SEA-DOO 4-TEC Series GTI GTX RXP RXT BOAT Workshop Manual

www.SeaDooManuals.net

2004 Shop Manual GTI, GTI LE, GTI RFI, GTI LE RFI, XP DI GTX 4-TEC /Supercharged /Limited Supercharged /Wakeboard Edition RXP 4-TEC Supercharged BOMBARDIER RECREATIONAL PRODUCTS INC. www.SeaDooManuals.net

Legal deposit: National Library of Quebec National Library of Canada 2004 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. © Bombardier Recreational Products Inc. 2004 Technical Publications Bombardier Recreational Products Inc. Valcourt (Quebec) Canada Printed in Canada ®TM Registered trademarks of Bombardier Recreational Products Inc. or its affiliates. † Bombardier and sprocket design are trademarks of Bombardier Inc, used under license. SEA-DOO ® BOMBARDIER-ROTAX ® BOMBARDIER LUBE ® BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil BOMBARDIER Formula XP-S DI Synthetic Injection Oil BOMBARDIER-ROTAX Injection Oil Sea-Doo Synthetic Grease Sea-Doo LK 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 Snap-on © is a trademark of Snap-on Tools Corporation AMP © is a trademark of Tyco Electronics Corporation www.SeaDooManuals.net

TABLE OF CONTENTS SAFETY NOTICE .................................................................................. XII INTRODUCTION .................................................................................. XIII HULL IDENTIFICATION NUMBER (H.I.N.) ..................................................................... XIII ENGINE IDENTIFICATION NUMBER (E.I.N.) .................................................................. XIV ARRANGEMENT OF THIS MANUAL ........................................................................... XV LIST OF ABBREVIATIONS USED IN THIS MANUAL ....................................................... XVIII GENERAL INFORMATION...................................................................................... XVIII ILLUSTRATIONS AND PROCEDURES ......................................................................... XIX ENGINE EMISSIONS INFORMATION .......................................................................... XIX SELF-LOCKING FASTENERS PROCEDURE ................................................................... XX LOCTITE APPLICATION PROCEDURE .......................................................................... XX THREADLOCKER .................................................................................................. XX STRIPPED THREAD REPAIR ..................................................................................... XXI GASKET COMPOUND ........................................................................................... XXII MOUNTING ON SHAFT ......................................................................................... XXII CASE-IN COMPONENTS ....................................................................................... XXIII TIGHTENING TORQUES ....................................................................................... XXIV 01 SERVICE TOOLS AND PRODUCTS 01 – MANDATORY SERVICE TOOLS ............................................................................. 1 ENGINE ................................................................................................................ 1 COOLING/FUEL/OIL SYSTEMS ...................................................................................... 5 PROPULSION SYSTEM............................................................................................... 6 STEERING SYSTEM................................................................................................... 8 02 – OPTIONAL SERVICE TOOLS ................................................................................ 9 ENGINE ................................................................................................................ 9 COOLING/FUEL/OIL SYSTEMS ..................................................................................... 14 PROPULSION SYSTEM.............................................................................................. 14 BODY.................................................................................................................. 15 WATERCRAFT HANDLING .......................................................................................... 15 03 – SERVICE PRODUCTS ....................................................................................... 17 02 MAINTENANCE 01 – PERIODIC INSPECTION CHART............................................................................ 21 02 – FLUSHING AND LUBRICATION............................................................................ 27 GENERAL ............................................................................................................. 27 PROCEDURE ......................................................................................................... 27 ANTICORROSION TREATMENT .................................................................................... 32 03 – WATER-FLOODED ENGINE ................................................................................. 33 GENERAL ............................................................................................................. 33 PROCEDURE ......................................................................................................... 33 04 – STORAGE ..................................................................................................... 39 ENGINE DRAINING .................................................................................................. 39 PROPULSION SYSTEM.............................................................................................. 40 FUEL SYSTEM........................................................................................................ 41 ENGINE OIL CHANGE AND FILTER ................................................................................ 41 COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION ...................................... 41 ENGINE LUBRICATION .............................................................................................. 41 BATTERY .............................................................................................................. 42 WATERCRAFT CLEANING........................................................................................... 42 ADDITIONAL RECOMMENDED PROTECTION ................................................................... 42 I www.SeaDooManuals.net

TABLE OF CONTENTS ANTICORROSION TREATMENT .................................................................................... 48 CHECKLIST ........................................................................................................... 48 03 TROUBLESHOOTING 01 – TROUBLESHOOTING CHART .............................................................................. 49 ENGINE WILL NOT START .......................................................................................... 49 ENGINE HARD TO START ........................................................................................... 52 ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED .............................................................. 52 ENGINE MISFIRES, RUNS IRREGULARLY......................................................................... 53 ENGINE CONTINUALLY BACKFIRES ............................................................................... 55 ENGINE DETONATION OR PINGING ............................................................................... 55 ENGINE LACKS ACCELERATION OR POWER .................................................................... 56 ENGINE STOPS RUNNING .......................................................................................... 57 ENGINE CANNOT REACH MAXIMUM RPM ...................................................................... 57 ENGINE RUNS TOO FAST (VEHICLE CANNOT REACH ITS TOP SPEED)....................................... 58 ENGINE OVERHEATS ................................................................................................ 58 O.P.A.S. SYSTEM FAULTS (GTX 4-TEC MODELS)................................................................. 59 ENGINE SMOKE IN THE EXHAUST (4-TEC SERIES) .............................................................. 59 LOW OR NO ENGINE OIL PRESSURE (4-TEC SERIES) .......................................................... 60 ENGINE OIL CONTAMINATION (MILKY) (4-TEC SERIES) ........................................................ 60 UNUSUAL ENGINE NOISE AND/OR VIBRATION (4-TEC SERIES) ............................................... 61 ABNORMAL NOISE FROM PROPULSION SYSTEM.............................................................. 61 04 ENGINE (2-STROKE) 01 – LEAK TEST .................................................................................................... 63 GENERAL ............................................................................................................. 63 PREPARATION ....................................................................................................... 63 TESTING PROCEDURE .............................................................................................. 63 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART .................................................................. 69 02 – REMOVAL AND INSTALLATION........................................................................... 71 GENERAL ............................................................................................................. 71 ENGINE REMOVAL .................................................................................................. 71 CLEANING ............................................................................................................ 76 INSTALLATION ....................................................................................................... 76 03 – MAGNETO SYSTEM......................................................................................... 83 DISASSEMBLY ....................................................................................................... 86 CLEANING ............................................................................................................ 93 ASSEMBLY ........................................................................................................... 93 04 – TOP END....................................................................................................... 99 GENERAL ........................................................................................................... 102 DISASSEMBLY ..................................................................................................... 104 CLEANING .......................................................................................................... 111 INSPECTION........................................................................................................ 112 USED PISTON MEASUREMENT.................................................................................. 113 ASSEMBLY ......................................................................................................... 116 ADJUSTMENT ...................................................................................................... 125 05 – BOTTOM END ............................................................................................... 129 DISASSEMBLY ..................................................................................................... 132 CLEANING .......................................................................................................... 139 INSPECTION........................................................................................................ 140 ASSEMBLY ......................................................................................................... 144 II www.SeaDooManuals.net

TABLE OF CONTENTS 06 – ROTARY VALVE ............................................................................................. 153 GENERAL ........................................................................................................... 154 INSPECTION ON WATERCRAFT .................................................................................. 154 DISASSEMBLY ..................................................................................................... 155 CLEANING .......................................................................................................... 157 INSPECTION........................................................................................................ 157 ASSEMBLY ......................................................................................................... 158 ROTARY VALVE TIMING ........................................................................................... 162 07 – EXHAUST SYSTEM......................................................................................... 165 REMOVAL .......................................................................................................... 168 TUNED PIPE REPAIR .............................................................................................. 174 INSTALLATION ..................................................................................................... 174 05 ENGINE (4-TEC) 01 – LEAK TEST ................................................................................................... 181 LEAK TEST PROCEDURE .................................................................................. 181 PREPARATION ..................................................................................................... 181 PROCEDURE ....................................................................................................... 182 INSTALLATION ..................................................................................................... 183 LEAK TEST PROCEDURE FOR INTERCOOLER ......................................................... 184 02 – INTAKE SYSTEM ............................................................................................ 185 INSPECTION........................................................................................................ 189 REMOVAL .......................................................................................................... 191 DISASSEMBLY ..................................................................................................... 198 ASSEMBLY ......................................................................................................... 201 INSTALLATION ..................................................................................................... 205 03 – EXHAUST SYSTEM......................................................................................... 209 EXHAUST PIPE ..................................................................................................... 210 EXHAUST MANIFOLD ............................................................................................. 213 MUFFLER ........................................................................................................... 214 RESONATOR ....................................................................................................... 214 EXHAUST OUTLET ................................................................................................. 215 04 – REMOVAL AND INSTALLATION.......................................................................... 217 GENERAL ........................................................................................................... 217 ENGINE REMOVAL ................................................................................................ 217 CLEANING .......................................................................................................... 221 INSTALLATION ..................................................................................................... 221 05 – PTO HOUSING/MAGNETO................................................................................ 225 GENERAL ........................................................................................................... 226 PTO HOUSING ..................................................................................................... 226 PTO SEAL ........................................................................................................... 229 COUPLING .......................................................................................................... 229 STATOR ............................................................................................................. 230 ROTOR AND ENCODER WHEEL ................................................................................. 231 RING GEAR ......................................................................................................... 231 STARTER DRIVE ASS'Y ............................................................................................ 232 OIL SPRAY NOZZLE ............................................................................................... 233 06 – LUBRICATION SYSTEM .................................................................................... 235 GENERAL ........................................................................................................... 237 OIL LEVEL VERIFICATION......................................................................................... 237 ENGINE OIL PRESSURE TEST .................................................................................... 238 OIL FILTER .......................................................................................................... 240 III www.SeaDooManuals.net

TABLE OF CONTENTS OIL STRAINERS .................................................................................................... 241 ENGINE OIL PRESSURE REGULATOR ........................................................................... 244 OIL PRESSURE PUMP............................................................................................. 245 OIL SUCTION PUMP............................................................................................... 248 OIL COOLER ....................................................................................................... 251 OIL SEPARATOR ................................................................................................... 252 07 – CYLINDER HEAD AND VALVES........................................................................... 255 GENERAL ........................................................................................................... 256 SPARK PLUG ....................................................................................................... 256 VALVE COVER ...................................................................................................... 256 ROCKER ARM ...................................................................................................... 257 CAMSHAFT TIMING GEAR........................................................................................ 260 TIMING CHAIN ..................................................................................................... 262 CYLINDER HEAD................................................................................................... 262 CAMSHAFT ......................................................................................................... 263 VALVE SPRING ..................................................................................................... 265 VALVE ............................................................................................................... 266 08 – ENGINE BLOCK.............................................................................................. 273 GENERAL ........................................................................................................... 275 CRANKSHAFT LOCKING .......................................................................................... 275 CRANKSHAFT ...................................................................................................... 275 TIMING CHAIN ..................................................................................................... 279 CHAIN TENSIONER ................................................................................................ 280 BALANCER SHAFT................................................................................................. 280 ENGINE BLOCK .................................................................................................... 283 PISTON/CONNECTING ROD ...................................................................................... 288 PISTON RINGS ..................................................................................................... 294 06 ENGINE MANAGEMENT (RFI) 01 – OVERVIEW ................................................................................................... 297 AIR INDUCTION ............................................................................................. 298 FUEL DELIVERY ............................................................................................. 298 FUEL PUMP ........................................................................................................ 298 FUEL PRESSURE REGULATOR ................................................................................... 298 FUEL FILTERS ...................................................................................................... 298 FUEL PUMP MODULE ............................................................................................ 299 FUEL INJECTORS .................................................................................................. 299 ELECTRONIC MANAGEMENT ............................................................................ 299 ELECTRONIC CONTROL UNIT (ECU) ............................................................................ 299 MPEM (MULTI-PURPOSE ELECTRONIC MODULE) ............................................................ 300 02 – DIAGNOSTIC PROCEDURES ............................................................................. 303 INTRODUCTION.................................................................................................... 303 SELF-DIAGNOSTIC MODE ........................................................................................ 303 ADVANCED DIAGNOSTIC ......................................................................................... 303 FAULT CODE TABLES ............................................................................................. 305 03 – COMPONENT INSPECTION .............................................................................. 307 GENERAL ..................................................................................................... 307 AIR INDUCTION SYSTEM ................................................................................. 309 THROTTLE BODY .................................................................................................. 309 FUEL DELIVERY ............................................................................................. 309 FUEL FILTER........................................................................................................ 309 FUEL PUMP ........................................................................................................ 309 IV www.SeaDooManuals.net

TABLE OF CONTENTS REGULATOR........................................................................................................ 309 FUEL INJECTOR ................................................................................................... 310 LEAK TEST (SUPPLY AND VENTILATION CIRCUITS) ........................................................... 311 HIGH PRESSURE TEST (FUEL PUMP CIRCUIT) ................................................................. 311 ELECTRONIC MANAGEMENT ............................................................................ 312 THROTTLE POSITION SENSOR (TPS)............................................................................ 312 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 313 AIR TEMPERATURE SENSOR (ATS) .............................................................................. 314 WATER TEMPERATURE SENSOR (WTS) ........................................................................ 314 AIR PRESSURE SENSOR (APS) ................................................................................... 315 RAVE SOLENOID................................................................................................... 316 RFI SENSORS RESISTANCE VALUES ............................................................................ 317 04 – TROUBLESHOOTING SUMMARY........................................................................ 319 ENGINE DOES NOT START ............................................................................... 319 FLOODED ENGINE FEATURE ............................................................................. 319 SPARK PLUG INSPECTION ................................................................................ 319 ECU FAULT CODES ......................................................................................... 319 ENGINE STARTS BUT RUNS POORLY .................................................................. 319 ENGINE RUNS ONLY ON ONE CYLINDER.............................................................. 319 ENGINE CANNOT REACH MAXIMUM REVOLUTIONS............................................... 320 05 – ADJUSTMENT ............................................................................................... 321 THROTTLE CABLE ADJUSTMENT ....................................................................... 321 THROTTLE POSITION SENSOR (TPS) ................................................................... 321 CLOSED TPS ....................................................................................................... 321 IDLE SPEED ........................................................................................................ 321 06 – REMOVAL AND INSTALLATION ......................................................................... 323 MPEM/ECU ................................................................................................... 323 THROTTLE POSITION SENSOR (TPS) ................................................................... 323 AIR TEMPERATURE SENSOR (ATS) ..................................................................... 323 AIR PRESSURE SENSOR (APS)........................................................................... 323 WATER TEMPERATURE SENSOR (WTS) ............................................................... 323 CRANKSHAFT POSITION SENSOR (CPS) .............................................................. 323 FUEL PUMP ASSEMBLY ................................................................................... 323 REGULATOR........................................................................................................ 324 FUEL FILTER........................................................................................................ 324 FUEL INJECTORS ........................................................................................... 324 07 ENGINE MANAGEMENT (DI) 01 – OVERVIEW ................................................................................................... 327 OPERATING PRINCIPLE .................................................................................... 327 AIR INDUCTION ............................................................................................. 327 AIR COMPRESSOR SYSTEM.............................................................................. 327 FUEL DELIVERY SYSTEM.................................................................................. 327 BASIC OPERATION ................................................................................................ 327 AIR/FUEL RAIL ASSEMBLY ....................................................................................... 328 FUEL PUMP MODULE ............................................................................................ 328 ELECTRONIC MANAGEMENT ............................................................................ 329 MPEM (MULTI-PURPOSE ELECTRONIC MODULE) ............................................................ 329 MPEM — ENGINE MANAGEMENT FUNCTIONS ............................................................... 332 IGNITION SYSTEM................................................................................................. 334 02 – COMPONENT INSPECTION AND ADJUSTMENT ..................................................... 335 GENERAL ..................................................................................................... 335 V www.SeaDooManuals.net

TABLE OF CONTENTS FUEL SYSTEM...................................................................................................... 335 ELECTRICAL SYSTEM ............................................................................................. 336 AMP CONNECTOR PIN-OUT...................................................................................... 337 QUICK FUEL PRESSURE TEST ........................................................................... 337 AIR INDUCTION SYSTEM ................................................................................. 339 THROTTLE BODY .................................................................................................. 339 AIR COMPRESSOR ......................................................................................... 342 PRESSURE TEST ................................................................................................... 342 REPAIR .............................................................................................................. 343 FUEL DELIVERY ............................................................................................. 346 FUEL PRESSURE REGULATOR ................................................................................... 346 FUEL INJECTOR ................................................................................................... 348 AIR/FUEL RAIL ..................................................................................................... 349 DIRECT INJECTOR................................................................................................. 350 FUEL PUMP ........................................................................................................ 352 FUEL FILTERS ..................................................................................................... 354 ELECTRONIC MANAGEMENT ............................................................................ 357 MPEM REPLACEMENT ........................................................................................... 357 THROTTLE POSITION SENSOR (TPS)............................................................................ 358 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 360 MANIFOLD AIR TEMPERATURE SENSOR (MATS) ............................................................. 362 WATER TEMPERATURE SENSOR (WTS) ........................................................................ 362 MANIFOLD AIR PRESSURE SENSOR (MAPS) .................................................................. 363 EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................................................... 364 KNOCK SENSOR (KS) .............................................................................................. 364 RAVE SOLENOID................................................................................................... 365 IGNITION COIL ..................................................................................................... 366 IGNITION TIMING .................................................................................................. 368 SPARK PLUGS ...................................................................................................... 372 CRANKING SYSTEM ............................................................................................... 373 DI SYSTEM TEST SUMMARY..................................................................................... 373 03 – DIAGNOSTIC PROCEDURES .............................................................................. 377 GENERAL ..................................................................................................... 377 FAULT DETECTION AND COMPENSATORY ACTIONS ............................................... 379 COMPONENT FAILURE WARNING SYSTEM.................................................................... 379 VCK (VEHICLE COMMUNICATION KIT) ................................................................. 381 DI SYSTEM FAULT CODES ................................................................................ 382 08 ENGINE MANAGEMENT (4-TEC) 01 – OVERVIEW ................................................................................................... 391 COMPLETE ELECTRICAL SYSTEM OVERVIEW ........................................................ 391 MAGNETO SYSTEM AND POWER SUPPLY ............................................................ 393 OPERATING PRINCIPLE OF ENGINE MANAGEMENT ................................................ 393 AIR INDUCTION ............................................................................................. 393 FUEL DELIVERY SYSTEM.................................................................................. 394 BASIC OPERATION ................................................................................................ 394 FUEL PUMP MODULE ............................................................................................ 396 ELECTRONIC MANAGEMENT ............................................................................ 396 EMS (ENGINE MANAGEMENT SYSTEM)........................................................................ 396 EMS — GENERAL FUNCTIONS .................................................................................. 397 EMS — ENGINE MANAGEMENT FUNCTIONS ................................................................. 399 MPEM — MULTI-PURPOSE ELECTRONIC MODULE .......................................................... 402 VI www.SeaDooManuals.net

TABLE OF CONTENTS 02 – COMPONENT INSPECTION AND ADJUSTMENT ..................................................... 403 GENERAL ..................................................................................................... 403 FUEL SYSTEM...................................................................................................... 403 ELECTRICAL SYSTEM ............................................................................................. 404 ENGINE CONNECTOR PIN-OUT .................................................................................. 405 CONNECTORS ON ENGINE....................................................................................... 406 AIR INDUCTION SYSTEM ................................................................................. 407 THROTTLE BODY .................................................................................................. 407 FUEL DELIVERY ............................................................................................. 411 FUEL PUMP ........................................................................................................ 412 FUEL FILTER ....................................................................................................... 414 FUEL RAIL .......................................................................................................... 414 FUEL INJECTOR ................................................................................................... 415 ELECTRONIC MANAGEMENT ............................................................................ 417 ECM AND MPEM REPLACEMENT .............................................................................. 417 ENGINE WIRING HARNESS....................................................................................... 419 THROTTLE POSITION SENSOR (TPS)............................................................................ 421 IDLE BYPASS VALVE ............................................................................................... 423 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 424 CAMSHAFT POSITION SENSOR (CAPS)......................................................................... 425 MANIFOLD AIR TEMPERATURE SENSOR (MATS) ............................................................. 426 COOLANT TEMPERATURE SENSOR (CTS) ...................................................................... 427 MANIFOLD AIR PRESSURE SENSOR (MAPS) .................................................................. 428 EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................................................... 429 KNOCK SENSOR (KS) .............................................................................................. 429 OIL PRESSURE SENSOR (OPS) .................................................................................. 431 OIL SEPARATOR PRESSURE SENSOR (OSPS) ................................................................. 431 TOPS VALVE (BLOW-BY) .......................................................................................... 433 IGNITION COILS ................................................................................................... 436 IGNITION TIMING .................................................................................................. 437 ENGINE START/STOP SWITCH VERIFICATION ................................................................. 437 SAFETY LANYARD SWITCH VERIFICATION ..................................................................... 437 SPARK PLUGS ...................................................................................................... 438 CRANKING SYSTEM ............................................................................................... 438 03 – DIAGNOSTIC PROCEDURES .............................................................................. 439 GENERAL ........................................................................................................... 439 SELF-DIAGNOSTIC MODE................................................................................. 441 VCK (VEHICLE COMMUNICATION KIT) ................................................................. 443 4-TEC SYSTEM FAULT CODES ........................................................................... 444 4-TEC SYSTEM FAULT CODES CHART .......................................................................... 447 BURNT FUSE AND RELATED FAULT CODE ..................................................................... 465 09 COOLING SYSTEM 01 – CIRCUIT, COMPONENTS AND CARE .................................................................... 467 CIRCUIT ............................................................................................................. 473 COMPONENTS ..................................................................................................... 476 CARE ................................................................................................................ 480 CIRCUIT ............................................................................................................. 488 COOLING SYSTEM LEAK TEST................................................................................... 488 INSPECTION........................................................................................................ 490 DRAINING THE SYSTEM .......................................................................................... 490 CLEANING .......................................................................................................... 490 VII www.SeaDooManuals.net

SEA-DOO 4-TEC Series GTI GTX RXP RXT BOAT Workshop Manual

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