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TABLE OF CONTENTS
SECTION SUBJECT PAGE
SAFETY NOTICE.............................................................................................................. II
INTRODUCTION............................................................................................................... III
01
SERVICE TOOLS
AND PRODUCTS
01 - Mandatory Tools..............................................................................................01-01-1
02 - Recommended Tools.......................................................................................01-02-1
03 - Service Products..............................................................................................01-03-1
02
MAINTENANCE
00 - Table of Contents.............................................................................................02-00-1
01 - Periodic Inspection Chart.................................................................................02-01-1
02 - Flushing and Lubrication..................................................................................02-02-1
03 - Water-Flooded Engine.....................................................................................02-03-1
04 - Storage............................................................................................................02-04-1
03
TROUBLESHOOTING..................................................................................................................................... 03-00-1
04
ENGINE
00 - Table of Contents.............................................................................................04-00-1
01 - Removal and Installation..................................................................................04-01-1
02 - Top End............................................................................................................04-02-1
03 - Bottom End......................................................................................................04-03-1
04 - Rotary Valve.....................................................................................................04-04-1
05 - Exhaust System...............................................................................................04-05-1
05
COOLING SYSTEM
00 - Table of Contents.............................................................................................05-00-1
01 - Components....................................................................................................05-01-1
02 - Circuit...............................................................................................................05-02-1
06
FUEL SYSTEM
00 - Table of Contents.............................................................................................06-00-1
01 - Fuel Circuit.......................................................................................................06-01-1
02 - Air Intake..........................................................................................................06-02-1
03 - Carburetors......................................................................................................06-03-1
07
LUBRICATION SYSTEM
00 - 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
02 - Drive System...................................................................................................09-02-1
03 - Reverse System..............................................................................................09-03-1
04 - Variable Trim System.......................................................................................09-04-1
10
STEERING SYSTEM
00 - Table of Contents.............................................................................................10-00-1
01 - SP and XP Series.............................................................................................10-01-1
02 - GTS and GTI Models........................................................................................10-02-1
03 - HX Model.........................................................................................................10-03-1
04 - Alignment........................................................................................................10-04-1
11
SUSPENSION
00 - Table of Contents.............................................................................................11-00-1
01 - Direct Action Suspension................................................................................11-01-1
12
HULL / BODY
00 - Table of Contents.............................................................................................12-00-1
01 - Adjustment and Repair....................................................................................12-01-1
02 - Painting............................................................................................................12-02-1
13
TECHNICAL DATA
01 - SP and SPI Models..........................................................................................13-01-1
02 - SPX and XP Models.........................................................................................13-02-1
03 - GTS and GTI Models........................................................................................13-03-1
04 - HX Model.........................................................................................................13-04-1
14
WIRING DIAGRAMS..........................................................................................................................................14-00-1
www.SeaDooManuals.net
- 219 100 031 2
- SAFETY NOTICE 5
- All Engines Except the 787 6
- 787 Engine Only 6
- ARRANGEMENT OF THIS 7
- TYPICAL PAGE 8
- GENERAL INFORMATION 10
- ILLUSTRATIONS AND 10
- PROCEDURES 10
- MANDATORY TOOLS 11
- ENGINE (continued) 12
- COOLING / FUEL/ OIL SYSTEMS 14
- PROPULS1ON SYSTEM 15
- RECOMMENDED TOOLS 16
- PROPULSION SYSTEM 20
- WATERC RAFT HANDING 21
- SERVICE PRODUCTS 22
- ❑ AIIlsEAn ) 26
- Geicotee 28
- PERIODIC INSPECTION CHART 1 30
- Section 02 MAINTENANCE 32
- Procedure 34
- Engine Draining 36
- Fuel System 36
- Internal Lubrication 36
- Propulsion System 36
- Watercraft Cleaning 37
- Anticorrosion Treatment 37
- Sub-Section 04 (STORAGE) 38
- TROUBLESHOOTING 0 39
- Section 03 TROUBLESHOOTING 40
- Section 04 ENGINE 43
- REMOVAL FROM WATERCRAFT 44
- Tuned Pipe 45
- Air Intake Silencer 45
- Carburetor(s) 45
- Engine Support Mounts 45
- Lifting Engine 46
- Engine Support and Nut 48
- Oil Injection Hoses 48
- Positive Starter Cable 48
- Engine / Jet Pump Alignment 48
- Engine Support Screws 49
- Final Inspection 49
- TOP END 2 50
- Sub-Section 02 (TOP END) 51
- ENGINE DESCRIPTION 52
- Cylinder Taper 55
- Cylinder Out of Round 55
- Ring End Gap 56
- 16, Cylinder Base Gasket 56
- 5, Circlip 59
- 10,17,18, Cylinder Screw 61
- 10 8 2 4 6 12 63
- 113 1 59 7 63
- RAVE SYSTEM 64
- Maintenance 65
- BOTTOM END 3 68
- Sub-Section 03 (BOTTOM END) 69
- CRANKSHAFT MISALIGNMENT 71
- AND DEFLECTION 71
- Crankshaft Deflection 75
- ROTARY VALVE 4 80
- INSPECTION ON WATERCRAFT 81
- Sub-Section 04 (ROTARY VALVE) 82
- 13, Rotary Valve 87
- TEMPLATE 88
- EXHAUST SYSTEM 5 91
- TUNED PIPE REMOVAL 94
- 1,3, Collar and Hose 95
- 4, Clamp 95
- 23, Screw 95
- 6, Screw 95
- EXHAUST MANIFOLD REMOVAL 96
- MUFFLER REMOVAL 96
- TUNED PIPE REPAIR 96
- EXHAUST MANIFOLD, TUNED 97
- PIPE AND MUFFLER 97
- 16, Sealing Ring 98
- 20, Gasket 98
- 7,9, Screw and Nut 98
- TABLE OF CONTENTS 100
- COMPONENTS 1 101
- Section 05 COOLING SYSTEM 102
- Sub-Section 01 (COMPONENTS) 102
- 3, Elbow Fitting 105
- 1, Clamp 105
- 2, Fitting Spigot 105
- 4, Water Flow Regulator Valve 106
- 5,6, Spring and Cover 106
- 7, Fitting 107
- 8, Tapered Needle 107
- 9,10, Valve and Bellows 107
- CIRCUIT 2 108
- Max. 90° 108
- Sub-Section 02 (CIRCUIT) 109
- 587 ENGINE COOLING SYSTEM 110
- 717 ENGINE COOLING SYSTEM 111
- 787 ENGINE COOLING SYSTEM 112
- FUEL CIRCUIT 1 114
- Section 06 FUEL SYSTEM 115
- Sub-Section 01 (FUEL CIRCUIT) 115
- 1,2, Fuel Filter and Bowl 118
- 2,3, Bowl and Gasket 118
- INSPECTION 119
- ASSEMBLY 120
- FUEL SYSTEM PRESSURIZATION 121
- AIR INTAKE 2 122
- 5, Flame Arrester 124
- 9, Gasket 124
- CARBURETORS 3 125
- Sub-Section 03 (CARBURETORS) 126
- CARBURETOR REMOVAL 127
- CLEANING 127
- DISASSEMBLY AND INSPECTION 127
- PUMP VERIFICATION 128
- CARBURETOR ASSEMBLY 129
- 9,10, Main Jet and Pilot Jet 130
- CARBURETOR INSTALLATION 131
- ADJUSTMENTS 132
- 2, Low Speed Screw 133
- 14, High Speed Screw 133
- 15, Idle Speed Screw 134
- OIL INJECTION SYSTEM 1 137
- HX Model 138
- OIL SYSTEM PRESSURIZATION 139
- OIL INJECTION PUMP 2 140
- XP Model 141
- CHECKING OPERATION 144
- Bench Test 145
- MAGNETO SYSTEM 1 147
- Section 08 ELECTRICAL SYSTEM 148
- 4,5, Armature Plate and Screw 150
- Engine Crankcase Replacement 150
- 15,16, Rotor and Flywheel 151
- DISASSEMBLY 152
- INSTALLATION 154
- Ignition Coil 157
- Magneto Rotor / Trigger Coil 158
- DC-CDI Module 158
- IGNITION TIMING PROCEDURE 159
- Static Test 160
- Dynamic Test 161
- Ignition Timing Adjustment 162
- BOMBARDIER IGNITION TESTER 165
- IGNITION SYSTEM TESTING 166
- PROCEDURE 166
- Generating Coil Verification 167
- Trigger Coil Verification 168
- DC-CDI Module Verification 169
- (MPEM) Verification 169
- Holder Relay Verification 169
- Ignition Coil Verification 170
- SPARK PLUGS 171
- Spark Plug Analysis 172
- Spark Plug Installation 172
- Spark Plug Chart 172
- CHARGING SYSTEM 3 174
- Battery Charging Coil 175
- Troubleshooting 177
- Cleaning 177
- Inspection 177
- Hydrometer Test 177
- Battery Storage 178
- Activation of a New Battery 178
- Servicing 180
- CHARGING A VERY FLAT OR 180
- Battery Charging Equipment 181
- Installation of Battery 181
- STARTING SYSTEM 4 182
- PARTS INSPECTION 185
- STARTER REMOVAL 185
- STARTER DISASSEMBLY 185
- STARTER ASSEMBLY 186
- 1,10, Housing and Yoke Ass’y 187
- Through Bolt 187
- STARTER INSTALLATION 188
- STARTER SPECIFICATION 189
- Variable Trim Gauge 191
- Fuel Baffle Pick-Up Sensor 191
- Oil Sensor 192
- Speed Sensor 193
- STATIC TEST 193
- DYNAMIC TEST 193
- VTS Switch 193
- VTS Motor 194
- VTS Control Module 194
- RESISTANCE TEST 194
- DIGITALLY ENCODED SECURITY 195
- SYSTEM 6 195
- Basic Self-Diagnostic Mode 196
- Advanced Self-Diagnostic Mode 197
- Section 09 PROPULSION SYSTEM 199
- JET PUMP 1 200
- PLASTIC PUMP 201
- JET PUMP INSPECTION ON 202
- WATERCRAFT 202
- Oil Inspection 203
- Oil Check 203
- Oil Replacement 203
- JET PUMP REMOVAL 204
- 5, Nozzle 205
- RIDE SHOE REMOVAL 206
- JET PUMP SUPPORT REMOVAL 207
- JET PUMP DISASSEMBLY 207
- 14,15, Boot and Ring 208
- 16, Fitting 208
- 19, Impeller 209
- 20, Wear Ring 209
- 21, Seal 210
- F01J0XAF01J0XA 210
- Sub-Section 01 (JET PUMP) 212
- JET PUMP ASSEMBLY 215
- Oil Fill 219
- PUMP PRESSURIZATION 220
- JET PUMP SUPPORT 221
- RIDE SHOE INSTALLATION 221
- JET PUMP INSTALLATION 222
- Locking Disk and Nozzle 224
- Steering and Reverse Cables 224
- Steering Cable 225
- Trim Systems 225
- DRIVE SYSTEM 2 227
- Section 09 PROLPUSION SYSTEM 228
- Sub-Section 02 (DRIVE SYSTEM) 228
- 1, Large Clamp 229
- 2, Small Clamp 229
- 3, Drive Shaft 230
- 4, Rear Drive Shaft 230
- 5,6, Floating Ring and O-ring 230
- 13, Seal 235
- 12, Seal Carrier 235
- REVERSE SYSTEM 3 239
- 6, Reverse Support 242
- Sliding Block 242
- VARIABLE TRIM SYSTEM 4 245
- ASSEMBLY AND INSTALLATION 246
- ADJUSTMENT 250
- SP /XP SERIES 1 252
- REMOVAL AND ASSEMBLY 253
- Support and Handlebar 254
- Supports 254
- Section 10 STEERING SYSTEM 256
- GTS AND GTI MODELS 2 257
- HX MODEL 3 261
- Sub-Section 03 (HX MODEL) 262
- STEERING CABLE REMOVAL 263
- STEERING ALIGNMENT 264
- ALIGNMENT 4 265
- Section 00 STEERING SYSTEM 266
- Sub-Section 04 (ALIGNMENT) 266
- DIRECT ACTION SUSPENSION 1 268
- COIL OVER SHOCK REMOVAL 269
- OUTER BOOT REMOVAL 270
- COIL OVER SHOCK 270
- ADJUSTMENT AND REPAIR 1 272
- Section 12 HULL / BODY 273
- SEAT ADJUSTMENT 280
- STORAGE COMPARTMENT 281
- ACCESS PANEL ADJUSTMENT 281
- DRAIN PLUG INSTALLATION 282
- SEAT REMOVAL 282
- SEAT COVER REPLACEMENT 283
- BUMPER REPLACEMENT 283
- SPONSON REPLACEMENT 284
- BAFFLE SEALING (GTS / GTI 284
- HOOD REMOVAL 284
- DECALS REPLACEMENT 284
- HULL AND BODY REPAIR 285
- HULL INSERT REPAIR 288
- PAINTING 0 290
- PARTS THAT CAN BE PAINTED 291
- Section 12 HULL/BODY 292
- Sub-Section 02(PAINTING) 292
- PAINTING PROCEDURE 293
- SP AND SPI MODELS 1 296
- Section 13 TECHNICAL DATA 297
- SPX AND XP MODELS 2 301
- GTS AND GTI MODELS 3 306
- HX MODEL 4 311
- Sub-Section 04 (HX MODEL) 312
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