SeaDoo 2002 GTX 4-TEC Operator'S Manual Download Page 99

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Please verify with your selling dealer to ensure your SEA-DOO watercraft
has been registered with Bombardier.

WATERCRAFT

MODEL No.

HULL

IDENTIFICATION NUMBER (H.I.N.)

ENGINE

IDENTIFICATION NUMBER (E.I.N.)

Owner:

Purchase Date

YEAR

MONTH

DAY

Warranty Expiry Date

YEAR

MONTH

DAY

To be completed by the authorized Sea-Doo dealer at the time of the sale.

DEALER IMPRINT AREA

NAME

No.

STREET

APT

CITY

STATE/PROVINCE

ZIP/POSTAL CODE

smo2002-003d.FM Page 93 Friday, October 12, 2001 2:06 PM

Summary of Contents for 2002 GTX 4-TEC

Page 1: ......

Page 2: ...remain with the craft at the time of resale Knight s Spray Nine is a trademark of Korkay System Ltd GTX is a trademark of Castrol Ltd used under license The following trademarks are the property of Bombardier Inc or its subsidiaries SEA DOO BOMBARDIER ROTAX BOMBARDIER LUBE BOMBARDIER ROTAX Formula XP S Synthetic Injection Oil BOMBARDIER Formula XP S DI Synthetic Injection Oil BOMBARDIER ROTAX Inje...

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

Page 4: ...ATION 25 CONTROLS COMPONENTS AND INSTRUMENTS FUNCTIONS 27 1 Safety Lanyard engine cut off cord 27 2 Handlebar 28 3 Throttle Lever 28 4 Engine Start Stop Button 28 5 Shift Lever 28 6 Speedometer 29 7 Tachometer 29 8 Information Center Gauge Buttons 29 9 Glove Box 34 10 Fuel Tank Cap 34 11 Front Storage Compartment Cover 35 12 Front Storage Compartment Cover Latch 36 13 Tool Kit 36 14 Air Intake Ope...

Page 5: ...Level 48 Engine Coolant Level 49 Steering System 49 Throttle System 49 Shifter System 49 Storage Compartment Covers and Seat 49 Safety Lanyard and Engine Start Stop Button 49 OPERATING INSTRUCTIONS 50 Principle of Operation 50 Boarding the Watercraft 53 Starting 55 Rough Water or Poor Visibility Operation 55 Crossing Waves 56 Stopping Docking 56 Beaching 56 Shutting Off the Engine 56 POST OPERATIO...

Page 6: ...l Injection System 69 Steering Alignment 69 Vacuum Bailer Pick Ups 70 Fuses 70 General Inspection and Cleaning 74 TRAILERING STORAGE AND PRE SEASON PREPARATION 75 Trailering 75 Launching Loading 76 Storage 76 Body Rinsing Repair 76 Fuel System 76 Engine Oil and Filter Replacement 76 Exhaust Cooling System Flushing and Engine Internal Lubrication 76 Battery 77 Engine Cooling System 77 Bilge Cleanin...

Page 7: ...cy of continuous improvement of its products without imposing upon it self any obligation to install them on products previously manufactured Because of its ongoing commitment to product quality and innovation Bombardier reserves the right at any time to discontinue or change specifica tions designs features models or equipment without incurring obligation The illustrations in this document show t...

Page 8: ...and RIGHT star board indications in the text always refers to driving position when sitting on watercraft Furthermore in the marine industry FRONT is referred to BOW and REAR as STERN 1 Left port 2 Right starboard F01L451 1 2 ...

Page 9: ... of the wa tercraft read and understand all on product warnings Operation Always perform the pre operation checks as specified in this guide Operator and passenger s should at all times wear a coast guard approved personal flotation device PFD that is suitable for personal watercraft Operator and passenger s should wear protective clothing Severe in ternal injuries can occur if water is forced int...

Page 10: ... vere injury or watercraft damage may occur In shallow water proceed with cau tion and at very low speeds Ground ing or abrupt stops may result in in jury Debris may also be picked up and be thrown rearward by the jet pump onto people or property Respect no wake zones the rights of other water users and the environ ment As the skipper and owner of a watercraft you are responsible for damage to oth...

Page 11: ... spark plugs if so equipped The bilge should be kept clean of oil water or other foreign materials Do not attempt to lift the watercraft without special equipment and train ing The engine and the corresponding components identified in this guide should not be utilized on product s other than for those they were de signed Maintenance procedures and specified tightening torque should be strictly adh...

Page 12: ...ontact the service manager or owner of the Sea Doo dealership To find the nearest authorized Sea Doo dealer dial 1 800 882 2900 NOTE If outside Canada or USA consult your local authorized Sea Doo distributor USA Except Puerto Rico BOMBARDIER MOTOR CORPORATION OF AMERICA 7575 Bombardier Court WAUSAU WI 54401 Phone 715 848 4957 Fax 715 847 6879 www bombardier com CANADA BOMBARDIER INC RECREATIONAL P...

Page 13: ...DOO RX DI SEA DOO GTX DI SEA DOO LRV DI AND SEA DOO GTX 4 TEC TWELVE 12 CONSECUTIVE MONTHS for the emission related components providing input to emission control e g sensors The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date CALIFORNIA RESIDENTS purchasing a SEA DOO RX DI or a SEA DOO G...

Page 14: ...airs done by a person that is not an authorized servicing BOMBARDIER SEA DOO dealer Damage caused by abuse abnormal use neglect or operation of the product in a man ner inconsistent with the recommended operation described in the Operator s Guide Damage resulting from accident submersion fire theft vandalism or any act of God Operation with fuels oils or lubricants which are not suitable for use w...

Page 15: ...thorized BOMBARDIER dealer and gives the coordinates of the new owner or b BOMBARDIER or an authorized BOMBARDIER dealer receives a proof that the former owner agreed to the transfer of ownership in addition to the coordinates of the new owner 9 CONSUMER ASSISTANCE a In the event of a controversy or a dispute in connection with this BOMBARDIER LIM ITED WARRANTY BOMBARDIER suggests that you try to ...

Page 16: ...anty Protects consumer for worry free operation One Star Low Emission The one star label identifies engines that meet the Air Resources Board s 2001 exhaust emission standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 standards for marine engines Two Stars Very Low Emission The two star...

Page 17: ...cer tified and produced by BOMBARDIER for sale in California that are originally sold in Cali fornia to a California resident The BOMBARDIER North America Limited warranty condi tions for Sea Doo watercraft are still applicable to these models with the necessary modifications Select emission control parts of your 2002 SEA DOO RX DI SEA DOO GTX DI SEA DOO LRV DI and SEA DOO GTX 4 TEC personal water...

Page 18: ...our Operator s Guide BOMBARDIER recommends that you retain all receipts covering maintenance on your personal watercraft engine but BOMBARDIER cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance As the personal watercraft engine owner you should however be aware that BOMBARDIER may deny you warranty coverage if your personal w...

Page 19: ...tributor dealer and then only after the BOMBARDIER specified pre delivery inspection process is completed and documented Warranty coverage only be comes available upon proper registration of the product by a BOMBARDIER dealer Such limitations are necessary in order to allow BOMBARDIER to preserve both the safety of its products and also that of its consumers and the public Routine maintenance outl...

Page 20: ...ON ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRAN TY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVER AGE UNDER THIS WARRANTY SOME COUNTRIES DO NOT ALLOW FOR THE DIS CLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY N...

Page 21: ...ve the issue at the distributorship dealership level We recommend discussing the issue with the autho rized dealer s service manager or owner b If further assistance is required the distributor s service department should be contact ed in order to resolve the matter 2001 Bombardier Inc All rights reserved Registered trademark of Bombardier Inc or its subsidiaries ...

Page 22: ...fer to follow ing illustration for location The registration number should appear on each side of the watercraft On applicable models install registration number to the left of the star label 1 Registration number location NOTE The registration number must be above the water line Ensure also that the numbers are of the correct size and color Check with local applicable regula tions F18L01L 1 ...

Page 23: ...e following labels are on your watercraft If missing or damaged they can be replaced free of charge See an authorized Sea Doo dealer Please read the following labels carefully before operating this watercraft 9 10 F18L03M 3 4 6 1 7 2 5 8 11 ...

Page 24: ...22 Label 1 Label 2 Label 3 Label 4 Label 5 F12L0FL F02L2D0 F00L2XY WARNING DO NOT BOOST BATTERY WHILE INSTALLED F00L050 F07L11Z ...

Page 25: ...23 Label 6 Label 7 Label 8 SOME MODELS Label 9 Label 10 Label 11 Label 12 F00L2MY F00A1AY F00L2YY F18L0NY F18L10Y A01A2EY F18L0YY ...

Page 26: ...ber H I N is located on footboard at the rear of watercraft 1 Hull Identification Number It is composed of 12 digits Engine NOTE Refer to SPECIFICATIONS sec tion to find what engine is used on each model The Engine Identification Number E I N is located on the front end of the engine 1 Engine Identification Number E I N 1 F18L0ZY Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number F00A0CZ Month of pr...

Page 27: ...NENTS AND INSTRUMENTS LOCATION NOTE Some components do not apply or are optional on some models GTX 4 TEC F18L0PL 8 21 3 2 7 6 4 21 1 5 9 34 35 30 26 27 28 29 20 19 36 22 31 32 14 20 11 10 12 15 17 13 16 25 18 23 24 33 ...

Page 28: ...ch 13 Tool Kit 14 Air Intake Opening 15 Seat Strap 16 Seat Extension Latch 17 Seat Latch 18 Rear Grab Handle 19 Rear Storage Basket 20 Front and Rear bow stern Eyelets 21 Mooring Cleats 22 Footboard 23 Boarding Pads 24 Boarding Platform 25 Boarding Step 26 Flushing Connector 27 Bilge Drain Plugs 28 Jet Pump Nozzle 29 Reverse Gate 30 Jet Pump Water Intake 31 Fuses 32 Battery 33 Side Vanes 34 Engine...

Page 29: ...y lan yard on its post when engine is not running will slowly discharge the bat tery Digitally Encoded Security System DESS The safety lanyard cap specifically con tains an electronic circuit that gives it a unique electronic serial number This is the equivalent of a conventional key This safety lanyard cannot be used on another watercraft and conversely the one from another watercraft cannot be u...

Page 30: ...craft is gradually stopped by water drag 4 Engine Start Stop Button To start engine depress and hold the start stop button Release immediate ly after engine is started To stop engine depress the start stop button When stopped disconnect safe ty lanyard from the post It is suggested to release throttle lever first 1 Engine start stop button 5 Shift Lever A push pull lever forward neutral reverse WA...

Page 31: ...The speed sensor mounted on the transom sends the signal to the infor mation center 7 Tachometer An analog tachometer indicates the revolutions per minute RPM of the engine Multiply by 1000 to obtain the actual revolutions 8 Information Center Gauge Buttons This is a multifunction gauge that sup plies several real time useful informa tion to the driver Components Description 1 Speedometer 2 Tachom...

Page 32: ...isplayed Units such as KMH MPH HOUR etc are displayed This section also display navigational and system fault informations See the gauge functions and message lists below for more details Gauge Functions Clock Indicates the actual time in hours and minutes hh mm Compass Displays the cardinal points to indicate the orientation of the water craft Average Speed The information cen ter approximately c...

Page 33: ... hourmeter water temperature exterior temperature and trip hour meter 1 Press to change display mode When you are satisfied with your choice stop pressing the button and it will be come active Display Priorities As a self test at start up the needles of the speedometer and tachometer will sweep to their maximum position all LCD segments and the LED will turn on for 3 seconds each time the informat...

Page 34: ... Functions The following describes how to select other available functions Language Option While in the clock compass mode 1 Press and hold for 2 seconds 1 Repeatedly press 1 Press to end English Metric System Allows to display the units in the metric system or in the SAE English system NOTE This function is not available when information center displays the clock compass hourmeter or trip hour me...

Page 35: ...tedly press to adjust MINUTES 1 Press TOGETHER to end NOTE If MODE and SET buttons are not pressed at the end the default dis play will come back after 10 seconds and the time entered will remain Trip Hour Meter While in the trip hour meter mode 1 Press to start or stop trip hour meter 1 F18L090 1 F18L091 1 F18L092 1 F18L090 1 F18L092 ...

Page 36: ...ized Sea Doo dealer when other messages occur NOTE If a fault occurs this system generates numbered fault codes P XXXX that can be displayed through the information center using a special procedure In case of a failure you may call your authorized Sea Doo dealer and he would be able to assist you to have the codes displayed to help trou bleshooting Warning Light The red warning LED Light Emitting ...

Page 37: ...ing straps 2 Extinguisher WARNING Always stop the engine before refu eling Fuel is flammable and explo sive under certain conditions Al ways work in a well ventilated area Do not smoke or allow open flames or sparks in the vicinity Fuel tank may be pressurized slowly turn cap when opening Never use an open flame to check fuel level When fu eling keep watercraft level Do not overfill or top off the...

Page 38: ...will get in side bilge CAUTION If the air intake opening is kept under water such as turning constantly in tight circles water will get inside bilge which may cause severe damage to internal parts of the engine 15 Seat Strap The seat strap provides a handhold to assist boarding and is used as a hand hold for the passenger 16 Seat Extension Latch Removing the seat extension allows access to the rea...

Page 39: ...carry personal articles 1 Rear storage basket Spare Spark Plug Holder The storage basket features a spare spark plug holder To keep spare spark plugs dry and pre vent shocks that might affect the ad justment or break them a holder is provided Unscrew cap counterclockwise to ex pose the holder and insert spark plug in their holes Reinstall cap 1 Storage basket 2 Spare spark plug holder cap 3 Spark ...

Page 40: ...ing Cleats These cleats can be temporarily used for docking while refueling for example 1 Mooring cleats CAUTION Never use mooring cleats to pull or lift the watercraft 22 Footboard User s feet should rest on the footboard when riding 23 Boarding Pads Provide a cushioned surface for the knees when boarding from rear of wa tercraft 24 Boarding Platform Provides a large surface for easier board ing ...

Page 41: ...er prior to unscrewing drain plugs TYPICAL 1 Drain plugs 2 Tighten 3 Unscrew Tilt the watercraft slightly to the rear so that the water can completely flow out of the bilge It is suggested to drain bilge on a ramp CAUTION Make sure drain plugs are properly secured prior to launching the watercraft in water 28 Jet Pump Nozzle Jet pump nozzle turns side to side via rider input at the handlebar This ...

Page 42: ... heat ex changer for the ENGINE cooling system 1 Water intake 2 Ride plate 31 Fuses Fuses are located under seat in bilge and in front of fuel tank Refer to MAINTENANCE for more details F18J05Z 1 F18J05Y 1 WARNING Keep away from intake grate while engine is on Items such as long hair loose clothing or personal flo tation device straps can become entangled in moving parts result ing in severe injur...

Page 43: ...cription of the system 34 Engine Oil Dipstick Located in engine compartment on the engine It indicates the engine oil level 1 F18H0JY 1 F18H0AY WARNING Check handlebar and correspond ing side vanes operation before starting Never use side vanes as a supporting point to board the wa tercraft or to lift it Never turn han dlebar while someone is nearby rear of watercraft Keep away from steering movin...

Page 44: ...S for more details 36 Cooling System Expansion Tank Cap Located in engine compartment It pro vides access to the expansion tank fill ing neck Remove seat extension and storage basket to expose expansion tank 1 Expansion tank 2 Cap Refer to LIQUIDS for more details 1 F18D04Y 1 F18D09Y WARNING Certain components in the engine compartment may be very hot Di rect contact may result in skin burn 1 F18E...

Page 45: ... motor oil for internal engine lubrication Ensure to respect the following requirements Use 4 stroke engine oil that meets or exceeds the requirements for API ser vice classification SG SH or SJ Al ways check the API service label on the oil container to be sure it includes those letters Only use high quality high detergent oil CAUTION Never use any two stroke engine oil Oil Viscosity SAE 10W40 is...

Page 46: ...ge en gine and or exhaust system 3 Warm up engine then let idle for 30 seconds before stopping 4 Stop engine 5 Wait at least 30 seconds then pull dipstick out and wipe clean CAUTION Never run engine longer than 5 minutes Drive line seal has no cooling when watercraft is out of wa ter 6 Reinstall dipstick push in complete ly 7 Remove dipstick and read oil level It should be between marks 1 Full 2 A...

Page 47: ...ansion tank 1 Expansion tank With vehicle on a level surface liquid should be between MIN and MAX level marks of coolant reservoir when engine is cold 1 Level between marks when engine is cold NOTE The watercraft is level when it is in water When on a trailer raise trail er tongue and block in this position when bumper rail is level Add coolant to have the level between marks as required Use a fun...

Page 48: ...s contribute to a good break in CAUTION Continued wide open throttle runs and prolonged cruising without speed variations should be avoided this can cause engine dam age during the break in period NOTE Never add oil in fuel tank dur ing break in period 10 Hour Inspection It is highly recommended that after the first 10 hours of operation the water craft be checked by an authorized Sea Doo dealer T...

Page 49: ...laws WARNING Engine should be off and the safety lanyard should always be removed from its post prior to verifying any of the following points Only start wa tercraft once all items have been checked and operate properly ITEM OPERATION Hull Inspect Jet pump water intake Inspect clean Bilge Drain Ensure plugs are secured Battery Inspect tightness of cables and retaining fasteners Fuel tank Refill En...

Page 50: ...n plugs Battery Fuel Tank With the watercraft horizontal fill the fuel tank to specified level Check fuel tankretaining straps fasteners Engine Compartment Engine Oil Level Ensure oil level is appropriate as spec ified in LIQUIDS section Check for oil leaks on engine and in engine com partment WARNING When operating the engine while the watercraft is out of the water the heat exchanger in the ride...

Page 51: ...n gate should be in middle posi tion With shift lever in reverse position gate should be in downward position Storage Compartment Covers and Seat Ensure they are closed and latched Safety Lanyard and Engine Start Stop Button Position shift lever in neutral Ensure that both switches operate properly Start en gine and stop it using each switch indi vidually WARNING When operating the engine while th...

Page 52: ...y familiar with all controls and the function of each Should any control or instruc tion not be fully understood refer to an authorized Sea Doo dealer WARNING Whenever the engine is to be start ed the operator and passenger s should always be properly sitting on the watercraft and be wearing protective clothingincludinga Coast Guard approved PFD and a wet suit bottom F18J06Y WARNING Keep away from...

Page 53: ...e gate in downward position NOTE To obtain maximum efficiency and control from the reverse increase engine speed to slightly above idle Too much RPM will create water tur bulence and reduce reverse efficiency In reverse position turn the handlebar in the same direction that you want to move the rear of the watercraft For example to steer the rear of the wa tercraft to the left side turn the handle...

Page 54: ...t path when steering is turned after throttle has been released or engine stopped The side vanes on the rear sides of the hull turn as the steering is turned to assist the watercraft turning At first carefully experiment turning with this system 1 Side vanes turn following steering movement When engine is running at approximate ly 75 or more RPM the side vanes are automatically raised to upper pos...

Page 55: ...balance the watercraft while holding the handlebar Then bring the other foot over the seat and put it on the other footboard Push the watercraft away from the dock F18K02Y 1 1 F18K01Y WARNING Engine should be OFF when board ing the watercraft or when using boarding step Keep limbs away from jet or intake grate Stay on center of the step Only one person at a time on the step Never use the step for ...

Page 56: ...rap Bring your feet on the footboard while maintaining balance Sit astride the seat Operator with a Passenger The operator climbs on the watercraft the same way as explained previously In choppy water the passenger while in the water may hold the watercraft to help the operator in climbing aboard The passenger then climbs on the wa tercraft while the operator maintains balance by sitting as close ...

Page 57: ...should be observed between the cranking cycles to let starter cool down Pay attention not to discharge battery The engine should be start ed only after boarding when there is at least 90 cm 3 ft of water below the hull Do not accelerate fast Release engine start stop button im mediately after engine is started Cold and Warm Engine Do not depress the throttle lever to start either a cold or warm en...

Page 58: ...when leav ing the watercraft on the beach so that the side vanes do not rub or hit the ground due to the rocking move ment It might eventually damage components of the O P A S system Shutting Off the Engine To keep watercraft directional control the engine should be running until the watercraft is at idle To stop engine depress the start stop button When stopped disconnect safe ty lanyard from the...

Page 59: ...ystem Flushing General Flushing the exhaust cooling system with fresh water is essential to neutral ize corroding effects of salt or other chemical products present in water It will help to remove sand salt shells or other particles in water jackets and or hoses Flushing should be performed when the watercraft is not expected to be used further the same day or when the watercraft is stored for any...

Page 60: ...ic ing CAUTION Never run engine longer than 5 minutes Drive line seal has no cooling when watercraft is out of wa ter Close the water tap then stop the en gine CAUTION Always close the water tap before stopping the engine Anticorrosion Treatment To prevent corrosion spray a corrosion inhibitor salt water resistant such as BOMBARDIER LUBE lubricant or equiv alent over metallic components in en gine...

Page 61: ...tically set default pa rameters to ensure the adequate oper ation of the watercraft if an electronic component is not operating properly Depending on the severity of the mal function the watercraft speed may be reduced and not allowed to reach its top speed as usual In this mode it may be necessary to depress the throttle quite slowly to al low engine RPM to increase and oper ate the watercraft to...

Page 62: ...nd remove blockage manually If the aforementioned method does not work the following can be performed With engine running and before ap plying throttle put shift lever in re verse position and vary throttle quick ly several times Repeat procedure if necessary On Beach Water Cleaning Place a cardboard or a carpet beside the watercraft to prevent scratching when turning the watercraft for cleaning R...

Page 63: ...amaged As soon as possible check for pres ence of water in the bilge Drain as necessary when back to the shore Submerged Watercraft To limit damages to the engine per form the following procedure as soon as possible Drain bilge If it was submerged in salt water spray bilge and all components with fresh water using a garden hose to stop the salt corroding effect CAUTION Never try to crank or start ...

Page 64: ...ark plug and hook it to then extract spark plug Install new spark plugs if avalaible or dry spark plugs using a rag Cover spark plug holes with a rag Crank engine several times while keeping throttle fully depressed Reinstall spark plugs and ignition coils Install clean dry spark plugs if possible Reconnect ignition coil connector NOTE Priortoinsertingtheignitioncoilto its location apply some BOMB...

Page 65: ...exhaust system Without the engine running there isn t any exhaust pres sure to carry the water out the exhaust outlet CAUTION Failure to do this may re sult in damage to the engine If you must tow a stranded watercraft in water and do not have a hose pinch er be sure to stay well below the maximum towing speed of 24 km h 15 MPH To ease access to the hose the vent tube can be temporarily removed 1 ...

Page 66: ... the engine After removal of hose pincher proper ly reinstall and lock vent tube When pushing tube in place you should hear a click that validates it is locked Low Charge Battery Condition See an authorized Sea Doo dealer to have it charged or replaced WARNING Do not charge or boost the battery while installed on the watercraft Electrolyte is poisonous and dan gerous Avoid contact with eyes skin a...

Page 67: ...ner Responsibility The owner operator is required to have engine maintenance performed to maintain emission levels within pre scribed certification standards The owner operator is not to and should not allow anyone to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications EPA Emission Regulations Allnew 1999 an...

Page 68: ...ea Doo dealer The schedule should be adjust ed according to operating conditions and use NOTE The chart gives an equivalence between number of hours and months year Perform the maintenance opera tion to whatever time comes first IMPORTANT Schedule for watercraft rental operations or higher number of hour use will require greater frequen cy of inspection and maintenance WARNING Only perform procedu...

Page 69: ...rottle cable inspection lubrication O Fuel injection system sensors visual inspection D Throttle body cleaning and inspection Fault code reading D Fuel vent line pressure relief valve inspection D Fuel lines connections and fuel system pressurization D Visual inspection throttle body sensors fuel lines fuel rail and fittings D Air intake silencer fit tightness D Fuel tank straps visual inspection ...

Page 70: ...ery year DESCRIPTION FREQUENCY FIRST 10 HOURS EVERY 25 HOURS OR 3 MONTHS EVERY 50 HOURS OR 6 MONTHS EVERY 100 HOURS OR 1 YEAR TO BE PERFORMED BY O P A S SYSTEM Check O P A S system operation and condition including filter D PROPULSION SYSTEM Drive shaft protection boot inspection and lubrication D Shifter system cable adjustment D Drive shaft rubber bumper replacement D Impeller shaft seal sleeve ...

Page 71: ...Replacement The oil change and filter replacement should be performed by an authorized Sea Doo dealer Valve Adjustment There is no valve adjustment to be per formed on this engine Coolant Replacement The coolant replacement should be performed by an authorized Sea Doo dealer Fuel Injection System The fuel injection system inspection should be performed by an authorized Sea Doo dealer Fuel system p...

Page 72: ... below Fuses can be found on the MPEM in en gine compartment and one can be find in front of fuel tank NOTE To understand the acronyms used here refer to ABBREVIATIONS USED IN THIS MANUAL section at the end of the guide WARNING Ensure the handlebar and jet pump nozzle operate freely from side to side and are not stressing the steer ing cable or brackets Never turn handlebar while someone is near b...

Page 73: ...ENTIFICATION 1 F18H0JY 10A 2A 10A 1A 10A 10A 3A 5A 10A 2A 7 5A 5A F18H07L Spare T O P S Cylinder 3 ignition coil and injection Information center EMS start stop circuit VTS optional MPEM Electric starter fuel pump Bilge pump optional Beeper diagnostic connector Cylinder 2 ignition coil and injection Cylinder 1 ignition coil and injection Spare fuse ...

Page 74: ...s To gain access to spare fuses remove the cover identified SPARE FUSES INSIDE Look inside cover and pull the rubber protector with a finger Take care not to drop the fuses 1 Rubber protector 1 Rubber protector 2 Spare fuses When finished reinstall the remaining fuse s and reinstall the protector over fuse s CAUTION Do not install more than 4 fuses in cover to allow proper in stallation of cover F...

Page 75: ...use lift tab while pulling holder out Pull fuse out using cover on MPEM as shown above Main Fuse near front of Fuel Tank To reach it do the following Open front storage compartment cover Remove extinguisher if one is installed Remove darts retaining front panel 1 Front panel 2 Dart Pull front panel out 1 Fuel tank 2 Main fuse 1 F18H0EY 2 1 F18H0FY 2 2 F18L12Y 1 2 F18H0GY 1 ...

Page 76: ...u thorized Sea Doo dealer to remove any fuel oil electrolyte deposits and mildew Occasionally wash the body with wa ter and soap only use mild detergent Remove any marine organisms from engine and or hull Apply non abrasive wax such as silicone wax CAUTION Never clean fiberglass and plastic parts with strong detergent degreasing agent paint thinner ace tone etc Stains may be removed from seat and ...

Page 77: ...g a trailer especially the following rules brake system tow vehicle weight mirrors Take the following precautions when towing the watercraft Tie the watercraft to both front and rear bow stern eyelets so that it is firmly retained on the trailer Use additional tie downs if necessary CAUTION Do not route ropes or tie downs over the seat or grab handle as they could produce permanent damage Wrap rop...

Page 78: ... proper use CAUTION Fuel stabilizer should be added prior to engine lubrication to ensure fuel system components pro tection against varnish deposits Engine Oil and Filter Replacement The oil change and filter should be per formed by an authorized Sea Doo dealer Exhaust Cooling System Flushing and Engine Internal Lubrication Lubrication Connect a garden hose to cool the ex haust system as explaine...

Page 79: ...ny residual water from the engine Disconnect the garden hose NOTE It is recommended to fog the engine valves with BOMBARDIER LUBE lubricant Contact your autho rized Sea Doo dealer Battery Contact your authorized Sea Doo dealer Engine Cooling System Test the density of the coolant using an antifreeze hydrometer NOTE Follow hydrometer manufactur er s instructions for proper use The reading should be...

Page 80: ...ft should never be left in water for storage Never leave the watercraft stored in direct sunlight Pre Season Preparation Use the following chart Since technical skills and special tools are required some operations should be performed by an authorized Sea Doo dealer WARNING Onlyperformproceduresasdetailedin this guide It is recommended that the assistance of an authorized Sea Doo dealer be periodi...

Page 81: ...ection of cooling system coolant level hoses and components Dealer FUEL SYSTEM Fuel filter replacement Dealer Fuel injection sensors verification Dealer Fuel system check valves lines fasteners pressurization Dealer Filler neck fuel tank and fuel cap condition Dealer Fuel tank straps Operator Refill fuel tank Operator ELECTRICAL SYSTEM Battery condition charging and reinstallation Set the time and...

Page 82: ...e start stop button Bad DESS system connection Reinstall safety lanyard cap cor rectly over post Wrong safety lanyard Use a safety lanyard that has been programmed for the water craft Defective safety lanyard Use another programmed safety lanyard Dried salt water in safety lanyard cap Clean safety lanyard cap to re move salt water Improper operation of engine ECU or defective wiring harness Refer ...

Page 83: ...ECU failure Refer to an authorized Sea Doo dealer Bilge pump circuit low or high voltage if so equipped Refer to an authorized Sea Doo dealer Starter solenoid circuit malfunction Refer to an authorized Sea Doo dealer Continuously beeps High engine temperature cool ant See engine OVERHEATING High exhaust temperature Refer to an authorized Sea Doo dealer Low engine oil pressure Refer to Engine Low O...

Page 84: ...r Seized engine Refer to an authorized Sea Doo dealer Seized jet pump Try to clean Otherwise refer to an authorized Sea Doo dealer Engine turns slowly Loose batterycable connections Check clean tighten Discharged or weak battery Refer to an authorized Sea Doo dealer Worn starter Refer to an authorized Sea Doo dealer Engine turns normally Fuel tank empty or water contaminated Refill Siphon and fill...

Page 85: ...l mixture high fuel consumption Defective sensor or engine ECU Refer to an authorized Sea Doo dealer OTHER OBSERVATION POSSIBLE CAUSE REMEDY Oil level too high Refer to an authorized Sea Doo dealer Internal engine damage Refer to an authorized Sea Doo dealer OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine coolant level too low Refer to LIQUIDS Clogged jet pump water intake Clean Clogged exhaust coo...

Page 86: ... Cavitation Jet pump water intake clogged Clean Damaged impeller Replace Refer to an authorized Sea Doo dealer The SEA DOO Learning KeyTM safety lanyard is used which does not allow watercraft to reach its top speed Use a regular safety lanyard The monitoring system put the watercraft in limp home mode due to a component malfunction Refer to Monitoring System in SPECIAL PROCEDURES O P A S TM side ...

Page 87: ... vanes do not go up while watercraft is at speed Clogged filter square rings dam aged leakage in hoses or me chanical malfunction Refer to an authorized Sea Doo dealer O P A S side vanes do not go down while engine is at idle Broken spring inside side vane cylinder Refer to an authorized Sea Doo dealer OTHER OBSERVATION POSSIBLE CAUSE REMEDY Cavitation Weeds or debris jammed around impeller Clean ...

Page 88: ...7650 50 RPM COOLING SYSTEM Type Liquid cooled Closed circuit see also exhaust system Coolant Ethylene glycol 50 50 antifreeze water Coolant containing corrosion inhibitors for internal combustion aluminum engines ELECTRICAL SYSTEM Magneto generator output 360 W 6000 RPM Ignition system type Digital inductive type Ignition timing Not adjustable Spark plug Make and type NGK DCPR8ES Gap 0 75 mm 030 i...

Page 89: ...ody 52 mm 2 04 in PROPULSION Propulsion system Bombardier Formula pump Jet pump type Axial flow single stage Greased bearings Transmission Direct drive Reverse system Yes O P A S system Yes Pivoting angle of direction nozzle 20 Minimum required water level for jet pump 90 cm 3 ft DIMENSIONS Number of passengers 3 Overall length 331 cm 130 in Overall width 122 cm 48 in Overall height 113 cm 44 in W...

Page 90: ...ter kilometer per hour knot SYMBOL m kg N L C kPa N m km h kn PREFIXES PREFIX kilo centi milli micro SYMBOL k c m µ MEANING one thousand one hundredth of one thousandth of one millionth of VALUE 1000 0 01 0 001 0 000001 CONVERSION FACTORS TO CONVERT in in in in ft oz lb lbf lbf in lbf ft lbf ft PSI imp oz imp oz imp gal imp gal U S oz U S gal U S quart knot MPH Fahrenheit Celsius hp TO mm cm cm cm...

Page 91: ... N Engine identification number EPA Environmental protection agency HP Horse power LCD Liquid Crystal Display LED Light emitting diode MAG Magneto MPEM Multi purpose electronic module MPH Mile per hour N A Not applicable O P A S Off power assisted steering OPT Optional PFD Personal flotation device P N Part number PTO Power take off STD Standard TBD To be determined TDC Top dead center T O P S Tip...

Page 92: ...vices and offers please let us know by writing to the address below Also note that from time to time carefully selected and trustworthy organisations may be permitted to use the coordinates of our clients to promote quality prod ucts and services If you prefer not to have your name and address released please let us know by writing to the address below BOMBARDIER INC RECREATIONAL PRODUCTS WARRANTY...

Page 93: ...____________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOL...

Page 94: ... safety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 ...

Page 95: ..._____________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL ...

Page 96: ... safety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 ...

Page 97: ..._____________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL ...

Page 98: ... safety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 ...

Page 99: ...r WATERCRAFT MODEL No HULL IDENTIFICATION NUMBER H I N ENGINE IDENTIFICATION NUMBER E I N Owner Purchase Date YEAR MONTH DAY Warranty Expiry Date YEAR MONTH DAY To be completed by the authorized Sea Doo dealer at the time of the sale DEALER IMPRINT AREA NAME No STREET APT CITY STATE PROVINCE ZIP POSTAL CODE ...

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Summary of Contents for 2002 GTX 4-TEC

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