Service Manual

Rotax 1503 4–TEC

150, 150 ECT, 200 ECT, 250 ECT

*462050* Version A
All rights reserved. No parts of this Manual may be reproduced in any form without the prior written per-
mission of Bombardier Recreational Products Inc.
©Bombardier Recreational Products Inc. (BRP) 2017

™®Trademarks of BRP or its affiliates.

This document contains the trademarks of the following companies:
Zerex Super Cleaner ® is a registered trademark of Valvoline.
 TABLE OF CONTENTS

S E R V I C E T O O L S I N D E X ......................................................................................................................... 1

S A F E T Y ...................................................................................................................................................... 1
S A F E T Y N O T I C E . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 1

I N T R O D U C T I O N ....................................................................................................................................... 3
G E N E R A L . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 3
POWER PACK INFORMATION .............................................................................................. 3
HULL IDENTIFICATION NUMBER (HIN) ....................................................................................... 3
ENGINE IDENTIFICATION NUMBER ........................................................................................... 3
ENGINE EMISSIONS INFORMATION.................................................................................... 3
MANUAL PROCEDURES .......................................................................................................... 4
TIGHTENING TORQUE .......................................................................................................... 5
FASTENER INFORMATION ................................................................................................... 6
SELF-LOCKING FASTENERS .................................................................................................... 6
LOC-TITE APPLICATION PROCEDURE....................................................................................... 6
THREADLOCKER APPLICATION FOR UNCOVERED HOLES (BOLTS AND NUTS) ............................. 6
THREADLOCKER APPLICATION FOR BLIND HOLES .................................................................... 6
THREADLOCKER APPLICATION FOR STUD INSTALLATION IN BLIND HOLES ................................. 7
THREADLOCKER APPLICATION FOR PRE-ASSEMBLED PARTS ................................................... 7
THREADLOCKER APPLICATION FOR AN ADJUSTMENT SCREW................................................... 7
APPLICATION FOR STRIPPED THREAD REPAIR ......................................................................... 7
STANDARD THREAD REPAIR ................................................................................................... 7
REPAIR OF SMALL HOLES/FINE THREADS ................................................................................ 8
PERMANENT STUD INSTALLATION (LIGHT DUTY) ...................................................................... 8
GASKET COMPOUND APPLICATION ......................................................................................... 8
THREADLOCKER APPLICATION FOR MOUNTING ON A SHAFT..................................................... 8
MOUNTING WITH A PRESS ...................................................................................................... 8
MOUNTING IN TANDEM ........................................................................................................... 8
THREADLOCKER APPLICATION FOR CASE-IN COMPONENTS (METALLIC GASKETS) ..................... 9

I N S P E C T I O N S A N D M A I N T E N A N C E .................................................................................................. 1 1
P E R I O D I C M A I N T E N A N C E S C H E D U L E . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 1
S T O R A G E P R O C E D U R E . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 4
ENGINE INTERNAL LUBRICATION ..................................................................................... 14
ENGINE COMPARTMENT CLEANING ................................................................................ 14
ANTICORROSION TREATMENT ......................................................................................... 15
PRESEASON PREPARATION.............................................................................................. 15
S P E C I A L P R O C E D U R E S . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 6
TOWING THE BOAT IN THE WATER .................................................................................. 16
SUBMERGED BOAT ............................................................................................................. 17
WATER-FLOODED ENGINE ................................................................................................ 17
EXHAUST SYSTEM DRAINING ........................................................................................... 17
INTAKE SYSTEM DRAINING................................................................................................ 17
THROTTLE BODY LUBRICATION ....................................................................................... 18
ENGINE OIL AND FILTER REPLACEMENT ........................................................................ 18
BOIL OUT PROCEDURE ...................................................................................................... 18
PROCEDURE WITH BOAT ON TRAILER IN A WATER RAMP ........................................................ 18
PROCEDURE WITH BOAT ON TRAILER CONNECTED TO A FLUSH KIT ........................................ 19

III
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E N G I N E .................................................................................................................................................... 2 1
E N G I N E R E M O V A L A N D I N S T A L L A T I O N . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 2 1
GENERAL .............................................................................................................................. 23
ENGINE ACCESS.................................................................................................................. 23
ENGINE REMOVAL............................................................................................................... 23
ENGINE INSTALLATION....................................................................................................... 23
ENGINE ALIGNMENT ........................................................................................................... 24
ENGINE RUBBER MOUNTS................................................................................................. 26
ENGINE RUBBER MOUNT INSPECTION ................................................................................... 26
ENGINE RUBBER MOUNT REPLACEMENT ............................................................................... 26
A I R I N T A K E S Y S T E M . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 2 7
150 CAT AND NON-CAT ENGINES...................................................................................... 28
200 CAT ENGINE .................................................................................................................. 29
250 CAT ENGINE .................................................................................................................. 30
AIR FILTER ............................................................................................................................ 31
AIR FILTER REMOVAL ........................................................................................................... 31
AIR FILTER CLEANING........................................................................................................... 31
AIR INTAKE INSTALLATION .................................................................................................... 31
AIR INTAKE TUBE................................................................................................................. 31
AIR INTAKE TUBE REMOVAL .................................................................................................. 31
AIR INTAKE TUBE INSTALLATION ........................................................................................... 31
I N T A K E M A N I F O L D . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 3 2
150 AND 250 ENGINES ........................................................................................................ 33
200 ENGINES ........................................................................................................................ 34
PROCEDURES...................................................................................................................... 35
INTAKE MANIFOLD .............................................................................................................. 35
INTAKE MANIFOLD REMOVAL ................................................................................................ 35
INTAKE MANIFOLD INSPECTION............................................................................................. 35
INTAKE MANIFOLD INSTALLATION.......................................................................................... 35
ENGINE CONTROL MODULE .............................................................................................. 36
FLAME ARRESTER .............................................................................................................. 36
FLAME ARRESTER LOCATION................................................................................................ 36
FLAME ARRESTER INSPECTION............................................................................................. 36
FLAME ARRESTER REPLACEMENT ........................................................................................ 36
I N T E R C O O L E R . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 3 8
250 ENGINE........................................................................................................................... 39
INTERCOOLER AIR HOSES ................................................................................................ 40
INTERCOOLER WATER HOSES ......................................................................................... 41
MAINTENANCE ..................................................................................................................... 42
INTERCOOLER FLUSHING ..................................................................................................... 42
PROCEDURES...................................................................................................................... 42
INTERCOOLER CLEANING ..................................................................................................... 42
INTERCOOLER LEAK TEST .................................................................................................... 42
INTERCOOLER REMOVAL...................................................................................................... 43
INTERCOOLER INSTALLATION ............................................................................................... 43
E X H A U S T S Y S T E M .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5
SINGLE ENGINE NON-CAT MODELS ................................................................................. 47
SINGLE ENGINE CAT MODELS........................................................................................... 48
TWIN ENGINE NON-CAT MODELS ..................................................................................... 49
TWIN ENGINE CAT MODELS............................................................................................... 50
MAINTENANCE ..................................................................................................................... 51
EXHAUST SYSTEM FLUSHING................................................................................................ 51
PROCEDURES...................................................................................................................... 52
MUFFLER............................................................................................................................. 52

IV
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EXHAUST PIPE ..................................................................................................................... 56

EXHAUST MANIFOLD ............................................................................................................ 57
RESONATOR........................................................................................................................ 58
HEATED OXYGEN SENSOR (HO2S)......................................................................................... 59
CATALYST (FOR CAT MODELS ONLY) ..................................................................................... 59
P T O H O U S I N G A N D M A G N E T O . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 6 5
PTO HOUSING AND MAGNETO DIAGRAM ........................................................................ 67
PROCEDURES...................................................................................................................... 68
PTO HOUSING ...................................................................................................................... 68
PTO SEAL ............................................................................................................................ 72
PTO COUPLING .................................................................................................................... 73
STARTER DRIVE BEARINGS................................................................................................... 73
STATOR............................................................................................................................... 74
ROTOR, TRIGGER WHEEL AND RING GEAR............................................................................. 77
STARTER DRIVE ................................................................................................................... 78
L U B R I C A T I O N S Y S T E M .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 8 1
ENGINE BLOCK LUBRICATION SYSTEM........................................................................... 83
MAGNETO LUBRICATION SYSTEM ................................................................................... 84
ENGINE LUBRICATION CIRCUIT ........................................................................................ 85
LUBRICATION SYSTEM DIAGRAM ..................................................................................... 86
MAINTENANCE ..................................................................................................................... 87
ENGINE OIL.......................................................................................................................... 87
OIL FILTER ........................................................................................................................... 88
INSPECTION ......................................................................................................................... 89
ENGINE OIL PRESSURE ........................................................................................................ 89
OIL PRESSURE TEST REQUIREMENT ..................................................................................... 89
OIL PRESSURE SPECIFICATIONS ........................................................................................... 89
TEST AT THE OIL PRESSURE SWITCH LOCATION .................................................................... 89
TEST AT THE CYLINDER HEAD LOCATION............................................................................... 90
TROUBLESHOOTING........................................................................................................... 90
LOW OR NO ENGINE OIL PRESSURE ...................................................................................... 90
HIGH OIL CONSUMPTION ...................................................................................................... 90
OIL CONTAMINATION ............................................................................................................ 91
PROCEDURES...................................................................................................................... 92
OIL PRESSURE SWITCH (OPS) ............................................................................................... 92
PTO OIL STRAINER ............................................................................................................... 93
SUCTION PUMP OIL STRAINER .............................................................................................. 94
ENGINE OIL PRESSURE REGULATOR ..................................................................................... 95
OIL PRESSURE PUMP ........................................................................................................... 96
ROTARY SEAL ...................................................................................................................... 99
OIL SUCTION PUMP ............................................................................................................ 100
SUPERCHARGER OIL SPRAY NOZZLE .................................................................................. 103
PISTON OIL SPRAY NOZZLES............................................................................................... 104
OIL SEPARATOR COVER ..................................................................................................... 104
BLOW-BY VALVE................................................................................................................. 106
TOPS SWITCH (NON-CAT ENGINES ONLY) ............................................................................ 108
OIL COOLER....................................................................................................................... 110
C O O L I N G S Y S T E M . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 1 2
CLOSED LOOP COOLING SYSTEM.................................................................................. 114
SINGLE ENGINE COOLING SYSTEM COMPONENTS .................................................... 115
TWIN ENGINE COOLING SYSTEM COMPONENTS ........................................................ 116
ENGINE COOLING SYSTEM COMPONENTS................................................................... 117
GENERAL ............................................................................................................................ 118
COOLING SYSTEM DESCRIPTION......................................................................................... 118
COOLING SYSTEM TECHNICAL SPECIFICATIONS .................................................................. 118
COOLING SYSTEM MAINTENANCE ................................................................................. 118

V
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ENGINE COOLANT .............................................................................................................. 118

RECOMMENDED COOLANT ................................................................................................. 118
DRAINING THE ENGINE COOLANT SYSTEM........................................................................... 118
CLEANING THE ENGINE COOLANT SYSTEM .......................................................................... 119
REFILLING THE ENGINE COOLANT SYSTEM .......................................................................... 119
INSPECTION ....................................................................................................................... 120
COOLING SYSTEM LEAK TEST ............................................................................................. 120
COOLING SYSTEM TROUBLESHOOTING ............................................................................... 120
PROCEDURES.................................................................................................................... 122
PRESSURE CAP ................................................................................................................. 122
CLAMPS ............................................................................................................................ 122
WATER PUMP HOUSING...................................................................................................... 122
WATER PUMP IMPELLER ..................................................................................................... 124
THERMOSTAT .................................................................................................................... 124
HEAT EXCHANGER (TWIN ENGINES) .................................................................................... 124
C Y L I N D E R H E A D . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 2 6
CYLINDER HEAD SERVICE CHART ................................................................................. 128
GENERAL ............................................................................................................................ 129
INSPECTION ...................................................................................................................... 129
TROUBLESHOOTING........................................................................................................... 131
PROCEDURES.................................................................................................................... 133
C Y L I N D E R B L O C K . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 5 0
CYLINDER BLOCK SERVICE CHART ............................................................................... 152
CRANKSHAFT, BALANCE SHAFT AND PISTONS SERVICE CHART............................. 153
GENERAL ............................................................................................................................ 154
CYLINDER BLOCK TROUBLESHOOTING................................................................................ 154
PROCEDURES.................................................................................................................... 155
TIMING CHAIN .................................................................................................................... 155
CHAIN TENSIONER ............................................................................................................. 155
PISTONS AND CONNECTING RODS ...................................................................................... 155
PISTON RINGS ................................................................................................................... 161
CRANKSHAFT .................................................................................................................... 163
BALANCER SHAFT .............................................................................................................. 166
CYLINDER BLOCK............................................................................................................... 168
SUPERCHARGER............................................................................................................... 173
SUPERCHARGER 200 AND 250 ENGINE MODELS ................................................................... 174
SUPERCHARGER INSPECTION ............................................................................................ 175
TROUBLESHOOTING........................................................................................................... 176
SUPERCHARGER PROCEDURES.......................................................................................... 176

E L E C T R O N I C M A N A G E M E N T S Y S T E M .......................................................................................... 1 8 1
E N G I N E M A N A G E M E N T S C H E M A T I C .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 8 1
E N G I N E M A N A G E M E N T S Y S T E M D E S C R I P T I O N . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 8 2
ENGINE CONTROL MODULE (ECM)................................................................................. 182
ENGINE SPEED SYNCHRONIZATION.............................................................................. 182
DROWNED MODE .............................................................................................................. 183
MONITORING SYSTEM...................................................................................................... 183
LIMP HOME MODE ............................................................................................................. 183
DIAGNOSTIC MODE........................................................................................................... 183
C O M M U N I C A T I O N P R O T O C O L S . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 8 4
CONTROLLER AREA NETWORK (CAN) ........................................................................... 184
CAN 1 (550K) DIAGRAMS................................................................................................... 185
LOCAL INTERCONNECT NETWORK (LIN)....................................................................... 187
D I A G N O S T I C T I P S . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 8 9
CAN COMMUNICATION PROBLEMS................................................................................ 189

VI
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CAN CONTINUITY TESTS.................................................................................................. 189

LIN CONTINUITY TESTS.................................................................................................... 189
C O M M U N I C A T I O N T O O L S A N D B . U . D . S . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 9 0
DIAGNOSTIC CONNECTOR LOCATION AND B.U.D.S.................................................... 190
MPI-2 STATUS LIGHTS ...................................................................................................... 190
PREREQUISITE FOR USB COMMUNICATION ................................................................ 190
PREREQUISITE FOR CAN COMMUNICATION ................................................................ 191
COMMUNICATION PROBLEMS WHEN USING B.U.D.S.................................................. 191
MISSING MODULE............................................................................................................... 191
NO VEHICLE DETECTED...................................................................................................... 191
PROCEDURES.................................................................................................................... 191
MPI-2................................................................................................................................. 191
MPI-2 POWER..................................................................................................................... 192
CONNECTING THE PC TO THE BOAT FOR DIAGNOSTICS ........................................................ 192
B.U.D.S. ............................................................................................................................... 192
HOW TO READ THE ELECTRONIC CONTROL UNITS USING B.U.D.S.......................................... 192
ELECTRONIC CONTROL MODULE UPDATES.......................................................................... 193
OBD-M COMMUNICATION .................................................................................................... 194
D I A G N O S T I C A N D F A U L T C O D E S . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 9 5
MONITORING SYSTEM...................................................................................................... 195
LIMP HOME MODE ............................................................................................................. 195
INDICATOR LIGHTS AND MESSAGE DISPLAY INFORMATION..................................... 196
BEEPER SIGNALS .............................................................................................................. 196
FAULT CODES .................................................................................................................... 196
FAULT CODE TYPES ........................................................................................................... 197
FAULT CODE STATES ......................................................................................................... 197
READING FAULT CODES USING THE INFORMATION CENTER.................................................. 197
READING FAULT CODES USING B.U.D.S................................................................................ 198
CLEARING FAULT CODES USING B.U.D.S. ............................................................................. 198
SEVERAL FAULT CODES ARE ACTIVE SIMULTANEOUSLY....................................................... 198
FAULT CODE P0562 ............................................................................................................ 198
FAULT CODE P0563 ............................................................................................................ 198
FAULT CODE U0300 ............................................................................................................ 198
FAULT CODE U16A1, U16A2, U16A3 ...................................................................................... 199
FAULT CODE TABLE .......................................................................................................... 200
FAULT CODE CROSS REFERENCE: P-CODE TO OBD-M.............................................. 234

F U E L S Y S T E M ...................................................................................................................................... 2 3 7
I N T E L L I G E N T T H R O T T L E C O N T R O L . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 2 3 7
INTELLIGENT THROTTLE CONTROL FOR SINGLE ENGINE MODELS ........................ 238
INTELLIGENT THROTTLE CONTROL FOR TWIN ENGINE MODELS............................. 239
GENERAL ............................................................................................................................ 240
INTELLIGENT THROTTLE CONTROL SYSTEM DESCRIPTION ................................................... 240
PROCEDURES.................................................................................................................... 240
THROTTLE ACCELERATOR SENSOR .................................................................................... 240
E L E C T R O N I C F U E L I N J E C T I O N ( E F I ) .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 2 4 3
GENERAL ............................................................................................................................ 244
SYSTEM DESCRIPTION ....................................................................................................... 244
EFI ELECTRICAL SYSTEM.................................................................................................... 244
EFI AIR INTAKE SYSTEM...................................................................................................... 244
FUEL SYSTEM .................................................................................................................... 245
ADJUSTMENTS................................................................................................................... 245
CLOSED THROTTLE RESET ................................................................................................. 245
TROUBLESHOOTING........................................................................................................... 246
PROCEDURES.................................................................................................................... 247

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F U E L T A N K A N D F U E L P U M P . . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 7 7
FUEL TANK AND FUEL PUMP SERVICE CHART............................................................. 278
FUEL SYSTEM DIAGNOSTIC FLOW CHART ................................................................... 279
SYSTEM DESCRIPTION..................................................................................................... 280
FUEL PUMP OPERATION ..................................................................................................... 280
FUEL LEVEL INDICATION ..................................................................................................... 280
INSPECTION ....................................................................................................................... 281
FUEL PUMP PRESSURE TEST .............................................................................................. 281
PROCEDURES.................................................................................................................... 281
FUEL HOSE AND HOSE CLAMPS .......................................................................................... 281
FUEL PUMP........................................................................................................................ 282
FUEL FILTER ...................................................................................................................... 284
FUEL LEVEL SENDER.......................................................................................................... 285

E L E C T R I C A L S Y S T E M ........................................................................................................................ 2 8 7
P O W E R D I S T R I B U T I O N . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 8 7
G E N E R A L . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 8 8
ELECTRICAL SYSTEM ACTIVATION ................................................................................ 288
MAIN CUT-OFF SWITCH .................................................................................................... 288
MAIN CUT-OFF SWITCH DESCRIPTION.................................................................................. 288
MAIN CIRCUIT BREAKER .................................................................................................. 288
MAIN CIRCUIT BREAKER LOCATION ..................................................................................... 288
FUSES ................................................................................................................................. 288
FUSE BOX LOCATION.......................................................................................................... 288
CHARGING SYSTEM............................................................................................................ 289
TAS SIGNAL VALIDATION..................................................................................................... 289
MAIN RELAY ....................................................................................................................... 289
MAIN RELAY LOCATION....................................................................................................... 289
MAIN GROUNDS................................................................................................................. 289
ENGINE GROUNDS ............................................................................................................. 289
I G N I T I O N S Y S T E M . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 9 0
SYSTEM DESCRIPTION..................................................................................................... 290
IGNITION TIMING ................................................................................................................ 290
ENGINE RPM LIMITER ......................................................................................................... 290
KNOCK SENSOR................................................................................................................. 291
IGNITION SYSTEM TROUBLESHOOTING........................................................................ 291
IGNITION SYSTEM TESTING................................................................................................. 291
DIAGNOSTIC GUIDELINES ................................................................................................... 291
PROCEDURES.................................................................................................................... 292
IGNITION COIL.................................................................................................................... 292
SPARK PLUGS.................................................................................................................... 295
C H A R G I N G S Y S T E M . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 9 7
GENERAL ............................................................................................................................ 297
SYSTEM DESCRIPTION ....................................................................................................... 297
INSPECTION ...................................................................................................................... 297
ELECTRICAL SYSTEM TROUBLESHOOTING .......................................................................... 299
PROCEDURES.................................................................................................................... 299
S T A R T I N G S Y S T E M .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 0 1
STARTER SERVICE DIAGRAM ......................................................................................... 302
STARTING SYSTEM SCHEMATICS .................................................................................. 303
GENERAL ............................................................................................................................ 303
ENGINE CRANKING CONDITIONS ......................................................................................... 303
DIAGNOSTIC TIPS............................................................................................................... 304
STARTING SYSTEM DIAGNOSTIC GUIDELINES ...................................................................... 304
PROCEDURES.................................................................................................................... 305

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ENGINE START STOP SWITCH ............................................................................................. 305

NEUTRAL SWITCH .............................................................................................................. 305
STARTER SOLENOID........................................................................................................... 306
STARTER........................................................................................................................... 308

P R O P U L S I O N ........................................................................................................................................ 3 1 1
R E V E R S E S Y S T E M .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 1 1
PROCEDURES.................................................................................................................... 313
REVERSE CABLE ................................................................................................................ 313
REVERSE GATE.................................................................................................................. 313
REVERSE GATE LEVER ....................................................................................................... 314
REVERSE GATE SUPPORT .................................................................................................. 315
J E T P U M P . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 1 7
JET PUMP SERVICE CHART ............................................................................................. 318
GENERAL ............................................................................................................................ 319
JET PUMP MAIN COMPONENTS............................................................................................ 319
INSPECTION ....................................................................................................................... 319
IMPELLER CONDITION ........................................................................................................ 319
IMPELLER WEAR RING CLEARANCE ..................................................................................... 319
IMPELLER SHAFT RADIAL PLAY ........................................................................................... 319
PROCEDURES.................................................................................................................... 320
VENTURI............................................................................................................................ 320
JET PUMP HOUSING ........................................................................................................... 321
IMPELLER COVER............................................................................................................... 322
IMPELLER .......................................................................................................................... 324
WEAR RING........................................................................................................................ 326
IMPELLER SHAFT AND BEARING .......................................................................................... 327
D R I V E S H A F T . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 3 3
DRIVE SHAFT SERVICE CHART ....................................................................................... 334
DRIVE SHAFT MAINTENANCE.......................................................................................... 335
DRIVE SHAFT CORROSION PROTECTION ............................................................................. 335
PROCEDURES.................................................................................................................... 335
DRIVE SHAFT ..................................................................................................................... 335
DRIVE SHAFT BOOT............................................................................................................ 341
CARBON RING.................................................................................................................... 341
DRIVE SHAFT PROTECTOR ................................................................................................. 341

S T E E R I N G S Y S T E M ............................................................................................................................ 3 4 3
S I N G L E E N G I N E S T E E R I N G S Y S T E M S E R V I C E D I A G R A M . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 4 3
T W I N E N G I N E S T E E R I N G S Y S T E M S E R V I C E D I A G R A M . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 4 4
STEERING SYSTEM ADJUSTMENTS............................................................................... 345
STEERING ALIGNMENT ....................................................................................................... 345
STEERING SYSTEM TROUBLESHOOTING PROCEDURES .......................................... 346
TWIN ENGINE NOZZLE LINK ROD ......................................................................................... 346
NOZZLE ............................................................................................................................. 346
T H R O T T L E S H I F T E R C O N T R O L . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 4 9
SINGLE ENGINE THROTTLE SHIFTER CONTROL ......................................................... 350
TWIN ENGINE THROTTLE SHIFTER CONTROL.............................................................. 351
INTELLIGENT NEUTRAL REVERSE ................................................................................. 351
INR SYSTEM OVERVIEW...................................................................................................... 351
INR MODULE INSTALLATION ................................................................................................ 352
ETHROTTLE CONTROLLER AND HARNESS INSTALLATION ..................................................... 352
SHIFT CABLE INSTALLATION ............................................................................................... 353
SHIFT CABLE ADJUSTMENT................................................................................................. 354

IX
TABLE OF CONTENTS

PROCEDURES.................................................................................................................... 356
THROTTLE SHIFTER CONTROL ............................................................................................ 356
THROTTLE ACCELERATOR SENSOR .................................................................................... 356
REVERSE CABLE ................................................................................................................ 359

H U L L ....................................................................................................................................................... 3 6 3
S I N G L E E N G I N E H U L L S E R V I C E C H A R T . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 6 3
T W I N E N G I N E H U L L S E R V I C E C H A R T . . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 6 4
P R O C E D U R E S . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 6 5
INLET GRATE...................................................................................................................... 365
INLET GRATE REMOVAL...................................................................................................... 365
INLET GRATE CLEANING ..................................................................................................... 365
INLET GRATE INSTALLATION ............................................................................................... 365
RIDE PLATE ........................................................................................................................ 366
RIDE PLATE REMOVAL ........................................................................................................ 366
RIDE PLATE CLEANING ....................................................................................................... 366
RIDE PLATE INSTALLATION ................................................................................................. 366
JET PUMP SUPPORT ......................................................................................................... 368
JET PUMP SUPPORT REMOVAL ........................................................................................... 368
JET PUMP SUPPORT CLEANING........................................................................................... 368
JET PUMP SUPPORT INSTALLATION..................................................................................... 368

T E C H N I C A L S P E C I F I C A T I O N S ......................................................................................................... 3 7 1
T E C H N I C A L S P E C I F I C A T I O N S T A B L E . . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 7 1

E L E C T R I C A L C O N N E C T O R S ............................................................................................................ 3 7 9
G E N E R A L . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 7 9
WIRING DIAGRAM LOCATION .......................................................................................... 379
WIRING DIAGRAM CODES ................................................................................................ 379
WIRE COLOR CODES .......................................................................................................... 379
GENERAL WIRE COLOR USE................................................................................................ 379
WIRING HARNESS CONNECTORS .................................................................................. 379
EFB, VCM AND ECM CONNECTORS................................................................................ 379

X
 SERVICE TOOLS INDEX

150 Engines Impeller Remover Cable Installer ECM Adapter Tool

Installer P/N 461464 P/N 460762
P/N 460728

Page:324, 326–327, 332 Page:360 Page:93, 109, 241, 247–248,

256, 261, 263, 267, 269, 271–
272, 275, 293, 305, 386
250 Engines Impeller Remover Camshaft Locking Tool
Installer P/N 460732
P/N 460744 ECM Terminal Remover 2.25
P/N 460766

Page:324, 326–327, 332 Page:138

Page:387
Adapter Hose Crankshaft Locking Tool
P/N 460720 P/N 460729
ECM Terminal Remover 3.36
P/N 460765
Page:89 Page:164, 166, 173

Alignment Shaft Adapter Page:387

Crimping Tool (Heavy Gauge
P/N 460723
Wire)
P/N 460725 Engine Alignment Plate
P/N 460719
Page:24 Page:390

Alignment Shaft Support Digital Induction Tachometer Page:24

P/N 460839 P/N 460732

Engine Leak Down Test Kit

P/N 460721
Page:24 Page:245

Alignment Shaft
Drive shaft Adapter Page:130
P/N 460709
P/N 460745

Floating Ring Tool

Page:24 P/N 460840
Page:129

BLIND HOLE BEARING PULL-

ER SET Drive Shaft Holder Page:335
P/N 460760 P/N 460746

Page:74 Page:335, 340

1
SERVICE TOOLS INDEX

Fluke 115 Multimeter Impeller Shaft Pusher Pressure Gauge

P/N 460735 P/N 460743 P/N 460722

Page:93, 109, 247–248, 255– Page:328–329 Page:281

256, 261–265, 267–272, 275,
292–293, 298, 305–307
Large Hose Pincher Pressure Gauge
P/N 460717 P/N 460736
Flushing Connector Adapter
P/N 460711

Page:16, 18–19, 42 Page:89

Page:51
MPI-2 Diagnostic Cable PTO Support Tool
P/N 460768 P/N 460734
Fuel Hose Adapter
P/N 460752

Page:190 Page:335, 339

Page:281
MPI-2 Interface Card Seal Bearing Pusher
Fuel Hose Disconnect Tool P/N 460751 P/N 460727
P/N 460756

Page:190 Page:330
Page:251
OETIKER PLIERS STARTER DRIVE SEAL
Fuel Pump Module Socket P/N 460708 PUSHER
P/N 460820 P/N 460713

Page:73, 122
Page:284 Page:74

Oil Seal Guide

HANDLE P/N 460730 Suction Pump
P/N 460714 P/N 460736

Page:98
Page:74 Page:18, 88

Impeller Shaft Bearing Tool Piston Circlip Installer Supercharger Gear Holder
P/N 460763 P/N 460726 P/N 460753

Page:329–330 Page:159 Page:176

2
 SERVICE TOOLS INDEX

Supercharger Oil Spray Nozzle Valve Guide Remover

Tool P/N 460758
P/N 460761

Page:148
Page:103

Supercharger Retaining Key Valve Spring Compressor Cup

P/N 460755 P/N 460757

Page:178 Page:142

Support Plate Valve Spring Compressor

P/N 460740 P/N 460724

Page:176, 178 Page:142

Test Cap
P/N 460762 Water Pump Seal Pusher
P/N 460731

Page:120
Page:98, 100
Torx Adapter
P/N 460739

Page:177, 180

Vacuum/Pressure Pump
P/N 460736

Page:43, 120

Valve Guide Pusher 6 mm

P/N 460759

Page:148

3
 Safety
Safety Notice

Safety 1

Safety Notice
This manual has been prepared as a guide to cor- This manual emphasizes particular information
rectly service and repair the BRP Marine Power Denoted by the following wording and symbols.
Pack.
DANGER
This edition was primarily published to be used by
technicians who are already familiar with all serv- Indicates a hazardous situation which, if not
ice procedures relating to BRP products. Techni- avoided, will result in death or serious injury.
cians should attend training courses given by
BRPTI. WARNING
Please note that the instructions will apply only if Indicates a hazardous situation which, if not
proper hand tools and special service tools are avoided, could result in death or serious
used. injury.
The contents of this manual depicts parts and pro-
cedures applicable to the particular product at the CAUTION
time of writing. Service and warranty bulletins may Indicates a hazardous situation which, if not
be published to update the content of this manual. avoided, could result in minor or moderate
Dealer modifications that were carried out after personal injury.
manufacturing of the product, whether or not au-
thorized by BRP, are not included.
NOTICE
In addition, the sole purpose of the illustrations Indicates an instruction which, if not followed,
throughout the manual is to assist identification of could severely damage engine components
the general configuration of the parts. They are or other property.
not to be interpreted as technical drawings or ex-
act replicas of the parts.
I M P O R T A N T : Identifies information that con-
The use of BRP parts is most strongly recom- trols correct assembly and operation of the
mended when considering replacement of any product.
component of the Power Pack. Dealer and/or dis-
tributor assistance should be sought in case of ENVIRONMENTAL NOTE
doubt. A note which provides tips and behaviors related
The engines and the corresponding components to protecting the environment.
identified in this document should not be utilized
on product (s) other than those mentioned in this N O T E : Indicates supplementary information re-
document. quired to fully complete an instruction.
It is understood that certain modifications may ren- Although the mere reading of such information
der use of the boat illegal under existing federal, does not eliminate the hazard, your understanding
provincial, and state regulations. of the information will promote its correct use.
Always observe common shop safety practice.
Unless otherwise noted, the engine must be
stopped.
Before carrying out any inspection or maintenance
procedure on the watercraft, wait until the engine
and exhaust have cooled down to avoid potential
burns.

1
Safety
Safety Notice

Strictly adhere to torque wrench tightening specifi-

cations. Use the torque values and service prod-
ucts as in the exploded views or in the procedures
when noted.
Locking devices when removed must be replaced
(e. g.: locking tabs, elastic stop nuts, self-locking
fasteners, cotter pins, etc.).
Hoses, cables and locking ties removed during a
procedure must be reinstalled as per factory
standards.
When ordering parts always refer to the specific
model PARTS CATALOG.
We strongly recommend that any services be car-
ried out and/or verified by a highly skilled profes-
sional mechanic.
It is understood that this manual may be translated
into another language. In the event of any discrep-
ancy, the English version shall prevail.
BRP disclaims liability for all damages and/or inju-
ries resulting from the improper use of the
contents.

2
 Introduction
General

Introduction
General 2
SERVICE PRODUCTS
Description Part Number Page

LOC–TITE PRIMER N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460362 ......................... 6

The information and component/system descrip-

tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differen-
ces between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.

Power Pack Information

Hull Identification Number (HIN)
The Hull Identification Number is composed of 13
digits and is located at the right hand rear side of
the hull.
Engine Identification Number
The Engine Identification Number is located on
front end of the engine.

1. Engine Identification Number (EIN)

Engine Emissions Information

Manufacturer's Responsibility

Since production of the 1999 model year engines,

manufacturers of marine engines are required to
determine the exhaust emission levels for each
engine horsepower family and certify these en-
gines with the United States of America Environ-
mental Protection Agency (EPA). An emissions
control information label, showing emission levels
and engine specifications, must be placed on each
vehicle at the time of manufacture.

3
Introduction
General

Dealer Responsibility Ann Arbor, MI 48105 USA

EPA Internet Web Site:
When servicing all 1999 and more recent BRP Ro-
tax powered boats that carry an emissions control www.epa.gov/otaq
information label, adjustments must be kept within
published factory specifications. Manual Procedures
Many of the procedures in this manual are interre-
Replacement or repair of any emission related lated. Before undertaking any task, you should
component must be executed in a manner that read and thoroughly understand the entire section
maintains emission levels within the prescribed or subsection in which the procedure is contained.
certification standards.
A number of procedures throughout the book re-
Dealers are not to modify the engine in any man- quire the use of special tools. Before commencing
ner that would alter the horsepower or allow emis- any procedure, be sure that you have on hand all
sion levels to exceed their predetermined factory the tools required, or their approved equivalents.
specifications.
In the marine industry, FRONT is called BOW,
Exceptions include manufacturer's prescribed REAR is called STERN, RIGHT is called STAR-
changes, such as altitude adjustments. BOARD and LEFT is called PORT. They always
refer to the operator's position sitting in boat.
Owner Responsibility

The owner/operator is required to have engine

maintenance performed to maintain emission lev-
els within prescribed certification standards.
The owner/operator is not to, and should not allow
anyone else to modify the engine in any manner
that would alter the horsepower or allow emissions
levels to exceed their predetermined factory
specifications.

1. BOW (front)
EPA Emission Regulations 2. STARBOARD (right side)
3. STERN (rear)
4. PORT (left side)
All new 1999 and more recent Rotax inboards are
certified to the EPA as conforming to the require- Other common terms used in the marine industry
ments of the regulations for the control of air pollu- are the BOW (front of the boat), and the STERN
tion from new watercraft marine spark ignition (rear of the boat).
outboards. This certification is contingent on cer-
tain adjustments being set to factory standards. This manual uses technical terms which m a y b e
For this reason, the factory procedure for servicing different from the ones in the PARTS
the product must be strictly followed and, when- CATALOGS.
ever practical, returned to the original intent of the When ordering parts always refer to the specific
design. The responsibilities listed above are gen- model P A R T S C A T A L O G S .
eral and in no way a complete listing of the rules
and regulations pertaining to the EPA require-
ments on exhaust emissions for marine products.
For more detailed information on this subject, you
may contact the following locations:
U.S. Environmental Protection Agency
Certification Division
Gasoline Engine Compliance Center
2000 Traverwood Drive

4
 Introduction
General

Tightening Torque
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When a
torque is not specified, the torque normally recommended for a specific fastener should be used. Refer
to the following table.

WARNING 2
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following
procedure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.

NOTICE
Be sure to use the recommended tightening torque for the specified fastener used.

N O T E : When possible, always apply torque on the nut.

3. Tighten fastener to the recommended torque value.

N O T E : Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific se-
quence and torque pattern as detailed in the installation procedure.

FASTENER GRADE/TORQUE
FASTENER SIZE
5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5–2 N·m 2.5–3 N·m 3.5–4 N·m 4–5 N·m
M4 (13–18 lbf·in) (22–27 lbf·in) (31–35 lbf·in) (35–44 lbf·in)
3–3.5 N·m 4.5–5.5 N·m 7–8.5 N·m 8–10 N·m
M5 (27–31 lbf·in) (40–47 lbf·in) (62–75 lbf·in) (71–89 lbf·in)
6.5–8.5 N·m 8–12 N·m 10.5–15 N·m 16 N·m
M6 (58–75 lbf·in) (71–106 lbf·in) (93–133 lbf·in) (142 lbf·in)
15 N·m 25 N·m 32 N·m 40 N·m
M8 (133 lbf·in) (18 lbf·ft) (24 lbf·ft) (30 lbf·ft)
29 N·m 48 N·m 61 N·m 73 N·m
M10 (21 lbf·ft) (35 lbf·ft) (45 lbf·ft) (54 lbf·ft)
52 N·m 85 N·m 105 N·m 128 N·m
M12 (38 lbf·ft) (63 lbf·ft) (77 lbf·ft) (94 lbf·ft)
85 N·m 135 N·m 170 N·m 200 N·m
M14 (63 lbf·ft) (100 lbf·ft) (125 lbf·ft) (148 lbf·ft)

5
Introduction
General

Fastener Information 2. Apply Loc– Tite PRIMER N (P/N 460362) on

Self-Locking Fasteners threads and allow to dry.
3. Choose proper strength Loc–Tite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Threadlocker Application for Blind Holes

TYPICAL-SELF LOCKING FASTENER

The following describes common procedures used

when working with self-locking fasteners.
Use a metal brush or a tap to clean the hole prop-
erly then use a solvent. Allow the solvent time to
act, approximately 30 minutes, then wipe off. Sol-
vent utilization is to ensure proper adhesion of the
product used for locking the fastener. 1. On fastener threads
2. On threads and at the bottom of hole
Loc-Tite Application Procedure
The following describes common procedures used 1. Clean threads (bolt and hole) with solvent.
when working with Loc–Tite products.
Required Chemical
I M P O R T A N T : Always use proper strength Loc
– Tite product as recommend in this Installation Loc–Tite PRIMER N
Manual.
P/N 460362
Threadlocker Application for Uncovered Holes
(bolts and nuts) 2. Apply Loc — Tite PRIMER N (P/N 460362) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loc–Tite 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.

1. Apply here
2. Do not apply

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

Required Chemical

Loc–Tite PRIMER N
P/N 460362

6
 Introduction
General

Threadlocker Application For Stud Installation I M P O R T A N T : For preventive maintenance on

In Blind Holes existing equipment, retighten nuts and apply prop-
er strength Loc–Tite on bolt/nut contact surfaces.
Threadlocker Application For An Adjustment
Screw 2

1. On stud threads
2. On threads and in the hole
3. On retaining nut threads

1. Clean threads (stud and hole) with solvent. 1. Apply here

2. Apply Loc– Tite PRIMER N (P/N 460362) on 2. Plunger
threads and allow to dry.
3. Put 2 or 3 drops of proper strength Loc– Tite 1. Adjust screw to proper setting.
threadlocker on female threads and in hole. 2. Apply a few drops of proper strength Loc–Tite
threadlocker on screw/body contact surfaces.
I M P O R T A N T : To avoid a hydro lock situation, 3. Avoid touching metal with tip of flask.
do not apply too much Loc–Tite.
I M P O R T A N T : If it is difficult to readjust, heat
4. Apply several drops of proper strength Loc– screw with a soldering iron 232 °C (450 °F).
Tite on stud threads.
5. Install stud. Application For Stripped Thread Repair
6. Install cover. part, etc.
7. Apply a few drops of proper strength Loc–Tite
on uncovered stud threads.
8. Install and tighten retaining nut(s) as required.
Threadlocker Application For Pre-assembled
Parts

1. Release agent
2. Stripped threads
3. Form A thread
4. Tapes
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker

1. Apply here Standard Thread Repair

2. Do not apply
Follow the instructions on Loc-Tite Form-A-Thread
1. Clean bolts and nuts with solvent. 81688 package.
2. Assemble components.
3. Tighten nuts. If a plate is used to align bolt:
4. Apply a few drops of proper strength Loc–Tite 1. Apply release agent on mating surfaces.
on bolt/nut contact surfaces. 2. Put waxed paper or similar film on the
5. Avoid touching metal with tip of flask. surfaces.

7
Introduction
General

3. Twist bolt when inserting it to improve thread 5. Place gasket on mating surfaces and assem-
conformation. ble parts immediately.
I M P O R T A N T : NOT intended for engine stud I M P O R T A N T : If the cover is bolted to blind
repairs. holes, apply proper strength Loc– Tite in the hole
and on threads. Tighten fastener.
Repair of Small Holes/Fine Threads
O p t i o n 1 : Enlarge damaged hole, then follow 6. If holes are sunken, apply proper strength Loc–
Standard Thread Repair, page 7 procedure. Tite on bolt threads.
7. Tighten as usual.
O p t i o n 2 : Apply Loc– Tite Form-A-Thread on the
screw and insert in damaged hole. Threadlocker Application For Mounting On A
Shaft
Permanent Stud Installation (Light Duty)
1. Use a stud of the desired thread length.
2. DO NOT apply release agent on stud.
3. Follow Standard Thread Repair, page 7
procedure.
4. Allow 30 minutes for Loc– Tite Form-A-Thread
to cure.
5. Complete part assembly.
Gasket Compound Application

1. Bearing
2. Proper strength Loc-Tite
3. Shaft

Mounting With A Press

1. Clean shaft external contact surface.
2. Clean internal contact surface of part to be in-
stalled on shaft.
3. Apply a strip of proper strength Loc–Tite on cir-
cumference of shaft contact surface at inser-
tion or engagement point.
I M P O R T A N T : Retaining compound is always
forced out when applied on shaft.
4. DO NOT use antiseize Loc–Tite or any similar
1. Proper strength Loc-Tite product.
2. Loc– Tite Primer N and Gasket Eliminator 518 on both sides of 5. No curing period is required.
gasket
3. Loc–Tite Primer N only Mounting In Tandem
1. Remove old gasket and other contaminants 1. Apply retaining compound on internal contact
using Loc–Tite Chisel, P/N 460797. Use a me- surface (bore) of parts to be installed.
chanical means only if necessary. 2. Continue parts assembly as per previous
illustration.
I M P O R T A N T : Avoid grinding.
2. Clean both mating surfaces with solvent.
3. Spray Loc–Tite Primer N, P/N 460362, on both
mating surfaces and on both sides of gasket
and allow to dry 1 or 2 minutes.
4. Apply Loc–Tite 518, P/N 460361 on both sides
of gasket, using a clean applicator.

8
 Introduction
General

Threadlocker Application For Case-In

Components (Metallic Gaskets)

1. Proper strength Loc-Tite

1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with Loc–Tite Primer
N, P/N 460362.
3. Apply a strip of proper strength Loc– Tite on
leading edge of outer metallic gasket diameter.
I M P O R T A N T : Any Loc– Tite product can be
used here. A low strength liquid is recommended
as normal strength and gap are required.
4. Install according to standard procedure.
5. Wipe off excess product.
6. Allow 30 minutes for product to cure.
I M P O R T A N T : Normally used on worn-out
housing to prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.

9
Notes

Notes Notes
Technician’s Notes Related Documents
Bulletins

Instruction Sheets

Other

10
 Inspections and Maintenance
Periodic Maintenance Schedule

Inspections and Maintenance

Periodic Maintenance Schedule

Maintenance is very important for keeping the Power Pack in a safe operating condition. The Power Pack
should be serviced as per the maintenance schedule.
Carry out all maintenance as listed in the schedule whenever the hours or time of each column is
3
reached.

WARNING
Failure to properly maintain the power pack according to the maintenance schedule and proce-
dure can make it unsafe.

The maintenance schedule does not exempt the pre-ride inspection.

A: ADJUST FIRST 50 HOURS OR 1 YEAR

C: CLEAN EVERY 100 HOURS OR 6 MONTHS
I: INSPECT EVERY 200 HOURS OR 2 YEARS
L: LUBRICATE TO BE PERFORMED BY
R: REPLACE
RS: REPAIR SHOP
O: OPERATOR
PART/TASK LEGEND
ENGINE
Engine Oil and Filter R R(1) RS (1) At storage period of after 100
hours of use whichever comes
Rubber mounts I I O, RS first.
(2) Replace at 200 hours of use,
irrespective the number of years
(3) Spray an anti-corrsosion
Corrosion protection L(4) O
lubricant on metallic components
in engine compartment

EXHAUST SYSTEM
Exhaust system
(includes hoses, (1) At storage period of after 100
I I, C(5) O, RS hours of use whichever comes
fasteners, components
and leaks) first.
(5) Daily flushing in salt water or
Exhaust system foul water use
I, C(1),(5) O
flushing
COOLING SYSTEM
Hoses and fasteners I I O, RS
Coolant I R O, RS

11
Inspections and Maintenance
Periodic Maintenance Schedule

FUEL SYSTEM
Throttle body I I O, RS
Fuel lines, connections,
pressure relief valve I I RS
and fuel
ENGINE MANAGEMENT SYSTEM (EMS)
Fault codes I I I
AIR INTAKE SYSTEM
Air filter I(6) RS (6) replace if required

ELECTRICAL SYSTEM
Test the engine cut-off
switch and the
monitoring beeper at
first 50 hours and every I I
100 hours or once a
year
Spark plugs I I R RS
Ignition coils I I,L RS
Electrical connections
and fastening (visual I I RS
inspection)
STEERING SYSTEM
Steering cable and I(4) I O
connections (4) Every 10 hours in salt water
use
Steering nozzle and
I(4) I O,RS
bushings
PROPULSION SYSTEM
Carbon ring and rubber (4) Every 10 hours in salt water
boot (drive shaft) I I RS use

Shifter system, cable I(4) O,RS

I
and connections
Reverse gate L(4) L O
Drive shaft/impeller
I,L RS
splines
Drive shaft L(7)
(7) Lubricate for corrosion
Impeller boot I I RS protection

Impeller shaft seal,

I R(2) RS
sleeve and O-ring

12
 Inspections and Maintenance
Periodic Maintenance Schedule

Impeller and wear ring (2) Replace at 200 hours of use,

I I RS irrespective of the number of years
clearance
(8) Inspect each month (every two

Sacrificial anode I(8) O weeks in salt) and change when

necessary

HULL/BODY
Ride plate and water
intake grate I O 3

13
Inspections and Maintenance
Storage Procedure

Storage Procedure

SERVICE PRODUCTS
Description Part Number Page

XPS LUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460786 . . . . . . . . . . . . . . . . . . . . . 14–15

Engine Internal Lubrication

NOTICE
Improper antifreeze density may result in
coolant freezing should the vehicle be stored
in an area where the freezing point is at-
tained. This could seriously damage the
engine.

Engine must be lubricated to prevent corrosion on

internal parts.
To lubricate the engine, proceed as follows:

WARNING
When disconnecting coil from spark plug, al-
ways disconnect coil from main harness first. 1. Ignition coil
2. Spark plug
Never check for engine ignition spark from an
open coil and/or spark plug in the engine
compartment as the spark may cause fuel va- Required Chemical
pors to ignite.
XPS LUBE
1. Disconnect ignition coil connectors.
P/N 460786
NOTICE
Never cut the locking ties of ignition coil con- 6. Spray XPS LUBE (M) (P/N 460786) into each
nectors. This would allow mixing of the wires spark plug hole.
between cylinders. 7. Crank the engine a few turns to distribute the
oil on cylinder wall.
2. Clean the area around the ignition coils to N O T E : To crank engine, use the drowned mode
avoid dirt falling into a cylinder. to avoid injecting fuel. Refer to D R O W N E D
3. Remove ignition coils. M O D E for proper procedure.
4. Unscrew spark plugs.
5. Using an ignition coil as a puller, remove spark 8. Reinstall spark plugs and ignition coils.
plugs.
N O T E : Refer to I G N I T I O N S Y S T E M for details
on installing the spark plugs and ignition coils.

9. Reconnect ignition coil connectors.

10. Install all other removed parts.

Engine Compartment Cleaning

1. Clean the bilge with hot water and a mild deter-
gent, or using bilge cleaner.
2. Rinse thoroughly.

14
 Inspections and Maintenance
Storage Procedure

3. Lift front end of boat to completely drain bilge.

Anticorrosion Treatment
1. Wipe off any residual water in the engine
compartment.

Required Chemical

XPS LUBE 3
P/N 460786

2. Spray XPS LUBE (M) (P/N 460786) over all

metallic components in engine compartment.

Preseason Preparation
Proper boat preparation is necessary after the
winter months or when a boat has not been used
during 4 months.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced.
If not, proceed with the replacement.
Referring to the maintenance schedule, carry out
the maintenance procedures for every item speci-
fied in the columns 100 HOURS OR 1 YEAR.

1. Use this column

Perform a fuel system leak test and a fuel pump

pressure test as described in the F U E L T A N K
A N D F U E L P U M P subsection.

N O T E : It is of the utmost importance to inspect

the fuel system.

15
Inspections and Maintenance
Special Procedures

Special Procedures

SERVICE TOOLS
Description Part Number Page

LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . 16, 18–19

SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 18

Towing The Boat In The Water

Special precautions should be taken when towing
a BRP ROTAX powered boat in water to prevent
the exhaust system and engine from filling with
water.
Maximum recommended towing speed is 24 km/h
(15 MPH).

N O T E : On models with twin engines, this proce-

dure must be followed for both engines.
1. Pinch the water supply hose cooling the inter-
ON 150 CAT ENGINES
cooler (if applicable) and exhaust system.

Required Tool

Large Hose Pincher

P/N 460717

ON 200 CAT ENGINES

ON-NON CAT ENGINES

1. Hose pincher

N O T E : Make sure the water supply lines on all

power packs are blocked off from water flow dur-
ing towing as per the following diagrams.

16
 Inspections and Maintenance
Special Procedures

If engine is water-flooded, it must be serviced with-

in a few hours after the event. Otherwise engine
will have to be overhauled.
Whenever the engine is stopped, all the valves
close thus preventing water from being ingested in
the engine.
NOTICE
Never try to crank or start engine. Water
trapped in the intake manifold would flow to-
3
wards the engine and possibly cause severe
engine damage.

ON 250 CAT ENGINES

NOTICE
NOTICE A water flooded engine must be properly
drained, lubricant replaced (oil change), op-
Failure to do this may result in damage to the
erated (boil out procedure), then lubricant re-
engine. If you must tow a stranded boat in
placed again, otherwise parts will be
water and do not have a hose pincher be sure
seriously damaged.
to stay well below the maximum towing speed
of 24 km/h (15 MPH).
If water is suspected to be in the intake and the ex-
haust system, it must be drained as follows:
NOTICE
When finished towing the boat, the hose 1. Remove the intake manifold and drain it.
pincher must be removed before operating it. 2. Suck out the water from the intake valve ports.
Failure to do so will result in engine damage. Refer to I N T A K E M A N I F O L D .
3. Remove the water from oil/air separator
breather hose.
Submerged Boat 4. Remove the exhaust pipe and drain it.
NOTICE 5. Either remove the mufflers to drain them or si-
phon the water out of them. Refer to E X -
Never try to crank or start engine. Water HAUST SYSTEM.
trapped in the intake manifold would flow to- 6. If water gets in the oil (oil will be milky), change
wards the engine and possibly cause severe the engine oil and filter. Refer to E n g i n e O i l
engine damage. and Filter Replacement.

1. Drain bilge. Exhaust System Draining

2. If the boat was submerged in salt water, rinse If water is suspected to be in the exhaust system,
the bilge and all components thoroughly with remove the exhaust pipe and muffler. Drain them
fresh water using a garden hose to stop the or siphon the water out of them. Refer to E X -
salt corroding effect. HAUST SYSTEM.
3. Check for water in the intake system.
4. If water found in the intake system, refer to Intake System Draining
WATER-FLOODED ENGINE.
5. Inspect the engine oil. Refer to W A T E R - If water is suspected to be in the intake silencer,
FLOODED ENGINE. empty it. Refer to A I R I N T A K E S Y S T E M
6. Inspect the fuel. Check the fuel reservoir for subsection.
water contamination. If necessary, siphon and On 250 engines, check for water intrusion in the
refill with fresh fuel. supercharger inlet hose. Remove hose to empty it.
Water-Flooded Engine Remove the water from blow-by valve hose.

N O T E : his procedure must be followed for both If water is suspected in the intake manifold, re-
engines. move the intake manifold and drain it. Then siphon

17
Inspections and Maintenance
Special Procedures

the water out from the intake valve ports. Refer to

INTAKE MANIFOLD.

Throttle Body Lubrication

Throttle body should be lubricated flush out any
water infiltration and to prevent corrosion. Refer to
STORAGE PROCEDURE.

Engine Oil and Filter Replacement

If the engine oil is contaminated with water (oil will
be milky), change the engine oil and filter as per
following procedure.
TYPICAL
1. Siphon the contaminated oil from the engine 1. Pump tube with tape
2. Edge of cylinder block
reservoir through dipstick hole.
11. Remove the pump tube.
Required Tool 12. Reinstall cylinder head cover.
13. Install a NEW oil filter and reinstall the oil filter
Suction Pump cap.
14. Replenish the engine with appropriate amount
P/N 460736 of the recommended engine oil. Refer to L U -
BRICATION SYSTEM.
NOTICE 15. Proceed with the B o i l O u t P r o c e d u r e .
Never crank or start engine when siphon tube
is in dipstick hole. Never start engine when Boil Out Procedure
there is no oil in engine. N O T E : This procedure is intended to evaporate
the small quantity of water contained in the oil sys-
2. Remove the pump from the dipstick hole. tem. The procedure with the boat in water is the
3. While in drowned engine mode, crank the en- preferred one, but it can also be done using the
gine for 5 seconds. Refer to E N G I N E M A N - flush kit.
AGEMENT SYSTEM.
4. Remove the oil filter cap and the oil filter. Refer Procedure With Boat On Trailer In A Water
to L U B R I C A T I O N S Y S T E M . Ramp
5. Again, siphon the contaminated oil from the 1. Connect the vehicle to B.U.D.S. to monitor the
reservoir. coolant temperature. It must exceed 100° C
6. Remove cylinder head cover. Refer to C Y L I N - (212° F) in order for the water boil out. Once
DER HEAD. the boiling point is reached, it won't take long
to evaporate the water.
2. Run the engine for 5 minutes at 3500 RPM.

WARNING
Make sure to safely secure the boat.

Required Tool
1. Cylinder head cover
Large Hose Pincher
7. The contaminated oil in the PTO area of the
engine is siphoned using the same pump as P/N 460717
above.
8. Put a tape at 400 mm (16 in) from the end of 3. With the engine still running at 3500 RPM,
the pump tube. pinch the coolant line going to the oil cooler us-
9. Insert the tube in the PTO area until the tape ing the Large Hose Pincher, P/N 460717.
reach the cylinder-block edge.
10. Siphon contaminated oil out.

18
 Inspections and Maintenance
Special Procedures

2. Connect the vehicle to B.U.D.S. to monitor the

WARNING
coolant temperature. It must exceed 100° C
Certain components in the engine compart- (212° F) in order for the water boil out. Once
ment may be very hot. Direct contact may re- the boiling point is reached, it won't take long
sult in skin burn. Do not touch any electrical to evaporate the water.
parts or jet pump area when engine is 3. Connect a flush kit to the coolant line.
running.
NOTICE
Never run the engine without supplying water
to the exhaust cooling system when boat is 3
out of water.

4. Run the engine for 5 minutes at 3000 RPM.

Required Tool

Large Hose Pincher

P/N 460717

5. With the engine still running at 3000 RPM,

1. Oil cooler coolant inlet hose pinch the coolant line going to the oil cooler us-
4. Continue to run the engine at 3500 RPM for 15 ing the Large Hose Pincher, P/N 460717.
more minutes (20 minutes total run time).
5. Shut the engine off. WARNING
6. Remove the hose pincher from the coolant Certain components in the engine compart-
line. ment may be very hot. Direct contact may re-
sult in skin burn. Do not touch any electrical
NOTICE parts or jet pump area when engine is
Hose pincer must be removed prior to operat- running.
ing the boat. Failure to do this will result in
damage to the engine.

7. Change the oil and the filter again.

Procedure With Boat On Trailer Connected To
A Flush Kit
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
running.
1. Oil cooler coolant inlet hose
1. On drive shaft, remove the C-clip then move
forward the ring seal carrier. Refer to D R I V E 6. Continue to run the engine at 3000 RPM for 15
SYSTEM. more minutes (20 minutes total run time).
7. Shut off the engine.
NOTICE 8. Remove the hose pincher from the coolant
Make sure that the ring seal carrier is not in line.
contact with the PTO seal assembly or the
carbon ring.

19
Inspections and Maintenance
Special Procedures

NOTICE
Hose pincer must be removed prior to operat-
ing the boat. Failure to do this will result in
damage to the engine.

9. Change the oil and filter again.

10. Move rearward the ring seal carrier and rein-
stall the C-clip. Refer to D R I V E S Y S T E M .

20
 Engine
Engine Removal and Installation

Engine

Engine Removal and Installation

SERVICE TOOLS
Description Part Number Page

ADAPTER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460720 . . . . . . . . . . . . . . . . . . . . . . . . 89

ALIGNMENT SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460723 . . . . . . . . . . . . . . . . . . . . . . . . 24 4
ALIGNMENT SHAFT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460839 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460709 . . . . . . . . . . . . . . . . . . . . . . . . 24
BLIND HOLE BEARING PULLER SET . . . . . . . . . . . . . . . . . . . . . P/N 460760 . . . . . . . . . . . . . . . . . . . . . . . . 74
CAMSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 138
CRANKSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460729 . . . . . . . . . . . . . . . 164, 166, 173
DRIVE SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460745 . . . . . . . . . . . . . . . . . . . . . . . 129
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . 93, 109
ENGINE ALIGNMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460719 . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE LEAK DOWN TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460721 . . . . . . . . . . . . . . . . . . . . . . . 130
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . . . . . . . . . . . . . . . 93, 109
FLUSHING CONNECTOR ADAPTER . . . . . . . . . . . . . . . . . . . . . . P/N 460711 . . . . . . . . . . . . . . . . . . . . . . . . 51
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460714 . . . . . . . . . . . . . . . . . . . . . . . . 74
LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . . . . . . . 42
OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460708 . . . . . . . . . . . . . . . . . . . . 73, 122
OIL SEAL GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460730 . . . . . . . . . . . . . . . . . . . . . . . . 98
PISTON CIRCLIP INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460726 . . . . . . . . . . . . . . . . . . . . . . . 159
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 89
STARTER DRIVE SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460713 . . . . . . . . . . . . . . . . . . . . . . . . 74
SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 88
SUPERCHARGER GEAR HOLDER . . . . . . . . . . . . . . . . . . . . . . . P/N 460753 . . . . . . . . . . . . . . . . . . . . . . . 176
SUPERCHARGER OIL SPRAY NOZZLE TOOL . . . . . . . . . . . . . . P/N 460761 . . . . . . . . . . . . . . . . . . . . . . . 103
SUPERCHARGER RETAINING KEY . . . . . . . . . . . . . . . . . . . . . . P/N 460755 . . . . . . . . . . . . . . . . . . . . . . . 178
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460740 . . . . . . . . . . . . . . . . . . . 176, 178
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . . . . 120
TORX ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460739 . . . . . . . . . . . . . . . . . . . 177, 180
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . 43, 120
VALVE GUIDE PUSHER 6 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460759 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE GUIDE REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460758 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE SPRING COMPRESSOR CUP . . . . . . . . . . . . . . . . . . . . . P/N 460757 . . . . . . . . . . . . . . . . . . . . . . . 142
VALVE SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460724 . . . . . . . . . . . . . . . . . . . . . . . 142
WATER PUMP SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460731 . . . . . . . . . . . . . . . . . . . . 98, 100

SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,
108, 111, 125, 137, 141, 172,
179–180
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119

21
Engine
Engine Removal and Installation

SERVICE PRODUCTS
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798 . . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179

22
 Engine
Engine Removal and Installation

General
Engine Access
Remove the engine compartment cover as de-
scribed in the Manual of the boats manufacturer.

Engine Removal
1. Turn main cut-off switch to OFF and discon-
nect the battery.
2. Unplug fuel hose from fuel rail. Refer to E L E C -
TRONIC FUEL INJECTION (EFI).
3. Drain coolant. Refer to C O O L I N G S Y S T E M .
4. Detach the expansion tank from its support
and temporarily tie it to engine. 1. Lifting location
4
5. Disconnect the “B” connector from the ECM.
6. Disconnect the engine connector. N O T E : Be careful when lifting the engine, shims
7. Disconnect the magneto connector (remove could have been installed. Shims control engine
the connector housing from the ECM support). alignment. Always note position of shims for re-
8. Remove the two engine bay harness grounds installation.
located on the front of the engine.
9. Disconnect the regulator/rectifier connectors. 23. Disconnect the starter cable from the starter.
10. Disconnect the O2 sensor connectors. 24. Remove the engine ground cable located
11. Remove the tie straps holding connectors and under the exhaust manifold.
harnesses to the engine. 25. Continue lifting the engine to remove it from
12. Remove the engine bay harness. the engine compartment.
13. Remove the air intake system up to the super-
charger or throttle body depending on which NOTICE
model. Refer to A I R I N T A K E S Y S T E M . Be careful not to scratch or to hit any engine
14. O n C A T - e n g i n e s : Remove the CAT and muf- component.
fler assembly. Refer to E X H A U S T S Y S T E M .
15. O n N O N - C A T - e n g i n e s : Remove the exhaust
Required Chemical
and muffler assembly. Refer to E X H A U S T
SYSTEM.
16. Remove the supercharger. Refer to Pulley Flange Cleaner
SUPERCHARGER. P/N 460798
17. Remove the water hoses from the exhaust
manifold.
26. Wipe off any spillage in bilge. Clean with the
18. Remove the heat exchanger hoses from water
PULLEY FLANGE CLEANER (M) (P/N
pump housing.
460798).
19. Remove the drive shaft. Refer to DRIVE
SHAFT. Engine Installation
20. Remove the engine mounting screws.
21. Cut any locking ties from hoses or wiring har- Installation of engine in boat is essentially the re-
ness that prevent engine removal. verse of removal procedures. However pay partic-
22. Slightly lift the engine using a suitable lifting ular attention to the following.
device.
NOTICE
Whenever engine is removed from boat, en-
gine alignment must be performed at re-
installation.

1. Check tightness and condition of rubber

mounts. Refer to E N G I N E R U B B E R
MOUNTS.

23
Engine
Engine Removal and Installation

2. Before completely lowering engine, install 15. Verify all electrical connections (ground wires
ground cable, starter cable and cooling hoses and battery).
on exhaust manifold. 16. Run engine and ensure there are no leaks.

N O T E : Ensure contact surface is perfectly clean NOTICE

then reconnect grounds cable to engine. If boat is out of water, exhaust system must
be cooled using the flushing kit.
Required Chemical
Engine Alignment
Loc-Tite 243
1. Remove jet pump and drive shaft. Refer to
P/N 460790 STEERING AND PROPULSION.

3. Apply LOCTITE 243 (BLUE) (M) (P/N 460790) Required Tool

on threads of ground cable screw or use a new
screw with self-locking product. Engine Alignment
4. Tighten ground cable screw to 23 N·m (17 Plate
lbf·ft).
5. Torque starter cable nut to 7 N·m (62 lbf·in). P/N 460719
6. Install protective cap over the starter cable
end. Alignment Shaft
7. Connect exhaust manifold water inlet and drain Adapter
hoses. Tighten clamps to 1.7 N·m (15 lbf·in).
P/N 460723
8. Place engine into boat.
9. Install engine support screws and previously
removed shims. Alignment Shaft
Support
N O T E : Do not apply thread locker to engine sup- P/N 460839
port screws and do not torque yet.
10. Perform the engine alignment procedure. Re- Alignment Shaft
fer to E N G I N E A L I G N M E N T . P/N 460709
NOTICE
2. Install ENGINE ALIGNMENT PLATE (P/N
The engine alignment must be completed be-
460719) and ALIGNMENT SHAFT SUPPORT
fore finalizing the engine installation.
(P/N 460839) onto the pump support with
washer and nuts. Hand tighten the adapter
11. Install and properly align exhaust and muffler nuts in a cross pattern.
assembly or CAT and muffler assembly. Refer
to E X H A U S T S Y S T E M .
12. Reinstall all removed parts and connect all
connectors.
13. Ensure contact surface is perfectly clean then
reconnect the 3 grounds wires to the front end
of engine.

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.
3. Install the ALIGNMENT SHAFT ADAPTER (P/
14. Check hose condition and pressure test fuel
system. Refer to F U E L S Y S T E M . N 460723) in engine PTO housing.

24
 Engine
Engine Removal and Installation

1. Engine alignment adapter TYPICAL

1. Shim
4
4. Carefully slide ALIGNMENT SHAFT (P/N
460709) through support. 8. The engine forward/aft position must be re-
5. Insert shaft end into engine alignment adapter. spected to ensure proper drive shaft bellow
compression.
N O T E : Ensure the protective hose and carbon
ring is removed to check engine alignment. If the
alignment is correct, the shaft will slide easily with-
out any deflection in engine alignment adapter.

9. With the drive shaft fully inserted into the en-

gine, the drive shaft should extend 22.24 mm
from pump support surface.
TYPICAL
1. Engine alignment adapter
2. Alignment shaft

6. If the alignment is incorrect loosen engine sup-

port screws to enable to align engine alignment
adapter with shaft end.
7. Install shim (s) between engine supports and
the sub frame/stringer to correct the alignment.
Refer to the exploded view and the following
table for shims position, thickness and
quantity.

Required Chemical

Loc-Tite 243
P/N 460790

25
Engine
Engine Removal and Installation

10. Remove engine support screws and apply

Loc-Tite 243, P/N 460790, on screw threads.
11. Torque engine support screws as per following
table when procedure is completed.

PART TORQUE
Engine support screw 25 N·m (18 lbf·ft)

12. Remove alignment tools.

Engine Rubber Mounts

Engine Rubber Mount Inspection
Check tightness and condition of rubber mounts.
Engine Rubber Mount Replacement
N O T E : Engine removal is not necessary to re-
place a rubber mount. Hold the engine using lifting
brackets.

Be careful when removing screws from rubber FRONT RUBBER MOUNT

mount adapters, shims could have been installed 1. Shims
underneath. Shims control engine alignment. Al-
ways note position of shims for re-installation to
avoid altering engine alignment.
1. Check tightness and condition of rubber
mounts.
Required Chemical

Loc-Tite 243
P/N 460790

2. If the rubber mounts have been removed, ap-

ply Loc-Tite 243 (BLUE) (M) (P/N 460790) on
screw threads.
3. Torque screws to 25 N·m (18 lbf·ft).

REAR RUBBER MOUNT

1. Shims

NOTICE
Strict adherence to this torque is important to
avoid damaging threads of hull aluminum
inserts.

26
 Engine
Air Intake System

Air Intake System

SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,
108, 111, 125, 137, 141, 172,
179–180 4
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798 . . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179

27
Engine
Air Intake System

150 CAT and Non-CAT Engines

6 N•m
(54 lbf•in)

4 N•m
(35 lbf•in)
6 N•m
(54 lbf•in)

1.7 N•m
(15 lbf•in)

4 N•m
(35 lbf•in)

28
 Engine
Air Intake System

200 CAT Engine

6 N•m
(54 lbf•in)

4 N•m
(35 lbf•in)
6 N•m
(54 lbf•in)
4

1.7 N•m
(15 lbf•in)

4 N•m
(35 lbf•in)

29
Engine
Air Intake System

250 CAT Engine

6 N•m
(54 lbf•in)

4 N•m
(35 lbf•in)
6 N•m
(54 lbf•in)

1.7 N•m
(15 lbf•in)

4 N•m
(35 lbf•in)

30
 Engine
Air Intake System

Air Filter
Air Filter Removal
NOTICE
Never remove or modify any component from
the air intake system. Otherwise, engine per-
formance degradation can occur. The engine
management system is calibrated to operate
specifically with these components.

1. Loosen clamp securing air filter to air intake

tube.
TYPICAL
1. Rectifier/regulator connectors
4
2. Rectifier/Regulator
3. Air intake tube
4. Air filter

3. Unplug the blow-by valve hose from the air in-

take tube.
4. Remove clamp securing air intake tube adapt-
er to throttle body.
5. Unscrew bolt that attach air intake tube to its
bracket.
6. Remove clamp securing air intake tube to
supercharger inlet hose.
TYPICAL 7. Unscrew bolt that attach air intake tube to its
1. Air filter bracket.
2. Clamp 8. Remove remaining clamp securing the air in-
3. Air intake tube
take tube.
2. Pull air filter to remove the filter from the 9. Remove the air intake tube.
engine.
Air Intake Tube Installation
Air Filter Cleaning 1. The installation is the reverse of the removal
This air filter should never need to be cleaned. procedure.
However, if the filter is dirty, it can be washed in
soapy water, dried, and re oiled.
1. To oil the air filter, use the AIR FILTER OIL(M)
(P/N 460800) or use K&N filter oil.

Required Chemical

Air Filter Oil

P/N 460800

Air Intake Installation

1. The installation is the reverse of the removal
procedure.

Air Intake Tube

Air Intake Tube Removal
1. Remove the air filter. Refer to Air Filter Remov-
al, page 31.
2. Unplug rectifier/regulator connectors or re-
move rectifier/regulator from air intake tube.

31
Engine
Intake Manifold

Intake Manifold
SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,
108, 111, 125, 137, 141, 172,
179–180
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798 . . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179

32
 Engine
Intake Manifold

150 and 250 Engines

33
Engine
Intake Manifold

200 Engines

34
 Engine
Intake Manifold

Procedures
Intake Manifold
Intake Manifold Removal
To access engine(s), refer to Engine Access, page
23.
1. Turn main battery cut-off switch to OFF
position.
2. Remove the air intake silencer. Refer to A I R
INTAKE SYSTEM.
3. Remove oil dipstick.
4. Disconnect the blow-by valve hose from the air
intake silencer cover.
11. Lift intake manifold up to pull it out of the
4
5. Disconnect the supercharger inlet hose from
mounting brackets.
the throttle body.
6. Cut all locking ties securing the engine wiring
harness to the intake manifold.
7. Unplug the following 8 engine related connec-
tors, refer to C O N N E C T O R I N F O R M A T I O N .
Only the following engine harness connectors
are necessary to remove manifold:
– Ignition coils (3)
– Crankshaft position sensor
– Coolant temperature sensor
– Camshaft position sensor
– Exhaust temperature sensor
– Knock sensor (remove connector from
bracket) 1. Mounting brackets
– Oil pressure switch
12. Pull intake manifold out.
8. Unplug the following 4 engine bay harness re-
lated connectors, refer to CONNECTOR IN- Intake Manifold Inspection
FORMATION. Only the following engine bay Check intake manifold for cracks, warping at
harness connectors are necessary to remove flanges or any other visible damage.
manifold:
Check if intake manifold gaskets are cracked, brit-
– ECU B connector tle or otherwise damaged.
– Engine power connector
– O2 sensor connectors (if applicable) Replace damaged parts as necessary.
– Regulator/rectifier connectors Intake Manifold Installation
9. Move the engine bay wiring harness away from For installation, reverse the removal procedure.
intake manifold. Refer to exploded views at the beginning of this
10. Remove manifold retaining screws and push subsection for service products and tightening tor-
the oil dipstick tube out of the manifold slot. que values. However, pay attention to following
details.
1. Ensure that all gaskets are properly installed
and in a good condition.

35
Engine
Intake Manifold

INTAKE MANIFOL D TIGHTENING SEQUENCE — INTAKE MANIFOLD SCREWS

1. Gaskets
6. Ensure to properly route and secure wiring har-
2. Position intake manifold on front mounting ness with locking ties.
bracket then push manifold toward engine to
then proceed with rear mounting bracket. WARNING
3. When installing the intake manifold, lift up the
oil dipstick tube a little bit and insert it into the Whenever doing any type of repair on boat or
manifold slot. if any components of the fuel system are dis-
connected, a pressure test must be done be-
fore starting engine.

Engine Control Module

ECM RETAINING SCREWS
TORQUE 5.5 N·m (49 lbf·ft)

Flame Arrester
Flame Arrester Location
The flame arrester is integrated in the intake
manifold.
1. Oil dipstick tube

Required Chemical

Loc-Tite 243
P/N 460790

4. Apply Loc-Tite 243, P/N 460790, on the intake

manifold screws.
5. Tighten intake manifold to specification using
the following sequence.

TORQUE 1. Flame arrester

Intake manifold screws 9 N·m Flame Arrester Inspection

The flame arrester in the intake manifold is main-
tenance free.
Flame Arrester Replacement
N O T E : The flame arrester cannot be removed
from the intake manifold.

36
 Engine
Intake Manifold

Replace intake manifold if necessary.

37
 Engine
Intercooler

Intercooler
SERVICE TOOLS
Description Part Number Page

ADAPTER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460720 . . . . . . . . . . . . . . . . . . . . . . . . 89

ALIGNMENT SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460723 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460839 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460709 . . . . . . . . . . . . . . . . . . . . . . . . 24
BLIND HOLE BEARING PULLER SET . . . . . . . . . . . . . . . . . . . . . P/N 460760 . . . . . . . . . . . . . . . . . . . . . . . . 74
CAMSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 138
CRANKSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460729 . . . . . . . . . . . . . . . 164, 166, 173
DRIVE SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460745 . . . . . . . . . . . . . . . . . . . . . . . 129
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . 93, 109
ENGINE ALIGNMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460719 . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE LEAK DOWN TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460721 . . . . . . . . . . . . . . . . . . . . . . . 130
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . . . . . . . . . . . . . . . 93, 109
FLUSHING CONNECTOR ADAPTER . . . . . . . . . . . . . . . . . . . . . . P/N 460711 . . . . . . . . . . . . . . . . . . . . . . . . 51
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460714 . . . . . . . . . . . . . . . . . . . . . . . . 74
LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . . . . . . . 42
OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460708 . . . . . . . . . . . . . . . . . . . . 73, 122
OIL SEAL GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460730 . . . . . . . . . . . . . . . . . . . . . . . . 98
PISTON CIRCLIP INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460726 . . . . . . . . . . . . . . . . . . . . . . . 159
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 89
STARTER DRIVE SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460713 . . . . . . . . . . . . . . . . . . . . . . . . 74
SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 88
SUPERCHARGER GEAR HOLDER . . . . . . . . . . . . . . . . . . . . . . . P/N 460753 . . . . . . . . . . . . . . . . . . . . . . . 176
SUPERCHARGER OIL SPRAY NOZZLE TOOL . . . . . . . . . . . . . . P/N 460761 . . . . . . . . . . . . . . . . . . . . . . . 103
SUPERCHARGER RETAINING KEY . . . . . . . . . . . . . . . . . . . . . . P/N 460755 . . . . . . . . . . . . . . . . . . . . . . . 178
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460740 . . . . . . . . . . . . . . . . . . . 176, 178
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . . . . 120
TORX ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460739 . . . . . . . . . . . . . . . . . . . 177, 180
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . 43, 120
VALVE GUIDE PUSHER 6 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460759 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE GUIDE REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460758 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE SPRING COMPRESSOR CUP . . . . . . . . . . . . . . . . . . . . . P/N 460757 . . . . . . . . . . . . . . . . . . . . . . . 142
VALVE SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460724 . . . . . . . . . . . . . . . . . . . . . . . 142
WATER PUMP SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460731 . . . . . . . . . . . . . . . . . . . . 98, 100

38
 Engine
Intercooler

250 Engine

39
Engine
Intercooler

Intercooler Air Hoses

40
 Engine
Intercooler

Intercooler Water Hoses

41
Engine
Intercooler

Maintenance 2. Pour fresh water into the water outlet fitting.

Intercooler Flushing
Flushing the intercooler with fresh water is essen-
tial to neutralize corroding effects of salt or other
chemical products present in water. It will help to
clean up sand, salt, shells or other particles in
intercooler.

N O T E : Intercooler is flushed with the exhaust

system, as they are on the same circuit.
Exhaust system and intercooler should be flushed
each time:
– Boat is used in salt water and is not expected
to be used further the same day. 1. Intercooler water inlet fitting
– Boat is used in foul water. 2. Intercooler water outlet fitting
– Boat is stored for any extended time. 3. Leave water to soak and to loosen deposits for
Refer to E X H A U S T S Y S T E M subsection for many hours. Occasionally, shake the inter-
flushing procedure. cooler to loosen deposits.
4. Rinse the intercooler using a garden hose in-
NOTICE stalled on water outlet.
Failure to flush the system, when necessary, 5. Let water flow to evacuate internal deposits.
will severely damage the engine intercooler 6. Check water flow.
or exhaust system. WATER FLOW

Procedures 1. Repeat cleaning

procedure
Intercooler Cleaning LOW OR ERRATIC
2. Replace the
CAUTION
intercooler
Let the engine cool down prior to working on
the intercooler. HIGH AND Intercooler is not
REGULAR clogged
If temperature in intake manifold gets too high or if
engine is down in performance, the intercooler 7. Perform a leak test before installing the inter-
may need to be cleaned. cooler in the boat. Refer to I N T E R C O O L E R
LEAK TEST.
The exhaust system should be flushed first, as it
may unclog the intercooler. If not, proceed with Intercooler Leak Test
the intercooler cleaning procedure. 1. Use the Large Hose Pincher, P/N 460717, to
block the intercooler water inlet and outlet
N O T E : The exhaust temperature will decrease hoses.
when the intercooler is clogged due to more water
being routed through the exhaust system. Required Tool

NOTICE Large Hose Pincher

Never try to clean the intercooler with chemi-
cal products. Only use fresh water. Chemical P/N 460717
products will permanently damage the inter-
nal parts of the intercooler.

To clean the intercooler, do the following:

1. Remove the intercooler from the boat. Refer to
INTERCOOLER REMOVAL.

42
 Engine
Intercooler

TYPICAL
1. Intercooler air inlet hose
2. Intercooler air outlet hose
4
TYPICAL — SOME PARTS REM OVED FOR CLARITY 2. Detach intercooler retaining straps.
1. Intercooler
2. Intercooler water outlet hose
3. Intercooler water inlet hose

2. Unplug the intercooler water inlet hose from

the intercooler.
Required Tool

Vacuum/Pressure
Pump
TYPICAL
P/N 460736 1. Intercooler straps

3. Disconnect water hoses from the rear left side

3. Install the Vacuum/Pressure Pump, P/N of intercooler.
460716, onto the intercooler water inlet fitting.
4. Pressurize the intercooler.
PRESSURE TEST
69 kPa (10 PSI)

If there is a pressure drop, first spray tool, hoses

and adapters with a soapy water solution to en-
sure they are not leaking.
Otherwise, replace the intercooler.
Intercooler Removal
1. Access the engine compartment and discon-
nect both air hoses from the intercooler. TYPICAL
1. Intercooler water inlet hose
2. Intercooler water outlet hose

4. Remove the intercooler

Intercooler Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following:
1. Ensure hoses are routed correctly and locking
ties are positioned at proper locations.

43
Engine
Intercooler

2. Run engine above 4000 RPM for 30 seconds

to push air out and allow intercooler to fill
completely.

44
 Engine
Exhaust System

Exhaust System

SERVICE TOOLS
Description Part Number Page

ADAPTER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460720 . . . . . . . . . . . . . . . . . . . . . . . . 89

ALIGNMENT SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460723 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460839 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460709 . . . . . . . . . . . . . . . . . . . . . . . . 24
BLIND HOLE BEARING PULLER SET . . . . . . . . . . . . . . . . . . . . . P/N 460760 . . . . . . . . . . . . . . . . . . . . . . . . 74
CAMSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 138
CRANKSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460729 . . . . . . . . . . . . . . . 164, 166, 173 4
DRIVE SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460745 . . . . . . . . . . . . . . . . . . . . . . . 129
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . 93, 109
ENGINE ALIGNMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460719 . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE LEAK DOWN TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460721 . . . . . . . . . . . . . . . . . . . . . . . 130
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . . . . . . . . . . . . . . . 93, 109
FLUSHING CONNECTOR ADAPTER . . . . . . . . . . . . . . . . . . . . . . P/N 460711 . . . . . . . . . . . . . . . . . . . . . . . . 51
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460714 . . . . . . . . . . . . . . . . . . . . . . . . 74
LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . . . . . . . 42
OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460708 . . . . . . . . . . . . . . . . . . . . 73, 122
OIL SEAL GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460730 . . . . . . . . . . . . . . . . . . . . . . . . 98
PISTON CIRCLIP INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460726 . . . . . . . . . . . . . . . . . . . . . . . 159
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 89
STARTER DRIVE SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460713 . . . . . . . . . . . . . . . . . . . . . . . . 74
SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 88
SUPERCHARGER GEAR HOLDER . . . . . . . . . . . . . . . . . . . . . . . P/N 460753 . . . . . . . . . . . . . . . . . . . . . . . 176
SUPERCHARGER OIL SPRAY NOZZLE TOOL . . . . . . . . . . . . . . P/N 460761 . . . . . . . . . . . . . . . . . . . . . . . 103
SUPERCHARGER RETAINING KEY . . . . . . . . . . . . . . . . . . . . . . P/N 460755 . . . . . . . . . . . . . . . . . . . . . . . 178
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460740 . . . . . . . . . . . . . . . . . . . 176, 178
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . . . . 120
TORX ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460739 . . . . . . . . . . . . . . . . . . . 177, 180
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . 43, 120
VALVE GUIDE PUSHER 6 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460759 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE GUIDE REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460758 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE SPRING COMPRESSOR CUP . . . . . . . . . . . . . . . . . . . . . P/N 460757 . . . . . . . . . . . . . . . . . . . . . . . 142
VALVE SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460724 . . . . . . . . . . . . . . . . . . . . . . . 142
WATER PUMP SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460731 . . . . . . . . . . . . . . . . . . . . 98, 100

SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,
108, 111, 125, 137, 141, 172,
179–180
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798

45
Engine
Exhaust System

SERVICE PRODUCTS
. . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179

46
 Engine
Exhaust System

Single Engine Non-CAT Models

16 N•m
(142 lbf•ft)
4
Loctite 567
(pipe sealant)

9.5 N•m
(84 lbf•ft)

4 N•m
4 N•m (35 lbf•ft)
(35 lbf•ft)

See ELECTRONIC FUEL

INJECTION (EFI)

23 N•m
(17 lbf•in)

Loctite 5150
(silicone sealant)

47
Engine
Exhaust System

Single Engine CAT Models

See
tightening sequence

23 N•m Loctite 243

(17 lbf•ft) 24 N•m
Loctite 243 (18 lbf•ft)
9.5 N•m
(84 lbf•in)

4 N•m
4 N•m (35 lbf•ft)
(35 lbf•ft)

23 N•m
(17 lbf•ft)

Loctite 5150
(silicone sealant)

48
 Engine
Exhaust System

Twin Engine Non-CAT Models

4 N•m
(35 lbf•in)
4 N•m
(35 lbf•in)

16 N•m
4
(142 lbf•in)

Loctite 567
(pipe sealant)

9,5 N•m
16 N•m (84 lbf•in)
(142 lbf•in)
Loctite 567 4 N•m
(pipe sealant) (35 lbf•in)
9,5 N•m 4 N•m
(84 lbf•in) (35 lbf•in)
See ELECTRONIC FUEL
INJECTION (EFI)
23 N•m
(17 lbf•ft)
4 N•m
(35 lbf•in) Loctite 5150
(silicone sealant)
23 N•m
(17 lbf•ft)
4 N•m See ELECTRONIC FUEL
(35 lbf•in) INJECTION (EFI)

Loctite 5150
(silicone sealant)

4 N•m
(35 lbf•in)

4 N•m
(35 lbf•in)

49
Engine
Exhaust System

Twin Engine CAT Models

See
tightening sequence

Loctite 567
(pipe sealant)
16 N•m
(142 lbf•in)

23 N•m Loctite 243

(17 lbf•ft) 24 N•m
Loctite 243 (18 lbf•ft)

4 N•m
See ELECTRONIC FUEL (35 lbf•in)
INJECTION (EFI) 4 N•m
9,5 N•m
(84 lbf•in) (35 lbf•in)

9,5 N•m
(84 lbf•in)
4 N•m
(35 lbf•in)

See ELECTRONIC FUEL

INJECTION (EFI)
23 N•m
4 N•m (17 lbf•ft)
(35 lbf•in)
Loctite 5150
(silicone sealant)

4 N•m
(35 lbf•in)

4 N•m
(35 lbf•in)

50
 Engine
Exhaust System

Maintenance
Exhaust System Flushing
Flushing the exhaust 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 particles
in water jackets, exhaust system, intercooler (su-
percharged engines) and hoses.
Exhaust system flushing should be performed
when the boat is not expected to be used further
the same day or when the boat is stored for any
extended time. 4
NOTICE TYPICAL
Failure to flush the system, when necessary, 1. Flushing connector
2. Quick connect adapter and flushing connector adapter (optional)
will severely damage the engine intercooler 3. Garden hose
or exhaust system. Make sure the engine op-
erates during the entire flushing procedure.
N O T E : The following tool is recommended when
a quick connect adapter is used to ease garden
WARNING hose installation.
Perform these operations in a well ventilated
area. Certain components in the engine com- Required Tool
partment may be very hot. Direct contact may
result in skin burn. So not touch any electrical Flushing Connector
part or jet pump area when engine is running. Adapter
P/N 460711
WARNING
When performing these operations while the
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.

1. Connect a garden hose to connector located at

the rear of boat on jet pump support. Do not
open water tap yet.
1. Quick connect adapter
2. Flushing connector adapter

2. To flush the exhaust system, start the engine

then immediately open the water tap.

NOTICE
Always start the engine before opening the
water tap. Open water tap immediately after
engine is started to prevent overheating.
Never run engine without supplying water to
the exhaust system when boat is out of water.

3. Run the engine about 20 seconds at a fast idle

between 4000 - 5000 RPM.

51
Engine
Exhaust System

NOTICE
Never run engine longer than 2 minutes.
Drive line seal has no cooling when boat is
out of water.

4. Ensure water flows out of jet pump while

flushing.
5. Close the water tap, then stop the engine.

NOTICE
Always close water tap before stopping the
engine.
TYPICAL
6. Disconnect the garden hose. 1. Exhaust manifold water outlet hose
2. Exhaust manifold fitting
NOTICE 4. Gently disconnect the hose from blow-by
Remove flushing connector adapter after op- valve.
eration (if used). 5. Unscrew exhaust clamp.

Procedures NOTICE
Muffler Do not use pneumatic or electric tools as
seizure of the fastener may occur.
Muffler Access
To access engine compartment, refer to Engine
Access, page 23.
Muffler Removal (Non-CAT Engines)
1. Disconnect exhaust hose from muffler outlet.

TYPICAL
1. Exhaust clamp

6. Move exhaust clamp onto exhaust manifold.

TYPICAL
1. Exhaust hose
2. Muffler

2. Cut locking tie securing water outlet hose (ex-

haust system) and blow-by hose.
3. Disconnect the upper water outlet hose from
the exhaust manifold.
TYPICAL
1. Opened exhaust clamp on exhaust manifold

7. Disconnect the exhaust gas temperature sen-

sor (EGTS) from muffler.

52
 Engine
Exhaust System

TYPICAL
1. Exhaust gas temperature sensor
2. Muffler 4
8. Cut locking ties and move or remove other ho-
ses as required to permit removal of muffler.
1. EGTS connector
Note the position of locking ties and hoses for 2. Exhaust gas temperature sensor
installation. 3. Muffler

Required Tool 4. Remove muffler and catalyst as an assembly.

Refer to C A T A L Y S T R E M O V A L .
Spring Installer/ N O T E : If the muffler and catalyst cannot be re-
Remover moved as an assembly due to space constraints
P/N 460748 on a twin, the cat must be raised up or completely
removed before the muffler can be removed from
9. Use the Spring Installer/Remover, P/N the CAT housing.
460748, to detach the muffler straps.
10. Move muffler backward to extract exhaust 5. Mark housing of catalyst assembly (CAT) for
manifold from exhaust pipe. reference before removal. Mark the muffler as
11. Remove the muffler from boat. well for proper alignment if the hose has to be
removed from the muffler.
Muffler Removal (CAT Models)
1. Loosen retaining clamps holding exhaust hose
to muffler.

1. Retaining clamp (rubber adapter to CAT)

2. Marks

6. Loosen the rubber adapter clamp on CAT side

and remove muffler with rubber adapter as an
1. Retaining clamps (Exhaust hose to muffler) assembly.
2. Remove exhaust hose.
3. Remove electrical connector of exhaust gas
temperature sensor (EGTS).

53
Engine
Exhaust System

TYPICAL
1. Hook-tool 1. Engine lifting ring
2. Spacer
7. Remove the muffler from boat. 3. Exhaust pipe fitting

Muffler Inspection (All Models) 6. Confirm the index mark on the exhaust pipe is
aligned with the index mark on the exhaust
NOTICE manifold.
Replace any defective parts.

Check muffler for:

– Cracks
– Corrosion
– Other damages
On Non-CAT Models:
– Brittle
– Hard
– Cracked TYPICAL
1. Exhaust manifold index mark
– Otherwise damaged 2. Exhaust pipe index mark

On CAT Models: 7. Tighten exhaust clamp.

– Brittle
– Hard NOTICE
– Otherwise damaged Do not use pneumatic or electric tools as
seizure of the fastener may occur.
Muffler Installation (Non-CAT Models)
N O T E : Observe the tightening torques on the TIGHTENING TORQUE
exploded views on the first pages.
Exhaust clamp 11 N·m (97 lbf·in)
With a new muffler, install the EGTS sensor. Refer
to E L E C T R O N I C F U E L I N J E C T I O N ( E F I ) . NOTICE
1. Place the muffler in hull. When installing exhaust hoses on all muffler/
2. Align the exhaust pipe flange to the exhaust resonator inlets and outlets ensure the
manifold. Rotate and move muffler so that the clamps are located between the bulges and
exhaust pipe flange makes perfect contact with do not overlap.
exhaust manifold.
3. Install exhaust clamp with the nut upward. 8. Install the muffler strap.
4. Tighten clamp loosely.
5. Using a 50mm (2 in) spacer (in this case a NOTICE
bolt), position the exhaust pipe. See following Do not rotate the muffler during strap installa-
illustration. tion. The use of soapy water solution on inner
side of muffler strap is recommended.

54
 Engine
Exhaust System

9. Install all other removed parts.

10. After installation, test run the engine while sup-
plying water to the exhaust system. Ensure
there is no water or exhaust gas leakage when
engine is running.
NOTICE
Never run engine without supplying water to
the exhaust system when the boat is out of
water.

Muffler Installation (CAT Models)

N O T E : Observe the tightening torques on the 4
exploded views on the first pages.
1. Retaining clamp (rubber adapter to muffler)
2. Muffler
NOTICE
Do not use pneumatic or electric tools as 3. Put a second retaining clamp onto the rubber
seizure of the fastener may occur. adapter and install muffler and rubber adapter
as an assembly onto the catalyst assembly.
With a new muffler, install the EGTS sensor. Refer N O T E : Push up against the machining ridge,
to E L E C T R O N I C F U E L I N J E C T I O N ( E F I ) . see following illustration.
1. Install the rubber adapter with retaining clamp
onto the muffler. Measure the dimension of the
projecting part of rubber adapter.

N O T E : Dimension must be between 41 -

44.5 mm (1 5/8 - 1 3/4 in). Check in all 4
quadrants!

4. Tighten the retaining clamp on rubber adapter

to catalyst assembly.

TIGHTENING TORQUE
Rubber adapter
9.5 N·m (84 lbf·in)
retaining clamps

NOTICE
2. Tighten the retaining clamp on rubber adapter
to muffler. When installing exhaust hoses on all muffler/
resonator inlets and outlets ensure the
TIGHTENING TORQUE clamps are located between the bulges and
do not overlap.
Rubber adapter
9.5 N·m (84 lbf·in)
retaining clamps 5. Install the exhaust hose with exhaust clamp.

55
Engine
Exhaust System

NOTICE
Ensure alignment marks have been re-
spected and that there is proper clearance
between muffler and all surrounding fiber-
glass and components.

6. Tighten the exhaust clamp.

TIGHTENING TORQUE
Exhaust clamp 4 N·m (35 lbf·in)
TYPICAL
7. Install all other removed parts. 1. Muffler
2. Rubber adapter
8. After installation, test run the engine while sup- 3. Clamps
plying water to the exhaust system. Ensure 4. Exhaust pipe
there is no water or exhaust gas leakage when
engine is running. 4. Remove exhaust pipe and the rubber adapter.
Exhaust Pipe Inspection
NOTICE
1. Inspect the exhaust pipe for:
When installing exhaust hoses on all muffler/
resonator inlets and outlets ensure the – Cracks
clamps are located between the bulges and – Flange damages
do not overlap. – Other damages
2. Replace the exhaust pipe as required.
Exhaust Pipe 3. Check if the rubber adapter is:
Exhaust Pipe Removal – Brittle
1. Remove the muffler. Refer to Muffler, page 52. – Hard
2. Disconnect the water inlet hose from the ex- – Otherwise damaged
haust pipe fitting. 4. Replace rubber adapter if necessary.
Exhaust Pipe Installation
1. Trace an index mark to locate the middle of the
bulge opening on the muffler.

TYPICAL
1. Water inlet hose
2. Exhaust pipe

3. Loosen rubber adapter clamps.

TYPICAL
1. Bulge
2. Middle of the opening

2. Install the rubber adapter on exhaust pipe. En-

sure rubber adapter is properly seated against
exhaust pipe shoulder.

56
 Engine
Exhaust System

TYPICAL
1. Exhaust pipe shoulder
2. Rubber adapter
4
N O T E : Do not use soap or lubricant to install TYPICAL
hose. 1. Middle of rubber identification band
2. Center index mark of the muffler bulge opening
3. Center the identification band on the rubber 8. Using a caliper, measure the distance between
adapter between both exhaust pipe marks. the exhaust pipe shoulder and the outside of
the muffler bulge.
9. Position the muffler to 95 mm ± 2 mm (3.74 in±
.079 in). Check the distance in several places.

TYPICAL
1. Identification band on rubber adapter
2. Retaining clamp
3. Exhaust pipe index marks
TYPICAL
4. Tighten retaining clamp. 1. Rubber adapter end
2. Outside of the muffler bulge
TIGHTENING TORQUE 3. A. 95mm ± 2mm (3.74 in ± .079 in)

Rubber adapter 93 N·m (84 lbf·in) 10. Tighten retaining clamp.

retaining clamp
TIGHTENING TORQUE
5. Slide the other clamp on the rubber adapter. Rubber adapter 9 N·m (80 lbf·in)
6. Insert the exhaust pipe into the muffler. retaining clamp
7. Align the center of the identification band on
the rubber adapter with the index mark previ- 11. Install muffler in vehicle. Refer to M U F F L E R
ously traced on the muffler. INSTALLATION.
Exhaust Manifold
Exhaust Manifold Access
To access the engine compartment refer to E N -
GINE INSTALLATION.

57
Engine
Exhaust System

Exhaust Manifold Removal

TIGHTENING TORQUE
1. Move the muffler rearwards to allow enough
room for removal. Refer to M u f f l e r R e m o v a l . Rubber adapter 9 N·m (80 lbf·in)
2. Disconnect the lower water outlet hose from retaining clamp
the aft end of the exhaust manifold.
3. Disconnect the cooling system supply hose
from underneath the front part of the exhaust
manifold.
4. Unscrew the exhaust manifold starting with the
lower screws.
N O T E : This will help to secure the manifold as
you remove the screws.

5. Remove the exhaust manifold from the boat.

Exhaust Manifold Inspection
1. Inspect exhaust manifold condition, pay atten-
tion for cracks or other damages.
2. Check contact surfaces and hose. Replace
TYPICAL — MANIFOL D TORQUE SEQUENCE
any defective part.
3. Inspect plane surfaces, ensure they are not 4. Install all other removed parts, refer to applica-
warped. ble exploded view for service products and
torques.
N O T E : Small deformations can be corrected by 5. After installation, test run the engine while sup-
grinding the surface with a fine sand paper. Lay
plying water to the flushing connector. Ensure
the sand paper on a plane surface and rub part
there is no water or exhaust gas leakage when
against oiled sand paper.
the engine is running.
4. Clean all metal components in a solvent.
NOTICE
Exhaust Manifold Installation Never run an engine without supplying water
Installation is essentially the reverse of removal to the exhaust cooling system when the boat
procedures. However, pay particular attention to is out of the water.
the following.
Resonator
NOTE: There is no gasket between cylinder
block and exhaust manifold. Resonator Access
To access engine compartment, refer to E N G I N E
1. Apply Loc-Tite 243, P/N 460790, onto the ACCESS.
threads of the screws.
Resonator Removal
Required Chemical 1. Disconnect both hoses from the resonator.
2. Remove the resonator retaining straps.
Loct-Tite 243
P/N 460790

2. To help hold the exhaust manifold while instal-

ling screws, first insert the manifold into the ex-
haust pipe then, install the upper front screw.
Continue with the remaining screws.
3. Tighten retaining clamp.

58
 Engine
Exhaust System

Catalyst (For CAT Models Only)

Catalyst Access
To access the engine compartment, refer to En-
gine Access, page 23.
Remove muffler. Refer to Muffler Removal (CAT
Models), page 53.
Catalyst Removal
TYPICAL N O T E : During the removal process, pay close
1. Hose from muffler
2. Resonator outlet hose attention to clamp placement and orientation.
3. Resonator strap Clamps must be in the same orientation to allow
access and avoid interference with other 4
3. Carefully remove the resonator from the en- components.
gine compartment.
All Engines
Resonator Inspection
1. Loosen retaining clamp holding the air intake
1. Visually inspect the resonator for:
tube.
– Deformation
– Cracks
– Other damage
2. Visually inspect the hoses and the retaining
straps for damage.
3. Replace any damaged or defective parts.
Resonator Installation
Installation is the reverse of the removal proce-
dures, however, pay attention to the following.
1. Remove the outlet hose from the exhaust
outlet.
2. Install the outlet hose onto the resonator.
3. Install the resonator in position while installing
the outlet hose onto the exhaust outlet. 1. Retaining clamp (air intake tube)
4. Install all other removed parts. 200 And 250 Engines
NOTICE 1. Loosen the retaining clamp holding the air in-
take hose to the throttle body.
Never run an engine without supplying water
to the exhaust cooling system when the boat
is out of the water.

5. After installation, test run the engine while sup-

plying water to the exhaust system. Ensure
there is no water or exhaust gas leakage when
the engine is running.
Heated Oxygen Sensor (HO2S)
Refer to ELECTRONIC FUEL INJECTION SYS-
TEM (EFI) for testing and replacement
procedures.

1. Retaining clamp (air intake to supercharger)

59
Engine
Exhaust System

All Engines
1. Remove air intake hose.
2. Loosen retaining clamps holding exhaust hose
to resonator inlet.

TYPICAL
1. Exhaust gas temperature sensor
2. Muffler

250 Engines
1. Loosen retaining clamp holding intercooler ex-
haust hose from intercooler.

1. Retaining clamp (exhaust hose to resonator inlet)

3. Loosen retaining clamps holding exhaust hose

to muffler.

1. Retaining clamp (intercooler)

2. Loosen retaining clamp holding intercooler ex-

haust hose from throttle body.

1. Retaining clamp (exhaust hose to muffler)

4. Remove exhaust hose.

5. Remove the exhaust gas temperature sensor
(EGTS) electrical connector.

TYPICAL — 150 NA SHOWN

1. Retaining clamp (throttle body)

3. Remove the intercooler exhaust hose.

4. Loosen the retaining clamp holding the inter-
cooler intake hose from the intercooler.

60
 Engine
Exhaust System

1. O2 sensor connector
4
2. Locking ties
1. Retaining clamp (intercooler intake hose)
2. Loosen retaining clamp and disconnect lower
5. Loosen the retaining clamp holding the inter- catalyst water supply hose on PORT side CAT
cooler intake hose from supercharger. housing.

1. Retaining clamp (lower catalyst water supply hose to CAT

housing)
1. Retaining clamp (intercooler to supercharger)
3. Loosen retaining clamp and disconnect upper
6. Remove the intercooler intake hose. catalyst water supply hose at exhaust
All Engines manifold.
1. Cut locking ties securing the two O2 sensor
connectors and disconnect them from harness.

1. Retaining clamp (upper catalyst water supply hose at exhaust

manifold)

1. O2 sensor connector
2. Locking ties

61
Engine
Exhaust System

4. Loosen retaining clamp and disconnect cata-

lyst water outlet hose on STBD side CAT
housing.

1. Retaining clamp (catalyst water outlet hose on CAT housing)

5. Loosen retaining clamp and disconnect cata- 1. Long 6 mm ball Allen socket
lyst vent outlet hose on STBD side CAT
housing. 7. Remove the plastic protective cap and loosen
the exhaust retaining clamp holding the cata-
lyst to the exhaust manifold.

NOTICE
Do not use pneumatic or electric tools as
seizure of the fastener may occur.

1. Retaining clamp (catalyst vent outlet hose on CAT housing)

6. Remove the two catalyst mounting bolts hold-

ing the center housing to the mounting bracket.
N O T E : A long 6 mm ball Allen socket is needed
to reach the socket head screws.
1. Exhaust retaining clamp

8. The catalyst can now be removed from the ve-

hicle as an assembly along with the muffler.

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 Engine
Exhaust System

N O T E : On some TWIN applications clearance 2. Apply Loc-Tite 243, P/N 460790, to the catalyst
could be a problem when removing the catalyst housing retaining screws.
and muffler as an assembly. If necessary the muf- 3. Tighten retaining screws to the following
fler can be removed from the catalyst tail housing specifications.
by loosening the “upper” hose retaining clamp and
hose which secures the muffler to the housing. TIGHTENING TORQUE
The muffler and hose can then be rotated and/or
pushed downwards off the tail housing in order to First tightening
6 N·m (53 lbf·in)
facilitate the removal. sequence
Second tightening
12 N·m (106 lbf·in)
sequence
Third tightening
sequence
24 N·m (212 lbf·in) 4
Fourth tightening
24 N·m (212 lbf·in)
sequence

Catalyst Installation
N O T E : Before tightening the CAT housing to
manifold and center housing to bracket make sure
the assembly is aligned (counterclockwise when
1. Catalyst
looking at the rear of the engine). This will raise
2. Muffler the muffler off of the stringer allowing clearance
3. O2 sensor for engine/muffler movement without contacting
4. O2 sensor
5. Water outlet hose
the vehicles stringer.
N O T E : If the muffler was removed from the as-
Catalyst Disassembly sembly during removal, make sure the rotation
and final orientation of the muffler allows for clear-
N O T E : Catalyst assemblies should never be dis- ance to the fiberglass pump box area in the rear
assembled unless direct catalyst repairs are and stringer/engine components in the front.
needed.
Installation is the reverse of removal. However
Remove retaining screws securing catalyst hous- pay attention to the following:
ing to:
– Head pipe assembly 1. Apply Loc-Tite 243, P/N 460790, to the bracket
– Cone tail exhaust assembly retaining screws.
Remove and discard O-ring and catalyst from cat- Required Chemical
alyst housing.
Catalyst Assembly Loc-Tite 243

N O T E : Always reassemble the catalyst housing P/N 460790

using NEW O-rings.
2. Install catalyst to bracket and torque screws to
Assembly is the reverse of disassembly. However specifications.
pay attention to the following:
TIGHTENING TORQUE
1. Tighten all retaining screws.
Bracket retaining 24 N·m (18 lbf·ft)
Required Chemical screw

Loc-Tite 243 3. Install the hose onto the catalyst and retaining
clamp and tighten to specification.
P/N 460790

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Engine
Exhaust System

TIGHTENING TORQUE
Retaining clamp 9.5 N·m (84 lbf·in)

4. Connect and tighten all hoses and clamps as

previously removed.
5. Reconnect the O2 sensor connectors and the
EGT connector.
N O T E : Hoses, cables and locking ties removed
during a procedure must be reinstalled as per fac-
tory standards.

6. Install all other removed parts.

7. After installation, test run the engine while sup-
plying water to the exhaust system. Ensure
there is no water or exhaust gas leakage when
the engine is running.

NOTICE
Never run engine without supplying water to
the exhaust system when the boat is out of
water.

64
 Engine
PTO Housing and Magneto

PTO Housing and Magneto

SERVICE TOOLS
Description Part Number Page

ADAPTER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460720 . . . . . . . . . . . . . . . . . . . . . . . . 89

ALIGNMENT SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460723 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460839 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460709 . . . . . . . . . . . . . . . . . . . . . . . . 24
BLIND HOLE BEARING PULLER SET . . . . . . . . . . . . . . . . . . . . . P/N 460760 . . . . . . . . . . . . . . . . . . . . . . . . 74
CAMSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 138
CRANKSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460729 . . . . . . . . . . . . . . . 164, 166, 173 4
DRIVE SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460745 . . . . . . . . . . . . . . . . . . . . . . . 129
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . 93, 109
ENGINE ALIGNMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460719 . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE LEAK DOWN TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460721 . . . . . . . . . . . . . . . . . . . . . . . 130
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . . . . . . . . . . . . . . . 93, 109
FLUSHING CONNECTOR ADAPTER . . . . . . . . . . . . . . . . . . . . . . P/N 460711 . . . . . . . . . . . . . . . . . . . . . . . . 51
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460714 . . . . . . . . . . . . . . . . . . . . . . . . 74
LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . . . . . . . 42
OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460708 . . . . . . . . . . . . . . . . . . . . 73, 122
OIL SEAL GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460730 . . . . . . . . . . . . . . . . . . . . . . . . 98
PISTON CIRCLIP INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460726 . . . . . . . . . . . . . . . . . . . . . . . 159
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 89
STARTER DRIVE SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460713 . . . . . . . . . . . . . . . . . . . . . . . . 74
SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 88
SUPERCHARGER GEAR HOLDER . . . . . . . . . . . . . . . . . . . . . . . P/N 460753 . . . . . . . . . . . . . . . . . . . . . . . 176
SUPERCHARGER OIL SPRAY NOZZLE TOOL . . . . . . . . . . . . . . P/N 460761 . . . . . . . . . . . . . . . . . . . . . . . 103
SUPERCHARGER RETAINING KEY . . . . . . . . . . . . . . . . . . . . . . P/N 460755 . . . . . . . . . . . . . . . . . . . . . . . 178
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460740 . . . . . . . . . . . . . . . . . . . 176, 178
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . . . . 120
TORX ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460739 . . . . . . . . . . . . . . . . . . . 177, 180
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . 43, 120
VALVE GUIDE PUSHER 6 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460759 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE GUIDE REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460758 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE SPRING COMPRESSOR CUP . . . . . . . . . . . . . . . . . . . . . P/N 460757 . . . . . . . . . . . . . . . . . . . . . . . 142
VALVE SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460724 . . . . . . . . . . . . . . . . . . . . . . . 142
WATER PUMP SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460731 . . . . . . . . . . . . . . . . . . . . 98, 100

SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,
108, 111, 125, 137, 141, 172,
179–180
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798

65
Engine
PTO Housing and Magneto

SERVICE PRODUCTS
. . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179

66
 Engine
PTO Housing and Magneto

PTO Housing and Magneto Diagram

67
Engine
PTO Housing and Magneto

Procedures 4. Disconnect the air intake hose at the throttle

PTO Housing body.
5. On supercharged models, remove the super-
PTO Housing Access charger. Refer to the S U P E R C H A R G E R .
1. Remove parts as required to access engine,
refer to Engine Access, page 23.
2. Turn the main battery cut-off switch to OFF
when working on the engine.

TYPICAL
1. Supercharger

6. Disconnect the CPS connector.

1. ON position

3. Move muffler rearwards. On CAT engines: Re-

move CAT assembly. Refer to Exhaust Sys-
tem, page 45.
4. Remove the jet pump, drive shaft and drive
shaft boot. Refer to P R O P U L S I O N .
5. Drain the engine oil. Refer to L U B R I C A T I O N
SYSTEM.
6. Drain the engine coolant. Refer to C O O L I N G
SYSTEM.
PTO Housing Removal
TYPICAL — CPS CONNECTOR
1. Remove the cylinder head cover. Refer to
CYLINDER HEAD. 7. Disconnect the magneto connector.
2. Insert the tube of the suction pump into the
lower area of the timing chain.
3. Siphon remaining oil out of the lower timing
chain case.

TYPICAL
TYPICAL 1. Magneto connector
1. Suction pump tube 2. ECM
2. Edge of cylinder block 3. Throttle body

68
 Engine
PTO Housing and Magneto

8. Place rags under the PTO housing to prevent 11. Remove LH rear engine support.
oil spillage.

Required Chemical

Pulley Flange Cleaner

P/N 460798

N O T E : Up to 250 ml (8 U.S. oz) of oil could flow

out when removing the PTO housing. If spillage
occurs, clean immediately with Pulley Flange
Cleaner, P/N 460798, to prevent oil stains. 4
9. Remove both rear engine support screws. TYPICAL
1. Engine support

12. Remove water pump housing, refer to C O O L -

ING SYSTEM.

TYPICAL — RIGHT SIDE OF VEHICLE

1. Rear engine support screw
TYPICAL
1. Water pump housing
N O T E : When removing the rear engine support
screws, secure the shims from each mount (as ap- 13. Remove PTO housing retaining screws.
plicable) in a separate bag, identified to the mount
position (LH or RH side). N O T E : Note the position of the CPS harness re-
taining clamp as indicated in the following illustra-
tion for re-installation.

TYPICAL — L EFT SIDE OF VEHICLE

1. Rear engine support screw

10. Slightly lift aft end of engine and insert a safely

block under the engine to secure it in this
position.

69
Engine
PTO Housing and Magneto

PTO Housing Inspection

1. Inspect the PTO housing for cracks or any oth-
er damage. Replace if necessary.
2. Inspect the needle bearing used to support the
starter drive shaft in the PTO housing.

N O T E : Clean all disassembled metal compo-

nents in a non-ferrous metal cleaner.
3. Inspect oil strainer for contaminants, debris or
other particles. Clean as required.

1. PTO housing
2. CPS harness retaining clam
3. CPS

14. Remove PTO housing from engine.

NOTICE
To prevent damaging contact surface, be
sure to use prying lugs to separate PTO
housing from engine.

N O T E : Carefully separate PTO housing from en-

gine using two flat screwdrivers prying equally on TYPICAL
opposite sides of the housing and at the same 1. PTO oil strainer
time. Proceed slowly to prevent starter drive
spring discs and thrust washer from falling down PTO Housing Installation
into bilge area. For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Apply lubricants, sealers or thread locker as
specified in exploded view.
2. Apply torques as specified in exploded view.
3. Install starter drive. Refer to S T A R T E R
DRIVE INSTALLATION.
4. Install a new PTO housing gasket.
5. Rotate the oil/water pump shaft to align the
pump shaft with the balance shaft.
6. Align the starter drive shaft with the PTO hous-
ing needle bearing.
7. Install the PTO housing.

TYPICAL
1. Spring discs
2. Thrust washer
3. Starter drive

15. Remove the PTO housing gasket. Discard the

gasket.

70
 Engine
PTO Housing and Magneto

4
TYPICAL
1. CPS harness retaining clamp
TYPICAL
1. Pay attention the gasket remains properly positioned on this 9. Install the PTO housing screws finger tight,
surface then torque them as per following table and se-
8. Refer to the following illustration to identify the quence numbered in the illustration.
locations of the various housing screws.
PTO HOUSING INSTALLATION
SCREW
GASKET PRODUCT
TORQUE
LOCTITE 243, 9 N·m (7 lbf·ft)
NEW
P/N 460790

1. Screws M6x35
2. Screws M6x85

N O T E : Install the CPS harness retaining clamp

at the position noted during the PTO housing
removal. PTO HOUSING TORQUE SEQUENCE

10. Reinstall LH engine support as per following

table.
LH ENGINE SUPPORT INSTALLATION
PRODUCT TORQUE
LOCTITE 243, P/N 23 N·m (17 lbf·ft)
460790

11. Remove the safety block from under the

engine.
12. Install both rear engine support screws
loosely.

71
Engine
PTO Housing and Magneto

13. Align the engine. Refer to Engine Alignment, Required Chemical

page 24.

NOTICE Pulley Flange Cleaner

An engine alignment procedure must be car- P/N 460798
ried out to ensure proper engine alignment or
severe component damage may occur.
N O T E : Take note of seal position and orientation
of Oetiker clamp for installation.
14. Install all remaining parts, reconnect hoses
and electrical connectors. Refer to applicable 2. Remove the Oetiker clamp retaining the seal to
service manual sections for procedures and the PTO housing.
specific details (torques, service products or
instructions).
15. Refill the engine oil. Refer to LUBRICATION
SYSTEM.
16. Refill the engine coolant. Refer to COOLING
SYSTEM.
PTO Seal
PTO Seal Inspection
1. Inspect the PTO seal on the PTO housing. If
brittle, hard or damaged, or if you see a sign of
oil leakage, replace it.
2. Inspect ball bearing within PTO seal for exces-
sive play and smooth operation.
3. Replace PTO seal if oil seal or ball bearing is
damaged. TYPICAL
1. Oetiker clamp
2. PTO seal

3. Pull the seal from the PTO housing.

PTO Seal Installation
1. Insert a NEW Oetiker clamp over the seal.
2. Push seal onto PTO housing. Be sure to align
seal and clamp as noted at removal.
NOTICE
When installing the PTO seal onto super-
charged engines, make sure to position the
Oetiker clamps as illustrated.

TYPICAL
1. PTO seal

PTO Seal Removal

1. Place rags under PTO housing to prevent spill-
age. If spillage occurs, clean immediately with
Pulley Flange Cleaner, P/N 460798, to prevent
oil stains.

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 Engine
PTO Housing and Magneto

REQUIRED TOOL

Impeller Remover/
Installer
P/N 460728

NOTICE
Apply engine oil to the removal tool to protect
the seal located within the PTO coupling.

TYPICAL
1. Oetiker clamps

3. Crimp the Oetiker clamp.

REQUIRED TOOL

OETIKER PLIERS
P/N 460708

PTO Coupling TYPICAL — TURN CLOCKWISE TO REMOVE

1. Impeller removal tool

PTO Coupling Inspection

1. Inspect seal within coupling, if it is brittle,
cracked or hard, replace it.
2. Check coupling for worn or damaged splines.
3. Replace as required.
Starter Drive Bearings

1. PTO Coupling
2. Seal
3. Stop sleeve

PTO Coupling Removal

1. Lock the crankshaft. Refer to CYLINDER
BLOCK for the procedure.
2. Remove the PTO seal. Refer to PTO Seal Re- TYPICAL — PTO HOUSING
1. Starter drive bearing
moval, page 72.
3. Unscrew the PTO coupling from the
crankshaft.

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Engine
PTO Housing and Magneto

Stator
Stator Output Voltage Test
1. Disconnect the magneto connector.

TYPICAL — CYLINDER BLOCK

1. Starter drive bearing
TYPICAL
1. Magneto connector
Starter Drive Bearing Removal 2. ECM
1. Remove PTO housing. Refer to PTO Housing 3. Throttle body
Removal, page 68.
2. Install the following harness adapter onto the
2. Unscrew the coupling from the crankshaft.
magneto connector.
REQUIRED TOOL N O T E : Do not connect the magneto harness
adapter to the vehicle harness connector.
BLIND HOLE BEAR-
ING PULLER SET REQUIRED TOOL
P/N 460760
3–PIN MAGNETO
Starter Drive Bearing Installation HARNESS
ADAPTER
1. Grease the starter drive bearing using Isoflex
Grease Topas NB 52, P/N 460783. P/N 460750

REQUIRED CHEMICAL 3. Start the engine.

4. Connect a multimeter between each pair of
ISOFLEX GREASE TOPAS NB 52 YELLOW wires as per the following table.
Measure the voltage between each pair of
P/N 460783 wires.
2. Install the starter drive bearing into the PTO
housing or into the cylinder block.

REQUIRED TOOLS

STARTER DRIVE
SEAL PUSHER
P/N 460713

HANDLE
P/N 460714
TYPICAL
1. Connect adapter to magneto connector
2. Leave vehicle harness disconnected

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 Engine
PTO Housing and Magneto

5. Read voltage as per the following table.

STATOR OUTPUT VOLTAGE

TEST VOLTAGE
ENGINE TERMINAL (AC)
SPEED
1 and 2
Approx. 50
4000 RPM 1 and 3
Vac
2 and 3

6. If voltage is lower than specification, carry out

a STATOR CONTINUITY TEST and a STA- TYPICAL — STATOR CONTINUITY TEST
4
1. Connector adapter to magneto connector
TOR INSULATION TEST. Refer to STATOR 2. Leave vehicle connector disconnected
CONTINUITY TEST and STATOR INSULA-
TION TEST. 4. Read resistance.
Stator Continuity Test STATOR CONTINUITY TEST
1. Disconnect the magneto connector. RESISTANCE
TERMINAL 20 °C
@2 C ( 6 8 °F
F)
1 and 2
1 and 3 0.1–1 Ω
2 and 3

5. If any result is out of specification, replace the

stator.
Stator Insulation Test
1. Disconnect the magneto connector.

TYPICAL
1. Magneto connector
2. ECM
3. Throttle body

2. Install the following harness into the magneto

connector.

N O T E : Do not connect the magneto harness

adapter to the vehicle harness connector.

REQUIRED TOOL

3–PIN MAGNETO TYPICAL

HARNESS 1. Magneto connector
ADAPTER 2. ECM
3. Throttle body
P/N 460750
2. Install the following harness into the magneto
3. Connect a multimeter between each pair of connector.
YELLOW wires. N O T E : Do not connect the magneto harness
adapter to the vehicle harness connector.

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Engine
PTO Housing and Magneto

REQUIRED TOOL

3–PIN MAGNETO
HARNESS
ADAPTER
P/N 460750

3. Set the multimeter to Ω.

4. Connect multimeter between any YELLOW
wire and engine ground.

TYPICAL
1. Screws
2. Holding plate

3. Remove the stator retaining screws.

4. Remove the stator from the PTO housing.

STATOR INSULATION TEST

1. Connector adapter to magneto connector
2. Leave vehicle harness disconnected

5. Read resistance.
STATOR INSULATION TEST
RESISTANCE
TERMINAL 20 °C
@2 C ( 6 8 °F
F)
Any YELLOW wire and
∞ (open circuit)
engine ground
TYPICAL
6. If there is a resistance or continuity to engine 1. Stator screws
ground, the stator coils and/or the wiring is 2. Stator
grounded and needs to be repaired or
replaced. Stator Installation
Stator Removal 1. For installation, reverse the removal proce-
dure. Pay attention to the following during
1. Remove PTO housing. Refer to PTO Housing
installation.
Removal, page 68.
2. Remove the stator cable holding plate from the N O T E : The position of the stator in the PTO
PTO housing. housing determined by a key on the stator and a
notch in the magneto housing.

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 Engine
PTO Housing and Magneto

TRIGGER WHEEL AND RING GEAR

INSPECTION.
4. Remove an discard the rotor retaining screws.
5. Pull the rotor, trigger wheel and ring gear off
the end of the crankshaft.

TYPICAL 4
1. Notch for stator

2. Place the stator cable rubber grommet in the

notch provided in the PTO housing.

TYPICAL
1. Rotor retaining screw
2. Rotor
3. Trigger wheel
4. Ring gear

Rotor, Trigger Wheel and Ring Gear

Inspection
Inspect ring gear for damages, especially for worn,
cracked, or broken teeth.
Inspect rotor and trigger wheel condition. Pay par-
ticular attention to the inside of the rotor for:
TYPICAL – Cracks
1. Stator cable grommet
– Rub marks
3. Apply threadlocker and torque stator and cable – Discoloration
holding plate screws as per following table. Replace parts if necessary.
STATOR INSTALLATION Check the trigger wheel for bent teeth using the
following procedure.
TORQUE (STATOR
PRODUCT AND CABLE 1. Install a dial indicator onto the crankcase
HOLDING PLATE) casting.
2. Position the gauge on a tooth and set it to zero
LOCTITE 243, P/N 9 N·m (80 lbf·in) (0).
460790
N O T E : Be sure to lock the indicator dial to pre-
4. Install the PTO housing. Refer to PTO Housing vent movement of the dial during the remainder of
Installation, page 70. the procedure.
Rotor, Trigger Wheel and Ring Gear 3. Draw a line on the tooth to indicate it as the first
Rotor, Trigger Wheel and Ring Gear Removal tooth measured (reference tooth).
4. Gently lift the gauge contact point off the tooth
1. Lock the crankshaft. Refer to CYLINDER
and rotate the rotor to the next tooth.
BLOCK.
2. Remove the PTO housing. Refer to PTO Hous- N O T E : When lifting contact point off the tooth for
ing Removal, page 68. rotor rotation, be careful not to move gauge posi-
3. Inspect the Rotor, Trigger Wheel and Ring tion or test readings taken on next tooth will not be
Gear for bent teeth. Refer to ROTOR, accurate with reference to the reference tooth.

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Engine
PTO Housing and Magneto

5. Gently set the gauge contact point on the next

tooth and read the dial indicator.
6. Repeat this procedure taking a reading at each
tooth.
7. Recheck reading on reference tooth to ensure
gauge has not changed position (gauge should
still read zero).

TRIGGER WHEEL TEETH INSPECTION

MAXIMUM ALLOWABLE DIFFERENCE
0.15 mm (.006 in)
TYPICAL
1. Location pin
2. Location pin hooks

2. Install new OEM rotor screws and torque them

as per the following table.

ROTOR RETAINING SCREWS

INSTALLATION
TORQUE
(CRISS FINAL
PARTS CROSS TORQUE
PATTERN)

NEW OEM 15 N·m (133

lbf·in) Additional 50
rotor screws

TYPICAL
NOTICE
1. Trigger wheel Always install NEW OEM screws with pre-ap-
2. Dial indicator
plied thread locker. These are stretch screws
that are one time use only. Failure to replace
N O T E : If the reading exceeds the maximum al- the rotor screws may lead to engine damage
lowable difference, straighten the tooth or replace and failure.
the trigger wheel.
Starter Drive
Rotor, Trigger Wheel and Ring Gear
Installation Starter Drive Removal
For installation, reverse the removal procedure. 1. Remove the PTO housing and ring gear. Refer
Pay attention to the following during installation. to PTO Housing Removal, page 68 and Rotor,
Trigger Wheel and Ring Gear Removal, page
1. Align the ring gear and trigger wheel onto the
77.
crankshaft using the location pin on the
2. Remove the starter drive.
crankshaft.

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 Engine
PTO Housing and Magneto

1. Position the spring discs and thrust washer on-

to the starter drive shaft as per following
illustration.

TYPICAL
4
1. Starter drive
TYPICAL
NOTICE 1. Spring discs
2. Thrust washer
Be careful not to lose the spring discs and 3. Starter drive
thrust washer located in the starter drive
2. Oil the shaft, gear teeth and splines with en-
shaft.
gine oil.

REQUIRED CHEMICAL

Isoflex Grease Topas NB 52

P/N 460783

3. Apply Isoflex Grease Topas NB 52, P/N

460783, onto the starter drive bearings located
in the cylinder block and in the PTO housing.

TYPICAL
1. Spring discs
2. Thrust washer
3. Starter drive

Starter Drive Inspection

Inspect all starter drive parts for excessive wear,
cracks and other defects. Pay attention to the con-
dition of the drive gear teeth.
TYPICAL - CYLINDER BL OCK
Ensure proper operation of the starter drive sprag 1. Starter drive bearing
clutch.
If any part of the assembly shows signs of abnor-
mal wear, cracks, broken teeth or malfunction
(sprag clutch), replace the faulty part.
Starter Drive Installation
For installation, reverse the removal procedure.
However, pay attention to the following.

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Engine
PTO Housing and Magneto

TYPICAL - PTO HOUSING

1. Starter drive bearing

NOTICE
Be sure not to forget the spring discs and
thrust washer on the starter drive shaft during
assembly.

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Lubrication System

Lubrication System

SERVICE TOOLS
Description Part Number Page

ADAPTER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460720 . . . . . . . . . . . . . . . . . . . . . . . . 89

ALIGNMENT SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460723 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460839 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460709 . . . . . . . . . . . . . . . . . . . . . . . . 24
BLIND HOLE BEARING PULLER SET . . . . . . . . . . . . . . . . . . . . . P/N 460760 . . . . . . . . . . . . . . . . . . . . . . . . 74
CAMSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 138
CRANKSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460729 . . . . . . . . . . . . . . . 164, 166, 173 4
DRIVE SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460745 . . . . . . . . . . . . . . . . . . . . . . . 129
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . 93, 109
ENGINE ALIGNMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460719 . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE LEAK DOWN TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460721 . . . . . . . . . . . . . . . . . . . . . . . 130
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . . . . . . . . . . . . . . . 93, 109
FLUSHING CONNECTOR ADAPTER . . . . . . . . . . . . . . . . . . . . . . P/N 460711 . . . . . . . . . . . . . . . . . . . . . . . . 51
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460714 . . . . . . . . . . . . . . . . . . . . . . . . 74
LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . . . . . . . 42
OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460708 . . . . . . . . . . . . . . . . . . . . 73, 122
OIL SEAL GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460730 . . . . . . . . . . . . . . . . . . . . . . . . 98
PISTON CIRCLIP INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460726 . . . . . . . . . . . . . . . . . . . . . . . 159
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 89
STARTER DRIVE SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460713 . . . . . . . . . . . . . . . . . . . . . . . . 74
SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 88
SUPERCHARGER GEAR HOLDER . . . . . . . . . . . . . . . . . . . . . . . P/N 460753 . . . . . . . . . . . . . . . . . . . . . . . 176
SUPERCHARGER OIL SPRAY NOZZLE TOOL . . . . . . . . . . . . . . P/N 460761 . . . . . . . . . . . . . . . . . . . . . . . 103
SUPERCHARGER RETAINING KEY . . . . . . . . . . . . . . . . . . . . . . P/N 460755 . . . . . . . . . . . . . . . . . . . . . . . 178
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460740 . . . . . . . . . . . . . . . . . . . 176, 178
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . . . . 120
TORX ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460739 . . . . . . . . . . . . . . . . . . . 177, 180
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . 43, 120
VALVE GUIDE PUSHER 6 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460759 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE GUIDE REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460758 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE SPRING COMPRESSOR CUP . . . . . . . . . . . . . . . . . . . . . P/N 460757 . . . . . . . . . . . . . . . . . . . . . . . 142
VALVE SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460724 . . . . . . . . . . . . . . . . . . . . . . . 142
WATER PUMP SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460731 . . . . . . . . . . . . . . . . . . . . 98, 100

SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,
108, 111, 125, 137, 141, 172,
179–180
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798

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Engine
Lubrication System

SERVICE PRODUCTS
. . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179

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Lubrication System

Engine Block Lubrication System

83
Engine
Lubrication System

Magneto Lubrication System

9 N•m
(80 lbf•in) Engine oil

9 N•m
(80 lbf•in)
NEW

Engine oil 9 N•m

(80 lbf•in)

9 N•m
(80 lbf•in)
3 N•m
(27 lbf•in)
Left hand Loctite 243
threads NEW

250 engine
NEW Loctite 243
Engine
oil

19 N•m 11 N•m
(168 lbf•in) (97 lbf•in)

Engine oil

Loctite 5910 9 N•m

Engine oil (80 lbf•in)

13 N•m Loctite 243

(115 lbf•in)
Loctite 243
NEW = Component must be replaced when removed.

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 Engine
Lubrication System

Engine Lubrication Circuit

LEGEND

Pressurized oil
Scavenged oil
Blow-by gas

1. Oil dipstick 8. From oil filter

2. Rocker arm (intake) 9. Piston cooling
3. Rocker arm (exhaust) 10. Connecting rod
4. Hydraulic valve lifter 11. Balance shaft
5. Camshaft 12. Crankshaft
6. Piston pin 13. Oil pan
7. Into PTO housing

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Engine
Lubrication System

Lubrication System Diagram

1. To air intake silencer 8. Cylinder head 15. Piston pin 22. Oil pressure switch 29. Oil tank

2. Rocker arm (intake) 9. Blow-by valve 16. Connecting rod 23. Balance shaft 30. Oil strainer (scavenge
pump)

3. Rocker arm (exhaust) 10. Supercharger (if so 17. Piston cooling 24. PTO housing 31. Oil drainage (PTO
equipped) housing)

4. Rocker arm axle 11. Oil filter 18. Oil spray nozzle 25. Pressure pump 32. Oil cooler

5. Camshaft 12. Hydraulic chain 19. Drive shaft 26. Pressure relief valve 33. Scavenge of oil and
tensioner blow-by gas

6. Pressure relief valve 13. Supercharger bearing 20. Crankshaft 27. Oil strainer 34. Oil filler cap

7. Oil separator 14. Friction clutch 21. PTO seal 28. Scavenge pump

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 Engine
Lubrication System

Maintenance N O T E : If the boat is out of water, link a garden

Engine Oil hose to the hose adapter. Refer to Exhaust Sys-
tem Flushing, page 51.
Recommended Oil
Use XPS 4-Stroke Synth Blend Oil (Summer), P/N NOTICE
460787. When the boat is out of the water:
Naturally Aspirated Engine – Never run the engine without supplying
If the recommended XPS™ engine oil is not avail- water to the exhaust system.
able, use a 5W40 or 10W40 engine oil meeting – Never run the engine longer than 2 mi-
the requirements for API service classification SM, nutes when the boat is out of the water.
SL or SJ. Always check the API service label cer- – The driveline seal has no cooling when
tification on the oil container, it must contain at the boat is out of the water.
least one of the above standards. 4
2. Let the engine idle for 30 seconds.
Supercharged Intercooled Engine 3. Stop the engine.
If XPS™ engine oil is not available, use a 10W40 4. Access the engine compartment.
mineral engine oil compatible with wet clutches. 5. Wait at least 30 seconds for the oil to setting in
the engine.
N O T E : The XPS engine oil has been thoroughly 6. Pull the oil dipstick out and wipe clean.
tested to be free of any additives that could impair
the functionality of the supercharger clutch. WARNING
Engine oil may be hot. Certain components in
NOTICE the engine compartment may be very hot. Di-
Never use synthetic oil. This would impair the rect contact may result in skin burn.
proper operation of the supercharger clutch.
Do not add any additives to the recom-
mended oil. Mineral oils not recommended by 1
BRP may also contain additives (friction
modifiers) that may cause inappropriate slip- 2
page of the supercharger and eventually lead
to premature wear. For this reason, XPS Syn-
thetic Blend oil (Summer Grade) or a BRP ap-
proved equivalent are the only recommended
oils. Use of any oil not recommended by BRP
may void BRP’s limited warranty.

Oil Level Verification TYPICAL

1. Dipstick
NOTICE 2. Oil cap
Check level frequently and refill if necessary. 7. Reinstall the oil dipstick completely.
Do not overfill. If the engine oil is over filled 8. Remove the dipstick and read the oil level. The
the engine will smoke and experience re- oil level should read between the FULL and
duced power. Operating the engine with an ADD marks on the dipstick. Otherwise, add oil
improper oil level may severely damage the until its level is between marks as required.
engine. Wipe off any spillage.

Check the oil level as follows.

N O T E : Is is of the utmost importance to follow

this procedure in order to obtain an accurate read-
ing of the engine oil level.

1. Start and warm-up the engine.

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Engine
Lubrication System

NOTICE
When the boat is out of the water:
– Never run the engine without supplying
water to the exhaust system.
– Never run the engine longer than 2 mi-
nutes when the boat is out of the water.
– The driveline seal has no cooling when
the boat is out of the water.
1. Full
2. Add N O T E : To properly position the suction pump
3. Operating range hose is located at the proper height to siphon oil, it
is suggested to put some electrical tape on hose
9. To add oil, unscrew oil cap.
at 475 mm (18-11/16 in) from its end. Then, insert
10. Place a funnel into the oil filler neck opening
the hose until you reach the tape.
and add the recommended oil to the proper
level. Do not overfill. 5. Pull suction pump hose out of dipstick tube.
Oil Change 6. Fully depress the throttle lever and HOLD it
while cranking engine for 10 seconds. Siphon
N O T E : Oil and oil filter must be replaced at the oil again. Repeat the crank-siphon cycle 2 - 3
same time. Oil change and oil filter replacement times.
should be done with a warm engine. 7. Refill engine with the recommended oil. Refer
to Recommended Oil, page 87.
1. Bring the engine to normal operating 8. Reinstall the oil filler cap and the dipstick.
temperature. 9. Replace the oil filter. Refer to O I L F I L T E R .
NOTICE Oil Filter
When the boat is out of the water: Oil Filter Removal
– Never run the engine without supplying 1. Remove the oil filter screw.
water to the exhaust system. 2. Remove the oil filter cover.
– Never run the engine longer than 2 mi- 3. Remove the oil filter.
nutes when the boat is out of the water.
– The driveline seal has no cooling when
the boat is out of the water.

2. 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.
3. Remove oil filler cap and dipstick.
WARNING
Engine oil may be hot. Certain components in
the engine compartment may be very hot. Di-
rect contact may result in skin burn.
TYPICAL
REQUIRED TOOL 1. Oil filter screw
2. Oil filter cover
3. Oil filter
Suction Pump
P/N 460736 REQUIRED CHEMICAL

4. Use Suction Pump, P/N 460736, to siphon the Pulley Flange Cleaner
engine oil through the dipstick tube.
P/N 460798

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4. Place rags in filler area to prevent spillage. If Inspection

spill-age occurs, clean immediately using Pul- Engine Oil Pressure
ley Flange Cleaner, P/N 460798, to prevent
Oil Pressure Test Requirement
stains.
1. Bring the engine to normal operating tempera-
Oil Filter Inspection ture (N.O.T.)
Check oil filter cover O-rings and oil filter screw O-
ring. Replace the O-rings if necessary. WARNING
Certain components in the engine compart-
Check and clean the oil filter inlet and outlet area
ment may be very hot. Direct contact may re-
for dirt and other contaminations.
sult in skin burn. Do not touch any electrical
parts or jet pump area when engine is
running.
4
NOTICE
When the boat is out of the water:
– Never run the engine without supplying
water to the exhaust system.
– Never run the engine longer than 2 mi-
nutes when the boat is out of the water.
– The driveline seal has no cooling when
the boat is out of the water.

REQUIRED TOOLS Description

1. Inlet hose from the oil pump to the oil filter Pressure Gauge
2. Outlet bore to the engine oil providing system
P/N 460736
Oil Filter Installation
For installation, reverse the removal procedure. Adapter Hose
Pay attention to the following details during
installation. P/N 460720

1. Install a new oil filter.

2. Install the O-ring onto the oil filter cover. N O T E : A 1/8 NPT pipe extension may ease the
3. Apply engine oil into the filter ring, filter cover installation.
O-rings and onto the oil filter screw O-ring. Oil Pressure Specifications
REQUIRED CHEMICAL Use the following table to compare the oil pressure
at different RPM.
Super Lube Grease OIL PRESSURE
P/N 460784 448 kPa — 648 kPa
Idle (cold) (65 PSI — 94 PSI for a
N O T E : In salt water areas it is recommended to very short time)
coat the mating surfaces of the covers with Super
Lube Grease, P/N 460784. Idle (at 80°C (176°F)) Min. 228 kPa (33 PSI)

TORQUE 400 kPa — 496 kPa

4000 — 7500 (58 PSI — 72 PSI)
Oil filter screw 9 N·m (80 lbf·in)
Test at the Oil Pressure Switch Location
1. Remove the oil pressure switch and install the
gauge.

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Troubleshooting
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and it
should not be assumed to list all possible
problems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to EN-
GINE MANAGEMENT.
LOW OR NO ENGINE OIL PRESSURE
1. Oil level too low.
– Refill engine oil
– Check for high oil consumption
– Check for oil leaks (oil leaking out of leak in-
TYPICAL — PRESSURE SWITCH L OCATION dicator hole, gaskets, oil seal or O-rings).
1. Remove the oil pressure switch and install the gauge here
Repair or replace as necessary.
2. Ground OPS to engine. 2. Oil pressure switch defective
3. Plug OPS to harness.
4. Start engine. – Check and replace as necessary
5. While engine is running, unplug OPS from 3. Oil filter clogged
harness.
6. Read oil pressure at different RPM ranges. – Replace the engine oil and the engine oil fil-
Compare those numbers to the Oil Pressure ter at the same time
table found in Oil Pressure Specifications, 4. Oil pressure regulator valve sticks open, or
page 89. spring load is too small
7. Reinstall oil pressure switch.
– Clean oil regulator piston and its bore. Re-
Test at the Cylinder Head Location place as necessary
The oil pressure may be measured from the cylin- – Measure the spring free length. Replace if
der head if necessary. out of specification
5. Oil pump(s) worn or damaged
1. Remove plug located on cylinder head and in-
stall gauge. – Check oil pump rotors and its bore for wear
limits. Replace if out of specification
6. Engine oil strainers are clogged
– Remove and clean engine oil strainers
7. Heavy wear on plain bearings
– Check the radial clearance of the plain
bearings. Replace if out of specification
HIGH OIL CONSUMPTION
1. Oil in breathing system
– Check if breather V-ring is brittle, hard or
damaged. Replace the V-ring if necessary
2. Valve stem seals worn or damaged.
TYPICAL — INSTALLATION AT CYL INDER HEAD – Replace valve stem seals.
1. Remove the plug and install the gauge here
3. Piston rings worn out (blue colored exhaust
2. Start the engine and read the pressure at dif- smoke)
ferent RPM ranges according to the table
found in Oil Pressure Specifications, page 89. – Replace piston rings
3. Reinstall the plug.

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OIL CONTAMINATION
1. Water ingestion through drive shaft and float-
ing ring.
– Check if water is leaking between drive
shaft and floating ring. Repair or replace
defective parts. Refer to PTO HOUSING
AND MAGNETO.
– Change engine oil and filter
2. Oil seal and rotary seal on water pump shaft
leaking.
– Replace oil seal and water pump shaft
assembly 4
– Change engine oil and oil filter.
3. Cylinder head gasket leaking
– Replace cylinder head gasket and tighten
cylinder head with recommended torque.
– Change the engine oil and engine oil filter
4. Cylinder head screws not properly tightened.
– Retighten the screws to the recommended
torque.
– Change the engine oil
5. Oil cooler O-rings are leaking.
– Replace the O-rings
– Change the engine oil and engine oil filter
6. Cylinder block or cylinder head casting is
leaking.
– Check for internal cracks in casting. Re-
place damaged components.
– Change the engine oil and engine oil filter

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Procedures ENGINE NOT RUNNING

Oil Pressure Switch (OPS)
RESIST
Oil Pressure Switch Operation TEST PROBES ANCE (Ω)
The switch threshold value to send a signal of low
oil pressure may vary from a minimum of 180 kPa OPS Close to 0
(26 PSI) to a maximum of 220 kPa (32 PSI). Connector Engine ground (normally
(pin 1) closed switch)

ENGINE RUNNING
RESIST
TEST PROBES ANCE (Ω)
Out of Limit —
high (OL)
when
OPS
pressure
Connector Engine ground
reaches 180
(pin 1)
kPa (26 PSI)
and 220 kPa
(32 PSI)

TYPICAL
1. OPS

Oil Pressure Switch Inspection

First, carefully check the condition of the connec-
tor terminals. Clean to remove dirt and corrosion
that could affect proper operation of the OPS.
I M P O R T A N T : Do not apply dielectric grease on
the terminal.

Before checking the function of the OPS, an oil

pressure test has to be performed to be sure the
oil pressure is not in fault.
When the engine oil pressure tests good but the
OIL message in the information center is present If the resistance values are incorrect, replace
and the beeper sounds: OPS.
– Ensure the OPS connector is plugged into the If the values are correct, check the continuity of
switch. the wiring harness.
– Check the resistance of the OPS while engine
is off and while engine is running Oil Pressure Switch Circuit Continuity Test
Oil Pressure Switch Resistance Test 1. Disconnect the ECM connector A from the
ECM. Install the ECM connector onto the appli-
1. Disconnect the connector from the OPS. cable ECM adapter tool and test for continuity
2. Use a multimeter to check the resistance as of circuit as per model.
shown. 2. If continuity test failed, repair or replace the
connector and wiring between ECM connector
and OPS.

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OPS RESIST REQUIRED CHEMICAL

ECM ANCE @
CONNEC
ADAPTER 20°C (68°F)
TOR Loc-Tite 243
Close to 0 Ω P/N 460790
Pin 1 A-6 (continuity)
2. Install the oil pressure switch.
REQUIRED TOOLS 3. Torque the oil pressure switch to specification.

TORQUE
ECM Adapter Tool
Oil pressure switch 9 N·m (80 lbf·in)
P/N 460762
PTO Oil Strainer 4
Fluke 115 Multimeter
PTO Oil Strainer Removal
P/N 460735 1. Remove the engine oil. Refer to Oil Change,
page 88.
OPS RESIST 2. Remove the PTO housing. Refer to PTO Hous-
ECM ANCE @ ing Removal, page 68.
CONNEC
ADAPTER 20°C (68°F) 3. Remove the oil strainer.
TOR
Close to 0 Ω
Pin 1 A-E3 (continuity)

If the continuity test succeeded, check the ECM.

Refer to ELECTRONIC FUEL INJECTION (EFI).
Oil Pressure Switch Removal
1. Remove the throttle body. Refer to ELEC-
TRONIC FUEL INJECTION (EFI).
2. Unplug the oil pressure switch connector.
3. Unscrew and remove the oil pressure switch.

1. PTO oil strainer

PTO Oil Strainer Cleaning and Inspection

Clean the oil strainer with a part cleaner. Use com-
pressed air to dry the oil strainer.
Check and clean the oil outlet area for dirt and oth-
er contaminations.

TYPICAL
1. OPS

Oil Pressure Switch Installation

1. Apply Loc-Tite 243, P/N 460790, onto the
threads of the oil pressure switch.

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Engine
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1. Oil inlet to the oil pump

PTO Oil Strainer Installation

1. Oil strainer
For installation, reverse the removal procedure. 2. Suction pump cover
Pay attention to the following during installation.
1. Clean the cylinder block to remove all remain- Suction Pump Oil Strainer Cleaning and
ing silicone residues in the oil strainer area. Inspection
Clean the oil strainer with a parts cleaner.
REQUIRED CHEMICAL
Use compressed air to dry the oil strainer.
Loc-Tite 5910 Inspect the rubber ring gasket.
P/N 460792

2. Apply a thin layer of Loc-Tite 5910, P/N

460792, onto the oil strainer side.
3. Install the oil strainer into the PTO hsousing.
4. Install the PTO housing. Refer to PTO Housing
Installation, page 70.
5. Refill the engine to the proper level using the
recommended engine oil. Refer to Engine Oil,
page 87.
Suction Pump Oil Strainer
Suction Pump Oil Strainer Removal
N O T E : The oil strainer does not need to be
cleaned at every oil change. Clean it during other
1. suction pump cover gasket
inspections, especially when the engine is 2. Oil filler tube gasket
disassembled.
Clean both contact surfaces of oil suction pump
1. Remove the oil filler tube and the suction pump cover.
cover.
2. Remove the oil strainer from the suction pump Check and clean the oil inlet and outlet area for
cover. dirt and other contaminations.

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4
1. Oil inlet
2. Oil outlet
TIGHTENING SEQUENCE

Suction Pump Oil Strainer Installation Engine Oil Pressure Regulator

For installation, reverse the removal procedure.
Oil Pressure Regulator Operation
Pay attention to the following during installation.
The oil pressure regulator is located on the bottom
1. Apply Loc– Tite 243, P/N 460790, onto the of the PTO housing.
threads of the suction pump cover screws and
torque to specification

TORQUE
Suction pump cover 9 N·m (80 lbf·in)
screws

2. Position screws according to their length as

shown.

TYPICAL
1. Oil pressure regulator

The oil pressure regulator system opens when the

oil pressure exceeds 400 kPa (58 PSI).
Oil Pressure Regulator Removal
1. Remove the engine oil. Refer to Oil Change,
page 88.
2. Remove the following items:
– Oil pressure regulator plug
– Compression springs
– Valve piston
– Valve piston guide
1. Screws M6x25
2. Screws stainless steel M6x45

3. Torque the suction pump cover screws accord-

ing to the sequence illustrated below.

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Engine
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2. Apply Loc-Tite 243, P/N 460790, onto the

threads of the oil pressure regulator plug.
3. Torque the plug screw to the proper
specification.

TORQUE
Oil pressure regulator
13 N·m (115 lbf·in)
plug

Oil Pressure Pump

TYPICAL
Oil Pressure Pump Removal
1. Valve piston guide The oil pressure pump is located in the PTO hous-
2. Valve piston ing and is driven by the balance shaft.
3. Inner compression spring
4. Outer compression spring
5. Oil pressure regulator plug
1. Remove the engine oil. Refer to Oil Change,
6. O-ring page 88.
2. Remove the PTO housing. Refer to PTO Hous-
WARNING ing Removal, page 68.
The oil pressure regulator plug on the oil 3. Remove the water pump housing and the im-
pump housing is spring loaded. peller. Refer to COOLING SYSTEM.
4. Remove the screws securing the oil pump
Oil Pressure Regulator Inspection cover.
1. Inspect the valve piston guide for scoring or
other damages.
2. Check the free length of the outer compression
spring.

OUTER COMPRESSION SPRING FREE

LENGTH
NEW NOMINAL 60 mm (2.362 in.)

SERVICE LIMIT 50.3 mm (1.98 in.)

3. Replace the inner and outer compression

spring as an assembly.
4. Replace the components if excessive wear or
damage is present.
5. Clean the bore and threads in the PTO housing
of any metal shavings or other contaminants.
1. Screws
Oil Pressure Regulator Installation 2. Oil pump cover

For installation, reverse the removal procedure. 5. Pull and remove the outer oil pump rotor.
Pay attention to the following during installation.
1. Install the O-ring onto the plug screw.
I M P O R T A N T : Be sure the O-ring on the plug
screw is properly in place before installing the plug
screw.
REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

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 Engine
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1. Pitting on the teeth.

4
Using a feeler gauge, measure the clearance be-
tween the inner and outer rotors.

TYPICAL
1. Outer oil pump rotor

6. Extract the coolant/oil pump shaft from outside

of the PTO housing cover with a pusher.

1. Outer rotor
2. Inner rotor

1. Pusher OUTER AND INNER ROTOR CLEARANCE

2. Coolant/oil pump shaft
SERVICE LIMIT
7. Remove the rotary seal and oil seal. Refer to
ROTARY SEAL. A

Oil Pressure Pump Inspection B 0.25 mm (.0098 in.)

Inspect the coolant/oil pump shaft, housing and C
cover for marks or other damage.
If the clearance between the inner and outer rotors
Check the inner rotor for corrosion pin-holes or exceeds the tolerance, replace the coolant/oil
other damage. If damage is found, replace the pump shaft.
coolant/oil pump shaft.
Inspect the oil pump housing and cover. If damage
Inspect the oil pump housing and cover. If damage is found, replace the pump housing or cover.
is found replace the housing or cover.
If the clearance between the outer rotor and the
bore in the oil pump exceeds the tolerance, re-
place the complete oil pump and the PTO
housing.

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Engine
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Use a vernier depth gauge to measure the side Oil Pressure Pump Installation
wear as shown. For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Install a new rotary seal and a new oil seal. Re-
fer to ROTARY SEAL.
2. Install the coolant/oil pump shaft.

NOTICE
Never use a hammer for the coolant/oil pump
shaft installation. Only use a press to avoid
damaging the ceramic component of the ro-
tary seal.

REQUIRED TOOLS

Oil Seal Guide

1. PTO housing surface
2. Vernier depth gauge P/N 460730

Water Pump Seal

Pusher
P/N 460731

1. Oil pump outer rotor surface

2. Vernier depth gauge

Clearance between the pump housing and the

outer rotor should not exceed the following 1. Oil seal guide
specification. 2. Coolant/oil pump shaft

If the clearance is not within specifications, re-

place the complete oil pump assembly.

CLEARANCE BETWEEN PUMP HOUSING

AND OUTER ROTOR
SERVICE LIMIT 0.1 mm (.004 in.)

When the axial clearance of the coolant/oil pump

shaft increases, the oil pressure decreases.
Check the inside of the oil pump housing and its
cover for scoring or other damage. If damage is
found, replace the oil pump housing and cover.
1. Coolant/oil pump shaft with oil seal guide
2. Rotary seal pusher to support PTO housing

98
 Engine
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REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

3. Apply Loc-Tite 243, P/N 460790, onto the

threads of the oil pump cover screws.
4. Tighten the oil pump cover screws to
specification.

TORQUE
Oil pump cover screws 9 N·m (80 lbf·in) 1. Oil seal
4
5. After the engine is completely assembled, start 4. Discard the rotary seal and the oil seal.
the engine and ensure the oil pressure is within Rotary Seal Inspection
specification.
Inspect the leak indicator hole for an oil or coolant
Rotary Seal leak.
Rotary Seal Removal
1. Remove the coolant/oil pump shaft. Refer to
Oil Pressure Pump Removal, page 96.
2. Using a screwdriver, carefully remove the ro-
tary seal.

1. Leak indicator hole

Coolant leaking from the leak indicator hole indi-

NOTICE cates a defective rotary seal. Leaking oil indicates
Be careful not to damage the surface of the a faulty oil seal.
rotary seal bore in the PTO housing.
If leaks are seen, replace the rotary seal and oil
seal together.
3. Remove the oil seal behind the rotary seal.
For rotary seal replacement procedures, refer to
Rotary Seal Removal, page 99 and Rotary Seal
Installation, page 99.
Rotary Seal Installation
The installation is the opposite of the removal pro-
cedure. Pay attention to the following during
installation.
1. Be sure the vent/weep hole is clear of any ob-
structions. If the hole is clogged, clean and ver-
ify the passages between the seals are clear.

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Engine
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4. Install the coolant/oil pump shaft. Refer to Oil

NOTICE Pressure Pump Installation, page 98.
Never use oil in the press fit area of the oil
seal and rotary seal. Oil Suction Pump
Oil Suction Pump Removal
2. Push the new oil seal in place by hand. The oil suction pump is located on the front side of
the engine inside of the oil suction pump housing
at the bottom of the oil filler tube.
1. Remove the retaining screws from the oil filler
tube.

1. Oil seal

3. Install the new rotary seal.

REQUIRED TOOLS

Water Pump Seal TYPICAL

Pusher 1. Oil filler tube screws

P/N 460731 2. Remove the oil filler tube.

3. Remove the retaining screws.
NOTICE
Never use a hammer for the rotary seal in-
stallation. Only use a press to avoid damag-
ing the ceramic component.

1. Suction pump cover screws

REQUIRED CHEMICAL
1. Rotary seal
2. Rotary seal installer
Pulley Flange Cleaner
P/N 460798

100
 Engine
Lubrication System

4. Place rags under the cover to prevent spillage. pump shaft. Be sure to check the oil pump housing
If spillage occurs, clean using Pulley Flange and cover and replace if damaged.
Cleaner, P/N 460798.
5. Remove the oil suction pump housing.
6. Remove the oil pump screws and cover.

4
1. Pitting on teeth

Using a feeler gauge, measure the clearance be-

tween the inner and outer rotors.

TYPICAL
1. Oil pump cover
2. Oil pump cover screws

7. Remove the oil pump shaft.

8. Remove the outer rotor.

1. Outer rotor
2. Inner rotor

OUTER AND INNER ROTOR CLEARANCE

SERVICE LIMIT
A
B 0.25 mm (.0098 in.)
C
TYPICAL If the clearance between the inner and outer rotors
1. Oil pump shaft
2. Outer rotor exceeds the tolerance, replace the oil pump shaft.
Inspect the oil pump housing and cover for dam-
Oil Suction Pump Inspection age. If damage is found, replace as necessary.
Inspect the oil pump shaft, housing and cover for
If the clearance between the outer rotor and the
marks or other damage.
bore in the oil pump exceeds the tolerance, re-
Inspect the inner rotor for corrosion, pin-holes or place the complete oil pump and PTO housing.
other damage. If damage is found, replace the oil
Measure the side wear using a vernier depth
gauge.

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Engine
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REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

2. Tighten the screws to specification.

TORQUE
Suction pump cover 9 N·m (80 lbf·in)
screws

3. Position the screws according to length as

shown.
1. Oil pump housing surface
2. Vernier depth gauge

1. Outer rotor
2. Inner rotor
1. Screws M6x25
The clearance between the pump housing and the 2. Screws stainless steel M6x45
outer rotor should not exceed specification. If the 4. Tighten the suction pump cover screw as per
clearance is out of specification, replace the com- the following sequence.
plete oil pump assembly.

CLEARANCE BETWEEN PUMP HOUSING

AND OUTER ROTOR
SERVICE LIMIT 0.1 mm (.004 in.)

When the axial clearance of the oil pump shaft in-

creases, the oil pressure decreases.
Inspect the inside of the oil pump housing and cov-
er for scoring or other damage. If damage is found,
replace as necessary.
Oil Suction Pump Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Apply Loc-Tite 243, P/N 460790, onto the TIGHTENING SEQUENCE
threads of the suction pump cover screws. 5. Refer to the appropriate procedures for instal-
lation of all other removed components.

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Supercharger Oil Spray Nozzle 5. Torque the banjo bolt to the proper
specification.
Supercharger Oil Spray Nozzle Removal
1. Remove the PTO housing. Refer to PTO Hous- TORQUE
ing Removal, page 68.
2. Remove the torx screw securing the oil spray Oil spray nozzle banjo 19 N·m (168 lbf·in)
nozzle support. bolt
3. Unscrew the banjo bolt.
6. Adjust the position of the oil spray nozzle.

REQUIRED TOOL

Supercharger Oil
Spray Nozzle Tool 4
P/N 460761

7. The distance between the adjustment tool and

the oil spray nozzle must be within 1 mm
(0.039 in)
1. Banjo bolt
2. Supercharger oil spray nozzle
3. Oil spray nozzle support
4. Torx screw
1
Supercharger Oil Spay Nozzle Inspection
Inspect the oil spray nozzle for the following:
– Dirt
– Bends or kinks
– Other damage.
If damage is found, replace as necessary.
1. 1 mm (0.039 in)
Supercharger Oil Spray Nozzle Installation
For installation, reverse the removal process. Pay NOTICE
attention to the following during installation. Make sure that the oil spray nozzle is facing
to the center of the tool. Not following this
1. Apply Loc-Tite 243, P/N 460790, onto the
procedure will lead to an insufficient oiling of
threads of the torx screw.
the supercharger and a supercharger failure
REQUIRED CHEMICAL can occur. Adjust the oil spray nozzle if nec-
essary by slightly bending it, take care not to
Loc-Tite 243 over bend the oil spray nozzle.

P/N 460790

2. Install the oil spray nozzle support.

3. Install the Torx screw and tighten to
specification.

TORQUE
Oil spray nozzle
support screw (Torx 11 N·m (97 lbf·in)
screw) 1. Center of supercharger oil spray nozzle tool

4. Install the oil spray nozzle using the banjo bolt.

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Piston Oil Spray Nozzles

Piston Oil Spray Nozzles Operation
The piston oil spray nozzles are located on the
upper half of the cylinder block.

1. Ball
2. Spring
3. Banjo fitting
4. Oil spray nozzle

1. Piston oil spray nozzles IF the oil spray nozzle is damaged or bent while
working in the cylinder block, replace the nozzle
When the scope of the repair work requires the
immediately.
cylinder block be split, clean the oil spray nozzles.
Piston Oil Spray Nozzle Installation
Piston Oil Spray Nozzle Removal
1. Remove the lower half of the cylinder block. NOTICE
Refer to CYLINDER BLOCK. At assembly make sure the contact surface of
2. Remove the oil spray nozzle and Banjo fitting the oil spray nozzle is tightly installed into the
from the upper half of the cylinder block. cylinder block. If left loose, the oil spray di-
rection will change causing potential engine
damage.

1. Install the oil spray nozzle and banjo bolt into

the cylinder block.
2. Torque the banjo bolt to 19 N·m (168 lbf·in).

1. Banjo fitting
2. Oil spray nozzle

Piston Oil Spray Nozzle Cleaning and

Inspection
Use a parts cleaner to clean the oil spray nozzle
and Banjo fitting of any dirt and debris. Use com- 1. Oil spray nozzle
2. Contact surface
pressed air to dry the components.
Oil Separator Cover
Inspect the ball inside of the Banjo fitting to ensure
the ball moves freely. Oil Separator Cover Removal
1. Remove the blow-by valve. Refer to BLOW BY
VALVE REMOVAL.

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2. Remove the camshaft position sensor.

1. Rocker arm
4
2. Camshaft guide
3. Chain guide.

1. Camshaft position sensor 8. Move the camshaft backwards as far as

2. Screw possible.
9. Release the holding clips to remove the oil
3. Remove the cylinder head. Refer to CYLIN- separator cover from the timing gear.
DER HEAD REMOVAL.
4. Remove the thrust washer form the oil separa-
tor cover.

N O T E : Be sure not to lose the thrust washer dur-

ing removal from the oil separator cover. If lost,
the thrust washer can fall into the PTO housing.

1. Camshaft
2. Oil separator cover

N O T E : Be careful not to break the holding clips

off of the oil separator cover when removed from
the timing gear.
Oil Separator Cover Inspection
1. Thrust washer
Inspect the oil separator for marks or other
2. Oil separator cover damage.
5. Remove the spark plug tube. Inspect the holding clips of the oil separator cover
6. Remove the rocker arm shaft along with the and thrust washer for damage.
rocker arms. Refer to CYLINDER HEAD.
If damage is found replace as necessary.
7. Remove the chain guide and the camshaft
guide.

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Engine
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1. Holding clips

Oil Separator Cover Installation

For installation, reverse the removal procedure.
Pay attention to the following during installation.
BLOW-BY VALVE
1. Properly install the oil separator cover and
thrust washer. Blow-By Valve Operation
Normal Operation
N O T E : The oil separator cover and thrust wash-
er need to be in an even position with the timing During normal operation, the blow-by valve allows
gear when installed. Be sure not to lose the thrust crankcase vapors to return into the intake system
washer during installation. where they are harmlessly burned.

2. Install the rocker arm shaft and rocker arms.

Refer to CYLINDER HEAD.
3. Install all other removed parts.
Blow-By Valve
Blow-By Valve Description
The function of the blow-by valve is to circulate the
engine oil vapors.

TYPICAL-NORMAL OPERATION

Bypass Function
If the valve piston gets stuck at normal operation
and the crankcase pressure exceeds 40 kPa (6
PSI), the pressure will unseat a check ball and
crankcase vapors are able to bypass the valve
piston.

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4
TYPICAL NON-CAT ENGINES
1. TOPS switch connector
2. Retaining screws

3. Remove and discard the O-ring and V-ring.

TYPICAL -BYPASS FUNCTION
NOTE: The blow-by valve cannot be
Blow-By Valve Removal disassembled.
1. Remove the ventilation hose from the blow-by
valve.
2. Remove the CPS connector from the support
on the blow-by valve.

TYPICAL TYPICAL
1. Blow-by valve 1. Blow-by valve
2. CPS connector 2. V-ring
3. O-ring

Blow-By Valve Removal for Non-CAT Engines

Blow-By Valve Inspection
1. Disconnect the TOPS switch connector on the
blow-by valve. Inspect the blow-by valve for damage. If damage
2. Unscrew and remove the blow-by valve. is found, replace as necessary.
Clean all contact surfaces of the blow-by valve.
Place a clean rag on the valve inlet.
Blow air through the inlet port. Air must flow freely
to the outlet port.

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Engine
Lubrication System

TORQUE
Blow-by valve screws 9 N·m (80 lbf·in)

4. Tighten the blow-by valve screws to

specification.
5. Reinstall all other removed components.
TOPS Switch (Non-CAT Engines Only)
Tip Over Protection Switch (TOPS Switch)
Function
The function of the TOPS switch is to protect the
engine in the event of a capsized vessel.
During normal operation, the TOPS switch is OFF
Turn the valve upside down and blow air again. Air therefore sending no signal to the ECM.
must not flow out of the valve.
If the vessel capsizes, gravity causes a valve pis-
ton to close preventing engine oil from leaking out
of the blow-by valve.
In this event, a pin with a magnet opens a passage
to the TOPS and the TOPS changes its state to
ON.
Once the TOPS is ON, it will send a signal to the
ECM.
When the ECM receives the signal from the
TOPS, the ECM will shut the engine down by stop-
ping the ignition and fuel injection cycles.

If the test fails, replace the blow-by valve.

Blow-By Valve Installation
The installation is the reverse of the removal pro-
cedure. Pay attention to the following during
installation.
1. Install the blow-by valve with a new O-ring and
a new V-ring.

REQUIRED CHEMICAL BLOW-BY VALVE CUT-AWAY

1. Valve housing
Loc-Tite 243 2. Valve sleeve
3. Valve piston
P/N 460790 4. Check ball
5. Valve pin (with magnet)
6. TOPS on the blow-by valve
2. Apply Loc-Tite 243. P/N 460790, onto the
threads of the blow by valve screws.
3. Install the screws and torque to specification.

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 Engine
Lubrication System

REQUIRED TOOL

Fluke 115 Multimeter

P/N 460735

TIP OVER FUNCTION

TOPS Input Voltage Test

BLOW-BY VALVE IN NORMAL POSITION
1. Disconnect the TOPS connector on the blow- 1. Blow-by valve
by valve. 2. RED probe into pin 2
2. Install the safety lanyard (if applicable) onto 3. BLACK probe into pin 1
the engine cut-off switch.
3. Turn the ignition key to the ON position. TOPS BLOW-BY
4. Probe the terminals as shown to the check the CONNEC VALVE VOLTAGE
voltage output from the ECM. TOR POSITION
TOPS CONNECTOR VOLTAGE Pin 1 and Pin Normal
position 0.4 ± 0.1 Vdc
2
Pins 2 and 3 Approximately 5 Vdc
Pin 1 and Pin Upside down 4.4 ± 0.2 Vdc
2
Normal
position or Approximately
Pin 2 and 3
upside down 5 Vdc

3. Replace the TOPS if the readings are not with-

in specification during this test.
TOPS Circuit Continuity Test
1. Disconnect the TOPS connector on the blow-
by valve.
5. If the results are within specification, test the 2. Disconnect connector A from the ECM.
TOPS output voltage. Refer to TOPS OUTPUT 3. Test the continuity of the blow-by valve TOPS
VOLTAGE TEST. circuit as per the following table.
6. If the voltage test is not within specification,
test the continuity of the blow-by valve TOPS REQUIRED TOOLS
circuit.
7. After the voltage tests have been completed, ECM Adapter Tool
clear any fault codes in the ECM using B.U.D.
S. P/N 460762
TOPS Output Voltage Test
1. Remove the blow-by valve. Fluke 115 Multimeter
2. Back probe the TOPS connector and check P/N 460735
the voltage.

109
Engine
Lubrication System

TOPS
ECM RESIST
CONNEC
ADAPTER ANCE
TOR
Pin 1 Pin F4
Close to 0 Ω
Pin 2 Pin G1 (continuity)
Pin 3 Pin C4

1. TOPS valve inscriptions

Oil Cooler
Oil Cooler Location
The oil cooler is located below the air intake
manifold.

1. Pin 1
2. Pin 2
3. Pin 3

4. If the continuity reading is within specification,

test the ECM. Refer to ELECTRONIC FUEL
INJECTION.
5. If the continuity reading is not within specifica-
tion, repair or replace the defective wires or
connectors.
TOPS Replacement
1. Remove the blow-by valve and turn it upside
down.
2. Insert a small screwdriver between the TOPS
and the retaining tab.
3. Twist and hold the TOPS then release the sec-
1. Oil cooler
ond retaining tab.
Oil Cooler Removal
1. Remove the engine from the vehicle. Refer to
Engine Removal and Installation, page 21.
2. Disconnect the cooling hoses form the oil
cooler.
3. Remove the screws securing the oil cooler to
the engine.

4. When installing the TOPS, be sure the printed

information on the switch is visible.

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 Engine
Lubrication System

REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

2. Apply Loc-Tite 243, P/N 460790 onto the

threads of the oil cooler screws.
3. Install the O-rings and the oil cooler and secure
using the oil cooler screws.
4. Torque the screws to the proper specification.

TORQUE 4
1. Oil cooler screws Oil cooler screws 9 N·m (80 lbf·in)
2. Oil cooler

4. Remove the oil cooler from the engine.

N O T E : Do not lose the O-rings located between
the oil cooler and the engine.

1. O-rings

Oil Cooler Inspection

Inspect the O-rings. Replace the O-ring if the O-
rings are brittle, cracked or hard.
Clean both contact surfaces of the oil cooler.
Inspect and clean the oil inlet and outlet area for
dirt and other contaminants.
Oil Cooler Installation
Installation is the reverse of the removal proce-
dure. Pay attention to the following during
installation.
1. Apply engine oil to the O-rings.

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 Engine
Cooling System

Cooling System

SERVICE TOOLS
Description Part Number Page

ADAPTER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460720 . . . . . . . . . . . . . . . . . . . . . . . . 89

ALIGNMENT SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460723 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460839 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460709 . . . . . . . . . . . . . . . . . . . . . . . . 24
BLIND HOLE BEARING PULLER SET . . . . . . . . . . . . . . . . . . . . . P/N 460760 . . . . . . . . . . . . . . . . . . . . . . . . 74
CAMSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 138
CRANKSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460729 . . . . . . . . . . . . . . . 164, 166, 173
DRIVE SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460745 . . . . . . . . . . . . . . . . . . . . . . . 129
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . 93, 109
ENGINE ALIGNMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460719 . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE LEAK DOWN TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460721 . . . . . . . . . . . . . . . . . . . . . . . 130
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . . . . . . . . . . . . . . . 93, 109
FLUSHING CONNECTOR ADAPTER . . . . . . . . . . . . . . . . . . . . . . P/N 460711 . . . . . . . . . . . . . . . . . . . . . . . . 51
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460714 . . . . . . . . . . . . . . . . . . . . . . . . 74
LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . . . . . . . 42
OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460708 . . . . . . . . . . . . . . . . . . . . 73, 122
OIL SEAL GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460730 . . . . . . . . . . . . . . . . . . . . . . . . 98
PISTON CIRCLIP INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460726 . . . . . . . . . . . . . . . . . . . . . . . 159
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 89
STARTER DRIVE SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460713 . . . . . . . . . . . . . . . . . . . . . . . . 74
SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 88
SUPERCHARGER GEAR HOLDER . . . . . . . . . . . . . . . . . . . . . . . P/N 460753 . . . . . . . . . . . . . . . . . . . . . . . 176
SUPERCHARGER OIL SPRAY NOZZLE TOOL . . . . . . . . . . . . . . P/N 460761 . . . . . . . . . . . . . . . . . . . . . . . 103
SUPERCHARGER RETAINING KEY . . . . . . . . . . . . . . . . . . . . . . P/N 460755 . . . . . . . . . . . . . . . . . . . . . . . 178
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460740 . . . . . . . . . . . . . . . . . . . 176, 178
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . . . . 120
TORX ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460739 . . . . . . . . . . . . . . . . . . . 177, 180
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . 43, 120
VALVE GUIDE PUSHER 6 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460759 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE GUIDE REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460758 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE SPRING COMPRESSOR CUP . . . . . . . . . . . . . . . . . . . . . P/N 460757 . . . . . . . . . . . . . . . . . . . . . . . 142
VALVE SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460724 . . . . . . . . . . . . . . . . . . . . . . . 142
WATER PUMP SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460731 . . . . . . . . . . . . . . . . . . . . 98, 100

SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,
108, 111, 125, 137, 141, 172,
179–180
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798

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 Engine
Cooling System

SERVICE PRODUCTS
. . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179

113
Engine
Cooling System

Closed Loop Cooling System

1. Coolant temperature sensor (CTS activates 6. Heat exchanger

when temperature exceeds 100°C (212°F))
2. Expansion coolant tank 7. Coolant return from heat exchanger
3. Bleed hose from cylinder head to expansion 8. Coolant return from oil cooler
coolant tank
4. Water pump housing including thermostat that 9. Oil cooler
opens at 87°C (188°F)
5. Coolant flow to heat exchanger 10. Coolant flow to oil cooler

114
 Engine
Cooling System

Single Engine Cooling System

Components

115
Engine
Cooling System

Twin Engine Cooling System

Components

4 N•m
(35 lbf• in )
4 N•m
(35 lbf• in )
Hull

Loctite 577
(thread sealant)

8.5 N•m
(75 lbf• in )

Loctite 567
(pipe sealant)

NEW
8 N•m
(71 lbf• in )

NEW = Component must be replaced when removed.

116
 Engine
Cooling System

Engine Cooling System Components

NEW = Component must be replaced when removed.

117
Engine
Cooling System

General Cooling System Technical Specifications

Cooling System Description
TECHNICAL SPECIFICATIONS
A closed loop cooling system is utilized on the RO-
TAX 4-TEC engines. This cooling system offers Closed loop cooling
TYPE system
efficient engine cooling while keeping dirt and salt
water out of the cooling system. This system
keeps the temperature constant and prevents in- Flow from the water
COOLANT FLOW pump
ternal engine corrosion.
A separate coolant tank ensures enough engine TEMPERATURE
Thermostat
coolant is in the circuit during any operating CONTROL
condition.
Self-bleed type
The coolant flow comes from the water pump im- through coolant tank
SYSTEM BLEEDING (hose at uppermost
peller into the cylinder block. The coolant then
travels around the cylinders and straight up to the point of circuit)
cylinder head. A smaller quantity of engine coolant
enters the cylinder block on the exhaust side for Turns on at 100°C
more efficient cooling. In the cylinder head, the (212°F) on naturally
water channels flow around the exhaust and then MONITORING aspirated engines.
to the intake valves and finally leaving the engine BEEPER Turns on at 110°C
through a large hose. The coolant goes back to (230°F) on
the water pump housing and depending on the en- supercharged engines
gine temperature, it flows through the thermostat
directly back to the water pump impeller, or it takes Cooling System Maintenance
its way through the heat exchanger. Engine Coolant
Engine coolant is also directed towards the oil WARNING
cooler (coolant type). To avoid potential burns, do not remove the
The Coolant temperature sensor and bleed hose coolant tank cap or loosed the ride plate or
nipple are located on the cylinder head. heat exchanger drain plug if the engine is hot.

Recommended Coolant
Use BRP Premixed Coolant, P/N 460777, or a
blend of 50% antifreeze with 50% demineralized
water.

NOTICE
Never modify the cooling system. Serious en-
gine damage can occur.

To prevent antifreeze deterioration, always use

the same brand of coolant. Never mix brands un-
less the cooling system is completely flushed and
refilled.
1. Bleed hose nipple
2. Coolant temperature sensor (CTS) Draining the Engine Coolant System
1. Remove the coolant tank cap.
NOTICE 2. Install a drain pan underneath the ride plate or
Never modify the cooling system. Serious en- heat exchanger.
gine damage can occur.
N O T E : Raising the front of the boat aid in drain-
ing the cooling system.
3. Dispose of coolant as per the local regulations.

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 Engine
Cooling System

I M P O R T A N T : Do not install the drain plug if the TIGHTENING TORQUE

cleaning procedure is to be performed at this
time.. Drain plug 8 N·m (71 lbf·in)
Cleaning the Engine Coolant System
8. Continue to pour and fill the coolant tank until
NOTICE the coolant level reaches between the Min and
Never modify the cooling system. Serious en- Max lines on the coolant tank.
gine damage can occur.

1. Drain the cooling system. Refer to Draining the

Engine Coolant System, page 118.
2. Add a cleaning product such as Zerex Super
Cleaner ® (or equivalent) into the coolant tank. 4
3. Fill the cooling system with demineralized
water.
4. Reinstall the cap onto the coolant tank.
5. Start the engine and let run for approximately
15 minutes.

N O T E : Ensure the thermostat opens to allow the

cleaning product to flow properly into the ride plate
or heat exchanger.
6. Stop the engine and leave the cleaning product
in the cooling system for 12–16 hours.
7. Operate the engine to soak off deposits.
8. Drain the cooling system and thoroughly rinse
with water.
1. Level between marks when engine is cold
9. Refill the cooling system. Refer to REFILLING
THE COOLING SYSTEM. 9. Do not install the pressure cap at this time.
Refilling the Engine Coolant System 10. Link a garden hose to the hose adapter at the
back of the boat. Refer to EXHAUST SYSTEM
1. Place the boat on a level surface. FLUSHING.
2. Ensure the engine is cold.
3. Remove the drain plug. NOTICE
4. Place a container under the drain plug to catch
Never run an engine without supplying water
antifreeze that will be coming out during this
to the exhaust cooling system when the boat
procedure.
is out of the water.
REQUIRED CHEMICAL
11. Start the engine and let run for a maximum of 2
minutes.
Loc-Tite 567 12. Turn the water off and stop the engine.
P/N 460360 13. Wait 15 minutes to allow time for the engine to
cool.
5. Apply Loc-Tite 567, P/N 460360, onto the drain 14. Refill the coolant tank as necessary.
plug threads. 15. Repeat this run-stop cycle 2– 3 times until the
6. Ask someone to pour recommended antifreeze thermostat opens then stop the engine.
into the coolant tank.
7. When antifreeze flows out of the ride plate or
heat exchanger drain hole, reinstall the drain
plug. Torque the drain plug to the proper
specification.

119
Engine
Cooling System

1. Vacuum/pressure pump

2. Inspect all hoses, ride plate or heat exchanger,

engine and oil cooler for coolant leaks.
3. Spray a soap and water solution and look for
1. This hose becomes hot when thermostat is open air bubbles.
16. Refill the coolant tank. 4. Check the leak indicator hole if there is oil or
17. Install the pressure cap. coolant. Replace as necessary.
18. When the engine is completely cool, check the
coolant level in the coolant tank. Fill as
necessary.

Inspection
Cooling System Leak Test
WARNING
To avoid potential burns, do not remove the
coolant tank cap or loosed the ride plate or
heat exchanger drain plug if the engine is hot.

1. Pressurize the system through the coolant tank

to 90 kPa (13 PSI).

N O T E : It is not necessary to install a hose pinch-

er onto the overflow hose. 1. Leak indicator hole

REQUIRED TOOLS Cooling System Troubleshooting

The following is provided to help in diagnosing the
Test Cap probable source of troubles.

P/N 460762 This is a guideline and should not be assumed to

list all possible problems.
Vacuum/Pressure Always check for fault codes. If a fault code is de-
Pump tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES.
P/N 460736
ENGINE OVERHEATING

1. Low coolant level

– Refill the cooling system and check for
leaks (coolant leaking out of engine leak in-
dicator hole, hoses or clamps missing or
defective, cylinder head gasket leaks, ride

120
 Engine
Cooling System

plate or heat exchanger leaking, etc.). Re-

pair or replace components as necessary.
2. Air in the cooling system
– Refill and bleed the cooling system.
3. Thermostat defective (does not open when the
engine gets hot).
– Inspect and replace defective components
as necessary.
4. Water pump failure
– Inspect and replace defective components
5. Water temperature sensor defective
– Inspect and replace damaged components 4
as necessary
6. Ride plate or heat exchanger hoses damaged
– Inspect and replace damaged components
as necessary
7. Exhaust system clogged
– Flush the exhaust system
8. Internal passage blocked in cooling system
– Inspect and clean

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Engine
Cooling System

Procedures
Pressure Cap
Pressure Cap Inspection
Using a pressure cap tester, check pressure cap
efficiency. If the efficiency is feeble, install a new
90 kPa (13 PSI) cap (do not exceed this
pressure).
Clamps
Clamp Replacement
1. To cut or secure Oetiker clamps of cooling sys-
tem hoses, use special pliers
TYPICAL
REQUIRED TOOL 1. Supercharger
2. Inlet hose
OETIKER PLIERS 3. Outlet hose

P/N 460708 Water Pump Housing Removal

1. Drain the cooling system. Refer to Draining the
N O T E : Always check the general condition of Engine Coolant System, page 118.
hoses and clamp tightness. 2. Disconnect all coolant hoses from the water
pump housing.
Water Pump Housing 3. Remove the water pump housing retaining
Water Pump Housing Access screws.

1. Water pump housing

For models with supercharged intercooled en- TYPICAL

gines, remove the supercharger inlet and outlet
hoses to allow enough room to access the water 4. Pull the water pump housing away from the
pump housing. engine.
Water Pump Housing Inspection
Inspect the water pump housing gasket. If the gas-
ket is hard, brittle or damaged replace as
necessary.

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 Engine
Cooling System

Water Pump Housing Installation

The installation is the opposite of the removal. Pay
attention to the following during installation.
1. Apply Loc-Tite 243, P/N 460790, onto the
threads of the water pump housing screws.

REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

2. Install the screws as per the following 4

illustration.

1. Water pump housing gasket

Inspect the condition of the thermostat. Refer to

THERMOSTAT.
Water Pump Housing Leak Test
1. Plug the connections of the oil cooler return
hose, coolant tank hose, ride plate or heat ex-
changer return hose and cylinder head hose
with a rag.

1. Screws M6 x 25
2. Screws M6 x 105

NOTICE
To prevent leaking, take care the gaskets are
exactly in the groove during installation of the
water pump housing.

3. Tighten the screws to the proper specification

using the torque sequence in the following
illustration.
TIGHTENING TORQUE
Water pump housing
9 N·m (80 lbf·in)
retaining screws

1. Oil cooler return connection

2. Coolant tank hose connection
3. Ride plate or heat exchanger return hose connection
4. Cylinder head return hose connection

2. Fill the water pump housing with water.

3. If a larger quantity of coolant leaks out at the
ride plate or heat exchanger outlet connection,
replace the water pump housing.
4. If there is no leak, verify the operation of the
thermostat.

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Engine
Cooling System

2. Remove the thermostat.

N O T E : The thermostat is located inside the

water pump housing.
Thermostat Test
1. To check the operation of the thermostat, place
the thermostat into water and heat the water.
2. Look inside the cylinder head return hose to
see the movement of the thermostat.
3. The thermostat should open when the water
temperature reaches 87°C (189°F)
4. If there is no movement of the thermostat, re-
place the water pump housing.
WATER PUMP HOUSING TIGHTENING SEQ UENCE
Thermostat Installation
Water Pump Impeller 1. For installation, reverse the removal
Water Pump Impeller Removal procedure.
1. Remove the water pump housing. Refer to 2. Install the water pump housing. Refer to Water
Water Pump Housing Removal, page 122. Pump Housing Installation, page 123.
2. Remove the impeller. Heat Exchanger (Twin Engines)
NOTICE Heat Exchanger Removal
Coolant/oil pump shaft and impeller have left-
N O T E : On single engine models, the heat ex-
hand threads. Remove by turning clockwise
changer is integrated into the ride plate.
and install by turning counterclockwise.
1. Drain the cooling system.
Water Pump Impeller Inspection 2. Disconnect both heat exchanger hoses from
Inspect the water pump impeller for cracks or oth- inside the hull.
er damage. If damage is found, replace as 3. Remove the bolts securing the heat exchanger
necessary. to the hull.
Water Pump Impeller Installation
The installation procedure is the opposite of the
removal procedure. Pay attention to the following
during installation.
1. Install the water pump impeller and tighten to
specification.
NOTICE
Be careful not to damage the impeller wings
during installation.
TYPICAL
TIGHTENING TORQUE
Water pump impeller 4. Push on the heat exchanger fittings to force
3 N·m (27 lbf·in) the heat exchanger out of the hull recesses.
(left hand threads)
5. When a sufficient gap is obtained, grab the
Thermostat heat exchanger from the outside of the hull
and pull to remove.
Thermostat Removal 6. Clean the hull of any sealant residue.
The thermostat is a single action type. Heat Exchanger Installation
1. Remove the water pump housing. Refer to 1. Apply Loc-Tite Instant Gasket, P/N 460778,
Water Pump Housing Removal, page 122. around all holes and both hose fittings.

124
 Engine
Cooling System

REQUIRED CHEMICALS

Loc-Tite Instant Gasket

P/N 460778

Loc-Tite 243
P/N 460790

2. Apply Loc-Tite 243, P/N 460790, onto the

threads of the heat exchanger bolts.
3. Position the heat exchanger into the hull
recess. 4
4. Install and tighten the heat exchanger bolts.

TIGHTENING TORQUE
Heat exchanger bolts 25 N·m (18 lbf·ft)

TYPICAL
1. Bolt
2. Flat washers
3. Nut
4. Loc-Tite Instant Gasket
5. Heat exchanger
6. Hull

5. Connect the heat exchanger hoses.

6. Refill the cooling system. Refer to Refilling the
Engine Coolant System, page 119.

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 Engine
Cylinder Head

Cylinder Head

SERVICE TOOLS
Description Part Number Page

ADAPTER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460720 . . . . . . . . . . . . . . . . . . . . . . . . 89

ALIGNMENT SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460723 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460839 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460709 . . . . . . . . . . . . . . . . . . . . . . . . 24
BLIND HOLE BEARING PULLER SET . . . . . . . . . . . . . . . . . . . . . P/N 460760 . . . . . . . . . . . . . . . . . . . . . . . . 74
CAMSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 138
CRANKSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460729 . . . . . . . . . . . . . . . 164, 166, 173
DRIVE SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460745 . . . . . . . . . . . . . . . . . . . . . . . 129
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . 93, 109
ENGINE ALIGNMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460719 . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE LEAK DOWN TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460721 . . . . . . . . . . . . . . . . . . . . . . . 130
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . . . . . . . . . . . . . . . 93, 109
FLUSHING CONNECTOR ADAPTER . . . . . . . . . . . . . . . . . . . . . . P/N 460711 . . . . . . . . . . . . . . . . . . . . . . . . 51
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460714 . . . . . . . . . . . . . . . . . . . . . . . . 74
LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . . . . . . . 42
OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460708 . . . . . . . . . . . . . . . . . . . . 73, 122
OIL SEAL GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460730 . . . . . . . . . . . . . . . . . . . . . . . . 98
PISTON CIRCLIP INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460726 . . . . . . . . . . . . . . . . . . . . . . . 159
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 89
STARTER DRIVE SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460713 . . . . . . . . . . . . . . . . . . . . . . . . 74
SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 88
SUPERCHARGER GEAR HOLDER . . . . . . . . . . . . . . . . . . . . . . . P/N 460753 . . . . . . . . . . . . . . . . . . . . . . . 176
SUPERCHARGER OIL SPRAY NOZZLE TOOL . . . . . . . . . . . . . . P/N 460761 . . . . . . . . . . . . . . . . . . . . . . . 103
SUPERCHARGER RETAINING KEY . . . . . . . . . . . . . . . . . . . . . . P/N 460755 . . . . . . . . . . . . . . . . . . . . . . . 178
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460740 . . . . . . . . . . . . . . . . . . . 176, 178
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . . . . 120
TORX ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460739 . . . . . . . . . . . . . . . . . . . 177, 180
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . 43, 120
VALVE GUIDE PUSHER 6 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460759 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE GUIDE REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460758 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE SPRING COMPRESSOR CUP . . . . . . . . . . . . . . . . . . . . . P/N 460757 . . . . . . . . . . . . . . . . . . . . . . . 142
VALVE SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460724 . . . . . . . . . . . . . . . . . . . . . . . 142
WATER PUMP SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460731 . . . . . . . . . . . . . . . . . . . . 98, 100

SERVICE TOOLS — OTHER SUPPLIER

Description Part Number Page

SNAP-ON PISTON RING COMPRESSOR PLIERS . . . . . . . . . . . P/N RC980 . . . . . . . . . . . . . . . . . . . . . . . 160

SNAP-ON VALVE STEM PLIERS . . . . . . . . . . . . . . . . . . . . . . . . P/N YA8230 . . . . . . . . . . . . . . . . . . . . . . . 144

SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,

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 Engine
Cylinder Head

SERVICE PRODUCTS
108, 111, 125, 137, 141, 172,
179–180
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798 . . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179
4

127
Engine
Cylinder Head

Cylinder Head Service Chart

128
 Engine
Cylinder Head

General 5. Unplug and remove the ignition coils.

I M P O R T A N T : When diagnosing an engine 6. Remove the spark plugs.
problem, always perform an engine leak test. This N O T E : Ignition coils may be used as spark plug
will help pin-point a problem. Refer to ENGINE extractors.
LEAK TEST.

When disassembling parts that are duplicated in

the engine (e.g.: valves, springs, etc.), it is strongly
recommended to note their position and to keep
the parts of the same assembly as a “group”. If
you find a defective component, it will be much
easier to find the root cause of the failure. Since
parts were broken in together during engine oper-
ation, they will keep their matched fit when parts
4
are assembled together within their “group”.
Inspection
Engine Leak Test
WARNING 1. Ignition coil
2. Spark plug
Beware of burns when working on a hot
engine. 7. Remove the cylinder head cover. Refer to
CYLINDER HEAD COVER REMOVAL.
This procedure needs to be completed when the REQUIRED TOOL
engine operating temperature reaches approxi-
mately 70°C (158°F). Drive shaft Adapter
1. Remove the necessary components to gain ac- P/N 460745
cess to the engine.
2. Remove the jet pump. Refer to JET PUMP
REMOVAL. 8. Install the Drive Shaft Adapter, P/N 460745,
3. Remove the coolant pressure cap. and an appropriate wrench lever onto the drive
shaft end.
WARNING
Leak Test Procedure
To avoid potential burns, only remove the
coolant pressure cap by wearing the appro- N O T E : Cylinder numbers are molded onto the
priate safety equipment. cylinder head cover.

4. Remove the oil dipstick. 1. Rotate the engine crankshaft counterclockwise

until cylinder 1 is at Top Dead Center (TDC).
2. As the engine crankshaft is turned, observe
the movement of the intake rocker arm of the
cylinder being tested.
3. After the piston completes its cycle and the in-
take valve closes, observe the piston.
4. The piston has reached TDC when the piston
reaches its uppermost position.

1. Oil dipstick

129
Engine
Cylinder Head

1. Intake rocker arms TYPICAL

1. Leak down tester gauge
5. Secure the wrench lever at the end of the drive 2. Gauge adapter
3. Air supply hose
shaft against the hull to prevent further
cranking. 11. Note the amount of leaking or percentage de-
pending on the style of gauge used.
REQUIRED TOOLS
LEAKAGE ENGINE
Engine Leak Down PERCENTAGE CONDITION
Test Kit
Up to 15% Excellent condition
P/N 460721
16% - 25% Good condition
6. To install the leak down test tool, install the ap- Fair condition; engine
propriate gauge adapter into the spark plug will run and
hole. 26% - 40% performance might not
7. Connect the leak down tester gauge to the be optimal in some
gauge adapter. cases
8. Connect an adequate air supply to the gauge
adapter. Poor condition;
9. Set the gauge to (0). 41% and higher diagnose and repair
engine as necessary
N O T E : Each tester will have specific instructions
on the gauge. Refer to manufacturer’s 12. Repeat these steps for the remaining
instructions. cylinders.
10. Apply air to the combustion chamber. Diagnostic Test
Pressurize the area to be tested.
Spray a soapy water solution at the indicated loca-
tion and look for air bubbles.
OBSERVATION CAUSE
Air escaping on intake
Leaking intake valve(s)
port
Air escaping on Leaking exhaust
exhaust port valve(s)

Air escaping into Excessively worn and/

crankcase or broken piston rings

130
 Engine
Cylinder Head

OBSERVATION CAUSE 8. Camshaft is worn out.

– Check if the camshaft radial clearance is
Air bubbles out of Leaking cylinder head out of specification
coolant tank gasket
Air/water escaping OIL LEAKAGE FROM CYLINDER HEAD
Damaged gasket and/
from cylinder block/
or loose screws
head 1. Cylinder head cover gasket is leaking.
Coolant escaping from Damaged gasket and/ – Replace the cylinder head cover gasket
water pump housing or loose screws and torque the screws to the proper
specification
Coolant escaping from Damaged rotary seal 2. Cylinder head cover screw are leaking.
leak indicator hole on water pump shaft – Replace the cylinder head cover screws 4
Oily contamination on Damaged oil seal on 3. Spark plug tube gasket is leaking.
leak indicator hole water pump shaft – Remove the cylinder head cover and re-
place the spark plug tube gasket
When the testing is complete, assemble the – Clean the spark plug area from oil spillage
engine. 4. Blow-by valve is leaking.
Use the torque values and service products found – Replace the blow-by valve O-ring
in the service chart. 5. Camshaft sensor O-ring is leaking.
Troubleshooting – Replace the camshaft sensor O-ring
The following is provided to help in diagnosing the 6. Cylinder head gasket is leaking.
probable source of problems. It is a guideline and – Remove the cylinder head and check for
it should not be assumed to list all possible damage
problems. – Replace the cylinder head gasket are tight-
en the screws to the proper specification
Always check for fault codes. If a fault code is
present, service the fault code first.
ENGINE LACKS ACCELERATION OR
UNUSUAL ENGINE NOISE OR POWER
VIBRATIONS 1. Incorrect camshaft timing adjustment.
1. Incorrect camshaft timing adjustment. – Replace damaged components and adjust
the properly adjust the camshaft timing
– Replace damaged components and
readjust 2. Intake or exhaust valves are leaking.
2. Camshaft timing gear screws are loose. – Perform and engine leak test. Refer to En-
gine Leak Test, page 129
– Tighten the screws to the proper
– Check if the valve seats properly in the
specification.
valve seat
3. Rocker arm (s) hydraulic element is broken or – Repair or replace damaged components
worn out (improper valve adjustment).
3. Broken valve springs.
– Replace faulty rocker arm(s)
– Replace defective parts
4. Rocker arm screw not properly tightened.
4. Broken rocker arm(s).
– Tighten screws to the proper specification
– Replace defective parts
5. Faulty chain tensioner.
– Replace the chain tensioner Troubleshooting
6. Chain guide is worn out. The following is provided to help in diagnosing the
probable source of problems. It is a guideline and
– Replace the chain guide it should not be assumed to list all possible
7. Stretched timing chain or worn out sprocket. problems.
– Replace the timing chain and sprocket

131
Engine
Cylinder Head

Always check for fault codes. If a fault code is ENGINE LACKS ACCELERATION OR
present, service the fault code first. POWER

UNUSUAL ENGINE NOISE OR 1. Incorrect camshaft timing adjustment.

VIBRATIONS – Replace damaged components and adjust
the properly adjust the camshaft timing
1. Incorrect camshaft timing adjustment. 2. Intake or exhaust valves are leaking.
– Replace damaged components and – Perform and engine leak test. Refer to En-
readjust gine Leak Test, page 129
2. Camshaft timing gear screws are loose. – Check if the valve seats properly in the
valve seat
– Tighten the screws to the proper
– Repair or replace damaged components
specification.
3. Broken valve springs.
3. Rocker arm (s) hydraulic element is broken or
worn out (improper valve adjustment). – Replace defective parts
– Replace faulty rocker arm(s) 4. Broken rocker arm(s).
4. Rocker arm screw not properly tightened. – Replace defective parts
– Tighten screws to the proper specification
5. Faulty chain tensioner.
– Replace the chain tensioner
6. Chain guide is worn out.
– Replace the chain guide
7. Stretched timing chain or worn out sprocket.
– Replace the timing chain and sprocket
8. Camshaft is worn out.
– Check if the camshaft radial clearance is
out of specification

OIL LEAKAGE FROM CYLINDER HEAD

1. Cylinder head cover gasket is leaking.
– Replace the cylinder head cover gasket
and torque the screws to the proper
specification
2. Cylinder head cover screw are leaking.
– Replace the cylinder head cover screws
3. Spark plug tube gasket is leaking.
– Remove the cylinder head cover and re-
place the spark plug tube gasket
– Clean the spark plug area from oil spillage
4. Blow-by valve is leaking.
– Replace the blow-by valve O-ring
5. Camshaft sensor O-ring is leaking.
– Replace the camshaft sensor O-ring
6. Cylinder head gasket is leaking.
– Remove the cylinder head and check for
damage
– Replace the cylinder head gasket are tight-
en the screws to the proper specification

132
 Engine
Cylinder Head

Procedures
Cylinder Head Cover
Cylinder Head Cover Access
Access the engine. Refer to Engine Access, page
23.
1. Remove the cylinder head cover cowl.

N O T E : On CAT engines, remove the air intake

adapter, air filter, regulator / rectifier, mounting
bracket and blow-by hose as an assembly to ac-
cess the valve cover.
Cylinder Head Cover Removal
4
1. Unplug and remove the ignition coils. 1. Cylinder head cover
2. Gasket

Cylinder Head Cover Inspection

Inspect the cylinder head cover gasket and the
cylinder head cover screw bushings.
If brittle, cracked or hard, replace as necessary.
Cylinder Head Cover Installation
The installation procedure is the reverse of the re-
moval procedure. Pay attention to the following
during installation.
1. Properly seat the gasket into the cylinder head
cover groove.
2. Install the cylinder head cover.
3. Install the cylinder head cover screws and
1. Ignition coils
tighten to the proper specification using the tor-
2. Remove the screws securing the cylinder head que sequence seen in the following image.
cover.

1. Cylinder head cover screws

3. Remove the cylinder head cover and gasket.

CYLINDER HEAD COVER SCREWS TORQUE SEQUENCE

TORQUE
Cylinder head cover 9 N·m (80 lbf·in)
screws

133
Engine
Cylinder Head

4. Install all other components that were removed Rocker Arms

during the removal process. Refer to the ap- Rocker Arm Removal
propriate sections in this manual for the instal- 1. Remove the cylinder head cover. Refer to Cyl-
lation procedures. inder Head Cover Removal, page 133.
Spark Plug Tubes 2. Remove the spark plug tubes. Refer to Spark
Spark Plug Tube Removal Plug Tube Removal, page 134.
3. Remove and discard the rocker arm shaft
1. Remove the cylinder head cover. Refer to Cyl- screws.
inder Head Cover Removal, page 133.
2. Pull the spark plug tubes to remove them.

1. Spark plug tube

1. Spark plug tube 4. Remove the rocker arm shaft and rocker arms
as an assembly.
Spark Plug Tube Inspection
Inspect the seals on the spark plug tube.
If the seals are brittle, cracked or hard, replace the
spark plug tube.

1. Spark plug tube

Rocker Arm Inspection

TYPICAL Inspect each rocker arm for cracks and scored
1. Spark plug tube friction surfaces. If damage is found, replace the
2. Seal to the cylinder head cover rocker arm assembly.
3. Seal to the cylinder head
Inspect the rocker arm rollers for free movement.
Spark Plug Tube Installation wear and excessive radial play. If damage is
Installation is the reverse of the removal proce- found, replace the rocker arm assembly.
dure. Pay attention to the following during
installation.
1. Apply engine oil to the seals of the spark plug
tubes.
2. Install the spark plug tubes.
3. Ensure the spark plug tubes are seated prop-
erly after installation.

134
 Engine
Cylinder Head

ROCKER ARM SHAFT DIAMETER

19.980 mm - 19.993
4 NEW mm (.7866 in. -.7871
in.)

SERVICE LIMIT 19.970 mm (.7862 in.)

Inspect and clean oil orifices to ensure proper

rocker arm shaft lubrication.

1. Rocker arm (intake side)

4
2. Rocker arm (exhaust side)
3. Rollers
4. Rocker arm inside diameter

Measure the rocker arm inside diameter. If the di-

ameter is out of specification, change the rocker
arm assembly.

ROCKER ARM INSIDE DIAMETER

20.007 mm - 20.020
NEW mm (.7787 in. - .7882
in.)

SERVICE LIMIT 20.050 mm (.7894 in.)

1. Oil orifice from the camshaft to the rocker arm shaft, then to the
rocker arms and finally to the valve adjustment
Press the hydraulic lifter. If the hydraulic lifter can
be fully depressed by hand, replace the rocker Rocker Arm Installation
arm. The lifter must turn freely in the rocker arm For installation, reverse the removal procedure.
bore. If the lifter does not turn freely, replace the Pay attention to the following during installation.
lifter.
N O T E : The rocker arm shaft can only be in-
stalled one way. The camshaft has to be posi-
Rocker Arm Shaft tioned with the locking pin when the cylinder 3
piston is at TDC.
Inspect the rocker arm shaft for scored friction sur-
faces. If damage is found, replace the rocker arm 1. Lock the camshaft. Refer to CAMSHAFT.
shaft. 2. Be sure the position lines on the oil separator
cover are lined up as shown in the following
Measure the rocker arm shaft diameter. image.

1
1. Measure rocker arm shaft diameter here

135
Engine
Cylinder Head

TORQUE
10 N·m (89
Step 1
lbf·in)
20 N·m (15
Rocker arm Step 2
lbf·ft)
shaft screws
Apply an
Step 3 additional 90°
rotation

1. Position lines

3. Apply engine oil onto the rocker arm shaft.

4. Position the rocker arm shaft using the
notches.

TORQUE SEQUENCE

Camshaft Timing Gear

Camshaft Timing Gear Removal
N O T E : Although it is not necessary to position
the crankshaft to TDC for disassembly, it is helpful
in determining if the valve timing is correct.

1. Lock the crankshaft. Refer to CYLINDER

1. Rocker arm shaft BLOCK.
2. Rocker arm shaft notches 2. Remove the cylinder head cover. Refer to Cyl-
5. Install NEW rocker arm shaft screws. inder Head Cover Removal, page 133.
3. Lock the camshaft. Refer to CAMSHAFT.
NOTICE 4. Remove the oil separator cover. Refer to Oil
Separator Cover Removal, page 104.
This assembly uses stretch screws. As the
5. Remove the chain tensioner. Refer to CYLIN-
screws have been stretched from the pre-
DER BLOCK.
vious installation, it is very important to use
6. Remove the chain guide.
new screws during installation. Failure to re-
7. Remove the timing gear screws.
place the screws and follow the torque proce-
8. Remove the timing gear.
dure may cause the screws to become loose
and cause engine damage.

6. Torque the rocker arm shaft screws according

to the following sequence.

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 Engine
Cylinder Head

4
1. Chain guide
2. Camshaft timing gear screws
3. Camshaft timing gear

9. Secure the timing chain with a retaining wire.

Camshaft Timing Gear Inspection
Inspect the camshaft timing gear for wear or
deterioration. 1. Good (1503 aligned)
2. Never
If the timing gear is worn or damaged, replace the
2. Install the timing chain. Refer to CYLINDER
camshaft timing gear and timing chain as a set.
BLOCK.
Refer to CYLINDER BLOCK for replacement
3. Ensure the chain guides are properly installed.
procedure.
4. Loosely install the camshaft timing gear
Camshaft Timing Gear Installation screws.
For installation, reverse the removal procedure. 5. Install the chain tensioner.
Pay attention to the following during installation.
N O T E : There can be 2 different positions to in-
NOTICE stall the timing gear on the camshaft. Basically
both positions are working well, since the cam-
Improper camshaft timing will damage engine shaft and crankshaft are locked in their proper po-
components. Make sure the camshaft and the sition. Due to some tolerances, there could be one
crankshaft are still locked. If they are not position which fits better than the other one. To
locked, lock them before starting this check this, perform the following test.
procedure.
6. Check if the camshaft timing gear screws are
1. Install the camshaft timing gear with the writing still loose.
visible according to the following image.
N O T E : If screws are squeezed by the timing
gear, remove the chain tensioner again and rotate
timing gear by one tooth clockwise. Then install
the chain tensioner again.
7. Remove the camshaft timing gear screws one
at a time.
REQUIRED CHEMICALS

Loc-Tite 243
P/N 460790

8. Apply Loc-Tite 243, P/N 460790 onto the

threads of the camshaft timing gear screws.

137
Engine
Cylinder Head

9. Install the camshaft timing gear screws and 4. Insert the camshaft locking too into the hole
torque to the proper specification. behind the camshaft timing gear.
5. Make sure the position lines on the oil separa-
TORQUE tor cover are aligned as seen in the following
image.
Camshaft timing gear 9 N·m (80 lbf·in)
screws

NOTICE
The crankshaft and the camshaft must be
locked at TDC to place the camshaft timing
gear and the timing chain in the proper posi-
tion. To check, look at the timing gear lines.
They must be parallel to the cylinder head
surface.

1. Camshaft locking tool

2. Position lines

Camshaft Removal
1. Remove the camshaft timing gear. Refer to
Camshaft Timing Gear Removal, page 136.
2. Remove the rocker arm. Refer to Rocker Arm
Removal, page 134.
3. Remove the camshaft lock to remove the
camshaft.

1. Position lines

NOTICE
Be sure to remove the crankshaft and cam-
shaft locking tools when finished.

10. Install all other removed parts.

Camshaft
Camshaft Locking Procedure
1. Remove the cylinder head cover. Refer to Cyl-
inder Head Cover Removal, page 133.
2. Lock the crankshaft. Refer to CYLINDER
BLOCK. 1. Camshaft lock
2. Camshaft
REQUIRED TOOL
Camshaft Inspection
Camshaft Locking Inspect each camshaft lobe and bearing journal
Tool for scoring, scuffing, cracks or other signs of wear.
P/N 460732 Use a micrometer to measure the camshaft bear-
ing journal and lobe height.
3. Lock the camshaft using the Camshaft Locking
Measure the clearance between both ends of the
Tool, P/N 460732.
camshaft and cylinder head.

138
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Cylinder Head

4 1 4 1 3 3 1 2 1 3 3 1 2 1 3 CAMSHAFT TOLERANCES
CAMSHAFT BEARING INNER DIAMETER
(ENGINE FRONT)
25.000 mm to 25.013
NEW mm (.9843 in. to .9848
in.)
1. Camshaft lobe (exhaust valves)
2. Camshaft lobe (intake valves) SERVICE LIMIT 25.050 mm (.9862 in.)
3. Camshaft bearing journal
4. Camshaft bearing journal (engine front)
Replace any components that are not within
specification.
CAMSHAFT TOLERANCES
Camshaft Installation
4
CAMSHAFT LOBE HEIGHT — EXHAUST For installation, reverse the removal procedure.
VALVE Pay attention to the following during installation.
31.430 mm to 31.630 1. Grease the camshaft bearing journals using
NEW mm (1.2374 in. to Isoflex Grease TOPAS NB 52, P/N 460783.
1.2453 in.)
31.380 mm (1.2354 REQUIRED CHEMICAL
SERVICE LIMIT in.)
Isoflex Grease TOPAS NB 52
CAMSHAFT LOBE HEIGHT — INTAKE VALVE
P/N 460783
31.540 mm to 31.740
NEW mm (1.2417 in. to 2. Install the camshaft.
1.2496 in.) 3. Place the camshaft lock in place.

SERVICE LIMIT 31.50 mm (1.2402 in.)

CAMSHAFT BEARING JOURNAL
39.892 mm to 39.905
NEW mm (1.5706 in. to
1.5711 in.)
39.880 mm (1.5701
SERVICE LIMIT in.)
CAMSHAFT BEARING JOURNAL (ENGINE
FRONT)
24.939 mm to 24.960
mm (.9819 in. to .9827 1. Camshaft lock
NEW
in.) 4. Install all other removed components. Refer to
the proper sections for the installation
SERVICE LIMIT 24.910 mm (.9807 in.)
procedures.
CAMSHAFT BEARING INNER DIAMETER Cylinder Head
40.000 mm to 40.020 Cylinder Head Removal
NEW mm (1.5748 in. to 1. Lock the crankshaft. Refer to CYLINDER
1.5756 in.) BLOCK.
2. Drain the coolant. Refer to Draining the Engine
40.050 mm (1.5768 Coolant System, page 118.
SERVICE LIMIT in.)

139
Engine
Cylinder Head

3. Remove the blow-by valve from the cylinder

head. Refer to Blow-By Valve Removal, page
107.
4. Unplug the camshaft position sensor (CAPS).
5. Unplug the coolant temperature sensor (CTS).
6. Disconnect the bleed hose.
7. Disconnect the cylinder head outlet hose.

1. M6 cylinder head screws

12. Remove and discard the M11 cylinder head

screws securing the cylinder head to the cylin-
der block.

TYPICAL
1. Coolant temperature sensor
2. Bleeding nipple
3. Cylinder head outlet hose

8. Remove the exhaust manifold. Refer to Ex-

haust Manifold Removal, page 58.
9. Unscrew the oil filler tube support from the cyl-
inder head.

1. M11 cylinder head screws

13. Remove the cylinder head.

14. Remove and discard the cylinder head gasket.
Cylinder Head Cleaning
1. Remove any carbon deposits from the com-
bustion chamber, exhaust port and the top of
the pistons.
2. Clean the cylinder head.
3. Clean the cylinder head screw surface from oil
spillage.
1. Retaining screws
4. Use compressed air to blow out the oil orifices
2. Oil filler tube support and ensure they are not clogged.
10. Remove the camshaft timing gear. Refer to
Camshaft Timing Gear Removal, page 136.
11. Remove the M6 cylinder head screws.

140
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Cylinder Head

Cylinder Head Installation

For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Check the dowel pins are in place.
2. Install a NEW cylinder head gasket.

NOTICE
Each installation of the cylinder head re-
quires a new cylinder head gasket. Reuse of
a cylinder head gasket will result in engine
damage even if the engine has not been run.
1. Oil orifices
REQUIRED CHEMICALS
4
Cylinder Head Inspection
Inspect the cylinder head for cracks between the Loc-Tite 243
valve seats or other damage. If damage is found,
replace the cylinder head as necessary. P/N 460790
Use a straight edge to check the flatness of the 3. Apply Loc-Tite 243, P/N 460790, onto the
cylinder head. threads of the M6 cylinder head screws.
4. Install the M6 screws and tighten manually.
5. Install new M11 cylinder head screws and
tighten manually.

NOTICE
This assembly uses stretch screws. As the
screws have been stretched from the pre-
vious installation, it is very important to use
new screws during installation. Failure to re-
place the screws and follow the torque proce-
dure may cause the screws to become loose
and cause engine damage.
1. Cylinder head
2. Flat bar 6. Using the following torque sequence and tor-
3. Feeler gauge
que specifications, tighten the M11 cylinder
Check the cylinder head for warping. head screws.

CYLINDER HEAD WARPARGE

Maximum 0.15 mm (.006 in.)

If the cylinder head exceeds the warpage specifi-

cations, resurface the cylinder head as follows.
Use a 400– 600 grit wet sandpaper on a surface
plate and gently grind the mating surface.
N O T E : To ensure an even surface, rotate the
cylinder head several times during the resurfacing
process.

If the resurfacing process fails, replace the cylin-

der head.

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Engine
Cylinder Head

REQUIRED TOOLS

Valve Spring
Compressor
P/N 460724

Valve Spring Com-

pressor Cup
P/N 460757

3. Compress the valve springs using the Valve

Spring Compressor, P/N 460724, and the
Valve Spring Compressor Cup, P/N 460757.

CYLI NDER HEAD SCREWS TIGHTENING SEQUENCE

N O T E : Always complete a step in ALL M11 cyl-

inder head screws before proceeding to the next
step.

TORQUE
40 N·m (30
Step 1
lbf·ft)
Apply an
M11 Cylinder Step 2 additional
Head Screws 120° rotation
Apply an
Step 3 additional 90°
rotation

7. Install and tighten the M6 cylinder head screws 1. Valve spring compressor
to the proper specification. 2. Valve spring compressor cup

TORQUE 4. Locate the Valve Spring Compressor in the

center of the valve as seen in the image below.
M6 Cylinder Head 9 N·m (80 lbf·in)
Screws

8. Remove the crankshaft and camshaft locking

tools.
9. Install all other removed parts.
Valve Springs
Valve Spring Removal
1. Remove the rocker arm shaft. Refer to Rocker
Arm Removal, page 134.
2. Remove the cylinder head. Refer to Cylinder
Head Removal, page 139.

142
 Engine
Cylinder Head

1
1. Valve spring length 4
VALVE SPRING FREE LENGTH
VAL VE SPRING COMPRESSOR LOCATED IN THE CENTER
OF THE VALVE SPECIFICATIONS

5. Remove the valve cotters. OUTER VALVE SPRING FREE LENGTH

6. Remove the valve spring compressor, valve
spring retainer and valve springs. NEW NOMINAL 45.45 mm (1.789 in.)

SERVICE LIMIT 43.00 mm (1.693 in.)

INNER VALVE SPRING FREE LENGTH
NEW NOMINAL 41.02 mm (1.615 in.)

SERVICE LIMIT 38.8 mm (1.528 in.)

Valve Spring Installation

For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Place the colored area of the valve spring on
top.
1. Valve cotters 2. Ensure the valve cotters are properly engaged
2. Valve spring retainer in the valve stem grooves.
3. Inner valve spring
4. Outer valve spring

Valve Spring Inspection

Inspect the valve springs for rust, corrosion or oth-
er visible damage.
If damage is found, replace the faulty valve
springs.
Inspect the valve springs free length and
straightness.
Replace the valve springs the free length or
straightness is not within specifications.

1. Position of the valve spring

143
Engine
Cylinder Head

Valves
Valve Removal
1. Remove the valve spring. Refer to Valve
Spring Removal, page 142.
2. Push the valve stem then pull the valves out of
the valve guides.

1. Intake valve 38 mm
2. Exhaust valve 31 mm

3. Remove the valve stem seal and discard.

REQUIRED TOOL Valve Inspection
Valve Stem Seal Inspection
Snap-On Valve Stem Pliers Always install a NEW valve stem seal whenever
P/N YA8230 the valves have been removed.
Valve Inspection
Inspect the valve surface.
Check for abnormal stem wear and bending.
If damage is found, replace as necessary.
Valve Stem and Valve Guide Clearance
Clean the valve guides of any carbon deposits.
Using a micrometer and a small bore gauge,
measure the valve stem and valve guide in three
place.
Replace the valve if the valve stem is not within
specification.
Replace the valve if excessive wear is found.

144
 Engine
Cylinder Head

Valve Face and Seat Inspection

4
1. Valve seat
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)

Inspect the valve face and seat for burning or pit-

ting. Replace the valve or cylinder head if damage
is found.
1. Valve stem diameter Ensure the valves seat properly. Apply some lap-
ping compound onto the valve face and work valve
VALVE STEM DIAMETER onto the valve seat using a lapping tool.

NEW Measure the valve face contact width.

5.946 mm – 5.960 mm The location of the contact area should be in the

EXHAUST (.2341 in. - .2346 in.) center of the valve seat.
Using a caliper, measure the valve seat width.
5.961 mm – 5.975 mm
INTAKE (.2347 in. - .2352 in.) VALVE SEAT CONTACT WIDTH
SERVICE LIMIT NEW
EXHAUST 1.25 mm – 1.55 mm
5.93 mm (.233 in.) EXHAUST
INTAKE (.049 in. - .061 in.)
1.10 mm – 1.30 mm
If the valve guide is out of specification or dam- INTAKE (.0.43 in. - .051 in.)
aged, replace the valve guide. Refer to VALVE
GUIDE. SERVICE LIMIT
VALVE GUIDE INNER DIAMETER EXHAUST 1.8 mm (.071 in.)
NEW INTAKE 1.6 mm (.063 in.)
EXHAUST 5.994 mm – 6.018 mm
(.236 in. - .2369 in.) If the valve seat contact width is too wide or has
INTAKE dark spots, replace the cylinder head.
SERVICE LIMIT
EXHAUST
6.060 mm (.2386 in.)
INTAKE

145
Engine
Cylinder Head

1 1

1. Valve face contact width

2. Valve seat contact width
1. Valve seat outer diameter INTAKE
Valve Seat Grinding
N O T E : The valve seats may be reground with a VALVE SEAT OUTER DIAMETER
valve seat grinder which centers on the valve
guide. INTAKE 37.35 mm (1.4705 in.)

1. Grind the valve seat at 45°. Remove no more EXHAUST 30.3 mm (1.1929 in.)
material than is absolutely necessary to clean
the seat. 3. Using a 55° stone for the intake and an 80°
2. Using a 35° stone, narrow the valve seat until stone for the exhaust valve, reduce the valve
the appropriate outer diameter is obtained. seat contact width to the appropriate value
mentioned above.
4. Using a manual valve grinding mandrel, coat
the valve seat surface with a fine paste of valve
grinding compound.
5. Lightly grind the valves until a smooth, even,
unformed sealing surface of the appropriate in-
side and outside diameter is obtained on both
the valve and the seat.
6. While grinding, rotate the valve back and forth
through about 45°.
1
7. Advance the valve 45° before repeating this
operation.
Valve Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.

1. Valve seat outer diameter EXHAUST

1. Install a NEW valve stem seal.

146
 Engine
Cylinder Head

4. Ensure the valve springs and valve spring re-

tainers are properly locked by tapping on the
valve stem end with a soft hammer so the
valve opens and closes a few times.
NOTICE
An improperly locked valve spring will cause
engine damage.

Valve Guide
Valve Guide Removal
NOTICE
Do not heat the cylinder head to perform this 4
procedure.

NOTICE
The sharp edge near the top of the valve
1. Valve stem seal guide must be machined away. If this is not
2. Apply engine oil to the valve stem and install completed the valve guide hole in the cylinder
the valve. head will foul and as the valve guide is re-
moved the cylinder head will be destroyed.
NOTICE
Be careful when the valve stem is passed 1. Use a special reamer as far as the top of the
though the sealing lips of the valve stem seal. notch.

1. Sealing lips of valve stem seal

3. Install the valve springs. Refer to Valve Spring TYPICAL

Installation, page 143. 1. Special reamer
2. Notch
N O T E : To ease installation of cotters, apply en-
gine oil or grease to hold in place while releasing
the spring.

147
Engine
Cylinder Head

REQUIRED TOOL

Valve Guide
Remover
P/N 460758

2. Using the Valve Guide Remover, chase the

valve guide out of the cylinder head towards
the combustion chamber.

TYPICAL
1. Valve guide leading end
2. Cylinder head bore
TYPICAL 3. Valve guide pusher (6 mm)
1. Punch

Valve Guide Installation

1. Grease the bore in the cylinder head and the
leading end of the valve guide using Molykote
G-N, P/N 460799.

REQUIRED CHEMICAL

Molykote G-N
P/N 460799
1
REQUIRED TOOL

Valve Guide Pusher

6 mm
P/N 460759

2. Use the Valve Guide Pusher 6 mm, P/N TYPICAL

1. Protrusion
460759, to press the valve guide into the
COLD cylinder head as shown.

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 Engine
Cylinder Head

VALVE GUIDE PROTRUSION

MINIMUM 12.4 mm (.4882 in.)

MAXIMUM 12.8 mm (.5039 in.)

N O T E : After installing new guides, they must be

reamed with a standard 6 mm reamer tool. These
are available from various tool suppliers.
3. Clean the cylinder head carefully. Refer to Cyl-
inder Head Cleaning, page 140.
4. Verify the valve seat is concentric with the new
guide axis (check the contact surface with en-
4
gineer’s blue).

149
 Engine
Cylinder Block

Cylinder Block

SERVICE TOOLS
Description Part Number Page

ADAPTER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460720 . . . . . . . . . . . . . . . . . . . . . . . . 89

ALIGNMENT SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460723 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460839 . . . . . . . . . . . . . . . . . . . . . . . . 24
ALIGNMENT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460709 . . . . . . . . . . . . . . . . . . . . . . . . 24
BLIND HOLE BEARING PULLER SET . . . . . . . . . . . . . . . . . . . . . P/N 460760 . . . . . . . . . . . . . . . . . . . . . . . . 74
CAMSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 138
CRANKSHAFT LOCKING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460729 . . . . . . . . . . . . . . . 164, 166, 173
DRIVE SHAFT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460745 . . . . . . . . . . . . . . . . . . . . . . . 129
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . 93, 109
ENGINE ALIGNMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460719 . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE LEAK DOWN TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460721 . . . . . . . . . . . . . . . . . . . . . . . 130
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . . . . . . . . . . . . . . . 93, 109
FLUSHING CONNECTOR ADAPTER . . . . . . . . . . . . . . . . . . . . . . P/N 460711 . . . . . . . . . . . . . . . . . . . . . . . . 51
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460714 . . . . . . . . . . . . . . . . . . . . . . . . 74
LARGE HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460717 . . . . . . . . . . . . . . . . . . . . . . . . 42
OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460708 . . . . . . . . . . . . . . . . . . . . 73, 122
OIL SEAL GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460730 . . . . . . . . . . . . . . . . . . . . . . . . 98
PISTON CIRCLIP INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460726 . . . . . . . . . . . . . . . . . . . . . . . 159
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 89
STARTER DRIVE SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460713 . . . . . . . . . . . . . . . . . . . . . . . . 74
SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . . . . . 88
SUPERCHARGER GEAR HOLDER . . . . . . . . . . . . . . . . . . . . . . . P/N 460753 . . . . . . . . . . . . . . . . . . . . . . . 176
SUPERCHARGER OIL SPRAY NOZZLE TOOL . . . . . . . . . . . . . . P/N 460761 . . . . . . . . . . . . . . . . . . . . . . . 103
SUPERCHARGER RETAINING KEY . . . . . . . . . . . . . . . . . . . . . . P/N 460755 . . . . . . . . . . . . . . . . . . . . . . . 178
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460740 . . . . . . . . . . . . . . . . . . . 176, 178
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . . . . . 120
TORX ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460739 . . . . . . . . . . . . . . . . . . . 177, 180
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460736 . . . . . . . . . . . . . . . . . . . . 43, 120
VALVE GUIDE PUSHER 6 MM . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460759 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE GUIDE REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460758 . . . . . . . . . . . . . . . . . . . . . . . 148
VALVE SPRING COMPRESSOR CUP . . . . . . . . . . . . . . . . . . . . . P/N 460757 . . . . . . . . . . . . . . . . . . . . . . . 142
VALVE SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460724 . . . . . . . . . . . . . . . . . . . . . . . 142
WATER PUMP SEAL PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460731 . . . . . . . . . . . . . . . . . . . . 98, 100

SERVICE TOOLS — OTHER SUPPLIER

Description Part Number Page

SNAP-ON PISTON RING COMPRESSOR PLIERS . . . . . . . . . . . P/N RC980 . . . . . . . . . . . . . . . . . . . . . . . 160

SNAP-ON VALVE STEM PLIERS . . . . . . . . . . . . . . . . . . . . . . . . P/N YA8230 . . . . . . . . . . . . . . . . . . . . . . . 144

SERVICE PRODUCTS
Description Part Number Page

AIR FILTER OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460800 . . . . . . . . . . . . . . . . . . . . . . . . 31

ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 79
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . 139
ISOFLEX GREASE TOPAS NB 52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 . . . . . . . . . . . . . . . . . . . . . . . . 74
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 24–26, 36, 63, 93, 99, 102–103,

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Cylinder Block

SERVICE PRODUCTS
108, 111, 125, 137, 141, 172,
179–180
LOC-TITE 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460360 . . . . . . . . . . . . . . . . . . . . . . . 119
LOC-TITE 5910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460792 . . . . . . . . . . . . . . . . 94, 171, 179
LOC-TITE CHISEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460797 . . . . . . . . . . . . . . . . . . . 171, 179
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 125
LOCT-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . . . . . . 58
MOLYKOTE G-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460799 . . . . . . . . . . . . . . . . . . . . . . . 148
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798 . . . . . . . . . . . . . . 23, 69, 72, 100
SUPER LUBE GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460784 . . . . . . . . . . . . . . . . . . . . . . . . 89
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460885 . . . . . . . . . . . . . . . . . . . . . . . 179
4

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Cylinder Block

Cylinder Block Service Chart

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Cylinder Block

Crankshaft, Balance Shaft and Pistons

Service Chart

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Engine
Cylinder Block

General Engine Suddenly Turns OFF (Poor Idling)

When disassembling parts that are duplicated in
the engine (e.g.: valves, springs, etc.), it is strongly 1. Piston rings are worn out
recommended to note their position and to keep – Replace the piston rings
the parts of the same assembly as a “group”. If 2. Piston/cylinder all clearance is out of
you find a defective component, it will be much specification
easier to find the root cause of the failure. Since – Check the piston/cylinder wall clearance
parts were broken in together during engine oper- – Replace if out of specification
ation, they will keep their matched fit when parts
are assembled together within their “group”. 3. Melted or broken piston
– Check if the oil spray nozzle is clogged. Re-
Cylinder Block Troubleshooting fer to Piston Oil Spray Nozzles, page 104.
The following is provided to help in diagnosing the – Replace the piston and cylinder block if
probable source of troubles. It is a guideline and it necessary
should not be assumed to list all possible
problems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES.

Unusual Engine Noise or Vibrations

1. Heavy wear on plain bearings

– Check radial play of plain bearings
– Check if the plain bearings are out of
specification
2. Crankshaft and balance shaft are not properly
aligned
– Disassemble the cylinder block and check if
the timing marks are properly aligned
3. Crankshaft or balance shaft axial play out of
specification
– Measure crankshaft and balance shaft axial
play
– If axial play is out of specification, replace
the trust washers
4. Connecting rod axial play out of specification
– Measure connecting rod axial play on
crankshaft
– Replace the connecting rod or crankshaft if
out of specification
5. Connecting rod screws are loose
– Replace any damaged components and
torque the connecting rod screws to
specification

Blue Smoke In The Exhaust

1. Oil scraper rings are worn out

– Replace the piston rings

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Cylinder Block

Procedures 1. Remove the chain tensioner plug screw.

Timing Chain 2. Remove the gasket ring.
3. Remove the chain tensioner.
Timing Chain Removal
1. Remove the engine oil. Refer to Engine Oil
and Filter Replacement, page 18.
2. Remove the engine from the vehicle. Refer to
Engine Removal, page 23.
3. Remove the cylinder head. Refer to Cylinder
Head Removal, page 139.
4. Remove the PTO housing. Refer to PTO Hous-
ing Removal, page 68.
5. Remove the timing chain. 4
Timing Chain Inspection
Inspect the timing chain on the camshaft gear for
excessive radial play.
Inspect the timing chain for excessive wear. 1. Plug screw
2. Gasket ring
Inspect the rollers for excessive wear. 3. Chain tensioner

Chain Tensioner Inspection

Inspect the chain tensioner for excessive wear or
cracks.
Check the free movement of the chain tensioner
piston.
If damage is found or the piston does not move
1. Timing chain freely, replace the chain tensioner.

If the chain is excessively worn or damaged, re- Chain Tensioner Installation

place the camshaft timing gear and the timing For installation, reverse the removal procedure.
chain as a set. Pay attention to the following during installation.
Timing Chain Installation 1. Install the chain tensioner.
For installation, reverse the removal procedure. 2. Install a NEW gasket ring.
Pay attention to the following during installation. 3. Install the chain tensioner plug screw and tight-
en to the proper specification.
1. Ensure to perform proper valve timing.
TIGHTENING TORQUE
NOTICE
Improper valve timing will damage engine Chain tensioner plug 17 N·m (150 lbf·in)
components. screw

Pistons and Connecting Rods

2. Lock the crankshaft and camshaft at TDC. Re-
fer to Camshaft Locking Procedure, page 138 Piston and Connecting Rod Removal
and CRANKSHAFT LOCKING PROCEDURE. 1. Measure the connecting rod big end axial play
3. Install the timing chain. prior to removing the connecting rod. Refer to
4. Install the timing chain tensioner. CONNECTING ROD BIG END AXIAL PLAY.
2. Disassemble the cylinder block. Refer to CYL-
Chain Tensioner
INDER BLOCK DISASSEMBLY.
Chain Tensioner Removal 3. Remove the connecting rod cap screws.
Removal of the intake manifold can ease in the re-
moval process of the chain tensioner. Refer to In-
take Manifold Removal, page 35.

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Cylinder Block

N O T E : It is not necessary to remove both circlips

to remove the piston pin.

1. Connecting rod screws

4. Mark the connecting rod caps for proper

installation.
5. Remove the connecting rod caps.
1. Piston
2. Piston pin
3. Circlip

9. Remove the piston from the connecting rod.

Connecting Rod Inspection
Connecting Rod Big End Axial Play
Using a feeler gauge, measure the distance be-
tween the butting face of the connecting rod and
the crankshaft counterweight.
If the distance exceeds the specified tolerance, re-
place the worn part.

1. Mark on connecting rod

6. Remove the piston and connecting rod from

the cylinders.
7. Remove the piston circlip and discard.

1. Crankshaft
2. Feeler gauge

1. Piston circlip

8. Push the piston pin out of the piston.

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CONNECTING ROD BIG END AXIAL PLAY CONNECTING ROD SMALL END RADIAL
PLAY
0.100 mm - 0.352 mm
NEW (.004 in. - .014 in.) 0.080 mm (.003 in.)
SERVICE LIMIT
SERVICE LIMIT 0.500 mm (.02 in.) Connecting Rod Big End Radial Play
Measure the inside diameter of the connecting rod
Connecting Rod Small End Radial Play big end.
Measure the connecting rod small end.
Compare the reading to the diameter of the crank-
shaft pin.
To measure the connecting rod big end diameter,
use the OLD screws. 4
Install the OLD bearings as they were initially
installed.
Tighten the connecting rod screws. Refer to PIS-
TON AND CONNECTING ROD INSTALLATION.

1. Bore gauge
2. Connecting rod 1

CONNECTING ROD SMALL END

DIAMETER
23.01 mm - 23.02 mm
NEW (.9059 in. - .9063 in.) 1. Connecting rod big end bearing

SERVICE LIMIT 23.07 mm (.908 in.)

CONNECTING ROD BIG END DIAMETER
If the connecting rod small end is out of specifica- 45.080 mm (1.775 in.)
SERVICE LIMIT
tion, replace the small end bearing sleeve.
N O T E : For small end bearing sleeve replace- CONNECTING ROD SMALL END
ment, contact a machine shop. After install a new DIAMETER
small end bearing sleeve onto the connecting rod,
SERVICE LIMIT 0.09 mm (.0035 in.)
the inner diameter and the oil holes need to be
machined to specification.
Use NEW bearings when the connecting rod big
Measure the piston pins. Refer to PISTON PIN end diameter is out of specification.
INSPECTION.
Piston Pin Inspection
Compare the readings to the inside diameter of Using synthetic abrasive woven, clean the piston
the connecting rod to obtain the small end radial pin of any deposits.
play.

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Cylinder Block

Inspect the piston pin for scoring, cracking or other

damage.
Measure the piston pin. Refer to the following im-
age for the proper measurement position.

1
1. Piston pin diameter in the area of the bushing
1. Measuring perpendicularly (90°) to piston pin axis
2. 18 mm (.709 in.)
CONNECTING ROD BIG END RADIAL
PLAY If the piston is not within specification, replace the
22.996 mm - 23.000 piston.
NEW mm (.905 in. - .906 in.)
PISTON MEASUREMENT
SERVICE LIMIT 22.990 mm (.905 in.) 150 ENGINE
Measure the connecting rod small end diameter. 99.951 mm - 99.969
Refer to Connecting Rod Small End Radial Play, NEW mm (3.935 in. - 3.936
page 157to check the connecting rod small end ra- in.)
dial play.
SERVICE LIMIT 99.90 mm (3.933 in.)
Piston Inspection
200 AND 250 ENGINES
Inspect the piston for scoring, cracking or other
damage. 99.931 mm - 99.949
NEW mm (3.934 in. - 3.935
If damage is found, replace the piston.
in.)
Using a micrometer, measure the piston at 18 mm
(.709 in.) perpendicularly (90°) to piston pin axis. SERVICE LIMIT 99.90 mm (3.933 in.)

Piston to Cylinder Wall Clearance

Adjust and lock a micrometer to the piston
dimension.

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Cylinder Block

Set the dial bore gauge to 62 mm (2.44 in.) above

the cylinder base.
Measure perpendicularly (90°) to the piston pin
axis.
Read the measurement on the cylinder bore
gauge.
The result of these measurements is the piston to
cylinder wall clearance.
1. Micrometer set to the piston dimension PISTON MEASUREMENT

NOTE: Ensure the piston is not excessively

150 ENGINE 4
worn. 0.024 mm - 0.056 mm
NEW (.001 in. - .002 in.)
With the micrometer set to the dimension, adjust a
cylinder bore gauge to the micrometer dimension SERVICE LIMIT 0.100 mm (.004 in.)
and se the indicator to 0 (zero).
200 AND 250 ENGINES
0.044 mm - 0.076 mm
NEW (.0017 in. - .003 in.)

SERVICE LIMIT 0.100 mm (.004 in.)

If the clearance is out of specification, hone the

cylinder sleeve and replace the piston with an
oversized piston.
I M P O R T A N T : Do not replace a piston with an
oversized piston if the clearance is within specifi-
cations. Mixed standard and oversized pistons are
not a problem.

1. Use the micrometer to set the cylinder bore gauge Piston and Connecting Rod Assembly
2. Dial bore gauge For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Apply engine oil to the piston pin.
2. Insert the piston pin into the piston and con-
necting rod.

REQUIRED TOOL

Piston Circlip
Installer
P/N 460726

3. Using the Piston Circlip Installer, P/N 460726,

install a new piston circlip.
1. Indicator set to 0 (zero)
NOTICE
IMPORTANT: Make sure the cylinder bore Secure the piston pun with a NEW piston.
gauge indicator is set exactly to the same position
as with the micrometer or the reading will be false.
4. Properly position the hook of the piston circlip.

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Engine
Cylinder Block

1. Sleeve with piston circlip inside

2. Assembly jig from piston circlip

NOTICE
Install the pistons with the punched arrow to-
wards the exhaust side of the cylinder.

Piston and Connecting Rod Installation

1. Using a piston ring compressor, slide the pis-
ton into the cylinder.

REQUIRED TOOL
1. Arrows toward exhaust side
Snap-On Piston Ring Compressor Pliers
P/N RC980 2. Carefully clean the split surfaces of the con-
necting rod and the connecting rod cap.
3. Correctly install the bearings.

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 Engine
Cylinder Block

4
1. Angle torque wrench

Piston Rings
1. Half bearing of connecting rod big end Piston Ring Removal
2. Split surface of the connecting rod 1. Remove the pistons. Refer to Piston and Con-
3. Protrusion of bearing in line with connecting rod groove
necting Rod Removal, page 155.
4. Install the connecting rod caps. 2. Remove the piston rings from the piston.
5. Install the connecting rod screws and torque to
the proper specification using the following Piston Ring Inspection
table. Ring to Piston Groove Clearance
Using a feeler gauge, measure each ring to piston
NOTE: Do NOT apply threadlocker to the groove clearance.
threads of the connecting rod screws.
If the clearance is too large, the piston and piston
TIGHTENING PROCEDURE rings should be replaced.

Step 1 on 45 N·m (33 RING TO PISTON GROOVE CLEARANCE

Connecting each screw lbf·ft)
NEW
rod screws Step 2 on
+90° 0.025 mm - 0.070 mm
each screw RECTANGULAR (.001 in. - .0028 in.)
NOTICE 0.015 mm - 0.060 mm
TAPER-FACE (.0006 in. - .0024 in.)
Failure to strictly follow the tightening proce-
dure for the connecting rod screws may
cause the screws to become loose. If the 0.020 mm - 0.055 mm
OIL SCRAPER RING (.0008 in. - .0022 in.)
screws become loose engine damage will oc-
cur. Always use NEW connecting rod screws SERVICE LIMIT
during assembly.
NEW 0.15 mm (.006 in.)

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Cylinder Block

PISTON RING INSTALLATION

Stamped “E”
SECOND Taper-face
and “TOP”
STEP ring
facing UP
Stamped “E”
Rectangular
THIRD STEP and “TOP”
ring
facing UP

1. Piston
2. Feeler gauge

Ring End Gap

RING END GAP

NEW
0.30 mm - 0.50 mm
RECTANGULAR (.012 in. - .02 in.)
1. Rectangular ring
0.35 mm - 0.55 mm 2. Taper-face ring
TAPER-FACE (.014 in. - .022 in.)
3. Oil scraper ring

0.35 mm - 0.50 mm
NOTICE
OIL SCRAPER RING (.014 in. - .02 in.) Ensure the top ring and the second ring are
not interchanged.
SERVICE LIMIT
NEW 1.50 mm (.0591 in.) 2. Use a ring expander to install the rings onto
the piston.
Measure the position for ring gap end in the area I M P O R T A N T : Do NOT install the oil ring using
of 8 mm to 16 mm (.315 in. to 0.63 in.) from the a ring expander. Install the oil ring by hand.
top of the cylinder.
3. Check the rings rotate freely after installation.
N O T E : In order to correctly position the ring in 4. Space the piston ring end gaps 120° apart.
the cylinder, use the piston as a pusher.
IMPORTANT: Do NOT align the piston ring
Using a feeler gauge, check ring end gap. If the gaps with the piston bore or the thrust side axis.
piston ring exceeds to the service limit specifica-
tion, replace the piston ring.
Piston Ring Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Install the piston rings according the table
below.
PISTON RING INSTALLATION
ORDER RING POSITION
Oil scraper Stamped dot
FIRST STEP ring facing UP

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3
3 3

2 4
1. Crankshaft access plug screw
2. Gasket ring

5. Turn the engine counterclockwise.

6. Bring the no 3 cylinder to TDC. Use a dial
1. Do NOT align ring gap with piston thrust side axis gauge or another similar tool to ensure the no
2. Do NOT align ring gap with piston bore axis 3 piston is at TDC.
3. 120°

Crankshaft N O T E : When the no 3 piston is at TDC, the posi-

tion lines on the oil separator cover must be
Crankshaft Locking Procedure aligned as shown in the following image.
NOTICE
NOTICE
The crankshaft must be locked at TDC for re-
moval and installation of the crankshaft, bal- Do not scratch or damage the piston or cylin-
ance shaft and camshaft. der surface.

N O T E : When the crankshaft is locked, the no. 3

piston will be at TDC.

1. Remove the intake manifold. Refer to Intake

Manifold Removal, page 35.
2. Remove the spark plugs.
3. Remove the cylinder head. Refer to Cylinder
Head Removal, page 139.
4. Remove the crankshaft access plug screw and
gasket.

1. Dial gauge

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1. Position lines
1. Crankshaft
7. Use a small screw driver to check if the groove
in the crankshaft is aligned with the hole. Crankshaft Inspection
Crankshaft Gear Inspection
REQUIRED TOOL
Inspect the crankshaft gear for excessive wear or
other damage.
Crankshaft Locking
Tool If excessive wear or damage is found, replace the
crankshaft.
P/N 460729

8. Using the Crankshaft Locking Tool, P/N

460729, lock the crankshaft in position.
Crankshaft Removal
1. Disassemble the cylinder block. Refer to CYL-
INDER BLOCK DISASSEMBLY.
2. Remove the connecting rod screws. Refer to
Piston and Connecting Rod Removal, page
155.
3. Remove the thrust washers.

1. Balancer gear
2. Crankshaft timing gear

Crankshaft Pin
Using a micrometer, measure all crankshaft pin
diameters.
Compare the readings to the inside diameter of
the connecting rod bearings. Refer to Connecting
Rod Inspection, page 156.

1. Thrust washer

4. Remove the crankshaft.

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Crankshaft Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.
I M P O R T A N T : Before installing the crankshaft,
make sure the timing chain is on the crankshaft
and the chain guide has been installed. The timing
chain and chain guide cannot be installed when
the crankshaft is in the way.
1. Align the balance shaft gear and crankshaft
gear marks.

4
1. Micrometer
2. Crankshaft area for bearing

CRANKSHAFT PIN DIAMETER

45.032 mm - 45.048
NEW mm (1.7729 in. -
1.7735 in.)
45.029 mm (1.7728
SERVICE LIMIT in.)

Crankshaft Axial Clearance 1. Mark on balance shaft

When assembling the cylinder block, measure the 2. Mark on crankshaft
crankshaft axial clearance. 2. Install the pistons and connecting rods. Refer
to Piston and Connecting Rod Installation,
page 160.
NOTICE
If this process is not followed, engine damage
will occur.

3. Insert the thrust washers as soon as the crank-

shaft is in place.
NOTICE
Install the thrust washer in the center of the
crankshaft to control axial adjustment.

1. Dial gauge
2. Crankshaft

CRANKSHAFT AXIAL CLEARANCE

0.08 mm - 0.22 mm
NEW (.003 in. - .009 in.)

SERVICE LIMIT 0.35 mm (.014 in.)

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Cylinder Block

THRUST WASHER INSERT DIRECTION

1. Thrust washer

NOTICE 1. Crankshaft locking tool

Thrust washers have to be flush with the cyl- 7. Assemble the engine. Refer to the proper sec-
inder block sealing surface. tions for assembly.
Balancer Shaft
Balance Shaft Removal
1. Disassemble the cylinder block. Refer to CYL-
INDER BLOCK.
2. Remove the thrust washers.

1. Thrust washer
2. Sealing surface

4. Install the lower half of the cylinder block. Refer

to CYLINDER BLOCK.
REQUIRED TOOL
1. Thrust washer

Crankshaft Locking 3. Remove the balancer shaft.

Tool
Balancer Shaft Inspection
P/N 460729 Inspect the balancer shaft and replace if
damaged.
5. Position the crankshaft at TDC and lock in
place using the Crankshaft Locking Tool, P/N If the gear on the balancer shaft is damaged, re-
460729. place the balancer shaft.
6. Install the camshaft and the rocker arms. Refer
Inspect the gear on the crankshaft during the
to CYLINDER HEAD.
inspection.
Balancer Shaft Seat Play
Measure all of the balancer shaft bearing seats.

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 Engine
Cylinder Block

Compare the readings to the inside diameter of BALANCER SHAFT AXIAL CLEARANCE
the balancer shaft bearings. Refer to CYLINDER
BLOCK INSPECTION. 0.02 mm - 0.25 mm
NEW (.001 in. - .01 in.)

SERVICE LIMIT 0.35 mm (.014 in.)

Balancer Shaft Installation

For installation, reverse the removal procedure.
Pay attention to the following during installation.

NOTICE
The balancer shaft and the crankshaft marks
must be aligned or engine damage will occur.
4
1. Align the crankshaft and the balancer shaft
marks.
1. Micrometer
2. Balance shaft area for bearing

BALANCER SHAFT SEAT DIAMETER

31.984 mm – 32.000
NEW mm (1.2592 in. -
1.2598 in.)
31.950 mm (1.2579
SERVICE LIMIT in.)

BALANCER SHAFT SEAT RADIAL

CLEARANCE
SERVICE LIMIT 0.07 mm (.0028 in.)
1. Mark on balancer shaft
2. Mark on crankshaft
Balancer Shaft Axial Clearance
When assembling the cylinder block, measure the NOTICE
balance shaft axial play. Never forget the thrust washers on the PTO
side to control the axial adjustment on the
balancer shaft.

2. Insert the thrust washer as soon as the bal-

ancer shaft is in place.

1. Dial gauge
2. Balancer shaft

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Cylinder Block

5. Remove the oil suction pump. Refer to Oil Suc-

tion Pump Removal, page 100.
6. Remove the engine mounting brackets.
7. Remove the oil reservoir plug screw and O-
ring.

THRUST WASHER INSERT DIRECTION

1. Mark on crankshaft ENGINE UPSIDE DOWN
1. Oil reservoir plug screw and O-ring
NOTICE
8. Remove the cylinder block screws.
Thrust washers have to be flush with the cyl-
inder block sealing surface.

1. Cylinder block screws

9. Remove the cylinder block lower half.

10. Remove the crankshaft cover with O-rings.
1. Thrust washer
11. Remove the balancer shaft. Refer to Balance
2. Sealing surface Shaft Removal, page 166.
12. Remove the crankshaft. Refer to Crankshaft
3. Install the cylinder block lower half. Refer to Removal, page 164.
CYLINDER BLOCK. 13. Remove the pistons and connecting rods. Re-
4. Assemble the engine using the proper sections fer to Piston and Connecting Rod Removal,
within this manual. page 155.
Cylinder Block Bearings
Cylinder Block Disassembly When the bearings need to be removed from the
1. Remove the engine oil. Refer to Engine Oil cylinder block, mark them to identify the correct
and Filter Replacement, page 18. position during installation.
2. Remove the engine from the vehicle. Refer to
Engine Removal, page 23.
3. Remove the cylinder head. Refer to Cylinder
Head Removal, page 139.
4. Remove the PTO housing. Refer to PTO Hous-
ing Removal, page 68.

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 Engine
Cylinder Block

4
5
1

4
1. First measuring diameter
2. Second measuring diameter
3. Third measuring diameter
4. 60 mm (2.362 in.)
5. 110 mm (4.331 in.)

CYLINDER TAPER IN DIAMETER

1. Marks on balancer shaft bearings
2. Marks on crankshaft bearings NEW MAXIMUM 0.038 mm (.001 in.)

SERVICE LIMIT 0.100 mm (.004 in.)

Cylinder Block Inspection
Cylinder The distance between the measurements should
Inspect the cylinder for cracks, scoring and wear not exceed the service limit in the table above.
ridges at the top and bottom of the cylinder.
Cylinder Out Of Round
If damage is found, replace the cylinder. Measure the cylinder diameter in piston axis direc-
Cylinder Taper tion from the top of the cylinder.
Measure the cylinder bore. Take another measurement 90° from the first
If the cylinder bore measurements are not within measurement.
specifications, hone the cylinder sleeve and re- Compare the two measurements.
place the piston with first oversize.
N O T E : Take the same measuring points as de-
N O T E : It is not necessary to have all cylinders scribed in Cylinder Taper, page 169.
honed if they are within specification.
Measure the cylinder bore at 3 different positions.

1
2

1. Perpendicular to crankshaft axis

2. Parallel to crankshaft axis

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Cylinder Block

CYLINDER OUT OF ROUND BALANCER SHAFT BEARING INSIDE

DIAMETER
NEW MAXIMUM 0.008 mm (.0003 in.)
SERVICE LIMIT 32.11 mm (1.2642 in.)
SERVICE LIMIT 0.015 mm (.0006 in.)
Replace the bearings if the readings are out of
Crankshaft Bearings specification.
To measure the wear of the crankshaft bearings
and the balancer shaft bearings, both cylinder Cylinder Block Assembly
block halves with OLD bearings have to be For installation, reverse the removal procedure.
screwed together. Pay attention to the following during installation.
Measure the inside diameter of the bearings using 1. Install the banjo screw and tighten to
a bore gauge. specification.

TIGHTENING TORQUE
Banjo screw 19 N·m (168 lbf·in)

2. Use NEW bearings when the diameters are

out of specification.
3. If the OLD bearings can be used again, ensure
they are installed in the same position as when
they were removed.
4. Correctly install the bearings.

N O T E : The top crankshaft bearings has a bore

which must be placed in the upper cylinder block.

ENGINE UPSIDE DOWN

1. Bore gauge

CRANKSHAFT BEARING INSIDE

DIAMETER
SERVICE LIMIT 50.1 mm (1.9724 in.)

1. Cylinder block upper half

2. Oil bore in cylinder block
3. Oil bore in bearing

N O T E : Bearings have to be flush with the cylin-

der block split surface and their protrusions have
to fit in the notched areas in the cylinder block
seat.

ENGINE UPSIDE DOWN

1. Bore gauge

170
 Engine
Cylinder Block

NOTICE
Do not wiper with rags. Use a new clean hand
towel only.

I M P O R T A N T : When beginning the application

of the crankcase sealant, the assembly and the
first torquing should be dine within 10 minutes. It is
suggested to have everything needed for this pro-
cedure readily available.

N O T E : It is recommended to apply the specific

sealant as described in this procedure to get a uni-
formed application. If you do not use the roller 4
method, you may use your finger to uniformly dis-
tribute this sealant.

1. Bearing protrusion in cylinder block notch

REQUIRED CHEMICAL

5. Apply engine oil onto all of the bearings, into Loc-Tite 5910
the bottom of the cylinder bore and onto the
band of the piston ring compressor tool. P/N 460792
6. Install the pistons and connecting rods. Refer
to Piston and Connecting Rod Installation, 11. Apply Loc-Tite 5910, P/N 460792, onto the
page 160. mating surfaces.
I M P O R T A N T : Before installing the crankshaft, NOTICE
make sure the timing chain is on the crankshaft Do not use other products to seal the crank-
and the chain guide has been installed. The timing case. Do not use an activator with Loc-Tite
chain and chain guide cannot be installed when 5910. Using other products or non-silicone
the crankshaft is in the way. based sealant over a previously sealed
crankcase with Loc-Tite 5910, will lead to
7. Clean all oil passages and make sure there is
poor sealing and possibly a leaking
no debris clogging the passages.
crankcase.
8. Clean all metal components in a solvent.

REQUIRED CHEMICAL N O T E : Refer to the product label for the sealant

curing time. Respect the manufacturer’s recom-
mendations before stating the engine.
Loc-Tite Chisel
P/N 460797 12. Use a 50 mm – 75 mm (2 – 3 in.) soft rubber
roller to apply a thin uniformed coat of sealant
9. Use Loc-Tite Chisel, P/N 460797, to brush a to a Plexiglass plate.
first pass in one direction. 13. Apply the sealant onto the crankcase mating
10. Brush the Loc-Tite perpendicularly 90° to the surfaces.
first pass (cross-hatch).

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Engine
Cylinder Block

TIGHTENING PROCEDURE
40 N·m (30
Step 1
lbf·ft)
M10 cylinder
block screws 55 N·m (41
Step 2
lbf·ft)

16. Install the M10 cylinder block screws and tight-

en according to the image below.

I M P O R T A N T : Do not apply the sealant in ex-

cess as it will spread inside of the crankcase.

REQUIRED CHEMICAL

Loc-Tite 243 TIGHTENING PROCEDURE

P/N 460790 40 N·m (30
Step 1
lbf·ft)
14. Apply Loc-Tite 243, P/N 460790, onto the M10 cylinder
threads of the cylinder block screws. block screws 55 N·m (41
Step 2
15. Tighten the M10 cylinder block screws. Refer lbf·ft)
to the following image for the proper torque
sequence. 17. Check the axial clearance of the balancer shaft
and crankshaft. Refer to Crankshaft Axial
Clearance, page 165 and Balancer Shaft Axial
Clearance, page 167.
18. Install the crankshaft cover.
19. Apply engine oil onto the O-ring and install
cover.
I M P O R T A N T : The crankshaft cover has to be
flush with the cylinder block surface when properly
installed.

M10 CYLINDER BLOCK SCREW TORQUE SEQUENCE

NOTICE
Always perform as step on ALL M10 cylinder
block screws.

172
 Engine
Cylinder Block

1. O-ring
2. Crankshaft cover

20. Mount the engine bracket.

21. Position the crankshaft at TDC.
22. Install the camshaft and the rocker arms. Refer
to Rocker Arm Installation, page 135 and Cam-
shaft Installation, page 139.

REQUIRED TOOL

Crankshaft Locking
Tool
P/N 460729

23. Install the crankshaft locking tool.

1. Crankshaft locking tool

24. Assemble the engine using the proper sections

in this manual.

Supercharger

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Engine
Cylinder Block

Supercharger 200 and 250 Engine Models

174
 Engine
Cylinder Block

Supercharger Inspection 4. Turn the engine by rotation the supercharger

nut counterclockwise until the position lines on
Supercharger Inlet Cleanliness
the oil separator cover are lined up as shown
A lower than usual maximum RPM at full throttle in the following image.
might be caused by a dirty supercharger inlet. 5. Lock the camshaft using the camshaft locking
To access the supercharger, refer to SUPER- tool. Refer to Camshaft Locking Procedure,
CHARGER ACCESS. page 138.

Visually inspect the supercharger inlet side for oil,

salt or other deposits.

1. Camshaft locking tool

2. Position lines

6. Check the slipping moment clockwise.

1. Dirt here

If dirt is found, proceed as follows:

1. Remove the supercharger and perform the
clutch slipping moment test.
2. Inspect the bearings and friction clutch.
3. Replace the bearings and clutch components
as necessary.
4. Clean the internal housing and turbine of any 1. Torque wrench
oil deposits using a brush and cleaning
solvent. 7. Turn the clutch 3 complete revolutions before
5. Blow dry using compressed air. checking the supercharger slipping moment.
8. The supercharger should start to turn at a tor-
NOTICE que within the specifications.
Do not let the turbine spin when using com-
pressed air. SUPERCHARGING SLIPPING
SPECIFICATIONS
Supercharger Clutch Slipping Moment (On SLIPPING MOMENT (NEW SUPERCHARGER)
Engine)
1. Access the supercharger. Refer to SUPER- 9 N·m to 14 N·m (80 lbf·in to 124 lbf·in)
CHARGER ACCESS.
2. Remove the cylinder head cover. Refer to Cyl-
inder Head Cover Removal, page 133.
3. Remove the spark plugs.

175
Engine
Cylinder Block

SUPERCHARGING SLIPPING
SPECIFICATIONS
SLIPPING MOMENT (BREAK-IN
SUPERCHAGER)
8 N·m to 12 N·m (71 lbf·in to 106 lbf·in)

9. If the torque is not within specifications, repair

the supercharger clutch.
10. Verify the proper functionality of the clutch
components.
Supercharger Clutch Slipping Moment (Bench
Test) 1. Torque wrench
1. Mount the supercharger on Support Plate, P/N 2. Supercharger hear holder
460740.
REQUIRED TOOL N O T E : Before checking the supercharger slip-
ping moment on a new or rebuilt supercharger,
turn the clutch for a minimum of 3 complete revolu-
Support Plate tions. This will dissipate grease or oil on the friction
P/N 460740 shims for a proper reading.
4. The supercharger should start to turn at a tor-
REQUIRED TOOLS que within specifications.

Supercharger Gear SUPERCHARGER SLIPPING MOMENT

Holder (ON BENCH) TEST SPECIFICATIONS
P/N 460753 SLIPPING MOMENT (NEW SUPERCHARGER)

2. Hold the supercharger gear using Supercharg- 9 N·m to 14 N·m (80 lbf·in to 124 lbf·in)
er Gear Holder, P/N 460753.
SLIPPING MOMENT (BREAK-IN
SUPERCHARGER)
8 N·m to 12 N·m (71 lbf·in to 106 lbf·in)

5. If the torque is not within specifications, re-

place the supercharger assembly.
Troubleshooting
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and it
should not be assumed to list all possible
problems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to EN-
GINE MANAGEMENT.
Supercharger Procedures
3. Check the slipping moment counterclockwise.
Supercharger Access
1. Open the engine compartment.
2. Remove the air inlet and outlet hoses from the
supercharger.

176
 Engine
Cylinder Block

1. Rubber adapter
2. Exhaust pipe 4
1. Air inlet hose
2. Hose clamp 5. Loosen the clamp securing the rubber adapter
to the exhaust pipe.
6. Detach the muffler strap.
7. Move the muffler back ± 5 cm (2 in.).
Supercharger Removal
N O T E : On CAT engines, remove the CAT as-
sembly prior to removing the supercharger.
1. Remove the supercharger retaining screws.

1. Air outlet hose

2. Hose clamp

3. Remove the blow-by valve screws and move

the blow-by valve to the side.

1. Retaining screws
2. Upper retaining screw (hidden behind supercharger)

REQUIRED TOOL

1. Blow-by valve Torx Adapter

2. Supercharger
P/N 460739
4. Trace a mark on the rubber adapter and ex-
haust pipe. 2. Use the Torx Adapter, P/N 460739, to remove
the upper retaining screw.

177
Engine
Cylinder Block

1. Upper retaining screw

3. Remove the supercharger.

1. Retaining screws
Supercharger Disassembly 2. Housing half (intake side)
3. Housing half (engine side)
NOTICE
Be scrupulous when working on supercharg- 3. Use a plastic hammer to help split the super-
er parts. Supercharger rotation reaches charger housing.
45,000 RPM. Any modification, improper re-
pair, assembly or damage on the parts may
result in supercharger damage.

1. Secure the supercharger on Support Plate, P/

N 460740.
REQUIRED TOOL

Support Plate
P/N 460740

2. Remove the housing screws and split the

supercharger housing.

PLASTI C HAMM ER

REQUIRED TOOL

Supercharger Re-
taining Key
P/N 460755

4. Loosen the cap nut on the supercharger using

the Supercharger Retaining Key, P/N 460755.
Supercharger Assembly
1. Clean the supercharger housing halves using
a part cleaner. Use compressed air to dry.

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 Engine
Cylinder Block

I M P O R T A N T : Be sure that deposits do not get REQUIRED CHEMICAL

into the bearing area.

NOTICE Loc-Tite 243

Do not let the impeller spin when using com- P/N 460790
pressed air.
7. Apply Loc-Tite 243, P/N 460790, onto the re-
REQUIRED CHEMICAL taining screws.
8. Tighten the supercharger housing screws to
the proper specification according to the follow-
Loc-Tite Chisel
ing image.
P/N 460797

2. Clean the supercharger housing mating surfa-

TIGHTENING TORQUE 4
Supercharger housing 9 N·m (80 lbf·in)
ces using Loc-Tite Chisel, P/N 460797.
screws
NOTICE
Never grind or polish the mounting surfaces
of the supercharger. Abrasive dust may
cause severe damage to the supercharger.

3. Using a brass brush, brush in one direction,

then perpendicularly (90°) to the first pass.

REQUIRED CHEMICAL

Loc-Tite 5910
P/N 460792

4. Using a soft rubber roller, apply Loc-Tite 5910,

P/N 460792, onto a plexiglass plate in a thin SUPERCHARGER TIGHTENING SEQUENCE
uniformed coat.
Supercharger Installation
5. Apply the sealant onto the supercharger hous-
ing sealing surface. 1. Install new O-rings.

N O T E : Ensure not to apply too much sealant to REQUIRED CHEMICAL

the mating surfaces as it will spread inside of the
supercharger. Triple Guard Grease
P/N 460885

2. Apply Triple Guard Grease, P/N 460885, to the

mounting surface of the supercharger.

1. Sealing surface

6. Assemble the supercharger housing halves.

179
Engine
Cylinder Block

7. Mount the Torx Adapter, P/N 460739, 90° to

the torque wrench.

1
1. Torx adapter perpendicular to torque wrench
2. 90°
1. Mounting surface with O-rings
8. Install the upper retaining screw and torque to
3. Install the supercharger onto the PTO housing. specification.
NOTICE NOTICE
Never use a hammer when installing the Failure to install the Torx Adapter properly
supercharger. Do not tap the impeller shaft at will change the torque applied to the upper
any time during installation. retaining screw.

4. Turn the impeller while installing the super-

charger to engage the supercharger drive
gear.

CAUTION
The impeller has sharp edges. Wear safety
gloves when turning the supercharger at the
impeller.

REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

5. Apply Loc-Tite 243, P/N 460790, onto the

threads of the supercharger retaining screws.
6. Install the supercharger and tighten the retain-
ing screws to the proper specification.

TIGHTENING TORQUE
Supercharger retaining 8–10 N·m (71–89
screws lbf·in)

REQUIRED TOOL

Torx Adapter
P/N 460739

180
 Electronic Management System
Engine Management Schematic

Electronic Management System

Engine Management Schematic

A. Engine Wiring Harness EGTS — Exhaust Gas MATS — Manifold Air Injector
Connector Temperature Sensor Temperature Sensor

B. Vehicle Wiring harness ETA — Electric Throttle OPS — Oil Pressure Sensor In
Connector Actuator

CAPS — Camshaft Position HO2S Pr — Heated oxygen TAS — Throttle Accelerator Out
Sensor sensor, pre-catalytic Sensor
converter (upstream)

CPS — Crankshaft Position HO2 Po — Heated oxygen TOPS — Tip-Over Protection

Sensor sensor, post catalytic System (only available on
converter (downstream) Non-CAT engines)

CTS — Coolant Temperature KS — Knock Sensor TPS — Throttle Position

Sensor Sensor

ECM — Engine Control MAPS — Manifold Absolute Ignition coil

Module Pressure Sensor

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Electronic Management System
Engine Management System Description

Engine Management System Description

A highly advanced engine management system
(EMS) is used to ensure a high power output with
cleaner combustion. To accomplish this, other
systems must interact with the EMS.
The main systems that interact with the engine
management system are:
– Electronic fuel injection
– Ignition system
– Starting system
– T.O.P.S. (Tip-Over Protection System), only
on NON-CAT engines
– iTC (intelligent Throttle Control system)

Engine Control Module (ECM)

1. ECM on intake manifold

The ECM features a permanent memory that will

store fault codes, customer information and other
engine information, even when the battery is re-
moved from the vehicle.
The ECM controls the following engine manage-
ment functions:
– Engine Speed Limiter
The ECM limits maximum engine speed. It
monitors engine RPM through the CPS.
The ECM varies fuel injection, ignition and
The ECM is mounted on the intake manifold. The throttle plate opening as necessary to limit en-
ECM is the main component of the engine man- gine RPM.
agement system. It controls the electrical system – Engine Speed Control
and the engine management functions by proc- Idle speed is not adjustable. The ECM controls
essing the information obtained from various the engine idle RPM.
switches, controls and sensors that it compares to The throttle/shift lever is connected to the TAS
predetermined parameters stored in the ECM. (Throttle Accelerator Sensor) actuator lever via
a cable. When the throttle lever is pushed for-
It also interacts with other electronic systems ward, it acts upon the TAS located in the helm,
through the CAN bus (information center) for vari- which sends signals to the ECM that are pro-
ous functions that affect engine management. portional to the change in speed or power de-
On Twin engine models, the ECMs (one ECM per sired. The ECM then varies the engine speed
engine) also communicate with each other for by commanding the electric throttle actuator
functions such as engine synchronization. (ETA) towards open or close based on throttle
position and various other inputs. The ETA al-
so allows for other functions of the iTC system
such as cruise and ski modes.

Engine Speed Synchronization

Engine synchronization is used to synchronize
both engines speed on twin engine models.
Engine SYNC mode is a function of both the multi-
function gauge and ECMs. Engine speed synchro-
nization is achieved by the iTC.

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 Electronic Management System
Engine Management System Description

Drowned Mode Diagnostic Mode

If an engine is flooded and does not start, this spe- The ECM features a self-diagnostic mode that is
cial mode can be activated to prevent fuel injection initiated on system power up for certain systems
and ignition while cranking to ventilate the engine and components (when pressing the START but-
and allow the cylinder walls to dry. ton), and when the engine is running for others.
I M P O R T A N T : Engine(s) must be stopped when
using drowned mode to vent a flooded engine.
Proceed as follows to activate drowned mode:
1. Ensure the engine(s) are OFF.
2. Place the throttle lever in NEUTRAL.
3. Move the TAS to WOT and hold.

1. Throttle accelerator sensor (TAS)

2. Wide open throttle position (WOT)

4. Turn the ignition switch to the ON position.

5. Press and hold the START/STOP button.

N O T E : The ECM will allow the engine to crank

while stopping fuel injection and ignition. Do not
crank the engine for more than 10 seconds.
Releasing the TAS will allow the ECM to revert
back to normal mode.
If the engine does not start, it may be necessary to
remove the spark plugs and cranks the engine
with rags over the spark plug holes.

Monitoring System
The ECM monitors electrical and electronic com-
ponents of the engine system, the information
center (gauge), some components of the electrical
system as well as signals from other electronic
modules.

Limp Home Mode

The ECM may automatically put the engine in
LIMP HOME MODE using default parameters
when certain major faults are detected.

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Electronic Management System
Communication Protocols

Communication Protocols
Controller Area Network (CAN) All modules monitor each other. If a component or
The CAN (Controller Area Network) protocol is an system malfunction is detected, a module may
ISO standard for serial data communication. generate a fault code, which it transmits through
the CAN bus as a signal. The fault signal may be
The CAN bus links the electronic modules (ECUs) used for various functions such as triggering the
together so that they communicate to interact as display of an error message in the gauge, turning
required. on a fault indicator light, limiting or inhibiting ve-
hicle or engine operation, or viewed using the B.U.
The communication link is also used to communi- D.S. software for troubleshooting.
cate with the B. U. D. S. software (BRP Utility and
Diagnostic System). On these models, there are 2 isolated CAN
networks.
CAN lines consist of a pair of twisted wires
(WHITE/BLACK-CAN Low and WHITE/RED CAN
High).

CAN PROTOCOL USAGE

– Links the electronic modules (ECUs) together:

ECM, depth sounder, touch screen display
and PC computer connected to B.U.D.S.
CAN 1 (550k) – Transmits the fault codes between ECUs and
to B.U.D.S.
– CAN 1 lines wire color: WHITE/BLACK and
WHITE/RED.

– ROTAX 4-TEC ECT Power Packs will have an

additional CAN network (at 250k) for OBD-M.
CAN 2 (250k) It uses a module called Gateway which hooks
up to standard CAN network and transfers
data in order to provide required information
following SAE J1939 protocol.

184
 Electronic Management System
Communication Protocols

CAN 1 (550K) Diagrams

CAN BUS HI (FUSE BOX ) (500 k)

C5 C4 C7 C6

W/R

W/R

W/R

W/R
B-C1 C1:15 B 1
OBD-M DIAGNOSTIC
ECM GAUGE Gateway CONNECTOR

B-C2 C1:16 A 2
W/BK

W/BK

W/BK

W/BK
C11 C10 C12 C9

CAN BUS LOW (FUSE BOX ) (500 k)

5
SINGLE-ENGINE SERIES GAUGE
CAN BUS HI (FUSE BOX 1) BK = BLACK
CAN BUS LOW (FUSE BOX 1) R = RED
DIAGNOSTIC CONNECTOR W = WHITE
ECM — ENGINE CONTROL MODULE

ADDITIONAL WIRING FOR ECT MODEL TO MEET OBD-M REQUIREMENT. CONNECTION

BETWEEN GATEWAY AND OBD-M COMMUNICATION PORT

185
Electronic Management System
Communication Protocols

CAN BUS HI (FUSE BOX, PORT SIDE) (500 k)

G1 G2 D7 G5 G4 G3
W/R

W/R

W/R

W/R

W/R
B-C1 B B-C1 C1:15 1

ECM OBD-M ECM DIAGNOSTIC

Gateway (STARBOARD) GAUGE
(PORT) CONNECTOR

B-C2 A B-C2 C1:16 2

W/BK

W/BK
W/BK
W/BK
W/BK

G8 G9 E7 G12 G11 G10

CAN BUS LOW (FUSE BOX, PORT SIDE) (500 k)

TWIN ENGINE — MULTIFUNCTION GAUGE NEW DIAGNOSTIC CONNECTOR

CAN BUS HI PORT SIDE
CAN BUS LOW STARBOARD SIDE
DIAGNOSTIC CONNECTOR BK = BLACK
ECM — ENGINE CONTROL MODULE R = RED
FUSE BOX W = WHITE
GAUGE

186
 Electronic Management System
Communication Protocols

ADDITIONAL WIRING FOR ECT MODEL TO MEET OBD-M REQUIREMENT. CONNECTION

BETWEEN GATEWAY AND OBD-M COMMUNICATION PORT.
Local Interconnect Network (LIN)
The LIN bus is a simple broadcast serial network comprising one master and up to 16 slaves. It is used
as a complement to the CAN networks to integrate the following devices.

LIN PROTOCOL
MASTER SLAVE
Analog temperature gauge
Multifunction Gauge Analog fuel sender
Analog speedometer

The master communicates to one slave at a time and supplies the requested information. The analog
gauge can then display the related data (fuel level for example).
One wire connects each component. The LIN line
consists of a WHITE or GREY wire.

187
Electronic Management System
Communication Protocols

ANALOG FUEL LEVEL GAUGE

ANALOG TEMPERATURE GAUGE
GAUGE
GY = GREY

188
 Electronic Management System
Diagnostic Tips

Diagnostic Tips
CAN Communication Problems
Check the fault codes using B.U.D.S. software as a first troubleshooting step.
The following chart gives some symptoms and behaviors relative to the CAN component in question.
The list is not exhaustive or specific to a model. Only the most significant items are given to aid in
troubleshooting.

CAN FAULTY WIRES (NO BOAT BEHAVIOR OR

COMMUNICATION) OBSERVATION IN B.U.D.S.
OBSERVATION IN GAUGE
Engine is set to limp home mode – B.U.D.S. will not be able to
communicate with any
Short circuit in CAN wires electronic module 5
Check engine light is ON – *No vehicle detected*
message will be displayed in
B.U.D.S.
Check engine light is ON – Missing modules
– Cluster tab and its data will
Gauge Some functions not displayed not be available in B.U.D.S.
such as engine hours and RPM – ECM will report a cluster
CAN problem
Engine is set to limp home mode
Check engine light is ON – Missing modules
ECM (Engine Control Module) – ECM tab and its data will not
Some functions not displayed be available in B.U.D.S.
such as engine hours and RPM

– B.U.D.S. will not be able to

communicate with any
Diagnostic Connector No symptom electronic module
– *No vehicle detected*
message will be displayed in
B.U.D.S.
CAN Continuity Tests
If a communication problem is present, perform
the appropriate continuity test relating to the com-
ponent reported by, or not available in B. U. D. S.,
before assuming the component is at fault.

LIN Continuity Tests

For models with a touch screen display, there is
no fault reporting on the LIN Network.

189
Electronic Management System
Communication Tools and B.U.D.S.

Communication Tools and B.U.D.S.

SERVICE TOOLS
Description Part Number Page

MPI-2 DIAGNOSTIC CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460768 . . . . . . . . . . . . . . . . . . . . . . . 190

MPI-2 INTERFACE CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460751 . . . . . . . . . . . . . . . . . . . . . . . 190

Diagnostic Connector Location and B. REQUIRED TOOLS

U.D.S.
B.U.D.S. MPI-2 Interface Card
CONNEC P/N 460751
MODEL NOTE
TOR
LOCATION
MPI-2 Diagnostic
1 diagnostic Cable
Engine
connector —
compartment P/N 460768
SINGLE communicates
next to fuse
with cluster
box 2. Make sure all connections are made and ve-
and ECM
hicle is powered up before starting B.U.D.S. to
Engine 1 diagnostic allow proper communication between the ve-
compartment connector — hicle and B.U.D.S..
next to fuse communicates
TWIN MPI-2 Status Lights
box support with cluster
on starboard and both The MPI-2 includes 2 status lights that indicate the
side ECMs connection condition: USB and CAN. Both lights
must be GREEN for the MPI-2 to function prop-
erly. Otherwise, refer to the following charts.

Prerequisite For USB Communication

1. Turn ON the personal laptop.
2. Connect the MPI-2 interface card USB connec-
tion to a USB connector on the computer.
1. A persona laptop, MPI-2 Cable and MPI-2 In-
terface Card will be needed to use B.U.D.S.

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 Electronic Management System
Communication Tools and B.U.D.S.

No Vehicle Detected
USB LIGHT
If an “X” is shown in the status bar and the protocol
STATUS ACTION tool is blinking between Kw2000 500K and
Kw2000, it means that no “ECU” is communicating
– Check the USB with the MPI.
connection
between the MPI-2
Light is OFF and laptop
– Check the USB
operation on the
laptop (hardware or
Windows driver)

– Communication is
GOOD.
Light is GREEN TYPICAL
Communication
can take place on
the PC side
1. Check the connections between the laptop and 5
the vehicle.
2. Activate the boat electrical system without
Prerequisite For CAN Communication starting the engine.
1. Connect the MPI-2 cable and card to the boat’s
diagnostic connector. N O T E : The tether cord must be installed on the
2. Power up the electrical system to provide engine cut off switch.
power to the ECM.
3. Install the tether cord onto the engine cut-off 3. Ensure both USB and CAN lights on the MPI-2
switch. are GREEN. Refer to MPI-2 Status Lights,
4. Start B.U.D.S. and log in. page 190.
4. If B.U.D.S. does not automatically exit the fol-
CAN LIGHT lowing message box, click the Try active detec-
tion mode button. This will manually establish
STATUS ACTION the communication with the ECUs.
– Check the
connection
Light is OFF between the MPI-2
and vehicle
diagnostic
connector
5. If the following message box is displayed in B.
– Check the CAN
U.D.S., click on the OK button.
Light is RED wires and
6. Ensure the tether cord is properly installed.
connectors on the
7. Click on the Read Data button in B.U.D.S.
vehicle

– Connections are
GOOD.
Light is GREEN Communication
can happen on the
CAN side.

Communication Problems When Using Procedures

B.U.D.S. MPI-2
Missing Module The MPI-2 (Multi-Purpose Interface-2) in conjunc-
If one or more ECUs are not communicating with tion with the MPI-2 diagnostic cable is used with
the MPI-2, refer to DIAGNOSTIC AND FAULT B.U.D.S. software to communicate with the ECM
CODES. (engine control module) and other modules.

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Electronic Management System
Communication Tools and B.U.D.S.

MPI-2 Power 6. Use B.U.D.S. software as described. Refer to

The MPI-2 interface card uses the power from the B.U.D.S. SOFTWARE.
PC computer's USB port.
B.U.D.S.
Connecting The PC To The Boat For
Diagnostics B.U.D.S. (BRP Utility and Diagnostic Software) is
designed to allow programming key (s) to the ve-
1. Locate the 6– pin diagnostic connector. Refer hicle, allow electrical and electronic component
to Diagnostic Connector Location and B. U. D. monitoring, activation of certain components for di-
S., page 190. agnostic purposes, and to carry out settings
2. Disconnect the 6– pin diagnostic connector changes.
from the protective cap.
3. Connect one end of the MPI-2 Diagnostic Ca- For more information pertaining to the use of the
ble to the vehicle connector. B.U.D.S. software, use its help which contains de-
4. Connect the other end of the diagnostic cable tailed information on its functions.
to the MPI-2 Interface Card.
Always use the latest applicable B.U.D.S. version.
How to Read the Electronic Control Units
Using B.U.D.S.
1. Connect the PC to the boat.
2. Ensure the safety lanyard is properly installed
onto the engine cut-off switch.
3. Apply power to the electrical system without
starting the engine.
4. Start B.U.D.S. and log on.
DIAGNOSTIC CABLE CONNECTED TO M PI-2 INTERFACE 5. Ensure the status bar shows the proper
CARD Kw2000 protocol and the appropriate number
of modules according to the vehicle model.
5. Connect the MPI-2 Interface Card to the USB 6. If the proper number of modules are not com-
port of the laptop. municating, refer to MPI-2 Status Lights, page
190.

1. Connection protocol
2. Number of modules read

7. Read the ECM by clicking the Read Data

button.

MPI-2 INTERFACE CARD CONNECTED TO USB PORT

CAUTION
If the computer you are using is connected to
a power outlet, there is a potential risk of
electric shock when working in contact with
water. Be careful not to touch water while
working with the computer.

8. B.U.D.S. is now ready to be used.

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 Electronic Management System
Communication Tools and B.U.D.S.

9. For twin engine applications, when clicking on 2. Use the Module submenu and check all mod-
the Read Data button, B. U. D. S. will read the ules one at a time to see which module(s) can
cluster module and the ECM on both engines be updated.
through CAN bus.
10. To view the information from a specific ECM or
to change settings in a specific ECM, click on
the Starboard (R) or Port (L) button icon to
choose the ECM you wish to communicate
with (R) or (L). The L or R icon selected will be
highlighted in red and move to the forefront of
the button.

5
MODUL E SUBM ENU L IST

1. Port (L) ECm selected

N O T E : If the Update option is grayed out, no up-
2. Starboard (R) ECM available date file is available for this module. If the Update
option is black, an update file is available for this
Electronic Control Module Updates module.
NOTICE
Failure to strictly follow a procedure to up-
date a module may permanently damage a
module.

N O T E : On twin engine models, this procedure

must be carried out for both ECM’s.
1. Start B.U.D.S. and check for an update icon in
the B.U.D.S. status bar.

1. Grayed out: No update to perform — Black: update file available

Writing Changes In The ECU

1. When making a data setting change in an ECU
using B.U.D.S., save the new data in the ECU
by clicking the Write Data button.
N O T E : A message box will confirm a successful
operation.

2. Remove the tether cord from the engine cut-off

switch.
3. Disconnect the MPI connectors and store the
N O T E : If the icon is visible, it indicates that a file vehicle diagnostic connector in the protective
is available in B. U. D. S. to update at least one of cap.
the electronic modules. If an update file is avail-
able on BOSS Web but the B. U. D. S. software N O T E : There is a 120 Ω resistor in the protective
being used is not up to date, the update icon will cap to minimize the possibility of communication
not appear. errors.

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Electronic Management System
Communication Tools and B.U.D.S.

4. Reinstall all other removed parts. Refer to the

appropriate sections for installation
procedures.
OBD-M Communication
For all Rotax 4-TEC ECT Power Packs, an OBD-
M communication port is available. OBD-M related
fault codes and parameters information can be
read using an OBD-M generic diagnostic tool such
as Rinda (www.rinda.com).

194
 Electronic Management System
Diagnostic and Fault Codes

Diagnostic and Fault Codes

Monitoring System – Sends out warning signals to the information
This system monitors the electronic components center so that an audio/visual alert can be acti-
of the EMS (engine management system) the in- vated to inform the rider of a particular
formation center and other components of the condition.
electrical system to detect if they are faulty or de- –
fective. The monitoring system becomes active When a minor or transient fault occurs, the fault
when the electrical system is energized and the message and/or beeper will cease automatically if
ECM is powered up. the condition that caused the fault does not exist
anymore.
N O T E : Some components need the engine to
be running to be monitored (fuel injectors for Diagnostic trouble code information will be stored
example). in ECM.

The following tables provide lists of components If a minor fault is active, the engine will operate
or functions that may be monitored, and are not without a noticeable loss of performance. 5
specific to a particular model. Releasing the throttle and letting the engine re-
turn to idle speed may allow normal operation to
EMS MONITORING resume. If this does not work, try the following:
Battery voltage – Turn off ignition switch. ECM shut down (ap-
prox. time: 60 sec)
EMS sensors (TAS, TPS, CPS, CAPS, MAPS, – Start engine.
MATS, CTS, OPS, EGTS, TOPS, (except ECT – Check if the fault code is still active.
models), knock sensor). Throttle actuator,
ignition coils and fuel injectors The electronic system will react differently de-
pending on the fault type. If a severe failure oc-
ECM curs, the engine may not be allowed to be started.
In other cases, the engine may operate in limp
Engine RPM home mode (reduced speed) or not be affected at
CAN all.

START switch and starter solenoid These strategies are used to protect the engine
system from damage and to maintain safe opera-
Fuel pump tion of the boat.
Information center (cluster) Limp Home Mode
Speed/temp sensor When a major component of the EMS is not oper-
ating properly, limp home mode will be set. Engine
speed will be limited and therefore boat speed.
INFORMATION CENTER MONITORING
This mode allows the rider to return home which
Information center would otherwise not be possible without this ad-
CAN vanced system.
GPS When a major EMS fault occurs that activates limp
home mode, an audio alert (buzzer signal) will be
Fuel level sensor heard.
When a malfunction is currently detected, the re- Fault codes maybe present without MIL (Malfunc-
lated electronic module: tion Indicator Lamp) active. On the other hand,
during healing the MIL can be ON with no fault
– Sets an active fault code and sends informa-
code displayed in the cluster (means cluster only
tion on CAN network.
shows active fault codes).
– Adapts the proper protection strategy accord-
ing to the failure.

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Electronic Management System
Diagnostic and Fault Codes

Indicator Lights and Message Display TYPICAL — MAY VARY DEPENDING ON

Information THE BOAT OEM REQUIREMENTS
Indicator lights (pilot lamps) inform the rider of a
selected function, a normal condition, a system Beeper Description Action
anomaly, or a serious malfunction. SIGNALS

Some indicator lights may not apply to all models. A 2 second

Refuel. If
threshold
problem
For detailed information refer to manufacturers beep when
Low fuel level continues,
specific cluster section. crossing the
check the fule
low fuel
TYPICAL level sensor.
threshold
Pilot Lamps Message – High
Description – Refer to
(ON) display engine
Cooling
coolant
System,
Low oil tempera
OIL page 112
pressure ture
– Refer to
Continuous – High
Exhaust
beep exhaust
System,
CHECK tempera
Check engine page 45
ENGINE ture
– Refer to
– Low or
Lubrication
high
Engine or System,
engine oil
exhaust page 81
HI-TEMP pressure
system
overheating
Fault Codes
A fault code is an indication that a malfunction is
FUEL LOW Low fuel level detected by the monitoring system of the boat.
A fault code consists of a letter followed by 4 dig-
its that are a combination of numbers and letters.
Low/high
The first letter defines the type of fault code while
12 V LOW/HI battery
the remaining digits refer to a unique fault.
voltage
Verify if the check engine light is ON. If so, look for
fault codes to diagnose the trouble. The fault co-
MAINTE Maintenance des recorded in the related module can be
NANCE reminder checked on the information center (if applicable)
or by using the B.U.D.S.
Beeper Signals If many fault codes become active at the same
When one of the conditions listed in the following time, it is likely to be caused by a burnt fuse(s) or a
tables occurs, the monitoring system emits beep bad bus bar connection in one of the fuse boxes.
signals. For more information pertaining to the fault codes
(state, count, first, etc.) and report, refer to B.U.D.
S. Online help.
When a fault is no longer active, its status is
changed from active to occurred and it is stored in
the related module. Stored fault codes are kept in
the module even if the battery is disconnected.
When using the service action suggested in the
Fault section of B.U.D.S., the system circuits may

196
 Electronic Management System
Diagnostic and Fault Codes

be referred to as A-M4 for instance. It means ECM Occurred Fault Codes

connector "A" and the circuit wire M4. An occurred fault code indicates a fault that was
After a problem has been solved, be sure to clear active, but no longer is. The occurred fault does
the fault(s) in the related module. Refer to CLEAR- not presently affect system or component opera-
ING FAULT CODES USING B. U. D. S. in this tion but is retained as a history of the faults that
subsection. were detected.

Fault Code Types Fault code will erased itself from the memory after
40 consecutive driving cycles in which no active
There are 4 types of fault codes that can be used: fault is being monitored.
– “B” for body, which include information center
and switch faults (Bxxxx) The fault may have been generated due to a sys-
– “C” for chassis system faults (Cxxxx) tem or component that was momentarily operating
– “P” for power train and related system faults, outside normal parameters. Repeated occurred
which include the ECM (Pxxxx) faults of this type should be considered when trou-
– “U” for CAN communication faults (Uxxxx). bleshooting a problem, and may require that main-
tenance action be taken.
The modules that store the fault codes are:
An occurred fault may also be generated when
5
– ECM (Engine Control Module) disconnecting and reconnecting a component, re-
– Cluster (Information Center) placing a burnt fuse, or may be due to a momenta-
The ECM stores mainly “P” codes and some “U” ry high or low voltage.
codes. Reading Fault Codes Using the Information
The Cluster stores “B” and “P” codes. Center
Fault Code States N O T E : Only active faults will be displayed.
The various electronic control units (ECUs) used
in the boat generate a variety of fault codes de- 1. Press the MODE button repeatedly until the
pending on the level of monitoring they are capa- FAULT CODE function is visible in the multi-
ble of. Fault codes have 3 possible states: function display.
– Active State N O T E : The fault code menu will only be avail-
– Occurred State able when active faults are present in the ECM.
– Inactive State
2. Press the SET button or the UP or DOWN ar-
All types of fault codes may be viewed in the row button to enter the function and display the
Faults page of B.U.D.S. Only fault codes in an ac- first fault code.
tive state may be viewed in the cluster (as 3. Press the UP or DOWN arrow button repeat-
applicable). edly to display each subsequent code.
Malfunction indicator lamp (check engine) will
come on after 3 consecutive driving cycles which N O T E : When the last fault code has been dis-
an active faults is being monitored. played and the button is pressed again, the sys-
tem loops back to the first fault code displayed,
Active Fault Codes and all fault codes can again be displayed. If there
An active fault code is an indication of a fault that was one active fault code when entering FAULT
is presently active. The active fault may or may CODE mode, and it becomes occurred (no longer
not compromise normal operation of the system(s) active), a NO ACTIVE FAULT CODE message will
in question as indicated by the fault code(s). Serv- scroll in the display.
ice action should be taken to correct the problem
that caused the fault code. 4. To exit the FAULT CODE display function, the
MODE or SET button must be pressed once.
Once the cause of the active fault is corrected, the There is no time out on this function.
fault code must be cleared using B.U.D.S. to pre-
vent it from being retained in memory.

197
Electronic Management System
Diagnostic and Fault Codes

FAULT TAB, ALL FAULTS

This will reset the appropriate counter (s) and will

also record that the problem has been fixed in the
related module memory.
An active fault code cannot be cleared. In other
TYPICAL - FAULT CODE DISPL AY FUNCTION words, the problem must be repaired before the
fault code can be cleared.
Several Fault Codes Are Active
Simultaneously
If there are several fault codes occurring simulta-
neously, check the following:
– Check fuses
– Check the bus bar condition and connections
in the fuse boxes
– Check the diagnostic connector for the pres-
ence of water or corrosion
– Check the CAN wires
Fault Code P0562
Battery voltage is low. It occurs when both battery
voltage and engine RPM conditions are met. See
following chart. Refer to CHARGING SYSTEM
TYPICAL - ENGI NE FAULT CODE EXAMPL E
subsection.
Reading Fault Codes Using B.U.D.S.
BATTERY VOLTAGE ENGINE SPEED
Connect the latest B.U.D.S. software to the boat.
Refer to COMMUNICATION TOOLS AND B.U.D. Lower than 6.5 Vdc Lower than 1280 RPM
S. Greater than 1280
Lower than 11.8 Vdc
Click on the Read Data button. RPM
Select the Faults page tab. Fault Code P0563
For twin engine models, connect to each engine Battery voltage too high. It occurs when battery
diagnostic connector to read the faults codes voltage is above 16 Vdc when engine is running.
stored in each ECM. Refer to CHARGING SYSTEM.
Clearing Fault Codes Using B.U.D.S. Fault Code U0300
The fault (s) (occurred state) can be cleared by Incorrect ECM or information center for the en-
pressing the Clear Occurred Faults button in B.U. gine. Installed part is not appropriate for the boat.
D.S. Using B.U.D.S., check if the security coding of the
cluster is matched with the ECM security coding.
Engine will crank but will not start.

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 Electronic Management System
Diagnostic and Fault Codes

Fault Code U16A1, U16A2, U16A3

Cluster CAN time-out error-missing CAN ID xxxh.
This fault may occasionally appear as occurred.
Normal operation is not affected. If the count is
high, check the related components.

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Electronic Management System
Diagnostic and Fault Codes

Fault Code Table

The following table provides a general list of fault codes that may be set by an ECU of a jet boat. The
fault codes listed may not be applicable to every jet boat model.
Always refer to the fault code list available in the latest applicable version of B.U.D.S.

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Generic cluster
fault that is
normally related to
B2220 CLUSTER GPS signal lost,
which occurs
when you start a
boat inside.
Wire between
Heater Power PRE-CAT O2 Check wiring
Stage fault for O2 Sensor Pin C & harness. Refer to
P0031 ECM sensor upstream Fuse Box Pin B1 Schematic
of catalyst - short is short to ground. Diagram, Replace
circuit to GND Or defective O2 O2 sensor.
Sensor
Wire between
Heater Power PRE-CAT O2 Check wiring
Stage fault for O2 Sensor Pin D & harness. Refer to
P0032 ECM sensor upstream ECM B-L2 is short Schematic
of catalyst - short to 12V. Or Diagram, Replace
circuit to V+ defective O2 O2 sensor.
Sensor
Wire between
Heater Power
POST-CAT O2 Check wiring
Stage fault for O2
Sensor Pin C & harness. Refer to
sensor
P0037 ECM Fuse Box Pin B1 Schematic
downstream of
is short to ground. Diagram, Replace
catalyst - short
Or defective O2 O2 sensor.
circuit to GND
Sensor
Wire between
Heater Power
POST-CAT O2 Check wiring
Stage fault for O2
Sensor Pin D & harness. Refer to
sensor
P0038 ECM ECM B-L3 is short Schematic
downstream of
to 12V. Or Diagram, Replace
catalyst - short
defective O2 O2 sensor.
circuit to V+
Sensor

200
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Sensing port dirty Check system
or blocked. circuits A-B4, A-
G4, A-H2. Make
Sensor failure or sure that the
unexpected sensor housing is
reading at idle. correctly inserted
Sensor fallen out into the manifold.
of housing or Check sensor
Intake pressure leaking inlet. connector for: 5
sensor out of volts supply from
P0106 ECM
range ECM on pin 1.
Ground supply
For a leak of the from ECM on pin
Intake Manifold, 2. Analog voltage
the ECM will
diagnose it only if
from sensor to
ECM on pin 3.
5
the RPM is greater Refer to the
than 5000 RPM. SERVICE
MANUAL for more
details.
Check system
Sensing port dirty circuits A-B4, A-
or blocked. G4, A-H2.
Make sure that the
Sensor failure or sensor housing is
unexpected correctly inserted
reading at idle. into the manifold.
Manifold absolute Check sensor
pressure sensor connector for:
P0107 ECM
shorted to ground Sensor fallen out
or not connected. of housing or 5 volts on pin 1.
leaking inlet.
For a leak of the 0 volt on pin 2.
Intake Manifold,
the ECM will
diagnose it only if 0 volt on pin 3.
the RPM is greater
than 5000 RPM.

201
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check system
Sensing port dirty circuits A-B4, A-
or blocked. G4, A-H2.
Make sure that the
Sensor failure or sensor housing is
Manifold absolute correctly inserted
pressure sensor unexpected
P0108 ECM reading at idle. into the manifold.
open circuit or Check sensor
shorted to battery connector for:
5 volts on pin 1.
Sensor fallen out
of housing or 0 volt on pin 2.
leaking inlet.
0 volt on pin 3.
Value coming out
of Air temp sensor
Air intake is considered non Check for intake
temperature plausible by ECM
P0111 ECM air temperature
sensor fault (non monitoring logic. signal.
plausible) Defective sensor
or wiring harness
issue.
Check the sensor
for approximately
2280 to 2736
ohms at 19 to
21°C (66 to 70°F).

Damaged sensor, Check for

Intake manifold damaged circuit approximately
temperature wires, damaged 2280 to 2736
P0112 ECM sensor shorted to connector or ohms at 19 to
ground damaged ECM 21°C (66 to 70°F)
pins. between ECM
connector pins A-
H3 and A-J3.
Refer to the
SERVICE
MANUAL for more
details.

202
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check the sensor
for approximately
2280 to 2736
ohms at 19 to
Damaged sensor, 21°C (66 to 70°F).
Intake manifold
damaged circuit
temperature
wires, damaged Check for
P0113 ECM sensor open
connector or approximately
circuit or shorted
damaged ECM 2280 to 2736
to battery
pins. ohms at 19 to
21°C (66 to 70°F)
between ECM
connector pins A-
H3 and A-J3.
Check for debris 5
or blockage in
cooling system.
Check the sensor
for approximately
Damaged sensor, 2280 to 2736
damaged circuit ohms at 19 to
Engine coolant
wires, damaged 21°C (66 to 70°F).
P0116 ECM temperature signal
connector or Check for
not plausible
damaged ECM approximately
pins. 2280to 2736 ohms
at 19 to 21°C (66
to 70°F) between
ECM connector
pins A-A1 and A-
J2.
Check for debris
or blockage in
cooling system.
Check the sensor
for approximately
Damaged sensor, 2280 to 2736
Engine coolant damaged circuit ohms at 19 to
temperature wires, damaged 21°C (66 to 70°F).
P0117 ECM connector or
sensor fault - Check for
Short to GND damaged ECM approximately
pins. 2280 to 2736
ohms at 19 to
21°C (66 to 70°F)
between ECM
connector pins A-
A1 and A-J2.

203
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check for debris
or blockage in
cooling system.
Check the sensor
for approximately
Engine coolant 2280 to 2736
Engine
temperature ohms at 19 to
overheated or
sensor fault - 21°C (66 to 70°F).
P0118 ECM damaged sensor.
Short circuit to V+ Check for
Connector
or connector approximately
disconnected.
disconnected. 2280 to 2736
ohms at 19 to
21°C (66 to 70°F)
between ECM
connector pins A-
A1 and A-J2.
Check system
circuits B-E1, B-
K1, B-K3.
Damaged sensor,
TAS (Throttle Check for 0 volt on
damaged circuit
Accelerator sensor connector
wires, damaged
P0122 ECM sensor) 1 fault pin E. Check for 5
connector or
(short circuit to volts on sensor
damaged ECM
GND) connector pin D.
pins.
Check for 0.5 to 3
volts on sensor
connector pin F.
Check system
circuits B-E1, B-
K1, B-K3.
Damaged sensor,
TAS (Throttle Check for 0 volt on
damaged circuit
Accelerator sensor connector
wires, damaged
P0123 ECM sensor) 1 fault pin E. Check for 5
connector or
(short circuit to volts on sensor
damaged ECM
battery) connector pin D.
pins.
Check for 0.5 to 3
volts on sensor
connector pin F.

204
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

High air intake
temperature
detected. Fault
can be detected Check that engine
when engine is compartment
running and ventilation works
stopped. For properly. Check
High air intake engine cooling
ROTAX 200 & 250
P0127 ECM temperature circuit. For Rotax
engine, it can be a
detected 200 and 250
signed of a
blocked engines, clean
intercooler water intercooler water
circuit. Sensors circuit system.
contaminated by
salt water may
cause this issue.
5
Wire between
PRE-CAT O2
O2 Sensor fault Check wiring
Sensor Pin B &
upstream of harness. Refer to
ECM B-D2 is short
P0130 ECM catalyst - signal Schematic
to either Pin C or
not plausible Diagram. Replace
Pin D. Or
O2 sensor.
defective O2
Sensor.
Wire between
PRE-CAT O2 Check wiring
O2 Sensor fault
Sensor Pin B & harness. Refer to
upstream of
P0131 ECM ECM B-D2 is short Schematic
catalyst - short
to ground. Or Diagram. Replace
circuit to GND
defective O2 O2 sensor.
Sensor
Wire between
PRE-CAT O2 Check wiring
O2 Sensor fault
Sensor Pin B & harness. Refer to
upstream of
P0132 ECM ECM B-D2 is short Schematic
catalyst - short
to 12V. Or Diagram. Replace
circuit to V+
defective O2 O2 sensor.
Sensor.
O2 sensor
upstreams of PRE-CAT sensor
Replace PRE-
P0133 ECM catalyst reacts to poisoned, aged or
CAT O2 sensor.
slow — defective.
contaminated
O2 sensor
PRE-CAT sensor
upstream of Replace PRE-
P0134 ECM poisoned, aged or
catalyst reacts to CAT O2 sensor.
defective.
slow — defective
O2 Sensor heating PRE-CAT sensor
fault upstream of Replace PRE-
P0135 ECM broken heater
catalyst. CAT O2 sensor.
element.

205
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Wire between
POST-CAT O2
O2 Sensor fault Check wiring
Sensor Pin B &
downstream of harness. Refer to
ECM B-G3 is short
P0136 ECM catalyst - signal Schematic
to either Pin C or
not plausible. Diagram, Replace
Pin D. Or
O2 sensor.
defective O2
Sensor.
Wire between
POST-CAT O2 Check wiring
O2 Sensor fault
Sensor Pin B & harness. Refer to
downstream of
P0137 ECM ECM B-G3 is short Schematic
catalyst — short
to ground. Or Diagram, Replace
circuit to GND
defective O2 O2 sensor.
Sensor
Wire between
POST-CAT O2 Check wiring
O2 Sensor fault
Sensor Pin B & harness. Refer to
downstream of
P0138 ECM ECM B-G3 is short Schematic
catalyst — short
to 12V. Or Diagram, Replace
circuit to V+
defective O2 O2 sensor.
Sensor.
Downstream O2 In system but not
POST-CAT
Sensor Slow tested, this fault
P013A ECM sensor poisoned,
Response - Rich code should never
aged or defective.
to Lean be occurring
Downstream O2 POST-CAT
Sensor Slow sensor poisoned, Replace POST-
P013B ECM
Response - Lean aged or defective. CAT O2 sensor
to Rich
Downstream O2 In system but not
Sensor Delayed POST-CAT
tested, this fault
P013E ECM Response sensor poisoned,
code should never
(Transient) - Rich aged or defective.
be occurring
to Lean
Downstream O2
Sensor Delayed POST-CAT
sensor poisoned, Replace POST-
P013F ECM Response
aged or defective. CAT O2 sensor
(Transient) - Lean
to Rich
O2 Sensor heating POST-CAT
fault downstream Replace POST-
P0141 ECM sensor broken
of catalyst CAT O2 sensor
heater element.
Upstream O2
PRE-CAT sensor
Sensor Slow Replace PRE-
P014D ECM poisoned, aged or
Response - Lean CAT O2 sensor
defective.
to Rich

206
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Upstream O2
PRE-CAT sensor
Sensor Slow Replace PRE-
P014C ECM poisoned, aged or
Response - Rich CAT O2 sensor
defective.
to Lean
Check Injector
Multiplicative Fuel delivery and/or Fuel pump.
mixture adaptation about 25% leaner For NON-CAT an
P0171 ECM exceeds upper than target during open signal of
limit — mixture too dynamic operation CTS or MATS can
lean trigger this fault.
Check Injector
Fuel delivery and/or Fuel pump.
Multiplicative about 15% richer NOTE: For NON-
P0172 ECM
mixture adaptation
below lower limit
that target during CAT an open 5
dynamic signal of CTS or
— mixture too rich operation. MATS can trigger
this fault.
Check for 11.4 to
12.6 ohms
between engine
connector pin 2
Damaged injector, and ECM
damaged circuit connector pin A-
Injection Power
wires, damaged B3. Check for 12
P0201 ECM Stage fault - open
connector or volts on pin 2 of
line/Cylinder 1
damaged ECM injector connector.
output pins. Check fuse #13
(refer to wiring
diagram). Check
for damaged
circuit wires.
Check for 11.4 to
12.6 ohms
between engine
Damaged injector, connector pin 2
damaged circuit and ECM
Injection Power
wires, damaged connector pin A-
P0202 ECM Stage fault - open
connector or K1. Check for 12
line/Cylinder 2
damaged ECM volts on pin 2 of
output pins. injector connector.
Check for
damaged circuit
wires

207
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check for 11.4 to
12.6 ohms
between engine
Damaged injector, connector pin 3
damaged circuit and ECM
Injection Power connector pin A-
wires, damaged
P0203 ECM Stage fault - open J1. Check for 12
connector or
line/Cylinder 3 volts on pin 2 of
damaged ECM
output pins. injector connector.
Check fuse.
Check for
damaged circuit
wires.
Check for debris
or blockage in
cooling system.
Check the sensor
for approximately
2280 to 2736
High engine High engine ohms at 19 to
coolant coolant 21°C (66 to 70°F).
P0217 ECM
temperature temperature Check for
detected detected approximately
2280 to 2736
ohms at 19 to
21°C (66 to 70°F)
between ECM
connector pins A-
A1 and A-J2.
Check system
circuits B-A3, B-
B3, B-J3. Check
Damaged sensor, for 0 volt on
TAS (Throttle
damaged circuit sensor connector
Accelerator
wires, damaged pin B. Check for 5
P0222 ECM sensor) 2 fault
connector or volts on sensor
(short circuit to
damaged ECM connector pin A.
GND)
pins. Check for 0.25 to
1.5 volts on
sensor connector
pin C.

208
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check system
circuits B-A3, B-
B3, B-J3. Check
Damaged sensor, for 0 volt on
TAS (Throttle
damaged circuit sensor connector
Accelerator
wires, damaged pin B. Check for 5
P0223 ECM sensor) 2 fault
connector or volts on sensor
(short circuit to
damaged ECM connector pin A.
battery)
pins. Check for 0.25 to
1.5 volts on
sensor connector
pin C.
Check for
approximately 1
ohm between pins
5
A and B of the fuel
Damaged pump, pump connector.
damaged circuit Check fuse.
Fuel pump open
wires, damaged Check for
P0231 ECM circuit or short to
connector or damaged circuit
ground
damaged ECM wires. Check for
output pins. damaged
connector,
damaged ECM
output pins or
ECM failure.
Check for
approximately 1
ohm between pins
A and B of the fuel
Damaged pump, pump connector.
damaged circuit Check fuse.
Fuel pump short wires, damaged Check for
P0232 ECM circuit to battery connector or damaged circuit
damaged ECM wires. Check for
output pins. damaged
connector,
damaged ECM
output pins or
ECM failure.

209
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check for 11.4 to
12.6 ohms
between engine
Damaged injector, connector pin 1
damaged circuit and ECM
Injector 1 open connector pin A-
wires, damaged
P0261 ECM circuit or shorted B3. Check for 12
connector or
to ground volts on pin 2 of
damaged ECM
output pins. injector connector.
Check fuse.
Check for
damaged circuit
wires.
Check for 11.4 to
12.6 ohms
between engine
Damaged injector, connector pin 1
damaged circuit and ECM
Injector 1 shorted wires, damaged connector pin A-
P0262 ECM to battery connector or B3. Check for 12
damaged ECM volts on pin 2 of
output pins. injector connector.
Check fuse.
Check for
damaged circuit
wires.
Check for 11.4 to
12.6 ohms
between engine
Damaged injector, connector pin 2
damaged circuit and ECM
Injector 2 open connector pin A-
wires, damaged
P0264 ECM circuit or shorted K1. Check for 12
connector or
to ground volts on pin 2 of
damaged ECM
output pins. injector connector.
Check fuse.
Check for
damaged circuit
wires.
Check for 11.4 to
12.6 ohms
between engine
Damaged injector, connector pin 2
damaged circuit and ECM
Injector 2 shorted wires, damaged connector pin A-
P0265 ECM to battery connector or K1. Check for 12
damaged ECM volts on pin 2 of
output pins. injector connector.
Check fuse.
Check for
damaged circuit
wires.

210
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check for 11.4 to
12.6 ohms
between engine
Damaged injector, connector pin 3
damaged circuit and ECM
Injector 3 open connector pin A-
wires, damaged
P0267 ECM circuit or shorted J1. Check for 12
connector or
to ground volts on pin 2 of
damaged ECM
output pins. injector connector.
Check fuse.
Check for
damaged circuit
wires.
Check for 11.4 to
12.6 ohms 5
between engine
Damaged injector, connector pin 3
damaged circuit and ECM
Injector 3 shorted wires, damaged connector pin A-
P0268 ECM to battery connector or J1. Check for 12
damaged ECM volts on pin 2 of
output pins. injector connector.
Check fuse.
Check for
damaged circuit
wires.
Injector not
providing sufficient
fuel delivery,
engine running Check Injector,
lean. Ignition coil Ignition Coil and/or
or spark plug not spark plugs.
lighting up Check for water
Multiple misfire combustion. accumulation in
P0300 ECM
detected Water intake manifold
accumulating in due to leaking
intake manifold Intercooler or
prevent normal excessive
combustion event condensation.
from happening
during
acceleration.

211
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Injector not
providing sufficient
fuel delivery,
engine running Check Injector,
lean. Ignition coil Ignition Coil and/or
or spark plug not spark plugs.
Misfire Cylinder lighting up Check for water
Specific (physical combustion. accumulation in
P0301 ECM
cylinder 1) Water intake manifold
accumulating in due to leaking
intake manifold Intercooler or
prevent normal excessive
combustion event condensation.
from happening
during
acceleration.
Injector not
providing sufficient
fuel delivery,
engine running Check Injector,
lean. Ignition coil Ignition Coil and/or
or spark plug not spark plugs.
Misfire Cylinder lighting up Check for water
Specific (physical combustion. accumulation in
P0302 ECM
cylinder 2) Water intake manifold
accumulating in due to leaking
intake manifold Intercooler or
prevent normal excessive
combustion event condensation.
from happening
during
acceleration.
Injector not
providing sufficient
fuel delivery,
engine running Check Injector,
lean. Ignition coil Ignition Coil and/or
or spark plug not spark plugs.
Misfire Cylinder lighting up Check for water
Specific (physical combustion. accumulation in
P0303 ECM
cylinder 3) Water intake manifold
accumulating in due to leaking
intake manifold Intercooler or
prevent normal excessive
combustion event condensation.
from happening
during
acceleration.

212
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Bring engine to
Damaged sensor,
5000 RPM. If fault
damaged circuit
code appears then
wires, damaged
Knock sensor 1 check for
P0325 ECM connector or
fault approximately 5 M
damaged ECM
ohms between
output pins. Open
system circuits A-
circuit.
C3 and A-G2.
Damaged sensor,
damaged circuit
For the CPS,
wires, damaged
check for 700 to
connector,
Crankshaft signal 900 ohms
P0335 ECM damaged ECM
error between terminals
pins or damaged
tooth wheel.
A-H1 and A-K2 of
ECM connector.
5
Connector
disconnected.
For the CAPS,
check for 12 volts
Damaged sensor,
on sensor
damaged circuit
connector pin 3.
wires, damaged
Check continuity
connector,
Camshaft 1 signal for circuits A-D4,
P0340 ECM damaged ECM
error A-E2 and terminal
pins or damaged
4 on engine
tooth wheel.
connector. Check
Connector
fuse. Engine must
disconnected.
run to erase the
corrected fault.
Check for 0.85 to
1.15 ohms
between engine
Damaged coil, connector pin 1
Ignition Power damaged circuit and ECM
Stage fault - short wires, damaged connector pin A-
P0357 ECM circuit to V+/ connector or M4.
Cylinder 1 damaged ECM
output pins. Check for 12 volts
on pin 2 of coil
connector. Check
fuse.

213
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check for 0.85 to
1.15 ohms
between engine
Damaged coil, connector pin 1
Ignition Power damaged circuit and ECM
Stage fault - short wires, damaged connector pin A-
P0358 ECM circuit to V+/ connector or M2.
Cylinder 2 damaged ECM
output pins. Check for 12 volts
on pin 2 of coil
connector. Check
fuse.
Check for 0.85 to
1.15 ohms
between engine
Damaged coil, connector pin 3
Ignition Power damaged circuit and ECM
Stage fault - short wires, damaged connector pin A-
P0359 ECM circuit to V+/ connector or M1.
Cylinder 3 damaged ECM
output pins. Check for 12 volts
on pin 2 of coil
connector. Check
fuse.
Check for 0.85 to
1.15 ohms
between engine
Ignition Power connector pin 1
Signal not and ECM
stage max error &
plausible, verify connector pin A-
P0360 ECM false detection of
battery voltage too M4.
low battery
low during ignition.
voltage/Cylinder 1 Check for 12 volts
on pin 2 of coil
connector. Check
fuse.
Check for 0.85 to
1.15 ohms
between engine
Ignition Power connector pin 1
Signal not and ECM
stage max error &
plausible, verify connector pin A-
P0361 ECM false detection of
battery voltage too M2.
low battery
low during ignition.
voltage/Cylinder 2 Check for 12 volts
on pin 2 of coil
connector. Check
fuse.

214
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check for 0.85 to
1.15 ohms
between engine
Ignition Power connector pin 3
Signal not and ECM
stage max error &
plausible, verify connector pin A-
P0362 ECM false detection of
battery voltage too M1.
low battery
low during ignition.
voltage/Cylinder 3 Check for 12 volts
on pin 2 of coil
connector. Check
fuse.
Injector not
providing sufficient
fuel delivery, 5
engine running
lean. Ignition coil
or spark plug not Inspect catalyst for
lighting up damage, and
Catalyst
combustion. repair root cause.
P0420 ECM conversion
Water Check
insufficient
accumulating in downstream O2
intake manifold sensor.
prevent normal
combustion event
from happening
during
acceleration.
Check C.A.N.
circuits wires.
Replace
Cluster fault instrument
detected by ECM Cluster. Verify
Vehicle speed C.A.N. circuit
P0500 ECM outside of the
signal fault failure, Instrument building if the GPS
cluster or ECM LED becomes
failure active after 1
minute and stays
steady.
Check C.A.N.
circuits wires.
Replace
instrument
Cluster or C.A.N. Cluster. Verify
Vehicle speed not
P0501 ECM circuit failure, or outside of the
plausible
ECM failure. building if the GPS
LED becomes
active after 1
minute and stays
steady.

215
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Damaged
solenoid, Verify FUSE #16
Starter power damaged circuit (5AMP). Check for
P0512 ECM stage detects high wires, damaged 12 volts on pin 2 of
current connector or the starter relay.
damaged ECM.
Engine leak, oil
pump failure, Check resistance
damaged sensor, at 0 RPM and
Oil pressure above 3500 RPM.
damaged circuit
P0520 ECM switch functional Switch is normally
wires, damaged
problem closed, ECM
connector or
damaged ECM connector pin A-
pins. E3

Engine leak, oil

pump failure,
damaged sensor,
damaged circuit
wires, damaged Check resistance
Oil pressure connector or
P0523 ECM at 0 RPM and
sensor fault damaged ECM above 3500 RPM.
pins. Fault
detected when the
engine is running
or stopped.
Low oil level, Check oil level.
Low oil pressure engine leak, oil
P0524 ECM Check impedance
condition pump fault. of sensor.
Check for
Damaged sensor, approximately
Exhaust gas damaged circuit 2280 to 2736
temperature wires, damaged ohms at
P0544 ECM sensor functional connector or temperature of 19
problem damaged ECM to 21°C (66 to
output pins. 70°F) between
system circuits A-
H4 and A-J4.
Check for
Damaged sensor, approximately
Exhaust gas damaged circuit 2280 to 2736
temperature wires, damaged ohms at
P0545 ECM sensor shorted to connector or temperature of 19
ground damaged ECM to 21°C (66 to
output pins. 70°F) between
system circuits A-
H4 and A-J4.

216
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check for
Damaged sensor, approximately
Exhaust gas 2280 to 2736
damaged circuit
temperature ohms at
wires, damaged
P0546 ECM sensor open temperature of 19
connector or
circuit or shorted to 21°C (66 to
damaged ECM
to battery 70°F) between
output pins.
system circuits A-
H4 and A-J4.
Battery failure, Check fuse
rectifier failure,
damaged circuit
wires, battery
Battery voltage not terminal
P0560 ECM plausible connection,
Check ground
continuity to the
5
damaged AC engine block.
generator or
damaged
connectors.
Battery failure, Check fuse
rectifier failure,
damaged circuit
wires, battery
Battery voltage too terminal Check ground
P0562 ECM
low connection, continuity to the
damaged AC engine block.
generator or
damaged
connectors.
Battery failure,
Battery voltage too Check for
rectifier failure or
P0563 ECM high regulator-rectifier
battery terminal
failure.
connection.
Verify the cruise
The cruise switch
switch if it is
is shorted or
P0564 ECM Cruise switch fault normally open and
activated more
close when
than 60 seconds.
activated.
P0606 ECM ECM ADC fault Damaged ECM. Replace ECM
Check ECM
Variant coding Wrong ECU for
P0610 ECM application
fault application.
compatibility

217
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check system
circuits B-E1, B-
K1, B-K3, B-A3, B-
B3, B-J3
Check for 0 volt on
Damaged sensor, sensor connector
TAS (Throttle damaged circuit pin B & E.
Accelerator wires, damaged
P060D ECM sensor) Check for 5 volts
connector or
synchronization on sensor
damaged ECM
error connector pin A &
pins.
D.
Check for 0.5 to 3
volts on sensor
connector pin F
and 0.25 to 1.5 on
C
Throttle Actuator -
Controller Fault-
P060E ECM digital position
control exceeds
limit
Variant coding
P0610 ECM
fault
Check for 2.6
ohms (full tank) to
Damaged sensor, 93.6 ohms (empty
damaged circuit tank) between pin
Fuel sensor wires, damaged C and pin D at the
P0629 ECM connector or
disconnected fault fuel pump
damaged ECM connector. Check
output pins. system circuit at
the gauge Pin 19
and 20.
Check C.A.N.
circuits wires.
Replace
Cluster fault instrument
Cluster CAN error detected by ECM. Cluster. Verify
- Loss of vehicle C.A.N. circuit outside of the
P062C ECM
speed information failure, Instrument building if the GPS
from cluster cluster or ECM LED becomes
failure. active after 1
minute and stays
steady.
ECM EEPROM
P062F ECM fault - exchange Damaged ECM. Replace ECM
ECM

218
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

ECM Fast ADC
P06B6 ECM fault (knock
detection line)
Wire between
Heater Power PRE-CAT O2
Stage fault for Sensor Pin D &
Check wiring
lambda sensor ECM B-L2 and/or
P1030 ECM harness. Replace
upstream of Pin. C & FB Pin
O2 sensor.
catalyst - open line B1 is open. Or
defective O2
Sensor
Wire between
POST-CAT O2
Heater Power
Stage fault for Sensor Pin D &
Check wiring
harness. Refer to
5
lambda sensor ECM B-L3 and/or
P1036 ECM Schematic
downstreams of Pin C & FB Pin B1
Diagram, Replace
catalyst - open line is open. Or
O2 sensor.
defective O2
Sensor
Altitude correction
factor (fho) not
P1106 ECM plausible - out of Defective MAPS
range
Damaged throttle Check system
Throttle positions actuator, circuit, perform
calculated from damaged circuit closed throttle with
P1120 ECM TPS 1 and TPS 2 wires, damaged B.U.D.S. Replace
not corresponding connector or throttle actuator,
damaged ECM. replace ECM.
Wire between
PRE-CAT O2
O2 Sensor fault
Sensor Pin B & Check wiring
upstream of
P1130 ECM ECM B-D2 and /or harness. Replace
catalyst - open
Pin A & B-J1 are O2 sensor.
line.
open. Or defective
O2 Sensor.
Wire between
POST-CAT O2
O2 Sensor fault Sensor Pin B & Check wiring
P1136 ECM downstream of ECM B-G3 and /or harness. Replace
catalyst - open line Pin A & B-H4 are O2 sensor.
open. Or defective
O2 Sensor

219
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check Injector
Additive mixture Fuel delivery and/or Fuel pump.
adaptation offset by +12.5% NOTE: For NON-
P1171 ECM exceeds upper during idle CAT an open
limit — mixture too operation. signal of CTS or
lean MATS can trigger
this fault
Check Injector
Fuel delivery and/or Fuel pump.
Additive mixture
offset by -12.5% NOTE: For NON-
adaptation below
P1172 ECM during idle CAT an open
lower limit —
operation signal of CTS or
mixture too rich
MATS can trigger
this fault
Boat or sensor
upside down,
damaged circuit Check continuity
P1502 — Non T.O.P.S.
ECM wires, damaged for circuits A-C4,
CAT Models only functional problem
connector or A-G1, A-F4.
damaged ECM
output pins.
Boat or sensor
upside down,
damaged circuit Check continuity
P1503 — Non T.O.P.S. switch
ECM wires, damaged for circuits A-C4,
CAT Models only short circuit to 12V connector or A-G1, A-F4.
damaged ECM
output pins.
Boat or sensor
upside down,
T.O.P.S. switch damaged circuit Check continuity
P1504 — Non
ECM short circuit to wires, damaged for circuits A-C4,
CAT Models only
ground connector or A-G1, A-F4.
damaged ECM
output pins.
Boat or sensor
upside down,
damaged circuit Check continuity
P1505 — Non T.O.P.S. switch
wires, damaged for circuits A-C4,
CAT Models only ECM fault not plausible
connector or A-G1, A-F4.
state
damaged ECM
output pins. Open
circuit.

220
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Boat or sensor
upside down,
damaged circuit Check continuity
P1506 — Non T.O.P.S. switch wires, damaged
ECM for circuits A-C4,
CAT Models only open circuit connector or A-G1, A-F4.
damaged ECM
output pins. Open
circuit.

ECM ADC fault - No service action

P1606 ECM Damaged ECM. available for fault
exchange ECM
P1606.
Damaged throttle Check system
Throttle Actuator - actuator, circuit, perform
P160E ECM
Controller Fault - damaged circuit closed throttle with 5
digital position wires, damaged B.U.D.S. Replace
control below limit connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Throttle Actuator - damaged circuit closed throttle with
P1610 ECM Power Stage fault wires, damaged B.U.D.S. Replace
connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Throttle Actuator - damaged circuit closed throttle with
P1611 ECM Power Stage fault wires, damaged B.U.D.S. Replace
connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Throttle Actuator - damaged circuit closed throttle with
P1612 ECM Power Stage fault wires, damaged B.U.D.S. Replace
connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Throttle Actuator - damaged circuit closed throttle with
P1613 ECM Power Stage fault wires, damaged B.U.D.S. Replace
connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
Throttle Actuator - actuator, circuit, perform
Return-Spring damaged circuit closed throttle with
P1614 ECM check not passed/ wires, damaged B.U.D.S. Replace
Spring does not connector or throttle actuator,
close damaged ECM. replace ECM.

221
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Damaged throttle Check system
actuator, circuit, perform
Throttle Actuator -
damaged circuit closed throttle with
P1615 ECM Position
wires, damaged B.U.D.S. Replace
monitoring fault
connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
Throttle Actuator - actuator, circuit, perform
Default position damaged circuit closed throttle with
P1616 ECM wires, damaged B.U.D.S. Replace
check or learning
fault connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
Throttle Actuator - actuator, circuit, perform
Adaptation of damaged circuit closed throttle with
P1619 ECM wires, damaged B.U.D.S. Replace
upper mechanical
limit failed connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
Throttle Actuator - actuator, circuit, perform
Adaptation of damaged circuit closed throttle with
P1620 ECM wires, damaged B.U.D.S. Replace
lower mechanical
limit failed connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Throttle Actuator -
damaged circuit closed throttle with
P1621 ECM Abortion of
wires, damaged B.U.D.S. Replace
adaptation
connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Throttle Actuator -
damaged circuit closed throttle with
P1622 ECM Repeated abortion
wires, damaged B.U.D.S. Replace
of adaptation
connector or throttle actuator,
damaged ECM. replace ECM.
ECU pin B-M4 is
permanently
Main Relay Permanent 12V is supplied thru 15
P1679 ECM Stinking present on ECM amp FUSE and it
Pin B-M4. should be
accessory 12 Vdc.
P16C0 ECM Fault of ECM ADC
P16C1 ECM Fault of ECM ADC
Fault of ECM
P16C2 ECM monitoring module

222
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Monitoring fault
P16C3 ECM due to Accelerator
Sensor check
Monitoring fault
P16C4 ECM due to engine
speed check
Safety fuel cut off
P16C5 ECM active - Monitoring
level 1
Safety fuel cut off
P16C6 ECM active - Monitoring
level 2
Damaged throttle Check system 5
Monitoring fault actuator, circuit, perform
due to throttle damaged circuit closed throttle with
P16C7 ECM wires, damaged B.U.D.S. Replace
valve plausibility
check connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
Monitoring fault actuator, circuit, perform
due to exceeding damaged circuit closed throttle with
P16C8 ECM permitted throttle wires, damaged B.U.D.S. Replace
valve position connector or throttle actuator,
damaged ECM. replace ECM.
ECU detected
P16CA ECM faulty watch dog Damaged ECM. Replace ECM.
line - ECU defect
ECU switch off
through watch dog
P16CB ECM line (hardware Damaged ECM. Replace ECM.
fault) — ECU
defective
Check for
Damaged sensor, approximately
damaged circuit 2280 to 2736
Exhaust ohms at
wires, damaged
P2080 ECM temperature not temperature of 19
connector or
plausible to 21°C (66 to
damaged ECM
output pins. 70°F) between
system circuits A-
H4 and A-J4.

223
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Intermittent Check for

connection. approximately
Damaged sensor, 2280 to 2736
Exhaust damaged circuit ohms at
P2081 ECM temperature wires, damaged temperature of 19
sensor fault connector or to 21°C (66 to
damaged ECM 70°F) between
output pins. system circuits A-
H4 and A-J4.
Closed Loop
Control system
Post Catalyst Fuel
shifting on lean Check PRE-CAT
P2096 ECM Trim System Too
side due to aging O2 sensor.
Lean
of PRE-CAT O2
sensor.
Closed Loop
Control system
Post Catalyst Fuel
shifting on rich Check PRE-CAT
P2097 ECM Trim System Too
side due to aging O2 sensor
Rich
of PRE-CAT O2
sensor.
Damaged throttle Check system
actuator, circuit, perform
Electrical lower- damaged circuit closed throttle with
P212C ECM range violation wires, damaged B.U.D.S. Replace
TPS 2 connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Electrical upper- damaged circuit closed throttle with
P212D ECM range violation wires, damaged B.U.D.S. Replace
TPS 2 connector or throttle actuator,
damaged ECM. replace ECM.
O2 Sensor aging
fault downstream POST-CAT
sensor poisoned Check POST-CAT
P2245 ECM of catalyst –
or aged. O2 sensor
Sensor Voltage
too low
O2 Sensor aging
fault downstream POST-CAT
of catalyst – sensor poisoned Check POST-CAT
P2246 ECM
Sensor Voltage or aged. O2 sensor
too high

224
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Check for air leak
around intake
Engine speed
Air intake manifold manifold. Check
greater than
P2279 ECM leak downstream for excessive
5000rpm with idle
of throttle adjustment of Idle
condition active.
controller, perform
idle reset.
Check cooling
system for
Exhaust overheat,
High exhaust blockage. Check if
damaged sensor
P2428 ECM temperature the exhaust
or damaged circuit
detected injection valve is
wires.
properly
calibrated.
5
Damaged throttle Check system
actuator, circuit, perform
TPS value not damaged circuit closed throttle with
P2620 ECM plausible wires, damaged B.U.D.S. Replace
connector, or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Electrical lower- damaged circuit closed throttle with
P2621 ECM range violation wires, damaged B.U.D.S. Replace
TPS 1 connector or throttle actuator,
damaged ECM. replace ECM.
Damaged throttle Check system
actuator, circuit, perform
Electrical upper- damaged circuit closed throttle with
P2622 ECM range violation wires, damaged B.U.D.S. Replace
TPS 1 connector, or throttle actuator,
damaged ECM. replace ECM.
Check continuity:
PORT CAN-LO :
ECM B-C2 to
PORT FB G8
ECU could not ECM CAN PORT CAN-HI:
establish CAN Network not ECM B-C1 to
U0100 ECM communication established PORT FB G1
with partner ECU correctly. STBD CAN-LO:
ECM B-C2 to
PORT FB G12
STBD CAN-HI:
ECM B-C1 to
PORT FB G5
Software / Data
Check ECM
compatibility error Wrong ECU for
U1301 ECM application
between starboard application.
compatibility.
and port ECUs

225
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Install proper
Exchange security Incorrect ECM or recommended
U0300 ECM - Wrong ECM cluster for engine. ECM or cluster for
vehicle.
Cluster fault
detected by ECM. Check C.A.N.
Cluster CAN
C.A.N. circuit circuits wires.
Timeout error-
U16A1 ECM failure, Instrument Replace
Missing CAN ID
cluster or ECM instrument
514h
failure, or cluster Cluster.
not fitted.
Cluster fault
detected by ECM. Check C.A.N.
Cluster CAN
C.A.N. circuit circuits wires.
Timeout error-
U16A2 ECM failure, Instrument Replace
Missing CAN ID
cluster or ECM instrument
230h
failure, or cluster Cluster.
not fitted.
Cluster fault
detected by ECM. Check C.A.N.
Cluster CAN
C.A.N. circuit circuits wires.
Timeout error-
U16A3 ECM failure, Instrument Replace
Missing CAN ID
cluster or ECM instrument
408h
failure, or cluster Cluster.
not fitted.
Cluster CAN Missing Cluster
Timeout error- CAN input to Cluster fault, or
U16A4 ECM
Missing CAN ID ECM, or cluster not fitted.
410h not fitted.
Cluster fault
Check C.A.N.
detected by ECM.
Cluster check sum circuits wires.
C.A.N. circuit
U16A6 ECM error - CAN Replace
failure, Instrument
ID230h instrument
cluster or ECM
Cluster.
failure.
Cluster fault
Check C.A.N.
detected by ECM.
Cluster check sum circuits wires.
C.A.N. circuit
U16A7 ECM error - CAN Replace
failure, Instrument
ID408h instrument
cluster or ECM
Cluster.
failure.
ECM CAN
Starboard ECU – network not
U16AC ECM Check sum error - established
CAN ID 014h correctly.

226
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

ECM CAN
Port ECU – Check network not
U16AD ECM sum error - CAN established
ID 015h correctly.
ECM CAN
Starboard ECU – network not
U16AE ECM Check sum error - established
CAN ID 016h correctly.
ECM CAN
Port ECU – Check network not
U16AF ECM sum error - CAN established
ID 017h correctly.

Starboard ECU –
ECM CAN 5
network not
U16B0 ECM Check sum error - established
CAN ID 01Ah correctly.
ECM CAN
Port ECU – Check network not
U16B1 ECM sum error - CAN established
ID 01Bh correctly.
ECM CAN
Starboard ECU – network not
U16B2 ECM Check sum error - established
CAN ID 102h correctly.
ECM CAN
Port ECU – Check network not
U16B3 ECM sum error - CAN established
ID 1A2h correctly.

Starboard ECU — ECM CAN

CAN Timeout network not
U16B4 ECM established
error-Missing CAN
ID 014h correctly.

Port ECU – CAN ECM CAN

Timeout error- network not
U16B5 ECM established
Missing CAN ID
015h correctly.

Starboard ECU — ECM CAN

CAN Timeout network not
U16B6 ECM established
error-Missing CAN
ID 016h correctly.

Port ECU — CAN ECM CAN

Timeout error- network not
U16B7 ECM established
Missing CAN ID
017h correctly.

227
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Starboard ECU — ECM CAN
CAN Timeout network not
U16B8 ECM established
error-Missing CAN
ID 01Ah correctly.

Starboard ECU — ECM CAN

CAN Timeout network not
U16B9 ECM established
error-Missing CAN
ID 01Bh correctly.

Starboard ECU — ECM CAN

CAN Timeout network not
U16BA ECM established
error-Missing CAN
ID 102h correctly.

Port ECU – CAN ECM CAN

Timeout error- network not
U16BB ECM established
Missing CAN ID
1A2h correctly.
Check continuity:
PORT CAN-LO :
ECM B-C2 to
PORT FB G8
Error in CAN ECM CAN PORT CAN-HI:
communication for network not ECM B-C1 to
U16BD ECM engine established PORT FB G1
synchronization. correctly. STBD CAN-LO:
ECM B-C2 to
PORT FB G12
STBD CAN-HI:
ECM B-C1 to
PORT FB G5
Verify wiring
CAN
harness
communication
U0410 CLUSTER connection and/or
loss with iNR
power source to
module
iNR module.
Check continuity
between B-E3, B-
ECM CAN D3 & B-A1, should
ECU could not
network not be CLOSE on
U1700 iNR detect its position
established PORT and OPEN
(starboard/port).
correctly. on STBD. Refer to
schematic
diagram
Check continuity
Partner ECU could ECM CAN between B-E3, B-
not detect its network not D3 & B-A1, should
U1701 iNR position established be CLOSE on
(starboard/port). correctly. PORT and OPEN
on STBD.

228
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Both ECUs Check continuity

ECM CAN between B-E3, B-
detected same
network not D3 & B-A1, should
U1702 iNR installation
established be CLOSE on
position
correctly. PORT and OPEN
(starboard/port).
on STBD.
Perform Auto-
calibration
Invalid sensors
C2100 iNR Defective unit procedure, if fault
calibration
persists, replace
iNR module
Perform Auto-
Interrupted
calibration
programming
C2120 iNR Invalid calibration
session or invalid
procedure, if fault 5
persists, replace
calibration used
iNR module
Perform Auto-
Power lost/ calibration
C2121 iNR Internal parameter procedure, if fault
unexpected reset
persists, replace
iNR module
Perform Auto-
Last session was Power lost/ calibration
C2122 iNR interrupted unexpected reset procedure, if fault
persists, replace
iNR module
Perform Auto-
ECM is not calibration
following torque Bad ECM
C0073 iNR procedure, if fault
limitation request firmware or status
persists, replace
iNR module
Perform Auto-
Defective position calibration
Position sensor
C2110 iNR sensor (internal) procedure, if fault
failure
persists, replace
iNR module
Excessive
mechanical
resistance. In Perform Auto-
Unable to move calibration
some rare
C2102 iNR the actuator to the procedure, if fault
situation, it could
target persists, replace
be defective
electronics iNR module
(internal)

Defective position Perform Auto-

Intermittent sensor or strong calibration
C2112 iNR position sensor mechanical procedure, if fault
vibration/impact persists, replace
iNR module

229
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Perform Auto-
calibration
procedure, check
binding or damage
Slow to move the of the shift cable.
Excessive
actuator to the Verify the reverse
C2101 iNR mechanical
target bucket
resistance
mechanism is not
damaged. If fault
code persists,
replace the iNR
module
Defective
electronics. Could Verify the harness
also be jammed connections
Software breaker
C2150 iNR mechanical between the iNR
for battery input
components in module and the
some rare breaker panel
situations
Defective
electronics. Could Verify the harness
be jammed connections
Software breaker
C2130 iNR mechanical between the iNR
for motor output
components in module and the
some rare breaker panel
situations
Defective Perform Auto-
Motor short to electronics or calibration
C2131 iNR ground excessive procedure, if fault
mechanical persists, replace
resistance iNR module

Defective Perform Auto-

electronics or calibration
C2113 iNR Bridge overheat procedure, if fault
excessive ambient
temperature persists, replace
iNR module
iNR module
Unit deactivated internal lock was Replace iNR
C2151 iNR by software not release in module
production
Verify harness
connections
between iNR
module, boat CAN
Supply voltage too Charging system network and
C2161 iNR
low or harness breaker panel. No
supply voltage at
main 2 pin
Deutsch power
connector

230
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Defective unit
(active),
interrupted Perform Auto-
Monitoring calibration
programming
C2114 iNR processor is not procedure, if fault
session
communicating persists, replace
(occurred),
unexpected reset iNR module
(occurred)
Verify harness
ECM problem or
ECM messages connections
CAN connectivity.
U0401 iNR not present between iNR
ECM not seen by
module and boat
iNR
CAN network
Cluster problems Verify harness 5
or CAN connections
Cluster messages
U0457 iNR connectivity. between iNR
not present
Cluster not seen module and boat
by iNR CAN network
Perform Auto-
Monitoring calibration
C2115 iNR processor is Monitoring fault procedure, if fault
disabling the unit persists, replace
iNR module
Verify harness
Shifter sensor Sensor power connections
C2145 iNR supply voltage too supply failure or between iNR
low short to ground module and
throttle controller
Verify harness
connections
Sensor power between iNR
Shifter supply module and
C2144 iNR supply failure or
voltage too high throttle controller.
short to battery
If the fault persists
replace the throttle
controller
Verify harness
connections
Shifter sensors not between iNR
reporting the same Defective shifter module and
C2146 iNR
reading sensor throttle controller.
If the fault persists
replace the throttle
controller

231
Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Verify harness
connections
Shifter sensor A is between iNR
open or short to Open condition or module and
C0042 iNR
ground defective sensor throttle controller.
If the fault persists
replace the throttle
controller
Verify harness
connections
Shifter sensor B is Defective shifter between iNR
open or short to sensor or module and
C2142 iNR
ground intermittent/wire throttle controller.
oxidation If the fault persists
replace the throttle
controller
Verify harness
connections
Shifter sensor B is between iNR
open or short to Defective shifter module and
C0043 iNR
ground sensor throttle controller.
If the fault persists
replace the throttle
controller
Verify harness
connections
between iNR
Shifter sensor B is Defective shifter module and
C2143 iNR shorted to battery sensor throttle controller.
If the fault persists
replace the throttle
controller
Verify harness
Implausible ROM connections
ECM defective
C2111 iNR data received over between iNR
sensor
CAN module and boat
CAN network
Perform Auto-
Motor activated calibration
C2315 iNR too long the same Internal fault procedure, if fault
direction persists, replace
iNR module
Perform Auto-
Interrupted
calibration
programming
C2318 iNR Invalid calibration procedure, if fault
session or invalid
persists, replace
calibration used
iNR module

232
 Electronic Management System
Diagnostic and Fault Codes

FAULT CODE MODULE DESCRIPTION CAUSE ACTION

Perform Auto-
Gate moving calibration
C2328 iNR toward reverse Internal fault procedure, if fault
without reason persists, replace
iNR module
Perform Auto-
Lever position Defective lever calibration
C2329 iNR sensor out of sensor or harness/ procedure, if fault
range connectors persists, replace
iNR module

233
Electronic Management System
Diagnostic and Fault Codes

Fault Code Cross Reference: P-Code

to OBD-M
OBD-M SPN are fault codes that can be retrieved from OBD-M communication port using generic
OBD-M tool.

OBD-M P-CODE DESCRIPTION

3052 P0300 Multiple misfire detected

3052 P0302 Misfire cylinder 0 (physical cylinder 2)

3052 P0303 Misfire cylinder 1 (physical cylinder 3)

3052 P0301 Misfire cylinder 2 (physical cylinder 1)

3055 P0171 Multiplicative mixture adaptation exceeds upper limit — mixture too lean

3055 P0172 Multiplicative mixture adaptation below lower limit — mixture too rich

3055 P1171 Additive mixture adaptation exceeds upper limit — mixture too lean

3055 P1172 Additive mixture adaptation below lower limit — mixture too rich

3060 P0117 Engine coolant temperature sensor fault (short circuit to GND)

3060 P0118 Engine coolant temperature sensor fault (short circuit to V+)

3060 P0116 Engine coolant temperature signal not plausible

3222 P0135 Lambda Sensor heating fault upstream of catalyst

Heater power stage fault for lambda sensor upstream of catalyst - short
3222 P0032
circuit to V+
Heater power stage fault for lambda sensor upstream of catalyst - short
3222 P0031
circuit to GND
Heater power stage fault for lambda sensor upstream of catalyst - open
3222 P1030
line
3225 P014D O2 sensor slow response - lean to rich

3225 P014C O2 sensor slow response - rich to lean

3225 P0133 Oxygen sensor upstream of catalyst reacts to slow — contaminated

3225 P0134 Oxygen sensor upstream of catalyst reacts to slow — defective

3225 P0132 Lambda sensor fault upstream of catalyst - short circuit to V+

3225 P0131 Lambda sensor fault upstream of catalyst - short circuit to GND

3225 P0130 Lambda sensor fault upstream of catalyst - signal not plausible

3225 P1130 Lambda sensor fault upstream of catalyst - open line

3232 P0141 Lambda sensor heating fault downstream of catalyst

Heater power stage fault for lambda sensor downstream of catalyst - short
3232 P0038
circuit to V+

234
 Electronic Management System
Diagnostic and Fault Codes

OBD-M P-CODE DESCRIPTION

Heater power stage fault for lambda sensor downstream of catalyst - short
3232 P0037
circuit to GND
Heater power stage fault for lambda sensor downstream of catalyst - open
3232 P1036
line
3235 P013E O2 sensor delayed response (transient) - rich to lean

3235 P013F O2 sensor delayed response (transient) - lean to rich

3235 P013A O2 sensor slow response - rich to lean

3235 P013B O2 sensor slow response - lean to rich

Lambda sensor aging fault downstream of catalyst – sensor voltage too
3235 P2246 high
Lambda sensor aging fault downstream of catalyst – sensor voltage too
5
3235 P2245
low
3235 P0138 Lambda sensor fault downstream of catalyst - short circuit to V+

3235 P0137 Lambda sensor fault downstream of catalyst - short circuit to GND

3235 P0136 Lambda sensor fault downstream of catalyst - signal not plausible

3235 P1136 Lambda sensor fault downstream of catalyst - open line

3235 P2097 Post catalyst fuel trim system too rich

3235 P2096 Post catalyst fuel trim system too lean

4203 P0335 Crankshaft signal error

5321 P0108 Electrical upper-range violation MAP sensor (short circuit to V+)

5321 P0107 Electrical lower-range violation MAP sensor (short circuit to GND)

5321 P0106 MAP sensor value not plausible

5375 P1120 Throttle positions calculated from TPS 1 and TPS 2 not corresponding

5375 P2622 Electrical upper-range violation TPS 1

5375 P2621 Electrical lower-range violation TPS 1

5375 P212D Electrical upper-range violation TPS 2

5375 P212C Electrical lower-range violation TPS 2

5375 P2620 TPS value not plausible

5375 P1610 Throttle actuator - power stage fault

5375 P1611 Throttle actuator - power stage fault

5375 P1612 Throttle actuator - power stage fault

5375 P1613 Throttle actuator - power stage fault

235
Electronic Management System
Diagnostic and Fault Codes

OBD-M P-CODE DESCRIPTION

5375 P1614 Throttle actuator - return-spring check not passed / spring does not close

5375 P1615 Throttle actuator - position monitoring fault

5375 P1616 Throttle actuator - default position check or learning fault

5375 P060E Throttle actuator - controller fault- digital position control exceeds limit

5375 P160E Throttle actuator - controller fault - digital position control below limit

5375 P1619 Throttle actuator - adaptation of upper mechanical limit failed

5375 P1620 Throttle actuator - adaptation of lower mechanical limit failed

5375 P1621 Throttle actuator - abortion of adaptation

5375 P1622 Throttle actuator - repeated abortion of adaptation

5380 P0231 Fuel pump power stage fault - (short circuit to ground)

5380 P0232 Fuel pump power stage fault - (short circuit to V+)
Injection power stage fault - short circuit to V+ / cylinder 1 (physical
5380 P0265 cylinder 2)
Injection power stage fault - short circuit to GND / cylinder 1 (physical
5380 P0264 cylinder 2)

5380 P0202 Injection power stage fault - open line / cylinder 1 (physical cylinder 2)
Injection power stage fault - short circuit to V+ / cylinder 2 (physical
5380 P0268 cylinder 3)
Injection power stage fault - short circuit to GND / cylinder 2 (physical
5380 P0267 cylinder 3)

5380 P0203 Injection power stage fault - open line / cylinder 2 (physical cylinder 3)
Injection power stage fault - short circuit to V+ / cylinder 3 (physical
5380 P0262 cylinder 1)
Injection power stage fault - short circuit to GND / cylinder 3 (physical
5380 P0261 cylinder 1)

5380 P0201 Injection power stage fault - open line / cylinder 3 (physical cylinder 1)

236
 Fuel System
Intelligent Throttle Control

Fuel System

Intelligent Throttle Control

SERVICE TOOLS
Description Part Number Page

DIGITAL INDUCTION TACHOMETER . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 245

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . 241, 247–248, 256, 261, 263,
267, 269, 271–272, 275
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . 247–248, 255–256, 261–265,
267–272, 275
FUEL HOSE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460752 . . . . . . . . . . . . . . . . . . . . . . . 281
FUEL HOSE DISCONNECT TOOL . . . . . . . . . . . . . . . . . . . . . . . . P/N 460756 . . . . . . . . . . . . . . . . . . . . . . . 251
FUEL PUMP MODULE SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460820 . . . . . . . . . . . . . . . . . . . . . . . 284
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460722 . . . . . . . . . . . . . . . . . . . . . . . 281
6
SERVICE TOOLS — OTHER SUPPLIER
Description Part Number Page

FLUKE AUTOMOTIVE BACK PROBE . . . . . . . . . . . . . . . . . . . . . . . P/N TP40 . . . . . . . . . . . . . . . . . . . 241, 265

FLUKE SUREGRIP INSULATED TEST LEADS . . . . . . . . . . . . . . P/N TL224 . . . . . . . . . . . . . . . . . . . . . . . 265

SERVICE PRODUCTS
Description Part Number Page

LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . 242, 252, 263, 270, 275

LOC-TITE 518 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460361 . . . . . . . . . . . . . . . . . . . . . . . 271
LOC-TITE 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460791 . . . . . . . . . . . . . . . . . . . . . . . 274

237
Fuel System
Intelligent Throttle Control

Intelligent Throttle Control For Single

Engine Models

238
 Fuel System
Intelligent Throttle Control

Intelligent Throttle Control For Twin

Engine Models

239
Fuel System
Intelligent Throttle Control

General targeted opening, the ECM stops the throttle

Intelligent Throttle Control System Description actuator.
The iTC is an electronic throttle control system Procedures
that includes:
Throttle Accelerator Sensor
– A throttle accelerator sensor (TAS) controlled
by the throttle/shift control via a cable. TAS Description
– An electric throttle actuator (ETA) located on The TAS (throttle accelerator sensors) is a double
the throttle body. hall effect sensor that sends a signal to the ECM
– A throttle position sensor (TPS) located on the which is proportional to the throttle/shift lever an-
throttle body. gle. The redundancy is used for security
purposes.
N O T E : The ETA and TPS are par of the throttle
body and cannot be replaced separately. On twin-engine models, there is one TAS per en-
gine, controlled by the throttle/shift lever via a
The iTC is often referred to as a “throttle by wire” cable.
system.

TWIN ENGINE MODELS

1. TAS
1. Cable
2. Port TAS
3. Starboard TAS

TAS Access
Refer to THROTTLE SHIFTER CONTROL to gain
access to the TAS.
TAS Signal Validation
Carry out steps 1 to 4 of TAS ADJUSTMENT to
validate if the TAS signal reaches the ECM.
TAS Voltage Test
NOTICE
Do not use sharp end probes as they can
damage the connector seal.
1. Throttle body
2. Throttle actuator
1. Enable the electrical system.
According to the driver's torque demand and many
EMS inputs, the ECM powers the ETA motor using
pulse width modulation (PWM), to open or close
the throttle plate. When the ECM detects through
the TPS that the throttle plate has reached the

240
 Fuel System
Intelligent Throttle Control

REQUIRED TOOL

ECM Adapter Tool

P/N 460762

2. Set the multimeter to Vdc

REQUIRED TOOL

Fluke Automotive
Back Probe
P/N TP40
1. Bracket
3. Use the Fluke Automotive Back Probe, P/N 2. Bracket retaining screws
TP40, to back probe the TAS connector using
the following table information. 2. Disconnect the electrical connectors.
3. Remove the bolt or the cotter pin.
TAS CONNECTOR PINOUT 4. Remove the TAS retaining screws.

WIDE
6
IDLE
OPEN
TAS CONNECTOR POSI
POSI
TION
TION
PIN (1) VOLTAGE (Vdc)
A (1) B (2) 4.9–5.1
B (2) C (3) 0.15–0.35 1.4–1.6
D (4) E (5) 4.9–5.1
E (5) F (6) 0.4–0.6 2.9–3.1
TYPICAL-TWIN ENGINE MODEL S
If voltage is as per specification, the TAS is 1. Cotter pin
functional. 2. TAS retaining screws

If voltage is out of specification, check continu- 5. Remove the TAS from the bracket.
ity of wires between the ECM and the sensor.
If continuity is good, replace sensor. TAS Installation
4. Install all other removed components. 1. For models with a throttle cable end linked with
a cotter pin, install a new cotter pin.
TAS Removal 2. Bend one side of the cotter pin after
1. Remove the bracket retaining screws. installation.
3. For models with a throttle cable end linked with
a nut and bolt, snug the nut.
4. Ensure the throttle cable operates without
bending the inner wire.
5. For all models, refer to the exploded view at
the beginning of this subsection for parts lay-
out, thread locker and tightening torque
information.
TAS Adjustment
1. Connect the vehicle to the latest version of B.
U.D.S.

241
Fuel System
Intelligent Throttle Control

2. Enable the electrical system.

3. Select Monitoring>ECM.
4. Read the TAS position shown in % for each
TAS.

1. TAS cable adjuster

N O T E : In neutral, the TAS arms should rest

against the stoppers without any tension on the
cable.
1. TAS % window

5. For twin engine models, click on the Starboard/ 9. Tighten the TAS cable adjuster lock nut.
Port button to change between the starboard
REQUIRED CHEMICAL
and port ETA readings.
Loc-Tite 243
P/N 460790

10. If the cable adjuster does not allow correct ad-

justment, use the threaded end of the cable lin-
er attached to the bracket. In such a case,
apply Loc-Tite 243, P/N 460790, to the cable
liner threads.
11. After adjusting at WOT, check the readings in
neutral and make sure the TAS arms rest
against the stoppers and the cable moves
1. Starboard/Port button
freely.
6. Refer to the following table for adjustments.

CORRECT TAS ADJUSTMENT

THROTTLE/SHIFT
READING
LEVER POSITION
Neutral 0%
Wide Open 100%

7. Loosen the TAS cable adjuster lock nut.

N O T E : The adjuster is located inside the star-
board console.

8. Turn the adjuster in order to get the specific

readings.

242
 Fuel System
Electronic Fuel Injection (EFI)

Electronic Fuel Injection (EFI)

SERVICE TOOLS
Description Part Number Page

DIGITAL INDUCTION TACHOMETER . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 245

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . 241, 247–248, 256, 261, 263,
267, 269, 271–272, 275
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . 247–248, 255–256, 261–265,
267–272, 275
FUEL HOSE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460752 . . . . . . . . . . . . . . . . . . . . . . . 281
FUEL HOSE DISCONNECT TOOL . . . . . . . . . . . . . . . . . . . . . . . . P/N 460756 . . . . . . . . . . . . . . . . . . . . . . . 251
FUEL PUMP MODULE SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460820 . . . . . . . . . . . . . . . . . . . . . . . 284
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460722 . . . . . . . . . . . . . . . . . . . . . . . 281

SERVICE TOOLS — OTHER SUPPLIER

Description Part Number Page
6
FLUKE AUTOMOTIVE BACK PROBE . . . . . . . . . . . . . . . . . . . . . . . P/N TP40 . . . . . . . . . . . . . . . . . . . 241, 265
FLUKE SUREGRIP INSULATED TEST LEADS . . . . . . . . . . . . . . P/N TL224 . . . . . . . . . . . . . . . . . . . . . . . 265

SERVICE PRODUCTS
Description Part Number Page

LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . 242, 252, 263, 270, 275

LOC-TITE 518 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460361 . . . . . . . . . . . . . . . . . . . . . . . 271
LOC-TITE 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460791 . . . . . . . . . . . . . . . . . . . . . . . 274

243
Fuel System
Electronic Fuel Injection (EFI)

General EFI Electrical System

System Description ECM (Electronic Control Module)
WARNING From input signals, the ECM acknowledges driver
Fuel is flammable and explosive under cer- demands and converts them to an engine torque
tain conditions. Do not smoke or allow open requirement through calculation of several varia-
flames or sparks in the vicinity. bles. Then, the ECM controls the iTC, the injection
system and the ignition system to meet the torque
requirement.
WARNING
The ECM manages the engine torque require-
Always turn the main battery cut-off switch to ments and controls engine operation to ensure it
OFF prior to work on the fuel system. is delivering optimum performance, fuel economy
and meeting emission regulations. The ECM also
WARNING controls idle RPM and limits maximum engine
Fuel lines remain under pressure at all times. speed.
Always proceed with care and use appropri- EFI Sensors
ate safety equipment when working on a
The ECM reads the inputs from the sensors which
pressurized fuel system. Proceed with care it compares to predetermined parameters stored
when removing/installing pressure test in the ECM, makes computations, and activates
equipment or disconnecting fuel line the outputs accordingly (injectors, ignition coils
connections. etc.).

WARNING Signals from sensors are used by the ECM to de-

termine the injection and ignition parameters (ref-
Do not allow fuel to spill on hot engine parts erenced to fuel maps) as required to maintain the
and/or on electrical connectors. Wipe off any optimum air-fuel ratio.
fuel spillage in the bilge area, if so, vent the
bilge thoroughly. EFI Air Intake System
Air Filter
WARNING Air is drawn directly into a air filter.
Always perform the fuel pressure test if any
fuel line has not been removed or discon- An air duct is used to channel the air to the throttle
nected. Replace any damage, leaking or de- body (150 engine) or to the supercharger (250
teriorated fuel lines or connections. engine).
Intercooler (Supercharged Engines)
WARNING Air that exits the supercharger has been warmed
Hoses, cables or locking ties removed during up during the air compression process. The air
a procedure must be reinstalled as per fac- that enters the intercooler is cooled down by circu-
tory standards. lating between small tubes in which cooling water
flows. The cooling water is supplied by the jet
I M P O R T A N T : When the repair or test is com- pump. This increases the air density which aug-
pleted, ensure that all hoses are connected and ments the amount of air entering the engine.
secured. Perform the FUEL SYSTEM PRESSURE 250 Supercharged Engine
TEST and the FUEL SYSTEM LEAK TEST. The intercooler used on the 250 engine is a sepa-
The electronic fuel injection system (EFI) is com- rate unit externally mounted.
prised of various sensors used for detecting on- This intercooler configuration is more efficient as it
going operating conditions of the engine and boat, cools the air from the supercharger before it
and includes all the actuators that perform the re- passes through the throttle body using a larger in-
quired adjustment to the engine. tercooler. It provides for better cooling, higher
mass air flow and higher engine horsepower.

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 Fuel System
Electronic Fuel Injection (EFI)

Adjustments
Idle Speed Adjustment
Idle speed is not adjustable. The ECM controls the
idle speed of the engine.
1. Wrap the tachometer's wire a few times around
the protruding part of the ignition coil.

REQUIRED TOOL
1. Supercharger
2. Supercharger inlet Digital Induction
3. Supercharger outlet Tachometer
4. Intercooler
5. Intercooler air inlet — warm air from supercharger P/N 460732
6. Intercooler air outlet — cooled air
7. Throttle body
8. Cooling water outlet — warmed water
9. Intercooler cooling water inlet — cold weather

Throttle Body
A throttle body is mounted on the intake manifold.
Air for combustion is drawn in by the engine or by 6
a mechanically driven supercharger. The air flows
through the throttle body and is controlled by a
throttle plate.
Fitted on the throttle body, an electronic throttle
actuator (ETA) allows the ECM to electronically
control the throttle plate opening which regulates
the amount of air that enters the engine, and
therefore engine speed.
There is no idle air control valve (IACV).
2. Start engine, read the engine RPM on the in-
Fuel System duction tachometer.
Fuel Rail IDLE SPEED
A single fuel rail is mounted on the intake mani-
fold. The fuel rail ensures that enough fuel can be 1750 ± 50 RPM
delivered to the fuel injectors throughout the en-
gine operating range. If idle speed is not within specifications, check if
there is any occurred or active fault code(s).
The fuel rail is fed by the fuel pump. The fuel pres-
sure applied to the fuel rail is regulated by the fuel If not, perform the CLOSED THROTTLE RESET.
pressure regulator located in the fuel pump If idle speed is still not adequate, there is probably
module. a mechanical problem.
Fuel Injectors Closed Throttle Reset
Three fuel injectors are used to inject fuel into the This operation performs a reset of the TPS values
intake ports of the cylinder head. One injector is of the throttle body in the ECM.
used per cylinder.
Closed throttle reset must be carried out only
Fuel Pump when:
An electric fuel pump with an integrated pressure – Replacing the throttle body
regulator is used. For more details on the fuel – Replacing the ECM
pump unit, refer to FUEL TANK AND FUEL
PUMP.

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Fuel System
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Closed Throttle Reset Procedure Troubleshooting

1. Connect the vessel to the latest version of B.U. The following is provided to help in diagnosing the
D.S. probable source of troubles. It is a guideline and it
2. Ensure the throttle/shifter control is in the NEU- should not be assumed to list all possible
TRAL position. problems.
3. Ensure the tether cord is properly installed on
the engine cut-off switch. Always check for fault codes. If a fault code is de-
4. Energize the electrical system without starting tected, service the fault code first. Refer to EN-
the engine. GINE MANAGEMENT.
5. Start B.U.D.S. and logon.\ EFI Troubleshooting
6. Once logged on, click the ECM Setting tab.
7. Click the Reset button.
Diagnostic Tips

Engine problems are not necessarily related to the

fuel injection system.
It is important to ensure that the engine and pro-
pulsion system, fuel delivery and electrical sys-
tems are functioning normally.
For diagnostics purposes, use B.U.D.S. software.
See Communication Tools and B. U. D. S., page
190.
ECM SETTING IN B.U.D.S. After a problem has been solved, be sure to clear
1. Reset button
the fault(s) in the ECM using B.U.D.S.
8. The following message will confirm the Never use a battery charger to temporarily substi-
operation. tute the battery as it may cause the ECM to func-
tion erratically, or not at all.
Check related-circuit fuse solidity and condition
with an ohmmeter. A visual inspection could lead
to a false diagnosis.

Electrical Related Problems

It is important to check the following in the electri-
cal system:
– Battery voltage
9. Click the OK box. – Fuses
– Bus bar condition in fuse boxes
10. Exit B.U.D.S. It is not necessary to click on the
– Ground connections
Write button before closing B.U.D.S.
– Wiring and connectors
N O T E : If the throttle valve was not within the al- Ensure that all electronic components are genuine
lowed range when the Closed Throttle reset was OEM. Any modification to the wiring harness may
carried out, no error message would be displayed. lead to poor system operation or generate fault
However, a fault code would be set when the en- codes.
gine is started.

11. Start engine and make sure the engine oper- Electrical Connections
ates normally through the full engine RPM
range. Pay particular attention to ensure that terminals
12. Check for fault codes using B.U.D.S. If a fault and pins are not out of their connectors, corroded,
code related to the throttle actuator appears, or out of shape.
clear it, then carry out another Closed Throttle
Reset procedure.

246
 Fuel System
Electronic Fuel Injection (EFI)

When probing terminals, pay attention not to de- This tool will prevent deforming or enlarging termi-
form the terminals as this could cause a loose or nals which would lead to bad ECM terminal con-
intermittent connection that would be difficult to tact creating intermittent or permanent problems.
troubleshoot.
ECM Power Supply Test
Procedures 1. Disconnect connector "B" from the ECM.
ECM Connector Identification REQUIRED TOOLS
There are 2 connectors connected to the ECM.
The engine harness female connector is con- ECM Adapter Tool
nected to the ECM module male connector A.
P/N 460762
The vehicle system control harness female con-
nector is connected to the ECM module male con-
nector B. Fluke 115 Multimeter
P/N 460735

2. Install the required ECM Adapter Tool, P/N

460762, onto the ECM connector.
3. Install a jumper wire between B-H2 and B-M2.
4. Activate the electrical system.
5. Select the Vdc position on the multimeter and
6
check voltage as follows.

ECM
BATTERY VOLTAGE
ADAPTER
Battery
1. Connector A B-M4 Negative post
2. Connector B voltage
The ECM connectors have 48 pins. 6. If voltage is not measured check the main re-
For connector information, cleaning and probing, lay, wiring and connections.
refer to CONNECTOR INFORMATION.
ECM Power Circuit Continuity Test
ECM Validation Tool 1. Turn the main battery cut-off switch to the OFF
1. Use the ECM Adapter Tool, P/N 460762, to position.
probe ECM connector terminals.
REQUIRED TOOLS

ECM Adapter Tool

P/N 460762

Fluke 115 Multimeter

P/N 460735

2. With the adapter tool still connected, probe ter-

minals as per following table.

ALL
REQUIRED TOOLS
ECM
FUSE BOX RESISTANCE
ECM Adapter Tool ADAPTER

P/N 460762 Terminal C1-

Pin B-M4 Close to 0 Ω
A5-E5

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Fuel System
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3. If an open circuit is measured, repair or replace

wiring and connectors.
4. If the ECM power circuit tests good, test the
ECM ground circuit.
ECM Ground Circuits Continuity Test
1. Using the ECM Adapter Tool and a multimeter,
probe the terminals according to the following
table.
REQUIRED TOOLS

ECM Adapter Tool

TYPICAL-FRONT OF ENGINE
P/N 460762 1. Engine grounds

Fluke 115 Multimeter

P/N 460735

ECM BATTERY RESIST

ADAPTER POST ANCE
B-L1
Close to 0 Ω
B-M2 Ground (continuity)
B-M3
1. Battery ground cable
2. Exhaust manifold water inlet fitting

ECM Removal
1. If a new ECM is being installed, refer to the
procedures found in ECM REPLACEMENT.
2. Turn the main battery cut-off switch to the OFF
position.
3. Disconnect both ECM connectors from ECM.
4. Unscrew all retaining screws and remove the
engine ECM from its support on the intake
manifold.
If the measurement is out of specification, check
the grounds on the following components:
– Ground bus bar in fuse box
– Ground wires and connections
– Engine grounds
– Battery grounds

1. ECM
2. Retaining screws

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 Fuel System
Electronic Fuel Injection (EFI)

ECM Installation
Installation is the reverse of the removal proce-
dure. Pay attention to the following during
installation.
1. Install and secure the ECM using the ECM
mounting screws.
2. Tighten the mounting screws to the proper
specification.
NOTICE
Always replace the ECM using the same part
number or by a BRP approved equivalent.

TIGHTENING TORQUE 3. Click once on the Folder Up button in the Open

box.
ECM mounting screws 5.5 N·m (49 lbf·in)

3. Reconnect ECM connectors.

4. Turn main battery cut-off switch to ON position.
5. If a new ECM is installed, refer to ECM
REPLACEMENT.
6
ECM Replacement
Prior to replacing a suspected ECM, ensure that
all the recommendations in the general introduc-
tion of this subsection have been followed.
When installing a new ECM, data must be entered
and a reset is required.
To transfer/enter data to the new ECM, refer to 4. Double click on the A u t o S a v e folder.
ECM MANUAL DATA ENTRY.
ECM Manual Data Entry
There are 2 possible methods to collect the re-
quired information.
1.
2. Use B. U. D. S. software and obtain the data
from a saved .mpem file on your PC computer.
3. Collect the information from the vehicle.
Obtaining the Data from a Saved .mpem File
1. Use the B.U.D.S. software.
N O T E : It is not necessary to perform any con- N O T E : You may have to go to another A u t o -
nection. The PC computer can be used alone for S a v e folder from a previous version of B.U.D.S.
this task.
5. Choose the latest file saved for this specific
2. In B.U.D.S., click on the Open button. vehicle.

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Fuel System
Electronic Fuel Injection (EFI)

Entering The Collected Data Into The ECM

1. Use the latest applicable B. U. D. S. software.
Refer to Communication Tools and B. U. D. S.,
page 190.
2. Install the tether cord on the engine cut-off
switch and turn ignition key to ON position.
3. In B.U.D.S., click the Read Data button to read
the new ECM.

I M P O R T A N T : Be sure to use the file that specif-

ically matches the vehicle you are servicing.

N O T E : The file name structure is as follows:

BUDS version_VIN_date read (yyyymmdd)_
hour read (hhmmss).mpem 4. The following screen window will pop up.
Example:
P2.3.22.12_2BPSBK8C68V000168_20090206_
111640.mpem
Therefore:
B.U.D.S. version P2.3.22.12
VIN: 2BPSBK8C68V000168
Date: 2009 02 06
Hour: 11h 16m 40s

6. Go in the Vehicle tab and record the following

information: 5. Enter the vehicle model number.
– Vehicle serial number
– Engine serial number (without the leading
NOTICE
“M” Enter only the appropriate product model
– Vehicle model number number as obtained when gathering the
– Customer name information.

VEHICLE TAB

7. Enter recorded data in ECM as detailed in EN- 6. Click the Vehicle tab and enter the following
TERING THE COLLECTED INFORMATION information:
INTO THE ECM.
– Vehicle serial number

250
 Fuel System
Electronic Fuel Injection (EFI)

– Engine number (do not enter the “M” at the

beginning of the engine number)
– Customer name

10. Perform the Closed Throttle Reset Procedure.

Refer to Closed Throttle Reset Procedure,
VEHICL E TAB page 246.
11. Reinstall remaining removed parts.
7. Click on the following tabs:
Fuel Rail
– History
– Part Replacement Fuel Rail Hose Disconnection
– Add Part in History. 1. Disconnect fuel pump electrical connector.
8. Enter the old ECM serial number in the Add 2. Crank engine. This will relieve the fuel
pressure.
6
Part In History window.
3. Turn the main battery cut-off switch to OFF
position.
4. Place an absorbent shop rag under the fuel
supply hose fitting at the fuel rail to catch any
fuel leakage.

REQUIRED TOOL

Fuel Hose Discon-

nect Tool
P/N 460756

HISTORY, PART REPLACEMENT, ADDING PART IN HISTORY 5. Use the Fuel Hose Disconnect Tool, P/N
TABS
460756, to disconnect fuel hose from fuel rail.
N O T E : The ECM serial number can be found on
the ECM sticker that also identifies the part
number
9. Click on the Write Data button.

251
Fuel System
Electronic Fuel Injection (EFI)

1. Retaining screws

3. Gently move the fuel rail side to side.

It may be necessary to rotate fuel hose fitting to
align the tool ends with the openings of the locking
mechanism.
Fuel Rail Removal
1. Cut locking ties retaining engine harness to
fuel rail.

1. Fuel rail

4. Disconnect all injector connectors.

5. Pull fuel rail out with fuel injectors.
Fuel Rail Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Apply Loc-Tite 243, P/N 460790, onto the
1. Cut locking ties threads of the fuel rail retaining screws.
2. Remove screws retaining the fuel rail. REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

2. Install the fuel rail and secure using the fuel rail
retaining screws.
3. Torque fuel rail retaining screws to
specification.

TIGHTENING TORQUE
Fuel rail retaining 9 N·m (80 lbf·in)
screws

252
 Fuel System
Electronic Fuel Injection (EFI)

2. Push fuel hose fitting on fuel rail until it “clicks”.

3. Try pulling fuel hose off fuel rail to ensure fitting
is properly locked.
4. Pressurize the fuel system and check for a fuel
leak. Refer to FUEL SYSTEM LEAK TEST.
5. Reinstall all remaining removed parts.
Fuel Injector
Fuel Injector Dynamic Operation Test With B.
U.D.S.
1. Connect B.U.D.S. software. Refer to Commu-
nication Tools and B.U.D.S., page 190.
2. Start the engine.
3. If the boat is out of water, connect a garden
1. Retaining screws hose to the hose adapter to cool exhaust sys-
tem. Refer to Exhaust System Flushing, page
4. Properly install new locking ties to secure en- 51.
gine harness to fuel rail. 4. In B.U.D.S., click Read Data > Monitoring.
5. Using B.U.D.S., shut down each engine cylin-
der one at a time by clicking on the button
under the applicable cylinder. 6

1. New locking ties

Fuel Rail Hose Connection

1. Cylinder shut down button
1. Apply engine oil onto the O-rings of the fitting.
If the engine RPM drops when clicking on a cylin-
N O T E : Always make sure O-rings are in proper der, the injector and the ignition of this cylinder are
condition and not cracked, brittle or hard, before functioning normally.
installing fuel hose fitting.
If the engine RPM does not drop when clicking on
a cylinder, this cylinder is not functioning properly.
Check the following:
– Fuel injector operation. Refer to FUEL INJEC-
TOR OPERATION TEST WITH B.U.D.S.
(STATIC).
– Spark plug and ignition coil. Refer to IGNITION
SYSTEM.
– Engine condition.

1. Apply oil on O-rings

253
Fuel System
Electronic Fuel Injection (EFI)

Fuel Injector Static Operation Test With B.U.

D.S.
NOTICE
After fuel injector activation using B.U.D.S.,
always crank engine in drowned mode to ven-
tilate engine and prevent a potential backfire
due to fuel accumulation in the engine.

1. Connect B.U.D.S. software. Refer to Commu-

nication Tools and B.U.D.S., page 190.
2. Activate the electrical system.
3. In B.U.D.S., click Read Data > Activation tab.
4. On the ECM Activation page, energize the fuel ACTIVATION AND ECM TABS
injector to be tested by clicking on it in B.U.D. 1. Fuel Pump activation button
S. 6. Fuel pressure must be within specification. Re-
fer to FUEL TANK AND FUEL PUMP.
7. Re-activate fuel pump as necessary.
8. In B.U.D.S., energize fuel injector No. 1.

ACTIVATION AND ECM TABS

1. Injector of cylinder

5. Listen to the injector.

ACTIVATION AND ECM TABS
If you can hear the injector, it validates its opera- 1. Injector of cylinder
tion. Carry out the FUEL INJECTOR BALANCE
TEST WITH B.U.D.S. 9. Record the fuel pressure drop for injector No.
1.
If you do not hear the injector, carry out the IN- 10. In B.U.D.S., click the Fuel Pump button to acti-
JECTOR INPUT VOLTAGE TEST. vate fuel pump.
Fuel Injector Balance Test With B.U.D.S.
NOTICE
After fuel injector activation using B.U.D.S.,
always crank engine in drowned mode to ven-
tilate engine and prevent a potential backfire
due to fuel accumulation in the engine.

1. Install a fuel pressure gauge as described in

FUEL PUMP PRESSURE TEST of FUEL
TANK AND FUEL PUMP.
2. Connect B.U.D.S. software. Refer to Commu-
nication Tools and B.U.D.S., page 190.
3. Activate the electrical system. ACTIVATION AND ECM TABS
4. In B.U.D.S., click Read Data > Activation tab. 1. Fuel Pump activation button
5. In B.U.D.S., click the Fuel Pump button to acti-
vate the fuel pump.

254
 Fuel System
Electronic Fuel Injection (EFI)

11. Repeat the procedure for fuel injectors No. 2 REQUIRED TOOL
and No. 3 and record the pressure drop for
each injector.
12. The maximum fuel pressure drop between in- Fluke 115 Multimeter
jectors should not exceed the following P/N 460735
specification.

MAXIMUM FUEL PRESSURE DROP 3. Using the Fluke 115 Multimeter, P/N 460735,
ALLOWED BETWEEN FUEL INJECTORS select Vdc.
4. Read input voltage to the applicable injector as
10 kPa (1.5 PSI) per following table.

13. If pressure drop of any fuel injector is greater PROBE INJECTOR MEASURE
than the specification, replace that injector then CONNECTOR MENT
repeat the test. Battery Battery
VIOLET wire
14. Using the valve on the fuel pressure gauge, re- ground voltage
with a tracer
lease the pressure in the system (if so
equipped).
15. Remove fuel pressure gauge and reinstall re-
moved parts.
Fuel Injector Input Voltage Test 6
1. Disconnect fuel injector connectors.

N O T E : Push against tab underneath connector

as illustrated to unlock it.

5. If battery voltage is measured, carry out the

Fuel Injector Ground Circuit Test. Refer to
FUEL INJECTOR GROUND CIRCUIT TEST.
6. If battery voltage is not measured, carry out the
Fuel Injector Power Circuit Continuity Test. Re-
fer to FUEL INJECTOR POWER CIRCUIT
CONTINUITY TEST.
Fuel Injector Power Circuit Continuity Test
PUSH HERE TO UNLOCK 1. Remove the long bus bar from the fuse box.

REQUIRED TOOL

Fluke 115 Multimeter

P/N 460735

2. Using the Fluke 115 Multimeter, P/N 460735,

select Ω.
3. Measure resistance value between terminals
1. Fuel injector connectors
as per the following table.

2. Activate the electrical system.

255
Fuel System
Electronic Fuel Injection (EFI)

ALL MODELS 6. If resistance values of the ground circuit are

within specification, carry out the Fuel Injector
INJECTOR RESISTANCE Continuity Test (At Component). Refer to
FUSE BOX @ 20°C FUEL INJECTOR CONTINUITY TEST (AT
CONNECTOR
TERMINAL (68°F) COMPONENT).
PIN
F11 injector Fuel Injector Resistance Test At Component
#1 1. Remove injector connector.
F9 injector #2 2 11.4–12.6 Ω
REQUIRED TOOLS
F7 injector #3
Fluke 115 Multimeter
If resistance value are not as specified, check the P/N 460735
fuse or repair and replace wiring and connectors
as necessary.
2. Use the Fluke 115 Multimeter to check the re-
If resistance values are as specified, carry out the sistance value between injector pins as per fol-
Fuel Injector Ground Circuit Test. Refer to FUEL lowing table.
INJECTOR GROUND CIRCUIT TEST.
RESIST
Fuel Injector Ground Circuit Test INJECTOR PIN ANCE @
1. Disconnect the ECM A connector. 20°C (68°F)
REQUIRED TOOLS 1 2 11.4–12.6 Ω

ECM Adapter Tool

P/N 460762

Fluke 115 Multimeter

P/N 460735

2. Install the ECM Adapter Tool, P/N 460762, on-

to the ECM connector.
3. Using the Fluke 115 Multimeter, P/N 460735,
select Ω.
4. Probe terminals as per the following table.

ALL MODELS
INJECTOR RESISTANCE If readings are not as specified, replace injector.
FUSE BOX @ 20°C
CONNECTOR Fuel Injector Removal
TERMINAL (68°F)
PIN 1. Remove fuel rail. Refer to Fuel Rail Removal,
Pin A-B3 page 252.
(injector #1 - 2. Remove the injector clip.
rear)
1(BROWN
Pin A-K1 wire with a Close to 0 Ω
(injector #2) tracer)
Pin A-J1
(injector #3)

5. If ground circuit is at fault, repair or replace wir-

ing and connectors.

256
 Fuel System
Electronic Fuel Injection (EFI)

Throttle Body
Electronic Throttle Actuator

FUEL RAIL ASSEMBLY

1. Fuel injector
2. Injector clip
3. O-ring

3. Pull the fuel injector out of the fuel rail.

Fuel Injector Installation
WARNING 1. Throttle body

Always carry out a fuel system high pressure

2.
3.
Throttle plate
Throttle actuator (electric motor inside)
6
leak test after working in the fuel system. 4. Throttle position sensor (TPS inside)

The electronic throttle actuator (ETA) is a DC mo-

For installation, reverse the removal procedure. tor on the throttle body that regulates the throttle
Pay attention to the following during installation. plate via a drive gear. Pulse width modulation
1. If you reinstall a used injector, carefully inspect (PWM) is used to control the motor.
O-ring condition before re-installation. Replace Throttle Plate Operating Positions
O-ring with a new one if damaged. Two torsional springs are connected to the throttle
2. Apply a thin film of engine oil to O-rings. plate. A main spring and another one in a plunger
3. Insert the fuel injector in the fuel rail. mechanism.
4. Secure injector to fuel rail with a retaining clip.
5. Install fuel rail on engine. Refer to Fuel Rail In- When there is no power to the throttle actuator
stallation, page 252. (ETA), the plunger mechanism maintains the throt-
6. Pressurize the fuel system and check for a fuel tle plate at a rest position.
leak. Refer to FUEL SYSTEM LEAK TEST.
7. Reinstall all remaining removed parts, refer to When the throttle plate is opened by the ETA as
applicable subsections. commanded by the ECM, it acts against the main
spring. If the ETA failed, the return spring would
bring the throttle plate back to the limp home
position.

257
Fuel System
Electronic Fuel Injection (EFI)

THROTTLE THROTTLE
ECM ENGINE ECM ENGINE
BODY BODY
Throttle Throttle
actuator: Off actuator: ON
Throttle plate: Throttle plate:
Rest position, Moves from
maintained the rest
OFF Stopped
opened at position to the
approximately idle position
8° (1). This is (approximate
also the limp Started. ly 1-3°)
home position. Normal according to
ON
operation at ECM injection
Throttle idle and ignition
actuator: ON maps. Throttle
Throttle plate: plate is
Moves from opened and
the rest closed as
position to necessary to
approximately control the idle
14°. it then speed.
moves back to
the rest Throttle
position. This actuator: ON
is the Throttle plate:
diagnostic Started. Opens and
mode when Normal closes
ON
the rest operation at according to
ON Not started various RPM
position, ECM torque
actuator management
opening force priorities.
to overcome
(1) Degree values are given from the fully closed position.
the return
spring and the
motor return Throttle Body Cleaning
rate are 1. Remove air inlet hose from throttle body.
monitored. If 2. Check throttle body cleanliness using a flash-
any of these light. Fully open throttle plate and verify:
parameters
are out of – Throttle body bore
range, a fault – Throttle plate edge. Look for:
code is – Dirt
initiated. – Oily surfaces
– Carbon and salt deposits on throttle plate
and the surrounding bore.
3. Clean as necessary.
4. Use a throttle body cleaner such as GUNK IN-
TAKE MEDIC or an equivalent.

258
 Fuel System
Electronic Fuel Injection (EFI)

NOTICE
Only use appropriate throttle body cleaner
that will not damage O-rings and EFI
sensors.

WARNING
Use product in well ventilated area. Refer to
product manufacturer’s warnings. Wipe off
any product leakage in the bilge.

5. To avoid getting dirt into engine, spray cleaner

on a clean rag (outside the bilge) then rub rag
TYPICAL — SETTING TAB
against throttle plate and bore. A toothbrush 1. ETA position
works well too.
6. If result is out of specification, carry out a
WARNING closed throttle reset. Refer to Idle Speed Ad-
Ensure ECM is off. If ECM should suddenly justment, page 245.
turn off, it would quickly close the throttle
N O T E : The ETA is reset at the same time as the
plate which could cause serious injury.
TPS. 6
6. Manually open throttle and hold fully open to 7. After the reset, test ETA again.
reach all surfaces. 8. If the result is still out of specification, check
wire continuity between ECM and throttle body
WARNING before assuming the ETA is at fault.
Ensure nobody activate the electrical system.
The ECM would turn on and the throttle ac- Throttle Body Removal
tuator (ETA) would cycle. This could cause 1. Disconnect inlet hose from throttle body.
serious finger injury as the throttle plate 2. Press the locking tab and remove the throttle
moves quickly. body connector.

7. To remove residual dirt, spray cleaner on throt-

tle plate and on bore.
8. Reinstall removed parts.
Throttle Body Actuator Test With B.U.D.S.
N O T E : Use the Setting tab, to confirm ETA
movement. The Monitoring page will not read the
actual ETA movement.

1. Enable electrical system.

2. Connect vehicle to the latest B.U.D.S. version.
3. Click the Setting, then ECM tabs.
4. Click on the Starboard/Port button for star-
board or port ETA readings for twin engine
applications.
PRESS HERE TO UNLOCK
5. Slowly move throttle or throttle/shift lever from
NEUTRAL to WOT. The ETA should go from
0% to 100%.

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Fuel System
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Throttle Position Sensor

TPS Description
The throttle position sensor (TPS) is a double po-
tentiometer that sends a signal to the ECM that is
proportional to the throttle plate angle. The TPS is
located inside the throttle body.
TPS Reset
For the TPS reset procedure, refer to Closed
Throttle Reset Procedure, page 246.
1. Throttle body TPS Wear Test
2. Inlet hose
3. Connector 1. With the engine turned off, slowly move throttle
lever forwards and pay attention for smooth
3. Remove retaining screws from throttle body. operation without physical stops.
2. Activate the electrical system.
3. Connect B.U.D.S. software. Refer to Commu-
nication Tools and B.U.D.S., page 190.
4. In B.U.D.S., click Monitoring > ECM tab.
5. Slowly move the throttle lever through the op-
erating range.
6. Observe the Throttle Opening needle move-
ment in B.U.D.S.

1. Throttle body
2. Screws

4. Remove the throttle body from the intake

manifold.
Throttle Body Installation
For installation, reverse the removal procedure.
Pay attention to the following for installation. MONITORING AND ECM TABS

1. Install the throttle body onto the intake 7. The needle should move gradually and regu-
manifold. larly as the throttle lever is moved.
2. Secure the throttle body using the retaining
screws. N O T E : If the needle “sticks”, bounces or sud-
3. Torque the screws to the proper specification. denly drops, it may indicate a worn TPS. An initial
slight delay after the throttle lever is moved and
TIGHTENING TORQUE before the needle starts to move is normal.
Throttle body retaining 9 N·m (80 lbf·in) 8. If the needle behavior is not as expected, pro-
screws ceed with the following steps.
9. Manually move the throttle plate in throttle
4. Perform the Closed Throttle Reset Procedure. body using a blunt tool.
Refer to Closed Throttle Reset Procedure,
page 246. CAUTION
Do not move throttle plate with your fingers. If
ECM should turn off, it would quickly close
the throttle plate causing finger injury.

260
 Fuel System
Electronic Fuel Injection (EFI)

FULLY FULLY
ECM CLOSED OPEN
ADAPTER THROTTLE THROTTLE
P L A T E (1) PLATE
A-A2 A-K4 875 1625 875 1625
A-A2 A-K3 954 1934 228 585
A-A2 A-F3 254 634 980 1983
A-K3 A-K4 228 585 954 1934
A-K3 A-F3 1385 2315 1385 2315
A-K4 A-F3 980 1983 254 634
(1) To obtain the fully closed position, it is necessary to push against
the throttle plate in the throttle body with your hand and hold it in this
1. Push here position for the measurement.

10. Check needle movement again.

11. If needle moves as expected, check the throttle
accelerator sensor (TAS). Refer to Throttle Ac- 6
celerator Sensor, page 240.
12. If needle does not move as expected, perform
the TPS Resistance Test. Refer to TPS RE-
SISTANCE TEST.
TPS Resistance Test
1. Ensure the throttle body connector is properly
connected.
2. Disconnect ECM connector A from the ECM.
REQUIRED TOOLS 6. If any resistance value is incorrect, check wire
continuity between ECM and throttle body be-
fore assuming the TPS is at fault.
ECM Adapter Tool
P/N 460762

Fluke 115 Multimeter

P/N 460735

3. Install the ECM Adapter Tool, P/N 460762, on-

to the ECM connector.
4. Using the Fluke 115 Multimeter, select Ω.
5. Probe circuit as per following table while using
your hand to manually move throttle plate.
TPS CONNECTOR PIN-OUT

FULLY FULLY
ECM CLOSED OPEN
ADAPTER THROTTLE THROTTLE
P L A T E (1) PLATE
RESISTANCE Ω
PIN MIN MAX MIN MAX

261
Fuel System
Electronic Fuel Injection (EFI)

Crankshaft Position Sensor

CPS CONNECTOR MEASUREMENT
PIN VOLTAGE
Approximately 2.3
1 2
VAC

1. Crankshaft Position Sensor (CPS)

Take into account that a CPS fault can be trig-

gered by a bent or missing trigger wheel tooth.
First check for fault codes, then test the CPS. If it
tests good, check trigger wheel teeth condition.
Refer to PTO Housing and Magneto, page 65.
5. If voltage is not as specified, carry out a CPS
CPS Voltage Test Resistance Test.
1. Remove the required parts to access the CPS. 6. If voltage is as specified, check continuity of
Refer to CPS REPLACEMENT. wiring between CPS connector and ECM
2. Disconnect CPS connector. connector.
CPS Resistance Test
1. Set the Fluke 115 Multimeter, P/N 460735, to
Ω.
REQUIRED TOOLS

Fluke 115 Multimeter

P/N 460735

2. Probe CPS terminals as per following table.

CPS CONNECTOR MEASUREMENT

RESISTANCE @ 20°C
PIN (68°F)
3. Activate drowned mode. Refer to Drowned
Mode, page 183. 1 2 700–900 Ω

REQUIRED TOOLS

Fluke 115 Multimeter

P/N 460735

4. While cranking the engine, use the Fluke 115

Multimeter, P/N 460735, to probe the CPS ter-
minals as per the following table.

262
 Fuel System
Electronic Fuel Injection (EFI)

NOTE: It is not necessary to drain oil from

engine.

2. Disconnect the CPS connector.

3. If resistance is not within specifications, re-

place the CPS.
4. If resistance tests good, test CPS circuit. Refer
to CPS RESISTANCE TEST (AT ECM). 3. Remove wire retaining clip (as applicable).
4. Remove CPS retaining screw.
6
CPS Resistance Test At ECM
1. Connect the CPS connector and disconnect
ECM connector A from the ECM.
REQUIRED TOOLS

ECM Adapter Tool

P/N 460762

Fluke 115 Multimeter

P/N 460735

2. Install the ECM Adapter Tool, P/N 460762.

3. Test circuit resistance through CPS as per fol-
lowing table.
1. Wire retaining clip
ECM ADAPTER MEASUREMENT 2. CPS retaining screw

RESISTANCE (Ω) @ 5. Remove CPS.

PIN 20°C (68°F) CPS Installation
1 2 700 - 900 Ω For installation, reverse the removal procedure.
Pay attention to the following during installation.
4. If resistance measured is not as specified and 1. Apply Loc-Tite 243, P/N 460790, onto the
CPS tested good, repair or replace wiring and threads of the CPS retaining screw.
connectors between ECM and the CPS.
CPS Removal REQUIRED CHEMICAL
1. Drain oil from PTO housing. Refer to PTO
Housing and Magneto, page 65. Loc-Tite 243
P/N 460790

263
Fuel System
Electronic Fuel Injection (EFI)

2. Install the CPS and secure using the CPS re- REQUIRED TOOLS
taining screw.
3. Tighten the retaining screw to the proper
specification. Fluke 115 Multimeter
P/N 460735
TIGHTENING TORQUE
CPS retaining screws 9 N·m (80 lbf·in) 4. Use the Fluke 115 Multimeter, P/N 460735, to
probe the harness connector terminals as per
4. Refill engine oil and check oil level. Refer to the following table.
Engine Oil and Filter Replacement, page 18.
CAPS CONNECTOR MEASUREMENT
Camshaft Position Sensor (CAPS)
CAPS Voltage Test (Harness Side) PIN VOLTAGE
3 1 Battery voltage

1.

1. Remove the parts required to access the

CAPS. Refer to CAPS REPLACEMENT.
2. Disconnect CAPS connector.
5. If battery voltage is read, proceed with CAPS
DYNAMIC TEST further in this subsection.
6. If battery voltage is not read, use the multi-
meter to probe the circuit according to the fol-
lowing table.

MEASURE
CAPS CONNECTOR
MENT
PIN VOLTAGE
Battery Battery
3 ground voltage

1. CAPS connector

3. Activate the electrical system.

264
 Fuel System
Electronic Fuel Injection (EFI)

6. If a high resistance or an open circuit is meas-

ured, repair or replace wiring and connectors
from fuse box terminal to CAPS connector.
7. Reinstall bus bar and fuse box cover.
CAPS Dynamic Test
1. Remove the parts required to access the
CAPS, refer to CAPS REPLACEMENT.
2. Remove CAPS sensor from engine.

N O T E : To safely probe wire terminals through

the back of the connector, use only the recom-
mended probe.

NOTICE
7. If voltage is read to battery ground, check con- Do not use sharp end probes as they can
tinuity of ground circuit as per the following ta- damage the connector seal.
ble. Repair or replace wiring and connectors.

MEASURE REQUIRED TOOLS

CAPS ECM
MENT
Fluke Suregrip Insu- 6
PIN RESISTANCE lated Test Leads
Pin 1 A-D4 Close to 0 Ω P/N TL224
8. If voltage is not read to battery ground, perform Fluke Automotive
a CAPS POWER CIRCUIT CONTINUITY Back Probe
TEST.
P/N TP40
CAPS Power Circuit Continuity Test
1. Remove cover from fuse box. 3. Insert the Fluke Automotive Back Probes, P/N
2. Remove the long bus bar. TP40, at the end of the Fluke Suregrip Insu-
lated Test Leads, P/N TL224.
REQUIRED TOOLS
REQUIRED TOOLS
Fluke 115 Multimeter
Fluke 115 Multimeter
P/N 460735
P/N 460735
3. Using the Fluke 115 Multimeter, P/N 460735,
select Ω. 4. Back probe the connector and read voltage on
4. Read the resistance of the CAPS circuit as per the Fluke 115 Multimeter, P/N 760735, as
the following table. follows.

ALL CAPS
VOLT
CONDI CAPS CONNECTOR
CAPS AGE
FUSE BOX RESISTANCE TION
CONNECTOR
Close to 0
TERMINAL PIN Ω Free 3 2
Vdc
Close to 0 Ω
B5 3 (continuity)

5. If continuity is good, wiring and connectors are

functional.

265
Fuel System
Electronic Fuel Injection (EFI)

2. Disconnect CAPS connector.

CAPS
VOLT
CONDI CAPS CONNECTOR
AGE
TION
Metallic
Close to 0
object or 3 2
Vdc
sensor

1. CAPS connector

3. Unscrew the CAPS retaining screw.

4. Pull CAPS from engine.
CAPS Installation
1. Install the new CAPS and O-ring.
2. Apply Loc-Tite 243, P/N 460790, onto the
threads of the CAPS retaining screw.
3. Tighten the retaining screw to the proper
specification.
1. Metallic object
TIGHTENING TORQUE
5. If voltage is as specified, repair or replace wir- CPAS retaining screw 9 N·m (80 lbf·in)
ing and connectors between sensor and ECM.
6. If wiring is good, check ECM. Refer to Engine
Control Module (ECM), page 182.
7. If battery voltage is not measured as specified,
try a new CAPS.
CAPS Removal
1. Detach CPS connector from the holder.

266
 Fuel System
Electronic Fuel Injection (EFI)

Manifold Air Temperature Sensor (MATS) MATS Resistance Test At ECM

MATS Resistance Test 1. Disconnect the ECM connector A on the ECM.
REQUIRED TOOLS

ECM Adapter Tool

P/N 460762

Fluke 115 Multimeter

P/N 460735

2. Install the appropriate ECM adapter tool.

3. Use the Fluke 115 Multimeter, P/N 460735,
and probe the adapter terminals as follows.

ALL
MEASURE
1. Manifold air temperature sensor (MATS) ECM ADAPTER
1. Disconnect the MATS connector.
MENT 6
See MATS
REQUIRED TOOLS A-J3 A-H3 RESISTANCE
CHART
Fluke 115 Multimeter
MATS RESISTANCE CHART
P/N 460735
TEMPERATURE RESISTANCE (Ω)
2. Set the Fluke 115 Multimeter, P/N 460735, to NOMI
Ω and probe the MAPS sensor terminals. °C °F LOW HIGH
NAL
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800
- 10 14 9500 8000 11000
0 32 5900 4900 6900
10 50 3800 3100 4500
20 68 2500 2200 2800
30 86 1700 1500 1900
40 104 1200 1080 1320
50 122 840 750 930
60 140 630 510 750
70 158 440 370 510
3. The resistance value measured should be as 80 176 325 280 370
specified in the Mats Resistance Chart that fol-
90 194 245 210 280
lows. Otherwise, replace the MATS.
4. If resistance value is as specified, test the 100 212 195 160 210
MAPS circuit. Refer to MATS RESISTANCE
TEST AT ECM.

267
Fuel System
Electronic Fuel Injection (EFI)

MATS RESISTANCE CHART

110 230 145 125 160
120 248 115 100 125

4. If resistance value is not as specified and

MATS tested good, repair or replace wiring
and connectors between the ECM and the
MATS.
MATS Replacement
1. Disconnect the MATS connector.
2. Unscrew the MATS from the engine.
3. Install a new thrust washer onto the MATS.
4. Install new MATS and torque screw to
specification.

TIGHTENING TORQUE
3. If the resistance measured is not as specified,
MATS retaining screw 17 N·m (150 lbf·in) replace the CTS.
4. If the resistance measured is as specified, test
Coolant Temperature Sensor (CTS) the CTS circuit. Refer to CTS RESISTANCE
TEST AT ECM.
CTS Replacement
1. Disconnect CTS connector and remove CTS.
2. Install the new CTS and torque to
specification.

TIGHTENING TORQUE
CTS 18 N·m (159 lbf·in)

3. Reinstall remaining removed parts.

Manifold Absolute Pressure Sensor (MAPS)

1. Coolant temperature sensor (CTS)

An overheat indication will be triggered in the infor-

mation center when the coolant temperature
reaches 110°C (230°F).
CTS Resistance Test
1. Disconnect the connector from the CTS.
REQUIRED TOOLS

Fluke 115 Multimeter

P/N 460735
1. Manifold absolute pressure sensor (MAPS)
2. Use the Fluke 115 Multimeter, P/N 460735,
and test the resistance of the sensor. Refer to This sensor is a dual function device. When the
the CTS Resistance Chart. engine is started and runs at idle speed, the sen-
sor measures atmospheric pressure and stores it

268
 Fuel System
Electronic Fuel Injection (EFI)

in the ECM. Thereafter, it measures manifold ab-

solute pressure at operating RPMs.
Ensure sensor is correctly installed on intake
manifold. Otherwise, the MAPS could generate a
fault code for an unexpected sensor range at idle
when it reads atmospheric pressure. Remove sen-
sor and check for oil or dirt on its end and if prob-
lem persists, check the condition and the position
of the throttle plate and the wiring harness. Per-
form the following tests.
MAPS Voltage Test
1. Disconnect connector from MAPS.

5. If voltage measured is as specified, replace the

MAPS.
6. If voltage measured is not as specified, refer to
MAPS CIRCUIT CONTINUITY TEST.
6
MAPS Circuit Continuity Test
1. Disconnect ECM connector A from the ECM.
REQUIRED TOOLS

ECM Adapter Tool

1. Disconnect
P/N 460762
2. Activate the electrical system.
Fluke 115 Multimeter
REQUIRED TOOLS
P/N 460735
Fluke 115 Multimeter
P/N 460735 2. Install ECM Adapter Tool. P/N 460762.
3. Use the Fluke 115 Multimeter, P/N 460735, to
test for circuit continuity as per following table.
3. On the Fluke 115 Multimeter, select Vdc.
4. Read voltage as per following table. ALL
MAPS CONNECTOR VOLTAGE MAPS ECM
RESISTANCE
CONNECTOR CONNECTOR
Terminal 1 to battery
Approx. 5 V Pin 1 A-B4
ground
Close to 0 Ω
Terminal 2 to battery Pin 2 A-H2 (continuity)
Approx. 0 V
ground Pin 3 A-G4
Terminal 3 to battery 4. If wiring harness is good, check ECM. Refer to
Approx. 0 V
ground Engine Control Module (ECM), page 182.
5. If a high resistance or an open circuit is meas-
ured, repair or replace wiring and connectors
between the ECM and the MAPS.

269
Fuel System
Electronic Fuel Injection (EFI)

MAPS Replacement
1. Disconnect MAPS connector and remove the
MAPS.
2. Install the new MAPS paying attention to index
its tab into the adapter notch.

REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

3. Apply Loc-Tite 243, P/N 460790, onto the

thread of the retaining screw and torque to
specification.

TIGHTENING TORQUE 3. The resistance should be as per the EGTS RE-

SISTANCE CHART that follows. Otherwise, re-
MAPS retaining screw 10 N·m (89 lbf·in) place the EGTS.
4. Reinstall remaining parts removed. EGTS RESISTANCE CHART
Exhaust Gas Temperature Sensor (EGTS) TEMPERATURE RESISTANCE (Ω)
NOMI
°C °F LOW HIGH
NAL
- 30 - 22 12600 11800 13400
- 20 -4 11400 11000 11800
- 10 14 9500 8000 11000
0 32 5900 4900 6900
10 50 3800 3100 4500
20 68 2500 2200 2800
30 86 1700 1500 1900
40 104 1200 1080 1320
1. Muffler 50 122 840 750 930
2. Exhaust gas temperature sensor (EGTS)
60 140 630 510 750
An overheat indication will be triggered in the infor-
mation center when the coolant temperature 70 158 440 370 510
reaches 110°C (230°F).
80 176 325 280 370
EGTS Resistance Test
90 194 245 210 280
1. Disconnect the connector from the EGTS.
100 212 195 160 210
REQUIRED TOOLS
110 230 145 125 160
Fluke 115 Multimeter 120 248 115 100 125
P/N 460735
4. If the EGTS resistance is within specifications,
test EGTS circuit. Refer to EGTS RESIST-
2. Set the Fluke 115 Multimeter, P/N 460735, to ANCE TEST AT ECM.
Ω and measure the resistance of the sensor.

270
 Fuel System
Electronic Fuel Injection (EFI)

EGTS Resistance Test At ECM 5. Torque the sensor to specification.

1. Disconnect ECM connector A from the ECM.
TIGHTENING TORQUE
REQUIRED TOOLS
EGTS 16 N·m (142 lbf·in)
ECM Adapter Tool
6. Install the EGTS connector.
P/N 460762 7. Install all other removed parts.
Heated Oxygen Sensor (HO2S)
Fluke 115 Multimeter HO2S Location
P/N 460735 These boats are equipped with 2 heated oxygen
sensors:
2. Install the ECM Adapter Tool, P/N 460762. – Pre-catalytic converter sensor: Upstream the
3. Use the Fluke 115 Multimeter, P/N 460735, catalytic converter on the exhaust pipe
and check the circuit resistance as per the fol- – Post-catalytic converter sensor: Downstream
lowing table. the catalytic converter on the exhaust pipe

ALL

ECM ADAPTER
MEASURE
MENT
6
See EGTS
A-J4 A-H4 RESISTANCE
CHART

4. If resistance value is not within specifications

and EGTS tested good, repair or replace wiring
and connectors between the ECM and the
EGTS.
1. Catalytic converter
EGTS Replacement 2. Pre-catalytic converter
1. Disconnect the EGTS connector. 3. Post catalytic converter
2. Unscrew EGTS from muffler. Oxygen Sensor General Precautions
REQUIRED CHEMICAL Take the following precautions to avoid sensor
malfunction:
Loc-Tite 518 – Do not use any product on sensor probe
– Do not expose sensor to water, oil, windshield
P/N 460361 cleaner, anti-corrosion oil, grease, terminal
cleaner, etc
3. Apply Loc-Tite 518, P/N 0460361, onto the – Do not drop or use an oxygen sensor that has
middle threads of the new EGTS. been dropped
– Do not use any compound on sensor threads
unless labeled as compatible with oxygen
sensor
– Do not use impact wrench or conventional
socket type wrench to install sensor
– Do not allow sensor or wire to touch exhaust
system or any other hot component
Oxygen Sensor Service Life
The following tips may indicate whether a sensor
1. Apply Loctite 518 in this area has reached the end of its service life and need to
4. Install the EGTS. be replaced:

271
Fuel System
Electronic Fuel Injection (EFI)

– Poor fuel economy RESIST

– Higher exhaust emissions ANCE @
HO2S PIN
– Engine surging and/or hesitation 20°C (68°F)
– Rough idling
– Catalytic converter failure Approximately
– Check engine light is ON C D
7–11 Ω
– An oxygen sensor fault code can be read in B.
U.D.S. 2. If reading is not within specification, replace
HO2S Input Voltage Test the oxygen sensor.
This test validates the heater element circuit. HO2S Circuit Continuity Test
1. Disconnect the oxygen sensor connector from This test validates the heater element circuit and
each sensor. the sensor circuits.
2. Activate the electrical system. 1. Remove connector "B" from the ECM and con-
nect to ECM Adapter Tool, P/N 460762.
REQUIRED TOOLS
REQUIRED TOOLS
Fluke 115 Multimeter
P/N 460735 ECM Adapter Tool
P/N 460762
3. Set the Fluke 115 Multimeter, P/N 460735, to
Vdc and read the input voltage provided to the Fluke 115 Multimeter
sensor heater.
P/N 460735
OXYGEN SENSOR
CONNECTOR (HARNESS MEASURE
MENT 2. Set a Fluke 115 Multimeter, P/N 460735, to Ω
SIDE)
and test for continuity between the oxygen
PIN sensor harness connector and the ECM adapt-
er as per following tables replace the wiring
Battery Battery and connectors.
C ground voltage
PRE-CATALYTIC CONVERTER SENSOR
4. If Input voltage is good, carry out an HO2S RE- ECM RESISTANCE
SISTANCE TEST and an HO2S CIRCUIT OXYGEN @ 20°C
CONNECTOR
CONTINUITY TEST. SENSOR PIN (68°F)
“B”
5. If input voltage is not good, test the wire con-
tinuity between pin 3 of sensor connector to A J1
fuse 5 in fuse box #1.
6. If input voltage wire continuity is at fault, repair B L2 Close to 0 Ω
or replace wiring or connector. D D2
HO2S Resistance Test
1. Set the Fluke 115 Multimeter to Ω and test the POST-CATALYTIC CONVERTER SENSOR
resistance value of the oxygen sensor between ECM RESISTANCE
the sensor pins as follows. OXYGEN @ 20°C
CONNECTOR
SENSOR PIN (68°F)
“B”
REQUIRED TOOLS
A H4
Fluke 115 Multimeter B L3 Close to 0 Ω
P/N 460735 D G3

272
 Fuel System
Electronic Fuel Injection (EFI)

Oxygen Sensor Removal

1. Disconnect oxygen sensor connector.
2. Unscrew O2 sensor from exhaust pipe.

NOTICE
Handle oxygen sensor with clean hands.
Oxygen sensor probe must remain free of oil,
grease, antiseize lubricant and any other
matter that could affect its operation.

Oxygen Sensor Inspection

A visual inspection is usually insufficient to deter-
mine whether the oxygen sensor is functioning VISUAL
correctly. However, the following should be CAUSE REMEDY
ASPECT
checked:
– Signs of erosion Replace
– Overheating sensor.
– Carbon build up Drain fuel
– Obstruction of holes in the probe tank and
A
Shiny
deposits
Lead in
fuel
refill with
the
6
recom
mended
unleaded
fuel.
Too rich a
Excessive fuel
carbon/ mixture or Replace
B thick soot faulty sensor
deposits sensor
heater
Silicone
contamina Replace
tion by sensor.
use of Use only
White adhesives products
C deposits / silicone compati
based ble with
products oxygen
on sensor sensors
or threads

Replace oxygen sensor as required.

NOTICE
The cause of a problem should be rectified
and the sensor changed to avoid further
problems including damage to the catalytic
converter.

273
Fuel System
Electronic Fuel Injection (EFI)

Oxygen Sensor Installation (Same Sensor) Knock Sensor

1. If the same oxygen sensor is installed, apply
Loc-Tite 767, P/N 460791, on the first two
threads.
REQUIRED CHEMICAL

Loc-Tite 767
P/N 460791

1. Knock sensor (KS)

KS Dynamic Test
1. Connect the vessel to the latest version of B.U.
D. S. Refer to Communication Tools and B. U.
1. Apply antiseize lubricant first two threads D.S., page 190.
2. Must be free of any product 2. In B.U.D.S., click the Faults tab and look for a
Knock sensor fault.
NOTICE 3. Start the engine and bring engine RPM above
Do not apply any antiseize lubricant to the 5000 RPM.
sensor prove as it could affect its operation. 4. If the boat is out of water, connect a garden
hose to the hose adapter to cool exhaust sys-
2. Screw sensor in the applicable exhaust pipe. tem. Refer to Exhaust System Flushing, page
51.
TIGHTENING TORQUE
NOTICE
O2 Sensor 43 N·m (32 lbf·in) Never run engine without supplying water to
the exhaust system when the boat is out of
3. Install all other removed parts. water.
Oxygen Sensor Installation (New Sensor) 5. Using the B.U.D.S. software, monitor the knock
If a new oxygen sensor is installed, threads are al- sensor for a fault code.
ready coated with an anti-seize product. Sensor is 6. Stop engine.
ready for installation. 7. If no fault occurs, the knock sensor is good.
1. Install sensor in the applicable exhaust pipe 8. If a fault occurs, ensure sensor and cylinder
and tighten to specification. head contact surfaces are clean and the cor-
rect mounting bolt and washer are used and
TIGHTENING TORQUE are properly torqued.
9. Check the knock sensor resistance. Refer to
O2 Sensor 43 N·m (32 lbf·in) KS RESISTANCE TEST.

2. Install all other removed parts. N O T E : NOTE: It is necessary to remove the in-
take manifold to inspect the contact surfaces.
KS Resistance Test
1. Disconnect the knock sensor connector.

274
 Fuel System
Electronic Fuel Injection (EFI)

REQUIRED TOOLS

ECM Adapter Tool

P/N 460762

6. Install the ECM Adapter Tool, P/N 460762.

7. Check circuit resistance through the knock
sensor as per following table.

ALL
MEASURE
ECM ADAPTER MENT @
20°C (68°F)
1. KS connector
Approximately
A-C3 A-G2
REQUIRED TOOLS 5 MΩ

8. If an open circuit is measured, repair or replace

Fluke 115 Multimeter wiring and connectors between ECM and
knock sensor.
6
P/N 460735
KS Replacement
2. Use the Fluke 115 Multimeter, P/N 460735, to 1. Remove the intake manifold. Refer to INTAKE
measure the resistance between the knock MANIFOLD.
sensor terminals. 2. Disconnect KS sensor connector.

1. Knock Sensor
2. Knock Sensor connector

3. Unscrew and remove knock sensor from

KNOCK SENSOR RESISTANCE @ 20°C engine.
(68°F) 4. Clean contact surfaces.

Approximately 5 MΩ REQUIRED CHEMICAL

3. If resistance is not as specified, replace knock Loc-Tite 243

sensor.
P/N 460790
4. If resistance is as specified, reconnect the
knock sensor connector.
5. Apply Loc-Tite 243, P/N 460790, into threaded
5. Disconnect connector A from the ECM.
hole then install the new knock sensor.

275
Fuel System
Electronic Fuel Injection (EFI)

6. Torque sensor retaining screw to specification.

TIGHTENING TORQUE
Knock sensor retaining 23 N·m (17 lbf·in)
screw

NOTICE
Improper torque might prevent sensor to work
properly and lead engine to severe damage
or internal components.

7. Reconnect knock sensor connector.

276
 Fuel System
Fuel Tank and Fuel Pump

Fuel Tank and Fuel Pump

SERVICE TOOLS
Description Part Number Page

DIGITAL INDUCTION TACHOMETER . . . . . . . . . . . . . . . . . . . . . P/N 460732 . . . . . . . . . . . . . . . . . . . . . . . 245

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . 241, 247–248, 256, 261, 263,
267, 269, 271–272, 275
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . 247–248, 255–256, 261–265,
267–272, 275
FUEL HOSE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460752 . . . . . . . . . . . . . . . . . . . . . . . 281
FUEL HOSE DISCONNECT TOOL . . . . . . . . . . . . . . . . . . . . . . . . P/N 460756 . . . . . . . . . . . . . . . . . . . . . . . 251
FUEL PUMP MODULE SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460820 . . . . . . . . . . . . . . . . . . . . . . . 284
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460722 . . . . . . . . . . . . . . . . . . . . . . . 281

277
Fuel System
Fuel Tank and Fuel Pump

Fuel Tank and Fuel Pump Service

Chart
25 N•m
(18 lbf•ft)

278
 Fuel System
Fuel Tank and Fuel Pump

Fuel System Diagnostic Flow Chart

279
Fuel System
Fuel Tank and Fuel Pump

System Description
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appropri-
ate safety equipment when working on a
pressurized fuel system. Proceed with care
when removing/installing pressure test
equipment or disconnecting fuel line
connections.

WARNING
Always turn the main battery cut-off switch to FUEL PUMP MODULE
OFF prior to work on the fuel system. 1. Fuel pump reservoir
2. Lower inlet filter
3. Upper outlet filter
WARNING 4. Fuel pressure regulator
5. Float type fuel level sensor
Always carry out a fuel system high pressure
leak test after working in the fuel system. Fuel Pump Operation
When the pump is in operation, it draws fuel into
WARNING the canister through a lower inlet filter and a disk
type valve.
Ensure wires and hoses are routed and se-
cured away from any vibrating, rotating, mov- The pressurized fuel is pushed through an upper
ing or hot components or sharp edges. Use outlet filter to the fuel rail.
appropriate shields and fastening devices as
per factory standards. Excess fuel pressure generated by the pump is
routed from the upper filter back to the pump can-
ister reservoir by a pressure regulator mounted on
NOTICE the pump reservoir cover.
Whenever repairing the fuel system, always When the electrical system is activated, the fuel
check for water infiltration in the fuel tank. pump will come on for approximately 2 seconds to
Replace any damaged, leaking or deteriorat- pressurize the fuel rail in preparation for the en-
ing fuel line. gine start.

The fuel pump module is basically comprised of: The ECM supplies the ground signal to turn on the
fuel pump motor.
1. An electric fuel pump mounted inside a canis-
ter type pump reservoir The pressure regulator will ensure appropriate fuel
2. A lower inlet filter pressure is supplied to the injectors.
3. An upper outlet filter When the ECM receives a signal to shut down the
4. A pressure regulator engine it removes the fuel pump ground signal.
5. A float type fuel level sensor.
Fuel Level Indication
An electric float type fuel level sensor is mounted
on the side of the fuel pump reservoir. As the float
moves with changing fuel levels, it varies a resist-
ance that changes the voltage signal coming from
the fuel level gauge. This signal is representative
of the fuel level.
The fuel level gauge interprets the voltage signal
that comes back from the fuel level sensor. It then
displays the proper fuel level and activates a low
fuel warning signal when required.

280
 Fuel System
Fuel Tank and Fuel Pump

The fuel level sensor resistance is at its lowest val-

ue when the fuel tank is full, and at its highest val-
ue when the tank is empty.
Refer to the FUEL LEVEL SENDER for fuel level
sensor testing procedures.

Inspection
Fuel Pump Pressure Test
The pressure test will show the available pressure
at the fuel pump outlet. It validates the pressure
regulator, the fuel pump and leaks in the system.
1. Ensure the battery is fully charged. Battery 1. Hose disconnected from fuel pump
voltage must be over 12 volts. 2. In-line installation of fuel pressure gauge
2. Turn main battery cut-off switch to OFF
position. 8. Turn main battery cut-off switch to ON position.
3. Ensure there is enough gas in fuel tank. 9. Activate electrical system and observe fuel
4. Ensure there is no leak from hoses and fittings. pressure. Do not crank engine.
Repair any leak. 10. Repeat test twice and compare readings to
specifications in following table.
5. Disconnect the pressure outlet hose from the
fuel pump.
6
FUEL PRESSURE
WARNING 386 kPa to 414 kPa (56 PSI to 60 PSI)
Cover the fuel line connection with an ab-
sorbent shop rag. Wipe off any fuel spillage 11. Release pressure using the valve on the pres-
inside the bilge. sure gauge between each test so that the
gauge is “reset” to zero (0).
6. Access the fuel pump. Refer to FUEL TANK 12. Crank or start engine and observe fuel pres-
ACCESS. sure. The fuel pressure should be the same as
above.
REQUIRED TOOLS 13. Stop engine.

Pressure Gauge If pressure is good, fuel pump and pressure regu-

lator are working adequately.
P/N 460722
If pressure is maintained after engine is stopped,
there is no leakage in the system.
Fuel Hose Adapter
A rapid pressure drop after engine is stopped indi-
P/N 460752 cates leakage either from the fuel rail or from the
fuel pump check valve. Check fuel rail for leaks.
7. Install the Pressure Gauge, P/N 460722, and A slow pressure drop after engine is stopped indi-
the Fuel Hose Adapter, P/N 460752, between cates leakage either from the fuel injector or from
the disconnected hose and fuel pump fitting. the fuel pressure regulator. Check fuel injector for
leaks (see below). If it is not leaking then replace
fuel pump module.

Procedures
Fuel Hose and Hose Clamps
Fuel Hose and Clamp Inspection
WARNING
Never use a hose pincher on high pressure
hoses.

281
Fuel System
Fuel Tank and Fuel Pump

Inspect all fuel hoses for wear or cracks. Inspect

all clamps for tightness.
Fuel Hose Replacement
WARNING
Use of improper fuel lines could compromise
fuel system integrity.

When replacing the fuel lines, use only fuel homo-

logated hoses to ensure proper and safe
operation.
For all hoses, position clamp 6.35 mm (1/4 in) from
the end of hose, fully behind the barb and keep
clamping screws rotated 180°.
Perform a fuel system leak test after replacing a If pump does not run, replace the fuel pump
fuel hose or clamp. Refer to Fuel Pump Pressure module.
Test, page 281.
If pump runs, carry out the FUEL PUMP CIRCUIT
Fuel Pump TEST.
Fuel Pump Operation Test Fuel Pump Circuit Test
When activating the electrical system, the fuel Check voltage at fuel pump connector.
pump should run for 2 seconds to build up the
pressure in the system.
If the pump does not work, check fuel pump fuse.
Disconnect fuel pump connector.
Install a temporary connector on the fuel pump
with wires long enough to make the connection
outside the bilge.
Connect fuel pump to a 12 V battery. Respect
polarity.

NOTICE
Running a pump a few minutes with reverse
polarity can damage the pump.

Activate the fuel pump.

282
 Fuel System
Fuel Tank and Fuel Pump

OBSERVATION SIGNIFICATION MODEL ECM CIRCUIT

– Normal operation. All Fuse black pin 5

– It validates the
ground circuit If voltage is good, check wiring and connectors be-
Battery voltage is read through the ECM tween fuse and fuel pump.
for approx. 2 seconds – When voltage
then, it will drop to If voltage is not good, check fuse block.
drops to approx. 11
approx. 11 Vdc Vdc, it validates the Fuel Pump Ground Circuit
ECM switches the 1. Check continuity of fuel pump ground going to-
fuel pump ON and wards ECM.
OFF
MODEL ECM CIRCUIT
– Fuel pump power
supply circuit is All B-M1
Battery voltage is not defective
read – Fuel pump ground 2. Turn main battery cut-off switch to OFF posi-
circuit to ECM is tion. Access the fuel pump.
defective 3. Disconnect electrical connector.
4. Slowly disconnect all hoses from fuel pump.
If battery voltage is not read, check the fuel pump 6
power supply and ground circuits. Refer to FUEL
PUMP POWER SUPPLY and FUEL PUMP
GROUND CIRCUIT.
Fuel Pump Power Supply
Check voltage between fuel pump connector and
battery ground.

1. Quick connect fitting (high pressure fuel hose)

2. Harness connector

5. Trace alignment marks on fuel pump and on

fuel tank. They will be used for indexing at
installation.

TYPICAL FUEL PUMP INPUT VOLTAGE TEST

MODEL ECM CIRCUIT

TEST
VOLTAGE
PROBES
Battery
Pin B (+ Battery
ground (-
probe) voltage
probe)

If battery voltage is not read, back-probe the pin

indicated in the next table with battery ground. 1. Trace alignment marks

283
Fuel System
Fuel Tank and Fuel Pump

REQUIRED TOOL REQUIRED TOOL

Fuel Pump Module Fuel Pump Module

Socket Socket
P/N 460820 P/N 460820

6. Pull fuel pump out from opening. 5. Use the Fuel Pump Module Socket, P/N
460820, to tighten the fuel pump nut.
NOTICE
While pulling out the fuel pump, pay attention TIGHTENING TORQUE
to fuel sensor float arm. Float arm can get
Fuel pump nut 25 N·m (18 lbf·ft)
stuck and bend which can reduce the fuel
sensor capabilities. Wipe off any fuel
spillage. 6. Carry out a Fuel Pump Operation Test. Refer
to Fuel Pump Operation Test, page 282.

WARNING Fuel Filter

The upper filter and fuel pump reservoir on Fuel Filter Removal
the fuel pump module contain fuel which will The fuel filter does not require replacement under
drain out when fuel pump module is not in an normal operating conditions. Replace only if per-
upright position. manently clogged or damaged. The fuel pump as-
sembly has to be removed from the fuel tank to
Fuel Pump Installation have access to the fuel filter.
For installation, reverse the removal procedure.
Pay attention to the following during installation. 1. Remove fuel pump. Refer to Fuel Pump, page
282.
1. : Wipe off gasket and mating surfaces to pre- 2. Turn fuel pump upside down.
vent fuel pump from turning while torquing fuel 3. Using a small flat screwdriver, remove the fuel
pump nut. filter by prying the filter locking tabs.
2. Install a NEW fuel pump module gasket.
3. Carefully insert fuel pump module in fuel tank.

NOTICE
Take care not to bend fuel sender float arm.

4. Index fuel pump with fuel tank using previously

traced alignment marks.

1. Fuel filter locking tab (x2)

2. Filter locking pin (x2)

Fuel Filter Inspection

Check if particles are present in fuel filter. If so, re-
place it.
Fuel Filter Installation
New filter can be pressed back on by hand. En-
1. Trace alignment marks sure it is fully seated for complete filtering of the
fuel.

284
 Fuel System
Fuel Tank and Fuel Pump

Reinstall fuel pump. Refer to Fuel Pump Installa-

tion, page 284.
Fuel Level Sender
Fuel Level Sender Resistance Test
Disconnect the fuel pump/fuel level sender
connector.
Set multimeter to Ohms.
Measure resistance as per table.

MEASURE
FUEL SENDER PIN MENT @
20°C (68°F)
See next table
C D for resistance
value

RESISTANCE (Ω)
FUEL LEVEL
6
Full 2.8 ± 2.2
Empty 89.8 ± 3.6

285
Notes

Notes Notes
Technician’s Notes Related Documents
Bulletins

Instruction Sheets

Other

286
 Electrical System
Power Distribution

Electrical System

Power Distribution

SOL IS
30A

B7

FB

A = AMPERES 7
ENG = ENGINE
ENG C-O SW = ENGINE CUT OFF SWITCH
FB = FUSE BOX
M C-O SW = MAIN CUT OFF SWITCH
SOL = STARTER SOLENOID
IS = IGNITION SWITCH

287
Electrical System
General

General
Electrical System Activation
The electrical system can be activated without
starting the engine. Proceed as follows:
1. Turn main cut-off switch to ON.
2. Turn ignition switch (key) to ON.
3. Install safety lanyard (if applicable) on the en-
gine cut-off switch.

Main Cut-Off Switch

Main Cut-Off Switch Description
The main cut-off switch is used to control main
electrical power application. When set to:
– ON position, the battery provides current to the
1. Test button
electrical system. 2. Reset lever tripped (off position)
– OFF position, the battery is isolated from the
electrical system. Main Circuit Breaker Location
The main circuit breaker is located near the main
On ECT Power Packs, the ECM is kept alive even
cut-off switch.
though main switch is turned off. The power is
controlled via a relay. This had to be done to fulfill
OBD-M fault management requirement and give
sufficient time to ECM to do post drive shutdown
and transfer fault entries from non-volatile memo-
ries into RAM.

1. Main breaker
2. Main cut-off switch

Fuses
1. ON position
Fuses are grouped in the fuse box (one per
engine).
Main Circuit Breaker Refer to the fuse cover decal for fuse
A main circuit breaker (30 A) is recommended to identification.
be installed to protect the electrical circuits.
“O2 Sensors” and “OBD-M” fuses are only re-
The main circuit breaker can be manually tripped. quired for ECT Power Packs.
Fuse Box Location
The fuse box is located in the engine
compartment.

288
 Electrical System
General

Main Grounds
Engine Grounds

1. Fuse box

Charging System
The fuse holder for the charging system of each
engine is located beside the fuse box.
TAS Signal Validation 1. Engine grounds

Carry out steps 1 to 4 of TAS Adjustment, page

241, to validate if the TAS signal reaches the
ECM.
7

1. Charging system fuse holder

Main Relay
Main Relay Location

MAIN RELAY
MODEL
LOCATION
SINGLE Fuse box
Fuse box (1 per
TWIN engine)

289
Electrical System
Ignition System

Ignition System

SERVICE TOOLS
Description Part Number Page

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . 293, 305

FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . 292–293, 298, 305–307

SERVICE PRODUCTS
Description Part Number Page

DIELECTRIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460781 ....................... 310

ISOFLEX GREASE TOPAS NB52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 ....................... 309
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 ....................... 309
LOC-TITE 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460791 ....................... 296

System Description
WARNING
Never check for engine ignition spark from an
open coil and/or spark plug as spark may
cause potential fuel vapors to ignite. Always
use an approved spark tester.

The ignition system is a digital inductive type

system.
Ignition system parameters, such as ignition tim-
ing, spark duration, and firing order, as well as
many other engine related functions are controlled
by the engine management system (EMS) in order
1. Ignition coils
to meet engine operational requirements. The
EMS can detect many abnormalities including a Ignition Timing
short circuit in the primary winding of the ignition Ignition timing is not adjustable.
coils as well as its associated circuits.
The ECM is programmed with data (ignition map-
Three separate ignition coils receive power from pings) that it uses to establish optimum ignition
three separate fuses. timing under all engine operating conditions.
When a ground signal is provided by the ECM to It receives signals from a variety of sensors that it
an ignition coil primary winding, a high voltage is compares with the ignition mappings and uses it
induced in the coil secondary winding that is used to control the ignition spark timing, duration and fir-
to produce a spark at the spark plug electrode. ing order.
The firing of each spark plug is independent of the
others.
Engine RPM Limiter
The ECM will limit the maximum engine speed by
cutting off ignition spark and fuel at a predeter-
mined engine RPM.

290
 Electrical System
Ignition System

ENGINE RPM LIMITER 4. If one cylinder is not firing and there is no fault
code, replace each spark plug with a known
150 7750 RPM good spark plug until the faulty plug is located.
5. If the fault is not found, carry out an Ignition
250 8300 RPM Coil Test Using B. U. D. S. Refer to IGNITION
COIL TEST USING B.U.D.S.
The ECM does also control the throttle plate open-
ing through the iTC system (intelligent Throttle Diagnostic Guidelines
Control) to limit maximum RPM. This is accom- The following is provided to help in diagnosing the
plished using an electronically controlled throttle probable cause of a problem. It is a guideline and
body that uses and ETA (Electric Throttle Actua- should not be assumed to list all possible causes.
tor) and TPS (Throttle Position Sensor).
Knock Sensor ENGINE WILL NOT START (ENGINE
A knock sensor is mounted on the cylinder block TURNS OVER)
behind the intake manifold. It detects specific vi-
brations that would typically be generated by en- 1. Fouled or defective spark plug
gine detonation. – Replace spark plug
If detonation occurs, the knock sensor detects it 2. Defective CPS
and the ECM goes into a specific operating mode – Check operation of CPS and replace if nec-
whereby it temporarily retards the ignition advance essary. Refer to CPS Removal, page 263
until detonation stops. and CPS Installation, page 263.
The ECM is able to identify in which cylinder the 3. Defective trigger wheel
knocking occurs and modifies the ignition advance – Check. Refer to Rotor, Trigger Wheel and 7
on that cylinder only. Ring Gear Inspection, page 77.
Refer to Electronic Fuel Injection (EFI), page 243 4. Defective ignition circuit
for testing and replacement procedures. – Check fuses, ignition coils, wiring and
connectors.
Ignition System Troubleshooting
It is good practice to check for fault codes using B. ENGINE HARD TO START
U.D.S. as a first troubleshooting step. Refer to Di-
agnostic and Fault Codes, page 195. 1. Spark plug faulty, fouled, or worn out
Always refer to the proper Electrical Schematic – Check spark plug condition. Replace if
when troubleshooting an electrical circuit. necessary.
Ignition System Testing
1. Ensure Cyl 1, Cyl 2, and Cyl 3 fuses are in ENGINE MISFIRES, RUNS
good condition (ignition/injection fuses). IRREGULARLY
2. If a fuse is burnt, test for a short circuit or faulty
component on that fuse circuit before replacing 1. Fouled, defective, worn spark plugs
the fuse. – Check spark plug condition. Replace if
required.
WARNING
2. Defective T.O.P.S.
Due to the possibility of flammable vapors ac-
cumulating in the bilge, you should always – Check T.O.P.S.
test for a short circuit which may produce a 3. Damaged trigger wheel/loose CPS
spark and ignite the vapors before replacing – Check.
a burnt fuse. 4. Defective ignition circuit
– Check ignition coils, CYL fuses, wiring and
3. If a primary winding of an ignition coil or a cir-
connectors condition.
cuit is at fault, a fault code will be set. Refer to
Diagnostic and Fault Codes, page 195. 5. Poor engine grounds

291
Electrical System
Ignition System

– Check ground condition. Refer to Power

Distribution, page 287.

ENGINE CONTINUALLY BACKFIRES

1. Fouled, defective spark plugs

– Clean/replace.
2. Damaged trigger wheel/defective or loose CPS
– Check.

ENGINE DETONATION OR PINGING

1. Knock sensor disconnected or faulty

– Check, refer to Knock Sensor, page 274.
1. Activation tab
2. ECM tab
ENGINE LACKS ACCELERATION OR 3. Click on the desired ignition coil
POWER
You should hear the spark occurring. If in doubt,
1. Weak spark use a sealed vapor proof spark tester or an induc-
– Check spark plugs, coils, wiring and tive spark tester as available from tool suppliers,
connections. to prevent a spark from occurring in the bilge.
If there is no ignition at one or more coils, carry out
Procedures an IGNITION COIL INPUT VOLTAGE TEST.
Ignition Coil
If spark is weak, try a new spark plug. If spark is
Ignition Coil Test Using B.U.D.S. still weak, try a new ignition coil.
WARNING The voltage required to produce a spark in the
Never check for engine ignition spark from an combustion chamber is higher when the engine is
open coil and/or spark plug in the engine as a running.
spark may cause fuel vapors which have ac- Ignition Coil Input Voltage Test
cumulated in the bilge to ignite.
Make sure all key switch fuses are good before
testing.
1. Connect to the latest applicable B.U.D.S. Refer
to Communication Tools and B. U. D. S., page 1. Disconnect the applicable ignition coil
190. connector.
2. In B.U.D.S., select Activation tab > ECM tab.
3. Test the ignition coil by selecting the coil on the REQUIRED TOOLS
engine illustration.
Fluke 115 Multimeter
P/N 460735

2. Set the Fluke 115 Multimeter, P/N 460735, to

Vdc.
3. Activate the electrical system without starting
the engine.
4. Measure voltage as per following table. Repeat
for each ignition coil.

292
 Electrical System
Ignition System

TEST PROBES VOLTAGE RESIST

IGNITION ANCE @ 20°
FUSE BOX
PURPLE/ COIL WIRE (68°F)
BLUE wire
(ignition coil PURPLE/
#1) BLUE wire
(ignition coil Terminal F11
PURPLE/ #1)
Battery
GREEN wire Battery
negative (–)
(ignition coil voltage PURPLE/
post
#2) GREEN wire
(ignition coil Terminal F9 Close to 0 Ω
PURPLE/ #2)
ORANGE wire
(ignition coil PURPLE/
#3) ORANGE wire
(ignition coil Terminal F7
#3)

If test succeeded, the ignition coil power circuit is

functional. Carry out an IGNITION COIL CON-
TROL CONTINUITY TEST wiring between the
ignition coil and the ECM.
If test to any ignition coil failed, test the following
items separately and repair or replace as required.
7
Fuses (CYL 1, CYL 2, CYL 3).
Wiring from fuse box to ignition coil.
Refer to appropriate Electrical Schematic for
details.
Ignition Coil Control Circuit Continuity Test
IGNITION COIL INPUT VO LTAGE TEST
1. Disconnect ECM connector “A”.
If test succeeded, refer to IGNITION COIL CON- 2. Disconnect ignition coil connector.
TROL CIRCUIT CONTINUITY TEST.
REQUIRED TOOLS
If test failed, refer to IGNITION COIL POWER
CIRCUIT CONTINUITY TEST. ECM Adapter Tool
Ignition Coil Power Circuit Continuity Test P/N 460762
1. Set the Fluke 115 Multimeter, P/N 460735, to
the Ω position.
Fluke 115 Multimeter
REQUIRED TOOLS P/N 460735

Fluke 115 Multimeter 3. Install the ECM connector on the applicable

P/N 460735 ECM Adapter Tool, P/N 460762, and use the
Fluke 115 Multimeter, P/N 460735, to test the
continuity of circuit as per model.
2. Read resistance of the applicable ignition coil
circuit.

293
Electrical System
Ignition System

RESIST
IGNITION ECM ANCE @ 20°
COIL WIRE ADAPTER (68°F)
BROWN/
BLACK wire
(ignition coil A-M4
#1)
BROWN/
ORANGE wire
(ignition coil A-M2 Close to 0 Ω
#1) SECONDARY WINDING

BROWN/ RESIST
YELLOW wire CIRCUIT TERMINAL ANCE @
(ignition coil A-M1 20°C (68°F)
#1) Secondary 1 and spark
winding plug terminal 9.5 - 13.5 kΩ
If test failed, repair the connector or replace the
engine wiring harness. If any test failed, replace ignition coil.
If test succeeded, carry out an IGNITION COIL Ignition Coil Removal
RESISTANCE TEST.
1. Disconnect ignition coil connector.
Ignition Coil Resistance Test
An ignition coil with a good resistance measure- NOTICE
ment can still be faulty. Current leakage can occur Do not remove the ignition coil before discon-
at high voltage levels, which is not detectable with necting the input connector or the wires may
an ohmmeter. Replacing the ignition coil may be be damaged. Do not pry up ignition coil with a
necessary as a test. screwdriver to avoid damage.
1. Remove ignition coil. Refer to IGNITION COIL
REMOVAL. 2. Remove ignition coil from spark plug.
2. Perform a visual inspection of the ignition coils.
N O T E : Twist ignition coil in both directions as
3. Check for corrosion, bent pins, loose or burnt
you pull it up to ease removal.
contacts, and cracked or torn insulator.
4. Test the resistance in both primary and secon- IGNITION COIL LUBRICATION
dary windings. 1. Pull rubber seal down.

PRIMARY WINDING

RESIST
CIRCUIT TERMINAL ANCE @ 1. Rubber seal pulled down
20°C (68°F) 2. Apply Dow Corning 111, P/N 460796, or equiv-
Primary alent to rubber seal seat as shown.
winding 1 and 2 0.85 - 1.15 Ω

294
 Electrical System
Ignition System

NOTICE
Do not remove the ignition coil before discon-
necting the input connector or the wires may
be damaged. Do not pry up ignition coil with a
screwdriver to avoid damage.

2. Remove ignition coil from spark plug.

N O T E : Twist ignition coil in both directions as

you pull it up to ease removal.
IGNITION COIL INSTALLATION
I M P O R T A N T : Prior to inserting the ignition coil
1. Apply product here on its spark plug, apply sealant as described in
3. Pull rubber seal back on its seat making sure IGNITION COIL LUBRICATION, page 294
the tabs on the ignition coil and the slots in the
seal properly match together. 1. Install coil in cylinder head hole.
4. Leave a ring of grease on top of the seal as 2. Push the ignition coil down to securely install
shown to act as a water barrier. Wipe off the the coil in place over the spark plug.
excess. 3. Ensure the seal seats properly with top surface
of engine valve cover.

1. Correctly shaped excess of product

5. Apply DOW CORNING 111, P/N 460796, or TYPICAL

1. Seal properly seated
equivalent on rubber seal contact area.
Spark Plugs
Spark Plug Removal
1. Disconnect the ignition coil input connector.
2. Remove ignition coil.

WARNING
Never remove an ignition coil from a spark
plug without disconnecting it from the wiring
1. Apply product here harness. Flammable vapors may be present
in the bilge. Should the tether cord be in-
Ignition Coil Removal stalled on the engine cut-off switch, a spark
1. Disconnect ignition coil connector. could be generated at the spark plug end of
the coil possible resulting in an explosion.

3. Using a spark plug socket, release the torque

applied to the spark plug.

295
Electrical System
Ignition System

Spark Plug Analysis

1. Overheated (light gray, white)

2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, gray, melted coating
1. Approved socket
2. Improper socket
The plug face reveals the condition of the engine,
4. Clean the spark plug and cylinder head with operating condition, method of driving and fuel
pressurized air. mixture. For this reason it is advisable to inspect
5. Unscrew spark plug then use the ignition coil the spark plug at prescribed intervals, examining
to take spark plug out of spark plug hole. the plug face (i.e. the part of the plug projecting in-
to the combustion chamber).
Spark Plug Installation
Prior to installation, ensure the contact surfaces of
the cylinder head and spark plugs are free of
contaminants.
1. Using a wire feeler gauge, set electrode gap
as specified in the following chart.

SPARK GAP MM (IN)

TORQUE
PLUG
18 N·m (13 0.75 mm (.03
NGK DCPR8E lbf·ft) in)

REQUIRED CHEMICAL
1. Ignition coil
2. Spark plug
Loc-Tite 767
Troubleshooting A Fouled Spark Plug P/N 460791
Fouling of the spark plug is indicated by irregular
running or misfiring of the engine, decreased en- 2. Apply Loc-Tite 767, P/N 460791, over the
gine speed due to misfiring, reduced performance, spark plug threads to prevent possible seizure.
and increased fuel consumption. 3. Hand screw spark plug into cylinder head.
4. Tighten the spark plug clockwise with an ap-
Other possible causes are: use of an incorrect or proved spark plug socket and a torque wrench.
bad fuel, defective ignition system, incorrect spark 5. Install ignition coil.
plug gap, loss of compression, or lubricating oil 6. Complete the installation in the reverse order
entering the combustion chamber. of the removal.
The plug face of a fouled spark plug has either a
wet or dry black carbon deposit. Such coatings
form a conductive connection between the center
electrode and the ground electrode.

296
 Electrical System
Charging System

Charging System

SERVICE TOOLS
Description Part Number Page

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . 293, 305

FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . 292–293, 298, 305–307

General At low engine RPM operation and high current

System Description load conditions, it supplements the magneto out-
put and helps to maintain a steady system
The purpose of the charging system is to maintain voltage.
the battery at a full state of charge and to provide
the electrical system with the required electrical Inspection
power for normal vehicle operation.
Charging System Output
Magneto Ensure the battery is in good condition prior to per-
The magneto is the primary source of electrical forming any tests on the charging system. Refer to
energy. It transforms a magnetic field into an elec- the battery manufacturer's instructions.
tric current (AC).
Check for fault codes using the B.U.D.S. as a first
The magneto has a 3 phase, delta wound, 18 pole troubleshooting step. Refer to Diagnostic and
stator that is rated at 420 watts for AF and older
models and 650 watts for AG and newer models.
Fault Codes, page 195. 7
Output Voltage Test Using B.U.D.S.
1. Connect to the latest applicable version of B.U.
D. S. Refer to Communication Tools and B. U.
D.S., page 190.
2. Select Monitoring and ECM tabs.
3. Start engine.

NOTICE
If boat is out of water, connect a garden hose
to cool exhaust system.

4. Increase engine RPM as specified in the fol-

lowing table and read voltage in B.U.D.S.

OUTPUT VOLTAGE TEST USING B.U.D.S.

Voltage Regulator Rectifier TEST ENGINE VOLTAGE (DC)
The rectifier receives AC current from the magne- SPEED
to and transforms it into direct current (DC). 5500 RPM 14.5 ± 5 Vdc
The voltage regulator, included in the same unit,
limits voltage to a maximum level to prevent any
damage to electrical components.
Battery
The battery supplies DC power to the electric
starter for cranking the engine. During engine
starting, it also supplies DC power to every electri-
cal and electronic system in the vehicle as well as
all accessories.

297
Electrical System
Charging System

NOTICE
If boat is out of water, connect a garden hose
to cool exhaust system.

4. Increase engine RPM as specified in the fol-

lowing table and read voltage with the
multimeter.
OUTPUT VOLTAGE TEST USING A
MULTIMETER
1. Monitoring tab TEST ENGINE VOLTAGE (DC)
2. ECM tab SPEED
3. Battery voltage
5500 RPM 14.5 ± .5 Vdc
If voltage is above specification, replace voltage
regulator/rectifier. If voltage is above specification, replace voltage
If voltage is below specification, check stator out- regulator/rectifier.
put and wiring harness prior to concluding that If voltage is below specification, check stator out-
voltage regulator/rectifier is defective. Refer to put and wiring harness prior to concluding that
PTO Housing and Magneto, page 65. voltage regulator/rectifier is defective.
Output Voltage Test Using A Multimeter Output Current Test With An Inductive
1. Set multimeter to Vdc. Ammeter
REQUIRED TOOLS 1. Use an inductive ammeter such as the Extech
Inductive Ammeter or equivalent.
Fluke 115 Multimeter
P/N 460735

2. Connect multimeter to battery posts.

2. Turn on the ammeter and select 40 Adc.

3. Zero the ammeter.
4. Clamp the ammeter around the battery positive
(+) cable (RED).
5. Start the engine.

NOTICE
If boat is out of water, connect a garden hose
to cool exhaust system.

6. Increase engine RPM as specified in the fol-

lowing table and read the current with the
ammeter.
TYPICAL - CHARGING SYSTEM VOLTAG E TEST AT BAT-
TERY POSTS TEST ENGINE
CURRENT
SPEED
3. Start engine.
5500 RPM Approx. 10 A

298
 Electrical System
Charging System

If the current reading is far below specification, – Check for damaged wiring.
check the stator, wiring harness and voltage regu- – Check for damaged or loose connections.
lator/rectifier. 4. Defective voltage regulator/rectifier.
Electrical System Troubleshooting – Replace.
Troubleshooting Guidelines
DISCHARGED OR WEAK BATTERY REPETITIVE BLOWN CHARGING
SYSTEM FUSE
1. Battery posts and/or cable terminal oxidized.
1. Defective voltage regulator/rectifier.
– Clean battery terminals, posts, and coat
with dielectric grease. – Refer to VOLTAGE REGULATOR/RECTI-
FIER TEST FOR BLOWN CHARGING
2. Loose or bad connections. SYSTEM FUSE.
– Check for wiring and connector tightness, 2. Damaged wiring harness.
frayed or broken wires. Repair or replace
cables or connectors. – Check.
3. Worn or faulty battery (sulfated, fretting,
shorted plates or cell, damaged casing, loose FREQUENT LOW ELECTROLYTE LEVEL
post). REQUIRING ADDITION OF DISTILLED
– Carry out a BATTERY VOLTAGE TEST WATER
(LOAD APPLIED).
– Replace battery. 1. High charging system voltage.
4. Burnt fuse(s). – Refer to Charging System Output, page
– Check charging system fuse(s). 297. 7
5. Faulty regulator/rectifier or stator. 2. Old battery with reduced current storage
capacity.
– Check charging system output.
– If charging system output is not within spec- – Carry out a battery voltage test (load ap-
ification, check stator. plied). Refer to battery manufacturers'
– If stator is good, replace voltage regulator/ instructions.
rectifier. – Replace battery.
6. Parasitic or "Key Off" current loads. 3. Cracked, leaking or improperly sealed battery.
– Isolate, reduce or eliminate such loads. – If battery is cracked or leaking electrolyte,
– Recharge battery as recommended if ve- replace battery and clean surrounding area.
hicle is not used for extended periods of Refer to BATTERY.
time. Procedures
– “Key Off” or parasitic loads may be loads
due to installed accessories. Parasitic loads Voltage Regulator Rectifier Test for Blown
may also be due to water infiltration in con- Charging System Fuse
nectors, or partial short circuits that slowly 1. Disconnect the voltage regulator/rectifier 2-
drain a battery without causing a fuse to wire connector.
burn. 2. Install a new fuse.
3. If the fuse still burns, check for a shorted wire
or connector pin.
LOW OR NO CHARGING SYSTEM 4. If fuse does not burn, replace regulator/
VOLTAGE rectifier.
1. Blown charging system fuse. Voltage Regulator Rectifier Continuity Test
– Check charging system fuse. Due to internal circuitry, there is no static test
2. Defective stator. available to check continuity.
– Test stator. Refer to PTO Housing and Voltage Regulator Rectifier Removal
Magneto, page 65. 1. Turn the main battery cut-off switch to the OFF
3. Defective charging system wiring or position.
connections.

299
Electrical System
Charging System

1. OFF position

2. Disconnect the two connectors from the volt-

age regulator/rectifier.
3. Remove the voltage regulator/rectifier.
Voltage Regulator Rectifier Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Install the voltage regulator rectifier.
2. Connect the two connectors into the appropri-
ate connection points.
3. Set the main battery cut-off switch to the ON
position.
4. Start engine and ensure proper charging sys-
tem operation.
Battery
For battery inspection, charging, testing and stor-
age refer to battery manufacturer's
recommendations.
NOTICE
Never use an automotive type battery. Its me-
chanical construction is not designed to with-
stand the shock conditions of boating
operations. Use only the recommended type
of battery.

300
 Electrical System
Starting System

Starting System

SERVICE TOOLS
Description Part Number Page

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460762 . . . . . . . . . . . . . . . . . . . 293, 305

FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460735 . . . . . . 292–293, 298, 305–307

SERVICE PRODUCTS
Description Part Number Page

DIELECTRIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460781 ....................... 310

ISOFLEX GREASE TOPAS NB52 . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460783 ....................... 309
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 ....................... 309
LOC-TITE 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460791 ....................... 296

301
Electrical System
Starting System

Starter Service Diagram

302
 Electrical System
Starting System

Starting System Schematics

Dielectric
grease

Dielectric
grease

See WIRING DIAGRAM

General 3. The safety lanyard (if applicable) securely in-

Engine Cranking Conditions stalled on the engine cut-off switch.
4. START/STOP button pressed and held.
The following conditions must be met to allow en-
gine cranking:
1. Main battery cut-off switch turned to ON
position.
2. Neutral position selected.

303
Electrical System
Starting System

Diagnostic Tips – Check/charge/replace. Refer to battery

Starting System Diagnostic Guidelines manufacturer's recommendations.
The following is provided to help in diagnosing the 4. Low voltage from starter solenoid
probable cause of a problem. It is a guideline and – Carry out a SOLENOID DYNAMIC TEST.
should not be assumed to list all possible causes. 5. Worn starter
– Check
ENGINE DOES NOT CRANK 6. Obstructed jet pump
1. Burnt fuse – Inspect jet pump. Remove debris, repair as
required.
– Inspect circuit. Replace fuse.
2. Discharged battery
ENGINE CRANK OVER, BUT DOES NOT
– Check/recharge. Refer to battery manufac-
FIRE (ONLY SOME EXAMPLES)
turer's recommendations.
3. Defective START/STOP switch or ignition 1. Wrong security coding in cluster. Fault code
switch display will show U0300.
– Test switch, wiring and connections. Re- – Check, if wrong put in the correct coding.
place as required.
2. No fuel in tank, damaged injectors, fuel pump
4. Neutral switch without function.
– Ensure shifter lever is at the neutral – Check/fill up/replace.
position.
3. No spark, damaged spark plugs, or ignition
– Check neutral switch and circuit continuity.
coils.
5. Battery connections
– Check/repair/replace.
– Check/clean/tighten
6. Poor/bad or corroded ground contacts (engine,
battery ground cable, starter etc.) STARTER TURNS, BUT STARTER DRIVE
DOES NOT MESH WITH RING GEAR
– Check/clean/repair.
7. Starter solenoid 1. Worn starter drive gear
– Test solenoid. Replace as required. – Replace starter drive.
8. Starter malfunction 2. Defective drive
– Test starter. Replace as required. – Replace starter drive.
9. Obstructed starter drive gear assembly 3. Poor movement of drive on splines
– Check/repair. – Clean and correct.
10. No ground provided by ECM for starter 4. Worn starter drive bushing
solenoid – Replace clutch.
– Test ECM grounds. 5. Worn or damaged ring gear
11. Engine cannot be rotated (possibly seized) – Replace ring gear.
– Inspect engine. Repair as required.
STARTER KEEPS RUNNING
ENGINE CRANKS SLOWLY
1. Shorted solenoid winding
1. Loose, corroded or dirty battery cable – Test. Replace solenoid.
connections
2. Melted solenoid contacts
– Check/clean/repair.
– Inspect. Replace solenoid.
2. Loose, corroded or dirty starter cable
connections 3. Sticking or defective starter drive
– Check/clean/repair. – Lubricate or replace.
3. Discharged/weak battery

304
 Electrical System
Starting System

Procedures Neutral Switch Continuity Test

Engine Start Stop Switch 1. Put main battery cut-off switch to OFF position.
2. Disconnect the starter relay connector.
WARNING
When carrying out any kind of maintenance REQUIRED TOOLS
on the starting system, always disconnect the
battery ground cable. This will eliminate the Fluke 115 Multimeter
possibility of shoring out a power cable, and
generating a spark which could result in a fire P/N 460735
or an explosion. Do not place any tool on the
battery. 3. Select Ω (Ohm) position on the Fluke 115 Mul-
timeter, P/N 460735.
Continuity Test of Start/Stop Switch 4. Test for neutral switch continuity as per follow-
1. Disconnect the ECM-B connector. ing table.

REQUIRED TOOLS SHIFTER

CON
READ
ECM Adapter Tool TROL PROBE
ING
POSI
P/N 460762 TION
SINGLE:
Fluke 115 Multimeter Open
Forward Fuse
circuit
P/N 460735 or reverse block 1 Starter
pin B3 relay
(infinite)
7
2. Install the ECM Adapter Tool, P/N 460762, on- TWIN: connector
to the ECM connector. Fuse pin A
Close to 0
3. Set the Fluke 115 Multimeter, P/N 460735, to Neutral block 2 Ω
Vdc. pin F1
4. Measure voltage as follows.
If test fails, carry out a continuity test of the switch
SWITCH and switch circuit. Refer to the applicable Electri-
READ
POSI PROBE cal Schematic for circuit details.
ING
TION
Neutral Switch Voltage Test
Released 0 Vdc
ECM-B Engine 1. Disconnect starter solenoid connector.
Pressed pin D1 ground Battery 2. Set main battery cut-off switch to ON.
and held voltage 3. Install safety lanyard (if applicable).
4. Turn ignition key to ON.
If the readings obtained are not as specified, carry
out the following: REQUIRED TOOLS
– Test fuse.
– Continuity tests of the switch and wiring Fluke 115 Multimeter
separately. P/N 460735
Refer to applicable Electrical Schematic for circuit
details. 5. Set the Fluke 115 Multimeter, P/N 460735, to
Vdc.
If the readings obtained are as specified, start
switch and wiring from fuse box to ECM are good.
Neutral Switch
When the shifter lever is not set to NEUTRAL, the
neutral switch prevents engine cranking when the
start button is pressed. Refer to the appropriate
Electrical Schematic for details.

305
Electrical System
Starting System

SHIFTER SOLENOID INPUT VOLTAGE TEST

READ
POSI PROBE (SOLENOID COIL)
ING
TION
SOLENOID VOLTAGE
Forward BATTERY
CONNECTOR READING
or Solenoid 0 Vdc
Reverse Battery Negative Battery
connector Pin A
ground battery post voltage
pin A Battery
Neutral voltage (1) If test succeeded, test/repair the solenoid control
(1) If the reading is more than 0.2 Vdc below battery voltage, the circuit.
switch could be faulty or have bad contacts.
If test failed, test/repair solenoid input circuit. Re-
fer to the applicable Electrical Schematic for circuit
details.
Solenoid Resistance Test
1. Set the Fluke 115 Multimeter, P/N 460735, to
Ω.
REQUIRED TOOLS

Fluke 115 Multimeter

P/N 460735

2. Measure solenoid coil resistance as follows.

If the tests succeeded, switch circuit is good.
PINS RESISTANCE
If any test failed, check neutral switch circuit from
EFB to starter solenoid. Refer to the applicable A and B Approx. 5 Ω
Electrical Schematic for circuit details.
Starter Solenoid
The starter solenoid is located in the engine co-
partment near the battery or EFB (as applicable to
model).
Starter Solenoid Input Voltage Test
1. Disconnect starter solenoid connector.
2. Ensure main battery cut-off switch is set to ON.
3. Set ignition switch to ON.
4. Install safety lanyard (if applicable) on the en-
gine cut-off switch.
5. Ensure shifter lever is set to NEUTRAL
position. 3. Test solenoid main contact as follows.

REQUIRED TOOLS RESIST

SOLENOID POST
ANCE
Fluke 115 Multimeter Solenoid Solenoid OL (open
P/N 460735 battery post starter post circuit)

6. Use the Fluke 115 Multimeter, P/N 460735, to

measure voltage as per following table.

306
 Electrical System
Starting System

1. Starter motor
2. Starter solenoid

6. If test failed, check battery and cable from bat-

tery to solenoid.
7. If test succeeded, continue with next step.

SOLENOID DYNAMIC TEST

If readings are out of specification, replace TEST PROBES VOLTAGE
solenoid.
Solenoid Battery Battery
If readings are as specified, carry out a SOLE- starter post ground voltage
NOID DYNAMIC TEST.
Solenoid Dynamic Test
1. Remove the cylinder 1, 2 and 3 fuses to deacti-
7
vate ignition and injection and prevent engine
starting.

REQUIRED TOOLS

Fluke 115 Multimeter

P/N 460735
1. Starter motor
2. Starter solenoid
2. Set the Fluke 115 Multimeter to Vdc.
8. If test failed, replace solenoid.
3. Activate the boat electrical system.
9. If test succeeded, continue with next step.
4. Depress the START/STOP button.
5. While the engine is cranking, measure for volt- SOLENOID DYNAMIC TEST
age as per the following tables.
TEST PROBES VOLTAGE
SOLENOID DYNAMIC TEST
Solenoid Solenoid
TEST PROBES VOLTAGE battery post starter post 0.2 Vdc max

Solenoid Battery Battery

starter post ground voltage

1. Starter motor
2. Starter solenoid

307
Electrical System
Starting System

10. If test failed, replace solenoid. to starter and perform a Solenoid Dynamic
11. If all solenoid dynamic tests are as specified, Test. Refer to Solenoid Dynamic Test, page
carry out a STARTER QUICK TEST. 307.
12. Reinstall removed parts. 5. If the above items all test good, replace the
starter.
Starter
Starter Removal
Starter Quick Test
1. Disconnect battery.
This procedure tests the electric starter, the starter
power cable and the battery to engine ground WARNING
cable.
Always disconnect the BLACK (–) battery ca-
WARNING ble first and reconnect last.
Fuel, oil, or electrolyte vapors are flammable
and may become explosive if certain condi- 2. Disconnect starter power cable.
tions are met. These vapors may collect near 3. Remove starter retaining screws.
the bottom of the hull when present. All types
of ignition including electrical sparks are to
be avoided when maintaining or testing boat.

WARNING
Always wear safety glasses when working
with or around batteries. Be sure to leave the
booster battery out of the boat.

1. Connect the red booster cable to the starter

post on the starter solenoid and to the positive
terminal of the external battery.
2. Connect the black booster cable to the nega-
tive battery terminal.
3. Momentarily apply the second clip to the nega- 1. Exhaust manifold
2. Starter
tive terminal of the external battery. 3. Starter retaining screws
4. Starter power cable retaining nut

Starter Gear Removal

1. Remove starter.
2. Remove and discard gear retaining circlip.
3. Pull out starter gear.

1. Step 1: Connect cable to solenoid starter post

2. Step 2: Connect cable to vehicle battery positive post
3. Step 3: Connect cable to external battery negative post
4. Step 4: Make a momentary contact

4. If engine does not crank (or cranks slowly),

check the booster cable connections, vehicle
battery ground cable connections to engine,
starter power cable/connections from solenoid

308
 Electrical System
Starting System

1. Retaining circlip
2. Starter gear
1. Apply Isoflex Grease here

Starter Gear Installation 7

REQUIRED CHEMICAL
For installation, reverse the removal procedure.
Pay attention to the following during installation.
Loc-Tite 243
1. Install the starter gear into the starter.
2. Secure using a NEW circlip. P/N 460790

Starter Installation 3. Apply Loc-Tite 243, P/N 460790, onto the

For installation, reverse the removal procedure. threads of the starter retaining screws.
Pay attention to the following during installation. 4. Install the starter and secure using the retain-
ing screws.
1. Ensure starter and engine mating surfaces are
free of debris. Serious problems may arise if I M P O R T A N T : If starter does not mesh properly
starter is not properly aligned. with the intermediate gear: Pull starter out, slightly
rotate the starter gear, and then reinstall the start-
REQUIRED CHEMICAL er. Temporarily removing both O-rings makes it
easier to align both gears. Once gears are aligned,
Isoflex Grease Topas NB52 remove starter to install O-rings being careful not
to rotate starter gear out of position, then reinstall
P/N 460783 the starter.
2. Apply Isoflex Grease Topas NB52, P/N 5. Torque the retaining screws to the proper
460783, onto the starter O-rings. specification.

TIGHTENING TORQUE
Starter retaining 10 N·m (89 lbf·in)
screws

6. Connect the RED positive cable to the starter.

7. Install the starter cable nut to secure the cable
and torque the nut to the proper specification.

309
Electrical System
Starting System

TIGHTENING TORQUE
Starter cable nut 7 N·m (62 lbf·in)

REQUIRED CHEMICAL

Dielectric Grease
P/N 460781

8. Apply Dielectric Grease, P/N 460781, onto the

terminal and nut.
9. Install rubber protector over starter power ca-
ble retaining nut.
10. Reinstall all other removed parts.

310
 Propulsion
Reverse System

Propulsion

Reverse System

SERVICE PRODUCTS
Description Part Number Page

ANTICORROSION SPRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460776 . . . . . . . . . . . . . . . . . . . . . . . 335

BRP HEAVY DUTY CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460780 . . . . . . . . . . . . . . . . . . . . . . . 341
CLEAR SILICONE SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460793 . . . . . . . . . . . . . . . . . . . . . . . 341
JET PUMP BEARING GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460785 . . . . . . . . . . . . . . . 323, 330, 332
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . 316, 320–321
LOC-TITE 271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460788 . . . . . . . . . . . . . . . . . . . . . . . 315
LOC-TITE 577 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460789 . . . . . . . . . . . . . . . . . . . . . . . 326
LOC-TITE 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460791 . . . . . . . . . . . . . . . . . . . . . . . 325
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 341
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798 . . . . . . . . . . . . . . . . . . . . . . . 337
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460794 . . . . . . . . . . . . . . . . . . . 321, 338
TRIPLE-GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460794 . . . . . . . . . . . . . . . . . . . . . . . 326
XPS BRAKES AND PARTS CLEANER . . . . . . . . . . . . . . . . . . . . . P/N 460779 . . . . . . . . . . . . . . . . . . . . . . . 325
XPS LUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460786 . . . . . . . . . . . . . . . . . . . 325, 336

311
Propulsion
Reverse System

STARBOARD
SIDE
Triple-Guard
Grease

Triple-Guard
Grease

Triple-Guard
Grease

Triple-Guard
Grease

Triple-Guard PORT SIDE

Grease

312
 Propulsion
Reverse System

Procedures
Reverse Cable
Reverse Cable Replacement And Adjustment
Refer to THROTTLE/SHIFTER CONTROL.
Reverse Gate
Starboard Side Reverse Gate Removal
1. To remove reverse gate, put the shift lever into
the reverse position.
2. Remove the reverse cable from the reverse
gate lever and discard nut.
1. Reverse gate screw
2. Flat washer
3. Reverse gate

Port Side Reverse Gate Removal

1. Remove the screws securing the reverse rod
to the reverse gate.

1. Reverse cable
2. Reverse gate lever

3. Remove the screws securing the reverse link 8

rod to the reverse gate.

2. Remove screws, flat washers, plastic washers,

sleeves, and bushings holding reverse gate to
reverse gate support.

4. Remove the lever pin on the reverse gate

lever.
5. Remove the elastic nut on the reverse gate
lever.
6. Remove the flat washer on the reverse gate
lever. 1. Reverse gate screw
7. Remove screws, flat washers, plastic washers, 2. Flat washer
sleeves, and bushings holding reverse gate to 3. Reverse gate
reverse gate support.
Reverse Gate Inspection
Visually inspect gate for wear or cracks. Replace if
necessary.

313
Propulsion
Reverse System

Reverse Gate Installation

The installation is the reverse of the removal
procedure.

REVERSE GATE SCREWS

Loc–Tite 243, P/N
PRODUCT
460790
TORQUE 9 N·m (80 lbf·in)

REVERSE LINK ROD SCREWS 1. Shoulder nut

2. Reverse gate lever
Loc–Tite 243, P/N 3. Reverse cable
PRODUCT
460790 4. Reverse gate

TORQUE 1.7 N·m (15 lbf·in) 3. Remove bushings inside lever holes.

REVERSE CABLE RETAINING NUT (NEW)

TORQUE 2.5 N·m (22 lbf·in)

Reverse Gate Lever

Reverse Gate Lever Removal
1. Remove reverse cable from the reverse gate
lever. Discard nut.

1. Shoulder nut
2. Bushings
3. Reverse gate lever
4. Shoulder bolt

Reverse Gate Lever Installation

For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Reverse cable 1. Install bushings in lever holes.
2. Reverse gate lever

2. Unscrew the shoulder nut then remove the

shoulder bolt.

N O T E : It may be necessary to heat shoulder nut

to break the thread locker.

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 Propulsion
Reverse System

1. Reverse cable
1. Reverse gate lever 2. Reverse gate lever
2. Reverse gate bump
3. Hook lever 2. Remove cotter pin retaining the reverse cable
4. Reverse gate
5. Shoulder nut bushing. Discard cotter pin.
3. Remove the reverse cable bushing then pull
the brass bushing out of the reverse gate
REQUIRED CHEMICAL support.
Loc-Tite 271
P/N 460788

2. Apply Loc-Tite 271, P/N 460788, to the threads

of the shoulder bolt.
3. Install the shoulder bolt and nut and torque to
the proper specification.
8
TORQUE
Shoulder nut 18 N·m (159 lbf·in)
1. Cotter pin
Reverse cable 2. Reverse cable bushing
2.5 N·m (22 lbf·in) 3. Brass bushing
retaining nut (NEW) 4. Reverse cable

4. Install the reverse cable onto the pin. 4. Remove screws securing reverse link rod to re-
5. Install the NEW reverse cable retaining nut verse gate.
and torque to specification.
Reverse Gate Support
Starboard Side Reverse Gate Support
Removal
N O T E : The reverse gate support can be re-
moved with the reverse gate in place.
1. Remove reverse cable from the reverse gate
lever. Discard nut.

5. Remove the screw that attaches the steering

link rod to nozzle.

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Propulsion
Reverse System

6. Detach steering cable from nozzle. 2. Remove the screw that attaches the steering
link rod to the nozzle.
3. Remove socket screws holding the support
and the venturi to the pump housing.
4. Pull out reverse gate support with reverse
gate.
Reverse Gate Support Inspection
Visually inspect support for wear or cracks. Re-
place if necessary.
Reverse Gate Support Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Steering cable
2. Nozzle
1. Torque screws holding reverse gate support
and venturi to pump housing to specification.
7. Remove socket screws holding the support
and the venturi to the pump housing. TORQUE
Reverse gate retaining 21 N·m (15 lbf·ft)
screws

REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

2. Apply Loc — Tite 243, P/N 460790, onto the

threads of the steering link rod screw then tor-
que screw to specification.

8. Pull out reverse gate support with reverse TORQUE

gate. Steering link rod 13 N·m (115 lbf·in)
Port Side Reverse Gate Support Removal screws
1. Remove screws securing reverse link rod to re-
verse gate. 3. Reinstall reverse cable.
TORQUE
Reverse cable
2.5 N·m (22 lbf·in)
retaining nut (NEW)

316
 Propulsion
Jet Pump

Jet Pump

SERVICE TOOLS
Description Part Number Page

150 ENGINES IMPELLER REMOVER INSTALLER . . . . . . . . . . . P/N 460728 . . . . . . . . . . 324, 326–327, 332
250 ENGINES IMPELLER REMOVER INSTALLER . . . . . . . . . . . P/N 460744 . . . . . . . . . . 324, 326–327, 332
DRIVE SHAFT HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460746 . . . . . . . . . . . . . . . . . . . 335, 340
FLOATING RING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460840 . . . . . . . . . . . . . . . . . . . . . . . 335
IMPELLER SHAFT BEARING TOOL . . . . . . . . . . . . . . . . . . . . . . . P/N 460763 . . . . . . . . . . . . . . . . . . . 329–330
IMPELLER SHAFT PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460743 . . . . . . . . . . . . . . . . . . . 328–329
PTO SUPPORT TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460734 . . . . . . . . . . . . . . . . . . . 335, 339
SEAL BEARING PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460727 . . . . . . . . . . . . . . . . . . . . . . . 330

SERVICE PRODUCTS
Description Part Number Page

ANTICORROSION SPRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460776 . . . . . . . . . . . . . . . . . . . . . . . 335

BRP HEAVY DUTY CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460780 . . . . . . . . . . . . . . . . . . . . . . . 341
CLEAR SILICONE SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460793 . . . . . . . . . . . . . . . . . . . . . . . 341
JET PUMP BEARING GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460785 . . . . . . . . . . . . . . . 323, 330, 332
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . 316, 320–321
LOC-TITE 271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460788 . . . . . . . . . . . . . . . . . . . . . . . 315
LOC-TITE 577 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460789 . . . . . . . . . . . . . . . . . . . . . . . 326
LOC-TITE 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460791 . . . . . . . . . . . . . . . . . . . . . . . 325
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . . . . . 341 8
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460798 . . . . . . . . . . . . . . . . . . . . . . . 337
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460794 . . . . . . . . . . . . . . . . . . . 321, 338
TRIPLE-GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460794 . . . . . . . . . . . . . . . . . . . . . . . 326
XPS BRAKES AND PARTS CLEANER . . . . . . . . . . . . . . . . . . . . . P/N 460779 . . . . . . . . . . . . . . . . . . . . . . . 325
XPS LUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460786 . . . . . . . . . . . . . . . . . . . 325, 336

317
Propulsion
Jet Pump

Jet Pump Service Chart

318
 Propulsion
Jet Pump

General
Jet Pump Main Components

MAXIMUM WEAR
MODEL
CLEARANCE
All models 0.35 mm (.014 in)
1. Nozzle Impeller Shaft Radial Play
2. Venturi
3. Jet pump housing Radial play is critical for jet pump life span. To
4. Wear ring check radial play:
5. Impeller
6. Stator
1. Remove the jet pump.
Inspection 2. Make sure impeller shaft turns freely and
smoothly.
Impeller Condition
3. Retain housing in a soft jaw vise making sure
Condition of impeller, impeller boot and wear ring not to damage housing lug.
can be quickly checked from underneath hull 4. Set a dial gauge and position the tip onto the
through the inlet grate. metal end close to the end of the impeller hub.
Check for contact between impeller boot and drive 5. Move shaft end up and down. The difference
between highest and lowest dial gauge reading
shaft guard.
is radial play. 8
Replace impeller boot and inspect drive shaft
guard for wear if contact is found.

1. Impeller
2. Impeller boot 1. Dial gauge
3. Wear ring 2. Measure close to impeller hub end
Impeller Wear Ring Clearance
This clearance is critical for jet pump performance. RADIAL PLAY
To check clearance, remove jet pump. 0 mm (0 in.)
Using a feeler gauge, measure clearance between
Excessive play can come either from worn bearing
impeller blade tip and wear ring. Measure each
or damaged jet pump housing bearing surface.
blade at its center.

319
Propulsion
Jet Pump

Procedures 4. Detach steering cable from nozzle.

Venturi
NOTE: Whenever removing a part, visually
check for damage such as: corrosion, cracks, split,
break, porosity, cavitation, deformation, distortion,
heating discoloration, wear pattern, defective plat-
ing, missing or broken balls in ball bearing, water
damage diagnosed by black-colored spots on met-
al parts, etc. Replace any damaged parts. As a
quick check, manually feel clearance and end
play, where applicable, to detect excessive wear.
Venturi Removal
1. Steering cable
N O T E : On twin engines models, the steering 2. Nozzle
and reverse cables are located on the starboard
side. 5. For twin engine models, Remove the reverse
link rod. Refer to REVERSE SYSTEM.
1. Remove reverse cable from the reverse gate 6. Remove the steering link rod. Refer to STEER-
lever. Discard nut. ING SYSTEM.
7. Remove socket screws holding the support
and the venturi to the pump housing.

1. Reverse cable
2. Reverse gate lever

2. Remove cotter pin retaining the reverse cable

bushing. Discard cotter pin. 8. Pull out venturi, reverse gate and nozzle.
3. Remove the reverse cable bushing then pull Venturi Inspection
the brass bushing out of the reverse gate Visually inspect venturi for wear or cracks. Re-
support. place if necessary.
Venturi Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. Install the venturi.
REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790
1. Cotter pin
2. Reverse cable bushing 2. Apply Loc — Tite 243, P/N 460790, onto the
3. Brass bushing threads of the socket screws (or use NEW self-
4. Reverse cable
locking screws).

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 Propulsion
Jet Pump

3. Install the socket screws, lock washers and flat support and the jet pump on the inlet side. The
washers. reducer is color coded.
4. Torque the screws to the proper specification.
ENGINES REDUCER COLOR
PARTS TORQUE All Green
Venturi retaining
21 N·m (15 lbf·ft) 2. Make sure that the reducer is installed as
screws (socket screw)
shown.
5. Reinstall all other removed parts. NOTICE
Jet Pump Housing A faulty installation can cause overheating
and damage to the exhaust system.
Jet Pump Housing Removal
1. Remove the venturi. Refer to Venturi Removal,
page 320.
N O T E : The jet pump housing can be removed
with the reverse gate, nozzle and venturi. This is
the preferred procedure when either the drive
shaft or engine removal is required. To do so, fol-
low the venturi removal procedure but do NOT un-
screw the venturi.
2. Remove nuts that attach jet pump housing to
pump support.

1. Color coded reducer

REQUIRED CHEMICAL
8
Triple Guard Grease
P/N 460794

3. Lubricate drive shaft splines and the impeller

splines with Triple Guard Grease, P/N 460794.
4. Apply a small amount of Triple Guard Grease
to lubricate the forward sealing lips only of im-
peller boot
5. Ensure neoprene seal is properly installed on
3. Remove the jet pump. the jet pump housing.
Jet Pump Housing Inspection 6. Install jet pump. If necessary, wiggle jet pump
to engage drive shaft splines in impeller.
Visually inspect jet pump housing. Pay attention to
the stator. Ensure the assembly is clean and free REQUIRED CHEMICAL
of any debris and defects.
Ensure the neoprene seal is in good condition. Re- Loc-Tite 243
place it as required.
P/N 460790
Jet Pump Housing Installation
1. Brush and clean impeller splines and drive 7. Apply Loc — Tite 243, P/N 460790, onto the
shaft splines using Pulley Flange Cleaner, P/N stud threads of the jet pump housing.
460798 until splines are free of any residue. 8. Install the bushings into the fastener holes.

The exhaust system water flow is controlled by

a reducer located between the jet pump

321
Propulsion
Jet Pump

1. Slot

1. Bushings
2. Aluminum housing

9. Install all other removed parts.

Impeller Cover
Impeller Cover Removal
1. Remove the venturi. Refer to Venturi Removal,
page 320.
2. With the jet pump housing in the vertical posi-
tion, remove and discard the 3 retaining
screws.

5. Remove both O-rings.

3. Using a fiber hammer, gently tap impeller cov-

er to help release it from the jet pump housing.
4. Use a flat screwdriver in the slots provided as
pry points to remove it from the jet pump
housing. 1. O-rings

Impeller Cover Inspection

Check for presence of water in cover and bearing
area. If water is found, replace seals on impeller
side. Also replace O-rings and/or impeller cover.

322
 Propulsion
Jet Pump

1. Seal on impeller side

REQUIRED CHEMICAL

Jet Pump Bearing Grease

P/N 460785

2. Put 23 ml (.8 U. S. oz) of Jet Pump Bearing

Grease, P/N 460785, into the impeller cover.

8
1. O-rings

Check impeller boot and O-rings condition on im-

peller. Replace as required.

3. Install impeller cover by aligning the cover in-

dex mark with the pump top fin as shown.

1. Impeller boot
2. Impeller O-ring
3. Pump housing O-ring

Impeller Cover Installation

1. Install O-rings in their respective groove.

323
Propulsion
Jet Pump

1. Align mark with top fin

N O T E : Cover can only be installed in one posi-

tion as screw holes are not located symmetrically.

4. Secure cover with NEW self-locking screws.

5. Push cover against pump housing while alter-
1. Unscrew clockwise
nately tightening screws.
6. Make sure O-rings are positioned correctly and 4. Mount the flat sides of impeller shaft in a vise.
they are not damaged when pushing the cover.
7. Torque cover screws as per following table.

PARTS TORQUE
Cover screws 7.5 N·m (66 lbf·in)

Impeller
Impeller Removal
N O T E : If impeller shaft is to be disassembled,
loosen the impeller shaft nut prior to removing the
impeller.

1. Remove jet pump. Refer to Jet Pump Housing

Removal, page 321.
2. Remove impeller cover. Refer to Impeller Cov- 1. Flat side
er Removal, page 322.
3. Remove impeller boot by turning it clockwise REQUIRED TOOL
(LH threads).
150 Engines Impeller
Remover Installer
P/N 460728

250 Engines Impeller

Remover Installer
P/N 460744

5. Unscrew the impeller counterclockwise using

the proper impeller remover/installer.

324
 Propulsion
Jet Pump

2. Clean the impeller shaft using XPS Brakes

NOTICE And Parts Cleaner, P/N 460779.
Never use an impact wrench to loosen 3. Apply Loc — Tite 767, P/N 460791, onto the
impeller. threads of the impeller shaft.

4. Apply XPS Lube, P/N 460786, onto the wear

6. To pull impeller out of the pump, apply a rotat- ring surface.
ing movement as you pull on the impeller.
Impeller Installation
1. Mount the flat sides of the impeller shaft in a
vise.

1. XPS lube

5. Start screwing the impeller on the impeller

shaft.

1. Flat side

REQUIRED CHEMICAL

XPS Brakes And Parts Cleaner

P/N 460779

Loc-Tite 767
P/N 460791

XPS Lube
P/N 460786

325
Propulsion
Jet Pump

REQUIRED TOOL REQUIRED CHEMICALS

150 Engines Impeller Loc-Tite 577

Remover Installer
P/N 460789
P/N 460728
Triple-Guard Grease
250 Engines Impeller
P/N 460794
Remover Installer
P/N 460744 9. Apply Loc-Tite 577, P/N 460789. onto the im-
peller boot threads.
6. Mount the proper Impeller Remover Installer 10. Apply Triple-Guard Grease, P/N 460794, to
into the impeller splines. the impeller splines and a small amount only
7. Torque the impeller to the proper specification. onto the forward sealing lips of the impeller
boot.
PART TORQUE 11. Install impeller boot onto the impeller and tight-
en counterclockwise.
Impeller 125 N·m (92 lbf·ft)
Wear Ring
8. Remove the Impeller Remover Installer. Wear Ring Removal
NOTICE Cutting The Wear Ring
Never use an impact wrench to tighten impel- 1. Remove jet pump. Refer to Jet Pump Housing
ler shaft. Removal, page 321.
2. Remove impeller from jet pump housing. Refer
to Impeller Removal, page 324.
3. Place jet pump housing in a vise with soft jaws.
It is best to clamp housing using a lower ear.
4. Cut wear ring at two places using a jigsaw, a
small grinder or a low clearance hacksaw.

NOTICE
When cutting ring, be careful not to damage
jet pump housing.

5. Insert a screwdriver blade between jet pump

housing and ring outside diameter.
6. Push ring so that it can collapse internally.
7. Pull the wear ring out.

326
 Propulsion
Jet Pump

Using A Freezer
1. Place the jet pump housing and the wear ring
into a freezer for approximately 1.5 hours at -
14°F(-10°C).
2. Remove the housing and wear ring from the
freezer and pull the wear ring from the jet pump
housing.
Wear Ring Inspection
Inspect the wear ring for:
– Deep scratches
– Irregular surfaces
– Apparent damage
– Wear impeller to wear ring clearance. Refer to
Impeller Wear Ring Clearance, page 319
Wear Ring Installation
1. Use a square steel plate of approximately 180 1. Piece of wood
x 180 mm x 6 mm thick (7 x 7 in x 1/4 in) and a 2. Rounded edge
press. 3. Wear ring
2. Manually engage ring in housing making sure Wear Ring Installation Using A Freezer
it is equally inserted all around.
Place the jet pump housing into the freezer for ap-
3. Press ring until it seats into bottom of housing.
proximately 1.5 hours at -14°F(-10°C).
While the housing is still cold, insert the wear ring
properly into the jet pump housing.
Impeller Shaft And Bearing
8
Impeller Shaft And Bearing Removal
1. Remove impeller cover. Refer to Impeller Cov-
er Removal, page 322.

REQUIRED TOOL

150 Engines Impeller

Remover Installer
P/N 460728

250 Engines Impeller

Remover Installer
1. Bounded edge
2. Press wear ring P/N 460744
4. If a press is not readily available, a piece of
wood such as a 2 x 4 in x 12 in long, can be 2. Mount the proper Impeller Remover Installer
used. into a vise.
5. Manually engage ring in housing making sure 3. Install jet pump housing over impeller remover/
it is equally inserted all around. installer tool.
6. Place wood piece over ring.
7. Using a hammer, strike on wood to push ring.
8. Strike one side then rotate wood piece about
90° and strike again.
9. Frequently rotate wood piece so the ring slides
evenly until the ring seats into the bottom of
the housing.

327
Propulsion
Jet Pump

4. Using a 30 mm socket, unscrew the impeller 1. Nut

shaft nut counterclockwise. 7. Remove impeller. Refer to Impeller Removal,
5. If impeller loosens instead of shaft nut, refer to page 324.
IMPELLER SHAFT NUT REMOVAL IF IMPEL- 8. From the impeller side, remove circlip, seals,
LER HAS LOOSENED. spacer and O-ring.

1. Circlip
2. Seal

6. Remove impeller shaft nut. REQUIRED TOOL

Impeller Shaft
Pusher
P/N 460743

9. Use the Impeller Shaft Pusher, P/N 460743, to

press impeller shaft out of pump housing.

N O T E : Bearing will come out with the impeller

shaft.

328
 Propulsion
Jet Pump

11. Remove the bearing and shaft as an assembly,

if the impeller has loosened. The nut can then
be loosened with a 30 mm wrench while the
shaft is being held in a vise by the flats.
Impeller Shaft And Bearing Inspection
With your finger nail, feel seal lip contact surface
on shaft. If any irregular surface is found, replace
shaft and seals.
Check condition of shaft threads.

1. Threads
2. Seal lip contact surface
3. Threads

Inspect ball bearing for corrosion.

Impeller Shaft And Bearing Installation
Bearing Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation. 8
REQUIRED TOOL 1. Protect the impeller shaft threads.

REQUIRED TOOL
Impeller Shaft Bear-
ing Tool
Impeller Shaft Bear-
P/N 460763 ing Tool
P/N 460763
10. Use the Impeller Shaft Bearing Tool, P/N
460763, to press the bearing off impeller shaft.
Impeller Shaft
Pusher
P/N 460743

2. Use the Impeller Shaft Bearing Tool, P/N

460763, and the Impeller Shaft Pusher, P/N
460743, to press the bearing onto the impeller
shaft.
N O T E : The bearing can be installed in either
direction.

1. Impeller shaft and bearing

2. Bearing tool on INNER race

329
Propulsion
Jet Pump

REQUIRED CHEMICAL

Jet Pump Bearing Grease

P/N 460785

6. Coat shaft surface with Jet Pump Bearing

Grease, P/N 460785.
7. Install O-ring at bottom.

1. Impeller shaft bearing tool on INNER race

2. Impeller shaft and bearing
3. Impeller shaft installer/pusher tool

3. Press the bearing until it bottoms.

Impeller Shaft Installation
1. Ensure there are no O-rings in pump housing
on the cover side.
REQUIRED TOOL
1. O-ring at bottom
Impeller Shaft Bear- 2. Coat surface
ing Tool
8. Apply 4 ml (.1 U. S. oz) of Jet Pump Bearing
P/N 460763 Grease, P/N 460785, onto the bearing.

2. From the outlet side of the pump, use the Im-

peller Shaft Bearing Tool, P/N 460763, to
press the impeller shaft assembly into the
housing.

REQUIRED TOOL

1. Bearing tool
2. Impeller shaft and bearing
Seal Bearing Pusher

3. Press bearing until it bottoms. P/N 460727

4. Ensure impeller shaft turns freely and
smoothly. 9. Using the Seal Bearing Pusher, press a NEW
5. Turn pump upside down. double lip seal until seal bottoms. Make sure
seal lips are facing upwards.

330
 Propulsion
Jet Pump

1. Seal lip up
1. Seal lip facing up

11. Install the circlip.

8
1. Seal lip facing up
1. Circlip

12. Turn pump upside down.

13. Install the two O-rings in pump housing.

1. Seal bearing pusher

10. Install spacer and then the other seal (thin).

Ensure seal lip is facing up and that the seal is
thoroughly seated below the circlip groove.
1. O-rings

14. Before installing any other parts, pressurize jet

pump to insure proper seal installation.
15. Install impeller. Refer to Impeller Installation,
page 325.

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Propulsion
Jet Pump

REQUIRED TOOL

150 Engines Impeller

Remover Installer
P/N 460728

250 Engines Impeller

Remover Installer
P/N 460744

16. Mount the proper Impeller Remover Installer

into a vise.

REQUIRED CHEMICAL

Jet Pump Bearing Grease

P/N 460785

19. Apply 24 ml (.8 U. S. oz) of Jet Pump Bearing

Grease, P/N 460785, onto the bearing (nut
side).

1. Impeller Remover Installer tool

17. Install jet pump housing over this tool.

20. Install the impeller cover. Refer to Impeller

Cover Installation, page 323.

18. Using a 30 mm socket, screw the impeller shaft

nut on clockwise and torque to specification.

TORQUE
Impeller shaft nut 125 N·m (92 lbf·ft)

332
 Propulsion
Drive Shaft

Drive Shaft
SERVICE TOOLS
Description Part Number Page

150 ENGINES IMPELLER REMOVER INSTALLER . . . . . . . . . . . P/N 460728 . . . . . . . . . . 324, 326–327, 332
250 ENGINES IMPELLER REMOVER INSTALLER . . . . . . . . . . . P/N 460744 . . . . . . . . . . 324, 326–327, 332
DRIVE SHAFT HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460746 . . . . . . . . . . . . . . . . . . . 335, 340
FLOATING RING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460840 . . . . . . . . . . . . . . . . . . . . . . . 335
IMPELLER SHAFT BEARING TOOL . . . . . . . . . . . . . . . . . . . . . . . P/N 460763 . . . . . . . . . . . . . . . . . . . 329–330
IMPELLER SHAFT PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460743 . . . . . . . . . . . . . . . . . . . 328–329
PTO SUPPORT TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460734 . . . . . . . . . . . . . . . . . . . 335, 339
SEAL BEARING PUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460727 . . . . . . . . . . . . . . . . . . . . . . . 330

SERVICE PRODUCTS
Description Part Number Page

ANTICORROSION SPRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460776 . . . . . . . . . . . . . . . . . . . . . . . 335

BRP HEAVY DUTY CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460780 . . . . . . . . . . . . . . . . . . . . . . . 341
CLEAR SILICONE SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460793 . . . . . . . . . . . . . . . . . . . . . . . 341
JET PUMP BEARING GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460785 . . . . . . . . . . . . . . . 323, 330, 332
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . 316, 320–321
LOC-TITE 271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460788 . . . . . . . . . . . . . . . . . . . . . . . 315
LOC-TITE 577 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460789 . . . . . . . . . . . . . . . . . . . . . . . 326
LOC-TITE 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460791 . . . . . . . . . . . . . . . . . . . . . . . 325
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULLEY FLANGE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P/N 460778
P/N 460798
. . . . . . . . . . . . . . . . . . . . . . . 341
. . . . . . . . . . . . . . . . . . . . . . . 337
8
TRIPLE GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460794 . . . . . . . . . . . . . . . . . . . 321, 338
TRIPLE-GUARD GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460794 . . . . . . . . . . . . . . . . . . . . . . . 326
XPS BRAKES AND PARTS CLEANER . . . . . . . . . . . . . . . . . . . . . P/N 460779 . . . . . . . . . . . . . . . . . . . . . . . 325
XPS LUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460786 . . . . . . . . . . . . . . . . . . . 325, 336

333
Propulsion
Drive Shaft

Drive Shaft Service Chart

334
 Propulsion
Drive Shaft

Drive Shaft Maintenance

Drive Shaft Corrosion Protection
1. To prevent possible drive shaft corrosion in salt
water, apply Anticorrosion Spray, P/N 460776.

REQUIRED CHEMICAL

Anticorrosion Spray
P/N 460776

2. Drive shaft should be dry and clean prior to ap-

plying the anti-corrosion product. 1. Drive shaft holder
3. From inside bilge, lift rubber protector to ex- 3. Open engine cover.
pose PTO seal assembly. 4. Remove supercharger if applicable. Refer to
4. On supercharged engines, remove inlet hose Supercharger Removal, page 177.
from supercharger to gain access.
5. Cover carbon seal ring and floating ring with a REQUIRED TOOL
rag or plastic wrap to prevent the anti-corrosion
product to reach the carbon ring.
6. Place a rag on bottom of hull to recover the ex- PTO Support Tool
cess of sprayed anti-corrosion product. P/N 460734
7. Spray the visible portion of drive shaft.
8. When done, dispose soiled rag as per your lo-
5. Lift rubber protector to expose PTO seal as-
cal environmental regulations.
sembly. Install the PTO Support Tool, P/N
9. Install inlet hose to supercharger. Reposition
460734, onto the bottom of the PTO seal
rubber protector.
assembly.
10. Wait 2 hours prior to using the boat to allow the
anti-corrosion product to dry.
8
Procedures
Drive Shaft
Drive Shaft Removal
N O T E : 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. If engine cannot be started, remove oil from
the PTO area.
1. Remove jet pump. Refer to Jet Pump Housing
Removal, page 321.

REQUIRED TOOL
1. Insert in groove of PTO seal assembly
Drive Shaft Holder
P/N 460746 REQUIRED TOOL

2. Install the drive shaft holder, P/N 460746. Floating Ring Tool
P/N 460840

335
Propulsion
Drive Shaft

6. Install the Floating Ring Tool, P/N 460840, with

its largest opening on PTO seal side.
7. Remove the drive shaft holder.
8. Turn screw clockwise so the tool pushes the
PTO seal forward and the drive shaft to the
rear to expose the O-rings contact area.
9. Continue to pull drive shaft out from the rear of
the boat until there is a distance of 18 mm (23/
32 in) between the telltale groove and the tool
edge.

REQUIRED CHEMICAL
1. Drive shaft holder
XPS Lube
13. Install the floating ring tool with its largest
P/N 460786 opening on the floating ring side.

10. Lubricate O-rings contact area with XPS Lube,

P/N 460786.

1. Largest opening on PTO seal side

14. Push floating ring rearwards to expose circlip

and remove it. Discard circlip.
15. Polish off any corrosion build up in this area if
present. Lubricate the shaft to ease in the re-
moval of the floating ring.
4

1. Largest opening here

2. Telltale groove
3. Lubricate O-rings contact area
4. 18 mm (23/32 in)

11. Remove the floating ring tool.

12. Push drive shaft in and install drive shaft holder
tool.

1. Largest opening here

2. Floating ring
3. PTO seal support tool
4. Remove circlip

336
 Propulsion
Drive Shaft

16. Remove drive shaft holder tool then the float- difference between highest and lowest dial gauge
ing ring tool. reading is deflection.
17. Place rags under PTO housing to prevent
spillage.

REQUIRED CHEMICAL

Pulley Flange Cleaner

P/N 460798

18. If spillage occurs, clean immediately with the

Pulley Flange Cleaner, P/N 460798.
19. Remove the drive shaft.
Drive Shaft Inspection And Lubrication
Inspect condition of circlip groove. If there is any 1. Dial gauge
2. V-blocks
damage or severe wear, replace drive shaft.
Maximum permissible deflection is 0.5 mm (.02
in).
To prevent possible drive shaft corrosion when the
vehicle is used in salt water, apply Anticorrosion
Spray, P/N 460776, onto the drive shaft.
Drive shaft should be dry and clean prior to apply-
ing the anti-corrosion product. If the drive shaft is
slightly corroded, a rotating wire brush may be
used.
8
1

1. Circlip groove

Inspect condition of drive shaft splines. If splines 2

are damaged, replace drive shaft.
150 ENGINES
Inspect the machined surface of drive shaft. If any 1. 89 mm (3-1/2 in)
irregular surface are found, replace the drive 2. 131 mm (5-5/32 in) - zone to apply anticorrosion spray
shaft.
1

1. 101 mm (4 in)
2. 180 mm (7-3/32 in) - zone to apply anticorrosion spray
1. Surface condition
2. Splines condition Wait 2 hours prior to using the boat to allow anti-
corrosion product to dry.
Excessive deflection could cause vibration and
damage to drive shaft splines, impeller or floating Inspect condition of O-rings and contact surface of
ring. the floating ring. Replace if necessary.
Place drive shaft on V-blocks and set-up a dial
gauge in center of shaft. Slowly rotate shaft;

337
Propulsion
Drive Shaft

Drive Shaft Installation

1. Before installing drive shaft, discard both O-
rings inside PTO seal and install NEW ones.

1. Inner sleeve not flush with outer circumference

1. O-rings REQUIRED CHEMICAL

2. Inspect PTO seal assembly. The inner sleeve
Triple Guard Grease
must be flush with outer circumference of the
assembly. Otherwise, gently push or tap on in- P/N 460794
ner sleeve until flush.
3. Apply a thin coat of Triple Guard Grease, P/N
460794, onto the floating ring O-rings. Do not
get grease on floating ring contact surface.

1. Apply grease on O-rings

2. No grease on contact surface
1. Inner sleeve flush with outer circumference 4. Remove the damper at the end of drive shaft
and replace it with a NEW one.

338
 Propulsion
Drive Shaft

1. Damper

REQUIRED TOOL
9. Maintain PTO seal assembly in the proper po-
PTO Support Tool sition and tap shaft end until it bottoms against
engine. At this time, the telltale groove MUST
P/N 460734 NOT be visible. This validates the correct
position.
5. Install the PTO Support Tool, P/N 460734, on-
to the PTO seal assembly. NOTICE
6. Slide drive shaft far enough to install floating If the telltale groove is exposed, the installa-
ring. tion is wrong and PTO seal assembly will be
pressed into crankshaft splines which could
rub a hole in seal thus creating an oil leak.

1. PTO seal support

2. Drive shaft end
3. Insert floating ring on shaft end

7. Continue pushing drive shaft towards engine

care-fully guiding it in the PTO seal then in
crankshaft splines. It may be necessary to
move PTO seal assembly up and down to posi-
tion it in the same axis as the drive shaft.
8. If drive shaft does not enter into the PTO seal,
1. PTO seal assembly
check engine alignment. 2. Shaft pushed in, hiding telltale groove
3. Inner sleeve flush with outer circumference

339
Propulsion
Drive Shaft

1. Largest opening on PTO seal side

12. Push floating ring rearwards and install a NEW

circlip.

1. PTO assembly
2. Telltale groove visible
3. Inner sleeve NOT flush with outer circumference

REQUIRED TOOL

Drive Shaft Holder

P/N 460746

10. Install the Drive Shaft Holder, P/N 460746.

1. Largest opening here

2. Floating ring
3. PTO seal support tool
4. Remove circlip

13. Remove drive shaft holder tool then the float-

ing ring tool.
Ensure everything is properly positioned:
– Telltale groove is not visible
– Inner sleeve is flush with outer circumference
of PTO seal assembly
– Circlip is not exposed
1. Drive shaft holder
If telltale groove is visible, push PTO seal assem-
11. Reinstall the floating ring tool with its largest bly rearwards to fully extend it.
opening on the floating ring side.
If inner sleeve is not flush, gently tap it until it is
flush.
Reposition rubber protector. Reconnect EGTS
sensor.
Install jet pump.
Check engine oil level. Refill as necessary.

340
 Propulsion
Drive Shaft

Run boat then ensure there is no oil leak in PTO 2. Clean hull surface with BRP Heavy Duty
seal area. Cleaner, P/N 460780, to eliminate grease, dust
and any residue of sealant.
Drive Shaft Boot
Drive Shaft Protector Installation
Drive Shaft Boot Removal
1. Apply Loc-Tite Instant Gasket, P/N 460778, on
1. Remove drive shaft. Refer to Drive Shaft Re- the flat side of drive shaft protector (all around
moval, page 335. perimeter and screw holes).
2. Loosen gear clamp holding boot, then carefully
pull boot and carbon ring from hull insert. REQUIRED CHEMICAL
Drive Shaft Boot Inspection
Inspect the condition of boot. If there is any dam- Loc-Tite Instant Gasket
age or evidence of wear, replace it. P/N 460778
Drive Shaft Boot Installation
The installation is the reverse of the removal
procedure.

GEAR CLAMP TORQUE

2 N·m (18 lbf·in)

Carbon Ring
Carbon Ring Removal
1. Remove drive shaft. Refer to Drive Shaft Re-
moval, page 335.
2. Loosen gear clamp then pull carbon ring from
drive shaft boot. 1. Apply the product here 8
Carbon Ring Installation 2. Install the protector on hull with its bolts. Posi-
The installation is the reverse of the removal tion bolts in the top holes and torque them to 5
procedure. N·m (44 lbf·in).
3. Install drive shaft. Refer to Drive Shaft Installa-
Torque the gear clamp to 2 N·m (18 lbf·in). tion, page 338.
Drive Shaft Protector
REQUIRED CHEMICAL
Drive Shaft Protector Removal
1. Remove the drive shaft. Refer to Drive Shaft Clear Silicone Sealant
Removal, page 335.
2. Inside hull, remove silicone sealant applied on P/N 460793
nuts.
3. Unscrew the bolts securing the drive shaft pro- 4. Inside hull, apply Clear Silicone Sealant, P/N
tector to the hull. 460793, onto the end of the drive shaft protec-
4. Slide a flexible blade between protector and tor bolts.
hull to cut the sealant.
5. Remove the protector from hull.
Drive Shaft Protector Cleaning
1. Scrape off all excess sealant from protector
and hull.
REQUIRED CHEMICAL

BRP Heavy Duty Cleaner

P/N 460780

341
Notes

Notes Notes
Technician’s Notes Related Documents
Bulletins

Instruction Sheets

Other

342
 Steering System
Single Engine Steering System Service Diagram

Steering System

Single Engine Steering System Service Diagram

343
Steering System
Twin Engine Steering System Service Diagram

Twin Engine Steering System Service Diagram

SERVICE PRODUCTS
Description Part Number Page

LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . 346–347, 358–359

344
 Steering System
Twin Engine Steering System Service Diagram

Steering System Adjustments

Steering Alignment
1. Position steering in straight ahead position.

1. Ball joint nut

2. Ball joint

6. When adjustment is done, reinstall all removed

2. Check alignment of starboard jet pump nozzle parts and make sure ball joint is parallel with
and steering centering by placing a straight the nozzle arm.
edge across nozzle end. Straight edge must
be parallel with transom. Twin Engine Steering Alignment
1. Install a straight edge across nozzle ends.
Straight edge must be parallel with transom
and touch both edges of each nozzle.

1. Parallel with transom

2. Measure distance between transom and straight edge

3. Take two measurements, one of each side of

the nozzle. 1. Parallel with transom
4. A small adjustment can be made with the cable
ball joint. Remove ball joint nut, unlock ball joint 2. To align nozzle, loosen lock nuts of nozzle link
and rotate it to adjust. rod. While holding rod end, turn nozzle link rod
5. A minimum of 7 turns of the ball joint on the ca- to adjust.
ble is necessary to assure a proper 3. Ball joint ends must thread on link rod a mini-
engagement. mum of 10 turns.

345
Steering System
Twin Engine Steering System Service Diagram

1. Make sure the ball joint ends are threaded on

link rod a minimum of 10 turns.
REQUIRED CHEMICAL

Loc-Tite 243
P/N 460790

2. Apply Loc– Tite 243, P/N 460790, onto the

threads of ball joint screws.

TORQUE
Ball joint retaining 12.5 N·m (111 lbf·in)
screw

1. Lock nut Link rod nut 11 N·m (97 lbf·in)

2. Nozzle link rod

4. When finished, tighten lock nuts to

specification.

TORQUE
Nozzle link rod nut 11 N·m (97 lbf·in)

Steering System Troubleshooting

Procedures
Twin Engine Nozzle Link Rod
Nozzle Link Rod Removal 1. Nozzle link rod
1. Remove screws that attach the ball joint of 2. Link rod lock nut
3. Ball joint retaining screw
nozzle link rod to nozzles. 4. Ball joint end

3. Proceed with steering alignment.

Nozzle
Nozzle Removal
1. Disconnect steering cable from jet pump
nozzle.

Nozzle Link Rod Inspection

Check if the nozzle link rod is straight. If not re-
place the link rod.
Check if ball joint ends move freely.
Check ball joint end for wear and excessive free
play.
Nozzle Link Rod Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.

346
 Steering System
Twin Engine Steering System Service Diagram

1. Bushing offset
1. Steering cable nut
2. Steering cable 4. Position their flanges from inside of nozzle. In-
sert sleeves in bushings.
2. For twin engine models, remove the nozzle link
5. Install nozzle on venturi. Position the steering
rod.
cable attachment arm on the RH side.

3. Remove retaining screws, sleeves and wash- 9

ers on top and underneath nozzle.
4. Remove nozzle.
Nozzle Installation
1. Steering cable attachment arm
1. Before installing the nozzle, check threads in 2. Nozzle opening
venturi for looseness or damages.
2. Insert lower bushing in nozzle.
3. Insert upper bushing in nozzle with its offset REQUIRED CHEMICAL
pointing rearward.
Loc-Tite 243
P/N 460790

6. Apply Loc — Tite 243, P/N 460790, onto the

nozzle screw threads.
7. Install nozzle screws and washer then torque
to specification.

TORQUE
Nozzle screw 25 N·m (18 lbf·ft)

8. Install nozzle link rod.

347
Steering System
Twin Engine Steering System Service Diagram

9. Apply Loc — Tite 243, P/N 460790, onto the

threads of ball joint retaining screws and tor-
que them as per following table.

TORQUE
Ball joint retaining 12.5 N·m (111 lbf·in)
screw

10. Proceed with steering alignment.

348
 Steering System
Throttle Shifter Control

Throttle Shifter Control

SERVICE TOOLS
Description Part Number Page

CABLE INSTALLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 461464 . . . . . . . . . . . . . . . . . . . . . . . 360

SERVICE PRODUCTS
Description Part Number Page

LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . 346–347, 358–359

349
Steering System
Throttle Shifter Control

Single Engine Throttle Shifter Control

NEW

TAS
cable
Reverse
cable
Loctite 243

8 N•m Reverse cable

(71 lbf•in)

2.5 N•m
10 N•m (22 lbf•in)
(89 lbf•in)

See
REVERSE
SYSTEM

5.5 N•m
(49 lbf•in) TAS
Loctite cable
243

8 N•m
(71 lbf•in)
Loctite
243

Loctite
243
Loctite 8 N•m
243 (71 lbf•in)

30 N•m
(22 lbf•ft)
3 N•m
NEW = Component must be replaced when removed. (27 lbf•in)

350
 Steering System
Throttle Shifter Control

Twin Engine Throttle Shifter Control

NEW

TAS
cable
Reverse
cable
Loctite 243

8 N•m Reverse cable

(71 lbf•in)

2.5 N•m
10 N•m (22 lbf•in)
(89 lbf•in)

See
REVERSE
SYSTEM
9
5.5 N•m
(49 lbf•in) TAS
Loctite cable
243

8 N•m
(71 lbf•in)
Loctite
243

Loctite
243
8 N•m
Loctite (71 lbf•in)
243
30 N•m
(22 lbf•ft)
3 N•m
NEW = Component must be replaced when removed. (27 lbf•in)

Intelligent Neutral Reverse The iNR actuator controls the position of the re-
iNR System Overview verse gate via a push/pull cable in order to provide
forward thrust, reverse thrust & neutral.
The iNR (intelligent Neutral & Reverse) is an elec-
tronically controlled neutral & reverse system.

351
Steering System
Throttle Shifter Control

The cluster gauge is used as the electronic hub 2. Disconnect the Black (-) battery cable from the
managing the flow of information between the iNR (-) battery post.
module & the ECM.
The operator commands the position of the iNR
actuator via the throttle controller. The mechanical
load of the gate operation is now taken by the iNR
actuator which provides the operator with more
accurate control of the vessel.
The Neutral adjustment can be achieved during 1
engine operation via the helm cluster gauge. An
optimized neutral position could be selected within
a 30 increment window (+15/-15 increments).
When the Neutral adjustment is completed and
perfect balance of the lateral thrust is achieved, 1. Black (-) battery disconnect location
the value is stored in the system memory.
3. Access the engine compartment and install the
Since the cluster is the electronic hub of the sys- iNR Module, P/N 461418 either on the flat side
tem, it will need to be coded accordingly through of the engine compartment or at an angle at-
B.U.D.S. in order to activate all the necessary sys- tached to the side wall of the engine
tem monitoring functions. compartment.
iNR Module Installation 4. The iNR Module, P/N 461418, can be installed
on either the port or the starboard side of the
I M P O R T A N T : Install the iNR Module, P/N engine compartment.
461418, into a location where it will be free of ob-
struction during normal operation. Be sure the
Shift Cable, P/N 461352, is not binding in any lo-
cations. Ensure the Shift Cable, P/N 461352, does 1
not exceed a 12 inch bend radius.
I M P O R T A N T : The iNR Module, P/N 461418,
can be installed on the flat side of the engine com-
partment or at an angle attached to the side wall
of the engine compartment.

WARNING
Failure to disconnect the battery in the proper
1. Starboard side iNR Module installation for twin engine
sequence could result in personal injury or applications
death.
eThrottle Controller and Harness Installation
1. Access the battery and disconnect the Red (+) NOTICE
battery cable from the (+) battery post. Failure to connect the electrical harness
properly could result in machine damage.

1 1. The Throttle Accelerator Sensor (TAS) adjust-

ment with the pull cable system is the same as
the traditional system. Adjust to approximately
34% +/- 2% when in the full reverse position.

1. Red (+) battery disconnect location

352
 Steering System
Throttle Shifter Control

Shift Cable Installation

1. Route the Shift Cable, P/N 461352, from the
outside of the boat through the B plate.
2. Route the Shift Cable, P/N 461352, through
the starboard B plate for twin engine
applications.
3. Be sure the Shift Cable, P/N 461352, does not
exceed a 12 inch bend radius and does not
bind in any locations.
4. Secure the Shift Cable, P/N 461352, to the iNR
Module, P/N 461418, using the Brass Pivot
SCHEMATIC FOR HARNESS INSTALLATION
Nut, P/N 461398, and the Cotter Pin, P/N
305650.
2. Connect the Electrical Harness, P/N 461353, 5. The Brass Pivot Nut, P/N 461398, needs to be
to the Throttle Accelerator Sensor (TAS). screwed all the way in during this step.
3. Lay the harness down in the gunwale towards
the starboard fuse box.
4. Connect the 6 pin Deutsch connector to the B.
U.D.S. diagnostic connector.
N O T E : The system can be connected in series
with the CCK module. If the iNR and the CCK are
used together, install the iNR first. 1

1. Brass Pivot Nut, P/N 461398 and cotter pin

WARNING
Failure to connect the battery in the proper
sequence could result in serious personal in- 9
jury or death.

NOTICE
1. 6 pin Deutsch connector
Failure to ensure all electrical connections
5. Connect the 2 pin Deutsch connector to a dedi- are tight before connecting the battery could
cated 30A breaker. result in machine damage.

6. Connect the Red (+) battery cable to the (+)

battery post.

1. 2 pin Deutsch connector

6. Connect the main 16 pin Molex connector to

the iNR Module, P/N 461418.

353
Steering System
Throttle Shifter Control

1
1

2 3

1. Settings tab
1. Red (+) battery disconnect location
2. Cluster tab
3. eReverse Configuration
7. Connect the Black (-) battery cable to the (-)
battery post. 5. Click the Write Data button after the iNR is
activated.

1
1

1. Black (-) battery disconnect location

1. Write Data button
Shift Cable Adjustment
6. Activate the “eReverse Override” function from
I M P O R T A N T : The shift cable needs to be ad- the cluster SETTINGS page.
justed so when the throttle is in the full forward po-
sition, the gate locking mechanism operates N O T E : The override function enables the iNR
properly. Module, P/N 461418, to move without having to
start the engine and should only be used during
I M P O R T A N T : Engine PPS adjustment with the adjustments.
pull cable system is the same as the traditional
system. Adjust to approximately 34% +/- 2% when 7. Move the eThrottle Controller to the FOR-
in the full reverse position. WARD position.
NOTICE
Failure to make all electrical connections be-
fore turning the key to the ON position could
result in machine damage.

1. Turn the key to the ON position.

2. Before turning the key to the ON position, be
sure all of the electrical connections have been
made and are tight.
3. Properly connect a PC with B.U.D.S.-P 3.7.0.6.
1
software to the diagnostic connector.
4. Using B.U.D.S. diagnostic software, select Set- 1. eThrottle Controller in the FORWARD position
tings-Cluster and activate the eReverse from
the eReverse Configuration box. 8. Click Activations > eReverse > Enable in the
eReverse Cable Adjustment box.

354
 Steering System
Throttle Shifter Control

1 3
2

1. Activations tab
2. eReverse tab ETHROTTLE CONTROLLER IN NEUTRAL POSITION
3. Enable button

9. Move the reverse gate to the locking position. 13. Using B.U.D.S., click Activations.
10. Adjust the brass nut located in the pump box
area until the shift cable end attaches to the
gate locking mechanism. Start with the nut in
the in the middle of the threads during this
step.
1

1. Activations tab

14. Click the Disabled button in the eReverse Ca-

ble Adjustment box.

9
1. Pump box shift cable adjustment nut

11. Install the washer and lock nut securing the

shift cable to the gate lock mechanism.
1
1

1. Disable button

3 15. Clear any active fault codes with B.U.D.S.

2 16. Cycle the key switch leaving the switch in the
ON position.
17. Reactivate the “eReverse Override” function
1. Shift cable using the cluster Settings menu.
2. Nut 18. Move the eThrottle controller from the Full For-
3. Washer ward position to the Full Reverse position and
12. Set the eThrottle Controller to the NEUTRAL verify the proper functionality of the iNR. If the
position. iNR is functioning properly, the reverse gate
must lock in the up position when the eThrottle
Controller is in the full FORWARD position.

355
Steering System
Throttle Shifter Control

Procedures 4. Remove throttle/shifter control from upper deck

Throttle Shifter Control and detach both cables (throttle accelerator
sensor (TAS) cable and reverse cables).
Throttle Shifter Control Removal 5. Unplug the neutral switch connector.
1. Remove both chrome trims and lever cap.

1. Lever cap 1. Reverse cable

2. Chrome trims 2. TAS cable
3. Neutral switch
2. Remove lever and bezel.
Throttle Shifter Control Installation
For installation, reverse the removal procedure.
Pay attention to the following during installation.
1. When reinstalling throttle/shifter control, be
careful not to bend cables.
2. Ensure everything works properly before oper-
ating craft.
Throttle Accelerator Sensor
TAS Cable Inspection
Check cable for wear and oxidation. Replace as
necessary.
TAS Cable Removal
1. Lever bolt
2. Bezel screws 1. Locate the TAS sensor on your particular
vehicle.
3. Detach throttle/shifter control support from 2. Remove the bracket retaining screws.
upper deck.

1. Support screws
2. Control retaining screw

356
 Steering System
Throttle Shifter Control

5. Unscrew cable locking nut and remove cable

from the bracket.

1. Bracket 1. TAS cable

2. Bracket retaining screws 2. Locking nut
3. For single engine models, remove the retaining 6. Cut locking ties securing TAS cable.
screw, bushing, washer and nut.

1. Locking ties

TAS Cable Removal At Throttle Shifter Control

1. Remove throttle/shifter control from upper
deck.
2. Remove and discard the cotter pin securing
9
the brass adapter to throttle/shifter control
1. Retaining screw plate.
2. Bushing
3. Washer
4. Nut

4. For twin engine models, removed and discard

the cotter pin.

1. Cotter pin
2. Brass adapter
3. Throttle/shifter control plate

3. Remove the hairpin clip that locks the TAS

cable.

1. Cotter pin

357
Steering System
Throttle Shifter Control

5. Align the groove in metallic portion of cable

with the gap in cable support and install the
hairpin clip.

1. Hairpin clip
2. TAS cable

4. Remove the brass adapter from the TAS cable.

Remove the TAS cable from the throttle/shifter 1. Align the groove with this opening
control. 6. Insert the brass adapter end in the upper hole
5. Pull the cable out of driver's cockpit and upper of throttle/shifter control plate and secure it us-
deck. ing a new cotter pin.
TAS Cable Installation 7. Fold both ends of cotter pin.
TAS Cable Installation At Throttle Shifter TAS Cable Installation At TAS Sensor Bracket
Control
1. Install the cable on bracket and secure it using
1. Tighten the brass adapter on threaded end of the locking nut so that approximately 5 threads
cable until approximately 11 threads are are exposed.
exposed.
REQUIRED CHEMICAL
REQUIRED CHEMICAL
Loc-Tite 243
Loc-Tite 243
P/N 460790
P/N 460790
2. Unscrew the locking nut a few turns and apply
2. Unscrew the brass adapter a few turns and ap- Loc — Tite 243, P/N 460790, onto threads of
ply Loc-Tite 243, P/N 460790 onto the threads the TAS cable.
of the TAS cable. 3. Tighten the locking nut.
3. Reposition the adapter and secure it on throt-
tle/shifter control plate with a new cotter pin.
4. Fold both ends of cotter pin.

1. Approximately 5 threads exposed

2. Loc—Tite 243, P/N 460790

4. Secure the TAS cable loosely with two new

1. Approximately 11 threads exposed
2. Loc—Tite 243.P/N 460790 locking ties and secure the TAS bracket with
the TAS bracket screw.
5. Torque the screw to the proper specification.

358
 Steering System
Throttle Shifter Control

TORQUE N O T E : The adjuster is located inside the star-

board console.
TAS bracket screw 2.5 N·m (22 lbf·in)
8. Turn the adjuster in order to get the specific
TAS Adjustment readings.
1. Connect the vehicle to the latest version of B.
U.D.S.
2. Enable the electrical system.
3. Select Monitoring>ECM.
4. Read the TAS position shown in % for each
TAS.

1. TAS cable adjuster

N O T E : In neutral, the TAS arms should rest

against the stoppers without any tension on the
cable.
9. Tighten the TAS cable adjuster lock nut.
1. TAS % window
REQUIRED CHEMICAL
5. For twin engine models, click on the Starboard/
Port button to change between the starboard
and port ETA readings. Loc-Tite 243
P/N 460790

10. If the cable adjuster does not allow correct ad-

9
justment, use the threaded end of the cable lin-
er attached to the bracket. In such a case,
apply Loc-Tite 243, P/N 460790, to the cable
liner threads.
11. After adjusting at WOT, check the readings in
neutral and make sure the TAS arms rest
against the stoppers and the cable moves
freely.
1. Starboard/Port button Reverse Cable
6. Refer to the following table for adjustments. Pump Side Reverse Cable Removal
1. Remove reverse gate support. Refer to Re-
CORRECT TAS ADJUSTMENT verse Gate, page 313.
THROTTLE/SHIFT 2. Remove venturi from jet pump housing.
READING 3. Unscrew the brass bushing to remove it from
LEVER POSITION
reverse cable.
Neutral 0%
Wide Open 100%

7. Loosen the TAS cable adjuster lock nut.

359
Steering System
Throttle Shifter Control

1. Brass bushing
2. Reverse cable
1. Reverse cable
2. Cotter pin
3. Cable connector
REQUIRED TOOL
Pump Side Reverse Cable Installation
Cable Installer
For installation, reverse the removal procedure.
P/N 461464 Pay attention to the following during installation.
1. Torque reverse cable lock to specification.
4. Use the Cable Installer, P/N 461464, to un-
screw the reverse cable lock then remove rub- TIGHTENING TORQUE
ber grommet from jet pump.
Reverse cable lock 10 N·m (89 lbf·in)

2. Install venturi and reverse gate support.

3. Screw brass bushing on reverse cable and in-
stall it in its hole located into reverse gate
support.
4. Make sure bushing is in place into reverse gate
support hole.
5. Install the reverse cable bushing over brass
bushing then install a NEW cotter pin.

1. Steering cable tool

2. Reverse cable

Shifter Side Reverse Cable Removal

1. Remove the throttle/shifter control. Refer to
Throttle Shifter Control Removal, page 356.
2. Detach reverse cable from the throttle/shifter
control before pulling the cable out of bilge. 1. Cotter pin
3. Remove and discard the cotter pin. 2. Reverse cable bushing
4. Remove the cable connector from the end of 3. Brass bushing
4. Reverse cable
cable.
6. Install the reverse cable on reverse gate lever
with a NEW elastic stop nut and torque to
specification.

360
 Steering System
Throttle Shifter Control

TIGHTENING TORQUE
Reverse cable nut 2.5 N·m (22 lbf·in)

Shifter Side Reverse Cable Installation

1. Place reverse gate in the up position. Place
shifter lever in reverse position.
2. The cable threaded end must be screwed at
least 6 turns into the cable connector.
3. Turn the cable connector until the connector
end can be inserted in shifter plate hole.
1. Cotter pin
2. Reverse cable bushing
N O T E : Due to cable length variation, more than 3. Brass bushing
one hole is available on shifter plate to install the 4. Reverse cable
cable. Select the appropriate hole.

1. Alternate cable location

4. Secure the cable connector with a new cotter 9

pin.
5. Fold both ends of the cotter pin.
6. Install throttle/shifter control. Refer to Throttle
Shifter Control Installation, page 356.
Reverse Cable Adjustment
1. At the back of boat, remove and discard cotter
pin securing the reverse cable bushing over
brass bushing.
2. Remove the brass bushing from the reverse
gate support.
3. Turn the brass bushing, one turn at the time, to
adjust the reverse cable.
4. Move reverse lever to check gate operation
and readjust cable as required.
5. The reverse gate latch must be full engaged
when the gate is in the forward position.
6. If adjustment cannot be achieved, the reverse
cable may be not properly installed.
7. Install the reverse cable bushing and a NEW
cotter pin.

361
Notes

Notes Notes
Technician’s Notes Related Documents
Bulletins

Instruction Sheets

Other

362
 Hull
Single Engine Hull Service Chart

Hull
Single Engine Hull Service Chart

10

363
Hull
Twin Engine Hull Service Chart

Twin Engine Hull Service Chart

364
 Hull
Procedures

Procedures
SERVICE PRODUCTS
Description Part Number Page

BRP HEAVY DUTY CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460780 . . . . . . . . . . . . . . . 365–366, 368

CLEAR SILICONE SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460793 . . . . . . . . . . . . . . . . . . . . . . . 367
LOC-TITE 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460790 . . . . . . . . . . . . . . . . . . . 367–368
LOC-TITE 271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460788 . . . . . . . . . . . . . . . . . . . . . . . 365
LOC-TITE 518 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460361 . . . . . . . . . . . . . . . . . . . . . . . 368
LOC-TITE INSTANT GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 460778 . . . . . . . . . . . . . . . . . . . 365, 368

Inlet Grate
Inlet Grate Removal
1. Using a heat gun, heat screws to break thread
locker.
2. Use an impact drive to loosen screws and re-
move inlet grate.
Inlet Grate Cleaning
1. Scrape off all excess sealant from inlet grate
and hull.
REQUIRED CHEMICAL

BRP Heavy Duty Cleaner SINGLE ENGINE MODELS

P/N 460780 2. When installing inlet grate, apply Loc — Tite

271, P/N 460788, onto the threads of the
2. Clean the hull surface with BRP Heavy Duty screws.
Cleaner, P/N 460780, or an equivalent to elimi- 3. Tighten the screws following the torquing se-
nate grease, dust and any residue of sealant. quence shown in the following illustration.
Inlet Grate Installation
1. Apply Loc — Tite Instant Gasket, P/N 460778,
10
as indicated by the shaded area in the next
illustrations.
REQUIRED CHEMICAL

Loc-Tite Instant Gasket

P/N 460778

Loc-Tite 271
P/N 460788
SINGLE ENGINE MODELS
1. Step 1:1 to 5: hand tighten
2. Step 2:1 to 3: 11 N·m (97 lbf·in)
3. Step 3: 4 and 5: 26 N·m (19 lbf·ft)

365
Hull
Procedures

Ride Plate Cleaning

1. Scrape off all excess sealant from ride plate
and hull.
REQUIRED CHEMICAL

BRP Heavy Duty Cleaner

P/N 460780

2. Clean hull surface with BRP Heavy Duty

Cleaner, P/N 460780, or an equivalent to elimi-
nate grease, dust and any residue of sealant.
Ride Plate Installation
1. Apply Loc — Tite Instant Gasket, P/N 460778,
as indicated in the next illustrations. The bead
size should be 9.5 mm (3/8 in). minimum.

REQUIRED CHEMICAL
TWIN ENGINE MODELS
1. Step 1:1 to 4: hand tighten
2. Step 2:5 to 8: 11 N·m (97 lbf·in) Loc-Tite Instant Gasket
3. Step 3:9 and 10: 18 N·m (13 lbf·ft)
P/N 460778
Ride Plate
Ride Plate Removal
1. Remove jet pump. Refer to Jet Pump Housing
Removal, page 321.
2. Use an impact driver to loosen ride plate
screws.
3. Using a low height hydraulic bottle jack and 2
wood blocks, pry out ride plate.

1. Hydraulic bottle jack

2. Aluminum ride plate
3. Wood blocks

366
 Hull
Procedures

SINGLE ENGINE MODELS

TWIN ENGINE MODELS 10

1. Ride plate, port side
2. Ride plate, starboard side
3. Loc—Tite Instant Gasket

REQUIRED CHEMICAL

2. Tighten screws to specification following the Clear Silicone Sealant

torque sequence shown.
P/N 460793
TIGHTENING TORQUE
Loc-Tite 243
Ride plate screws 10 N·m (89 lbf·in)
P/N 460790

3. Inside hull, apply Clear Silicone Sealant, P/N

460793, onto the end of the ride plate screws.
4. For twin engine models, install the blocking
plate on the starboard ride plate.
5. Apply Loc-Tite 243, P/N 460790, onto the
screws and tighten screws to specification.

367
Hull
Procedures

TIGHTENING TORQUE N O T E : If shims have been installed between

sup-port and body. Do not remove these shims,
Blocking plate screws 4.5 N·m (40 lbf·in) otherwise jet pump alignment will be altered.
Port Engine
Jet Pump Support 1. Remove jet pump. Refer to Jet Pump Housing
Jet Pump Support Removal Removal, page 321.
Starboard Engine 2. Remove inlet grate and ride plate.
3. Inside hull, disconnect both engine cooling ho-
1. Remove jet pump. Refer to Jet Pump Housing ses and both exhaust water hoses.
Removal, page 321. 4. Remove nuts, lock washers and flat washers
2. Remove inlet grate and ride plate. retaining jet pump support from inside hull.
3. Remove ball joint, nut and washer from steer- 5. Using a heat gun, heat jet pump support until it
ing cable. Remove from transom. is possible to pull it.
4. Remove boot, pivot and lock nut from reverse
cable. Remove from transom. N O T E : If shims have been installed between
sup-port and body. Do not remove these shims,
otherwise jet pump alignment will be altered.
Jet Pump Support Cleaning
1. Scrape off all excess sealant from jet pump
support and hull.

REQUIRED CHEMICAL

BRP Heavy Duty Cleaner

P/N 460780

2. Clean hull surface with BRP Heavy Duty

Cleaner, P/N 460780, or an equivalent to elimi-
nate grease, dust and any residue of sealant.
1. Reverse cable
2. Steering cable Jet Pump Support Installation
5. Disconnect the water hoses from inside of the 1. Apply Loc—Tite 518, P/N 460361, against the
hull. contact surface of the studs with the jet pump
support.

REQUIRED
CHEMICAL

Loc-Tite 518
P/N 460361

Loc-Tite 243
P/N 460790

1. Reverse cable Loc-Tite Instant

2. Steering cable Gasket
3. Exhaust water supply hose
4. Exhaust water return hose P/N 460778
6. Remove nuts, lock washers and flat washers
retaining jet pump support from inside hull.
7. Using a heat gun, heat jet pump support until it
is possible to pull it.

368
 Hull
Procedures

TIGHTENING TORQUE
Jet pump support 31 N·m (23 lbf·ft)
screws or nuts

1. Apply Loc—Tite 518 here

2. Apply Loc — Tite 243, P/N 460790, onto the

threads of the jet pump screws.
3. Apply Loc — Tite Instant Gasket, P/N 460778,
as indicated by the shaded areas in the next il-
lustrations. The bead size should be 6.35 mm 5. Install any other removed parts.
(1/4 in) minimum.
N O T E : The sealant should circle each individual
opening and also go around the inside and outside
perimeter of the plate to avoid possibility of ventila-
tion of the pump system.

10
SINGL E ENGINE M ODELS

TWIN ENGINE MODELS

4. Install jet pump support on transom and tighten

screws or nuts to specification using the follow-
ing sequence.

369
Notes

Notes Notes
Technician’s Notes Related Documents
Bulletins

Instruction Sheets

Other

370
 Technical Specifications
Technical Specifications Table

Technical Specifications

Technical Specifications Table

MODEL 150 ENGINE 200/250 ENGINE
ENGINE
ROTAX® 1503 4-TEC, 4-stroke, Single
Engine Type
Over Head Camshaft (SOHC)
Number of engines 1
Supercharged
Naturally intercooled with
Induction aspirated external
intercooler
Number of cylinders 3
12 valves with hydraulic lifters (no
Number of valves adjustment)

Bore 100 mm (3.9 in)

Stroke 63.4 mm (2.5 in)

Displacement 1 494 cm3 (91 in3)
Compression ratio 10.6:1 8.4:1

Type Dry sump (2 oil pumps). Replaceable

oil filter. Water cooled oil cooler.
Maximum RPM Oil Type XPS synthetic blend oil, P/N 460787
3 L (3.2 qt (U.S. liq.)) oil change w/filter
Capacity
4.5 L (4.8 qt (U.S. liq.)) total
Intake valve opening 0° BTDC 11
Intake valve closing 50° ABDC
Exhaust valve opening 50° BBDC
Exhaust valve closing 0° ATDC
5.961 mm to 5.975 mm (.2347 in to
New .2352 in)
Intake
Wear Limit 5.930 mm (.233 in)
Valve stem
diameter 5.946 mm to 5.960 mm (.2341 in to
New .2346 in)
Exhaust
Wear Limit 5.930 mm (.233 in)

371
Technical Specifications
Technical Specifications Table

MODEL 150 ENGINE 200/250 ENGINE

5.994 mm to 6.018 mm (.236 in to
New .2369 in)
Valve guide diameter
Wear Limit 6.060 mm (.2386 in)

New 41.02 mm (1.615 in)

Inner
Valve Spring Free Wear Limit 38.80 mm (1.528 in)
Length 45.45 mm (1.789 in)
New
Outer
Wear Limit 43.00 mm (1.693 in)

New 1.10 mm to 1.30 mm (.043 in to .051 in)

Intake
Wear Limit 1.60 mm (.063 in)
Valve seat contact
width New 1.25 mm to 1.55 mm (.049 in to .061 in)
Exhaust
Wear Limit 1.80 mm (.071 in)
20.007 mm to 20.020 mm (.7877 in to
New .7882 in)
Rocker arm inner diameter
Wear Limit 20.050 mm (.7894 in)
19.980 mm to 19.993 mm (.7866 in to
New .7871 in)
Rocker arm shaft diameter
Wear Limit 19.970 mm (.7862 in)
Cylinder head maximum warpage Service Limit 0.15 mm (.006 in)
99.951 mm - 99.931 mm -
New 99.969 mm (3.935 99.949 mm (3.934
Piston diameter in - 3.936 in) in - 3.935 in)

Service Limit 99.90 mm (3.933 in)

1st Upper compression ring, rectangular

Piston ring type and quantity 2nd Lower compression ring, tapered face

3rd Oil scraper ring

Rectangular New 0.30 mm to 0.50 mm (.012 in to .02 in)
Taper-Face New 0.35 mm to 0.55 mm (.014 in to .022 in)
Ring End Gap
Oil scraper rings New 0.35 mm to 0.50 mm (.014 in to .02 in)

All Wear limit 1.50 mm (.059 in)

372
 Technical Specifications
Technical Specifications Table

MODEL 150 ENGINE 200/250 ENGINE

0.025 mm to 0.070 mm (.001 in to .003
Rectangular New in)
0.015 mm to 0.06 mm (.0006 in to
Ring/piston Taper-Face New .0024 in)
groove clearance
0.020 mm to 0.055 mm (.001 in to .002
Oil scraper rings New in)

All Wear limit 0.15 mm (.006 in)

0.024 mm to 0.056 0.044 mm to 0.076
New mm (.0009 in to mm (.0017 in to
Piston/cylinder wall clearance .0022 in) .003 in)

Wear limit 0.100 mm (.0039 in)

Cylinder taper Wear limit 0.100 mm (.0039 in)
Cylinder out of round (maximum) 0.015 mm (.0006 in)
24.939 mm to 24.960 mm (.9819 in to
New .9827 in)
Front
Camshaft bearing Wear Limit 24.910 mm (.9807 in)
journal diameter 39.892 mm to 39.905 mm (1.5706 in to
New 1.5711 in)
PTO and Center
Wear Limit 39.880 mm (1.5701 in)
25.000 mm to 25.013 mm (.9843 in to
New .9848 in)
Front
Wear Limit 25.050 mm (.9862 in)
Camshaft bearing
inner diameter 40.000 mm to 40.020 mm (1.5748 in to
New 1.5756 in)
PTO and Center
Wear Limit 40.050 mm (1.5768 in)
31.540 mm to 31.740 mm (1.2417 in to
11
New 1.2496 in)
Intake
Wear Limit 31.50 mm (1.2402 in)
Cam lobe height
31.430 mm to 31.630 mm (1.2374 in to
New 1.2453 in)
Exhaust
Wear Limit 31.380 mm (1.2354 in)

Crankshaft deflection Maximum 0.05 mm (.002 in)

0.080 mm to 0.220 mm (.0031 in to
New .0087 in)
Crankshaft axial clearance
Wear Limit 0.35 mm (.014 in)

373
Technical Specifications
Technical Specifications Table

MODEL 150 ENGINE 200/250 ENGINE

49.991 mm to 50.000 mm (1.9681 in to
New 1.9685 in)
Crankshaft bearing journal diameter
Wear Limit 49.950 mm (1.9665 in)

Crankshaft radial clearance Wear Limit 0.07 mm (.0028 in)

Connecting rod big end diameter Service Limit 45.080 mm (1.7748 in)
Connecting rod big end radial play Service Limit 0.090 mm (.0035 in)
0.100 mm to 0.352 mm (.004 in to .014
New in)
Connecting rod big end axial play
Wear Limit 0.500 mm (.0197 in)
23.010 mm to 23.020 mm (.9059 in to
New .9063 in)
Connecting rod small end diameter
Wear Limit 23.070 mm (.9083 in)
22.996 mm to 23.000 mm (.9054 in to
New .9055 in)
Piston pin diameter
Wear Limit 22.990 mm (.9051 in)
Connecting rod small end radial play Wear Limit 0.080 mm (.0031 in)
31.984 mm to 32.000 mm (1.2592 in to
New 1.2598 in)
Balance shaft journal diameter
Wear Limit 31.950 mm (1.2579 in)

Balance shaft radial clearance Wear Limit 0.070 mm (.0028 in)

0.020 mm to 0.250 mm (.0008 in to
Balance shaft axial clearance New .0098 in)
14.460 mm to
New — 14.500 mm (.5693
Supercharger shaft driven plate journal in to .5709 in)
depth
14.600 mm (.5748
Wear Limit — in)
11.000 mm to
New — 11.050 mm (.4331
Supercharger drive gear thickness in to .435 in)
10.900 mm (.4291
Wear Limit — in)
4.050 mm to 4.150
New — mm (.1594 in to
Supercharger lock washer thickness .1634 in)
3.950 mm (.1555
Wear Limit — in)

374
 Technical Specifications
Technical Specifications Table

MODEL 150 ENGINE 200/250 ENGINE

10.900 mm to
New — 10.700 mm (.4291
Supercharger spring washer package in to .4213 in)
height (not compressed)
10.200 mm (.4016
Wear Limit — in)
AIR INTAKE SYSTEM
Intake spark arrestor Tubular, wire screen
ENGINE COOLING SYSTEM
Type Closed loop cooling system
Ethylene-glycol and distilled water
(50%/50%). Use premix coolant from
Coolant BRP or a coolant specially formulated
for aluminum engines
Cooling system capacity 5.5 L (5.8 qt (U.S. liq.)) total

Thermostat 87°C (189°F)

Monitoring beeper setting 100°C (212°F)
EXHAUST SYSTEM
Water cooled/water injected (opened
Type
loop). Direct flow from jet pump
3 x 3.5 mm (.138 in) on exhaust pipe
Water injection in muffler
and 1 x 3.5 mm (.138 in) on muffler
ELECTRICAL SYSTEM

11

375
Technical Specifications
Technical Specifications Table

MODEL 150 ENGINE 200/250 ENGINE

F1: Unused —
F2: Battery 30 A
F3: Unused —
F4: CAPS 3A
F5: Unused —
F6: Starter solenoid 3A
F7: Unused —
F8: O2 Sensors (CAT only) 3A
F9: Cylinder 1 10 A
Fuse Box F10: Unused —
F11: Cylinder 2 10 A
F12: Unused —
F13: Cylinder 3 10 A
F14: Unused —
F15: Fuel pump 10 A
F16: Unused —
15 A (Unused on TWIN Engine Port
F17: Diagnostic tool
CAT & NON-CAT)
F18: Unused —
On SINGLE
Engine CAT +
F19: OBD-M 5A
TWIN engine Port
CAT Fuse box
On TWIN Engine
STBD CAT +
TWIN Engine F19: Neutral switch 5A
STBD NON-CAT
Fuse box
AA, AB, AF Models 360 W @ 6000
RPM
Magneto generator output
AG and Newer Models 550 W @ 6000
RPM
Stator 0.1 to 1.0 W
Not supplied. 12 V group 24, marine
Battery starting battery with top-mounted,
round taper type battery post
Ignition system type DI (Digital Inductive)

376
 Technical Specifications
Technical Specifications Table

MODEL 150 ENGINE 200/250 ENGINE

Ignition timing Variable (electronically controlled)
Make and Type NGK DCPR8E
Spark plug
Gap 0.7 mm to 0.8 mm (.028 in to .031 in)
Primary 0.85 to 1.15 W
Ignition coil
Secondary 9.5 to 13.5 KW
Engine RPM limiter setting 7750 RPM 8300 RPM
FUEL SYSTEM
Multipoint Fuel Injection with intelligent
Fuel injection type Throttle Control (iTC). Single throttle
body (60 mm) with an integrated
actuator
Fuel pressure 386 kPa to 414 kPa (56 PSI to 60 PSI)
Fuel injector Quantity 3
Type Unleaded gasoline
Inside North America: 87 (RON +
Octane rating (minimum) MON)/2 Outside North America: 92
RON
Fuel
Inside North
America: 91 (RON
Octane rating (optimum performance) — + MON)/2 Outside
North America: 95
RON
Idle speed 1750 ± 50 RPM (not adjustable)
PROPULSION SYSTEM
Type Axial flow single stage
Jet Pump
Grease Type Jet pump bearing grease, P/N 460785 11
Rotation (seen from rear) Counterclockwise
159 mm ± 0.06
Impeller 155 mm ± 0.06 mm (6.26 in ± .002
Outside diameter mm (6.102 in ± in) Only on 250
.002 in) SINGLE: 161mm
(6.339 in)

New 0 mm to 0.23 mm (0 in to .009 in)

Impeller/wear ring clearance
Wear limit 0.35 mm (.0138 in)
End play (new) 0
Impeller shaft
Side play 0

377
Technical Specifications
Technical Specifications Table

MODEL 150 ENGINE 200/250 ENGINE

Coupling type Crowned splines, direct drive
Drive shaft Deflection
0.5 mm (.02 in)
(maximum)
Steering nozzle pivoting angle 20°
90 cm (3 ft) underneath the lowest rear
Minimum required water level for propulsion system
portion of hull

378
 Electrical Connectors
General

Electrical Connectors
General
Wiring Diagram Location connector is written next to it, and may be accom-
The wiring diagrams are located at the back of this panied by the name of the component or system it
manual. is connected to (ex: C-223, FUEL LEVEL STBD).
The position of the connector terminals is identi-
Wiring Diagram Codes fied either by a number or a letter depending on
Wire Color Codes the connector. Usually, it is stamped/molded on
YL - BK the connector.

1 2
1. Wire main color
2. Tracer (thin colored line)

General Wire Color Use

COLOR USE
12 Vdc power (from
RED battery, not usually
switched or fused)
FUEL PUMP MODULE CONNECTOR
12 Vdc power (from 1. Terminal identification on the schematic

RED + tracer battery, not usually

switched or fused)
Continuous power
(when there is a
PURPLE programmed key on
Engine Cut-Off Switch)
Switched power (when
there is a programmed
PURPLE + tracer key on Engine Cut-Off
Switch)
Alternating current
YELLOW (AC) from magneto
1. Terminal identification on a connector 12
BLACK Ground
EFB, VCM And ECM Connectors
Switched ground (by
Engine Cut-Off Switch, EFB, VCM and ECM connectors are identified by
BLACK + tracer
ECM) letters (A, B or C) on the proper Electrical
Schematic.
WHITE / RED CAN HI wires The position of the terminals is identified by a
WHITE / BLACK CAN LO wires number for the ECM, and can be a letter or a num-
ber for the EFB and VCM. Usually, it is stamped/
Wiring Harness Connectors molded on the connector.
Connectors are identified on the appropriate Elec- Refer to the following table for examples.
trical Schematic. The identification code of the

379
Electrical Connectors
General

IDENTIFICATION
MODULE CODE CONNEC TERMI
TOR NAL
ECM A-A3 A 3
ECM A-B3 A B3
ECM B-5 B 5
ECM B-A3 B A3
EFB and
C-B C B
VCM

380
 Connector Information

Connector
Information

381
Connector Information

General
Deutsch Connectors Deutsch Connector Disconnect
Deutsch Connector Application 1. To disconnect a Deutsch connector, press the
release tab and twist a small flat screwdriver
A variety of Deutsch connectors are used on vari- between the male and female housing to dis-
ous systems: engage and disconnect the connector.
– Engine connector
– Magneto connector
The following procedures may be used on each as
they are similar in construction.

Deutsch Connector Removal From

Support
1. Insert a small flat screwdriver between the
sup-port and the Deutsch connector.
2. Pry the connector away from the support
slightly while sliding it out in the direction
shown.

1. Release tab
2. Deutsch connector

1. Insert screwdriver here

1. Deutsch connector
2. Press release button

1. Insert screwdriver here

382
 General

Figure 1. FEMALE CONNECTOR

1. Flat screwdriver
2. Deutsch connector

Deutsch Connector Disassembly And

Assembly
FEMAL E CONNECTO R
1. Female lock

Figure 2. MALE CONNECTOR

1. Male connector
2. Female connector
3. Secondary lock
4. Sealing cap

NOTICE
Do not apply dielectric grease on terminal in- MALE CONNECTOR
side connector. 1. Male connector

2. Push wire forward to relieve pressure on re-

Deutsch Connector Terminal Removal taining tab.
1. Using long nose pliers, pull out the secondary 3. Insert a 4.8 mm (.189 in) wide screwdriver
plastic lock from between the terminals. blade inside the front of the terminal cavity.
4. Pry the retaining tab away from the terminal
while gently pulling the wire and terminal out of
the back of the connector.

383
Connector Information

Figure 3. FEMALE CONNECTOR – VCM

– EFB

Three Pin Packard Connector

FEMALE CONNECTO R
1. Retaining tab
1. Identification letters
Deutsch Connector Terminal Insertion
1. For insertion of a terminal, ensure the secon- 1. To remove a terminal from a 3-pin Packard
dary plastic lock is removed. connector, use the Snap-On Terminal Remov-
2. Insert terminal through the back of the connec- er Tool, P/N TT600-4.
tor in the appropriate position, and push it in as
far as it will go. You should feel or hear the ter- REQUIRED TOOL
minal lock engage.
3. Pull back on the terminal wire to be sure the re- Snap-On Terminal
tention fingers are holding the terminal. Remover Tool
4. After all required terminals have been inserted,
P/N TT600–4
the lock must be installed.
2. Ensure all terminals are properly crimped on
wires and connectors are properly fastened.

Molex Connector
Molex Connector Application
The Molex connector is used on the Bosch ECM.
There are 2 MOLEX connectors on the ECM. The
engine wiring harness connector is connected to
ECM connector “A”. The vehicle wiring harness
connector is connected to ECM connector “B”.
Each ECM connector has 48 pins.

1. Terminal identification on a connector

Packard Connectors
Packard Connector Application
Packard connectors are used to connect:
– Electrical harnesses
– Gauges

384
 General

Figure 5. CONNECTOR LOCKING CAM

ROTATION TO RELEASE

Molex Connector Removal

1. Access the ECM.
2. Press and hold the locking tab on the connec-
tor to be disconnected.
Figure 4. LOCKING TAB TO PRESS AND CONNECTOR LOCKING CAM ROTATION TO RELEASE
HOLD
4. Pull the connector off of the ECM.

LOCKING TAB TO PRESS AND HOLD

Molex Connector Inspection
3. Hold the locking tab and rotate the connector
1. Ensure connector locking mechanism is func-
locking cam until it stops.
tioning properly.
2. Ensure all wire terminals (pins) are properly
locked in the connector.
3. Ensure they are very tight, make good contact
with the pins in the ECM.
4. Ensure the pins in the harness connector and
the ECM connector are clean, shiny and corro-
sion free.
5. Check wiring harness for signs of scoring.
6. A “defective ECM module” could possibly be
repaired simply by disconnecting and recon-
necting it.

385
Connector Information

NOTICE
Do not apply any lubricant product to the pins
of the ECM connector.

Molex Connector Installation

1. Fully open connector locking cam.
Figure 6. CONNECTOR LOCKING CAM
ROTATION TO RELEASE

Molex Connector Probing

The most recommended and safest method to
probe the Molex (ECM) connector terminals is to
use the ECM Adapter Tool, P/N 460762. This tool
will prevent deforming or enlarging of the termi-
nals, which would lead to bad ECM terminal con-
tact creating intermittent or permanent problems.
CONNECTOR LOCKING CAM ROTATION TO RELEASE

2. Insert connector on ECM.

3. Push the connector onto the ECM and rotate
the connector locking cam until it snaps
locked.

1. Disconnect the ECM connector to be probed

and install the ECM Adapter Tool, P/N 460762.

REQUIRED TOOLS

ECM Adapter Tool

P/N 460762

1. Locked here
2. Probe wire terminals of the circuit to be tested
4. Ensure the locking tab is fully out. directly in the adapter holes.

386
 General

1. ECM connector
2. ECM adapter

NOTICE
Never probe directly on the ECM harness 5. Insert tool to unlock terminal.
connector. This could change the shape or
enlarge the terminals and create intermittent
contact problems.

Molex Connector Terminal Removal

1. To remove a signal terminal from the ECM har-
ness connector, use the ECM Terminal Re-
mover 2.25, P/N 460766.

REQUIRED TOOLS

ECM Terminal Re-

mover 2.25
P/N 460766
1. Unlock here

ECM Terminal Re- 6. Gently pull on the wire to extract the terminal
mover 3.36 out the back of the connector.
P/N 460765

2. To remove a power terminal, use the ECM Ter-

minal Remover 3.36, P/N 460765.
3. Remove rear protector from connector.
4. Pull out the connector lock.

387
Connector Information

2. Release the pin in the front of the connector.

NOTICE
Before installing wire terminals in the con- 1. Unlock here
nector, ensure all terminals are properly
crimped on wires. After installation of wire 3. Gently pull on the wire to extract the pin out the
terminals in the connectors, ensure they are back of the connector.
properly locked by gently pulling on them as if
to extract them.

Delphi Connector
Delphi Connector Application
Delphi connectors come in various configurations.
They are used for the:
– Information center NOTICE
– TAS
Before installing wire terminals in the con-
– Starter solenoid
nector, ensure all terminals are properly
Delphi Connector Terminal Removal crimped on wires. After installation of wire
terminals in the connectors, ensure they are
Information Center Connector Removal properly locked by gently pulling on them as if
1. To remove a terminal from the connector, first to extract them.
remove the locking cap in the front of the
connector. TAS and Starter Solenoid Connector Removal
1. To remove a terminal (pin) from the connector,
use the Delphi Terminal Extractor, P/N
12094429.
REQUIRED TOOL

Delphi Terminal
Extractor
P/N 12094429

2. Grind the tool end to a taper.

3. Carefully insert the tool in the space provided
to release the pin lock.
4. Push the pin out the front of the connector by
1. Pry out locking cap pushing on the wire.

388
 General

1. Unlock terminal here

Furukawa Connector
Furukawa Connector Application
The Furukawa connector is found on the voltage
regulator/rectifier.

Furukawa Connector Terminal

Removal
1. Remove the secondary lock (plastic insert).

NOTICE
Before installing wire terminals in the con-
nector, ensure all terminals are properly
crimped on wires. After installation of wire
terminals in the connectors, ensure they are
properly locked by gently pulling on them as if
to extract them.

FCI Connector
FCI Connector Application
The FCI connector is used on the touch screen
displays.
1. Remove the secondary lock

REQUIRED TOOL

GM Terminal
Extractor
P/N 12094430

2. Carefully insert the GM Terminal Extractor, P/

N 12094430, between the lock and the pin to
release the pin.

389
Connector Information

1. 10 mm (3/8 in)

2. Make sure not to cut wire strands while strip-

ping the wire.
3. Install the appropriate terminal on the wire ac-
1. Insert GM extractor tool (P/N 12094430) cord-ng to the requirement.
3. Gently pull on the wire to extract the pin out the
Figure 7. INSTALLATION OF TERMINAL
back of the connector.

INSTALLATION OF TERMINAL

REQUIRED TOOL

Crimping Tool
(Heavy Gauge Wire)
1. Pull wire to extract pin
P/N 460725
NOTICE
Before installing wire terminals in the con- 4. Follow the instructions provided with the
nector, ensure all terminals are properly Crimping Tool (Heavy Gauge Wire), P/N
crimped on wires. After installation of wire 460725, to select the proper position of the
terminals in the connectors, ensure they are tool.
properly locked by gently pulling on them as if
to extract them.
N O T E : Different wires require different crimping
pliers settings.
Battery And Starter Cable
Terminals
Battery And Starter Cable Crimping
1. Carefully strip the wire approximately to 10 mm
(3/ 8 in) in length, using a wire stripping tool or
sharp blade/knife.

390
 General

NOTICE
Never weld the wire to the terminal. Welding
can change the property of the wire and it can
become brittle and break.

7. Install the protective heat shrink rubber tube on

the terminal.
8. Heat the heat shrink rubber tube using the heat
gun so that it grasps the wire and the terminal.
NOTICE
Make sure that the protective heat shrink rub-
ber tube has been properly installed and no
1. Press part of wire is exposed.
2. Rotate

5. After positioning the crimping pliers, crimp the

terminals already installed on the wire.
Figure 8. CRIMPING OF WIRE

CRIMPING OF WIRE

Figure 9. PROPERLY CRIMPED WIRE

PROPERL Y CRIM PED WIRE

6. To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at
the same time from both directions.

391
Notes

Notes Notes
Technician’s Notes Related Documents
Bulletins

Instruction Sheets

Other

392
 Index

Index

393
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