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SeaDoo
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SeaDoo GTI User Manual
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4-TEC
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22 Nm
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16
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4 Nm
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Up
www.SeaDooManuals.net
511
513
Table of Contents
Default Chapter
4
Table of Contents
4
Safety Notice
15
Introduction
16
Hull Identification Number (H.I.n.)
16
Engine Identification Number (E.I.n.)
17
Arrangement of this Manual
18
List of Abbreviations Used in this Manual
21
General Information
21
Illustrations and Procedures
22
Engine Emissions Information
22
Self-Locking Fasteners Procedure
23
Loctite Application Procedure
23
Threadlocker
23
Stripped Thread Repair
24
Gasket Compound
25
Mounting on Shaft
25
Case-In Components
26
Tightening Torques
27
Service Tools and Products
28
Mandatory Service Tools
28
Engine
28
Cooling/Fuel/Oil Systems
32
Propulsion System
33
Steering System
35
Optional Service Tools
36
Engine
36
Cooling/Fuel/Oil Systems
41
Propulsion System
41
Body
42
Watercraft Handling
42
Service Products
43
Maintenance
47
Periodic Inspection Chart
47
Flushing and Lubrication
53
General
53
Procedure
53
Anticorrosion Treatment
58
Water-Flooded Engine
59
General
59
Procedure
59
Storage
65
Engine Draining
65
Propulsion System
66
Fuel System
67
Engine Oil Change and Filter
67
Cooling System Flushing and Engine Internal Lubrication
67
Engine Lubrication
67
Battery
68
Watercraft Cleaning
68
Additional Recommended Protection
68
Anticorrosion Treatment
74
Checklist
74
Troubleshooting
75
Troubleshooting Chart
75
Engine will Not Start
75
Engine Hard to Start
78
Engine Starts but Runs Only at Idle Speed
78
Engine Misfires, Runs Irregularly
79
Engine Continually Backfires
81
Engine Detonation or Pinging
81
Engine Lacks Acceleration or Power
82
Engine Stops Running
83
Engine Cannot Reach Maximum Rpm
83
Engine Runs too Fast (Vehicle Cannot Reach Its Top Speed)
84
Engine Overheats
84
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 System
87
Engine (2-Stroke)
88
Leak Test
88
General
88
Preparation
88
Testing Procedure
88
Engine Leakage Diagnostic Flow Chart
94
Removal and Installation
96
General
96
Engine Removal
96
Cleaning
101
Installation
101
Magneto System
107
Disassembly
110
Cleaning
117
Assembly
117
Top End
122
General
125
Disassembly
127
Cleaning
134
Inspection
135
Used Piston Measurement
136
Assembly
139
Adjustment
148
Bottom End
151
Disassembly
154
Cleaning
161
Inspection
162
Assembly
166
Rotary Valve
175
General
176
Inspection on Watercraft
176
Disassembly
177
Cleaning
179
Inspection
179
Assembly
180
Rotary Valve Timing
184
Exhaust System
186
Removal
189
Tuned Pipe Repair
195
Installation
195
Engine (4-Tec)
202
Leak Test
202
Leak Test Procedure
202
Preparation
202
Procedure
203
Installation
204
Leak Test Procedure for Intercooler
205
Intake System
206
Inspection
210
Removal
212
Disassembly
219
Assembly
222
Installation
226
Exhaust System
229
Exhaust Pipe
230
Exhaust Manifold
233
Muffler
234
Resonator
234
Exhaust Outlet
235
Removal and Installation
236
General
236
Engine Removal
236
Cleaning
240
Installation
240
Pto Housing/Magneto
243
General
244
Pto Housing
244
Pto Seal
247
Coupling
247
Stator
248
Rotor and Encoder Wheel
249
Ring Gear
249
Starter Drive Ass'y
250
Oil Spray Nozzle
251
Lubrication System
253
General
255
Oil Level Verification
255
Engine Oil Pressure Test
256
Oil Filter
258
Oil Strainers
259
Engine Oil Pressure Regulator
262
Oil Pressure Pump
263
Oil Suction Pump
266
Oil Cooler
269
Oil Separator
270
Cylinder Head and Valves
272
General
273
Spark Plug
273
Valve Cover
273
Rocker Arm
274
Camshaft Timing Gear
277
Timing Chain
279
Cylinder Head
279
Camshaft
280
Valve Spring
282
Valve
283
Engine Block
289
General
291
Crankshaft Locking
291
Crankshaft
291
Timing Chain
295
Chain Tensioner
296
Balancer Shaft
296
Engine Block
299
Piston/Connecting Rod
304
Piston Rings
310
Engine Management (Rfi)
312
Overview
312
Air Induction
313
Fuel Delivery
313
Fuel Pump
313
Fuel Pressure Regulator
313
Fuel Filters
313
Fuel Pump Module
314
Fuel Injectors
314
Electronic Management
314
Electronic Control Unit (Ecu)
314
Mpem (Multi-Purpose Electronic Module)
315
Diagnostic Procedures
317
Introduction
317
Self-Diagnostic Mode
317
Advanced Diagnostic
317
Fault Code Tables
319
Output Signal Faults
320
Component Inspection
321
General
321
Air Induction System
323
Throttle Body
323
Fuel Delivery
323
Fuel Filter
323
Fuel Pump
323
Regulator
323
Fuel Injector
324
Leak Test (Supply and Ventilation Circuits)
325
High Pressure Test (Fuel Pump Circuit)
325
Electronic Management
326
Throttle Position Sensor (Tps)
326
Crankshaft Position Sensor (Cps)
327
Air Temperature Sensor (Ats)
328
Water Temperature Sensor (Wts)
328
Air Pressure Sensor (Aps)
329
Rave Solenoid
330
Rfi Sensors Resistance Values
331
Troubleshooting Summary
332
Engine Does Not Start
332
Flooded Engine Feature
332
Spark Plug Inspection
332
Ecu Fault Codes
332
Engine Starts but Runs Poorly
332
Engine Runs Only on One Cylinder
332
Engine Cannot Reach Maximum Revolutions
333
Adjustment
334
Throttle Cable Adjustment
334
Throttle Position Sensor (Tps)
334
Closed Tps
334
Idle Speed
334
Removal and Installation
335
Mpem/Ecu
335
Throttle Position Sensor (Tps)
335
Air Temperature Sensor (Ats)
335
Air Pressure Sensor (Aps)
335
Water Temperature Sensor (Wts)
335
Crankshaft Position Sensor (Cps)
335
Fuel Pump Assembly
335
Regulator
336
Fuel Filter
336
Fuel Injectors
336
Engine Management (DI)
338
Overview
338
Operating Principle
338
Air Induction
338
Air Compressor System
338
Fuel Delivery System
338
Basic Operation
338
Air/Fuel Rail Assembly
339
Fuel Pump Module
339
Electronic Management
340
Mpem (Multi-Purpose Electronic Module)
340
Mpem - Engine Management Functions
343
Ignition System
345
Component Inspection and Adjustment
346
General
346
Fuel System
346
Electrical System
347
Amp Connector Pin-Out
348
Quick Fuel Pressure Test
348
Air Induction System
350
Throttle Body
350
Air Compressor
353
Pressure Test
353
Repair
354
Fuel Delivery
357
Fuel Pressure Regulator
357
Fuel Injector
359
Air/Fuel Rail
360
Direct Injector
361
Fuel Pump
363
Fuel Filters
365
Electronic Management
368
Mpem Replacement
368
Throttle Position Sensor (Tps)
369
Crankshaft Position Sensor (Cps)
371
Manifold Air Temperature Sensor (Mats)
373
Water Temperature Sensor (Wts)
373
Manifold Air Pressure Sensor (Maps)
374
Exhaust Gas Temperature Sensor (Egts)
375
Knock Sensor (Ks)
375
Rave Solenoid
376
Ignition Coil
377
Ignition Timing
379
Spark Plugs
383
Cranking System
384
DI System Test Summary
384
Diagnostic Procedures
387
General
387
Fault Detection and Compensatory Actions
389
Component Failure Warning System
389
Vck (Vehicle Communication Kit)
391
DI System Fault Codes
392
Engine Management (4-Tec)
400
Overview
400
Complete Electrical System Overview
400
Magneto System and Power Supply
402
Operating Principle of Engine Management
402
Air Induction
402
Fuel Delivery System
403
Basic Operation
403
Fuel Pump Module
405
Electronic Management
405
Ems (Engine Management System)
405
Ems - General Functions
406
Ems - Engine Management Functions
408
Mpem - Multi-Purpose Electronic Module
411
Component Inspection and Adjustment
412
General
412
Fuel System
412
Electrical System
413
Engine Connector Pin-Out
414
Connectors on Engine
415
Air Induction System
416
Throttle Body
416
Fuel Delivery
420
Fuel Pump
421
Fuel Filter
423
Fuel Rail
423
Fuel Injector
424
Electronic Management
426
Ecm and Mpem Replacement
426
Engine Wiring Harness
428
Throttle Position Sensor (Tps)
430
Idle Bypass Valve
432
Crankshaft Position Sensor (Cps)
433
Camshaft Position Sensor (Caps)
434
Manifold Air Temperature Sensor (Mats)
435
Coolant Temperature Sensor (Cts)
436
Manifold Air Pressure Sensor (Maps)
437
Exhaust Gas Temperature Sensor (Egts)
438
Knock Sensor (Ks)
438
Oil Pressure Sensor (Ops)
440
Oil Separator Pressure Sensor (Osps)
440
Tops Valve (Blow-By)
442
Ignition Coils
445
Ignition Timing
446
Engine Start/Stop Switch Verification
446
Safety Lanyard Switch Verification
446
Spark Plugs
447
Cranking System
447
Diagnostic Procedures
448
General
448
Self-Diagnostic Mode
450
Vck (Vehicle Communication Kit)
452
4-Tec System Fault Codes
453
4-Tec System Fault Codes Chart
456
Burnt Fuse and Related Fault Code
474
Cooling System
475
Circuit, Components and Care
475
Circuit
481
Components
484
Care
488
Circuit
496
Cooling System Leak Test
496
Inspection
498
Draining the System
498
Cleaning
498
Coolant Replacement
499
Coolant Pump Housing
500
Thermostat
501
Coolant Pump Impeller
502
Rotary Seal
502
Care
504
Fuel System
507
Fuel Circuit
507
General
513
Removal
514
Inspection
516
Assembly
517
Fuel System Pressurization
517
Air Intake (2-Stroke)
519
General
521
Removal
521
Assembly
522
Removal
524
Assembly
525
Carburetor
526
General
527
Removal
527
Cleaning
527
Disassembly and Inspection
528
Assembly
530
Installation
532
Adjustments
532
Lubrication System (2-Stroke)
535
Oil Injection System
535
General
537
Oil System Pressurization
537
Oil Injection Pump
538
Oil Pump Identification
541
Removal
541
Disassembly
541
Cleaning
541
Assembly
541
Adjustment
543
Checking Operation
546
Electrical System
547
Ignition System
547
General
547
Multi-Purpose Electronic Module (Mpem)
548
Ignition Timing
548
Procedure
556
Spark Plugs
559
Spark Plug Chart
560
Charging System
562
General
562
Testing Procedure
565
Battery
569
Battery Storage
571
Cable Terminal Installation
575
Starting System
577
General
580
Starting System Troubleshooting
581
Starter Removal
582
Starter Disassembly
582
Cleaning
586
Parts Inspection
586
Starter Assembly
587
Starter Installation
589
Starter Specification
591
Instruments and Accessories
592
General
592
Power Supply Cut-Off Relay Verification
592
Multi-Purpose Electronic Module (Mpem)
592
Information Center
593
Addition of Electrical Accessories
601
Inspection
601
Dess (Carbureted and Rfi Engines)
610
General
610
Dess Key Programming
612
Propulsion
615
Jet Pump
615
General
616
Jet Pump Inspection on Watercraft
616
Removal
618
Disassembly
620
Cleaning
622
Parts Inspection
623
Assembly
625
Pump Pressurization
633
Installation
633
General
637
Jet Pump Inspection on Watercraft
637
Removal
638
Pump Assembly
638
Reverse Gate
639
Disassembly
641
Cleaning
644
Parts Inspection
644
Assembly
646
Pump Pressurization
649
Installation
650
Drive System
653
General
656
Removal
656
Inspection
663
Assembly
665
Installation
666
Lubrication
673
Reverse System
675
Disassembly
676
Shift Lever
677
Inspection
678
Assembly
678
Adjustment
678
Variable Trim System
679
General
681
Removal
681
Disassembly
681
Inspection
682
Assembly
682
Installation
683
Adjustment
683
Steering System
685
1 Steeringsystem
687
Disassembly
687
Assembly
692
Disassembly
697
Assembly
700
Off-Power Assisted Steering System (O.p.a.s.)
702
General
703
Side Vane
703
Cylinder Support
704
Tie Rod
705
Sealed Tube
706
Filter
706
Valve
707
Water Hose
707
Cross Support Plate
708
Alignment
709
Suspension
711
Direct Action Suspension
711
Removal
712
Inspection
713
Assembly
714
Hull/Body
715
Adjustment and Repair
715
General
733
Glove Box
733
Engine Cover
735
Seat Adjustment
736
Storage Compartment Inner Shell
737
Storage Cover Shock
744
Storage Compartment Cover Adjustment
745
Access Panel Adjustment
746
Mirror
746
Info Center (Lcd Gauge)
747
Deflector And/Or Upper Grid
747
Finition Plate
748
Inlet Grate
748
Riding Plate
749
Jet Pump Support
750
Drain Plug Installation
751
Seat Removal
752
Seat Cover Replacement
753
Bumper Replacement
753
Wake Pylon
754
Sponson Replacement
756
Engine Compartment Cover Removal
756
Decals Replacement
757
Hull and Body Repair
758
Tools and Materials List
760
Thru-Hull Fitting Installation
761
Technical Data
762
Gti and Gti Le Models
762
Gti Rfi and Gti Le Rfi Models
765
Xp DI Model
768
Rxp 4-Tec Models
772
Gtx 4-Tec Models
778
Wiring Diagram
784
Wiring Diagrams
784
Wire Color Codes
784
Wire Digit Codes
784
Deutsch Connectors
784
Packard Connector
787
Amp Plug Connector
787
Identification of Connector Pins
790
Ecm Connectors
791
Main Fuse Holder Joint Connector
794
5
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SeaDoo GTI Specifications
General
Seating Capacity
3
Manufacturer
Sea-Doo
Fuel Type
Gasoline
Fuel Capacity
15.9 gallons
Type
Recreational
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