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Page 2 ® SHOP MANUAL 219 100 048 www.SeaDooManuals.net...
Page 3 Legal deposit: National Library of Quebec National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1996 Printed in Canada ® *Registered trademarks of Bombardier Inc.
Page 4: Table Of Contents
05 - Variable Trim System ..................08-05-1 STEERING SYSTEM 01 - Table of Contents................... 09-01-1 02 - SP and SPX Models ..................09-02-1 03 - GTS Model..................... 09-03-1 04 - GS, GSI, GSX, GTI and GTX Models .............. 09-04-1 05 - XP and HX Models ..................09-05-1 06 - Alignment ......................
Page 5: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual was primarily published to be used by watercraft technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made Sea- Doo watercraft. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into another language.
Page 6: Hull Identification Number
(H.I.N.) Year of production number* Month of production SP, SPX, GTS and HX Models It is located at right rear side of hull. F00A0CA *A letter may also be used as a digit. *A letter may also be used as a digit.
Page 7 1997 BOMBARDIER WATERCRAFT SHOP MANUAL 787 Engine ARRANGEMENT OF THIS MANUAL The Engine Identification Number is located on the crankcase on PTO side. The manual is divided into 13 major sections: 01 MAINTENANCE 02 TROUBLESHOOTING 03 ENGINE 04 COOLING SYSTEM 05 FUEL SYSTEM 06 LUBRICATION SYSTEM 07 ELECTRICAL SYSTEM...
Page 8 1997 BOMBARDIER WATERCRAFT SHOP MANUAL TYPICAL PAGE Page heading indicates section and sub-section detailed. Sub-section title indicates Section 03 ENGINE beginning of the Sub-Section 04 (MAGNETO SYSTEM) sub-section. MAGNETO SYSTEM 717 Engine Italic sub-tiltle above exploded 5 N•m view indicate Drop represents a (44 lbf•in) pertaining models.
Page 9 1997 BOMBARDIER WATERCRAFT SHOP MANUAL TYPICAL PAGE Sub-title with part number(s) from exploded view followed by part name(s). Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) Title indicates main procedure to be CARBURETOR REMOVAL DISASSEMBLY AND INSPECTION carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly, lows: spring screw, check valve housing, etc.).
Page 10: General Information
1997 BOMBARDIER WATERCRAFT SHOP MANUAL GENERAL INFORMATION ILLUSTRATIONS AND PROCEDURES The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on The illustrations show the typical construction of watercraft). the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function.
Page 11 Section 01 MAINTENANCE Sub-Section 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 WATER-FLOODED ENGINE....................01-04-1 GENERAL ........................... 01-04-1 PROCEDURE ........................01-04-1 STORAGE..........................01-05-1 01-01-1 www.SeaDooManuals.net...
Page 12: Periodic Inspection Chart
Section 01 MAINTENANCE Sub-Section 02 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency. FREQUENCY Every 100 DESCRIPTION Every Every Every hours or 10 hours 25 hours 50 hours seasonally Lubrication/corrosion protection of metallic components Engine ignition timing Spark plug replacement...
Page 13: Flushing And Lubrication
Sub-Section 03 (FLUSHING AND LUBRICATION) FLUSHING AND LUBRICATION GENERAL SP, SPX, GTS and XP Models Remove dust cap from fitting spigot and attach Flushing the cooling system with fresh water is coupler hose (P/N 295 500 258). Make sure cou- essential to neutralize corroding effects of salt or pler hose is properly locked to fitting spigot.
Page 14 Section 01 MAINTENANCE Sub-Section 03 (FLUSHING AND LUBRICATION) All Models Start the engine then immediately open the water tap. CAUTION Always start the engine before opening the water tap. Open water tap immediately after engine is started to prevent overheating. Run the engine about 3 minutes at a fast idle around 3500 RPM.
Page 15 If used, remove the quick hose connector from watercraft. F00H0DA SPX, GS, GSI, GSX, GTI AND GTX MODELS SP, SPX, GTS and XP Models 1. Spark plug cables on grounding device Unlock and remove coupler hose. Reinstall dust cap over fitting spigot.
Page 16 Section 01 MAINTENANCE Sub-Section 03 (FLUSHING AND LUBRICATION) NOTE: Engine fogging should be done with BOMBARDIER LUBE lubricant whenever the wa- tercraft is to be stored for a few days or a long period. CAUTION Never leave rags or tools in the engine com- partment or in the bilge.
Page 17: Water-Flooded Engine
WARNING Never crank engine with spark plugs re- moved unless spark plug cables are con- nected to the grounding device. SP, GTS and HX Models F00H0AA 1. Grounding device All Models Remove spark plugs and dry them with a clean cloth.
Page 18 Section 01 MAINTENANCE Sub-Section 04 (WATER-FLOODED ENGINE) Spray BOMBARDIER LUBE lubricant (P/N 293 600 016) into spark plug holes. Crank engine again. Reinstall spark plugs and spark plug cables. SPX, GSX, GTX and XP Models On the 787 engine, remove the drain plug of the counterbalance shaft located on the PTO side of the lower crankcase.
Page 19: Storage
Section 01 MAINTENANCE Sub-Section 05 (STORAGE) STORAGE Engine Draining XP and HX Models Check engine drain hose. Make sure there is no sand or other particles in it and that it is not ob- structed so that water can leave the engine. Clean hose and fitting as necessary.
Page 20: Propulsion System
Section 01 MAINTENANCE Sub-Section 05 (STORAGE) Propulsion System Lubricant in impeller shaft reservoir should be drained. Reservoir should be cleaned and refilled with SEA-DOO synthetic 75W90 GL5 polyolester oil. Refer to PROPULSION SYSTEM 08-02. CAUTION Use only SEA-DOO jet pump oil or equiva- lent synthetic gear oil, otherwise component life span could be reduced.
Page 21 Section 01 MAINTENANCE Sub-Section 05 (STORAGE) Anticorrosion Treatment Wipe off any residual water in the engine com- partment. Spray BOMBARDIER LUBE lubricant over all me- tallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant. NOTE: A cable luber can be used on throttle cable end to inject BOMBARDIER LUBE lubricant.
Page 22 Section 01 MAINTENANCE Sub-Section 05 (STORAGE) F05E03A TYPICAL 1. Engine water supply hose 2. Engine water return hose F00E03A Install temporarily one hose to engine water inlet at cylinder head. TYPICAL 1. Hold hoses higher than tuned pipe Insert a funnel into hose and pour about 1 liter (1 qt) 2.
Page 23: Troubleshooting Chart
Section 02 TROUBLESHOOTING Sub-Section 01 (TROUBLESHOOTING CHART) TROUBLESHOOTING CHART The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to have all causes for all problems. ENGINE WILL NOT START OTHER OBSERVATION POSSIBLE CAUSE REMEDY...
Page 24 Section 02 TROUBLESHOOTING Sub-Section 01 (TROUBLESHOOTING CHART) ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark • Fouled, defective, worn spark plugs • Check/verify heat range/gap/replace • Faulty rev limiter or ignition module • Check, refer to section 07-02 •...
Page 25 Section 02 TROUBLESHOOTING Sub-Section 01 (TROUBLESHOOTING CHART) ENGINE DETONATION OR PINGING OTHER OBSERVATION POSSIBLE CAUSE REMEDY Ignition • Timing too far advanced • Check/reset • Spark plug heat range too high • Check/change to correct range • Defective ignition module •...
Page 26 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS LEAK TEST..........................03-02-1 GENERAL ........................... 03-02-1 PREPARATION ........................03-02-1 TESTING PROCEDURE ..................... 03-02-1 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............03-02-6 REMOVAL AND INSTALLATION..................03-03-1 GENERAL ........................... 03-03-1 ENGINE REMOVAL ......................03-03-1 CLEANING .........................
Page 27 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) EXHAUST SYSTEM ....................... 03-08-1 TUNED PIPE REMOVAL ..................... 03-08-4 EXHAUST MANIFOLD REMOVAL..................03-08-6 MUFFLER REMOVAL......................03-08-6 TUNED PIPE REPAIR ......................03-08-6 INSTALLATION ........................03-08-7 03-01-2 www.SeaDooManuals.net...
Page 28: Leak Test
Section 03 ENGINE Sub-Section 02 (LEAK TEST) LEAK TEST GENERAL PREPARATION A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) Verify fuel system for leaks. is available to help diagnose engine problems such as engine seizure, poor performance, oil WARNING leakage, etc.
Page 29 Section 03 ENGINE Sub-Section 02 (LEAK TEST) F01B2UB F01B2WA 717 ENGINES — REAR VIEW 787 ENGINE 1. Engine drain hose blocked with a hose pincher 1. Loop hose and use clamps 2. Hose with clamps. Plug end with a screw 3.
Page 30 Section 03 ENGINE Sub-Section 02 (LEAK TEST) Install plates no. 4 with fasteners from the kit and Activate pump and pressurize engine to 34 kPa (5 PSI). tighten adequately. CAUTION NOTE: On engines with the RAVE system, the boot and O-ring can be checked for leakage with Do not exceed this pressure.
Page 31 Section 03 ENGINE Sub-Section 02 (LEAK TEST) Rotary Valve Shaft NOTE: It is preferable to drain the injection oil from the rotary valve shaft, but it is not mandato- Block oil return hose of the rotary valve shaft with a hose pincher. F01B32A 717 ENGINES 1.
Page 32 Section 03 ENGINE Sub-Section 02 (LEAK TEST) If the above mentioned components are not leak- ing and there is a pressure drops, remove the ro- tary valve cover. Check the seal of the rotary valve shaft. If the rotary valve shaft is not leaking, it could indi- cates a defective engine casting.
Page 33: Engine Leakage Diagnostic Flow Chart
Section 03 ENGINE Sub-Section 02 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART PRESSURIZE ENGINE COOLING SYSTEM CHECK TESTING KIT IS SYSTEM LEAKING? REPLACE O-RING OF CYLINDER HEAD PRESSURIZE ENGINE AND/OR CYLINDER BASE GASKET IS ENGINE LEAKING? RECHECK ENGINE SEALING CHECK TESTING KIT CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS.
Page 34: General
To remove tuned pipe, refer to ENGINE 03-08. connecting fuel lines. Air Intake Silencer SP and GTS Models To remove air intake silencer, refer to FUEL SYS- Remove battery holding straps and disconnect TEM 05-03.
Page 35 Section 03 ENGINE Sub-Section 03 (REMOVAL AND INSTALLATION) XP and HX Models Only Disconnect choke and throttle cables from carbu- retor linkage. Disconnect fuel supply and fuel return hoses. Engine Support(s) NOTE: Be careful when removing engine sup- port(s) or rubber mount adapters, shims could have been installed underneath.
Page 36 Section 03 ENGINE Sub-Section 03 (REMOVAL AND INSTALLATION) CAUTION Take care not to damage cable or oil injec- tion hoses. Remove rear engine support. F01H1JB TYPICAL 1. Disconnect RED positive cable Carry on engine lifting then tilt engine so that it can be removed from the body opening.
Page 37: Cleaning
Section 03 ENGINE Sub-Section 03 (REMOVAL AND INSTALLATION) Loctite F01D7RA F00D0BA TYPICAL — 787 ENGINE TYPICAL 1. Torque to 35 N•m (26 lbf•ft) CLEANING Four-Piece Engine Support Wipe off any spillage in bilge. Clean with a bilge Torque front and rear engine supports as shown in cleaner.
Page 38 Section 03 ENGINE Sub-Section 03 (REMOVAL AND INSTALLATION) F01L2RC 1. Housing (P/N 295 000 090) 2. Alignment shaft (P/N 295 000 093) or (P/N 295 000 141) for the F00B06A HX and XP models TYPICAL HX and XP Models – Insert shaft end into PTO flywheel. On these models, the PTO flywheel adapter (P/N NOTE: Ensure the protective hose and carbon 295 000 157) must be used in conjunction with...
Page 39 Section 03 ENGINE Sub-Section 03 (REMOVAL AND INSTALLATION) F00D0CA TYPICAL 1. Shim CAUTION Whenever shims are used to correct align- ment, never install more than 6 mm (0.240 in) shim thickness. If alignment can- not be obtained verify for engine support bending.
Page 40: Magneto System
(80 lbf•in) Loctite Loctite 6 N•m (53 lbf•in) Loctite 6 N•m (53 lbf•in) 6 N•m (53 lbf•in) Loctite 242 SP, GTS and Loctite HX models 4 N•m (35 lbf•in) Loctite 145 N•m (107 lbf•ft) Anti-seize lubricant 9 N•m (80 lbf•in)
Page 41 Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) 787 Engine Loctite 242 Lithium grease 10 N•m (88 lbf•in) Loctite 648 10 N•m (88 lbf•in) Loctite 648 Loctite 242 105 N•m (77 lbf•ft) 4.5 N•m (40 lbf•in) 10 N•m (88 lbf•in) 10 N•m (88 lbf•in) 9 N•m (80 lbf•in)
Page 42: General
Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) GENERAL The following procedures can be performed with- out removing engine from watercraft. However, battery removal will be required on SP and GTS models. REMOVAL 717 Engines 1, Magneto Housing Cover Remove screws no. 2, wire supports no. 17 and no.
Page 43 Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) Engine Crankcase Replacement 717 Engines Since replacement crankcases do not have timing mark for armature plate location, indexing marks should be made on armature plate and crankcase to ease reassembly and further ignition timing. The following procedure is to find a common ref- erence point on both crankcases (old and new) to position armature plate.
Page 44 Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) The new mark on crankcase will be used for fur- ther assembly positioning as a pre-timing posi- tion. F01D4GA F01D4EA TYPICAL TYPICAL 1. For further assembly, use these marks 1. Lug end of crankcase 2.
Page 45: Cleaning
Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) F01D85A F01D7YA 1. Ring gear blocking tool with retaining plate 1. Puller If desired, magneto rotor can be removed without Tighten puller screw and at the same time, tap on the engine flywheel. Remove the 6 screws screw head using a hammer to release engine fly- no.
Page 46 Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) F01D3AA 1. Magneto flywheel 11, Generating Coil To replace generating coil: – Heat the armature plate to 93°C (200°F) around A25E0QA the screw holes to break the threadlocker 1. Uncrimp and unsolder wire here bond.
Page 47: Assembly
Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) – Uncrimp and unsolder ground wire (BLACK) CAUTION from coil core. Before reinstalling the magneto, remove the loose epoxy from harness. 13, Battery Charging Coil Position new coil, crimp and solder all wires. Prior to assembly, apply Loctite 242 (blue).
Page 48: Installation
Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) Whenever replacing either ring gear or magneto 14, Trigger Coil flywheel, Gun Kote must be applied to prevent Install the trigger coil in magneto housing cover possible corrosion. no. 1 and torque screws no. 15 to 10 N•m (88 lbf•in).
Page 49 Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) Ignition Timing 4,5, Rotor and Flywheel For ignition timing procedures of 717 engines, re- When reinstalling magneto rotor to engine fly- fer to ELECTRICAL SYSTEM 07-02. wheel, apply Loctite 648 to mating surfaces. One of the protuberance end of magneto rotor 787 Engine must align with hole of engine flywheel.
Page 50: Top End
Section 03 ENGINE Sub-Section 05 (TOP END) TOP END 717 Engines 24 N•m Loctite 242 (17 lbf•ft) Synthetic grease Synthetic grease 24 N•m (17 lbf•ft) Loctite Loctite rollers Synthetic grease rollers Synthetic grease F00D0DS PARTS FLAT RATE 03-05-1 www.SeaDooManuals.net...
Page 51 Section 03 ENGINE Sub-Section 05 (TOP END) 787 Engine Loctite 242 24 N•m (17 lbf•ft) Synthetic grease Synthetic grease Synthetic 40 N•m grease (30 lbf•ft) Loctite Loctite 26 25 34 rollers Synthetic grease Synthetic grease 34 rollers F01D7DS PARTS FLAT RATE 03-05-2 www.SeaDooManuals.net...
Page 52: General
Section 03 ENGINE Sub-Section 05 (TOP END) GENERAL Located above the exhaust port is a guillotine- type slide valve. This rectangular valve is connect- The 2-stroke ROTAX engine rotates counterclock- ed by a shaft to a diaphragm which is working wise seen from the rear (PTO flywheel).
Page 53 Section 03 ENGINE Sub-Section 05 (TOP END) F01D7HA VALVE FULLY CLOSED A18C02A The RAVE valve does not allow an engine to make higher peak horsepower than an engine not so MAINTENANCE equipped, it can make moving the peak higher There are no wear parts anywhere in the system practical because of its effect on the rest of the and there are no adjustments to be periodically power curve.
Page 54: Disassembly
Section 03 ENGINE Sub-Section 05 (TOP END) DISASSEMBLY Remove bellow no. 23 from valve piston no. 22. Unscrew valve piston no. 22 from sliding valve 787 Engine no. 24. 30, RAVE Valve NOTE: Hold the sliding valve to prevent it from turning.
Page 55 Section 03 ENGINE Sub-Section 05 (TOP END) All Engines Remove tuned pipe and exhaust manifold, refer to ENGINE 03-08. Remove screws no. 17. Remove cylinders, being careful that connecting rods do not hit crankcase edge. WARNING If screws need to be heated for removal when engine is in watercraft, fuel system pressurization must be done first.
Page 56: Cleaning
Section 03 ENGINE Sub-Section 05 (TOP END) F01D2YA – The needles, thrust washers and the expansion F01B0VA sleeve remain in the connecting rod bore and PISTON PIN PULLER (P/N 290 877 092) may be used again. 1. Bushing (P/N 290 877 181) 2.
Page 57: Inspection
Section 03 ENGINE Sub-Section 05 (TOP END) Clean piston ring grooves with a groove cleaner TOLERANCES tool, or a piece of broken ring. ENGINE NEW PARTS WEAR MEASUREMENT INSPECTION (min.) (max.) LIMIT 0.05 mm 0.1 mm 787 Engine Cylinder Taper N.A.
Page 58 Section 03 ENGINE Sub-Section 05 (TOP END) Piston/Cylinder Wall Clearance PISTON MEASUREMENT Used Piston Using a micrometer, measure piston at 25 mm (1 in) from skirt end perpendicularly (90º) to piston pin. F01D8AA 1. Measuring perpendicularly (90 ° ) to piston pin axis 2.
Page 59 Section 03 ENGINE Sub-Section 05 (TOP END) F00B08A 1. Micrometer set to the piston dimension F00B0AA PISTON/CYLINDER WALL CLEARANCE 1. Indicator set to zero MEASUREMENT Position the dial bore gauge at 16 mm (5/8 in) be- Used and New Pistons low cylinder top edge.
Page 60: Assembly
Section 03 ENGINE Sub-Section 05 (TOP END) F01D0XA 1. Feeler gauge 2. Rectangular ring (bottom) F01D67A 1. Identification holes Ring End Gap Position ring halfway between exhaust port and GASKET IDENTIFICATION top of cylinder. THICKNESS HOLES NOTE: In order to correctly position ring in cylin- 0.3 mm der, use piston as a pusher.
Page 61 Section 03 ENGINE Sub-Section 05 (TOP END) F01D8KA 1. Sliding valve 2. O-ring 3. “TOP” Install a new gasket no. 26. It must be installed at F01D8LA the same time as the sliding valve no. 24. All Engines Position the valve housing no. 27 onto the cylin- der so that its opening is toward the bottom.
Page 62 Section 03 ENGINE Sub-Section 05 (TOP END) – Insert extractor spindle into the piston pin, screw on extracting nut. – Rotate handle to pull piston pin carefully into the piston. F01D31A F01D7EA Plastic Mounting Device Method 787 ENGINE SHOWN This is an alternate method when no service tool 1.
Page 63 Section 03 ENGINE Sub-Section 05 (TOP END) F01D0VA 1. Thrust washer each side F01D0SA – Insert piston pin into piston until it comes flush with inward edge of piston hub. – As necessary, pull halves of inner sleeve with long nose pliers. F01D0RA F01D0TA 1.
Page 64 Section 03 ENGINE Sub-Section 05 (TOP END) F01D0WA F01D0YA 1. Circlip opening at 6 o’clock (at bottom) CAUTION WARNING Circlips must not move freely after installa- Always wear safety glasses when installing tion. piston circlips. 9, Cylinder To easily insert circlip no. 5 into piston no. 3, use To easily slide cylinder no.
Page 65 Section 03 ENGINE Sub-Section 05 (TOP END) 717 Engines The aligning tool (P/N 290 876 902) or the exhaust manifold can be used to align cylinders. F01D0ZA 1. Ring end gap aligned with piston locating pin Slide cylinder no. 9 over piston no. 3. F01D44A 717 ENGINES 1.
Page 66: Cylinder Head
Section 03 ENGINE Sub-Section 05 (TOP END) 787 Engine 787 Engine The exhaust manifold is used to align cylinders. Prior installation, apply synthetic grease below screw head and Loctite 515 on screw threads. Install M10 x 105 screws on exhaust side and the M10 x 73,5 on opposite side.
Page 67: Adjustment
Section 03 ENGINE Sub-Section 05 (TOP END) 1, Cylinder Head Cover This will ensure the correct preload on the return spring no. 29 in order to open and close the RAVE Install cylinder head cover. valve at the proper RPM. Apply Loctite 242 (blue) below head of screws no.
Page 68 Section 03 ENGINE Sub-Section 05 (TOP END) 2. Obtain a graduated burette (capacity 0-50 cc) NOTE: The liquid level in cylinder must not drop and fill with an equal part (50/50) of gasoline for a few seconds after filling. If so, there is a leak and injection oil.
Page 69: Bottom End
Section 03 ENGINE Sub-Section 06 (BOTTOM END) BOTTOM END 717 Engines Loctite Lithium grease Anti-seize lubricant Loctite Anti-seize lubricant Anti-seize lubricant Loctite Loctite 24 N•m (17 lbf•ft) Lithium grease Synthetic Loctite grease Loctite Synthetic grease 24 N•m (17 lbf•ft) 10 N•m 40 N•m (88 lbf•in) (30 lbf•ft)
Page 70 Section 03 ENGINE Sub-Section 06 (BOTTOM END) 787 Engine 30 mL (1 oz) Loctite SAE 30 motor oil Anti-seize lubricant Lithium grease Lithium grease Anti-seize Loctite lubricant Anti-seize Anti-seize lubricant lubricant Lithium grease Loctite Loctite Loctite Synthetic grease Anti-seize Synthetic lubricant Loctite Loctite...
Page 71: Crankshaft Misalignment And Deflection
Section 03 ENGINE Sub-Section 06 (BOTTOM END) CRANKSHAFT MISALIGNMENT – Remove flywheel nut (and magneto rotor for the 787 engine). Refer to ENGINE 03-04 for AND DEFLECTION procedures. Since it is an assembled crankshaft it can become – Install Bombardier degree wheel (P/N 295 000 misaligned or deflected.
Page 72: Disassembly
Section 03 ENGINE Sub-Section 06 (BOTTOM END) Crankshaft Alignment at Connecting Rod Journal Such misalignment may cause a crankshaft hard to be manually turned. Verification can be done by measuring deflection each end of crankshaft. Re- fer to Inspection paragraph. If deflection is found greater than specified toler- ance, this indicates worn bearing(s), bent and/or disaligned crankshaft.
Page 73 Section 03 ENGINE Sub-Section 06 (BOTTOM END) All Engines NOTE: To facilitate ring or distance ring installa- tion lubricate their inside diameters. F01B09A F01D1OA 1. Puller (P/N 290 876 298) 2. Protective cap (P/N 290 876 557) TYPICAL 3. Distance ring, MAG side (P/N 290 876 569) 1.
Page 74 Section 03 ENGINE Sub-Section 06 (BOTTOM END) NOTE: If the inner PTO bearing needs to be re- placed, remove the Woodruff key on the crank- shaft. 16, Counterbalance Shaft Bearings no. 12 can be removed by using the fol- lowing tools: F04B03A 1.
Page 75: Cleaning
Section 03 ENGINE Sub-Section 06 (BOTTOM END) INSPECTION Visually inspect parts for corrosion damage. Inspect plane surfaces for warpage. Small defor- mation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper. Inspect crankshaft bearings.
Page 76 Section 03 ENGINE Sub-Section 06 (BOTTOM END) Crankshaft Deflection Crankshaft deflection is measured each end with a dial indicator. First, check deflection with crankshaft in crank- case. If deflection exceeds the specified toler- ance, it can be either ball bearings wear, bent or twisted crankshaft at connecting rod journal.
Page 77: Assembly
Section 03 ENGINE Sub-Section 06 (BOTTOM END) Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. F01B0HA 1. Distance gauge F01D1WA 1. Measuring big end axial play 2. Feeler gauge ASSEMBLY Assembly is essentially the reverse of disassem- bly procedures.
Page 78 Section 03 ENGINE Sub-Section 06 (BOTTOM END) F00D0LA F00D0NA 1. Woodruff key on the crankshaft 1. Seal against the retaining shim All Engines 6, Drive Pin Make sure drive pins of bearings are properly in- stalled in crankcase recesses at assembly. F00D0MA 1.
Page 79 Section 03 ENGINE Sub-Section 06 (BOTTOM END) Proceed as follows to check if the gear no. 18 is 12,16, Bearing and Counterbalance properly positioned on the counterbalance shaft: Shaft – Temporarily install the counterbalance shaft in Prior to installation, place bearings into a container the crankcase.
Page 80 Section 03 ENGINE Sub-Section 06 (BOTTOM END) 717 Engines NOTE: On aluminum material it is recommended to use Loctite Primer N to reduce curing time and 7,8,9, Crankcase Screw increase gap filling capability. Refer to manufac- turer’s instructions. Apply Loctite 515 on screw threads and synthetic grease below head screws.
Page 81 Section 03 ENGINE Sub-Section 06 (BOTTOM END) F01D4KA F01D81A 1. Install starter before engine support As a final step, torque only M10 screws no. 8 of crankcase to 40 N•m (30 lbf•ft) as per following 787 Engine sequence. When engine assembly is completed, add 30 mL (1oz) of motor oil SAE 30 to the counterbalance shaft gear through the crankcase filler plug.
Page 82: Rotary Valve
Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) ROTARY VALVE Lithium grease 787 Engine 20 N•m (15 lbf•ft) 717 Engines 20 N•m (15 lbf•ft) F01D7SS PARTS FLAT RATE 03-07-1 www.SeaDooManuals.net...
Page 83: General
1. 45 ° feeler gauge 05-04. If rotary valve cover clearance is out of specifica- NOTE: On the 717D engine (SP model), rotary tion, machine rotary valve cover seating surface valve cover and carburetor are removed as an as- or replace the cover.
Page 84 Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) F01D3PA TYPICAL 1. Solder If rotary valve cover clearance is out of specifica- F01D3OA tion, machine rotary valve cover seating surface SAME AMOUNT REMOVED FROM COVER SEATING SURFACE or replace the cover. AND O-RING GROOVE BASE 1.
Page 85 Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) DISASSEMBLY 3, Rotary Valve Shaft To remove the rotary valve shaft assembly, first remove snap ring no. 4 from crankcase. F01D61A 1. Hold bolt F01D22A 1. Removing snap ring CAUTION Bottom end must be opened to remove rota- ry valve shaft.
Page 86 Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) 8, Bearing Snap-on hammer puller including: Handle CJ93-1 To remove bearing use a bearing extractor such as Snap-on no CJ-950 as illustrated. Slide off dis- Hammer CJ125-6 tance sleeve, remove snap ring no. 7 and press Claws CJ93-4 shaft out.
Page 87 Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) INSPECTION Deflection must not exceed 0.08 mm (.003 in). Replace shaft as necessary. 1, Rotary Valve Cover ASSEMBLY Inspect rotary valve cover for warpage. Small de- formation can be corrected by surfacing with fine Assembly is essentially the reverse of disassem- sand paper on a surface plate.
Page 88 Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) F01D2DA 1. Shield side (toward gear) A13C0FB Push bearing until it stops on its seat. 1. Seal 2. Ball bearing 3. Bearing extractor Snap-on CJ-950 Install shim no. 15, snap ring no. 7 and slide dis- tance sleeve no.
Page 89 Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) 717 Engines Push shaft until it stops on bearing seat. To install rotary valve shaft in crankcase, use a pusher (P/N 290 876 605). A00C0YA 1. Pusher Push shaft until its stops on bearing seat. F01D8OA All Engines 4, Snap Ring...
Page 90 Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) 159° TEMPLATE 159° (cut-out angle) (cut-out angle) 290 924 502 actual size 132° (cut-out angle) 290 924 504 actual size F01D8SS 03-07-9 www.SeaDooManuals.net...
Page 91: Rotary Valve Timing
Section 03 ENGINE Sub-Section 07 (ROTARY VALVE) ROTARY VALVE TIMING CAUTION Never use the ridge molded in crankcase as a timing mark. The following tools are required to measure rotary valve opening and closing angles in relation with MAG side piston. 295 000 007 F01D2IA 1.
Page 92 Install O-ring no. 12 and cover then torque screws no. 2 to 20 N•m (15 lbf•ft) in a criss-cross sequence. NOTE: For the 717D engine (SP model), install engine in watercraft first; then, install rotary valve cover, intake manifold and carburetor as an as- sembly.
Page 93: Exhaust System
Section 03 ENGINE Sub-Section 08 (EXHAUST SYSTEM) EXHAUST SYSTEM SP, GS, GSI, GTS and GTI Models 25 N•m Loctite (18 lbf•ft) model 25 N•m (18 lbf•ft) Loctite 242 Loctite 242 Loctite 6 25 N•m (18 lbf•ft) Synthetic 10 N•m 25 N•m grease (88 lbf•in)
Page 94 Section 03 ENGINE Sub-Section 08 (EXHAUST SYSTEM) HX Model 25 N•m Loctite 242 (18 lbf•ft) 10 N•m (88 lbf•in) 25 N•m (18 lbf•ft) Loctite 242 Sealant Loctite 24 N•m 25 N•m (17 lbf•ft) (18 lbf•ft) 4 N•m Loctite 4 N•m Synthetic (35 lbf•in) (35 lbf•in)
Page 95 Section 03 ENGINE Sub-Section 08 (EXHAUST SYSTEM) SPX, XP, GSX and GTX Models 25 N•m 25 N•m (18 lbf•ft) (18 lbf•ft) Loctite Loctite Loctite Loctite 40 N•m (30 lbf•ft) Sealant 40 N•m (30 lbf•ft) 10 N•m Synthetic (88 lbf•in) grease Loctite 242 4 N•m 40 N•m...
Page 96: Tuned Pipe Removal
Disconnect strap no. 2 retaining muffler no. 13. Remove exhaust hose no. 3 from tuned pipe by pulling muffler. Remove clamp no. 22 from tuned pipe (except SP model). Remove tuned pipe cone no. 5 (except SP mod- el).
Page 97 Section 03 ENGINE Sub-Section 08 (EXHAUST SYSTEM) SPX, XP, GSX and GTX Models Disconnect water supply hose and water injection hose at tuned pipe head. F01D76A 1. Screw Remove tuned pipe head no. 10. F01D3YA Remove both screws no. 6 retaining tuned pipe 1.
Page 98: Exhaust Manifold Removal
Section 03 ENGINE Sub-Section 08 (EXHAUST SYSTEM) SPX Model Only Disconnect upper exhaust hose no. 25 in front of muffler. Move tuned pipe cone no. 12 in front of bilge be- tween body and fuel tank. Disconnect both water injection hoses and both water drain hoses from muffler.
Page 99: Installation
Section 03 ENGINE Sub-Section 08 (EXHAUST SYSTEM) NOTE: Prior to verify leaks, plug all holes and pressurize tuned pipe while immerging it in water. CAUTION Always ensure water passages are not blocked partially or completely while weld- ing tuned pipe. INSTALLATION Installation is essentially the reverse of removal procedures.
Page 100 Section 03 ENGINE Sub-Section 08 (EXHAUST SYSTEM) F01D69A TYPICAL F01D0IA 1. Sealing ring TYPICAL Apply a thin layer of heat resistant sealant (P/N Step : Torque screw(s) of tuned pipe cone to 12 N•m (9 lbf•ft) 413 709 200) all around sealing ring. Step : Torque nut and screws of tuned pipe flange in a criss-cross sequence to 12 N•m (9 lbf•ft)
Page 101 Section 03 ENGINE Sub-Section 08 (EXHAUST SYSTEM) NOTE: Due to exhaust cone angle, it may have to be rotated to obtain alignment. Push cone no. 5 until it touches tuned pipe, then tighten exhaust clamp no. 22 and torque to 10 N•m (88 lbf•in).
Page 102 Section 04 COOLING SYSTEM Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS COMPONENTS ........................04-02-1 GENERAL ........................... 04-02-6 CIRCUIT..........................04-03-1 GENERAL ........................... 04-03-1 717 ENGINE COOLING SYSTEM..................04-03-4 787 ENGINE COOLING SYSTEM..................04-03-5 04-01-1 www.SeaDooManuals.net...
Page 103 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) COMPONENTS SP and GTS Models Loctite 1.2 N•m (11 lbf•in) Loctite model only Loctite 1.2 N•m (11 lbf•in) Loctite 1.2 N•m 1.2 N•m (11 lbf•in) (11 lbf•in) 1.2 N•m (11 lbf•in) 2.5 N•m (22 lbf•in)
Page 104 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) SPX Model Loctite 592 Loctite 592 Loctite 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) 2 N•m (18 lbf•in) 1.2 N•m (11 lbf•in) Loctite Loctite Loctite 1.2 N•m (11 lbf•in) 2.5 N•m 0.11 N•m (22 lbf•in) Loctite (1 lbf•in)
Page 105 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) GS, GSI and GTI Models Loctite 1.2 N•m (11 lbf•in) Loctite 1.2 N•m (11 lbf•in) Loctite 1.2 N•m (11 lbf•in) Loctite 1.2 N•m (11 lbf•in) Loctite F00E02S PARTS FLAT RATE 04-02-3 www.SeaDooManuals.net...
Page 106 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) XP, GSX and GTX Models Loctite Loctite 592 1.2 N•m (11 lbf•in) 1.2 N•m Loctite (11 lbf•in) 1.2 N•m (11 lbf•in) Loctite Loctite 1.2 N•m (11 lbf•in) 0.11 N•m 0.11 N•m (1 lbf•in) Loctite (1 lbf•in) Loctite...
Page 107 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) HX Model Loctite Loctite 592 1.2 N•m (11 lbf•in) Loctite 592 1.2 N•m (11 lbf•in) Loctite 1.2 N•m (11 lbf•in) Body 1.2 N•m (11 lbf•in) Loctite Engine water outlet Engine water outlet F05E04S PARTS FLAT RATE 04-02-5...
Page 108 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) GENERAL 3, Elbow Fitting Water injection used on exhaust system cools the CAUTION exhaust gases to obtain maximum performance from the tuned pipe. The elbow fitting has a cali- All hoses and fittings of the cooling system brated inside diameter to optimize water flow in have calibrated inside diameters to assure tuned pipe.
Page 109 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) 4, Water Flow Regulator Valve Adjustment The water flow regulator valve has been calibrat- A water flow regulator valve has been developed ed at the factory and should not be modified. for the 787 engine so that it can produce the max- imum horsepower output and yet maintain the NOTE: Water flow regulator valves ordered from necessary diameter of the injection fitting at the...
Page 110 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) F01E1RA F01E1TA 1. Spring 1. Tapered needle 2. Cover Remove the tapered needle from valve housing. 7, Fitting Remove fitting from valve housing. F01E20A 1. Remove tapered needle F01E1SA 1. Fitting 8, Tapered Needle Unscrew the tapered needle.
Page 111 Section 04 COOLING SYSTEM Sub-Section 02 (COMPONENTS) 9,10, Valve and Bellows Pull the valve slightly. Using pliers, release the clamp which retains the bellows. Remove valve and bellows. F01E21A Loosen clamp to separate valve from bellows. F01E24A 1. Clamp Inspection Inspect parts for damage.
Page 112 Snugly install the hose pincher on the water sup- flushing procedure, refer to MAINTENANCE 01- ply hose as shown in the following illustrations. SP, GS, GSI, GTS and GTI Models For winterization of cooling system, refer to MAINTENANCE 01-05. Towing the Watercraft in Water Special precautions should be taken when towing a Sea-Doo watercraft in water.
Page 113 Section 04 COOLING SYSTEM Sub-Section 03 (CIRCUIT) XP and HX Models Water is pre-heated by the exhaust system before entering the cylinder cooling jackets. Water enters cylinder cooling jacket through pas- sages located below exhaust ports from tuned pipe. F01E1YA 1.
Page 114 717 ENGINES 1. Drain hose SYSTEM FLUSHING: Fitting spigot or hose adapter. MONITORING BEEPER: SP, SPX and GTS models: turns on at 95-103°C (203-217°C). GS, GSI, GSX, GTI, GTX, HX and XP models: turns on at 86-94°C (187-201°C). 04-03-3 www.SeaDooManuals.net...
Page 115: Engine Cooling System
Section 04 COOLING SYSTEM Sub-Section 03 (CIRCUIT) 717 ENGINE COOLING SYSTEM 04-03-4 www.SeaDooManuals.net...
Page 116 Section 04 COOLING SYSTEM Sub-Section 03 (CIRCUIT) 787 ENGINE COOLING SYSTEM 787 ENGINE COOLING SYSTEM Temperature Calibrated sensor activates Uppermost point of cylinder monitoring circuit (tuned pipe) Water regulated head limits beeper when allows bleeding by the water flow water flow temperature regulator valve exceeds 96-99°C...
Page 117 Section 05 FUEL SYSTEM Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT........................05-02-1 GENERAL ........................... 05-02-6 REMOVAL........................... 05-02-7 INSPECTION ........................05-02-9 ASSEMBLY......................... 05-02-10 FUEL SYSTEM PRESSURIZATION ................... 05-02-10 AIR INTAKE ..........................05-03-1 REMOVAL........................... 05-03-2 ASSEMBLY......................... 05-03-2 CARBURETORS ........................05-04-1 GENERAL ...........................
Page 118: Fuel Circuit
Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) FUEL CIRCUIT SP and GTS Models 2 N•m (18 lbf•in) 6 N•m (53 lbf•in) 1 N•m (9 lbf•in) 22 N•m (16 lbf•ft) 4 N•m (35 lbf•in) 3 N•m (27 lbf•in) Loctite 242 3 N•m...
Page 119 Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) SPX Model 3 N•m (27 lbf•in) Body 2 N•m (18 lbf•in) 6 N•m (53 lbf•in) 1 N•m (9 lbf•in) 22 N•m (16 lbf•ft) 4 N•m (35 lbf•in) 4 3 N•m (27 lbf•in) 4 N•m (35 lbf•in) 4 Engine...
Page 120 Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) GS, GSI and GTI Models 3 N•m (27 lbf•in) 2 N•m (18 lbf•in) Body 6 N•m (53 lbf•in) 1 N•m (9 lbf•in) 22 N•m (16 lbf•ft) 4 N•m (35 lbf•in) 3 N•m (27 lbf•in) 4 N•m (35 lbf•in)
Page 121 Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) GSX and GTX Models 3 N•m (27 lbf•in) 2 N•m (18 lbf•in) Body 6 N•m (53 lbf•in) 1 N•m (9 lbf•in) 22 N•m (16 lbf•in) 4 N•m (35 lbf•in) 3 N•m (27 lbf•in) Engine F06F03S PARTS...
Page 122 Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) HX and XP Models Body 3 N•m (27 lbf•in) 2 N•m 6 N•m (18 lbf•in) (53 lbf•in) Body 1 N•m (9 lbf•in) 22 N•m (16 lbf•in) 4 N•m (35 lbf•in) 3 N•m (26 lbf•in) 4 N•m (35 lbf•in)
Page 123: General
Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) GENERAL WARNING Whenever repairing the fuel system, always verify for water infiltration in reservoir. To open or secure reusable clamps on fuel lines, use pliers (P/N 295 000 054). To open clamp, place flat side of plier on clamp embossment, squeeze and twist plier.
Page 124: Removal
Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) REMOVAL 1, Fuel Filter All Models Except HX and XP Open storage compartment cover. Remove basket. HX and XP Models Open engine cover. GTS Model Press on vent tube upper part to enable to with- draw tube from body.
Page 125 Fuel is flammable and explosive under cer- tain conditions. Always work in a well venti- lated area. Always wipe off any fuel spillage from the watercraft. SP, SPX and GTS Models Open storage compartment cover. F05F02A Remove storage basket from watercraft.
Page 126: Inspection
Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) F01F21A F01F02A TYPICAL 1. Gasket in bowl 1. Wiring harness 2. Baffle pick up adapter WARNING 3. Fuel hoses Loosen lower clamp no. 10 of baffle pick up Ensure that there is no leakage from the fuel adapter and pull out baffle no.
Page 127: Assembly
Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) ASSEMBLY Assembly is essentially the reverse of disassem- bly procedures. However pay particular attention to the following. 8, Baffle Pick Up Slide adapter no. 11 onto baffle pick up no. 8 until it stops on rib.
Page 128 Section 05 FUEL SYSTEM Sub-Section 02 (FUEL CIRCUIT) F01F0KA TYPICAL 1. Disconnect air inlet hose 2. Install a hose pincher to vent hose – Connect pump gauge tester (P/N 295 021 800) to air inlet hose. NOTE: This pump is included in the ENGINE LEAK TESTER KIT (P/N 295 500 352).
Page 129: Air Intake
Section 05 FUEL SYSTEM Sub-Section 03 (AIR INTAKE) AIR INTAKE 10 N•m (88 lbf•in) 10 N•m (88 lbf•in) Loctite Loctite Loctite Twin carbs Loctite 242 10 N•m (88 lbf•in) Single carb Loctite 515 Loctite 515 F01F1WS PARTS FLAT RATE 05-03-1 www.SeaDooManuals.net...
Page 130: Removal
Section 05 FUEL SYSTEM Sub-Section 03 (AIR INTAKE) REMOVAL 7, Flame Arrester Base Remove flame arrester no. 5. 1, Air Intake Silencer Cover Remove screws no. 8 retaining support no. 6 of Unlock retaining slides holding air intake silencer flame arrester base to the cylinder head cover cover and remove cover.
Page 131 Section 05 FUEL SYSTEM Sub-Section 03 (AIR INTAKE) 5, Flame Arrester Inspect condition of flame arrester. Replace or clean as necessary. WARNING Do not operate watercraft without flame ar- rester. 787 Engine Position the flame arrester with its embossment toward TOP. F00F04A 9, Gasket Inspect condition of gasket.
Page 132: Carburetors
Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) CARBURETORS Mikuni BN-38 Loctite Loctite Anti-seize lubrifiant F02F0KS PARTS FLAT RATE 05-04-1 www.SeaDooManuals.net...
Page 133 Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) Mikuni BN-38I, BN-40I Loctite 20 N•m (15 lbf•ft) Loctite Loctite 242 Anti-seize lubricant Synthetic grease Synthetic grease F01F05S PARTS FLAT RATE 05-04-2 www.SeaDooManuals.net...
Page 134: General
6. Main jet and high-speed screw REMOVAL To remove carburetor(s) from engine, proceed as follows: Remove air vent tube support (SP, SPX, GS, GSI and GSX models). Remove air intake silencer. Refer to FUEL SYS- TEM 05-03. Turn fuel valve to OFF position.
Page 135: Cleaning
Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) DISASSEMBLY AND INSPECTION Inspect parts for corrosion damage (shaft, throttle plate, spring, screw, check valve housing, etc.). 1, Needle Valve Inspect needle valve tip for a grooved condition. If worn, needle and seat must be replaced as a matched set.
Page 136: Assembly
Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) WARNING Some fuel may be present in fuel pump. Be careful not to swallow fuel when under vac- uum. F01F0YA TYPICAL 1. Filter ASSEMBLY When assembling pump, ensure to properly posi- F01F0WA tion components together. Refer to previous illus- TYPICAL trations if necessary.
Page 137 Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) F01F34A LOW LEVER Step : Depress here Step : Pry up here POP-OFF PRESSURE TEST Proceed as follows: – Install pump gauge tester on carburetor fuel in- let nipple. – Obstruct fuel return nipple with a finger. –...
Page 138 Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) NOTE: Pressure test should be performed three times to obtain a valid reading. If pop-off pressure is not within specification, check control lever adjustment. Replace spring as necessary. CAUTION Do not stretch or cut spring. LEAK TEST Needle valve must stand a pressure of 69 kPa (10 PSI) for 30 seconds.
Page 139: Installation
Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) 13, O-ring When installing O-rings of low speed and high speed screws, apply some BOMBARDIER LUBE (P/N 293 600 016) to prevent sticking. INSTALLATION At installation, pay attention to the following: Install carburetor(s) with gasket(s) to intake mani- fold (rotary valve cover for the 787 engine).
Page 140: Adjustments
Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) Properly install clamps. WARNING Make sure there is no leak in fuel system. For fuel system pressurization, refer to FUEL SYSTEM 05-02. ADJUSTMENTS Throttle Cable Lubricate cable with BOMBARDIER LUBE lubri- cant. F01F0TF Throttle lever must reach handlebar grip without causing strain to cable or carburetor cable bracket.
Page 141 Tighten low speed screw until a slight resistance is felt. Then, back it off to the specification as per F01F0VA following chart. TYPICAL — SINGLE CARB Watercraft SP/GS/GSI/ SPX/XP/ 1. High speed screw model GTS/GTI GSX/GTX Low speed...
Page 142 Section 05 FUEL SYSTEM Sub-Section 04 (CARBURETORS) F01F32C TWIN CARBS F01F2Q A 1. Idle speed screw TYPICAL — TWIN CARBS NOTE: On twin carburetor engines, there is only 1. High speed screws one idle speed screw. 15, Idle Speed Screw Connect an induction-type tachometer (P/N 295 000 100) on spark plug cable of magneto side to Turning screw clockwise increases engine idle...
Page 143 Section 06 LUBRICATION SYSTEM Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM ...................... 06-02-1 GENERAL ........................... 06-02-4 OIL SYSTEM PRESSURIZATION ..................06-02-4 OIL INJECTION PUMP ......................06-03-1 REMOVAL........................... 06-03-3 DISASSEMBLY........................06-03-3 CLEANING ......................... 06-03-3 ASSEMBLY......................... 06-03-3 ADJUSTMENTS ........................ 06-03-4 CHECKING OPERATION....................
Page 144: Oil Injection System
Section 06 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM SP, SPX and GTS Models 27 N•m (20 lbf•ft) SP model only 3.5 N•m (31 lbf•in) 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) To engine crankcase (return)
Page 145 Section 06 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION SYSTEM) XP and HX Models To engine 1.2 N•m crankcase (11 lbf•in) (supply) To oil injection pump 1.2 N•m (11 lbf•in) To engine crankcase (return) F05G03S PARTS FLAT RATE 06-02-2 www.SeaDooManuals.net...
Page 146 Section 06 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION SYSTEM) GS, GSI, GSX, GTI and GTX Models To engine crankcase 27 N•m (return) To oil (20 lbf•ft) injection pump 3.5 N•m (31 lbf•in) To engine crankcase (supply) 1.2 N•m 1.2 N•m (11 lbf•in) (11 lbf•in) 3.5 N•m...
Page 147: General
Section 06 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION SYSTEM) GENERAL Whenever repairing the oil injection system, al- ways verify for water infiltration in reservoir. Perform also a pressure test of the oil injection system. All Models Except XP and HX 1,2, Clamp and Hose Verify oil filler neck hose for damage.
Page 148: Oil Injection Pump
Sub-Section 03 (OIL INJECTION PUMP) OIL INJECTION PUMP 717 Engines Twin carbs 6 N•m (53 lbf•in) Single carb Loctite 6 N•m (53 lbf•in) SP/GTI 10 N•m (89 lbf•in) Loctite 6 N•m (53 lbf•in) 6 N•m (53 lbf•in) 8 N•m (71 lbf•in) 10 N•m...
Page 149 Section 06 LUBRICATION SYSTEM Sub-Section 03 (OIL INJECTION PUMP) 787 Engine 6 N•m (53 lbf•in) 4.5 N•m 4.5 N•m (40 lbf•in) (40 lbf•in) Loctite 4.5 N•m (40 lbf•in) F01G0TS PARTS FLAT RATE 06-03-2 www.SeaDooManuals.net...
Page 150: Removal
Section 06 LUBRICATION SYSTEM Sub-Section 03 (OIL INJECTION PUMP) REMOVAL DISASSEMBLY NOTE: Some oil pump parts are not available in 717 Engines single parts. A gasket set is available for the Remove air intake silencer (refer to FUEL SYS- pump. TEM 05-03).
Page 151: Adjustments
Section 06 LUBRICATION SYSTEM Sub-Section 03 (OIL INJECTION PUMP) 4, Intake Manifold Turn idle speed screw until it contacts stopper. Turn idle speed screw 2 turns. Install intake manifold to rotary valve cover and torque screws no. 6 to 10 N•m (89 lbf•in). Turn cable adjustment nut to align marks on pump.
Page 152 Section 06 LUBRICATION SYSTEM Sub-Section 03 (OIL INJECTION PUMP) All Engines 717 Engines Start and bring engine to normal operating tem- perature. CAUTION If watercraft is out of water, engine must be cooled using the flush kit. If air bubbles are present in the oil injection system, bleed system before operating engine.
Page 153: Checking Operation
Section 06 LUBRICATION SYSTEM Sub-Section 03 (OIL INJECTION PUMP) If not, run engine at idle speed while manually holding pump lever in fully open position. Do not activate throttle lever. CAUTION If watercraft is out of water, engine must be cooled using the flush kit.
Page 154 Section 07 ELECTRICAL SYSTEM Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION SYSTEM........................ 07-02-1 GENERAL ........................... 07-02-1 IGNITION TIMING PROCEDURE ..................07-02-4 BOMBARDIER IGNITION TESTER ..................07-02-11 IGNITION SYSTEM TESTING PROCEDURE ..............07-02-11 SPARK PLUGS ........................07-02-16 CHARGING SYSTEM......................07-03-1 GENERAL ...........................
Page 155: Ignition System
The flywheel contains 4 permanent magnets and spins around the generating coil. This electric cur- rent flows to the ignition coil (SP, GTS and HX models) or the Multi-Purpose Electronic Module F01H2NA (GS, GSI and GTI models).
Page 156 – engine rev limiter at low RPM. Fuses are directly mounted onto the MPEM. SPX, GSX and GTX Models SP, GTS and HX Models The high amperage/voltage components are lo- cated into a rear electrical box (next to the bat- tery).
Page 157 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Trigger Coil Multi-Purpose Electronic Module (MPEM) The trigger coil is mounted outside the rotor (in- side the magneto housing of the engine) and is The MPEM is directly powered by the battery. It not adjustable.
Page 158: Ignition Timing Procedure
Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) CAUTION The relation between the PTO flywheel mark position and crankshaft position may change as the PTO flywheel is screwed on the crankshaft. As an example, when the PTO flywheel is reinstall on the crankshaft, it can slightly turns on the crankshaft when the engine is accelerated, even if it is properly torqued.
Page 159 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 717 Engines 3. Install timing mark pointer tool on engine using wing nuts previously removed. F01H5TA TYPICAL F01H5SA 1. TDC gauge on MAG side 1. Timing mark pointer tool (P/N 295 000 130) 5.
Page 160 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) IGNITION TIMING ENGINE (BTDC) 717D/717 2.59 mm (.102 in) 3.38 mm (.133 in) 7. Scribe a thin mark on PTO flywheel in the mid- dle of tool slot (717 engines) or aligned with timing mark pointer tool (787 engine).
Page 161 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) If timing mark aligns with tool slot, timing is prop- erly set. If not, refer to Ignition Timing Adjust- ment in this sub-section. 787 Engine 1. Connect an induction-type tachometer (P/N 295 000 100) to spark plug wire. F00H0HA 1.
Page 162 If it is not the case, refer to Ignition Timing Adjustment in this sub-section. Ignition Timing Adjustment 717 Engines Remove battery (SP and GTS models). Remove magneto housing cover and wire support. For removal of magneto, refer to ENGINE 03-04. Timing is performed by moving armature plate;...
Page 163 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Recheck ignition timing (make sure engine is cold). Repeat armature plate positioning procedure if timing mark position is not adequate. 787 Engine To correct the ignition timing, the data of the MPEM is changed using the MPEM programmer (P/N 295 000 127).
Page 164 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Examples: – You recheck the timing with the timing light and if the mark is aligned, the ignition timing a. You found the flywheel mark advanced. You is properly set. must retard the ignition timing. Proceed as follows to adjust the ignition timing –...
Page 165: Bombardier Ignition Tester
Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) BOMBARDIER IGNITION TESTER INDICATOR LAMP LIGHTS AT LOWER SETTING Use of Bombardier Ignition Tester This indicates that the output is less than that de- This tester (P/N 295 000 008) can verify generat- signed to operate in a satisfactory manner.
Page 166 Multi-Purpose Electronic Module Measure resistance, it must be an open circuit (MPEM) Verification (switch is normally open). Depress and hold SP, GTS and HX Models switch, the ohmmeter should read close to 0 ohm. The multi-purpose electronic module testing must be done with all wires disconnected from circuit.
Page 167 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Meter (+) lead Meter (-) Value < 1Ω (ring terminal) (female terminal) Red/Purple < 1Ω (ring terminal) (female terminal) Black > 20 kΩ (ring terminal) (ring terminal) F01B28A Black TYPICAL Black/Red > 10 kΩ (ring terminal) Check resistance with a high-sensitivity ohmme- ter.
Page 168 2. Install the six-pin magneto harness adapter an ohmmeter. (P/N 295 000 136). Primary Winding SP, GTS and HX Models Due to the integrated CDI module, it is not possi- ble to take any resistance measurement. 07-02-14 www.SeaDooManuals.net...
Page 169 IGNITION COIL PART NAME WIRE RESISTANCE Secondary End of each spark winding plug cable, spark 9 - 15 kΩ (SP/GTS/HX) plug caps removed Secondary F01H5MA End of each spark winding plug cable, spark 8.4 - 15.6 kΩ TYPICAL (all other plug caps removed 1.
Page 170: Spark Plugs
Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) All Models Except SP, GTS and HX Heat Range As an alternate method, use KOWA ignition coil The proper heat range of the spark plugs is deter- tester (or equivalent), available from after-market mined by the spark plugs ability to dissipate the tool/equipment suppliers.
Page 171 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Fouling 2. Apply anti-seize lubricant over the spark plug threads to prevent possible seizure. Fouling of the spark plug is indicated by irregular 3. Hand screw spark plug into cylinder head and running of the engine, decreased engine speed tighten with a torque wrench and a proper due to misfiring, reduced performance, and in-...
Page 172 Section 07 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Spark Plug Symbol Explanation WIDE GAP PREFIX SUFFIX 10: 1.0 mm (.040") 11: 1.1 mm (.044") B R 8 E S 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...
Page 173: Charging System
4 amperes for the 717 engines or 5 amperes for the 787 engine. If not, Fuse check magneto output prior to concluding that SP, GTS and HX Models rectifier is faulty. A 15 A fuse protects the charging system. Voltage Test Proceed as follows: –...
Page 174 Section 07 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) If voltmeter reads over 15 volts, regulator is de- DYNAMIC TEST fective. Replace it. 1. Disconnect the magneto wiring harness con- NOTE: If it is continually necessary to add distilled nector. water to the battery, this indicates an over voltage 2.
Page 175 Section 07 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) 787 Engine Stator STATIC TEST: CONTINUITY 1. Disconnect the magneto wiring harness con- nector. 2. Install the six-pin magneto harness adapter (P/N 295 000 136). 3. Check resistance between two of the YELLOW wires.
Page 176: Battery
Section 07 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) BATTERY CAUTION Troubleshooting Should any electrolyte spillage occur, imme- diately wash off with a solution of baking SYMPTOM: DISCHARGED OR WEAK BATTERY soda and water. CAUSE REMEDY Cleaning 1. Battery posts and/or Clean and coat with cable terminal oxi- dielectric grease.
Page 177 Electrolyte temperature: –1°C (30°F) Electrolyte temperature: 38°C (100°F) Subtract .016 Sp. Gr. Add .012 Sp. Gr. Corrected Sp. Gr. is 1.234 Corrected Sp. Gr. is 1.247 A new battery is factory fresh dry charged. For storage purposes, it is fitted with a temporary Battery Storage sealing tube.
Page 178 Section 07 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) Perform the following operations anytime a new battery is to be installed. 1. Remove the sealing tube from the vent elbow. WARNING Failure to remove the sealing tube could re- sult in an explosion. 2.
Page 179 Section 07 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) Do not charge a frozen battery. If the battery charge is very low, the battery may freeze. If it is suspected to be frozen, keep it in a heated area for about 2 hours before charging. WARNING Always charge battery in a well ventilated area.
Page 180 Section 07 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) – Measure the voltage at the battery posts with an accurate voltmeter. If it is below 10 volts, the battery will accept current at very low rate, in term of milliamperes, because electrolyte is nearly pure water as explained above.
Page 181 SPX, GSX AND GTX MODELS 1. Negative battery cable on top of small ground wire 5. Apply dielectric grease on battery posts. 6. Verify cable routing and attachment. SP and GTS Models Secure RED positive battery cable using right strap of battery. F01H0AA 1.
Page 182: Starting System
Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTING SYSTEM 717 Engines 22 N•m (16 lbf•ft) Loctite 242 5 N•m (44 lbf•in) Dielectric grease 22 N•m (16 lbf•ft) Loctite 271 Ground cable 22 N•m (16 lbf•ft) Loctite 242 F00H0BS PARTS FLAT RATE 07-04-1 www.SeaDooManuals.net...
Page 183 Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) 787 Engine 22 N•m (16 lbf•ft) Loctite 242 5 N•m (44 lbf•in) Dielectric grease 22 N•m (16 lbf•ft ) 14 Loctite 242 16 22 N•m Loctite 271 (16 lbf•ft) Ground cable Loctite 242 25 N•m (18 lbf•ft) 19 16 22 N•m...
Page 184: General
Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) GENERAL Safety Lanyard Switch The following continuity tests can be performed Causes of troubles are not necessarily related to using an ohmmeter: starter but may be due to a burnt fuse, faulty bat- tery, start/stop switch, safety lanyard switch, Disconnect switch wires.
Page 185: Starting System Troubleshooting
Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY Starter does not turn. Burnt 5A fuse. Check wiring condition and replace fuse. Poor contact of battery terminal(s). Clean and tighten terminal(s). Poor battery ground cable connection. Clean and tighten.
Page 186: Starter Removal
Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTER REMOVAL Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. Disconnect RED cable connection from battery. Remove the following parts: – cables from starter A03E04A 1.
Page 187: Parts Inspection
Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) PARTS INSPECTION 2, Brush Holder Check brush holder for insulation using an ohm- 11, Armature meter. Place one test probe on insulated brush holder and the other test probe on brush holder NOTE: An ohmmeter may be used for the follow- plate.
Page 188 Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) Slide stop collar no. 7 over circlip no. 6 and se- cure in place by punching it at 2 or 3 places. F01H0SA 1. Locating protrusion is the higher one A03E0EA 1. Armature shaft 2.
Page 189: Starter Installation
Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) 17, Nut Connect the RED battery cable to the starter and torque nut to 6 N•m (53 lbf•in). Apply dielectric grease on terminal and nut. 14,15, Screw and Teeth Washer Apply Loctite 271 (red) on screw. Connect BLACK cable to starter using flat washer, teeth washer and screw.
Page 190: Starter Specification
Section 07 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) 787 Engine Only 18, Locking Collar Install the locking collar of the fuel hose. Apply Loctite 242 (blue) on nut no. 19 and torque to 25 N•m (18 lbf•ft). F07H03A 1. Locking collar 2.
Page 191: Instruments And Accessories
Section 07 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL Lake Temperature Sensor GTX Model It is possible to activate the instruments when the engine is not running. The lake temperature sensor is integrated with the speed sensor located on the ride plate. Make sure the safety lanyard is removed, then de- press the start/stop button.
Page 192 Section 07 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) Tachometer To check if the speed sensor is operational, dis- connect the speed sensor connector housing GTX Model from inside bilge. Using an appropriate terminal remover (Snap-on TT600-4), remove the PURPLE/YELLOW and BLACK/ORANGE wires from the tab housing of the speed sensor.
Page 193 Section 07 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) Info Center Operation SCROLLING FUNCTIONS GSI, GSX and GTX Models Press the MODE button until the desired function is displayed on the Info Center. RESET To reset a function such as the chronometer, peak Bombardier speed, trip meter, etc., select the desired function using the MODE button then press and hold the...
Page 194 Section 07 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) Press the MODE button to adjust the hours and LOW FUEL RESISTANCE FUEL LEVEL the SET button to adjust the minutes. LEVEL RED (Ω) LCD GRAPHIC Press again on both the MODE and SET buttons LIGHT to exit the setting mode (or the gauge will auto- 0 + 2.2...
Page 195 Section 07 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) LAKE TEMPERATURE NOTE: The gauge must be activated to obtain a reading. Disconnect the 2-circuit connector housing of the Info Center which contains a BLACK/ORANGE RESISTANCE DISPLAY and TAN/ORANGE wires. (Ω) TEMPERATURE (°C) Connect potentiometer test probes to the 25590.1...
Page 196 Section 07 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) Bombardier Bombardier F01H4RA F01G07A SPX, GTS, HX AND XP MODELS TYPICAL 1. Low oil warning light 1. Bow up 2. Bow down Accuracy of gauge can be checked with a potenti- ometer.
Page 197 27.8 ± 2.2 Oil Sensor From 135.1 to 162 ± 5 37.8 ± 2.2 All Models Except the SP From 108.1 to 135 ± 5 47.8 ± 2.2 The sensor sends the signal to the low-oil level From 81.1 to 108 ± 5 57.8 ±...
Page 198 Section 07 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) F03H0BA 1. Measure resistance here 2. Sensor reservoir F00H0LA 1. Oil sensor To reinstall sensor: The bottom of the sensor has a small reservoir – Remove rubber seal from sensor. with two small holes underneath to let the oil en- –...
Page 199 Section 07 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) If motor seems to jam and it has not reached the end of its stroke, the following test could be per- formed. First remove motor, refer to PROPULSION SYS- TEM 08-05. Then manually rotate worm to verify VTS system actuating mechanism for free opera- tion.
Page 200: Digitally Encoded Security System
Section 07 ELECTRICAL SYSTEM Sub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM) DIGITALLY ENCODED SECURITY SYSTEM GENERAL The Digitally Encoded Security System (DESS) features an anti-start protection against unautho- rized use of the watercraft. The following components are specially designed for this system: Multi-Purpose Electronic Module (MPEM), safety lanyard cap and safety lanyard switch.
Page 201 Section 07 ELECTRICAL SYSTEM Sub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM) Basic Self-Diagnostic Mode It is self-activated when the safety lanyard is being installed on the watercraft switch. It gives immediate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
Page 202 Section 07 ELECTRICAL SYSTEM Sub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM) Advanced Self-Diagnostic Mode It needs to be enabled manually. Proceed as follows: 1. Remove safety lanyard from watercraft switch. 2. Press 5 times on the watercraft start/stop button. NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3.
Page 203 Section 08 PROPULSION SYSTEM Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ..........................08-02-1 GENERAL ........................... 08-02-2 JET PUMP INSPECTION ON WATERCRAFT ..............08-02-2 REMOVAL........................... 08-02-4 DISASSEMBLY........................08-02-6 CLEANING ......................... 08-02-8 PARTS INSPECTION ......................08-02-9 ASSEMBLY......................... 08-02-11 PUMP PRESSURIZATION ....................08-02-18 INSTALLATION ........................
Page 204: Jet Pump
Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) JET PUMP SP/SPX/GTS Loctite Synthetic grease SPX/GSI/GSX/HX/XP Loctite SP/GS/GTS/GTI/GTX 20 N•m (15 lbf•ft) Loctite Loctite Loctite Synthetic Loctite Loctite 20 N•m (15 lbf•ft) F00J05S PARTS FLAT RATE 08-02-1 www.SeaDooManuals.net...
Page 205: General
To work on watercraft, securely install it on a stand. Thus, if access is needed to water inlet ar- On the SP, GS and GSI models, the jet pump ea, it will be easy to slide underneath watercraft. housing is a one piece plastic unit, including the stator.
Page 206 Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) F01J0DA TYPICAL F01J0EA 1. Inspect impeller and boot TYPICAL — MEASURING FROM WATER INLET SIDE Impeller/Wear Ring Clearance 1. Feeler gauge This clearance is critical for jet pump perfor- mance. Clearance can be checked from water inlet open- ing or from venturi side.
Page 207: Removal
Remove venturi as described in Oil Inspection. 5, Nozzle Remove 3 screws retaining cover. Disconnect steering cable from jet pump nozzle. SP, GS, GTS, GTI and GTX Models Remove 2 retaining screws no. 1, 2 sleeves no. 2, 4 locking disks no. 4. 08-02-4...
Page 208 (if ap- plicable). Disconnect ball joint of VTS link rod. SP, SPX and GTS Models HX Model Remove air vent tube support from body opening Loosen fasteners retaining trim support to nozzle.
Page 209: Disassembly
Using 2 screws previously removed from venturi, where applicable, to detect excessive wear. secure shaft holder to housing. SP, SPX and GTS Models 17, Fitting Fittings can be removed with deep socket or vise grip. Do not contact hose mounting area.
Page 210 Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) Heat impeller center with a propane torch to ap- Rotate impeller remover tool counterclockwise proximately 150°C (300°F) to break the Loctite and unscrew completely impeller. bond. CAUTION Install shaft holder in a vice. Never use any impact wrench to loosen im- peller.
Page 211: Cleaning
Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) F01J0WA TYPICAL F00J0MA 1. Snap-on HS3 1. Bearing/seal remover tool After cutting ring, insert a screwdriver blade be- tween impeller housing and ring outside diameter. NOTE: It is always recommended to renew both bearings, even if only one bearing needs to be re- Push ring so that it can collapse internally.
Page 212: Parts Inspection
Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) Brush and clean impeller shaft threads, impeller and drive shaft splines with Loctite Safety solvent 755 (P/N 293 800 019) or equivalent. Free threads and splines from any residue. CAUTION Be careful not to damage impeller shaft di- ameter.
Page 213 Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) F01J18A F01J1AA TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY 1. Inspect for wear at the bearing pilot 2. Radial bearing raceway 1. Dial gauge 2. Measure close to threads at shaft end NOTE: If shaft is to be replaced, it is recommend- To check both bearings, proceed the same way ed to replace both bearings at the same time.
Page 214: Assembly
Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) 18,24, Cover and Impeller Shaft END PLAY End play of impeller shaft is checked with shaft in housing, without impeller and with cover in- stalled. Retain housing in a soft jaw vise making sure not to damage housing lug.
Page 215 Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) NOTE: To ease insertion into housing, apply BOMBARDIER LUBE lubricant (P/N 293 600 016) onto outside circumference of wear ring. To install ring in housing, use a square steel plate of approximately 180 × 180 mm × 6 mm thick (7 ×...
Page 216 Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) Bearing on impeller side must be 1.5 to 2.5 mm (.060 – .100 in) inside reservoir measured from seal seat. Bearing on venturi side must be 2 to 3 mm (.080 – .120 in) inside reservoir measured from thrust washer seat.
Page 217 Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) F01J1KA F01J1MA 1. Raised edge of seal this side 1. Loctite 518 all around and behind 2. Raised edge of seal lip this side CAUTION 25, Thrust Washer Position jet pump housing no. 9 with the stator Prevent sealant from contacting any needles vanes on top.
Page 218 Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) NOTE: If jet pump housing rest against a table, raise it slightly to allow complete shaft insertion with the shaft guide. Remove shaft guide. 20, Impeller Apply Loctite primer N (P/N 293 600 012) on threads of impeller shaft no.
Page 219 Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) Torque impeller to 70 N•m (52 lbf•ft) then remove tools. CAUTION Never use any impact wrench to tighten im- peller. Apply synthetic grease (P/N 293 550 010) on im- peller splines. Insert a new boot no. 15 and ring no. 16 to impel- ler.
Page 220 If needed, install new O-rings no. 10 around bailer F02J0TA passages. 1. Torque screws to 21 N•m (16 lbf•ft) 17, Fitting SP, SPX and GTS Models Apply Loctite PST 592 on plastic fitting threads. Then thread fitting into pump housing until threads are bottomed. 08-02-17...
Page 221: Pump Pressurization
– Connect pump gauge tester (P/N 295 000 085) 28, Neoprene Seal to fitting. SP, SPX and GTS Models – Pressurize pump to a maximum of 70 kPa (10 PSI). If neoprene seal is damaged, replace it with a new one.
Page 222 Sub-Section 02 (JET PUMP) F01J0IA 1. Bailer tubes 2. Water inlet hose F01J21A Reinstall air vent tube support onto body (SP/SPX 1. Apply Loctite 598 Ultra Black where indicated models). All Models Generously apply synthetic grease on drive shaft 5, Nozzle splines.
Page 223: Steering Cable
Section 08 PROPULSION SYSTEM Sub-Section 02 (JET PUMP) Steering Cable Refer to STEERING SYSTEM 09. Trim System Refer to PROPULSION SYSTEM 08-05. Reverse Cable Refer to PROPULSION SYSTEM 08-04. F01J3BA TYPICAL 1. Locking disks 2. Torque screws to 20 N•m (15 lbf•ft) WARNING Whenever removing screw always renew locking disks.
Page 224: Drive System
Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) DRIVE SYSTEM SP, SPX, GS, GSI, GTS and GTI Models Loctite 2 N•m (18 lbf•in) 2 N•m (18 lbf•in) Synthetic grease Synthetic grease F01I0ES PARTS FLAT RATE 08-03-1 www.SeaDooManuals.net...
Page 225 Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) GSX and GTX Models 2 N•m (18 lbf•in) 2 N•m (18 lbf•in) Synthetic grease Synthetic grease F06I01S PARTS FLAT RATE 08-03-2 www.SeaDooManuals.net...
Page 226 Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) XP and HX Models 22 N•m (16 lbf•ft) Loctite 242 22 N•m (16 lbf•ft) Loctite 242 22 N•m (16 lbf•ft) Loctite 242 Loctite Synthetic grease Loctite 7 N•m Loctite (62 lbf•in) Synthetic grease 2 N•m (18 lbf•in)
Page 227: General
Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) GENERAL Jet pump must be removed to replace any com- ponents of the drive system. Refer to PROPUL- SION SYSTEM 08-02 for jet pump removal procedure. REMOVAL All Models Except the XP and HX Remove seat.
Page 228 Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) XP and HX Models Remove rear access panel. All Models 5,6, Floating Ring and O-ring Hold floating ring no. 5 and compress boot no. 9; then, pull out O-ring no. 6 from drive shaft groove. F01I05A 1.
Page 229 Refer to ENGINE 03-04 and fol- low the procedure to lock the magneto flywheel. NOTE: Do not remove the magneto flywheel. SP, GS, GSI, GTS and GTI Models F05I04A PTO flywheel is loosen using PTO flywheel re- 1.
Page 230 Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) F01D4AA TYPICAL F01D1AA 1. Extension handle locking crankshaft TYPICAL SPX, GSX, GTX, XP and HX Models 1. PTO flywheel remover (P/N 295 000 001) PTO flywheel is loosen using PTO flywheel re- Using a suitable wrench or socket, unscrew PTO mover (P/N 295 000 156).
Page 231: Disassembly
Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) F01I0FA 1. Floating ring contact surface 2. Groove condition F06I02A 3. Splines condition SPX, GSX AND GTX MODELS Excessive deflection could cause vibration and 1. PTO flywheel remover damage to drive shaft splines, impeller, flywheel Install the extension handle (P/N 295 000 125) on or floating ring.
Page 232: Assembly
Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) XP and HX Models Only 5,18, Floating Ring and O-ring Inspect condition of O-rings and floating ring con- 14, Needle Bearing tact surface. Properly support seal carrier when installing seals and bearing. CAUTION Ensure to install stamped end of bearing (showing identification markings) first on...
Page 233 Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) 13, Seal Pack seals and bearing with synthetic grease (P/N 293 550 010). Install double-lip seal with protector toward jet pump. 12, Seal Carrier On both seals, raised edge of lip must be located Properly index flanges together.
Page 234 Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) F05I08A F05I0FA 1. Alignment tool ENGINE SIDE SHOWN 2. Seal carrier 1. Damper 2. Bushing Torque seal carrier nuts no. 19 to 7 N•m (62 lbf•in) in a criss-cross sequence as per following illustra- 7,20, Front Drive Shaft and Coupler tion.
Page 235 Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) All Models All Models Except the XP and HX 5,6, Floating Ring and O-ring 3, Drive Shaft Position the O-ring no. 6 of the drive shaft in the Install drive shaft. flange of the floating ring no. 5. CAUTION Take care not to break the O-ring in the float- ing ring flange while inserting the drive...
Page 236 Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) All Models Except the XP and HX 1, Large Clamp Secure large clamp no. 1 as follows: – Use pliers (P/N 295 000 069) as for removal. – Manually engage holding hook in large window. This is a pre-clamping position only.
Page 237: Lubrication
Section 08 PROPULSION SYSTEM Sub-Section 03 (DRIVE SYSTEM) 2, Small Clamp XP and HX Models Lubricate mid bearing with synthetic grease (P/N To secure small clamp no. 2, place notch side of 293 550 010). plier on clamp embossment and squeeze plier. F05I09A 1.
Page 238: Reverse System
Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) REVERSE SYSTEM GTS Model Synthetic grease 2.5 N•m (22 lbf•in) 8 N•m (71 lbf•in) 7 N•m (62 lbf•in) 10 N•m 6 N•m 3 N•m (88 lbf•in) (53 lbf•in) (27 lbf•in) 8 N•m (71 lbf•in) 7 N•m (62 lbf•in)
Page 239: General
Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) GENERAL It is not necessary to remove reverse system from watercraft for servicing. However reverse system removal is necessary to replace reverse support. DISASSEMBLY Remove storage tray from watercraft. Press on vent tube upper part to enable to with- draw tube from body.
Page 240: Assembly
Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) 7, Reverse Gate Unhook reverse gate springs and remove ball joint fasteners to release reverse cable from reverse gate. F02J06A TYPICAL 1. Reverse support 2. Reverse cable 3. Triangular lever F02J08A 6, Reverse Support 1.
Page 241: Shift Lever
Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) Torque triangular lever screw to 8 N•m (71 lbf•in). CAUTION Install sliding block to lever and torque nut to 8 N•m (71 lbf•in). Always hook reverse gate springs in order to ease reverse gate operation. 1,5, Locking Lever and Sliding Block Insert locking lever end in support hole then align lever and sliding block holes.
Page 242: Adjustments
Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) ADJUSTMENTS 2, Spring Insert spring in lever stem hole and then install 7, Reverse Gate curved end in sliding block groove. Position handlebar in a straight ahead position, nozzle should be parallel to rear of watercraft. Using a square, set it to 129 ±...
Page 243 Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) Tighten adjustment nuts and recheck gate posi- tion. Reinstall vent tube. WARNING Vent tube must be in place to provide proper bilge ventilation. F02J0FA 1. REVERSE position If reverse gate needs to be readjusted, it can be done at support with adjustment nuts.
Page 244 Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) GTI and GTX Models 3 N•m (27 lbf•in) Loctite 242 Synthetic Loctite grease 3.5 N•m (31 lbf•in) 2.5 N•m (22 lbf•in) Sealant 4 N•m 6 N•m 3 N•m (35 lbf•in) (53 lbf•in) (27 lbf•in) Loctite 7 N•m...
Page 245: Disassembly
Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) DISASSEMBLY 1, Reverse Gate Put shift lever in reverse position. Disconnect reverse cable by loosing bolt no. 2 and lock nut no. 3 from cable lever. Loosen 2 Allen screws no. 4 and remove reverse gate.
Page 246: Assembly
Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) ASSEMBLY Make sure the shift lever action is smooth and precise. Forward, neutral and reverse positions Assembly is essentially the reverse of disassem- should be easy to select with a detent position be- bly procedures.
Page 247: Adjustment
Section 08 PROPULSION SYSTEM Sub-Section 04 (REVERSE SYSTEM) 21, Reverse Cable Install reverse cable to cable lever as per following illustration. F07J09A 1. Reverse cable support 2. Loosen bolts 3. Adjustment nut F07J08A When adjustment is completed, there should be gap of 2 to 3 mm (5/64 to 7/64 in) between handle 1.
Page 248: Variable Trim System
Section 08 PROPULSION SYSTEM Sub-Section 05 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM MANUAL TRIM 21 N•m (16 lbf•ft) Loctite 13 N•m 10 N•m (10 lbf•ft) (89 lbf•in) Loctite 242 Loctite 13 N•m (10 lbf•ft) Loctite 242 13 N•m (10 lbf•ft) F05J07S PARTS FLAT RATE...
Page 249: Removal
Section 08 PROPULSION SYSTEM Sub-Section 05 (VARIABLE TRIM SYSTEM) REMOVAL Loosen screw no. 1, bolt no. 2 and lock nut no. 3 retaining support from trim ring. F05J08A 1. Screw 2. Bolt 3. Lock nut Remove manual trim. 4, Trim Ring To remove trim ring/nozzle assembly from venturi, loosen side screws no.
Page 250: Electric Trim
Section 08 PROPULSION SYSTEM Sub-Section 05 (VARIABLE TRIM SYSTEM) ELECTRIC TRIM 7 N•m (62 lbf•in) 6 N•m (53 lbf•in) 10 N•m (88 lbf•in) 13 N•m (10 lbf•ft) 2.5 N•m (23 lbf•in) Loctite 7 N•m (62 lbf•in) 13 N•m (10 lbf•ft) Loctite 13 N•m Loctite...
Page 251: General
Section 08 PROPULSION SYSTEM Sub-Section 05 (VARIABLE TRIM SYSTEM) GENERAL To test VTS control module, motor or switch, refer to ELECTRICAL SYSTEM 07-05. REMOVAL Disconnect ball joint no. 1. Loosen gear clamps no. 2. Remove boot no. 3. To loosen nut no. 4, use VTS socket tool (P/N 295 000 133).
Page 252: Assembly
Section 08 PROPULSION SYSTEM Sub-Section 05 (VARIABLE TRIM SYSTEM) ASSEMBLY INSTALLATION Assembly is essentially the reverse of disassem- Installation is essentially the reverse of removal bly procedures. However pay particular attention procedures. However pay particular attention to to the following. the following.
Page 253: Adjustment
Section 08 PROPULSION SYSTEM Sub-Section 05 (VARIABLE TRIM SYSTEM) ADJUSTMENT Push on VTS button up position until motor stops. When the nozzle is up (8°), nozzle edge must not interfere with venturi (there should be a gap of 1 mm (.039 in)). NOTE: Activate timer to be able to position VTS.
Page 254 Section 09 STEERING SYSTEM Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SP AND SPX MODELS......................09-02-1 REMOVAL AND INSTALLATION ..................09-02-2 STEERING ALIGNMENT ....................09-02-5 GTS MODEL........................... 09-03-1 REMOVAL AND INSTALLATION ..................09-03-2 STEERING ALIGNMENT ....................09-03-5 GS, GSI, GSX, GTI AND GTX MODELS................
Page 255: Sp And Spx Models
Section 09 STEERING SYSTEM Sub-Section 02 (SP AND SPX MODELS) SP AND SPX MODELS 1 N•m (8.5 lbf•in) 14 N•m 14 N•m 1 N•m (10 lbf•ft) (10 lbf•ft) (8.5 lbf•in) 0.5 N•m 26 N•m (4 lbf•in) (19 lbf•ft) 8 N•m (72 lbf•in)
Page 256: Removal And Installation
Section 09 STEERING SYSTEM Sub-Section 02 (SP AND SPX MODELS) REMOVAL AND INSTALLATION When installing the grip insert in the handlebar no. 12, ensure that its notch is properly inserted 1, Cover in the hole beneath the handlebar. To replace the cover, loosen set screws no. 19 of Install grip no.
Page 257 Section 09 STEERING SYSTEM Sub-Section 02 (SP AND SPX MODELS) F01K17A F01K0HA 1. Bolts REAR SUPPORT 2. Steering stem arm 1. Apply synthetic grease 2. Thrust ring shown removed for more clarity Remove support no. 11 and steering stem arm no.
Page 258 Section 09 STEERING SYSTEM Sub-Section 02 (SP AND SPX MODELS) F01K09A F01K0AA TYPICAL 1. Install handlebar assembly 2. Route throttle cable and wiring harnesses at the same time 1. Support 2. Steering stem arm Push handlebar assembly until steering stem 3.
Page 259: Steering Alignment
Section 09 STEERING SYSTEM Sub-Section 02 (SP AND SPX MODELS) Torque bolts of steering stem arm no. 10 to 6 N•m (53 lbf•in). F01K1OA SP MODEL 1. One washer each side of arm 2. Torque nut to 2 N•m (18 lbf•in) F01K1NA 1.
Page 260: Gts Model
Section 09 STEERING SYSTEM Sub-Section 03 (GTS MODEL) GTS MODEL 3.5 N•m (30 lbf•in) Loctite 26 N•m (19 lbf•ft) 14 N•m (10 lbf•ft) Anti-seize lubricant 3.5 N•m (30 lbf•in) 15 N•m (11 lbf•ft) Loctite 15 N•m (11 lbf•ft) Loctite 15 N•m (11 lbf•ft) Loctite Loctite...
Page 261: Removal And Installation
Section 09 STEERING SYSTEM Sub-Section 03 (GTS MODEL) REMOVAL AND INSTALLATION Install grip no. 4 on handlebar no. 29 matching it to the hex form on the grip insert. 1, Cover Install flat washer no. 7 and screw no. 6. To replace the cover, loosen set screws no.
Page 262 Section 09 STEERING SYSTEM Sub-Section 03 (GTS MODEL) INSTALLATION WARNING 14, Grommet The recommended torque and Loctite must Insert throttle cable through dashboard hole and be applied on screw. Steering arm mortise slide grommet on cable. must seat properly on steering stem tenon. Insert grommet in dashboard hole and pull it from inside bilge.
Page 263 Section 09 STEERING SYSTEM Sub-Section 03 (GTS MODEL) F01K10A STEERING CABLE NOT SHOWN FOR MORE CLARITY 1. Steering stem head screw 2. Locking plate 3. Steering stopper screw 4. 8 mm flat washers 5. Torque nut to 7 N•m (62 lbf•in) F02K0DE TYPICAL 1.
Page 264: Steering Alignment
Section 09 STEERING SYSTEM Sub-Section 03 (GTS MODEL) CAUTION Ensure the ball joint is parallel (± 5°) to the nozzle arm. F02K0HA 1. One washer each side of arm 2. Torque nut to 2 N•m (18 lbf•in) STEERING ALIGNMENT For steering alignment procedure, refer to STEER- ING SYSTEM 09-06.
Page 265: Gs, Gsi, Gsx, Gti And Gtx Models
Section 09 STEERING SYSTEM Sub-Section 04 (GS, GSI, GSX, GTI AND GTX MODELS) GS, GSI, GSX, GTI AND GTX MODELS 14 N•m (10 lbf•ft) 26 N•m (19 lbf•ft) Loctite 242 10 N•m (89 lbf•in) 4 N•m (35 lbf•in) 14 N•m (10 lbf•ft) Loctite 242 6 N•m...
Page 266: Disassembly
Section 09 STEERING SYSTEM Sub-Section 04 (GS, GSI, GSX, GTI AND GTX MODELS) DISASSEMBLY 8, Cable Support Loosen bolts no. 9 and remove retaining block 1,21, Grip and Grip Insert no. 10. To remove grip, pull out cap no. 2 and remove screw no.
Page 267 Section 09 STEERING SYSTEM Sub-Section 04 (GS, GSI, GSX, GTI AND GTX MODELS) F07K03A F07K05A 1. Steering support TYPICAL 2. Bolts 1. Tie rap 2. Connectors Remove support. Disconnect the steering cable from the steering 12, Steering Support stem arm no. 15. Cut tie rap securing wiring harness boot.
Page 268: Assembly
Section 09 STEERING SYSTEM Sub-Section 04 (GS, GSI, GSX, GTI AND GTX MODELS) ASSEMBLY Assembly is essentially the reverse of disassem- bly procedures. However, pay particular attention to the following. CAUTION Apply all specified torques and service prod- ucts as per main illustration at the beginning of this sub-section.
Page 269: Steering Alignment
Section 09 STEERING SYSTEM Sub-Section 04 (GS, GSI, GSX, GTI AND GTX MODELS) GSI and GSX Models 15,16, Steering Stem Arm and Support Position steering stem arm and support onto steering stem. WARNING Make sure the integrated flat keys of the steering stem arm and support are properly seated in steering stem keyways.
Page 270: Hx And Xp Models
Section 09 STEERING SYSTEM Sub-Section 05 (HX AND XP MODELS) HX AND XP MODELS 14 N•m (10 lbf•ft) 26 N•m (19 lbf•ft) 7 N•m 7 N•m (62 lbf•in) (62 lbf•in) 6 N•m (53 lbf•in) 3 N•m (27 lbf•in) 6 N•m (53 lbf•in) 6 N•m (53 lbf•in)
Page 271: Removal
Section 09 STEERING SYSTEM Sub-Section 05 (HX AND XP MODELS) REMOVAL 18,20, Steering Stem and Handlebar Remove the hood cover by loosening the 4 plastic 1, Cover Phillips screws. They may need to be replaced af- To remove the cover, loosen set screws no. 29 of ter one use.
Page 272: Disassembly
Section 09 STEERING SYSTEM Sub-Section 05 (HX AND XP MODELS) Open hood. Disconnect ball joint no. 23 of steering cable no. 9 from jet pump nozzle. Disconnect throttle cable from carburetor linkage. Remove ball joint no. 23, boots no. 24 and Pull out boot from hood and remove throttle cable no.
Page 273 Section 09 STEERING SYSTEM Sub-Section 05 (HX AND XP MODELS) 15,16, Steering Stem Arm and Support Position steering stem arm and support onto steering stem arm no. 18. WARNING Make sure integrated flat keys of steering stem arm and support are properly seated in steering stem keyways.
Page 274: Steering Alignment
Section 09 STEERING SYSTEM Sub-Section 05 (HX AND XP MODELS) STEERING ALIGNMENT For steering alignment procedure, refer to STEER- ING SYSTEM 09-06. 09-05-5 www.SeaDooManuals.net...
Page 275: Alignment
1. Steering support 2. Hole Loosen retaining block at cable support. SP, SPX, XP, HX and GTS Models Turn adjustment nut as required. Position handlebar in straight ahead position by measuring each side the distance from handlebar grip end to floorboard.
Page 276 Section 09 STEERING SYSTEM Sub-Section 06 (ALIGNMENT) All Models Except GTS GTS Model F01K18A F03K03A 1. Retaining block 1. Retaining block 2. Adjustment nut 2. Adjustment nut 3. Bolts 3. Bolts All Models After adjustment, torque retaining block bolts to 6 N•m (53 Ibf•in).
Page 277 Section 10 SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DIRECT ACTION SUSPENSION.................... 10-02-1 DISASSEMBLY........................10-02-2 INSPECTION ........................10-02-3 ASSEMBLY......................... 10-02-3 10-01-1 www.SeaDooManuals.net...
Page 278: Direct Action Suspension
Section 10 SUSPENSION Sub-Section 02 (DIRECT ACTION SUSPENSION) DIRECT ACTION SUSPENSION XP and HX Models Loctite 34 N•m (25 lbf•ft) Loctite 5 N•m (44 lbf•in) 10 N•m (88 lbf•in) 5 N•m (44 lbf•in) 34 N•m (25 lbf•ft) Loctite 5 N•m (44 lbf•in) 10 N•m (88 lbf•in)
Page 279: Disassembly
Section 10 SUSPENSION Sub-Section 02 (DIRECT ACTION SUSPENSION) DISASSEMBLY 1, Shock Absorber Remove bottom cover of seat with grab handle (HX model). F05L0JA 1. Collar Remove bolt no. 6 and lock nut no. 7 from shock absorber lower support no. 8. F05L0HA TYPICAL —...
Page 280: Inspection
Section 10 SUSPENSION Sub-Section 02 (DIRECT ACTION SUSPENSION) F05L0LA 1. Collar F05L0NA Remove bolt no. 10 and lock nut no. 11 from shock absorber upper support. Compress spring and remove cup. Unload tool and remove spring from shock ab- sorber. INSPECTION 3,5, Boot Inspect condition of boots.
Page 281 Section 11 HULL/BODY Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ADJUSTMENT AND REPAIR ....................11-02-1 SEAT ADJUSTMENT......................11-02-15 STORAGE COMPARTMENT COVER ADJUSTMENT ............11-02-17 ACCESS PANEL ADJUSTMENT ..................11-02-17 INLET GRATE REMOVAL....................11-02-18 RIDING PLATE........................11-02-18 JET PUMP SUPPORT ......................11-02-19 DEFLECTOR ........................
Page 282: Adjustment And Repair
Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR SP and SPX Models Loctite Loctite Loctite 5 N•m (44 lbf•in) 5 N•m (44 lbf•in) Loctite 8 N•m Sealant (71 lbf•in) 5 N•m (44 lbf•in) Sealant Loctite Loctite 271 Sealant 732 15 N•m...
Page 283 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) Loctite 6 N•m (53 lbf•in) 15 N•m (11 lbf•ft) Sealant Loctite Loctite Sealant Sealant 732 1.5 N•m (13 lbf•in) F01L6IS PARTS FLAT RATE 11-02-2 www.SeaDooManuals.net...
Page 284 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) GTS Model Loctite Loctite 271 Loctite 5 N•m 8 N•m (44 lbf•in) (71 lbf•in) Loctite 5 N•m (44 lbf•in) Loctite Sealant 9 10 5 N•m (44 lbf•in) Sealant 15 N•m (11 lbf•ft) Loctite F02L26S PARTS...
Page 285 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) 7 N•m (62 lbf•in) Loctite 242 15 N•m (11 lbf•ft) Loctite Sealant 732 1.5 N•m (13 lbf•in) Sealant F02L27S PARTS FLAT RATE 11-02-4 www.SeaDooManuals.net...
Page 286 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) GS, GSI and GSX Models 5 N•m (44 lbf•in) Loctite 5 N•m (44 lbf•in) Loctite 5 N•m (44 lbf•in) Loctite 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) 5 N•m Loctite (44 lbf•in) Loctite 5 N•m (44 lbf•in)
Page 287 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) Loctite Loctite 8 N•m (71 lbf•in) 15 N•m (11 lbf•ft) Sealant Loctite Sealant 2.5 N•m (22 lbf•in) Sealant F06L02S PARTS FLAT RATE 11-02-6 www.SeaDooManuals.net...
Page 288 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) GTI and GTX Models Loctite Loctite 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) Loctite 8 N•m (71 lbf•in) Loctite Loctite 5 N•m (44 lbf•in) 8 N•m (71 lbf•in) Loctite Loctite Sealant 5 N•m (44 lbf•in) Body...
Page 289 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) Loctite Loctite 8 N•m (71 lbf•in) 15 N•m (11 lbf•ft) Loctite Loctite 8 N•m Sealant (71 lbf•in) Sealant 1.5 N•m (13 lbf•ft) Sealant F07L04S PARTS FLAT RATE 11-02-8 www.SeaDooManuals.net...
Page 290 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) 8 N•m (71 lbf•in) 1.4 N•m (12 lbf•in) 0.8 N•m (7 lbf•in) Loctite Loctite 5 N•m (44 lbf•in) 5 N•m (44 lbf•in) 8 N•m (71 lbf•in) Loctite 3 N•m (26 lbf•in) Loctite 242 5 N•m (44 lbf•in) F07L05S...
Page 291 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) Loctite 242 4 N•m (35 lbf•in) 5 N•m (44 lbf•in) Loctite 242 Loctite 242 4 N•m (35 lbf•in) Loctite 242 5 N•m (44 lbf•in) Loctite 242 5 N•m (44 lbf•in) F07L06S PARTS FLAT RATE 11-02-10 www.SeaDooManuals.net...
Page 292 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) HX Model Loctite Body Body 5 N•m (44 lbf•in) 5 N•m (44 lbf•in) Loctite Body 15 N•m (11 lbf•ft) 2.5 N•m (22 lbf•in) Sealant F05L0PS PARTS FLAT RATE 11-02-11 www.SeaDooManuals.net...
Page 293 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) Body 4 N•m Loctite (35 lbf•in) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 4 N•m 8 N•m (35 lbf•in) (71 lbf•in) Loctite Loctite 8 N•m Body (71 lbf•in) F05L0QS PARTS FLAT RATE 11-02-12 www.SeaDooManuals.net...
Page 294 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 1.2 N•m (11 lbf•in) 5 N•m Loctite (44 lbf•in) 4 N•m (35 lbf•in) 5 N•m 4 N•m (44 lbf•in) (35 lbf•in) Body 13 N•m (10 lbf•in) F05L0RS PARTS...
Page 295 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) Loctite 6 N•m (53 lbf•in) 6 N•m (53 lbf•in) 22 N•m (16 lbf•ft) F05L0SS PARTS FLAT RATE 11-02-14 www.SeaDooManuals.net...
Page 296: Seat Adjustment
A. 22.5 (+1, –0) mm (51/64 (+1/32, –0) in) F02L24A Adjust lock pin no. 2 as per following specifica- tions: SP, SPX, GTI AND GTX MODELS 1. Seat retainer 2. Adjustment nut (Loctite 271) 3. Nut (Loctite 242). Torque to 8 N•m (71 lbf•in) A.
Page 297 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) F06L03A F07L08A GS, GSI AND GSX MODELS GTI AND GTX MODELS — FRONT SEAT 1. Lock pin 1. Lock pin 2. Adjustment nut (apply Loctite 271) 2. Adjustment nut (Loctite 271) A. 33.5 ± 1 mm (1-5/16 ± 3/64 in) A.
Page 298: Storage Compartment Cover Adjustment
It is normal to have a front and aft F02L25C play of the lock pin. To adjust, tighten lock pin until SP, SPX AND GTS MODELS any vertical play is eliminated. Make sure a front 1. Lock pin and aft play remains when pressing by hands.
Page 299: Inlet Grate Removal
NOTE: An impact screwdriver should be used to loosen tight screws. Using a low height hydraulic bottle jack and 2 steel plates, pry out riding plate. F01J1VA SP, SPX AND GTS MODELS 1. Apply Loctite 598 Ultra Black as indicated by the shaded area 11-02-18 www.SeaDooManuals.net...
Page 300: Jet Pump Support
Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) F05K02A TYPICAL F07L0DA 1. Unscrew nut GS, GSI, GSX, GTI AND GTX MODELS Remove ball joint, boot, nut, half rings and O-rings from reverse cable (GTI and GTX models). Remove boot and nut from VTS sliding shaft (XP, GSI and GSX models).
Page 301 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) NOTE: Shims may have been installed between support and body. Do not remove these shims, otherwise jet pump alignment will be altered. Installation Apply Loctite 598 Ultra Black as indicated by the shaded areas in the next illustrations.
Page 302: Deflector
Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) DEFLECTOR SEAT REMOVAL GS, GSI, GSX, GTI and GTX Models HX Model Only Remove seat bottom cover no. 17 and grab han- Removal dle no. 18. Using a heat gun, heat deflector and pry it using a piece of wood.
Page 303: Seat Cover Replacement
Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) Loosen upper collar of coil over shock inner boot; Seat installation is essentially the reverse of re- then, pull boot downward. moval procedure. Refer to the main illustration of seat at the beginning of this sub-section for prop- er torque specifications and service products to be used.
Page 304: Bumper Replacement
1. Remove trim no. 5 from side bumper rail Remove seat (access cover for the XP model). no. 4. Remove air vent tube support (SP, SPX, GS, GSI 2. Drill pop rivets no. 12 to remove side bumper and GSX models).
Page 305: Baffle Sealing (Gts Model)
Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) BAFFLE SEALING (GTS MODEL) Installation There are 2 types of decals used on watercraft. Apply Sikaflex primer 449 (P/N 293 530 012) on One has a protective film on back side and the rear baffle no.
Page 306: Hull And Body Repair
Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) INSTALLATION ON PLASTIC (STORAGE NOTE: Fiberglass repair kit is available through COVER) automotive or marine suppliers. Gelcoat repair kits are available through regular channel. Clean surface with isopropyl alcohol. Using a pencil and the decal as a template, mark WARNING the area where decal will be located.
Page 307 Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) SANDING Numerous Fractures Begin block sanding the patch with 320-grit sand- Using a grinder with a 24-grit disk, remove the paper until you come close to the original surface. gelcoat. Sand the area edge with 220-grit sandpa- Remove dust with a water soaked cloth and con- per.
Page 308: Tools And Materials List
Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) Compound Fractures Using a clean paintbrush, brush the mixed resin on the surface. Place the smallest piece of mat Possible Causes: over the fracture and then wet out the mat. Fol- – Thickness of fiberglass laminate. low with the remaining pieces of mat and final lay- er of cloth.
Page 309: Hull Insert Repair
Section 11 HULL/BODY Sub-Section 02 (ADJUSTMENT AND REPAIR) – heavy-duty polisher Mix epoxy glue (3M-05900), follow manufacturer instructions. – power sander Apply epoxy glue on aluminum insert (P/N 292 – paint brush 000 075) knurled surface and on plastic insert in- –...
Page 310 Section 12 TECHNICAL DATA Sub-Section 01 (SP AND SPX MODELS) SP AND SPX MODELS ENGINE SP (5879) SPX (5834/5661) Engine type Bombardier-Rotax 717D Bombardier-Rotax 787 Induction type Rotary valve Exhaust system Type Water cooled, water injected Water cooled, water injected...
Page 311 Section 12 TECHNICAL DATA Sub-Section 01 (SP AND SPX MODELS) ELECTRICAL SP (5879) SPX (5834/5661) Magneto generator output 160 W @ 6000 RPM 180 W @ 6000 RPM or 4.0 A @ 2000 RPM or 5.0 A @ 6000 RPM...
Page 312 Section 12 TECHNICAL DATA Sub-Section 01 (SP AND SPX MODELS) PROPULSION SP (5879) SPX (5834/5661) 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...
Page 313 Section 12 TECHNICAL DATA Sub-Section 01 (SP AND SPX MODELS) MATERIALS SP (5879) SPX (5834/5661) Hull Composite Inlet grate Plastic Impeller housing/stator/venturi/nozzle Plastic/plastic/ Plastic/brass/plastic/ plastic/plastic aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding...
Page 314 Section 12 TECHNICAL DATA Sub-Section 01 (SP AND SPX MODELS) TIGHTENING TORQUES SP (5879) SPX (5834/5661) Exhaust manifold screw 24 N•m (17 lbf•ft) (4) 40 N•m (30lbf•ft) (3) (4) Magneto flywheel nut 145 N•m (107 lbf•ft) (1) 105 N•m (77 lbf•ft) (81 lbf•ft)
Page 315 Section 12 TECHNICAL DATA Sub-Section 02 (GS AND GSI MODELS) GS AND GSI MODELS ENGINE GS (5621) GSI (5622) Engine type Bombardier-Rotax 717 Induction type Rotary valve Exhaust system Type Water cooled, water injected Water injection fitting 3.5 mm (.139 in) (head) Water injection fitting 3.5 mm (.139 in)
Page 316 Section 12 TECHNICAL DATA Sub-Section 02 (GS AND GSI MODELS) ELECTRICAL GS (5621) GSI (5622) Magneto generator output 160 W @ 6000 RPM or 4.0 A @ 2000 RPM Ignition system type Digital CDI Spark plug Make and type NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) Ignition timing mm (in)
Page 317 Section 12 TECHNICAL DATA Sub-Section 02 (GS AND GSI MODELS) PROPULSION GS (5621) GSI (5622) 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 Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5...
Page 318 Section 12 TECHNICAL DATA Sub-Section 02 (GS AND GSI MODELS) MATERIALS GS (5621) GSI (5622) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/plastic Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding Thermoplastic with Polyethylene foam Fuel tank Polyethylene Oil injection reservoir...
Page 319 Section 12 TECHNICAL DATA Sub-Section 02 (GS AND GSI MODELS) TIGHTENING TORQUES GS (5621) GSI (5622) Exhaust manifold screw 24 N•m (17 lbf•ft) Magneto flywheel nut 145 N•m (107 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) Crankcase screws 24 N•m (17 lbf•ft) (3) (4) 40 N•m...
Page 320 Section 12 TECHNICAL DATA Sub-Section 03 (GSX MODEL) GSX MODEL ENGINE GSX (5624) Engine type Bombardier-Rotax 787 Induction type Rotary valve Exhaust system Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Water injection fitting (cone) Not applicable Water injection fitting 3.5 mm (.139 in)
Page 321 Section 12 TECHNICAL DATA Sub-Section 03 (GSX MODEL) ELECTRICAL GSX (5624) Magneto generator output 180 W @ 6000 RPM or 5.0 A @ 6000 RPM Ignition system type Digital DC-CDI Spark plug Make and type NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) Ignition timing mm (in) 3.38 (.133)
Page 322 Section 12 TECHNICAL DATA Sub-Section 03 (GSX MODEL) PROPULSION GSX (5624) 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 Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 26°...
Page 323 Section 12 TECHNICAL DATA Sub-Section 03 (GSX MODEL) MATERIALS GSX (5624) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/brass/plastic/aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding Thermoplastic with polyethylene foam Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat...
Page 324 Section 12 TECHNICAL DATA Sub-Section 03 (GSX MODEL) TIGHTENING TORQUES GSX (5624) 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) Crankcase screws 24 N•m (17 lbf•ft) (3) (4) 40 N•m (30 lbf•ft)
Page 325 Section 12 TECHNICAL DATA Sub-Section 04 (GTS MODEL) GTS MODEL ENGINE GTS (5818) Engine type Bombardier-Rotax 717 Induction type Rotary valve Exhaust system Type Water cooled, water injected Water injection fitting (head) 3.5 mm (.139 in) Water injection fitting (cone) 3.5 mm (.139 in) Starting system Electric start...
Page 326 Section 12 TECHNICAL DATA Sub-Section 04 (GTS MODEL) ELECTRICAL GTS (5818) Magneto generator output 160 W @ 6000 RPM or 4.0 A @ 2000 RPM Ignition system type Digital CDI Spark plug Make and type NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) Ignition timing mm (in) 2.59 (.102)
Page 327 Section 12 TECHNICAL DATA Sub-Section 04 (GTS MODEL) PROPULSION GTS (5818) 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 Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 26°...
Page 328 Section 12 TECHNICAL DATA Sub-Section 04 (GTS MODEL) MATERIALS GTS (5818) Hull Composite Inlet grate Plastic Impeller housing/stator/venturi/nozzle Plastic/brass/plastic/plastic Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding Thermoplastic elastomer with polystyrene foam Fuel tank Polyethylene Oil injection reservoir Polyethylene...
Page 329 Section 12 TECHNICAL DATA Sub-Section 04 (GTS MODEL) TIGHTENING TORQUES GTS (5818) Exhaust manifold screws 24 N•m (17 lbf•ft) Magneto flywheel nut 145 N•m (107 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) Crankcase screws 24 N•m (17 lbf•ft) (3) (4) 40 N•m (30 lbf•ft) (3) (4)
Page 330 Section 12 TECHNICAL DATA Sub-Section 05 (GTI AND GTX MODELS) GTI AND GTX MODELS ENGINE GTI (5641) GTX (5642) Engine type Bombardier-Rotax 717 Bombardier-Rotax 787 Induction type Rotary valve Exhaust system Type Water cooled, water injected Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in)
Page 331 Section 12 TECHNICAL DATA Sub-Section 05 (GTI AND GTX MODELS) ELECTRICAL GTI (5641) GTX (5642) Magneto generator output 160 W @ 6000 RPM 180 W @ 6000 RPM or 4.0 A @ 2000 RPM or 5.0 A @ 6000 RPM Ignition system type Digital CDI Digital DC-CDI...
Page 332 Section 12 TECHNICAL DATA Sub-Section 05 (GTI AND GTX MODELS) PROPULSION GTI (5641) GTX (5642) 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 Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5...
Page 333 Section 12 TECHNICAL DATA Sub-Section 05 (GTI AND GTX MODELS) MATERIALS GTI (5641) GTX (5642) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/brass/plastic/ plastic Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding Thermoplastic with polyethylene foam Fuel tank Polyethylene Oil injection reservoir...
Page 334 Section 12 TECHNICAL DATA Sub-Section 05 (GTI AND GTX MODELS) TIGHTENING TORQUES GTI (5641) GTX (5642) Exhaust manifold screw 24 N•m (17 lbf•ft) (4) 40 N•m (30 lbf•ft) (3) (4) Magneto flywheel nut 145 N•m (107 lbf•ft) (1) 105 N•m (77 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft)
Page 335 Section 12 TECHNICAL DATA Sub-Section 06 (HX AND XP MODELS) HX AND XP MODELS ENGINE HX (5882) XP (5662) Engine type Bombardier-Rotax 717 Bombardier-Rotax 787 Induction type Rotary valve Exhaust system Type Water cooled, water injected Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in)
Page 336 Section 12 TECHNICAL DATA Sub-Section 06 (HX AND XP MODELS) ELECTRICAL HX (5882) XP (5662) Magneto generator output 160 W @ 6000 RPM 180 W @ 6000 RPM or 4.0 A @ 2000 RPM or 5.0 A @ 6000 RPM Ignition system type Digital CDI Digital DC-CDI...
Page 337 Section 12 TECHNICAL DATA Sub-Section 06 (HX AND XP MODELS) PROPULSION HX (5882) XP (5662) 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 Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5...
Page 338 Section 12 TECHNICAL DATA Sub-Section 06 (HX AND XP MODELS) MATERIALS HX (5882) XP (5662) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/brass/plastic/ plastic Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding Thermoplastic elastomer Thermoplastic with with polystyrene foam polyethylene foam...
Page 339 Section 12 TECHNICAL DATA Sub-Section 06 (HX AND XP MODELS) TIGHTENING TORQUES HX (5882) XP (5662) Exhaust manifold screw 24 N•m (17 lbf•ft) (4) 40 N•m (30 lbf•ft) (3) (4) Magneto flywheel nut 145 N•m (107 lbf•ft) (1) 105 N•m (77 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft)
Page 340: Wire Color Codes
Section 13 WIRING DIAGRAMS Sub-Section 01 (WIRING DIAGRAMS) WIRING DIAGRAMS WIRE COLOR CODES AMP CONNECTOR First color of a wire is the main color. Second color GS, GSI, GSX, GTI and XP Models is the tracer. These connectors are found on the MPEM of the Example: YELLOW/BLACK is a YELLOW wire aforementioned watercraft.
Page 341 Section 13 WIRING DIAGRAMS Sub-Section 01 (WIRING DIAGRAMS) Contact Removal Insert a screwdriver blade between the housing and wedge lock on the lock tab side. Pry the wedge lock to unlock the tab (open posi- tion). F00H0QA 1. Rotate wire back and forth 2.
Page 342 Section 13 WIRING DIAGRAMS Sub-Section 01 (WIRING DIAGRAMS) Release the locking tabs by squeezing them in- ward. F00H0RA 1. Squeeze locking tab (both sides) Slide the wedge lock until it is flush with the hous- ing. 13-01-3 www.SeaDooManuals.net...
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This manual is also suitable for:

Spx Gts Gs Gti Gtx Xp ... Show all

Sea-doo SP Shop Manual

Table of Contents

Section

Table of Contents

Table of Contents

Periodic Inspection Chart

Flushing and Lubrication

04

05

06

07

Table of Contents

Leak Test

Magneto System

01

02

03

Table of Contents

Air Intake

Carburetors

Table of Contents

Oil Injection Pump

Table of Contents

Charging System

Starting System

Instruments and Accessories

Digitally Encoded Security System

Table of Contents

Drive System

Reverse System

Variable Trim System

Manual Trim

Electric Trim

Table of Contents

Gts Model

Gs, Gsi, Gsx, Gti and Gtx Models

Hx and Xp Models

Table of Contents

Adjustment and Repair/Adjustment and Repair

08

09

10

11

12

Alignment

Quick Links

Chapters

Troubleshooting

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Questions and answers

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Summary of Contents for Sea-doo SP