Now that the ROTAX 4-TEC Marine Engines have been out on waterways long enough to show a few of it’s tricks, one aspect is proving to be important to pay attention to for ensuring smooth operation and to avoid any potential issues. Most of the steps we will outline in this first installment of DOCTOR DOO can help the die-hard 2-Stroke fans and any other spark plug installation

It is important to keep spark plugs fresh and replace them from time to time as outlined in your BRP/Sea-Doo owner’s manual and we are going to share a few tips on how to do this with the proper technique. First, be sure to conduct your maintenance work in a well-lit and ventilated area and always wear safety glasses. After removing the spark plug cap or coil “stick”, use a controlled amount of compressed air to blow any and all moisture or debris away from the spark plug tube and area. Follow this with the actual spark plug removal using the proper fitting spark plug socket.

If any resistance is found when backing out the spark plug, be as gentle as possible as the threaded spark plug hole in the cylinder head is made of aluminum.

The spark plug’s threads are made of a much harder steel, so the relatively low priced spark plug isn’t nearly as important to protect as the threads of the precious cylinder head.  If you do indeed face a difficult removal, do not force the spark plug and consult a certified BRP/Sea-Doo technician.  Sometimes it’s too late at this point as damage may have occurred a the last spark plug install, not at the removal.

Recommended lubricants

Let’s get on to proper installation. Using a quality spark plug, BRP specified gap and correct heat range, apply a small amount of quality anti-seize lubricant on the threads of the spark plug.  PPG uses “Loctite”brand anti-seize compound (BRP part number 293 800 070) it’s really good stuff and available at most BRP/Sea-Doo/Ski-Doo/Can-Am dealers. This product can be used in many places on all of your mechanical devices to make living with them much easier thanks to it’s anti-corrosive properties.


Apply anti-seize equally to threads

Apply a small amount of the anti-seize, evenly spread over the spark plugs’ threads prior to installation. Using one of the cap/coil ‘sticks’ or similar device, thread the plug into the spark plug hole in the cylinder head making sure the plug bottoms into the plug base surface easily.  Then tighten by applying the proper BRP suggested torque (17 foot pounds will do nicely) to seat the spark plug completely.


If it looks worn, replace it!

Now onto the spark plug cap/coil “stick” install. The rubber grommet at the upper section of the coil is a major protector of not only the coil itself but the deep recess that the spark plug resides in. If the grommet isn’t fitting very tight around the coil, replace it! If the multi-rib sealing, outer rings are flattened, broken, or disfigured, replace it!


Apply Dielectric grease to cap seat

Apply a liberal amount of dielectric grease/compound to the fitment as shown in the images and it will not only protect the coil, it will keep out debris and water. PPG uses Dow Corning 111 compound and this too can be purchased at most BRP dealerships (part number 413 707 000). One tube can last a very long time is stored properly.


Protect all electrical connections with dielectric grease.

PPG also applies dielectric grease to all wiring termination points and its anti corrosion qualities are worth every cent! The images show that our technicians use it on the harness connection and the spark plug cap/plug fitment.


Simple preventive maintenance efforts can go a long way in ensuring your time on the water with your Sea-Doo boat or watercraft are trouble free and can also save you money in addition to headaches in the long run. Sea-Doo product are engineered to last over a decade but you have to do your part in maintaining proper operations.
Perry Performance Group is an authorized BRP/Sea-Doo/Can-Am service center based in Dania Beach, Florida specializing in Sea-Doo service and performance headed by powersports business veteran Glen Perry who also host the enthusiasts forum sea-doo.net. Perry is appropriately and deservingly this edition’s, Doctor Doo