SeaDoo SP manuals

Seadoo SP Service Manual (316 pages)

Brand: Seadoo | Category: Engine | Size: 15.35 MB |

English

Table of contents

219 100 031

2

SAFETY NOTICE

5

All Engines Except the 787

6

787 Engine Only

6

ARRANGEMENT OF THIS

7

TYPICAL PAGE

8

GENERAL INFORMATION

10

ILLUSTRATIONS AND

10

PROCEDURES

10

MANDATORY TOOLS

11

ENGINE (continued)

12

COOLING / FUEL/ OIL SYSTEMS

14

PROPULS1ON SYSTEM

15

RECOMMENDED TOOLS

16

PROPULSION SYSTEM

20

WATERC RAFT HANDING

21

SERVICE PRODUCTS

22

❑ AIIlsEAn )

26

Geicotee

28

PERIODIC INSPECTION CHART 1

30

Section 02 MAINTENANCE

32

Procedure

34

Engine Draining

36

Fuel System

36

Internal Lubrication

36

Propulsion System

36

Watercraft Cleaning

37

Anticorrosion Treatment

37

Sub-Section 04 (STORAGE)

38

TROUBLESHOOTING 0

39

Section 03 TROUBLESHOOTING

40

Section 04 ENGINE

43

REMOVAL FROM WATERCRAFT

44

Tuned Pipe

45

Air Intake Silencer

45

Carburetor(s)

45

Engine Support Mounts

45

Lifting Engine

46

Engine Support and Nut

48

Oil Injection Hoses

48

Positive Starter Cable

48

Engine / Jet Pump Alignment

48

Engine Support Screws

49

Final Inspection

49

TOP END 2

50

Sub-Section 02 (TOP END)

51

ENGINE DESCRIPTION

52

Cylinder Taper

55

Cylinder Out of Round

55

Ring End Gap

56

16, Cylinder Base Gasket

56

5, Circlip

59

10,17,18, Cylinder Screw

61

10 8 2 4 6 12

63

113 1 59 7

63

RAVE SYSTEM

64

Maintenance

65

BOTTOM END 3

68

Sub-Section 03 (BOTTOM END)

69

CRANKSHAFT MISALIGNMENT

71

AND DEFLECTION

71

Crankshaft Deflection

75

ROTARY VALVE 4

80

INSPECTION ON WATERCRAFT

81

Sub-Section 04 (ROTARY VALVE)

82

13, Rotary Valve

87

TEMPLATE

88

EXHAUST SYSTEM 5

91

TUNED PIPE REMOVAL

94

1,3, Collar and Hose

95

4, Clamp

95

23, Screw

95

6, Screw

95

EXHAUST MANIFOLD REMOVAL

96

MUFFLER REMOVAL

96

TUNED PIPE REPAIR

96

EXHAUST MANIFOLD, TUNED

97

PIPE AND MUFFLER

97

16, Sealing Ring

98

20, Gasket

98

7,9, Screw and Nut

98

TABLE OF CONTENTS

100

COMPONENTS 1

101

Section 05 COOLING SYSTEM

102

Sub-Section 01 (COMPONENTS)

102

3, Elbow Fitting

105

1, Clamp

105

2, Fitting Spigot

105

4, Water Flow Regulator Valve

106

5,6, Spring and Cover

106

7, Fitting

107

8, Tapered Needle

107

9,10, Valve and Bellows

107

CIRCUIT 2

108

Max. 90°

108

Sub-Section 02 (CIRCUIT)

109

587 ENGINE COOLING SYSTEM

110

717 ENGINE COOLING SYSTEM

111

787 ENGINE COOLING SYSTEM

112

FUEL CIRCUIT 1

114

Section 06 FUEL SYSTEM

115

Sub-Section 01 (FUEL CIRCUIT)

115

1,2, Fuel Filter and Bowl

118

2,3, Bowl and Gasket

118

INSPECTION

119

ASSEMBLY

120

FUEL SYSTEM PRESSURIZATION

121

AIR INTAKE 2

122

5, Flame Arrester

124

9, Gasket

124

CARBURETORS 3

125

Sub-Section 03 (CARBURETORS)

126

CARBURETOR REMOVAL

127

CLEANING

127

DISASSEMBLY AND INSPECTION

127

PUMP VERIFICATION

128

CARBURETOR ASSEMBLY

129

9,10, Main Jet and Pilot Jet

130

CARBURETOR INSTALLATION

131

ADJUSTMENTS

132

2, Low Speed Screw

133

14, High Speed Screw

133

15, Idle Speed Screw

134

OIL INJECTION SYSTEM 1

137

HX Model

138

OIL SYSTEM PRESSURIZATION

139

OIL INJECTION PUMP 2

140

XP Model

141

CHECKING OPERATION

144

Bench Test

145

MAGNETO SYSTEM 1

147

Section 08 ELECTRICAL SYSTEM

148

4,5, Armature Plate and Screw

150

Engine Crankcase Replacement

150

15,16, Rotor and Flywheel

151

DISASSEMBLY

152

INSTALLATION

154

Ignition Coil

157

Magneto Rotor / Trigger Coil

158

DC-CDI Module

158

IGNITION TIMING PROCEDURE

159

Static Test

160

Dynamic Test

161

Ignition Timing Adjustment

162

BOMBARDIER IGNITION TESTER

165

IGNITION SYSTEM TESTING

166

PROCEDURE

166

Generating Coil Verification

167

Trigger Coil Verification

168

DC-CDI Module Verification

169

(MPEM) Verification

169

Holder Relay Verification

169

Ignition Coil Verification

170

SPARK PLUGS

171

Spark Plug Analysis

172

Spark Plug Installation

172

Spark Plug Chart

172

CHARGING SYSTEM 3

174

Battery Charging Coil

175

Troubleshooting

177

Cleaning

177

Inspection

177

Hydrometer Test

177

Battery Storage

178

Activation of a New Battery

178

Servicing

180

CHARGING A VERY FLAT OR

180

Battery Charging Equipment

181

Installation of Battery

181

STARTING SYSTEM 4

182

PARTS INSPECTION

185

STARTER REMOVAL

185

STARTER DISASSEMBLY

185

STARTER ASSEMBLY

186

1,10, Housing and Yoke Ass’y

187

Through Bolt

187

STARTER INSTALLATION

188

STARTER SPECIFICATION

189

Variable Trim Gauge

191

Fuel Baffle Pick-Up Sensor

191

Oil Sensor

192

Speed Sensor

193

STATIC TEST

193

DYNAMIC TEST

193

VTS Switch

193

VTS Motor

194

VTS Control Module

194

RESISTANCE TEST

194

DIGITALLY ENCODED SECURITY

195

SYSTEM 6

195

Basic Self-Diagnostic Mode

196

Advanced Self-Diagnostic Mode

197

Section 09 PROPULSION SYSTEM

199

JET PUMP 1

200

PLASTIC PUMP

201

JET PUMP INSPECTION ON

202

WATERCRAFT

202

Oil Inspection

203

Oil Check

203

Oil Replacement

203

JET PUMP REMOVAL

204

5, Nozzle

205

RIDE SHOE REMOVAL

206

JET PUMP SUPPORT REMOVAL

207

JET PUMP DISASSEMBLY

207

14,15, Boot and Ring

208

16, Fitting

208

19, Impeller

209

20, Wear Ring

209

21, Seal

210

F01J0XAF01J0XA

210

Sub-Section 01 (JET PUMP)

212

JET PUMP ASSEMBLY

215

Oil Fill

219

PUMP PRESSURIZATION

220

JET PUMP SUPPORT

221

RIDE SHOE INSTALLATION

221

JET PUMP INSTALLATION

222

Locking Disk and Nozzle

224

Steering and Reverse Cables

224

Steering Cable

225

Trim Systems

225

DRIVE SYSTEM 2

227

Section 09 PROLPUSION SYSTEM

228

Sub-Section 02 (DRIVE SYSTEM)

228

1, Large Clamp

229

2, Small Clamp

229

3, Drive Shaft

230

4, Rear Drive Shaft

230

5,6, Floating Ring and O-ring

230

13, Seal

235

12, Seal Carrier

235

REVERSE SYSTEM 3

239

6, Reverse Support

242

Sliding Block

242

VARIABLE TRIM SYSTEM 4

245

ASSEMBLY AND INSTALLATION

246

ADJUSTMENT

250

SP /XP SERIES 1

252

REMOVAL AND ASSEMBLY

253

Support and Handlebar

254

Supports

254

Section 10 STEERING SYSTEM

256

GTS AND GTI MODELS 2

257

HX MODEL 3

261

Sub-Section 03 (HX MODEL)

262

STEERING CABLE REMOVAL

263

STEERING ALIGNMENT

264

ALIGNMENT 4

265

Section 00 STEERING SYSTEM

266

Sub-Section 04 (ALIGNMENT)

266

DIRECT ACTION SUSPENSION 1

268

COIL OVER SHOCK REMOVAL

269

OUTER BOOT REMOVAL

270

COIL OVER SHOCK

270

ADJUSTMENT AND REPAIR 1

272

Section 12 HULL / BODY

273

SEAT ADJUSTMENT

280

STORAGE COMPARTMENT

281

ACCESS PANEL ADJUSTMENT

281

DRAIN PLUG INSTALLATION

282

SEAT REMOVAL

282

SEAT COVER REPLACEMENT

283

BUMPER REPLACEMENT

283

SPONSON REPLACEMENT

284

BAFFLE SEALING (GTS / GTI

284

HOOD REMOVAL

284

DECALS REPLACEMENT

284

HULL AND BODY REPAIR

285

HULL INSERT REPAIR

288

PAINTING 0

290

PARTS THAT CAN BE PAINTED

291

Section 12 HULL/BODY

292

Sub-Section 02(PAINTING)

292

PAINTING PROCEDURE

293

SP AND SPI MODELS 1

296

Section 13 TECHNICAL DATA

297

SPX AND XP MODELS 2

301

GTS AND GTI MODELS 3

306

HX MODEL 4

311

Sub-Section 04 (HX MODEL)

312

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