Page 1 www.SeaDooManuals.net...
Page 2 ® SHOP MANUAL 219 100 031 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 writ- permission of Bombardier Inc. cBombardier Inc. 1995 Printed in Canada r*Registered trademarks of Bombardier Inc. Loctiter is a trademark of Loctite Corporation Snap-onr is a trademark of Snap-on Tools Corpo- ration...
Page 4: Table Of Contents
TABLE OF CONTENTS SECTION SUBJECT PAGE SAFETY NOTICE ......................INTRODUCTION ....................... SERVICE TOOLS 01 - Mandatory Tools ....................01-01-1 02 - Recommended Tools ..................01-02-1 AND PRODUCTS 03 - Service Products....................01-03-1 MAINTENANCE 00 - Table of Contents .....................02-00-1 01 - Periodic Inspection Chart .................02-01-1 02 - Flushing and Lubrication ..................02-02-1 03 - Water-Flooded Engine ..................02-03-1 04 - Storage ......................02-04-1...
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: Introduction
1996 BOMBARDIER WATERCRAFT SHOP MANUAL INTRODUCTION ENGINE IDENTIFICATION NUMBER (E.I.N.) This Shop Manual covers BOMBARDIER made SEA-DOO® watercraft models SPþ5876, SPX All Engines Except the 787 5877, SPI 5878, XPþ5858, HX 5881, GTSþ5817 The Engine Identification Number is located on and GTIþ5865þ/þ5866.
Page 7 1996 BOMBARDIER WATERCRAFT SHOP MANUAL ARRANGEMENT OF THIS MANUAL The manual is divided into 14 major sectionsþ: 01SERVICE TOOLS AND PRODUCTS 02MAINTENANCE 03TROUBLESHOOTING 04ENGINE 05COOLING SYSTEM 06FUEL SYSTEM 07LUBRICATION SYSTEM 08ELECTRICAL SYSTEM 09PROPULSION SYSTEM 10STEERING SYSTEM 11SUSPENSION 12HULL / BODY 13TECHNICAL DATA 14WIRING DIAGRAMS Several sections are divided in various sub-sec-...
Page 8 1996 BOMBARDIER WATERCRAFT SHOP MANUAL TYPICAL PAGE Page heading indicates section and sub-section detailed. Sub-section title indicates Section 08 ELECTRICAL beginning of the sub-section. Sub-Section 01 (MAGNETO SYSTEM) MAGNETO SYSTEM 587 and 717 Engines Italic sub-tiltle above exploded 5 N•m view indicate Drop represents a (44 lbf•in)
Page 9 1996 BOMBARDIER WATERCRAFT SHOP MANUAL TYPICAL PAGE Sub-title beginning with part number(s) of above exploded view following 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
1996 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: Mandatory Tools
S e c t i o n 0 1 S E R V I C E T O O L S A N D P R O D U C T S (MANDATORY TOOLS) Sub-Section 01 MANDATORY TOOLS NOTE : The numbers outlined in black (example : ) are reference numbers to tools from other dlvlslons both products, even if the part numbers are different: ENGINE...
Page 12: And Products
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) ENGINE (continued) Puller PTO flywheel remover/ Piston pin puller P / N 295000106 290877092 P / N 295000001 295000105 m — 3 – m F01JOT4 F01BOV4 AOOC1A4 APPLICATION APPLICATION All models. A) 657, 717 and 787 engines P / N 290876080 NOTE : This tool is also...
Page 13 Section 01 SERVICE TOOLS AND PRODUCTS (MANDATORY TOOLS) Sub-Section 01 ENGINE (continued) R i n g g e a r b l o c k i n g t o o l . : 295000134 P / N APPLICATION 787 engine. Ring gear puller tool P / N 420976235 APPLICATION...
Page 14 Section 01 SERVICE TOOLS AND PRODUCTS (MANDATORY TOOLS) Sub-Section 01 COOLING / FUEL/ OIL SYSTEMS Hose pincher Pliers P / N 295000054 APPLICATION , AO1 B214 All models. APPLICATION NOTE : This tool is also used All models. for the propulsion system. Gear holder Flush kit...
Page 15 Section 01 SERVICE TOOLS AND PRODUCTS (MANDATORY TOOLS) Sub-Section 01 PROPULS1ON SYSTEM Impeller remover / Bearing / seal installer VTS tool i nsta I Ie r P / N 295000107 P/’ N 295000133 295000001 P / N APPLICATION APPLICATION All models. XP 1995 and 1996 models.
Page 16: Recommended Tools
Section 01 SERVICE AND PRODUCTS TOOLS (RECOMMENDED TOOLS) Sub-Section 02 RECOMMENDED TOOLS NOTE : The numbers outlined in black (example : ) are reference numbers to tools from other divisions reference numbers indicate the same tool is being used on Jet Boats).
Page 17 Section 01 SERVICE TOOLS AND PRODUCTS (RECOMMENDED TOOLS) Sub-Section ENGINE (continued) Timing mark pointer Terminal remover P / N 295000130 P / N 290876330 Not sold by Bombardier (halves) (2) Snap-on APPLICATION All models. APPLICATION , FO1 B204 787 engine Slide hammer puller APPLICATION Not sold by Bombardier...
Page 18 Section 01 SERVICE TOOLS AND PRODUCTS (RECOMMENDED TOOLS) Sub-Section ENGINE (continued) Safety lanyard switch tool ~ Handle Ring compressor P / N 295000121 P / N 290877650 A) P / N 290876972 B) P / N 295000112 APPLICATION APPLICATION DESS switch. A) 587 engine (76 mm).
Page 19 Section 01 SERVICE TOOLS AND PRODUCTS 02 (RECOMMENDED TOOLS) Sub-Section COOLING / FUEL/ OIL SYSTEMS gauge Screwdriver Spring compressor (carburetor Not sold by Bombardier P / N 529027100 P / N 295000114 Snap-on i--l SDD-143 APPLICATION All models. Lighted adjustable mirror A01B404 Not sold by Bombardier APPLICATION...
Page 20: Propulsion System
Section 01 SERVICE TOOLS AND PRODUCTS 02 (RECOMMENDED TOOLS) Sub-Section PROPULSION SYSTEM Fitting Machinist’s square Bearing remover P / N 295000086 Not sold by Bombardier P / N 295000144 Snap-on APPLICATION All models. “.. -. J ; - “’ -- -’ “’ - “ --- “...
Page 21 Section 01 SERVICE TOOLS AND PRODUCTS (RECOMMENDED TOOLS) Sub-Section WATERC RAFT HANDING (with wheels) Lift kit Tie-down with ratchet : : P / N 295000126 A) P / N 295100012 : c 3.60 m (12 ft) long P / N 295100 0! 1 APPLICATION F01B014 Beach wheels (2)
Page 22: Service Products
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) SERVICE PRODUCTS NOTE : The numbers outlined in black. (example : ) are reference numbers to tools from other divisions both products, even if the part numbers are differen~ Assure High strength Medium strength thread locker...
Page 23 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) General purpose instant Solvent Gasket eliminator adhesive P / N 293800019 P / N 293800007 Solvent 755 AOOB2VA AOOB2T4 APPLICATION APPLICATION Rubber to metal bonding and Cylinder sleeve / O-ring groove. most hard plastlc.
Page 24 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) Heat resistant sealant Dielectric grease P / N 293800001 P / N 413709200 P / N 293550004 Dow Corning 736 Dow Cornlncj ‘ 100 150 g) APPLICATION APPLICATION APPLICATION Tuned pipe. Battery posts and cable con- nectors.
Page 25 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) Sea-Doo fuel stabilizer Anti-seize lubricant Lubricant P / N 413408600 P / N 293800023 Not sold B o m b a r d i e r G E. Versllube G341 M 12 Oz (454 g) Esso Be;;on 325...
Page 26 Jet pump P/N 293600011 (12 X 6 OZ) Bombardier-Rotax Formula XP-S Dow Corning (90 synthetic injection oil Sea-Doo P / N 413711000 (3 X 4 L) synthetic jet pump 011 P / N 413710700 (205 L) APPLICATION Ride shoe screws.
Page 27 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) Sealant Spray paint for metallic parts only P / N 293800029 A) Violet A) White (140 g) P / N 293500029 P / N 293500068 Tremco clear B) Purple (140 g) B) Yellow (140 g) P / N 293500020 P / N 293500078...
Page 28 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) Sea-Doo spray paint for gelcoat A) Super white (140 g) A) Super white (1 L) A) P / N 295500216 P / N 293500076 P / N 293500075 P / N 295500340...
Page 29: Maintenance
Section 02 MAINTENANCE Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS PERIODIC INSPECTION CHART....................02-01-1 FLUSHING AND LUBRICATION....................02-02-1 GENERAL ..........................02-02-1 PROCEDURE ........................02-02-1 WATER-FLOODED ENGINE..................... 02-03-1 STORAGE..........................02-04-1 02-00-1 www.SeaDooManuals.net...
Page 30: Periodic Inspection Chart
Section 02 MAINTENANCE Sub-Section 01 (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...
Page 31: Flushing And Lubrication
Section 02 MAINTENANCE Sub-Section 02 (FLUSHING AND LUBRICATION) FLUSHING AND LUBRICATION GENERAL Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. It will help to clean up sand, salt, shells or other particles in water jackets (engine, exhaust manifold, tuned pipe) and / or hoses.
Page 32 Section 02 MAINTENANCE Sub-Section 02 (FLUSHING AND LUBRICATION) All Models Start the engine then immediately open the water tap. CAUTION : Always start the engine be- fore opening the water tap. Open water tap immediately after engine is started to pre- vent overheating.
Page 33 Section 02 MAINTENANCE Sub-Section 02 (FLUSHING AND LUBRICATION) All Models Remove both spark plugs and spray BOMBAR- DIER LUBE lubricant into each cylinder. Wipe up any residual water from the engine. Crank the engine a few turns to distribute the oil Remove spark plug cables and connect them on onto cylinder wall.
Page 34: Water-Flooded Engine
Section 02 MAINTENANCE Sub-Section 03 (WATER-FLOODED ENGINE) WATER-FLOODED ENGINE General XP Model Only If engine is water-flooded, it must be serviced within a few hours after the event. Otherwise en- gine will have to be overhauled. CAUTION : A water-flooded engine must be properly lubricated, operated then lu- bricated again, otherwise parts will be serious- ly damaged.
Page 35 Section 02 MAINTENANCE Sub-Section 03 (WATER-FLOODED ENGINE) NOTE : If engine does not start after sever- al attempts, check ignition system for spark occurence. Refer to ELECTRICAL SYSTEM, 08- Check crankshaft if needed, it can become mis- aligned or deflected. Refer to ENGINE, 04-03. After engine has started, spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running.
Page 36: Storage
Fuel System Check engine drain hose. Make sure there is no Sea-Doo Fuel Stabilizer (P / N 413 408 600) can be sand or other particles in it and that it is not ob- added in fuel tank to prevent fuel deterioration structed so that water can leave the engine.
Page 37 Section 02 MAINTENANCE Sub-Section 04 (STORAGE) Wash the body with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull. Apply a nonabrasive wax. CAUTION : Never clean apparent fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc.
Page 38 Section 02 MAINTENANCE Sub-Section 04 (STORAGE) All Models Except the HX Disconnect engine water supply hose and engine water return hose. Install coupler hose to fitting spigot. Install a hose pincher to engine water return hose (beside fitting spigot). F05E03A 1.
Page 39: Troubleshooting
Section 03 TROUBLESHOOTING TROUBLESHOOTING 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 Engine does not turn over •...
Page 40 Section 03 TROUBLESHOOTING ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark • Fouled, defective, worn spark plugs • Check / verify heat range / gap / replace • Check, refer to section 08-02 • Faulty rev limiter or ignition •...
Page 41 Section 03 TROUBLESHOOTING 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 Engine temperature • Engine overheats •...
Page 42 Section 04 ENGINE Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS REMOVAL AND INSTALLATION .................... 04-01-1 GENERAL ..........................04-01-1 REMOVAL FROM WATERCRAFT ..................04-01-1 CLEANING ........................... 04-01-4 INSTALLATION ........................04-01-4 TOP END ..........................04-02-1 587 AND 717 ENGINES ....................... 04-02-1 787 ENGINE .........................
Page 43: Engine
Section 04 ENGINE Sub-Section 00 (TABLE OF CONTENTS) EXHAUST MANIFOLD, TUNED PIPE AND MUFFLER INSTALLATION ......04-05-7 04-00-2 www.SeaDooManuals.net...
Page 44: Removal And Installation
Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL All Models Disconnect thermosensor wire and spark plug It is not necessary to remove engine from water- cables. craft for TOP END nor PTO FLYWHEEL AND Connect spark plug cables onto grounding device. MAGNETO servicing.
Page 45 Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) Disconnect magneto wiring harness. HX Model Only Disconnect choke and throttle cables from carbu- retors. Disconnect fuel supply and fuel return hoses. Engine Support Mounts All Models Except the HX Remove engine support mount screws. NOTE : Be careful when removing engine support mount screws, shims could have been installed between engine support and rub-...
Page 46 Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) HX Model Using a chain block, a hoist or other suitable equi- pment, slightly lift engine to ease the remaining Loosen screws of engine rubber mount adapters. component removal. NOTE : Rubber mount adapters sit on CAUTION : Take care not to damage cable shims which control engine / jet pump align- or oil injection hoses.
Page 47: Cleaning
Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) All Models Install a hose pincher to oil supply hoses of oil injection pump and rotary valve shaft ; then, dis- connect hoses. F01D40A TYPICAL - ALL MODELS EXCEPT THE XP A01B2JB TYPICAL 1.
Page 48 Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) CAUTION : Strict adherence to this torque is important to avoid damaging threads of aluminum insert in bilge. NOTE : Always remove rubber mounts one at a time and reinstall each shim to its origi- nal location.
Page 49 Section 04 ENGINE Sous-section 01 (REMOVAL AND INSTALLATION) Final Inspection Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. After its ins- tallation, properly adjust and bleed oil injection pump as specified in LUBRICATION SYSTEM 07- Pressure test fuel system, refer to FUEL SYSTEM 06-01.
Page 50: Top End
Section 04 ENGINE Sub-Section 02 (TOP END) TOP END 587 and 717 Engines 9 N•m 9 N•m 24 N•m Loctite 242 (80 lbf•in) (80 lbf•in) (17 lbf•ft) 717 Engine Loctite 515 Synthetic grease Engine Synthetic grease 24 N•m (17 lbf•ft) Synthetic grease Loctite...
Page 51 Section 04 ENGINE Sub-Section 02 (TOP END) 787 Engine Loctite 242 24 N•m (17 lbf•ft) Synthetic grease Synthetic grease Synthetic grease 40 N•m (30 lbf•ft) Loctite Loctite 34 rollers Synthetic grease Synthetic grease 34 rollers F01D7DS PARTS 040-02-2 www.SeaDooManuals.net...
Page 52: Engine Description
Section 04 ENGINE Sub-Section 02 (TOP END) ENGINE DESCRIPTION 1,2, Cylinder Head Cover and Cylinder Head 587, 717 and 787 Engines Remove cylinder head cover. The 2-stroke ROTAX engine rotates counterclock- NOTE : With the 717 and 787 engines, cyl- wise seen from the rear (PTO flywheel).
Page 53 Section 04 ENGINE Sub-Section 02 (TOP END) If the other cylinder has been removed, complete- ly cover its opening with a clean rag. F01B0VA PISTON PIN PULLER (P / N 290 877 092) 1. Bushing (P / N 290 877 181) F01D43A 2.
Page 54: Cleaning
Section 04 ENGINE Sub-Section 02 (TOP END) CLEANING Discard all gaskets and O-rings. Clean all metal components in a solvent. Clean water passages and make sure they are not clogged. Remove carbon deposits from cylinder exhaust port, cylinder head and piston dome. Clean piston ring grooves with a groove cleaner tool, or a piece of broken ring.
Page 55 Section 04 ENGINE Sub-Section 02 (TOP END) NOTE : Replacement cylinder sleeves are available if necessary. Also, oversize pistons of 0.25 mm (.010 in) are available for all engines and oversize pistons of 0.5 mm (.020 in) are avail- able for the 587 and 717 engines. Cylinder Taper Using a cylinder bore gauge, measure cylinder di- ameter at 16 mm (5/8 in) from top of cylinder just...
Page 56 Section 04 ENGINE Sub-Section 02 (TOP END) Measure cylinder at 16 mm (5/8 in) below its top Ring End Gap edge. Position ring halfway between exhaust port and top of cylinder. NOTE : In order to correctly position ring in cylinder, use piston as a pusher.
Page 57 Section 04 ENGINE Sub-Section 02 (TOP END) GASKET IDENTIFICATION THICKNESS HOLES 0.3 mm (.012 in) 0.4 mm (.016 in) 0.5 mm (.020 in) 0.6 mm (.024 in) 0.8 mm (.031 in) F01D7EA 787 ENGINE SHOWN NOTE : Squish gap measurement is dis- 1.
Page 58 Section 04 ENGINE Sub-Section 02 (TOP END) – Warm piston to approximately 50-60°C (122- 140°F) and install it over connecting rod. – Insert extractor spindle into the piston pin, screw on extracting nut. – Rotate handle to pull piston pin carefully into the piston.
Page 59 Section 04 ENGINE Sub-Section 02 (TOP END) F01D0SA F01D0WA 1. Circlip opening at 6 o’clock (at bottom) – As necessary, pull halves of inner sleeve with long nose pliers. WARNING : Always wear safety glasses when installing piston circlips. CAUTION : Always use new circlips. At in- stallation, take care not to deform them.
Page 60 Section 04 ENGINE Sub-Section 02 (TOP END) F01D0YA F01D0ZA 3,7,8,9, Piston, Ring and Cylinder 1. Ring end gap aligned with piston locating pin To easily slide cylinder over piston, install on pis- Slide cylinder over piston. ton ring compressor P / N 290 876 972 for the 587 engine or P / N 290 876 979 for the 717 and 787 engines.
Page 61 Section 04 ENGINE Sub-Section 02 (TOP END) F01D44A F01D35A ALL ENGINES EXCEPT THE 787 787 Engine 1. Exhaust flange aligning tool 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 62 Section 04 ENGINE Sub-Section 02 (TOP END) Apply Loctite 515 in O-ring groove of cylinder sleeves. F01D15A 1. Longer screws F01D14A 2,12, Cylinder Head and O-ring Make sure to install large O-rings around spark 717 and 787 Engines plug holes and small O-ring where shown. Make sure to install O-rings around spark plug holes and O-ring of cylinder head as shown in the following illustration.
Page 63: Squish Area
Section 04 ENGINE Sub-Section 02 (TOP END) Torque cylinder head screws to 12 N•m (9 lbf•ft) as per following illustrated sequence. Repeat the procedure, retightening all screws to 24 N•m (17 lbf•ft). F01D5WA 1. Squish gap If the squish gap is increased, a loss in power will occur, while too small a squish gap will lead to F01D46A detonation.
Page 64: Rave System
Section 04 ENGINE Sub-Section 02 (TOP END) When an engine of this design is run at a medium speed, efficiency falls off quickly. The relatively high exhaust port effectively shortens the useful power stroke and because the exhaust system is tuned for maximum power, there is a large in- crease of fresh charge losses.
Page 65 Section 04 ENGINE Sub-Section 02 (TOP END) Item P1 in figure is the pressure of the return spring against the diaphragm. The exhaust pres- sure must be high enough to overcome this pres- sure before the valve begins opening. Item P2 is the pressure required to completely open the RAVE valve.
Page 66 Section 04 ENGINE Sub-Section 02 (TOP END) Boring Precaution 21, Allen Screw In its stock configuration the RAVE valve guillotine Loosen Allen screws and remove RAVE valve. has a minimum of 0.5 mm (.020 in) clearance to the cylinder bore measured at the center line of the cylinder.
Page 67 Section 04 ENGINE Sub-Section 02 (TOP END) Inspection 27, Valve Housing Check bellow for cracks. Position the valve housing onto the cylinder so that its opening is toward the bottom. Check if passages of valve housing and cylinder are not obstructed. F01D8JB 1.
Page 68: Bottom End
Section 04 ENGINE Sub-Section 03 (BOTTOM END) BOTTOM END 587 Engine Loctite Lithium grease Anti-seize lubricant Loctite Anti-seize lubricant Anti-seize lubricant Loctite Loctite Anti-seize lubricant Anti-seize lubricant Lithium 24 N•m grease (17 lbf•ft) Loctite Loctite Loctite 40 N•m Synthetic (30 lbf•ft) Loctite grease Synthetic...
Page 69 Section 04 ENGINE Sub-Section 03 (BOTTOM END) 717 Engine Loctite Lithium grease Anti-seize lubricant Loctite Anti-seize lubricant Anti-seize lubricant Loctite Loctite 24 N•m (17 lbf•ft) Lithium grease Loctite Synthetic Loctite grease Synthetic grease 24 N•m (17 lbf•ft) 40 N•m 10 N•m (30 lbf•ft) (88 lbf•in) F01D06S...
Page 70: 787 Engine
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 787 Engine 30 mL (1 oz) Loctite FORMULA XP-S synthetic injection oil Anti-seize lubricant Lithium grease Lithium grease Anti-seize Loctite lubricant Anti-seize lubricant Anti-seize lubricant Lithium grease Loctite Loctite Loctite Synthetic grease Anti-seize Synthetic lubricant Loctite...
Page 71: Crankshaft Misalignment And Deflection
Section 04 ENGINE Sub-Section 03 (BOTTOM END) CRANKSHAFT MISALIGNMENT – Remove spark plugs. AND DEFLECTION – Insert a screwdriver in one spark plug hole. – Insert a longer screwdriver in the other spark Since it is an assembled crankshaft it can become plug hole.
Page 72: Disassembly
Section 04 ENGINE Sub-Section 03 (BOTTOM END) 1, Seal If crankshaft end seal(s) has / have to be replaced, bottom end must be opened (except for the MAG side seal on the 787 engine, which is mounted on the ignition housing). 3, Crankcase Remove the following parts : –...
Page 73 Section 04 ENGINE Sub-Section 03 (BOTTOM END) F01B09A F01D1KA 1. Separate halves by prying at provided lugs 1. Puller (P / N 290 876 298) 2. Protective cap (P / N 290 876 557) 3. Distance ring, MAG side (P / N 290 876 569) 4.
Page 74: Cleaning
Section 04 ENGINE Sub-Section 03 (BOTTOM END) All Engines Clean all metal components in a solvent. Remove old Loctite from crankcase mating sur- faces with gasket remover (P / N 295 000 110). CAUTION : Be careful not to spray clean- er on the painted surface of the engine.
Page 75 Section 04 ENGINE Sub-Section 03 (BOTTOM END) F01D1QA F01D1TA 1. Ruler must be aligned with edge of connecting rod here 1. Measuring MAG side deflection in crankcase 2. Align ruler here Remove crankshaft bearings and check deflection Crankshaft Deflection again on V-shaped blocks as illustrated. Crankshaft deflection is measured each end with a dial indicator.
Page 76: Assembly
Section 04 ENGINE Sub-Section 03 (BOTTOM END) Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. F01D1XA 1. Bearing against a steel plate 2. Propane torch 3. Heat plate through bearing bore F01D1WA 5, Outer PTO Bearing 1.
Page 77 Section 04 ENGINE Sub-Section 03 (BOTTOM END) F01D1YA F01D80A TYPICAL 1. Marks 1. Distance gauge 2. PTO side outer bearing 3, Crankcase 15, Distance Ring Crankcase halves are factory matched and there- fore, are not interchangeable or available as single When installing the distance ring on the magneto halves.
Page 78 Section 04 ENGINE Sub-Section 03 (BOTTOM END) 587 and 717 Engines 7,8,9, Crankcase Screw Torque crankcase screws to 24 N•m (17 lbf•ft) as per following illustrated sequence. 5 13 F01D81A F01D20A 8, Crankcase Screw 8, Crankcase Screw As a final step, torque only M10 screws of crank- case to 40 N•m (30 lbf•ft) as per following se- Torque 2 M10 crankcase screws to 40 N•m (30 quence.
Page 79 Section 04 ENGINE Sub-Section 03 (BOTTOM END) F01D4KA 1. Install starter before engine support 787 Engine Add 30 mL (1 oz) of FORMULA XP-S synthetic in- jection oil in the small hole near the transfer of the PTO cylinder. F01D86A TYPICAL 1.
Page 80: Rotary Valve
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) ROTARY VALVE Lithium grease 787 Engine 20 N•m (15 lbf•ft) 717 Engines 20 N•m (15 lbf•ft) F01D7SS PARTS 04-04-1 www.SeaDooManuals.net...
Page 81: General
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) GENERAL The following verification procedures such as clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without re- moving engine from watercraft. However engine must be removed from water- craft to work on rotary valve shaft / components.
Page 82 Section 04 ENGINE Sub-Section 04 (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 83: Disassembly
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) DISASSEMBLY 3,4, Rotary Valve Shaft and Snap Ring To remove rotary valve shaft assembly, first re- move snap ring from crankcase. F01D61A 1. Hold bolt F01D22A 1. Removing snap ring CAUTION : Bottom end must be opened to remove rotary valve shaft.
Page 84: Cleaning
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 7,8, Snap Ring and Bearing To remove bearing use a bearing extractor such as Snap-on no CJ-950 as illustrated. Slide off dis- tance sleeve, remove snap ring and press shaft out. F01J0ZA Close puller claws so that they can be inserted in end bearing.
Page 85: Assembly
Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 8,9 Bearing 9, Bearing Inspect bearings. Check for scoring, pitting, chip- To install end bearing in crankcase, use a pusher ping or other evidence of wear. Make sure plastic (P / N 290 876 500). cage (on bigger bearing) is not melted.
Page 86 Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 3,11, Rotary Valve Shaft and Seal 3,4, Rotary Valve Shaft Ass’y and Snap Ring Apply lithium grease on seal lips. Position seal with shielded portion against shaft splines. CAUTION : Crankcase halves must be separated and crankshaft must not be 3,7,8, Rotary Valve Shaft, Snap Ring present to install rotary valve shaft ass’y in...
Page 87 Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 787 Engine All Engines To install rotary valve shaft in crankcase, use a At snap ring installation, position it so that its pusher (P / N 290 876 609) and handle (P / N 290 sharp edge faces outwards.
Page 88 Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 159 ° 159° TEMPLATE (cut-out angle) (cut-out angle) 290 924 502 actual size 147 ° 147° (cut-out angle) (cut-out angle) 290 924 508 actual size F01D89S 04-04-9 www.SeaDooManuals.net...
Page 89: Rotary Valve Timing
Section 04 ENGINE Sub-Section 04 (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 90 Section 04 ENGINE Sub-Section 04 (ROTARY VALVE) 65° F01D3EB CLOSING MARK Step : Top of MAG inlet port. Align 360 ° line of degree wheel : Find 65 ° on degree wheel and mark here Step – Remove degree wheel. –...
Page 91: Exhaust System
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) EXHAUST SYSTEM SP Series, GTS and GTI Models Loctite 25 N•m SPI, SPX, (18 lbf•ft) model GTS and GTI models 25 N•m (18 lbf•ft) Loctite 242 Synthetic grease 24 N•m (17 lbf•ft) Loctite 4 N•m (35 lbf•in) Loctite...
Page 92: Hx Model
Section 04 ENGINE Sub-Section 05 (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 93: Xp Model
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) XP Model 25 N•m (18 lbf•ft) 25 N•m (18 lbf•ft) Loctite Loctite Loctite Loctite 40 N•m Sealant (30 lbf•ft) 40 N•m 10 N•m (30 lbf•ft) (88 lbf•in) Synthetic grease Loctite 242 4 N•m 8 40 N•m (35 lbf•in) (30 lbf•ft)
Page 94: Tuned Pipe Removal
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) TUNED PIPE REMOVAL 6, Screw Remove tuned pipe retaining screw(s) from ex- All Models Except HX and XP haust manifold side. NOTE : For SP series, remove air vent tube support from body opening. 7,8,9, Screw, Nut and Flat Washer Disconnect water inlet hose and water injection Remove screws, nut and flat washers from tuned...
Page 95 Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) Disconnect water supply hose and water injection hose at tuned pipe head. F01D76A 1. Screw F01D3YA Remove tuned pipe head. 1. Water supply hose 2. Water injection hose 6, Screw 1,3, Collar and Hose Remove two screws retaining tuned pipe cone to engine.
Page 96: Exhaust Manifold Removal
Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) 12, Tuned Pipe Cone HX Model Only 1, Collar Move tuned pipe cone in front of bilge between body and fuel tank. Loosen exhaust hose collar at tuned pipe cone outlet (only if tuned pipe cone is not re- moved).
Page 97 Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) Test : XP Model Only Except for two screws, apply synthetic grease on – Use compressed air at 124 kPa (18 PSI) to pres- screw threads. Apply Loctite 515 on the other two surize tuned pipe.
Page 98 Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) 20, Gasket Make sure that gasket is properly located on ex- haust manifold prior to finalizing pipe installation. 4,6,7,8,23, Clamp, Screw and Nut Apply Loctite 242 (blue) on stud and retaining screw threads. Hand-tighten nut and screws and assure that tuned pipe bushing(s) rests against manifold.
Page 99 Section 04 ENGINE Sub-Section 05 (EXHAUST SYSTEM) SPI, SPX, GTS and GTI Models 5,21,22, Tuned Pipe Cone, Collar and Clamp Install tuned pipe cone with collar and clamp. Position clamp as illustrated. Do not tighten clamp yet. F01D41A 1. Clamp 2.
Page 100: Cooling System
Section 05 COOLING SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS COMPONENTS ........................0-01-1 SP / SPI AND GTS MODELS ....................0-01-1 SPX AND GTI MODELS ...................... 0-01-2 HX MODEL ........................... 0-01-3 XP MODEL ........................... 0-01-4 GENERAL ..........................0-01-5 CIRCUIT............................
Page 101: Components
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) COMPONENTS SP / SPI and GTS Models Loctite 592 Loctite Loctite Loctite Loctite Loctite Loctite F01E0SS PARTS 05-01-1 www.SeaDooManuals.net...
Page 102: Spx And Gti Models
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) SPX and GTI 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) Loctite F01E1PS PARTS...
Page 103: Hx Model
Section 05 COOLING SYSTEM Sub-Section 01 (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 05-01-3 www.SeaDooManuals.net...
Page 104: Xp Model
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) XP 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: General
Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) GENERAL 3, Elbow Fitting Water injection used on exhaust system cools the CAUTION : All hoses and fittings of the exhaust gases to obtain maximum performance cooling system have calibrated inside di- from the tuned pipe. The elbow fitting has a cali- ameters to assure proper cooling of the en- brated inside diameter to optimize water flow in gine.
Page 106 Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) 4, Water Flow Regulator Valve If the maximum engine speed can not be attained or if the engine has poor performance, the water XP Model flow regulator valve should be considered in the troubleshooting of the problem.
Page 107 Section 05 COOLING SYSTEM Sub-Section 01 (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 9,10, Valve and Bellows 1.
Page 108: Circuit
For winterization of cooling system, refer to MAINTENANCE 02-04. Max. 90° Special precautions should be taken when towing a Sea-Doo watercraft. When towing your watercraft pinch the water supply hose from the impeller housing to the en- gine with the Hose Pincher (large) Pþ/þN 529 030 400.
Page 109 Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) For a minimum back pressure in the exhaust, en- TECHNICAL DATA gine water outlet hose is not connected to the ex- haust. It has its own fitting at the rear of the hull. TYPE : TLCS (Total Loss Cooling System).
Page 110 Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) 05-02-3 www.SeaDooManuals.net...
Page 111 Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) 05-02-4 www.SeaDooManuals.net...
Page 112: Engine Cooling System
787 ENGINE COOLING SYSTEM Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) 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 and injected (205-210°F)
Page 113: Fuel System
Section 06 FUEL SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT.......................... 06-01-1 SP, SPI AND GTS MODELS....................06-01-1 SPX, XP AND GTI MODELS....................06-01-2 HX MODEL ........................... 06-01-3 GENERAL ..........................06-01-4 INSPECTION ........................06-01-6 REMOVAL..........................06-01-6 ASSEMBLY........................... 06-01-7 FUEL SYSTEM PRESSURIZATION ..................
Page 114: Fuel Circuit
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) FUEL CIRCUIT SP , SPI 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 (27 lbf•in)
Page 115: Spx, Xp And Gti Models
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) SPX, XP and GTI Models Loctite 242 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) 3 N•m (27 lbf•in) 4 N•m...
Page 116: Hx Model
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) HX Model Body 3 N•m (27 lbf•in) Loctite 6 N•m 2 N•m (53 lbf•in) (18 lbf•in) Body 1 N•m (9 lbf•in) 22 N•m (16 lbf•ft) 3 N•m (26 lbf•in) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) Engine...
Page 117: General
1. Securing clamp in limited access WARNING : Replace any damaged, leak- ing or deteriorated fuel lines. When replacing fuel lines on SEA-DOO water- craft, be sure to use «B1» hoses as available from To secure or cut Oetiker clamps on fuel lines, use Bombardier parts department.
Page 118 Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) 1,2, Fuel Filter and Bowl REMOVAL All Models Except HX Open storage compartment cover. Remove basket. HX Model Only Open hood. GTS and GTI Models Only Press on vent tube upper part to enable to with- draw tube from body.
Page 119: Inspection
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) 6, Pressure Relief Valve This valve will eliminate fuel spillage when the watercraft is upside down. If pressure is built up in fuel system the valve should open at 10 kPa (1.5 PSI) to release the pressure. WARNING : If pressure relief valve is stuck, the pressure in fuel system will build up and it may cause fuel leakage in en-...
Page 120: Assembly
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) WARNING : Fuel is flammable and explo- sive under certain conditions. Always work in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Al- ways wipe off any fuel spillage from the water- craft.
Page 121: Fuel System Pressurization
Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) Install baffle pick up into fuel tank and push it until it sits on fuel tank neck. Install clamp and torque both clamps to 3 N•m (27 lbf•in). HX Model Only Make sure to align notch of baffle pick up with the mark on the fuel tank.
Page 122: Air Intake
Section 06 FUEL SYSTEM Sub-Section 02 (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) Loctite 515 Single carb Loctite 515 F01F1WS PARTS 06-02-1 www.SeaDooManuals.net...
Page 123: Removal
Section 06 FUEL SYSTEM Sub-Section 02 (AIR INTAKE) REMOVAL 5,6,7,8, Flame Arrester, Support, Base and Screw 1, Air Intake Silencer Cover Remove flame arrester. Unlock retaining slides holding air intake silencer Remove screws holding support of flame arrester cover and remove cover. base to the cylinder head cover (587 and 717 en- gines) or to the tuned pipe (787 engine).
Page 124 Section 06 FUEL SYSTEM Sub-Section 02 (AIR INTAKE) 5, Flame Arrester Inspect condition of flame arrester. Replace or clean as necessary. WARNING : Do not operate watercraft without flame arrester. 9, Gasket Inspect condition of gasket. Make sure to proper- ly installed gasket.
Page 125: Carburetors
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) CARBURETORS 587 Engine Loctite Loctite Anti-seize lubrifiant F02F0KS PARTS 06-03-1 www.SeaDooManuals.net...
Page 126: 717 And 787 Engines
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 717 and 787 Engines Loctite 20 N•m (15 lbf•ft) Loctite Loctite 242 Anti-seize lubricant Synthetic grease Synthetic grease F01F05S PARTS 06-03-2 www.SeaDooManuals.net...
Page 127: General
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) GENERAL Twin Carburetor Models Only The following illustration shows which part of the 16,17, Screw and Lock Washer carburetor begins to function at different throttle Remove screws and lock washers retaining car- plate openings. buretors.
Page 128: Pump Verification
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 2, Low Speed Screw PUMP VERIFICATION Check tip for a grooved condition. Replace if nec- Check fuel pump valves operation as follows : essary. Connect a clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with the mouth.
Page 129: Carburetor Assembly
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) CARBURETOR ASSEMBLY When assembling pump, ensure to properly posi- tion components together. Refer to previous illus- trations if necessary. 6,7, Choke Plate and Throttle Plate When installing plate onto shaft, close plate so that it centers into carburetor bore.
Page 130 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) Refer to the following table for specifications of the pop off pressure for each model. POP OFF MINIMUM MODELS PRESSURE STABILIZED (PSI) PRESSURE 21-37 40-56 F01F0HA 21-37 HIGH LEVER Step depress here 21-37 Step push tab down 40-56...
Page 131: Carburetor Installation
Section 06 FUEL SYSTEM Sub-Section 03 (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. CARBURETOR 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 132: Adjustments
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) WARNING : Make sure there is no leak in fuel system. For fuel system pressurization, refer to FUEL SYSTEM 06-01. ADJUSTMENTS Throttle Cable Lubricate cable with BOMBARDIER LUBE lubri- cant. Throttle lever must reach handlebar grip without causing strain to cable or carburetor cable bracket.
Page 133 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) F01F32B F01F33A 717 AND 787 ENGINES 717 AND 787 ENGINES 1. Throttle lever stoppers (behind levers) 1. Low speed screw (PTO) 2. Adjustment nut 2. Low speed screw (MAG) Tighten jam nut and recheck adjustment. CAUTION : Do not attempt to set engine idle speed with low-speed screw.
Page 134 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 15, Idle Speed Screw Turning screw clockwise increases engine idle speed and turning screw counterclockwise de- creases engine idle speed. F01F0VA TYPICAL - 587 ENGINE 1. High speed screw F01F0TE 587 ENGINE 1. Idle speed screw F01F2QA TYPICAL - 717 AND 787 ENGINES 1.
Page 135 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) NOTE : On twin carburetor engines, there is only one idle speed screw. Connect an induction-type tachometer (P / N 295 000 100) on spark plug cable of magneto side to measure engine speed. NOTE : To adjust idle speed, ensure flame arrester and air intake silencer are installed.
Page 136: Table Of Contents
Section 07 LUBRIFICATION SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM ......................0-01-1 ALL MODELS EXCEPT HX ....................0-01-1 HX MODEL ........................... 0-01-2 OIL INJECTION PUMP ......................0-02-1 ALL MODELS EXCEPT XP ....................0-02-1 XP MODEL ........................... 0-02-2 REMOVAL..........................
Page 137: Oil Injection System
Section 07 LUBRIFICATION SYSTEM Sub-Section 01 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM All Models Except HX SP Model Only 4 N•m (35 lbf•in) 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) F01G0CS PARTS 07-01-1 www.SeaDooManuals.net...
Page 138: Hx Model
Section 07 LUBRIFICATION SYSTEM Sub-Section 01 (OIL INJECTION SYSTEM) HX Model 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) F05G02S PARTS 07-01-2 www.SeaDooManuals.net...
Page 139 Section 07 LUBRIFICATION SYSTEM Sub-Section 01 (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. 1,2, Clamp and Hose Verify oil filler neck hose for damage. Always en- sure that clamps are well positioned and tight- ened.
Page 140: Oil Injection Pump
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) OIL INJECTION PUMP All Models Except XP Loctite Twin Carbs 6 N•m (53 lbf•in) Single Carb 6 N•m (53 lbf•in) Loctite 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)
Page 141: Xp Model
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) XP Model 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 07-02-2 www.SeaDooManuals.net...
Page 142: Removal
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) REMOVAL CLEANING Discard all seals and O-rings. Clean metal compo- All Models Except XP nents in a solvent. Remove air intake silencer (refer to FUEL SYS- TEM 06-02). ASSEMBLY Remove rotary valve cover (refer to ENGINE 04- 05).
Page 143: Adjustments
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) 587 and 717 Engines F01D4RC TYPICAL F01D4RE A. 10 N•m (89 lbf• TYPICAL 1. Jam nut XP Model Only 2. Adjustment nut 3. Aligned marks 8,9,10,11, Screw, Flat Washer, Pump 787 Engine and Shaft NOTE : The adjustment screw and jam nut Install shaft in crankshaft end.
Page 144: Checking Operation
Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) Final Synchronization 787 Engine Eliminate throttle cable free-play by depressing throttle lever until a slight resistance is felt. In this position, marks on pump body and lever must align. NOTE : A mirror may be used to facilitate this verification.
Page 145 Section 07 LUBRIFICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) Bench Test For an accurate test, each port should be checked separately to ensure equal delivery on both ports. The oil pump must be removed out of watercraft. To obtain a precise result of the oil pump delivery Connect a hose filled with injection oil to main line rate, rotate it counterclockwise at 1500 RPM for a fitting.
Page 146: Electrical System
Section 08 ELECTRICAL SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS MAGNETO SYSTEM ....................... 08-01-1 587 AND 717 ENGINES ....................... 08-01-1 787 ENGINE ......................... 08-01-2 GENERAL ..........................08-01-3 REMOVAL..........................08-01-3 CLEANING ........................... 08-01-6 DISASSEMBLY........................08-01-6 ASSEMBLY........................... 08-01-7 INSTALLATION ........................08-01-8 IGNITION SYSTEM........................
Page 147: Magneto System
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) MAGNETO SYSTEM 587 and 717 Engines 5 N•m (44 lbf•in) 9 N•m (80 lbf•in) Loctite Loctite 6 N•m (53 lbf•in) Loctite 6 N•m (53 lbf•in) 6 N•m Loctite (53 lbf•in) Loctite Loctite 145 N•m (107 lbf•ft) Anti-seize...
Page 148: 787 Engine
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (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...
Page 149: General
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) GENERAL The following procedures can be performed with- out removing engine from watercraft. However, battery removal will be required (except for the XP and HX). REMOVAL 587 and 717 Engines 1,2, Magneto Housing Cover and Screw Remove screws, wire support and spark plug grounding device then withdraw cover.
Page 150 Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) Engine Crankcase Replacement 587 and 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 151 Section 08 ELECTRICAL SYSTEM Sub-Section 01 (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 152: Cleaning
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) If desired, magneto rotor can be removed without CAUTION : Clean coils and magnets us- the engine flywheel. Remove the 6 screws. ing only a clean cloth. Clean crankshaft taper and threads. DISASSEMBLY 587 and 717 Engines 3,10, MAG Flywheel and Ring Gear...
Page 153: Assembly
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) – Remove screws. – BLACK wires from coil. – Uncrimp and unsolder BLACK / RED wire from — Uncrimp and unsolder ground wire (BLACK) from coil core. coil. A25E0SA A25E0QA 1. .Uncrimp and unsolder ground wire (BLACK) here 1.
Page 154: Installation
Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) 420 8769 22 F01D3BA A25E0RD 1. Teeth chamfer 1. Magneto coil centering tool (P / N 290 876 922) NOTE : Ensure that ring gear contacts MAG CAUTION : Before reinstalling the magne- flywheel flange.
Page 155 Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) 4,5, Armature Plate and Screw Position the armature plate on the crankcase, aligning the marks on both parts. Apply a drop of Loctite 242 (blue) on screw threads and torque to 6 N•m (53 lbf•in). 3,14,15, Magneto Flywheel, Woodruff Key and Nut Apply Loctite 242 (blue) on crankshaft taper.
Page 156 Section 08 ELECTRICAL SYSTEM Sub-Section 01 (MAGNETO SYSTEM) CAUTION : Never use any type of impact wrench at magneto installation. All Engines 1,2, Magneto Housing Cover and Screw Properly install O-ring in magneto housing. Apply Loctite 767 Anti-seize on screw threads, install cover, wire support and spark plug grounding de- vice (587 and 717 engines) then torque screws in a criss-cross sequence to 9 N•m (80 lbf•in).
Page 157: Ignition System
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) IGNITION SYSTEM GENERAL Ignition Coil It receives its energy from the generating coil via 587 and 717 Engines a BLACK / RED wire. The generating coil allows a The Capacitor Discharge Ignition system includes current flow through ignition coil with its integrat- the following components : ed CDI module and through primary windings.
Page 158 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 787 Engine The 787 engine has a digital DC-CDI (Direct Cur- rent-Capacitor Discharge Ignition) system. The high amperage / voltage components are located into a rear electrical box (next to the battery). The other components are located in the conventional electrical box.
Page 159: Ignition Timing Procedure
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) To check engine rev limiter, connect an induction WIRE FUNCTION tachometer (P / N 295 000 100), start engine and WH/GY Communication for DESS lanyard check its maximum speed ; it should be around 6550 ±...
Page 160 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Static Test All Engines 1. Disconnect MAG side spark plug wire and con- nect wire to grounding device then remove spark plug. 2. Remove PTO flywheel guard. 587 and 717 Engines 3. Install timing mark pointer tool on engine using wing nuts previously removed.
Page 161 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 1. Connect timing light pick-up to MAG side spark ENGINE IGNITION TIMING (BTDC) plug wire. 2.41 mm (.095 in) 2. Connect an induction-type tachometer (P / N 295 000 100) to spark plug wire. 2.59 mm (.102 in) 3.38 mm (.133 in) 7.
Page 162 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 3. Start engine and point timing light straight in Ignition Timing Adjustment line with timing tool slot. Bring engine to 6000 587 and 717 Engines RPM . Remove battery (except HX). Remove magneto housing cover and grounding device.
Page 163 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) A25E0VA F01H5VA TYPICAL 1. Retarded timing 1. Retaining screw In this case, turn armature plate counterclockwise Example 1 when facing it. When PTO flywheel mark is on right side of timing After adjustment, tighten armature plate retaining tool slot, it indicates advanced timing.
Page 164 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) The timing mark refer to the physical component – You estimate the correction should be set to position when the spark must occur. The DC-CDI 1° (advanced) to align flywheel mark. Back in module must be synchronized with the mark.
Page 165: Bombardier Ignition Tester
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 10. Press 8 to choose Save + Quit (even if item 2. Follow test procedure sequence. no. 8 is not visible on the display, it is active 3. Install cap over safety lanyard switch and crank when you select it).
Page 166: Ignition System Testing Procedure
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) SAFETY PRECAUTIONS Delay Timer Verification WARNING : To prevent powerful electric The timer is integrated into the MPEM. shocks while cranking engine, neither Always confirm first that the fuses are in good touch any electronic ignition components (ig- condition.
Page 167 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Most of circuit can be tested with an ohmmeter but a 100 % test doesn’t mean the MPEM is in perfect condition. CAUTION : Whenever connecting MPEM, always have battery disconnected from circuit.
Page 168 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 5. Measure resistance; it should be between 190- 300 ohms. F01H5XA 1. Bombardier ignition tester 2. Four-pin magneto harness adapter F01H5YA 3. Probe ‘’N’’ to RED / BLUE wire 4. Probe ‘’P’’ to BLACK wire 1.
Page 169 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) DC-CDI Module Verification + Meter Lead - Meter Lead Value STATIC TEST : CONTINUITY RE/PU < 1 Ω (male connector) + Meter Lead - Meter Lead Value RE/PU RE/PU < 1 Ω RE/PU 2.6 kΩ...
Page 170 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Ignition Coil Verification 1. Install the test adapter to spark plug cable close to MAG side spark plug. STATIC TEST 2. Connect Bombardier Ignition Tester probes NOTE : An ignition coil with good resis- then set switch and dial as follows : tance measurement can still be faulty.
Page 171: Spark Plugs
Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) 787 Engine Only The longer the heat path between the electrode tip to the plug shell, the hotter the spark plug op- As an alternate method, use KOWA ignition coil erating temperature will be – and inversely, the tester (or equivalent), available from after market shorter the heat path, the colder the operating tool / equipment suppliers.
Page 172 Section 08 ELECTRICAL SYSTEM Sub-Section 02 (IGNITION SYSTEM) Fouling Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and in- creased fuel consumption. This is due to a loss of compression.
Page 173 Section 08 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 P 5 E S 13 : 1.3 mm (.050") 14 : 1.4 mm (.055") 15 : 1.5 mm (.060") 20 : 2.0 mm (.080") Thread...
Page 174: Charging System
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL The rectifier / regulator is often the culprit of a blown fuse. To check, simply disconnect the rec- tifier / regulator from the circuit. Magneto If the fuse still burns, check for a defective wire. The purpose of the charging system is to keep the battery at a full state of charge.
Page 175 Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) NOTE : If it is continually necessary to add 2. Install the four-pin magneto harness adapter (P distilled water to the battery, this indicates / N 295 000 131). an over voltage situation, requiring replacement 3.
Page 176 Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) 3. Check resistance between two of the YELLOW wires. The resistance should be between 0.1 - 1.0 ohm. F01H60A 1. Multimeter 2. Magneto harness adapter 3. + lead to YELLOW wire 4. - lead to ground F01H5ZA 1.
Page 177: Battery
Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) BATTERY Cleaning Clean the battery casing, caps, cables and battery Troubleshooting posts using a solution of baking soda and water. CAUTION : Do not allow cleaning solution SYMPTOM : DISCHARGED OR WEAK BATTERY to enter battery.
Page 178 Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) This chart will be useful to find the correct read- During the storage period, recheck electrolyte lev- ing. el and specific gravity readings at least every month. If necessary, keep the battery at its upper level line and near full charge as possible (trickle ELECTROLYTE charge).
Page 179 Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) 3. Allow the battery to stand for 30 minutes MIN- CAUTION : If charging rate raises higher IMUM so that electrolyte soak through battery than 2.4 A reduce it immediately. If cell cells.
Page 180 Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) 10.Reinstall battery. Hook up battery cables ob- – State of charge : Because the electrolyte is serving correct polarity and coat terminals with nearly pure water in a completely discharged dielectric grease. battery, it cannot accept current as well as elec- trolyte.
Page 181 Section 08 ELECTRICAL SYSTEM Sub-Section 03 (CHARGING SYSTEM) – If the charging current is measurable before the Proceed as follows : end or at the end of about 10 hours, the battery 1. Install battery in its emplacement. is good and charging should be completed in 2.
Page 182: Starting System
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTING SYSTEM 5 N•m Dielectric (44 lbf•in) grease Loctite 271 Ground cable Dielectric grease 22 N•m (16 lbf•ft) F01H1MT PARTS 08-04-1 www.SeaDooManuals.net...
Page 183: General
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) GENERAL Solenoid NOTE : Solenoid is located in the electrical Causes of troubles are not necessarily related to box. starter but may be due to a burnt fuse, faulty bat- tery, start /stop switch, safety lanyard switch, so- Inspect connections and clean as necessary.
Page 184: Starting System Troubleshooting
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY Starter does not turn. Burnt fuse 5A. 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 185: Starter Removal
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTER REMOVAL Disconnect BLACK cable ground connection from battery. WARNING : Always disconnect ground cable first and reconnect last. Disconnect RED cable connection from battery. Remove the following parts. – cables from starter –...
Page 186: Starter Assembly
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) Check commutator for roughness, burnt or scored surface. If necessary, turn commutator on a lathe, enough to resurface only. Check commutator for mica depth. If depth is less than 0.20 mm (.008 in), undercut mica. Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed.
Page 187 Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) A03E0EA F01H0SA 1. Armature shaft 1. Locating protrusion is the higher one 2. Circlip 3. Pinion stop collar 4. Punch 1,10, Housing and Yoke Ass’y Align previously traced indexing marks. F01H0TA 1. Brush holder locating notch To ease end frame installation, retain brush holder with a small screwdriver while installing end frame.
Page 188: Starter Installation
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) 15, 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. 16,17, Screw and Teeth Washer Apply Loctite 271 (red) on screw. Connect BLACK cable to starter using flat washer, teeth washer and screw.
Page 189: Starter Specification
Section 08 ELECTRICAL SYSTEM Sub-Section 04 (STARTING SYSTEM) STARTER SPECIFICATION Nominal output 0.6 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise (viewed from pinion side) Weight Approx. 2 kg (4.4 lb) Performance Specification at 20 °C (68 °F) No load 11.5 V 20 A max.
Page 190: Instruments And Accessories
Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL It is possible to activate the fuel gauge / low oil warning light, multifunction gauge or VTS gauge when the engine is not running. Make sure the safety lanyard is removed, then de- press the start / stop button.
Page 191 Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) – Adjust potentiometer to the resistance values – Adjust potentiometer to the resistance values as per following chart to test accuracy of as per following chart to test accuracy of gauge. gauge.
Page 192 Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) The resistance measured between PINK / BLACK The bottom of the sensor has a small reservoir and PINK wires must be in accordance with fuel with two small holes underneath to let the oil en- level (measured from under the flange) as speci- ter inside and one at the top to let the air enter fied in the following charts.
Page 193 Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) NOTE : This sensor turns the low-level oil DYNAMIC TEST light to ON if the connector has been forgot- To verify speed sensor, a dynamic test can also be ten unconnected even when there is enough oil in performed using a battery and a voltmeter.
Page 194 Section 08 ELECTRICAL SYSTEM Sub-Section 05 (INSTRUMENTS AND ACCESSORIES) VTS Motor Push on VTS switch down position until motor stops. Always confirm first that the fuse is in good con- Read the resistance on the ohmmeter, it should dition. indicate a resistance of 24 ohms ± 1%. Motor condition can be checked with an ohmme- Push on VTS switch up position until motor stops.
Page 195: Digitally Encoded Security System
Section 08 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 196 Section 08 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 197 Section 08 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.
Page 198: Propulsion System
Section 09 PROPULSION SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ..........................0-01-1 ALUMINUM PUMP......................0-01-1 PLASTIC PUMP........................0-01-2 GENERAL ..........................0-01-3 JET PUMP INSPECTION ON WATERCRAFT ..............09-01-3 JET PUMP REMOVAL......................0-01-4 RIDE SHOE REMOVAL ......................0-01-7 JET PUMP SUPPORT REMOVAL..................
Page 199 Section 09 PROPULSION SYSTEM Sub-Section 00 (TABLE OF CONTENTS) VARIABLE TRIM SYSTEM ....................... 09-04-1 SPI AND HX MODELS......................09-04-1 REMOVAL ..........................09-04-2 DISASSEMBLY ........................09-04-2 ASSEMBLY AND INSTALLATION..................09-04-2 SPX AND XP MODELS ......................09-04-3 GENERAL..........................09-04-4 REMOVAL ..........................09-04-4 DISASSEMBLY ........................
Page 200: Jet Pump
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) JET PUMP ALUMINUM PUMP Loctite 598 Ultra Black Loctite 242 70 N•m 8 N•m (52 lbf•ft) (71 lbf•in) Loctite 242 10 N•m (88 lbf•in) 13 4.5 N•m Loctite (40 lbf•in) Loctite 4 N•m (35 lbf•in) Loctite Loctite...
Page 201: Plastic Pump
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) PLASTIC PUMP Loctite 598 Ultra Black Loctite 70 N•m 8 N•m (52 lbf•ft) 10 N•m (71 lbf•in) (88 lbf•in) Loctite Loctite Loctite 22 16 Loctite Loctite 4 N•m 15 N•m (35 lbf•in) (11 lbf•ft) 35 N•m (26 lbf•ft)
Page 202: General
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) GENERAL The impeller housing, venturi and nozzle are ei- ther made of aluminum or plastic, depending on which model of watercraft. Plastic is a light weight material and it is not af- fected by corrosion.
Page 203 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Oil Check Remove housing cover plug. F01J0EA F01J5IA MEASURING FROM WATER INLET SIDE TYPICAL 1. Feeler gauge 1. Remove plug Check oil level, it should be at bottom of hole threads. If oil level is low, check impeller shaft housing for leaks.
Page 204: Jet Pump Removal
Pour approximately 90 mL (3 oz) of oil through hole until oil reaches the bottom of hole threads. Use SEA-DOO JET PUMP SYNTHETIC OIL (P / N 293 600 011) only. Oil will drain slowly into center area of housing, wait a few minutes and readjust oil level.
Page 205 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) SP, GTS and GTI Models 1,2,4,5, Screw, Sleeve, Locking Disk and Nozzle Remove 2 retaining screws, 2 sleeves, 4 locking disks and withdraw nozzle. F01I0CA 1. Floating seal 2. O-ring Disconnect engine water inlet hose and both bail- er pick-up tubes from impeller housing.
Page 206: Ride Shoe Removal
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 6,7, Nut and Impeller Housing Remove nuts retaining impeller housing to hull. Using screws previously removed from nozzle, in- stall impeller housing remover tool (P / N 295 000 113) on venturi. NOTE : It may be possible to remove jet pump without using puller.
Page 207: Jet Pump Support Removal
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) JET PUMP SUPPORT REMOVAL HX Model Only Remove ball joint, boot, nut, half rings and O-rings from steering cable. F05D04A Remove nuts, lock washers and flat washers re- taining jet pump support. Using a heat gun, heat jet pump support until it is possible to pull it off.
Page 208 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 14,15, Boot and Ring Pull out ring from boot F01J0SA 1. Hold raised with drive shaft while striking F01J09A 16, Fitting 1. Pull out ring Fittings can be removed with deep socket or vise Insert a screwdriver blade between impeller and grip.
Page 209 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 17,18, Housing Cover and Screw 20, Wear Ring With pump assembly in horizontal position, re- Place impeller housing in a vise with soft jaws. It move 3 retaining screws of housing cover. is best to clamp housing using a lower ear.
Page 210 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 21, Seal Close puller claws so that they can be inserted be- tween seal and bearing. Holding claws, turn puller To remove seal, proceed as follows : shaft clockwise so that claws open and tighten CAUTION : It is not recommended to against seal.
Page 211: Cleaning
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 22, Needle Bearing CLEANING NOTE : It is always recommended to renew Sealant can be removed with a wire brush (disc) both bearings, even if only one bearing mounted on a drill or a scraper. needs to be replaced.
Page 212 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) F01J16A F02J0VA 1. Replaced if blunted round or damaged 1. Stamped part number Check impeller for cavitation damage, deep WATERCRAFT IMPELLER MATERIAL PITCH scratches or any other damage. MODEL P / N 271 000 016 Aluminium 18.8°...
Page 213 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 20, Wear Ring To check both bearings, proceed the same way with other shaft end. Position gauge tip on diam- Check wear ring for deep scratches, irregular sur- eter, close to flats on shaft. face or any apparent damage.
Page 214 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 24,25, Thrust Washer and Thrust Bearing Visually inspect thrust washer, thrust bearing and their contact surface. Check for scoring, pitting, flaking, discoloration or other evidence of wear. For best inspection, use a 7X magnifying glass to check wear pattern.
Page 215: Jet Pump Assembly
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) F01J53A 1. Impeller shaft nose F01J5DA 21, Seal 1. Seal lip 2. Press wear ring Carefully inspect seal lips. Make sure that lips are If a press is not readily available, a piece of wood not worn, distorted, cracked or show signs of any such as a 2 x 4 x 12 in long, can be used.
Page 216 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) 21,22, Seal and Needle Bearing Bearings and seal will be properly installed in housing using bearing / seal installer tool (P / N 295 000 107). F01J4KA BEARING / SEAL INSTALLER TOOL 1.
Page 217 F01J1KA vertical. 1. Raised edge of seal this side Apply Sea-Doo jet pump synthetic oil (P / N 293 CAUTION : Prevent sealant from contact- 600 011) on both sides of thrust bearing then in- ing any needles of bearing.
Page 218 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) To prevent seal lip damage when inserting impel- ler shaft, use impeller shaft guide (P / N 295 000 002). F01J1OA Insert tool onto shaft end then carefully slide housing over shaft. F01J1Q A 1.
Page 219 Place housing horizontally as in its operating posi- tion so that filler plug is located on top. Remove filler plug from cover. Pour SEA-DOO JET PUMP SYNTHETIC OIL (P / N 293 600 011) in reservoir until oil comes level with bottom of hole. Let oil...
Page 220: Pump Pressurization
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Aluminum Impeller Housing 14,15,19, Boot, Ring and Impeller Apply Loctite 242 (blue) on screw threads. Apply synthetic grease (P / N 293 550 010) on im- peller splines. Install screws and washers then torque to 25 N•m (18 lbf•ft) in a criss-cross sequence.
Page 221: Jet Pump Support Installation
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) F05J05A Installation of support is essentially the reverse of F01J2IA removal procedure. – Pump must maintain this pressure for at least RIDE SHOE INSTALLATION 10 minutes. CAUTION : Repair any leak, failure to cor- Apply Loctite 598 Ultra Black on ride shoe as rect a leak will lead to premature wear of shown in the following illustrations.
Page 222: Jet Pump Installation
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Miscellaneous Generously apply synthetic grease on drive shaft splines. Make sure rubber damper is on drive shaft ends. Apply Loctite 598 Ultra Black around bailer and water inlet supply fittings. F05J06A HX MODEL 1.
Page 223 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Apply Loctite 242 (blue) on stud threads of jet pump housing. Install flat washers, lock washers and nuts. Tight- en nuts of impeller housing in a criss-cross se- quence and torque to 35 N•m (26 lbf•ft). Push the floating ring to compress the protective hose.
Page 224 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) F01J0IA 1. Bailer tubes 2. Water inlet hose F01J3BA Secure flywheel guard to engine studs using 1 nut TYPICAL and 1 washer on each side of guard. 1. Locking disks 2. Torque to 20 N•m (15 lbf•ft) Reinstall air vent tube support onto body (SP / XP WARNING : Whenever removing screw series).
Page 225: Steering Cable
Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) Steering Cable Secure ball joint of steering cable. F02J02C TYPICAL - PLASTIC NOZZLE 1. Torque nut of steering cable ball joint to 7 N•m (62 lbf•in) F01J58A 2. Torque nut of reverse cable ball joint to 7 N•m (62 lbf•in) (if applicable) TYPICAL 1.
Page 226 Section 09 PROPULSION SYSTEM Sub-Section 01 (JET PUMP) SPI and HX Models Secure support of manual trim. F05J08B 1. Torque nut to 10 N•m (89 lbf• All Models NOTE : Ball joint must be parallel. If not, loosen jam nut and adjust ball joint. Torque jam nut to 2.5 N•m (23 lbf•in).
Page 227: Drive System
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) DRIVE SYSTEM All Models Except HX Loctite 2 N•m (18 lbf•in) 2 N•m (18 lbf•in) Synthetic grease Loctite Synthetic grease Loctite 495 F01I0ES PARTS 09-02-1 www.SeaDooManuals.net...
Page 228 Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) HX Model 22 N•m 22 N•m (16 lbf•ft) (16 lbf•ft) Loctite 242 22 N•m Loctite Loctite (16 lbf•ft) Loctite 242 22 N•m (16 lbf•ft) Loctite Synthetic grease 2 N•m Loctite (18 lbf•in) 2 N•m Loctite (18 lbf•in)
Page 229: General
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) GENERAL Jet pump must be removed to replace any com- ponents of the drive system. Refer to PROPUL- SION SYSTEM 09-01 for jet pump removal procedure. REMOVAL All Models Except the HX 1, Large Clamp Unfasten large clamp of PTO flywheel boot as fol- lows :...
Page 230 Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) 3, Drive Shaft If the drive shaft is jammed into PTO flywheel, make the following tool and use it in conjunction with impeller housing remover (P / N 295 000 113) to withdraw drive shaft. Raw Material : –...
Page 231 Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) 7, Front Drive Shaft 11, PTO Flywheel Remove bolt, lock nut and sleeve from support. Remove magneto housing cover. Refer to ELEC- TRICAL SYSTEM 08-01. All Models Except XP To remove PTO flywheel, magneto is locked with puller plate (P / N 290 876 080), sleeves (P / N 290 847 220) and extension handle (P / N 295 000 111).
Page 232 Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) Lock ring gear using special tool (P / N 295 000 134). F01D49A TYPICAL 1. Extension handle locking crankshaft As an alternate method to remove PTO flywheel when splines are worn out and PTO flywheel re- 1.
Page 233: Disassembly
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) HX Model Only PTO flywheel is loosen using flywheel remover. F01J11A A. 22 mm (.865 in) dia. B. 28 mm (1.115 in) dia. C. 90 mm (3-1/2 in) D. 345 mm (13-1/2 in) Properly support seal carrier when removing seals F05I0CA and bearing.
Page 234: Assembly
Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) Place drive shaft on V-blocks and set-up a dial 6, O-ring gauge in center of shaft. Slowly rotate shaft ; dif- Check also condition of drive shaft O-ring. Re- ference between highest and lowest dial gauge place as necessary.
Page 235 Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) NOTE : Bearing can also be installed with Push seals until tool comes in contact with hous- the same driver used at disassembly. Cen- ing. ter bearing in longitudinal axis of housing. F01J2TA F01J1YA 1.
Page 236 Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) Install alignment tool at rear of watercraft. Torque seal carrier nuts to 10 N•m (89 lbf•in) in a criss-cross sequence as per following illustration. NOTE : It is very important to tighten nuts of seal carrier in a criss-cross sequence to maintain its alignment.
Page 237 Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) F01J23A PRE-CLAMPING POSITION F02J0IA 1. Holding hook 2. Large window 1. Press to engage hooks in windows – Insert pointed tips of pliers first in closing NOTE : At installation, clamp tail should be hooks.
Page 238 Section 09 PROLPUSION SYSTEM Sub-Section 02 (DRIVE SYSTEM) F02J0PB 1. Squeeze plier 09-02-12 www.SeaDooManuals.net...
Page 239: Reverse System
Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) REVERSE SYSTEM GTS and GTI Models 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...
Page 240: General
Section 09 PROPULSION SYSTEM Sub-Section 03 (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 basket from watercraft. Press on vent tube upper part to enable to with- draw tube from body.
Page 241: Assembly
Section 09 PROPULSION SYSTEM Sub-Section 03 (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 242 Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) CAUTION : Always hook reverse gate Install sliding block to lever and torque nut to 8 springs in order to ease reverse gate oper- N•m (71 lbf•in). ation. 1,5, Locking Lever and Sliding Block Insert locking lever end in support hole then align lever and sliding block holes.
Page 243: Adjustments
Section 09 PROPULSION SYSTEM Sub-Section 03 (REVERSE SYSTEM) 2, Spring Using a square, set it to 129 ± 3 mm (5-5/64 ± 7/ 64 in), then position square end at the top middle Insert spring in lever stem hole and then install of nozzle.
Page 244 Section 09 PROPULSION SYSTEM Sub-Section 03 (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 245: Variable Trim System
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM SPI and HX Models 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...
Page 246: Removal
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) REMOVAL 1,2,3, Screw, Bolt and Lock Nut Loosen venturi screw, bolt and nut retaining sup- port from trim ring. F05J08A 1. Screw 2. Bolt 3. Lock nut Remove manual trim. 4,5, Trim Ring and Screws To remove trim ring / nozzle assembly from ven- turi, loosen side screws of trim ring.
Page 247: Spx And Xp Models
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) SPX and XP Models 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...
Page 248: General
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) GENERAL 8, Motor Disconnect wires of motor. To test VTS control module, motor or switch, refer to ELECTRICAL SYSTEM 08-05. Remove retaining nuts. REMOVAL 1,2,3, Ball Joint, Boot and Gear Clamp Disconnect ball joint of link rod.
Page 249: Assembly
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) 9, Worm Inspect threads and splines of worm for wear. If worm replacement is necessary, renew also slid- ing shaft. F01J2GA Tighten nuts of motor to 7 N•m (62 Ibf•in). Connect wires of motor. CAUTION : Make sure wire color codes F01J25A match.
Page 250: Adjustment
Section 09 PROPULSION SYSTEM Sub-Section 04 (VARIABLE TRIM SYSTEM) 1, Ball Joint If an adjustment is necessary, loosen jam nut of ball joint at link rod. Turn adjustment nut of ball Install ball joint on right side of sliding shaft. joint to obtain the desired gap between trim ring Torque fasteners to 10 N•m (88 lbf•in).
Page 251: Steering System
Section 10 STEERING SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS SPÞ/ÞXP SERIES ........................10-01-1 REMOVAL AND ASSEMBLY ....................10-01-2 GTS AND GTI MODELS ......................10-02-1 REMOVAL AND ASSEMBLY ....................10-02-2 HX MODEL..........................10-03-1 REMOVAL ..........................10-03-2 DISASSEMBLY........................10-03-3 STEERING CABLE REMOVAL .....................
Page 252 Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) SP /XP SERIES Two types of assembly 14 N•m (10 lbf•ft) 6 N•m 26 N•m (53 lbf•in) (19 lbf•ft) Loctite 8 N•m (72 lbf•in) 15 N•m (11 lbf•ft) Loctite 15 N•m (11 lbf•ft) Synthetic grease...
Page 253: Removal And Assembly
Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) REMOVAL AND ASSEMBLY 1,2,3, Cover, Screw and Washer To replace the cover, just remove and reinstall 4 screws and washers. F01K1PA 1. Grip insert 2. Grip 3. Flat washer 4. Torque bolt to 14 N•m (10 lbf•ft) 5.
Page 254 Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) CAUTION : While performing this proce- dure, take precautions to avoid damaging throttle cable and wiring harnesses. To install handlebar assembly: Installation is essentially the reverse of removal procedures. However, pay particular attention to the following.
Page 255 Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) 9,10,11,12, Steering Stem, Arm, Support and Handlebar Install support to steering stem arm. NOTE : Insert lock nuts in support. Screw only a few threads of the bolts. F01K0AA 1. Install handlebar assembly 2.
Page 256 Section 10 STEERING SYSTEM Sub-Section 01 (SP /XP SERIES) F01K1NA 1. Steering stem 2. Steering stem arm 3. Support 4. Torque to 6þN•m (53þlbf•in) 5. Integrated flat key must be seated in keyway and steering stem arm locked in place NOTE : Once steering stem arm is properly tightened, look between body and front sup- port to make sure there is no gap between steer-...
Page 257: Gts And Gti Models
Section 10 STEERING SYSTEM Sub-Section 02 (GTS AND GTI MODELS) GTS AND GTI MODELS 3.5 N•m Loctite (30 lbf•in) 26 N•m (19 lbf•ft) 6 N•m (53 lbf•in) Anti-seize 3.5 N•m lubricant 15 N•m (30 lbf•in) (11 lbf•ft) Loctite 15 N•m (11 lbf•ft) 15 N•m Loctite 242...
Page 258: Removal And Assembly
Section 10 STEERING SYSTEM Sub-Section 02 (GTS AND GTI MODELS) REMOVAL AND ASSEMBLY Install grip on handlebar matching it to the U form of the handlebar. 1,2,3, Cover, Screw and Washer Apply Loctite 242 (blue) on bolt threads. To replace the cover, just remove and reinstall 4 Install flat washer and bolt;...
Page 259 Section 10 STEERING SYSTEM Sub-Section 02 (GTS AND GTI MODELS) TO INSTALL HANDLEBAR ASSEMBLY : 14, Grommet Insert throttle cable through dashboard hole and slide grommet on cable. Insert grommet in dashboard hole and pull it from inside bilge. NOTE : To ease installation, apply water on grommet.
Page 260 Section 10 STEERING SYSTEM Sub-Section 02 (GTS AND GTI MODELS) 24,25,26,27, Nut, Half Ring, Rubber Washer and Retaining Ring From bilge, unscrew nut retaining steering cable to hull. Remove half rings, rubber washer and retaining ring. NOTE : Move selector lever in reverse posi- tion to lower reverse gate.
Page 261: Hx Model
Section 10 STEERING SYSTEM Sub-Section 03 (HX MODEL) HX MODEL 6 N•m (53 lbf•in) 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) Synthetic grease 6 N•m (53 lbf•in) Synthetic grease...
Page 262: Removal
Section 10 STEERING SYSTEM Sub-Section 03 (HX MODEL) REMOVAL 11, Retaining Block Remove retaining block of cable support. 1,2,3, Cover, Screw and Washer To remove the cover, just remove 4 screws and washers. F01K0WA 1. Screw 2. Thermoplastic cover 4,5,6,7,8, Grip, Cap, Bolt, Washer and Grip Insert To remove grip, pull out cap from grip end and re- move bolt.
Page 263: Disassembly
Section 10 STEERING SYSTEM Sub-Section 03 (HX MODEL) F05L0FA F05K06A 1. Boot 1. Steering stem arm 12,13,14, Steering Support, Bolts and 12,18,19, Steering Support, Steering Nuts Stem and Cable Support Loosen bolts and nuts of steering support. Pull out steering stem from steering support. Remove lever from cable support.
Page 264: Steering Alignment
Section 10 STEERING SYSTEM Sub-Section 03 (HX MODEL) WARNING : Make sure integrated flat keys of steering stem arm and support are properly seated in steering stem keyways. F01K1RA 1. Notch inserted in handlebar hole Install grip on handlebar matching it to the U form of the handlebar.
Page 265: Alignment
Section 10 STEERING SYSTEM Sub-Section 04 (ALIGNMENT) ALIGNMENT Position handlebar in straight ahead position by If necessary, steering alignment adjustment measuring each side the distance from handlebar should be performed at steering cable support grip end to floorboard. near steering stem. Slacken retaining block at cable support.
Page 266 Section 00 STEERING SYSTEM Sub-Section 04 (ALIGNMENT) GTS / GTI Models F03K03A 1. Retaining block 2. Adjustment nut 3. Bolts All Models After adjustment, torque retaining block bolts to 6 N•m (53 Ibf•in). CAUTION : Verify when the handlebar is turned completely to the left or right side, that there is no interference with venturi hous- ing.
Page 267: Suspension
Section 11 SUSPENSION Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS DIRECT ACTION SUSPENSION ......................11-01-1 HX MODEL ............................11-01-1 COIL OVER SHOCK REMOVAL ......................11-01-2 OUTER BOOT REMOVAL ........................11-01-3 COIL OVER SHOCK DISASSEMBLY....................11-01-3 ASSEMBLY ............................11-01-3 11-00-1 www.SeaDooManuals.net...
Page 268: Direct Action Suspension
Section 11 SUSPENSION Sub-Section 01 (DIRECT ACTION SUSPENSION) DIRECT ACTION SUSPENSION HX Model 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) F05L0GS...
Page 269: Coil Over Shock Removal
Section 11 SUSPENSION Sub-Section 01 (DIRECT ACTION SUSPENSION) COIL OVER SHOCK REMOVAL Remove bottom cover of seat with grab handle. F05L0JA 1. Collar 5,6 Bolt and Lock Nut F05L0HA 1. Grab handle Remove bolt and lock nut from shock absorber 2.
Page 270: Section 11 Suspension
Section 11 SUSPENSION Sub-Section 01 (DIRECT ACTION SUSPENSION) 3,7, Inner Boot and Collar COIL OVER SHOCK DISASSEMBLY Loosen upper collar of coil over shock inner boot ; then, remove boot. Remove boot. Install spring compressor tool (P / N 529 027 100) in a vise.
Page 271: Hull / Body
Section 12 HULL / BODY Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS ADJUSTMENT AND REPAIR........................12-01-1 SP / XP SERIES ............................ 12-01-1 GTS / GTI MODELS ..........................12-01-3 HX MODEL ............................12-01-5 SEAT ADJUSTMENT..........................12-01-9 STORAGE COMPARTMENT COVER ADJUSTMENT ................12-01-10 ACCESS PANEL ADJUSTMENT ......................
Page 272: Adjustment And Repair
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR SP / XP Series 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) 10 Sealant Loctite Loctite 271 Sealant 732...
Page 273 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) Loctite 242 6 N•m (53 lbf•in) 15 N•m (11 lbf•ft) Sealant 732 Loctite SPX / XP models Loctite 271 Sealant Sealant 732 1.5 N•m (13 lbf•in) F01L6IS PARTS 12-01-2 www.SeaDooManuals.net...
Page 274 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) GTS / GTI Models Loctite 271 Loctite 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...
Page 275 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) 7 N•m (62 lbf•in) Loctite 242 15 N•m (11 lbf•ft) Loctite Sealant 1.5 N•m (13 lbf•in) Sealant F02L27S PARTS 12-01-4 www.SeaDooManuals.net...
Page 276 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) HX Model Loctite 271 Body Body 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) Loctite 271 Body 15 N•m (11 lbf•ft) 1.5 N•m (13 lbf•in) Sealant F05L0PS PARTS 12-01-5 www.SeaDooManuals.net...
Page 277 Section 12 HULL / BODY Sub-Section 01 (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 12-01-6 www.SeaDooManuals.net...
Page 278 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) 1.2 N•m 5 N•m Loctite (11 lbf•in) (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•ft) F05L0RS...
Page 279 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) Loctite 6 N•m (53 lbf•po) 6 N•m (53 lbf•po) 15 N•m (11 lbf•pi) F05L0SS PARTS 12-01-8 www.SeaDooManuals.net...
Page 280: Seat Adjustment
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) SEAT ADJUSTMENT 2, Lock Pin Adjust lock pin of seat as per following specifica- All Models Except HX tions. 1, Front Hook Adjust front hook as per following specifications : F02L25C SP / XP SERIES 1.
Page 281: Storage Compartment Cover Adjustment
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) STORAGE COMPARTMENT ACCESS PANEL ADJUSTMENT COVER HX Model Only ADJUSTMENT 3, Lock Pin All Models Except HX Adjust lock pin of access panel as per following 3, Lock Pin specifications. Adjust lock pin of storage compartment cover as per following specifications.
Page 282: Drain Plug Installation
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) DRAIN PLUG INSTALLATION Loosen collar of coil over shock outer bootþ; then, pull outer boot downward. 14, Drain Plug Refer to the following illustration for drain plug in- stallation. F05L0IA 1.
Page 283: Seat Cover Replacement
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) Remove bolt and lock nut from shock absorber upper support. F05L0MA 1. Bolt 2. Lock nut Tilt seat. F01L3YA Loosen side screws retaining seat frame to pivot TYPICAL blocks. 1. Piece of wood 2.
Page 284: Sponson Replacement
Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) 4. Slide bumper rail under front bumper. Reinstall muffler. Tighten hose clamps to 4 N•m (35 lbf•in). 5. Using a 4.80 mm (3/16 in) drill bit, drill first hole through bumper rail at front of bow section. Reinstall air vent tube support (SP / XP series).
Page 285: Hull And Body Repair
BOTH SIDES catalyst which is sprayed into the mold. These decals usually contain graphics and are The body and hull of the Sea-Doo are constructed used on gelcoat or plastic. of chopped fiberglass, saturated with resin. It is sprayed on the layer of gelcoat along with pieces...
Page 286 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) WARNING : Protect skin, wear gloves BUFFING AND WAXING when in contact with resin, hardeners and Buff the surface using a heavy duty polisher with gelcoat. A barrier skin cream may also be used. a buffing pad.
Page 287 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) FILLING THE REPAIR AREA Compound fractures are those that have gone past the gelcoated surface and in through the lay- Small Fractures : ers of fiberglass laminate. Two types of repairs Refer to the same procedure as in the air bubbles.
Page 288: Hull Insert Repair
– safety glasses – air mask – white cloths – sanding block – putty knife – plastic film – stirring stick – cover sheets (for Sea-Doo) – scissors – buffing pad F01L2UA – heavy-duty polisher 1. Hull 2. Plastic hull insert –...
Page 289 Section 12 HULL / BODY Sub-Section 01 (ADJUSTMENT AND REPAIR) CAUTION : If you notice any clearance be- tween plastic insert and aluminum insert, fill gap with epoxy glue to obtain good adhe- sion of aluminum insert. F01L2VA 1. Knurled surface 2.
Page 290: Painting
82-51-624-8221 82-2-792-2477 PPG paint for Sea-Doo watercraft is not available in spray can. For best result it must be applied by a professional painter. For fast touch up on metallic and gelcoat surfaces, refer to the appropriate Bombardier Sea-Doo Parts Catalog to find the available products.
Page 291: Parts That Can Be Painted
Section 12 HULL/BODY Sub-Section 02 (PAINTING) PARTS THAT CAN BE PAINTED F02B03S 1. Body 10. Magneto Housing Cover 2. Hull 11. Flame Arrester Base 3. Storage Cover (if applicable) 12. Ride Shoe 4. Engine 13. Impeller Housing* 5. Tuned Pipe 14.
Page 292 Section 12 HULL/BODY Sub-Section 02 (PAINTING) SEA-DOO MODELS PPG COLOR CHART Body COLOR White White Yellow White White White PPG no. 98260 98260 M506 98260 98260 98260 Hull Marine COLOR White Yellow Yellow White White green PPG no. 98260 M506...
Page 293: Concepttm Painting Procedure
Section 12 HULL/BODY Sub-Section 02 (PAINTING) CONCEPT PAINTING PROCEDURE For additional information refer to PPG P-Bulletin no. 168. SURFACE PREPARATION FULL PANEL AND OVERALL REPAIRS Prepare and clean surface consistent with good Application painting practices. Apply 1 medium wet coat and give 5-10 minutes Primer flash, followed by 2 wet coats with 15 minutes flash time between each coat.
Page 294: Deltatm Painting Procedure
Section 12 HULL/BODY Sub-Section 02 (PAINTING) DELTA PAINTING PROCEDURE (with low VOC, mainly in California) For additional information refer to PPG P-Bulletin no. 157. SURFACE PREPARATION Primerþ: DELTA PRIME DPU 166. DELTA 2800, COLOR How to Mix Mix DELTA 2800 2:1, 2 parts Colors to 1 DU 6 Catalyst. Application Apply 2 coats of DELTA Polyurethane Color.
Page 295: Technical Data
Section 13 TECHNICAL DATA Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS SP AND SPI MODELS ......................13-01-1 SPX AND XP MODELS......................13-02-1 GTS AND GTI MODELS ......................13-03-1 HX MODEL..........................13-04-1 13-00-1 www.SeaDooManuals.net...
Page 296: Sp And Spi Models
Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) SP AND SPI MODELS ENGINE SP (5876) SPI (5878) Engine type Bombardier-Rotax 587 Induction type Rotary valve Exhaust system Type Water cooled, water injected Water injection fitting 4.6 mm (.181 in) Starting system Electric start Lubrication...
Page 297 Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) ELECTRICAL SP (5876) SPI ( 5878) Magneto generator output 160 W @ 6000 RPM or 4.0 A @ 2000 RPM Ignition system type Spark plug Make and type NGK BR7ES 0.5þ-þ0.6 mm (.020þ-þ.024 in) Ignition timing mm (in)
Page 298 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° Trim nozzle pivoting angle Not applicable Minimum required water level 90 cm...
Page 299 Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) MATERIALS SP (5876) SPI (5878) Hull Composite 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 Seat Polyurethane foam...
Page 300 Section 13 TECHNICAL DATA Sub-Section 01 (SP AND SPI MODELS) TIGHTENING TORQUES SP (5876) SPI (5878) 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 301: Spx And Xp Models
Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) SPX AND XP MODELS ENGINE SPX (5877) XP (5858 / 5859) Engine type Bombardier-Rotax 717 Bombardier-Rotax 787 Induction type Rotary valve Exhaust system Water cooled, water injected Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm...
Page 302 Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) ELECTRICAL SPX (5877) XP (5858 / 5859) Magneto generator output 160 W @ 6000 RPM 180 W @ 6000 RPM or 4.0 A @ 2000 RPM or 5.0 A @ 2000 RPM Ignition system type DC-CDI Spark plug...
Page 303 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° Trim nozzle pivoting angle ± 8° Minimum required water level 90 cm...
Page 304 Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) MATERIALS SPX (5877) XP (5858 / 5859) Hull Composite Inlet grate Plastic Impeller housing / venturi / nozzle Plastic / Plastic / Aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding...
Page 305 Section 13 TECHNICAL DATA Sub-Section 02 (SPX AND XP MODELS) TIGHTENING TORQUES SPX (5877) XP (5858 / 5859) 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...
Page 306: Gts And Gti Models
Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) GTS AND GTI MODELS ENGINE GTS (5817) GTI (5865 / 5866) Engine type Bombardier-Rotax 587 Bombardier-Rotax 717 Induction type Rotary valve Exhaust system Type Water cooled, water injected Water injection fitting (head) 4.6 mm (.181 in) 3.5 mm (.139 in) Water injection fitting (cone)
Page 307 Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) ELECTRICAL GTS (5817) GTI ( 5865 / 5866) Magneto generator output 160 W @ 6000 RPM or 4.0 A @ 2000 RPM Ignition system type Spark plug Make and type NGK BR7ES NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in)
Page 308 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° Trim nozzle pivoting angle Not applicable Minimum required water level 90 cm...
Page 309 Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) MATERIALS GTS (5817) GTI (5865 / 5866) Hull Composite Inlet grate 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...
Page 310 Section 13 TECHNICAL DATA Sub-Section 03 (GTS AND GTI MODELS) GTS (5817) GTI (5865 / 5866) TIGHTENING TORQUES 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)
Page 311: Hx Model
Section 13 TECHNICAL DATA Sub-Section 04 (HX MODEL) HX MODEL ENGINE HX (5881) 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...
Page 312 Section 13 TECHNICAL DATA Sub-Section 04 (HX MODEL) ELECTRICAL HX ( 5881) Magneto generator output 160 W @ 6000 RPM or 4.0 A @ 2000 RPM Ignition system type Spark plug Make and type NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) Ignition timing mm (in) 2.59 (.102)
Page 313 Counterclockwise Transmission Direct drive / split FR and RR Coupling type Driving claw with rubber cushion Oil type SEA-DOO JET PUMP SYNTHETIC POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 26ø Trim nozzle pivoting angle ñ10ø Minimum required water level...
Page 314 Section 13 TECHNICAL DATA Sub-Section 00 (TABLE OF CONTENTS) MATERIALS HX (5881) Hull Composite Inlet grate Aluminum Impeller housing 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 315 Section 13 TECHNICAL DATA Sub-Section 04 (HX MODEL) TIGHTENING TORQUES HX (5881) 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) 24 N•m (17 lbf•ft) (3) (4) Crankcase screws 40 N•m (30 lbf•ft) (3) (4)
Page 316 www.SeaDooManuals.net...

Sea-doo SP 5876 Shop Manual

Table of Contents

Section

Safety Notice

Introduction

And Products

Maintenance

Table of Contents

Removal and Installation

Top End

Bottom End

Rotary Valve

Exhaust System

Cooling System

Fuel System

Fuel Circuit

Air Intake

Carburetors

Table of Contents

07

Oil Injection System

Oil Injection Pump

Electrical System

Magneto System

Ignition System

Charging System

Starting System

Instruments and Accessories

Digitally Encoded Security System

Propulsion System

09

Jet Pump

Aluminum Pump

Plastic Pump

Gts and Gti Models

Reverse System

Spi and Hx Models

Variable Trim System

Spx and Xp Models

Steering System

GTS and GTI Models

HX Model

Alignment

Suspension

Hull / Body

Adjustment and Repair

General

Painting

Parts that Can be Painted

Concepttm Painting Procedure

Deltatm Painting Procedure

Technical Data

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Sea-doo SP 5876

Summary of Contents for Sea-doo SP 5876