Sea-doo 2004 3D RFI Install guide

Smr-2004 BRP suppl 3d rfi ang.FH8 Thu Sep 23 10:31:37 2004 Page 1
C M Y CM MY CY CMY K
www.SeaDooManuals.net

2004
Shop Manual Supplement
3DTM RFITM
BOMBARDIER RECREATIONAL PRODUCTS INC.
www.SeaDooManuals.net

Legal deposit:
National Library of Quebec
National Library of Canada 2004
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc.
©Bombardier Recreational Products Inc. 2004
Technical Publications
Bombardier Recreational Products Inc.
Valcourt (Quebec) Canada
PrintedinCanada
®TMRegistered trademarks of Bombardier Recreational Products Inc. or its affiliates.
* Bombardier is a trademark of Bombardier Inc., used under license.
SEA-DOO®
ROTAX®
BOMBARDIER* LUBE®
XP-STM Synthetic Injection Oil
XP-STM Synthetic Blend Injection Oil
XP-STM Mineral Injection Oil
Sea-Doo Synthetic Grease
Sea-Doo LKTM
DESSTM
O.P.A.S.TM
TOPSTM
O.T.A.S.TM
3DTM
This document contains the trademarks of the following companies:
Knight’s Spray-Nine†is a trademark of Korkay System Ltd
GTX†is a trademark of Castrol Ltd. Used under license
Loctite®is a trademark of Loctite Corporation
Snap-on®is a trademark of Snap-on Tools Corporation
Gelcote®is a trademark of Gelcote International Limited
Molykote©is a trademark of Dow Corning Corporation
Snap-on©is a trademark of Snap-on Tools Corporation
AMP©is a trademark of Tyco Electronics Corporation
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TABLE OF CONTENTS
NOTE: Refer to shop manual for sections NOT covered in this supplement.
SAFETY NOTICE ................................................................................... III
INTRODUCTION ................................................................................... V
HULL IDENTIFICATION NUMBER (H.I.N.) ...................................................................... V
ENGINE IDENTIFICATION NUMBER (E.I.N.) ................................................................... V
02 MAINTENANCE
01 – PERIODIC INSPECTION CHART............................................................................ 1
04 – STORAGE ..................................................................................................... 5
ENGINE DRAINING .................................................................................................. 5
PROPULSION SYSTEM.............................................................................................. 5
FUEL SYSTEM........................................................................................................ 6
COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION ...................................... 6
BATTERY.............................................................................................................. 7
WATERCRAFT CLEANING........................................................................................... 7
ANTIFREEZING PROTECTION...................................................................................... 7
ANTICORROSION TREATMENT.................................................................................... 8
03 TROUBLESHOOTING
01 – TROUBLESHOOTING CHART.............................................................................. 9
ENGINE WILL NOT START.......................................................................................... 9
O.T.A.S.TM SYSTEM NOT FUNCTIONAL ........................................................................... 9
BILGE PUMP DOES NOT WORK................................................................................... 9
WARNING LIGHT IS ON/ENGINE NOT RUNNING ................................................................ 10
STEERING POLE IS HEAVIER THAN USUAL ...................................................................... 10
STEERING POLE IS STIFFER THAN USUAL....................................................................... 10
ENGINE CANNOT REACH MAXIMUM RPM (LACK OF PERFORMANCE)...................................... 10
04 ENGINE (2-STROKE)
07 – EXHAUST SYSTEM.......................................................................................... 11
REMOVAL ............................................................................................................ 13
INSTALLATION ....................................................................................................... 17
06 ENGINE MANAGEMENT (RFI)
02 – DIAGNOSTIC PROCEDURES .............................................................................. 23
ADVANCED DIAGNOSTIC........................................................................................... 23
05 – ADJUSTMENT................................................................................................ 25
THROTTLE CABLE ADJUSTMENT........................................................................ 25
09 COOLING SYSTEM
01 – CIRCUIT, COMPONENTS AND CARE ..................................................................... 27
CIRCUIT............................................................................................................... 28
COMPONENTS....................................................................................................... 28
CARE.................................................................................................................. 28
TOWING THE WATERCRAFT IN WATER........................................................................... 28
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TABLE OF CONTENTS
10 FUEL SYSTEM
01 – FUEL CIRCUIT ................................................................................................ 31
11 LUBRICATION SYSTEM (2-STROKE)
02 – OIL INJECTION PUMP....................................................................................... 33
ADJUSTMENT........................................................................................................ 33
12 ELECTRICAL SYSTEM
02 – CHARGING SYSTEM ........................................................................................ 35
GENERAL............................................................................................................. 35
TESTING PROCEDURE.............................................................................................. 35
03 – STARTING SYSTEM ......................................................................................... 39
GENERAL............................................................................................................. 39
04 – INSTRUMENTS AND ACCESSORIES..................................................................... 41
GENERAL............................................................................................................. 41
VEHICLE CONTROL MODULE (VCM).............................................................................. 41
MULTI-PURPOSE ELECTRONIC MODULE (MPEM) .............................................................. 45
INSPECTION.......................................................................................................... 47
05 – DESS (CARBURETED AND RFI ENGINES)............................................................... 49
DESS KEY PROGRAMMING................................................................................ 49
13 PROPULSION
01 – JET PUMP..................................................................................................... 51
02 – DRIVE SYSTEM............................................................................................... 53
REMOVAL ............................................................................................................ 54
04 – VARIABLE TRIM SYSTEM .................................................................................. 57
REMOVAL ............................................................................................................ 58
DISASSEMBLY ....................................................................................................... 58
ASSEMBLY ........................................................................................................... 58
14 STEERING SYSTEM
01 – STEERING SYSTEM ......................................................................................... 59
INSPECTION.......................................................................................................... 62
DISASSEMBLY ....................................................................................................... 63
ASSEMBLY ........................................................................................................... 73
02 – ALIGNMENT .................................................................................................. 79
16 HULL/BODY
01 – ADJUSTMENT AND REPAIR ............................................................................... 81
CLEANING............................................................................................................ 81
BILGE VENT TUBES ................................................................................................. 81
REAR ACCESS COVER .............................................................................................. 81
KART SEAT ........................................................................................................... 81
17 TECHNICAL DATA
06 – 3D RFI MODEL................................................................................................ 83
18 WIRING DIAGRAM
01 – WIRING DIAGRAMS......................................................................................... 87
VCM CONNECTORS................................................................................................. 87
II
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SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the 2004 3DTM RFITMSEA-DOO
watercraft. This Shop Manual Supplement must be used in conjunction with the 2004 Sea-doo Shop
Manual (P/N 219 100 192). Refer to this manual when a particular system is not covered in this Supple-
ment.
This edition was primarily published to be used by watercraft mechanical technicians who are already fa-
miliar with all service procedures relating to BRP made watercraft. Mechanical technicians should attend
training courses given by BRP Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual Supplement uses technical terms which may be slightly different from the ones used
in the Parts Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any component.
Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
WARNING
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: lock-
ing 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.
WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
III
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SAFETY NOTICE
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents.
We strongly recommend that any services be carried out and/or verified by a highly skilled professional
mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing
federal, provincial and state regulations.
IV
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INTRODUCTION
INTRODUCTION
This Shop Manual Supplement covers the follow-
ing BRP made SEA-DOO®2004 3DTM RFITM wa-
tercraft models.
MODEL ENGINE
TYPE
MODEL
NUMBER
3D RFI 787 RFI 6157
3D RFI International 787 RFI 6158
HULL IDENTIFICATION NUMBER
(H.I.N.)
It is located on platform at the rear of watercraft.
F22L06A
1
1. Hull Identification Number (H.I.N.)
The Hull Identification Number is composed of 12
digits:
Z Z N 1 2 3 4 5 L 4 9 5
Model year
Serial
number*
F00A0CB
Mon h of produc ion
Year of produc ion
* A le er may also be used as a digi .
Manufac urer
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
The Engine Identification Number is located on the
upper crankcase on PTO side.
F01D87A 1
1. Engine Identification Number (E.I.N.)
V
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Section02MAINTENANCE
Subsection 01 (PERIODIC INSPECTION CHART)
PERIODIC INSPECTION CHART
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 watercraft rental operations or higher number of hour use, will require greater
frequency of inspection and maintenance.
DESCRIPTION INTERVAL
I: Inspect, verify, clean, adjust, lubricate.
Replace if necessary
C:Clean
L: Lubricate
R: Replace
FIRST
10
HOURS
EVERY
25 HOURS
OR
3MONTHS
EVERY
50 HOURS
OR
6MONTHS
EVERY
100 HOURS
OR
1YEAR
GENERAL
Lubrication/corrosion protection (1) L
ENGINE
Support and rubber mount I I
Seals and fasteners I I
Exhaust system fasteners (5) I I
Expansion pipe I
RAVE valve (5) C C
Counterbalance shaft oil level I I
Spark plug (5) I(4) R
Ignition timing (5) I
COOLING SYSTEM
Flushing C(3)
Hose and fasteners I I
Engine drain tubes I(1)
FUEL SYSTEM
Throttle cable (1) I
Fuel injection system sensors (except throttle body) (5) I I
Throttle body and TPS (5) I I
Fuel lines, fuel rail, fittings, check-valve, relief valve
and fuel system pressurization (5) I I
Air intake silencer fit/tightness I I
Fuel tank straps I I
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Section 02 MAINTENANCE
Subsection 01 (PERIODIC INSPECTION CHART)
DESCRIPTION INTERVAL
I: Inspect, verify, clean, adjust, lubricate.
Replace if necessary
C:Clean
L: Lubricate
R: Replace
FIRST
10
HOURS
EVERY
25 HOURS
OR
3MONTHS
EVERY
50 HOURS
OR
6MONTHS
EVERY
100 HOURS
OR
1YEAR
LUBRICATION SYSTEM
Oil injection pump (5) I I
Oil lines I I
Oil filter I I R
Oil reservoir straps I
ELECTRICAL SYSTEM
Electrical connections and fastening (ignition system,
starting system, fuel injectors, etc.) (5) I I
MPEM and ECU mounting support/fasteners I
Digitally Encoded Security System and safety
lanyard/post I I
Monitoring beeper I I
Battery support/fasteners I I
STEERING SYSTEM
Steering cable I I
Steering pole I I
Handlebar and adjuster operation I I
“Moto”seat I I
O.T.A.S.tm SYSTEM
O.T.A.S. system operation I I
PROPULSION SYSTEM
Drive shaft protection hose I(2)
Seal carrier L L
Driveshaft/impeller splines L
VTS (Variable Trim System) I I
Jet pump reservoir oil R I R
Jet pump cover pusher I
Impeller shaft seal R(4)
Impeller and impeller/wear ring clearance I(2)
Water intake grate I(2)
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Section02MAINTENANCE
Subsection 01 (PERIODIC INSPECTION CHART)
DESCRIPTION INTERVAL
I: Inspect, verify, clean, adjust, lubricate.
Replace if necessary
C:Clean
L: Lubricate
R: Replace
FIRST
10
HOURS
EVERY
25 HOURS
OR
3MONTHS
EVERY
50 HOURS
OR
6MONTHS
EVERY
100 HOURS
OR
1YEAR
HULL/BODY
Bailer pick-ups, check for obstructions I I
Kart seat (if so equipped) I I
Hull I I
(1) Every 10 hours in salt water use.
(2) These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in
this chart.
(3) Daily flushing in salt water or foul water use.
(4) Replace at 150 hours or after 2 years, whichever comes first.
(5) Emission-related component.
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Section02MAINTENANCE
Subsection 04 (STORAGE)
STORAGE
ENGINE DRAINING
Disconnect the water supply hose used to cool
the magneto. It features a quick connect fitting.
Press both tabs and pull fitting in order to discon-
nect hose.
This hose is located at the bottom of the magneto
cover beside the engine support.
F22E02A
1
1. Press tabs here and disconnect hose
Water should flow out of the fitting (magneto cool-
ing circuit) and hose (crankcase heat exchanger).
Push and hold hose against bilge so that draining
can take place.
NOTE: It may be necessary to position the end of
thehoseinalowerareaofthebilgetoallowproper
drainage.
1
2
F17E0BA
1. Fitting
2. Hose
CAUTION: Water in heat exchanger system
must be free to flow out. Should water freeze
in engine, severe damage will occur.
Reconnect hose when done.
PROPULSION SYSTEM
Jet Pump
Lubricant in impeller shaft reservoir should be
drained. Reservoir should be cleaned and refilled
with SEA-DOO synthetic 75W90 GL5 polyester
oil. Refer to JET PUMP in the Shop Manual for
proper procedure.
CAUTION: Use only SEA-DOO jet pump oil or
equivalent synthetic gear oil, otherwise com-
ponent service life could be reduced. Do not
mix oil brands or types.
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Section 02 MAINTENANCE
Subsection 04 (STORAGE)
Seal Carrier
Remove rear access cover.
Lubricate seal carrier of drive shaft support with
synthetic grease. Stop lubricating when grease is
just coming out of seal.
F22J05A
1
1. Grease seal carrier
FUEL SYSTEM
Inspect fuel hoses. Replace damaged hoses or
clamps if necessary.
Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equiv-
alent should be added in fuel tank to prevent fuel
deterioration. Follow manufacturer's instructions
forproperuse.
CAUTION: Fuel stabilizer should be added
prior to engine lubrication to ensure fuel sys-
tem components protection against varnish
deposits.
Fill up fuel tank completely. Ensure there is no
water inside fuel tank.
CAUTION: Should any water be trapped inside
fuel tank, severe internal damage will occur to
the fuel injection system.
WARNING
Fuel is inflammable and explosive under
certain conditions. Always work in a well
ventilated area. Do not smoke or allow open
flames or sparks in the vicinity. Fuel tank
may be pressurized, slowly turn cap when
opening. When fueling, keep watercraft lev-
el. Do not overfill or top off the fuel tank and
leave watercraft in the sun. As temperature
increases, fuel expands and might overflow.
Always wipe off any fuel spillage from the
watercraft. Periodically inspect fuel system.
COOLING SYSTEM FLUSHING
AND ENGINE INTERNAL
LUBRICATION
Cooling system has to be flushed with fresh water
to prevent salt, sand or dirt accumulation which
will clog water passages.
Engine must be lubricated to prevent corrosion on
internal parts.
For proper procedure, refer to FLUSHING AND
LUBRICATION in the Shop Manual. Follow in-
structions for RFI models.
NOTE: On the 3D RFI, the hose adapter is located
on the right hand side on the jet pump support.
F22J01A
1
1. Hose adapter
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Section02MAINTENANCE
Subsection 04 (STORAGE)
BATTERY
Disconnect battery cables.
WARNING
Battery BLACK negative cable must be dis-
connected FIRST.
Disconnect vent tube from battery.
Unfasten battery support.
Using battery strap, remove battery.
For battery cleaning and storage, refer to CHARG-
ING SYSTEM in the Shop Manual.
WATERCRAFT CLEANING
Refer to STORAGE in the Shop Manual.
ANTIFREEZING PROTECTION
In cool regions (where freezing point may be en-
countered), cooling system should be filled with
pure antifreeze.
CAUTION: Antifreeze must be fed in cool-
ing system. Otherwise remaining water will
freeze. If antifreezing is not performed ad-
equately engine/exhaust system may freeze
and cause severe damage. Always use ethy-
lene glycol antifreeze containing corrosion
inhibitors specifically recommended for alu-
minum engines.
CAUTION: Use only undiluted antifreeze (100%
concentration). The pre-mixed antifreeze
available from Bombardier Recreational Prod-
ucts Inc. is not suitable for this particular appli-
cation. Its concentration will be reduced when
mixed with remaining water trapped in water
jackets. Always use ethylene glycol antifreeze
containing corrosion inhibitors specifically
recommended for aluminum engines. Never
use antifreeze for RV (recreational vehicles).
NOTE: When available, it is recommended to
use biodegradable antifreeze compatible with
internal combustion aluminum engines. This will
contribute to protect the environment.
NOTE: Theenginewillnothavetorunduringthis
operation but should have been ran before, to ex-
haust as much water as possible, from cooling
system components.
NOTE: This procedure requires approximately
2.5 L (2.6 U.S. qt) of antifreeze.
Engine and Tuned Pipe
Remove rear access panel and engine cover. Lock
steering pole in upright position with the holder.
WARNING
Always install steering pole holder while
working in the engine compartment.
Install hose pinchers and disconnect hoses at the
following locations.
F22E03A
2
1
1. Pinch Engine cylinder drain hose
2. Pinch Engine heat exchanger drain hose
F22E04A
1
2
3
1. Disconnect water supply hose
2. Pinch water outlet hose
3. Install a temporary hose to engine fitting
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Section 02 MAINTENANCE
Subsection 04 (STORAGE)
Insert a funnel into the temporary hose and pour
antifreeze in engine until the colored solution ap-
pears at the cooling system bleed outlet. Use a
container to recover the water/antifreeze.
F07E0LA
TYPICAL
F22L0HA 1
COOLING SYSTEM BLEED OUTLET
1. Recover water/antifreeze from this outlet
Place a container at rear of watercraft to recov-
er the water/antifreeze from the vehicle hose
adapter.
Remove the 2 hose pinchers from the engine drain
hoses.
Most of the antifreeze will drain out when remov-
ing the hose pinchers. Use a container to recover
it. DISPOSE ANTIFREEZE AS PER YOUR LOCAL
LAWS AND REGULATIONS.
Expansion Pipe and Muffler
Disconnect the tuned pipe water supply hose at
T-fitting.
F22E06A
1
1. Disconnect hose from T-fitting
Insert a funnel into the hose.
Raise the hose as high as possible and pour 1.2 L
(1.3 U.S. qt) of antifreeze.
CAUTION: It is important to keep the hose as
high as possible so the antifreeze can reach the
end of the expansion pipe.
Reconnect hose to the T-fitting.
Complete Cooling System
NOTE: For the above engine and exhaust sys-
tem procedures, although most of the antifreeze
drained out, it has mixed with any water in the wa-
ter jackets.
At preseason preparation, flush out the remaining
antifreeze from cooling system prior to using the
watercraft.
ANTICORROSION TREATMENT
Refer to STORAGE in the Shop Manual.
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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. Only the systems not covered in the Shop
Manual are outlined. Refer to the Shop Manual for the other systems.
ENGINE WILL NOT START
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Discharged battery or bad connections Check battery state of charge and battery
posts
Defective DESS post Check DESS post. Refer to
INSTRUMENTS AND ACCESSORIES
Burnt 20 A fuse Check fuse
No power at VCM Check for battery voltage on VCM wire
connector pin 6-G
Bad ground Check for continuity with ground on VCM
wire connector pin 6-D
Engine does not turn
over/no beep/indicator
light cluster not working
Defective VCM Replace
Engine does not turn
over/no beep/indicator
light cluster working No power at MPEM Check voltage on MPEM wire connector
pin 3-26
O.T.A.S.TM SYSTEM NOT FUNCTIONAL
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Defective O.T.A.S. solenoid circuit Check PU/WH, BK wires and connections.
Defective O.T.A.S. solenoid Check. Refer to INSTRUMENTS AND
ACCESSORIES
Warning light flashes
Defective VCM Replace
BILGEPUMPDOESNOTWORK
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Defective bilge pump circuit Check BW and BK wires. Check
connections
Defective bilge pump Check/replace
Warning light flashes
Defective VCM Replace
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Section 03 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
WARNING LIGHT IS ON/ENGINE NOT RUNNING
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Beeper signal (4 short
beeps every 3 seconds) Safety lanyard on DESS post Remove safety lanyard from DESS post
STEERING POLE IS HEAVIER THAN USUAL
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Steering pole return spring adjustment Adjust
Broken steering pole return spring) Replace
STEERING POLE IS STIFFER THAN USUAL
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Dirty/damage parts Inspect/clean/replace mounting bridge,
clamps, tube and spring guide
ENGINE CANNOT REACH MAXIMUM RPM (LACK OF PERFORMANCE)
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Increased exhaust
noise/smoke in bilge Broken expansion pipe Inspect/replace. Refer to EXHAUST
SYSTEM
Water inside expansion
pipe Broken expansion pipe (water jacket) Inspect/replace. Refer to EXHAUST
SYSTEM
Melted exhaust
hose/fitting Exhaust restriction or external water leak from exhaust cooling system Inspect/repair
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Section 04 ENGINE (2-STROKE)
Subsection 07 (EXHAUST SYSTEM)
EXHAUST SYSTEM
3D RFI
25
7
40 Nm
(30 lbff )
F22D03S
Loc i e 518
Molyko e 111
13
15
16
12
11
11 Nm
(97 lbfin)
211
Loc i e 592
Loc i e 592
17
4
26 Nm
(19 lbff )
17
18
Loc i e 243
39 Nm
(29 lbff )
24
Loc i e 518
17
17
5
26 Nm
(19 lbff )
18
26 Nm
(19 lbff )
348 Nm
(35 lbff )
1
Loc i e 592
Loc i e 592
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Section 04 ENGINE (2-STROKE)
Subsection 07 (EXHAUST SYSTEM)
F22D04S
19
22
23
21
9
20
Loc i e 5150
11
High empera ure
RTV sealan
10
12
8
High empera ure
RTV sealan
14
High empera ure
RTV sealan
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Section 04 ENGINE (2-STROKE)
Subsection 07 (EXHAUST SYSTEM)
REMOVAL
Tuned Pipe
Remove engine cover then lift and lock steering
pole.
Remove air intake silencer.
NOTE: In some of the following illustrations,
flame arrester and throttle body were removed
for clarity only.
Disconnect hoses from tuned pipe no. 1.
F22D05A
F22D07A
Loosen clamp no. 2 thensliderearwardtorelease
the joint.
F22D05B
Remove:
–screws no. 3.
F22D05C
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