Sea-doo GTI Operator's Manual
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Sea-doo GTI Operator's Manual

Jetski 2004
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  • Page 1 www.SeaDooManuals.net...
  • Page 2 This Operator’s Guide utilizes the following symbols to emphasis particular infor- mation: The Safety Alert Symbol indicates a potential personal injury hazard. Indicates a potentially hazardous situation which, if not WARNING avoided, could result in serious injury or death. CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.
  • Page 3 FOREWORD The Operator’s Guide has been pre- It is understood that this guide may be pared to acquaint the owner/operator translated into another language. In or passenger with this personal water- the event of any discrepancy, the En- craft and its various controls, mainte- glish version shall prevail.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION INTRODUCTION................SAFETY CHECK LIST ..............General ....................GETTING UNDERWAY ..............10 To Wear ....................To Bring ....................To Do ....................... OPERATION ................13 Collision Avoidance.................. Safe Riding ....................Operator/Passenger Awareness.............. Maneuverabitily of the Watercraft/Towing ..........OPERATING RULES ..............
  • Page 5 12) Fuel Tank Valve ................. 13) Fuel Tank Cap ................... 14) Oil Injection Reservoir Cap..............15) Front Storage Compartment Cover........... 16) Front Storage Compartment Cover Latch......... 17) Tool Kit ....................18) Air Intake Opening ................19) Seat Strap ..................20) Seat Latch (if so equipped) ............... 21) Seat Extension Latch (if so equipped)..........
  • Page 6 Engine Compartment ................Steering System ..................Throttle System ..................Shifter System (if so equipped) ............... VTS (Variable Trim System) (if so equipped) ..........Storage Compartment Covers and Seat..........Safety Lanyard and Engine Start/Stop Button ......... OPERATING INSTRUCTIONS ............57 Principle of Operation ................Boarding the Watercraft ................
  • Page 7 MAINTENANCE ................83 Lubrication....................Throttle and Choke Cable Inspection ............Carburetor Adjustment................Fuel Injection System................Fuel and Oil Filters................... Steering Alignment.................. VTS Adjustment (if so equipped)............. Vacuum Bailer Pick-Ups ................Fuses....................... O.P.A.S. System (if so equipped) ............General Inspection and Cleaning............. TRAILERING, STORAGE AND PRESEASON PREPARATION..

  • Page 8: Safety Information

    SAFETY INFORMATION SAFETY INFORMATION www.SeaDooManuals.net...

  • Page 9: Introduction

    INTRODUCTION Congratulations, you are now the proud • This safety section is for initial ref- owner of a Sea-Doo personal water- erence and its content is therefore craft. You have selected one of the limited. section It should be read in most popular craft on water.

  • Page 10: Safety Check List

    SAFETY CHECK LIST q Boarding in deep water can be To fully appreciate the pleasures, en- joyment and excitement of boating strenuous. Practice in chest-deep there are some basic rules that should water before operating or embark- be observed and followed by any boat- ing your watercraft in deep water.

  • Page 11: Getting Underway

    GETTING UNDERWAY To Wear q The operator and passenger(s) must wear a Coast Guard approved Per- sonal Flotation Device (PFD) that is suitable for PWC use. q An operator and the watercraft’s passenger(s) should have ready ac- cess to shatterproof glasses should riding conditions or personal prefer- ence warrant.
  • Page 12 Eye protection Vest-type personal flotation device Gloves Wet suit or wet suit bottom Foot protection F00A12L SAFETY INFORMATION www.SeaDooManuals.net...

  • Page 13: To Bring

    To Bring To Do q Always carry the regulatory safety q Read and understand all warning/ items and have them conveniently caution labels on your Sea-Doo PWC, on board available for use. Check the your Operator’s Guide, all other safe- local regulations or consult your au- ty documents, and watch properly thorized Sea-Doo dealer.

  • Page 14: Operation

    OPERATION Collision Avoidance Safe Riding q Do not release throttle when trying q Always keep in mind that as the to steer away from objects. You throttle lever is released to idle po- need throttle to steer. sition, less directional control is available, and as the engine is off, q Always keep a constant lookout for directional control is lost.

  • Page 15: Operator/Passenger Awareness

    Operator/Passenger Maneuverabitily of the Awareness Watercraft/Towing q Never turn handlebar while someone q Do not overload the watercraft or is nearby rear of watercraft. Keep take on more passengers than des- away from steering moving parts ignated for the particular watercraft. (nozzle, side vanes, linkage, etc.).

  • Page 16: Operating Rules

    OPERATING RULES Operating a watercraft can be com- Meeting Head-On pared with driving unmarked highways Keep right. and roads. To prevent collisions or avoid other boaters, a system of oper- ating rules must be followed. It’s not only common sense...it’s the law! Remember these Rules of the Road F00A15Y...

  • Page 17: Waterskiing Signals

    WATERSKIING SIGNALS For your information, here are the most commonly used waterskiing signals. Slower Stop Faster Turn right Back to dock Speed OK Turn left Fallen skier — Watch out F00A17L SAFETY INFORMATION www.SeaDooManuals.net...

  • Page 18: Web Sites

    WEB SITES Sea-Doo website: www.sea-doo.com Canadian Coast Guard (Office of www.ccg-gcc.gc.ca/obs-bsn/sbg-gsn/main_e.htm Boating Safety) United States www.uscgboating.org/regulations/boating_laws.htm Coast Guard Alabama www.dcnr.state.al.us/mp/menu.htm Alaska www.dnr.state.ak.us/parks/boating Arizona www.azgfd.com Arkansas www.agfc.state.ar.us/ California www.dbw.ca.gov Colorado http://parks.state.co.us/boating/ Connecticut http://dep.state.ct.us/rec/prgactiv.htm Delaware www.dnrec.state.de.us/fw/index.htm Florida http://floridaconservation.org/law (freshwater) Florida www.dep.state.fl.us/law (saltwater) Georgia www.boat-ed.com Hawaii...
  • Page 19 Montana www.fwp.state.mt.us/education/outdoorskills.asp Nebraska www.ngpc.state.ne.us/boating Nevada http://www.boatnevada.org/ New Hampshire www.state.nh.us/safety/ss/links.html New Jersey www.state.nj.us/mvs/boats.htm www.emnrd.state.nm.us/nmparks/pages/question/regulate/rules/ New Mexico nmac172.pdf North Carolina www.ncwildlife.org/fs_index_02_regulations.htm North Dakota http://www.state.nd.us/gnf/boating/ Ohio www.dnr.state.oh.us/odnr/watercraft Oregon www.osmb.state.or.us Pennsylvania www.fish.state.pa.us Rhode Island www.state.ri.us/dem/topics/boating.htm South Carolina www.dnr.state.sc.us/etc/boating.html South Dakota www.state.sd.us/gfp/divisionwildlife/boating/index.htm Tennessee www.state.tn.us/twra/boatmain.html Texas www.tpwd.state.tx.us/boat/boat.htm Utah www.stateparks.utah.gov/parks/safety.htm...

  • Page 20: Location Of The Important Labels

    The following labels are on your watercraft. If missing or damaged, they can be replaced free of charge. See an authorized Sea-Doo dealer. Please read the following labels carefully before operating this watercraft. GTI, GTI LE, GTI RFI and GTI LE RFI Models 5-12 6-11-13...
  • Page 21 XP DI Models 6-11 F08L1UM TYPICAL SAFETY INFORMATION www.SeaDooManuals.net...
  • Page 22 Label 1 F16L0PL ACCORDING TO WATERCRAFT MODEL SAFETY INFORMATION www.SeaDooManuals.net...
  • Page 23 F08A04L ACCORDING TO WATERCRAFT MODEL SAFETY INFORMATION www.SeaDooManuals.net...
  • Page 24 Label 2 F00A21Y ACCORDING TO WATERCRAFT MODEL F00L2XY ACCORDING TO WATERCRAFT MODEL Label 5 F00A22Y ACCORDING TO WATERCRAFT MODEL Label 3 F00A23Y Label 6 F02L2D0 Label 4 F00A24Y ACCORDING TO WATERCRAFT MODEL F00L29Y ACCORDING TO WATERCRAFT MODEL F00A25Y ACCORDING TO WATERCRAFT MODEL SAFETY INFORMATION www.SeaDooManuals.net...
  • Page 25 Label 7 Label 11 F08G04Y F00A28Y SOME MODELS Label 12 Label 8 WARNING / AVERTISSEMENT PRESSURIZED FUEL Do not unscrew protective cap. Must be used only by Bombardier certified technician. Do not operate the watercraft without cap properly installed. ESSENCE SOUS PRESSION Ne pas dévisser le capuchon protecteur.

  • Page 26: Vehicle Information

    VEHICLE INFORMATION www.SeaDooManuals.net...

  • Page 27: Registration Number Location

    REGISTRATION NUMBER LOCATION All personal watercraft are required by federal law to be registered and legally numbered. Due to space availability for proper display of registration number, refer to follow- ing illustration for location. The registration number should appear on each side of the watercraft.

  • Page 28: Identification Numbers

    IDENTIFICATION NUMBERS Engine The main components of the water- craft (engine and hull) are identified by NOTE: Refer to SPECIFICATIONS sec- different serial numbers. It may some- tion to find what engine is used on each times become necessary to locate model.
  • Page 29 947 DI Engine The Engine Identification Number (E.I.N.) is located on the upper crankcase on MAGNETO side. F06D15Y TYPICAL 1. Engine Identification Number (E.I.N.) www.SeaDooManuals.net...

  • Page 30: Controls/Instruments/Equipments

    CONTROLS/INSTRUMENTS/EQUIPMENTS NOTE: Some components do not apply or are optional on some models. GTI, GTI LE, GTI RFI and GTI LE RFI Models 26 19 20 27-28 15-17 36-37 F17L11M www.SeaDooManuals.net...
  • Page 31 GTI and GTI LE Models F17L12M GTI RFI Models F17L17L www.SeaDooManuals.net...
  • Page 32 GTI LE RFI Models F17L13M www.SeaDooManuals.net...
  • Page 33 XP DI Models 27-28 F08L1WM TYPICAL www.SeaDooManuals.net...
  • Page 34 1. Safety Lanyard 21. Seat Extension Latch 2. Handlebar 22. Rear Grab Handle 3. Throttle Lever 23. Rear Storage Basket 4. Engine Start/Stop Button 24. Bow and Stern Eyelets 5. Variable Trim System (VTS) Button 25. Mooring Cleats 6. Choke Lever 26.

  • Page 35: Controls/Instruments/Equipments Functions

    CONTROLS/INSTRUMENTS/EQUIPMENTS FUNCTIONS 1) Safety Lanyard WARNING (engine cut-off cord) Should the engine be stopped, wa- The safety lanyard cap should be se- tercraft directional control is lost curely snapped onto its post to be fully (reduced on models with O.P .A.S. operational.

  • Page 36: Handlebar

    However, the DESS brings a great flex- 2) Handlebar ibility. You can buy an additional safety The handlebar controls the direction of lanyard and have it programmed for the watercraft. Turning the handlebar your watercraft. to the right steers the watercraft to the The DI models also offers a special right and inversely.

  • Page 37: Variable Trim System (Vts) Button (If So Equipped)

    To stop engine, fully release throttle le- 6) Choke Lever ver then depress the start/stop button Carburetor-Equipped Models and disconnect safety lanyard from the post. The choke is provided to supply a rich- er fuel/air mixture when starting a cold WARNING engine.

  • Page 38: Fuel Gauge/Low Oil Warning Light (If So Equipped)

    From the forward position, pull the le- 8) Fuel Gauge/Low Oil ver to reverse. Push back to go to for- Warning Light ward. Always set in forward when fin- (if so equipped) ished. To find the neutral, set in reverse then push back until the watercraft Analog gauge indicates the amount of stops moving backwards.
  • Page 39 Resetting a Function When you are satisfied with your choice, stop pressing the button.The display To reset a function (such as the chro- you have chosen will remain until it is nometer, distance, etc.) press and hold changed. When safety lanyard is in- the SET button for 2 seconds while in stalled, the last chosen display will come the appropriate mode.
  • Page 40 Diode) blinks along with the message function was set, the compass will be display to catch your attention. displayed. On models without the compass function, the word “SeaDoo” Fuel Level Display will be displayed. Bar gauge continuously indicates the In the event of a warning message, the...

  • Page 41: Glove Box

    Language Option Chronometer While in the compass mode (while While in the chronometer mode: “SeaDoo” is displayed on models without compass): F00L2B0 1. Press to start or stop chronometer F00L2B0 1. Press and hold for 2 seconds F00L2B0 1. Press and hold for 2 seconds to reset...

  • Page 42: Fuel Tank Valve

    12) Fuel Tank Valve Unscrew the cap counterclockwise. Af- ter fueling, reinstall cap and fully tighten. Carburetor-Equipped Models WARNING Always stop the engine before re- fueling. Fuel is flammable and ex- plosive under certain conditions. Always work in a well ventilated area.

  • Page 43: Front Storage Compartment Cover

    1. Oil injection reservoir cap ment cover open. To add injection oil in the reservoir, un- screw the cap counterclockwise. GTI, GTI LE, GTI RFI and GTI LE RFI Do not overfill. Make sure oil level Models does not exceed the level shown on If there is water in the storage area, the following drawing.

  • Page 44: Front Storage Compartment Cover Latch

    NOTE: Verify periodically the lock pin tightness of storage cover. Tighten if needed and make sure storage cover latches properly. 17) Tool Kit Contains tools needed to perform basic watercraft maintenance. 18) Air Intake Opening This is where air enters to supply the engine and to ventilate the engine compartment.

  • Page 45: Seat Extension Latch (If So Equipped)

    All Models except XP DI To remove the seat, pull the latch lever upward and hold. Lift and pull the seat rearward. NOTE: It is necessary to remove the seat extension first. When reinstalling the seat, place seat cavity over body hook. F00L2TY 1.

  • Page 46: Rear Grab Handle

    All Models 24) Bow and Stern Eyelets Bow Eyelet Eyelets can be used for mooring, tow- ing and as a tie-down point during traile- ring. F17L0FY 1. Seat extension latch 2. Rear grab handle 22) Rear Grab Handle Provides a handhold for boarding when needed and a handhold for the passen- ger or the spotter on 3-up seat mod- els.

  • Page 47: Mooring Cleats

    All Models All Models 25) Mooring Cleats 28) Boarding Platform These cleats can be temporarily used Provides a large surface for easier board- for docking, while refueling for exam- ing from rear of watercraft. ple. 29) Boarding Step CAUTION: Never use mooring cleats (if so equipped) to pull or lift the watercraft.

  • Page 48: Cooling System Bleed Outlet

    30) Cooling System Bleed Outlet All Models F18L0TY F12L05Y TYPICAL TYPICAL Refer to POST-OPERATION CARE sec- 1. Bleed outlet tion for proper use. When engine is running, water should 32) Bilge Drain Plugs flow from the outlet. This allows air in engine cooling system to escape.

  • Page 49: Jet Pump Nozzle

    Tilt the watercraft slightly to the rear so that the water can completely flow out of the bilge. It is suggested to drain bilge on a ramp. CAUTION: Make sure drain plugs are properly secured prior to launching the watercraft in water. 33) Jet Pump Nozzle Jet pump nozzle turns side to side via rider input at the handlebar.

  • Page 50: Fuses

    36) Fuses XP DI Models 39) Rear Access Cover All Models except XP DI Fuses are located under seat in bilge. It gives access to the battery, drive Refer to MAINTENANCE for more de- system, suspension, exhaust system tails. and bailer pick-ups. Always relatch cover.

  • Page 51: Liquids

    LIQUIDS All Models WARNING CAUTION: Scrupulously follow the Always stop the engine before re- instructions of this section. Failure fueling. Fuel is flammable and ex- to do so may reduce the engine’s life plosive under certain conditions. and/or performance. Always work in a well ventilated area.

  • Page 52: Recommended Oil

    MODELS OIL TYPE never mix these with outboard motor oil. Do not use NMMA TC-W, TC-W2 • BOMBARDIER GTI, GTI LE or TC-W3 outboard two-stroke en- Formula XP-S II gine oils or ashless two-stroke engine synthetic injection oil oils. Avoid mixing different brands of API TC oil as resulting chemical reac- •...

  • Page 53: Break-In Period

    BREAK-IN PERIOD CAUTION: Scrupulously follow the To add injection oil in the fuel tank, pro- instructions of this section. Failure ceed as follows: to do so may reduce the engine’s life Fill fuel tank with approximately 15 li- and/or performance. ters (4 gal) of gasoline;...

  • Page 54: Pre-Operation Checks

    PRE-OPERATION CHECKS WARNING The pre-operation check is very important prior to operating the watercraft. Always check the proper operation of critical controls, safety features and mechanical components, before starting as listed hereinafter. If not done as specified here, severe injury or death might occur. Bring all safety equip- ment required by local laws.

  • Page 55: Hull

    Hull Water Flow in Cooling System (only when Inspect hull for cracks or damage. temperature is below or Jet Pump Water Intake close to freezing point) Remove weeds, shells, debris or any- In Northern areas, if watercraft is to be thing else that could restrict the flow used when temperature is below or of water and damage cooling system...

  • Page 56: Battery

    WARNING WARNING Do not use any electrical heating Check handlebar and correspond- device to heat the cooling system. ing steering nozzle operation be- Electrical devices may generate fore starting. Never turn handle- sparks that would ignite fuel va- bar while someone is nearby rear pors that might be present in the of watercraft.

  • Page 57: Storage Compartment Covers And Seat

    Storage Compartment Covers and Seat Ensure they are closed and latched. WARNING Make sure seat is securely latched. Safety Lanyard and Engine Start/Stop Button Position shift lever in neutral. Ensure that both switches operate properly. Start en- gine and stop it using each switch indi- vidually.

  • Page 58: Operating Instructions

    OPERATING INSTRUCTIONS WARNING WARNING Keep away from intake grate while Always perform the PRE-OPERATION engine is on. Items such as long CHECKS before operating the water- hair, loose clothing or personal flo- craft. Become thoroughly familiar tation device straps can become with all controls and the function of entangled in moving parts result- each.
  • Page 59 F17J02Y F17L0BZ 1. Reverse gate in downward position 1. Shift lever in neutral position NOTE: To obtain maximum efficiency and control from the reverse, increase engine speed to slightly above idle. Too much RPM will create water tur- bulence and reduce reverse efficiency. In reverse position, turn the handlebar in the same direction that you want to move the rear of the watercraft.
  • Page 60 WARNING Shift lever should only be used when the engine is idling and watercraft is completely stopped. Do not use re- verse to stop the watercraft. Variable Trim System (if so equipped) The variable trim system (VTS) chang- es the angle of the jet pump nozzle to provide the operator with a fast, effec- tive system to compensate for load, thrust, riding position and water condi-...
  • Page 61 Turning the handlebar pivots the jet pump nozzle which controls the water- craft direction. Turning the handlebar to the right will turn the watercraft to the right and inversely. The throttle should be applied to turn the watercraft. WARNING Throttle should be applied and handlebar turned to change the di- rection of the watercraft.

  • Page 62: Boarding The Watercraft

    CAUTION : Co mb us tion engine On some models, boarding is facilitat- needs air to operate; consequently ed by using a step. this watercraft cannot be totally wa- WARNING tertight. Any maneuvers such as fig- ure eights etc., that cause the upper Inexperienced riders should practice deck to be under water may cause how to get aboard (all methods ex-...
  • Page 63 CAUTION: Starting the engine or riding the watercraft in shallower water might damage the impeller or other jet pump components. F01L4KY Sit astride the seat. Operator with a Passenger F18L0XY The operator climbs on the watercraft the same way as explained previously. A.

  • Page 64: Starting

    CAUTION: Ensure there is at least 90 cm (3 ft) of water underneath the lowest rear portion of the hull when all passengers are aboard prior to starting the engine. Otherwise dam- age to the impeller or other jet pump components might occur.

  • Page 65: Rough Water Or Poor Visibility Operation

    It may be necessary to reapply the choke When crossing wakes, always keep a and if necessary, slightly apply throttle to safe distance from watercraft ahead. keep engine running. WARNING Warm Engine When crossing wakes, slow down. The choke does not need to be applied. Operator and passenger(s) can brace themselves by posting.

  • Page 66: Beaching

    Shutting Off the Engine WARNING To keep watercraft directional control, On models with O.P.A.S. direc- the engine should be running until the tional control is reduced when the watercraft is at idle. throttle is released and/or when en- To shut off the engine, completely re- gine is off.

  • Page 67: Post-Operation Care

    POST-OPERATION CARE Engine lubrication and flushing should WARNING be performed when the watercraft is not expected to be used further the Allow engine to cool before per- same day or when the watercraft is forming any maintenance. stored for any extended time. General Care WARNING Remove the watercraft from the water...
  • Page 68 Flushing and Lubrication To flush cooling system, start the en- gine then immediately open the water tap. WARNING Components inside engine com- partment may be hot. Do not touch any electrical parts or jet pump area when engine is running. CAUTION: Never flush a hot engine.

  • Page 69: Anticorrosion Treatment

    MAG side spark plug. F01H7DY GTI RFI AND GTI LE RFI MODELS 1. Grounding device Remove both spark plugs and spray BOMBARDIER LUBE lubricant or equiv- alent into each cylinder.

  • Page 70: Special Procedures

    SPECIAL PROCEDURES Monitoring System These performance-reduced modes allow the rider to go back home which All Models except DI Models would not be possible without this ad- To assist you when using the water- vanced system. If this occurs, see an craft, a system monitors some compo- authorized SEA-DOO dealer as soon as nent of the watercraft and sends audi-...

  • Page 71: Capsized Watercraft

    TYPICAL If the aforementioned method does not work, the following can be performed: GTI RFI and GTI LE RFI Models – With engine running and before ap- Rotate the watercraft clockwise (seen plying throttle, put shift lever in re- from rear) to its right side for cleaning.

  • Page 72: Submerged Watercraft

    F00A24Y ing device. Be careful when crank- ing engine, water will spray out GTI RFI and GTI LE RFI Models from spark plug holes. Rotate the watercraft counterclock- wise (seen from rear). Remove spark plugs and dry them with a clean and dry cloth.

  • Page 73: Fuel-Flooded Engine

    DI Models To prevent fuel to be injected and also to cut the ignition at the engine start- ing, proceed as follows. While engine is stopped, fully depress throttle lever and HOLD for cranking. NOTE: A 1 second beep every second indicates the drowned mode is active.

  • Page 74: Out Of Fuel

    DI Models To prevent fuel to be injected and also to cut the ignition at the engine start- ing, proceed as follows. While engine is stopped, fully depress throttle lever and HOLD for cranking. Crank engine approximately 5 sec- onds. NOTE: A 1 second beep every second indicates the drowned mode is active.
  • Page 75 24 km/h F17E0CY (15 MPH). GTI RFI AND GTI LE RFI MODELS Snugly install the hose pincher on the 1. Follow this hose towards rear water supply hose as shown.

  • Page 76: Low-Charge Battery Condition

    F08E08Y XP DI MODELS 1. Hose pincher on water supply hose CAUTION: When finished towing the watercraft, hose pincher must be re- moved before operating it. Failure to do so will result in damage to the en- gine. Low-Charge Battery Condition See an authorized SEA-DOO dealer to have it charged or replaced.

  • Page 77: Maintenance Information

    MAINTENANCE INFORMATION www.SeaDooManuals.net...

  • Page 78: Engine Emissions Information

    Maintenance, replacement, or repair The owner/operator is not to, and should of the emission control devices and not allow anyone to modify the engine systems may be performed by any in any manner that would alter the marine SI (spark ignition) engine re- horsepower or allow emissions levels to pair establishments or individual.

  • Page 79: General

    General • Only perform servicing procedures which are detailed in this guide. Fur- ther assistance or information can be obtained from your authorized Sea-Doo dealer. In many instances proper tools and training is required for certain servicing or repair proce- dures.

  • Page 80: Maintenance Chart

    MAINTENANCE CHART The maintenance is very important, if you are not familiar with safe service prac- tices and adjustment procedures, see your authorized SEA-DOO dealer. Periodic Inspection Routine maintenance is necessary for all mechanized products. A periodic inspec- tion contributes to the product’s life span. The following maintenance chart gives guidelines for regular watercraft servicing scheduled to be performed by you and/or by an authorized SEA-DOO dealer.
  • Page 81 DESCRIPTION FREQUENCY I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace FUEL SYSTEM Carburetor including choke/throttle cables (carburetor-equipped models) Throttle/choke cables ➀ (carburetor-equipped models) Fuel filter (except RFI models) and lines Fuel filter (except DI and RFI models) ➇...
  • Page 82 DESCRIPTION FREQUENCY I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace O.P.A.S. SYSTEM O.P.A.S. system PROPULSION SYSTEM I ➁ Drive shaft boot and splines (if so equipped) I ➁ Drive shaft protection hose PTO flywheel Seal carrier (XP DI models) Shifter system/cable VTS (Variable Trim System) (if so equipped)

  • Page 83: Maintenance

    MAINTENANCE Using a grease gun, carefully lubricate WARNING PTO flywheel at grease fitting until PTO flywheel boot begins to expand. Only perform procedures as de- CAUTION: Immediately stop lubri- tailed in this guide. It is recom- cating as soon as PTO flywheel boot mended that the assistance of an begins to expand to prevent damage authorized SEA-DOO dealer be...
  • Page 84 Carburetor-Equipped Models Choke Lever Fully pull choke lever and lubricate the metallic portion. All Models Seat Opening Mechanism, Tab, Hook and Lock Pin F01L7UY TYPICAL F08E0BY 1. Front tab 2. Rear mechanism 1. Grease seal carrier of mid bearing All Models Anticorrosion Protection Throttle/Choke Cables Lubricate the throttle and choke cables...

  • Page 85: Throttle And Choke Cable Inspection

    Throttle and Choke Cable Carburetor Adjustment Inspection Carburetor adjustment is very impor- tant to allow good engine operation and Throttle Cable therefore watercraft performance. Car- Depress and release the throttle lever. buretor adjustment requires technical It should operate smoothly and return knowledge and experience to have the to its initial position without any hesi- correct mixture supplied to the engine.

  • Page 86: Vts Adjustment (If So Equipped)

    If VTS needs to be readjusted, refer to WARNING an authorized SEA-DOO dealer. Ensure the handlebar and jet pump CAUTION: Trim ring and/or nozzle nozzle operate freely from side to should not interfere at any position. side and are not stressing the steer- ing cable or brackets.
  • Page 87 GTI and GTI LE Models FUSE IDENTIFICATION 5 A: MPEM Locate MPEM besides engine. 15 A: Battery GTI RFI and GTI LE RFI Models Locate MPEM in front of engine. F17H02Y TYPICAL 1. MPEM Fuses are identified, look besides the F17H06Y fuse holder.
  • Page 88 Fuses are identified, look above and besides the fuse holder. F18H06Y FUSE IDENTIFICATION 1. Fuse identification F17H05Y 2. Fuse description 1. Battery Fuse identification: The fuses (F) are 2. MPEM identified from 1 to 6. 3. Fuel pump Fuse description: The fuses are de- SPR means spare (fuse).
  • Page 89 F06H1TY 1. Fuse cover 2. Fuse tabs Electrical Box 2° GTI and GTI LE Models Remove seat. 1° Remove darts retaining tubes then pull out both vent tubes each side of elec- trical box at rear of hull.
  • Page 90 Properly reinstall removed components. XP DI Models To access fuses in the electrical box, open front storage compartment cover. Remove storage tray. Locate electrical box on the right side of watercraft. 2° 1° F08H0KY 1. Electrical box Unclip and remove cover of the electri- cal box to expose the holder of the main fuse.

  • Page 91: System (If So Equipped)

    O.P.A.S. System Cleaning (if so equipped) The bilge should be cleaned by an au- thorized SEA-DOO dealer to remove any The O.P.A.S. system operation and fuel/oil/electrolyte deposits and mildew. condition should be checked by an au- thorized SEA-DOO dealer. Occasionally, wash the body with wa- ter and soap (only use mild detergent).

  • Page 92: Trailering, Storage And Preseason Preparation

    TRAILERING, STORAGE AND PRESEASON PREPARATION Trailering Make sure that oil reservoir and fuel tank caps are properly installed. Models with O.P.A.S. System WARNING CAUTION : To avoid damaging O.P.A.S. side vanes, the maximum Never tip this vehicle on end for trailer wood bunks span including transporting.

  • Page 93: Storage

    Launching/Loading Carburetor-Equipped Models CAUTION: Before launching the wa- tercraft, ensure the bilge plugs are fully screwed. After loading the wa- tercraft, ensure they are removed to drain bilge. Storage WARNING Because fuel and oil are flamma- ble, have an authorized SEA-DOO dealer inspect the fuel and oil sys- tems integrity as specified in the periodic inspection chart.
  • Page 94 Water should flow out of the fitting (magneto cooling circuit) and hose (crankcase heat exchanger). F17E0BY TYPICAL 1. Fitting F08E0FY 2. Hose 1. Disconnect engine drain hose (crankcase cooling outlet) Reconnect hose when done. 2. Air compressor drain line XP DI Models All Models Remove rear access panel.
  • Page 95 Propulsion System Antifreezing Protection Lubricant in jet pump reservoir should NOTE: This procedure requires approxi- be drained and reservoir cleaned. Re- mately 2.5 L (2.6 U.S. qt.) (2.8 L (3 U.S. fer to an authorized SEA-DOO dealer qt.) on XP DI models) of antifreeze. for this operation.
  • Page 96 All Models except DI Models Install hose pinchers at the following location: F17E02Y F17E0AZ GTI AND GTI LE MODELS (717 ENGINES) GTI RFI AND GTI LE RFI MODELS 1. Engine drain hose (787 RFI ENGINES) 1. Fitting properly connected F17E03Y GTI AND GTI LE MODELS (717 ENGINES) 1.
  • Page 97 Disconnect hoses at the following lo- cation: F06E0EZ F15E02Y GTI, GTI LE, GTI RFI AND GTI LE RFI MODELS TYPICAL (717 AND 787 RFI ENGINES) 1. Hose connecting to inlet fitting of cylinder 1. Disconnect engine water inlet hose head 2.
  • Page 98 Install a hose pincher just below T-fitting. XP DI Models F15E03Y TYPICAL 1. Hose pincher below T-fitting Pour approximately 300 mL (10 oz) of antifreeze in the water regulator valve supply hose to allow antifreeze flow- ing through the valve and into muffler to protect it.
  • Page 99 Hose Disconnection Pour antifreeze mix in engine until the colored solution appears at cooling Disconnect the bottom hose at the wa- system bleed outlet. ter regulator valve on muffler. At this point, install a hose pincher on bleed outlet hose. F08E0SY 1.
  • Page 100 NOTE: Most of the antifreeze will drain out when removing the hose pinchers. Use a container to recover it. DISPOSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS. 1. Bleed outlet hose. 2. Engine drain hose (crankcase cool- ing cover outlet). 3.

  • Page 101: Preseason Preparation

    Anticorrosion Treatment Preseason Preparation Wipe off any residual water in the en- Use the following chart. gine compartment. Since technical skills and special tools Spray BOMBARDIER LUBE lubricant are required, some operations should be or equivalent over metallic compo- performed by an authorized SEA-DOO nents in engine compartment.
  • Page 102 Preseason Preparation Chart NOTE: It is highly recommended that an authorized SEA-DOO dealer perform the annual safety inspection and factory campaigns in addition to the preseason prep- aration all at the same time. TO BE OPERATIONS PERFORMED Lubrication/corrosion protection Operator GENERAL Spark plug replacement ➀...

  • Page 103: Troubleshooting

    TROUBLESHOOTING The following chart is provided to help in diagnosing the probable source of simple troubles. You may be able to solve many of these problems rather quickly, but others may require the skills of a mechanical technician. In such cases, consult an authorized SEA-DOO dealer for servicing.
  • Page 104 Engine Will Not Start OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Safety lanyard removed. Engine does not turn over. Install cap over post. • Burnt fuse on MPEM or in elec- Check wiring then replace fuse(s). trical box: battery, starting sys- tem, fuel pump (DI models).

  • Page 105: Engine Overheats

    Engine Misfires, Runs Irregularly OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Fouled/defective/worn spark Weak spark. Replace. plugs. • Faulty MPEM. Refer to an authorized SEA-DOO dealer. • Too much oil supplied to engine. Improper oil pump adjustment, refer to an authorized SEA-DOO dealer.

  • Page 106: Engine Lacks Acceleration Or Power

    Engine Lacks Acceleration or Power OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Weak spark. Refer to engine MISFIRES, RUNS IRREGULARLY. • Incorrect fuel mixture Refer to engine MISFIRES, RUNS (carburetor-equipped models). IRREGULARLY. • Water in fuel or injection oil. Siphon and replace. Overheated engine.

  • Page 107: Specifications

    SPECIFICATIONS GTI, GTI LE GTI RFI, GTI LE RFI MODELS (6133/6134/6135/6136) (6137/6138/6139/6140) ENGINE Engine type Rotax ® 717, 2-stroke Rotax ® 787 RFI, 2-stroke Induction type Rotary valve Water cooled/water Exhaust system Water cooled/water injected injected with regulator Rotax Adjustable Variable Exhaust valve N.A.
  • Page 108 GTI, GTI LE GTI RFI, GTI LE RFI MODELS (6133/6134/6135/6136) (6137/6138/6139/6140) FUEL SYSTEM Type Regular unleaded gasoline Minimum Fuel Inside North America: 87 (R + M)/2 octane Outside North America: 91 RON number BN 40i (diaphragm). Carburetor Fuel accelerator pump.
  • Page 109 XP DI MODEL (6151/6152) ENGINE Engine type Rotax 947 DI, 2-stroke Induction type Reed valve Exhaust system Water cooled/water injected with regulator Exhaust valve Rotax Adjustable Variable Exhaust (RAVE) Type Oil injection Lubrication BOMBARDIER Formula XP-S II Oil type synthetic injection oil Number of cylinders Displacement 951.2 cm...
  • Page 110 XP DI MODEL (6151/6152) PROPULSION Propulsion system Bombardier Formula pump Jet pump type Axial flow, single stage Transmission Direct drive/split front and rear Reverse system SEA-DOO synthetic Jet pump oil type polyolester oil SAE 75W90 GL5 Pivoting angle of direction (nozzle) ~ 20°...

  • Page 111: Si Metric Information

    SI* METRIC INFORMATION BASE UNITS DESCRIPTION UNIT SYMBOL length ..........meter........mass............ kilogram......force ............ newton ....... liquid............ liter ........temperature......... Celsius ........ °C pressure ..........kilopascal ......torque..........newton-meter..... N•m land velocity......... kilometer per hour ....km/h navigation velocity....... knot ........

  • Page 112: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS MANUAL DESCRIPTION Alternate current American petroleum institute CARB California air resource board Direct current Digitally encoded security DESS system Engine control module Electronic control unit Engine management system E.I.N. Engine identification number Environmental protection agency Horse power Liquid Crystal Display Light-emitting diode Magneto...
  • Page 113 WARRANTY www.SeaDooManuals.net...

  • Page 114: List Of Distributors

    LIST OF DISTRIBUTORS NORTH AMERICA BOMBARDIER MOTOR CORPORATION OF AMERICA 7575 Bombardier Court WAUSAU, WI. 54401 Phone: (715) 848-4957 (Except Puerto Rico) Fax: (715) 847-6879 www.bombardier.com CANADA BOMBARDIER INC. RECREATIONAL PRODUCTS 75 J. A. BOMBARDIER ST. SHERBROOKE, QC J1L 1W3 Phone: (819) 566-3366 Fax: (819) 566-3062 www.bombardier.com...

  • Page 115: Bombardier North America Limited Warranty: 2004 Sea-Doo Personal Watercraft

    BOMBARDIER NORTH AMERICA LIMITED ® WARRANTY: 2004 SEA-DOO PERSONAL WATERCRAFT 1. SCOPE In Canada, Bombardier Inc. ("Bombardier"), and in the USA, Bombardier on behalf of Bombardier Motor Corporation of America warrants its Sea-Doo personal watercraft from defects in material or workmanship for the period and under the conditions described below. All genuine Bombardier parts and accessories, installed by an authorized Bombardier dealer (as hereinafter defined) at the time of delivery of the Sea-Doo personal watercraft, carry the same warranty as that of the personal watercraft.
  • Page 116 4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE The customer must notify an authorized servicing Bombardier dealer within two (2) days of the appearance of a defect, and provide it with reasonable access to the product and reason- able opportunity to repair it. The customer must also present to the authorized Bombardier dealer, proof of purchase of the product and must sign the repair/work order prior to the start of the repair in order to validate the warranty repair.
  • Page 117 Neither the distributor, any Bombardier dealer nor any other person has been authorized to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Bombardier. Bombardier reserves the right to modify this warranty at any time, being understood that such modification will not alter the warranty conditions applicable to the products sold while this warranty is in effect.

  • Page 118: California Emission Control Warranty Statement For Model-Year 2004 Sea-Doo Personal Watercraft With 947 Di Engines

    CALIFORNIA EMISSION CONTROL WARRANTY ® STATEMENT FOR MODEL-YEAR 2004 SEA-DOO PERSONAL WATERCRAFT WITH 947 DI ENGINES Your Sea-Doo personal watercraft has a special environmental label required by the Califor- nia Air Resources Board. The label has 1, 2, 3 or 4 stars. A hangtag, provided with your personal watercraft, describes the meaning of the star rating system.
  • Page 119 For more information: Cleaner Watercraft - Get the Facts 1-800-END-SMOG www.arb.ca.gov YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Bombardier inc. on behalf of Bombardier Motor Corporation of America (’’Bombardier’’) are pleased to explain the emission control system warranty on your model-year 2004 Sea-Doo personal watercraft equipped with a 947 DI engine.
  • Page 120 Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted by Bombardier for the period of time before the first scheduled replacement date for that part. Emission warranty parts that are scheduled for regular inspection, but not regular replacement, are warranted by Bombardier for the entire warranty period of the personal watercraft.

  • Page 121: Bombardier International Limited Warranty: 2004 Sea-Doo Personal Watercraft

    BOMBARDIER INTERNATIONAL LIMITED ® WARRANTY: 2004 SEA-DOO PERSONAL WATERCRAFT 1. SCOPE Bombardier Inc. ("Bombardier") warrants its Sea-Doo personal watercraft from defects in material or workmanship for the period described below. All genuine Bombardier parts and accessories, installed by an authorized Bombardier distributor/ dealer (as hereinafter defined) at the time of delivery of the Sea-Doo personal watercraft, carry the same warranty as that of the personal watercraft.
  • Page 122 5. WHAT BOMBARDIER WILL DO Bombardier’s obligations under this warranty are limited to, at its sole discretion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine Bombardier parts without charge for parts and labor, at any authorized Bombardier distributor/dealer.
  • Page 123 8. TRANSFER If the ownership of a product is transferred during the warranty coverage period, this war- ranty shall also be transferred and be valid for the remaining coverage period provided that Bombardier is notified of such transfer of ownership in the following way: Bombardier or an authorized Bombardier distributor/dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the co-ordinates of the new owner.

  • Page 124: Privacy Obligations/Disclaimer

    PRIVACY OBLIGATIONS/DISCLAIMER We wish to inform you that your coordinates will be used for safety and warranty purposes. Sometimes, we also use the coordinates of our clients to inform them about our products and to present them offers. Should you prefer not to receive information on our products, services and offers, please let us know by writing to the address below.

  • Page 125: Change Of Address/Ownership

    CHANGE OF ADDRESS/OWNERSHIP CHANGE OF ADDRESS/OWNERSHIP If your address has changed or if you are the new owner of the personal water- craft, be sure to notify Bombardier by either: • mailing the card below; • calling at (715) 848-4957 (USA) or (819) 566-3366 (Canada); •...

  • Page 126: Change Of Address

    CHANGE OF ADDRESS OTE: This card is strictly for change of address only. CHANGE OF ADDRESS ✁ AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75, J.A. BOMBARDIER ST. SHERBROOKE (QUÉBEC) CANADA J1L 1W3 www.SeaDooManuals.net...
  • Page 127 CHANGE OF ADDRESS/OWNERSHIP If your address has changed or if you are the new owner of the personal water- craft, be sure to notify Bombardier by either: • mailing the card below; • calling at (715) 848-4957 (USA) or (819) 566-3366 (Canada); •...
  • Page 128 CHANGE OF ADDRESS OTE: This card is strictly for change of address only. CHANGE OF ADDRESS ✁ AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75, J.A. BOMBARDIER ST. SHERBROOKE (QUÉBEC) CANADA J1L 1W3 www.SeaDooManuals.net...
  • Page 129 WATERCRAFT MODEL No. HULL IDENTIFICATION NUMBER (H.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Owner: NAME STREET CITY STATE/PROVINCE ZIP/POSTAL CODE Purchase Date YEAR MONTH Warranty Expiry Date YEAR MONTH To be completed by the authorized Sea-Doo dealer at the time of the sale. DEALER IMPRINT AREA Please verify with your selling dealer to ensure your SEA-DOO watercraft has been registered with Bombardier.
  • Page 130 www.SeaDooManuals.net...

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