HSR S4 Standup 2007 User manual

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Table of Content
1. General Information......................................................................7
1.1. 2007 HSR personal watercraft Identification Numbers.......................................7
1.2. HIN number .............................................................................................................7
1.3. Engine number .......................................................................................................8
1.4. Three stars – ultra low emission...........................................................................8
1.5. Safety instructions .................................................................................................8
1.6. CE Sticker................................................................................................................8
1.7. Service Guidelines - Safety Warnings..................................................................9
1.8. General data..........................................................................................................11
1.8.1. Standard Torque Specifications......................................................................12
1.8.2. Convertion Chart.............................................................................................12
1.9. Service Tools ........................................................................................................14
1.10. Operating materials..............................................................................................15
1.11. Fuel ........................................................................................................................15
1.12. Lubricant ...............................................................................................................16
1.13. Running the Engine..............................................................................................16
1.14. Operating the engine without sea water.............................................................16
2. Maintenance ................................................................................18
2.1. Maintenance work by the user of the vehicle ....................................................19
2.1.1. Regular checks before driving ........................................................................19
2.1.2. Rinse sea water cooling circuit after driving ...................................................19
2.2. Maintenance intervals..........................................................................................20
2.3. Decommissioning at the end of the season.......................................................20
2.4. Motor oil and oil filter...........................................................................................21
2.4.1. Oil level check.................................................................................................21
2.4.2. Changing the motor oil and oil filter ................................................................23
2.4.3. Draining the motor oil......................................................................................23
2.4.4. Changing the oil filter ......................................................................................25
2.4.5. Refilling the motoroil .......................................................................................26
2.5. Spark Plugs...........................................................................................................26
2.5.1. Checking the spark plugs ...............................................................................26
2.5.2. Removing the spark plugs ..............................................................................26
2.5.3. Checking the spark plugs ...............................................................................28
2.6. Valve play..............................................................................................................28

2.6.1. Checking and setting the valve play ...............................................................28
2.6.2. Removing the valve cover ..............................................................................29
2.6.3. Checking the valve play..................................................................................30
2.6.4. Adjusting the valve play ..................................................................................31
2.6.5. Checking the valve of the 2nd cylinder.............................................................34
2.7. Malfunctions .........................................................................................................34
2.7.1. Engine does not crank ....................................................................................34
2.7.2. Engine cranks but does not start ....................................................................36
2.7.3. Engine stalls but can be started again............................................................37
2.7.4. Engine stalls and cannot be started again......................................................37
2.7.5. Engine loses power (speed limitations) ..........................................................38
3. Engine Removal and Installation...............................................40
3.1. Engine Removal....................................................................................................40
3.2. Engine Installation................................................................................................41
4. Engine Disassembly/Assembly.................................................43
4.1. Engine Specifications ..........................................................................................43
4.1.1. Engine Fastener Torque Specifications..........................................................47
4.1.2. Engine Specific Fastener Torque Specifications ............................................48
4.1.3. Engine Specific Fastener Torque Specifications ............................................49
4.1.4. Turbocharger Specific Fastener Torque Specifications..................................49
4.1.5. Intake Manifold Specific Fastener Torque Specifications ...............................50
4.1.6. Alternator Assembly Specific Fastener Torque Specifications .......................50
4.1.7. Fuel Rail Specific Fastener Torque Specifications .........................................50
4.1.8. Engine Management Components/ Sensor Specific Fastener Torque
Specifications ..................................................................................................................51
4.1.9. Balance Plate/ PTO Specific Fastener Torque Specifications........................51
4.1.10. Engine Mounts Specific Fastener Torque Specifications................................51
4.2. Oil filter assembly.................................................................................................52
4.3. Valve cover assembly ..........................................................................................53
4.4. Valve train assembly............................................................................................54
4.5. Dry sump oil pump assembly..............................................................................55
4.6. Thermostat housing assembly............................................................................56
4.7. High pressure oil pump assembly......................................................................57
4.8. Exhaust-side chain guide/tensioner assembly..................................................58
4.9. Engine case/cylinder head assembly.................................................................59
4.10. Piston assembly ...................................................................................................61
4.11. Valve assemblies..................................................................................................62
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4.12. Balance plate/PTO assembly...............................................................................63
4.13. Crankshaft/Counter balancer assemblies..........................................................64
4.14. Engine Disassembly Process..............................................................................65
4.15. Engine inspection procedures............................................................................73
4.15.1. Valve Inspection .............................................................................................73
4.15.2. Cylinder Head Inspection................................................................................75
4.15.3. Cylinder Block Inspection ...............................................................................76
4.15.4. Camshaft Inspection .......................................................................................76
4.15.5. Rocker Arm Inspection ...................................................................................78
4.15.6. Crankshaft Inspection .....................................................................................79
4.15.7. Connection Rod Inspection.............................................................................81
4.15.8. Balance Shaft Inspection ................................................................................82
4.15.9. Piston Inspection ............................................................................................82
4.15.10. High Pressure Oil Pump Inspection............................................................84
4.15.11. Chain Tensioner..........................................................................................85
4.15.12. Starter Motor Clutch....................................................................................85
4.15.13. Timing Chain...............................................................................................86
4.16. Engine Assembly..................................................................................................86
4.17. Timing Chain Installation/TDC Procedure..........................................................91
4.17.1. Timing Chain Installation ................................................................................91
4.17.2. Engine Assembly ............................................................................................95
4.18. Thermostat Removal/Installation......................................................................100
4.19. Water Pump Removal/Installation.....................................................................100
4.20. Oil Lubrication System ......................................................................................101
4.20.1. Low Pressure Oil Circuit ...............................................................................102
4.20.2. High Pressure Circuit....................................................................................102
4.20.3. Crankcase Ventillation ..................................................................................103
4.20.4. Low Pressure Pump Removal/Installation ....................................................103
4.20.5. High Pressure Pump Removal/Installation ...................................................104
4.20.6. High Pressure Oil Supply..............................................................................105
5. Electrical System ......................................................................107
5.1. Installing the Keyspan USB to RS-232 Adapter...............................................107
5.2. Configure the Keyspan Adapter........................................................................111
5.3. Configure the HSR Diagnostic Tool..................................................................115
5.4. Diagnostics .........................................................................................................117
5.4.1. Installation.....................................................................................................117
5.4.2. Starting the diagnostic program for the first time ..........................................119
5.4.3. Diagnostic .....................................................................................................120
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5.4.4. ECU Setup....................................................................................................126
5.4.5. Control the throttle body attitude...................................................................127
5.5. Electrical System................................................................................................130
6. Appendix....................................................................................132
6.1. General Data .......................................................................................................132
6.2. Directives ............................................................................................................132
6.3. Proof of maintenance for work carried out......................................................133
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1.General Information
Model information, Identification number, Engine number, safety warning
1.1. 2007 HSR personal watercraft Identification Numbers
The engine I.D. number and hull I.D. number are used to register the watercraft. They are
unique numbers that distinguish each watercraft from others of the same model.
If the watercraft is ever stolen these numbers will help identify it. The owner should keep a
record of these numbers in a place other than the watercraft. A second hull number is hidden
inside the Hull, only the manufacturer knows where is this number on each ski.
1.2. HIN number
AT : Manufacturing Country
HSR : HydroSpace Racing Manufacture
000608 : Sequential Serial Numbers
Production Month : K (Month code : AJanuary, BFebruary)
Production Year : 6
Model Year : 06 (Model year : 6= 2006)
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1.3. Engine number
Number is above the starter motor
Engine Number : #10017203
1.4. Three stars – ultra low emission
The three-star label identifies engines that meet the
Air Resources Board’s Personal Waterwraft and
Outboard marine engine 2008 exhaust emission
standards. Engines meeting these standards have
65% lower emissions than One Star – Low Emission
Engines
1.5. Safety instructions
Under the handpole
1.6. CE Sticker
Under the handpole bracket
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1.7. Service Guidelines - Safety Warnings
Clean inside and outside of watercraft prior to servicing.
Clean all parts before installing.
Always use a service apron to prevent damage to foot well and top- deck fiberglass.
Watch for sharp edges which can cause personal injury.
Protect hands and arms when working with sharp components.
Always use a soft- faced hammer and extreme care when removing difficult or stuck
components.
Some fasteners are installed with locking agents or lubricants. Use of impact drivers will aid
in fastener removal.
Always follow torques specifications located throughout manual.
Fasteners secured with either too little or too much torque may fail and cause severe
property damage, injury or death.
Always follow torque sequence patterns when founding this manual.
Tighten each fastener evenly and to the specified torque value, and with specified locking
agent.
Always use new gaskets, o- rings and seals, clips, cir- clips, and snap rings when
assembling components.
Never reuse Nylokt or Flex Lockt nuts when assembling components.
Never reuse Oetikert clamps when removed from fuel lines. Replace with small gear clamps.
Always use Hydrospace authorized lubricants, greases, and locking agents when assembling
components. Failure to do so may cause severe engine or vehicle damage.
Always disconnect the black (- ) negative cable first from the battery when removing the
battery. When installing the battery, attach the red (+) positive cable first, then the black (- )
negative cable.
Wear appropriate clothing, eye protection, and rubber gloves when working with batteries.
Battery acid contains sulphuric acid and is extremely poisonous. Serious burns can result
when in contact with skin, clothing, eyes or internal body components. If battery acid is
ingested, drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or
vegetable oil. Call a physician immediately. Flush eyes for15minutes with water and seek
prompt medical attention if acid comes in contact with eyes. Thoroughly wash affected
external body parts that come in contact with battery acid with water.
Keep hands, arms, legs, feet and hair away from rotating parts, hot engine and exhaust
components, drive pump and impeller and engine induction when engine is running.
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Never attempt engine or driveline inspections and/or repairs without first removing lanyard
and battery cables.
Gasoline is highly flammable and explosive under certain conditions.
Always exercise extreme care when handling gasoline.
Do not smoke or allow open flames in or near the area where refueling is performed or where
gasoline is stored.
Always refuel the watercraft outdoors and in a well- ventilated area.
Do not fill the tank to the fuel cap.
If you get gasoline or oil on your skin or clothing, wash it off immediately with soap and water
and change clothing.
The engine exhaust from this product contains chemicals known to cause cancer, birth
defects or other reproductive harm.
Only run engine outdoors or in a well- ventilated area.
Never run the engine for more than 15 seconds without cooling water supply.
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