Sea-doo 2004 3D RFI Operation Manual
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Sea-doo 2004 3D RFI Operation Manual

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  • Page 1 www.SeaDooManuals.net...
  • Page 2 ® BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil O.P.A.S. BOMBARDIER Formula XP-S DI Synthetic Injection Oil Rotax 4–TEC Sea-Doo Synthetic Grease ® DESS Sea-Doo O.T.A.S. Printed in Canada. (smo2004-004 en SH) ®™Trademarks of Bombardier Recreational Products Inc. or its affiliates. ©2004 Bombardier Recreational Products Inc. All rights reserved.
  • Page 3 Furthermore, in the marine industry, the WARRANTY section in this guide, FRONT is referred to BOW and REAR and/or an authorized Sea-Doo dealer. as STERN. In USA, products are distributed by Bombardier Motor Corporation of America.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION INTRODUCTION ..............8 SAFETY CHECK LIST..
  • Page 5 16) Flushing Connector............37 17) Bilge Drain Plugs ............38 18) Jet Pump Nozzle..
  • Page 6 POST-OPERATION CARE............63 General Care ..............63 Additional Care for Foul Water or Salt Water ..
  • Page 7 ® BRP NORTH AMERICA LIMITED WARRANTY: 2004 SEA-DOO PERSONAL WATERCRAFT ............105 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT FOR ®...

  • Page 8: Safety Information

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

  • Page 9: Introduction

    Congratulations, you are now the This safety section is for initial refer- ence and its content is therefore lim- proud owner of a Sea-Doo personal watercraft. You have selected one of ited. section It should be read in con- the most popular craft on water. Your junction with the rest of this Opera- tor’s Guide, the safety videocassette...

  • Page 10: Safety Check List

    SAFETY CHECK LIST To fully appreciate the pleasures, en- A PWC will not self-right if capsized. joyment and excitement of boating The operator must know the proper there are some basic rules that should righting procedure as explained in the be observed and followed by any Operator’s Guide.

  • Page 11: Getting Underway

    GETTING UNDERWAY To Wear The operator must wear a Coast Guard approved Personal Flotation Device (PFD) that is suitable for PWC use. An operator should have ready access to shatterproof glasses should riding conditions or personal preference war- rant. Wind, water spray and speed may cause a person’s eyes to water and create blurred vision.
  • Page 12 ____________ ___________ SAFETY INFORMATION www.SeaDooManuals.net...

  • Page 13: Helmets

    “bucket”, and put severe authorized Sea-Doo dealer. Such re- stresses on the neck or spine. This quired safety items usually include, could result in choking, severe or per- without limitation, a sound signaling manent neck or spine injury, or death.

  • Page 14: To Do

    To Do Read and understand all warning/cau- tion labels on your Sea-Doo PWC, your Operator’s Guide, all other safety documents, and watch properly your safety videocassette, before operat- ing. Always keep in mind that the “ “ symbol, the Warning symbol,...

  • Page 15: Operation

    OPERATION Collision Avoidance Ride within your limits and level of riding ability. Avoid aggressive ma- Do not release throttle when trying to neuvers to reduce the risk of loss of steer away from objects. You need control, ejection and collision. Under- throttle to steer.

  • Page 16: Maneuverability Of The Watercraft

    Maneuverability of the In shallow water, proceed with caution and at very low speeds. Grounding Watercraft or abrupt stops may result in injury. Do not overload the watercraft or take Debris may also be picked up and be on a passenger. Overloading can af- thrown rearward by the jet pump onto fect maneuverability, stability and per- people or property.

  • Page 17: Operating Rules

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

  • Page 18: Web Sites

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

  • Page 20: Location Of The Important Labels

    LOCATION OF THE IMPORTANT LABELS The following labels are on your watercraft. If missing or damaged, they can be replaced free of charge. See an authorized Sea-Doo dealer. Please read the following labels carefully before operating this watercraft. “MOTO“ CONFIGURATION...
  • Page 21 KART SEAT CONFIGURATION (IF SO EQUIPPED) Label 1 To reduce the risk of SEVERE INJURY or DEATH: WEAR A PERSONAL FLOTATION DEVICE (PFD). All riders must wear a Coast Guard approved PFD that is suitable for personal watercraft (PWC) use. WEAR PROTECTIVE CLOTHING.
  • Page 22 Label 2 Label 4 Label 3 Label 5 Label 6 ____________ ___________ SAFETY INFORMATION www.SeaDooManuals.net...
  • Page 23 Label 7 Label 8 Label 10 WARNING / AVERTISSEMENT :$51,1* PRESSURIZED FUEL To avoid loss of control or ejection: Do not unscrew protective cap. Must be used only ALWAYS INSERT KNUCKLE FULLY INTO SOCKET AND LOCK-IN by Bombardier certified technician. Do not operate the watercraft without cap properly installed.
  • Page 24 Label 12 Label 13 Label 14 ____________ ___________ SAFETY INFORMATION www.SeaDooManuals.net...

  • Page 25: Vehicle Information

    VEHICLE INFORMATION _____________________ www.SeaDooManuals.net...

  • Page 26: Registration Number Location

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

  • Page 27: Identification Numbers

    IDENTIFICATION NUMBERS Engine The main components of the water- craft (engine and hull) are identified The Engine Identification Number by different serial numbers. It may (E.I.N.) is located on the upper sometimes become necessary to lo- crankcase on PTO (Power Take-Off) cate these numbers for warranty pur- side.

  • Page 28: Controls/Instruments/Equipments

    CONTROLS/INSTRUMENTS/EQUIPMENTS NOTE: Some components do not apply or are optional on some models. “VERT” CONFIGURATION ______________________ www.SeaDooManuals.net...
  • Page 29 “MOTO” CONFIGURATION KART CONFIGURATION (IF SO EQUIPPED) 1. Safety Lanyard (engine cut-off cord) 18. Jet Pump Nozzle 2. Handlebar 19. VTS Adjuster 3. Handlebar Adjuster 20. Jet Pump Water Intake 4. Throttle Lever 21. Fuses 5. Engine Start/Stop Button 22. Battery 6.

  • Page 30: Controls/Instruments/Equipments Functions

    CONTROLS/INSTRUMENTS/EQUIPMENTS FUNCTIONS 1) Safety Lanyard (engine cut-off cord) The safety lanyard cap should be se- curely snapped onto its post to be fully operational. 1. Safety lanyard cap on the post 2. Safety lanyard secured on operator's PFD 1. Safety lanyard on its post Pulling the safety lanyard cap from its post stops the engine operation.

  • Page 31: Handlebar

    WARNING your watercraft. Prior to using the watercraft: To have additional safety lanyard, refer - Ensure handlebar is properly ad- to an authorized Sea-Doo dealer. justed and locked. - Locate and practice using start/ 2) Handlebar stop button. The handlebar controls the direction of the watercraft.

  • Page 32: Throttle Lever

    1. Throttle lever O.T.A.S. System (Off-Throttle Assisted Steering) The O.T.A.S. (Off-Throttle Assisted Steering) system provides additional maneuverability in off-throttle situa- tions. The O.T.A.S. system is elec- tronically activated and slightly in- A. Rearward position creases engine speed under a pre-pro- B.

  • Page 33: Indicator Light Cluster

    The warning light will turn on when- ever there is a problem with the en- gine management system. It will blink when there is a problem with the O.T.A.S. system or the electric bilge pump. NOTE: When engine is not running 1.

  • Page 34: Fuel Tank Cap

    Ensure to adjust handlebar to the de- First, stop the engine then raise and sired position before use. Refer to stabilize the steering pole at its highest HANDLEBAR ADJUSTER. position. Pull the latch lever upward to unlock 8) Fuel Tank Cap the engine cover.
  • Page 35 1. Holder end here 1. Insert holder here Ensure fire extinguisher is properly po- WARNING sitioned in its location prior to rein- stalling engine cover. Components inside engine com- When reinstalling engine cover, prop- partment may be hot. When start- erly insert engine cover tab into ing or operating the engine, do not C-hook of body.

  • Page 36: Oil Injection Reservoir Cap

    10) Oil Injection Reservoir Remove engine cover to expose oil reservoir cap. Lock steering pole with the holder. WARNING Always install steering pole holder immediately after engine cover re- moval to support the pole securely while working in the engine com- partment.

  • Page 37: Air Intake Opening

    POST-OPERA- TION CARE and look for COOLING SYSTEM FLUSHING or refer to an authorized Sea-Doo dealer for ser- vicing. 16) Flushing Connector A convenient connector is provided to allow easy installation of a garden 1.

  • Page 38: Bilge Drain Plugs

    18) Jet Pump Nozzle Jet pump nozzle turns side to side via rider input at the handlebar. This pro- vides directional control when engine is running. 1. Flushing connector Refer to POST-OPERATION CARE section for proper use. 17) Bilge Drain Plugs Should water be found in the bilge, it can be easily drained by unscrewing 1.

  • Page 39: Jet Pump Water Intake

    21) Fuses The fuses are located in the engine compartment. Refer to MAINTE- NANCE for more details. 22) Battery The battery is located in the engine compartment. Refer to SPECIAL PROCEDURES. F05J02Y 23) Rear Access Cover 1. Trim knob 2. Reference numbers NOTE: If the “moto“...

  • Page 40: Moto" Seat Release Button

    When safety lanyard cap is installed on its post, the bilge pump is automati- cally turned on. It will remain on until all water is evacuated,then it will shut down automatically. When engine is running, the bilge pump will automatically start periodi- cally to evacuate water.
  • Page 41 CAUTION: Ensure to maintain the seat high enough so as to have room to pull the seat post out with- out touching the body. Pull the red locking lever rearward and pull the post out of the seat. 1. Post vertical 2.
  • Page 42 1. Slide seat rearward 1. Hold steering pole 2. Firmly push seat down Push the seat forward so that the seat Ensure the seat is properly locked by post becomes vertical. Lift the seat to pulling up on it. release the post from its receiver. WARNING To avoid loss of control, always ensure that the seat is properly...

  • Page 43: Moto" Seat Post Receiver

    26) “Moto” Seat Post Receiver The receiver locks the seat post into position on the deck. For instructions, refer to “MOTO” SEAT INSTALLA- TION/STOWAGE above. Firmly push the post in the seat until you hear a “clunk“. CAUTION: Make sure to maintain the seat high enough so that the post clears the body when rotated 1.
  • Page 44 If you cannot rest your feet com- fortably on the footr ests, install the footrest spacers (refer to your autho- rized Sea-Doo dealer for more infor- mation). This will help achieve a more stable riding position. ______________________ www.SeaDooManuals.net...

  • Page 45: Steering Pole Retainer (If So Equipped)

    Continue lowering the steering pole down until the retainer can be inserted into the body hook. Then, push re- tainer to lock in position. 1. Lever 2. Push and hold 3. Lift seat CAUTION: To prevent permanent 1. Position retainer in body hook deformation of the foam shape, al- 2.

  • Page 46: Liquids

    Fuel tank may be pressurized, turn Use only two-stroke engine injection cap slowly when opening. Never oil sold by authorized Sea-Doo dealers. use an open flame to check fuel level. When fueling, keep water- craft level. Do not overfill or top off the fuel tank and leave water- craft in the sun.

  • Page 47: Oil Injection System

    Immedi- brication, engine cleanliness and mini- ately refer to an authorized Sea-Doo mum spark plug fouling. dealer to have the oil injection sys- The BOMBARDIER Formula XP-S II tem inspected.

  • Page 48: Break-In Period

    CAUTION: Scrupulously follow the instructions of this section. Failure to do so may reduce the engine’s life and/or performance. With Sea-Doo watercraft powered by Rotax ® engines, a break-in period of 10 hours is required before continuous operation at full throttle.

  • Page 49: Pre-Operation Checks

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

  • Page 50: Hull

    NOTE: Pay attention that some water sary. If any obstruction can not be re- will also flow out of exhaust outlet. moved, refer to an authorized Sea-Doo Make sure water is effectively flowing dealer for servicing. out of jet pump.

  • Page 51: Battery

    Battery Steering Pole Check steering pole up and down WARNING movement for free and smooth op- eration. Pay attention to the weight Verify tightness of battery cables to feeling of the pole. It can be ad- their posts and condition of battery justed.

  • Page 52: Optional Configurations

    Optional Configurations Refer to CONTROLS/INSTRUMENTS/ EQUIPMENTS. WARNING To make sure you are in a riding position that allows you to be in control of the craft, always check that any optional seat or accessory that you are using are properly latched and stable before turning on the watercraft engine.

  • Page 53: Operating Instructions

    Become thor- oughly familiar with all controls and the function of each. Should any control or instruction not be fully understood, refer to an au- thorized Sea-Doo dealer. This watercraft is designed for one person only. WARNING WARNING - Never allow a passenger on- board.
  • Page 54 When first using the watercraft, the Steering operator should become familiar with the use of the variable trim system (VTS) at varying speeds and water con- ditions. A mid-range trim is generally used when cruising. Experience alone will dictate the best trim for the condi- tions.
  • Page 55 WARNING Throttle should be applied and handlebar turned to change the direction of the watercraft. Steer- ing efficiency will differ depending on load, water conditions and en- vironmental factors such as the wind. Unlike a car, a watercraft needs some throttle to turn.

  • Page 56: Boarding The Watercraft

    We recommend that you familiarize yourself with this feature during your first ride. Boarding the Watercraft General As with any watercraft, boarding should be done carefully and engine should not be running. WARNING Engine should be OFF when boarding the watercraft. Keep limbs away from jet or intake NOTE:...
  • Page 57 CAUTION: Starting the engine or operating the watercraft in shallow water can draw sand, pebbles, or rocks through the jet pump, which might damage the impeller or other pump components. Boarding in Deep Water Swim to the rear of the watercraft. Put your hands on the boarding plat- form and pull yourself up until your knee can reach the boarding platform,...

  • Page 58: Starting

    NOTE: When boarding a watercraft with the kart seat configuration (if so equipped), you can use the seat as an additional support point to keep your balance. Once aboard, take the appropriate rid- ing position. Starting Preparation Before unloading the watercraft from the trailer, it can be started for about 10 seconds to verify proper operation.

  • Page 59: Riding

    Riding NOTE: If you hear anything other than 2 short beeps from DESS sys- Evenly accelerate to reach deeper wa- tem, it indicates a particular condition ter. Do not apply full throttle until the that should be corrected. Refer to the engine is warm.
  • Page 60 CAUTION: Hanging to handlebar WARNING while falling might damage the In the “moto” configuration, the steering pole or other components. proper riding position is to sit The steering pole length multiply straddled on the “moto” seat the effect of your weight and this with both feet resting firmly on creates an important stress on the the deck.

  • Page 61: Rough Water Or Poor Visibility Operation

    Rough Water or Poor Visibility Operation Avoid operation in these conditions. If you must do so, proceed with caution and prudence using minimum speed. Crossing Waves Reduce speed. Reduce speed to idle. Always be prepared to steer and bal- ance as necessary. WARNING When crossing wakes, always keep a safe distance from watercraft ahead.

  • Page 62: Shutting Off The Engine

    Shutting Off the Engine To keep watercraft directional control, the engine should be running until the watercraft is at idle. To shut off the engine, completely re- lease throttle lever and press the en- gine start/stop button. Remove safety lanyard from watercraft. WARNING Should the engine be shut off, wa- tercraft directional control is lost.

  • Page 63: Post-Operation Care

    POST-OPERATION CARE Cooling System Flushing WARNING and Engine Internal Allow engine to cool before per- Lubrication forming any maintenance. General General Care Flushing the cooling system with fresh Take the watercraft out of the water water is essential to neutralize cor- every day to prevent marine organism roding effects of salt or other chemi- growth.
  • Page 64 NOTE: The quick connect adapter has to be removed once the procedure is completed. Flushing and Lubrication To flush cooling system, start the en- gine then immediately open the water tap. WARNING Components inside the engine compartment may be hot. Keep away from electrical parts or jet pump area when engine is run- 1.

  • Page 65: Anticorrosion Treatment

    Remove both spark plugs and spray BOMBARDIER LUBE or an equivalent lubricant into each cylinder. Remove safety lanyard from its post. Depress the throttle lever at full throt- tle position and hold. Reinstall the safety lanyard cap on its post. Crank the engine a few turns to distrib- ute the oil on the cylinder walls.

  • Page 66: Special Procedures

    CARE. move blockage manually. If engine still overheats, refer to an au- On-Beach Water Cleaning thorized Sea-Doo dealer for servicing. WARNING Jet Pump Water Intake and Impeller Cleaning Always remove safety lanyard cap...

  • Page 67: Submerged Watercraft

    Start engine normally. severe damage to the engine com- ponents. Fuel-Flooded Engine Bring the watercraft to be serviced by To prevent fuel to be injected in the an authorized Sea-Doo dealer as soon engine, proceed as follows. as possible. _____________________ www.SeaDooManuals.net...

  • Page 68: Towing The Watercraft On The Water

    Sea-Doo dealer. Towing the Watercraft on the Water Special precautions should be taken when towing a Sea-Doo watercraft on the water. The maximum recommended towing speed is 24 km/h (15 MPH). When towing your watercraft on 1.

  • Page 69: Low-Charge Battery Condition

    Fail- ure to do so will result in severe damage to the engine. Low-Charge Battery Condition See an authorized Sea-Doo dealer to recharge or replace the battery. WARNING Do not charge or boost the battery while installed in the watercraft.

  • Page 70: Maintenance Information

    MAINTENANCE INFORMATION _____________________ www.SeaDooManuals.net...

  • Page 71: Engine Emissions Information

    When performing service on all 1999 taining to the EPA requirements on ex- and more recent Sea-Doo watercrafts haust emissions for marine products. that carry an emissions control infor- For more detailed information on this...

  • Page 72: General

    Only perform servicing procedures which are detailed in this safety sec- tion. Further assistance or informa- tion can be obtained from your au- thorized Sea-Doo dealer. In many instances proper tools and training is required for certain servicing or repair procedures.

  • Page 73: Maintenance Chart

    The following maintenance chart gives guidelines for regular watercraft servicing scheduled to be performed by you and/or by an authorized Sea-Doo dealer. The schedule should be adjusted according to operating conditions and use.
  • Page 74 I: Inspect, verify, clean, adjust, lubricate or EVERY replace if necessary C: Clean To be First performed L: Lubricate 25 h 50 h 100 h 10 h R: Replace 3 months 6 months 1 year FUEL SYSTEM Throttle cable Customer Fuel filter Dealer Fuel injection system sensors...
  • Page 75 I: Inspect, verify, clean, adjust, lubricate or EVERY replace if necessary C: Clean To be First performed L: Lubricate 25 h 50 h 100 h 10 h R: Replace 3 months 6 months 1 year O.T.A.S. SYSTEM O.T.A.S. system operation Dealer PROPULSION SYSTEM Drive shaft boot and splines...

  • Page 76: Maintenance

    MAINTENANCE WARNING Only perform procedures as de- tailed in this guide. It is recom- mended that the assistance of an authorized Sea-Doo dealer be peri- odically obtained on other compo- nents/systems not covered in this guide. Unless otherwise speci- fied, engine must not be running...

  • Page 77: Throttle Cable Inspection

    Repeat the test for each ad- the straight ahead position, the jet justable handlebar position. Refer to pump nozzle should be in the same an authorized Sea-Doo dealer if neces- direction allowing the watercraft to sary. run in a straight line.

  • Page 78: Handlebar And Adjuster Operation

    If any of the above tests fail, do not operate the watercraft and refer to Install the seat post in its receiver and an authorized Sea-Doo dealer. ensure it latches properly. Inspect latch mechanism for wear. Try pulling out the post without releasing the Handlebar and Adjuster latch.

  • Page 79: System

    Otherwise, repeat the test and turn handlebar earlier after throttle release. If the RPM still does not increase, re- fer to an authorized Sea-Doo dealer. VTS Adjustment Turn the adjuster knob so that the noz- zle reaches its highest position. Turn the adjuster knob in the opposite direc- tion to reach the lowest position.

  • Page 80: Fuses

    If a fuse has burnt out, the source of the malfunction must be determined and corrected be- fore restarting. See an authorized Sea-Doo dealer for servicing. Fuses can be found on the MPEM and beside the VCM (Vehicle Control Mod- ule).

  • Page 81: General Inspection And Cleaning

    Cleaning while working in the engine com- partment. The bilge should be cleaned by an authorized Sea-Doo dealer to remove any fuel/oil/electrolyte deposits and Check engine cover tabs and C-hooks mildew. as well as latch co ndition.
  • Page 82 Occasionally, wash the body with wa- ter and soap (only use mild detergent). Remove any marine organisms from engine and/or hull. Apply non-abrasive wax such as silicone wax. CAUTION: Never clean fiberglass and plastic parts with strong deter- gent, degreasing agent, paint thin- ner, acetone, etc.

  • Page 83: Trailering, Storage And Preseason Preparation

    Kart Seat Configuration (if that you carry the vehicle in its so equipped) normal operating position. If a Sea-Doo cover is not used, the steering pole must be locked down to Check the laws and regulations in your prevent any movement during trans- area that apply, especially the rules portation.

  • Page 84: Storage

    It is strongly recommended that the watercraft be serviced by an autho- rized Sea-Doo dealer for storage but the following operations can be per- formed by you with a minimum of tools.
  • Page 85 Lubricant in jet pump reservoir should Antifreezing Protection be drained and reservoir cleaned. Re- In cool regions where freezing point fer to an authorized Sea-Doo dealer for may be encountered, cooling system this operation. should be filled with pure antifreeze.
  • Page 86 Sea-Doo dealer. 1. Pinch engine cylinder drain hose CAUTION: 2. Pinch engine heat exchanger drain hose Use only undiluted an- tifreeze (100% concentration).
  • Page 87 NOTE: Most of the antifreeze will drain out when removing the hose pinchers. ALWAYS DISPOSE OF AN- TIFREEZE IN ACCORDANCE WITH YOUR LOCAL LAWS AND REGULA- TIONS. Remove the temporary hose from engine and reinstall the water supply hose to the cylinder head. Remove hose pincher from engine outlet hose.
  • Page 88 If any avoid condensation and potential repairs are needed to body or to the corrosion. hull contact your authorized Sea-Doo dealer. For paint touch up to mechan- ical parts use BRP spray paint. Anticorrosion Treatment Wipe off any residual water in the en- gine compartment.

  • Page 89: Preseason Preparation

    WARNING Only perform procedures as de- tailed in this guide. It is recom- mended that the assistance of an authorized Sea-Doo dealer be periodically obtained on other components/ systems not covered in this guide. Unless otherwise specified, engine must not be run-...

  • Page 90: Preseason Preparation Chart

    Preseason Preparation Chart NOTE: It is highly recommended that an authorized Sea-Doo dealer perform the annual safety inspection and factory campaigns in addition to the preseason preparation all at the same time. TO BE PERFORMED OPERATIONS Lubrication/corrosion protection Operator GENERAL...
  • Page 91 TO BE PERFORMED OPERATIONS O.T.A.S. SYSTEM Dealer Check O.T.A.S. system operation PROPULSION VTS (Variable Trim System) Dealer SYSTEM Propulsion system inspection Dealer Jet pump oil replacement Dealer Inspection of bailer pick-ups Dealer HULL AND BODY Kart seat (if so equipped) Dealer (1) Before installing new spark plugs, it is suggested to burn the excess BOMBARDIER LUBE lubricant or equivalent by starting the engine using the old spark plugs.

  • Page 92: Troubleshooting

    You may be able to solve many of these problems rather quickly, but others may require the skills of a mechanical technician. In such cases, con- sult an authorized Sea-Doo dealer for servicing. Monitoring Beeper Coded Signals CODED SIGNALS...
  • Page 93 Safety lanyard removed. Install cap over post. Burnt fuse on MPEM: battery, Check wiring then replace or main fuse. fuse(s). Discharged battery. Refer to an authorized Sea-Doo dealer. Battery connections, corroded Refer to an authorized Sea-Doo or loose. dealer. Water-flooded engine.

  • Page 94: Engine Overheats

    REMEDY Lean fuel mixture. Fuel: Level too low, stale or Siphon and/or refill. water-contaminated. Fuel filter clogged. Refer to an authorized Sea-Doo dealer. Clogged injectors. Refer to an authorized Sea-Doo dealer. Defective sensor or MPEM. Refer to an authorized Sea-Doo dealer.

  • Page 95: Engine Lacks Acceleration Or Power

    POSSIBLE CAUSE REMEDY Weeds or debris jammed Cavitation. Clean and check for damage. around impeller. Damaged impeller shaft or Refer to an authorized Sea-Doo drive shaft. dealer. Steering Pole is Heavier than Usual OTHER OBSERVATION POSSIBLE CAUSE REMEDY Steering pole return spring Set the adjuster to reduce the adjustment.

  • Page 96: Specifications

    SPECIFICATIONS VEHICLES (6157/6158) ENGINE Type Rotax ® 787 RFI , 2-stroke Induction Type Rotary valve Exhaust system Water cooled Exhaust valve Rotax Adjustable Variable Exhaust (RAVE) Type Oil injection Lubrication BOMBARDIER FORMULA XP-S II Oil type synthetic injection oil Number of cylinders Displacement 781.6 cc (47.7 cu.
  • Page 97 VEHICLES (6157/6158) FUEL SYSTEM Fuel Type Regular unleaded gasoline Minimum octane Inside North America: 87 (R + M) / 2 number Outside North America: 91 RON Rotax fuel injection (RFI Fuel injection Single throttle body (56 mm (2.21 in)) PROPULSION Propulsion system Bombardier Formula pump Jet pump type...
  • Page 98 VEHICLES (6157/6158) CAPACITIES Fuel tank (including reserve) 32 L (8.5 U.S. gal) Fuel tank reserve (from low level signal) 5 L (1.3 U.S. gal) Oil injection reservoir 4 L (1 U.S. gal) Capacity 100 mL (3.4 U.S. gal) Impeller shaft reservoir Oil level Up to plug...

  • Page 99: International System Metric Information

    INTERNATIONAL SYSTEM METRIC INFORMATION BASE UNITS length ..........meter ........ mass ..........kilogram ......force........... newton......liquid ..........liter ........temperature ........Celsius ......°C pressure ..........kilo pascal......torque ..........newton-meter ....land velocity ........kilometer per hour..... km/h navigation velocity ......

  • Page 100: Abbreviations Used In This Manual

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

  • Page 101: Warranty

    WARRANTY _____________________ www.SeaDooManuals.net...
  • Page 102 Fax: (819) 566–3062 www.brp.com If your Sea-Doo watercraft requires warranty service, you should take it to any authorized Sea-Doo dealer. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the service manager or owner of the Sea-Doo dealership.

  • Page 103: Brp North America Limited Warranty: 2004 Sea-Doo ® 3D Tm Rfi Tm Personal Watercraft

    All genuine Sea-Doo parts and accessories, installed by an authorized BRP dealer (as hereinafter defined) at the time of delivery of the Sea-Doo personal watercraft, carry the same warranty as that of the personal watercraft.
  • Page 104 BRP’s obligations under this warranty are limited to, at its sole discretion, re- pairing parts found defective under normal use, maintenance and service, or re- placing such parts with new genuine Sea-Doo parts without charge for parts and labor, at any authorized BRP dealer.
  • Page 105 6. EXCLUSIONS The following are not warranted under any circumstances: – Normal wear and tear; – Routine maintenance items, tune ups, adjustments; – Damage caused by failure to provide proper maintenance and/or storage, as described in the Operator’s Guide; – Damage resulting from removal of parts, improper repairs, service, mainte- nance, modifications or use of parts not manufactured or approved by BRP or resulting from repairs done by a person that is not an authorized servicing BRP dealer;...
  • Page 106 8. TRANSFER If the ownership of a product is transferred during the warranty coverage period, this warranty shall also be transferred and be valid for the remaining coverage period provided that BRP is notified of such transfer of ownership in the following way: (a) The former owner contacts BRP (at the phone number provided below) or an authorized BRP dealer and gives the co-ordinates of the new owner;...

  • Page 107: California Emission Control Warranty Statement For ® Personal Watercraft With Rfi

    PERSONAL WATERCRAFT WITH RFI ENGINES. Your Sea-Doo personal watercraft may have a special environmental label re- quired by the California Air Resources Board. The label has 1, 2, 3 or 4 stars. A hangtag, provided with your personal watercraft, describes the meaning of the star rating system.
  • Page 108 California to a California resident or subsequently war- ranty registered to a California resident. The BRP limited warranty conditions for Sea-Doo personal watercraft are still applicable to these models with the neces- sary modifications. _____________________...
  • Page 109 Select emission control parts of your 2004 Sea-Doo personal watercraft equipped with RFI engine are warranted from the date of delivery to the first retail con- sumer for a period of 4 years, or for 250 hours of use, whichever occurs first.
  • Page 110 Emission warranty parts that are scheduled for replacement, as required main- tenance, are warranted by BRP for the period of time before the first scheduled replacement date for that part. Emission warranty parts that are scheduled for regular inspection, but not regular replacement, are warranted by BRP for the entire warranty period of the personal watercraft.

  • Page 111: Brp International Limited Warranty: 2004 Sea-Doo 3D Tm Rfi Tm Personal Watercraft

    This warranty coverage is available only on Sea-Doo personal watercraft pur- chased as new and unused by its first owner from a BRP distributor/dealer au- thorized to distribute Sea-Doo products in t he country in which the sale occurred (“BRP distributor/dealer”), and then only after the BRP specified pre-delivery in- spection process is completed and documented.
  • Page 112 BRP’s obligations under this warranty are limited to, at its sole discretion, re- pairing parts found defective under normal use, maintenance and service, or re- placing such parts with new genuine Sea-Doo parts without charge for parts and labor, at any authorized BRP distributor/dealer.
  • Page 113 7. LIMITATIONS OF LIABILITY THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR- TICULAR PURPOSE. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.

  • Page 114: Privacy Information

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

  • Page 115: Change Of Address/Ownership

    STOLEN UNITS: If your personal watercraft is stolen, you should notify BRP or an authorized Sea-Doo dealer. We will ask you to provide your name, address, phone number, the hull identification number of your personal watercraft and the date it was stolen.
  • Page 116 AFFIX PROPER POSTAGE Bombardier Recreational Products Inc. _____________________ www.SeaDooManuals.net...
  • Page 117 WATERCRAFT HULL ENGINE Owner: Purchase Date Warranty Expiry Date Please verify with your selling dealer to ensure your SEA-DOO watercraft has been registered with BRP. _____________________ www.SeaDooManuals.net...
  • Page 118 www.SeaDooManuals.net...

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