INSTALLATION INSTRUCTIONS
Contents
1. m RACING Z N PERFORMANCE PRODUCTS amp ACCESSORIES Sea Doo 4 TEC Open Loop Cooling Kit PART RS1013 50 We strongly recommend the use of a service manual to familiarize yourself with the various components and procedures involved with this installation Please note that some of the original clamps hoses and hardware removed in the disassembly process will be used in the installation process These instructions have been written in point form and refer to illustrations Please follow these step by step instructions and illustrations carefully Water routing illustrations are provided as a reference during installation APPLICATIONS 255 215hp Sea Doo Models zez ALLOW ENGINE TO COOL COMPLETELY BEFORE PERFORMING INSTALLATION xxx Required tools Part Oetiker Pliers C 84550347 E 8 Star Socket RS90531 8 pc set Dremmel Tool N A Drain Pan LG N A Service Manual CALL INSTALLATION INSTRUCTIONS Remove seats At pump disconnect steering cable and reverse cable from steering nozzle Disconnect VTS rod from VTS motor rod Drain engine coolant following steps outlined in the Sea Doo Vehicle Shop Manual 4 TEC Manual Please recycle or dispose of coolant properly Coolant expansion tank holder removal RXP X RXP Models Only Unclip engine coolant overflow tank Disconnect hoses and remove overflow tank Hemove engine compartment cowling 5 bolts RXT X RXT Unclip engine coolant overflow tank Disconnect2. to 3 4 bypass using stock hose clamp Replace supercharger air inlet components NOTE Do not over tighten bolts Replace intercooler air inlet and outlet tubes NOTE Do not over tighten bolts If using a stock water box replace exhaust outlet tube NOTE Do not over tighten clamps At rear of craft in pump area replace OE water inlet reducer with supplied reducer NOTE Supplied water reducer has a larger LD and is stamped with an X on one side If a RIVA Performance Ride Plate will be installed continue with the instructions included with ride plate Otherwise apply glass cleaner to rubber seal on pump assembly Install pump into craft and secure using supplied bolts NOTE Apply blue Loc tite to bolts Torque to 31 Nem 23 Ibf ft in a criss cross pattern Reconnect VTS rod reverse cable and steering cable NOTE Do not over tighten bolts If O P A S was removed proceed to next step Otherwise reconnect O P A S bracket to steering nozzle NOTE Use blue Loc Tite Torque bolt to 25 Nem 18 Ibfeft RXP X RXP Models Only Replace engine compartment cowling 5 bolts RXT X RXT Replace engine compartment cross section 4 bolts Check bilge for tools rags etc Run craft on flush kit to check for leaks and to ensure smooth operation IMPORTANT MAINTENANCE INFORMATION Flushing To assure optimal performance with this kit extra care must be used with flushing The Open Loop flush connector will b
3. e or loss of use while being repaired A copy of the original invoice and a Return Authorization Number DAS must accompany all warranty claims Warranted replacement parts will be returned freight collect Word doc RS1013 50 H1 12 16 09 255hp Intercooler Upgrade Kit amp 215hp GEN 2 Power Cooler Kit Water Routing Illustration p 8 Bypass Fitting 3 4 0 D x 24 L 3 4 0 D x 24 L u vU 3 COOLING 3 4 0 D x 12 L LINE B GEN 2 INTERCOOLER tO co x lt m 3 4 0 D x33 L S COOLING S LINE A y x x Q 1 2 0 D x 24 L Q o o Ss ei q e 7 1 2 0 D x 32 L SS Epor FLUSH KIT A FITTING OUTLET 3 4 0 D x 33 L m 2 lt T gt es e gt Tl o e C OIL COOLER INTAKE MANIFOLD CYLINDER HEAD Supplied Oetiker Clamp OE Hose Clamp Supplied Barbed Hose Splicer O u s 215hp GEN 2 Power Cooler Kit Water Routing Illustration Supplied 3 4 Bypass Fitting PUMP TRANSOM BE po di GEN 1 P d Dish 3 4 0 D x 24 L 3 4 0 D x 24 L 3 4 0 D x 16 L De E E 3 x COOLING FLUSH KIT e LINE B FITTING o set e 1 2 0 D x 12 L 3 4 0 D x 33 L 1 2 0 D x 24 L A io COOLING 1 2 0 D x 36 L M LINE A e o set e _ 31 0 i THERMOSTAT UNIT OUTLET GQ O3INVIN LS VHX3 OIL COOLER INTAKE MANIFOLD CYLINDER HEAD Supplied Oetiker Clamp OE Hose Clamp Supplied Barbed Hose Sp
4. e used in place of the stock flush kit fitting in the pump We strongly recommend the use of a salt deposit remover such as Salt Away which can be purchased through RIVA Racing s parts department When flushing with a salt deposit remover do not flush with fresh water afterwards Allow salt deposit remover to remain in cooling system This will prevent build up of salt or deposits from residual water in cooling system At the end of your riding season we recommend winterizing your craft if you are unable to ride for an extended period of time Sacrificial Anode Open Loop Cooling Kit water pump cover is equipped with a sacrificial anode This is to prevent corrosion from occurring in the motor should you forget to flush your craft However it is not intended to be used as an alternative to flushing your craft Anode will deteriorate over time and should be replaced each season or as needed Check anode at beginning and end of riding season When replacing apply pipe thread sealant to threads and do not over tighten Replacement anodes are available through RIVA Racing s parts department Remember the water belongs to everyone Please ride responsibly and respect the environment Technical Support For answers to questions regarding installation or trouble shooting RIVA Performance Products contact RIVA Technical Support directly at 954 247 0705 or by e mail at tech _support rivamotorsports com Limited Warranty RIVA Open Loop C
5. ed 24 length of 1 2 waterline between lower cooling line oil cooler outlet line and 3 8 transom fitting Secure to oil cooler line using supplied 21 0 Oetiker Secure to transom fitting using stock clamp Install the supplied 36 length of 1 2 waterline to the upper cooling line oil cooler inlet line Secure using Houte waterline under drive shaft and towards exhaust pipe water box joint Attach to applicable fitting see below and secure using stock hose clamp Trim excess as needed 08 amp newer attach to fitting under end of exhaust manifold 07 amp older attach to fitting at top of J pipe trim excess as needed Secure using stock hose clamp Replace VTS motor unit into thru hull fitting making sure rubber grommet at bottom of housing is installed onto VTS mounting bracket Word doc RS1013 50 H1 12 16 09 At rear of craft in pump area replace and secure VTS motor nut Replace and secure rubber boot sealing VTS motor shaft NOTE Do not over tighten nut Replace Power Filter Tube NOTE Apply blue Loc tite to bolts Do not over tighten bolts Do not over tighten clamps Replace throttle body and secure using OE bolts NOTE Torque bolts to 11 Nem 97 Ibf in in a criss cross pattern Install 36 length of supplied 3 4 cooling line between thermostat on cylinder head and 3 4 bypass fitting in hull Trim excess as needed Secure to thermostat using supplied 30 1 Oetiker Secure
6. hoses and remove overflow tank Hemove engine compartment cross section 4 bolts If O P A S was removed previously proceed to next step Otherwise remove bolt securing O P A S bracket to underside of steering nozzle Word doc RS1013 50 H1 12 16 09 1 Remove bolts 4 securing pump assembly to hull Hemove pump assembly Remove rubber boot sealing VTS motor shaft Remove nut securing VTS motor unit to hull If using a RIVA Pro Series Water Box proceed to next step Otherwise remove exhaust tube between water box and thru hull outlet Remove intercooler air inlet and outlet tubes Loosen the four bolts securing throttle body to intake manifold Remove throttle body and move forward in engine compartment Remove the two bolts securing front of RIVA Power Filter tube to engine bracket This will allow you to move Power Filter tube as needed during installation process Inside hull remove VTS motor unit from thru hull fitting and move forward in engine compartment Disconnect hoses 6 connected to thermostat housing Completely remove all hoses except for the two connected to oil cooler s 3 amp 5 Word doc RS1013 50 H1 12 16 09 Coolant to oil cooler 3 Coolant from engine oO Coolant to ride plate Coolant from expansion tank Coolant to oil cooler Coolant from Coolant from oil cooler ride plate If a RIVA Performance Ride Plate will be installed pr
7. licer O u s 3 4 0 D x 33 L
8. nd transom NOTE Enough cooling line is provided so that bypass can be installed in transom near rear exhaust outlet However bypass can be installed in pump transom tunnel if desired Install supplied 3 4 cooling line assembly labeled A between the intercooler and motor The 15 length attaches to billet water pump cover Secure with stock hose clamp The 33 length attaches to fitting at front of exhaust manifold route under drive shaft and motor Secure with stock hose clamp Route open end 14 length towards intercooler support bracket Install supplied 3 4 cooling line assembly labeled B Attach 24 length to transom inlet fitting Route 12 length towards intercooler Route flush kit so it can be secured in an accessible location Attach 3 4 cooling lines to intercooler Secure with stock hose clamps Word doc RS1013 50 H1 12 16 09 E d i H wg A r K P 1 V Lu gt VY 7 d ho rd d A 1 Line in to intercooler from transom flush kit 2 Line out from intercooler to motor Replace intercooler and secure to support bracket On right side of engine cut oil cooler lines just before support bracket Install supplied 1 2 x 5 8 brass hose splicer into each hose and secure using supplied 25 6 Oetikers m x e Si SE A m E ben d AC 1 J k L Lar NOTE Larger end of splicer goes into oil cooler hose Install suppli
9. oceed to next step Otherwise install supplied vinyl caps over stock ride plate fittings and secure using supplied zip ties Remove bolts 8 securing thermostat housing to engine Remove thermostat housing from engine NOTE Do not remove impeller from engine Transfer o ring from back of thermostat housing to back of supplied billet water pump cover Apply a thin coat of grease to o ring Install billet water pump cover onto engine and secure using OE bolts Torque to 89 Ibf in 10 Nem NOTE Apply blue Loc tite to bolts At rear of cylinder head remove the barbed brass fitting for coolant overflow hose Install supplied stainless steel block off screw d n 4 1 N r e te i m N a mmm NOTE Apply pipe thread sealant to threads Tighten screw until head is flush with cylinder head Install supplied thermostat unit onto rear of cylinder head Secure using the supplied 47 0 Oetiker Cooling Line Removal 255hp Models Only Locate and completely remove cooling lines with T fitting coming in from transom to intercooler and exhaust manifold as well as cooling lines with T fitting going to transom from exhaust manifold and intercooler Word doc RS1013 50 H1 12 16 09 215hp Models Only Locate and completely remove the cooling lines from transom to intercooler and from intercooler to exhaust manifold Locate and remove 3 8 waterline between top of J pipe a
10. ooling Kits carry a 1 year limited warranty to the original purchaser They are warranted to be free of defects in materials and workmanship under normal use and service Customer modified components will be void of warranty This warranty is limited to defects in the primary components only Finish and or wear marks in or on primary components are not covered under this warranty RIVA Racing s liability is expressly limited to the repair or replacement of the components contained within or associated with this kit RIVA Racing agrees to repair or at RIVA s option replace any defective unit without charge if product is returned to RIVA Racing freight prepaid within the warranty period Any equipment returned which in RIVA s opinion has been subjected to misuse abuse overheating or accident shall not be covered by this warranty RIVA Racing shall have no liability for special incidental or consequential damages or injury to persons or property from any cause arising from the sale installation or use of this product No other warranty express or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose applies Various states do not allow for the limitation of incidental or consequential damages and therefore the above exclusion or limitation may not apply to you Warranty does not include the expenses related to freight or transportation of parts or compensation for any inconvenienc
Download Pdf Manuals
Related Search