2004 Speedster Shop Manual

Shop Manual
SPEEDSTER™ 200
(TWIN 1503)
Legal deposit:
National Library of Quebec

4th trimester 2003
National Library of Canada
All rights reserved. No parts of this manual may be reproduced in any

form without the prior written permission of Bombardier Inc.
©Bombardier Inc. 2003
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®*Registered trademarks of Bombardier Inc.
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
TABLE OF CONTENTS
SECTION SUBSECTION PAGE
SAFETY NOTICE .................................................................................................................................. II

INTRODUCTION ................................................................................................................................... III
01 SERVICE TOOLS 01 - Table of contents ...................................................................... 01-01-1
AND PRODUCTS 02 - Mandatory service tools............................................................ 01-02-1
03 - Optional service tools................................................................ 01-03-1
04 - Service products ....................................................................... 01-04-1
02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1
02 - Periodic inspection chart ........................................................... 02-02-1
03 - Flushing and lubrication............................................................. 02-03-1
04 - Water-flooded engine................................................................ 02-04-1
05 - Storage...................................................................................... 02-05-1
03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1
04 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 04-01-1
02 - Leak test ................................................................................... 04-02-1
03 - Intake system............................................................................ 04-03-1
04 - Exhaust system......................................................................... 04-04-1
05 - Removal and installation ........................................................... 04-05-1
06 - PTO housing/Magneto .............................................................. 04-06-1
07 - Lubrication system.................................................................... 04-07-1
08 - Cylinder head and valves........................................................... 04-08-1
09 - Engine block.............................................................................. 04-09-1
05 ENGINE 01 - Table of contents ...................................................................... 05-01-1
MANAGEMENT 02 - Overview................................................................................... 05-02-1
(4-TEC) 03 - Component inspection and adjustment .................................... 05-03-1
04 - Diagnostic procedures .............................................................. 05-04-1
06 COOLING SYSTEM 01 - Table of contents ...................................................................... 06-01-1
02 - Circuit, components and care ................................................... 06-02-1
07 FUEL SYSTEM 01 - Table of contents ...................................................................... 07-01-1
02 - Fuel circuit................................................................................. 07-02-1
03 - Air intake ................................................................................... 07-03-1
08 ELECTRICAL 01 - Table of contents ...................................................................... 08-01-1
SYSTEM 02 - Charging system ....................................................................... 08-02-1
03 - Starting system ......................................................................... 08-03-1
04 - Instruments and accessories .................................................... 08-04-1
09 PROPULSION 01 - Table of contents ...................................................................... 09-01-1
SYSTEM 02 - Jet pump ................................................................................... 09-02-1
03 - Drive system ............................................................................. 09-03-1
10 STEERING 01 - Table of contents ...................................................................... 10-01-1
SYSTEM 02 - Steering system ........................................................................ 10-02-1
03 - Alignment.................................................................................. 10-03-1
04 -Throttle/Shifter controller ........................................................... 10-04-1
11 HULL/DECK 01 - Table of contents ...................................................................... 11-01-1
02 - Components.............................................................................. 11-02-1
03 - Repair ........................................................................................ 11-03-1
12 TECHNICAL DATA 01 - Speedster 200 ........................................................................... 12-01-1
13 WIRING DIAGRAMS 01 - Wiring diagrams ........................................................................ 13-01-1
LMR2004_001_002A.FM I
SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the SEA-DOO Speedster™
200 sport boat.
This edition was primarily published to be used by sport boat mechanical technicians who are already
familiar with all service procedures relating to Bombardier made sport boats. Mechanical technicians
should attend training courses given by the Bombardier Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This 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 discrepancy,
the english version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
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 Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. 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.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.
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
possibility 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 the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
Bombardier Inc. 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.
II LMR2004_001_002A.FM
INTRODUCTION
INTRODUCTION
This Shop Manual covers the following Bombardier ENGINE IDENTIFICATION
made Sea-Doo® sport boat model.
NUMBER (E.I.N.)
ENGINE MODEL 1503 Engine
MODELS
TYPE NUMBER
The engine identification number is located at front
Twin 1503 of engine.
Speedster™ 200 5773/5160
4-TEC™
HULL IDENTIFICATION NUMBER

(H.I.N.)
It is located at the rear of sport boat.
Speedster™ 200
F09D0UA 1
1. Engine Identification Number (E.I.N.)
ARRANGEMENT OF THIS
F13A04A 1 MANUAL
1. Hull Identification Number (H.I.N.) The manual is divided into 13 major sections:
Refer to the next illustration for a description of the 01 SERVICE TOOLS AND PRODUCTS
Serial Number. 02 MAINTENANCE
03 TROUBLESHOOTING
ABC12345L495 04 ENGINE (4-TEC)
Model year 05 ENGINE MANAGEMENT (4-TEC)
Serial 06 COOLING SYSTEM
number* Year of production
07 FUEL SYSTEM
Month of production
Identification code 08 ELECTRICAL SYSTEM
F00A2PA
09 PROPULSION SYSTEM
* A letter may also be used as a digit.
10 STEERING SYSTEM
11 HULL/DECK
12 TECHNICAL DATA
13 WIRING DIAGRAMS
Several sections are divided in various subsec-
tions. There is a table of contents at the beginning
of many sections.
LMR2004_001_002A.FM III
INTRODUCTION
TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
indicates
beginning of the
subsection. Subsection 04 (MAGNETO SYSTEM)
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.
Loctite
243
Loctite
243
Dotted box
contains parts of
a particular
Exploded view assits Loctite model or an
243
you in identifying exploded view.
parts and related
positions. Loctite
243
Loctite
243
Bold face number

indicates special
procedure
concerning this part.
Loctite
648
145 Nm
(107 lbfft)
Anti-seize
lubricant
F01D4WS
Illustration number
for publishing
process.
03-04-1
Page numbering system:

03: ENGINE section
04: MAGNETO SYSTEM subsection
1: First page of this subsection
F01A0CS
IV LMR2004_001_002A.FM
INTRODUCTION
TYPICAL PAGE
Sub-title with part

name(s) from
exploded view.
Section 06 FUEL SYSTEM

Subsection 03 (CARBURETORS)
Title indicates main

procedure to be CARBURETOR REMOVAL DISASSEMBLY AND INSPECTION
carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly,
lows: spring screw, check valve housing, etc.).
Remove air vent tube support.
Sub-sub-title in
Unlock retaining slides holding air intake silencer base.
Diaphragm capital indicates a
Remove air intake silencer base from watercraft. PUMP DIAPHRAGM LEAK TEST particular testing,
Remove screws holding flame arrester base support Using a suitable pump gauge tester, perform the fol- adjustment or
lowing test proceeding as follows:
to cylinder head cover.
- Install pump gauge tester (P/N 295 000 083) on pulse
repair procedure.
Unscrew base retaining screws then remove base from
Service tool to be carburetors and move to front of watercraft. nipple.
used to perform a Turn the valve to OFF position. - Pump tester until it reaches 28 kPa (4 PSI).
certain procedure. NOTE: For fuel line removal, use pliers (P/N 295
000 054). 1 A
Disconnect pulse line from fuel pump.
Disconnect fuel fuel supply line from fuel pump. Illustration
Disconnect fuel return line. always follows
Title in italic indicates a Disconnect oil injection pump cable, throttle cable and text it is
particular procedure choke cable.
pertained to.
concerning a model. XP Model Only
Remove screws no. 6 and lock washers no. 7 retaining
carburetors.
Sub-sub-title in this All Others Models

case indicates that Remove 4 bolts no. 8 and lock washers no. 12 from
rotary valve cover then move carburetors and rotary 2 1 2 TYPICAL mention
particular procedure valve cover on top of engine.
F01F0XB
indicates a general
for XP is finished, so NOTE: When removing rotary valve cover , pay
TYPICAL
view which does not
from this point, all
1
attention that the rotary valve stay in place, other-wise
represent full detail.
2
it must be timed.
others models are
Remove carburetors from intake manifold.
concerned. Diaphragm must stand pressure for 10 seconds. If
Disconnect fuel bypass line between carburetors (twin
carburetors). pressure drops, replace diaphragm. Numbers in a frame
Remove carburetor(s) from rotary valve cover. are used to give a
sequence to be
perfomed.
Letters are used for

any measures.
06-03-4
Bold numbers in the

text refer to the parts Numbers are used
shown in the exploded for description of
view at the beginning components.
of the subsection.
F01A0BS
LMR2004_001_002A.FM V
INTRODUCTION
LIST OF ABBREVIATIONS USED DESCRIPTION

IN THIS MANUAL MAG Magneto
DESCRIPTION MAPS Manifold Air Pressure Sensor
AC Alternate Current MATS Manifold Air Temperature Sensor
ADC Analog to Digital Conversion MPH Mile Per Hour
APS Air Pressure Sensor MPI Multi Protocol Interface
ATS Air Temperature Sensor N.A. Not Applicable
Bombardier Utility and Diagnostic OPS Oil Pressure Sensor
B.U.D.S.
Software
OPT Optional
CAPS Camshaft Position Sensor
OSPS Oil Separator Pressure Sensor
CDI Capacitor Discharge Ignition
P/N Part Number
CPS Crankshaft Position Sensor
PFD Personal Flotation Device
CSI Cooling System Indicator
PSI Pound Per Square Inch
CTS Coolant Temperature Sensor
PTO Power Take Off
DC Direct Current
RPM Revolution Per Minute
DESS Digitally Encoded Security System
STD Standard
DLA Digital Linear Actuator
TBD To Be Determined
E.I.N. Engine Identification Number
TDC Top Dead Center
ECU Electronic Control Unit
TOPS Tip-Over Protection System
EGT Exhaust Gas Temperature
TPS Throttle Position Sensor
EMS Engine Management System
VCK Vehicle Communication Kit
EPA Environmental Protection Agency (USA)
VDC Volt Direct Current
HP Horse Power
WTS Water Temperature Sensor
KS Knock Sensor
VI LMR2004_001_002A.FM
INTRODUCTION
GENERAL INFORMATION ILLUSTRATIONS AND

In the marine industry, PORT, STARBOARD, BOW PROCEDURES
and STERN are used to refer to LEFT, RIGHT, The illustrations show the typical construction of
FRONT and REAR respectively. They always refer the different assemblies and, in all cases, may not
to the operator’s position sitting in boat. reproduce the full detail or exact shape of the parts
shown, however, they represent parts which have
1 the same or a similar function.
CAUTION: These sport boat are designed with
parts dimensioned mostly in the metric sys-
tem. However some components may be from
the imperial system. When replacing fasteners,
make sure to use only those recommended by
Bombardier.
As many of the procedures in this manual are in-
terrelated, we suggest that before undertaking
4 2 any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure 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.
ENGINE EMISSIONS
3
F04L03C
INFORMATION
TYPICAL
1. BOW (front)
2. STARBOARD (RH)
Manufacturer’s Responsibility
3. STERN (rear) Beginning with 1999 model year engines, sport
4. PORT (LH)
boat manufacturers of marine engines must deter-
The information and component/system descrip- mine the exhaust emission levels for each engine
tions contained in this manual are correct at time horsepower family and certify these engines with
of writing. Bombardier Inc. however, maintains a the United States of America Environmental Pro-
policy of continuous improvement of its products tection Agency (EPA). An emissions control infor-
without imposing upon itself any obligation to in- mation label, showing emission levels and engine
stall them on products previously manufactured. specifications, must be placed on each vehicle at
Because of our ongoing commitment to product the time of manufacture.
quality and innovation, Bombardier Inc. reserves
the right at any time to discontinue or change Dealer Responsibility
specifications, designs, features, models or equip- When performing service on any 1999 and newer
ment without incurring obligation. Sea-Doo sport boat carrying an emissions control
This Shop Manual uses technical terms which information label, adjustments must be kept with-
may be different from the ones in the Parts Cata- in published factory specifications.
logs. Replacement or repair of any emission related
When ordering parts always refer to the specif- component must be executed in a manner that
ic model Parts Catalogs. 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.
LMR2004_001_002A.FM VII
INTRODUCTION
Exceptions include manufacturer’s prescribed SELF-LOCKING FASTENERS

changes, such as altitude adjustments for example.
PROCEDURE
Owner Responsibility The following describes the most common appli-
The owner/operator is required to have engine cation procedures when working with self-locking
maintenance performed to maintain emission lev- fasteners.
els within prescribed certification standards. Use a metal brush or a screw tap to clean the hole
The owner/operator is not to, and should not allow properly then use a solvent (Methyl-Chloride), let
anyone to modify the engine in any manner that act during 30 minutes and wipe off. The solvent
would alter the horsepower or allow emissions utilization is to ensure the adhesive works properly.
levels to exceed their predetermined factory spec-
ifications. LOCTITE APPLICATION
PROCEDURE
EPA Emission Regulations
The following describes the most common appli-
All 1999 and newer Sea-Doo sport boats manufac- cation procedures when working with Loctite™
tured by Bombardier are certified to the EPA as products.
conforming to the requirements of the regulations
for the control of air pollution from new sport boat NOTE: Always use proper strength Loctite prod-
engines. This certification is contingent on certain uct as recommended in this Shop Manual.
adjustments being set to factory standards. For
this reason, the factory procedure for servicing the THREADLOCKER
product must be strictly followed and, whenever
practicable, returned to the original intent of the Uncovered Holes (bolts and nuts)
design.
The responsibilities listed above are general and in
no way a complete listing of the rules and regula-
tions pertaining to the EPA requirements on ex-
haust emissions for marine products. For more de- 1
tailed information on this subject, you may contact
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 2
Washington, DC 20460 A00A3LA
1. Apply here
2. Do not apply
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources 1. Clean threads (bolt and nut) with solvent.
Engine Programs and Compliance Division 2. Apply Loctite Primer N (P/N 293 800 041) on
Engine Compliance Programs Group (6403J) threads and allow to dry.
501 3rd St. NW 3. Choose proper strength Loctite threadlocker.
Washington, DC 20001
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
EPA INTERNET WEB SITE: tightened nut engagement area.
http:/www.epa.gov/omswww
6. Position nut and tighten as required.
VIII LMR2004_001_002A.FM
INTRODUCTION
Blind Holes 1. Clean threads (stud and hole) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
1 3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
2 4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3MA
1. On threads
Preassembled Parts
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
1
seconds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole and
at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Stud in Blind Holes 2

A00A3OA
1. Apply here
2. Do not apply
1 3
1. Clean bolts and nuts with solvent.
2. Assemble components.
2
3. Tighten nuts.
4. Apply drops of proper strength Loctite on bolt/
nut contact surfaces.
5. Avoid touching metal with tip of flask.
A00A5RA NOTE: For preventive maintenance on existing
1. On threads
equipment, retighten nuts and apply proper
2. On threads and in the hole strength Loctite on bolt/nut contact surfaces.
3. Onto nut threads
LMR2004_001_002A.FM IX
INTRODUCTION
Adjusting Screw Standard Thread Repair

1. Follow instructions on Loctite FORM-A-THREAD
81668 package.
2 2. If a plate is used to align bolt:
1
a. Apply release agent on mating surfaces.
b. 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 STAN-
DARD THREAD REPAIR procedure.
A00A3PA
Option 2: Apply FORM-A-THREAD on the screw
1. Apply here and insert in damaged hole.
2. Plunger
Permanent Stud Installation (light duty)
1. Adjust screw to proper setting.
1. Use a stud or thread on desired length.
2. Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces. 2. DO NOT apply release agent on stud.
3. Avoid touching metal with tip of flask. 3. Perform a STANDARD THREAD REPAIR (see
above).
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)). 4. Allow to cure for 30 minutes.
5. Assemble.
STRIPPED THREAD REPAIR
GASKET COMPOUND
Stripped Threads
All Parts
5
1 2
1
6
8
2
3
1
A00A3QA 4 7
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker A00A3SA 1 3
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
X LMR2004_001_002A.FM
INTRODUCTION
1. Remove old gasket and other contaminants 3. DO NOT use anti-seize Loctite or any similar
with Loctite Chisel remover (P/N 413 708 500). product.
Use mechanical means if necessary. 4. No curing period is required.
NOTE: Avoid grinding.
Mounting in Tandem
2. Clean both mating surfaces with solvent.
1. Apply retaining compound on internal element
3. Spray Loctite Primer N on both mating surfaces bore.
and on both sides of gasket. Allow to dry 1 or 2
2. Continue to assemble as shown above.
minutes.
4. Apply GASKET ELIMINATOR 518 (P/N 293 800 CASE-IN COMPONENTS
038) on both sides of gasket, using a clean ap-
plicator. Metallic Gaskets
5. 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.
6. Tighten as usual.
MOUNTING ON SHAFT
Mounting with a Press
A00A3VA 1
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with Loctite Primer N
1 (P/N 293 800 041).
3. Apply a strip of proper strength Loctite on lead-
2 ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
3 low strength liquid is recommended as normal
strength and gap are required.
A00A3UA 4. Install according to standard procedure.
1. Bearing 5. Wipe off surplus.
3. Shaft 6. Allow it to cure for 30 minutes.
Standard NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
1. Clean shaft external part and element internal
part. It is generally not necessary to remove gasket
compound applied on outer gasket diameter.
2. Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
LMR2004_001_002A.FM XI
INTRODUCTION
TIGHTENING TORQUES N•m

FASTENER SIZE
Lbf•ft
(8.8 grade)
Tighten fasteners to torque mentioned in explod-
37 27
ed views and text. When they are not specified
refer to following table.The table also gives the 38 28
metric conversion. 39 29
40 30
FASTENER SIZE
N•m Lbf•in 41 30
(8.8 grade)
42 31
1 9
43 32
2 M4 18
44 32
3 27
45 33
4 M5 35
46 34
5 44
47 35
6 53
48 M10 35
7 62
49 36
8 71 50 37
9 80 51 38
10 M6 89 52 38
11 97 53 39
12 106 54 40
13 115 55 41
14 124 56 41
15 133 57 42
16 142 58 43
17 150 59 44
18 159 60 44
19 168 61 45
62 46
FASTENER SIZE 63 46
N•m Lbf•ft
(8.8 grade)
64 47
20 15
65 48
21 15
66 49
22 16
67 49
23 M8 17
68 50
24 18
69 51
25 18
70 52
26 19
71 52
27 20
72 53
28 21
73 54
29 21
74 55
30 22
75 55
31 23
76 56
32 24
77 57
33 24
78 58
34 25
79 58
35 26
80 M12 59
36 27
XII LMR2004_001_002A.FM
INTRODUCTION
FASTENER SIZE FASTENER SIZE

N•m Lbf•ft N•m Lbf•ft
(8.8 grade) (8.8 grade)
81 60 116 86
82 60 117 86
83 61 118 87
84 62 119 88
85 63 120 89
86 63 121 89
87 64 122 90
88 65 123 91
89 66 124 91
90 66 125 92
91 67 126 93
92 68 127 94
93 69 128 94
94 69 129 95
95 70 130 96
96 71 131 97
97 72 132 97
98 72 133 98
99 73 134 99
100 74 135 M14 100
101 74 136 100
102 75 137 101
103 76 138 102
104 77 139 103
105 77 140 103
106 78 141 104
107 79 142 105
108 80 143 105
109 80 144 106
110 81 145 107
111 82 146 108
112 83 147 108
113 83 148 109
114 84 149 110
115 85 150 111
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
Technical Publications
Bombardier Inc.
Valcourt (Quebec), Canada
LMR2004_001_002A.FM XIII
Section 01 SERVICE TOOLS AND PRODUCTS
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS 0
MANDATORY SERVICE TOOLS ........................................................................................... 01-02-1
ENGINE .............................................................................................................................. 01-02-1
COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-02-2
PROPULSION SYSTEM..................................................................................................... 01-02-3
OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1

ENGINE .............................................................................................................................. 01-03-1
COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-03-3
PROPULSION SYSTEM..................................................................................................... 01-03-4
SPORT BOAT HANDLING ................................................................................................. 01-03-4
SERVICE PRODUCTS ............................................................................................................ 01-04-1
LMR2004-030_01_01ATOC.FM 01-01-1
Subsection 02 (MANDATORY SERVICE TOOLS)
MANDATORY SERVICE TOOLS 0

ENGINE
NEW Alignment shaft Handle
P/N 295 000 141 P/N 420 877 650
Piston circlip installer
P/N 529 035 765
F00B0G4
A00C3V4
APPLICATION
APPLICATION
All models.
V04B0B4
Use with pushers (P/N 290 876 609
and 290 877 740).
NEW
Starter drive bearing pusher
P/N 290 876 502 Oil pressure gauge (1 to 8 bars)
Alignment adaptor
P/N 529 035 719 P/N 529 035 709
F06B054
Alignment support plate kit F18B0C4
P/N 529 035 506

VCK (Vehicle Communication Kit)
1) Alignment plates
P/N 529 035 507 P/N 529 035 844
2) Support Individual B.U.D.S. diskettes v1.1
P/N 529 035 511 P/N 529 035 845
3) Screw (2) Individual CD-Rom V00B064
P/N 207 182 544 P/N 529 035 886

4) Lock washer (2) Engine oil pressure adapter
P/N 234 181 601 P/N 529 035 652
5) Flat washer (2)
P/N 234 081 410
F00B0F4
V00B074
APPLICATION
All models.
155.6 mm jet pump.
F12H0A4
APPLICATION
All models.
LMR2004-002_01_02A.FM 01-02-1
ENGINE (continued)
NEW NEW
Crankshaft locking tool Camshaft locking tool

P/N 529 035 821 P/N 529 035 839
F18B074
F18B064
COOLING/FUEL/OIL SYSTEMS
Pliers Fuel pressure gauge NEW
P/N 295 000 070 P/N 529 035 591

Oetiker 1099 Coolant pump seal pusher
P/N 529 035 823
F01D174
APPLICATION
All models.
F18B084
Pliers F02B0B4
P/N 295 000 054

Caillau NEW
Oil seal guide

P/N 529 035 822
F01B1T4
APPLICATION
All models.
NOTE: This tool is also used for the
propulsion system. F18B094
01-02-2 LMR2004-002_01_02A.FM
PROPULSION SYSTEM
Impeller remover/installer NEW NEW
P/N 529 035 820

Drive shaft holder Shaft pusher
P/N 529 035 871 P/N 529 035 818
F01J0T4
Pliers
P/N 295 000 069
Oetiker 1090
F18B0G4
NEW
Drive shaft/floating ring

F01D184
P/N 529 035 841 F18B0E4
APPLICATION
All models.
NEW
Pliers Pressure cap

P/N 295 000 054 P/N 529 035 843
Caillau
F18B044
NEW
F01B1T4
Seal/bearing pusher
APPLICATION
P/N 529 035 819
All models. F18B054
NOTE: This tool is also used for the

fuel system.
NEW
PTO seal support

F18B0D4
P/N 529 035 842
F18B0F4
LMR2004-002_01_02A.FM 01-02-3
Subsection 03 (OPTIONAL SERVICE TOOLS)
OPTIONAL SERVICE TOOLS 0

ENGINE
Digital/induction type Protective mat NEW
tachometer P/N 295 000 129

P/N 529 014 500 Digital multimeter
P/N 529 035 868
F04L1V4
F01B1G4
APPLICATION
APPLICATION All models.
All models.
NEW
Terminal (Packard) remover
Not sold by Bombardier Spring installer/remover
Snap-on P/N 529 035 559
TT 600-4
V00B0H4
APPLICATION
F01B1J4
All models.
APPLICATION
A00C3S4 NEW
All models.
Exhaust outlet tool Valve spring compressor clamp

Safety lanyard switch tool
P/N 295 000 132 P/N 529 035 724
P/N 529 034 600
F01B2A4
F01B244 APPLICATION
APPLICATION All models. V00B044
All models.
Steering cable tool NEW
P/N 295 000 145

Valve spring compressor cup
P/N 529 035 725
F01B2P4
APPLICATION
All models.
V04B094
LMR2004-002_01_03A.FM 01-03-1
ENGINE (continued)
NEW NEW Leak test kit pump
P/N 529 021 800
Ring compressor Valve stem seal installer
Not sold by Bombardier P/N 529 035 687
Snap-on RC980
V04B084
NEW V04B0H4
Special pliers for valve stem seal NEW

V00B084
removal
Not sold by Bombardier Torque angle gauge NEW
Snap-on YA 8230 Not sold by Bombardier
Snap-on TA362 Oil VAC
P/N 529 035 880
V02B064
V04B0I4
F18B0B4
01-03-2 LMR2004-002_01_03A.FM
COOLING/FUEL/OIL SYSTEMS
Lighted adjustable mirror Hose pincher Flushing adapter
Not sold by Bombardier P/N 295 000 076 P/N 295 500 473
Snap-on
50101
F01B1I4
APPLICATION
All models. F00B104
A01B2I4
APPLICATION
APPLICATION
Hose pincher All models.
All models. Use with coupler hose (P/N 295
P/N 529 032 500
500 258).
Flexible spout (oil)
P/N 414 837 300 NEW
Test radiator cap

P/N 295 021 400
F04B044
F01B234 APPLICATION
APPLICATION All models.
PA
UD
All models.
S
OU A
V RIR A CH
F18E1P4
LMR2004-002_01_03A.FM 01-03-3
PROPULSION SYSTEM
Hacksaw
Not sold by Bombardier
Snap-on
HS3
F01B1M4
APPLICATION
All models.
SPORT BOAT HANDLING

Tie-down
1.04 m (3 ft 5 in) long
P/N 204 990 054
F00B014
APPLICATION
All models.
01-03-4 LMR2004-002_01_03A.FM
Subsection 04 (SERVICE PRODUCTS)
SERVICE PRODUCTS 0
Loctite® is a trademark of Loctite™ Corporation.
Permatex® is a trademark of Loctite™ Corporation.
Dow Corning® is a trademark of Dow Corning Corporation.
Medium strength threadlocker High temperature threadlocker Retaining compound
P/N 293 800 060 P/N 420 899 788 P/N 413 703 100
Loctite 243 (blue) Loctite 648 (green) Loctite RC/609 (green)
(10 mL) (5 g) (10 mL)
A00B3D4 A00B2S4
F00A0O4
High temperature retaining General purpose instant adhesive

High strength threadlocker compound P/N 293 800 021
P/N 293 800 005 P/N 293 800 054 Loctite 495
Loctite 271 (red) Loctite 642
(10 mL) (50 mL)
A00B2V4
Gasket eliminator
P/N 293 800 038
Loctite 518
(50 mL)
F00B024
F01B124
A00B2U4
LMR2004-002_01_04A.FM 01-04-1
Flange sealant Solvent Pipe sealant

P/N 293 800 081 P/N 413 711 809 A) P/N 293 800 013
Loctite 5910 Loctite Safety Solvent B) P/N 293 800 018
(300 mL) 320 g (11 oz)
A) Loctite 567 (250 mL)
B) Loctite 592 (50 mL)
F00B1A4
A00B2W4
NEW
Hylomar sealant
RTV silicone sealant P/N 293 800 001
P/N 293 800 066 PL-32
(100 g)
Loctite 5900
(300 mL)
A00B4X4
A00B3F4
Molykote 111
A02B0B4
Sealant
P/N 413 707 000
P/N 293 530 011
Chisel gasket remover Sikaflex 221 (black)
111
P/N 413 708 500 (350 mL)
(510 mL)
A00B3W4
F01B1D4
Primer for gasket eliminator

P/N 293 800 041 NEW
Loctite 764
High temperature RTV sealant
P/N 293 800 090
Ultra Copper
(80 mL)
A00B574
A00B3N4
Thread sealant
P/N 293 800 050
Loctite 577
(250 mL)
A00B5A4
F00B0W4
01-04-2 LMR2004-002_01_04A.FM
Dielectric grease Super Lube grease NEW
P/N 293 550 004 P/N 293 550 030

Dow Corning Loctite 82328 Grease Isoflex
(150 g)
P/N 293 550 021
(50 g)
A00B1X4
Deoxit contact lubricant

P/N 293 550 015
(200 mL)
V00B0I4 A00B554
Anti-seize lubricant BOMBARDIER LUBE lubricant

P/N 293 800 070 P/N 293 600 016
Loctite 76764 (12 x 14 oz)
454 g (16 oz)
F00B0X4
Grease
P/N 293 550 005
(400 g)
A00B2L4
A00B624
Synthetic grease
P/N 293 550 010 A00B594
(400 g)
F01B154
LMR2004-002_01_04A.FM 01-04-3
BOMBARDIER storage oil NEW NEW
P/N 413 711 600

(12 x 350 g) Premixed coolant 50/50 BOMBARDIER Formula XP-S II
- 37°C (- 35°F) synthetic injection oil
P/N 293 600 038 P/N 293 600 245
(16 x 1 L) (12 x 1 L)
A00B634
A00B5T4
Sea-Doo fuel stabilizer
P/N 413 408 600 A00B5X4
P/N 293 600 246
236 mL (8 oz) (3 x 4 L)
Sealant adhesive
P/N 293 800 086
Loctite 5150
(29647)
A00B5S4 A00B5U4
P/N 293 600 247

(205 L)
A00B604
732 Multi-purpose sealant

P/N 293 800 086
Dow Corning (90 mL)
(clear)
F01B1C4
01-04-4 LMR2004-002_01_04A.FM
NEW Sea-Doo Cleaner

P/N 293 110 001 (400 g)
Instant gasket P/N 293 110 002 (4 L)
P/N 293 800 088
(7 oz)
F01B2J4
NEW
Pulley flange cleaner

A02B0C4 P/N 413 711 809
Jet pump synthetic oil

P/N 293 600 011
(12 x 6 oz)
A00B5V4
F01B0P4
NEW
Jet pump grease

P/N 293 550 032
(110 g)
LMR2004-002_01_04A.FM 01-04-5
Section 02 MAINTENANCE
TABLE OF CONTENTS 0
PERIODIC INSPECTION CHART ........................................................................................... 02-02-1
FLUSHING AND LUBRICATION ........................................................................................... 02-03-1

GENERAL ........................................................................................................................... 02-03-1
WATER-FLOODED ENGINE .................................................................................................. 02-04-1

GENERAL ........................................................................................................................... 02-04-1
PROCEDURE ...................................................................................................................... 02-04-1
STORAGE............................................................................................................................... 02-05-1
FUEL SYSTEM ................................................................................................................... 02-05-1
ENGINE OIL CHANGE AND FILTER ................................................................................. 02-05-1
COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION .................... 02-05-1
BATTERY............................................................................................................................ 02-05-2
SPORT BOAT CLEANING ................................................................................................. 02-05-2
ADDITIONAL RECOMMENDED PROTECTION ................................................................ 02-05-2
ANTICORROSION TREATMENT ....................................................................................... 02-05-2
CHECKLIST ........................................................................................................................ 02-05-2
LMR2004-030_02_01ATOC.FM 02-01-1
Subsection 02 (PERIODIC INSPECTION CHART)
PERIODIC INSPECTION CHART 0

The schedule should be adjusted according to operating conditions and use.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte-
nance operation to whatever time comes first.
IMPORTANT: Schedule for sport boat rental operations or higher number of hour use, will require greater
frequency of inspection and maintenance.
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
10 HOURS
DESCRIPTION
1 YEAR
EVERY
EVERY
EVERY
FIRST
GENERAL
Lubrication/corrosion protection ✔
ENGINE
Engine oil and filter replacement ✔ ✔
Support and rubber mount condition/tightness ✔ ✔
Condition of seals and fasteners ✔ ✔
Exhaust system fasteners ➄ ✔ ✔
Spark plug replacement ➄ ✔
COOLING SYSTEM
Flushing (exhaust system) ✔ ➂
Hose and fasteners condition ✔ ✔
Coolant replacement ➆
Coolant expansion tank cap/cooling system pressure test ➃
FUEL SYSTEM
Throttle cable, inspection/lubrication ✔
Fuel injection system sensors visual inspection ➄ ✔ ✔
Throttle body cleaning and inspection. Fault code reading ➄ ➀ ✔
Fuel vent line pressure relief valve inspection ✔
Fuel lines, connections and fuel system leak test ➄ ✔ ✔
Visual inspection: throttle body, sensors, fuel lines, fuel rail and fittings ➄ ✔ ✔
Air intake silencer fit/tightness ✔ ✔
Fuel tank straps visual inspection ✔ ✔
ELECTRICAL SYSTEM
Check fault codes ✔ ✔
Electrical connections condition and fastening
✔ ✔
(ignition system, starting system, fuel injectors etc.)
EMS ECU connectors inspection and lubrication ✔➀
Digitally Encoded Security System and safety lanyard/post condition ✔ ✔
Monitoring beeper ✔ ✔
Battery condition and fasteners ✔ ✔
LMR2004-003_02_02A.FM 02-02-1
Subsection 02 (PERIODIC INSPECTION CHART)
FREQUENCY
100 HOURS OR
25 HOURS OR
50 HOURS OR
3 MONTHS
6 MONTHS
10 HOURS
DESCRIPTION
1 YEAR
EVERY
EVERY
EVERY
FIRST
STEERING SYSTEM
Inspection and cable adjustment ✔ ✔
PROPULSION SYSTEM
Drive shaft protection boot inspection ✔ ➁
Grease splines in jet pump ✔ ➁
Shifter system/cable adjustment ✔ ✔
Impeller shaft seal replacement ➅
Impeller condition and impeller/wear ring clearance ✔ ➁
Inlet Clearance System (ICS) grate condition ✔ ➁
Ride plate inspection including coolant leak ✔ ✔
HULL AND BODY
Bilge Pump, check for obstructions ✔ ✔
Hull condition ✔ ✔
➀ In salt water use.

➁ These items have to be initially checked after 25 hours. Thereafter, service as specified in this chart.
➂ Daily flushing in salt water or foul water use.
➃ Every 200 hours or 2 years.
➄ Emission-related component.
➅ Replace after the vehicle has completed 100 hours of use, not every year.
➆ Replace for storage period.
02-02-2 LMR2004-003_02_02A.FM
Subsection 03 (FLUSHING AND LUBRICATION)
FLUSHING AND LUBRICATION 0

GENERAL NOTE: An optional quick connect adapter can be
used (P/N 295 500 473). No hose pincher is re-
NOTE: This procedure to be performed for each quired to flush engines.
engine.
Closed Loop Cooling System
4-TEC engines are equipped with a closed loop
cooling system which does not need to be flushed
even after salt water use.
Open Loop Cooling System
Flushing the exhaust cooling system with fresh
water is essential to neutralize corroding effects of
salt or other chemical products present in water. It
will help to remove sand, salt, shells or other parti-
cles in water jackets and/or hoses.
Flushing should be performed for each engine
when the sport boat is not expected to be used fur- F07E01C 3 2 1
ther the same day or when the sport boat is stored for
any extended time. TYPICAL
1. Hose adapter
 WARNING
2. Quick connect adapter (optional, not mandatory)
3. Garden hose
Perform this operation in a well ventilated area.
Do not touch any electrical part or jet pump Flushing
area when engine is running. To flush the exhaust cooling system, start that en-
gine then immediately open the water tap.
Proceed as follows:
Clean jet pumps by spraying water into inlets and  WARNING
outlets and then apply a coating of BOMBARDIER Certain components in the engine compartment
LUBE™ lubricant or equivalent. may be very hot. Direct contact may result in skin
burn. Do not touch any electrical part or jet pump
 WARNING area when an engine is running.
Always remove safety lanyard cap from switch
to prevent unexpected engine starting before CAUTION: Never flush a hot engine. Always
cleaning the jet pump area. Engine must not be start the engine before opening the water tap.
running for this operation. Open water tap immediately after engine is start-
ed to prevent overheating.
One engine at a time, connect a garden hose to Run the engine about 20 seconds between 4000 -
connector located at the rear of sport boat on each 5000 RPM.
jet pump support. CAUTION: Never run an engine without supply-
 WARNING ing water to the exhaust cooling system of that
engine when sport boat is out of water.
When operating the engine while the sport
boat 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 occur.
LMR2004-003_02_03A.FM 02-03-1
Subsection 03 (FLUSHING AND LUBRICATION)
Ensure water flows out of exhaust outlet while

flushing. Otherwise, refer to an authorized Sea-Doo
dealer for servicing.
CAUTION: Never run engine longer than 5 min-
utes. Drive line seal has no cooling when wa-
tercraft is out of water.
Close the water tap, then stop the engine.
CAUTION: Always close the water tap before
stopping the engine.
NOTE: Engine valves fogging should be done when-
ever the sport boat is to be stored for a long period.
Refer to STORAGE section.
02-03-2 LMR2004-003_02_03A.FM
Subsection 04 (WATER-FLOODED ENGINE)
WATER-FLOODED ENGINE 0
GENERAL Oil Change Procedure
NOTE: This procedure to be performed for each ENGINE WITHOUT THE SCAVENGE OIL PUMP
engine. COVER DRAIN PLUG
If an engine becomes water-flooded, it must be CAUTION: Never crank or start an engine when
serviced within a few hours after the event. Oth- siphon tube is in dipstick hole. Never start an
erwise engine(s) will have to be overhauled. engine when there is no oil in that engine.
CAUTION: Each water-flooded engine must be 1. Using the oil VAC (P/N 529 035 880), siphon oil
properly lubricated, operated then lubricated through dipstick hole.
again, otherwise parts will be seriously dam- 2. Remove the oil VAC tool from the dip stick
aged. hole.
3. While in drowned engine mode, crank the en-
PROCEDURE gine for 5 seconds.
Check fuel reservoir for water contamination. If 4. Remove the oil filter cap and the oil filter.
necessary, siphon and refill with fresh fuel. 5. Again, siphon oil from the reservoir.
To limit damages to the engine(s), perform the fol- 6. Install a new oil filter and reinstall the oil filter
lowing procedure as soon as possible for each en- cap.
gine.
7. Fill up the reservoir with fresh oil.
Drain bilge if water is present.
8. Run the engine for 3 minutes in a test tank or
If it was submerged in salt water, spray bilge and connected to a flush kit
all components with fresh water using a garden
hose to stop the salt corroding effect. 9. Repeat the above steps 1 to 7.
CAUTION: Never try to crank or start the 10. Boil out the remaining water as follows:
engines. Water trapped in the intake manifold a. Recommended procedure: BOIL OUT PRO-
would enter the combustion chambers CEDURE IN A TEST TANK OR TIED TO A
through the intake valves and may cause dam- TRAILER WITH SPORT BOAT IN WATER.
age to the engines. b. Optional procedure: BOIL OUT PROCEDURE
Whenever the engines are stopped, all the valves CONNECTED TO A FLUSH KIT.
close to prevent water from being ingested in the
engines.
If water is suspected to be in the intake manifolds
and the exhaust systems, they must be drained as
follows:
Remove each intake manifold and suck out the
water from the intake valve ports. Refer to subsec-
tion INTAKE SYSTEM.
Remove the water from each engine’s oil/air sep-
arator breather hose.
Remove the exhaust pipes, the mufflers and the
resonators and drain them. Refer to subsection
EXHAUST SYSTEM.
If water gets in the oil (oil will appear milky), F18D19A 1
change the engine oil and filter as follows for each 1. Scavenge oil pump cover drain plug
engine:
LMR2004_004_02_04A.FM 02-04-1
ENGINE WITH THE SCAVENGE OIL PUMP A. Boil Out Procedure with Sport Boat in Water
COVER DRAIN PLUG 1. Run the engine for 5 minutes at 3500 RPM.
CAUTION: Never crank or start an engine when 2. With the engine still running at 3500 RPM, in-
siphon tube is in dipstick hole. Never start an stall a hose pincher to the coolant line going to
engine when there is no oil in that engine. the oil cooler.
1. Using the oil VAC (P/N 529 035 880), siphon oil
through dipstick hole.  WARNING
2. Remove the oil vac tool from the dip stick hole. Certain components in the engine compart-
3. While in drowned engine mode, crank the en- ment may be very hot. Direct contact may re-
gine for 5 seconds. sult in skin burn. Do not touch any electrical
parts or jet pump area when engine is run-
4. Remove the oil filter cap and the oil filter. ning.
5. Again, siphon oil from the reservoir.
6. Put a rag under the scavenge oil pump cover. 1
7. Remove the scavenge oil pump cover drain
plug and install fitting (P/N 293 710 037).
8. Connect the oil vac tool Bombardier (P/N 529
035 880) to the fitting.
9. The front of the engine must be tilted down
approximately 15 degrees to facilitate the re-
moval of the oil. Raise the rear of the boat ac-
cordingly. Siphon the oil from the fitting.
10. Level the engine.
11. Remove the oil vac tool and the fitting. Rein-
stall the drain plug.
F18E1QA
NOTE: Do not forget to install the sealing washer
1. Oil cooler coolant inlet hose
on the drain plug.
NOTE: If spillage occurs, clean immediately with the 3. Continue to run the engine at 3500 RPM for 15
pulley flange cleaner (P/N 413 711 809) to prevent oil more minutes (20 minutes total run time).
stains. 4. Shut the engine off.
12. Install a new oil filter and reinstall the oil filter 5. Remove the hose pincher on the coolant line
cap. going to the oil cooler.
13. Fill up the reservoir with fresh oil. CAUTION: Hose pincher should be removed
14. Boil out the remaining water as follows: before operating the engine. Failure to do this
will result in damage to the engine.
 WARNING 6. Change the oil and filter again.
Make sure to safely secure the sport boat be- 7. Procedure is now completed.
fore starting engine(s).
B. Boil Out Procedure Connected to a Flush Kit
a. Recommended procedure: BOIL OUT PRO- 1. On drive shaft, remove the C-clip then move for-
CEDURE WITH SPORT BOAT IN WATER. ward the ring seal carrier. Refer to DRIVE SYS-
b. Optional procedure: BOIL OUT PROCEDURE TEM section.
CONNECTED TO A FLUSH KIT. CAUTION: Make sure that the ring seal carrier
is not in contact with the PTO seal assembly,
neither with the carbon ring.
02-04-2 LMR2004_004_02_04A.FM
2. Connect a flush kit to the coolant line.

CAUTION: Never run engines without supply-
ing water to the exhaust cooling systems when
sport boat is out of water.
3. Run the engine for 5 minutes at 3000 RPM.
4. With the engine still running at 3000 RPM, in-
stall a hose pincher to the coolant line going to
the oil cooler.
 WARNING
Certain components in the engine compart-
ment may be very hot. Direct contact may re-
sult in skin burn. Do not touch any electrical
parts or jet pump area when engine is run-
ning.
5. Continue to run the engine at 3000 RPM for 15

more minutes (20 minutes total run time).
6. Shut off the engine
7. Remove the hose pincher on the coolant line
going to the oil cooler.
CAUTION: Hose pinchers should be removed
before operating the engines. Failure to do this
will result in damage to the engine(s).
8. Change the oil and filter again.
9. Move rearward the Ring Seal Carrier and rein-
stall the C-clip. Refer to DRIVE SYSTEM sec-
tion.
10. Procedure is now completed.
LMR2004_004_02_04A.FM 02-04-3
Subsection 05 (STORAGE)
STORAGE 0
FUEL SYSTEM – Remove the two bolts that hold the fuel rail on.
– Remove the rail along with the three fuel injec-
Verify fuel system. Check all fuel lines and injec-
tors.
tors for leaks. Replace damaged hoses or clamps
if necessary. – Apply Bombardier Lube™ lubricant into the in-
take ports.
CAUTION: Sea-Doo fuel stabilizer (P/N 413 408
600) or equivalent should be added in fuel tank – Crank engine briefly to prevent fuel injection
prior to engine lubrication to prevent fuel sys- and ignition.
tem components deterioration and protect – Reinstall the injectors.
against varnish deposits. Follow manufactur-
CAUTION: Install new O-rings.
er’s instructions for proper use.
– Torque the two bolts that hold the fuel rail on.
Fill fuel tank completely. Ensure there is no water
inside fuel tank.
CAUTION: Should any water be trapped inside
 WARNING
At preseason preparation, perform a fuel
fuel tank, severe internal damage may occur to
pressure test to ensure there are no leaks.
the fuel injection system.
Run engine and check for leaks. Refer to EN-
 WARNING GINE MANAGEMENT section.
Fuel is flammable and explosive under cer- – Pull engine cover upward to remove it.
tain conditions. Always work in a well venti- – Disconnect ignition coil connectors.
lated area. Do not smoke or allow open
flames or sparks in the vicinity. Fuel tank may
be pressurized, slowly turn cap when open-  WARNING
ing. Never use an open flame to check fuel When disconnecting coil from spark plug, al-
level. When fueling, keep sport boat level. Do ways disconnect coil from main harness first.
not overfill or top off the fuel tank and leave Never check for engine ignition spark from an
sport boat in the sun. As temperature increas- open coil and/or spark plug in the engine
es, fuel expands and might overflow. Always compartment as spark may cause fuel vapor
remove any fuel spillage from the sport boat. to ignite.
IMPORTANT: Never cut the locking ties of coil

ENGINE OIL CHANGE AND FILTER connectors. This would allow mixing the wires be-
tween cylinders.
Change the oil and filter for each engine. Refer to
LUBRICATION in ENGINE section. – Remove ignition coils.
CAUTION: Ensure there is no dirt in coil holes
COOLING SYSTEM FLUSHING before removing the spark plugs. Otherwise,
dirt will fall into cylinder and damage the inter-
AND ENGINE INTERNAL nal components.
LUBRICATION – Remove the spark plugs.
Engine Lubrication – Apply Bombardier Lube lubricant into the cylin-
ders.
Fogging each engine is recommended at the end
of the season and before any extended storage – Reinstall spark plugs and ignition coils.
period. This will lubricate the intake engine valves, – Reconnect ignition coil connectors.
the cylinders and the exhaust valves.
NOTE: Prior to inserting the ignition coil into its
To fog the intake engine valves proceed as follows location, apply some Bombardier Lube lubricant
for each engine: around the seal area that touches the spark plug
hole. After installation, ensure the seal seats prop-
erly with the engine top surface.
LMR2004_005_02_05A.FM 02-05-1
Subsection 05 (STORAGE)
– To reinstall engine cover, push it downward until ADDITIONAL RECOMMENDED

it snaps into position.
PROTECTION
– Crank engine several times briefly.
Refer to the COOLING SYSTEM section.
1
ANTICORROSION TREATMENT
Remove any residual water in the engine compart-
ment.
Spray Bombardier Lube lubricant over all metallic
components in engine compartment.
Lubricate the throttle cables with Bombardier
Lube lubricant.
The engine compartment lid should be partially left
opened during storage. Remove the engine com-
partment storage tray and store in a safe place.
This will avoid engine compartment condensation
F18M01A
and possible corrosion.
1. Engine intake ports
CHECKLIST
BATTERY OPERATION ✔
For battery removal, cleaning and storage, refer to
Verify fuel system
CHARGING SYSTEM.
Add Sea-Doo fuel stabilizer
SPORT BOAT CLEANING Change oil and filter for each engine
Clean the bilge with hot water and mild detergent
Flush each exhaust cooling system by
or with bilge cleaner. Rinse thoroughly. Lift front running the engines
end of sport boat to completely drain bilge. If any
repairs are needed to body or to the hull, touch up Lubricate each engine
paint and Gelcote® repair kits are available. Re-
Remove, clean and store the battery
place damaged labels/decals.
Wash the body with soap and water solution (only Clean the bilge
use mild detergent). Rinse thoroughly with fresh Wash the body
water. Remove marine organisms from the hull.
Apply a nonabrasive wax. Replace antifreeze for each engine. Check
solution concentration in the cooling system
CAUTION: Never clean fiberglass and plastic
(in cool regions)
parts with strong detergent, degreasing agent,
paint thinner, acetone, etc. Spray Bombardier Lube over all metallic
If the sport boat is to be stored outside, cover it components in engine compartment and on
throttle cable
with an opaque tarpaulin to prevent sun rays and
grime from affecting the plastic components,
sport boat finish as well as preventing dust accu-
mulation.
CAUTION: The sport boat must never be left in
water for storage. Never leave the sport boat
stored in direct sunlight.
02-05-2 LMR2004_005_02_05A.FM
Section 03 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
TROUBLESHOOTING CHART
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 problems.
NOTE: Always check for fault codes recorded in the ECM ECU first using the VCK (vehicle communication
kit (P/N 529 035 844). If a fault code is detected, service the fault code and recheck operating conditions.
Refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT section.
ENGINE WILL NOT START
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
• Wrong safety lanyard • Use one that has been programmed
for that sport boat
• DESS operation non functional • If 2 short beeps are not heard when in-
stalling safety lanyard, refer to ELEC-
TRICAL SYSTEM and ENGINE MAN-
AGEMENT
• Safety lanyard switch faulty or discon- • Replace
nected or harness damaged
• Burnt fuse in engine fuseblock, bat- • Check wiring then replace fuse
tery, starting system, fuel pump
• Starting system fuse keeps on burn- • Check wiring and starting system sole-
ing noid
Engine does not turn over • Discharged or disconnected battery • Check/recharge
• Defective or disconnected start/stop • Check, refer to STARTING SYSTEM or
switch ENGINE MANAGEMENT
• Battery connections • Check/clean/tighten
• Water/fuel hydrolock • Check, refer to MAINTENANCE
• Starter malfunction • Check, refer to ELECTRICAL SYSTEM
• Starter solenoid • Check, refer to ELECTRICAL SYSTEM
• Seized or obstructed engine • Check/repair, refer to ENGINE
• Seized jet pump • Check, refer to PROPULSION SYSTEM
• Faulty ECM ECU • Check faulty codes in ECM ECU mem-
ory, refer to ENGINE MANAGEMENT
LMR2004_006_03_01A.FM 03-01-1
ENGINE WILL NOT START (cont’d)

• Loose battery cable connections • Check/clean/tighten
• Discharged/weak battery • Check/charge/replace
• Restriction in jet pump • Check/clean pump
• Partial seizure in jet pump • Inspect, refer to PROPULSION SYS-
TEM
Engine turns slowly • Partial engine hydrolock • Check, refer to MAINTENANCE
• Partial engine seizure • Check compression, refer to ENGINE
• Worn starter • Check, refer to ELECTRICAL SYSTEM
• Outside temperature too low • Oil is too “thick”. Change oil viscosity
• Battery capacity is not sufficient for cold
temperature
• Low battery voltage • Recharge or replace battery
• No spark at the spark plug • Check spark plugs condition and re-
place as necessary
• Check ignition system and repair
• Defective ECM ECU • Replace ECM ECU
• Defective crankshaft position sensor • Check operation of CPS and replace if
necessary
• Water-contaminated fuel • Check/siphon and refill
• Dirty fuel filter • Clean/replace
Engine turns over
• Fouled or defective spark plug • Replace
• Water in engine • Check, refer to MAINTENANCE
• Defective ignition circuit • Check, refer to ELECTRICAL SYSTEM
• Internal engine damage • Check, refer to ENGINE
• Defective encoder wheel • Check, refer to ENGINE MANAGEMENT
• Insufficient engine compression • Replace defective part(s)
• Incorrectly aligned flywheel and en- • Properly position flywheel and encod-
coder wheel er wheel, refer to PTO HOUSING/
MAGNETO
• Spark plug faulty, fouled or worn out • Check spark plug condition
No spark at spark plugs • Ignition • Check, refer to ELECTRICAL SYSTEM
• Faulty ECM ECU • Replace ECM ECU
03-01-2 LMR2004_006_03_01A.FM
ENGINE HARD TO START

• Defective idle bypass valve • Refer to ENGINE MANAGEMENT
• Wrong TPS zero setting • Refer to ENGINE MANAGEMENT
• Wrong throttle body mechanical ad- • Refer to ENGINE MANAGEMENT
justment of cable
• Temperature too low for available • Battery capacity is not sufficient for cold
battery capacity temperature
• Air lock in fuel rail • Refer to ENGINE MANAGEMENT
• Water in intake system • Check and remove water
(defective sensor) • Refer to intake system in ENGINE MAN-
AGEMENT
• Water in fuel reservoir or contami- • Flush reservoir and refill with fresh gas
nated fuel
• Mechanical engine failure • Check cylinder compression
• Check for cylinder head leaks
• Check starting system
• Spark plug faulty, fouled or worn out • Check spark plug condition
• Low fuel pressure • Check fuel pump operation. Refer to EN-
GINE MANAGEMENT
• Check fuel pressure regulator. Refer to
ENGINE MANAGEMENT
ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED

• The system is in limp home mode • Refer to ENGINE and check the fault
codes in the ECM ECU
• Broken or loose throttle cable • Change/readjust
ENGINE MISFIRES, RUNS IRREGULARLY

• Fouled, defective, worn spark plugs • Check/verify heat range/gap/replace
• Faulty ECM ECU • Check, refer to ENGINE MANAGEMENT
• Defective encoder wheel • Check, refer to ENGINE MANAGEMENT
Weak spark
• Bad ignition coil wiring • Check wiring condition and proper ground-
ing of ignition coil
• Faulty ignition coil, or bad connector • Check coil. Refer to ENGINE MANAGE-
MENT
LMR2004_006_03_01A.FM 03-01-3
ENGINE MISFIRES, RUNS IRREGULARLY (cont’d)

• Low fuel level • Check/refill
• Low fuel pressure • Check pump, regulator, injectors and
hose pinchers or if filter is plugged. Re-
place if necessary
Lean fuel mixture.
Dry spark plug (except • Stale or water fouled fuel • Check/siphon and refill
when water fouled) • Fuel filter dirty or restricted • Check/clean/replace
• Clogged fuel injectors • Remove and clean fuel injectors
• Defective sensor or ECM ECU • Check faulty codes in ECM ECU mem-
ory, refer to ENGINE MANAGEMENT
• Flame arrester dirty or restricted • Check/replace
• Faulty fuel injector(s) • Remove and replace fuel injector(s), re-
fer to ENGINE MANAGEMENT
• Defective sensor or ECM ECU • Check fault codes in ECM ECU memo-
Rich fuel mixture. ry, refer to ENGINE MANAGEMENT
Fouled spark plug
• Fuel pressure fluctuating • Inspect fuel pressure regulators. Refer
to ENGINE MANAGEMENT
• High fuel pressure • Check pump, regulator, injectors, hose
pinchers or if filter is plugged. Replace
if necessary
• Check spark plug condition, check • Check, refer to ENGINE MANAGEMENT.
fault codes in the ECM ECU memo- If some work has been performed on
ry, check fuel pressure the unit, make sure injector wire con-
Starts but runs poorly
nectors were not mixed. Refer to the
wiring diagram for wire colors and posi-
tions
• Bent or missing tooth on encoder • Check, refer to ENGINE MANAGEMENT
wheel under component inspection and ad-
Also fuel injection justment
malfunction • Injector wiring reversed • Check with wiring diagram
• Damaged fuel injector • Check, refer to ENGINE MANAGEMENT
03-01-4 LMR2004_006_03_01A.FM
ENGINE CONTINUALLY BACKFIRES

Weak spark • Fouled, defective spark plugs • Clean/replace
Spark plugs • Ignition coil leads or wiring reversed • Check with wiring diagram
Ignition timing/TDC setting • Defective encoder wheel • Check, refer to ENGINE MANAGEMENT
Engine • Intake or exhaust valve(s) leak • Pressure check engine, refer to ENGINE
ENGINE DETONATION OR PINGING

• Timing too far advanced • Check/reset
Ignition
• Spark plug heat range too high • Check/change to correct range
• Engine overheats and exhaust over- • Check, see engine overheats
heats
Engine/exhaust high • Fuel octane too low/of poor quality • Use good quality fuel
temperature • KS disconnected or faulty • Check, refer to ENGINE MANAGEMENT
• Bad KS connection • Check, refer to ENGINE MANAGEMENT
• Bad Kostal connection (on engine) • Check, refer to ENGINE MANAGEMENT
ENGINE LACKS ACCELERATION OR POWER

• Weak spark • Check/replace, refer to ELECTRICAL
SYSTEM
• Throttle does not open fully • Check/readjust, refer to ENGINE MAN-
AGEMENT
• Low compression • Check/repair, refer to ENGINE
• Water in fuel • Check/siphon/replace
• Impeller leading edge damaged • Check/replace, refer to PROPULSION
SYSTEM
• Too much engine oil • Siphon or adjust level. Refer to LUBRI-
CATION
• Poor fuel quality • Siphon then refill with fresh fuel
• Clogged fuel injectors • Remove and clean fuel injectors
• Low fuel pressure • Check fuel line and fuel pump pressure
• Incorrect throttle position sensor (TPS) • Check and adjust TPS, refer to ENGINE
adjustment MANAGEMENT
• Improper timing chain alignment • Refer to CYLINDER HEAD
• Overheated engine • See ENGINE OVERHEATS in this chart
Engine revs lower than • Limp home mode activated • Refer to ENGINE MANAGEMENT
its maximum operational
RPM
LMR2004_006_03_01A.FM 03-01-5
ENGINE STOPS RUNNING

• Spark plug heat range too high • Check/change to correct range
Engine dies during regular
• Compression ratio is too high • Install genuine parts
operation (piston seizure)
• Poor oil quality • Use proper BOMBARDIER oil
Engine stalls at idle • Air in fuel rail • Refill fuel tank
Engine starts but stops • Engine running out of fuel • Refill fuel tank
after approximately • Air in fuel rail • Check fuel delivery system for proper
2 seconds fuel pressure and delivery
ENGINE CANNOT REACH MAXIMUM RPM

• The system is in limp home mode. • Refer to ENGINE and check the fault
codes in the ECM ECU
• Low fuel pressure • Check fuel pump pressure output
• Jet pump related problem • Check propulsion components. Refer
to JET PUMP
• Limp home mode activated • Refer to ENGINE MANAGEMENT
• Exhaust gases in bilge (leak) • Check exhaust system for leaks
ENGINE RUNS TOO FAST (vehicle cannot reach its top speed)
• Faulty rev limiter in ECM ECU • Check, refer to ENGINE
MANAGEMENT
• Improper impeller pitch (too low) • Check/replace, refer to PROPULSION
Engine RPM too high SYSTEM
• Incorrect throttle position sensor (TPS) • Check and adjust TPS, refer to ENGINE
adjustment MANAGEMENT
• Damaged impeller • Replace impeller. Refer to PROPULSION
• Damaged leading or trailing edge of • Check/replace
impeller NOTE: Leading edge damage contributes
to poor performance from start. Trailing
Jet pump cavitation edge damage contributes to poor top per-
formance and stator vanes erosion.
• Sealing of ride plate, jet pump support • Check/reseal, refer to PROPULSION
or jet pump SYSTEM or HULL/BODY
03-01-6 LMR2004_006_03_01A.FM
ENGINE OVERHEATS
• Coolant level low • Refill/check for leaks
• Water leaking out of weep hole (PTO • Replace rotary seal
housing)
Coolant level too low
• Hoses or clamps missing/defect • Repair/replace
• Cylinder head gasket leaks (white ex- • Replace cylinder head gasket
haust gas)
• Temperature sensor defect • Check/replace. Refer to ENGINE MAN-
AGEMENT
• Worn water pump impeller • Check/replace
Monitoring beeper sounds
• Cooling system restriction • Check/flush, refer to MAINTENANCE
continuously
• Damaged ride plate or hoses • Check, refer to COOLING SYSTEM and
HULL/BODY
• Thermostat defective • Check/replace
ENGINE SMOKE IN THE EXHAUST

• Coolant leak • Check/repair. Refer to LEAK TEST
• Damaged head gasket • Check/replace the head gasket
White smoke
• Water ingestion • Inspect the intake manifold for the
presence of water
• Valve guide seals • Check/replace valve guide seals, refer
to CYLINDER HEAD AND VALVES
Blue smoke
• Oil rings worn out • Replace rings
• at engine starting
• Oil rings • Inspect/repair oil rings, refer to ENGINE
• with engine under load BLOCK
• Oil level too high • Siphon some oil from the oil tank
LOW OR NO ENGINE OIL PRESSURE

• Oil level too low • Refill. See TECHNICAL DATA for spec-
ifications
• Leaking gasket • Replace
• Oil leaking out of weep hole • Replace oil seal on pump shaft
(PTO housing)
• Oil pressure sensor defective • Check/replace
• Oil pump malfunctioning • Clean rotor and check wear limits
• Oil regulator valve sticks open, or • Clean/replace
spring load to small
• Heavy wear on plain bearings • Replace
LMR2004_006_03_01A.FM 03-01-7
ENGINE OIL CONTAMINATION (WHITE APPEARANCE)

• Oil seal and rotary seal on water pump • Replace both seals. Refer to PTO HOUS-
shaft leaking ING. Change oil
• Cylinder head gasket leaking • Replace gasket. Refer to CYLINDER
HEAD. Change oil
Water and oil mixture
• Loose screws on cylinder head, PTO • Retorque. Change oil
leaking out of weep hole
housing or oil separator
(PTO housing)
• Oil contamination due to metal or • Replace possibly damaged parts.
plastic particles Change oil
• Water ingestion (intake manifold, • Refer to MAINTENANCE
TOPS valve, dipstick)
UNUSUAL ENGINE NOISE AND/OR VIBRATION

• Worn chain tensioner • Replace
• Worn chain guide • Replace
• Stretched chain and/or worn out sprock- • Replace chain and sprockets
ets
• Sprocket screws got loose • Retorque
• Hydraulic element inside rocker arm(s) • Replace faulty rocker arm(s)
is (are) worn out (valve adjustment)
• Rocker arm screws not tightened • Retorque
• Heavy wear on crankshaft and/or bal- • Replace
ancer shaft bearings
• Crankshaft and balancer shaft not • Check marks and readjust shafts
aligned
• Heavy wear on thrust washers, or • Check/replace
thrust washers missing
ABNORMAL NOISE FROM PROPULSION SYSTEM

• Weeds/debris caught in intake grate • Check/clean
or impeller
• Damaged or bent drive shaft • Check/replace, refer to PROPULSION
SYSTEM
• Idle speed too low • Check fault codes
• Broken engine mounts • Check/replace, refer to ENGINE
NOTE: Prior to replacing a ECM ECU, refer to the appropriate ECM ECU section or ECM ECU REPLACE-
MENT in the ENGINE MANAGEMENT section and read carefully the tests to do before replacing a ECM
ECU that could otherwise be good.
03-01-8 LMR2004_006_03_01A.FM
Section 04 ENGINE (4-TEC)
TABLE OF CONTENTS 0
LEAK TEST ............................................................................................................................. 04-02-1
LEAK TEST PROCEDURE .................................................................................................. 04-02-1
PREPARATION................................................................................................................... 04-02-1
PROCEDURE ...................................................................................................................... 04-02-2
INSTALLATION.................................................................................................................. 04-02-3
INTAKE SYSTEM ................................................................................................................... 04-03-1

REMOVAL........................................................................................................................... 04-03-2
ASSEMBLY......................................................................................................................... 04-03-5
EXHAUST SYSTEM............................................................................................................... 04-04-1

EXHAUST PIPE .................................................................................................................. 04-04-3
EXHAUST MANIFOLD ...................................................................................................... 04-04-5
MUFFLERS (port engine) .................................................................................................. 04-04-6
MUFFLERS (starboard engine) ........................................................................................ 04-04-7
EXHAUST OUTLET (port and starboard) ........................................................................ 04-04-8
REMOVAL AND INSTALLATION.......................................................................................... 04-05-1

GENERAL ........................................................................................................................... 04-05-1
ENGINE REMOVAL............................................................................................................ 04-05-1
CLEANING ......................................................................................................................... 04-05-2
INSTALLATION .................................................................................................................. 04-05-2
PTO HOUSING/MAGNETO .................................................................................................. 04-06-1

GENERAL ........................................................................................................................... 04-06-2
PTO HOUSING................................................................................................................... 04-06-2
PTO SEAL ........................................................................................................................... 04-06-5
COUPLING ......................................................................................................................... 04-06-5
STATOR ............................................................................................................................. 04-06-6
ROTOR AND ENCODER WHEEL....................................................................................... 04-06-7
RING GEAR ........................................................................................................................ 04-06-7
STARTER DRIVE ASS’Y .................................................................................................... 04-06-8
LMR2004-030_04_01ATOC.FM 04-01-1
LUBRICATION SYSTEM......................................................................................................... 04-07-1

GENERAL............................................................................................................................ 04-07-3
OIL LEVEL VERIFICATION ................................................................................................. 04-07-3
ENGINE PRESSURE TEST ................................................................................................. 04-07-3
OIL FILTER .......................................................................................................................... 04-07-6
OIL STRAINERS.................................................................................................................. 04-07-6
ENGINE OIL PRESSURE REGULATOR ............................................................................. 04-07-9
OIL PRESSURE PUMP ....................................................................................................... 04-07-10
OIL SUCTION PUMP .......................................................................................................... 04-07-13
OIL FILTER BYPASS........................................................................................................... 04-07-15
OIL COOLER ....................................................................................................................... 04-07-16
OIL SEPARATOR ................................................................................................................ 04-07-17
CYLINDER HEAD AND VALVES ........................................................................................... 04-08-1

GENERAL............................................................................................................................ 04-08-2
SPARK PLUG ...................................................................................................................... 04-08-2
VALVE COVER .................................................................................................................... 04-08-3
ROCKER ARM..................................................................................................................... 04-08-3
CAMSHAFT TIMING GEAR................................................................................................ 04-08-7
TIMING CHAIN ................................................................................................................... 04-08-8
CYLINDER HEAD ................................................................................................................ 04-08-8
CAMSHAFT......................................................................................................................... 04-08-10
VALVE SPRING................................................................................................................... 04-08-11
VALVE ................................................................................................................................. 04-08-12
ENGINE BLOCK ...................................................................................................................... 04-09-1

GENERAL............................................................................................................................ 04-09-3
CRANKSHAFT LOCKING ................................................................................................... 04-09-3
CRANKSHAFT .................................................................................................................... 04-09-3
TIMING CHAIN ................................................................................................................... 04-09-8
CHAIN TENSIONER............................................................................................................ 04-09-8
BALANCER SHAFT............................................................................................................. 04-09-8
ENGINE BLOCK .................................................................................................................. 04-09-11
PISTON/CONNECTING ROD ............................................................................................. 04-09-16
PISTON RINGS ................................................................................................................... 04-09-21
04-01-2 LMR2004-030_04_01ATOC.FM
Subsection 02 (LEAK TEST)
LEAK TEST 0
LEAK TEST PROCEDURE 1
NOTE: This procedure to be performed for each
engine.
This procedure has to be done when engine operat-
ing temperature of approx. 70°C (158°F) is reached.
 WARNING
Prevent burning yourself while handling the
hot engine.
PREPARATION
Remove:
– safety lanyard R1503motr153A
 WARNING 1. Oil dipstick
Safety lanyard must be removed to prevent – unplug ignition coils and remove
engine from being cranked while fuel rail is re- – spark plugs from cylinder head.
moved in order to prevent fuel being sprayed
out. Fuel is flammable. CAUTION: Ensure there is no dirt in coil holes
before removing the spark plugs. Otherwise,
– fuel rail cover, then remove fuel rail retaining dirt will fall into cylinder and damage the inter-
screws and move away just enough to see the nal components.
injection holes NOTE: Ignition coil may be used as an extractor for
– exhaust pipe (refer to EXHAUST SYSTEM) spark plugs.
– drive shaft 2 1
(refer to JET PUMP in PROPULSION SYSTEM)
– coolant tank cap
 WARNING
To prevent burning yourself, only remove the
coolant tank cap by wearing the appropriate
safety equipment.
– oil dipstick
R1503motr154A
1. Ignition coil
2. Spark plug
LMR2004_007_04_02A.FM 04-02-1
– Remove valve cover cowl. Hold the crankshaft in this position by using the
– Unscrew and remove valve cover. impeller remover/installer tool (P/N 529 035 820)
and a wrench.
2 1 Install gauge adapter into previously cleaned spark
plug hole.
Connect to adequate air supply.
NOTE: Each tester will have specific instructions
on gauge operation and required pressure.
Set needle of measuring gauge to zero.
Supply combustion chamber with air.
R1503motr155A
1. Valve cover 3
2. Valve cover screw
2
PROCEDURE
NOTE: The following procedure must be performed
for each cylinder separately, because of the 120°
offset between the TDCs.
Rotate crankshaft until all valves are closed by using
PTO flywheel remover/installer (P/N 529 035 820). R1503motr157A
Therefore you have to monitor the rocker arms. 1. Measuring gauge

2. Adequate adapter for spark plug hole
1 3. Air supply
Note the amount of leaking or percentage (depend-

ing on tester).
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 7% Excellent condition.
Fair condition; proceed with
8% to 15%
tune up or adjustment.
Poor condition; engine will run
16% to 30% and performance might be
down in some cases.
Very poor condition, diagnose
30% and higher
and repair engine.
R1503motr156A
1. Intake rocker arms
Rotate the crankshaft counterclockwise until the

intake rocker arm has performed a full stroke.
Then rotate crankshaft for another half turn to be
sure that the valves are closed.
04-02-2 LMR2004_007_04_02A.FM
Diagnose – air/water escaping from cylinder/head means

damaged gasket(s) and/or loosened screws
Pressurize area to be tested, spray soap/water so-
(refer to CYLINDER HEAD AND VALVES)
lution at the indicated location and look and/or lis-
ten for air bubbles. – oily contamination on weep hole (speed sensor
area) means a damaged oil seal on coolant pump
– air escaping on intake port means leaking intake
shaft
valve(s)
– coolant out of weep hole means a damaged ro-
– air escaping on exhaust port means leaking ex-
tary seal on coolant pump shaft
haust valve(s)
(refer to COOLING SYSTEM)
– air bubbles out of coolant tank means leaking
cylinder head gasket
– air escaping into crankcase area means exces-
sively worn and/or broken piston rings.
INSTALLATION
NOTE: For installation use the torque values and
Loctite products from the exploded views (refer to
proper engine subsection).
For installation, reverse the preparation procedure.
NOTE: Prior to inserting the ignition coil to its lo-
cation, apply some BOMBARDIER LUBE™ lubri-
cant around the seal area that touches the spark
plug hole. After installation, ensure the seal seats
properly with the engine top surface. R1503motr158A 1
1. Weep hole
General Engine Leakage
– coolant escaping from coolant pump housing
Spray soap/water solution at the indicated location means damaged gasket(s) and/or loosened
and look and/or listen for air bubbles. screws (refer to COOLING SYSTEM).
Pay attention to the following checkpoints: NOTE: For all the checkpoints mentioned above
– clamp(s) tightened see the appropriate engine section to diagnose
– coolant hoses and repair the engine.
– air/oil escaping from crankcase means dam-
aged gasket(s) and/or loosened screws
(refer to ENGINE BLOCK)
LMR2004_007_04_02A.FM 04-02-3
Subsection 03 (INTAKE SYSTEM)
INTAKE SYSTEM 0
Loctite 243
10 Nm
(89 lbfin)
Oil
Loctite 243
6 Nm 10 Nm
(53 lbfin) (89 lbfin)
Loctite 243
Loctite 243
10 Nm
(89 lbfin)
Loctite 243
6 Nm 18 Nm 10 Nm
(53 lbfin) (159 lbfin) (89 lbfin)
R1503motr63S
LMR2004_008_04_03A.FM 04-03-1
REMOVAL Cut locking ties where shown.
Air Intake Manifold

engine. 1
Remove oil dipstick.
Pull fuel rail cover out.
Disconnect battery cables from battery.
 WARNING 1
Always disconnect battery cables exactly in
the specified order, BLACK negative cable
F18D0CA
first then the RED positive battery cable last.
1. Cut locking ties
Release the fuel pressure in the system, refer to
ENGINE MANAGEMENT section. Unplug connectors from ignition coils, TOPS valve,
OSPS, TPS, idle bypass valve, engine connector,
Disconnect fuel hose connector at fuel rail. CTS, CAPS, KS, CPS, magneto, OPS and EGT.
1 2 3 10
1
2
1
2 9
8
7
1 1
R1503motr60A 5 4
1.Ignition coils
2.TOPS
3.TPS (hidden behind throttle body)
4.Idle bypass valve
R1503motr78A 5.Engine connector
6.KS
Step 1 : Squeeze 7.CPS
8.Magneto
Step 2 : Pull out 9.“B” Kostal connector
1. Supporting tabs 10. OSPS
2. Squeeze in middle of supporting tabs, hold and pull out
04-03-2 LMR2004_008_04_03A.FM
For the TOPS valve connector, refer to the follow-

ing illustration.
1
R1503motr64A 1
1. CTS connector
R1503motr69A
1. Push here and hold while pulling connector out
NOTE: The TPS connector is hidden behind the

TOPS hose. Disconnect hose from TOPS valve
then move away to access the TPS connector.
Slightly pry locking tab of connector to unlock.
R1503motr65A 1
1. CAPS connector
R1503motr75A
1. TOPS hose disconnected and moved away

2. TPS connector
3. Slightly pry tab to unlock
R1503motr66A 1
1. EGT connector
LMR2004_008_04_03A.FM 04-03-3
Pull the connectors for KS, CPS and magneto out

of the ECU support.
Pull wiring harness away from intake manifold.
Slacken air intake silencer collar.
Unlock throttle cable housing from throttle body.
Cable is to be detached further.
1
F18D0BA 1 2
1. Oil filter housing
2. OPS
Unplug the “B” Kostal connector from the Engine

ECU.
R1503motr72A
1. Air intake silencer collar

2. Unlock throttle cable housing
Remove 7 retaining screws and push the oil dip-

stick tube out of the manifold slot.
R1503motr70A 1
1. Push this end to unlock
R1503motr59A
R1503motr71A
1. Pull here to release
04-03-4 LMR2004_008_04_03A.FM
Lift intake manifold up to pull it out of the mount-

ing brackets just enough to reach throttle cable
end.
R1503motr274A
TYPICAL
R1503motr61A 1
NOTE: The flame arrester in intake manifold is
1. Mounting brackets
maintenance free.
Detach throttle cable end from throttle body.
ASSEMBLY
Assembly is essentially the reverse of removal
procedures. However pay particular attention to
the following.
CAUTION: Do not modify air intake system,
otherwise calibration will be affected.
Air Intake Manifold

Ensure that all gaskets are properly installed and
in a good condition.
R1503motr76A 1
1. Detach cable end from throttle body
Pull intake manifold out.
R1503motr62A 1
INTAKE MANIFOLD
1. Gaskets
LMR2004_008_04_03A.FM 04-03-5
First, position intake manifold on front mounting

bracket then push manifold toward engine to thus
allow proceeding with rear mounting bracket.
When installing the intake manifold, lift up the oil
dipstick tube a little bit to fit in the slot of the man-
ifold.
1
R1503motr59B
1. Oil dipstick tube
Apply Loctite 243 (blue) (threadlocker) on the in-

take manifold screws. Torque them to 10 N•m
(89 lbf•in) following the tightening sequence
shown.
5 3 1
6
2 7
4
R1503motr210A
Ensure to properly route and resecure wiring har-

ness with locking ties.
 WARNING
Always check O-ring for damage such as defor-
mation at reinstallation. Replace the O-ring if it is
damaged.
04-03-6 LMR2004_008_04_03A.FM
Subsection 04 (EXHAUST SYSTEM)
EXHAUST SYSTEM 0
PORT SIDE VIEW
17 18
16
21
16
16 20
17
12
13
20
19
22
Hull
14
F13D04S
LMR2004-009-04-04A.FM 04-04-1
STARBOARD VIEW
5
13
6
18
12
16
17
16 20
19 20
22
Hull
14
F13D05S
04-04-2 LMR2004-009-04-04A.FM
EXHAUST PIPE
engine.
Removal
 WARNING
Certain components in the engine compart-
ment may be very hot. Direct contact may re-
sult in skin burn. Let exhaust system cool down
prior to removing parts.
Disconnect the 3 cooling hoses from exhaust pipe

no. 1.
F13D08A 1 2
1. Exhaust pipe clamp
2. Exhaust pipe
1 Loosen both sets of exhaust hose clamps no. 16

and remove the exhaust hose no. 17 between the
mufflers no. 7 and no. 19.
Detach the strap no. 12 from the muffler no. 7 us-
ing the spring installer/remover (P/N 529 035 559).
3 A00C3SA
1 2
F13D07A
TYPICAL — PORT ENGINE SHOWN

1. Exhaust pipe
2. Gear clamp
3. Exhaust clamp
Loosen the exhaust hose clamps no. 6 to the hose

no. 18 between muffler no. 7 and the exhaust
pipe no. 1.
F13D09A
TYPICAL
1. Muffler
2. Strap
LMR2004-009-04-04A.FM 04-04-3
Slowly unscrew exhaust clamp nut no. 5 and re- Inspection

move it.
Inspect exhaust pipe condition paying attention
NOTE: Unscrewing the nut too fast generates heat for cracks or other damage. Check joints, coupling
that will make it harder to unscrew. areas, heat shield and hoses. Replace any defec-
tive part.
2 1
Installation
Installation is essentially the reverse of the remov-
al procedures. However, pay particular attention to
the following:
Insert the exhaust pipe end in the exhaust hose.
Align the exhaust pipe flange with the engine man-
ifold.
To achieve a good fit, it could be necessary to push
the exhaust pipe further down into the hose over
the step of the exhaust pipe. Take note of the di-
mension it is over the step, then cut the hose by
this dimension, if necessary.
Pre-align the exhaust pipe no. 1 by rotating (axial-
F18D0SA
ly) and moving (longitudinally) the muffler no. 7 so
that the exhaust pipe flange makes perfect con-
TYPICAL tact with the engine manifold. A maximum gap of
1. Exhaust clamp
2. Exhaust pipe 1 mm (3/64 in) is allowed.
Move muffler no. 7 backward enough to allow the 2 1

exhaust pipe to be pulled out.
Apply sealant (P/N 413 710 200) on the welds of the
exhaust tube, while the exhaust pipe is removed
from the muffler no. 7.
F18D0UA
1. Engine manifold
2. Exhaust pipe flange
CAUTION: Exhaust pipe alignment with the

F18D0TA 2 1 manifold is critical to the bellows life. Any con-
straint on the flexible joint will result in the bel-
1. Sealant (P/N 413 710 200) lows failure. Gap between the exhaust pipe
2. Exhaust tube
flange and the engine manifold should not ex-
ceed 1 mm (3/64 in).
04-04-4 LMR2004-009-04-04A.FM
Reinstall the exhaust clamp no. 5 to the exhaust EXHAUST MANIFOLD

pipe flange and tighten enough to maintain the ex-
haust pipe in the proper position. Removal
Disconnect the cooling hoses from the exhaust
pipe no. 1.
Remove the exhaust clamp no. 5 and detach the
muffler no. 7 from its support. Move the muffler
no. 7 rearwards to separate the exhaust pipe from
the manifold if necessary. See above in EXHAUST
PIPE.
Disconnect the cooling system supply hose no. 9
underneath the front part of the exhaust manifold.
F18D0XA 3 2 1
1. Exhaust pipe flange
2. Exhaust clamp
3. Engine manifold
Torque the exhaust clamp no. 5 to 11 N•m

(97 lbf•in) while maintaining the exhaust pipe in
the proper position.
R1503motr151A 2 1
Reinstall the muffler no. 7 strap no. 12 using the
1. Exhaust manifold
spring installer/remover (P/N 529 035 559). Care 2. Cooling system supply hose location
must be taken not to induce strain in the flexible
joint of the exhaust tube. Unscrew the exhaust manifold no. 10 beginning
with the bottom screws. This will help hold the man-
Torque the clamps located in the upper part of the ifold in place while you remove the screws.
muffler no. 7 hose to 8 N•m (71 lbf•in). Care must
be taken not to induce strain in the flexible joint of Remove the manifold.
the exhaust tube.
Inspection
Reconnect the water lines to the exhaust pipe and
torque gear clamps to 8 N•m (71 lbf•in). Inspect exhaust manifold condition paying atten-
tion for cracks or other damage. Check contact
CAUTION: Never run engine without supplying surfaces and hose. Replace any defective part.
water to the exhaust cooling system when
sport boat is out of water. Inspect plane surfaces for warpage. Small defor-
mation can be corrected by grinding surface with
After installation, ensure there is no water or ex- a fine sand paper. Install sand paper on a surface
haust gas leak when engine is running. Test run plate and rub part against oiled sand paper.
the engine while supplying water to the flushing
connector. Clean all metal components in a solvent.
LMR2004-009-04-04A.FM 04-04-5
Installation
Installation is essentially the reverse of removal
procedures. However, pay particular attention to
the following: 1
NOTE: There is no gasket between engine block
and exhaust manifold.
Apply Loctite 518 (red) (gasket eliminator) on threads
of screws. 2
To help hold the manifold in place while installing
screws, first insert the exhaust manifold into the
exhaust pipe no. 1, then install the upper front
screw. Continue with the remaining screws.
Torque screws to 10 N•m (89 lbf•in) as per follow- F13D0AA
ing illustrated sequence. Repeat the procedure, TYPICAL

torquing screws again to 10 N•m (89 lbf•in). 1. Temperature sensor connector
2. Outlet hose
7 5 1 3 9 11
ing the spring installer/remover (P/N 529 035 559).
A00C3SA
1 2
R1503motr152A 8 6 4 2 10 12
CAUTION: Never run engine without supplying

water to the exhaust cooling system when wa-
tercraft is out of water.
After installation, ensure there is no coolant or ex-
haust gas leak when the engine is running. Test
run the engine while supplying water to the flush-
ing connector.
MUFFLERS (port engine) F13D09A
1. Muffler
Removal 2. Strap
Remove the exhaust pipe no. 1. See above. Carefully pull out the muffler no. 7.
Disconnect the temperature sensor connector. Loosen clamps no. 20 and disconnect the exhaust
hose no. 21.
Loosen clamps no. 16 and disconnect the outlet
hose no. 17.
04-04-6 LMR2004-009-04-04A.FM
Carefully remove the muffler no. 19.
1
1
2
F13D0CA
F13D0BA
TYPICAL
1. Muffler 1. Disconnect inlet and outlet hoses from muffler
2. Strap
Inspection ing the spring installer/remover (P/N 529 035 559).
Inspect parts condition paying attention for cracks
or other damage. Check hoses. Replace any de-
fective part.
Installation
Installation is the reverse of the removal proce- A00C3SA
dures.
After installation, ensure there is no coolant or ex-
haust gas leak when the engine is running. Test
run the engine while supplying water to the flush- 2
ing connector.
1
MUFFLERS (starboard engine)
Removal
Loosen both sets of exhaust hose clamps no. 16
and no. 20 and disconnect the exhaust hoses
no. 8 and no. 17 from the muffler no. 19.
F13D0DA
1. Muffler
2. Strap
Carefully pull out the muffler no. 19.
LMR2004-009-04-04A.FM 04-04-7
Inspection Inspection
Inspect parts condition paying attention for cracks Inspect parts condition paying attention for cracks or
or other damage. Check hoses. Replace any defec- other damage. Check hose. Replace any defective
tive part. part.
Installation Installation
Installation is the reverse of the removal procedures. Installation is essentially the reverse of the remov-
After installation, ensure there is no coolant or ex- al procedures. However, pay particular attention to
haust gas leak when the engine is running. Test the following:
run the engine while supplying water to the flush- Apply Loctite silicone sealant (P/N 293 800 086)
ing connector. on the stabilizing washer to seal the bilge.
Ensure to tighten exhaust outlet hose clamps no. 20
EXHAUST OUTLET to 8 N•m (71 lbf•in).
(port and starboard) Test the bilge for water leaks.
Removal
Loosen the two exhaust hose clamps no. 20 from
the exhaust outlet no. 14 and disconnect the ex-
haust hose.
From inside of hull, unscrew nut no. 22 with the
exhaust outlet tool (P/N 295 000 132).
F01B2AA
F09D0WA 1 2
TYPICAL
1. Exhaust outlet nut
2. Tool
04-04-8 LMR2004-009-04-04A.FM
Subsection 05 (REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION 0

GENERAL Drive System
NOTE: This procedure to be performed for each To withdraw drive shaft, refer to PROPULSION sec-
engine. tion.
Engine removal is necessary to repair BOTTOM Cooling System
END.
To remove cooling system hoses, refer to COOLING
SYSTEM section.
ENGINE REMOVAL
Use the VCK (Vehicle Communication Kit) (P/N 529 Exhaust Pipe
035 844) and release the fuel pressure in the fuel To remove exhaust pipe, refer to EXHAUST SYSTEM
system. Refer to ENGINE MANAGEMENT section. in ENGINE section.
In order to remove engine from sport boat proceed
as follows. Air Intake Silencer
First, disconnect battery cables from battery. To remove air intake silencer, refer to INTAKE.
 WARNING Engine Support

Always disconnect battery cables exactly in NOTE: Be careful when removing engine sup-
the specified order, BLACK negative cable port(s) or rubber mount adapters, shims could
first then the RED positive battery cable last. have been installed underneath. Shims control en-
gine/jet pump alignment. Always note position of
shims for reinstallation, to avoid altering engine
Electrical Connections alignment.
It is recommended to disconnect electrical con- Remove engine support mount screws.
nections prior to disconnecting fuel lines.
Disconnect magneto wiring harness.
Disconnect the throttle position sensor (TPS), mani-
fold air pressure sensor (MAPS) and manifold air tem-
perature sensor (MATS) (refer to INTAKE section).
Refer to ENGINE MANAGEMENT for location of
sensors and connectors.
Jet Pump Removal

To withdraw jet pump, refer to PROPULSION sec-
tion.
CAUTION: Whenever removing engine from
sport boat, engine/jet pump alignment must be
performed at reinstallation.
F04D1SA 1
TYPICAL — FRONT SUPPORT
1. Remove screw
LMR2004_010_04_05A.FM 04-05-1
Removal of Remaining Components

Disconnect RED positive cable from starter post.
1
F18D14A 1
TYPICAL — REAR SUPPORT
1. Remove screws
Lifting Engine
F04H72A
Using a chain block, a hoist or other suitable equip-
ment, slightly lift engine to ease the remaining com- TYPICAL
ponent removal. 1. Disconnect RED positive cable
CAUTION: Take care not to damage cables. Carry on the lifting engine to remove it through the
body opening.
1
CAUTION: Be careful not to scratch body or to
hit any component.
CLEANING
Remove any spillage in bilge. Clean with a bilge
cleaner.
Clean external parts of engine.
INSTALLATION
Installation of engine in sport boat is essentially
the reverse of removal procedures. However pay
particular attention to the following.
F04D1TA 1
TYPICAL
1. Transport brackets
04-05-2 LMR2004_010_04_05A.FM
Engine Support
Loctite 243 Loctite

243 1
1
F00B0FA 1 2
1
TYPICAL
1. Plate
Loctite 2. Support
243
Alignment shaft (P/N 295 000 141).
F18D10A
1. Torque screws to 25 N•m (18 lbf•ft)
Positive Starter Cable

Torque nut of positive starter cable to 7 N•m F00B0GA 1
(62 lbf•in). Apply dielectric grease on nut. 1. Alignment shaft
Engine/Jet Pump Alignment Engine alignment adapter (P/N 529 035 719).
Alignment is necessary to eliminate possible vi-
bration and/or damage to components. Check
alignment of engine using the following alignment
tools.
Support plate kit (P/N 529 035 506).
F18D16A 1
NOTE: Use plate (P/N 529 035 507) for the 155.6 mm
(6-1/8 in) jet pump. 1. Engine alignment adapter
LMR2004_010_04_05A.FM 04-05-3
To verify alignment proceed as follows:

– Install the appropriate plate with the support to
hull with four nuts.
F18D17A 1 2
TYPICAL
1. Engine alignment adapter
2. Alignment shaft
F04J4GA
If the alignment is incorrect loosen engine support
screws to enable to align engine alignment adap-
TYPICAL
tor with shaft end.
– Install adaptor (P/N 529 035 719) on drive shaft. NOTE: Use shim(s) (P/N 270 000 024 or P/N 270
000 025) as necessary between engine supports
and rubber mounts to correct alignment.
F18D18A 1
TYPICAL
1. Engine alignment adaptor F18D15A 1
– Carefully slide shaft through support. TYPICAL
1. Shim
– Insert shaft end into engine alignment adaptor.
CAUTION: Whenever shims are used to correct
NOTE: Ensure the protective hose and carbon alignment, never install more than 5 mm (0.196 in)
ring (or seal carrier) is removed to check engine shim thickness.
alignment. If the alignment is correct, the shaft will
slide easily without any deflection in engine align-
ment adaptor.
04-05-4 LMR2004_010_04_05A.FM
Engine Support Screws

Apply Loctite 243 (blue) (threadlocker) (P/N 293 800
060) on screw threads.
Torque engine support screws to 25 N•m (18 lbf•ft)
when procedure is completed.
Loctite 243 Loctite

243 1
1
F18D14A 1
TYPICAL
1. Torque to 25 N•m (18 lbf•ft)
Rubber Mount, Shim and Screw

Check tightness and condition of rubber mounts. If
1 they have been removed, apply Loctite 243 (blue) on
screw threads. Torque screws to 25 N•m (18 lbf•ft).
Loctite CAUTION: Strict adherence to this torque is im-
243 portant to avoid damaging threads of alumi-
num insert in bilge.
Properly align exhaust pipe. Refer to EXHAUST
F18D10A SYSTEM in ENGINE section.
Final Inspection
Check throttle cable conditions and lubricate ca-
bles with BOMBARDIER LUBE™ lubricant.
After installation, properly adjust throttle cables as
specified in ENGINE MANAGEMENT.
Check hose condition and pressure test fuel sys-
tem, refer to FUEL SYSTEM section.
 WARNING
Whenever doing any type of repair on sport
boat or if any components of the fuel system
are disconnected, a pressure test must be
done before starting engine.
F04D1SA 1 Verify all electrical connections.

Run each engine to ensure there is no leakage.
CAUTION: If sport boat is out of water, each en-
gine must be cooled using the flush kit.
LMR2004_010_04_05A.FM 04-05-5
Subsection 06 (PTO HOUSING/MAGNETO)
PTO HOUSING/MAGNETO
10 Nm
10 Nm (89 lbfin)
(89 lbfin)
1 Engine oil
24 Nm(18 lbfft)
Loctite 10 Nm Multi-purpose
243 (89 lbfin) grease
3 30 Nm Loctite
2 (22 lbfft) 243
10
11
Engine oil
9 24 Nm
(18 lbfft) 76
8
15
14
3 Nm (27 lbfin)
Left handed threads 10 Nm
4 (89 lbfin)
Engine oil
18 250 Nm
10 Nm (89 lbfin) (184 lbfft)
Loctite 5 17 16 13
243 Loctite
12
Loctite 5910 243
Engine oil 19
18 Nm 20
(159 lbfin) Engine
Loctite 243 21 oil
Engine 10 Nm
12 Nm oil (89 lbfin) Loctite anti-seize
(106 lbfin) Loctite
243
R1503motr57S
LMR2004_011_04_06A.FM 04-06-1
GENERAL A tube is to be inserted to siphon oil out of PTO

housing. To ensure tube will be inserted far in
NOTE: This procedure to be performed for each enough, measure 381 mm (15-3/8 in) from tube
engine. end (the end that will be inserted in engine) and
Always perform the electric tests before removing trace a mark or put tape on the tube at this loca-
or installing any components. tion.
Clean threads before using Loctite when installing Insert the tube along timing chain as shown until
the screws. you reach the mark (or tape). Then, siphon the oil
out using the oil VAC (P/N 529 035 880).
PTO HOUSING 1
Removal
NOTE: When drive shaft will be removed, some
oil will flow out. To prevent it, start engine, run at
4000 RPM for 10 seconds and stop engine at this
RPM. This will move oil out of PTO housing into
oil tank.
CAUTION: Never run engine(s) without supply-
ing water to the exhaust cooling system when
If engine(s) cannot be started, up to 1 L (34 oz)
could flow out at PTO housing removal. To prevent
this, follow instructions REMOVING OIL IN PTO
HOUSING WHEN ENGINE CANNOT BE START-
ED below. Otherwise, skip to instructions PTO
HOUSING REMOVAL below.
F18D2KA A
Removing Oil in PTO Housing when Engine
cannot be Started PTO HOUSING AND MAGNETO REMOVED FOR EXPLANATION
1. Siphon tube
Remove chain tensioner plug screw and tensioner. A. 381 mm (15-3/8 in) from tube end
Refer to ENGINE BLOCK subsection.
PTO Housing Removal
3 2 Drain engine oil. Refer to LUBRICATION in EN-
GINE section.
Place rags under PTO housing to prevent spillage.
Up to 250 mL (8 oz) of oil could flow out when re-
moving PTO housing. If spillage occurs, clean im-
mediately with the pulley flange cleaner (P/N 413
711 809) to prevent oil stains.
Disconnect CPS and magneto generator from wir-
ing harness.
 WARNING
Always disconnect battery or starter cables
exactly in the specified order, BLACK nega-
R1503motr39A 1 tive cable first. Disconnect electrical connec-
tions prior to disconnecting fuel lines.
1. Plug screw
2. Gasket ring
3. Chain tensioner
Remove valve cover. Refer to CYLINDER HEAD

AND VALVES subsection.
04-06-2 LMR2004_011_04_06A.FM
Remove: NOTE: Carefully separate the PTO housing from

– jet pump the engine using two flat screwdrivers prying
(refer to JET PUMP in PROPULSION SYSTEM) equally at the same time. Proceed slowly so that
starter gear disc springs no. 6 and washer no. 7
– drive shaft (refer to DRIVE SYSTEM in PRO- do not fall down.
PULSION SYSTEM)
– PTO housing no. 5
– slightly lift rear part of engine and safely block in
this position. Remove rear LH side engine sup- CAUTION: Ensure to use prying lugs to sepa-
port no. 1. rate PTO housing to prevent damaging contact
surface.
1 2
R1503motr50A
1. Engine support R1503motr58A
Remove: 1. Disc springs

2. Washer
– thru-hull fitting boot 3. Starter drive gear
– gasket no. 9.
2
Inspection
Check PTO housing for cracks or other damages.
Replace if necessary.
Installation
NOTE: Clean all metal component in a non-ferrous
metal cleaner.
 WARNING
Wear safety glasses and work in a well venti-
lated area when working with strong chemical
products. Also wear suitable non-absorbent
F18J0BA 1 gloves to protect your hands.
1. Thru-hull fitting boot
2. Remove this collar For installation, reverse the removal procedure.
However, pay attention to the following.
– coolant pump housing no. 2
(refer to COOLING SYSTEM) NOTE: Turn the oil/coolant pump shaft in the right
position to fit into the balance shaft.
– screws nos. 3 and 4
LMR2004_011_04_06A.FM 04-06-3
Position the disc springs no. 6 and washer no. 7

2 1 2 2
as per the following illustration.
1 2 3 4
R1503motr46A
1. Washer
2. Disc spring
3. Flange washer
4. Starter drive ass’y 1 2
CAUTION: Ensure the starter drive gear shaft is 1
well engaged in its bore. R1503motr15A 2
Gently install PTO housing. 1. Screws M6 x 35
2. Screws M6 x 85
CAUTION: While installing housing, pay partic-
ular attention that gasket does not get pinched Tightening sequence for screws on PTO housing
or slide out of its contact surface in the area is as per following illustration.
shown in the following illustration. Never force
to install cover. If there is a strong resistance, 15 14 1 13 12 11 10
remove housing and check oil/coolant pump
alignment and starter gear alignment.
1
16
9
17
18
8
19 7
20 6
R1503motr15B
21 2 3 4 5
Reinstall LH engine support. Apply Loctite 243 (blue)

on screw threads then torque to 24 N•m (18 lbf•ft).
Remove block under engine.
F18D2LA
Properly reinstall chain tensioner. Refer to EN-
1. Pay attention that gasket remains properly positioned on this GINE BLOCK subsection.
surface
Properly reinstall valve cover. Refer to CYLINDER-
Refer to the following illustration for proper instal- HEAD AND VALVES subsection.
lation of screws.
Refill engine with oil and cooling system with cool-
ant. Refer to ENGINE and COOLING SYSTEM sec-
tions. Check engine alignment. Refer to REMOV-
AL AND INSTALLATION in ENGINE section.
04-06-4 LMR2004_011_04_06A.FM
PTO SEAL COUPLING

Inspection Removal
Check the PTO seal no. 10 on the PTO housing. If Lock crankshaft with locking tool (P/N 529 035
brittle, hard or damaged, or if you see a sign of oil 821). Refer to CRANKSHAFT LOCKING in ENGINE
leakage, replace it. BLOCK subsection.
Remove:
Removal
– jet pump
NOTE: When drive shaft will be removed, some
oil will flow out. To prevent it, start engine, run at – drive shaft
4000 RPM for 10 seconds and stop engine at this – PTO seal as described above
RPM. This will move oil out of PTO housing into – coupling no. 12 using impeller remover/installer
oil tank. (P/N 529 035 820).
CAUTION: Never run engine without supplying CAUTION: Apply some oil on the tool to protect
water to the exhaust cooling system when the seal located in the PTO coupling.
If spillage occurs, clean immediately with the Pul-
ley Flange Cleaner (P/N 413 711 809) to prevent
oil stains.
Remove:
– Oetiker clamp no. 11 located close to the PTO
housing
– jet pump
(refer to JET PUMP in PROPULSION SYSTEM)
– drive shaft (refer to DRIVE SYSTEM in PROPUL-
SION SYSTEM)
R1503motr48A
– PTO seal no. 10.
2
Inspection
Check if seal no. 13 is brittle, cracked or hard. Check
coupling for worn splines.
If damaged, replace faulty part.
R1503motr47A 1
1. PTO seal
2. Oetiker clamps
Installation R1503motr49A
Reinstall removed parts in the reverse order.
LMR2004_011_04_06A.FM 04-06-5
Installation 1 2
For installation, reverse the removal procedure.
Torque PTO coupling to 250 N•m (184 lbf•ft). Ap-
ply Loctite anti-seize on threads.
STATOR
Removal
Remove:
– PTO housing (refer to PTO HOUSING REMOV-
AL elsewhere in this section)
– holding plate no. 14 with CPS no. 15
R1503motr26A
1. Stator screws
2. Stator
Inspection
Check stator and CPS condition. If damaged re-
place the faulty part.
For electrical inspection, refer to CHARGING SYS-
TEM for the stator and to ENGINE MANAGE-
MENT for the CPS.
3
Installation
R1503motr21A 1 2 NOTE: There is only one position for the stator
1. CPS screws
(notch in the magneto housing cover).
2. Holding plate
3. CPS
– screws no. 16
– stator no. 17.
R1503motr51A 1
1. Notch for stator
04-06-6 LMR2004_011_04_06A.FM
Place the rubber grommets on both cables in the Inspection

proper notches at the PTO housing.
Check rotor, bent teeth and encoder wheel condi-
2 1 tion. If damaged, replace faulty part.
Installation
Encoder wheel position has to be located with the
location pin on the crankshaft gear.
IMPORTANT: If rotor has balancing holes, never
install it so that they are inside the large gap be-
tween encoder wheel teeth. This would create a
non-starting condition of the engine.
R1503motr52A
1. Grommet on CPS cable

2. Grommet on stator cable
Apply Loctite 243 on threads.Torque stator and 4

CPS screws to 10 N•m (89 lbf•in).
ROTOR AND ENCODER WHEEL

Removal
Lock crankshaft with locking tool (P/N 529 035
821). Refer to CRANKSHAFT LOCKING in ENGINE
BLOCK subsection.
F18D0AA 2 1 3
Remove:
WRONG INSTALLATION
– PTO housing 1. Rotor
– hexagonal screws no. 18 retaining rotor. 2. Balancing holes
3. Encoder wheel
4. Large gap
Withdraw rotor no. 19 with encoder wheel no. 20.
Apply Loctite 243 on threads.Torque rotor screws
to 24 N•m (18 lbf•ft).
3
RING GEAR
2 Removal
1
Lock crankshaft with locking tool (P/N 529 035
821). Refer to CRANKSHAFT LOCKING in ENGINE
BLOCK subsection.
Remove:
1 – PTO housing cover
– hexagonal screws no. 18.
R1503motr53A
1. Hexagonal screws
2. Rotor
3. Encoder wheel
LMR2004_011_04_06A.FM 04-06-7
Withdraw rotor no. 19, encoder wheel no. 20 and STARTER DRIVE ASS’Y
starter ring no. 21.
Removal
4
Remove:
3
– PTO housing and ring gear as described above
2 – starter drive ass’y no. 8.
R1503motr54A
1. Hexagonal screws
2. Rotor
3. Encoder wheel
4. Ring gear 1
Inspection
Check ring gear condition, especially teeth condi- R1503motr55A
tion. If damaged, replace faulty part. 1. Starter drive ass’y
CAUTION: Be careful not to lose the distance

Installation washer, disc springs no. 6 and washer no. 7 lo-
For installation, reverse the removal procedure. cated on the starter drive shaft.
Ring gear and encoder wheel position has to be
located with the location pin on the crankshaft
gear. 3
1
2
1
R1503motr58A
1. Disc springs
R1503motr54B 2. Washer
3. Starter drive gear
1. Location pin
2. Location pin holes
Inspection
Apply Loctite 243 on threads.Torque rotor screws Check condition of the teeth, shaft, etc. and if the
to 24 N•m (18 lbf•ft). sprag clutch operates well. If damaged, replace
faulty part.
04-06-8 LMR2004_011_04_06A.FM
Installation
Apply some Isoflex Topas NB52 grease (P/N 293
550 021) on the starter drive bearing located in the
engine block and on the starter drive support in the
PTO housing cover.
R1503motr56A
1. Starter drive bearing
R1503motr45A
1. Starter drive support
CAUTION: Be sure to remember the distance

washer, disc springs and washer on the starter
drive shaft when assembling.
LMR2004_011_04_06A.FM 04-06-9
Subsection 07 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
10 Nm
10 Nm (89 lbfin)
(89 lbfin) 1
2 Engine oil
Loctite 4
Multi-purpose
243 3 10 Nm grease
(89 lbfin)
28 Nm
(21 lbfft)
24 Nm
(18 lbfft)
Loctite
19 243
3 Nm (27 lbfin) 32
20 10 Nm
Left handed threads 25 (89 lbfin)
26
Engine oil
33
31
10 Nm (89 lbfin) 6
Loctite
Loctite 243 5 243
18
17 39 Loctite 5910
Engine oil
16
23
15 24
21
Loctite 243 22 10 Nm
12 Nm (89 lbfin)
18 Nm
(106 lbfin) (159 lbfin)
Engine Loctite
oil 243
R1503motr112S
LMR2004_012_04_07A.FM 04-07-1
Oil
18 Nm
(159 lbfin)
10 Nm
Loctite 243 Loctite 243 (89 lbfin)
18 Nm
(159 lbfin) 8
10 Nm
(89 lbfin)
10 Nm
Oil 7 (89 lbfin)
34 10 Nm Loctite 243
(89 lbfin) Loctite
243
Loctite 243
Oil
35 Loctite 243
Oil
Loctite 243 Horizontal
to exhaust side
14
Oil 13 9
27
38 28 29 5-25 Nm
37
Oil
36 30 Oil (44-221 lbfin)
40
10 Nm Loctite 243 18 Nm 10
(89 lbfin) (159 lbfin) Loctite 243 10 Nm
(89 lbfin)
42 12
10 Nm 10 Nm Loctite 243
(89 lbfin) (89 lbfin) 11
R1503motr113S
04-07-2 LMR2004_012_04_07A.FM
GENERAL 2. If out of water, raise trailer tongue and block in

position when bumper rail is level. Install a gar-
NOTE: This procedure to be performed for each en- den hose to the flushing connector. Refer to
gine. FLUSHING in MAINTENANCE and follow the
Prior to changing the oil, ensure vehicle is on a procedures.
level surface. CAUTION: Failure to flush exhaust cooling sys-
Oil and oil filter must be replaced at the same time. tems, when engines are out of water, may se-
Oil change and oil filter replacement should be verely damage engines and/or exhaust sys-
done with a warm engine. tems.
3. Warm-up engine then let idle for 30 seconds
 WARNING before stopping.
The engine oil can be very hot. Wait until en- 4. Stop engine.
gine oil is warm.
5. Wait at least 30 seconds then pull dipstick out
Dispose of oil and filter(s) as per your local envi- and wipe clean.
ronmental regulations.
 WARNING
OIL LEVEL VERIFICATION Engine oil may be hot. Certain components in
the engine compartment may be very hot. Di-
CAUTION: Check levels frequently and refill if rect contact may result in skin burn.
necessary. Do not overfill — it would make the
engines smoke and reduce power. Operating CAUTION: Never run engine(s) longer than 5
the engines with an improper oil level may se- minutes. Drive line seals have no cooling when
verely damage engines. Wipe off any spillage. sport boat is out of water.
6. Reinstall dipstick, push in completely.
1
7. Remove each dipstick and read oil level. Oil lev-
el reading should be between marks.
3
F18D05A 2 1
1. Full
2. Add
3. Operating range
8. Otherwise, add oil up to have the level between

marks as required.
NOTE: This procedure to be performed for each en-
gine.
F04G0NA
To add oil, unscrew oil cap. Place a funnel into the
1. Dipstick
opening and add the recommended oil to the prop-
Check the oil level as follows: er level. Do not overfill.
1. Sport boat must be level. Check oil level either
with sport boat in water or out of water. Engine ENGINE PRESSURE TEST
should be warm. NOTE: The engine pressure test should be done
CAUTION: Never run engine(s) without supply- with a warm engine and the recommended oil.
ing water to the exhaust cooling systems when Remove plug below oil filter housing.
LMR2004_012_04_07A.FM 04-07-3
Use oil pressure gauge (P/N 529 035 709) and CAUTION: Failure to flush exhaust cooling sys-
hose adaptor (P/N 529 035 652) and install where tems, when engines are out of water, may se-
shown. verely damage engines and/or exhaust sys-
Start engine and read pressure at different RPM tems.
as per following table.
 WARNING
Engine oil may be hot. Certain components in
the engine compartment may be very hot. Di-
rect contact may result in skin burn.
CAUTION: Never run engines longer than 5

minutes. Drive line seals have no cooling when
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.
Remove oil filler cap and dipstick.
Using the oil VAC (P/N529 035 880), siphon oil
through dipstick hole.
F18G03A 1 2 CAUTION: Never crank or start an engine when
siphon tube is in dipstick hole. Never start an
1. Oil filter housing engine when there is no oil in it.
2. Pressure test plug
NOTE: So that siphon tube is located at the proper
NOTE: Oil pressure switch works between 180 kPa height to siphon oil, it is suggested to put some
(26 PSI) and 220 kPa (32 PSI). electrical tape on siphon tube at 475 mm (18.7 in)
The engine oil pressure should be within the fol- from its end. Then, insert siphon tube until you
lowing values. reach the tape.
OIL PRESSURE TEST
ENGINE RPM PRESSURE kPa (PSI)
Idle (cold) 300 - 400 (44 - 58)
Idle (at 80°C (176°F)) min. 160 (23)
4000 - 7500 300 - 400 (44 - 58) 2
If the engine oil pressure is out of specifications,

check the points described in TROUBLESHOOT-
ING section.
Reinstall plug.
Oil Change
Engine in Vehicle 1
NOTE: If water is found in oil (oil will appear milky),

refer to submerged engine in MAINTENANCE sec-
tion and follow the procedure to flush it.
F13G01A
Bring engine to its normal operating temperature.
TYPICAL
CAUTION: Never run engines without supply- 1. Oil VAC
ing water to the exhaust cooling systems when 2. Siphon tube to dipstick hole
04-07-4 LMR2004_012_04_07A.FM
From engine compartment, have a second person

hold throttle bell crank in fully opened position.
F13G04A 1
1. Correct
F13G02A 1
Engine Removed
1. Fully-opened position
Each engine has two separate drain plugs. One is
Crank engine for 10 seconds. Siphon oil again. Re- located in the lower crankcase half and the other
peat the crank-siphon cycle 2-3 times. one in the PTO housing.
Once oil change is completed, ensure throttle ca-
ble is positioned correctly in the throttle bell crank.
R1503motr211A 1
1. Drain plugs
Place a drain pan under the engine drain plug area.

Clean the drain plug area.
Unscrew drain plugs no. 39 and no. 40 then re-
move dipstick.
F13G03A 1 CAUTION: Pay attention not to lose gasket
1. Incorrect rings on drain plug.
Wait a while to allow oil to flow out of oil filter.
Change gasket ring on drain plug if damaged.
Inspection
Oil condition gives information about the engine
condition. See TROUBLESHOOTING section.
Installation
Reinstall removed parts and fill in the new engine oil.
LMR2004_012_04_07A.FM 04-07-5
Oil Type and System Capacity

Refer to TECHNICAL DATA. For refilling proce-
dure, refer to OIL LEVEL VERIFICATION above.
OIL FILTER
Removal
Remove:
– engine oil (refer to OIL CHANGE)
– oil filter screw no. 1
– oil filter cover no. 2
– oil filter no. 3.
3 2 1 R1503motr115A 2 1
1. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system
Installation
The installation is the opposite of the removal pro-
cedure. Pay attention to the following details.
Install a new oil filter.
Install O-ring on oil filter cover.
R1503motr114A
1. Oil filter screw

2. Oil filter cover
3. Oil filter
Place rags in fillet area to prevent spillage. If spill-

age occurs, clean immediately with the pulley
flange cleaner (P/N 413 711 809) to prevent stains.
 WARNING
Wear safety glasses and work in a well venti- R1503motr116A

products. Also wear suitable non-absorbent Torque oil filter screw to 10 N•m (89 lbf•in).
gloves to protect your hands.
OIL STRAINERS
Inspection The oil strainers do not need to be cleaned at every
Check oil filter cover O-ring no. 4 and oil filter screw oil change. Clean them during other inspections,
O-ring, change if necessary. especially when the engine is disassembled.
Check and clean the oil filter inlet and outlet area
for dirt and other contaminations.
04-07-6 LMR2004_012_04_07A.FM
PTO - Oil Strainer

Removal
Remove:
– PTO cover no. 5
(refer to PTO COVER/MAGNETO section)
– oil strainer no. 6.
R1503motr118A 1
1. Oil inlet to the oil pump
Installation
Refill engine at the proper level with the recom-
mended oil. Refer to TECHNICAL DATA for capac-
ity and OIL LEVEL VERIFICATION above for pro-
R1503motr117A cedure.
1. Oil strainer
Suction Pump - Oil Strainer
Cleaning and Inspection Removal
Clean oil strainer with a part cleaner then use an – Remove blow-by ventilation hose no. 7.
air gun to dry it.
1
 WARNING
Always wear eye protection. Chemicals can
cause a rash to break out in and/or an injury
to your eyes.
Check and clean the oil outlet area for dirt and oth-
er contaminants.
R1503motr133A
1. Blow-by ventilation hose
– Disconnect wiring harness from blow-by valve

no. 8 and blow-by pressure switch no. 9.
– Detach air intake hose from the throttle body.
LMR2004_012_04_07A.FM 04-07-7
– Disconnect battery cables then remove battery. Inspect rubber rings no. 13 and no. 14.
Refer to BATTERY in CHARGING SYSTEM sec-
tion for proper procedures.
– Remove retaining screws no. 10 and no. 11. 1
– Place rags under cover to prevent spillage. If
spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent
stains.
 WARNING 2
products. Also wear suitable non-absorbent
gloves to protect your hands.
R1503motr121A
– Remove suction pump cover with oil separator.
1. O-ring
– Remove oil strainer no. 12. 2. Rubber ring gasket
If rubber rings are brittle, cracked or hard, replace

them.
Clean both contact surfaces of oil strainer cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.
R1503motr120A 1
1. Oil strainer
Cleaning and Inspection

1
Clean oil strainer with a part cleaner then use an R1503motr122A
air gun to dry it.
1. Oil inlet to the oil pump
 WARNING
Always wear eye protection. Chemicals can
cause a rash to break out in and/or an injury
to your eyes.
04-07-8 LMR2004_012_04_07A.FM
Installation
Position screw length as shown.
R1503motr123A
1. Oil pressure regulator
NOTE: The oil pressure regulator system opens

when the oil pressure exceeds 400 kPa (58 PSI).
R1503motr119A 1 2
Removal
1. Screws M6 x 25
Remove:
2. Screws M6 x 85 – engine oil (refer to OIL CHANGE)
Torque suction pump cover screws to 10 N•m – oil pressure regulator plug no. 15, compression
(89 lbf•in) as per sequence illustrated below. Ap- spring no. 16, valve piston no. 17 and valve pis-
ply Loctite 243 on threads. ton guide no. 18.
6  WARNING
Oil pressure regulator plug on oil pump hous-
ing is spring loaded.
1
2
3
R1503motr144A 4
ENGINE OIL PRESSURE

REGULATOR
The oil pressure regulator is located on the bottom
of the PTO housing.
R1503motr124A 4 3 2 1
1. Valve piston guide
2. Valve piston
3. Compression spring
4. Oil pressure regulator plug
LMR2004_012_04_07A.FM 04-07-9
Inspection 2
Inspect valve piston and valve piston guide for
scoring or other damages.
Check compression spring for free length.
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 60 mm (2.362 in)
SERVICE LIMIT 50.3 mm (1.980 in)
Replace parts if important wear or damage are

present.
Clean bore and threads in the PTO housing from
metal shavings and other contaminations.
R1503motr125A 1
Installation
1. Screws
For installation, reverse the removal procedure. 2. Oil pump cover
Pay attention to the following details. – outer oil pump rotor no. 23.
Be careful that the O-ring on plug screw is in place.
1
Torque plug screw to 12 N•m (106 lbf•in) maxi-
mum. Apply Loctite 243 on threads.
OIL PRESSURE PUMP

The oil pressure pump is located in the PTO hous-
ing and is driven by the balance shaft.
Removal
Remove:
– PTO housing
(refer to PTO HOUSING/MAGNETO section)
– Coolant pump housing no. 19 and impeller R1503motr126A
no. 20. (refer to COOLING SYSTEM section) 1. Outer oil pump rotor
– screws no. 21 – Extract the coolant/oil pump shaft no. 24 from
– oil pump cover no. 22 outside PTO housing with a pusher.
– Remove rotary seal no. 25 with a screwdriver.
04-07-10 LMR2004_012_04_07A.FM
R1503motr129A 1
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be-

R1503motr127A
tween inner and outer rotors.
CAUTION: Be careful not to damage the surface
of the rotary seal bore in PTO housing cover.
– Oil seal no. 26. B
1
A
R1503motr130A 2 1
R1503motr128A 1. Outer rotor
2. Inner rotor
1. Oil seal
OUTER AND INNER ROTOR CLEARANCE
Inspection mm (in)
Inspect oil pump shaft assembly, housing and cov- SERVICE LIMIT
er for marks or other damages. A
Check inner rotor for corrosion pin-holes or other B 0.25 mm (.009 in)
damages. If so, replace oil pump shaft assembly.
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 assembly. 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.
LMR2004_012_04_07A.FM 04-07-11
Using a vernier depth gauge, measure side wear Installation

as shown.
Pay attention to the following details.
NOTE: Never use oil in the press fit area of the
rotary seal.
Push coolant/oil pump shaft seal in place by using
thumb.
1
R1503motr131A 2 1
1. PTO housing surface
2. Vernier depth gauge
R1503motr128A
1. Oil seal
Install the new rotary seal by using the rotary seal

pusher (P/N 529 035 823).
CAUTION: Never use a hammer for the rotary
seal or coolant/oil pump shaft installation. Only
use a press to avoid damaging the ceramic
component.
R1503motr132A 2 1
1. Oil pump outer rotor surface
2. Vernier depth gage
Difference between pump housing and outer rotor

should not exceed 0.1 mm (.004 in). If so, replace
replace the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de-
creases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam-
aged.
R1503motr141A 2 1
1. Rotary seal
2. Rotary seal pusher
04-07-12 LMR2004_012_04_07A.FM
Install the coolant/oil pump shaft using the rotary OIL SUCTION PUMP
seal pusher (P/N 529 035 823) on the opposite
side to support the rotary seal. Use the oil seal The oil suction pump is located on the front side
guide (P/N 529 035 822) with a press. of the engine at the bottom of the oil separator.
Removal
– Remove blow-by ventilation hose no. 7.
R1503motr142A 2 1
1. Oil seal guide
2. Coolant/oil pump shaft
R1503motr133A
– Disconnect wiring harness from blow-by pres-

sure switch no. 9 and blow-by valve no. 8.
– Detach air silencer from throttle body.
– Disconnect battery cables and vent tube then
remove battery. Refer to BATTERY in CHARG-
ING SYSTEM section for proper procedures.
– Remove retaining screws no. 42.
R1503motr143A 2
– Place rags under cover to prevent spillage. If
1. Coolant/oil pump shaft with oil seal guide
2. Rotary seal pusher spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent
Tighten oil pump cover screws and torque to 10 N•m stains.
(89 lbf•in). Apply Loctite 243 on threads.
Final Test  WARNING

After engine is completely reassembled, start en- lated area when working with strong chemical
gine and make sure oil pressure is within specifi- products. Also wear suitable non-absorbent
cations. gloves to protect your hands.
– Remove oil suction pump housing with oil sep-

arator.
LMR2004_012_04_07A.FM 04-07-13
– Remove oil pump screws no. 27 and cover

no. 28. 1
R1503motr137A
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be-

tween inner and outer rotors.
R1503motr135A 1
1. Oil pump cover
– Remove oil pump shaft ass’y no. 29. A

– Remove outer rotor no. 30. B
C
R1503motr138A 2 1
1. Outer rotor
2. Inner rotor
OUTER AND INNER ROTOR CLEARANCE

mm (in)
R1503motr136A 1 2
SERVICE LIMIT
1. Oil pump shaft ass’y
2. Outer rotor A
B 0.25 mm (.009 in)
Inspection C
Inspect oil pump shaft assembly, housing and cov-
er for marks or other damages. If clearance between inner and outer rotors ex-
ceeds the tolerance, replace oil pump shaft as-
Check inner rotor for corrosion, pin-holes or other
sembly. Ensure to also check oil pump housing
damages. If so, replace oil pump shaft assembly.
and cover and replace if damaged.
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.
04-07-14 LMR2004_012_04_07A.FM
Using a vernier depth gauge, measure side wear Installation

as shown.
1
R1503motr139A 1 2
1. Oil pump housing surface
2. Vernier depth gauge
R1503motr134A 2 2
1. Screws M6 x 85
2. Screws M6 x 25
Torque oil pump cover screws to 10 N•m (89 lbf•in).

Tighten suction pump screws as per following se-
quence and torque to 10 N•m (89 lbf•in). Apply
Loctite 243 (blue) on threads.
1
R1503motr140A 1 2
1. Oil pump outer rotor surface
2. Vernier depth gauge 7
Difference between pump housing and outer rotor 3

should not exceed 0.1 mm (.004 in). If so, replace 6
the complete oil pump assembly. 4
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de- R1503motr145A 2 5
creases.
Check the inside of oil pump housing and its cover OIL FILTER BYPASS
for scoring or other damages and replace if dam-
aged. The oil filter bypass valve is located in the PTO
housing below the oil filter.
LMR2004_012_04_07A.FM 04-07-15
Removal OIL COOLER

Remove the PTO housing. Refer to PTO HOUSING/ The oil cooler is located below the air intake man-
MAGNETO section. ifold.
Remove plug screw no. 31 and pull out the oil fil-
ter bypass valve ball no. 32 and spring no. 33.
3 2 1
R1503motr110A
1
1. Oil cooler
R1503motr146A Removal
1. Plug screw Remove:
2. Compression spring
3. Ball – cooling hoses no. 34 and no. 35
– retaining screws no. 36
Inspection
– oil cooler no. 37
Inspect ball for scoring or other damages.
Check compression spring for free length. 2 1
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 21.5 mm (0.846 in)
SERVICE LIMIT 21 mm (0.826 in)
Replace parts if important wear or damage are

present.
Clean bore and threads in the PTO housing from
metal shavings and other contaminations.
Installation R1503motr147A 1
For installation, reverse the removal procedure. 1. Screws
2. Oil cooler
Torque plug screw to 28 N•m (21 lbf•ft). Apply
Loctite 243 (blue) on threads.
04-07-16 LMR2004_012_04_07A.FM
– O-rings no. 38.

1
R1503motr148A 1
1. O-rings
R1503motr133A
Inspection 1. Blow-by ventilation hose

If O-rings are brittle, cracked or hard, replace
– Disconnect wiring harness from blow-by valve
them.
no. 8 and blow-by pressure switch no. 9.
Clean both contact surfaces of oil cooler.
– Detach air intake hose from the throttle body.
Check and clean the oil inlet and outlet area for dirt
– Disconnect battery cables and vent tube then
and other contaminations.
remove battery. Refer to BATTERY in CHARG-
ING SYSTEM section for proper procedures.
Installation
– Remove retaining screws no. 42.
Pay attention to the following details. – Place rags under cover to prevent spillage. If
spillage occurs, clean immediately with the pul-
Apply grease on O-rings. ley flange cleaner (P/N 413 711 809) to prevent
Torque oil pump cover screws to 10 N•m (89 lbf•in). stains.
Apply Loctite 243 (blue) on threads.
 WARNING
OIL SEPARATOR Wear safety glasses and work in a well venti-
Pressure Test products. Also wear suitable non-absorbent
Refer to ENGINE MANAGEMENT section. gloves to protect your hands.
Removal – Remove suction pump cover with oil separator

ass’y.
– Remove blow-by ventilation hose no. 7.
– Remove blow-by valve no. 8 from oil separator.
Refer to BLOW-BY VALVE in ENGINE MAN-
AGEMENT section.
– Completely disassemble oil separator ass’y.
LMR2004_012_04_07A.FM 04-07-17
Inspection
If O-rings and rubber rings are brittle, cracked or
hard, replace them.
Clean all contact surfaces of oil separator.
Check and clean the oil and blow-by channels for
dirt and other contaminations.
Installation
R1503motr119A 1 2
1. Screws M6 x 25
2. Screws M6 x 85
Apply grease on O-rings and rubber rings.

Torque screws to 10 N•m (89 lbf•in). Apply Loc-
tite 243 (blue) on threads.
04-07-18 LMR2004_012_04_07A.FM
Subsection 08 (CYLINDER HEAD AND VALVES)
CYLINDER HEAD AND VALVES 0

NOTE: For cylinder head removal, it is not necessary to remove engine from vehicle.
10 Nm
1 (89 lbfin)
Engine oil
10 5
Grease Klueber 6
Isoflex Topas NB52
11
9
10
Engine 7 20 Nm (177 lbfin) + 90°
Loctite oil 8
243 18 Nm
6 Nm 24 (159 lbfin)
(53 lbfin) 10 Nm
12 25 10 Nm (89 lbfin)
14 22 (89 lbfin)
23 2 Loctite
243
13 21 28
29 16
10 Nm 15 30 10 Nm Loctite
(89 lbfin) (89 lbfin) 243
20 Engine
oil
Loctite 40 Nm (30 lbfft)

243 + 120° + 90°
17
6 Nm
(53 lbfin)
18 Nm
(159 lbfin) 18
Engine oil
Engine oil
19
26
Loctite 243
27
10 Nm (89 lbfin)
R1503motr43S
LMR2004-013_04_08A.FM 04-08-1
GENERAL Clean spark plug and single-spark ignition coil area

before disassembly.
Unscrew spark plug no. 2 then use the single-spark
engine.
ignition coil to take spark plug out of spark plug hole.
NOTE: When diagnosing an engine problem, al-
ways perform a cylinder leak test. This will help 1
pin-point a problem. Refer to the instructions in-
cluded with your leak tester and LEAK TEST sec- 2
tion for procedures.
Always place the vehicle on level surface.
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
To perform the following instructions, it is not nec-
essary to remove engine from vehicle.
Always disconnect the negative wire from the bat-
tery before working on the engine.
Even if the removal of many parts is not necessary R1503motr44A
to reach another part, it is recommended to remove
1. Single-spark ignition coil
these parts in order to check them. 2. Spark plug
For installation, use the torque values and Loctite
products as mentioned. Clean threads before us- Inspection
ing Loctite product when installing screws. Check spark plug and single-spark ignition coil con-
When disassembling parts that are duplicated in dition (refer to ENGINE MANAGEMENT SYSTEM).
the engine, (e.g.: valves, bushings), it is strongly
recommended to note their position (cylinder 1, 2 Installation
or 3) and to keep them as a “group”. If you find a For installation, reverse the removal procedure.
defective component, it would be much easier to Pay attention to the following details.
find the cause of the failure among its group of
parts (e.g.: you found a worn valve guide. A bent Check spark plug gap.
spring could be the cause and it will be easy to Place spark plug into single-spark ignition coil,
know which one among the springs is the cause screw spark plug then remove the single-spark ig-
to replace it if you grouped them at disassembly). nition coil. Torque spark plug. Reinstall the single-
Besides, since used parts have matched together spark ignition coil.
during the engine operation, they will keep their NOTE: Prior to inserting the ignition coil to its lo-
matched fit when you reassemble them together cation, apply some BOMBARDIER LUBE lubricant
within their “group”. around the seal area that touches the spark plug
hole. After installation, ensure the seal seats prop-
SPARK PLUG erly with the engine top surface.
Removal
Remove fuel rail cover from engine.
Unplug the single-spark ignition coil connector on
the spark plug you need to remove.
Remove the single-spark ignition coil no. 1.
04-08-2 LMR2004-013_04_08A.FM
VALVE COVER Installation

Removal
NOTE: Install the valve cover screws according to
Remove: following sequence.
– valve cover shield no. 3
3 1 5
– valve cover screws no. 4
7
1
R1503motr159A 8 2 4 6
R1503motr81A
1. Valve cover screws Torque screws to 10 N•m (89 lbf•in).

– valve cover no. 5 and profile sealing ring no. 6.
ROCKER ARM
2 Removal
Lock crankshaft with crankshaft locking tool
(P/N 529 035 821), refer to CRANKSHAFT LOCK-
ING in ENGINE BLOCK section.
Remove:
– spark plug
– valve cover
1 – spark plug tube no. 7
R1503motr82A
1. Valve cover 1
2. Profile sealing ring
Inspection
Check the profile sealing ring on the valve cover
and the rubber bushing on the valve cover screws
if they are brittle, cracked or hard. If so, replace the
profile sealing ring or the valve cover screw ac-
cordingly.
R1503motr83A
1. Spark plug tube
LMR2004-013_04_08A.FM 04-08-3
– rocker arm shaft screws no. 8. Discard screws. Inspection

Spark Plug Tube
1
Check seals on spark plug tube. If seals are brittle,
cracked or hard, replace spark plug tube.
R1503motr93B 2 1 3
R1503motr86A
1. Rocker arm shaft screws

1. Spark plug tube
2. Seal to the valve cover
– rocker arm shaft no. 9 with rocker arm assem- 3. Seal to the cylinder head
bly (exhaust side no. 10 and intake side no. 11).
Rocker Arm
1 Inspect each rocker arm for cracks and scored fric-
tion surfaces. If so, replace rocker arm assembly.
3 Check the rocker arm rollers for free movement,
wear and excessive radial play. Replace rocker
arm assembly as necessary.
R1503motr84A 2
1. Rocker arm shaft
2. Rocker arms (exhaust side)
3. Rocker arm (intake side)
1
A
1 2
R1503motr87A
1. Rocker arm (intake side)

2. Roller
A. Bore for rocker arm shaft
R1503motr85A
1. Oil supply from the camshaft to the rocker arm shaft, then to the
rocker arms and finally to the valve adjustment
04-08-4 LMR2004-013_04_08A.FM
Rocker Arm Shaft

Check for scored friction surfaces, if so, replace
parts.
Measure rocker arm shaft diameter.
ROCKER ARM SHAFT DIAMETER

NEW MINIMUM 19.980 mm (.7866 in)
NEW MAXIMUM 20.007 mm (.7877 in)
A
SERVICE LIMIT 19.965 mm (.7860 in)
1
R1503motr88A 2
1. Rocker arm (exhaust side)
2. Roller
A. Bore for rocker arm shaft
Measure rocker arm bore diameter. If diameter is

out of specification, change the rocker arm assem-
bly. R1503motr90A A
ROCKER ARM BORE DIAMETER A. Measure rocker arm shaft diameter here
NEW MINIMUM 20.007 mm (.7877 in) Any area worn excessively will require parts re-
placement.
SERVICE LIMIT 20.035 mm (.7887 in) Installation
Press the hydraulic lifter with your thumb. If the For installation, reverse the removal procedure.
hydraulic lifter groove disappears inside rocker Pay attention to the following details.
arm casting, replace rocker arm assembly. Lifter Apply engine oil on rocker arm shaft.
must turn freely in rocker arm bore. Otherwise, IMPORTANT: The rocker arm shaft can only be
replace. installed in one specific position. Therefore crank-
shaft as well as camshaft has to be positioned
with their locking pins when the piston of cylinder
no. 3 is on ignition TDC. Refer to CRANKSHAFT
LOCKING in ENGINE BLOCK section for crank-
shaft and the following for the camshaft locking.
R1503motr89A
1. Hydraulic lifter groove
LMR2004-013_04_08A.FM 04-08-5
Use camshaft locking tool (P/N 529 035 839). Ro-

1
tate camshaft so that tool can be pushed in cam- 2
shaft hole and lock camshaft in place.
R1503motr91A
1. Rocker arm shaft

R1503motr111A
2. Rocker arm shaft notches
1. Camshaft locking tool
Install NEW rocker arm shaft screws no. 8. Torque
Then, the camshaft sprocket lines should be lined as per following procedure:
up as shown in the following illustration. CAUTION: This assembly uses stretch screws. As
the screws have been stretched from the previous
1 1
installation, it is very important to use new screws
at assembly. Failure to replace screws and to
strictly follow the torque procedure may cause
screws to loosen and lead to engine damage.
– Torque screws at first to 10 N•m (89 lbf•in) ac-
cording to following sequence.
1 3 4
5 2
6
R1503motr95A
1. Position lines
Position the rocker arm shaft with the notches on

top.
R1503motr93A
– Torque screws to 20 N•m (177 lbf•in).

– Finish tightening screws turning an additional
90° rotation with a torque angle gauge.
04-08-6 LMR2004-013_04_08A.FM
2
Installation
1 Pay attention to the following details.
Using the camshaft locking tool (P/N 529 035 839),
lock camshaft on TDC position.
R1503motr92A
1. Rocker arm shaft screw

2. Torque angle gauge 2
CAMSHAFT TIMING GEAR

R1503motr94A
NOTE: Although it is not necessary to position
crankshaft to TDC for disassembly, it is a good prac- 1. Camshaft locking tool
tice to do it, as a troubleshooting step, to know be- 2. Camshaft on TDC position
fore disassembly if valve timing was appropriate. Install the camshaft timing gear with the writing
visible, i.e. to be able to see the position lines
Removal when looking from outside of engine.
Lock crankshaft with crankshaft locking tool (P/N 529
035 821), refer to CRANKSHAFT LOCKING in EN- 1
GINE BLOCK section.
Remove:
– valve cover
– chain tensioner. Refer to CHAIN TENSIONER
REMOVAL in ENGINE BLOCK section
– chain guide no. 12
– Allen screws no. 13
– camshaft timing gear no. 14. 2
NOTE: Secure timing chain no. 15 with a retaining

wire.
Inspection
Check camshaft timing gear for wear or deteriora-
tion.
If gear is worn or damaged, replace it as a set R1503motr97A
(camshaft timing gear and timing chain).
1. Good (with 1503 aligned)
For crankshaft timing gear, refer to ENGINE BLOCK 2. Never
section. Install timing chain. Refer to ENGINE BLOCK sec-
tion.
LMR2004-013_04_08A.FM 04-08-7
Ensure chain guides are in place. Remove:

Loosely install screws. – exhaust manifold (refer to EXHAUST MANIFOLD
Install chain tensioner. REMOVAL elsewhere in this section)
Tighten screws and torque to 10 N•m (89 lbf•in). – engine coolant outlet hose
Remove locking tools. 2
CAUTION: Crankshaft and camshaft must be
locked on TDC position to place camshaft tim-
ing gear and timing chain in the proper posi-
1
tion. To double check, take a look at the timing
gear lines. They must be parallel to the cylinder
head surface.
1 1
R1503motr253A
TYPICAL
1. Coolant hose
– coolant hose
– chain tensioner (refer to CHAIN TENSIONER RE-
R1503motr95A MOVAL in ENGINE BLOCK section)
1. Position lines – valve cover shield
CAUTION: Ensure to remove locking tools when – valve cover and profile sealing ring
finished. (see VALVE COVER REMOVAL above)
– camshaft timing gear
TIMING CHAIN – cylinder head screws M6 no. 16
Refer to ENGINE BLOCK section.
CYLINDER HEAD
Removal 1
Lock crankshaft with crankshaft locking tool
(P/N 529 035 821), refer to CRANKSHAFT LOCK-
ING in ENGINE BLOCK section.
Drain coolant (refer to COOLING SYSTEM).
Disconnect coolant temperature and cam position
sensors (CTS and CAPS).
R1503motr98A
1. Cylinder head screws M6
04-08-8 LMR2004-013_04_08A.FM
– cylinder head screws M11 no. 17 retaining cyl- Install cylinder head screws M11 no. 17. Torque
inder head to engine block. screws as per following procedure.
CAUTION: This assembly uses stretch screws.
As the screws have been stretched from the pre-
1 vious installation, it is very important to measure
each screw at assembly. If screw is out of speci-
fication, replace. Failure to replace screws and to
strictly follow the torque procedure may cause
screws to loosen and lead to engine damage.
CYLINDER HEAD SCREW M11

Torque screws according to following sequence.

R1503motr99A First torque to 40 N•m (30 lbf•ft).
1. Cylinder head screws M11 Then tighten screws turning an additional 120° ro-
tation with a torque angle gauge and finish tight-
Pull up cylinder head no. 18. ening with a 90° rotation. Torque screws no. 16 to
Remove gasket no. 19. 10 N•m (89 lbf•in).
Cleaning 1
Remove carbon deposits from combustion cham- 2
ber, exhaust port and piston top.
Inspection
Check for cracks between valve seats, if so, re-
place cylinder head.
Check mating surface between cylinder and cylin-
der head for contamination. If so, clean both sur-
faces.
Installation
R1503motr100A
1. Cylinder head screws M11
Ensure dowel pins are in place. 2. Angle torque wrench
Install new cylinder head gasket. Remove crankshaft locking tool then install plug
CAUTION: Each installation of the cylinder head with sealing ring.
requires a new cylinder head gasket. Using a
gasket twice will cause engine damage, even if
the engine had not run.
LMR2004-013_04_08A.FM 04-08-9
CAMSHAFT CAMSHAFT LOBE - EXHAUST VALVE

NEW MINIMUM 31.699 mm (1.248 in)
Removal
NEW MAXIMUM 31.809 mm (1.252 in)
Remove:
– valve cover
CAMSHAFT LOBE - INTAKE VALVE
– rocker arms
– chain tensioner (refer to CHAIN TENSIONER NEW MINIMUM 31.480 mm (1.239 in)
REMOVAL in ENGINE BLOCK section) NEW MAXIMUM 31.590 mm (1.244 in)
– camshaft timing gear SERVICE LIMIT 31.450 mm (1.238 in)
– camshaft lock no. 20 CAMSHAFT BEARING JOURNAL
– camshaft no. 21. NEW MINIMUM 39.892 mm (1.5705 in)
1
2 CAMSHAFT BEARING JOURNAL -
ENGINE FRONT
CAMSHAFT BORE
MEASURED IN DIAMETER
R1503motr101A NEW MAXIMUM 40.016 mm (1.5754 in)
1. Camshaft lock SERVICE LIMIT 40.050 mm (1.5767 in)
2. Camshaft
CAMSHAFT BORE - ENGINE FRONT
Inspection MEASURED IN DIAMETER
Check each lobe and bearing journal of camshaft NEW MINIMUM 25.000 mm (.9842 in)
for scoring, scuffing, cracks or other signs of wear. NEW MAXIMUM 25.013 mm (.9848 in)
Measure camshaft bearing journal diameter and SERVICE LIMIT 25.050 mm (.9862 in)
lobe height using a micrometer.
Replace parts that are not within specifications.
Measure clearance between both ends of cam-
shaft and cylinder head.
Installation
D A B A C C A B A C C A B A C
Grease the camshaft bearing journals well by us-
ing the grease Klueber Isoflex (P/N 293 550 021)
or a similar product.
R1503motr102A
A. Camshaft lobe (exhaust valves)

B. Camshaft lobe (intake valves)
C. Camshaft bearing journal
D. Camshaft bearing journal — engine front
04-08-10 LMR2004-013_04_08A.FM
Install camshaft then place the camshaft lock no. 20

in the slot.
2
1
1
R1503motr101B
1. Camshaft lock position
For other parts, refer to proper installation proce- R1503motr103A
dure. 1. Valve spring compressor clamp

2. Valve spring compressor cup
VALVE SPRING
Removal
Remove:
– rocker arms
– cylinder head.
Compress valve springs no. 22 and no. 23. Use
valve spring compressor clamp (P/N 529 035 724)
and valve spring compressor cup (P/N 529 035
725).
 WARNING
Always wear safety glasses when disassem-
bling valve springs. Be careful when unlock- R1503motr104A
ing valves. Components could fly away be-

LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF
cause of the strong spring preload. THE VALVE
LMR2004-013_04_08A.FM 04-08-11
Remove valve cotters no. 24. Installation

Withdraw valve spring compressor, valve spring For installation, reverse the removal procedure.
retainer no. 25 and valve springs. Pay attention to the following details.
1 Colored area of the valve spring must be placed
2 on top.
3 NOTE: Valve cotters must be properly engaged in
valve stem grooves.
R1503motr105A
1. Valve spring retainer

2. Inner valve spring
3. Outer valve spring
Inspection R1503motr105B
Check valve springs for rust, corrosion or other vis- 1. Position of the valve spring
ible damages. If so, replace faulty valve springs.
Check valve springs for free length and straight- VALVE
ness.
Replace valve springs if not within specifications. Removal
Remove valve spring.
Push valve stem then pull valves no. 26 and
no. 27 out of valve guides.
A 2
R610motr122A
A. Valve spring length
OUTER VALVE SPRING FREE LENGTH

R1503motr106A
SERVICE LIMIT 43 mm (1.693 in)

1. Intake valve 38 mm
INNER VALVE SPRING FREE LENGTH 2. Exhaust valve 31 mm

04-08-12 LMR2004-013_04_08A.FM
Remove valve stem seal no. 28 with special pliers

such as Snap-On YA 8230.
R610motr126A
A. Valve stem diameter
VALVE STEM DIAMETER mm (in)

R610motr125A
NEW MINIMUM
Exhaust 5.946 mm (.2341 in)
Inspection Intake 5.961 mm (.2347 in)
Valve Stem Seal NEW MAXIMUM
Inspection of valve stem seals is not needed be- Exhaust 5.960 mm (.2346 in)
cause new seals should always be installed when-
ever cylinder head is removed. Intake 5.975 mm (.2352 in)
Valve SERVICE LIMIT
Inspect valve surface, check for abnormal stem Exhaust

5.93 mm (.233 in)
wear and bending. If so, replace by a new one. Intake
Valve Stem and Valve Guide Clearance Replace valve guide if it is out of specification or
Measure valve stem and valve guide in three plac- has other damages such as wear or friction sur-
es, using a micrometer and a small bore gauge. face.
NOTE: Clean valve guide to remove carbon de-
posits before measuring. VALVE GUIDE DIAMETER mm (in)
Change valve if valve stem is out of specification NEW MINIMUM

or has other damages such as wear or friction sur- Exhaust
face. 5.994 mm (.2359 in)
Intake
NEW MAXIMUM
Exhaust
6.018 mm (.2369 in)
Intake
SERVICE LIMIT
Exhaust
6.060 mm (.2386 in)
Intake
LMR2004-013_04_08A.FM 04-08-13
Valve Face and Seat If valve seat contact width is too wide or has dark
spots, replace the cylinder head.
2 3
A B
R1503motr107A 1 V01C1HA
1. Valve seat A. Valve face contact width

2. Exhaust valve contaminated area B. Valve seat contact width
3. Valve face (contact surface to valve seat)
Check valve face and seat for burning or pittings Installation

and replace valve or cylinder head if there are For installation, reverse the removal procedure.
signs of damage. Pay attention to the following details.
Ensure to seat valves properly. Apply some lap- Install thrust washer no. 30, valve spring guide
ping compound to valve face and work valve on its no. 29 then valve stem seal no. 28.
seat with a lapping tool.
Measure valve face contact width. 3
NOTE: The location of contact area should be in

center of valve seat.
Measure valve seat width, using a caliper.
VALVE SEAT CONTACT WIDTH mm (in)

NEW
1.25 to 1.55 mm
Exhaust
(.049 to .061 in)
1.10 to 1.30 mm
Intake
(.043 to .051 in)
SERVICE LIMIT
R1503motr108A 2 1
Exhaust 2 mm (.078 in)
1. Thrust washer
Intake 1.8 mm (.07 in) 2. Valve spring guide
3. Valve stem seal
04-08-14 LMR2004-013_04_08A.FM
Apply engine oil on valve stem and install it.

CAUTION: Be careful when valve stem is passed
through sealing lips of valve stem seal.
R1503motr108B
1. Sealing lips of valve stem seal
To ease installation of cotters, apply oil or grease

to them so that they remain in place while releas-
ing the spring.
After spring is installed, ensure it is properly
locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times.
CAUTION: An improperly locked valve spring
will cause engine damage.
LMR2004-013_04_08A.FM 04-08-15
Subsection 09 (ENGINE BLOCK)
ENGINE BLOCK 0
Grease Klueber Isoflex Topas NB52 Grease

Loctite 243 Engine
oil
10 Nm
24 Nm 21 (89 lbfin)
(18 lbfft)
22 Loctite 243
Engine
oil 20
Loctite 243 19
18 Nm
(159 lbfin)
18
Engine
10 Nm oil
24 Nm (89 lbfin)
(18 lbfft)
Engine
oil Loctite 243
16
Loctite 243
18 Nm 24 Nm
17 (159 lbfin)
(18 lbfft)
Loctite 243
24 Nm
(18 lbfft)
Engine
oil Loctite 243
3 18 Nm
(159 lbfin)
2
7 24 Nm
(18 lbfft)
10 Nm 1 40 Nm 55 Nm
(89 lbfin) (30 lbfft) + (41 lbfft)
Loctite 243 24 Nm
(18 lbfft)
R1503motr01S
LMR2004_014_04_09A.FM 04-09-1
9 Engine
8
oil 10
Engine Engine
oil oil
Engine
oil
Engine 23
260 Nm oil
(191 lbfft) Engine
4 oil
Loctite
Engine anti-seize 4 12
oil
Engine
oil
Engine
oil 45 Nm
11 (33 lbfft) + 90°
6
13
Engine
oil
6
Engine 5
oil
Engine
15 oil
14
Engine Engine
Engine oil
oil oil
15
R1503motr02S
04-09-2 LMR2004_014_04_09A.FM
GENERAL 1
engine.
When disassembling parts that are duplicated in the
engine, (e.g.: pistons, connecting rods etc.), it is
strongly recommended to note their position (Cylin-
der 1, 2 or 3) and to keep them as a “group”. If you
find a defective component, it would be much eas-
ier to find the cause of the failure among its group
of parts (e.g.: you found a worn valve guide. A bent
spring could be the cause and it will be easy to know
which one among the springs is the cause in order
to replace it if you grouped them at disassembly).
Besides, since used parts have matched together
R1503motr03A
during engine operation, they will keep their
matched fit when you reassemble them together 1. Screwdriver
within their “group”. In this position, the crankshaft can be locked by
using crankshaft locking tool (P/N 529 035 821).
CRANKSHAFT LOCKING When finished, reinstall all removed parts.
Remove:
– air intake manifold (refer to AIR INTAKE MANI- CRANKSHAFT
FOLD REMOVAL in ENGINE section)
– fuel rail cover
Removal
Remove:
– spark plugs
– screw plug. – engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
2 1 – engine from vehicle
(refer to REMOVAL AND INSTALLATION)
– cylinder head (refer to CYLINDER HEAD RE-
MOVAL in CYLINDER HEAD section)
AL in PTO HOUSING/MAGNETO section)
– starter gear (refer to STARTER GEAR REMOV-
– starter drive ass’y
– oil suction pump with oil separator ass’y
(refer to SUCTION PUMP REMOVAL in LUBRI-
CATION section)
– engine mounting brackets
R1503motr04A
1. Screw plug
2. Gasket ring
Put a screwdriver or similar device into the spark

plug hole of cylinder # 3 and feel when the piston
reaches TDC.
LMR2004_014_04_09A.FM 04-09-3
– oil tank screw plugs no. 1 with O-ring no. 2 NOTE: Before removing the connecting rod bear-
ing caps, mark them to remember the right posi-
1 tion when reassembling.
R1503motr05A
ENGINE UPSIDE DOWN

1. Oil tank screw plug with O-ring
– engine block screws no. 3 and no. 7

R1503motr07A 1
1. Mark on connecting rod
– thrust washers no. 4
1
R1503motr06A
BOTTOM VIEW OF ENGINE

1. Screws
– bottom engine block half

– connecting rod screws R1503motr09A
1 1. Thrust washer
R1503motr08A
1. Connecting rod screws
04-09-4 LMR2004_014_04_09A.FM
– crankshaft no. 5.
1 2
1
R1503motr12A
R1503motr10A
1. Crankshaft
1. Crankshaft 2. Feeler gauge
Inspection CONNECTING ROD BIG END

Replace crankshaft if the gears are worn or other- mm (in)
wise damaged. NEW MINIMUM 0.150 mm (.006 in)
2 NEW MAXIMUM 0.302 mm (.012 in)
Crankshaft Radial Play

Measure all crankshaft journals. Compare to inside
diameter of crankshaft bushings (elsewhere in this
section).
1
R1503motr11A
1. Balancer gear
2. Crankshaft timing gear
Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between 2
butting face of connecting rod and crankshaft coun-
terweight. If the distance exceeds specified toler-
ance, replace the worn part.
R1503motr13A
1. Micrometer
2. Crankshaft area for bushing
LMR2004_014_04_09A.FM 04-09-5
CRANKSHAFT JOURNAL DIAMETER Installation

mm (in) For installation, reverse the removal procedure.
NEW MINIMUM 49.91 mm (1.9650 in) Pay attention to following details.
NOTE: Before installing the crankshaft, make
sure that the timing chain is on the crankshaft and
SERVICE LIMIT 49.88 mm (1.9637 in) the chain tension guide has been installed first.
Those parts cannot be installed as soon as the
CRANKSHAFT JOURNAL RADIAL CLEARANCE crankshaft is in place.
mm (in) CAUTION: Crankshaft must be aligned with bal-
SERVICE LIMIT 0.07 mm (.0028 in) ance shaft. Align grooves on crankshaft and bal-
ance shaft.
Crankshaft Pin
Measure all crankshaft pin diameters. Compare to
inside diameter of connecting rod bushings (else-
where in this section).
1 2
R1503motr17A 1 2
1. Groove on balance shaft
2. Groove on crankshaft
For correct installation of the connecting rods refer

R1503motr14A
to CONNECTING ROD INSTALLATION elsewhere
in this section.
1. Micrometer
2. Crankshaft pin area for bushing CAUTION: It is absolutely necessary to follow
this procedure. Otherwise severe engine dam-
CRANKSHAFT PIN DIAMETER age can occur.
mm (in)
CAUTION: Never forget thrust washers no. 4 for
NEW MINIMUM 45.032 mm (1.7729 in) axial adjustment on crankshaft center.
CRANKSHAFT PIN RADIAL CLEARANCE

mm (in)
04-09-6 LMR2004_014_04_09A.FM
Insert thrust washers as soon as crankshaft is in Install the crankshaft cover before mounting the
place according to following illustration. engine bracket. Put some oil on O-ring and press
the cover in. The crankshaft cover has to be even
with the engine block surface.
1
R1503motr09A
THRUST WASHER INSERT DIRECTION

1. Thrust washer
CAUTION: Thrust washers must be even with the R1503motr19A 2

engine block sealing surface.
1. O-ring
1 2. Crankshaft cover
CAUTION: Install crankshaft locking tool (P/N 529

035 821) right away to put crankshaft in TDC po-
sition before installing the camshaft and rockers
2
(refer to CYLINDER AND HEAD).
1
R1503motr16A
1. Thrust washer
2. Sealing surface
Install lower engine block half. Refer to ENGINE

BLOCK ASSEMBLY elsewhere in this section for
proper procedure to clean surfaces, apply Loctite
5910 and proper torquing sequence. R1503motr18A
1. Crankshaft locking tool
LMR2004_014_04_09A.FM 04-09-7
TIMING CHAIN CHAIN TENSIONER

Inspection Removal
Check timing chain on camshaft timing gear for NOTE: Removal of the air intake manifold allows
excessive radial play. easier access to the chain tensioner, but is not
Check chain condition for wear and rollers condi- necessary. Refer to AIR INTAKE MANIFOLD RE-
tion. MOVAL in INTAKE section.
Remove:
– chain tensioner screw plug no. 18 with gasket
ring no. 19
– chain tensioner no. 20.
3 2
R610motr201A 1
1. Timing chain
If chain is excessively worn or damaged, replace

it as a set (camshaft timing gear and timing chain).
Removal
Remove:
– engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
– engine from vehicle
– cylinder head (refer to CYLINDER HEAD RE- R1503motr39A 1
1. Screw plug
– PTO housing (refer to PTO HOUSING REMOV- 2. Gasket ring
3. Chain tensioner
– crankshaft (refer to CRANKSHAFT REMOVAL Inspection
elsewhere in this section) Check chain tensioner for excessive wear or cracks.
– timing chain. Also check free movement of the chain tensioner
piston.
Installation
The installation is essentially the reverse of the re- Installation
moval procedure but, pay attention to the follow- The installation is essentially the reverse of the re-
ing details. moval procedure but, pay attention to the follow-
Ensure to perform proper valve timing. Lock cranking details.
shaft and camshaft at TDC (refer to CYLINDER Torque chain tensioner screw plug to 18 N•m
HEAD). (159 lbf•in).
Install chain, then install chain tensioner.
CAUTION: Improper valve timing will damage BALANCER SHAFT
engine components.
Removal
Remove:
– engine oil (refer to OIL CHANGE in LUBRICA-
TION section)
04-09-8 LMR2004_014_04_09A.FM

1
– cylinder head (refer to CYLINDER HEAD RE-
– starter gear (refer to STARTER GEAR REMOV-
CATION section)
– engine mounting brackets
– oil tank screw plugs no. 1 with O-ring no. 2 R1503motr20A
1. Thrust washer
1
– balance shaft.
Inspection
Check balancer shaft and replace if damaged.
If the gear on the balancer shaft is damaged, re-
place balancer shaft.
Check gear(s) on the crankshaft at the same time
and replace crankshaft if necessary (refer to CRANK-
R1503motr05A
SHAFT above).
ENGINE UPSIDE DOWN
Balance Shaft Bushing Seat Play
1. Oil tank screw plug with O-ring
Measure all balance shaft bushing seats. Compare
– engine block screws no. 3 to inside diameter of balance shaft bushings (else-
where in this section).
1
1
2
R1503motr06A
1. Screws
R1503motr23A
– bottom engine block half
1. Micrometer
– thrust washers no. 6 2. Balance shaft area for bushings
LMR2004_014_04_09A.FM 04-09-9
BALANCE SHAFT SEAT DIAMETER 1

mm (in)
BALANCE SHAFT SEAT RADIAL CLEARANCE

mm (in)
Installation
Pay attention to following detail. R1503motr20B
CAUTION: Balance shaft must be aligned with THRUST WASHER INSERT DIRECTION
crankshaft. Align grooves on crankshaft and 1. Thrust washer
balance shaft. CAUTION: Thrust washers must be even with
the engine block sealing surface.
2
R1503motr17A 1 2
1. Groove on balance shaft R1503motr22A
2. Groove on crankshaft
1. Thrust washer
CAUTION: Never forget thrust washers no. 6 2. Sealing surface
for axial adjustment on balance shaft PTO side.
Install lower engine block half. Refer to ENGINE
Insert thrust washers as soon as balance shaft is BLOCK ASSEMBLY elsewhere in this section for
in place according to following illustration. proper procedure to clean surfaces, apply Loctite
5910 and the proper torquing sequence.
04-09-10 LMR2004_014_04_09A.FM
Install the crankshaft cover before mounting the ENGINE BLOCK

engine bracket. Put some oil on O-ring and press
the cover in. The crankshaft cover has to be even Removal
with the engine block surface. Remove:
1 – engine oil
(refer to OIL CHANGE in LUBRICATION section)
– cylinder head (refer to CYLINDER HEAD REMOV-
AL in CYLINDER HEAD section)
– PTO housing (refer to PTO HOUSING REMOVAL
in PTO HOUSING/MAGNETO section)
– starter gear (refer to STARTER GEAR REMOVAL
in PTO HOUSING/MAGNETO section)
R1503motr19A 2 CATION section)
1. O-ring
– balance shaft (refer to BALANCE SHAFT REMOV-
2. Crankshaft cover AL elsewhere in this section)
CAUTION: Install crankshaft locking tool (P/N 529 – crankshaft (refer to CRANKSHAFT REMOVAL
035 821) right away to put crankshaft in TDC po- elsewhere in this section)
sition before installing the camshaft and rockers – piston with connecting rod (refer to PISTON RE-
(refer to CYLINDER AND HEAD). MOVAL elsewhere in this section).
1 Bushings
When bushings need to be removed from the en-
gine block, mark them to identify the correct posi-
tion at installation. See the following illustration for
an example:
1
R1503motr18A
1. Crankshaft locking tool
R1503motr37A 2
1. Mark on balance shaft bushings
2. Mark on crankshaft bushings
LMR2004_014_04_09A.FM 04-09-11
Starter Drive Bearing Cylinder Taper

Check bearing no. 21 of starter drive assembly Measure cylinder bore and if it is out of specifica-
no. 22 in engine block and replace if damaged. tions, rehone cylinder sleeve and replace piston
ass’y with first oversize.
NOTE: It is not necessary to have all cylinders re-
honed if they are not all out of specification. Mixed
standard size and oversize cylinders are allowed.
Measure cylinder bore at 3 recommended posi-
tions. See the following illustration.
1 B
3
R1503motr40A 1
1. Bearing of starter drive assembly
Starter drive bearing can be easily removed from

lower crankcase half using the following suggest- R1503motr24A
ed tool or equivalent: 1. First measuring diameter

– Snap-on hammer puller including: 2. Second measuring diameter
3. Third measuring diameter
A. 60 mm (2.362 in)
– handle CJ93-1 B. 110 mm (4.331 in)
– hammer CJ125-6
– claws CJ93-4. CYLINDER TAPER IN DIAMETER
mm (in)

F01J0ZA
Distance between measurements should not ex-
Close puller claws so that they can be inserted in ceed the service limit mentioned above.
end bearing. Holding claws, turn puller shaft clock- Cylinder Out of Round
wise so that claws open and become firmly tight
against bearing. Measure cylinder diameter in piston axis direction
from top of cylinder. Take an other measurement
Slide puller hammer outwards and tap puller end. 90° from first one and compare.
Retighten claws as necessary to always maintain
them tight against bearing. Continue this way until NOTE: Take the same measuring points like de-
bearing completely comes out. scribed in CYLINDER TAPER above.
Inspection
Cylinder
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, replace
cylinder.
04-09-12 LMR2004_014_04_09A.FM
CRANKSHAFT BUSHING INSIDE DIAMETER

mm (in)
R1503motr25A
A. Perpendicular to crankshaft axis

B. Parallel to crankshaft axis
CYLINDER OUT OF ROUND

mm (in)
NEW MAXIMUM 0.008 mm (.0003 in) R1503motr34A 1

SERVICE LIMIT 0.015 mm (.0006 in) ENGINE UPSIDE DOWN
1. Radial gauge
Bushings BALANCE SHAFT BUSHING INSIDE DIAMETER

To measure the wear of the crankshaft bushings mm (in)
no. 13 and no. 14 and balance shaft bushings SERVICE LIMIT 32.11 mm (1.2642 in)
no. 15, both engine block halves with OLD bush-
ings have to be screwed together according to Replace bushings if they are out of specifications.
tightening procedure described below.
Oil Spray Nozzles
Measure the inside diameter of the bushings with
a radial gauge. Remove oil spray nozzle no. 16 and banjo screw
no. 17 from engine block.
1
R1503motr33A
R1503motr38A
ENGINE UPSIDE DOWN
1. Radial gauge 1. Banjo screw
2. Oil spray nozzle
LMR2004_014_04_09A.FM 04-09-13
Check free movement of ball inside the banjo Bushings have to be even with the engine block split
screw. Clean nozzle and banjo screw from dirt and surface and their protrusions have to fit in the
debris. notched areas in the engine block seat.
Installation 1
Torque oil spray nozzle to 18 N•m (159 lbf•in).
To install starter drive bearing no. 21 of starter
drive assembly, use pusher (P/N 290 876 502) and
handle (P/N 420 877 650).
R1503motr36A
1. Bushing protrusion in engine block notch

2
Apply engine oil on all bushings, in the bottom area
F06D32A
of the cylinder bore and also on the band of the
1. Handle piston ring compressor tool.
2. Pusher
For proper installation of pistons, refer to PISTON
Use NEW bushings when diameters are out of INSTALLATION elsewhere in this section.
specification. NOTE: Before installing the crankshaft, make
If OLD bushings can be used again, make sure sure that the timing chain is on the crankshaft and
they are at the same position as they were before. the chain tension guide has been installed first.
Put bushings correctly in place. Top crankshaft bush- Those parts cannot be installed after as the crank-
ing halves have a bore which has to be placed in the shaft is in place.
upper engine block. Clean oil passages and make sure they are not
clogged.
Clean all metal components in a solvent.
Engine block mating surfaces are best cleaned us-
ing a combination of the chisel gasket remover
(P/N 413 708 500) and a brass brush. Brush a first
1 2 pass in one direction then make the final brushing
perpendicularly (90°) to the first pass (cross hatch).
3
CAUTION: Do not wipe with rags. Use a new
clean hand towel only.
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
R1503motr35A time.
1. Upper engine block half
2. Oil bore in engine block
3. Oil bore in bushing
04-09-14 LMR2004_014_04_09A.FM
NOTE: It is recommended to apply this specific

sealant as described here to get an uniform appli- 6 16 15 14 4 9 2 10 11 12 13 8
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (unlike the Dreibond sealing
compound, using a finger will not affect the adhe-
sion).
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces.
CAUTION: Do not use Loctite 515 or 518 to seal
crankcase. Do not use Loctite Primer N with the
Loctite 5910. Using these products or non silicone-
based sealant over a previously sealed crankcase
with Loctite 5910 will lead to poor adhesion and
possibly a leaking crankcase. These products are
chemically incompatible. Even after cleaning, the 5 23 22 3 21 17 18 1 19 20 7
Loctite 5910 would leave incompatible microscop- R1503motr06B
ic particles.
Use a plexiglas plate and apply some sealant on it. Apply Loctite 243 (blue) on threads. Torque engine
Use a soft rubber roller (50 - 75 mm (2 - 3 in)) block screws no. 3 at first to 40 N•m (30 lbf•ft)
(available in arts products suppliers for printmak- and in a second sequence to 55 N•m (41 lbf•ft).
ing) and roll the sealant to get a thin uniform coat Torque engine block screws no. 7 to 22 N•m
on the plate (spread as necessary). When ready, (16 lbf•ft).
apply the sealant on crankcase mating surfaces. Before continuing the installation process, the ax-
ial clearance of balance shaft and crankshaft must
be checked.
1
F12R17A
Do not apply in excess as it will spread out inside

R1503motr41A 2
crankcase.
1. Dial gauge
NOTE: Do not use Loctite Primer N with this seal- 2. Crankshaft
ant. The sealant curing time is similar to the Loc-
tite 518 without using the Primer N, which is 4 to CRANKSHAFT AXIAL CLEARANCE mm (in)
24 hours.
Tighten engine block screws according to follow-
ing sequence. NEW MAXIMUM 0.22 mm (.009 in)
LMR2004_014_04_09A.FM 04-09-15
1 1
R1503motr42A 2 R1503motr18A
1. Dial gauge
2. Balance shaft 1. Crankshaft locking tool
Install cylinder head, PTO housing and the other

BALANCE SHAFT AXIAL CLEARANCE mm (in) parts in accordance with the proper installation
NEW MINIMUM 0.02 mm (.001 in) procedures.
PISTON/CONNECTING ROD
Removal
Install the crankshaft cover before mounting the
engine bracket. Put some oil on O-ring and press Disassemble engine block according to ENGINE
the cover in. The crankshaft cover must be even BLOCK REMOVAL above.
with the engine block surface. Remove connecting rod screws.
1 1
R1503motr08A
1. Connecting rod screws

R1503motr19A 2
NOTE: Before removing the connecting rod bear-
1. O-ring
2. Crankshaft cover
ing caps, mark them to remember the right posi-
tion when reassembling.
CAUTION: Install crankshaft locking tool (P/N 529
Pull piston with connecting rod out of the cylinders.
035 821) right away to put crankshaft in TDC po-
sition before installing the camshaft and rockers
(refer to CYLINDER AND HEAD).
04-09-16 LMR2004_014_04_09A.FM
Remove one piston circlip no. 8 and discard it.
2
1
R610motr134A 1
1. Piston circlip
NOTE: The removal of both piston circlips is not

necessary to remove piston pin.
Push piston pin no. 9 out of piston.
R610motr73A
1 2 3
1. Bore gauge
2. Connecting rod
R610motr137A A
R1503motr27A A. Piston pin diameter in the area of the bushing
1. Piston
2. Piston pin CONNECTING ROD SMALL END DIAMETER
3. Circlip mm (in)
Detach piston no. 10 from connecting rod. NEW MINIMUM 23.01 mm (.9059 in)
Inspection NEW MAXIMUM 23.02 mm (.9063 in)
Connecting Rod/Piston Pin Clearance SERVICE LIMIT 23.07 mm (.908 in)

Measure piston pin. Compare to inside diameter
of connecting rod no. 23. PISTON PIN DIAMETER
mm (in)
LMR2004_014_04_09A.FM 04-09-17
PISTON PIN BORE CLEARANCE Piston

mm (in) Inspect piston for scoring, cracking or other dam-
ages. Replace piston and piston rings if necessary.
Using a micrometer, measure piston at 18 mm
If the connecting rod small end diameter is out of (.709 in) perpendicularly (90°) to piston pin axis.
specification, replace connecting rod.
Connecting Rod Big End Radial Play
Measure inside diameter of connecting rod big
end. Compare to crankpin.
To measure the connecting rod big end diameter,
use the OLD screws no. 11.
Install the OLD bushings no. 12 as they were
mounted initially.
Do the torque procedure as described below. A
R610motr136A 1
1. Measuring perpendicularly (90°) to piston pin axis
A. 18 mm (.709 in)
The measured dimension should be as described

in the subsequent table. If not, replace piston.
PISTON MEASUREMENT
mm (in)
A
99.951 to 99.969 mm
NEW NOMINAL
(3.935 to 3.936 in)
R610motr76A
A. Connecting rod big end bushing

Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
CONNECTING ROD BIG END DIAMETER sion.
mm (in)
1
CONNECTING ROD BIG END CLEARANCE

mm (in)
Use NEW bushings no. 12, when connecting rod

big end diameter is out of specification.
F00B08A
1. Micrometer set to the piston dimension
04-09-18 LMR2004_014_04_09A.FM
With the micrometer set to the dimension, adjust If clearance exceeds specified tolerance, rehone
a cylinder bore gauge to the micrometer dimen- cylinder sleeve and replace piston ass’y by over-
sion and set the indicator to 0 (zero). size.
NOTE: It is not necessary to have all pistons re-
placed with an oversize if they are not all out of spec-
ification. Mixed standard size and oversize piston
are allowed.
NOTE: Make sure the cylinder bore gauge indica-
2 1 tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Piston Pin
Using synthetic abrasive woven, clean deposits
from piston pin.
Inspect piston pin for scoring, cracking or other
damages.
F00B09A
Measure piston pin. See the following illustration
1. Use the micrometer to set the cylinder bore gauge for the proper measurement positions.
2. Dial bore gauge
Piston Pin/Connecting Rod Bushing Clearance
Measure inside diameter of connecting rod.
CONNECTING ROD SMALL END DIAMETER

mm (in)
F00B0AA
TYPICAL
1. Indicator set to 0 (zero)
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 clear- 2
1
ance.
PISTON/CYLINDER CLEARANCE mm (in)
0.024 to 0.056 mm
NEW NOMINAL
(.0009 to .0022 in)
SERVICE LIMIT 0.090 mm (.004 in) R610motr73A
1. Bore gauge
NOTE: Make sure used piston is not worn. See PIS- 2. Connecting rod
TON MEASUREMENT above.
LMR2004_014_04_09A.FM 04-09-19
Replace connecting rod if diameter of connecting Using a piston ring compressor plier, such Snap-
rod small end is out of specifications. Refer to On RC-980, slide piston into cylinder.
CRANKSHAFT AND BALANCER SHAFT for remov-
al procedure of connecting rod.
Installation
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
Use the piston circlip installer (P/N 529 035 765)
to assemble the piston circlip.
CAUTION: Secure piston pin with new piston
circlips.
NOTE: Take care that the hook of the piston circlip
R1503motr29A
is positioned properly.
1 CAUTION: Take care that piston will be installed
with the punched arrow on piston top to the ex-
haust side.
2 1
R1503motr28A
1. Sleeve with piston circlip inside

2. Assembly jig from piston clip installer
R1503motr30A
1. Arrow should indicate to the exhaust side
R610motr134B
CORRECT POSITION OF THE PISTON CIRCLIP
04-09-20 LMR2004_014_04_09A.FM
Put bushings correctly in place and clean the split PISTON RINGS
surface on both sides (cracked area) carefully.
3 1 2
Removal
Remove piston assembly as described above.
Remove rings.
Inspection
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.
RING/PISTON GROOVE CLEARANCE

mm (in)
NEW MINIMUM
UPPER
0.025 mm (.001 in)
R610motr79A COMPRESSION RING
1. Half bushing of connecting rod big end LOWER
2. Split surface of the connecting rod 0.015 mm (.0006 in)
3. Protrusion of bushing in line with connecting rod groove COMPRESSION RING
Torque NEW connecting rod screws no. 11 as per OIL SCRAPER RING 0.020 mm (.0008 in)
following procedure:
NEW MAXIMUM
– Install screws and torque to 45 N•m (33 lbf•ft).
Do not apply any thread locker product. UPPER
0.070 mm (.0028 in)
COMPRESSION RING
– Finish tightening the screws with an additional
90° turn using an angle torque wrench. LOWER
0.060 mm (.0024 in)
CAUTION: Failure to strictly follow this proce- COMPRESSION RING
dure may cause screw to loosen and lead to en- OIL SCRAPER RING 0.055 mm (.0021 in)
gine damage. Besides, as the screws have been
stretched from the previous installation, it is SERVICE LIMIT
very important to use new screws at assembly.
ALL 0.15 mm (.006 in)
R1503motr31A
R1503motr32A 1
1. Angle torque wrench
1. Piston
2. Filler gauge
LMR2004_014_04_09A.FM 04-09-21
Ring End Gap CAUTION: Ensure that upper and lower rings
are not interchanged.
RING END GAP
mm (in)
NOTE: Use a ring expander to prevent breakage
during installation. The oil ring must be installed by
NEW MINIMUM hand.
UPPER
Check that rings rotate smoothly after installation.
0.15 mm (.006 in)
COMPRESSION RING Space the piston ring end gaps 120° apart and do
not align the gaps with the piston pin bore or the
LOWER thrust side axis.
0.15 mm (.006 in)
COMPRESSION RING
OIL SCRAPER RING 0.15 mm (.006 in) A

A A
NEW MAXIMUM
UPPER
0.35 mm (.014 in)
COMPRESSION RING
LOWER
0.35 mm (.014 in)
COMPRESSION RING
1
OIL SCRAPER RING 0.30 mm (.012 in)
SERVICE LIMIT
2
ALL 1 mm (.04 in)
Measure position for ring end gap in the area of 8

to 16 mm (.315 to .630 in) from top of cylinder. A31C2OA
NOTE: In order to correctly position the ring in the 1. DO NOT align ring gap with piston trust side axis
cylinder, use piston as a pusher. 2. DO NOT align ring gap with piston pin bore axis
A. 120°
Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds above described specified tol-
erance.
Installation
Install the oil scraper ring first, then the lower com-
pression ring with the word “TO” facing up, then
the upper ring with the word “T” facing up.
3
A31C2NA
1. Upper compression ring

2. Lower compression ring
3. Oil scraper ring
04-09-22 LMR2004_014_04_09A.FM
Section 05 ENGINE MANAGEMENT (4-TEC)
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 05-02-1
COMPLETE ELECTRICAL SYSTEM OVERVIEW .............................................................. 05-02-2
MAGNETO SYSTEM AND POWER SUPPLY ................................................................... 05-02-3
OPERATING PRINCIPLE OF ENGINE MANAGEMENT ................................................... 05-02-3
AIR INDUCTION................................................................................................................. 05-02-3
FUEL DELIVERY SYSTEM................................................................................................. 05-02-3
BASIC OPERATION ........................................................................................................... 05-02-3
INTAKE MANIFOLD........................................................................................................... 05-02-4
FUEL PUMP MODULE....................................................................................................... 05-02-4
ELECTRONIC MANAGEMENT.......................................................................................... 05-02-5
ECM (ENGINE CONTROL MODULE)................................................................................ 05-02-5
ECM — GENERAL FUNCTIONS ....................................................................................... 05-02-6
EMS — ENGINE MANAGEMENT FUNCTIONS............................................................... 05-02-8
VCM — VEHICLE CONTROL MODULE ............................................................................ 05-02-10
COMPONENT INSPECTION AND ADJUSTMENT .............................................................. 05-03-1

GENERAL ........................................................................................................................... 05-03-1
FUEL SYSTEM ................................................................................................................... 05-03-1
ELECTRICAL SYSTEM....................................................................................................... 05-03-2
ENGINE CONNECTOR PIN-OUT ...................................................................................... 05-03-3
CONNECTORS ON ENGINE ............................................................................................. 05-03-4
AIR INDUCTION SYSTEM................................................................................................. 05-03-5
THROTTLE BODY .............................................................................................................. 05-03-5
FUEL DELIVERY................................................................................................................. 05-03-8
FUEL PUMP ....................................................................................................................... 05-03-9
FUEL SYSTEM PRESSURIZATION ................................................................................... 05-03-10
FUEL RAIL .......................................................................................................................... 05-03-12
FUEL INJECTOR ................................................................................................................ 05-03-12
ELECTRONIC MANAGEMENT.......................................................................................... 05-03-14
ECM ECU AND VCM REPLACEMENT .............................................................................. 05-03-14
ENGINE WIRING HARNESS ............................................................................................. 05-03-15
THROTTLE POSITION SENSOR (TPS) ............................................................................. 05-03-17
IDLE BYPASS VALVE ........................................................................................................ 05-03-19
CRANKSHAFT POSITION SENSOR (CPS) ....................................................................... 05-03-19
CAMSHAFT POSITION SENSOR (CAPS) ......................................................................... 05-03-21
MANIFOLD AIR TEMPERATURE SENSOR (MATS)......................................................... 05-03-22
COOLANT TEMPERATURE SENSOR (CTS)..................................................................... 05-03-23
MANIFOLD AIR PRESSURE SENSOR (MAPS) ................................................................ 05-03-23
EXHAUST GAS TEMPERATURE SENSOR (EGT) ............................................................ 05-03-24
KNOCK SENSOR (KS) ....................................................................................................... 05-03-24
LMR2004-030_05_01ATOC.FM 05-01-1
OIL PRESSURE SWITCH (OPS) ......................................................................................... 05-03-25

OIL SEPARATOR PRESSURE SWITCH (OSPS)................................................................ 05-03-26
TOPS VALVE (blow-by) ...................................................................................................... 05-03-28
IGNITION COILS................................................................................................................. 05-03-29
TDC SETTING (Top Dead Center) ..................................................................................... 05-03-31
ENGINE START/STOP SWITCH VERIFICATION ............................................................... 05-03-31
SAFETY LANYARD SWITCH VERIFICATION.................................................................... 05-03-31
SPARK PLUGS.................................................................................................................... 05-03-31
CRANKING SYSTEM.......................................................................................................... 05-03-32
DIAGNOSTIC PROCEDURES................................................................................................. 05-04-1

GENERAL............................................................................................................................ 05-04-1
SELF-DIAGNOSTIC MODE ................................................................................................ 05-04-2
VCK (Vehicle Communication Kit) ................................................................................... 05-04-3
4-TEC SYSTEM FAULT CODES......................................................................................... 05-04-3
05-01-2 LMR2004-030_05_01ATOC.FM
Subsection 02 (OVERVIEW)
OVERVIEW 0
ENGINE CONTROL MODULE OVERVIEW
ROTAX 4-TEC 1503
Cyl. 1 Cyl. 2 Cyl. 3
Con. B
MAGNETO Con. A
KS MAPS
CPS MATS
OPS TPS
CTS
CAPS ECM IDLE BYPASS VALVE
INJECTOR 1, 2, 3 ECU TOPS SWITCH

TOPS VALVE
OSPS
IGNITION COIL 1, 2, 3
EGT
MUFFLER
BATTERY ENGINE POWER SUPPLY

ENGINE
REGULATOR/
FUSE
RECTIFIER BLOCK ECM ECU Engine Management System
Electronic Control Unit
KS Knock Sensor
CPS Cranshaft Position Sensor
OSPS Oil Separator Pressure Sensor
CTS Coolant Temperature Sensor
CAPS Camshaft Position Sensor
EGT Exhaust Gas Temperature
MAPS Manifold Air Pressure Sensor
MATS Manifold Air Temperature Sensor
TOPS Tip-Over Protection System
Con. A Connector for Engine Wiring Harness
R1503motr212S
Con. B Connector for Boat Wiring Harness
LMR2004_015_05_02A.FM 05-02-1
COMPLETE ELECTRICAL SYSTEM OVERVIEW

COMMUNICATION
LINK
- TPS - POWER TO
WH/BK
- MAPS ECM ECU WH/RE ENGINE FUSE BLOCK ECM ECU
- MATS - ENGINE
WARNINGS
- CTS
- TACHOMETER
- EGT
- SPEED SENSOR/
- KS
SPEEDOMETER
- OPS - FUEL LEVEL
- OSPS SENDER
- CPS - BEEPER
- DESS
COMMUNICATION LINK
- IDLE
BYPASS
VALVE WH/BK VCK
WH/RE (COMMUNICATION
- START/STOP PORT)
SWITCH
- STARTING WH/BK
SOLENOID WH/RE VCM - BEEPER
- FUEL PUMP - ENGINE
WARNINGS
- FUEL INJECTORS
- TACHOMETER
- IGNITION COILS
- DESS SWITCH
- TOPS VALVE
- TOPS SWITCH
- CAPS
ECM
COLOUR CODE
These components are shared between the ENGINE FUSE BLOCK and the WH = WHITE
ECM ECU. The ENGINE FUSE BLOCK supplies the power while the EMS ECU BK = BLACK
F18L33S controls and completes the circuit by switching it to the ground. RE = RED
NOTE: This procedure to be performed for each For communication link troubleshooting, refer to
engine. INSTRUMENTS AND ACCESSORIES in ELECTRI-
The complete electrical system is managed by CAL section.
micro-controllers working together. Overall, the The communication link is also used to communi-
VCM (vehicle control module) manages the vehicle cate informative messages, monitoring and diag-
electrical system, the ECM (engine control mod- nostic codes to the VCK (vehicle communication kit)
ule) controls the engine. where B.U.D.S.™ (Bombardier Utility and Diagnos-
A communication link is used between the elec- tic System) is used for diagnosing and troubleshoot-
tronic modules to communicate with each other. ing the system.
It consists of a twisted pair of wires (WHITE/RED The fault codes can be seen from B.U.D.S. Refer to
and WHITE/ BLACK). DIAGNOSTIC PROCEDURES section.
05-02-2 LMR2004_015_05_02A.FM
MAGNETO SYSTEM AND NOTE: “ECM” stands for engine control module.
“ECM” includes an ECU (electronic control unit),
POWER SUPPLY sensors, injectors, electromagnetic valves and igni-
The magneto is the primary source of electrical en- tion system.
ergy. It transforms magnetic field into electric cur-
rent (AC). AIR INDUCTION
The magneto has a 3 phases, delta wound stator on Air for combustion is drawn directly at the front of
18 poles. Capacity is 380 watts. the engine through one 52 mm throttle body. The
It supplies DC current to battery after being trans- air flow is controlled by a throttle plate and an idle
formed by the voltage regulator/rectifier. Refer to bypass valve respectively. The air continues through
CHARGING SYSTEM. the intake manifold, which contains the flame ar-
rester and goes into the cylinder head.
OPERATING PRINCIPLE OF
2
ENGINE MANAGEMENT
A highly advanced engine control module (ECM)
has been used to ensure a high power output with
cleanest combustion. The ECM calculates the
proper air/fuel mixture and ignition timing for each
cylinder separately. The fuel is injected into the in-
take port of each cylinder.
NOTE: On the 1503, PTO and magneto (MAG) are
on the same engine side (rear). Each cylinder is
referenced as 1, 2 and 3 instead of PTO, CENTRE
and MAG. The numbers are stamped on the valve
cover.
1 2 3
R1503motr216A 1
52 mm THROTTLE BODY
1. Idle bypass valve
2. Throttle position sensor (TPS)
FUEL DELIVERY SYSTEM

BASIC OPERATION
When the intake valve reaches the correct posi-
tion, the ECM ECU (Electronic Control Module)
opens the fuel injector and fuel is discharged into
the intake port at the air intake manifold by the
high fuel pressure inside the fuel rail. The air/fuel
R1503motr218A
mixture enters then the combustion chamber
through the open intake valve. This mixture is then
1. Cylinder 1 ignited by the spark plug.
2. Cylinder 2
3. Cylinder 3
LMR2004_015_05_02A.FM 05-02-3
INTAKE MANIFOLD Throttle Body

It is a 52 mm throttle body mounted on intake man-
3 2 ifold. Fitted on the throttle body, there is the TPS and
5
the idle bypass valve which allows the ECM ECU to
control the RPM while the throttle plate is closed.
1
FUEL PUMP MODULE
R1503motr214B
6 7 4
INTAKE MANIFOLD
1. Electronic Control Unit (ECM ECU)
2. Fuel rail
3. Injector
4. Throttle body
5. Ignition coil
6. Manifold air pressure sensor (MAPS)
7. Manifold air temperature sensor (MATS)
The intake manifold is mounted on the engine block

on the engine starboard side. It provides support for R1503motr217A
the fuel injectors, the fuel rail, the ECM ECU, the
flame arrester and the throttle body. The air intake The fuel pump modules are located inside the fuel
manifold is a resonator between the throttle body tank. Each module includes fuel pump, fuel pres-
and the air intake at the cylinder head with the sure regulator and fuel level sensor.
flame arrester.
Fuel Pump
Fuel Rail
It provides fuel pressure and flow rate to the system.
The fuel rail is a small tube on which the three injec-
tors are mounted. It ensures all the time, that Fuel Pressure Regulator
enough fuel at the right pressure can be delivered
to the fuel injectors. The fuel rail is fed by the fuel A fuel pressure regulator controls the pressure in
pump with a fuel pressure of approximately 303 kPa the system and allows the excess of fuel to return
(44 PSI). to the fuel tank. The fuel pressure regulator regu-
lates the fuel pressure at approximately 303 kPa
Fuel Injector (44 PSI).
Three fuel injectors (one per cylinder) are used to Fuel Filter
inject fuel into the intake port of the cylinder head.
A mesh filter is located at the bottom of the fuel
Flame Arrester pump module inside the fuel tank.
The flame arrester is a tube inside the air intake

manifold. It prevents flames leaving through the
intake system if the engine backfires.
05-02-4 LMR2004_015_05_02A.FM
ELECTRONIC MANAGEMENT ECM FUNCTIONS

ECM (Engine Control Module) Fuel injection
system
The engine control module is controlled by the
ECM ECU.
Ignition system
1
Starting system
ENGINE
CONTROL Data transfer
MODULE with VCM
(ECM)
DESS system
and learning key
RPM limiter
Limp home mode

R1503motr219A
The ECM ECU gets its power by the engine fuse

R1503motr215A
block which is directly powered by the battery. It is
1. ECM ECU responsible for the following engine management/
electrical functions:
ECM ECU
– interpreting information
The ECM ECU is mounted on the intake manifold.
It controls all engine management functions, by pro- – distributing information
cessing the information given by various sensors. – start/stop function
– timer
– DESS (Digitally Encoded Security System)
1
– ignition timing control
– injection control
– The ECM ECU applies the proper map (injection
and ignition) for optimum engine operation in all
conditions.
– engine RPM limiter
– etc.
The ECM ECU features a permanent memory that
will keep the programmed safety lanyard(s) active,
fault codes and other engine information, even
R1503motr214A when the battery is removed from the sport boat.
1. ECM ECU on intake manifold
LMR2004_015_05_02A.FM 05-02-5
ECM — GENERAL FUNCTIONS When connecting a safety lanyard cap on the post,
the DESS is activated and will emit audible signals:
Safety Lanyard Reminder – 2 short beeps indicate a working safety lanyard.
If engine is not started within 5 seconds after in- Engine starting can take place.
stalling the safety lanyard on its post, 4 very short – 1 long beep indicates a wrong safety lanyard is
beeps every 3 second interval will sound for ap- being used or that something is defective. En-
proximately 5 minutes to remind you to start the gine starting is not allowed.
engine or to remove safety lanyard. Afterwards, the
beeps will stop. The same will occur when safety The memory of the ECM ECU features a self-
lanyard is left on its post 5 seconds after engine is diagnostic mode for the DESS operation. Refer to
stopped. DIAGNOSTIC PROCEDURES section for more in-
formation.
CAUTION: Leaving the safety lanyard on its post
when engine is not running will slowly discharge The memory of the ECM ECU is permanent. If the
battery. battery is disconnected, no information is lost.
When ordering a new ECM ECU from the regular
Antistart Feature parts channel, the DESS circuitry will be activated.
This system allows starting the vehicle only with
safety lanyard(s) that has been programmed to op- Engine Starting
erate a specific sport boat. This functionality is the If the ECM ECU recognizes a valid safety lanyard,
DESS system. See below for details. it allows engine to start when the start/stop switch
is pressed.
Digitally Encoded Security System If start/stop button is held after engine has started,
(DESS™) the ECM ECU automatically stops the starter
The following components are specially designed when the engine speed reaches 1600 RPM.
for this system: Vehicle Control Module (VCM),
ECM ECU, safety lanyard cap and safety lanyard Engine RPM Limiter
post. The ECM ECU will limit the maximum engine speed.
The safety lanyard cap contains a magnet and a
ROM chip. The magnet actually closes the reed Engine Stopping
switch inside the post which is the equivalent of a There are 2 ways to stop the engine.
mechanical ON/OFF switch. The chip has a unique
digital code. Press and hold start/stop switch or remove the safe-
ty lanyard cap from its post.
The DESS circuitry in the ECM ECU is activated at
the factory. Therefore, a safety lanyard must be If the engine is stopped by removing the safety
programmed to start the engine. lanyard, it is impossible to restart the engine as
explained in the engine starting section.
NOTE: Actually, it is the memory of the ECM ECU
which is programmed to recognize the digital code If safety lanyard cap is reconnected within 15 sec-
of the safety lanyard cap. This is achieved with the onds, the current supply to the engine manage-
VCK (Vehicle Communication Kit) (P/N 529 035 ment is not cut and the safety lanyard will be vali-
844). Refer to B.U.D.S.™ help system to program dated.
a safety lanyard.
Low-Oil Pressure Warning Device
The system is quite flexible. Up to 8 safety lan-
yards may be programmed in the memory of the When the oil pressure falls under a certain level,
sport boat ECM. They can also be erased individ- the ECM ECU sends out a signal for the beeper
ually. and to the warning gauge. Additionally the engine
goes into limp home mode.
NOTE: If desired, a safety lanyard can be used on
other sport boats equipped with the DESS™. It
only needs to be programmed for that sport boat.
05-02-6 LMR2004_015_05_02A.FM
High Coolant Temperature and EGT The engine fuse block distributes power from the
Warning Device battery to all engine components and boat gauges.
When the coolant temperature or the exhaust gas 6 5 4
temperature is getting too high, the ECM ECU sends
signals to the beeper and the warning gauge. Addi-
tionnally the engine goes into limp home mode.
Fuse Block
The fuse block for each engine is mounted on the
hull just underneath the port and starboard rear
storage compartments. Remove rear seat storage
tubs to access fuse blocks.
The ECM ECU switches the ground to complete
the electrical circuits it controls. Take this into
account when troubleshooting the electrical sys-
tem. Refer to the illustration at the beginning of F04H79A 1 2 3
this section. TYPICAL
1. Fuel pump
2. Cylinder 3
3. ECM
4. Cylinder 1
5. Cylinder 2
6. Gauges
F04H73A 1
1. Port fuse block
F04H74A 1
1. Starboard fuse block
LMR2004_015_05_02A.FM 05-02-7
EMS — ENGINE MANAGEMENT FUNCTIONS
1503 4-TEC CONTROL SYSTEM
INPUTS OUTPUTS
Throttle position (TPS) Fuel pump
Crankshaft position (CPS) Starter solenoid
Camshaft position (CAPS) TOPS valve

ENGINE CONTROL
Coolant temperature (CTS) MODULE Ignition coil (3)
(ECM)
Manifold air pressure (MAPS) Fuel injector
Manifold air temperature (MATS) Idle bypass valve
Exhaust gas temperature (EGT) Communication

port to VCM
Oil pressure (OPS)
Oil separator pressure (OSPS)
Knock sensor (KS)
Battery voltage (BV)
Digitally Encoded
Security System (DESS)
Start/Stop switch
Tip-over protection system (TOPS)
R1503motr220S
05-02-8 LMR2004_015_05_02A.FM
This engine management system controls both All three ignition coils are located on the cylinder
the fuel injection and the ignition timing. head directly on the spark plugs.
As shown in the 1503 4-TEC CONTROL SYSTEM
1
illustration, the ECM ECU is the central point of
the fuel injection system. It reads the inputs,
makes computations, uses pre-determined pa-
rameters and sends the proper signals to the out-
puts for proper engine management.
The ECM ECU also stores the fault codes and gen-
eral information such as: operating conditions, ve-
hicle hours, serial numbers, customer and mainte-
nance information.
Electronic Fuel Injection

The ECM ECU reads the signals from different
sensors which indicate engine operating condi- R1503motr213A
tions at milli-second intervals.

1. Ignition coils
Signals from sensors are used by the ECM ECU
to determine the injection parameters (fuel maps) Ignition Timing
required for optimum air-fuel ratio. The ECM ECU is programmed with data (it con-
The CPS, the MATS, the MAPS and the TPS are tains ignition mappings) for optimum ignition tim-
the primary sensors used to control the injection ing under all operating conditions. Using engine
and ignition timing. Other sensors (like tempera- operating conditions provided by the sensors, the
ture sensors, etc.) are used for secondary input. ECM ECU controls the ignition timing for optimum
NOTE: The EGT, OPS and OSPS sensors do not engine operation.There is no mechanical adjust-
provide control inputs to the ECM ECU. Their sole ment to perform.
purpose is to protect the engine components by
emitting a warning signal and/or a fault code in the Knock Sensor
event of overheating or low oil pressure or TOPS A knock sensor is mounted on the engine block
valve fault. behind the air intake manifold. It detects specific
vibrations that would be typically generated by en-
Ignition System gine detonation. If detonation occurs, the knock
The ignition system is a digital inductive type. The sensor detects this and the ECM ECU retards the
ECM ECU controls the ignition system parame- ignition advance temporarily (it goes in a specific
ters, such as spark timing, duration and firing in mode) until detonation stops. The ECM ECU is able
order to achieve the proper engine requirements. to evaluate the knocking cylinder and modifies the
ignition advance on just the one detonating.
Ignition Coils
Engine Modes of Operation
Three separate ignition coils induce voltage to a
high level in the secondary windings to produce a The ECM ECU controls different operation modes
spark at the spark plug. of the engine to allow proper operation for all pos-
sible conditions: Cranking, start-up, idle, warm up,
The ignition coils receive input from the ECM ECU. part load, full load, engine speed limiter, drowned
Each coil provides high voltage to its correspond- engine and limp home (see below).
ing spark plug.
This ignition system allows spark plugs to spark Fuel-Flooded Engine
independently.
If engine is fuel-flooded and does not start, this
NOTE: Ignition coil cables are not interchangeable special mode can be activated to prevent fuel in-
due to different lengths. jection and ignition while cranking. Proceed as fol-
lows to activate it.
LMR2004_015_05_02A.FM 05-02-9
With safety lanyard on its post while engine is Diagnostic Mode

stopped, press and HOLD throttle lever in neutral
The malfunctions are recorded in the memory of
position.
the ECM ECU. The memory of the ECM ECU can
Press the start/stop button. The mode is now on. be checked using the VCK (Vehicle Communication
Releasing throttle lever will bring back to its normal Kit) (P/N 529 035 844) to see the fault codes. The
mode. ECM ECU and the VCK are able to communicate
through a connector on the vehicle. Refer to the
If engine does not start, it may be necessary to
DIAGNOSTIC PROCEDURES section. B.U.D.S.™
remove spark plugs and crank engine with rags
Version 1.1 and up must be used for this system.
over spark plug holes. Refer to COMPONENT IN-
SPECTION AND ADJUSTMENT subsection.
VCM — VEHICLE CONTROL
 WARNING MODULE
When disconnecting coil from spark plug, al-
ways disconnect coil from main harness first. Power Distribution
Never check for engine ignition spark from an The VCM distributes power from battery to all ac-
open coil and/or spark plug in the engine com- cessories. Accessories are protected by fuses in-
partment as spark may cause fuel vapor to ig- tegrated in the VCM. Fuse ratings are identified
nite. beside their holder.
If engine is water-flooded, refer to WATER FLOOD-
ED ENGINE in MAINTENANCE section.
Limp Home Modes 1

Besides the signals seen above, the ECM ECU 2
may automatically set default parameters to the 3
engine management to ensure the adequate op- 4
eration of the sport boat if a component of the fuel 5
injection system is not operating properly. 6
The following components failure will trigger a limp
home mode: CTS, EGT, OPS, OSPS and TOPS.
When minor faults occur, the fault and message/
beeper will stop automatically, once the condition
no longer exists.
Idling throttle and letting the engine return to idle F04H70A
speed may allow normal operation to return. If this 1. Courtesy lights

does not work, try removing and reinstalling the 2. Navigation lights
3. Bilge pump
safety lanyard on its post. 4. Blower
5. Radio
Depending on the malfunction, the sport boat speed 6. Accessories
may be reduced and not allowed to reach its usual
top speed. The engine speed will be limited to 2500 IMPORTANT: Some components are continuously
or 5000 RPM. powered with the supply from the battery through
VCM.
These performance-reduced modes allow the op-
erator to go back home which would not be possi-
ble without this advanced system. Refer to the DI-
AGNOSTIC PROCEDURES for a complete chart.
If a fault occurs and involves a limp home mode
operation, the engine management system will re-
duce engine RPM gradually to the proper level.
05-02-10 LMR2004_015_05_02A.FM
Gauges Current Supply

The purpose of this function is to allow reading of
gauges without the engine running.
Gauges are supplied with current whenever the
safety lanyard cap is installed on its post.
NOTE: The fuel pump will be activated for 2 sec-
onds to build up pressure in the fuel injection sys-
tem, only when connecting the safety lanyard cap
to the post.
Monitoring System
The ECM ECU monitors the electronic components
of the fuel injection system and also the engine
components of the electrical system. When a fault
occurs, it sends audible signals through a beeper to
inform you of a particular condition. Refer to the
DIAGNOSTIC PROCEDURES section for the beep-
er coded signals chart.
LMR2004_015_05_02A.FM 05-02-11
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)
COMPONENT INSPECTION AND

ADJUSTMENT 0
engine.  WARNING
Fuel lines remain under pressure at all times.
GENERAL Always proceed with care and use appropriate
safety equipment when working on pressur-
Engine problems are not necessarily related to the ized fuel system. Wear safety glasses and work
electronic fuel injection system. in a well ventilated area. Do not allow fuel to
It is important to ensure that the mechanical integ- spill on hot engine parts and/or on electrical
rity of the engine/propulsion system is present: connectors. Proceed with care when removing/
installing high pressure test equipment or dis-
– good jet pump/drive system operation connecting fuel line connections. Use the VCK
– good engine compression and properly operat- (Vehicle Communication Kit) to release fuel
ing mechanical components, no leaks etc. pressure prior to removing a hose. Cover the
– fuel pump connection and fuel lines without fuel line connection with an absorbent shop
leaks. rag. Slowly disconnect the fuel hose to mini-
mize spilling. Wipe off any fuel spillage in the
Check the chart in TROUBLESHOOTING section bilge. Fuel is flammable and explosive under
to have an overview of problems and suggested certain conditions. Always work in a well ven-
solutions. tilated area. Always disconnect battery prior to
When replacing a component, always check its working on the fuel system. After performing a
operation after installation. pressure test, use the valve on the fuel pres-
Whenever sport boat is out of water and engine is sure gauge to release the pressure (if so
running, ensure to supply water through the con- equipped).
nector on jet pump support to cool down exhaust
system. – Always disconnect battery properly prior to
working on the fuel system. Refer to BATTERY
CAUTION: Never run engines without supply- section.
ing water to the exhaust cooling systems when
sport boat is out of water. When the job is done, ensure that hoses from fuel
rail going to fuel pump are properly secured in their
supports. Then, pressurize the fuel system. Per-
FUEL SYSTEM form the high pressure test as explained in this
section and pressurize the fuel tank and fuel lines
 WARNING as explained in FUEL SYSTEM section.
The fuel system of a fuel injection system Properly reconnect the battery.
holds much more pressure than on a carbu-
reted sport boat. Prior to disconnecting a hose
or to removing a component from the fuel
 WARNING
Verify fuel line connections for damage and
system, follow the recommendation de-
that NO fuel line is disconnected prior to install-
scribed here. Some hoses may have more
ing the safety lanyard on the DESS post. Al-
than one clamp at their ends. Ensure to rein-
ways perform the high pressure test if any
stall the same quantity of clamps at assembly.
component has been removed. A pressure test
– Use the VCK (Vehicle Communication Kit) (P/N must be done before connecting the safety lan-
529 035 844) to release the fuel pressure in the yard. The fuel pump is started each time the
system. Look in the Activation section of safety lanyard is installed and it builds pressure
B.U.D.S. very quickly.
LMR2004-016_05_03A.FM 05-03-1
To check fuel rail for leaks, first pressurize the sys- To perform verifications, a good quality multimeter
tem then spray soapy water on all hose connec- such as Fluke 111 (P/N 529 035 868) should be used.
tions, regulators and injectors. Air bubbles will Pay particular attention to ensure that pins are not
show the leaking area. Check also for fuel leaks or out of their connectors or bent. The troubleshoot-
odors. ing procedures cover problems not resulting from
one of these causes.
 WARNING
Never use a hose pincher on high pressure  WARNING
hoses. Ensure all terminals are properly crimped on
wires and connector housings are properly
ELECTRICAL SYSTEM fastened.
It is important to check that the electrical system Before replacing an VCM or ECM ECU, always
is functioning properly: check electrical connections. Make sure that they
– battery are very tight and they make good contact and that
they are corrosion-free. Particularly check VCM and
– fuses ECM ECU ground connections. Ensure that con-
– DESS tacts are good and clean. A “defective module”
– ignition (spark) could possibly be repaired simply by unplugging
and replugging the VCM or ECM ECU. The voltage
– ground connections and current might be too weak to go through dirty
– wiring connectors. wire pins. Check carefully if pins show signs of
It is possible that a component seems to operate moisture, corrosion or if they look dull. Clean pins
in static condition but in fact, it is defective. In this properly and then coat them prior to assembling as
case, the best way to solve this problem is to re- follows:
move the original part and replace it with one ECM ECU connectors, OPS and OSPS connec-
which is in good condition. tors: Apply a thin coat of DEOXIT contact lubricant
Never use a battery charger to substitute tempo- (P/N 293 550 034).
rarily the battery, as it may cause the VCM/ECM Other connectors: Apply a silicon-based dielectric
ECU to work erratically or not to work at all. Check grease or other appropriate lubricant. If the newly
related-circuit fuse solidity and condition with an replaced VCM or ECM ECU is working, try the old
ohmmeter. Visual inspection could lead to false re- one and recheck if it works.
sults. Ensure that all electronic components are genuine
— any modification on the wiring harness may
 WARNING generate fault codes or bad operation.
All electrical actuators (idle bypass valve, NOTE: For diagnostics purposes, use Vehicle
TOPS valve, injectors, fuel pump, ignition Communication Kit (VCK). See DIAGNOSTIC PRO-
coils and starter solenoid) are permanently CEDURES subsection.
supplied by the battery when the safety lan-
yard is installed. Always disconnect the bat- After a problem has been solved, ensure to clear
tery prior to disconnecting any electric or elec- the fault(s) in the ECM ECU using the VCK. Refer
tronic parts. to DIAGNOSTIC PROCEDURES subsection.
05-03-2 LMR2004-016_05_03A.FM
Resistance Measurement NOTE: In case of overheating, EGT and CTS do not

generate codes. The beeper will be activated and
When measuring the resistance with an ohmme-
the ECM will be set in limp home mode.
ter, all values are given for a temperature of 20°C
(69°F). The resistance value of a resistance varies
with the temperature. The resistance value for ENGINE CONNECTOR PIN-OUT
usual resistor or windings (such as injectors) in-
creases as the temperature increases. However, Connector Position
our temperature sensors are NTC types (Negative
Temperature Coefficient) and work the opposite
which means that the resistance value decreases
as the temperature increases. Take it into account
when measuring at temperatures different from
20°C (68°F). Use this table for resistance variation
relative to temperature for temperature sensors.
TEMPERATURE RESISTANCE (ohms)
°C °F NOMINAL LOW HIGH
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800
- 10 14 9500 8000 11000
R1503motr166A 1 2
0 32 5900 4900 6900
1. ECM ECU connector A
10 50 3800 3100 4500 2. Engine connector
20 69 2500 2200 2800
ECM ECU Connector
30 86 1700 1500 1900
Use this diagram to locate the pin numbers on the
40 104 1200 1080 1320
ECM ECU connector A of the wiring harness when
50 122 840 750 930 performing tests.
60 140 630 510 750
70 158 440 370 510 13 1
80 176 325 280 370
28
90 194 245 210 280 14
100 212 195 160 210
110 230 145 125 160
120 248 115 100 125 41 29
R1503motr176A
CONVERSION CHART FOR TEMPERATURE SENSORS
ECM ECU CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
The resistance value of a temperature sensor may
test good at a certain temperature but it might be CAUTION: Probe on top of terminal only. Do not
defective at other temperatures. If in doubt, try a try to probe inside terminal or to use a paper
new sensor. clip to probe inside terminal, it can damage the
Also remember this validates the operation of the square-shaped terminal.
sensor at ambient temperature. It does not vali- CAUTION: Do not disconnect the ECM ECU con-
date the over temperature functionality. To test it, nector needlessly. They are not designed to be
the sensor could be removed from the engine/ disconnected/reconnected repeatedly.
muffler and heated with a heat gun while it is still
connected to the harness to see if the ECM ECU
will detect the high temperature condition and gen-
erate a fault code.
LMR2004-016_05_03A.FM 05-03-3
Engine Connector 3 2
Use this diagram to locate the pin numbers on the
Engine connector of the wiring harness when per-
forming tests.
1 4
2 3
R1503motr192A
ENGINE CONNECTOR PIN-OUT (WIRING HARNESS SIDE)

F18Z0KA 1
CONNECTORS ON ENGINE 1. Engine connector bracket
2. Deutsch connector
3. Flat screwdriver
Removal
To disconnect two connectors slide a flat screw-
To remove connectors from engine connector driver between each other to disengage, press the
bracket, slide a flat screwdriver between the con- release button and disconnect them.
nector bracket and the connectors and remove
connectors. 1
F18Z0LA 2
F18Z0JA 1 1. Flat screwdriver

2. Connectors
1. Engine connector bracket
2. Connectors
05-03-4 LMR2004-016_05_03A.FM
2 AIR INDUCTION SYSTEM

THROTTLE BODY
6
5
F18Z0MA 1 2 2
1. Release button
2. Connectors R1503motr160A 1 3
1. Throttle body
2. Throttle cable attachment
3. Throttle plate
4. TPS
5. Idle bypass channel
6. Idle bypass valve
Mechanical Inspection
Check that the throttle plate moves freely and
smoothly while moving the throttle lever. Take
this opportunity to lubricate the throttle cable.
IMPORTANT: The throttle body is designed to be
tamper proof. Changing the idle stop or modifying
it in any way will not increase performance or
change the idle speed but may cause poor start-
F18Z0NA 2 1 ability and erratic idling.
1. Connectors Before replacing any part, check the following as
2. Press release button these could be causing the fault. Perform the test
while the engine is not running.
– Throttle cable adjustment too tight. Not return-
ing fully to idle stop.
– Throttle body idle set screw is loose or worn.
– TPS is loose.
– Idle bypass valve is loose.
– Corroded or damaged wiring or connectors.
– Throttle body has been replaced and the closed
throttle and idle actuator reset has not been per-
formed.
– ECM ECU has been replaced and the closed
throttle and idle actuator reset has not been per-
formed.
LMR2004-016_05_03A.FM 05-03-5
Electrical Inspection Adjustment

Refer to THROTTLE POSITION SENSOR (TPS) and
1
IDLE BYPASS VALVE in ELECTRONIC MANAGE-
MENT below.
Replacement
Removal
To remove the throttle body from engine, proceed
as follows:
– Disconnect air intake silencer hose from throt-
tle body.
– Remove retaining screws of throttle body.
R1503motr161A
THROTTLE BODY
2 1. Idle stop screw
CAUTION: Do not make any changes to the idle

stop screw.
The adjustment of the idle stop screw is optimized
by the throttle body manufacturer and locked to
prevent any modification.
CAUTION: Never attempt to adjust the idle
speed through the throttle body tamper proof
screw. If so, it would impair the idle speed stabil-
R1503motr205A 1 2 ity. Besides, no adjustment could be performed
1. Throttle body by the dealer nor the factory to correct the idle
2. Screws speed. The throttle body would need to be re-
– Slightly pull throttle body out. placed. Also take into account that this might
change the engine emission level and the engine
– Disconnect connectors from idle bypass valve, might not meet the EPA/CARB requirements.
and TPS.
CAUTION: Do not alter or tamper with throttle
– Disconnect throttle cable. cable adjustment or routing. It may cause poor
Installation startability and erratic idling.
Installation of the new throttle body is the reverse The only thing that has to be performed when the
of the removal procedure. throttle body has been replaced is the closed throt-
For TPS and idle bypass valve replacement proce- tle and idle actuator reset. Refer to THROTTLE PO-
dures, refer to the respective paragraph in ELEC- SITION SENSOR (TPS) in ELECTRONIC MANAGE-
TRONIC MANAGEMENT below. MENT below.
05-03-6 LMR2004-016_05_03A.FM
Throttle Cable Adjustment

Mechanically adjust the throttle cable.
Lubricate cable with BOMBARDIER LUBE lubricant.
When throttle lever is at the idle position, the cable
must have a free play of 0.5 - 4.0 mm (1/64 - 5/32 in).
Ensure throttle body is fully open at full throttle
position. At this position, throttle lever stopper is
almost in contact with throttle body.
NOTE: Apply a light pressure on the throttle plate,
a slight play should be obtained.
CAUTION: If there is no free-play at idle posi-
tion, it may cause poor idling and startability.
Improper cable adjustment will cause strain on
cable and/or damage cable bracket or throttle
lever.
To adjust, loosen jam nut then turn adjustment nut
as necessary.
F18F07A 3 2 1
1. Adjustment nut
2. Jam nut
3. Throttle lever stopper
Tighten jam nut and recheck adjustment.
 WARNING
Make sure idle speed stopper contacts throt-
tle cam when throttle lever is fully to the rear.
Closed Throttle and Idle Actuator Reset

Perform the closed throttle and idle actuator reset
as described in THROTTLE POSITION SENSOR
(TPS) in ELECTRONIC MANAGEMENT below.
LMR2004-016_05_03A.FM 05-03-7
FUEL DELIVERY
4-TEC FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART
Fuel pump does not run Connect safety lanyard Fuel pump runs
for 2 sec. then stops
Check fuses. Install fuel pressure gauge

Check safety lanyard connection. on fuel pressure line
Check fuel pump operation.
Repair or replace if necessary. Replace fuel
pump module
Connect safety lanyard
Fuel pump runs
Repair or Fuel pressure less Fuel pressure is Fuel pressure more

replace than 303 kPa (44 PSI) 303 kPa (44 PSI) than 303 kPa (44 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 303 kPa (44 PSI) than 303 kPa (44 PSI) 303 kPa (44 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
R1503motr209S
05-03-8 LMR2004-016_05_03A.FM
FUEL PUMP
engine.
Before proceeding to the pressure test ensure the
battery is fully charged. Battery voltage must be
over 12 volts.
Release the fuel pressure in the system using
B.U.D.S. Look in the Activation tab.
 WARNING
The fuel hose may be under pressure. Cover
the fuel line connection with an absorbent
shop rag. Slowly disconnect the fuel hose to F18R08A 2 1
release the pressure. Wipe off any fuel spill- TYPICAL
age inside bilge. 1. Hose disconnected from fuel pump
2. In-line installation of fuel pressure gauge
The pressure test will show the available pressure Install safety lanyard and observe fuel pressure. Do
at the fuel pump outlet. It validates the pressure not crank engine. Repeat twice. Release pressure
regulator, the fuel pump and leaks in the system. using B.U.D.S. between tests so that the gauge is
Ensure there is no leak from hoses and fittings. Re- “reset” to zero (0).
pair any leak.
Ensure there is enough gas in fuel tank. FUEL PRESSURE
(when installing safety lanyard)
To access fuel pump for this test, refer to FUEL
PUMP REPLACEMENT in this section. 303 kPa (44 PSI)
Disconnect outlet hose from fuel pump.
Crank or start engine and observe fuel pressure.
Install fuel pressure gauge (P/N 529 035 591) be- The fuel pressure should be the same as above.
tween disconnected hose (inline installation).
If pressure is within limits, fuel pump and pressure
regulator are working adequately.
A rapid pressure drop indicates leakage either from
the fuel rail or from the fuel pump check valve.
Check fuel rail for leaks. If it is not leaking then re-
place fuel pump.
A slow pressure drop indicates leakage either from
the fuel injector or from the fuel pressure regulator.
Check fuel injector for leaks (see below). If it is not
leaking then replace fuel pump module.
Release fuel pressure in the system using B.U.D.S.
Look in the Activation tab.
Remove pressure gauge and reinstall fuel hose.
 WARNING
F02B0BA Wipe off any fuel spillage in the bilge. Fuel is
FUEL PRESSURE GAUGE (P/N 529 035 591)
flammable and explosive under certain con-
ditions. Always work in a well ventilated area.
Reinstall removed parts.
LMR2004-016_05_03A.FM 05-03-9
FUEL SYSTEM PRESSURIZATION 1 2
 WARNING
Whenever doing any type of repair on boat or
if any components of the fuel system are dis-
connected, a pressure test must be done be-
fore starting engine and/or releasing boat to
customer.
CAUTION: Check fuel line ends for damage. Al-

ways trim damaged end(s) before reinstalla-
tion.
Pressure Test
F21F05A
Proceed as follows:
TYPICAL
– Fill up fuel tank. 1. Pressurized to 34 kPa (5 PSI)
2. Pressure test cap
– Remove fuel cap from chain. Ensure to remove
chain at fuel cap end only. – If pressure is not maintained, locate leak and
repair/replace leaking component. To ease leak
search, spray a solution of soapy water on com-
ponents. Bubbles will indicate leak location.
Check that leak does not come from improperly
sealed hoses.
NOTE: To minimize time of fuel system pressur-
ization, the fuel tank should be quite full. The sys-
tem must maintain a pressure of 34 kPa (5 PSI) for
10 minutes. Never pressurize over 34 kPa (5 PSI).
1
 WARNING
If any leak is found, do not start the engine. Re-
move any fuel leakage. Failure to correct a leak
could lead to an explosion. Do not use electric-
powered tools on boat unless system has been
verified for no leaks.
F21F04A
TYPICAL
Remove pressure test cap and retrieve chain from
1. Remove chain at fuel cap end only
filler neck.
Reconnect chain to fuel cap and firmly tighten fuel
– Place chain in filler neck for later retrieval.
cap into filler neck.
– Thread pressure test cap (P/N 529 035 870) into
filler neck. Electrical Test
– Connect pump gauge tester (P/N 529 021 800 When connecting the safety lanyard to the DESS
from kit P/N 295 500 352) to pressure test cap. post, the fuel pump should run for 2 seconds to
– Pressurize fuel system to 34 kPa (5 PSI). build up the pressure in the system.
If the pump does not work, disconnect the plug
connector from the fuel pump.
05-03-10 LMR2004-016_05_03A.FM
Install a temporary connector to the fuel pump with

1 1
wires long enough to make the connection outside
the bilge and apply voltage (12 V) to this test har-
2 2
ness.
If pump does not run, replace the fuel pump module.
Otherwise, probe terminals A and D of fuel pump 3
connector on vehicle harness side. When installing
safety lanyard, you should read battery voltage for
approximately 2 seconds (then voltage will drop to
approximately 11 V). If battery voltage is read, the
problem can be in harness or in fuel pump connec-
tor. Repair or replace appropriate part.
If battery voltage is not read, probe pin A and bat-
F13F03A
tery ground.
TYPICAL
a. If battery voltage is read, check continuity of cir- 1. Disconnect inlet hose
cuit B-29 going towards ECM ECU. If it is good, 2. Disconnect electrical connector
try a new ECM ECU. 3. Disconnect fuel pump connecting hose
b. If battery voltage is not read, check continuity of Remove fuel pump retaining nuts.
circuit going towards fuse block. If it is good, try Remove fuel pump from fuel tank.
a new fuse block.
Installation
Fuel Pump Replacement For installation, reverse the removal process but
NOTE: Check fuel pump fuse first. pay attention to the following.
Gasket fits on mounting bracket only one way with
Removal gasket tab tell-tale in the up position. Align arrow
Unsnap port and starboard rear seat cushions, lift, of fuel pump with gasket tab.
remove and carefully store for reinstallation. Refer to following illustration for tightening se-
Remove port and starboard rear storage tubs from quence. Torque to 2.5 N•m (22 lbf•in).
deck and carefully store for reinstallation.
3 7
6
8
1 1 5
2 9
13
F13L1WA
TYPICAL 10
1. Remove these screws from port and starboard tubs 4 12
Release the fuel pressure in the system using 11
B.U.D.S. Look in the Activation tab.
Disconnect electrical connector. F04F1QA
Disconnect inlet hose from fuel pump. TIGHTENING SEQUENCE

Disconnect either side of hose connecting fuel Perform a pressure test on fuel tank. Refer to FUEL
pumps. SYSTEM section.
LMR2004-016_05_03A.FM 05-03-11
FUEL RAIL Disconnect wiring harness from the three fuel in-
jectors.
Pressure at fuel rail is supplied and controlled by Cut locking ties and remove the wiring harness
the fuel pump module. Refer to FUEL PUMP for from the fuel rail.
pressure test.
Unscrew rail retaining screws.
Fuel Rail Replacement Gently pull rail up by hand, working each side slightly
Removal at a time.
Pull rail out with fuel injectors.
Remove fuel rail cover from the engine.
Release the fuel pressure in the system using If necessary remove fuel injectors as described
B.U.D.S. Look in the Activation tab. below.
Insert pointed tools each side. Installation
Disconnect fuel hose at the connector. For installation, reverse the removal process but
pay attention to the following.
1 A thin film of injection oil should be applied to O-rings
of fuel injectors to ease installation in intake mani-
fold.
Apply Loctite 243 on rail retaining screws then
torque to 10 N•m (89 lbf•in).
When installing fuel line connector to the fuel rail,
put some oil on the O-ring to ease installation.
 WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.
R1503motr162A FUEL INJECTOR

1. Insert pointed tools each side
Leakage Test
Wrap a rag around the hose end to prevent rail drain- To perform a leakage test, the injectors and fuel
ing. rail have to be removed from the engine. Refer to
REMOVAL in FUEL RAIL REPLACEMENT for the
procedure.
NOTE: Do not detach injectors from the fuel rail.
Reconnect the fuel line and the wiring harness.
Place each injector in a clean bowl.
Install the safety lanyard cap on the DESS post to
activate the fuel pump.
Check for fuel leakage from the injector nozzle.
There should be less than 1 drop per minute. Per-
form the test for 2 minutes.
If not within specification, replace the fuel injec-
tor(s).
R1503motr163A 1 The leakage test is validated when performing the
1. Fuel injector connectors FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section.
05-03-12 LMR2004-016_05_03A.FM
Electrical Test
Safety lanyard must be on DESS post.
Using the vehicle communication kit (VCK) with 1 4
B.U.D.S., energize the fuel injector from the Acti-
vation section.
If the injector does not work, disconnect the plug 2 3
connector from the injector.
R1503motr192A
Install a temporary connector to the injector with
wires long enough to make the connection out- ENGINE CONNECTOR
side the bilge and apply voltage (12 V) to this test
harness. 15 14
This will validate the injector mechanical and elec-
trical operation.
If it does not work, replace it.
Using B.U.D.S., activate injector while probing pin
2 (of injector on harness side) and battery ground.
a. If 12 V is read, check continuity of circuit as per
following table. If it is good, try a new ECM
ECU.
CIRCUIT NUMBER INJECTOR R1503motr193A
33
(ECM ECU connector “A“) NUMBER
ECM ECU CONNECTOR
A-15 1
A-33 2 COMPONENT CONTACT LOCATION
A-14 3 Fuel injector 1 (engine connector) and A-15
cylinder 1 (ECM ECU connector)
b. If it does not read 12 V, check continuity of cir-
cuit as per following table. If it is good, try a new Fuel injector 2 (engine connector) and A-33
VCM.
Fuel injector 3 (engine connector) and A-14
CIRCUIT NUMBER INJECTOR
(fuse block connector “B“) NUMBER
B-C 1 The resistance should be between 11.4 and 12.6 Ω .
B-D 2 If resistance value is correct, try a new ECM ECU.
B-G 3 Refer to ECM ECU REPLACEMENT procedures
elsewhere in this section.
Otherwise, check the resistance of the fuel injec- If resistance value is incorrect, repair the wiring
tor circuit. harness/connectors or replace the wiring harness
Reconnect the injector and disconnect the ECM between ECM ECU plug connector and fuel injector.
ECU connector A ECM ECU.
Using a multimeter, check resistance value be-
tween terminals as follows.
LMR2004-016_05_03A.FM 05-03-13
Fuel Injector Replacement ELECTRONIC MANAGEMENT

Removal
ECM ECU AND VCM
Before removing the injectors, the fuel rail has to
be removed from the engine. Refer to REMOVAL
REPLACEMENT
in FUEL RAIL REPLACEMENT for the procedure. General
3 2 Prior to replacing a suspected ECM ECU or VCM,
ensure that all the recommendations in the gener-
al introduction of this section have been followed.
IMPORTANT: When the ECM ECU is replaced,
the safety lanyard(s) and the Closed Throttle and
Idle Actuator must be reprogrammed/reset. Re-
fer to their specific section for adjustment.
To allow transferring previously recorded informa-
tion from the old ECM ECU to the new one, use
the vehicle communication kit (VCK) with B.U.D.S.
R1503motr164A 1 Use Replace ECM in the ECU menu. Follow in-
FUEL RAIL ASS’Y structions in its Help system.
1. Fuel injector NOTE: If the old ECM ECU is working, it must be
2. Injector clip
3. O-ring read inside B.U.D.S. prior to removing it from the
vehicle to carry vehicle information and history to
Then remove the injector clip. Now the fuel injec- the new ECM ECU.
tor can be easily pulled out of the fuel rail.
Installation ECM ECU Replacement
For the installation, reverse the removal proce- Disconnect battery cables.
dure. Pay attention to the following details:
Install new O-rings, if you reinstall a used injector  WARNING
then insert the fuel injector in place with your Battery BLACK negative cable must always
hand. Do not use any tool. Ensure clip and injector be disconnected first and connected last.
are properly installed.
NOTE: A thin film of engine oil should be applied Disconnect both ECM ECU connectors from ECM
to O-rings to ease insertion in rail. ECU.
Apply Loctite 243 on rail retaining screws then 2 1
torque to 10 N•m (89 lbf•in).
 WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.
R1503motr180A 2
1. ECM ECU
2. Retaining screws
05-03-14 LMR2004-016_05_03A.FM
Unscrew all retaining screws and remove the en- ENGINE WIRING HARNESS
gine ECM ECU from intake manifold.
Install the new ECM ECU to the engine. 4 5 6 8 7 10
Reconnect ECM ECU connectors to ECM ECU 9
then battery cables.
3 11
Transfer the data from the previous ECM ECU to
2
the new one using B.U.D.S. then proceed with the
required resets and reprogram safety lanyard(s), if
you were unable to transfer the data. 1
NOTE: If data cannot be transferred, manually en- 20

ter information in Vehicle tab.
12
After performing the required resets, ensure to 19
clear all faults from the newly replaced ECM ECU. 13
18
Start the engine and increase engine speed above 17 14
16 15
5000 RPM to be sure no fault appears. R1503motr199A
1.ECM ECU connector

VCM Replacement 2.CTS connector
3.EGT connector
4.CAPS connector
Disconnect battery cables. 5.Fuel injector connector (cylinder 1)
6.Ignition coil connector (cylinder 1)
 WARNING 7.Fuel injector connector (cylinder 2)
8.Ignition coil connector (cylinder 2)
9.Fuel injector connector (cylinder 3)
Battery BLACK negative cable must always 10. Ignition coil connector (cylinder 3)
be disconnected first and connected last. 11. TOPS valve connector
12. OSPS connector
13. TPS connector
14. Idle bypass valve connector
15. MATS connector
16. Engine connector
17. MAPS connector
18. OPS connector
19. KS connector
20. CPS connector
Resistance Test
Check continuity of the circuits according to the
wiring diagram in the WIRING DIAGRAMS section
of this manual.
If wiring harness is good, check the respective
sensor/actuator as described in this section.
Otherwise, repair the connectors, replace the wir-
F04H7AA ing harness or the ECM ECU/VCM as diagnosed.
TYPICAL
Pull VCM out.

Install the new VCM in vehicle.
LMR2004-016_05_03A.FM 05-03-15
Removal Lead the cable bundle with the injector and igni-
tion coil connectors to the fuel rail and fix it also by
Remove fuel rail cover.
using 4 locking ties.
Disconnect the wiring harness from all sensors/
actuators. 1 1
Disconnect the ECM ECU connector from the ECM
ECU.
Cut all tie raps which are holding the wiring harness
in position.
R1503motr202A
1. Locking ties
Connect the fuel injectors, ignition coils, CAPS,

CTS and EGT to the wiring harness.
 WARNING
1 Pay attention not to mix injectors or ignition
R1503motr200A
coils wires between cylinders. The location of
the splice connectors indicate which cylinder
1. Wiring harness
wires belong to.
Remove complete wiring harness.
Install the engine connector on the appropriate
Installation bracket on the wiring support.
First connect the ECM ECU connector A to the ECM Then fix the other bundle on the appropriate sup-
ECU and fix the harness on the wiring support with ports on the wiring support and the ECM ECU
a locking tie. bracket with locking ties.
1
R1503motr203A
R1503motr201A 1
1. Locking ties
1. Locking tie
05-03-16 LMR2004-016_05_03A.FM
Connect the CPS, KS, OPS, and the MAPS to the IMPORTANT: Prior to testing the TPS, ensure that
wiring harness. mechanical components/adjustments are adequate
Also connect now the MATS, TPS, OSPS, idle by- according to THROTTLE BODY in AIR INDUCTION
pass and TOPS valve to the wiring harness. SYSTEM above.
Fix the wiring for the MATS with a locking tie to The ECM may generate several fault codes per-
support the cables. taining to the TPS. Refer to SYSTEM FAULT
CODES in DIAGNOSTIC PROCEDURES section
for more information.
Wear Test
While engine is not running, activate throttle and
pay attention for smooth operation without physi-
cal stops of the cable.
Using the vehicle communication kit (VCK) with
B.U.D.S., use the Throttle Opening display under
Monitoring.
Slowly and regularly move the throttle. Observe
the needle movement. It must change gradually
and regularly as you move the throttle. If the nee-
dle “sticks”, bounces, suddenly drops or if any dis-
R1503motr204A 1 crepancy between the throttle movement and the
needle movement is noticed, it indicates a worn
1. Locking tie
TPS that needs to be replaced.
Install all remaining parts, which have been re-
moved. Voltage Test
Check the voltage output from ECM ECU to the
THROTTLE POSITION SENSOR desired throttle position sensor.
(TPS)
General
The throttle position sensor (TPS) is a potentiom-
eter that sends a signal to the ECM ECU which is
proportional to the throttle shaft angle. 3
1
2
R1503motr167A
TPS
Disconnect plug connector from throttle position

sensor. To unlock connector, insert a small screw-
driver between the folded tab. To see the connec-
tor pin-out, temporarily remove the connector
R1503motr165A
shield joining the harness, to expose the pin num-
bers. Connect a voltmeter between pin 1 and 3 and
1. Throttle position sensor (TPS) also between pin 1 and 2 in the wiring harness.
LMR2004-016_05_03A.FM 05-03-17
Remove and reinstall the safety lanyard to activate Now check the resistance with the throttle plate
the ECM ECU. in wide open position.
Check the voltage readings as follows. The resistance should be 2600 - 2700 Ω .
CONNECTION VOLTAGE NOTE: When measuring between pins A-24 and
A-39, resistance value decreases while depress-
Pin 1 with engine ground 0V ing throttle lever. When measuring between pins
Pin 2 with engine ground 5V A-24 and A-25, resistance value increases while
Pin 3 with engine ground 4.75 - 5 V depressing throttle lever. The resistance value
should change smoothly and proportionally to
If voltage test is good, replace the TPS. throttle movement. Otherwise, replace TPS.
If voltage test is not good, check the resistance of If resistance values are correct, try a new ECM ECU.
the TPS circuit. Refer to ECM ECU REPLACEMENT procedures
Resistance Test If resistance values are incorrect, repair connector
Reconnect the TPS. or replace the wiring harness between ECM ECU
connector and the TPS.
Disconnect the ECM ECU connector A on the ECM
ECU. Replacement
25 24 Remove the throttle body as described above.
Loosen two screws retaining the TPS.
Remove TPS.
1
R1503motr191A
39
Using a multimeter, check resistance value be-

tween terminal A-25 and A-39.
The resistance should be 1600 - 2400 Ω .
Check the resistance between terminal A-24 and
R1503motr168A 2
terminal A-39 with the throttle plate in idle posi-
tion. THROTTLE BODY
1. Throttle position sensor (TPS)
The resistance should be approximately 2500 Ω . 2. Screws
Check the resistance between terminal A-24 and Apply Loctite 243 on screw threads, install the new
terminal A-39 with the throttle plate in wide open TPS.
position.
Reinstall remaining removed parts.
Proceed with the closed throttle and idle actuator
Check the resistance between terminal A-24 and reset. See below.
A-25 with throttle plate in idle position.
05-03-18 LMR2004-016_05_03A.FM
Closed Throttle and Idle Actuator Reset Resistance Test

NOTE: This operation performs a reset of the val- Disconnect idle bypass valve from the wiring har-
ues in the ECM ECU. ness.
This reset is very important. The setting of the TPS Using a multimeter, check the resistance in both
will determine the basic parameters for all fuel windings.
mapping and several ECM ECU calculations and Check the resistance between pin A and pin D and
the setting of the idle bypass valve will determine also between pin C ad pin B of the idle bypass
the basic parameters for the idle speed control of valve.
the engine.
The resistance in each winding should be approx-
NOTE: Reset must be done each time the throttle imately 50 Ω at 23°C (73°F).
position sensor (TPS) or the idle bypass valve is
loosened or removed or throttle body is replaced If the resistance of one or both windings is not
or ECM ECU is replaced. good, replace the idle bypass valve.
CAUTION: An improperly set TPS or idle by- If resistance test of valve windings is good, check
pass valve may lead to poor engine perfor- continuity of circuits A-35, A-36, A-37, A-38.
mance and emission compliance could possi- Visual Inspection
bly be affected.
Remove idle bypass valve from throttle body.
Use the vehicle communication kit (VCK) with
Check the piston and bypass channel for dirt/
B.U.D.S. to perform this adjustment.
deposits which can cause a sticking piston.
Ensure the throttle body plate stop lever rests
CAUTION: Do not try to operate the piston of the
against its stopper. Open throttle approximately
idle bypass valve when it is dismounted. Also do
one quarter then quickly release. Repeat 2 - 3
not move the piston by hand. The screw drive is
times to settle throttle plate. If stopper does not
very sensitive and will be destroyed.
rest against its stop lever, perform throttle cable
adjustment. Refer to THROTTLE BODY in AIR IN- Clean the parts and install the idle bypass valve on
DUCTION SYSTEM above. the throttle body.
Push the Reset button in the Setting section of Proceed with the closed throttle and idle actuator
B.U.D.S. reset. See above.
NOTE: No message will be displayed if operation
is good. If operation is wrong, an error message CRANKSHAFT POSITION
will be displayed. SENSOR (CPS)
NOTE: There is no idle speed adjustment to per-
form. The ECM ECU takes care of that. If TPS is 1
not within the allowed range while resetting the
Closed Throttle and Idle Actuator, the ECM ECU
will generate a fault code and will not accept the
setting.
Start engine and make sure it operates normally
through its full engine RPM range. If fault codes ap-
pear, refer to SYSTEM FAULT CODES in DIAGNOS-
TIC PROCEDURES section for more information.
IDLE BYPASS VALVE

An idle bypass valve with good resistance mea-
surement can still be faulty. It is also possible that
a mechanical failure occurs which is not detect-
R1503motr169A
able without measuring the air flow. Replacing the
idle bypass valve may be necessary as a test. 1. CPS connector
LMR2004-016_05_03A.FM 05-03-19
NOTE: Take into account that a CPS fault can be Replacement

triggered by bent or missing encoder wheel teeth.
Disconnect connectors and remove the PTO cov-
First check fault codes then check the teeth con-
er. Refer to PTO HOUSING/MAGNETO in ENGINE
dition if necessary. See below.
section.
Disconnect CPS wiring harness connector. Probe
Remove CPS.
terminals coming from CPS while cranking en-
gine. Voltage should be within 1-2 Vac. Otherwise, 1
inspect wiring and replace CPS if wiring is good.
Resistance Test
Disconnect the CPS plug connector from the wiring
harness and check the resistance of the sensor itself.
The resistance should be between 190 Ω and 290 Ω .
Otherwise, replace the CPS.
If resistance tests good, reconnect the CPS and
disconnect the ECM ECU connector A on the ECM
ECU.
5
R1503motr170A
1. CPS inside PTO cover
Apply Loctite 243 on screw threads then install the

new CPS. Torque to 10 N•m (89 lbf•in).
Encoder Wheel Inspection

To check the encoder wheel for bent teeth, pro-
R1503motr182A
19 ceed as follows.
Using a multimeter, recheck resistance value be- Remove PTO cover. Refer to PTO HOUSING/
MAGNETO in ENGINE section.
tween terminals 5 and 19.
Install a dial indicator on crankcase casting. Posi-
If resistance value is correct, try a new ECM ECU. tion the gauge on a tooth and set it to zero (0).
Refer to ECM ECU REPLACEMENT procedures Rotate flywheel and check needle movement. The
elsewhere in this section. maximum allowed difference between teeth is
If resistance value is incorrect, repair the connec- 0.15 mm (.006 in). Otherwise, straighten the tooth
tors or replace the wiring harness between ECM or replace the encoder wheel.
ECU connector and the MATS.
05-03-20 LMR2004-016_05_03A.FM
Probe pin 3 of CAPS connector (wiring harness

2
side) and battery ground.
a. If 12 V is read, check continuity of circuits A-20
and A-34. If they test good, perform the CAPS
voltage test as explained below. If CAPS tests
good, try a new ECM ECU.
20
R1503motr177A 1
1. Encoder wheel
R1503motr183A
34
2. Dial indicator
ECM ECU CONNECTOR
Properly reinstall cover.
b. If 12 V is not read, check continuity of connector B,
CAMSHAFT POSITION SENSOR pin A of engine fuse block to the CAPS. If it tests
good, try a new engine fuse block. Otherwise, re-
(CAPS) pair wiring harness.
Remove the CAPS from the cylinder head.
Set up the following electric circuit to perform the
voltage test.
3 2 1
R1503motr178A 1
1. CAPS
Voltage Test (harness)

Disconnect the connector from the wiring harness.
R1503motr184A
To see the connector pin-out, temporarily remove
the connector shield joining the harness, to ex- CAPS PIN-OUT
pose the pin numbers.
Remove and reinstall safety lanyard to activate the
system.
LMR2004-016_05_03A.FM 05-03-21
1200 W Voltmeter MANIFOLD AIR TEMPERATURE

V SENSOR (MATS)
+
3 2 1
12 V CAPS
-
R1503motr208A
Touch the CAPS with a conductor (ex.: screwdriver)

and look if the voltage at the multimeter switches
from 12 V to less than 1 V. R1503motr171A 1
INTAKE MANIFOLD
2 V
1. Manifold air temperature sensor (MATS)
Resistance Test
Disconnect the plug connector from the MATS
and check the resistance of the sensor itself.
The resistance should be between 2280 Ω and
2740 Ω at 20°C (68°F).
Otherwise, replace the MATS.
If resistance tests good, reconnect the MATS and
disconnect the ECM ECU connector A on the ECM
ECU.
1 Pin 1 Pin 2 Pin 3

R1503motr207A 1200 W resistor
1. CAPS
2. Conductor
If the voltage is not good, replace the CAPS.
Replacement
Unscrew the retaining screw and replace the
21
CAPS. Ensure to reinstall O-ring. R1503motr186A
Apply Loctite 243 (blue) on thread and torque to Using a multimeter, recheck resistance value be-
6 N•m (53 lbf•in). tween terminals 7 and 21.
If resistance value is correct, try a new ECM ECU.
Refer to ECM ECU REPLACEMENT procedures
If resistance value is incorrect, repair the connec-
tors or replace the wiring harness between ECM
ECU connector and the MATS.
05-03-22 LMR2004-016_05_03A.FM
Replacement If resistance value is correct, try a new ECM ECU.

Disconnect the connector of the MATS.
Screw MATS out and install the new one. Torque
If resistance value is incorrect, repair the connec-
to 18 N•m (159 lbf•in).
tors or replace the wiring harness between ECM
ECU connector and the CTS.
COOLANT TEMPERATURE
SENSOR (CTS) Replacement
Remove the fuel rail cover.
Disconnect CTS connector and remove CTS.
Install the new CTS and torque to 18 N•m (159 lbf•in).
MANIFOLD AIR PRESSURE

SENSOR (MAPS)
R1503motr172A 1
1. Coolant temperature sensor (CTS)
Resistance Test
Disconnect the plug connector from the CTS and
check the resistance of the sensor itself.
The resistance should be between 2280 Ω and
2740 Ω at 20°C (68°F).
Otherwise, replace the CTS. R1503motr173A 1
1. Manifold air pressure sensor (MAPS)
If resistance tests good, reconnect the CTS and
disconnect the ECM ECU connector A on the ECM NOTE: This sensor is a dual function device. When
ECU. engine is started and it runs at idle speed, the sen-
sor takes the atmospheric pressure and stores it in
11 the ECM ECU. Thereafter, it takes the manifold air
pressure at operating RPMs.
Ensure sensor is correctly installed on intake man-
ifold. Otherwise, the MAPS could generate a fault
code for an unexpected sensor range at idle when
it reads the atmospheric 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.
R1503motr187A
27
Using a multimeter, recheck resistance value be-

tween terminals 11 and 27.
LMR2004-016_05_03A.FM 05-03-23
Voltage Test Resistance Test

Check the voltage output from ECM ECU to the Disconnect the plug connector from the EGT and
manifold air pressure sensor (MAPS). check the resistance of the sensor itself.
Disconnect plug connector from maps and con- The resistance should be between 2280 Ω and
nect a voltmeter between pin 1 and 3 and also 2740 Ω at 20°C (68°F).
between pin 1 and 2 of wiring harness. Otherwise, replace the EGT.
Remove and reinstall the safety lanyard to activate If resistance tests good, reconnect the EGT and
the ECM ECU. There should be 5 Vdc in each test. disconnect the ECM ECU connector A on the ECM
If voltage test is good, replace the MAPS. ECU.
If voltage test is not good, check the continuity of Using a multimeter, recheck resistance value be-
the MAPS circuit. tween terminals 10 and 26.
If resistance value is correct, try a new ECM ECU.
Resistance Test Refer to ECM ECU replacement procedures else-
Disconnect the ECM ECU connector A on the ECM where in this section.
ECU. If resistance value is incorrect, repair the connec-
Using a multimeter, check continuity of circuits 12, tor or replace the wiring harness between ECM
28 and 40. ECU connector and the EGT.
If wiring harness is good, try a new ECM ECU.
Refer to ECM ECU REPLACEMENT procedures Replacement
elsewhere in this section. Disconnect EGT connector and remove EGT.
Otherwise, repair the connectors or replace the Apply Loctite 518 on threads of the EGT then in-
wiring harness between ECM ECU connector and
stall.
the MAPS.
Replug connector.
Replacement
Disconnect MAPS connector and remove the MAPS. KNOCK SENSOR (KS)
Install the new MAPS paying attention to index its
tab into the adaptor notch. Apply Loctite 243 (blue)
on screw then torque to 10 N•m (89 lbf•in).
EXHAUST GAS TEMPERATURE

SENSOR (EGT)
1 2
R1503motr174A 1
1. Knock sensor (KS)
F18D2IA
TYPICAL
1. Muffler
2. Exhaust gas temperature sensor (EGT)
05-03-24 LMR2004-016_05_03A.FM
Dynamic Test Replacement

Using the vehicle communication kit (VCK) with Remove the intake manifold. Refer to INTAKE
B.U.D.S., monitor the knock sensor using the Faults MANIFOLD REPLACEMENT in INTAKE section.
section. Unscrew and remove knock sensor.
Start the engine and bring engine RPM above Clean contact surface, apply Loctite 243 in thread-
5000 RPM. If no fault code occurs, the knock sen- ed hole then install the new knock sensor.
sor is good.
Torque screw to 24 N•m (18 lbf•ft).
Otherwise, do the following.
CAUTION: Improper torque might prevent sen-
Ensure sensor and head contact surfaces are sor to work properly and lead to severe damage
clean and mounting bolt and washer are correct of internal engine components.
and properly torqued down.
Replug connector.
NOTE: It is necessary to remove intake manifold
to inspect contact surfaces. Refer to INTAKE SYS-
TEM section. OIL PRESSURE SWITCH (OPS)
Check the knock sensor resistance.
Disconnect the connector from knock sensor har-
ness.
Static Resistance Test

Using a multimeter, check the resistance between
both terminals on the knock sensor harness side.
The resistance should be approximately 5 MΩ .
If resistance is not good, replace knock sensor.
If resistance is good, reconnect the knock sensor
connector and disconnect the ECM ECU connec-
tor A from the ECM ECU.
9 R1503motr194A 1
1. OPS
Oil Pressure Test

To check the function of the oil pressure switch, an
oil pressure test has to be performed. Refer to OIL
PRESSURE TEST in LUBRICATION SYSTEM sec-
tion.
If the engine oil pressure is out of specifications,
check the points described in TROUBLESHOOT-
R1503motr188A
23 ING section.
If the engine oil pressure is good, check the resis-
Using a multimeter, recheck resistance value be- tance of the OPS while engine is off and while en-
tween terminals 9 and 23. gine is running.
If wiring harness is good, try a new ECM ECU. Refer
to ECM ECU REPLACEMENT procedures else-
where in this section.
Otherwise, repair the connector or replace the wir-
ing harness between ECM ECU connector and
knock sensor.
LMR2004-016_05_03A.FM 05-03-25
Resistance Test OIL SEPARATOR PRESSURE

Disconnect the plug connector from the OPS and SWITCH (OSPS)
use a multimeter to check the resistance between
OPS pin and engine ground while engine is
stopped (without oil pressure) and while engine is
running (with oil pressure).
When engine is stopped the resistance is infinitely
high (normally open switch).
When engine is running and the oil pressure reach-
es 180 - 220 kPa (26 - 32 PSI), the resistance of
the OPS is close to 0 Ω .
If resistance values are incorrect, replace OPS.
If the values are correct, check the continuity of
the wiring harness. 1
Disconnect the ECM ECU connector A from the
ECM ECU and check continuity of circuit 6.
6
R1503motr189A
1. OSPS
TOPS Pressure Test
 WARNING
The TOPS system might be pressurized. When
the TOPS valve is disconnected from the wir-
ing harness, never open the oil filler cap. Stop
R1503motr195A the engine and wait at least 30 seconds before
opening it, to release the pressure.
If wiring harness is good, try a new ECM ECU. Refer
to ECM ECU REPLACEMENT procedures else- To check the function of the oil separator pressure
where in this section. switch, disconnect the TOPS valve and perform a
Otherwise, repair the connector or replace the wir- TOPS pressure test. Refer to TOPS PRESSURE
ing harness between ECM ECU connector and OPS. TEST in LUBRICATION SYSTEM section.
If the engine blow-by pressure does not reach
40 kPa (6 PSI), check the points described in the
illustration shown on following page.
Otherwise, check the resistance of the OSPS
while engine is off and while engine is running.
05-03-26 LMR2004-016_05_03A.FM
Resistance Test
Disconnect the plug connector from the OSPS and
use a multimeter to check the resistance between
OSPS pin and engine ground while engine is
stopped (without blow-by pressure) and while en-
gine is running (with blow-by pressure).
When engine is stopped and the blow-by pressure
is released, the resistance of the OPS is close to
0 Ω (normally closed switch).
When engine is running and the blow-by pressure
exceeds 40 kPa (6 PSI), the resistance is infinitely
high.
If resistance values are incorrect, replace OSPS.
If the values are correct, check the continuity of
the wiring harness.
Disconnect the ECM ECU connector A from the
ECM ECU and check continuity of circuit 31.
R1503motr198A
31
If wiring harness is good, try a new ECM ECU.

Otherwise, repair the connector or replace the wir-
ing harness between ECM ECU connector and OPS.
LMR2004-016_05_03A.FM 05-03-27
TOPS VALVE (blow-by)
TOPS DIAGNOSTIC FLOW CHART

Connect safety
lanyard
Repair or
TOPS valve opens No replace
(short knocking noise)
Yes
Check Fails
wiring harness
Install oil pressure gauge
on oil dipstick tube
OK
Lower than 8 V
Check output voltage
Start engine on wiring harness
Greater than 8 V
No
Pressure drops Pressure stays below
down directly after 40 kPa (5.8 PSI) for 10 min. Replace Check fuse 1 on
reaching 40 kPa (5.8 PSI) (TOPS valve is open) TOPS valve engine fuse block
(TOPS valve opens again)
Yes Retest
No
Yes No
Working ?
Check OK
OSPS Yes Try a new
ECM ECU
Fails
Fails
Replace TOPS OK
Retest OK Retest
OSPS
R1503motr275S
05-03-28 LMR2004-016_05_03A.FM
The valve is turned on as soon as safety lanyard is

installed on its post. The valve opening allows ven-
tilation of crankcase.
The OSPS monitors the pressure to detect a mal-
function of this valve. If pressure rises above a pre-
set threshold, the valve is re-energized again and
if it fails, a fault code is generated.
1 1
2
3
R1503motr181A 4
1. Solenoid valve
2. Spring
3. Valve disc
4. Retaining washer
 WARNING
The spring on the TOPS valve is tensioned and
can shoot away the valve disc. Hold the valve
disc with fingers while removing the washer.
Remove the valve disc and the spring on the bot-

tom of the TOPS valve after removing the retain-
R1503motr179A
ing washer.
1. TOPS valve Unscrew and remove the TOPS valve.
Resistance Test Install the new valve with new gasket. Apply Loc-
tite 243 (blue) on threads and torque to 10 N•m
Disconnect the plug connector from the TOPS (89 lbf•in).
valve and check the resistance of the solenoid it-
self. Reinstall remaining removed parts.
The resistance should be between 1.27 Ω and
2.47 Ω . IGNITION COILS
Otherwise, replace the TOPS valve.
1
Dynamic Test
Activate the TOPS valve by installing the safety lan-
yard on the DESS post.
If you can hear the movement of the piston (knock-
ing), the valve works fine, otherwise follow the pro-
cedure shown in the chart on preceeding page.
TOPS Valve Replacement

Disconnect the wiring harness from the TOPS valve.
Remove the oil separator cover. Refer to OIL SEPA-
RATOR REPLACEMENT in the LUBRICATION SYS-
R1503motr175A
TEM section.
1. Ignition coil
LMR2004-016_05_03A.FM 05-03-29
NOTE: The engine fuse block energizes the pri- The voltage should be 12 V.
mary side of each ignition coil individually. If 12 V is NOT read, check continuity of circuits B-C,
Using the vehicle communication kit (VCK) with B-D, B-G of fuse block and fuse 2, 4 and 5 of en-
B.U.D.S., energize the ignition coil from the Acti- gine fuse block. If it tests good, try a new fuse
vation section. block.
You should hear the spark occurring. In doubt, use If 12 V is read, disconnect the ECM ECU connec-
an inductive spark tester or a sealed tester – avail- tor A from the ECM ECU and check the continuity
able from after-market tool/equipment suppliers – of appropriate circuit 41 (cylinder 1), 1 (cylinder 2)
to prevent spark occurring in the bilge. Otherwise, or 29 (cylinder 3).
perform the following checks.
An ignition coil with good resistance measure- 1
ment can still be faulty. Voltage leak can occur at
high voltage level which is not detectable with an
ohmmeter. Replacing the ignition coil may be nec-
essary as a test.
 WARNING
Never make a spark test with spark plug re-
moved. Flammable vapors may be present in
the bilge and ignited by a spark which could
cause an explosion. R1503motr190A
41 29
ECM ECU CONNECTOR
Voltage Test If wiring harness is defective, repair the connector
or replace the wiring harness between ECM ECU
 WARNING connector and the ignition coil.
When disconnecting coil from spark plug, al- If wiring harness is good, test resistance of prima-
ways disconnect coil from main harness first. ry and secondary winding of ignition coil.
Never check for engine ignition spark from an
open coil and/or spark plug in the engine Resistance Test
compartment as spark may cause fuel vapor
to ignite. CAUTION: Do not remove the ignition coil be-
fore disconnecting the connector, or the wires
Disconnect the plug connector from the ignition will be damaged. Do not pry up ignition coil
coil and check the voltage supplied by the engine with a screwdriver to avoid damage.
fuse block. Remove ignition coil from spark plug.
1 1
1 R1503motr197A
2
2
1. Spark plug terminal
R1503motr196A
Using a multimeter, check the resistance in both
primary and secondary windings.
Install safety lanyard on the DESS post. For primary winding check the resistance between
Check voltage between terminal 2 of ignition coil pin 1 and pin 2 of the ignition coil.
connector on the wiring harness and battery ground. The resistance should be between 0.85 and 1.15 Ω
at 20°C (68°F).
05-03-30 LMR2004-016_05_03A.FM
For secondary winding check the resistance be- Measure resistance, it must be an open circuit
tween pin 1 and spark plug terminal. (switch is normally open). Depress and hold switch,
The resistance should be between 9.5 and 13.5 kΩ the ohmmeter should read lower than 200 ohms.
at 20°C (68°F). Otherwise, replace switch. Reconnect connector.
If the resistance of one of both windings is not Test continuity of circuit A-7 of engine fuse block.
good, replace the defective ignition coil. If it is good, try a new engine fuse block. Other-
wise, repair harness/connectors.
If the windings test good, try a new engine ECM
ECU. Test continuity of circuit B-19 of ECM ECU. If it is
good, try a new ECM ECU. Otherwise, repair harness/
NOTE: Prior to inserting the ignition coil to its lo- connectors.
cation, apply some silicone lubricant (P/N 293 600
041) around the seal area that touches the spark
plug hole. After installation, ensure the seal seats SAFETY LANYARD SWITCH
properly with engine top surface. VERIFICATION
If 2 short beeps are not heard when installing the
 WARNING safety lanyard, refer to DIAGNOSTIC PROCE-
Always reconnect ignition coil cables at the DURES.
same spark plugs where they come from. The following continuity tests can also be performed
Otherwise, severe backfire may occur with using an ohmmeter.
possible damage to exhaust system compo-
nents. The genuine wiring harness is de- Disconnect switch wires.
signed to prevent a cable mixing by using dif- Safety Lanyard Removed
ferent cable lengths.
Connect test probes to switch BLACK and BLACK/
YELLOW wires. Measure resistance, there should
TDC SETTING (Top Dead Center) be NO continuity (open circuit).
The ECM is able to determine the exact position Connect one test probe to the WHITE/GRAY wire
of camshaft and crankshaft. That means that no and the other test probe to the switch top terminal.
TDC setting has to be performed. It is used for Measure resistance, it must be close to 0 ohm.
both injection and ignition timings. Connect one test probe to the BLACK wire and the
other test probe to the switch ring. Measure resis-
ENGINE START/STOP SWITCH tance, it must be close to 0 ohm.
VERIFICATION
SPARK PLUGS
A quick operation test can be done using the vehicle
communication kit (VCK) with B.U.D.S., using the Disassembly
Monitoring section. Press the start button and look
at the start button LED. It should turn on, indicating
the starting system is working on the input side of
 WARNING
Never remove ignition coil from the spark
the starting system (start button, engine fuse block,
plug without disconnecting it from the wiring
ECM ECU and wiring). You know now the problem
harness. Flammable vapors may be present
is on the output side of the starting system (VCM
in the bilge and ignited by a spark which
output signal to starting solenoid, wiring harness go-
could cause an explosion.
ing to the solenoid and starter motor. Refer to
STARTING SYSTEM for testing procedures). Other- Disconnect the wiring harness from the ignition
wise, check the input side as follows. coil.
Disconnect the start/stop switch connector. Using Remove the ignition coil.
an ohmmeter, connect test probes to YELLOW/
RED and PURPLE wires. First unscrew the spark plug one turn.
Clean the spark plug and cylinder head with pres-
surized air then completely unscrew.
LMR2004-016_05_03A.FM 05-03-31
Spark Plug Installation

Prior to installation make sure that contact surfac-
es of the cylinder head and spark plug are free of
grime.
1. Using a wire feeler gauge, set electrode gap ac-
cording to the following chart.
2. Apply anti-seize lubricant over the spark plug
threads to prevent possible seizure.
3. Hand screw spark plug into cylinder head. Then,
tighten the spark plug clockwise an additional
1/4 turn with a proper socket.
1 2
A00E0BA
1. Proper socket
2. Improper socket
SPARK GAP
ENGINE TORQUE
PLUG mm (in)
Hand tighten
1503 NGK + 1/4 turn 0.6
4-TEC DCPR8-E with (.24)
a socket
CRANKING SYSTEM
See above for start/stop switch and the DESS post
testing. Refer to STARTING SYSTEM section for
other tests.
05-03-32 LMR2004-016_05_03A.FM
Subsection 04 (DIAGNOSTIC PROCEDURES)
DIAGNOSTIC PROCEDURES 0
GENERAL Terminology
NOTE: This procedure to be performed for each Some documents or software use technical terms
engine. that may be different from the ones used in this
manual. The following table will help find the equiv-
Here is the basic order suggested to diagnose a alence.
suspected engine management or fuel injection
related problem: TERMS USED IN
TERMS USED
– Check the chart in TROUBLESHOOTING sec- OTHER DOCUMENTS/
IN THIS MANUAL
tion to have an overview of problems and sug- SOFTWARES
gested solutions. MAPS
APS
– Check all fuses. (manifold air pressure
(air pressure sensor)
sensor)
– Check fuel rail pressure.
– Check spark plug condition. MATS
ATS
(manifold air
– Check fuel pump pressure. (air temperature sensor)
temperature sensor)
– Check all connections of the wiring harness.
CTS WTS
– Refer to COMPONENT INSPECTION AND AD- (coolant temperature (water temperature
JUSTMENT section for procedures. sensor) sensor)
EGT ETS
(exhaust gas (exhaust temperature
temperature) sensor)
TOPS valve
(tip-over protection Blow-by valve
system)
- DLA
(digital linear actuator)
Idle bypass valve
- Idle actuator
- Idle valve
OSPS OTPS
(oil separator pressure (oil tank pressure
switch) switch)
Safety lanyard Key
LMR2004-017_05_04A.FM 05-04-1
SELF-DIAGNOSTIC MODE
Refer to the following chart. For other problems, refer to COMPONENT INSPECTION AND ADJUSTMENT
section.
CODED SIGNALS POSSIBLE CAUSE REMEDY

2 short beeps • Confirms safety lanyard signal operation. Engine can be started.
(while installing • Safety lanyard is recognized by the ECM ECU.
safety lanyard on
post). • Good contact between safety lanyard and
DESS post.
1 long beep • Bad DESS system connection. Reinstall safety lanyard cap correctly over
(while installing post.
safety lanyard on • Wrong safety lanyard. Use a safety lanyard that has been pro-
post). grammed for the sport boat. If it does not
work, check safety lanyard condition with
B.U.D.S. Replace safety lanyard if reported
defective.
• Defective safety lanyard. Use another programmed safety lanyard.
• Dried salt water or dirt in safety lanyard cap. Clean safety lanyard cap to remove salt
water.
• Defective DESS post. Refer to ENGINE MANAGEMENT section.
• Improper operation of ECM ECU or defective Refer to ENGINE MANAGEMENT section.
wiring harness.
4 very short beeps • Safety lanyard has been left on its post with- To prevent battery discharge, remove the
every 3 seconds out starting engine or after engine was safety lanyard from its post.
interval for 10 min. stopped.
A 2 seconds beep • High pressure in oil separator tank. Refer to LUBRICATION SYSTEM section.
every minute
interval.
A 2 seconds beep • Engine coolant temperature sensor or circuit Refer to ENGINE MANAGEMENT section.
every 15 minutes malfunction.
interval. • Exhaust temperature sensor or circuit mal- Refer to ENGINE MANAGEMENT section.
function.
• Engine oil pressure sensor or circuit malfunc- Refer to ENGINE MANAGEMENT section.
tion.
• Low pressure in oil separator tank (engine oil Refer to ENGINE MANAGEMENT section.
leak).
• TOPS valve solenoid or circuit malfunction. Refer to ENGINE MANAGEMENT section.
• ECM ECU failure. Refer to ENGINE MANAGEMENT section.
• Starter solenoid circuit malfunction. Refer to ENGINE MANAGEMENT section.
• Communication link fault detected by VCM. Refer to ENGINE MANAGEMENT section.
• ECM ECU communication link message miss- Refer to ENGINE MANAGEMENT section.
ing (detected by VCM).
Continuous beeps. • High engine temperature coolant. Refer to COOLING SYSTEM.
• High exhaust temperature. Refer to COOLING SYSTEM.
05-04-2 LMR2004-017_05_04A.FM
VCK
(Vehicle Communication Kit)
kW2000
The VCK (Vehicle Communication Kit) (P/N 529
035 844) is the primary tool to diagnose engine
management and fuel injection related problems. F18H0WA
NOTE: The VCM programmer does not work on ONLY ONE “ECU” IS WORKING. THERE IS A PROBLEM
4-TEC models. If an “X” is shown, the safety lanyard is not in-
The 4-TEC requires B.U.D.S. version 1.1 or above. stalled on its post or there is a problem with both
B.U.D.S. diskettes are available under P/N 529 035 “ECUs“. Ensure VCK is working properly and
845 and CD-ROM under P/N 529 035 886. check connections on VCK and sport boat.
B.U.D.S. (Bombardier Utility and Diagnostic Soft-
ware) is designed to allow actuators, sensors and VCK Supply
electronic equipment inspection, diagnostic op- The VCK (MPI box) can use the sport boat power
tions and reset such as the closed throttle and idle for its supply.
actuator. The safety lanyard must be connected in order to
For more information pertaining to the use of use the sport boat as a power source.
B.U.D.S., use its HELP button which contains de- If sport boat power is used, every time the safety
tailed information on its functions. lanyard is taken off the DESS post, the kW2000
protocol will have to be re-activated.
 WARNING
If the computer you are using is connected to Changes in ECM ECU
the 110 Vac power outlet, there is a potential
Anytime a change is brought in ECM ECU through
risk of electrocution when working in contact
B.U.D.S., there will be an “ECM Tracking” mes-
with water. Be careful not to touch water
sage that will say “Remove key from vehicle“.
while working with the VCK.
When this occurs, remove the safety lanyard from
IMPORTANT: When using B.U.D.S., with the 4-TEC its post and wait until the message disappears (it
engines, ensure that the protocol “kW2000” is prop- lasts approximately 15 seconds after lanyard re-
erly selected in “MPI” under “Choose protocol”. moval).
When B.U.D.S. is connected with VCM and ECM
ECU, the status bar shows the protocol (kW2000)
4-TEC SYSTEM FAULT CODES
and a number 1 or 2 to the right. To work with the
sport boat, number 2 must be displayed.
General
Number 2 means that 2 “ECUs” are connected The faults registered in the VCM/ECM ECU are
(VCM and ECM ECU). kept when the battery is disconnected.
IMPORTANT: After a problem has been solved,
ensure to clear the fault(s) in the VCM/ECM ECU
using the VCK. This will properly reset the appro-
kW2000 priate counter(s). This will also record that the
problem has been fixed in the VCM/ECM ECU
F18H0XA
memory.
VCM AND ECM ECU ARE CONNECTED Many fault codes at the same time will likely be a
burnt fuse(s).
Number 1 means that 1 “ECU” is connected (ei-
ther VCM or ECM ECU). Therefore, there is a prob- For more information pertaining to the code faults
lem. Check fuses and connections. (state, count, first, etc.) and report, refer to B.U.D.S.
online help.
LMR2004-017_05_04A.FM 05-04-3
Supplemental Information for Some

Specific Faults
ECM ECU fault codes P0601, P0602, P0604 and
P605: These codes may occur in the following sit-
uations:
– Electrical noise is picked up by the ECM ECU.
Ensure that all connections are in good condi-
tion, also grounds (battery, ECM ECU, engine
and ignition system), they are clean and well
tightened and that all electronic components
are genuine — particularly in the ignition sys-
tem. Installing resistive caps, non-resistive
spark plugs or knock sensor wiring/routing may
lead to generate this fault code.
– Electrical noise might also lead engine to occa-
sional cutout without generating a fault code
when engine is restarted. When looking at the
fault code, pay attention to the “count” value in
B.U.D.S. A value between 1 and 9 confirms an
electrical noise problem. A value of 10 and
above will generate a fault code.
– When installing a new ECM ECU. It is not prop-
erly programmed from the factory. The ECM ECU
must be returned to be properly “activated”.
– If everything is in good condition, try a new
ECM ECU.
When using the service action suggested in the
Fault section of B.U.D.S., the system circuits are
referred as 4-23 for instance. It means Amp con-
nector no. 4 and the circuit wire no. 23 as found in
the wiring diagram.
When they are referred as A-41, it means connec-
tor “A” on the ECM ECU and the circuit 41.
TPS (Throttle Position Sensor) Faults

Faults which are reported in B.U.D.S. fall into two
groups TPS faults and adaption faults. These are
displayed on the B.U.D.S. system as TPS OUT OF
RANGE and TPS ADAPTION FAILURE.
05-04-4 LMR2004-017_05_04A.FM
TPS “OUT OF RANGE” Fault

It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole
range of movement of the throttle.
To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom-
mended to release the throttle quickly as this may also show up a fault that is intermittent.
POSSIBLE CAUSES RESULT ACTION
Check if connector is disconnected from TPS. Yes • Fix.
• Fix and reset Closed Throttle and Idle Ac-
Check if sensor is loose. Yes
tuator.
• Replace and reset Closed Throttle and Idle
Inspect sensor for damage or corrosion. Yes Actuator.
Inspect wiring (voltage test). Failed • Repair.
• If bad wiring, repair.
Inspect wiring and sensor (resistance test). • If bad TPS, replace and reset Closed Throt-
Failed tle and Idle Actuator.
• Replace and reset Closed Throttle and Idle
Test sensor operation (wear test). Actuator.
TPS “ADAPTATION FAILURE” Fault

It is caused by the idle position moving out of an acceptable range.
Following failures can be effected by a TPS “Adaption Failure“:
– Idle speed is out of range.
– Engine stops, when throttle is released quickly.
– Engine runs inconsistent in low partload or low RPM.
POSSIBLE CAUSES RESULT ACTION
Sensor has been replaced and TPS closed • Reset Closed Throttle and Idle Actuator.
Yes
position not reset.
Throttle body has been replaced and TPS • Reset Closed Throttle and Idle Actuator.
Yes
closed position not reset.
ECM ECU has been replaced and TPS closed • Reset Closed Throttle and Idle Actuator.
Yes
position not reset.
Throttle cable too tight. Yes
tuator.
Sensor is loose. Yes • Fix and reset Closed Throttle and Idle Ac-
tuator.
Throttle bracket is loose. Yes tuator.
Adjustment screw worn or loose. Yes • Change throttle body.
• Reset Closed Throttle and Idle Actuator
Idle bypass valve replaced but not reset. Yes
using B.U.D.S.
LMR2004-017_05_04A.FM 05-04-5
Section 06 COOLING SYSTEM
TABLE OF CONTENTS 0
CIRCUIT, COMPONENTS AND CARE................................................................................... 06-02-1
CIRCUIT .............................................................................................................................. 06-02-4
COOLING SYSTEM LEAK TEST........................................................................................ 06-02-4
INSPECTION ...................................................................................................................... 06-02-6
DRAINING THE SYSTEM (port or starboard).................................................................. 06-02-6
COOLANT REPLACEMENT ............................................................................................... 06-02-6
COOLANT PUMP HOUSING............................................................................................. 06-02-8
THERMOSTAT ................................................................................................................... 06-02-9
COOLANT PUMP IMPELLER ............................................................................................ 06-02-9
ROTARY SEAL ................................................................................................................... 06-02-10
CARE .................................................................................................................................. 06-02-12
LMR2004-030_06_01ATOC.FM 06-01-1
Subsection 02 (CIRCUIT, COMPONENTS AND CARE)
CIRCUIT, COMPONENTS AND CARE 0

4-TEC Engines — Closed Loop System
4
6
7
2 5
14
8 15
13
11
10
9
12
F18E0ZS
LMR2004-018-06-02A.FM 06-02-1
4-TEC Engines — Open Loop System
STARBOARD VIEW Hull
25 Nm
(18 lbfft)
Loctite 243
Body
Pipe
sealant
8 Nm
(71 lbfin)
Port side
F18E1XS
06-02-2 LMR2004-018-06-02A.FM
4-TEC Engines
Coolant temperature
sensor (CTS) activates
when temperature
exceeds 100°C (212°F)
Expansion
coolant tank
Bleed hose from

cylinder head to
expansion coolant tank
Coolant flows
to oil cooler
Coolant returns
from oil cooler
Coolant housing
including thermostat
opens at 87°C (188°F)
and coolant pump
impeller Oil cooler
Coolant
flows to heat
exchanger
Heat exchanger
Coolant returns
from heat exchanger
F18E1YS
TYPICAL
LMR2004-018-06-02A.FM 06-02-3
1503 Engines CAUTION: Never modify cooling system ar-

rangement, otherwise serious engine damage
CIRCUIT could occur.
Closed Loop System
Pressure Cap
NOTE: These procedures to be performed on each
engine. Check if cap will pressurize the system. If not, in-
stall a new 90 kPa (13 PSI) cap (do not exceed this
A closed loop cooling system is utilized on the pressure).
1503 4-TEC engines, which offers an efficient en-
gine cooling while keeping dirt and salt water out
of the cooling system. This system keeps the tem-
COOLING SYSTEM LEAK TEST
perature constant and prevents internal engine
corrosion.  WARNING
A separate coolant expansion tank ensures that To prevent burning yourself, do not remove
enough engine coolant is in the circuit during any the expansion tank cap or loosen the heat ex-
operating condition. changer drain plug if the engine is hot.
The coolant flow comes from the coolant pump Install test radiator cap (P/N 529 021 400) and hose
impeller into the engine block. It goes around the pincher (P/N 295 000 076) on overflow hose. Pres-
cylinders and straight up to the cylinder head. A surize all system through coolant expansion tank
smaller quantity of engine coolant enters the en- to 90 kPa (13 PSI).
gine block on the exhaust side for additional cool-
ing. In the cylinder head the water channels flow
around the exhaust and then the intake valve pock-
ets leaving the engine through a large hose. From
there the coolant goes back to the coolant pump
housing and depending on the engine tempera-
ture, it flows through the thermostat directly back
to the coolant pump impeller, or it makes its way
through the heat exchanger and back to the cool-
ant pump.
1
A smaller quantity of engine coolant is also direct-
ed through the oil cooler, located under the air in-
2
take manifold, to increase cooling efficiency.
A coolant temperature sensor and bleed nipple are
located on the cylinder head of each engine.
1 F18E1ZA
TYPICAL
1. Hose pincher on this hose
2 2. Pressure pump (P/N 529 021 800)
Check all hoses, heat exchanger, engine and oil

cooler for coolant leaks. Spray a soap/water solu-
tion and look for air bubbles only if performing test
with empty system.
Remove hose pincher and test pressure cap.
F18E0XA
1. Bleed nipple
2. Coolant temperature sensor (CTS)
06-02-4 LMR2004-018-06-02A.FM
Open Loop System Water enters exhaust pipe and flows in the water
jacket of pipe.
The water supply is provided by a pressurized area
in the jet pump between the impeller and venturi. 3 1
The water flow is controlled by a reducer located
between the jet pump support and the jet pump
on the inlet side. The reducer is black on the 4-TEC
models.
Water is directed to the exhaust manifold fitting
located at front of manifold.
1
2
F18E1FA 2
1. Exhaust manifold
2. Water inlet
3. Water outlet
Water enters water jacket of the manifold front

F18E1GA
end and is directed to the rear of exhaust manifold.
TYPICAL
Water exits exhaust manifold through 2 hoses at 1. Exhaust pipe
rear of manifold and enters exhaust pipe. 2. Outlet holes of exhaust pipe
3. Muffler
3 2 1
The total loss system is self-bleeding, with bleed-
ing of the exhaust system accomplished by the
bleed hose located at the upper most point of the
circuit of the exhaust pipe.
Water exits exhaust pipe through holes at the end
of the water jacket and mixes with exhaust gas in
the muffler.
Water is expulsed from mufflers through the ex-
haust outlet in transom area.
F18E1EA
TYPICAL
1. Water coming from exhaust manifold
2. Exhaust pipe
3. Bleed hose
LMR2004-018-06-02A.FM 06-02-5
Clamp DRAINING THE SYSTEM

To cut or secure non-reusable Oetiker clamps of (port or starboard)
cooling system hoses, use pliers (P/N 295 000 070).
 WARNING
Never drain or refill cooling system when en-
gine is hot.
Remove expansion tank cap.

To drain cooling system, unscrew cooling system
drain plug at the rear of the heat exchanger.
1
2
F01B2KA
1. Cutting clamp
2. Securing clamp
INSPECTION
Check general condition of hoses and clamp tight-
ness.
F18E20A
Check the weep hole for oil or coolant.
TYPICAL
1. Cooling drain plug
Use an appropriate container to collect coolant.

Dispose of coolant as per local regulations.
Reinstall drain plug.
Ensure to put pipe sealant (Loctite 567) on threads
of drain plug.
Torque to 8.3 N•m (73 lbf•in).
COOLANT REPLACEMENT
Recommended Coolant
F18E1CA 1
Use a blend of 50% antifreeze with 50% water.
1. Weep hole Premixed antifreeze/water is available (P/N 293
NOTE: Coolant flowing from weep hole indicates 600 038).
a damaged rotary seal. Oil out of the weep hole CAUTION: To prevent antifreeze deterioration or
indicates a non- working oil seal. If any leaks are gelling, always use the same brand. Never mix
detected, determine cause and repair. different brands unless cooling system is com-
pletely flushed and refilled.
06-02-6 LMR2004-018-06-02A.FM
Reinstall pressure cap.

CAUTION: To prevent rust formation or freezing
condition in cold areas, always replenish the
system with 50% antifreeze and 50% water. Pure
antifreeze will freeze at a higher temperature 1
than the optimal water/antifreeze mix. Always
use ethylene glycol antifreeze containing corro-
sion inhibitors specifically recommended for
aluminum engines.
System Capacity
Port side system uses approximately 5.2 L (5.5 U.S.
quarts).
2
Starboard side system uses approximately 4.7 L F18E21A
(5 U.S. quarts).
TYPICAL
1. Loosen this clamp
Coolant Replacement Procedure 2. Remove this hose
 WARNING Raise hose as high as possible and fill until coolant

solution begins to run out of coolant pump hous-
To prevent burning yourself do not remove ing.
the expansion tank cap or loosen the ride
plate drain plug if the engine is hot. Quickly reinstall hose onto coolant pump housing.
Torque clamp to 3 - 5 N•m (26.5 - 44 lbf•in).
Drain the system completely as described above.
Clean excess coolant from bilge.
Sport boat should be level, and engine cold for re-
filling. Dispose of coolant as per local regulations.
NOTE: Test the density of the coolant using an an- Remove coolant expansion tank pressure cap and
tifreeze hydrometer. Follow hydrometer manufac- add coolant.
turer instructions for proper use. Fill expansion tank to MAX line.
The reading should be some degrees below the
coldest temperature you expect in the area where
the sport boat is to be used or stored. Add water
or antifreeze accordingly. Refill to the proper level.
CAUTION: Pure antifreeze will freeze at a higher
temperature than the optimal water/antifreeze
mix.
Loosen clamp and remove hose from coolant
pump housing shown in the next photo. 1
F18E0NA
1. Level between marks when engine is cold
Install pressure cap.
LMR2004-018-06-02A.FM 06-02-7
Test boat in water 10 - 15 minutes at various throt- – oil cooler outlet hose no. 3
tle speeds to obtain engine operating tempera- – screws no. 4 and no. 5 retaining coolant pump
ture, periodically checking coolant level in coolant housing no. 6
expansion tanks. When the pressure cap is re-
moved and the pressure relieved, the level in the – coolant pump housing no. 6.
tanks will rise as the rubber hoses contract.
Inspection
An alternative to water testing is as follows:
Check if gasket no. 7 is brittle, hard or damaged
Properly cool exhaust system by installing a gar- and replace as necessary.
den hose to flush fitting (or water test). Refer to
flushing in MAINTENANCE section. 1
Start engine and let run for 2 minutes. Stop engine
and wait 15 minutes to cool down. Refill tank as
necessary.
Repeat this run-stop cycle 2 - 3 times until thermo-
stat opens and stop engine.
Last, refill expansion tank and reinstall cap.
When engine has completely cooled down, re-
check coolant level in radiator and coolant tank and
top off as necessary.
Wipe up and remove any coolant spilled in the
bilge/engine compartment. F18E11A
Dispose of spilled coolant per local regulations. 1. Weep hole pump housing gasket
Check if thermostat is in good condition. Refer to

COOLANT PUMP HOUSING THERMOSTAT elsewhere in this section.
Installation
cedure. Install screws as per the following illustra-
tion.
2 2 1
1
1 1
F18E0YA
1. Coolant pump housing
Removal 1
Drain cooling system and engine oil, refer to LU-
BRICATION SYSTEM. F18E10A 1 1
Remove from housing: 1. Screw M6 x 25
2. Screw M6 x 105
– heat exchanger inlet and outlet hoses
– cylinder head outlet hose no. 1
– oil cooler inlet hose no. 2
06-02-8 LMR2004-018-06-02A.FM
CAUTION: To prevent leaking, take care that

the gaskets are exactly in groove when you re-
install the coolant pump housing.
Apply Loctite 243 on screw threads and torque to
10 N•m (89 lbf•in).
Tightening sequence for screws on coolant pump
housing is as per following illustration.
7 8 1
4
6 2
5
F18E12A 1 3
1. Oil cooler return connection
4 2. Coolant tank hose connection
3. Heat exchanger return hose connection
4. Cylinder head return hose connection
F18E10B 2 3 Fill the coolant pump housing with water.

If a bigger quantity of coolant leaks out at the heat
exchanger outlet connection, replace the coolant
THERMOSTAT pump housing. Refer to COOLANT PUMP HOUS-
The thermostat is a single action type. ING in this section.
If there is no leak, check the operation of the ther-
Removal mostat.
Remove the coolant pump housing from the PTO
cover. Refer to COOLANT PUMP HOUSING RE- Dynamic Test
MOVAL elsewhere in this section. To check the operation of the thermostat, put it in
NOTE: The thermostat is located inside the cool- water and heat water. Look inside the cylinder
ant pump housing. head return hose connection to see the move-
ment of the thermostat. Thermostat should open
Leak Test when water temperature reaches 87°C (188°F).
Plug the connections of the oil cooler return hose, If there is no operation, replace coolant pump
coolant tank hose, heat exchanger return hose and housing and thermostat.
cylinder head return hose with a rag.
Installation
For installation, reverse the removal procedure,
paying attention to the following details.
Refer to COOLANT PUMP HOUSING REPLACE-
MENT in this section.
COOLANT PUMP IMPELLER

Removal
Remove:
– unscrew the impeller no. 8 clockwise.
LMR2004-018-06-02A.FM 06-02-9
Coolant leaking out of the hole indicates a defec-

tive rotary seal. Leaking oil indicates a faulty oil
1 seal.
However, if seal is disassembled both parts have
to be replaced together.
Removal
Remove:
CAUTION: Always unscrew the impeller clock-
wise otherwise you can damage the compo-
nents.
F18E13A
– unscrew the impeller no. 8 clockwise
1. Impeller
– remove PTO cover no. 10. Refer to PTO HOUSING/
CAUTION: Coolant/oil pump shaft no. 9 and im- MAGNETO section
peller no. 8 have left-hand threads. Remove by – remove screws no. 11 retaining oil pump cover
turning clockwise and install by turning coun-
terclockwise. 2
Inspection
Check impeller for cracks or other damage. Re-
place impeller if damaged.
Installation
1
CAUTION: Be careful not to damage impeller
vanes during installation.
Torque impeller to 3 N•m (27 lbf•in). F18E14A
1. Retaining screws
ROTARY SEAL 2. Oil pump cover
Inspection – remove oil pump cover no. 12

Check weep hole for oil or coolant leak. – remove outer oil pump rotor no. 13
1
F18E1CA 1
F18E15A
1. Weep hole
1. Outer oil pump rotor
06-02-10 LMR2004-018-06-02A.FM
– extract the coolant/oil pump shaft no. 9 from Installation

outside PTO housing cover with a pusher
1
2 NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Push water pump shaft oil seal in place by using
thumb.
Install the new rotary seal using the rotary seal in-
staller (P/N 529 035 823).
CAUTION: Never use a hammer for the rotary
seal or water/oil pump shaft installation. Only
use a press to avoid damaging the ceramic com-
ponent.
F18E16A
2 1
1. Pusher
– remove rotary seal no. 14 with a screwdriver
F18E19A
1. Rotary seal
2. Rotary seal installer
F18E17A
Install the coolant/oil pump shaft using the rotary
CAUTION: Be careful not to damage the sur- seal installer (P/N 529 035 823) on the opposite
face of the rotary seal bore in magneto housing side to the rotary seal and the oil seal protector
cover. (P/N 529 035 82) with a press.
– always replace the oil seal no. 15 behind the 2 1
rotary seal.
F18E1AA
1. Oil seal protector

F18E18A
1. Oil seal
LMR2004-018-06-02A.FM 06-02-11
This will prevent the exhaust cooling system from

1 filling which may lead to water being injected into
and filling the exhaust system and the engine.
Without the engine running there isn’t any ex-
haust pressure to carry the water out the exhaust
outlet.
CAUTION: Failure to do this may result in dam-
age to the engine. If you must tow a stranded
sport boat in water and do not have a hose
pincher be sure to stay well below the maximum
2 towing speed of 24 km/h (15 MPH).
F18E1BA
Snugly install the hose pincher on the water sup-
ply hose as shown in the following illustrations.
1. Coolant/oil pump shaft with oil seal protector
2. Rotary seal installer
CARE
For flushing purposes, the exhaust cooling system
is equipped with a hose adapter.
To connect to the fitting spigot. A garden hose is
used to flush the whole system by backwash. For
flushing procedure, refer to FLUSHING AND LU-
BRICATION.
For winterization of cooling system, refer to
STORAGE.
When servicing the hull, rotate sport boat either
way (seen from the rear) maximum to 90°.
Towing the Sport Boat in Water

NOTE: These procedures to be performed on
each engine.
Special precautions should be taken when towing
a Sea-Doo sport boat in water.
M axim um re comm ended tow ing speed is
24 km/h (15 MPH).
When towing your sport boat in water, pinch the 1
water supply hose from the jet pump housing to the F18E0RA
engine with a large hose pincher (P/N 529 032 500).
TYPICAL
1. Hose pincher
CAUTION: When finished towing the sport

boat, the hose pincher must be removed before
operating the engines.
F01B23A
06-02-12 LMR2004-018-06-02A.FM
TECHNICAL DATA
TYPE:
Closed and open loop cooling system.
COOLANT FLOW:
Pressure build-up at coolant pump.
TEMPERATURE CONTROL:
Thermostat.
SYSTEM BLEEDING:
Self-bleed type through expansion tank
(hose at uppermost point of circuit).
SYSTEM DRAINING:
Self-drain type on the exhaust cooling system
(hose at lowest point of circuit).
SYSTEM FLUSHING:
Required only for exhaust cooling system
(open loop system).
MONITORING BEEPER:
Turns on at 100°C (212°F).
COOLANT LIFE CYCLE:
2 years.
LMR2004-018-06-02A.FM 06-02-13
TABLE OF CONTENTS 0
FUEL CIRCUIT ........................................................................................................................ 07-02-1
GENERAL ........................................................................................................................... 07-02-2
REMOVAL........................................................................................................................... 07-02-2
INSPECTION ...................................................................................................................... 07-02-3
ASSEMBLY......................................................................................................................... 07-02-3
FUEL SYSTEM PRESSURIZATION ................................................................................... 07-02-3
AIR INTAKE ............................................................................................................................ 07-03-1

REMOVAL........................................................................................................................... 07-03-2
ASSEMBLY ........................................................................................................................ 07-03-2
LMR2004-030_07_01ATOC.FM 07-01-1
Subsection 02 (FUEL CIRCUIT)
FUEL CIRCUIT
Loctite 271
7.2-8.8 Nm
To battery (63.7-77.8 lbfin)
Loctite 271 8
ground 7.2-8.8 Nm 8
(63.7-77.8 lbfin)
Loctite 271
7.2-8.8 Nm
(63.7-77.8 lbfin)
Body
8 8
3 7
2.5-3 Nm 4-6 Nm 1
(22.1-26.5 lbfin) (35.4-53.1lbfin)
2
6
4
3
2.5-3 Nm
(22.1-26.5 lbfin)
F13F04S
LMR2004-019_07_02A.FM 07-02-1
GENERAL
 WARNING
The fuel system of a fuel injection system holds
much more pressure than on a carbureted
sport boat. Prior to disconnecting a hose or to
removing a component from the fuel system,
follow the recommendations described in EN-
GINE MANAGEMENT under FUEL SYSTEM. F01B04A 1
 WARNING
1. Securing clamp
Whenever repairing the fuel system, always

verify for water infiltration in reservoir. Replace
any damaged, leaking or deteriorated fuel
lines.
When working with fuel, pay attention to the fol-

lowing warning.
 WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well venti-
lated area. Always wipe off any fuel spillage 1
F01B05A
from the sport boat.
1. Securing clamp in limited access
To secure or cut Oetiker clamps on fuel lines, use
When replacing fuel lines on Sea-Doo sport boat,
pliers (P/N 295 000 070).
be sure to use “A1” hoses as available from
Bombardier parts department. Use hoses ass’y
available as parts replacement only. This will en-
sure continued proper and safe operation.
 WARNING
Use of improper fuel lines could compromise
fuel system integrity.
REMOVAL
1
Fuel Filter
F01B03A
The fuel filter is located at the electric fuel pump
1. Cutting clamp inlet. The pump has to be removed from the fuel
tank to have access to its filter. Refer to ENGINE
MANAGEMENT section.
07-02-2 LMR2004-019_07_02A.FM
Electric Fuel Pump ASSEMBLY

Refer to appropriate ENGINE MANAGEMENT Assembly is essentially the reverse of disassem-
section. bly procedures.
Fuel Tank Install fuel pump on fuel tank and torque nuts to
2.5 N•m (22 lbf•in).
NOTE: It is necessary to remove the engines. Re-
fer to REMOVAL AND INSTALLATION and COM- 6 37
PONENTS subsection.
Siphon fuel tank no. 1.
Disconnect EMS connectors.
8
Remove TOPS switch from electrical harness. 15
Disconnect fuel pump connections.
29
Disconnect fuel tank filler hose no. 2. 13
Disconnect fuel tank vent hose no. 6.
10
Disconnect all fuel tank connections. 4 12
11
Cut locking ties as required to release wiring har-
nesses. F09F0HA
Remove fuel tank from the vehicle. TORQUE AS PER SEQUENCE
 WARNING Ensure rubber pads no. 4 are in place.

Check that fiberglass is not exposed. Insert tank and fasten tank straps no. 8.
Properly secure harnesses.
INSPECTION
FUEL SYSTEM PRESSURIZATION
The filter at fuel pump inlet is not replaceable indi-
vidually. The complete fuel pump unit has to be
replaced.
 WARNING
Whenever doing any type of repair on boat or
Fuel Filler Hose if any components of the fuel system are dis-
connected, a pressure test must be done be-
Verify fuel filler hose no. 2 for damage. Ensure that fore starting engine and/or releasing boat to
clamps no. 3 are well-positioned and tightened. customer.
Torque clamps to 2.5 - 3 N•m (22 - 26.5 lbf•in).
CAUTION: Check fuel line ends for damage. Al-
Fuel Tank Vent Hose ways trim damaged end(s) before reinstallation.
Verify fuel tank vent hose no. 6 for damage. Ensure
that clamps no. 7 are well-positioned and tightened.
Torque clamps to 4 - 6 N•m (35.4 - 53.1 lbf•in).
Fuel Tank
Visually inspect the outside of the fuel tank necks
for cracks. If the fuel tank is questionable, perform
a fuel system pressurization test.
Inspect rubber pads no. 4 under tank for damage
or misalignment.
LMR2004-019_07_02A.FM 07-02-3
Pressure Test – If pressure is not maintained locate leak and

repair/replace leaking component. To ease leak
Proceed as follows:
search spray a solution of soapy water on com-
– Fill up fuel tank. ponents. Bubbles will indicate leak location.
– Remove fuel cap from chain. Ensure to remove Check that leaks do not come from improperly
chain at fuel cap end only. sealed hoses.
NOTE: To minimize time of fuel system pressur-
ization, the fuel tank should be quite full. The sys-
tem must maintain a pressure of 34 kPa (5 PSI) for
10 minutes. Never pressurize over 34 kPa (5 PSI).
 WARNING
If any leak is found, do not start the engine.
Remove any fuel leakage. Failure to correct a
leak could lead to an explosion. Do not use
1 electric-powered tools on boat unless system
has been verified for no leaks.
Remove pressure test cap and retrieve chain from

filler neck.
F13F0CA
Reconnect chain to fuel cap and firmly tighten fuel
cap into filler neck.
TYPICAL
1. Remove chain at fuel cap end only
High Pressure Test (fuel pump circuit)
– Place chain in filler neck for later retrieval. Refer to the appropriate ENGINE MANAGEMENT
– Thread pressure test cap (P/N 529 035 870) into section.
filler neck.
– Connect pump gauge tester (P/N 529 021 800)  WARNING
from kit (P/N 295 500 352) to pressure test cap. Prior to installing the safety lanyard, refer to
– Pressurize fuel system to 34 kPa (5 PSI). the appropriate ENGINE MANAGEMENT sec-
tion for necessary safety precautions.
1 2
F13F0DA
TYPICAL
1. Pressurized to 34 kPa (5 PSI)
2. Pressure test cap
07-02-4 LMR2004-019_07_02A.FM
Subsection 03 (AIR INTAKE)
AIR INTAKE 0
1
4
2 Nm
(18 lbfin)
2
4 Nm
3 (35 lbfin)
F09F12S
TYPICAL
LMR2004-019_07_03A.FM 07-03-1
Subsection 03 (AIR INTAKE)
REMOVAL Loosen clamp no. 2 and remove intake hose no. 3

from intake silencer.
Detach straps no. 4 using hook tool (P/N 529 035
engine.
559).
Air Intake Silencer
ASSEMBLY
Turn main battery cut-off switch to OFF position.
Disconnect regulator harness connectors from Assembly is essentially the reverse of removal
top of air intake box no. 1, as shown below. procedures. However pay particular attention to
the following.
4 NOTE: Air intake silencer is a sealed unit and is
not user seviceable.
CAUTION: Do not modify air intake system,
otherwise calibration will be affected.
Replace air intake silencer inside engine compart-
1 ment and between mounting rails located at seat
back.
Fasten air intake silencer with straps no. 4, using
hook tool (P/N 529 035 559).
Attach intake hose no. 3 to intake silencer and
tighten clamp no. 2 to 2 N•m (18 lbf•in).
Attach regulator harness connectors no. 1.
Turn main battery cut-off switch to ON position.
F13F0EA 2 3
TYPICAL
1. Regulator harness connectors
2. Clamp
3. Intake hose
4. Straps
07-03-2 LMR2004-019_07_03A.FM
Section 08 ELECTRICAL SYSTEM
TABLE OF CONTENTS 0
CHARGING SYSTEM............................................................................................................. 08-02-1
GENERAL ........................................................................................................................... 08-02-1
TESTING PROCEDURE ..................................................................................................... 08-02-1
BATTERY ............................................................................................................................ 08-02-2
STARTING SYSTEM .............................................................................................................. 08-03-1

GENERAL ........................................................................................................................... 08-03-1
STARTING SYSTEM TROUBLESHOOTING ..................................................................... 08-03-2
STARTER REMOVAL.......................................................................................................... 08-03-3
STARTER DISASSEMBLY.................................................................................................. 08-03-3
CLEANING ......................................................................................................................... 08-03-4
PARTS INSPECTION .......................................................................................................... 08-03-5
STARTER ASSEMBLY........................................................................................................ 08-03-5
STARTER INSTALLATION ................................................................................................. 08-03-6
STARTER SPECIFICATION ................................................................................................ 08-03-7
INSTRUMENTS AND ACCESSORIES .................................................................................. 08-04-1

ADDITION OF ACCESSORIES .......................................................................................... 08-04-1
INSPECTION ...................................................................................................................... 08-04-1
LMR2004-030_08_01ATOC.FM 08-01-1
Subsection 02 (CHARGING SYSTEM)
CHARGING SYSTEM 0
NOTE: This procedure to be performed for each Rectifier/Regulator
engine.
STATIC TEST: CONTINUITY
GENERAL Due to internal circuitry, no static test can be done.
Magneto DYNAMIC TEST

The purpose of the charging system is to keep the Current Test
battery at a full state of charge. Proceed as follows:
The magneto is the primary source of electrical – Start engine.
energy. It transforms a magnetic field into electric – Lay an inductive ammeter on positive cable of
current (AC). battery.
The magneto has a 3 phase, delta wound stator – Bring engine to approximately 6000 RPM.
on 18 poles. Capacity is 380 watts.
Current reading should be approximately 5 am-
Rectifier/Regulator peres, depending on battery state. If not, check
magneto output prior to concluding that rectifier is
The rectifier receives AC current from the magne- faulty.
to and transforms it into direct current (DC).
Voltage Test
The regulator, included in the same unit, limits volt-
age at a maximum level (14.5 to 14.8 volts) to pre- Proceed as follows:
vent any damage to components. – Set multimeter to Vdc scale. Connect a multime-
The regulator/rectifier is a 3-phase series type ter to battery posts. Connect RED test lead to
which transforms (AC) from the magneto into (DC) positive (+) and BLACK lead to negative (-) battery
to allow battery charging. posts.
– Note the battery voltage. A fully-charged bat-
Battery tery should read approximately 12.6 vdc.
The battery is the DC source for the electric starter, – Bring engine to approximately 5500 RPM.
the ECU/EMS and all accessories. If multimeter reads over 15 volts, regulator is de-
fective. Replace it.
Fuse
If the voltage reading does not rise above battery
If the battery is regularly discharged, check fuse voltage indicated previously, the system is not
condition. charging.
The rectifier/regulator could cause blown fuses. To NOTE: If distilled water must continually be added,
check, simply disconnect the rectifier/regulator from it indicates an over voltage situation requiring re-
the circuit. placement of the rectifier/regulator. If, on the other
If the fuse still fails, check for a defective wire. hand, the battery does not stay charged, the prob-
CAUTION: Do not use a higher rated fuse as lem can come from any of the charging circuit com-
this could cause severe damage. ponents. If these all check good, it would be accurate
to assume the problem comes from the rectifier/
The charging system is protected by 1 fuse (30 A) regulator.
attached to the starter relay.
TESTING PROCEDURE
NOTE: Ensure that the battery is in good condition
prior to performing the following tests. A low or
dead battery will affect test results.
LMR2004-020-08-02A.FM 08-02-1
Stator 2 3
STATIC TEST: CONTINUITY
Disconnect the magneto wiring harness connec-
tor and probe the three connectors.
1. Check resistance between two of the YELLOW
wires. The resistance should be between 0.1 to
1.0 ohm.
2 1
F04H6YA 4 1
TYPICAL
1. Multimeter
2. Magneto harness adapter
3. Positive (+) probe to YELLOW wire
4. Negative (-) probe to ground
3. Repeat test with the other two YELLOW wires

of the 3-pin magneto harness adapter.
NOTE: There should be no continuity (infinity) be-
F04H6XA 3 tween the magneto insulated coils and ground. If
TYPICAL there is a reading, the magneto coils and/or the
1. Multimeter wiring from the coils is grounded and needs to be
2. Magneto harness connector replaced or repaired.
3. YELLOW wires
2. Place either meter lead into the remaining YEL- DYNAMIC TEST
LOW wire and note the resistance (same as Disconnect the magneto wiring harness connec-
step no. 1). If the readings are out of specifica- tor and probe the three connectors.
tion, the stator will need to be replaced. 1. Connect the test probes of the multimeter to
STATIC TEST: INSULATION two of the YELLOW wires of the 3-pin magneto
harness adapter.
Disconnect the magneto wiring harness connec-
tor and probe the three connectors. 2. Set multimeter to Vac scale.
1. Insert multimeter positive (+) probe to one of 3. Start and rev engine to 3500 RPM. The obtained
the YELLOW wires of the 3-pin magneto har- value should be approximately 25 Vac.
ness adapter. 4. If the magneto is out of specification, replace it.
2. Ground the multimeter negative (-) probe to the
engine or the stator iron core and note the read- BATTERY
ing.
Recommended
Exide RV24-130, 12 V, 25 A•h (130 minutes re-
serve) or equivalent, with top-mounted, round
taper type battery posts.
Battery maximum allowed size: 285 mm (11-1/4 in)
long x 190 mm (7-1/2 in) wide x 238 mm (9-3/8 in)
high.
08-02-2 LMR2004-020-08-02A.FM
Troubleshooting Cleaning
Clean the battery casing, caps, cables and battery
SYMPTOM: DISCHARGED OR WEAK BATTERY
posts using a solution of baking soda and water.
CAUSE REMEDY CAUTION: Do not allow cleaning solution to
1. Battery posts and/or Clean and coat with enter battery.
cable terminal dielectric grease. Remove corrosion from battery cable terminals
oxidized. and battery posts using a firm wire brush. Rinse
2. Loose or bad Check wiring and with clear water and dry well.
connections. connector cleanliness,
damaged or short circuit. Inspection
3. Faulty battery Replace. Visually inspect battery casing for cracks or other
(sulfated, doesn’t possible damage. If casing is damaged, replace
keep a full charge, battery and thoroughly clean battery tray and close
damaged casing, area with water and baking soda.
loose post).
Inspect battery posts for security of mounting.
4. 15 amp fuse(s) burnt First check fuse.
or faulty rectifier. If it is in good condition,
Inspect for cracked or damaged battery caps, re-
check rectifier/regulator. place defective caps.
5. Faulty battery
charging coil (or
Replace.  WARNING
stator). Battery electrolyte is caustic. To prevent spill-
age, battery cell cap should be sufficiently
tight to properly seal.
Removal
 WARNING Electrolyte Level

Battery BLACK negative cable must always Check electrolyte level in each cell, add distilled
be disconnected first and connected last. water to upper level as per battery manufacturer’s
Never charge or boost battery while installed specifications.
in sport boat. CAUTION: Add only distilled water into an ac-
tivated battery.
Proceed as follows:
1. Disconnect the BLACK negative cable first. Battery Testing
2. Disconnect the RED positive cable last. There are 2 types of battery tests: electrolyte read-
ing and load test. An electrolyte reading is made
3. Remove the hold down.
on a battery without discharging current. It is the
4. Withdraw battery from bilge. simplest and most commonly used. A loaded test
gives more accuracy of the battery condition.
 WARNING Electrolyte Reading
Electrolyte is poisonous and dangerous.
Avoid contact with eyes, skin and clothing. Check charge condition using either a hydrometer
Wear a suitable pair of non-absorbent gloves or multimeter.
when removing the battery by hand. With a multimeter, voltage readings appear in-
stantly to show the state of charge. Always re-
CAUTION: Should any electrolyte spillage oc- spect polarity. A fully charge battery will have a
cur, immediately wash off with a solution of reading of 12.6 Vdc.
baking soda and water.
LMR2004-020-08-02A.FM 08-02-3
A hydrometer measures the charge of a battery in SPECIFIC GRAVITY READING

terms of specific gravity of the electrolyte. A fully USING A HYDROMETER
charged battery will have a specific gravity be-
tween 1.265 to 1.280. ELECTROLYTE
STATE OF TEMPERATURE
Most hydrometers only give a true reading at 21°C
CHARGE
(70°F). 27°C (80°F) 4°C (40°F)
100% 1.26/1.27 1.27/1.28
75% 1.21/1.22 1.22/1.23
1 50% 1.16/1.17 1.17/1.18
25% 1.12/1.13 1.13/1.14
0% 1.10 or less 1.11 or less
Load Test
This is the best test of battery condition under a
A17E0JA
starting load. Use a load testing device that has an
adjustable load.
1. Specific gravity 1.265
Apply a load of 3 times the ampere-hour rating of
In order to obtain correct readings, adjust the initial the battery. At 14 seconds into the test, check bat-
reading by adding .004 points to the hydrometer tery voltage; if battery is in good condition, it will
readings for each 5.5°C (10°F) above 21°C (70°F) have at least 10.5 Vdc.
and by subtracting .004 point for every 5.5°C
(10°F) below 21°C (70°F). Battery Storage
This chart will be useful to find the correct reading. CAUTION: Battery storage is critical for battery
life. Regularly charging the battery during stor-
ELECTROLYTE age will prevent cell sulfation. Keeping the bat-
TEMPERATURE OPERATION TO tery in vehicle for storage may lead to contacts
PERFORM degradation/corrosion and case damage if
°C °F freezing occurs. A discharged battery will
freeze and break in area where freezing point is
38 100 .012 Add experienced. Electrolyte leakage will damage
32 90 .008 to the
surrounding parts. Always remove battery
27 80 .004 reading
from vehicle for storage and regularly charge
21 70 CORRECT READING
to keep an optimal condition.
Disconnect and remove battery from sport boat as
16 60 .004 explained in REMOVAL.
Subtract
10 50 .008
from the Check electrolyte level in each cell, add distilled
4 40 .012
-1 30 .016
reading water up to upper level line.
CAUTION: Do not overfill.
EXAMPLE NO. 1 EXAMPLE NO. 2
TEMPERATURE ABOVE 21°C TEMPERATURE ABOVE 21°C The battery must always be stored in fully charged
(70°F): (70°F): condition. If required, charge until specific gravity
Hydrometer reading: 1.250 Hydrometer reading: 1.235
Electrolyte temperature: - 1°C (30°F) Electrolyte temperature: 38°C (100°F) of 1.265 is obtained.
Subtract .016 Sp. Gr. Add .012 Sp. Gr.
Corrected Sp. Gr. is 1.234 Corrected Sp. Gr. is 1.247 CAUTION: Battery electrolyte temperature must
not exceed 50°C (122°F). The casing should not
feel hot.
08-02-4 LMR2004-020-08-02A.FM
Clean battery terminals and cable connections us- The time required to charge a battery will vary de-
ing a wire brush. Apply a light coat of dielectric pending on some factors such as:
grease on terminals. – Battery temperature: The charging time is in-
Clean battery casing and caps using a solution of creased as the temperature goes down. A cold
baking soda and water. battery accepts a lower rate of charging current
CAUTION: Do not allow cleaning solution to than will a warm battery.
enter battery. – State of charge: Because the electrolyte is near-
Rinse battery with clear water and dry well using ly pure water in a completely discharged bat-
a clean cloth. tery, it cannot accept current as well as more
concentrated electrolyte. This is the reason the
Store battery in a cool dry place. Such conditions battery will not accept current when the charg-
reduce self-discharging and keep fluid evaporation ing cycle first begins. As the battery remains on
to a minimum. Keep battery away from dew, high the charger, the current from the charger caus-
moisture and direct sunlight. es the electrolytic acid content to rise which
During the storage period, recheck electrolyte lev- makes the electrolyte a better conductor and
el and specific gravity readings at least every then, the battery will accept a higher charging
month. If necessary, keep the battery at its upper rate.
level line and near full charge as possible (trickle – Type of charger: Battery chargers vary in the
charge). amount of voltage and current that they can
supply. Therefore, the time required for the bat-
Activation of a New Battery tery to begin accepting measurable current will
also vary.
 WARNING Charging a Weak or Completely Discharged
Never charge or boost battery while installed Battery
in sport boat.
The battery charger should have an adjustable
Follow battery manufacturer’s recommendations. charging rate. Variable adjustment is preferred,
but a unit which can be adjusted in small incre-
Charging a Used Battery ments is acceptable.
The battery charger must be equipped with an am-
 WARNING meter capable of accurately measuring current of
Never charge battery while installed in sport less than 1 ampere.
boat. Unless this procedure is properly followed, a good
battery may be needlessly replaced.
For best results, battery should be charged when
the electrolyte and the plates are at room temper- – Measure the voltage at the battery posts with
ature. A battery that is cold may not accept current an accurate voltmeter. If it is below 10 volts, the
for several hours after charging has begun. battery will accept current at a very low rate, in
term of milliamperes, because the electrolyte is
Do not charge a frozen battery. If the battery nearly pure water as explained above. It could
charge is very low, the battery may freeze. If it is be some time before the charging rate increas-
suspected to be frozen, keep it in a heated area es. Such low current flow may not be detect-
for about 2 hours before charging. able on some charger ammeters and the bat-
tery will seem not to accept any charge.
 WARNING – Except for this particular case, set the charger
Always charge battery in a well ventilated area. to a high rate.
LMR2004-020-08-02A.FM 08-02-5
NOTE: Some chargers have a polarity protection

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. Fol-
low the charger manufacturer’s instruction on how
to bypass or override this circuitry so that the charger
will turn on and charge a low-voltage battery.
– Since the battery chargers vary in the amount
of voltage and current they provide, the time
required for the battery to accept measurable
charger current might be up to 10 hours or
more.
– If the charging current is not up to a measurable
amount at the end of about 10 hours, the bat-
tery should be replaced.
– If the charging current is measurable before the
end or at the end of about 10 hours, the battery
is good and charging should be completed in
the normal manner as specified in the manufac-
turer’s recommendations.
– It is recommended that any battery recharged
by this procedure be load tested prior to return-
ing it to service.
Battery Installation
 WARNING
Always connect battery cables exactly in the
specified order, RED positive cable first BLACK
negative cable last.
Proceed as follows:
1. Install battery in supplied tray.
2. First connect RED positive cable. Tighten nuts.
3. Connect BLACK negative cable last. Tighten nuts.
4. Apply dielectric grease on battery posts.
5. Verify cable routing and attachment.
08-02-6 LMR2004-020-08-02A.FM
Subsection 03 (STARTING SYSTEM)
STARTING SYSTEM 0
The solenoid may be the cause of a burnt fuse. If
Grease Klueber Isoflex the solenoid checks good, an accessory may be
Topas NB 52 defective.
4 3 2
Battery
5 To check battery condition, refer to CHARGING
1
SYSTEM.
VCM/ECM
If 2 short beeps are not heard when installing the
safety lanyard, refer to ENGINE MANAGEMENT
section.
Engine Start/Stop Switch and Safety

Lanyard Switch
Refer to ENGINE MANAGEMENT section.
Solenoid
NOTE: Solenoid is located near the fuse block for
4-TEC engines.
F18H0MA
Inspect connections and clean as necessary.

Static Test: Continuity
engine.
With a multimeter, check primary winding resis-
GENERAL tance. It should be approximately 5.0 Ω (ohms).
Measure the resistance value through pins 1 and 2.
Causes of trouble are not necessarily related to
starter but may be due to a burnt fuse, faulty battery,
start/stop switch, safety lanyard switch, engine fuse
block or ECM, solenoid, electrical cables, connec-
tions, hydrolock or engine mechanical failure.
Check these components before removing starter.
Consult the starting system troubleshooting table
on page 2 for a general view of possible problems.
 WARNING
Short circuiting electric starter is always a
danger, therefore disconnect the battery
ground cable before performing any kind of
maintenance on starting system. Do not place
tools on battery.
F04H71A 1
Fuse
1. Pins 1 and 2
Make sure the starting system fuse on engine
fuse block is in good condition. There should be no continuity between the posi-
tive posts of the solenoid.
LMR2004_021_08_03A.FM 08-03-1
Dynamic Test Electrical Cables or Connections

Depress start/stop button and measure the voltage Check all connections, cables and wires. Tighten
on the solenoid positive posts with a multimeter. any loose cables. Replace any chafed wires.
If there is no voltage and battery is in good condi-
tion, replace the solenoid.
STARTING SYSTEM TROUBLESHOOTING

NOTE: Other causes of the problem may not be related to the starting system. Refer to TROUBLESHOOT-
ING section.
SYMPTOM CAUSE REMEDY
STARTER DOES NOT TURN. Burnt fuse on engine fuse block. Check wiring condition and replace
fuse.
Poor contact of battery terminal(s). Clean and tighten terminal(s).
Poor battery ground cable connection. Clean and tighten.
Weak battery. Recharge or replace battery.
Poor contact of start/stop switch, Check connectors and clean contacts.
safety lanyard switch or solenoid. Check and replace defective parts.
Open circuit: start/stop switch or Check and replace.
solenoid.
Safety lanyard. Refer to ENGINE MANAGEMENT.
STARTER ENGAGES; Engine hydrolocked. Refer to MAINTENANCE.
BUT DOES NOT CRANK
Poor battery cable connections. Clean battery cable connections.
THE ENGINE.
Poor contact of brushes. Straighten commutator and brushes.
Burnt commutator. Turn commutator on a lathe.
Worn commutator segments. Undercut mica.
Shorted armature. Repair or replace armature.
Weak brush spring tension. Replace brush holder or spring.
Weak magnet. Replace yoke assembly.
Worn bushings. Replace clutch.
Weak battery. Recharge or replace battery.
STARTER TURNS, BUT Worn clutch pinion gear. Replace clutch.
OVERRUNNING CLUTCH
Defective clutch. Replace clutch.
PINION DOES NOT MESH
WITH RING GEAR. Poor movement of clutch on splines. Clean and correct.
Worn clutch bushing. Replace clutch.
Worn ring gear. Replace ring gear.
STARTER MOTOR KEEPS Shorted solenoid winding. Replace solenoid.
RUNNING. Melted solenoid contacts. Replace solenoid.
Sticking or defective starter clutch. Lubricate or replace.
08-03-2 LMR2004_021_08_03A.FM
STARTER REMOVAL
Disconnect BLACK cable ground connection from
battery.
 WARNING
Always disconnect ground cable first and re-
connect last.
Disconnect RED cable connection from battery.

Remove retaining screws no. 1 from starter.
Pull starter no. 3 out. Lift starter enough to reach
starter cable then disconnect from starter (nut
no. 2).
4 2
1 F18H0NA 1 2
1. Starter gear
2. Retaining circlip
Locate index marks on yoke and end covers.

3
F18H0UA
1. Exhaust manifold
2. Starter
3. Retaining screws
4. Nut
STARTER DISASSEMBLY
Remove gear retaining circlip no. 4 and starter F18H0OA 1
gear no. 5.
1. Index marks
LMR2004_021_08_03A.FM 08-03-3
Loosen through bolts.
F06H1JA 1
1 TYPICAL
1. Pull armature shaft
Remove brushes from brush holder by loosening

retaining screws.
1 2 3
F18H0PA
1. Through bolts
Remove end cover.

Remove thrust washers from armature shaft.
F18H0QA
1. Brushes
2. Retaining screw
3. Brush holder
Remove springs.
F06H1HA 1
TYPICAL CLEANING
1. Thrust washers
CAUTION: Yoke ass’y and drive unit assembly
Remove the other end cover containing brushes and must not be immersed in cleaning solvent.
brush holder assembly.
Discard all O-rings.
Remove armature.
Clean brushes and holders with a clean cloth soaked
in solvent. Brushes must be dried thoroughly with a
clean cloth.
08-03-4 LMR2004_021_08_03A.FM
Blow brush holders clean using compressed air. Brush Holder

 WARNING Check brush holder for insulation using an ohm-
meter. Place one test probe on insulated brush
Always wear safety glasses when using com- holder and the other test probe on brush holder
pressed air. plate. If continuity is found, brush holder has to be
repaired or replaced.
Remove dirt, oil or grease from commutator using
a clean cloth soaked in a suitable solvent. Dry well Brush
using a clean, dry cloth.
Measure brush length. If less than 8.5 mm (.335 in),
Clean engine ring gear teeth and drive unit (clutch). replace them.
NOTE: Bushings or bearings must not be cleaned NOTE: New brush length is 12 mm (.472 in).
with grease dissolving agents.
Immerse all metal components in cleaning solu-
tion. Dry using a clean, dry cloth.
PARTS INSPECTION 1 2
Armature
NOTE: An ohmmeter may be used for the follow-
ing testing procedures, except for the one con-
cerning shorted windings in armature.
Check commutator for rough, burnt or scored sur-
face. If necessary, turn commutator on a lathe, A03E05A
enough to resurface only.
TYPICAL
Check commutator for mica depth. If depth is less 1. New
than 0.20 mm (.008 in), undercut mica. Be sure 2. Wear limit, 8.5 mm (.335 in)
that no burrs are left and no copper dust remains
between segments after undercutting operation Overrunning Clutch
is completed. Pinion of overrunning clutch should turn smoothly
Check commutator condition with an indicator. If in clockwise direction, and should not slip in a
out of specification, replace the starter. counterclockwise direction. If defective, replace.
Check pinion teeth for wear and damage. If defec-
tive, replace.
NOTE: Always check engine ring gear teeth for
1 wear and damage. If defective replace ring gear.
Refer to MAGNETO.
STARTER ASSEMBLY
Reverse the order of disassembly to reassemble
starter. However, attention should be paid to the
following operations.
Install new O-rings.
F18H0RA
1. Commutator undercut 0.20 mm (.008 in)
LMR2004_021_08_03A.FM 08-03-5
Insert thrust washer onto armature shaft. Nut

CAUTION: Use ONLY a 1/4-20 UNC stainless nut
on starter cable stud.
Connect the RED positive cable to the starter and
torque nut to 7 N•m (62 lbf•in). Apply dielectric
grease on terminal and nut.
Slide protective boot over nut to shield metallic parts
from potential electrical shorting and corrosion.
F06H1HA 1
1. Thrust washer
When installing end covers to yoke, align index marks.

Apply Loctite 271 (red) on through bolts and torque
to 6 N•m (53 lbf•in).
STARTER INSTALLATION 2 3 1

procedure. However, pay particular attention to the
following. F18H0UB
Make sure that starter and engine mating surfaces 1. Grease on O-rings
2. Torque nut to 7 N•m (62 lbf•in) and apply dielectric grease and
are free of debris. Serious trouble may arise if start- install protection cover
er is not properly aligned. 3. Apply Loctite 243 to threads and torque screws to 10 N•m
(89 lbf•in)
Apply grease Isoflex Topas NB52 (P/N 293 550 021)
on O-rings of starter.  WARNING
Install Starter. Always connect RED positive cable first then
NOTE: If starter does not mesh properly, try to pull BLACK negative cable last. Whenever con-
it out and slightly rotate the starter gear; then rein- necting the RED positive cable to the starter
stall starter. If necessary, temporarily remove both motor make sure the battery cables are dis-
O-rings, properly mesh gears then remove starter connected to prevent electric shock.
to reinstall O-rings, being careful not to rotate gear
to keep its position, to finally reinstall starter.
Apply Loctite 243 (blue) on retaining screws no. 1
and torque to 10 N•m (89 lb•in).
08-03-6 LMR2004_021_08_03A.FM
STARTER SPECIFICATION
Nominal output 0.9 kW
Voltage 12 V
Rated time 30 seconds
Rotation Counterclockwise (viewed from pinion side)
Weight 2.5 kg (5.39 lb)
No load 11.4 V 23 A max. 8600 RPM
Performance specification at 20°C (68°F) Load 8.5 V 140 A max. 5200 RPM
Stall 3.75 V 330 A max. 0 RPM
Battery 12 V, 30 Ah
LMR2004_021_08_03A.FM 08-03-7
Subsection 04 (INSTRUMENTS AND ACCESSORIES)
INSTRUMENTS AND ACCESSORIES 0

ADDITION OF ACCESSORIES Install safety lanyard to activate system.
Slowly rotate the paddle wheel. Every 1/8 turn, the
Every time an accessory is added, it must be reg-
observed voltage should fluctuate between 5.5
istered using B.U.D.S. to activate it in the MPEM.
and 8.5 Vdc.
If an option is checked in B.U.D.S. but not installed
in vehicle, a fault code will be generated. Fuel Gauge and Sender Check
Use the OPTIONS area in the Setting tab in B.U.D.S. Ensure accessory fuse is good and gauge is getting
power (PURPLE wire) and a proper ground (BLACK
INSPECTION wire).
Speed Sensor Fuel Gauge Verification

The speedometer gives a reading through a speed Ensure battery is charged and battery switch is on.
sensor. Speed sensor is installed on the hull. Wa- Remove rear seat cushions.
ter passing under the hull turns a magnetic paddle
wheel that triggers an electronic pick-up that in
turn sends a speed signal to the speedometer.
The paddle wheel is protected by the pick-up
housing.
1
F13F06A
1. Remove these cushions
1 2 Remove rear seat storage tubs.

F13H08A
1. Pick-up housing
2. Paddle wheel
To check if the speed sensor is operational, discon-

nect the speed sensor connector housing from in-
side bilge.
Using an appropriate terminal remover (Snap-on
TT600-4), remove the PURPLE/YELLOW and
BLACK/ORANGE wires from the tab housing of
the speed sensor.
Reconnect the PURPLE/YELLOW and BLACK/ 1
ORANGE wires in the receptacle housing.
F13F05A
Connect the positive probe of a multimeter to
speed sensor PURPLE/YELLOW wire and the neg- 1. Remove these storage tubs
ative probe to speed sensor BLACK/ORANGE wire. Install lanyard on DESS post.
LMR2004-022-08-04A.FM 08-04-1
Subsection 04 (INSTRUMENTS AND ACCESSORIES)
Unplug the two-wire connector (PINK and PINK/ RESISTANCE WET HEIGHT FROM
BLACK wires) near fuel pump module. (Ω) BOTTOM (mm)
4.8 ± 2.2 247 ± 5.0
17.8 ± 2.2 207 ± 5.0
27.8 ± 2.2 183 ± 5.0
37.8 ± 2.2 158 ± 5.0
47.8 ± 2.2 133 ± 5.0
57.8 ± 2.4 105 ± 5.0
67.8 ± 2.8 76 ± 5.0
77.8 ± 3.6 55 ± 5.0
89.8 ± 3.6 35.3 ± 5.0
Fuel Baffle Pick-Up Sender

F13F07A
The fuel pick-up system is part of the fuel pump
module mounted inside the fuel reservoir.
UNPLUG THIS CONNECTOR
The fuel level gauge sender is also mounted on
Momentarily short the PINK and PINK/BLACK wires this module.
of the harness together using a jumper wire. With-
out a jumper the gauge should read empty. When
the wires are jumped the gauge should read full.
F13F08A
1. Jump PINK and PINK/BLACK wires F07F09A
If the gauge needle does not move when the wires TYPICAL — FUEL LEVEL GAUGE SENDER MOUNTED ON FUEL
are jumped, check the harness connections at the PUMP MODULE
gauge or replace gauge. Refer to ENGINE MANAGEMENT.
If the gauge needle moves to “FULL” when the
wires are jumped, the gauge is working correctly.
If the sending unit is suspect, connect an Ohm
meter to the PINK and PINK/BLACK wires of the
fuel module (NOT the harness) and note the read-
ing. The resistance reading should be somewhere
between 2.6 and 93 ohms (see following chart).
08-04-2 LMR2004-022-08-04A.FM
Section 09 PROPULSION SYSTEM
TABLE OF CONTENTS 0
JET PUMP .............................................................................................................................. 09-02-1
GENERAL ........................................................................................................................... 09-02-2
JET PUMP INSPECTION ON SPORT BOAT..................................................................... 09-02-2
REMOVAL........................................................................................................................... 09-02-3
DISASSEMBLY................................................................................................................... 09-02-4
CLEANING ......................................................................................................................... 09-02-7
PARTS INSPECTION .......................................................................................................... 09-02-8
ASSEMBLY......................................................................................................................... 09-02-9
PUMP PRESSURIZATION ................................................................................................. 09-02-13
INSTALLATION .................................................................................................................. 09-02-13
DRIVE SYSTEM ..................................................................................................................... 09-03-1

GENERAL ........................................................................................................................... 09-03-2
REMOVAL........................................................................................................................... 09-03-2
INSPECTION ...................................................................................................................... 09-03-5
INSTALLATION .................................................................................................................. 09-03-6
LMR2004-030_09_01ATOC.FM 09-01-1
Subsection 02 (JET PUMP)
JET PUMP 0
Loctite 3
518 2
Loctite
6 Nm 454
(53 lbfin)
1
44
40
41
25 31
31 Nm
34 (23 lbfft)
35 46
36 Alsaco
grease 24 Nm
(18 lbfft)
Pipe sealant
30 592
21
32
33 24 23
Primer N and 45
22
Loctite 243 28
37
13
26
7.5 Nm
(66 lbfin) 42
43
39 20
8 Loctite 243
21 Nm
(15 lbfft)
F04J4FS
LMR2004-023-09-02A.FM 09-02-1
 WARNING
Screws must be torqued as specified.

each engine.
1
GENERAL
4
2
5 F02J0VA
1 1. Stamped part number
SPORT BOAT IMPELLER

MATERIAL PITCH
MODELS P/N
6
Progressive
Stainless
5773/5160 271 001 386 pitch
F00J0SA steel
13° - 23°
TYPICAL
1. Nozzle
2. Venturi
3. Housing
JET PUMP INSPECTION ON
4. Wear ring SPORT BOAT
5. Impeller
6. Stator To work on sport boat, securely install it on a stand.
Thus, if access is needed to water inlet area, it will
Disassembly Preparation be easy to slide underneath sport boat.
Hands, tools, bench, rags must be clean before
pump disassembly. Impeller Condition
CAUTION: Pump grease tube must be opened Condition of impeller no. 1, boot no. 2 and ring
at the very last moment to avoid contamination. no. 3 can be quickly checked from underneath of
the sport boat. Remove grate and look through
Impeller Identification water inlet opening.
To identify the impellers refer to the following il-
lustration and chart.
F01J0DA
TYPICAL
1. Inspect impeller and boot
09-02-2 LMR2004-023-09-02A.FM
Impeller/Wear Ring Clearance REMOVAL

This clearance is critical for jet pump performance. Pump Assembly
Clearance can be checked from water inlet open-
ing or from venturi side. However, the last method
requires more work.
To check clearance from water inlet side, remove
inlet grate.
To check clearance from venturi side, remove venturi/
nozzle assembly.
Using a feeler gauge with 30 cm (12 in) blades,
measure clearance between impeller blade tip and
wear ring. Measure each blade at its center. Clear-
ance should not exceed 0.35 mm (.014 in). If clear-
ance is greater, disassemble jet pump and inspect
impeller and wear ring. Renew worn parts.
1 F13J01A 1 2
1. Reverse cable
2. Steering cable
Disconnect steering and reverse cables.

Remove 4 pump retaining nuts no. 25.
Pull out pump.
Reverse Gate
To remove reverse gate no. 4, put shift lever in
reverse position.
Remove reverse cable.
F01J0EA
TYPICAL — MEASURING FROM WATER INLET SIDE

1. Feeler gauge
F04J4CA 1
1. Screw no. 8 (portside)
Remove both reverse gate screws no. 8.
F01J0FA 1
TYPICAL — MEASURING FROM VENTURI SIDE
1. Feeler gauge
LMR2004-023-09-02A.FM 09-02-3
Nozzle 1
Remove reverse gate.
Disconnect steering cable from jet pump nozzle.
Remove 2 retaining screws no. 21, 2 sleeves no. 22,
2 washers no. 23.
Remove nozzle.
Venturi
Remove:
– reverse gate
– nozzle.
Remove 4 retaining screws no. 39 and withdraw
venturi no. 24. F02J0TA 1
It’s possible to remove the venturi without remov- TYPICAL
ing the reverse gate and the nozzle, see the fol- 1. Remove screws
lowing instructions.
Disconnect: Jet Pump Housing
– steering cable Remove pump as an assembly or remove the fol-
lowing:
– reverse cable.
– nozzle
– venturi.
Loosen 4 hexagonal nuts no. 25 and remove flat
washers no. 40 and lock washers no. 41 from jet
pump housing.
Remove jet pump with a wiggle movement.
CAUTION: When removing pump unit, a shim
could have been installed between hull and
pump housing. Be sure to reinstall it otherwise
engine and jet pump alignment will be altered.
NOTE: After jet pump removal, if drive shaft re-
mains in the PTO flywheel, simply pull it out. If
drive shaft is seized in the PTO flywheel, refer to
DRIVE SYSTEM.
F13J01A 1 2
1. Reverse cable
2. Steering cable DISASSEMBLY
Remove 4 retaining screws no. 39 and withdraw NOTE: Whenever removing a part, visually check
venturi no. 24. for damage such as: corrosion, crack, split, break,
porosity, cavitation, deformation, distortion, heat
discoloration, wear pattern, missing plating, miss-
ing or broken balls in ball bearing, water damage
diagnosed by black-colored spots on metal parts,
etc. Renew any damaged part. As a quick check,
manually feel clearance and end play, where appli-
cable, to detect excessive wear.
09-02-4 LMR2004-023-09-02A.FM
Cover
With pump housing in vertical position, remove 3
retaining screws no. 26.
F18J0NA
F18J0LA
Using a fiber hammer, gently tap cover to release

it from jet pump housing. Use flat screwdriver to
remove cap.
F18J0OA
Impeller
Remove ring no. 3, impeller boot no. 2. Replace
them if damaged.
Mount impeller remover/installer (P/N 529 035 820)
in a vise.
529 035 820

F18J0MA
Check for presence of water in cone and bearing.

If so, replace oil seal no. 35 and sleeve no. 30.
Remove both O-rings no. 37 and circlip no. 45.
F18J0PA
LMR2004-023-09-02A.FM 09-02-5
Install pump over this tool.
F18J0SA
F18J0QA Remove shield no. 34.
Using a 12 mm Allen key, unscrew the impeller.

NOTE: It may be necessary to heat the impeller in
order to break Loctite bond.
F18J0TA
Use the impeller shaft pusher (P/N 529 035 818)

F18J0RA to press impeller shaft no. 28 out of pump hous-
ing. Bearing no. 33, shaft sleeve no. 30, O-ring
CAUTION: Never use an impact wrench to loos- no. 46 and spacer no. 32 will come out with the
en the impeller. impeller shaft.
To remove the impeller, rotate and pull at the same
time. Slide impeller out of housing.
Remove pump housing. 529 035 818
F18J0UA
09-02-6 LMR2004-023-09-02A.FM
CAUTION: Bearing inner race being in 2 parts, After cutting ring, insert a screwdriver blade be-
bearing may fall apart during removal. tween jet pump housing and ring outside diameter.
Use the seal/bearing pusher (P/N 529 035 819) to Push ring so that it can collapse internally.
press out bearing no. 33 from impeller shaft. Pull ring out.
CLEANING
Thoroughly clean jet pump housing by applying Loc-
tite Stripper (P/N 293 110 004). Allow it some time
to dissolve the old dried Loctite (10 to 15 minutes).
 WARNING
Technician should wear gloves when using this
cleaning product.
CAUTION: DO NOT use Loctite Stripper on wear

ring since it will cause irreparable damage to it.
Remove Loctite Stripper from surface with a clean
F18J0VA 529 035 819 cloth.
Make sure surface is cleaned and dried of Loctite
From the outlet side of pump, use the seal/bearing Stripper.
pusher (P/N 529 035 819) to press out the oil seal Sealant on the jet pump housing can be removed
no. 35. with a wire brush (disc) mounted on a drill or a
scraper.
Properly clean all threads.
529 035 819 Remove all O-rings and clean parts in a solvent.
Carefully check water passages. Blow low pres-
sure compressed air through them and make sure
they are clear.
1
F18J0WA
Remove large O-ring no. 36 from pump housing.
Wear Ring
Remove the screws retaining wear ring in the jet
pump housing.
Place jet pump housing in a vise with soft jaws. It
F18J0XA
is best to clamp housing using a lower ear.
1. Water passages
Cut wear ring at two places.
CAUTION: When cutting ring, be careful not to Brush and clean impeller shaft threads, impeller
damage jet pump housing. and drive shaft splines with pulley flange cleaner
(P/N 413 711 809) or equivalent. Free threads and
NOTE: Wear ring can be cut using a jigsaw, a small splines from any residue.
grinder or a low clearance hacksaw such as Snap-on
HS3 or equivalent.
LMR2004-023-09-02A.FM 09-02-7
PARTS INSPECTION Wear Ring

Check wear ring no. 31 for deep scratches, irreg-
Impeller ular surface or any apparent damage.
Visually inspect impeller splines. Check for wear If impeller/wear ring clearance is too large and im-
or deformation. Renew parts if damaged. peller is in good shape, renew wear ring.
NOTE: Check also PTO flywheel and drive shaft con-
dition. Refer to BOTTOM END and DRIVE SYSTEM. Ball Bearing and Impeller Shaft
Examine impeller in wear ring for distortion. WEAR
Check if blade tips are blunted round, chipped or IMPORTANT: Make sure to reassemble ball cage,
broken. Such impeller is unbalanced and will vi- bearing inner and outer races to their original position.
brate and damage wear ring, impeller shaft, shaft
seal or bearings. Renew if damaged. Inspect ball bearing no. 33. Check for corrosion,
scoring, pitting, chipping or other evidence of wear.
1
With your finger nail, feel contact surface of sleeve.
If any irregular surface is found, renew sleeve
no. 30 and seal.
Install bearing, then install impeller shaft and ro-
tate it. Make sure it turns smoothly.
RADIAL PLAY
Radial play is critical for jet pump unit life span.
Radial play of impeller shaft is checked with shaft
in housing, with impeller.
Retain housing in a soft jaw vise making sure not
to damage housing lug.
Set a dial gauge and position its tip onto metal end,
close to end of threads.
Move shaft end up and down. Difference between
F18J1BA
highest and lowest dial gauge reading is radial play.
1. Replace if blunted round or damaged
Maximum permissible radial play is 0.75 mm (.029 in).
Check impeller for cavitation damage, deep scratch-

es or any other damage.
F18J1DA 1 2
MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
F18J1CA 2. Measure close to threads at shaft end
1. Check for cavitation, deep scratches or other damage
09-02-8 LMR2004-023-09-02A.FM
Excessive play can come either from worn bearing

or damaged jet pump housing bearing surface.
Seal
Carefully inspect seal lips. Make sure that lips are
not worn, distorted, cracked or show signs of any
other damage. Replace after 100 hours.
Bearing
Replace bearing whenever the marks of corrosion
and presence of water is found.
ASSEMBLY F08J07A
Hands, tools, bench, rags must be clean before To install ring in housing, use a square steel plate
pump assembly. of approximately 180 x 180 mm x 6 mm thick (7 x
CAUTION: Pump grease tube must be opened 7 in x 1/4 in) and a press.
at very last moment to avoid contamination. Manually engage ring in housing making sure it is
equally inserted all around. Press ring until it seats
Wear Ring into bottom of housing.
This model is equipped with a large pump. It is im-
portant that the screws retaining wear ring to hous-
ing are installed on this model.
F01J5DA
F08J06A 1. Seal lip

2. Press wear ring
If a press is not readily available, a piece of wood

such as a 2 x 4 in x 12 in long, can be used.
LMR2004-023-09-02A.FM 09-02-9
Manually engage ring in housing making sure it is

equally inserted all around. Place wood piece over
ring. Using a hammer, strike on wood to push ring.
Strike one side then rotate wood piece about 90°
and strike again. Frequently rotate wood piece so
that ring slides in evenly until it seats into bottom 529 035 819
of housing.
F18J0YA
3
Install spacer no. 32 on shaft no. 28.
Install O-ring no. 46 in sleeve no. 30.
2
1
1
F01J5EA
1. Piece of wood
2. Seal lip facing upward
3. Wear ring
NOTE: Do not forget, install two retaining screws

on top of the large pump models.
Bearing
F18J0ZA
Using the seal/bearing pusher (P/N 529 035 819)
press the bearing no. 33 by its inner race on the 1. O-ring
impeller shaft no. 28. Coat shaft surface with jet pump bearing grease
Be careful when removing the plastic retainer from (P/N 293 550 032) then, install sleeve no. 30 on
the bearing no. 33 to avoid the inner races from impeller shaft no. 28.
falling apart. Make sure to reassemble bearing
parts to their original position.
The bearing no. 33 can be installed either side.
F18J10A
09-02-10 LMR2004-023-09-02A.FM
From the outlet side of pump, press impeller shaft

1
assembly into housing using shaft pusher (P/N 529
035 818).
529 035 818
F18J13A
1. Lips facing up
529 035 819

F18J11A
Install circlip no. 45 and O-rings no. 37.

Apply 10 cc of jet pump bearing grease (P/N 293
550 032) on bearing.
F18J14A
On the outlet side, install 2 O-rings no. 37 in their

respective groove.
Before installing any other parts, pump can be
pressurized to insure proper seal installation. See
F18J12A
PUMP PRESSURIZATION below.
Press oil seal no. 35 using seal/bearing pusher On the impeller side, install shield no. 34.
(P/N 529 035 819) until tool bottoms. Make sure
seal lips are facing up.
LMR2004-023-09-02A.FM 09-02-11
Apply Loctite 243 on impeller shaft and impeller Apply 50 cc of jet pump bearing grease (P/N 293
threads. 550 032) in the impeller shaft area.
F18J17A
F18J15A
Apply another 50 cc of jet pump bearing grease

(P/N 293 550 032) in the impeller cover.
F18J16A
Apply BOMBARDIER LUBE on the wear ring sur- F18J18A
face. Start screwing the impeller on its shaft. If

impeller is too tight, use impeller tool to turn im- Install impeller cover with new self-locking screws.
peller to machine wear ring before installing on ve- Torque to 7 N•m (62 lbf•in).
hicle. Make sure to turn it smooth enough so that
engine starter should turn it. Venturi
Mount impeller remover/installer (P/N 529 035 820) Position venturi no. 24 with bailer passages on top.
in a vise. Apply Loctite 243 (blue) on threads of screws no. 39.
Install partially screwed impeller on it. Install screws no. 39, lock washers and flat wash-
Use a 12 mm Allen key to torque impeller shaft to ers then torque to 21 N•m (15 lbf•ft).
125 N•m (92 lbf•ft) then remove tool.
CAUTION: Never use any impact wrench to tight-
en impeller shaft.
09-02-12 LMR2004-023-09-02A.FM
NOTE: If there is a pressure drop spray soapy wa-

1 ter around cover. If there are no bubbles, impeller
shaft, impeller shaft seal, or jet pump housing is
leaking through porosity and has to be replaced.
Jet pump unit has to be disassembled. There may
be 2 or 3 bubbles coming out from sleeve no. 30
seal area. This small leak is acceptable. Leaks from
other areas must be repaired.
– Disconnect pump gauge tester and remove pres-
sure cap.
– Reinstall impeller cover no. 13 with 3 new self-
locking screws.
INSTALLATION
F02J0TA 1
Jet Pump Housing
1. Torque screws to 21 N•m (15 lbf•ft)
Make sure that black rubber covered reducer
no. 44 is installed as shown.
PUMP PRESSURIZATION
CAUTION: Misinstallation can cause overheat-
Whenever doing any type of repair on jet pump, a ing and damage to exhaust system.
pressure test should be done to check for leakage.
Proceed as follows: 1
– Remove impeller cover no. 13. Install pressure

cap (P/N 529 035 843) on pump housing.
– Connect pump gauge tester (P/N 529 021 800)
to fitting.
– Pressurize pump to a maximum of 70 kPa (10 PSI).
529 035 843
F18J0IA
1. Black rubber covered reducer
Generously apply synthetic grease on drive shaft

splines.
Make sure rubber damper is on drive shaft PTO end.
Install jet pump. If necessary, wiggle jet pump to
engage drive shaft splines in impeller.
CAUTION: Some boats require a shim between
F18J19A hull and pump; if shim has been removed at
pump removal, be sure to reinstall it, otherwise
– Pump must maintain this pressure for at least 5 engine alignment will be altered.
minutes. Apply Loctite 243 (blue) on stud threads of jet pump
CAUTION: Repair any leak, failure to correct a housing.
leak will lead to premature wear of pump com- Install flat washers no. 40, lock washers no. 41
ponents. and nuts no. 25. Tighten nuts of jet pump housing
in a criss-cross sequence and torque to 31 N•m
(23 lbf•ft).
LMR2004-023-09-02A.FM 09-02-13
NOTE: Slightly lubricate wear ring with BOMBARDIER Position their flanges from inside of nozzle.
LUBE lubricant to minimize friction during initial start. Insert sleeves no. 22 in bushings no. 42 and no. 43.
Nozzle Install nozzle on venturi no. 24; position its steer-
ing arm on RH side. Apply Loctite 243 (blue) on
Insert bushing no. 42 in nozzle no. 20. screw threads (or use new self-locking screws). In-
Insert bushing no. 43 in nozzle no. 20 with its off- stall screws no. 21 and washer no. 23 then torque
set pointing forward. to 24 N•m (18 lbf•ft).
 WARNING
Screws must be torqued as specified.
Reverse Gate
Install reverse gate with spacer and washer. Torque
to 20 N•m (177 lbf•in).
Steering Cable
Refer to section, STEERING SYSTEM.
1 Reverse Cable
Refer to STEERING SYSTEM (THROTTLE/SHIFTER
CONTROLLER).
F04J4EA
1. Bushing offset
09-02-14 LMR2004-023-09-02A.FM
Subsection 03 (DRIVE SYSTEM)
DRIVE SYSTEM
4-TEC Models
5
6
7
8
9
10
11
Loctite
antiseize 15
lubricant
12
16
Synthetic
grease
F18I01S
LMR2004-024_09_03A.FM 09-03-1
GENERAL
each engine.
Jet pump must be removed to replace any com-
ponents of the drive system. Refer to JET PUMP
for removal procedure.
REMOVAL
NOTE: When drive shaft is removed, some oil will
flow out. To prevent this, start engine, run at 4000 1
RPM for 10 seconds and stop engine at this RPM.
This will move oil out of PTO housing into oil tank.
Floating Ring and PTO Seal

CAUTION: Strictly follow this procedure other- F18I04A
wise damage to component(s) might occur. Lift 1. Insert in groove of PTO seal assembly
splash guard to expose PTO seal assembly. In-
stall PTO seal support tool (P/N 529 035 842) on Remove jet pump. Refer to JET PUMP section.
bottom of PTO seal assembly as shown. Install drive shaft holder (P/N 529 035 871) on
pump support as shown.
NOTE: This is necessary so the drive shaft cannot
move rearwards when using the drive shaft/floating
1
ring tool.
F18B01A 1
1. PTO seal support tool
F18B02A
1. Drive shaft holder
09-03-2 LMR2004-024_09_03A.FM
2 1
F18B03A
TYPICAL
Install drive shaft/floating ring tool (P/N 529 035

841) as shown.
F18I05A
1. Largest opening here

2. Floating ring
F18B04A Turn screw clockwise so that the tool pushes the

floating ring rearwards to expose the C-clip. Do
DRIVE SHAFT/FLOATING RING TOOL
not remove clip at this time.
NOTE: This step is done to ensure floating ring is
free and not stuck on the drive shaft.
Remove drive shaft/floating ring tool and drive
shaft holder.
LMR2004-024_09_03A.FM 09-03-3
Reinstall drive shaft/floating ring tool as shown.

1
F18B03A
TYPICAL

Push floating ring rearwards to expose C-clip and
2
remove it.
2 1
F18I08A

2. Lubricate both O-rings
Turn screw clockwise so that the tool pushes the

PTO seal forward and the drive shaft to the rear
to expose both O-rings. Lubricate O-rings with
BOMBARDIER LUBE (P/N 293 600 016).
NOTE: This is necessary to ease drive shaft re-
moval later. F18I0BA
Remove drive shaft/floating ring tool and PTO seal 1. Largest opening here
2. Remove C-clip
support.
Remove drive shaft holder tool then drive shaft/
floating ring tool.
NOTE: Use this sequence to minimize the
amount of movement the drive will slide back into
PTO seal assembly.
Drive Shaft
Simply pull out drive shaft.
09-03-4 LMR2004-024_09_03A.FM

If spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent oil
stains.
NOTE: It may require a slight jerk to the rear to
remove the O-rings from the PTO seal assembly.
Boot
1
Loosen gear clamp no. 11 holding boot, then care-
fully pull boot and carbon ring no. 8 from hull in-
sert.
Carbon Ring
F01J15A 2
Loosen gear clamp no. 9 then pull carbon ring
from boot no. 10. MEASURING DRIVE SHAFT DEFLECTION
1. Dial gauge
2. V-blocks
INSPECTION
Damper
Drive Shaft
Discard damper and install a new one.
Inspect condition of drive shaft and PTO flywheel
splines. Floating Ring and O-Ring
Inspect condition of groove. Inspect condition of O-rings no. 7 and floating ring
With your finger nail, feel machined surface of no. 6 contact surface.
drive shaft. If any irregular surface is found, renew
drive shaft. 1
2
F01I0FA 1 2 3
TYPICAL
1. Surface condition
2. Groove condition
F01I0GA
3. Splines condition
Discard both O-rings no. 16 and install new ones. 1. O-rings

2. Floating ring contact surface
Excessive deflection could cause vibration and
damage to drive shaft splines, impeller, flywheel Boot
or floating ring (seal carrier depending upon the Inspect the condition of boot. If there is any dam-
model). age or evidence of wear, replace it.
Place drive shaft on V-blocks and set-up a dial To verify the preload of the boot no. 10, proceed
gauge in center of shaft. Slowly rotate shaft; dif- as follows:
ference between highest and lowest dial gauge
reading is deflection. Refer to the following illus- NOTE: To verify the boot preload and free length,
tration. jet pump and drive shaft must be installed.
Maximum permissible deflection is 0.5 mm
(.020 in).
LMR2004-024_09_03A.FM 09-03-5
Measure boot length when normally installed on INSTALLATION

drive shaft. Ensure circlip no. 5 is properly in-
stalled into groove. Installation is essentially the reverse of removal
procedure. However, pay particular attention to
1 the following.
Drive Shaft and Dampers

Ensure to install a new damper no. 15 and new
O-rings no. 16 on drive shaft no. 12.
NOTE: Ensure to install floating ring before insert-
ing the drive shaft on PTO seal assembly.
Before installing drive shaft, inspect PTO seal as-
sembly. The inner sleeve must be flush with outer
circumference of the assembly. Otherwise, gently
push or tap on inner sleeve until flush.
F04J4AA
TYPICAL
1. Boot
A. Measure here
The measured distance of dimension “A” should

be between 63 mm (2.48 in) and 71 mm (2.80 in).
If the length is more than 71 mm (2.80 in), install
a spacer (P/N 293 250 017) between boot and thru
hull fitting.
1 F18I0EA 1
CORRECT INSTALLATION
1. Inner sleeve flush with outer circumference
F00J04B
TYPICAL
1. Spacer
NOTE: Drive shaft must be removed to install

spacer.
F18I0FA 1
Inspect PTO seal assembly. Refer to PTO HOUSING/
WRONG INSTALLATION
MAGNETO SECTION.
1. Inner sleeve not flush with outer circumference
09-03-6 LMR2004-024_09_03A.FM
Slightly apply BOMBARDIER LUBE (P/N 293 600 Slide drive shaft far enough to install floating ring.
016) on O-rings of drive shaft.
Apply a thin coat of synthetic grease (P/N 293 550
010) on the O-rings of floating ring and on splines
going in impeller. Do not get grease on it’s sealing
surface.
1 2
F18I02A
F18I0KA
Continue pushing drive shaft towards engine care-
1. Synthetic grease fully guiding it in the PTO seal then in crankshaft
2. No lubrication
splines.
CAUTION: Note that drive shaft features a tell-
Then, push drive shaft until it bottoms against the
tale groove. If exposed after installation, the in-
engine.
stallation is wrong and PTO seal assembly will
be pressed into crankshaft splines which could While someone is pushing drive shaft, slide float-
rub a hole in seal thus creating an oil leak. ing ring rearward and guide drive shaft in PTO seal
assembly. It may be necessary to move PTO seal
assembly up and down to position it in the same
axis as the drive shaft.
When properly aligned, maintain PTO seal assem-
bly in the proper position and tap shaft end until it
bottoms against engine. At this time, the tell-tale
MUST NOT be visible. This validates the correct
position.
F18I0GA 1
1. Tell-tale groove
Install PTO seal assembly.

Install PTO seal support tool on PTO seal assem-
bly. F18I0HA 1 2 3
1. PTO seal support
2. Drive shaft end
3. Insert floating ring on shaft end
LMR2004-024_09_03A.FM 09-03-7
Install drive shaft holder tool.

3 1
F18B03A
Install Drive shaft/floating ring tool as shown. En-

sure PTO seal support is still in place.
F18I0IA 2
Push floating ring rearwards and install C-clip.
GOOD INSTALLATION
1. PTO seal assembly 2 1
2. Shaft pushed in, hiding tell-tale groove
3. Inner sleeve flush with outer circumference
3 1
F18I06A
1. Largest opening
2. Install C-clip
Remove drive shaft/floating ring tool, drive shaft

F18I0JA 2 holder then PTO seal support.
WRONG INSTALLATION NOTE: Pushing boot no. 10 rearwards will ease
1. PTO seal assembly removal of PTO seal support tool.
2. Tell-tale groove visible
3. Inner sleeve NOT flush with outer circumference
09-03-8 LMR2004-024_09_03A.FM
Now ensure everything is properly positioned: Tell

tale is not exposed, inner sleeve is flush with outer
circumference of PTO seal assembly and C-clip is
not exposed.
If tell-tale mark is exposed, push PTO seal assem-
bly rearwards to fully extend it.
If inner sleeve is not flush, gently tap it until it is
flush.
Reposition splash guard.
Install jet pump. Refer to JET PUMP section.
Check engine oil level. Refill as necessary.
Run sport boat then ensure there is no oil leak in
PTO seal area.
LMR2004-024_09_03A.FM 09-03-9
Section 10 STEERING SYSTEM
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 10-02-1
STEERING SYSTEM INSPECTION ................................................................................... 10-02-2
STEERING CABLE REPLACEMENT .................................................................................. 10-02-2
STEERING HELM REPLACEMENT ................................................................................... 10-02-3
ALIGNMENT .......................................................................................................................... 10-03-1

VERIFICATION ................................................................................................................... 10-03-1
ADJUSTMENT ................................................................................................................... 10-03-1
THROTTLE/SHIFTER CONTROLLER .................................................................................... 10-04-1

REMOVAL........................................................................................................................... 10-04-2
INSPECTION ...................................................................................................................... 10-04-2
LUBRICATION .................................................................................................................... 10-04-2
CABLE REMOVAL.............................................................................................................. 10-04-2
CABLE INSTALLATION ..................................................................................................... 10-04-3
ADJUSTMENTS ................................................................................................................ 10-04-3
ASSEMBLY......................................................................................................................... 10-04-4
LMR2004-030_10_01ATOC.FM 10-01-1
Subsection 02 (STEERING SYSTEM)
STEERING SYSTEM 0
7.5 Nm 16
(66 lbfin)
11
15 14 Nm
8 (124 lbfin)
Woodruff 10
key 12
7
3 Nm
(26 lbfin) 14 20 Nm
(15 lbfft)
1.7 Nm 6
(15 lbfin) 13
9 3 Nm
30 Nm (26 lbfin)
(22 lbfft)
6 Nm 5
(53 lbfin)
7.5 Nm
(66 lbfin)
2
Silicone sealant
3
2.5 Nm
4 (22 lbfin)
1
7 Nm Loctite 243
F13K0GS (62 lbfin)
LMR2004-026-10_02A.FM 10-02-1
STEERING SYSTEM INSPECTION Check cable movement. Replace as necessary.

Turn steering from side to side, if rotation move-
Check operation of steering. It must turn easily ment is abnormal or if end play is excessive, re-
and smoothly with a regular resistance from side place steering helm as an assembly.
to side. Rotating resistance must be at a minimum.
No friction should be felt. No frictional sound should
be heard. Check steering end play. If something is  WARNING
wrong, isolate cable from steering helm to diag- Disassembly of the steering helm can lead to
nose faulty part. Proceed as follows. steering failure. Replace complete assembly.
Visually check cable for wear and oxidation at For cable assembly, use supplied hardware
steering helm and at nozzle. Check at end of cable only. Do not use substitutes.
housing. Replace as necessary.
Detach cable end from helm arm no. 11. STEERING CABLE REPLACEMENT
Removal
Remove nut no. 1 from bolt no. 2, then from nozzle
and adjuster no. 4.
Remove nut no. 3 from cable no. 5.
From inside of hull, remove silicone around cable.
Pull cable out of transom.
Detach nut no. 10 from cable end on rotating arm
no. 6 to release cable.
Remove nut no. 8 and no. 14 from adjuster no. 7
2 on helm arm no. 11 to release cable no. 5.
1
Rotate steering wheel (or shaft) to release tension
F04K1IA
on throttle cable.
TYPICAL
Detach cable housing no. 5 from helm arm no. 11.
1. Remove nut and detach from arm (underneath) Unscrew pivot no. 12 and adjuster no. 7 from ca-
2. Loosen this nut to allow moving cable
ble to allow removal of steering cable.
Remove cable from hull.
Installation
Reinstall removed parts and pay attention to the
following:
1 – Pass cable through transom.
– Screw external nut no. 3.
– Position adjuster no. 4 half way on threaded
length of cable end.
– Secure adjuster on nozzle.
– Secure steering cable to helm.
– Proceed with steering adjustment
F04K1JA (refer to ALIGNMENT).
HELM REMOVED FOR CLARITY PURPOSE ONLY – From inside of hull, apply Adseal 4511 (P/N 293
(REMOVAL IS NOT REQUIRED FOR THE VERIFICATION) 800 033) on cable and nut area to seal hull.
1. Check for wear (particularly brass bushing wear) or oxidation in
this area – Check cable/hull watertightness.
10-02-2 LMR2004-026-10_02A.FM
STEERING HELM REPLACEMENT Once steering wheel is unlocked, remove steering

wheel puller, nut with washer and steering wheel.
Removal
To release steering cover, push tabs inside then
pull cover, as shown in the next photo.
F09K06A 2 1
TYPICAL
1. Loosen this nut first
2. Use a 24 mm (15/16 in) socket
Be careful to keep Woodruff key for reinstallation.

F13K04A
Open driver storage cover and remove console
CAREFULLY REMOVE WITH SMALL SCREWDRIVER storage bucket.
Loosen lock nut no. 9. Use a 19 mm (3/4 in) socket. Disconnect steering cable as described above.
Use of puller tool (P/N 295 000 161) is recommend- Remove screws no. 15 and withdraw steering helm
ed to ease steering wheel removal and to prevent no. 16. Pay attention, spacer(s) may be present.
damage.
Installation
Reinstall removed parts and pay attention to the
following:
– Prior to installing steering helm to boat, position
rotating arm as shown.
F04B0FA
2
Install steering wheel puller, hold steering wheel
firmly and tighten puller screw to detach wheel 1
from the shaft.
CAUTION: Do not hammer on the shaft to dis-
F04K0TA
lodge the steering wheel.
TYPICAL
1. Correct position
2. Rotating arm
LMR2004-026-10_02A.FM 10-02-3
– When installing steering helm to boat, reinstall

spacer(s) if some were present then position
screws no. 15 as required in slots on mounting
plate to keep space between helm/cable and
body. Centering screws in slots is a good start-
ing point.
F04K06A 2
TYPICAL
1. Screw centered in slot
2. Mounting plate
– Torque screws as indicated in exploded view.

– Ensure to install Woodruff key.
– Apply anti-seize lubricant (P/N 293 800 023) on
helm shaft.
– Install steering wheel.
– Install lock nut and torque steering wheel nut as
indicated in exploded view.
– Proceed with steering alignment
(refer to ALIGNMENT).
10-02-4 LMR2004-026-10_02A.FM
Subsection 03 (ALIGNMENT)
ALIGNMENT 0
VERIFICATION 1
Position steering in straight ahead position.
F04K01A
F13K06A 2
Check alignment of jet pump nozzles and steering
TYPICAL
centering by placing a straight edge across nozzle 1. Lock nut
ends. Straight edge must be parallel with transom 2. Link rod
and lean on both edges of each nozzle.
When finished, apply Loctite 243 (P/N 293 800 060)
on lock nut threads and retighten.
After adjustment, install rod ends parallel to each
other.
If not enough adjustment is available, adjust cable
end on steering helm arm.
CAUTION: Cable end must remain protruding
through helm mounting block.
F13K05A 1
TYPICAL
1. Parallel with transom
ADJUSTMENT
Loosen lock nut of steering link rod. While holding
rod end, turn link rod to adjust.
F04K1NA 1
1. Adjust here. Cable end must remain protruding
Ensure to apply Loctite on parts as indicated on

exploded view.
LMR2004-026-10_03A.FM 10-03-1
Subsection 04 (THROTTLE/SHIFTER CONTROLLER)
THROTTLE/SHIFTER CONTROLLER 0
1 1.3 Nm
(12 lbfin)
Loctite 425
3
4.6 Nm
2 (41 lbfin)
Anti-seize lubricant
4
4.6 Nm
(41 lbfin)
Reverse
Install pin
then slide
UP (typ.)
Alternate holes may be

used for variations
in cable length
7.2 - 8.8 Nm

(64 - 78 lbfin)
Loctite 243
Reverse cable
F13K0HS
LMR2004-026-10_04A.FM 10-04-1
REMOVAL
Remove lever handles no. 3.
Unscrew retaining screws no. 1 and no. 2.
Pull throttle/shifter controller no. 4 out of its re-
ceptacle.
CAUTION: Use a protective mat (P/N 295 000
129) in shifter area when withdrawing controller.
INSPECTION
Check all moving parts for free movement and for
excessive play.
Check cables for wear and oxidation. F13K08A
Replace parts as required. REMOVE LOCK PIN
LUBRICATION
Lubricate moving parts with synthetic grease
(P/N 293 550 010). Where not possible, apply
BOMBARDIER LUBE (P/N 293 600 016).
CABLE REMOVAL
At Shifter Location
F13K09A
REMOVE CABLE END FROM SHIFTER
F13K07A
USE SCREWDRIVER TO SLIDE OFF LOCKING BRACKET
F13K0AA
LOOSEN SCREW, REMOVE BRACKET AND PULL CABLE OUT

1. Loosen this screw
10-04-2 LMR2004-026-10_04A.FM
At Jet Pump Location

Detach shifter cable from reverse gate, remove
shifter cable retainer then loosen bellows. Refer to
previous pages for complete detailed procedure.
1
2
F13K0CA
THROTTLE/SHIFTER CONTROLLER
1. Install shifter cable in this hole
2. Install throttle cables in these holes
F13K0BA 1 2
1. Shifter cable
2. Steering cable
CABLE INSTALLATION
Reverse removal procedure and pay attention to
the following:
F10K0CA
ENSURE LOCKING BRACKET TAB IS PROPERLY LOCKED IN

CONNECTOR RECESS
ADJUSTMENTS
Perform throttle and shifter cable adjustments at
engine and jet pump locations.
F10K0AA
CABLE THREADED ENDS MUST BE SCREWED AT LEAST 6

TURNS INTO CONNECTOR
LMR2004-026-10_04A.FM 10-04-3
Shifter Cable Adjustment Levers Friction Adjustment

Shifter cable has been pre-set at the factory. Friction for shifter and throttle cables has been
Should adjustment be needed, end of cable at the pre-set at the factory.
shifter may be relocated as shown in the following
photo. Shifter Lock Adjustment
The locking action can be adjusted. The positions
Forward/Neutral/Reverse are “notched” by means
of a steel ball no. 5 pushed by a spring no. 6
against a notch on shifter plate.
Turning the set screw no. 7 clockwise will increase
spring pressure and therefore “hardens” shifter lock
action. Conversely turning screw counterclockwise
“softens” lock action.
The set screw is located on the same side as
shifter lever.
1  WARNING
Ensure to adjust shifter lock mechanism to
between 3.9 - 4.5 kg (8 - 10 lb).
F13K0DA
1. Alternate cable locations
Throttle Cable Adjustment

Some throttle cable adjustment is available from 1
the engine compartment. Remove rear seat stor-
age trays to access cables for adjustment as shown
in the following photo.
F13K0FA
1. Shifter lever
2. Set screw (shifter lock)
ASSEMBLY
When reinstalling throttle/shifter controller no. 4,
be careful not to bend cables.
Ensure everything works properly.
F13K0EA 1 2
1. Starboard throttle adjuster
2. Port throttle adjuster
10-04-4 LMR2004-026-10_04A.FM
Section 11 HULL/DECK
TABLE OF CONTENTS 0
COMPONENTS ...................................................................................................................... 11-02-1
BUMPER REPLACEMENT ................................................................................................. 11-02-9
DECAL REPLACEMENT..................................................................................................... 11-02-9
ENGINE COVER ................................................................................................................. 11-02-10
REAR LATCH ADJUSTMENT............................................................................................ 11-02-11
BOW STORAGE COVER SHOCKS.................................................................................... 11-02-11
BOW STORAGE COVER REMOVAL ..................................................................................... 11-02-11
BILGE PUMP/DECK DRAIN AND WATER BYPASS SYSTEM OUTLETS LOCATION .... 11-02-12
DRAIN TUBES REPLACEMENT ........................................................................................ 11-02-12
DRAIN PLUG INSTALLATION ........................................................................................... 11-02-13
SEAT AND BACKREST REMOVAL/INSTALLATION......................................................... 11-02-13
ARMREST REMOVAL/INSTALLATION ............................................................................. 11-02-14
SUN PAD DOORS.............................................................................................................. 11-02-15
REPLACEMENT OF ENGINE COVER LATCH CABLE ...................................................... 11-02-15
WINDSCREEN.................................................................................................................... 11-02-15
LUBRICATION OF LOCKS ................................................................................................. 11-02-15
SKI POST............................................................................................................................ 11-02-15
RIDING PLATE.................................................................................................................... 11-02-16
JET PUMP SUPPORT ........................................................................................................ 11-02-17
FUEL PUMP MODULE REMOVAL/REPLACEMENT ........................................................ 11-02-18
FUEL TANK REPLACEMENT ............................................................................................ 11-02-19
ICS (INLET CLEARANCE SYSTEM) .................................................................................. 11-02-24
REPAIR ................................................................................................................................... 11-03-1

GENERAL ........................................................................................................................... 11-03-1
TOOLS AND MATERIALS REQUIRED FOR REPAIRS...................................................... 11-03-1
AIR BUBBLES .................................................................................................................... 11-03-2
BLISTERS ........................................................................................................................... 11-03-3
MINOR GELCOAT FRACTURES........................................................................................ 11-03-3
COMPOUND FRACTURES ................................................................................................ 11-03-4
LMR2004-030_11_01ATOC.FM 11-01-1
Subsection 02 (COMPONENTS)
COMPONENTS 0
Cover
13 - 16 Nm 5 - 6 Nm
(115 - 141.6 lbfin) (44.2 - 53 lbfin)
Loctite
243
Loctite Loctite 6 Nm

271 243 (53 lbfin)
Silicone sealant
4.5 Nm
(40 lbfin)
Loctite
243
1
3 2
Loctite 5.5 Nm Loctite 271

243 (48.6 lbfin) 13 - 16 Nm
(115 - 141.6 lbfin)
Silicone
sealant
F13L1ZS
LMR2004_027-11_02A.FM 11-02-1
Deck 8 - 9 Nm 1.8 - 2.2 Nm

(70.1 - 79.5 lbfin) (16 - 19.5 lbfin)
10 Hull
6
1.8 - 2.2 Nm
(16 - 19.5 lbfin) 7
9
3 - 5 Nm
(26.5 - 44.2 lbfin)
Hull
3 - 5 Nm
(26.5 - 44 lbfin)
Silicone
sealant
11 8
See
electric
Hull
1.0 - 1.5 Nm

(8.8 - 13.2 lbfin)
Loctite
243
7.2 - 8.8 Nm

(63.7 - 77.8 lbfin)
13 Silicone
sealant
F13L20S
11-02-2 LMR2004_027-11_02A.FM
Body
12
Body
5.3 - 6.5 Nm
(46.9 - 57.5 lbfin)
Body Body
Loctite
243
25 Nm
(18 lbfft)
5.3 - 6.5 Nm

(46.9 - 57.5 lbfin) 22
21
Body
Loctite
243 23
20
5.3 - 6.5 Nm

(46.9 - 57.5 lbfin)
F13L21S
LMR2004_027-11_02A.FM 11-02-3
Body
1.1 - 1.3 Nm Loctite

(9.7 - 11.5 lbfin) 243 5.3 - 6.5 Nm
5 - 6 Nm (46.9 - 57.5 lbfin)
(44.2 - 53 lbfin) Engine
Loctite 243 cover
28
Body
Body
4
Body
Body
F13L22S
11-02-4 LMR2004_027-11_02A.FM
STARBOARD VIEW
2 - 3 Nm
(17.7 - 26.5 lbfin)
PORT SIDE VIEW STARBOARD VIEW
1.5 - 1.9 Nm

(13.2 - 16.8 lbfin)
Body
2.1 - 2.3 Nm

(18.5 - 20.3 lbfin)
Body
F13L23S
LMR2004_027-11_02A.FM 11-02-5
45 - 55 Nm
(33 - 40.5 lbfft)
5.5 - 6.5 Nm

(48.6 - 57.5 lbfin)
Loctite 243
2.5 - 2.8 Nm

(22.1 - 24.7 lbfin) 5.5 - 6.5 Nm
(48.6 - 57.5 lbfin)
Loctite 243
F13L24S
11-02-6 LMR2004_027-11_02A.FM
STARBOARD
26 Sundeck seats
5 - 6 Nm
(44.2 - 53.1 lbfin)
PORT SIDE
26
Loctite
243
27
Spoiler
27
Spoiler
Spoiler
Body
Body
Body
24
15
17
16
Front seats Rear seats

F13L25S
LMR2004_027-11_02A.FM 11-02-7
To control
module
To power
NOTE: Thread pivot onto supply
cable end at least 6 threads.
32
Loctite
243 To main harness
Loctite 243
2.2 - 2.8 Nm
(19.4 - 24.7 lbfin)
Loctite 243
6 - 8 Nm 9 - 11 Nm 33
(53.1 - 70.8 lbfin) (79.6 - 97.3 lbfin) 9 - 11 Nm
Loctite (79.6 - 97.3 lbfin)
243
38
33
31
34
31 Loctite 243
34
Loctite 243 Hull
See
propulsion 30
system Hull
Starboard
30 29
35 37 Port side
4 - 5 Nm 29 4 - 5 Nm
F13L26S 36 (35.4 - 44.2 lbfin) Loctite 243 (35.4 - 44.2 lbfin)
11-02-8 LMR2004_027-11_02A.FM
BUMPER REPLACEMENT 7. Install trim using soapy water. Gently tapping trim
with a rubber hammer will help to fit trim in rail.
Bumper and Trim 8. Reinstall bumper cover.
NOTE: Prior to beginning job, place bumper trim 9. Check fit between bumper and body. Fill gaps
in a container of hot water to soften material and with silicone sealant as necessary.
ease installation. In cool weather, bumper rail may
be warmed too.
DECAL REPLACEMENT
1. Remove bumper cover no. 1 at rear of boat.
2. Remove trim no. 2 from bumper rail no. 3. Removal
3. Drill pop rivets to remove bumper rail. Using a heat gun, warm up one end of decal for a
4. Mark hole positions on body. few seconds until decal can roll off when rubbing
decal edge with your finger.
5. Using a 4.80 mm (3/16 in) drill bit, drill a first hole
through bumper rail at any rear end. Use locat- Pull decal slowly and when necessary apply more
ing mark as a guide and install a rivet. heat to ease removal on the area that has to be
peeled off.
CAUTION: When drilling, be careful not to dam-
age bumper rail, hull and resonators located in- If decal tears while pulling off, it has to be heated
side engine compartment. for a few seconds longer. If decal tends to stretch
while pulling off, stop heating and wait a few sec-
NOTE: Check condition of silicone joint between onds to let it cool, then peel it off.
hull and body. Reseal as necessary with Adseal
4511 sealant (P/N 293 800 033) or equivalent with- Installation
out acetic acid vapors.
There are 2 types of decals used on sport boats.
6. Position bumper rail properly onto body all
One has a protective film on back side and the
around coming back to other rear end and cut
other has a protective film on both sides. They are
excess length if necessary.
used on 3 types of materials; plastic, gelcoat and
NOTE: Masking tape may be used to temporarily metal.
retain bumper rail ahead of your work. Prior to in-
stalling trim in bumper rail for rear corners, apply Decals Having a Protective Film on Back Side
Adseal 4511 sealant (P/N 293 800 033) inside Only
bumper rail all around boat, as shown. This is re- These decals usually contain written information
quired so that trim properly remains attached to rail. (ex.: warning) and are used on gelcoat or metal.
Clean surface with a good solvent such as ACRYL-
ICLEAN DX 330 from PPG or equivalent (refer to
manufacturer’s instructions).
Using a pencil and the new decal as a template,
mark the area where decal will be located.
Remove half of the decal back protective film and
align decal with marks. Start sticking it from center
and remove the other half of the film to stick it
completely. Carefully squeegee decal beginning at
center and working outward using, firm, short,
1 overlapping strokes.
Decals Having a Protective Film on Both Sides
2 These decals usually contain graphics and are
used on gelcoat or plastic.
F04L9OC
TYPICAL
1. Bumper rail
2. Adseal 4511 sealant in grooves
LMR2004_027-11_02A.FM 11-02-9
Installation on Gelcoat Shocks Removal

Clean surface with a good solvent such as ACRYLI- Using a flat screwdriver, lift tab as shown in the
CLEAN DX 330 from PPG or equivalent (refer to man- next photo.
ufacturer’s instructions).
For best result apply an activator (P/N 293 530
036) to prepare the surface using a clean cloth.
After a few seconds, when the activator evapo-
rates, the surface is ready.
Using a pencil and the new decal as a template,
mark the area where decal will be located.
For better adhesion a dry application is recom-
mended; however, to ease decal installation a mild
solution of soapy water can be sprayed over sur-
face where decal will be installed.
Remove back protective film from decal and align
decal with marks. When well-aligned squeegee
decal beginning at center and working outward us-
ing, firm, short, overlapping strokes.
Remove protective film once decal has adhered to
hull. F04LBHA
Installation on Plastic Front TYPICAL — LIFT TAB

(front storage cover)
Detach shock end.
Clean surface with isopropyl alcohol.
Using a pencil and the decal as a template, mark Cover Removal
the area where decal will be located. NOTE: To ease working in engine compartment,
Apply an activator (P/N 293 530 036) to prepare it is suggested to remove engine cover no. 4 from
the surface using a clean cloth. After a few sec- boat.
onds, when the activator evaporates, the surface To remove engine cover, remove both hinge pins
is ready. then pull cover out.
CAUTION: Do not use soapy water as a cleaner Another way to remove cover is to mark hinge po-
to prepare the surface or to locate decal on cover. sition with a pencil, as shown in the next photo,
Remove back protective film from decal and care- then unscrew hinge from deck.
fully align decal with marks.
Apply pressure to center of decal using a squeegee
then slide outward using a firm, short overlapping
stroke. Repeat as necessary.
Remove protective film from front of decal after
application.
ENGINE COVER
If engine cover no. 4 does not lift by itself (or with
a little help), when latch is released, replace gas
shocks no. 5. Each shock should be checked indi-
vidually by detaching them one at a time. At shock
installation, position each shock so that the piston F00L0KA 1
rod is at bottom.
TYPICAL — MARK HINGE POSITION
1. Remove these three screws
11-02-10 LMR2004_027-11_02A.FM
 WARNING BOW STORAGE COVER SHOCKS

Always ask for help to hold engine cover when To remove bow storage cover shocks no. 13 pro-
removing hinge pins in order to avoid person- ceed as follows:
al injuries.
 WARNING
Cover Installation Make sure to have a 2 x 4 piece of wood around
the work bench to support the bow storage
Installation is the reverse of removal. Ensure to cover while changing the cover shocks.
torque hinge screws to 6.9 N•m (61 lbf•in).
Install shocks with piston rod at bottom. – Open storage cover lid.
– Lift locking tabs from each shock end with a flat
REAR LATCH ADJUSTMENT screwdriver and detach shock ends from mount-
ing plates.
Engine and Sun Pad cover latches are adjustable.
If a cover is not tight enough or if it is hard to close,
adjust as necessary.
1. Loosen lock nut. See next illustration.
2. Turn locking pin and adjustment nut as required
and check cover fit and locking action.
1
3. When adjustment is satisfactory, temporarily
remove lock nut and apply Loctite 243 (P/N 293
800 060) on lock pin threads.
4. If locking pin does not properly center in latch
hole, loosen lock nut until latch may move freely
sidewards.
5. Close cover so that locking pin auto centers in
latch. Reopen cover and tighten locking nut in F13L27A
this position.
1. Lift each tab
6. Torque nut to 5 N•m (44 lbf•in).
Remove shock ends from fittings.
Installation is the reverse of removal.
1 At shock installation, position each shock so that
the piston rod is at bottom.
BOW STORAGE COVER REMOVAL

To remove storage cover no. 12 proceed as follows:
2
– open storage cover
– Remove cover shocks
3
 WARNING
Make sure to have a 2 x 4 piece of wood around
F02L25B the work bench to support the bow storage
TYPICAL — MOUNTED UPSIDE DOWN cover while removing the cover shocks.
1. Locking pin
2. Adjustment nut. Torque to 5 N•m (44 lbf•in)
3. Lock nut
LMR2004_027-11_02A.FM 11-02-11
– remove 6 hinge screws. – Disconnect drain tube from bilge pump and re-
move tube.
– Cut new tube to proper length.
– Reconnect tube at each end and resecure tube
1 with locking ties.
– Drill a 0.8 mm (1/32 in) hole where the tube is
formed into a loop. This will prevent any type of
siphoning that could occur in certain situations.
– Ensure tube does not leak in bilge.
1
2
F13L27B
1. Remove shocks from cover

2. Remove these screws
Installation is the reverse of removal. Pay attention to

torque storage cover screws to 5.9 N•m (52 lbf•in).
At shock installation, position each shock so that
the piston rod is at bottom.
BILGE PUMP/DECK DRAIN AND

WATER BYPASS SYSTEM
OUTLETS LOCATION F10L2IA
TYPICAL — PROPER TUBE INSTALLATION

1. Drill here
1 2 3
Deck Drain
– Disconnect drain tube no. 9 from transom fitting
no. 8.
– Cut locking ties all along drain tube from transom
toward deck storage compartment.
– From engine compartment, disconnect drain tube
from deck fitting no. 10.
– Cut new tube to proper length.
– Reconnect tube at each end and resecure with
F13L28A
locking ties.
1. Water bypass outlet – Ensure tube does not leak in bilge.
2. Deck drain outlet
3. Bilge pump outlet
Scupper Valve
DRAIN TUBES REPLACEMENT Check that ball is clean and moves freely.
Bilge Pump Drain Removal
– Disconnect drain tube no. 7 from hull fitting no. 6. Remove all 4 screws retaining existing scupper valve
Note the loop there, you will have to remake it. no. 11.
– Cut locking ties all along drain tube from tran-
som toward bilge pump.
11-02-12 LMR2004_027-11_02A.FM
1 DRAIN PLUG INSTALLATION

Refer to the following illustration to install drain
plug no. 14.
1
F04LBKA
TYPICAL
1. Remove all 4 screws
Installation 2
Install valve membrane taking care to properly po-
sition membrane lip facing ball. Ensure membrane 3
F04LC1A
positioning holes are properly aligned with valve 1. Drain plug

knob. See next photo. 2. Torque screws to 1.0 - 1.5 N•m (8.9 - 13 lbf•in)
3. Hull
CAUTION: Make sure to assemble all the parts
exactly in the same position as illustrated. If
scupper valve is assembled wrong, water will
SEAT AND BACKREST
seep through. REMOVAL/INSTALLATION
2 Driver Seats
Both driver seat cushions no. 18 are secured with
pop rivets. To detach backrest cushion, drill out
3 pop rivets as shown in the next photo.
F04L9VB 1
1. Ball
2. Membrane lip
3. Membrane positioning hole aligned with valve knob
Carefully clean the inside of the plastic bushing.

Install scupper valve assembly onto plastic fitting.
F13L29A
Secure using screws.
TYPICAL
Tighten screws as specified in exploded view. 1. Remove these rivets
LMR2004_027-11_02A.FM 11-02-13
Use a 4.75 mm (3/16 in) drill bit. Darts may need to be replaced. Use P/N 293 730
To remove seat cushion no. 19, drill out rivets on 021.
both sides of seat bucket and lift cushion out.
ARMREST REMOVAL/
Front Backrest Cushions INSTALLATION
Port front backrest cushion no. 24 is removed by
first removing the front port cup holder. Armrests
Using an 11 mm wrench, loosen and remove nut Armrests no. 17 are secured to deck with darts
and washer from center of backrest cushion. and S-clip. Carefully pry darts from deck as shown
in the next photo.
Lift cushion at each end up and away from gunwale.
Starboard front backrest no. 24 is removed by first
opening the starboard console cover (windscreen).
1
Remove storage bucket.
Loosen and remove nut and washer as above.
Lift cushion at each end up and away from gunwale.
Front Seat Cushions

To remove front seat cushions no. 25, unsnap fas-
teners, lift cushion and pull away from retaining
blocks.
To install front seat cushions, place cushion into
position with retaining blocks and snap fasteners.
Rear Backrest Cushions

Rear backrests no. 15 are secured with darts and
S-clips. F13L2BA
To remove, pull backrest from bottom to release TYPICAL

darts and lift upwards to release from S-clip. 1. Lift pad along edge
To install, position cushion onto S-clip and push
Pull inner side of armrest towards self and lift up
down. Align darts with mounting holes and tap
and away from S-clip.
into position with a rubber mallet.
To install, position darts 1/2 way into holes. Position
side of armrest over S-clip and push downwards.
Tap darts into place with a rubber mallet.
F13L2AA
TYPICAL
11-02-14 LMR2004_027-11_02A.FM
SUN PAD DOORS Tape the end of the new cable to the end of the old
cable. Detach front portion of cable in front port
Open sun pad doors no. 26. storage compartment and pull cable toward front
Lift tabs from each shock no. 27 and detach from thus pulling the new cable at the same time.
mounting bracket. CAUTION: Existing cable is attached with lock-
Remove bolts from door cover hinges. ing ties, use extreme caution when pulling to
insert new cable.
Complete parts assembling in the reverse order of
disassembly.
WINDSCREEN
2 2
Cleaning
First rinse with fresh water to remove dried salt
1 1 water.
2 2
Wash with Bombardier cleaner (P/N 293 110 001).
Clean only with flannel clothes or Kimtowels®
F13L2CA wipes no. 58-380 from Kimberly-Clark.
1. Lift tabs and remove shocks CAUTION: It is necessary to use flannel cloths
2. Remove these screws or “Kimtowels” wipes on windscreen to avoid
damaging surface.
REPLACEMENT OF ENGINE To remove scratches on windscreen: Start with
COVER LATCH CABLE “Slip Streamer Motorcycle Windshield Heavy Duty
Remove latch mechanism no. 28 from body and Scratch, Remover”. Finish with “Slip Streamer Mo-
open it by removing the plate underneath. torcycle Cleaner and Polish”.
Detach cable end from the rod. NOTE: The later product may be used alone if only
light scratches are noticeable.
CAUTION: Never clean windscreen with strong
detergent, degreasing agent, paint thinner, ac-
etone, products containing chlorine, etc.
LUBRICATION OF LOCKS
Locks should be lubricated with BOMBARDIER
LUBE lubricant (P/N 293 600 016) to keep them
working properly. This will help dissolving dried salt
water.
SKI POST
F04L7HA 1
1. Detach cable end from rod
Removal
From inside engine compartment, remove ski post
lock no. 20 and loosen collar stop screws no. 21,
lift and pull out ski post assembly.
LMR2004_027-11_02A.FM 11-02-15
Refer to the following photo sequence for detailed Check post operation.
procedure. Secure ski post lock using latch.
Operation
Inner post must move up and down and stop when
reaching ski post lock.
2 RIDING PLATE
1
Removal
Remove jet pump. Refer to JET PUMP.
NOTE: When drive shaft is removed, some oil will
flow out. To prevent this, start engine, run at 4000
RPM for 10 seconds and stop engine at this RPM.
This will move oil out of PTO housing into oil tank.
Remove the speed sensor from the riding plate (if
applicable).
Loosen and remove riding plate screws.
F13L2MA NOTE: An impact screwdriver should be used to
loosen tight screws.
TYPICAL
1. Ski post lock Using a low height hydraulic bottle jack and 2 steel
2. Pull latch to remove ski post lock plates, pry out riding plate.
F04LBSA 1
LOOSEN BOLTS THEN REMOVE POST ASSEMBLY
1. Ski post deck bolts
Disassembly 2
1
Pull inner post no. 22 out of outer post no. 23. F13L2NA
TYPICAL
Installation 1. Hydraulic bottle jack
2. Riding plate
procedure. However pay attention to the following. Cleaning
Torque collar stop screws to 5.9 N•m (52 lbf•in). – Scrape off all excess of sealant from riding plate
Apply BOMBARDIER LUBE lubricant (P/N 293 600 and hull.
016) to inner ski post before returning if to outer – Clean hull surface with an acetone based sol-
post. vent to eliminate grease, dust and any residue
of sealant.
11-02-16 LMR2004_027-11_02A.FM
Installation – Remove boot, pivot, nut and washer from re-

verse cable. Remove from transom.
Apply Loctite RTV silicone sealant (P/N 293 800
066) as indicated by the shaded areas in the next – Disconnect water supply hose, water return hose
illustration. and bailer hoses.
5 1
1 4
3
4 3
2 2 5
6
6
2
5
1
F13L2DA
3 F13L2OA
TYPICAL
TYPICAL
1. Bailer plug
2. Coolant inlet
Follow the torque sequence shown. 3. Coolant return
4. Water inlet
Torque screws to 9 - 11 N•m (79.6 - 97.3 lbf•in). 5. Water outlet
– Remove nuts, lock washers and flat washers

JET PUMP SUPPORT retaining jet pump support from inside hull.
Removal
– Remove jet pump. Refer to JET PUMP.
– Remove inlet grate and riding plate.
– Remove ball joint, nuts, and washer from steer-
ing cable. Remove from transom.
1
F04LBVA
TYPICAL
1. Remove nuts
F04LCNA 2 – Using a heat gun, heat jet pump support until it

TYPICAL
is possible to pull it.
1. Remove from support and transom NOTE: Shims may have been installed between
2. Remove from support and transom
support and body. Do not remove these shims,
otherwise jet pump alignment will be altered.
LMR2004_027-11_02A.FM 11-02-17
Installation To remove front fuel pump module it will be nec-

essary to install scissors jack on starboard side of
Apply Loctite RTV silicone sealant (P/N 293 800
front module between fuel tank and deck.
066) as indicated by the shaded areas in the next
illustration. Follow the torque sequence shown.
1 2
1
3
F18L28A 4
F13L2EA
1. Scissors jack installed

FUEL PUMP MODULE
REMOVAL/REPLACEMENT Open jack to increase clearance for module re-
moval past and over starboard side of tank near
Removal jack.
Remove rear seat cushions no. 16 and storage tubs. Open jack carefully and with minimum expansion
necessary for fuel pump module removal.
With engines in place, remove rear fuel pump
module. Damage to the fuel pump module can occur if too
much pressure is applied from the jack.
Rear fuel pump module is removed to insure front
stud ring is reinserted properly. Remove nuts, washers and gasket from stud ring
and carefully lift fuel pump module from tank while
Remove nuts, washers and gasket from stud ring rotating module 180° in order to allow fuel float
and carefully lift fuel pump module from tank while clearance out of tank.
rotating module 180° in order to allow fuel float
clearance out of tank. Replacement
NOTE: Front fuel pump module float points to
PORT.
NOTE: Rear fuel pump module float points to
1 STARBOARD.
NOTE: Gasket fits on stud ring only one way with
gasket tab tell-tale in the up position. Align arrow
of each fuel pump module with gasket tab.
Insert front module from starboard side with scis-
sors jack installed. Align with studs. Reach
through rear module hole and ensure that front
module studs are properly seated.
F13L2FA
1. Fuel float
11-02-18 LMR2004_027-11_02A.FM
Lube studs thoroughly with Loctite 518.
F13L2PA
F13L2QA
LOCTITE 518 ON RING STUD THREADS

1. Fuel system pressurization retaining bracket in position
Install fuel pump module gasket over ring studs, This retaining bracket prevents the fuel pump
with tab tell-tale pointing upwards. modules from being dislodged from their respec-
Install washers and nuts and cross-tighten to tive tank detents during the pressure test.
specified torques and sequence.
Remove scissors jack. FUEL TANK REPLACEMENT
Install rear module from starboard side at an angle
for clearance purposes. Engine Cover Removal
Carefully push pump down over stud ring without NOTE: To ease working in engine compartment,
dislodging studs. it is suggested to remove engine cover no. 4 from
boat.
Lube studs thoroughly with Loctite 518 as shown
above. Using a flat screwdriver, lift tab as shown in the
next photo.
Install fuel pump module gasket over ring studs,
with tab tell-tale pointing upwards.
Install washers and nuts and cross-tighten to spec-
ified torques and sequence.
Reinstall any fittings loosened during procedure.
Pressurize fuel system and inspect for leaks as per
procedure in FUEL CIRCUIT SECTION.
NOTE: It will be necessary to install the Fuel sys-
tem pressurization retainer (P/N 529 035 978) as
shown in the photo below before performing the
fuel system pressurization test.
F04LBHA
TYPICAL — LIFT TAB
LMR2004_027-11_02A.FM 11-02-19
Detach each shock end from engine cover. NOTE: Following procedures to be performed on
To remove engine cover, remove both hinge pins each engine.
then pull cover off. Remove venturi and reverse gate supports from
NOTE: Always ask for help to hold engine cover each engine. Both units remain connected.
when removing hinge pins in order to avoid per-
sonal injuries.
Another way to remove cover is to mark hinge po-
sition with a pencil, as shown in the next photo,
then loosen screws and remove hinge from deck.
F13L2GA
TYPICAL
Remove the 4 retaining nuts from each pump.
F00L0KA 1
TYPICAL — MARK HINGE POSITION
1. Remove these three screws from each hinge
Pump Removal
Remove shifter and steering cables from starboard
reverse gate and nozzle.
F13L2HA
TYPICAL
Pull out pumps.
F04J4BA 1 2
TYPICAL — DISCONNECT STEERING AND REVERSE CABLES
1. Shifter cable
2. Steering cable
11-02-20 LMR2004_027-11_02A.FM
Floating Ring and PTO Seal

CAUTION: Strictly follow this procedure other-
wise damage to component(s) might occur.
Lift splash guard to expose PTO seal assembly.
Install PTO seal support tool (P/N 529 035 842) on
bottom of PTO seal assembly as shown.
1
1
F18B02A
1. Drive shaft holder
NOTE: This is necessary so the drive shaft cannot

move rearwards when using the drive shaft/
floating ring tool.
F18B01A
1. PTO seal support tool
F18B03A
TYPICAL
F18I04A
1. Insert in groove of PTO seal assembly
Insert drive shaft holder (P/N 529 035 871) on

pump support as shown.
F18B04A
DRIVE SHAFT/FLOATING RING TOOL
LMR2004_027-11_02A.FM 11-02-21
Install drive shaft/floating ring tool (P/N 529 035 841) 1

as shown.
2 1
F18I08A
F18I05A
1. Largest opening here 1. Largest opening here

2. Floating ring 2. Lubricate both O-rings
Turn screw clockwise so that the tool pushes the Turn screw clockwise so that the tool pushes the
floating ring rearwards to expose the C-clip. Do PTO seal forward and the drive shaft to the rear to
NOT remove clip at this time. expose both O-rings. Lubricate O-rings with
Bombardier Lube (P/N 293 600 016).
NOTE: This step is done to ensure floating ring is
free and not stuck on the drive shaft. NOTE: This is necessary to ease drive shaft re-
moval later.
Remove drive shaft/floating ring tool and drive
shaft holder.
11-02-22 LMR2004_027-11_02A.FM
Remove drive shaft/floating ring tool and PTO seal Drive Shaft
support.
Simply pull out drive shaft.
If spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent oil
stains.
NOTE: It may require a slight jerk rearwards to re-
move the O-rings from the PTO seal assembly.
Engines
Clamp off port and starboard heat exchanger cool-
ant hoses using four hose clamps (P/N 529 032
500).
F18B03A
TYPICAL

1 2
Push floating ring rearwards to expose C-clip and
remove it.
2 1
F13L2IA
1. Clamp off Port hoses

2. Clamp off Starboard hoses
Remove exhaust hoses from the tuned pipes and

the center mufflers. Remove two center mufflers
from engine compartment.
At this point, loosen and remove hoses previously
clamped off from heat exchanger fittings.
Pull coolant expansion tanks from wall brackets
and lay atop engines.
Remove starter cables, all electrical connections
and both harnesses.
F18I0BA
Cut all necessary locking ties.
2. Remove C-clip Remove throttle cables.
Remove drive shaft holder tool then drive shaft/ Remove engine-to-engine grounding strap.
floating ring tool. Loosen and remove TOP motor mount bolts. Do
NOTE: Use this sequence to minimize the amount not remove motor mounts from hull. This allows
of movement the drive will slide back into PTO removal of engines while allowing any alignment
seal assembly. shims installed beneath the mounts to remain in
place.
Remove engines, marking Port and Starboard en-
gines for alignment purposes.
LMR2004_027-11_02A.FM 11-02-23
For further information regarding reinstallation and

alignment, refer to REMOVAL AND INSTALLATION
section.
Fuel Tank
Siphon fuel tank.
Remove all hoses and wiring harness connectors
from fuel tank and fuel pump modules.
Loosen fuel tank strap bolts from hull at rear of fuel
tank.
F13L2LA
1 TYPICAL
Installation is reverse of this removal procedure.

Reinstall all fittings to their proper torques.
Apply Loctite 271 to fuel tank strap mounting bolts.
Apply Loctite 243 to motor mount bolts.
Apply Loctite 243 on reverse gate Allen bolts.
Apply Loctite anti-seize on 4 pump mounting studs.
F13L2JA
ICS (Inlet Clearance System)
1. Loosen and remove bolts
Operation
Mark or scribe locations of front motor mounts. The ICS (Inlet Clearance System) is an electrically-
Identify Port and Starboard mounts and any shims controlled device for removal of weeds and other
for reinstallation. debris picked up by the action of the jet pump.
Remove front motor mounts, port and starboard. The actuator switch is located next to the driver
seat below the throttle/shifter as shown below.
1 2
1
F13L2KA
1. Port front motor mount

2. Starboard front motor mount
F13L2RA
Pull tank from hull.
TYPICAL
1. ICS switch
11-02-24 LMR2004_027-11_02A.FM
Shifter must be in NEUTRAL position in order to

operate ICS.
NOTE: With shifter in NEUTRAL position, press
and hold ICS button for 10 seconds. This allows
grates to fully extend. Release ICS button and wait
10 seconds BEFORE shifting from NEUTRAL to
allow grates to fully close. Repeat as needed to
clear system. Never shift into Forward or Reverse
while activating the ICS. This can leave the grates
in the down position and create a hazardous oper-
ating condition. The ICS must be fully retracted
before operating the vehicle.
2
Cable Replacement
1
NOTE: Following procedure to be performed for
each cable.
Remove bolt and nylon washer no. 29 from ICS
grate and joint fitting no. 30. F13L2TA
Remove joint fitting no. 30 from end of cable. TYPICAL

1. Loosen cable lock
2. Pull cable up through hull
Tie a line to end of cable for later retrieval if re-

placement is necessary.
From front starboard console access, remove piv-
ot arm bolt no. 32 from pivot arm no. 38.
Loosen locking nuts no. 33 from ICS mounting plat-
form.
2 1
F13L2SA
1. Remove this bolt and washer

2. Remove this fitting
Loosen cable lock no. 31 from hull inside engine

compartment near drive shaft.
Pull cable up through hull into engine compartment.
F13L2UA
1. Remove this bolt

2. Loosen these nuts
Pull cable out from starboard console access com-

partment.
LMR2004_027-11_02A.FM 11-02-25
Using line previously tied to cable end, attach to Tighten screw to 4 - 5 N•m (35.4 - 44.2 lbf•in).
new cable and pull new cable through to engine From inside starboard console access, insert cable
compartment. into appropriate slot on ICS support bracket no. 35.
Insert cable through cable lock no. 31, and install The Port cable is placed in the Port slot no. 36.
half-rings no. 34.
The Starboard cable is placed in the Starboard slot
Insert cable through rubber washer and through no. 37.
hull.
Apply Loctite 243 to cable threads and screw onto
joint fitting no. 30 as far as possible.
Insert screw through nylon washer and into tine
slot shown below. 1
F13L2UB
1. Port slot
2. Starboard slot
Place the cable end(s) in the pivot arm and install

the pivot arm bolt no. 32 through the cable end(s).
Tighten to 6 - 8 N•m (53.1 - 70.8 lbf•in).
F13L2SB
Adjust cable(s) to pull the ICS grate(s) level with
the ride plate.
TYPICAL
1. Tine slot with cable end installed
Tighten cable lock nut(s) in this position to 9 - 11 N•m
(79.6 - 97.3 lbf•in).
11-02-26 LMR2004_027-11_02A.FM
Subsection 03 (REPAIR)
REPAIR 0
GENERAL For all Gelcoat requests, please contact the follow-
ing:
Gelcoat is the smooth and durable cosmetic finish
Gelcote International LTD
which coats the fiberglass hull and body of a Sea-
29-174 Colonnade RD South
Doo sport boat. It also provides a protective barrier
Nepean, Ontario, K2E 7J5
against water and sun. It consists of a mixture of
Canada
resin, pigment (coloring), fillers, monomers and
catalyst which is sprayed into the mold. Phone: (613) 225-2177
The body and hull of the Sea-Doo sport boat are Fax: (613) 225-5297
constructed of chopped fiberglass, saturated with Canadian and North American toll free:
resin. It is sprayed on the layer of gelcoat along 1 877 435-2683
with pieces of fiberglass mat, cloth and woven
E-Mail: Gelcote@comnet.ca
roving which are added at required areas. This
type of construction is very accommodating for Web site address: www.comnet.ca\~gelcote\
high quality repairs. With patience, the proper
techniques and materials, a damaged area can be TOOLS AND MATERIALS
restored to an original finish. REQUIRED FOR REPAIRS
The content presented here is not intended to re-
place the use of a complete fiberglass and gelcoat Tools
repair manual. Its main purpose is to help you un- – safety glasses
derstand what factors are involved when making
a damage assessment or estimate. – air mask
All requests for Gelcoat repair or factory color – white cloths
match should be made directly to Gelcote Interna- – sanding block
tional LTD. They are set up to handle all requests – putty knife
and as a Gelcoat supplier, they can respond to all
needs and questions with greater product knowl- – plastic film
edge. – stirring stick
NOTE: Fiberglass repair kit is available through au- – scissors
tomotive or marine suppliers. Gelcote® repair kits – buffing pad
are available through the regular channels.
– heavy-duty polisher
 WARNING – power sander
Protect skin. Wear gloves when in contact – paint brush
with resin, hardeners and gelcoat. A barrier – plastic container (mixing)
skin cream may also be used. Do not expose
work area to open flame or a lit cigarette. – spray gun
Some of the materials are flammable. Protect – plastic squeegee.
eyes. Wear safety glasses when grinding,
sanding or spraying. Use a dust mask when
sanding or grinding. When spraying wear a
respirator or paint mask. Always read warning
labels on products.
LMR2004_027-11_03A.FM 11-03-1
Materials 2. Filling the Cavity

– fiberglass mat The prepared surface must be cleaned with ace-
– fiberglass cloth tone on a cloth. Use the Gelcote® repair kit. Follow
the mixing instructions in the kit when preparing
– polyester resin
the gelcoat putty.
– cardboard
Carefully mix the required amount while making
– masking tape sure there are no air bubbles in the mixture. With
– sandpaper (100-grit, 220-grit, 320-grit, 400-grit, a putty knife fill the repair area, as shown in the
600-grit, 1000-grit) next photo, and cover with a plastic film to smooth
– 24-grit sanding disks surface. Curing time may depend on temperature,
– gelcoat putty amount of putty and percentage of catalyst.
– liquid gelcoat After 2 hours, press lightly on the surface with fin-
gers to test the hardness. When the area becomes
– acetone hard, remove the plastic film.
– cabosil
– epoxy filler
– medium compound (white)
– fine compound (white)
– wax.
AIR BUBBLES
Possible Cause
– Air pocket trapped between layers of laminate F09L30A
and gelcoat. DAMAGED AREA FILLED
1. Preparation of Surface 3. Sanding

Remove all of the damaged gelcoat surrounding Begin block sanding the patch with 320-grit sand-
the air bubble with a putty knife or preferably a paper until you come close to the original surface.
carbide grinding tip. Make sure all loose and weak Remove dust with a water soaked cloth and con-
areas are completely removed. Sand a small area tinue sanding with a 400-grit wet paper. Finish wet
of the gelcoat surface with 220-grit sandpaper. If sanding with a 600-grit to remove deeper scratch-
needed, sand the cavity itself. These areas must es. If needed you can wet sand with finer grit pa-
have a rough surface to allow the gelcoat putty to per such as 1000-grit.
bond properly.
4. Buffing and Waxing
Buff the surface using a heavy duty polisher with
a buffing pad. Make sure the pad is free of dirt or
you may damage the gelcoat. Carefully begin buff-
ing with a white medium compound RM 856. Fin-
ish off using a fine RM 852 compound. While buff-
ing, pay close attention to avoid overheating the
surface.
F09L2ZA
REMOVE DAMAGED GELCOAT
11-03-2 LMR2004_027-11_03A.FM
BLISTERS 2. Filling the Repair Area

Small Fractures
Possible Causes
Refer to the same procedure as in the air bubbles.
– Inert catalyst.
Numerous Fractures Over Large Surface
– Improper catalyst/gelcoat ratio.
Prepare the area for spray application of liquid
A blister is a visible bump on the Sea-Doo sport gelcoat. Wipe down the surface with acetone.
boat surface that may not necessarily come right Mask the surrounding area to protect the boat from
through the gelcoat layer. If there are only a few overspray.
blisters, you may follow the same repair proce-
dure as for air bubbles. If they are numerous and Mix the needed quantity of gelcoat and catalyst
in close concentration, you may have to spray liq- according to supplier’s recommendations. The
uid gelcoat to achieve proper repair. This proce- gelcoat can be thinned with acetone up to 10%. If
dure is covered in the next problem. it needs more consistency you can add cabosil.
CAUTION: Ensure blistered area is completely Make sure that the air supply is free of oil, dirt and
dry before attempting repairs. water.
Test spray the gelcoat mixture on paper to verify
MINOR GELCOAT FRACTURES its consistency and pattern. You may have to apply
5 or 6 coats to cover the area properly. Overlap
Possible Causes each coat further than the last, leaving at least 30
seconds between passes. Avoid trying to coat the
– Flexing of fiberglass laminate. surface with only a few heavy coats, as this will
– Gelcoat thickness. not allow the gelcoat to dry properly.
– Direct result of impact. Apply a coat of polyvinyl alcohol to seal off the air
In case of fractures which have not penetrated and protect the gelcoat surface from dust. PVA
past the gelcoat layer, the repair concerns the speeds up the curing process because gelcoat will
gelcoat only. If flex cracking or impact are evident, not cure properly when exposed to air.
then additional reinforcement may be necessary.
This subject will be covered in the next problem. 3. Sanding
Wash the polyvinyl alcohol off with water. Depend-
1. Preparing the Surfaces ing on the size of the area repaired, you can either
Small Fractures block sand as per previous procedure or you may
use an air sander. Sand the surface down with pro-
Open the cracks up with a sharp triangular can gressively finer grits of sandpaper until the desired
opener or preferably a carbide tipped die grinder. finish is achieved.
The V groove will provide a good bonding area for
the gelcoat. With 220-grit sandpaper, sand the 4. Buffing and Waxing
sides of the notched-out areas.
Buff the surface using a heavy duty polisher with
Numerous Fractures a buffing pad. Make sure the pad is free of dirt or
Using a grinder with a 24-grit disk, remove the you may damage the gelcoat. Carefully begin buff-
gelcoat. Sand the edge area with 220-grit sandpa- ing with a white medium compound RM 856. Fin-
per. ish off using a fine RM 852 compound. While buff-
ing, be careful not to overheat the surface.
LMR2004_027-11_03A.FM 11-03-3
COMPOUND FRACTURES Using a clean paintbrush, brush the mixed resin on

the surface. Place the smallest piece of mat over
Possible Causes the fracture and then wet out the mat. Follow with
the remaining pieces of mat and final layer of cloth.
– Thickness of fiberglass laminate. While wetting the pieces make sure you work the
– Direct result of impact. air bubbles out and saturate all the pieces evenly.
Compound fractures are those that have gone past Try to work quickly, you may only have 15 or 20
the gelcoated surface and in through the layers of minutes. You may clean the brush with acetone.
fiberglass laminate. Two types of repairs have to Wait until the repair has hardened before moving
be performed. The first is to restore the structural on to the interior repair. If the size of the opening
integrity of the damaged area. Fracture types can is too large for the pieces to maintain the proper
vary from a simple crack to a large hole. Usually, shape, you will have to use a backing support. It is
fiberglass reinforcement becomes necessary, es- a shaped piece of cardboard that fits flush to the
pecially if the fracture can be attributed to weak- interior surface and has a plastic layer on the repair
ness. The final part of the repair is the gelcoating, side. It is held in place by tape or a support.
which cannot be applied until the interior and exte-
Inside
rior laminate surfaces have been repaired.
Wipe down the area with acetone on a cloth. Ap-
Outside ply the same procedure as for outside repair when
Remove the damaged gelcoat and fiberglass with laminating the alternating pieces of fiberglass ma-
a 24-grit disk using a power sander. Grind outward terial. If a backing support was used, remove it
at least 2 inches from the fracture to allow the before starting the repair. After the area has hard-
patch to bond to strong material. Cut enough pieces ened, remove sharp edges of material from sur-
of fiberglass mat necessary to build up the area. face. If required paint the surface.
The pieces should be cut so they overlap each oth-
er by at least half an inch. For a smoother finish, Sanding
the last layer should be fiberglass cloth. If the frac-
Outside
ture is small enough all you may have to do is fill
the area with an epoxy filler. This surface will have to be prepared for applica-
tion of gelcoat. The size of the area will determine
Inside the gelcoating procedure to be used. Refer to the
For the interior repair, you can grind more. This will repair procedure for minor gelcoat fractures.
allow for more fiberglass material which will
strengthen the area. If the fracture opening is too Buffing and Waxing
large after surface preparation, you may need a Refer to the buffing and waxing for minor gelcoat
backing support to cover the opening. Cut alternat- fractures. If painting the exterior is preferred, refer
ing pieces of fiberglass mat and cloth in overlap- to PAINTING subsection.
ping 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 Bombardier gelcoat repair put-
ty. When laying up a larger area you will use mat,
cloth and fiberglass resin and hardener. Use a
clean container to mix the resin, mix only what you
will need. Follow the recommended catalyst ratio.
11-03-4 LMR2004_027-11_03A.FM
Section 12 TECHNICAL DATA
Subsection 01 (SPEEDSTER 200)
SPEEDSTER 200 0
ENGINE SPEEDSTER 200
Number of engines 2
BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke,
Engine type
Over Head Camshaft (OHC), liquid cooled (x 2)
Number of cylinders 3 (x 2)
Number of valves 12 valves with hydraulic lifters (no adjustment)
Bore Standard 100 mm (3.9 in)
Stroke 63.4 mm (2.49 in)
Displacement 1498 cm³ (91.41 in³)
Compression ratio 10.6 ± 0.4:1
Rev limiter setting 7650 ± 50 RPM
Dry sump with replaceable oil filter
Lubrication 4-stroke engine oil SAE 10W40
(API Service classification SG, SH or SJ)
Oil filter CHAMPION
Exhaust system Type Water cooled, water injected with regulator
Intake valve opening 10° BTDC
Intake valve closing 45° ABDC
Exhaust valve opening 50° BBDC
Exhaust valve closing 5° ATDC
Starting system Electric start
New minimum 5.961 mm (.2347 in)
Intake New maximum 5.975 mm (.2352 in)
Wear limit 5.930 mm (.2330 in)
Valve stem diameter
Exhaust New maximum 5.960 mm (.2346 in)
Valve guide diameter New maximum 6.018 mm (.2369 in)
New nominal 41.02 mm (1.615 in)
Inner
Wear limit 38.8 mm (1.499 in)
Valve spring free length
New nominal 45.45 mm (1.789 in)
Outer
Wear limit 43 mm (1.693 in)
New nominal 1.1 to 1.3 mm (.043 to .051 in)
Intake
Valve seat contact width
New nominal 1.25 to 1.55 mm (.049 to .061 in)
Exhaust
Rocker arm bore diameter New maximum 20.020 mm (.7881 in)
Rocker arm shaft diameter New maximum 19.993 mm (.7871 in)
LMR2004-028_12_01A.FM 12-01-1

Cylinder head screw Service limit 148.5 mm (5.846 in)
1st Rectangular
Piston ring type and quantity 2nd Taper-face
3rd Oil scraper ring
Rectangular 0.15 mm (.006 in)
Taper-face New minimum 0.15 mm (.006 in)
Oil scraper ring 0.15 mm (.006 in)
Ring end gap Rectangular 0.3 mm (.012 in)
Taper-face New maximum 0.3 mm (.012 in)
All Wear limit 1.5 mm (.06 in)
Taper-face New minimum 0.015 mm (.0006 in)
Ring/
piston groove clearance
Taper-face New maximum 0.06 mm (.0024 in)
All Wear limit 0.15 mm (.006 in)
New minimum 0.024 - 0.056 mm (.001 - .0022 in)
Piston/cylinder wall clearance
Cylinder taper (maximum) 0.03 mm (.0011 in)
Cylinder out of round (maximum) 0.008 mm (.0003 in)
Front New maximum 24.960 mm (.9827 in)
Camshaft bearing journal
New minimum 39.892 mm (1.5705 in)
PTO and
New maximum 39.905 mm (1.5711 in)
center
Front New maximum 25.013 mm (.9848 in)
Camshaft bore
PTO and
New maximum 40.016 mm (1.5754 in)
center
Intake New maximum 31.590 mm (1.2437 in)
Cam lobe
Exhaust New maximum 31.809 mm (1.2523 in)
Crankshaft axial clearance
New maximum 0.22 mm (.0087 in)
Connecting rod big end clearance Wear limit 0.09 mm (.0035 in)
12-01-2 LMR2004-028_12_01A.FM

Crankshaft journal diameter New maximum 50.000 mm (1.9685 in)
Crankshaft radial clearance Wear limit 0.007 mm (.0028 in)
Connecting rod big end diameter Service limit 45.080 mm (1.7740 in)
Connecting rod big end clearance Service limit 0.09 mm (.0035 in)
Connecting rod big end axial play New maximum 0.287 mm (.0113 in)
Crankshaft deflection 0.050 mm (.002 in)
Connecting rod small end diameter New maximum 23.020 mm (.9063 in)
Piston pin diameter New maximum 23.000 mm (.9055 in)
Piston pin bore clearance Wear limit 0.080 mm (.0035 in)
Balance shaft journal diameter New maximum 32.000 mm (1.2598 in)
Balance shaft radial clearance Wear limit 0.07 mm (.0028 in)
Balance shaft axial clearance
New maximum 0.25 mm (.0098 in)
ADDITIONAL INFORMATION:
LMR2004-028_12_01A.FM 12-01-3
ELECTRICAL SPEEDSTER 200

Magneto generator output 380 W @ 6000 RPM
Ignition system type DI (Digital Induction)
Ignition timing Not adjustable
Make and type NGK DCPR8E
Spark plug
Gap 0.75 mm (.030 in)
Generating coil N.A.
Battery charging coil 0.1 - 1.0 Ω
Primary 0.45 - 0.55 Ω
Ignition coil
Secondary 6.8 - 10.2 kΩ
Engine RPM limiter setting 7650 RPM
Battery 12 V, 30 A•h (not supplied)
TOPS 10 A
Battery fuse (rectifier) 30 A
Cylinder 1, ignition coil and injection 10 A
Electric bilge pump (2) 7.5 A
Starting system, electric fuel pump 10 A
ECM, start/stop circuit 5A
Main (engine fuse block) 15 A
Fuses Charging system 15 A (2)
Bilge air blower 7.5 A
Navigation lights 3A
Gauges supply 5A
Auxiliary system 10 A
Radio 10 A
12-volt jack 10 A
Navigation lights 3A
Blower 7.5 A
Main fuses (2) 20 A
12-01-4 LMR2004-028_12_01A.FM
FUEL SYSTEM SPEEDSTER 200

Rotax EMS (engine management system)
Fuel injection type multipoint fuel injection.
Single throttle body (52 mm (2.05 in))
Fuel pressure 42 PSI - 45 PSI
Idle speed (in water/out of water) 1800 ± 50 RPM
Throttle Position Sensor (TPS) 1.6 kΩ - 2.4 kΩ
Crankshaft Position Sensor (CPS) 5 volts
Camshaft Position Sensor (CAPS) 12 volts
Camshaft Position Sensor (CAPS) 1.2 kΩ
Manifold Air Temperature Sensor (MATS) 2.28 kΩ - 2.74 kΩ
Coolant Temperature Sensor (CTS) 2.28 kΩ - 2.74 kΩ
Exhaust Gas Temperature Sensor (EGT) 2.28 kΩ - 2.74 kΩ
Manifold Air Pressure Sensor (MAPS) 0 Ω (continuity between terminals 3 and 1)
Knock Sensor (KS) 5 MΩ
Oil Pressure Switch (OPS) 0 Ω, if oil pressure is greater than 26 - 32 PSI
Oil Separator Pressure Switch (OSPS) 0 Ω, if blow-by pressure is less than 6 PSI
TOPS valve 1.27 Ω - 2.47 Ω
Fuel injector 11.4 Ω - 12.6 Ω
Regular unleaded gasoline with 87 octane
Type
Fuel (Ron + Mon)/2 specification
Minimum octane no. 87
COOLING SPEEDSTER 200

Type Liquid cooled. Closed loop for engine -
open loop for exhaust system
Ethylene-glycol 50%/50% antifreeze/water.
Coolant Coolant containing corrosion inhibitors for
internal combustion aluminum engines
Thermostat 87°C (188°F)
Monitoring beeper setting 110°C (230°F)
LMR2004-028_12_01A.FM 12-01-5
PROPULSION SPEEDSTER 200

Propulsion system BOMBARDIER Formula pump
Number of jet pumps 2
Jet pump type Axial flow single stage. Greased bearings
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
Coupling type Crown splines
Reverse system Yes
Jet pump bearing grease (P/N 293 550 032),
Grease type 10 mL front bearing, 50 mL rear of bearing,
50 mL in pump cap
Steering nozzle pivoting angle 26°
Minimum required water level for jet pumps 90 cm (3 ft)
Drive shaft deflection (maximum) 0.5 mm (.020 in)
Impeller outside diameter 155.3 ± 0.3 mm (6.122 ± .0118 in)
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller/wear ring clearance
Impeller shaft end play (new) 0
Impeller shaft side play 0.75 mm (.029 in)
Impeller material Stainless steel
ADDITIONAL INFORMATION: Do not mix different brands or oil types.
DIMENSIONS SPEEDSTER 200

Number of passenger (driver incl.) 7
Overall length 6.02 m (237 in)
Overall width 2.44 m (96 in)
Overall height 1.42 m (56 in)
Dry weight 1256.5 kg (2770 lb)
Draft 30 cm (12 in)
Dead rise 20°
Load limit (passenger and luggage) 635 kg (1400 lb)
CAPACITIES SPEEDSTER 200

3 L (3.2 U.S. qt) oil change
Engine oil
w/filter 4.5 L (4.8 U.S. qt) total
Cooling system (coolant) 6.65 L (7.03 U.S. qt) total (x 2)
Fuel tank (including reserve) 151 L (40 U.S. gal)
Impeller shaft reservoir capacity 80 mL (2.7 U.S. oz)
Impeller shaft reservoir oil level Up to plug
12-01-6 LMR2004-028_12_01A.FM
MATERIALS SPEEDSTER 200

Hull Composite
Inlet grate Aluminum
Steering cover Thermoplastic
Impeller housing/stator/venturi/nozzle Plastic/stainless steel/aluminum/aluminum
Air intake silencer N.A.
Flame arrester Tubular wire screen
Fuel tank Polyethylene
Seat Polyurethane foam
PERFORMANCE SPEEDSTER 200

Estimated pump power 57 kW (76.44 HP) (x 2)
Maximum fuel consumption at wide open throttle 41.1 L/h (10.8 U.S. gal/h)
Cruising time at full throttle Fuel tank 117 minutes
LMR2004-028_12_01A.FM 12-01-7
Section 13 WIRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)
WIRING DIAGRAMS 0
WIRE COLOR CODES DEUTSCH CONNECTORS
First color of a wire is the main color. Second color Removal
is the tracer.
To disconnect two Deutsch connectors, slide a flat
Example: YELLOW/BLACK (YL-BK) is a YELLOW
screwdriver between each other to disengage,
wire with a BLACK tracer.
press the release button and disconnect them.
WIRE DIGIT CODES 1
MPEM and Vehicle Electrical System

First number indicates in which connector the
wire is plugged in.
Second number indicates the position of the wire
in the connector.
The letter at the end of the number (if applicable)
indicates a common circuit in the MPEM printed
circuit with another wire bearing the same letter.
Example: 2-18 (g)
The first number indicates that the wire is posi-
tioned in the connector no. 2 of the MPEM.
F18Z0LA 2
The second number indicates that the wire is po-
1. Flat screwdriver
sitioned in the terminal no. 18. 2. Deutsch connectors
The letter (g) indicates a common circuit with an-
other wire(s) bearing the same letter (g) in the cir- 2
cuit.
EMS ECU
On the EMS ECU, circuits are identified by a letter
followed by a number.
The letter indicates in which connector the wire is
plugged in.
The number indicates the position of the wire in
the connector.
The connector “A” is connected to the engine wir-
ing harness.
The connector “B” is connected to the sport boat F18Z0MA 1 2
wiring harness.
1. Release button
2. Deutsch connectors
LMR2004_029_13_01A.FM 13-01-1
F18Z0NA 2 1
1. Deutsch connectors
2. Press release button
Deutsch connectors are used to connect wiring

harness to the magneto and to the VCK. V01G0OA 1
FEMALE HOUSING
1. Female lock
3 1
3
2
4
F00H1CA
1. Male housing
2. Female housing
3. Secondary lock
4. Sealing cap
CAUTION: Do not apply dielectric grease on

contacts inside plug connector.
To remove wire contacts from housing, proceed
as follows: V01G0PA 1
– Using a long nose pliers, pull out the lock. MALE HOUSING
1. Male lock
NOTE: Before extraction, push wire forward to re-

lieve pressure on retaining tab.
– Insert a 4.8 mm (.189 in) wide screwdriver blade
inside the front of the contact cavity.
13-01-2 LMR2004_029_13_01A.FM
– Pry back the retaining tab while gently pulling Deutsch 6 pin Connector Electrical Box
wire back until contact is removed.
1 1
F04H6KA
6-PIN CONNECTOR
1. Wires identification numbers
V01G0QA 1
FEMALE CONNECTOR HOUSING PACKARD CONNECTOR
1. Retaining tabs
Packard connectors are used to connect electrical
To install: harnesses and gauges.
– For insertion of signal contact, make sure the
lock is removed.
– Insert contact into appropriate circuit cavity and
push as far as it will go.
– Pull back on the contact wire to be sure the re-
tention fingers are holding the contact.
1
– After all required contacts have been inserted,
the lock must be installed.
C B A
F04H45A
1 1 VIEW OF A 3-POSITION PACKARD CONNECTOR

1. Identification letters
To remove terminal from Packard connector hous-

ing, use Snap-on TT600-4 tool.
F04H6LA F01B1JA
1. Wire identification numbers
LMR2004_029_13_01A.FM 13-01-3
Removal
 WARNING
Ensure all terminals are properly crimped on To remove the plug connector from the header as-
wires and connector housings are properly sembly, press both tabs and pull plug.
fastened.
1
AMP PLUG CONNECTOR 2
These connectors are found on the MPEM.
When servicing electrical system, special care
must be taken when working with AMP plug con-
nectors in order to prevent any malfunction of the
system.
Description
5
F00H0NA
9
Step 1 : Press tabs (both sides)
Step 2 : Pull plug
1
Installation
2 Apply a thin coat of DEOXIT contact lubricant (P/N
293 550 034) to the pins of the header on the
MPEM only.
7 4
89
F00H0WB 6
AMP PLUG CONNECTOR
1. Plug assembly
2. Cover assembly
3. Mating seal
4. Wedge lock
5. Header assembly
6. Seal plug
7. Power wire
8. Signal wire
9. Locking tab
1
F00H11A
1. Apply a thin coat of DEOXIT contact lubricant
CAUTION: Do not apply lubricant excessively.

Care must be taken so that the lubricant will not
come in contact with the mating seal; the seal
may loose its sealing capacities. Do not apply
lubricant on contacts inside plug connector.
13-01-4 LMR2004_029_13_01A.FM
Each plug assembly is mechanically keyed to mate

1 2
only with identical mechanical keyed header on
the MPEM.
F00H0OA
1. Screwdriver between wedge lock and connector

2. Locking tab
Repeat the same steps for the other locking tab

retaining the wedge lock.
The wedge lock is now in the open position.
1 1
F00H12A
1. Mechanically keyed
Contact Removal
Signal Wire
Insert a screwdriver blade between the connector
and the wedge lock tab.
F00H0PA
Release the locking tab and at the same time, pry

1. Wedge lock opened
open the wedge lock to open position.
CAUTION: The wedge lock should never be re-
moved from the connector for insertion or re-
moval of the signal wire contacts.
LMR2004_029_13_01A.FM 13-01-5
While rotating the wire back and forth over a half Before extraction, push wire forward to relieve
turn (1/4 turn in each direction), gently pull the wire pressure on retaining tab.
until the contact is removed. Insert a 4.8 mm (.189 in) wide screwdriver blade
inside the front of the contact cavity.
F00H0QA
1. Rotate wire back and forth

2. Pull wire
Power Wire Contact

NOTE: The wedge lock must be removed to ex-
tract power contact.
Open the wedge lock.
Pull both locking tabs and remove wedge lock
from plug assembly.
F00H0ZA
1
Pry back the retaining tab while gently pulling wire
back until contact is removed.
Contact Crimping
The size of the wires must be 20 to 16 AWG with
a wire insulation diameter having a minimum di-
mension of 1.7 mm (.067 in) and a maximum di-
mension of 2.78 mm (.106 in).
The wire strip length shall be 5.1 mm (13/64 in).
NOTE: When stripping wires, ensure conductor is
not nicked, scraped or cut. Wire stripping tool jaws
may leave marks on the surface of the wire insu-
lation. If these marks occur at the location of the
wire seal, leakage may result. Insulation surface
F00H0RA
within 25 mm (1 in) from the tip of the contact
1. Pull locking tab (both sides) must be smooth.
All contacts in AMP plug connectors must be
crimped using the crimping tool (P/N 295 100 164).
13-01-6 LMR2004_029_13_01A.FM
CAUTION: If contacts are not crimped using CAUTION: Do not pierce the diaphragm with a
the proper crimping tool, the wire seal may be sharp point for electrical troubleshooting. The
damaged. resulting pinholes in the insulation will allow
moisture to penetrate the system and possibly
result in system failure.
Contact Installation
For insertion of signal contact, make sure the
wedge lock is in the open position.
NOTE: For insertion of power contact, the wedge
lock may or may not be on the open position.
Insert contact into appropriate circuit cavity and
push as far as it will go.
Pull back on the contact wire to be sure the reten-
F00B0EA tion fingers in the housing are holding the contact
CRIMPING TOOL (P/N 295 100 164) properly.
After all required contacts have been inserted, the
All circuits are sealed by a diaphragm in the rubber
wedge lock must be closed to its locked position.
wire seal. When installing wire contacts in plug
connector, the diaphragm is pierced as the contact
passes through it. IDENTIFICATION OF
If the diaphragm is pierced and the cavity is not CONNECTOR PINS
used, install a seal plug, large end first, into circuit
cavity as far as it will go.
AMP Connectors of MPEM
NOTE: It is suggested that all unused circuit cavi-
ties be sealed with a seal plug, even if they are not
pierced.
1
26 25 24
23 16
15 9
8 1
F04H6RA
F00H10A 2
1. Seal plug
2. Wire seal
LMR2004_029_13_01A.FM 13-01-7
AMP Connectors of Wiring Harness Crimping and Installation Tools

Required
To install EMS ECU connector terminal pins or ter-
minal wire, three tools are required; EMS ECU
crimping tool, EMS ECU extraction tool and a stan-
dard flat screwdriver.
F04H6GA
1
F18Z03A
EMS ECU CONNECTORS 1. EMS ECU crimping tool

2. EMS ECU connector terminal extraction tool
There are two EMS ECU connectors used on the 3. Standard flat screwdriver
4-TEC models and they are connected on the EMS
ECU. The engine harness female connector is con- Defective Terminal Removal
nected on the module male connector “A” and the Unlock the terminal cover by disengaging the ter-
sport boat system control harness female connec- minal cover locking device on both side with a flat
tor is connected to the module male connector screwdriver.
“B”. The engine connector has 41 pins.
3
2
2
1
1
F18Z02A
F18Z04A
1. EMS ECU
2. A connector (engine harness) 1. Terminal connector cover
3. B connector (sport boat system harness) 2. Terminal cover locking device
13-01-8 LMR2004_029_13_01A.FM
Lift wire harness and note the terminal pinout num-

ber. The EMS ECU connector has 41 terminals.
The pins are split into three groups; 1 to 13, 14 to
1 28 and 29 to 41. Make sure you have located the
proper terminal.
F18Z05A
1. Terminal connector cover

2. Terminal cover locking device 2
Lift the cover by pushing it forward.
F18Z08A
1. Wire harness
2. Terminal pinout numbers
1 Once the defective terminal is identified, unlock

the red terminal locking plate by using the flat
screwdriver and release the locking device at each
end of the connector. Remove the red terminal
locking plate by sliding it outside the connector.
F18Z06A
1. Cover
Cut both locking ties.
2 1
F18Z09A
1. First locking device

2. Red terminal locking plate
F18Z07A
1. Locking ties
LMR2004_029_13_01A.FM 13-01-9
Release the defective terminal from connector

with the extraction tool. Align the extraction tool
pin properly with the terminal cavity and push the
tool downward. That will release the wire with the
terminal.
1 2
2
1 3
F18Z0AA
1. Second locking device

F18Z0DA
1. Terminal cavity
2. Extraction tool
1 3. Extraction tool pin
F18Z0BA
Remove the red terminal locking plate and acquire

the EMS ECU extraction tool.
2
1
F18Z0EA
1. Extraction tool
2. Connector terminal housing
F18Z0CA 1
2. EMS ECU extraction tool
13-01-10 LMR2004_029_13_01A.FM
2
3
1
F18Z0HA
1 1. Crimping tool swivel

2. Crimping tool
3. Wire
F18Z0FA 2
1. Connector terminal housing
CAUTION: Probe on top of terminal only. Do
2. Defective wire and terminal not try to probe inside terminal or to use a pa-
per clip to probe inside terminal, it can damage
If the wire is in good condition but the terminal is the square-shaped terminal.
rusted or corroded, remove defective terminal and
crimped a new one. If wire and terminal are defec- CAUTION: Do not disconnect the EMS ECU
tive, acquire a new genuine wire and new terminal connector needlessly. They are not designed to
and crimp them together as follow. be disconnected/reconnected frequently.
IMPORTANT: Use genuine wires only. Otherwise
wires will not fit properly.
Lubrication
Apply a thin coat of DEOXIT contact lubricant (P/N
Terminal and Wire Crimping 293 550 034) to the pins of the header on the EMS
ECU only.
To crimp a new terminal to a good wire, acquire
the EMS ECU crimping tool. Install the new termi-
nal in the crimping tool swivel. Close the swivel in
place. Place the wire on terminal barrel and crimp
the wire firmly.
2 3
1
F18Z0GA
1. New terminal
2. Crimping tool swivel
3. Crimping tool
LMR2004_029_13_01A.FM 13-01-11
2004 SPEEDSTER 200
AVERTISSEUR
Porte-fusibles du moteur
ALIMENTATION
EN ESSENCE
MOTEUR MOTEUR
GAUCHE DROIT
Interface des
Porte-fusibles du moteur
INDICATEURS
HAUT-PARLEUR HAUT-PARLEUR
BABORD TRIBORD
ARRIÈRE ARRIÈRE
Température Bas niveau Tr/mn Bas niveau Tr/mn

Vitesse AVERTISSEUR – Batt. faible Vérif. moteur
d’huile Batt. faible Vérif. moteur Température d’huile
élevée élevée
Ligne de comm. Ligne de comm. Interrupteur Signal Ligne de comm. Ligne de comm. Interrupteur Signal
Interrupteur Masse Signal (HAUT) (BAS) Masse de DESS du DESS
de DESS du DESS (HAUT) (BAS) Masse
de DESS du DESS du DESS
ALIMENTATION VOYANTS
DES ALIMENTATION
INDICATEURS DES
INDICATEURS
Interrupteur
de DESS
Porte-fusibles du moteur gauche Porte-fusibles du moteur droit TACHYMÈTRE
BLOC DE JONCTION
VOYANTS
FEU DE PONT
TACHYMÈTRE
FEU FEU FEU

DE PONT DE PONT DE PONT
INDICATEUR
DE VITESSE
INDICTEUR
DE NIVEAU
D’ESSENCE/HUILE
INTERRUPTEUR
DÉMARRAGE/ARRÊT
(GAUCHE)
INTERRUPTEUR
DÉMARRAGE/ARRÊT
(DROIT)
INTERRUPTEUR
DISP. NETTOYAGE
ALIMENTATION COMMANDE GRILLES D’ADM. D’EAU
DISP. NETTOYAGE DISP. NETTOYAGE
INTERRUPTEUR FEU FEU GRILLES GRILLES
DE POINT MORT D’ADM. D’EAU D’ADM. D’EAU
(GAUCHE)
INTERRUPTEUR
DE POINT MORT
(DROIT)
F13Z02
PORTE-FUSIBLES
vers le relais de démarreur
F13Z03
INTERRUPTEUR DE DESS
ALIMENTATION DES INDICATEURS
INTERFACE
MASSE
MASSE
MASSE
DU MOTEUR
DU PORTE-FUSIBLES
INTERFACE
LIGNE DE
voir page 1
COMM. (BAS)
INTERFACE
2004 SPEEDSTER 200
LIGNE DE
interface des indicateurs

COMM. (HAUT)
RELAIS DE
DÉMARREUR
DU SGM –
RELAIS DE INTERRUPTEUR
DÉMARREUR – DE POINT MORT
RELAIS DE
DÉMARREUR +
POMPE À
ESSENCE
RELAIS DE
DÉMARREUR
DIAGNOSTIC
ESSENCE
POMPE À
MASSE
DIAGNOSTIC
LIGNE DE
COMM. (BAS)
DIAGNOSTIC
LIGNE DE
COMM. (HAUT)
DIAGNOSTIC
CONNECTEUR DE
LIGNE K
SGM
SGM
PORTE-FUSIBLES DU MOTEUR
DÉMARRAGE/
ARRÊT
RELAIS –
SGM
MONITEUR
DE DESS
SOUPAPE
ANTI-RETOUR
BOBINES
CYLINDRE 3
BOBINES
CYLINDRE 2
BOBINES
CYLINDRE 1
MASSE
SOUPAPE DE RALENTI A
MASSE
MASSE
SOUPAPE DE RALENTI B
DU MOTEUR
MASSE
SOUPAPE
DE RALENTI
SOUPAPE DE RALENTI C
MASSE
MASSE
SOUPAPE DE RALENTI D
DU MOTEUR
INJECTEUR 1 –
BOBINE 1
BOBINE 1 –
INJECTEUR 2 –
BOBINE 2
BOBINE 2 –
INJECTEUR 3 –
BOBINE 3
BOBINE 3 –
SIGNAL CPAC
CPAC
CPAC –
ANTI-RETOUR –
ANTI-RETOUR
SPH
SPH RÉSERVOIR
STA
STA –
STA +
SIGNAL DU CPA
CPA
CPA +
CPA –
STE
STE –
STE +
STGE
STGE –
STGE +
SPH
SYSTÈME DE GESTION DU MOTEUR
SPH MOTEUR
DÉTECTEUR DE
DÉTONATION –
DÉTECTEUR DE
DÉTONATION +
DÉTECTEUR
DE DÉTONATION
SIGNAL DE LA SPA
SPA
MAPS +
MAPS –
CPV
CPV +
CPV –
INTERRUPTEUR
DE DESS
MASSE
DE DESS
ALIMENTATION DE
L’ACCUMULATEUR
RELAIS –
INTERRUPTEUR
DE DÉMARRAGE
DÉMARRAGE/ARRÊT
LIGNE DE
COMM. (BAS)
LIGNE DE
COMM. (HAUT)
LIGNE K
POMPE À ESSENCE
RELAIS DE DÉMARREUR
SIGNAL DU DESS

2004 Speedster Shop Manual

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2004 Speedster Shop Manual

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SECTION SUBSECTION PAGE

SAFETY NOTICE .................................................................................................................................. II

HULL IDENTIFICATION NUMBER

Bold face number

Page numbering system:

Sub-title with part

Section 06 FUEL SYSTEM

Title indicates main

Sub-sub-title in this All Others Models

Letters are used for

Bold numbers in the

LIST OF ABBREVIATIONS USED DESCRIPTION

GENERAL INFORMATION ILLUSTRATIONS AND

Exceptions include manufacturer’s prescribed SELF-LOCKING FASTENERS

VIA U.S. POSTAL SERVICE:

Blind Holes 1. Clean threads (stud and hole) with solvent.

1. Clean threads (bolt and hole) with solvent.

Stud in Blind Holes 2

Adjusting Screw Standard Thread Repair

1. Clean inner housing diameter and outer gasket

TIGHTENING TORQUES N•m

FASTENER SIZE FASTENER SIZE

OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1

SERVICE PRODUCTS ............................................................................................................ 01-04-1

MANDATORY SERVICE TOOLS 0

Alignment support plate kit F18B0C4

P/N 529 035 506

P/N 207 182 544 P/N 529 035 886

Crankshaft locking tool Camshaft locking tool

P/N 295 000 070 P/N 529 035 591

P/N 295 000 054

Oil seal guide

P/N 529 035 820

Drive shaft/floating ring

Pliers Pressure cap

NOTE: This tool is also used for the

PTO seal support

OPTIONAL SERVICE TOOLS 0

tachometer P/N 295 000 129

Exhaust outlet tool Valve spring compressor clamp

P/N 295 000 145

Special pliers for valve stem seal NEW

Test radiator cap

SPORT BOAT HANDLING

High temperature retaining General purpose instant adhesive

Flange sealant Solvent Pipe sealant

Primer for gasket eliminator

Dielectric grease Super Lube grease NEW

P/N 293 550 004 P/N 293 550 030

Deoxit contact lubricant

Anti-seize lubricant BOMBARDIER LUBE lubricant

BOMBARDIER storage oil NEW NEW

P/N 413 711 600

P/N 293 600 247

732 Multi-purpose sealant

NEW Sea-Doo Cleaner

Pulley flange cleaner

Jet pump synthetic oil

Jet pump grease

FLUSHING AND LUBRICATION ........................................................................................... 02-03-1