Subsection XX (COOLING SYSTEM)
COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
HANDLE ........................................................................................ 420 877 650 ........................................... 11
OETIKER PLIERS........................................................................... 295 000 070 ............................................. 6
OIL SEAL PUSHER........................................................................ 529 036 210 ........................................... 11
ROTARY SEAL INSTALLER ........................................................... 529 036 211 ........................................... 11
TEST CAP ...................................................................................... 529 035 991 ............................................. 5
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ............................................. 5
SERVICE PRODUCTS
Description Part Number Page
DOW CORNING 111 ..................................................................... 413 707 000 ............................................. 8
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ........................................... 11
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 12
LOCTITE 5900 ............................................................................... 293 800 066 ........................................... 15
LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ....................................... 5, 13
smr2014-017 1
Subsection XX (COOLING SYSTEM)
ENGINE COMPONENTS
See ELECTRONIC FUEL
INJECTION (EFI)
Engine oil
16 ± 2 N•m
(142 ± 18 lbf•in)
Dow Corning
111
Engine oil 9 ± 1 N•m
(80 ± 9 lbf•in) Engine oil
NEW
Isoflex grease
Topas NB 52
NEW
Loctite 243
+
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW = Component must be replaced when removed.
Smr2014-017-001_a
2 smr2014-017
Subsection XX (COOLING SYSTEM)
COOLANT FLOW
smr2014-017-099_a
smr2014-017 3
Subsection XX (COOLING SYSTEM)
VEHICLE COMPONENTS
1.7 ± 0.2 N•m
(15 ± 2 lbf•in)
NEW
4 ± 1 N•m
(35 ± 9 lbf•in)
4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
1 N•m
(9 lbf•in)
NEW
NEW
4 ± 1 N•m
(35 ± 9 lbf•in)
Loctite 5900
NEW = Component must be replaced when removed.
smr2014-017-199_a
4 smr2014-017
Subsection XX (COOLING SYSTEM)
GENERAL TECHNICAL SPECIFICATIONS
Coolant bleed hose nipple is located on the cylin- TYPE Closed loop cooling system.
der head.
COOLANT FLOW Flow from water pump.
TEMPERATURE
Thermostat.
CONTROL
Self-bleed type through
SYSTEM
coolant tank (hose at
BLEEDING
uppermost point of circuit).
MONITORING
Turns on at 100°C (212°F).
BEEPER
LONG LIFE ANTIFREEZE
COOLANT TYPE
(P/N 219 702 685)
INSPECTION
smr2014-017-100_a
1. Bleed hose nipple COOLING SYSTEM LEAK TEST
NOTE: It is a good practice to check for fault WARNING
codes using B.U.D.S. software as a first trou- To avoid potential burns, do not remove the
bleshooting step. Refer to the DIAGNOSTIC coolant tank cap if the engine is hot.
AND FAULT CODES subsection.
During assembly/installation, use the torque NOTE: This test confirms if there is a leak in the
values and service products as shown in the ex- cooling system, including the engine.
ploded views. Pressurize cooling system through coolant reser-
Clean threads before applying a threadlocker. Re- voir.
fer to SELF-LOCKING FASTENERS and LOCTITE
REQUIRED TOOL
APPLICATION at the beginning of this manual for
complete procedure.
TEST CAP (P/N 529 035 991)
WARNING
To avoid potential burns, do not remove the
coolant tank cap or loosen the cooling drain VACUUM/PRESSURE PUMP
plug if the engine is hot. (P/N 529 021 800)
WARNING COOLING SYSTEM LEAK TEST
Torque wrench tightening specifications 110 kPa (16 PSI)
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced with new ones.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
smr2014-017 5
Subsection XX (COOLING SYSTEM)
ENGINE OVERHEATING
1. Low coolant level.
- Refill and check for leaks (coolant leaking out of
leak indicator hole, hoses or clamps missing or
defective, or cylinder head gaskets leaks). Repair
or replace.
2. Dirty heat exchanger.
- Flush heat exchanger. Replace heat exchanger as
required.
3. Air in cooling system.
- Refill. Perform COOLING SYSTEM LEAK TEST.
mmr2009-112-033
TYPICAL 4. Defective thermostat (does not open when en-
gine is warm up).
If pressure drops, check all hoses, heat exchanger - Replace thermostat.
and engine for coolant leaks. Spray a soap/water
solution and look for air bubbles. 5. Exhaust system clogged
- Flush exhaust system.
Check the leak indicator hole if there is oil or
coolant leaking. 6. Defective water pump.
NOTE: In general leaking coolant indicates a dam- - Inspect and replace defective components.
aged rotary seal. Leaking oil indicates a damaged 7. Coolant temperature sensor defective.
oil seal. If either seal is leaking, both seals must
- Check and replace if necessary. Refer to ELEC-
be replaced at the same time. Refer to WATER TRONIC FUEL INJECTION (EFI).
PUMP in this subsection.
8. Wrong coolant concentration.
- Check and adjust coolant concentration according
to BRP's recommendations or replace coolant.
9. Defective coolant reservoir cap.
- Replace cap.
10. Internal passage blocked in cooling system
- Inspect and clean.
PROCEDURES
COOLANT RESERVOIR CAP
Coolant Reservoir Cap Test
Using a pressure cap tester, check the efficiency
smr2014-017-002_a of coolant reservoir cap. If the efficiency is weak,
1. Leak indicator hole replace the cap.
CAP OPENING PRESSURE
TROUBLESHOOTING
110 kPa ± 7 kPa (16 PSI ± 1 PSI)
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
should not be assumed to show all causes for all CLAMPS
problems.
Clamp Replacement
Always check for fault codes. If a fault code is de-
tected, service the fault code first. To cut or secure Oetiker clamps of cooling system
hoses, use the OETIKER PLIERS (P/N 295 000 070).
6 smr2014-017
Subsection XX (COOLING SYSTEM)
Thermostat Access
1. Remove central body. Refer to BODY.
Thermostat Removal
1. Drain engine coolant. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.
1 2. Disconnect outlet hose from thermostat hous-
ing.
2
F01B2KA
1. Cutting clamp
2. Securing clamp
NOTE: Always check general condition of hoses
and clamp tightness.
THERMOSTAT smr2014-017-101_a
1. Thermostat housing outlet hose clamp
Thermostat Location 2. Thermostat housing outlet hose
The thermostat is located on engine MAG side.
3. Proceed with WATER PUMP HOUSING RE-
MOVAL. See procedure in this subsection.
4. Remove thermostat housing then thermostat.
smr2014-017-003_a
1. Thermostat housing
smr2014-017-005_a
1. Thermostat housing
2. Thermostat
NOTE: Use shop rags to catch any spilled engine
coolant.
Thermostat Test
To check thermostat, put it in water and heat wa-
smr2014-017-004_a
ter.
1. Thermostat
2. Thermostat housing
smr2014-017 7
Subsection XX (COOLING SYSTEM)
THERMOSTAT TEMPERATURE
Starts to open 80°C (176°F)
Fully open 95°C (203°F)
Replace thermostat if out of specification.
Thermostat Installation
The installation is the reverse of removal proce-
dure, however pay attention to the following.
Install NEW O-ring on thermostat housing.
Lubricate O-ring.
THERMOSTAT HOUSING O-RING
smr2014-017-007_a
DOW CORNING 111
Service Product 1. Thermostat tabs
(P/N 413 707 000) 2. Magneto cover recess
Fit thermostat in thermostat housing. Install water pump housing, refer to WATER
PUMP HOUSING INSTALLATION in this subsec-
tion.
Refill and bleed cooling system. Refer to PERI-
ODIC MAINTENANCE PROCEDURES subsec-
tion.
WATER PUMP
Water Pump Location
The water pump is located on engine MAG side.
smr2014-017-006
Align both tabs of thermostat with the recess in
the magneto cover.
smr2014-017-003_b
1. Water pump
Water Pump Access
1. Remove central body. Refer to BODY.
Water Pump Housing Removal
1. Drain engine coolant. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.
8 smr2014-017
Subsection XX (COOLING SYSTEM)
2. Disconnect outlet hose from thermostat hous-
ing.
3. Disconnect inlet hose from water pump.
smr2014-017-010_a
1. Retaining screws
2. Sealing washer
smr2014-017-101_b
1. Water pump outlet hose NOTE: Use shop rags to catch any spilled engine
2. Water pump inlet hose
coolant.
4. Remove both locking ties securing magneto
wires. Water Pump Disassembly
1. Unscrew impeller counterclockwise using ap-
propriate pliers.
smr2014-017-008_a mmr2011-071-013_a
1. Locking ties 1. Impeller
2. Pliers
5. Remove retaining screws of water pump hous-
ing. 2. Remove magneto cover. Refer to MAGNETO
6. Discard sealing washer.
AND STARTER subsection.
3. Remove the following components from mag-
7. Remove water pump housing from magneto
neto cover:
cover.
– Water pump gear
– Needle pin
– Thrust washer.
smr2014-017 9
Subsection XX (COOLING SYSTEM)
NOTICE Be careful not to damage the surface
of the rotary seal bore in the magneto cover.
6. Separate rotary seal from water pump shaft.
mmr2011-071-014_a
1. Water pump gear
2. Needle pin
3. Thrust washer
4. Remove water pump shaft using a plastic mal-
let. mmr2011-071-017_a
1. Water pump shaft.
2. Rotary seal
Water Pump Inspection
Check area of water pump housing for cracks or
other visible damage.
Check water pump gear for wear or broken teeth.
Check if housing gasket is brittle, hard or dam-
aged.
Check water pump shaft for visible damage.
Replace parts if necessary.
Water Pump Assembly
mmr2011-071-015_a
NOTE: Always replace oil seal and rotary seal at
1. Water pump shaft the same time.
5. Remove the following components from mag- 1. Clean rotary seal surface from old sealant.
neto cover:
– Oil seal
– Remaining parts of rotary seal.
mmr2011-071-018_b
1. Clean surface
mmr2011-071-016 2. Apply engine oil on the press fit area of oil seal.
10 smr2014-017
Subsection XX (COOLING SYSTEM)
NOTICE Never use engine oil on the press fit REQUIRED TOOL
area of the rotary seal.
Press
3. Install NEW oil seal.
ROTARY SEAL INSTALLER
REQUIRED TOOL (P/N 529 036 211)
OIL SEAL PUSHER (P/N 529 NOTICE Never use a hammer for rotary seal
036 210)
installation. Only use a press to avoid damag-
HANDLE (P/N 420 877 650) ing the ceramic component.
mmr2011-071-025_a
mmr2011-071-020_a
1. Rotary seal
1. Oil seal 2. Rotary seal installer
6. Assemble the following components onto wa-
ter pump shaft.
– Needle pin
– Thrust washer.
mmr2011-071-039_a
1. Oil seal correctly installed
mmr2011-071-040_a
4. Lubricate sealing lip of the oil seal. 1. Water pump shaft
2. Thrust washer
3. Needle pin
OIL SEAL
ISOFLEX GREASE 7. Slide water pump shaft into rotary seal using a
Service Product TOPAS NB 52 (P/N 293 press.
550 021) NOTE: To avoid damaging the rotary seal and to
achieve the proper preload support the rotary seal
5. Install NEW rotary seal. with the ROTARY SEAL INSTALLER (P/N 529 036 211)
NOTE: Prior to installing, ensure that press fit
sealing of rotary seal is not damaged.
smr2014-017 11
Subsection XX (COOLING SYSTEM)
Water Pump Housing Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTICE To prevent leaking, take care that the
new gasket is exactly in groove when you rein-
stall the water pump housing.
Install a NEW sealing washer on drain screw.
Tighten water pump housing retaining screws to
specification as per the following procedure.
WATER PUMP HOUSING RETAINING SCREWS
LOCTITE 243 (BLUE)
Service product
mmr2011-071-041_a (P/N 293 800 060)
1. Press
2. Water pump shaft 9 N•m ± 1 N•m
Tightening torque
3. Needle pin (80 lbf•in ± 9 lbf•in)
4. Thrust washer
5. Rotary seal installer
8. Carefully press water pump shaft until needle
pin touches thrust washer.
smr2014-017-013_a
mmr2012-134-201_a
1. Press TIGHTENING SEQUENCE
2. Rotary seal installer
3. Needle pin touches thrust washer Tighten coolant hose clamps to specification.
NOTICE Never use a hammer to install water TIGHTENING TORQUE
pump shaft into rotary seal. 4 N•m ± 1 N•m
Coolant hose clamps
(35 lbf•in ± 9 lbf•in)
NOTE: After installation, water pump shaft must
rotate freely.
9. Screw impeller clockwise using appropriate pli- WATER PUMP DRIVE GEAR
ers.
Water Pump Drive Gear Location
NOTICE Be careful not to damage impeller The water pump drive gear is located behind the
wings during its installation. magneto cover.
10. Install magneto cover. Refer to MAGNETO
AND STARTER subsection.
12 smr2014-017
Subsection XX (COOLING SYSTEM)
Apply engine oil on bearing sleeve.
Tighten water pump drive gear retaining screw to
specification.
WATER PUMP DRIVE GEAR RETAINING SCREW
9 N•m ± 1 N•m
Tightening torque
(80 lbf•in ± 9 lbf•in)
HEAT EXCHANGER
Heat Exchanger Inspection
Inspect Heat exchanger for leaks, cracks or sedi-
ments. Replace if necessary.
mmr2011-071-035_a
1. Water pump drive gear 31 T
2. Intermediate gear, refer to LUBRICATION SYSTEM
Heat Exchanger Cleaning
NOTICE Cleaning the cooling system as per
Water Pump Drive Gear Access the following procedure should be performed
Refer to MAGNETO AND STARTER subsection when cooling system is contaminated, or foul-
and remove: ing is suspected. It is not necessary to clean
– Magneto cover the cooling system if the same LONG LIFE AN-
– Magneto flywheel. TIFREEZE (P/N 219 702 685) (orange color) is used
for refilling or replacing.
Water Pump Drive Gear Removal 1. Start with a cool engine.
1. Remove screw securing water pump drive 2. Completely drain coolant. Refer to PERIODIC
gear. MAINTENANCE PROCEDURES.
2. Remove bearing sleeve. 3. Add coolant system flushing agent according to
3. Slide off water pump drive gear. instructions.
4. Run the engine according to flushing agent in-
structions. Allow the engine to cool.
5. Drain flushing agent.
6. Add demineralized water to the cooling system
and run the engine according to flushing agent
instructions to clear out the system flushing
agent. Allow engine to cool.
7. Drain demineralized water.
8. Refill the cooling system with the recom-
mended type and quantity of coolant. Refer to
PERIODIC MAINTENANCE PROCEDURES.
9. Start the engine and test for proper operation of
mmr2011-071-036_a cooling system.
1. Water pump drive gear 31 T
2. Bearing sleeve
3. M6 x 20 screw Heat Exchanger Removal
Air intake system and other components removed
Water Pump Drive Gear Inspection for clarity.
Inspect gear for wear or other damage. 1. Remove central body. Refer to BODY.
Replace gear if necessary. 2. Follow image sequence
Water Pump Drive Gear Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
smr2014-017 13
Subsection XX (COOLING SYSTEM)
smr2014-017-102_a
HEAT EXCHANGER REMOVAL- VIEW INSIDE HULL
1. Heat exchanger outlet hose
2. Heat exchanger inlet hose
smr2014-017-105_a
3. Remove starboard side engine mount clamps. HEAT EXCHANGER RETAINING NUTS - UNDER ENGINE
Refer to ENGINE REMOVAL AND INSTALLA- MOUNT CLAMP
TION.
NOTE: Shims must be re-installed in original loca-
tion for proper engine alignment.
smr2014-017-104_a
HEAT EXCHANGER CARRIAGE BOLTS
1. Rear heat exchanger carriage bolt
2. Heat exchanger retaining nuts under rear engine mount clamp
3. Heat exchanger retaining nuts under front engine mount clamp
smr2014-042-019_a
HEAT EXCHANGER- UNDER WATERCRAFT
1. Heat exchanger
2. Prybar
4. Clean off sealant residues from hull and heat
exchanger.
smr2014-017-103_a
Heat Exchanger Disassembly
REAR HEAT EXCHANGER CARRIAGE BOLT
smr2014-017-107_a
smr2014-017-108
14 smr2014-017
Subsection XX (COOLING SYSTEM)
smr2014-017-109
Heat Exchanger Assembly
Heat exchanger assembly is the reverse of disas-
sembly.
Heat Exchanger Installation
1. Apply LOCTITE 5900 (P/N 293 800 066) beads as
indicated.
smr2014-017-110_a
LOCTITE 5900 12 MM (15/32 IN) DIAMETER BEAD APPLICATION
smr2014-017-111_a
LOCTITE 5900 13.5 MM (17/32 IN) DIAMETER BEAD
APPLICATION
Heat exchanger installation is the reverse of re-
moval.
TIGHTENING TORQUE
M8 heat exchanger 25 N•m ± 3 N•m
retaining nuts (18 lbf•ft ± 2 lbf•ft)
Refill and bleed cooling system. Refer to PERI-
ODIC MAINTENANCE PROCEDURES subsec-
tion.
Place watercraft in test tank and ensure no water
enters the hull.
smr2014-017 15
