FASTENER GRADE/TORQUE N m (22 27 lbf in) N m (40 47 lbf in) 8 12 N m (71 106lbf in)

Transcription

1 Watercraft WAKE PYLON (P/N ) WARNING For safety reasons, this kit must be installed by an authorized Sea-Doo watercraft dealer. Should removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required when undergoing disassembly/assembly, always replace with a new one. Torque wrench tightening specifications must strictly be adhered to. This instruction sheet must be given to the purchaser. This kit is designed for specific applicable models only (your authorized Sea-Doo watercraft dealer will confirm models). It is not recommended for units other than those for which it was sold. NOTE: The following table is to be consulted for tightening torques when not specified in the text. FASTENER SIZE FASTENER GRADE/TORQUE 5.8 Grade 8.8 Grade 0.9 Grade.9 Grade M4.5 N m (3 8 lbf in).5 3 N m ( 7 lbf in) N m (3 35 lbf in) 4 5 N m (35 44 lbf in) M N m (7 3 lbf in) N m (40 47 lbf in) N m (6 75 lbf in) 8 0 N m (7 89 lbf in) M N m (58 75 lbf in) 8 N m (7 06lbf in) N m (93 33lbf in) 6 N m (4 lbf in) M8 5 N m ( lbf ft) 4.5 N m (8 lbf ft) 3.5 N m (3 lbf ft) 40 N m (30 lbf ft) M0 9 N m ( lbf ft) 48 N m (35 lbf ft) 6 N m (45 lbf ft) 7.5 N m (53 lbf ft) M 5 N m (38 lbf ft) 85 N m (63 lbf ft) 05N m(77lbf ft) 7.5 N m (94 lbf ft) M4 85 N m (63 lbf ft) 35 N m (00 lbf ft) 70 N m (5 lbf ft) 00 N m (48 lbf ft) NOTE: The illustrations in this document show typical construction of the different assemblies and may not reproduce the full detail or exact shape of the parts; however, they represent parts that have the same or similar function. Notice This Instruction Sheet uses the following symbols: WARNING Indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death. CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. NOTE: Indicates supplementary information needed to fully complete an instruction. Printed in Canada. (ssi MD) / Bombardier Recreational Products Inc. All rights reserved. Trademarks of Bombardier Recreational Products Inc. or its affiliates. * Bombardier and the sprocket design are trademarks of Bombardier Inc., used under license.

2 NOTE: Installation time is approximately.0 hour. PARTS TO BE INSTALLED P5 P7 P6 P8 P3 P P F8P0B ITEM P/N DESCRIPTION QTY P Wake Pylon Assembly P Bilingual Warning Label (already on) P M8 Flat Washer P M6 x 5 Hexagonal Bolt (not illustrated) 4 P M8 x 40 Cylindrical Allen Head Bolt P M8 Flat Washer P M8 Flat Washer P M8 Elastic Stop Nut 6 P mm (4 in) Locking Tie (not illustrated) P P Lower Exhaust Hose (not illustrated) (for GTX 4-TEC 00 only) ➀ Lower Exhaust Hose (not illustrated) (for GTX 4-TEC Supercharged 003 only) ➀ ➀ To be ordered separately as per watercraft model (not included in kit) GTX is a trademark of Castrol Ltd, used under license. NOTE: Items [P0] and[p] (not illustrates) must be ordered as specified in above Parts Table. /

3 INSTRUCTION Remove rear seat. Remove grab handle assembly by unscrewing side bolts [], on each side; discard bolts but keep flat washers for reuse. Photo shows left side. NOTE: Lift coolant reservoir out of its bracket and set it aside in order to ease removal of right forward bolt. F8P03A Remove two M8 x 45 hexagonal bolts [] thatare retaining grab handle at rear center; discard their elastic stop nuts but keep inside and outside flat washers with bolts for reuse. Remove and set grab handle aside. Cut locking tie around upper exhaust hose and, with a bungy strap, pull and secure hose forward; this will provide more working space. F8P04A Cut locking tie [] to unhook and set bailer hoses aside; notice that locking tie is secured onto the 90 fittings. CAUTION: This is how bailer hoses will have to be secured once wake pylon installation is completed. If installation is performed on a 00 GTX 4 TEC or on a 003 GTX 4 TEC Supercharged, loosen lower exhaust hose clamps, remove lower exhaust hose and remove clamps. Install new lower exhaust hose [P0] or[p] (as per watercraft model) and secure using same clamps. F8P05A / 8

4 Remove U-clamp/hook assembly; keep U-clamp [] but discard hook [], finish plate [3] andboth M8 elastic stop nuts. NOTE: Keep inside retainer plate (already trapped in silicone). CAUTION: Proper understanding of the following step is of the utmost importance; make sure it is understood before starting to drill hole through hull. 3 F8P06A Using a square (A = 90 ),setat6.6mm(-7/64 in) [],startatcenterofbothu-clampholes (respect the angle of the body [3]) and project the most center position [] on the rear hull. Mark that spot with a marker pen. 3 A 3 F8P0HA ProperWaytoUsetheSquare In the photo, [] shows angle of body and [] shows square laid flat, respecting angle of body. F8P0IA 4 /

5 WrongWaytoUsetheSquare In photo, [] shows angle of body and [] shows square not laid flat thus not respecting angle of body. F8P0JA Punch mark that spot as a guide for the drilling operation. WARNING Always wear eye protection and gloves when using power tools. F8P08A Using a 4.7 mm (3/6 in) bit, gently drill a hole in hull. Take care not to press too hard to start so bit will not skid off position, thus damaging paint surface / 8

6 Using a 57 mm (-/4 in) hole saw gently start piercing the hull in a perfect vertical alignment []. Saw will bite at front first; slowly keep on drilling in that perfect vertical alignment until saw goes through complete fiberglass thickness. NOTE: Photo also shows [] parallel with bumper line and [A] givinga90 angle. Clean outside and inside hull from fiberglass residue. Slide wake pylon [P] through hole. At this stage, make sure that - the pylon slides easily up and down, - downward movement is slowed down by X-ring, - safety lock pin operates properly and - pressure screw stops cylinder at its most upward position; then carry out the procedure. F8P0AB A Lean upper bracket and align with U-clamp/hook holes. Insert M8 flat washers [P3] onto kept U-clamp and insert U-clamp [] through holes. Photo also shows wake pylon upper bracket []. Secure with M8 elastic stop nuts [P8]. Tighten to 3-6 N m (5-4 lbf in). P3 P3 F8P0BB With wake pylon secured at its upper bracket, drill holes through hull using pylon base as a template. Clean outside and inside hull from fiberglass residue. 6 /

7 Secure in place using M8 x 40 bolts [P5] with M8 flat washers [P6] under bolt heads, M8 flat washers [P7] underneath and M8 elastic stop nuts [P8]. Tighten to 3-6 N m (5-4 lbf in). Secure bailer hoses in place with a new locking tie [P9] remembering to align locking tie onto 90 fitting and not on hoses. Remove bungy strap so upper exhaust hose sets to its position and secure upper exhaust hose with a locking tie [P9]. Reinstall grab handle using new M6 x 5 hexagonal bolts [P4] on sides. Tighten to 6-9 N m (53-80 lbf in). F8P0DB P5 P6 P5 Secure grab handle at rear using kept M8 x 45 hexagonal bolts and flat washers with new M8 elastic stop nuts [P8]. Tightento6-9N m (53-80 lbf in). At this stage, make sure inside cylinder slides up and down freely without obstruction from grab handle; then resume the procedure. Reinstall coolant reservoir into its brackets. Reinstall seat. Installation is now complete. WARNING Completely retract ski post when not used. Do not hold rear grab handle while retracting ski post. Make sure ski post is fully extended and locked before use. Spotter must always keep hands on ski post grips while pulling a skier or a wakeboarder. F8P0EA / 8

8 Warning Label This product comes with the following, already apposed, bilingual warning label containing important safety information. F8P0KA Bilingual Label [P] (P/N ) The label should be considered permanent part of this product. If the label comes off or becomes hard to read, please contact an authorized dealer for replacement. Any person who intends to use this product should read and understand the information contained on the warning label before doing so. 8 /