SeaDoo SP Manual de Serviço Página 61
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Section 04 ENGINE
Sub-Section 02 (TOP END)
040-02-12
ALL ENGINES EXCEPT THE 787
1. Exhaust flange aligning tool
ALL ENGINES
1. Aligning cylinders using exhaust manifold
10,17,18, Cylinder Screw
587 and 717 Engines
Apply synthetic grease below the screw head.
For the 717 engine, apply also Loctite 242 (blue)
on screw threads.
Install and torque screws in a criss-cross se-
quence for each cylinder to 24 N•m (17 lbf•ft). Re-
fer to the following illustration.
787 Engine
Prior installation, apply synthetic grease below
screw head and Loctite 515 on screw threads.
Install M10 x 105 screws on exhaust side and the
M10 x 73,5 on opposite side.
Torque screws in a criss-cross sequence for each
cylinder to 20 N•m (15 lbf•ft). Repeat the proce-
dure, retightening all cylinder screws to 40 N•m
(30 lbf•ft).
2,11,12, Cylinder Head, Screw and O-ring
587 Engine
Apply synthetic grease below screw head and on
screw threads.
F01D44A
1
F01D45A
1
F01D35A
1 4 1 4
3
2 3 2
F01D7FA
2 3 3 2
4 1 1 4
www.SeaDooManuals.net
- 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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