SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to cor-
rectly service and repair Sea-Doo® watercraft.
This edition was primarily published to be used
by technicians who are already familiar with all
service procedures relating to BRP products.
Mechanical technicians should attend training
courses given by BRPTI.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
The contents of this manual depicts parts and pro-
cedures applicable to the particular product at the
time of writing. Service and Warranty Bulletins
may be published to update the content of this
manual. Dealer modifications that were carried
out after manufacturing of the product, whether
or not authorized by BRP, are not included.
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 ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended 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.
It is understood that certain modifications may
render use of the watercraft illegal under existing
federal, provincial and state regulations.
This manual emphasizes particular information de-
noted by the following wording and symbols:
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
CAUTION Indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE Indicates an instruction which, if not
followed, could result in severe damage to ve-
hicle components or other property.
NOTE: Indicates supplementary information re-
quired to fully complete an instruction.
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Although the mere reading of such information
does not eliminate the hazard, your understanding
of the information will promote its correct use.
Always observe common shop safety practice.
Unless otherwise noted, the engine must be
stopped and the tether cord must be removed
prior to perform any services.
Before carrying out any inspection or maintenance
procedure on the watercraft, wait until the engine
and exhaust have cooled down to avoid potential
burns.
Torque wrench tightening specifications must be
strictly adhered to. Use the torque values and ser-
vice products as in the exploded views or in the
procedures when noted.
Locking devices when removed must be replaced
(e.g.: locking tabs, elastic stop nuts, self-locking
fasteners, cotter pins, etc.).
Hoses, cables and locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
When ordering parts always refer to the specific
model PARTS CATALOG.
We strongly recommend that any services be car-
ried out and/or verified by a highly skilled profes-
sional mechanic.
It is understood that this manual may be trans-
lated into another language. In the event of any
discrepancy, the English version shall prevail.
BRP disclaims liability for all damages and/or in-
juries resulting from the improper use of the con-
tents.
I
INTRODUCTION

INTRODUCTION
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.
Due to late changes, there may be some differ-
ences between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
219100941-005-001_a

TYPICAL - GTI, GTR, GTS AND WAKE 155

VEHICLE INFORMATION 1. Hull Identification Number (HIN)

HULL IDENTIFICATION NUMBER

(HIN)
The hull identification number is composed of
12 digits:
YDV 12345 L 4 95
Model year
Year of production
Month of production
Serial number (a letter may also be used as a digit)
Manufacturer
219001840-029_a

TYPICAL - RXP-X
It is located on the deck at the rear of watercraft. 1. Hull Identification Number (HIN)

ENGINE IDENTIFICATION
NUMBER (EIN)
The Engine Identification Number is located on
front end of the engine.

smr2014-005-003_a

TYPICAL - SPARK
1. Hull Identification Number (HIN)

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219001840-033_a
TYPICAL - 130, 155, 230 AND 300
1. Engine Identification Number (EIN)
smo2014-005-094_a
TYPICAL - 900 ACE
1. Engine Identification Number (EIN)
HOISTING A WATERCRAFT
To work on a watercraft, you should mount it se-
curely on a stand.
The LIFTING STRAP (P/N 529 036 189) MUST be
used to hoist and mount the watercraft on a
stand.
NOTICE Using any other lifting strap kit than
the one recommended may cause damage to
the vehicle. Bumpers could be torn off.
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INTRODUCTION
sbl2009-004-003
TYPICAL
ENGINE EMISSIONS
INFORMATION
Manufacturer's Responsibility
Manufacturers of engines must determine the
exhaust emission levels for each engine horse-
power family and certify these engines with
the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
engine specifications, must be placed on each
vehicle at the time of manufacture.
Dealer Responsibility
When servicing any vehicle that carry an emis-
sions control information label, adjustments must
be kept within published factory specifications.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturers' prescribed
changes, such as altitude adjustments.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
III
INTRODUCTION

The owner/operator is not to, and should not al-

low anyone else to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.

Emission Regulations
The vehicle you are servicing may have been
certified to applicable emission regulations in
your country or state. Not as an exhaustive list;
this may include standards for engine exhaust
emissions, crankcase emissions, permeation smr2009-011-002_a
emissions and evaporative emissions. Servic- TYPICAL
ing procedures in this manual must be strictly 1. Left (port)
2. Right (starboard)
followed in order to keep the vehicle within the
factory specifications. Failure to follow servicing Other common terms used in the marine indus-
procedures in this manual may lead a vehicle to try are the BOW (front of the watercraft), and the
be out of compliance with applicable emission STERN (rear of the watercraft).
regulations.
This manual uses technical terms which may be
When servicing any vehicle; adjustments must be different from the ones in the PARTS CATALOGS.
kept within published factory specifications. Re-
placement or repair of any emission related com-
ponent must be executed in a manner that main- MANUAL LAYOUT
tains emission levels within the applicable certifi- This manual is divided into many major sections as
cation standards. Nobody is allowed to modify the can be seen in the main table of contents at the
engine in any manner that would alter the horse- beginning of the manual.
power or allow emission levels to exceed their
Each section is divided into various subsections,
predetermined factory specifications. Exceptions
and again, each subsection has one or more divi-
include manufacturer’s prescribed changes.
sions.
The owner/operator is required to have engine
Illustrations and photos show the typical construc-
maintenance performed to maintain emission lev-
tion of various assemblies and, in all cases, may
els within the prescribed certification standards.
not reproduce the full detail or exact shape of the
The owner/operator is allowed and should not
parts used in a particular model vehicle. However,
allow anyone else to modify the engine in any
they represent parts which have the same or a
manner that would alter the horsepower or allow
similar function.
emissions levels to exceed their predetermined
factory specifications.

MANUAL INFORMATION
MANUAL PROCEDURES
Many of the procedures in this manual are inter-
related. Before undertaking any task, you should
read and thoroughly understand the entire section
or subsection in which the procedure is contained.
A number of procedures throughout the book
require the use of special tools. Before com-
mencing any procedure, be sure that you have
on hand all the tools required, or their approved
equivalents.
The use of RIGHT (starboard) and LEFT (port) in-
dications in the text are always referenced to the
driving position (when sitting on the watercraft).
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 INTRODUCTION

TYPICAL PAGE

Section 06 ENGINE Page heading

Subsection 01 (MAGNETO) indicates section
and subsection.

Subsection title MAGNETO

Indicates applicable Models
models.

Loctite 243 Drop represents a

service product
Exploded view assists Model
to be applied.
you in identifying parts
and their related Dotted box contains
positions. parts applicable to a
specific model.

Bold face number

1 is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced NEW
with a new one.

5 N•m
(44 lbf•in)

Illustration number
for publishing process. XXX0000

Document number for 55 Page number

publishing process.
mmr2008-001

NOTICE Pay attention to torque specifications.

Some of these are in lbf in instead of lbf ft.
Use appropriate torque wrench.
Typical_iso_2008_en

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INTRODUCTION

TYPICAL PAGE

Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be GENERAL
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker. Re-
specific section fer to the SELF-LOCKING FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. “TYPICAL”
WARNING indicates a general
Torque wrench tightening specifications
view which may
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic 1 details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYPICAL
1. Starting pulley

PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component neto flywheel with a socket as shown. to above illustration.
procedures apply to. MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific a clean cloth. Illustration always
procedure to be Magneto Flywheel Removal follows text to which
carried out. Remove muffler, refer to the EXHAUST SYSTEM it applies.
section.
Remove acoustic panel.
Remove rewind starter. mmr2007-016-002

Remove starting pulley no. 2. TYPICAL Italic bold face type-

Models
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
model(s).

mmr2008-001 57

Bold face number following part

name refers to exploded view
at beginning of subsection.
typical_txt_2008_en

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 INTRODUCTION

TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, the torque normally recommended for a specific fastener should be used. Refer
to the following table.

WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock-
ing fasteners, cotter pins, etc.).

In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
NOTICE Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: Whenever possible, always apply torque on the nut.
3. Tighten fastener to the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (e.g. a cylinder head). Some parts must be torqued according to a specific se-
quence and torque pattern as detailed in the installation procedure.

4.8 8.8 9.8 10.9 12.9

Property
class and
head 4.8 8.8 9.8 10.9 12.9
markings
4.8 8.8 9.8 10.9 12.9 12.9

5 8 10 12
Property
class and
12
10

nut
5

markings
A00A8BS

FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 N•m - 2 N•m 2.5 N•m - 3 N•m 3.5 N•m - 4 N•m 4 N•m - 5 N•m
M4
(13 lbf•in - 18 lbf•in) (22 lbf•in - 27 lbf•in) (31 lbf•in - 35 lbf•in) (35 lbf•in - 44 lbf•in)
3 N•m - 3.5 N•m 4.5 N•m - 5.5 N•m 7 N•m - 8.5 N•m 8 N•m - 10 N•m
M5
(27 lbf•in - 31 lbf•in) (40 lbf•in - 49 lbf•in) (62 lbf•in - 75 lbf•in) (71 lbf•in - 89 lbf•in)
6.5 N•m - 8.5 N•m 8 N•m - 12 N•m 10.5 N•m - 15 N•m
M6 16 N•m (142 lbf•in)
(58 lbf•in - 75 lbf•in) (71 lbf•in - 106 lbf•in) (93 lbf•in - 133 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (24 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (54 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 128 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)

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INTRODUCTION
FASTENER INFORMATION
NOTICE Most fasteners are metric. Mis-
matched or incorrect fasteners could cause
damage to the vehicle.
SELF-LOCKING FASTENER
PROCEDURE
A00A6LA
TYPICAL — SELF-LOCKING FASTENER
The following describes common procedures
used when working with self-locking fasteners.
Use a metal brush or a tap to clean the hole prop-
erly, then use a solvent. Allow the solvent time
to act, approximately 30 minutes, then wipe off.
Solvent utilization is to ensure proper adhesion of
the product used for locking the fastener.
LOCTITE® APPLICATION
PROCEDURE
The following describes common procedures
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
NOTICE When applying threadlocker prod-
ucts (anaerobic products), pay attention to
prevent the product from coming into contact
with ABS plastic parts (painted parts).
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Threadlocker Application for
Uncovered Holes (Bolts and Nuts)
1
2
A00A3LA
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
on threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Threadlocker Application for Blind
Holes
1
2
lmr2007-040-004_a
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
on threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
219100941-005
 INTRODUCTION

4. Apply several drops along the threaded hole Threadlocker Application for
and at the bottom of the hole. Pre-Assembled Parts
5. Apply several drops on bolt threads.
6. Tighten as required.

Threadlocker Application for Stud

Installation in Blind Holes 1

1 3

2
A00A3OA

1. Apply here
lmr2007-040-005_a 2. Do not apply
1. On stud threads
2. On threads and in the hole 1. Clean bolts and nuts with solvent.
3. On retaining nut threads
2. Assemble components.
1. Clean threads (stud and hole) with solvent. 3. Tighten nuts.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041) 4. Apply a few drops of proper strength Loctite on
on threads and allow to dry. bolt/nut contact surfaces.
3. Put 2 or 3 drops of proper strength Loctite 5. Avoid touching metal with tip of flask.
threadlocker on female threads and in hole.
NOTE: For preventive maintenance on exist-
NOTE: To avoid a hydro lock situation, do not ap- ing equipment, retighten nuts and apply proper
ply too much Loctite. strength Loctite on bolt/nut contact surfaces.
4. Apply several drops of proper strength Loctite
on stud threads. Threadlocker Application for an
5. Install stud. Adjustment Screw
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on 2
1
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.

A00A3PA

1. Apply here
2. Plunger

1. Adjust screw to proper setting.

2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.

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INTRODUCTION

NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

a soldering iron (232°C (450°F)).

Application for Stripped Thread Repair 1 2

5
1
6
8
2
1

A00A3QA 4 7
1. Release agent
2. Stripped threads 1 3
3. Form-A-Thread
lmr2007-040-006_a
4. Tape
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only

Standard Thread Repair
Follow instructions on Loctite FORM-A-THREAD
81668 package.
If a plate is used to align bolt:
1. Apply release agent on mating surfaces.
2. Put waxed paper or similar film on the surfaces.
3. Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow
STANDARD THREAD REPAIR procedure.
Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole.
Permanent Stud Installation (Light Duty)
1. Use a stud of the desired thread length.
2. DO NOT apply release agent on stud.
3. Follow Standard Thread Repair procedure.
4. Allow 30 minutes for Loctite FORM-A-THREAD
to cure.
5. Complete part assembly.
1. Remove old gasket and other contaminants us-
ing LOCTITE CHISEL (GASKET REMOVER) (P/N 413
708 500). Use a mechanical means only if nec-
essary.
NOTE: Avoid grinding.
2. Clean both mating surfaces with solvent.
3. Spray Loctite Primer N on both mating surfaces
and on both sides of gasket and allow to dry 1
or 2 minutes.
4. Apply LOCTITE 518 (P/N 293 800 038) on both
sides of gasket, using a clean applicator.
5. Place gasket on mating surfaces and assemble
parts immediately.
NOTE: If the cover is bolted to blind holes, apply
proper strength Loctite in the hole and on threads.
Tighten fastener.
If holes are sunken, apply proper strength Loctite
on bolt threads.
6. Tighten as usual.

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 INTRODUCTION

Threadlocker Application for Mounting Threadlocker Application for Case-In

on a Shaft Components (Metallic Gaskets)
Mounting with a Press

3 A00A3VA
A00A3UA
1. Bearing
2. Proper strength Loctite
3. Shaft
1. Clean shaft external contact surface.
2. Clean internal contact surface of part to be in-
stalled on shaft.
3. Apply a strip of proper strength Loctite on cir-
cumference of shaft contact surface at inser-
tion or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
4. DO NOT use antiseize Loctite or any similar
product.
5. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be installed.
2. Continue parts assembly as per previous illus-
tration.
1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket
diameter.
2. Spray housing and gasket with LOCTITE 7649
(PRIMER) (P/N 293 800 041).
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
5. Wipe off excess product.
6. Allow 30 minutes for product to cure.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.

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 Subsection XX (MAINTENANCE SCHEDULE)

MAINTENANCE SCHEDULE
Maintenance is very important for keeping the watercraft in a safe operating condition. The watercraft
should be serviced as per the maintenance schedule.
A repair shop or person of the owner's choosing may maintain, replace, or repair emission control devices
and systems. These instructions do not require components or service by BRP or authorized Sea-Doo
dealers. Although an authorized Sea-Doo dealer has an in-depth technical knowledge and tools to service
the Sea-Doo personal watercraft, the emission-related warranty is not conditioned on the use of an au-
thorized Sea-Doo dealer or any other establishment with which BRP has a commercial relationship. For
emission-related warranty claims, BRP is limiting the diagnosis and repair of emission-related parts to
the authorized Sea-Doo dealers. For more information, please refer to the US EPA EMISSION-RELATED
WARRANTY contained herein. Proper maintenance is the owner’s responsibility. A warranty claim may
be denied if, among other things, the owner or operator caused the problem through improper mainte-
nance or use.
You must follow the instructions for fuel requirements in the fueling section of this manual. Even if gaso-
line containing greater than ten volume percent ethanol is readily available, the US EPA issued a prohibi-
tion against the use of gasoline containing greater than 10 vol% ethanol that applies to this vehicle. The
use of gasoline containing greater than 10 vol% ethanol with this engine may harm the emission control
system.
Carry out all maintenance as listed in the schedule whenever the hours or time is reached.
NOTE: As an example, at 200 hours or 2 years, complete all items in this table and ALSO all items in the
EVERY 100 hours or 1 year table.

WARNING
Failure to properly maintain the watercraft according to the maintenance schedule and proce-
dures can make it unsafe to operate.

The maintenance schedule does not exempt the pre-ride inspection.

AFTER EACH RIDE IN SALT, DIRT OR FOUL WATER
Rinse engine compartment with fresh water and drain salt water
Flush the exhaust system

EVERY MONTH IN SALT, DIRT OR FOUL WATER

Spray an anticorrosion lubricant to metallic components in engine compartment (every 10 hours in salt
water use)
Inspect sacrificial anode

AFTER FIRST 6 MONTH OR 50 HOURS OF OPERATION (WHICHEVER COMES FIRST)

Replace engine oil and filter (RXP-X models)

EVERY YEAR AT PRESEASON OR 100 HOURS OF OPERATION (WHICHEVER COMES FIRST)

Check for fault codes
Perform all items indicated in the Pre-Ride Inspection and Post-Operation Care
Replace engine oil and filter
Inspect engine rubber mounts
Inspect the cooling system (coolant level, hoses and fasteners for leaks)
Inspect and lubricate throttle body and connecting socket to intake manifold
Inspect the air intake for damage on hoses and clamps.

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Subsection XX (MAINTENANCE SCHEDULE)

EVERY YEAR AT PRESEASON OR 100 HOURS OF OPERATION (WHICHEVER COMES FIRST)

Inspect spark plugs and ignition coils (900 ACE engines)
Inspect electrical connections and fastening (ignition system, starting system, fuel injectors, fuse boxes etc.)
Verify O.T.A.S. operation (Inspect operation) - (O.T.A.S. equipped vehicles only)
Inspect carbon ring and drive shaft rubber boot (more frequently when using PWC in foul or dirt water) (If
applicable)
Inspect impeller, impeller boot and impeller o-ring
Measure impeller and impeller wear ring clearance
Inspect the jet pump housing, impeller cover, O-rings & seals for signs of water intrusion
Inspect jet pump shaft condition and radial play
Verify and lubricate splines of the drive shaft and impeller
Inspect fuel cap, filler neck, fuel tank, fuel tank straps, fuel lines and connections

EVERY 2 YEARS OR 200 HOURS OF OPERATION (WHICHEVER COMES FIRST)

Replace spark plugs
Inspect flame arrestor (900 ACE engines)
Inspect and lubricate drive shaft/PTO splines (900 ACE engines)
The following must be performed every 200 hours (irrespective of the number of years):
Inspect, lubricate PTO sleeve and replace oil seal and two water seals. (Inspect for possible leaks or
damages on oil seal or on two water seals, and PTO sleeve surface. Lubricate grease chamber (between
the two water seals.) (900 ACE engines)

MAINTENANCE FREE
(Supercharged engines)
The supercharger is maintenance free*.
*Inspect supercharger every 200 hours (irrespective of the number of years) when vehicle is used in intense
conditions such as off-shore riding, continuous operation at wide open throttle, etc.

NOTICE Do not attempt to replace components of the supercharger assembly as the unit is fac-
tory- balanced to precise specifications. Failure to follow this recommendation may lead to super-
charger and / or engine damage.
EVERY 5 YEARS OR 300 HOURS OF OPERATION
(WHICHEVER COMES FIRST)
Replace the coolant

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 Subsection XX (STORAGE PROCEDURE)

STORAGE PROCEDURE
SERVICE PRODUCTS
Description Part Number Page
ANTICORROSION SPRAY ............................................................. 219 700 304 ............................................. 3
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ............................................. 3
XPS FUEL STABILIZER.................................................................. 413 408 601 ............................................. 1
XPS LUBE...................................................................................... 293 600 016 ......................................... 1, 3

PROCEDURES Flushing the Exhaust System

Flush the exhaust system. Refer to EXHAUST
PROPULSION SYSTEM SYSTEM subsection.
Cleaning and Protecting the Draining the Intercooler
Propulsion System
It is important to expel any trapped water that may
Clean jet pump by spraying water in its inlet have accumulated from condensation in the exter-
and outlet and then apply a coating of XPS LUBE nal intercooler.
(P/N 293 600 016) or equivalent.
NOTICE Failure to drain the intercooler may
Inspecting the Jet Pump cause severe damage to this component.
Remove impeller cover and check if jet pump is 230 Engines
water contaminated; if so, refer to JET PUMP sub-
section for the repair procedure. 1. Ensure there is an alignment line drawn on the
intercooler inlet hose. This will ensure the hose
is not twisted or kinked on reinstallation.
FUEL SYSTEM
Inspecting the Fuel System
Verify fuel system. Check fuel hoses for leaks.
Replace damaged hoses or clamps if necessary.

Protecting the Fuel System

XPS FUEL STABILIZER (P/N 413 408 601) (or equiva-
lent) should be added in the fuel tank to prevent
fuel deterioration and fuel system gumming. Fol-
low manufacturer's instructions for proper use.
NOTICE Fuel stabilizer should be added
prior to engine lubrication to ensure fuel sys-
tem component protection against varnish
deposits.
smr2016-007-001_a

Fill up fuel tank completely. Ensure there is no wa- TYPICAL - PARTS REMOVED FOR CLARITY
1. Air inlet hose
ter inside fuel tank. 2. Air outlet hose
NOTICE Should any water be trapped inside 2. Loosen the clamp retaining the intercooler inlet
fuel tank, severe internal damage will occur to hose.
the fuel injection system.
3. Remove the intercooler inlet hose from the in-
tercooler.
ENGINE
NOTE: This hose feeds the hot, compressed air
Replacing the Engine Oil and the Filter from the supercharger to the intercooler inlet.
Change engine oil and filter. Refer to LUBRICA-
TION SYSTEM subsection.

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Subsection XX (STORAGE PROCEDURE)

The air side of the intercooler is self-draining into TIGHTENING TORQUE

the inlet manifold of the intercooler. By discon-
necting the air inlet hose from the intercooler, the
presence of condensate water can be visually as-
sessed and properly drained off without running
the engine.
4. Reinstall the intercooler air inlet hose, ensure it
is properly aligned as prior to removal to ensure
proper engine operation.
TIGHTENING TORQUE
4 N•m ± 1 N•m
Intercooler hose clamp
(35 lbf•in ± 9 lbf•in)
300 Engines
1. Remove seats.
2. Remove engine service cover.
3. Ensure there is an alignment line drawn on the
intercooler air inlet hose. This will ensure the
hose is not twisted or kinked on reinstallation.
4 N•m ± 1 N•m
Intercooler hose clamp
(35 lbf•in ± 9 lbf•in)
Draining the Exhaust System
The exhaust system is self draining, but the ex-
haust manifold and intercooler need to be drained
to avoid damages should the watercraft be stored
in an area where the temperature attains the
freezing point of water.
Using the flushing connector located at the rear of
vehicle, inject pressurized air (at 380 kPa (55 PSI))
in the system until there is no more water flowing
from jet pump.
All models except Spark Series

219001840-004_a

TYPICAL
1. Flushing connector

Spark Series models

219100893-007-002_a

TYPICAL - PARTS REMOVED FOR CLARITY

1. Air inlet hose
2. Air outlet hose

4. Loosen the clamp retaining the intercooler inlet

hose.
5. Remove the intercooler inlet hose from the in-
tercooler.
The air side of the intercooler is self-draining into
the inlet manifold of the intercooler. By discon-
necting the air inlet hose from the intercooler, the smo2014-005-069_a

presence of condensate water can be visually as- TYPICAL - JET NOZZLE REMOVED FOR CLARITY
1. Flushing connector
sessed and properly drained off without running
the engine. The following hose can be fabricated to ease
6. Reinstall the intercooler air inlet hose, ensure it draining procedure.
is properly aligned as prior to removal to ensure
proper engine operation.

2 https://brp-manuals.com/pwc_seadoo 219100941-007

smo2008-001-053_a
TYPICAL
1. Flushing adaptor (P/N 295 500 473)
2. Hose 13 mm (1/2 in)
3. Air hose male adapter
NOTICE Failure to drain the exhaust mani-
fold may cause severe damage to components.
Replacing the Engine Coolant
Antifreeze should be replaced every 300 hours or
every 5 years (whichever comes first) to prevent
antifreeze deterioration.
NOTICE Failure to replace the antifreeze as
recommended may allow its degradation that
could result in poor engine cooling.
If coolant is not replaced, test the coolant density
using an antifreeze hydrometer.
Replace coolant if necessary. For the coolant re-
placement procedure, refer to COOLING SYSTEM
subsection.
NOTICE Improper antifreeze density may
result in coolant freezing should the vehicle
be stored in area where the freezing point
is attained. This could seriously damage the
engine.
Lubricating the Internal Parts of the
Engine
Engine must be lubricated to prevent corrosion on
internal parts.
Lubrication of the engine is recommended at the
end of the season and before any extended stor-
age period to provide additional corrosion protec-
tion. This will lubricate the engine intake valves,
the cylinders and the exhaust valves.
To lubricate the engine, proceed as follows:
Spark Series models
1. Remove the central body. Refer to BODY sec-
tion.
All models except Spark Series
1. Open seat.
All models
2. Disconnect ignition coil connectors.
3. Clean the area around the ignition coils to avoid
dirt falling into a cylinder.
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Subsection XX (STORAGE PROCEDURE)
4. Remove ignition coils.
5. Unscrew spark plugs.
6. Using an ignition coil as a puller, remove spark
plugs.
7. Spray XPS LUBE (P/N 293 600 016) into each
spark plug hole.
8. Crank the engine a few turns to distribute the
oil on cylinder wall.
NOTE: To crank engine, use the drowned mode
to avoid injecting fuel. Fully depress throttle lever
and hold for cranking engine.
9. Apply a small amount of LOCTITE 767 (ANTI-
SEIZE LUBRICANT) (P/N 293 800 070) on spark
plug threads then reinstall them.
NOTE: Refer to IGNITION SYSTEM subsection
for details on installing the spark plugs and igni-
tion coils.
10. Reinstall ignition coils.
11. Ensure the seal seats properly with the engine
top surface.
12. Reconnect ignition coil connectors.
13. Install all other removed parts.
ELECTRICAL SYSTEM
Removing the Battery
For battery removal, cleaning and storage, refer to
CHARGING SYSTEM subsection.
ENGINE COMPARTMENT
Cleaning the Engine Compartment
1. Clean the bilge with hot water and a mild deter-
gent, or using bilge cleaner.
2. Rinse thoroughly.
3. Lift front end of watercraft to completely drain
bilge. Refer to appropriate HULL subsection for
bilge drain plug removal.
Applying an Anticorrosion Treatment
Wipe off any residual water in the engine compart-
ment.
Spray XPS LUBE (P/N 293 600 016) or ANTICOR-
ROSION SPRAY (P/N 219 700 304) or an equivalent
product over all metallic components only in en-
gine compartment while minimizing overspray.
NOTE: The seat should be left partially open
during storage. This will prevent engine compart-
ment condensation and possible corrosion.
3
Subsection XX (STORAGE PROCEDURE)

BODY AND HULL

Cleaning and Repair
To clean and repair, refer to appropriate CLEAN-
ING AND REPAIR subsection.
Protecting the Body and the Hull
Apply a good quality marine wax on body and hull.
If the watercraft is to be stored outside, cover it
with an opaque tarpaulin to prevent sun rays and
grime from affecting the plastic components, wa-
tercraft finish as well as preventing dust accumu-
lation.
NOTICE The watercraft should never be left
in water for storage, stored in direct sunlight
or stored in a plastic bag.

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 Subsection XX (PRESEASON PREPARATION)

PRESEASON PREPARATION
Proper vehicle preparation is necessary after the
winter months or when a watercraft has not been
used during 4 months.
Any worn, broken or damaged parts found must
be replaced.
Using the MAINTENANCE SCHEDULE, perform
the items titled EVERY 100 HOURS OR 1 YEAR.

smr2016-008-001

Furthermore, proceed with the following:

Watercraft Prepared as per Storage Procedure
– Ensure battery is fully charged.
– Reinstall the battery.
– Test ride watercraft to confirm proper opera-
tion.
Watercraft Not Prepared as per Storage Proce-
dure
– Ensure battery is fully charged.
– Replace engine oil and filter.
– Drain fuel tank and fill with fresh fuel.
– Reinstall the battery.
– Test ride watercraft to confirm proper opera-
tion.

smr2016-008
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SPECIAL PROCEDURES
SERVICE TOOLS
Description
LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 2
SUCTION PUMP ........................................................................... 529 035 880 ........................................... 2
GENERAL
Refer to the following special procedures accord-
ing to the specific event. Procedures described
may not be applicable to every watercraft model.
PROCEDURES
TOWING THE WATERCRAFT IN
WATER
Special precautions should be taken when towing
a Sea-Doo watercraft in water.
The maximum recommended towing speed is
24 km/h (15 MPH).
This will prevent the exhaust system from fill-
ing with water, which may lead to water being
injected into and filling the engine. Without the
engine running, there isn't any exhaust pressure
to push the water out the exhaust outlet.
NOTICE Failure to follow these instructions
may result in damage to the engine. If you
must tow a stranded watercraft in water, be
sure not to exceed the maximum towing speed
of 24 km/h (15 MPH).
SUBMERGED WATERCRAFT
NOTICE Never try to crank or start engine.
Water trapped in the intake manifold would
flow towards the engine and possibly cause
severe engine damage.
1. Drain bilge.
2. If the watercraft was submerged in salt water,
rinse the bilge and all components thoroughly
with fresh water using a garden hose to stop
the salt corroding effect.
3. Check for water in the intake system. If water
is found in the intake system, refer to WATER-
FLOODED ENGINE in this subsection.
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Subsection XX (SPECIAL PROCEDURES)
Part Number Page
Lubricating the Engine
Refer to WATER-FLOODED ENGINE in this sub-
section.
Inspecting the Fuel
Check fuel tank for water contamination. If nec-
essary, siphon and refill with fresh fuel.
WATER-FLOODED ENGINE
If the engine is flooded with water, it must be ser-
viced within a few hours after the event. Other-
wise, the engine will have to be overhauled.
NOTICE
– Never try to crank or start the engine. Water
trapped in the intake manifold would enter
the combustion chamber through the intake
valves and may cause damage to the engine.
– An engine flooded with water must be prop-
erly drained, lubricant replaced (oil change),
operated (boil out procedure), then lubricant
replaced again, otherwise parts will be seri-
ously damaged.
Draining the Exhaust System
If water is suspected to be in the exhaust system,
remove the exhaust pipe and the muffler. Drain
them or siphon the water out of them. Refer to
EXHAUST SYSTEM subsection.
Draining the Intake System
1. If water is present in the air intake silencer,
empty it. Refer to AIR INTAKE SYSTEM sub-
section.
2. Remove the air intake silencer and check for
water in the supercharger inlet hose. Remove
hose to empty it.
3. Remove the water from blow-by valve hose.
4. If water is suspected in the intake manifold,
remove the intake manifold and drain it. Then
siphon the water out from the intake valve
ports. Refer to INTAKE MANIFOLD subsec-
tion.
1
Subsection XX (SPECIAL PROCEDURES)

Servicing the Supercharger

If there is water in the oil or in the supercharger in-
let hose, the supercharger should be taken apart,
all the components dried, and the slip clutch nee-
dle bearings and shaft ball bearings replaced. Re-
fer to SUPERCHARGER subsection.

Replacing the Engine Oil and the Filter

If the engine oil is contaminated with water (oil will
be milky), change the engine oil and filter as per
following procedure. smr2006-006-003_a

1. Using the SUCTION PUMP (P/N 529 035 880), TYPICAL

siphon the contaminated oil from the engine
reservoir through the dipstick hole.
529035880
NOTICE Never crank or start engine when
siphon tube is in dipstick hole. Never start
engine when there is no oil in engine.
2. Remove the suction pump tube from the dip-
stick hole.
3. Fully depress throttle lever and HOLD it for
cranking.
4. Crank the engine for 5 seconds.
5. Remove the oil filter cap and the oil filter. Refer
to appropriate LUBRICATION SYSTEM subsec-
tion.
6. Again, siphon the contaminated oil from the oil
filter reservoir.
7. Remove valve cover. Refer to CYLINDER
HEAD subsection.
8. Wrap a piece of tape around the suction pump
tube 475 mm (18-11/16 in) from the end of the
tube.
9. Insert the tube in the PTO area until the tape is
even with the cylinder-block edge.
10. Siphon contaminated oil out.
1. Suction pump tube with tape
2. Edge of cylinder-block
11. Remove the suction pump tube.
12. Reinstall valve cover.
13. Install a NEW oil filter and reinstall the oil filter
cap.
14. Fill the engine with appropriate amount of the
recommended engine oil. Refer to LUBRICA-
TION SYSTEM subsection .
15. Proceed with the BOIL OUT PROCEDURE
that follows.
NOTE: The boil out procedure is intended to evap-
orate a small quantity of water contained in the oil
system.
Boil Out Procedure in a Test Tank or Tied to a
Trailer with Watercraft in Water
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2) to monitor the coolant tempera-
ture. Coolant temperature must exceed 100°C
(212°F) in order for the water to boil out. Once
the boiling point is attained, the water will evap-
orate quickly.
2. Run the engine for 5 minutes at 3500 RPM.
WARNING
Be sure to safely secure the watercraft.
3. With the engine still running at 3500 RPM, in-
stall a LARGE HOSE PINCHER (P/N 529 032 500)
on the coolant line going to the oil cooler.

529032500

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 Subsection XX (SPECIAL PROCEDURES)

WARNING
Certain components in the engine compart-
ment may be very hot. Direct contact may re-
sult in skin burn. Do not touch any electri-
cal parts or jet pump area when the engine
is running.

smr2009-015-001_a

TYPICAL
1. Oil cooler coolant inlet hose

4. Continue to run the engine at 3500 RPM for 15

more minutes (20 minute total run time).
5. Shut the engine off.
6. Remove the hose pincher from coolant line go-
ing to the oil cooler.
NOTICE Hose pincher must be removed prior
to operating the watercraft. Failure to do this
will result in damage to the engine.
7. Change the oil and filter again.
8. Procedure is now complete.

CAPSIZED WATERCRAFT
Capsized for More than 5 Minutes
Refer to WATER-FLOODED ENGINE in this sub-
section.

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 Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

ENGINE REMOVAL AND INSTALLATION

(900 ACE ENGINES)
SERVICE TOOLS
Description Part Number Page
ALIGNMENT SHAFT SUPPORT .................................................... 529 035 506 ............................................. 7
ALIGNMENT SHAFT ..................................................................... 295 000 141 ......................................... 7–8
ENGINE LIFTING TOOL ................................................................ 529 036 217 ............................................. 6
FUEL HOSE DISCONNECT TOOL ................................................ 529 036 037 ......................................... 3–4
LARGE HOSE PINCHER................................................................ 529 032 500 ......................................... 3, 5
PTO ADAPTER .............................................................................. 529 036 273 ......................................... 7, 9
PUMP PLATE................................................................................. 529 036 224 ............................................. 7
SUCTION PUMP ........................................................................... 529 035 880 ............................................. 3

SERVICE PRODUCTS
Description Part Number Page
BLACK NEOPRENE PAINT............................................................ 909570 ............................................. 7
XPS ALL PURPOSE CLEANER ..................................................... 219 701 709 ............................................. 7

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Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

26 ± 2 N•m
(19 ± 1 lbf•ft)
NEW

‘‘T‘‘ marks ‘‘T‘‘ marks

upwards upwards

26 ± 2 N•m
(19 ± 1 lbf•ft)

26 ± 2 N•m
(19 ± 1 lbf•ft) NEW
26 ± 2 N•m
NEW (19 ± 1 lbf•ft)
12 ± 2 N•m
(106 ± 18 lbf•in)
NEW
12 ± 2 N•m
(106 ± 18 lbf•in)

NEW = Component must be replaced when removed.

219100941-037-100_a

2 https://brp-manuals.com/pwc_seadoo 219100941-037
 Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

GENERAL PROCEDURES
WARNING ENGINE
When electrically disconnecting or removing
the throttle body from the intake manifold, al- Removing the Engine
ways remove the tether cord from the engine REQUIRED TOOL
cut-off switch and disconnect the battery.
SUCTION PUMP
WARNING (P/N 529 035 880)

Always disconnect battery prior to working FUEL HOSE

on the fuel system. Always disconnect bat- DISCONNECT TOOL
tery exactly in the specified order, BLACK (P/N 529 036 037)
(-) cable first. Electrical connections should LARGE HOSE PINCHER
be disconnected prior to disconnecting fuel (P/N 529 032 500)
lines.
1. Place vehicle on a workstation equipped with
WARNING an engine-lifting hoist.
Fuel is flammable and explosive under cer- 2. Remove the following components:
tain conditions. Work in a well ventilated – Body (refer to BODY subsection
area. Do not smoke or allow open flames or – Jet pump housing (refer to JET PUMP sub-
sparks in the vicinity. section
– Drive shaft (refer to DRIVE SHAFT subsec-
WARNING tion
Fuel lines remain under pressure at all times. – Muffler (refer to EXHAUST SYSTEM) subsec-
Always proceed with care and use appro- tion.
priate safety equipment when working on a 3. Disconnect BLACK (-) lead from battery.
pressurized fuel system. Do not allow fuel
to spill on hot engine parts and/or on elec- 4. Drain engine coolant using the SUCTION PUMP
trical connectors. Proceed with care when (P/N 529 035 880).
removing or installing high pressure test
equipment, or disconnecting fuel line con-
nections. Wipe off any fuel spillage in the
bilge. Never use a hose pincher on high
pressure hoses.

Cover the fuel line connection with an absorbent

shop rag before disconnecting them. Slowly dis-
connect the fuel hose to minimize spilling.
When the repair is completed, ensure the hose
from the fuel rail to the fuel pump is properly con-
nected and secured in its support.

WARNING smr2014-012-001_a

TYPICAL
After working on the fuel system, always 1. Coolant reservoir
pressurize the fuel system and check for fuel 2. Suction pump hose
leaks. Refer to FUEL SYSTEM PRESSUR-
IZATION in FUEL TANK AND FUEL PUMP 5. Detach air intake silencer hose from throttle
subsection. body.
5.1 Loosen air intake silencer hose clamp.
WARNING
If a gasoline leak and/or odor is present, do
not start the engine. Repair the leak.

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Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

smr2014-012-004_a

1. Fuel hose fitting

2. Fuel hose disconnect tool

7. Detach the wiring harness from intake mani-

fold.
219100941-037-002_a

1. Loosen this clamp

5.2 Detach blow-by hose from cylinder valve

cover.

smr2017-304-001_a

smr2014-012-003_a
8. Disconnect coolant return hose.
1. Blow-by hose
8.1 Cut locking tie securing the hose to wiring
6. Disconnect fuel inlet hose from fuel rail. harness.
6.1 Place a rag around fuel hose fitting.
6.2 Disconnect fuel hose from fuel rail us-
ing the FUEL HOSE DISCONNECT TOOL
(P/N 529 036 037)

4 https://brp-manuals.com/pwc_seadoo 219100941-037
 Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

smr2014-012-008_a

TYPICAL
1. Large hose pinchers

10. Unplug knock sensor connector.

219100941-037-001_a

1. Cut this locking tie

8.2 Loosen clamp on cylinder head.

smr2014-012-009_a

TYPICAL
1. Knock sensor connector

smr2014-012-007_a 11. Unplug the "A" connector from the ECM.

TYPICAL
1. Coolant return hose clamp

9. Disconnect inlet and outlet radiator hoses.

9.1 Install a LARGE HOSE PINCHER (P/N 529 032
500) on each hose.
9.2 Loosen hoses clamps and disconnect
hoses from thermostat housing.

smr2017-304-002_a

12. Cut locking ties securing engine harness to ve-

hicle harness.
13. Unplug magneto connector from voltage reg-
ulator/rectifier.
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Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

smr2014-012-013_a

TYPICAL smr2014-012-016_a

1. Voltage regulator/rectifier 1. Starter cable

2. Magneto connector
17. Remove and discard elastic nuts retaining en-
14. Disconnect inlet and outlet hoses from ex-
gine mount clamps.
haust manifold.

smr2014-012-014_a smr2014-012-017_a

TYPICAL TYPICAL
1. Exhaust manifold inlet hose
2. Exhaust manifold outlet hose

15. Unscrew both ground wires from engine.

smr2014-012-018_a

TYPICAL
1
18. Remove exhaust manifold and install the EN-
GINE LIFTING TOOL (P/N 529 036 217).
2
smr2017-304-301_a

1. Engine/vehicle grounds
2. Battery ground
3. Dipstick

16. Detach starter cable from starter.

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 Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

Check fuel hose condition and pressure test the

fuel system, refer to FUEL TANK AND FUEL
PUMP subsection.
To avoid potential corrosion of ground and
starter cable, apply BLACK NEOPRENE PAINT
(P/N 909570)on bolt and eyelet connector.

WARNING
Whenever doing any type of repair on wa-
tercraft or if any components of the fuel sys-
tem are disconnected, a pressure test must
529036217 be done before starting engine.

Verify all electrical connections (ground wires and

battery).
Fill and bleed the engine cooling system. Refer to
COOLING SYSTEM subsection
Run engine and ensure there is no leakage.
NOTICE If watercraft is out of water, exhaust
system must be cooled using the flush kit.
Never run engine more than 2 minutes.

Performing the Engine Alignment

Engine alignment is required only when one of the
smr2014-012-070 following parts is removed and/or replaced with
new one.
19. Slowly lift the engine out of hull.
– Engine supports (from cylinder block)
Installing the Engine – Engine mount base (more than one)
The installation is the reverse of the removal pro- – Jet pump support
cedure. However, pay attention to the following. – Hull.
Wipe off any spillage in bilge. Clean with the XPS REQUIRED TOOLS
ALL PURPOSE CLEANER (P/N 219 701 709). DESCRIPTION QTY
Place engine into vehicle.
PUMP PLATE
Install all engine mount clamps and secure them 1
(P/N 529 036 224)
loosely using new M8 elastic stop nuts.
According to the situation: ALIGNMENT SHAFT
SUPPORT (P/N 529 1
– Perform the engine alignment, or 035 506)
– Tighten all engine mount clamps nuts.
ALIGNMENT SHAFT
1
NOTICE The engine alignment must be com- (P/N 295 000 141)
pleted before finalizing the engine installation.
PTO ADAPTER (P/N 529
1
TIGHTENING TORQUE 036 273)

Engine mount clamp 26 N•m ± 2 N•m To verify alignment of engine proceed as follows:
nuts (19 lbf•ft ± 1 lbf•ft)
1. Remove jet pump, drive shaft and drive shaft
Install and properly align muffler. Refer to EX- boot. Refer to STEERING AND PROPULSION
HAUST SYSTEM subsection. section.
Reinstall all other removed parts. 2. Assemble alignment tool.
2.1 Install the alignment shaft support on en-
gine alignment plate.

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Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

2.2 Secure using M8 x 25 x 1.25 hexagonal

screws.

295 000 141

sbs2014-016-001_a

smr2011-007-005_a
1. Alignment shaft support (P/N 529 035 506)
2. Support plate (P/N 529 036 224)
3. M8 x 25 x 1.25 hexagonal screws
3. Install the alignment tool as follows.
3.1 Position the alignment tool against the
pump support.
3.2 Push the alignment tool upward and hold
it in this position.
5. Insert alignment shaft end into crankshaft PTO
coupler.
NOTE: A small resistance during shaft insertion is
normal.
If the Engine Alignment is Correct
1. Check the longitudinal position of engine.
If the Engine Alignment is Incorrect
1. Remove all engine mount clamps.
2. Loosen nuts securing engine mount base.

1
2
3
smr2011-007-006_a 4
Step 1: Place alignment tool against pump support
Step 2: Push alignment tool upward

TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m sbs2014-016-006_a
Alignment tool screws
(18 lbf•ft ± 3 lbf•ft) TYPICAL
1. Engine mount clamp nut
2. Flat washer
4. Carefully slide the ALIGNMENT SHAFT (P/N 295 3. Engine mount clamp
000 141) through the engine alignment tool. 4. Engine mount base

3. Add or remove shims as required.

4. Try to insert the alignment shaft into crankshaft
PTO coupler again.
5. Repeat all steps until alignment is done.
6. When engine alignment is correct, check the
longitudinal position of engine.
Verifying the Engine Longitudinal Position
The longitudinal verification is taken between the
PTO adapter and the end of the alignment tool.

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 Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

2. Carefully slide the alignment shaft through the

engine alignment tool and lean it against the
1 2 PTO adapter.
3. While holding the alignment shaft in this posi-
3 tion, check the location of the marks (previously
drawn at the beginning of this procedure).
4. Engine is properly positioned longitudinally
when the engine alignment tool is between
both shaft marks.
– If one mark is visible, the engine is properly
A positioned.
– If both marks are visible, the engine must be
moved forward.
219100941-009-200 – If no mark is visible, the engine must be
1. PTO adapter moved rearward.
2. Alignment shaft
3. Alignment tool
A. Required longitudinal distance of engine

Trace two thin lines on alignment shaft as per the

following table.

smr2012-007-002_a
sbs2014-016-003_a
PROPER POSITION
1. Engine alignment tool
LINES DISTANCE 2. Alignment shaft
3. Mark at 600 mm (23.622 in)
Line A at 598 mm (23.543 in)
If an adjustment is required:
Line B at 600 mm (23.622 in)
– Remove all engine mount clamps.
1. Insert the PTO ADAPTER (P/N 529 036 273) into – Loosen nuts securing engine mount base.
the crankshaft PTO coupler. – Move the engine forwards or rearwards to
reach the required position.

529 036 273

sbs2014-016-004_a

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Subsection XX (ENGINE REMOVAL AND INSTALLATION (900 ACE ENGINES))

1
2
3
4

sbs2014-016-006_a smr2011-007-004_a

TYPICAL 1. T mark
1. Engine mount clamp nut
2. Flat washer Recheck engine alignment.
3. Engine mount clamp
4. Engine mount base Reinstall all removed parts in accordance with
proper subsection information.
5. Retighten engine mount base nuts.
6. Install and secure engine mount clamps.
TIGHTENING TORQUE
12 N•m ± 2 N•m
Engine mount base nuts
(106 lbf•in ± 18 lbf•in)
Engine mount clamp 25 N•m ± 3 N•m
nuts (18 lbf•ft ± 2 lbf•ft)

7. Repeat all steps until alignment is done.

8. When the engine alignment is completed, re-
place nuts retaining the engine mount clamps
with NEW ones.
NOTICE When the tightening is completed,
make sure to leave a minimum of 3 mm (1/8 in)
of free threads over the engine mount clamp
nuts.

smr2014-012-050_a

A. 3 mm (1/8 in) minimum

NOTE: Position conical spring washer with the "T"

mark upwards.

10 https://brp-manuals.com/pwc_seadoo 219100941-037
 Subsection XX (ENGINE REMOVAL AND INSTALLATION (130,
155, 230 AND 300 ENGINES))

ENGINE REMOVAL AND INSTALLATION

(130, 155, 230 AND 300 ENGINES)
SERVICE TOOLS
Description Part Number Page
ALIGNMENT SHAFT ADAPTER .................................................... 529 035 719 ............................................. 6
ALIGNMENT SHAFT SUPPORT .................................................... 529 035 506 ............................................. 6
ALIGNMENT SHAFT ..................................................................... 295 000 141 ......................................... 6–7
PUMP PLATE................................................................................. 529 036 224 ............................................. 6

SERVICE PRODUCTS
Description Part Number Page
BLACK NEOPRENE PAINT............................................................ 909570 ............................................. 5
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 5, 8
XPS ALL PURPOSE CLEANER ..................................................... 219 701 709 ............................................. 5

219100941-009
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Subsection XX (ENGINE REMOVAL AND INSTALLATION (130,
155, 230 AND 300 ENGINES))

ENGINE SUPPORTS
Wake 155 model
26 ± 2 N•m
(19 ± 1 lbf•ft)
NEW

‘‘T‘‘ marks
upwards
‘‘T‘‘ marks
upwards

26 ± 2 N•m
(19 ± 1 lbf•ft)
NEW Maximum Thickness:
5 mm (13/64 in)

‘‘T‘‘ marks
upwards 26 ± 2 N•m
(19 ± 1 lbf•ft)
NEW

Maximum Thickness:
5 mm (13/64 in)
‘‘T‘‘ marks
upwards

‘‘T‘‘ marks
upwards

Maximum Thickness:
5 mm (13/64 in)

NEW = Component must be replaced when removed.

219100941-009-101_a

2 https://brp-manuals.com/pwc_seadoo 219100941-009
 Subsection XX (ENGINE REMOVAL AND INSTALLATION (130,
155, 230 AND 300 ENGINES))

Other models
26 ± 2 N•m
(19 ± 1 lbf•ft)
NEW

‘‘T‘‘ marks
upwards
26 ± 2 N•m
(19 ± 1 lbf•ft)
NEW

‘‘T‘‘ marks
upwards

Maximum Thickness:
26 ± 2 N•m 5 mm (13/64 in)
(19 ± 1 lbf•ft)
NEW

26 ± 2 N•m
‘‘T‘‘ marks (19 ± 1 lbf•ft)
upwards
NEW

‘‘T‘‘ marks
upwards
‘‘T‘‘ marks
Maximum Thickness: upwards
5 mm (13/64 in)
Maximum Thickness:
5 mm (13/64 in)

219100941-009-102_a

219100941-009
https://brp-manuals.com/pwc_seadoo 3
Subsection XX (ENGINE REMOVAL AND INSTALLATION (130,
155, 230 AND 300 ENGINES))

PROCEDURES
ENGINE
Removing the Engine - Guideline
Remove the seat.
Disconnect the battery. Refer to CHARGING SYS-
TEM subsection.
Remove the intake manifold. Refer to INTAKE
MANIFOLD subsection.
Disconnect the following:
– CAPS
– CPS
– CTS
– EGTS
– Engine ground cables
– OTS
219100893-010-004_a
– Magneto connector from the voltage regula- TYPICAL
tor/rectifier. 1. Engine mounting screws
Drain coolant. Refer to COOLING SYSTEM sub- – Cut any locking ties from hoses or wiring
section. harness that prevent engine removal.
On supercharged models, unplug both hoses – Slightly lift the engine using a suitable
from the supercharger. lifting device.
Unplug the front exhaust hose from the muffler.
Unplug the blow-by valve hose.
Unplug the ride plate hoses from water pump
housing.
Remove muffler. Refer to EXHAUST SYSTEM
subsection.
Remove the drive shaft. Refer to DRIVE SHAFT
subsection.
Remove the engine mounting screws.
smr2011-007-050_a

– Unplug water hoses from exhaust manifold.

– Disconnect the starter cable from the starter.
– Disconnect the engine ground cable located
under the exhaust manifold.

4 https://brp-manuals.com/pwc_seadoo 219100941-009
 Subsection XX (ENGINE REMOVAL AND INSTALLATION (130,
219100893-010-003_a
1. Exhaust manifold water hoses
2. Starter cable
3. Engine ground cable
– Unplug coolant tank hose from water pump
housing.
– Carry on engine lifting to remove it from the
body opening.
NOTICE Be careful not to scratch body or
to hit any engine component during engine
removal.
Installing the Engine
Installation of engine in watercraft is essentially
the reverse of removal procedures. However pay
particular attention to the following.
NOTICE Whenever engine is removed from
watercraft, engine alignment must be per-
formed at reinstallation.
Wipe off any spillage in bilge. Clean with the XPS
ALL PURPOSE CLEANER (P/N 219 701 709).
Check tightness and condition of engine rubber
mounts. Refer to ENGINE MOUNTS in this sub-
section.
Before completely lowering engine, install ground
cable, starter cable and water hoses on exhaust
manifold. Follow these guide lines.
– Ensure contact surface is perfectly clean then
reconnect ground cable to engine.
– Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of ground cable screw or use a new
screw with self-locking product.
– Install and secure the ground cable.
– Torque starter cable nut.
– To avoid potential corrosion of ground and
starter cable, apply BLACK NEOPRENE PAINT
(P/N 909570)on bolt and eyelet connector.
219100941-009
https://brp-manuals.com/pwc_seadoo
155, 230 AND 300 ENGINES))
– Install protective cap over the starter cable end.
– Connect exhaust manifold water inlet and out-
let hoses.
– Connect coolant hoses to water pump housing.
TIGHTENING TORQUE
23.5 N•m ± 1.5 N•m
Ground cable screw
(17 lbf•ft ± 1 lbf•ft)
10 N•m ± 1 N•m
Starter cable nut
(89 lbf•in ± 9 lbf•in)
1.7 N•m ± 0.2 N•m
Small hose clamps
(15 lbf•in ± 2 lbf•in)
3.5 N•m ± 0.5 N•m
Large hose clamps
(31 lbf•in ± 4 lbf•in)
Place engine into vehicle.
Install engine support screws. Do not apply
threadlocker to engine support screws and do
not torque yet.
Align engine. Refer to ENGINE ALIGNMENT in
this subsection for complete procedure.
NOTICE The engine alignment must be com-
pleted before finalizing the engine installation.
Install and properly align exhaust pipe. Refer to
EXHAUST SYSTEM subsection.
Reinstall all other removed parts.
Check hose condition and pressure test fuel sys-
tem, refer to FUEL SYSTEM section.
WARNING
Whenever doing any type of repair on wa-
tercraft or if any components of the fuel sys-
tem are disconnected, a pressure test must
be done before starting engine.
Verify all electrical connections (ground wires and
battery).
Verify the level of coolant and oil.
Run engine and ensure there is no leakage.
NOTICE If watercraft is out of water, exhaust
system must be cooled using the flush kit.
5
Subsection XX (ENGINE REMOVAL AND INSTALLATION (130,
155, 230 AND 300 ENGINES))

Engine Alignment
REQUIRED TOOLS

PUMP PLATE
(P/N 529 036 224)

ALIGNMENT SHAFT SUPPORT

(P/N 529 035 506)
ALIGNMENT SHAFT ADAPTER
(P/N 529 035 719)
ALIGNMENT SHAFT smr2011-007-006_a

(P/N 295 000 141) Step 1: Place alignment tool against pump support
Step 2: Push alignment tool upward
To verify alignment of engine proceed as follows:
TIGHTENING TORQUE
1. Remove jet pump and drive shaft. Refer to
STEERING AND PROPULSION section. Alignment tool nuts 24 N•m (18 lbf•ft)

2. Remove drive shaft boot. Install the ALIGNMENT SHAFT ADAPTER (P/N 529
3. Assemble alignment tool. 035 719) on the end of the ALIGNMENT SHAFT
(P/N 295 000 141).
3.1 Install the alignment shaft support on
pump plate.
3.2 Secure using M8 x 25 x 1.25 hexagonal
screws.

529035719

295000141

Trace two thin lines on alignment shaft.

smr2011-007-005_a

1. Alignment shaft support (P/N 529 035 506)

2. Support plate (P/N 529 036 224)
3. M8 x 25 x 1.25 hexagonal screws

TIGHTENING TORQUE
Alignment tool screws 24 N•m (18 lbf•ft)

4. Install the alignment tool as follows.

smr2009-016-200_a
4.1 Position the alignment tool against the
pump support. LINES DISTANCE
4.2 Push the alignment tool upward and hold Line A at 739.5 mm (29.114 in)
it in this position.
Line B at 742.5 mm (29.232 in)

5. Remove the ALIGNMENT SHAFT ADAPTER

(P/N 529 035 719) from the end of the alignment
shaft and install it in engine PTO housing.
NOTICE Ensure alignment shaft adapter is
fully inserted into the engine PTO housing.

6 https://brp-manuals.com/pwc_seadoo 219100941-009
 Subsection XX (ENGINE REMOVAL AND INSTALLATION (130,
155, 230 AND 300 ENGINES))

smr2009-016-029_a

TYPICAL
1. Alignment shaft adapter

6. Carefully slide the ALIGNMENT SHAFT (P/N 295

000 141) through the engine alignment tool. smr2016-046-002_a

REAR STARBOARD ENGINE MOUNT SHOWN

1. Engine mounting screw
2. Engine mount retaining screws
3. Shim(s)

10. When engine alignment is correct, check the

longitudinal position of engine.
Verifying the Engine Longitudinal Position
With alignment shaft installed, check the location
of the marks (previously drawn at the beginning of
the engine alignment procedure).
Engine is properly positioned longitudinally when
smr2011-007-007_a
the engine alignment tool is between both shaft
1. Alignment shaft (P/N 295 000 141) marks.
2. Alignment tool
– If one mark is visible, the engine is properly po-
7. Insert alignment shaft end into alignment sitioned.
shaft adapter. If the alignment is correct, the – If both marks are visible, the engine must be
alignment shaft end should slide through the moved forward.
adapter. – If no mark is visible, the engine must be moved
NOTE: A small resistance during shaft insertion is rearward.
normal.
8. If the alignment is incorrect, loosen engine
mount retaining screws (Allen socket screws).
9. Add or remove shims as required.
NOTE: Shims location is between engine mount
and engine mount plate.
NOTICE Whenever shims are used to cor-
rect alignment, never install more than 5 mm
(13/64 in) of shims.

smr2012-007-002_a

PROPER POSITION
1. Engine alignment tool
2. Alignment shaft
3. Mark at 742.5 mm (29.232 in)

219100941-009
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Subsection XX (ENGINE REMOVAL AND INSTALLATION (130,
155, 230 AND 300 ENGINES))

When alignment and longitudinal position of en-

gine are correct, tighten engine mount screws.
Refer to ENGINE MOUNTS in this subsection.
Recheck engine alignment.

ENGINE MOUNTS
If engine mounts have been removed, apply LOC-
TITE 243 (BLUE) (P/N 293 800 060) on screw threads
or use new screws with self-locking product.
TIGHTENING TORQUE
26 N•m ± 2 N•m
Engine mount screws
(19 lbf•ft ± 1 lbf•ft)

NOTE: Position conical spring washer with the "T"

mark upwards.

smr2011-007-004_a

1. T mark

8 https://brp-manuals.com/pwc_seadoo 219100941-009
 Subsection XX (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM

SERVICE TOOLS
Description Part Number Page
OETIKER PLIER ............................................................................. 295 000 070 ......................................... 4–5

smr2017-305
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Subsection XX (AIR INTAKE SYSTEM)

INTAKE MANIFOLD

9 ± 1 N•m
(80 ± 9 lbf•in)

MAPTS
See ELECTRONIC FUEL
INJECTION (EFI)
See ELECTRONIC FUEL
INJECTION (EFI)

NEW
4,5 ± 0,5 N•m
(40 ± 4.5 lbf•in) NEW

9 ± 1 N•m NEW
(80 ± 9 lbf•in)
See tightening sequence

NEW See ELECTRONIC FUEL

INJECTION (EFI)

1900 N or 2,2 mm ± 1 mm
(427.1 lbf or 0.087 in ± 0.039 in)

NEW
9 ± 1 N•m
(80 ± 9 lbf•in)
See tightening sequence

NEW = Component must be replaced when removed.

smr2014-013-001_a

2 https://brp-manuals.com/pwc_seadoo smr2017-305
 Subsection XX (AIR INTAKE SYSTEM)

AIR INTAKE SILENCER

5.25 ± 0.75 N•m

(46 ± 7 lbf•in)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

NEW

2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW = Component must be replaced when removed.
smr2017-305-100_a

smr2017-305
https://brp-manuals.com/pwc_seadoo 3
Subsection XX (AIR INTAKE SYSTEM)

PROCEDURES
FLAME ARRESTOR
Location of the Flame Arrestor
The flame arrestor is integrated in the intake man-
ifold.

Accessing the Flame Arrestor

Remove Oetiker clamp and discard it.
REQUIRED TOOL

OETIKER PLIER (P/N 295

000 070)
smr2014-013-002_a

1. Flame arrestor
2. Intake manifold

Removing the Flame Arrestor

Carefully insert a small flat screwdriver between
flame arrestor gasket and intake manifold.
Pry out flame arrestor from intake manifold in al-
ternate diagonally order.

smr2014-013-003_a

1. Oetiker clamp
2. Connecting socket
3. Throttle body

Remove connecting socket from intake manifold. smr2014-013-004_a

Move connecting socket with throttle body aside. 1. Flame arrestor

2. Intake manifold
3. Flat screwdriver
Inspecting the Flame Arrestor
Check if flame arrestor is clogged. Cleaning the Flame Arrestor
NOTE: A clogged flame arrestor may have a neg- Clean flame arrestor with solvent and com-
ative impact on engine performance. pressed air.

Inspecting the Connecting Socket

Check if connecting socket is cracked, brittle or
otherwise damaged. Replace if necessary.

4 https://brp-manuals.com/pwc_seadoo smr2017-305
 Subsection XX (AIR INTAKE SYSTEM)

OETIKER CLAMP CRIMPING

2.2 mm ± 1 mm (.087 in ± .039 in) or
1 900 N (427.1 lbf)

smr2014-013-012

CONNECTING SOCKET

Installing the Flame Arrestor

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Always install a NEW gasket on the flame arrestor.
Make sure to index connecting socket notch with
intake manifold tab.
smr2014-013-021_a
1. Oetiker clamp
A. Crimp to 2.2 mm ± 1 mm (.087 in ± .039 in)
INTAKE MANIFOLD
Removing the Intake Manifold
1. Disconnect manifold absolute pressure and
temperature sensor (MAPTS).

smr2014-013-006_a

1. MAPTS connector
smr2014-013-016_a 2. Intake manifold
1. Connecting socket notch
2. Intake manifold tab 2. Cut locking ties securing MAPTS harness to in-
3. Oetiker clamp
take manifold.
Crimp Oetiker clamp beside the intake manifold
tab.
REQUIRED TOOL

OETIKER PLIER (P/N 295

000 070)

smr2017-305
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Subsection XX (AIR INTAKE SYSTEM)

smr2014-013-011_a

1. Intake manifold screws

smr2014-013-007_a

1. Locking ties 7. Remove intake manifold from engine.

8. Remove and discard intake manifold gaskets.
3. Remove screws retaining the throttle body to
connecting socket. 9. If required, remove the following parts from in-
take manifold:
– Connecting socket. Refer to FLAME AR-
RESTOR in this subsection.
– Flame arrestor. Refer to FLAME ARRESTOR
in this subsection.
– MAPTS. Refer to ELECTRONIC FUEL INJEC-
TION (EFI) subsection.
– Fuel rail with injectors. Refer to ELEC-
TRONIC FUEL INJECTION (EFI) subsection.
Inspecting the Intake Manifold
Check intake manifold for cracks, warping at
flanges or any other visible damages. Replace if
smr2014-013-008_a required.
1. Retaining screws
2. Throttle body Check if intake manifold gaskets are brittle, hard
or otherwise damaged. Replace if necessary.
4. Move throttle body aside. Drain intake manifold if any liquids accumulated.
5. Disconnect fuel injector connectors. Flush intake manifold with solvent and let it dry
out.

Installing the Intake Manifold

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install NEW gaskets with tab properly inserted
into notch.

smr2014-013-009_a

1. Fuel injector connectors

6. Remove screws securing intake manifold to

cylinder head.

6 https://brp-manuals.com/pwc_seadoo smr2017-305
 Subsection XX (AIR INTAKE SYSTEM)

Refer to FLAME ARRESTOR in this subsection to

install:
– Flame arrestor
– Connecting socket.
Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection to install:
– MAPTS
– Throttle body
– Fuel rail with injectors.

AIR INTAKE SILENCER

smr2014-013-013_b

1. Gaskets tab properly inserted Removing the Air Intake Silencer

Remove the ECM bracket.
Ensure that rubber grommets are properly in-
serted.

smr2017-305-007_a

smr2014-013-014_a
Loosen throttle body clamp.
1. Rubber grommets

Tighten intake manifold screws to specification as

per the following sequence.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Intake manifold screws
(80 lbf•in ± 9 lbf•in)

smr2014-013-503_a

Detach the retaining straps.

smr2014-013-011_b

TIGHTENING SEQUENCE

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Subsection XX (AIR INTAKE SYSTEM)
smr2014-013-504
Loosen clamp and remove vent hose from the
cylinder head cover.
smr2014-013-508_a
Pull the air intake silencer out of the vehicle.
Disassembling the Air Intake Silencer
Remove screws securing upper section of air in-
take silencer to the lower section.
smr2017-305-004_a
Release all retaining tabs.
Separate upper and lower sections.
8 https://brp-manuals.com/pwc_seadoo
smr2017-305-006_a
Assembling the Air Intake Silencer
Align the rubber tab in the notch.
smr2014-013-515_a
Make sure that air intake tube is well locked
(groove) in the upper section of the air intake
silencer.
smr2014-013-516_a
1. Air intake tube
2. Air intake silencer upper section
3. Retaining groove
Secure the upper section to lower section using
previously removed K40 x 16 Torx screws.
smr2017-305
 Subsection XX (AIR INTAKE SYSTEM)

TIGHTENING TORQUE
1.5 N•m ± 0.3 N•m
K40 x 16 Torx screws
(13 lbf•in ± 3 lbf•in)

In case of a broken clip, install a K40 x 16 Torx

screw (P/N 250 000 287) on each side of the de-
fective clip.

smr2014-013-517_a

1. Broken clip
2. K40 x 16 Torx screws (P/N 250 000 287)

TIGHTENING TORQUE
1.5 N•m ± 0.3 N•m
K40 x 16 Torx screws
(13 lbf•in ± 3 lbf•in)

Installing the Air Intake Silencer

The installation is the reverse of the removal pro-
cedure.
However, pay attention to the following:
TIGHTENING TORQUE
Cylinder head cover 1.7 N•m ± 0.2 N•m
hose clamp (15 lbf•in ± 2 lbf•in)
2.5 N•m ± 0.5 N•m
Throttle body clamp
(22 lbf•in ± 4 lbf•in)
5.25 N•m ± 0.75 N•m
ECM bracket screw
(46 lbf•in ± 7 lbf•in)

smr2017-305
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 Subsection XX (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM

130 and 155 Engines

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

4 ± 1 N•m
(35 ± 4 lbf•in)

smr2017-309 201 _a

smr2017-309
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Subsection XX (AIR INTAKE SYSTEM)

230 and 260 Engines

4 ± 1 N•m
(35 ± 4 lbf•in)

smr2017-309 200 _a

2 https://brp-manuals.com/pwc_seadoo smr2017-309
 Subsection XX (AIR INTAKE SYSTEM)

PROCEDURES 6. Disconnect gauge and O.T.A.S. connectors.

AIR INTAKE SILENCER

Accessing the Air Intake Silencer
1. Open the front storage compartment cover.
2. Remove the storage bin.
3. Remove partitions. Refer to BODY subsection.

smr2012-008-006_a

1. Disconnect the OTAS connector

2. Disconnect the gauge connector

Removing the Air Intake Silencer

1. Open or remove the seat.
2. From seat opening, cut locking tie securing the
wiring harness and the fuel supply hose to air
intake silencer.
smr2016-011-001

4. Unplug the top of ventilations tubes and place

them lower in hull.

smr2011-008-011_a

TYPICAL
1. Cut this locking tie

3. Detach rear retaining strap retaining air intake

smr2011-008-014_a
silencer and fuel tank.
1. Ventilation tubes

5. Cut locking ties securing wiring harness and

fuel hoses to air intake silencer.

smr2011-008-012_a

TYPICAL
1. Rear retaining strap – under glove box

4. Loosen clamp securing the air intake silencer

outlet hose to air intake tube.
smr2012-008-005_a

1. Cut these locking ties

smr2017-309
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Subsection XX (AIR INTAKE SYSTEM)

smr2016-011-002
smr2017-305-004_a

5. From the front storage compartment, cut lock-

ing ties securing the wiring harness and the fuel Release all retaining tabs.
hose to air intake silencer. Separate upper and lower sections.

smr2012-008-005_a

TYPICAL
smr2017-305-006_a
1. Cut these locking ties

6. Detach the front retaining straps. Assembling the Air Intake Silencer
Install the baffle into the outlet hose. Ensure
marks are aligned.

smr2011-008-008_a

1. Front retaining straps smr2011-008-023_a

TYPICAL
7. Carefully pull the air intake silencer forward to 1. Baffle mark
remove it from the vehicle. 2. Outlet hose mark

Install the assembly in the air intake silencer.

Disassembling the Air Intake Silencer
Remove screws securing upper section of air in-
take silencer to the lower section.

4 https://brp-manuals.com/pwc_seadoo smr2017-309
 Subsection XX (AIR INTAKE SYSTEM)

AIR INTAKE TUBE

Removing the Air Intake Tube
Supercharged Engine
1. Open seat.
2. Detach the seat bridge from the body and move
it aside to make room.
3. Loosen clamps retaining the air intake tube.

smr2016-011-006_a

1. Baffle tab into air intake silencer slot

2. Air intake silencer rib into the outlet hose groove

Install the inlet tubes. Ensure each end is properly

attached.

smr2016-011-008_a

1. Air intake tube

2. Retaining clamps

4. Detach the air intake tube from both hoses.

5. Open the front compartment storage cover and
remove the storage bin.
smr2016-011-007
6. Remove compartment panel. Refer to BODY
subsection.
Press both halves of the air intake silencer to- 7. Slide the air intake tube over the air intake
gether until all tabs are locked. Do not force, silencer and through the front compartment
make sure all tubes are properly installed. opening.
TIGHTENING TORQUE
Installing the Air Intake Tube
Air intake silencer
Hand tight The installation is the reverse of the removal pro-
screws
cedure. However pay attention to the following.
Installing the Air Intake Silencer Make sure air intake tube is perfectly inserted into
air intake hoses before tightening the clamps.
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. TIGHTENING TORQUE
Ensure wiring harness and fuel hoses are properly 4 N•m ± 1 N•m
Retaining clamps
routed. (35 lbf•in ± 9 lbf•in)
Install new locking ties
Make sure hoses are perfectly inserted into air in-
take tube before tightening the clamps.
TIGHTENING TORQUE
4 N•m ± 1 N•m
Retaining clamps
(35 lbf•in ± 9 lbf•in)

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 Subsection XX (EXHAUST SYSTEM)

EXHAUST SYSTEM
SERVICE TOOLS
Description Part Number Page
FLUSHING CONNECTOR ADAPTER ............................................ 295 500 473 ............................................. 3

SERVICE PRODUCTS
Description Part Number Page
P80 GRIP-IT ................................................................................... 296 000 406 ............................................. 6

4 ± 1 N•m
(35 ± 9 lbf•in)

4 ± 1 N•m
(35 ± 9 lbf•in)
4 ± 1 N•m
(35 ± 9 lbf•in)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)
1.7 ± 0.2 N•m
(15 ± 2 lbf•in)

4 ± 1 N•m
(35 ± 9 lbf•in)
smr2017-306 101_a

smr2017-310
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Subsection XX (EXHAUST SYSTEM)

GENERAL Exhaust System Technical

Specifications
SYSTEM DESCRIPTION Total Loss Cooling System
TYPE
The exhaust system is cooled by water provided (TLCS)
by a pressurized area in the jet pump (open loop Flow from jet pump
WATER FLOW
system). (no water pump)
Water exits exhaust manifold through holes to in- TEMPERATURE Calibrated outlet fittings
ject water in muffler. CONTROL (no thermostat)
SYSTEM
Self-bleed type
BLEEDING
SYSTEM
Self-drain type
DRAINING

MAINTENANCE
EXHAUST SYSTEM FLUSHING
Flushing the exhaust system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
smr2017-306 001_a
help to clean up sand, salt, shells or other particles
1. Exhaust manifold in water jackets (exhaust system, intercooler and
2. Exhaust manifold water inlet
3. Exhaust manifold water outlet (to hull) hoses).
Exhaust system flushing should be performed
when the watercraft is not expected to be used
further the same day or when the watercraft is
stored for any extended time.
NOTICE Failure to flush the system, when
necessary, will severely damage intercooler
and exhaust system. Make sure engine oper-
ates during entire procedure.

WARNING
Perform these operations in a well ventilated
area. Certain components in the engine
smr2014-015-001_a
compartment may be very hot. Direct con-
EXHAUST MANIFOLD
1. Injection holes tact may result in skin burn. Do not touch
2. Manifold outlet to jet pump support any electrical part or jet pump area when
3. Manifold inlet from jet pump support
engine is running.
Water is evacuated through the exhaust outlet in
transom area. WARNING
When operating the engine while the water-
craft is out of the water, the heat exchanger
in the ride plate may become very hot. Avoid
any contact with ride plate as burns may oc-
cur.

Connect a garden hose to connector located at the

rear of watercraft. Do not open water tap yet.

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 Subsection XX (EXHAUST SYSTEM)

NOTICE Remove flushing connector adapter

after operation (if used).

PROCEDURES
MUFFLER
CAUTION Certain components in the
engine compartment may be very hot. Let
exhaust system cool down prior to removing
parts.
smr2009-021-004_a

1. Water inlet connector Removing the Muffler

NOTE: The following tool is recommended when
a quick connect adapter is used to ease garden
hose installation.
RECOMMENDED TOOL
1. Remove or open seat.
2. Set aside the coolant reservoir.
3. Mark manifold to muffler hose location on muf-
fler.

FLUSHING CONNECTOR
ADAPTER (P/N 295 500 473)

F00E05A 1 2
smr2014-015-118_a
1. Quick connect adapter 1. Trace a mark here
2. Flushing connector adapter
NOTICE Do not use pneumatic or electrical
To flush the exhaust system, start the engine then
immediately open the water tap. tools as seizure may occur.

NOTICE Always start the engine before 4. Loosen muffler hose clamps and disconnect
opening the water tap. Open water tap im- EGTS.
mediately after engine is started to prevent
overheating. Never run engine without sup-
plying water to the exhaust system when
watercraft is out of water.
Run the engine about 20 seconds at a fast idle
between 4000 - 5000 RPM.
NOTICE Never run engine longer than 2 min-
utes. Drive line seal has no cooling when wa-
tercraft is out of water.
Ensure water flows out of jet pump while flushing.
Close the water tap, then stop the engine. smr2017-306 003_a

1. Muffler hose clamps

NOTICE Always close the water tap before 2. EGTS
stopping the engine.
5. Remove the muffler.
Disconnect the garden hose.

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Subsection XX (EXHAUST SYSTEM)

smr2014-015-120_a

smr2014-015-113_a
Inspecting the Muffler MANIFOLD TO MUFFLER EXHAUST HOSE - PORT SIDE VIEW
Check muffler for: A. Muffler engagement length 40 mm ± 2 mm (1.57 in ± .08 in)

– Cracks 2. Install muffler.

– Corrosion 3. Position muffler support on rear starboard en-
– Other damages. gine mount.
Check if exhaust hose is:
– Brittle
– Hard
– Cracked
– Otherwise damaged.
Replace any defective part.

Installing the Muffler

With a new muffler, install the EGTS sensor. Re-
fer to ELECTRONIC FUEL INJECTION (EFI) sub-
section.
With a new muffler, mark muffler as per specifi-
cation in step 1. smr2014-015-112_a

1. Ensure mark on muffler, inscribed during re-
moval, provides correct engagement length
into manifold to muffler exhaust hose.
NOTE: Because of manufacturing tolerances, the
measurement must be taken as illustrated. From
the muffler to the end of the hose.
MUFFLER SUPPORT - STARBOARD SIDE VIEW
1. Rear starboard engine mount
2. Muffler support
NOTE: Ensure muffler support is properly seated
on rear starboard engine mount.
Ensure manifold to muffler exhaust hose is
aligned with mark on inscribed muffler.
4. Reposition rear support.
5. Install all other removed parts.
6. Test run the engine while supplying water to
the exhaust system.
7. After installation, ensure there is no water or
exhaust gas leak when engine is running.
NOTICE Never run engine without supplying
water to the exhaust system when watercraft is
out of water.

4 https://brp-manuals.com/pwc_seadoo smr2017-310
 Subsection XX (EXHAUST SYSTEM)

EXHAUST MANIFOLD NOTE: There is no gasket between cylinder block

and exhaust manifold.
Removing the Exhaust Manifold
Insert the exhaust manifold into the exhaust hose.
Move muffler rearwards to make room. Refer to
REMOVING THE MUFFLER in this subsection.
Unscrew the exhaust manifold screws.

smr2014-015-002_a

1. Exhaust manifold screws smr2014-015-003_a

2. Exhaust manifold
EXHAUST MANIFOLD TIGHTENING SEQUENCE

Inspecting the Exhaust Manifold Tighten screws to specification as per following il-
Inspect exhaust manifold condition paying atten- lustrated sequence. Repeat the procedure twice.
tion for cracks or other damage. Check contact TIGHTENING TORQUE
surfaces and hose. Replace any defective part.
Exhaust manifold 23 N•m ± 3 N•m
Inspect plane surfaces for warpage. Small defor- screw (17 lbf•ft ± 2 lbf•ft)
mation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a flat sur- TIGHTENING TORQUE
face and rub part against oiled sand paper.
Exhaust manifold 1.7 N•m ± 0.2 N•m
Clean all metal components in a solvent. hose clamp (15 lbf•in ± 2 lbf•in)
Check if the injection holes (4x) are not clogged.
After installation, ensure there is no water or ex-
haust gas leak when the engine is running. Test
run the engine while supplying water to the flush-
ing connector.
NOTICE Never run engine without supplying
water to the exhaust system when watercraft is
out of water.

smr2014-015-004_a

1. Injection holes

Installing the Exhaust Manifold

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

smr2017-310
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Subsection XX (EXHAUST SYSTEM)

RESONATOR
Removing the Resonator

smr2016-012-013_a

smr2017-306 005

smr2016-012-014_a

Inspecting the Resonator

Inspect parts condition paying attention for defor-
smr2017-306 006
mation, cracks or other damage. Check hoses.
Replace any defective part.

Installing the Resonator

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

smr2017-306 007

smr2016-012-016_a

1. Spray P80 GRIP-IT (P/N 296 000 406)

After installation, ensure there is no water or ex-

haust gas leak when the engine is running. Test
run the engine while supplying water to the ex-
haust system.

6 https://brp-manuals.com/pwc_seadoo smr2017-310
 Subsection XX (EXHAUST SYSTEM)

NOTICE Never run engine without supplying

water to the exhaust system when watercraft is
out of water.

smr2017-310
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 Subsection XX (EXHAUST SYSTEM)

EXHAUST SYSTEM
SERVICE TOOLS
Description Part Number Page
FLUSHING CONNECTOR ADAPTER ............................................ 295 500 473 ........................................... 6

SERVICE PRODUCTS
Description Part Number Page
P80 GRIP-IT ................................................................................... 296 000 406 ........................................... 13

smr2017-310
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Subsection XX (EXHAUST SYSTEM)

11 ± 1 N•m
(97 ± 9 lbf•in)

See tightening Loctite 567

sequence (pipe sealant)
16 ± 1 N•m
(142 ± 9 lbf•in)

Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in)
9.5 ± 0.5 N•m
(84 ± 4 lbf•in)

9.5 ± 0.5 N•m

(84 ± 4 lbf•in)

4 ± 1 N•m
(35 ± 9 lbf•in)

See ELECTRONIC FUEL

INJECTION (EFI)

4 ± 1 N•m
(35 ± 9 lbf•in)

32 ± 2 N•m
(24 ± 1 lbf•ft)
smr2016-012-100_a

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 Subsection XX (EXHAUST SYSTEM)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

NEW

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

NEW = Component must be replaced when removed.

smr2011-013-100_a

smr2017-310
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Subsection XX (EXHAUST SYSTEM)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

NEW

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)
4 ± 1 N•m
(35 ± 4 lbf•in)
4 ± 1 N•m
(35 ± 4 lbf•in)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

NEW = Component must be replaced when removed.

smr2017-010-100_a

4 https://brp-manuals.com/pwc_seadoo smr2017-310
 Subsection XX (EXHAUST SYSTEM)

GENERAL Exhaust System Technical

Specifications
SYSTEM DESCRIPTION Total Loss Cooling System
TYPE
The exhaust system is cooled by water provided (TLCS)
by a pressurized area in the jet pump (open loop Flow from jet pump
WATER FLOW
system). (no water pump)
Water exits exhaust manifold through holes to in- TEMPERATURE Calibrated outlet fittings
ject water in muffler. CONTROL (no thermostat)
SYSTEM
Self-bleed type
BLEEDING
SYSTEM
Self-drain type
DRAINING

MAINTENANCE
EXHAUST SYSTEM FLUSHING
Flushing the exhaust system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
help to clean up sand, salt, shells or other particles
smr2016-012-017_a in water jackets (exhaust system, intercooler and
1. Exhaust manifold hoses).
2. Exhaust manifold water inlet
3. Exhaust manifold water outlet (to hull) Exhaust system flushing should be performed
4. Exhaust manifold water outlet (to exhaust pipe and muffler)
when the watercraft is not expected to be used
further the same day or when the watercraft is
stored for any extended time.
NOTICE Failure to flush the system, when
necessary, will severely damage intercooler
and exhaust system. Make sure engine oper-
ates during entire procedure.

WARNING
Perform these operations in a well ventilated
area. Certain components in the engine
compartment may be very hot. Direct con-
tact may result in skin burn. Do not touch
smr2014-015-001_a

EXHAUST MANIFOLD
any electrical part or jet pump area when
1. Injection holes engine is running.
2. Manifold outlet to jet pump support
3. Manifold inlet from jet pump support
WARNING
Water is evacuated through the exhaust outlet in
When operating the engine while the water-
transom area.
craft is out of the water, the heat exchanger
in the ride plate may become very hot. Avoid
any contact with ride plate as burns may oc-
cur.

Connect a garden hose to connector located at the

rear of watercraft. Do not open water tap yet.

smr2017-310
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Subsection XX (EXHAUST SYSTEM)

NOTICE Remove flushing connector adapter

after operation (if used).

PROCEDURES
MUFFLER
CAUTION Certain components in the
engine compartment may be very hot. Let
exhaust system cool down prior to removing
parts.
smr2009-021-004_a

1. Water inlet connector Removing the Muffler

NOTE: The following tool is recommended when
a quick connect adapter is used to ease garden
hose installation.
RECOMMENDED TOOL

FLUSHING CONNECTOR
ADAPTER (P/N 295 500 473)

smr2016-010-005

Set aside the coolant reservoir.

F00E05A 1 2 Mark manifold to muffler hose location on muffler.
1. Quick connect adapter
2. Flushing connector adapter

To flush the exhaust system, start the engine then

immediately open the water tap.
NOTICE Always start the engine before
opening the water tap. Open water tap im-
mediately after engine is started to prevent
overheating. Never run engine without sup-
plying water to the exhaust system when
watercraft is out of water.
smr2014-015-118_a
Run the engine about 20 seconds at a fast idle
between 4000 - 5000 RPM. NOTICE Do not use pneumatic or electrical
NOTICE Never run engine longer than 2 min- tools as seizure may occur.
utes. Drive line seal has no cooling when wa-
tercraft is out of water.
Ensure water flows out of jet pump while flushing.
Close the water tap, then stop the engine.
NOTICE Always close the water tap before
stopping the engine.
Disconnect the garden hose.

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 Subsection XX (EXHAUST SYSTEM)

Inspecting the Muffler

Check muffler for:
– Cracks
– Corrosion
– Other damages.
Check if exhaust hose is:
– Brittle
– Hard
– Cracked
– Otherwise damaged.
smr2016-010-008_a
Replace any defective part.

Installing the Muffler

With a new muffler, install the EGTS sensor. Re-
fer to ELECTRONIC FUEL INJECTION (EFI) sub-
section.
Open muffler adjusters by sliding adjuster blocks.

smr2016-010-007_a

smr2008-013-026_a

TYPICAL – RUBBER PAD REMOVED FOR CLARITY PURPOSE

Step 1: Lift adjuster tab
Step 2: Move adjuster outward

Insert the muffler in hull.

smr2016-012-001
Align the exhaust pipe flange with the exhaust
manifold. Rotate and move muffler so that the
exhaust pipe flange makes perfect contact with
exhaust manifold.
Slide both adjuster blocks against muffler to sup-
port it in position.
NOTE: Ensure muffler is in contact with both ad-
juster blocks. Readjust as required.
Install exhaust clamp with the nut upward.
Tighten clamp loosely.
Using a spacer, position the exhaust pipe.

smr2016-010-016_a

Remove the muffler.

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Subsection XX (EXHAUST SYSTEM)

REQUIRED SPACER After installation, ensure there is no water or ex-

haust gas leak when engine is running.
All models 50 mm (2 in)
Test run the engine while supplying water to the
exhaust system.
NOTICE Never run engine without supplying
water to the exhaust system when watercraft is
out of water.

EXHAUST HOSES

smr2008-013-027_a

TYPICAL
1. Engine lifting ring
2. Spacer (in this case a bolt)
3. Exhaust pipe fitting

Confirm that the exhaust pipe mark is aligned with

the mark on the exhaust manifold.

smr2016-012-002_a

1. Muffler
2. Front exhaust hose
3. Resonator
4. Rear exhaust hose

Front Exhaust Hose

Removing the Front Exhaust Hose

smr2016-012-018_a

1. Exhaust manifold rib wall facing the engine

2. Exhaust pipe mark
A. 35 mm (1-3/8 in)

Tighten exhaust clamp to specification.

TIGHTENING TORQUE
Exhaust clamp 11 N•m (97 lbf•in)

NOTICE Do not use pneumatic or electric smr2016-010-001_a

tools as seizure may occur. GTX LTD SHOWN

Install the muffler strap.

NOTICE Ensure not to rotate muffler during
strap installation. The use of a soapy water so-
lution on inner side of muffler strap is recom-
mended.
Install all other removed parts.

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 Subsection XX (EXHAUST SYSTEM)

smr2016-010-005 smr2016-012-004_a

1. New locking tie

All Models 2. Elbow fittings tied on highest part of hose

TIGHTENING TORQUE
Front exhaust hose 4 N•m ± 1 N•m
clamp (35 lbf•in ± 9 lbf•in)

After installation, ensure there is no water or ex-

haust gas leak when the engine is running. Test
run the engine while supplying water to the ex-
haust system.
NOTICE Never run engine without supplying
water to the exhaust system when watercraft is
out of water.
smr2016-012-003_a

Rear Exhaust Hose

Removing the Rear Exhaust Hose
Remove the resonator. See procedure in this sub-
section.
Loosen clamp securing the rear exhaust hose to
RH fixing plate.

smr2016-012-005

Installing the Front Exhaust Hose

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

smr2016-012-006

Installing the Rear Exhaust Hose

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

smr2017-310
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Subsection XX (EXHAUST SYSTEM)

smr2008-013-033_a
smr2016-012-015_a

A. 90° 1. Water inlet hose

2. Exhaust pipe
TIGHTENING TORQUE Remove exhaust pipe and the rubber adapter.
Rear exhaust hose 4 N•m ± 1 N•m
clamp (35 lbf•in ± 9 lbf•in) Inspecting the Exhaust Pipe
Inspect exhaust pipe for:
After installation, ensure there is no water or ex-
– Cracks
haust gas leak when the engine is running. Test
run the engine while supplying water to the ex- – Flange damages
haust system. – Other damages.
NOTICE Never run engine without supplying Replace exhaust pipe as required.
water to the exhaust system when watercraft is Check if the rubber adapter is:
out of water. – Brittle
– Hard
EXHAUST PIPE – Otherwise damaged.
Replace rubber adapter if necessary.

Installing the Exhaust Pipe

Install rubber adapter on muffler.

smr2012-014-011_a

1. Exhaust pipe
2. Rubber adapter
3. Muffler
smr2016-012-020_a

Removing the Exhaust Pipe SECTION VIEW

A. 57 mm ± 2 mm (2-1/4 in ± 5/64 in)
Remove MUFFLER, see procedure in this subsec-
tion. Center the muffler pre-mark with the BLUE strip
Loosen rubber adapter clamps. on rubber adapter.

10 https://brp-manuals.com/pwc_seadoo smr2017-310
 Subsection XX (EXHAUST SYSTEM)

Install muffler in vehicle. Refer to INSTALLING

THE MUFFLER in this subsection for complete
procedure.

EXHAUST MANIFOLD
Removing the Exhaust Manifold
Move muffler rearwards to make room. Refer to
REMOVING THE MUFFLER in this subsection.

smr2016-049-010_a

1. Muffler pre-mark
2. Blue strip on rubber adapter

Secure the rubber adapter to the muffler using re-

taining clamp.
Install the exhaust pipe in the rubber adapter. En-
sure rubber adapter is properly seats against ex-
haust pipe shoulder. smr2016-012-007

Unscrew the exhaust manifold screws.

smr2008-013-038_a

1. Exhaust pipe shoulder

2. Rubber adapter

Center the rubber adapter strip of the rubber

adapter between both exhaust pipe marks.
smr2016-012-008_b
Tighten retaining clamp. 1. Remove first
2. Remove last

Inspecting the Exhaust Manifold

Inspect exhaust manifold condition paying atten-
tion for cracks or other damage. Check contact
surfaces and hose. Replace any defective part.
Inspect plane surfaces for warpage. Small defor-
mation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a flat sur-
face and rub part against oiled sand paper.
Clean all metal components in a solvent.
Check if the injection holes (4x) are not clogged.
smr2008-013-036_a

1. Rubber adapter strip

2. Retaining clamp
3. Exhaust pipe marks

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Subsection XX (EXHAUST SYSTEM)

After installation, ensure there is no water or ex-

haust gas leak when the engine is running. Test
run the engine while supplying water to the flush-
ing connector.
NOTICE Never run engine without supplying
water to the exhaust system when watercraft is
out of water.

RESONATOR
Removing the Resonator
Remove the muffler. See the procedure in this
subsection.
Remove the intercooler. Refer to INTERCOOLER
subsection.
smr2014-015-004_a

1. Injection holes

Installing the Exhaust Manifold

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTE: There is no gasket between cylinder block
and exhaust manifold.
Insert the exhaust manifold into the exhaust hose.

smr2017-008 001

smr2016-012-008_a

EXHAUST MANIFOLD TIGHTENING SEQUENCE

Tighten screws to specification as per following il-

smr2017-008 002
lustrated sequence. Repeat the procedure twice.
TIGHTENING TORQUE
Exhaust manifold 9 N•m ± 1 N•m
screw (80 lbf•in ± 9 lbf•in)

TIGHTENING TORQUE
Exhaust manifold 1.7 N•m ± 0.2 N•m
hose clamp (15 lbf•in ± 2 lbf•in)

12 https://brp-manuals.com/pwc_seadoo smr2017-310
 Subsection XX (EXHAUST SYSTEM)

smr2017-008 003 smr2016-012-016_a

1. Spray P80 GRIP-IT (P/N 296 000 406)

After installation, ensure there is no water or ex-

haust gas leak when the engine is running. Test
run the engine while supplying water to the ex-
haust system.
NOTICE Never run engine without supplying
water to the exhaust system when watercraft is
out of water.

smr2016-012-013_a

smr2016-012-014_a

Inspecting the Resonator

Inspect parts condition paying attention for defor-
mation, cracks or other damage. Check hoses.
Replace any defective part.

Installing the Resonator

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

smr2017-310
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 Subsection XX (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
ADAPTER HOSE ........................................................................... 529 035 652 ............................................. 4
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 6
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 6
PRESSURE GAUGE....................................................................... 529 035 709 ............................................. 4

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 4, 7

R900ACE_MY17-002
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Subsection XX (LUBRICATION SYSTEM)

2
7

6
3

smr2014-016-001_a

ENGINE LUBRICATION CIRCUIT

1. Oil channel to camshaft bearing
2. Oil pressure switch
3. Crankshaft main bearing
4. Oil strainers
5. Oil pressure regulator
6. Oil filter
7. Oil cooler

2 https://brp-manuals.com/pwc_seadoo R900ACE_MY17-002
 Subsection XX (LUBRICATION SYSTEM)

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243
NEW

Oil filter Engine oil

See PERIODIC MAINTENANCE
PROCEDURES

NEW See tightening

procedure
12 ± 1 N•m
(106 ± 9 lbf•in)

Loctite 243

12 ± 1 N•m
(106 ± 9 lbf•in)
Loctite 243 NEW

NEW
Engine oil

17 ± 2 N•m
(150 ± 18 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)

Engine oil

Engine oil
9 ± 1 N•m
(80 ± 9 lbf•in)

Engine oil
NEW
Engine oil
See tightening procedure 9 ± 1 N•m
(80 ± 9 lbf•in)

Engine oil
NEW

See tightening procedure Engine oil

9 ± 1 N•m
9 ± 1 N•m (80 ± 9 lbf•in)
(80 ± 9 lbf•in)
NEW = Component must be replaced when removed.

R900ACE_MY17-002-001_a

R900ACE_MY17-002
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Subsection XX (LUBRICATION SYSTEM)

GENERAL
SYSTEM DESCRIPTION
This engine uses dry sump lubrication. The oil
from the cylinder block, timing chain chamber and
magneto cover is pumped by two suction pumps.
Both suction pumps are integrated into one mod-
ule.
The large 20 mm (.79 in) oil suction pump returns
the crankshaft and magneto chamber oil to the
reservoir.
smr2014-016-004_a
The small 11 mm (.43 in) oil suction pump returns 1. Adapter hose
the timing chain chamber oil to the oil reservoir.
An oil filter and three oil strainers are used to filter 4. Connect the pressure gauge to adapter hose.
dirt and debris from the oil circuit. REQUIRED TOOL
The oil strainers are located between oil sump
cover and crankcase underneath the oil pressure PRESSURE GAUGE (P/N 529
pump. 035 709)
The oil pressure is provided by a pump and regu-
lated by a spring loaded pressure regulator. 5. Start engine and check the oil pressure.
ENGINE OIL PRESSURE @ 100°C (212°F)
INSPECTION
ENGINE SPEED MINIMUM PRESSURE
ENGINE OIL PRESSURE Idle 80 kPa (11.6 PSI)

1. Remove central body. Refer to BODY subsec- 4000 RPM 270 kPa (39.16 PSI)
tion. 6000 to 8000 RPM 350 kPa (50.76 PSI)
2. Remove oil pressure test plug screw from cylin-
der block. If the engine oil pressure is out of specification,
refer to TROUBLESHOOTING in this subsection.
6. Remove engine oil pressure test tools.
7. Clean threads of oil pressure test plug screw
before installing the plug screw.
8. Tighten oil pressure test plug screw to specifi-
cation.
TIGHTENING TORQUE
12 N•m ± 1 N•m
(106 lbf•in ± 9 lbf•in)
Oil pressure test plug
+
screw
LOCTITE 243 (BLUE)
(P/N 293 800 060)
smr2014-016-003_a

1. Oil pressure test plug screw

2. Timing chain tensioner

3. Install the adapter hose on cylinder block.

REQUIRED TOOLS

ADAPTER HOSE
(P/N 529 035 652)

4 https://brp-manuals.com/pwc_seadoo R900ACE_MY17-002
 Subsection XX (LUBRICATION SYSTEM)

HIGH OIL CONSUMPTION

1. Oil in breathing system.
- Check if breather V-ring is brittle, hard or dam-
aged. Replace V-ring.
- Check if oil separator cover is damaged or miss-
ing.
2. Valve stem seals worn or damaged.
- Replace valve stem seals.
3. Piston rings worn out (blue colored exhaust
smoke).
- Replace piston rings.
smr2014-016-003_a

1. Oil pressure test plug screw OIL CONTAMINATION

2. Timing chain tensioner
9. Reinstall all removed parts.
TROUBLESHOOTING
Always check for fault codes. If a fault code is de-
tected, service the fault code first.
LOW OR NO ENGINE OIL PRESSURE
1. Oil level is too low.
- Refill engine oil.
- Check for high oil consumption. See below.
- Check for oil leaks (oil leaking out of leak indica-
tor hole, gaskets, oil seal or O-rings). Repair or
replace.
2. Defective or clogged oil filter.
- Replace engine oil and filter.
3. Use of a bad grade oil.
- Replace engine oil with BRP recommended oil.
4. Oil pressure regulator valve sticks open, or
spring load is insufficient.
- Clean oil regulator piston and its bore. Replace if
necessary.
- Measure spring free length. Replace if out of
specification.
5. Oil pump(s) worn or damaged.
- Check if oil pump drive gears are damaged. Re-
place if necessary.
- Check oil pump rotors and its bore for wear limits.
Replace if out of specification.
6. Engine oil strainer is clogged.
- Remove and clean engine oil strainer.
7. Heavy wear on plain bearings.
- Check radial clearance of plain bearings. Replace
if out of specification.
(WHITE APPEARANCE)
NOTICE Inspect and replace engine coolant if
contaminated.
1. Oil seal and rotary seal on water pump shaft
leaking.
- Replace oil seal, rotary seal and water pump
shaft. Change engine oil.
2. Cylinder head gasket leaking.
- Replace cylinder head gasket. Change engine oil.
3. Cylinder head screws not properly tightened.
- Retighten screws with recommended torque.
Change engine oil.
4. Oil cooler gasket leaking.
- Replace oil cooler gasket. Change engine oil.
5. PTO seal leaking.
- Replace PTO seals. Change engine oil.
PROCEDURES
OIL PRESSURE SWITCH (OPS)
OPS Activation
The oil pressure switch activates when the engine
oil pressure is lower than following specified pres-
sure range.
NOTE: ECM does not trigger the OPS signal be-
low 4500 rpm.
OIL PRESSURE SWITCH ACTIVATION RANGE
130 kPa to 170 kPa (18.85 PSI to 24.66 PSI)
OPS Access
Remove central body. Refer to BODY subsection.

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Subsection XX (LUBRICATION SYSTEM)

OPS Inspection If the resistance is correct, continue procedure. It

First, ensure oil pressure is adequate. Refer to will be necessary to use jumper wires.
ENGINE OIL PRESSURE. 4. Start engine.
If the oil pressure is good, check the resistance of 5. Read result and compare to table.
the oil pressure switch.
RESISTANCE ( )
Inspecting the OPS Resistance ENGINE RUNNING
The engine must be warm to check the oil pres- Infinitely high
sure switch properly. OPS pin Engine ground
(OL)

WARNING If resistance is out of specification, replace the oil

Be careful when working near hot part. To
avoid potential burns, never touch exhaust
system components immediately after the
engine has been running as these compo-
nents are very hot. Always use long sleeves
and gloves.
1. Cut locking tie and disconnect the OPS connec-
tor.
pressure switch.
If the resistance is correct, check the oil pressure
switch circuit continuity.
Testing the OPS Circuit Continuity
1. Disconnect ECM connector A. Refer to ECM
CONNECTOR ACCESS in ELECTRONIC FUEL
INJECTION) subsection.
2. Install connector A to the ECM adapter.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

3. Cut locking tie and disconnect the OPS connec-

tor.

smr2014-016-005_a

UNDER EXHAUST MANIFOLD

1. Locking tie
2. OPS connector

2. Check the oil pressure switch resistance.

REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868) smr2014-016-005_a

1. Locking tie
2. OPS connector
3. Read result and compare to table.
4. Check continuity as follows.
RESISTANCE ( )
REQUIRED TOOL
ENGINE NOT RUNNING
Close to 0 FLUKE 115 MULTIMETER
OPS pin Engine ground (normally (P/N 529 035 868)
closed switch)

If resistance is out of specification, replace the oil

pressure switch.

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 Subsection XX (LUBRICATION SYSTEM)

CIRCUIT CONTINUITY TIGHTENING TORQUE

OPS connector ECM A pin E3 Close to 0 12 N•m ± 1 N•m
(106 lbf•in ± 9 lbf•in)
If the continuity is good and all other tests, try a Oil pressure switch +
NEW ECM. LOCTITE 243 (BLUE)
(P/N 293 800 060)
If the continuity is bad, repair or replace defective
wire or connectors. Install all other removed parts.
Removing the OPS NOTICE When installing the locking tie on
1. Cut locking tie and unplug the OPS switch con- the OPS connector, take care that the wires do
nector. not make a sharp bend.

OIL FILLER TUBE

Removing the Oil Filler Tube
1. Remove intake manifold, refer to AIR INTAKE
SYSTEM subsection.
2. Remove the oil filler tube retaining screw.

smr2014-016-005_a

1. Locking tie
2. OPS connector

2. Unscrew and remove the OPS.

smr2014-016-007_a

1. Oil filler tube

2. Retaining screw

3. Pull filler tube out of the oil tank cover.

Installing the Oil Filler Tube

1. Install NEW O-rings on the oil filler tube.
smr2014-016-006_a

1. Oil pressure switch

Installing the OPS

Install oil pressure switch as per the following in-
formations.

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Subsection XX (LUBRICATION SYSTEM)

OIL TANK
Removing the Oil Tank Cover
1. Drain engine oil. Refer to PERIODIC MAINTE-
NANCE PROCEDURES subsection.
2. Remove the engine from vehicle. Refer to EN-
GINE REMOVAL AND INSTALLATION subsec-
tion.
3. Remove intake manifold. Refer to AIR INTAKE
SYSTEM subsection.
4. Place a drain pan underneath oil tank.
smr2014-016-008_a
5. Unscrew oil tank cover retaining screws.
1. Oil filler tube O-rings

2. Lubricate the oil tank cover bore with engine oil.

smr2014-016-012_a

RETAINING SCREWS
1. Oil tank

6. Remove oil tank from the engine.

Installing the Oil Tank Cover

1. Install NEW gasket.
2. Install the oil tank on the engine, then tighten
screws in two steps as follows:
2.1 Tighten the following screws to the speci-
fied torque and sequence.
TIGHTENING TORQUE
smr2014-016-009_a

1. Lubricate the oil tank cover bore Oil tank 5 N•m ± 0.6 N•m
Step A
2. Retaining screw screws (44 lbf•in ± 5 lbf•in)
3. Oil filler tube

3. Install the oil filler tube.

4. Tighten retaining screw to the specified torque.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Oil filler tube screw
(80 lbf•in ± 9 lbf•in)

5. Install all other removed parts.

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 Subsection XX (LUBRICATION SYSTEM)

Removing the Oil Cooler

1. Refer to PERIODIC MAINTENANCE PROCE-
DURES subsection to:
– Drain engine oil
– Drain cooling system.
2. Place rags or towels under oil cooler to catch
remaining oil and coolant.
3. Remove oil cooler retaining screws.
4. Lift harness bracket.

smr2014-016-012_b

TIGHTENING SEQUENCE STEP A

2.2 Tighten the following screws to the speci-

fied torque and sequence.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Oil tank screws Step B
(80 lbf•in ± 9 lbf•in)

R900ACE_MY17-002-002_a

1. Retaining screws M6x55

2. Retaining screws M6x45
3. Harness bracket

5. Remove:
– Oil cooler
– Gasket (discard it)

smr2014-016-012_c

TIGHTENING SEQUENCE STEP B

3. Wipe off any oil spillage.

4. Install the engine in the vehicle. Refer to EN-
GINE REMOVAL AND INSTALLATION subsec-
tion.
5. Install intake manifold. Refer to AIR INTAKE
SYSTEM subsection.
6. Fill up oil tank and check oil level. Refer to PERI-
ODIC MAINTENANCE PROCEDURES subsec-
tion. R900ACE_MY17-002-003_a

1. Oil cooler
2. Gasket
OIL COOLER
Oil Cooler Access Inspecting the Oil Cooler
Check oil cooler for cracks and other damage.
Remove central body. Refer to BODY subsection.

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Subsection XX (LUBRICATION SYSTEM)

OIL PRESSURE REGULATOR

Oil Pressure Regulator Location
The engine oil pressure regulator is located inside
the magneto cover.

smr2014-016-015_a

1. Check for cracks

Replace parts as necessary.

Installing the Oil Cooler

For installation, reverse the removal procedure. mmr2011-070-022_a

However, pay attention to the following. 1. Engine oil pressure regulator location

Tighten oil cooler screws in two steps to the spec- Removing the Oil Pressure Regulator
ified torque following the illustrated sequence.
1. Drain engine oil. Refer to PERIODIC MAINTE-
TIGHTENING TORQUE NANCE PROCEDURES subsection.
5 N•m ± 0.6 N•m 2. Remove regulator plug and sealing washer.
Step A
Oil tank (44 lbf•in ± 5 lbf•in) Discard sealing washer.
screws 9 N•m ± 1 N•m 3. Pull oil pressure regulator parts out of the mag-
Step B
(80 lbf•in ± 9 lbf•in) neto cover.

mmr2012-133-003_a

1. Plug
2. Sealing washer
R900ACE_MY17-002-002_b 3. Regulator spring
TIGHTENING SEQUENCE OIL-COOLER 4. Regulator piston

Wipe off any oil and coolant spillage.
Refer to PERIODIC MAINTENANCE PROCE-
DURES subsection for following procedures:
– Fill up oil tank and check oil level.
– Refill and bleed cooling system.
Inspecting the Oil Pressure Regulator
Clean bore and thread in the magneto cover from
any contamination.
Inspect oil pressure regulator piston and its bore
in cylinder block for scoring or other damages.
Check if piston moves easily in its bore.
Check compression spring for free length.

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 Subsection XX (LUBRICATION SYSTEM)

SPRING FREE LENGTH – Rotor

– Sprag clutch gear.
New nominal 46 mm (1.811 in)
2. Unscrew oil pump intermediate gear screws.
Service limit 45 mm (1.772 in)

Visually check compression spring for square-

ness.
Replace worn or damaged components.

Installing the Oil Pressure Regulator

For installation, reverse the removal procedure.
However, pay attention to the following.
Install a NEW sealing washer on plug.
Tighten regulator plug to the specified torque.
TIGHTENING TORQUE
Oil pressure regulator 17 N•m ± 2 N•m mmr2011-070-024_b

plug (150 lbf•in ± 18 lbf•in) 1. Retaining screws

2. Intermediate gears
Wipe off any oil spillage.
3. Remove bearing sleeves and oil pump interme-
Fill up oil tank and check oil level. Refer to PE- diate gears.
RIODIC MAINTENANCE PROCEDURES subsec-
tion.
Install all other removed parts.

OIL PUMP DRIVE GEARS

Oil Pump Drive Gear Location
The oil pump gears are located on the MAG side,
behind the magneto cover.

mmr2011-070-026_a

1. Intermediate gears
2. Bearing Sleeves

4. Remove oil pump gears and needle pins.

mmr2011-070-024_a

1. Oil pump drive gear

2. Intermediate gears
3. Oil pressure pump gear
4. Oil suction pump gear

Oil Pump Drive Gear Removal

1. Refer to MAGNETO AND STARTER subsection mmr2011-070-027_a

to remove: 1. Oil pump gears

2. Needle pins
– Magneto cover

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Subsection XX (LUBRICATION SYSTEM)

Inspecting the Oil Pump Drive Gear

Inspect gears for wear, cracks or other damage.
Replace if damaged.

Installing the Oil Pump Drive Gear

For installation, reverse the removal procedure,
however, pay attention to the following.
1. Ensure not to mix up the oil pump gears, see
next illustration.
1.1 Install the BROWN oil pump gear
(29 teeth) on oil pressure pump.
mmr2011-070-030_a

1.2 Install the BLACK oil pump gear (28 teeth) 1. Oil pressure pump
on oil suction pump.
Removing the Oil Pressure Pump
1. Remove OIL PUMP DRIVE GEARS, see proce-
dure in this subsection.
2. Remove oil pump cover.

mmr2011-070-028_a

1. BROWN oil pump gear - 29 teeth

2. BLACK oil pump gear - 28 teeth

2. Lubricate intermediate gears bearing sleeves

with engine oil, then install gears.
3. Install all other removed parts. mmr2011-070-030_b

4. Fill up oil tank and check oil level. Refer to PERI- 1. Retaining screws
2. Oil pump cover
ODIC MAINTENANCE PROCEDURES subsec-
tion. 3. Remove the following parts.

OIL PRESSURE PUMP

Oil Pressure Pump Location
The oil pressure pump is located in the cylinder
block, behind the magneto cover.

mmr2011-070-032_a

1. Inner rotor
2. Oil pump shaft
3. Needle pin
4. Outer rotor

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 Subsection XX (LUBRICATION SYSTEM)

Inspecting the Oil Pressure Pump NOTE: If clearance of inner and outer rotors ex-
Inspect oil pump and oil pump cover bore for ceeds the tolerance, replace oil pump.
marks, scratches or other damage. Replace any Axial Clearance
damaged parts.
Measure outer rotor thickness with a micrometer.
Check oil pump cover for damages and for surface
straightness with a straight edge.
Check inner rotor for corrosion, worn pin slots or
other damages. If so, replace inner and outer rotor
at the same time.

rmr2008-011-020

OUTER ROTOR THICKNESS

Using a depth gauge, measure the depth of oil

pump bore in the lower crankcase.

vmr2008-012-016_a

1. Pitting on the teeth

Radial Clearance
Using a feeler gauge, measure the clearance of
outer rotor and inner rotor where shown with the
arrows.

mmr2011-070-056

OIL PUMP BORE DEPTH (OIL PUMP COVER)

Substract bore depth from rotor thickness to ob-

tain axial clearance.
OIL PUMP AXIAL CLEARANCE
Service limit 0.15 mm (.0059 in)

NOTE: When the axial clearance of the oil pump

assembly increases, the oil pressure decreases.

Installing the Oil Pressure Pump

For installation, reverse the removal procedure,
however, pay attention to the following.
1. Lubricate outer rotor with engine oil.
NOTICE Install rotors with the marks out-
vmr2008-012-014_c wards.
OIL PUMP RADIAL CLEARANCE 2. Install outer rotor into crankcase oil pump bore.
Service limit 0.25 mm (.0098 in)

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Subsection XX (LUBRICATION SYSTEM)

OIL SUCTION PUMP MODULE

Oil Suction Pump Module Location
The oil suction pump module is located in the
cylinder block, behind the magneto cover.

vmr2008-012-014_b

TYPICAL mmr2011-070-039_a
1. Marks on inner and outer rotor 1. Oil suction pump module

3. Install needle pin in oil pump shaft.

NOTICE The oil pump shaft is not symmetri-
cal, the longer side must be installed inward.
Disassembling the Oil Suction Pump
Module
1. Remove OIL PUMP DRIVE GEARS, see proce-
dure in this subsection.
2. Remove oil pump module cover.

mmr2011-070-057_a

1. Towards engine
A. 16.96 mm (.67 in)
B. 11.43 mm (.45 in)
C. 60.5 mm (2.38 in)

4. Place inner rotor onto the oil pump shaft. Lubri-

cate oil pump shaft and inner rotor with engine
oil. mmr2011-070-040_a

1. Oil pump module cover

5. Install oil pump shaft assembly into the 2. Retaining screws
crankcase.
After installation of the remaining parts, check for 3. Disassemble the large oil suction pump as
smooth operation of the oil pump assembly and shown.
axial play of the oil pump shaft.
6. Fill up oil tank and check oil level. Refer to PERI-
ODIC MAINTENANCE PROCEDURES subsec-
tion.
Start engine and make sure oil pressure is within
specifications (refer to ENGINE OIL PRESSURE in
this subsection).

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 Subsection XX (LUBRICATION SYSTEM)

Inspecting the Oil Suction Pumps

The inspection of both oil suction pumps is the
same as for the oil pressure pump. Refer to OIL
PRESSURE PUMP in this subsection.
Assembling the Oil Suction Pump
Module
For installation, reverse the removal procedure,
however, pay attention to the following.
1. Lubricate small oil suction pump outer rotor
with engine oil.
mmr2011-070-041_a

1. Inner rotor NOTICE When installing the oil pump rotors,

2. Needle pin
3. Outer rotor make sure both marks are pointing toward the
inside of the crankcase.
4. Disassemble the small oil suction pump as
shown.

mmr2011-070-046_a

1. Mark on inner rotor

mmr2011-070-042_a
2. Mark on outer rotor
1. Oil pump cover
2. Oil pump shaft
3. Needle pin 2. Install small oil suction pump outer rotor into
4. Inner rotor crankcase oil pump bore.
5. Outer rotor

5. Remove and discard the oil pump cover O-ring.

mmr2012-133-004_a

1. Small oil suction pump outer rotor

mmr2011-070-043_a
3. Install needle pin in bore of the oil pump shaft
1. Oil pump cover O-ring
and place the small inner rotor on the shaft.

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Subsection XX (LUBRICATION SYSTEM)

8. Align tab of the oil pump cover with the upper

recess in the crankcase. Push cover in until a
click is heard, indicating the cover is properly
installed.

mmr2012-133-005_a

1. Needle pin
2. Oil pump shaft
3. Small suction pump inner rotor

4. Lubricate oil pump shaft and inner rotor with

engine oil.
5. Install oil pump shaft assembly into the
crankcase.
mmr2011-070-048_a

1. Oil pump cover tab properly positioned

9. Install large oil suction pump needle pin.

10. Install large oil suction pump inner rotor and
outer rotor with the marks outwards.

mmr2011-070-045_a

1. Oil pump shaft with small oil suction pump

6. Install a NEW oil pump cover O-ring.

mmr2011-070-050_a

1. Marks on inner and outer rotor

11. Lubricate large oil suction pump parts with en-

gine oil.
12. Install other removed parts.
After installation is complete, check for smooth
operation of the oil pump assembly and axial play
of the oil pump shaft.
13. Fill up oil tank and check oil level. Refer to PE-
RIODIC MAINTENANCE PROCEDURES sub-
mmr2011-070-047_a
section.
1. Oil pump cover O-ring
Start engine and make sure oil pressure is within
7. Lubricate both sides of the oil pump cover with specifications (refer to ENGINE OIL PRESSURE in
engine oil. this subsection).

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 Subsection XX (LUBRICATION SYSTEM)

OIL SUMP COVER

Oil Sump Cover Location
The oil sump cover is located on the engine bot-
tom.

smr2014-016-018_a

1. Engine oil strainers

2. Oil sump cover

Inspecting the Oil Sump Cover

Clean oil sump cover and engine oil strainers with
smr2014-016-016_a
a part cleaner, then use an air gun to dry it.
BOTTOM OF ENGINE Blow out the oil orifices and check if they are not
1. Oil sump cover
clogged.
Removing the Oil Sump Cover
1. Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
2. Drain engine oil, refer to PERIODIC MAINTE-
NANCE PROCEDURES subsection.
3. Unscrew oil sump cover retaining screws.
4. Remove oil sump cover. Discard gasket.

smr2014-016-020_a

1. Oil drain bores

Check oil sump cover for cracks or other damage.

Check oil sump cover for flatness with straight
edge.
Replace oil sump cover if necessary.
Check engine oil strainers for damage and change
smr2014-016-017_a
if necessary.
1. Retaining screws
2. Oil sump cover Installing the Oil Sump Cover
3. Gasket
1. Install a NEW oil sump cover gasket.
5. Remove and clean engine oil strainers. 2. Install the strainers as shown.

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Subsection XX (LUBRICATION SYSTEM)

smr2014-016-017_b smr2014-016-016_c

1. Oil sump cover TIGHTENING SEQUENCE STEP B

2. Gasket
3. Engine oil strainers
3. Install the oil sump cover on the engine, then
tighten screws in two steps as follows:
3.1 Tighten the following screws to the speci-
fied torque and sequence.
4. Install engine in vehicle. Refer to ENGINE RE-
MOVAL AND INSTALLATION subsection.
5. Fill up oil tank and check oil level. Refer to PERI-
ODIC MAINTENANCE PROCEDURES subsec-
tion.

TIGHTENING TORQUE
Oil sump 5 N•m ± 0.6 N•m
Step A
cover screws (44 lbf•in ± 5 lbf•in)

smr2014-016-016_b

TIGHTENING SEQUENCE STEP A

3.2 Tighten the following screws to the speci-

fied torque and sequence.
TIGHTENING TORQUE
Oil sump cover 9 N•m ± 1 N•m
Step B
screws (80 lbf•in ± 9 lbf•in)

18 https://brp-manuals.com/pwc_seadoo R900ACE_MY17-002
 Subsection XX (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
BACK PROBE TEST WIRES .......................................................... 529 036 063 ........................................... 27
CERAMIC SEAL PULLER .............................................................. 529 036 365 ........................................... 17
ECM ADAPTER TOOL................................................................... 529 036 166 ..................................... 10, 28
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................... 10, 27–28
HANDLE ........................................................................................ 420 877 650 ........................................... 17
OIL PRESSURE HOSE .................................................................. 529 036 394 ............................................. 8
OIL SEAL GUIDE........................................................................... 529 035 822 ........................................... 16
OIL SEAL PUSHER........................................................................ 529 035 757 ........................................... 17
PRESSURE GAUGE....................................................................... 529 036 395 ............................................. 8
SUCTION PUMP ........................................................................... 529 035 880 ............................................. 7
WATER PUMP SEAL PUSHER...................................................... 529 035 823 ..................................... 16, 18

SERVICE PRODUCTS
Description Part Number Page
BLACK NEOPRENE PAINT ............................................................ 909570 ........................................... 12
LOCTITE 243 (BLUE)..................................................................... 293 800 060 .......11, 14, 16, 20–22, 26, 29
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ....................................... 7, 18
SUPER LUBE GREASE.................................................................. 293 550 030 ............................................. 8
XPS 4-STROKE SYNTH. BLEND OIL............................................. 293 600 121 ............................................. 6

RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)

Engine oil
NEW

Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in) NEW

17 ± 2 N•m
(150 ± 18 lbf•in)
Black Neoprene
paint

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243

Engine oil

NEW

19 ± 2 N•m
(168 ± 18 lbf•in)

NEW

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243

Engine oil

Engine oil
Engine oil

Loctite 243 See

11 ± 1 N•m tightening
NEW (97 ± 9 lbf•in) sequence
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW = Component must be replaced when removed. Loctite 243

RTX1503ACEMY18-002-001_a

2 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-002
 Subsection XX (LUBRICATION SYSTEM)

9 ± 1 N•m
(80 ± 9 lbf•in)

Engine oil

Engine oil

NEW

9 ± 1 N•m
(80 ± 9 lbf•in)

Engine oil
NEW

3 ± 0,4 N•m
(27 ± 4 lbf•in)
left-hand threads
SUPERCHARGER
4,5 ± 0,5 N•m
(40 ± 4 lbf•in)
NEW
Loctite 243
NEW

Engine oil

Engine oil
Multi purpose
grease
9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243

Engine oil

13 ± 1 N•m
(115 ± 9 lbf•in)
Loctite 243

NEW = Component must be replaced when removed.

smr2016-013-002_b

RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)

ENGINE LUBRICATION CIRCUIT

Legend
1
Pressurized oil
2
Scavenged oil
3 Blow-by gas

4
5

8
7
9
10

11

12

13

smr2009-023-100_en

1. Oil dipstick
2. Rocker arm (intake)
3. Rocker arm (exhaust)
4. Hydraulic valve lifter
5. Camshaft
6. Piston pin
7. Into PTO housing
8. From oil filter
9. Piston cooling
10. Connecting rod
11. Balance shaft
12. Crankshaft
13. Oil tank

4 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-002
 Subsection XX (LUBRICATION SYSTEM)

ENGINE LUBRICATION CIRCUIT (CONT'D)

35

Légende
Huile sous pression
Huile sous barbotage
Recirculation des gas du carter
smr2016-013-003_en_b

1. To air intake silencer 18. Oil spray nozzle (if so equipped)

2. Rocker arm (intake) 19. Drive shaft
3. Rocker arm (exhaust) 20. Crankshaft
4. Rocker arm axle 21. PTO seal
5. Camshaft 22. Oil pressure switch
6. Pressure relief valve 23. Balance shaft
7. Oil separator 24. PTO housing
8. Cylinder head 25. Pressure pump
9. Blow-by valve 26. Pressure relief valve
10. Supercharger (if so equipped) 27. Oil strainer (pressure pump)
11. Oil filter 28. Suction pump
12. Hydraulic chain tensioner 29. Oil tank
13. Supercharger bearing (if so equipped) 30. Oil strainer (scavenge pump)
14. Friction clutch 31. Oil drainage (PTO housing)
15. Piston pin 32. Oil cooler
16. Connecting rod 33. Scavenge of oil and blow-by gas
17. Piston cooling 34. Oil filler cap
35. Oil temperature sensor

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Subsection XX (LUBRICATION SYSTEM)
MAINTENANCE
ENGINE OIL
Recommended Oil
ENGINE OIL
XPS 4-STROKE SYNTH.
BRP RECOMMENDED
BLEND OIL (P/N 293
PRODUCT
600 121)
10W 40 mineral engine
ALTERNATIVE, OR IF oil compatible with wet
NOT AVAILABLE clutches (JASO MA
certified oils)
NOTE: The XPS engine oil has been thoroughly
tested to be free of any additives that could impair
the functionality of the supercharger clutch.
NOTICE NEVER use synthetic oil. This would
impair the proper operation of the super-
charger clutch. Do not add any additives to
the recommended oil. Mineral oils not recom-
mended by BRP may also contain additives
(friction modifiers) that may cause inappropri-
ate slippage of the supercharger and eventu-
ally lead to premature wear. For this reason,
XPS Synthetic Blend oil (Summer Grade) or a
BRP approved equivalent are the only recom-
mended oils. Use of any oil not recommended
by BRP may void BRP's limited warranty.
Verifying the Engine Oil Level
NOTICE Do not overfill — it would make the
engine smoke and reduce its power. Operat-
ing the engine with an improper level may se-
verely damage engine. Wipe off any spillage.
219001695-301_a
TYPICAL
1. Oil dipstick location
Check the oil level as follows:
6 https://brp-manuals.com/pwc_seadoo
NOTE: It is of the utmost importance to follow
this procedure in order to obtain an accurate read-
ing of the engine oil level.
1. Watercraft must be level. Check oil level either
with watercraft in water or out of water.
NOTE: If the watercraft is out of water, link
a garden hose to the hose adapter. Refer to
FLUSHING THE EXHAUST SYSTEM in the EX-
HAUST SYSTEM subsection.
NOTICE When watercraft is out of water:
– Never run engine without supplying water to
the exhaust system.
– Never run engine longer than 2 minutes.
Drive line seal has no cooling when water-
craft is out of water.
2. Warm-up engine then let idle for 30 seconds
before stopping.
3. Stop engine.
4. Open or remove seat.
5. Wait at least 30 seconds for the oil to settle
in the engine, then pull dipstick out and wipe
clean.
CAUTION Engine oil may be hot. Certain
components in the engine compartment may
be very hot. Direct contact may result in skin
burn.
6. Reinstall dipstick, push in completely.
7. Remove dipstick and read oil level. It should be
between the FULL and ADD marks.
lmr2007-053-100_a
1. Full
2. Add
3. Operating range
Otherwise, add oil until its level is between marks
as required.
NOTE: The oil quantity between FULL and ADD
marks is 1 L (1.06 qt (U.S. liq.)).
To add oil, unscrew oil cap. Place a funnel into the
valve cover opening opening and add the recom-
mended oil to the proper level. Do not overfill.
Reinstall oil filler cap.
RTX1503ACEMY18-002
 Subsection XX (LUBRICATION SYSTEM)

NOTICE Ensure that oil filler cap is tighten OIL FILTER

properly. Otherwise engine oil can spill out.
Removing the Oil Filter
Engine Oil Change Remove the oil filter cover and the oil filter.
NOTE: Oil and oil filter must be replaced at the
same time. Oil change and oil filter replacement
should be done with a warm engine.
Bring engine to its normal operating temperature.
NOTICE When watercraft is out of water:
– Never run engine without supplying water to
the exhaust system.
– Never run engine longer than 2 minutes.
Drive line seal has no cooling when water-
craft is out of water.
Run engine for 10 seconds at 4000 RPM and shut
it off at this RPM. This will move oil from PTO
housing to oil tank to allow maximum oil draining. smr2016-013-004_a

TYPICAL
Remove oil filler cap and dipstick. 1. Oil filter screw
2. Oil filter cover
3. O-rings
CAUTION Engine oil may be hot. Certain 4. Oil filter
components in the engine compartment may
be very hot. Direct contact may result in skin Place rags in filler area to prevent spillage. If
burn. spillage occurs, clean immediately with the PUL-
LEY FLANGE CLEANER (P/N 413 711 809) to prevent
Siphon oil through the dipstick tube.
stains.
To siphon the maximum amount of oil from the
crank chamber do the following: Inspecting the Oil Filter
– Put some electrical tape on hose at 475 mm Check oil filter screw O-ring, change if necessary.
(18-11/16 in) from its end
Check and clean the oil filter inlet and outlet area
– Then insert the hose until the tape flushes with for dirt and other contaminations.
the edge of the dipstick tube.
REQUIRED TOOL

SUCTION PUMP
(P/N 529 035 880)

NOTICE Never crank or start engine when

suction pump hose is in the dipstick tube.
Never start engine when there is no oil in en-
gine.
Pull suction pump hose out of dipstick tube.
Fully depress the throttle lever and HOLD it while smr2016-013-005_a

cranking engine for 10 seconds. Siphon oil again. TYPICAL

Repeat the crank-siphon cycle 2 - 3 times.
Refill engine with the recommended oil, see REC-
OMMENDED OIL in this subsection.
Reinstall oil filler cap and dipstick.
Replace OIL FILTER, see procedure in this sub-
section.
1. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system
Installing the Oil Filter
For installation, reverse the removal procedure.
Pay attention to the following details.
Install a NEW oil filter.

RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)

Install NEW O-rings on oil filter cover. OIL PRESSURE

Apply engine oil on: 448 kPa - 648 kPa
– Oil filter ring Idle (cold) (65 PSI - 94 PSI)
– Filter cover O-rings for a very short time
– Oil filter screw O-ring Idle (at 80°C (176°F)) Min. 228 kPa (33 PSI)
NOTE: In salt water area, it is recommended to 400 kPa - 496 kPa
coat mating surface of cover with SUPER LUBE 4000 - 7500
(58 PSI - 72 PSI)
GREASE (P/N 293 550 030).
Torque oil filter screw to specification. Test at the Oil Pressure Switch
TIGHTENING TORQUE Location
9 N•m ± 1 N•m
Remove oil pressure switch and install gauge.
Oil filter screw
(80 lbf•in ± 9 lbf•in)

INSPECTION
ENGINE OIL PRESSURE
Oil Pressure Test Requirement
Bring engine to its normal operating temperature.

CAUTION Certain components in the en-

gine compartment may be very hot. Direct
contact may result in skin burn.
NOTICE When watercraft is out of water: smr2016-013-006_a

– Never run engine without supplying water to TYPICAL

the exhaust system. 1. Oil pressure switch

– Never run engine longer than 2 minutes. To prevent the EMS to go in limp home mode (at
Drive line seal has no cooling when water- 2500 RPM) or to generate a fault code, do the fol-
craft is out of water. lowing:
Required Tools for Oil Pressure Test 1. Ground OPS to engine.
2. Plug OPS to harness.
REQUIRED TOOLS
3. Start engine.
PRESSURE GAUGE 4. While engine is running, unplug OPS from har-
(P/N 529 036 395) ness.
Read oil pressure at different RPM as per table
above.
OIL PRESSURE HOSE
(P/N 529 036 394) Reinstall oil pressure switch.

NOTE: A 1/8 NPT pipe extension may ease the
installation.
Oil Pressure Specifications
Use the following table to compare the oil pres-
sure at different RPM.
Test at the Cylinder Head Location
The oil pressure may be measured from cylinder
head if desired.
Remove plug located on cylinder head and install
gauge.

8 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-002

smr2009-023-006_a
1. Remove plug and install gauge here
Start engine and read pressure at different RPM
as per table above.
Reinstall plug.
TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
it should not be assumed to list all possible prob-
lems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to EN-
GINE MANAGEMENT section.
LOW OR NO ENGINE OIL PRESSURE
1. Oil level too low.
- Refill engine oil.
- Check for high oil consumption. See below.
- Check for oil leaks (oil leaking out of leak indica-
tor hole, gaskets, oil seal or O-rings). Repair or
replace.
2. Oil pressure switch defective.
- Check and replace if necessary.
3. Oil filter clogged.
- Replace engine oil and oil filter at the same time.
4. Oil pressure regulator valve sticks open, or
spring load is too small.
- Clean oil regulator piston and its bore. Replace if
necessary.
- Measure spring free length. Replace if too small.
5. Oil pump(s) worn or damaged.
- Check oil pump rotors and its bore for wear limits.
Replace if out of specification.
6. Engine oil strainers are clogged.
- Remove and clean engine oil strainers.
RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)
7. Heavy wear on plain bearings.
- Check radial clearance of plain bearings. Replace
if out of specification.
HIGH OIL CONSUMPTION
1. Oil in breathing system.
- Check if breather V-ring is brittle, hard or dam-
aged. Replace V-ring.
2. Valve stem seals worn or damaged.
- Replace valve stem seals.
3. Piston rings worn out (blue colored exhaust
smoke).
- Replace piston rings.
OIL CONTAMINATION (WHITE
APPEARANCE)
1. Water ingestion through drive shaft and floating
ring
- Check if water is leaking between drive shaft
and floating ring. Repair or replace defective
parts. Refer to PTO HOUSING, MAGNETO AND
STARTER subsection.
- Change engine oil and filter.
2. Oil seal and rotary seal on water pump shaft
leaking.
- Replace oil seal and water pump shaft assembly.
- Change engine oil and oil filter.
3. Cylinder head gasket leaking.
- Replace cylinder head gasket and tighten cylinder
head with recommended torque.
- Change engine oil and oil filter.
4. Cylinder head screws not properly tightened.
- Retighten screws with recommended torque.
- Change engine oil.
5. Oil cooler O-rings are leaking.
- Replace O-rings.
- Change engine oil and oil filter.
6. Cylinder block or cylinder head casting is leak-
ing.
- Check for internal cracks in casting. Replace dam-
aged components.
- Change engine oil and oil filter.
9
Subsection XX (LUBRICATION SYSTEM)

PROCEDURES Use a multimeter to check the resistance as

shown.
OIL PRESSURE SWITCH (OPS) ENGINE NOT RUNNING
TEST PROBES RESISTANCE ( )
OPS
Engine Close to 0 (normally
connector
ground closed switch)
(pin 1)

ENGINE RUNNING
TEST PROBES RESISTANCE ( )
Infinitely high (OL)
OPS
Engine when pressure reaches
connector
ground 180 kPa (26.11 PSI) and
(pin 1)
220 kPa (32 PSI)

smr2016-013-006_a

1. OPS

Oil Pressure Switch Access

Remove the throttle body. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.

Oil Pressure Switch Operation

The oil pressure switch activates, if the engine oil
pressure is lower than following specified pres-
sure range. smr2009-023-102_a

OIL PRESSURE SWITCH ACTIVATION RANGE TYPICAL

180 kPa to 220 kPa (26.11 PSI to 31.91 PSI) If resistance values are incorrect, replace OPS.
If the values are correct, check the continuity of
Inspecting the Oil Pressure Switch the wiring harness.
First, carefully check the condition of the connec-
tor terminals. Clean to remove dirt and corrosion Testing the Oil Pressure Switch Circuit
that could affect proper operation of the OPS. Continuity
IMPORTANT: Do not apply dielectric grease on Disconnect the ECM connector "A" from the ECM.
terminal. Check continuity of OPS circuit as per following
Before checking the function of the OPS, an oil table.
pressure test has to be performed to be sure the REQUIRED TOOL
oil pressure is not in fault. Refer to INSPECTION
in this subsection. ECM ADAPTER TOOL
When the engine oil pressure tests good but the (P/N 529 036 166)
OIL message in the information center is present
and the beeper sounds:
FLUKE 115 MULTIMETER
– Ensure OPS connector is plugged to the switch. (P/N 529 035 868)
– Check the resistance of the OPS while engine
is off and while engine is running.

Testing the Oil Pressure Switch

Resistance
Disconnect the connector from the OPS.

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 Subsection XX (LUBRICATION SYSTEM)

OPS ECM
RESISTANCE
OIL TEMPERATURE SENSOR
CONNECTOR ADAPTER (OTS)
Close to 0
Pin 1 Pin E3
(continuity)

smr2016-013-033_a
smr2009-023-102_b

TYPICAL 1. Oil temperature sensor (OTS)

If continuity test failed, repair or replace the con- NOTE: Engine will be set to limp home mode and
nector and wiring between ECM connector and an overheat indication will come on in the informa-
OPS. tion center when the oil temperature reaches:
If continuity test succeeded, check the ECM. Re- ENGINE
OVERHEAT TEMPERATURE
fer to ELECTRONIC FUEL INJECTION (EFI) sub- TYPE
section. 130 and 155 115°C (239°F)

Removing the Oil Pressure Switch 230 120°C (248°F)

Unplug the OPS connector.
Unscrew and remove the oil pressure switch.
Installing the Oil Pressure Switch
Torque oil pressure switch to specification.
TIGHTENING TORQUE
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
Oil pressure switch +
LOCTITE 243 (BLUE)
(P/N 293 800 060)
Check for debris or blockage in lubrication system.
OTS Access
Remove the throttle body. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
Testing the OTS Resistance
1. Disconnect the connector from the OTS and
test the resistance of the sensor. Refer to the
OTS RESISTANCE CHART in this subsection.

smr2016-013-034_a

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Subsection XX (LUBRICATION SYSTEM)

If resistance measured is not as specified, replace TIGHTENING TORQUE

the OTS.
17 N•m ± 2 N•m
If the resistance measured is as specified, pro- Oil temperature switch
(150 lbf•in ± 18 lbf•in)
ceed with the following steps.
2. Reconnect the OTS connector and disconnect 3. Apply sealant around OTS as defined in the il-
ECM connector "A" from the ECM. lustration.
3. Check the OTS circuit resistance as per table. NOTE: Gasket ring of OTS must be coated com-
pletely.
OTS RESISTANCE TEST
SERVICE PRODUCT
ECM ADAPTER PIN RESISTANCE
BLACK NEOPRENE PAINT (P/N 909570)
See OTS RESISTANCE
A-H4 A-J4
CHART

OTS RESISTANCE CHART

TEMPERATURE RESISTANCE (OHMS)
°C °F NOMINAL LOW HIGH
- 30 - 22 12600 11800 13400
- 20 - 4 11400 11000 11800
- 10 14 9500 8000 11,000
0 32 5900 4900 6900
10 50 3800 3100 4500 RTX1503ACEMY18-002-002_a

20 68 2500 2200 2800 1. OTS

2. Apply Black Neoprene Paint here
30 86 1700 1500 1900
4. Reinstall remaining removed parts.
40 104 1200 1080 1320
50 122 840 750 930 PTO OIL STRAINER
60 140 630 510 750 Removing the PTO Oil Strainer
70 158 440 370 510 Remove the PTO housing. Refer to PTO HOUS-
80 176 325 280 370 ING, MAGNETO AND STARTER subsection.
90 194 245 210 280 Remove the oil strainer.
100 212 195 160 210
110 230 145 125 160
120 248 115 100 125

If the resistance value measured is as specified,

check ECM. Refer to ECM in the ELECTRONNIC
FUEL INJECTION (EFI) subsection.
If the resistance value is not within specification,
repair or replace wiring and connectors between
ECM connector and the OTS.

Replacing the OTS

1. Disconnect OTS connector and remove OTS.
R1503ACE_MY17-002_004_b
2. Install the new OTS.
1. PTO oil strainer

12 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-002
 Subsection XX (LUBRICATION SYSTEM)

Cleaning and Inspecting the PTO Oil
Strainer
Clean oil strainer with a part cleaner then use com-
pressed air to dry it.
Check oil strainer for damage, replace if neces-
sary.
Check and clean the oil strainer compartment and
oil bores for dirt and other contaminations.
Install it in the PTO housing.
Install the PTO housing using the procedure de-
scribed in the PTO HOUSING, MAGNETO AND
STARTER subsection.
Refill engine at the proper level with the recom-
mended oil. Refer to ENGINE OIL for the proce-
dure.
ENGINE OIL PRESSURE
REGULATOR
The oil pressure regulator is located on the bottom
of the PTO housing.

R1503ACE_MY17-002_002_a

1. Oil strainer compartment

2. Oil bore to the oil pump
3. Oil bore from the oil pump
Installing the PTO Oil Strainer
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Apply a small amount of grease on the frame of
the oil strainer to keep it in place while installing
the PTO cover.
smr2016-013-008_a
TYPICAL
1. Oil pressure regulator
NOTE: The oil pressure regulator system opens
when the oil pressure exceeds 400 kPa (58 PSI).
Removing the Oil Pressure Regulator
Remove engine oil. See ENGINE OIL CHANGE in
this subsection.
Remove the oil pressure regulator.

R1503ACE_MY17-002_004_a

SERVICE PRODUCT
Multi Purpose Grease BP LS 3

RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)

OIL PRESSURE PUMP

The oil pressure pump is located in the PTO hous-
ing and is driven by the balance shaft.

Removing the Oil Pressure Pump

1. Remove the PTO housing. Refer to PTO
HOUSING, MAGNETO AND STARTER subsec-
tion.
2. Remove water pump housing and the impeller.
Refer to COOLING SYSTEM subsection.
smr2011-015-003_b
3. Remove screws securing the oil pump cover.
TYPICAL
1. Valve piston guide
2. Valve piston
3. Inner compression spring
2
4. Outer compression spring
5. Oil pressure regulator plug
6. O-ring

NOTE: Oil pressure regulator plug on oil pump

housing is spring loaded.

Inspecting the Oil Pressure Regulator

Inspect valve piston and valve piston guide for
scoring or other damages.
Check outer compression spring for free length.
OUTER COMPRESSION SPRING FREE LENGTH
New 60 mm (2.362 in)
Service limit 57 mm (2.244 in) R1503motr125A 1
TYPICAL
Replace inner and outer compression spring as an 1. Screws
assembly. 2. Oil pump cover

Replace parts if important wear or damage are 4. Pull and remove the outer oil pump rotor.
present.
Clean bore and threads in the PTO housing from 1
metal shavings and other contaminations.

Installing the Oil Pressure Regulator

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
details.
Make sure that the O-ring is on the plug screw.
Torque plug screw to specification.
NOTICE Make sure not over tighten the plug.
Damages to springs may cause oil pressure
regulator malfunction.
TIGHTENING TORQUE
R1503motr126A
13 N•m ± 1 N•m
(115 lbf•in ± 9 lbf•in) TYPICAL
Oil pressure regulator 1. Outer oil pump rotor
+
plug
LOCTITE 243 (BLUE) 5. Extract the coolant/oil pump shaft by pushing it
(P/N 293 800 060)
from outside PTO housing cover.

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 Subsection XX (LUBRICATION SYSTEM)

1
2
B

F18E16A

TYPICAL
1. Pusher
2. Coolant/oil pump shaft
R1503motr130A 2 1
6. Remove rotary seal and oil seal. Refer to RO- 1. Outer rotor
TARY SEAL further in this subsection. 2. Inner rotor

Inspecting the Oil Pressure Pump OUTER AND INNER ROTOR CLEARANCE
Inspect coolant/oil pump shaft, housing and cover SERVICE LIMIT
for marks or other damages. A
Check inner rotor for corrosion pin-holes or other B 0.25 mm (.0098 in)
damages. If so, replace coolant/oil pump shaft.
Ensure to also check oil pump housing and cover C
and replace if damaged.
If clearance between inner and outer rotors ex-
ceeds the tolerance, replace coolant/oil pump
shaft. Ensure to also check oil pump housing and
cover and replace if damaged.
If clearance between outer rotor and its bore in
oil pump exceeds the tolerance, replace the com-
plete oil pump and the PTO housing.
Using a depth gauge, measure axial clearance as
shown.

R1503motr129A 1
1. Pittings on the teeth

Using a feeler gauge, measure the clearance be-

tween inner and outer rotors.

smr2016-013-010_a

1. Depth gauge
2. Oil pump outer rotor surface
3. PTO housing surface

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Subsection XX (LUBRICATION SYSTEM)

Clearance between pump housing and outer rotor 1

should not exceed the following specification. If
so, replace the complete oil pump assembly.
CLEARANCE BETWEEN PUMP HOUSING
AND OUTER ROTOR
0.1 mm (.004 in)

NOTE: When the axial clearance of the coolant/oil

pump shaft increases, the oil pressure decreases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam-
aged.

Installing the Oil Pressure Pump

For installation, reverse the removal procedure. R1503motr143A 2
Pay attention to the following details. TYPICAL
1. Coolant/oil pump shaft with oil seal guide
Install a NEW rotary seal and a NEW oil seal. Re- 2. Rotary seal pusher to support PTO housing
fer to ROTARY SEAL in this subsection.
Tighten oil pump cover screws to specification.
Install the coolant/oil pump shaft.
TIGHTENING TORQUE
NOTICE Never use a hammer for the
coolant/oil pump shaft installation. Only use a 9 N•m ± 1 N•m
press to avoid damaging the ceramic compo- (80 lbf•in ± 9 lbf•in)
Oil pump cover screws +
nent of the rotary seal.
LOCTITE 243 (BLUE)
REQUIRED TOOL (P/N 293 800 060)

OIL SEAL GUIDE After engine reassembly:

(P/N 529 035 822) – Refill engine oil to proper level
– Ensure oil pressure is within specifications.
WATER PUMP SEAL PUSHER
(P/N 529 035 823)
ROTARY SEAL
Removing the Rotary Seal
Remove the coolant/oil pump shaft. Refer to OIL
PRESSURE PUMP in this subsection.
Carefully remove the inner ring of the rotary seal
with a screwdriver.

R1503motr142A 2 1
1. Oil seal guide
2. Coolant/oil pump shaft

16 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-002
 Subsection XX (LUBRICATION SYSTEM)

smr2016-013-011_a smr2016-013-013_a

TYPICAL 1. Ceramic seal puller

1. Inner ring of rotary seal 2. Bearing puller lever

NOTICE Be careful not to damage the surface Remove ceramic seal from bearing puller and dis-
of the rotary seal bore or the sealing surface of card it.
the water pump housing in PTO housing. Remove oil seal behind the rotary seal.
REQUIRED TOOL

CERAMIC SEAL PULLER

(P/N 529 036 365)

Put ceramic seal puller into the ceramic seal and

turn the bearing puller until it's clamping.

smr2016-013-035_a

TYPICAL
1. Oil seal

Discard rotary seal and oil seal.

Installing the Rotary Seal

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
smr2016-013-012_a
details.
1. Ceramic seal puller
2. Bearing puller NOTICE Never use oil in the press fit area of
3. Ceramic seal
the oil seal and rotary seal.
NOTE: Take care that the bearing puller end is ex-
actly positioned between the oil seal and the ce- Install NEW oil seal.
ramic seal. REQUIRED TOOL
Start turning the lever clockwise until the ceramic OIL SEAL PUSHER (P/N 529
seal is completely pulled out the PTO housing. 035 757)

HANDLE (P/N 420 877 650)

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Subsection XX (LUBRICATION SYSTEM)

OIL SUCTION PUMP

smr2016-013-036_a

TYPICAL
1. Handle with oil seal pusher
2. Oil seal smr2016-013-041

TYPICAL - LOCATION OF OIL SUCTION PUMP

Install NEW rotary seal.
REQUIRED TOOL Removing the Oil Suction Pump
1. Remove retaining screws.
WATER PUMP SEAL PUSHER
(P/N 529 035 823)

NOTICE Never use a hammer for the rotary

seal installation. Only use a press to avoid
damaging the ceramic component.

2 1

smr2016-013-014_a

TYPICAL
1. Suction pump cover screws

2. Place rags under cover to prevent spillage. If

spillage occurs, clean with the PULLEY FLANGE
CLEANER (P/N 413 711 809).

F18E19A
3. Remove the oil suction pump housing.
TYPICAL
4. Remove the oil pump cover.
1. Rotary seal
2. Rotary seal installer

Install the coolant/oil pump shaft. Refer to OIL

PRESSURE PUMP in this subsection.

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 Subsection XX (LUBRICATION SYSTEM)

R1503motr137A

smr2008-015-006_a 1. Pittings on the teeth

TYPICAL
1. Oil pump cover Using a feeler gauge, measure the clearance be-
2. Oil pump screws tween inner and outer rotors.
5. Remove the outer rotor and the strainer.

A
B
C

smr2016-013-015_a
R1503motr138A 2 1
TYPICAL
1. Oil strainer 1. Outer rotor
2. Cover gasket 2. Inner rotor
3. Outer rotor
4. Oil pump shaft
OUTER AND INNER ROTOR CLEARANCE
Inspecting the Oil Suction Pump SERVICE LIMIT
Inspect oil pump shaft, housing and cover for A
marks or other damages.
B 0.25 mm (.0098 in)
Check inner rotor for corrosion, pin-holes or other
damages. If so, replace oil pump shaft. Ensure C
to also check oil pump housing and cover and re-
If clearance between inner and outer rotors ex-
place if damaged.
ceeds the tolerance, replace oil pump shaft. En-
sure to also check oil pump housing and cover and
replace if damaged.
If clearance between outer rotor and its bore in
oil pump exceeds the tolerance, replace the com-
plete oil pump and the oil pump housing.
Using a depth gauge, measure axial clearance as
shown.

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Subsection XX (LUBRICATION SYSTEM)

Clean both contact surfaces of oil suction pump

cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.

smr2016-013-016_a

1. Depth gauge
2. Oil pump outer rotor surface
3. Oil pump housing surface

Clearance between pump housing and outer rotor

should not exceed the following specification. If
smr2016-013-018_a
so, replace the complete oil pump assembly.
1. Oil inlet
2. Oil outlet
CLEARANCE BETWEEN PUMP HOUSING
AND OUTER ROTOR Tighten oil pump screws to specifications.
0.1 mm (.004 in)
TIGHTENING TORQUE
NOTE: When the axial clearance of the oil pump 9 N•m ± 1 N•m
shaft assembly increases, the oil pressure de- (80 lbf•in ± 9 lbf•in)
creases. Oil pump screws +
LOCTITE 243 (BLUE)
Check the inside of oil pump housing and its cover (P/N 293 800 060)
for scoring or other damages and replace if dam-
aged. Make sure oil strainer is properly installed in the
Inspect rubber ring gaskets. oil suction pump cover.
Apply engine oil on rubber ring gasket.

smr2016-013-017_a

1. Suction pump cover gasket smr2016-013-017_a

1. Suction pump cover gasket

If gasket is brittle, cracked or hard, replace it.
Tighten suction pump cover screws to specifica-
Installing the Oil Suction Pump tions as per following sequence.
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
details.

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 Subsection XX (LUBRICATION SYSTEM)

TIGHTENING TORQUE Inspecting the Suction Pump Oil

Strainer
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in) Clean oil strainer with a part cleaner then use com-
Suction pump cover pressed air to dry it.
+
screws
LOCTITE 243 (BLUE) Check oil strainer for tear or other damages. Re-
(P/N 293 800 060)
place it if necessary.

Installing the Suction Pump Oil

Strainer
For installation of the suction pump cover, refer to
OIL SUCTION PUMP in this subsection.

SUPERCHARGER OIL SPRAY

NOZZLE
130 and 155 Engines
NOTE: On engines without supercharger the
thread for the oil spray nozzle is blocked by a plug
screw.
smr2016-013-014_b

TYPICAL - TIGHTENING SEQUENCE

Refer to the appropriate procedures and install all

other removed parts.

SUCTION PUMP OIL STRAINER

NOTE: The oil strainer does not need to be
cleaned at every oil change. Clean it during other
inspections, especially when the engine is disas-
sembled.

Removing the Suction Pump Oil

Strainer
RTX1503ACEMY18-002-003_a
Remove oil strainer from the suction pump cover,
refer to REMOVING THE OIL SUCTION PUMP in Supercharger Oil Spray Nozzle
this subsection. Location
The supercharger oil spray nozzle is located in
the cylinder block right hand side above the sprag
clutch.

Removing the Supercharger Oil Spray

Nozzle
Remove the PTO housing. Refer to PTO HOUS-
ING, MAGNETO AND STARTER subsection.
Unscrew the oil spray nozzle.

smr2016-013-019_a

1. Oil strainer
2. Suction pump cover

RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)

NOTE: When the scope of repair work obligates

you to split the cylinder block, take this opportu-
nity to inspect the oil spray nozzles.

Inspecting the Piston Oil Spray Nozzle

Check if the oil spray nozzle is damaged or bent.
Check for cracks at soldering.
Replace as necessary.
If damaged replace immediately.

Removing the Piston Oil Spray Nozzle

smr2016-013-020_a Remove cylinder block lower half. Refer to CYLIN-
1. Oil spray nozzle DER BLOCK subsection.
Remove oil spray nozzle and Banjo fitting and dis-
Inspecting the Supercharger Oil Spray card it.
Nozzle
Check oil spray nozzle for dirt or other damages.
Replace if necessary.

Installing the Supercharger Oil Spray

Nozzle
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install oil spray nozzle.
TIGHTENING TORQUE
4.5 N•m ± 0.5 N•m
(40 lbf•in ± 4 lbf•in)
Oil spray nozzle + mmr2009-111-048_a
LOCTITE 243 (BLUE) 1. Banjo fitting
(P/N 293 800 060) 2. Oil spray nozzle

Installing the Piston Oil Spray Nozzle

PISTON OIL SPRAY NOZZLES
Install NEW oil spray nozzle and Banjo fitting.
The piston oil spray nozzles are located on the up-
per half of cylinder block. NOTICE At assembly make sure the contact
surface of the oil spray nozzle is well fitted onto
the cylinder block. If this is not ensured, the oil
spray direction will change, causing potential
engine damage.

smr2009-023-012_a

1. Piston oil spray nozzles

22 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-002
 Subsection XX (LUBRICATION SYSTEM)

mmr2009-111-050_a smr2016-013-026_a

1. Oil spray nozzle 1. Thrust washer

2. Contact surface 2. Oil separator cover

TIGHTENING TORQUE 5. Refer to CYLINDER HEAD subsection and re-

move:
Piston oil spray nozzle 19 N•m ± 2 N•m
banjo bolt (168 lbf•in ± 18 lbf•in) – Spark plug tubes
– Rocker arm shaft together with rocker arms
– Chain guide
OIL SEPARATOR COVER
– Camshaft lock.
Removing the Oil Separator Cover
1. Remove the blow-by valve. See procedure in
this subsection.
2. Remove camshaft position sensor, refer to
ELECTRONIC FUEL INJECTION (EFI) subsec-
tion.

smr2016-013-027_a

1. Rocker arm
2. Camshaft guide
3. Chain guide

6. Move camshaft backwards as far as possible.

7. Remove oil separator cover from timing gear by
smr2016-013-025_a
releasing the holding clips.
1. Camshaft position sensor
2. Screw

3. Remove valve cover, refer to CYLINDER HEAD

subsection.
4. Remove thrust washer from oil separator cover.
NOTE: Make sure not to loose thrust washer
when removing it from oil separator cover, oth-
erwise thrust washer would fall into the PTO
housing.

RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)

BLOW-BY VALVE
Blow-By Valve Description
The function of the blow-by valve is the circulation
of the oil vapors.

Blow-By Valve Operation

Normal Operation
During its normal operation, the blow-by valve al-
lows crankcase vapors to return in the intake sys-
tem where they are harmlessly burned.

smr2016-013-028_a

1. Camshaft
2. Oil separator cover

NOTICE Be careful not to break the hold-

ing clips from oil separator cover when its
removed from the timing gear.

Inspecting the Oil Separator Cover

Inspect oil separator cover for marks or other dam-
ages. Ensure to check also the holding clips of oil
separator cover and for thrust washer. If any dam-
age is visible replace oil separator cover.

smr2009-023-019_a

NORMAL OPERATION

By-Pass Function
If, for any reason, the valve piston gets stuck
at normal operation and the crankcase pressure
exceeds 40 kPa (6 PSI), the pressure unseats a
check ball and crankcase vapors can bypass the
valve piston.

smr2016-013-029_a

1. Holding clips

Installing the Oil Separator Cover

The installation is the reverse of the removal pro-
cedure. Pay attention to the following details.
Properly install oil separator cover and thrust
washer. They need to be in a perfect even posi-
tion with timing gear.
NOTE: Make sure not to lose thrust washer when
installed on oil separator cover.
Install all other removed parts.

24 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-002
 Subsection XX (LUBRICATION SYSTEM)

smr2016-013-025_b

1. Blow-by valve
2. CPS connector

Disconnect the TOPS switch connector of the

smr2009-023-021_a
blow-by valve.
BY-PASS FUNCTION
Unscrew and remove the blow-by valve.
Blow-By Valve Location

smr2009-023-014_a
smr2016-013-042
TYPICAL
TYPICAL 1. TOPS switch connector
2. Retaining screws
Removing the Blow-By Valve Remove and discard O-ring and V-ring.
Remove ventilation hose from blow-by valve. NOTE: The blow-by valve can not be disassem-
Remove the CPS connector from its support on bled.
blow-by valve.

RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)

smr2009-023-024_a

If test fails, replace blow-by valve.

smr2009-023-022_a Installing the Blow-By Valve

1. Blow-by valve
2. V-ring The installation is the reverse of the removal pro-
3. O-ring cedure. However, pay attention to the following.
Inspecting the Blow-By Valve Install the blow-by valve with NEW O-ring and
V-ring.
If blow-by valve is damaged, replace it.
Tighten blow-by valve screws to specification.
Clean all contact surfaces of blow-by valve.
TIGHTENING TORQUE
Place a clean rag on valve inlet.
9 N•m ± 1 N•m
Blow air through inlet port. Air must flow freely to
(80 lbf•in ± 9 lbf•in)
the outlet port. Blow-by valve screws +
LOCTITE 243 (BLUE)
(P/N 293 800 060)

Reinstall remaining removed parts.

TOPS SWITCH
Tip Over Protection Switch (TOPS
Switch) Function
The function of the TOPS switch is the engine pro-
tection in the event the watercraft tip over.
During normal operation the TOPS switch state is
OFF, no signal to the ECM.
If the watercraft tips over, gravity causes a valve
smr2009-023-023_a piston to close and no engine oil will leak out of
the blow-by valve.
Turn valve upside down and blow air again. Air
In this event, a pin (with magnet) opens a gap
must not flow out.
to the TOPS switch (Hall effect sensor) and the
TOPS changes its state to ON and sends a signal
to the ECM.
The ECM will shut down the engine by cutting the
ignition and the fuel injection.

26 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-002
 Subsection XX (LUBRICATION SYSTEM)

smr2009-023-103_a

If voltage test is good, check the TOPS switch out-

put voltage.
smr2009-023-018_a
If voltage test is not good, check the continuity of
BLOW-BY VALVE CUT-AWAY the blow-by valve TOPS switch circuit.
1. Valve housing
2. Valve sleeve NOTE: After voltage test, clear the fault codes in
3. Valve piston
4. Check ball the ECM using BUDS2.
5. Valve pin (with magnet)
6. TOPS switch of the blow-by valve
Testing the TOPS Switch Output
Voltage
Remove the blow-by valve.
Back-probe TOPS connector and check voltage.
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)

NOTE: To easily probe wire terminals through the

back of the connector, use the BACK PROBE TEST
WIRES (P/N 529 036 063) or an equivalent.

smr2009-023-020_a

TIP OVER FUNCTION

Testing the TOPS Switch Input Voltage

Disconnect the TOPS switch connector of the
blow-by valve.
Briefly press the START/STOP button to wake-up
the ECM.
Probe terminals as shown to check the voltage
output from the ECM.
529036063

TOPS SWITCH CONNECTOR VOLTAGE

Approximately
Pins 2 and 3
5 Vdc

RTX1503ACEMY18-002
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Subsection XX (LUBRICATION SYSTEM)

smr2009-023-103_b

1. Pin 1
smr2009-023-050_a
2. Pin 2
3. Pin 3
BLOW-BY VALVE IN NORMAL POSITION
1. Blow-by valve
2. RED probe into pin 2 If continuity test is good, check ECM. Refer to
3. BLACK probe into pin 1 ELECTRONIC FUEL INJECTION (EFI) subsection.
BLOW-BY If continuity test is not good, repair or replace de-
TOPS SWITCH fective wires or connectors.
VALVE VOLTAGE
CONNECTOR
POSITION
Replacing the TOPS Switch
Pin 1 and pin 2 Normal position 0.4 ± 0.1 Vdc
Remove blow-by valve and turn it upside down.
Pin 1 and pin 2 Upside down 4.4 ± 0.2 Vdc
Insert a small screwdriver between TOPS switch
Normal position Approximately and its retaining tab. Twist and hold the TOPS
Pin 2 and pin 3
or upside down 5 Vdc switch then release the other retaining tab.
Replace TOPS switch if not within specification.

Testing the TOPS Switch Circuit

Continuity
Disconnect the TOPS switch connector of the
blow-by valve.
Disconnect the connector "A" from the ECM.
Check continuity of the blow-by valve TOPS
switch circuit as per following table.
smr2009-023-051

REQUIRED TOOL
When installing the TOPS switch, make sure
ECM ADAPTER TOOL printed information is visible.
(P/N 529 036 166)

FLUKE 115 MULTIMETER

(P/N 529 035 868)

TOPS SWITCH ECM

RESISTANCE
CONNECTOR ADAPTER
Pin 1 Pin F4
Close to 0
Pin 2 Pin G1
(continuity)
Pin 3 Pin C4 smr2009-023-052_a

1. TOPS valve inscriptions

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 Subsection XX (LUBRICATION SYSTEM)

OIL COOLER
The oil cooler is located below the air intake man-
ifold.

R1503motr148A 1
1. O-rings

Inspecting the Oil Cooler

If O-rings are brittle, cracked or hard, replace
them.
Clean both contact surfaces of oil cooler.
R1503ACE_MY17-002_003_a

1. Oil cooler Check and clean the oil inlet and outlet area for dirt
and other contaminations.
Removing the Oil Cooler
Remove engine from vehicle. Refer to ENGINE
Installing the Oil Cooler
REMOVAL AND INSTALLATION subsection. For installation, reverse the removal procedure.
Pay attention to the following details.
Disconnect cooling hoses from oil cooler.
Apply engine oil on O-rings.
Remove screws securing oil cooler.
Tighten oil cooler screws to specification.
TIGHTENING TORQUE
11 N•m ± 1 N•m
(97 lbf•in ± 9 lbf•in)
Oil cooler screws +
LOCTITE 243 (BLUE)
(P/N 293 800 060)

smr2007-015-007_a

1. Oil cooler crews

2. Oil cooler

Ensure not to lose O-rings located between oil

cooler and engine.

RTX1503ACEMY18-002
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 Subsection XX (COOLING SYSTEM - ENGINE)

COOLING SYSTEM - ENGINE

SERVICE TOOLS
Description Part Number Page
HANDLE ........................................................................................ 420 877 650 ........................................... 10
OETIKER PLIER ............................................................................. 295 000 070 ............................................. 5
OIL SEAL PUSHER........................................................................ 529 036 210 ........................................... 10
ROTARY SEAL INSTALLER ........................................................... 529 036 211 ........................................... 10
TEST CAP ...................................................................................... 529 035 991 ............................................. 4
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ............................................. 4

SERVICE PRODUCTS
Description Part Number Page
DOW CORNING 111 ..................................................................... 413 707 000 ............................................. 6
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 10
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 11

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Subsection XX (COOLING SYSTEM - ENGINE)

ENGINE COMPONENTS

See ELECTRONIC FUEL

INJECTION (EFI)
Engine oil
16 ± 2 N•m
(142 ± 18 lbf•in)

Dow Corning
111

Engine oil 9 ± 1 N•m

(80 ± 9 lbf•in) Engine oil

NEW

Isoflex grease
Topas NB 52

NEW

Loctite 243
+
9 ± 1 N•m
(80 ± 9 lbf•in)

NEW = Component must be replaced when removed.

Smr2014-017-001_a

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 Subsection XX (COOLING SYSTEM - ENGINE)

COOLANT FLOW

smr2014-017-099_a

https://brp-manuals.com/pwc_seadoo 3
Subsection XX (COOLING SYSTEM - ENGINE)

GENERAL INSPECTION
Coolant bleed hose nipple is located on the cylin-
der head. COOLING SYSTEM LEAK TEST
WARNING
To avoid potential burns, do not remove the
coolant tank cap if the engine is hot.

NOTE: This test confirms if there is a leak in the

cooling system, including the engine.
Pressurize cooling system through coolant reser-
voir.
REQUIRED TOOL

TEST CAP (P/N 529 035 991)

smr2014-017-100_a

1. Bleed hose nipple

VACUUM/PRESSURE PUMP
NOTE: It is a good practice to check for fault (P/N 529 021 800)
codes using the BRP diagnostic software BUDS2
as a first troubleshooting step. Refer to the DI-
AGNOSTIC AND FAULT CODES subsection. COOLING SYSTEM LEAK TEST
During assembly/installation, use the torque 110 kPa (16 PSI)
values and service products as shown in the ex-
ploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
To avoid potential burns, do not remove the
coolant tank cap or loosen the cooling drain
plug if the engine is hot.

WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced with new ones.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
mmr2009-112-033
TYPICAL
If pressure drops, check all hoses, heat exchanger
and engine for coolant leaks. Spray a soap/water
solution and look for air bubbles.
Check the leak indicator hole if there is oil or
coolant leaking.
NOTE: In general leaking coolant indicates a dam-
aged rotary seal. Leaking oil indicates a damaged
oil seal. If either seal is leaking, both seals must
be replaced at the same time. Refer to WATER
PUMP in this subsection.

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 Subsection XX (COOLING SYSTEM - ENGINE)

9. Defective coolant reservoir cap.

- Replace cap.
10. Internal passage blocked in cooling system
- Inspect and clean.

PROCEDURES
CLAMPS
Replacing Oetiker Clamp
To cut or secure Oetiker clamps of cooling system
hoses, use the OETIKER PLIER (P/N 295 000 070).

smr2014-017-002_a

1. Leak indicator hole

TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
should not be assumed to show all causes for all 1
problems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first.

ENGINE OVERHEATING
1. Low coolant level.
2
- Refill and check for leaks (coolant leaking out of F01B2KA
leak indicator hole, hoses or clamps missing or
defective, or cylinder head gaskets leaks). Repair 1. Cutting clamp
or replace. 2. Securing clamp

2. Dirty heat exchanger. NOTE: Always check general condition of hoses

- Flush heat exchanger. Replace heat exchanger as and clamp tightness.
required.
3. Air in cooling system. THERMOSTAT
- Refill. Perform COOLING SYSTEM LEAK TEST. Thermostat Location
4. Defective thermostat (does not open when en- The thermostat is located on engine MAG side.
gine is warm up).
- Replace thermostat.
5. Exhaust system clogged
- Flush exhaust system.
6. Defective water pump.
- Inspect and replace defective components.
7. Coolant temperature sensor defective.
- Check and replace if necessary. Refer to ELEC-
TRONIC FUEL INJECTION (EFI).
8. Wrong coolant concentration.
- Check and adjust coolant concentration according
to BRP's recommendations or replace coolant.

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Subsection XX (COOLING SYSTEM - ENGINE)

smr2014-017-003_a smr2014-017-005_a

1. Thermostat housing 1. Thermostat housing

2. Thermostat

NOTE: Use shop rags to catch any spilled engine

coolant.

Testing the Thermostat

To check thermostat, put it in water and heat wa-
ter.
THERMOSTAT TEMPERATURE
smr2014-017-004_a
Starts to open 80°C (176°F)
1. Thermostat
2. Thermostat housing Fully open 95°C (203°F)
Removing the Thermostat Replace thermostat if out of specification.
1. Drain engine coolant..
2. Disconnect outlet hose from thermostat hous-
Installing the Thermostat
ing. The installation is the reverse of removal proce-
dure, however pay attention to the following.
Install NEW O-ring on thermostat housing.
Lubricate O-ring.
THERMOSTAT HOUSING O-RING
DOW CORNING 111
Service Product
(P/N 413 707 000)

Fit thermostat in thermostat housing.

smr2014-017-101_a

1. Thermostat housing outlet hose clamp

2. Thermostat housing outlet hose

3. REmove the water pump. See the procedure in

this subsectioné
4. Remove thermostat housing then thermostat.

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 Subsection XX (COOLING SYSTEM - ENGINE)

smr2014-017-006 smr2014-017-003_b

Align both tabs of thermostat with the recess in
the magneto cover.
1. Water pump
Removing the Water Pump Housing
1. Drain engine coolant.
2. Disconnect outlet hose from thermostat hous-
ing.
3. Disconnect inlet hose from water pump.

smr2014-017-007_a

1. Thermostat tabs
2. Magneto cover recess
smr2014-017-101_b
Install water pump housing, refer to INSTALLING 1. Water pump outlet hose
THE WATER PUMP HOUSING in this subsection. 2. Water pump inlet hose
Refill and bleed cooling system. 4. Remove both locking ties securing magneto
wires.
WATER PUMP
Water Pump Location
The water pump is located on engine MAG side.

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Subsection XX (COOLING SYSTEM - ENGINE)

mmr2011-071-013_a

1. Impeller
smr2014-017-008_a
2. Pliers
1. Locking ties
2. Remove magneto cover. Refer to MAGNETO
5. Remove retaining screws of water pump hous- AND STARTER subsection.
ing. 3. Remove the following components from mag-
6. Discard sealing washer. neto cover:
7. Remove water pump housing from magneto – Water pump gear
cover. – Needle pin
– Thrust washer.

mmr2011-071-014_a
smr2014-017-010_a
1. Water pump gear
1. Retaining screws 2. Needle pin
2. Sealing washer 3. Thrust washer

NOTE: Use shop rags to catch any spilled engine 4. Remove water pump shaft using a plastic mal-
coolant. let.

Disassembling the Water Pump

1. Unscrew impeller counterclockwise using ap-
propriate pliers.

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 Subsection XX (COOLING SYSTEM - ENGINE)

mmr2011-071-017_a
mmr2011-071-015_a
1. Water pump shaft.
1. Water pump shaft
2. Rotary seal

5. Remove the following components from mag-

neto cover: Inspecting the Water Pump
– Oil seal Check area of water pump housing for cracks or
– Remaining parts of rotary seal. other visible damage.
Check water pump gear for wear or broken teeth.
Check if housing gasket is brittle, hard or dam-
aged.
Check water pump shaft for visible damage.
Replace parts if necessary.

Assembling the Water Pump

NOTE: Always replace oil seal and rotary seal at
the same time.
1. Clean rotary seal surface from old sealant.

mmr2011-071-016

NOTICE Be careful not to damage the surface

of the rotary seal bore in the magneto cover.
6. Separate rotary seal from water pump shaft.

mmr2011-071-018_b

1. Clean surface

2. Apply engine oil on the press fit area of oil seal.

NOTICE Never use engine oil on the press fit
area of the rotary seal.
3. Install NEW oil seal.

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Subsection XX (COOLING SYSTEM - ENGINE)

REQUIRED TOOL NOTICE Never use a hammer for rotary seal

installation. Only use a press to avoid damag-
OIL SEAL PUSHER (P/N 529 ing the ceramic component.
036 210)

HANDLE (P/N 420 877 650)

mmr2011-071-025_a

1. Rotary seal
2. Rotary seal installer
mmr2011-071-020_a
6. Assemble the following components onto wa-
1. Oil seal
ter pump shaft.
– Needle pin
– Thrust washer.

mmr2011-071-040_a
mmr2011-071-039_a 1. Water pump shaft
1. Oil seal correctly installed 2. Thrust washer
3. Needle pin
4. Lubricate sealing lip of the oil seal.
7. Slide water pump shaft into rotary seal using a
OIL SEAL press.
ISOFLEX GREASE NOTE: To avoid damaging the rotary seal and to
Service Product TOPAS NB 52 (P/N 293 achieve the proper preload support the rotary seal
550 021) with the ROTARY SEAL INSTALLER (P/N 529 036 211)

5. Install NEW rotary seal.

NOTE: Prior to installing, ensure that press fit
sealing of rotary seal is not damaged.
REQUIRED TOOL
Press
ROTARY SEAL INSTALLER
(P/N 529 036 211)

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 Subsection XX (COOLING SYSTEM - ENGINE)

Installing the Water Pump Housing

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTICE To prevent leaking, take care that the
new gasket is exactly in groove when you rein-
stall the water pump housing.
Install a NEW sealing washer on drain screw.
Tighten water pump housing retaining screws to
specification as per the following procedure.
TIGHTENING TORQUE
9 N•m ± 1 N•m
mmr2011-071-041_a (80 lbf•in ± 9 lbf•in)
Water pump housing
1. Press +
2. Water pump shaft screws
LOCTITE 243 (BLUE)
3. Needle pin
4. Thrust washer (P/N 293 800 060)
5. Rotary seal installer

8. Carefully press water pump shaft until needle

pin touches thrust washer.

mmr2012-134-201_a smr2014-017-013_a

1. Press TIGHTENING SEQUENCE

2. Rotary seal installer
3. Needle pin touches thrust washer
Tighten coolant hose clamps to specification.
NOTICE Never use a hammer to install water TIGHTENING TORQUE
pump shaft into rotary seal.
4 N•m ± 1 N•m
Coolant hose clamps
NOTE: After installation, water pump shaft must (35 lbf•in ± 9 lbf•in)
rotate freely.
9. Screw impeller clockwise using appropriate pli- WATER PUMP DRIVE GEAR
ers.
Water Pump Drive Gear Location
NOTICE Be careful not to damage impeller
wings during its installation. The water pump drive gear is located behind the
magneto cover.
10. Install magneto cover. Refer to MAGNETO
AND STARTER subsection.

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Subsection XX (COOLING SYSTEM - ENGINE)

TIGHTENING TORQUE
Water pump drive 9 N•m ± 1 N•m
gear screws (80 lbf•in ± 9 lbf•in)

mmr2011-071-035_a

1. Water pump drive gear 31 T

2. Intermediate gear, refer to LUBRICATION SYSTEM

Removing the Water Pump Drive Gear

1. Remove the magneto cover and the magneto
flywheel. Refer to MAGNETO AND STARTER
subsection.
2. Remove screw securing water pump drive
gear.
3. Remove bearing sleeve.
4. Slide off water pump drive gear.

mmr2011-071-036_a

1. Water pump drive gear 31 T

2. Bearing sleeve
3. M6 x 20 screw

Inspecting the Water Pump Drive Gear

Inspect gear for wear or other damage.
Replace gear if necessary.

Installing the Water Pump Drive Gear

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Apply engine oil on bearing sleeve.
Tighten water pump drive gear retaining screw to
specification.
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 Subsection XX (COOLING SYSTEM - ENGINE)

COOLING SYSTEM - ENGINE

SERVICE TOOLS
Description Part Number Page
OETIKER PLIER ............................................................................. 295 000 070 ........................................... 4
TEST CAP ...................................................................................... 529 035 991 ........................................... 3
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ........................................... 3

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 6

RTX1503ACEMY18-003
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Subsection XX (COOLING SYSTEM - ENGINE)

NEW

NEW

NEW
Loctite 243
4,5 ± 0,5 N•m
(40 ± 4 lbf•in)
Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in)

3 ± 0,4 N•m
(27 ± 4 lbf•in)
left-hand
threads

NEW NEW

NEW
Engine oil

See
ELECTRONIC FUEL
INJECTION (EFI)
17 ± 2 N•m
(150 ± 18 lbf•in)

NEW

NEW = Component must be replaced when removed.

RTX1503ACEMY18-003-001_a

2 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-003
 Subsection XX (COOLING SYSTEM - ENGINE)

GENERAL Technical Specifications

TYPE Closed loop cooling system.
SYSTEM DESCRIPTION
COOLANT FLOW Flow from water pump.
A closed loop cooling system is utilized on the
TEMPERATURE
these engines, which offers an efficient engine CONTROL
Thermostat.
cooling while keeping dirt and salt water out of the
cooling system. This system keeps the tempera- Self-bleed type through
SYSTEM
ture constant and prevents internal engine corro- coolant tank (hose at
BLEEDING
sion. uppermost point of circuit).
A separate coolant tank ensures that enough en- MONITORING
Turns on at 102°C (216°F).
gine coolant is in the circuit during any operating BEEPER
condition.
The coolant flow comes from the water pump im- INSPECTION
peller into the cylinder block. It goes around the
cylinders and straight up to the cylinder head. A COOLING SYSTEM LEAK TEST
smaller quantity of engine coolant enters the cylin-
der block on the exhaust side for a better cool- WARNING
ing. In the cylinder head the water channels flow To avoid potential burns, do not remove the
around the exhaust and then the intake valves and coolant tank cap or loosen the ride plate drain
leave the engine through a large hose. From there plug if the engine is hot.
the coolant goes back to the water pump hous-
ing and depending on the engine temperature, it
Open or remove seat.
flows through the thermostat directly back to the
water pump impeller, or it takes its way through Install test cap on the coolant tank.
the heat exchanger. REQUIRED TOOL
Engine coolant is also directed towards the oil
cooler (coolant type).
TEST CAP (P/N 529 035 991)
Coolant temperature sensor and bleed hose fitting
are located on the cylinder head.
NOTE: It is not necessary to install a hose pincher
on overflow hose.
Pressurize system through coolant tank.
REQUIRED TOOL

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

COOLING SYSTEM LEAK TEST

90 kPa (13 PSI)

smr2016-014-002_a

TYPICAL
1. Bleed hose fitting
2. Coolant temperature sensor (CTS)

NOTICE Never modify cooling system ar-

rangement, otherwise serious engine damage
could occur.

RTX1503ACEMY18-003
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Subsection XX (COOLING SYSTEM - ENGINE)

2. Air in cooling system

- Refill and bleed cooling system.
3. Thermostat defective (does not open when en-
gine gets hot)
- Replace thermostat housing.
4. Water pump failure
- Inspect and replace defective components.
5. Water temperature sensor defective
- Check or replace. Refer to ELECTRONIC FUEL
INJECTION (EFI).
smr2009-024-103_a

TYPICAL 6. Ride plate or hoses damaged

1. Vacuum/pressure pump - Check or replace damaged components.
2. Test cap
7. Exhaust system clogged
Check all hoses, ride plate, engine, intermediate
cooler and oil cooler for coolant leaks. Spray a - Flush exhaust system.
soap and water solution and look for air bubbles. 8. Internal passage blocked in cooling system
Check the leak indicator hole if there is oil or - Inspect and clean.
coolant. If so, replace appropriate water pump
shaft seal. PROCEDURES
CLAMPS
Clamp Replacement
REQUIRED TOOL

OETIKER PLIER (P/N 295

000 070)

RTX1503ACEMY18-003-002_a

After the leak test, rinse with water to remove

soap residue.

TROUBLESHOOTING
The following is provided to help in diagnosing the 1
probable source of troubles. It is a guideline and
it should not be assumed to list all possible prob-
lems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES subsection. 2
F01B2KA
ENGINE OVERHEATING
1. Cutting clamp
1. Low coolant level. 2. Securing clamp
- Refill and check for leaks (coolant leaking out NOTE: Always check general condition of hoses
of engine leak indicator hole, hoses or clamps
missing/defective, cylinder head gaskets leaks, and clamp tightness.
ride plate leaking, etc.). Repair or replace.

4 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-003
 Subsection XX (COOLING SYSTEM - ENGINE)

COOLANT TEMPERATURE
SENSOR (CTS)
Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection.

WATER PUMP HOUSING

R1503ACE_MY17-003_002_a

TYPICAL
1. Water pump housing
2. Cylinder head hose
3. Oil cooler inlet hose
4. Oil cooler outlet hose

4. Remove water pump housing screws.

smr2009-024-004_b

TYPICAL
1. Water pump housing

Removing the Water Pump Housing

IMPORTANT: The water pump housing can be re-
moved with the engine installed in the vehicle. If
the engine is out of the vehicle, go directly to step
3.
1. Drain cooling system and engine oil.
2. Disconnect ride plate, thermostat housing and smr2008-016-004_a
coolant tank hoses from water pump housing. TYPICAL

5. Pull the water pump housing to remove it.

Inspecting the Water Pump Housing

Check if gasket is brittle, hard or damaged and re-
place as necessary.

smr2009-024-107_a

TYPICAL
1. Ride plate outlet hose
2. Ride plate inlet hose

3. Disconnect the cylinder head outlet hose and oil

cooler hoses.

RTX1503ACEMY18-003
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Subsection XX (COOLING SYSTEM - ENGINE)

WATER PUMP IMPELLER

Removing the Water Pump Impeller
Remove the WATER PUMP HOUSING, see pro-
cedure in this subsection.
Unscrew the impeller clockwise.

RTX1503ACEMY18-003-003_a

1. Water pump housing gasket

Check if thermostat is in good condition. Refer to

THERMOSTAT in this subsection.
Installing the Water Pump Housing
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. F18E13A

NOTICE Take care that the gaskets are ex- TYPICAL

1. Impeller
actly in groove when you reinstall the water
pump housing. NOTICE Coolant/oil pump shaft and impeller
have left-hand threads.
Tighten screws to specification using the follow-
ing sequence. Inspecting the Water Pump Impeller
Check impeller for cracks or other damage. Re-
place impeller if damaged.

Installing the Water Pump Impeller

The installation is the opposite of the removal pro-
cedure. Pay attention to the following details.
NOTICE Be careful not to damage impeller
wings during installation.
Torque impeller to specification.
TIGHTENING TORQUE
Water pump impeller 3 N•m ± 0.4 N•m
smr2016-014-006_a (left hand threads) (27 lbf•in ± 4 lbf•in)
TYPICAL

TIGHTENING TORQUE THERMOSTAT

9 N•m ± 1 N•m The thermostat is a single action type.
(80 lbf•in ± 9 lbf•in)
Water pump housing
+ Removing the Thermostat
screws
LOCTITE 243 (BLUE)
(P/N 293 800 060) Remove the WATER PUMP HOUSING, see pro-
cedure in this subsection.
NOTE: The thermostat is located inside the water
pump housing.

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 Subsection XX (COOLING SYSTEM - ENGINE)

Testing the Thermostat

To check the operation of the thermostat, put it in
water and heat water.
Look inside the cylinder head return hose connec-
tion to see the movement of the thermostat.
THERMOSTAT OPENING TEMPERATURE
Water pump housing
80°C (176°F)
thermostat

If there is no operation, replace the water pump

housing.

Installing the Thermostat

Refer to WATER PUMP HOUSING in this subsec-
tion.

ROTARY SEAL
Inspecting the Rotary Seal
Check leak indicator hole for oil or coolant leak:
– Leaking coolant indicates a defective rotary seal
– Leaking oil indicates a faulty oil seal.

smr2009-024-004_a

TYPICAL
1. Leak indicator hole

Rotary seal and oil seal must be replaced together.

Replacing the Rotary Seal

Refer to LUBRICATION SYSTEM subsection.

RTX1503ACEMY18-003
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 Subsection XX (COOLING SYSTEM - VEHICLE)

COOLING SYSTEM - VEHICLE

SERVICE TOOLS
Description Part Number Page
OETIKER PLIER ............................................................................. 295 000 070 ........................................... 6
TEST CAP ...................................................................................... 529 035 991 ........................................... 5
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ........................................... 5

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 567 (PIPE SEALANT) ..................................................... 293 800 013 ........................................... 4
LONG LIFE ANTIFREEZE(F) .......................................................... 619 590 204 ........................................... 3
LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ........................................... 3

COOLANT FLOW

smr2017-307-100_a

smr2017-307
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Subsection XX (COOLING SYSTEM - VEHICLE)

VEHICLE COMPONENTS

1.7 ± 0.2 N•m 1.7 ± 0.2 N•m

(15 ± 2 lbf•in) (15 ± 2 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

smr2017-307-101_a

2 https://brp-manuals.com/pwc_seadoo smr2017-307
 Subsection XX (COOLING SYSTEM - VEHICLE)

GENERAL
During assembly/installation, use the torque
values and service products as shown in the ex-
ploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
To avoid potential burns, do not remove the smr2017-307-001_a
coolant tank cap or loosen the cooling drain 1. Bleed hose nipple
plug if the engine is hot. 2. Coolant temperature sensor (CTS)

NOTICE Never modify cooling system ar-

WARNING rangement, otherwise serious engine damage
Torque wrench tightening specifications could occur.
must strictly be adhered to.
Locking devices when removed (e.g.: locking Technical Specifications
tabs, elastic stop nuts, cotter pin, etc.) must
TYPE Closed loop cooling system.
be replaced with new ones.
COOLANT FLOW Flow from water pump.

NOTICE Hoses, cables and locking ties re- TEMPERATURE

Thermostat.
CONTROL
moved during a procedure must be reinstalled
as per factory standards. SYSTEM
Self-bleed type through
coolant tank (hose at
BLEEDING
uppermost point of circuit).
SYSTEM DESCRIPTION
MONITORING
A closed loop cooling system is utilized on the 900 Turns on at 102°C (216°F).
BEEPER
ACE engine, which offers an efficient engine cool-
ing while keeping dirt and salt water out of the
cooling system. This system keeps the tempera- MAINTENANCE
ture constant and prevents internal engine corro-
sion. ENGINE COOLANT
A separate coolant tank ensures that enough en-
gine coolant is in the circuit during any operating WARNING
condition. To avoid potential burns, do not remove the
The coolant flow comes from the water pump coolant tank cap or loosen the ride plate drain
impeller into the cylinder block. It goes around plug if the engine is hot.
the cylinders and straight up to the cylinder head.
From there the coolant goes back to the water Recommended Coolant
pump housing and depending on the engine tem- COOLANT
perature, it flows again through the engine, or it
takes its way through the thermostat, to the ride Finland, LONG LIFE
plate (heat exchanger). Norway and ANTIFREEZE(F)
BRP Sweden (P/N 619 590 204)
Coolant temperature sensor and bleed hose fitting recommended
are located on the cylinder head. product LONG LIFE
All Other
ANTIFREEZE
Countries
(P/N 219 702 685)
Distilled water and
antifreeze solution
Alternative, or _ (50% distilled
if not available
water,
50% antifreeze)

smr2017-307
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Subsection XX (COOLING SYSTEM - VEHICLE)
If the recommended coolant is not available, use
a low silicate, extended life ethylene-glycol pre-
mixed coolant (50%-50%) specifically formulated
for internal combustion aluminum engines.
To prevent antifreeze deterioration, always use
the same brand and grade. Never mix different
brands or grades unless cooling system is com-
pletely flushed and refilled.
Draining the System
WARNING
Never drain or refill cooling system when en-
gine is hot.
Remove seat.
Install a drain pan underneath the ride plate.
Unscrew the drain plug on ride plate.
NOTE: Raising the front of the watercraft will con-
tribute to drain the cooling system.
smr2009-024-102_a
1. Coolant drain plug
Remove the coolant tank cap.
Dispose coolant as per local regulations.
Do not reinstall drain plug at this time.
Cleaning the System
NOTICE Cleaning the cooling system as per
the following procedure is required when en-
gine overheats (assuming everything else is
operating normally) or each time coolant is
replaced.
Drain the cooling system.
Add a cleaning product such as the Zerex® Super
Cleaner by Valvoline (or an equivalent) in coolant
tank then fill cooling system with demineralized
water.
Reinstall cap on coolant tank.
4 https://brp-manuals.com/pwc_seadoo
Install watercraft in a test basin or ride on a water
plane. Start engine and run for approximately 15
minutes.
IMPORTANT: Ensure thermostat opens so that
the cleaning product flows in ride plate properly.
Stop engine and let the cleaning product work for
12 to 16 hours.
Thereafter, engine can be run one last time to soak
off deposits.
Drain and thoroughly rinse the cooling system
with clean fresh water.
Refill cooling system as described below.
Refilling the System
Watercraft should be level, engine cold and drain
plug removed for refilling.
Place a container under drain plug to collect an-
tifreeze.
Apply LOCTITE 567 (PIPE SEALANT) (P/N 293 800
013) on drain plug threads.
Ask someone to pour recommended antifreeze in
coolant tank.
When antifreeze flows out from the ride plate
drain hole, reinstall drain plug. Torque drain plug
to specification.
TIGHTENING TORQUE
8.5 N•m ± 0.5 N•m
Drain plug
(75 lbf•in ± 4 lbf•in)
Continue to pour and fill coolant tank between
marks.
smr2017-307-003
Do not install pressure cap at this time.
smr2017-307
 Subsection XX (COOLING SYSTEM - VEHICLE)

Link a garden hose to the hose adapter at the back REQUIRED TOOL
of the watercraft. Refer to FLUSHING THE EX-
HAUST SYSTEM in the EXHAUST SYSTEM sub-
section. TEST CAP (P/N 529 035 991)
NOTICE Never run engine without supplying
water to the exhaust system.
VACUUM/PRESSURE PUMP
Start engine and let run for a maximum of 2 min- (P/N 529 021 800)
utes. Stop engine and wait 15 minutes to cool
down. Refill tank as necessary.
COOLING SYSTEM LEAK TEST
NOTICE Never run engine longer than 2 min- 110 kPa (16 PSI)
utes. Drive line seal has no cooling when wa-
tercraft is out of water.
Repeat this run-stop cycle 2-3 times until thermo-
stat opens and stop engine.

mmr2009-112-033

TYPICAL

If pressure drops, check all hoses, heat exchanger

smr2017-307-002_a
1. This hose becomes hot when thermostat opens
Last, refill coolant tank and install pressure cap.
When engine has completely cooled down,
recheck coolant level in the coolant tank and top
up if necessary.
INSPECTION
COOLING SYSTEM LEAK TEST
WARNING
To avoid potential burns, do not remove the
coolant tank cap if the engine is hot.
and engine for coolant leaks. Spray a soap/water
solution and look for air bubbles.
Check the leak indicator hole if there is oil or
coolant leaking.
NOTE: In general leaking coolant indicates a dam-
aged rotary seal. Leaking oil indicates a damaged
oil seal. If either seal is leaking, both seals must
be replaced at the same time. Refer to WATER
PUMP in COOLING SYSTEM - ENGINE in the ap-
propriate engine shop manual.

NOTE: This test confirms if there is a leak in the

cooling system, including the engine.
Pressurize cooling system through coolant reser-
voir.

smr2017-307
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Subsection XX (COOLING SYSTEM - VEHICLE)

9. Defective coolant reservoir cap.

- Replace cap.
10. Internal passage blocked in cooling system
- Inspect and clean.

PROCEDURES
COOLANT RESERVOIR CAP
Testing the Coolant Reservoir Cap
Using a pressure cap tester, check the efficiency
of coolant reservoir cap. If the efficiency is weak,
replace the cap.
smr2014-017-002_a
CAP OPENING PRESSURE
1. Leak indicator hole
110 kPa ± 7 kPa (16 PSI ± 1 PSI)
TROUBLESHOOTING
The following is provided to help in diagnosing the CLAMPS
probable source of troubles. It is a guideline and
should not be assumed to show all causes for all
Clamp Replacement
problems. REQUIRED TOOL
Always check for fault codes. If a fault code is de-
tected, service the fault code first. OETIKER PLIER (P/N 295
000 070)
ENGINE OVERHEATING
1. Low coolant level.
- Refill and check for leaks (coolant leaking out of
leak indicator hole, hoses or clamps missing or
defective, or cylinder head gaskets leaks). Repair
or replace.
2. Dirty heat exchanger.
- Flush heat exchanger. Replace heat exchanger as
required.
1
3. Air in cooling system.
- Refill. Perform COOLING SYSTEM LEAK TEST.
4. Defective thermostat (does not open when en-
gine is warm up).
- Replace thermostat.
5. Exhaust system clogged 2
F01B2KA
- Flush exhaust system.
1. Cutting clamp
6. Defective water pump. 2. Securing clamp
- Inspect and replace defective components.
NOTE: Always check general condition of hoses
7. Coolant temperature sensor defective. and clamp tightness.
- Check and replace if necessary. Refer to ELEC-
TRONIC FUEL INJECTION (EFI).
8. Wrong coolant concentration.
- Check and adjust coolant concentration according
to BRP's recommendations or replace coolant.

6 https://brp-manuals.com/pwc_seadoo smr2017-307
 Subsection XX (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
OETIKER PLIER ............................................................................. 295 000 070 ........................................... 11
TEST CAP ...................................................................................... 529 035 991 ........................................... 10
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ........................................... 10

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 567 (PIPE SEALANT) ..................................................... 293 800 013 ........................................... 9
LONG LIFE ANTIFREEZE(F) .......................................................... 619 590 204 ........................................... 9
LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ........................................... 9

ROTAX 900 HO ACE Cooling System (Closed loop)

219100941-12-001_a

1. Ride plate (operates as heat exchanger) 4. Expansion coolant tank

2. Coolant flows to ride plate 5. Bleed hose from cylinder head to expansion coolant tank
3. Coolant returns from ride plate

smr2017-009
https://brp-manuals.com/pwc_seadoo 1
Subsection XX (COOLING SYSTEM)

ROTAX 1630 ACE, ROTAX 1500 HO ACE, ROTAX 1503 NA and ROTAX
1503 Cooling System (Closed loop)

5
2

1 10

9 8

219100941-12-002_a

TYPICAL
1. Ride plate (operates as heat exchanger) 6. Expansion coolant tank
2. Coolant flows to ride plate 7. Bleed hose from cylinder head to expansion coolant tank
3. Coolant returns from ride plate 8. Oil cooler
4. Water pump cover / thermostat housing - Thermostat opens at 9. Coolant flows to oil cooler
80°C (176°F) 10. Coolant returns from oil cooler
5. Coolant temperature sensor (CTS) activates when monitoring
beeper turns on at 110°C (230°F)

2 https://brp-manuals.com/pwc_seadoo smr2017-009
 Subsection XX (COOLING SYSTEM)

Cooling system (open loop)

219100893-013-102_a

TYPICAL
1. Water exits the intake manifold 6. Bleed hose from intercooler
2. Water enters the intake manifold 7. Water enters intercooler
3. Air enters intercooler 8. Water exits system
4. Water exits the intercooler 9. Water enters system
5. Air returns from intercooler

smr2017-009
https://brp-manuals.com/pwc_seadoo 3
Subsection XX (COOLING SYSTEM)

ROTAX 900 HO ACE Cooling System Components (closed loop)

1.7 ± 0.2 N•m 3.5 ± 0.5 N•m

(15 ± 2 lbf•in) (31 ± 4 lbf•in)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in) 3.5 ± 0.5 N•m
(31 ± 4 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

219100941-12-100_a

4 https://brp-manuals.com/pwc_seadoo smr2017-009
 Subsection XX (COOLING SYSTEM)

ROTAX 1630 ACE, ROTAX 1500 HO ACE, ROTAX 1503 NA and ROTAX 1503 Cooling System
Components (closed loop)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

219100941-12-102_a

smr2017-009
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Subsection XX (COOLING SYSTEM)

ROTAX 1503 NA, ROTAX 1503 and ROTAX 900 HO ACE Cooling system components (open loop)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

NEW = Component must be replaced when removed.

219100893-013-103_a

6 https://brp-manuals.com/pwc_seadoo smr2017-009
 Subsection XX (COOLING SYSTEM)

ROTAX 1630 ACE and ROTAX 1500 HO ACE Cooling system components (open loop)

4 ± 1 N•m
(35 ± 9 lbf•in)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

NEW = Component must be replaced when removed.

219100893-013-104_a

smr2017-009
https://brp-manuals.com/pwc_seadoo 7
Subsection XX (COOLING SYSTEM)

GENERAL
SYSTEM DESCRIPTION
A closed loop cooling system is utilized on all
BRP watercraft engines, which offers an efficient
engine cooling while keeping dirt and salt water
out of the cooling system. This system keeps
the temperature constant and prevents internal
engine corrosion.
A separate coolant tank ensures that enough en-
gine coolant is in the circuit during any operating
condition.
The coolant flow comes from the water pump im- 219100941-12-003_a

peller into the cylinder block. It goes around the ROTAX 900 HO ACE MODELS
1. Coolant temperature sensor (CTS)
cylinders and straight up to the cylinder head. A 2. Bleed hose nipple
smaller quantity of engine coolant enters the cylin-
der block on the exhaust side for a better cool- NOTICE Never modify cooling system ar-
ing. In the cylinder head the water channels flow rangement, otherwise serious engine damage
around the exhaust and then the intake valves and could occur.
leave the engine through a large hose. From there
the coolant goes back to the water pump hous- Technical Specifications
ing and depending on the engine temperature, it TYPE Closed loop cooling system.
flows through the thermostat directly back to the
water pump impeller, or it takes its way through COOLANT FLOW Flow from water pump.
the heat exchanger. TEMPERATURE
Thermostat.
Engine coolant is also directed towards the oil CONTROL
cooler (coolant type). Self-bleed type through
SYSTEM
Coolant temperature sensor and bleed hose fitting coolant tank (hose at
BLEEDING
are located on the cylinder head. uppermost point of circuit).
MONITORING
Turns on at 110°C (230°F).
BEEPER

MAINTENANCE
ENGINE COOLANT
WARNING
To avoid potential burns, do not remove the
coolant tank cap or loosen the ride plate drain
plug if the engine is hot.

smr2009-024-002_a

ROTAX 1630 ACE, ROTAX 1500 HO ACE, ROTAX 1503 NA AND

ROTAX 1503 MODELS
1. Bleed hose nipple
2. Coolant temperature sensor (CTS)

8 https://brp-manuals.com/pwc_seadoo smr2017-009
 Subsection XX (COOLING SYSTEM)

Recommended Coolant Dispose coolant as per local regulations.

COOLANT Do not reinstall drain plug at this time.
Finland, LONG LIFE Cleaning the System
Norway and ANTIFREEZE(F)
BRP Sweden (P/N 619 590 204) NOTICE Cleaning the cooling system as per
recommended the following procedure is required when en-
product LONG LIFE
All Other gine overheats (assuming everything else is
ANTIFREEZE
Countries operating normally) or each time coolant is
(P/N 219 702 685)
replaced.
Distilled water and
antifreeze solution Drain the cooling system.
Alternative, or _ (50% distilled
if not available Add a cleaning product such as the Zerex® Super
water,
50% antifreeze) Cleaner by Valvoline (or an equivalent) in coolant
tank then fill cooling system with demineralized
If the recommended coolant is not available, use water.
a low silicate, extended life ethylene-glycol pre- Reinstall cap on coolant tank.
mixed coolant (50%-50%) specifically formulated Install watercraft in a test basin or ride on a water
for internal combustion aluminum engines. plane. Start engine and run for approximately 15
To prevent antifreeze deterioration, always use minutes.
the same brand and grade. Never mix different IMPORTANT: Ensure thermostat opens so that
brands or grades unless cooling system is com- the cleaning product flows in ride plate properly.
pletely flushed and refilled.
Stop engine and let the cleaning product work for
Draining the System 12 to 16 hours.
Thereafter, engine can be run one last time to soak
WARNING off deposits.
Never drain or refill cooling system when en- Drain and thoroughly rinse the cooling system
gine is hot. with clean fresh water.
Refill cooling system as described below.
Remove seats.
Remove engine service cover. Refilling the System
Install a drain pan underneath the ride plate. Watercraft should be level, engine cold and drain
Unscrew the drain plug on ride plate. plug removed for refilling.
NOTE: Raising the front of the watercraft will con- Place a container under drain plug to collect an-
tribute to drain the cooling system. tifreeze.
Apply LOCTITE 567 (PIPE SEALANT) (P/N 293 800
013) on drain plug threads.
Ask someone to pour recommended antifreeze in
coolant tank.
When antifreeze flows out from the ride plate
drain hole, reinstall drain plug. Torque drain plug
to specification.
TIGHTENING TORQUE
8.5 N•m ± 0.5 N•m
Drain plug
(75 lbf•in ± 4 lbf•in)

Continue to pour and fill coolant tank between

219100893-013-002_a
marks.
TYPICAL
1. Cooling drain plug

Remove the coolant tank cap.

smr2017-009
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Subsection XX (COOLING SYSTEM)

INSPECTION
COOLING SYSTEM LEAK TEST
WARNING
To avoid potential burns, do not remove the
coolant tank cap if the engine is hot.

NOTE: This test confirms if there is a leak in the

cooling system, including the engine.
Pressurize cooling system through coolant reser-
219100941-12-004_a voir.
LEVEL BETWEEN MARKS WHEN ENGINE IS COLD
REQUIRED TOOL
Do not install pressure cap at this time.
Link a garden hose to the hose adapter at the back TEST CAP (P/N 529 035 991)
of the watercraft. Refer to FLUSHING THE EX-
HAUST SYSTEM in the EXHAUST SYSTEM sub-
section.
VACUUM/PRESSURE PUMP
NOTICE Never run engine without supplying (P/N 529 021 800)
water to the exhaust system.
Start engine and let run for a maximum of 2 min- COOLING SYSTEM LEAK TEST
utes. Stop engine and wait 15 minutes to cool 110 kPa (16 PSI)
down. Refill tank as necessary.
NOTICE Never run engine longer than 2 min-
utes. Drive line seal has no cooling when wa-
tercraft is out of water.
Repeat this run-stop cycle 2-3 times until thermo-
stat opens and stop engine.

smr2009-024-103_a

TYPICAL
1. Vacuum/pressure pump
2. Test cap

If pressure drops, check all hoses, heat exchanger

219100941-12-005_a
1. This hose becomes hot when thermostat opens
Last, refill coolant tank and install pressure cap.
When engine has completely cooled down,
recheck coolant level in the coolant tank and top
up if necessary.
and engine for coolant leaks. Spray a soap/water
solution and look for air bubbles.
Check the leak indicator hole if there is oil or
coolant leaking.
NOTE: In general leaking coolant indicates a dam-
aged rotary seal. Leaking oil indicates a damaged
oil seal. If either seal is leaking, both seals must
be replaced at the same time. Refer to WATER
PUMP in COOLING SYSTEM - ENGINE in the ap-
propriate engine shop manual.

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 Subsection XX (COOLING SYSTEM)

4. Water pump failure

- Inspect and replace defective components.
5. Water temperature sensor defective
- Check or replace. Refer to ELECTRONIC FUEL
INJECTION (EFI).
6. Ride plate or hoses damaged
- Check or replace damaged components.
7. Exhaust system clogged
- Flush exhaust system.
8. Internal passage blocked in cooling system
219100893-013-005_a
- Inspect and clean.
ROTAX 1630 ACE, ROTAX 1500 HO ACE, ROTAX 1503 NA AND
ROTAX 1503 MODELS
1. Leak indicator hole PROCEDURES
PRESSURE CAP
Testing the Pressure Cap
Using a pressure cap tester, check cap opening
pressure. If opening pressure is out of range, in-
stall a new pressure cap.
CAP OPENING PRESSURE
90 kPa ± 10 kPa
Opening range
(13 PSI ± 1.5 PSI)

219100941-12-006_a
CLAMPS
ROTAX 900 HO ACE MODELS
1. Leak indicator hole
Replacing the Oetiker Clamp
REQUIRED TOOL
TROUBLESHOOTING
OETIKER PLIER (P/N 295
The following is provided to help in diagnosing the 000 070)
probable source of troubles. It is a guideline and
it should not be assumed to list all possible prob-
lems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES subsection.
ENGINE OVERHEATING
1. Low coolant level.
- Refill and check for leaks (coolant leaking out 1
of engine leak indicator hole, hoses or clamps
missing/defective, cylinder head gaskets leaks,
ride plate leaking, etc.). Repair or replace.
2. Air in cooling system
- Refill and bleed cooling system.
3. Thermostat defective (does not open when en- 2
gine gets hot) F01B2KA

- Replace thermostat housing. 1. Cutting clamp

2. Securing clamp

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Subsection XX (COOLING SYSTEM)

NOTE: Always check general condition of hoses

and clamp tightness.

12 https://brp-manuals.com/pwc_seadoo smr2017-009
 Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

MAGNETO AND STARTER

SERVICE TOOLS
Description Part Number Page
CRANKSHAFT PROTECTOR ......................................................... 529 036 213 ........................................... 93
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 91, 97
FLYWHEEL PULLER...................................................................... 420 976 235 ........................................... 93

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 93–94
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ........................................... 96
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 89
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ..................................... 94–95
TRIPLE-GUARD GREASE .............................................................. 296 000 329 ........................................... 98

smr2014-018
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Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

9 ± 1 N•m
(80 ± 9 lbf•in)

Triple Guard Grease

Engine oil

Loctite 648
Engine oil
30 ± 2 N•m
(22 ± 1.5 lbf•ft)

9 ± 1 N•m
(80 ± 9 lbf•in) Loctite 243
150 ± 10 N•m
(111 ± 7 lbf•ft)

Loctite 243

NEW

CPS 9 ± 1 N•m
See ELECTRONIC FUEL (80 ± 9 lbf•in)
INJECTION (EFI)

9 ± 1 N•m
(80 ± 9 lbf•in)
Engine oil
NEW = Component must be replaced when removed.
smr2014-018-001_a

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 Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

GENERAL
WARNING
Always disconnect BLACK (-) battery cable
first and reconnect last.

During assembly/installation, use the torque val-

ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for mmr2011-072-004_a

complete procedure. 1. CPS

5. Remove magneto cover retaining screws.

WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (ex: locking
tabs, cotter pin, etc.) must be replaced.

NOTICE Hoses, cables or locking ties re-

moved during a procedure must be reinstalled
as per factory standards.

PROCEDURES
MAGNETO COVER
Magneto Cover Access
1. Remove central body. Refer to BODY. mmr2012-135-004_a

MAGNETO COVER SCREWS

2. Remove battery. Refer to CHARGING SYS-
TEM . 6. Place an oil pan under magneto area to catch
3. Remove air intake silence. Refer to AIR INTAKE remaining oil.
SYSTEM . 7. Pull magneto cover off.
4. Remove fuel tank. Refer to FUEL TANK AND
FUEL PUMP.
Magneto Cover Inspection
Check magneto cover for cracks or other damage.
5. Remove central foam (under fuel tank).
Replace if necessary.
Magneto Cover Removal Magneto Cover Installation
1. Refer to PERIODIC MAINTENANCE PROCE-
1. Clean magneto cover.
DURES and:
– Drain coolant MAGNETO COVER CLEANING
– Drain engine oil. LOCTITE CHISEL
2. Refer to COOLING SYSTEM and remove: Service product (GASKET REMOVER)
(P/N 413 708 500)
– Water pump housing
– Thermostat housing. 2. Install a NEW magneto cover gasket.
3. Refer to LUBRICATION SYSTEM subsection 3. Ensure starter drive gear pin is in place.
and remove:
4. Apply engine oil on starter drive gear pin.
– Oil pressure regulator
– Oil cooler.
4. Remove the CPS.

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Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

CAUTION Magnetic force between mag-

neto flywheel and stator is very high. Avoid
finger contusions.
7. Tighten magneto cover screws according to the
following sequence.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Magneto cover screws
(80 lbf•in ± 9 lbf•in)

mmr2011-072-005_a

1. Starter drive gear pin

5. Apply engine oil on water pump shaft.

mmr2011-072-002_b

TIGHTENING SEQUENCE

8. Install all other removed parts.

mmr2011-072-006_a
STATOR
1. Water pump shaft - apply engine oil Stator Connector Access
NOTICE Make sure that the stator cable har- Remove central body. Refer to BODY.
ness is embedded into the channel. The part of Follow image sequence.
the harness that is out of the channel must be
tight, otherwise it might chafe or jam.

smr2014-018-100_a

STATOR CONNECTOR ACCESS

mmr2011-072-007_a
1. Stator harness at magneto cover
1. Embedded in that area 2. Stator connector
2. Tight in this area

6. Carefully install magneto cover.

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 Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

Stator Continuity Test

1. Disconnect battery.
2. Disconnect the stator connector from voltage
regulator, refer to STATOR CONNECTOR AC-
CESS in this subsection.
3. Set the multimeter to .
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)
smr2014-018-101_a

4. Probe each pair of YELLOW wires by touching

(NOT inserting) terminals lock tabs as shown.
NOTICE Never insert a multimeter probe into
a terminal as it would ruin the terminal.

smr2014-018-102_a

vbs2012-014-001

smr2014-018-103_a

mmr2009-113-036_a

1. Pin #1
2. Pin #2
3. Pin #3

5. Read resistance as per following table.

smr2014-018-104_a

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Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

STATOR CONTINUITY TEST

YELLOW WIRES RESISTANCE @
(EACH PAIR) 20°C (68°F)
Pins 1 and 2
Pins 1 and 3 0.1 - 1
Pins 2 and 3

If any resistance reading is not as specified, the

stator or the wiring (including connector) is open mmr2009-113-036_c

and needs to be repaired or replaced. 4. Read voltage.

If resistance is good, perform the stator insulation
test. STATOR OUTPUT VOLTAGE TEST
TEST ENGINE
Stator Insulation Test TERMINAL VOLTAGE
SPEED
1. Connect multimeter between any YELLOW 1 and 2
wire and chassis ground.
Idle speed 1 and 3 ± 25 Vac
2 and 3

If any voltage reading is significantly lower than

specification, replace the stator.

Stator Removal
1. Remove the MAGNETO COVER, see proce-
dure in this subsection.
2. Remove stator retaining screws.
mmr2009-113-036_b

2. Read resistance.
STATOR INSULATION TEST
RESISTANCE @
PROBE POSITIONS
20°C (68°F)
Any YELLOW wire and
Infinity (OL)
chassis ground

If any resistance reading is not as specified, the

stator or the wiring is shorted to ground and needs
to be repaired or replaced.
If the insulation test is good, perform the output
voltage test. mmr2011-072-008_a

1. Stator
2. Stator retaining screws
Stator Output Voltage Test
1. With the stator connector unplugs from the 3. Remove stator.
voltage regulator/rectifier, start engine and let
it reach its operating temperature. Stator Inspection
2. Set multimeter to Vac scale. Check stator windings and insulation for cracks
and other damages. If damaged replace it.
3. With engine idling, connect multimeter be-
tween each pair of YELLOW wires. Check if stator wires are brittle, hard or otherwise
damaged.

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 Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

Stator Installation
1. Ensure that the stator cable is underneath the
cable holder during installation of the stator.

mmr2011-072-010_a

1. Retaining screw
2. Lock washer
3. Rotor

4. Remove rotor.
mmr2011-072-009_a

1. Cable holder REQUIRED TOOL

2. Stator cable
CRANKSHAFT PROTECTOR
2. Install stator retaining screws and tighten to the (P/N 529 036 213)
specified torque.
FLYWHEEL PULLER (P/N 420
TIGHTENING TORQUE 976 235)
LOCTITE 243 (BLUE)
Service product NOTE: Apply some grease on the crankshaft pro-
(P/N 293 800 060)
tector surface to ease puller operation.
9 N•m ± 1 N•m
Stator retaining screws
(80 lbf•in ± 9 lbf•in)

3. Reinstall MAGNETO COVER, see procedure in

this subsection.

ROTOR
Rotor Removal
1. Remove the MAGNETO COVER, see proce-
dure in this subsection.
2. Lock crankshaft. Refer to CYLINDER BLOCK
subsection.
3. Remove rotor retaining screw and lock washer.
mmr2011-072-023_a

1. Rotor
2. Flywheel puller screw

Rotor Inspection
Check the inner side of the rotor for scratches or
other damage.
Check keyway for wear or damages.
Check if trigger wheel teeth are bent or otherwise
damaged.

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Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

4. Install sprag clutch gear onto the rotor.

mmr2011-072-012_b

1. Rotor with trigger wheel

2. Oil passage in magneto hub mmr2011-072-014_a

3. Rotor taper 1. Apply engine oil here

2. Sprag clutch
Check woodruff key and keyway on the crank- 3. Sprag clutch housing
4. Sprag clutch gear
shaft for wear or damages.
Replace parts as necessary. 5. Slide rotor along with the sprag clutch gear onto
the crankshaft. The woodruff key and keyway
Rotor Installation must be aligned.
Installation is the reverse of the removal proce- 6. Rotate sprag clutch gear counterclockwise to
dure. However, pay attention to the following. align with starter double gear.
1. Blow the oil passage in the magneto hub using
compressed air. Check if it is clogged.
2. Using PULLEY FLANGE CLEANER (P/N 413 711
809), clean:
– The oil passage
– The crankshaft thread
– The crankshaft taper
– The rotor taper.
NOTICE Taper on crankshaft and rotor must
be free of grease.

mmr2011-072-015_a

Step 1: Rotate to align teeth

1. Sprag clutch gear
2. Starter double gear

7. Install washer and retaining screw.

8. Tighten to the specified torque.
ROTOR RETAINING SCREW
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
150 N•m ± 10 N•m
Tightening torque
mmr2011-072-013_b (111 lbf•ft ± 7 lbf•ft)
1. Crankshaft taper
2. Oil passage
3. Thread

3. Apply oil on sprag clutch and needle bearing.

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 Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

SPRAG CLUTCH Rotate sprag clutch gear clockwise. Gear must ro-
tate freely.
Sprag Clutch Removal
1. Remove the MAGNETO COVER, see proce-
dure in this subsection.
2. Lock crankshaft. Refer to CYLINDER BLOCK
subsection.
3. Loosen and remove sprag clutch housing
screws.

mmr2011-072-018_a

Step 1: Free

Rotate sprag clutch gear counterclockwise. Gear

must lock.
mmr2011-072-016_a

1. Sprag clutch housing screws

2. Rotor

4. Remove ROTOR, see procedure in this subsec-

tion.
5. Remove sprag clutch housing.
6. Remove sprag clutch from sprag clutch hous-
ing.

mmr2011-072-018_b

Step 1: Lock

Sprag Clutch Installation

1. Clean sprag clutch housing with a parts cleaner.
NOTICE Threads of sprag clutch housing
must be free of any lubricants.
mmr2011-072-017_a SPRAG CLUTCH HOUSING
1. Sprag clutch housing screws
2. Rotor PULLEY FLANGE
3. Sprag clutch Service product CLEANER (P/N 413
4. Sprag clutch housing 711 809)
Sprag Clutch Inspection 2. Apply thread locker on threads of sprag clutch
Inspect sprag clutch and sprag clutch housing for housing screws.
wear and damage.
Check the collar of the sprag clutch gear, refer to
SPRAG CLUTCH GEAR.
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Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

SPRAG CLUTCH HOUSING SCREWS

LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)

3. Loosely install screws.

4. Apply engine oil on sprag clutch and sprag
clutch gear needle bearing.

mmr2011-072-014_b

1. Sprag clutch gear

2. Rotor

Sprag Clutch Gear Inspection

Inspect gear, especially teeth and sprag clutch col-
lar for wear and other damage.
Check needle bearing for wear and pittings.

mmr2011-072-014_a

1. Apply engine oil here

2. Sprag clutch
3. Sprag clutch housing
4. Sprag clutch gear

5. Install ROTOR, see procedure in this subsec-

tion.
6. Tighten sprag clutch housing screws to the
specified torque.
TIGHTENING TORQUE
Sprag clutch housing 30 N•m ± 2 N•m
screws (22 lbf•ft ± 1 lbf•ft)
mmr2011-072-019_a

7. Install all other removed parts.
SPRAG CLUTCH GEAR
Sprag Clutch Gear Removal
1. Remove rotor and sprag clutch gear together.
Refer to ROTOR in this subsection.
2. Pull sprag clutch gear out of the rotor.
1. Teeth
2. Collar
3. Needle bearing
Replace sprag clutch gear if necessary.
Sprag Clutch Gear Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTE: Apply engine oil on needle bearing and col-
lar of sprag clutch gear.

STARTER DRIVE GEARS

The starter drive gears are located on the engine
MAG side behind the magneto cover.

Starter Drive Gear Removal

1. Remove MAGNETO COVER, see procedure in
this subsection.

96 https://brp-manuals.com/pwc_seadoo smr2014-018

Subsection 06 (MAGNETO AND STARTER)
2. Remove location pin and starter double gear.
mmr2011-072-005_c
1. Location pin
2. Starter double gear
Starter Drive Gear Inspection
Inspect starter drive gears and location pin for
wear and damage.
Replace parts if necessary.
Starter Drive Gear Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Apply engine oil on the location pin.
STARTER
Starter Operation Test
Before carrying out any starter test, make sure:
– Battery is fully charged and in good condition.
– Cable connections at battery, starter and sole-
noid are tight.
– Cables are in good condition.
1. Disconnect the negative battery cable.
2. Using booster cables and a fully charged bat-
tery or a power pack, carefully supply current
directly to the starter.
2.1 Connect the negative booster cable or
power pack cable to a good ground such
as an engine support.
2.2 Temporarily touch the starter positive ter-
minal.
WARNING
Sparks can occur when connecting jumper
cables. To avoid fire hazard, be sure that no
flammable liquids or fuel vapors are in the
test area.
smr2014-018
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Section 02 ENGINE
smr2014-018-105_a
1. Engine support
2. Starter positive terminal
If starter turns at normal speed, test the starting
circuit. Refer to STARTING SYSTEM subsection.
If starter turns slowly, carry out the STARTER
VOLTAGE DROP TEST (AT BATTERY).
If starter does not turn, replace starter.
Starter Voltage Drop Test (at Battery)
NOTE: This test will confirm if starter draws too
much current. Battery must be fully charged and
in good condition.
1. Set the multimeter to Vdc.
REQUIRED TOOL
FLUKE 115 MULTIMETER
(P/N 529 035 868)
2. Probe the battery posts.
3. Crank engine in drowned mode. Refer to EN-
GINE MANAGEMENT SYSTEM .
4. Read voltage while cranking.
NOTE: Battery voltage will drop approximately
2 Vdc and fluctuate with starter cranking load.
If the result is close to battery voltage, the starter
is in good condition.
If the result is below battery voltage (- 2 Vdc and
more), the starter may be defective.
Starter Access
Remove central body. Refer to BODY.
Starter Removal
1. Disconnect the BLACK (–) cable from the bat-
tery.
2. Remove the starter cable from starter.
3. Remove starter retaining screws.
97
Section 02 ENGINE
Subsection 06 (MAGNETO AND STARTER)

smr2014-018-005_a

1. Lubricate starter end

2. Lubricate starter O-rings
smr2014-018-003_a

1. Starter 3. Insert starter gear into engine.

2. Starter retaining screws
4. Install starter screws and tighten to the speci-
4. Pull starter off the cylinder block. fied torque.

Starter Installation TIGHTENING TORQUE

1. Ensure starter and engine mating surfaces are 9 N•m ± 1 N•m
Starter screws
free of debris. (80 lbf•in ± 9 lbf•in)

NOTICE Serious problems may arise if the 5. Connect the starter cable to the starter and
starter is not properly aligned. tighten nut to the specified torque.
TIGHTENING TORQUE
7 N•m ± 1 N•m
Starter cable nut
(62 lbf•in ± 9 lbf•in)

6. Install all other removed parts.

7. Reconnect BLACK (–) cable on battery post.
8. Test for proper starter operation.

smr2014-018-004_a

1. Clean mating surfaces

2. Lubricate on starter end and starter O-rings be-

fore installation.
STARTER END +O-RINGS
TRIPLE-GUARD
Service product GREASE (P/N 296
000 329)

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 Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

PTO HOUSING, MAGNETO AND

STARTER
SERVICE TOOLS
Description Part Number Page
HANDLE ........................................................................................ 420 877 650 ........................................... 13
IMPELLER REMOVER/INSTALLER ............................................... 529 035 820 ............................................. 7
OETIKER PLIER............................................................................. 295 000 070 ............................................. 7
STARTER DRIVE SEAL PUSHER................................................... 420 876 502 ........................................... 13
SUCTION PUMP ........................................................................... 529 035 880 ............................................. 3

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 15
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 13
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................. 6, 10, 15
LOCTITE 5910 ............................................................................... 293 800 081 ............................................. 5
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ............................................. 8
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ............................................. 8
TRIPLE-GUARD GREASE .............................................................. 296 000 329 ........................................... 15

RTX1503ACEMY18-004
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Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243

See tightening
sequence

NEW
Loctite 5910

See tightening
sequence 9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243

Loctite 243
9 ± 1 N•m Multi purpose grease
(80 ± 9 lbf•in)
NEW

TripleGuard
Grease
Isoflex grease
Topas Nb52
Engine oil
NEW
9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243
See tightening
procedure
NEW
Isoflex grease
Topas Nb52
Engine oil

Loctite 648
NEW

250 ± 10 N•m
(184 ± 7 lbf•ft)
NEW = Component must be replaced when removed.
smr2016-015-001_b

2 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-004
 Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

GENERAL
It is good practice to check for fault codes using
the BRP diagnostic software (BUDS2) as a first
troubleshooting step. Refer to the DIAGNOSTIC
AND FAULT CODES subsection.
Always carry out electrical tests on components
before removing or installing them.

PROCEDURES
PTO HOUSING
Removing the PTO Housing
1. Remove the engine from the watercraft. Re-
fer to ENGINE REMOVAL AND INSTALLATION
subsection.
2. Drain the engine oil. Refer to LUBRICATION
SYSTEM subsection.
RTX1503ACEMY18-004-007_a
3. Remove the supercharger (if applicable). Refer PARTS REMOVED FOR CLARITY
to SUPERCHARGER subsection.
4. Syphon engine oil through oil dipstick tube. Re- 7. Disconnect CPS connector from wiring har-
fer to ENGINE OIL CHANGE in the LUBRICA- ness.
TION SYSTEM subsection.
5. Remove the valve cover. Refer to CYLINDER
HEAD subsection.
6. Syphon remaining oil out of the lower timing
chain case:
6.1 Put some electrical tape on suction pump
hose at 450 mm (17.72 in) from its end.
6.2 Insert the suction pump hose in the lower
area of the timing chain until the tape
flushes with the edge of the cylinder
head.
RTX1503ACEMY18-009-006_a
REQUIRED TOOL
TYPICAL
1. CPS connector
SUCTION PUMP
(P/N 529 035 880) 8. Disconnect the stator connector, refer to STA-
TOR CONNECTOR ACCESS in this subsection.
9. Place rags under PTO housing to prevent oil
spillage.
NOTE: Up to 250 ml (8 U.S. oz) of oil could flow
out when removing PTO housing.
10. Remove LH rear engine support.

RTX1503ACEMY18-004
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Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

13. Pry off the PTO housing from engine using

two flat screwdrivers.
NOTICE Avoid scoring or damaging contact
surfaces.
NOTICE Be careful not to loose the disc
springs and thrust washer located on the
starter drive shaft.

R1503motr50A

TYPICAL
1. Engine support

11. Remove water pump housing, refer to COOL-

ING SYSTEM subsection.

smr2005-034-002_a

1. Disc springs
2. Thrust washer
3. Starter drive

14. Remove PTO housing gasket and discard it.

smr2007-016-003_c

1. Water pump housing

12. Remove PTO housing retaining screws and
CPS harness retaining clamp.
If necessary remove following parts from PTO
housing:
– Stator, refer to procedure in this subsection
– Oil filter, refer to LUBRICATION SYSTEM
– Oil pressure pump, refer to LUBRICATION SYS-
TEM
– Engine oil pressure regulator, refer to LUBRICA-
TION SYSTEM
– Crankshaft position sensor (CPS)

Inspecting the PTO Housing

Inspect PTO housing for cracks or any other dam-
ages. Replace if necessary.
Inspect the starter drive needle bearing in the PTO
housing.
NOTE: Clean all disassembled metal components
in a non-ferrous metal cleaner.
smr2009-022-001_a
Inspect oil strainer for contaminants, debris or
TYPICAL other particles. Clean as required.
1. PTO housing
2. CPS harness retaining clamp
3. CPS

4 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-004
 Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

STATOR CABLE GROMMET SEALING

LOCTITE 5910 (P/N 293
Service product
800 081)

smr2016-015-007_a

1. PTO oil strainer

Installing the PTO Housing

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install disc springs and thrust washer of starter
drive, see INSTALLING THE STARTER DRIVE in
this subsection.
Install a NEW PTO housing gasket.
Apply a small amount of grease on the frame of
the oil strainer to keep it in place while installing
the PTO cover.
smr2016-015-010_b
APPLY SEALING COMPOUND HERE
Install PTO housing.
NOTICE During installation ensure:
– That thrust washer and spring discs are
placed on starter drive shaft
– Oil/water pump shaft alignment with bal-
ance shaft (rotate shaft slightly)
– Starter drive gear alignment with needle
bearing
– Proper PTO housing gasket alignment.
NOTICE This engine uses thrust washer with
specific thickness. Using any other thrust
washer may cause severe engine damage.
THRUST WASHER THICKNESS
1.5 mm (.06 in)

R1503ACE_MY17-002_004_a

SERVICE PRODUCT
Multi Purpose Grease BP LS 3

Clean stator cable grommet and cylinder block

to remove all remaining silicone residues in oil
strainer area.
Apply sealing compound on stator cable grom-
met.
smr2009-022-002_a

1. Pay attention that gasket remains properly positioned

on this surface

RTX1503ACEMY18-004
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Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

Install the CPS harness retaining clamp.
RTX1503ACEMY18-009-005_c
Carry out an engine alignment, refer to the
ENGINE REMOVAL AND INSTALLATION subsec-
tion.
NOTICE An engine alignment procedure
must be carried, otherwise severe component
damage may occur.
Install all remaining parts, reconnect hoses and
electrical connectors. Refer to applicable subsec-
tions for procedures.
Refill engine oil and coolant. Refer to LUBRICA-
TION SYSTEM and COOLING SYSTEM subsec-
tions.

TYPICAL PTO SEAL

Tighten PTO housing screws as per following se- PTO Seal Location
quence. The PTO seal is located over the PTO coupling.
TIGHTENING TORQUE
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
PTO housing
+
screws
LOCTITE 243 (BLUE)
(P/N 293 800 060)

smr2016-015-011_a

TYPICAL
1. PTO seal

Inspecting the PTO Seal

Inspect the PTO seal on the PTO housing. If brit-
tle, hard, damaged or leaking, replace it.
Inspect ball bearing within PTO seal for excessive
smr2016-015-006_b play and smooth operation.
TYPICAL
Replace PTO seal if oil seal or ball bearing is dam-
Reinstall LH engine support as per following table. aged.
TIGHTENING TORQUE Removing the PTO Seal
23 N•m ± 3 N•m Remove drive shaft. Refer to STEERING AND
(17 lbf•ft ± 2 lbf•ft) PROPULSION section.
LH engine support
+
screws Remove supercharger (if applicable). Refer to SU-
LOCTITE 243 (BLUE)
(P/N 293 800 060) PERCHARGER subsection.
Remove Oetiker clamp retaining the seal to the
Reinstall the engine, Refer to ENGINE REMOVAL PTO housing.
AND INSTALLATION subsection.

6 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-004
 Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

PTO COUPLING

R1503ACE_MY17-004_001_a

TYPICAL
1. Oetiker clamps
2. PTO seal
smr2010-022-002_a

Pull seal from PTO housing. 1. PTO coupling

2. Seal
3. Stop sleeve
Installing the PTO Seal
Insert a NEW Oetiker clamp over the seal. Inspecting the PTO Coupling
Push seal onto PTO housing. Be sure to align seal Inspect seal within coupling, if it is brittle, cracked
and clamp as noted at removal. or hard, replace it.
NOTICE Ensure to Check coupling for worn or damaged splines. Re-
position the Oetiker
place as required.
clamps as illustrated.
Removing the PTO Coupling
Remove engine from vehicle, refer to ENGINE RE-
MOVAL AND INSTALLATION subsection.
Lock crankshaft. Refer to CYLINDER BLOCK sub-
section for the procedure.
Refer to procedures in this subsection and re-
move:
– PTO housing
– Rotor and trigger wheel
– Ring gear
– Starter drive
Heat up PTO coupling with a heat gun to break
R1503ACE_MY17-004_001_b
threadlocker.
TYPICAL
1. Oetiker clamps Unscrew coupling from crankshaft.
Crimp Oetiker clamp. REQUIRED TOOL

REQUIRED TOOL IMPELLER

REMOVER/INSTALLER
OETIKER PLIER (P/N 529 035 820)
(P/N 295 000 070)

RTX1503ACEMY18-004
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Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

TIGHTENING TORQUE
250 N•m ± 10 N•m
(184 lbf•ft ± 7 lbf•ft)
PTO Coupling +
LOCTITE 648 (GREEN)
(P/N 413 711 400)

NOTE: Always install a NEW oil seal into PTO

coupling.

smr2016-015-014_a

TURN COUNTERCLOCKWISE TO REMOVE

1. Impeller removal tool

Installing the PTO Coupling

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Clean following:
– Thread inside PTO coupling
– Thread on crankshaft.
smr2016-015-013_a
PTO COUPLING AND CRANKSHAFT THREADS
1. Oil seal
2. PTO coupling
PULLEY FLANGE
Service product CLEANER (P/N 413
711 809) STATOR
Install stop sleeve into PTO coupling. Testing the Stator Continuity
Probe each pair of YELLOW wires by touching
(NOT inserting) terminals lock tabs as shown.

smr2016-015-002_a

1. Stop sleeve
2. PTO coupling

vbs2012-014-001

8 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-004
 Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

Removing the Stator

Remove PTO housing, see procedure in this sub-
section.
Remove the following components:

mmr2009-113-036_a

1. Pin #1
2. Pin #2
3. Pin #3

STATOR CONTINUITY TEST

RESISTANCE @
TERMINAL
20°C (68°F)
1 and 2
1 and 3 0.1 - 1 smr2016-015-017_a

TYPICAL
2 and 3 1. Screws
2. Holding plate
If any resistance reading is not as specified, the 3. Stator screws
4. Stator
stator or the wiring (including connector) is open
and needs to be repaired or replaced. Clean cable grommet from sealing compound.
If resistance is good, perform the stator insulation
test. Installing the Stator
The installation is the reverse of the removal pro-
Testing the Stator Insulation cedure. However, pay attention to the following.
Connect multimeter between any YELLOW wire NOTE: There is only one position for the stator
and engine ground. (notch in the housing).

mmr2009-113-036_b

STATOR INSULATION TEST

RESISTANCE @
TERMINAL RTX1503ACEMY18-004-005_a
20°C (68°F) 1. Notch for stator
2. PTO housing notch
Any YELLOW wire and 3. Stator cable grommet
Infinity (open circuit)
engine ground

If any resistance reading is not as specified, the

stator or the wiring is shorted to ground and needs
to be repaired or replaced.
If the insulation test is good, perform the output
voltage test.

RTX1503ACEMY18-004
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Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

TIGHTENING TORQUE
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
Cable holding screws +
LOCTITE 243 (BLUE)
(P/N 293 800 060)

Install PTO housing as per procedures in this sub-

section.

ROTOR AND TRIGGER WHEEL

Rotor and Trigger Wheel Access
Remove PTO housing, see procedure in this sub-
section. smr2009-022-015_a

TYPICAL
Inspecting the Rotor and the Trigger 1. Trigger wheel
2. Dial indicator
Wheel
Inspect rotor and trigger wheel condition. Pay par- If the reading exceeds the maximum allowable tol-
ticular attention to the inside of the rotor for: erance, straighten the tooth or replace the trigger
– Cracks wheel.
– Rub marks 8. Properly reinstall PTO housing.
– Discoloration.
Removing the Rotor and the Trigger
If damaged, replace faulty part.
Wheel
Check the trigger wheel for bent teeth using the
Lock crankshaft, refer to CYLINDER BLOCK sub-
following procedure.
section for procedure.
1. Install a dial indicator on crankcase casting.
Remove the rotor.
2. Position the gauge on a tooth and set it to zero
(0). Be sure to lock the indicator dial to prevent
movement of the dial during the remainder of
the procedure.
3. Mark the first measured tooth (reference
tooth).
4. Gently lift the gauge contact point off the tooth
and rotate the rotor to the next tooth.
NOTE: When lifting contact point off the tooth for
rotor rotation, be careful not to move gauge posi-
tion or test readings taken on next tooth will not
be accurate with reference to the reference tooth.
5. Gently set the gauge contact point on the next
tooth and read the dial indicator. smr2016-015-021_a

TYPICAL
6. Repeat this procedure taking a reading at each 1. Rotor retaining screws (discard)
tooth. 2. Rotor
3. Trigger wheel
7. Recheck reading on reference tooth to ensure
gauge has not changed position (gauge should Installing the Rotor and the Trigger
still read zero). Wheel
TRIGGER WHEEL TEETH INSPECTION The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Maximum allowable
0.15 mm (.006 in) 1. Align the trigger wheel with the location pin on
difference
the crankshaft end.

10 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-004
 Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

smr2016-015-024_a

1. Thrust washer
smr2016-015-004_a 2. Disc springs
3. Starter drive
TYPICAL
1. Location pin
2. Trigger wheel Remove the rotor.
2. Install NEW OEM rotor screws and torque
4
them in a crisscross pattern as per following
procedure. 3

NOTICE This assembly uses stretch screw 2

with pre-applied threadlocker. Always use
NEW OEM screws and strictly adhere to the
tightening procedure.
1
NOTE: Always perform step A on all rotor screws
before going to the step B.
TIGHTENING TORQUE
R1503motr54A
15 N•m ± 1 N•m
STEP A
Rotor screws (133 lbf•in ± 9 lbf•in) 1. Rotor retaining screws (discard)
2. Rotor
STEP B Additional 50° ± 5° 3. Trigger wheel
4. Ring gear

RING GEAR Inspecting the Ring Gear

Inspect ring gear for damages. Pay particular at-
Removing the Ring Gear tention to teeth condition. If badly worn, cracked,
Lock crankshaft. Refer to CYLINDER BLOCK sub- or broken teeth are found, replace ring gear.
section for procedure.
Remove the PTO housing, see procedure in this Installing the Ring Gear
subsection. The installation is the reverse of the removal pro-
Remove thrust washer and disc springs from cedure. However, pay attention to the following.
starter drive shaft. Align the ring gear and trigger wheel with the lo-
cation pin on the crankshaft end.

RTX1503ACEMY18-004
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Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

If any part of the assembly shows signs of ab-

1
normal wear, cracks, broken teeth or malfunction
2 (sprag clutch), replace the faulty part.
Check needle bearings for excessive play and
smooth operation. If damaged see REPLACING
THE STARTER DRIVE BEARING in this subsec-
tion.

R1503motr54B

1. Location pin
2. Location pin holes

Install rotor and trigger wheel, refer to the proce-

dures in this subsection.
Install disc springs and thrust washers of starter
drive, see INSTALLING THE STARTER DRIVE in
this subsection.

STARTER DRIVE smr2016-015-015_a

PTO HOUSING
1. Starter drive bearing
Removing the Starter Drive
Refer to the procedures in this subsection and re-
move:
– PTO housing
– Rotor and trigger wheel
– Ring gear.
Remove starter drive.

smr2016-015-016_a

TYPICAL - CYLINDER BLOCK

1. Starter drive bearing

Replacing the Starter Drive Bearing

Remove starter drive bearing from PTO housing
and/or cylinder block.
smr2016-015-022_a REQUIRED TOOL
1. Starter drive
Blind hole bearing puller set
Inspecting the Starter Drive
Install starter drive bearing in the PTO housing or
Inspect all starter drive parts for excessive wear, in the cylinder block.
cracks and other defects. Pay attention to the
condition of the drive gear teeth.
Ensure proper operation of the starter drive sprag
clutch.

12 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-004
 Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

REQUIRED TOOLS
STARTER DRIVE SEAL
PUSHER (P/N 420 876 502)
HANDLE
(P/N 420 877 650)

Installing the Starter Drive

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Position the spring discs and thrust washer onto
the starter drive shaft as per following illustration.
smr2016-015-016_a

TYPICAL - CYLINDER BLOCK

1. Starter drive bearing

smr2005-034-100_a

TYPICAL
1. Thrust washer
2. Spring discs
3. Starter drive

When installing a NEW starter drive lubricate:

– Shaft
– Gear teeth smr2016-015-015_a

PTO HOUSING
– Splines. 1. Starter drive bearing
STARTER DRIVE
Service product Engine oil
STARTER
Starter Quick Test
Lubricate starter drive needle bearings.
To easily bypass the starter solenoid and the start
STARTER DRIVE NEEDLE BEARINGS control circuits, proceed as follows.
ISOFLEX GREASE – Use a fully charged 12 V battery with a capacity
Service product TOPAS NB 52 (P/N 293 of at least 30 A-h.
550 021) – Use a set of booster cables to power the
starter.
This procedure tests the following:
– Electric starter
– Starter power cable
– Battery to engine ground cable.

RTX1503ACEMY18-004
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Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

WARNING – Vehicle battery ground cable connections to en-

gine
Fuel, oil, or electrolyte vapors are flammable
and may become explosive if certain con- – Starter power cable/connections from solenoid
ditions are met. These vapors may collect to starter
near the bottom of the hull when present. All – Carry out a SOLENOID DYNAMIC TEST.
types of ignition including electrical sparks If the above items all test good, replace the
are to be avoided when maintaining or test- starter.
ing vehicle.
Starter Location
Connect booster cables in this strict order:
1. Connect one RED clip to the starter post on the
starter solenoid.
2. Connect the other RED clip to the positive (+)
terminal on the external battery.
3. Connect one BLACK clip to the negative (-) bat-
tery terminal in the vehicle.
4. Momentarily apply the second BLACK clip to
the negative (-) terminal of the external battery.

WARNING
Always use an external battery for this test to
prevent any electrical sparks from occurring
within the hull. Always make the final con- RTX1503ACEMY18-001-002_b

nection to the external battery negative (-) ter- TYPICAL

minal using the BLACK booster cable clip. Do
not short starter solenoid contacts across the
main power connections on the relay with a
tool that would cause electrical sparks. Fail-
ure to follow this procedure may result in an
explosion.
4 2
Removing the Starter
1. Disconnect battery. Refer to CHARGING SYS-
TEM subsection.
NOTE: For better access to the starter, work from
RH side and lay across the watercraft.
2. Disconnect starter power cable.
3. Remove starter retaining screws.

3 M

smr2009-034-011_a

Step 1: Connect cable to solenoid starter post

Step 2: Connect cable to external battery positive post
Step 3: Connect cable to vehicle battery negative post
Step 4: Make a momentary contact
smr2007-025-008_a

If engine does not crank (or cranks slowly), check 1. Exhaust manifold
2. Starter
the following: 3. Starter retaining screws
– Booster cable connections 4. Starter power cable retaining nut

14 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-004
 Subsection XX (PTO HOUSING, MAGNETO AND STARTER)

Removing the Starter Gear

Remove:
– Circlip
– Starter gear.

smr2016-015-023_b

1. Lubricate starter O-rings

Install starter.
TIGHTENING TORQUE

smr2016-015-023_a
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
1. Retaining circlip
2. Starter gear Starter retaining screws +
LOCTITE 243 (BLUE)
Installing the Starter Gear (P/N 293 800 060)
The installation is the reverse of removal proce-
dure. However, pay particular attention to the fol- WARNING
lowing. To prevent electric shock whenever connect-
ing the RED power cable to the starter motor,
Install a NEW circlip.
ensure the BLACK (-) battery cable is discon-
Installing the Starter nected.
The installation is the reverse of the removal pro- 3. Apply DIELECTRIC GREASE (P/N 293 550 004) on
cedure. However, pay attention to the following. terminal and nut.
1. Ensure starter and engine mating surfaces are 4. Install rubber protector over starter power cable
free of debris. Serious problems may arise if retaining nut.
starter is not properly aligned.
2. Lubricate starter O-rings.
STARTER O-RINGS
TRIPLE-GUARD
Service product GREASE (P/N 296
000 329)

smr2016-052-001_a

1. Power cable retaining nut

2. Rubber protector
3. Starter retaining screws

5. Reinstall all remaining removed parts.

RTX1503ACEMY18-004
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 Subsection XX (INTAKE MANIFOLD)

INTAKE MANIFOLD
SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 7

13 0 an d 15 5 En gine s

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243
See ELECTRONIC FUEL
INJECTION (EFI)

NEW
Engine oil

MAPTS
See ELECTRONIC FUEL
INJECTION (EFI) 11 ± 1 N•m
5,5 ± 0,6 N•m (97 ± 9 lbf•in)
(49 ± 5 lbf•in)
See Loctite 243
Loctite 243 tightening
sequence

See ELECTRONIC FUEL

INJECTION (EFI)

NEW

See ELECTRONIC FUEL

INJECTION (EFI)
See
ELECTRONIC FUEL
INJECTION (EFI)

Engine
Loctite 243 oil
5,5 ± 0,6 N•m Loctite 243
(49 ± 5 lbf•in) 4,5 ± 0,5 N•m
(40 ± 4 lbf•in)

Loctite 243
17 ± 2 N•m 9 ± 1 N•m
(150 ± 18 lbf•in) (80 ± 9 lbf•in)

NEW = Component must be replaced when removed.

RTX1503ACEMY18-005
https://brp-manuals.com/pwc_seadoo 1
Subsection XX (INTAKE MANIFOLD)

23 0 E ngin es

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243
See ELECTRONIC FUEL
INJECTION (EFI)

NEW
9 ± 1 N•m Engine oil
See ELECTRONIC FUEL
(80 ± 9 lbf•in) INJECTION (EFI) 11 ± 1 N•m
See (97 ± 9 lbf•in)
tightening Loctite 243
sequence

See ELECTRONIC FUEL

INJECTION (EFI)
5,5 ± 0,6 N•m
(49 ± 5 lbf•in) NEW
Loctite 243

See
ELECTRONIC FUEL
INJECTION (EFI)
5,5 ± 0,6 N•m
(49 ± 5 lbf•in)
Loctite 243

Engine
oil
Loctite 243
4,5 ± 0,5 N•m
(40 ± 4 lbf•in) MAPTS
See ELECTRONIC FUEL
5,5 ± 0,6 N•m INJECTION (EFI)
(49 ± 5 lbf•in)
Loctite 243
Loctite 243
17 ± 2 N•m
(150 ± 18 lbf•in)

NEW = Component must be replaced when removed.

smr2016-016-001_a

2 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-005
 Subsection XX (INTAKE MANIFOLD)

PROCEDURES
INTAKE MANIFOLD
Removing the Intake Manifold
Disconnect the intake hose from the throttle body.

smr2016-016-015_a

TYPICAL
1. Connector "B"
2. Retaining screws
3. ECM

Cut locking ties securing the wiring harnesses to

the intake manifold.

RTX1503ACEMY018-005-201

130 AND 155 ENGINES

RTX1503ACEMY18-009-001_a

RTX1503ACEMY018-005-200

230 ENGINES

Remove the oil dipstick.

Disconnect fuel hose connector at fuel rail. Refer
to ELECTRONIC FUEL INJECTION (EFI) subsec-
tion.
Unplug the "B" connector from the ECM. Refer to
CONNECTOR INFORMATION subsection for pro- smr2016-016-016

cedure. TYPICAL - LOCKING TIES (3X)

Unscrew ECM retaining screws.

RTX1503ACEMY18-005
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Subsection XX (INTAKE MANIFOLD)

RTX1503ACEMY18-009-007_b

1. KS connector
RTX1503ACEMY18-005-002_a 2. MAPTS connector
TYPICAL
1. Locking tie (130 and 155 only) 2 30 En gine s
13 0 a nd 1 55 En gine s Unplug the manifold absolute pressure and tem-
perature sensor (MAPTS) and the engine connec-
Unplug:
tor.
– Throttle body connector
– Engine connector.

smr2016-016-017_a

TYPICAL
1. MAPTS connector
RTX1503ACEMY18-005-003_a 2. Engine connector location
1. Throttle body connector
2. Engine connector Cut locking tie from throttle body connector.
Cut locking tie from MAPTS connector. Unplug:
Unplug: – Knock sensor (KS)
– Knock sensor (KS) – Throttle body connector.
– Manifold absolute pressure and temperature
sensor (MAPTS)

4 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-005
 Subsection XX (INTAKE MANIFOLD)

RTX1503ACEMY18-005-006_a RTX1503ACEMY18-005-007_a

TYPICAL TYPICAL
1. Locking tie
2. Throttle body connector
3. KS connector
Unplug the oil pressure switch (OPS).

All En gine s
Remove ECM from its support.
Unscrew the ignition coil screws and move the
GND connectors aside.
Unplug the ignition coil and fuel injector connec-
tors.

smr2009-018-011_a

TYPICAL
1. Oil pressure switch (OPS)

Pull the engine wiring harness with the ECM

plugged away from intake manifold.
Remove manifold retaining screws.

RTX1503ACEMY18-005-004_a

1. GND connectors
2. Ignition coil connectors
3. Fuel injector connectors

Detach the knock sensor (KS) connector from the

ECM support. For more details, refer to CONNEC-
TOR INFORMATION subsection.

RTX1503ACEMY18-005-008_a

Carefully tilt intake manifold.

Then push the oil dipstick tube out of the manifold
slot and pull it out of its bore in the cylinder block.

RTX1503ACEMY18-005
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Subsection XX (INTAKE MANIFOLD)

smr2016-016-009_a

1. Oil dipstick tube

2. Intake manifold R1503motr62A 1
Lift intake manifold up to pull it out of the mount- INTAKE MANIFOLD
ing brackets. 1. Gaskets

First, position intake manifold on front mounting

bracket then push manifold toward engine, then
proceed with rear mounting bracket.

smr2016-016-010_a

TYPICAL
1. Mounting brackets

Pull intake manifold out. smr2016-016-010_b

Remove and discard intake manifold gaskets. TYPICAL

1. Front mounting bracket
2. Rear mounting bracket
Inspecting the Intake Manifold
When installing the intake manifold, lift up the oil
Check intake manifold for cracks, warping at dipstick tube a little bit to fit in the slot of the man-
flanges or any other visible damage. ifold.
Check if intake manifold gaskets are cracked, brit-
tle or otherwise damaged.
Replace damaged parts as necessary.

Installing the Intake Manifold

The installation is the reverse of the removal pro-
cedure. However, pay attention to following de-
tails.
Properly install NEW gaskets.

6 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-005
 Subsection XX (INTAKE MANIFOLD)

FLAME ARRESTER
Flame Arrester Location
The flame arrester is integrated in the intake man-
ifold.

smr2016-016-009_b

1. Oil dipstick tube

Tighten intake manifold to specification using the

following sequence.
TIGHTENING TORQUE
11 N•m ± 1 N•m
RTX1503ACEMY18-005-009_a
(97 lbf•in ± 9 lbf•in)
TYPICAL
Intake manifold screws + 1. Flame arrester inside intake manifold
LOCTITE 243 (BLUE)
(P/N 293 800 060) Inspecting the Flame Arrester
The flame arrester in the intake manifold is main-
tenance free.

Replacing the Flame Arrester

NOTE: The flame arrester can not be removed
from the intake manifold.
Replace intake manifold if necessary. Refer to IN-
TAKE MANIFOLD in this subsection.

RTX1503ACEMY18-005-008_b

TIGHTENING SEQUENCE

Ensure to properly route and secure wiring har-

ness with locking ties.
Install the ECM on its support.
TIGHTENING TORQUE
5.5 N•m ± 0.6 N•m
(49 lbf•in ± 5 lbf•in)
ECM retaining screws +
LOCTITE 243 (BLUE)
(P/N 293 800 060)

Install all other removed parts.

RTX1503ACEMY18-005
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 Section 02 ENGINE
Subsection 07 (TIMING CHAIN)

TIMING CHAIN
SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................. 102, 106

50 ± 3 N•m
(37 ± 2 lbf•ft)

Loctite 243

Engine oil
Engine oil

17 ± 2 N•m
(150 ± 18 lbf•in)

NEW

9 ± 1 N•m
(80 ± 9 lbf•in)

Loctite 243

Engine oil

NEW = Component must be replaced when removed.

smr2014-019-001_a

smr2014-019
https://brp-manuals.com/pwc_seadoo 99
Section 02 ENGINE
Subsection 07 (TIMING CHAIN)

GENERAL 2. Chain guide(s) worn out.

Engine removal is necessary to work on the fol-
lowing components:
– Timing chain
– Timing chain guide (tensioner side).
Always disconnect BLACK (-) cable from the bat-
tery, then RED (+) cable before working on the en-
gine.
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.
During assembly/installation, use torque values
and service products as specified in the exploded
view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced.
- Replace chain guide(s).
3. Stretched timing chain or worn sprockets.
- Replace timing chain and sprockets.
4. Camshaft timing gear screws loose.
- Retighten screws to recommended torque.
5. Incorrect camshaft timing adjustment.
- Replace damaged components and readjust
camshaft timing.
ENGINE LACKS ACCELERATION OR
POWER
1. Incorrect camshaft timing adjustment.
- Replace damaged components and readjust
camshaft timing.
PROCEDURES
TIMING CHAIN TENSIONER
Timing Chain Tensioner Location
The timing chain tensioner is located in the cylin-
der head beside the intake port of the PTO cylin-
der.

Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards.
When disassembling parts that are duplicated
in the engine, (e.g.: valves, springs, etc.), it is
strongly recommended to note their position
and to keep the parts of the same assembly as
a “group”. If you find a defective component,
it will be much easier to find the cause of the
failure. Since parts were broken-in together dur-
ing engine operation, they will maintain their
matched fit when reassembled together within
their “group”.

TROUBLESHOOTING
smr2014-019-002_a
The following is provided to help in diagnosing the
1. Screw plug location, timing chain tensioner
probable source of troubles. It is a guideline and
should not be assumed to provide solutions to ev- Timing Chain Tensioner Access
ery cause of all problems.
Remove central body. Refer to BODY.
UNUSUAL ENGINE NOISE OR
VIBRATIONS Timing Chain Tensioner Removal
1. Faulty chain tensioner. 1. Lock crankshaft, refer to CYLINDER BLOCK
subsection.
- Replace chain tensioner.

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 Section 02 ENGINE
Subsection 07 (TIMING CHAIN)

2. Remove screw plug and discard the sealing

washer.
3. Pull out spring and chain tensioner.

smr2014-019-003_a smr2014-019-004_a

1. Screw plug TIMING CHAIN TENSIONER INSTALLATION

2. Sealing washer 1. Plunger
3. Spring 2. Chain tensioner
4. Chain tensioner 3. Tensioner bore in cylinder head

Timing Chain Tensioner Inspection 3. Install spring on chain tensioner.

1. Check chain tensioner for scoring and freedom
of movement in bore.
2. Compress chain tensioner and check for proper
operation.
NOTE: The chain tensioner is difficult to com-
press when properly charged with oil, and easily
compressed when it is not.
3. Check spring for straightness, corrosion and
other visible damage.
Timing Chain Tensioner Installation
1. Apply engine oil on chain tensioner.
2. Insert chain tensioner in its bore with the
plunger pointing outwards.
4. Tighten screw plug to specified torque.
SCREW PLUG TIMING CHAIN TENSIONER
Sealing washer NEW
17 N•m ± 2 N•m
Tightening torque
(150 lbf•in ± 18 lbf•in)
5. Install all other removed parts.
CAMSHAFT TIMING GEARS
Camshaft Timing Gear Removal
Remove camshaft assembly. Refer to CYLINDER
HEAD subsection.
Clamp camshaft in a vice using aluminium protec-
tors.
NOTICE Take care not damaging the cams.
Unscrew and remove camshaft timing gear
screw.
Remove camshaft timing gear.

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Section 02 ENGINE
Subsection 07 (TIMING CHAIN)

Install breather cover on exhaust camshaft.

smr2014-020-048_a

1. Breather cover
smr2014-019-007_a

1. Camshaft timing gear screw Install remaining parts.

2. Camshaft timing chain gear
3. Camshaft
4.
5.
Aluminium protectors
Vice TIMING CHAIN
Timing Chain Removal
Camshaft Timing Gear Inspection
1. Remove engine from vehicle. Refer to ENGINE
Check camshaft timing gears for wear or dete- REMOVAL AND INSTALLATION subsection.
rioration. If a gear is worn or damaged, replace
camshaft timing gears and timing chain as a set. 2. Remove air intake manifold, refer to AIR IN-
TAKE SYSTEM subsection.
NOTE: For crankshaft timing gear inspection, re-
fer to CYLINDER BLOCK subsection. 3. Remove valve cover, refer to CYLINDER HEAD
subsection.
Camshaft Timing Gear Installation 4. Refer to LUBRICATION SYSTEM subsection
Installation is the reverse of the removal proce- and remove the following parts:
dure. However, pay attention to the following de- – Oil tank
tails. – Oil pressure regulator valve
Tighten camshaft timing gear screw to specifica- – Oil cooler
tion. – Oil sump cover.
NOTICE Do not torque timing gear screws 5. Refer to COOLING SYSTEM subsection and re-
when camshafts are installed in cylinder head move following parts:
to avoid overstressing timing chain. – Water pump housing
– Thermostat.
TIMING GEAR SCREWS
6. Check timing chain for excessive radial play
LOCTITE 243 (BLUE) while still installed on timing gears.
Service product
(P/N 293 800 060)
50 N•m ± 3 N•m
Tightening torque
(37 lbf•ft ± 2 lbf•ft)

NOTICE Improper camshaft timing will dam-

age engine components. Make sure camshafts
and crankshaft are still locked. If not, lock
them before beginning this procedure. Refer
to CAMSHAFTS in the CYLINDER HEAD sub-
section.
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 Section 02 ENGINE
Subsection 07 (TIMING CHAIN)

mmr2011-073-025_a

1. Radial play mmr2011-073-021_a

1. Crankshaft thrust washers

7. Remove the CAMSHAFTS, refer to CYLINDER
HEAD subsection. 13. Slightly lift the crankshaft.
8. Refer to MAGNETO AND STARTER subsection
and remove the following parts:
– Magneto cover
– Rotor
– Starter drive gears.
9. Remove oil pump intermediate gears, refer to
LUBRICATION SYSTEM subsection.

smr2014-019-010_a

LIFT CRANKSHAFT
1. Crankshaft

14. Remove timing chain.

NOTE: Make a mark on the timing chain to indi-
cate the operating direction of the chain before re-
moval.
15. Remove lower timing chain guide from lower
half of cylinder block.
mmr2011-073-020_a

1. Oil pump intermediate gears

10. Remove crankshaft locking bolt.

11. Separate cylinder block, refer to CYLINDER
BLOCK subsection.
12. Remove crankshaft thrust washers.

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Section 02 ENGINE
Subsection 07 (TIMING CHAIN)

NOTE: Also check the chain guide, tensioner

side. Refer to CHAIN GUIDE INSPECTION (TEN-
SIONER SIDE) in this subsection.
Timing Chain Installation
Installation is the reverse of the removal proce-
dure. However, pay attention to the following de-
tails.
1. Install timing chain on crankshaft timing gear.
NOTE: If the same timing chain is reinstalled, be
sure to reinstall it in the same operating direction
as marked during removal procedure.
smr2014-019-011_a

1. Lower timing chain guide 2. Install crankshaft.

2. Lower half of cylinder block

Timing Chain Inspection

Check timing chain for wear and teeth condition.

mmr2009-114-015_a

1. Check teeth condition

NOTICE If timing chain is excessively smr2014-019-012_a

worn or damaged, replace timing chain and 1. Timing chain
camshaft timing gears as a set. 2. Crankshaft

Check lower chain guide for wear, cracks or defor-
mation. Replace as required.
3. Properly install the crankshaft thrust washers
with the slots facing against crankshaft counter-
weights.
NOTE: Crankshaft thrust washers must be flush
with the cylinder block sealing surface.

mmr2011-073-027_a

1. Lower chain guide

Replace lower chain guide if timing chain wear

grooves are visible. smr2014-019-013_a

1. Crankshaft thrust washers

CHAIN GUIDE GROOVE DEPTH 2. Sealing surface

No timing chain wear 4. Reinstall lower chain guide in lower half of cylin-
SERVICE LIMIT
groove allowed der block.

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 Section 02 ENGINE
Subsection 07 (TIMING CHAIN)

smr2014-019-014_a smr2014-019-016_a

1. Lower chain guide 1. PTO cover

2. Lower half of cylinder block 2. Screw plug location

5. Reassemble cylinder block, refer to CYLINDER 3. Use an M6 bolt to pull chain guide bearing pin
BLOCK subsection. out of cylinder block.
6. Lock crankshaft, refer to CRANKSHAFT LOCK-
ING PROCEDURE in the CYLINDER BLOCK
subsection.
7. Reinstall timing chain properly on camshaft tim-
ing gears. Refer to CAMSHAFT INSTALLATION
in the CYLINDER HEAD subsection.
NOTICE Improper camshaft timing will dam-
age engine components.
8. Install all other removed parts.
NOTE: Be sure to remove camshaft and crank-
shaft locking tools when timing chain is com-
pletely installed.
smr2014-019-017_a

1. Chain guide bearing pin

CHAIN GUIDE (TENSIONER SIDE) 2. M6 bolt

Chain Guide Removal (Tensioner Side) 4. Remove chain guide (tensioner side).
NOTE: Removal of chain guide is not recom-
mended if there is no need for replacement.
1. Remove the CAMSHAFTS. Refer to CYLINDER
HEAD subsection.
2. Remove screw plug that covers the chain guide
bearing pin.

smr2014-019-018_a

1. Chain guide (tensioner side)

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Section 02 ENGINE
Subsection 07 (TIMING CHAIN)

Chain Guide Inspection SCREW PLUG

(Tensioner Side)
LOCTITE 243 (BLUE)
Check chain guide for wear, cracks or deforming. Service product
(P/N 293 800 060)
Replace as required.
9 N•m ± 1 N•m
Replace chain guide if groove depth caused by Tightening torque
(80 lbf•in ± 9 lbf•in)
timing chain exceeds service limit.
4. Properly reinstall camshafts. Refer to
CHAIN GUIDE GROOVE DEPTH
CAMSHAFTS in the CYLINDER HEAD sub-
SERVICE LIMIT 1 mm (.039 in) section.
NOTICE Improper camshaft timing will dam-
age engine components.

mmr2009-114-022_a

TYPICAL
1. Chain guide

Chain Guide Installation

(Tensioner Side)
Installation is the reverse of the removal proce-
dure however, pay attention to the following de-
tails.
1. Insert chain guide.
2. Apply engine oil on bearing pin and install it with
M6 threads facing outwards.
NOTICE Ensure chain guide bearing pin is
properly inserted in the chain guide.

smr2014-019-020_a

1. Bearing pin
2. Apply engine oil here
3. M6 threads facing outwards

3. Tighten screw plug as specified.

NOTE: Install screw plug only in final assembled
cylinder block to avoid warpage of sealing surface.

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 Subsection XX (CYLINDER HEAD)

CYLINDER HEAD
SERVICE TOOLS
Description Part Number Page
CAMSHAFT LOCKING TOOL........................................................ 529 036 206 ........................................... 12
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ........................................... 5
PTO ADAPTER .............................................................................. 529 036 273 ........................................... 5
VALVE SPRING COMPRESSOR CUP............................................ 529 036 209 ........................................... 18
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ........................................... 18

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON VALVE HOLDER............................................................ VL2 ........................................... 21
SNAP-ON VALVE STEM SEAL PLIERS ......................................... YA 8230 ........................................... 19

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Subsection XX (CYLINDER HEAD)

VALVE COVER

9 ± 1 N•m
(80 ± 9 lbf•in)

9 ± 1 N•m
(80 ± 9 lbf•in)
See tightening procedure

Engine oil 9 ± 1 N•m

(80 ± 9 lbf•in)
NEW

Engine oil

NEW

NEW

NEW

13 ± 1 N•m
(115 ± 9 lbf•in)

NEW = Component must be replaced when removed.

smr2014-020-001_a

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 Subsection XX (CYLINDER HEAD)

CAMSHAFTS

See tightening
procedure

NEW

Engine oil

Engine oil
NEW

NEW

NEW = Component must be replaced when removed.

smr2014-020-002_a

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Subsection XX (CYLINDER HEAD)

CYLINDER HEAD

Engine oil
Engine oil

NEW See tightening

sequence
See tightening
sequence

NEW

15 ± 2 N•m
(133 ± 18 lbf•in)

Loctite 243

NEW

Engine oil
Engine oil

NEW = Component must be replaced when removed.

smr2014-020-003_a

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 Subsection XX (CYLINDER HEAD)

GENERAL REQUIRED TOOL

NOTE: For a better understanding, some illustra-
ENGINE LEAK DOWN TEST
tions are taken with engine out of the vehicle.
KIT (P/N 529 035 661)
When disassembling parts that are duplicated
in the engine, (e.g.: valves, springs, etc.), it is
strongly recommended to note their position 2. Connect the leak down tester to an adequate
and to keep the parts of the same assembly as a air supply.
“group”. If you find a defective component, it will 3. Set gauge needle to zero.
be much easier to find the cause of the failure. NOTE: All testers have specific instructions on
Since parts were broke-in together during engine gauge operation and required pressure. Refer to
operation, they will maintain their matched fit manufacturer's instructions.
when reassembled together within their “group”.
4. Supply combustion chamber with air pressure.
INSPECTION 5. Note the amount or percentage of leakage (de-
pending on tester).
CYLINDER LEAK TEST LEAKAGE ENGINE
PERCENTAGE CONDITION
General
0% to 15% Excellent condition
Before performing the cylinder leak test, verify the
following: 16% to 25% Good condition
– Clamp tightness Fair condition; reduced
26% to 40%
– Hoses condition. engine performance
NOTE: For best accuracy, the leak test should be 41% and higher
Poor condition, diagnose
done with the engine at normal operating temper- and repair engine
ature.
Diagnosis
CAUTION Engine parts could be hot.
Listen for air leaks.
NOTE: The following steps are the same for each – Air escaping on intake port or throttle body
cylinder. means leaking intake valve(s).
Preparation – Air escaping on exhaust port means leaking ex-
haust valve(s).
1. Remove the VALVE COVER, see procedure in
– Air bubbles out of coolant tank means leaking
this subsection.
cylinder head gasket.
2. Remove spark plug. – Air or coolant escaping from cylinder head
3. Turn the engine counterclockwise to bring pis- means damaged gasket or loosened screws.
ton to TDC of compression stoke. Use a dial – Air escaping into crankcase area means exces-
gauge or a suitable tool to position the piston sively worn cylinder or broken piston rings.
to TDC. – Air or oil escaping from crankcase means dam-
REQUIRED TOOL aged gasket or loosened screws.
PTO ADAPTER (P/N 529 Repair Tips
036 273)
Blue exhaust gas means damaged or worn piston
rings or valve stem seals.
NOTE: The piston must be set precisely to TDC
of compression stroke. If not, the engine will con- White exhaust gas means damaged cylinder head
tinue to rotate when pressure builds up. gasket.
Coolant tank cap opening without overheat means
Leak Test damaged cylinder head gasket.
1. Install a gauge adaptor into spark plug hole. Leaking valves can be caused by carbon deposits
or burnt valve face.

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Subsection XX (CYLINDER HEAD)

Assembly 4. Leaking cylinder head gasket.

Reverse the preparation procedure. - Check cylinder head for damage.
- Replace cylinder head gasket and retighten
screws with recommended torquing procedure.
TROUBLESHOOTING
Always check for fault codes. If a fault code is de- ENGINE SUDDENLY TURNS OFF OR
tected, service the fault code first. Refer to DI- LACKS ACCELERATION OR POWER
AGNOSTIC SYSTEM AND FAULT CODES subsec- 1. Incorrect camshaft timing.
tion.
- Replace damaged components and readjust
NOTE: When diagnosing an engine problem, al- camshaft timing.
ways perform the cylinder leak test. This will help
2. Leaking intake or exhaust valves.
pinpoint a problem. Refer to CYLINDER LEAK
TEST in this subsection. - Perform a CYLINDER LEAK TEST. Repair or re-
place damaged components.
UNUSUAL ENGINE NOISE OR 3. Broken valve spring(s).
VIBRATIONS - Replace defective parts.
1. Discharged or defective valve lifters.
- Check engine oil pressure, refer to LUBRICATION PROCEDURES
SYSTEM subsection.
- Replace valve lifters. VALVE COVER
2. Camshaft(s) or camshaft holder(s) worn out. Valve Cover Access
- Check and replace damaged parts.
Remove central body. refer to BODY.
3. Faulty chain tensioner. Remove the air intake silencer. Refer to AIR IN-
- Replace chain tensioner. Refer to TIMING CHAIN TAKE SYSTEM subsection.
subsection.
Disconnect vent tube from the blow-by-connec-
4. Chain guide(s) worn out. tor.
- Replace chain guide(s). Refer to TIMING CHAIN
subsection.
5. Stretched timing chain or worn out sprockets.
- Replace timing chain and sprockets. Refer to
TIMING CHAIN subsection.
6. Loose timing chain gear screws.
- Retighten screws with recommended torque.
7. Incorrect camshaft timing.
- Replace damaged components and readjust
camshaft timing.
smr2014-021-500_a

OIL LEAKAGE FROM CYLINDER HEAD 1. Clamp

2. Vent tube
1. Leaking valve cover gasket.
- Replace valve cover gaskets and retighten valve Valve Cover Removal
cover with recommended torque. 1. Unplug CAPS (camshaft position sensor).
- Check valve cover for cracks or other damage.
2. Unplug ignition coils.
2. Leaking spark plug tube O-rings.
- Replace spark plug tube O-rings.
- Clean spark plug area from oil spillage.
3. Blow-by connector is leaking.
- Replace blow by connector O-ring.

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 Subsection XX (CYLINDER HEAD)

smr2014-020-007_a smr2014-020-010_a

1. Ignition coil connectors 1. Valve cover screws

2. CAPS connector
6. Remove the valve cover and its gasket.
3. Remove ignition coils with gaskets.

smr2014-020-011_a
smr2014-020-008_a
1. Valve cover
1. Retaining screws 2. Gasket
2. Ignition coils
3. Gaskets
7. Remove valve cover small gaskets (spark plug
4. Remove screws securing the electrical harness tubes).
to the valve cover.

smr2014-020-012_a

smr2014-020-009_a
1. Small gaskets
1. Cable clamps
2. Retaining screws Valve Cover Inspection
5. Remove valve cover retaining screws. Check the valve cover for cracks or other damage.
Check if the valve cover gaskets are brittle, hard
or otherwise damaged.
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Subsection XX (CYLINDER HEAD)

Replace defective parts.

Valve Cover Installation

For installation reverse the removal procedure.
However, pay attention to the following details.
1. Properly fit the small gaskets into the camshaft
holder grooves.
2. Properly fit the large gasket into the valve cover
groove.
3. Apply engine oil to the sealing surface of the
V-ring.
smr2014-020-014_a

Step 1: Move valve cover towards MAG side

5.2 Put valve cover onto cylinder head.

5.3 Push valve cover towards the PTO side to
ensure that the V-ring properly seals on
sealing surface inside the cover.

smr2014-020-013_a

INSIDE VALVE COVER

1. Apply engine oil here

4. If engine is in the vehicle, slide the valve cover

inside engine compartment by the LH side of
the vehicle.
5. Install valve cover.
smr2014-020-015_a

NOTICE Adhere to the following proce- Step 1: Push valve cover towards PTO side
dure, otherwise damage to the V-ring will
6. Install valve cover screws and tighten as per fol-
occur causing crankcase venting malfunc-
lowing sequence:
tion.
VALVE COVER SCREWS TIGHTENING
5.1 Move the valve cover towards the MAG PROCEDURE
side.
9 N•m ± 1 N•m
Step A
(80 lbf•in ± 9 lbf•in)
9 N•m ± 1 N•m
Step B
(80 lbf•in ± 9 lbf•in)

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 Subsection XX (CYLINDER HEAD)

smr2014-020-047_b

smr2014-020-010_b 1. Upper timing chain guide

TIGHTENING SEQUENCE 2. Timing chain guide

4. Remove timing chain from camshaft timing

CAMSHAFTS gears.
Camshaft Removal 5. Remove camshaft holder retaining screws (16).
1. Remove VALVE COVER, see procedure in this
subsection.
2. Lock crankshaft, refer to CRANKSHAFT LOCK-
ING PROCEDURE in the CYLINDER BLOCK
subsection.
Remove timing chain tensioner. Refer to TIMING
CHAIN subsection.
3. Remove:
3.1 Breather cover

smr2014-020-018_a

1. Camshaft holder retaining screws

6. Remove the camshaft holder upper half.

smr2014-020-048_a

1. Breather cover

3.2 Upper timing chain guide

3.3 Timing chain guide. smr2014-020-019_a

1. Upper half of camshaft holder

7. Put timing chain aside.

8. Remove camshafts with timing gears.

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Subsection XX (CYLINDER HEAD)

CAMSHAFT JOURNAL DIAMETER

PTO JOURNAL (A)
25.967 mm to 25.980 mm
NEW
(1.0223 in to 1.0228 in)
SERVICE LIMIT 25.940 mm (1.0213 in)
CENTER AND MAG JOURNAL (B)
22.957 mm to 22.970 mm
NEW
(.9038 in to .9043 in)
SERVICE LIMIT 22.930 mm (.9028 in)

smr2014-020-021_a CAMSHAFT LOBE HEIGHT

1. Intake camshaft
2. Exhaust camshaft EXHAUST and INTAKE CAMSHAFT (C)

9. Remove camshaft timing gears only if neces- 38.35 mm to 38.55 mm

sary. Refer to TIMING CHAIN subsection.
Camshaft Inspection
1. Check each lobe and bearing journal for scoring,
scuffing, cracks, or other signs of wear.
2. Check V-ring if it is brittle, hard or otherwise
damaged.
3. Measure camshaft bearing journal diameter
and lobe height, using a micrometer.
NEW
(1.51 in to 1.518 in)
SERVICE LIMIT 38.33 mm (1.509 in)
Replace parts if necessary.
For camshaft journal radial clearance and
camshaft holder bearing diameter refer to
CAMSHAFT HOLDER in this subsection.
4. Check timing chain guide for wear, cracks or
deformation. Replace as required.
5. Replace timing chain guide if any groove
caused by timing chain exceeds service limit.
CHAIN GUIDE GROOVE DEPTH
SERVICE LIMIT 1 mm (.039 in)

mmr2011-073-012_a

1. Timing chain guide

smr2014-020-022_a
Camshaft Installation
A. Camshaft journal (PTO)
B. Camshaft journal (center and MAG) The assembly is the reverse of the removal proce-
C. Camshaft lobes dure. However pay attention to the following de-
tails.
1. Ensure crankshaft is still locked.
2. Apply engine oil on camshaft bearings.

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 Subsection XX (CYLINDER HEAD)

smr2014-020-023_a smr2014-020-040_a
1. Areas where to apply engine oil 1. Exhaust camshaft
2. Camshaft timing gear
NOTE: The camshafts are not identical. Any 3. Mark "EX"
mix-up of the components would lead to engine
6. Install intake camshaft assembly with mark "IN"
damage. The exhaust camshaft has a machined
parallel to cylinder head gasket.
area on MAG side for the V-ring.

smr2014-020-024_a

1. Machined area
2. Exhaust camshaft smr2014-020-041_a
3. Intake camshaft
1. Intake camshaft
2. Camshaft timing gear
3. If removed, reinstall camshaft timing gears 3. Mark "IN"
on camshafts. Refer to CAMSHAFT TIMING
GEARS in the TIMING CHAIN subsection. 7. Install the camshaft holder upper half, then
tighten screws as per following sequence:
4. Apply engine oil on camshaft journal diameter.
5. Install exhaust camshaft assembly with mark CAMSHAFT HOLDER TIGHTENING PROCEDURE
"EX" parallel to cylinder head gasket. 5 N•m ± 0.5 N•m
STEP A
(44 lbf•in ± 4 lbf•in)

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Subsection XX (CYLINDER HEAD)

smr2014-020-018_b
smr2014-020-042_a
CAMSHAFT HOLDER TIGHTENING SEQUENCE - STEP A
1. Camshaft locking tool
CAMSHAFT HOLDER TIGHTENING PROCEDURE 9. Lift timing chain out of timing chain compart-
9 N•m ± 1 N•m ment.
STEP B
(80 lbf•in ± 9 lbf•in) 10. Pull timing chain up on exhaust side and install
it on the exhaust camshaft timing gear.

smr2014-020-018_c

CAMSHAFT HOLDER TIGHTENING SEQUENCE - STEP B smr2014-020-043_a

1. Timing chain
NOTE: After the reassembly of the camshafts is 2. Exhaust camshaft timing gear
completed, check if camshafts can be turned eas-
ily. 11. Pull timing chain towards intake side and in-
stall it on the intake camshaft timing gear.
8. Lock camshafts.
REQUIRED TOOL
CAMSHAFT LOCKING TOOL
(P/N 529 036 206)

smr2014-020-044_a

1. Intake camshaft timing gear

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 Subsection XX (CYLINDER HEAD)

12. Install timing chain guide.

smr2014-020-047_a

CAMSHAFT TIMING GEARS

1. Marks must be aligned
smr2014-020-045_a

1. Timing chain guide 16. Install breather cover.

13. Install upper timing chain guide on camshaft
holder.

smr2014-020-046_a

1. Upper timing chain guide

smr2014-020-048_a

1. Breather cover
14. Install TIMING CHAIN TENSIONER, refer to
TIMING CHAIN subsection. 17. Remove camshaft locking tool.
15. Ensure marks on camshaft timing gears are
still aligned. If not, repeat procedure.
NOTICE After installation of timing chain ten-
sioner, the marks "IN" on intake and "EX" on ex-
haust camshafts must be aligned.

smr2014-020-049_a

1. Camshaft locking tool removal

18. Remove crankshaft locking tool.

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Subsection XX (CYLINDER HEAD)

CAMSHAFT HOLDER
Camshaft Holder Removal
Remove camshafts, see procedure in this subsec-
tion.
Remove the camshaft holder lower half with gas-
kets from cylinder head.
Remove gaskets from camshaft holder halves and
discard gaskets.

smr2014-020-027_a

1. Camshaft holder lower half - view from beneath

2. Camshaft holder lower half - view from above
3. Gaskets
4. Oil orifices

Install camshaft holder on cylinder head.

Tighten camshaft holder screws to specification,
refer to CAMSHAFT INSTALLATION in this sub-
smr2014-020-025_a
section.
1. Camshaft holder lower half Measure camshaft holder bearing diameter.

Camshaft Holder Inspection

1. Check camshaft holder for scoring, scuffing,
cracks, or other signs of wear.
2. Make sure oil orifices are not clogged. Blow
them out with pressurized air.

smr2014-020-028_a

CAMSHAFT HOLDER BEARINGS

1. PTO bearings
2. Center and MAG bearings
A. Diameter PTO bearing
B. Diameter center and MAG bearing

smr2014-020-026_a

1. Camshaft holder upper half - view from beneath

2. Camshaft holder upper half - view from above
3. Gaskets
4. Oil orifices

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 Subsection XX (CYLINDER HEAD)

CAMSHAFT HOLDER BEARING DIAMETER

PTO BEARING
26.000 mm to 26.021 mm
NEW
(1.024 in to 1.024 in)
SERVICE LIMIT 26.050 mm (1.026 in)
CENTER AND MAG BEARING
23.000 mm to 23.021 mm
NEW
(.906 in to .906 in)
SERVICE LIMIT 23.050 mm (.907 in)

Measure clearance between camshaft journals

and camshaft holder, using the plastic feeler
gauge.
vmr2008-016-066_b
NOTE: The plastic feeler gauge is available at au-
TYPICAL
tomotive parts retailer. 1. Pressed plastic gauge
2. Graduated scale
Install camshaft holder lower half on cylinder
head. CAMSHAFT JOURNAL RADIAL CLEARANCE
Place the camshafts in the camshaft holder lower PTO, CENTER AND MAG BEARING
half and apply a plastic-gauge on the camshaft
bearing journal. 0.020 mm to 0.054 mm
NEW
(.001 in to .002 in)
SERVICE LIMIT 0.080 mm (.003 in)

Replace parts if necessary.

Camshaft Holder Installation

Install camshaft holder lower half.
Continue procedure as explained in CAMSHAFT
INSTALLATION in this subsection.

HYDRAULIC VALVE LIFTERS

Hydraulic Valve Lifter Removal
NOTE: Hydraulic valve lifter are maintenance
free.
See procedures in this subsection to remove:
vmr2008-016-066_a

TYPICAL
– Valve cover
1. Plastic gauge – Camshafts
2. Camshaft bearing journal
– Camshaft holder.
Install camshaft holder upper half in the proper po- Pull hydraulic valve lifter off the cylinder head.
sition and tighten screws to specification, refer to
CAMSHAFT INSTALLATION in this subsection. NOTE: When disassembling the hydraulic valve
lifter, it is strongly recommended to note their
Unfasten camshaft holder. original position.
Measure the maximum width of the pressed plas-
tic gauge with the corresponding graduated scale.

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Subsection XX (CYLINDER HEAD)

CYLINDER HEAD
Cylinder Head Access
Remove central body. Refer to BODY.
Remove exhaust manifold. Refer to EXHAUST.
Remove intake manifold. Refer to AIR INTAKE
SYSTEM.
Cylinder Head Removal
See procedures in this subsection to remove:
– Valve cover
– Camshafts
smr2014-020-030_a

1. Hydraulic valve lifter – Camshaft holder

– Hydraulic valve lifters.
Hydraulic Valve Lifter Inspection Remove M6 cylinder head screws.
1. Check surface of hydraulic valve lifter for scor-
ing or other damage.
2. Measure valve lifter diameter. Replace if out of
specification.
HYDRAULIC VALVE LIFTER
28.354 mm to 28.370 mm
NEW
(1.1163 in to 1.1169 in)
SERVICE LIMIT 28.34 mm (1.1157 in)
HYDRAULIC VALVE LIFTER RADIAL CLEARANCE
SERVICE LIMIT 0.100 mm (.0039 in)

Hydraulic Valve Lifter Installation smr2014-020-031_a

For installation reverse the removal procedure. 1. Remove M6 cylinder head screws
However pay attention to the following details.
Remove and discard M9 cylinder head screws.
1. Apply engine oil on the outside diameter of the
hydraulic valve lifter.

smr2014-020-032_a

1. Remove M9 cylinder head screws

smr2014-020-030_b

1. Apply engine oil on outer diameter Pull cylinder head off the cylinder block.
Remove and discard cylinder head gasket.

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 Subsection XX (CYLINDER HEAD)

Cylinder Head Cleaning If warpage exceeds specification, resurface the

1. Remove carbon deposits from combustion
chambers, exhaust ports and piston tops.
2. Clean cylinder head, especially cylinder head
screw surface from oil spillage.
3. Blow out the oil orifices with pressurized air and
make sure they are not clogged.
cylinder head as follows.
Use a 400 - 600 grit wet sandpaper on a surface
plate and gently grind off the mating surface.
NOTE: To ensure an even surface, rotate cylinder
head several times during resurfacing.
Replace cylinder head, if resurfacing fails.

Cylinder Head Installation

For installation, reverse the removal procedure.
However, pay attention to the following details.
1. Install a NEW cylinder head gasket.
NOTICE Each installation of the cylinder
head requires a NEW cylinder head gasket.
Using a gasket twice would cause engine
damage.
2. Install cylinder head on the cylinder block.
3. Install NEW M9 cylinder head screws.

smr2014-020-033_a
NOTICE This assembly uses stretch screws.
1. Oil orifices Always use NEW screws and strictly adhere to
the tightening procedure.
Cylinder Head Inspection 4. Tighten cylinder head screws as follows:
Check for cracks between valve seats or other
NOTE: Always perform step 1 on all M9 cylinder
damage, if so, replace cylinder head.
head screws before going to the next step.
Check cylinder head mating surface for flatness
using a straight edge. CYLINDER HEAD M9 SCREWS TIGHTENING
PROCEDURE
Check hydraulic valve lifter bores for scoring or
other damage, if so, replace cylinder head. 20 N•m ± 2 N•m
STEP A
(15 lbf•ft ± 1 lbf•ft)
STEP B Additional 150° ± 5°

smr2014-020-034_a

1. Cylinder head
2. Straight edge
3. Feeler gauge smr2014-020-032_b

M9 SCREWS TIGHTENING SEQUENCE

Check cylinder head warpage.
NOTE: Use a torque angle gauge to carry out the
CYLINDER HEAD WARPAGE
second step.
SERVICE LIMIT 0.15 mm (.0059 in)

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Subsection XX (CYLINDER HEAD)

smr2014-020-035_a smr2014-020-036_a

1. Torque angle gauge 1. Valve spring compressor clamp

2. Valve spring compressor cup
5. Install M6 screws. Tighten as follows.
3. Remove valve cotters.
M6 CYLINDER HEAD SCREWS
4. Withdraw valve spring compressor tools.
9 N•m ± 1 N•m 5. Remove valve spring retainer and valve spring.
Tightening torque
(80 lbf•in ± 9 lbf•in)

smr2014-020-031_b mmr2011-074-039_a

M6 SCREWS TIGHTENING SEQUENCE 1. Valve cotters

2. Valve spring retainer
3. Valve spring
VALVE SPRINGS
NOTE: Identify the position of each part very care-
Valve Spring Removal fully, so it can be reinstalled in its original place.
1. Remove CYLINDER HEAD, see procedure in
this subsection. Valve Spring Inspection
2. Compress valve spring. 1. Check valve spring for rust, corrosion or other
visible damage.
REQUIRED TOOLS
2. Check valve spring free length and straight-
VALVE SPRING COMPRESSOR ness.
(P/N 529 035 724)

VALVE SPRING COMPRESSOR

CUP (P/N 529 036 209)

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 Subsection XX (CYLINDER HEAD)

VALVES
Valve Removal
1. Remove VALVE SPRING, see procedure in this
subsection.
2. Push on the valve stem, then pull valves out of
cylinder head.

R400motr80A A
A. Spring free length

VALVE SPRING FREE LENGTH

NEW 31.35 mm (1.2343 in)
SERVICE LIMIT 29.5 mm (1.1614 in)

Replace valve spring, if out of specification.

Valve Spring Installation

For installation, reverse the removal procedure. mmr2009-115-070_a
Pay attention to the following details. 1. Intake valves 29 mm
2. Exhaust valves 25 mm
NOTE: Ensure to reinstall all parts in their original
position as marked during removal. 3. Remove and discard valve stem seal with spe-
1. Apply some grease on valve cotters, so that cial pliers.
they remain in place while releasing the valve REQUIRED TOOL
spring.
SNAP-ON VALVE STEM SEAL
2. Make sure valve cotters are properly engaged PLIERS (P/N YA 8230)
into valve stem groove.

mmr2011-074-040_a
mmr2011-074-042_a
1. Valve cotters 1. Valve stem seal

3. After spring is installed, ensure it is properly
locked by lightly tapping on valve stem end with
a soft punch and a hammer so that valve opens
and closes a few times.
NOTICE Improperly locked valve spring will
cause severe engine damage and hitting the
valve stem end with excessive force could
damage the valve.
NOTE: Identify the position of each part very care-
fully, so it can be reinstalled in its original place.
Valve Inspection
Inspect valve surface, check for abnormal stem
wear and bending.

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Subsection XX (CYLINDER HEAD)

2. Measure valve guide inner diameter, using a

small bore gauge.
NOTE: Clean valve guide from carbon deposits
before measuring.

mmr2009-115-072_a

VALVE OUT OF ROUND

INTAKE AND EXHAUST VALVE
NEW 0.005 mm (.0002 in)
SERVICE LIMIT 0.06 mm (.0024 in) mmr2009-115-073_a

1. Valve guides
Replace valve if out of specification. A. Valve guide inner diameter

Valve Stem and Valve Guide Clearance VALVE GUIDE INNER DIAMETER
1. Measure valve stem at three places, using a mi- 5.000 mm to 5.012 mm
crometer. NEW
(.1969 in to .1973 in)
SERVICE LIMIT 5.05 mm (.1988 in)

Replace cylinder head, if valve guide is out of

specification.
Valve Face and Seat

2 3

R400motr83A

A. Valves stem diameter

VALVE STEM DIAMETER

INTAKE VALVE
4.958 mm to 4.972 mm
NEW
(.1952 in to .1957 in)
SERVICE LIMIT 4.94 mm (.1945 in)
R1503motr107A 1
EXHAUST VALVE
TYPICAL
4.956 mm to 4.970 mm 1. Valve seat
NEW 2. Exhaust valve contaminated area
(.1951 in to .1957 in)
3. Valve face (contact surface to valve seat)
SERVICE LIMIT 4.94 mm (.1945 in)
1. Check valve face and seat for burning, pitting
Replace valve if stem is out of specification or if and other signs of damage.
its surface is damaged or worn.

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 Subsection XX (CYLINDER HEAD)

2. Check if valve seats properly in cylinder head.
Proceed as follows.
2.1 Apply some lapping compound on valve
face and work valve on its seat with a lap-
ping tool.
REQUIRED TOOL
SNAP-ON VALVE HOLDER (P/N VL2)
NOTE: The location of contact area should
be in center of valve face.
2.2 Repeat procedure until valve seat and
valve face fit together.
3. Measure valve seat contact width, using a
caliper.
NOTE: Ensure to reinstall all parts in their original
position as marked during removal.
1. Install a NEW valve stem seal whenever valve
is removed.
2. Apply engine oil on valve stem and carefully
slide through cylinder head and valve stem seal.
NOTICE Be careful when passing the valve
stem through the sealing lip of the seal.
1

A B

R1503motr254B

TYPICAL
1. Sealing lips of valve stem seal

3. Install VALVE SPRING. See procedure in this

subsection.
V01C1HA
4. Install all other removed parts.
A. Valve face contact width
B. Valve seat contact width

VALVE SEAT CONTACT WIDTH (B)

INTAKE VALVE
1.05 mm to 1.35 mm
NEW
(.041 in to .053 in)
SERVICE LIMIT 1.7 mm (.067 in)
EXHAUST VALVE
1.25 mm to 1.45 mm
NEW
(.049 in to .057 in)
SERVICE LIMIT 1.8 mm (.0709 in)

Replace parts if out of specification.

Valve Installation
For installation reverse the removal procedure.
Pay attention to the following details.

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 Subsection XX (CYLINDER HEAD)

CYLINDER HEAD
SERVICE TOOLS
Description Part Number Page
CAMSHAFT LOCKING TOOL........................................................ 529 035 839 ........................................... 10
DRIVE SHAFT ADAPTER............................................................... 529 035 985 ............................................. 3
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ............................................. 4
VALVE GUIDE PUSHER (6 MM) .................................................... 529 036 087 ........................................... 19
VALVE GUIDE REMOVER (6 MM) ................................................ 529 036 086 ........................................... 19
VALVE SPRING COMPRESSOR CUP............................................ 529 036 073 ........................................... 14
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ........................................... 14

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON VALVE STEM SEAL PLIERS ......................................... YA8230 ........................................... 16

SERVICE PRODUCTS
Description Part Number Page
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 12
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 10, 14
MOLYKOTE G-N ............................................................................ 420 297 433 ........................................... 19

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Subsection XX (CYLINDER HEAD)

9 ± 1 N•m
(80 ± 9 lbf•in)
See
tightening
sequence
See IGNITION
SYSTEM 9 ± 1 N•m
(80 ± 9 lbf•in)

NEW

Engine oil

9 ± 1 N•m
(80 ± 9 lbf•in) Engine oil NEW
Loctite 243 Engine oil
16 ± 2 N•m Engine oil
(142 ± 18 lbf•in) See
tightening
Loctite 243 procedure

Engine oil 11 ± 1 N•m

(97 ± 9 lbf•in) Engine oil

9 ± 1 N•m
See ELECTRONIC FUEL (80 ± 9 lbf•in)
NEW
INJECTION (EFI)
NEW
Engine oil
Isoflex
TopasNb52 See
tightening
procedure

Loctite 243
4,5 ± 0,5 N•m
(40 ± 4 lbf•in)

Loctite 243
Engine oil 9 ± 1 N•m
(80 ± 9 lbf•in)

Engine oil
NEW
9 ± 1 N•m
NEW = Component must be replaced when removed. (80 ± 9 lbf•in)
smr2016-017-001_a

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 Subsection XX (CYLINDER HEAD)

GENERAL
NOTE: When diagnosing an engine problem, al-
ways perform an engine leak test. This will help
pin-point a problem. Refer to ENGINE LEAK TEST
in this subsection for procedures.
When disassembling parts that are duplicated in
the engine, (e.g.: valves, bushings), it is strongly
recommended to note their position and to keep
them as a “group”. If you find a defective com-
ponent, it will be much easier to find the cause
of the failure. Since parts were break-in together
RTX1503ACEMY18-009-001_c
during the engine operation, they will keep their
matched fit when parts are reassemble together 6. Unplug and remove ignition coils.
within their “group”.
7. Remove spark plugs.
INSPECTION
ENGINE LEAK TEST
The procedure has to be done when engine oper-
ating temperature of approximately 70°C (158°F)
is reached.
WARNING
Be careful to burns when working on a hot
engine.

Preparation
1. Remove any required parts to give access to smr2016-017-003_a
engine. 1. Retaining screw
2. Remove the tether cord. 2. Ignition coil
3. Spark plug
3. Remove jet pump (refer to JET PUMP subsec-
tion). 8. Remove VALVE COVER, see procedure in this
subsection.
4. Remove coolant pressure cap.
9. Install the drive shaft adapter and an appropri-
WARNING ate wrench lever on drive shaft end.
To avoid potential burns, only remove the REQUIRED TOOL
coolant pressure cap by wearing the appro-
priate safety equipment. DRIVE SHAFT ADAPTER
(P/N 529 035 985)
5. Remove oil dipstick.

Leak Test Procedure

NOTE: Cylinder numbers are molded on valve
cover.
1. Rotate engine crankshaft counterclockwise un-
til the cylinder 1 is at Top Dead Center (TDC)
compression stroke.
1.1 As the engine crankshaft is turned over,
observe the movement of intake rocker
arm of the cylinder to be checked.

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Subsection XX (CYLINDER HEAD)

1.2 After piston completes its cycle and the

intake valve closes, observe the piston.
1.3 When it reaches its uppermost position
this is TDC compression stroke. 1

R1503motr157A

TYPICAL
1. Leak down tester gauge
smr2016-017-004_a 2. Gauge adapter
3. Air supply hose
TYPICAL
1. Intake rocker arms
5. Note the amount of leaking or percentage (de-
2. Secure the wrench lever, at the end of the drive pending on tester).
shaft, against hull to prevent further crankshaft
LEAKAGE
rotation. ENGINE CONDITION
PERCENTAGE
3. Install the leak down test tool.
Up to 15% Excellent condition
REQUIRED TOOL 16% to 25% Good condition
ENGINE LEAK Fair condition; engine will run
DOWN TEST KIT 26% to 40% and performance might be
(P/N 529 035 661) down in some cases

3.1 Install the appropriate gauge adapter into Poor condition, diagnose and
41% and higher
repair engine
spark plug hole.
3.2 Connect the leak down tester gauge to the 6. Proceed the same way with remaining cylin-
gauge adapter. ders.
3.3 Connect to an adequate pressurized air
supply. Diagnostic
3.4 Set needle of measuring gauge to zero (0). Pressurize area to be tested, spray soap/water so-
lution at the indicated location and look and/or lis-
NOTE: Each tester will have specific instruction ten for air bubbles.
on the gauge operation and required pressure.
Refer to manufacturer's instructions. OBSERVATION CAUSE
4. Supply combustion chamber with air. Air escaping on intake
Leaking intake valve(s)
port
Air escaping on
Leaking exhaust valve(s)
exhaust port
Air escaping into Excessively worn and/or
crankcase broken piston rings
Air bubbles out of Leaking cylinder head
coolant tank gasket

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 Subsection XX (CYLINDER HEAD)

OBSERVATION CAUSE 7. Stretched timing chain or worn out sprocket

- Replace timing chain and sprocket.
Air/water
Damaged gasket and/or
escaping from 8. Camshaft is worn out
loosened screws
cylinder-block/head - Check if camshaft radial clearance is out of spec-
Damaged gasket and/or ification.
Coolant escaping from
loosened screws (refer to
water pump housing OIL LEAKAGE FROM CYLINDER HEAD
COOLING SYSTEM)
Damaged rotary seal on 1. Valve cover gasket is leaking
Coolant escaping from
water pump shaft (refer to - Replace valve cover gasket and retighten screws
leak indicator hole
COOLING SYSTEM) with recommended torque.
Oily contamination on Damaged oil seal on water - Check valve cover for cracks or other damage.
leak indicator hole pump shaft Replace if necessary.
2. Valve cover screws are leaking
Reassembly - Replace valve cover screws.
For reassembly, reverse the preparation proce- 3. Spark plug tube gasket is leaking
dure. Use torque values and service products - Remove valve cover and replace spark plug tube
from the exploded views (refer to proper ENGINE gasket.
subsections). - Clean spark plug area from oil spillage.
Properly install ignition coils. Refer to IGNITION
4. Blow by valve is leaking
COILS AND SPARK PLUGS subsection.
- Replace blow by valve O-ring.
TROUBLESHOOTING 5. Camshaft sensor O-ring is leaking
- Replace camshaft sensor O-ring.
The following is provided to help in diagnosing the
probable source of problems. It is a guideline and 6. Cylinder head gasket is leaking
it should not be assumed to list all possible prob- - Remove cylinder head and check for damage.
lems. - Replace cylinder head gasket and retighten
Always check for fault codes. If a fault code is de- screws with recommended torquing procedure.
tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES section. ENGINE LACKS ACCELERATION OR
POWER
UNUSUAL ENGINE NOISE OR 1. Incorrect camshaft timing adjustment
VIBRATIONS - Replace damaged components and readjust
1. Incorrect camshaft timing adjustment camshaft timing.
- Replace damaged components and readjust 2. Intake or exhaust valves are leaking
camshaft timing.
- Perform ENGINE LEAK TEST.
2. Camshaft timing gear screws got loose - Check if valve seats properly in valve seat.
- Retighten screws with the recommended torque. - Repair or replace damaged components.
3. Rocker arm(s) hydraulic element is broken or 3. Broken valve spring(s)
worn out (improper valve adjustment). - Replace defective parts.
- Replace faulty rocker arm(s).
4. Broken rocker arm(s)
4. Rocker arm screw not properly tightened - Replace defective parts.
- Retighten screws with recommended torquing
procedure.
PROCEDURES
5. Faulty chain tensioner
- Replace chain tensioner. VALVE COVER
6. Chain guide is worn out Removing the Valve Cover
- Replace chain guide.
1. Remove the ignition coils. Refer to IGNITION
COILS AND SPARK PLUGS subsection.

RTX1503ACEMY18-006
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Subsection XX (CYLINDER HEAD)

2. Remove the valve cover. . TIGHTENING TORQUE

All valve cover screws 9 N•m ± 1 N•m
(Step A) (80 lbf•in ± 9 lbf•in)
Valve cover screws (1 9 N•m ± 1 N•m
- 4) (Step B) (80 lbf•in ± 9 lbf•in)

Install ignition coils, refer to IGNITION COILS AND

SPARK PLUGS subsection.
Install all other removed parts. Refer to proper
subsection for procedure.

SPARK PLUG TUBES

Removing the Spark Plug Tube
smr2016-017-007_a
Remove the VALVE COVER, see procedure in this
1. Valve cover screws subsection.
2. Valve cover
3. Gasket (discard) Pull spark plug tubes to remove them.

Inspecting the Valve Cover

Check the valve cover for cracks or other damage.
Check if rubber bushing on the valve cover screws
are brittle, cracked or hard. If so, replace valve
cover screw accordingly.

Installing the Valve Cover

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Properly seat NEW gasket in the cover groove.
Install the valve cover screws according to follow-
ing sequence.
smr2016-017-009_a

1. Spark plug tubes

Inspecting the Spark Plug Tube

Check seals on spark plug tube. If seals are brittle,
cracked or hard, replace spark plug tube.

smr2016-017-008_a
smr2005-036-001_a
TIGHTENING SEQUENCE
TYPICAL
NOTICE Tighten screws 1 - 4 twice. 1. Spark plug tube
2. Seal to the valve cover
3. Seal to the cylinder head

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 Subsection XX (CYLINDER HEAD)

Installing the Spark Plug Tube

The installation is the reverse the removal proce-
dure. However, pay attention to the following de-
tail.
Apply engine oil on seals.

ROCKER ARMS
Removing the Rocker Arm
1. See procedure in this subsection to remove: smr2008-017-006_a

– Valve cover 1. Rocker arm (intake side)

2. Rocker arm (exhaust side)
– Spark plug tubes. 3. Rollers
2. Remove and discard rocker arm shaft screws. A. Rocker arm inside diameter

Measure rocker arm inside diameter. If diameter

is out of specification, change the rocker arm as-
sembly.
ROCKER ARM INSIDE DIAMETER
20.007 mm to 20.020 mm
New
(.7877 in to .7882 in)
Service limit 20.050 mm (.7894 in)

Press the hydraulic lifter with your thumb. If the

hydraulic lifter can be fully pressed in, replace
rocker arm. Lifter must turn freely in rocker arm
bore. Otherwise, replace.

smr2016-017-010_a
Rocker Arm Shaft
1. Rocker arm shaft screws Check for scored friction surfaces, if so, replace
parts.
3. Remove rocker arm shaft with rocker arms.
Measure rocker arm shaft diameter.
1

R1503motr90A A
A. Measure rocker arm shaft diameter here

R1503motr84A 2 ROCKER ARM SHAFT DIAMETER

1. Rocker arm shaft 19.980 mm to 19.993 mm
New
2. Rocker arms (exhaust side) (.7866 in to .7871 in)
3. Rocker arm (intake side)
Service limit 19.970 mm (.7862 in)
Inspecting the Rocker Arm
Inspect each rocker arm for cracks and scored fric- Any area worn excessively will require parts re-
tion surfaces. If so, replace rocker arm assembly. placement.
Check the rocker arm rollers for free movement, Verify and clean oil orifices to ensure a good rocker
wear and excessive radial play. Replace rocker arm shaft lubrication.
arm assembly as necessary.

RTX1503ACEMY18-006
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Subsection XX (CYLINDER HEAD)

smr2016-017-012_a

1. Rocker arm shaft

R1503motr85A
2. Rocker arm shaft notches
1. Oil orifices from the camshaft to the rocker arm shaft, then to
the rocker arms and finally to the valve adjustment 4. Install NEW rocker arm shaft screws.

Installing the Rocker Arm NOTICE This assembly uses stretch screws.
Always use NEW screws and strictly adhere to
The installation is the reverse of the removal pro- the tightening procedure.
cedure. However, pay attention to the following
details. 5. Tighten screws according to following se-
NOTE: The rocker arm shaft can only be installed quence.
in one specific position. Therefore strictly adhere NOTE: Always perform a step on ALL rocker arm
to following procedure. shaft screws before going to the next step.
1. Lock camshaft. Refer to CAMSHAFT in this TIGHTENING PROCEDURE
subsection.
20 N•m ± 2 N•m
Rocker arm Step A
NOTICE Make sure the printed marks on oil (15 lbf•ft ± 1 lbf•ft)
separator cover are parallel to the cylinder shaft screws
Step B Additional 90° ± 5°
head base.

smr2016-017-016_a smr2016-017-010_b

1. Printed marks TIGHTENING SEQUENCE

2. Oil separator cover

2. Apply engine oil on rocker arm shaft. CAMSHAFT TIMING GEAR

3. Position the rocker arm shaft with the notches Removing the Camshaft Timing Gear
on top. Lock crankshaft, refer to CYLINDER BLOCK sub-
section.

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 Subsection XX (CYLINDER HEAD)

Remove VALVE COVER, see procedure in this

subsection.
Remove camshaft position sensor. Refer to
ELECTRONIC FUEL INJECTION (EFI) subsection.
Lock camshaft. Refer to CAMSHAFT in this sub-
section.
Remove thrust washer from oil separator cover.

smr2016-017-014_a

1. Timing gear screws

2. Camshaft timing gear with oil separator cover

NOTE: Secure timing chain with a retaining wire.

Inspecting the Camshaft Timing Gear

Check camshaft timing gear for wear or deteriora-
tion.
smr2016-013-026_a If gear is worn or damaged, replace it as a set
1. Thrust washer (camshaft timing gear and timing chain).
2. Oil separator cover
NOTE: For crankshaft timing gear replacement,
Unplug oil temperature sensor. refer to CYLINDER BLOCK subsection.

Installing the Camshaft Timing Gear

The installation is reverse of the removal proce-
dure. However, pay attention to the following de-
tails.
Install oil separator cover on camshaft timing gear.
NOTICE Crankshaft and camshaft must be
locked on TDC position.
Place camshaft timing gear along with timing
chain on the camshaft.
NOTE: The printed marks on the oil separator
cover must be parallel to the cylinder head base.
smr2016-017-025_a

1. Oil temperature sensor

Remove the chain tensioner. Refer to CYLINDER

BLOCK subsection.
Remove:
– Chain guide
– Camshaft timing gear with oil separator cover.

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Subsection XX (CYLINDER HEAD)

smr2016-017-015_a smr2016-017-014_b

1. Timing chain 1. Printed marks

2. Oil separator cover 2. Cylinder head surface
3. Printed marks
Remove crankshaft and camshaft locking tools.
Ensure chain guides are properly installed.
Install all other removed parts.
Loosely install timing gear screws.
Install chain tensioner. CAMSHAFT
NOTE: There can be 2 different positions to install
the timing gear on the camshaft. To find best po- Camshaft Locking Procedure
sition strictly follow the procedure. 1. Remove VALVE COVER, see procedure in this
Check if timing gear screws are still loose. If subsection.
screws are squeezed by the timing gear, remove 2. Lock crankshaft, refer to procedure in CYLIN-
the chain tensioner again and rotate timing gear DER BLOCK subsection.
by one tooth clockwise. NOTE: Make sure that printed marks on oil sepa-
Install the chain tensioner again. rator cover are parallel to the cylinder head base.
Remove timing gear screws and apply thread 3. Insert the camshaft locking tool into the
locker on threads. hole behind the camshaft timing gear to lock
Tighten timing gear screws to specification. camshaft.
REQUIRED TOOL
TIGHTENING TORQUE
16 N•m ± 2 N•m CAMSHAFT LOCKING TOOL
(142 lbf•in ± 18 lbf•in) (P/N 529 035 839)
Camshaft timing gear
+
screws
LOCTITE 243 (BLUE)
(P/N 293 800 060)

NOTICE Printed marks on the oil separator

cover must be parallel to the cylinder head
surface.

smr2016-017-016_b

1. Camshaft locking tool

2. Printed marks

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 Subsection XX (CYLINDER HEAD)

Removing the Camshaft ENGINE CAMSHAFT LOBE HEIGHT —

See procedure in this subsection and remove: TYPE EXHAUST VALVE
– Camshaft timing gear 31.430 mm to 31.630 mm
New
– Rocker arm. 130 and (1.2374 in to 1.2453 in)
Remove the camshaft. 155 Service
31.380 mm (1.2354 in)
limit
30.630 mm to 30.830 mm
New
(1.2059 in to 1.2138 in)
230
Service
30.580 mm (1.2039 in)
limit

ENGINE CAMSHAFT LOBE HEIGHT —

TYPE INTAKE VALVE
31.540 mm to 31.740 mm
New
130 and (1.2417 in to 1.2496 in)
155 Service
31.500 mm (1.2402 in)
limit
30.513 mm to 30.713 mm
New
smr2016-017-017_a (1.2013 in to 1.2092 in)
1. Camshaft lock
230
2. Camshaft Service
30.473 mm (1.1997 in)
limit
Inspecting the Camshaft
CAMSHAFT BEARING JOURNAL
Check each lobe and bearing journal of camshaft
for: 39.892 mm to 39.905 mm
New
(1.5706 in to 1.5711 in)
– Scoring
– Scuffing Service limit 39.880 mm (1.5701 in)
– Cracks
CAMSHAFT BEARING JOURNAL
– Other signs of wear. (ENGINE FRONT)
Measure camshaft bearing journal and lobe height 24.919 mm to 24.940 mm
using a micrometer. New
(.9811 in to .9819 in)
Measure clearance between both ends of
Service limit 24.890 mm (.9799 in)
camshaft and cylinder head.
CAMSHAFT BEARING INNER DIAMETER
D A B A C C A B A C C A B A C 40.000 mm to 40.020 mm
New
(1.5748 in to 1.5756 in)
Service limit 40.050 mm (1.5768 in)

CAMSHAFT BEARING INNER DIAMETER

R1503motr102A (ENGINE FRONT)
A. Camshaft lobe (exhaust valves) 25.000 mm to 25.013 mm
B. Camshaft lobe (intake valves) New
C. Camshaft bearing journal (.9843 in to .9848 in)
D. Camshaft bearing journal — engine front
Service limit 25.050 mm (.9862 in)

Replace parts that are not within specifications.

Installing the Camshaft

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
details.

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Subsection XX (CYLINDER HEAD)

Lubricate the camshaft bearing journals.

CAMSHAFT BEARING JOURNALS
ISOFLEX GREASE
Service product TOPAS NB 52 (P/N 293
550 021)

Install camshaft then turn and check if it moves

freely. Place the camshaft lock in its slot.

smr2016-017-013_a

TYPICAL
1. Camshaft position sensors (CAPS) connector
2. Coolant temperature sensor (CTS) connector
3. Bleeding nipple
4. Cylinder head outlet hose

Remove the intake manifold. Refer to INTAKE

MANIFOLD subsection.
Remove the exhaust manifold. Refer to EX-
HAUST SYSTEM subsection.
smr2016-017-017_b

1. Camshaft lock Remove the CAMSHAFT TIMING GEAR, see pro-

cedure in this subsection.
For other parts, refer to the proper installation pro-
Remove the M6 cylinder head screws.
cedures in this subsection.

CYLINDER HEAD
Removing the Cylinder Head
Lock crankshaft, refer to CYLINDER BLOCK sub-
section.
Drain coolant, refer to COOLING SYSTEM sub-
section.
Remove blow-by valve from cylinder head. Refer
to LUBRICATION SYSTEM subsection.
Unplug:
– Camshaft position sensors (CAPS)
– Coolant temperature sensor (CTS).
Disconnect:
– Bleeding hose
– Cylinder head outlet hose.
smr2016-017-018_a

1. M6 cylinder head screws

Remove and discard the M11 cylinder head

screws.

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smr2016-017-019_a
1. M11 cylinder head screws
Remove the cylinder head and discard the gasket.
Cleaning the Cylinder Head
Remove carbon deposits from combustion cham-
ber, exhaust port and piston top.
Clean cylinder head, especially cylinder head
screw surface from oil spillage.
Blow out the oil orifices and check if they are not
clogged.
smr2009-025-010_a
1. Oil orifices
Inspecting the Cylinder Head
Check for cracks between valve seats or other
damages, if so, replace cylinder head.
Check cylinder head mating surface for flatness,
using a straight edge.
RTX1503ACEMY18-006
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Subsection XX (CYLINDER HEAD)
smr2006-016-063_a
1. Cylinder head
2. Flat bar
3. Feeler gauge
Check cylinder head warpage.
CYLINDER HEAD WARPAGE
Maximum 0.100 mm (.004 in)
If warpage exceeds specification, replace cylinder
head.
Installing the Cylinder Head
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
details.
Ensure dowel pins are in place.
smr2016-017-020_a
1. Dowel pins
Install NEW cylinder head gasket.
NOTICE Each installation of the cylinder
head requires a new cylinder head gasket. Us-
ing a gasket twice will cause engine damage.
Install NEW M11 cylinder head screws and
tighten as per following procedure.
NOTICE This assembly uses stretch screws.
Always use NEW screws and strictly adhere to
the tightening procedure.
13
Subsection XX (CYLINDER HEAD)

NOTE: Always perform a step on ALL M11 cylin-

der head screws before going to the next step.

smr2016-017-019_b

TIGHTENING SEQUENCE - STEP A smr2016-017-018_b

TIGHTENING SEQUENCE
TIGHTENING PROCEDURE
M11 cylinder 40 N•m ± 3 N•m TIGHTENING TORQUE
Step A
head screws (30 lbf•ft ± 2 lbf•ft) 11 N•m ± 1 N•m
(97 lbf•in ± 9 lbf•in)
M6 cylinder head screws +
LOCTITE 243 (BLUE)
(P/N 293 800 060)

Remove crankshaft and camshaft locking tools.

Install all removed parts.

VALVE SPRINGS
Removing the Valve Spring
See procedures in this subsection to remove:
– ROCKER ARM
– CYLINDER HEAD.
smr2016-017-019_c
.
TIGHTENING SEQUENCE - STEP B AND C Compress valve springs.
TIGHTENING PROCEDURE REQUIRED TOOL
Additional 120° VALVE SPRING COMPRESSOR
Step B
M11 cylinder ± 5° (P/N 529 035 724)
head screws Additional 120°
Step C VALVE SPRING
± 5°
COMPRESSOR CUP
Tighten M6 cylinder head screws to specification. (P/N 529 036 073)

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 Subsection XX (CYLINDER HEAD)

Inspecting the Valve Spring

Check valve springs for rust, corrosion or other
visible damages. If so, replace faulty valve
springs.
Check valve springs for free length and straight-
ness.
Replace valve springs if not within specifications.

smr2016-017-021_a

1. Valve spring compressor clamp

2. Valve spring compressor cup

R400motr80A A
A. Valve spring length

OUTER VALVE SPRING FREE LENGTH

New 45.45 mm (1.789 in)
Service limit 43.00 mm (1.693 in)

INNER VALVE SPRING FREE LENGTH

New 41.02 mm (1.615 in)
Service limit 38.80 mm (1.528 in)
smr2016-017-022

LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF

THE VALVE Installing the Valve Spring
The installation is the reverse of the removal pro-
Remove valve cotters.
cedure. However, pay attention to the following
Withdraw valve spring compressor tools. details.
Remove valve springs. Colored area of the valve spring must be placed
on top.
NOTE: Valve cotters must be properly engaged in
valve stem grooves.

smr2008-017-009_a

1. Valve cotters
2. Valve spring retainer
3. Inner valve spring
4. Outer valve spring

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Subsection XX (CYLINDER HEAD)

R1503motr105B
smr2016-017-011_a
1. Position of the valve spring 1. Valve stem seal

VALVES Inspecting the Valve

Removing the Valve Valve Stem Seal
Remove valve spring. Always install NEW seals whenever valves are re-
moved.
Push valve stem then pull valves out of valve
guides. Inspection of valve stem seals is not needed
because NEW seals should always be installed
whenever cylinder head is removed.
Valve
Inspect valve surface, check for abnormal stem
wear and bending. If so, replace by a new one.
Valve Stem and Valve Guide Clearance
Measure valve stem and valve guide in three
places, using a micrometer and a small bore
gauge.
NOTE: Clean valve guide to remove carbon de-
posits before measuring.
Change valve if valve stem is out of specification
or has other damages such as wear or friction sur-
smr2016-017-023_a
face.
1. Intake valve 38 mm
2. Exhaust valve 31 mm

Remove and discard valve stem seal.

REQUIRED TOOL
SNAP-ON VALVE STEM SEAL PLIERS (P/N YA8230)

R400motr83A

A. Valve stem diameter

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 Subsection XX (CYLINDER HEAD)

VALVE STEM DIAMETER - INTAKE VALVE VALVE SEAT CONTACT WIDTH - INTAKE VALVE
5.961 mm to 5.975 mm 1.10 mm to 1.30 mm
New New
(.2347 in to .2352 in) (.043 in to .051 in)
Service limit 5.930 mm (.2335 in) Service limit 1.60 mm (.063 in)

VALVE STEM DIAMETER - EXHAUST VALVE VALVE SEAT CONTACT WIDTH - EXHAUST VALVE
5.946 mm to 5.960 mm 1.25 mm to 1.55 mm
New New
(.2341 in to .2346 in) (.049 in to .061 in)
Service limit 5.930 mm (.2335 in) Service limit 1.80 mm (.071 in)

Replace valve guide if it is out of specification or If valve seat contact width is too wide or has dark
has other damages such as wear or friction sur- spots, replace the cylinder head.
face. Refer to VALVE GUIDE in this subsection.
VALVE GUIDE INNER DIAMETER
(INTAKE AND EXHAUST VALVE)
5.994 mm to 6.018 mm
New
(.236 in to .2369 in)
Service limit 6.060 mm (.2386 in)

Valve Face and Seat

2 3

smr2016-017-024_a

A. Valve seat contact width - Exhaust valve

B. Valve seat contact width - Intake valve

Valve Seat Grinding

NOTE: The valve seats may be reground with
a valve seat grinder which centers on the valve
guide.
1. Grind the valve seat at 45°. Remove no more
material than absolutely necessary to clean the
seat up.
R1503motr107A 1
2. Using a 35° stone, narrow the valve seat until
1. Valve seat the appropriate outer diameter is obtained.
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)

Check valve face and seat for burning or pittings

and replace valve or cylinder head if there are
signs of damage.
Ensure to seat valves properly. Apply some lap-
ping compound on valve face and work valve on
its seat with a lapping tool.
NOTE: The location of contact area should be in
center of valve seat.
Measure valve seat width, using a caliper.

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Subsection XX (CYLINDER HEAD)

EXHAUST 80° Installing the Valve

The installation is the reverse of the removal pro-
cedure. however, pay attention to the following
details.
Install NEW valve stem seal.
45°
35° 1
A
35°

45°

80°

R1503motr259A

A. Valve seat outer diameter EXHAUST

INTAKE
55°

35° 45°
A R1503motr254A

35° 1. Valve stem seal

45°
Apply engine oil on valve stem and install valve.
55°
NOTICE Be careful when valve stem is
passed through sealing lips of valve stem
R1503motr260A seal.
A. Valve seat outer diameter INTAKE
1
VALVE SEAT OUTER DIAMETER
INTAKE 37.35 mm (1.4705 in)
EXHAUST 30.30 mm (1.1929 in)

3. Using a 55° stone for the intake and an 80°

stone for the exhaust valve, reduce the valve
seat contact width to the appropriate value
mentioned above.
4. Finally, coat the valve seating surface with a
fine paste of valve grinding compound using a
manual valve grinding mandrel. Lightly grind
the valves until a smooth, even, uniform sealing
surface of the appropriate inside and outside
diameter is obtained on both the valve and R1503motr254B
the seat. Use only a hand held valve grinding
mandrel with a suction cup, rotating the valve 1. Sealing lips of valve stem seal
back and forth through about 45°, and then To ease installation of cotters, apply oil or grease
advancing the valve 45° before repeating this on them so that they remain in place while relea-
operation. sing the spring.

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 Subsection XX (CYLINDER HEAD)

After springs are installed, ensure valve springs

and valve spring retainer are properly locked by
tapping on valve stem end with a soft hammer so
that valve opens and closes a few times.
1
NOTICE An improperly locked valve spring
will cause engine damage.

VALVE GUIDE
Replacing the Valve Guide
NOTICE Do not heat cylinder head for this
procedure.
NOTICE The sharp edge near the top of the R1503motr255A

valve guide must be machined away. Other- TYPICAL

wise it will foul the valve guide hole in the
cylinder head and destroy the cylinder head,
as the valve guide is removed.
Use a special reamer as far as the top of the notch.
1
2 (P/N 529 036 087)
1. Punch
Check valve guide bore for abreased material.
The inlet and exhaust valve guides have the same
length and are interchangeable.
NOTE: If valve guide has caused scoring during
extraction, replace the cylinder head.
Grease the bore in cylinder head and the leading
end of valve guide with MOLYKOTE G-N (P/N 420
297 433).
Press the valve guide into the COLD cylinder head
as shown.
REQUIRED TOOL
VALVE GUIDE PUSHER (6 MM)

R1503motr258A

TYPICAL
1. Special reamer
2. Notch

Chase valve guide out of the cylinder head to-

wards combustion chamber.
REQUIRED TOOL
VALVE GUIDE
REMOVER (6 MM)
(P/N 529 036 086)

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Subsection XX (CYLINDER HEAD)

Clean cylinder head carefully. Check that the valve

seat is concentric with the new guide axis (check
contact surface with engineer's blue).

R1503motr256A

TYPICAL
1. Valve guide leading end
2. Cylinder head bore
3. Jig

R1503motr257A

TYPICAL
A. Protrusion

VALVE GUIDE PROTRUSION

(MEASUREMENT “A”)
12.4 mm to 12.8 mm (.488 in to .504 in)

NOTE: After installing new guides, they must be

reamed with a standard 6 mm reamer tool. These
are available from various tool suppliers.

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

CYLINDER BLOCK
(WITHOUT REPLACEABLE PTO
SLEEVE)
SERVICE TOOLS
Description Part Number Page
CRANKSHAFT LOCKING TOOL .................................................... 529 036 272 ........................................... 14
OIL SEAL INSTALLER ................................................................... 529 036 277 ............................................. 5
PISTON CIRCLP INSTALLER......................................................... 529 036 207 ........................................... 20
PISTON RING COMPRESSOR ...................................................... 529 036 208 ........................................... 21
PTO ADAPTER .............................................................................. 529 036 273 ........................................... 14

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 6
LOCTITE 5910 ............................................................................... 293 800 081 ........................................... 11
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ............................................. 9
TRIPLE-GUARD GREASE .............................................................. 296 000 329 ......................................... 5–6

smr2016-115
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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

See tightening 9 ± 1 N•m

procedure 10 ± 1 N•m
28 ± 3 N•m (80 ± 9 lbf•in) (89 ± 9 lbf•in)
(21 ± 2 lbf•ft) Loctite 243 23 ± 3 N•m
(17 ± 2 lbf•ft)
Loctite 243 NEW Loctite 243

12 ± 1 N•m
(106 ± 9 lbf•in)
Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in)
See ELECTRONIC FUEL
Loctite 243 INJECTION (EFI)

Triple-guard
23 ± 3 N•m grease
(17 ± 2 lbf•ft) See tightening
See tightening NEW procedure
sequence Engine oil 9 ± 1 N•m
Triple-guard (80 ± 9 lbf•in)
grease
3-6g Loctite 243
30 ± 3 N•m
(22 ± 2 lbf•ft)
Loctite 243 Engine oil

30 ± 3 N•m
(22 ± 2 lbf•ft)
Engine oil

Loctite 5910

23 ± 3 N•m
(17 ± 2 lbf•ft)

Loctite 243
Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in) 30 ± 3 N•m
NEW (22 ± 2 lbf•ft)

See tightening
Loctite 243
sequence 20 ± 2 N•m
(15 ± 1 lbf•ft)
+150° 30 ± 3 N•m
(22 ± 2 lbf•ft)
NEW = Component must be replaced when removed.
smr2014-021-001_a

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

NEW

Engine oil

NEW

Engine oil

See tightening
sequence
12 ± 2 N•m
(106 ± 18 lbf•in) NEW
Engine oil
+70°

Engine oil

Engine oil

NEW = Component must be replaced when removed.

smr2014-021-002_a

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

GENERAL
When disassembling parts that are duplicated in
the engine, (e.g.: pistons, connecting rods etc.),
it is strongly recommended to note their position
and to keep the parts of the same assembly as
a “group”. If you find a defective component, it
would be much easier to find the cause of the fail-
ure. Since parts were broken-in during engine op-
eration, they will maintain their matched fit when
reassembled together within their “group”.
TROUBLESHOOTING
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to DI-
AGNOSTIC SYSTEM AND FAULT CODES subsec-
tion.
PROCEDURES
PTO COVER AND PTO OIL SEALS
PTO Cover Access
NOTE: To replace the PTO oil seal, it is not nec-
essary to remove engine from the vehicle.
Remove central body. Refer to BODY.
Remove drive shaft. Refer to DRIVE SHAFT.
PTO Cover Removal
Remove screws retaining the PTO cover.
Remove PTO cover and discard gasket.

UNUSUAL ENGINE NOISE OR

VIBRATIONS
1. Heavy wear on plain bearings.
- Check radial play of plain bearings. Replace if out
of specification.
2. Crankshaft axial play out of specification.
- Measure crankshaft axial play. If crankshaft axial
play is out of specification, replace thrust wash-
ers.
3. Connecting rod axial play out of specification. smr2014-021-003_a

1. PTO cover screws

- Measure connecting rod axial play on crankshaft. 2. PTO cover
Replace connecting rod or crankshaft if out of 3. Gasket
specification.
4. Connecting rod screws got loose. PTO Oil Seals Replacement
- Replace damaged components and retighten PTO Oil Seals Removal
screws with the recommended torque.
1. Use pliers to remove inner retaining ring.
BLUE SMOKE IN THE EXHAUST 2. Pry out inner oil seal and discard it.
1. Oil scraper rings worn out.
- Replace piston rings.

ENGINE SUDDENLY TURNS OFF (POOR

IDLING)
1. Piston rings worn out.
- Replace piston rings.
2. Piston/cylinder clearance out of specification.
- Check piston/cylinder clearance. Replace if out of
specification.
3. Melted or broken piston.
- Replace piston and cylinder block if necessary.

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

4. Press NEW outer oil seal in PTO cover.

NOTICE Oil seal must be installed with seal-
ing lip facing away from the engine.
REQUIRED TOOL

OIL SEAL INSTALLER (P/N 529

036 277)

5. Install distance ring.

6. Apply engine oil on oil seal seat in PTO cover.
7. Backfill middle oil seal with grease.
OIL SEALS LUBRICATION
smr2014-021-004_a TRIPLE-GUARD
1. Inner retaining ring Service product GREASE (P/N 296
2. Inner oil seal 000 329)
3. PTO cover

3. Use pliers to remove outer retaining ring.
4. Pry out middle oil seal and discard it.
5. Remove distance ring.
6. Pry out outer oil seal and discard it.
8. Press NEW middle oil seal in PTO cover.
NOTICE Oil seal must be installed with seal-
ing lip facing away from the engine.
9. Lubricate sealing lips of oil seals and backfill
room between outer and middle oil seal with
3 g to 6 g (.1 oz to .2 oz) of specified grease.
OIL SEALS LUBRICATION
TRIPLE-GUARD
Service product GREASE (P/N 296
000 329)

10. Install outer retaining ring.

11. Apply engine oil on oil seal seat in PTO cover.
12. Press NEW inner oil seal in PTO cover.
NOTICE Oil seal must be installed with seal-
ing lip towards the engine.
13. Lubricate sealing lip of oil seal.
OIL SEALS LUBRICATION
smr2014-021-005_a

1. Outer retaining ring TRIPLE-GUARD

2. Middle oil seal Service product GREASE (P/N 296
3. Distance ring 000 329)
4. Outer oil seal
5. PTO cover
14. Install inner retaining ring.
PTO Oil Seals Installation
NOTE: Check the oil seal running surface of
crankshaft for grooves and deposits, before in-
stallation of NEW oil seals.
1. Clean crankshaft PTO side from deposits.
2. Clean oil seal areas in PTO cover.
3. Apply engine oil on oil seal seat in PTO cover.

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

smr2014-021-011_a

PTO COVER TIGHTENING SEQUENCE - STEP A

smr2014-021-006_a

1. Outer oil seal

2. Distance ring PTO COVER TIGHTENING PROCEDURE
3. Middle oil seal
4. Inner oil seal LOCTITE 243 (BLUE)
Apply TRIPLE-GUARD GREASE (P/N 296 000 329)on Service product
5. (P/N 293 800 060)
sealing lips
6. Backfill middle oil seal and room between oil seals 5 N•m ± 0.6 N•m
STEP A
(44 lbf•in ± 5 lbf•in)
PTO Cover Installation
For installation, reverse the removal procedure.
Pay attention to following details.
Install a NEW PTO cover gasket in proper position.

smr2014-021-011_b

smr2014-021-010_a PTO COVER TIGHTENING SEQUENCE - STEP B

1. Gasket
2. Tab PTO COVER TIGHTENING PROCEDURE
Tighten PTO cover screws as per following se- LOCTITE 243 (BLUE)
Service product
quence. (P/N 293 800 060)
23 N•m ± 3 N•m
STEP B
(17 lbf•ft ± 2 lbf•ft)

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

CYLINDER BLOCK NOTE: Before splitting the cylinder block, mea-

sure crankshaft axial play. Refer to CRANKSHAFT
Cylinder Block Disassembly in this subsection.
1. Remove engine from the vehicle. Refer to EN- 13. Remove crankshaft locking tool.
GINE REMOVAL AND INSTALLATION subsec-
tion. 14. Remove cylinder block screws.
2. Refer to PERIODIC MAINTENANCE PROCE- 14.1 Start removing the M6 screws.
DURES and drain engine oil. 14.2 Then remove the M8 screws.
3. Refer to CYLINDER HEAD subsection and re- 14.3 Finally remove and discard the M9
move: screws.
– Ignition coils
– Valve cover
– Spark plugs.
4. Lock crankshaft, refer to CRANKSHAFT LOCK-
ING PROCEDURE in this subsection.
5. Remove air intake manifold. Refer to AIR IN-
TAKE SYSTEM subsection.
6. Refer to COOLING SYSTEM subsection and re-
move:
– Water pump housing
– Thermostat
– Water pump drive gear.
7. Refer to LUBRICATION SYSTEM subsection smr2014-021-012_a

and remove: INTAKE SIDE

1. Cylinder block screws (M6) screwed from top to bottom
– Oil tank
– Oil cooler
– Oil pressure regulator
– Oil pump drive gears and oil pumps
– Oil sump cover
– Oil strainers.
8. Refer to MAGNETO AND STARTER subsection
and remove:
– Magneto cover
– Rotor
– Starter drive gears
– Electric starter.
smr2014-021-013_a
9. Remove engine mount brackets. EXHAUST SIDE
1. Cylinder block screw (M6) screwed from top to bottom
10. Refer to TIMING CHAIN subsection and re-
move:
– Timing chain tensioner
– Timing chain guides.
11. Refer to CYLINDER HEAD subsection and re-
move:
– Camshaft holders
– Cylinder head.
12. Remove PTO cover. Refer to PTO COVER
AND PTO OIL SEALS in this subsection.

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

smr2014-021-014_a

BOTTOM SIDE smr2014-021-016_a

1. M6 screws 1. Mark on crankshaft plain bearings
2. M8 screws
3. M9 screws (discard)
Cylinder Block Cleaning
15. Carefully remove cylinder block lower half by
Clean cylinder block using a part cleaner, then use
using a soft hammer.
compressed air to dry it.
NOTE: Take care not to damage the sealing sur-
Blow out the oil orifices using compressed air and
faces of the cylinder block halves.
make sure they are not clogged.

smr2014-021-015

16. Remove connecting rod caps. Refer to PIS- smr2014-021-017_a

TONS AND CONNECTING RODS in this sub- CYLINDER BLOCK UPPER HALF
1. Oil orifices
section.
17. Refer to CRANKSHAFT in this subsection and
remove:
– Crankshaft thrust washers
– Crankshaft.
18. Remove pistons and connecting rods. See
procedure in this subsection.
Plain Bearing Removal
When the plain bearings need to be removed from
the cylinder block, mark them to identify the cor-
rect position at installation. See the illustration as
an example.

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

smr2014-021-018_a

CYLINDER BLOCK - REAR smr2014-021-021_a

1. Oil orifices CYLINDER BLOCK LOWER HALF
1. Oil orifices

smr2014-021-019_a

CYLINDER BLOCK - MAG SIDE

1. Oil orifices
smr2014-021-022_a

CYLINDER BLOCK LOWER HALF

1. Oil orifices

Clean all metal components in a solvent.

Clean cylinder block mating surfaces with LOCTITE
CHISEL (GASKET REMOVER) (P/N 413 708 500) and
a brass brush. Brush a first pass in one direction
then make the final brushing perpendicularly (90°)
to the first pass (cross hatch).
NOTE: Do not wipe with rags. Use a new clean
hand towel only.

Cylinder Block Inspection

smr2014-021-020_a

CYLINDER BLOCK - TOP

Check cylinder block for cracks or other damage.
1. Oil orifices Check cylinder block mating surfaces for flatness
using a straight edge.
Replace cylinder block if necessary.
Check cylinder bores for cracks, scoring and wear
ridges on top and bottom of the cylinders.

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

Cylinder Taper
Measure cylinder bore diameter at 4 recom-
mended positions. See illustration.

smr2014-021-025_a

1. Perpendicular to piston pin axis

2. Parallel to piston pin axis

To obtain the cylinder out of round, calculate the

difference between the perpendicular measures.
mmr2011-075-022_a
CYLINDER OUT OF ROUND
TYPICAL
1. First measure NEW MAXIMUM 0.008 mm (.0003 in)
2. Second measure
3. Third measure SERVICE LIMIT 0.030 mm (.0012 in)
4. Fourth measure
A. 5 mm to 10 mm (.197 in to .394 in)
B. 30 mm to 35 mm (1.181 in to 1.378 in) Crankshaft Plain Bearings Inside Diameter
C. 57 mm to 62 mm (2.244 in to 2.441 in)
D. 111 mm to 113 mm (4.37 in to 4.449 in) Check the plain bearings for scoring or other dam-
ages.
The difference between measurements should
not exceed the service limit mentioned in next Measure plain bearing inside diameter and com-
table. pare with crankshaft bearing journal diameter (re-
fer to CRANKSHAFT in this subsection). Proceed
CYLINDER TAPER as follows.
NEW MAXIMUM 0.030 mm (.0012 in) – Use the OLD plain bearings and put both cylin-
der block halves together.
SERVICE LIMIT 0.050 mm (.002 in)
– Tighten screws as described in CYLINDER
Cylinder Out of Round BLOCK ASSEMBLY.
– Measure the inside diameter of the crankshaft
Measure cylinder bore diameter as shown and at plain bearings using a bore gauge.
the same measuring points as for CYLINDER TA-
PER.

mmr2011-075-024_a

1. Bore gauge
2. Crankshaft plain bearing

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

CRANKSHAFT PLAIN BEARING INSIDE 1.4 Bearings must be flush with the cylinder
DIAMETER block split surface and their protrusions
have to fit in the notched areas in the
SERVICE LIMIT 36.080 mm (1.4205 in)
cylinder block seat.
Replace bearings if they are out of specifications.
1
Cylinder Block Assembly
For assembly, reverse the disassembly proce-
dure. Pay attention to the following details.
1. Correctly reinstall plain bearings as follows.
1.1 Use NEW bearings if diameters are out of
specification. Refer to PLAIN BEARING
INSPECTION in this subsection.
1.2 Install bearings with lubrication grooves in
the cylinder block upper half.

R1503motr36A

TYPICAL
1. Bearing protrusion in cylinder block notch

2. Install pistons, refer to PISTONS AND CON-

NECTING RODS in this subsection.
3. Apply engine oil on all plain bearings.
4. Install the following components:
– Crankshaft and thrust washers (refer to
CRANKSHAFT)
– Connecting rod caps (refer to PISTONS AND
smr2014-021-016_b CONNECTING RODS).
1. Plain bearings 5. Apply LOCTITE 5910 (P/N 293 800 081) on mating
2. Lubrication grooves
surface of cylinder block lower half as shown on
1.3 Install flat bearings in the cylinder block next illustration.
lower half. IMPORTANT: When beginning the application of
the cylinder block sealant, the assembly and first
tightening have to be done within 12 minutes. It
is suggested to have all you need on hand to save
time.

smr2014-021-022_b

1. Flat bearings

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

NOTICE This assembly uses stretch

screws. Always use NEW screws and
strictly adhere to the tightening proce-
dure.
6.1 Torque the M9 screws according the se-
quence.
CYLINDER BLOCK M9 SCREWS
TIGHTENING PROCEDURE
20 N•m ± 2 N•m
STEP A
(15 lbf•ft ± 1 lbf•ft)

smr2014-021-026_a

1. Apply Loctite 5910 following this pattern

NOTICE Ensure not to apply too much

sealant, as it will spread out inside the cylinder
block.
NOTICE Take care that the bypass passage of
the engine oil pressure regulator is not clogged
with sealant.

smr2014-021-014_b

M9 SCREWS TIGHTENING SEQUENCE - FIRST AND SECOND

STEPS

6.2 Use a torque angle gauge to carry out

the second step, following the same se-
quence.
CYLINDER BLOCK M9 SCREWS
TIGHTENING PROCEDURE
STEP B Additional 150° ± 5°

7. Install the M8 screws and tighten as follows.

CYLINDER BLOCK M8 SCREWS
23 N•m ± 2 N•m
Tightening torque
(17 lbf•ft ± 1 lbf•ft)

smr2014-021-027_a

1. Bypass passage of engine oil pressure regulator

2. Loctite 5910 applied

6. Install NEW cylinder block M9 screws and

tighten as follows.

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

smr2014-021-013_b

smr2014-021-014_c M6 SCREW TIGHTENING SEQUENCE (EXHAUST SIDE OF

CRANKCASE)
M8 SCREWS TIGHTENING SEQUENCE

8. Install the M6 screws and tighten as follows.
CYLINDER BLOCK M6 SCREWS
Tightening torque
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
NOTE: Check the crankshaft axial play before
continuing the assembly. Refer to CRANKSHAFT
in this subsection for the procedure.
9. Lubricate PTO oil seals properly before rein-
stalling the PTO cover. Refer to PTO COVER
AND PTO OIL SEALS in this subsection.
10. Reassemble engine in accordance with the
proper assembly procedures.

CRANKSHAFT
Crankshaft Locking Procedure
NOTICE When crankshaft is locked, the sec-
ond cylinder is set to TDC.
Crankshaft must be locked whenever the mag-
neto rotor retaining nut has to be removed or
whenever working on the valve train.

smr2014-021-014_d
NOTICE When working on the valve train or
M6 SCREWS TIGHTENING SEQUENCE (BOTTOM OF timing chain, crankshaft must be locked with
CRANKCASE) the marks "IN" and "EX" on the camshaft timing
gears facing each other.
1. If working on the valve train or timing chain,
remove the valve cover. Refer to CYLINDER
HEAD subsection.
2. Remove spark plugs.
3. Remove crankshaft access plug and discard
gasket ring.

smr2014-021-012_b

M6 SCREWS TIGHTENING SEQUENCE (INTAKE SIDE OF

CRANKCASE)

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

smr2014-021-029_a smr2014-021-030_a

1. Crankshaft access plug 1. Crankshaft locking tool

4. Turn engine on PTO side counterclockwise to Crankshaft Removal

bring crankshaft to locking position.
1. Disassemble CYLINDER BLOCK, see proce-
REQUIRED TOOL dure in this subsection.
PTO ADAPTER (P/N 529 2. Remove connecting rod caps. Refer to PIS-
036 273) TONS AND CONNECTING RODS in this sub-
section.
3. Remove crankshaft thrust washers.

smr2014-021-028_a

1. Crankshaft PTO side R1503motr09A

2. PTO adapter
TYPICAL
NOTICE Crankshaft locking position is 1. Thrust washer
reached when marks "IN" and "EX" on the
4. Remove crankshaft from cylinder block.
camshaft timing gears face each other.
5. Use a flashlight to check if the groove in the
crankshaft is aligned with the hole.
6. Lock crankshaft.
REQUIRED TOOL
CRANKSHAFT LOCKING TOOL
(P/N 529 036 272)

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

smr2014-021-031_a mmr2009-116-030_a

1. Crankshaft TYPICAL
1. Micrometer
2. Crankshaft area for plain bearing
Crankshaft Inspection
Check each bearing journal of crankshaft for scor- To obtain the radial play, calculate the difference
ing, scuffing, cracks or other signs of wear. between the bearing journal diameter and the
crankshaft plain bearings inner diameter (see
Check if crankshaft gears are worn or otherwise
CYLINDER BLOCK).
damaged.
CRANKSHAFT BEARING JOURNAL DIAMETER
35.990 mm to 36.006 mm
NEW
(1.4169 in to 1.4176 in)
SERVICE LIMIT 35.960 mm (1.4157 in)

CRANKSHAFT RADIAL PLAY

SERVICE LIMIT 0.08 mm (.0031 in)

Crankshaft Pin Diameter

smr2014-021-032_a
1. Oil pump drive gear
2. Crankshaft timing gear
Replace crankshaft if damaged.
Blow the oil orifices using compressed air and
make sure they are not clogged.
Measure crankshaft pin diameter, using a microm-
eter.
To obtain the radial play, calculate the difference
between the crankshaft pin diameter and the
connecting rod plain bearings inner diameter (see
CONNECTING ROD INSPECTION).

smr2014-021-032_b

1. Check oil orifices

mmr2009-116-031_a
Crankshaft Radial Play TYPICAL
1. Micrometer
Measure crankshaft bearing journal diameter, us- 2. Crankshaft pin area for plain bearing
ing a micrometer.

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

CRANKSHAFT PIN DIAMETER Crankshaft Installation

35.979 mm to 35.995 mm For installation, reverse the removal procedure.
NEW Pay attention to following details.
(1.416 in to 1.417 in)
SERVICE LIMIT 35.969 mm (1.416 in) Turn cylinder block upside down.
NOTICE Be careful that connecting rods do
CONNECTING ROD BIG END RADIAL PLAY not hit the cylinder block.
SERVICE LIMIT 0.08 mm (.0031 in)
Apply engine oil on all plain bearings before in-
Crankshaft Axial Play stalling them.
With the crankshaft in the cylinder block, measure Install crankshaft along with the timing chain.
the crankshaft axial play, using a dial indicator. Lubricate (both sides) and reinstall crankshaft
thrust washers with the slots facing against
crankshaft counterweights.
NOTE: Thrust washers have to be flush with the
cylinder block sealing surface.

mmr2009-116-032_a

TYPICAL
1. Dial indicator
2. Crankshaft

CRANKSHAFT AXIAL PLAY

0.120 mm to 0.352 mm
NEW
(.005 in to .014 in) R1503motr16A

SERVICE LIMIT 0.450 mm (.018 in) TYPICAL

If play is out of specification, replace the crank-
shaft thrust washers and repeat measurement.
1. Thrust washer
2. Sealing surface
Install connecting rod caps. Refer to PISTONS
AND CONNECTING RODS in this subsection.
NOTICE It is absolutely necessary to follow
this procedure. Otherwise severe engine dam-
age can occur.
Install cylinder block lower half. Refer to CYLIN-
DER BLOCK in this subsection.
Lock crankshaft before further assembly of the
engine. See CRANKSHAFT LOCKING PROCE-
DURE in this subsection.

mmr2009-116-033_a

TYPICAL
1. Crankshaft thrust washers

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

PISTONS AND CONNECTING NOTE: The removal of both piston pin circlips is
RODS not necessary to remove the piston pin.
2. Push piston pin out of the piston.
Piston and Connecting Rod Removal
NOTE: It is recommended to measure connecting 1 2 3
rod big end axial play prior to remove connecting
rod. Refer to CONNECTING ROD INSPECTION.
1. Disassemble CYLINDER BLOCK as per proce-
dure in this subsection.
2. Remove connecting rod cap.
NOTICE Mark cylinder position of connecting
rod before disassembly.

R1503motr27A

TYPICAL
1. Piston
2. Piston pin
3. Circlip

3. Detach piston from connecting rod.

Connecting Rod Inspection

Connecting Rod Big End Axial Play
Using a feeler gauge, measure distance between
butting face of connecting rod and crankshaft
smr2014-021-034_a
counterweight. If the distance exceeds specified
1. Connecting rod screws
2. Connecting rod cap tolerance, replace the worn part.

3. Remove CRANKSHAFT as per procedure in this

subsection.
4. Turn cylinder block and push piston with con-
necting rod out of the cylinder.

Piston and Connecting Rod

Disassembly
1. Remove one piston pin circlip and discard it.

smr2014-021-035_a

1. Crankshaft
2. Connecting rod
3. Feeler gauge

CONNECTING ROD BIG END AXIAL PLAY

0.100 mm to 0.352 mm
NEW
mmr2009-116-075_a (.004 in to .014 in)
TYPICAL
1. Piston pin circlip SERVICE LIMIT 0.450 mm (.018 in)

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

Connecting Rod Small End Radial Play

Measure connecting rod small end, using a bore
gauge.

vmr2006-044-039_a

TYPICAL
A. Connecting rod big end bearing

CONNECTING ROD BIG END DIAMETER

2 1
SERVICE LIMIT 36.06 mm (1.4197 in)

To obtain the connecting rod big end radial play,

R1004motr11A calculate the difference between the big end
diameter and the crankshaft pin diameter (see
TYPICAL
1. Bore gauge CRANKSHAFT INSPECTION).
2. Connecting rod
CONNECTING ROD BIG END RADIAL PLAY
CONNECTING ROD SMALL END DIAMETER
SERVICE LIMIT 0.080 mm (.0031 in)
17.010 mm to 17.020 mm
NEW
(.6697 in to .6701 in) If connecting rod big end diameter is out of spec-
SERVICE LIMIT 17.060 mm (.6717 in) ification, install NEW plain bearings.

If the connecting rod small end diameter is out of
specification, replace the connecting rod.
To obtain the radial play, calculate the difference
between the piston pin diameter (PISTON PIN IN-
SPECTION) and the connecting rod small end in-
ner diameter.
CONNECTING ROD SMALL END RADIAL PLAY
SERVICE LIMIT 0.040 mm (.0016 in)
Piston Pin Inspection
Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracks or other
damage.
Measure piston pin diameter, using a micrometer.
See the following illustration for the proper mea-
surement position.

Connecting Rod Big End Radial Play

1. Measure inside diameter of connecting rod big
end.
1.1 Install the OLD plain bearings as they were
mounted initially.
1.2 Perform the tightening procedure as de-
scribed in PISTON AND CONNECTING R400motr30A A
ROD INSTALLATION in this subsection.
TYPICAL
NOTE: To measure the connecting rod big A. Measure piston pin diameter here
end diameter, ALWAYS use the OLD con-
necting rod screws. PISTON PIN DIAMETER
1.3 Measure inside diameter in longitudinal di- 16.996 mm to 17.00 mm
NEW
rection of the connecting rod. (.6691 in to .6693 in)
SERVICE LIMIT 16.986 mm (.6687 in)

Replace the piston pin if it is out of specification.

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

Piston Inspection
Inspect piston for scoring, scuffing, cracks or
other damage. Replace piston and piston rings if
necessary.
Using a micrometer, measure piston perpendicu- 2 1
larly (90°) to piston pin axis at 8.5 mm (11/32 in)
from the skirt edge.

F00B09A

TYPICAL
1. Use the micrometer to set the cylinder bore gauge
2. Cylinder bore gauge

A
R400motr96A

TYPICAL
1. Measuring perpendicularly (90°) to piston pin axis
A. 8.5 mm (11/32 in)

PISTON MEASUREMENT
73.950 mm to 73.966 mm
NEW
(2.911 in to 2.912 in)
SERVICE LIMIT 73.92 mm (2.9102 in)

Replace piston if it is out of specification.

1
Piston/Cylinder Clearance
1. Adjust and lock a micrometer to the piston di- F00B0AA
mension.
TYPICAL
1. Indicator set to 0 (zero)
1
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
3. Position the cylinder bore gauge 35 mm
(1-3/8 in) below the cylinder head mating sur-
face, measuring perpendicularly (90°) to piston
pin axis.
4. Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder
F00B08A clearance.
TYPICAL PISTON/CYLINDER CLEARANCE
1. Micrometer set to the piston dimension
0.037 mm to 0.067 mm
NEW
NOTE: Make sure used piston is not worn. (.0015 in to .0026 in)
2. With the micrometer locked at step 1, adjust a SERVICE LIMIT 0.08 mm (.0031 in)
cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero). If clearance exceeds the specified tolerance, re-
place the piston and repeat the measurement pro-
cedure.

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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

Piston and Connecting Rod Assembly

For assembly, reverse the disassembly proce-
dure. Pay attention to the following details.
1. Apply engine oil on the piston pin.
2. Insert piston pin into piston and connecting rod.
NOTE: Ensure to reinstall all parts in their original
position as marked during removal.
3. Install NEW piston pin circlip(s).
mmr2011-075-029_a

REQUIRED TOOL 1. Circlip

2. Sleeve
PISTON CIRCLP 3. Installer handle
4. Distance sleeve
INSTALLER (P/N 529
036 207) 3.4 Remove distance sleeve and insert in-
staller handle into the sleeve.
NOTICE Always replace removed piston
pin circlips by NEW ones. 3.5 Insert the end of the handle into the piston
pin, then push to engage the circlip into
3.1 Place the circlip in the sleeve and push the piston groove.
piston circlip installer handle until circlip
reaches the mid position in the sleeve. 1

R1503motr28A

mmr2011-075-041_a
TYPICAL
TYPICAL 1. Sleeve with piston circlip inside
1. Circlip 2. Piston clip installer handle
2. Sleeve
3. Installer handle
NOTE: Take care that the hook of the piston
3.2 Put the distance sleeve on the installer pin circlip is positioned properly.
handle.
3.3 Push piston circlip installer handle until
distance sleeve makes contact with the
sleeve.

R400motr102A

CORRECT POSITION OF THE PISTON PIN CIRCLIP

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

NOTICE If piston pin circlip installation fails, – Cylinder bore

repeat step 3 by using a NEW circlip. – Connecting rod bearings.
4. Correctly install plain bearings and carefully 2. Slide piston into cylinder bore. Pay attention to
clean split surface on both sides (cracked area) the following.
with compressed air. REQUIRED TOOL
PISTON RING
COMPRESSOR
(P/N 529 036 208)
1

3
2

R1004motr20A
mmr2009-116-017

TYPICAL
1. Half bearing of connecting rod big end
2. Split surface of the connecting rod
3. Protrusion of bearing in line with connecting rod groove
NOTICE The arrow on top of the piston and
the punched marks on the connecting rods
must always point towards exhaust.
TYPICAL
2.1 If reused, install piston in its original bore.
2.2 Make sure piston rings are properly
spaced.
NOTICE The ring gaps of both compres-
sion rings should always be 180° from
each other and 90° from the arrow on top
of the piston.

mmr2011-075-042_a

1. Piston
2. Arrow on top
3. Connecting rod
4. Punched marks mmr2011-075-044_a

RING GAPS AT 180° FROM EACH OTHER AND 90° FORM

Piston and Connecting Rod Installation ARROW
1. Rectangular ring - ring gap
1. Use engine oil and lubricate: 2. Taper-face ring - ring gap
3. Arrow
– Piston
– Piston rings 2.3 The arrow on top of the piston must point
towards exhaust.
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Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

NOTICE Piston installed with the arrow in the CONNECTING ROD SCREWS
wrong direction would cause serious engine TIGHTENING SEQUENCE
damage.
12 N•m ± 0.2 N•m
FIRST STEP
(106 lbf•in ± 2 lbf•in)

7.2 Use a torque angle gauge to carry out the

second step.
CONNECTING ROD SCREWS
TIGHTENING SEQUENCE
SECOND
Additional 70° ± 5°
STEP

smr2014-021-037_a

1. Arrows
2. Exhaust

3. Turn cylinder block upside down.

4. Install CRANKSHAFT as per procedure in this
subsection.
5. Oil the crankshaft pin.
6. Install connecting rod caps.
NOTE: Printed marks on connecting rod and cap smr2014-021-038_a

must point together. 1. Torque angle gauge

NOTICE Failure to strictly follow this proce-

dure may cause screws to loosen and lead to
severe engine damage.
8. Install all other removed parts.

PISTON RINGS
Piston Ring Removal
1. Remove piston, see procedure in this subsec-
tion.
2. Remove rings from piston.

mmr2009-116-019_a
Piston Ring Inspection
TYPICAL
1. Printed marks Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston
NOTICE This assembly uses stretch screws. groove clearance.
Always use NEW screws and strictly adhere to
the tightening procedure.
7. Tighten connecting rod screws as follows:
7.1 Torque both connecting rod screws of a
connecting rod.

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 Subsection XX (CYLINDER BLOCK(WITHOUT REPLACEABLE PTO SLEEVE))

RING END GAP

UPPER COMPRESSION RING
0.20 mm to 0.35 mm
NEW
(.008 in to .014 in)
2 SERVICE LIMIT 1.2 mm (.047 in)
LOWER COMPRESSION RING
0.30 mm to 0.50 mm
NEW
(.012 in to .02 in)
SERVICE LIMIT 1.2 mm (.047 in)
OIL SCRAPER RING
R1503motr32A 1 0.20 mm to 0.70 mm
NEW
TYPICAL (.0079 in to .0276 in)
1. Piston
2. Feeler gauge SERVICE LIMIT 1.2 mm (.047 in)

RING/PISTON GROOVE CLEARANCE If ring end gap is out of specification, replace pis-
UPPER COMPRESSION RING ton rings.

NEW
0.030 mm to 0.066 mm Piston Ring Installation
(.0012 in to .0026 in)
1. Install piston rings in the following order.
SERVICE LIMIT 0.12 mm (.0047 in)
NOTE: Use a ring expander to prevent break-
LOWER COMPRESSION RING age during installation. The oil ring must be
0.020 mm to 0.056 mm
installed by hand.
NEW
(.0008 in to .0022 in) 1.1 Install oil scraper ring.
SERVICE LIMIT 0.12 mm (.0047 in) 1.2 Install the lower compression ring with the
letter “N” facing up.
OIL SCRAPER RING
1.3 Install upper compression ring with the let-
0.010 mm to 0.040 mm ter “N” facing up.
NEW
(.0004 in to .0016 in)
SERVICE LIMIT 0.15 mm (.0059 in)

If clearance is out of specification, the piston and

rings should be replaced.
Ring End Gap
1. Place piston ring in the cylinder bore between
8 mm to 16 mm (5/16 in to 5/8 in) from the top
of cylinder.
NOTE: In order to correctly position the ring in the
cylinder bore, use a piston as a pusher.
2. Using a feeler gauge, check ring end gap. mmr2011-075-046_a

1. Rectangular ring
2. Taper-face ring
3. Oil scraper ring
4. Letter “N” facing up

NOTICE Ensure that upper and lower

compression rings are not interchanged.
2. Check that rings rotate smoothly after installa-
tion.

smr2016-115
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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

CYLINDER BLOCK (130, 155 AND 230

ENGINES)
SERVICE TOOLS
Description Part Number Page
CRANKSHAFT LOCKING TOOL .................................................... 529 035 821 ............................... 12, 15, 23
PISTON CIRCLIP INSTALLER........................................................ 529 035 765 ............................................. 9

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON PISTON RING COMPRESSOR PLIERS ....................... RC980 ............................................. 9

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 22
LOCTITE 5910 ............................................................................... 293 800 081 ........................................... 21
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 19

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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

Loctite 243
23 ± 3 N•m
(17 ± 2 lbf•ft)
23 ± 3 N•m
(17 ± 2 lbf•ft)
Loctite 243
Loctite 243
28 ± 3 N•m
(21 ± 2 lbf•ft)
17 ± 2 N•m
(150 ± 18 lbf•in)
Engine oil

NEW

Engine oil
See ELECTRONIC FUEL
INJECTION (EFI)
Loctite 243 Loctite 243
23 ± 3 N•m 28 ± 3 N•m
(17 ± 2 lbf•ft) (21 ± 2 lbf•ft)

Loctite 243 NEW

9 ± 1 N•m
(80 ± 9 lbf•in) Loctite 5910

Loctite 243
23 ± 3 N•m
(17 ± 2 lbf•ft)

See tightening procedure 30 ± 3 N•m

(22 ± 2 lbf•ft)
See tightening sequence
23 ± 3 N•m
(17 ± 2 lbf•ft)
Loctite 243 NEW

NEW = Component must be replaced when removed.

smr2016-018-001_a

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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

Engine oil

NEW

NEW
Engine oil

Engine oil

Engine oil

Engine oil

Engine oil
Engine oil
See tightening
procedure
NEW
Engine oil

Engine oil

Engine oil
Engine oil
Engine oil

Engine oil
Engine oil

NEW = Component must be replaced when removed.

smr2016-018-002_b

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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

GENERAL 2. Piston/cylinder wall clearance out of specifica-

tion
When disassembling parts that are duplicated in - Check piston/cylinder wall clearance.
the engine, (e.g.: pistons, connecting rods etc.),
- Replace if out of specification.
it is strongly recommended to note their position
and to keep them as a “group”. If you find a 3. Melted or broken piston
defective component, it will be much easier to - Check if oil spray nozzle is not clogged. Refer to
find the cause of the failure. Since parts were LUBRICATION SYSTEM subsection.
break-in together during the engine operation, - Replace piston and cylinder block if necessary.
they will keep their matched fit when parts are
reassemble together within their “group”.
PROCEDURES
TROUBLESHOOTING TIMING CHAIN
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and Inspecting the Timing Chain
it should not be assumed to list all possible prob- Check timing chain on camshaft gear for exces-
lems. sive radial play.
Always check for fault codes. If a fault code is de- Check chain condition for wear and rollers condi-
tected, service the fault code first. Refer to DIAG- tion.
NOSTIC AND FAULT CODES subsection.
UNUSUAL ENGINE NOISE OR
VIBRATIONS
1. Heavy wear on plain bearings
- Check radial play of plain bearings.
- Replace plain bearings if out of specification. R610motr201A 1
2. Crankshaft and balancer shaft are not properly 1. Timing chain
aligned
If chain is excessively worn or damaged, replace
- Disassemble cylinder block and check if marks
are properly aligned. it as a set (camshaft timing gear and timing chain).

3. Crankshaft or balancer shaft axial play out of
specification
- Measure crankshaft and balancer shaft axial play.
- If axial play is out of specification, replace thrust
washers.
4. Connecting rod axial play out of specification
- Measure connecting rod axial play on crankshaft.
- Replace connecting rod or crankshaft if out of
specification.
5. Connecting rod screws got loose
- Replace damaged components and retighten
screws with the recommended torque.
BLUE SMOKE IN THE EXHAUST
1. Oil scrapper rings worn out
- Replace piston rings.
ENGINE SUDDENLY TURNS OFF (POOR
IDLING)
1. Piston rings worn out
- Replace piston rings.
Removing the Timing Chain
Remove:
– Engine from vehicle (refer to ENGINE RE-
MOVAL AND INSTALLATION subsection)
– Cylinder head (refer to CYLINDER HEAD sub-
section)
– PTO housing (refer to PTO HOUSING, MAG-
NETO AND STARTER subsection)
– Crankshaft (refer to CRANKSHAFT in this sub-
section)
– Timing chain.
Installing the Timing Chain
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
details.
Ensure to perform proper valve timing.
NOTICE Improper valve timing will damage
engine components.

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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

Lock crankshaft and camshaft at TDC (refer to Tighten the chain tensioner plug screw to specifi-
CYLINDER HEAD subsection for the camshaft cation.
locking procedure).
TIGHTENING TORQUE
Install chain, then install chain tensioner.
Chain tensioner plug 17 N•m ± 2 N•m
screw (150 lbf•in ± 18 lbf•in)
CHAIN TENSIONER
Chain Tensioner Access PISTONS AND CONNECTING
Removal of the intake manifold allows easier ac- RODS
cess to the chain tensioner, but is not necessary.
Refer to INTAKE MANIFOLD subsection. Removing Piston and Connecting Rod
1. Disassemble CYLINDER BLOCK as per proce-
Removing the Chain Tensioner dure in this subsection.
Lock crankshaft, refer to CRANKSHAFT LOCKING NOTE: It is recommended to measure connect-
PROCEDURE in this subsection. ing rod big end axial play prior to remove connect-
Remove the chain tensioner. ing rod. Refer to INSPECTING THE CONNECTING
ROD below.
2. Remove the connecting rod caps.

smr2016-018-003_a

1. Plug screw
2. Gasket ring (discard)
3. Chain tensioner R1503motr08A

1. Connecting rod screws

Inspecting the Chain Tensioner
Check chain tensioner for: NOTE: Before removing the connecting rod caps,
– excessive wear mark them to remember the right position when
reassembling.
– cracks
– free movement of the chain tensioner piston.

Installing the Chain Tensioner

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
details.
Install plug screw with a NEW gasket ring.
NOTICE This engine uses gasket ring with
specific thickness. Using any other gasket ring
may cause severe engine damage.
GASKET RING THICKNESS
1.5 mm (.06 in)

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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

1 2 3

R1503motr07A 1 R1503motr27A

1. Connecting rod mark
3. Pull piston with connecting rod out of the cylin-
ders.
4. Remove one piston circlip and discard it.
TYPICAL
1. Piston
2. Piston pin
3. Circlip
6. Detach piston from connecting rod.
Inspecting the Connecting Rod
Connecting Rod Big End Axial Play
Using a feeler gauge, measure distance between
butting face of connecting rod and crankshaft
counterweight. If the distance exceeds specified
tolerance, replace the worn part.

1 2

smr2016-018-004

TYPICAL
1. Piston circlip

5. Push piston pin out of piston.

R1503motr12A

1. Crankshaft
2. Feeler gauge

CONNECTING ROD BIG END AXIAL PLAY

0.100 mm to 0.352 mm
New
(.0039 in to .0139 in)
Service limit 0.500 mm (.0197 in)

Connecting Rod Small End Radial Play

Measure connecting rod small end.

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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

CONNECTING ROD BIG END DIAMETER

Service limit 45.080 mm (1.7748 in)

CONNECTING ROD BIG END

RADIAL PLAY
Service limit 0.09 mm (.0035 in)

2 1 Use NEW bearings, when connecting rod big end

diameter is out of specification.

Inspecting the Piston Pin

R1004motr11A Using synthetic abrasive woven, clean piston pin
1. Bore gauge from deposits.
2. Connecting rod
Inspect piston pin for scoring, cracking or other
CONNECTING ROD SMALL END DIAMETER damages.
23.01 mm to 23.02 mm Measure piston pin. See the following illustration
New for the proper measurement position.
(.9059 in to .9063 in)
Service limit 23.07 mm (.9083 in)

If the connecting rod small end diameter is out of

specification, replace the connecting rod.
Measure piston pins, refer to INSPECTING THE
PISTON PIN in this subsection. Compare to inside
diameter of connecting rod to obtain connecting
rod small end radial play.
R400motr30A A
CONNECTING ROD SMALL END RADIAL PLAY
A. Piston pin diameter here
Service limit 0.080 mm (.0031 in)
PISTON PIN DIAMETER
Connecting Rod Big End Radial Play
22.996 mm to 23.000 mm
Measure inside diameter of connecting rod big New
(.9054 in to .9055 in)
end. Compare to crankshaft pin.
Service limit 22.990 mm (.9051 in)
To measure the connecting rod big end diameter,
use the OLD screws. Measure connecting rod small end diameter, refer
Install the OLD bearings as they were mounted to CONNECTING RODS INSPECTION in this sub-
initially. section to check connecting rod small end radial
play.
Tighten connecting rod screws, refer to IN-
STALLING THE PISTON AND CONNECTING Inspecting the Piston
ROD in this subsection.
Inspect piston for scoring, cracking or other dam-
ages. Replace piston and piston rings if neces-
sary.
Using a micrometer, measure piston at 5 mm
(.197 in) perpendicularly (90°) to piston pin axis.

vmr2006-044-039_a

A. Connecting rod big end bearing

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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

2 1

A
R400motr96A

TYPICAL
1. Measuring perpendicularly (90°) to piston pin axis
A. 5 mm (.197 in)
F00B09A
The measured dimension should be as described
in the subsequent table. If not, replace piston. 1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
ENGINE
PISTON MEASUREMENT
TYPE
99.951 mm to 99.969 mm
New
130 and (3.9351 in to 3.9358 in)
155 Service
99.900 mm (3.9331 in)
limit
99.931 mm to 99.949 mm
New
(3.9343 in to 3.935 in)
230
Service
99.900 mm (3.9331 in)
limit

Piston/Cylinder Wall Clearance 1

Adjust and lock a micrometer to the piston dimen-
sion. F00B0AA

1. Indicator set to 0 (zero)

1
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Position the dial bore gauge 62 mm (2.44 in) above
cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
F00B08A
ENGINE
PISTON/CYLINDER CLEARANCE
1. Micrometer set to the piston dimension TYPE

NOTE: Make sure used piston is not worn. 0.024 mm to 0.056 mm

130 and New
(.0009 in to .0022 in)
With the micrometer set to the dimension, adjust 155
a cylinder bore gauge to the micrometer dimen- Service limit 0.100 mm (.0039 in)
sion and set the indicator to 0 (zero). 0.044 mm to 0.076 mm
New
230 (.0017 in to .003 in)
Service limit 0.100 mm (.0039 in)

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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

If clearance exceeds specified tolerance, replace

cylinder block and pistons.

Piston and Connecting Rod Assembly

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following
details.
1. Apply engine oil on the piston pin.
2. Insert piston pin into piston and connecting rod.
NOTE: Be sure to reinstall all parts in their original
position as marked during removal.
3. Install NEW piston circlip.
smr2016-018-004_a
REQUIRED TOOL TYPICAL - CORRECT POSITION OF THE PISTON CIRCLIP
PISTON CIRCLIP INSTALLER
(P/N 529 035 765) Installing the Piston and Connecting
Rod
NOTICE Always replace removed piston pin 1. Use engine oil and lubricate:
circlips by NEW ones. – Piston
– Piston rings
1 – Band of the piston ring compressor tool
– Connecting rod bearings.
– Cylinder bore
2
2. Slide piston into cylinder.
RECOMMENDED TOOL
SNAP-ON PISTON RING COMPRESSOR PLIERS
(P/N RC980)

R1503motr28A

TYPICAL
1. Sleeve with piston circlip inside
2. Assembly jig from piston clip installer

NOTICE If piston pin circlip installation fails,

repeat step 3 by using a NEW circlip.
NOTE: Ensure that hook of the piston circlip is po-
sitioned properly.

smr2016-018-005

TYPICAL

NOTICE Install piston with punched arrow to-

ward exhaust side.

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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

smr2016-018-006_a

TYPICAL
1. Arrows toward exhaust side R1503motr31A

3. Correctly install bearings and carefully clean 1. Angle torque wrench

split surface on both sides (cracked area).
PISTON RINGS
Removing the Piston Ring
1 Remove piston, see procedure in this subsection.
Remove piston rings.
3 Inspecting the Piston Ring Inspection
2
Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston
groove clearance. If the clearance is too large, the
piston and the piston rings should be replaced.
ENGINE GROOVE CLEARANCE -
TYPE RECTANGULAR
0.025 mm to 0.070 mm
New
(.001 in to .0028 in)
R1004motr20A All
Service
TYPICAL 0.150 mm (.0059 in)
1. Half bearing of connecting rod big end limit
2. Split surface of the connecting rod
3. Protrusion of bearing in line with connecting rod groove ENGINE GROOVE CLEARANCE -
TYPE TAPER-FACE
4. Tighten NEW connecting rod screws as per fol-
lowing procedure: New
0.015 mm to 0.060 mm
(.0006 in to .0024 in)
NOTICE This assembly uses stretch screws. All
Always use NEW screws and strictly adhere to Service
0.150 mm (.0059 in)
the tightening procedure. limit

NOTICE All connecting rod screws must be

torque FIRST according to step A before per-
forming the step B.
TIGHTENING PROCEDURE
45 N•m ± 3 N•m
Connecting rod Step A
(33 lbf•ft ± 2 lbf•ft)
screws
Step B Additional 90° ± 5°

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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

ENGINE GROOVE CLEARANCE - OIL Using a feeler gauge, check ring end gap. Replace
TYPE SCRAPER RING ring if gap exceeds service limit.
0.020 mm to 0.055 mm Installing the Piston Ring
New
130 and (.0008 in to .0022 in)
155 The installation is the reverse of the removal pro-
Service cedure. However, pay attention to the following
0.150 mm (.0059 in)
limit details.
0.010 mm to 0.180 mm Install rings in the following order and layout:
New
(.0004 in to .0071 in)
230 PISTON RING INSTALLATION
Service
0.200 mm (.0079 in)
limit ORDER RING POSITION
FIRST STEP Oil scraper ring equal
SECOND Stamped "E" and
Taper-face ring
STEP "TOP" facing UP
Rectangular Stamped "E" and
THIRD STEP
ring "TOP" facing UP

R1503motr32A 1
TYPICAL
1. Piston
2. Filler gauge

Ring End Gap

RING END GAP - RECTANGULAR
0.30 mm to 0.50 mm smr2016-018-007_a
New
(.012 in to .02 in) TYPICAL
1. Rectangular ring
Service limit 1.20 mm (.047 in) 2. Taper-face ring
3. Oil scraper ring
RING END GAP - TAPER-FACE NOTICE Ensure that top and second rings are
New
0.35 mm to 0.55 mm not interchanged.
(.014 in to .022 in)
NOTE: Use a ring expander to prevent breakage
Service limit 1.20 mm (.047 in) during installation. The oil ring must be installed
by hand.
RING END GAP - OIL SCRAPER RING
Check that rings rotate smoothly after installation.
0.35 mm to 0.50 mm
New Space the piston ring end gaps 120° apart and do
(.014 in to .02 in)
not align the gaps with the piston pin bore or the
Service limit 1.20 mm (.047 in) thrust side axis.
Measure position for ring end gap in the area
of 8 mm to 16 mm (.315 in to .63 in) from top of
cylinder.
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.

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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

Turn engine counterclockwise.

A
Bring piston of cylinder 3 to ignition TDC, using a
A A dial gauge or another similarly suitable tool.
NOTICE Do not scratch or damage piston and
cylinder surface.

A31C2OA

TYPICAL
1. DO NOT align ring gap with piston trust side axis
2. DO NOT align ring gap with piston pin bore axis
A. 120°
smr2016-018-009_a

CRANKSHAFT 1. Dial gauge

Crankshaft Locking Procedure NOTE: When the piston of cylinder 3 is at ignition

TDC, the position lines on oil separator cover must
NOTICE The crankshaft must be locked at be lined up as shown in the following illustration.
TDC for removal and installation of crankshaft,
balancer shaft and camshaft.
NOTE: When the crankshaft is locked, the piston
of cylinder 3 is at ignition TDC.
Remove:
– Intake manifold (refer to INTAKE MANIFOLD
subsection)
– Spark plugs
– Valve cover (refer to CYLINDER HEAD subsec-
tion
– Crankshaft access plug screw.

smr2016-017-016_a

1. Position lines
2. Oil separator cover

Use a small screwdriver to check if the groove in

the crankshaft is aligned with the hole.
In this position, lock the crankshaft.
REQUIRED TOOL
CRANKSHAFT LOCKING TOOL
(P/N 529 035 821)

smr2016-018-008_a

TYPICAL
1. Crankshaft access plug screw
2. Gasket ring

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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

smr2016-018-013_a

1. Crankshaft locking tool R1503motr10A

After removing the crankshaft locking tool install 1. Crankshaft

plug screw with a NEW gasket ring.
Inspecting the Crankshaft
TIGHTENING TORQUE
Inspecting the Crankshaft Gear
17 N•m ± 2 N•m
Plug screw Replace crankshaft if the gears are worn or other-
(150 lbf•in ± 18 lbf•in)
wise damaged.
Removing the Crankshaft
2
1. Disassemble CYLINDER BLOCK as per proce-
dure described in this subsection.
2. Remove connecting rod screws. Refer to PIS-
TONS AND CONNECTING RODS in this sub-
section.
3. Remove thrust washers.

1
R1503motr11A

1. Balancer gear
2. Crankshaft timing gear
1
Crankshaft Radial Play
Measure all crankshaft journals. Compare to
inside diameter of crankshaft bearings, refer to
CYLINDER BLOCK in this subsection.

R1503motr09A

1. Thrust washer

4. Remove crankshaft.

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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

CRANKSHAFT PIN RADIAL CLEARANCE

Service limit 0.090 mm (.0035 in)

Crankshaft Axial Clearance

When assembling the cylinder-block, measure the
crankshaft axial clearance.

smr2016-018-010_a

1. Micrometer
2. Crankshaft area for bearing

CRANKSHAFT JOURNAL DIAMETER

49.991 mm to 50.010 mm
New
(1.9681 in to 1.9689 in)
Service limit 49.950 mm (1.9665 in) smr2016-018-012_a

TYPICAL
CRANKSHAFT JOURNAL RADIAL CLEARANCE 1. Dial gauge
2. Crankshaft
Service limit 0.07 mm (.0028 in)
CRANKSHAFT AXIAL CLEARANCE
Crankshaft Pin 0.08 mm to 0.22 mm
New
Measure all crankshaft pin diameters. Compare (.003 in to .009 in)
to inside diameter of connecting rod bearings, re- Service limit 0.35 mm (.014 in)
fer to PISTONS AND CONNECTING RODS in this
subsection.
Installing the Crankshaft
The installation is the reverse of the removal pro-
cedure. However, pay attention to following de-
tails.
NOTE: Be careful that connecting rods do not hit
the cylinder block.
NOTICE Before installing the crankshaft, en-
sure that:
– chain guide is already installed
– timing chain is installed on crankshaft timing
gear.
Those parts cannot be installed when the
crankshaft is in place.
smr2016-018-011_a
Install crankshaft with the timing chain.
1. Micrometer
2. Crankshaft pin area for bearing NOTICE Crankshaft and balancer shaft marks
CRANKSHAFT PIN DIAMETER must be aligned.

45.032 mm to 45.048 mm
New
(1.7729 in to 1.7735 in)
Service limit 45.029 mm (1.7728 in)

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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

R1503motr17A 1 2 R1503motr16A

1. Mark on balancer shaft 1. Thrust washer

2. Mark on crankshaft 2. Sealing surface

Install connecting rod caps, refer to PISTONS Install cylinder block lower half. Refer to CYLIN-
AND CONNECTING RODS in this subsection. DER BLOCK in this subsection.
NOTICE It is absolutely necessary to follow Lock crankshaft at TDC before installing the
this procedure. Otherwise severe engine dam- camshaft and the rocker arms (refer to CYLIN-
age can occur. DER HEAD subsection).
Insert thrust washers as soon as crankshaft is in REQUIRED TOOL
place as per following illustration. CRANKSHAFT LOCKING TOOL
(P/N 529 035 821)

R1503motr09A

THRUST WASHER INSERT DIRECTION smr2016-018-013_a

1. Thrust washer
1. Crankshaft locking tool
NOTICE Thrust washers have to be flush with
the cylinder block sealing surface. BALANCER SHAFT
Removing the Balancer Shaft
1. Disassemble CYLINDER BLOCK, see proce-
dure in this subsection.
2. Remove thrust washers.

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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

1 BALANCER SHAFT JOURNAL DIAMETER

31.984 mm to 32.000 mm
New
(1.2592 in to 1.2598 in)
Service limit 31.950 mm (1.2579 in)

BALANCER SHAFT JOURNAL RADIAL

CLEARANCE
Service limit 0.070 mm (.0028 in)

Balancer Shaft Axial Clearance

When assembling the cylinder-block, measure the
balance shaft axial play.

R1503motr20A

1. Thrust washer

3. Remove balancer shaft.

Inspecting the Balancer Shaft

Check balancer shaft and replace if damaged.
If the gear on the balancer shaft is damaged, re-
place balancer shaft.
Check gear on the crankshaft at the same time
and replace crankshaft if necessary (refer to
CRANKSHAFT in this subsection).
smr2016-018-015_a

Balancer Shaft Bearing Seat Play 1. Dial gauge

2. Balancer shaft
Measure all balancer shaft bearing journals. Com-
pare to inside diameter of balancer shaft bearings BALANCER SHAFT AXIAL CLEARANCE
(see INSPECTING THE CYLINDER BLOCK in this 0.02 mm to 0.25 mm
subsection). New
(.001 in to .01 in)
Service limit 0.35 mm (.014 in)

Installing the Balancer Shaft

The installation is the reverse of the removal pro-
cedure. However, pay attention to following de-
tails.
NOTICE Balancer shaft and crankshaft marks
have to be aligned.

smr2016-018-014_a

1. Micrometer
2. Balancer shaft area for bearing

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 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

R1503motr17A 1 2 R1503motr22A

1. Mark on balancer shaft 1. Thrust washer

2. Mark on crankshaft 2. Sealing surface

Install thrust washers in place as per following il- Install cylinder block lower half. Refer to CYLIN-
lustration. DER BLOCK in this subsection.
Reassemble engine in accordance with the proper
1 assembly procedures.

CYLINDER BLOCK
Disassembling the Cylinder Block
Refer to PTO HOUSING, MAGNETO AND
STARTER subsection and remove:
– PTO housing
– Starter gear
– Starter drive.
Remove engine mounting brackets.
Refer to LUBRICATION SYSTEM subsection and
remove oil suction pump.
R1503motr20B

THRUST WASHER INSERT DIRECTION

1. Thrust washer

NOTICE Thrust washers must be flush with

the cylinder block sealing surface.

smr2016-018-016_a

TYPICAL
1. Retaining screws
2. Engine mounting bracket

RTX1503ACEMY18-007
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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

RTX1503ACEMY18-007-001_a

TYPICAL smr2016-018-019_a
1. Retaining screws
2. Hose bracket TYPICAL
3. Engine mounting bracket 1. M8 screws
2. M10 screws
Refer to CYLINDER HEAD subsection and re- Carefully remove cylinder block lower half by us-
move cylinder head. ing a soft hammer.
NOTE: Before splitting the cylinder block, mea- NOTE: Take care not to damage the sealing sur-
sure crankshaft axial play. Refer to CRANKSHAFT faces of the cylinder block halves.
in this subsection.
Remove oil reservoir plug screws with O-rings.

smr2016-018-020

TYPICAL
smr2016-018-018_a

TYPICAL Remove crankshaft cover with O-ring.

1. Oil reservoir plug screw
2. O-ring

Remove cylinder block screws:

1. Start removing the M8 screws.
2. Then remove the M10 screws.

18 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-007
 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

Clean all metal components in a solvent.

Cylinder block mating surfaces are best cleaned
using a combination of the LOCTITE CHISEL (GAS-
KET REMOVER) (P/N 413 708 500) and a brass brush.
Brush a first pass in one direction then make the fi-
nal brushing perpendicularly (90°) to the first pass
(cross hatch).
NOTICE Do not wipe with rags. Use a new
clean hand towel only.

Inspecting the Cylinder Block

Cylinder Block and Cylinder Bores
smr2016-018-021_a

1. Crankshaft cover Check cylinder block for cracks or other damage.

2. O-ring
Check cylinder block mating surfaces for flatness
Refer to procedures in this subsection and re- using a straight edge.
move: Check cylinder bores for cracks, scoring and wear
– Balancer shaft ridges on the top and bottom of the cylinder.
– Crankshaft Replace cylinder block if necessary.
– Piston with connecting rod. Cylinder Taper
Removing the Plain Bearings Measure cylinder bore and if it is out of specifica-
When the plain bearings of crankshaft and bal- tions.
ancer shaft need to be removed from the cylinder Measure cylinder bore at 3 recommended posi-
block, mark them to identify the correct position tions. See the following illustration.
at installation. See the following illustration for an
example:

RTX1503ACEMY18-007-002_a

TYPICAL
1. First measuring diameter
2. Second measuring diameter
3. Third measuring diameter
A. 5 mm (.2 in)
B. 62 mm (2.44 in)
C. 115 mm (4.53 in)
R1503motr37A 2
TYPICAL
CYLINDER TAPER IN DIAMETER
1. Marks on balancer shaft bearings
2. Marks on crankshaft bearings New maximum 0.036 mm (.0014 in)
Service limit 0.100 mm (.0039 in)
Cleaning the Cylinder Block
Clean cylinder block using a part cleaner, then use If a cylinder bore is out of specification, please re-
compressed air to dry it. place cylinder block assembly.
Blow out the oil orifices using compressed air and
make sure they are not clogged.
RTX1503ACEMY18-007
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Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

Cylinder Out of Round

Measure cylinder diameter in piston axis direction
from top of cylinder. Take an other measurement
90° from first one and compare.
NOTE: Take the same measuring points as de-
scribed in CYLINDER TAPER. 1

B
R1503motr33A

ENGINE UPSIDE DOWN

1. Bore gauge

CRANKSHAFT BEARING INSIDE DIAMETER

Service limit 50.10 mm (1.9724 in)
R1503motr25A

TYPICAL
A. Perpendicular to crankshaft axis
B. Parallel to crankshaft axis

CYLINDER OUT OF ROUND

New maximum 0.008 mm (.0003 in)
Service limit 0.025 mm (.001 in)

Bearings
Measure plain bearing inside diameter and com-
pare with crankshaft bearing journal diameter (re-
fer to CRANKSHAFT in this subsection). Proceed
as follows:
– Use the OLD plain bearings and put both cylin-
der block halves together. R1503motr34A 1
– Tighten screws as described in ASSEMBLING
ENGINE UPSIDE DOWN
THE CYLINDER BLOCK. 1. Bore gauge
– Measure the inside diameter of the crankshaft
plain bearings using a bore gauge BALANCER SHAFT BEARING INSIDE DIAMETER
Service limit 32.11 mm (1.2642 in)

Replace plain bearings if they are out of specifica-

tions.

Assembling the Cylinder Block

The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow-
ing details.
Install the following components:
– Piston oil nozzles, refer to LUBRICATION SYS-
TEM subsection

20 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-007
 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))
– Oil cooler, refer to LUBRICATION SYSTEM sub-
section
– Electric starter, refer to PTO HOUSING, MAG-
NETO AND STARTER subsection
– Chain tensioner guide.
If OLD bearings will be used again, reinstall them
at the same position as they were before.
Correctly install bearings. Top crankshaft bearing
halves have a bore which has to be placed in the
upper cylinder block.
1 2
3 CYLINDER BLOCK SEALANT
R1503motr35A
1. Cylinder block upper half
2. Oil bore in cylinder block
3. Oil bore in bearing
Bearings have to be flush with the cylinder block
split surface and their protrusions have to fit in the
notched areas in the cylinder block seat.
R1503motr36A
1. Bearing protrusion in cylinder block notch
Apply engine oil on all plain bearings.
RTX1503ACEMY18-007
https://brp-manuals.com/pwc_seadoo
For proper installation of pistons, refer to PIS-
TONS AND CONNECTING RODS in this subsec-
tion.
NOTICE Before installing the crankshaft, en-
sure that:
– chain guide is already installed
– timing chain is installed on crankshaft timing
gear.
Those parts cannot be installed after as the
crankshaft is in place.
IMPORTANT: When beginning the application of
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is
suggested to have all you need on hand to save
time.
Apply sealant on mating surfaces.
LOCTITE 5910 (P/N 293
Service product
800 081)
REQUIRED TOOL
Plexiglas plate
Soft rubber roller
Apply some sealant on the plate and get a thin
uniform coat (spread as necessary).
Then apply the sealant on cylinder block lower half
sealing surface.
F12R17A
NOTE: If you do not use the roller method, you
may use your finger to uniformly distribute this
sealant.
Do not apply in excess as it will spread out inside
crankcase.
21
Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

Tighten M10 cylinder block screws as per follow- TIGHTENING TORQUE

ing sequence.
M8 cylinder block 30 N•m ± 3 N•m
screws (22 lbf•ft ± 2 lbf•ft)

NOTE: Check axial clearance of balancer shaft

and crankshaft before continuing the assembly.
Refer to CRANKSHAFT and BALANCER SHAFT
in this subsection for the procedure.
Install oil reservoir plug screws with O-rings.

smr2016-018-019_b

TYPICAL - M10 SCREWS TIGHTENING SEQUENCE

NOTICE All M10 cylinder block screws must

be torque FIRST according to step A before per-
forming to step B.
TIGHTENING PROCEDURE smr2016-018-018_a

TYPICAL
40 N•m ± 3 N•m 1. Oil reservoir plug screw
(30 lbf•ft ± 2 lbf•ft) 2. O-ring
+
Step A TIGHTENING TORQUE
M10 cylinder LOCTITE 243
block screws (BLUE) (P/N 293 23 N•m ± 3 N•m
800 060) (17 lbf•ft ± 2 lbf•ft)
55 N•m ± 4 N•m Oil reservoir plug screw +
Step B LOCTITE 243 (BLUE)
(41 lbf•ft ± 3 lbf•ft)
(P/N 293 800 060)
Tighten M8 cylinder block screws as per following
sequence. Apply engine oil on O-ring and press in crankshaft
cover.

smr2016-018-021_b
smr2016-018-019_c
1. O-ring
TYPICAL - M8 SCREWS TIGHTENING SEQUENCE 2. Crankshaft cover

22 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-007
 Subsection XX (CYLINDER BLOCK (130, 155 AND 230 ENGINES))

Position crankshaft at TDC before installing the

camshaft and the rocker arms (refer to CYLINDER
HEAD subsection).
REQUIRED TOOL
CRANKSHAFT LOCKING TOOL
(P/N 529 035 821)

smr2016-018-013_a

1. Crankshaft locking tool

Reassemble engine in accordance with the proper

assembly procedures.

RTX1503ACEMY18-007
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 Subsection XX (SUPERCHARGER)

SUPERCHARGER
SERVICE TOOLS
Description Part Number Page
CAMSHAFT LOCKING TOOL........................................................ 529 035 839 ............................................. 3
SUPERCHARGER GEAR HOLDER................................................ 529 036 025 ............................................. 4
SUPPORT PLATE........................................................................... 529 035 947 ......................................... 4, 6
TORX ADAPTER............................................................................ 529 035 938 ......................................... 6, 8

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 7–8
LOCTITE 5910 ............................................................................... 293 800 081 ............................................. 7
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ............................................. 7
TRIPLE-GUARD GREASE .............................................................. 296 000 329 ............................................. 8

RTX1503ACEMY18-008
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Subsection XX (SUPERCHARGER)

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243

Loctite 5910

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243

Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in)
Super Lube
grease

NEW = Component must be replaced when removed.

R1503_MY17-008-001_b

2 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-008
 Subsection XX (SUPERCHARGER)

INSPECTION TESTING THE SLIPPING

MOMENT OF THE CLUTCH
SUPERCHARGER INLET (ON ENGINE)
CLEANLINESS Remove:
A lower than usual maximum RPM at full throttle – Spark plugs, refer to IGNITION COILS AND
might be caused by a dirty supercharger inlet. SPARK PLUGS subsection
Visually inspect supercharger inlet side for oil, salt – Valve cover, refer to CYLINDER HEAD subsec-
or any other deposits. tion.
Turn engine by rotating the supercharger nut
counterclockwise until the position lines on oil
separator cover are lined up as shown in the
following illustration.
Lock camshaft.
REQUIRED TOOL
CAMSHAFT LOCKING TOOL
(P/N 529 035 839)

smr2006-012-010_a

1. Dirt here

If dirt is found, proceed as follows.

smr2009-025-007_a
1. Remove supercharger. 1. Camshaft locking tool
2. Position lines
2. Separate supercharger housing.
3. Clean internal housing and turbine using a brass Check slipping moment counterclockwise.
brush and cleaning solvent to get rid of oil de-
REQUIRED TOOLS
posits.
Torque wrench with actual torque viewer
4. Blow dry with compressed air.
A mirror is useful to see the viewer
NOTICE Do not let impeller spin when using
compressed air.
5. Complete usual assembly procedures as de-
scribed in this subsection.

RTX1503ACEMY18-008
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Subsection XX (SUPERCHARGER)

smr2009-020-004_a

1. Torque wrench
smr2006-074-101

NOTE: Before checking the supercharger slipping Check slipping moment counterclockwise.
moment, turn the clutch for a minimum of 3 com-
plete revolutions. This will dissipate grease or oil REQUIRED TOOL
on the friction shims for a precise reading. Torque wrench with actual torque viewer
Supercharger should start to turn at a torque
within the specified values.
SLIPPING MOMENT
9 N•m to 14 N•m
New supercharger
(80 lbf•in to 124 lbf•in)
8 N•m to 12 N•m
Break-in supercharger
(71 lbf•in to 106 lbf•in)

If the torque is not within specifications, remove

supercharger from the engine and repeat super-
charger clutch slipping moment test on the bench.

TESTING THE SLIPPING smr2006-074-100_a

MOMENT OF THE CLUTCH 1. Torque wrench

2. Supercharger gear holder
(BENCH TEST)
Mount supercharger on support plate. NOTE: Before checking the supercharger slipping
moment, turn the clutch for a minimum of 3 com-
Hold supercharger gear. plete revolutions. This will dissipate grease or oil
REQUIRED TOOLS on the friction shims for a proper reading.
Supercharger should start to turn at a torque
SUPPORT PLATE within the specified values.
(P/N 529 035 947)
SLIPPING MOMENT
SUPERCHARGER GEAR HOLDER 9 N•m to 14 N•m
(P/N 529 036 025) New supercharger
(80 lbf•in to 124 lbf•in)
8 N•m to 12 N•m
Break-in supercharger
(71 lbf•in to 106 lbf•in)

If the torque is not within specification, replace su-

percharger assembly.

4 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-008
 Subsection XX (SUPERCHARGER)

TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
it should not be assumed to list all possible prob-
lems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES subsection.
ENGINE WILL NOT START (ENGINE DOES smr2009-020-012_a

NOT TURN OVER) 1. Air inlet hose

2. Hose clamp
1. Supercharger seized or obstructed
- Inspect and replace supercharger assembly, if
necessary
- Inspect supercharger oil spray nozzle, refer to LU-
BRICATION SYSTEM subsection.

ENGINE LACKS ACCELERATION OR

POWER (DOES NOT REACH MAXIMUM
RPM)
1. Supercharger inlet is dirty
- Check and clean supercharger inlet.
- Check engine oil. Siphon excess of oil.
smr2009-020-013_a
2. Supercharger slipping clutch defective 1. Air outlet hose
- Check slipping clutch moment. 2. Hose clamp

- Replace supercharger assembly if out of specifi- Unscrew blow-by valve screws and move it aside
cation.
to make room.
PROCEDURES
SUPERCHARGER OIL SPRAY
NOZZLE
Refer to LUBRICATION SYSTEM subsection.

SUPERCHARGER
Removing the Supercharger
Remove air inlet and outlet hoses from super-
charger.
smr2008-012-010_a

1. Blow-by valve
2. Supercharger

Using a marker, trace a mark on rubber adapter

and exhaust pipe.

RTX1503ACEMY18-008
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Subsection XX (SUPERCHARGER)

smr2008-012-011_a

1. Rubber adapter
2. Exhaust pipe
R1503motr250A
Loosen clamp securing rubber adapter to exhaust
pipe. 1. Upper retaining screw

Detach muffler strap. Remove supercharger from the engine.

Move muffler back (± 5 cm (2 in)).
Disassembling the Supercharger
Remove retaining screws and pull out the super-
charger. NOTICE Be scrupulous when working on
supercharger parts. Supercharger rotation
reaches 45 000 RPM. Any modification, im-
proper handling or damage on the parts, may
result in damage of the supercharger. Strictly
follow the described procedures.
1. Secure the supercharger on its support plate.
REQUIRED TOOL

SUPPORT PLATE
(P/N 529 035 947)

2. Remove supercharger housing screws.

smr2009-020-005_a

TYPICAL
1. Retaining screws
2. Upper retaining screw (hidden behind the supercharger)

NOTE: Use the following tool to remove the up-

per retaining screw.
REQUIRED TOOL
TORX ADAPTER
(P/N 529 035 938)

RTX1503ACEMY18-008-001_a

3. Separate supercharger housing.

6 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-008
 Subsection XX (SUPERCHARGER)

NOTICE When beginning the applica-

tion of the supercharger housing sealant,
the assembly and the first torquing should
be done within 10 minutes. It is suggested
to have all you need on hand to save time.
REQUIRED TOOL
Plexiglas plate
Soft rubber roller

3.1 Apply some sealant on the plate and get a

thin uniform coat (spread as necessary).
RTX1503ACEMY18-008-002

PLASTIC HAMMER 3.2 Then apply the sealant on supercharger

housing sealing surface.
NOTICE All components of the supercharger
NOTE: Ensure not to apply too much sealant, as
are balanced together to obtain an optimal it will spread out inside supercharger housing.
performance and a smooth operation. Conse-
quently it is not possible to repair the super-
charger.

Assembling the Supercharger

1. Clean supercharger housing halves using a part
cleaner, then use compressed air to dry it. Take
care that deposits do not get into the bearing
area.
NOTICE Do not let impeller spin when using
compressed air.
2. Clean supercharger housing mating surfaces.
NOTICE Never grind or polish the mounting RTX1503ACEMY18-008-003_a

1. Apply Loctite 5910 on sealing surface

surface of the supercharger. Abrasive dust
may cause severe supercharger damage. 4. Assemble supercharger housing halves.
Brush in one direction then make the final brush- 5. Tighten supercharger housing screws accord-
ing perpendicularly (90°) to the first pass. ing to the following sequence.
SUPERCHARGER HOUSING MATING TIGHTENING TORQUE
SURFACES CLEANING
9 N•m ± 1 N•m
LOCTITE CHISEL (80 lbf•in ± 9 lbf•in)
Service product (GASKET REMOVER) Supercharger housing +
(P/N 413 708 500) halves screws LOCTITE 243
(BLUE) (P/N 293
REQUIRED TOOL 800 060)
Brass brush

3. Apply supercharger housing sealant:

SUPERCHARGER HOUSING
SEALING SURFACE
LOCTITE 5910
Service product
(P/N 293 800 081)

RTX1503ACEMY18-008
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Subsection XX (SUPERCHARGER)

CAUTION Impeller has sharp edges.

Wear safety gloves when turning the super-
charger at the impeller.
4. Tighten supercharger retaining screws to spec-
ifications.
TIGHTENING TORQUE
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
Supercharger retaining
+
screws
LOCTITE 243 (BLUE)
(P/N 293 800 060)

NOTE: For the upper retaining screw the follow-

RTX1503ACEMY18-008-001_b ing tool must be used mounted 90° to torque
SUPERCHARGER TIGHTENING SEQUENCE wrench.
Installing the Supercharger REQUIRED TOOL
NOTE: Handle the supercharger with care. TORX ADAPTER
(P/N 529 035 938)
1. Install NEW O-rings.
2. Grease mounting surface of the supercharger
with O-rings.
SUPERCHARGER MOUNTING SURFACE AND
OIL RETURN BORE SEALING
TRIPLE-GUARD
Service product GREASE (P/N 296 A
000 329)

F00B1UA 1
1. Torx adapter perpendicular to torque wrench
A. 90°

NOTICE Not installing the tool as shown will

change the torque applied to the screw.

R1503_MY17-008-002_a

1. Mounting surface with O-rings

3. Install supercharger on PTO housing.

NOTICE Never use a hammer when installing
the supercharger. Do not tap the impeller shaft
at any time.
Turn the impeller while installing the supercharger
to engage the supercharger drive gear.

8 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-008
 Subsection XX (INTERCOOLER)

INTERCOOLER
SERVICE TOOLS
Description Part Number Page
LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 4
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ........................................... 4

ROTAX 1630 ACE engines

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)
4 ± 1 N•m
(35 ± 4 lbf•in) 13.5 ± 1 N•m
(119 ± 9 lbf•in)
4 ± 1 N•m
(35 ± 4 lbf•in)
NEW

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)
1.7 ± 0.2 N•m
(15 ± 2 lbf•in)
1.7 ± 0.2 N•m
(15 ± 2 lbf•in)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)
NEW = Component must be replaced when removed.
219100893-014-100_b

219100941-013
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Subsection XX (INTERCOOLER)

ROTAX 1500 HO ACE engines

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

4 ± 1 N•m
NEW (35 ± 4 lbf•in) 4 ± 1 N•m
(35 ± 4 lbf•in)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)
1.7 ± 0.2 N•m
(15 ± 1 lbf•in)
13.5 ± 1 N•m
1.7 ± 0.2 N•m (119 ± 9 lbf•in)
(15 ± 1 lbf•in)
1.7 ± 0.2 N•m
1.7 ± 0.2 N•m (15 ± 1 lbf•in)
(15 ± 1 lbf•in) 1.7 ± 0.2 N•m
(15 ± 1 lbf•in)

1.7 ± 0.2 N•m

(15 ± 1 lbf•in)
1.7 ± 0.2 N•m
(15 ± 1 lbf•in)

NEW = Component must be replaced when removed.

219100941-013-100_b

2 https://brp-manuals.com/pwc_seadoo 219100941-013
 Subsection XX (INTERCOOLER)

MAINTENANCE
INTERCOOLER FLUSHING
Flushing the intercooler with fresh water is essen-
tial to neutralize corroding effects of salt or other
chemical products present in water. It will help to
clean up sand, salt, shells or other particles in in-
tercooler.
NOTE: Intercooler is flushed with the exhaust
system, as they are on the same circuit.
Exhaust system and intercooler should be flushed
each time:
– Watercraft is used in salt water and is not ex-
pected to be used further the same day.
– Watercraft is used in foul water.
– Watercraft is stored for any extended time. 219100893-014-009_a

Refer to EXHAUST SYSTEM subsection for flush-
ing procedure.
NOTICE Failure to flush the system, when
necessary, will severely damage engine inter-
cooler and/or exhaust system.
1. Sacrificial anode for the ROTAX 1630 ACE engine models
Sacrificial Anode maintenance
Inspect and replace sacrificial anode according to
MAINTENANCE SCHEDULE.

PROCEDURES INTERCOOLER
WARNING
SACRIFICIAL ANODE Let engine cool down prior to work on or near
Sacrificial Anode location intercooler.
Sacrificial Anode is located on the front of the inter
cooler for the ROTAX 1630 ACE engine models
Cleaning the Intercooler
and on the back of the intercooler for the ROTAX If temperature in intake manifold is too high or if
1500 HO ACE engine models. engine is down in performance, intercooler may
require to be cleaned.
The exhaust system should be flushed first, as
it may unclog the intercooler. If not, then pro-
ceed with the intercooler cleaning procedure as
detailed here.
NOTE: The exhaust temperature will decrease
when the intercooler is clogged because more
water is rerouted through the exhaust system.
To clean the intercooler, do the following:
NOTICE Never try to clean the intercooler
with chemical products. Only use fresh water.
Chemical products will permanently damage
the internal parts of intercooler.
1. Remove the intercooler from the watercraft.
See procedure further in this subsection.
2. Pour fresh water into the water outlet fitting.
219100893-014-008_a

1. Sacrificial anode for the ROTAX 1500 HO ACE engine models

219100941-013
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Subsection XX (INTERCOOLER)

smr2009-019-009_a

TYPICAL
1. Garden hose installed on water outlet
2. High and regular water flow
219100893-014-001_a

ROTAX 1630 ACE ENGINE INTERCOOLER 7. Perform a leak test before installing the inter-
1. Intercooler water outlet fitting cooler in the watercraft.
2. Intercooler water inlet fitting
3. Intercooler bleeding hose fitting
Sacrificial anode maintenance
Inspect and replace sacrificial anode according to
MAINTENANCE SCHEDULE.
Intercooler Leak Test
Block intercooler water outlet and bleed hoses.
REQUIRED TOOL

LARGE HOSE PINCHER

(P/N 529 032 500)

219100893-014-002_a

ROTAX 1500 HO ACE ENGINE INTERCOOLER

1. Intercooler water outlet fitting
2. Intercooler water inlet fitting
3. Intercooler bleeding hose fitting

3. Let water soak in intercooler for a couple of

hours. Occasionally, shake the intercooler to
soak off deposits.
4. Rinse the intercooler using a garden hose in-
stalled on water outlet.
5. Let water flow out of intercooler a few minutes
to evacuate internal deposits.
6. Check water flow.
WATER FLOW
219100893-014-006_a
LOW OR 1. Repeat cleaning procedure.
MANY PARTS REMOVED FOR CLARITY PURPOSE - TYPICAL
ERRATIC 2. Replace the intercooler. 1. Intercooler bleed hose
2. Intercooler outlet hose
HIGH AND 3. Intercooler inlet hose
Intercooler is not clogged.
REGULAR
Unplug the intercooler water inlet hose from the
intercooler.
Install the VACUUM/PRESSURE PUMP (P/N 529 021
800) on intercooler water inlet fitting.

4 https://brp-manuals.com/pwc_seadoo 219100941-013
 Subsection XX (INTERCOOLER)

529021800

VACUUM/PRESSURE PUMP

Pressurize the intercooler.

PRESSURE TEST
69 kPa (10 PSI) for 10 minutes minimum
219100893-014-005_a

If there is a pressure drop, first spray tool, hoses 1. Intercooler air hoses
and adapters with a soapy water solution to en-
sure they are not leaking. If they are not leaking, 4. Disconnect intercooler water hoses and inter-
replace the intercooler. cooler bleed hose.

Locating the Intercooler

Intercooler is located on the rear right side of the
watercraft.

219100893-014-006_a

1. Intercooler bleed hose

2. Intercooler outlet hose
3. Intercooler inlet hose

5. Untie intercooler straps.

219100893-014-004_a

PARTS REMOVED FOR CLARITY

Removing the Intercooler

1. Remove seats. Refer to BODY subsection.
2. Remove engine service cover. Refer to BODY
subsection.
3. Disconnect intercooler air hoses.

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Subsection XX (INTERCOOLER)

smr2016-020-007_a

FRONT RH SIDE ATTACHMENT

219100893-014-007_a

1. Intercooler straps

Installing the Intercooler

The installation is the reverse of the removal pro-
cedure.
NOTE: Ensure hoses are routed correctly and
locking ties are positioned at proper locations.
TIGHTENING TORQUE
Intercooler air hoses 4 N•m ± 1 N•m smr2016-020-008_a
clamp (35 lbf•in ± 9 lbf•in) FRONT LH SIDE ATTACHMENT
Intercooler water hoses 1.7 N•m ± .2 N•m
clamp (15 lbf•in ± 2 lbf•in)
Intercooler bleed hose 1.7 N•m ± .2 N•m
clamp (15 lbf•in ± 2 lbf•in)

REPLACING INTERCOOLER
ATTACHMENTS
Remove the intercooler.
Drill the head of the rivets.
NOTICE Drilling rivets too deep may leads to
hull damage. smr2016-020-009_a

REAR ATTACHMENT

Install the attachment with new rivets and new

locking tie if required.

6 https://brp-manuals.com/pwc_seadoo 219100941-013
 Subsection XX (ENGINE MANAGEMENT SYSTEM (900 ACE SERIES))

ENGINE MANAGEMENT SYSTEM (900

ACE SERIES)
900 HO ACE SERIES

MAPTS

INJ-1 EGTS

INJ-2
IGN-1
INJ-3
CAPS

ETA IGN-2

IGN-3

OPS
CTS

KS
ECMA

RE1

CPS

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Subsection XX (ENGINE MANAGEMENT SYSTEM (900 ACE SERIES))

903 4-TEC CONTROL SYSTEM

INPUTS OUTPUTS

Throttle accelerator sensor (TAS) Relay

Throttle position sensor (TPS) Fuel pump

Crankshaft position (CPS) Starter solenoid

Camshaft position (CAPS) Ignition coil (3)

ENGINE CONTROL
MODULE (ECM)
Coolant temperature (CTS) Fuel injector (3)

Manifold absolute pressure / Electric throttle

temperature (MAPTS) actuator (ETA)

Exhaust gas temperature (EGTS) Controller area

network (CAN)
Oil pressure (OPS)

Knock sensor (KS)

Battery voltage (BV)

Start/Stop switch (SSS)

Engine cut-off (DS)

Off-throttle assisted steering (O.T.A.S.)

Controller area network (CAN)

smr2014-022-002_aen

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 Subsection XX (ENGINE MANAGEMENT SYSTEM (900 ACE SERIES))

GENERAL Engine Control Module (ECM)

SYSTEM DESCRIPTION
An engine management system (EMS) is used to
ensure a high power output with cleaner combus-
tion.
There are 5 main systems that interact with the
engine management system:
1. Electronic fuel injection smr2009-027-005
2. Ignition System ECM
3. Starting System
The ECM is the main component of the engine
4. O.T.A.S. management system. It controls the electrical
(Off-Throttle Assisted Steering) system and the engine management functions by
5. iControl System processing the information obtained from various
switches, controls and sensors that it compares
Air management to predetermined parameters stored in the ECM.
The quantity of air admitted into the engine is cal- It also interacts with the other electronic systems
culated by the throttle angle (TPS), the intake air through the CAN bus (multifunction gauge and
temperature (IAT) and the manifold pressure/vac- iControl System) for various functions that affect
uum sensor (MAP) on the intake manifold. engine management.
NOTE: the MAPTS combines the pressure and The ECM is mounted on the air intake silencer.
temperature sensors into one sensor.
The operator’s demands on the throttle lever are
captured by the throttle accelerator sensor (TAS)
and result in the movement of the electronic throt-
tle actuator (ETA).

Fuel management
The coolant temperature sensor (CTS) is used
to determine engine temperature. The ECM will
slightly lean out the fuel mixture to bring a cold
engine to operating temperature faster. Once the
engine is at operating temperature, this stops.
NOTE: On some engines the oil temperature sen-
sor is also used to calculate engine temperature.
In response to changes in air management, the smr2014-022-001_a

ECM will adjust the quantity of fuel injected to op- TYPICAL

timize combustion.
The ECM will vary injection duration and timing to
minimize emissions and maximize power.
1. ECM
2. Air intake silencer
A. Connector "A" (Engine harness)
B. Connector "B" (Vehicle harness)
It features a permanent memory that will store
fault codes, customer information and other
engine information, even when the engine is
stopped and the battery is removed from the
vehicle.
The ECM controls the following engine manage-
ment functions:
Throttle Protection
If the throttle is not completely closed during en-
gine startup, the engine will not start.

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Subsection XX (ENGINE MANAGEMENT SYSTEM (900 ACE SERIES))

To revert to normal operation, completely release Limp Home Mode

the throttle lever. The ECM may automatically set the engine in
Engine RPM Limiter LIMP HOME MODE using default parameters
when certain major faults are detected. For more
The ECM monitors engine RPM through the CPS information, refer to DIAGNOSTIC AND FAULT
and CAPS. It then varies fuel injection, ignition and CODES.
throttle plate opening as necessary to limit maxi-
mum engine speed. Diagnostic Mode
Engine Speed Control The ECM features a self-diagnostic mode that is
initiated on system power up for certain systems
The ECM controls the engine idle RPM. In addi- and components (when pressing the START but-
tion, it can vary the engine speed by command- ton), and when the engine is running for others.
ing the electronic throttle actuator (ETA) to open or Refer to DIAGNOSTIC AND FAULT CODES sub-
close based on throttle position and various other section for more information.
inputs. The ETA also allows for other functions of
the iControl system.
Drowned Mode
If the engine is flooded and does not start, this
special mode can be activated to prevent fuel in-
jection and ignition while cranking in order to ven-
tilate the engine to dry the cylinder walls.
NOTE: This mode can also be used if the engine
is water-flooded.
To activate DROWNED MODE, proceed as per fol-
lowing steps.
1. Install the tether cord cap on the engine cut-off
switch.
2. While the engine is stopped, fully pull in and
HOLD the throttle lever.
3. Press the START/STOP button. DROWNED
MODE is now on.
Releasing the throttle lever will allow the ECM to
revert back to normal mode.
If the engine does not start, it may be necessary
to disable the ignition system, remove the spark
plugs and crank the engine with rags over the
spark plug holes. Refer to IGNITION SYSTEM
subsection.
Monitoring System
The ECM monitors:
– The electrical and electronic components of the
engine system
– The iControl system
– The multifunction gauge
– Some components of the electrical system
For more information, refer to DIAGNOSTIC AND
FAULT CODES.

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 Subsection XX (ENGINE MANAGEMENT SYSTEM (1500 SERIES))

ENGINE MANAGEMENT SYSTEM (1500

SERIES)
1503 4-TEC HO (260)

IGN-3
ECMA
ECMA
IGN-1 IGN-2 INJ-3

INJ-1 INJ-2
CTS

MAP

CAPS IAT

CPS
ETA
OPS
KS

smr2017-313_099_a

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Subsection XX (ENGINE MANAGEMENT SYSTEM (1500 SERIES))

1500 HO ACE (230)

IGN-3
IGN-2 INJ-3
IGN-1 INJ-2 ECMA
ECMA
INJ-1
CTS

MAPTS
MAPTS

CAPS

CPS
ETA
OPS KS

smr2017-313_199_a

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 Subsection XX (ENGINE MANAGEMENT SYSTEM (1500 SERIES))

EMS INPUTS AND OUTPUTS

INPUTS OUTPUTS

Throttle accelerator sensor (TAS) Relay

Throttle position sensor (TPS) Fuel pump

Crankshaft position (CPS) Starter solenoid

ENGINE CONTROL
Camshaft position (CAPS) MODULE (ECM) Ignition coil (3)

Coolant temperature (CTS) Fuel injector (3)

Manifold absolute pressure / Electric throttle

1 temperature (MAPTS) actuator (ETA)

Exhaust gas temperature (EGTS) Controller area

network (CAN)
Oil pressure (OPS)

Knock sensor (KS)

Battery voltage (BV)

Start/Stop switch (SSS)

Engine cut-off (DS)

Off-throttle assisted steering (O.T.A.S.)

Controller area network (CAN)

1 Or separate IAT and MAP sensors
EN_smr2017-313_001_aen

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Subsection XX (ENGINE MANAGEMENT SYSTEM (1500 SERIES))
GENERAL
SYSTEM DESCRIPTION
An engine management system (EMS) is used to
ensure a high power output with cleaner combus-
tion.
There are 7 main systems that interact with the
engine management system:
1. Electronic fuel injection
2. D.E.S.S. System
3. Ignition System
4. Starting System
5. O.T.A.S.
(Off-Throttle Assisted Steering)
6. T.O.P.S.
(Tip-Over Protection System)
7. iControl System
Air management
The quantity of air admitted into the engine is cal-
culated by the throttle angle (TPS), the intake air
temperature (IAT) and the manifold pressure/vac-
uum sensor (MAP) on the intake manifold.
NOTE: the MAPTS combines the pressure and
temperature sensors into one sensor.
The operator's demands on the throttle lever are
captured by the throttle accelerator sensor (TAS)
and result in the movement of the electronic throt-
tle actuator (ETA).
Fuel management
The coolant temperature sensor (CTS) is used
to determine engine temperature. The ECM will
slightly lean out the fuel mixture to bring a cold
engine to operating temperature faster. Once the
engine is at operating temperature, this stops.
NOTE: On some engines the oil temperature sen-
sor is also used to calculate engine temperature.
In response to changes in air management, the
ECM will adjust the quantity of fuel injected to op-
timize combustion.
The ECM will vary injection duration and timing to
minimize emissions and maximize power.
4 https://brp-manuals.com/pwc_seadoo
Engine Control Module (ECM)
smr2009-027-005
ECM
The ECM is the main component of the engine
management system. It controls the electrical
system and the engine management functions by
processing the information obtained from various
switches, controls and sensors that it compares
to predetermined parameters stored in the ECM.
It also interacts with the other electronic systems
through the CAN bus (information center and
iControl System) for various functions that affect
engine management.
It features a permanent memory that will store
fault codes, customer information and other
engine information, even when the battery is
removed from the vehicle.
The ECM controls the following engine manage-
ment functions:
Engine RPM Limiter
The ECM limits maximum engine speed. It moni-
tors engine RPM through the CPS and varies fuel
injection, ignition and throttle plate opening as
necessary.
Engine Speed Control
The ECM controls the engine idle RPM. In addi-
tion, it can vary the engine speed by command-
ing the electronic throttle actuator (ETA) to open or
close based on throttle position and various other
inputs. The ETA also allows for other functions of
the iControl system.
Drowned Mode
If the engine is flooded and does not start, this
special mode can be activated to prevent fuel in-
jection and ignition while cranking in order to ven-
tilate the engine to dry the cylinder walls.
NOTE: This mode can also be used if the engine
is water-flooded.
To activate DROWNED MODE, proceed as per fol-
lowing steps.
1. Install the tether cord cap on the engine cut out
switch.
smr2017-313
 Subsection XX (ENGINE MANAGEMENT SYSTEM (1500 SERIES))

2. While the engine is stopped, fully pull and

HOLD the throttle lever.
3. Press the START/STOP button. DROWNED
MODE is now on.
Releasing the throttle lever will allow the ECM to
revert back to normal mode.
If the engine does not start, it may be necessary to
remove the spark plugs and crank the engine with
rags over the spark plug holes. Refer to IGNITION
SYSTEM subsection.
Monitoring System
The ECM monitors:
– The electrical and electronic components of the
engine system
– The iControl system
– The information center (gauge)
– Some components of the electrical system
– Signals from other electronic modules
For more information, refer to DIAGNOSTIC AND
FAULT CODES.
Limp Home Mode
The ECM may automatically set the engine in
LIMP HOME MODE using default parameters
when certain major faults are detected. For more
information, refer to DIAGNOSTIC AND FAULT
CODES.
Diagnostic Mode
The ECM features a self-diagnostic mode that is
initiated on system power up for certain systems
and components (when pressing the START but-
ton), and when the engine is running for others.
Refer to DIAGNOSTIC AND FAULT CODES sub-
section for more information.

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 Subsection XX (iCONTROL SYSTEM)

iCONTROL SYSTEM
GENERAL
The iControl (intelligent Control) system may con-
sist of the following systems depending on the
PWC model:
– Intelligent Throttle Control (iTC)
– Intelligent Brake and Reverse (iBR).
The information center (gauge) and handlebar
switches are used to navigate through and select
several functions, modes of operation and change
certain settings and system parameters using the
appropriate handlebar controls.
Each control is electronic and provides a com-
mand signal to an electronic module whose
function is to assure proper operation of its sys-
tem within set parameters.
For a comprehensive and complete description
of the information center, refer to INFORMATION
CENTER (GAUGE) subsection.

iTC (INTELLIGENT THROTTLE

CONTROL)
The iTC is an electronic throttle control system
(ETC) that includes a cable-less throttle control
(TAS) located on the RH side of handlebar and
an electric throttle actuator (ETA) located on the
throttle body.
The iTC allows functions such as touring/sport
mode, cruise control, slow speed mode, ski mode
and O.T.A.S. as well as a more precise control of
the engine power.
For a comprehensive and complete description
of this system, refer to INTELLIGENT THROTTLE
CONTROL (ITC) subsection.

iBR (INTELLIGENT BRAKE AND

REVERSE)
The iBR is a brake and reverse system used to
avoid obstacles, gradually slow down or stop
the watercraft, or drive backwards by lowering
the iBR gate that redirects the water flow at the
outlet of the jet pump nozzle.
For a comprehensive and complete description of
this system, refer to IBR, REVERSE AND VTS sub-
section.

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 Subsection XX (CONTROLLER AREA NETWORK (CAN))

CONTROLLER AREA NETWORK (CAN)

GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an ISO standard for serial data communication.
The CAN bus is the nervous system of the iControl system and the engine management system (EMS).
It links the electronic modules (ECMs) together so that they communicate to interact as required.
Two wires connect each component and they are in constant communication with each other at a rate of
about every 10 or 100 milliseconds depending on the component. CAN lines consist of a pair of twisted
wires (WHITE/BLACK and WHITE/BEIGE).

(Optional)

smr2017-013-001_aen

CAN BUS DIAGRAM

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Subsection XX (CONTROLLER AREA NETWORK (CAN))

TROUBLESHOOTING
DIAGNOSTIC TIPS
Check the fault codes using BUDS2 as a first troubleshooting step. Refer to DIAGNOSTIC AND FAULT
CODES subsection.
Make sure the modules are powered before testing CAN.

CAN Communication Problems

The following chart gives some symptoms and behaviors relative to the CAN component in cause. The
list is not exhaustive, only the most significant items are given to help in troubleshooting.
CAN FAULTY WIRES VEHICLE BEHAVIOR OR OBSERVATION
OBSERVATION IN BUDS2
(no communication) IN INFORMATION CENTER
Diagnostic connector CAN intermittent problems. Nothing
not secured NOTE: Occurs more frequently on watercraft
in its holder equipped with 2 electronic modules.
(holder contains a
120 resistor)
Water in holder of Communication problems and strange Nothing
diagnostic connector behavior of information center.
(particularly with salt Inoperative electronic systems in watercraft.
water)
Short circuit in CAN Engine is set to limp home mode. BUDS2 will not be able
wires iBR gate will not move. "Locked" in neutral. to communicate with
iBR light is ON. any electronic module.
Check engine light is ON. "No vehicle detected" message
will be displayed in BUDS2.
Information center Check engine light is ON. 2 modules instead of 3 will be active.
(gauge) iBR light is ON. "Cluster" tab and its data will
Some functions not displayed such not be available in BUDS2
as: Engine hours, VTS and RPM. ECM and iBR will report a cluster CAN
problem.
ECM (Engine Control Engine is set to limp home mode. 2 modules instead of 3 will be active.
Module) Check engine light is ON. ECM tab and its data will
iBR light is ON. not be available in BUDS2
iBR gate "locked" in neutral. iBR will report an ECM CAN problem.
Some functions not displayed such as: Engine
hours and RPM.
iBR (intelligent Brake Engine is set to limp home mode. 2 modules instead of 3 will be active.
and Reverse) iBR gate will not move. "Locked" in neutral. iBR tab and its data will
iBR light is ON. not be available in BUDS2
Check engine light is ON. ECM will report an iBR CAN problem.
Some functions not displayed such as: Lake
water temperature, no VTS, no F, N and R
indication.
Depth sounder The menu Depth Sounder Nothing will be observable.
Indicator will not be visible.
The Depth menu will not be available.
Diagnostic connector Nothing will be observable. BUDS2 will not be able
to communicate with
any electronic module.
"No vehicle detected" message
will be displayed in BUDS2.

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 Subsection XX (CONTROLLER AREA NETWORK (CAN))

If the gauge cannot communicate with an optional accessory (e.g.: depth sounder) during the initial power
up, the gauge will interpret this as if the vehicle is not equipped with it. No further test of the system
occurs and no indication or fault message will be visible. If communication is interrupted after the gauge
has already detected them, then the gauge will indicate that there is a communication fault.

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 Subsection 04 (COMMUNICATION TOOLS AND B.U.D.S.)

COMMUNICATION TOOLS AND

B.U.D.S.
GENERAL
Use BUDS2.
Refer to the B.U.D.S. directory on KNOWLEDGE USB
CENTER for all BUDS related information, includ-
ing:
CAN
– Current version download link
– User manual (programming keys, reading fault
codes, writing data to modules etc.)
– Installation instructions vmr2016-128-001_a
– Navigation through menus MPI-3 CARD
– BRP BUDS chart
Prerequisite for USB Communication:
Search keyword: "BUDS". – PC Computer turned ON
– MPI connected to PC computer.
COMMUNICATION PROBLEM (USB)
STATUS WHAT TO DO
mmr2017-025-001
– Check USB connection between MPI-2
USB
and PC computer.
TROUBLESHOOTING Light is
OFF – Check USB operation on PC computer
Refer to the BRP BUDS chart to ensure you are (hardware or Windows drivers).
using the appropriate hardware and tools.
USB – Connections are GOOD.
COMMUNICATION PROBLEMS Light is Communication can take place on
GREEN USB side.
MPI Connection Troubleshooting
MPI Status Lights
Prerequisite for CAN Communication:
The MPI includes 2 status lights to show the con-
nection conditions: USB and CAN. Both lights 1. MPI connected to diagnostic connector.
must be GREEN for the MPI to function properly. 2. The tether cord cap (D.E.S.S. key) is installed on
Otherwise, refer to the following charts. the engine cut-off switch.
3. BUDS2 started and logged.
4. ECM is powered.

vdd2006-001-151_b

MPI-2 CARD

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Subsection 04 (COMMUNICATION TOOLS AND B.U.D.S.)

COMMUNICATION PROBLEM (CAN)

STATUS WHAT TO DO
– BUDS2 does not communicate with the
vehicle.
– Check connections from computer to
CAN vehicle.
Light is – Check if BUDS2. is started.
OFF – Check if vehicle is powered: is cluster
turned ON? If it is not ON, install the
tether cord cap (D.E.S.S. key) on the
engine cut-off switch.
This occurs when BUDS2 looses
communication with vehicle.
– Check connections from computer to
CAN
vehicle.
Light is
RED – Check if vehicle is powered: is cluster
turned ON? If not, install the tether cord
cap (D.E.S.S. key) on the engine cut-off
switch.
CAN – Connections are GOOD.
Light is BUDS2 communicates normally
GREEN with the vehicle.

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 Subsection XX (DIAGNOSTIC AND FAULT CODES)

DIAGNOSTIC AND FAULT CODES

GENERAL INFORMATION CENTER MONITORING
Information center
MONITORING SYSTEM VTS, Sport and ECO switch
This system monitors the electronic components MODE and SET switch
of the EMS (engine management system), iBR, in-
formation center, iS and other components of the Cruise switch
electrical system to detect if they are faulty or de- CAN
fective. The monitoring system becomes active
when the START button is pressed. GPS

NOTE: Some components need the engine to be Fuel level sensor

running to be monitored (fuel injectors for exam- Depth sounder
ple).
ECM
The following components or functions are moni-
tored. iBR module

EMS MONITORING When a malfunction is currently detected, the re-

Battery voltage lated electronic module:
– Sets an active fault code.
EMS sensors (TAS, TPS, CPS, CAPS, MAPS,
MATS, CTS, OPS, EGTS, TOPS, knock sensor). – Adapts the proper protection strategy accord-
Throttle actuator, ignition coils and fuel injectors ing to the failure.
– Sends out warning signals to the information
ECM center/beeper codes to inform the rider of a par-
Engine RPM ticular condition.
CAN
When a minor or transient fault occurs, the fault
message and beeper will cease automatically if
D.E.S.S. system the condition that caused the fault does not exist
START switch and starter solenoid anymore.
If a minor fault is active, the engine will operate
Fuel pump
without a noticeable loss of performance.
O.T.A.S.
Releasing the throttle and letting the engine re-
Information center turn to idle speed may allow normal operation to
iBR module
resume. If this does not work, try the following:
– Remove tether cord from the engine cut-off
iBR MONITORING switch.
– Wait 3 minutes to allow the ECM to shut down.
iBR module and motor
– Start engine.
BRLS – Check if the fault code is still active.
Engine RPM The electronic system will react differently de-
Vehicle speed pending on the fault type. If a severe failure
occurs, the engine may not be allowed to be
iBR gate position
started. In other cases, the engine may operate
CAN in limp home mode (reduced speed) or not be
affected at all.
Information center
These strategies are used to protect the engine
ECM system from damage and to maintain safe opera-
tion of the vehicle.

Limp Home Mode

When a major component of the EMS or the iBR is not operating properly, limp home mode will be set.
Engine speed will be limited and therefore vehicle speed.
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Subsection XX (DIAGNOSTIC AND FAULT CODES)

This mode allows the rider to return home which would otherwise not be possible.
When this mode is active, LIMP HOME MODE will be displayed in the information center.

Indicator Lights and Message Display Information

The fault indicators and messages displayed in the information center will inform you of a particular con-
dition or if an anomaly occurs.
Standard Gauge
FAULT
MESSAGE DISPLAY DESCRIPTION
INDICATOR (ON)

HIGH TEMPERATURE Engine or exhaust system overheating

Check engine (minor fault req. maint.) or

CHECK ENGINE or LIMP
iBR system fault or
HOME MODE
LIMP HOME MODE (major eng. fault)
LOW or HIGH BATTERY
Low/high battery voltage
VOLTAGE
LOW OIL PRESSURE Low engine oil pressure detected

iBR MODULE ERROR iBR system fault

FAULT MESSAGES
RIGHT OR LEFT KEYPAD ERROR Gauge control button malfunction
LOW OIL PRESSURE Engine low oil pressure detected
HIGH EXHAUST TEMPERATURE High exhaust temperature detected
HIGH TEMPERATURE High engine temperature detected
Engine management system malfunction or
CHECK ENGINE
maintenance required
HIGH BATTERY VOLTAGE High battery voltage detected
LOW BATTERY VOLTAGE Low battery voltage detected
LIMP HOME MODE Major fault detected, engine power limited
FUEL SENSOR DEFECTIVE Fuel level sensor fault
CALIBRATION CHECKSUM ERROR Information center programming corrupted
MAINTENANCE REQUIRED Watercraft maintenance required
DEPTH SOUNDER MODULE COMMUNICATION Error message if depth sounder is disconnected while
PROBLEM riding
Error message if communication with the iBR module
iBR MODULE ERROR
is lost while riding
Message when a function is not or cannot be properly
FUNCTION CANNOT BE ACTIVATED
activated
WRONG KEY Key not programmed for this watercraft
O.T.A.S. MAINTENANCE REQUIRED Maintenance on O.T.A.S. required

Beeper Signals
When one of the below conditions occurs, the monitoring system emits the following beep signals.

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 Subsection XX (DIAGNOSTIC AND FAULT CODES)

BEEPER CODES DESCRIPTION

A 1 second beep
every 5 second interval
(while installing D.E.S.S. key
on engine cut-off switch if ECM
is on)
A 2 second beep every 5 minute
interval
Continuously beeps
Bad D.E.S.S. system connection.
Reinstall tether cord correctly over engine cut-off switch.
Wrong D.E.S.S. key.
Use a tether cord with a D.E.S.S. key that has been programmed for the
watercraft.
Defective D.E.S.S. key.
Use another programmed D.E.S.S. key.
Defective engine cut-off switch.
Check. Refer to IGNITION SYSTEM subsection.
Improper operation of ECM or defective wiring harness.
Check. Refer to ELECTRONIC FUEL INJECTION (EFI) subsection.
Low fuel level.
Refill fuel tank. If problem persists, check sensor and circuit. Refer to FUEL
TANK AND FUEL PUMP subsection.
Fuel tank level sensor or circuit malfunction.
Check sensor and circuit. Refer to FUEL TANK AND FUEL PUMP
subsection.
High engine coolant temperature.
Refer to COOLING SYSTEM subsection.
High exhaust temperature.
Refer to ELECTRONIC FUEL INJECTION (EFI) subsection.
Low oil pressure.
Turn off engine as soon as possible. Check oil level and refill. Refer to
LUBRICATION subsection.

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Subsection XX (DIAGNOSTIC AND FAULT CODES)

FAULT CODES
A fault code is an indication that a glitch or mal-
function is detected by the monitoring system of
the vehicle.
When there is a problem, the ECM can provide
fault codes to ease troubleshooting.
The faults registered in the ECM are stored in
memory.
IMPORTANT: After a problem has been solved,
be sure to clear the fault(s) in the ECM using the
BUDS2 software. This will properly reset their
states.

How to Read Fault Codes Using

BUDS2 Software
Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
For more information pertaining to the faults code
status and report, refer to BUDS2 online help.

How to Read Fault Codes on the

Multifunction Gauge
Same gauges can display fault codes. Refer to
Displaying “P” Codes in the applicable GAUGE
subsection.

How to Find Fault Code Descriptions

Connect BUDS2 to the vehicle. Refer to COM-
MUNICATION TOOLS AND BUDS subsection.
Navigate to the faults page in BUDS2.
Browse lists of active/ occured and inactive fault
codes.

4 https://brp-manuals.com/pwc_seadoo smr2017-315

Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))
INTELLIGENT THROTTLE CONTROL
(iTC)
GENERAL
SYSTEM DESCRIPTION
The iTC is an electronic throttle control system
that includes a cableless throttle control located
on the RH side of the handlebar, an electric throt-
tle actuator (ETA) located on the throttle body and
the engine control module (ECM). The iTC is often
referred to as a "throttle by wire" system.
smr2014-028-001_a
1. Throttle lever
2. Throttle accelerator sensor (TAS)
smr2014-028-002_a
1. Throttle body
2. Electric throttle actuator (ETA)
The throttle lever operates the throttle accelera-
tor sensor (TAS). It is a double output hall effect
sensor. The redundancy is used for security pur-
poses.
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https://brp-manuals.com/pwc_seadoo
Section 04 FUEL SYSTEM
The throttle actuator (ETA) is a DC motor on the
throttle body that regulates the throttle plate po-
sition via a drive gear. The ETA must always dis-
place the throttle plate against a spring load that
tends to return the throttle plate to its rest posi-
tion. Pulse width modulation (PWM) is used to
control the motor.
In the throttle body, there is also a double throt-
tle position sensor (TPS). The redundancy is used
for security purposes. The TPS is a potentiometer
that supplies the ECM the actual angular position
of the throttle plate.
According to the torque demand from the TAS,
the ECM powers the ETA motor to rotate towards
open, or close, the throttle plate. When the ECM
detects through the TPS that the throttle plate
has reached the targeted position, the ECM com-
mands the throttle actuator to hold the throttle
plate at that position.
The iTC allows the throttle actuator to be moved ir-
respective of the accelerator sensor position since
it is not directly linked by a throttle cable.
The use of the iTC also allows the following addi-
tional engine modes of operation.
Touring Mode
Touring mode provides for a smooth and progres-
sive throttle response at certain engine speed.
Available engine power and acceleration is re-
duced when accelerating from a complete stop
and when operating in the low engine power
range under certain conditions.
When throttle is applied, the engine will pro-
gressively accelerate through its operating range
whereby full power eventually becomes available.
If the engine is throttled down sufficiently and for
a long enough period of time, engine power and
acceleration will again be reduced.
Sport Mode
Sport mode provides a crisper, more instanta-
neous throttle response.
Maximum engine power is available throughout
the engine operational range.
NOTE: Touring/Sport mode selection is only avail-
able on the ACE 900 HO engine.
179
Section 04 FUEL SYSTEM
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))
O.T.A.S. TM System (Off-Throttle
Assisted Steering)
The O.T.A.S. (Off-Throttle Assisted Steering)
system provides additional maneuverability in
off-throttle situations. The O.T.A.S. system is
electronically activated and slightly increases en-
gine speed under a pre-defined RPM when the
driver initiates a full turn. When the handlebar is
brought back to its center position, the throttle
reverts to idle.
The throttle plate will open and close as necessary
to assist the steering.
Limitations
The O.T.A.S. system cannot help maintaining con-
trol or prevent collisions in all situations.
OPERATING MODES
NOTE: Touring/Sport mode selection is only avail-
able on the ACE 900 HO engine.
Touring Mode
By default, the watercraft is set to TOURING
mode of operation when started.
A TOURING mode indicator is ON in the multi-
function gauge to confirm the active mode of op-
eration.
TOURING MODE INDICATOR
Sport Mode
When selected, SPORT MODE provides for
instant throttle response and more rapid acceler-
ations than TOURING MODE.
Once activated, SPORT MODE will remain active
until it is deactivated by the operator, or the engine
is shut down whereby it defaults back to TOUR-
ING MODE.
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Activating Sport Mode
To activate sport mode, carry out the following:
WARNING
When activating sport mode, be sure to
maintain situational awareness of other wa-
tercrafts, obstacles, or persons in the water.
1. Start engine.
2. Depress and hold the SET button for at least 1
second.
smo2014-005-052_e
TYPICAL
1. SET button
Two beeps will be heard and the following mes-
sage will be displayed in the multifunction gauge:
MESSAGE DISPLAYED
ENTERING SPORT MODE - INCREASED
ACCELERATION - INSTRUCT PASSENGERS TO
HOLD - PRESS_MODE_BUTTON
WARNING
Ensure passengers are advised that sport
mode provides for increased accelerations
and that they are to hold on tightly.
3. Press the SET button again to acknowledge the
message and activate sport mode.
One beep will be heard and a scrolling SPORT
MODE ACTIVATED message will momentarily
confirm that sport mode has been activated.
smr2014-028
 Section 04 FUEL SYSTEM
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))

Deactivating Sport Mode

To deactivate sport mode, carry out the following:

WARNING
When deactivating sport mode, be sure to
maintain situational awareness of other wa-
tercrafts, obstacles, or persons in the water.

1. Depress and hold the MODE button for at least

MESSAGE DISPLAYED 1 second.

SPORT MODE ACTIVATED

NOTE: After a few seconds, the gauge will revert

to its normal display.
4. Ensure the SPORT mode indicator is turned on.

smo2014-005-052_e

TYPICAL
1. MODE button

NOTE: The following message will scroll in the

multifunction display: SPORT MODE DEACTI-
VATED.

SPORT MODE INDICATOR

NOTE: The SPORT mode indicator will come on

and stay on as long as sport mode is active. If the
throttle is not fully released and the engine is not
at idle, SPORT mode cannot be activated. The fol-
lowing message will then appear in the multifunc-
tion gauge. MESSAGE DISPLAYED
SPORT MODE DEACTIVATED

NOTE: After a few seconds, the gauge will revert

to its normal display.
2. Ensure the TOURING mode indicator is on.

MESSAGE DISPLAYED
SPORT MODE - RETURN TO IDLE TO ACTIVATE

Release the throttle. Once the engine has re-

turned to idle, SPORT mode will be activated.
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Section 04 FUEL SYSTEM
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))
TOURING MODE INDICATOR
PROCEDURES
THROTTLE ACCELERATOR
SENSOR (TAS)
General
The throttle accelerator sensor (TAS) is a double
hall effect sensor that sends a signal to the ECM
which is proportional to the throttle lever angle.
smr2014-028-001_a
1. Throttle lever
2. Throttle accelerator sensor (TAS)
First ensure the throttle lever functions ade-
quately. Pull the throttle lever fully in towards the
handlebar, then release it. It must reach the wide
open position and return to the idle position freely
when released. Otherwise, refer to STEERING
SYSTEM for an inspection.
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TAS Test Using B.U.D.S.
1. Connect vehicle to B.U.D.S.. Refer to COM-
MUNICATION TOOLS AND B.U.D.S. subsec-
tion.
2. Press START button.
3. Install tether cord on engine cut-off switch.
4. In B.U.D.S., select the following:
– Read Data button
– Monitoring page tab
– ECM page.
5. While slowly pulling in and letting out throttle
lever, ensure the TAS % indication on the RH
side of the monitoring page changes with throt-
tle activation.
NOTE: The TAS % indication is not directly pro-
portional to the percentage of the throttle lever
travel.
smr2014-028-003
If the TAS % indication changes changes the
throttle activation, the TAS and the wiring har-
ness are good.
If the TAS % indication does not change, look for
a fault code in B.U.D.S. and carry out service ac-
tions. Refer to the wiring diagram to carry out the
following continuity tests:
– Steering connector to TAS connector
– Steering connector to ECM-B connector.
If continuity is NOT good, repair or replace wiring
and connectors.
If continuity is good, replace the TAS.
TAS Replacement
1. Remove RH steering cover. Refer to STEER-
ING SYSTEM .
2. Pry out sensor locking tabs and pull out sensor.
smr2014-028
 Section 04 FUEL SYSTEM
Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))

smr2009-030-100_a

Step 1: Pry out

Step 2: Pull out sensor

3. Pull up on the connector end of the TAS and

gently pull it out of the throttle handle.
4. Remove connector from TAS sensor.
5. For installation, reverse the removal procedure.
Pay attention to the following.
6. Align sensor pins in their holes.

smr2009-030-101_a

1. Align pin into hole

7. Press sensor into position until locking tabs en-

gage. Ensure it is properly locked in place.
8. When installation is complete, ensure throttle
lever functions properly.

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

ELECTRONIC FUEL INJECTION (900

ACE SERIES)
SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL................................................................... 529 036 166 ........... 6–7, 20, 26–28, 30–31
FLUKE 115 MULTIMETER ............................................................ 529 035 868 .................................. 6–7, 12,
19–20, 23, 26–27, 29
FUEL HOSE DISCONNECT TOOL ................................................ 529 036 037 ............................................. 9

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
FLUKE AUTOMOTIVE BACK PROBE PIN..................................... TP40 ........................................... 23
FLUKE SUREGRIP INSULATED TEST LEADS............................... TL224 ........................................... 24

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE ................................................................... 293 550 004 ...................22, 25, 28, 30, 32
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 22, 32
LOCTITE 518 ................................................................................. 293 800 038 ........................................... 30

GENERAL
WARNING
When electrically disconnecting or removing
the throttle body from the intake manifold, al-
ways remove the tether cord from the engine
cut-off switch and disconnect the battery.
WARNING
Always disconnect battery prior to working
on the fuel system. Always disconnect bat-
tery exactly in the specified order, BLACK
(-) cable first. Electrical connections should
be disconnected prior to disconnecting fuel
lines.
WARNING
Fuel is flammable and explosive under cer-
tain conditions. Work in a well ventilated
area. Do not smoke or allow open flames or
sparks in the vicinity.
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appro-
priate safety equipment when working on a
pressurized fuel system. Wear safety glasses.
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors. Proceed with
care when removing or installing high pres-
sure test equipment, or disconnecting fuel
line connections. Wipe off any fuel spillage
in the bilge. Never use a hose pincher on
high pressure hoses.
Desactivate the fuel pump and run the engine until
it stalls.
Cover the fuel line connection with an absorbent
shop rag before disconnecting them. Slowly dis-
connect the fuel hose to minimize spilling.
When the repair is completed, ensure the hose
from the fuel rail to the fuel pump is properly con-
nected and secured in its support. Perform the
FUEL SYSTEM HIGH PRESSURE LEAK TEST as
described in FUEL TANK AND FUEL PUMP sub-
section.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))
WARNING
Replace any damaged, leaking or deterio-
rated fuel lines or connections. After work-
ing on the fuel system, always pressurize the
fuel system and check for fuel leaks. Refer
to FUEL SYSTEM PRESSURIZATION in FUEL
TANK AND FUEL PUMP subsection.
WARNING
Always perform the fuel system high pres-
sure leak test if any fuel line has been re-
moved or disconnected from a component.
WARNING
If a gasoline leak and/or odor is present, do
not start the engine. Repair the leak.
SYSTEM DESCRIPTION
The electronic fuel injection system (EFI) is com-
prised of various sensors used for detecting on-
going operating conditions of the engine, and in-
cludes all the components that perform the re-
quired adjustments to the engine.
Electrical System
ECM (Engine Control Module)
The ECM reads input signals that it receives
from the throttle lever as well as various sensors.
Through calculation of several variables, which it
compares to stored parameters (fuel maps), the
ECM controls the iTC (intelligent Throttle Control),
the injection system and the ignition system to
meet driver demands and to ensure safe engine
operation.
Through its management of the engine systems,
the ECM ensures the engine is delivering op-
timum performance, fuel economy and meets
emission regulations. The ECM also controls idle
RPM by modulating the electric throttle actuator
(ETA) and limits maximum engine speed through
ETA, the ignition system, and fuel injection sys-
tem.
EFI Sensors
To control the injection system, the engine man-
agement uses input signals from the following
sensors:
– Camshaft position sensor (CAPS)
– Crankshaft position sensor (CPS)
– Manifold absolute pressure and temperature
sensor (MAPTS)
2 https://brp-manuals.com/pwc_seadoo
– Throttle position sensor (TPS)
– Throttle accelerator sensor (TAS).
The ECM reads the inputs from the sensors which
it compares to predetermined parameters stored
in the ECM (fuel and ignition maps), makes com-
putations, and activates the outputs accordingly
(injectors, ignition coils etc.).
Air Intake System
Throttle Body
smr2014-029-001
A 46 mm throttle body is mounted on the intake
manifold.
Air for combustion is drawn in by the engine.
The air flows through the throttle body and is
controlled by a throttle plate.
Fitted on the throttle body, an electric throttle ac-
tuator (ETA) allows the ECM to electronically con-
trol the throttle plate opening which regulates the
amount of air that enters the engine, and there-
fore engine speed.
There is no idle air control valve (IACV).
Fuel System
Fuel Rail
A fuel rail is mounted on the intake manifold. The
fuel rail, which is used to secure the injectors to
the manifold, also provides to the injectors the
fuel pressure that it receives from the fuel pump.
The fuel pressure applied to the fuel rail is regu-
lated by the fuel pressure regulator located in the
fuel pump module.
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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

ADJUSTMENT
IDLE SPEED
Idle speed is not adjustable. The EMS (Engine
Management System) controls the idle speed of
the engine through the iTC system by control-
ling throttle plate opening using the ETA (electric
throttle actuator).
With the engine running, engine RPM may be ver-
ified using BUDS2 software, refer to COMMUNI-
CATION TOOLS AND B.U.D.S. subsection.
NOTICE The engine must not be run out of
smr2014-029-002_a
water without providing proper cooling to the
1. Fuel rail exhaust system. Maximum engine run time
out of water is 2 minutes. Failure to do so may
Fuel Injectors result in damage to the exhaust system and
Three fuel injectors are used to inject fuel into the engine. Refer to EXHAUST SYSTEM subsec-
intake ports of the cylinder head. One injector is tion.
used per cylinder.
CLOSED THROTTLE RESET
General Information
This operation performs a reset of the TPS values
of the throttle body in the ECM.
The Closed throttle Reset must be carried out only
when:
– Replacing the throttle body.
– Replacing the ECM.

Closed Throttle Reset Procedure

Use the BUDS2 software to perform this set-
ting. Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
smr2014-029-002_b
1. Press the START/STOP button to wake up the
1. Fuel injectors ECM.
2. Install the tether cord on the engine cut-off
Fuel is injected in accordance with injection sig-
switch.
nals received from the ECM.
3. Ensure throttle lever is completely released.
Fuel Pump
4. In BUDS2, select
An electric fuel pump with an integrated pressure – Settings button
regulator and fuel system filters is used. For more
details on the fuel pump unit, refer to FUEL TANK – ECM page tab
AND FUEL PUMP subsection. – Initialization Tab page
– Reset TPS.
Reset is completed.
NOTE: It is not necessary to click on the Write
button in BUDS2.
Exit BUDS2.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))
NOTE: If the throttle valve was not within the al-
lowed range when the Closed Throttle Reset was
carried out, no error message would be displayed.
However, a fault code would be set when the en-
gine is started.
5. Start engine and make sure it operates normally
through its full engine RPM range.
NOTICE The engine must not be run out of
water without providing proper cooling to the
exhaust system. Maximum engine run time
out of water is 2 minutes. Failure to do so may
result in damage to the exhaust system and
engine. Refer to EXHAUST SYSTEM subsec-
tion.
6. Check for fault codes using BUDS2 If a fault
code related to the throttle actuator appears,
clear it, then carry out another Closed Throttle
Reset procedure. To clear faults, refer to DIAG-
NOSTIC AND FAULT CODES subsection.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Engine problems are not necessarily related to the
fuel injection system.
It is important to ensure that the engine and
propulsion system, fuel delivery and electrical
systems are functioning normally.
For diagnostics purposes, use BUDS2 software.
See COMMUNICATION TOOLS AND B.U.D.S.
subsection.
After a problem has been solved, be sure to clear
the fault(s) recorded in the ECM using the BRP
diagnostic software BUDS2.
WARNING
Electrical actuators and electronic mod-
ules may be powered up as soon as the
START/STOP button is depressed. Always
disconnect the battery prior to disconnecting
any electrical or electronic parts.
IMPORTANT: Never use a battery charger to tem-
porarily substitute the battery as it may cause the
ECM to function erratically, or not at all.
Check related-circuit fuse solidity and condition
with an ohmmeter. A visual inspection could lead
to a false diagnosis.
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Poor Idling
If poor idling is experienced, check the following:
– Poor quality fuel or water in the fuel
– Fault codes using BUDS2
– Throttle body and flame arrestor cleanliness
– Engine leaks or other mechanical problem.
Electrical Related Problems
It is important to check the following in the elec-
trical system:
– Battery voltage
– Fuses
– Ground connections
– Wiring and connectors.
Ensure that all electronic components are original
BRP recommended components. Any modifica-
tion to the wiring harness may lead to poor sys-
tem operation or generate fault codes.
Electrical Connections
Pay particular attention to ensure that terminals
and pins are not out of their connectors, corroded,
or out of shape.
When probing terminals, pay attention not to de-
form the terminals as this could cause a loose or
intermittent connection that would be difficult to
troubleshoot.
NOTE: Do not apply dielectric grease or other lu-
bricants on the ECM connectors and on the starter
relay connector.
PROCEDURES
ENGINE CONTROL MODULE
(ECM)
NOTE: As a first troubleshooting step, always
check for applicable fault codes using the BRP
diagnostic software BUDS2.
ECM Location
The ECM is located in front of the engine.
smr2017-316
 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

ECM Power Circuit Diagram

- +

C3
00
(F3)
C4 C6 00
(F2)
B6
A6 C5

(R1)
RD/WH
B4
A4
B2
START/STOP
00 switch (4)
smr2017-316-001
(F1)
YE/RD
B1
B-M4
ECM Connector Identification Power (1)
B-H2
Signal (2)
There are 2 connectors connected to the ECM: Wake up (3)
B-D1
– Engine harness connected to ECM-A L1, M2, M3

– Vehicle system control harness connected to

ECM-B. smr2014-029-400_a

1. Power
2. Signal
3. Wake up
4. START/STOP switch

Validating the ECM Power Circuit

Briefly press START/STOP button.
This should wake up the ECM . The ECM will then
activate relay 1 which will turn ON all power. Af-
ter approximately 12 seconds, the multifunction
gauge indications will go out if the tether cord is
not installed, and all electrical power will be turned
lmr2010-022-002_a
off after approximately 3 minutes.
ECM CONNECTOR IDENTIFICATION - COOLING FINS FACING
OUT If the tether cord is installed when the
1. Connector A
2. Connector B START/STOP button is pressed, the multifunction
gauge and electrical power will stay on for
The ECM connectors have 48 pins. approximately 3 minutes if the START/STOP
NOTE: For connector information, cleaning and button is not pressed again, or if the engine is
probing, refer to WIRING HARNESS AND CON- not started.
NECTOR subsection. QUICK INDICATION THAT ECM IS POWERED
(ASSUMING THE OBSERVED COMPONENT
IS WORKING)

Multifunction gauge comes ON.

Fuel pump turns on for approx. 2 seconds (if tether

cord installed).

If ECM does not turn on, check the following:

– Fuse F1, F2 and F3.
– Battery voltage. Refer to CHARGING SYSTEM
subsection.
– Relay R1.
– START/STOP switch. Refer to STARTING SYS-
TEM subsection.
– ECM power circuit wires and ground wires.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

For testing of fuses and relay R1, refer to POWER

DISTRIBUTION AND GROUNDS subsection.
NOTE: When relay 1 is not working, the EMS (en-
gine management system) and the complete ve-
hicle electrical system will not be powered.

ECM Wake Up Logic

With Tether Cord Installed
When the START/STOP button is pressed to start
engine: 529035868

– ECM pin B-D1 receives current from battery via MULTIMETER PROBES READING CONDITION
the START/STOP switch. ECM is woken up.
Battery Power is
– ECM pin B-H2 provides a ground to the relay voltage ON
coil in fuse box. Fuse F1 Battery
contacts ground Power is
– The relay contacts close and provide main No voltage
12 Vdc power to the ECM at pin B-M4. OFF
– The relay also powers the other components in
the electrical system. ECM Shut Down Logic
– ECM pin B-E4 monitors for a tether cord in- When the engine is stopped by using the
stalled on the engine cut-off switch. START/STOP button or by removing the tether
– When the tether cord is installed on the engine cord from the engine cut-off switch, the following
cut-off switch, it completes a circuit that pro- occurs:
vides a ground to the ECM, pin B-F2. This tells – ECM stops the engine.
the ECM the tether cord is installed and the en- – After a few seconds, the multifunction gauge
gine can be started. If the engine is not started, turns off.
the power will be turned off after approximately – After 60 seconds, ECM (pin B-H2) removes the
3 minutes. ground to the relay coil.
Without a Tether Cord Installed – Relay contacts open and power to the ECM is
removed.
When the START/STOP button is pressed:
– Power is also removed on all other electrical
– The multifunction gauge turns on, goes through
systems.
the self-test function, displays applicable mes-
sages and turns off a few seconds later. Testing the ECM Wake Up Circuit
– The engine cannot be cranked.
1. Disconnect ECM-B connector
– The ECM stays powered up until it removes
the ground to the relay coil after 3 minutes (pin 2. Install ECM-B connector on the ECM adapter
B-H2). tool.
– Relay contacts open and power to the ECM is REQUIRED TOOL
removed.
– Power is also removed on all other electrical ECM ADAPTER TOOL
systems. (P/N 529 036 166)

Testing Electrical System Power After

Multifunction Gauge Shutdown 3. Use a multimeter and select Vdc.
1. Remove LH access cover. 4. While pressing START/STOP button, read volt-
age as follows.
2. Remove fuse box cover.
3. Using a multimeter set to Vdc, check for power
at the contacts on top of the ACC 10A fuse (F1).
REQUIRED TOOL
FLUKE 115 MULTIMETER (P/N 529 035 868)

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

ECM If voltage is not measured, check the wiring and

BATTERY MEASUREMENT connections between ECM and junction JT-1 VT/
ADAPTER
GY, refer to the WIRING DIAGRAM subsection.
Battery
D1 Battery voltage If all items mentioned in this test and in TESTING
ground
THE ECM WAKE UP CIRCUIT tested good, try a
If voltage is as per specification, refer to TESTING new ECM.
THE ECM POWER CIRCUIT.
If voltage is out of specification:
Testing the Continuity of ECM Ground
Circuits
– Test the START/STOP switch, refer to START-
ING SYSTEM subsection. 1. Connect ECM-B connector on the ECM adapter
– If START/STOP switch tests good, test wiring tool.
and connectors from battery to ECM. Refer to REQUIRED TOOL
WIRING DIAGRAM.
ECM ADAPTER TOOL
Testing the ECM Power Circuit (P/N 529 036 166)
1. Connect ECM connector "B" on the ECM
adapter tool.
2. Using the FLUKE 115 MULTIMETER (P/N 529 035
868) set to , probe adapter terminals as per
ECM ADAPTER TOOL
following table.
(P/N 529 036 166)
ECM BATTERY
RESISTANCE
ADAPTER POST
2. Install an appropriate fused jumper wire be-
tween the following terminals on the ECM Pins L1, M2 Close to 0
Ground
adapter tool. and M3 (continuity)

JUMPER WIRE COORDINATES ON ECM ADAPTER

H2 M2, M3 or L1

NOTE: When the jumper is installed, the multi-

function gauge should come on.
If the multifunction gauge did not come on, check
the following:
– Fuses F1, F2 and F3
– Relay 1
– Wiring between ECM-B contact 2H and fuse smr2009-030-010_a
F3, refer to the WIRING DIAGRAM subsection
– ECM ground circuit, refer to CONTINUITY TEST If any measurement is out of specification refer to
OF ECM GROUND CIRCUITS in this subsec- POWER DISTRIBUTION AND GROUNDS subsec-
tion. tion and check the following:
For testing of fuses and relay R1, refer to POWER – Wiring and connections
DISTRIBUTION AND GROUNDS subsection. – Engine grounds
If gauge came on, carry on with the following – Battery ground.
step.
Removing the ECM
3. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select Vdc. NOTE: If a new ECM is to be installed, first read
the procedures in REPLACING THE ECM in this
4. Check for voltage as follows. subsection.
ECM 1. Disconnect battery cables.
BATTERY VOLTAGE
ADAPTER
NOTICE Always disconnect the BLACK nega-
B-4M Negative post Battery voltage tive (–) battery cable first, then disconnect RED
positive (+) cable.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

2. Disconnect both ECM connectors from ECM. Make sure you are at: C:\Program
3. Remove ECM retaining screws and remove the Files(x86)\BRP\BUDS2\Files.
ECM. IMPORTANT: Be sure to use the file that specifi-
cally matches the vehicle you are servicing.
Installing the ECM
NOTE: The file name structure is as follows:
1. Reverse removal procedure however, pay at-
tention to the following. VIN_date read (yyyymmdd)_hour read (hhmmss).mpem

TIGHTENING TORQUE Example:

5.3 N•m ± 0.7 N•m 2BPSBK8C68V000168_20090206_111640.buds2
ECM screws
(47 lbf•in ± 6 lbf•in)
Therefore:
2. Reconnect ECM connectors.
VIN: 2BPSBK8C68V000168
3. Reconnect battery cables. Date: 2009 02 06
Hour: 11h 16m 40s
WARNING
Always reconnect the RED positive (+) battery 3. Select the Summary/ Vehicle page tab and
cable first, then reconnect BLACK negative (–) record (write down) the following information.
cable. 1. Vehicle serial number
2. Engine serial number
4. If a new ECM is installed, refer to REPLACING 3. Vehicle model number
THE ECM in this subsection. 4. Customer name.
NOTICE Always replace ECM by the same 2nd Collecting Method: Collect the
part number or by a BRP approved equivalent. Information from the Vehicle and BOSSWeb
Replacing the s ECM 1. Record engine serial number.
NOTE: Prior to replacing an ECM, ensure that all
the recommendations in the general introduction
of this subsection have been followed and all ap-
plicable testing procedures have been carried out.
When installing a new ECM, data must be entered
and a reset is required.

ECM Data Entry for ECM Replacement

Use one of the following 2 methods to collect the
required information. The 1st being the easiest:
1. Use BUDS2 to obtain the data from a saved
.buds2 file on your PC computer.
2. Collect the information from the vehicle and on
the Knowledge Center.
Once the required information has been collected, smr2014-029-006_a

LH SIDE OF ENGINE
refer to ENTERING THE COLLECTED INFORMA- 1. Engine serial number plate
TION INTO THE ECM. 2. Exhaust manifold

1st Collecting Method: Obtaining the Data 2. Record the following numbers from BOSSWeb.
from a Saved .buds2 File Look in Sales menu and choose Unit history.
1. Start the BRP diagnostic software BUDS2 1. Vehicle serial number
NOTE: It is not necessary to perform any connec- 2. Vehicle model number
tion. The PC computer can be used alone. 3. Customer name.
2. In BUDS2, click on the Open a BUDS2 file but-
ton.

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

NOTICE Do not enter SBOAT for a PWC. En-

ter only the appropriate product model num-
ber as obtained when gathering the informa-
tion.
NOTICE Pay particular attention when typ-
ing the V.I.N. and model numbers. Once Write
Data button is pressed, the data cannot be
modified.
4. Perform the CLOSED THROTTLE RESET pro-
cedure, refer to ADJUSTMENTS in this subsec-
tion.
5. Start the engine and ensure proper operation.
smr2014-026-004_a NOTICE The engine must not be run out of
SERVICE, UNIT HISTORY water without providing proper cooling to the
1. Click on SALES menu
2. Select Unit History exhaust system. Maximum engine run time
out of water is 2 minutes. Failure to do so may
result in damage to the exhaust system and
engine. Refer to EXHAUST SYSTEM subsec-
tion.
6. Reinstall any remaining removed parts.

smr2014-026-005_a
1. Vehicle Serial Number here
3. Enter the recorded data in the new ECM as de-
tailed in ENTERING THE COLLECTED INFOR-
MATION INTO THE ECM.
Entering the Collected Information Into the
ECM
1. Connect the vehicle to BUDS2. Refer to COM-
MUNICATION TOOLS AND B.U.D.S. subsec-
tion.
2. In BUDS2, click the Scan button to read the
new ECM.
3. Select the Summary/ Vehicle page tab and
FUEL RAIL
Removing the Fuel Rail
Disconnect battery, refer to POWER DISTRIBU-
TION AND GROUNDS.
Remove central body. Refer to BODY subsection.
Disconnecting the Fuel Rail Hose
1. Place an absorbent shop rag around the fuel
supply hose fitting at the fuel rail to catch any
fuel leakage.
2. Disconnect fuel hose from fuel rail.
REQUIRED TOOL
FUEL HOSE DISCONNECT TOOL (P/N 529 036 037)
529036037

write all of the following information you

recorded previously.
1. Vehicle serial number (VIN)
2. Engine serial number
3. Vehicle model number
4. Customer name.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

Fuel Rail Hose Connection

1. Apply engine oil on O-rings of the fuel rail hose
connector.

lmr2006-008-010

NOTE: It may be necessary to rotate fuel hose fit-

ting to align the tool ends with the openings of the mmr2009-121-022_a

1. Apply oil on O-rings

locking mechanism.
Removing the Fuel Rail
1. Disconnect all injector connectors.
2. Remove screws retaining the fuel rail.
2. Connect fuel hose to fuel rail.
IMPORTANT: Push fuel hose fitting on fuel rail un-
til you hear a "click". Try pulling fuel hose off fuel
rail to ensure fitting is properly locked.
3. Pressurize the fuel system and check for a fuel
leak. Refer to FUEL SYSTEM HIGH PRESSURE
LEAK TEST in FUEL TANK AND FUEL PUMP
subsection.
WARNING
Failure to pressurize the fuel system may re-
sult in severe injury or a life threatening situ-
ation should a leak occur.

4. Reinstall all remaining removed parts.

FUEL INJECTOR
Testing the Fuel Injector Operation
smr2014-029-007_a (Dynamic)
1. Fuel rail
2. Fuel injector connectors 1. Connect watercraft to BUDS2 software. Refer
3. Retaining screws to COMMUNICATION TOOLS AND B.U.D.S.
3. Gently wiggle fuel rail side to side as you pull 2. Start engine.
the fuel rail out with fuel injectors. NOTICE The engine must not be run out of
Installing the Fuel Rail water without providing proper cooling to the
exhaust system. Maximum engine run time
Reverse the removal procedure. However, pay at- out of water is 2 minutes. Failure to do so may
tention to the following. result in damage to the exhaust system and
Apply engine oil on each injector O-rings. engine. Refer to EXHAUST SYSTEM subsec-
tion.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Fuel rail screws
(80 lbf•in ± 9 lbf•in)

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))
3. In BUDS2, click the following:
– Scan button
– Functions tab.
4. Using the BUDS2 software, shut down each
engine cylinder one at a time by clicking on the
button under the applicable cylinder.
If the engine RPM drops when clicking on a cylin-
der, the injector and the ignition of this cylinder are
functioning normally.
If the engine RPM does not drop when clicking on
a cylinder, this cylinder is not functioning properly.
Check the following:
– Fuel injector operation. Refer to TESTING THE
FUEL INJECTOR OPERATION WITH BUDS2
(STATIC).
– Spark plug and ignition coil. Refer to IGNITION
SYSTEM.
– Engine condition.
Testing the Fuel Injector Operation
(Static)
NOTICE After fuel injector activation us-
ing BUDS2, always crank engine in drowned
mode to ventilate engine and prevent a poten-
tial backfire due to fuel accumulation in the
engine.
1. Connect watercraft to BUDS2 software. Refer
to COMMUNICATION TOOLS AND B.U.D.S.
2. Press the START/STOP button to wake up the
ECM.
3. Install the tether cord on the engine cut-off
switch.
4. In BUDS2, click the following:
– Scan button
– Functions tab
– ECM page.
5. click on the fuel injector to be tested
6. Listen for the injector activation.
If you can hear the injector, it validates its oper-
ation. Carry out the FUEL INJECTOR BALANCE
TEST.
If you do not hear the injector, carry out the TEST-
ING THE INJECTOR INPUT VOLTAGE.
smr2017-316
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Testing the Fuel Injector Balance with
BUDS2
NOTICE After fuel injector activation us-
ing BUDS2, always crank engine in drowned
mode to ventilate engine and prevent a po-
tential backfire due to fuel accumulation in
engine.
1. Install a fuel pressure gauge as described in
FUEL PUMP PRESSURE TEST of FUEL TANK
AND FUEL PUMP subsection.
2. Connect watercraft to BUDS2 software. Refer
to COMMUNICATION TOOLS AND B.U.D.S.
3. Press the START/STOP button to wake up the
ECM.
4. Install tether cord on engine cut-off switch.
5. In BUDS2, click the following:
– Scan button
– Functions tab
– ECM page.
6. click the Fuel Pump button to activate fuel
pump.
Fuel pressure must be within specification. Re-
fer to FUEL TANK AND FUEL PUMP subsection.
Re-activate fuel pump as necessary.
7. In BUDS2, energize fuel injector no. 1.
8. Record the fuel pressure drop for injector no. 1.
9. click the Fuel Pump button to activate fuel
pump.
10. Repeat step 6 and 7 for fuel injectors no. 2 and
no. 3 and record the pressure drop for each
injector.
The maximum fuel pressure drop between injec-
tors should not exceed the following specification:
MAXIMUM FUEL PRESSURE DROP ALLOWED
BETWEEN FUEL INJECTORS
10 kPa (1.5 PSI)
If pressure drop of any fuel injector is greater than
the specification, replace that injector then repeat
the test.
11. Using the valve on the fuel pressure gauge,
release the pressure in the system (if so
equipped).
12. Remove fuel pressure gauge and reinstall re-
moved parts.
Testing the Fuel Injector Resistance
(at Component)
1. Remove injector connector.
11
Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

2. Check resistance value between injector pins PROBE INJECTOR

as per followings table. MEASUREMENT
CONNECTOR
RESISTANCE @ VIOLET wire with a
INJECTOR PIN Battery voltage
20°C (68°F) tracer to battery ground
1 2 11.4 - 12.6

smr2009-030-029_a

If battery voltage is measured, refer to TESTING

smr2014-029-039_a
If readings are not as specified, replace injector.
If readings are as specified, repair or replace
wiring and connectors from ECM to injector.
Testing the Fuel Injector Input Voltage
1. Disconnect fuel injector connectors.
NOTE: Press against tab underneath connector
as illustrated to unlock it.
THE FUEL INJECTOR SIGNAL.
If battery voltage is not measured, check con-
tinuity between fuse box and injector. Refer to
WIRING DIAGRAM.
Testing the Fuel Injector Signal
1. Connect vehicle to BUDS2 Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection.
2. Press the START/STOP button to wake up the
ECM.
3. Install the tether cord on the engine cut-off
switch.
4. In BUDS2, select:
– Scan button
– Functions tab.
5. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and set it to Vdc.
NOTE: Make sure multimeter is in the Auto
Range mode.

smr2009-030-028_a

PRESS HERE TO UNLOCK

2. Press the START/STOP button to wake up the

ECM.
3. Install tether cord on engine cut-off switch.
4. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select Vdc.
5. Read input voltage to the applicable injector as
per following table.

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

INJECTOR
INJECTOR CONNECTOR BATTERY MEASUREMENT
CONTACT
BROWN/RED
No. 1
wire
BROWN/BLUE Battery Approximately
No. 2
wire ground 40 Hz
BROWN/Gray
No. 3
wire

If there is a frequency reading, the control circuit

is functional.
If there is no reading, check continuity of control
circuit (ECM to injectors). Refer to WIRING DIA-
GRAM for circuit details.
Removing the Fuel Injector
mmr2009-120-020_a
1. Remove fuel rail and injectors as an assembly.
6. Press the Hz button so that the display shows Refer to FUEL RAIL in this subsection.
Hz. 2. Remove the injector retaining clip.

smr2014-029-010_a

FUEL RAIL ASSEMBLY

1. Fuel injector
2. O-rings
3. Injector retaining clip

mmr2009-120-020_b
7. Connect the multimeter probes as indicated in
the following table and using the BUDS2 soft-
ware, activate each injector and read the fre-
quency on the multimeter.
NOTE: The multimeter counts the pulses per sec-
onds (Hertz) of current the ECM sends to the in-
jector.
3. Pull the fuel injector out of the fuel rail and dis-
card the O-rings..
Installing the Fuel Injector
NOTICE If installing the removed injector(s),
always install NEW O-rings.
1. Apply a thin film of engine oil to O-rings to pre-
vent possible damage and to ease insertion in
rail.
NOTICE Install fuel injector with your hand.
Do not use any tool.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

For the installation, reverse the removal proce-

dure however, pay attention to the following
details.
2. Ensure proper positioning of the intake mani-
fold O-ring on injector as in following illustra-
tion.

mmr2009-121-022_a

FUEL PRESSURE HOSE FITTING

1. Apply oil on O-rings

6. Connect fuel pressure hose to fuel rail.

vmr2006-014-071_a
TYPICAL - INTAKE MANIFOLD O-RING POSITION
NOTICE Gently push O-ring in evenly all
around while inserting injector. O-ring must
be completely inserted and not visible, before
completing the insertion of the injector.
IMPORTANT: Push fuel hose fitting on fuel rail un-
til you hear a "click". Try pulling on fuel hose fitting
to ensure it is properly locked.
7. Pressurize the fuel system and check for fuel
leaks. Refer to FUEL SYSTEM PRESSURIZA-
TION in FUEL TANK AND FUEL PUMP subsec-
tion.
WARNING
Failure to pressurize the fuel system and
checking for fuel leaks may result in severe
injury or a life threatening situation should a
leak occur.

8. Reinstall all remaining removed parts.

THROTTLE BODY
Throttle Body Description

vmr2006-014-072_a

TYPICAL

3. Firmly push injector in until it bottoms out.

4. Install fuel rail on injectors. Refer to IN-
STALLING THE FUEL RAIL in this subsection.
5. Apply engine oil on O-rings of fuel pressure
hose fitting. smr2009-030-016_a

1. Throttle body
2. Throttle plate
3. Throttle actuator (electric motor inside)
4. Throttle position sensor (TPS) (inside)

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

Electric Throttle Actuator (ETA) FAULT EFFECT

The electric throttle actuator (ETA) is a DC mo-
tor on the throttle body that regulates the throttle
plate via a drive gear. It receives its control signal
from the ECM. Pulse width modulation (PWM) is
used to control the motor.
Throttle Plate Operating Positions
Two torsional springs are connected to the throttle
plate. A main spring and another one in a plunger
mechanism.
When there is no power to the throttle actuator
(ETA), the plunger mechanism maintains the throt-
tle plate at a rest position. This also serves as the
limp home position.
When the throttle plate is opened by the ETA as
commanded by the ECM, it acts against the main
spring. If the ETA failed, the return spring would
bring the throttle plate back to the limp home po-
sition.
ECM ENGINE THROTTLE BODY
Throttle actuator: Off.
Throttle plate: Rest position, maintained
OFF Stopped
opened at approximately 8° (1). This is
also the limp home position.
Throttle actuator: On.
Throttle plate: Moves from the
rest position to approximately 15°. It
then moves back to the rest position.
Not This is the diagnostic mode where the
ON
started rest position, actuator opening force to
overcome the return springs and the
motor return rate are monitored. If any
of these parameters are out of range, a
fault code is initiated.
Throttle actuator: On.
Throttle plate: Moves from the
Started.
rest position to idle position
Normal
ON (approximately 1-3°) according to
operation
ECM injection and ignition maps.
at idle
Throttle plate is opened and closed as
necessary to control the idle speed.
Started.
Throttle actuator: On.
Normal
Throttle plate: Opens and closes
ON operation
according to ECM torque management
at various
priorities.
RPM
(1) Degree values are given from the fully closed position.
Throttle-Body Faults and Effects
NOTE: Among other things, a weak or broken
spring and a sticky throttle plate are validated by
the throttle body diagnostic mode.
Limp home mode. Engine speed limited to idle.
ECM will use the remaining TAS sensor.
Partial failure
Fault code set and beeper
of TAS sensor
activated to emit warning signals.
(one internal
sensor only)
Check engine light is turned ON.
Driveability could be reset by releasing
and reapplying the throttle.
Complete Limp home mode. Engine
failure of speed limited to 2500 RPM.
TAS sensor Fault code set and beeper
(both internal activated to emit warning signals.
sensors) Check engine light is turned ON.
Limp home mode. Engine
speed limited to 2500 RPM.
Engine speed can still be increased up
Any throttle
to 3200 RPM using the throttle lever.
body failure
Fault code set and beeper
activated to emit warning signals.
Check engine light is turned ON.
NOTE: When one of these faults is active, O.T.A.S. will
continue to monitor its input signals. However, since the
engine speed is limited, the O.T.A.S. will not be activated.
Lubricating the Throttle Body
No lubrication is required.
Testing the Electric Throttle Actuator
(ETA)
Electric Throttle Actuator (ETA) Test
1. Connect vehicle to BUDS2. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection.
2. Press the START/STOP button to wake up the
ECM.
3. Install the tether cord on the engine cut-off
switch.
4. In BUDS2, select:
– Scan button
– Setting page tab.
NOTE: Use the Setting page to confirm ETA
movement. The Measurements page will not
read the actual ETA movement.
5. Slowly depress the throttle lever from the idle
to WOT. The ETA should go from almost 10%
to 100%.
If result is out of specification, carry out a CLOSED
THROTTLE RESET. Refer to ADJUSTMENT in
this subsection.
NOTE: The ETA is reset at the same time as the
TPS.
After the reset, test ETA again.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

If the result is still out of specification, check wire
continuity between ECM and throttle body before
assuming the ETA is at fault.
Inspecting the Throttle Body
Always check for corroded terminals or damaged
wiring when diagnosing throttle body problems.
Throttle Body Dynamic Tests
1. Remove the parts required to access the throt-
tle body, refer to THROTTLE BODY REMOVAL.
2. Remove the air inlet hose from the throttle
body.
3. Observe the throttle plate with the engine
stopped.
NOTE: The throttle plate should be in the rest po-
sition (slightly opened).
Throttle Body Static Tests
WARNING
First ensure the ECM is off. Do not move the
throttle plate using your fingers. Otherwise,
should the START/STOP button be pressed,
the ECM would turn on and quickly cycle the
throttle plate which could cause serious fin-
ger injury.
1. Using a blunt tool, push in on the throttle plate
and ensure it opens smoothly within the throt-
tle body.

WARNING
Keep your fingers out of the throttle plate
area while the ECM turns on. The throttle
actuator will cycle. This could cause seri-
ous finger injuries as throttle plate quickly
moves.

4. As you observe the throttle plate, have some-

one press the START/STOP button to wake up
the ECM. smr2009-030-016_b

1. Push here to open

NOTE: The throttle plate should cycle quickly
from the rest position to a partially open position NOTE: The throttle plate must open fully and re-
(approximately 15°), then back to the rest posi- turn freely to the rest position (slightly opened)
tion. when released.
5. Install the tether cord on the engine cut-off 2. Push throttle plate closed as indicated in follow-
switch. ing illustration. It must close completely and re-
NOTE: The throttle plate should cycle again. turn freely to the rest position (slightly opened)
when released.
6. As you observe the throttle plate, have some-
one gradually and evenly pull in the throttle
lever, then release it in the same way.
NOTE: The throttle plate should open then close
according to throttle lever position however, the
movement of the throttle plate may not be linear
with the displacement of the throttle lever.
If any test failed, proceed with the THROTTLE
BODY STATIC TESTS.

smr2009-030-016_c

1. Push here to close

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

If the throttle plate does not move smoothly or WARNING

does not return freely to the rest position, the
problem is mechanical. Check for salt accumu- Ensure nobody presses the START/STOP but-
lation on throttle plate shaft. It may also be an ton. The ECM would turn on and the throttle
actuator or gear problem. Replace throttle body actuator (ETA) would cycle. This could cause
as necessary. serious finger injury as the throttle plate
moves quickly.
If throttle plate operates normally, the problem is
electrical. Check electric throttle actuator (ETA) To remove residual dirt, spray cleaner on throttle
wiring continuity, throttle position sensor (TPS) plate and on bore.
and throttle accelerator sensor (TAS).
Reinstall removed parts.
WARNING
If the throttle plate does not return to its rest
Replacing the Throttle Body
position properly after a proper cleaning, re- Removing the Throttle Body
place the throttle body. 1. Remove central body. Refer to BODY subsec-
tion.
Cleaning the Throttle Body 2. Disconnect inlet hose from throttle body.
Remove the parts required to access the throttle
3. Disconnect throttle body connector.
body, refer to REMOVING THE THROTTLE BODY.
Check throttle body cleanliness using a flashlight.
Fully open throttle plate and verify:
– Throttle body bore
– Throttle plate edge.
Look for:
– Dirt
– Oily surfaces
– Carbon and salt deposits on throttle plate and
the surrounding bore.
Clean as necessary.
NOTICE Only use an appropriate throttle
body cleaner that will not damage O-rings and
EFI sensors. smr2014-029-012_a

TYPICAL
WARNING 1. Throttle body
2. Inlet hose
Use the product in well ventilated area. Refer 3. Inlet hose clamp
4. Throttle body connector
to product manufacturer's warnings. Wipe
off any product leakage in bilge.

To avoid getting dirt into engine, spray cleaner on

a clean rag (outside the bilge) then rub rag against
throttle plate and bore. A toothbrush works well
too.
WARNING
First ensure ECM is off. Otherwise, if ECM
should suddenly turn off, it would quickly
close the throttle plate which could cause
serious finger injury.

Manually open throttle and hold fully open to

reach all surfaces. smr2009-030-031_a

PRESS HERE TO UNLOCK

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

4. Remove retaining screws from throttle body. THROTTLE POSITION SENSOR

(TPS)
General
NOTE: The TPS is part of the throttle body.
The throttle position sensor (TPS) is a double po-
tentiometer that sends signals to the ECM that
are proportional to the throttle plate angle. The
TPS is located inside the throttle body.

Testing the TPS Wear

1. With the engine turned off, slowly pull in throt-
tle lever and pay attention for smooth operation
without physical stops.
2. Press the START/STOP button to wake up the
smr2014-029-013_a
ECM.
1. Throttle body screws 3. Install the tether cord on the engine cut-off
switch.
5. Pull throttle body off intake manifold.
4. Connect watercraft to BUDS2 software. Refer
Installing the Throttle Body to COMMUNICATION TOOLS AND B.U.D.S.
Installation of the new throttle body is the reverse subsection.
of the removal procedure. However, pay attention 5. In BUDS2 click the following:
to the following. – Measurements tab
1. Tighten retaining screws to specification as per – ECM tab.
following sequence.
6. Slowly and regularly depress the throttle lever.
TIGHTENING PROCEDURE 7. Observe the Throttle Opening needle move-
5 N•m ± 0.6 N•m ment in BUDS2
Step 1
Throttle body (44 lbf•in ± 5 lbf•in) NOTE: The needle should move gradually and
screws Step 2 9 N•m ± 1 N•m regularly as you move the throttle lever. If the
through 5 (80 lbf•in ± 9 lbf•in) needle “sticks”, bounces or suddenly drops, it
may indicate a worn TPS that needs to be re-
placed. An initial slight delay after the throttle
lever is pulled and before the needle starts to
move is normal.
If the needle behavior is not as expected, proceed
with the following steps.
8. Manually move the throttle plate in throttle
body using a blunt tool (without sharp tip).

WARNING
Do not move throttle plate with your fingers.
Otherwise, if ECM should turn off, it would
quickly close the throttle plate which could
cause serious finger injury.
smr2014-029-013_b

2. Perform the CLOSED THROTTLE RESET. See

procedure in ADJUSTMENTS.

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

FULLY CLOSED FULLY OPEN

ECM THROTTLE THROTTLE
ADAPTER PLATE (1) PLATE
RESISTANCE ( )
PIN MIN. MAX. MIN. MAX.
A-A2 A-K4 625 3000 625 3000
A-A2 A-K3 678 3768 163 1260
A-A2 A-F3 178 1368 700 3840
A-K3 A-K4 163 1260 678 3768
A-K3 A-F3 925 4800 925 4800
smr2009-030-016_b A-K4 A-F3 700 3840 178 1368
1. Push here
(1) To obtain the fully closed position, it is necessary
9. Check needle movement again. to push against the throttle plate in the throttle
– If needle moves as expected, check the throttle body with a finger and hold it in this position for the
measurement.
accelerator sensor (TAS). Refer to THROTTLE
ACCELERATOR SENSOR (TAS) in the INTELLI-
GENT THROTTLE CONTROL (ITC) subsection.
– If needle does not move as expected, go to
TESTING THE TPS RESISTANCE in this subsec-
tion.

Testing the TPS Resistance

1. Remove the parts required to access the throt-
tle body, refer toREMOVING THE THROTTLE
BODY in this subsection.
2. Ensure the throttle body connector is properly vmr2008-022-005_a
connected.
3. Disconnect ECM-A connector from the ECM, If any resistance value is incorrect, check wire
refer to ECM CONNECTOR ACCESS in this continuity between ECM and throttle body before
subsection. assuming the TPS is at fault. Refer to WIRING
DIAGRAM subsection.
4. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select .
5. Probe circuit as per following table while using
a finger to manually move throttle plate.

smr2009-030-032_a

TPS CONNECTOR PIN-OUT

If the TPS resistance values are correct, try a new

ECM. Refer to ENGINE CONTROL MODULE
(ECM) in this subsection.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

CRANKSHAFT POSITION
SENSOR (CPS)
CPS TROUBLESHOOTING
When troubleshooting a CPS fault, take into ac-
count that a CPS fault can be triggered by bent or
missing encoder wheel teeth.
Push START/STOP button and crank engine. If en-
gine does not start within 15 seconds check for
fault codes using BUDS2. 529035868

CPS and CPS Connector Location 4. Measure the resistance of the sensor as per fol-
lowing table.
RESISTANCE
ECM A CONNECTOR
@ 20°C (68°F)
Pin H1 Pin K2 775 - 950

If resistance is as specified, test continuity of

wiring between ECM-A and CPS connectors.
Refer to WIRING DIAGRAM subsection.
If resistance value is not as specified, reconnect
ECM-A connector to the ECM and refer to CPS
RESISTANCE TEST AT CPS CONNECTOR.
Testing the CPS Resistance at CPS
smr2014-029-014_a
Connector
TYPICAL - RH SIDE OF ENGINE 1. Disconnect CPS wiring harness connector.
1. CPS location
2. CPS connector location

Testing the CPS Resistance at ECM

Connector
1. Remove parts required to access ECM-A con-
nector, refer to ECM CONNECTOR ACCESS in
this subsection.
2. Disconnect ECM-A connector from the ECM
and connect it to the ECM adapter.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

smr2014-029-015_a
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
FRONT OF ENGINE
868) to . 1. CPS connector location

2. Probe CPS connector terminals as per following

table.
CPS CONNECTOR MEASUREMENT
RESISTANCE
PIN
@ 20°C (68°F)
1 2 775 - 950

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

If voltage is as specified, check continuity of

wiring between CPS connector and ECM connec-
tor. Refer to WIRING DIAGRAM.

Replacing the CPS

1. Remove air intake silencer to access the CPS,
refer to AIR INTAKE SYSTEM subsection.
2. Take note of factory CPS wire harness routing
for reinstallation.
3. Disconnect CPS connector and cut harness
locking ties.

smr2014-029-029_a

If resistance is not within specifications, replace

the CPS.
If resistance tests good, carry out a CPS OUTPUT
VOLTAGE TEST.
Testing the CPS Voltage
1. Press the START/STOP button to wake up the
ECM.
2. Install the tether cord on the engine cut-off
switch.
smr2014-029-016_a
3. Pull the throttle lever completely in to the han- 1. CPS
dlebar and hold (drowned mode). 2. CPS wiring harness
3. CPS connector
4. While cranking the engine, probe CPS termi- 4. Locking ties
nals.
4. Remove CPS retaining screw and pull on CPS
CPS CONNECTOR MEASUREMENT to remove it from engine.
PIN VOLTAGE
1 2 Approximately 3.7 Vac

smr2014-029-017_a

1. CPS
2. Retaining screw

5. Apply engine on O-ring of the new CSP.

smr2014-029-029_b
6. Install the CPS.
If voltage is not as specified, carry out a CPS RE-
SISTANCE TEST.
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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

TIGHTENING TORQUE
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
CPS screw +
LOCTITE 243 (BLUE)
(P/N 293 800 060)

Apply DIELECTRIC GREASE (P/N 293 550 004) on

CPS connector.
7. Route and secure CPS harness using locking
ties as noted prior to removal.
8. Reconnect CPS connector.
9. Install air intake silencer, refer to AIR INTAKE
SYSTEM subsection. smr2014-029-019_b

1. CAPS connector
NOTE: Ensure tab on air hose is aligned between
the two marks on the intake silencer. 3. Press the START/STOP button to wake up the
10. Install all remaining removed parts, refer to ap- ECM.
plicable subsection. 4. Install tether cord on engine cut-off switch.
5. Probe harness connector terminals as per fol-
CAMSHAFT POSITION SENSOR lowing table.
(CAPS) CAPS CONNECTOR MEASUREMENT
PIN VOLTAGE
3 1 Battery voltage

smr2014-029-019_a

1. CAPS
smr2014-029-032_a

1. CAPS
Testing the CAPS Voltage(Harness 2. CAPS connector
Side)
1. Remove the parts required to access the CAPS. If battery voltage is read, proceed with CAPS DY-
NAMIC TEST further in this subsection.
2. Disconnect CAPS connector.
If battery voltage is not read, probe circuit as per
following table.
CAPS CONNECTOR MEASUREMENT
PIN VOLTAGE
Battery
3 Battery voltage
ground

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

smr2014-029-032_b

If voltage is read to battery ground, check continu- smr2014-029-021_a

ity of ground circuit between CAPS pin 1 and ECM
connector "A" pin E2. Repair or replace wiring and
connectors.
If voltage is not read to battery ground, carry out
a CONTINUITY TEST OF CAPS POWER CIRCUIT.
Testing the Continuity of CAPS Power
Circuit
1. Remove cover from fuse box. Refer to POWER
DISTRIBUTION.
2. Remove 10 amp ACC fuse (F1).
If continuity is good, wiring and connectors are
functional.
If a high resistance or an open circuit is measured,
refer to WIRING DIAGRAM and check the follow-
ing:
– Continuity from CAPS connector pin 3 to engine
connector pin 4
– Continuity from engine connector pin 4 to fuse
box contact B1
Pay attention to connector pin contact and junc-
tion JT-1 (VT/GY).
Repair or replace wiring and connectors as re-
quired.
5. Reinstall all removed parts.

Testing the CAPS (Dynamic)

1. Remove the parts required to access the CAPS.
2. Remove CAPS sensor from engine.
3. Back-probe connector and read voltage as fol-
lows.
NOTE: To safely probe wire terminals through the
back of the connector, use the following tool or an
equivalent.
smr2014-029-020_a
REQUIRED TOOL
1. Pull out fuse (F1)
FLUKE AUTOMOTIVE BACK PROBE PIN (P/N TP40)
3. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select .
4. Read resistance of the CAPS circuit as per fol-
lowing table.
TP40
CAPS
FUSE BOX RESISTANCE FLUKE AUTOMOTIVE BACK PROBE PIN P/N TP40
CONNECTOR
TERMINAL PIN NOTICE Do not use sharp end probes. They
could damage the connector seal.
Close to 0
B1 3
(continuity)

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

Probes can be inserted at the end of the FLUKE

SUREGRIP INSULATED TEST LEADS (P/N TL224).

tl224

smr2007-021-009_c
4. Briefly press the START/STOP button to wake TYPICAL
up the ECM. 1. Metallic object

5. Install the tether cord cap on the engine cut-off If voltage is as specified, repair or replace wiring
switch. and connectors between sensor and ECM.
6. Read voltage as per following tables. If wiring is good, check ECM. Refer to ENGINE
CAPS CAPS CONTROL MODULE (ECM).
VOLTAGE
CONDITION CONNECTOR If battery voltage is not measured as specified, try
Free 3 2 Close to 0 Vdc a new CAPS.

Replacing the CAPS

1. Disconnect CAPS connector.

smr2007-021-010_a smr2014-029-019_b

TYPICAL 1. CAPS connector

CAPS CAPS
VOLTAGE 2. Unscrew the CAPS retaining screw.
CONDITION CONNECTOR
Metallic
object on 3 2 Battery voltage
sensor

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

MAPTS Pressure Function

Before the engine is started, when power is ap-
plied to the system, the sensor measures the
ambient atmospheric air pressure. The ambient
air pressure is at that moment stored in the ECM.
Thereafter, once the engine is started, it mea-
sures the air pressure in the intake manifold at
operating RPMs.
The sensor must be correctly installed on the in-
take manifold. Otherwise, the MAPTS could gen-
erate a fault code for an unexpected sensor range
at idle when it reads an erroneous intake manifold
pressure. If this is the case, remove sensor and
check for oil or dirt on its end and if problem per-
smr2014-029-019_c

1. CAPS retaining screw

sists, check throttle plate condition/position and
the wiring harness. Perform the following tests.
3. Pull CAPS from engine.
MAPTS Quick Test (Pressure Function)
4. Install the new CAPS.
1. Connect vehicle to BUDS2 Refer to COMMU-
NOTICE Be sure to install new O-ring on the NICATION TOOLS AND B.U.D.S. subsection.
new CAPS. 2. In BUDS2, select the following:
TIGHTENING TORQUE – Scan
– Measurements page tab
9 N•m ± 1 N•m
CAPS screw
(80 lbf•in ± 9 lbf•in) – ECM page.
3. Look for and take note of the MAPTS pressure
Apply DIELECTRIC GREASE (P/N 293 550 004) on reading while the engine is stopped.
CAPS connector. NOTE: The indicated intake air pressure in
BUDS2 must be within 3.4 kPa (.5 PSI) of lo-
MANIFOLD ABSOLUTE cal atmospheric pressure when the engine is
PRESSURE AND TEMPERATURE stopped.
SENSOR (MAPTS) MAPTS PRESSURE FUNCTION QUICK TEST
NOTE: This sensor is a multifunction device. It RESULT SERVICE ACTION
measures manifold absolute pressure and intake Circuit
air temperature for air flow calculations. Continuity MAPTS
Repair or
NO Test of Input
MAPTS Access replace
READING MAPTS Voltage
wiring
Pressure Test
Function
VALUE IS
OUT OF Replace MAPTS
RANGE

4. Perform the same test with a new MAPTS and

compare both readings.
Testing the MAPTS Input Voltage
1. Remove parts required to access the MAPTS,
refer to MAPTS ACCESS.
2. Remove electrical connector from MAPTS.

smr2014-029-018_a

MAPTS LOCATION
1. Manifold air pressure and temperature sensor (MAPTS)

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

ECM ADAPTER TOOL

(P/N 529 036 166)

3. Using the FLUKE 115 MULTIMETER (P/N 529 035

868) set to and check continuity of the follow-
ing circuits.

smr2014-029-023_a

1. MAPTS connector

3. Briefly press START/STOP button.

4. Install tether cord cap on engine shut-off
switch. 529035868

5. Using a FLUKE 115 MULTIMETER (P/N 529 035

MAPTS CIRCUIT CONTINUITY (PRESSURE
868) set to Vdc, measure for MAPTS input volt-
FUNCTION)
age as per following table.
MAPTS RESISTANCE
MAPTS CONNECTOR MEASUREMENT ECM-A
CONNECTOR VALUE
PIN VOLTAGE Pin B4 Pin 3
1 3 5 Vdc Pin G4 Pin 4 Close to 0
Pin H2 Pin 1

If resistance is not within specification, repair or

replace the wiring harness between ECM connec-
tor and the MAPTS. Refer to WIRING DIAGRAM.

MAPTS Temperature Function

smr2014-029-033_a
If voltage test is good, replace the MAPTS.
If voltage test is not good, carry out the MAPTS
CIRCUIT CONTINUITY TEST (PRESSURE FUNC-
TION).
Testing the MAPTS Circuit Continuity
(Pressure Function)
1. Remove parts required to access ECM connec-
tors, refer to ECM CONNECTOR ACCESS in
this subsection.
2. Disconnect the ECM-A connector from the
ECM and connect it to the ECM adapter tool.
26 https://brp-manuals.com/pwc_seadoo
The MAPTS also monitors the temperature of the
air in the intake manifold.
Testing the MAPTS (Temperature Function)
1. Connect vehicle to BUDS2 Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection.
2. In BUDS2, select the following:
– Scan
– Measurements page tab
– ECM page.
3. Look for the Intake Air temperature reading
while the engine is stopped.
NOTE: If the complete vehicle is at room temper-
ature, BUDS2 should display the ambient air tem-
perature at the intake manifold.
4. Perform the same test with a new MAPTS and
compare both readings.
smr2017-316
 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

If the engine's MAPTS temperature reading is sig- 4. Install ECM-A connector on the ECM adapter
nificantly different than the new MAPTS, replace tool.
it.
REQUIRED TOOL
NOTE: Both sensors must feel same ambient air
temperature. ECM ADAPTER TOOL
If there is no reading, carry out a MAPTS RESIS- (P/N 529 036 166)
TANCE TEST (TEMPERATURE FUNCTION).
Testing the MAPTS Resistance (Temperature 5. Using a multimeter, recheck resistance value as
Function) per following table.
1. Disconnect the MAPTS connector. ECM
MEASUREMENT
2. Using the FLUKE 115 MULTIMETER (P/N 529 035 ADAPTER
868) set to , test MAPTS resistance at the sen-
PIN Refer to MAPTS TEMPERATURE
sor as per following tables.
H2 H3 SENSOR TABLE
MAPTS MEASUREMENT
PIN MAPTS TEMPERATURE SENSOR TEST RESULTS
Refer to MAPTS
1 2 TEMPERATURE SENSOR TABLE RESULT SERVICE ACTION
Circuit
Continuity MAPTS
Repair or
NO Test of Input
replace
READING MAPTS Voltage
wiring
Temperature Test
Function
INCORRECT
Check condition of connector
RESISTANCE
pins, replace MAPTS
VALUE
CORRECT
RESISTANCE Try a new ECM
VALUE

Testing the MAPTS Circuit Continuity

(Temperature Function)
smr2014-029-034_a
MAPTS CIRCUIT CONTINUITY (TEMPERATURE
FUNCTION)
MAPTS TEMPERATURE SENSOR TABLE
ECM MAPTS RESISTANCE
RESISTANCE ADAPTER CONNECTOR VALUE
TEMPERATURE
(ohms)
Pin H2 Pin 1
°C °F MAPTS Close to 0
Pin H3 Pin 2
- 40 - 40 40528 to 56935
- 10 - 14 8103 to 10919 Repair or replace wiring as required.
20 68 2193 to 2863
80 176 294 to 368
120 248 98 to 122

If resistance is not within specification, replace

the MAPTS.
If resistance tests good, reconnect the MAPTS
and proceed with the following steps.
3. Disconnect the ECM-A connector.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

Replacing the MAPTS Overheat Warning

The CTS will cause the engine overheat warning
to come on when the coolant temperature is
above 100°C (212°F).

Testing the CTS

1. Connect the vehicle BUDS2 Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection.
2. In BUDS2, select the following:
– Scan button
– Measurements page tab
– ECM page.
3. Look for the engine temperature indication.
smr2014-029-022_a The engine temperature gauge in BUDS2 should
1. MAPTS provide an indication of the actual engine coolant
2. MAPTS connector
3. Retaining screw temperature. Otherwise, perform the TESTING
4. Intake manifold THE CTS RESISTANCE.
1. Disconnect MAPTS connector and remove the Testing the CTS Resistance
MAPTS from the intake manifold.
1. Remove parts required to access ECM connec-
2. Install new MAPTS as per following table. tors, refer to ECM CONNECTOR ACCESS in
TIGHTENING TORQUE this subsection.
4.5 N•m ± 0.5 N•m 2. Disconnect the ECM-A connector.
MAPTS screw
(40 lbf•in ± 4 lbf•in) 3. Install ECM-A connector on the ECM adapter
tool.
Apply DIELECTRIC GREASE (P/N 293 550 004) on
MAPTS connector. REQUIRED TOOL

COOLANT TEMPERATURE ECM ADAPTER TOOL

(P/N 529 036 166)
SENSOR (CTS)
4. Using a multimeter, check resistance from the
ECM connector as per following table.
ECM
MEASUREMENT
ADAPTER
PIN Refer to CTS
TEMPERATURE SENSOR TABLE
A1 J2

If resistance test is good, refer to REPLACING

THE ECM.
If resistance is out of specification, proceed with
the following steps.
5. Disconnect the CTS connector.
6. Check continuity of wiring between ECM and
smr2014-029-024_a CTS connector, refer to WIRING DIAGRAM. If
there is an open circuit, repair or replace wiring
TYPICAL - FORWARD END OF ENGINE
1. Oil cooler and connectors.
2. Water pump
3. Coolant temperature sensor (CTS) 7. If continuity of wiring is good, test the resis-
tance of the sensor as per following tables.

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

CTS
MEASUREMENT
EXHAUST GAS TEMPERATURE
SENSOR SENSOR (EGTS)
PIN Refer to CTS
1 2 TEMPERATURE SENSOR TABLE

CTS TEMPERATURE SENSOR TABLE

TEMPERATURE RESISTANCE (OHMS)
°C °F LOW HIGH
- 40 - 40 38457 52630
- 10 14 8208 10,656
20 68 2233 2780
80 176 297 349
120 248 105 122

NOTE: To test sensor at various temperatures, re-

move sensor and use a heat gun, ice and a ther- smr2014-029-025_a

mometer. Refer to REPLACING THE CTS. 1. Exhaust gas temperature sensor (EGTS)

If resistance value is correct, repair the connec- An overheat signal will come on in the multifunc-
tors or replace the wiring harness between ECM tion gauge when the exhaust gases reach the fol-
connector and CTS connector. lowing temperature.
If resistance value is incorrect, replace the CTS. OVERHEAT TEMPERATURE
Replacing the CTS 95°C (203°F)
1. Drain engine coolant to below CTS level, refer
to COOLING SYSTEM subsection. Testing the EGTS Resistance
2. Cut locking ties on wiring harnesses and move 1. Remove the parts required to access the EGTS.
wiring aside for access. Be sure to take note of 2. Disconnect the EGTS connector.
their position.
3. Disconnect CTS connector.
4. Remove CTS from engine.
5. Install new CTS and tighten to specified torque.
TIGHTENING TORQUE
16 N•m ± 2 N•m
CTS
(142 lbf•in ± 18 lbf•in)

6. Reinstall remaining removed parts. Be sure to

secure wiring harnesses as noted prior to re-
moval.
smr2014-015-106_a
7. Refill and bleed the cooling system, refer to
EGTS
PERIODIC MAINTENANCE PROCEDURES
subsection. 3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to selection and measure the resistance
of the sensor.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

ECM ADAPTER MEASUREMENT

See EGTS RESISTANCE
J4 H4
CHART

If resistance value is as specified, check ECM. Re-

fer to ENGINE CONTROL MODULE (ECM) in this
subsection.
If resistance value is not within specifications, re-
pair or replace wiring and connectors between the
529035868 ECM and the EGTS.

Replacing the EGTS

1. Disconnect the EGTS connector.
2. Unscrew EGTS from muffler.
3. ApplyLOCTITE 518 (P/N 293 800 038) on treads of
new EGTS.
4. Install new EGTS.

smr2014-029-026_a

smr2008-013-041_a

The resistance should be as per the EGTS RESIS- 1. Apply Loctite 518 in this area
TANCE CHART that follows. Otherwise, replace
the EGTS. TIGHTENING TORQUE
EGTS TEMPERATURE SENSOR TABLE 16 N•m ± 2 N•m
EGTS
(142 lbf•in ± 18 lbf•in)
TEMPERATURE RESISTANCE (OHMS)
°C °F LOW HIGH 5. Apply DIELECTRIC GREASE (P/N 293 550 004) on
- 40 - 40 38457 52630 EGTS connector before reinstall it.
- 10 14 8208 10,656 6. Install all other removed parts, refer to applica-
20 68 2233 2780 ble subsections.
80 176 297 349
120 248 105 122

If the EGTS resistance is within specifications,

proceed with the following steps.
1. Reconnect the EGTS.
2. Disconnect ECM-A connector.
3. Using a multimeter and the ECM adapter tool,
check the circuit resistance as per following ta-
ble.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

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 Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

KNOCK SENSOR (KS) 3. Using a multimeter, measure the resistance be-

tween the knock sensor terminals.

smr2014-029-027_a

KNOCK SENSOR LOCATION - LH SIDE OF ENGINE smr2014-029-035_a

1. Knock sensor (KS)

2. Knock sensor connector KNOCK SENSOR RESISTANCE @ 20°C (68°F)
3. Exhaust manifold
Approximately 5 M
Testing the KS (Dynamic)
1. Connect watercraft to BUDS2 software, refer If resistance is not as specified, replace knock
to COMMUNICATION TOOLS AND B.U.D.S. sensor.
subsection. If resistance is as specified, carry on with the fol-
2. In BUDS2, click the Faults tab and look for a lowing steps.
Knock sensor fault. 4. Reconnect knock sensor connector.
NOTICE The engine must not be run out of 5. Disconnect ECM-A connector.
water without providing proper cooling to the 6. Using a multimeter and ECM adapter tool,
exhaust system. Maximum engine run time check circuit resistance through the knock sen-
out of water is 2 minutes. Failure to do so may sor as per following table.
result in damage to the exhaust system and
REQUIRED TOOL
engine. Refer to EXHAUST SYSTEM subsec-
tion.
ECM ADAPTER TOOL
3. Start engine and throttle it to above 5000 RPM. (P/N 529 036 166)
4. Using the BUDS2 software, monitor the knock
sensor for a fault code. ECM ADAPTER MEASUREMENT
If no fault occurs, knock sensor is good.
RESISTANCE
If a fault occurs, carry out following steps. PIN
@ 20°C (68°F)
5. Ensure sensor and cylinder head contact sur- A-C3 A-G2 Approximately 5 M
faces are clean.
6. Ensure correct mounting bolt and washer are If wiring harness is good, check ECM. Refer to
used and properly torqued. ENGINE CONTROL MODULE (ECM) in this sec-
tion.
7. Check knock sensor resistance, refer to TEST-
ING THE KS RESISTANCE. If an open circuit is measured, repair or replace
wiring and connectors between ECM and knock
Testing the KS Resistance sensor.
1. Remove parts required to access knock sensor,
refer to REPLACING THE KS.
Replacing the KS
1. Disconnect KS sensor connector.
2. Disconnect knock sensor connector.

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Subsection 02 (ELECTRONIC FUEL INJECTION (900 ACE SERIES))

2. Unscrew and remove knock sensor from en-

gine.

smr2014-029-027_a

1. Knock sensor (KS)

2. Knock sensor connector
3. Exhaust manifold

3. Clean contact surfaces.

4. Apply LOCTITE 243 (BLUE) (P/N 293 800 060)in
threaded hole then install the new knock sen-
sor.
5. Tighten sensor retaining screw as specified.
TIGHTENING TORQUE
23 N•m ± 3 N•m
KS mounting screw
(17 lbf•ft ± 2 lbf•ft)

NOTICE Improper torque may interfere with

knock sensor operation and lead to severe in-
ternal engine damage.
6. Reconnect knock sensor connector. Apply DI-
ELECTRIC GREASE (P/N 293 550 004) on knock
sensor connector before reinstall it. .
7. Reinstall remaining removed parts, refer to ap-
plicable subsections.

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 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL................................................................... 529 036 166 ................................ 5, 11–12,
18–19, 23, 26–28, 30
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................ 4–5, 10–12,
18–19, 21, 23, 25–27, 30
FUEL HOSE DISCONNECT TOOL ................................................ 529 036 037 ............................................. 7

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
FLUKE AUTOMOTIVE BACK PROBE PIN..................................... TP40 ........................................... 22
FLUKE SUREGRIP INSULATED TEST LEADS............................... TL224 ........................................... 22

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 .................6, 8, 20, 23, 27, 31
LOCTITE 518 ................................................................................. 293 800 038 ........................................... 29

GENERAL
WARNING
Always disconnect battery prior to working
on the fuel system. Always disconnect bat-
tery exactly in the specified order, BLACK
(-) cable first. Electrical connections should
be disconnected prior to disconnecting fuel
lines.
WARNING
Fuel vapors are flammable and explosive un-
der certain conditions. Ensure work area is
well ventilated. Do not smoke or allow open
flames or sparks in the vicinity.
Use the BRP diagnostic software (BUDS2) to re-
lease the fuel pressure in the system prior to dis-
connecting a fuel line. Refer to FUEL TANK AND
FUEL PUMP subsection.
Cover the fuel line connection with an absorbent
shop rag before disconnecting them. Slowly dis-
connect the fuel hose to minimize spilling.
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appro-
priate safety equipment when working on a
pressurized fuel system. Do not allow fuel
to spill on hot engine parts and/or on elec-
trical connectors. Proceed with care when
removing or installing high pressure test
equipment, or disconnecting fuel line con-
nections. Wipe off any fuel spillage in the
bilge. Never use a hose pincher on high
pressure hoses.
When the repair is completed, ensure the hose
from the fuel rail to the fuel pump is properly
connected and secured in its support. Test for
fuel leaks as described in FUEL TANK AND FUEL
PUMP subsection.
WARNING
Always perform the fuel system high pres-
sure leak test if any component has been
removed or disconnected.
WARNING
If a gasoline leak and/or odor is present, do
not start the engine. Repair the leak.

RTX1503ACEMY18-009
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
SYSTEM DESCRIPTION
The electronic fuel injection system (EFI) is com-
prised of various sensors used for detecting ongo-
ing operating conditions of the engine and water-
craft, and includes all the actuators that perform
the required adjustment to the engine.
This system also introduces torque management
functions.
Electrical System
ECM (Electronic Control Module)
From input signals (e.g. throttle lever, iBR lever),
the ECM acknowledges driver demands and
converts them to an engine torque requirement
through calculation of several variables. Then, the
ECM controls the iTC (intelligent Throttle Control),
the injection system and the ignition system to
meet the torque requirement.
The ECM manages the engine torque require-
ments and controls engine operation to ensure it
is delivering optimum performance, fuel economy
and meeting emission regulations. The ECM also
controls idle speed and limits maximum engine
speed.
Since the ECM manages several torque require-
ments at the same time including contradictory
demands (such as the throttle lever and the iBR
lever being fully pulled in at the same time), it
must prioritize the most important requirement
according to predefined conditions and apply the
proper action.
EFI Sensors
The ECM reads the inputs from the sensors
which it compares to predetermined parameters
stored in the ECM, makes computations, and ac-
tivates the outputs accordingly (injectors, ignition
coils etc.).
Signals from sensors are used by the ECM to de-
termine the injection and ignition parameters (ref-
erenced to fuel and ignition maps) as required to
maintain the optimum air-fuel ratio.
Air Induction
Throttle Body
A 60 mm throttle body is mounted on the intake
manifold.
Air for combustion is drawn in by a mechani-
cally-driven supercharger. The air flows through
the throttle body and is controlled by a throttle
plate.
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Fitted on the throttle body, an electronic throttle
actuator (ETA) allows the ECM to electronically
control the throttle plate opening which regulates
the amount of air that enters the engine, and
therefore engine speed.
There is no idle air control valve (IACV).
Fuel System
Fuel Rail
A single fuel rail is mounted on the intake mani-
fold. The fuel rail ensures that enough fuel can be
delivered to the fuel injectors throughout the en-
gine operating range.
The fuel rail is fed by the fuel pump. The fuel pres-
sure applied to the fuel rail is regulated by the fuel
pressure regulator located in the fuel pump mod-
ule.
Fuel Injectors
One injector per cylinder is used to inject fuel into
the intake ports of the cylinder head.
Fuel Pump
An electric fuel pump with an integrated pressure
regulator is used. Refer to FUEL TANK AND FUEL
PUMP subsection.
ADJUSTMENT
IDLE SPEED
Idle speed is not adjustable. The ECM controls
the idle speed of the engine through the iTC sys-
tem by controlling throttle plate opening using the
ETA (electronic throttle actuator).
Idle speed can be monitored in BUDS2
CLOSED THROTTLE RESET
General Information
This operation performs a reset of the TPS values
of the throttle body in the ECM.
Closed throttle reset must be carried out only
when:
– Replacing the throttle body.
– Replacing the ECM.
Closed Throttle Reset Procedure
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. Press the START button to wake up the ECM.
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 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
3. Install the tether cord on the engine cut-off
switch.
4. In BUDS2, go to:
– Settings page
– ECM button
– Initializations tab
– Reset TPS
5. Follow instructions displayed on screen.
6. Start engine and make sure it operates normally
through its full engine RPM range.
7. Check for fault codes using BUDS2. If a fault
code related to the throttle actuator appears,
clear it, then carry out another Closed Throttle
reset procedure. To clear faults, refer to DIAG-
NOSTIC AND FAULT CODES subsection.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Engine problems are not necessarily related to the
fuel injection system.
It is important to ensure that the engine/propul-
sion system, fuel delivery and electrical systems
are functioning normally.
It is a good practice to check for fault codes us-
ing the BRP diagnostic software (BUDS2) as a first
troubleshooting step.
When a problem was solved, clear the fault in the
ECM using the BRP diagnostic software
WARNING
All electrical actuators and electronic mod-
ules are powered as soon as the START
button is pressed. Always disconnect the
battery prior to disconnecting any electrical
or electronic parts.
Never use a battery charger to temporarily substi-
tute the battery as it may cause the ECM to func-
tion erratically, or not at all.
Check related-circuit fuse solidity and condition
with an ohmmeter. A visual inspection could lead
to a false diagnosis.
Electrical Related Problems
It is important to check the following in the elec-
trical system:
– Battery voltage
– Fuses
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– Ground connections
– Wiring and connectors.
Ensure that all electronic components are genuine
OEM. Any modification to the wiring harness may
lead to poor system operation or generate fault
codes.
Electrical Connections
Pay particular attention to ensure that terminals
and pins are not out of their connectors, corroded,
or out of shape.
When probing terminals, pay attention not to de-
form the terminals as this could cause a loose or
intermittent connection that would be difficult to
troubleshoot.
PROCEDURES
ENGINE CONTROL MODULE
(ECM)
ECM Location
The ECM is located above the valve cover.
ECM Connector Identification
There are 2 connectors connected to the ECM.
– Engine harness connected to ECM-A
– Vehicle system control harness connected to
ECM-B.
lmr2010-022-002_a
ECM CONNECTOR IDENTIFICATION
1. Connector A
2. Connector B
The ECM connectors have 48 pins.
NOTE: For connector information, cleaning and
probing, refer to WIRING HARNESS AND CON-
NECTORS subsection.
ECM Power Circuit Validation
Press the START button.
NOTE: Do not install the tether cord.
3
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

QUICK INDICATION THAT ECM IS POWERED – Relay contacts open and power to the ECM is
(assuming the observed component is working) removed.
Information center turns on. – Power is also removed on all other electrical
systems except the GPS supply to the informa-
Fuel pump turns on for approximately 5 seconds. tion center.
NOTE: Since the tether cord is not installed, the ECM Shut Down Logic
information center will turn off a few s econds af-
When the engine is stopped by using the STOP
ter the self-test, but the ECM and electrical sys-
button or by removing the tether cord from the
tem will stay powered for approximately 3 min-
engine cut-off switch, the following occurs:
utes longer.
– ECM stops the engine.
If the ECM does not turn on, check the following:
– After 5 seconds, the information center turns
– of ECM, Start/Stop and Fuel Pump fuses off.
– Battery voltage. Refer to CHARGING SYSTEM – After 60 seconds, ECM (pin B-H2) removes the
– Relay and wiring. Refer to POWER DISTRIBU- ground to the relay coil.
TION – Relay contacts open and power to the ECM is
– ECM power supply wires and ground wires. removed.
See following procedure. – Power is also removed on all other electrical
systems except the GPS supply to the informa-
ECM Wake Up Logic tion center.
With Tether Cord Installed
Testing ECM Power Supply
When the START button is pressed to start en-
gine: 1. Press the START button to wake up the ECM.
– ECM pin B-D1 receives current from battery via NOTE: Do not install the tether cord.
the START switch. ECM is woken up. 2. Use the FLUKE 115 MULTIMETER (P/N 529 035
– ECM pin B-H2 provides a ground to the relay 868) and select Vdc.
coil in fuse box. 3. Probe ECM fuse F11.
– The relay contacts close and provides main
12 Vdc power to the ECM at pin B-M4. NOTE: This will validate the fuse at the same
time.
– The relay also powers the other components in
the electrical system. FUSE BOX
BATTERY
VOLTAGE
– ECM pin B-E4 monitors for a tether cord in- POST
stalled on the engine cut-off switch. Fuse F11
– When a tether cord is installed, the magnet in terminal at E1
the tether cord cap closes the reed switches Ground Battery voltage
Fuse F11
in the engine cut-off switch and the ECM pin terminal at E2
B-F2 provides a ground. This tells the ECM the
tether cord is installed. If battery voltage is measured at E1 but not at E2,
– ECM pin B-B2 reads the D.E.S.S. key in the replace the fuse.
tether cap and determines if it is valid. If so, the If voltage is not measured at E2, check the wiring
engine can be started. and connections between the relay output and
Without a Tether Cord Installed F11 output. Refer to WIRING DIAGRAM.
When the START button is pressed: If voltage is as per specification, carry out the
– The information center turns on, goes through CONTINUITY TEST OF ECM POWER CIRCUIT.
the self-test function, displays applicable mes-
sages and turns off a few seconds later.
Testing Continuity of ECM Power
Circuit
– The engine cannot be cranked.
– The ECM stays powered up until it removes 1. Wait for electrical power to go off (approxi-
the ground to the relay coil after 3 minutes (pin mately 3 minutes).
B-H2). 2. Disconnect "B" connector from ECM.

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 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

3. Install ECM ADAPTER TOOL (P/N 529 036 166) on

ECM connector.

smr2009-030-010_a

If any measurement is out of specification refer to

smr2009-030-010
POWER DISTRIBUTION AND GROUNDS subsec-
tion and check the following:
4. Use the FLUKE 115 MULTIMETER (P/N 529 035 – Wiring and connections
868) and select . – Engine ground
5. Probe terminals as per following table. – Battery ground.
ECM If everything tests good and ECM does not power
FUSE BOX RESISTANCE
ADAPTER up, try a new ECM. Refer to REPLACING THE
Terminal E1 Pin B-M4
ECM .
Close to 0

If an open circuit is measured, repair or replace

Removing the ECM
wiring and connectors. NOTE: If a new ECM is to be installed, first read
the procedures in REPLACING THE ECM in this
If the ECM power circuit tests good, the problem
subsection.
may be one of the following:
– Start switch circuit open to ECM, refer to 1. Disconnect battery cables.
STARTING SYSTEM subsection.
– ECM not providing a ground to relay in fuse
WARNING
box, refer to POWER DISTRIBUTION AND Always disconnect the BLACK negative (–)
GROUNDS subsection. battery cable first, then disconnect RED pos-
– ECM ground wire open circuit, refer to CONTI- itive (+) cable.
NUITY TEST OF ECM GROUND CIRCUITS in
this subsection. 2. Disconnect both ECM connectors from ECM.
– ECM internal problem. 3. Unscrew all retaining screws and remove the
engine ECM from its support on the intake man-
Testing Continuity of ECM Ground ifold.
Circuits
1. With the B connector still connected to the ECM
ADAPTER TOOL (P/N 529 036 166).
2. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select .
3. Probe adapter terminals as per following table.
ECM BATTERY
RESISTANCE
ADAPTER POST
Pins B-L1, Close to 0
Ground
B-M2 and B-M3 (continuity)

smr2009-030-025_b

1. ECM
2. Retaining screws

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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Installing the ECM NOTE: The file name structure is as follows:

The installation is the reverse of the removal pro- BUDS version_VIN_date read (yyyymmdd)_hour read
cedure. However, pay attention to the following. (hhmmss).mpem
1. Install ECM. Example:
TIGHTENING TORQUE
P2.3.22.12_2BPSBK8C68V000168_20090206_111640.mpem
5.5 N•m ± 0.6 N•m
(49 lbf•in ± 5 lbf•in) Hence:
ECM retaining screws + B.U.D.S. version: P2.3.22.12
LOCTITE 243 (BLUE) VIN: 2BPSBK8C68V000168
(P/N 293 800 060) Date: 2009 02 06
Hour: 11h 16m 40s
2. Reconnect ECM connectors.
3. In BUDS2, go to:
3. Reconnect battery cables.
– Summary page
WARNING – Vehicle button.
Always reconnect the RED positive (+) battery 4. Record (write down) the following information.
cable first, then reconnect BLACK negative (–) 1. Vehicle serial number (VIN)
cable. 2. Engine serial number
3. Vehicle model number
4. If a new ECM is installed, refer to REPLACING
4. Customer name.
THE ECM in this subsection.
NOTE: Do not forgot to press the WRITE button
Replacing the ECM at the end of the line.
Prior to replacing a suspected ECM, ensure that all 5. Enter recorded data in ECM as detailed in
the recommendations in the general introduction ENTERING THE COLLECTED INFORMATION
of this subsection were followed and all applicable INTO THE ECM.
testing procedures were carried out.
2nd Collecting Method: Collect the
When installing a new ECM, data must be entered Information from the Vehicle and Knowledge
into the ECM. Center
Refer to ECM DATA ENTRY FOR ECM REPLACE- 1. Record the following numbers from BOSSWeb.
MENT in this subsection. Look in Sales menu and choose Unit history.
1. Vehicle serial number
ECM Data Entry for ECM Replacement 2. Vehicle model number
Use one of the following methods to collect the 3. Customer name.
required information. The 1st being the easiest:
1. Use the BRP diagnostic software (BUDS2) to
obtain the data from a saved .buds2 file on
your computer.
2. Collect the information from the vehicle and on
the Knowledge Center.
1st Collecting Method: Obtaining the Data
from a Saved .buds2 File
1. Start BUDS2.
NOTE: It is not necessary to perform any connec-
tion. The computer can be used alone.
2. Click on the Open a buds2 file button.
Make sur you are at: C:\Program Files
(x86)\BRP\BUDS2\Files smr2016-027-001_a

1. Engine serial number

IMPORTANT: Be sure to use the file that specifi-
cally matches the vehicle you are servicing.

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 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

NOTICE Enter only the appropriate product

model number as obtained when gathering
the information. Pay particular attention when
typing the V.I.N. and model numbers. Once
Write Data button is pressed, the data cannot
be modified.
6. Program all D.E.S.S. key(s).
7. Perform the Closed throttle reset. Refer
to Closed Throttle Reset (TPS) in ADJUST-
MENTS in this subsection.
8. Reinstall remaining removed parts.
9. Start the engine and, if possible, test ride the
vehicle to ensure proper operation.
smr2014-026-004_a

SERVICE, UNIT HISTORY

1. Click on SALES menu FUEL RAIL
2. Select Unit History
Fuel Rail Location
Fuel rail is located above intake manifold.

Removing the Fuel Rail

Fuel Rail Hose Disconnection
1. Release fuel pressure. Refer to FUEL PUMP in
FUEL TANK AND FUEL PUMP subsection.
2. Place an absorbent shop rag under the fuel sup-
ply hose fitting at the fuel rail to catch any fuel
leakage.
3. Disconnect fuel hose from fuel rail.
REQUIRED TOOL
smr2014-026-005_a

1. Vehicle Serial Number here FUEL HOSE DISCONNECT

TOOL (P/N 529 036 037)
2. Enter the recorded data in the new ECM as de-
tailed in ENTERING THE COLLECTED INFOR-
MATION INTO THE ECM.
Entering the Collected Information into the
ECM
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. Press the START button to wake up the ECM.
3. Install the tether cord on the engine cut-off
switch.
4. In BUDS2, go to:
– Summary page
– Vehicle button.
5. Enter the information you recorded previously.
1. Vehicle serial number (VIN)
2. Engine number lmr2006-008-010

3. Vehicle model number NOTE: It may be necessary to rotate fuel hose fit-
4. Customer name. ting to align the tool ends with the openings of the
locking mechanism.
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Removing the Fuel Rail Installing the Fuel Rail

1. Cut locking ties retaining engine harness to fuel Reverse the removal procedure. However, pay at-
rail. tention to the following.
1. Install fuel rail with injectors.
Lubricate O-rings of fuel injectors.
FUEL INJECTOR O-RINGS
Service product Engine oil

2. Tighten fuel rail retaining screws to specifica-

tion.
TIGHTENING TORQUE
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
RTX1503ACEMY18-009-001_a
Fuel rail retaining screws +
LOCTITE 243 (BLUE)
2. Remove screws retaining the fuel rail. (P/N 293 800 060)

RTX1503ACEMY18-009-002_a RTX1503ACEMY18-009-002_a

3. Gently pull fuel rail side to side (wiggle). 3. Properly install NEW locking ties to secure en-
gine harness to fuel rail.

RTX1503ACEMY18-009-003_a

RTX1503ACEMY18-009-001_a
4. Disconnect all injector connectors.
5. Pull fuel rail out with fuel injectors. Fuel Rail Hose Connection
1. Apply engine oil on O-rings of fitting.

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mmr2009-121-022_a
1. Apply oil on O-rings
2. Connect fuel hose to fuel rail.
IMPORTANT: Push fuel hose fitting on fuel rail un-
til you hear a "click". Try pulling fuel hose off fuel
rail to ensure fitting is properly locked.
3. Pressurize the fuel system and check for a fuel
leak. Refer to FUEL TANK AND FUEL PUMP
subsection.
WARNING
Failure to pressurize the fuel system may re-
sult in severe injury or a life threatening situ-
ation should a leak occur.
4. Reinstall all remaining removed parts.
FUEL INJECTOR
smr2016-027-003
Testing the Fuel Injector Operation
with BUDS2 (Dynamic)
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. Start engine.
NOTICE If watercraft is out of water, exhaust
system must be cooled using the flush kit.
Never run engine more than 2 minutes.
3. In BUDS2, go to :
– Functions page
– ECM button
– IO Controls tab
– Activate Fuel Injectors.
4. Select the injector and click on the ACTIVATE
button.
If the engine RPM drops when clicking on a cylin-
der, the injector and the ignition of this cylinder are
functioning normally.
If the engine RPM does not drop when clicking on
a cylinder, this cylinder is not functioning properly.
Check the following:
– Fuel injector operation. Refer to TESTING THE
FUEL INJECTOR OPERATION in this subsec-
tion.
– Spark plug and ignition coil. Refer to IGNITION
COILS AND SPARK PLUGS subsection.
– Engine condition.
Testing the Fuel Injector Operation
with BUDS2 (Static)
NOTICE After fuel injector activation us-
ing BUDS2, always crank engine in drowned
mode to ventilate engine and prevent a poten-
tial backfire due to fuel accumulation in the
engine.
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. Press the START button to wake up the ECM.
3. Install the tether cord on the engine cut-off
switch.
4. In BUDS2, go to :
– Functions page
– ECM button
– IO Controls tab
– Activate Fuel Injectors.
5. Select the injector and click on the ACTIVATE
button.
6. Listen to the injector.
If you can hear the injector, it validates its oper-
ation. Carry out TESTING THE FUEL INJECTOR
BALANCE.

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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

If you do not hear the injector, carry out TESTING NOTE: Push against tab underneath connector as
THE INJECTOR INPUT VOLTAGE. illustrated to unlock it.

Testing the Fuel Injector Balance with

BUDS2
NOTICE After fuel injector activation us-
ing BUDS2, always crank engine in drowned
mode to ventilate engine and prevent a po-
tential backfire due to fuel accumulation in
engine.
1. Install a fuel pressure gauge as described in
FUEL TANK AND FUEL PUMP subsection.
2. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
smr2009-030-028_a
3. Press the START button to wake up the ECM. PUSH HERE TO UNLOCK
4. Install tether cord on engine cut-off switch.
5. In BUDS2, go to :
– Functions page
– ECM button
– IO Controls tab
– Activate Fuel Pump.
6. Fuel pressure must be within specification. Re-
fer to FUEL TANK AND FUEL PUMP subsec-
tion. Re-activate fuel pump as necessary.
7. In BUDS2, activate the fuel injector no. 1.
8. Record the fuel pressure drop for injector no. 1.
RTX1503ACEMY18-009-001_b
9. In BUDS2, activate fuel pump.
10. Repeat the procedure for fuel injectors no. 2 3. Press the START button to wake up the ECM.
and no. 3 and record the pressure drop for 4. Install tether cord on engine cut-off switch.
each injector. 5. Read input voltage to the applicable injector as
11. The maximum fuel pressure drop between in- per following table.
jectors should not exceed the following spec- 6. Set multimeter to Vdc.
ification:
REQUIRED TOOL
MAXIMUM FUEL PRESSURE DROP ALLOWED
BETWEEN FUEL INJECTORS
FLUKE 115 MULTIMETER
10 kPa (1.5 PSI) (P/N 529 035 868)
If pressure drop of any fuel injector is greater than
the specification, replace that injector then repeat PROBE INJECTOR
the test. MEASUREMENT
CONNECTOR
12. Using the valve on the fuel pressure gauge, VIOLET wire with a
release the pressure in the system (if so Battery voltage
tracer to battery ground
equipped).
13. Remove fuel pressure gauge and reinstall re-
moved parts.

Testing the Fuel Injector Input Voltage

1. Remove ECM from its support.
2. Disconnect fuel injector connectors.
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 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

FLUKE 115 MULTIMETER

(P/N 529 035 868)
smr2009-030-029_a

If battery voltage is measured, carry out TESTING 3. Set multimeter to .

THE INJECTOR CONTROL CIRCUIT.
4. Disconnect the required injector connector.
If battery voltage is not measured, check continu-
5. Probe terminals as per following table.
ity between fuse box and injector as follows.
ECM
INJECTOR INJECTOR MEASUREMENT
Testing the Continuity of Injector ADAPTER
Power Circuit 1 (rear) Pin A-B3
BROWN
1. Remove cover of fuse box. Refer to POWER
2 Pin A-K1 wire with Close to 0
DISTRIBUTION subsection. a tracer
2. Read resistance of the applicable injector circuit 3 Pin A-J1
as per following table.
3. Set multimeter to .
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)

INJECTOR
INJECTOR FUSE BOX MEASUREMENT
CONNECTOR
smr2009-030-010_c
1 (rear)
VIOLET wire If control circuit is at fault, repair or replace wiring
2 Terminal B1 Close to 0
with a tracer and connectors.
3
If control circuit and all tests applicable to the in-
If continuity is good, the fuse, wiring and connec- jector are good, try a new ECM. Refer to ECM in
tors are functional. this subsection.
If continuity is not obtained, first check the fuse Testing the Fuel Injector Resistance (at
and replace as required. ECM Connector)
4. If fuse is good, repair/replace wiring and con- 1. Reconnect the injector connectors.
nectors from fuse box to injector. Refer to
WIRING DIAGRAM subsection. 2. Disconnect the ECM-A connector.
3. Install ECM connector on ECM adapter.
Testing the Fuel Injector Control Circuit
1. Disconnect ECM-A connector.
2. Install ECM connector on ECM adapter.

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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

REQUIRED TOOL If readings are as specified, repair or replace

wiring and connectors from ECM to injector.
ECM ADAPTER TOOL Removing the Fuel Injector
(P/N 529 036 166)
1. Remove fuel rail. Refer to FUEL RAIL in this
subsection.
2. Remove the injector clip.
FLUKE 115 MULTIMETER
(P/N 529 035 868)

4. Set multimeter to .
5. Measure resistance value between terminals
as follows.
ECM
FUSE BOX RESISTANCE @
INJECTOR ADAPTER
TERMINAL 20°C (68°F)
PIN
1 A-B3
2 B1 A-K1 11.4 - 12.6
3 A-J1

If resistance values are as specified, injector coil smr2016-027-006_a

FUEL RAIL ASSEMBLY

is in good condition. 1. Fuel rail
2. Injector clip
If resistance value are not as specified, repeat test 3. Fuel injector
at injector connector. 4. O-rings

Testing the Fuel Injector Resistance (at 3. Pull the fuel injector out of the fuel rail.
Component) Installing the Fuel Injector
1. Remove injector connector.
Installation is the reverse of the removal proce-
2. Check resistance value between injector pins dure. However, pay attention to the following de-
as per followings table. tails.
RESISTANCE @ FUEL INJECTOR IDENTIFICATION
INJECTOR PIN
20°C (68°F)
INJECTOR COLOR
1 2 11.4 - 12.6 ENGINE
CODE
All YELLOW/GRREEN

1. If you reinstall a used injector replace O-rings

with NEW ones.
2. Apply a thin film of engine oil to O-rings.
3. Insert the fuel injector in the fuel rail.
4. Secure injector to fuel rail with a retaining clip.
5. Install fuel rail on engine. Refer to FUEL RAIL
in this subsection.
6. Pressurize the fuel system and check for a fuel
leak. Refer to FUEL TANK AND FUEL PUMP
subsection.

smr2016-027-005_a
WARNING
Always carry out a fuel system high pressure
If readings are not as specified, replace injector. leak test after working on the fuel system.

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 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

7. Reinstall all remaining removed parts, refer to ECM ENGINE THROTTLE BODY
applicable subsections.
Throttle actuator: Off.
Throttle plate: Rest position, maintained
THROTTLE BODY OFF Stopped
opened at approximately 8° (1). This is
also the limp home position.
Throttle Body Description
Throttle actuator: On.
Throttle plate: Moves from the
rest position to approximately 14°. It
then moves back to the rest position.
Not This is the diagnostic mode where the
ON
started rest position, actuator opening force to
overcome the return springs and the
motor return rate are monitored. If any
of these parameters are out of range, a
fault code is initiated.
Throttle actuator: On.
Throttle plate: Moves from the
Started.
rest position to idle position
Normal
ON (approximately 1-3°) according to
operation
ECM injection and ignition maps.
at idle
Throttle plate is opened and closed as
smr2009-030-016_a
necessary to control the idle speed.
1. Throttle body
2. Throttle plate Started.
3. Throttle actuator (electric motor inside) Throttle actuator: On.
4. Throttle position sensor (TPS) (inside) Normal
Throttle plate: Opens and closes
ON operation
according to ECM torque management
Electronic Throttle Actuator (ETA) at various
priorities.
RPM
The electronic throttle actuator (ETA) is a DC mo- (1)
tor on the throttle body that regulates the throt- Degree values are given from the fully closed position.
tle plate via a drive gear. Pulse width modulation
(PWM) is used to control the motor. Throttle-Body Faults and Effects
NOTE: Among other things, a weak or broken
Throttle Plate Operating Positions spring and a sticky throttle plate (carbon build-up,
Two torsional springs are connected to the throttle dried salt water etc) are validated by the throttle
plate. A main spring and another one in a plunger body diagnostic mode.
mechanism.
When there is no power to the throttle actuator
(ETA), the plunger mechanism maintains the throt-
tle plate at a rest position. This also serves as the
limp home position.
When the throttle plate is opened by the ETA as
commanded by the ECM, it acts against the main
spring. If the ETA failed, the return spring would
bring the throttle plate back to the limp home po-
sition.

RTX1503ACEMY18-009
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

FAULT EFFECT If the result is still out of specification, check wire

continuity between ECM and throttle body before
Limp home mode. Engine speed limited to idle. assuming the ETA is at fault.
ECM will use the remaining TAS sensor.
Partial failure
Fault code set and beeper
of TAS sensor
activated to emit warning signals.
Inspecting the ETA
(one internal Always check for corroded terminals or damaged
Check engine light is turned ON.
sensor only)
Driveability could be reset by releasing wiring when diagnosing throttle body problems.
and reapplying the throttle.
Testing the ETA (Dynamic)
Complete Limp home mode. Engine
failure of speed limited to 2500 RPM. 1. Remove the parts required to access the throt-
TAS sensor Fault code set and beeper tle body.
(both internal activated to emit warning signals. 2. Remove the air inlet hose from the throttle
sensors) Check engine light is turned ON. body.
Limp home mode. Engine 3. Observe the throttle plate with the engine
speed limited to 2500 RPM. stopped. The throttle plate should be in the
Engine speed can still be increased up rest position (slightly opened).
Any throttle
to 3200 RPM using the throttle lever.
body failure
Fault code set and beeper
activated to emit warning signals.
WARNING
Check engine light is turned ON. Keep your fingers out of the throttle plate
area while the ECM turns on. The throttle
NOTE: When one of these faults is active, iBR will continue
actuator will cycle. This could cause seri-
to monitor input signals. Since the ECM cannot control the
throttle body, the iBR may produce a fault since the ECM does ous finger injuries as throttle plate quickly
not react to its specific torque requests. It all depends on the moves.
circumstances when the iBR is applied. (vehicle and engine
speed will be a factor). 4. As you observe the throttle plate, have some-
one press the START button to wake up the
Lubricating the Throttle Body ECM.
No lubrication is required. The throttle plate should cycle quickly from the
rest position to a partially open position (approx-
Testing the ETA imately 14°), then back to the rest position.
5. Install the tether cord on the engine cut-off
Testing the Throttle Body Actuator (ETA) with switch.
BUDS2
The throttle plate should cycle again.
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2). 6. As you observe the throttle plate, have some-
one gradually and evenly pull in the throttle
2. Press the START button to wake up the ECM.
lever, then release it in the same way.
3. In BUDS2, go to:
The throttle plate should open then close accord-
– Measurements page ing to throttle lever position. However, the move-
– ECM button ment of the throttle plate may not be linear with
– ECM - Basic tab the displacement of the throttle lever.
– TAS (%DK) If any test failed, proceed with the TESTING THE
4. Slowly depress the throttle lever from the idle ETA (STATIC).
to WOT. The ETA should go from 0% to 100%.
If result is out of specification, carry out a CLOSED
THROTTLE RESET. Refer to ADJUSTMENT in this
subsection.
NOTE: The ETA is reset at the same time as the
TPS.
After the reset, test ETA again.

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 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
Testing the ETA (Static)
WARNING
First ensure the ECM is off. Do not move the
throttle plate using your fingers. Otherwise,
if the START button is pressed the ECM turn
on and quickly cycle the throttle plate which
could cause serious finger injury.
1. Using a blunt tool, push in on the throttle plate
and ensure it opens smoothly within the throt-
tle body.
smr2009-030-016_b
1. Push here to open
NOTE: The throttle plate must open fully and re-
turn freely to the rest position (slightly opened)
when released.
2. Push throttle plate closed as indicated in follow-
ing illustration. It must close completely and re-
turn freely to the rest position (slightly opened)
when released.
smr2009-030-016_c
1. Push here to close
RTX1503ACEMY18-009
https://brp-manuals.com/pwc_seadoo
If the throttle plate does not move smoothly or
does not return freely to the rest position, the
problem is mechanical. Check for salt accumu-
lation on throttle plate shaft. It may also be an
actuator or gear problem. Replace throttle body
as necessary.
If throttle plate operates normally, the problem
is electrical. Check throttle actuator (ETA) wiring
continuity, throttle position sensor (TPS) and
throttle accelerator sensor (TAS).
WARNING
If the throttle plate does not return properly
after a proper cleaning, replace the throttle
body.
Cleaning the Throttle Body
Remove the parts required to access the throttle
body.
Check throttle body cleanliness using a flashlight.
Fully open throttle plate and verify:
– Throttle body bore
– Throttle plate edge.
Look for:
– Dirt
– Oily surfaces
– Carbon and salt deposits on throttle plate and
the surrounding bore.
Clean as necessary.
NOTICE Only use an appropriate throttle
body cleaner that will not damage O-rings and
EFI sensors.
WARNING
Refer to product manufacturer's warnings.
Wipe off any product leakage in bilge.
To avoid getting dirt into engine, spray cleaner on
a clean rag (outside the bilge) then rub rag against
throttle plate and bore. A toothbrush works well
too.
WARNING
First ensure ECM is off. Otherwise, if ECM
should suddenly turn off, it would quickly
close the throttle plate which could cause
serious finger injury.
Manually open throttle and hold fully open to
reach all surfaces.
15
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

WARNING
Ensure nobody presses the START button.
The ECM would turn on and the throttle ac-
tuator (ETA) would cycle. This could cause
serious finger injury as the throttle plate
moves quickly.

To remove residual dirt, spray cleaner on throttle

plate and on bore.
Reinstall removed parts.

Throttle Body Replacement

Throttle Body Location
RTX1503ACEMY018-009-200_a

NATURALLY-ASPIRATED ENGINES
1. Throttle body
2. Inlet hose
3. Connector

RTX1503ACEMY18-009-004_a

NATURALLY-ASPIRATED ENGINES

RTX1503ACEMY018-009-201_a

SUPERCHARGED ENGINES
1. Throttle body
2. Inlet hose
3. Connector

smr2016-027-106

SUPERCHARGED ENGINES

Removing the Throttle Body

1. Disconnect inlet hose from throttle body.
2. Disconnect throttle body connector.
To remove connector from throttle body, press
connector locking tab illustrated. smr2009-030-031_a

TYPICAL - PRESS HERE TO UNLOCK

3. Remove retaining screws from throttle body.

16 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-009
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

– ECM button
– ECM - Basic tab
– Throttle Opening (%DK)
6. Slowly and regularly depress the throttle lever.
7. Observe the Throttle Openingvalue.
NOTE: The value should move gradually and reg-
ularly as you move the throttle lever. If the value
“sticks”, bounces or suddenly drops, it may indi-
cate a worn TPS that needs to be replaced. An
initial slight delay after the throttle lever is pulled
and before the value starts to change is normal.
If the value behavior is not as expected, proceed
smr2016-027-007_a with the following steps.
TYPICAL
1. Throttle body 8. Manually move the throttle plate in throttle
2. Retaining screws body using a blunt tool (without sharp tip).
4. Pull throttle body off intake manifold. WARNING
Installing the Throttle Body Do not move throttle plate with your fingers.
Installation is the reverse of the removal proce- Otherwise, if ECM should turn off, it would
dure. However, pay attention to the following. quickly close the throttle plate which could
cause serious finger injury.
1. Tighten retaining screws in a criss-cross se-
quence.
TIGHTENING TORQUE
Throttle body retaining 9 N•m ± 1 N•m
screws (80 lbf•in ± 9 lbf•in)

2. Perform the Closed Throttle reset. See proce-

dure in ADJUSTMENTS in this subsection.

TPS (THROTTLE POSITION

SENSOR)
General
NOTE: The TPS is part of the throttle body.
The throttle position sensor (TPS) is a double po-
smr2009-030-016_b
tentiometer that sends signals to the ECM that
1. Push here
are proportional to the throttle plate angle. The
TPS is located inside the throttle body. 9. Check the value again.
– If the value changes as expected, check the
Testing the TPS Wear throttle accelerator sensor (TAS). Refer to
1. With the engine turned off, slowly pull in throt- INTELLIGENT THROTTLE CONTROL (ITC)
tle lever and pay attention for smooth operation subsection.
without physical stops. – If the value does not change as expected, per-
2. Connect the vehicle to the BRP diagnostic soft- form TESTING THE TPS RESISTANCE in this
ware (BUDS2). subsection.
3. Press the START button to wake up the ECM.
Testing the TPS Resistance
4. Install the tether cord on the engine cut-off
1. Remove the parts required to access the throt-
switch.
tle body.
5. In BUDS2, go to:
– Measurements page
RTX1503ACEMY18-009
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

2. Ensure the throttle body connector is properly
connected.
3. Disconnect ECM-A connector from the ECM,
refer to ECM ACCESS in this subsection.
4. Install ECM connector on ECM adapter.
REQUIRED TOOL
If any resistance value is incorrect, check wire
continuity between ECM and throttle body before
assuming the TPS is at fault. Refer to WIRING
DIAGRAM subsection.

ECM ADAPTER TOOL

(P/N 529 036 166)

FLUKE 115 MULTIMETER

(P/N 529 035 868)
smr2009-030-032_a

TPS CONNECTOR PIN-OUT

5. Set multimeter to . If the TPS resistance values are correct, try a new
6. Probe circuit as per following table while using ECM. Refer to ENGINE CONTROL MODULE
a finger to manually move throttle plate. (ECM) in this subsection.
FULLY CLOSED FULLY OPEN
ECM THROTTLE THROTTLE CRANKSHAFT POSITION
ADAPTER PLATE (1) PLATE SENSOR (CPS)
RESISTANCE ( ) Troubleshooting the CPS
PIN MIN. MAX. MIN. MAX. NOTICE Take into account that a CPS fault
A-A2 A-K4 875 1625 875 1625 can be triggered by electronic or mechanical
A-A2 A-K3 954 1934 228 585
fault:
1. Check for fault codes
A-A2 A-F3 254 634 980 1983
2. Test the CPS as per following procedure
A-K3 A-K4 228 585 954 1934 3. If it tests good, check trigger wheel teeth
A-K3 A-F3 1385 2315 1385 2315 condition. Refer to PTO HOUSING, MAG-
NETO AND STARTER subsection.
A-K4 A-F3 980 1983 254 634
(1)To obtain the fully closed position, it is necessary CPS and CPS Connector Location
to push against the throttle plate in the throttle
body with a finger and hold it in this position for the
measurement.

RTX1503ACEMY18-009-005_a

TYPICAL - CPS
vmr2008-022-005_a

18 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-009
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Testing the CPS Resistance at CPS

Connector
1. Probe CPS connector terminals as per following
table.
CPS CONNECTOR MEASUREMENT
RESISTANCE
PIN
@ 20°C (68°F)
1 2 775 - 950

RTX1503ACEMY18-009-006_a

TYPICAL - CPS CONNECTOR

Testing the CPS Voltage

1. Disconnect CPS wiring harness connector.
2. Press the START button to wake up the ECM.
3. Install the tether cord on the engine cut-off
switch.
4. Pull the throttle lever completely in to the han-
dlebar and hold (drowned mode).
5. While cranking the engine, probe CPS termi-
nals.
smr2016-027-009_b
CPS CONNECTOR MEASUREMENT TYPICAL
PIN VOLTAGE
If resistance is not within specifications, replace
1 2 Approximately 3.7 Vac the CPS.
If resistance tests good carry out TESTING THE
CPS RESISTANCE AT ECM CONNECTOR.
Testing the CPS Resistance at ECM
Connector
1. Remove parts required to access ECM-A con-
nector.
2. Disconnect ECM-A connector from the ECM.
3. Install ECM connector on ECM adapter.
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)
smr2016-027-009_a

TYPICAL

If voltage is not as specified, carry out TESTING ECM ADAPTER TOOL

THE CPS RESISTANCE AT CPS CONNECTOR. (P/N 529 036 166)
If voltage is as specified, check continuity of
wiring between CPS connector and ECM connec-
tor. Refer to TESTING THE CPS RESISTANCE AT 4. Set multimeter to .
ECM CONNECTOR. 5. Probe CPS terminals as per following table.

RTX1503ACEMY18-009
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

ECM-A CONNECTOR MEASUREMENT

RESISTANCE
PIN
@ 20°C (68°F)
A-H1 A-K2 775 - 950

RTX1503ACEMY18-009-005_b

TYPICAL
1. CPS harness retaining clamp
2. CPS retaining screw
3. CPS

vmr2008-022-005_a
5. Pull out CPS.
6. Install the new CPS.
If resistance measured is as specified, check
ECM. Refer to ENGINE CONTROL MODULE 7. Tighten CPS retaining screw to specification.
(ECM) in this subsection. TIGHTENING TORQUE
If resistance measured is not as specified, repair 9 N•m ± 1 N•m
or replace wiring and connectors between ECM (80 lbf•in ± 9 lbf•in)
and the CPS. CPS retaining screw +
LOCTITE 243 (BLUE)
CPS Replacement (P/N 293 800 060)
1. Drain oil from PTO housing. Refer to PTO
HOUSING, MAGNETO AND STARTER subsec- 8. Reinstall CPS harness retaining clamp and con-
tion. nect the connector.
NOTE: It is not necessary to drain oil from engine. 9. Refill engine oil and check oil level, refer to LU-
BRICATION SYSTEM subsection.
2. Disconnect CPS connector.
CAMSHAFT POSITION SENSOR
(CAPS)

RTX1503ACEMY18-009-006_a

TYPICAL

3. Remove CPS harness retaining clamp.

4. Remove CPS retaining screw.
smr2016-027-011_a

TYPICAL
1. CAPS

20 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-009
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Testing the CAPS Voltage (Harness MEASUREMENT VOLTAGE

Side)
CAPS
1. First check fuse F11 in fuse box. Replace as Battery
connector Battery voltage
required. ground
pin 3
2. Remove the parts required to access the CAPS.
3. Disconnect CAPS connector.

smr2016-027-012_b

If voltage is read to battery ground, check conti-

smr2016-027-011_b

TYPICAL
nuity of ground circuit between CAPS pin 1 and
1. CAPS connector ECM-A connector pin D4. Repair or replace wiring
and connectors.
4. Press the START button to wake up the ECM.
If voltage is not read to battery ground, carry out
5. Install tether cord on engine cut-off switch. TESTING THE CONTINUITY OF CAPS POWER
6. Probe harness connector terminals as per fol- CIRCUIT.
lowing table.
Testing the Continuity of CAPS Power
CAPS CONNECTOR MEASUREMENT Circuit
PIN VOLTAGE 1. Read resistance of the CAPS circuit as per fol-
3 1 Battery voltage lowing table.
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)

2. Set multimeter to .
CAPS
FUSE BOX RESISTANCE
CONNECTOR
TERMINAL PIN
Close to 0
E1 3
(continuity)

If continuity is good, wiring and connectors are

smr2016-027-012_a
If battery voltage is read, proceed with TESTING
THE CAPS (DYNAMIC) in this subsection.
If battery voltage is not read, probe circuit as per
following table.
functional.
If a high resistance or an open circuit is measured,
repair or replace wiring and connectors from fuse
box terminal to CAPS connector.

RTX1503ACEMY18-009
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Testing the CAPS (Dynamic)

1. Remove the parts required to access the CAPS.
2. Remove CAPS sensor from engine.
3. Back-probe connector and read voltage as fol-
lows.
NOTE: To safely probe wire terminals through
the back of the connector, using following tools
or equivalent. Care must be taken not to damage
connector seals.
REQUIRED TOOL
FLUKE AUTOMOTIVE BACK
PROBE PIN (P/N TP40)

FLUKE SUREGRIP INSULATED smr2007-021-009_c

TEST LEADS (P/N TL224) 1. Metallic object

NOTE: Check several times if voltage follows the

placement of the metallic object. Voltage must
NOTICE Do not use sharp end probes. They change each time.
could damage the connector seal. If voltage is as specified, repair or replace wiring
CAPS CAPS and connectors between sensor and ECM.
VOLTAGE
CONDITION CONNECTOR If wiring is good, check ECM. Refer to ENGINE
Free 2 1 Close to 12 Vdc CONTROL MODULE (ECM).
If voltage is not measured as specified, try a new
CAPS.

CAPS Replacement
1. Detach CPS connector from its holder.

RTX1503ACEMY18-009-006_a
smr2007-021-010_a

TYPICAL TYPICAL

CAPS CAPS 2. Disconnect CAPS connector.

VOLTAGE
CONDITION CONNECTOR
Metallic
object on
sensor just 2 1 Close to 0 Vdc
for a few
seconds

22 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-009
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

NOTE: The CTS will cause the engine overheat

warning to come on when the coolant tempera-
ture is above:
OVERHEAT TEMPERATURE
110°C (230°F)

Check for debris or blockage in cooling system.

CTS Quick Test

1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. Install the tether cord on the engine cut-off
smr2016-027-011_b
switch.
TYPICAL 3. Start the engine
1. CAPS connector
4. In BUDS2, go to:
3. Unscrew the CAPS retaining screw. – Measurements page
4. Pull CAPS from engine. – ECM button
5. Install the CAPS. – ECM - Basic tab
– Engine Temperature
NOTICE Be sure to install new O-ring on a
reused CAPS. 5. Look for the engine temperature indication.
The engine temperature gauge in BUDS2 should
6. Tighten CAPS retaining screw to specification. provide an indication of the actual engine coolant
TIGHTENING TORQUE temperature. Otherwise, test the CTS RESIS-
TANCE .
9 N•m ± 1 N•m
(80 lbf•in ± 9 lbf•in)
CAPS retaining screw +
Testing the CTS Resistance
LOCTITE 243 (BLUE) 1. Remove parts required to access ECM connec-
(P/N 293 800 060) tors.
2. Disconnect the ECM-A connector.
COOLANT TEMPERATURE 3. Install ECM connector on ECM adapter.
SENSOR (CTS) REQUIRED TOOL
The CTS is located between the intake manifold
and the oil filter cover. FLUKE 115 MULTIMETER
(P/N 529 035 868)

ECM ADAPTER TOOL

(P/N 529 036 166)

4. Set multimeter to .
5. Check the CTS circuit resistance as per table.

smr2016-027-017_a

TYPICAL
1. Coolant temperature sensor (CTS)
2. Oil filter cover
3. Intake manifold

RTX1503ACEMY18-009
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

CTS RESISTANCE TEST NOTE: To test sensor at various temperatures, re-

move sensor and use a heat gun, ice and a ther-
ECM ADAPTER PIN RESISTANCE mometer. Refer to REPLACING THE CTS.
See CTS If the resistance value measured is as specified,
A-A1 A-J2 TEMPERATURE repair the connectors or replace the wiring har-
SENSOR TABLE ness between ECM connector and CTS connec-
tor.
If resistance test is good, replace the ECM.
If the resistance value is not within specification
If resistance is out of specification, proceed with
replace CTS.
the following steps.
6. Remove the parts required to access the CTS. Replacing the CTS
7. Disconnect the CTS connector. 1. Drain engine coolant to below CTS level, refer
8. Check continuity of wiring between ECM and to COOLING SYSTEM subsection.
CTS connector, refer to WIRING DIAGRAM. If 2. Cut locking tie on wiring harness and move
there is an open circuit, repair or replace wiring wiring aside for access. Be sure to take note
and connectors. of their position.
9. If continuity of wiring is good, test the resis- 3. Disconnect CTS connector and remove CTS.
tance of the sensor as per following tables. 4. Install the new CTS and tighten to specification.
TIGHTENING TORQUE
Coolant temperature 17 N•m ± 2 N•m
switch (150 lbf•in ± 18 lbf•in)

5. Reinstall remaining removed parts. Be sure

to secure wiring harness as noted prior to re-
moval.
6. Refill and bleed the cooling system, refer to
COOLING SYSTEM subsection.
7. Reinstall remaining removed parts.

MANIFOLD ABSOLUTE
smr2016-027-013_a
PRESSURE AND TEMPERATURE
TYPICAL SENSOR (MAPTS)
CTS RESISTANCE TEST
This sensor is a multifunction device. It measures
manifold absolute pressure and intake air temper-
CTS SENSOR PIN RESISTANCE ature for air flow calculations.
See CTS Naturally-Aspirated Engines
1 2 TEMPERATURE
SENSOR TABLE

CTS TEMPERATURE SENSOR TABLE

TEMPERATURE RESISTANCE (OHMS)
°C °F LOW HIGH
- 40 - 40 38457 52630
- 10 14 8208 10656
20 68 2233 2780
80 176 297 349
120 248 105 122
RTX1503ACEMY18-009-007_a

REAR SIDE OF ENGINE

24 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-009
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Supercharged Engines MAPTS PRESSURE FUNCTION QUICK TEST

RESULT
(1 KPA = SERVICE ACTION
10 HPA)
Circuit
Continuity MAPTS
Repair or
NO Test of Input
replace
READING MAPTS Voltage
wiring
Pressure Test
Function
VALUE IS
OUT OF Replace MAPTS
RANGE

RTX1630MY18-009-004_a 6. Perform the same test with a new MAPTS and

FRONT SIDE OF ENGINE compare both readings.

MAPTS Pressure Function Testing the MAPTS Input Voltage (Pressure

Function)
This sensor is a dual function device. Before
1. Remove the parts required to access the
the engine is started, when power is applied to
MAPTS.
the system, the sensor measures the ambient
atmospheric pressure and stores it in the ECM. 2. Disconnect connector from MAPTS.
Thereafter, once the engine is started, it mea-
sures the air pressure in the intake manifold at
operating RPMs.
Ensure sensor is correctly installed on intake
manifold. Otherwise, the MAPTS could generate
a fault code for an unexpected sensor range at
idle when it reads an erroneous intake manifold
pressure. Remove sensor and check for oil or dirt
on its end and if problem persists, check throttle
plate condition/position and the wiring harness.
Perform the following tests.
MAPTS Pressure Function Quick Test
1. Connect the vehicle to the BRP diagnostic soft- RTX1630MY18-009-004_b
ware (BUDS2). TYPICAL
2. Press the START button to wake up the ECM.
3. Press the START button to wake up the ECM.
3. Install the tether cord on the engine cut-off
switch. 4. Install the tether cord on the engine cut-off
switch.
4. In BUDS2, go to:
5. Set multimeter to Vdc.
– Measurements page
– ECM button 6. Read voltage as per following table.
– ECM - Basic tab REQUIRED TOOL
– Intake Air Pressure (hPa)
5. Look for and take note of the MAPTS pressure FLUKE 115 MULTIMETER
reading while the engine is stopped. (P/N 529 035 868)
Values have to be within ± 3.4 kPa (.5 PSI).

RTX1503ACEMY18-009
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

MAPTS CONNECTOR VOLTAGE

Terminal 3 to battery ground Approx. 5 V
Terminal 4 to battery ground Approx. 0 V
Terminal 1 to battery ground Approx. 0 V

RTX1630MY18-009-005_b

TYPICAL

If resistance is not within specification, repair or

replace the wiring harness between ECM connec-
tor and the MAPTS. Refer to WIRING DIAGRAM.

RTX1630MY18-009-005_a
MAPTS Temperature Function
TYPICAL The sensor monitors the air temperature inside
the intake manifold.
If voltage measured is as specified, replace the
MAPTS. MAPTS Quick Test (Temperature Function)
If voltage measured is not as specified, refer to 1. Connect the vehicle to the BRP diagnostic soft-
TESTING THE CONTINUITY OF MAPTS WIRING ware (BUDS2).
HARNESS (PRESSURE FUNCTION). 2. Press the START button to wake up the ECM.
Testing the Continuity of MAPTS Wiring 3. Install the tether cord on the engine cut-off
Harness (Pressure Function) switch.
1. Disconnect ECM-A connector from the ECM. 4. In BUDS2, go to:
2. Install ECM connector on ECM adapter. – Measurements page
3. Test for circuit continuity as per following table. – ECM button
– ECM - Basic tab
REQUIRED TOOL – Intake Temperature
5. Look for the temperature reading while the en-
ECM ADAPTER TOOL gine is stopped.
(P/N 529 036 166)
NOTE: If the complete vehicle is at room temper-
ature, BUDS2 should display the ambient air tem-
perature at the intake manifold.
FLUKE 115 MULTIMETER
(P/N 529 035 868)
6. Perform the same test with a new MAPTS and
compare both readings.
If the engine's MAPTS temperature reading is sig-
4. Set multimeter to . nificantly different than the new MAPTS, replace
5. Test for circuit continuity as per following table. it.
NOTE: Both sensors must measure the same
MAPTS ECM ambient air temperature.
RESISTANCE
CONNECTOR CONNECTOR
If there is no reading, carry out TESTING THE
Pin 1 A-H2 MAPTS RESISTANCE (TEMPERATURE FUNC-
Close to 0 TION).
Pin 3 A-B4
continuity
Pin 4 A-G4

26 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-009
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Testing the MAPTS Resistance REQUIRED TOOL

(Temperature Function)
Disconnect the connector from the MAPTS. ECM ADAPTER TOOL
Set multimeter to . (P/N 529 036 166)
Check the resistance of the sensor itself as
shown.
Using a multimeter, recheck resistance value as
REQUIRED TOOL per following table.
ECM CONNECTOR MEASUREMENT
FLUKE 115 MULTIMETER
(P/N 529 035 868) PIN Refer to MAPTS
TEMPERATURE
A-H2 A-H3 SENSOR TABLE
MAPTS MEASUREMENT
MAPTS TEMPERATURE SENSOR TEST RESULTS
PIN Refer to MAPTS
RESULT SERVICE ACTION
TEMPERATURE
1 2 SENSOR TABLE Circuit
Continuity MAPTS
Repair or
NO Test of Input
replace
READING MAPTS Voltage
wiring
Temperature Test
Function
INCORRECT
RESISTANCE Replace MAPTS
VALUE
CORRECT
RESISTANCE Try a new ECM
VALUE

Testing the MAPTS Circuit Continuity

(Temperature Function)
smr2016-027-010_b
MAPTS CIRCUIT CONTINUITY TEST
TYPICAL (TEMPERATURE FUNCTION)
MAPTS TEMPERATURE SENSOR TABLE MAPTS RESISTANCE
ECM-A
CONNECTOR VALUE
TEMPERATURE RESISTANCE (OHMS)
Pin H2 Pin 1
°C °F LOW HIGH Close to 0
Pin H3 Pin 2
- 40 - 40 40528 56935
- 10 14 8103 10919
MAPTS Replacement
20 68 2193 2863
1. Disconnect MAPTS connector and remove the
80 176 294 368 MAPTS.
120 248 98 122 2. Install the new MAPTS paying attention to in-
dex its tab into the adaptor notch.
If resistance is not within specification, replace 3. Tighten retaining screw to specification.
the MAPTS.
TIGHTENING TORQUE
If resistance tests good, reconnect the MAPTS
and disconnect the ECM-A connector. 5.5 N•m ± 0.6 N•m
(49 lbf•in ± 5 lbf•in)
Install ECM connector on ECM adapter. MAPTS retaining screw +
LOCTITE 243 (BLUE)
(P/N 293 800 060)

RTX1503ACEMY18-009
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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

Naturally-Aspirated Engines
4. Secure the MAPTS wire to the sensor.

smr2008-023-018_a

RTX1503ACEMY18-009-007_c

REAR SIDE OF ENGINE

The resistance should be as per the EGTS RESIS-
TANCE CHART that follows. Otherwise, replace
All Engines the EGTS.
5. Reinstall remaining parts removed, refer to ap- If the EGTS resistance is within specifications,
plicable subsections. proceed with the following steps.
4. Reconnect the EGTS and disconnect ECM-A
EXHAUST GAS TEMPERATURE connector from the ECM.
SENSOR (EGTS) 5. Install ECM connector on ECM adapter.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

6. Using a multimeter ECM adapter tool check the

circuit resistance as per following table.
ECM ADAPTER MEASUREMENT
smr2009-030-040_a
PIN RESISTANCE
1. Muffler
2. Exhaust gas temperature sensor (EGTS) See EGTS RESISTANCE
B-F3 B-G4
CHART
NOTE: An overheat signal will come on in the in-
formation center when the exhaust temperature EGTS RESISTANCE CHART
reaches.
TEMPERATURE RESISTANCE (OHMS)
OVERHEAT TEMPERATURE
°C °F NOMINAL LOW HIGH
110°C (230°F)
- 30 - 22 12600 11800 13400
- 20 - 4 11400 11000 11800
Testing the EGTS Resistance
- 10 14 9500 8000 11,000
1. Remove the parts required to access the EGTS.
2. Disconnect the connector from the EGTS. 0 32 5900 4900 6900

3. Measure the resistance of the sensor. 10 50 3800 3100 4500

20 68 2500 2200 2800
30 86 1700 1500 1900
40 104 1200 1080 1320

28 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-009
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

EGTS RESISTANCE CHART TIGHTENING TORQUE

TEMPERATURE RESISTANCE (OHMS) 16 N•m ± 2 N•m
EGTS
(142 lbf•in ± 18 lbf•in)
°C °F NOMINAL LOW HIGH
50 122 840 750 930 5. Install the EGTS connector.
60 140 630 510 750 6. Install all other removed parts, refer to applica-
ble subsections.
70 158 440 370 510
80 176 325 280 370 KNOCK SENSOR (KS)
90 194 245 210 280
Knock Sensor Location
100 212 195 160 210 The KS is located in the cylinder block behind the
110 230 145 125 160 intake manifold
120 248 115 100 125

vmr2008-022-005_a

If resistance value is as specified, check ECM. Re- smr2016-027-014_a

fer to ENGINE CONTROL MODULE (ECM) in this 1. Knock sensor (KS)

subsection.
If resistance value is not within specifications, re- Testing the KS (Dynamic)
pair or replace wiring and connectors between the 1. Connect the vehicle to the BRP diagnostic soft-
ECM and the EGTS. ware (BUDS2).
2. In BUDS2, go to:
Replacing the EGTS
– Faults page
1. Disconnect the EGTS connector. – ECM button.
2. Unscrew EGTS from muffler. 3. Start engine and throttle it to above 5000 RPM.
3. Apply LOCTITE 518 (P/N 293 800 038) on the mid-
dle threads of the new EGTS. NOTICE The engine must not run out of the
water without providing proper cooling to the
exhaust system. Maximum engine run time
out of water is 2 minutes. Failure to do so may
result in damage to the exhaust system and
engine. Refer to EXHAUST SYSTEM subsec-
tion.
4. Using the BUDS2, monitor the knock sensor for
smr2008-013-041_a
a fault code.
1. Apply Loctite 518 in this area
If no fault occurs, the knock sensor is good.
4. Install the EGTS.
If a fault occurs, carry out the following steps.
5. Ensure sensor and cylinder block contact sur-
faces are clean.

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Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

6. Ensure the correct mounting bolt and washer
are used and are properly torqued.
NOTE: It is necessary to remove the intake man-
ifold to inspect the contact surfaces. Refer to IN-
TAKE MANIFOLD subsection.
7. Check the knock sensor resistance, refer to
TESTING THE KS RESISTANCE.
Testing the KS Resistance
1. Remove parts required to access knock sensor,
2. Disconnect the knock sensor connector.
KNOCK SENSOR RESISTANCE @ 20°C (68°F)
Approximately 5 M
If resistance is not as specified, replace knock
sensor.
If resistance is as specified, carry on with the fol-
lowing steps.
6. Reconnect the knock sensor connector.
7. Disconnect ECM-A connector.
8. Check circuit resistance through the knock sen-
sor as per following table.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

Install ECM connector on ECM adapter.

ECM ADAPTER MEASUREMENT
RESISTANCE
PIN
@ 20°C (68°F)
A-C3 A-G2 Approximately 5 M
RTX1630MY18-009-006_a

TYPICAL

3. Set multimeter to .
4. Measure the resistance between the knock
sensor terminals.
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)

vmr2008-022-005_a

5. Set multimeter to .
If wiring harness is good, check ECM. Refer to
ENGINE CONTROL MODULE (ECM) in this sec-
tion.
If an open circuit is measured, repair or replace
wiring and connectors between ECM and knock
sensor.

KS Replacement
1. Disconnect KS sensor connector.

RTX1630MY18-009-007_a

TYPICAL

30 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-009
 Subsection XX (ELECTRONIC FUEL INJECTION (EFI))

smr2016-027-014_b

TYPICAL - INTAKE MANIFOLD REMOVED

1. Knock sensor
2. Knock sensor connector

2. Unscrew and remove knock sensor from en-

gine.
3. Clean contact surfaces.
4. Apply thread locker in threaded hole.
5. Install the new knock sensor and tighten retain-
ing screw to specification.
NOTICE Improper torque may interfere with
knock sensor operation and lead to severe in-
ternal engine damage.
TIGHTENING TORQUE
23 N•m ± 3 N•m
(17 lbf•ft ± 2 lbf•ft)
KS retaining screw +
LOCTITE 243 (BLUE)
(P/N 293 800 060)

6. Reconnect knock sensor connector.

7. Reinstall remaining removed parts, refer to ap-
plicable subsections.

RTX1503ACEMY18-009
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 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

FUEL TANK AND FUEL PUMP (900 ACE

ENGINES)
SERVICE TOOLS
Description Part Number Page
DIAGNOSTIC HARNESS ............................................................... 529 036 384 ................................. 8, 12, 15
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 11
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................... 12, 15–16
FUEL HOSE ADAPTER.................................................................. 529 036 396 ............................................. 9
FUEL PUMP MODULE SOCKET................................................... 529 036 125 ........................................... 13
FUEL TANK TEST CAP .................................................................. 529 036 242 ............................................. 6
OETIKER PLIER ............................................................................. 295 000 070 ........................................... 10
PRESSURE GAUGE....................................................................... 529 036 395 ............................................. 9
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ......................................... 6–7
VENTED CAP TEST ADAPTER ...................................................... 529 036 141 ............................................. 7

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Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

FUEL TANK AND FUEL PUMP

SPARK Series

NEW

NEW

60 ± 7 N•m
NEW (44 ± 5 lbf•ft)

5.5 ± .5 N•m NEW

(49 ± 4 lbf•in)

1.2 ± .2 N•m
(11 ± 2 lbf•in)

3.5 ± .5 N•m
(31 ± 4 lbf•in)

NEW = Component must be replaced when removed. NEW

smr2014-030-001_a

2 https://brp-manuals.com/pwc_seadoo 2191009410-014
 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

GTS and GTI Series

NEW

60 N•m
(44 lbf•ft)
22 N•m
(161 lbf•ft) NEW
NEW

3.5 N•m
(31 lbf•in)

NEW = Component must be replaced when removed.

smr2012-027-001_a

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Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

FUEL SYSTEM DIAGNOSTIC FLOW CHART

Fuel pump does not run Press Start button Fuel pump runs
for 2 sec. then stops

Check fuses. Install fuel pressure gauge

Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.
Replace fuel
pump module
Press Start button

Fuel pump runs

Repair or Fuel pressure less Fuel pressure is Fuel pressure more

replace than 399 kPa (58 PSI) 399 kPa (58 PSI) than 399 kPa (58 PSI)

Fails
Check fuel line/
rail for leaks

Fails OK Crank or start

Perform fuel pump test engine
OK

Fast Fuel pressure less Fuel pressure more Fuel pressure is

pressure drop than 399 kPa (58 PSI) than 399 kPa (58 PSI) 399 kPa (58 PSI)

No
Yes
Check
OK fuel line/
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK

Fails OK
Fails

OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK Fails

smr2012-027-004_aen

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 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))
GENERAL
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appro-
priate safety equipment when working on a
pressurized fuel system.
WARNING
Always disconnect battery prior to work-
ing on the fuel system. Fuel vapors are
flammable and explosive under certain con-
ditions. Always work in a well ventilated
area. Do not allow fuel to spill on hot en-
gine parts and/or on electrical connectors.
Proceed with care when removing/installing
high pressure test equipment or disconnect-
ing fuel line connections. Cover the fuel
line connection with an absorbent shop rag.
Wipe off any fuel spillage in the bilge.
WARNING
When the repair is completed, ensure that
hoses and connections from fuel rail to the
fuel pump are properly secured. Then, pres-
surize the fuel system. After carrying out a
fuel pump pressure test, use the valve on the
fuel pressure gauge to release the pressure
(if so equipped).
WARNING
The fuel pump is energized for a few seconds
each time the START button is depressed.
It builds fuel system pressure very quickly.
Prior to pressing the START button, ensure
there are no disconnected or damaged fuel
lines that may leak fuel. A high pressure
leak test must be carried out whenever a fuel
system component has been disconnected.
WARNING
Ensure wires and hoses are routed and se-
cured away from any vibrating, rotating,
moving or hot components or sharp edges.
Use appropriate shields and fastening de-
vices as per factory standards.
NOTICE Whenever repairing the fuel system,
always check for water infiltration in the fuel
tank. Replace any damaged, leaking or deteri-
orated fuel line.
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SYSTEM DESCRIPTION
The fuel system is comprised of:
– A fuel tank
– A vented fuel tank cap
– A fuel pump module mounted inside the fuel
tank, and
– A variety of hoses.
The fuel pump module is basically comprised of:
– An electric fuel pump mounted inside a canister
type pump reservoir
– A lower inlet filter
– An upper outlet filter
– A pressure regulator
– A float type fuel level sensor.
smr2008-022-007_a
FUEL PUMP MODULE
1. Fuel pump reservoir
2. Lower inlet filter
3. Upper outlet filter
4. Fuel pressure regulator
5. Float type fuel level sensor
Fuel Pump Operation
When the pump is in operation, it draws fuel into
the canister through a lower inlet filter and a disk
type valve.
The pressurized fuel is pushed through an upper
outlet filter to the fuel rail.
Excess fuel pressure generated by the pump is
routed from the upper filter back to the pump can-
ister reservoir by a pressure regulator mounted on
the pump reservoir cover.
When the START button is pressed, the electrical
system is powered. The fuel pump will come on
for approximately 2 seconds to pressurize the fuel
rail in preparation for the engine start.
The ECM supplies the ground signal to turn on the
fuel pump motor.
The pressure regulator will ensure appropriate
fuel pressure is supplied to the injectors.
5
Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

When the ECM receives a signal to shut down GTI and GTS Series
the engine (START/STOP switch or engine cut-off 2. Open front storage compartment cover.
switch) it removes the fuel pump ground signal.
3. Remove partitions. Refer to BODY subsection.
Fuel Level Indication 4. Disconnect the top of the two front air ventila-
An electric float type fuel level sensor is mounted tion hoses, refer to BODY subsection.
on the side of the fuel pump reservoir. As the float
moves with changing fuel levels, it varies a resis-
tance that changes the voltage signal coming from
the multifunction gauge. This signal is representa-
tive of the fuel level.
The multifunction gauge interprets the fuel level
voltage signal that comes back from the fuel level
sensor. It then displays the proper fuel level in the
multifunction gauge and a low fuel warning mes-
sage when required.
The multifunction gauge will also trigger the
beeper which produces the appropriate beep
signal to warn the driver of a low fuel condition.
The fuel level sensor resistance is at its lowest
value when the fuel tank is full, and at its highest
value when the tank is empty.
Refer to the FUEL LEVEL SENSOR in this subsec-
tion for fuel level sensor testing procedures. 219100941-014-001_a

TYPICAL – FRONT AIR VENTILATION HOSES

Fuel Tank Venting
The entire vent system is incorporated within the All Models
fuel tank cap. 5. Visually inspect condition of hoses and clamps.
6. Remove fuel tank cap.
WARNING
7. Fill up fuel tank.
If the cap requires replacement, it must be re-
placed with an approved vented cap of the 8. Install test cap on the fuel tank filler neck.
same type supplied by BRP. Use of any other REQUIRED TOOL
cap, or use of a non-vented cap will not al-
low proper venting of the fuel tank. The re-
sult may be engine fuel starvation, fuel tank FUEL TANK TEST CAP
overpressure, or fuel leaks which could lead (P/N 529 036 242)
to a fire or an explosion.
9. Use the following tool to pressurize fuel tank.
NOTE: BRP is the only supplier of the vented fuel
tank cap. There is no equivalent vented fuel tank REQUIRED TOOL
cap available on the market today.
VACUUM/PRESSURE PUMP
INSPECTION (P/N 529 021 800)

FUEL TANK LEAK TEST

SPARK Series NOTE: A Y-fitting and a check valve can be in-
stalled to use compressed air for quick pressure
1. Remove central body. Refer to BODY subsec- build-up when the fuel tank is not full.
tion.
NOTE: To access all fuel system components for
a thorough inspection, the central body must be
removed.

6 https://brp-manuals.com/pwc_seadoo 2191009410-014
 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

To locate a leak, check for a fuel smell or leaking

mmr2009-121-004_a
1. Y-fitting (P/N 293 710 059)
2. Check valve (P/N 275 500 505)
3. Apply compressed air here
fuel.
If a leak is not visible, spray a soapy water solu-
tion on components to ease locating the leak(s);
bubbles will indicate the leak location(s).
NOTE: If the pressure drops and no leak has
been found, it could possibly be a fuel pump
check valve problem.
NOTICE When the fuel system leak test is
completed, thoroughly rinse all components
of the soapy water solution with clear water.
A soapy water residue may cause premature
deterioration and must be rinsed away.

10. Connect the vacuum/pressure pump to the

nipple of fuel tank test cap.
11. Set vacuum/pressure pump to PRESSURE.
WARNING
If a leak is found, do not start the engine.
Wipe off any fuel that leaked and ventilate
the hull thoroughly to remove any accu-
mulated fuel vapors. Do not use electric
powered tools on watercraft unless system
has passed the leak test.

13. Remove test cap.

FUEL TANK CAP LEAK TEST

To test the fuel tank cap, use the following tools.
REQUIRED TOOLS

VACUUM/PRESSURE
smr2009-031-012_a
PUMP (P/N 529 021 800)
1. Pressure selected

12. Pressurize fuel tank to specification.

VENTED CAP TEST
NOTICE Do not exceed the specification ADAPTER (P/N 529
when pressurizing the fuel tank. 036 141)
FUEL TANK LEAK TEST
TIME WITHOUT
PRESSURE
PRESSURE DROP
21 kPa (3 PSI) 10 minutes

If the pressure drops, locate fuel leak(s), repair/re-

place leaking component(s) and retest.
Possible leak areas are: 529036141

– Filler neck, hose and connections

– Fuel tank Inlet Check Valve Function Test
– Fuel tank neck Install the fuel tank cap onto the vented cap test
– Fuel pump gasket adapter.
– Fuel pump check valve (unlikely). Set vacuum/pressure pump to the VACUUM func-
tion.

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Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

Connect vacuum/pressure pump to nipple of REQUIRED TOOL

vented cap test adapter.
Squeeze the vacuum/pressure pump handle sev-
eral times to draw air in through the check valve DIAGNOSTIC HARNESS
of fuel tank cap. (P/N 529 036 384)

Air should be drawn in freely and vacuum indica-

tion on pump should remain at zero. If vacuum
rises, replace the fuel tank cap. 4. Remove tether cord from the engine cut-off
switch to prevent engine starting.
Pressure Relief Valve Function Test 5. Press the START button to turn on the fuel
Set the vacuum/pressure pump to the PRESSURE pump for a few seconds and pressurize the
function. fuel system.
Squeeze the vacuum/pressure pump handle to ap- NOTE: As you press the START button, take
ply pressure to the check valve of fuel tank cap a firm hold of the fuel pump outlet hose. You
and observe the pressure rise. It should be as per should feel the fuel pump operation.
specification. 6. Check for fuel odor and visually inspect hoses,
fittings and components for leaking fuel.
FUEL TANK CAP TEST
– If a leak is detected, repair or replace the
PRESSURE TEST RESULT leaking component and repeat leak test after
Up to 6.9 kPa (1 PSI) Pressure must hold the repair.
– If no leak is found, engine can be started.
Above 6.9 kPa (1 PSI) and Pressure must
below 13.8 kPa (2 PSI) release
FUEL PUMP PRESSURE TEST
If pressure holds above specification, replace the
fuel tank cap. Preparation
The pressure test will show the available pressure
Remove test adapter.
at the fuel pump outlet. It validates the pressure
Reinstall/close fuel tank cap. regulator, the fuel pump and check valve and it
tests for leaks in the system.
FUEL SYSTEM HIGH PRESSURE 1. Ensure the battery is fully charged, refer to
LEAK TEST CHARGING SYSTEM.
WARNING 2. On SPARK models, install the following tool
on the disconnected steering connector. This
A high pressure leak test must be carried will permit activation of the electrical system for
out before starting the engine anytime a fuel testing using the vehicle controls.
system component has been disconnected
for maintenance or replacement. REQUIRED TOOL

1. Visually inspect fuel system to ensure all fuel

DIAGNOSTIC HARNESS
system connections are properly made.
(P/N 529 036 384)
2. Lightly pull on hoses at each connection to en-
sure they are properly locked at the quick con-
nect fittings. 3. Ensure hoses and fittings are not leaking. Re-
3. Install the following tool on the disconnected pair any leak.
steering connector. This will permit activation
4. Ensure there is enough gas in the fuel tank.
of the electrical system for testing using the ve-
hicle controls. 5. Disconnect the pressure outlet hose from the
fuel pump.

WARNING
Cover the fuel line connection with an ab-
sorbent shop rag. Wipe off any fuel spillage
inside the bilge.

8 https://brp-manuals.com/pwc_seadoo 2191009410-014
 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

Test when Engine Is Stopped

1. Remove tether cord from the engine cut-off
switch to prevent engine starting.
2. Press the START button and observe fuel pres-
sure.
3. Release pressure in system using the valve on
the pressure gauge between each test so that
the reading returns to zero (0).
NOTE: Be sure to drain the fuel pressure into an
approved fuel container.
4. Repeat test twice and compare readings to
specifications in following table.

smr2014-030-002_a

TYPICAL
1. Outlet hose

6. Install pressure test tools between discon-

nected hose and fuel pump fitting (in line
installation).
REQUIRED TOOLS

PRESSURE GAUGE
(P/N 529 036 395)

smr2014-030-003_b

TYPICAL - FUEL PUMP PRESSURE TEST

1. Pressure relief valve on gauge
2. Hose to a fuel drain bottle

FUEL HOSE ADAPTER FUEL PRESSURE

(P/N 529 036 396) (WHEN PRESSING THE START BUTTON)
386 kPa - 414 kPa (56 PSI - 60 PSI)

Test when Cranking or Starting Engine

NOTICE The engine must not be run out of
water without providing proper cooling to the
exhaust system. Maximum engine run time
out of water is 2 minutes. Failure to do so may
result in damage to the exhaust system and
engine. Refer to EXHAUST SYSTEM subsec-
tion.
1. Crank or start engine and observe fuel pres-
sure. The fuel pressure should be the same as
in previous test.
If pressure is good, fuel pump and pressure regu-
smr2014-030-003 _a lator are functioning correctly.
TYPICAL
1. Connect to fuel pump 2. Stop the engine.
2. Connect to outlet hose

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Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))
A rapid pressure drop indicates leakage either
from the fuel rail or from the fuel pump check
valve. Check fuel rail for leaks.
If a pressure drop occurs when pressing the
START button and the fuel rail is not leaking, then
replace the fuel pump module.
A slow pressure drop indicates leakage either
from a fuel injector or from the fuel pressure
regulator in the fuel pump module. To check
fuel injectors for leaks, refer to the ELECTRONIC
FUEL INJECTION (EFI) subsection. If injectors
are not leaking, then replace fuel pump.
3. Release fuel pressure in system using the valve
on the pressure gauge.
4. Remove pressure gauge and reinstall fuel hose
on fuel pump module.
WARNING
Wipe off any fuel spillage in the bilge. Fuel is
flammable and explosive under certain con-
ditions.
5. Reinstall all other removed parts, refer to appli-
cable subsections.
PROCEDURES
FUEL HOSES AND OETIKER
CLAMPS
NOTE: To access all fuel system components for
a thorough inspection, the central body must be
removed. Refer to BODY subsection.
Inspecting the Fuel Hose
1. Inspect all fuel hoses for wear, kinks, cracks or
any other types of damages.
2. Inspect all clamps for tightness.
Replacing the Fuel Hose
When replacing fuel hoses, be sure to use OEM
hoses and clamps. This will ensure continued
proper and safe operation.
WARNING
Use of fuel lines other than those recom-
mended by BRP may compromise fuel sys-
tem integrity.
10 https://brp-manuals.com/pwc_seadoo
WARNING
– Never use a hose pincher on high pressure
hoses.
– Never change the routing of a fuel hose.
– Always reinstall the corrugated protective
tubing on fuel hoses.
– Secure fuel hoses using the appropriate
locking tie or fastener to prevent contact
with sharp edges or hot, rotating and mov-
ing parts.
– After connecting a hose or a quick connect
fitting, pull on the hose near the fitting to
make sure it is securely locked.
– Always validate fuel system tightness
by performing a FUEL PUMP PRESSURE
TEST.
Replacing the Oetiker Clamps
REQUIRED TOOL
OETIKER PLIER
(P/N 295 000 070)
WARNING
Whenever removing a hose in the fuel sys-
tem, always use new Oetiker clamps at as-
sembly.
FUEL PUMP
Fuel Pump Operation Test
1. Remove tether cord from the engine cut-off
switch to prevent engine starting.
2. Press START button.
3. The fuel pump should run for 2 seconds to build
up fuel system pressure.
NOTE: As you press the START button, take
a firm hold of the fuel pump outlet hose. You
should feel the fuel pump operation.
4. If fuel pump runs, carry out the FUEL PUMP
PRESSURE TEST as described in INSPECTION
of this subsection.
5. If the fuel pump does not run:
– Check if multifunction gauge comes on when
start button is pressed.
2191009410-014
 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

– If the gauge does not come on, check fuses REQUIRED TOOL
F1, F2 and F3. If a fuse is faulty, replace it
and repeat the test.
ECM ADAPTER TOOL
– If the gauge came on, connect the vehicle to (P/N 529 036 166)
BRP diagnostic software (BUDS2) and check
for fault codes. Carry out service actions.
4. Set multimeter to and test pump circuit as per
Fuel Pump Pressure Test following table.
Refer to INSPECTION in this subsection.
PUMP CIRCUIT TEST THROUGH FUEL PUMP
Fuel Pump Circuit Test RESISTANCE @
TEST PROBES
1. Remove fuse box cover. 20°C (68°F)
2. Remove relay from fuse box. Fuse box ECM connector B
Approx. 12
terminal A4 pin B-M1

smr2014-030-004_a

1. Relay to remove
smr2014-030-006_a

3. Remove ECM-B connector and install it on the
ECM adapter tool.
5. If test succeeded, the fuel pump and its wiring
harness are electrically good. The problem may
be a mechanical problem internal to the fuel
pump, or an internal ECM problem that does
not provide the control ground for the pump.
6. If test failed:
– Disconnect fuel pump connector.
– Test wiring continuity as per following table.

smr2014-030-005_a

TYPICAL
1. ECM-B connector to remove

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Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

FUEL PUMP HARNESS CONTINUITY Fuel Pump Input Voltage Test

TEST (WIRING ONLY) 1. Ensure the relay is installed in the fuse box and
RESISTANCE @ that fuses F1, F2 and F3 are in good condition.
TEST PROBES
20°C (68°F) NOTE: The fuel pump does not have a dedicated
Pump harness Fuse fuse. However, if any one of the listed fuses is
connector pin B box terminal A4 open circuit, electrical power will not come on, or
Close to 0 stay on.
ECM (continuity)
Pump harness 2. On SPARK models, install the following tool
connector B
connector pin A on the disconnected steering connector. This
pin B-M1
will permit activation of the electrical system for
testing using the vehicle controls.
REQUIRED TOOL

DIAGNOSTIC HARNESS
(P/N 529 036 384)

3. Use the FLUKE 115 MULTIMETER (P/N 529 035

868).
4. Select Vdc.
5. Press the START button.
6. Read voltage at fuel pump harness connector
smr2014-030-007_c as per following table.
TYPICAL
NOTICE Do not force a probe in the connec-
tor sockets. If so, the sockets may be perma-
nently damaged causing poor pin contact with
socket resulting in the requirement to replace
the socket(s), or the connector.
INPUT VOLTAGE TEST
TEST PROBES VOLTAGE
Pin B Battery ground
Battery voltage
(+ probe) (- probe)

smr2014-030-007_a

TYPICAL

If there is an open circuit to FB-A4, repair

wiring/connector or JT VT between fuel pump
and fuse box. Refer to wiring diagram.
If there is good there is an open circuit to the
ECM, repair or replace wiring and connectors as
required.
If the test succeeded, carry out the FUEL PUMP
INPUT VOLTAGE TEST. smr2014-030-007_b

FUEL PUMP INPUT VOLTAGE TEST

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 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))
If battery voltage is read, power circuit is good.
Test the fuel pump control circuit from ECM. Refer
to FUEL PUMP CIRCUIT TEST.
If battery voltage is not read, power circuit is
faulty. Test continuity of power circuit wiring
between fuse box and fuel pump. Refer to FUEL
PUMP CIRCUIT TEST in this subsection.
If every test succeeded and fuel pump still does
not work, the problem may be a mechanical fuel
pump problem, or the ECM that does not provide
the ground control signal to the fuel pump. Refer
to ELECTRONIC FUEL INJECTION (EFI) subsec-
tion.
Removing the Fuel Pump
1. Disconnect the negative battery terminal, refer
to CHARGING SYSTEM subsection.
2. Disconnect fuel pump electrical connector.
3. Wrap shop rags around the high pressure fuel
hose fitting, then press on the release button
of the quick connect fitting and disconnect the
hose.
smr2014-030-002_b
TYPICAL
1. Fuel pump harness connector
2. Quick connect fitting (high pressure fuel hose)
4. Unscrew the fuel pump retaining nut.
REQUIRED TOOL
FUEL PUMP MODULE SOCKET
(P/N 529 036 125)
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smr2014-030-008_a
TYPICAL
1. Fuel pump module socket
2. Fuel pump retaining nut
NOTICE While pulling out the fuel pump
module, pay attention to the corrugated tubes
and fuel sensor float arm. Float arm can get
caught up and bend which will reduce fuel sen-
sor accuracy. If fuel pump module is dropped
or damaged, it must be replaced.
5. Slowly pull fuel pump module up through
opening until corrugated tubes contact sides
of opening. Tilt the fuel pump module as you
slowly pull the pump upwards.
WARNING
The upper filter and fuel pump reservoir on
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.
6. Carefully pull fuel pump module out.
WARNING
Always wipe off any fuel spillage from the
watercraft. When working with fuel or fuel
system and its components, always work in
a well ventilated area.
Installing the Fuel Pump
Reverse the removal procedure however, pay at-
tention to the following.
1. Carefully insert fuel pump module in fuel tank
so as not to bend float arm.
2. Install a NEW fuel pump module gasket each
time the module is reinstalled.
NOTE: Wipe off parts to prevent fuel pump from
turning while torquing fuel pump nut.
13
Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

3. Align arrow on top of fuel pump module with
index mark on top of fuel tank or fuel sensor
accuracy will be affected.
NOTE: Index mark and arrow locations are high-
lighted for clarity in following illustration.
Removing the Fuel Filter
The lower fuel filter on the fuel pump module does
not require replacement under normal operating
conditions. Replace only if permanently clogged
or damaged.
1. Remove fuel pump. Refer to FUEL PUMP in
this subsection.
WARNING
The upper filter and fuel pump reservoir on
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.

2. Turn fuel pump upside down.

3. Using a small flat screwdriver, pry up the filter
locking tabs.

smr2014-030-009_a

TYPICAL - FUEL PUMP MODULE INDEXING

1. Align marks

4. Tighten fuel pump nut to specification.

TIGHTENING TORQUE
60 N•m ± 7 N•m
Fuel pump nut
(44 lbf•ft ± 5 lbf•ft)

5. Carry out a FUEL TANK LEAK TEST and a FUEL

SYSTEM HIGH PRESSURE LEAK TEST. See
procedures in this subsection. smr2008-022-013_a

1. Fuel filter locking tab (x2)

2. Filter locking pin (x2)
FUEL FILTER
4. Pull filter off fuel pump reservoir housing.
Fuel Filter Inspection
Inspect fuel filter. If dirty, partially clogged or dam- Installing the Fuel Filter
aged, replace it. 1. Align new filter with pump reservoir housing.
2. Press new filter on by hand. Ensure it is fully
seated and locked onto the pump reservoir
housing.
3. Reinstall fuel pump as per procedure in this sub-
section.
4. Carry out a FUEL SYSTEM HIGH PRESSURE
LEAK TEST as described in this subsection.
5. Install or other removed parts, refer to applica-
ble subsection.

smr2009-031-025_a

1. Fuel filter

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 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

FUEL LEVEL SENSOR 2. Connect the DIAGNOSTIC HARNESS (P/N 529 036
384)to make an in-line connection between the
Fuel Level System Overview disconnected connectors.
A float type fuel level sensor mounted on the fuel
pump module sends a signal to the multifunction
gauge.

529036384

3. Briefly press the START button to wake up the

ECM.
smr2008-022-007_b
4. Install the tether cord on the engine cut-off
TYPICAL — FUEL PUMP MODULE
1. Fuel level sensor switch.
5. Use the FLUKE 115 MULTIMETER (P/N 529 035
The multifunction gauge interprets this signal and 868) and select .
turns on the appropriate number of segments of a
bar type fuel level indication in the lower RH side 6. Alternately drain then fill fuel tank and measure
of the digital screen in the multifunction gauge. the sensor resistance between pin 19 and bat-
tery ground.
Fuel Level Troubleshooting RESISTANCE ( ) FLOAT HEIGHT (MM)
FUEL LEVEL TROUBLESHOOTING 4.8 ± 2.2 260.2 ± 3.0 (FULL)
SYMPTOM POSSIBLE CAUSE 17.8 ± 2.2 220.9 ± 3.0
– Wiring/connectors 27.8 ± 2.2 198.1 ± 3.0
Fuel gauge always
display EMPTY – Fuel level sensor 37.8 ± 2.2 173.2 ± 3.0
– Float stuck in low position
47.8 ± 2.2 147.6 ± 3.0 (HALF)
– Water in fuel pump
Fuel gauge always 57.8 ± 2.2 117.6 ± 3.0
connector
display FULL
– Float stuck in full position 67.8 ± 2.2 84.6 ± 3.0
Fuel level sensor – Wiring/connectors 77.8 ± 2.2 59.3 ± 3.0
fault code – Fuel level sensor 89.8 ± 2.2 27.3 ± 3.0 (EMPTY)
Fuel gauge displays – Low battery voltage
wrong level – Fuel level sensor fault

Use the BRP diagnostic software (BUDS2) to

check for a fault code. Refer to DIAGNOSTIC
AND FAULT CODES.
Fuel Level Sensor Resistance Test at
Steering Connector A. Float height
1. Disconnect steering connector. Refer to
NOTE: If fuel tank is not full or empty, the resis-
WIRING HARNESS AND CONNECTORS sub-
tance value will be proportional to the fuel level
section for location.
(somewhere in-between).

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Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

If readings are as per specifications, check con- Fuel Level Sensor Resistance Test at
tinuity of wire from steering connector to multi- Information Center
function gauge connector. Refer to WIRING DIA- 1. Disconnect information center (multifunction
GRAM. gauge) connector. Refer to INFORMATION
If continuity is good, the fuel level circuit and sen- CONNECTOR subsection.
sor are good. If fuel level does not work in multi- 2. Use the FLUKE 115 MULTIMETER (P/N 529 035
function gauge, try a new one. 868) and select .
If readings are out of specifications at the steer- 3. Alternately drain then fill fuel tank and measure
ing connector, perform the FUEL LEVEL SENSOR the sensor resistance between the following
RESISTANCE TEST AT INFORMATION CENTER. pins.
Repair or replace wiring and connectors as re- – SPARK Series: 3 and 4
quired. – GTS and GTI Series: 19 and 20
7. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select Vdc. RESISTANCE ( ) FLOAT HEIGHT (MM)

8. Measure the voltage at the test connector of 4.8 ± 2.2 268.9 ± 3.0 (FULL)
the diagnostic harness as follows. 17.8 ± 2.2 240.6 ± 3.0
SPARK Series 27.8 ± 2.2 219.1 ± 3.0
TEST 37.8 ± 2.2 193.8 ± 3.0
FUEL TANK CONNECTOR
VOLTAGE 47.8 ± 2.2 161.9 ± 3.0 (HALF)
LEVEL OF DIAGNOSTIC
HARNESS 57.8 ± 2.2 128.3 ± 3.0
Full 0.14 Vdc 67.8 ± 2.2 94.1 ± 3.0
Pins 11 and 19
Empty 2.7 Vdc 77.8 ± 2.2 60.6 ± 3.0
89.8 ± 2.2 28.8 ± 3.0 (EMPTY)
GTI and GTS Series
TEST
FUEL TANK CONNECTOR
VOLTAGE
LEVEL OF DIAGNOSTIC
HARNESS
Full 0.14 Vdc
Pins 12 and 19
Empty 2.7 Vdc

NOTE: Voltage could be slightly different depend- A. Float height

ing on battery voltage but should remain relatively
close to this range. If fuel tank is not full or empty,
the voltage value will be proportional to the fuel
level (somewhere in-between).
If voltage is as per specifications the fuel level cir-
cuit and sensor are good. If fuel level does not
work in information center, try a new one.
If voltage is out of specifications, test the FUEL
LEVEL SENSOR RESISTANCE AT INFORMATION
CENTER as described in this subsection.
Remove diagnostic harness and reconnect con-
nector.
NOTE: If fuel tank is not full or empty, the resis-
tance value will be proportional to the fuel level
(somewhere in-between).
If readings are as per specifications, the fuel level
circuit and sensor are good. If fuel level does not
work in information center, try a new one.
If readings are out of specifications, perform the
FUEL LEVEL SENSOR RESISTANCE TEST AT
FUEL PUMP.
If an open circuit is measured, carry out a conti-
nuity test of the wiring from the information cen-
ter to the 20-pin steering connector, and from the
20-pin steering connector to the fuel pump mod-
ule connector. Refer to WIRING DIAGRAM.
If the wiring is good, carry out a FUEL LEVEL SEN-
SOR RESISTANCE TEST AT FUEL PUMP.

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 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))
4. Reconnect information center (multifunction
gauge) connector.
Fuel Level Sensor Resistance Test at
Fuel Pump
SPARK Series
1. Remove central body, refer to BODY subsec-
tion.
2. Disconnect fuel pump module connector.
smr2014-030-002_c
TYPICAL
1. Fuel pump module connector
3. Alternately drain then fill fuel tank and measure
the sensor resistance between pins "C" and "D"
of the fuel pump connector. See table in FUEL
LEVEL SENSOR RESISTANCE TEST AT MULTI-
FUNCTION GAUGE.
smr2012-027-011_d
TYPICAL - FUEL LEVEL SENSOR RESISTANCE TEST
If readings are out of specifications, replace sen-
sor.
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When everything else has been tested and fuel
level is still not working, try a new information
center.
Removing the Fuel Level Sensor
smr2008-022-029
FUEL LEVEL SENSOR
1. Remove fuel pump module from fuel tank, see
FUEL PUMP REMOVAL in this subsection.
WARNING
The upper filter and fuel pump reservoir on
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.
2. Drain all fuel from the upper fuel filter and fuel
pump reservoir in an appropriate container.
NOTE: Note routing of fuel level sensor wires
prior to disconnecting the sensor from the fuel
pump module flange.
3. Disconnect the fuel level sensor connector
from the fuel pump module upper flange.
smr2008-022-021_a
1. Fuel level sensor connector
17
Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

4. Disconnect the ground wire from the pressure

regulator. Be careful not to bend the ground
contact on the pressure regulator.

smr2008-022-024_a

1. Pressure regulator locking tab

2. Pressure regulator rotated clockwise over locking tab

6. Once the pressure regulator is rotate over the

smr2008-022-022_a
locking tab, pull up on it to remove it from the
1. Pressure regulator pump reservoir cover.
2. Ground wire contact on pressure regulator
3. Ground wire disconnected

5. Using a flat screwdriver, press down on the

locking tab just below the pressure regulator
to release it from the pump reservoir cover,
and rotate it clockwise simultaneously so that
it slips over the locking tab.

smr2008-022-025_a

1. Pressure regulator alignment tabs

2. Fuel pump reservoir alignment tabs

NOTE: The pressure regulator cover must not be

removed from the pressure regulator housing as-
sembly.

smr2008 022-023_a

1. Pressure regulator
2. Pressure regulator locking tab

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 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

Installing the Fuel Level Sensor

Installation is the reverse of the removal proce-
dure however, pay attention to the following.
1. Ensure fuel level sensor locking pins are prop-
erly engaged into the fuel pump reservoir.

smr2008-022-028_a

1. Do not remove pressure regulator cover at locking tabs

2. Pressure regulator cover
3. Pressure regulator housing

7. Push in on the release tabs at the top of the

fuel level sensor to unlock it from the fuel pump
reservoir housing, and simultaneously pull up
smr2008-022-026_b
on the fuel level sensor to remove it.
1. Ensure engagement of sensor locking pins

2. Align the fuel pressure regulator tabs into the

pump reservoir cover and turn it counterclock-
wise until it locks properly.

smr2008-022-026_a

1. Fuel level sensor release tabs

2. Locking pins

smr2008-022-025_b

PRESSURE REGULATOR INSERTION INTO PUMP RESERVOIR

COVER
1. Pressure regulator alignment tabs
2. Fuel pump reservoir alignment tabs

smr2008-022-027_a

1. Pull up on fuel level sensor

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Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))
smr2008-022-030_a
TAB UP WHEN PRESSURE REGULATOR PROPERLY LOCKED
1. Pressure regulator locking tab
3. Reconnect the ground wire onto the pressure
regulator.
smr2008-022-031_a
1. Pressure regulator ground wire installed
4. Ensure fuel level sensor connector is locked
into the module flange connector.
smr2008-022-021_a
1. Fuel level sensor connector
5. Carry out a FUEL LEVEL SENSOR RESISTANCE
TEST as described in this subsection.
20
6. Reinstall the fuel pump module. Refer to FUEL
PUMP INSTALLATION in this subsection.
FUEL TANK
Fuel Tank Inspection
1. Inspect fuel tank retaining straps for wear,
cracks or any other damages. Inspect strap
clip anchors and bolts.
2. Inspect fuel tank for wear caused by any ab-
normal contact or rubbing with other compo-
nent(s).
3. Disconnect fuel filler hose from fuel tank.
4. Inspect fuel tank filler hose for wear, cracks or
other damages.
5. Visually inspect the inside and outside of the
fuel tank filler necks for crack(s). If crack(s) are
found, replace fuel tank.
6. With your fingers, feel the inside and outside
surfaces of fuel tank, especially near the filler
neck.
7. Flex fuel tank neck to ensure there are no hid-
den cracks.
NOTE: A fuel tank is comprised of 2 components:
the tank and the filler neck. The filler neck is in-
jection molded and the tank is then blow molded
over the neck. During the molding process, a
small molding seam may appear on the inner
side of the neck at approximately 4 mm (5/32 in)
from the base of the neck. It is normal to have a
molding seam and it should not be confused with
a crack.
4 2
F07F06A
3 A 5
1. Tank upper surface area
2. Inspect outer upper surface at filler neck
3. Normal molding seam
4. Inspect upper surface area inside filler neck
5. Base of filler neck
A. Approx. 4 mm (5/32 in)
8. Install filler hose and tighten retaining clamps to
specification.
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 Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

smr2014-030-009_c smr2014-030-009_b

TYPICAL - INDEXING WITH FUEL TANK TYPICAL

1. Index mark on fuel tank 1. Detach fuel tank retaining straps here
2. Index mark drawn on hose before removal
4. Remove fuel tank from the vehicle.
TIGHTENING TORQUE
5. Remove fuel pump as necessary. Refer to
Filler hose retaining FUEL PUMP in this subsection.
3.5 N•m (31 lbf•in)
clamps
6. Inspect hull and flotation foams for wear.
9. Reinstall all other removed parts. Refer to ap- NOTE: If replacing fuel tank with a new one, be
propriate subsection. sure to mark the fuel filler hose position with the
hose index mark on the fuel tank before removing
Removing the Fuel Tank the hose from the old tank. This will ease align-
1. Siphon fuel tank. ment of the retaining screws of the filler neck
adapter to the central body.
2. Disconnect fuel pump connections. Do not cut
any locking ties. It is not necessary for fuel tank Installing the Fuel Tank
removal.
NOTE: Apply torque values as specified in the ex-
ploded view.
1. Reinstall fuel pump if it was removed. Refer to
FUEL PUMP in this subsection.
2. If replacing fuel tank with a new one, be sure
to align mark on filler hose with index mark on
fuel tank.

smr2014-030-002_b

TYPICAL
1. Fuel pump harness connector
2. Quick connect fitting (high pressure fuel hose)

NOTE: Take note of wiring harness, hose and

cable routing for proper reinstallation. Also note
method used for securing with locking ties.
3. Detach fuel tank retaining straps.

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Subsection XX (FUEL TANK AND FUEL PUMP (900 ACE ENGINES))

smr2014-030-009_c smr2014-030-009_b

1. Index mark on fuel tank TYPICAL

2. Index mark drawn on hose before removal 1. Fuel tank retaining strap

3. Ensure flotation foam is properly positioned un-
der fuel tank.
4. Ensure fuel tank retaining straps are properly
secured to anchor points in hull using locking
ties.
7. Properly secure wire harness, cables and hose
as prior to removal using appropriate locking
ties.
8. Reinstall all other removed parts Refer to appli-
cable subsections.
9. When vehicle reassembly is complete, carry
out a FUEL TANK LEAK TEST and a FUEL
SYSTEM HIGH PRESSURE LEAK TEST as de-
scribed in this subsection.
10. Reinstall the central body. Refer toBODY sub-
section.
NOTE: If the retaining screws for the filler neck
adapter do not align with the holes in the central
body, loosen the filler hose clamp and slightly ro-
tate the hose. Be sure to retighten hose clamp to
specification.

smr2014-030-010_a

1. Fuel tank retaining strap

2. Strap clip secured with locking tie to anchor point in hull

5. Insert fuel tank in hull.

6. Secure retaining strap ends on top of fuel tank.

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 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

FUEL TANK AND FUEL PUMP (130, 155,

230 AND 300 ENGINES)
SERVICE TOOLS
Description Part Number Page
DIAGNOSTIC HARNESS ............................................................... 529 036 384 ........................................... 13
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 9
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ....................................... 9, 13
FUEL HOSE ADAPTER.................................................................. 529 036 396 ............................................. 7
FUEL PUMP MODULE SOCKET................................................... 529 036 125 ........................................... 11
FUEL TANK TEST CAP .................................................................. 529 036 242 ............................................. 5
OETIKER PLIER ............................................................................. 295 000 070 ............................................. 9
PRESSURE GAUGE....................................................................... 529 036 395 ............................................. 7
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ......................................... 5–6
VENTED CAP TEST ADAPTER (THREADED)................................ 529 036 243 ............................................. 6

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Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

NEW

NEW

22.5 ± 2.5 N•m 60 ± 7 N•m

(17 ± 2 lbf•ft) (44 ± 5 lbf•ft)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

NEW

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

NEW = Component must be replaced when removed.

219100941-014-100_a

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 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

FUEL SYSTEM DIAGNOSTIC FLOW CHART

Fuel pump does not run Press Start button Fuel pump runs
for 2 sec. then stops

Check fuses. Install fuel pressure gauge

Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.
Replace fuel
pump module
Press Start button

Fuel pump runs

Repair or Fuel pressure less Fuel pressure is Fuel pressure more

replace than 399 kPa (58 PSI) 399 kPa (58 PSI) than 399 kPa (58 PSI)

Fails
Check fuel line/
rail for leaks

Fails OK Crank or start

Perform fuel pump test engine
OK

Fast Fuel pressure less Fuel pressure more Fuel pressure is

pressure drop than 399 kPa (58 PSI) than 399 kPa (58 PSI) 399 kPa (58 PSI)

No
Yes
Check
OK fuel line/
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK

Fails OK
Fails

OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK Fails

smr2012-027-004_aen

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Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))
GENERAL
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appro-
priate safety equipment when working on a
pressurized fuel system. Wear safety glasses.
WARNING
Always disconnect battery prior to work-
ing on the fuel system. Fuel vapors are
flammable and explosive under certain con-
ditions. Always work in a well ventilated
area. Do not allow fuel to spill on hot en-
gine parts and/or on electrical connectors.
Proceed with care when removing/installing
high pressure test equipment or disconnect-
ing fuel line connections. Cover the fuel
line connection with an absorbent shop rag.
Wipe off any fuel spillage in the bilge.
WARNING
When the repair is completed, ensure that
hoses and connections from fuel rail to the
fuel pump are properly secured. Then, pres-
surize the fuel system. After carrying out a
fuel pump pressure test, use the valve on the
fuel pressure gauge to release the pressure
(if so equipped).
WARNING
The fuel pump is energized for a few seconds
each time the START button is depressed.
It builds fuel system pressure very quickly.
Prior to pressing the START button, ensure
there are no disconnected or damaged fuel
lines that may leak fuel. A high pressure
leak test must be carried out whenever a fuel
system component has been disconnected.
WARNING
Ensure wires and hoses are routed and se-
cured away from any vibrating, rotating,
moving or hot components or sharp edges.
Use appropriate shields and fastening de-
vices as per factory standards.
NOTICE Whenever repairing the fuel system,
always check for water infiltration in the fuel
tank. Replace any damaged, leaking or deteri-
orated fuel line.
4 https://brp-manuals.com/pwc_seadoo
SYSTEM DESCRIPTION
The fuel system is comprised of:
– A fuel tank
– A vented fuel tank cap
– A fuel pump module mounted inside the fuel
tank
– A variety of hoses.
The fuel pump module is basically comprised of:
– An electric fuel pump mounted inside a canister
type pump reservoir
– A lower inlet filter
– An upper outlet filter
– A pressure regulator
– A float type fuel level sensor.
smr2008-022-007_a
FUEL PUMP MODULE
1. Fuel pump reservoir
2. Lower inlet filter
3. Upper outlet filter
4. Fuel pressure regulator
5. Float type fuel level sensor
Fuel Pump Operation
When the pump is in operation, it draws fuel into
the canister through a lower inlet filter and a disk
type valve.
The pressurized fuel is pushed through an upper
outlet filter to the fuel rail.
Excess fuel pressure generated by the pump is
routed from the upper filter back to the pump can-
ister reservoir by a pressure regulator mounted on
the pump reservoir cover.
When the START button is pressed, the electrical
system is powered. The fuel pump will come on
for approximately 2 seconds to pressurize the fuel
rail in preparation for the engine start.
The ECM supplies the ground signal to turn on the
fuel pump motor.
The pressure regulator will ensure appropriate
fuel pressure is supplied to the injectors.
219100941-034
 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

When the ECM receives a signal to shut down 5. Use the following tool to pressurize fuel tank.
the engine (START/STOP switch, engine cut-off
REQUIRED TOOL
switch, or T.O.P.S. switch) it removes the fuel
pump ground signal.
VACUUM/PRESSURE PUMP
Fuel Level Indication (P/N 529 021 800)
An electric float type fuel level sensor is mounted
on the side of the fuel pump reservoir. As the float
moves with changing fuel levels, it varies a resis- FUEL TANK TEST CAP
tance that changes the voltage signal coming from (P/N 529 036 242)
the information center (multifunction gauge). This
signal is representative of the fuel level. NOTE: A Y-fitting and a check valve can be in-
The information center interprets the fuel level stalled to use compressed air for quick pressure
voltage signal that comes back from the fuel level build-up when the fuel tank is not full.
sensor. It then displays the proper fuel level in
the information center and a low fuel warning
message when required.
The information center will also trigger the beeper
which produces the appropriate beep signal to
warn the driver of a low fuel condition.
The fuel level sensor resistance is at its lowest
value when the fuel tank is full, and at its highest
value when the tank is empty.
Refer to the FUEL LEVEL SENSOR in this subsec-
tion for fuel level sensor testing procedures.

Fuel Tank Venting mmr2009-121-004_a

1. Y-fitting (P/N 293 710 059)

The entire vent system is incorporated within the 2. Check valve (P/N 275 500 505)
fuel tank cap. 3. Apply compressed air here

WARNING 6. Connect the vacuum/pressure pump to the nip-

ple of fuel tank test cap.
If the cap requires replacement, it must be re-
placed with an approved vented cap of the
same type supplied by BRP. Use of any other
cap, or use of a non-vented cap will not al-
low proper venting of the fuel tank. The re-
sult may be engine fuel starvation, fuel tank
overpressure, or fuel leaks which could lead
to a fire or an explosion.

NOTE: BRP is the only supplier of the vented fuel

tank cap. There is no equivalent vented fuel tank
cap available on the market today.

INSPECTION
FUEL TANK LEAK TEST smr2009-031-010_a

TYPICAL
1. Inlet valve end
1. Visually inspect condition of hoses and clamps. 2. Vacuum/pressure pump
3. Compressed air supply
2. Remove fuel tank cap.
3. Fill up fuel tank. 7. Set vacuum/pressure pump to PRESSURE.
4. Install test cap on filler neck.

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Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

9. Remove test cap.

FUEL TANK CAP LEAK TEST

To test the fuel tank cap, use the following tools.
REQUIRED TOOL

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

smr2009-031-012_a VENTED CAP TEST ADAPTER

1. Pressure selected (THREADED) (P/N 529
036 243)
8. Pressurize fuel tank to specification.
NOTICE Do not exceed the specification
Inlet Check Valve Function Test
when pressurizing the fuel tank.
Install the fuel tank cap onto the vented cap test
FUEL TANK LEAK TEST adapter.
TIME WITHOUT Set vacuum/pressure pump to the VACUUM func-
PRESSURE
PRESSURE DROP tion.
21 kPa (3 PSI) 10 minutes Connect vacuum/pressure pump to nipple of
vented cap test adapter.
If the pressure drops, locate fuel leak(s), repair/re- Squeeze the vacuum/pressure pump handle sev-
place leaking component(s) and retest. eral times to draw air in through the check valve
Possible leak areas are: of fuel tank cap.
– Filler neck, hose and connections Air should be drawn in freely and vacuum indica-
– Fuel tank tion on pump should remain at zero. If vacuum
– Fuel tank neck rises, replace the fuel tank cap.
– Fuel pump gasket
Pressure Relief Valve Function Test
– Fuel pump check valve (unlikely)
Set the vacuum/pressure pump to the PRESSURE
To locate a leak, check for a fuel smell or leaking function.
fuel.
Squeeze the vacuum/pressure pump handle to ap-
If a leak is not visible, spray a soapy water solu- ply pressure to the check valve of fuel tank cap
tion on components to ease locating the leak(s); and observe the pressure rise. It should be as per
bubbles will indicate the leak location(s). specification.
NOTE: If the pressure drops and no leak has been
found, it is possibly fuel pump check valve. FUEL TANK CAP TEST
PRESSURE TEST RESULT
NOTICE When the fuel system leak test is
completed, thoroughly rinse all components Up to 6.9 kPa (1 PSI) Pressure must hold
of the soapy water solution with clear water. Above 6.9 kPa (1 PSI) and Pressure must
A soapy water residue may cause premature below 13.8 kPa (2 PSI) release
deterioration and must be rinsed away.
If pressure holds above specification, replace the
WARNING fuel tank cap.
If a leak is found, do not start the engine. Remove test adapter.
Wipe off any fuel that leaked and ventilate
the hull thoroughly to remove any accu- Reinstall/close fuel tank cap.
mulated fuel vapors. Do not use electric
powered tools on watercraft unless system
has passed the leak test.
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 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

FUEL SYSTEM HIGH PRESSURE

LEAK TEST
WARNING
A high pressure leak test must be carried
out before starting the engine anytime a fuel
system component has been disconnected
for maintenance or replacement.

1. Visually inspect fuel system to ensure all fuel

system connections are properly made.
2. Lightly pull on hoses at each connection to en-
sure they are properly locked at the quick con-
nect fittings. smr2012-027-010_a

3. Remove tether cord from the engine cut-off 1. Outlet hose

switch to prevent engine starting.
5. Install pressure test tools between discon-
4. Press the START button to turn on the fuel nected hose and fuel pump fitting (in line
pump for a few seconds and pressurize the installation).
fuel system.
REQUIRED TOOLS
5. Check for fuel odor and visually inspect hoses,
fittings and components for leaking fuel.
6. If a leak is detected, repair or replace the leaking
component and repeat leak test after the repair.
7. If no leak is found, engine can be started. PRESSURE GAUGE
(P/N 529 036 395)
FUEL PUMP PRESSURE TEST
Preparation
The pressure test will show the available pressure
at the fuel pump outlet. It validates the pressure FUEL HOSE ADAPTER
regulator, the fuel pump and check valve and it (P/N 529 036 396)
tests for leaks in the system.
1. Ensure the battery is fully charged, refer to
CHARGING SYSTEM.
2. Ensure hoses and fittings are not leaking. Re-
pair any leak.
3. Ensure there is enough gas in the fuel tank.
4. Disconnect the pressure outlet hose from the
fuel pump.

WARNING
Cover the fuel line connection with an ab-
sorbent shop rag. Wipe off any fuel spillage
inside the bilge.

smr2009-031-018_a

TYPICAL
1. Connect to fuel pump
2. Connect to outlet hose

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Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))
Test when Engine Is Stopped
1. Remove tether cord from the engine cut-off
switch to prevent engine starting.
2. Press the START button and observe fuel pres-
sure.
3. Release pressure in system using the valve on
the pressure gauge between each test so that
the reading returns to zero (0).
4. Repeat test twice and compare readings to
specifications in following table.
smr2009-031-019_a
FUEL PUMP PRESSURE TEST
1. Valve on gauge
FUEL PRESSURE
(WHEN PRESSING THE START BUTTON)
386 kPa - 414 kPa (56 PSI - 60 PSI)
Test when Cranking or Starting Engine
1. Crank or start engine and observe fuel pres-
sure. The fuel pressure should be the same as
in previous test.
If pressure is good, fuel pump and pressure regu-
lator are functioning correctly.
2. Stop the engine.
A rapid pressure drop indicates leakage either
from the fuel rail or from the fuel pump check
valve. Check fuel rail for leaks.
If a pressure drop occurs when pressing the
START button and the fuel rail is not leaking, then
replace the fuel pump module.
A slow pressure drop indicates leakage either
from a fuel injector or from the fuel pressure
regulator in the fuel pump module. To check
fuel injectors for leaks, refer to the ELECTRONIC
FUEL INJECTION (EFI) subsection. If injectors
are not leaking, then replace fuel pump.
8 https://brp-manuals.com/pwc_seadoo
3. Release fuel pressure in system using the valve
on the pressure gauge.
4. Remove pressure gauge and reinstall fuel hose
on fuel pump module.
WARNING
Wipe off any fuel spillage in the bilge. Fuel is
flammable and explosive under certain con-
ditions.
5. Reinstall all other removed parts, refer to appli-
cable subsections.
PROCEDURES
FUEL HOSES AND OETIKER
CLAMPS
Inspecting the Fuel Hose
1. Inspect all fuel hoses for wear, kinks, cracks or
any other types of damages.
2. Inspect all clamps for tightness.
Replacing the Fuel Hose
When replacing fuel hoses, be sure to use OEM
hoses and clamps. This will ensure continued
proper and safe operation.
WARNING
Use of fuel lines other than those recom-
mended by BRP may compromise fuel sys-
tem integrity.
WARNING
– Never use a hose pincher on high pressure
hoses.
– Never change the routing of a fuel hose.
– Always reinstall the corrugated protective
tubing on fuel hoses.
– Secure fuel hoses using the appropriate
locking tie or fastener to prevent contact
with sharp edges or hot, rotating and mov-
ing parts.
– After connecting a hose or a quick connect
fitting, pull on the hose near the fitting to
make sure it is securely locked.
– Always validate fuel system tightness
by performing a FUEL PUMP PRESSURE
TEST.
219100941-034
 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

Replacing the Oetiker Clamps INPUT VOLTAGE TEST

REQUIRED TOOL TEST PROBES VOLTAGE
Pin B Battery ground
OETIKER PLIER Battery voltage
(+ probe) (- probe)
(P/N 295 000 070)

WARNING
Whenever removing a hose in the fuel sys-
tem, always use new Oetiker clamps at as-
sembly.

FUEL PUMP
Fuel Pump Operation Test
1. Remove tether cord from the engine cut-off
switch to prevent engine starting.
2. Press START button.
3. The fuel pump should run for 2 seconds to build
up fuel system pressure. smr2012-027-011_a

4. If fuel pump runs, carry out the FUEL PUMP FUEL PUMP INPUT VOLTAGE TEST
PRESSURE TEST as described in INSPECTION
in this subsection. If battery voltage is read, power circuit is good.
Test the fuel pump circuit. Refer to FUEL PUMP
5. If the fuel pump does not run: CIRCUIT TEST.
– Ensure ECM is powered. Refer to ELEC-
TRONIC FUEL INJECTION (EFI) subsection. If battery voltage is not read, power circuit is
faulty. Test continuity of power circuit wiring
– Check fuse F2. If fuse is faulty, replace it between fuse box and fuel pump. Refer to FUEL
and repeat test. If fuse is good, carry out the PUMP CIRCUIT TEST in this subsection.
FUEL PUMP INPUT VOLTAGE TEST in this
subsection. Fuel Pump Circuit Test
Reconnect throttle body connector. 1. Reconnect the fuel pump harness connector.
Fuel Pump Pressure Test 2. Remove cover of fuse box.
Refer to INSPECTION in this subsection. 3. Remove ECM connector "B" and install it on the
ECM ADAPTER TOOL (P/N 529 036 166).
Fuel Pump Input Voltage Test
1. Ensure the fuel pump fuse (F2) is in good con-
dition.
2. Disconnect fuel pump harness connector. Re-
fer to FUEL PUMP REMOVAL.
3. Use the FLUKE 115 MULTIMETER (P/N 529 035
868).
4. Select Vdc.
5. Press the START button.
6. Read voltage at fuel pump harness connector 529036166

as per following table.

4. Set multimeter to and test pump circuit as per
following table.

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Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

PUMP CIRCUIT TEST THROUGH FUEL PUMP

RESISTANCE @
TEST PROBES
20°C (68°F)
Fuse box ECM connector B
Approx. 12
terminal B2 pin B-M1

219100893-021-002_b

219100893-021-001_a

5. If test succeeded, the fuel pump, its fuse and

its wiring harness are good.
6. If test failed, test wiring continuity as per table.
FUEL PUMP HARNESS CONTINUITY
TEST (WIRING ONLY) smr2012-027-011_c

RESISTANCE @ If there is an open circuit to FB-F2, repair

TEST PROBES
20°C (68°F) wiring/connector between fuel pump and fuse
Pump harness Fuse box.
connector pin B box terminal B1 If there is good continuity to FB-F2 and fuel pump
Close to 0
ECM (continuity)
fuse (F18) is good, check continuity of the wire
Pump harness jumper between D2 and E2. Repair or replace
connector B
connector pin A wiring as required.
pin B-M1
If every test succeeded and fuel pump still does
not work, try a new ECM. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
Removing the Fuel Pump
1. Disconnect the negative battery terminal, refer
to CHARGING SYSTEM subsection.
2. Disconnect fuel pump electrical connector.
3. Disconnect the vent tube from the fuel pump.
4. Wrap shop rags around the high pressure fuel
hose fitting, then press on the release button
of the quick connect fitting and disconnect the
hose.

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 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

WARNING
The upper filter and fuel pump reservoir on
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.

7. Carefully pull fuel pump module out.

WARNING
Always wipe off any fuel spillage from the
watercraft. When working with fuel or fuel
system and its components, always work in
a well ventilated area.
smr2012-027-010_b

1. Quick connect fitting (high pressure fuel hose) Installing the Fuel Pump
2. Harness connector
Reverse the removal procedure however, pay at-
5. Unscrew the fuel pump retaining nut. tention to the following.
REQUIRED TOOL 1. Carefully insert fuel pump module in fuel tank
so as not to bend float arm.
FUEL PUMP MODULE SOCKET 2. Install a NEW fuel pump module gasket each
(P/N 529 036 125) time the module is reinstalled.
NOTE: Wipe off parts to prevent fuel pump from
turning while torquing fuel pump nut.
3. Align arrow on top of fuel pump module with
index mark on top of fuel tank or fuel sensor
accuracy will be affected.
NOTE: Index mark and arrow locations are high-
lighted for clarity in following illustration.

smr2009-031-022_a

1. Fuel pump module socket

2. Fuel pump retaining nut

NOTICE While pulling out the fuel pump

module, pay attention to the corrugated tubes
and fuel sensor float arm. Float arm can get
caught up and bend which will reduce fuel sen-
sor accuracy. If fuel pump module is dropped
or damaged, it must be replaced.
6. Slowly pull fuel pump module up through smr2012-027-012_a

opening until corrugated tubes contact sides FUEL PUMP MODULE INDEXING
1. Align marks
of opening. Tilt the fuel pump module as you
slowly pull the pump upwards. 4. Tighten fuel pump nut.
TIGHTENING TORQUE
60 N•m ± 7 N•m
Fuel pump nut
(44 lbf•ft ± 5 lbf•ft)

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Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

5. Carry out a FUEL TANK LEAK TEST and a FUEL

SYSTEM HIGH PRESSURE LEAK TEST. See
procedures in this subsection.

FUEL FILTER
Fuel Filter Inspection
Inspect fuel filter. If dirty, partially clogged or dam-
aged, replace it.

smr2008-022-013_a

1. Fuel filter locking tab (x2)

2. Filter locking pin (x2)

4. Pull filter off fuel pump reservoir housing.

Installing the Fuel Filter

smr2009-031-025_a
1. Fuel filter
Removing the Fuel Filter
NOTE: The lower fuel filter on the fuel pump mod-
ule does not require replacement under normal
operating conditions. Replace only if permanently
clogged or damaged.
1. Remove fuel pump. Refer to FUEL PUMP in
this subsection.
WARNING
The upper filter and fuel pump reservoir on
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.
1. Align new filter with pump reservoir housing.
2. Press new filter on by hand. Ensure it is fully
seated and locked onto the pump reservoir
housing.
3. Reinstall fuel pump as per procedure in this sub-
section.
4. Carry out a FUEL SYSTEM HIGH PRESSURE
LEAK TEST as described in this subsection.
5. Install or other removed parts, refer to applica-
ble subsection.
FUEL LEVEL SENSOR
Fuel Level System Overview
A float type fuel level sensor mounted on the fuel
pump module sends a signal to the information
center.

2. Turn fuel pump upside down.

3. Using a small flat screwdriver, pry up the filter
locking tabs.

smr2008-022-007_b

TYPICAL — FUEL PUMP MODULE

1. Fuel level sensor

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 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

The information center interprets this signal and 6. Use the FLUKE 115 MULTIMETER (P/N 529 035
turns on the appropriate number of segments of 868) and select Vdc.
a bar type fuel level indication in the lower RH side 7. Measure the voltage at the test connector of
of the digital screen in the information center. the diagnostic harness as follows.
Fuel Level Troubleshooting TEST
FUEL TANK CONNECTOR
FUEL LEVEL TROUBLESHOOTING VOLTAGE
LEVEL OF DIAGNOSTIC
SYMPTOM POSSIBLE CAUSE HARNESS
Full 0.14 Vdc
– Wiring/connectors Pins 12 and 19
Fuel gauge always
– Fuel level sensor Empty 2.7 Vdc
display EMPTY
– Float stuck in low position
NOTE: Voltage could be slightly different depend-
– Water in fuel pump ing on battery voltage but should remain relatively
Fuel gauge always
connector close to this range. If fuel tank is not full or empty,
display FULL
– Float stuck in full position the voltage value will be proportional to the fuel
level (somewhere in-between).
Fuel level sensor – Wiring/connectors
fault code – Fuel level sensor If voltage is as per specifications the fuel level cir-
cuit and sensor are good. If fuel level does not
Fuel gauge displays – Low battery voltage work in information center, try a new one.
wrong level – Fuel level sensor fault
If voltage is out of specifications, perform the
Use the BRP diagnostic software (BUDS2) to
FUEL LEVEL SENSOR RESISTANCE TEST AT
check for a fault code. Refer to DIAGNOSTIC
INFORMATION CENTER as described in this sub-
section.
AND FAULT CODES.
Remove diagnostic harness and reconnect con-
Fuel Level Sensor Voltage Test nector.
1. First ensure battery is fully charged.
Fuel Level Sensor Resistance Test at
2. Disconnect the steering connector (HIC1). Re- Information Center
fer to WIRING HARNESS AND CONNECTORS
subsection for location. 1. Disconnect information center (multifunction
gauge) connector. Refer to INFORMATION
3. Connect the DIAGNOSTIC HARNESS (P/N 529 036 CENTER subsection.
384) to make an in-line connection between the
disconnected connectors. NOTICE Pull connector lock out. Do not twist
the screwdriver.

529036276

smr2009-042-002_a
4. Briefly press the START button to wake up the 1. Gauge connector
ECM. 2. Pull out to unlock connector
5. Install the tether cord on the engine cut-off 2. Use the FLUKE 115 MULTIMETER (P/N 529 035
switch. 868) and select .

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Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

3. Alternately drain then fill fuel tank and measure

the sensor resistance between pins 19 and 20
as follows.
RESISTANCE ( ) FLOAT HEIGHT (MM)
4.8 ± 2.2 268.9 ± 3.0 (FULL)
17.8 ± 2.2 240.6 ± 3.0
27.8 ± 2.2 219.1 ± 3.0
37.8 ± 2.2 193.8 ± 3.0
47.8 ± 2.2 161.9 ± 3.0 (HALF)
57.8 ± 2.2 128.3 ± 3.0
67.8 ± 2.2 94.1 ± 3.0
smr2012-027-010_c
77.8 ± 2.2 60.6 ± 3.0 FUEL PUMP MODULE
1. Fuel pump module connector
89.8 ± 2.2 28.8 ± 3.0 (EMPTY)
2. Alternately drain then fill fuel tank and measure
the sensor resistance between pins "C" and "D"
of the fuel pump connector. See table in FUEL
LEVEL SENSOR RESISTANCE TEST AT INFOR-
MATION CENTER.

A. Float height

NOTE: If fuel tank is not full or empty, the resis-

tance value will be proportional to the fuel level
(somewhere in-between).
If readings are as per specifications, the fuel level
circuit and sensor are good. If fuel level does not
work in information center, try a new one.
If readings are out of specifications, perform the
FUEL LEVEL SENSOR RESISTANCE TEST AT
FUEL PUMP.
If an open circuit is measured, carry out a conti-
smr2012-027-011_d
nuity test of the wiring from the information cen-
FUEL LEVEL SENSOR RESISTANCE TEST
ter to the 20-pin steering connector, and from the
20-pin steering connector to the fuel pump mod- If readings are out of specifications, replace sen-
ule connector. Refer to WIRING DIAGRAM. sor.
If the wiring is good, carry out a FUEL LEVEL SEN- When everything else has been tested and fuel
SOR RESISTANCE TEST AT FUEL PUMP. level is still not working, try a new information
4. Reconnect information center (multifunction center.
gauge) connector.

Fuel Level Sensor Resistance Test at

Fuel Pump
1. Disconnect fuel pump module connector.

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 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

Removing the Fuel Level Sensor

smr2008-022-022_a

smr2008-022-029
FUEL LEVEL SENSOR
1. Remove fuel pump module from fuel tank, see
FUEL PUMP REMOVAL in this subsection.
WARNING
The upper filter and fuel pump reservoir on
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.
1. Pressure regulator
2. Ground wire contact on pressure regulator
3. Ground wire disconnected
5. Using a flat screwdriver, press down on the
locking tab just below the pressure regulator
to release it from the pump reservoir cover,
and rotate it clockwise simultaneously so that
it slips over the locking tab.

2. Drain all fuel from the upper fuel filter and fuel
pump reservoir in an appropriate container.
NOTE: Note routing of fuel level sensor wires
prior to disconnecting the sensor from the fuel
pump module flange.
3. Disconnect the fuel level sensor connector
from the fuel pump module upper flange.

smr2008 022-023_a

1. Pressure regulator
2. Pressure regulator locking tab

smr2008-022-021_a

1. Fuel level sensor connector

4. Disconnect the ground wire from the pressure

regulator. Be careful not to bend the ground smr2008-022-024_a
contact on the pressure regulator. 1. Pressure regulator locking tab
2. Pressure regulator rotated clockwise over locking tab

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Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

6. Once the pressure regulator is rotate over the

locking tab, pull up on it to remove it from the
pump reservoir cover.

smr2008-022-026_a

1. Fuel level sensor release tabs

2. Locking pins

smr2008-022-025_a

1. Pressure regulator alignment tabs

2. Fuel pump reservoir alignment tabs

NOTE: The pressure regulator cover must not be

removed from the pressure regulator housing as-
sembly.

smr2008-022-027_a

1. Pull up on fuel level sensor

Installing the Fuel Level Sensor

Installation is the reverse of the removal proce-
dure however, pay attention to the following.
1. Ensure fuel level sensor locking pins are prop-
erly engaged into the fuel pump reservoir.
smr2008-022-028_a

1. Do not remove pressure regulator cover at locking tabs

2. Pressure regulator cover
3. Pressure regulator housing

7. Push in on the release tabs at the top of the

fuel level sensor to unlock it from the fuel pump
reservoir housing, and simultaneously pull up
on the fuel level sensor to remove it.

smr2008-022-026_b

1. Ensure engagement of sensor locking pins

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 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))
2. Align the fuel pressure regulator tabs into the
pump reservoir cover and turn it counterclock-
wise until it locks properly.
smr2008-022-025_b
PRESSURE REGULATOR INSERTION INTO PUMP RESERVOIR
COVER
1. Pressure regulator alignment tabs
2. Fuel pump reservoir alignment tabs
smr2008-022-030_a
TAB UP WHEN PRESSURE REGULATOR PROPERLY LOCKED
1. Pressure regulator locking tab
3. Reconnect the ground wire onto the pressure
regulator.
smr2008-022-031_a
1. Pressure regulator ground wire installed
219100941-034
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4. Ensure fuel level sensor connector is locked
into the module flange connector.
smr2008-022-021_a
1. Fuel level sensor connector
5. Carry out a FUEL LEVEL SENSOR RESISTANCE
TEST as described in this subsection.
6. Reinstall the fuel pump module. Refer to FUEL
PUMP INSTALLATION in this subsection.
FUEL TANK
Fuel Tank Inspection
1. Inspect fuel tank retaining straps for wear,
cracks or any other damages. Inspect strap
clip anchors and bolts.
2. Inspect fuel tank for wear caused by any ab-
normal contact or rubbing with other compo-
nent(s).
3. Disconnect fuel filler hose from fuel tank.
4. Inspect fuel tank filler hose for wear, cracks or
other damages.
5. Visually inspect the inside and outside of the
fuel tank filler necks for crack(s). If crack(s) are
found, replace fuel tank.
6. With your fingers, feel the inside and outside
surfaces of fuel tank, especially near the filler
neck.
7. Flex fuel tank neck to ensure there are no hid-
den cracks.
NOTE: A fuel tank is comprised of 2 components:
the tank and the filler neck. The filler neck is in-
jection molded and the tank is then blow molded
over the neck. During the molding process, a
small molding seam may appear on the inner
side of the neck at approximately 4 mm (5/32 in)
from the base of the neck. It is normal to have a
molding seam and it should not be confused with
a crack.
17
Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

4 2

F07F06A
3 A 5

1. Tank upper surface area

2. Inspect outer upper surface at filler neck
3. Normal molding seam
4. Inspect upper surface area inside filler neck
5. Base of filler neck
smr2012-027-010_b
A. Approx. 4 mm (5/32 in)
1. Quick connect fitting (high pressure fuel hose)
2. Harness connector
8. Install filler hose and torque retaining clamps.
5. Disconnect filler hose from fuel tank.
NOTE: Removing retaining screws of the filler
neck may help to disconnect hose from fuel tank.

smr2012-027-012_b

INDEXING WITH FUEL TANK

1. Align mark with the writing on hose

TIGHTENING TORQUE smr2012-027-012_c

Filler hose retaining 3.5 N•m ± 0.5 N•m 1. Filler hose

2. Retaining clamp
clamps (31 lbf•in ± 4 lbf•in)
NOTE: Take note of wiring harness, hose and
9. Reinstall all other removed parts. Refer to ap- cable routing for proper reinstallation. Also note
propriate subsection. method used for securing with locking ties.
Removing the Fuel Tank 6. Detach fuel tank retaining straps.
1. Remove engine. Refer to ENGINE REMOVAL 7. Remove fuel tank from the vehicle.
AND INSTALLATION. 8. Remove fuel pump as necessary. Refer to
2. Remove the air intake silencer. Refer to AIR IN- FUEL PUMP in this subsection.
TAKE SYSTEM subsection. 9. Inspect hull and flotation foams for wear.
3. Siphon fuel tank.
Installation the Fuel Tank
4. Disconnect fuel pump connections.
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

18 https://brp-manuals.com/pwc_seadoo 219100941-034
 Subsection XX (FUEL TANK AND FUEL PUMP (130, 155, 230 AND 300 ENGINES))

Apply torque values as specified in the exploded TIGHTENING TORQUE

view.
Filler hose retaining 3.5 N•m ± .5 N•m
1. Reinstall fuel pump if it was removed. Refer to clamps (31 lbf•in ± 4 lbf•in)
FUEL PUMP in this subsection.
2. Ensure flotation foams are properly positioned 8. Reinstall all other removed parts. Refer to their
under fuel tank. subsections.
3. Insert fuel tank in hull. 9. When vehicle reassembly is complete, carry
out a FUEL TANK LEAK TEST and a FUEL
If anchoring clips have been removed, torque re-
SYSTEM HIGH PRESSURE LEAK TEST as de-
taining screws to 10 N•m (89 lbf•in).
scribed in this subsection.
4. Place fuel tank retaining strap ends in anchoring
clips. Temporarily use tape to hold straps on the
top of fuel tank.

smr2009-031-027_a

TYPICAL
1. Fuel tank retaining strap
2. Clip anchor securing strap to hull

5. Secure retaining strap ends on top of fuel tank.

6. Properly secure wire harness, cables and hose
as prior to removal using appropriate locking
ties.
7. Install fuel tank filler hose as illustrated.

smr2012-027-012_b

INDEXING WITH FUEL TANK

1. Align mark with the writing on hose

219100941-034
https://brp-manuals.com/pwc_seadoo 19
 Subsection XX (POWER DISTRIBUTION AND GROUNDS)

POWER DISTRIBUTION AND GROUNDS

GENERAL Fuse Identification
Power distribution is shown in red on the color
wiring diagram. Refer to KNOWLEDGE CENTER.

OVERVIEW
The battery is the primary source of power for the
electrical system, it is recharged by the magneto.
Some components are permanently connected to
the battery (unswitched) while some require the
main relay to be closed (switched). Refer to the
color WIRING DIAGRAM on KNOWLEDGE CEN-
TER. smr2014-031-004_a

The ECM energizes and closes the main relay. FUSE BOX PIN IDENTIFICATION
At high RPM if the magneto power is greater Fuses and numbers are listed on the fuse box
than the loads, the rectifier/regulator will regulate cover, in the TECHNICAL SPECIFICATIONS sub-
power as necessary. section and on the WIRING DIAGRAM.
The system uses an external voltage regula-
tor/rectifier. RELAY
FUSE BOX Relay Pin Identification
The relay is in the fuse box. Refer to FUSE BOX
Fuse Box Location LOCATION.
RELAY PIN IDENTIFICATION
FUNCTION FUSE BOX PIN CONDITION
Direct battery
12-volt input at
A6 power
winding
from fuse F3
Grounded
by ECM B
Control B4 pin H2 once
START/STOP
is depressed
Direct battery
12-volt input at
smr2017-318-001
B6 power
TYPICAL - GTI contacts
from fuse F3
12-volt output A4 -

smr2017-318
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Subsection XX (POWER DISTRIBUTION AND GROUNDS)

GROUNDS
Ground Location
The battery ground is located on the LH side of
engine, just under the exhaust manifold.

smr2017-318-004_a

1. Battery ground

iBR and accessories are grounded on rear of en-

gine.

smr2017-318-003_a

1. iBR ground
2. Accessories gound

2 https://brp-manuals.com/pwc_seadoo smr2017-318
 Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

POWER DISTRIBUTION AND GROUNDS

SERVICE PRODUCTS
Description Part Number Page
BLACK NEOPRENE PAINT............................................................ 909570 ........................................... 3

GENERAL Fuse Identification

POWER DISTRIBUTION DIAGRAM

Refer to the appropriate WIRING DIAGRAM.
NOTE: Refer to WIRING DIAGRAM INFORMA-
TION for how to properly interpret the WIRING
DIAGRAM.

FUSE BOX

219100893-022-005_a

FUSE BOX PIN IDENTIFICATION

NUMBER OF CAVITIES BY ROW

ROW NUMBER OF CAVITIES
A-F 6

219100941-015-001_a

219100941-015
https://brp-manuals.com/pwc_seadoo 1
Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

NO. DESCRIPTION
Through relay:
– Fuel pump
F2 15 A
– Fuel injectors
– Ignition coils

Through relay and F13:

F3 3A
– Blige Pump

Direct power:
F6 30 A
– Regulator/rectifier
Through relay:
F7 – Cluster 5A
– D.E.S.S. Key
219100893-022-003_a Through relay and F13:
F8 3A
FUSE IDENTIFICATION – Depth Sounder
Direct power:
F9 30A
– iBR control
Direct power (through F12):
F10 5A
– START/STOP
Through relay:
F11 5A
– ECM
Direct power:
– Relay
F12 30 A
– F10
– F14
Through relay:
– F3
F13 15 A
– F8
– Diag Tool 2
Direct power (through F12):
F14 15 A
– Diag Tool 1

2 https://brp-manuals.com/pwc_seadoo 219100941-015
 Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

RELAY
Relay Pin Identification
The relay is in the fuse box. Refer to FUSE BOX.
RELAY PIN IDENTIFICATION
FUNCTION FUSE BOX PIN CONDITION
Direct battery
12-volt input at
B6 power
winding
from fuse F12
Grounded
by ECM B
Control B4 pin H2 once
START/STOP
is depressed
Direct battery
12-volt input at
A6 power
contacts
from fuse F12
12-volt output A4 -

GROUNDS
All the ground terminals are located on the front
of engine.

219100893-022-004_a

FRONT OF ENGINE
1. Battery ground
2. Electrical components grounds
3. Exhaust manifold

NOTE: Always apply BLACK NEOPRENE PAINT

(P/N 909570) on ground screws to prevent corro-
sion and potential ground problems.

219100941-015
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 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

WIRING HARNESS AND CONNECTORS

(GTS, GTI, GTR AND WAKE 155
MODELS)
SERVICE TOOLS
Description Part Number Page
CRIMPING TOOL (HEAVY GAUGE WIRE) .................................... 529 035 730 ........................................... 16
DIAGNOSTIC HARNESS ............................................................... 529 036 384 ........................................... 13
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 10
ECM TERMINAL REMOVER 2.25................................................. 529 036 175 ........................................... 11
ECM TERMINAL REMOVER 3.36................................................. 529 036 174 ........................................... 11

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
DELPHI TERMINAL EXTRACTOR ................................................. 12094429 ..................................... 11–12
FCI TERMINAL EXTRACTOR TOOL ............................................. 54241678 ..................................... 13–14
GM TERMINAL EXTRACTOR........................................................ 12094430 ........................................... 15
MOLEX 150 TERMINAL EXTRACTOR TOOL ............................... 63813 - 1500 ..................................... 13–14

219100941-016
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Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

900 HO ACE Engines

219100941-016-100_a

2 https://brp-manuals.com/pwc_seadoo 219100941-016
 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

1503 NA and 1500 HO ACE Engines

219100941-016-101_a

219100941-016
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Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

900 HO ACE engines

219100941-016-103_a

4 https://brp-manuals.com/pwc_seadoo 219100941-016
 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

1503 NA engines

219100941-016-102_a

219100941-016
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Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

1500 HO ACE engines

219100893-023-101_a

6 https://brp-manuals.com/pwc_seadoo 219100941-016
 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

GENERAL
ACRONYM DESCRIPTION ACRONYM DESCRIPTION
BAT+ Battery + GND3 Engine Ground
BAT- Battery - GND4 Battery Ground
Brake and Reverse Lever
BRLS HIC Harness Inter Connector to Engine
Sensor
CAPS Camshaft Position Sensor HIC1 Harness Inter Connector to Steering 1
CL Cluster HIC2 Harness Inter Connector to Steering 2
COM Communication iBR Intelligent Braking and Reverse
CPS Crankshaft Position Sensor KS Knock Sensor
CS Cruise Switch MAPTS Manifold Air Pressure Sensor
CTS Coolant Temperature sensor MSL Multi Switch Left
DS DESS post MSR Multi Switch Right
ECMA ECM connector A OPS Oil Pressure Sensor
ECMB ECM connector B OTS Oil temperature sensor
EGTS Exhaust Gas Temperature O.T.A.S. Off Throttle Assisted Steering
ETC Electronic Throttle Control REG Voltage Regulator/Rectifier connector
FB Fusebox SSS Start/Stop Switch
FP Fuel Pump STS Starter Solenoid
GND Battery Ground STR Starter
GND1 Engine Ground TAS Throttle Accelerator Sensor
GND2 Engine Ground TOPS Tip Over Position Sensor

PROCEDURES DIAGNOSTIC CONNECTOR

WARNING
(DEUTSCH)
When disassembling any connector for re- Connector Disassembly and
pair or replacement on the vehicle, always Reassembly
disconnect the battery to ensure all electrical
power is removed and prevent any possi-
bility of a short circuit. Refer to CHARGING 3 1
SYSTEM subsection.

3
2
4
F00H1CA

TYPICAL - DEUTSCH CONNECTOR

1. Male connector
2. Female connector
3. Secondary lock
4. Sealing cap

219100941-016
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Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

NOTICE Do not apply dielectric grease on ter- 3. Pry the retaining tab away from the terminal
minal inside connector. while gently pulling the wire and terminal out
of the back of the connector.
To remove terminals from connector, proceed as
follows:
1
1. Using long nose pliers, pull out the plastic lock
from between the terminals.

V01G0QA 1
TYPICAL - FEMALE CONNECTOR
1. Retaining tabs

To install:
1. For insertion of a terminal, ensure the plastic
V01G0OA 1 lock is removed.
TYPICAL - FEMALE CONNECTOR 2. Insert terminal through the back of the connec-
1. Female lock tor in the appropriate position, and push it in as
far as it will go. You should feel or hear the ter-
minal lock engage.
3. Pull back on the terminal wire to ensure the re-
tention fingers are holding the terminal.
4. After all required terminals have been inserted,
the lock must be installed.

1 1

V01G0PA 1
TYPICAL - MALE CONNECTOR
1. Male lock

NOTE: Before pin extraction, push wire forward

F04H6LA
to relieve pressure on retaining tab.
2. Insert a 4.8 mm (.189 in) wide screwdriver TYPICAL - CONNECTOR PIN-OUT
1. Terminal position identification numbers
blade inside the front of the terminal cavity.

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 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

ECM CONNECTOR (MOLEX)

There are 2 connectors on the ECM.
The engine wiring harness connector is con-
nected to ECM connector "A". The vehicle wiring
harness connector is connected to ECM connec-
tor "B".
Each ECM connector has 48 pins however, con-
nectors "A" and "B" are not interchangeable due to
their specific keyways.

smr2009-045-012_a

CONNECTOR LOCKING CAM ROTATION TO RELEASE

4. Pull connector off ECM.

smr2009-027-005

ECM CONNECTORS

Connector Removal
1. To access the ECM, refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
2. Press and hold the locking tab on the connec-
tor to be disconnected.

smr2009-045-013_a

Connector Installation
1. Fully open connector locking cam.

smr2009-045-011_a

LOCKING TAB TO PRESS AND HOLD

3. As you hold the locking tab, rotate the connec-

tor locking cam until it stops.

smr2009-045-013_b

CONNECTOR LOCKING CAM IN RELEASE POSITION

2. Insert connector on ECM.

219100941-016
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Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

3. As you push the connector onto the ECM, ro-
tate the connector locking cam until it snaps
locked.
NOTE: A “defective ECM module” could possi-
bly be repaired simply by disconnecting and recon-
necting it.
NOTICE Do not apply any lubricant product
to the pins of the ECM connector.

Connector Probing
The most recommended and safest method to
probe the MOLEX (ECM) connector terminals is
to use the ECM ADAPTER TOOL (P/N 529 036 166).
This tool will prevent deforming or enlarging of
the terminals, which would lead to bad ECM ter-
minal contact creating intermittent or permanent
problems.

smr2009-045-011_b

1. Locked here

4. Ensure the locking tab is fully out.

529036166

1. Disconnect the ECM connector to be probed,

and reconnect it on the ECM adapter.
2. Probe wire terminals of the circuit to be tested
directly in the adapter holes.

smr2009-045-011_a

LOCKING TAB FULLY OUT

Connector Inspection
Before replacing an ECM, always check electrical
connections.
1. Ensure connector locking mechanism is func- vmr2008-139-016_a

tioning properly. TYPICAL

2. Ensure all wire terminals (pins) are properly
locked in the connector.
3. Ensure they are very tight, make good contact
with the pins in the ECM.
4. Ensure the pins in the harness connector
and the ECM connector are clean, shiny and
corrosion-free.
5. Check wiring harness for signs of scoring.
1. ECM connector
2. ECM adapter
NOTICE Never probe directly on the ECM
harness connector. This could change the
shape or enlarge the terminals and create in-
termittent or permanent contact problems.

10 https://brp-manuals.com/pwc_seadoo 219100941-016
 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
Connector Terminal Removal (Harness
Connector)
To remove a signal terminal from the ECM har-
ness connector, use the ECM TERMINAL RE-
MOVER 2.25 (P/N 529 036 175).
To remove a power terminal, use the ECM TERMI-
NAL REMOVER 3.36 (P/N 529 036 174).
529036175
1. Remove rear protector from connector.
2. Pull out the connector lock.
smr2009-045-025_a
3. Insert tool to unlock terminal.
smr2009-045-026_a
1. Unlock here
219100941-016
https://brp-manuals.com/pwc_seadoo
GTR AND WAKE 155 MODELS))
4. Gently pull on the wire to extract the terminal
out the back of the connector.
smr2009-045-027_a
NOTICE Before installing wire terminals in
the connector, ensure all terminals are prop-
erly crimped on wires. After installation of
wire terminals in the connectors, ensure they
are properly locked by gently pulling on them
as if to extract them.
DS, STS, FP, TAS, BRLS, FB, MSL,
MSR O.T.A.S. CONNECTORS
(DELPHI/PACKARD)
Connector Terminal Removal
To remove a terminal (pin) from the connector, use
a special tool such as the DELPHI TERMINAL EX-
TRACTOR (P/N 12094429).
smr2010-052-001
DELPHI TERMINAL EXTRACTOR (P/N 12094429)
NOTE: Grinding the tool end to a taper is required.
1. Carefully insert the tool in the space provided to
release the pin lock.
2. Push the pin out the front of the connector by
pushing on the wire.
11
Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

smr2010-052-001

DELPHI TERMINAL EXTRACTOR (P/N 12094429)

smr2009-045-014_a

1. Unlock terminal here

smr2009-045-024_a

1. Unlock here

3. Gently pull on the wire to extract the pin out the

back of the connector.

smr2009-045-015_a

NOTICE Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
are properly locked by gently pushing on them
as if to extract them.

MSL, MSR CONNECTORS

(DELPHI)
Terminal Removal
1. To remove a terminal from connector, first re- smr2009-045-028_a
move the locking cap.
NOTICE Before installing terminals in the
connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
are properly locked by gently pushing on them
as if to extract them.

HIC, HIC1,HIC2 (MOLEX)

NOTE: 20 pin Molex is shown

smr2009-045-023_a

1. Pry out locking cap

2. Carefully insert the DELPHI TERMINAL EXTRAC-

TOR (P/N 12094429) in the space provided to re-
lease the pin lock.

12 https://brp-manuals.com/pwc_seadoo 219100941-016
 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

Socket Extraction (Female Connector)

1. Insert a small flat screwdriver in the pry holes
of the socket locator, on the socket side of the
connector.

smr2014-030-012_a

1. Female connector pin-out (sockets)

Connector Disconnect
Pull back the red secondary lock from the connec-
tor latch lever. Do not remove it from the latch. smr2014-030-012_b

Push the two connector assemblies together to 1. Socket locator

2. Pry holes
unload the latch. 3. Holes for inserting terminal extractor tool
Depress the latch lever and pull the two connector
assemblies apart. 2. Carefully pull out the socket locator out to the
detent position (approximately 5 mm).
NOTE: Do not remove the socket locator from the
connector housing.
3. Insert the extractor tool in the small hole adja-
cent to the socket.
NOTE: Push the extractor tool in only as far as re-
quired to release the lock from the socket. The
tool should slide along the socket and be inserted
between the socket and the lock.
REQUIRED TOOL
FCI TERMINAL EXTRACTOR TOOL
(P/N 54241678) or,

smr2014-045-003_a
MOLEX 150 TERMINAL EXTRACTOR TOOL
1. Red secondary lock (shown out) (P/N 63813 - 1500)
2. Latch lever

Connector Probing
1. Disconnect the steering connector in the vehi-
cle and connect it to the DIAGNOSTIC HARNESS smr2010-052-002
(P/N 529 036 384). FCI TERMINAL EXTRACTOR TOOL (P/N 54241678)
2. Probe the applicable circuit using the test con-
nector on the diagnostic harness.
NOTICE Attempting to probe the connector
without using the diagnostic connector may
damage the connector pins, or even cause a smr2014-045-001

short circuit if testing an energized circuit. MOLEX 150 TERMINAL EXTRACTOR TOOL 6(P/N 3813 - 1500)

4. Gently pull on the wire to extract the socket out

the back of the connector.
219100941-016
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Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))
Pin Extraction (Male Connector)
1. Using a pair of thin long nose pliers, pull the
pin locator out to the detent position (approxi-
mately 5 mm). This will allow unlocking of the
pins.
NOTICE Do not attempt to remove the pin lo-
cator or damage will occur. Be careful not to
bend the pins when using the pliers.
smr2014-045-002_a
1. Pin locator
2. Insert long nose pliers here
3. Holes for inserting terminal extractor tool
2. Insert the extractor tool in the small hole adja-
cent to the pin.
NOTE: Push the extractor tool in only as far as
required to release the lock from the pin. The
tool should slide along the pin and be inserted
between the pin and the lock.
REQUIRED TOOL
FCI TERMINAL EXTRACTOR TOOL
(P/N 54241678) or,
MOLEX 150 TERMINAL EXTRACTOR TOOL
(P/N 63813 - 1500)
smr2010-052-002
FCI TERMINAL EXTRACTOR TOOL (P/N 54241678)
smr2014-045-001
MOLEX 150 TERMINAL EXTRACTOR TOOL 6(P/N 3813 - 1500)
3. Gently pull on the wire to extract the pin out the
back of the connector.
14 https://brp-manuals.com/pwc_seadoo
Pin Insertion
1. Ensure the terminal (pin) is properly crimped
onto the wire.
2. Ensure the pin locator (the white plastic insert
in the connector) is out in the detent position.
3. Insert the pin in through the back of the connec-
tor.
NOTE: When inserting the pin, insert the
stepped portion facing the notch in the con-
nector pin hole.
smr2014-045-004_a
TYPICAL - PIN INSERTION
1. Notch
2. Stepped portion towards notch
4. Push the pin in until the pin lock engages the
pin.
5. Gently pull on the pin to ensure it is properly
locked.
6. Repeat previous steps for each pin to be in-
serted.
7. Push the pin locator into the connector to the
locked position.
Reconnecting the MOLEX Connector
1. Insert the male connector into the female con-
nector and push it in until the latch lever fully
engages.
2. Push in the secondary lock (red tab) until it fully
engages into the latch lever.
219100941-016
 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

smr2010-050-022_a

Step 2: Insert GM extractor tool (P/N 12094430)

smr2014-045-003_a

1. Red secondary lock (shown out) 3. Gently pull on the wire to extract the pin out the
2. Latch lever back of the connector.

VOLTAGE
REGULATOR/RECTIFIER
CONNECTOR (FURUKAWA)
Terminal Removal
1. Remove the secondary lock (plastic insert).

smr2010-050-023_a

Step 3: Pull wire to extract pin

NOTICE Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
smr2010-050-021_a are properly locked by gently pushing on them
Step 1: Remove the secondary lock as if to extract them.
2. Carefully insert the GM TERMINAL EXTRACTOR
(P/N 12094430) between the lock and the pin to BATTERY CABLES
release the pin. Battery Cable Crimping
Carefully strip the wire approximately to 10 mm
(3/8 in) in length, using a wire stripping tool or
sharp blade/knife.
smr2010-052-003

GM TERMINAL EXTRACTOR (P/N 12094430)

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Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

A
A32E2QA

A. 10 mm (3/8 in)

NOTE: Make sure not to cut wire strands while

stripping the wire. 2
Install the appropriate terminal on the wire ac- A32E2SA

cording to the requirement. Refer to appropriate POSITIONING THE CRIMPING PLIERS

PARTS CATALOG. Step 1: Press
Step 2: Rotate

After positioning the crimping pliers, crimp the ter-

minal already installed on wire.

A32E2RA

INSTALLATION OF TERMINAL

Follow the instructions provided with the CRIMP-

ING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
to select the proper position of the tool.

A32E2TA
529035730

CRIMPING OF WIRE
NOTE: Different wires require different crimping
pliers settings, so make sure to follow the instruc-
tion supplied with the tool.

A32E2UA

PROPERLY CRIMPED WIRE

To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.

16 https://brp-manuals.com/pwc_seadoo 219100941-016
 Subsection XX (WIRING HARNESS AND CONNECTORS (GTS, GTI,
GTR AND WAKE 155 MODELS))

NOTICE Never weld the wire to the terminal.

Welding can change the property of the wire
and it can become brittle and break.
Install the protective heat shrink rubber tube on
the terminal. Heat the heat shrink rubber tube us-
ing the heat gun so that it grasps the wire and the
terminal.
NOTICE Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.

219100941-016
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 Subsection XX (IGNITION SYSTEM)

IGNITION SYSTEM
SERVICE TOOLS
Description Part Number Page
D.E.S.S. POST REMOVER ............................................................ 529 035 943 ............................................. 7
DIAGNOSTIC HARNESS ............................................................... 529 036 188 ............................................. 7
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 4
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 4, 7

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ............................................. 6

GENERAL
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.) must be replaced.

Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards. smr2014-032-001_a

1. Ignition coils
WARNING
Never check for engine ignition spark from When a ground signal is provided by the ECM,
an open coil and/or spark plug as spark may the primary ignition coil winding starts charging.
cause potential fuel vapors to ignite. Always When the ECM releases the ground signal, a high
use an approved spark tester. voltage is induced in the coil secondary winding
that is used to produce a spark at the spark plug
electrode.
SYSTEM DESCRIPTION
Cylinder 1 is located on the PTO side of the en-
The ignition system is a digital inductive type (IDI) gine. Each cylinder is identified by a number on
system. cylinder block housing.
Ignition system parameters such as ignition tim-
ing, spark duration, and firing order, as well as
many other engine related functions are con-
trolled by the engine management system (EMS)
in order to meet engine operational requirements.
The EMS can detect many abnormalities includ-
ing a short circuit in the primary winding of the
ignition coils as well as its associated circuits.
Three direct ignition coils receive power from the
fuse F3 through the relay.

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Subsection XX (IGNITION SYSTEM)
smr2014-032-060_a
1. Cylinder identification numbers
Ignition Timing
Ignition timing is not adjustable.
The ECM is programmed with data (ignition map-
pings) that it uses to establish optimum ignition
timing under all engine operating conditions.
It receives signals from a variety of sensors that
it compares with the ignition mappings and uses
it to control the ignition spark timing, duration and
firing order.
The firing of each spark plug is independent of the
others.
Engine RPM Limiter
The ECM will limit the maximum engine speed by
cutting off ignition spark and fuel at a predeter-
mined engine RPM.
ENGINE SPEED LIMITER
8300 RPM
SETTING
Knock Sensor
A knock sensor is mounted on the cylinder block
below the exhaust manifold, see ENGINE MAN-
AGEMENT SYSTEM subsection. It detects spe-
cific vibrations that would typically be generated
by engine detonation.
If detonation occurs, the knock sensor detects
it and the ECM goes into a specific operating
mode whereby it temporarily retards the ignition
advance until detonation stops.
The ECM is able to identify in which cylinder the
knocking occurs and modifies the ignition advance
on that cylinder only.
Refer to the ELECTRONIC FUEL INJECTION
(EFI) subsection for testing and replacement pro-
cedures.
2 https://brp-manuals.com/pwc_seadoo
TROUBLESHOOTING
It is good practice to check for fault codes using
BUDS2 as a first troubleshooting step. Refer to
DIAGNOSTIC AND FAULT CODES subsection.
Refer to POWER DISTRIBUTION for fuses and re-
lay information.
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
IGNITION SYSTEM TESTING
The ECM controls the ignition system.
If a fault is detected by the ECM, the check engine
light will turn on.
The ECM can detect a problem on the primary
winding or circuit of the ignition coils.
The secondary winding of the ignition coils is not
monitored by the ECM.
Other sensors in relation with the ignition system
are also monitored by the ECM.
Ignition System Testing Sequence
Check for fault codes using BUDS2 software as a
first troubleshooting step. Refer to DIAGNOSTIC
SYSTEM AND FAULT CODES subsection.
Ensure fuse F3 and relay are powered and in good
condition.
If a fuse is burnt, test for a short circuit or faulty
component on that fuse circuit before replacing
the fuse.
WARNING
Due to the possibility of flammable vapors ac-
cumulating in the bilge, you should always
test for a short circuit which may produce a
spark and ignite the vapors before replacing
a burnt fuse.
Check ignition spark, refer to IGNITION COIL
QUICK TEST USING BUDS2 in this subsection.
DIAGNOSTIC GUIDELINES
The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and
should not be assumed to list all possible causes.
smr2017-324
 Subsection XX (IGNITION SYSTEM)

ENGINE WILL NOT STOP WHEN 2. Damaged trigger wheel/defective or loose CPS
REMOVING KEY FROM ENGINE CUT-OFF - Check, refer to MAGNETO AND STARTER and
SWITCH ELECTRONIC FUEL INJECTION (EFI) subsec-
tions.
1. Defective engine cut-off switch
- Check engine cut-off switch. Replace if neces- ENGINE DETONATION OR PINGING
sary.
1. Faulty or disconnected knock sensor
ENGINE WILL NOT START (ENGINE - Check, refer to ELECTRONIC FUEL INJECTION
TURNS OVER) (EFI) subsection.

1. Fouled or defective spark plug ENGINE LACKS ACCELERATION OR

- Check spark plug condition. Replace if necessary. POWER
2. Defective CPS 1. Weak spark
- Test CPS, refer to ELECTRONIC FUEL INJEC- - Check spark plugs, coils, wiring and connections.
TION (EFI) subsection.
3. Defective trigger wheel PROCEDURES
- Check. Refer to MAGNETO AND STARTER sub-
section. IGNITION COILS
4. Defective ignition circuit WARNING
- Check fuses, ignition coils, wiring and connec-
tors.
Never check for engine ignition spark from
an open coil and/or spark plug in the engine
ENGINE HARD TO START compartment as a spark may cause fuel va-
pors which may have accumulated in the
1. Faulty, fouled or worn out spark plug bilge to ignite.
- Check spark plug condition. Replace if necessary.
2. Drowned engine Ignition Coil Location
- Check engine temperature value using BUDS2. 1. Remove the seat.
monitoring page. If the temperature read is lower
than the ambient temperature, CTS sensor may Ignition coils are located on top of the valve cover.
be defective or have a bad connection. There-
fore, the ECM would erroneously set the engine
in cold start mode and it could flood the spark
plugs.

ENGINE MISFIRES, RUNS IRREGULARLY

1. Fouled, defective, worn spark plugs
- Check spark plug condition. Replace if necessary.
2. Damaged trigger wheel/loose CPS
- Check. Refer to MAGNETO AND STARTER sub-
section.
3. Defective ignition circuit
- Check fuses, ignition coils, wiring and connec- smr2014-032-001_a

tors. 1. Ignition coils

4. Poor engine grounds Testing Ignition Coils Using BUDS2

- Check ground condition, refer to POWER DISTRI-
BUTION AND GROUNDS subsection.
ENGINE CONTINUALLY BACKFIRES
1. Fouled, defective spark plugs
- Check spark plug condition. Replace if necessary.
1. Connect BUDS2. Refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
2. Select the Functions page.
3. Activate the ignition coil to be tested.

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Subsection XX (IGNITION SYSTEM)

You should hear the spark occurring. If in doubt, Testing Ignition Coil Power Circuit
use a sealed vapor proof spark tester or an induc- Continuity
tive spark tester as available from tool suppliers, 1. Use the FLUKE 115 MULTIMETER (P/N 529 035
to prevent a spark from occurring in the bilge. 868) and select .
If there is no ignition at one or more coils, carry 2. Read resistance of the desired ignition coil cir-
out a TESTING IGNITION COIL INPUT VOLTAGE. cuit.
If spark is weak, try a new spark plug. If spark is
still weak, try a new ignition coil. IGNITION
IGNITION FUSE
COIL MEASUREMENT
NOTE: The voltage required to produce a spark in COIL BOX
WIRE
the combustion chamber is higher when the en-
1
gine is running. (rear)
VT/BU
Terminal
Close to 0
Testing Ignition Coil Input Voltage 2 VT/GN A4
Make sure fuse F3 and the relay are good before 3 VT/OG
testing.
1. Disconnect the applicable ignition coil connec- If test fails at any ignition coil, test the following
tor. items separately and repair/replace wiring or ter-
minals from fuse box to the applicable ignition coil.
2. Remove tether cord from the engine cut-off Refer to WIRING DIAGRAM for details.
switch.
– Wiring from fuse box to engine connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035 – Wiring from engine connector to ignition coil.
868) to Vdc.
4. Press the START button to activate the ECM. Testing Ignition Coil Control Circuit
5. Measure voltage. Continuity
1. Disconnect ECM connector "A". For connector
TEST PROBES VOLTAGE
identification, refer to WIRING HARNESS AND
VIOLET/BLUE wire CONNECTOR subsection.
(ignition coil no. 1)
2. Connect ECM connector to the ECM ADAPTER
VIOLET/GREEN wire Battery Battery TOOL (P/N 529 036 166).
(ignition coil no. 2) ground voltage
VIOLET/ORANGE wire
(ignition coil no. 3)

529036166

3. Disconnect ignition coil connector.

4. Test for continuity of circuit as per following ta-
ble.
smr2014-032-011_a

IGNITION COIL INPUT VOLTAGE TEST

If test succeeds, carry out an TESTING IGNITION

COIL RESISTANCE.
If test fails, carry out an TESTING IGNITION COIL
POWER CIRCUIT CONTINUITY.

4 https://brp-manuals.com/pwc_seadoo smr2017-324
 Subsection XX (IGNITION SYSTEM)

IGNITION RESISTANCE @
IGNITION ECM CIRCUIT TERMINAL
COIL RESISTANCE 20°C (68°F)
COIL ADAPTER
WIRE
Primary
1 and 2 0.85 - 1.15
Cylinder 1 winding
BN/BK ECMA-M4
(rear)
Close to 0
Cylinder 2 BN/OG ECMA-M2 (continuity)
Cylinder 3 BN/YE ECMA-M1

smr2014-032-013_a

SECONDARY WINDING

RESISTANCE @
CIRCUIT TERMINAL
20°C (68°F)
Secondary 1 and spark
9.5 - 13.5 k
winding plug terminal

smr2014-032-011_b If any test fails, replace ignition coil.

IGNITION COIL CONTROL CIRCUIT TEST
If test fails, repair the connector or replace the en-
gine wiring harness.
Testing Ignition Coil Resistance
An ignition coil with a good resistance measure-
ment can still be faulty. Current leakage can occur
at high voltage levels which is not detectable with
an ohmmeter. Replacing the ignition coil may be
necessary as a test.
1. Remove ignition coil. Refer to REMOVING THE
IGNITION COIL in this subsection.
2. Perform a visual inspection of the ignition coils.
Check for corrosion, bent pins, loose or burnt
contacts, and cracked or torn insulator.
3. Using a multimeter, test the resistance in both
primary and secondary windings.
If test succeeds, carry out an TESTING IGNITION
COIL CONTROL CIRCUIT CONTINUITY.
Removing the Ignition Coil
1. Disconnect ignition coil connector.
2. Remove ignition coil retaining screw.
NOTICE Do not pry on ignition coil with a
tool.
3. Remove ignition coil from spark plug by rotating
coil side to side as you pull up.
Installing the Ignition Coil
Install the ignition coil on the spark plug.
Align the retaining screw hole of the ignition coil
with the threaded hole on the valve cover.
Push the ignition coil all the way down until it rests
on the valve cover.
Install and tighten retaining screw.
TIGHTENING TORQUE
Ignition coil retaining 9 N•m ± 1 N•m
screw (80 lbf•in ± 9 lbf•in)

Connect ignition coil connector.

smr2014-032-012_a

PRIMARY WINDING
SPARK PLUG
Removing the Spark Plug
1. Remove ignition coil. Refer to REMOVING THE
IGNITION COIL in this subsection.
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Subsection XX (IGNITION SYSTEM)
WARNING
Never remove an ignition coil from a spark
plug without disconnecting it from the wiring
harness. Flammable vapors may be present
in the bilge. Should the tether cord be in-
stalled on the engine cut-off switch, a spark
could be generated at the spark plug end of
the coil possibly resulting in an explosion.
2. Using a spark plug socket, release the torque
applied to the spark plug.
1 2
A00E0BA
1. Approved socket
2. Improper socket
3. Clean the spark plug and cylinder head with
pressurized air.
4. Unscrew spark plug then use the ignition coil to
take spark plug out of spark plug hole.
smr2014-032-051_a
1. Ignition coil
2. Spark plug
Troubleshooting a Fouled Spark Plug
Fouling of the spark plug is indicated by irregular
running or misfiring of the engine, decreased
engine speed due to misfiring, reduced perfor-
mance, and increased fuel consumption.
6 https://brp-manuals.com/pwc_seadoo
Other possible causes are: use of an incorrect
or bad fuel, defective ignition system, incorrect
spark plug gap, loss of compression, or lubricating
oil entering the combustion chamber.
The plug face of a fouled spark plug has either a
wet or dry black carbon deposit. Such coatings
form a conductive connection between the center
electrode and the ground electrode.
Spark Plug Analysis
A00E0AA 1 2 3
TYPICAL
1. Overheated (light gray, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, gray, melted coating)
The plug face reveals the condition of the engine,
operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
the spark plug at prescribed intervals, examining
the plug face (i.e. the part of the plug projecting
into the combustion chamber).
Installing the Spark Plug
Prior to installation, ensure the contact surfaces of
the cylinder head and spark plug are free of grime.
1. Using a wire feeler gauge, check electrode gap
as specified in TECHNICAL SPECIFICATIONS.
2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) over the spark plug threads to
prevent possible seizure.
3. Hand screw spark plug into cylinder head.
Then, tighten the spark plug to specification
with an approved spark plug socket.
TIGHTENING TORQUE
13 N•m ± 1 N•m
Spark plug
(115 lbf•in ± 9 lbf•in)
4. Install ignition coil. Refer to INSTALLING THE
IGNITION COILS in this subsection.
5. Complete the installation in the reverse order of
the removal.
smr2017-324
 Subsection XX (IGNITION SYSTEM)

ENGINE CUT-OFF SWITCH

The electrical system provides power to RFID-D.
The ECM provides 5Vdc to the DESS module
DS-C. The ECM provides a ground to the DESS
module DS-A. When a key (tether cord) is installed
on the DESS post, a hall effect switch closes and
sends a 12-15Vdc signal to the ECM.

529036188

1. Connect the diagnostic harness to the vehicle

steering connector.

mmr2015-131-005_a

1. RFID D.E.S.S. post

SPECIFICATIONS
WITH TETHER CORD
RFID CONNECTOR PIN INSTALLED AND
ELECTRICAL SYSTEM
(WAKE-UP OR ON)
smr2017-324-001
A ECM ground STEERING CONNECTOR

B 3.3 Vdc 2. Push start button to wake up ECM.

Data communication
C
2 -4.5 Vdc
NOTICE Do not attempt to probe the steering
connector on the watercraft. Use the test con-
D 12 - 15 Vdc nector on the diagnostic harness.
3. Set multimeter to Vdc.
Testing Engine Cut-Off Switch
Connect BUDS2 and use the measurements 4. Probe test connector on diagnostic harness to
page to monitor key status and ensure the DESS check voltage between pins 11 and 13 as fol-
module recognizes that a key is instaleld on the lows.
DESS post. DIAGNOSTIC
TETHER CORD READING
Ensure power and ground are available at DESS HARNESS
connector. Removed Probe between 3.3 Vdc
REQUIRED TOOLS Installed pins 11 and 13 0 Vdc
DIAGNOSTIC HARNESS (P/N 529 036 188)
NOTE: This tests for voltage at DESS connector
FLUKE 115 MULTIMETER (P/N 529 035 868) pin B.
If test fails:
– Check steering harness between steering con-
nector and DESS module. Repair or replace.
– If harness is good, replace the DESS module.

Replacing Engine Cut-Off Switch

REQUIRED TOOL
D.E.S.S. POST REMOVER (P/N 529 035 943)

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Subsection XX (IGNITION SYSTEM)

529035943

8 https://brp-manuals.com/pwc_seadoo smr2017-324
 Subsection XX (IGNITION SYSTEM)

IGNITION SYSTEM
SERVICE TOOLS
Description Part Number Page
D.E.S.S. POST REMOVER ............................................................ 529 035 943 ........................................... 6
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 4

GENERAL Cylinder 1 is located on the PTO side of the en-

gine. Each cylinder is identified by a number on
WARNING the valve cover.
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.) must be replaced.

Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards.
WARNING
Never check for engine ignition spark from
an open coil and/or spark plug as spark may
cause potential fuel vapors to ignite. Always RTX1503ACEMY18-010-001_a

use an approved spark tester. 1. Ignition coils

2. Cylinder identification number on valve cover

SYSTEM DESCRIPTION Ignition Timing

The engine control module (ECM) controls the ig- Ignition timing is not adjustable.
nition system, as well as many other engine re- The ECM is programmed with ignition maps that
lated functions. it uses along with data received from a variety of
The battery supplies power to the primary side of sensors to establish optimum ignition timing un-
the ignition coils through a relay while the ECM der all engine operating conditions.
completes the circuit to each coil primary winding The firing of each spark plug is independent of the
by switching it to ground at the appropriate mo- others.
ment.
The ignition system is a digital inductive type sys- Engine RPM Limiter
tem. The ECM will limit the maximum engine speed by
Ignition system parameters such as ignition tim- cutting off ignition spark and fuel at a predeter-
ing, dwell time and firing order are controlled by mined engine RPM.
the ECM in order to meet engine operational re- ENGINE TYPE RPM LIMITER
quirements.
130 7850 RPM
Direct ignition coils (stick coils) are used for each
cylinder. 155 8100 RPM
Three separate ignition coils receive power from 230 and 300 8450 RPM
three separate fuses.
When a ground signal is provided by the ECM to Knock Sensor
an ignition coil primary winding, a high voltage is A knock sensor is mounted on the cylinder block
induced in the coil secondary winding that is used behind the intake manifold. It detects specific vi-
to produce a spark at the spark plug electrode. brations that would typically be generated by en-
gine detonation.

RTX1503ACEMY18-010
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Subsection XX (IGNITION SYSTEM)
If detonation occurs, the knock sensor detects
it and the ECM goes into a specific operating
mode whereby it temporarily retards the ignition
advance until detonation stops.
The ECM is able to identify in which cylinder the
knocking occurs and modifies the ignition advance
on that cylinder only.
Refer to the ELECTRONIC FUEL INJECTION
(EFI) subsection for testing and replacement pro-
cedures.
TROUBLESHOOTING
It is good practice to check for fault codes using
the BUDS2 as a first troubleshooting step. Refer
to DIAGNOSTIC AND FAULT CODES subsection.
Refer to POWER DISTRIBUTION AND GROUNDS
for fuses and relay information.
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
TESTING THE IGNITION SYSTEM
1. Ensure fuses F2 is powered and in good condi-
tion.
2. If the fuse is burnt, test for a short circuit or
faulty component on that fuse circuit before re-
placing the fuse.
WARNING
Due to the possibility of flammable vapors ac-
cumulating in the bilge, you should always
test for a short circuit which may produce a
spark and ignite the vapors before replacing
a burnt fuse.
3. If there is no active fault code, start diagnostic
by testing IGNITION COIL USING BUDS2
4. If a primary winding of an ignition coil or a cir-
cuit is at fault, a fault code will be set. Refer to
DIAGNOSTIC AND FAULT CODES subsection.
DIAGNOSTIC GUIDELINES
The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and
should not be assumed to list all possible causes.
ENGINE WILL NOT STOP WHEN
REMOVING KEY FROM ENGINE CUT-OFF
SWITCH
1. Defective engine cut-off switch
- Check engine cut-off switch. Replace if neces-
sary.
2 https://brp-manuals.com/pwc_seadoo
ENGINE WILL NOT START (ENGINE
TURNS OVER)
1. Fouled or defective spark plug
- Check spark plug condition. Replace if necessary.
2. Defective CPS
- Test CPS, refer to ELECTRONIC FUEL INJEC-
TION (EFI) subsection.
3. Defective trigger wheel
- Check. Refer to PTO HOUSING, MAGNETO AND
STARTER subsection.
4. Defective ignition circuit
- Check fuses, ignition coils, wiring and connec-
tors.
ENGINE HARD TO START
1. Faulty, fouled or worn out spark plug
- Check spark plug condition. Replace if necessary.
2. Drowned engine
- Check engine temperature value using BUDS2
(Measurement page). If the temperature read is
lower than the ambient temperature, CTS sen-
sor may be defective or have a bad connection.
Therefore, the ECM would erroneously set the
engine in cold start mode and it could flood the
spark plugs.
ENGINE MISFIRES, RUNS IRREGULARLY
1. Fouled, defective, worn spark plugs
- Check spark plug condition. Replace if necessary.
2. Defective T.O.P.S. sensor
- Test T.O.P.S. Refer to LUBRICATION SYSTEM
subsection.
3. Damaged trigger wheel/loose CPS
- Check. Refer to PTO HOUSING, MAGNETO AND
STARTER subsection.
4. Defective ignition circuit
- Check fuses, ignition coils, wiring and connec-
tors.
5. Poor engine grounds
- Check ground condition, refer to POWER DISTRI-
BUTION AND GROUNDS subsection.
ENGINE CONTINUALLY BACKFIRES
1. Fouled, defective spark plugs
- Check spark plug condition. Replace if necessary.
2. Damaged trigger wheel/defective or loose CPS
- Check, refer to PTO HOUSING, MAGNETO AND
STARTER and ELECTRONIC FUEL INJECTION
(EFI) subsections.
RTX1503ACEMY18-010
 Subsection XX (IGNITION SYSTEM)

ENGINE DETONATION OR PINGING 4. Measure voltage within 3 minutes after de-

pressing START/STOP button.
1. Faulty or disconnected knock sensor
- Check, refer to ELECTRONIC FUEL INJECTION 5. Set multimeter to Vdc.
(EFI) subsection. TEST PROBES VOLTAGE
ENGINE LACKS ACCELERATION OR VIOLET/BLUE wire
POWER (ignition coil no. 1)
1. Weak spark VIOLET/GREEN wire Battery Battery
(ignition coil no. 2) ground voltage
- Check spark plugs, coils, wiring and connections.
VIOLET/ORANGE wire
PROCEDURES (ignition coil no. 3)

IGNITION COILS
WARNING
Never check for engine ignition spark from
an open coil and/or spark plug in the engine
compartment as a spark may cause fuel va-
pors which may have accumulated in the
bilge to ignite.

Testing the Ignition Coil Using BUDS2

1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. In BUDS2, go to: smr2016-030-001_a

– Functions page IGNITION COIL INPUT VOLTAGE TEST

– ECM button
If test succeeds, carry out TESTING THE IGNI-
– Activate Ignition Coils TION COIL RESISTANCE.
3. Select the ignition coils to be tested and clicking If test fails, carry out TESTING THE IGNITION
on the ACTIVATE button. COIL POWER CIRCUIT CONTINUITY.
You should hear the spark occurring. If in doubt,
use a sealed vapor proof spark tester or an induc- Testing the Ignition Coil Power Circuit
tive spark tester as available from tool suppliers, Continuity
to prevent a spark from occurring in the bilge. 1. Remove fuses F2.
If there is no ignition at one or more coils, carry out 2. Read resistance of the desired ignition coil cir-
TESTING THE IGNITION COIL INPUT VOLTAGE. cuit.
If spark is weak, try a new spark plug. If spark is 3. Set multimeter to .
still weak, try a new ignition coil.
IGNITION
NOTE: The voltage required to produce a spark in IGNITION
COIL
FUSE
MEASUREMENT
the combustion chamber is higher when the en- COIL BOX
WIRE
gine is running.
1
VT/BU
Testing the Ignition Coil Input Voltage (rear)
Terminal
Close to 0
Make sure fuse F2 is good before testing. 2 VT/GN B1
1. Disconnect the applicable ignition coil connec- 3 VT/OR
tor.
2. Remove tether cord from the engine cut-off If test fails at any ignition coil, repair or replace
switch. wiring or terminals from fuse box to the applicable
ignition coil.
3. Press the START button to activate the ECM.

RTX1503ACEMY18-010
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Subsection XX (IGNITION SYSTEM)

Testing the Ignition Coil Control Circuit Primary Winding

Continuity 1. Remove ignition coil. Refer to REMOVING THE
1. Disconnect ECM connector "A". For connector IGNITION COIL in this subsection.
identification, refer to WIRING HARNESS AND 2. Perform a visual inspection of the ignition coils.
CONNECTOR subsection. Check for corrosion, bent pins, loose or burnt
2. Connect ECM connector to the ECM adapter contacts, and cracked or torn insulator.
tool. 3. Using a multimeter, measure the resistance of
REQUIRED TOOL the primary winding.

ECM ADAPTER TOOL

(P/N 529 036 166)

3. Disconnect ignition coil connector.

4. Test for continuity of circuit as per following ta-
ble.
IGNITION
ECM
COIL COIL RESISTANCE
ADAPTER
WIRE
mmr2009-122-009_a
Cylinder 1 PRIMARY WINDING
BN/BK A-M4
(rear)
Close to 0
Cylinder 2 BN/OG A-M2 (continuity) RESISTANCE @
TERMINAL
20°C (68°F)
Cylinder 3 BN/YE A-M1
1 and 3 0.80 - 0.97

If test fails, replace ignition coil.

If test succeeds, carry out TESTING THE IGNI-
TION COIL CONTROL CIRCUIT CONTINUITY.
Secondary Winding
The secondary winding on this type of ignition coil
cannot be tested.

Removing the Ignition Coil

1. Disconnect ignition coil connector.
NOTICE Do not pry on ignition coil using any
tool.
smr2016-030-001_b

IGNITION COIL CONTROL CIRCUIT TEST

If test fails, repair the connector or replace the en-
gine wiring harness.
Testing the Ignition Coil Resistance
An ignition coil with a good resistance measure-
ment can still be faulty. Current leakage can occur
at high voltage levels which is not detectable with
an ohmmeter. Replacing the ignition coil may be
necessary as a test.
2. Remove ignition coil retaining screw.
3. Remove ignition coil from spark plug by rotating
coil side to side as you pull up.
Installing the Ignition Coil
1. Install ignition coil on spark plug.
2. Align the retaining screw hole of the ignition coil
with the threaded hole on the valve cover.
3. Push the ignition coil all the way down until it
rests on the valve cover.
4. Place GND connector on ignition coil.
5. Install and tighten retaining screw.

4 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-010

RTX1503ACEMY18-010-002_a
1. GND connector
2. Retaining screw
TIGHTENING TORQUE
Ignition coil retaining 9 N•m ± 1 N•m
screw (80 lbf•in ± 9 lbf•in)
6. Reconnect ignition coil connector.
SPARK PLUGS
Removing the Spark Plug
1. Remove ignition coil. Refer to REMOVING THE
IGNITION COIL in this subsection.
WARNING
Never remove an ignition coil from a spark
plug without disconnecting it from the wiring
harness. Flammable vapors may be present
in the bilge. Should the tether cord be in-
stalled on the engine cut-off switch, a spark
could be generated at the spark plug end of
the coil possibly resulting in an explosion.
2. Using an appropriate spark plug socket with re-
tention spring, release the torque applied and
unscrew the spark plug.
3. Clean the spark plug and cylinder head with
pressurized air.
Troubleshooting a Fouled Spark Plug
Fouling of the spark plug is indicated by irregular
running or misfiring of the engine, decreased
engine speed due to misfiring, reduced perfor-
mance, and increased fuel consumption.
Other possible causes are: use of an incorrect
or bad fuel, defective ignition system, incorrect
spark plug gap, loss of compression, or lubricating
oil entering the combustion chamber.
RTX1503ACEMY18-010
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Subsection XX (IGNITION SYSTEM)
The plug face of a fouled spark plug has either a
wet or dry black carbon deposit. Such coatings
form a conductive connection between the center
electrode and the ground electrode.
Spark Plug Analysis
A00E0AA 1 2 3
TYPICAL
1. Overheated (light gray, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, gray, melted coating)
The plug face reveals the condition of the engine,
operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
the spark plug at prescribed intervals, examining
the plug face (i.e. the part of the plug projecting
into the combustion chamber).
Installing the Spark Plug
Prior to installation, ensure the contact surfaces of
the cylinder head and spark plug are free of grime.
1. Check electrode gap as specified.
NOTICE Do not adjust gap on this type of
spark plug. The adjustment could weaken the
negative electrode which may lead to elec-
trode breakage and severe engine damage.
REQUIRED TOOL
Wire feeler gauge
ELECTRODE GAP
NOT adjustable
130
155
0.80 mm to 0.90 mm
(.031 in to .035 in)
230
0.7 mm to 0.8 mm
300
(.028 in to .031 in)
2. Hand screw spark plug into cylinder head.
3. Then tighten the spark plug clockwise to speci-
fication using an appropriate spark plug socket.
5
Subsection XX (IGNITION SYSTEM)

TIGHTENING TORQUE
18 N•m ± 2 N•m
Spark plug
(159 lbf•in ± 18 lbf•in)

4. Install ignition coil. Refer to INSTALLING THE

IGNITION COIL in this subsection.
5. Complete the installation in the reverse order of
the removal.

ENGINE CUT-OFF SWITCH

Refer to D.E.S.S. subsection for operation.

Replacing the Cut-Off Switch

REQUIRED TOOL
smr2016-030-103
D.E.S.S. POST REMOVER (P/N 529 035 943)

529035943

smr2016-030-102

6 https://brp-manuals.com/pwc_seadoo RTX1503ACEMY18-010
 Subsection 03 (CHARGING SYSTEM)

CHARGING SYSTEM
SERVICE TOOLS – OTHER SUPPLIER
Description Part Number Page
ELECTRO SPECIALTIES BATTERY LOAD TESTER....................... 710 ........................................... 7
EXTECH INDUCTIVE AMMETER .................................................. 380941 ........................................... 2

GENERAL
SYSTEM DESCRIPTION
The purpose of the charging system is to maintain
the battery at a full state of charge and to provide
the electrical system with the required electrical
power for normal vehicle operation.

Magneto
The magneto is the primary source of electrical
mmr2016-026-006
energy. It transforms a magnetic field into an elec-
tric current (AC).
Battery
The magneto has a 3 phase, delta wound, 18 pole
stator. Refer to TECHNICAL SPECIFICATIONS for
rated output.

mmr2016-026-003

The battery supplies DC power to the electric

F18H1RA
TYPICAL
Voltage Regulator/Rectifier
The rectifier receives AC current from the mag-
neto and transforms it into direct current (DC).
The voltage regulator, included in the same unit,
limits voltage to a maximum level to prevent any
damage to electrical components.
starter for cranking the engine. During engine
starting, it also supplies DC power to every elec-
trical and electronic system in the vehicle as well
as all accessories.
At low engine RPM operation and high current
load conditions, it supplements the magneto
output and helps to maintain a steady system
voltage.
INSPECTION
CHARGING SYSTEM OUTPUT
First ensure that battery is in good condition prior
to performing the following tests.

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Subsection 03 (CHARGING SYSTEM)
NOTE: It is good practice to check for fault codes
using the B.U.D.S. as a first troubleshooting step.
Refer to DIAGNOSTIC AND FAULT CODES sub-
section.
Testing Output Voltage Using B.U.D.S.
1. Connect to the latest applicable B.U.D.S. soft-
ware. Refer to COMMUNICATION TOOLS
AND B.U.D.S. subsection.
2. Select the Monitoring and ECM tabs.
3. Start engine.
NOTE: Connect a garden hose to cool exhaust
system. Refer to EXHAUST SYSTEM subsection.
4. Increase engine RPM as specified in the follow-
ing table and read voltage in B.U.D.S.
OUTPUT VOLTAGE TEST USING B.U.D.S.
TEST ENGINE SPEED VOLTAGE (DC)
5500 RPM 14.5 ± .5 Vdc
smr2009-033-001_a
TYPICAL
1. Monitoring tab
2. ECM tab
3. Battery voltage
If voltage is above specification, replace voltage
regulator/rectifier.
If voltage is below specification, check stator
output and wiring harness prior to concluding
that voltage regulator/rectifier is defective. Refer
to PTO HOUSING, MAGNETO AND STARTER
subsection.
2 https://brp-manuals.com/pwc_seadoo
Testing Output Voltage Using a
Multimeter
For battery access, refer to BATTERY ACCESS in
this subsection.
1. Set multimeter to Vdc.
2. Connect multimeter to battery posts.
3. Start engine.
NOTE: Connect a garden hose to cool exhaust
system. Refer to EXHAUST SYSTEM subsection.
4. Increase engine RPM as specified in the follow-
ing table and read voltage with the multimeter.
OUTPUT VOLTAGE TEST USING A MULTIMETER
TEST ENGINE SPEED VOLTAGE (DC)
5500 RPM 14.5 ± .5 Vdc
If voltage is above specification, replace voltage
regulator/rectifier.
If voltage is below specification, check stator
output and wiring harness prior to concluding
that voltage regulator/rectifier is defective. Refer
to PTO HOUSING, MAGNETO AND STARTER
subsection.
Testing Output Current with an
Inductive Ammeter
Use an inductive ammeter such as the EXTECH IN-
DUCTIVE AMMETER (P/N 380941) or equivalent.
1. Turn on the ammeter and select 40 Adc.
NOTE: Zero set the ammeter before use or read-
ing may be erroneous.
VOLTAGE REGULATOR
RE1-1
smr2016-031-003_a
smr2016-211

2. Start engine.
NOTE: Connect a garden hose to cool exhaust
system. Refer to EXHAUST SYSTEM subsection.
3. Increase engine RPM as specified in the follow-
ing table and read current with the ammeter.
TEST ENGINE
CURRENT
SPEED
Approx. 10 A
5500 RPM
NOTE: Initial current reading will be higher than
specified due to the battery drain from the engine
start. This is an indication that the charging sys-
tem is operating normally. Current load will come
down as the battery recovers its charge.
If current reading is far below specification, test
stator output and wiring harness prior to conclud-
ing the voltage regulator/rectifier is faulty.
NOTE: If the battery is in poor condition or is not
at a full state of charge, current reading will be
above specification. Refer to BATTERY in this
subsection for battery testing.
TROUBLESHOOTING
DISCHARGED OR WEAK BATTERY
1. Battery posts and/or cable terminal oxidized.
- Clean battery terminals, posts, and coat with di-
electric grease.
2. Loose or bad connections.
- Check for wiring and connector tightness, frayed
or broken wires. Repair or replace cables or con-
nectors.
3. Worn or faulty battery (sulfated, fretting,
shorted plates or cell, damaged casing, loose
post).
- Test BATTERY VOLTAGE (LOAD APPLIED).
- Replace battery.
4. Burnt fuse(s) or faulty rectifier.
- First check fuse(s). If in good condition, check
voltage regulator/rectifier.
5. Faulty stator.
- Test stator and replace as required.
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Subsection 03 (CHARGING SYSTEM)
6. Parasitic or “Key Off” current loads.
- Isolate, reduce or eliminate such loads.
- Recharge battery as recommended if vehicle is
not used for extended periods of time.
NOTE: “Key Off” or parasitic loads may be loads
due to installed accessories. Parasitic loads may
also be due to water infiltration in connectors, or
partial short circuits that slowly drain a battery
without causing a fuse to burn.
LOW OR NO CHARGING SYSTEM
VOLTAGE
1. Blown F6 fuse.
- Check F6 fuse.
2. Defective stator.
- Test stator. Refer to PTO HOUSING, MAGNETO,
AND STARTER subsection.
3. Defective charging system wiring or connec-
tions.
- Check for damaged wiring.
- Check for damaged or loose connections.
REPETITIVE BLOWN F6 FUSE
1. Voltage regulator/rectifier internal circuit
shorted to ground.
- Refer to TESTING VOLTAGE REGULATOR/REC-
TIFIER FOR BLOWN F6 FUSE in this subsection.
PROCEDURES
VOLTAGE
REGULATOR/RECTIFIER
Testing the Voltage
Regulator Continuity
Due to internal circuitry, there is no static test
available to check continuity.
3
Subsection 03 (CHARGING SYSTEM)

Voltage Regulator/Rectifier Location

smr2016-031-008

3. Rotate and remove regulator/rectifier.

smr2016-031-007

Testing Voltage Regulator/Rectifier for

Blown F6 Fuse
1. Detach the voltage regulator/rectifier from
the electrical component support. Refer to
REMOVING THE VOLTAGE REGULATOR/REC-
TIFIER in this subsection.
2. Disconnect the voltage regulator/rectifier
2-wire connector.
3. Install a new fuse.
If the fuse still burns, check for a shorted wire or smr2016-031-010_a
connector pin.
If fuse does not burn, replace regulator/rectifier. Installing the Voltage
Regulator/Rectifier
Removing the Voltage Installation is the reverse of the removal proce-
Regulator/Rectifier dure
1. Disconnect both connectors from the voltage TIGHTENING TORQUE
regulator/rectifier.
Regulator/Rectifier 5 N•m ± 1 N•m
Screw (44 lbf•in ± 9 lbf•in)

ELECTRICAL COMPONENT
SUPPORT

smr2016-031-009

2. Remove screw.

smr2016-031-017

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 Subsection 03 (CHARGING SYSTEM)

Removing the Electrical Component

Support
Remove the following components from the elec-
trical component support.

smr2016-031-014

DIAGNOSTIC CONNECTOR

smr2016-031-011

FUSE BOX

smr2016-031-015

BATTERY

smr2016-031-012

REGULATOR/RECTIFIER

smr2016-031-016

RETAINING SCREWS

Installing the Electrical Component

Support
Installation is the reverse of removal procedure.
TIGHTENING TORQUE
16 N•m ± 2 N•m
Retaining Screws
(142 lbf•in ± 18 lbf•in)
smr2016-031-013

STARTER SOLENOID
WARNING
Replace all locking ties.

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Subsection 03 (CHARGING SYSTEM)

Removing the Battery

smr2016-031-018

BATTERY

smr2016-031-021

Cleaning the Battery

Clean the battery casing, caps, cables and battery
posts using a solution of baking soda and water.
NOTICE Do not allow cleaning solution to en-
mmr2016-026-003
ter battery.
Battery Location Remove corrosion from battery cable terminals
and battery posts using a firm wire brush. Rinse
with clear water then dry well.

Inspecting the Battery

– Keep the top free of grime
– Check casing, cables, clamps, and case for ob-
vious damage or loose connections.
– Clean terminals and connectors as necessary
Refer to battery manufacturer guidelines.

Battery Testing
smr2016-031-019
There are 3 types of battery tests.
TEST
COMMENT
METHOD
A dynamic voltage test with a load
Testing applied gives an accurate indication
voltage of the condition of the battery.
(load applied) This is the most recommended
method.
A static voltage test is carried out
Testing without discharging current. It is
voltage the simplest and most commonly
(no load) used but the most likely to give
false results.

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Testing Battery Voltage(Load Applied)
Use a load testing device such as the ELECTRO
SPECIALTIES BATTERY LOAD TESTER (P/N 710). It
has a 500 A carbon pile adjustable load.
Follow battery load tester instructions.
Apply a load of 3 times the ampere-hour rating
of the battery for 14 seconds, then check battery
voltage.
BATTERY VOLTAGE TEST (LOAD APPLIED)
VOLTAGE
TIME TO MEASURE
(WITH LOAD
INTO TEST
APPLIED)
14 seconds 10.5 Vdc min.
If battery voltage has dropped below specifica-
tion, the battery storage capacity has decreased
appreciably and the battery should be replaced.
Testing Battery Voltage(No Load)
NOTE: Be aware that the voltage test can indi-
cate that the battery is in good condition even
though the battery does not have enough stored
energy to crank the engine. A load test gives a
more accurate indication of the condition of the
battery.
If the battery has just received a charge, wait 1-2
hours before taking a voltage reading.
Set multimeter to Vdc and measure voltage at bat-
tery terminals.
FULLY CHARGED BATTERY VOLTAGE (NO LOAD)
12.6 Vdc minimum
Storing the Battery
Disconnect and remove battery from watercraft
as explained in BATTERY REMOVAL.
NOTICE Battery storage is critical for battery
life. Regularly charging the battery during
storage will prevent cell sulfation. Keeping the
battery in vehicle for storage may lead to con-
tacts degradation/corrosion and case damage
if freezing occurs. A discharged battery will
freeze and crack in areas where freezing condi-
tions are experienced. Electrolyte leakage will
damage surrounding parts. Always remove
battery from vehicle for storage and regularly
recharge it to keep an optimal condition.
The battery must always be stored fully charged.
If required, recharge until the recommended spe-
cific gravity is obtained prior to storage.
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Subsection 03 (CHARGING SYSTEM)
NOTICE Battery electrolyte temperature
must not exceed 50°C (122°F) during charging.
The battery casing should not feel hot to the
touch.
Clean battery terminals and cable connections us-
ing a wire brush.
Apply a light coat of dielectric grease on terminals.
Clean battery casing and caps using a solution of
baking soda and water.
Rinse battery with clear water and dry well using
a clean cloth.
Store battery in a cool dry place. Such conditions
reduce self-discharging and keep fluid evaporation
to a minimum. Keep battery away from dew, high
moisture and direct sunlight.
AMBIENT CHARGING
TEMPERATURE FREQUENCY
Below 16°C (60°F) Every month
Above 16°C (60°F) Every 2 weeks
WARNING
Batteries must always be stored out of reach
of children.
Activating a New Battery
YTX20-L batteries are factory activated. Test and
charge battery as required before installing it.
Charging a Used Battery
To find the recommended charger current output
in amps for a specific battery, divide the battery
amp hour rating by 10. For example a 14 AH bat-
tery should be charged at 1.4 amps (14 AH ÷ 10
= 1.4 amp current).
WARNING
Never charge battery while installed in water-
craft.
For best results, battery should be charged when
it is at room temperature. A battery that is cold
may not accept current for several hours after
charging has begun.
Do not charge a frozen battery. If the battery
charge is very low, the battery may freeze. If
you suspect the battery to be frozen, move it to a
heated area for about 2 hours (or more if required)
to let it thaw out before charging.
7
Subsection 03 (CHARGING SYSTEM)

WARNING 4. If the charging current is not up to a measurable

amount after 10 hours, the battery should be
Always charge a battery in a well ventilated replaced.
area.
5. If the charging current is measurable before the
The time required to charge a battery will vary de- end of the 10 hour period, the battery is good
pending on several factors, such as: and charging should be completed at a lower
– Battery temperature: The charging time is in- rate.
creased for a cold battery as charging current 6. It is recommended that any battery recharged
accepted by a cold battery will be lower than using this procedure be tested under load prior
for a warm battery. As the battery warms up, to returning it to service.
it will accept a higher rate of charge.
– State of charge: As a battery discharges, it Installing the Battery
gives up its stored energy. The greater the dis- Installation is the reverse of removal procedure.
charge, the longer it will take to fully recharge
it. WARNING
– Type of charger: Battery chargers vary in the Always connect battery cables in the spec-
amount of voltage and current that they can ified order, RED positive cable first, BLACK
supply. negative cable last.
Charging a Very Flat or Completely
Discharged Battery 1. Connect RED (+) cable.
The battery charger used should have an ad- 2. Connect BLACK (-) cable last.
justable charging rate. A unit which can be 3. Apply dielectric grease on battery posts.
adjusted in small increments is acceptable. 4. Verify cable routing and attachments.
The battery charger must be equipped with an am-
meter capable of accurately measuring current of
less than 1 ampere.
Unless this procedure is properly followed, a good
battery may be needlessly replaced.
1. Measure the voltage at the battery posts with
an accurate voltmeter. If it is below 10 volts,
the battery will accept current at very low rate.
It could be some time before the charging rate
increases. Such low current flow may not be
detectable on some charger ammeters and the
battery will not seem to accept the charge.
2. Exceptionally for this particular case, set the
charger to a high rate.
NOTE: Some chargers have a polarity protec-
tion feature which prevents charging unless the
charger leads are connected to the correct battery
terminals. A completely discharged battery may
not have enough voltage to activate this circuitry,
even though the leads are connected properly.
This will make it appear that the battery will not
accept a charge. Follow the charger manufac-
turer's instruction on how to bypass or override
this circuitry so that the charger will turn on and
charge a low-voltage battery.
3. Since battery chargers vary in the amount of
voltage and current they provide, the time re-
quired for the battery to accept a measurable
charger current may be up to 10 hours or more.

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 Subsection XX (STARTING SYSTEM)

STARTING SYSTEM
SERVICE TOOLS
Description Part Number Page
DIAGNOSTIC HARNESS ............................................................... 529 036 384 ............................................. 3
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 2, 4
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 2–4

GENERAL – Battery, refer to CHARGING SYSTEM

– START/STOP switch
BASIC STARTING SYSTEM – Starter solenoid
OPERATION – Engine cut-off switch
– ECM
Engine Cranking Conditions
– Wiring/connections.
The following conditions must be met to allow en-
gine cranking: Check these components before removing the
starter.
1. START/STOP button pressed and released to
activate the ECM. NOTE: This subsection assumes the problem is
2. The tether cord securely installed on the en- related to an electrical component of the starting
gine cut-off switch and the D.E.S.S. key recog- system. If the starting system tests good, ensure
nized by the ECM as valid (2 short beeps) engine and jet pump integrity. Refer to applicable
subsection.
3. START/STOP button pressed and held.

Starting System Logic DIAGNOSTIC GUIDELINES

If the ECM recognizes a valid D.E.S.S. key, it al- NOTHING HAPPENS WHEN START/STOP
lows engine cranking by providing the ground to BUTTON PRESSED
the starter solenoid when the START/STOP but-
ton is pressed and held. 1. Battery not connected
- Connect battery.
If the START/STOP button is activated while the
throttle lever is depressed more than 60%, the en- 2. Burnt fuse
gine will crank but will not start (engine drowned - START/STOP switch circuit.
mode). - Main DC power fuses.
If the START/STOP button is held after engine has - ECM power fuse.
started, the ECM automatically stops the starter if
engine speed reaches at least 1400 RPM. 3. Defective relay or related circuits
- Test relay and circuits.
If the START/STOP button is pressed when the
engine is running, the engine will shut down. 4. Defective START/STOP switch
- Test START/STOP switch, wiring and connec-
TROUBLESHOOTING tions.

ENGINE DOES NOT CRANK

DIAGNOSTIC TIPS
NOTE: It is a good practice to check for fault
codes using the BRP diagnostic software
(BUDS2) as a first troubleshooting step. Refer to
DIAGNOSTIC AND FAULT CODES subsection.
Starting system failures are not necessarily re-
lated to the starter but may be due to one the
following:
– Starter solenoid fuse
1. D.E.S.S. not functional or wrong D.E.S.S. key
- If 2 short beeps are not heard when press-
ing the START/STOP button, refer to RADIO
FREQUENCY DIGITALLY ENCODED SECURITY
SYSTEM subsection.
2. Burnt fuse
- Starter solenoid power. Carry out TESTING THE
SOLENOID INPUT VOLTAGE.

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Subsection XX (STARTING SYSTEM)
3. Discharged battery
- Recharge and test. Refer to CHARGING SYSTEM
subsection.
4. Battery connections
- Check/clean/tighten.
5. Poor/bad or corroded ground contacts (engine,
battery ground cable, starter etc.)
- Check/clean/repair, refer to POWER DISTRIBU-
TION AND GROUNDS subsection.
6. Starter solenoid
- Test solenoid, wiring and connections.
7. Damaged starter or ground cables
- Carry out TESTING THE SOLENOID (DYNAMIC).
8. Obstructed starter drive gear assembly
- Check/repair, refer to PTO HOUSING, MAGNETO
AND STARTER.
9. No ground provided by ECM to starter solenoid
- Refer to TESTING THE CONTINUITY OF
START/STOP SWITCH CONTROL CIRCUIT in
this subsection.
10. Engine cannot be rotated (possibly seized or jet
pump blocked)
- Refer to ENGINE subsection.
ENGINE CRANKS SLOWLY
1. Loose, corroded or dirty battery cable connec-
tions
- Check/clean/tighten.
2. Discharged/weak battery
- Recharge and test. Refer to CHARGING SYSTEM
subsection.
3. Low voltage from starter solenoid
- Carry out a TESTING THE SOLENOID (DY-
NAMIC).
4. Damaged starter or ground cables
- Carry out TESTING THE SOLENOID (DYNAMIC).
5. Worn starter
- Check.
STARTER TURNS, BUT STARTER DRIVE
DOES NOT MESH WITH RING GEAR
1. Worn starter drive gear/starter gear/ring gear
- Replace worn parts. Refer to STARTER GEAR in
this subsection and PTO HOUSING, MAGNETO
AND STARTER subsection.
2 https://brp-manuals.com/pwc_seadoo
2. Defective drive
- Replace starter drive. Refer to PTO HOUSING,
MAGNETO AND STARTER subsection.
STARTER KEEPS RUNNING
1. Shorted solenoid winding
- Replace solenoid.
2. Melted solenoid contacts
- Replace solenoid.
3. Sticking or defective starter drive
- Lubricate or replace. Refer to PTO HOUSING,
MAGNETO AND STARTER.
PROCEDURES
WARNING
When carrying out any kind of maintenance
on the starting system, always disconnect the
battery ground cable. This will eliminate the
possibility of shorting out a power cable, and
generating a spark which could result in a fire
or and explosion. Do not place any tool on
the battery.
ENGINE START/STOP SWITCH
Testing the START/STOP Switch Circuit
Continuity
1. Remove START/STOP switch fuse.
For fuse box access, refer to POWER DISTRIBU-
TION AND GROUNDS subsection.
Disconnect connector "B" from the ECM, refer to
WIRING HARNESS AND CONNECTOR subsec-
tion.
Install ECM ADAPTER TOOL (P/N 529 036 166) on
ECM harness connector "B".
529036166
Set the FLUKE 115 MULTIMETER (P/N 529 035 868)
to .
219100941-019
 Subsection XX (STARTING SYSTEM)

Press and hold the START/STOP switch and test

for continuity of the switch circuit as per following
table.
900 ACE series
CONTINUITY TEST OF START/STOP SWITCH
CIRCUIT (BUTTON PRESSED AND HELD)
ECM
FUSE BOX RESISTANCE
CONNECTOR B
Close to 0
Pin C5 B-D1
(continuity)

1500 series
CONTINUITY TEST OF START/STOP SWITCH sbl2010-034-019_c

CIRCUIT (BUTTON PRESSED AND HELD) 1. 24-pin steering connector

ECM 3. Connect the DIAGNOSTIC HARNESS (P/N 529 036

FUSE BOX RESISTANCE
CONNECTOR B 384) to make an in-line connection between the
Close to 0 disconnected connector.
Pin E3 B-D1
(continuity)

2. If the reading is as specified, the START/STOP

switch and its wiring are good.
3. If a high resistance or an open circuit is mea-
sured, carry out TESTING THE START/STOP
SWITCH CONTINUITY.
Testing the START/STOP Switch
Continuity
1. Remove START/STOP switch fuse.
Open front storage compartment cover.
Remove front storage bin. 529036276

Disconnect the top air ventilation hoses. 4. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select .
5. Measure resistance through switch as per fol-
lowing table.

sbl2010-004-002

FRONT AIR VENTILATION HOSES

2. Disconnect the 24-pin steering connector:

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Subsection XX (STARTING SYSTEM)

CONTINUITY TEST OF START/STOP STARTER SOLENOID

SWITCH CIRCUIT
Starter Solenoid Location
DIAGNOSTIC
SWITCH
HARNESS RESISTANCE
POSITION
CONNECTOR
Released Infinite (OL)
Pressed and Pins 1 and 4
Close to 0
held

smr2016-032-001

Testing Solenoid Input Voltage

1. Make sure the starter solenoid fuse is powered
and in good condition before testing.
2. Disconnect solenoid connector.
3. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to Vdc.
4. Install tether cord on the engine cut-off switch.
smr2010-038-003_a
5. Press the START/STOP button to activate ECM.
If the switch does not test as specified, replace 6. Measure voltage within 3 minutes after
the engine START/STOP switch. START/STOP switch has been depressed.
If the switch tests as specified, check for an open
SOLENOID INPUT VOLTAGE TEST
circuit between connections as per table: (SOLENOID COIL)
900 ACE series VOLTAGE
TEST PROBES
OPEN CIRCUIT TEST READING

CIRCUIT CONNECTIONS RESISTANCE Pin A Battery ground Battery voltage

Fuse box pin C5

Steering If test succeeded, carry out TESTING SOLENOID
connector pin 1 Must be close CONTROL CIRCUIT.
Steering ECM connector to 0 If test failed, carry out TESTING THE START/STOP
connector pin 4 B, pin D1 SWITCH CIRCUIT CONTINUITY.
1500 series Testing Solenoid Control Circuit
OPEN CIRCUIT TEST Continuity
1. Set the FLUKE 115 MULTIMETER (P/N 529 035
CIRCUIT CONNECTIONS RESISTANCE
868) to .
Steering 2. Disconnect connector "B" from ECM.
Fuse box pin E3
connector pin 1 Must be close
to 0 3. Install ECM ADAPTER TOOL (P/N 529 036 166) on
Steering ECM connector ECM harness connector.
connector pin 4 B, pin D1
4. Test continuity of wiring from solenoid to ECM
as per following table.

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 Subsection XX (STARTING SYSTEM)

SOLENOID CONTROL CIRCUIT TEST 2 1

SOLENOID ECM
RESISTANCE
M
CONNECTOR CONNECTOR B
Close to 0
Pin B B-L4
(continuity)

If test failed, repair or replace wiring/connectors.

If test succeeded, carry out TESTING SOLENOID smr2009-034-010_a
COIL RESISTANCE. 1. Starter motor
2. Starter solenoid
Testing Solenoid Coil Resistance
7. If test failed, check battery positive cable (from
1. Set multimeter to . battery to solenoid).
2. Disconnect solenoid connector. 8. If test succeeded, continue with next step.
3. Measure solenoid coil resistance as per follow-
ing table. SOLENOID DYNAMIC TEST (ENGINE CRANKING)
TEST PROBES VOLTAGE (DC)
SOLENOID COIL RESISTANCE TEST
Solenoid
SOLENOID CONNECTOR RESISTANCE Battery ground Battery voltage
starter post
Pin A Pin B 4.5 to 5.5

If test fails, replace solenoid. 2 1

Testing Solenoid (Dynamic)

1. Ensure starter solenoid fuse, battery and starter M
solenoid are properly connected.
2. Make sure the battery ground cable is securely
connected to the engine. Refer to POWER DIS-
TRIBUTION AND GROUNDS.
smr2009-034-010_b
3. Set ECM in engine drowned mode: 1. Starter motor
3.1 Depress throttle lever. 2. Starter solenoid

3.2 Install a rubber band to hold lever in full 9. If test failed, carry out a TESTING SOLENOID
throttle position. INPUT VOLTAGE.
4. Set multimeter to Vdc. 10. If test succeeded, continue with next step.
5. Crank engine. SOLENOID DYNAMIC TEST (ENGINE CRANKING)
6. As engine is cranking, measure the voltage as TEST PROBES VOLTAGE (DC)
per following tables.
Solenoid Solenoid
SOLENOID DYNAMIC TEST (ENGINE CRANKING) 0.2 Vdc max.
battery post starter post
TEST PROBES VOLTAGE (DC)
Solenoid
Battery ground Battery voltage 2 1
battery post

smr2009-034-010_c

1. Starter motor
2. Starter solenoid

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Subsection XX (STARTING SYSTEM)

If test failed, replace solenoid.

If all solenoid dynamic tests are as specified, re-
place starter.
11. Remove rubber band from throttle lever.
12. Attach the electrical component support to the
battery holder. Refer to ELECTRICAL COM-
PONENT SUPPORT in CHARGING SYSTEM
subsection.
13. Reinstall removed parts.

Removing the Solenoid

1. Disconnect battery. Refer to CHARGING SYS- smr2016-032-004_a

TEM subsection.
WARNING
Always disconnect the BLACK (-) battery ca-
ble first and reconnect last.

smr2016-032-005

Installing the Solenoid

The installation is the reverse of the removal pro-
cedure.

STARTER
smr2016-032-006_a

For starter information refer to PTO HOUSING,

2. Disconnect solenoid cables. MAGNETO AND STARTER subsection.

219100941-019-001_a

TYPICAL
1. Cables

6 https://brp-manuals.com/pwc_seadoo 219100941-019
 Subsection XX (RADIO FREQUENCY DIGITALLY ENCODED SECU-
RITY SYSTEM (RF D.E.S.S.))

RADIO FREQUENCY DIGITALLY

ENCODED SECURITY SYSTEM (RF
D.E.S.S.)
GENERAL
SYSTEM DESCRIPTION
The following components are specially designed
for this system: ECM, D.E.S.S. key (inside tether
cord cap) and engine cut-off switch.
The D.E.S.S. key contains a magnet and a RFID
chip.
– The magnet closes the hall effect switch inside
the engine cut-off switch.
– The RFID chip contains a unique digital code. It smr2015-008-001_a
is the equivalent of the tooth-pattern cut on a 1. D.E.S.S. Key
conventional ignition key. 2. Tether cord float

The D.E.S.S. system allows the engine to start Upon tether cord installation, the key type used
only if a tether cord cap is installed on the engine is momentarily displayed by the multifunction
cut-off switch and the D.E.S.S. key is recognized gauge.
as valid by the ECM.
Learning keys provide a mode of operation
The D.E.S.S. key is quite flexible: whereby engine power and speed is limited.
– Up to 8 D.E.S.S. keys may be programmed in
There are 5 speed settings available for the learn-
the ECM memory using the B.U.D.S. The keys
ing key mode. By default, the key modes are
can also be erased individually.
preset to the speed setting (3). Refer to INTELLI-
– The same D.E.S.S. key can be used on another GENT THROTTLE CONTROL (iTC) subsection.
vehicle equipped with the D.E.S.S. system. It
only needs to be programmed for that vehicle. NOTE: Changing key settings is only available
when the engine is not running.
D.E.S.S. Key Types
D.E.S.S. Key Beeper Codes
Three types of keys can be used:
– Normal key BEEPER SIGNIFICATION
– Learning key A 0.5 second
Indicates the D.E.S.S. is reading the
beep every
To ease key type recognition, the tether cord float key.
5 seconds
comes in different colors.
Indicates the D.E.S.S. recognizes
KEY TYPE FLOAT COLOR 2 short beeps
the key.
Normal Yellow or Black A 1 second
Indicates the D.E.S.S. does not
Learning Green beep every
recognize the key.
5 seconds

NOTE: Other beeps not related to D.E.S.S. can

be heard. Refer to DIAGNOSTIC AND FAULT
CODES.

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Subsection XX (RADIO FREQUENCY DIGITALLY ENCODED SECU-
RITY SYSTEM (RF D.E.S.S.))

TROUBLESHOOTING 5. No voltage at RFID-D connector

- Refer to WIRING DIAGRAM and / or IGNITION
DIAGNOSTIC GUIDELINES SYSTEM and troubleshoot D.E.S.S. / Engine Cut-
Off Switch
The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and INVALID KEY
should not be assumed to list all possible causes. 1. Key not programmed to ECM
- Program key
NO BEEP CODE WHEN KEY IS INSTALLED
ON ENGINE CUT-OFF SWITCH — ENGINE
CAN NOT BE STARTED PROCEDURES
1. Gauge shuts-down after its WOW test: Defec-
tive engine cut-off switch D.E.S.S. KEY
- Check engine cut-off switch. Refer to IGNITION D.E.S.S. Key Recognition
SYSTEM subsection.
To allow key recognition, carry out the following
NO BEEP CODE WHEN KEY IS INSTALLED steps:
ON ENGINE CUT-OFF SWITCH — ENGINE 1. Briefly press the START/STOP button to wake
CAN BE STARTED up the ECM.
1. Defective gauge beeper 2. Securely install the tether cord on watercraft
engine cut-off switch.
- Check gauge beeper. Refer to INFORMATION
CENTER (GAUGE). 3. Press and hold the START/STOP button to start
engine.
GAUGE DISPLAYS "READING KEY" AND
THERE IS NO KEY INSTALLED ON ENGINE Programming D.E.S.S. Keys
CUT-OFF SWITCH 1. Connect the watercraft to BUDS2. Refer to
1. Gauge shuts-down after 3 minutes: Defective COMMUNICATION TOOLS AND B.U.D.S. sub-
engine cut-off switch section.
- Check engine cut-off switch. IMPORTANT: Ensure all connections have been
made before starting BUDS2 to allow proper op-
KEY NOT READ (CONDITION CAN BE eration.
DUPLICATED WITH A MAGNET ON THE 2. Briefly press START/STOP button to power the
D.E.S.S. POST) ECM.
1. Damaged RFID chip 3. Install a tether cord on the engine cut-off switch
to program a D.E.S.S. key.
2. No voltage at RFID-D connector
3. No voltage at RFID-C connector
- Try a new key
- Refer to WIRING DIAGRAM and / or IGNITION
SYSTEM and troubleshoot D.E.S.S. / Engine Cut-
Off Switch

KEY NOT PRESENT (CONDITION CAN BE

DUPLICATED BY UNPLUGGING THE RFID
CONNECTOR)
1. No key installed
2. No ground at RFID-A connector
3. No voltage at RFID-B connector
4. No voltage at RFID-C connector
smr2015-008-002

4. Read ECM.
5. Click on Keys tab.
2 https://brp-manuals.com/pwc_seadoo smr2017-023
 Subsection XX (RADIO FREQUENCY DIGITALLY ENCODED SECU-
RITY SYSTEM (RF D.E.S.S.))

Adding a Key
1. Click on the Add Key button.
2. Follow instructions on BUDS2 screen.
Adding Another Key
1. Remove the tether cord from the engine cut-off
switch.
2. Install the next tether cord on the engine cut-off
switch.
3. Click on the Add Key button.
Erasing Keys
1. Install the tether cord on the engine cut-off
switch.

smr2015-008-002

2. Click on Erase Key.

After approximately 10 seconds the following
message will appear.
The key is now erased.
Erasing All Keys
1. Click on Erase All Keys.
2. When done, program at least one new key to
the vehicle. Refer to ADDING A KEY in this sub-
section.

D.E.S.S. / Engine Cut-Off Operation

Normal Operation
The electrical system provides power to RFID-D.
The ECM provides 5Vdc to the DESS module
DS-C. The ECM provides a ground to the DESS
module DS-A. When a key (tether cord) is installed
on the DESS post, a hall effect switch closes and
sends a 12-15Vdc signal to the ECM.
Refer to IGNITION SYSTEM subsection for test-
ing procedures.

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 Subsection XX (INFORMATION CENTER (GAUGE))

INFORMATION CENTER (GAUGE)

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE ................................................................... 293 550 004 ..................................... 11, 17

GENERAL
INFORMATION CENTER
WARNING
Do not adjust the display while riding, you could lose control.

Information Center Description

1 9 3 4 8 2

4 13 4 4
6 15 10 12 16 5
219100941-020-100_a

GTR 230, GTI LTD

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Subsection XX (INFORMATION CENTER (GAUGE))

1 4 9 3 11 8 4 2

7
6 14 10 13 12 4 5
219100941-020-007_a

RXP-X 300, GTR-X 230

219100893-027-002_a

ALL OTHER MODELS

1) Speedometer
The speedometer provides an analog indication of the speed of the watercraft in miles per hour (MPH)
and kilometers per hour (km/h).
The speed indication is based on a GPS (Global Positioning System) incorporated within the information
center.
If for some reason the GPS signal is lost, a default mode is used whereby, the speed is calculated using
information received from other systems to provide an estimated watercraft speed.

2 https://brp-manuals.com/pwc_seadoo 219100941-020
 Subsection XX (INFORMATION CENTER (GAUGE))

2) Tachometer
The tachometer provides an analog indication of the revolutions per minute (RPM) of the engine.

3) Multifunction Gauge
The multifunction gauge, located in the center of the information center, is capable of displaying different
indications simultaneously.
Numerical and multifunction displays in the digital screen indicator can be used to display various indica-
tions, or for selecting modes of operation and changing settings as explained in their respective sections.

4) Indicator Lights
Indicator lights (pilot lamps), inform you of a selected function or a system anomaly.
An indicator light may be accompanied by a scrolling message in the multifunction display.
See the following table for information on the usual pilot lamps. Refer to MONITORING SYSTEM for
details on malfunction pilot lamps.
PILOT LAMPS
MESSAGE DISPLAY DESCRIPTION
(ON)

Maintenance required. MAINTENANCE REMINDER

Low fuel level, approx. 25% tank capacity, 14 L

LOW-FUEL
(3.7 U.S. gal.) or fuel level sensor disconnected.

Scrolling SLOW SPEED

CRUISE mode or SLOW SPEED MODE engaged.
MODE message

Scrolling SKI MODE

Ski Mode activated.
messages

SPORT Scrolling SPORT MODE

MODE Sport Mode activated.
messages

FUEL ECO Fuel Economy Mode

Scrolling HIGH
Engine or exhaust overheating
TEMPERATURE

5) Fuel Level Indication When the fuel tank is full, 8 segments (bars) of
A bar gauge located in the bottom RH side of the the indicator are turned on. The top segment is
multifunction display continuously indicates the not used.
amount of fuel in the fuel tank while riding. Low Fuel Level Warning
It is active when there is only 2 segments of fuel
indicated (approximately 25% fuel tank capacity or
in
lap
AM
RPMgal/h
14 L (3.7 U.S. gal.).

6) VTS Position (If equipped)

The VTS position indication located in the bottom
LH side of the digital screen shows the riding at-
FUEL LEVEL INDICATION
titude of the watercraft.

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Subsection XX (INFORMATION CENTER (GAUGE))

A single segment of a bar gauge type indicator is – Provide various indications as selected by the
turned on to indicate the relative position of the operator.
watercraft bow. – Activating and setting various functions and
modes of operation.
– Display scrolling messages of function activa-
in
lap
AM
RPMgal/h
tion or system faults.
– Display fault codes.
NOTE: The default indication in the multifunction
display is the compass direction.

VTS POSITION INDICATION

10) Water Depth Display
The water depth display provides an indication of
Refer to OPERATING INSTRUCTIONS for more the lake water depth.
details on using the VTS. The system is capable of indicating water depth
under the hull in single increments up to 50 m
7) Launch Control Indicator (If (164 ft).
equipped)
NOTE: Under certain conditions, the display may
The launch Control indicators are not visible when stop indicating. The display ability to provide an in-
the function is activated dication of the water depth depends on the con-
ditions of use.
in
lap
AM
RPMgal/h

1. Launch control indicators

1
8) Numerical Display
WATER DEPTH DISPLAY (WITHOUT DEPTH
The numerical display is used to provide a variety
FINDER INDICATOR)
of indications as selected by the operator using
the DISPLAY function in the multifunction display. 1. Water depth indication

2
in
lap
AM in
RPMgal/h lap
AM
RPMgal/h

1
NUMERICAL DISPLAY
WATER DEPTH DISPLAY (WITH DEPTH FINDER
INDICATOR)
The available indications are dependent on the wa-
tercraft model or option installed. 1. Depth finder indicator
When the information center is first powered up, 2. Water depth indication
the numerical display defaults to the last selected
indication. NOTE: The water depth indication is only avail-
able when a depth finder is installed and detected.
9) Multifunction Display
The multifunction display is used to:
WARNING
– Display the WELCOME message on power up. Never use the depth finder as a warning de-
vice to ride in shallow water.
– Display the KEY recognition message.
4 https://brp-manuals.com/pwc_seadoo 219100941-020
 Subsection XX (INFORMATION CENTER (GAUGE))

11) Boost Gauge (If equipped) This is confirmed when the COMPASS active in-
dicator is visible in the digital screen.
mBAR PSI
BOOST

in
lap
AM
RPMgal/h

BOOST INDICATOR
COMPASS (GAUGE WITHOUT BOOST GAUGE)
The boost gauge indicates the manifold pressure
of the engine provided by the supercharger. 1. Compass indication
2. Compass active indicator
12) Hour Meter Display (HR)
Continuously displays the accumulated engine mBAR PSI
BOOST

hours.
1
in
lap
AM
RPMgal/h

2
COMPASS (GAUGE WITH BOOST GAUGE)
1. Compass indication
HOUR METER DISPLAY 2. Compass active indicator

NOTE: The compass indication is only available

13) iBR Position above 5 km/h (3 MPH).
Provides an indication of the iBR gate position.
– N (neutral) WARNING
– F (forward) Use the compass as a guide only. Not to be
– R (reverse). used for precision navigation purposes.

15) Touring Mode Indicator

in
lap
AM
When the TOURING mode indicator is ON, the de-
RPMgal/h

fault TOURING mode is active.

in
lap
AM
RPMgal/h

iBR POSITION INDICATOR

14) Compass (If equipped)

A GPS incorporated in the information center pro-
TOURING MODE INDICATOR
vides the indication in the multifunction display.
The cardinal points, intermediate cardinal points,
as well as the azimuth the watercraft is travelling
are displayed in the multifunction display by de-
fault when the watercraft is moving.
For a compass indication to be displayed, the GPS
must have a good link with the navigation satel-
lites.

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Subsection XX (INFORMATION CENTER (GAUGE))

16) Sport Mode Indicator

in
lap
AM
RPMgal/h

in
lap
AM
RPMgal/h

SPORT MODE INDICATOR (GAUGE WITHOUT
BOOST GAUGE)
When selected, the sport mode indicator will
come on and stay on until deactivation, or the
watercraft is shut down.
NOTE: The sport mode is not the default riding
mode. To be active, it must be selected after start-
ing the engine.
All exept RXP-X Models
In addition to the sport mode indicator in the mul-
tifunction display, a SPORT MODE indicator light
turns ON in the tachometer on these vehicule.
RXP-X
There is no sport mode indicator in the multifunc-
tion display, only a SPORT MODE indicator light
turns ON in the tachometer.
Navigating the Multifunction Display
When the electrical system is powered up and
the cluster has completed its self test function,
a WELCOME ABOARD SEA-DOO scrolling mes-
sage will appear for a few seconds. After the wel-
come message, nothing will appear in the display
until the watercraft is operated.
When the watercraft is being operated, the multi-
function display provides an indication of compass
heading or scrolling messages from the monitor-
ing system.
The multifunction display is also used to display a
menu for the selection of various functions which,
permit changing the numerical display indication,
system modes of operation, settings, active sys-
tem fault codes, and a lap timer.
WARNING
Selecting various numerical displays, sys-
tem modes of operation or changing settings
should only be carried out with the watercraft
stopped. Selecting these various functions
while operating the watercraft at speed is
not recommended as it deters your attention
from situational awareness.
MULTIFUNCTION DISPLAY
To change the unit of measurement, refer to SET-
TING THE UNITS OF MEASUREMENT AND LAN-
GUAGE in this subsection.
Selecting Functions
When operating at speed, the multifunction dis-
play normally provides an indication of the com-
pass direction and azimuth the watercraft is trav-
eling.
To select the various functions available through
the multifunction display, press the MODE button
repeatedly until the desired function is visible:
– LAP TIME
– SKI MODE
– LAP TIME
– FUEL CONSUMPTION
– VTS MODE
– DISPLAY
– FAULT CODES
– KEY MODE
– SETTINGS.
Then press the SET button to enter that function.
NOTE: The fault code function is only available
when there is an active fault. The settings and
key mode functions are only available when the
engine is shut off. The key mode function is only
available with a normal key.
Function Description
Lap Timer
The lap timer can be used to record up to 50 indi-
vidual lap times.
To activate and use the lap timer, carry out the fol-
lowing:
1. Press the MODE button repeatedly until LAP
TIME is visible in the multifunction display.

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 Subsection XX (INFORMATION CENTER (GAUGE))

2
in in
lap lap
AM AM
RPMgal/h RPMgal/h

LAP TIME MESSAGE DISPLAYED: LAP TIMER

2. Press the SET button to enter the function, the 1. Total time
lap timer will be activated and visible in the dis- 2. ALL is displayed here
play.
To reset the lap timer and lap counter, press and
2 hold the SET button until the timer and counter are
in
reset to 0 (zero).
lap
AM
RPMgal/h

1
FUNCTION SELECTED: LAP TIMER
1. Lap time
2. Lap count
3. To start the timer, press the SET button.
NOTE: The timer starts immediately when press-
ing the SET button.
4. To record each lap time, press the SET button
at the start of each lap.
NOTE: The lap time will be recorded, the lap
counter in the numerical display will count the
number of laps recorded, and the timer will con-
tinue to run.
5. To save the last lap and stop the timer, press
the MODE button.
To view each lap time, use the UP or DOWN but-
ton. The lap counter will indicate which lap is in-
dicated.
To view the cumulative lap time of all laps
recorded, use the UP or DOWN button until
ALL is visible in the lap counter.
Ski Mode
Ski mode is used for repeated controlled launches
when towing a skier or wakeboarder. Refer to OP-
ERATOR'S GUIDE.
Fuel Consumption
The FUEL CONSUMPTION function is used to dis-
play the watercrafts fuel consumption in four dif-
ferent ways.
– Instant fuel flow per hour (gal/h or l/h)
– Average fuel flow per hour (gal/h or l/h)
– Distance to empty (Mi or Km)
– Time to empty (h or min).
The fuel consumption functions are not continu-
ously active.
A fuel consumption function becomes active only
when selected as the indication in the numerical
display.
When the LOW FUEL indications come on in the
multifunction gauge, the "TIME TO EMPTY" and
"DISTANCE TO EMPTY" functions will indicate "0"
(zero) if they are the selected indication.
To display the watercraft fuel consumption, carry
out the following:
1. Press the MODE button repeatedly until FUEL
CONSUMPTION is visible in the multifunction
display.

in
lap
AM
RPMgal/h

FUEL CONSUMPTION

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Subsection XX (INFORMATION CENTER (GAUGE))

2. Press the UP or DOWN button to toggle to the Changing Numerical Display Indication
desired fuel consumption display mode. To change the indication in the numerical display,
carry out the following:
2
in
1. Press the MODE button on the RH handlebar
lap
AM
RPMgal/h repeatedly until DISPLAY is visible in the multi-
1 function display.

in
lap
AM
RPMgal/h

FUEL CONSUMPTION DISPLAY MODE

1. INSTANT FUEL CONSUMPTION message
2. Fuel consumption value

3. Press the SET button to save the setting and DISPLAY

return to the main display.
NOTE: The fuel consumption value will be dis- 2. Press the SET button to enter the DISPLAY
played in the numerical display. Double click the function.
SET button to reset the average fuel consumption 3. Press the UP or DOWN button until the pre-
indication. The display will momentarily indicate ferred available indication appears.
zero (0). – RPM
VTS Mode – SPEED
The VTS MODE function is used to manually set – DEPTH
the VTS or change VTS PRESET settings. Refer – ENGINE TEMP
to OPERATING INSTRUCTIONS subsection in the – ALTITUDE (only on Limited models)
OPERATOR'S GUIDE for details. – TOP SPEED
Display – AVG SPEED
– TOP RPM
The DISPLAY function is used to change the indi-
cation in the numerical display. Refer to CHANG- – AVG RPM
ING NUMERICAL DISPLAY INDICATION. – CLOCK.
Fault Codes 2
The FAULT CODES function is used to display ac- in
lap
AM

tive fault codes. Refer to MONITORING SYSTEM RPMgal/h

1
subsection.
Key Mode
The KEY MODE function is used for changing
LEARNING key settings. Refer to OPERATING NUMERICAL DISPLAY SELECTION
INSTRUCTIONS subsection in the OPERATOR'S
GUIDE for details. 1. Type of selected numerical display indication
2. Applicable value
Settings
The SETTINGS function is used for: 4. Press the SET button to select and save the pre-
– Clock setting. Refer to MULTIFUNCTION ferred indication, or wait for the display function
GAUGE SETUP to time out. The last indication visible will be au-
– iBR override function for maintenance. tomatically saved.
The following abbreviations are used in the nu-
merical display:
– FT or M
– RPM
– MPH or Km/h

8 https://brp-manuals.com/pwc_seadoo 219100941-020
 Subsection XX (INFORMATION CENTER (GAUGE))

– °F or °C
– AM or PM
– Gal/h or l/h.

Resetting Numerical Display Indication

The following numerical display indications can be
reset:
– Average fuel consumption
– Top speed
– Average speed
– Top RPM
– Average RPM.
To reset indications, double click the SET button.
The numerical display will momentarily indicate
zero (0).
NOTE: Each of these functions become active
ONLY when selected as the numerical display
indication.

Multifunction Display Messages

For a list of usual messages that may be displayed
in the multifunction display, refer to MULTIFUNC-
TION DISPLAY MESSAGES in this section.

OPERATING MODES
Refer to INTELLIGENT THROTTLE CONTROL
(ITC) SUBSECTION or OPERATOR'S GUIDE.

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Subsection XX (INFORMATION CENTER (GAUGE))

MULTIFUNCTION DISPLAY MESSAGES

FAULT MESSAGES
WRONG KEY Wrong key selected for model
RIGHT KEYPAD ERROR MODE/SET, UP/DOWN arrow button malfunction
LOW OIL PRESSURE Engine low oil pressure detected
HIGH EXHAUST TEMPERATURE High exhaust temperature detected
HIGH ENGINE TEMPERATURE High engine temperature detected
CHECK ENGINE Engine system malfunction or maintenance required
HIGH BATTERY VOLTAGE High battery voltage detected
LOW BATTERY VOLTAGE Low battery voltage detected
LIMP HOME MODE Major fault detected, engine power limited
FUEL SENSOR DEFECTIVE Fuel level sensor fault
Cluster programming corrupted, need to be re-flashed using
CALIBRATION CHECKSUM ERROR
BUDS2
MAINTENANCE REQUIRED Watercraft maintenance required
DEPTH finder MODULE COMMUNICATION Error message if depth finder is disconnected while riding
PROBLEM
Error message if communication with the iBR module is lost
iBR MODULE ERROR
while riding
OTAS DEFECTIVE – MAINTENANCE OTAS is not correctly adjusted
REQUIRED

TROUBLESHOOTING 2. Install the tether cord on the engine cut-off

DIAGNOSTIC TIPS
NOTE: It is a good practice to check for fault
codes using the BRP diagnostic software
(BUDS2) as a first troubleshooting step. Re-
fer to COMMUNICATION TOOLS AND BUDS2
subsection.
IMPORTANT: When troubleshooting an electrical
system fault, check battery condition, cables and
connections first.
Electrical System Activation
1. Press the START/STOP button.
NOTE: Pressing the START/STOP button without
the tether cord (D.E.S.S. key) installed on the en-
gine cut-off switch will turn on electrical power
without starting the engine; the information cen-
ter will cycle through a self-test function and shut
off its display after a few seconds. However, the
electrical system will stay powered up for approx-
imately seventy-five (75) seconds after the START
button was pressed.
switch to activate ECM and Information Center
when testing procedures require a component
or system to be supplied with electrical power.
IMPORTANT: When BUDS2 is being used, the
ECM will stay powered ON. If connection is lost
with the system, briefly press the START button.
Do not hold the start button to avoid engine
starting
Circuit Testing
Check the related-circuit fuse condition with a
fuse tester or ohmmeter (a visual inspection
could lead to a wrong conclusion).
Electrical Connection Inspection
When replacing an electric or electronic compo-
nent, always check electrical connections. Make
sure they are tight, make good contact, and are
corrosion-free. Dirty, loose or corroded contacts
are poor conductors and are often the source of a
system or component malfunction.
Pay particular attention to ensure that pins are not
bent or pushed out of their connectors.

10 https://brp-manuals.com/pwc_seadoo 219100941-020
 Subsection XX (INFORMATION CENTER (GAUGE))
Ensure all wire terminals are properly crimped on
wires, and connector housings are properly fas-
tened.
Check for signs of moisture, corrosion or dullness.
Clean pins properly and coat them with DIELEC-
TRIC GREASE (P/N 293 550 004) or other appropriate
lubricant when reassembling them, except if oth-
erwise specified such as for the ECM connectors.
Pay attention to ground wires.
TROUBLESHOOTING
GUIDELINES
Press the START/STOP button and install the
tether cord on the engine cut-off switch.
NOTE: Information center should come on, cycle
through its self test function, and stay on for
approximately sixty (60) minutes, while the key
is connected, after which all electrical power will
turn off.
Briefly press the START/STOP button every sixty
(60) minutes to reenergize the electrical system.
Do not hold the START/STOP button to avoid en-
gine starting.
NOTE: When troubleshooting using the following
guidelines, it is important to remember that some
indications, functions and features described may
not apply to every PWC model, or may be avail-
able as an option.
Information Center “Does Not Turn
ON”
ROTAX 900 ACE Engines
If the information center does not turn ON when
the START/STOP button is pressed, the power cir-
cuit or ground circuit to the information center is
probably open.
Test the 5A START/STOP fuse (fuse 2) in fuse
box (FB).
If the fuse tests good, test INFORMATION CEN-
TER INPUT VOLTAGE.
If the information center input voltage test is
good, test for continuity of the gauge ground
circuit (gauge connector pin 11 (BLACK wire) to
the ground bus-bar (pin H7) in FB1.
Refer to WIRING DIAGRAM for circuit details.
All other Models
If the information center does not turn ON when
the START/STOP button is pressed, the power cir-
cuit or ground circuit to the information center is
probably open.
219100941-020
https://brp-manuals.com/pwc_seadoo
Test the 5A CLUSTER fuse (fuse 7) in fuse box
(FB).
If the fuse tests good, test INFORMATION CEN-
TER INPUT VOLTAGE.
If the information center input voltage test is
good, test for continuity of the gauge ground
circuit (gauge connector pin 11 (BLACK wire) to
the ground bus-bar (pin H7) in FB1.
Refer to WIRING DIAGRAM for circuit details.
Information Center Turns ON with
Some Indications Missing
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. Read the fault codes, refer to DIAGNOSTIC
AND FAULT CODES subsection.
If a fault code is related to a communication prob-
lem, carry out a continuity test of the CAN bus
wires to the applicable module. Refer to WIRING
DIAGRAM and CONTROLLER AREA NETWORK
(CAN) subsections.
NOTE: The information center, ECM, iBR module,
and the diagnostic connector are linked together
through CAN bus-bars in fuse box 1. If one wire
of the two wire CAN bus system is open, commu-
nication will be slower than normal. Multiple fault
codes may be generated and the ECM will put the
watercraft in LIMP HOME mode.
If one module cannot be seen in BUDS2, the fault
may be the wires that link the module to the CAN
wires, or a problem internal to that module. Test
the continuity of the CAN wires to the faulty mod-
ule before assuming the problem is the module.
Information Center Goes Blank Except
for:
– GPS indicator ON
– Compass ON (if watercraft moving)
– Fuel level ON
– iBR fault indicator light ON
– Indicated speed
– No other indications visible.
There is no communication between the informa-
tion center and all other modules (ECM, iBR).
Carry out a continuity check of the CAN bus wires
from the ECM connectors to the information cen-
ter (pins 2 and 3). Refer to the WIRING DIAGRAM
and CONTROLLER AREA NETWORK (CAN) sub-
sections for details.
If an open circuit is detected, carry out same test
from the pin steering connector (pins 2 and 3).
11
Subsection XX (INFORMATION CENTER (GAUGE))
All Indications ON Except for:
All Models Except GTS
– VTS indication
– iBR position indication
– CHECK ENGINE light is on.
The iBR CAN bus circuit is open or the iBR module
is at fault.
NOTE: The ECM will generate several fault codes
and engage LIMP HOME mode.
Carry out a continuity check of the CAN bus wires
to the iBR module (pins 3 and 4). Refer to the
WIRING DIAGRAM and CONTROLLER AREA
NETWORK (CAN) subsections for details.
NO RPM Indication and NO Engine
Hour Display
If there is NO RPM indication and NO engine
hour display, and the watercraft is in LIMP HOME
mode, the CAN bus to the ECM is open.
Carry out a continuity check of the CAN bus wires
from steering connector (pin 2 and pin 3) to the
ECM module, connector "B" pins C1 and C2 (B-C1
and B-C2). Refer to the WIRING DIAGRAM and
CONTROLLER AREA NETWORK (CAN) subsec-
tions for details.
NO Fuel Level Indication
If there is no fuel level indication, test the fuel
level sensor and its wiring circuit to the infor-
mation center. Refer to FUEL TANK AND FUEL
PUMP subsection.
NO Depth Gauge Indication
If there is no depth gauge indication available and
the depth finder active indicator is not on, refer to
DEPTH FINDER in this subsection.
NOTE: If communication with the depth finder
cannot be established when electrical power is
first applied, the monitoring system assumes this
is a normal situation (PWC not equipped with
depth finder) and will not display an error mes-
sage.
NO Speed or Compass Indication
All Models Except GTS
To obtain a speed or compass reading and to turn
on the GPS indicator, the GPS requires a good up-
link to at least three navigation satellites.
12 https://brp-manuals.com/pwc_seadoo
If there is no speed or compass indication, look for
the GPS indicator icon. If the GPS indicator is off,
either the GPS cannot uplink with the satellites,
or the GPS system in the information center is at
fault.
If another watercraft nearby displays a good GPS
uplink (GPS indicator light on in cluster), the infor-
mation center may need to be replaced.
NOTE: If the GPS uplink is lost while navigating
at speed, the speedometer will provide an esti-
mated speed indication based on other parame-
ters. The compass indication will not be available
until a good satellite uplink is reestablished.
Speed and Compass Indication Slow
to Come ON
All Models Except GTS
When initially powering up the watercraft and driv-
ing away, the speed and compass indications may
be slow to come on. This is normal as the GPS
requires time to establish an uplink with the navi-
gation satellites (cold start).
If the watercraft was run long enough to display
the compass and speed indications, shut down
for a short period of time and then restarted (hot
start), the speed and compass indications should
not take more than 30 seconds to come on.
If the speed and compass indications take more
than 30 seconds to come on, test for the follow-
ing:
– GPS fuse 4 in FB1
– Battery voltage at pin 1 of the information cen-
ter
– Continuity of wire between information center
(pin 1) and contact A5 of FB1.
NOTE: This circuit provides 12 Vdc to the GPS in
the information center so that it memorizes the
satellites it was linked to for a period of two hours.
This allows the indications to be available within
a few seconds of restarting the watercraft (hot
start). After a two hour period, the GPS will have
to reestablish new satellite links.
Beeper Does Not Function
The beeper is incorporated within the information
center.
If no beep code is heard when installing the
tether cord, first ensure ECM is powered. Refer
to ELECTRONIC FUEL INJECTION (EFI) subsec-
tion.
219100941-020
 Subsection XX (INFORMATION CENTER (GAUGE))

In BUDS2, carry out the following:

– Cluster Buzzer Test on the cluster activation
page
– Check for fault codes. Carry out service actions
as applicable.
If the Cluster Buzzer Test failed, the ECM is
powered, and the ECM and information center
are communicating properly through the CAN
bus, replace the information center.

PROCEDURES
INFORMATION CENTER smo2009-002-114_y

FUNCTION SELECTED: SETTINGS

Information Center Self Test Function
When the START/STOP button is pressed mo- 2. Press the UP or DOWN arrow button repeat-
mentarily and the vehicle powers up, all LCD edly until CLOCK is visible.
segments and indicator lights in the information
center will turn ON for 3 seconds (self test func-
tion). This self test function allows the driver
time to ensure that all indications are functioning
properly.
It also validates the information centers internal AM

circuits, however, this does not validate proper op-

eration of the individual external circuits and sen-
sors that provide inputs to the information center.
If a system fault is detected by the ECM, the ap-
plicable message and/or indicator light will be dis-
played, and a beep code may be heard.
If the tether cord is not installed, the indications
in the information center will shut off a few sec-
smo2010-002-107
onds after the self test function, but the electri-
FUNCTION SELECTED: CLOCK
cal system power stays on for approximately sev-
enty-five (75) seconds. Installing the tether cord 3. Press the SET button to enter the function.
on the engine cut-off switch will turn the indica- CHANGE CLOCK OFFSET message will be
tions back on. displayed.
If the tether cord is installed, the cluster will stay
on for approximately sixty (60) minutes.
NOTE: If the START/STOP button is pressed and
held without the tether cord installed, the informa-
tion center will stay on as long as the START but-
ton is held. AM

Multifunction Gauge Setup

Setting the Clock
1. Press the MODE button repeatedly until SET-
TINGS is visible in the multifunction display.

smo2010-002-108

FUNCTION SELECTED: CHANGE CLOCK OFFSET

219100941-020
https://brp-manuals.com/pwc_seadoo 13
Subsection XX (INFORMATION CENTER (GAUGE))

4. Press the UP or DOWN arrow button to adjust Information Center Pin-Out

the clock to the correct local time. NOTE: Depending on watercraft model and in-
5. Press the SET button to save the setting and stalled accessories, some multifunction gauge
return to the main display. connector pins may not be used. Refer to
NOTE: The clock uses the GPS signal to main- WIRING DIAGRAM.
tain the appropriate time referenced to Greenwich
Mean Time (GMT). When setting the clock, only Testing Information Center Input
the hour digits may be changed. For the clock to Voltage
function, the GPS requires a good satellite uplink. 1. Disconnect the gauge connector.
Setting the Units of Measurement and 2. Press the START button and install the tether
Language cord on the engine cut-off switch.
1. Connect the vehicle to the BRP diagnostic soft- INPUT VOLTAGE TEST AT GAUGE CONNECTOR
ware (BUDS2).
PROBE VOLTAGE
2. Press the START/STOP button to energize the
Pin 1 (Hot at
electrical system. Pin 11
all times)
3. In BUDS2, go to: (Permanent Battery voltage
Pin 12 (Hot with ground)
– SETTINGS page main relay on)
– CLUSTER button
– CONFIGURATION tab
– Change Cluster Units 10 1

Clearing the Maintenance Reminder

Indicators
When the watercraft, engine or supercharger are
due for maintenance, the maintenance reminder
indicator will come on, and a scrolling MAIN-
TENANCE REQUIRED or SUPERCHARGER 11 20
MAINTENANCE REQUIRED message will scroll smr2009-036-003_e

in the digital screen. These maintenance re- TYPICAL - GAUGE CONNECTOR PIN-OUT
minders must be cleared using BUDS2.
If battery voltage is measured as specified, re-
1. Connect the vehicle to the BRP diagnostic soft- place the information center.
ware (BUDS2).
If battery voltage is measured to battery ground
2. Press the START/STOP button to energize the but not to pin 11, test CONTINUITY OF GAUGE
electrical system. GROUND WIRE circuit from the gauge connector
3. In BUDS2, go to: to the ground bus-bar contact in FB as described
– SUMMARY page further in this subsection.
– VEHICLE button 3. If battery voltage is not measured at the gauge
4. At the bottom RH side of the LAST SERVICE connector, check wiring. Refer to WIRING DI-
table, press the RESET SERVICE button. AGRAM.
5. At the bottom RH side of the vehicle page in the Testing Gauge Ground Wire Continuity
Last Service field, choose Reset Service.
1. Disconnect the steering connector.
NOTE: If the supercharger maintenance was car-
ried out before the reminder appeared in the in-
formation center, the supercharger maintenance
reminder must be reset in order to reset the su-
percharger maintenance hour counter and prevent
the reminder from appearing prematurely.

14 https://brp-manuals.com/pwc_seadoo 219100941-020
 Subsection XX (INFORMATION CENTER (GAUGE))
219100941-020-009_a
TYPICAL - 20-PIN STEERING CONNECTOR DISCONNECT
Step 1: Pull out safety lock
Step 2: Press in on release tab
Step 3: Pull locking collar down
GROUND TEST AT STEERING CONNECTOR
PROBE VOLTAGE
Pin 11 (Permanent
Battery voltage
ground)
2. Repair wiring and connectors as required.
Removing the Information Center
1. Remove the bezel that covers the information
center and mirrors, refer to BODY subsection.
2. Press in on the two retaining tabs at the top of
the information center.
smr2011-032-004_a
3. Pull gauge out of console.
4. Disconnect electrical connector.
Installing the Information Center
Installation of the information center is the reverse
of the removal procedure. However, pay attention
to the following.
If the information center was replaced, con-
nect the vehicle to the BRP diagnostic software
(BUDS2) and apply any available updates.
219100941-020
https://brp-manuals.com/pwc_seadoo
MODE/SET AND UP/DOWN
ARROW BUTTONS
Overview
The MODE/SET and UP/DOWN arrow buttons
assembly contains a series of 4 diodes for the
MODE and SET switches, and another 4 diodes
for the UP/DOWN arrow switches. Refer to
WIRING DIAGRAM for simplified diagram of
switches.
The center wire to the switches (pin C), is com-
mon to both sides of the switch assembly (some-
what like a ground wire). The other two wires
(pins A and B), act as signal wires to the infor-
mation center for each set of switches. They
actually each form one branch of an electronic
circuit within the information center.
Each diode (in circuit) drops a nominal 0.6 Vdc
when conducting electricity. If the circuit current
passes through all four diodes (say MODE and
SET switches open), a drop of 2.4 Vdc would be
measured across the 4 the diodes (pin B to pin
C). This voltage drop of 2.4 Vdc measured at pin
B tells the gauge the MODE and SET switches
are open.
If the MODE switch is pressed, 2 diodes are by-
passed. The remaining two diodes in the circuit
drop 1.2 Vdc (at pin B).
If the SET switch is pressed, 1 diode is bypassed.
The remaining three diodes in the circuit drop
1.8 Vdc (at pin B).
The gauge senses these voltages through pin 17
of the gauge connector, and interprets them as
signals that tell it which switch is activated.
If the command signal generated by the closure
of a switch concerns another module, a circuit
within the gauge will translate it to CAN protocol
and transmit it through the CAN circuit. The ap-
plicable module will react to the command, carry
out the function, and transmit the result back
through the CAN circuit.
The information center will use the signals from
the switches and the transmitted information
from the other modules, convert them to an in-
dication, and cancel the command signal it sent
out once the function has been carried out.
Command signals from the MODE and SET
switches are used by the information center only.
The UP/DOWN arrow switch commands are used
by the gauge for certain functions and settings.
They will also be translated and sent out through
the CAN circuit to be used by the ECM for the
CRUISE, SKI mode and SLOW SPEED functions
15
Subsection XX (INFORMATION CENTER (GAUGE))

for increasing or decreasing speed when the func- MODE/SET SWITCH TEST
tions are active, and by the iBR for iBR gate posi-
tioning in SLOW SPEED mode of operation. SWITCH FLUKE GAUGE
VOLTAGE
POSITION 115 CONNECTOR
The UP/DOWN switches are also used for VTS
trim on models without VTS buttons. Approx.
RED lead
Pin 17 2 Vdc
NOTE: The voltages stated previously vary BLACK
Pin 18 or OL (see
slightly depending on the actual voltage ap- Switch lead
note 1)
plied to the circuit and the current flow through released
BLACK
the diodes. When using a Fluke 115 multimeter lead
Pin 17
OL
for testing in diode test mode, the voltage and Pin 18
RED lead
current applied by the multimeter are lower than
in circuit. The quality of probe contact, the actual RED lead
Pin 17 Approx.
probes and leads, and the precision of the meter BLACK
Pin 18 1.1 Vdc
calibration will all affect the results, which will MODE lead
most likely be slightly lower than nominal values depressed BLACK
Pin 17
stated. lead
Pin 18
OL
RED lead
Testing MODE/SET and UP/DOWN BLACK
Buttons Using BUDS2 lead
Pin 17 Approx.
Pin 18 1.6 Vdc
1. Connect the vehicle to the BRP diagnostic soft- SET RED lead
ware (BUDS2). depressed BLACK
Pin 17
2. Press the START/STOP button to energize the lead OL
Pin 18
electrical system. RED lead
3. In BUDS2, go to: UP/DOWN ARROW SWITCH TEST
– MEASUREMENT page
SWITCH FLUKE GAUGE
– CLUSTER button VOLTAGE
POSITION 115 CONNECTOR
4. Press each of the MODE/SET and UP/DOWN
Approx.
arrow buttons and look for the applicable indica- RED lead
Pin 16 2 Vdc
tor light to come on in the Switch Inputs field. BLACK
Pin 18 or OL (see
Switch lead
If each of the gauge button indicator lights come note 1)
on when the applicable switch is pressed, the released
BLACK
problem may be related to the information center. Pin 16
lead OL
Pin 18
If one or all of the indicator lights does not come RED lead
on, test MODE/SET AND UP/DOWN ARROW RED lead
SWITCH USING A MULTIMETER. Pin 16 Approx.
BLACK
Pin 18 1.1 Vdc
UP lead
Testing MODE/SET and UP/DOWN depressed
Switch Using a Multimeter BLACK
Pin 16
lead OL
NOTE: It is important to set the multimeter Pin 18
RED lead
to the diode check function when testing the
MODE/SET and UP/DOWN arrow switches as it RED lead
Pin 16 Approx.
BLACK
contain diodes. lead
Pin 18 1.6 Vdc
DOWN
1. Test the MODE/SET and UP/DOWN arrow depressed BLACK
switches as per following tables. Pin 16
lead OL
Pin 18
RED lead

NOTE: Remember that each diode should drop

approximately 0.6 Vdc when positively biassed,
and read as an OL (open circuit) when negatively
biassed (leads reversed).

16 https://brp-manuals.com/pwc_seadoo 219100941-020
 Subsection XX (INFORMATION CENTER (GAUGE))

If the readings are correct when testing with the GTI, GTR and WAKE Models
switch depressed UP and DOWN, while it was OL
with the switch released, then the switch is func-
tional.
When measuring between pins 17 and 18, or 16
and 18, if an OL is obtained with both positive
and negative diode biassing, test the continuity of
each wire between the gauge and switch assem-
bly. If continuity is good, replace the switch as-
sembly.
If any reading is significantly different than speci-
fied, carry out the same test at the switch connec-
tor, refer to the wiring diagram. If you obtain the 219100941-020-012_a

same results, replace the switch assembly. TYPICAL

If voltages measured on every switch are as spec-
ified (or very close to it), the switches and the
wiring harness are good. The fault may be within
the gauge. Replace the gauge.
Replacing the MODE/SET and
UP/DOWN Switch Assembly
1. Remove steering cover.
2. Disconnect connector from switch assembly.
RXP-X and GTR-X Models
1. MODE/SET and UP/DOWN switch connector
3. Remove switch assembly from support by lift-
ing it off the support.
4. Apply a small amount of DIELECTRIC GREASE
(P/N 293 550 004) on new switch contact pins.
5. Install connector on new switch assembly.
6. Insert switch assembly in switch support.
7. Install the steering cover.
DEPTH FINDER

smr2016-034-004

219100893-027-001_a

TYPICAL
1. MODE/SET and UP/DOWN switch connector

219100941-020
https://brp-manuals.com/pwc_seadoo 17
Subsection XX (INFORMATION CENTER (GAUGE))

Depth Finder Troubleshooting

DEPTH FINDER TROUBLESHOOTING
POSSIBLE
SYMPTOM REMEDY
CAUSE
Properly
Depth finder
connect depth
not connected.
finder.
Make sure
depth finder
is properly
installed in
Depth finder
battery holder
not properly
Nothing is base. There
installed.
displayed in must be no air
the information gap between
center hull and silicone
pad(s).
12 Vdc wire or
Check fuse
ground wire to
and wiring
depth finder
harnesses.
open.
Problem with
Check wires to
communication
CAN circuit.
link wires.
Launch
Watercraft is watercraft in
not in water. water and
recheck.
There is air
between
- - - - (ft or m) is silicone pad and
Remove depth
displayed depth finder
finder. Replace
or between
silicone pad.
depth finder
and battery
holder base.
Depth finder is Try a new depth
defective. finder.

Replacing the Depth Finder

Do not attempt remove the depth finder. Epoxy
glue holds it in place.
Order a new depth finder from accessories (PAC)
and follow the instructions provided with the kit.

Testing Depth Finder Operation

1. Press START/STOP button to activate gauge.
2. Confirm the depth finder icon is active in gauge.
NOTE: When watercraft is not in water, the icon
is active but there is no reading. To verify proper
operation, launch watercraft in water and com-
pare depth indication with actual depth.

18 https://brp-manuals.com/pwc_seadoo 219100941-020
 Subsection XX (STEERING)

STEERING
SERVICE TOOLS
Description Part Number Page
STEERING CABLE TOOL .............................................................. 295 000 145 ........................................... 10

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 5
LOCTITE 567 (PIPE SEALANT) ..................................................... 293 800 013 ........................................... 10
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 8

219100941-021
https://brp-manuals.com/pwc_seadoo 1
Subsection XX (STEERING)

STEERING COLUMN
ALL Except X Models

2.5±0.5 N•m
(22±4 lbf•in)

4±0.5 N•m
(35±4 lbf•in)
0.6±0.2 N•m
(6±1 lbf•in) 2.5±0.5 N•m
(22±4 lbf•in)
0.6±0.2 N•m
(6±1 lbf•in)
XPS
2.5±0.5 N•m synthetic
(22±4 lbf•in) grease
5.5±0.5 N•m 4±0.5 N•m
(49±4 lbf•in) (35±4 lbf•in)
2.5±0.5 N•m
(22±4 lbf•in)

6±1 N•m
(53±9 lbf•in)

3.5±0.5 N•m
(31±1 lbf•in)

Loctite 5150
(silicone sealant)

7±1 N•m
(62±9 lbf•in)

219100941-021-100_a

2 https://brp-manuals.com/pwc_seadoo 219100941-021
 Subsection XX (STEERING)

X Models

0.8±0.1 N•m
10±0.5 N•m (7±1 lbf•in)
(89±4 lbf•in)
0.6±0.2 N•m
(6±1 lbf•in)
10±0.5 N•m
1±0.2 N•m (89±4 lbf•in)
(9±2 lbf•in)
0.6±0.2 N•m
(6±1 lbf•in) 7±1 N•m
(62±9 lbf•in)

3.5±0.5 N•m 1±0.2 N•m

(31±1 lbf•in) (9±2 lbf•in)

7±1 N•m 2±1 N•m

(62±9 lbf•in) (18±9 lbf•in)
9±1 N•m
(80±9 lbf•in) 2±1 N•m
(18±9 lbf•in)

9±1 N•m
(80±9 lbf•in)

Loctite 5150
(silicone sealant)

6±1 N•m
(53±9 lbf•in) 7±1 N•m
(62±9 lbf•in)
Loctite 567
(pipe sealant)
219100941-021-002_a

219100941-021
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Subsection XX (STEERING)

ADJUSTMENT ACCESS FROM ENGINE COMPARTMENT

WATERCRAFT
ADJUSTING THE ALIGNMENT BEHAVIOR
WHAT TO DO
OF THE STEERING Turn steering cable
Work from engine compartment to reach adjust- adjustment nut as shown
ment nut.
1. Loosen steering cable clamp bolts. Do NOT re-
move bolts. Pulls on left
side

Turn steering cable

adjustment nut as shown

Pulls on right
side

smr2012-034-030_a

ACCESS FROM ENGINE COMPARTMENT

1. Loosen bolts

2. Turn adjustment nut 1 turn at a time in the di-

rection shown in following table. 3. Tighten steering cable clamp bolts to specifica-
tion.
REQUIRED TOOL
TIGHTENING TORQUE
Cut a 22 mm (7/8 in) opened
wrench to 100 mm (4 in) Steering cable
6 N•m (53 lbf•in)
of length adjustment nut

4. Test watercraft.
5. Readjust adjustment nut as necessary.

PROCEDURES
HANDLEBAR GRIP
Removing the Handlebar Grip
To remove handlebar grip, remove the cap, then
the retaining screw.
Pull out handlebar grip and remove grip insert
from handlebar.
NOTE: Verify grip insert for damage.

4 https://brp-manuals.com/pwc_seadoo 219100941-021
 Subsection XX (STEERING)

TIGHTENING TORQUE

1 7 N•m ± 1 N•m
2 Handlebar grip screw
3 (62 lbf•in ± 9 lbf•in)
5 4
Install cap.

2 3 4
1

smr2016-035-001_a

TYPICAL
1. Handlebar grip cap
2. Handlebar grip screw smr2016-035-002_a
3. Flat washer
4. Handlebar grip TYPICAL
5. Handlebar grip insert 1. Grip
2. Flat washer
3. Screw
Installing the Handlebar Grip 4. Cap

When installing the grip insert in the handlebar,

ensure that it is properly inserted in the slot at the HANDLEBAR SWITCH COVER
end of the handlebar tubing. (LH OR RH)
Removing the Handlebar Switch Cover
(LH or RH)
1. Insert the end of a small screwdriver in one of
cover slots.

smr2016-035-003_a

TYPICAL smr2009-037-010_a
1. Grip insert TYPICAL
2. Handlebar slot 1. Cover slots

Install handlebar grip on handlebar matching it to

the notch in the handlebar.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
screw threads (or use new self-locking screws).
Install flat washer and handlebar grip screw.
NOTICE Ensure to install flat washer other-
wise screw will damage the grip end.
Torque handlebar grip screw to specification.

219100941-021
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Subsection XX (STEERING)

219100941-021-003_a

TYPICAL
smr2010-031-009_b
1. Cover slots
Step 1: Ensure wiring is properly routed
2. Twist screwdriver to open cover. Step 2: Install housing cover
Step 3: Ensure proper corrugated conduit positioning
3. Remove the switch cover.
4. Position the upper housing on the handlebar
Installing the Handlebar Switch Cover housing.
(LH or RH) 5. Ensure proper engagement of the upper hous-
ing and cover tabs.
X Models
Reverse removal procedure.
All except X Models
1. Install the round rubber button in the cover.
2. Insert the front tab and tilt the cover over the
switches (applicable models).

smr2010-031-010_b

Step 4: Ensure engagement of housing cover retaining tabs

Step 5: Ensure engagement of upper housing locking tabs

6. Install the three retaining screws for the upper

smr2009-037-012_a housing and torque them to specification.
TYPICAL — RH SIDE SHOWN
1. Front tab TIGHTENING TORQUE

3. Press on the cover to lock it. Upper housing screws 2 N•m (18 lbf•in)

Installation is the reverse of the removal proce- 7. Ensure proper operation of throttle lever.
dure however, pay attention to the following.
1. Route wires to avoid pinching them.
2. Position the housing cover onto the handlebar
housing.
3. Ensure positioning of corrugated conduit.

6 https://brp-manuals.com/pwc_seadoo 219100941-021
 Subsection XX (STEERING)

STEERING COVER (EXCEPT X

MODELS)
Removing the Steering Cover
1. Remove the engine cut-off switch (D.E.S.S.
post) retaining nut. Refer to IGNITION SYS-
TEM.
2. Remove both handlebar switch covers. See
procedure in this subsection.
smr2009-037-016_a
3. Unlock steering cover from steering. 1. Retaining tabs
3.1 Insert a small tool, such as an Allen key,
into a steering cover hole. Press the tool 3.4 Remove the foam inside the steering
against the retaining tab to unlock it. Re- cover.
peat for the other side. 3.5 Remove the engine cut-off switch from
the steering cover.
NOTICE The tool must be inserted per-
fectly straight to avoid breaking the tab Installing the Steering Cover
holder.
1. Install the engine cut-off switch.
1.1 Index the alignment pin of the engine cut-
off switch with the notch of steering cover.

smr2009-037-013_a

1. Allen key

3.2 In both cavities at the back of steering

cover, release both inner retaining tabs
using a long screwdriver. smr2017-026-701_a

1. Steering cover notch

1.2 Press the engine cut-off switch until retain-

ing tab is positioned correctly.

smr2009-037-014_a

1. Rear cavity

3.3 Release the five retaining tabs at the rear

of steering cover. smr2009-037-018_a

1. Retaining tab

2. Install the engine cut-off switch nut.

219100941-021
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Subsection XX (STEERING)

TIGHTENING TORQUE Replacing the Lever

Engine cut-off switch nut 2 N•m (18 lbf•in)
3. Install the foam.
4. Place the engine cut-off switch harness in foam
slot.
5. Install the steering cover.
5.1 Check if all harnesses are route properly.
All harness must be inserted in its slot.
1. Remove HANDLEBAR SWITCH COVER, see
procedure in this subsection.
2. Remove the screw and washer securing throt-
tle lever.
3. Remove throttle lever and its bushings.

smr2009-037-031_a

1. Retaining screw
2. Washer
3. Bushings
smr2009-037-019_a 4. Throttle lever
1. Harness slots
4. Clean throttle lever area from dust or any de-
5.2 Clip the top of the cover. posits.
5.3 Stretch the bottom of the steering cover 5. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
until the cover edge passes over the inner on bushings and on the outer surface of the re-
ribs. turn tab.

smr2009-037-032_a
smr2009-037-020_a
1. Apply grease here
STEERING REMOVED FOR CLARITY PURPOSE
1. Inner ribs 6. Install the lever.
5.4 Push both side of the cover to lock it with 6.1 Install both bushings in lever hole.
the steering column. 6.2 Insert sensor lever end into throttle lever
5.5 Install switch covers. fork.
6.3 Position the return tab against the handle-
THROTTLE AND iBR LEVERS bar.
NOTE: The following procedure demonstrates 6.4 Secure the lever with washer and screw.
the replacement of the throttle lever but the same
procedure will be used for the iBR lever.

8 https://brp-manuals.com/pwc_seadoo 219100941-021
 Subsection XX (STEERING)

TIGHTENING TORQUE 1.5 Free steering cable from the clamp.

0.7 N•m ± 0.1 N•m 2. At rear of the watercraft, disconnect ball joint
Lever screw from jet pump nozzle arm.
(6 lbf•in ± 1 lbf•in)

7. Reinstall all removed parts using appropriate

procedures.

STEERING CABLE
Replacing the Steering Cable
Open the seat and the front storage compartment
cover.
Remove the storage basket.
Remove the gauge support. Refer to INFORMA-
TION CENTER (GAUGE) subsection.
smr2009-037-004_a
1. Detach steering cable from steering column. 1. Steering cable bolt
1.1 Remove the bolt securing the ball joint to 2. Nozzle arm
the steering column arm. 3. Remove ball joint and jam nut from cable.

smr2009-037-021_a
smr2009-042-006_a
1. Steering cable
1. Steering cable ball joint 2. Jam nut
2. Steering column arm 3. Ball joint

1.2 Remove the steering cable clamp bolts. 4. Loosen steering cable nut.
1.3 Unhook steering cable clamp.

smr2009-042-007_a

TYPICAL
1. Steering column
2. Steering column clamp bolts
3. Steering column clamp smr2011-033-011_a

4. Steering cable adjusting nut 1. Steering cable nut

2. Steering cable
1.4 Place steering in its lower position (models
with tilt steering).

219100941-021
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Subsection XX (STEERING)

REQUIRED TOOL A
STEERING CABLE TOOL
(P/N 295 000 145)

5. Remove steering cable nut, half rings and

O-ring.
smr2006-031-006_a

A. 9 mm ± 1 mm (.354 in ± .039 in)

12.2 Tighten jam nut to specification.

12.3 Position the steering cable ball joint to the
nozzle as per following illustration.

smr2009-037-023_a

TYPICAL - PUMP AND iBR SYSTEM REMOVED FOR CLARITY

PURPOSE ONLY
1. Steering cable
2. Steering cable nut
3. Half rings
4. O-ring

6. Remove the adjusting nut from the new steer-

ing cable. smr2009-037-025_a

7. From inside the hull, pull the aft end of the cable TYPICAL
1. Ball joint bolt
through the hull fitting. 2. Ball joint under nozzle arm
3. Washer
8. Using a piece of hose, attach one end of the 4. Nut
new cable to the opposite end of the old cable
together. 12.4 Tighten ball joint nut to specification.
9. Route the new cable in the hull by slowly pulling TIGHTENING TORQUE
the old one, then separate cable ends. 2.5 N•m ± 0.3 N•m
Ball joint jam nut
10. From inside of the hull, pass the aft end of the (22 lbf•in ± 3 lbf•in)
cable through the hull fitting.
7 N•m ± 1 N•m
11. Secure the steering cable to the hull fitting. Ball joint nut
(62 lbf•in ± 9 lbf•in)
11.1 Install O-ring and half rings.
1. Carry out ADJUSTING THE ALIGNMENT OF
11.2 Apply LOCTITE 567 (PIPE SEALANT) THE STEERING. See procedure in this subsec-
(P/N 293 800 013) on nut threads. tion.
11.3 Secure steering cable with the steering 2. Insert the steering cable through the bottom
cable nut. end of the steering column.
TIGHTENING TORQUE 3. Install steering cable clamp and its bolts. Do
6 N•m ± 1 N•m not tighten bolts yet.
Steering cable nut
(53 lbf•in ± 9 lbf•in)

12. Install the ball joint on the end of the steering

cable.
12.1 The threaded portion of steering cable
inserted into ball joint should be within
9 mm ± 1 mm (.354 in ± .039 in).

10 https://brp-manuals.com/pwc_seadoo 219100941-021
 Subsection XX (STEERING)

3. Refer to STEERING CABLE in this subsection

and:
– Detach steering cable end from steering col-
umn.
– Unhook steering cable from retaining clamp
of steering column support.
4. Position jet pump nozzle as follows:
4.1 Place a straight edge on the nozzle end.
smr2009-042-007_a

1. Steering column
4.2 Measure the distance from the transom
2. Steering column clamp bolts each side of the straight edge.
3. Steering column clamp
4. Steering cable adjusting nut

4. Attach steering cable to steering column arm.

smr2011-033-010_a

VIEW FROM UNDERNEATH THE HULL

1. Straight edge
2. Nozzle
A. LH side measure
B. RH side measure
smr2009-042-006_a

1. Steering cable ball joint 4.3 Turn nozzle so that measures A and B are
2. Steering column arm equal.
TIGHTENING TORQUE 5. Adjust steering cable as follows:
Front steering cable 3.5 N•m ± 0.5 N•m 5.1 Turn adjustment nut to reach specification.
screw (31 lbf•in ± 4 lbf•in) STEERING ADJUSTMENT
SPECIFICATION
5. Install other removed parts.
187.7 mm (7.39 in)
Adjusting the Steering Cable NOTE: This specification gives the
1. Steering cable adjustment is required only if: proper nozzle adjustment to offset the
– A steering cable end ball joint has been re- jet pump thrust.
placed or loosened/tightened.
NOTE: Be careful not to move inner rod as it
– Steering cable adjustment nut has been loos- would alter nozzle position.
ened/tightened.
– Steering cable has been replaced.
– Steering column or support has been re-
placed.
2. Raise the iBR gate by activating the iBR over-
ride function. Refer to iBR, REVERSE AND VTS
subsection.

219100941-021
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Subsection XX (STEERING)

STEERING COLUMN
Removing the Steering Column
Open the front storage cover and remove the stor-
age basket.
Remove the gauge support. Refer to INFORMA-
TION CENTER (GAUGE) subsection.
1. Disconnect both connectors under the steering
column.
smr2012-034-005_c

1. Adjustment nut
2. Do NOT move inner rod
A. 187.7 mm (7.39 in)

5.2 Recheck nozzle position. If it moved, repo-

sition it and readjust cable nut.
5.3 Reinstall steering cable. Pay attention not
to turn the adjustment nut as it would alter
adjustment.
NOTE: Tape can be used over adjustment
nut to prevent altering adjustment.

smr2010-046-015_a

1. Steering connector
2. O.T.A.S. connector (models without iBR)

2. Remove both screws securing the steering col-

umn.

smr2012-034-006_a

1. Tape adjustment nut to cable housing to prevent altering

adjustment

5.4 Tighten steering cable clamp bolts to spec-

ification.
TIGHTENING TORQUE
smr2009-037-027_a

Steering cable 1. Steering column screws

6 N•m (53 lbf•in)
clamp bolts
3. Pull steering column out of its support.
NOTE: When handlebar is in straight position and
steering cable is installed, steering nozzle may not Inspecting the Steering Column
be parallel to transom. This is to offset jet pump Check steering column for:
thrust. – Cracks
6. Test ride watercraft. – Stress marks
6.1 If watercraft pull on one side, carry out – Sings of wear.
STEERING ALIGNMENT in this subsec- Check steering column support bushings.
tion.

12 https://brp-manuals.com/pwc_seadoo 219100941-021
 Subsection XX (STEERING)

Check wear sleeve behind the steering column

arm.

smr2009-037-029_a
smr2010-046-015_a
1. Wear sleeve
2. Steering column arm 1. Steering connector
3. Steering column support 2. O.T.A.S. connector (models without iBR)

Replace any damaged or worn parts. 4. Remove the gauge support. Refer to INFOR-
MATION CENTER (GAUGE) subsection.
Installing the Steering Column 5. On both sides, remove both pivot bushings
The installation is essentially the reverse of the re- (steering column support and steering adjust-
moval procedure. However, pay attention to the ment handle).
following.
Carefully, drive steering column through steering
column support.
Tighten steering column screws to specifications.
TIGHTENING TORQUE
Steering column screws 6 N•m (53 lbf•in)

Reinstall all removed parts using appropriate pro-

cedure.

STEERING COLUMN SUPPORT smr2009-037-033_a

1. Pivot bushing of steering column support

Removing the Steering 2. Pivot bushing of steering adjustment handle

Column Support NOTE: If pivot bushings retaining steering column

are hard to remove, remove the retaining screw
1. Refer to BODY and remove the following parts: from the center hole and tighten it into the offset
– Storage compartment cover hole. Tighten screw until the pivot bushing comes
– Body covers. out of steering column support.
2. Remove storage basket.
3. Disconnect both connectors under the steering
column.

smr2009-037-040_a

1. Center hole
2. Offset hole

219100941-021
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Subsection XX (STEERING)

6. Remove steering column support and steering

adjustment handle from vehicle.
7. Remove STEERING COLUMN from its support.
See the procedure in this subsection.

Installing the Steering Column

Support
Installation is the reverse of the removal proce-
dure.

14 https://brp-manuals.com/pwc_seadoo 219100941-021
 Subsection XX (O.T.A.S)

O.T.A.S
SERVICE TOOLS
Description Part Number Page
DIAGNOSTIC HARNESS ............................................................... 529 036 384 ............................................. 2
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 2

GENERAL Raise engine speed higher than 4000 RPM for

more than 1 second.
O.T.A.S. SYSTEM DESCRIPTION Release throttle while steering is in the straight
ahead position.
The O.T.A.S. (Off-Throttle Assisted Steering) pro-
vides additional maneuverability in off-throttle sit- Within 1 to 3 seconds, turn handlebar all the way
uations on vehicles not equipped with the iBR sys- to one side.
tem. The O.T.A.S. should come on by keeping or
The system uses a pair of magnets attached to the increasing engine speed to approximately
steering column and a Hall effect switch attached 3000 RPM.
to the steering column support. Then, engine speed will gradually decrease to idle
When activated by a magnet, the O.T.A.S. switch speed within approximately 5 seconds.
sends a signal to the ECM. Repeat test for the other side.
The ECM activates a pre-programmed RPM set- If the engine does not behave as described, carry
ting when the driver initiates a full turn after relea- out the TESTING THE O.T.A.S. SWITCH USING
sing throttle lever. The engine RPM is controlled BUDS2
by the Intelligent Throttle Control (iTC).
The O.T.A.S. system is activated in the following TROUBLESHOOTING
conditions:
– The engine speed must be above 4000 RPM for O.T.A.S. DIAGNOSTIC TIPS
at least 1.5 second (approximately).
– The throttle lever must be released completely. Check fault codes as a first troubleshooting step.
– The steering must be fully turned within approx- If O.T.A.S. works when handlebar is turned on one
imately 4 seconds after throttle release. side only, check:
The O.T.A.S. will stay activated for a random – Magnets condition
period of time as long as the O.T.A.S. switch is – If magnets and switch are securely installed.
closed. To confirm if the O.T.A.S. is functional, carry out
O.T.A.S. will be deactivated if: O.T.A.S. OPERATION TEST in this subsection. If
– The throttle is reapplied, or it is not possible, carry out TESTING THE O.T.A.S.
SWITCH USING BUDS2
– The steering is turned sufficiently to open the
O.T.A.S. switch for more than one second.
PROCEDURES
INSPECTION
O.T.A.S. SWITCH
O.T.A.S. OPERATION O.T.A.S. Switch Location
This test is to be performed with the watercraft in The O.T.A.S. switch is located on the rear portion
the water (test tank or on a trailer). of the steering column.
NOTICE If the test is performed on a trailer, Testing the O.T.A.S. Switch Using
ensure no debris or rocks can damage the jet BUDS2
pump.
Connect the vehicle to the BRP diagnostic soft-
Start engine. ware (BUDS2).

219100941-031
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Subsection XX (O.T.A.S)

In BUDS2, go to:
– Measurement page
– iBR button.
Briefly press the START/STOP button to wake up
the ECM.
Install the tether cord on the engine cut-off
switch.
Completely turn steering in one direction and keep
it in this position.
The O.T.A.S. indicator should turn on when han-
dlebar reaches the stopper. 529036276

Repeat test for the other side.

Press the START/STOP button to activate the
If O.T.A.S. indicator does not turn on, carry out electrical system.
the TESTING THE O.T.A.S. SWITCH INPUT VOLT-
Using the FLUKE 115 MULTIMETER (P/N 529 035
AGE.
868), measure voltage as follows.
Testing the O.T.A.S. Switch Input VOLTAGE
TEST PROBES
Voltage (VDC)
Disconnect the O.T.A.S. connector (keep the PIN A
Battery
24-pin steering harness connected). (3-pin
negative post
Battery voltage
connector)

If voltage is not as specified, check wiring and

connectors.
If voltage is as specified, carry out the TESTING
THE O.T.A.S. SWITCH GROUND.
Testing the O.T.A.S. Switch Ground
With the DIAGNOSTIC HARNESS (P/N 529 036 384)
still connected, press the START/STOP button to
activate the electrical system.
Check ground circuit as follows.
VOLTAGE
TEST PROBES
(VDC)
smr2010-046-015_a
PIN A PIN B
1. Steering connector
2. O.T.A.S. connector (3-pin (3-pin Battery voltage
connector) connector)
Connect the DIAGNOSTIC HARNESS (P/N 529 036
384) in-line between the disconnected O.T.A.S. If voltage is not as specified, check wiring and
connectors. connectors.
If voltage is as specified, carry out the TESTING
THE O.T.A.S. SWITCH SIGNAL.
Testing the O.T.A.S. Switch Signal
With the DIAGNOSTIC HARNESS (P/N 529 036 384)
still connected, press the START/STOP button to
activate the electrical system.

2 https://brp-manuals.com/pwc_seadoo 219100941-031
 Subsection XX (O.T.A.S)

HANDLEBAR
TEST PROBES VOLTAGE
POSITION
Straight 0.6 to 0.8
ahead Vdc
Turned
PIN C PIN B
completely
(3-pin (3-pin
to the right 2.0 to 2.5
connector) connector)
Turned Vdc
completely
to the left

If voltage is not as specified, replace the switch.

smr2011-033-008_a
NOTE: To avoid useless switch replacement,
1. Magnets
make sure magnets are in good condition. Also, 2. Steering column
make sure magnets and switch are securely
clipped. Reverse removal procedure to reinstall the mag-
nets.
Replacing the O.T.A.S. Switch
Remove steering column, see procedure in
STEERING subsection.
1. Using a small screwdriver, unhook the switch
from steering support.

smr2009-037-038_a

1. Switch retaining tabs

Reverse removal procedure to reinstall the

O.T.A.S. switch.

O.T.A.S. MAGNETS
Replacing the Magnets
1. Remove STEERING COLUMN, see procedure
in STEERING subsection.
2. Pull magnets off the steering column.

219100941-031
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 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

JET PUMP (ALL MODELS EXCEPT

SPARK SERIES)
SERVICE TOOLS
Description Part Number Page
IMPELLER REMOVER/INSTALLER ............................................... 529 035 956 ............................... 10–11, 16
IMPELLER SHAFT BEARING TOOL ............................................. 529 036 168 ..................................... 13–14
IMPELLER SHAFT PUSHER.......................................................... 529 035 955 ..................................... 13–14
PRESSURE CAP ............................................................................ 529 036 172 ............................................. 4
PUMP PLATE................................................................................. 529 036 224 ............................................. 6
SEAL/BEARING PUSHER .............................................................. 529 035 819 ........................................... 15
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ............................................. 4

SERVICE PRODUCTS
Description Part Number Page
JET PUMP BEARING GREASE ..................................................... 293 550 032 ........................... 9, 14–15, 17
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 12
LOCTITE 438 ................................................................................. 296 000 424 ........................................... 11
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ........................................... 10
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ............................................. 6
TRIPLE-GUARD GREASE .............................................................. 296 000 329 ................................... 6–7, 11
XPS LUBE...................................................................................... 293 600 016 ....................................... 7, 11

smr2017-028
https://brp-manuals.com/pwc_seadoo 1
Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

NEW
9 ± 1 N•m
(80 ± 9 lbf• in)

Triple-Guard
grease
125 ± 10 N•m
(92 ± 7 lbf•ft)

Loctite 518

NEW
Loctite 438

Loctite 767 Triple-Guard

(antiseize lubricant) grease

NEW
NEW

2.5 ± 0.5 N•m

(22 ± 4 lbf• in)
Jet pump
bearing
grease Jet pump
bearing grease 12 ± 1 N•m 8 ± 1 N•m
(106 ± 9 lbf• in) (71 ± 9 lbf• in )

125 ± 10 N•m
(92 ± 7 lbf•ft)
NEW
NEW 8 ± 1 N•m
(71 ± 9 lbf• in)

NEW NEW
Jet pump
7.5 ± 0.5 N•m bearing grease
(62 ± 4 lbf• in) 2.5 ± 0.5 N•m
(22 ± 4 lbf• in)

219100941-023-100_a

2 https://brp-manuals.com/pwc_seadoo smr2017-028
 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

GENERAL To check clearance, remove jet pump.

Using a feeler gauge, measure clearance between
JET PUMP MAIN COMPONENTS impeller blade tip and wear ring. Measure each
blade at its center.
NOTE: For nozzle information, refer to iBR, RE-
VERSE AND VTS subsection.

smr2006-027-008

MAXIMUM WEAR
MODEL
CLEARANCE
All models 0.35 mm (.014 in)
smr2016-037-001_a

TYPICAL
1. Venturi
2. Stator
IMPELLER SHAFT RADIAL PLAY
3. Jet pump housing
4. Wear ring Radial play is critical for jet pump life span.
5. Impeller
To check radial play, remove jet pump.
Make sure impeller shaft turns freely and
INSPECTION smoothly.
IMPELLER CONDITION 1. Retain housing in a soft jaw vise making sure
not to damage housing lug.
Condition of impeller, impeller boot and wear 2. Set a dial gauge and position its tip onto metal
ring can be quickly checked from underneath the end, close to the end of the impeller hub.
watercraft. With the vehicle on the trailer, use
a flashlight to visually inspect them through the 3. Move shaft end up and down. Difference be-
inlet grate. tween highest and lowest dial gauge reading is
radial play.

smr2007-028-001_a

TYPICAL — UNDERNEATH HULL

1. Impeller
2. Impeller boot
3. Wear ring smr2016-037-015_a

TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY

1. Dial gauge
IMPELLER/WEAR RING 2. Measure close to impeller hub end
CLEARANCE
This clearance is critical for jet pump performance.

smr2017-028
https://brp-manuals.com/pwc_seadoo 3
Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

RADIAL PLAY
0.5 mm (.02 in)

Excessive play can come either from worn bearing

or damaged jet pump housing bearing surface.

LEAK TEST
Whenever performing any type of repair on the jet
pump, a leak test should be carry out.
Proceed as follows:
1. Remove impeller cover. Refer to IMPELLER
COVER in this subsection. smr2008-029-005

2. Install the PRESSURE CAP (P/N 529 036 172) on TYPICAL

pump housing. 4. Pressurize pump.
LEAK TEST PRESSURE
Maximum 70 kPa (10 PSI)

5. Pump must maintain this pressure for at least

529036172
3. Connect the VACUUM/PRESSURE PUMP (P/N 529
021 800) to the pressure cap fitting.
5 minutes.
NOTE: If there is 2 or 3 bubbles coming out from
the seal on the impeller side, it's acceptable.
Leaks from other areas must be repaired.

529021800 smr2009-006-002_a

TYPICAL
1. Small leak here is acceptable

NOTICE Repair any leak. Failure to correct a

leak will lead to premature wear of pump com-
ponents.
6. Disconnect pump and remove pressure cap.
7. Reinstall impeller cover. Refer to IMPELLER
COVER in this subsection.

4 https://brp-manuals.com/pwc_seadoo smr2017-028
 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

PROCEDURES
NOTE: Whenever removing a part, visually check
for damage such as: corrosion, cracks, split,
break, porosity, cavitation, deformation, distor-
tion, heating discoloration, wear pattern, defec-
tive plating, missing or broken balls in ball bearing,
water damage diagnosed by black-colored spots
on metal parts, etc. Replace any damaged parts.
As a quick check, manually feel clearance and end
play, where applicable, to detect excessive wear.

SACRIFICIAL ANODES
Inspecting the Sacrificial Anodes
Check for wear. If worn more than half, replace
anode.
219100893-030-001_a

Installing the Sacrificial Anode

Installation is the reverse of the removal proce-
dure.
TIGHTENING TORQUE
8 N•m ± 1 N•m
Sacrificial anode screw
(71 lbf•in ± 9 lbf•in)

VENTURI
smr2016-037-002_a
Removing the Venturi
TYPICAL 1. Remove the iBR gate, VTS trim ring and nozzle.
1. Sacrificial anode location Refer to iBR, REVERSE AND VTS subsection.
Removing the Sacrificial Anode 2. Remove the venturi from the jet pump housing.
Remove and discard screw and anode. Installing the Venturi
The installation is the reverse of the removal pro-
cedure.
TIGHTENING TORQUE
25 N•m ± 1 N•m
Venturi retaining screw
(18 lbf•ft ± 1 lbf•ft)

JET PUMP HOUSING

Removing the Jet Pump Housing
1. Remove the iBR gate, VTS trim ring and nozzle.
Refer to iBR, REVERSE AND VTS subsection.
smr2016-037-003_a 2. Remove the venturi.
3. Remove and discard the nuts that retain the jet
pump to the pump support.

smr2017-028
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Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

smr2016-037-005_a

4. Pull back jet pump housing to remove it from smr2016-037-006_a

the pump support. It may be necessary to wig- 1. Pressure outlet

gle it slightly as you pull back on the pump.
3. Ensure cap screw is tight.
Temporarily fasten the PUMP PLATE (P/N 529 036
4. Ensure the neoprene seal is in good condition.
224) to pump support to support drive shaft and
Replace as required.
avoid PTO oil seal damage.
5. On RXP-X models, ensure the cooling holes are
clean and free of any debris.

529036224

Inspecting and Cleaning the Jet Pump

Housing
1. Visually inspect jet pump housing. Pay atten-
tion to the stator. Ensure the assembly is clean
and free of any debris and defects.
Do the following as applicable. smr2016-037-007_a

2. Blow low pressure compressed air through the 1. Cap screw

2. Neoprene seal
pressure outlet fitting and make sure it is clear.
Installing the Jet Pump Housing
Clean impeller splines and drive shaft splines with
PULLEY FLANGE CLEANER (P/N 413 711 809) or
equivalent. Splines must be free of any residue.
NOTICE To avoid damaging the drive shaft
finish, never use a metallic brush.
Lubricate drive shaft splines, impeller splines and
the inside of the impeller boot with TRIPLE-GUARD
GREASE (P/N 296 000 329).
Ensure the neoprene seal is properly installed on
the jet pump.

6 https://brp-manuals.com/pwc_seadoo smr2017-028
 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

smr2016-037-007_b

1. Neoprene seal

Install new O-rings then slide water outlet adapter

onto pump. 219100893-030-002_a

1. Install new O-rings

2. O-rings (with tabs)

Generously apply TRIPLE-GUARD GREASE (P/N 296

000 329) on drive shaft splines.
Install jet pump.
1
NOTE: If necessary, wiggle jet pump to engage
drive shaft splines in impeller.
Install new nuts and torque as per table and the
illustrated sequence.
2
TIGHTENING TORQUE
27 N•m ± 1 N•m
Jet pump nuts
(20 lbf•ft ± 1 lbf•ft)

smr2016-037-008_a

1. Slide adapter onto pump

2. New O-rings here 1 5 3
Install new O-rings on pump support.

2 6
smr2016-037-005_b

Slightly lubricate wear ring with XPS LUBE (P/N 293

600 016) to minimize friction during initial impeller
start.

smr2017-028
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Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

IMPELLER COVER
Removing the Impeller Cover
1. Remove the jet pump housing.
2. With pump housing in vertical position, remove
and discard the 3 retaining screws.

smr2016-037-012_a

1. Cover O-rings

Inspecting the Impeller Cover

Check for presence of water in cover and bearing
smr2016-037-010_a
area. If water is found, replace seals on impeller
side. Also replace O-rings and/or impeller cover.
3. Using a fiber hammer, gently tap impeller cover
to help release it from the jet pump housing.
4. Use a flat screwdriver in the slots provided as
pry points to remove it from the jet pump hous-
ing.
1

smr2016-037-013_a

1. Seal on impeller side

smr2016-037-011_a

5. Remove both cover O-rings.

smr2016-037-012_a

1. Cover O-rings

8 https://brp-manuals.com/pwc_seadoo smr2017-028
 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

Check impeller boot and O-rings condition on im-

peller. Replace as required.

1
2
sdd2009-001-114_c

1. Align mark with top fin

NOTE: Cover can only be installed in one position

as screw holes are not located symmetrically.
smr2016-037-014_a 4. Secure cover with NEW self-locking screws.
1. Impeller boot
2. Impeller O-ring NOTE: Push cover against pump housing while
alternately tightening screws. Make sure O-rings
Perform a leak test. Refer to LEAK TEST in this are positioned correctly and they are not damaged
subsection. when pushing the cover.

Installing the Impeller Cover TIGHTENING TORQUE

1. Apply a thin layer of JET PUMP BEARING GREASE 7.5 N•m ± 0.5 N•m
Cover screw
(P/N 293 550 032) in O-ring grooves. (66 lbf•in ± 4 lbf•in)
2. Install O-rings in their respective groove and
make sure they are properly lubricated. IMPELLER
Removing the Impeller
NOTE: If impeller shaft is to be disassembled,
loosen the impeller shaft nut prior to removing
the impeller.
1. Remove jet pump housing. Refer to JET PUMP
HOUSING in this subsection.
2. Remove impeller cover. Refer to IMPELLER
COVER in this subsection.
3. Remove impeller boot by turning it clockwise
(LH threads).

F18J0NA

TYPICAL

3. Install impeller cover by aligning the cover index

mark with the pump top fin as shown.

smr2017-028
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Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

NOTICE Never use an impact wrench to

loosen impeller.

smr2009-006-006_b

F19J06A TYPICAL

TYPICAL 6. To pull impeller out of the pump, apply a rotating

1. Unscrew clockwise
movement as you pull on the impeller.
4. Mount the flat sides of impeller shaft in a vise.
Installing the Impeller
1. Mount the flat sides of the impeller shaft in a
vise.

smr2009-006-005_a

TYPICAL
1. Flat side
smr2009-006-005_a
5. Unscrew the impeller counterclockwise using
TYPICAL
the required tool. 1. Flat side
REQUIRED TOOL 2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
IMPELLER REMOVER/INSTALLER (P/N 529 (P/N 293 800 070) on threads of impeller shaft.
035 956)

529035956

TYPICAL

10 https://brp-manuals.com/pwc_seadoo smr2017-028
 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

REQUIRED TOOL
IMPELLER REMOVER/INSTALLER (P/N 529
035 956)

529035956

TYPICAL
smr2009-006-002_b
6. Torque impeller as per table.
TYPICAL
1. Antiseize lubricant
NOTICE Never use an impact wrench to
3. Apply XPS LUBE (P/N 293 600 016) on the wear tighten impeller shaft.
ring surface.
TIGHTENING TORQUE
125 N•m ± 10 N•m
Impeller
(92 lbf•ft ± 7 lbf•ft)

Remove tool.
7. Apply LOCTITE 438 (P/N 296 000 424) on impeller
boot threads.
8. Apply TRIPLE-GUARD GREASE (P/N 296 000 329)
inside impeller boot.
9. Install impeller boot on impeller and tighten
counterclockwise.

smr2009-006-002_c
WEAR RING
TYPICAL
1. Spray XPS lube on this surface
Inspecting the Wear Ring
Check wear ring for:
4. Start screwing the impeller on its shaft. – Deep scratches
– Irregular surface
– Any apparent damage.
Check IMPELLER/WEAR RING CLEARANCE, see
procedure at the beginning of this subsection.

Removing the Wear Ring

1. Remove jet pump housing. Refer to JET PUMP
HOUSING in this subsection.
2. Remove impeller, refer to IMPELLER in this
subsection.
3. On models equipped with 230 and 300 en-
gines, remove screws securing the wear ring.
smr2009-006-007

TYPICAL

5. Mount the required tool in impeller splines.

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Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

On models equipped with the 230 and 300 en-

gines, the wear ring must be secured by screws.
Drill pilot holes in the wear ring using a #24 drill
bit (5/32 in) and apply LOCTITE 243 (BLUE) (P/N 293
800 060) on screw threads.
TIGHTENING TORQUE
2.5 N•m ± 0.5 N•m
Wear ring screws
(22 lbf•in ± 4 lbf•in)

Method Using a Press

To install wear ring in housing, use a square steel
plate of approximately 180 x 180 mm x 6 mm thick
(7 x 7 in x 1/4 in) and a press.
smr2016-037-016_a
Manually engage ring in housing making sure it is
1. Wear ring screws
equally inserted all around. Press ring until it seats
Two methods can be used to remove the wear into bottom of housing.
ring, use the most appropriate as your situation.
Method Using a Freezer
1. Place the jet pump housing and the new wear
ring in a freezer for approximately 1-1/2 hour at
-10°C (14°F).
2. Remove the housing from the freezer and pull
the wear ring out.
1
Method by Cutting the Wear Ring
1. Place jet pump housing in a vise with soft jaws.
It is best to clamp housing using a lower ear.
2. Cut wear ring at two places.
NOTICE When cutting ring, be careful not to 2
damage jet pump housing.
F01J1DA
NOTE: Wear ring can be cut using a jigsaw, a
small grinder or a low clearance hacksaw. 1. Rounded edge
2. Press wear ring
3. After cutting ring, insert a screwdriver blade be-
tween jet pump housing and ring outside diam- On models equipped with 230 and 300 engines,
eter. the wear ring must be secured by screws. Drill pi-
4. Push ring so that it can collapse internally. lot holes in the wear ring using a #24 drill bit (5/32
in) and apply LOCTITE 243 (BLUE) (P/N 293 800 060)
5. Pull ring out.
on screw threads.
Installing the Wear Ring TIGHTENING TORQUE
Like the removing procedure, two methods can 2.5 N•m ± 0.5 N•m
be used to install the wear ring, use the most ap- Wear ring screws
(22 lbf•in ± 4 lbf•in)
propriate as your situation.
Method Using a Freezer
While the housing is still cold, insert the new wear
ring (previously placed in the freezer) in the hous-
ing.

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 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

IMPELLER SHAFT, BEARING AND

SEALS
Removing the Impeller Shaft, Bearing
and Seals
Removing the Shaft
1. Loosen the impeler shaft nut.
2. Remove impeller. Refer to IMPELLER in this
subsection.
3. Use the IMPELLER SHAFT PUSHER (P/N 529 035
955) to press impeller shaft out of pump hous- smr2009-006-011
ing. TYPICAL
NOTE: Bearing will come out with the impeller
shaft. Removing the Bearing
1. Use the IMPELLER SHAFT BEARING TOOL
(P/N 529 036 168) to press bearing off impeller
shaft.

529035955

smr2009-006-012_a

TYPICAL
1. Impeller shaft and bearing
2. Bearing tool on INNER race

Removing The Seals

1. Remove and discard the circlip securing the
seals.
smr2009-006-010_a

TYPICAL

smr2016-037-017_a

1. Circlip

smr2017-028
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Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

2. Using an appropriate tool, press seals out of the

housing.

Inspecting the Impeller Shaft and its

Bearing
With your finger nail, feel seal lip contact surface
on shaft. If any irregular surface is found, replace
shaft and seals.
Check condition of shaft threads.
Check shaft seal lip surface for cracks, flacking or
irregularities.

smr2009-006-013_a

TYPICAL
1. Impeller shaft bearing tool on INNER race
2. Impeller shaft and bearing
3. Impeller shaft installer/pusher tool

3. Press bearing until it bottoms.

Installing the Impeller Shaft and Seals
smr2009-006-019_a
NOTE: Ensure there is no O-ring in pump housing
TYPICAL
on the cover side.
1. Threads 1. From the outlet side of pump, press impeller
2. Seal lip contact surface
3. Threads shaft assembly into housing using the IM-
PELLER SHAFT BEARING TOOL (P/N 529 036
Inspect ball bearing for corrosion. 168).
Installing the Impeller Shaft, Bearing
and Seals
Installing the Bearing
The installation is essentially the reverse of the re-
moval procedure. However, pay attention to the
following.
1. Using the IMPELLER SHAFT BEARING TOOL
(P/N 529 036 168) on the bearing inner race,
press the bearing on the impeller shaft.
2. Use the IMPELLER SHAFT PUSHER (P/N 529 035
955) to protect the impeller shaft threads.
NOTE: The bearing can be installed in either direc-
tion. smr2009-006-014_a

TYPICAL
1. Bearing tool
2. Impeller shaft and bearing

2. Press bearing until it bottoms.

NOTE: Ensure impeller shaft turns freely and
smoothly.
3. Turn pump upside down.
4. Coat shaft surface with JET PUMP BEARING
GREASE (P/N 293 550 032).
5. Install O-ring at bottom.

14 https://brp-manuals.com/pwc_seadoo smr2017-028
 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

smr2009-006-015_a

1. Seal lip up

F19J07A 2 1 1
TYPICAL
1. O-ring at bottom
2. Coat surface

6. Apply 4 ml (.1 U.S. oz) of JET PUMP BEARING

GREASE (P/N 293 550 032) on bearing.

F18J13A

1. Seal lip facing up

F18J12A

TYPICAL

7. Press a NEW double lip seal using the

SEAL/BEARING PUSHER (P/N 529 035 819) until
seal bottoms. Make sure seal lip are facing
upwards.

F18J14B

TYPICAL
1. Seal/bearing pusher

8. Install spacer and then the other seal (thin). En-

sure seal lip is facing up.

smr2017-028
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Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

smr2009-006-016_a
F18J0PB
1. Seal lip facing up
1. Impeller remover/installer tool
9. Install circlip.
14. Install jet pump housing over this tool.

smr2006-027-007_c

TYPICAL
1. Circlip

10. Turn pump upside down.

F18J0QA
11. Before installing any other parts, pressurize jet
TYPICAL
pump to insure proper seal installation. Refer
to LEAK TEST in this subsection. 15. Using a 30 mm socket, screw the impeller
12. Install impeller. Refer to IMPELLER in this shaft nut on clockwise.
subsection. 16. Torque nut as specified in exploded view.
13. Mount in a vise the impeller remover/installer.
REQUIRED TOOL
IMPELLER REMOVER/INSTALLER (P/N 529
035 956)

529035956

TYPICAL

smr2009-006-009_b

16 https://brp-manuals.com/pwc_seadoo smr2017-028
 Subsection XX (JET PUMP (ALL MODELS EXCEPT SPARK SERIES))

17. Apply 26 ml (.9 U.S. oz) of JET PUMP BEARING

GREASE (P/N 293 550 032) on the bearing (nut
side) and in O-ring grooves.

smr2009-006-018

18. Install the two O-rings in pump housing and

make sure they are properly lubricated.

smr2009-006-017_a

TYPICAL
1. O-rings

19. Install the impeller cover. Refer to IMPELLER

COVER in this subsection.

smr2017-028
https://brp-manuals.com/pwc_seadoo 17
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

iBR, REVERSE AND VTS (ALL MODELS

EXCEPT SPARK SERIES)
SERVICE TOOLS
Description Part Number Page
DIAGNOSTIC HARNESS ............................................................... 529 036 384 ........................................... 23
IBR NUT SOCKET.......................................................................... 529 036 379 ........................................... 15

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 271 (RED)....................................................................... 293 800 005 ........................................... 18
LOCTITE 5900 ............................................................................... 293 800 066 ..................................... 16, 21

iBR ACTUATOR
Models with 130, 155 and 230 engine

Loctite 5900

17.5 ± 2.5 N•m

(155 ± 22 lbf•ft)

1.7 ± 0.2 N•m

(15 ± 2 lbf•in)

2.5 ± 0.5 N•m

NEW (22 ± 4 lbf•in)
NEW

29 ± 1 N•m
(21 ± 1 lbf•ft)
Loctite 271

NEW

NEW = Component must be replaced when removed.

219100893-029-101_a

219100941-022
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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

900 ACE
5 ± 1N•m
(44 ± 9 lbf•in) Loctite 5900
NEW

2.5 ± 0.5 N•m

1.7 ± 0.2N•m (22 ± 4 lbf•in)
(15 ± 2 lbf•in) 29 ± 1N•m
NEW NEW (21 ± 1 lbf•ft)
Loctite 5900

17.5 ± 2.5 N•m

(155 ± 22 lbf•in)

NEW

NEW = Component must be replaced when removed.

219100941-022-100_a

2 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

iBR GATE SUPPORT BRACKET

Loctite 5900

NEW
24 ± 2 N•m
(18 ± 1 lbf•ft)

NEW
18 ± 2 N•m
(159 ± 18 lbf•in)

NEW
29 ± 1 N•m
NEW = Component must be replaced when removed. (21 ± 1 lbf•ft)
smr2017-327-101_a

219100941-022
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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

VTS TRIM RING

24 ± 2 N•m
(18 ± 1 lbf•ft)
NEW

NEW
5 ± 1 N•m
(44 ± 9 lbf•in)

NEW
24 ± 2 N•m
NEW (18 ± 1 lbf•ft)
5 ± 1 N•m
(44 ± 9 lbf•in)

219100941-022-008_a

4 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

iBR GATE

5 ± 1 N•m
(44 ± 9 lbf•in)
NEW

Loctite 5900

24 ± 2 N•m
(18 ± 1 lbf•ft)
NEW NEW
5 ± 1 N•m
(44 ± 9 lbf•in)

NEW
24 ± 2 N•m
(18 ± 1 lbf•ft)

5.5 ± 0.5 N•m

(49 ± 4 lbf•in)

5 ± 1 N•m
(44 ± 9 lbf•in)
NEW

NEW = Component must be replaced when removed.

smr2017-327-103_a

219100941-022
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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

NOZZLE AND STEERING MULTIPLIER

Steering multiplier on applicable models

10 ± 2 N•m
(89 ± 18 lbf•in) NEW

10 ± 2 N•m
NEW (89 ± 18 lbf•in)
NEW = Component must be replaced when removed.
smr2016-036-050_a

6 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

GENERAL
During assembly/installation, use torque values
and service products as indicated in the exploded 1
view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE 2
APPLICATION at the beginning of this manual for
complete procedure.

WARNING 4 3 3
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic 4
stop nuts, self-locking fasteners, cotter pins, smr2017-209-012_a

etc.) must be replaced with new ones. TYPICAL

1. Protective guard (models without boarding platform)
2. Gate
Hoses, cables or locking ties removed during a 3. Support plates
4. Gate bushings
procedure must be reinstalled as per factory stan-
dards. The iBR (intelligent Brake and Reverse) is an elec-
tronically controlled braking and reverse system.
SYSTEM DESCRIPTION (iBR) The iBR module controls the position of the iBR
gate to provide forward thrust, reverse thrust,
iBR System Components
braking thrust, and neutral.
The operator commands the position of the iBR
gate using either the throttle lever for forward
thrust, or the iBR lever for neutral, reverse, and
for the braking function.
The iBR lever is located on the LH side of the han-
dlebar.

219100893-029-001_a

TYPICAL
1. Actuator
2. Air chamber
3. iBR nut
4. Actuator shaft
5. Connecting arm
6. Connecting arm bellows smr2016-036-006_a
7. iBR Reverese Gate
TYPICAL

When the iBR lever is pulled in, it operates the

brake and reverse lever sensor (BRLS). It is a dou-
ble output hall effect sensor. The redundancy is
used for security purposes.
The BRLS sends the signals to the iBR module.
The iBR module controls an electric motor that in
turn raises or lowers the iBR gate through a me-
chanical drive unit.

219100941-022
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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

219100893-029-007_a

iBR ACTUATOR AIR CHAMBER MOVEMENT - TYPICAL

NOTE: The iBR gate will move when commanded

by the iBR lever only if the engine is running. For
maintenance purposes, the iBR OVERRIDE func-
smr2014-119-001_a
tion available through the gauge can be used to
TYPICAL - FORWARD
electrically move the gate to the desired position.
Depending on vehicle speed and how far the iBR
lever is pulled in, the iBR module will automatically
adjust the iBR gate movement speed and stroke.
NOTE: The iBR lever must be pulled in at least
25% of its travel (approximately) before the iBR
gate starts to move. The first 25% of iBR lever
travel has no effect on the iBR gate.
Every time the iBR gate moves when commanded
by the iBR lever, engine RPM is momentarily re-
duced to idle speed as the gate moves.

WARNING
If it is necessary to remove any foreign ob-
ject catch in the iBR gate, nozzle or linkages,
strictly observe the following before proceed-
ing:
– Remove tether cord from engine cut-off
switch.
– Wait at least 5 minutes or remove iBR
fuses.
– Do not press on START/STOP button. If
START/STOP button is pressed, wait an-
smr2016-036-051
other 5 minutes.
TYPICAL - REVERSE
iBR Override Function
iBR override moves the iBR actuator through its
full range of motion.

8 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))
NOTICE Remove any foreign object that may
obstruct iBR actuator movement.
Activating iBR Override Function
1. Press the START/STOP button.
2. Install the tether cord.
NOTE: Do not start the engine. The tether cord
must be installed to ensure the information center
will not shut off all indications after its self test
function. Briefly press the START/STOP button to
reactivate the electrical system when required.
3. Pull in the iBR lever;
3.1 There will be a beep.
3.2 Press the SET button on the information
center (gauge).
Models with a VTS Switch
4. Press the VTS UP or DOWN button to move the
iBR gate.
Models Without a VTS Switch
5. Press the UP/DOWN arrow button (RH handle-
bar) to move the iBR gate.
Forward Mode
To engage forward:
– Start engine
– Pull in the throttle lever.
The iBR gate will automatically move to the for-
ward position (full up).
NOTE: The full up position of the iBR gate is de-
pendent on the selected VTS trim position.
Reverse Mode
If the watercraft speed is below 14 km/h (9 MPH)
when the iBR lever is pulled in, reverse mode is
engaged.
When the iBR lever is pulled in to engage the re-
verse, the following occurs:
– Engine RPM is reduced to idle.
– The iBR gate moves to the reverse position.
– Engine RPM ramps up to the engine power
commanded by the throttle lever.
When operating in reverse mode, the iBR lever
controls the iBR gate position and the engine RPM
is controlled by the throttle lever.
Maximum engine RPM in reverse is 5000 RPM.
219100941-022
https://brp-manuals.com/pwc_seadoo
Braking Mode
If the watercraft speed is 14 km/h (9 MPH) per
hour and above when the iBR lever is pulled in,
braking mode is engaged.
When the iBR lever is pulled in to engage braking,
the following occurs:
– Engine RPM is reduced to idle.
– The iBR gate moves to the maximum down po-
sition.
– Engine RPM ramps up to the engine power
commanded by the iBR lever.
When operating in braking mode, the iBR gate al-
ways moves to the maximum down position. The
throttle lever signal is overridden and engine RPM
is now dependent on watercraft speed and how
far the iBR lever is pulled in.
If watercraft speed is high when braking is ap-
plied, engine power will be initially low and
then ramp up to the power commanded by the
iBR lever position. The engine RPM may be in-
creased, as necessary, to apply a stronger braking
effect with the jet pump thrust when the condi-
tions dictate.
As the watercraft slows to less than 8 km/h
(5 MPH), the following occurs:
– Braking mode ceases.
– Reverse mode takes over if the iBR lever is not
released.
– Throttle control reverts back to the throttle
lever.
Neutral Mode
Every time the iBR lever is pulled in and released,
the iBR gate will default to the neutral position,
except if the throttle lever is still pulled in when
the iBR lever is released. If the throttle lever is
still pulled, the iBR gate will move to the forward
position when the iBR lever is released and the
watercraft will accelerate forward.
SYSTEM DESCRIPTION (VTS)
The VTS system is actually part of the iBR system.
It provides watercraft pitch trim adjustments by
adjusting the vertical position of the jet nozzle.
The VTS can be electrically trimmed to the desired
attitude within the VTS range, or to one of 2 preset
trim positions (on applicable models).
The VTS switch (or Up/Down switch) sends com-
mand signals to the gauge. The gauge converts
them to CAN protocol and sends them through
9
Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

the CAN bus to the iBR module on the iBR actua-

tor. The actuator then moves the iBR gate which
moves the nozzle to the desired trim position.
NOTE: The nozzle and iBR gate move together
in the VTS trim range up to the maximum noz-
zle down position. If NEUTRAL, BRAKING or RE-
VERSE is engaged, the iBR gate moves past the
VTS full down position. When FORWARD thrust
is reengaged, the nozzle and iBR gate move up to
the last selected VTS trim position.
The nozzle trim position can be seen on the VTS
position indicator in the information center.
NOTE: Changing the VTS trim position only
changes the indication. The nozzle will move
to the selected VTS trim position when forward
thrust is engaged.
219100893-029-009_a

1. VTS UP/DOWN control buttons

Using the Up/Down Button

(RH Side of Handlebar)
1. Press the MODE button to display the VTS
function in the gauge.
2. Press the UP or DOWN arrow button to change
the VTS setting.

sdd2009-001-042_a

INFORMATION CENTER — VTS POSITION INDICATOR

1. Bow up
2. Bow down

NOTE: Only the segment indicating the relative

position of the VTS will be on. The illustration
shows all segments on as can be seen during the
self test function.
The VTS system provides the following features
according to models
– Nozzle trimming
– Selection of 2 preset trim positions
– Recording of 2 preset trim positions.
219100893-029-022_a

Nozzle Trimming 1. UP DOWN arrow buttons

Watercraft must be operating in forward position.
Depending on the model, 5 or 9 trim positions are
available.
Using the VTS Button
(LH Side of Handlebar)
Press the UP or DOWN arrow button to change
the VTS setting.

10 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))
smo2010-002-106_a
FUNCTION SELECTED - VTS
1. VTS setting
3. Press the SET button to save the desired set-
ting.
Using Preset Trim Positions
Two preset trim positions can be selected.
To select the highest trim position, double-click
on the VTS UP arrow button (bow up).
To select the lowest trim position, double-click on
the VTS DOWN arrow button (bow down).
Recording Preset Trim Positions
Two different VTS trim positions may be recorded
for quickly selecting the preferred watercraft trim
attitude.
When the VTS PRESET trim positions are
changed, the new settings will remain recorded
in memory.
To record VTS preset trim positions:
1. Press the START/STOP button.
2. Install the tether cord on the engine cut-off
switch.
3. Press the MODE button repeatedly until VTS
MODE is displayed.
219100941-022
https://brp-manuals.com/pwc_seadoo
smo2009-002-114_d
FUNCTION SELECTED - VTS MODE
4. Press the SET button to display PRESET 1.
5. Press the VTS UP/DOWN button to change the
PRESET 1 VTS position.
2
1
3
smo2009-002-114_e
FUNCTION SELECTED - PRESET 1
1. Preset 1 function
2. VTS setting selected to 1
3. VTS position indicator at setting 1 (bow down)
6. Press the SET button to save PRESET 1 and
display PRESET 2.
7. Set PRESET 2
8. Press the SET button to save the settings.
NOTE: The VTS system will compare the preset
trim settings recorded, the highest position will be
assigned to the UP arrow (bow up), the lowest to
the DOWN arrow.
Launch Control (If equipped)
The Launch Control is an automatic adjustment
of the VTS to achieve optimum acceleration.
When the speed is below 20 km/h (12 MPH), the
iBR lowers to it's lowest position and the iVTS
11
Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

indicator flashes to indicate the system is ready.
When the speed exceeds 30 km/h (19 MPH) the
iBR returns to the user selected position.
Press on the LOCK button.
Unlock the iBR Actuator (Activate)
To unlock or activate the iBR actuator, press the
UNLOCK button.

sdd2009-001-042_b
1. Launch Control indicator
To activate the Launch Control, press simultane-
ously both the UP and DOWN buttons. To deac-
tivate the Launch Control, press simultaneously
both UP/DOWN buttons again. The Launch Con-
trol also deactivates when the engine is shut off.
ADJUSTMENT
iBR FLASHING
NOTICE Make sure the unit's battery is fully
charged before undertaking this operation.
NOTICE Continuous power to the computer
is mandatory while performing this operation.
Perform after replacing the iBR actuator.
Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
In BUDS2, go to:
– Flash page
– iBR button
Select the update file in the VALID FIRMWARE
UPDATES window and click YES when prompted.

sbs2017-005-003a

The following message will confirm that the up-

date has been donne successfully.
219001878-014_a

VTS CONTROL BUTTON

1. Up
2. Down

Lock/Unlock iBR Actuator

Locking the iBR Actuator
When working on the iBR, it may be interesting to
lock the iBR to avoid accidental movement.
Connect the vehicle to te BRP diagnostic software
(BUDS2). sbs2017-005-004a

In BUDS2, go to: Click OK and proceed to the iBRM update.

– Functions page
– iBR button
– IO Controls tab
– Move iBR Up/Down
12 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

iBRM FLASHING In BUDS2, go to:

– Functions page
NOTICE Make sure the unit's battery is fully – iBR button
charged before undertaking this operation. – IO Controls tab
NOTICE Continuous power to the computer – Move iBR Up/Down
is mandatory while performing this operation. Start the iBR auto calibration by pressing the auto
calibration button.
Perform after flashing the iBR.
Connect the vehicle to the BRP diagnostic soft- NOTICE Make sure the iBR actuator is un-
ware (BUDS2). locked before pressing the Auto Calibration
button.
In BUDS2, go to:
– Flash page MAINTENANCE
– iBRM button
Refer to PERIODIC MAINTENANCE PROCE-
Select the update file in the VALID FIRMWARE
DURES subsection of the appropriate shop man-
UPDATES window and click YES when prompted.
ual.

PROCEDURES
SWITCHES LOCATION AND
PIN-OUT

sbs2017-005-008a

The following message will confirm that the up-

date has been donne successfully.

sbs2017-005-009a
219100893-029-011_a

BRLS LOCATION - TYPICAL

iBR AUTO CALIBRATION
NOTICE iBR auto-calibration must be per-
formed with the complete reverse gate as-
sembly properly installed. Performing the
auto-calibration procedure without the reverse
gate assembly in place will damage the actu-
ator.
Perform after repairing or removing the jet pump
and/or iBR system components.
Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).

219100941-022
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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

smr2014-119-008_a

BRLS PINOUT

smr2017-327-013_a

TYPICAL - IBR ACTUATOR CONNECTOR LOCATION

smr2014-119-010_a
smr2017-327-012_a
IBR ACTUATOR CONNECTOR
STEERING CONNECTOR LOCATION

iBR ACTUATOR
Specifications
IBR ACTUATOR CONNECTOR
PIN SIGNAL
Battery voltage
iBR-1
(Hot at all times)
Battery voltage
iBR-2
(Hot with main relay on)
iBR-8 Ground

iBR ACTUATOR CURRENT DRAW

DOWN SELECTION -5 to -15 A
smr2014-030-012_a

STEERING CONNECTOR UP SELECTION +10 to +20 A

Testing iBR Actuator Operation

1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. In BUDS2, go to:
– Functions page
– iBR button button

14 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

– IO Controls tab
– Move iBR Up/Down
3. Click iBR UP and iBR DOWN buttons alter-
nately and look for a change in iBR Position
(Deg).
If the iBR moves using these buttons but does not
move using the iBR lever, test BRLS VOLTAGE in
this subsection.
If the iBR does not move, check the iBR fuse(s)
in fuse box. If fuse(s) are good, check power and
ground circuits.

Testing iBR Actuator Motor Current

1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2). smr2016-036-020

2. In BUDS2, go to: 3. Remove connecting arm pin and screw.

– Measurements page
– iBR button
3. Note the Gate Position (°) indication.
4. Activate the iBR override function.
5. Move the iBR to the full up position and look for
the Motor Current (A) indication. Also look for
a change of Gate Position (°) indication.
NOTE: Current draw indication will not be stable.
High and low peaks will be observed. Look for the
maximum average current draw.
6. Move the iBR to the full down position and look
for the Motor Current (A) draw indication. Also
look for a change of iBR Position (°) indication. smr2016-036-045

If current draw is abnormally high (between 20 4. Remove iBR nut and bellows.IBR NUT SOCKET
and 30 A), check the following: (P/N 529 036 379).
– Ensure iBR gate is free of debris.
– Check for excessive friction in gate movement.
– Check roller bushings, plastic bushings and iBR
ramps.
– Check for proper voltage to the iBR actuator.
– Check for fault codes using BUDS2.
smr2016-036-046
Remove debris, replace iBR gate components, or
replace the iBR actuator as applicable. 5. Move muffler. Refer to EXHAUST SYSTEM.
6. Unplug electrical connector.
Removing the iBR Actuator
7. Remove retaining strap.
NOTICE Do not try to manually force the iBR
8. Remove iBR actuator and air chamber.
gate when all components are installed.
1. Remove iBR gate assembly.
2. Remove the small Oetiker clamp retaining the
connecting arm bellows.

219100941-022
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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

Installing the iBR Actuator
NOTICE Failure to adhere to the sequence in
the following steps will cause the iBR air cham-
ber to rupture or burst and cause premature
failure of the iBR actuator.
1. Install the air chamber on the iBR actuator.
1.1 Tighten the clamp.
8. If equipped, install iBR actuator retaining strap.
9. Install connecting arm.
10. Reinstall other removed parts. Refer to appro-
priate subsections for procedures.
NOTICE Allow 24 hours for thread locker on
retaining screws to cure.
11. Perform iBR FLASHING procedure.
12. Perform iBR AUTO-CALIBRATION procedure.

iBR GATE ASSEMBLY

smr2016-036-036

TYPICAL

2. Connect iBR actuator connector.

3. Install iBR actuator shaft through hull opening.
4. Slide the o-ring into position on iBR nut. smr2016-036-043

Removing the iBR Gate Assembly

1. Remove the guard.

smr2016-036-013_a

5. If the same actuator is reinstalled, clean smr2016-036-042

all residues of sealing compound near the

threaded area. 2. Use the iBR override function to lower the gate
until the holes align.
6. Apply LOCTITE 5900 (P/N 293 800 066) on actua-
tor, between actuator housing and threads, as 3. Disconnect the connecting arm.
shown in the exploded view.
NOTICE Ensure no sealing agents contact the
iBR shaft.
7. Torque iBR nut.
TIGHTENING TORQUE
17.5 N•m ± 2.5 N•m
iBR nut
(155 lbf•in ± 22 lbf•in)

16 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

smr2016-036-037

4. Disconnect the steering cable. Refer to STEER-

ING AND O.T.A.S. subsection.
5. Remove L-plate retaining nuts.

smr2016-036-052

TYPICAL - TOP: GATE LOWERED / BOTTOM: GATE RAISED (BY

HAND)

NOTICE Do not drop the venturi when re-

moving the iBR Gate Assembly.
smr2016-036-024_a
Installing the iBR Gate Assembly
6. Remove the iBR gate support bracket screws.
TIGHTENING SEQUENCE

Reverse removal procedure.

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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

NOTICE Allow 24 hours for thread locker on Installing the iBR Reverse Gate
retaining screws to cure. The installation is the reverse of the removal pro-
Perform IBR AUTO-CALIBRATION procedure. cedure.
TIGHTENING TORQUE
iBR REVERSE GATE 27 N•m ± 1 N•m
(20 lbf•ft ± 1 lbf•ft)
iBR Reverse Gate
+
retaining screws
LOCTITE 271 (RED)
(P/N 293 800 005)

NOTICE Allow 24 hours for thread locker on

retaining screws to cure
Perform iBR AUTO-CALIBRATION procedure.

CONNECTING ARM
smr2016-036-034

Removing the iBR Reverse Gate

Remove the iBR gate assembly.

smr2016-036-049

Removing the Connecting Arm

1. Remove the iBR gate assembly. Refer to IBR
GATE ASSEMBLY.
smr2016-036-043

Remove the iBR reverse gate.

smr2016-036-043

smr2016-036-028_a
2. Remove the small Oetiker clamp retaining the
connecting arm bellows.

18 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

2. Install connecting arm pin and screw.

2.1 Torque screw.

smr2016-036-020
smr2016-036-045

3. Remove connecting arm pin and screw.

3. Position the bellows over the connecting arm.

smr2016-036-045

4. Remove connecting arm.

Installing the Connecting Arm

Use iBR override function to move iBR actuator to
the full down setting.
NOTE: The bellows should already be installed
and clamped on the iBR nut. smr2016-036-021_a

4. Compress the air chamber (attached to iBR ac-

tuator).
4.1 Clamp the Oetiker clamp on the connect-
ing arm bellows.

smr2016-036-047

NOTICE Failure to adhere to the sequence in

the following steps will cause the iBR air cham-
ber to rupture or burst and cause premature
failure of the iBR actuator.
1. Push the bellows back towards iBR actuator.
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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

smr2016-036-048_a
smr2016-036-028_a

Reverse removal procedure.

2. Remove the trim ring and nozzle assembly.
NOTICE Allow 24 hours for thread locker on
retaining screws to cure.
Perform IBR AUTO-CALIBRATION procedure.

iBR GATE SUPPORT BRACKET

smr2016-036-029_a

Installing the iBR Gate Support Bracket

The installation is the reverse of the removal pro-
cedure.
NOTICE Allow 24 hours for thread locker on
smr2016-036-030
retaining screws to cure.
Removing the iBR Gate Support Perform IBR AUTO-CALIBRATION procedure.
Bracket
Remove the iBR Gate Assembly.
1. Remove the iBR gate.

20 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

L-PLATE

smr2016-036-040_a

1. Loosely install L-plate nuts.

smr2016-036-038

The L plate is pre-aligned from factory. It should

not be removed unless it is damaged.

Removing the L-Plate

Remove iBR gate assembly.
Remove L-Plate retaining nuts.
NOTE: The top studs and plate are sealed to
smr2016-036-041
the hull. If removed, they must be cleaned and
sealed. 2. Install gate support bracket with the iBR gate
assembly and tighten the 4 bolts and 2 nuts.
3. Tighten L-plate nuts.

smr2016-036-039

L-PLATE TOP STUDS AND PLATE

Installing the L-Plate

If removed, the top studs and plate must be
sealed with LOCTITE 5900 (P/N 293 800 066).

219100941-022
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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

TIGHTENING SEQUENCE VTS TRIM RING

smr2016-036-031

Removing the VTS Trim Ring

1. Remove iBR gate assembly.
2. Remove iBR reverse gate.
3. Remove nozzle pivot screws.

Installing the VTS Trim Ring

The installating is the reverse of the removal pro-
cedure.
NOTICE Allow 24 hours for thread locker on
retaining screws to cure.
The installation is the reverse of the removal pro-
cedure. Perform IBR AUTO-CALIBRATION procedure.
NOTICE Allow 24 hours for thread locker on
retaining screws to cure. BRAKE AND REVERSE LEVER
SWITCH (BRLS)
Perform IBR AUTO-CALIBRATION procedure.
Testing and Specifications
BRLS PINOUT
PIN SIGNAL
BRLS-A 5 VDC
BRLS-B GND
BRLS-C View signal % in BUDS2
BRLS-D 5VDC
BRLS-E GND
BRLS-F View signal % in BUDS2

Connect the vehicle to the BRP diagnostic soft-

ware (BUDS2).
NOTE: When moving BRLS lever, the BRLS per-
centage should increase or decrease in a steady
linear fashion.
22 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

If BUDS2 does not show BRLS percentage mov-

ing or if reading is erratic:
– Check for BRLS reference voltage.
– Check for BRLS ground.
– Carry out a continuity test of the wiring be-
tween the iBR actuator and the BRLS.
NOTE: When installed on vehicle the BRLS-C Vdc
signal should always be half of the BRLS-F Vdc
signal when testing with a multimeter.
To test, install DIAGNOSTIC HARNESS (P/N 529 036
384) between steering harness connectors.

smr2017-209-005_a

smr2014-119-017_a 1
APPROXIMATE BRLS SIGNAL VOLTAGE CURVE PINS F AND C
1. BRLS released 2
2. BRLS at 50% pulled
3. BRLS fully pulled

Removing the BRLS

Remove cover.
smr2017-209-006_a
Refer to STEERING subsection of the appropriate
shop manual.
Installing the BRLS
The installation is the reverse of the removal pro-
cedure.
TIGHTENING TORQUE
2 N•m ± 1 N•m
M6 x 16 Torx screws (2x)
(18 lbf•in ± 9 lbf•in)

CAN COMMUNICATION TEST

CAN WIRE RESISTANCE TEST
IBR
COM
ACTUATOR SPECIFIED
CONNECTOR
CONNECTOR RESISTANCE
PIN
PIN
smr2017-209-004_a iBR-3 COM-1 0
iBR-4 COM-2 0

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Subsection XX (iBR, REVERSE AND VTS (ALL MODELS EXCEPT SPARK SERIES))

smr2014-119-011_a

Refer to PROCEDURES in this subsection for

wiring diagram and pinouts.
Refer to CONTROLLER AREA NETWORK (CAN)
subsection for additional information.

24 https://brp-manuals.com/pwc_seadoo 219100941-022
 Subsection XX (DRIVE SHAFT)

DRIVE SHAFT
SERVICE TOOLS
Description Part Number Page
DRIVE SHAFT C-CLIP REMOVER ................................................. 529 036 026 ............................................. 2
FLOATING RING TOOL (TYPE II) .................................................. 529 036 116 ............................................. 2
PTO SUPPORT TOOL ................................................................... 529 035 842 ......................................... 3, 6

SERVICE PRODUCTS
Description Part Number Page
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ............................................. 4
XPS LUBE...................................................................................... 293 600 016 ............................................. 3
XPS SYNTHETIC GREASE............................................................. 293 550 010 ............................................. 6

Engine oil
NEW

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)
XPS
synthetic
grease

Triple-Guard
Grease

NEW = Component must be replaced when removed.

219100941-024-100_a

219100941-024
https://brp-manuals.com/pwc_seadoo 1
Subsection XX (DRIVE SHAFT)

PROCEDURES
DRIVE SHAFT
Drive Shaft Access
Remove the seat support. Refer to BODY subsec-
tion.

Removing the Drive Shaft

Preparation
Refer to DRIVE SHAFT ACCESS to remove re-
quired parts according to model.
Procedures smr2011-036-002_a

NOTE: Ensure jet pump is installed before begin- TYPICAL

ning this procedure. 1. Fork against floating ring
2. Adjustable arm
1. Lift rubber protector to expose PTO seal as-
sembly. 2.3 Move the tool handle toward the front of
vehicle to push floating ring rearward.
2. Confirm the floating ring is not stuck on drive
shaft as follows:
REQUIRED TOOL
DRIVE SHAFT C-CLIP REMOVER
(P/N 529 036 026)

529036026

2.1 Place the fork of drive shaft C-clip remover
against floating ring.
2.2 Place the adjustable arm against the en-
gine or the arm of the tool against the su-
percharger.
smr2011-036-003_a
TYPICAL
The next steps (3 to 11) should be performed only
if the floating ring seems stuck or hard to move.
Otherwise, go to the step 12.
NOTE: Do not remove circlip at this time.
3. Remove the drive shaft C-clip remover.
4. Remove the supercharger. Refer to appropriate
SUPERCHARGER subsection.
5. Install the following tool on drive shaft with its
largest opening on PTO side.
REQUIRED TOOL
FLOATING RING TOOL (TYPE II)
(P/N 529 036 116)

2 https://brp-manuals.com/pwc_seadoo 219100941-024
 Subsection XX (DRIVE SHAFT)

F18I0OA 1
TYPICAL
1. Largest opening on PTO seal side 1
2

smr2011-036-031_a

TYPICAL
1. Telltale groove
2. Lubricate this area
A. 18 mm (11/16 in)
smr2011-036-030_a

TYPICAL 8. Remove the floating ring tool.

1. Largest opening here
9. Install the following tool to PTO seal assembly.
6. To expose the O-ring contact area, tighten tool
screw until the following gap is obtained. REQUIRED TOOL
PTO SUPPORT TOOL (P/N 529 035 842)
GAP BETWEEN TELLTALE GROOVE AND
TOOL EDGE
18 mm (11/16 in)

7. Lubricate O-ring contact area with XPS LUBE

(P/N 293 600 016).
NOTE: This is necessary to ease drive shaft re-
moval later in this procedure.

529035842

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Subsection XX (DRIVE SHAFT)

3
2

1 1

F18C02A

TYPICAL
1. Largest opening here
F18I04A 2. Floating ring
3. PTO seal support tool
1. Insert in groove of PTO seal assembly 4. Remove circlip

NOTICE Strictly follow this procedure other-
wise damage to component might occur.
10. Reinstall the floating ring tool as shown.
13. Remove the floating ring tool.
14. Place rags under PTO housing to prevent
spillage. If spillage occurs, clean immediately
with the PULLEY FLANGE CLEANER (P/N 413
711 809) to prevent oil stains.
15. Remove jet pump. Refer to JET PUMP sub-
section.
16. Remove drive shaft.
NOTE: A slight jerk to the rear may be required to
remove the drive shaft from the PTO seal assem-
bly.

Inspecting the Drive Shaft

Drive Shaft
Inspect condition of circlip groove. If there is any
F18I0OA 1 damage or severe wear, replace drive shaft.
TYPICAL
1. Largest opening on PTO seal side

11. Tighten tool screw to push floating ring rear-

ward and expose circlip.
12. Remove and discard circlip.

smr2011-036-004_a

1. Circlip groove

Inspect condition of drive shaft splines. If splines

are damaged, replace drive shaft and check
splines of impeller and PTO housing.

4 https://brp-manuals.com/pwc_seadoo 219100941-024
 Subsection XX (DRIVE SHAFT)

With your finger nail, feel machined surface of Replace as required.

drive shaft. If any irregular surface is found, re-
place drive shaft.

1 2

F18I0KA

1. O-rings
2. Contact surface

Installing the Drive Shaft

Before installing drive shaft, discard both O-rings
smr2017-339-001_a
inside PTO seal and install NEW ones.
TYPICAL
1. Surface condition
2. Splines condition

Place drive shaft on V-blocks and set-up a dial

gauge in center of shaft. Slowly rotate shaft; dif-
ference between highest and lowest dial gauge
reading is deflection. Refer to the following illus-
tration.
NOTE: Excessive deflection could cause vibra-
tion and damage to drive shaft splines, impeller 1
or floating ring.

F18C01A

1. O-rings

Inspect PTO seal assembly. The inner sleeve

must be flush with outer circumference of the
assembly. Otherwise, gently push or tap on inner
sleeve until flush.
1

F01J15A 2
MEASURING DRIVE SHAFT DEFLECTION
1. Dial gauge
2. V-blocks

MAXIMUM DEFLECTION
0.5 mm (.02 in)

Floating Ring
Inspect condition of O-rings and contact surface
of floating ring.

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Subsection XX (DRIVE SHAFT)

Apply a thin coat of XPS SYNTHETIC GREASE

(P/N 293 550 010) on the floating ring O-rings. Do
not get grease on floating ring contact surface.

1 2

F18I0KA
F18I0EA 1
1. XP-S synthetic grease on O-rings
CORRECT POSITION 2. No lubrication on contact surface
1. Inner sleeve flush with outer circumference
Slide drive shaft far enough to install floating ring.

1 F18I0HA 1 2 3
F18I0FA

1. PTO seal support

INCORRECT POSITION 2. Drive shaft end
1. Inner sleeve not flush with outer circumference 3. Insert floating ring on shaft end

Remove the damper at the end of drive shaft and
replace it with a NEW one.
Continue pushing drive shaft towards engine care-
fully guiding it in the PTO seal then in crankshaft
splines. It may be necessary to move PTO seal
assembly up and down to position it in the same
axis as the drive shaft.
NOTE: If drive shaft does not enter into the PTO
seal, check engine alignment.

smr2006-028-004_a

1. Damper

Install the PTO SUPPORT TOOL (P/N 529 035 842) on

PTO seal assembly.

6 https://brp-manuals.com/pwc_seadoo 219100941-024

F18I02A
TYPICAL
Maintain PTO seal assembly in the proper position
and tap shaft end until it bottoms against engine.
At this time, the telltale groove MUST NOT be vis-
ible. This validates the correct position.
NOTICE If the telltale groove is exposed, the
installation is wrong and PTO seal assembly
will be pressed into crankshaft splines which
could rub a hole in seal thus creating an oil
leak.
3 1
F18I0IA 2
CORRECT INSTALLATION
1. PTO seal assembly
2. Shaft pushed in, hiding telltale groove
3. Inner sleeve flush with outer circumference
219100941-024
https://brp-manuals.com/pwc_seadoo
Subsection XX (DRIVE SHAFT)
3 1
F18I0JA 2
IMPROPER INSTALLATION
1. PTO seal assembly
2. Telltale groove visible
3. Inner sleeve NOT flush with outer circumference
Temporarily install the jet pump housing.
Push floating ring rearwards and install a NEW cir-
clip.
Ensure everything is properly positioned:
– Telltale groove is not visible
– Inner sleeve is flush with outer circumference
of PTO seal assembly
– Circlip is not exposed.
If telltale groove is visible, pull PTO seal assembly
rearwards to fully extend it.
If inner sleeve is not flush, gently tap it until it is
flush.
Reposition rubber protector.
Permanently install jet pump. Refer to JET PUMP
subsection.
Test watercraft then ensure there is:
– No oil leak in PTO seal area
– No water intrusion by the thru-hull fitting area.
DRIVE SHAFT BELLOWS
Inspecting the Drive Shaft Bellows
Inspect the condition of bellows. If there is any
damage or evidence of wear, replace it.
Removing the Drive Shaft Bellows
Remove drive shaft. Refer to DRIVE SHAFT in this
subsection.
7
Subsection XX (DRIVE SHAFT)

Loosen gear clamp holding bellows, then carefully

pull bellows and carbon ring from hull insert.

smr2008-030-002_a

TYPICAL
1. Loosen this clamp
2. Drive shaft bellows

Installing the Drive Shaft Bellows

The installation is the reverse of the removal pro-
cedure.

CARBON RING
Removing the Carbon Ring
Remove DRIVE SHAFT BELLOWS. See proce-
dure in this subsection.
Loosen gear clamp then pull carbon ring from
drive shaft bellows.

smr2008-030-003_a

1. Drive shaft bellows

2. Carbon ring

Installing the Carbon Ring

The installation is the reverse of the removal pro-
cedure.

8 https://brp-manuals.com/pwc_seadoo 219100941-024
 Subsection XX (BODY (GTR-X))

BODY (GTR-X)
SERVICE TOOLS
Description Part Number Page
SUPERTANIUM DRILL BIT 3/16"................................................... 529 031 800 ........................................... 11

BODY PARTS NOMENCLATURE

3 4
2 5
1 6
7
8
11

10
9
smr2017-331-100_a

1. Storage compartment cover

2. Mirror support
3. Gauge and mirror trim
4. Lateral trim panel
5. Console
6. Glove box cover
7. Seat
8. Rear handle
9. Bumper
10. Sponson
11. Water deflector

smr2017-331
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Subsection XX (BODY (GTR-X))

STORAGE COMPARTMENT COVER

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

1.8 ± 0.2 N•m

(16 ± 2 lbf•in)

NEW

4 ± 0.5 N•m
(35 ± 4 lbf•in)
See tightening
sequence
8 ± 1 N•m
(71 ± 1 lbf•in)
NEW

See tightening
sequence
8 ± 1 N•m 1.8 ± 0.2 N•m
(71 ± 1 lbf•in) (16 ± 2 lbf•in)

NEW = Component must be replaced when removed.

smr2017-331-101_a

2 https://brp-manuals.com/pwc_seadoo smr2017-331
 Subsection XX (BODY (GTR-X))

BODY PARTS

1.4 ± 0.2 N•m

(14 ± 2 lbf•in)

4.5 ± 0.5 N•m

(40 ± 4 lbf•in)

5.5 ± 0.5 N•m

(49 ± 4 lbf•in) 0.5 N•m
(4 lbf•in)
5/8
6/8

4/8
1/8 6.5 ± 0.5 N•m
(58 ± 4 lbf•in)
2/8

3/8

7 ± 0.5 N•m
(62 ± 4 lbf•in)

7/8

4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
8/8
5.5 ± 0.5 N•m 4.5 ± 0.5N•m
(49 ± 4 lbf•in) (40 ± 4 lbf•in)
smr2017-331-102_a

smr2017-331
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Subsection XX (BODY (GTR-X))

BODY PARTS
8 ± 1 N•m
(71 ± 9 lbf•in)

8 ± 1 N•m
(71 ± 9 lbf•in)

NEW 3.3 ± 0.2 N•m

NEW
(29 ± 2 lbf•in)
NEW

4.5 ± 0.5 N•m

(40 ± 4 lbf•in)

6.5 ± 0.5 N•m

(58 ± 4 lbf•in)

11.5 ± 1.5 N•m

(102 ± 13 lbf•in)
NEW

NEW = Component must be replaced when removed.

smr2017-331-103_a

4 https://brp-manuals.com/pwc_seadoo smr2017-331
 Subsection XX (BODY (GTR-X))

VENTILATION

smr2017-331-104

smr2017-331
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Subsection XX (BODY (GTR-X))

SEAT

smr2017-331-105

6 https://brp-manuals.com/pwc_seadoo smr2017-331
 Subsection XX (BODY (GTR-X))

PROCEDURES 2. Remove inner shell retaining bolt.

GELCOAT, DECALS AND

CARPETS
For information and repair, refer to CLEANING
AND REPAIR subsection.

STORAGE COMPARTMENT
COVER
Removing the Storage Compartment
Cover smr2012-043-002_d

1. Open storage compartment cover. INNER SHELL RETAINING BOLT

2. Remove nuts and bolts securing storage com- 3. Remove inner shell retaining screws.
partment cover to hinge.

smr2012-043-002_a

INNER SHELL RETAINING SCREWS

4. Unlatch retaining tabs on both sides using a

smr2011-039-001_a
screwdriver.
1. Retaining nuts

3. Remove storage compartment cover.

Disassembling the Storage

Compartment Cover
Storage Compartment Cover Inner Shell
1. Remove BRP logo located at the front of cover.

smr2011-039-004

5. Disassemble inner shell from storage compart-

ment cover.
Storage Compartment Cover Latch
smr2012-043-001_a

1. BRP logo
1. Ensure that inner shell is removed.

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Subsection XX (BODY (GTR-X))

2. Remove latch by slightly pushing both retaining

holes toward the inside.

smr2012-043-002_b

TIGHTENING SEQUENCE

Installing the Storage Compartment

Cover
The installation is the reverse of the removal pro-
smr2011-039-005_a
cedure. However, pay attention to the following.
Assembling the Storage Compartment Tighten storage compartment cover retaining nuts
Cover to specification as per the following sequence.
The assembly is the reverse of the disassembly TIGHTENING TORQUE
procedure. However, pay attention to the follow- Storage compartment 8 N•m ± 1 N•m
ing. cover retaining nuts (71 lbf•in ± 9 lbf•in)
Tighten inner shell retaining bolt to specification.
TIGHTENING TORQUE
4 N•m ± 1 N•m
Inner shell retaining bolt
(35 lbf•in ± 9 lbf•in)

smr2011-039-007_a
smr2012-043-002_d TIGHTENING SEQUENCE
INNER SHELL RETAINING BOLT

Tighten inner shell retaining screws to specifica- STORAGE COMPARTMENT

tion as per the following sequence. COVER HINGE
TIGHTENING TORQUE Removing the Storage Compartment
Steps 1 1.8 N•m ± 0.2 N•m Cover Hinge
Inner shell to 8 (16 lbf•in ± 2 lbf•in) 1. Proceed with REMOVING THE STORAGE
retaining
screws Steps 9 2.8 N•m ± 0.2 N•m COMPARTMENT COVER and REMOVING THE
to 12 (25 lbf•in ± 2 lbf•in) LATERAL TRIM PANELS.
2. Remove the front deflector.

8 https://brp-manuals.com/pwc_seadoo smr2017-331
 Subsection XX (BODY (GTR-X))

Insert the steel hook on the lateral tab of hinge in

order to slightly load the spring.

smr2017-331-001_a

3. Remove screws securing storage compart-

ment cover hinge to deck.
smr2017-331-005

Tighten hinge retaining screws to specification as

per the following sequence.
TIGHTENING TORQUE
Storage compartment 8 N•m ± 1 N•m
cover hinge screws (71 lbf•in ± 9 lbf•in)

smr2017-331-002_a

HINGE RETAINING SCREWS

Installing the Storage Compartment

Cover Hinge
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Use a ø 6.5 mm (1/4 in) steel rod to make a hook smr2017-331-003_a

in order to lock the hinge. TIGHTENING SEQUENCE

TIGHTENING TORQUE
6.5 N•m ± 0.5 N•m
Deflector screws
(58 lbf•in ± 4 lbf•in)

GAUGE TRIM
Removing the Gauge Trim
1. Open storage compartment cover.
2. From underneath mirror, remove retaining
screws on both sides.

smr2011-039-009

TYPICAL

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Subsection XX (BODY (GTR-X))

smr2016-040-008_a

TOP OF GAUGE TRIM

smr2011-039-012_a

smr2011-039-015_a

BOTTOM OF GAUGE TRIM

smr2016-040-007_a

3. Hit with a sharp blow the front part of mirror
toward the rear to unlock it.
LATERAL TRIM PANEL
Removing the Lateral Trim Panel
1. Remove seat.
2. From inside storage compartment, remove
screws securing lateral trim panel to deck.

smr2012-043-003_a

4. Remove gauge trim from mirror support.

Installing the Gauge Trim

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Prior to inserting gauge trim into mirror support,
ensure that all tabs are properly aligned.
smr2017-331-004
LH TRIM PANEL SCREWS
3. From inside storage compartment, remove
plastic rivet securing lateral trim panel to deck.
4. Remove plastic rivet and retaining screw secur-
ing the rear portion of lateral trim panel.

10 https://brp-manuals.com/pwc_seadoo smr2017-331
 Subsection XX (BODY (GTR-X))

smr2012-043-004_a smr2012-043-005_a

1. Plastic rivet 1. Mirror support retaining rivets

2. Retaining screw
5. Remove fuel tank cap.
5. Slide and rotate panel toward the front to unlock
retaining tabs. 6. Place a clean cloth rag onto fuel tank tube.
7. Unlatch retaining tabs on both sides using a
screwdriver.
8. Unlatch retaining tabs on the top using a screw-
driver.
9. Remove mirror support by pulling it upwards.
10. Remove cloth rag and reinstall fuel tank cap.

smr2012-043-004_b
Installing the Lateral Trim Panel
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install new plastic rivets.
MIRROR SUPPORT
Removing the Mirror Support
1. Proceed with REMOVING THE LATERAL TRIM
PANEL. Refer to procedure in this subsection.
2. Remove the information center. Refer to IN-
FORMATION CENTER (GAUGE) subsection.
3. Remove steering column. Refer to STEERING
AND O.T.A.S. subsection.
4. Remove the following rivets securing mirror
support to deck.
REQUIRED TOOL
SUPERTANIUM DRILL BIT
3/16" (P/N 529 031 800)
WARNING
Fuel vapors are flammable and explosive
under certain conditions. Unless otherwise
noted, the fuel tank cap must always be in-
stalled on watercraft.
Installing the Mirror Support
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Prior to inserting mirror support into console, en-
sure that all tabs are properly aligned.
Install rivets upside down with washers on mirror
support top surface.
MIRRORS
Replacing the Mirror
1. Proceed with REMOVING THE GAUGE TRIM.
Refer to procedure in this subsection.
2. From inside gauge trim, slightly heat mirror.
3. Push at the back of mirror to remove it.
4. Properly clean gauge trim surface of any glue
residue.
5. Install mirror using adhesive tape at the back of
mirror.
6. Reinstall gauge trim as the reverse of removal.

smr2017-331
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Subsection XX (BODY (GTR-X))

CONSOLE
Removing the Console
1. Proceed with REMOVING THE MIRROR SUP-
PORT. Refer to procedure in this subsection.
2. Remove GLOVE BOX COVER. Refer to proce-
dure in this subsection.
3. Remove the following rivets securing console
to deck.

smr2011-039-028_a

3. Reinstall glove box cover as the reverse of re-

moval.

SEAT
Cleaning the Seat
For information, refer to CLEANING AND REPAIR
subsection.
smr2012-043-006_a Adjusting the Seat Latch
1. Console retaining rivets
NOTE: Apply threadlocker on threads of lock pin
4. Remove console by pulling it upwards. when the adjustment is required or when the lock
pin is removed. If a new lock pin is used, it is al-
Installing the Console ready coat with a threadlocker.
The installation is the reverse of the removal pro- 1. Loosen adjustment nut.
cedure. However, pay attention to the following. 2. Adjust lock pin height. Do not torque yet.
To ease installation of rivets located in glove box, 3. Position the lock pin longitudinally into the rear
proceed as follows: handle slot.
– Remove air intake silencer. Refer to AIR IN-
TAKE SYSTEM subsection. LOCK PIN POSITIONING
– Install rivets upside down with washers on con- MEASURE A 76 mm (2.992 in)
sole top surface. 30.7 mm ± 1.0 mm
MEASURE B
(1.209 in ± .039 in)
GLOVE BOX COVER
Replacing the Glove Box Cover
1. Open glove box cover.
2. Pull glove box cover upwards to release it from B
console hinge.

A
smr2016-040-004_a

A. 76 mm (2.992 in)
B. 30.7 mm ± 1.0 mm (1.209 in ± .039 in)

12 https://brp-manuals.com/pwc_seadoo smr2017-331
 Subsection XX (BODY (GTR-X))

4. Hold the lock pin in this position and tighten the TIGHTENING TORQUE
counter nut to specification.
8 N•m ± 1 N•m
Rear handle screws
TIGHTENING TORQUE (71 lbf•in ± 9 lbf•in)
8 N•m ± 1 N•m
Counter nut
(71 lbf•in ± 9 lbf•in)
5. Reinstall rear handle cover.
TIGHTENING TORQUE
5. Close the seat and readjust if required.
Rear handle cover 3.3 N•m ± 0.2 N•m
screws (29 lbf•in ± 2 lbf•in)
REAR HANDLE
Replacing the Rear Handle BUMPER
1. Remove seat.
Replacing the Bumper
2. Remove rear handle cover.
1. Remove screws securing front bumper.
2. Remove front bumper from deck.

smr2012-043-007_a

smr2016-040-005_a 1. Front bumper retaining screws

1. Rear handle cover retaining screws
2. Plastic darts
3. Remove screws securing rear handle to deck.
3. Remove screws securing both rear corner
bumpers.
4. Remove rear corner bumpers from deck.

smr2011-039-032_a

smr2016-040-006_a 1. Rear corner bumper retaining screws

1. Rear handle retaining screws
5. Slide side bumpers toward the rear to remove
4. Replace rear handle. them from deck.
6. Slide rear bumper toward the side to remove it
from deck.

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Subsection XX (BODY (GTR-X))

smr2012-043-011_a

7. Install new bumpers as the reverse of removal. smr2011-039-035_a

NOTE: Use soapy water to ease bumper installa- 3. Remove the following rivets securing ventila-
tion. tion duct housing to deck.
8. Tighten front bumper lower retaining screws to
specification.
TIGHTENING TORQUE
Front bumper lower 4.5 N•m ± 0.5 N•m
screws (40 lbf•in ± 4 lbf•in)

9. Tighten bumper retaining screws to specifica-

tion as per the following sequence.
TIGHTENING TORQUE
Rear corner
Steps 1 and 7 N•m ± 0.5 N•m
bumperslower
4 (62 lbf•in ± 4 lbf•in)
screws
Bumper
Steps 2-3 5.5 N•m ± 0.5 N•m
retaining smr2011-039-035_b
and 5 to 8 (49 lbf•in ± 4 lbf•in)
screws
4. If applicable, remove locking tie securing wiring
harness to ventilation duct.
5. Remove ventilation duct and its housing from
watercraft.
6. Reinstall parts as the reverse of removal.

smr2011-039-034_a

TIGHTENING SEQUENCE

VENTILATION DUCT
Replacing the Ventilation Duct
1. Proceed with REMOVING THE LATERAL TRIM
PANEL. Refer to procedure in this subsection.
2. Remove plastic rivet securing ventilation duct
to housing.
14 https://brp-manuals.com/pwc_seadoo smr2017-331
 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

BODY (GTS, GTI, GTR AND WAKE 155

MODELS)
SERVICE TOOLS
Description Part Number Page
SUPERTANIUM DRILL BIT 3/16"................................................... 529 031 800 ........................................... 12

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 14
XPS SYNTHETIC GREASE............................................................. 293 550 010 ..................................... 17–18

BODY PARTS NOMENCLATURE

1 2 3 4 5 6 7 8

9
smo2011-003-002_c

1. Storage compartment cover

2. Mirror support
3. Gauge trim
4. Lateral trim panel
5. Console
6. Glove box cover
7. Seat
8. Rear handle
9. Bumper

219100941-025
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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

STORAGE COMPARTMENT COVER

4.5 ± 0.5 N•m

(40 ± 4 lbf•in)

2 ± 0.2 N•m
(18 ± 2 lbf•in)

See
tightening
sequence
See tightening 8 ± 1 N•m
sequence (71 ± 9 lbf•in)
8 ± 1 N•m
(71 ± 9 lbf•in)

smr2012-041-100_a

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 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

BODY PARTS

1.4 ± 0.2 N•m

(14 ± 2 lbf•in)

NEW

2.5 ± 0.5 N•m

(22 ± 4 lbf•in)

NEW

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

Except Polytec hull

NEW = Component must be replaced when removed.

smr2017-330-101_a

219100941-025
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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

BODY PARTS
6.5 ± 0.5 N•m
(58 ± 4 lbf•in)
8 ± 1 N•m
(71 ± 9 lbf•in)

5.5 ± 0.5 N•m

(40 ± 4 lbf•in)

4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
7/8

11.5 ± 1.5 N•m

(102 ± 13 lbf•in)

8/8
6/8

4/8
5/8
3/8
2/8

5.5 ± 0.5 N•m

(49 ± 4 lbf•in) See procedure
1/8 5.5 ± 0.5 N•m
7 ± 0.5 N•m (49 ± 4 lbf•in)
(62 ± 4 lbf•in)
With Polytec hull
smr2017-330-100_a

4 https://brp-manuals.com/pwc_seadoo 219100941-025
 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

VENTILATION

smr2011-039-103

219100941-025
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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

SEAT

smr2011-039-104_a

6 https://brp-manuals.com/pwc_seadoo 219100941-025
 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

WAKEBOARD RACK AND WAKE PYLON

Wake 155

5 ± 0.5 N•m
(44 ± 4 lbf•in)
Loctite 5150
(silicon sealant)

8 ± 1 N•m
(71 ± 9 lbf•in)
NEW XPS
synthetic
grease

NEW
11.5 ± 1.5 N•m
(102 ± 13 lbf•in)
See tightening
sequence

See tightening sequence

NEW
11.5 ± 1.5 N•m
(102 ± 13 lbf•in)
See tightening
sequence

NEW = Component must be replaced when removed.

smr2016-039-107_a

219100941-025
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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

PROCEDURES
GELCOAT, DECALS AND
CARPETS
For information and repair, refer to CLEANING
AND REPAIR subsection.

STORAGE COMPARTMENT
COVER
Removing the Storage Compartment
Cover
1. Open storage compartment cover.
smr2011-039-002_b
2. Remove nuts and bolts securing storage com- 1. Inner shell retaining screws
partment cover to hinge. 2. Bolt

3. Unlatch both retaining tabs at the rear using a

screwdriver.

smr2011-039-001_a

1. Retaining nuts
smr2011-039-003_a

3. Remove storage compartment cover. RETAINING TABS

Disassembling the Storage 4. Unlatch retaining tabs on both sides using a

Compartment Cover screwdriver.
Storage Compartment Cover Inner Shell
1. Remove BRP logo located at the front of cover.
2. Remove inner shell retaining screws and bolt.

smr2011-039-004

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 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

5. Disassemble inner shell from storage compart- Installing the Storage Compartment
ment cover. Cover
Storage Compartment Cover Latch The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
1. Ensure that inner shell is removed.
Tighten storage compartment cover retaining nuts
2. Remove latch by slightly pushing both retaining
to specification as per the following sequence.
holes toward the inside.
TIGHTENING TORQUE
Storage compartment 8.0 N•m ± 1 N•m
cover retaining nuts (71 lbf•in ± 9 lbf•in)

smr2011-039-005_a

Assembling the Storage Compartment

Cover
The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow- smr2011-039-007_a

ing. TIGHTENING SEQUENCE

Tighten inner shell retaining screws and bolt to

specification as per the following sequence. STORAGE COMPARTMENT
TIGHTENING TORQUE
COVER HINGE
Inner shell retaining 2.0 N•m ± 0.2 N•m Removing the Storage Compartment
screws (18 lbf•in ± 2 lbf•in) Cover Hinge
Inner shell retaining 4.5 N•m ± 0.5 N•m 1. Proceed with REMOVING THE STORAGE
bolt and nut (40 lbf•in ± 4 lbf•in) COMPARTMENT COVER.
2. Use a ø 6.5 mm (1/4 in) steel rod to make a hook
in order to lock the hinge.

smr2011-039-006_a

TIGHTENING SEQUENCE

219100941-025
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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

Use the hook to lock the hinge.

Tighten hinge retaining screws to specification as
per the following sequence.
TIGHTENING TORQUE
Storage compartment 8.0 N•m ± 1 N•m
cover hinge screws (71 lbf•in ± 9 lbf•in)

smr2011-039-009

TYPICAL

smr2011-039-011_a

TIGHTENING SEQUENCE

GAUGE TRIM
Removing the Gauge Trim
smr2017-330-006_a
1. Open storage compartment cover.
DECK CROSS SECTION
2. From underneath mirror, remove retaining
3. Remove screws securing storage compart- screws on both sides.
ment cover hinge to deck.

smr2011-039-012_a
smr2011-039-008_a
RETAINING SCREWS
HINGE RETAINING SCREWS
3. Hit with a sharp blow the front part of mirror
Installing the Storage Compartment toward the rear to unlock it.
Cover Hinge
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

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 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

TIGHTENING TORQUE
1.6 N•m ± 0.2 N•m
Gauge trim screw
(14 lbf•in ± 2 lbf•in)

LATERAL TRIM PANEL

Removing the Lateral Trim Panel
1. Remove seat.
2. From inside storage compartment, remove
screws securing lateral trim panel to deck.

smr2011-039-013_a

4. Remove gauge trim from mirror support.

Installing the Gauge Trim

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Prior to inserting gauge trim into mirror support,
ensure that all tabs are properly aligned.

smr2011-039-017_a

RETAINING SCREWS

3. From inside storage compartment, remove

plastic rivets securing lateral trim panel to
deck.

smr2011-039-014_a

TOP OF GAUGE TRIM

smr2011-039-018_a

PLASTIC RIVETS

4. Remove plastic rivets securing the rear portion

of lateral trim panel.

smr2011-039-015_a

BOTTOM OF GAUGE TRIM

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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

4. Remove the following rivets securing mirror

support to deck.
REQUIRED TOOL
SUPERTANIUM DRILL BIT
3/16" (P/N 529 031 800)

smr2011-039-020_a

PLASTIC RIVETS

5. Slide panel toward the front to unlock retaining

tabs.

smr2011-039-023_a

1. Mirror support retaining rivets

5. Remove fuel tank cap.

6. Place a clean cloth rag onto fuel tank tube.
7. Unlatch retaining tabs on both sides using a
screwdriver.

smr2011-039-022_a

Installing the Lateral Trim Panel

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install new plastic rivets.
TIGHTENING TORQUE
3.5 N•m ± 0.5 N•m
Panel screw
(31 lbf•in ± 4 lbf•in)
smr2011-039-024_a

1. Side retaining tabs

MIRROR SUPPORT 8. Unlatch retaining tabs on the top using a screw-
Removing the Mirror Support driver.
1. Proceed with REMOVING THE LATERAL TRIM
PANEL. Refer to procedure in this subsection.
2. Proceed with REMOVING THE INFORMATION
CENTER. Refer to INFORMATION CENTER
(GAUGE) subsection.
3. Remove steering column. Refer to STEERING
subsection.

12 https://brp-manuals.com/pwc_seadoo 219100941-025
 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

2. Remove GLOVE BOX COVER. Refer to proce-

dure in this subsection.
3. Remove the following rivets securing console
to deck.

smr2011-039-025_a

1. Top retaining tab

9. Remove mirror support by pulling it upwards.

10. Remove cloth rag and reinstall fuel tank cap.
smr2011-039-026_a

WARNING 1. Console retaining rivets

Fuel vapors are flammable and explosive

under certain conditions. Unless otherwise
noted, the fuel tank cap must always be in-
stalled on watercraft.

Installing the Mirror Support

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Prior to inserting mirror support into console, en-
sure that all tabs are properly aligned.
Install rivets upside down with washers on mirror
support top surface.

MIRRORS smr2011-039-027_a

1. Console retaining rivets

Replacing the Mirror
1. Proceed with REMOVING THE GAUGE TRIM.
Refer to procedure in this subsection.
2. From inside gauge trim, slightly heat mirror.
3. Push at the back of mirror to remove it.
4. Properly clean gauge trim surface of any glue
residue.
5. Install mirror using adhesive tape at the back of
mirror.
6. Reinstall gauge trim as the reverse of removal.
CONSOLE
Removing the Console
1. Proceed with REMOVING THE MIRROR SUP-
PORT. Refer to procedure in this subsection.
4. Remove console by pulling it upwards.
Installing the Console
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
To ease installation of rivets located in glove box,
proceed as follows:
– Remove air intake silencer. Refer to AIR IN-
TAKE SYSTEM subsection.
– Install rivets upside down with washers on con-
sole top surface.
GLOVE BOX COVER
Replacing the Glove Box Cover
1. Open glove box cover.

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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

2. Pull glove box cover upwards to release it from

console hinge.

smr2011-039-029_a

A. 24.0 mm ± 1.0 mm (.945 in ± .039 in)

B. 30 mm ± 1.0 mm (1.181 in ± .039 in)
smr2011-039-028_a
4. Hold the lock pin in this position and tighten the
3. The installation is the reverse of the removal counter nut to specification.
procedure. TIGHTENING TORQUE
8.0 N•m ± 1 N•m
SEAT Counter nut
(71 lbf•in ± 9 lbf•in)
Cleaning the Seat
5. Close the seat and readjust if required.
For information, refer to CLEANING AND REPAIR
subsection.
REAR HANDLE
Adjusting the Seat Latch Replacing the Rear Handle
NOTE: Apply LOCTITE 243 (BLUE) (P/N 293 800 060) 1. Remove seat.
on threads of lock pin when the adjustment is re-
quired or when the lock pin is removed. If a new 2. Remove screws securing rear handle to deck.
lock pin is used, it is already coat with a thread-
locker.
1. Loosen adjustment nut.
2. Adjust lock pin height. Do not torque yet.
3. Position the lock pin longitudinally into the rear
handle slot.
LOCK PIN POSITIONING
MEASURE A MEASURE B
24.0 mm ± 1.0 mm 30 mm ± 1.0 mm
(.945 in ± .039 in) (1.181 in ± .039 in)

smr2011-039-030_a

1. Rear handle retaining screws

3. Replace rear handle.

4. Tighten rear handle screws to specification.
TIGHTENING TORQUE
8.0 N•m ± 1 N•m
Rear handle screws
(71 lbf•in ± 9 lbf•in)

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 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

BUMPER Installing the Bumper

Removing the Bumper The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
1. Remove screws securing front bumper.
Make sure the double face tape on the bumper is
2. Remove front bumper from deck. still sticky.
Tighten front bumper lower retaining screws to
specification.
TIGHTENING TORQUE
Front bumper lower 4.5 N•m ± 0.5 N•m
screws (40 lbf•in ± 4 lbf•in)

Tighten bumper retaining screws to specification

as per the following sequence.
TIGHTENING TORQUE
Rear corner
7 N•m ± 0.5 N•m
1-4 bumper center
(62 lbf•in ± 4 lbf•in)
screws
smr2011-039-031_a

1. Front bumper retaining screws 2-3-5 Lateral bumper 5.5 N•m ± 0.5 N•m
6-7-8 end screws (49 lbf•in ± 4 lbf•in)
3. Remove screws securing both rear corner
bumpers.
4. Remove rear corner bumpers from deck.

smr2011-039-034_a

TIGHTENING SEQUENCE

smr2011-039-032_a
1. Rear corner bumper retaining screws
5. Pull on bumpers to remove them from deck.
VENTILATION DUCT
Replacing the Ventilation Duct
1. Proceed with REPLACING THE LATERAL TRIM
PANEL. Refer to procedure in this subsection.
2. Remove plastic rivet securing ventilation duct
to housing.

smr2017-330-005_a

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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

smr2010-046-006_a

1. Lateral arms screws

smr2011-039-035_a
Remove bolts at the bottom of wake pylon.
3. Remove the following rivets securing ventila-
tion duct housing to deck.

smr2010-046-007_a

1. Wake pylon bottom bolts

Remove bolts securing the wake pylon support to

body.
smr2011-039-035_b

4. If applicable, remove locking tie securing wiring

harness to ventilation duct.
5. Remove ventilation duct and its housing from
watercraft.
6. Reinstall parts as the reverse of removal.

WAKE PYLON (WAKE)

Removing the Wake Pylon
Open the seat.
Remove both lateral arms. smr2010-046-008_a

1. Wake pylon support bolts

Lift the wake pylon to disengage its bottom from

the body.
Slide the bottom of the wake pylon rearward to
remove the wake pylon from vehicle.

16 https://brp-manuals.com/pwc_seadoo 219100941-025
 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

Handle
Extend handle approximately 75 mm to 90 mm
(3 in to 3-1/2 in).

smr2010-046-009_a

Disassembling the Wake Pylon

Extend the handle completely.
smr2008-035-016_a
Turn the wake pylon upside down.
A. 75 mm to 90 mm (3 in to 3-1/2 in)
Move both ends of locking strap to disengage the
inner lock and free the handle. Insert two thin feeler gauges between handle
stem and extension tube.

smr2008-035-014_a

1. Locking strap end

2. Handle stem smr2008-035-017_a

1. Handle stem
Locking Strap 2. Feeler gauges
3. Extension tube
Using a screwdriver or any other suitable tool, de-
tach a side of the locking strap from retaining pin. Place a rag around the joint to catch balls and
spring.
Hold feeler gauges and pull the handle.

Assembling the Wake Pylon

Handle
Install a loose locking tie on handle stem.
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) on
each ends of spring.
Insert the spring in the handle stem hole.
Position a ball on each ends of spring.
Install a feeler gauge over each balls.
Tighten the locking tie in order to retain feeler
smr2008-035-015_a
gauges and balls.
1. Locking strap

Remove locking strap and the inner lock.

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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

smr2008-035-018_a
smr2008-035-021_a
1. Feeler gauges
2. Ball 1. Retaining pin
2. Locking strap
Apply XPS SYNTHETIC GREASE (P/N 293 550 010) in
Using a suitable tool, position the locking strap in
both recesses of the extension tube.
its groove.

smr2008-035-022_a

1. Locking strap
smr2008-035-019_a 2. Locking strap groove
1. Extension tube
2. Recesses Reinstall the wake pylon trim.
Slide the handle stem into the extension tube. Do not install the handle into wake pylon yet.
Remove feeler gauges and locking tie. Installing the Wake Pylon
Locking Strap Position the wake pylon on vehicle.
Remove the wake pylon trim. Install and secure wake pylon and lateral arms us-
ing previously removed fasteners and new elastic
stop nuts.

smr2008-035-020_a smr2010-046-010_a

1. Wake pylon trim screws 1. Bottom of wake pylon

2. Rubber washers
3. Flat washers
Install lock and insert the end of the locking strap 4. New elastic stop nuts
over the retaining pin.

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 Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

smr2010-046-011_a

1. Flat washers smr2017-330-001_a

2. New elastic stop nuts
1. Handlebar connector
2. O.T.A.S. connector (if equipped)
Tighten all nuts by hand.
Ensure base of wake pylon is well leaned against
body.
Tighten all nuts to specification as per the follow-
ing sequence.
TIGHTENING TORQUE
Nut securing wake pylon 8 N•m ± 1 N•m
to lateral arms (71 lbf•in ± 9 lbf•in)
Lateral arms and wake 11.5 N•m ± 1.5 N•m
pylon nuts (102 lbf•in ± 13 lbf•in)

smr2017-330-002_a

COOLANT RESERVOIR

smr2011-039-016_a

TIGHTENING SEQUENCE

Insert the handle into the wake pylon.

Move both ends of the locking strap forward to
fully insert the handle. smr2017-330-003_a

FUEL FILLER NECK CLAMP

BODY (WITH POLYTEC HULL) 4. Insert a clean cloth rag in the fuel tank nozzle.
Removing the Body 5. Remove the body flange screws.
1. Disconnect steering cable from steering col-
umn. Refer to STEERING.
2. Remove the bumpers. Refer to BUMPER sub-
sections.
3. Remove fasteners or disconnect parts as per
the following illustrations.

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Subsection XX (BODY (GTS, GTI, GTR AND WAKE 155 MODELS))

Install and tighten rear screws first.

Tighten the screws to specification.
TIGHTENING TORQUE
5.5 N•m ± 0.5 N•m
Body flange screws
(49 lbf•in ± 4 lbf•in)

Reinstall other parts.

NOTE: Make sure to remove the cloth rag in the
fuel tank nozzle.

smr2017-330-004

6. Remove the body.

Installing the Body

Make sure the hull seal is good. Replace if re-
quired.
NOTE: Double face tape can be used to maintain
the hull seal in place while installing the body.

smr2017-332-015_a

DOUBLE FACE TAPE LOCATION

1. Bow
2. Stern
3. Seal joint

Make sure hull and body holes are aligned when

installing screws.
Use new insert to install the body.

smr2017-332-002

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 Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

HULL (GTS, GTI, GTR AND WAKE 155

MODELS)
SERVICE PRODUCTS
Description Part Number Page
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ................................. 8, 10–11
CLEAR SILICONE SEALANT ......................................................... 296 000 309 ..................................... 13, 15
LOCTITE 5900 ............................................................................... 293 800 066 ................................. 8, 10–11

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Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

Models equipped with 900 ACE engine and Wake 155

219100941-027-105_a

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 Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

GTI SE 130, GTI SE 155, GTI LTD, GTR and GTR-X

If equipped

219100941-027-103_a

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Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

Models equipped with 900 ACE engine

Clear silicone 14.5 ± 1.5 N•m
sealant (129 ± 13 lbf•in) 17.5 ± 1 N•m
NEW (155 ± 9 lbf•in)

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

17.5 ± 1 N•m
(155 ± 9 lbf•in)
Clear silicone
sealant NEW

7 ± 2 N•m
(62 ± 18 lbf•in)
NEW
8 ± 1 N•m
(71 ± 9 lbf•in)
NEW
Loctite
5900

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 425

NEW = Component must be replaced when removed.

219100941-027-102_a

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 Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

Wake 155 models

17.5 ± 1 N•m
Clear silicone (155 ± 9 lbf•in) 8 ± 1 N•m
14.5 ± 1.5 N•m (71 ± 9 lbf•in)
sealant (129 ± 13 lbf•in) Loctite 425
NEW

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

Clear silicone 17.5 ± 1 N•m

sealant (155 ± 9 lbf•in)
NEW

9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 5900

Loctite 5900
9 ± 1 N•m
(80 ± 9 lbf•in)

NEW = Component must be replaced when removed.

219100941-027-104_a

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Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

GTI SE 130, GTI SE 155, GTI LTD, GTR and GTR-X

14.5 ± 1.5 N•m

(129 ± 13 lbf•in)
NEW

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)

Loctite 425
8 ± 1 N•m
(71 ± 9 lbf•in)

Clear silicone 17.5 ± 1 N•m

sealant (155 ± 9 lbf•in)
NEW

8 ± 1 N•m
(71 ± 9 lbf•in)
NEW 9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 5900

6.5 ± 0.5 N•m

(58 ± 4 lbf•in)
NEW = Component must be replaced when removed.
219100941-027-101_a

6 https://brp-manuals.com/pwc_seadoo 219100941-027
 Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

3.5 ± 0.5 N•m

(31 ± 4 lbf•in)
NEW NEW
25 ± 1 N•m
(20 ± 1 lbf•ft)

Refer to procedure
Loctite 5900
NEW
27 ± 1 N•m
(20 ± 1 lbf•ft)

9 ± 1 N•m
(80 ± 9 lbf•in)

NEW
27 ± 1 N•m
(20 ± 1 lbf•ft)
NEW
27 ± 1 N•m
(20 ± 1 lbf•ft)

NEW
27 ± 1 N•m
(20 ± 1 lbf•ft)

Loctite 5900 NEW

Refer to procedure Loctite 567 9 ± 1 N•m
(pipe sealant) (80 ± 9 lbf•in)
NEW = Component must be replaced when removed.
219100941-027-100_a

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Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

PROCEDURES
HULL
Repairing the Hull
For hull repair, refer to CLEANING AND REPAIR
subsection in the appropriate shop manual.

Replacing the Hull

smr2017-332-003_a
The hull is sold separately and may be replaced if
damage is deemed too severe. 2. Remove inlet grate.
NOTICE The following list is not exhaustive Cleaning the Inlet Grate
and represents the general order in which to
proceed with hull replacement. Carefully scrape off all excess sealant from inlet
grate, jet pump support and hull.
Remove the following components: Clean ride plate and hull surface with BRP HEAVY
1. Deck. Refer to BODY. DUTY CLEANER (P/N 293 110 001) to eliminate
2. Battery. grease, dust and sealant residue. Clean fitting
3. Jet pump. Refer to JET PUMP. threads.
4. Drive shaft. Refer to DRIVE SHAFT.
Installing the Inlet Grate
5. Air intake silencer. AIR INTAKE SYSTEM.
1. Apply LOCTITE 5900 (P/N 293 800 066) on the in-
6. Engine. Refer to ENGINE REMOVAL AND IN-
let grate all around the front screw hole and on
STALLATION.
the edge that make contact with the jet pump
7. Remaining cooling system components. Refer support.
to COOLING SYTEM.
8. Remaining exhaust system components. Re-
fer to EXHAUST SYSTEM.
9. Remaining fuel system components. Refer to
FUEL SYSTEM.
10.Electrical harness.
11.Steering cable. Refer to STEERING subsection
12.Remaining hull components.
Reverse steps for reassembling.
Refer to INSTALLING THE BODY in BODY sub-
section for hull seal installation.
NOTE: If a new hull is installed, perform a flame
smr2017-332-021_a
treat where required, to increase the adhesion of
the Loctite 5900. 2. Install new inlet grate retaining screws and nut
at the proper location.
INLET GRATE INLET GRATE SCREWS
Removing the Inlet Grate LOCATION SCREW SIZE
1. Remove inlet grate retaining screws using an Front M8 x 45
impact tool. Discard screws, and nut.
Rear M8 x 16

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 Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

smr2017-332-004
smr2011-041-001_c

SCREW LOCATION
1. Front 6. Remove coolant hose fittings from the ride
2. Rear plate.
3. Tighten screws to the specified torque and se- NOTICE If possible, remove the hose fittings
quence. from the ride plate before removing the ride
TIGHTENING TORQUE plate. If fittings cannot be removed, proceed
with care when removing the ride plate.
First step
INLET Hand tighten 7. Using an impact tool, remove nuts and screws
(1-4)
GRATE
Second step 27 N•m ± 1 N•m and discard nuts.
SCREWS
(5-8) (20 lbf•ft ± 1 lbf•ft)

smr2016-217-001_a

TIGHTENING SEQUENCE

RIDE PLATE
Removing the Ride Plate
smr2011-041-002_a
1. Remove the deck. Refer to BODY subsection. 1. Ride plate retaining screws
2. Remove inlet grate. Refer to procedure in this
subsection.
3. Remove jet pump. Refer to JET PUMP.
4. Drain cooling system. Refer to COOLING SYS-
TEM.
5. From inside the hull, disconnect coolant hoses
from the ride plate.

smr2017-332-005

RIDE PLATE RETAINING NUTS

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Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

8. Install a low height hydraulic bottle jack and 2

steel plates between ride plate and hull as per
following illustration.

smr2011-047-001_a

SEALANT APPLICATION

3. Install both hose fittings on the ride plate.

Tighten to the specified torque.
smr2009-043-036_a

TYPICAL TIGHTENING TORQUE

1. Hydraulic bottle jack
2. Steel plates 9 N•m ± 1 N•m
Hose fittings
(80 lbf•in ± 9 lbf•in)
9. Start pumping the hydraulic jack slowly.
10. Using a sharp knife, carefully cut the sealant 4. Position ride plate on hull and thread new nuts
around the ride plate edges. by hand.
11. Pump the hydraulic jack slowly to pry the ride 5. Position inlet grate and thread new screws 5
plate from the hull. turns by hand. Refer to INLET GRATE in this
subsection.
Cleaning the Ride Plate 6. Tighten screws and nuts to the specified torque
Carefully scrape off all excess sealant from ride and sequence.
plate and hull. TIGHTENING TORQUE
Clean ride plate and hull surface with BRP HEAVY First step (1-6) Hand tighten
DUTY CLEANER (P/N 293 110 001) to eliminate Ride plate
grease, dust and sealant residue. Clean fitting nuts Second step 25 N•m ± 1 N•m
threads. (7-12) (18 lbf•ft ± 1 lbf•ft)

Installing the Ride Plate

1. Install seals on ride plate.

smr2016-217-002_a

RIDE PLATE TIGHTENING SEQUENCE

7. Tighten inlet grate screws to the specified

torque and sequence. Refer to INLET GRATE
smr2017-332-016
in this subsection.
2. Apply LOCTITE 5900 (P/N 293 800 066) sealant as 8. Remove the excess sealant.
illustrated.

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 Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

9. Smooth the sealant in the gap between the ride

plate and the hull.

smr2017-332-006

3. Remove jet pump support retaining nuts and

washers.
smr2017-332-017_a

GAP BETWEEN RIDE PLATE AND HULL

smr2017-332-007

smr2017-332-018_a 4. Pull jet pump support off the hull.

CROSS CUT - SIDE VIEW
1. Ride plate
2. Hull
3. Smoothed sealant
10. Reinstall coolant hoses on ride plate fittings.
NOTICE Make sure the coolant hose clamp
screws do not rub on any component.
11. Fill and bleed cooling system and carry out a
leak test. Refer to COOLING SYSTEM sub-
section.
12. Install all remaining parts. Refer to the appli-
cable procedures.
5. Note the alignment shims location.
NOTICE Alignment shims have to be rein-
stalled at the same location.
Cleaning the Jet Pump Support
Scrape off all excess sealant from jet pump sup-
port, ride plate, and hull.
Inspect pump support for cracks or other damage.
Clean jet pump support and hull surface with BRP
HEAVY DUTY CLEANER (P/N 293 110 001) to elimi-
nate grease, dust, and sealant residue.

Installing the Jet Pump Support

JET PUMP SUPPORT
Removing the Jet Pump Support
1. Remove the ride plate. Refer to procedure in
this subsection.
2. Disconnect hoses from jet pump support.
1. Make sure sealant contact areas are clean and
dry.
NOTE: If a new jet pump support is installed, per-
form a flame treat to increase the adhesion of the
Loctite 5900.
2. Apply LOCTITE 5900 (P/N 293 800 066) on the jet
pump support as shown.

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Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

smr2017-332-007_a

JET PUMP SUPPORT TIGHTENING SEQUENCE

8. Remove excess sealant.

9. Smooth the sealant in the gap between the jet
pump support and the hull.
219100941-027-003_a

SEALANT APPLICATION

smr2017-332-019_a

GAP BETWEEN JET PUMP SUPPORT AND HULL

219100941-027-004_a

SEALANT APPLICATION

3. Insert the studs in the jet pump support square

holes.
4. Slide the alignment shims on the studs.
5. Position the jet pump support against the hull.
6. Inside the hull, thread all 4 retaining nuts. smr2017-332-020_a

CROSS CUT - REAR VIEW

7. Tighten retaining nuts to the specified torque 1. Hull
and sequence. 2. Jet pump support
3. Smoothed sealant
TIGHTENING TORQUE
10. Reinstall other removed parts. Refer to appro-
Jet pump support 25 N•m ± 1 N•m priate subsections for procedures.
retaining nuts (18 lbf•ft ± 1 lbf•ft)

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 Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

FIXED REAR SPONSONS

NOTE: Removal and installation procedure for RH
and LH sponson is similar.

Removing the Fixed Rear Sponson

From inside hull, hold sponson nuts while remov-
ing sponson retaining bolts and washers.

smr2017-332-010_a

TYPICAL

4. Insert a bolt with washer through each hole and

install the sponson against the hull.
smr2017-332-008
5. From inside hull, secure each bolt with a
TYPICAL washer and a new elastic stop nut.
6. Tighten nuts to specification.
Installing the Fixed Rear Sponson
TIGHTENING TORQUE
1. Clean any residues of silicone sealant on hull
and sponsons. 17.5 N•m ± 1 N•m
Sponson retaining nuts
(155 lbf•in ± 9 lbf•in)
2. Apply CLEAR SILICONE SEALANT (P/N 296 000
309) on back side of sponson around screw
holes. BAILERS
Two bailers (one each side), draw water from the
bilge when watercraft is in operation.
The bailers are connected to syphon tubes
mounted in the jet pump venturi that use the
jet pump thrust to create a vacuum.

Inspecting the Bailer

Check opening in the bailer to see if they are ob-
structed. Clean if necessary.

smr2017-332-009_a

TYPICAL

3. Apply a small amount of silicone into each hull

hole.

smr2017-332-011

Check if the hole on each bailer hose elbow fitting

is obstructed. Clean elbow fittings if necessary.

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Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

smr2009-043-033

DRAIN NECK REMOVAL

smr2005-005-001_a
Installing the Drain Plug Neck
TYPICAL The installation is the reverse of the removal pro-
1. Elbow fitting holes
cedure. However, pay attention to the following.
NOTE: When repositioning the bailer hose el- TIGHTENING TORQUE
bows, attach them at the highest available point
on the exhaust hose. 9 N•m ± 1 N•m
Drain plug neck
(80 lbf•in ± 9 lbf•in)
DRAIN PLUGS
NOTE: Each drain plug on the stern are each con-
BOW AND STERN EYELETS
nected to a bailer. When watercraft is off the wa- Accessing Bow Eyelet
ter, the drain plugs can be removed to manually
Open the front storage cover.
drain the bilge.

Removing the Drain Plug Neck Accessing Stern Eyelets

1. Unscrew the drain plug. from the drain neck.
2. Use a small flat screwdriver to release the ar-
row head from the drain plug neck.
Remove seat.
Removing Eyelets
1. Unscrew and discard both bow eyelet retaining
nuts.
NOTE: Keep all washers for installation. Bow and
stern eyelets have the same hardware layout.

smr2017-332-013

TYPICAL
219100941-027-001_a
2. Pull eyelet off the hull.
3. Insert a ratchet extension in the square hole,
then unscrew the drain neck from the hull.

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 Subsection XX (HULL (GTS, GTI, GTR AND WAKE 155 MODELS))

Installing Eyelets (GTI SE 130, GTI SE TIGHTENING TORQUE

155, wake 155, and GTI LTD)
14.5 N•m ± 1.5 N•m
The installation is the reverse of the removal pro- Eyelet retaining nuts
(128 lbf•in ± 13 lbf•in)
cedure. However, pay attention to the following.
REQUIRED PRODUCT LOCATION
CLEAR SILICONE
SEALANT (P/N 296 Inside hull, around holes
000 309)

smr2017-332-014_a

TIGHTENING TORQUE
14.5 N•m ± 1.5 N•m
Eyelet retaining nuts
(128 lbf•in ± 13 lbf•in)

Installing Eyelets (GTI, GTI SE 90, and

GTS models)
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.

219100941-027-002_a

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 Subsection XX (CLEANING AND REPAIR)

CLEANING AND REPAIR

SERVICE TOOLS – OTHER SUPPLIER
Description Part Number Page
3MTM DURAMIXTM SEMI-RIGID PLASTIC REPAIR ....................... 04240 ............................................. 8
CHEM-PAK® PER-FIX BLACKTM POLYPROPYLENE ..................... 7500A ............................................. 8

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 5900 ............................................................................... 293 800 066 ....................................... 8, 10
XPS ALL PURPOSE CLEANER ..................................................... 219 701 709 ............................................. 1

PROCEDURES Do not use any silicone-based protectants. They

will extract the plasticizers, leaving the vinyl hard
WATERCRAFT CLEANING and brittle, and eventually cracking will occur.

Body and Hull RECOMMENDED PRODUCTS

Occasionally, wash the hull and various body com- XPS ALL PURPOSE CLEANER
1.
ponents with water and soap (use only mild de- (P/N 219 701 709)
tergent). Remove any marine organisms from en- 2. Dish Soap (Dawn or Ivory)
gine and/or hull. Apply non-abrasive wax such as
3. Fantastik
silicone wax.
4. 3M Citrus Cleaner
NOTICE Never clean fiberglass and plastic
parts with strong detergent, degreasing agent, 5. 303 Protectant
paint thinner, acetone, or other strong chemi-
cal or petroleum type cleaner.
Stains may be removed from the seat and fiber-
glass using XPS ALL PURPOSE CLEANER (P/N 219
701 709) or the equivalent.

WARNING
Never apply plastic or vinyl protector on the
carpets or seat as the surface will become
slippery and the occupants may slip off the
watercraft.

Cleaning the Seat

For general purpose cleaning, use XPS ALL PUR-
POSE CLEANER (P/N 219 701 709), Vinyl Finish
Cleaner, Fantastik or warm water with a mild dish
soap such as Dawn or Ivory. Gently scrub with a
small soft bristle brush.
For dirt build-up, use XPS ALL PURPOSE CLEANER
(P/N 219 701 709), Vinyl Finish Vinyl Cleaner or an
equivalent. Let soak for approximately 10 min-
utes, then gently scrub with a soft bristle brush.
For specific stain removal, refer to your cleaning
and care card.

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Subsection XX (CLEANING AND REPAIR)

Vinyl Cleaning Recommendations for Special Pull decal slowly and when necessary apply more
Stains heat to ease removal on the area that has to be
TYPE OF STEP STEP STEP
peeled off.
ACTION
STAIN 1 2 3 If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch
Ballpoint ink* E B A
A. Medium-soft brush,
while pulling off, stop heating and wait a few sec-
Chewing gum D A — onds to let it cool, then peel it off.
warm soapy water,
Coffee, tea, rinse/dry. Installing Decal (with a Protective Film on
B — —
chocolate Back Side)
Pen D B — These decals usually contain written information
— B. Vinyl Finish Cleaner, (e.g.: warning) and are used on gelcoat or metal.
Grease D B
rinse/dry.
Household soil A B — Using isopropyl alcohol, clean the surface and dry
thoroughly.
Ketchup A B —
Using a pencil and the decal as a template, mark
— C. One (1) tablespoon
Latex paint A B the area where decal will be located.
of ammonia, one-fourth
Lipstick A B — (1/4) cup of hydrogen Remove half of the decal back protective film and
peroxide, three-fourth align decal with marks. Start sticking it from cen-
Mildew or wet (3/4) cup of water,
leaves*
C B A ter and remove the other half of the film to stick
rinse/dry. it completely. Carefully squeegee decal beginning
Motor oil B — — at center and working outward using, firm, short,
Oil-based paint D B — overlapping strokes.
D. Wipe or scrape off Installing Decal (with a Protective Film on
Permanent
E B C excess (chill gum with Both Sides)
marker*
ice before hand).
Spray paint B B — These decals usually contain graphics and are
used on gelcoat or plastic.
Suntan lotion A B —
E. Denatured alcohol, Installation on Gelcoat
Tar/asphalt D B —
rinse/dry. Using isopropyl alcohol, clean the surface and dry
Yellow mustard A B C thoroughly.
*Suntan lotion, tree pollen, wet leaves and some other products Using a pencil and the decal as a template mark
can contain dyes that stain permanently. the area where decal will be located.
All cleaning methods must be followed by a thor- For better adhesion a dry application is recom-
ough rinse with warm water. mended, however, to ease decal installation a
mild solution of soapy water can be sprayed over
Certain household cleaners, powdered abrasives, surface where decal will be installed.
steel wool and industrial cleaners can cause dam-
age and discoloration and are not recommended. Remove back protective film from decal and align
Dry cleaning fluids and lacquer solvents should decal with marks. When well aligned squeegee
not be used as they will remove printed pattern decal beginning at center and working outward us-
and gloss. Waxes should be used with caution ing firm, short, overlapping strokes.
as many contain dyes or solvents that can perma- Remove front protective film once decal has ad-
nently damage the protective coating. hered to hull.

Decals Installation on Plastic surface

Removing Decal
Using a heat gun warm up one end of decal for a
few seconds until decal can roll off when rubbing
with your finger.
NOTE: When heating near light surfaces, duct
tape should be applied to protect the surface.
Otherwise the light color could become a yellow-
ish color.
2 https://brp-manuals.com/pwc_seadoo
Clean surface with isopropyl alcohol and dry thor-
oughly.
Using a pencil and the decal as a template, mark
the area where decal will be located.
NOTICE Do not use soapy water to locate de-
cal on plastic parts.
smr2017-335
 Subsection XX (CLEANING AND REPAIR)

Remove back protective film from decal and care- You can order on the web site and get confirma-
fully align decal with marks. When well aligned tion of your order within hours. Quick, reliable ser-
squeegee decal beginning at center and working vice is what is offered to all BRP dealers around
outward using firm, short, overlapping strokes. the world.
Remove front protective film once decal has ad- There are many services on this web site to
hered. make your ordering quick and informative. Or
you can call Gelcote International directly with
Carpets any question pertaining to gelcoat. Service, value
and knowledge is what you can expect when you
Cleaning Carpet
call Gelcote International.
To clean the carpets, use 3M™ Citrus Base
Cleaner or the equivalent. See the manufac- Gelcote International Ltd
turer's instructions. 174 Colonnade Road Suite 29
Ottawa, Ontario
Removing the Carpet Canada, K2E 7J5
Unstick a carpet corner. Phone: (613) 225-2177
Pull carpet vigorously to remove the carpet and its Phone: (877) 435-2683 (Toll Free)
glue from body. Fax: (613) 225-5297
To remove the remaining glue from body, use a Web Site: www.gelcoat.ca
plastic or rubber spatula. Scrape remaining glue E-mail: info@gelcote.com
with spatula.
NOTE: Do not use any products (alcohol, ace- WARNING
tone, thinner, etc.) or heat the remaining carpet Protect skin, wear gloves when in contact
glue. Chemical reactions make glue very hard to with resin, hardeners and gelcoat. A barrier
remove. skin cream may also be used. Do not expose
area to open flame or lit cigarette. Some of
Installing Carpet the materials are flammable. Protect eyes,
Clean body surface with isopropyl alcohol and dry wear safety glasses when grinding, sanding
thoroughly. or spraying. Use a dust mask when sanding
Install new carpet. or grinding. When spraying wear a respirator
or paint mask. Always read warning labels
on products.
FRP DECK (FIBER REINFORCED
POLYESTER) TOOLS
The deck is constructed of chopped fiberglass, Air mask Power sander
saturated with resin. It is sprayed on the layer Polishing pad Putty knife
of gelcoat along with pieces of fiberglass mat. Cover sheets Safety glasses
The cloth and the woven roving are added when
required in some areas. The inside finish is rough Heavy-duty polisher Sanding block
and grey. Paint brush Scissors
Plastic container (mixing) Spray gun
Gelcoat Repair Information Plastic film Stirring stick
All liquid gelcoat and repair kits can be purchased Plastic squeegee White cloths
directly from Gelcote International Ltd. BRP does
not distribute these products. MATERIALS
NOTE: Fiberglass repair kit is also available Acetone Epoxy filler
through automotive or marine suppliers. Masking tape
Cabosil
Gelcote International Ltd web site has all the Sea-
Cardboard Liquid gelcoat
Doo personal watercraft and sport boat gelcoat
colors. Fine compound Medium compound
(white) (white)
Fiberglass cloth Polyester resin

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Subsection XX (CLEANING AND REPAIR)
Fiberglass mat 24-grit sanding disks
Gelcoat putty Wax
Sandpaper (100-grit, 220-grit, 320-grit, 400-grit,
600-grit, 1000-grit)
Air Bubbles Repair
Possible cause:
– Air pocket trapped between layers of laminate
and gelcoat.
Preparation of Surface
Remove all of the damaged gelcoat surrounding
the air bubble with a putty knife or preferably a
carbide grinding tip. Make sure all loose and weak
areas are completely removed. Sand a small area
of the gelcoat surface with 220-grit sandpaper. If
needed, sand the cavity itself. These areas must
have a rough surface to allow the gelcoat putty to
bond properly.
Filling the Cavity
The prepared surface must be cleaned with ace-
tone on a cloth. Use a gelcoat repair kit. Follow
the mixing instructions in the kit when preparing
the gelcoat putty.
Carefully mix the required amount while making
sure there are no air bubbles in the mixture. With
a putty knife, fill the repair area and cover with
plastic film. Curing time may depend on tempera-
ture, amount of putty and percentage of catalyst.
After 2 hours, press lightly on the surface with
fingers to test the hardness. When the area be-
comes hard, remove the plastic film.
Sanding
Begin by sanding the patch with 320-grit sandpa-
per until you come close to the original surface.
Remove dust with a water soaked cloth and con-
tinue sanding with a 400-grit wet paper. Finish
wet sanding with a 600-grit to remove deeper
scratches. If needed you can wet sand with finer
grit paper such as 1000-grit.
Buffing and Waxing
Polish the surface using a heavy duty polisher with
a polishing pad. Make sure the pad is free of dirt
or you may damage the gelcoat. Carefully begin
polishing with a white medium compound. Finish
off using a fine compound. While polishing, pay
close attention to avoid overheating the surface.
4 https://brp-manuals.com/pwc_seadoo
Blisters Repair
Possible causes:
– Insert catalyst
– Improper catalyst/gelcoat ratio.
A blister is a visible bump on the watercraft sur-
face that may not necessarily come right through
the gelcoat layer. In the case of only a few blis-
ters, follow the same repair procedure as for air
bubbles. If they are numerous and in close con-
centration, spray liquid gelcoat to achieve proper
repair. This procedure is covered in MINOR GEL-
COAT FRACTURES.
Minor Repairs
Possible causes:
– Flexing of fiberglass laminate
– Gelcoat thickness
– Direct result of impact.
In case of fractures which have not penetrated
past the gelcoat layer, the repair concerns the gel-
coat only. If flex cracking or impact are evident,
then additional reinforcement may be necessary.
This subject will be covered in COMPOUND
FRACTURES.
Preparing the Surface
Small Fractures: Open the cracks up with a
sharp triangular can opener or preferably a car-
bide tipped die grinder. The V groove will provide
a good bonding area for the gelcoat. With 220-grit
sandpaper, sand the sides of the notched out ar-
eas.
Numerous Fractures: Using a grinder with a
24-grit disk, remove the gelcoat. Sand the area
edge with 220-grit sandpaper.
Filling the Repair Area
Small Fractures: Refer to the same procedure as
in the AIR BUBBLES.
Numerous Fractures Over Large Surface: Pre-
pare the area for spray application of liquid gel-
coat. Wipe down the surface with acetone. Mask
the area off to protect the watercraft from over-
spray.
Mix the needed quantity of gelcoat and catalyst
according to suppliers recommendations. The
gelcoat can be thinned with acetone up to 10%.
If it needs more consistency you can add cabosil.
Make sure that the air supply is free of oil, dirt and
water.
smr2017-335

Test spray the gelcoat mixture on paper to verify
its consistency and pattern. You may have to ap-
ply 5 or 6 coats to cover the area properly. Over-
lap each coat further than the last, leaving at least
30 seconds between passes. Avoid trying to coat
the surface with only a few heavy coats, this will
not allow the gelcoat to dry properly.
Apply a coat of polyvinyl alcohol (PVA) to seal off
the air and protect the gelcoat surface from dust.
PVA speeds up the curing process because gel-
coat will not cure properly when exposed to air.
Sanding
Wash the polyvinyl alcohol off with water. De-
pending on the size of the area repaired, you can
either sand by hand as per previous procedure
or you may use an air sander. Sand the surface
down with progressively finer grits of sandpaper
until the desired finish is achieved.
Polishing and Waxing
Polish the surface using a heavy duty polisher with
a polishing pad. Make sure the pad is free of dirt
or you may damage the gelcoat. Carefully begin
polishing with a white medium compound. Finish
off using a fine compound. While polishing, pay
close attention to avoid overheating the surface.
Major Repairs
Possible causes:
– Thickness of fiberglass laminate
– Direct result of impact.
Major repairs are those that have gone past the
gelcoated surface and in through the layers of
fiberglass laminate. Two types of repairs have to
be performed. The first is to restore the struc-
tural integrity of the damaged area. Fracture
types can vary from a simple crack to a large
hole. Usually, fiberglass reinforcement becomes
necessary, especially if the fracture can be at-
tributed to weakness. The final part of the repair
is the gelcoating, which cannot be done until the
interior and exterior laminate surfaces have been
repaired.
Outside: Remove the damaged gelcoat and fiber-
glass with a 24-grit disk using a power sander.
Grind outward at least 2 inches from the fracture
to allow the patch to bond to strong material.
Cut enough pieces of fiberglass mat necessary
to build up the area. The pieces should be cut
so they overlap each other by at least a half inch.
For a smoother finish, the last layer should be
fiberglass cloth. If the fracture is small enough all
you may have to do is fill the area with an epoxy
filler.
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Subsection XX (CLEANING AND REPAIR)
Inside: For the interior repair, you can grind more.
This will allow for more fiberglass material which
will strengthen the area. If the fracture opening is
too large after surface preparation, you may need
a backing support to cover the opening. Cut alter-
nating pieces of fiberglass mat and cloth in over-
lapping sizes.
Patching the Repair Area
Outside: The outside should be done first. Wipe
clean the area with acetone on a cloth, then mask
off area. For a small crack use an epoxy filler in
the same way you would use gelcoat repair putty.
When laying up a larger area you will use mat,
cloth and fiberglass resin and catalyst. Use a clean
container to mix the resin, mix only what you will
need. Follow the recommended catalyst ratio.
Using a clean paintbrush, brush the mixed resin
on the surface. Place the smallest piece of mat
over the fracture and then wet out the mat. Fol-
low with the remaining pieces of mat and final
layer of cloth. While wetting the pieces make sure
you work the air bubbles out and saturate all the
pieces evenly. Try to work quickly, you may only
have 15 or 20 minutes. You may clean the brush
with acetone.
Wait until the repair has hardened before moving
on to the interior repair. If the size of the opening
is too large for the pieces to maintain the proper
shape, you will have to use a backing support. It
is a shaped piece of cardboard that fits flush to the
interior surface and has a plastic layer on the repair
side. It is held in place by tape or a support.
Inside: Wipe down the area with acetone on a
cloth. Apply the same procedure as for outside
repair when laminating the alternating pieces
of fiberglass material. If a backing support was
used, remove it before starting the repair. After
the area has hardened, remove sharp edges of
material from surface. If required paint the sur-
face.
Sanding
Outside: This surface will have to be prepared for
application of gelcoat. The size of the area will de-
termine the gelcoating procedure to be used. Re-
fer to the MINOR REPAIRS.
Polishing and Waxing
Refer to the POLISHING AND WAXING in MINOR
REPAIRS.
5
Subsection XX (CLEANING AND REPAIR)

CM-TEC HULL (CLOSED MOLD Australia, South Pacific and Asia

TECHNOLOGY) ATL COMPOSITES
P.O. Box 2349/Southport 4215
The CM-Tec hull is a compound of polyester based Queensland, Australia
gelcoat, fiberglass, and polyester resin, all com-
pressed in a closed mold. The inner skin finish is Tel.: +61 7-5563-1222,
smooth and white. Fax: +61 7-5563-1585
E-mail: info@atlcomposites.com
Hull Repairs New Zealand, South Pacific and Asia
The repair procedures of the CM-Tec hull is the ADHESIVE TECHNOLOGIES LTD.
same as a standard gelcoat and fiberglass com- 17 Corbans Ave./Box 21-169, Henderson
posite deck. Either a standard polyester based Auckland, New Zealand
fiberglass repair kit or a two-part epoxy repair kit,
such as the WEST SYSTEM®, can be used for a Phone: 64-9-838-6961
Fax: 64-9-836-4849
major repair.
E-mail: enquiries@adhesivetechnologies.co.nz
To repair a hull with a standard polyester based
fiberglass repair kit, refer to FRP DECK.
POLYTEC DECK
An epoxy repair kit can be purchased directly from
WEST SYSTEM. The Polytec deck is made of a single thick skin of
Go to www.westsystem.com. injected polypropylene reinforced with fiberglass.
On this site you will find complete repair instruc- Fixing scratches
tions, click on HOW TO USE.
Perform a flame treatment on any body or hull sur-
Also training videos, tools and several products face.
are available on the web site.
A flame treatment:
Consumer Assistance – Is a quick movement over an area or part with
North and South America a blow torch
WEST SYSTEM – Should never be too intense. The part should
102 Patterson Ave. never melt to the point that it looks polished
P.O. Box 665 Bay City, MI 48707-0665 – Will burn any excess plastic around the scratch
– Will burn the oxygen on the surface of the part.
Phone: 989 684-7286
Toll free: 866 937-8797 The flame treatment will also restore the original
Fax: 989 684-1374 color of the plastic, painting is not necessary.
Europe, Middle East, Africa and Asia
WESSEX RESINS AND ADHESIVES LIMITED
Cupernham House, Cupernham Lane, Romsey
England SO51 7LF

Phone: 44-1-794-521-111
Fax: 44-1-794-517-779
E-mail: info@wessex-resins.com

WEST SYSTEM is a registered trademark of Gougeon Brother, Inc

6 https://brp-manuals.com/pwc_seadoo smr2017-335
 Subsection XX (CLEANING AND REPAIR)

POLYTEC HULL
The Polytec hull is made of a single thick skin of injected polypropylene reinforced with fiberglass.
The shaded areas are:
– Important structural sections of the hull
– Areas where clearance is tight.
The hull is not repairable in these areas.

sbs2014-010-009_a

SPARK SERIES

smr2017-332-001_a

GTS, GTI 90 AND GTI SE 90

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Subsection XX (CLEANING AND REPAIR)

Required Tools
DESCRIPTION

Drill bit 5 mm (13/64 in)

Counter bore 12.5 mm (1/2 in)

Grinding burr 3 mm (1/8 in)

Required Parts
DESCRIPTION PART NUMBER QUANTITY
Aluminum foil tape Available locally As needed
±150 grit sand paper Available locally As needed
M5 X 20 screw Available locally 2
M5 retaining nut Available locally 2

Stainless steel rivet 293 150 043 As needed

Stainless steel rivet washer 234 052 600 As needed

Fiber reinforced laminate with (polyester
Available locally As needed
or epoxy) resin
LOCTITE 5900 (P/N 293
Sealant As needed
800 066)
Black epoxy1 Available locally As needed
Multipurpose black paint (metal-wood-plastic)2 Available locally As needed
1 BRP has tested 3MTM DURAMIXTM SEMI-RIGID PLASTIC REPAIR (P/N 04240) with good results.
2 BRP has tested CHEM-PAK® PER-FIX BLACKTM POLYPROPYLENE (P/N 7500A) with good results.

3MTM and DuramixTM are trademarks of 3M Corporation

Chem-Pak® and Per-Fix BlackTM are trademarks of Chem-Pak Incorporated

8 https://brp-manuals.com/pwc_seadoo smr2017-335
 Subsection XX (CLEANING AND REPAIR)

Pop Rivet Procedure with Fiber Reinforced Laminating

NOTICE Cracks longer than 400 mm (15-1/4 in) should not be repaired.
If repairing a hole in the hull, read REPAIRING A HOLE in this subsection.

Mould a Fiber Reinforced Backing Skin

1. Lay down the aluminum foil tape over the area to be repaired. Extend the aluminum foil tape 150 mm
(6 in) beyond the crack.
2. Prepare the fiber reinforced backing skin using 3 skins of laminate.
2.1 Apply the mat, the resin and the catalyst over the aluminum foil tape.
2.2 Allow to dry.
3. Remove the newly moulded backing skin and trim to 50 mm (2 in) beyond the crack.
4. Remove the aluminum foil tape.

sbs2014-010-011_a

Drill Holes for Rivets

1. With the drill bit, drill a hole at each end of the crack to prevent it from growing longer.
2. Measure and mark drilling locations on the exterior of hull around crack.
3. Drill the hull at marked locations.
4. Install the backing skin over the area to be repaired from the interior.
5. Drill one hole in the backing skin using the hull as a template.
6. Install screw and retaining nut to prevent the backing skin from moving.
7. Repeat steps 5 and 6.
8. Drill all remaining holes.
9. Remove backing skin.
10. Counter bore all the drilled holes 3.5 mm (9/64 in) into the hull from the exterior.

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Subsection XX (CLEANING AND REPAIR)

sbs2014-010-001_a

sbs2014-010-005_a

1. Hole at end of crack

2. Mark drilling locations
3. Drill hull
4. Counter bore
A. 15 mm (19/32 in) from centerline of crack
B. 30 mm (1-13/64 in) from next hole

Seal the Backing Skin on Hull

1. Sand hull (inside only) to roughen surface.
2. Clean the area to be repaired with isopropyl alcohol.
3. Apply LOCTITE 5900 (P/N 293 800 066) on the inside hull around the drilled holes and the crack.
4. Align the backing skin over holes from interior. Push it against the sealant.
5. Use the screws and retaining nuts to hold the backing skin in place.
6. Install rivets from the exterior and washers from the interior.
7. Remove retaining nuts and screws.
8. Install remaining rivets with washers.
9. Apply LOCTITE 5900 (P/N 293 800 066) from the interior over the washers.

sbs2014-010-006_a

Exterior Aesthetics
1. Grind a 5 mm (5/32 in) wide by 3.5 mm (9/64 in) deep groove in the crack from the exterior.
2. Fill the groove and the counter bored holes with epoxy.

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 Subsection XX (CLEANING AND REPAIR)

3. Remove the excess epoxy before it cures.

sbs2014-010-007_a

4. Apply a thin layer of paint or perform a flame treatment.

sbs2014-010-008_a

Repairing a Hole
NOTICE Holes larger than 150 mm (6 in) in diameter should not be repaired.
If the broken piece is in your possession, ensure a good fit in its original location. If needed, rework some
portions of the piece to make it fit perfectly.
NOTE: If the broken piece is not in your possession, it is recommended to replace the hull.
1. Grind a chamfer of 3 mm (1/8 in) wide by 3 mm (1/8 in) deep around the exterior perimeter of the bro-
ken piece.
2. Repeat step 1 to the hole in the hull.
3. Tape the broken piece to the exterior of the hull so that it fits flush with the inside.
4. Continue with MOULD A FIBER REINFORCED BACKING SKIN in this subsection.

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Subsection XX (CLEANING AND REPAIR)

sbs2014-010-010_a

12 https://brp-manuals.com/pwc_seadoo smr2017-335
 Subsection XX (900 ACE (PWC))

900 ACE (PWC)

ENGINE

ROTAX® 900 ACE and 900 ACE HO

Engine type 4-stroke, Double Over Head Camshaft
(DOHC), dry sump, liquid cooled
Number of cylinders 3
12 valves (self adjusting hydraulic
Number of valves
valve lifters)
Bore 74 mm (2.91 in)
Stroke 69.7 mm (2.74 in)
Displacement 899.31 cm³ (54.88 in³)
Compression ratio 11.0 : 1
Maximum HP RPM 8000 (± 100) RPM
Intake valve opening 5° ATDC
Intake valve closing 40° ABDC
Exhaust valve opening 40° BBDC
Exhaust valve closing 5° BTDC
4.958 mm to 4.972 mm
New
Intake (.1952 in to .1957 in)

Valve stem Service limit 4.940 mm (.1945 in)

diameter 4.956 mm to 4.970 mm
New
Exhaust (.1951 in to .1957 in)
Service limit 4.940 mm (.1945 in)
5.0 mm to 5.012 mm
New
Valve guide diameter (.1969 in to .1973 in)
Service limit 5.050 mm (.1988 in)
New 0.005 mm (.0002 in)
Valve out of round
Service limit 0.060 mm (.0024 in)
New 31.35 mm (1.2343 in)
Valve spring free length
Service limit 29.50 mm (1.1614 in)
1.05 mm to 1.35 mm
New
Intake (.0413 in to .0531 in)

Valve seat Service limit 1.70 mm (.0669 in)

contact width 1.25 mm to 1.45 mm
New
Exhaust (.0492 in to .0571 in)
Service limit 1.80 mm (.0709 in)
Cylinder head warpage Service limit 0.15 mm (.0059 in)
73.95 mm to 73.966 mm
New
Piston measurement (2.9114 in to 2.912 in)
Service limit 73.920 mm (2.9102 in)

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Subsection XX (900 ACE (PWC))

ENGINE
0.037 mm to 0.067 mm
New
Piston/cylinder wall clearance (.0015 in to .0026 in)
Service limit 0.080 mm (.0031 in)
1st Upper compression ring, rectangular
Piston ring type 2nd Lower compression ring, tapered face
3rd Oil scraper ring
0.20 mm to 0.35 mm
New
Rectangular (.0079 in to .0138 in)
Service limit 1.20 mm (.0472 in)
0.30 mm to 0.50 mm
New
Ring end gap Taper-face (.0118 in to .0197 in)
Service limit 1.20 mm (.0472 in)
0.20 mm to 0.70 mm
New
Oil scraper ring (.0079 in to .0276 in)
Service limit 1.20 mm (.0472 in)
0.030 mm to 0.066 mm
New
Rectangular (.0012 in to .0026 in)
Service limit 0.120 mm (.0047 in)

Ring/piston 0.020 mm to 0.056 mm

New
groove Taper-face (.0008 in to .0022 in)
clearance Service limit 0.120 mm (.0047 in)
0.010 mm to 0.040 mm
New
Oil scraper ring (.0004 in to .0016 in)
Service limit 0.150 mm (.0059 in)
74.003 mm to 74.017 mm
Cylinder bore New
(2.9135 in to 2.9141 in)
Maximum New 0.030 mm (.0012 in)
Cylinder taper
Service limit 0.050 mm (.002 in)
Maximum New 0.008 mm (.0003 in)
Cylinder out of round
Service limit 0.03 mm (.0012 in)
25.967 mm to 25.980 mm
New
PTO (1.0223 in to 1.0228 in)
Camshaft
bearing Service limit 25.940 mm (1.0213 in)
journal 22.957 mm to 22.970 mm
diameter New
MAG/Center (.9038 in to .9043 in)
Service limit 22.930 mm (.9028 in)
26.00 mm to 26.021 mm
New
PTO (1.0236 in to 1.0244 in)
Camshaft Service limit 26.05 mm (1.0256 in)
holder bore
diameter 23.00 mm to 23.021 mm
New
MAG/Center (.9055 in to .9063 in)
Service limit 23.05 mm (.9075 in)

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 Subsection XX (900 ACE (PWC))

ENGINE

Camshaft 0.020 mm to 0.054 mm

New
journal radial All (.0008 in to .0021 in)
play Service limit 0.080 mm (.0031 in)
38.35 mm to 38.55 mm
New
Intake (1.51 in to 1.518 in)

Camshaft Service limit 38.33 mm (1.509 in)

lobe height 38.35 mm to 38.55 mm
New
Exhaust (1.51 in to 1.518 in)
Service limit 38.33 mm (1.509 in)
35.990 mm to 36.006 mm
New
Crankshaft bearing journal diameter (1.4169 in to 1.4176 in)
Service limit 35.960 mm (1.4157 in)
Crankshaft radial play Service limit 0.08 mm (.003 in)
35.979 mm to 35.995 mm
New
Crankshaft pin diameter (1.416 in to 1.417 in)
Service limit 35.969 mm (1.416 in)
0.120 mm to 0.353 mm
New
Crankshaft axial play (.0047 in to .0139 in)
Service limit 0.450 mm (.0177 in)
MAG 0.050 mm (.002 in)
Crankshaft deflection (maximum) CENTER 0.050 mm (.002 in)
PTO 0.080 mm (.003 in)
Crankshaft plain bearing inside
Service limit 36.08 mm (1.4205 in)
diameter
Connecting rod big end diameter Service limit 36.06 mm (1.4197 in)
Connecting rod big end radial play Service limit 0.08 mm (.0031 in)
0.100 mm to 0.352 mm
New
Connecting rod big end axial play (.0039 in to .0139 in)
Service limit 0.450 mm (.0177 in)
17.010 mm to 17.020 mm
New
Connecting rod small end diameter (.6697 in to .6701 in)
Service limit 17.060 mm (.6717 in)
16.996 mm to 17.000 mm
New
Piston pin diameter (.6691 in to .6693 in)
Service limit 16.986 mm (.6687 in)
Connecting rod small end radial play Service limit 0.04 mm (.0016 in)
Chain guide groove depth Service limit 1 mm (.039 in)

AIR INTAKE SYSTEM

Intake spark arrestor Tubular, wire screen

R900ACE_MY17-010
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Subsection XX (900 ACE (PWC))

LUBRICATION SYSTEM
Dry sump. Replaceable
Type
oil filter
BRP Rotax paper type,
Oil filter
replaceable
Capacity (oil change with filter) 1.8 L (1.9 qt (U.S. liq.))
Capacity (dry fill) 3.5 L (3.7 qt (U.S. liq.))
XPS 4-Stroke synthetic
Engine oil blend oil (Summer)
(P/N 293 600 121)
Recommended
(if not available, use a
SAE 5W 40 or 10W 40 API
service SN synthetic oil)
80 kPa (11.6 PSI) @ idle
speed
Engine oil pressure at 100°C (212°F) Minimum
350 kPa (51 PSI) @ 6000
to 8000 RPM
New 46 mm (1.811 in)
Oil pressure regulator spring free length
Service limit 45 mm (1.772 in)
Oil pump radial clearance Service limit 0.25 mm (.0098 in)
Oil pump axial clearance Service limit 0.15 mm (.0059 in)

COOLING SYSTEM
Type Closed loop cooling system
Ethyl glycol and distilled
water (50%/50%) or coolant
specifically formulated
for aluminum engines
Coolant For best performance
use BRP LONG
LIFE ANTIFREEZE
(P/N 219702685) or
(P/N 619590204)
Thermostat opening temperature 80°C (176°F)
Monitoring beeper setting 100°C (212°F)

FUEL SYSTEM
Fuel injection type Multipoint fuel injection
46 mm heated Dell'Orto
Throttle body type throttle body with iTC
(intelligent Throttle Control)
Fuel injector Quantity 3
Idle speed Normal idle 1400 ± 100 RPM

ELECTRICAL SYSTEM
Magneto generator output 420 W @ 6000 RPM @ 14 V
Magneto stator resistance
0.1 to 1 @ 20°C (68°F)
(between any pair of yellow wires)

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 Subsection XX (900 ACE (PWC))

ELECTRICAL SYSTEM
IDI (Inductive Digital
Ignition type
Ignition)
Variable (electronically
Ignition timing
control)
Make and type NGK CR8EB
Spark plug .70 mm to 0.80 mm
Gap
(.028 in to .031 in)
Primary 0.80 to 0.97
Ignition coil
Secondary 9.5 to 13.5
Engine speed limiter setting 8300 RPM

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 Subsection XX (ENGINE)

ENGINE
ENGINE
ROTAX® 1503 4-TEC™, 4-stroke,
Engine type Single Over Head Camshaft
(SOHC)
130 100 kW @ 7000 RPM
Declared Power 155 106 kW @ 7500 RPM
230 169 kW @ 8000 RPM
130
Naturally-Aspirated
Induction 155
230 Supercharged intercooled
Number of cylinders 3
12 valves with hydraulic lifters
Number of valves
(no adjustment)
Bore 100 mm (3.9 in)
Stroke 63.4 mm (2.5 in)
Displacement 1 493.8 cm³ (91 in³)
130
10.6:1
Compression ratio 155
230 8.4:1
130
0° BTDC
Intake valve opening 155
230 -2° BTDC
130
50° ABDC
Intake valve closing 155
230 42° ABDC
130
50° BBDC
Exhaust valve opening 155
230 48° BBDC
130
0° ATDC
Exhaust valve closing 155
230 -8° ATDC
5.961 mm to 5.975 mm
New
Intake (.2347 in to .2352 in)
Service limit 5.930 mm (.2335 in)
Valve stem diameter
5.946 mm to 5.960 mm
New
Exhaust (.2341 in to .2346 in)
Service limit 5.930 mm (.2335 in)
5.994 mm to 6.018 mm
New
Valve guide inner diameter (.236 in to .2369 in)
Service limit 6.060 mm (.2386 in)

RTX1503ACEMY18-011
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Subsection XX (ENGINE)

ENGINE
New 41.02 mm (1.615 in)
Inner
Valve spring free Service limit 38.80 mm (1.528 in)
length New 45.45 mm (1.789 in)
Outer
Service limit 43.00 mm (1.693 in)
1.10 mm to 1.30 mm
New
Intake (.043 in to .051 in)

Valve seat contact Service limit 1.60 mm (.063 in)

width 1.25 mm to 1.55 mm
New
Exhaust (.049 in to .061 in)
Service limit 1.80 mm (.071 in)
20.007 mm to 20.020 mm
New
Rocker arm inner diameter (.7877 in to .7882 in)
Service limit 20.050 mm (.7894 in)
19.980 mm to 19.993 mm
New
Rocker arm shaft diameter (.7866 in to .7871 in)
Service limit 19.970 mm (.7862 in)
Cylinder head maximum warpage Service limit 0.100 mm (.004 in)
Upper compression ring,
1st
rectangular
Piston ring type Lower compression ring,
2nd
tapered face
3rd Oil scraper ring
0.30 mm to 0.50 mm
New
Rectangular (.012 in to .02 in)
Service limit 1.20 mm (.047 in)
0.35 mm to 0.55 mm
New
Ring end gap Taper-face (.014 in to .02 in)
Service limit 1.20 mm (.047 in)
0.35 mm to 0.50 mm
New
Oil scraper ring (.014 in to .02 in)
Service limit 1.20 mm (.047 in)

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 Subsection XX (ENGINE)

ENGINE
0.025 mm - 0.070 mm
New
Rectangular (.001 in - .0028 in)
Service limit 0.150 mm (.0059 in)
0.015 mm - 0.060 mm
New
Taper-face (.0006 in - .0024 in)
Service limit 0.150 mm (.0059 in)
Ring/piston groove
clearance 130 0.020 mm - 0.055 mm
155 (.0008 in - .0022 in)
New
0.010 mm to 0.180 mm
230
Oil scraper ring (.0004 in to .0071 in)
130
0.150 mm (.0059 in)
Service limit 155
230 0.200 mm (.0079 in)
130 99.951 mm to 99.969 mm
155 (3.9351 in to 3.9358 in)
New
Piston measurement 99.931 mm to 99.949 mm
230
(3.9343 in to 3.935 in)
Service limit 99.900 mm (3.9331 in)
130 0.024 mm to 0.056 mm
155 (.0009 in to .0022 in)
New
Piston/cylinder wall clearance 0.044 mm to 0.076 mm
230
(.0017 in to .003 in)
Service limit 0.100 mm (.0039 in)
New maximum 0.036 mm (.0014 in)
Cylinder taper
Service limit 0.100 mm (.0039 in)
New maximum 0.008 mm (.0003 in)
Cylinder out of round (maximum)
Service limit 0.025 mm (.001 in)
24.919 mm to 24.940 mm
New
Front (.9811 in to .9819 in)

Camshaft bearing Service limit 24.890 mm (.9799 in)

journal diameter 39.892 mm to 39.905 mm
New
PTO and center (1.5706 in to 1.5711 in)
Service limit 39.880 mm (1.5701 in)
25.000 mm to 25.013 mm
New
Front (.9843 in to .9848 in)

Camshaft bearing Service limit 25.050 mm (.9862 in)

inner diameter 40.000 mm to 40.020 mm
New
PTO and center (1.5748 in to 1.5756 in)
Service limit 40.050 mm (1.5768 in)

RTX1503ACEMY18-011
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Subsection XX (ENGINE)

ENGINE
31.540 mm to 31.740 mm
New 130 (1.2417 in to 1.2496 in)
155
Service limit 31.50 mm (1.2402 in)
Intake
30.513 mm to 30.713 mm
New
230 (1.2013 in to 1.2092 in)
Service limit 30.473 mm (1.1997 in)
Cam lobe height
31.430 mm to 31.630 mm
New 130 (1.2374 in to 1.2453 in)
155
Service limit 31.380 mm (1.2354 in)
Exhaust
30.630 mm to 30.830 mm
New
230 (1.2059 in to 1.2138 in)
Service limit 30.580 mm (1.2039 in)
Crankshaft deflection Maximum 0.05 mm (.002 in)
0.08 mm to 0.22 mm
New
Crankshaft axial clearance (.003 in to .009 in)
Service limit 0.35 mm (.014 in)
49.991 mm to 50.01 mm
New
Crankshaft bearing journal diameter (1.9681 in to 1.9689 in)
Service limit 49.950 mm (1.9665 in)
Crankshaft radial clearance Service limit 0.07 mm (.0028 in)
Crankshaft bearing inside diameter Service limit 50.10 mm (1.9724 in)
45.032 mm to 45.048 mm
New
Crankshaft pin diameter (1.7729 in to 1.7735 in)
Service limit 45.029 mm (1.7728 in)
Crankshaft pin radial clearance Service limit 0.090 mm (.0035 in)
Connecting rod big end diameter Service limit 45.080 mm (1.7748 in)
Connecting rod big end radial play Service limit 0.090 mm (.0035 in)
0.100 mm to 0.352 mm
New
Connecting rod big end axial play (.0039 in to .0139 in)
Service limit 0.500 mm (.0197 in)
23.010 mm to 23.020 mm
New
Connecting rod small end diameter (.9059 in to .9063 in)
Service limit 23.070 mm (.9083 in)
Connecting rod small end radial play Service limit 0.080 mm (.0031 in)
22.996 mm to 23.000 mm
New
Piston pin diameter (.9054 in to .9055 in)
Service limit 22.990 mm (.9051 in)
31.984 mm to 32.000 mm
New
Balancer shaft journal diameter (1.2592 in to 1.2598 in)
Service limit 31.950 mm (1.2579 in)
Balancer shaft bearing inside diameter Service limit 32.11 mm (1.2642 in)

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 Subsection XX (ENGINE)

ENGINE
Balancer shaft radial clearance Service limit 0.070 mm (.0028 in)
0.02 mm to 0.25 mm
New
Balancer shaft axial clearance (.001 in to .01 in)
Service limit 0.35 mm (.014 in)
9 N•m to 14 N•m
New supercharger
(80 lbf•in to 124 lbf•in)
Supercharger clutch slipping moment
8 N•m to 12 N•m
Break-in supercharger
(71 lbf•in to 106 lbf•in)

AIR INTAKE SYSTEM

Tubular, wire screen, integrated
Intake spark arrester
in the intake manifold

LUBRICATION SYSTEM
XPS 4-stroke synthetic blend oil
(P/N 293 600 121) or a 10W40
Oil type mineral engine oil compatible
with wet clutches (JASO MA
certified oils)
Lubrication 3 L (3.2 qt (U.S. liq.))
Capacity oil change w/filter
5 L (5.3 qt (U.S. liq.)) total
Dry sump (2 oil pumps).
Type Replaceable oil filter.
Water-cooled oil cooler
Idle (cold) 448 kPa - 648 kPa (65 PSI - 87 PSI)
Oil pressure Idle (at 80°C (176°F)) Min. 228 kPa (33 PSI)
4000 - 7500 (at 100°C (212°F)) 400 kPa - 496 kPa (58 PSI - 72 PSI)

Oil pressure regulator outer compression New 60 mm (2.362 in)

spring free length Service limit 57 mm (2.244 in)

Limp home 130

Above 115°C (239°F)
Oil temperature sensor mode 155
activation 230 Above 120°C (248°F)
Outer and inner rotor clearance Service limit 0.25 mm (.0098 in)
Clearance between pump housing and
Service limit 0.1 mm (.004 in)
outer rotor

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Subsection XX (ENGINE)

COOLING SYSTEM
Type Closed loop cooling system
Ethylene-glycol / distilled water
mix (50%/50%). Use premix
Coolant coolant from BRP (Long life
antifreeze) or a coolant specially
formulated for aluminum engines

Thermostat (opening) 80°C (176°F)

Monitoring beeper setting 102°C (216°F)

FUEL SYSTEM
Multipoint fuel injection with
iTC (intelligent Throttle Control).
Fuel injection type
Single throttle body (62 mm)
with an actuator
386 kPa to 414 kPa
Fuel pressure
(56 PSI to 60 PSI)
Fuel injector Quantity 3
Idle speed 1750 ± 50 RPM (not adjustable)

ELECTRICAL SYSTEM
Magneto generator output 14V 420W @ 6000 RPM
Stator 0.1 to 1.0
Ignition system type IDI (Inductive Discharge Ignition)
Ignition timing Variable (electronically controlled)
Make and type NGK DCPR8E
Spark plug 0.80 mm to 0.90 mm
Gap
(.031 in to .035 in)
Primary 0.80 to 0.97
Ignition coil
Secondary N.A.
130 7850 RPM
Engine speed limiter setting 155 8100 RPM
230 8450 RPM

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 Subsection XX (VEHICLE (GTS, GTI, GTR AND WAKE 155 MODELS))

VEHICLE (GTS, GTI, GTR AND WAKE

155 MODELS)
COOLING SYSTEM
Type Closed loop cooling system
BRP long life antifreeze
Low silicate, extended life ethylene-glycol
Coolant premixed coolant (50%-50%) specifically
formulated for internal combustion
aluminum engines.
900 HO ACE Series 4.3 L (4.5 qt (U.S. liq.)) total
Cooling system capacity 1503 Series, 1503 NA
5.5 L (5.8 qt (U.S. liq.)) total
Series and 1500 HO ACE

Radiator cap opening pressure 90 kPa (13 PSI)

EXHAUST SYSTEM
D-Sea-Bel sound reduction system. Water
Type cooled/water injected (open loop). Direct
flow from jet pump
900 HO ACE Series 4 x 3.5 mm (.138 in) on exhaust pipe
Water injection in muffler All models except 900 3 x 3.5 mm (.138 in) on exhaust pipe and
HO ACE Series 1 x 3.5 mm (.138 in) on muffler

FUEL SYSTEM
Inside North America ((RON
87 recommended
+ MON)/2)
Fuel type
Outside North America
92 recommended
(RON)
Fuel tank (including reserve) 60 L (15.9 U.S. gal.)
Fuel tank reserve (from low level signal) approx. 12 L (3.2 U.S. gal.)

ELECTRICAL SYSTEM (900 HO ACE SERIES)

Battery 12 volt, 18 A.h.
Battery
Yuasa - YTX20HL
D.E.S.S. (Digitally Encoded Security System)
Anti-start system with selectable maximum vehicle speed
settings for learning key
F 1: Accessories 10 A
F 2: Start/stop Switch 5 A
Fuses
F 3: Battery 15 A
F 4: Charging 30 A

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Subsection XX (VEHICLE (GTS, GTI, GTR AND WAKE 155 MODELS))

ELECTRICAL SYSTEM (1503 SERIES, 1503 NA SERIES AND 1500 HO ACE)

Battery 12 volt, 18 A.h.
Battery
Yuasa - YTX20HL
RFDI D.E.S.S. (Radio Frequency
Identification Digitally Encoded
Anti-start system Security System) with selectable
maximum vehicle speed settings
for LK (learning key)
#1: Not used —
#2: Fuel Inj., Ing. Coils and Fuel Pump 15 A
#3: Bilge Pump (if equipped) 3 A
#4: Not used —
#5: Not used —

#6: Charge 30 A

#7: Cluster 5 A
Fuses
#8: Depth sounder (if equipped) 3 A
#9: iBR 30 A
#10: Start/Stop 3 A
#11: ECM 5 A
#12: Battery 30 A
#13: Diagnostic Tool 2 15 A
Diagnostic Tool 1, Accessory
#14: 15 A
connector

STEERING
Steering Fixed column
Steering nozzle pivoting angle 20°
O.T.A.S. (Off-Throttle Assisted Steering) (GTS models only) Electronically-controlled

PROPULSION
Type Axial flow single stage
Jet pump
Grease type Jet pump bearing grease (P/N 293 550 032)

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 Subsection XX (VEHICLE (GTS, GTI, GTR AND WAKE 155 MODELS))

PROPULSION
Rotation (seen from rear) Counterclockwise
GTI
GTI SE 11.5°/16°
GTS
GTI SE 130
Pitch GTI SE 155
11°/18°
GTI LTD 155
Wake 155
GTR
12°/17°
Impeller GTR-X
GTI
GTI SE 150 mm ± 0.06 mm (5.906 in ± .002 in)
GTS
GTI SE 130
Outside
GTI SE 155
diameter 155.5 mm ± 0.06 mm (6.122 in ± .002 in)
GTI LTD 155
Wake 155
GTR
161 mm ± 0.06 mm (6.339 in ± .002 in)
GTR-X
New 0 mm to 0.23 mm (0 in to .009 in)
Impeller/wear ring clearance
Wear limit 0.35 mm (.0138 in)
End play (new) 0
Impeller shaft
Side play 0
Coupling type Crowned splines, direct drive
Drive shaft
Deflection (max.) 0.5 mm (.02 in)
90 cm (3 ft) underneath the lowest
Minimum required water level for propulsion system
rear portion of hull

IBR AND VTS (EXCEPT GTS MODELS)

Intelligent Brake and Reverse activated by
a LH lever. Electronically-controlled iBR
Description
gate to provide brake, reverse, neutral
and forward position
Forward Approx. from +5° to -3°

Gate angle (from horizontal line Neutral Approx. -55°

of watercraft) Braking Approx. -70°
Reverse Approx. -70°
Electronically-controlled through the VTS
VTS system
control button with 2 preset positions
VTS range angle +6° / -0°
12 V, 75 A max. capacity. Reversible PWM
Actuator
(pulse-width modulation) motor

smr2017-333
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Subsection XX (VEHICLE (GTS, GTI, GTR AND WAKE 155 MODELS))

WEIGHT AND LOADING CAPACITY

GTS 286 kg (631 lb)
GTI
291 kg (642 lb)
GTI SE
GTI SE 130
GTI SE 155
Dry weight 359 kg (791 lb)
GTI Limited
155
GTR 367 kg (809 lb)
GTR-X 373 kg (822 lb)
Wake 155 363 kg (800 lb)
GTR-X 2
Number of passenger (driver incl.) All other
3
models
GTR-X 182 kg (401 lb)
Load limit (passenger and 10 kg (22 lb) luggage) All other
272 kg (600 lb)
models

DIMENSIONS

GTR-X 331.6 cm (130.6 in)

Overall length All other
336.8 cm (132.6 in)
models
Overall width 123.1 cm (48.5 in)
GTR-X 113.8 cm (44.8 in)
Overall height All other
111.8 cm (44 in)
models

MATERIALS
Impeller material Stainless steel
Impeller housing/stator Aluminum/aluminum
GTR-X CM-TEC process, composite
Deck All other
Fiberglass reinforced polypropylene
models
GTI
GTI SE Polytech process,
GTS (Fiberglass reinforced polypropylene)
Hull Wake 155
All other
CM-TEC process, composite
models
Inlet grate Aluminum
Steering cover Thermoplastic
Venturi Aluminum

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 Subsection XX (VEHICLE (GTS, GTI, GTR AND WAKE 155 MODELS))

MATERIALS
Nozzle Aluminum
Fuel tank Polyethylene
Seat Polyurethane/foam

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 Subsection XX (WIRING DIAGRAM INFORMATION)

WIRING DIAGRAM INFORMATION

GENERAL Terminal Identification on Connector
On the wiring diagram, a letter or a digit is used to
WIRING DIAGRAM LOCATION identify the terminal position in a connector.
The wiring diagrams are in the back cover pocket.

WIRING DIAGRAM CODES

Wire Color Codes

smr2015-009-002_a

1. Terminal position
smr2015-009-001_a

1. Wire main color On a connector, a letter or a digit is usually molded

2. Tracer (thin colored line)
on the connector to identify the terminal position.
General Wire Color Use
COLOR USE
Battery power (12 Vdc directly
RED
connected to battery)
Fused 12 Vdc power or switched
RED + tracer
power from relay
1 1
VIOLET or Fused 12 Vdc accessory power
VIOLET + tracer from fuse box
Alternating current (AC)
YELLOW
from magneto
BLACK Ground
WHITE/BEIGE CAN HI wires,
WHITE/BLACK CAN LO wires F04H6LA

TYPICAL
1. Wire identification numbers
Color Codes
COLOR CODES Terminal Identification on a Wiring
Diagram
CODE COLOR CODE COLOR
In-line connectors of wiring harnesses are identi-
BEIGE fied on the wiring diagram with their approximate
BG OR / OG ORANGE
(TAN) location and the following information.
BK BLACK PK PINK
BN BROWN RD RED
BU BLUE VT VIOLET
GN GREEN WH WHITE
GY GRAY YE YELLOW

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Subsection XX (WIRING DIAGRAM INFORMATION)

smr2015-009-003_a

TYPICAL
1. Connector location
2. Wire pin location in connector

Connectors Linked by a Dashed Line

Connectors may be divided into segments linked
by dashed lines, however, some segments of the
smr2012-047-004_a
same connector may be found elsewhere on the
TYPICAL
wiring diagram. 1. CAN wire
2. Wire origin
3. Destination terminal (as referenced at ECM)

Component Application
If a component in the wiring diagram is not appli-
cable to every vehicle model, or can be installed
as an option or accessory on certain models, the
component shall be enclosed in a dash line.
smr2015-009-003_b

TYPICAL
1. Connector identification and location
2. Connector pin number
3. Dashed line links connector segments as one

CAN Wire Circuit References

On the wiring diagram, CAN linked components
use the following coding.

smr2011-043-001_a

smr2015-009-004_a 1. Component(s) optional or applicable to certain models

2. Indicates each switch is a separate component
TYPICAL
1. CAN HI wire (x)
2. CAN LOW wire (o)
3. Wire destination
FB1 - G12 = : Terminal G12 in the fuse box no. 1

Corresponding CAN links are identified at fuse box

using the following coding.

2 https://brp-manuals.com/pwc_seadoo smr2016-044
 LEGEND

2018 SPARK
LINE TYPE COM DIAG TOOL
55 / 60 VOLTS WH = WHITE BK = BLACK 3 5 6 4 2 1
12 VOLTS SWITCHED RD = RED YE = YELLOW
12 VOLTS UNSWITCHED VT = VIOLET BG = BEIGE (TAN)

RD/BU

GY/PK
5 OR 3.3 VOLTS GN = GREEN BN = BROWN

BK

VT
DIGITAL SIGNAL GY = GREY BU = BLUE
AC VOLTAGE PK = PINK OG = ORANGE
POWER CONTROL
ANALOG SIGNAL
: JUNCTION POSITION (JT)
BRLS COMMUNICATION
: CAN HI WIRE
A-D GROUND : CAN LO WIRE
POWER GROUND

HALL HALL
SENSOR SENSOR

A C B D F E STEERING -3-
YE/WH

JT1 WH-BK
VT/WH
VT/BG
YE/BN

BK
BK

STEERING -2-
JT1 WH-BG

CAN LO

CAN HI
VT/BG
YE/BN

YE/WH
VT/WH

BK
BK

10 11 12 5 6 7
IBR -4-
iBR1 4
3
JT2 WH-BK IBR
2 EQUIPPED
IBR -3-
13
JT2 WH-BG ONLY
14
15

GY/PK
16
1
8

9
FUSE BOX (FB)

CLUSTER 3 / 4

JT1 WH-BG
5 / 9
JT1 WH-BK
6 / 10

2
4 / 8

CL
1 / 2
JT2 VT/GY
5 1 6 3 7 11 12

OTAS
EQUIPPED
ONLY

JT1 VT/GY

219100878-001

https://brp-manuals.com/pwc_seadoo
 2018 900 ACE/ 900 HO ACE
RD/BU
LINE TYPE LEGEND
YE/RD 55 / 60 VOLTS
WH = WHITE BK = BLACK
12 VOLTS SWITCHED
VTS SW.--SPORT-ECO SW. RD = RED YE = YELLOW
MODE / SET SW.--UP / DOWN SW. CRUISE OR SET 12 VOLTS UNSWITCHED VT = VIOLET BG = BEIGE (TAN)
START / STOP SW

GTS-GTI
5 OR 3.3 VOLTS
(NORMALY OPEN)
SPORT
(NORMALY OPEN) GN = GREEN BN = BROWN
DIGITAL SIGNAL GY = GREY BU = BLUE
ECO
AC VOLTAGE
PK = PINK OG = ORANGE
POWER CONTROL
BRLS
IBR
ANALOG SIGNAL
: JUNCTION POSITION (JT)
COMMUNICATION
: CAN HI WIRE
EQUIPPED 2 1 TAS A-D GROUND

RD/WH
YE/RD
: CAN LO WIRE
POWER GROUND
ONLY CLUSTER
2 1 DS
HALL
SENSOR
HALL
SENSOR
A C B B C A
WH/GN 14 17 OG/GN 1 2
BK/WH 15 18 BK/OG HALL HALL
COM DIAG TOOL
SENSOR SENSOR
YE/RD WH/BU 13 16 OG/BU
4 7 3 5 6 4 2 1
A C B D F E GY
+ - + -
YE/WH
VT/WH
VT/BG
YE/BN

5 6 8 1 19 20 9 2 3 11 12 10 BK

WH/BG
WH/BK
BK

RD/BU

GY/PK
BK

D A B C A C B D F E

BK

VT
WH/GY
BK/YE
BK
1 3

RD/WH
2 4 6 5

VT/YE
PK/BK
HIC 2

PK
JT BK
VT/BG
YE/BN

YE/WH
VT/WH

JT RD/WH JT VT
BK
BK

VT/YE

RD/WH

WH/BK
PK/BK

VT/YE
WH/BG
CAN LO

PK

BK
10 11 12 5 6 7
3 WH/BG JT2 WH/BG
CAN HI
iBR1 4 WH/BK JT2 WH/BK 1 19 12 2 3 11 20 6 9 5 13 15 14 16 18 17 4

VT/GY HIC 1
2 JT1 VT/GY

WH/BK

YE/GY
YE/BU
VT/YE

VT/GN
WH/BG

VT/BU
13

BK

BK
RD/WH

BK
14 STEERING -3-
15 JT1 WH-BK

JT1 WH/BG
JT1 WH/BK
16
STEERING -2-

JT BK
FB -D3-
RD/BK JT RD/BU JT1 WH-BG
1

BK
8

VT DIAG TOOL -6- IBR -4-

9
JT2 WH-BK IBR
ENGINE
1
GROUND IBR -3- EQUIPPED

ECM B-H2
JT2 WH-BG ONLY

PK-BK
VT
PK
BCD A

WH/BG
WH/GY

YE/RD

WH/BK
YE/GY
VT/GN

GY/PK
BG/PK

YE/BU
BK/YE

VT/BU
JT VT

BK

BK
BK

MOTOR ACTUATOR
FUEL LEVEL

WITH INTEGRATED
THROTTLE BODY
B-M1
SENSOR

B-D1

B-C2

B-C1
B-E4
B-B2

B-A3
B-B3
B-K1
B-E1
B-K3

B-A2
B-F2
3

B-J3
A-L2 BG/BK
M A-L1 BG/RD 5 M
FUEL PUMP A-K4 BG/YE 6
VOLTAGE REGULATOR /
RECTIFIER
FB -B4- BK/VT B-H2 A-F3 BG/WH 1
BN/RD 2
A-A2 BG/GY
4
1 FUEL A-K3 BG/GN
2 INJECTOR
VT/BU
#1 BN/RD
S
BU/YE1
RD/WH
RD/BU

RD/BU

BN/BK A-M4 A-H1

RD/BU

RD/BU

1
VT

VT

VT
BK-VT

VT/BU IGNITION
A-K2 YE/WH2
CPS
2 COIL # 1 N
C4

B2
D2

A6

A1
C5
C6
B6

A4

B
B4

BN/BK 1
RE1 RE2 A-H2 BK/BU
BN/BU 2

ENGINE
A-H3 WH/GY
(2)

3 U MAPTS
CONTROL CIRCUIT A-B4 PK/BU
ACC

1 FUEL
+12V

P
4
A
FUSE BOX (FB)

1 2 INJECTOR A-G4 WH/BU

VT VT/GN
5 AMP

2 #2 BN/BU A-K1
VT
3 1 BN/OG A-M2 2
VT VT/GN IGNITION A-A1 BG/OG
+ -
2 COIL # 2 A-J2 BK/OG 1 CTS

ECM
15 AMP
30 AMP

30 AMP

10 AMP

RELAY BN/OG
1 2 3 1 2 3 A-E3 BU
BN/GY 1
OPS
STEERING -11-
GND
ACC
RD/BK

(NORMALLY
YE

YE

YE

1
BK

FUEL
P
(4)

(5)

CLOSED)
(3)

(1)

2 INJECTOR
VT/OG
#3 BN/GY A-J1
ENGINE
3
B1
C2

D6

BN/YE
C3
C1

A-M1
D1

1
GROUND VT/OG IGNITION
VT/GY
RD/BK

2 COIL # 3
A-C3 YE/BU 2
RD

RD
RD

KNOCK
BK

A-G2 BG/BU 1 SENSOR

BN/YE
BK B-L1
BK

JT BK
BK B-M3

EGTS
DIAG TOOL -3- BK BK BK B-M2 2
A-H4 BG/GY

B-M4
B-H1

B-H3

A-D4
A-E2

B-L4
1
IF A-J4 BK/BG
OTAS
MA
ENGINE
2 EQUIPPED ONLY

VT/GY
BK/GN

YE/GN

BN/YE
GROUND

BK/GN
YE AC GENERATOR

BK
STEERING -20-
HALL
SENSOR

A C B
VT/GY
JT1 VT/GY
VT/GY

YE
YE RD VT/GY VT/GY OG/GN

ENGINE
4 3 2 1
RD
A

RD VT/GY VT/GY
B

IBR1 -2- VT/GY HALL

SENSOR
BK RD

IBR
RD
EQUIPPED
BATTERY STARTER
CAPS FUSE BOX (FB)
MOTOR
STS
ONLY
STARTER SOLENOID
219100878-002 BN/YE

https://brp-manuals.com/pwc_seadoo
 2018
RD/BK RD/BK

COM
JT VT/GN VT/GN
BRLS

6
YE/RD JT BK BK

3
MODE / SET SW.--UP / DOWN SW.

DIAG
GY/PK
VTS SW.--SPORT-ECO SW.

GTI / GTR / WAKE

SSS

4
START / STOP SW CRUISE OR SET
HALL HALL
SPORT
WH/BK

TOOL
SENSOR SENSOR
(NORMALY OPEN)

2
(NORMALY OPEN)
WH/BG

(130,155,230)
ECO

1
A C B D F E
YE/WH
VT/WH
VT/BG
YE/BN

TAS
BK
BK

1 3 2 4 6 5 2 1 CLUSTER B C A 2 1 STEERING -3-

DS

YE/RD
RD/WH
HIC 2 A C B
WH/GN 14 17 OG-GN JT1 WH-BK
YE/BN

YE/WH
VT/WH
VT/BG

BK/WH 15 18 BK/OG STEERING -2-

BK
BK

WH/BU 13 16 OG-BU
HALL
SENSOR
HALL
SENSOR JT1 WH-BG

CAN LO
4 7 GY

CAN HI
+ - + -
10 11 12 5 6 7 5 6 8 1 19 20 9 2 3 11 12 10 BK
3 WH/BG JT2 WH/BG
iBR 4 WH/BK JT2 WH/BK
A C B D F E

YE/GY
YE/BU

VT/GN
VT/BU
WH/BG

BK

BK
WH/BK
D A B C

PK/BK
RD/WH

VT/YE
2 VT/GY JT VT/GY

WH/GY
BK/YE
VT/YE
PK

BK

BK
13
14
15 IBR -4-
16 JT RD/WH JT2 WH-BK
RD/VT
1

IBR -3-

WH/BK

VT/YE
RD/WH

WH/BG
PK/BK
BK
JT2 WH-BG

BK
PK
8

9
ENGINE 1 19 12 2 3 11 20 6 9 5 13 15 14 16 18 17 4
GROUND HIC 1

WH/BK

VT/YE
RD/WH

WH/BG
PK/BK
1

BK
PK

WH/BG
GY/PK
WH/GY

WH/BK
YE/RD
YE/GY
VT/GN
YE/BU
BK/YE

VT/BU
FUSE BOX (FB)

BK
BK

BK
RD/BK

JT1 WH/BG
JT1 WH/BK
JT BK
FB -D3-

MOTOR ACTUATOR
WITH INTEGRATED
BK

THROTTLE BODY
B-C2

B-C1
B-E4
B-B2

B-A3
B-B3
B-K1
B-E1
B-K3

B-A2
B-D1
B-F2
5

B-J3
A-L2 BG/BK
1 2 3 A-L1 BG/RD 3 M
ENGINE
GROUND BG/PK B-M1 A-K4 BG/YE 2
3 A-F3 BG/WH 1
6
A-A2 BG/GY
REGULATOR / 4
A-C4 A-K3 BG/GN
RECTIFIER 3 RD/VT

SENSOR
HALL
TOPS 2
BK/BU A-C1
BU/GN A-F4
1 S
A-H1 BU/YE1

FUEL LEVEL
BG/PK

BCD A
CPS

SENSOR
PK/BK FB -B4- BK/VT B-H2 A-K2 YE/WH2

M
N
PK BN/RD
STERRING -20-

VT/BU
B
ECM -B-H2-

1 FUEL
FP INJECTOR 1
FUEL PUMP VT/BU 2 A-H2 BK/BN
JT VT/BU #1 2
1 2 3 A-H3 WH/GY
1 3 MAPTS
A
U
VT/BU IGNITION A-B4 PK/BU P
JT RD/BU JT VT JT VT/GN 4
YE
YE

YE

3 COIL # 1 A-G4 WH/BU

COM -6- BN/RD A-B3
BN/BK BN/BK A-M4
2

ENGINE
BN/BU A-A1 BG/OG
1 CTS
ECM
A-J2 BK/OG
VT/GN
VT/GN

VT/GN
VT/BU
RD/WH

BK/VT
RD/BU

RD/BU

RD/BU

RD/BK

VT/YE
RD/BU
RD/VT

1 FUEL
RD/BU
RD/BK

INJECTOR
VT

1 2
VT

VT
VT

VT

VT/BU VT/GN BN/BU A-K1

2 #2 2
VT/BU A-H4 BG/GY
C6
D2
E4

E3
E5

D3

A4

B2
F5

F2

D4
D5

F1
B6

B4

B1
E2
A6

F4

F3

VT/BU 3
VT/GN
1
IGNITION BN/OG A-M2 A-J4 BK/BG
1 OTS
3 COIL # 2
(10)
(14)

(13)
(7)

(2)

BN/OG
ACC

ACC
+12V

+12V
15 AMP

15 AMP

15 AMP

BN/GY BN/GY A-E3 BU

FUSE BOX (FB)

A-J1
5 AMP

5 AMP

1
BN/YE A-M1 OPS
1 FUEL (NORMALLY
A-C3
P

B-M4
B-M3

B-M2

B-G4
CLOSED)

A-D4
A-E2
INJECTOR

B-F3
B-L1

B-L4
2
VT/OG A-G2
#3
1

YE/BU
BG/BU
AMP
30 AMP

30 AMP

5 AMP

BG / GY
VT/OG

BK / BG
IGNITION

VT/GY

BN/YE
YE/GN
BK/GN
3

BK

BK

BK
COIL # 3
RELAY
(12) 30

GND
ACC

1 2
(11)

BN/YE 1 2
(6)
(9)

JT BK
COM -3- BK
D6

A1
E1
E6

F6

BK BK
VT/GY
RD
RD

RD

KNOCK SENSOR

BK
STEERING -11- BK
EGTS
LEGEND
YE
YE

YE

ENGINE WH = WHITE BK = BLACK

GROUND RD = RED YE = YELLOW
VT = VIOLET BG = BEIGE (TAN)
2 GN = GREEN BN = BROWN
GY = GREY BU = BLUE
PK = PINK OG = ORANGE

VT/GY
MA : JUNCTION POSITION
YE AC GENERATOR : CAN HI WIRE
RD VT/GY

YE/GN
BK/GN
: CAN LO WIRE
RD
A

RD VT/GY VT/GY VT/GY OG/GN LINE TYPE

ENGINE
4 3 2 1
55 / 60 VOLTS
JT VT/GY
B

IBR1 -2- VT/GY 12 VOLTS SWITCHED

BK RD 12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
HALL

YE
SENSOR
DIGITAL SIGNAL
YE RD AC VOLTAGE
BATTERY POWER CONTROL
STARTER ANALOG SIGNAL
MOTOR STS COMMUNICATION
BK
STARTER SOLENOID
BN/YE
CAPS A-D GROUND
219100878-003 POWER GROUND

https://brp-manuals.com/pwc_seadoo
 2018
RD/BK RD/BK

COM
JT VT/GN VT/GN
BRLS

6
YE/RD JT BK BK

3
RD/WH
YE/RD
GTX / RXT / WAKE PRO

DIAG
GY/PK
LH SWITCH RH SWITCH

4
B B
HALL HALL 1 2 WH/BK

TOOL
SENSOR SENSOR

2
WH/BG

1
C C

(NORMALY OPEN)
CRUISE OR SET
A A

(CS)
A C B D F E
VT/BG

YE/WH
VT/WH
YE/BN

WH/GN

OG/GN
BK

WH/BU

OG/BU
BK/WH

BK/OG
BK

1 3 2 4 6 5
SSS 2 1
START / STOP SW DS STEERING -3-

GY
BK
HIC 2 (NORMALY OPEN) TAS JT1 WH-BK
14 15 13 17 18 16
YE/BN

YE/WH
VT/WH
VT/BG

STEERING -2-
BK
BK

JT RD/WH 7 GY JT1 WH-BG

FUSE BOX (FB) RD/WH 1

CAN LO

CAN HI
7
10 BK
10 11 12 5 6 HALL HALL
3 WH/BG JT2 WH/BG JT VT/YE
SENSOR SENSOR

iBR 4 WH/BK JT2 WH/BK VT/YE 12

D A B C + - + -

WH/GY
VT/YE

BK/YE
2 VT/GY JT VT/GY IBR -4-

BK
CL JT2 WH-BK
13
DS -D- A C B D F E

YE/GY
YE/BU

VT/GN
VT/BU
14

20
19

11

BK

BK
2
3
15
IBR -3-
JT VT/YE JT2 WH-BG

WH/BG
WH/BK
16

PK/BK
PK

BK
RD/VT

RD/WH
1

YE/RD
VT/YE
BK
8

DEPTH -4-
JT RD/BK

9
ENGINE 1 20 2 3 12 19 11 6 9 5 13 15 14 16 18 17 4 JT3 WH-BK
RD/BK
VT/YE

GROUND HIC 1
BK

DEPTH -3-
BATTERY
1 JT3 WH-BG

BK
GROUND

JT1 WH/BG
JT1 WH/BK

WH/BG
GY/PK
WH/GY

WH/BK
YE/RD
PK/BK

YE/GY
VT/GN
YE/BU
BK/YE

VT/BU
8 7

BK
PK

BK

BK
JT BK
RD/BK HIC 1
RD/BK
VT/YE

MOTOR ACTUATOR
WITH INTEGRATED
BK
BK

THROTTLE BODY
B-C2

B-C1
B-E4
B-B2

B-A3
B-B3
B-K1
B-E1
B-K3

B-A2
B-D1
B-F2
5

B-J3
A-L2 BG/BK
1 2 3 A-L1 BG/RD 3 M
ENGINE
3 2 1 BG/YE 2
GROUND BG/PK B-M1 A-K4
3 A-F3 BG/WH 1
ACCESSORY A-A2 BG/GY
6
REGULATOR / 4
CONNECTION 3 RD/VT
A-C4 A-K3 BG/GN
PERM. 12V

RECTIFIER

SENSOR
HALL
TOPS
ACC 12V

BK/BU A-C1
2
BU/GN A-F4
GND

1 S
A-H1 BU/YE 1

FUEL LEVEL
BG/PK

BD C A
CPS

SENSOR
PK FB -B4- BK/VT B-H2 A-K2 YE/WH2

M
N
PK/BK BN/RD
VT/BU
B
ECM -B-H2-

1 FUEL
FP 2 INJECTOR 1
JT VT/BU FUEL PUMP VT/BU
#1 A-H2 BK/BN
2
1 2 3 A-H3 WH/GY
1 3 MAPTS
A
U
VT/BU IGNITION A-B4 PK/BU P
JT RD/BU JT VT JT VT/GN 4
YE
YE

YE

3 COIL # 1 A-G4 WH/BU

VT/GN COM-6- BN/RD A-B3
BN/BK BN/BK A-M4
2

ENGINE
BN/BU A-A1 BG/OG
1 CTS
ECM
A-J2 BK/OG
VT/GN
VT/GN

VT/GN
VT/BU
RD/WH

BK/VT
RD/BU

RD/BU

RD/BU

RD/BK

VT/YE
RD/BU

1
RD/VT

FUEL
RD/BU
RD/BK

INJECTOR
VT

1 2
VT

VT
VT

VT

VT/BU VT/GN BN/BU A-K1

2 #2 2
VT/BU A-H4 BG/GY
C6
D2
E4

E3
E5

D3

A4

B2
F5

F2

D4
D5

F1
B6

B4

B1
E2
A6

F4

F3

VT/BU
3
VT/GN
1
IGNITION BN/OG A-M2 A-J4 BK/BG
1 OTS
3 COIL # 2
(10)
(14)

(13)
(7)

(2)
FUSE BOX (FB)

BN/OG
15 AMP

15 AMP

15 AMP

BN/GY BN/GY A-J1 A-E3 BU

5 AMP

5 AMP

1
BN/YE A-M1 OPS
1 FUEL (NORMALLY
A-C3
P

B-M3

B-M2

B-M4

B-G2

BK / BG B-G4
INJECTOR CLOSED)

A-D4
A-E2

B-E2

BG / GY B-F3
B-L1

B-L4
2
VT/OG A-G2
#3

YE/BU
BG/BU
1
AMP
30 AMP

30 AMP

5 AMP

VT/OG IGNITION
3 AMP

VT/GY
3 AMP

BK/GN
YE/GN

BN/YE
IF 3

BG
BK
BK

BK

BK
COIL # 3
RELAY 1 2
(12) 30

EQUIPPED 1 2
BUS GND
(11)

BN/YE 1 2
(6)
(9)

WT
(8)
(3)

ONLY
COM -3- BK JT BK
C5
D6

A3
A2

A1
E1

D1
E6

F6

(SPARE)

BK BK
VT/OG
VT/GY
RD
RD

RD

BN

BK

KNOCK SENSOR
LTS LEGEND

BK

BK
DEPTH BILGE
YE

SOUNDER
YE

YE

PUMP STEERING -11- BK

1 IF EGTS WH = WHITE BK = BLACK
6 P RD = RED YE = YELLOW
1
2 ENGINE
GROUND
EQUIPPED VT = VIOLET BG = BEIGE (TAN)
WH/BK JT3 WH/BK
C B
4
WH/BG JT3 WH/BG 2 ONLY GN = GREEN BN = BROWN
GY = GREY BU = BLUE
A 3
PK = PINK OG = ORANGE
5

2
BK
: JUNCTION POSITION
MA VT/GY
: CAN HI WIRE

YE/GN
BK/GN
YE AC GENERATOR : CAN LO WIRE
RD VT/GY
RD VT/GY OG/GN
LINE TYPE

ENGINE
4 3 2 1
A

RD VT/GY VT/GY
JT VT/GY 55 / 60 VOLTS
12 VOLTS SWITCHED
B

BK RD 12 VOLTS UNSWITCHED
IBR1 -2- VT/GY HALL 5 OR 3.3 VOLTS
SENSOR
DIGITAL SIGNAL
YE AC VOLTAGE
YE RD
BATTERY POWER CONTROL
ANALOG SIGNAL
STARTER
MOTOR STS CAPS COMMUNICATION
STARTER SOLENOID A-D GROUND
BK BN/YE POWER GROUND
219100878-004

https://brp-manuals.com/pwc_seadoo
 2018 RXP X
RD/BK RD/BK

COM
JT VT/GN VT/GN
BRLS

6
JT1 BK BK

3
YE/RD

DIAG
1 2 GY/PK
LH SWITCH RH SWITCH

4
B B
HALL HALL WH/BK

TOOL
SENSOR SENSOR

2
WH/BG

1
C C

A C B D F E A A
YE/WH
VT/WH

SSS
VT/BG
YE/BN

WH/GN

OG/GN
BK

WH/BU

OG/BU
BK/WH

BK/OG
BK

START / STOP SW
(NORMALY OPEN)
1 3 2 4 6 5 STEERING -3-
HIC2 DS TAS JT1 WH-BK
14 15 13 17 18 16
YE/BN

YE/WH
VT/WH
VT/BG

STEERING -2-
FUSE BOX (FB) JT RD/WH
BK
BK

JT1 WH-BG
RD/WH 1

CAN LO

CAN HI
10 11 12 5 6 7 HALL HALL
3 WH/BG JT2 WH/BG JT VT/YE
SENSOR SENSOR

iBR 4 WH/BK JT2 WH/BK VT/YE 12

2 VT/GY JT VT/GY D A B C + - + -
IBR -4-

WH/GY
BK/YE
CL

FB -B4-
VT/YE
BK
RD/WH
13
DS -D- A C B D F E JT2 WH-BK

YE/GY
YE/BU

VT/GN
VT/BU
14
2 3 20 19

BK

BK
11
15
IBR -3-
JT VT/YE JT2 WH-BG

WH/BG
WH/BK
16

PK/BK
PK

BK
RD/VT
1

VT/YE
BK
8

9 DEPTH -4-
ENGINE 1 20 2 3 12 19 11 6 9 5 13 15 14 16 18 17 4 JT3 WH-BK
GROUND HIC 1
DEPTH -3-
1 JT3 WH-BG

BK
JT1 WH/BG
JT1 WH/BK

WH/BG
GY/PK
WH/GY

WH/BK
YE/RD
YE/GY
VT/GN
YE/BU
BK/YE

VT/BU
PK/BK

BK
BK

BK
RD/BK

PK

JT1 BK

MOTOR ACTUATOR
WITH INTEGRATED
BK

THROTTLE BODY
B-C2

B-C1
B-E4
B-B2

B-A3
B-B3
B-K1
B-E1
B-K3

B-A2
B-D1
B-F2
5

B-J3
A-L2 BG/BK
1 2 3 A-L1 BG/RD 3 M
ENGINE
GROUND BG/PK B-M1 A-K4 BG/YE 2
3 A-F3 BG/WH 1
6
A-A2 BG/GY
REGULATOR / 4
A-C4 A-K3 BG/GN
RECTIFIER 3 RD/VT

SENSOR
HALL
TOPS 2
BK/BU A-C1
BU/GN A-F4
1 S
A-H1 BU/YE1

FUEL LEVEL
BG/PK

BD C A
CPS

SENSOR
PK FB -B4- BK/VT B-H2 A-K2 YE/WH2

M
N
PK/BK BN/RD
ECM -B-H2-

VT/BU
1 FUEL B
FP 2 INJECTOR 1
FUEL PUMP VT/BU A-H2 BK/BN
JT VT/BU #1 2
1 2 3 A-H3 WH/GY
1 3 MAPTS
A
U
VT/BU IGNITION A-B4 PK/BU P
JT RD/BU JT VT JT VT/GN 4
YE
YE

YE

3 COIL # 1 A-G4 WH/BU

VT/GN COM-6- BN/RD A-B3
BN/BK BN/BK A-M4
2

ENGINE
BN/BU A-A1 BG/OG
1 CTS
ECM
A-J2 BK/OG
VT/GN
VT/GN

VT/GN
VT/BU
RD/WH

BK/VT
RD/BU

RD/BU

RD/BU

RD/BK

VT/YE

1
RD/BU
RD/VT

FUEL
RD/BU
RD/BK

INJECTOR
VT

1 2
VT

VT
VT

VT

VT/BU VT/GN BN/BU A-K1

2 #2 2
VT/BU A-H4 BG/GY
C6
D2
E4

E3
E5

D3

A4

B2
F5

F2

D4
D5

F1
B6

B4

B1
E2
A6

F4

F3

VT/BU
3
VT/GN
1
IGNITION BN/OG A-M2 A-J4 BK/BG
1 OTS
3 COIL # 2
(10)
(14)

(13)
(7)

(2)

BN/OG
FUSE BOX (FB)

15 AMP

15 AMP

15 AMP

BN/GY BN/GY A-J1 A-E3 BU

5 AMP

5 AMP

1
BN/YE A-M1 OPS
1 FUEL (NORMALLY
A-C3
P

B-M3

B-M2

B-M4

B-G4
INJECTOR CLOSED)

A-D4
A-E2

B-F3
B-L1

B-L4
2
VT/OG A-G2

YE/BU
BG/BU
#3
IF EQUIPPED
1
AMP
30 AMP

30 AMP

5 AMP

VT/OG

BG / GY
IGNITION
3 AMP

BK / BG
VT/GY
3 AMP

BN/YE
YE/GN
BK/GN
3

BK

BK

BK
COIL # 3 1 2
RELAY
(12) 30

BUS GND
(11)

BN/YE 1 2
(6)
(9)

(8)
(3)

COM -3- BK JT1 BK

C5
D6

A3
A2

A1
E1

D1
E6

F6

(SPARE)

BK BK
VT/OG
VT/GY
RD
RD

RD

BN

BK

KNOCK SENSOR
BILGE PUMP

BK

BK
DEPTH
SOUNDER STEERING -11- BK LEGEND
1 EGTS
P
YE
YE

YE

6
2 ENGINE WH = WHITE BK = BLACK
1 RD = RED YE = YELLOW
GROUND
WH/BK JT WH/BK VT = VIOLET BG = BEIGE (TAN)
4
3 WH/BG JT WH/BG 2 GN = GREEN BN = BROWN
5
GY = GREY BU = BLUE
BK PK = PINK OG = ORANGE
2
OTAS -A- VT/GY VT/GY
MA : JUNCTION POSITION
YE AC GENERATOR : CAN HI WIRE
RD VT/GY

YE/GN
BK/GN
: CAN LO WIRE
RD
A

RD VT/GY VT/GY VT/GY OG/GN LINE TYPE

ENGINE
4 3 2 1
55 / 60 VOLTS
JT VT/GY
B

IBR1 -2- VT/GY 12 VOLTS SWITCHED

BK RD 12 VOLTS UNSWITCHED
5 OR 3.3 VOLTS
HALL

YE
SENSOR
DIGITAL SIGNAL
YE RD AC VOLTAGE
BATTERY POWER CONTROL
STARTER ANALOG SIGNAL
MOTOR STS COMMUNICATION
BK
STARTER SOLENOID
BN/YE
CAPS A-D GROUND
219100878-005 POWER GROUND

https://brp-manuals.com/pwc_seadoo
2018 2 SPEAKERS WITH BLUETOOTH DONGLE
SEA-DOO SOUND SYSTEM

2 1
VT / YE VT / YE
3 3
BK BK
1
RD / BK 4

VT / BU 2
ACCESSORY
LT GN / BU 5
CONNECTION
LT GN / OR 6

GN / BG 7
BLUETOOTH DONGLE
GN / LT GN 8 ( BDG )

LEGEND
WH = WHITE BK = BLACK
1 +
BU
RD = RED YE = YELLOW
VT = VIOLET BG = BEIGE (TAN) BU / BK
GN = GREEN BN = BROWN
2
-
GY = GREY BU = BLUE LEFT SPEAKER
PK = PINK OG = ORANGE ( LS )

: JUNCTION POSITION
: CAN HI WIRE
: CAN LO WIRE
1
1 +
GY GY
2
LINE TYPE GY / BK GY / BK

55 / 60 VOLTS
2
-
GN / LT GN
LT GN / OR
LT GN / BU

RIGHT SPEAKER
GN / BG

12 VOLTS SWITCHED ( RS )
BU / BK

GY / BK
RD / BK

VT / BU

12 VOLTS UNSWITCHED
GY
BU
BK

5 OR 3.3 VOLTS
DIGITAL SIGNAL
AC VOLTAGE
POWER CONTROL 1 3 2 4 5 6 7 8 9 10 11 12
ANALOG SIGNAL
COMMUNICATION
A-D GROUND
POWER GROUND

AMPLIFIER
( AMP )

https://brp-manuals.com/pwc_seadoo
2018 with DC Converter
SEA-DOO USB CHARGER

LEGEND
WH = WHITE BK = BLACK
3 RD = RED YE = YELLOW
BK
2 VT = VIOLET BG = BEIGE (TAN)
VT / YE
1 GN = GREEN BN = BROWN
RD / BK
ACCESSORY GY = GREY BU = BLUE
OUT PK = PINK OG = ORANGE

: JUNCTION POSITION
: CAN HI WIRE
: CAN LO WIRE

1
RD / BK
2
VT / YE
3 BK
ACCESSORY
IN
4
BK / BU
3
GN
2
WH
1
RD
USB CABLE
LINE TYPE
55 / 60 VOLTS
12 VOLTS SWITCHED
12 VOLTS UNSWITCHED
BK / BU
VT / YE

5 OR 3.3 VOLTS

RD
WH
GN
BK

DIGITAL SIGNAL
AC VOLTAGE A B C D E F
POWER CONTROL
ANALOG SIGNAL
COMMUNICATION
A-D GROUND
POWER GROUND

DC CONVERTER

https://brp-manuals.com/pwc_seadoo
 INTRODUCTION
This publication governs all warranty labor allowances 4. JOB REQUIREMENTS
for 2018 BRP Sea-Doo. All the flat rate times mentioned in the following pages
1. HOW DOES IT WORK include the required operations such as: engine timing
(rotary valve and ignition), connecting rod(s) alignment,
We follow the procedures detailed in the BRP Sea-Doo cylinder head(s) torque or use of parallel bar, use of ig-
Shop Manual. The flat rate time is the maximum time nition tester, piston clearance/ring end gap measure-
allowed for a repair involving any given part. FLAT ment, crankshaft to crankcase measurement, cylinder
RATE TIME IS NOT CUMULATIVE. You must use the honing, engine leak test.
flat rate time given for the longest lasting operation.
NOTE: The Flat Rate Time Schedule was prepared by 5. ILLUSTRATIONS
skilled mechanics using the hand tool usually found in The illustrations contained in this manual do not neces-
workshops and all the special tools mentioned in the sarily show every components of a given system as
Shop Manual. Parts Catalog do. Their purpose is to facilitate recogni-
tion of parts related to a flat rate time. Item numbers
2. COMPILATION on illustrations correspond to the four digit Job
The Flat Rate Time Schedule is compiled as follows: Code.
The actual required time to perform the repair plus (+)
30% correction factor up to 3.0 hours or (+) 15% over 6. FLAT RATE TIME SUGGESTION
3.0 hours time to take into account, among others: SEND A WARRANTY CASE ON BOSSWeb INFO
– Vehicle handling CENTER
– Obtaining the parts In the case, you must provide the following information:
– Diagnosis Section Subject:
– Cleaning – Flat rate time suggestion
– Special compensation (rusted bolts).
Section Your Question:
3. HOW TO USE IT – Model year;
Refer to the system you need, locate part of series of – Model description;
parts replaced. List JOB CODE in the appropriate col- – Description job code;
umn on claim. – Job code;
SYSTEM PAGE – Present flat rate;
– Suggested flat rate;
01 ENGINE 04 – Detailed repair procedure;
02 CARBURETOR AND FUEL SYSTEM 24 To ensure that your case will be promptly and efficiently
processed please indicate the step by step repair pro-
03 IGNITION SYSTEM 31 cedure you performed.
04 STARTER 33

05 TRANSMISSION SYSTEM 35

06 BRAKE SYSTEM
STEERING SYSTEM AND FRONT
07 41
SUSPENSION
REAR SUSPENSION SYSTEM AND
08 TRACK
09 BODY 44

10 ELECTRICAL SYSTEM 56

NOTE: Unless otherwise specified, dismantling order

is: top to bottom, exterior to interior, front to rear.
All fractions of hours are in tenths:
0.1 = 6 minutes
0.2 = 12 minutes, and so on
LEGEND:
* REQUIRES PRIOR AUTHORIZATION BY DISTRIBUTOR.
INDICATE LABOUR TIME ON LINE “LABOUR ONLY“ OF
**
CLAIM.
INDICATE $$$ AMOUNT ON “SUB-CONTRACTED
***
LABOUR“ OF CLAIM.
IMPORTANT: Always use the longest flat rate time ap-
plicable to the repair performed.

Volume 2- Sea-Doo 1
2018 STF2018-002-GTS_GTI_RXP.FM
https://brp-manuals.com/pwc_seadoo
 INTRODUCTION
Cette publication détermine le temps de main-d’oeuvre LÉGENDE:
couvert par la garantie pour les motomarines BRP 2018. * AUTORISATION REQUISE AVANT LE REMPLACEMENT.
INSCRIRE LE TEMPS À LA LIGNE «MAIN-D’OEUVRE
**
1. UTILISATION DU MANUEL SEULEMENT».
En procédant de la façon indiquée dans le Manuel de *** INSCRIRE LE MONTANT $$$ À LA LIGNE «OUVRAGE
SOUS-CONTRACTÉ».
réparation motomarines BRP, chaque temps donné re-
présente le maximum permis pour une réparation por- IMPORTANT: Toujours utiliser le temps donné à l’opé-
tant sur cette pièce. LES TEMPS NE SONT PAS CU- ration qui nécessite le plus de temps.
MULATIFS. On doit inscrire le temps donné pour
l’opération qui prend le plus de temps. 4. TRAVAUX REQUIS
REMARQUE: Le Barème de temps à taux fixe a été Tous les temps mentionnés dans les pages suivantes
préparé par des mécaniciens compétents utilisant les incluent les opérations telles que: réglage du moteur
outils que l’on retrouve normalement dans les ateliers (valve rotative et allumage), alignement de la ou des
de réparation, en plus de tous les outils spéciaux men- bielles, couple de serrage de la ou des culasses ou l’uti-
tionnés dans le Manuel de réparation. lisation de barres parallèles, utilisation du vérificateur
d’allumage, mesure du jet des pistons/jeu en bout des
2. COMPILATION segments, mesure de l’écart entre le vilebrequin et le
Le Barème de temps à taux fixe a été établi en compi- carter, rectification du cylindre, vérification de fuite du
lant le temps nécessaire pour faire la réparation plus (+) moteur.
un facteur de correction de 30% lorsqu’un travail dure 5. ILLUSTRATIONS
3.0 heures et moins, ou (+) 15% lorsqu’un travail dure
plus de 3.0 heures. Cette compilation comprend, entre Contrairement aux Catalogues de pièces, les illustra-
autres, les étapes suivantes: tions de ce manuel ne montrent pas nécessairement
chacune des pièces qu’elles représentent, leur raison
– Manutention du véhicule d’être étant plutôt de faciliter la reconnaissance des
– Nettoyage pièces reliées à un barème de temps à taux fixe. Les
– Aller chercher les pièces, essais physiques numéros d’items sur les illustrations correspondent
– Compensation spéciale (boulons rouillés) aux quatre derniers chiffres du code de travail.
– Diagnostic. 6. SUGGESTION DE BARÈME DE TEMPS À
3. UTILISATION DU BARÈME TAUX FIXE
Se reporter à la section désirée, repérer la pièce ou l’en- ENVOYEZ UNE REQUÊTE GARANTIE BOSSWeb
semble de pièces remplacées et inscrire le CODE DE DEPUIS LA SECTION INFO CENTRE
TRAVAIL dans la colonne appropriée sur la formule de Dans cette requête, vous devez fournir les informations
réclamation. suivantes:
Section Objet:
SYSTÈME PAGE – Suggestion de barème de temps à taux fixe
01 MOTEUR 4 Section Votre Question:
CARBURATEUR ET SYSTÈME – L'année modèle;
02 24 – Description du modèle;
D’ALIMENTATION D’ESSENCE
– Description du code de travail;
03 SYSTÈME D’ALLUMAGE 31
– Code de travail;
04 DÉMARREUR 33 – Temps actuel;
– Temps suggéré;
05 SYSTÈME DE TRANSMISSION 35
– Détails de la marche à suivre;
06 SYSTÈME DE FREIN Pour s'assurer que votre demande sera traitée dans les
SYSTÈME DE DIRECTION ET plus brefs délais et efficacement, s.v.p. nous fournir
07 41 toutes les étapes de réparation dans les détails de la
SUSPENSION AVANT
marche à suivre.
SYSTÈME DE SUSPENSION ARRIÈRE ET
08
CHENILLE
09 CARROSSERIE 44

10 SYSTÈME ÉLECTRIQUE 56

REMARQUE: Sauf indication contraire, le démontage

doit s’effectuer de haut en bas, de l’extérieur vers l’in-
térieur, de l’avant vers l’arrière.
Toutes les fractions d’heures sont exprimées en dixiè-
mes:
0.1 = 6 minutes
0.2 = 12 minutes, et ainsi de suite

2 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 2018
Liquid Cooled Engines — Moteurs refroidis par liquide

MODEL/ ENGINE/ INTERCOOLER

TABLE DESCRIPTION iBR
MODÈLE MOTEUR REFROIDISSEUR
4 GTS 90 25JA/25JB 903H N/A N/A

GTI 90 37JA/37JB
5 24JA/24JB 903H N/A STD
GTI SE 90
24JC/24JD
29JA/29JB
6 GTI SE 130
29JC/29JD
1503 N/A STD

30JA/30JB
GTI SE 155
30JC/30JD
7 GTI LTD 155 39JA/39JB
1503N N/A STD

WAKE 155 35JA/35JB

GTR 230 36JA/36JB
8 1503H STD STD
GTR X 230 34JA/34JB
21JA/21JB
9 RXP X 300 1630 STD STD
21JC/21JD

Volume 2- Sea-Doo 3
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

130/155

RXP X
GTS

GTR
GTI

GTI
SYSTÈME
SYSTEM

CODE

DESCRIPTION
4 5 6/7 8 9

NO LABOR INVOLVED
01 00 0 0 0 0 0
AUCUNE MAIN-D’OEUVRE
MUFFLER, HOSE, STRAP, RUBBER STRIP
01 01
SILENCIEUX, BOYAU, SANGLE, BANDE CAOUTCHOUC
0.9 0.9 0.9 0.9 0.9

EXHAUST MANIFOLD AND/OR BOLT(S)

01 05
COLLECTEUR D’ÉCHAPPEMENT ET/OU BOULON(S)
1.2 1.2 1.2 1.8 1.8

01 08 ENGINE (ASS’Y) REMOVAL AND INSTALLATION

3.6 3.6 3.6 4.0 4.0
* DÉPOSE ET INSTALLATION DU MOTEUR (COMPLET)
TEMPERATURE SENSOR
01 12
CAPTEUR DE TEMPÉRATURE
0.3 0.3 0.3 0.3 0.3

CYLINDER HEAD
01 14
CULASSE
4.3 4.3 4.5 5.2 5.2

HOSE (L.H RESONATOR TO EXHAUST OUTLET)

01 35
BOYAU (RÉSONATEUR GAUCHE À LA SORTIE D’ÉCHAPPEMENT)
0.4 0.4 0.4 0.4 0.4

EXHAUST OUTLET
01 36 0.7 0.7 0.7 0.7 0.7
SORTIE D’ÉCHAPPEMENT
SHORT BLOCK
01 37
ENSEMBLE CARTER-CYLINDRES
6.9 7.5 7.5

BALANCE SHAFT (ASS’Y)

01 43 6.5 7.3 7.3
ARBRE D’ÉQUILIBRAGE (COMPLET)
RESONATOR (RIGHT)
01 52
RÉSONATEUR (DROIT)
0.5 0.5 0.5 0.5 1.1

MUFFLER SUPPORT
01 53
SUPPORT DE SILENCIEUX
1.1 1.1 1.1

REAR ENFINE SUPPORT (EACH)

01 54
SUPPORT MOTEUR ARRIERE (CHAQUE)
1.7 1.7

FRONT ENGINE SUPPORT (EACH)

01 55
SUPPORT MOTEUR AVANT (CHAQUE)
1.7 1.7

ENGINE RUBBER MOUNTS (REAR OR FRONT) (EACH)

01 56 1.3 1.3 0.8 0.8 0.8
TAMPON D’ANCRAGE MOTEUR (AVANT OU ARRIÈRE) (CHACUN)
REAR ENGINE SUPPORT
01 57
SUPPORT MOTEUR ARRIÈRE
0.9 0.9 0.9

HOSE (FROM PUMP SUPPORT TO HEAD PIPE ASS'Y)

01 61
BOYAU DU SUPPORT DE POMPE AU TUYAU COLLECTEUR (COMPLET)
0.3 0.3 0.3 0.3 0.3

SENSOR TEMPERATURE (MUFFLER)

01 63
CAPTEUR DE TEMPERATURE (SILENCIEUX)
0.3 0.3 0.3 0.3 0.3

NOISE SENSOR
01 65
CAPTEUR DE CLIQUETIS
0.9 0.9 0.9 0.9 0.9

ENGINE COVER
01 75
COUVERCLE DE MOTEUR
0.3 0.3 0.3

EXHAUST PIPE
01 82
TUYAU D’ÉCHAPPEMENT SOUDÉ
0.5 0.5 0.5

4 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

130/155

RXP X
GTS

GTR
GTI

GTI
SYSTÈME
SYSTEM

CODE DESCRIPTION
4 5 6/7 8 9

PISTON, RINGS, CIRCLIP, PIN (1)

01 83 6.3 6.3 7.0 7.4 7.4
PISTON, SEGMENTS, ANNEAU DE RETENUE, GOUPILLE (1)
PISTON, RINGS, CIRCLIP, PIN (2)
01 84
PISTON, SEGMENTS, ANNEAU DE RETENUE, GOUPILLE (2)
6.4 6.5 7.2 7.6 7.6

PISTON, RINGS, CIRCLIP, PIN (3)

01 85
PISTON, SEGMENTS, ANNEAU DE RETENUE, GOUPILLE (3)
6.5 6.5 7.4 7.8 7.8

INLET HOSE (RADIATOR TO PUMP)

01 86
BOYAU ENTRÉE D’EAU (RADIATEUR À POMPE)
0.5 0.5 0.5 0.5 0.5

WATER OUTLET (ENGINE TO RADIATOR)

01 87
SORTIE D’EAU (MOTEUR AU RADIATEUR)
0.5 0.5 0.5 0.5 0.5

HOSE FROM MUFFLER LEFT TO MUFFLER RIGHT

01 88 0.3 0.3 0.3 0.3 0.3
BOYAU DU SILENCIEUX GAUCHE AU SILENCIEUX DROIT
ENGINE BLOCK (CRANKCASE)
01 89
ENSEMBLE MOTEUR (CARTER)
6.6 6.6 8.6 9.0 9.0

ENGINE BLOCK RESEAL OR SEALANT

01 90 5.0 5.0 4.7 5.1 5.1
RESCELLEMENT DU MOTEUR OU SCELLANT
CRANKSHAFT AND/OR PLAIN BEARING AND/OR RING HALF
01 92
VILEBREQUIN ET/OU ROULEMENT PLAT ET/OU DEMI-BAGUE
7.0 7.0 8.1 8.5 8.5

WATER PUMP HOUSING (ASS’Y) AND/OR GASKET

01 93
BOÎTIER POMPE À EAU (COMPLET) ET/OU JOINT D’ÉTANCHÉITÉ
1.1 1.1 0.8 1.0 1.0

COOLING RESERVE
01 94
RÉSERVOIR ANTIGEL
0.3 0.3 0.3 0.3 0.3

RADIATOR AND/OR FITTING

01 95
RADIATEUR ET/OU RACCORD DROIT
3.0 3.0 3.0 3.0 3.0

CAMSHAFT POSITION SENSOR

01 96 0.3 0.3 0.3 0.3 0.3
CAPTEUR DE POSITION DE L’ARBRE À CAMES
VALVE COVER AND/OR GASKET
01 97
COUVERCLE DE SOUPAPE ET/OU JOINT D’ÉTANCHÉITÉ
1.2 1.2 0.3 0.3 0.3

CAMSHAFT
01 98
ARBRE À CAMES
1.1 1.1 1.1 1.1 1.1

CAMSHAFT GUIDE
01 99
GUIDE DE L’ARBRE À CAMES
0.6 0.6 0.6 0.6 0.6

TIMING GEARS
01 111 ENGRENAGES DE LA DISTRIBUTION 1.1 1.1

IGNITION COVER A/O GASKET

01 121 COUVERCLE ALLUMAGE E/O JOINT ÉTANCHE 3.3 3.3

OIL PUMP GEAR

01 132 ENGRENAGE DE LA POMPE À L’HUILE 3.6 3.6

OIL PUMP GEAR (2)

01 146 3.6 3.6
ENGRENAGE POMPE À L’HUILE
CAMSHAFT CHAIN
01 174 CHAÎNE DE L’ARBRE À CAMES 6.1 6.1 8.5 8.5 8.5

Volume 2- Sea-Doo 5
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

130/155

RXP X
GTS

GTR
GTI

GTI
SYSTÈME
SYSTEM

CODE

DESCRIPTION
4 5 6/7 8 9

TIMING GEAR
01 175 1.1 1.1 1.1 1.1 1.1
PIGNON DE DISTRIBUTION
ROCKER ARM (ASS’Y)
01 176 AXE DE CULBUTEUR (COMPLET) 0.6 0.6 0.6 0.6 0.6

EXHAUST VALVE, SPRINGS, SEAL, GUIDE (1)

01 177 SOUPAPE D’ÉCHAPPEMENT, RESSORTS, JOINT, GUIDE (1) 2.0 2.0 1.7 1.7 1.7

INTAKE VALVE, SRINGS, SEAL, GUIDE (1)

01 178 SOUPAPE D’ADMISSION, RESSORTS, JOINT, GUIDE (1) 2.0 2.0 1.7 1.7 1.7

CHAIN GUIDE
01 179 GUIDE DE CHAÎNE 2.0 2.0 0.4 0.4 0.4

OUTPUT SLEEVE, SEAL, STOP SLEEVE

01 180 2.1 2.1 1.7 2.4 2.4
MANCHON DE DÉBIT, JOINT, ARRÊT DU MANCHON
SEAL (OUTPUT SLEEVE)
01 181 JOINT (MANCHON DE DÉBIT) 1.0 1.8 1.8

OIL RADIATOR AND/OR O-RING

01 182 1.3 1.3 3.7 3.7 3.7
RADIATEUR D’HUILE ET/OU JOINT TORIQUE
OIL PUMP COVER AND/OR SHAFT AND/OR ROTOR (REAR)
01 183 COUVERCLE DE LA POMPE À L’HUILE ET/OU ARBRE ET/OU ROTOR (ARRIÈRE) 3.2 3.2 2.4 3.2 3.2

OIL PUMP HOUSING AND/OR ALL PARTS (FRONT)

01 184 BOÎTIER DE LA POMPE À L’HUILE ET/OU TOUTES LES PIÈCES (AVANT) 3.2 3.2 1.2 1.2 1.2

OIL SEPARATOR HOUSING AND/OR GASKET

01 186 BOÎTIER SÉPARATEUR D’HUILE ET/OU JOINT D’ÉTANCHÉITÉ 0.7 0.7

OIL SEPARATOR COVER

01 187 COUVERCLE SÉPARATEUR D’HUILE 1.0 1.0 1.0 1.0 1.0

OIL PRESSURE SWITCH

01 189 0.3 0.3 0.6 0.6 0.6
INTERRUPTEUR DE PRESSION D’HUILE
PTO HOUSING AND/OR GASKET
01 190 BOÎTIER PDM ET/OU JOINT D’ÉTANCHÉITÉ 2.1 2.1 2.7 3.5 3.5

CHAIN TENSION GUIDE

01 191 GUIDE DE TENSION DE CHAÎNE 5.3 5.3 5.4 5.8 5.8

CHAIN TENSIONER (ASS’Y)

01 192 TENDEUR DE CHAÎNE (COMPLET) 0.4 0.4 0.3 0.3 0.3

OIL SIEVE (PTO)

01 193 TAMIS D’HUILE (PDM) 4.5 4.5 2.1 3.1 3.1

OIL FILTER AND/OR O-RING

01 194 FILTRE À HUILE ET/OU JOINT TORIQUE 0.3 0.3 0.3 0.3 0.3

VALVE SEAT SLEEVE, PISTON, SPRING, PLUG AND O-RING

01 195 MANCHON DE SIÈGE DE SOUPAPE, PISTON, RESSORT, BOUCHON ET JOINT 2.2 3.2 3.2
T0RIQUE
WATER PUMP GEAR
01 200 ENGRENAGE POMPE À EAU 3.6 3.6

PRESSURE CAP
01 216 BOUCHON DE RADIATEUR 0.3 0.3 0.3 0.3 0.3

6 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

130/155

RXP X
GTS

GTR
GTI

GTI
SYSTÈME
SYSTEM

CODE DESCRIPTION
4 5 6/7 8 9

KNOCK SENSOR
01 224 0.5 0.5
CAPTEUR DE CLIQUETIS
WATER PUMP GEAR AND/OR SEAL
01 246 ARBRE POMPE A EAU ET/OU JOINT D’ÉTANCHEITE 3.6 3.6

BREATHER GEAR AND/OR V-RING

01 248 RENIFLARD ET/OU ANNEAU ETANCHEITE EN V
CRANKSHAFT POSITION SENSOR (CPS)
01 250 CAPTEUR POSITION DU VILEBREQUIN (CPV) 0.6 0.6 0.6 0.6 0.6

PRESSURE VALVE (ASS’Y)

01 251 SOUPAPE DE PRESSURISATION (COMPLET) 0.3 0.3 0.3 0.3 0.3

EXHAUST/INLET VALVES AND/OR SPRINGS AND/OR SEALS (4)

01 255 2.8 2.8 2.2 2.2 2.2
VALVES D’ÉCHAPPEMENT/D’ADMISSION ET/OU RESSORTS ET/OU ANNEAUX (4)
EXHAUST/INLET VALVES AND/OR SPRINGS AND/OR SEALS (8)
01 256 VALVES D’ÉCHAPPEMENT/D’ADMISSION ET/OU RESSORTS ET/OU ANNEAUX (8) 2.9 2.9 2.6 2.6 2.6

EXHAUST/INLET VALVES AND/OR SPRINGS AND/OR SEALS (12)

01 257 VALVES D’ÉCHAPPEMENT/D’ADMISSION ET/OU RESSORTS ET/OU ANNEAUX 3.3 3.3 3.0 3.0 3.0
(12)
COOLANT HOSE (WATER PUMP HOUSING TO ENGINE)
01 260 BOYAU DE REFROIDISSEMENT (BOÎTIER DE LA POMPE À EAU AU MOTEUR) 0.5 0.7 0.7

LONG BLOCK
01 264 ENSEMBLE CARTER-CYLINDRE-CULASSE 5.0 5.0 5.0 5.4 5.4

WATER PUMP DYNAMIC SEAL AND/OR OIL SEAL

01 301 ANNEAU D’ÉTANCHÉITÉ DYNAMIQUE POMPE À EAU ET/OU ANNEAU 3.5 3.5 2.4 3.2 3.2
D’ÉTANCHÉITÉ D’HUILE
CHAINS GUIDE (ALL)
01 305 GUIDE DE CHAINES (TOUS) 3.1 3.1

CAMSHAFT INTAKE/EXHAUST AND/OR CAMSHAFT BRACKETS

01 311 ARBRE A CAM ADMISSION/ECHAPPEMENT ET/OU SUPPORTS D’ARBRE A CAME 4.1 4.1

CYLINDER HEAD GASKET

01 308 3.5 3.5 1.1 1.1 1.1
JOINT D’ÉTANCHÉITÉ DE LA CULASSE
OIL SUMP COVER AND GASKET
01 315 COUVERCLE DE CARTER D’HUILE ET JOINT D’ÉTANCHEITÉ 4.5 4.5

COOLAND TANK SUPPORT

01 331 0.3 0.3 0.3 0.3 0.3
SUPPORT RÉSERVOIR D’ANTIGEL
BOIL OUT PROCEDURE
01 341 PROCÉDURE MOTEUR INONDÉ 3.0 3.0 3.0 3.0 3.0

BALL BEARINGS WITH BELLOW (ASS’Y)

01 344 SOUFFLET ET ROULEMENTS À BILLE 1.0 1.9 1.9

INJECTOR (ONE OR ALL)

01 353 INJECTEUR (UN OU TOUS) 0.4 0.4 0.4 0.4 0.4

THERMOSTAT
01 354 THERMOSTAT 4.7 4.7

OIL SUMP AND GASKET

01 355 5.2 5.2
CARTER D’HUILE ET JOINT D’ÉTANCHEITÉ

Volume 2- Sea-Doo 7
2018
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01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

130/155

RXP X
GTS

GTR
GTI

GTI
SYSTÈME
SYSTEM

CODE

DESCRIPTION
4 5 6/7 8 9

OIL PRESSURE REGULATOR (ASS’Y)

01 373 0.5 0.5
REGULATEUR DE PRESSION D’HUILE

8 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

903

0183
0184
0185

01180

0192

stf2014-001_1

Volume 2- Sea-Doo 9
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

903903
01224

0183 0189
0184
0185

01190

0192

0154

0189

01264
01180

0155

0192

01355

stf2014-001_1
stf2014-001_2

10 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

01194
903
01121
01182

01373

01189

01215

01184

01132
01183
01315
01193

01146 01146

01132
stf2014-001_3

Volume 2- Sea-Doo 11
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

0112
01200

01246
903

01354

0193

01301

0193

01121

stf2014-001_4

12 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

01177

01178
903

0105

0114

01308

01178
01177

stf2014-001_5

Volume 2- Sea-Doo 13
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

903

01311
01111

2
19
01

01179

01248

01174

01191

01305

stf2014-001_6

14 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

0157

01192
0157

01189

0165

01182

F18D0DT

Volume 2- Sea-Doo 15
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

0183
0184
0185

01181 0192

01180

0143

F18D0ES

16 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

0175

01187

Volume 2- Sea-Doo 17
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

01260

01194

01190

01250

01344

01301

0193

01183
01193
01195

F18G06V

18 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

01186

01184

F18G07S

Volume 2- Sea-Doo 19
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

0197

01176

01175

01176

0196

0199

01192
01179

01191
01174

stf2016-001-001

20 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

01251

0112

01189

01194

01182

01184

01183

01195

stf2016-001-002

Volume 2- Sea-Doo 21
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

0182

0152

0188

0163

0121

0135

0136
0153

stf2016-001-003

22 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 ENGINE
MOTEUR 01
SYSTEM/SYSTÈME

0195
0187

0186
01331

0194
01216

0161
Collecteur d’Échappement
Exhaust Manifold/

stf2011-001-001_a

Volume 2- Sea-Doo 23
2018
https://brp-manuals.com/pwc_seadoo
01
SYSTEM/SYSTÈME
ENGINE
MOTEUR

Engine/
Moteur

0182
0188

0152

0163

0135

0101

0136

stf2011-001-002_a 0153

24 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 FUEL SYSTEM
SYSTÈME D'ESSENCE 02
SYSTEM/SYSTÈME

130/155

RXP X
GTS

GTR
GTI
GTI
SYSTÈME
SYSTEM

CODE DESCRIPTION
4 5 6/7 8 9

NO LABOR INVOLVED
02 00 0 0 0 0 0
AUCUNE MAIN-D’OEUVRE
REMOVAL AND/OR INSTALLATION OF AIR SILENCER
02 01
DÉPOSE ET/OU INSTALLATION SILENCIEUX ADMISSION D’AIR
0.5 0.5 0.5 0.5 0.5

FUEL TANK CAP AND/OR SEAL

02 26
BOUCHON DU RÉSERVOIR À ESSENCE ET/OU ANNEAU
0.3 0.3 0.3 0.3 0.3

FUEL TANK FILLER NECK AND/OR GASKET

02 27
GOULOT DE REMPLISSAGE ET/OU JOINT D’ÉTANCHÉITÉ
0.4 0.4 0.4 0.4 0.4

FUEL TANK STRAPS (2 OR 5)

02 29
SANGLES DU RÉSERVOIR À ESSENCE (2 OU 5)
0.5 0.5 0.5 0.5 0.5

FUEL TANK
02 31 1.6 1.6 4.7 5.0 5.0
RÉSERVOIR À ESSENCE
FUEL TANK HOSE (FROM FILLER NECK TO FUEL TANK)
02 36
BOYAU À ESSENCE (GOULOT AU RÉSERVOIR)
0.3 0.3 0.3 0.3 0.3

THROTTLE BODY (ASS’Y)

02 63 0.6 0.6 0.6 0.7 0.7
CARTER D’ACCÉLÉRATEUR (COMPLET)
FUEL PUMP MODULE
02 66
MODULE POMPE À ESSENCE
0.4 0.4 0.4 0.4 0.4

FUEL PUMP INLET FILTER

02 67
FILTRE DU CONDUIT D’ENTRÉE DE POMPE À ESSENCE
0.4 0.4 0.4 0.4 0.4

FUEL RAIL
02 69
RAIL D’ESSENCE
0.3 0.3 0.3 0.3 0.3

AIR TEMPERATURE SENSOR (CARBURETOR ADAPTOR)

02 73
CAPTEUR DE TEMPÉRATURE D’AIR (ADAPTATEUR DE CARBURATEUR)
0.3 0.3 0.3 0.3 0.3

FUEL FEEDING HOSE (ASS’Y)

02 78 0.3 0.3 0.3 0.3 0.3
BOYAU D’ALIMENTATION D’ESSENCE (COMPLET)
AIR PRESSURE SENSOR
02 84
CAPTEUR PRESSION D’AIR
0.3 0.3 0.3 0.3 0.3

AIR INTAKE (ASS’Y)

02 85
ADMISSION D’AIR (COMPLET)
1.0 1.0 0.8 0.8 0.8

COMPRESSOR HOUSING AND/OR BOOSTER AND/OR O-RING

02 87
LOGEMENT DU COMPRESSEUR ET/OU PROPULSEUR ET/OU JOINT TORIQUE
1.2 1.2

COMPRESSOR SHAFT (ASS’Y) AND/OR BALL BEARING

02 89
AXE DE COMPRESSEUR (COMPLET) ET/OU ROULEMENT À BILLES
1.5 1.3

DRIVE GEAR AND/OR NEEDLE PIN AND/OR SPRING WASHER

02 90 ENGRENAGE D’ENTRAÎNEMENT ET/OU GOUPILLE À AIGUILLE ET/OU RONDELLE 1.2 1.2
RESSORT
INTERCOOLER AND/OR O-RING
02 91
REFROIDISSEUR ET/OU JOINT TORIQUE
0.9 0.5

INTERCOOLER SUPPORT AND/OR ALL PARTS

02 92
SUPPORT DU REFROIDISSEUR ET/OU TOUTES LES PIÈCES
0.8

FUEL PUMP NUT AND/OR GASKET

02 93
ÉCROU DE LA POMPE À ESSENCE ET/OU JOINT D'ÉTANCHÉITÉ
0.4 0.4 0.4 0.4 0.4

Volume 2- Sea-Doo 25
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02
SYSTEM/SYSTÈME
FUEL SYSTEM
SYSTÈME D'ESSENCE

130/155

RXP X
GTS

GTR
GTI
GTI
SYSTÈME
SYSTEM

CODE

DESCRIPTION
4 5 6/7 8 9

HOSE (BOOSTER INLET)

02 94 0.3 0.3
BOYAU (ENTRÉE DU PROPULSEUR)
HOSE (BOOSTER OUTLET)
02 96
BOYAU (SORTIE DU PROPULSEUR)
0.3 0.3

HOSE (THROTTLE BODY INLET)

02 97
BOYAU (ENTRÉE CARTER ACCÉLÉRATEUR)
0.3 0.3

FUEL LEVEL SENSOR

02 98
CAPTEUR NIVEAU D'ESSENCE
0.4 0.4 0.4 0.4 0.4

26 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 FUEL SYSTEM
SYSTÈME D'ESSENCE 02
SYSTEM/SYSTÈME

1503 NA ETC

0269

0263

0284
0285

0273

stf2011-001-003_b

GTR

Volume 2- Sea-Doo 27
2018
https://brp-manuals.com/pwc_seadoo
02
SYSTEM/SYSTÈME
FUEL SYSTEM
SYSTÈME D'ESSENCE

0287

0290

0287

0289
0287

stf2016-001-004

28 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 IGNITION
ALLUMAGE 03
SYSTEM/SYSTÈME

0226

0278

0227

0293

0266

0236

0267

0298 0229

0231

stf2012-002-001_a

Volume 2- Sea-Doo 29
2018
https://brp-manuals.com/pwc_seadoo
02
SYSTEM/SYSTÈME
FUEL SYSTEM
SYSTÈME D'ESSENCE

0201

0296

0292

0201

0291
0297

0294
0292

0294

stf2012-002-002_a

30 Sea-Doo - Volume 2
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 IGNITION
ALLUMAGE 03
SYSTEM/SYSTÈME

130/135
GTS

GTR

RXP
GTI
GTI
SYSTÈME
SYSTEM

CODE DESCRIPTION
4 5 6/7 8 9

NO LABOR INVOLVED
03 00 0 0 0 0 0
AUCUNE MAIN-D’OEUVRE
IGNITION COIL
03 04
BOBINE D’ALLUMAGE
0.3 0.3 0.3 0.3 0.3

MAGNETO FLYWHEEL
03 06
VOLANT MAGNÉTIQUE
2.6 2.6 2.5 3.6 3.6

STATOR PLATE (ASS’Y)

03 07
PLAQUE ARMATURE (COMPLET)
2.6 2.6 2.5 3.6 3.6

Volume 2- Sea-Doo 31
2018
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03
SYSTEM/SYSTÈME
IGNITION
ALLUMAGE

0307

0306

F18R07S

32 Sea-Doo - Volume 2
2018
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 STARTER
DÉMARREUR 04
SYSTEM/SYSTÈME

130/155

RXP X
GTS

GTR
GTI

GTI
SYSTÈME
SYSTEM

CODE DESCRIPTION
4 5 6/7 8 9

NO LABOR INVOLVED
04 00 0 0 0 0 0
AUCUNE MAIN-D’OEUVRE
ELECTRIC STARTER (ASS'Y)
04 02
DÉMARREUR ÉLECTRIQUE (COMPLET)
0.5 0.5 0.5 0.6 0.6

ONE OR ALL STARTER COMPONENTS

04 03
UNE OU TOUTES LES PIÈCES DU DÉMARREUR
0.7 0.7 0.7 0.8 0.8

STARTER RELAY
04 05
SOLÉNOÏDE DÉMARREUR
0.3 0.3 0.3 0.3 0.3

STARTER DRIVE (ASS’Y) AND/OR COVER

04 08
ENTRAÎNEMENT DU DÉMARREUR (COMPLET) ET/OU COUVERCLE
2.7 2.7 2.6 3.7 3.7

ELECTRIC STARTER DRIVE (ASS’Y)

04 10 2.6 2.6 2.5 3.6 3.6
ENTRAÎNEMENT DU DÉMARREUR ÉLECTRIQUE (COMPLET)

Volume 2- Sea-Doo 33
2018
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04
SYSTEM/SYSTÈME
STARTER
DÉMARREUR

0402

0410

0408

F09D0XS

34 Sea-Doo - Volume 2
2018
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 PROPULSION
PROPULSION 05
SYSTEM/SYSTÈME

130/155

RXP X
GTS

GTR
GTI

GTI
SYSTÈME
SYSTEM

CODE DESCRIPTION
4 5 6/7 8 9

NO LABOR INVOLVED
05 00 0 0 0 0 0
AUCUNE MAIN-D’OEUVRE
HOSE (FROM SCREEN BAILERS TO IMPELLER HOUSING)
05 02
BOYAU (TAMIS DÉCLENCHEMENT AU CARTER D’HÉLICE)
0.4 0.4 0.4 0.4 0.4

STEERING NOZZLE AND/OR BUSHING AND/OR SLEEVE

05 04
BUSE DE DIRECTION ET/OU DOUILLE ET/OU MANCHON
0.3 0.4 0.4 0.4 0.4

VENTURI AND/OR O-RING

05 05
VENTURI ET/OU JOINT TORIQUE
0.4 0.4 0.4 0.4 0.4

IMPELLER SHAFT HOUSING COVER AND/OR O-RINGS AND/OR GREASE

05 06
COUVERCLE ARBRE TURBINE ET/OU JOINT TORIQUE ET/OU GRAISSE
0.5 0.5 0.5 0.5 0.5

PTO FLYWHEEL RUBBER BOOT CLAMP (EACH)

05 07 0.3 0.3 0.3 0.3 0.3
COLLIER DE SERRAGE DU SOUFFLET VOLANT PDM (CHACUN)
RUBBER BOOT
05 08
SOUFFLET CAOUTCHOUC
0.9 0.9 0.9 1.2 1.2

IMPELLER HOUSING FITTING

05 10 0.4 0.4 0.4 0.4 0.4
RACCORD DU CARTER D'HÉLICE
DRIVE SHAFT AND/OR BUMPER PLUG
05 11
ARBRE DE TRANSMISSION ET/OU BOUCHON CONTRE CHOC
0.7 0.7 0.7 0.7 0.7

IMPELLER AND/OR SHAFT AND/OR WASHER AND/OR THRUST BEARING

05 12
TURBINE ET/OU ARBRE ET/OU RONDELLE ET/OU PALIER BUTÉE
1.1 1.1 1.1 1.1 1.1

IMPELLER HOUSING (ASS’Y)

05 13
CARTER D’HÉLICE (COMPLET)
1.1 1.1 1.1 1.1 1.1

IMPELLER SHAFT DOUBLE LIP SEAL AND/OR BEARING

05 14
ANNEAU ÉTANCHÉITÉ D'ARBRE TURBINE ET/OU ROULEMENT À BILLES
1.1 1.1 1.1 1.1 1.1

WEAR RING
05 15 1.4 1.4 1.4 1.4 1.4
BAGUE D’USURE
HULL STUDS (IMPELLER HOUSING) (1 OR 2)
05 16
GOUJONS COQUE (CARTER D’HÉLICE) (1 OU 2)
0.6 0.6 0.6 0.6 0.6

HULL STUDS (IMPELLER HOUSING) (3 OR 4)

05 17
GOUJONS COQUE (CARTER D’HÉLICE) (3 OU 4)
0.8 0.8 0.8 0.8 0.8

WATER INLET GRATE

05 18
GRILLE DE POMPE (ADMISSION D’EAU)
0.4 0.4 0.4 0.4 0.4

IMPELLER HOUSING REMOVAL AND INSTALLATION

05 21
DÉPOSE ET INSTALLATION DU CARTER D’HÉLICE
0.5 0.5 0.5 0.5 0.5

REVERSE GATE (ASS’Y)

05 30
DÉFLECTEUR DE MARCHE ARRIÈRE (COMPLET)
0.4 0.4 0.4 0.4

PUMP SUPPORT
05 38
SUPPORT DE POMPE
3.3 3.3 3.3 3.3 3.3

RING CARBONE
05 45 0.9 0.9 0.9 1.2 1.2
BAGUE AU CARBONE
FLOATING RING
05 57
BAGUE FLOTTANTE
0.9 0.9 0.9 1.2 1.2

Volume 2- Sea-Doo 35
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05
SYSTEM/SYSTÈME
PROPULSION
PROPULSION

130/155

RXP X
GTS

GTR
GTI

GTI
SYSTÈME
SYSTEM

CODE

DESCRIPTION
4 5 6/7 8 9

ARM BLACK
05 64 0.4 0.4 0.4 0.4 0.4
BRAS NOIR
ROD PIVOT
05 66
PIVOT DE RACCORD
0.4 0.4 0.4 0.4 0.4

iBR ACTUATOR
05 76
ACTUATEUR iBR
0.7 0.7 0.7 0.7 1.2

GUARD
05 77
PROTECTEUR
0.3 0.3 0.3 0.3 0.3

36 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 PROPULSION
PROPULSION 05
SYSTEM/SYSTÈME

0513
0510

0504
0514
0512

0505
0515
0513

0506

stf2011-001-005_a

Volume 2- Sea-Doo 37
2018
https://brp-manuals.com/pwc_seadoo
05
SYSTEM/SYSTÈME
PROPULSION
PROPULSION

0557

0511

0538
0516
0545 0517

0508
0507

0518

stf2011-001-006_b

38 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 PROPULSION
PROPULSION 05
SYSTEM/SYSTÈME

0564

0538 0530

0577
0566

0530

0566
0504

mtf2016-001-005

Volume 2- Sea-Doo 39
2018
https://brp-manuals.com/pwc_seadoo
05
SYSTEM/SYSTÈME
PROPULSION
PROPULSION

0576

0564

stf2016-001-006

40 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 STEERING AND CONTROLS
DIRECTION ET COMMANDES 07
SYSTEM/SYSTÈME

130/155

RXP X
GTS

GTR
GTI
GTI
SYSTÈME
SYSTEM

CODE DESCRIPTION
4 5 6/7 8 9

NO LABOR INVOLVED
07 00 0 0 0 0 0
AUCUNE MAIN-D’OEUVRE
HANDLE GRIP (1 OR 2)
07 01
GAINE DE GUIDON (1 OU 2)
0.3 0.3 0.3 0.3 0.3

HANDLE HOUSING (LEFT)

07 03
LOGEMENT DE GUIDON (GAUCHE)
0.3 0.3 0.3 0.3 0.3

THROTTLE HANDLE HOUSING (RIGHT)

07 04
LOGEMENT DE MANETTE D’ACCÉLÉRATEUR (DROIT)
0.3 0.3 0.3 0.3 0.3

STEERING COVER AND/OR FOAM

07 05
COUVRE-GUIDON ET/OU MOUSSE
0.4 0.4 0.4 0.4 0.4

HANDLEBAR
07 06 0.9 0.9 0.9
GUIDON
STEERING STEM ARM
07 07
BRAS DE TIGE DE DIRECTION
0.4 0.4 0.4 0.4 0.4

STEERING CABLE (FROM NOZZLE TO STEM ARM)

07 13 0.8 0.8 0.8 0.8 0.8
CÂBLE DE DIRECTION (DE LA BUSE AU BRAS DE TIGE)
FRONT BALL JOINT STEERING CABLE
07 14
JOINT À ROTULE AVANT (CÂBLE DE DIRECTION)
0.3 0.3 0.3 0.3 0.3

REAR BALL JOINT STEERING CABLE (1 OR 2)

07 15
JOINT À ROTULE ARRIÈRE (CÂBLE DE DIRECTION) (1 OU 2)
0.3 0.3 0.3 0.3 0.3

STEERING SUPPORT
07 44
SUPPORT DIRECTION
1.3 1.3 1.3 1.3 1.3

HANDLE BAR EXTENSION

07 79
RALLONGE DE GUIDON
0.4 0.4

THROTTLE HANDLE AND/OR BUSHINGS

07 81 0.4 0.4 0.4 0.4 0.4
MANETTE ACCÉLÉRATEUR ET/OU COUSSINETS
REVERSE HANDLE AND/OR BUSHINGS
07 82
MANETTE DE RENVERSE ET/OU COUSSINETS
0.4 0.4 0.4 0.4 0.4

WEAR RING
07 85
BAGUE D'USURE
0.6 0.6 0.6 0.6 0.6

ADAPTER CABLE
07 87
ADAPTATEUR DE CÂBLE
1.0 1.0 1.0 1.0 1.0

HANDLEBAR EXTENSION TUBE (RH)

07 88
TUBE D’EXTENSION DU GUIDON (DROIT)
0.4 0.4

HANDLEBAR EXTENSION TUBE (LH)

07 89
TUBE D’EXTENSION DU GUIDON (GAUCHE)
0.4 0.4

Volume 2- Sea-Doo 41
2018
https://brp-manuals.com/pwc_seadoo
07
SYSTEM/SYSTÈME
STEERING AND CONTROLS
DIRECTION ET COMMANDES

0703

0782

0705 0704

0701
0781

0785

0706 0744

0714

0707

0713

0787

0715

stf2011-001-008_a

42 Sea-Doo - Volume 2
2018
https://brp-manuals.com/pwc_seadoo
 STEERING AND CONTROLS
DIRECTION ET COMMANDES 07
SYSTEM/SYSTÈME

RXP X

0714

0713

0779
0705

0704

0715
0781
0701
0703
0788
0708

0707
0779
0782

0701
0789

0785

0744

stf2012-002-003_a

Volume 2- Sea-Doo 43
2018
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09
SYSTEM/SYSTÈME
BODY
CARROSSERIE

130/155

RXP X
GTS

GTR
GTI
GTI
SYSTÈME
SYSTEM

CODE

DESCRIPTION
4 5 6/7 8 9

NO LABOR INVOLVED
09 00 0 0 0 0 0
AUCUNE MAIN-D’OEUVRE
FRONT BUMPER
09 01
PARE-CHOCS AVANT
0.3 0.3 0.3 0.3 0.3

SIDE BUMPER (LEFT OR RIGHT) (1)

09 02
PARE-CHOCS LATÉRAL (GAUCHE OU DROIT) (1)
0.3 0.3 0.3 0.3 0.3

SIDE BUMPER (BOTH SIDE) (2)

09 04
PARE-CHOCS LATÉRAL (LES DEUX CÔTÉS) (2)
0.4 0.4 0.4 0.4 0.4

REAR BUMPER
09 06
PARE-CHOCS ARRIÈRE
0.3 0.3 0.3 0.3 0.3

CORNER BUMPER (LEFT OR RIGHT)1

09 08 0.3 0.3 0.3 0.3 0.3
PARE-CHOCS EN COIN (GAUCHE OU DROIT)
“U” CLAMP AND/OR SKI HOOK AND/OR FINITION/RETAINER PLATE
09 09
BRIDE EN «U» ET/OU CROCHET SKI ET/OU PLAQUE RETENUE
0.3 0.3 0.3 0.3 0.3

STORAGE COVER (ANY OR ALL PARTS)

09 10 0.5 0.5 0.5 1.5 1.5
COUVERCLE À BAGAGES (UNE OU TOUTES LES PIÈCES)
STORAGE COVER HINGE
09 11
CHARNIÈRE COUVERCLE À BAGAGES
0.4 0.4 0.4 0.4 0.4

STORAGE COVER LATCH

09 12
LOQUET DU COUVERCLE À BAGAGES
0.3 0.3 0.3 0.3 0.3

STORAGE COVER NEOPRENE SEAL

09 13
ANNEAU EN NÉOPRÈNE DU COUVERCLE À BAGAGES
0.3 0.3 0.3 0.3 0.3

STORAGE COVER DECAL

09 14
AUTOCOLLANT DU COUVERCLE À BAGAGES
0.6 0.6 0.6 0.6 0.6

SIDE BODY DECAL (RIGHT) (1 OR 2)

09 15 0.6 0.6 0.6 0.6 0.6
AUTOCOLLANT LATÉRAL DE LA CARROSSERIE (DROIT) (1 OU 2)
SIDE BODY DECAL (LEFT) (1 OR 2)
09 16
AUTOCOLLANT LATÉRAL DE LA CARROSSERIE (GAUCHE) (1 OU 2)
0.6 0.6 0.6 0.6 0.6

ALL BODY DECALS

09 17
TOUS LES AUTOCOLLANTS DE LA CARROSSERIE
1.2 1.4 1.4 1.4 1.4

SIDE CARPET (1)

09 19
TAPIS LATÉRAL (1)
0.3 0.3 0.3 0.3 0.3

SIDE CARPET (2)

09 20
TAPIS LATÉRAL (2)
0.5 0.5 0.5 0.5 0.5

REAR CARPET
09 21
TAPIS ARRIÈRE
0.3 0.5 0.5 0.5 0.5

SEAT (ASS’Y)
09 22
SIÈGE (COMPLET)
0.3 0.3 0.3 0.3 0.3

SEAT COVER
09 24 1.9 1.9 1.9 1.9 1.9
HOUSSE DE SIÈGE
SEAT BASE NEOPRENE SEAL
09 26
ANNEAU EN NÉOPRÈNE DE LA BASE DU SIÈGE
0.3 0.3 0.3 0.3 0.3

44 Sea-Doo - Volume 2
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 BODY
CARROSSERIE 09
SYSTEM/SYSTÈME

130/155

RXP X
GTS

GTR
GTI
GTI
SYSTÈME
SYSTEM

CODE DESCRIPTION
4 5 6/7 8 9

SEAT LACHT (ANY OR ALL PARTS)

09 28 0.3 0.3 0.3 0.3 0.3
LOQUET DE SIÈGE (UNE OU TOUTES LES PIÈCES)
SEAT LATCH HOOK
09 29
CROCHET DU LOQUET DU SIÈGE
0.3 0.3 0.3 0.3 0.3

LACHT STUD ( SEAT)

09 30
ERGOT D’ENCRAGE (SIÈGE)
0.3 0.3 0.3 0.3 0.3

FRONT TUBE VENT

09 31
BOYAU DE VENTILATION AVANT
0.3 0.3 0.3 0.3 0.3

BOX GLOVES
09 35
COFFRE À GANTS
1.0 1.0 1.0 1.0 1.0

PLATFORM CARPET (RIGHT OR LEFT)

09 36 0.3 0.3 0.3 0.3 0.3
TAPIS DE PLATE-FORME (DROIT OU GAUCHE)
GRAB HANDLE
09 37
POIGNÉE DE MAINTIEN
0.4 0.4 0.4 0.4 0.4

SPONSON (RIGHT OR LEFT) (EACH)

09 38 0.3 0.3 0.3 0.3 0.3
STABILISATEUR (DROIT OU GAUCHE) (CHACUN)
MIRROR (1)
09 39
RÉTROVISEUR (1)
0.3 0.3 0.3 0.3 0.3

MIRRORS (2)
09 40
RÉTROVISEURS (2)
0.4 0.4 0.4 0.4 0.4

SIDE HULL DECAL (1)

09 44
AUTOCOLLANT LATÉRAL DE LA COQUE (1)
0.4 0.4 0.4 0.4 0.4

SIDE HULL DECALS (RIGHT) (2)

09 45
AUTOCOLLANTS LATÉRAUX DE LA COQUE (2)
0.6 0.6 0.6 0.6 0.6

SIDE MOULDING (RIGHT OR LEFT)

09 46 0.3 0.3 0.3 0.3 0.3
ENJOLIVEUR LATÉRAL (DROIT OU GAUCHE)
REAR SIDE BODY DECAL
09 50
AUTOCOLLANT ARRIÈRE DE LA CARROSSERIE
0.3 0.3 0.3 0.3 0.3

BRP DECAL(S)
09 51
AUTOCOLLANT(S) BRP
0.3 0.3 0.3 0.3 0.3

REBORDING LADDER ANT/OR SUPPORT (ASS’Y)

09 55
ÉCHELLE D’EMBARQUEMENT ET/OU SUPPORT (COMPLET)
0.5 0.5

SIDE GRILL (RIGHT OR LEFT)

09 56
GRILLE LATÉRALE (DROITE OU GAUCHE)
0.3 0.3

DEFLECTOR
09 77
DÉFLECTEUR
0.3 0.3 0.3 0.3 0.3

LOWER STORAGE COVER (ANY OR ALL PARTS)

09 88 COUVERCLE DU COMPARTIMENT DE RANGEMENT INFÉRIEUR 0.5 0.5 0.5 1.4 1.4
(UNE OU TOUTES LES PIÈCES)
SPONSON SPACER
09 100 ENTRETOISE DU STABILISATEUR 1.0 1.0

SIDE CARPETS (3)

09 152 TAPIS LATÉRAUX (3) 0.7 0.7 0.7 0.7 0.7

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09
SYSTEM/SYSTÈME
BODY
CARROSSERIE

130/155

RXP X
GTS

GTR
GTI
GTI
SYSTÈME
SYSTEM

CODE

DESCRIPTION
4 5 6/7 8 9

FRONT GRILL
09 168 1.1 1.1
GRILLE FRONTALE
SIDE CARPETS (4)
09 204 TAPIS LATÉRAUX (4) 0.9 0.9 0.9 0.9 0.9

SIDE CARPETS (5)

09 205 TAPIS LATÉRAUX (5) 1.1 1.1 1.1 1.1 1.1

SIDE CARPETS (6)

09 206 TAPIS LATÉRAUX (6) 1.3 1.3 1.3 1.3 1.3

SIDE CARPETS (ALL)

09 207 TAPIS LATÉRAUX (TOUS) 1.5 1.5 1.5 1.5 1.5

HANDLE STEM (WAKE PYLON)

09 254 0.4
POIGNÉE (POTEAU WAKE)
EXTENSION TUBE (WAKE PYLON)
09 255 TUBE D’EXTENSION (POTEAU WAKE) 1.0

WAKE PYLON MOULDED

09 256 1.0
POTEAU WAKE MOULÉ
LOCKING STRAP
09 257 COURROIE DE BLOCAGE 0.3

BLEED PLUG
09 262 BOUCHON DE PURGE 0.3 0.3 0.3 0.3 0.3

BOX DOOR
09 284 PORTE DE COFFRE 0.4 0.4 0.4 0.4 0.4

DASHBOARD BEZEL
09 291 ENJOLIVEUR DE TABLEAU DE BORD 0.3 0.3 0.3 0.3 0.3

MIRROR SUPPORT
09 380 0.5 0.5 0.5 0.5 0.5
SUPPORT DE MIROIRS
DIVIDER
09 381 CLOISON 0.3 0.3 0.3 0.3 0.3

HULL INSERT
09 382 PASSE-COQUE 1.2 1.2 1.5 1.5 1.5

FOOTREST (RH OR LH)

09 390 APPUI-PIEDS (DROIT OU GAUCHE) 0.3 0.3

REAR COSMETIC AND COVER

09 391 ENJOPLIVEUR ARRIÈRE ET COUVERCLE 0.4 0.4

HANDLE COSMETIC (RH AND/OR LH)

09 392 ENJOLIVEUR DE POIGNÉE (DROIT ET/OU GAUCHE) 0.3 0.3

COSMETIC DEFLECTOR
09 393 DÉFLECTEUR ENLOLIVEUR 0.3 0.3

STORAGE COVER COSMETIC (RH OR LH)

09 394 1.1 1.1
ENJOLIVEUR DE COUVERCLE À BAGAGE (DROIT OU GAUCHE)
TRIM TAB
09 402 CORRECTEUR D’ASSIETTE 0.3 0.3

46 Sea-Doo - Volume 2
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 BODY
CARROSSERIE 09
SYSTEM/SYSTÈME

0939
0940
09291

09380

09284

0946
0956
0935

0946
0956
0946
0908

0977
0906
0956

09390

0908

0902
0904

09390

0902
0904 0901

09381

stf2012-002-004_a

Volume 2- Sea-Doo 47
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09
SYSTEM/SYSTÈME
BODY
CARROSSERIE

0909

09382

0938
0909

0962
09100 09402
stf2013-001-001_a

48 Sea-Doo - Volume 2
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 BODY
CARROSSERIE 09
SYSTEM/SYSTÈME

0919, 0920, 09152,

09204, 09205
09206,09207

0936

0930
0921

0937

09392

09391

09392

0909

stf2012-002-005_a

Volume 2- Sea-Doo 49
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09
SYSTEM/SYSTÈME
BODY
CARROSSERIE

09393

09168

0910

0912

0988

09394

0911
0913

stf2012-002-006_a

50 Sea-Doo - Volume 2
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 BODY
CARROSSERIE 09
SYSTEM/SYSTÈME

0912

0910

0988

0913

0911

stf2011-001-009_a

Volume 2- Sea-Doo 51
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09
SYSTEM/SYSTÈME
BODY
CARROSSERIE

09254

09255

09256 09257

Stf2009-001-002_a

52 Sea-Doo - Volume 2
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 BODY
CARROSSERIE 09
SYSTEM/SYSTÈME

0901

0902
0904
0902
0904
0937

0908
0906
0909

LTD

0908

stf2011-001-010_a

Volume 2- Sea-Doo 53
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09
SYSTEM/SYSTÈME
BODY
CARROSSERIE

0921

0936
09152
09204
09205
09206
09207
0919
0920

09381
09284

0946
0935
0939
0940

09380
09291

0946

stf2011-001-011_a

54 Sea-Doo - Volume 2
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 BODY
CARROSSERIE 09
SYSTEM/SYSTÈME

0938
09382

0938

09262

0955

stf2011-001-012_a

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10
SYSTEM/SYSTÈME
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE

130/155

RXP X
GTS

GTR
GTI
GTI
SYSTÈME
SYSTEM

CODE

DESCRIPTION
4 5 6/7 8 9

NO LABOR INVOLVED
10 00 0 0 0 0 0
AUCUNE MAIN-D’OEUVRE
BATTERY
10 03
BATTERIE
0.3 0.3 0.3 0.3 0.3

GROUND CABLE
10 04
CÂBLE DE MASSE
0.4 0.4 0.4 0.4 0.4

BATTERY RED CABLE (BATTERY TO STARTER RELAY)

10 05
CÂBLE ROUGE DE BATTERIE (BATTERIE AU SOLÉNOÏDE)
0.3 0.3 0.3 0.3 0.3

BATTERY RED CABLE (STARTER TO STARTER RELAY)

10 06
CÂBLE ROUGE DE BATTERIE (DÉMARREUR AU SOLÉNOÏDE)
0.5 0.5 0.5 0.5 0.5

REGULATOR (ASS'Y)/RECTIFIER (ASS’Y)

10 11 0.3 0.3 0.3 0.3 0.3
RÉGULATEUR (COMPLET)/REDRESSEUR (COMPLET)
MAIN HARNESS (ASS’Y)
10 12
CÂBLAGE PRINCIPAL (COMPLET)
2.2 2.2 2.2 2.2 2.2

BATTERY SUPPORT
10 15 0.3 0.3 0.3 0.3 0.3
SUPPORT DE BATTERIE
D.E.S.S. KEY
10 28
CLÉ D.E.S.S.
0.3 0.3 0.3 0.3 0.3

L.C.D INFO GAUGE (MULTIFUNCTION GAUGE)

10 46
CADRAN INFO MULTIFONCTION
0.3 0.3 0.3 0.3 0.3

ELECTRONIC CONTROL UNIT

10 56
UNITÉ CONTRÔLE ÉLECTRONIQUE
0.4 0.4 0.4 0.4 0.4

ENGINE HARNESS (ASS’Y)

10 61
CÂBLAGE MOTEUR (COMPLET)
1.0 1.0 1.0 1.0 1.0

STEERING HARNESS (ASS’Y)

10 62 0.8 0.8 0.8 0.8 0.8
CÂBLAGE GUIDON (COMPLET)
OTAS SWITCH
10 64
INTERRUPTEUR DE L’OTAS
0.6 0.6 0.6 0.6 0.6

D.E.S.S. POST
10 65
BORNE D.E.S.S.
0.7 0.7 0.7 0.7 0.7

TOPS SWITCH
10 66
INTERRUPTEUR TOPS
0.3 0.3 0.3 0.3 0.3

STARTING RELAY
10 77
RELAIS DE DÉMARRAGE
0.3 0.3 0.3 0.3 0.3

OTAS ACTUATOR
10 78
ACTIONNEUR DE L’OTAS
0.7 0.7 0.7 0.7 0.7

BRAKE SENSOR
10 79
CAPTEUR DE FREINAGE
0.3 0.3 0.3 0.3 0.3

THROTTLE SENSOR
10 80 0.3 0.3 0.3 0.3 0.3
CAPTEUR D'ACCÉLÉRATEUR
CONTROLE SWITCH (RIGHT OR LEFT)
10 81
INTERRUPTEUR DE CONTRÔLE (DROIT OU GAUCHE)
0.3 0.3 0.3 0.3 0.3

56 Sea-Doo - Volume 2
2018
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 ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE 10
SYSTEM/SYSTÈME

1046

1080

1064
1081

1012
1078
1065
1062

1077
1003
1028
1079
1081

1005
1015

1004
1011

stf2011-001-013_a

Volume 2- Sea-Doo 57
2018
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