Sea-doo 2005 WAKE Shop Manual

C M Y CM MY CY CMY K

www.SeaDooManuals.net

2005

Vehicle Shop Manual

4-TEC Series

www.SeaDooManuals.net

Legal deposit:

National Library of Quebec

National Library of Canada 2005

permission of Bombardier Recreational Products Inc. (BRP)

©

Bombardier Recreational Products Inc. (BRP) 2005

Technical Publications

Bombardier Recreational Products Inc. (BRP)

Valcourt (Quebec) Canada

PrintedinCanada

®TM

Registered trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.

* Trademark of Bombardier Inc. used under license.

SEA-DOO

®

BOMBARDIER-ROTAX

®

BOMBARDIER LUBE

®

Sea-Doo

®

Learning Key

TM

DESS

TM

Rotax

®

O.P.A.S.

TM

TOPS

TM

This document contains the trademarks of the following companies:

Knight’s Spray-Nine

†

is a trademark of Korkay System Ltd

GTX

†

is a trademark of Castrol Ltd. Used under license

Loctite

®

is a trademark of Loctite Corporation

Snap-on

®

is a trademark of Snap-on Tools Corporation

Gelcote

®

is a trademark of Gelcote International Limited

Molykote

©

is a trademark of Dow Corning Corporation

AMP

©

is a trademark of Tyco Electronics Corporation

www.SeaDooManuals.net

TABLE OF CONTENTS

SAFETY NOTICE................................................................................... VI

INTRODUCTION ................................................................................... VII

GENERAL INFORMATION......................................................................................... VII

ARRANGEMENT OF THIS MANUAL........................................................................... VIII

ABBREVIATIONS USED IN THIS MANUAL ................................................................... VIII

ILLUSTRATIONS AND PROCEDURES .......................................................................... IX

ENGINE EMISSIONS INFORMATION ........................................................................... XII

SELF-LOCKING FASTENERS PROCEDURE .................................................................... XII

LOCTITE APPLICATION PROCEDURE.......................................................................... XIII

TIGHTENING TORQUES ......................................................................................... XVI

01 MAINTENANCE

01 – MAINTENANCE CHART....................................................................................... 1

02 – PRESEASON PREPARATION................................................................................. 3

03 – STORAGE PROCEDURES..................................................................................... 5

PROPULSION SYSTEM............................................................................................... 5

FUEL SYSTEM......................................................................................................... 5

ENGINE OIL AND FILTER REPLACEMENT ......................................................................... 5

OPENED LOOP COOLING SYSTEM ................................................................................ 5

CLOSED LOOP COOLING SYSTEM (ENGINE) ..................................................................... 8

ENGINE LUBRICATION............................................................................................... 8

THROTTLE BODY LUBRICATION.................................................................................... 8

ANTIFREEZING PROTECTION....................................................................................... 8

BATTERY............................................................................................................... 9

WATERCRAFT CLEANING............................................................................................ 9

ANTICORROSION TREATMENT..................................................................................... 9

CHECKLIST........................................................................................................... 10

04 – SPECIAL PROCEDURES..................................................................................... 11

TOWING THE WATERCRAFT IN WATER........................................................................... 11

SUBMERGED WATERCRAFT ....................................................................................... 12

WATER-FLOODED ENGINE......................................................................................... 12

02 TROUBLESHOOTING

01 – TROUBLESHOOTING CHART.............................................................................. 15

ENGINE WILL NOT START.......................................................................................... 15

ENGINE HARD TO START........................................................................................... 17

ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED.............................................................. 18

ENGINE MISFIRES, RUNS IRREGULARLY......................................................................... 18

ENGINE CONTINUALLY BACKFIRES............................................................................... 19

ENGINE DETONATION OR PINGING............................................................................... 19

ENGINE LACKS ACCELERATION OR POWER .................................................................... 20

ENGINE STOPS RUNNING .......................................................................................... 20

ENGINE CANNOT REACH MAXIMUM RPM ...................................................................... 21

ENGINE RUNS TOO FAST (VEHICLE CANNOT REACH ITS TOP SPEED)....................................... 21

ENGINE OVERHEATS................................................................................................ 22

ENGINE SMOKE IN THE EXHAUST ................................................................................ 22

LOW OR NO ENGINE OIL PRESSURE............................................................................. 23

ENGINE OIL CONTAMINATION (MILKY)........................................................................... 23

UNUSUAL ENGINE NOISE AND/OR VIBRATION ................................................................. 24

INAPPROPRIATE SPEEDOMETER READING ..................................................................... 24

ABNORMAL NOISE FROM PROPULSION SYSTEM.............................................................. 24

I

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TABLE OF CONTENTS

03 ENGINE SYSTEM

01 – AIR INTAKE SYSTEM........................................................................................ 27

INSPECTION.......................................................................................................... 30

REMOVAL ............................................................................................................ 30

INSTALLATION....................................................................................................... 31

02 – LUBRICATION SYSTEM..................................................................................... 33

GENERAL............................................................................................................. 33

OIL LEVEL VERIFICATION........................................................................................... 33

OIL CHANGE ......................................................................................................... 34

OIL TYPE AND SYSTEM CAPACITY ................................................................................ 35

OIL FILTER............................................................................................................ 35

03 – COOLING SYSTEM .......................................................................................... 37

CLOSED LOOP COOLING SYSTEM (ENGINE) .......................................................... 38

CIRCUIT............................................................................................................... 39

COOLING SYSTEM LEAK TEST..................................................................................... 39

INSPECTION.......................................................................................................... 40

COOLANT REPLACEMENT ......................................................................................... 40

CARE .................................................................................................................. 42

TECHNICAL SPECIFICATIONS...................................................................................... 42

OPENED LOOP COOLING SYSTEM (EXHAUST SYSTEM)............................................ 43

CIRCUIT............................................................................................................... 45

CARE .................................................................................................................. 46

TECHNICAL SPECIFICATIONS...................................................................................... 47

04 – EXHAUST SYSTEM.......................................................................................... 49

EXHAUST PIPE....................................................................................................... 51

EXHAUST MANIFOLD............................................................................................... 54

MUFFLER............................................................................................................. 55

RESONATOR ......................................................................................................... 56

EXHAUST OUTLET................................................................................................... 56

05 – REMOVAL AND INSTALLATION........................................................................... 59

ENGINE REMOVAL .................................................................................................. 59

CLEANING............................................................................................................ 63

INSTALLATION....................................................................................................... 63

04 ENGINE MANAGEMENT (1503 4-TEC)

01 – OVERVIEW .................................................................................................... 67

OPERATING PRINCIPLE..................................................................................... 68

AIR INDUCTION...................................................................................................... 68

FUEL SYSTEM........................................................................................................ 70

ELECTRICAL SYSTEM............................................................................................... 70

ENGINE MANAGEMENT SYSTEM (EMS) ............................................................... 72

EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS......................................................... 74

02 – DIAGNOSTIC PROCEDURES............................................................................... 79

GENERAL............................................................................................................. 79

SELF-DIAGNOSTIC MODE.......................................................................................... 81

ENGINE MANAGEMENT SYSTEM FAULT CODES................................................................ 82

VCK (VEHICLE COMMUNICATION KIT).......................................................................... 105

03 – COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT ................................ 107

GENERAL..................................................................................................... 107

FUEL SYSTEM...................................................................................................... 107

ELECTRICAL SYSTEM............................................................................................. 108

TESTING PROCEDURES................................................................................... 111

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TABLE OF CONTENTS

IDLE SPEED ........................................................................................................ 111

IGNITION TIMING.................................................................................................. 111

SAFETY LANYARD SWITCH VERIFICATION..................................................................... 111

ECM AND MPEM.................................................................................................. 112

ENGINE WIRING HARNESS....................................................................................... 113

FUEL INJECTOR ................................................................................................... 115

THROTTLE BODY .................................................................................................. 117

THROTTLE POSITION SENSOR (TPS)............................................................................ 120

IDLE BYPASS VALVE............................................................................................... 122

CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 122

CAMSHAFT POSITION SENSOR (CAPS)......................................................................... 123

MANIFOLD AIR TEMPERATURE SENSOR (MATS) ............................................................. 124

COOLANT TEMPERATURE SENSOR(CTS)...................................................................... 125

MANIFOLD AIR PRESSURE SENSOR (MAPS) .................................................................. 125

EXHAUST GASTEMPERATURE SENSOR (EGTS)............................................................... 126

KNOCK SENSOR (KS).............................................................................................. 127

OIL PRESSURE SENSOR (OPS) .................................................................................. 128

TOPS VALVE........................................................................................................ 128

OIL SEPARATOR PRESSURE SENSOR (OSPS) ................................................................. 129

TOPS SWITCH...................................................................................................... 130

05 FUEL SYSTEM

01 – FUEL TANK AND FUEL PUMP ............................................................................ 133

GENERAL........................................................................................................... 135

REMOVAL .......................................................................................................... 136

INSPECTION........................................................................................................ 137

INSTALLATION..................................................................................................... 139

TESTING PROCEDURES .......................................................................................... 140

06 ELECTRICAL SYSTEM

01 – IGNITION SYSTEM ......................................................................................... 145

GENERAL........................................................................................................... 147

QUICK TEST WITH B.U.D.S. ...................................................................................... 147

VOLTAGE TEST..................................................................................................... 147

IGNITION COIL..................................................................................................... 148

SPARK PLUGS...................................................................................................... 149

IGNITION TIMING ................................................................................................. 149

02 – CHARGING SYSTEM ....................................................................................... 151

GENERAL..................................................................................................... 153

TESTING PROCEDURE..................................................................................... 153

RECTIFIER/REGULATOR .......................................................................................... 154

STATOR............................................................................................................. 155

BATTERY............................................................................................................ 157

03 – STARTING SYSTEM ........................................................................................ 163

STARTING SYSTEM TROUBLESHOOTING ...................................................................... 166

GENERAL........................................................................................................... 167

STARTER REMOVAL............................................................................................... 168

STARTER DISASSEMBLY.......................................................................................... 168

STARTER CLEANING .............................................................................................. 169

STARTER INSPECTION............................................................................................ 170

STARTER ASSEMBLY.............................................................................................. 170

STARTER INSTALLATION ......................................................................................... 170

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TABLE OF CONTENTS

STARTER SPECIFICATION ........................................................................................ 171

04 – INSTRUMENTS AND ACCESSORIES.................................................................... 173

GENERAL........................................................................................................... 173

COMPONENT DESCRIPTION..................................................................................... 173

PROCEDURES...................................................................................................... 177

07 PROPULSION

01 – JET PUMP.................................................................................................... 183

GENERAL........................................................................................................... 186

JET PUMP INSPECTION ON WATERCRAFT..................................................................... 186

REMOVAL .......................................................................................................... 187

DISASSEMBLY ..................................................................................................... 190

CLEANING.......................................................................................................... 193

PARTS INSPECTION ............................................................................................... 193

ASSEMBLY ......................................................................................................... 194

PUMP PRESSURIZATION ......................................................................................... 199

INSTALLATION..................................................................................................... 199

02 – DRIVE SYSTEM.............................................................................................. 203

GENERAL........................................................................................................... 205

REMOVAL .......................................................................................................... 205

INSPECTION........................................................................................................ 208

INSTALLATION..................................................................................................... 209

LUBRICATION...................................................................................................... 213

03 – REVERSE SYSTEM .. ....................................................................................... 215

DISASSEMBLY ..................................................................................................... 217

INSPECTION........................................................................................................ 219

ASSEMBLY ......................................................................................................... 219

ADJUSTMENT...................................................................................................... 219

04 – VARIABLE TRIM SYSTEM ................................................................................. 221

GENERAL........................................................................................................... 223

REMOVAL .......................................................................................................... 223

DISASSEMBLY ..................................................................................................... 223

INSPECTION........................................................................................................ 224

ASSEMBLY ......................................................................................................... 224

INSTALLATION..................................................................................................... 224

ADJUSTMENT...................................................................................................... 225

08 STEERING SYSTEM

01 – STEERING SYSTEM ........................................................................................ 227

DISASSEMBLY ..................................................................................................... 229

ASSEMBLY ......................................................................................................... 234

ALIGNMENT........................................................................................................ 236

02 – OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.).............................................. 239

GENERAL........................................................................................................... 242

SIDE VANE.......................................................................................................... 242

CYLINDER SUPPORT.............................................................................................. 243

TIEROD............................................................................................................. 246

SEALED TUBE...................................................................................................... 246

FILTER............................................................................................................... 247

VALVE ............................................................................................................... 247

WATER HOSE ...................................................................................................... 248

CROSS SUPPORT PLATE ......................................................................................... 248

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TABLE OF CONTENTS

09 HULL/BODY

01 – ADJUSTMENT AND REPAIR .............................................................................. 251

GENERAL........................................................................................................... 262

GLOVE BOX ........................................................................................................ 262

ENGINE COVER.................................................................................................... 263

SEAT ADJUSTMENT............................................................................................... 263

STORAGE COMPARTMENT INNER SHELL ..................................................................... 264

STORAGE COVER SHOCK........................................................................................ 269

STORAGE COMPARTMENT COVER ADJUSTMENT ........................................................... 270

MIRROR ............................................................................................................ 270

CLUSTER ........................................................................................................... 271

DEFLECTOR AND/OR UPPER GRID.............................................................................. 271

SIDE MOLDING.................................................................................................... 272

INLET GRATE....................................................................................................... 272

RIDING PLATE...................................................................................................... 273

JET PUMP SUPPORT.............................................................................................. 274

DRAIN PLUG INSTALLATION..................................................................................... 275

SEAT COVER REPLACEMENT.................................................................................... 276

BUMPER REPLACEMENT......................................................................................... 276

WAKE PYLON ...................................................................................................... 276

SPONSON REPLACEMENT....................................................................................... 278

SPONSON ADAPTOR.............................................................................................. 278

BAILER PICK-UPS INSPECTION .................................................................................. 278

DECALS REPLACEMENT.......................................................................................... 279

HULL AND BODY REPAIR......................................................................................... 280

TOOLS AND MATERIALS LIST ................................................................................... 282

10 TECHNICAL SPECIFICATIONS

01 – GTX, WAKE AND GTX SC MODELS ..................................................................... 283

02 – GTX LIMITED AND RXT MODELS........................................................................ 287

03 – RXP MODELS................................................................................................ 291

11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS

01 – ELECTRICAL CONNECTORS .............................................................................. 295

DEUTSCH CONNECTORS......................................................................................... 295

PACKARD CONNECTOR .......................................................................................... 298

AMP CONNECTOR ................................................................................................ 298

ECM CONNECTORS............................................................................................... 302

BATTERY AND STARTER CABLE TERMINALS.................................................................. 305

02 – WIRING DIAGRAMS........................................................................................ 307

WIRE COLOR CODES............................................................................................. 307

WIRE DIGITCODES ............................................................................................... 307

V

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SAFETY NOTICE

This manual has been prepared as a guide to correctly service and repair 2005 SEA-DOO watercraft as

describe in the model list in the INTRODUCTION.

This edition was primarily published to be used by watercraft mechanical technicians who are already fa-

miliar with all service procedures relating to BRP made watercraft. Mechanical technicians should attend

training courses given by BRP Training Dept.

Please note that the instructions will apply only if proper hand tools and special service tools are used.

This VEHICLE SHOP MANUAL uses technical terms which may be slightly different from the ones used

in the Parts Catalog.

It is understood that this manual may be translated into another language. In the event of any discrepan-

cy, the English version shall prevail.

The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-

vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read

and understand these.

In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the

general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas

of the parts.

The use of BRP parts is most strongly recommended when considering replacement of any component.

Dealer and/or distributor assistance should be sought in case of doubt.

The engines and the corresponding components identified in this document should not be utilized on

product(s) other than those mentioned in this document.



WARNING

Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair

procedures.

This manual emphasizes particular information denoted by the wording and symbols:



WARNING

Identifies an instruction which, if not followed, could cause serious personal injury including pos-

sibility of death.

CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-

nents.

NOTE: Indicates supplementary information needed to fully complete an instruction.

Although the mere reading of such information does not eliminate th

e hazard, your understanding of the

information will promote its correct use. Always use common shop

safety practice.

BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents.

We strongly recommend that any services be carried out and/or verified by a highly skilled professional

mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing

federal, provincial and state regulations.

VI

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INTRODUCTION

GENERAL INFORMATION

This VEHICLE SHOP MANUAL covers the following BRP made SEA-DOO

®

2005 watercraft models. It

should be used in conjunction with the 1503 4-TEC ENGINE SHOP MANUAL.

MODEL COLOR ENGINE MODEL NUMBER

GTX Twilight Blue Pearl 1503 Naturally Aspirated 145A, 145B

GTX Limited

Midnight Black Pearl

1503 Supercharged Intercooled

185A, 185B

GTX Supercharged Twilight Blue Pearl 1503 Supercharged 165A

RXP

Apple Green 1503 Supercharged Intercooled

215A, 215B

RXP Viper Red Metallic 1503 Supercharged Intercooled 215C, 215D

RXT

Apple Green 1503 Supercharged Intercooled

175A, 175B

RXT Viper Red Metallic 1503 Supercharged Intercooled 175C, 175D

WAKE Viper Red 1503 Naturally Aspirated 155A, 155B

The use of RIGHT (starboard) and LEFT (port) indi-

cations in the text, always refers to driving position

(when sitting on watercraft).

Besides, in the marine industry, FRONT is called

BOW and REAR is called STERN.

F01L45B

1

2

1. Left (port)

2. Right (starboard)

The information and component/system descrip-

tions contained in this manual are correct at time

of writing. BRP however, maintains a policy of

continuous improvement of its products without

imposing upon itself any obligation to install them

on products previously manufactured.

BRP reserves the right at any time to discontinue

or change specifications, designs, features, mod-

els or equipment without incurring obligation.

This VEHICLE SHOP MANUAL uses technical

terms which may be different from the ones of

the PARTS CATALOGS.

When ordering parts always refer to the specific

model PARTS CATALOGS.

Hull Identification Number (H.I.N.)

The Hull Identification Number is composed of 12

digits:

A B C 1 2 3 4 5 L 4 9 5

Model year

Serial

number*

Month of production

Year of production

*

A letter may also be used as a digit.

Manufacturer identification code

smr05-002-001_aen

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INTRODUCTION

It is located on footboard at the rear of watercraft.

F08L0QA

1

TYPICAL

1. Hull Identification Number (H.I.N.)

F00L2EA

1

TYPICAL

1. Hull Identification Number (H.I.N.)

Engine Identification Number (E.I.N.)

Refer to the 1503 4-TEC ENGINE SHOP MANUAL.

ARRANGEMENT OF THIS

MANUAL

The manual is divided into many major sections as

you can see in the main table of contents at the

beginning of the manual.

Several sections are divided in various subsec-

tions. There is a table of contents at the beginning

of many sections.

ABBREVIATIONS USED IN

THIS MANUAL

ABBREVIATION DESCRIPTION

4-TEC NA

Naturally-Aspirated Engine

ADC

Analog to Digital Conversion

AC

Alternate Current

APS

Air Pressure Sensor

ATS

Air Temperature Sensor

B.U.D.S.

BRP Utility and Diagnostic Software

CDI

Capacitor Discharge Ignition

CPS

Crankshaft Position Sensor

CSI

Cooling System Indicator

DC

Direct Current

DESS

Digitally Encoded Security System

DI

Direct Injection

E.I.N.

Engine Identification Number

ECM

Engine Control Module

ECU

Electronic Control Unit

EPA

Environmental Protection Agency (USA)

HP

Horse Power

LED

Light Emitting Diode

IC

Intercooler

LED

Light Emitting Diode

MAG

Magneto

MPEM

Multi-Purpose Electronic Module

MPH

Mile Per Hour

MPI

MultiProtocolInterface

N.A.

Not Applicable

OPT

Optional

P/N

Part Number

PFD

Personal Flotation Device

PSI

Pound Per Square Inch

PTO

Power Take Off

VIII

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INTRODUCTION

ABBREVIATION DESCRIPTION

RAVE

Rotax Adjustable Variable Exhaust

RFI

Rotax Fuel Injection

RPM

Revolution Per Minute

Sc

Supercharger

STD Standard

TBD

To Be Determined

TDC Top Dead Center

TPS

Throttle Position Sensor

VDC Volt Direct Current

VCK

Vehicle Communication Kit

Vdc Volt Direct Current

VTS

Variable Trim System

WTS Water Temperature Sensor

ILLUSTRATIONS AND

PROCEDURES

The illustrations show the typical construction of

the different assemblies and, in all cases, may not

reproduce the full detail or exact shape of the parts

shown, however, they represent parts which have

the same or a similar function.

CAUTION: These watercraft are designed with

parts dimensioned mostly in the metric sys-

tem. However some components may be from

the imperial system. When replacing fasten-

ers, make sure to use only those recommended

by BRP.

As many of the procedures in this manual are inter-

related, we suggest, that before undertaking any

task, you read and thoroughly understand the en-

tire section or subsection in which the procedure

is contained.

A number of procedures throughout the book re-

quire the use of special tools. Before undertaking

any procedure, be sure that you have on hand all

the tools required, or approved equivalents.

smr2005-002 IX

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INTRODUCTION

Subsection 04 (MAGNETO SYSTEM)

30

F01D4WS

Loctite

243

Loctite

243

Loctite

243

Loctite

243

Loctite

243

Loctite

648

145 Nm

(107 lbfft)

Anti-seize

lubricant

Page heading

indicates section

and subsection

detailed.

Exploded view

assists you in

identifying parts and

related positions.

TYPICAL PAGE

F01A0CT

Illustration number

for publishing

process.

Subsection title

indicates

beginning of the

subsection.

Dotted box

contains parts of

a particular

model or an

exploded view.

Page number

Italic sub-title

above exploded

view indicate

pertaining models.

Drop represents

a liquid product

to be applied to a

surface. In this case

Loctite 243 to

screw threads.

Bold face number

indicates special

procedure

concerning this part.

X

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INTRODUCTION

1

2

Section 06 FUEL SYSTEM

Subsection 03 (CARBURETORS)

31

Diaphragm

XP Model Only

CARBURETOR REMOVAL

Inspect parts for corrosion dammage (shaft, butterfly,

spring screw, check valve housing, etc.).

PUMP DIAPHRAGM LEAK TEST

TYPICAL

To remove carburetors from engine, proceed as fol-

lows:

Remove air vent tube support.

Unlock retaining slides holding air intake silencer base.

Remove air intake silencer base from watercraft.

Remove screws holding flame arrester base support

to cylinder head cover.

Unscrew base retaining screws then remove base from

carburetors and move to front of watercraft.

Turn the valve to OFF position.

NOTE: For fuel line removal, use pliers (P/N 295

000 054).

Disconnect pulse line from fuel pump.

Disconnect fuel fuel supply line from fuel pump.

Disconnect fuel return line.

Disconnect oil injection pump cable, throttle cable and

choke cable.

Remove screws no. 6 and lock washers no. 7 retaining

carburetors.

All Others Models

Remove 4 bolts no. 8 and lock washers no. 12 from

rotary valve cover then move carburetors and rotary

valve cover on top of engine.

NOTE: When removing rotary valve cover , pay

attention that the rotary valve stay in place, other-wise

it must be timed.

Remove carburetors from intake manifold.

Disconnect fuel bypass line between carburetors (twin

carburetors).

Remove carburetor(s) from rotary valve cover.

DISASSEMBLY AND INSPECTION

Using a suitable pump gauge tester, perform the fol-

lowing test proceeding as follows:

- Install pump gauge tester (P/N 295 000 083) on pulse

nipple.

- Pump tester until it reaches 28 kPa (4 PSI).

Diaphragm must stand pressure for 10 seconds. If

pressure drops, replace diaphragm.

F01F0XB

A

2

1

1 2

TYPICAL PAGE

Sub-title with part

name(s) from

exploded view.

TYPICAL mention

indicates a general

view which does not

represent full detail.

Sub-sub-title in this

case indicates that

particular procedure

for XP is finished, so

from this point, all

others models are

concerned.

Title in italic indicates a

particular procedure

concerning a model.

Service tool to be

used to perform a

certain procedure.

Title indicates main

procedure to be

carried-out.

Sub-sub-title in

capital indicates a

particular testing,

adjustment or

repair procedure.

Illustration

always follows

text it is

pertained to.

Numbered step are

used to give a

sequence to be

perfomed.

Numbers are used

for description of

components.

Letters are used for

any measures.

Bold numbers in the

text refer to the parts

shown in the exploded

view at the beginning

of the subsection.

F01A0BT

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INTRODUCTION

ENGINE EMISSIONS

INFORMATION

Manufacturer's Responsibility

Beginning with 1999 model year engines, PWC

manufacturers of marine engines must determine

the exhaust emission levels for each engine horse-

power family and certify these engines with the

United States of America Environmental Protec-

tion Agency (EPA). An emissions control informa-

tion label, showing emission levels and engine

specifications, must be placed on each vehicle at

the time of manufacture.

Dealer Responsibility

When performing service on all 1999 and more

recent Sea-Doo watercrafts 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 manufacturer's prescribed

changes, such as altitude adjustments for exam-

ple.

Owner Responsibility

The owner/operator is required to have engine

maintenance performed to maintain emission

levels within prescribed certification standards.

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

low anyone to modify the engine in any manner

that would alter the horsepower or allow emis-

sions levels to exceed their predetermined factory

specifications.

EPA Emission Regulations

All new 1999 and more recent Sea-Doo water-

crafts manufactured by BRP are certified to the

EPA as conforming to the requirements of the

regulations for the control of air pollution from

new watercraft engines. This certification is con-

tingent on certain adjustments being set to factory

standards. For this reason, the factory procedure

for servicing the product must be strictly followed

and, whenever practicable, returned to the origi-

nal intent of the design.

The responsibilities listed above are general and

in no way a complete listing of the rules and regu-

lations pertaining to the EPA requirements on ex-

haust emissions for marine products. For more

detailed information on this subject, you may con-

tact the following locations:

VIA U.S. POSTAL SERVICE:

Office of Mobile Sources

Engine Programs and Compliance Division

Engine Compliance Programs Group (6403J)

401 M St. NW Washington, DC 20460

VIA EXPRESS or COURIER MAIL:

Office of Mobile Sources

Engine Programs and Compliance Division

Engine Compliance Programs Group (6403J)

501 3

rd

St. NW Washington, DC 20001

EPA INTERNET WEB SITE:

http:/www.epa.gov/omswww

SELF-LOCKING FASTENERS

PROCEDURE

The following describes the most common appli-

cation procedures when working with self-locking

fasteners.

Use a metal brush or a screwtap to clean the hole

properly then use a solvent (Methyl-Chloride), let

act during 30 minutes and wipe off. The solvent

utilizationistoensuretheadhesiveworksproper-

ly.

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INTRODUCTION

LOCTITE APPLICATION

PROCEDURE

The following describes the most common ap-

plication procedures when working with Loctite

products.

NOTE: Always use proper strength Loctite prod-

uct as recommended in this SHOP MANUAL.

Threadlocker

Uncovered Holes (bolts and nuts)

A00A3LA

1

2

1. Apply here

2. Do not apply

– Clean threads (bolt and nut) with solvent.

– Apply Loctite Primer N (P/N 293 800 041) on

threads and allow to dry.

– Choose proper strength Loctite threadlocker.

– Fit bolt in the hole.

– Apply a few drops of threadlocker at proposed

tightened nut engagement area.

– Position nut and tighten as required.

Blind Holes

A00A3MA

1

2

1. On threads

2. On threads and at the bottom of hole

– Clean threads (bolt and hole) with solvent.

– Apply Loctite Primer N (P/N 293 800 041) on

threads (bolt and nut) and allow to dry for 30

seconds.

– Choose proper strength Loctite threadlocker.

– Apply several drops along the threaded hole and

at the bottom of the hole.

– Apply several drops on bolt threads.

– Tighten as required.

Stud in Blind Holes

A00A5RA

2

1

3

1. On threads

2. On threads and in the hole

3. Onto nut threads

– Clean threads (stud and hole) with solvent.

– Apply Loctite Primer N (P/N 293 800 041) on

threads and allow to dry.

– Put several drops of proper strength Loctite

threadlocker on female threads and in hole.

– Apply several drops

of proper strength Loctite

on stud threads.

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INTRODUCTION

– Install stud.

– Install cover, etc.

– Apply drops of proper strength Loctite on un-

covered threads.

– Tighten nuts as required.

Preassembled Parts

A00A3OA

1

2

1. Apply here

2. Do not apply

– Clean bolts and nuts with solvent.

– Assemble components.

– Tighten nuts.

– Apply drops of proper strength Loctite on

bolt/nut contact surfaces.

– Avoid touching metal with tip of flask.

NOTE: For preventive maintenance on exist-

ing equipment, retighten nuts and apply proper

strength Loctite on bolt/nut contact surfaces.

Adjusting Screw

A00A3PA

1

2

1. Apply here

2. Plunger

– Adjust screw to proper setting.

– Apply drops of proper strength Loctite thread-

locker on screw/body contact surfaces.

– Avoid touching metal with tip of flask.

NOTE: if it is difficult to readjust, heat screw with

a soldering iron (232°C(450°F)).

Stripped Thread Repair

A00A3QA

5

8

6

7

1

2

3

4

1. Release agent

2. Stripped threads

3. Form-A-Thread

4. Tape

5. Cleaned bolt

6. Plate

7. New threads

8. Threadlocker

Standard Thread Repair

– Follow instructions on Loctite FORM-A-

THREAD 81668 package.

– if a plate is used to align bolt:

a. Apply release agent on mating surfaces.

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INTRODUCTION

b. Put waxed paper or similar film on the sur-

faces.

– 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)

– Use a stud or thread on desired length.

– DO NOT apply release agent on stud.

– Do a STANDARD THREAD REPAIR.

– Allowtocurefor30minutes.

– Assemble.

Gasket Compound

A00A3SA

2

1

3

1

1. Proper strength Loctite

2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518

(P/N 293 800 038) on both sides of gasket

3. Loctite Primer N only

– Remove old gasket and other contaminants

with Loctite Chisel remover (P/N 413 708 500).

Use a mechanical mean if necessary.

NOTE: Avoid grinding.

– Clean both mating surfaces with solvent.

– Spray Loctite Primer N on both mating surfaces

andonbothsidesofgasket. Allowtodry1or

2 minutes.

– Apply GASKET ELIMINATOR 518 (P/N 293 800

038) on both sides of gasket, using a clean ap-

plicator.

– Place gasket on mating surfaces and assemble

immediately.

NOTE: If the cover is bolted to blind holes (above),

apply proper strength Loctite in the hole and on

threads. Tighten.

If holes are sunken, apply proper strength Loctite

on bolt threads.

– Tighten as usual.

Mounting on Shaft

Mounting with a Press

A00A3UA

1

2

3

1. Bearing

2. Proper strength Loctite

3. Shaft

– Clean shaft external part and element internal

part.

– Apply a strip of proper strength Loctite on shaft

circumference at insert or engagement point.

NOTE: Retaining compound is always forced out

whenappliedonshaft.

– DO NOT use anti-seize Loctite or any similar

product.

– No curing period is required.

Mounting in Tandem

1. Apply retaining compound on internal element

bore.

2. Continue to assemble as shown above.

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INTRODUCTION

Case-in Components

Metallic Gaskets

A00A3VA

1

1. Proper strength Loctite

– Clean inner housing diameter and outer gasket

diameter.

– Spray housing and gasket with Loctite Primer N

(P/N 293 800 041).

– 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.

– Install according to standard procedure.

– Wipe off surplus.

– Allowittocurefor30minutes.

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.

TIGHTENING TORQUES

Tighten fasteners to torque mentioned in explod-

ed views and/or text, When they are not specified,

refer to following table.



WARNING

Torque wrench tightening specifications

must strictly be adhered to. Locking devices

(ex.: locking tabs, elastic stop nuts, self-lock-

ing fasteners, etc.) must be installed or

replaced with new ones, where specified. If

the efficiency of a locking device is impaired,

it must be renewed.

In order to avoid a poor assembling, tighten

screws, bolts or nuts in accordance with the

following procedure:

– Manually screw all screws, bolts and/or nuts.

– Apply the half of the recommended torque value.

CAUTION: Be sure to use the proper tightening

torque for the proper strength grade.

NOTE: When possible, always apply torque on the

nut.

– Torque to the recommended torque value.

NOTE: Always torque screws, bolts and/or nuts in

a criss-cross sequence.

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INTRODUCTION

A00A8BS

Property

class

and

head

markings

Property

class

and

nut

markings

5

10

12

4.8

8.8

9.8

10.9

12.9

FASTENER GRADE/TORQUE

FASTENER

SIZE

5.8

Grade

8.8

Grade

10.9

Grade

12.9

Grade

M4

1.5 — 2N•m

(13 — 18 lbf•in)

2.5 — 3N•m

(22 — 27 lbf•in)

3.5 — 4N•m

(31 — 35 lbf•in)

4 — 5N•m

(35 — 44 lbf•in)

M5

3 — 3.5 N•m

(27 — 31 lbf•in)

4.5 — 5.5 N•m

(40 — 47 lbf•in)

7 — 8.5 N•m

(62 — 75 lbf•in)

8 — 10 N•m

(71 — 89 lbf•in)

M6

6.5 — 8.5 N•m

(58 — 75 lbf•in)

8 — 12 N•m

(71 — 106 lbf•in)

10.5 — 15 N•m

(93 — 133 lbf•in)

16 N•m (142 lbf•in)

M8 15 N•m(11lbf•ft) 24.5 N•m(18lbf•ft) 31.5 N•m(23lbf•ft) 40 N•m(30lbf•ft)

M10 29 N•m(21lbf•ft) 48 N•m(35lbf•ft) 61 N•m(45lbf•ft) 72.5 N•m(53lbf•ft)

M12 52 N•m(38lbf•ft) 85 N•m(63lbf•ft) 105 N•m(77lbf•ft) 127.5 N•m(94lbf•ft)

M14 85 N•m(63lbf•ft) 135 N•m(100lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)

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Sea-doo 2005 WAKE Shop Manual

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