Subsection XX (HULL)
HULL
SERVICE PRODUCTS
Description Part Number Page
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ..................................... 10, 12
LOCTITE 5900 ............................................................................... 293 800 066 ............................. 8–9, 11, 13
smr2014-042 1
Subsection XX (HULL)
Spark Series
NEW
14.5 ± 1.5 N•m
(128 ± 13 lbf•in)
Loctite 5900
(silicone sealant)
11 ± 1 N•m 4.5 ± 0.5 N•m
(97 ± 9 lbf•in) (40 ± 4 lbf•in) Convenience
Loctite 5900
(silicone sealant)
5 ± 1 N•m 7 ± 1 N•m
(44 ± 9 lbf•in) (62 ± 9 lbf•in)
NEW = Component must be replaced when removed.
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2 smr2014-042
Subsection XX (HULL)
3UP
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Subsection XX (HULL)
Spark Series
NEW
24 ± 2 N•m
(18 ± 1 lbf•ft)
NEW
24 ± 2 N•m
(18 ± 1 lbf•ft)
Loctite 5900 7 ± 1 N•m
Sealant (62 ± 9 lbf•in)
Loctite 5900
Loctite 5900 Sealant
Sealant
2.5 ± 0.5 N•m
(22 ± 4 lbf•in) 25 ± 1 N•m
(18 ± 1 lbf•ft)
Loctite 5900
Sealant
24 ± 2 N•m NEW
(18 ± 1 lbf•ft)
24 ± 2 N•m
(18 ± 1 lbf•ft)
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4 smr2014-042
Subsection XX (HULL)
PROCEDURES Installation Instructions
Use a N drill bit only.
HULL NOTICE Do not use 8mm drill bit.
Hull Replacement
1. Drill a minimum of 15 mm (.6 in) deep.
The hull is sold separately and may be replaced if
damage is deemed too severe. NOTICE Do not drill deeper than 20 mm
(.8 in).
NOTICE The following list is not exhaustive
and represents the general order in which to 2. Install brass insert, cut end first, into hull using
proceed with hull replacement. M6 X 20 screw and a spacer tube or nut.
Remove the following components: 3. Remove screw and spacer tube or nut.
1. All body parts. Refer to BODY. TIGHTENING TORQUE
2. Battery. 3.5 N•m ± 0.5 N•m
M6 X 20 screw
3. Jet pump. Refer to JET PUMP. (31 lbf•in ± 4 lbf•in)
4. Drive shaft. Refer to DRIVE SHAFT.
5. Air intake silencer. AIR INTAKE SYSTEM. HULL SEAL
6. Engine. Refer to ENGINE REMOVAL AND IN-
STALLATION. Do not reuse the hull seal if removed.
7. Remaining cooling system components. Refer
to COOLING SYTEM.
8. Remaining exhaust system components. Re-
fer to EXHAUST SYSTEM.
9. Remaining fuel system components. Refer to
FUEL SYSTEM.
10.Electrical harness.
11.Steering cable. Refer to STEERING AND OTAS
SYSTEMS
12.Remaining hull components.
Hull Thread Repair
In the event that proper torque on screws
threaded into the hull cannot be applied, a brass smr2014-042-012_b
insert can be installed. SEALS
1. Hull seal
2. Front body seal
3. Rear body seal
Hull Seal Removal
For all body removal procedures, refer to BODY
section.
smr2014-042-038_a 1. Remove central body.
BRASS INSERT 2. Remove front bumper.
1. Cut end
3. Remove front body.
The new insert is threaded and will not accept the
old self-tapping screw. A replacement M6 X 20 2UP models.
screw must be used with the brass insert. 4. Remove rear bumpers.
PARTS TO BE INSTALLED 3UP models.
PART PART NUMBER Remove 3UP boarding platform. Refer to 3UP
Brass insert 293 450 345 BOARDING PLATFORM in this section.
M6 X 20 screw 250 000 628
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Subsection XX (HULL)
All models.
5. Remove rear body.
6. Pull on hull seal to remove it.
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3UP BOARDING PLATFORM - VIEW FROM UNDERNEATH
2. M6.81 X 30 torx shoulder screws
3. Wiggle the 3UP boarding platform off the stern
of the watercraft.
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HULL SEAL
Hull Seal Installation
The hull seal is held in place by a perimeter groove
in the hull.
1. Properly position the hull seal above the hull.
2. Firmly press the hull seal into perimeter groove
in hull.
3. Install all removed parts.
3UP BOARDING PLATFORM
3Up Boarding Platform Removal smr2014-042-032_a
1. Loosen the following screws. 3Up Boarding Platform Installation
When installing 3UP boarding platform, ensure
1 1 1 splash tabs are properly positioned on hull.
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3UP BOARDING PLATFORM - VIEW FROM UNDERNEATH 3UP BOARDING PLATFORM
1. M6.31 X 30 hexagonal shoulder screws 1. Splash tabs
2. Remove the following screws.
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Subsection XX (HULL)
TIGHTENING TORQUE
M6.31 X 30 hexagonal 3.5 N•m ± 0.5 N•m
shoulder screw (31 lbf•in ± 4 lbf•in)
M6.81 X 30 torx shoulder 5.5 N•m ± 0.5 N•m
screw (49 lbf•in ± 4 lbf•in)
HULL REINFORCEMENT
There are no inserts glued to the hull of the wa-
tercraft. Instead, the watercraft makes use of hull
reinforcements and carriage bolts. The starboard
side hull reinforcement is also the heat exchanger
and will be covered under COOLING SYSTEM.
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PORT SIDE - VIEW TOWARDS REAR
1. Position of splash tab under hull
2. Port side sponson
Reverse removal sequence.
Install 3UP boarding platform onto hull
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PORT SIDE HULL REINFORCEMENT - UNDER WATERCRAFT
1. Hull reinforcement
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3UP BOARDING PLATFORM - VIEW FROM UNDERNEATH
2. Ensure these points snap into place
1 1 1
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PORT SIDE HULL REINFORCEMENT - INSIDE HULL
1. Hull reinforcement carriage bolt
Hull Reinforcement Removal
1. Remove central body. Refer to BODY.
2. Remove port side engine mount clamps. Refer
to ENGINE REMOVAL AND INSTALLATION.
NOTE: The number and position of shims under
2 engine mount clamps are important to maintain
for proper engine alignment.
3. From under watercraft, pry out hull reinforce-
smr2014-042-031_d ment.
3UP BOARDING PLATFORM - VIEW FROM UNDERNEATH
1. M6.31 X 30 hexagonal shoulder screw - tighten second
2. M6.81 X torx shoulder screw - install first
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Subsection XX (HULL)
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PORT SIDE HULL REINFORCEMENT
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HULL REINFORCEMENT - UNDER WATERCRAFT
1. Hull reinforcement
2. Prybar
4. Clean off sealant residues from hull and hull re-
inforcement.
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PORT SIDE HULL REINFORCEMENT
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Hull Reinforcement Assembly
PORT SIDE HULL REINFORCEMENT
1. Sealant residue Hull reinforcement assembly is the reverse of dis-
assembly.
Hull Reinforcement Disassembly
TIGHTENING TORQUE
1. The following images represent disassembly.
M5 X 25 Shoulder 5 N•m ± 1 N•m
screws (44 lbf•in ± 9 lbf•in)
Hull Reinforcement Installation
Hull reinforcement installation is the reverse of re-
moval.
1. Apply LOCTITE 5900 (P/N 293 800 066) beads as
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indicated.
PORT SIDE HULL REINFORCEMENT NOTE: Heat exchanger shown.
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PORT SIDE HULL REINFORCEMENT LOCTITE 5900 12 MM (15/32 IN) DIAMETER BEAD APPLICATION
INLET GRATE
Inlet Grate Removal
1. Remove central body. Refer to BODY.
2. Remove rear inlet grate screws.
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PORT SIDE HULL REINFORCEMENT
8 smr2014-042
Subsection XX (HULL)
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REAR VIEW - UNDER JET PUMP smr2014-042-035_a
1. Rear inlet grate screws
INLET GRATE SEALANT APPLICATION
3. Remove front inlet grate screws and retaining 2. Install inlet grate in position under watercraft.
nuts.
3. Loosely install front inlet grate retaining screws
and retaining nuts.
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FRONT INLET GRATE SCREWS
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FRONT INLET GRATE SCREWS
4. Hand tighten rear inlet grate screws.
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FRONT INLET GRATE RETAINING NUTS
1. Inlet grate retaining nuts REAR VIEW - UNDER JET PUMP
1. Rear inlet grate screws
4. Remove inlet grate.
5. Tighten screws to the specified torque and se-
Inlet Grate Installation quence.
1. Apply LOCTITE 5900 (P/N 293 800 066) sealant on
inlet grate as indicated.
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Subsection XX (HULL)
TIGHTENING TORQUE SEQUENCE
FASTENER TORQUE
Rear inlet grate 2.5 N•m ± 0.5 N•m
1
screws (22 lbf•in ± 4 lbf•in)
Front M8 inlet
24 N•m ± 2 N•m
2 grate retaining
(18 lbf•ft ± 1 lbf•ft)
nuts
RIDE PLATE
Ride Plate Removal smr2014-042-003_a
1. Remove central and rear body. Refer to BODY. RIDE PLATE RETAINING SCREWS
3UP models 6. Remove ride plate retaining nuts.
2. Remove 3UP boarding platform. See proce-
dure in this subsection.
All models
3. Remove resonator. Refer to EXHAUST.
4. Cut locking tie and remove hose from drain on
ride plate.
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RIDE PLATE RETAINING NUTS - INSIDE HULL
1. Ride plate retaining nuts
7. Remove ride plate retaining nuts and washers.
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DRAIN
1. Locking tie
5. Remove and discard ride plate retaining
screws.
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RIDE PLATE RETAINING NUTS AND WASHERS- ON JET PUMP
SUPPORT
1. M8 stainless steel washers
2. Brass M8 elastic nuts
Ride Plate Cleaning
1. Carefully scrape off all excess sealant from ride
plate and hull.
2. Clean hull surface with BRP HEAVY DUTY
CLEANER (P/N 293 110 001) to eliminate grease,
dust and sealant residue. Clean fitting threads.
10 smr2014-042
Subsection XX (HULL)
Ride Plate Installation 4. Remove jet pump assembly and hose to bailer
1. Apply LOCTITE 5900 (P/N 293 800 066) sealant as elbow. Refer to JET PUMP.
illustrated.
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JET PUMP ASSEMBLY
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RIDE PLATE SEALANT APPLICATION
5. Remove inlet grate.
2. Position ride plate on hull. 6. Remove ride plate with drain and drain hose.
3. Tighten ride plate retaining nuts and screws to 7. Disconnect water supply and return hoses from
the specified torque and sequence. jet pump support.
TIGHTENING TORQUE SEQUENCE
FASTENER TORQUE
M8 Ride plate
25 N•m ± 1 N•m
1 retaining nuts (on
(18 lbf•ft ± 1 lbf•ft)
jet pump support)
M8 Ride plate
24 N•m ± 2 N•m
2 retaining nuts (inside
(18 lbf•ft ± 1 lbf•ft)
hull)
4. Reinstall other removed parts. Refer to appro-
priate subsections for procedures.
smr2014-042-028_a
JET PUMP SUPPORT PORT SIDE - INSIDE THE HULL
1. Exhaust water supply hose
2. Exhaust water return hose
Jet Pump Support Removal
1. Remove central body. Refer to BODY. 8. Disconnect ground strap.
2. Cut locking ties on bailer elbow and pick up.
smr2014-042-043_a
1. Locking ties to cut
3. Remove steering cable. Refer to STEERING.
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Subsection XX (HULL)
Jet Pump Support Cleaning
1. Scrape off all excess sealant from jet pump sup-
port, ride plate, and hull.
2. Inspect pump support for cracks or other dam-
age.
3. Clean jet pump support and hull surface with
BRP HEAVY DUTY CLEANER (P/N 293 110 001) to
eliminate grease, dust, and sealant residue.
Jet Pump Support Installation
1. Install new jet pump support gasket.
2. Position the jet pump support against the hull.
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STARBOARD SIDE - INSIDE THE HULL
1. Ground strap
9. Remove jet pump support retaining screws and
washers.
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JET PUMP SUPPORT
1. Jet pump support to hull contact
3. Inside the hull, thread all 3 jet pump support
screws.
4. Tighten jet pump support screws.
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JET PUMP SUPPORT - VIEW FROM INSIDE HULL
1. Jet pump support retaining screws
10. Pull jet pump support off the hull.
11. Remove jet pump gasket.
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JET PUMP SUPPORT - VIEW FROM INSIDE HULL
1. Jet pump support screws
TIGHTENING TORQUE
M8 Jet pump support 24 N•m ± 2 N•m
screws (18 lbf•ft ± 1 lbf•ft)
smr2014-042-030_a 5. Reinstall other removed parts. Refer to appro-
JET PUMP SUPPORT priate subsections for procedures.
1. Jet pump support gasket
2. Jet pump support
3. Zinc anode
12 smr2014-042
Subsection XX (HULL)
FIXED REAR SPONSONS The bailer pick up is connected to a syphon tube
mounted in the jet pump venturi that use the jet
NOTE: Removal and installation procedure for pump thrust to create a vacuum. The bailer is also
port and starboard sponsons is similar. connected to the bilge drain plug on the ride plate.
Refer to exploded view at the beginning of this
section. Bailer Pick-Up Location
Fixed Rear Sponson Removal
smr2014-042-009_a
smr2014-042-006_a 1. Bailer pick-up
PORT SPONSON
Bailer Pick-Up Inspection
Fixed Rear Sponson Installation 1. Check holes in the bailer pick-up to see if ob-
1. Clean off any silicone sealant residues from hull structed. Clean if necessary.
and sponson. 2. Check if the hole on bailer hose elbow fitting is
2. Apply LOCTITE 5900 (P/N 293 800 066) on back obstructed. Clean if necessary.
side of sponsons.
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BACK OF PORT SPONSON
3. Apply a small amount of LOCTITE 5900 (P/N 293
800 066) into each hull hole. smr2014-042-009_b
1. bailer hose elbow fitting
NOTE: When repositioning the bailer hose elbow
fitting, position it at the highest available point on
the rear support.
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REAR PORT HULL
TIGHTENING TORQUE
11 N•m ± 1 N•m
Sponson screws
(97 lbf•in ± 9 lbf•in)
BAILER
The bailer pick up draws water from the bilge
when watercraft is in operation.
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Subsection XX (HULL)
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EYELET AND HARDWARE
1. Eyelet
2. Small stainless steel washer - outside hull
3. Large stainless steel washer - inside
4. M8 hexagonal nuts
smr2014-042-010_a
2. Remove eyelet.
FRONT (LEFT) AND REAR (RIGHT) VIEW OF REAR SUPPORT
1. Bailer hose elbow Eyelet Installation
2. Locking tie on rear support
TIGHTENING TORQUE
DRAIN PLUG M8 hexagonal nuts
11.5 N•m ± 1.5 N•m
(102 lbf•in ± 13 lbf•in)
NOTE: The drain plug on the ride plate is con-
nected to a bailer. When watercraft is off the
water, the drain plug can be unscrewed to man-
ually drain the bilge.
Drain Plug Neck Location
smr2014-042-016_a
DRAIN PLUG LOCATION
1. Drain plug
BOW EYELET
Eyelet Access
Remove central body. Refer to BODY.
Eyelet Removal
1. Unscrew and discard both M8 hexagonal nuts.
NOTE: Keep all washers for installation.
14 smr2014-042
