BOMBARDIER SEA-DOO GTX RFI 5666 1998 Manual
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BOMBARDIER SEA-DOO GTX RFI 5666 1998 Manual

BOMBARDIER SEA-DOO GTX RFI 5666 1998 Manual

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Summary of Contents for BOMBARDIER SEA-DOO GTX RFI 5666 1998

  • Page 2 Bombardier Inc. © Bombardier Inc. 1998 Printed in Canada ® *Registered trademarks of Bombardier Inc. ® Loctite is a trademark of Loctite Corporation ® Snap-on is a trademark of Snap-on Tools Corporation ®...
  • Page 3 TABLE OF CONTENTS PAGE SECTION SUBSECTION SAFETY NOTICE ..........................MAINTENANCE 01 - Table of contents ..............01-01-1 02 - Periodic inspection chart ............01-02-1 03 - Flushing and lubrication............. 01-03-1 04 - Storage..................01-04-1 ENGINE 01 - Table of contents ..............02-01-1 02 - Magneto system ...............
  • Page 4 Always use common shop safety practice. This information relates to the preparation and use of Bombardier watercraft and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents.

  • Page 5: Table Of Contents

    Section 01 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS PERIODIC INSPECTION CHART.................... 01-02-1 FLUSHING AND LUBRICATION.................... 01-03-1 GENERAL ........................... 01-03-1 PROCEDURE ........................01-03-1 STORAGE..........................01-04-1 VOLUME 1 1998 VOLUME 2 01-01-1...

  • Page 6: Periodic Inspection Chart

    Section 01 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency. FREQUENCY Every DESCRIPTION Every Every Every 100 hours or 10 hours 25 hours 50 hours seasonally Lubrication/corrosion protection of metallic components Engine ignition timing Spark plug replacement...

  • Page 7: Flushing And Lubrication

    Perform this operation in a well ventilated area. Do not touch any electrical parts or jet pump area when engine is running. Clean jet pump by spraying water in its inlet and outlet and then spray BOMBARDIER LUBE lubri- F00E01A cant. 1. Quick connect adapter...
  • Page 8 1. Grounding device Remove both spark plugs and spray BOMBAR- DIER LUBE lubricant into each cylinder. NOTE: For the storage period, use Bombardier storage oil (P/N 413 711 600). Fully apply the throttle lever then depress the start/stop button to crank the engine a few turns to distribute the oil onto cylinder wall.

  • Page 9: Storage

    Section 01 MAINTENANCE Subsection 04 (STORAGE) STORAGE Engine Draining CAUTION Disconnect the water supply hose used to cool the magneto. It features a quick connect fitting. Water in engine must be free to flow out. Press both tabs and pull fitting in order to discon- Should water freeze in engine, severe dam- nect hose.
  • Page 10 F01I0BA Wipe off any residual water in the engine com- partment. 1. Grease PTO flywheel Spray BOMBARDIER LUBE lubricant over all me- CAUTION tallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER Never leave any clothing, tool or other ob- LUBE lubricant.
  • Page 11 Section 01 MAINTENANCE Subsection 04 (STORAGE) Install a hose pincher to water return hose of the magneto cooling circuit. F06E0FA TYPICAL 1. Hose pincher installed on the engine water supply hose F07E07Y 1. Hose pincher to water return hose Temporarily install a short piece of hose to engine water outlet at cylinder head.
  • Page 12 Section 02 ENGINE Subsection 01 (TABLE OF CONTENT) TABLE OF CONTENT MAGNETO SYSTEM ......................02-02-1 CRANKCASE.......................... 02-03-1 VOLUME 1 1998 VOLUME 2 02-01-1...
  • Page 13 Section 02 ENGINE Subsection 02 (MAGNETO SYSTEM) MAGNETO SYSTEM 9 N•m (80 lbf•in) Loctite 242 Synthetic grease 9 N•m (80 lbf•in) 105 N•m (77 lbf•ft) Loctite 242 4 N•m (35 lbf•in) 9 N•m (80 lbf•in) Anti-seize lubricant 9 N•m (80 lbf•in) 6 N•m Synthetic (53 lbf•in)
  • Page 14 Section 02 ENGINE Subsection 03 (CRANKCASE) CRANKCASE 30 mL (1 oz) BOMBARDIER-ROTAX Injection oil Loctite 20 N•m Synthetic (15 lbf•ft) grease 9 N•m (80 lbf•in) Loctite 40 N•m (30 lbf•ft) Loctite Loctite Synthetic 24 N•m grease 24 N•m (17 lbf•ft) (17 lbf•ft)
  • Page 15 Section 03 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS CIRCUIT..........................03-02-1 VOLUME 1 1998 VOLUME 2 03-01-1...
  • Page 16 Section 03 COOLING SYSTEM Subsection 02 (CIRCUIT) CIRCUIT F07E08S 03-02-1...
  • Page 17 Section 04 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL INJECTION........................04-02-1 INTRODUCTION ........................ 04-02-1 AIR INDUCTION......................... 04-02-2 FUEL DELIVERY ......................... 04-02-2 ELECTRONIC MANAGEMENT..................04-02-3 DIAGNOSTIC PROCEDURES .................... 04-02-6 FAULT CODE TABLES....................... 04-02-7 COMPONENT INSPECTION....................04-02-8 AIR INDUCTION SYSTEM....................04-02-8 FUEL DELIVERY .........................

  • Page 18: Fuel Injection

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) FUEL INJECTION INTRODUCTION F07F0OS DESCRIPTION OF THE FUEL INJECTION SYSTEM 1. Fuel tank 9. Throttle plate 2. Fuel filter 10. Throttle Position Sensor (TPS) 3. Fuel pump 11. Air Pressure Sensor (APS) 4.

  • Page 19: Air Induction

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) The Rotax Fuel Injection (RFI) is a semi-direct FUEL DELIVERY electronic fuel injection system. An electric fuel pump supplies the fuel to the fuel Fuel is injected into each cylinder through the rear rail and injectors.

  • Page 20: Electronic Management

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) ELECTRONIC MANAGEMENT Electronic Control Unit (ECU) The electronic fuel injection is equipped with a Bosch Electronic Control Unit (ECU). F07F0LA 1. End cap of fuel pump assembly removed 2. Internal fuel filter All these components are comprised in a single module mounted in the fuel tank.
  • Page 21 Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) 5. Diagnostic mode It is responsible of the following electrical func- tions: The ECU is able to detect malfunctions in the sen- sor network. The malfunction is recorded in the – interpreting information memory of the ECU.
  • Page 22 Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) PARAMETERS FUEL SENSORS DELIVERY Intake air Air Pressure pressure Sensor Fuel tank (APS) Crankshaft Crankshaft position and Position Fuel filter Sensor (CPS) engine speed Throttle valve Throttle Position position (Idle to Fuel pump wide open throttle Sensor (TPS) Engine...

  • Page 23: Diagnostic Procedures

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) DIAGNOSTIC PROCEDURES The MPEM programmer is the primary tool to di- By selecting DIAGNOSIS the following message agnose fuel injection related problems. “INITIALIZING IN PROCESS” will be displayed a few seconds, then a new menu will appear on the The latest software designed for the RFI model screen.

  • Page 24: Fault Code Tables

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) FAULT CODE TABLES ECU Faults FAULT DETECTION FAULT CODE TYPE OF FAULT No fault detected FF FF 88 = no defect 00 = internal defect Electronic Control Unit not OK FF FF 1B = not plausible = EEPROM defect EEPROM not assembly-line FF FE...

  • Page 25: Component Inspection

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) COMPONENT INSPECTION Engine problems are not necessarily related to the electronic fuel injection system. It is important to check that the electrical system is functioning properly. – battery – fuses – DESS –...

  • Page 26: Electronic Management

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) Fuel Injector Reinstall both injectors to the fuel rail. Reconnect the wire connector of the injector. Place each injector in a clean bowl. Install the safety lanyard cap on the switch to ac- tivate the fuel pump.
  • Page 27 Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) NOTE: As an alternate method, the resistance of Crankshaft Position Sensor (CPS) the throttle position sensor can also be checked Check the resistance of the crankshaft position through the connector no. 4 of the MPEM follow- sensor.
  • Page 28 Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) Disconnect the connector of the air temperature Water Temperature Sensor (WTS) sensor. Check the water temperature sensor resistance. Using a multimeter, check the resistance be- tween both terminals. The resistance should be between 2.280 kΩ and 2.736 kΩ...
  • Page 29 Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) Check the air pressure sensor resistance. Disconnect the connector of the air pressure sen- sor. Using a multimeter, check the resistance be- tween the terminals 1 and 2 of the air pressure sensor.

  • Page 30: Troubleshooting Summary

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) TROUBLESHOOTING SUMMARY ENGINE DOES NOT START WARNING If the engine does not start, the following items Always use spark plug cable grounding de- should be verified in this order: vice when removing spark plug cables. –...

  • Page 31: Engine Starts But Stalls After Approximately 30 Seconds

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS The RPM signal (GREY wire) is short circuit to the ground. Check wire condition. If the wire test good, either the tachometer or Info Center is de- fective.

  • Page 32: Adjustment

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) ADJUSTMENT THROTTLE POSITION SENSOR Idle Speed (TPS) Turn idle speed screw until it touches the stopper. Turn idle speed screw 2-3/4 turns as a preliminary This adjustment is very important. The setting of adjustment.

  • Page 33: Removal And Installation

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) REMOVAL AND INSTALLATION THROTTLE POSITION SENSOR FUEL PUMP ASSEMBLY (TPS) Open the front storage compartment cover. Remove the air intake silencer. Remove the storage basket. Remove the flame arrester. Remove the glove box. Remove the air temperature sensor to ease re- Disconnect the wire connector from the fuel moval of the TPS.

  • Page 34: Fuel Injector

    Section 04 FUEL SYSTEM Subsection 02 (FUEL INJECTION) Regulator The regulator is not serviceable. Replace the fuel pump assembly if the regulator is defective. Fuel Filter The fuel filter is not serviceable. Replace the fuel pump assembly if the fuel filter must be replaced. FUEL INJECTOR Place a suitable container below the quick con- nect fitting of the fuel rail.
  • Page 35 Section 05 ELECTRICAL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION SYSTEM........................ 05-02-1 GENERAL ........................... 05-02-1 INSPECTION ........................05-02-1 IGNITION TIMING ......................05-02-1 CHARGING SYSTEM......................05-03-1 GENERAL ........................... 05-03-1 TESTING PROCEDURE ..................... 05-03-1 VOLUME 1 1998 VOLUME 2 05-01-1...
  • Page 36 Section 05 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION SYSTEM GENERAL IGNITION TIMING On this ignition system, the spark plugs spark in- Adjustment dependently. To perform this adjustment, proceed as follows: The Electronic Control Unit (ECU) controls the ig- NOTE: For the static and dynamic tests, refer to nition timing and signals the ignition coil at the the 1998 Sea-Doo Shop Manual .
  • Page 37 Section 05 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL TESTING PROCEDURE NOTE: First, ensure that battery is in good condi- Magneto tion prior to performing the following tests. The purpose of the charging system is to keep the battery at a full state of charge.
  • Page 38 Section 05 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) STATIC TEST: INSULATION DYNAMIC TEST 1. Disconnect the magneto wiring harness con- 1. Disconnect the magneto wiring harness con- nector. nector. 2. Install the 4-pin magneto harness adapter (P/N 2. Install the 4-pin magneto harness adapter (P/N 295 000 131).
  • Page 39 Section 06 TECHNICAL DATA Subsection 01 (GTX RFI MODEL) GTX RFI MODEL ENGINE GTX RFI (5666/5843) Engine type BOMBARDIER-ROTAX 787 Induction type Rotary valve Type Water cooled, water injected with regulator Water injection fitting 3.5 mm (.139 in) (head) Exhaust system...
  • Page 40 Section 06 TECHNICAL DATA Subsection 01 (GTX RFI MODEL) ELECTRICAL SYSTEM GTX RFI (5666/5843) Magneto generator output 270 W @ 6000 RPM Ignition system type Digital, inductive type Make and type NGK BR8ES Spark plug 0.6 - 0.8 mm (.024 - .031 in) mm (in) 0.858 (.0338) Ignition timing...
  • Page 41 Section 06 TECHNICAL DATA Subsection 01 (GTX RFI MODEL) PROPULSION GTX RFI (5666/5843) Propulsion system Bombardier Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC...
  • Page 42 Section 06 TECHNICAL DATA Subsection 01 (GTX RFI MODEL) MATERIALS GTX RFI (5666/5843) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Resonator Plastic Steering padding Thermoplastic with polyethylene foam Fuel tank Polyethylene Oil injection reservoir...
  • Page 43 Section 06 TECHNICAL DATA Subsection 01 (GTX RFI MODEL) TIGHTENING TORQUES GTX RFI (5666/5843) Exhaust manifold screw 40 N•m (30 lbf•ft) (3) (4) Magneto flywheel nut 105 N•m (77 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) 24 N•m (17 lbf•ft) (3) (4) Crankcase screws 40 N•m...

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Sea-doo gtx rfi 5843 1998

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