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Sea-doo 2004 GTI Operator'S Manual Download Page 97

97

TYPICAL — GTI, GTI LE, GTI RFI AND

GTI LE RFI MODELS
(717 AND 787 RFI ENGINES)

1. Engine water outlet hose

Hose Disconnection

Some hoses have to be disconnected.
Disconnect hoses at the following lo-
cation:

GTI, GTI LE, GTI RFI AND GTI LE RFI MODELS 
(717 AND 787 RFI ENGINES)

1. Disconnect engine water inlet hose

Antifreeze

717 engines only:

Temporarily install a

short piece of hose to engine water in-
let at cylinder head.

Insert a funnel into hose and pour an-
tifreeze mixed with water in engine un-
til the colored solution appears at the
cooling system bleed outlet.

787 RFI Engines

Disconnect hose just above T-fitting
from as shown.

TYPICAL

1. Hose connecting to inlet fitting of cylinder 

head

2. Disconnect hose above T-fitting

F17E01Y

1

F06E0EZ

1

F07E0LY

F15E02Y

1

2

smo2004-002a.book  Page 97  Thursday, August 21, 2003  2:54 PM

www.SeaDooManuals.net

Summary of Contents for 2004 GTI

Page 1: ...www SeaDooManuals net ...

Page 2: ...de and the labels on your vehicle Failure to follow these warnings can result in SEVERE INJURY OR DEATH Keep this Operator s Guide with the vehicle at all times WARNING Disregarding any of the safety precautions and instructions contained in this Operator s Guide Safety Videocassette and on product labels could cause injury including the possibility of death 2004 PWC Electro Magnetic Compatibility...

Page 3: ...ongoing commitment to product quality and innovation Bombardier reserves the right at any time to discontinue or change specifica tions designs features models or equipment without incurring obligation The illustrations in this document show the typical construction of the different assemblies and may not represent the full detail or exact shape of the parts However they represent parts that have ...

Page 4: ...EHICLE INFORMATION REGISTRATION NUMBER LOCATION 26 IDENTIFICATION NUMBERS 27 Hull 27 Engine 27 CONTROLS INSTRUMENTS EQUIPMENTS 29 CONTROLS INSTRUMENTS EQUIPMENTS FUNCTIONS 34 1 Safety Lanyard engine cut off cord 34 2 Handlebar 35 3 Throttle Lever 35 4 Engine Start Stop Button 35 5 Variable Trim System VTS Button if so equipped 36 6 Choke Lever 36 7 Shift Lever if so equipped 36 8 Fuel Gauge Low Oi...

Page 5: ...0 Cooling System Bleed Outlet 47 31 Flushing Connector if so equipped 47 32 Bilge Drain Plugs 47 33 Jet Pump Nozzle 48 34 Reverse Gate if so equipped 48 35 Jet Pump Water Intake 48 36 Fuses 49 37 Battery 49 38 Side Vanes if so equipped 49 39 Rear Access Cover 49 40 Automatic Bilge Pump 49 LIQUIDS 50 Fueling Procedure 50 Recommended Fuel 50 Recommended Oil 51 Oil Injection System 51 BREAK IN PERIOD...

Page 6: ...CARE 66 General Care 66 Additional Care for Foul Water or Salt Water 66 Cooling System Flushing and Engine Internal Lubrication 66 Anticorrosion Treatment 68 SPECIAL PROCEDURES 69 Monitoring System 69 Limp Home Mode 69 Engine Overheating 69 Jet Pump Water Intake and Impeller Cleaning 69 Capsized Watercraft 70 Submerged Watercraft 71 Water Flooded Engine 71 Fuel Flooded Engine 72 Out of Fuel 73 Tow...

Page 7: ...eason Preparation 101 TROUBLESHOOTING 103 SPECIFICATIONS 107 SI METRIC INFORMATION 111 ABBREVIATIONS USED IN THIS MANUAL 112 WARRANTY LIST OF DISTRIBUTORS 114 BOMBARDIER NORTH AMERICA LIMITED WARRANTY 2004 SEA DOO PERSONAL WATERCRAFT 115 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT FOR MODEL YEAR 2004 SEA DOO PERSONAL WATERCRAFT WITH 947 DI ENGINES 118 BOMBARDIER INTERNATIONAL LIMITED WARRANTY 2...

Page 8: ...SAFETY INFORMATION 7 SAFETY INFORMATION smo2004 002a book Page 7 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 9: ...fety section may result in se vere injury or death This safety section is for initial ref erence and its content is therefore limited section It should be read in conjunction with the rest of this Op erator s Guide the Safety Videocas sette and the on product warning caution labels It is also strongly rec ommended that operators obtain further information concerning Boating Rules from a local Coas...

Page 10: ...sengers know how to swim and how to reboard the watercraft from the water q Boarding in deep water can be strenuous Practice in chest deep water before operating or embark ing your watercraft in deep water q A PWC will not self right if capsized The operator and passengers must know the proper righting procedure as explained in the Operator s Guide Make sure engine is off before roll ing over the ...

Page 11: ...ppropriate Severe internal injuries can occur if wa ter is forced into body cavities as a result of falling into water or be ing near jet thrust nozzle Normal swimwear does not adequately protect against forceful water en try into the lower body open ing s of males or females footwear gloves and goggles glasses are also recommended Some type of lightweight flexible foot protection is recommended T...

Page 12: ...Y INFORMATION 11 Eye protection F00A12L Vest type personal flotation device Gloves Wet suit or wet suit bottom Foot protection smo2004 002a book Page 11 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 13: ...identifies an instruction which if not followed may cause serious per sonal injuries including the possibility of death q Check local and federal boating laws applicable to the waterways where you intend to use your water craft Learn the local rules of the road Know and understand the ap plicable navigation system such as buoys and signs q Know the waters in which the wa tercraft is to be operated...

Page 14: ...mind that as the throttle lever is released to idle po sition less directional control is available and as the engine is off directional control is lost You need throttle to steer q Ride within your limits and level of riding ability Avoid aggressive ma neuvers to reduce the risk of loss of control ejection and collision Un derstand and respect the perfor mance or your watercraft q Always ride res...

Page 15: ...r your judgement and reaction time q On a PWC never place your feet and legs in the water to aid turning Maneuverabitily of the Watercraft Towing q Do not overload the watercraft or take on more passengers than des ignated for the particular watercraft Overloading can affect maneuver ability stability and performance q Avoid adding on accessories or equipment which may alter your control of the wa...

Page 16: ... Navigational aids such as signs or buoys can assist you identify safe wa ters Buoys will indicate whether you should keep to the right starboard 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 indicate hazards or pertinent boat ing information Markers ...

Page 17: ...r your information here are the most commonly used waterskiing signals Slower F00A17L Fallen skier Watch out Stop Faster OK Speed OK Back to dock Turn right Turn left smo2004 002a book Page 16 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 18: ...ater http floridaconservation org law Florida saltwater www dep state 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...

Page 19: ...ulations htm North Dakota http www state nd us gnf boating Ohio www dnr state oh us odnr watercraft Oregon www osmb state or us Pennsylvania www fish state pa us Rhode Island www state ri us dem topics boating htm South Carolina www dnr state sc us etc 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 ...

Page 20: ... damaged they can be replaced free of charge See an authorized Sea Doo dealer Please read the following labels carefully before operating this watercraft GTI GTI LE GTI RFI and GTI LE RFI Models TYPICAL F17L07N 1 6 11 13 3 8 5 12 2 4 smo2004 002a book Page 19 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 21: ...20 SAFETY INFORMATION XP DI Models TYPICAL F08L1UM 8 4 2 7 9 3 5 1 10 6 11 smo2004 002a book Page 20 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 22: ...SAFETY INFORMATION 21 Label 1 ACCORDING TO WATERCRAFT MODEL F16L0PL smo2004 002a book Page 21 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 23: ...22 SAFETY INFORMATION ACCORDING TO WATERCRAFT MODEL F08A04L smo2004 002a book Page 22 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 24: ...bel 3 Label 4 ACCORDING TO WATERCRAFT MODEL ACCORDING TO WATERCRAFT MODEL Label 5 Label 6 ACCORDING TO WATERCRAFT MODEL ACCORDING TO WATERCRAFT MODEL F00A21Y F00A22Y F02L2D0 F00L29Y F00L2XY F00A23Y F00A24Y F00A25Y smo2004 002a book Page 23 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 25: ...FUEL Do not unscrew protective cap Must be used only by Bombardier certified technician Do not operate the watercraft without cap properly installed ESSENCE SOUS PRESSION Ne pas dévisser le capuchon protecteur Réservéseulementàl usaged untechniciencertifié par Bombardier Ne pas opérer la motomarine sans le capuchon bien installé F00A2QY F00A26Y smo2004 002a book Page 24 Thursday August 21 2003 2 5...

Page 26: ...25 VEHICLE INFORMATION smo2004 002a book Page 25 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 27: ...The registration number should appear on each side of the watercraft On applicable models install registration number to the left of the star label TYPICAL 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 regula tions F17L06L 1 smo2004 002a book Page 26 Thursday August...

Page 28: ...fer to SPECIFICATIONS sec tion to find what engine is used on each model 717 Engine The Engine IdentificationNumber E I N is located on the upper side of the mag neto housing TYPICAL 1 Engine Identification Number E I N 787 RFI Engine The Engine IdentificationNumber E I N is located on the upper crankcase on PTO Power Take Off side 1 Engine Identification Number E I N F00L2EY 1 Z Z N 1 2 3 4 5 L 4...

Page 29: ...heEngine IdentificationNumber E I N is located on the upper crankcase on MAGNETO side TYPICAL 1 Engine Identification Number E I N F06D15Y 1 smo2004 002a book Page 28 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 30: ...o not apply or are optional on some models GTI GTI LE GTI RFI and GTI LE RFI Models F17L11M 24 24 23 22 12 35 2 16 11 7 26 19 20 21 27 28 31 32 33 34 38 36 37 18 13 30 14 15 17 29 smo2004 002a book Page 29 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 31: ...30 GTI and GTI LE Models GTI RFI Models F17L12M 8 9 4 1 6 12 3 25 1 25 8 11 3 F17L17L smo2004 002a book Page 30 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 32: ...31 GTI LE RFI Models 1 F17L13M 10 9 4 11 25 3 smo2004 002a book Page 31 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 33: ...32 XP DI Models TYPICAL F08L1WM 18 39 22 25 17 16 40 14 36 37 25 13 3 26 27 28 30 24 15 11 19 35 24 31 32 33 1 5 4 10 9 2 smo2004 002a book Page 32 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 34: ...CompartmentCover Latch 17 Tool Kit 18 Air Intake Opening 19 Seat Strap 20 Seat Latch 21 Seat Extension Latch 22 Rear Grab Handle 23 Rear Storage Basket 24 Bow and Stern Eyelets 25 Mooring Cleats 26 Footboard 27 Boarding Pads 28 Boarding Platform 29 Boarding Step 30 Cooling System Bleed Outlet 31 Flushing Connector 32 Bilge Drain Plugs 33 Jet Pump Nozzle 34 Reverse Gate 35 Jet Pump Water Intake 36 ...

Page 35: ...d is left on its post 5 seconds after engine is stopped Always ensure safety lanyard is not left on its post after engine is stopped IMPORTANT Leaving the safety lan yard on its post when engine is not running will slowly discharge the bat tery Digitally Encoded Security System DESS The safety lanyard cap specifically con tains an electronic circuit that gives it a unique electronic serial number ...

Page 36: ...peed and watercraft is gradually stopped by water drag Carburetor Equipped Models Do not depress lever unnecessarily when engine is not running A fuel ac celerator pump delivers fuel to the en gine each time throttle lever is applied CAUTION Engine can be flooded if throttle lever is unnecessarily ap plied several times If engine is flood ed it will not start Refer to SPECIAL PROCEDURES for instru...

Page 37: ...ate Lever will automatically return to its normal position when released 1 Choke lever 7 Shift Lever if so equipped A push pull lever forward neutral reverse CAUTION Never rev the engine at high RPM in reverse WARNING On models without O P A S direc tional control is reduced when the throttle is released and lost when engine is off WARNING On models with O P A S direc tional control is reduced whe...

Page 38: ...ght 9 Speedometer if so equipped Analog speedometer indicates the speed of watercraft in miles per hour MPH and kilometers per hour km h The speed sensor mounted on the ride plate sends the signal to the speedom eter and information center if so equipped 10 Information Center Gauge Buttons if so equipped This is a LCD multifunction gauge Dif ferent displays and functions can be activated using 2 b...

Page 39: ...n of the watercraft Tachometer Indicates the revolutions per minute RPM of the engine Speedometer Indicates the speed of watercraft in kilometers per hour KPH or miles per hour MPH Average Speed The information cen ter approximately calculates and dis plays the average speed AV KPH or AV MPH of the watercraft since the last engine start Trip Meter The information center ap proximately calculates t...

Page 40: ...ng A low fuel condition is also indi cated when it occurs See MESSAGE DISPLAY above VTS Position Indicator if so equipped The VTS position indicator shows the riding angle of the watercraft 1 Position indicator 2 Bow up 3 Bow down Display Priorities As a self test all LCD segments and the LED will turn on for 3 seconds each time the information center is activated when safety lanyard is installed ...

Page 41: ...is reset every time en gine is turned off Maintenance Information When the watercraft is due for a mainte nance inspection the message MAINT will blink To clear the warning message while it is blinking 1 Press and hold for 2 seconds to reset NOTE If maintenance message MAINT continues to blink it indicates a fault with the fuel injection system on Di models Refer to an authorized SEA DOO dealer fo...

Page 42: ...o the vehicle illustration for oil injection reservoir cap location Open the front storage compartment cover to expose reservoir cap To add injection oil in the reservoir un screw the cap counterclockwise Do not overfill Reinstall cap and fully tight en it Close and latch storage compartment cover 1 F17L0DY 2 WARNING Always stop the engine before re fueling Fuel is flammable and ex plosive under c...

Page 43: ...s to carry personal articles Ideal location for spare spark plugs towrope first aid kit etc GTI GTI LE GTI RFI and GTI LE RFI Models If there is water in the storage area pull out the drain plug to let water go out Reinstall the plug when done NOTE The water will flow to the bilge If there is an important quantity of wa ter ensure to drain the bilge out of wa ter prior to using the watercraft 1 Dr...

Page 44: ...f the air intake opening is kept under water such as turning constantly in tight circles water will get inside bilge which may cause severe damage to internal parts of the engine 19 Seat Strap The seat strap provides a handhold to assist boarding and is used as a hand hold for the passenger 20 Seat Latch if so equipped Removing the seat allows access to the engine compartment The seat latch is loc...

Page 45: ...XP DI Removing the seat gives access to the engine mechanical electrical and fuel oil systems All Models 21 Seat Extension Latch if so equipped Removing the seat extension allows access to the rear storage basket It also gives access to the seat latch on models with a seat extension 1 F17L0NY 1 F17L0MY WARNING Components inside engine com partment may be hot When start ing or operating the engine ...

Page 46: ...rtight removable basket to carry personal articles The rear storage basket includes a latch to hold an approved fire extinguisher sold separately TYPICAL All Models 24 Bow and Stern Eyelets Bow Eyelet Eyelets can be used for mooring tow ing and as a tie down point during traile ring 1 Bow eyelet Stern Eyelet Some Models This eyelet allows a rope with a hook a closed end or an open end to be at tac...

Page 47: ...riding 27 Boarding Pads Provide a cushioned surface for the knees when boarding from rear of wa tercraft All Models 28 Boarding Platform Provides a large surface for easier board ing from rear of watercraft 29 Boarding Step if so equipped A convenient step to help reboarding the watercraft 1 Boarding step Pull down the step with your hand and hold until a foot is put on the step F18L0SY 1 F08L0TZ ...

Page 48: ...ook for COOLING SYS TEM FLUSHING or refer to an autho rized SEA DOO dealer for servicing 31 Flushing Connector if so equipped A convenient connector is provided to allow easy installation of a garden hose to flush the cooling system TYPICAL Refer to POST OPERATION CARE sec tion for proper use 32 Bilge Drain Plugs Should water be found in the bilge it can be easily drained by unscrewing the drain p...

Page 49: ...al or reverse position with the shift lever the re verse gate moves up or down to obtain the desired position TYPICAL 1 Reverse gate 35 Jet Pump Water Intake The water is drawn up by the impeller through this opening The water intake grate minimizes the entry of foreign objects into the propulsion system TYPICAL 1 Water intake 2 Ride plate F18J05Z 1 WARNING Keep away from intake grate while engine...

Page 50: ...access to the battery drive system suspension exhaust system and bailer pick ups Always relatch cover 40 Automatic Bilge Pump Bilge pump evacuates water from the bilge When safety lanyard cap is installed on its post bilge pump automatically turns on It will remain on until all water is evacuated if any then it will shut down automatically When engine is running bilge pump will automatically start...

Page 51: ...ls or fuel ratios Never use fuel containing more than 10 alco hol ethanol or methanol The use of non recommended fuel can result in watercraft performance deterioration and damage to critical parts in the fuel system and engine components WARNING Follow these safe boating fueling instructions explicitly WARNING Always stop the engine before re fueling Fuel is flammable and ex plosive under certain...

Page 52: ...AUTION Never use four stroke pe troleum or synthetic motor oil and never mix these with outboard motor oil Do not use NMMA TC W TC W2 or TC W3 outboard two stroke en gine oils or ashless two stroke engine oils Avoid mixing different brands of API TC oil as resulting chemical reac tions may cause severe engine dam age Oil Injection System This watercraft features an oil injection system which does ...

Page 53: ...me oil as in the injection oil reservoir in the fuel tank for the first full fuel tank filling only To add injection oil in the fuel tank pro ceed as follows Fill fuel tank with approximately 15 li ters 4 gal of gasoline then add the injection oil in the fuel Fill up fuel tank with gasoline Do not overfill NOTE It is important to proceed in this order to allow a proper mixing of the oil in the gas...

Page 54: ... post prior to verifying 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 ...

Page 55: ...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 ex plained in POST OPERATION CARE Ensure water flows out of jet pump Otherwise water is frozen in cooling system and restricts water flow Do not operate the watercraft in this condition NOTE Pay a...

Page 56: ... lever in forward position the gate should be in upward position and offering a resistance to go downward Withthe shiftlever in neutral position gate should be in middle posi tion With shift lever in reverse position gate should be in downward position VTS Variable Trim System if so equipped Push on arrows on VTS button to check nozzle movement WARNING Do not use any electrical heating device to h...

Page 57: ...d WARNING Should the safety lanyard cap be loose or fail to remain on its post replace it immediately in order to avoid unsafe use WARNING If engine does not shut off when pushing engine start stop button or by disconnecting the safety lan yard stop the engine by applying the choke and turning fuel tank valve if so equipped to OFF posi tion Do not operate the watercraft further see an authorized S...

Page 58: ...the function of each Should any control or instruc tion not be fully understood refer to an authorized SEA DOO dealer WARNING Whenever the engine is to be start ed the operator and passenger s should always be properly sitting on the watercraft and be wearing protective clothingincludingaCoast Guard approved PFD and a wet suit bottom F18J06Y WARNING Keep away from intake grate while engine is on I...

Page 59: ...in maximum efficiency and control from the reverse increase engine speed to slightly above idle Too much RPM will create water tur bulence and reduce reverse efficiency In reverse position turn the handlebar in the same direction that you want to move the rear of the watercraft For example to steer the rear of the wa tercraft to the left side turn the handle bar to the left side F17L0BZ 1 1 F17J01...

Page 60: ...ain familiarity of trim adjustment and its effects When the nozzle is positioned in an up ward angle the water thrust directs the bow of the watercraft upward This po sition is used to optimize high speed TYPICAL 1 Push on arrow pointing upward on VTS button 2 Bow up 3 Nozzle up NOTE VTS position is indicated on a bar gauge in the information center When the nozzle is directed down ward the bow is...

Page 61: ... and requires greater skill The passenger should always grip the seat strap or grab handle Reduce speed and avoid sharp turns Avoid choppy water conditions when carrying a passenger F08J0BY 2 1 3 8 F18J09Y WARNING Throttle should be applied and handlebar turned to change the di rection of the watercraft Steering efficiency will differ depending on the number of passengers load water conditions and...

Page 62: ... the watercraft while holding the handlebar Then bring the other foot over the seat and put it on the other footboard Push the watercraft away from the dock In shallow water board the watercraft either from the side or the rear Ensure there is at least 90 cm 3 ft of water underneath the lowest rear por tion of the hull Take into account that the hull will lower in water when all passengers are abo...

Page 63: ...ip the seat strap Bring your feet on the footboard while maintaining balance using the handle bar except 3 up seat models Sit astride the seat Operator with a Passenger The operator climbs on the watercraft the same way as explained previously In choppy water the passenger while in the water may hold the watercraft to help the operator in climbing aboard The passenger then climbs on the wa tercraf...

Page 64: ...ruptly To start engine depress and hold the engine start stop button Follow pro cedure below for cold or warm engine starting If engine fails to start after 10 seconds wait a few seconds then repeat proce dure CAUTION Do not hold start stop but ton more than 30 seconds to avoid starter overheating A rest period should be observed between the cranking cycles to let starter cool down Pay attention n...

Page 65: ...balance as necessary When crossing wakes always keep a safe distance from watercraft ahead Stopping Docking The watercraft is slowed by water drag The stopping distance will vary depend ing on the watercraft size weight speed water surface condition pres ence and direction of wind and current The operator should become familiar ized with the stopping distance under different conditions Release the...

Page 66: ... A S system 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 On models with O P A S direc tional control is reduced when the throttle is released and or when en gine is off F18A03Y ...

Page 67: ...g the cooling system with fresh water is essential to neutralize corrod ing effects of salt or other chemical prod ucts present in water It will help to re move sand salt shells or other particles in water jackets engine exhaust mani fold tuned pipe and or hoses Engine lubrication and flushing should be performed when the watercraft is not expected to be used further the same day or when the water...

Page 68: ...l plug 3 Spray BOMBARDIER LUBE here 947 DI ENGINES 1 Partially pull tube out of air box to inject BOMBARDIER LUBE lubricant or equivalent Push tube in when finished Lubrication of engine should be done for at least 1 minute After approximately half a minute close fuel valve to run engine out of fuel while lubricating CAUTION When engine begins to run irregularly because of fuel star vation immedia...

Page 69: ...drowned mode is active Crank the engine a few turns to distrib ute the oil on cylinder wall All Models Apply anti seize lubricant on spark plug threads then reinstall them Properly reconnect spark plug cables to spark plugs 1 MAG side spark plug cable Wipe up any residual water from the engine 717 and 787 RFI Engines Reinstall plug on air intake silencer cover Anticorrosion Treatment To prevent co...

Page 70: ...e limited to idle if some critical components fail In this case removing and reinstalling the safety lanyard on its post may allow normal operation to come back These performance reduced modes allow the rider to go back home which would not be possible without this ad vanced system If this occurs see an authorized SEA DOO dealer as soon as possible for inspection Engine Overheating All Models CAUT...

Page 71: ...craft in the proper direc tion eliminates the possibility of resid ual water in the tuned pipe entering the engine and causing engine damage GTI and GTI LE Models Rotate the watercraft counterclock wise seen from rear to its left side for cleaning TYPICAL GTI RFI and GTI LE RFI Models Rotate the watercraft clockwise seen from rear to its right side for cleaning Clean the water intake area If the s...

Page 72: ...er the damage will be to the engine Water Flooded Engine In the event the engine cannot be ser viced within a few hours remove spark plug cables and connect them on the grounding device Remove spark plugs and dry them with a clean and dry cloth Cover spark plug holes with a rag Carburetor Equipped Models Ensure choke lever is completely pushed in Fully depress the throttle lever and hold RFI Model...

Page 73: ...When the engine does not start after several attempts the engine may be fuel flooded Proceed as follows Carburetor Equipped Models Install the safety lanyard cap on its post Ensure choke lever is completely pushed in Fully depress the throttle lever and hold while starting the engine Try several times Crank the engine a few turns to distrib ute the oil on cylinder wall RFI Models To prevent fuel t...

Page 74: ...aler Out of Fuel DI Models When running the engine out of fuel it may be necessary to remove and in stall the safety lanyard 2 3 times to initially feed the fuel system after fuel tank refill Towing the Watercraft in Water All Models Special precautions should be taken when towing a SEA DOO watercraft in water Maximum recommended towing speed is 24 km h 15 MPH When towing your watercraft in water ...

Page 75: ...ater and do not have a hose pinch er be sure to stay well below the maximum towing speed of 24 km h 15 MPH Snugly install the hose pincher on the water supply hose as shown NOTE A red tape on the water supply hose indicates which hose to pinch GTI AND GTI LE MODELS 1 Hose pincher GTI RFI AND GTI LE RFI MODELS 1 Follow this hose towards rear 2 Hose coming from engine 3 Install hose pincher here on ...

Page 76: ...sult in damage to the en gine Low Charge Battery Condition See an authorized SEA DOO dealer to have it charged or replaced WARNING Do not charge or boost the battery while installed on the watercraft Electrolyte is poisonous and dan gerous Avoid contact with eyes skin and clothing F08E08Y 1 smo2004 002a book Page 75 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 77: ...77 MAINTENANCE INFORMATION smo2004 002a book Page 77 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 78: ...ed to 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 recentSEA DOO watercraft manufactured b...

Page 79: ... 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 re pairs unless the appro...

Page 80: ...equire greater frequency of inspection and maintenance DESCRIPTION FREQUENCY I Inspect verify clean adjust lubricate replace if necessary C Clean L Lubricate R Replace FIRST 10 HOURS EVERY 25 HOURS OR 3 MONTHS EVERY 50 HOURS OR 6 MONTHS EVERY 100 HOURS OR 1 YEAR TO BE PERFORMED BY GENERAL Lubrication corrosion protection L C ENGINE Support and rubber mount I I D Exhaust system fasteners I I D RAVE...

Page 81: ...fittings if so equipped I I D Air intake silencer fit tightness I I D Fuel tank straps I I C LUBRICATION SYSTEM Oil injection pump I I D Oil filter and lines I I D Oil filter R D Oil reservoir straps I C ELECTRICAL SYSTEM Electrical connections and fastening ignition system electrical box es starting system fuel injectors RFI and DI models etc I I D MPEM mounting brackets fasteners I D Digitally E...

Page 82: ...ines if so equipped I D Drive shaft protection hose I D PTO flywheel L L C Seal carrier XP DI models L L C Shifter system cable I I D VTS Variable Trim System if so equipped I I D Jet pump reservoir oil and oil level R I R D Jet pump cover pusher if so equipped I D Impeller shaft seal D Impeller and impeller wear ring clearance R D Water intake grate I C HULL AND BODY Bailer pick ups check for obs...

Page 83: ...ing 3 PTO flywheel boot Reinstall and secure PTO flywheel guard XP DI Models Seal Carrier Using a grease gun carefully lubricate seal carrier of mid bearing until grease is just coming out of seal 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 ...

Page 84: ...icant or equiv alent will help prevent corrosion of me tallic parts and maintain proper opera tion of moving mechanisms Carburetor Equipped Models Choke Lever Fully pull choke lever and lubricate the metallic portion All Models Seat Opening Mechanism Tab Hook and Lock Pin TYPICAL 1 Front tab 2 Rear mechanism TYPICAL Carburetor Throttle Body and Oil Injection Pump Lubricate springs shafts and expos...

Page 85: ...can occur with improper carburetor adjustment Fuel Injection System RFI and DI Models The fuel injection system inspection should be performed by an authorized SEA DOO dealer CAUTION Never use injector clean ing products They may contain ad ditives that could damage injector components All Models Fuel and Oil Filters The fuel filter and the oil filter should be replaced by an authorized SEA DOO de...

Page 86: ...d each side of the drive shaft tunnel Two pick ups use a low pressure area in the jet pump to siphon the water out of the bilge when the engine is operating Inspect each pick up screen for ob structions clean as necessary TYPICAL 1 Vacuum bailer pick ups Fuses If an electrical problem occurs check the fuses If a fuse is burnt replace by one of the same rating Follow proce dures below 1 Fuse 2 Chec...

Page 87: ...FUSE IDENTIFICATION 5 A MPEM 15 A Battery GTI RFI and GTI LE RFI Models Locate MPEM in front of engine 1 Engine 2 MPEM 3 Main fuse 4 Charging system fuse WARNING Do not use a higher rated fuse as this can cause severe damage If a fuse has burnt out source of mal function shouldbe determined and corrected before restarting See an authorized SEA DOO dealer for servicing F17H02Y 1 F17H01Y 1 4 F17H06Y...

Page 88: ...ion Fuse identification The fuses F are identified from 1 to 6 Fuse description The fuses are de scribed with abbreviation as follows FP Fuel pump ACC Accessories information center REG Regulator charging system VTS Variable Trim System BAT Battery INJ Injection system The fuse description is followed by the ampere rating A 1 F17H05Y 2 3 F08H0JY 1 F1 FP 15A F2 ACC 2A F3 REG 25A F4 VTS 7 5A F5 BAT ...

Page 89: ...Remove seat Remove darts retaining tubes then pull out both vent tubes each side of elec trical box at rear of hull TYPICAL 1 Vent tubes removed 2 Electrical box Unclip and remove cover of the electri cal box to expose the holder of the main fuse TYPICAL 1 Fuse holder F06H1SY 1 2 F06H1TY 1 2 F06H39Y 1 2 1 1 1 F18H1BY 2 smo2004 002a book Page 89 Thursday August 21 2003 2 54 PM www SeaDooManuals net...

Page 90: ...rical box Unclip and remove cover of the electri cal box to expose the holder of the main fuse TYPICAL 1 Fuse holder Electric bilge pump fuse is located at the bottom of the electrical box 1 Electric bilge pump fuse Properly reinstall removed components Properly relatch storage compartment cover F08H0KY 1 1 1 F18H1BY 2 F12H02Y 1 smo2004 002a book Page 90 Thursday August 21 2003 2 54 PM www SeaDooM...

Page 91: ...e any fuel oil electrolyte deposits and mildew 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 detergent degreasing agent paint thinner ace tone etc Stains may be removed from seat and fiberglass with Knight s Spray Nin...

Page 92: ...watercraft to both bow and stern front rear eyelets so that it is firmly retained on the trailer Use additional tie downs if necessary CAUTION Do not route ropes or tie downs over the seat as they could produce permanent damage Wrap ropes or tie downs with rags or sim ilar protectors where they can touch the watercraft body Ensure all storage compartment cov ers and seat are properly latched A SEA...

Page 93: ...ary 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 will occur Check engine drain hose for obstructions Carburetor Equipped Models TYPICAL 1 Engine drain hose RFI Models Disconnect the water supply hose used to cool the magneto It features a quick connect fitting Press both tabs and pull fitting in...

Page 94: ...the quick connect fitting Press both tabs and pull fitting 1 Disconnect engine drain hose crankcase cooling outlet 2 Air compressor drain line All Models Lower hose push and hold against bilge as necessary so that draining can take place Reconnect fitting when done DI Models Also ensure air compressor drain line is not obstructed Clean as necessary All Models Body Rinsing Repair Wash the body with...

Page 95: ...ere engine damage We strongly recommend this operation be performed by an authorized SEA DOO dealer CAUTION Always use ethylene gly col antifreeze containing corrosion inhibitors specifically recommended for aluminum engines NOTE When available it is recom mended to use biodegradable anti freeze compatible with internal com bustion aluminum engines This will contribute to protect the environment N...

Page 96: ...ENGINES 1 Engine drain hose GTI RFI AND GTI LE RFI MODELS 787 RFI ENGINES 1 Engine drain hose Make sure the fitting is properly con nected to the magneto cover GTI RFI AND GTI LE RFI MODELS 787 RFI ENGINES 1 Fitting properly connected GTI AND GTI LE MODELS 717 ENGINES 1 Hose pincher on injection hose going to tuned pipe F17E02Y 1 F15E01Y 1 1 F17E0AZ F17E03Y 1 smo2004 002a book Page 96 Thursday Aug...

Page 97: ...engines only Temporarily install a short piece of hose to engine water in let at cylinder head Insert a funnel into hose and pour an tifreeze mixed with water in engine un til the colored solution appears at the cooling system bleed outlet 787 RFI Engines Disconnect hose just above T fitting from as shown TYPICAL 1 Hose connecting to inlet fitting of cylinder head 2 Disconnect hose above T fitting...

Page 98: ...hose pinchers NOTE Most of the antifreeze will drain out when removing the hose pinchers Use a container to recover it DISPOSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS DI Models Hose Pinchers Installation Some hoses have to be plugged to prevent draining before filling cooling system jackets with the antifreeze Install hose pinchers at the following location XP DI Models 1 Water inlet hos...

Page 99: ...roximate ly 1 m 3 ft above the deck when pour ing the antifreeze to create enough pressure so that it flows properly A 1 m 3 ft to ease antifreeze flow Pour antifreeze mix in engine until the colored solution appears at cooling system bleed outlet At this point install a hose pincher on bleed outlet hose 1 Bleed outlet hose Continue to pour until antifreeze ap pears at the engine drain hose crank ...

Page 100: ...lator valve and into muffler to protect it Remove temporary hoses and recon nect the factory hose to water regula tor valve All Models NOTE Although antifreeze mainly drained out the antifreeze has mixed with the water that was possibly trapped in the water jackets This will prevent freezing problems At preseason preparation drain the re maining antifreeze from cooling system prior to using the wa...

Page 101: ...watercraft should never be left in water for storage Never leave the watercraft stored in direct sunlight Never completely seal watercraft in a plastic wrap Ventilation must be provided to avoid condensation and possible corrosion Preseason Preparation Use the following chart Since technical skills and special tools are required some operations should be performed by an authorized SEA DOO dealer W...

Page 102: ...r equipped models cable inspection adjustment Dealer Fuel filter replacement except RFI models Dealer Fuel injection sensors verification RFI and DI models Dealer Fuel system check valves lines fasteners pressurization Dealer Direct injector check for leakage DI models Dealer Filler neck fuel tank and fuel cap condition Dealer Flame arrester inspection DI models Dealer Fuel tank straps Operator Re...

Page 103: ...DOO dealer 1 second beep every second intervals DI models Engine drowned mode is active Release throttle to cancel this mode A 2 seconds beep every minute intervals RFI models Fuel tank level is low Refill 4 short beeps every 3 seconds interval for 2 hours Safety lanyard has been left on its post without starting engine or after engine was stopped To prevent battery discharge remove the safety lan...

Page 104: ...ghten Discharged or weak battery Refer to an authorized SEA DOO dealer Worn starter Refer to an authorized SEA DOO dealer Engine turns normally Closed fuel tank valve carburetor equipped models Turn fuel tank valve to ON posi tion Fuel tank empty or water contaminated Refill Siphon and fill with fresh fu el Fuel filter clogged or water contaminated carburetor equipped models Clean check fuel tank ...

Page 105: ...ed Clean or replace Partially closed choke carburetor equipped models Refer to an authorized SEA DOO dealer Defective sensor or MPEM RFI and DI models Refer to an authorized SEA DOO dealer OTHER OBSERVATION POSSIBLE CAUSE REMEDY Monitoring beeper sounds continuously Clogged jet pump water intake Clean Clogged coolant system Flush cooling system OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark Fo...

Page 106: ...watercraft in limp home mode due to a component malfunc tion DI models Try removing and reinstalling the safety lanyard on its post Refer to an authorized SEA DOO dealer OTHER OBSERVATION POSSIBLE CAUSE REMEDY Cavitation Jet pump water intake clogged Clean Damaged impeller Replace Refer to an authorized SEA DOO dealer The safety lanyard used purpose ly does not allow watercraft top speed DI models...

Page 107: ... oil Number of cylinders 2 Displacement 718 2 cm3 43 81 in3 781 6 cm3 47 7 in3 Rev limiter setting 7100 50 RPM 7200 50 RPM COOLING SYSTEM Type Water cooled total loss type Direct flow from propulsion unit ELECTRICAL SYSTEM Magneto generator output 160 W 6000 RPM 270 W 6000 RPM Ignition system type Digital CDI Digital inductive type Spark plug Make and type NGK BR8ES Gap 0 45 mm 018 in Starting sys...

Page 108: ...r Formula pump Jet pump type Axial flow single stage Transmission Direct drive Reverse system Yes Jet pump oil type SEA DOO synthetic polyolester oil SAE 75W90 GL5 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 passengers 3 Overall length 307 cm 121 in Overall width 120 cm 47 in Overall heig...

Page 109: ...L Magneto generator output 270 W 6000 RPM Ignition system type Digital inductive Spark plug Make and type NGK ZFR4F Gap 1 1 mm 043 in Starting system Electric starter with reduction gear Battery 12 V 19 A h Fuse Battery 25 A Main 30 A Charging system REG 25 A VTS system 7 5 A Informationcenter ACC N A Injection system INJ 15 A Fuel pump FP 15 A Bilge pump 3 A FUEL SYSTEM Fuel Type Regular unleaded...

Page 110: ...pump oil type SEA DOO synthetic polyolester oil SAE 75W90 GL5 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 passengers 2 Overall length 272 cm 107 in Overall width 112 cm 44 1 in Overall height 104 cm 40 6 in Weight 274 kg 605 lb Load limit passengers luggage 181 kg 400 lb CAPACITIES Fuel t...

Page 111: ...r knot SYMBOL m kg N L C kPa N m km h kn PREFIXES PREFIX kilo centi milli micro SYMBOL k c m µ MEANING one thousand one hundredth of one thousandth of one millionth of VALUE 1000 0 01 0 001 0 000001 CONVERSION FACTORS 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 knot MPH Fahrenheit Celsius hp TO mm cm cm cm m g kg N N m N m lbf in kPa U ...

Page 112: ... identification number EPA Environmental protection 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 O P A S Off power assisted steering OPT Optional PFD Personal flotation device P N Part number PTO Power take off STD Standard TBD To be determined TDC Top dead center TOPS Tip over protec...

Page 113: ...113 WARRANTY smo2004 002a book Page 113 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 114: ...he Sea Doo dealership To find the nearest authorized Sea Doo dealer dial 1 800 882 2900 NOTE If outside Canada or USA consult your local authorized Sea Doo distributor USA Except Puerto Rico BOMBARDIER MOTOR CORPORATION OF AMERICA 7575 Bombardier Court WAUSAU WI 54401 Phone 715 848 4957 Fax 715 847 6879 www bombardier com CANADA BOMBARDIER INC RECREATIONAL PRODUCTS 75 J A BOMBARDIER ST SHERBROOKE ...

Page 115: ... with generating income or any work or employment during any part of the warranty period A personal watercraft is also used commercially when at any point during the warranty period it has commercial tags or is licensed for commercial use The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration dat...

Page 116: ...authorized servicing Bombardier Sea Doo dealer Damage caused by abuse abnormal use neglect or operation of the product in a man ner inconsistent with the recommended operation described in the Operator s Guide Damage resulting from accident submersion fire theft vandalism or any act of God Operation with fuels oils or lubricants which are not suitable for use with the product see the Operator s Gu...

Page 117: ...dier dealer and gives the coordinates of the new owner or b Bombardier or an authorized Bombardier dealer receives a proof that the former owner agreed to the transfer of ownership in addition to the coordinates of the new owner 9 CONSUMER ASSISTANCE In the event of a controversy or a dispute in connection with this Bombardier limited warranty Bombardier suggests that you try to resolve the issue ...

Page 118: ...d two stroke engines These engines are equivalent to the U S EPA s 2006 standards for marine engines Two Stars Very Low Emission The two star label identifies personal watercraft outboard sterndrive and inboard engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One S...

Page 119: ...Sea Doo personal watercraft are still applicable to these models with the necessary modifications Select emission control parts of your 2004 Sea Doo personal watercraft equipped with a 947 DI engine are warranted from the date of delivery to the first retail consumer 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 ...

Page 120: ...Guide Bombardier recommends that you retain all receipts covering maintenance on your personal watercraft engine but Bombardier 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 Bombardier may deny you warranty coverage if your personal watercraft engine or a ...

Page 121: ...mercial use The repair or replacement of parts or the performance of service under this warranty 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 purchased as new and unused by its first owner from a Bombardier distributor dealer authorized to distribute Sea D...

Page 122: ...g but not limited to cosmetic gel coat finish blisters or fiberglass delamination caused by blisters crazing spyder or hairline cracks and Incidental or consequential damages or damages of any kind including without limita tion 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 ...

Page 123: ...ntroversy or a dispute in connection with this Bombardier limited warranty Bombardier 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 b If further assistance is required the distributor s service department should be contact ed in order to resolve the matter c If the matter still remains unre...

Page 124: ... by writing to the address below Also note that from time to time carefully selected and trustworthy organizations may be permitted to use the coordinates of our clients to promote quality prod ucts and services If you prefer not to have your name and address released please let us know by writing to the address below Bombardier Inc Recreational Products Warranty Department 75 J A Bombardier Stree...

Page 125: ... an autho rized 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 CHANGE OF ADDRESS CHANGE OF OWNERSHIP WATERCRAFT IDENTIFICATION NUMBERS Model Number Hull Identification Number H I N OLD ADDRESS OR PREVIOUS OWNER ______________________________________________ NAME _________________________...

Page 126: ... OTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUÉBEC CANADA J1L 1W3 www SeaDooManuals net ...

Page 127: ... Bombardier or an autho rized 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 CHANGE OF ADDRESS CHANGE OF OWNERSHIP WATERCRAFT IDENTIFICATION NUMBERS Model Number Hull Identification Number H I N OLD ADDRESS OR PREVIOUS OWNER ______________________________________________ NAME ___________...

Page 128: ... OTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUÉBEC CANADA J1L 1W3 www SeaDooManuals net ...

Page 129: ...N NUMBER H I N ENGINE IDENTIFICATION NUMBER E I N Owner Purchase Date YEAR MONTH DAY Warranty 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 smo2004 002a book Page 113 Thursday August 21 2003 2 54 PM www SeaDooManuals net ...

Page 130: ...www SeaDooManuals net ...

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