Sea-doo GSX Limited Shop Manual
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Sea-doo GSX Limited Shop Manual

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  • Page 1 GSX Limited www.SeaDooManuals.net...
  • Page 2 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. 1997 Printed in Canada ® *Registered trademarks of Bombardier Inc.

  • Page 3: Table Of Contents

    ELECTRICAL SYSTEM 01 - Ignition and Charging Systems........... 04-01-1 02 - Starter................. 04-02-1 PROPULSION SYSTEM 01 - Drive System and Jet Pump..........05-01-1 TECHNICAL DATA 01 - GSX Limited ............... 06-01-1 WIRING DIAGRAM ........................07-01-1 VOLUME 1 1997 VOLUME 2 www.SeaDooManuals.net...

  • Page 4: 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 5: Engine

    Section 01 ENGINE Subsection 01 (MAGNETO SYSTEM) MAGNETO SYSTEM 947 Engine 9 N•m (80 lbf•in) Loctite 242 Anti-seize lubricant 13 N•m (115 lbf•in) Loctite 242 9 N•m (80 lbf•in) Loctite 242 Loctite 648 115 N•m (85 lbf•ft) 13 N•m (115 lbf•in) Loctite F06D0IS PARTS...
  • Page 6 Section 01 ENGINE Subsection 01 (MAGNETO SYSTEM) DISASSEMBLY 1, Cover Loosen screws no. 2. Remove engine magneto cover. F06D0KA 1. Remove pulse fitting Turn engine manually until slot in crankshaft coun- terweight is aligned with the crankcase hole. In- sert a M8 x 50 fixation screw to lock crankshaft. F06D1RA 1.
  • Page 7 Section 01 ENGINE Subsection 01 (MAGNETO SYSTEM) If necessary, the magneto rotor can be removed without the engine flywheel. Remove the 6 screws no. 7. F06D0PA F06D0LA 1. Puller 1. Screw 8,9, Stator and Trigger Coil To remove the flywheel/rotor assembly, unscrew Loosen screws no.
  • Page 8 Section 01 ENGINE Subsection 01 (MAGNETO SYSTEM) ASSEMBLY Apply Loctite 648 (green) on screws no. 7 retain- ing rotor to flywheel and torque screws in a criss- cross sequence to 13 N•m (115 lbf•in). 8,9, Stator and Trigger Coil Apply Loctite 242 (blue) on crankshaft taper. Install the stator and trigger coil in engine magne- to cover.

  • Page 9: Top End

    Section 01 ENGINE Subsection 02 (TOP END) TOP END 947 Engine 34 N•m Loctite (25 lbf•ft) Synthetic grease 34 N•m (25 lbf•ft) Synthetic grease Loctite 22 23 24 3 N•m (26 lbf•in) Loctite 9 N•m (80 lbf•in) rollers Synthetic grease F06D17S PARTS FLAT RATE...

  • Page 10: Theory Of Operation

    Section 01 ENGINE Subsection 02 (TOP END) THEORY OF OPERATION RAVE Valve System On this engine, the RAVE valves are controlled by the Multi-Purpose Electronic Module (MPEM). The MPEM measures 2 factors to control the RAVE valves: engine speed (RPM) and its rate of acceler- ation.
  • Page 11 Section 01 ENGINE Subsection 02 (TOP END) To close the RAVE valves, the MPEM deactivates the solenoid which blocks the crankcase positive pres- sure. The RAVE valves are opened to the atmosphere. F06D16T RAVE VALVE CLOSED 1. Pulse from crankcase 2.
  • Page 12 Section 01 ENGINE Subsection 02 (TOP END) DISASSEMBLY Remove the compression spring no. 15. 11, RAVE Valve Loosen Allen screws no. 12 each side of RAVE valve. F06D25A 1. Remove spring Remove spring no. 16 retaining bellows no. 17 to valve piston no.
  • Page 13 Section 01 ENGINE Subsection 02 (TOP END) Remove bellows from valve piston. Remove compression spring no. 22. F06D0TA A06D26A 1. Bellows removed from piston 1. Remove spring Unscrew valve piston no. 18 from sliding valve no. 19. Remove supporting ring no. 23. NOTE: Hold the sliding valve to prevent it from turning.
  • Page 14 Section 01 ENGINE Subsection 02 (TOP END) Remove O-ring no. 24. Remove bellows no. 17. F06D28A F06D0VA 1. Remove O-ring 1. Remove bellows Remove sliding valve no. 19. 1,2, Cylinder Head and Cylinder Block Loosen cylinder head bolts no. 3 following the se- quence shown in the next photo.
  • Page 15 Section 01 ENGINE Subsection 02 (TOP END) Loosen nuts no. 4 following the sequence shown in the next photo. F06D2BA 1. Remove studs Remove cylinder block no. 2. F06D29A UNTORQUING SEQUENCE FOR THE NUTS Remove cylinder head no. 1. Remove cylinder head gasket no. 5. F06D0ZA 1.
  • Page 16 Section 01 ENGINE Subsection 02 (TOP END) 11, RAVE Valve Install the supporting ring no. 23 with the bevel side facing the O-ring no. 24. F06D10A 1. Piston notch F06D11A To extract piston pin no. 9, use puller. Refer to the 1.
  • Page 17 Section 01 ENGINE Subsection 02 (TOP END) To easily insert circlip no. 8, use circlip installer (P/N 290 877 517). A01C01A TYPICAL — PISTON DOME SHOWN 1. Exhaust side 9,10, Piston Pin and Roller Bearing F06B01A To install roller bearing and piston pin, use piston 1.
  • Page 18 Section 01 ENGINE Subsection 02 (TOP END) Torque bolts and nuts to 15 N•m (11 lbf•ft) as per fol- lowing sequence in the next photo. Repeat the torqu- ing sequence by retightening to 34 N•m (25 lbf•ft). F06D0WB TORQUING SEQUENCE 01-02-10 www.SeaDooManuals.net...

  • Page 19: Bottom End

    Section 01 ENGINE Subsection 03 (BOTTOM END) BOTTOM END 947 Engine 30 mL (1 oz) Formula XP-S synthetic Synthetic Synthetic grease grease Loctite Loctite 242 Loctite Loctite Anti-seize lubricant Synthetic 9 N•m grease (80 lbf•in) 9 N•m Loctite Anti-seize (80 lbf•in) lubricant Loctite Loctite...
  • Page 20 Section 01 ENGINE Subsection 03 (BOTTOM END) DISASSEMBLY Loosen bolt no. 5 retaining the PTO flywheel to the crankshaft. The following components should be removed prior to opening bottom end: – magneto cover – magneto flywheel – starter 1, Seal If a crankshaft end seal has to be replaced, bot- tom end must be opened.
  • Page 21 Section 01 ENGINE Subsection 03 (BOTTOM END) 6, Starter Drive Assembly 10, Reed Valve Loosen 2 Allen screws no. 7 retaining starter Remove both carburetor flanges. drive cover no. 8. F06D0JA 1. Carburetor flange Remove reed valves from crankcase. F06D1CA 1.
  • Page 22 Section 01 ENGINE Subsection 03 (BOTTOM END) F06B03A 1. Puller (P/N 420 877 635) 2. Protective cap (P/N 290 877 414) 3. Distance ring (P/N 290 876 569) 4. Ring (P/N 290 977 480) 5. Ring halves (P/N 290 876 330) 6.
  • Page 23 Section 01 ENGINE Subsection 03 (BOTTOM END) 10, Reed Valve Check reed valve petals no. 24 for cracks or other defects. The reed petals must lie completely flat against the reed valve body no. 25. To check, hold against light. F06D1HA 1.
  • Page 24 Section 01 ENGINE Subsection 03 (BOTTOM END) Bent stopper as required to obtain the proper dis- tance. 14, Crankshaft Refer to the 1997 Sea-Doo Shop Manual for com- plete procedure of crankshaft inspection. ASSEMBLY 15, Bearing Apply Loctite 767 anti-seize on part of crankshaft where bearings fit.
  • Page 25 Section 01 ENGINE Subsection 03 (BOTTOM END) Install the counterbalance shaft in crankcase low- er half. Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears. F06D1OA 1. Seal in place 11, Crankcase F06D1MA Crankcase halves are factory matched and there- fore, are not interchangeable or available as single 1.
  • Page 26 Section 01 ENGINE Subsection 03 (BOTTOM END) Apply synthetic grease below head of bolts 23, Bearing no. 12 and no. 13. To install bearing no. 23 of starter drive assembly, Apply also Loctite 518 on threads of bolts no. 12 use pusher (P/N 290 876 502) and handle (P/N 290 and no.

  • Page 27: Exhaust System

    Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) EXHAUST SYSTEM GENERAL To enhance performance and reduce noise level, the GSX Limited is equipped with a new plastic made resonator. F06E08A 1. Water inlet hose Disconnect at the tuned pipe head the water sup- ply hose of the water flow regulator valve.
  • Page 28 Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Disconnect the water injection hose at tuned pipe Loosen clamp retaining exhaust hose to tuned head. pipe cone. F06E0AA F06D14A 1. Water injection hose 1. Loosen clamp Disconnect the water bleed hose. Loosen and remove clamp retaining tuned pipe head to tuned pipe cone.

  • Page 29: Exhaust Manifold

    Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Loosen Allen screw of carburetor bracket. Loosen bolt of tuned pipe head above the engine magneto. F06D2DA F06D1UA 1. Loosen Allen screw 1. Remove bolt Loosen Allen screws and nut at tuned pipe flange. Remove tuned pipe head.
  • Page 30 Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Muffler INSTALLATION Disconnect front exhaust hose (if tuned pipe is Installation is essentially the reverse of removal not removed). procedures. However, pay particular attention to Disconnect top exhaust hose from muffler. the following. Disconnect hoses of the water flow regulator Exhaust Manifold valve (if tuned pipe is not removed).
  • Page 31 Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Tuned Pipe Torque bolt of tuned pipe head above the engine magneto to 25 N•m (18 lbf•ft). Make sure to install the sealing ring on tuned pipe cone if it was removed. Apply a thin layer of heat resistant sealant (P/N 413 709 200) all around sealing ring.
  • Page 32 Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Torque clamp of tuned pipe head to 14 N•m Torque exhaust hose clamp of tuned pipe cone to (10 lbf•ft). 4 N•m (35 lbf•in). F06D1SA F06D14A 1. Torque clamp to 14 N•m (10 lbf•ft) 1.

  • Page 33: Cooling System

    Section 02 COOLING SYSTEM Subsection 01 (CIRCUIT) CIRCUIT 947 Engine Cooling System After water has circulated in the cylinder-block water jackets, it is directed in the 1 piece cylinder As with other models, the water supply is provid- head which features improved combustion cham- ed by a pressurized area in the jet pump between ber and spark plug cooling.

  • Page 34: Water Flow Regulator Valve

    Section 02 COOLING SYSTEM Subsection 01 (CIRCUIT) Bleeding of the cooling system is accomplished Water Flow Regulator Valve by the bleed hose located at the uppermost point The water supply of the water flow regulator is of the circuit at the tuned pipe. The bleed hose provided by the water jacket of the tuned pipe also serves as the Cooling System Indicator (CSI).
  • Page 35 Section 02 COOLING SYSTEM Subsection 01 (CIRCUIT) Regulated water is injected in the tuned pipe by a calibrated fitting. F06E0AA 1. Injection fitting 02-01-3 www.SeaDooManuals.net...

  • Page 36: Fuel System

    Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) CARBURETION AIR INTAKE SILENCER The air intake silencer is a molded piece and it can not be opened. It contains a new flame arrester, which can not be removed. F06F06A 1. Fuel inlet hose 2.
  • Page 37 Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) Verify accelerator pump check valves operation as NOTE: Injectors are also equipped with check follows: valves. Connect a clean plastic tubing to the valve inlet Adjustment nipple and alternately apply pressure and vacuum. The check valve should release with pressure and Ensure throttle cable is properly adjusted and idle hold under vacuum.
  • Page 38 Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) F06F06B TYPICAL F06F09A 1. Apply synthetic grease to plunger 2. Apply BOMBARDIER LUBE on roller shaft 1. Throttle position switch BN-46I CARBURETORS The amplifier boost the signal received from the throttle position switch and activates the sole- On these carburetors, diaphragms are either noid.
  • Page 39 Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) The solenoid is responsible for changing the vent- ing position of the carburetors. The solenoid is lo- cated on the body, on left side. F06F0BB SOLENOID ACTIVATED 1. Inlet (carburetor diaphragms) 2. Outlet to atmosphere blocked F06F0BA 3.
  • Page 40 Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) Disconnect the wiring harness of the solenoid. Connect a 12 V battery to solenoid terminals. Using a voltmeter, connect the positive probe to Apply pressure to the inlet nipple. Air should be the PURPLE/BLUE wire and the negative probe to released to the outlet nipple leading to the air in- the BLACK/BLUE wire.

  • Page 41: Electrical System

    Section 04 ELECTRICAL SYSTEM Subsection 01 (IGNITION AND CHARGING SYSTEMS) IGNITION AND CHARGING SYSTEMS The ignition and charging systems of the 947 en- The MPEM is directly powered by the battery. It gine are of the same type as the 787 engine. has a micro-processor inside of its sealed case.

  • Page 42: Starter

    Section 04 ELECTRICAL SYSTEM Subsection 02 (STARTER) STARTER GENERAL DISASSEMBLY The 947 engine is equipped with a MITSUBA 12 V Locate index marks on yoke and end covers. starter. The starter is coupled to the drive assembly, which contains the overrunning clutch and gear reduction.
  • Page 43 Section 04 ELECTRICAL SYSTEM Subsection 02 (STARTER) Remove thrust washer from armature shaft. Release brush wires of yoke from brush holder. Remove brush holder. F06H1HA 1. Thrust washer F06H1KA Remove the other end cover and gasket. 1. Remove brush holder Remove the 3 washers from armature shaft.
  • Page 44 Section 04 ELECTRICAL SYSTEM Subsection 02 (STARTER) To remove bearing and seal in end cover, release Install the 3 washers onto armature shaft, with tabs of retainer. the thicker one in the middle. F06H1MA 1. Retainer F06H1NA INSPECTION 1. Thick washer in the middle When installing end covers to yoke, align index For parts inspection, refer to the 1997 Sea-Doo marks.

  • Page 45: Starter Specification

    Section 04 ELECTRICAL SYSTEM Subsection 02 (STARTER) STARTER SPECIFICATION Nominal output 0.8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise (viewed from pinion side) Weight 1.7 kg (3.7 lb) Performance specification at 20°C (68°F) No load 10.9 V 45 A max.

  • Page 46: Propulsion System

    Subsection 01 (DRIVE SYSTEM AND JET PUMP) DRIVE SYSTEM AND JET PUMP DRIVE SYSTEM JET PUMP For performance improvement, the GSX Limited Seal Carrier and Bearing features a new jet pump with an impeller diame- The drive system is equipped with a seal carrier ter of 155.6 mm (6-1/8 in).

  • Page 47: Technical Data

    Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) GSX LIMITED ENGINE GSX Limited (5625) Engine type Bombardier-Rotax 947 Induction type Reed valve Exhaust system Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Water injection fitting (cone) N.A.
  • Page 48 Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) ELECTRICAL GSX Limited (5625) 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)
  • Page 49 Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) COOLING GSX Limited (5625) Type Open circuit — Direct flow from jet propulsion unit Thermostat None Monitoring beeper setting 86-94°C (187-201°F) ADDITIONAL INFORMATION: Do not mix different brands or oil types. PROPULSION...
  • Page 50 Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) CAPACITIES GSX Limited (5625) Fuel tank 56.5 L (15 U.S. gal) Oil injection reservoir 6 L (1.6 U.S. gal) Impeller shaft reservoir Capacity 70 mL (2.4 U.S. oz) Oil level height Up to plug...
  • Page 51 Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) PERFORMANCE GSX Limited (5625) Estimated pump power 40.5 kW (54 hp) Maximum fuel consumption at wide open throttle 55 L/h (14.5 U.S. gal/h) Cruising time at full throttle Fuel tank without reserve...
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