2006 Seadoo 4-Tec Series Shop Manual – PDF DOWNLOAD
DESCRIPTION:
2006 Seadoo 4-Tec Series Shop Manual – PDF DOWNLOAD
This manual has been prepared as a guide to correctly service and repair 2006 SEA—DOC watercraft as described in the model list of the INTRODUCTION. This edition was primarily published to be used by watercraft mechanical technicians who are already familiar with all service procedures relating to BRP made watercraft.
- Mechanical technicians should attend training courses given by BRP Training Dept. Please note that the instructions will apply only if proper hand tools and special service tools are used. it is understood that this manual may be translated into another language. In the event of any discrepan— 3y, the English version shall prevail.
- The content depicts parts and/or procedures applicable to the particular product at time of writing. Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these.
- ln addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas at the parts. The use of BRP parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. The engines and the corresponding components identified in this document should not be utilized on aroduct(s) other than those mentioned in this document.
TABLE OF CONTENTS:
2006 Seadoo 4-Tec Series Shop Manual – PDF DOWNLOAD
SAFETY NOTICE VIII
INTRODUCTION IX
GENERAL INFORMATION IX
HULL IDENTIFICATION NUMBER (H I N ) IX
ENGINE IDENTIFICATION NUMBER (E I N ) X
ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES X
ENGINE EMISSIONS INFORMATION XIV
WORKING ON WATERCRAFT XIV
SELF·LOCKING FASTENERS PROCEDURE XIV
LOCTITE APPLICATION PROCEDURE XV
TIGHTENING TORQUES XIX
01 MAINTENANCE
01 – MAINTENANCE CHART 1
02 – PRESEASON PREPARATION , 3
03 – STORAGE PROCEDURES 5
PROPULSION SYSTEM 5
FUEL SYSTEM 5
ENGINE 6
ELECTRICAL SYSTEM 7
VEHICLE , 7
CHECKLIST 8
04 – SPECIAL PROCEDURES 9
TOWING THE WATERCRAFT IN WATER
SUBMERGED WATERCRAFT
WATER FLOODED ENGINE 10
02 TROUBLESHOOTING
01 – TROUBLESHOOTING CHART 13
ENGINE
STARTING SYSTEM ,
ELECTRICAL SYSTEM ,
PROPULSION , , 24
STEERING SYSTEM , 24
03 ENGINE
01 – ENGINE REMOVAL AND INSTALLATION 25
GENERAL 25
PROCEDURES 25
ENGINE REM OVAL 25
CLEANING , 29
INSTALLATION , 29
ENGINE ALIGNMENT ,, , 29
02 – ENGINE LEAK TEST 33
PREPARATION , 33
PROCEDURE 34
03 – AIR INTAKE SYSTEM 37
INSPECTION
REMOVAL
INSTALLATION 40
04 – INTAKE MANIFOLD AND INTERCOOLER 41
PROCEDURES 45
INTAKE MANIFOLD 45
INTERCOOLER 50
05- SUPERCHARGER 53
INSPECTION(SUPERCHARGER INSTALLED) , 55
REMOVAL
DISASSEMBLY
PARTS INSPECTION
ASSEMBLY
INSTALLATION 64
06- EXHAUST SYSTEM 67
GENERAL 69
EXHAUST SYSTEM COOLING , , 69
MAINTENANCE 72
EXHAUST SYSTEM FLUSHING , , , 72
PROCEDURES 74
EXHAUST PIPE , , , 74
EXHAUST MAN !FOLD , , , 77
MUFFLER , 78
RESONATOR 78
EXHAUST OUTL::T , 79
07 – PTO HOUSING AND MAGNETO 81
GENERAL 83
PROCEDURES 83
PTO HOUSING , , 83
PTO SEAL ” , , , 86
COUPLING , , , , , , 86
STATOR , , , , 87
ROTOR AND TRIGGER WHEEL , , , 88
RING GEAR , 89
STARTER DRIVE , 90
OIL SPRAY NOZZLE , , , 91
08 – LUBRICATION SYSTEM 93
MAINTENANCE 96
OIL LEVEL VERIFICATION , , 96
OIL CHANGE 96
OIL FILTER 97
INSPECTION 98
ENGINE OIL PRESSURE 98
PROCEDURES 99
PTO OIL STRAINER 99
SUCTION PUMP OIL STRAINER 100
ENGINE OIL PRESSURE REGULATOR 102
OIL PRESSURE PUMP 102
OIL SUCTION PUMP
OIL SEPARATOR COVER
TOPS VALVE 110
OIL COOLER 111
09 – COOLING SYSTEM 113
GENERAL 116
CIRCUIT 116
TECHNICAL SPECI FICATIONS 116
INSPECTION , 116
PRESSURE CAP 116
HOSES AND CLAMPS , 116
COOLING SYSTEM LEAK TEST 116
MAINTENANCE 117
COOLANT REPLACEMENT 117
PROCEDURES 119
www SeaDooManuals net
TABLE OF CONTENTS
CLAMPS 119
WATER PUMP HOUSING 120
WATER PUMP IMPELLER 121
THERMOSTAT 121
ROTARY SEAL 122
10 – CYLINDER HEAD 125
GENERAL 127
PROCEDURES 127
EXHAUST MANIFOLD ,
VALVE COVER
ROCKER ARM
CAMSHAFT TIMING GEAR 131
TIMING CHAIN 132
CYLINDER HEAD 132
CAMSHAFT 134
VALVE SPRING 135
VALVE 137
11 – CYLINDER BLOCK 143
GENERAL 146
PROCEDURES 146
TIMING CHAIN , , · , 146
CHAIN TENSIONER
PISTON/CONNECllNG ROD
PISTON RINGS
CRANKSHAFT
BALANCER SHAFT
CYLINDER BLOCK
04 ENGINE MANAGEMENT (1503 4~TEC)
01 – OVERVIEW 165
GENERAL 166
OPERATING PRINCIPLE 166
AIR INDUCTION 166
FUEL SYSTEM
ELECTRICAL SYSTEM
ENGINE MANAGEMENT SYSTEM (EMS)
ELECTRONIC FUEL INJECTION
IGNITION SYSTEM
ENGINE MODES OF OPERATION
MONITORING SYSTEM
DIAGNOSTIC MODE
ENGINE MANAGEMENT SYSTEM DIAGRAM
02 – EMS DIAGNOSTIC AND COMMUNICATION TOOLS
GENERAL
DIAGNOSTIC
MONITORING SYSTEM
FAULT CODES 177
COMMUNICATION TOOLS 179
MPI MULTI-PURPOSE INTERFACE! , 179
MPl-2 !MULTI-PURPOSE INTERFACE) 181
B U D S SOFTWARE 182
03 – ADJUSTMENT AND REPAIR PROCEDURES 185
GENERAL 185
FUEL SYSTEM
ELECTRICAL SYSTEM
BASIC ADJUSTMENTS
TABLE OF CONTENTS
IDLE SPEED 197
THROTTLE CABLE 191
CLOSED THROTTLE AND IDLE ACTUATOR RESET 192
IGNITION TIMING 192
REPAIR PROCEDURES 192
ENGINE CONTROL MODULE IECM) 192
MULTI-PURPOSE ELECTRONIC MODULE (MPEM) 193
FUEL INJECTOR 194
THROTTLE BODY ,, ,, 196
THROTTLE POSITION SENSOR (TPS) , ·· ·· 197
IDLE BYPASS VALVE 199
CRANKSHAFT POSITION SENSOR (CPSI , , 199
CAMSHAFT POSITION SENSOR (CAPS) 200
MANIFOLD AIR TEMPERATURE SENSOR (MATS) 201
COOLANT TEMPERATURE SENSOR (CTS) 202
MANIFOLD AIR PRESSURE SENSOR !MAPS) , 202
EXHAUST GAS TEMPERATURE SENSOR (EGTS) 203
KNOCK SENSOR (KS) 204
OIL PRESSURE SENSOR !OPS) 204
TOPS SWITCH 205
05 FUEL SYSTEM
01 – FUEL TANK AND FUEL PUMP 207
GENERAL 209
INSPECTION 209
FUEL SYSTEM LEAK TEST 209
FUEL PUMP PRESSURE TEST 211
PROCEDURES 212
FUEL HOSES AND OETIKER CLAMPS 212
FUEL FILTER 213
FUEL TANK 213
FUEL PUMP 215
06 ELECTRICAL SYSTEM
IV
01 – IGNITION SYSTEM 219
GENERAL 221
PROCEDURES 221
IGNITION COIL
SPARK PLUGS
02 – CHARGING SYSTEM
GENERAL
TESTING PROCEDURE
RECTIFIER/REGULATOR
STATOR
BATTERY
03 – STARTING SYSTEM
GENERAL
TEST
ELECTRICAL CABLES OR CONNECTIONS
FUSE
ENGINE CONTROL MODULE (ECM)
ENGINE START/STOP SWITCH
SOLENOID
PARTS REPLACEMENT
STARTER
STARTER GEAR
04- DIGITALLY ENCODED SECURITY SYSTEM (DESS) 245
GENERAL ···– –· · – 245
KEY PROGRAMMING 246
TROUBLESHOOTING _ ·–· –·- – 247
05 – GAUGE SENSORS AND FUSES 249
GENERAL 249
FUSES _ _ 250
INFORMATION CENTER 252
PROCEDURES 254
INFORMATION CENTER
FUEL BAFFLE PICK-UP SENDER
WATER TEMPERATURE SENSOR
COMPASS
SPEED SENSOR
DEPTH GAUGE
07 PROPULSION
01 – JET PUMP 259
GENERAL 262
INSPECTION 262
IMPELLER CONDITION 262
IMPELLER EAR RING CLEARANCE _ 262
Ll”AK TEST 262
PROCEDURES 263
SACRIFICIAL ANODE ,
VENTURI
JET PUMP HOUSING
IMPELLER COVER
IMPELLER
WEAR RING
IMPELLER SHAFT AND BEARING -· 270
02 – DRIVE SYSTEM 275
GENERAL 2n
MAINTENANCE 277
CORROSION PROTECTION 277
PROCEDURES 277
DRIVE SHAFT
BOOT
CARBON RII\G 284
03 – REVERSE SYSTEM 285
GENERAL 287
PROCEDURES 287
REVERSE CABLE 287
REVERSE CABLE LEVER 288
SHIFT LEVER
REVERSE CABLE SUPPORT
SHIFT LEVER HOUSING 290
REVERSE GATE _ 291
PIVOT SUPPORT 291
LINK ROD 291
PIVOT TRIANGLE _ 292
PIVOT ARM 292
04 – VARIABLE TRIM SYSTEM 293
GENERAL 295
TEST 295
SWITCH 295
TABLE OF CONTENTS
MOTOR 295
CONTROL MODULE 295
PROCEDURES 295
CONTROL MODULE AND MOTOR 295
08 STEERING SYSTEM
01 – STEERING SYSTEM 299
GENERAL 301
ADJUSTMENT 301
STEERING ALIGNMENT 301
PROCEDURES 302
NOZZLE
HANDLEBAR GRIP ····-
STEERING COVER
STEERING PADDING
HANDLEBAR
STEERING CABLE SUPPORT
STEERING SUPPORT
STEERING STEM 308
HANDLEBAR SUPPORT 308
STEERING CABLE 309
02 – OFF-POWER ASSISTED STEERING (0 P A S ) 311
GENERAL 314
PROCEDURES 314
FILTER
VALVE
WATER HOSE
SIDE VANE
CYLINDER SUPPORT
TIE ROD
SEALED TUBE
CROSS SUPPORT PLATE , ,
09 HULL JBODY
01 – ADJUSTMENT AND REPAIR 323
GENERAL 340
PARTS REPLACEMENT 340
DECALS
GLOVE BOX ,
SEAT
REMOVABLE SEAT COWLING
SEAT COVER
SEAT LATCH , , , , , 344
ENGINE COVER , 345
STORAGE COMPARTMENT COVER 345
STORAGE COMPARTMENT COVER HINGE
STORAGE COMPARTMENT COVER SHOCK
STORAGE COMPARTMENT COVER LATCH 348
STORAGE COMPARTMENT COVER INNER SHELL , 348
FRONT GRILL OF COMPARTMENT COVER 351
ACCESS COVER 352
CONSOLE , 352
MIRROR
DEFLECTOR AND/OR UPPER GRID
SIDE MOLDING
INLETGRATE
RIDING PLATE , 356
JET PUMP SUPPORT 357
THAU-HULL FITTING 358
BUMPER , , 359
WAKE PYLON , , 359
SPONSON 360
SPONSON ADAPTOR 361
DRAIN PLUG 361
CARPET 362
CLEANING 362
SEAT , 362
BODY AND HULL , , , , 363
CARPET 363
REPAIR , 363
HULL AND BODY
TOOLS AND MATERIALS LIST
10 TECHNICAL SPECIFICATIONS
01 – GTI AND GTI SE 367
02 – GTX AND GTX WAKE 373
03 – GTX SUPERCHARGED AND GTX LIMITED 379
04 – RXP AND RXT MODELS 385
11 ELECTRICAL CONNECTORS AND WIRING DIAGRAM
01 – ELECTRICAL CONNECTORS 391
DEI JTSCH CONNECTORS
PACKARD CONNECTOR
AMP CONNECTOR
ECM CONNECORS
BATTERY AND STARTER CABLE TERMINALS 400
02 – WIRING DIAGRAM 403
WIRE COLOR CODES
WIRE DIGIT CODES
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