMBLY ..................................................................................................... 237 CLEANING .......................................................................................................... 239 PARTS INSPECTION ............................................................................................... 240 ASSEMBLY ......................................................................................................... 242 PUMP PRESSURIZATION ......................................................................................... 248 INSTALLATION ..................................................................................................... 249 02 – DRIVE SYSTEM.............................................................................................. 251 GTI SERIES ................................................................................................... 252 GENERAL ........................................................................................................... 253 REMOVAL .......................................................................................................... 255 INSPECTION........................................................................................................ 255 INSTALLATION ..................................................................................................... 257 LUBRICATION ...................................................................................................... 257 3D SERIES .................................................................................................... 258 GENERAL ........................................................................................................... 259 REMOVAL .......................................................................................................... 259 INSPECTION........................................................................................................ 260 ASSEMBLY ......................................................................................................... 262 INSTALLATION ..................................................................................................... 264 LUBRICATION ...................................................................................................... 266 03 – REVERSE SYSTEM ......................................................................................... 267 DISASSEMBLY ..................................................................................................... 269 INSPECTION........................................................................................................ 271 ASSEMBLY ......................................................................................................... 271 ADJUSTMENT ...................................................................................................... 272 04 – VARIABLE TRIM SYSTEM ................................................................................. 273 REMOVAL .......................................................................................................... 275 DISASSEMBLY ..................................................................................................... 275 INSPECTION........................................................................................................ 275 ASSEMBLY ......................................................................................................... 276 INSTALLATION ..................................................................................................... 276 10 STEERING SYSTEM 01 – STEERING SYSTEM ........................................................................................ 277 GTI SERIES ................................................................................................... 278 DISASSEMBLY ..................................................................................................... 279 ASSEMBLY ......................................................................................................... 282 STEERING ALIGNMENT ........................................................................................... 284 3D SERIES .................................................................................................... 286 V

TABLE OF CONTENTS INSPECTION........................................................................................................ 288 DISASSEMBLY ..................................................................................................... 288 ASSEMBLY ......................................................................................................... 296 STEERING ALIGNMENT ........................................................................................... 302 02 – OFF-POWER ASSISTED STEERING (OPAS) ............................................................ 305 GENERAL ........................................................................................................... 307 PROCEDURES...................................................................................................... 307 03 – OFF-THROTTLE ASSISTED STEERING (O.T.A.S.) ..................................................... 311 GENERAL ........................................................................................................... 311 TESTING PROCEDURES .......................................................................................... 311 ADJUSTMENT ...................................................................................................... 312 11 HULL/BODY 01 – GTI SERIES ................................................................................................... 315 GENERAL ..................................................................................................... 320 PROCEDURES ............................................................................................... 320 GLOVE BOX ........................................................................................................ 320 SEAT................................................................................................................. 321 STORAGE COMPARTMENT INNER SHELL ..................................................................... 321 STORAGE COVER SHOCK ........................................................................................ 322 STORAGE COMPARTMENT COVER ............................................................................. 323 MIRROR ............................................................................................................ 323 INLET GRATE ....................................................................................................... 324 RIDING PLATE ...................................................................................................... 324 JET PUMP SUPPORT .............................................................................................. 325 DRAIN PLUG ....................................................................................................... 326 SEAT COVER ....................................................................................................... 326 BUMPER ............................................................................................................ 326 SPONSON .......................................................................................................... 327 SPONSON ADAPTOR.............................................................................................. 327 BAILER PICK-UPS .................................................................................................. 327 THRU-HULL FITTING .............................................................................................. 328 DECALS REPLACEMENT.......................................................................................... 329 HULL AND BODY REPAIR......................................................................................... 330 TOOLS AND MATERIALS LIST ................................................................................... 332 02 – 3D SERIES .................................................................................................... 333 GENERAL ..................................................................................................... 339 PROCEDURES ............................................................................................... 339 MOTO SEAT (IF SO EQUIPPED) .................................................................................. 339 KART SEAT (IF SO EQUIPPED) ................................................................................... 341 BILGE VENT TUBES ............................................................................................... 341 REAR ACCESS COVER ............................................................................................ 342 ENGINE COVER INNER SHELL ................................................................................... 342 INLET GRATE ....................................................................................................... 342 RIDING PLATE ...................................................................................................... 343 JET PUMP SUPPORT .............................................................................................. 343 DRAIN PLUG ....................................................................................................... 344 BUMPER ............................................................................................................ 345 SPONSON .......................................................................................................... 345 BAILER PICK-UPS .................................................................................................. 346 THRU-HULL FITTING .............................................................................................. 346 DECALS REPLACEMENT.......................................................................................... 347 VI

TABLE OF CONTENTS HULL AND BODY REPAIR......................................................................................... 348 TOOLS AND MATERIALS LIST ................................................................................... 351 12 TECHNICAL SPECIFICATIONS 01 – GTI MODELS ................................................................................................. 353 02 – GTI RFI AND GTI RFI LE MODELS ........................................................................ 355 03 – 3D RFI MODEL ............................................................................................... 357 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS 01 – ELECTRICAL CONNECTORS .............................................................................. 361 DEUTSCH CONNECTORS......................................................................................... 361 PACKARD CONNECTOR .......................................................................................... 362 AMP CONNECTOR ................................................................................................ 363 ECM CONNECTORS ............................................................................................... 366 VCM CONNECTORS ............................................................................................... 370 BATTERY AND STARTER CABLE CONNECTORS ............................................................... 372 02 – WIRING DIAGRAMS ........................................................................................ 375 WIRE COLOR CODES ............................................................................................. 375 WIRE DIGIT CODES ............................................................................................... 375 VII

2005 Seadoo 3D 2-Strokes Service & Repair Manual

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