Seadoo 3D - 3D Premium 2-Strokes 2005 Shop Service Repair Ma

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

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Seadoo 3D - 3D Premium 2-Strokes 2005 Shop Service Repair Ma

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