Sea-doo GS 5644 Operator'S Manual Download

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Seal Carrier

XP Models

Using a grease gun, carefully lubricate
seal carrier of mid bearing until grease
is just coming out of seal.

1. Grease seal carrier of mid bearing

Anticorrosion Protection

Throttle/Choke Cables

Lubricate the throttle and choke cables
with BOMBARDIER LUBE lubricant or
equivalent.

Electrical Connections

As necessary, apply anticorrosion
product such as dielectric grease on
battery posts and all exposed cable
connectors.

CAUTION:

Do not lubricate connec-

tors of the Multi-Purpose Electronic
Module.

Additional Lubrication

BOMBARDIER LUBE lubricant or
equivalent will help prevent corrosion
and metallic parts and maintain proper
operation of moving mechanisms.

Choke Lever

Fully pull choke lever and lubricate the
metallic portion.

Seat Opening Mechanism, Tab,
Hook and Lock Pin

All Models Except XP

1. Front tab
2. Rear mechanism

TYPICAL

Carburetor/Throttle Body and Oil
Injection Pump

Lubricate springs, shafts and exposed
portion of cables.

NOTE:

Grease carburetor linkage with

synthetic grease

(twin-carburetor

models)

TYPICAL

F08I01Y

F01L7UY

START

STOP

F01L51Y

F01F07Y

smo2000-002a.book Page 66 Tuesday, September 28, 1999 12:00 PM

www.SeaDooManuals.net

Summary of Contents for GS 5644

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

Page 2: ...tional Products After Sales Service Sherbrooke Quebec Canada J1L 1W3 Gelcote is a trademark of Gelcote International Knight s Spray Nine is a trademark of Korkay System Ltd The following trademarks are property of Bombardier Inc and or its subsidiaries SEA DOO BOMBARDIER ROTAX Bombardier Lube BOMBARDIER ROTAX Formula XP S Synthetic Injection Oil BOMBARDIER ROTAX Injection Oil Sea Doo Synthetic Gre...

Page 3: ...ty More serious boaters may want to obtain Chapman Piloting by Elbert S Maloney available at most book stores When introducing your family or friends to the sport be sure they fully understand the controls and operation of the watercraft and the importance of courteous responsible riding Each operator has a responsibility to ensure the passenger safety and the safety of other water users Please fo...

Page 4: ...o equipped 31 9 Speedometer if so equipped 31 10 Tachometer if so equipped 32 11 Variable Trim System VTS Gauge if so equipped 32 12 Info Center Gauge Buttons if so equipped 32 13 Glove Box if so equipped 33 14 Fuel Tank Valve 33 15 Fuel Tank Cap 34 16 Oil Injection Reservoir Cap 34 17 Front Storage Compartment Cover 34 18 Front Storage Compartment Cover Latch 35 19 Front Storage Compartment Cover...

Page 5: ...CATION 42 Fueling Procedure 42 Recommended Fuel 42 Recommended Oil 42 Oil Injection System 43 BREAK IN PERIOD 44 Engine 44 10 Hour Inspection 44 DAILY PRE OPERATION CHECKS 45 Hull 46 Jet Pump Water Intake 46 Bilge 46 Battery 46 Fuel Tank and Oil Reservoir 46 Engine Compartment 46 Steering System 46 Throttle System 46 Shifter System if so equipped 47 VTS Variable Trim System if so equipped 47 Safet...

Page 6: ...64 MAINTENANCE 65 Lubrication 65 Periodic Inspection 67 Periodic Inspection Chart 68 Throttle and Choke Cable Inspection 70 Carburetor Adjustment 70 Fuel and Oil Filters 70 Steering Alignment 70 VTS Adjustment if so equipped 71 Vacuum Bailer Pick Ups 71 Water Tank Trap Drains 71 Fuses 72 General Inspection and Cleaning 74 TRAILERING STORAGE AND PRE SEASON PREPARATION 75 Trailering 75 Storage 75 Pr...

Page 7: ... however main tains a policy of continuous improve ment of its products without imposing upon itself any obligation to install them on products previously manufac tured Because of our ongoing commitment to product quality and innovation Bom bardier Inc reserves the right at any time to discontinue or change specifica tions designs features models or equipment without incurring obligation The illus...

Page 8: ...v ice or inexperienced operator or an underage or disabled person is NOT RECOMMENDED Observe and follow all on product warning labels Become completely familiar with the controls and operation of the water craft before embarking on your first trip or taking on a passenger s If you have not had the opportunity to do so with your authorized Sea Doo dealer practice driving solo in a suitable area and...

Page 9: ...ce from all other crafts other waterusers or other objects Like any other craft this watercraft has no brake Stopping distance will vary depending on initial speed load wind and water conditions Practice stopping and docking in a safe traffic free area to have an idea of how long it will take to stop the watercraft un der varying conditions Do not re lease throttle when trying to steer away from o...

Page 10: ...In shallow water proceed with cau tion and at very low speeds Grounding or abrupt stops may re sult in injury Debris may also be picked up and be thrown rearward by the jet pump onto people or prop erty Respect no wake zones the rights of other water users and the environ ment As the skipper and owner of a watercraft you are responsible for damage to other crafts caused by the wake of your watercr...

Page 11: ... 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 those they were de signed Maintenance procedures and specified tightening torque should be strictly adhered to Never attempt repairs unless the appropri ate tools are available These water crafts are designed with parts dimen si...

Page 12: ...authorized Sea Doo distributor U S A Except Puerto Rico BOMBARDIER MOTOR CORPORATION OF AMERICA 5000 STEWART AVENUE WAUSAU WI 54401 Phone 715 842 8886 Fax 715 848 3455 http www bombardier com CANADA Alberta British Columbia Manitoba North West Territories Nunavut Ontario Quebec Saskatchewan Yukon New Brunswick Nova Scotia Prince Edward Island BOMBARDIER RECREATIONAL PRODUCTS 75 J A BOMBARDIER ST S...

Page 13: ... within two 2 days of the appearance of the defect in material and or workmanship and present to the servicing authorized SEA DOO dealer the SEA DOO Warranty Registration Card or a proof of purchase of the NEW and UNUSED 2000 SEA DOO watercraft and must sign the repair work order prior to the start of the repair in order to validate a warranty repair All parts replaced under this limited warranty ...

Page 14: ...this warranty at any time being under stood that such modification will not alter the warranty conditions applicable to the SEA DOO watercraft sold while this warranty is in effect 6 TRANSFER If the customer sells the watercraft guaranteed under the present he shall assign and transfer this warranty which shall be valid for the rest of the relevant PERIOD as defined in section 1 hereinabove to the...

Page 15: ...otify a local authorized SEA DOO dealer within two 2 days of the appearance of the defect in material and or workmanship and present to the servicing authorized SEA DOO watercraft dealer the SEA DOO Warranty Registra tion Card or a proof of purchase of the NEW and UNUSED 2000 SEA DOO water craft and must sign the repair work order prior to the start of the repair in order to validate a warranty re...

Page 16: ...e English version shall prevail It is the customer s responsibility to ensure that the SEA DOO watercraft complies with all boating regulations and standards of any country other than the original country of sale where the SEA DOO watercraft is intended to be used BOMBARDIER reserves the right to modify this warranty at any time being under stood that such modification will not alter the warranty ...

Page 17: ...fer to follow ing illustration for location The registration number should appear on each side of the watercraft 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 regulations F07A08L 1 smo2000 002a book Page 15 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 18: ... IMPORTANT LABELS Please read the following labels carefully before operating this watercraft GS Models TYPICAL F06L0RM 1 2 4 5 6 11 3 7 smo2000 002a book Page 16 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 19: ...17 XP Models TYPICAL F08L0PM 1 6 7 3 2 11 smo2000 002a book Page 17 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 20: ...18 GTS Models TYPICAL F02L2QM 1 9 2 11 8 3 7 5 6 smo2000 002a book Page 18 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 21: ...19 GTI GTX and GTX RFI Models TYPICAL F07L1SL 1 7 6 3 10 5 11 2 smo2000 002a book Page 19 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 22: ...T XP Label 2 XP MODELS Label 3 GS GTS AND GTI MODELS Label 4 XP GTX AND RFI MODELS Label 5 Label 6 F00A10L F08L1NL F00L060 F01L9EY F02L2D0 F06A03Z smo2000 002a book Page 20 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 23: ... AND RFI MODELS Label 10 GTS MODELS Label 11 GTS MODELS Label 12 Label 13 WARNING DO NOT BOOST BATTERY WHILE INSTALLED F00L050 F02L2EZ F06L0DZ F02L3FZ F02L2G1 F07L11Z F00L29Y smo2000 002a book Page 21 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 24: ...H I N Other Models The Hull Identification Number H I N is located on footboard at the rear of watercraft 1 Hull Identification Number H I N It is composed of 12 digits Engine 717 Engine The Engine Identification Number E I N is located on the upper side of the magneto housing TYPICAL 1 Engine Identification Number E I N F01L8XY 1 F08L0QY 1 Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number F00A0CZ ...

Page 25: ...Power Take Off side 1 Engine Identification Number E I N 947 Engine The Engine Identification Number E I N is located on the upper crank case on MAGNETO side 1 Engine Identification Number E I N F01D87Y 1 F06D15Y 1 smo2000 002a book Page 23 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 26: ...omponents do not apply or are optional on some models GS Models TYPICAL 17 F06L0ZM 15 31 18 2 26 37 28 29 38 39 42 45 34 41 43 47 16 22 19 34 4 9 5 35 1 3 35 6 14 12 smo2000 002a book Page 24 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 27: ...XP Models TYPICAL 23 F08L0SN 28 42 45 13 2 14 37 31 33 38 39 35 26 16 34 34 43 47 11 10 4 5 1 15 9 8 3 22 6 44 41 35 26 24 smo2000 002a book Page 25 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 28: ...26 GTS Models TYPICAL 17 F02L3IM 16 4 26 18 2 37 28 29 38 39 27 45 46 31 34 41 43 22 15 19 25 34 47 8 3 6 14 1 7 smo2000 002a book Page 26 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 29: ...TX RFI Models TYPICAL 17 F07L1UL 18 2 7 37 28 29 36 30 38 39 42 45 46 43 34 31 32 36 15 26 13 16 22 34 41 40 14 47 12 20 8 9 3 6 1 35 4 smo2000 002a book Page 27 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 30: ... 20 Front Storage Compartment Cover Lock 21 Tool Kit 22 Storage Compartment Engine Cover 23 Storage Compartment Engine Cover Latches 24 Water Tank Trap Drains 25 Air Intake Opening 26 Rear Vent Grills 27 Seat Strap 28 Seat Latch 29 Rear Seat Latch 30 Rear Grab Handle 31 Rear Storage Basket 32 Rear Access Cover 33 Bow and Stern Eyelets 34 Mooring Cleats 35 Cargo Cleats 36 Footboard 37 Boarding Pads...

Page 31: ...the safety lanyard re mains on the switch it can be restart ed within approximately 10 minutes by pressing the engine start stop button After this delay it is necessary to apply a slight pressure or the removal and re installation of the safety lanyard on the switch to allow engine starting Two short beeps should sound indicating the system is ready again to allow en gine starting Monitoring Syste...

Page 32: ... if throttle lever is applied several times If engine is flooded it will not start 4 Engine Start Stop Button To start engine depress and hold the button Release immediately after en gine is started To stop engine fully release throttle le ver then depress the button and discon nect safety lanyard from the switch 1 Engine start stop button With the Digitally Encoded Security System leaving the saf...

Page 33: ...reverse mark appears on rod Le ver locks in forward and in neutral po sitions only 8 Fuel Gauge Low Oil Warning Light if so equipped Analog gauge indicates the amount of fuel in the fuel tank and a warning light when level is low in oil reservoir 1 Low oil warning light NOTE With the safety lanyard discon nected electrical system can be acti vated for approximately 33 seconds by depressing the eng...

Page 34: ...ter includes the same functions as above and features the following additional ones clock compass exterior temperature Multifunction Gauge Operation Display Priorities The clock compass function is the ba sic mode of the Info Center gauge Use the compass as a guide only Not to be used for navigation pur poses The chronometer tachometer and speedometer are the only other modes that may be chosen to...

Page 35: ...k compass mode press and hold the MODE and SET buttons for 2 seconds Press the MODE button to adjust the hours and the SET button to adjust the minutes Press again on the MODE and SET buttons to return to the normal mode or it will return to the normal mode af ter 10 seconds Maintenance Information When the watercraft is due for a main tenance inspection the message MAINT will blink To clear the w...

Page 36: ...s The reservoir cap is located on the right hand side of the watercraft XP Models Open engine cover and remove stor age basket TYPICAL 1 Oil injection reservoir cap GTI GTX and GTX RFI Models Open the front storage compartment cover to expose reservoir cap The reservoir cap is located on the right hand side of the watercraft 17 Front Storage Compartment Cover It gives access to the front storage c...

Page 37: ...ent cover Always relatch NOTE Verify periodically the lock pin tightness of storage cover Tighten if needed and make sure storage cover latches properly 19 Front Storage Compartment Cover Hinge Locking Mechanism GS and GSX RFI Models Hinge is provided with a locking mech anism to hold front storage compart ment cover when fully open To close cover pull tab GTS Models Hinge is provided with a locki...

Page 38: ... properly 24 Water Tank Trap Drains if so equipped If water enters the air intake opening a water tank trap with a baffle sepa rates water from the air then evacu ates the water through the front of storage cover CAUTION Unusual maneuvers such as circles with the nose of the water craft under water will fill the bilge 25 Air Intake Opening This is where air enters to supply the engine and ventilat...

Page 39: ...ft and pull the seat rearward NOTE On the GTI GTX and GTX RFI models it is necessary to remove the rear seat first and repeat the same pro cedure to remove the front portion of the seat Engine Compartment This is where the mechanical electri cal and fuel oil systems are located When reinstalling the seat insert seat front tab into body hook for each por tion of the seat on the GTI GTX and GTX RFI ...

Page 40: ... personal articles 32 Rear Access Cover if so equipped It gives access to the drive system suspension exhaust system and bail er pick ups Always relatch cover 33 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 This eyelet allows a rope with a hook a closed end or an open end to be at tached 1 Stern eyelet...

Page 41: ...arding Platform Provides a large surface for easier board ing from rear of watercraft 39 Boarding Step if so equipped A convenient step to help reboarding the watercraft 1 Boarding step F00L0DY 1 F08L0TZ 1 F07L0XY 1 WARNING Engine should be OFF when using boarding step Keep limbs away from jet or intake grate Stay on center of the step Only one per son at the time on the step Never use the step fo...

Page 42: ...on of a garden hose to flush the cooling system Refer to POST OPERATION CARE sec tion for proper use 42 Bilge Drain Plugs Should water be found in the bilge it can be easily drained by unscrewing the drain plugs CAUTION Make sure drain plugs are properly secured prior to launch ing the watercraft in water 1 Unscrew 2 Tighten Tilt the watercraft slightly to the rear so that the water can completely...

Page 43: ...the desired position 46 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 WARNING Never use nozzle as a supporting point to board the watercraft or to lift it WARNING Never use gate as a supporting point to board the watercraft Do not reverse while at speed...

Page 44: ...injection oil is not available CAUTION Never use 4 stroke petro leum or synthetic motor oil and nev er mix these with outboard motor oil Do not use NMMA TC W TC W2 or TC W3 outboard motor oils or other ashless type 2 stroke oil Avoid mixing different brands of API TC oil as resulting chemical reaction may cause severe engine damage XP GTX and RFI Models Use BOMBARDIER ROTAX Formula XP S synthetic ...

Page 45: ...il appears at approx imately 13 mm 1 2 in from top of res ervoir Do not overfill CAUTION Always maintain a suffi cient amount of injection oil in the oil reservoir Check and refill every time you refuel Do not overfill If the engine runs out of oil severe engine damage will occur If the oil reser voir is found almost empty air can enter in the system and it should be bled Immediately refer to an a...

Page 46: ...l 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 gasoline If oil is added first in an empty fuel tank fuel lines will be filled up with injection oil leading in a no start condition o...

Page 47: ...ifying any of the following ITEM OPERATION Hull Inspect Jet pump water intake Inspect clean Bilge Drain Ensure plugs are secured Battery Inspect tightness of cables and retaining strap Fuel tank and oil reservoir Refill Engine compartment Verify for any fuel leak odor Steering system Check operation Throttle system Check operation Shifter system if so equipped Check operation VTS if so equipped Ch...

Page 48: ...necessary Check fuel tank and oil reservoir retain ing straps fasteners Engine Compartment Steering System Assisted by another person check steering operation for free movement When the handlebar is horizontal the jet pump nozzle should be in the straight ahead position Ensure the jet pump nozzle pivots easily when han dlebar is turned Throttle System Check throttle lever for free and smooth opera...

Page 49: ...gine start stop button Safety Lanyard and Engine Start Stop Button If craft is equipped with shift lever po sition lever in neutral Ensure that both switches operate properly Start en gine and stop it using each switch in dividually Storage Compartment Covers Ensure they are closed and latched WARNING Verify the reverse gate locking op eration before starting the engine WARNING If engine does not ...

Page 50: ...er half way The reverse gate will be in the middle position directing half of the thrust toward the front of the craft to minimize watercraft movement GTS MODELS 1 Shift lever in neutral position GTI GTX AND GTX RFI MODELS 1 Shift lever in neutral position WARNING Always perform the DAILY PRE OPERATION CHECKS before oper ating the watercraft Become thor oughly familiar with all controls and the fu...

Page 51: ...ncrease 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 opposite direction that you want to move the rear of the watercraft For example to steer the rear of the watercraft to the left side turn the handlebar to the right side 1 Handlebar turned to the right side 2 Rear of watercraft moving to...

Page 52: ...er speeds are recom mended it is an excellent opportunity to gain 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 position is used to optimize high speed TYPICAL 1 Push on arrow pointing upward on VTS button 2 Bow up 3 Nozzle up NOTE Models equipped with an Info Center VTS position is in...

Page 53: ...seat strap or grab handle Reduce speed and avoid sharp turns Avoid choppy water conditions when carry ing a passenger Boarding the Watercraft General As with any watercraft boarding should be done carefully and engine should not be running On some models boarding is facilitat ed by using a step CAUTION Never use jet pump com ponents as a supporting point to board the watercraft RES F01J4WY 1 2 3 8...

Page 54: ...he handle bar Then bring the other foot over the seat and put it on the other footboard Push the watercraft away from the dock A 90 cm 3 ft In shallow water board the watercraft either from the side or the rear Boarding in Deep Water Operator Alone Swim to the rear of the watercraft Grip the grab handle and pull yourself upward until your knee can reach the boarding platform then grip the seat str...

Page 55: ...e meaning of the coded signal Position shift lever to neutral Turn the fueltank valve if so equipped to ON position Firmly grip handlebar with your left hand and place both feet on the foot board 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 C...

Page 56: ...her a cold or warm engine Riding All Models Slowly accelerate to reach deeper wa ter Do not apply full throttle until the engine is warm CAUTION Avoid watercraft opera tion in weeded areas If unavoid able vary watercraft speed Rough Water or Poor Visibility Operation Avoid operation in these conditions If you should do so proceed with cau tion and prudence using minimum speed Crossing Waves Reduce...

Page 57: ... the beach Come slowly to the beach and shut off the using the safety lanyard when wa ter depth is 90 cm 3 ft under the hull then pull the watercraft to the beach 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 l...

Page 58: ...d in direct sunlight Cooling System Flushing and Engine Internal Lubrication General Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemi cal products present in water It will help to remove sand salt shells or other particles in water jackets en gine exhaust manifold tuned pipe and or hoses Engine lubrication and flushing should be perfo...

Page 59: ...h cooling system start the en gine then immediately open the water tap CAUTION Never flush a hot engine Always start the engine before open ing the water tap Open water tap immediately after engine is started to prevent overheating Run the engine about 3 minutes at a fast idle around 3500 RPM CAUTION Never run engine longer than 5 minutes Drive line seal has no cooling when watercraft is out of wa...

Page 60: ...s Close the water tap then stop the en gine CAUTION Always close the water tap before stopping the engine Final Steps Disconnect the garden hose GTS Models Unlock and remove coupler hose Re install dust cap over fitting spigot Remove hose pincher from water out let hose CAUTION Serious engine damage can occur if hose pincher is not re moved All Models Remove spark plug cables and con nect them on ...

Page 61: ...in this order no fuel will be injected into the engine All Models Apply anti seize lubricant on spark plug threads then reinstall them Reinstall plug on air intake silencer cover Properly reconnect spark plug cables to spark plugs Wipe up any residual water from the engine Anticorrosion Treatment To prevent corrosion spray a corrosion inhibitor salt water resistant such as BOMBARDIER LUBE lubrican...

Page 62: ... short period with out starting engine Most of the time this will remove the blockage Start en gine and make sure water flows out from bleed outlet and watercraft oper ates properly If system is still blocked move the craft out of the water and remove blockage manually Models with Reverse System If the aforementioned method does not work the following can be per formed With engine running and befo...

Page 63: ...ne is off grab the inlet grate step on bumper rail and use your weight to rotate the watercraft clock wise seen from rear XP GTX and RFI Models To return the watercraft upright en sure engine is off grab the inlet grate step on bumper rail and use your weight to rotate the watercraft coun terclockwise seen from rear Submerged Watercraft If the watercraft is submerged and en gine is water flooded i...

Page 64: ...Ensure choke lever is completely pushed in Depress the throttle lever at full throt tle position and hold while starting the engine Try several times RFI Models To prevent fuel to be injected in the en gine proceed as follows Remove safety lanyard from its switch Depress the throttle lever at full throt tle position and hold Reinstall the safety lanyard cap on its switch Try to start engine severa...

Page 65: ...ing the ex haust system Without the engine run ning there isn t any exhaust pressure to carry the water out the exhaust out let CAUTION Failure to do this may re sult in damage to the engine If you must tow a stranded watercraft in water 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 ...

Page 66: ...g it Fail ure to do so will result in damage to the engine 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 F07E04Y 1 smo2000 002a book Page 64 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 67: ...l PTO flywheel boot begins to expand CAUTION Immediately stop lubri cating as soon as PTO flywheel boot begins to expand to prevent damage or slipping 1 PTO flywheel 2 Grease fitting 3 PTO flywheel boot Reinstall and secure PTO flywheel guard WARNING Only perform procedures as de tailedin this guide It is recommend ed that the assistance of an autho rizedSea Doo dealer be periodically obtained on ...

Page 68: ...e Multi Purpose Electronic Module Additional Lubrication BOMBARDIER LUBE lubricant or equivalent will help prevent corrosion and metallic parts and maintain proper operation of moving mechanisms Choke Lever Fully pull choke lever and lubricate the metallic portion Seat Opening Mechanism Tab Hook and Lock Pin All Models Except XP 1 Front tab 2 Rear mechanism TYPICAL Carburetor Throttle Body and Oil...

Page 69: ... mechanized products A periodic in spection contributes to the product s life span The following maintenance chart gives guidelines for regular watercraft ser vicing scheduled to be performed by you and or by an authorized Sea Doo dealer The schedule should be adjust ed according to operating conditions and use IMPORTANT Schedule for watercraft rental operations or higher number of hour use will r...

Page 70: ... so equipped D FUEL SYSTEM Carburetor adjustment including choke throttle cable adjustments carburetor equipped models D Throttle choke cables inspection lubrication O Fuel filter carburetor equipped models and lines inspection D Fuel filter replacement carburetor equipped models D Fuel injector cleaning RFI models D Fuel injector sensors visual inspection RFI models D Fuel vent line pressure reli...

Page 71: ...tc D Digitally Encoded Security System D Monitoring beeper D Battery condition and straps D STEERING SYSTEM Inspection and cable adjustment D PROPULSION SYSTEM Drive shaft boot and spline condition if so equipped D PTO flywheel and seal carrier lubrication if so equipped O Shifter system cable adjustment if so equipped D VTS Variable Trim System if so equipped D Jet pump reservoir oil level oil co...

Page 72: ...nowledge and experience to have the correct mixture supplied to the engine CAUTION Serious engine damage can occur with improper carburetor adjustment All Models Fuel and Oil Filters The fuel filter carburetor equipped models and the oil filter should be re placed by an authorized Sea Doo deal er Fuel system pressurization should be conducted at the same time CAUTION An obstructed oil filter will ...

Page 73: ... to be readjusted refer to an authorized Sea Doo dealer CAUTION Trim ring and or nozzle should not interfere at any position Vacuum Bailer Pick Ups They are located 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 operat ing Inspect each pick up screen for ob structions clean as necessary TYPICAL 1 Vacu...

Page 74: ...heck fuse condition Make sure to properly close the fuse cap Properly close the electrical box cover making sure its seal is well positioned RFI Models To access fuses on the Multi Purpose Electronic Module open front storage compartment cover and remove bas ket Locate MPEM on the left side of wa tercraft Unclip the fuse cover from the MPEM TYPICAL 1 MPEM 2 Fuse cover Use the tabs of the fuse cove...

Page 75: ...e basket Locate MPEM on the left side of wa tercraft Remove fuse cover from the MPEM TYPICAL 1 MPEM 2 Fuse cover Use the tabs of the fuse cover to re move and reinstall fuses 1 Fuse cover 2 Fuse tabs To access fuse in the electrical box proceed as follows Open the engine cover and remove storage basket XP models Remove seat except XP models Remove vent tube support GS models F07H08Y 1 F07H0HZ 1 1 ...

Page 76: ...ould be cleaned by your dealer to remove 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 deter gent degreasing agent paint thin ner acetone etc Stains may be removed from sea...

Page 77: ... Loading Before launching the watercraft en sure the bilge plugs are fully screwed After loading the watercraft ensure they are removed to drain bilge Storage It is recommended that the watercraft be serviced by an authorized Sea Doo dealer for storage but the following op erations can be performed by you with a minimum of tools CAUTION Do not run the engine dur ing the storage period Engine Drain...

Page 78: ...s decals Propulsion System Lubricant in jet pump reservoir should be drained and reservoir cleaned Re fer to an authorized Sea Doo dealer for this operation Grease lubrication point s of propul sion system as explained in MAINTE NANCE section Fuel System SEA DOO fuel stabilizer or equiva lent can be added in fuel tank to pre vent fuel deterioration and carburetor gumming Follow manufacturer s in s...

Page 79: ...gine drain hose Install coupler hose to fitting spigot Install a hose pincher to engine water outlet hose beside fitting spigot 1 Coupler hose 2 Hose pincher 3 Fitting spigot Pour the antifreeze slowly mixed with water in coupler hose until the colored solution appears in the engine drain hose Remove hose pincher All Models Except GTS Install a hose pincher to engine drain hose TYPICAL 1 Hose pinc...

Page 80: ...e Remove hose pinchers All Models Most of the antifreeze will drain out when removing the hose pincher s Use a container to recover it DISPOSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS NOTE Although antifreeze will mainly drain out the antifreeze has mixed with the water that was possibly trapped in the water jackets and thus preventing freezing problems At pre season preparation drain the...

Page 81: ...be stored out side cover it with an opaque tarpaulin to prevent sun rays and grime from af fecting the plastic components water craft finish as well as preventing dust accumulation CAUTION The watercraft should never be left in water for storage Never leave the watercraft stored in direct sunlight Pre Season Preparation Use the following chart Since technical skills and special tools are required ...

Page 82: ...tment Dealer Fuel filter replacement carburetor equipped models Dealer Fuel injection sensors verification RFI models Dealer Fuel system check valves lines fasteners pressurization Dealer Filler neck fuel tank and fuel cap condition Dealer Flame arrester inspection except 947 engine Dealer Fuel tank straps Operator Refill fuel tank Operator LUBRICATION SYSTEM Oil injection pump adjustment Dealer O...

Page 83: ...re or remove and reinstall safety lanyard on switch Bad connection Reinstall safety lanyard cap correctly over switch Wrong safety lanyard 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 Improper operation of MPEM or defective wiring h...

Page 84: ...r Engine turns normally Closed fuel tank valve except RFI models Turn fuel tank valve to ON position Fuel tank empty or water contaminated Refill Siphon and fill with fresh fuel Fuel filter clogged or water contaminated except RFI models Clean check fuel tank for water Fouled defective spark plugs Replace Misuse of choke except RFI models Use only with cold engine Replace spark plugs Fuel flooded ...

Page 85: ...oo dealer Rich fuel mixture high fuel consumption Flame arrester dirty clogged if so equipped Clean or replace Partially closed choke except RFI models Refer to an authorized Sea Doo dealer Defective sensor or ECU RFI 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 ...

Page 86: ...FI models Refer to an authorized Sea Doo dealer Low fuel pressure RFI models Refer to an authorized Sea Doo dealer Stuck RAVE valves if so equipped 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 OTHER OBSERVATION POSSIBLE CAUSE REMEDY Cavitation Weeds or debr...

Page 87: ...stem type Digital CDI Spark plug Make and type NGK BR8ES Gap 0 5 0 6 mm 020 024 in Starting system Electric starter Battery 12 V 19 A h Fuse MPEM 5 A Electrical system 2 x 15 A VTS system N A CARBURETION Fuel type Regular unleaded gasoline Carburetor BN 40i diaphragm Fuel accelerator pump Quantity 1 PROPULSION Propulsion system Bombardier Formula pump Jet pump type Axial flow single stage Transmis...

Page 88: ...viously manu factured DIMENSIONS GS 5644 5827 Number of passengers 2 Overall length 270 cm 106 in Overall width 116 cm 45 7 in Overall height 99 cm 39 in Weight 219 kg 482 lb Load limit passengers luggage 159 kg 350 lb CAPACITIES Fuel tank 56 5 L 15 U S gal Oil injection tank 6 L 1 6 U S gal Impeller shaft reservoir Capacity 100 mL 2 7 U S oz Oil level Up to plug smo2000 002B fm Page 86 Tuesday Se...

Page 89: ...al DC CDI Spark plug Make and type NGK BR8ES Gap 0 5 0 6 mm 020 024 in Starting system Electric starter with reduction gear Battery 12 V 19 A h Fuse MPEM 5 A Electrical system 2 x 15 A VTS system 7 5 A Bilge pump 3 A CARBURETION Fuel type Regular unleaded gasoline Carburetor BN 46i diaphragm Fuel accelerator pump Quantity 2 PROPULSION Propulsion system Bombardier Formula pump Jet pump type Axial f...

Page 90: ...eviously manu factured DIMENSIONS XP 5651 5655 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 255 kg 561 lb Load limit passengers luggage 159 kg 350 CAPACITIES Fuel tank 54 L 14 U S gal Oil injection tank 4 L 1 1 U S gal Impeller shaft reservoir Capacity 120 mL 4 0 U S oz Oil level Up to plug smo2000 002B fm Page 88 Tuesday Sep...

Page 91: ...pe Digital CDI Spark plug Make and type NGK BR8ES Gap 0 5 0 6 mm 020 024 in Starting system Electric starter Battery 12 V 19 A h Fuse MPEM 5 A Electrical system 15 A CARBURETION Fuel type Regular unleaded gasoline Carburetor BN 40i diaphragm Fuel accelerator pump Quantity 1 PROPULSION Propulsion system Bombardier Formula pump Jet pump type Axial flow single stage Transmission Direct drive Jet pump...

Page 92: ...roducts previously manu factured DIMENSIONS GTS 5639 Number of passengers 3 Overall length 302 cm 119 in Overall width 119 cm 46 9 in Overall height 95 cm 37 4 in Weight 222 kg 488 lb Load limit passengers luggage 225 kg 495 lb CAPACITIES Fuel tank 47 L 12 U S gal Oil injection tank 4 5 L 1 2 U S gal Impeller shaft reservoir Capacity 80 mL 2 7 U S oz Oil level Up to plug smo2000 002B fm Page 90 Tu...

Page 93: ...or output 160 W 6000 RPM 180 W 6000 RPM Ignition system type Digital CDI Digital DC CDI Spark plug Make and type NGK BR8ES Gap 0 5 0 6 mm 020 024 in Starting system Electric starter Electric starter with reduction gear Battery 12 V 19 A h Fuse MPEM 5 A Electrical system 2 x 15 A VTS system N A CARBURETION Fuel type Regular unleaded gasoline Carburetor BN 40i diaphragm Fuel accelerator pump Quantit...

Page 94: ...ENSIONS GTI 5647 5657 GTX 5653 5690 Number of passengers 3 Overall length 315 cm 124 in Overall width 123 cm 48 4 in Overall height 104 cm 41 9 in Weight 275 kg 605 lb 301 kg 662 lb Load limit passengers luggage 243 kg 535 lb CAPACITIES Fuel tank 56 5 L 15 U S gal Oil injection tank 6 L 1 6 U S gal Impeller shaft reservoir Capacity 100 mL 2 7 U S oz 120 mL 4 0 U S oz Oil level Up to plug smo2000 0...

Page 95: ...type Digital inductive type Spark plug Make and type NGK BR8ES Gap 0 5 0 6 mm 020 024 in Starting system Electric starter Battery 12 V 19 A h Fuse MPEM 5 A Electrical system 2 x 20 A 1 x 15 A Fuel pump 10 A Info center 1 A VTS system N A 20 A FUEL SYSTEM Fuel type Regular unleaded gasoline Fuel injection Rotax Fuel Injection single throttle body 56 mm 2 21 in PROPULSION Propulsion system Bombardie...

Page 96: ...SX RFI 5645 5654 Number of passengers 3 2 Overall length 315 cm 124 in 270 cm 106 3 in Overall width 123 cm 48 4 in 116 cm 45 7 in Overall height 107 cm 42 1 in 99 cm 39 in Weight 292 kg 642 lb 234 kg 515 lb Load limit passengers luggage 243 kg 535 lb 159 kg 350 CAPACITIES Fuel tank 56 5 L 15 U S gal Impeller shaft reservoir Capacity 100 mL 4 0 U S oz Oil level Up to plug Oil injection reservoir 6...

Page 97: ... 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 S...

Page 98: ... Crystal Display LED Light emitting diode MAG Magneto MPEM Multi purpose electronic module MPH Mile per hour N A Not applicable OPT Optional P N Part number PFD Personal flotation device PTO Power take off RAVE Rotax adjustable variable exhaust RFI Rotax fuel injection RPM Revolution per minute STD Standard VROI Variable rate oil injection VTS Variable trim system smo2000 002a book Page 96 Tuesday...

Page 99: ...TION NUMBER H I N __________________________________ ENGINE IDENTIFICATION NUMBER E I N ___________________________________ IDENTIFICATION NUMBER E I N 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 smo2000 002a book Page 97 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 100: ...smo2000 002a book Page 98 Tuesday September 28 1999 12 00 PM www SeaDooManuals net ...

Page 101: ...T APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOLEN UNITS In the event that your watercraft is...

Page 102: ...nal warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE 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 QUEBEC CANADA J1L 1W3 smo2000 002a book Page 100 Tuesday September 28 1999 12 00 PM www SeaDooManuals ne...

Page 103: ...NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOLEN UNITS In the event that your water...

Page 104: ...nal warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE 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 QUEBEC CANADA J1L 1W3 smo2000 002a book Page 102 Tuesday September 28 1999 12 00 PM www SeaDooManuals ne...

Page 105: ...NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOLEN UNITS In the event that your water...

Page 106: ...nal warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE 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 QUEBEC CANADA J1L 1W3 smo2000 002a book Page 104 Tuesday September 28 1999 12 00 PM www SeaDooManuals ne...

Page 107: ...www SeaDooManuals net ...

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