Section 04 ENGINE (2-STROKE)
Subsection 01 (LEAK TEST)
LEAK TEST
GENERAL
A Sea-Doo Engine Leak Test Kit (P/N 295 500
352) and Supplementary Engine Leak Test Kit
(P/N 295 500 780) are available to help diagnose
engine problems such as engine seizure, poor
performance, oil leakage, etc.
Before disassembling any components of the en-
gine, it is important to perform a leakage test to
determine which part is defective.
It is also very important after servicing the engine,
even for a complete engine rebuilt, to perform an-
other leakage test; at this stage, it may avoid fur-
ther engine problems and minimizing the risk of
having to remove and reinstall the engine again.
Static bench testing is the most effective way to
conduct a leakage test. Inboard testing does not
allow complete access to, and observation of all
engine surfaces and should be avoided whenever
possible.
On the 717 engine, cylinders can not be verified
individually due to leakage from one cylinder to
another through a common intake manifold.
When installing hoses of the Engine Leak Test Kit
or Supplementary Engine Leak Test Kit, use the
collars provided in the kit to ensure a proper seal-
ing.
When pressurizing the engine, first confirm that
the components of the Engine Leak Test Kit or
Supplementary Engine Leak Test Kit are not leak-
ing by spraying a solution of soapy water on all
hoses, connections, fittings, plates, etc. If there
is a leak, bubbles will indicate leak location.
Three areas of the engine will be tested in se-
quence as per the diagnostic flow chart (see the
end of this subsection).
1) Engine Cooling System.
2) Bottom End and Top End.
3) Rotary Valve Shaft (except DI engine).
NOTE: If a leak is found, it is important to continue
testing as there is the possibility of having more
than one leak. Continue pumping to compensate
fortheairlosttofindanotherleak.
PREPARATION
Verify fuel system for leaks.
WARNING
If any fuel leak is found, do not start the en-
gine. Correct the leak and wipe off any fuel
spillage. Do not use electric powered tools
unless fuel system has passed pressure test.
Disconnect battery BLACK negative cable.
WARNING
Always disconnect battery cables in the spec-
ified order, BLACK negative cable first.
Disconnect battery RED positive cable.
TESTING PROCEDURE
Engine Cooling System
Remove the tuned pipe. Refer to EXHAUST SYS-
TEM.
Remove the exhaust manifold gasket and ensure
the surface is clean.
Disconnect engine cooling hoses.
Install the appropriate exhaust manifold plate from
the Engine Leak Test Kit (P/N 295 500 352) or
Supplementary Engine Leak Test Kit (P/N 295 500
780). Tighten plate using fasteners provided in the
kit.
NOTE: Do not torque plate excessively.
Install a hose pincher on engine drain hose.
Use hoses provided in the kit and install them on
the engine.
Install pump using reducer and appropriate tube(s)
as necessary.
smr2004-Complete Line Up 63
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