2009 Shop Manual RXT ® iS™255 GTX LIMITED iS™255
Bombardier Recreational Products Inc. (BRP) · Sea-Doo RXT iS255 GTX LIMITED · 555 стр.
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Legal deposit: National Library of Quebec National Library of Canada 2009 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) © Bombardier Recreational Products Inc. (BRP) 2009 Printed in Canada Technical Publications Bombardier Recreational Products Inc. (BRP) Valcourt (Quebec) Canada ®™Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates. 4-TEC iTC™ Sea-Doo ® D.E.S.S. O.T.A.S. Sea-Doo ® Learning Key™ iBR™ Rotax ® VTS™(Variable Trim System) iControl™ RXT ® XPS This document contains the trademarks of the following companies:
AMP ® is a trademark of Tyco Electronics Corporation Gelcote ® is a trademark of Gelcote International Limited GTX is a trademark of Castrol Ltd. Used under license Loctite ® is a trademark of Loctite Corporation Molykote ® is a trademark of Dow Corning Corporation Snap-on ® is a trademark of Snap-on Tools Corporation Spray-Nine ® is a trademark of Korkay System Ltd
TABLE OF CONTENTS SAFETY NOTICE ....................................................................................................... IX INTRODUCTION ......................................................................................................... X VEHICLE INFORMATION............................................................................................. X MANUAL INFORMATION........................................................................................... XI FASTENER INFORMATION ........................................................................................
XVI 01 MAINTENANCE 01 MAINTENANCE SCHEDULE .................................................................................... 1 02 PRESEASON PREPARATION ................................................................................... 5 03 STORAGE PROCEDURE ......................................................................................... 7 PROCEDURES................................................................................................. 7 PROPULSION SYSTEM ..................................................................................... 7 FUEL SYSTEM ..............................................................................................
7 ENGINE ..................................................................................................... 7 ELECTRICAL SYSTEM ...................................................................................... 9 VEHICLE .................................................................................................... 9 04 SPECIAL PROCEDURES ....................................................................................... 11 GENERAL .................................................................................................... 11 PROCEDURES...............................................................................................
11 TOWING THE WATERCRAFT IN WATER ................................................................. 11 SUBMERGED WATERCRAFT ............................................................................. 11 WATER-FLOODED ENGINE .............................................................................. 11 CAPSIZED WATERCRAFT ................................................................................ 13 02 ENGINE 01 ENGINE REMOVAL AND INSTALLATION .................................................................. 15 GENERAL ....................................................................................................
15 PROCEDURES............................................................................................... 15 ENGINE ................................................................................................... 15 ENGINE MOUNTS ........................................................................................ 23 02 AIR INTAKE SYSTEM .......................................................................................... 25 GENERAL .................................................................................................... 27 SYSTEM DESCRIPTION ..................................................................................
27 PROCEDURES............................................................................................... 27 REAR VENTILATION BOX ................................................................................ 27 FRONT VENTILATION BOX ............................................................................... 27 AIR INTAKE DUCT ........................................................................................ 27 AIR INTAKE SILENCER COVER ........................................................................... 28 AIR INTAKE SILENCER BAFFLE ..........................................................................
28 AIR INTAKE TUBE ........................................................................................ 28 AIR INTAKE SILENCER ................................................................................... 29 SUPERCHARGER AIR INLET HOSE ...................................................................... 29 03 INTAKE MANIFOLD ............................................................................................ 31 GENERAL .................................................................................................... 32 PROCEDURES...............................................................................................
32 INTAKE MANIFOLD ....................................................................................... 32 FLAME ARRESTER ....................................................................................... 35 04 SUPERCHARGER ............................................................................................... 37 GENERAL .................................................................................................... 39 INSPECTION................................................................................................. 39 SUPERCHARGER INLET CLEANLINESS .................................................................
39 SUPERCHARGER CLUTCH SLIPPING MOMENT (ON ENGINE) ......................................... 40 SUPERCHARGER CLUTCH SLIPPING MOMENT (BENCH TEST) ........................................ 41 I
TABLE OF CONTENTS 02 ENGINE (cont’d) 04 SUPERCHARGER (cont’d) TROUBLESHOOTING ...................................................................................... 42 PROCEDURES............................................................................................... 42 SUPERCHARGER ......................................................................................... 42 05 INTERCOOLER .................................................................................................. 53 GENERAL ....................................................................................................
54 MAINTENANCE............................................................................................. 54 INTERCOOLER FLUSHING ............................................................................... 54 PROCEDURES............................................................................................... 54 INTERCOOLER ........................................................................................... 54 INTERCOOLER ATTACHMENTS .......................................................................... 56 06 EXHAUST SYSTEM ............................................................................................
59 GENERAL .................................................................................................... 61 SYSTEM DESCRIPTION .................................................................................. 61 MAINTENANCE............................................................................................. 61 EXHAUST SYSTEM FLUSHING ........................................................................... 61 PROCEDURES............................................................................................... 62 MUFFLER .................................................................................................
62 EXHAUST HOSES ......................................................................................... 64 EXHAUST PIPE ........................................................................................... 65 EXHAUST MANIFOLD .................................................................................... 66 RESONATOR .............................................................................................. 67 07 PTO HOUSING AND MAGNETO ............................................................................ 69 GENERAL ....................................................................................................
71 TROUBLESHOOTING ...................................................................................... 71 PROCEDURES............................................................................................... 71 PTO HOUSING ............................................................................................ 71 PTO SEAL ................................................................................................. 76 PTO COUPLING .......................................................................................... 77 STARTER DRIVE BEARING ...............................................................................
77 STATOR ................................................................................................... 78 ROTOR AND TRIGGER WHEEL .......................................................................... 81 RING GEAR ............................................................................................... 82 STARTER DRIVE .......................................................................................... 83 08 LUBRICATION SYSTEM ....................................................................................... 85 GENERAL ....................................................................................................
90 MAINTENANCE............................................................................................. 90 ENGINE OIL ............................................................................................... 90 OIL FILTER ................................................................................................ 92 INSPECTION................................................................................................. 93 ENGINE OIL PRESSURE .................................................................................. 93 TROUBLESHOOTING ......................................................................................
94 PROCEDURES............................................................................................... 95 OIL PRESSURE SWITCH (OPS) ........................................................................... 95 PTO OIL STRAINER ....................................................................................... 96 SUCTION PUMP OIL STRAINER ......................................................................... 97 ENGINE OIL PRESSURE REGULATOR ................................................................... 98 OIL PRESSURE PUMP ....................................................................................
99 OIL SUCTION PUMP .................................................................................... 102 OIL SPRAY NOZZLE (SUPERCHARGER) ................................................................ 104 OIL SPRAY NOZZLES (PISTONS) ........................................................................ 105 OIL SEPARATOR COVER ................................................................................ 106 BLOW-BY VALVE ........................................................................................ 108 OIL COOLER ............................................................................................. 111 II