2005 SeaDoo 4-TEC, GTX, RXP, RXT, WAKE Shop Manual

www.SeaDooManuals.net

2005 Vehicle Shop Manual 4-TEC Series www.SeaDooManuals.net

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 (Quebec) Canada Printed in Canada ®TM Registered 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 GTX † is a trademark of Castrol Ltd. Used under license Loctite ® is a trademark of Loctite Corporation Snap-on ® is a trademark of Snap-on Tools Corporation Gelcote ® is a trademark of Gelcote International Limited Molykote © is a trademark of Dow Corning Corporation AMP © is a trademark of Tyco Electronics Corporation www.SeaDooManuals.net

TABLE OF CONTENTS SAFETY NOTICE ................................................................................... VI INTRODUCTION ................................................................................... VII GENERAL INFORMATION......................................................................................... VII ARRANGEMENT OF THIS MANUAL ........................................................................... VIII ABBREVIATIONS USED IN THIS MANUAL ................................................................... VIII ILLUSTRATIONS AND PROCEDURES .......................................................................... IX ENGINE EMISSIONS INFORMATION ........................................................................... XII SELF-LOCKING FASTENERS PROCEDURE .................................................................... XII LOCTITE APPLICATION PROCEDURE .......................................................................... XIII TIGHTENING TORQUES ......................................................................................... XVI 01 MAINTENANCE 01 – MAINTENANCE CHART ....................................................................................... 1 02 – PRESEASON PREPARATION ................................................................................. 3 03 – STORAGE PROCEDURES ..................................................................................... 5 PROPULSION SYSTEM............................................................................................... 5 FUEL SYSTEM......................................................................................................... 5 ENGINE OIL AND FILTER REPLACEMENT ......................................................................... 5 OPENED LOOP COOLING SYSTEM ................................................................................ 5 CLOSED LOOP COOLING SYSTEM (ENGINE) ..................................................................... 8 ENGINE LUBRICATION ............................................................................................... 8 THROTTLE BODY LUBRICATION.................................................................................... 8 ANTIFREEZING PROTECTION ....................................................................................... 8 BATTERY ............................................................................................................... 9 WATERCRAFT CLEANING............................................................................................ 9 ANTICORROSION TREATMENT ..................................................................................... 9 CHECKLIST ........................................................................................................... 10 04 – SPECIAL PROCEDURES ..................................................................................... 11 TOWING THE WATERCRAFT IN WATER........................................................................... 11 SUBMERGED WATERCRAFT ....................................................................................... 12 WATER-FLOODED ENGINE ......................................................................................... 12 02 TROUBLESHOOTING 01 – TROUBLESHOOTING CHART .............................................................................. 15 ENGINE WILL NOT START .......................................................................................... 15 ENGINE HARD TO START ........................................................................................... 17 ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED .............................................................. 18 ENGINE MISFIRES, RUNS IRREGULARLY......................................................................... 18 ENGINE CONTINUALLY BACKFIRES ............................................................................... 19 ENGINE DETONATION OR PINGING ............................................................................... 19 ENGINE LACKS ACCELERATION OR POWER .................................................................... 20 ENGINE STOPS RUNNING .......................................................................................... 20 ENGINE CANNOT REACH MAXIMUM RPM ...................................................................... 21 ENGINE RUNS TOO FAST (VEHICLE CANNOT REACH ITS TOP SPEED)....................................... 21 ENGINE OVERHEATS ................................................................................................ 22 ENGINE SMOKE IN THE EXHAUST ................................................................................ 22 LOW OR NO ENGINE OIL PRESSURE ............................................................................. 23 ENGINE OIL CONTAMINATION (MILKY) ........................................................................... 23 UNUSUAL ENGINE NOISE AND/OR VIBRATION ................................................................. 24 INAPPROPRIATE SPEEDOMETER READING ..................................................................... 24 ABNORMAL NOISE FROM PROPULSION SYSTEM.............................................................. 24 I www.SeaDooManuals.net

TABLE OF CONTENTS 03 ENGINE SYSTEM 01 – AIR INTAKE SYSTEM ........................................................................................ 27 INSPECTION.......................................................................................................... 30 REMOVAL ............................................................................................................ 30 INSTALLATION ....................................................................................................... 31 02 – LUBRICATION SYSTEM ..................................................................................... 33 GENERAL ............................................................................................................. 33 OIL LEVEL VERIFICATION........................................................................................... 33 OIL CHANGE ......................................................................................................... 34 OIL TYPE AND SYSTEM CAPACITY ................................................................................ 35 OIL FILTER ............................................................................................................ 35 03 – COOLING SYSTEM .......................................................................................... 37 CLOSED LOOP COOLING SYSTEM (ENGINE) .......................................................... 38 CIRCUIT ............................................................................................................... 39 COOLING SYSTEM LEAK TEST..................................................................................... 39 INSPECTION.......................................................................................................... 40 COOLANT REPLACEMENT ......................................................................................... 40 CARE .................................................................................................................. 42 TECHNICAL SPECIFICATIONS ...................................................................................... 42 OPENED LOOP COOLING SYSTEM (EXHAUST SYSTEM) ............................................ 43 CIRCUIT ............................................................................................................... 45 CARE .................................................................................................................. 46 TECHNICAL SPECIFICATIONS ...................................................................................... 47 04 – EXHAUST SYSTEM.......................................................................................... 49 EXHAUST PIPE ....................................................................................................... 51 EXHAUST MANIFOLD ............................................................................................... 54 MUFFLER ............................................................................................................. 55 RESONATOR ......................................................................................................... 56 EXHAUST OUTLET ................................................................................................... 56 05 – REMOVAL AND INSTALLATION........................................................................... 59 ENGINE REMOVAL .................................................................................................. 59 CLEANING ............................................................................................................ 63 INSTALLATION ....................................................................................................... 63 04 ENGINE MANAGEMENT (1503 4-TEC) 01 – OVERVIEW .................................................................................................... 67 OPERATING PRINCIPLE ..................................................................................... 68 AIR INDUCTION ...................................................................................................... 68 FUEL SYSTEM........................................................................................................ 70 ELECTRICAL SYSTEM ............................................................................................... 70 ENGINE MANAGEMENT SYSTEM (EMS) ............................................................... 72 EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS......................................................... 74 02 – DIAGNOSTIC PROCEDURES ............................................................................... 79 GENERAL ............................................................................................................. 79 SELF-DIAGNOSTIC MODE .......................................................................................... 81 ENGINE MANAGEMENT SYSTEM FAULT CODES................................................................ 82 VCK (VEHICLE COMMUNICATION KIT) .......................................................................... 105 03 – COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT ................................ 107 GENERAL ..................................................................................................... 107 FUEL SYSTEM...................................................................................................... 107 ELECTRICAL SYSTEM ............................................................................................. 108 TESTING PROCEDURES ................................................................................... 111 II www.SeaDooManuals.net

TABLE OF CONTENTS IDLE SPEED ........................................................................................................ 111 IGNITION TIMING .................................................................................................. 111 SAFETY LANYARD SWITCH VERIFICATION ..................................................................... 111 ECM AND MPEM .................................................................................................. 112 ENGINE WIRING HARNESS....................................................................................... 113 FUEL INJECTOR ................................................................................................... 115 THROTTLE BODY .................................................................................................. 117 THROTTLE POSITION SENSOR (TPS)............................................................................ 120 IDLE BYPASS VALVE ............................................................................................... 122 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 122 CAMSHAFT POSITION SENSOR (CAPS)......................................................................... 123 MANIFOLD AIR TEMPERATURE SENSOR (MATS) ............................................................. 124 COOLANT TEMPERATURE SENSOR (CTS) ...................................................................... 125 MANIFOLD AIR PRESSURE SENSOR (MAPS) .................................................................. 125 EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................................................... 126 KNOCK SENSOR (KS) .............................................................................................. 127 OIL PRESSURE SENSOR (OPS) .................................................................................. 128 TOPS VALVE ........................................................................................................ 128 OIL SEPARATOR PRESSURE SENSOR (OSPS) ................................................................. 129 TOPS SWITCH...................................................................................................... 130 05 FUEL SYSTEM 01 – FUEL TANK AND FUEL PUMP ............................................................................ 133 GENERAL ........................................................................................................... 135 REMOVAL .......................................................................................................... 136 INSPECTION........................................................................................................ 137 INSTALLATION ..................................................................................................... 139 TESTING PROCEDURES .......................................................................................... 140 06 ELECTRICAL SYSTEM 01 – IGNITION SYSTEM ......................................................................................... 145 GENERAL ........................................................................................................... 147 QUICK TEST WITH B.U.D.S....................................................................................... 147 VOLTAGE TEST ..................................................................................................... 147 IGNITION COIL ..................................................................................................... 148 SPARK PLUGS ...................................................................................................... 149 IGNITION TIMING ................................................................................................. 149 02 – CHARGING SYSTEM ....................................................................................... 151 GENERAL ..................................................................................................... 153 TESTING PROCEDURE ..................................................................................... 153 RECTIFIER/REGULATOR .......................................................................................... 154 STATOR ............................................................................................................. 155 BATTERY ............................................................................................................ 157 03 – STARTING SYSTEM ........................................................................................ 163 STARTING SYSTEM TROUBLESHOOTING ...................................................................... 166 GENERAL ........................................................................................................... 167 STARTER REMOVAL ............................................................................................... 168 STARTER DISASSEMBLY.......................................................................................... 168 STARTER CLEANING .............................................................................................. 169 STARTER INSPECTION ............................................................................................ 170 STARTER ASSEMBLY.............................................................................................. 170 STARTER INSTALLATION ......................................................................................... 170 III www.SeaDooManuals.net

TABLE OF CONTENTS STARTER SPECIFICATION ........................................................................................ 171 04 – INSTRUMENTS AND ACCESSORIES .................................................................... 173 GENERAL ........................................................................................................... 173 COMPONENT DESCRIPTION ..................................................................................... 173 PROCEDURES...................................................................................................... 177 07 PROPULSION 01 – JET PUMP .................................................................................................... 183 GENERAL ........................................................................................................... 186 JET PUMP INSPECTION ON WATERCRAFT..................................................................... 186 REMOVAL .......................................................................................................... 187 DISASSEMBLY ..................................................................................................... 190 CLEANING .......................................................................................................... 193 PARTS INSPECTION ............................................................................................... 193 ASSEMBLY ......................................................................................................... 194 PUMP PRESSURIZATION ......................................................................................... 199 INSTALLATION ..................................................................................................... 199 02 – DRIVE SYSTEM.............................................................................................. 203 GENERAL ........................................................................................................... 205 REMOVAL .......................................................................................................... 205 INSPECTION........................................................................................................ 208 INSTALLATION ..................................................................................................... 209 LUBRICATION ...................................................................................................... 213 03 – REVERSE SYSTEM ......................................................................................... 215 DISASSEMBLY ..................................................................................................... 217 INSPECTION........................................................................................................ 219 ASSEMBLY ......................................................................................................... 219 ADJUSTMENT ...................................................................................................... 219 04 – VARIABLE TRIM SYSTEM ................................................................................. 221 GENERAL ........................................................................................................... 223 REMOVAL .......................................................................................................... 223 DISASSEMBLY ..................................................................................................... 223 INSPECTION........................................................................................................ 224 ASSEMBLY ......................................................................................................... 224 INSTALLATION ..................................................................................................... 224 ADJUSTMENT ...................................................................................................... 225 08 STEERING SYSTEM 01 – STEERING SYSTEM ........................................................................................ 227 DISASSEMBLY ..................................................................................................... 229 ASSEMBLY ......................................................................................................... 234 ALIGNMENT ........................................................................................................ 236 02 – OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.) .............................................. 239 GENERAL ........................................................................................................... 242 SIDE VANE .......................................................................................................... 242 CYLINDER SUPPORT .............................................................................................. 243 TIE ROD............................................................................................................. 246 SEALED TUBE...................................................................................................... 246 FILTER............................................................................................................... 247 VALVE ............................................................................................................... 247 WATER HOSE ...................................................................................................... 248 CROSS SUPPORT PLATE ......................................................................................... 248 IV www.SeaDooManuals.net

TABLE OF CONTENTS 09 HULL/BODY 01 – ADJUSTMENT AND REPAIR .............................................................................. 251 GENERAL ........................................................................................................... 262 GLOVE BOX ........................................................................................................ 262 ENGINE COVER .................................................................................................... 263 SEAT ADJUSTMENT ............................................................................................... 263 STORAGE COMPARTMENT INNER SHELL ..................................................................... 264 STORAGE COVER SHOCK ........................................................................................ 269 STORAGE COMPARTMENT COVER ADJUSTMENT ........................................................... 270 MIRROR ............................................................................................................ 270 CLUSTER ........................................................................................................... 271 DEFLECTOR AND/OR UPPER GRID.............................................................................. 271 SIDE MOLDING .................................................................................................... 272 INLET GRATE ....................................................................................................... 272 RIDING PLATE ...................................................................................................... 273 JET PUMP SUPPORT .............................................................................................. 274 DRAIN PLUG INSTALLATION ..................................................................................... 275 SEAT COVER REPLACEMENT .................................................................................... 276 BUMPER REPLACEMENT......................................................................................... 276 WAKE PYLON ...................................................................................................... 276 SPONSON REPLACEMENT ....................................................................................... 278 SPONSON ADAPTOR.............................................................................................. 278 BAILER PICK-UPS INSPECTION .................................................................................. 278 DECALS REPLACEMENT.......................................................................................... 279 HULL AND BODY REPAIR......................................................................................... 280 TOOLS AND MATERIALS LIST ................................................................................... 282 10 TECHNICAL SPECIFICATIONS 01 – GTX, WAKE AND GTX SC MODELS ..................................................................... 283 02 – GTX LIMITED AND RXT MODELS........................................................................ 287 03 – RXP MODELS ................................................................................................ 291 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS 01 – ELECTRICAL CONNECTORS .............................................................................. 295 DEUTSCH CONNECTORS......................................................................................... 295 PACKARD CONNECTOR .......................................................................................... 298 AMP CONNECTOR ................................................................................................ 298 ECM CONNECTORS ............................................................................................... 302 BATTERY AND STARTER CABLE TERMINALS .................................................................. 305 02 – WIRING DIAGRAMS ........................................................................................ 307 WIRE COLOR CODES ............................................................................................. 307 WIRE DIGIT CODES ............................................................................................... 307 V www.SeaDooManuals.net

SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 2005 SEA-DOO watercraft as describe in the model list in the INTRODUCTION. This edition was primarily published to be used by watercraft mechanical technicians who are already fa- miliar with all service procedures relating to BRP made watercraft. Mechanical technicians should attend training courses given by BRP Training Dept. Please note that the instructions will apply only if proper hand tools and special service tools are used. This VEHICLE SHOP MANUAL uses technical terms which may be slightly different from the ones used in the Parts Catalog. It is understood that this manual may be translated into another language. In the event of any discrepan- cy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser- vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts. The use of BRP parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document.  WARNING Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair procedures. This manual emphasizes particular information denoted by the wording and symbols:  WARNING Identifies an instruction which, if not followed, could cause serious personal injury including pos- sibility of death. CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations. VI smr2005-002 www.SeaDooManuals.net

INTRODUCTION INTRODUCTION GENERAL INFORMATION This VEHICLE SHOP MANUAL covers the following BRP made SEA-DOO ® 2005 watercraft models. It should be used in conjunction with the 1503 4-TEC ENGINE SHOP MANUAL. MODEL COLOR ENGINE MODEL NUMBER GTX Twilight Blue Pearl 1503 Naturally Aspirated 145A, 145B GTX Limited Midnight Black Pearl 1503 Supercharged Intercooled 185A, 185B GTX Supercharged Twilight Blue Pearl 1503 Supercharged 165A RXP Apple Green 1503 Supercharged Intercooled 215A, 215B RXP Viper Red Metallic 1503 Supercharged Intercooled 215C, 215D RXT Apple Green 1503 Supercharged Intercooled 175A, 175B RXT Viper Red Metallic 1503 Supercharged Intercooled 175C, 175D WAKE Viper Red 1503 Naturally Aspirated 155A, 155B The use of RIGHT (starboard) and LEFT (port) indi- cations in the text, always refers to driving position (when sitting on watercraft). Besides, in the marine industry, FRONT is called BOW and REAR is called STERN. F01L45B 1 2 1. Left (port) 2. Right (starboard) The information and component/system descrip- tions contained in this manual are correct at time of writing. BRP however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. BRP reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This VEHICLE SHOP MANUAL uses technical terms which may be different from the ones of the PARTS CATALOGS. When ordering parts always refer to the specific model PARTS CATALOGS. Hull Identification Number (H.I.N.) The Hull Identification Number is composed of 12 digits:         smr05-002-001_aen smr2005-002 VII www.SeaDooManuals.net

2005 SeaDoo 4-TEC, GTX, RXP, RXT, WAKE Shop Manual

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