Sea-doo GTI 5865 Shop Manual Download | Manualshive

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Section 12

HULL / BODY

Sub-Section 01

(ADJUSTMENT AND REPAIR)

12-01-12

Remove bolt and lock nut from shock absorber
upper support.

1. Bolt
2. Lock nut

Tilt seat.

Loosen side screws retaining seat frame to pivot
blocks.

Lower seat.

Loosen upper screws retaining seat frame to piv-
ot blocks.

Remove seat.

Seat installation is essentially the reverse of re-
moval procedure. Refer to the main illustration of
seat at the beginning of this section for proper
torque specifications and service products to be
used.

SEAT COVER REPLACEMENT

Install staples with an electric tacker such as Ar-
row tacker no. ETN-50 or with a manual tacker
such as Arrow tacker no. T-50.

NOTE :

For an easier installation, it’s highly

recommended to use an electric tacker.

Ensure that the seat rest firmly against a hard sur-
face such as a piece of wood. This is done to get
the staples completely pushed in place.

TYPICAL

1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)

After cover installation cut all around the excess
of material.

BUMPER REPLACEMENT

4,5,12, Bumper, Trim and Rivet

1. Remove trim from side bumper rail.

2. Drill pop rivets to remove side bumper rail.

3. Mark hole positions on body straight and bow

sections.

1. Front bumper
2. Corner bumper
3. Straight section
4. Bow section

F05L0MA

1

2

F01L3YA

2

1

RES

1

2

4

3

F01L4GA

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Summary of Contents for GTI 5865

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

Page 2: ...0 0 SHOP MANUAL 0 219 100 031 www SeaDooManuals net ...

Page 3: ...d in any form without the prior writ ten permission of Bombardier Inc cBombardier Inc 1995 Printed in Canada r Registered trademarks of Bombardier Inc Loctiter is a trademark of Loctite Corporation Snap onr is a trademark of Snap on Tools Corpo ration Gelcoter is a trademark of Gelcote International Limited www SeaDooManuals net ...

Page 4: ... Table of Contents 07 00 1 01 Oil Injection System 07 01 1 02 Oil Injection Pump 07 02 1 08 ELECTRICAL SYSTEM 00 Table of Contents 08 00 1 01 Magneto System 08 01 1 02 Ignition System 08 02 1 03 Charging System 08 03 1 04 Starting System 08 04 1 05 Instruments and Accessories 08 05 1 06 Digitally Encoded Security System 08 06 1 09 PROPULSION SYSTEM 00 Table of Contents 09 00 1 01 Jet Pump 09 01 1 ...

Page 5: ...lled or replaced with new ones where specified If the efficiency of a locking device is impaired it must be renewed This manual emphasizes particular information denoted by the wording and symbolsþ WARNING Identifies an instruction which if not followed could cause serious personal injury including possibility of death CAUTION Denotes an instruction which if not followed could severely damage wate...

Page 6: ...s composed of 9 digitsþ ENGINE IDENTIFICATION NUMBER E I N All Engines Except the 787 The Engine Identification Number is located on the upper side of the magneto housing 1 Engine Identification Number E I N 787 Engine Only The Engine Identification Number is located on the upper side of the crankcase on PTO side 1 Engine Identification Number E I N F01L45A 1 Z Z N 1 2 3 4 5 L 4 9 5 Model year Ser...

Page 7: ...02MAINTENANCE 03TROUBLESHOOTING 04ENGINE 05COOLING SYSTEM 06FUEL SYSTEM 07LUBRICATION SYSTEM 08ELECTRICAL SYSTEM 09PROPULSION SYSTEM 10STEERING SYSTEM 11SUSPENSION 12HULL BODY 13TECHNICAL DATA 14WIRING DIAGRAMS Several sections are divided in various sub sec tions There is a table of contents at the beginning of many sections www SeaDooManuals net ...

Page 8: ...loded view assits you in identifying parts and related positions TYPICAL PAGE F01A09S Illustration number for publishing process CAUTION Pay attention to torque specifications Some of these are in lbf in instead of lbf ft Use appropriate torque wrench Sub section title indicates beginning of the sub section Dotted box contains parts of a particular model or an exploded view Page numbering system 0...

Page 9: ...e carburetors and rotary valve cover on top of engine ONOTE When removing rotary valve cover pay attention that the rotary valve stay in place other wise it must be timed Remove carburetors from intake manifold Disconnect fuel bypass line between carburetors twin carburetors Remove carburetor s from rotary valve cover DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester perform the fol lo...

Page 10: ...n of the different assemblies and in all cases may not reproduce the full detail or exact shape of the parts shown however they represent parts which have the same or a similar function CAUTION These watercraft are designed with parts dimensioned in both the metric and the imperial systems When replacing fas teners make sure to use only those recom mended by Bombardier Mismatched or incorrect fast...

Page 11: ...N All models 8 7 II 1 5 9 2 Q 4 J Sl 3 4 NIAG side PTO side 01 D884 1 Puller m II P N 290876298 2 Protective cap m A both ends P N 290876557 3 Ring both ends m P N 290977490 ing halves PTO m P N 290977475 2 istance ring MAG m P N 290876569 6 Ring halves MAG m P N 290276025 2 7 Screw M8 x 40 m P N 290840681 2 8 Screw M8 x 70 m 6 P N 290841201 2 APPLICATION All models Piston circlip installer A P N ...

Page 12: ...4 APPLICATION All engines A Alignment tool support m P N 295000090 B Alignment shaft P N 295000093 m C Alignment shaft P N 295000141 m t F01L2R4 APPLICATION A All models B All models except HX c l lx Piston pin puller A P N 290877092 m 6 P N 295000105 m I 2 3 m a F01BOV4 APPLICATION A 657 717 and 787 engines Replacement parts 1 Locating sleeve P N 290877181 m 2 Expansion sleeve P N 290877041 m 3 E...

Page 13: ... TOOLS ENGINE continued Ring gear blocking tool m P N 295000134 F01B264 APPLICATION 787 engine Ring gear puller tool P N 420976235 F01B294 APPLICATION 787 engine Distance gauge P N 290876826 FO1 BOH4 ml APPLICATION 587 and 657 engines 01 01 3 www SeaDooManuals net ...

Page 14: ... APPLICATION 717 engine Pliers p N 29 5 000 07 m 0 Oetlker 1099 FO1 D174 APPLICATION All models Pliers m 8 0 P N 295000054 Calllau F01B1T4 APPLICATION All models oNOTE This tool is also used for the propulsion system Flush kit m 4 P N 295500068 F01E014 APPLICATION 587 717 and 787 engines Coupler hose m P N 295500258 41 cm 16 in F01EOZ4 APPLICATION All models 01 01 4 www SeaDooManuals net ...

Page 15: ...ON All models Impeller shaft holder m 8 P N 295000082 F01BOW4 APPLICATION All models Bearing seal installer m o P N 295000107 F01J4K4 APPLICATION All models Impeller shaft guide m P N 295000002 b FO1J1O4 APPLICATION All models Pliers m I P N 295000054 Calllau F01B1T4 APPLICATION All models oNOTE This tool is also used for the fuel system VTS tool m O P N 295000133 F01B2P4 APPLICATION XP 1995 and 1...

Page 16: ...LICATION 717 and 787 engines 82 mm Coil centering tool P N 290876922 A01B1V4 APPLICATION 717 engine Cylinder aligning tool m t P N 290876904 AOOB084 APPLICATION All models Stroboscopic timing light P N 295000078 A01B2K4 APPLICATION All models Dial indicator UDC gauge P N 295000143 AOOB2E4 APPLICATION All models Distance gauge A P N 290876827 B P N 290876828 m 0 FOIBOH4 APPLICATION A 717 engine B 7...

Page 17: ...ngine Engine Ilftlng device Not sold by Bombardier Do It yourself Refer to Shop Manual sect on 04 01 v o FOIDOA4 APPLICATION All models except 787 Feeler gauge 45 Not sold by Bombardier Snap on FB 300A F01B1K4 APPLICATION All models Terminal remover Not sold by Bombardier Snap on TT 60 4 F01B1J4 APPLICATION All models Slide hammer puller Not sold by Bombardier Snap on Handle CJ93 I Hammer CJ1 25 6...

Page 18: ...787 engine Rotary valve shaft pusher P N 290876609 F01B2B4 APPLICATION 787 engine Handle m P N 290877650 AOOC3V4 APPLICATION 787 engine Exhaust outlet tool m P N 295000132 p F01B2A4 APPLICATION Exhaust nut on transom Gear bearing puller m P N 290877665 F04B034 APPLICATION 787 eng ne Ring compressor A P N 290876972 m t B P N 295000112 m A01B1T4 APPLICATION A 587 engine 76 mm B 657 engine 78 mm Cran...

Page 19: ...Y4 APPLICATION All models Screwdriver Not sold by Bombardier Snap on SDD 143 F01B1P4 APPLICATION All models Lighted adjustable mirror Not sold by Bombardier Snap on 50101 F01B114 APPLICATION All models Hose pincher P N 529030400 F01B234 APPLICATION All engines Spring compressor P N 529027100 i l A01B404 APPLICATION HX Suspension adjustment m wrench P N 529012200 A25A014 APPLICATION HX seat suspens...

Page 20: ...er Snap on HS3 FO1 B1 M4 APPLICATION All models Machinist s square Not sold by Bombardier Snap on P F I 22 0 II L j h J k 4 7 67 4 u LJ m J F02B064 APPLICATION Models equipped with reverse Fitting remover Not sold by Bombardier Do it yourself Refer to Shop Manua section 09 01 Deep socket 14 mm 9 1 6 In G 4 Q c F01J2RA APPLICATION All models Bearing remover P N 295000144 01 Jl14 APPLICATION All mod...

Page 21: ...s 2 m P N 295000005 F01B074 APPLICATION All models Lift kit A P N 295100012 c m B P N 295100 0 3 m t F01B1N4 APPLICATION A SP and XP series B GTS and GTX models 1 Tie down m A 1 50 m 5 ft long P N 295100010 FOOB014 APPLICATION All models Tie down with ratchet m 3 60 m 12 ft long P N 295100 0 1 APPLICATION AlI models 01 02 6 www SeaDooManuals net ...

Page 22: ...to coil screws Impeller housing cover screws except for plastic pumps Venturi impeller housing screws Intake grate screws Engine support screws Impeller housing hull nuts Steering nozzle screws Reverse gate screws High strength thread locker P N 293800005 Loctite 271 red 1 O mL LJwl m 71 A Em AOOB2U4 APPLICATION Impeller shaft thread High temperature threadlocker P N 290899788 Loctlte 648 green 5 ...

Page 23: ... Locquic Primer N 170 mL o Ulc y u PRIMERN m cnu AOOB3N4 APPLICATION Crankcase halves mating surface Impeller shaft thread Venturi impeller housing mating surface Gasket eliminator m P N 293800007 Loctite 515 50 m i a AOOB2T4 APPLICATION Cylinder sleeve O ring groove Crankcase halves mating surface Crankcase screws Gasket eliminator m P N 293800038 Loctlte 518 50 mL F01B124 APPLICATION Impeller ho...

Page 24: ...PPLICATION Tuned pipe Sealant m 8 P N 413710300 Loctlte 179 80 mL APPLICATION Exhaust system 787 engine Epoxy glue Not sold by Bombardier 3M 05900 APPLICATION All models Gun Kote Not sold by Bombardier Kal Gard Coating Mfg Corp APPLICATION Magneto and armature plate Dielectric grease m 8 P N 293550004 Dow Cornlncj 150 g 01 B164 APPLICATION Battery posts and cable con nectors Thermosensor switch Gr...

Page 25: ...e lubricant P N 293800023 Em Loctlte anti seize Iubrl cant 12 Oz 454 g F01B174 APPLICATION Crankshaft thread PTO flywheel Crankshaft bearing seat Spark plug threads Ignition housing cover screws Bombardier lube P N 293600016 12 x 14 Oz w F01BOS4 DB APPLICATION Throttle cable Wear ring when new Corroded parts Water flooded engine Storage Sea Doo fuel stabilizer m P N 413408600 8 OZ 7 II t D dflll w...

Page 26: ...oIl P N 413710500 12 X 1 L o a MBARDIER ROTAX c2Eiz3 I m s a FO1 B2GA APPLICATION All models Jet pump 011 m P N 293600011 12 X 6 OZ Sea Doo synthetic jet pump 011 b a ES smanaoo Jfl PUMP SYNIHEIEOtL FOI BOP4 APPLICATION All models A Silicone Ultra Black t m P N 293800030 B Silicone m o Ultra Black FIB P N 293800028 Loctlte 598 300 n l L u c K F01B1A4 APPLICATION Ride shoe Jet pump fittings 732 Mul...

Page 27: ... C Yellow 140 g m P N 293500008 m D Charcoal 140 g P N 293500030 E Grey 140 g m P N 293500009 F Blue m 9 P N 293500014 G Green m P N 293500061 H White m P N 293500082 1 Blue Violet m P N 293500077 Sea Doo paint B l a s o 7UR 1 wmEflg mri i xi F01BOQ4 APPLICATION A Engine assembly 1995 B Tuned pipe and muffler 1995 c D E F G H 1 SMC spray paint A Violet m A P N 293500068 B Yellow 140 g m 8A P N 293...

Page 28: ...995 c D E F G H 1 Gelcoat liquid A Super white 1 L P N 293500075 B White 1 L P N 293500033 C Mauve 1 L P N 293500034 D Grey 1 L P N 293500035 E Light grey P N 293500037 F Green 1 L P N 293500038 G Turquoise 1 L P N 293500039 H Teal 1 L P N 293500069 1 Yellow P N 293500081 APPLICATION A B c D E F G H SPX 1 Gelcoat repair kit A P N 295500216 m 9A B P N 295500340 C P N 295500100 m A D P N 295500009 m...

Page 29: ...ENANCE Sub Section 00 TABLE OF CONTENTS TABLE OF CONTENTS PERIODIC INSPECTION CHART 02 01 1 FLUSHING AND LUBRICATION 02 02 1 GENERAL 02 02 1 PROCEDURE 02 02 1 WATER FLOODED ENGINE 02 03 1 STORAGE 02 04 1 www SeaDooManuals net ...

Page 30: ...mp adjustment Fuel filter and oil filter inspection Fuel filter and oil filter replacement Engine head bolts retorque Steering system Reverse system reverse cable adjustment GTS GTI Variable trim system SPX XP Fastener tightening flame arrester support carburetor s engine mount exhaust system etc Muffler battery and reservoir fastening devices Fuel oil lines check valve and hose inspection fuel sy...

Page 31: ...URE WARNING Perform this operation in a well ventilated area Do not touch any electrical parts or jet pump area when engine is running Clean jet pump by spraying water in its inlet and outlet and then spray BOMBARDIER LUBE lubri cant WARNING Always remove safety lan yard cap from switch to prevent acciden tal engine starting before cleaning the jet pump area Engine must not be running for this ope...

Page 32: ...bout 3 minutes at a fast idle around 3500 RPM Pull plug from air intake silencer cover Spray BOMBARDIER LUBE lubricant through air intake silencer cover keeping engine at fast idle 1 1Air intake silencer cover 2 Pull plug 3 Spray BOMBARDIER LUBE here NOTE Lubrication of engine should be done ateast for one minute After approxi mately half a minute close fuel valve to run en gine out of fuel while ...

Page 33: ...ve both spark plugs and spray BOMBAR DIER LUBE lubricant into each cylinder Crank the engine a few turns to distribute the oil onto cylinder wall Apply anti seize lubricant on spark plug threads then reinstall them Reinstall plug on air intake silencer cover NOTE Engine fogging should be done with BOMBARDIER LUBE lubricant whenever the watercraft is to be stored for a few days or a long period CAU...

Page 34: ...o the grounding device All Models Except XP 1 Magneto housing 2 Grounding device 3 Spark plug cables XP Model Only 1 Grounding device All Models Remove spark plugs and dry them with a clean cloth A contact cleaner spray can be used It may be preferable to replace spark plugs Do NOT in stall spark plugs on engine Crank engine to drain crankcase CAUTION Be careful when cranking engine water will spr...

Page 35: ...t if needed it can become mis aligned or deflected Refer to ENGINE 04 03 After engine has started spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running 1 Air intake silencer cover 2 Pull plug 3 Spray BOMBARDIER LUBE here Run engine until it reaches its normal operating temperature CAUTION Water must be supplied to the engine to avoid overheating F01F25A 1 2 3 www SeaD...

Page 36: ...well ventilated area Do not smoke or allow open flames or sparks in the vicinity Al ways wipe off any fuel spillage from the water craft Always turn the fuel valve to OFF position when storing the watercraft Cooling System Flushing and Engine Internal Lubrication Cooling system has to be flushed with fresh wa ter to prevent salt sand or dirt accumulation which will clog water passages Engine must ...

Page 37: ...event sun rays and grime from affecting the plastic components wa tercraft finish as well as preventing dust accumu lation CAUTION The watercraft must never be Ieft in water for storage Never leave the watercraft stored in direct sunlight Anticorrosion Treatment Wipe off any residual water in the engine com partment Spray BOMBARDIER LUBE lubricant over all me tallic components in engine compartmen...

Page 38: ...ter return hose Install temporarily one hose to engine water inlet at cylinder head Insert a funnel into hose and pour about 1 liter 1 qt of antifreeze mixed with water in engine Remove temporary hose and reconnect engine water supply hose and engine water return hose Remove hose pincher All Models The following steps should be performed to pro vide the watercraft enhanced protection Remove muffle...

Page 39: ...eck refer to section 09 01 Engine turns slowly Discharged weak battery Restriction in jet pump Seizure in jet pump Partial engine hydrolock Partial engine seizure Worn starter Check charge replace Check clean pump Inspect refer to section 09 01 Check refer to section 02 03 Check compression refer to section 04 02 Check refer to section 08 04 Engine turns over No spark at spark plugs Fuel water con...

Page 40: ... needle s and seal s Excessive rotary valve clearance Check adjust choke cable Check clean replace Check clean adjust refer to section 06 03 Check refer to section 06 03 Check replace refer to section 04 04 Check adjust refer to section 07 02 Check refer to section 06 03 Check refer to section 04 04 Difficult to start Incorrect rotary valve timing Excessive rotary valve clearance Check adjust refe...

Page 41: ... 06 03 Check readjust refer to section 06 03 Check repair refer to section 04 02 Check clean Check siphon replace Check clean refer to section 06 03 Check replace refer to section 09 01 Check refer to section 04 03 Check refer to section 04 02 Check refer to section 04 02 OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine RPM too high Faulty rev limiter Improper impeller pitch too low Check refer to s...

Page 42: ...VE SYSTEM 04 02 15 BOTTOM END 04 03 1 587 ENGINE 04 03 1 717 ENGINE 04 03 2 787 ENGINE 04 03 3 CRANKSHAFT MISALIGNMENT AND DEFLECTION 04 03 4 DISASSEMBLY 04 03 5 CLEANING 04 03 7 INSPECTION 04 03 7 ASSEMBLY 04 03 9 ROTARY VALVE 04 04 1 GENERAL 04 04 2 INSPECTION ON WATERCRAFT 04 04 2 DISASSEMBLY 04 04 3 CLEANING 04 04 5 INSPECTION 04 04 5 ASSEMBLY 04 04 5 EXHAUST SYSTEM 04 05 1 SP SERIES GTS AND G...

Page 43: ...Section 04 ENGINE Sub Section 00 TABLE OF CONTENTS 04 00 2 EXHAUST MANIFOLD TUNED PIPE AND MUFFLER INSTALLATION 04 05 7 www SeaDooManuals net ...

Page 44: ...gine from watercraft pro ceed as follows CAUTION Whenever removing engine from watercraft engine jet pump align ment must be performed Jet Pump Removal To withdraw jet pump unit ass y refer to PRO PULSION SYSTEM 09 01 All Models Electrical Connections First remove BLACK negative cable from battery then RED positive cable WARNING Always disconnect starter or battery cables exactly in the specified ...

Page 45: ...FUEL SYSTEM 06 03 HX Model Only Disconnect choke and throttle cables from carbu retors Disconnect fuel supply and fuel return hoses Engine Support Mounts All Models Except the HX Remove engine support mount screws NOTE Be careful when removing engine support mount screws shims could have been installed between engine support and rub ber mounts To ease engine jet pump alignment indicate shim locati...

Page 46: ...ach spark plug as shown 1 Weld a lock washer 2 Old spark plug Remove spark plugs and replace by special tools Hook a sling into holes of special tools Using a chain block a hoist or other suitable equi pment slightly lift engine to ease the remaining component removal CAUTION Take care not to damage cable or oil injection hoses XP Model Engine can be easily lifted by inserting a hook into exhaust ...

Page 47: ... XP then tilt engine so that it can be removed from the watercraft CAUTION Be careful not to scratch body with engine support or to hit any compo nent TYPICAL ALL MODELS EXCEPT THE XP XP MODEL CLEANING Wipe off any spillage in bilge Clean with a bilge cleaner Clean external parts of engine INSTALLATION Installation of engine in watercraft is essentially the reverse of removal procedures However pa...

Page 48: ...p Alignment Alignment is necessary to eliminate possible vibration and or damage to components Check alignment of engine using alignment tool NOTE On the HX model it is not neces sary to perform engine alignment when the engine support is not loosen from rubber mounts 1 Housing P N 295 000 090 2 Alignment shaft P N 295 000 093 or P N 295 000 141 for the HX To verify alignment proceed as follows In...

Page 49: ... 18 lbf ft when procedure is completed NOTE Whenever alignment tool is not uti lized apply BOMBARDIER LUBE lubricant on its shaft and inside the housing to eliminate possible corrosion Final Inspection Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant After its ins tallation properly adjust and bleed oil injection pump as specified in LUBRICATION SYSTEM 07 02 Pressu...

Page 50: ...m 17 lbf ft Loctite 242 9 Loctite 515 16 Synthetic grease 717 Engine 587 Engine 6 4 3 7 8 7 8 3 4 Synthetic grease 717 Engine 587 Engine 9 24 N m 17 lbf ft Synthetic grease 10 2 Synthetic grease 11 Synthetic grease 24 N m 17 lbf ft 12 1 Loctite 515 9 N m 80 lbf in 13 14 9 N m 80 lbf in 587 Engine Loctite PST 592 Loctite 515 5 34 rollers 5 6 34 rollers www SeaDooManuals net PARTS ...

Page 51: ...DS 24 N m 17 lbf ft 15 Synthetic grease Loctite 242 Synthetic grease 40 N m 30 lbf ft 18 Loctite 515 16 3 Synthetic grease Synthetic grease 1 2 12 6 4 8 7 8 7 4 6 24 25 26 27 21 19 20 22 23 34 rollers Synthetic grease Loctite 515 34 rollers www SeaDooManuals net PARTS ...

Page 52: ...engine top end proceed as fol lows Electrical Connections Disconnect thermosensor wire and spark plug ca bles Connect spark plug cables on grounding device Exhaust System To withdraw tuned pipe refer to ENGINE 04 05 Air Intake Silencer To remove air intake silencer refer to FUEL SYS TEM 06 02 1 2 Cylinder Head Cover and Cylinder Head Remove cylinder head cover NOTE With the 717 and 787 engines cyl...

Page 53: ...expansion sleeve P N 290 877 041 onto the spindle Screw in extracting nut P N 290 877 155 with the movable extracting ring towards spindle PISTON PIN PULLER P N 290 877 092 1 Bushing P N 290 877 181 2 Expansion sleeve P N 290 877 041 3 Extractor sleeve 4 Extractor spindle 5 Extracting nut P N 290 877 155 Firmly hold puller and rotate handle to pull pis ton pin 1 Circlip at this side not to be remo...

Page 54: ...ing grooves with a groove cleaner tool or a piece of broken ring INSPECTION Visually inspect all parts for corrosion damage Inspect piston for damage Light scratches can be sanded with a fine sand paper Inspect plane surfaces for warpage Small defor mation can be corrected by grinding surface with a fine sand paper Install sand paper on a surface plate and rub part against oiled sand paper The ins...

Page 55: ...ut of Round Using a cylinder bore gauge measure cylinder di ameter at 16 mm 5 8 in from top of cylinder Measure diameter in piston pin axis direction then perpendicularly 90 to it If the difference be tween readings exceed specification cylinder should be rebored and honed or replaced 1 Measuring in piston pin axis 2 Measuring perpendicularly 90 to piston pin axis A 16 mm 5 8 in Piston Cylinder Wa...

Page 56: ... ring which is bottom ring 1 Feeler gauge 2 Rectangular ring bottom Ring End Gap Position ring halfway between exhaust port and top of cylinder NOTE In order to correctly position ring in cylinder use piston as a pusher Using a feeler gauge check ring end gap If gap exceeds specified tolerance rings should be re placed 1 Top of cylinder 2 Ring end gap 16 Cylinder Base Gasket 717 and 787 Engines On...

Page 57: ... as for disas sembly 4 6 Piston Pin and Roller Bearing 717 and 787 Engines To install roller bearing and piston pin use piston pin puller P N 290 877 092 proceed as follows Replacement bearings are held in place by a lo cating sleeve outside and 2 plastic cage halves inside Push needle bearing together with inner halves out of the locating sleeve into the connecting rod bore Use any suitable 23 mm...

Page 58: ...s follows Align replacement roller bearing with connect ing rod bore Carefully push inner plastic sleeve into con necting rod bore outer plastic ring will release rollers 1 Outer ring removal after inner sleeve insertion into bore Make sure thrust washers are present each side of rollers 1 Thrust washer each side Insert piston pin into piston until it comes flush with inward edge of piston hub 1 P...

Page 59: ...Always use new circlips At in stallation take care not to deform them Overstressed circlips will come loose and will damage engine Circlips must not move freely after installation To easily insert circlip into piston use circlip in staller P N 295 000 077 for the 587 engine or P N 290 877 016 for the 717 and 787 engines 1 Circlip installer Remove pusher from tool then insert circlip into its bore ...

Page 60: ...e parts Make sure to align ring end gap with piston locat ing pin Slide tool over rings 1 Ring end gap aligned with piston locating pin Slide cylinder over piston When reassembling cylinders to crankcase it is important to have them properly aligned so that exhaust flanges properly match up with exhaust manifold The aligning tool P N 290 876 902 can be used on the 587 and 717 engines or the ex hau...

Page 61: ...to 24 N m 17 lbf ft Re fer to the following illustration 787 Engine Prior installation apply synthetic grease below screw head and Loctite 515 on screw threads Install M10 x 105 screws on exhaust side and the M10 x 73 5 on opposite side Torque screws in a criss cross sequence for each cylinder to 20 N m 15 lbf ft Repeat the proce dure retightening all cylinder screws to 40 N m 30 lbf ft 2 11 12 Cy...

Page 62: ... cover screws to 9 N m 80 lbf in as per following illustrated sequence 1 Longer screws 2 12 Cylinder Head and O ring 717 and 787 Engines Make sure to install O rings around spark plug holes and O ring of cylinder head as shown in the following illustration Apply Loctite 515 in O ring groove of cylinder sleeves 1 O ring Install cylinder head 1 15 Cylinder Head Cover and Screw 717 and 787 Engines In...

Page 63: ...ber area creating a greater mixture turbulence Additionally the small volume and large surface area of the squish band allow a bet ter cooling of the end gases to help prevent deto nation CAUTION When reassembling an en gine always measure squish gap to make sure it is within the specified tolerance 1 Squish gap If the squish gap is increased a loss in power will occur while too small a squish gap...

Page 64: ...torque decreases along with a dramatic increase of the specific fuel consumption Higher torque along with lower fuel consumption can be ob tained at lower engine speeds if the time the ex haust port is open is shortened Bombardier Rotax has patented a remarkably sim ple system to automatically change the exhaust port height based on pressure in the exhaust sys tem Located above the exhaust port is...

Page 65: ... overcome this pres sure before the valve begins opening Item P2 is the pressure required to completely open the RAVE valve Between P1 and P2 the usable pow er curve of the engine is moving from power curve 1 to power curve 2 This transition takes place very rapidly at full throttle and from a practi cal standpoint can be considered to be instanta neous at item 7 Gradual application of the throttl...

Page 66: ...erating clearance the guillotine should be used with Clearance less than 0 375 mm 015 in will require reworking of the guillotine to achieve the proper clearance and radius Disassembly 19 20 Spring and Cover Remove the cover of the valve by releasing the spring WARNING Firmly hold cover to valve base The spring inside the valve is apply ing a pressure against the cover 1 Spring 21 Allen Screw Loos...

Page 67: ...to rod of sliding valve The TOP position of the sliding valve is indicated on one side 1 Sliding valve 2 O ring 3 TOP 26 Gasket Install a new gasket It must be installed at the same time as the sliding valve 27 Valve Housing Position the valve housing onto the cylinder so that its opening is toward the bottom 1 Bottom of valve housing 22 24 Valve Piston and Sliding Valve When the valve is mounted ...

Page 68: ... Loctite 515 Synthetic grease 40 N m 30 lbf ft 9 8 11 10 10 N m 88 lbf in 7 24 N m 17 lbf ft 24 N m 17 lbf ft Loctite 242 Anti seize lubricant F01D4HS Loctite 515 11 3 1 4 2 6 6 Anti seize lubricant Anti seize lubricant Lithium grease 2 5 1 Lithium grease Anti seize lubricant Anti seize lubricant 14 15 Loctite 642 www SeaDooManuals net PARTS ...

Page 69: ...4 2 6 5 Anti seize lubricant Loctite 242 Anti seize lubricant Lithium grease Lithium grease Anti seize lubricant 3 Loctite 515 Loctite 515 Synthetic grease 8 40 N m 30 lbf ft 10 10 N m 88 lbf in 11 7 24 N m 17 lbf ft Loctite 515 Synthetic grease 6 1 6 6 4 1 24 N m 17 lbf ft 9 www SeaDooManuals net PARTS ...

Page 70: ...cant Anti seize lubricant 14 Loctite 242 Loctite 642 Anti seize lubricant Lithium grease Loctite 515 Loctite 515 Synthetic grease 8 40 N m 30 lbf ft Loctite 515 Synthetic grease 7 24 N m 17 lbf ft Loctite 515 Synthetic grease 8 40 N m 30 lbf ft 24 N m 17 lbf ft Synthetic grease 30 mL 1 oz FORMULA XP S synthetic injection oil 5 6 2 6 12 12 2 6 4 6 3 7 www SeaDooManuals net PARTS ...

Page 71: ...rewdriver in the other spark plug hole Lay one hand over both screwdriver handles to feel piston displacements With the other hand slowly rotate engine by PTO flywheel TYPICAL 1 Lay one hand over screwdrivers to feel movement 2 Screwdrivers in spark plug holes As soon as one piston starts going up the other must immediately go down Any interval between strokes indicates a misaligned crankshaft Or ...

Page 72: ... s bent and or disaligned crankshaft DISASSEMBLY Engine has to be removed from watercraft to open bottom end Refer to ENGINE 04 01 1 Seal If crankshaft end seal s has have to be replaced bottom end must be opened except for the MAG side seal on the 787 engine which is mounted on the ignition housing 3 Crankcase Remove the following parts Engine support except for the 787 engine PTO flywheel Refer ...

Page 73: ...25 NOTE To facilitate ring or distance ring in stallation lubricate their inside diameters 1 Puller P N 290 876 298 2 Protective cap P N 290 876 557 3 Distance ring MAG side P N 290 876 569 4 Ring both side P N 290 977 490 5 MAG side ring halves P N 290 276 025 6 PTO side ring halves P N 290 977 475 7 Screw M8 x 40 P N 290 840 681 8 Screw M8 x 70 P N 290 841 201 787 Engine For MAG and PTO sides us...

Page 74: ...core marks incurred are detrimen tal to crankcase sealing INSPECTION Visually inspect parts for corrosion damage Inspect plane surfaces for warpage Small defor mation can be corrected by grinding surface with a fine sand paper Install sand paper on a surface plate and rub part against oiled sand paper Inspect crankshaft bearings Check for scoring pitting chipping or other evidence of wear Make sur...

Page 75: ...n be either ball bearings wear bent or twisted crankshaft at connecting rod journal 1 Measuring PTO side deflection in crankcase 1 Measuring MAG side deflection in crankcase Remove crankshaft bearings and check deflection again on V shaped blocks as illustrated 1 Measuring MAG side deflection on V shaped blocks 1 Measuring PTO side deflection on V shaped blocks NOTE Crankshaft deflection can not b...

Page 76: ...r as an alternate method apply heat with a pro pane torch Lay bearing on a steel plate then heat plate through bearing bore until smoke is noticed from bearing Install bearing carefully on crank shaft CAUTION Immediately stop heating as soon as smoke is noticed Overheating bearing will melt plastic cage Practice with used bearings on first try 1 Bearing against a steel plate 2 Propane torch 3 Heat...

Page 77: ...halves Prior to joining crankcase halves apply a light coat of Loctite 515 on mating surfaces Do not apply in excess as it will spread out inside crankcase NOTE On aluminum material it is recom mended to use Loctite Primer N to reduce curing time and increase gap filling capability Re fer to manufacturer s instructions CAUTION Rotary valve shaft must be in stalled in crankcase before closing halve...

Page 78: ...o 12 N m 9 lbf ft as per following sequence Repeat procedure re tightening all screws to 24 N m 17 lbf ft 8 Crankcase Screw As a final step torque only M10 screws of crank case to 40 N m 30 lbf ft as per following se quence Final Assembly For rotary valve timing and assembly procedures refer to ENGINE 04 04 587 and 717 Engines If engine support is installed on crankcase before ignition housing ele...

Page 79: ... 12 1 Install starter before engine support 787 Engine Add 30 mL 1 oz of FORMULA XP S synthetic in jection oil in the small hole near the transfer of the PTO cylinder TYPICAL 1 Add 30 mL 1 oz of injection oil F01D4KA 1 F01D86A 1 www SeaDooManuals net ...

Page 80: ...ENGINE Sub Section 04 ROTARY VALVE 04 04 1 ROTARY VALVE 4 F01D7SS 8 2 20 N m 15 lbf ft Lithium grease 1 7 10 6 9 5 11 3 4 13 12 14 15 1 787 Engine 717 Engines 2 13 12 1 20 N m 15 lbf ft www SeaDooManuals net PARTS ...

Page 81: ...d starting situation There is two methods to verify rotary valve cover clearance One with a 45 feeler gauge the other one with a solder 45 FEELER GAUGE METHOD Remove O ring from rotary valve cover Remove intake manifold from rotary valve cover except 787 engine Reinstall cover in place WITHOUT its O ring and torque screws to 20 N m 15 lbf ft Feeler gauge blade from 0 25 mm 010 in to 0 35 mm 014 in...

Page 82: ...E AND O RING GROOVE BASE 1 Cover seating surface 2 O ring groove depth must be 1 0 0 03 mm 039 001 in Reverify the clearance At assembly the rotary valve timing must remain as per original setting NOTE If rotary valve crankcase surface is worn it is possible to have it rework at the factory Contact your dealer or distributor Rotary Valve Shaft Gear Backlash Remove PTO flywheel guard Remove spark p...

Page 83: ...90 876 487 for the 587 and 717 engines or puller P N 290 876 488 for the 787 engine Place puller over rotary valve shaft end and screw on puller bolt into shaft While retaining bolt with a wrench turn puller nut CLOCKWISE until shaft comes out 1 Hold bolt 5 6 Circlip and Spring Seat If it is necessary to disassemble components of rotary valve shaft assembly use seat to compress spring and remove c...

Page 84: ...ws CJ93 4 Close puller claws so that they can be inserted in end bearing Holding claws turn puller shaft clockwise so that claws open and become firmly tight against bearing Slide puller sleeve outwards and tap puller end Retighten claws as necessary to always maintain them tight against bearing Continue this way un til bearing completely comes out 1 End bearing CLEANING Discard all seals and O ri...

Page 85: ... measured with a dial gauge Install rotary valve shaft in crankcase half without its gear NOTE End bearing must be in crankcase half Measure shaft deflection near gear mounting ar ea 1 Rotary valve shaft 2 End bearing in place Deflection must not exceed specified value Re place shaft as necessary ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attenti...

Page 86: ...istance sleeve on shaft 1 Seal 2 Ball bearing 3 Snap ring 4 Distance sleeve 5 Shim 0 5 mm 020 in 6 Rotary valve shaft 3 4 Rotary Valve Shaft Ass y and Snap Ring CAUTION Crankcase halves must be separated and crankshaft must not be present to install rotary valve shaft ass y in crankcase 587 and 717 Engines To install rotary valve shaft in crankcase use a pusher P N 290 876 605 Push shaft until its...

Page 87: ...outwards 13 Rotary Valve The rotary valve controls the opening and closing of the inlet ports Therefore its efficiency will de pend on the precision of its installation IDENTIFICATION OF THE ROTARY VALVE There is no identification code on the valves To find out the duration place an angle finder on the valve and measure the valve cut out angle or use the following templates F01B2FA 2 1 F01D8OA Eng...

Page 88: ...on 04 ENGINE Sub Section 04 ROTARY VALVE 04 04 9 F01D89S 290 924 502 actual size 290 924 508 actual size TEMPLATE 147 cut out angle 159 cut out angle 159 cut out angle 147 cut out angle www SeaDooManuals net ...

Page 89: ...ark crankcase at this point OPENING MARK Step Bottom of MAG inlet port Align 360 line of degree wheel Step Find 130 on degree wheel and mark here NOTE Do not rotate the crankshaft For closing mark first align 360 line of degree wheel with TOP of MAG side inlet port Then find 65 line on degree wheel and mark crank case at this point ENGINE TIMING OPENING BTDC CLOSING ATDC 587 130 5 65 5 717 147 5 6...

Page 90: ...symmetrical There fore try flipping it over then reinstall on splines to obtain best installation position Apply BOMBARDIER ROTAX injection oil on rota ry valve before reassembling rotary valve cover Remove TDC gauge 1 2 12 Rotary Valve Cover Screw and O ring Install O ring and cover then torque screws to 20 N m 15 lbf ft in a criss cross sequence NOTE For the 587 engine install engine in watercra...

Page 91: ...8 lbf ft 9 7 25 N m 18 lbf ft Loctite 242 9 Loctite 242 SP model 11 SPI SPX GTS and GTI models 19 18 19 6 25 N m 18 lbf ft Loctite 242 22 21 10 N m 88 lbf in 5 2 1 4 N m 35 lbf in 3 13 4 N m 35 lbf in 4 N m 35 lbf in 7 N m 162 lbf in Silicone Ultra Black 27 N m 20 lbf ft SPX and GTI models Sealant 732 4 N m 35 lbf in 19 Loctite 242 6 25 N m 18 lbf ft www SeaDooManuals net PARTS ...

Page 92: ...8 Loctite 242 9 7 25 N m 18 lbf ft Loctite 242 9 19 10 10 N m 88 lbf in 4 16 Sealant 736 25 N m 18 lbf ft 6 Loctite 242 12 4 N m 35 lbf in 1 3 4 N m 35 lbf in 14 24 N m 17 lbf ft Synthetic grease Loctite 592 9 15 20 17 4 N m 35 lbf in 2 4 N m 35 lbf in 13 19 18 25 www SeaDooManuals net PARTS ...

Page 93: ... 19 14 40 N m 30 lbf ft 24 15 17 Loctite 648 Loctite 515 14 40 N m 30 lbf ft 24 Synthetic grease 4 N m 35 lbf in 2 9 Loctite 242 7 40 N m 30 lbf ft 9 8 40 N m 30 lbf ft Loctite 242 4 N m 35 lbf in Sealant 732 27 N m 20 lbf ft 4 N m 35 lbf in 4 16 10 N m 88 lbf in Sealant 736 10 Loctite 242 23 19 19 www SeaDooManuals net PARTS ...

Page 94: ...t tuned pipe to release nut as necessary Take care not drop nut and flat washer 11 Tuned Pipe Head Withdraw tuned pipe in a forward and rotating movement HX Model Only NOTE It is possible to remove the tuned pipe head and cone at the same time If such is the case disconnect only the water outlet hose at cylinder head and do not remove the clamp retaining tuned pipe head to tuned pipe cone Disconne...

Page 95: ...se collar at tuned pipe cone outlet 4 Clamp Remove clamp securing tuned pipe cone to tuned pipe head 7 8 9 Screw Nut and Flat Washer Remove screws and nut with flat washers at tuned pipe head flange 23 Screw Remove retaining screw of tuned pipe head 1 Screw Remove tuned pipe head 6 Screw Remove two screws retaining tuned pipe cone to engine F01D3YA 2 1 F01D7IA F01D76A 1 F01D7KA F01D7LA www SeaDooM...

Page 96: ...uffler Pull muffler out of bilge HX Model Only 1 Collar Loosen exhaust hose collar at tuned pipe cone outlet only if tuned pipe cone is not re moved 2 Strap Remove rear access cover from body Disconnect upper exhaust hose in front of muf fler Disconnect retaining strap of muffler 1 Strap 13 Muffler Pull muffler out of bilge NOTE Lower exhaust hose of muffler may be disconnected or left with muffle...

Page 97: ...old Gasket and Lock Washer Make sure gasket s are properly positioned prior to finalizing manifold installation All Models Except XP Apply synthetic grease on screw threads Install and torque screws to 24 N m 17 lbf ft as per following illustrated sequence XP Model Only Except for two screws apply synthetic grease on screw threads Apply Loctite 515 on the other two screws Install screws Refer to t...

Page 98: ...ted on ex haust manifold prior to finalizing pipe installation 4 6 7 8 23 Clamp Screw and Nut Apply Loctite 242 blue on stud and retaining screw threads Hand tighten nut and screws and assure that tuned pipe bushing s rests against manifold Refer to the following illustration for the torquing sequence TYPICAL Step Torque screw s of tuned pipe cone to 12 N m 9 lbf ft Step Torque nut and screws of t...

Page 99: ...h hose removed align cone outlet with muf fler inlet NOTE Due to exhaust cone angle it may have to be rotated to obtain alignment Push cone until it touches tuned pipe then tight en exhaust collar clamp and torque to 10 N m 88 lbf in CAUTION There must be no gap be tween tuned pipe cone and tuned pipe head NOTE Exhaust collar clamp nuts should be tighten alternately to assure no leakage and to obt...

Page 100: ...SYSTEM Sub Section 00 TABLE OF CONTENTS TABLE OF CONTENTS COMPONENTS 0 01 1 SP SPI AND GTS MODELS 0 01 1 SPX AND GTI MODELS 0 01 2 HX MODEL 0 01 3 XP MODEL 0 01 4 GENERAL 0 01 5 CIRCUIT 0 02 1 GENERAL 0 02 1 www SeaDooManuals net ...

Page 101: ...COOLING SYSTEM Sub Section 01 COMPONENTS 05 01 1 COMPONENTS 1 SP SPI and GTS Models F01E0SS Loctite 592 Loctite 592 Loctite 592 3 1 Loctite 592 Loctite 592 Loctite 592 1 2 1 Loctite 592 www SeaDooManuals net PARTS ...

Page 102: ... 05 01 2 SPX and GTI Models F01E1PS Loctite 592 3 Loctite 592 Loctite 592 SP Model Only 1 2 N m 11 lbf in Loctite 592 Loctite 592 1 2 N m 11 lbf in 2 1 1 1 2 N m 11 lbf in 2 5 N m 22 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in www SeaDooManuals net PARTS ...

Page 103: ...PONENTS 05 01 3 HX Model F05E04S Loctite 592 Loctite 592 1 2 N m 11 lbf in Loctite 592 1 1 2 N m 11 lbf in Body Loctite 592 1 2 N m 11 lbf in 1 1 2 N m 11 lbf in 1 Loctite 592 Engine Water Outlet 1 Engine Water Outlet www SeaDooManuals net PARTS ...

Page 104: ... 11 lbf in Loctite 592 Loctite 592 Loctite 592 Loctite 592 Loctite 592 1 2 1 1 1 2 N m 11 lbf in 2 N m 18 lbf in 1 2 N m 11 lbf in 1 1 1 2 N m 11 lbf in 4 Loctite 592 2 5 N m 22 lbf in Loctite 592 6 5 9 10 0 11 N m 1 lbf in 0 6 N m 5 lbf in 8 7 Loctite 592 5 N m 44 lbf in www SeaDooManuals net PARTS ...

Page 105: ...aft 3 Elbow Fitting Water injection used on exhaust system cools the exhaust gases to obtain maximum performance from the tuned pipe The elbow fitting has a cali brated inside diameter to optimize water flow in tuned pipe The water injection also helps in reducing noise level and cools components of the exhaust sys tem CAUTION The elbow fittings are calibrat ed and can not be interchanged with one...

Page 106: ...icient to overcome the spring of the regulator valve more water is being delivered to the injection fitting at the tuned pipe At higher speed water pressure increases in the supply hose of the regulator valve and gradually overcomes the return spring of the regulator valve Less water is being delivered to the injec tion fitting at the tuned pipe Adjustment The water flow regulator valve has been c...

Page 107: ...1 Tapered needle Remove the tapered needle from valve housing 1 Remove tapered needle 9 10 Valve and Bellows Pull the valve slightly Using pliers release the clamp which retains the bellows Remove valve and bellows Inspection Inspect parts for damage Verify especially bel lows for cracks Assembly Assembly is essentially the reverse of disassem bly procedures F01E1RA 1 2 F01E1SA 1 F01E1TA 1 F01E20A...

Page 108: ...o the engine The water supply is taken from a pressurized area in the jet pump between the impeller and venturi The tuned pipe and exhaust manifold are de signed with a double wall to allow water circula tion Water is pre heated by the exhaust system be fore entering the cylinder cooling jackets When engine is running water must flow from bleed outlet s indicating that water circulates Check monit...

Page 109: ...ing system arrange ment refer to the next pages for each engine model CAUTION Never modify cooling system ar rangement otherwise serious engine dam age could occur F01E1GA 1 F01D7HA TECHNICAL DATA TYPE TLCS Total Loss Cooling System COOLANT FLOW Pressure build up at impeller housing no water pump TEMPERATURE CONTROL Calibrated outlet fittings no thermostat SYSTEM BLEEDING Self bleed type hose at u...

Page 110: ...am of water flows out of bleed outlets located near stern eyelet Calibrated outlet fittings limit water flow Pressure zone Lowest point of circuit allows draining whenever engine is stopped Water injected directly into exhaust gas for noise reduction and performance improvement Fresh water flows through tuned pipe and manifold water jackets Uppermost point of engine cylinder head cover allows blee...

Page 111: ...System Indicator CSI small stream of water flows out of bleed outlet located near stern eyelet Calibrated outlet fittings limit water flow Pressure zone Tuned pipe bleed hose injects water into muffler to cool exhaust components Lowest point of circuit allows draining whenever engine is stopped Water injected directly into exhaust gas for noise reduction and performance improvement Water flows thr...

Page 112: ...ng beeper when temperature exceeds 96 99 C 205 210 F Calibrated cylinder head limits water flow Water flows through tuned pipe and manifold water jackets Water regulated by the water flow regulator valve and injected directly into exhaust gas for noise reduction and performance improvement Lowest point of circuit allows draining whenever engine is stopped Water inlet hose of valve Water directly i...

Page 113: ...1 6 REMOVAL 06 01 6 ASSEMBLY 06 01 7 FUEL SYSTEM PRESSURIZATION 06 01 8 AIR INTAKE 06 02 1 REMOVAL 06 02 2 ASSEMBLY 06 02 2 CARBURETORS 06 03 1 587 ENGINE 06 03 1 717 AND 787 ENGINES 06 03 2 GENERAL 06 03 3 CARBURETOR REMOVAL 06 03 3 CLEANING 06 03 3 DISASSEMBLY AND INSPECTION 06 03 3 PUMP VERIFICATION 06 03 4 CARBURETOR ASSEMBLY 06 03 5 CARBURETOR INSTALLATION 06 03 7 ADJUSTMENTS 06 03 8 www SeaD...

Page 114: ...IT 06 01 1 FUEL CIRCUIT 1 SP SPI and GTS Models F01F19S 2 N m 18 lbf in 6 N m 53 lbf in 7 6 1 N m 9 lbf in 4 22 N m 16 lbf ft 4 N m 35 lbf in 5 4 4 N m 35 lbf in 3 N m 27 lbf in 8 SP Loctite 242 3 N m 27 lbf in 1 2 3 1 2 3 www SeaDooManuals net PARTS ...

Page 115: ... CIRCUIT 06 01 2 SPX XP and GTI Models F01F2ZS 2 N m 18 lbf in 6 N m 53 lbf in 7 6 Body 1 3 2 1 N m 9 lbf in 3 N m 27 lbf in 22 N m 16 lbf ft 4 4 N m 35 lbf in 5 4 4 N m 35 lbf in 8 Engine Loctite 242 3 N m 27 lbf in www SeaDooManuals net PARTS ...

Page 116: ...FUEL CIRCUIT 06 01 3 HX Model F05F09S 3 N m 27 lbf in Loctite 242 1 3 2 6 N m 53 lbf in 7 2 N m 18 lbf in Body 6 1 N m 9 lbf in 4 4 N m 35 lbf in 5 4 4 N m 35 lbf in 22 N m 16 lbf ft 3 N m 26 lbf in 8 Engine Body www SeaDooManuals net PARTS ...

Page 117: ...er on clamp embossment and squeeze plier WARNING Replace any damaged leak ing or deteriorated fuel lines To secure or cut Oetiker clamps on fuel lines use pliers P N 295 000 070 1 Cutting clamp 1 Securing clamp 1 Securing clamp in limited access When replacing fuel lines on SEA DOO water craft be sure to use B1 hoses as available from Bombardier parts department This will ensure continued proper a...

Page 118: ...ed area Do not smoke or allow open flames or sparks in the vicinity Unscrew fuel filler cap to remove any fuel pres sure in system Unscrew the fuel filter bowl counterclockwise then pull toward the bottom TYPICAL Pull fuel filter toward the bottom TYPICAL INSPECTION Check filter bowl for water contamination Inspect fuel filter condition Carefully use low pressure compressed air to clean fuel filte...

Page 119: ...elease the pressure WARNING If pressure relief valve is stuck the pressure in fuel system will build up and it may cause fuel leakage in en gine compartment NOTE It is a one way valve with an arrow to indicate the air flow 7 Check Valve Black side of the one way check valve is the valve outlet It allows air to get in reservoir REMOVAL 8 Baffle Pick Up NOTE The baffle pick up has an integrated fuel...

Page 120: ...ck up and disconnect wiring harness of fuel sensor if applicable Remove lower clamp from baffle pick up adapter and pull out baffle from fuel tank TYPICAL 1 Wiring harness 2 Baffle pick up adapter HX Model Only Pull down left vent tube 1 Vent tube Cut tie rap retaining fuel hoses to tie mount 1 Cut tie rap All Models Loosen lower clamp of baffle pick up adapter and pull out baffle from fuel tank R...

Page 121: ...pump gauge tester P N 295 000 085 to air inlet hose Turn fuel valve to OFF position and pressurize fuel system to 34 kPa 5 PSI If no leaks are found turn fuel valve to ON position and pres surize once more If pressure is not maintained locate leak and re pair replace component leaking To ease leak search spray a solution of soapy water on com ponents bubbles will indicate leak location NOTE The sy...

Page 122: ... AIR INTAKE 06 02 1 AIR INTAKE 2 F01F1WS 1 9 4 8 10 N m 88 lbf in 8 Loctite 242 Loctite 242 6 Loctite 242 2 10 N m 88 lbf in 5 Twin carbs 10 7 Loctite 515 3 Single carb Loctite 515 7 Loctite 242 10 N m 88 lbf in www SeaDooManuals net PARTS ...

Page 123: ...ort of flame arrester base to the cylinder head cover 587 and 717 en gines or to the tuned pipe 787 engine Remove screws from flame arrester base then withdraw base NOTE On single carburetor models re move choke cable from flame arrester base 1 Remove support and base ASSEMBLY Assembly is essentially the reverse of removal procedures However pay particular attention to the following CAUTION Do not...

Page 124: ...E 06 02 3 5 Flame Arrester Inspect condition of flame arrester Replace or clean as necessary WARNING Do not operate watercraft without flame arrester 9 Gasket Inspect condition of gasket Make sure to proper ly installed gasket www SeaDooManuals net ...

Page 125: ... 06 FUEL SYSTEM Sub Section 03 CARBURETORS 06 03 1 CARBURETORS 3 587 Engine F02F0KS 12 3 11 10 9 8 1 13 14 7 Loctite 242 4 19 5 15 Anti seize lubrifiant Loctite 242 6 2 13 18 17 16 www SeaDooManuals net PARTS ...

Page 126: ...URETORS 06 03 2 717 and 787 Engines F01F05S Loctite 242 6 14 Loctite 242 20 21 20 N m 15 lbf ft MAG 13 Loctite 242 7 15 Anti seize lubricant 19 5 4 18 17 16 PTO Synthetic grease Synthetic grease 2 13 1 8 10 9 11 3 12 www SeaDooManuals net PARTS ...

Page 127: ...s and rotary valve on top of engine NOTE When removing rotary valve cover pay attention that the rotary valve will stay in place otherwise it must be timed Remove carburetor from intake manifold CLEANING The entire carburetor should be cleaned with a general solvent and dried with compressed air be fore disassembly CAUTION Be careful at carburetor clean ing not to remove paint Paint removal will c...

Page 128: ...old under vacuum WARNING Some fuel may be present in fuel pump Be careful not to swallow fuel when under vacuum TYPICAL 1 Fuel outlet nipple 2 Pulse nipple 3 Inlet nipple Repeat the same procedure at the outlet nipple This time the outlet valve should hold with pres sure and release under vacuum 3 Diaphragm PUMP DIAPHRAGM LEAK TEST Using a suitable pump gauge tester perform the following test proc...

Page 129: ...sembling pump ensure to properly posi tion components together Refer to previous illus trations if necessary 6 7 Choke Plate and Throttle Plate When installing plate onto shaft close plate so that it centers into carburetor bore Firmly tighten screws CAUTION Always apply Loctite 242 blue on screw threads prior to installing screws 8 Needle Valve Lever Rounded end of needle valve lever must be flus...

Page 130: ...30 seconds Otherwise hold carburetor upside down pour oil over needle valve and apply pressure Check for bubbles If they come from seat or O ring bubbles will exit around seat Retighten as necessary If it still leaks remove needle and seat and replace O ring If bubbles come from needle replace needle and seat 9 10 Main Jet and Pilot Jet Pilot jet and main jet are replaceable Different jet sizes ar...

Page 131: ...IER LUBE P N 293 600 016 to prevent sticking CARBURETOR INSTALLATION At installation pay attention to the following Install carburetor s with gasket s to intake mani fold rotary valve cover for the 787 engine Single Carburetor Models Only Install lock washers and apply Loctite 242 blue on threads then torque nuts to 25 N m 18 lbf ft Twin Carburetor Models Only Apply Loctite 242 blue on screw threa...

Page 132: ...ine ends are damaged cut damaged end before reinstallation Properly install clamps WARNING Make sure there is no leak in fuel system For fuel system pressurization refer to FUEL SYSTEM 06 01 ADJUSTMENTS Throttle Cable Lubricate cable with BOMBARDIER LUBE lubri cant Throttle lever must reach handlebar grip without causing strain to cable or carburetor cable bracket 1 Must touch handlebar grip Ensur...

Page 133: ...f to the specification as per following chart NOTE Turning screw clockwise leans mix ture and turning screw counterclockwise enriches mixture Start and warm up engine CAUTION Water must be supplied to cool engine Check that engine idles and runs smoothly Make sure engine reacts quickly to throttle lever depres sion If necessary readjust low speed screw þ1 4 turn NOTE On twin carburetor engines bot...

Page 134: ...717 AND 787 ENGINES 1 High speed screws 15 Idle Speed Screw Turning screw clockwise increases engine idle speed and turning screw counterclockwise de creases engine idle speed 587 ENGINE 1 Idle speed screw 717 AND 787 ENGINES 1 Idle speed screw F01F0VA 1 F01F2QA 1 F01F0TE 1 F01F32C 1 www SeaDooManuals net ...

Page 135: ...e arrester and air intake silencer are installed Start engine and bring to normal operating tem perature CAUTION If watercraft is out of water water must be supplied to cool engine Turn screw so that engine idles at 1500 RPM if watercraft is in water If watercraft is out of water refer to the following chart to adjust idle speed to the specification Watercraft model Idle speed out of water RPM SP ...

Page 136: ...ABLE OF CONTENTS OIL INJECTION SYSTEM 0 01 1 ALL MODELS EXCEPT HX 0 01 1 HX MODEL 0 01 2 OIL INJECTION PUMP 0 02 1 ALL MODELS EXCEPT XP 0 02 1 XP MODEL 0 02 2 REMOVAL 07 02 3 CLEANING 07 02 3 ASSEMBLY 07 02 3 ADJUSTMENTS 0 02 4 CHECKING OPERATION 07 02 5 www SeaDooManuals net ...

Page 137: ...SYSTEM Sub Section 01 OIL INJECTION SYSTEM 07 01 1 OIL INJECTION SYSTEM 1 All Models Except HX F01G0CS 4 N m 35 lbf in 1 2 1 1 2 N m 11 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in 4 3 SP Model Only 3 www SeaDooManuals net PARTS ...

Page 138: ...Section 07 LUBRIFICATION SYSTEM Sub Section 01 OIL INJECTION SYSTEM 07 01 2 HX Model F05G02S 3 4 1 2 N m 11 lbf in 1 2 N m 11 lbf in www SeaDooManuals net PARTS ...

Page 139: ...line ends for damage Always cut damaged end before reinstallation Pressure Test Proceed as follows Fill up oil reservoir Install a hose pincher to rotary valve shaft oil supply hose Install a hose pincher to rotary valve shaft oil return hose Install a hose pincher to oil injection pump sup ply hose Connect pump gauge tester to check valve of oil injection reservoir vent TYPICAL 1 Connect pump to ...

Page 140: ... All Models Except XP F01G0DS Twin Carbs Single Carb Loctite 242 2 6 N m 53 lbf in 1 4 10 N m 89 lbf in 6 6 6 N m 53 lbf in 1 2 6 N m 53 lbf in Loctite 242 4 3 5 Loctite 242 6 N m 53 lbf in 8 N m 71 lbf in 8 N m 71 lbf in 4 5 N m 40 lbf in Loctite 242 5 N m 44 lbf in www SeaDooManuals net PARTS ...

Page 141: ...on 07 LUBRIFICATION SYSTEM Sub Section 02 OIL INJECTION PUMP 07 02 2 XP Model F01G0TS 11 10 9 8 4 5 N m 40 lbf in 6 N m 53 lbf in 7 4 5 N m 40 lbf in 4 5 N m 40 lbf in Loctite 242 www SeaDooManuals net PARTS ...

Page 142: ...rom fittings of oil injection pump DISASSEMBLY NOTE Some oil pump parts are not avail able in single parts A gasket set is available for the pump If the pump is found defective it should be re placed by a new one CLEANING Discard all seals and O rings Clean metal compo nents in a solvent ASSEMBLY All Models Except XP 3 4 5 Oil Injection Pump Intake Manifold and Screw Install oil injection pump to ...

Page 143: ...usted Ensure carburetor butterfly ies is are in closed position NOTE On a twin carburetor engine make sure carburetors are properly synchronized If necessary refer to FUEL SYSTEM 06 03 Turn idle speed screw until it contacts stopper Turn idle speed screw 2 turns Turn cable adjustment nut to align marks on pump NOTE A mirror may be used to facilitate this verification 587 and 717 Engines TYPICAL 1 ...

Page 144: ...ine 1 Bleed screw All Engines Keep bleeding until all air has escaped from line Make sure no air bubbles remain in oil supply line Tighten bleed screw Wipe any oil spillage Check small oil lines between pump and intake manifold They must be full of oil If not run engine at idle speed while manually holding pump lever in fully open position Do not activate throttle lever CAUTION Water must be suppl...

Page 145: ...tion 3 Counterclockwise reverse rotating drill 4 Oil must drip here For an accurate test each port should be checked separately to ensure equal delivery on both ports To obtain a precise result of the oil pump delivery rate rotate it counterclockwise at 1500 RPM for a total time of 30 seconds NOTE To ensure accuracy of test oil lines should be completely filled before starting test Compare the res...

Page 146: ...ER 08 02 8 IGNITION SYSTEM TESTING PROCEDURE 08 02 9 SPARK PLUGS 08 02 13 CHARGING SYSTEM 08 03 1 GENERAL 08 03 1 TESTING PROCEDURE 08 03 1 BATTERY 08 03 3 STARTING SYSTEM 08 04 1 GENERAL 08 04 2 STARTING SYSTEM TROUBLESHOOTING 08 04 3 STARTER REMOVAL 08 04 4 STARTER DISASSEMBLY 08 04 4 CLEANING 08 04 4 PARTS INSPECTION 08 04 4 STARTER ASSEMBLY 08 04 5 STARTER INSTALLATION 08 04 7 STARTER SPECIFIC...

Page 147: ...717 Engines F01D4WS 12 11 5 N m 44 lbf in 13 9 N m 80 lbf in Loctite 242 4 6 8 Loctite 242 7 6 N m 53 lbf in Loctite 242 6 N m 53 lbf in 9 Loctite 242 5 6 N m 53 lbf in 3 14 Loctite 242 4 Loctite 648 10 15 145 N m 107 lbf ft Anti seize lubricant 2 9 N m 80 lbf in 1 www SeaDooManuals net PARTS ...

Page 148: ...242 Loctite 242 Loctite 648 Loctite 648 10 7 9 6 5 8 1 2 4 11 10 N m 88 lbf in 10 N m 88 lbf in Synthetic grease Lithium grease 105 N m 77 lbf ft 10 N m 88 lbf in 6 N m 53 lbf in 10 N m 88 lbf in 9 N m 80 lbf in Anti seize lubricant 13 15 14 12 3 16 4 5 N m 40 lbf in www SeaDooManuals net PARTS ...

Page 149: ... 2 Extension handle 3 Puller plate 4 Sleeve Using 3 M8 x 35 screws P N 290 841 591 in stall screws through puller plate and slide sleeves on screws then secure puller plate on MAG fly wheel so that sleeves are against flywheel Install extension handle on end of puller plate TYPICAL 1 Sleeves on opposite side Using a suitable socket unscrew retaining nut COUNTERCLOCKWISE when facing it NOTE If sock...

Page 150: ...587 and 717 Engines Since replacement crankcases do not have timing mark for armature plate location indexing marks should be made on armature plate and crankcase to ease reassembly and further ignition timing The following procedure is to find a common ref erence point on both crankcases old and new to position armature plate Proceed as follows Find a crankcase locating lug the top one in this ex...

Page 151: ...n armature plate 2 Punch a mark on crankcase lug aligned with plate mark The new mark on crankcase will be used for fur ther assembly positioning as a pre timing posi tion TYPICAL 1 For further assembly use these marks 787 Engine 1 2 Magneto Housing Cover and Screw Remove engine magneto cover 15 16 Rotor and Flywheel Remove starter Lock ring gear using special tool P N 295 000 134 1 Ring gear bloc...

Page 152: ... 1 Puller Tighten puller screw and at the same time tap on screw head using a hammer to release engine fly wheel from its taper CLEANING Clean all metal components in a solvent CAUTION Clean coils and magnets us ing only a clean cloth Clean crankshaft taper and threads DISASSEMBLY 587 and 717 Engines 3 10 MAG Flywheel and Ring Gear Lay MAG flywheel on a steel plate Tap lightly on ring gear using a...

Page 153: ...ncrimp and unsolder YELLOW and YELLOW BLACK wires from coil Uncrimp and unsolder ground wire BLACK from coil core 1 Uncrimp and unsolder ground wire BLACK here 2 Uncrimp and unsolder YELLOW and YELLOW BLACK wires here ASSEMBLY 587 and 717 Engines 6 8 Generating Coil and Screw Strip end of old wire then crimp and solder on new coil Apply Loctite 242 blue to screws and install the new coil on armatu...

Page 154: ...enever replacing either ring gear or MAG fly wheel Gun Kote must be applied to prevent pos sible corrosion CAUTION Always assemble MAG fly wheel and ring gear prior to apply Gun Kote If not done correctly ring gear won t con tact MAG flywheel flange To apply Gun Kote proceed as follows 1 Clean thoroughly and degrease replacement part using a non oil base solvent 2 Apply coating in light thin coats...

Page 155: ...dures refer to ELECTRICAL SYSTEM 08 02 787 Engine 11 18 Magneto Housing and Seal To install oil seal of magneto housing use pusher P N 290 877 740 and handle P N 290 877 650 1 Pusher 2 Handle 11 12 13 Magneto Housing Gasket and Screw Install gasket between magneto housing and en gine crankcase Install magneto housing and torque screws to 9 N m 80 lbf in 15 16 17 Rotor Flywheel and Nut When reinsta...

Page 156: ...neto installation All Engines 1 2 Magneto Housing Cover and Screw Properly install O ring in magneto housing Apply Loctite 767 Anti seize on screw threads install cover wire support and spark plug grounding de vice 587 and 717 engines then torque screws in a criss cross sequence to 9 N m 80 lbf in www SeaDooManuals net ...

Page 157: ...D wire The generating coil allows a current flow through ignition coil with its integrat ed CDI module and through primary windings Ignition coil induces voltage to a high level in sec ondary windings to produce a spark at spark plug Multi Purpose Electronic Module It receives its current from the battery It includes the engine rev limiter and also an integrated delay timer which cut off the elect...

Page 158: ... Magnetic field outside of coil 5 Magnetic field crossing coil 6 Current to CDI module DC CDI Module The DC CDI module receives the input from the trigger coil and signals the ignition coil when to fire It also has the rev limiter function built into its circuitry as well as the ignition timing curve The DC CDI module is mounted in the cover of the conventional electrical box Multi Purpose Electro...

Page 159: ...elation between the PTO flywheel mark position and crankshaft po sition may change as the PTO flywheel is screwed on the crankshaft As an example when the PTO flywheel is reinstall on the crankshaft it can slightly turns on the crank shaft when the engine is accelerated even if it is properly torqued This is enough to obtain a false ignition timing reading Always verify PTO flywheel mark position ...

Page 160: ...uring the engine to the rear engine mount Reinstall screw with timing mark pointer tool 1 Timing mark pointer tool P N 295 000 135 All Engines 4 Install and adjust a TDC gauge P N 295 000 065 in MAG side spark plug hole TYPICAL 1 TDC gauge on MAG side 5 Rotate PTO flywheel counterclockwise when facing it until piston is at top dead center TYPICAL 1 Adjust gauge dial at zero 6 From this point rotat...

Page 161: ...rk plug and connect wire Dynamic Test 587 and 717 Engines To check ignition timing use Bombardier timing light P N 295 000 078 NOTE To perform this procedure make sure to use a stroboscopic timing light rated up to 6000 RPM Otherwise an inaccurate read ing will be obtained The ignition components are affected by temper ature variation therefore timing must be checked when engine is cold after idli...

Page 162: ...0 RPM and point beam of timing light straight in line with timing mark pointer CAUTION If engine is to be run more than a few seconds connect coupler hose P N 295 500 258 and supply water to the en gine to properly cool it NOTE If mark on PTO flywheel is perfectly aligned with timing mark pointer no adjust ment is required If it is not the case refer to Igni tion Timing Adjustment in this sub sect...

Page 163: ...gnition timing make sure engine is cold Repeat armature plate positioning procedure if timing mark position is not adequate 787 Engine Since the trigger coil on this engine is fixed and not movable to correct the ignition timing the MPEM programmer P N 295 000 127 is now used to set the timing when an adjustment is re quired The programmer will act as if you were moving the trigger coil to advance...

Page 164: ...recheck the timing with the timing light and found that the flywheel mark is still too advanced You know now that the correction made previously was not enough and you es timate the correction should be set to 2 re tarded to align flywheel mark Back in the chart look to find 2 retarded This gives number 6 Enter this number with the pro grammer You recheck the timing with the timing light and if th...

Page 165: ...ap over safety lanyard switch and crank engine until light turns on or otherwise for a maximum of 5 seconds 4 After every test that lights the indicator lamp RESET the indicator circuit by depressing the reset button Analysis of Test Results INDICATOR LAMP LIGHTS AT SPECIFIC SETTING Output is as specified Test results should repeat 3 times If readings do not repeat output is erratic and cause shou...

Page 166: ...h Verification Disconnect the BLACK and BLACK YELLOW wires in the electrical box Using an ohmmeter connect test probes to switch wires Measure resistance it must be close to 0 ohm when cap is over switch and an open circuit when removed Delay Timer Verification The timer is integrated into the MPEM Always confirm first that the fuses are in good condition To confirm operation of timer remove safet...

Page 167: ... a high sensitivity ohmme ter Refer to the following table for values and wire colors 1 Multimeter 2 Four pin magneto harness adapter 3 RED BLUE wire 4 BLACK wire DYNAMIC TEST 1 Connect spark plug cables to grounding device 2 Disconnect magneto wiring harness connector 3 Install the four pin magneto harness adapter P N 295 000 131 4 Connect probe N of Bombardier Ignition Tester to RED BLUE wire of...

Page 168: ...s a faulty generating coil Replace it 787 Engine Trigger Coil Verification STATIC TEST CONTINUITY 1 Disconnect magneto wiring harness connector 2 Install the six pin magneto harness adapter P N 295 000 136 3 Connect one multimeter lead to the WHITE wire of the six pin magneto harness adapter 4 Connect the other multimeter lead to the BLACK YELLOW wire of the six pin magneto harness adapter 5 Measu...

Page 169: ...d be no reading 3 Jumper DC battery voltage positive lead to PURPLE BLUE negative to BLACK 4 By energizing the coil the switch should have closed the ohmmeter should read less than 0 5 ohm resistance Meter Lead Meter Lead Value RE PU BK 2 6 kΩ YL WH BK 0 380 MΩ WH BK 2 208 MΩ BK OR BK infinity BK GR BK infinity BK BK 0 2 Ω WH BL BK 30 38 kΩ BK RE PU 2 690 kΩ BK YL WH 0 390 MΩ BK WH 2 2 MΩ BK BK OR...

Page 170: ...it will read 0 ohm or close to on ohmmeter DYNAMIC TEST A paper clip of approximately 20 mm 3 4 in will be used as a test adapter for the following test 1 Install the test adapter to spark plug cable close to MAG side spark plug 2 Connect Bombardier Ignition Tester probes then set switch and dial as follows TYPICAL 1 N lead on paper clip 2 P lead to grounding device 3 Start engine and observe indi...

Page 171: ... Heat Range The proper heat range of the spark plugs is deter mined by the spark plugs ability to dissipate the heat generated by combustion The longer the heat path between the electrode tip to the plug shell the hotter the spark plug op erating temperature will be and inversely the shorter the heat path the colder the operating temperature will be A cold type plug has a relatively short insulato...

Page 172: ...erating condition method of driving and fuel mixture For this reason it is advisable to inspect the spark plug at regular inter vals examining the plug face i e the part of the plug projecting into the combustion chamber and the piston dome Spark Plug Installation Prior to installation make sure that contact surfac es of the cylinder head and spark plug are free of grime 1 Using a wire feeler gaug...

Page 173: ... mm 10 mm 12 mm 8 mm 12 mm x 19 mm Reach A B C D E J Special Design Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V Type Half Heat Range Standard Center Electrode Fine Wire Center Electrode Booster Gap V Grooved Center Electrode A GV B C G L S V X Y Blank 18 mm ø 12 mm 31 64 14 mm ø 9 5 mm 3 8 Compact Type Projected Insulator Type Resistor Type Surface Dischar...

Page 174: ...g system If the battery is regularly discharged check fuse condi tion NOTE On the XP model there is two 15 A fuses The rectifier regulator is often the culprit of a blown fuse To check simply disconnect the rec tifier regulator from the circuit If the fuse still burns check for a defective wire CAUTION Do not use a higher rated fuse as this cause severe damage TESTING PROCEDURE NOTE First ensure t...

Page 175: ...eter 2 Magneto harness adapter 3 YELLOW and YELLOW BLACK wires DYNAMIC TEST 1 Disconnect the magneto wiring harness con nector 2 Install the four pin magneto harness adapter P N 295 000 131 3 Connect and set Bombardier Ignition Tester as per following table 1 Bombardier Ignition Tester 2 Magneto harness adapter 3 Probe N to YELLOW wire 4 Probe P to YELLOW BLACK wire 4 Crank engine and observe indi...

Page 176: ...r 2 Install the six pin magneto harness adapter P N 295 000 136 3 Insert multimeter lead to one of the YELLOW wire of the six pin magneto harness adapter 4 Ground the multimeter lead to the engine or the stator iron core and note the reading 1 Multimeter 2 Magneto harness adapter 3 lead to YELLOW wire 4 lead to ground 5 Repeat test with the other two YELLOW wires of the six pin magneto harness ada...

Page 177: ...ged replace battery and thoroughly clean battery tray and close area with water and baking soda WARNING Should the battery casing be damaged wear a suitable pair of non ab sorbent gloves when removing the battery by hand Inspect battery posts for security of mounting Inspect for cracked or damaged battery caps re place defective caps WARNING Battery caps do not have vent holes Make sure that vent ...

Page 178: ...full charge as possible trickle charge Activation of a New Battery WARNING Never charge or boost bat tery while installed in watercraft A new battery is factory fresh dry charged For storage purposes it is fitted with a temporary sealing tube CAUTION Do not remove the sealing tube or loosen battery caps unless activa tion is desired In case of accidental premature removal of caps or sealing tube b...

Page 179: ...ot discontinue charging tem porarily or reduce the charging rate WARNING Always charge in a well ven tilated area Keep battery away from ciga rettes or open flames Always turn battery charger off prior to disconnecting cables 6 Disconnect battery charger Step Unplug battery charger Step Disconnect lead Step Disconnect lead 7 Test battery state of charge Use a hydrometer 1 Specific gravity 1 260 8 ...

Page 180: ... when the charging cycle first be gins As the battery remains on the charger the current from the charger causes the electrolytic acid content to rise which makes the electro lyte a better conductor and then the battery will accept a higher charging rate Type of charger Battery chargers vary in the amount of voltage and current that they can supply Therefore the time required for the bat tery to b...

Page 181: ...d equal to number of battery to be charged multiply by 2 A For example Charging 5 batteries at a time re quires a 10 A rated charger 5 x 2 A 10 A TYPICAL 1 Two batteries 4 A WARNING Always charge in a well ven tilated area Installation of Battery WARNING Always connect battery ca bles exactly in the specified order RED positive cable first BLACK negative cable last Proceed as follows 1 Install bat...

Page 182: ... Sub Section 04 STARTING SYSTEM 08 04 1 STARTING SYSTEM 4 F01H1MT 12 11 10 9 6 8 7 1 2 3 4 5 13 5 N m 44 lbf in Dielectric grease 15 16 Loctite 271 Ground cable Dielectric grease 22 N m 16 lbf ft 14 17 www SeaDooManuals net PARTS ...

Page 183: ...ohmme ter Disconnect the YELLOW RED wire in the electri cal box Connect test probes to YELLOW RED wire and to ground near solenoid Measure resistance it must be an open circuit switch is normally open Depress and hold switch the ohmmeter should read close to 0 ohm Safety Lanyard Switch Disconnect the BLACK and BLACK YELLOW wires in the electrical box Using an ohmmeter connect test probes to switch...

Page 184: ...commutator Turn commutator in lathe Worn commutator segments Undercut mica Shorted armature Repair or replace armature Weak brush spring tension Replace brush holder or spring Weak magnet Replace yoke assembly Worn bushings Replace clutch Weak battery Recharge or replace battery Starter engages but does not crank the engine Worn clutch pinion gear Replace clutch Defective clutch Replace clutch Poo...

Page 185: ...Tap the pinion stop collar using a screwdriver Re move circlip Disassemble pinion stop collar and spring 1 Pinion stop collar 9 10 11 12 Clutch Ass y Housing O ring and Armature Turn assembly clockwise to remove it from arma ture assembly Pull housing from armature CLEANING CAUTION Yoke ass y and drive unit as sembly must not be immersed in cleaning solvent Discard all O rings and gasket Clean bru...

Page 186: ...easure brush length If less than 8 5 mm 335 in replace them NOTE New brush length is 12 mm 472 in 1 New 2 Wear limit 8 5 mm 335 in Overrunning Clutch Pinion of overrunning clutch should turn smoothly in clockwise direction and should not slip in a counterclockwise direction If defective replace Check pinion teeth for wear and damage If defec tive replace NOTE Always check engine ring gear teeth fo...

Page 187: ... Yoke Ass y End Frame and Through Bolt Open brushes and slide over commutator Align end frame locating notch with yoke locating protrusion and properly sit brush holder into yoke 1 Locating protrusion is the higher one 1 Brush holder locating notch To ease end frame installation retain brush holder with a small screwdriver while installing end frame A03E0EA 1 2 4 3 F01H0QA 1 F01H0SA 1 F01H0TA 1 ww...

Page 188: ...f ft 15 Nut Connect the RED battery cable to the starter and torque nut to 6 N m 53 lbf in Apply dielectric grease on terminal and nut 16 17 Screw and Teeth Washer Apply Loctite 271 red on screw Connect BLACK cable to starter using flat washer teeth washer and screw Torque screw to 22 N m 16 lbf ft Apply dielectric grease on terminal and screw Step Torque nut to 6 N m 53 lbf in Step Apply Loctite ...

Page 189: ...minal output 0 6 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight Approx 2 kg 4 4 lb Performance Specification at 20 C 68 F No load 11 5 V 20 A max 5500 RPM Load 8 5 V 170 A max 2200 RPM Stall 5 V 350 A max 0 RPM Battery 19 Ah www SeaDooManuals net ...

Page 190: ...ion oil level is low 1 Low oil warning light Multifunction Gauge A LCD gauge indicates the amount of fuel in the tank Warning lights will indicate a defective charging system an overheating engine low fuel level and low oil level 1 Fuel level bar graph 2 Engine overheats 3 Low oil level 4 Low fuel level 5 Low voltage Accuracy of gauge can be checked with a potenti ometer Disconnect 6 circuit tab h...

Page 191: ...ter to the resistance values as per following chart to test accuracy of gauge NOTE Gauge must be activated to obtain a reading If gauge is not within the specifications replace it Fuel Baffle Pick Up Sensor The baffle pick up has an integrated fuel sensor except SP and HX models To verify fuel sensor a resistance test should be performed with an ohmmeter allowing the float to move up through a seq...

Page 192: ...oil tank and its reservoir is empty resistance must be infinite open circuit NOTE Wait about 15 20 seconds before taking any reading to give the oil enough time to flow out or inside sensor reservoir Soak sensor in oil so that its reservoir fills up Maximum resistance should be approximately 2 Ω closed circuit 1 Measure resistance here 2 Sensor reservoir To reinstall sensor Remove rubber seal from...

Page 193: ...battery and a voltmeter Disconnect speed sensor wires from inside bilge With a 12 VDC battery connect the positive to sensor PURPLE YELLOW wire Connect the negative to the sensor BLACK wire Connect the voltmeter positive probe to sensor BLUE PURPLE wire and the negative probe to sensor BLACK wire Turn the paddle wheel slowly There should be a voltage fluctuation VTS Switch Always confirm first tha...

Page 194: ...ives its current from the battery It is pro tected by its own 7 5 A fuse RESISTANCE TEST Disconnect BROWN BLACK wire and BROWN WHITE wire of VTS control module located in front of bilge on left side Connect test probes of an ohmmeter to BROWN BLACK wire and BROWN WHITE wire of VTS control module NOTE To permit VTS actuation when en gine is not running remove safety lanyard from switch and depress ...

Page 195: ...the safety lanyard cap This is achieved with the MPEM programmer P N 295 000 127 Refer to its guide to program a safety lanyard The system is quite flexible Up to eight safety lanyards may be programmed in the memory of the watercraft MPEM They can also be erased NOTE If desired a safety lanyard can be used on any watercraft equipped with the DESS The memory of the MPEM is permanent If the battery...

Page 196: ...l 2 short beeps are heard to indicate the system is ready to allow engine starting Wrong safety lanyard Use the safety lanyard that has been programmed for the watercraft If it does not work check safety lanyard condition with the programmer Replace safety lanyard if reported defective If it still does not work enable more detail about the failure Salt water in safety lanyard cap Clean safety lany...

Page 197: ...SIGNAL CAUSE REMEDY No beep Engine actually starts Everything is correct 1 long and 1 short beeps No safety lanyard has ever been programmed in watercraft MPEM Use programmer and program a safety lanyard This code can occur only when you receive a new MPEM from the factory and no key has ever been programmed 2 short beeps MPEM can not read the digital code of the safety lanyardcap or the magnet is...

Page 198: ...SSEMBLY 0 01 8 CLEANING 0 01 12 PARTS INSPECTION 0 01 12 JET PUMP ASSEMBLY 0 01 15 PUMP PRESSURIZATION 0 01 20 JET PUMP SUPPORT INSTALLATION 0 01 21 RIDE SHOE INSTALLATION 0 01 21 JET PUMP INSTALLATION 0 01 22 DRIVE SYSTEM 09 02 1 ALL MODELS EXCEPT HX 09 02 1 GENERAL 09 02 2 REMOVAL 09 02 2 DISASSEMBLY 09 02 6 PARTS INSPECTION 09 02 6 ASSEMBLY 09 02 7 REVERSE SYSTEM 09 03 1 GTS AND GTI MODELS 09 0...

Page 199: ...SYSTEM 09 04 1 SPI AND HX MODELS 09 04 1 REMOVAL 09 04 2 DISASSEMBLY 09 04 2 ASSEMBLY AND INSTALLATION 09 04 2 SPX AND XP MODELS 09 04 3 GENERAL 09 04 4 REMOVAL 09 04 4 DISASSEMBLY 09 04 4 INSPECTION 09 04 4 ASSEMBLY 09 04 5 INSTALLATION 09 04 5 ADJUSTMENT 09 04 5 www SeaDooManuals net ...

Page 200: ...n 22 16 Loctite PST Loctite 518 21 Loctite 271 15 N m 11 lbf ft If required 6 35 N m 26 lbf ft 25 24 22 7 Loctite 271 Loctite 518 3 N m 27 lbf in Loctite PST 17 18 Loctite 242 4 N m 35 lbf in Loctite 242 1 20 N m 15 lbf ft SP GTS 2 5 4 SP GTS 3 4 3 SP GTS 2 1 20 N m 15 lbf ft Loctite 242 25 N m 18 lbf ft 10 Loctite 242 9 Loctite 518 8 70 N m 52 lbf ft 11 Loctite 242 10 N m 88 lbf in 13 www SeaDooM...

Page 201: ... N m 35 lbf in 21 22 16 Loctite PST 16 Loctite PST Loctite 518 15 N m 11 lbf ft Loctite 271 If required 6 26 23 25 24 22 Loctite 271 Loctite 518 3 N m 27 lbf in Loctite PST 17 Loctite 242 18 4 N m 35 lbf in Loctite 242 10 21 N m 16 lbf ft 70 N m 52 lbf ft 5 8 Loctite 518 35 N m 26 lbf ft GTI 1 4 2 3 20 N m 15 lbf ft Loctite 242 3 1 20 N m 15 lbf ft 4 2 GTI Loctite 242 12 www SeaDooManuals net PART...

Page 202: ... Condition and Impeller Wear Ring Clearance Impeller Condition Condition of impeller boot and ring can be quickly checked from underneath of the watercraft Re move grate and look through water inlet opening 1 Boot with ring Impeller Wear Ring Clearance This clearance is critical for jet pump perfor mance Clearance can be checked from water inlet open ing or from venturi side However the last meth ...

Page 203: ...be performed Refer to PUMP PRESSURIZATION in this section To check oil condition insert a wire through oil level hole then withdraw A whitish oil indicates water contamination This may involve defective impeller shaft seal and or O ring of housing cover Jet pump unit should be overhauled to replace seal If everything is correct apply Loctite PST 592 on plug and reinstall it on cover Properly reins...

Page 204: ... PUMP REMOVAL HX Model Disconnect steering cable from jet pump nozzle Loosen 4 hexagonal nuts and remove flat wash ers and lock washers from jet pump housing Remove jet pump All Models Except the HX Remove air vent tube support from body opening SP XP series Remove PTO flywheel guard TYPICAL ALL MODELS EXCEPT THE XP 1 PTO flywheel guard 2 Wing nuts XP MODEL 1 PTO flywheel guard 2 Wing nuts Using p...

Page 205: ...S SPX XP models Remove nut of manual trim from trim ring SPI and HX models Remove ball joint fasteners to release reverse ca ble from reverse gate GTS GTI models SP GTS and GTI Models 1 2 4 5 Screw Sleeve Locking Disk and Nozzle Remove 2 retaining screws 2 sleeves 4 locking disks and withdraw nozzle TYPICAL 1 Screw 2 Locking disks 3 Sleeve SPI SPX and XP Models 5 Nozzle Withdraw nozzle trim ring a...

Page 206: ...therwise engine and jet pump alignment will be altered NOTE After jet pump removal if drive shaft remains in PTO flywheel simply pull it out If drive shaft will not come out it is probably jammed into PTO flywheel Refer to PROPUL SION SYSTEM 09 02 RIDE SHOE REMOVAL 11 12 13 27 Ride Shoe Intake Grate and Screws NOTE Intake grate and impeller housing must be removed prior to ride shoe removal An imp...

Page 207: ...ossible to pull it off JET PUMP DISASSEMBLY NOTE Whenever removing a part visually check for damage such as corrosion crack split break porosity cavitation deformation dis tortion heating discoloration wear pattern miss ing plating missing or broken needles in needle bearing water damage diagnosed by black col ored spots on metal parts etc Renew any dam aged part As a quick check manually feel cle...

Page 208: ...R LUBE lubricant P N 293 600 016 1 Hold raised with drive shaft while striking 16 Fitting Fittings can be removed with deep socket or vise grip Do not contact hose mounting area Fitting can be removed from pump housing with the following suggested tool Use a 14 mm 9 16 in deep socket Drill deep socket with a 14 mm 9 16 in drill bit starting at hexagone head end as shown in fol lowing illustration ...

Page 209: ... impeller 1 Impeller remover installer tool 2 Impeller shaft holder tool CAUTION Never use any impact wrench to loosen impeller To remove impeller apply a rotating movement and pull at same time Slide impeller out of hous ing and remove tool from impeller Remove 2 screws holding impeller housing to shaft holder Lift impeller housing away from impeller shaft Slide thrust washer and thrust bearing o...

Page 210: ...Holding claws turn puller shaft clockwise so that claws open and tighten against seal Slide puller sleeve outwards and gently tap puller end Work with small strikes otherwise claws will slip out As soon as seal begins to slide out re tighten claws to maintain contact with seal Con tinue pulling until seal is out 1 Pulling seal out of housing NOTE If bearings and seal need to be re placed the speci...

Page 211: ...s and clean parts in a solvent Carefully check water passages bailer pick up cooling system and oil passages Blow low pres sure compressed air through them and make sure they are clear 1 Water passages 2 Oil passages Brush and clean impeller shaft threads impeller and drive shaft splines with Loctite Safety solvent 755 P N 293 800 019 or equivalent Free threads and splines from any residue CAUTION...

Page 212: ...ration and chart 1 Stamped part number F01J16A 1 F02J0UA 1 WATERCRAFT MODEL IMPELLER P N MATERIAL PITCH SP 271 000 016 Aluminium 18 8 SPX 271 000 497 Stainless steel Progressive pitch 11 24 SPI 271 000 182 Stainless steel Progressive pitch 11 26 XP 271 000 331 Stainless steel Progressive pitch 17 25 HX 271 000 497 Stainless steel Progressive pitch 11 24 GTS 271 000 416 Stainless steel Progressive ...

Page 213: ...ft end close to end of threads Move shaft end up and down Difference be tween highest and lowest dial gauge reading is radial play Maximum permissible radial play is 0 05 mm 002 in MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to threads at shaft end To check both bearings proceed the same way with other shaft end Position gauge tip on diam eter close to flats on shaft MEASURIN...

Page 214: ...over installed Retain housing in a soft jaw vise making sure not to damage housing lug Set a dial gauge and posi tion its tip on the end of shaft Move shaft end by pulling and pushing Difference between highest and lowest dial gauge reading is end play Maxi mum permissible end play new is 0 12 0 54 mm 005 021 in Make sure vise is secured and not adding to your measurement as you move im peller sha...

Page 215: ... 180 mm x 6 mm thick 7 x 7 in x 1 4 in and a press Manually engage ring in housing making sure it is equally inserted all around Press ring until it seats into bottom of housing 1 Seal lip 2 Press wear ring If a press is not readily available a piece of wood such as a 2 x 4 x 12 in long can be used Manually engage ring in housing making sure it is equally inserted all around Place wood piece over ...

Page 216: ...until it stops CAUTION This tool have been designed to properly position bearings and seal thus providing space for lubrication purposes The tool flanges allow this If a different pusher type is being used components must be prop erly positioned as follows Bearing on impeller side must be 1 5 to 2 5 mm 060 100 in inside reservoir measured from seal seat Bearing on venturi side must be 2 to 3 mm 08...

Page 217: ... 1 Loctite 518 all around and behind 2 Raised edge of seal lip this side 7 19 23 24 25 Impeller Housing Impeller Impeller Shaft Thrust Washer and Thrust Bearing Insert impeller shaft flats in a vise so that shaft is vertical Apply Sea Doo jet pump synthetic oil P N 293 600 011 on both sides of thrust bearing then in sert onto shaft followed by thrust washer Make sure bearing is leaning against sha...

Page 218: ... Loctite 271 red to shaft threads 1 Apply Loctite 271 red on threads Using 2 screws previously removed from venturi secure impeller shaft holder tool to housing In stall shaft holder tool in a vice To ease impeller installation apply BOMBARDIER LUBE lubricant on wear ring Insert impeller into wear ring Manually rotate im peller and push so that it slides on impeller shaft threads Carefully engage ...

Page 219: ...evel with bottom of hole Let oil drain into housing and after a few minutes add more oil until it is level with bottom of filler hole Oil capacity is 90 mL 3 oz CAUTION This is a synthetic oil Do not mix with mineral based oil Do not mix oil brands NOTE When filling reservoir oil must be poured into cover quite slowly to allow com plete housing fill 1 Pour oil slowly until it is level with bottom ...

Page 220: ...14 15 19 Boot Ring and Impeller Apply synthetic grease P N 293 550 010 on im peller splines Insert a new boot and ring to impeller 1 Insert boot and ring PUMP PRESSURIZATION Whenever doing any type of repair on jet pump a pressure test should be done to check for leak age NOTE After complete rebuilding of the jet pump oil MUST be added to the housing BEFORE performing the pressure test in order to...

Page 221: ... pump unit has to be disassembled Disconnect pump gauge tester and remove fit ting Check oil level Refill as necessary Apply Loctite PST 592 to threads of filler plug then secure it in cover JET PUMP SUPPORT INSTALLATION HX Model Only Apply Loctite 598 Ultra Black on support as shown in the following illustration Installation of support is essentially the reverse of removal procedure RIDE SHOE INS...

Page 222: ...n intake grate screw threads install and tighten Torque screws to 8 N m 71 lbf in JET PUMP INSTALLATION All Models Except HX 28 Neoprene Seal If neoprene seal is damaged replace it with a new one TYPICAL 1 Neoprene seal Miscellaneous Generously apply synthetic grease on drive shaft splines Make sure rubber damper is on drive shaft ends Apply Loctite 598 Ultra Black around bailer and water inlet su...

Page 223: ...oned over shaft end Apply Loctite 242 blue on stud threads of jet pump housing Install flat washers lock washers and nuts Tight en nuts of impeller housing in a criss cross se quence and torque to 35 N m 26 lbf ft Push the floating ring to compress the protective hose Insert the O ring in the drive shaft groove Step Push floating ring Step Insert O ring in the groove Slide the floating ring onto t...

Page 224: ... 5 Screw Sleeve Bushing Locking Disk and Nozzle Insert bushings in nozzle positioning their flanges from inside of nozzle Insert sleeves in bushings Install nozzle on venturi position its steering arm on RH side Apply Loctite 242 blue on screw threads or use new screws with pre applied Loc tite Install screws and locking disks then torque to 20 N m 15 lbf ft TYPICAL 1 Locking disks 2 Torque to 20 ...

Page 225: ... fit to install insert both sides at the same time taking care not to break plastic bushings Carefully use a plastic tip hammer if necessary Make sure steer ing arm of jet pump is on right side and trim arm is above venturi housing 1 Torque screws to 14 N m 10 lbf ft Steering Cable Secure ball joint of steering cable TYPICAL 1 Ball joint on top of arm 2 Torque nut to 7 N m 62 lbf in Trim Systems S...

Page 226: ... lbf in All Models NOTE Ball joint must be parallel If not loosen jam nut and adjust ball joint Torque jam nut to 2 5 N m 23 lbf in Check steering alignment Refer to STEERING SYSTEM 10 04 Slightly lubricate wear ring with BOMBARDIER LUBE lubricant before starting to minimize friction during initial start F05J08B 1 www SeaDooManuals net ...

Page 227: ...Section 02 DRIVE SYSTEM 09 02 1 DRIVE SYSTEM 2 All Models Except HX F01I0ES Loctite 271 2 6 18 10 9 8 2 N m 18 lbf in 2 N m 18 lbf in 5 1 11 Synthetic grease 15 3 Loctite 495 Synthetic grease 15 Loctite 495 www SeaDooManuals net PARTS ...

Page 228: ... 22 N m 16 lbf ft Loctite 242 16 17 7 22 N m 16 lbf ft Loctite 242 Loctite 242 13 14 13 Loctite 515 Synthetic grease Loctite 515 12 Loctite 242 10 N m 89 lbf in Loctite 271 2 N m 18 lbf in Synthetic grease 6 5 18 2 N m 18 lbf in 4 Synthetic grease 15 10 9 8 Loctite 598 Ultra Black Loctite 242 30 N m 22 lbf ft www SeaDooManuals net PARTS ...

Page 229: ... of PTO flywheel boot as fol lows Use pliers P N 295 000 069 Insert pointed tips of pliers in closing hooks TYPICAL 1 Closing hooks Squeeze pliers to draw hooks together and dis engage windows from locking hooks TYPICAL 1 Locking hooks 2 Small Clamp Unfasten small clamp of PTO flywheel boot as fol lows Use pliers P N 295 000 054 To open clamp place flat side of plier on clamp embossment squeeze an...

Page 230: ... in B 105 mm 4 1 8 in G 17 mm 43 64 in C 16 mm 5 8 in H 19 mm 3 4 in D 51 mm 2 in I 35 mm 1 3 8 in E 36 mm 1 25 64 in J 20 3 18 800 in 007 Mount on drive shaft puller the impeller housing remover then install assembly on drive shaft us ing screws TYPICAL 1 Impeller housing remover 2 Drive shaft puller 3 Screws CAUTION Be careful not to damage hull rear section or engine rubber mounts HX Model Only...

Page 231: ...o housing cover Refer to ELEC TRICAL SYSTEM 08 01 All Models Except XP To remove PTO flywheel magneto is locked with puller plate P N 290 876 080 sleeves P N 290 847 220 and extension handle P N 295 000 111 1 Screw 3 Puller plate 2 Extension handle 4 Sleeve Using 3 M8 x 35 screws P N 290 841 591 in stall screws through puller plate and slide sleeves on screws then secure puller plate on magneto so...

Page 232: ...lines TYPICAL 1 PTO flywheel remover P N 295 000 001 Using a suitable wrench or socket unscrew PTO flywheel COUNTERCLOCKWISE when facing it TYPICAL 1 Extension handle locking crankshaft As an alternate method to remove PTO flywheel when splines are worn out and PTO flywheel re mover cannot be used Use a pipe wrench and install it on PTO flywheel as illustrated TYPICAL 1 Extension handle locking cr...

Page 233: ...jet pump A 22 mm 865 in dia B 28 mm 1 115 in dia C 90 mm 3 1 2 in D 345 mm 13 1 2 in Properly support seal carrier when removing seals and bearing PARTS INSPECTION 3 Drive Shaft Inspect condition of splines Inspect condition of groove With your finger nail feel contact surface of float ing ring If any irregular surface is found renew drive shaft 1 Floating ring contact surface 2 Groove condition 3...

Page 234: ... O ring Re place as necessary All Model Except HX 11 PTO Flywheel Inspect spline condition of PTO flywheel NOTE There is a possibility that when drive shaft was removed the damper has remained in PTO flywheel Remove it if such is the case HX Model Only 4 14 Drive Shaft and Needle Bearing Inspect seal carrier needle bearing and its contact surface on drive shaft Check parts for scoring pit ting chi...

Page 235: ... 518 all around seals outside diame ter Seals can be carefully installed in housing using bearing seal installer tool P N 295 000 107 Push seals until tool comes in contact with hous ing TYPICAL NOTE Always install seal with its protector facing the impeller Pack seals and bearing with synthetic grease P N 293 550 010 All Models Except HX 3 4 15 Drive Shaft and Damper Install dampers on drive shaf...

Page 236: ...ollowing illustration NOTE It is very important to tighten nuts of seal carrier in a criss cross sequence to maintain its alignment 4 7 16 17 Drive Shaft Damper and Bushing Make sure to install damper and bushing on both drive shafts 1 Damper 2 Bushing All Models Except HX 1 Large Clamp Secure large clamp as follows Use pliers P N 295 000 069 as for removal Manually engage holding hook in large wi...

Page 237: ...dows are directly over the 2 locking hooks press those windows down to engage hooks in windows 1 Press to engage hooks in windows NOTE At installation clamp tail should be in opposite direction of engine rotation 1 Engine rotation counterclockwise 2 Tail in opposite direction 2 Small Clamp To secure small clamp place notch side of plier on clamp embossment and squeeze plier F01J23A 1 2 1 F01J2BA F...

Page 238: ...Section 09 PROLPUSION SYSTEM Sub Section 02 DRIVE SYSTEM 09 02 12 1 Squeeze plier 1 F02J0PB www SeaDooManuals net ...

Page 239: ...S and GTI Models F02J0NS 2 Synthetic grease 6 4 8 N m 71 lbf in 7 N m 62 lbf in 3 N m 27 lbf in 8 N m 71 lbf in 5 1 10 N m 88 lbf in 7 N m 62 lbf in 3 N m 27 lbf in 10 N m 88 lbf in 6 N m 53 lbf in 3 2 5 N m 22 lbf in 7 Loctite 242 Loctite 242 20 N m 15 lbf in www SeaDooManuals net PARTS ...

Page 240: ...ever To remove selector lever unhook spring from sliding block and pull spring from selector lever stem TYPICAL 1 Sliding block 2 Spring Withdraw selector lever stem and locking lever from sliding block then slide off locking lever from stem TYPICAL 1 Locking lever 4 5 Triangular Lever and Sliding Block Remove screw lock nut washers and bushing holding reverse cable to triangular lever Remove lock...

Page 241: ...and support TYPICAL 1 Guide plate 2 Allen screw 3 Screw and washer 7 Reverse Gate Unhook reverse gate springs and remove ball joint fasteners to release reverse cable from reverse gate 1 Reverse cable 2 Reverse gate spring each side Unscrew reverse gate retaining screws from ven turi housing then remove gate 1 Screw each side ASSEMBLY Assembly is essentially the reverse of disassem bly procedures ...

Page 242: ...ngular lever with bush ing plastic washer s and flat washers Torque cable screw to 7 N m 62 lbf in Torque triangular lever screw to 8 N m 71 lbf in Install sliding block to lever and torque nut to 8 N m 71 lbf in 1 5 Locking Lever and Sliding Block Insert locking lever end in support hole then align lever and sliding block holes TYPICAL 1 Support hole 1 3 5 Locking Lever Selector Lever and Sliding...

Page 243: ...liding block 3 Support plate ADJUSTMENTS Reverse Gate Position handlebar in a straight ahead position nozzle should be parallel to rear of watercraft Using a square set it to 129 3 mm 5 5 64 7 64 in then position square end at the top middle of nozzle A 129 3 mm 5 5 64 7 64 in Pull selector lever to REVERSE position TYPICAL 1 Lever to REVERSE position With the gate down to REVERSE position it shou...

Page 244: ...ion NOTE If reverse gate adjustment is not done adequately performance and steering control will be reduced at reverse position TYPICAL 1 Support 2 Adjustment nuts Tighten adjustment nuts and recheck gate posi tion Reinstall vent tube WARNING Vent tube must be in place to provide proper bilge ventilation 1 Install vent tube Reinstall storage basket F02J0FA 1 F02J06B 1 2 F02L14A 1 www SeaDooManuals...

Page 245: ...E TRIM SYSTEM 09 04 1 VARIABLE TRIM SYSTEM 4 SPI and HX Models F05J07S 7 8 6 21 N m 16 lbf ft 1 Loctite 242 10 2 9 13 N m 10 lbf ft Loctite 242 3 13 N m 10 lbf ft Loctite 242 13 N m 10 lbf ft Loctite 242 4 10 N m 89 lbf in 5 www SeaDooManuals net PARTS ...

Page 246: ...side screws of trim ring DISASSEMBLY 6 7 8 Nut Rubber Washer and Half Bushings Loosen nut from support then remove rubber washer and half bushings 9 10 Screw and Threaded Pivot Unscrew adjustment screw to remove threaded pivot ASSEMBLY AND INSTALLATION Assembly and installation are essentially the re verse of removal and disassembly procedures For torque specifications and service products to be u...

Page 247: ...EM 09 04 3 SPX and XP Models F01J56S 7 7 N m 62 lbf in 8 9 6 5 4 6 N m 53 lbf in 10 2 2 3 10 N m 88 lbf in 1 2 5 N m 23 lbf in 13 N m 10 lbf ft Loctite 242 13 N m 10 lbf ft Loctite 242 Loctite 242 13 N m 10 lbf ft 7 N m 62 lbf in 11 12 www SeaDooManuals net PARTS ...

Page 248: ...e VTS socket tool P N 295 000 133 6 VTS Assembly From bilge pull out VTS assembly DISASSEMBLY 7 Cover Remove VTS cover by pressing on tabs 1 Press tabs to remove cover 8 Motor Disconnect wires of motor Remove retaining nuts 1 Remove nuts 2 Disconnect wires Pull on motor to remove it 9 10 Worm and Sliding Shaft Simply pull on worm and sliding shaft in order to remove them INSPECTION 2 Boot Make sur...

Page 249: ...esh worm splines to gear of motor 1 Mesh worm spline to gear of motor Install motor worm and sliding shaft in VTS hous ing Tighten nuts of motor to 7 N m 62 Ibf in Connect wires of motor CAUTION Make sure wire color codes match Install cover NOTE Make sure seal is in place INSTALLATION Installation is essentially the reverse of removal procedures However pay particular attention to the following 4...

Page 250: ...n the nozzle is up 8 nozzle edge must not interfer with venturi there should be a gap of 1 mm 039 in NOTE Activate timer to be able to position VTS 1 No interference 2 Nozzle up If an adjustment is necessary loosen jam nut of ball joint at link rod Turn adjustment nut of ball joint to obtain the desired gap between trim ring and venturi 1 Turn adjustment nut of ball joint Tighten jam nut of ball j...

Page 251: ...Þ ÞXP SERIES 10 01 1 REMOVAL AND ASSEMBLY 10 01 2 GTS AND GTI MODELS 10 02 1 REMOVAL AND ASSEMBLY 10 02 2 HX MODEL 10 03 1 REMOVAL 10 03 2 DISASSEMBLY 10 03 3 STEERING CABLE REMOVAL 10 03 3 ASSEMBLY AND INSTALLATION 10 03 3 STEERING ALIGNMENT 10 03 4 ALIGNMENT 10 04 1 www SeaDooManuals net ...

Page 252: ...ease 7 N m 63 lbf in 10 N m 88 lbf in 6 N m 53 lbf in 2 5 N m 23 lbf in 6 N m 53 lbf in Synthetic grease Loctite 242 Loctite 242 2 5 N m 23 lbf in 15 N m 11 lbf ft 6 N m 53 lbf in Loctite 242 26 N m 19 lbf ft 14 N m 10 lbf ft Two types of assembly 1 2 3 4 5 6 7 8 8 4 5 6 7 11 10 12 15 13 13 9 14 Only with plastic nozzle www SeaDooManuals net PARTS ...

Page 253: ...aligned with the hole beneath the handlebar Install grip on handlebar matching it to the hex form on the grip insert Install flat washer and bolt torque bolt to 14 N m 10 lbf ft 1 Grip insert 2 Grip 3 Flat washer 4 Torque bolt to 14 N m 10 lbf ft 5 Cap CAUTION Ensure to install flat washer otherwise bolt will damage grip end TYPE B When installing the grip insert ensure that its notch is properly ...

Page 254: ...essary to remove steer ing cable from steering stem arm Pull out handlebar assembly CAUTION While performing this proce dure take precautions to avoid damaging throttle cable and wiring harnesses To install handlebar assembly Installation is essentially the reverse of removal procedures However pay particular attention to the following 13 14 15 Thrust Ring Rear and Front Supports Lubricate with sy...

Page 255: ...and front steering support CAUTION While performing this proce dure take precautions to avoid damaging throttle cable and wiring harnesses 1 Install handlebar assembly 2 Route throttle cable and wiring harnesses at the same time Push handlebar assembly until steering stem is well seated into steering supports 1 Rear support steering collar 2 Front support 3 Steering stem Position steering stem arm...

Page 256: ... between body and front sup port to make sure there is no gap between steer ing stem arm and its support If there is a gap components are not properly installed Connect wiring harnesses Route throttle cable alongside bilge Insert cable barrel into carburetor throttle lever Insert throttle cable alongside choke cable in tie blocks For throttle cable adjustment refer to FUEL SYS TEM 05 03 For steeri...

Page 257: ...nt 15 N m 11 lbf ft 3 5 N m 30 lbf in 15 N m 11 lbf ft 15 N m 11 lbf ft Loctite 271 40 N m 30 lbf ft 12 20 N m 15 lbf ft 2 5 N m 23 lbf in 7 N m 63 lbf in 10 N m 88 lbf in 7 N m 63 lbf in 8 Loctite 242 7 6 3 2 Loctite 242 Loctite 242 17 28 15 16 13 20 19 28 11 9 10 12 21 24 27 26 25 22 18 6 N m 53 lbf in Loctite 242 7 N m 63 lbf in 1 23 14 22 www SeaDooManuals net PARTS ...

Page 258: ... bolt threads Install flat washer and bolt torque to 6 N m 53 lbf in 1 Grip insert 2 Grip 3 Flat washer 4 Loctite 242 blue 5 Torque bolt to 6 N m 53 lbf in 6 Cap Handlebar Assembly TO REMOVE HANDLEBAR ASSEMBLY Disconnect wiring harnesses leading out of dash board hole Disconnect throttle cable at carburetor Remove throttle cable from tie block and clip 9 10 11 12 13 Locking Plate Steering Stem Arm...

Page 259: ...ll large flat washer lock washer and screw Torque to 40 N m 30 Ibf ft CAUTION Always install large flat wash er with the X stamped side facing the lock washer WARNING The recommended torque and Loctite must be applied on screw Steering arm mortise must seat properly on steering stem tenon TYPICAL 1 Steering stem arm 2 Steering stem tenon 3 Mortise 4 Large flat washer with X 5 Lock washer 6 Screw a...

Page 260: ...sher and Retaining Ring From bilge unscrew nut retaining steering cable to hull Remove half rings rubber washer and retaining ring NOTE Move selector lever in reverse posi tion to lower reverse gate It will ease part removal Remove steering cable from tie block and clips Pull out steering cable Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the f...

Page 261: ...m 27 lbf in 6 N m 53 lbf in 7 N m 62 lbf in 7 N m 62 lbf in 17 6 N m 53 lbf in 15 16 6 N m 53 lbf in Synthetic grease Synthetic grease 10 6 N m 53 lbf in 18 Synthetic grease Synthetic grease 26 N m 19 lbf ft 12 13 7 N m 62 lbf in 15 N m 11 lbf ft 14 19 9 2 5 N m 22 lbf in 10 N m 89 lbf in 11 www SeaDooManuals net PARTS ...

Page 262: ...ever Remove the hood cover by loosening the 4 plastic Phillips screws They may need to be replaced af ter one use Disconnect steering cable from lever of steering stem arm 1 Lever 2 Disconnect cable 11 Retaining Block Remove retaining block of cable support 1 Retaining block Miscellaneous Disconnect wires of monitoring beeper and start stop switch Open hood Disconnect throttle cable from carbureto...

Page 263: ...r from cable support STEERING CABLE REMOVAL Disconnect steering cable from lever of steering stem arm Remove retaining block of cable support Pull out boot of steering cable and throttle cable from hood Disconnect ball joint of steering cable from jet pump nozzle Remove ball joint boot nut half rings and O ring from steering cable Remove cable from watercraft ASSEMBLY AND INSTALLATION Assembly and...

Page 264: ...ct torque must be strict ly followed 4 5 6 7 8 Grip Cap Bolt Flat Washer and Grip Insert When installing the grip insert ensure that its notch is properly inserted in the hole beneath the handlebar 1 Notch inserted in handlebar hole Install grip on handlebar matching it to the U form of the handlebar Apply Loctite 242 blue on bolt threads Install flat washer and bolt torque to 6 N m 53 lbf in 1 Gr...

Page 265: ...lacing a straight edge on nozzle outer end Measure the distance on each side of the straight edge It must be equalled TYPICAL 1 Measure the distance on each side of the straight edge If necessary steering alignment adjustment should be performed at steering cable support near steering stem Slacken retaining block at cable support Turn adjustment nut as required SP XP Series and HX Models 1 Retaini...

Page 266: ...aining block 2 Adjustment nut 3 Bolts All Models After adjustment torque retaining block bolts to 6 N m 53 Ibf in CAUTION Verify when the handlebar is turned completely to the left or right side that there is no interference with venturi hous ing F03K03A 2 3 1 www SeaDooManuals net ...

Page 267: ...S 11 00 1 Section 11 SUSPENSION TABLE OF CONTENTS DIRECT ACTION SUSPENSION 11 01 1 HX MODEL 11 01 1 COIL OVER SHOCK REMOVAL 11 01 2 OUTER BOOT REMOVAL 11 01 3 COIL OVER SHOCK DISASSEMBLY 11 01 3 ASSEMBLY 11 01 3 www SeaDooManuals net ...

Page 268: ...ON 11 01 1 DIRECT ACTION SUSPENSION 1 HX Model F05L0GS 2 3 5 N m 44 lbf in 5 N m 44 lbf in 9 5 4 6 10 N m 88 lbf in 5 N m 44 lbf in Loctite 242 7 34 N m 25 lbf ft 11 Loctite 242 34 N m 25 lbf ft 10 Loctite 242 10 N m 88 lbf in 12 1 8 www SeaDooManuals net PARTS ...

Page 269: ...of coil over shock outer boot then pull outer boot downward 1 Collar 3 4 Inner Boot and Collar Remove rear access panel from body From bilge loosen lower collar of coil over shock inner boot then push boot upward 1 Collar 5 6 Bolt and Lock Nut Remove bolt and lock nut from shock absorber lower support 1 Bolt 2 Lock nut Tilt seat upward F05L0HA 1 2 F05L0IA 1 F05L0JA 1 F05L0KA 1 2 www SeaDooManuals ...

Page 270: ...boot Remove outer boot from body COIL OVER SHOCK DISASSEMBLY Remove boot Install spring compressor tool P N 529 027 100 in a vise WARNING Do not attempt to dismantle a spring without using the proper tool Install coil over shock in spring compressor tool Compress spring and remove cup Unload tool and remove spring from shock ab sorber ASSEMBLY Assembly is essentially the reverse of assembly proced...

Page 271: ...NT 12 01 10 DRAIN PLUG INSTALLATION 12 01 11 SEAT REMOVAL 12 01 11 SEAT COVER REPLACEMENT 12 01 12 BUMPER REPLACEMENT 12 01 12 SPONSON REPLACEMENT 12 01 13 BAFFLE SEALING GTS GTI MODELS 12 01 13 HOOD REMOVAL 12 01 13 DECALS REPLACEMENT 12 01 13 HULL AND BODY REPAIR 12 01 14 HULL INSERT REPAIR 12 01 17 PAINTING 12 02 1 GENERAL 12 02 1 PARTS THAT CAN BE PAINTED 12 02 2 CONCEPTTM PAINTING PROCEDURE 1...

Page 272: ...NT AND REPAIR 1 SP XP Series F01L6HS 3 Loctite 271 5 N m 44 lbf in Loctite 271 Loctite 242 8 N m 71 lbf in 1 2 Loctite 271 5 N m 44 lbf in Sealant 732 5 N m 44 lbf in 10 Sealant 732 7 8 9 Loctite 242 6 Loctite 271 Sealant 732 Body 15 N m 11 lbf ft www SeaDooManuals net PARTS ...

Page 273: ...on 01 ADJUSTMENT AND REPAIR 12 01 2 F01L6IS Loctite 242 6 N m 53 lbf in 15 N m 11 lbf ft Sealant 732 Loctite 271 SPX XP models Loctite 271 Sealant 732 1 5 N m 13 lbf in Sealant 732 12 4 4 12 4 5 12 4 12 5 www SeaDooManuals net PARTS ...

Page 274: ...R 12 01 3 GTS GTI Models F02L26S 3 Loctite 271 5 N m 44 lbf in 8 N m 71 lbf in Loctite 242 Loctite 271 1 2 Loctite 271 5 N m 44 lbf in Loctite 242 Sealant 732 8 7 9 10 5 N m 44 lbf in 6 11 Loctite 271 Sealant 732 15 N m 11 lbf ft www SeaDooManuals net PARTS ...

Page 275: ...HULL BODY Sub Section 01 ADJUSTMENT AND REPAIR 12 01 4 F02L27S Loctite 242 7 N m 62 lbf in 4 12 15 N m 11 lbf ft Loctite 271 Sealant 732 4 5 12 4 12 12 5 Sealant 732 1 5 N m 13 lbf in 4 www SeaDooManuals net PARTS ...

Page 276: ...L BODY Sub Section 01 ADJUSTMENT AND REPAIR 12 01 5 HX Model F05L0PS Body 5 N m 44 lbf in Loctite 271 3 5 N m 44 lbf in Body Body 1 5 N m 13 lbf in Loctite 271 Sealant 732 15 N m 11 lbf ft www SeaDooManuals net PARTS ...

Page 277: ...Sub Section 01 ADJUSTMENT AND REPAIR 12 01 6 F05L0QS Body 4 N m 35 lbf in 4 N m 35 lbf in 4 N m 35 lbf in Loctite 242 4 N m 35 lbf in Loctite 242 Loctite 242 8 N m 71 lbf in Body 8 N m 71 lbf in www SeaDooManuals net PARTS ...

Page 278: ... Section 01 ADJUSTMENT AND REPAIR 12 01 7 F05L0RS 4 N m 35 lbf in 4 N m 35 lbf in 4 N m 35 lbf in 1 2 N m 11 lbf in 5 N m 44 lbf in Loctite 242 5 N m 44 lbf in 4 N m 35 lbf in Body 13 N m 10 lbf ft www SeaDooManuals net PARTS ...

Page 279: ...Section 12 HULL BODY Sub Section 01 ADJUSTMENT AND REPAIR 12 01 8 F05L0SS 6 N m 53 lbf po 15 N m 11 lbf pi 6 N m 53 lbf po Loctite 242 13 www SeaDooManuals net PARTS ...

Page 280: ...orque to 8 N m 71 lbf in A 22 5 1 0 mm 51 64 1 32 0 in 2 Lock Pin Adjust lock pin of seat as per following specifica tions SP XP SERIES 1 Lock pin 2 Adjustment nut Loctite 271 3 Lock nut Torque to 5 N m 44 lbf in A 37 1 mm 1 29 64 3 64 in GTS GTI MODELS 1 Lock pin 2 Adjustment nut Loctite 271 3 Lock nut Torque to 5 N m 44 lbf in A 38 1 mm 1 1 2 3 64 in NOTE If watercraft is equipped with a op tion...

Page 281: ... 1 Lock pin 2 Adjustment nut Loctite 271 3 Lock nut Torque to 5 N m 44 lbf in A 37 0 5 1 mm 1 3 64 1 64 1 32 in ACCESS PANEL ADJUSTMENT HX Model Only 3 Lock Pin Adjust lock pin of access panel as per following specifications 1 Lock pin 2 Adjustment nut Loctite 271 3 Lock nut Torque to 5 N m 44 lbf in A 47 1 mm 1 27 32 3 64 in 13 Bolt Adjust bolts of access panel arms as per following specification...

Page 282: ...ant 3 Torque screws to 1 5 N m 13 lbf in 4 From inside bilge apply 732 sealant on screws SEAT REMOVAL HX Model Only Remove bottom cover of seat with grab handle 1 Cover Loosen collar of coil over shock outer bootþ then pull outer boot downward 1 Collar Loosen upper collar of coil over shock inner bootþ then pull boot downward 1 Collar F05L13A 1 2 3 4 4 F05L0HB 1 F05L0IA 1 F05L0LA 1 www SeaDooManua...

Page 283: ...c tacker such as Ar row tacker no ETN 50 or with a manual tacker such as Arrow tacker no T 50 NOTE For an easier installation it s highly recommended to use an electric tacker Ensure that the seat rest firmly against a hard sur face such as a piece of wood This is done to get the staples completely pushed in place TYPICAL 1 Piece of wood 2 ETN 50 electric or T 50 manual After cover installation cu...

Page 284: ...To ease flat washer and lock wash er installation use a flexible 4 claw Snap on pick up tool Reinstall muffler Tighten hose clamps to 4 N m 35 lbf in Reinstall air vent tube support SP XP series Reinstall seat Clean hull and sponsons of any sealant adhesive surplus WARNING Recommended torques and use of Loctite must be strictly followed BAFFLE SEALING GTS GTI MODELS 11 Rear Baffle Apply Sikaflex p...

Page 285: ...l installation a mild solution of soapy water can be sprayed over surface where decal will be installed Remove back protective film from decal and align decal with marks When well aligned squeegee decal beginning at center and working outward using firm short overlapping strokes Remove front protective film once decal has ad hered to hull Installation on Plastic Storage Cover Clean surface with is...

Page 286: ...it sand paper until you come close to the original surface Remove dust with a water soaked cloth and con tinue sanding with a 400 grit wet paper Finish wet sanding with a 600 grit to remove deeper scratches If needed you can wet sand with finer grit paper such as 1000 grit BUFFING AND WAXING Buff the surface using a heavy duty polisher with a buffing pad Make sure the pad is free of dirt or you ma...

Page 287: ...y ers of fiberglass laminate Two types of repairs have to be performed The first is to restore the structural integrity of the damaged area Fracture types can vary from a simple crack to a large hole Usually fiberglass reinforcement becomes nec essary especially if the fracture can be attributed to weakness The final part of the repair is the gelcoating which cannot be done until the interior and ...

Page 288: ... be used Refer to the repair procedure for minor gelcoat fractures BUFFING AND WAXING Refer to the buffing and waxing for minor gelcoat fractures If painting the exterior is preferred re fer to HULL BODY 11 02 Tools and Materials List Tools safety glasses air mask white cloths sanding block putty knife plastic film stirring stick cover sheets for Sea Doo scissors buffing pad heavy duty polisher po...

Page 289: ...uminum insert fill gap with epoxy glue to obtain good adhe sion of aluminum insert 1 Knurled surface 2 Inner bore Install aluminum insert into plastic hull insert NOTE Align aluminum insert as much as possible with PTO flywheel 1 Aluminum insert NOTE The epoxy glue curing time is 30 minutes F01L2VA 1 2 F01L2WA 1 www SeaDooManuals net ...

Page 290: ...coat surfaces refer to the appropriate Bombardier Sea Doo Parts Catalog to find the available products NORTH AMERICA CANADA Quebec Phone 1 800 363 2816 All Others Provinces Phone 1 905 855 5802 Communications are available in english and french U S A Phone 216 572 6100 This phone number is also good for all countries Communications are available in english french and spanish EUROPE DENMARK Phone 4...

Page 291: ... if applicable 4 Engine 5 Tuned Pipe 6 Muffler 7 Exhaust Manifold 8 Engine Support 9 Magneto Housing Except for parts made of plastic 10 Magneto Housing Cover 11 Flame Arrester Base 12 Ride Shoe 13 Impeller Housing 14 Venturi 15 Steering Nozzle F02B03S 3 2 1 5 4 9 10 11 13 12 15 14 8 7 6 www SeaDooManuals net ...

Page 292: ... 59962 Purple 59962 Purple 59962 Purple 59962 Purple 59962 Purple 59962 7 Exhaust Manifold COLOR PPG no White 98209 White 98209 White 98209 White 98209 White 98209 White 98209 8 Engine support COLOR PPG no Black 9551 Black 9551 Black 9551 Black 9551 Black 9551 Black 9551 9 Magneto housing COLOR PPG no White 98209 White 98209 White 98209 White 98209 White 98209 White 98209 10 Magnetohousing cover C...

Page 293: ...r is 6 to 8 hours at 21 C 70 F Medium solids option is 2 to 4 hours at 21 C 70 F FULL PANEL AND OVERALL REPAIRS Application Apply 1 medium wet coat and give 5 10 minutes flash followed by 2 wet coats with 15 minutes flash time between each coat Adjust metallic on the last full wet coat If necessary apply a mist coat For medium solids option apply 2 full wet coats Air Pressure 275 345 kPa 40 50 PSI...

Page 294: ...ED SPRAY EQUIPMENT Dry Time at 21 C 70 F Dust freeþ 25 35 minutes Tack freeþ 2 1 2 to 3 hours Tape Sandþ Overnight Force Dry Allow 20 minutes purge time at 27 32 C 80 90 F before bake Bake 75 minutes at 65 C 150 F or 40 minutes at 82 C 180 F Allow to cool after force dry before sanding or taping Gun Manufacturer De Vilbiss Binks Graco HVLP Gun Model JGA 62 800N Can Am Model 900 Fluid Type FF 1 4 m...

Page 295: ...13 00 1 Section 13 TECHNICAL DATA Sub Section 00 TABLE OF CONTENTS TABLE OF CONTENTS SP AND SPI MODELS 13 01 1 SPX AND XP MODELS 13 02 1 GTS AND GTI MODELS 13 03 1 HX MODEL 13 04 1 www SeaDooManuals net ...

Page 296: ...apez 1 Rectangular Ring end gap New 0 25 0 40 mm 010 016 in Wear limit 1 00 mm 039 in Ring piston groove clearance New 0 05 0 08 mm 002 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New 0 05 0 07 mm 002 003 in Wear limit 0 2 mm 008 in Cylinder taper maximum 0 100 mm 004 in Cylinder out of round maximum 0 080 mm 003 in Connecting rod bigend axial play New 0 39 0 74 mm 015 029 in We...

Page 297: ...xide 12 V 19 A h Fuse Starting system 5 A Charging system 15 A ADDITIONAL INFORMATION Engine cold 6000 RPM CARBURETION SP 5876 SPI 5878 Carburetor Type Mikuni BN 38 diaphragm Quantity 1 Main jet 142 5 147 5 Pilot jet 65 Adjustment Low speed screw 1 1 4 turn 1 4 High speed screw 0 Idle speed in water 1500 RPM Idle speed out of water 2400 RPM 2500 RPM Fuel Type Regular unleaded gasoline Minimum octa...

Page 298: ... 017 in ring clearance Wear limit 1 02 mm 040 in Impeller shaft end play new 0 12 0 54 mm 005 021 in Impeller shaft side play 0 05 mm 002 in Impeller pitchþ þmaterial 18 8 aluminum Progressive pitch 11 26 stainless steel ADDITIONAL INFORMATION þDo not mix different brands or oil types DIMENSIONS SP 5876 SPI 5878 Number of passenger driver incl 2 Overall length 254 cm 100 in Overall width 105 cm 41...

Page 299: ...l tank reserve Standard Monitoring beeper Standard Electric fuel gauge low oil warning light Optional Standard Tachometer Optional Manual trim system Optional Standard Reverse Not applicable Storage compartment Standard Rear grab handle Optional Standard Extinguisher holder Standard ADDITIONAL INFORMATION PERFORMANCE SP 5876 SPI 5878 Estimated pump power 18 3 kW 24 5 hp 21 7 kW 29 1 hp Maximum fue...

Page 300: ...t 1 Venturi pump housing screws 25 N m 18 lbf ft 1 Nozzle venturi screws 20 N m 15 lbf ft 1 Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 lbf in 1 Ride shoe screws 10 N m 88 lbf in 1 Cable retaining block bolts 6 N m 53 lbf in Steering cableþ þstem arm bolt 3 N m 26 lbf in Steering stem arm bolts 6 N m 53 lbf in Handlebar clamp bolts 26 N m 19 lbf ft Ball joint bolt 7 N m...

Page 301: ...1 in 781 6 cm 47 7 in3 Corrected compression ratio 6 2 1 5 9 1 Cylinder head warpage maximum 0 05 mm 002 in Piston ring type and quantity 1 Semi trapez 1 Rectangular Ring end gap New 0 25 0 40 mm 010 016 in Wear limit 1 00 mm 039 in Ring piston groove New 0 025 0 070 mm 001 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New 0 060 0 108 mm 0024 0043 in Wear limit 0 2 mm 008 in Cylin...

Page 302: ...PM Battery Yuasa Exide 12 V 19 A h Fuse Starting system 5 A Charging system 15 A 15 A 2 VTS system 7 5 A Holder relay Not applicable 5 A ADDITIONAL INFORMATION Engine cold 6000 RPM CARBURETION SPX 5877 XP 5858 5859 Carburetor Type Mikuni BN 38I diaphragm Mikuni BN 40I diaphragm Quantity 2 Main jet 130 142 5 Pilot jet 67 5 70 Adjustment Low speed screw 1 1 4 turn 1 4 1 turn 1 4 High speed screw 0 I...

Page 303: ...ive pitch 11 24 stainless steel Progressive pitch 17 25 stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS SPX 5877 XP 5858 5859 Number of passenger driver incl 2 Overall length 254 cm 100 in Overall width 105 cm 41 3 in Overall height 92 cm 36 2 in Dry weight 187 kg 412 lb 197 kg 434 lb Load limit passenger and 10 kg 22 lb luggage 160 kg 352 lb ADDITIONAL I...

Page 304: ... with polystyrene foam Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION STANDARD EQUIPMENT SPX 5877 XP 5858 5859 Safety lanyard Standard Tool kit Standard Fuel tank reserve Standard Monitoring beeper Standard Speedometer Optional Standard Multifunction gauge Standard Tachometer Optional Variable trim system VTS Standard Reverse Not applicabl...

Page 305: ...Pump hull nuts 35 N m 26 lbf ft 1 Venturi pump housing screws 21 N m 16 lbf ft 1 VTS ring screws 14 N m 10 lbf ft 1 Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 lbf in 1 Ride shoe screws 10 N m 88 lbf in 1 STEERING Cable retaining block bolts 6 N m 53 lbf in Steering cable stem arm bolt 3 N m 26 lbf in Steering stem arm bolts 6 N m 53 lbf in Handlebar clamp bolts 26 N m ...

Page 306: ...ston ring type and quantity 1 Semi Trapez 1 Rectangular Ring end gap New 0 25 0 40 mm 010 016 in Wear limit 1 00 mm 039 in Ring piston grooveclear ance New 0 05 0 08 mm 0 2 mm Wear limit 002 003 in 008 in Piston cylinder wall clear ance New 0 05 0 07 mm 002 003 in 0 06 0 11 mm 002 004 in Wear limit 0 2 mm 008 in Cylinder taper maximum 0 100 mm 004 in Cylinder out of round maximum 0 08 mm 003 in Co...

Page 307: ... Starting system 5 A Charging system 15 A ADDITIONAL INFORMATION Engine cold 6000 RPM CARBURETION GTS 5817 GTI 5865 5866 Carburetor Type Mikuni BN 38 diaphragm Mikuni BN 38I diaphragm Quantity 1 2 Main jet 147 5 130 Pilot jet 65 67 5 Adjustment Low speed screw 1 1 4 turn 1 4 High speed screw 0 Idle speed in water 1500 RPM Idle speed out of water 2500 RPM 3000 RPM Fuel Type Regular unleaded gasolin...

Page 308: ...ear limit 1 02 mm 040 in Impeller shaft end play new 0 12 0 54 mm 005 021 in Impeller shaft side play 0 05 mm 002 in Impeller pitch material Progressive pitch 10 25 stainless steel Progressive pitch 11 24 stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTS 5817 GTI 5865 5866 Number of passenger driver incl 3 3 5865 2 5866 Overall length 302 cm 119 0 in Ov...

Page 309: ...ndard Electric fuel gauge low oil warning light Standard Not applicable Multifunction gauge Optional Standard Digitally Encoded Security System D E S S Optional Standard Tachometer Optional Speedometer Optional Standard Variable trim system VTS Not applicable Reverse Standard Storage compartment Standard Rear grab handle Standard Extinguisher holder Standard ADDITIONAL INFORMATION PERFORMANCE GTS ...

Page 310: ...1 Venturi pump housing screws 21 N m 16 lbf ft 1 Nozzle venturi screws 20 N m 15 lbf ft 1 Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 lbf in 1 Ride shoe screws 10 N m 88 lbf in 1 STEERING Steering cable jam nuts 10 N m 88 lbf in Steering support collar screws 15 N m 11 lbf ft 1 Steering stem screw 40 N m 30 lbf ft 2 Handlebar nuts 26 N m 19 lbf ft Reverse gate screws 20...

Page 311: ...trapez 1 Rectangular Ring end gap New 0 25 0 40 mm 010 016 in Wear limit 1 00 mm 039 in Ring piston groove clearance New 0 025 0 070 mm 001 003 in Wear limit 0 2 mm 008 in Piston cylinder wall New 0 060 0 108 mm 0024 0043 in clearance Wear limit 0 2 mm 008 in Cylinder taper maximum 0 100 mm 004 in Cylinder out of round maximum 0 080 mm 003 in Connecting rod bigend axial play New 0 39 0 74 mm 015 0...

Page 312: ...Fuse Starting system 5 A Charging system 15 A Trim system Not applicable ADDITIONAL INFORMATION Engine cold 6000 RPM CARBURETION HX 5881 Carburetor Type Mikuni BN 38I diaphragm Quantity 2 Main jet 130 Pilot jet 75 Adjustment Low speed screw 1 1 2 turn ñ 1 4 High speed screw 0 Idle speed in water 1500 RPM Idle speed out of water 3000 RPM Fuel Type Regular unleaded gasoline Minimum octane no 87 Fuel...

Page 313: ...wearring clearance New 0 18 0 44 mm 007 017 in Wear limit 1 02 mm 040 in Impeller shaft end play new 0 12 0 54 mm 005 021 in Impeller shaft side play 0 05 mm 002 in Impeller pitch material Progressive pitch 11ø 24ø stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS HX 5881 Number of passenger driver incl 1 Overall length 273 cm 107 5 in Overall width 85 cm 3...

Page 314: ...X 5881 Safety lanyard Standard Tool kit Standard Fuel tank reserve Standard Monitoring beeper Standard Electric fuel gauge low oil warning light Optional Multifunction gauge Optional Tachometer Optional Manual trim system Standard Reverse Not applicable Storage compartment Not applicable Rear grab handle Standard Extinguisher holder Standard ADDITIONAL INFORMATION PERFORMANCE HX 5881 Estimated pum...

Page 315: ...mp housing screws 21 N m 16 lbf ft 1 VTS ring screws 14 N m 10 lbf ft Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 lbf in 1 Ride shoe screws 10 N m 88 lbf in 1 STEERING Cable retaining block bolts 6 N m 53 lbf in Steering cable lever 3 N m 26 lbf in Steering stem arm bolts 6 N m 53 lbf in Handlebar clamp bolts 26 N m 19 lbf ft Ball joint bolt 7 N m 62 lbf in Steering sup...

Page 316: ...www SeaDooManuals net ...

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XLT1200 WaveRunner 2002

Brand: Yamaha Pages: 142

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