Subsection XX (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
OETIKER PLIER ............................................................................. 295 000 070 ............................................. 8
OIL SEAL GUIDE........................................................................... 529 035 822 ........................................... 13
TEST CAP ...................................................................................... 529 035 991 ............................................. 7
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ............................................. 7
WATER PUMP SEAL PUSHER...................................................... 529 035 823 ..................................... 13–14

SERVICE PRODUCTS
Description Part Number Page
BRP PREMIXED COOLANT .......................................................... 219 700 362 ............................................. 5
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 11
LOCTITE 567 (PIPE SEALANT) ..................................................... 293 800 013 ............................................. 6

smr2010-024 1
Subsection XX (COOLING SYSTEM)

CLOSED LOOP COOLING SYSTEM

Expansion
coolant tank
Coolant temperature
sensor (CTS) Bleed hose
activates when from cylinder
temperature exceeds head to
100°C (212°F) expansion
coolant tank

Coolant housing
including thermostat
opens at 87°C (188°F)
and water pump
impeller

Coolant flows
to ride plate

Coolant
returns
from oil
cooler
Oil
cooler

Coolant flows
to oil cooler

Coolant returns
Ride plate from ride plate
(operates as heat
exchanger)

smr2009-024-100_en

2 smr2010-024
 Subsection XX (COOLING SYSTEM)

VEHICLE COMPONENTS

NEW
5 N•m
(44 lbf•in)

1.7 N•m
(15 lbf•in)

4 N•m
(35 lbf•in)

4 N•m
(35 lbf•in)

4 N•m
(35 lbf•in)

smr2010-024-002_a

smr2010-024 3
Subsection XX (COOLING SYSTEM)

ENGINE COMPONENTS

NEW

9 N•m
(80 lbf•in)

NEW
Loctite
243

9 N•m
(80 lbf•in)

NEW
3 N•m
(27 lbf•in)
(left-hand thread)

smr2010-024-100_a

4 smr2010-024
 Subsection XX (COOLING SYSTEM)

GENERAL
During assembly/installation, use torque values
and service products as in the exploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins, smr2009-024-002_a

etc.) must be replaced with new ones. 1. Bleed nipple

2. Coolant temperature sensor (CTS)

Hoses, cables or locking ties removed during a NOTICE Never modify cooling system ar-
procedure must be reinstalled as per factory stan- rangement, otherwise serious engine damage
dards. could occur.

SYSTEM DESCRIPTION Technical Specifications

A closed loop cooling system is utilized on the TYPE Closed loop cooling system.
1503 4-TEC engines, which offers an efficient COOLANT FLOW Flow from water pump.
engine cooling while keeping dirt and salt water
out of the cooling system. This system keeps TEMPERATURE
Thermostat.
the temperature constant and prevents internal CONTROL
engine corrosion. Self-bleed type through
SYSTEM
A separate coolant expansion tank ensures that expansion tank (hose at
BLEEDING
enough engine coolant is in the circuit during any uppermost point of circuit).
operating condition. Turns on at 100°C (212°F) on
The coolant flow comes from the water pump im- MONITORING naturally aspirated engines.
peller into the cylinder block. It goes around the BEEPER Turns on at 110°C (230°F) on
supercharged engines.
cylinders and straight up to the cylinder head. A
smaller quantity of engine coolant enters the cylin-
der block on the exhaust side for a better cool- MAINTENANCE
ing. In the cylinder head the water channels flow
around the exhaust and then the intake valves and ENGINE COOLANT
leave the engine through a large hose. From there
the coolant goes back to the water pump hous- WARNING
ing and depending on the engine temperature, it
To avoid potential burns, do not remove the
flows through the thermostat directly back to the
expansion tank cap or loosen the ride plate
water pump impeller, or it takes its way through
drain plug if the engine is hot.
the heat exchanger.
Engine coolant is also directed towards the oil Recommended Coolant
cooler (coolant type).
Use BRP PREMIXED COOLANT (P/N 219 700 362) or
Coolant temperature sensor and bleed nipple are a blend of 50% antifreeze with 50% demineral-
located on the cylinder head. ized water.
NOTE: Using a blend of 40% antifreeze with 60%
demineralized water will improve the cooling effi-
ciency when watercraft is used in particularly hot
weather and/or hot water condition.

smr2010-024 5
Subsection XX (COOLING SYSTEM)

NOTICE A blend of 40% antifreeze with 60% Cleaning the System

demineralized water will improve the cooling
efficiency. Using water tap instead of dem- NOTICE Cleaning the cooling system as per
ineralized water, would contribute to make the following procedure is required when en-
deposits in cooling system and to reduce an- gine overheats (assuming everything else is
tifreeze efficiency. This could lead to engine operating normally) or each time coolant is
overheating. replaced.

To prevent antifreeze deterioration, always use Drain the cooling system.

the same brand. Never mix different brands un- Add a cleaning product such as the Zerex® Super
less cooling system is completely flushed and Cleaner by Valvoline (or an equivalent) in coolant
refilled. expansion tank then fill cooling system with dem-
ineralized water.
NOTICE To prevent rust formation or freez-
ing condition in cold areas, always replenish Reinstall cap on coolant expansion tank.
the system with 50% antifreeze and 50% dem- Install watercraft in a test basin or ride on a water
ineralized water. Pure antifreeze will freeze at a plane. Start engine and run for approximately 15
higher temperature than the optimal water/an- minutes.
tifreeze mix. Always use ethylene glycol an- IMPORTANT: Ensure thermostat opens so that
tifreeze containing corrosion inhibitors specifi- the cleaning product flows in ride plate properly.
cally recommended for aluminum engines.
Stop engine and let the cleaning product work for
Draining the System 12 to 16 hours.
Thereafter, engine can be run one last time to soak
WARNING off deposits.
Never drain or refill cooling system when en- Drain and thoroughly rinse the cooling system
gine is hot. with clean fresh water.
Refill cooling system as described below.
Open seat.
On iS models, remove the rear ventilation box. Refilling the System
Remove the coolant expansion tank cap. Watercraft should be level, engine cold and drain
plug removed for refilling.
Install a drain pan underneath the ride plate.
Place a container under drain plug to collect an-
Unscrew the drain plug on ride plate.
tifreeze.
NOTE: Raising the front of the watercraft will con-
Apply LOCTITE 567 (PIPE SEALANT) (P/N 293 800
tribute to drain the cooling system.
013) on drain plug threads.
Ask someone to pour recommended antifreeze in
expansion tank.
When antifreeze flows out from the ride plate
drain hole, reinstall drain plug. Torque drain plug
to 8 N•m (71 lbf•in).
Continue to pour and fill expansion tank between
marks.

smr2009-024-102_a

1. Cooling drain plug

Dispose coolant as per local regulations.

Do not reinstall drain plug at this time.

6 smr2010-024
 Subsection XX (COOLING SYSTEM)

When engine has completely cooled down,

recheck coolant level coolant tank and top up if
necessary.

INSPECTION
COOLING SYSTEM LEAK TEST
WARNING
To avoid potential burns, do not remove the
expansion tank cap or loosen the ride plate
smo2009-002-137_a drain plug if the engine is hot.
1. Level between marks when engine is cold
Open seat.
Do not install pressure cap at this time.
On iS models, remove the deck extension. Refer
Link a garden hose to the hose adapter at the back
to BODY subsection.
of the watercraft. Refer to EXHAUST SYSTEM
FLUSHING in the EXHAUST SYSTEM subsection. Install the TEST CAP (P/N 529 035 991) on the
coolant expansion tank.
NOTICE Never run engine without supplying
water to the exhaust system.
Start engine and let run for a maximum of 2 min-
utes. Stop engine and wait 15 minutes to cool
down. Refill tank as necessary.
NOTICE Never run engine longer than 2 min-
utes. Drive line seal has no cooling when wa-
tercraft is out of water.
NOTE: Properly cool exhaust system by installing 529035991
a garden hose. Refer to EXHAUST SYSTEM sub-
section. NOTE: It is not necessary to install a hose pincher
Repeat this run-stop cycle 2-3 times until thermo- on overflow hose.
stat opens and stop engine. Connect the VACUUM/PRESSURE PUMP (P/N 529
021 800) to test cap and pressurize system
through coolant expansion tank to 90 kPa (13 PSI).

smr2009-024-103_a

1. Vacuum/pressure pump
smr2009-024-003_a
2. Test cap
1. This hose becomes hot when thermostat opens
Check all hoses, ride plate, engine and oil cooler
Last, refill expansion tank and install pressure cap. for coolant leaks. Spray a soap and water solution
and look for air bubbles.

smr2010-024 7
Subsection XX (COOLING SYSTEM)

Check the leak indicator hole if there is oil or 8. Internal passage blocked in cooling system
coolant. If so, replace appropriate water pump - Inspect and clean.
shaft seal.
PROCEDURES
PRESSURE CAP
Pressure Cap Inspection
Using a pressure cap tester, check pressure cap
efficiency. If the efficiency is feeble, install a new
90 kPa (13 PSI) cap (do not exceed this pressure).

CLAMPS
Clamp Replacement
To cut or secure Oetiker clamps of cooling system
hoses, use the OETIKER PLIER (P/N 295 000 070).
smr2009-024-004_a

1. Leak indicator hole

TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
it should not be assumed to list all possible prob-
lems. 1
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to MON-
ITORING SYSTEM AND FAULT CODES subsec-
tion.

ENGINE OVERHEATING
2
1. Low coolant level. F01B2KA

- Refill and check for leaks (coolant leaking out 1. Cutting clamp
of engine leak indicator hole, hoses or clamps 2. Securing clamp
missing/defective, cylinder head gaskets leaks,
ride plate leaking, etc.). Repair or replace. NOTE: Always check general condition of hoses
and clamp tightness.
2. Air in cooling system
- Refill and bleed cooling system.
3. Thermostat defective (does not open when en-
gine gets hot)
- Replace thermostat housing.
4. Water pump failure
- Inspect and replace defective components.
5. Water temperature sensor defective
- Check or replace. Refer to ELECTRONIC FUEL
INJECTION.
6. Ride plate or hoses damaged
- Check or replace damaged components.
7. Exhaust system clogged
- Flush exhaust system.

8 smr2010-024
 Subsection XX (COOLING SYSTEM)

WATER PUMP HOUSING

smr2010-024-201_a

SUPERCHARGED ENGINE
1. Detach intake hose at throttle body
2. Supercharger hose

On supercharged engines, remove also the hose

from the supercharger.
Drain cooling system and engine oil.
smr2009-024-004_b

1. Water pump housing Disconnect the coolant expansion tank hose from
water pump housing and move expansion tank
Water Pump Housing Removal aside to make room.
iS Models
Remove the moving deck and deck extension.
Refer to BODY subsection.
All Models
Remove the air intake silencer. Refer to AIR IN-
TAKE SYSTEM subsection.
Detach the air intake hose from the throttle body.

smr2009-024-105_a

1. Expansion tank hose

Disconnect exhaust hose from the resonator.

Place hose over muffler.

smr2010-024-200_a

NATURALLY-ASPIRATED ENGINE
1. Detach intake hose at throttle body

smr2009-024-106_a

1. Exhaust hose
2. Cut these locking ties
3. Retaining clamp

smr2010-024 9
Subsection XX (COOLING SYSTEM)

Disconnect ride plate hoses from water pump Water Pump Housing Inspection
housing. Check if gasket is brittle, hard or damaged and re-
place as necessary.

smr2009-024-107_a

1. Ride plate outlet hose

2. Ride plate inlet hose

Disconnect the cylinder head outlet hose and oil

cooler hoses. F18E11A

1. Water pump housing gasket

Check if thermostat is in good condition. Refer to

THERMOSTAT in this subsection.
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.

smr2009-024-006_a

1. Water pump housing

2. Cylinder head hose
3. Oil cooler inlet hose
4. Oil cooler outlet hose

Remove water pump housing screws.

4

F18E12A 1 3
1. Oil cooler return connection
2. Coolant tank hose connection
3. Ride plate return hose connection
4. Cylinder head return hose connection

Fill the water pump housing with water.

If a bigger quantity of coolant leaks out at the ride
smr2008-016-004_a plate outlet connection, replace the water pump
housing.
Pull the water pump housing to remove it.
If there is no leak, check the operation of the ther-
mostat.
10 smr2010-024
 Subsection XX (COOLING SYSTEM)

Water Pump Housing Installation

The installation is the opposite of the removal pro- 1
cedure. However, pay attention to the following.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of water pump housing screws.
Install screws as per the following illustration.

1 F18E13A

1. Impeller

NOTICE Coolant/oil pump shaft and impeller

1 have left-hand threads. Remove by turning
clockwise and install by turning counterclock-
wise.
F18E10A
Water Pump Impeller Inspection
1. Screws M6 x 25
2. Screws M6 x 105 Check impeller for cracks or other damage. Re-
place impeller if damaged.
NOTICE To prevent leaking, take care that the
gaskets are exactly in groove when you rein- Water Pump Impeller Installation
stall the water pump housing.
The installation is the opposite of the removal pro-
Tighten screws to 9 N•m (80 lbf•in) using the fol- cedure. Pay attention to the following details.
lowing sequence.
NOTICE Be careful not to damage impeller
wings during installation.
7 8 1
Torque impeller to 3 N•m (27 lbf•in).

6
THERMOSTAT
5
The thermostat is a single action type.

Thermostat Removal
Remove the WATER PUMP HOUSING, see pro-
cedure in this subsection.
4
NOTE: The thermostat is located inside the water
pump housing.
F18E10B 2 3
Thermostat Test
To check the operation of the thermostat, put it in
WATER PUMP IMPELLER water and heat water.
Water Pump Impeller Removal Look inside the cylinder head return hose con-
Remove the WATER PUMP HOUSING, see pro- nection to see the movement of the thermostat.
cedure in this subsection. Thermostat should open when water tempera-
ture reaches 87°C (189°F).
Unscrew the impeller clockwise.
If there is no operation, replace the water pump
housing.

smr2010-024 11
Subsection XX (COOLING SYSTEM)

Thermostat Installation 2
For installation, reverse the removal procedure,
paying attention to the following details.
Refer to WATER PUMP HOUSING in this subsec-
tion.

ROTARY SEAL
Rotary Seal Inspection 1
Check leak indicator hole for oil or coolant leak.

F18E14A

1. Oil pump cover screws

2. Oil pump cover

Remove oil pump cover.

Remove outer oil pump rotor.

smr2009-024-004_a

1. Leak indicator hole

Coolant leaking out of the hole indicates a defec-

tive rotary seal. Leaking oil indicates a faulty oil
seal.
However, if seal is disassembled both parts have
to be replaced together. F18E15A

1. Outer oil pump rotor

Rotary Seal Removal
Remove WATER PUMP HOUSING, see proce- Extract the coolant/oil pump shaft from outside
dure in this subsection. PTO housing cover with a pusher.
Unscrew the impeller clockwise.
NOTICE Always unscrew the impeller clock-
wise otherwise you can damage the compo-
nents.
Remove PTO housing Refer to PTO HOUSING
AND MAGNETO subsection.
Remove oil pump cover screws.

12 smr2010-024
 Subsection XX (COOLING SYSTEM)

NOTE: Never use oil in the press fit area of the oil
1
2 seal and rotary seal.
Push water pump shaft oil seal in place by using
thumb.
Install the NEW rotary seal using a press and the
WATER PUMP SEAL PUSHER (P/N 529 035 823).

F18E16A

1. Pusher 529035823
2. Coolant/oil pump shaft
NOTICE Never use a hammer for the rotary
Remove rotary seal with a screwdriver. seal or water/oil pump shaft installation. Only
use a press to avoid damaging the ceramic
component.

2 1

F18E17A

NOTICE Be careful not to damage the surface

of the rotary seal bore in PTO housing.
Always replace also the oil seal behind the rotary
seal. F18E19A

1. Rotary seal
2. Rotary seal installer
1 Install the OIL SEAL GUIDE (P/N 529 035 822) on the
end of coolant/oil pump shaft.

529035822

F18E18A

1. Oil seal

Rotary Seal Installation

The installation is the opposite of the removal pro-
cedure. Pay attention to the following details.

smr2010-024 13
Subsection XX (COOLING SYSTEM)

2 1

F18E1AA

1. Oil seal protector

2. Coolant/oil pump shaft

Using the WATER PUMP SEAL PUSHER (P/N 529

035 823) to support the PTO cover, install the
coolant/oil pump shaft.

2
F18E1BA

1. Coolant/oil pump shaft with oil seal protector

2. Rotary seal installer

Install all other removed parts.

14 smr2010-024