Sea doo rxt 255 manual

Also keep in mind that you probably have to rebuild the supercharger after engine hours, or every 2 years. The manufacturer recommends checking the coolant every year or after engine hours and replacing it every years depending on the model. For exact service intervals please refer to the manual.

Although Sea-Doos use a closed-loop cooling system, their exhaust system and the intercooler on the supercharged models are still cooled with external water! Because of this, you have to flush these systems first with fresh water to remove potential contamination like sand, debris, etc.

To do it properly, attach a garden hose to the flushing connector, start the engine first, and only after that turn on the water. Run the engine for a maximum of 2 minutes at idle speed, stop the water first, then shut off the engine. Rinse down the pump, iBR braking system , and the intake grate from the outside with the garden hose. Then, you have to flush the exhaust again, but with a mixture of water and antifreeze. To create this mixture, you should mix 1 gallon of non-toxic RV antifreeze with 1 gallon of water in a bucket.

Attach the hose to the flush connector and flush the system again with this mixture as described above. Lubricate the moving parts and the metallic components in the engine compartment, in the pump, and in the iBR to prevent corrosion. Contrary to popular belief, you have to remove the battery from the Sea-Doo and store it in a cool and secure place. The best practice is to hook it up on a battery tender to keep it charged during the winter months.

Depending on the type of the battery, it may also need maintenance. You may want to know how to remove a Sea-Doo battery, and how to charge it properly. Before you store your Sea-Doo for the winter months, the best practice is to clean it perfectly. Moreover, you can consider polishing it to restore its original shine. Finally, you have to cover and store your Sea-Doo properly.

Additionally, remove your valuables from the storage compartments, especially your cameras, GPS, VHS radio or other electronics. To winterize a Sea-Doo Spark, you have to remove the top deck first. Blow-by hose 4. Blow-by valve 5. Exhaust manifold mark 2. Remove exhaust hose from resonator. Cut locking tie retaining bailer hose elbow fittings to exhaust hose.

Remove front exhaust hose from vehicle. Middle of the opening 1. Middle of rubber adapter strip 2. Center of the muffler bulge opening Install the rubber adapter on exhaust pipe.

Ensure rubber adapter is properly seats against exhaust Using a caliper, measure the distance between pipe shoulder. To help holding the manifold while installing screws, first insert the exhaust manifold into the exhaust pipe then, install the upper front screw. After installation, ensure there is no water or ex- haust gas leak when the engine is running.

Test run the engine while supplying water to the ex- haust system. Remove the moving deck and deck extension. BODY Refer to subsection. Drain the engine oil. Remove LH rear engine support. Magneto connector 2. ECM 3. Replace if necessary. Inspect the needle bearing in the PTO housing used to support the starter drive assembly shaft.

NOTE: Clean all disassembled metal components in a non-ferrous metal cleaner. Thrust washer 2. Disc springs 3. Screws M6 x 35 2. Refer to sub- section for the procedure. Remove PTO seal as described in previous proce- dure. Connect adapter to magneto stator connector 1. Stator screws 2. Leave vehicle harness disconnected 2. Stator Read resistance. NOTE: The maximum allowable difference be- tween teeth is 0. If the reading exceeds the maximum allowable difference, straighten the tooth or replace the trigger wheel.

Magneto rotor retaining screws 2. Trigger wheel 1. Rotor retaining screws 4. Ring gear 2. Rotor 3. Oil dipstick 2. Rocker arm intake 3. Rocker arm exhaust 4. Hydraulic valve lifter 5. Camshaft 6. Piston pin 7. Into PTO cover 8. From oil filter 9. Piston cooling To air intake silencer Oil spray nozzle 2. Rocker arm intake Drive shaft 3. Rocker arm exhaust Crankshaft 4.

Rocker arm axle PTO seal 5. Full 2. Add 3. Operating range Otherwise, add oil until its level is between marks as required. To add oil, unscrew oil cap. Never start engine when there is no oil in engine.

Oil pressure regulator valve sticks open, or spring load is too small. Test at the Cylinder Head Location - Clean oil regulator piston and its bore.

Clean it during other Pin 1 Pin E3 continuity inspections, especially when the engine is disas- sembled. Suction pump cover For installation, reverse the removal procedure. The oil pressure regulator is located on the bottom of the PTO housing.

Remove engine oil. Remove the PTO housing. Remove water pump housing and the impeller. Pittings on the teeth Using a feeler gauge, measure the clearance be- tween inner and outer rotors. PTO housing surface 2. Vernier depth gauge 1. Remove the air intake silencer. Detach the muffler from the exhaust manifold and move muffler backwards. Remove engine support mount screws. Oil pump cover 2. Oil pump screws tween inner and outer rotors.

Remove oil pump shaft. Screws M6 x 25 1. Oil pump housing surface 2. Screws M6 x 45 2. Vernier depth gage Tighten suction pump cover screws as per follow- ing sequence. Oil pump outer rotor surface 2. Banjo bolt A. Oil spray nozzle 3. Torx screw ing to the center of the tool. Not following this Oil Spray Nozzle Inspection procedure will lead to an insufficient oiling of the supercharger and a supercharger failure can oc Camshaft 2. Oil separator cover NOTE: Be careful not to break the holding clips from oil separator cover when its removed from the timing gear.

To a accomplish the second function, the blow-by valve has a tip over protection switch TOPS. Air must flow freely to blow-by valve. Unscrew and remove the blow-by valve. Air 1. Oil cooler If O-rings are brittle, cracked or hard, replace them. Oil Cooler Removal Clean both contact surfaces of oil cooler. Remove the deck extension. Refer to BODY sub- section. If the efficiency is feeble, install a new 90 kPa 13 PSI cap do not exceed this pressure.

Expansion tank hose Disconnect exhaust hose from the resonator. Place hose over muffler. Refer to sub- section. Water Pump Housing Leak Test Plug the connections of the oil cooler return hose, coolant tank hose, ride plate return hose and cylin- der head return hose with a rag. Screws M6 x 25 2. Screws M6 x 1. Push water pump shaft oil seal in place by using thumb. Oil seal protector 2. Refer to in this subsection for procedures. Rotate engine crankshaft counterclockwise un- til the cylinder no.

Rocker arm screw not properly tightened 4. Broken rocker arm s - Retighten screws with recommended torquing - Replace defective parts. Faulty chain tensioner - Replace chain tensioner. Cylinder head cover screws 5. Remove the cylinder head cover and its gasket.

Spark plug tube 2. Seal to the cylinder head cover 3. Pay attention to the following detail. Rocker arm shaft 2. Rocker arms exhaust side 3. Position lines 7. Apply engine oil on rocker arm shaft. Finish tightening screws turning an additional 4. Remove the chain guide. Remove the Allen screws securing the camshaft timing gear. Remove the camshaft timing gear. Chain guide 1. Good with aligned 2. Remove the camshaft lock to remove the camshaft.

Oil orifices Cylinder Head Inspection 1. Cylinder head screws M6 Check for cracks between valve seats or other Remove the cylinder head screws M11 securing damages, if so, replace cylinder head.

Us- ing a gasket twice will cause engine damage, even if the engine had not run. Valve cotters 2. Valve spring retainer 3. Inner valve spring 4. Outer valve spring Valve Spring Inspection Check valve springs for rust, corrosion or other visible damages. If so, replace faulty valve 1. Valve Stem Seal Push valve stem then pull valves out of valve Inspection of valve stem seals is not needed guides. Valve seat A. Valve stem diameter 2. Exhaust valve contaminated area 3.

Valve face contact width B. Valve seat contact width Intake Other- wise it will foul the valve guide hole in the cylinder head and destroy the cylinder head, as the valve guide is removed. Punch Check valve guide bore for abreased material. The inlet and exhaust valve guides have the same length and are interchangeable. Crankshaft or balancer shaft axial play out of specification When disassembling parts that are duplicated in - Measure crankshaft and balancer shaft axial play.

Piston 1. Connecting rod screws 2. Piston pin 3. Circlip NOTE: Before removing the connecting rod caps, mark them to remember the right position when 6. Detach piston no. Connecting rod big end bearing 1. Piston Inspection Inspect piston for scoring, cracking or other dam- ages.

Position the dial bore gauge 62 mm 2. Knowing that the screws have been stretched from the previous installation, it is very important to use new screws at as- sembly. Rectangular ring 2. Taper-face ring 3. Piston 2. Position lines Use a small screwdriver to check if the groove in the crankshaft is aligned with the hole. Micrometer 2. Crankshaft area for bearing 1.

Mark on balancer shaft 2. Thrust washer 1. Crankshaft locking tool 2. Sealing surface Install cylinder block lower half. Balancer Shaft Removal Install the crankshaft cover before mounting the engine bracket.

Screws 1. Micrometer Remove cylinder block lower half. Balancer shaft area for bearing Remove thrust washers no. Pay attention to following details. Crankshaft locking tool 1. Holding claws, turn puller shaft Measure cylinder diameter in piston axis direction clockwise so that claws open and become firmly from top of cylinder. Cylinder block upper half 2. Clean all metal components in a solvent. Apply engine oil on O-ring and press cover in. Crankshaft cover has to be flush with cylinder block surface.

O-ring 2. Page Communication Tools And B. Normally Displayed Click on the OK button in B. Page B. After the write operation, remove D. The following conditions will trigger a limp home mode.

C or damaged iBR pins. Last session Unexpected battery Verify starting and charging system C interrupted power lost circuits. System disabled and System is locked. C Refer to the Service Manual for more need activation Need activation details. Intake manifold Damaged sensor, Check for approximately to temperature sensor damaged circuit wires, Check for 0 volt on sensor connector pin E.

Damaged injector, Check for 12 volts on pin 2 of injector damaged circuit wires, Injector 1 open circuit connector. Damaged injector, Check for 12 volts on pin 2 of injector damaged circuit wires, Injector 3 shorted to connector. Damaged coil, damaged Ignition coil 2 open Check for 12 volts on pin 2 of circuit wires, damaged P Damaged coil, damaged Ignition Power Stage Check for 12 volts on pin 2 of circuit wires, damaged P Replace ECM.

PE circuit wires, damaged digital position control Replace throttle actuator, replace connector or damaged P circuit wires, damaged Abortion of adaptation Replace throttle actuator, replace connector or damaged ECM. Exhaust overheat, Check if the exhaust injection High exhaust P damaged sensor or valve is properly calibrated.

When handlebar is and held, the ECM could close the throttle plate, brought back to its center position, the throttle instead of opening it, if the iBR lever were de- reverts to idle.

Route harness here Step 2: Pull out sensor When installation is completed, ensure throttle Revert removal procedure for installation. Pay at- lever works properly. Pull out to unlock connector 1. Read Data 2. Monitoring tab 6. Cluster tab 4. Cruise indicator light If the test succeeded, the switch and wiring are 7.

Reconnect gauge connector. Attach a string approximately 1. Repair the leak. It prevents flames leaving through the intake system if the engine backfires. Engine must not crank. When engine is running and the D. See below. Battery ground cable of its wires and connections with the engine 2. From B. Install and connect the new ECM. Use the B. Install the D. Customer name Perform the Closed throttle reset. Enter the old ECM serial number in the Part in this subsection.

Replacement under History tab. Click on Add Part in History. Fuel rail Unplug all injector connectors. Pull fuel rail out with fuel injectors.

Start engine. Using the B. Fuel pressure must be within specification. Re-activate fuel pump as necessary. NOTE: Push against tab underneath connector as shown to unlock it. Remove the long bus bar from fuse box 1.

Refer to in this subsec- tion. The throttle actuator will cycle. Push throttle plate where shown. It must com- pletely close and when released, freely return to the rest position slightly opened.

Do not start engine. If resistance values are correct, try a new ECM. Refer to Remove air intake silencer. Disconnect CPS connector. CAPS connector Unscrew the retaining screw. Install the CAPS. Ensure to reinstall O-ring. If wiring harness is good, check ECM. KS connector Otherwise, repair the connector or replace the wiring harness between ECM connector and Using a multimeter, check the resistance be- knock sensor.

Replace any damaged, leaking or deteri- orated fuel line. Fuel lines remain under pressure at all times. The fuel pump will come on for approximately 2 seconds to pressurize the fuel rail in preparation for the engine start. The ECM supplies the ground signal to turn on the fuel pump motor.

Ventilation box 2. Wipe off any fuel that leaked and ventilate the hull thoroughly to remove any accu- mulated fuel vapors. Do not use electric powered tools on watercraft unless system has passed the leak test. Vacuum selected eral times to pressurize air to the inlet valve.

Visually inspect fuel system to ensure all fuel sys- tem connections are installed. Page Procedures Inspect all clamps for tightness. Valve on gauge approved by BRP for pressurized hoses, and These hoses available from BRP meet our system requirements and will ensure continued proper and safe operation. Throttle body 2.

Inlet hose 3. Connector Remove D. All of the manual listed below are full factory workshop service manuals with hundreds of pages containing step by step instructions, full wiring diagrams and detailed illustrations and photos on how to repair, rebuild or maintain virtually anything to your Sea-Doo. It is fully printable, print 1 page, 1 chapter or print the entire manual and put it in a 3-ring binder. Once you download your manual it is yours forever.

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