Sea-doo 2004 3D RFI Operation Manual Download | Manualshive

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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.
However, warranty coverage based on the hourly period is only permitted for
personal watercraft equipped with the appropriate hour meters or their equiva-
lent. If any emission-related part on your engine is defective under warranty, the
part will be repaired or replaced by BRP.

Parts Covered for 2004 Sea-Doo Personal Watercraft
Equipped with RFI Engines:

Fuel Rail

Fuel Lines

Crankshaft Position Sensor
(CPS)

Rave Valve

Water Regulator

Coolant Temperature
Sensor (WTS)

Rotary Valve

Fuel Pump

Fuel Pressure Regulator

Tuned Pipe

Cylinder Head

Fuel Injectors

High-Tension Ignition Wires

Intake Manifold

Multi Purpose Electronic
Module (MPEM)

Electrical Harness

Throttle Position Sensor
(TPS)

Electronic Control Module
(ECU)

Throttle Body

Ignition Coil

Exhaust Manifold

Exhaust Hoses

Manifold Air Temperature
Sensor (ATS)

Airbox and Flame Arrester

Spark Plugs

Manifold Air Pressure
Sensor (MAPS)

All Emission Component
Related Gaskets; Head,
Base, Exhaust

The emission warranty covers damage to other engine components that is
caused by the failure of a warranted part.

The BRP Operator’s Guide provided contains written instructions for the proper
maintenance and use of your personal watercraft. All emission warranty parts
are warranted by BRP for the entire warranty period of the personal watercraft,
unless the part is scheduled for replacement as required maintenance in the Op-
erator’s Guide.

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Summary of Contents for 2004 3D RFI

Page 1: ...C M Y CM MY CY CMY K www SeaDooManuals net ...

Page 2: ...This Operator s Guide and the Safety Videocassette should remain with the ve hicle at the time of sale 2004 PWC Electro Magnetic Compatibility Directive Compliance with EC Directive 89 336EEC Knight s Spray Nine is a trademark of Korkay System Ltd GTX is a trademark of Castrol Ltd Used under license The following is a non exhausting list of trademarks that are the property of Bombardier Recreation...

Page 3: ...anufactured Because of its ongoing commitment to product quality and innovation BRP reserves the right at any time to dis continue or change specifications de signs features models or equipment without incurring obligation The illustrations in this document show the typical construction of the different assemblies and may not rep resent the full detail or exact shape of the parts However they repr...

Page 4: ...NUMBER LOCATION 26 IDENTIFICATION NUMBERS 27 Hull 27 Engine 27 CONTROLS INSTRUMENTS EQUIPMENTS 28 CONTROLS INSTRUMENTS EQUIPMENTS FUNCTIONS 30 1 Safety Lanyard engine cut off cord 30 2 Handlebar 31 3 Handlebar Adjuster 31 4 Throttle Lever 32 5 Engine Start Stop Button 32 6 Indicator Light Cluster 33 7 Steering Pole 33 8 Fuel Tank Cap 34 9 Engine Cover Latch 34 10 Oil Injection Reservoir Cap 36 11 ...

Page 5: ...PERIOD 48 10 Hour Inspection 48 PRE OPERATION CHECKS 49 Hull 50 Jet Pump Water Intake 50 Bilge 50 Water Flow in Cooling System only when temperature is below or close to freezing point 50 Battery 51 Fuel Tank and Oil Reservoir 51 Engine Compartment 51 Steering System 51 Steering Pole 51 Throttle System 51 VTS Variable Trim System 51 Safety Lanyard and Engine Start Stop Button 51 Optional Configura...

Page 6: ... 69 MAINTENANCE INFORMATION Engine Emissions Information 72 General 73 MAINTENANCE CHART 74 Periodic Inspection 74 MAINTENANCE 77 Lubrication 77 Throttle Cable Inspection 78 Fuel Injection System 78 Fuel and Oil Filters 78 Steering Alignment 78 Steering Pole 78 Handlebar and Adjuster Operation 79 Moto Seat 79 Kart Seat if so equipped 79 O T A S TM System 80 VTS Adjustment 80 Vacuum Bailer Pick Ups...

Page 7: ...RRANTY 2004 SEA DOO 3DTM RFITM PERSONAL WATERCRAFT 105 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT FOR MODEL YEAR 2004 SEA DOO PERSONAL WATERCRAFT WITH RFITM ENGINES 109 BRP INTERNATIONAL LIMITED WARRANTY 2004 SEA DOO 3DTM RFITM PERSONAL WATERCRAFT 113 PRIVACY INFORMATION 116 CHANGE OF ADDRESS OWNERSHIP 117 ______________________ 5 www SeaDooManuals net ...

Page 8: ...SAFETY INFORMATION ____________ SAFETY INFORMATION ____________ 7 www SeaDooManuals net ...

Page 9: ...lure to follow the instructions of this safety section may result in severe in jury or death This safety section is for initial refer ence and its content is therefore lim ited section It should be read in con junction with the rest of this Opera tor s Guide the safety videocassette and the on product warning caution la bels It is also strongly recommended that operators obtain further informa tio...

Page 10: ... to reboard the water craft from the water Boarding in deep water can be strenu ous Practice in chest deep water be fore operating or embarking your wa tercraft in deep water A PWC will not self right if capsized The operator must know the proper righting procedure as explained in the Operator s Guide Make sure engine is off before rolling over the water craft Your local Power Squadron or state pr...

Page 11: ...g fitting clothing that provides equivalent protection Thin bike shorts for example would not be appropriate Severe internal injuries can occur if water is forced into body cavities as a result of falling into water or being near jet thrust nozzle Normal swimwear does not adequately protect against forceful water entry into the lower body opening s of males or fe males footwear gloves and goggles ...

Page 12: ...Eye protection F00A12L Vest type personal flotation device Gloves Wet suit or wet suit bottom Foot protection ____________ SAFETY INFORMATION ___________ 11 www SeaDooManuals net ...

Page 13: ...nal experience Will there be a lot of traffic on the water What is your riding style The Bottom Line Since each option minimizes some risks but increases others before each ride you must decide whether to wear a helmet or not based on your particular situation If you decide to wear a helmet you must then decide what type is the most appropriate for the circum stances Look for helmets that meet DOT...

Page 14: ... the waters in which the water craft is to be operated Current tides rapids hidden obstacles wakes and waves etc can affect safe operation It is not advisable to operate the water craft in rough or inclement weather For safety reasons and proper care always perform Daily Pre Operation Checks as specified in your Opera tor s Guide before operating your wa tercraft Keep the engine shut off cord safe...

Page 15: ...ottle to steer Ride within your limits and level of riding ability Avoid aggressive ma neuvers to reduce the risk of loss of control ejection and collision Under stand and respect the performance or your watercraft Always ride responsibly and safely Use common sense and courtesy While your watercraft has the ca pacity of operating at high speeds it is strongly recommended that high speed operation...

Page 16: ... at all times when watercraft is in motion Keep away from intake grate while en gine is on Items such as long hair loose clothing or PFD straps can be come entangled in moving parts re sulting in severe injury or drowning To prevent accidental starting always detach the safety lanyard from the wa tercraft during removal of any weeds or debris from the intake grate It should be remembered that sun ...

Page 17: ...y to other craft and keep clear F00A16A Navigation System Navigational aids such as signs or buoys can assist you identify safe waters Buoys will indicate whether you should keep to the right star board or to the left port of the buoy or to which channel you can continue They may also indicate whether you are entering a restricted or controlled area such as a no wake or speed zone They may also in...

Page 18: ...e fl us law Georgia www boat ed com Hawaii www hawaii gov dlnr dbor dbor Idaho www idahoparks org rec boating html Indiana www state in us dnr regulations Iowa www iowadnr com Kansas www kdwp state ks us boating boating html Kentucky www state ky us agencies fw boating htm Louisiana www wlf state la us Maine www state me us ifw rv boatinglaws2003 htm Maryland www dnr state md us boating Massachuse...

Page 19: ...tc boating html South Dakota www state sd us gfp divisionwildlife boating index htm Tennessee www state tn us twra boatmain html Texas www tpwd state tx us boat boat htm Utah www stateparks utah gov parks safety htm Virginia www dgif state va us boating Washington www parks wa gov boating asp West Virginia www dnr state wv us law boating htm Wisconsin http www dnr state wi us org caer cs Registrat...

Page 20: ...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 F22L02L 13 1 6 10 3 8 2 5 7 9 4 14 F22L03L 11 MOTO CONFIGURATION ____________ SAFETY INFORMATION ___________ 19 www SeaDooManuals net ...

Page 21: ...Y THROTTLE WHEN ANYONE IS AT REAR OF PWC turn engine off or keep engine at idle Water and or debris exiting jet thrust nozzle can cause severe injury KEEP AWAY FROM INTAKE GRATE while engine is on Items such as long hair loose clothing or PFD straps can become entangled in moving parts resulting in severe injury or drow ning NEVER RIDE AFTER CONSUMING DRUGS OR ALCOHOL READ AND FOLLOW OPERATOR S GU...

Page 22: ...Label 2 F00A22Y Label 3 F02L2D0 Label 4 F22A02Y Label 5 F00A23Y Label 6 F22A03L ____________ SAFETY INFORMATION ___________ 21 www SeaDooManuals net ...

Page 23: ...K IN 9 57 66 0 17 Pour éviter toute perte de contrôle ou éjection TOUJOURS INSÉRÉR LA ROTULE COMPLÈTEMENT ET BIEN BARRER F22A04Y Label 11 51 1 9 57 66 0 17 WHEN INSTALLING KART SEAT 1 INSERT FRONT TAB properly in receptacle 2 LOCK IN REAR LATCH 3 LOCK IN HANDLEBAR POLE LATCH 4 INSTALL FOOTREST SPACERS if operator cannot reach regular footrests QUAND VOUS INSTALLEZ LE SIÈGE KART 1 INSÉREZ BIEN LA L...

Page 24: ...Label 12 F22A06Y Label 13 F22A07Y Label 14 F22A08Y ____________ SAFETY INFORMATION ___________ 23 www SeaDooManuals net ...

Page 25: ...VEHICLE INFORMATION _____________________ 25 www SeaDooManuals net ...

Page 26: ...tion number refer to follow ing illustration for location The registration number should appear on each side of the watercraft F22L0BL 1 1 Registration number location NOTE The registration number must be above the water line Ensure also that the numbers are of the correct size and color Check with local applicable regu lations 26 ______________________ www SeaDooManuals net ...

Page 27: ...ion Number H I N is located on platform at the rear of watercraft F22L06Y 1 1 Hull Identification Number It is composed of 12 digits Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number F00A0CZ Month of production Year of production A letter may also be used as a digit Manufacturer Engine The Engine Identification Number E I N is located on the upper crankcase on PTO Power Take Off side F01D87Y 1 1 En...

Page 28: ...S EQUIPMENTS NOTE Some components do not apply or are optional on some models F22L07L 12 10 15 11 20 17 18 19 12 16 13 23 14 8 9 7 24 21 22 4 25 1 3 5 2 6 VERT CONFIGURATION 28 ______________________ www SeaDooManuals net ...

Page 29: ... Injection Reservoir Cap 11 Air Intake Opening 12 Bow and Stern Eyelets 13 Boarding Pad 14 Rear Platform 15 Cooling System Bleed Outlet 16 Flushing Connector 17 Bilge Drain Plugs 18 Jet Pump Nozzle 19 VTS Adjuster 20 Jet Pump Water Intake 21 Fuses 22 Battery 23 Rear Access Cover 24 Automatic Bilge Pump 25 Moto Seat Release Button 26 Moto Seat Post Receiver 27 Moto Seat Post Release Lever 28 Kart S...

Page 30: ...Device PFD and snap the cap to the post to be able to start the engine Two short beeps indicates the sys tem is ready to allow engine start ing Otherwise refer to the TROU BLESHOOTING section for the coded signals chart F22L1TY 1 2 1 Safety lanyard cap on the post 2 Safety lanyard secured on operator s PFD F22L19Y 2 1 1 Safety lanyard cap on the post 2 Safety lanyard secured on operator s PFD WARN...

Page 31: ...r The handlebar controls the direction of the watercraft Turning the handlebar to the right steers the watercraft to the right and inversely WARNING Check handlebar and correspond ing steering nozzle operation be fore starting Never turn handle bar while someone is nearby rear of watercraft Keep away from steering moving parts nozzle linkage etc This watercraft features the O T A S system Refer to...

Page 32: ...provides additional maneuverability in off throttle situa tions The O T A S system is elec tronically activated and slightly in creases engine speed under a pre pro grammed RPM when the driver ini tiates a full turn When handlebar is brought back to its center position the throttle reverts to idle 5 Engine Start Stop Button To start engine depress and hold the start stop button Release immedi atel...

Page 33: ...approximately 3 L 8 U S gal is left Refer to the TROUBLESHOOT ING section for the coded signals 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 TM system or the electric bilge pump NOTE When engine is not running and safety lanyard is on its post the warning light will remain turned on un til safe...

Page 34: ...llow water to enter and to fill the bilge If you need to reach the storage area or the fire extin guisher while on water first turn off engine Ensure to be on calm water and adopt a stable stance Partially open engine cover just enough to reach the storage area Close and relatch engine cover as quickly as possible Removing the engine cover gives ac cess to the fire extinguisher storage area storag...

Page 35: ...ation prior to rein stalling engine cover When reinstalling engine cover prop erly insert engine cover tab into C hook of body A distinctive snap will be felt when en gaging the engine cover latch Make sure the engine cover is secure by giving it a tug If the engine cover cannot be latched easily check to make sure the fire extinguisher is po sitioned properly and no object in the storage tray is ...

Page 36: ... to store per sonal articles The tray is designed to receive the Safety equipment for small vessel kit sold separately Tool Kit Tool kit is located in storage tray It in cludes tools needed to perform basic watercraft maintenance 10 Oil Injection Reservoir Cap Remove engine cover to expose oil reservoir cap Lock steering pole with the holder WARNING Always install steering pole holder immediately ...

Page 37: ... boarding 14 Rear Platform Provides a large surface to position your feet in the vert configuration It also provides a convenient surface for easy boarding 15 Cooling System Bleed Outlet 1 F22L0HZ 1 Bleed outlet When engine is running water should flow out of the outlet This allows air in engine cooling system to escape It also confirms that water is circulating in the cooling system NOTE It may b...

Page 38: ...ested to drain bilge when the watercraft is on a ramp CAUTION Make sure the drain plugs are properly secured prior to launching the watercraft in the wa ter 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 F22J02Y 1 2 1 Jet pump nozzle 2 VTS adjuster 19 VTS Adjuster A trim knob is used to change the jet...

Page 39: ...AINTE NANCE for more details 22 Battery The battery is located in the engine compartment Refer to SPECIAL PROCEDURES 23 Rear Access Cover NOTE If the moto seat is in stalled stow it into steering pole Refer to MOTO SEAT INSTALLA TION STOWAGE If the kart seat is installed remove it Refer to KART SEAT INSTALLATION REMOVAL The cover gives access to the drive system exhaust system bilge pump and baile...

Page 40: ...ter or when se curely docked If this is not possible it should be done on calm water Moto Seat Installation WARNING Before installing or stowing the moto seat Stop the watercraft in a safe area away from traffic or obstacles Turn off engine Be on the look out for other crafts or obstacles Your water craft could drift while changing configuration Raise the steering pole to its highest position and ...

Page 41: ...NOTE Notice that when rotating post it will lock at an intermediate position Push the red lever again to release the lock and continue to rotate post until it becomes vertical F22L0NY 2 1 1 Post vertical 2 Receiver Lift the receiver cap and hold open while inserting the seat post in re ceiver Ensure post knuckle is fully in serted into the receiver F22L0OY 1 1 Lift receiver cap To lock post in pos...

Page 42: ...oto seat resting directly on the deck as the seat could damage the deck F22L17Y Moto Seat Stowage Unlock the seat post by lifting the red locking lever while firmly holding the steering pole by the handlebar NOTE Pushing down on handlebar can ease to unlock seat F22L0QY 1 1 Hold steering pole Push the seat forward so that the seat post becomes vertical Lift the seat to release the post from its re...

Page 43: ...tated forward into the pole 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 F22L0UY 1 1 Receiver 27 Moto Seat Post Release Lever The lever releases the seat post from within the seat It is used also to release the post from its receiver on the deck For instructions re fer to MOTO SEAT INSTALLA TIO...

Page 44: ...all the footrest spacers refer to your autho rized Sea Doo dealer for more infor mation This will help achieve a more stable riding position The spacers have 2 steps to accom modate different rider heights Use the one that best suits your leg size Make sure to latch the spacers se curely in the footwells of the water craft F22L18Y 1 2 1 Footrest spacers 2 Two available steps WARNING Never operate ...

Page 45: ...ed securely on calm water When using the kart seat it is nec essary to lock the steering pole down with this retainer to prevent any verti cal movement Pull the retainer out of the steering pole and hold while lowering the pole into position F22L10Y 1 1 Pull retainer out Continue lowering the steering pole down until the retainer can be inserted into the body hook Then push re tainer to lock in po...

Page 46: ...en fueling keep water craft level Do not overfill or top off the fuel tank and leave water craft in the sun As temperature increases fuel expands and might overflow Always wipe off any fuel spillage from the watercraft Periodically verify fuel system Recommended Fuel Use unleaded regular gasoline with the following recommended mini mum octane number LOCATION OCTANE NUMBER Inside North America 87 o...

Page 47: ...t use NMMA TC W TC W2 or TC W3 outboard two stroke engine oils or ashless two stroke engine oils Avoid mix ing different brands of API TC oil as resulting chemical reactions may cause severe engine damage CAUTION DO NOT allow any four stroke oil to be used or put two stroke oil into a used four stroke oil container If any four stroke oil enters the system the entire oil system pump reser voir line...

Page 48: ...ns contribute to a good break in CAUTION Continued wide open throttle runs and prolonged cruis ing without speed variations should be avoided this can cause engine damage during the break in period 10 Hour Inspection It is highly recommended that after the first 10 hours of operation the watercraft be checked by an autho rized Sea Doo dealer This inspection will also provide the opportunity to dis...

Page 49: ... any of the following points Only start wa tercraft once all items have been checked and operate properly ITEM OPERATION Hull Inspect Jet pump water intake Inspect clean Bilge Drain Ensure plugs are secured Water flow in cooling system only when temperature is below or close to freezing point Check if water properly flows out at jet pump Battery Inspect tightness of cables and retaining bracket s ...

Page 50: ... properly working do the following prior to using the watercraft The procedure is to be performed with watercraft out of water Connect a garden hose to the flush ing connector at jet pump Perform the flushing operation as explained in POST OPERATION CARE Ensure water flows out of jet pump Otherwise water is frozen in cool ing system and restricts water flow Do not operate the watercraft in this co...

Page 51: ...nd correspond ing steering nozzle operation be fore starting Never turn handle bar while someone is close to the rear of watercraft Keep away from steering moving parts noz zle linkage etc Steering Pole Check steering pole up and down movement for free and smooth op eration Pay attention to the weight feeling of the pole It can be ad justed Refer to CONTROLS INSTRU MENTS EQUIPMENTS Throttle System...

Page 52: ...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 52 ______________________ www SeaDooManuals net ...

Page 53: ... The venturi accelerates the water and produces thrust to move the water craft Depressing the throttle lever increases engine speed and therefore watercraft speed F22L1AY WARNING Whenever the engine is to be started the operator should al ways be properly standing or sit ting on the watercraft and be wear ing protective clothing including a Coast Guard approved PFD and a wet suit bottom WARNING Ke...

Page 54: ...n upward angle the water thrust directs the bow of the watercraft upward This position is used to optimize high speed F22J020 2 1 4 3 1 Adjuster 2 Nozzle up or down 3 To raise nozzle 4 To lower nozzle When the nozzle is directed down ward the bow is forced downward and enhances the watercraft turning capabilities As with any watercraft speed and operator body position and movement body English wil...

Page 55: ... good collision avoidance technique WARNING Directional control is reduced when the throttle is released and lost when engine is off Keeping your feet spread apart and leaning in while turning may help to keep your balance when riding in vert configuration CAUTION Combustion engine needs air to operate consequently this watercraft cannot be totally wa tertight Maneuvers such as figure eights etc t...

Page 56: ...r When boarding from a dock hold the handlebar and carefully place one foot in the middle of the watercraft rear platform Transfer your body weight to bring the other foot to the platform Push the watercraft away from the dock F22L1EY NOTE When boarding a watercraft with the moto or kart seat configu ration you can use the seat as an ad ditional support point to keep your bal ance In shallow water...

Page 57: ...e watercraft F22L1FY Put your hands on the boarding plat form and pull yourself up until your knee can reach the boarding platform then get on F22L1GY Bring your feet on the rear platform while maintaining balance using the handlebar F22L1HY F22L1IY F22L1JY NOTE When boarding a watercraft with the moto seat configuration you can find helpful to use the seat strap F22L1KY F22L1LY __________________...

Page 58: ...opriate rid ing position Starting Preparation Before unloading the watercraft from the trailer it can be started for about 10 seconds to verify proper operation WARNING Components inside the engine compartment may be hot Keep away from electrical parts or jet pump area when engine is run ning Attach the safety lanyard to your PFD and snap the cap to its post before starting the engine 58 _________...

Page 59: ...t stop button more than 30 sec onds to avoid starter overheating A rest period should be observed between the cranking cycles to let the starter cool down Be careful not to discharge battery Release the engine start stop but ton immediately once the engine is started Cold or Warm Engine Never depress the throttle lever to start engine wether it is warm or cold Riding Evenly accelerate to reach dee...

Page 60: ...r to operating the watercraft WARNING In the moto configuration the proper riding position is to sit straddled on the moto seat with both feet resting firmly on the deck Other riding positions may not allow to remain in con trol of the craft or may not offer enough visibility of your surround ing which could lead to accidents collisions and possible serious in juries Kart Configuration Refer to th...

Page 61: ...with the stopping distance under dif ferent conditions Release the throttle at a sufficient dis tance before the expected landing or docking area When riding in vert configuration moving a foot slightly forward or rear ward may help to keep your balance and compensate for the watercraft de celeration F22L1XY Reduce speed to idle WARNING Directional control is reduced when the throttle is released ...

Page 62: ... 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 Never leave the safety lanyard on its post when watercraft is not in operation in order to prevent acci dental engine starting or to avoid unauthorized use by children or others or theft 62 ______________________ www SeaDooManuals net ...

Page 63: ... when wa tercraft is used in salt water will result in damage to the watercraft and its components Never leave the watercraft stowed in direct sun light Cooling System Flushing and Engine Internal Lubrication General Flushing the cooling system with fresh water is essential to neutralize cor roding effects of salt or other chemi cal products present in water It will help to remove sand salt shells...

Page 64: ...e lines CAUTION Never run engine longer than 5 minutes The drive line seal has no cooling when wa tercraft is out of water Spray BOMBARDIER LUBE or an equivalent lubricant through the hole in the air intake silencer while keeping engine at fast idle during one minute F22D01Y 2 1 1 Air intake silencer 2 Pull plug Lubrication of engine should be done for at least 1 minute CAUTION When engine begins ...

Page 65: ... seize lubricant on spark plug threads then reinstall them Properly reconnect spark plug cables to spark plugs Wipe off any residual water from the engine Reinstall plug on air intake silencer cover Anticorrosion Treatment To prevent corrosion spray a corrosion inhibitor salt water resistant such as BOMBARDIER LUBE or an equivalent lubricant over metallic components in engine compartment Apply die...

Page 66: ... and or impeller A clogged water intake may cause troubles such as Cavitation Engine speed is high but watercraft moves slowly due to reduced jet thrust jet pump compo nents may be damaged Overheating Since the jet pump operation controls the flow of wa ter to cool the engine a clogged in take will cause the engine to over heat and cause damage to internal components Weed clogging area can be clea...

Page 67: ...ge will be to the engine Water Flooded Engine In the event the engine cannot be serviced within a few hours remove spark plug cables and connect them on the grounding device WARNING Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device Be careful when cranking engine water will spray out from spark plug holes Remove the spark plugs and wipe them...

Page 68: ... 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 the water pinch the water supply hose from the impeller housing to the engine with a large hose pincher P N 529 032 500 F01B23Y This will prevent the cooling system from filling up which may lead to water fl...

Page 69: ...vere 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 Electrolyte is poisonous and dan gerous Avoid contact with eyes skin or clothing _____________________ 69 www SeaDooManuals net ...

Page 70: ...MAINTENANCE INFORMATION _____________________ 71 www SeaDooManuals net ...

Page 71: ...o have engine maintenance performed to maintain emission levels within pre scribed certification standards The owner operator is not to and should not allow anyone to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications EPA Emission Regulations All new 1999 and more recent Sea Doo watercraft manufactured by B...

Page 72: ...lugs The bilge should be kept clean of oil water or other foreign materials Do not attempt to lift the watercraft without special equipment and train ing The engine and the corresponding components identified in this guide should not be utilized on product s other than for which they were de signed Maintenance procedures and specified tightening torque should be strictly adhered to Never attempt r...

Page 73: ...ce is very important if you are not familiar with safe service prac tices and adjustment procedures see your authorized Sea Doo dealer I Inspect verify clean adjust lubricate or replace if necessary EVERY C Clean L Lubricate R Replace First 10 h 25 h or 3 months 50 h or 6 months 100 h or 1 year To be performed by GENERAL Lubrication corrosion protection 1 L Customer ENGINE Support and rubber mount...

Page 74: ...ke silencer fit tightness I I Dealer Fuel tank straps I I Dealer LUBRICATION SYSTEM Oil injection pump 5 I I Dealer Oil filter and lines I I Dealer Oil filter I R Dealer Oil reservoir straps I Customer ELECTRICAL SYSTEM Electrical connections and fastening ignition system electrical box es starting system fuel injectors etc 5 I I Dealer MPEM and VCM mounting brackets fasteners I Dealer Digitally E...

Page 75: ...ir oil and oil level R I R Dealer Impeller shaft seal R 4 Dealer Impeller and impeller wear ring clearance R 2 Dealer Water intake grate I 2 Customer HULL AND BODY Bailer pick ups check for obstructions I I Customer Kart seat if so equipped I I Customer Hull I I Customer NOTE Some items are included in the PRE OPERATION CHECKS and not nec essarily repeated in this chart 1 Every 10 hours in salt wa...

Page 76: ...y lubricate seal carrier of mid bearing until grease is just coming out of the seal F22J05Y 1 1 Grease seal carrier of mid bearing Reinstall properly all removed parts Anticorrosion Protection Throttle Cable Lubricate the throttle cable with BOM BARDIER LUBE or an equivalent lubri cant Electrical Connections As necessary apply anticorrosion product such as dielectric grease on battery posts and al...

Page 77: ...UTION An obstructed oil filter will cause oil starvation resulting in serious engine damage Steering Alignment When the handlebar is positioned in the straight ahead position the jet pump nozzle should be in the same direction allowing the watercraft to run in a straight line Refer to an authorized Sea Doo dealer if an adjustment is necessary WARNING Ensure the handlebar and jet pump nozzle operat...

Page 78: ... lateral play Also check for excessive play of seat post in seat F22L0S0 1 2 3 4 1 Latch mechanism 2 Seat structure 3 Check play of seat post 4 Check lateral play of seat structure Inspect the seat post receiver in the deck Check for dirt sand or other de bris Check for excessive wear En sure that the cover moves freely Install the seat post in its receiver and ensure it latches properly Inspect l...

Page 79: ...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 The nozzle should be move up and down without interfering with the ven turi F22J020 2 1 4 3 1 Adjuster knob 2 Nozzle up or down 3 To raise nozzle 4 To lower nozzle CAUTION Trim ring and or nozzle should be free of interference ...

Page 80: ...de the VCM Vehicle Control Mod ule To access fuses remove engine cover and lock the steering pole with the holder in the upright position WARNING Always install steering pole holder immediately after engine cover re moval to support the pole securely while working in the engine com partment MPEM Locate the MPEM in front of engine F22H03Y 1 2 1 Engine 2 MPEM Fuse ratings are identified on the MPEM ...

Page 81: ...make sure engine cover latches prop erly Check engine compartment for any damage or leaks from the fuel oil injec tion systems Ensure all hose clamps are secure and no hose is cracked kinked or shows any other damage WARNING If any gasoline leak and or odor are present do not start the engine Have the watercraft serviced by an authorized Sea Doo dealer Inspect muffler battery fuel tank and oil res...

Page 82: ...s necessary to use flannel cloths or an equivalent on engine cover steering pole nose and top to avoid further damaging the surfaces to clean To remove scratches on engine cover steering pole nose or top pieces use BOMBARDIER Scratch Remover Kit P N 861 774 800 CAUTION Never clean plastic parts or engine cover with strong detergent degreasing agent paint thinner acetone products contain ing chlori...

Page 83: ...y Make sure that the engine cover the kart seat if so equipped or moto seat are properly latched WARNING Make sure the kart seat if so equipped or moto seat is se curely latched prior to trailering A Sea Doo cover will help to protect the watercraft particularly when driv ing on dirt roads This will prevent dirt entry through the air intake opening s In addition the cover will properly re tain ste...

Page 84: ...ot run the engine during the storage period Engine Draining Check engine drain hose lowest hose of engine Make sure it is free of sand or other particles and unobstructed so that water can drain out of the engine Clean hose and fitting as necessary CAUTION Water in engine drain hose should be free to flow out otherwise water could be trapped in engine Should water freeze in engine severe damage wo...

Page 85: ...nd gumming Fol low manufacturer s instructions for proper use CAUTION Fuel stabilizer should be added prior to engine lubrication to ensure fuel system components protection against varnish deposits WARNING Always stop the engine before re fueling Fuel is flammable and ex plosive under certain conditions Always work in a well ventilated area Do not smoke or allow open flames or sparks in the vicin...

Page 86: ...mpatible with internal combustion aluminum engines This will contribute to protect the environ ment NOTE The engine will not have to run during this operation but should have been ran before to exhaust as much water as possible from cooling system components Procedure for Engine and Tuned Pipe NOTE This procedure requires ap proximately 2 5 L 2 6 U S qt of an tifreeze Remove rear access panel to g...

Page 87: ...YS 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 Procedure for Exhaust Pipe and Muffler Disconnect hose as shown F22E06Y 1 1 Disconnect hose from T fitting Raise the hose as high as it will go and hold in this position Insert a funn...

Page 88: ... to completely drain bilge If any repairs are needed to body or to the 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 Spray BOMBARDIER LUBE lubricant or equivalent over metallic compo nents in engine compartment WARNING Do not lubricate the safety lanyard post Lub...

Page 89: ... 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 ning and the safety lanyard must be removed from its post for all maintenance procedures Com ponents inside engine compart ment may be hot When compo nents condition seems less than satisfactory replace with genuine BOMBARDIER parts or ap...

Page 90: ...ent Dealer Fuel injection sensors verification Dealer Fuel system check valves lines fasteners pressurization 2 Dealer Filler neck fuel tank and fuel cap condition 2 Dealer Fuel tank straps Dealer FUEL SYSTEM Refill fuel tank Operator Oil injection pump adjustment and bleeding Dealer Oil filter replacement Dealer Oil injection reservoir straps Operator LUBRICATION SYSTEM Oil injection reservoir fi...

Page 91: ...et 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 2 Safety item covered in the annual safety inspection 92 ______________________ www SeaDooManuals net ...

Page 92: ...d Use a safety lanyard that has been programmed for the watercraft Defective safety lanyard Use another programmed safety lanyard Dried salt water in safety lanyard cap Clean safety lanyard cap to remove salt water Defective DESS post 1 long beep while installing safety lanyard on watercraft post Improper operation of MPEM or defective wiring harness Refer to an authorized Sea Doo dealer A 2 secon...

Page 93: ... turns slowly Worn starter Refer to an authorized Sea Doo dealer Fuel tank empty or water contaminated Refill Siphon and fill with fresh fuel Fuel filter clogged Clean check fuel tank for water Fouled defective spark plugs Replace Fuel flooded engine Refer to FUEL FLOODED ENGINE in SPECIAL PROCEDURES Faulty component in the fuel injection system Refer to an authorized Sea Doo dealer Burnt fuel pum...

Page 94: ... intake Clean Monitoring beeper sounds continuously Clogged coolant system Flush cooling system Engine Continually Backfires OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark Fouled defective worn spark plugs Replace See engine OVERHEATS Refer to an authorized SEA DOO dealer Overheated engine Spark plug leads or wiring reversed Connect spark plug cables at their proper location Otherwise refer to...

Page 95: ... Engine RPM does not increase when throttle lever is released and steering is turned Improper sequence or timing of events when trying it Refer to MAINTENANCE If it still does not work refer to an authorized Sea Doo dealer Abnormal Noise from Propulsion System OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weeds or debris jammed around impeller Clean and check for damage Cavitation Damaged impeller shaft...

Page 96: ...m 2 91 in Compression ratio corrected 6 0 1 Rev limiter setting 7200 50 RPM COOLING SYSTEM Type Water cooled total loss type Direct flow from propulsion unit ELECTRICAL SYSTEM Magneto generator output 270 W 6000 RPM Ignition system type Digital inductive mm in 1 02 040 Ignition timing BTDC Degrees 12 1 fixed timing mode at any RPM up to 6000 RPM Make and type NGK BR8ES Spark plug Gap 0 45 mm 018 i...

Page 97: ...ing Transmission Direct drive Reverse system No O T A S TM system Yes VTS Yes adjuster on jet pump unit Pivoting angle of direction nozzle 20 Minimum required water level for jet pump 90 cm 3 ft underneath the lowest rear portion of hull DIMENSIONS Number of passenger 1 1 Overall length 272 cm 107 in Overall width 112 cm 44 in Overall height VERT 92 cm 36 25 in MOTO 112 cm 44 25 in KART 96 cm 37 7...

Page 98: ... S gal Impeller shaft reservoir Oil level Up to plug N A Not applicable 1 Refer to load limit Bombardier Recreational Products Inc reserves the right to make changes in design and specifications and or to make additions to or improvements in its products without im posing any obligation upon itself to install them on its products previously manufactured _____________________ 99 www SeaDooManuals n...

Page 99: ... TO CONVERT in in in in ft oz lb lbf lbf in lbf ft lbf ft PSI imp oz imp oz imp gal imp gal U S oz U S gal MPH Fahrenheit Celsius hp TO mm cm cm cm m g kg N N m N m lbf in kPa U S oz mL U S gal L mL L km h Celsius Fahrenheit kW MULTIPLY BY 25 4 2 54 6 45 16 39 0 3 28 35 0 45 4 4 0 11 1 36 12 6 89 0 96 28 41 1 2 4 55 29 57 3 79 1 61 F 32 1 8 C x 1 8 32 75 navigation velocity knot kn F00A2YL 1 To ob...

Page 100: ...tection agency HP Horse power LCD Liquid Crystal Display LED Light emitting diode MAG Magneto MPEM Multi purpose electronic module MPH Mile per hour N A Not applicable NA engine Naturally aspirated engine O P A S Off power assisted steering O T A S Off throttle assisted steering OPT Optional PFD Personal flotation device P N Part number PTO Power take off STD Standard TBD To be determined TDC Top ...

Page 101: ...WARRANTY _____________________ 103 www SeaDooManuals net ...

Page 102: ...oo 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 To find the nearest authorized Sea Doo dealer dial 1 800 882 2900 NOTE If outside Can...

Page 103: ...below are covered for TWENTY FOUR 24 CONSECUTIVE MONTHS OR 200 HOURS OF ENGINE USE whichever occurs first b FOUR 4 CONSECUTIVE MONTHS for commercial use owners except that the emission related components providing input to emission control see list below are covered for TWENTY FOUR 24 CONSECUTIVE MONTHS OR 200 HOURS OF ENGINE USE whichever occurs first A personal watercraft is used commercially wh...

Page 104: ...se owner or commercial use owner if the preceding conditions have not been met Such limitations are necessary in order to allow BRP to pre serve the safety of its products consumers and the general public Routine maintenance outlined in the Operator s Guide must be timely performed in order to maintain warranty coverage BRP reserves the right to make warranty coverage contingent upon proof of prop...

Page 105: ...ion towing storage telephone rental taxi inconvenience insurance coverage loan payments loss of time loss of income 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 PARTICULAR PURPOSE TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPL...

Page 106: ...nnection with this BRP limited war ranty BRP suggests that you try to resolve the issue at the dealership level We recommend discussing the issue with the authorized dealer s service manager or owner If the issue has not yet been resolved please submit your complaint in writing or call the appropriate number below In Canada In USA BOMBARDIER RECREATIONAL PRODUCTS INC CONSUMER SERVICES GROUP VALCOU...

Page 107: ...Longer Emission Warranty Protects consumer for worry free operation One Star Low Emission The one star label identifies personal watercraft outboard sterndrive and in board engines that meet the Air Resources Board s Personal Watercraft and Out board marine engine 2001 exhaust emission standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke engines...

Page 108: ...ped with RFI engine In California new personal water craft engines must be designed built and equipped to meet the State s stringent anti smog standards BRP must warrant the emission control system on your personal watercraft engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your personal water craft engine Your emission control system ...

Page 109: ...ressure Regulator Tuned Pipe Cylinder Head Fuel Injectors High Tension Ignition Wires Intake Manifold Multi Purpose Electronic Module MPEM Electrical Harness Throttle Position Sensor TPS Electronic Control Module ECU Throttle Body Ignition Coil Exhaust Manifold Exhaust Hoses Manifold Air Temperature Sensor ATS Airbox and Flame Arrester Spark Plugs Manifold Air Pressure Sensor MAPS All Emission Com...

Page 110: ...ng maintenance on your personal watercraft engine but BRP cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance As the personal watercraft owner you should however be aware that BRP may deny you warranty coverage if your personal watercraft engine or a part has failed due to abuse neglect improper maintenance or unapproved modif...

Page 111: ... it has commercial tags or is licensed for commercial use The repair or replacement of parts or the performance of service under this war ranty does not extend the life of this warranty beyond its original expiration date 3 CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on Sea Doo personal watercraft pur chased as new and unused by its first owner from a BRP distribu...

Page 112: ...s 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 B...

Page 113: ...d while this warranty is in effect 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 BRP is notified of such transfer of ownership in the following way BRP or an authorized BRP distributor dealer receives a proof that the former owner agreed to the transfer of o...

Page 114: ...t us know by writing to the address below Also note that from time to time carefully selected and trustworthy organiza tions may be permitted to use the coordinates of our clients to promote quality products and services If you prefer not to have your name and address released please let us know by writing to the address below Bombardier Recreational Products Inc Warranty Department 75 J A Bombard...

Page 115: ... necessary like when safety recalls are initiated It is the owner s responsibility to notify BRP of a change of address or owner 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 F00A2ZL CHANGE OF ADDR...

Page 116: ...Bombardier Recreational Products Inc WARRANTY DEPARTMENT 75 J A Bombardier Sherbrooke QC Canada J1L 1W3 V00A2G AFFIX PROPER POSTAGE 118 _____________________ www SeaDooManuals net ...

Page 117: ... Expiry Date YEAR MONTH DAY To be completed by the authorized Sea Doo dealer at the time of the sale DEALER IMPRINT AREA NAME No STREET APT CITY STATE PROVINCE ZIP POSTAL CODE F00A30L Please verify with your selling dealer to ensure your SEA DOO watercraft has been registered with BRP _____________________ 119 www SeaDooManuals net ...

Page 118: ...C M Y CM MY CY CMY K www SeaDooManuals net ...

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