SeaDoo GTI - Exhaust System

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Section 05 ENGINE (4-TEC)

Subsection 03 (EXHAUST SYSTEM)

EXHAUST SYSTEM

F19D02S

6

Loctite

518

2

1

3

7

4

8

5

12

9

11

10

13

Sealant

Loctite

5150

High

temperature

RTV sealant

8

11 Nm

(97 lbfin)

smr2004-Complete Line Up 209

www.SeaDooManuals.net

Table of Contents

Default Chapter4
- Table of Contents4
Safety Notice15
Introduction16
- Hull Identification Number (H.I.n.)16
- Engine Identification Number (E.I.n.)17
- Arrangement of this Manual18
- List of Abbreviations Used in this Manual21
- General Information21
- Illustrations and Procedures22
- Engine Emissions Information22
- Self-Locking Fasteners Procedure23
- Loctite Application Procedure23
- Threadlocker23
- Stripped Thread Repair24
- Gasket Compound25
- Mounting on Shaft25
- Case-In Components26
- Tightening Torques27
Service Tools and Products28
- Mandatory Service Tools28
- Optional Service Tools36
- Service Products43
Maintenance47
- Periodic Inspection Chart47
- Flushing and Lubrication53
- Water-Flooded Engine59
  - General59
  - Procedure59
- Storage65
Troubleshooting75
- Troubleshooting Chart75
- Engine will Not Start75
- Engine Hard to Start78
- Engine Starts but Runs Only at Idle Speed78
- Engine Misfires, Runs Irregularly79
- Engine Continually Backfires81
- Engine Detonation or Pinging81
- Engine Lacks Acceleration or Power82
- Engine Stops Running83
- Engine Cannot Reach Maximum Rpm83
- Engine Runs too Fast (Vehicle Cannot Reach Its Top Speed)84
- Engine Overheats84
- System Faults (Gtx 4-Tec Models)85
- Engine Smoke in the Exhaust (4-Tec Series)85
- Low or no Engine Oil Pressure (4-Tec Series)86
- Engine Oil Contamination (Milky) (4-Tec Series)86
- Unusual Engine Noise And/Or Vibration (4-Tec Series)87
- Abnormal Noise from Propulsion System87
Engine (2-Stroke)88
- Leak Test88
- Removal and Installation96
- Magneto System107
- Top End122
- Bottom End151
- Rotary Valve175
- Exhaust System186
Engine (4-Tec)202
- Leak Test202
  - Leak Test Procedure202
  - Leak Test Procedure for Intercooler205
- Intake System206
- Exhaust System229
- Removal and Installation236
- Pto Housing/Magneto243
- Lubrication System253
- Cylinder Head and Valves272
- Engine Block289
Engine Management (Rfi)312
- Overview312
- Diagnostic Procedures317
- Component Inspection321
- Troubleshooting Summary332
- Adjustment334
  - Throttle Cable Adjustment334
  - Throttle Position Sensor (Tps)334
    - Closed Tps334
    - Idle Speed334
- Removal and Installation335
Engine Management (DI)338
- Overview338
- Component Inspection and Adjustment346
- Diagnostic Procedures387
Engine Management (4-Tec)400
- Overview400
- Component Inspection and Adjustment412
- Diagnostic Procedures448
Cooling System475
- Circuit, Components and Care475
- Circuit481
- Components484
- Care488
- Circuit496
- Cooling System Leak Test496
- Inspection498
- Draining the System498
- Cleaning498
- Coolant Replacement499
- Coolant Pump Housing500
- Thermostat501
- Coolant Pump Impeller502
- Rotary Seal502
- Care504
Fuel System507
- Fuel Circuit507
- Air Intake (2-Stroke)519
- Carburetor526
Lubrication System (2-Stroke)535
- Oil Injection System535
  - General537
  - Oil System Pressurization537
- Oil Injection Pump538
Electrical System547
- Ignition System547
- Charging System562
  - General562
  - Testing Procedure565
- Starting System577
- Instruments and Accessories592
- Dess (Carbureted and Rfi Engines)610
  - General610
  - Dess Key Programming612
Propulsion615
- Jet Pump615
- Drive System653
- Variable Trim System679
Steering System685
- 1 Steeringsystem687
- Alignment709
Suspension711
- Direct Action Suspension711
- Removal712
- Inspection713
- Assembly714
Hull/Body715
- Adjustment and Repair715
- General733
- Glove Box733
- Engine Cover735
- Seat Adjustment736
- Storage Compartment Inner Shell737
- Storage Cover Shock744
- Storage Compartment Cover Adjustment745
- Access Panel Adjustment746
- Mirror746
- Info Center (Lcd Gauge)747
- Deflector And/Or Upper Grid747
- Finition Plate748
- Inlet Grate748
- Riding Plate749
- Jet Pump Support750
- Drain Plug Installation751
- Seat Removal752
- Seat Cover Replacement753
- Bumper Replacement753
- Wake Pylon754
- Sponson Replacement756
- Engine Compartment Cover Removal756
- Decals Replacement757
- Hull and Body Repair758
- Tools and Materials List760
- Thru-Hull Fitting Installation761
Technical Data762
- Gti and Gti Le Models762
- Gti Rfi and Gti Le Rfi Models765
- Xp DI Model768
- Rxp 4-Tec Models772
- Gtx 4-Tec Models778
Wiring Diagram784
Wiring Diagrams784
- Wire Color Codes784
- Wire Digit Codes784
- Deutsch Connectors784
- Packard Connector787
- Amp Plug Connector787
- Identification of Connector Pins790
- Ecm Connectors791
- Main Fuse Holder Joint Connector794

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