10 - Sea-Doo.net

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Section 10Subsection 02FUEL SYSTEM(FUEL CIRCUIT)Remove TOPS switch from electrical harness orMPEM bracket.Remove air box. (Refer to AIR INTAKE SYSTEMsub section.From storage compartment disconnect fuel pumpconnections.Remove fuel pump from fuel tank. Refer to EN-GINE MANAGEMENT section.Detach reverse system support.Fuel Filter BowlCheck filter bowl for water contamination.GasketInspect gasket condition. Make sure gasket no. 3is well positioned into the filter bowl no. 2.1F18F0BA1. ScrewsRemove battery. Refer to CHARGING SYSTEMsub section.Disconnect fuel tank connections.Cut locking ties as required to release wiring harness.Detach straps with hook tool (P/N 529 035 559).Remove fuel tank from the vehicle. WARNINGCheck that fiberglass is not exposed.INSPECTIONFuel FilterAll Models except RFI, DI and 4-TEC ModelsInspect fuel filter condition. Carefully use lowpressure compressed air to clean fuel filter. Replacefilter if permanently clogged or damaged.1F01F02A1. Gasket in bowl WARNINGEnsure that there is no leakage from the fuelfilter.RFI ModelsThe filter at fuel pump inlet is not replaceable individually.The complete fuel pump unit has to bereplaced. Refer to ENGINE MANAGEMENT.DI ModelsInspect inline filter condition. Carefully use lowpressure compressed air to clean. Replace if permanentlyclogged or damaged.NOTE: The fuel filter needs to be replaced after250 hours.Fuel Filler HoseAll ModelsVerify fuel filler hose no. 5 for damage. Always ensurethat clamps no. 4 are well positioned andtightened. Torque clamps to 4 N•m (35 lbf•in).SMR2003-030_10_02A.FM 10-02-9
Section 10 FUEL SYSTEMSubsection 02 (FUEL CIRCUIT)Pressure Relief ValveThis valve will eliminate fuel spillage when the watercraftis upside down. If pressure is built up infuel system the valve should open at 3.5 kPa (0.5PSI) for DI, 4-TEC and RFI models and at 10 kPa(1.5 PSI) for all other models to release the pressure. WARNINGIf pressure relief valve is stuck, the pressurein fuel system will build up and it may causefuel leakage in engine compartment.NOTE: It is a one-way valve with an arrow to indicatethe air flow.Check ValveBlack side of the one-way check valve no. 7 is thevalve outlet. It allows air to get in reservoir.Baffle Pick Up FilterAll Models except RFI, DI and 4-TECInspect filter no. 9 of baffle pick up. Clean or replaceas necessary.Fuel TankAll ModelsVisually inspect the inside and outside of the fueltank necks for crack(s). If crack(s) are existing, replacefuel tank no. 14.Check with your finger to feel the inside and outsidesurfaces of fuel tank. Flex fuel tank necks toensure there are no hidden cracks.4 2NOTE: A fuel tank is comprised of 3 components:the tank, the fuel pick up neck and the filler neck.The necks are injection molded and the tank isthen blow molded over the necks. During themolding process, a small molding seam may appearon the inner side of the necks at approximately4 mm (5/32 in) from the base of the neck. It is anormal situation to have a molding seam and itshould not be confused with a crack.ASSEMBLYAssembly is essentially the reverse of disassemblyprocedures. However pay particular attentionto the following.Reinstall fuel pump. Refer to ENGINE MANAGE-MENT section.4-TEC EnginesEnsure rubber carpet is in place.Insert tank, air box and straps.Place straps in clips (bottom) and in guides of airbox.Insert strap ends in hoops. Use tape to hold inplace.Properly secure harnesses.Reinstall fuel pump. Refer to ENGINE MANAGE-MENT section.Baffle Pick UpAll Models except RFI, DI and 4-TECSlide adapter no. 11 onto baffle pick up no. 8 untilit stops on rib. Install clamp no. 12.Install baffle pick up no. 8 into fuel tank and push ituntil it sits on fuel tank neck. Install clamp no. 10and torque both clamps to 3 N•m (27 lbf•in).F07F06A3 A 51. Tank upper surface2. Inspect outside, above upper surface3. Normal molding seam4. Inspect inside, above upper surface5. Base of the neckA. Approx. 4 mm (5/32 in)1FUEL SYSTEM PRESSURIZATION WARNINGWhenever doing any type of repair on watercraftor if any components of the fuel systemare disconnected, a pressure test must bedone before starting engine. Ensure to verifyfuel line ends for damage. Always cut damagedend before reinstallation.10-02-10 SMR2003-030_10_02A.FM
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