SeaDoo SP Manual de Serviço

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00-0-71996 BOMBARDIER WATERCRAFT SHOP MANUALGENERAL INFORMATIONThe use of RIGHT and LEFT indications in the text,always refers to driving position (wh

05-00-1Section 05 COOLING SYSTEMSub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSCOMPONENTS...

Section 05 COOLING SYSTEMSub-Section 01 (COMPONENTS)05-01-1COMPONENTS 1SP / SPI and GTS ModelsF01E0SSLoctite 592Loctite592Loctite59231Loctite592Loctit

Section 05 COOLING SYSTEMSub-Section 01 (COMPONENTS)05-01-2SPX and GTI ModelsF01E1PSLoctite5923Loctite592Loctite592SPModel Only1.2 N•m(11 lbf•in)Locti

Section 05 COOLING SYSTEMSub-Section 01 (COMPONENTS)05-01-3HX ModelF05E04SLoctite 592Loctite5921.2 N•m(11 lbf•in)Loctite 59211.2 N•m(11 lbf•in)BodyLoc

Section 05 COOLING SYSTEMSub-Section 01 (COMPONENTS)05-01-4XP ModelF01E1QSLoctite 59231.2 N•m(11 lbf•in)Loctite 592Loctite592Loctite592Loctite592Locti

Section 05 COOLING SYSTEMSub-Section 01 (COMPONENTS)05-01-5GENERALCAUTION : All hoses and fittings of thecooling system have calibrated inside di-amet

Section 05 COOLING SYSTEMSub-Section 01 (COMPONENTS)05-01-64, Water Flow Regulator ValveXP ModelA water flow regulator valve has been developedfor the

Section 05 COOLING SYSTEMSub-Section 01 (COMPONENTS)05-01-71. Spring2. Cover7, FittingRemove fitting from valve housing.1. Fitting8, Tapered NeedleUns

Section 05 COOLING SYSTEMSub-Section 02 (CIRCUIT)05-02-1CIRCUIT 2GENERALThe cooling system is equipped with a fitting spig-ot for flushing purposes (a

Section 05 COOLING SYSTEMSub-Section 02 (CIRCUIT)05-02-2For a minimum back pressure in the exhaust, en-gine water outlet hose is not connected to the

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 01 (MANDATORY TOOLS)MANDATORY TOOLSoNOTE : The numbers outlined in black (example : ❑ ) are reference

Section 05 COOLING SYSTEMSub-Section 02 (CIRCUIT)05-02-3F01E0PS587 ENGINE COOLING SYSTEMTemperaturesensor activatesmonitoring beeperwhen temperatureex

Section 05 COOLING SYSTEMSub-Section 02 (CIRCUIT)05-02-4F01E0JS717 ENGINE COOLING SYSTEMTemperaturesensor activatesmonitoring beeperwhen temperatureex

Section 05 COOLING SYSTEMSub-Section 02 (CIRCUIT)05-02-5787 ENGINE COOLING SYSTEMF01E1USUppermost point ofcircuit (tuned pipe)allows bleedingCooling S

06-00-1Section 06 FUEL SYSTEMSub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSFUEL CIRCUIT...

Section 06 FUEL SYSTEMSub-Section 01 (FUEL CIRCUIT)06-01-1FUEL CIRCUIT 1SP, SPI and GTS ModelsF01F19S2 N•m(18 lbf•in)6 N•m(53 lbf•in)761 N•m(9 lbf•in)

Section 06 FUEL SYSTEMSub-Section 01 (FUEL CIRCUIT)06-01-2SPX, XP and GTI ModelsF01F2ZS2 N•m(18 lbf•in)6 N•m(53 lbf•in)76Body1321 N•m(9 lbf•in)3 N•m(2

Section 06 FUEL SYSTEMSub-Section 01 (FUEL CIRCUIT)06-01-3HX ModelF05F09S3 N•m(27 lbf•in)Loctite2421326 N•m(53 lbf•in)72 N•m(18 lbf•in)Body61 N•m(9 lb

Section 06 FUEL SYSTEMSub-Section 01 (FUEL CIRCUIT)06-01-4GENERALWARNING : Whenever repairing the fuelsystem, always verify for water infiltrationin r

Section 06 FUEL SYSTEMSub-Section 01 (FUEL CIRCUIT)06-01-51,2, Fuel Filter and BowlREMOVALAll Models Except HXOpen storage compartment cover.Remove ba

Section 06 FUEL SYSTEMSub-Section 01 (FUEL CIRCUIT)06-01-61. Gasket in bowlWARNING : Ensure that there is no leakagefrom the fuel filter.GTS and GTI M

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 01 (MANDATORY TOOLS)ENGINE (continued)PullerE.P / N 295000106AOOC1A4-——————————Pulier platem,4P / N

Section 06 FUEL SYSTEMSub-Section 01 (FUEL CIRCUIT)06-01-7WARNING : Fuel is flammable and explo-sive under certain conditions. Alwayswork in a well ve

Section 06 FUEL SYSTEMSub-Section 01 (FUEL CIRCUIT)06-01-8Install baffle pick up into fuel tank and push it untilit sits on fuel tank neck. Install cl

Section 06 FUEL SYSTEMSub-Section 02 (AIR INTAKE)06-02-1AIR INTAKE 2F01F1WS194810 N•m(88 lbf•in)8Loctite242Loctite2426Loctite242210 N•m(88 lbf•in)5Twi

Section 06 FUEL SYSTEMSub-Section 02 (AIR INTAKE)06-02-2REMOVAL1, Air Intake Silencer CoverUnlock retaining slides holding air intake silencercover an

Section 06 FUEL SYSTEMSub-Section 02 (AIR INTAKE)06-02-35, Flame ArresterInspect condition of flame arrester. Replace orclean as necessary.WARNING : D

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-1CARBURETORS 3587 EngineF02F0KS123111098113147Loctite242419515Anti-seizelubrifiantLoctite24262

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-2717 and 787 EnginesF01F05SLoctite242614Loctite242202120 N•m(15 lbf•ft)MAG13Loctite 242715Anti

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-3GENERALThe following illustration shows which part of thecarburetor begins to function at dif

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-42, Low Speed ScrewCheck tip for a grooved condition. Replace if nec-essary.PUMP VERIFICATIONC

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-5TYPICAL1. Pump gauge tester2. Install on pulse nippleDiaphragm must stand pressure for 10 sec

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 01 (MANDATORY TOOLS)ENGINE (continued)Ring gear blocking tool . :mP / N 295000134F01B264APPLICATION7

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-6HIGH LEVERStep depress hereStep push tab downLOW LEVERStep depress hereStep pry up herePOP OF

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-7TYPICAL1. Pilot jet2. Gasket3. Main jet4. Check valve housing removed11, Check Valve Assembly

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-81. Jam nuts2. Adjustment nut3. Flat surfacesTighten jam nuts and torque to 3 N•m (27 lbf•in).

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-9717 AND 787 ENGINES1. Throttle lever stoppers (behind levers)2. Adjustment nutTighten jam nut

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-10TYPICAL - 587 ENGINE1. High speed screwTYPICAL - 717 AND 787 ENGINES1. High speed screws15,

Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-11NOTE : On twin carburetor engines, there isonly one idle speed screw.Connect an induction-ty

07-00-1Section 07 LUBRIFICATION SYSTEMSub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSOIL INJECTION SYSTEM...

Section 07 LUBRIFICATION SYSTEMSub-Section 01 (OIL INJECTION SYSTEM)07-01-1OIL INJECTION SYSTEM 1All Models Except HXF01G0CS4 N•m(35 lbf•in)1211.2 N•m

Section 07 LUBRIFICATION SYSTEMSub-Section 01 (OIL INJECTION SYSTEM)07-01-2HX ModelF05G02S341.2 N•m(11 lbf•in)1.2 N•m(11 lbf•in)www.SeaDooManuals.netP

Section 07 LUBRIFICATION SYSTEMSub-Section 01 (OIL INJECTION SYSTEM)07-01-3GENERALWhenever repairing the oil injection system, al-ways verify for wate

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 01 (MANDATORY TOOLS)COOLING / FUEL/ OIL SYSTEMSHose pincherP / N 295000076Q, AO1 B214APPLICATIONAll

Section 07 LUBRIFICATION SYSTEMSub-Section 02 (OIL INJECTION PUMP)07-02-1OIL INJECTION PUMP 2All Models Except XPF01G0DSTwin CarbsSingle CarbLoctite24

Section 07 LUBRIFICATION SYSTEMSub-Section 02 (OIL INJECTION PUMP)07-02-2XP ModelF01G0TS1110984.5 N•m(40 lbf•in)6 N•m(53 lbf•in)74.5 N•m(40 lbf•in)4.5

Section 07 LUBRIFICATION SYSTEMSub-Section 02 (OIL INJECTION PUMP)07-02-3REMOVALAll Models Except XPRemove air intake silencer (refer to FUEL SYS-TEM

Section 07 LUBRIFICATION SYSTEMSub-Section 02 (OIL INJECTION PUMP)07-02-4TYPICALA. 10 N•m (89 lbf•in)XP Model Only8,9,10,11, Screw, Flat Washer, Pump

Section 07 LUBRIFICATION SYSTEMSub-Section 02 (OIL INJECTION PUMP)07-02-5Final SynchronizationEliminate throttle cable free-play by depressingthrottle

Section 07 LUBRIFICATION SYSTEMSub-Section 02 (OIL INJECTION PUMP)07-02-6Bench TestThe oil pump must be removed out of watercraft.Connect a hose fille

08-00-1Section 08 ELECTRICAL SYSTEMSub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSMAGNETO SYSTEM ...

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-1MAGNETO SYSTEM 1587 and 717 EnginesF01D4WS12115 N•m(44 lbf•in)139 N•m(80 lbf•in)Loct

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-2787 EngineF01D7TSLoctite 242Loctite 242Loctite 648Loctite 64810796581241110 N•m(88 l

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-3GENERALThe following procedures can be performed with-out removing engine from water

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 01 (MANDATORY TOOLS)PROPULS1ON SYSTEMImpeller remover /i nsta I Ie rP / N 295000001F01JOT4APPLICATIO

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-4Fully thread on puller in puller plate.Tighten puller bolt and at the same time, tap

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-5TYPICAL1. Lug end of crankcase2. Align mark and lug end here– Find manufacturer’s ma

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-6If desired, magneto rotor can be removed withoutthe engine flywheel. Remove the 6 sc

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-7– Remove screws.– Uncrimp and unsolder BLACK / RED wire fromcoil.1. Uncrimp and unso

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-81. Magneto coil centering tool (P / N 290 876 922)CAUTION : Before reinstalling the

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-94,5, Armature Plate and ScrewPosition the armature plate on the crankcase,aligning t

Section 08 ELECTRICAL SYSTEMSub-Section 01 (MAGNETO SYSTEM)08-01-10CAUTION : Never use any type of impactwrench at magneto installation.All Engines1,2

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-1IGNITION SYSTEM 2GENERAL587 and 717 EnginesThe Capacitor Discharge Ignition system

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-2787 EngineThe 787 engine has a digital DC-CDI (Direct Cur-rent-Capacitor Discharge

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-3Holder RelayThe holder relay is used to prevent discharge ofthe battery, through th

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 02 (RECOMMENDED TOOLS)RECOMMENDED TOOLSoNOTE : The numbers outlined in black (example : ❑ ) are re

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-4Static TestAll Engines1. Disconnect MAG side spark plug wire and con-nect wire to g

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-57. Scribe a thin mark on PTO flywheel in the mid-dle of tool slot (587 and 717 engi

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-63. Start engine and point timing light straight inline with timing tool slot. Bring

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-7TYPICAL1. Retaining screwExample 1When PTO flywheel mark is on right side of timing

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-8The timing mark refer to the physical componentposition when the spark must occur.

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-910. Press 8 to choose Save + Quit (even if itemno. 8 is not visible on the display

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-10SAFETY PRECAUTIONSWARNING : To prevent powerful electricshocks while cranking engi

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-11Most of circuit can be tested with an ohmmeterbut a 100 % test doesn’t mean the MP

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-121. Bombardier ignition tester2. Four-pin magneto harness adapter3. Probe ‘’N’’ to

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-13DC-CDI Module VerificationSTATIC TEST : CONTINUITYMulti-Purpose Electronic Module

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 02 (RECOMMENDED TOOLS)ENGINE (continued)Timing mark pointerP / N 295000130, FO1 B204APPLICATIONAll e

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-14Ignition Coil VerificationSTATIC TESTNOTE : An ignition coil with good resis-tanc

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-15787 Engine OnlyAs an alternate method, use KOWA ignition coiltester (or equivalent

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-16FoulingFouling of the spark plug is indicated by irregularrunning of the engine, d

Section 08 ELECTRICAL SYSTEMSub-Section 02 (IGNITION SYSTEM)08-02-17Spark Plug Symbol ExplanationBP5ES15ThreaddiameterHeat ratingnumbersReachFiring en

Section 08 ELECTRICAL SYSTEMSub-Section 03 (CHARGING SYSTEM)08-03-1CHARGING SYSTEM 3GENERALMagnetoThe purpose of the charging system is to keep theba

Section 08 ELECTRICAL SYSTEMSub-Section 03 (CHARGING SYSTEM)08-03-2NOTE : If it is continually necessary to adddistilled water to the battery, this in

Section 08 ELECTRICAL SYSTEMSub-Section 03 (CHARGING SYSTEM)08-03-33. Check resistance between two of the YELLOWwires. The resistance should be betwee

Section 08 ELECTRICAL SYSTEMSub-Section 03 (CHARGING SYSTEM)08-03-4BATTERYTroubleshootingRemovalWARNING : Battery BLACK negative ca-ble must always be

Section 08 ELECTRICAL SYSTEMSub-Section 03 (CHARGING SYSTEM)08-03-5This chart will be useful to find the correct read-ing.Battery StorageDisconnect an

Section 08 ELECTRICAL SYSTEMSub-Section 03 (CHARGING SYSTEM)08-03-63. Allow the battery to stand for 30 minutes MIN-IMUM so that electrolyte soak thro

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 02 (RECOMMENDED TOOLS)ENGINE (continued)Safety lanyard switch tool ~P / N 295000121F01B244APPLICATIO

Section 08 ELECTRICAL SYSTEMSub-Section 03 (CHARGING SYSTEM)08-03-710.Reinstall battery. Hook up battery cables ob-serving correct polarity and coat t

Section 08 ELECTRICAL SYSTEMSub-Section 03 (CHARGING SYSTEM)08-03-8– If the charging current is measurable before theend or at the end of about 10 hou

Section 08 ELECTRICAL SYSTEMSub-Section 04 (STARTING SYSTEM)08-04-1STARTING SYSTEM 4F01H1MT121110968712345135 N•m(44 lbf•in)Dielectricgrease1516Loctit

Section 08 ELECTRICAL SYSTEMSub-Section 04(STARTING SYSTEM)08-04-2GENERALCauses of troubles are not necessarily related tostarter but may be due to a

Section 08 ELECTRICAL SYSTEMSub-Section 04 (STARTING SYSTEM)08-04-3STARTING SYSTEM TROUBLESHOOTINGSYMPTOM CAUSE REMEDYStarter does not turn. Burnt fus

Section 08 ELECTRICAL SYSTEMSub-Section 04(STARTING SYSTEM)08-04-4STARTER REMOVALDisconnect BLACK cable ground connection frombattery.WARNING:Always d

Section 08 ELECTRICAL SYSTEMSub-Section 04 (STARTING SYSTEM)08-04-5Check commutator for roughness, burnt orscored surface. If necessary, turn commutat

Section 08 ELECTRICAL SYSTEMSub-Section 04(STARTING SYSTEM)08-04-61. Armature shaft2. Circlip3. Pinion stop collar4. Punch1,10, Housing and Yoke Ass’y

Section 08 ELECTRICAL SYSTEMSub-Section 04 (STARTING SYSTEM)08-04-7Step Retaining brush holder with a screwdriverStep Align hereAlign end frame notch

Section 08 ELECTRICAL SYSTEMSub-Section 04(STARTING SYSTEM)08-04-8STARTER SPECIFICATIONNominal output 0.6 kWVoltage 12 VRated time 30 secondsRotation

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 02 (RECOMMENDED TOOLS)COOLING / FUEL/ OIL SYSTEMSmPump gauge tester : .(carburetorP / N 295000114F01

Section 08 ELECTRICAL SYSTEMSub-Section 05 (INSTRUMENTS AND ACCESSORIES)08-05-1INSTRUMENTS AND ACCESSORIES 5GENERALIt is possible to activate the fuel

Section 08 ELECTRICAL SYSTEMSub-Section 05 (INSTRUMENTS AND ACCESSORIES)08-05-2– Adjust potentiometer to the resistance valuesas per following chart t

Section 08 ELECTRICAL SYSTEMSub-Section 05 (INSTRUMENTS AND ACCESSORIES)08-05-3The resistance measured between PINK / BLACKand PINK wires must be in a

Section 08 ELECTRICAL SYSTEMSub-Section 05 (INSTRUMENTS AND ACCESSORIES)08-05-4NOTE : This sensor turns the low-level oillight to ON if the connector

Section 08 ELECTRICAL SYSTEMSub-Section 05 (INSTRUMENTS AND ACCESSORIES)08-05-5VTS MotorAlways confirm first that the fuse is in good con-dition.Motor

Section 08 ELECTRICAL SYSTEMSub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM)08-06-1DIGITALLY ENCODED SECURITY SYSTEM 6GENERALThe Digitally Encoded S

Section 08 ELECTRICAL SYSTEMSub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM)08-06-2Basic Self-Diagnostic ModeIt is self-activated when the safety la

Section 08 ELECTRICAL SYSTEMSub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM)08-06-3Advanced Self-Diagnostic ModeIt needs to be enabled manually. Pro

09-00-1Section 09 PROPULSION SYSTEMSub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSJET PUMP...

Section 09 PROPULSION SYSTEMSub-Section 00 (TABLE OF CONTENTS)09-00-2VARIABLE TRIM SYSTEM...

00SHOPMANUAL0®219 100 031www.SeaDooManuals.net

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 02 (RECOMMENDED TOOLS)PROPULSION SYSTEMFittingP / N 295000086, FO1 BOZ4APPLICATIONAll models.Slide h

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-1JET PUMP 1ALUMINUM PUMPF01J5LS27Loctite 2428 N•m(71 lbf•in)12Loctite 598Ultra Black2019141

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-2PLASTIC PUMPF01J5MS2019141528Loctite 598Ultra BlackLoctite242278 N•m(71 lbf•in)10 N•m(88 l

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-3GENERALThe impeller housing, venturi and nozzle are ei-ther made of aluminum or plastic, d

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-4MEASURING FROM WATER INLET SIDE1. Feeler gaugeMEASURING FROM VENTURI SIDE1. Feeler gaugeOi

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-5Pour approximately 90 mL (3 oz) of oil throughhole until oil reaches the bottom of hole th

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-61. Floating seal2. O-ringDisconnect engine water inlet hose and both bail-er pick-up tubes

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-76,7, Nut and Impeller HousingRemove nuts retaining impeller housing to hull.Using screws p

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-8JET PUMP SUPPORT REMOVALHX Model OnlyRemove ball joint, boot, nut, half rings and O-ringsf

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-914,15, Boot and RingPull out ring from boot1. Pull out ringInsert a screwdriver blade betw

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-1017,18, Housing Cover and ScrewWith pump assembly in horizontal position, re-move 3 retain

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 02 (RECOMMENDED TOOLS)WATERC RAFT HANDINGDolley (with wheels) : .mP / N 295000126F01B014.———————————

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-1121, SealTo remove seal, proceed as follows :CAUTION : It is not recommended topush seal o

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-1222, Needle BearingNOTE : It is always recommended to renewboth bearings, even if only one

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-131. Replaced if blunted round or damagedCheck impeller for cavitation damage, deepscratche

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-1420, Wear RingCheck wear ring for deep scratches, irregular sur-face or any apparent damag

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-1524,25, Thrust Washer and Thrust BearingVisually inspect thrust washer, thrust bearing and

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-161. Impeller shaft nose21, SealCarefully inspect seal lips. Make sure that lips arenot wor

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-1721,22, Seal and Needle BearingBearings and seal will be properly installed inhousing usin

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-18Apply Loctite 518 (P / N 293 800 038) to seal hous-ing, all around outer diameter and on

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-19To prevent seal lip damage when inserting impel-ler shaft, use impeller shaft guide (P /

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-201. Impeller remover / installer tool2. Impeller shaft holder tool17,26, Housing Cover and

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 03 (SERVICE PRODUCTS)SERVICE PRODUCTSoNOTE : The numbers outlined in black. (example : ❑ ) are refere

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-21Aluminum Impeller HousingApply Loctite 242 (blue) on screw threads.Install screws and was

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-22– Pump must maintain this pressure for at least10 minutes.CAUTION : Repair any leak, fail

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-23HX MODEL1. Apply Loctite 598 Ultra Black as indicated by shaded areaCarefully install rid

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-241. O-ring2. Floating ringPosition the floating ring between the carbon ringand the PTO fl

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-251. Bailer tubes2. Water inlet hoseSecure flywheel guard to engine studs using 1 nutand 1

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-26TYPICAL - PLASTIC NOZZLE1. Torque nut of steering cable ball joint to 7 N•m (62 lbf•in)2.

Section 09 PROPULSION SYSTEMSub-Section 01 (JET PUMP)09-01-27SPI and HX ModelsSecure support of manual trim.1. Torque nut to 10 N•m (89 lbf•in)All Mod

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-1DRIVE SYSTEM 2All Models Except HXF01I0ESLoctite271261810982 N•m(18 lbf•in)2 N•m(18 lb

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-2HX ModelF05I02S1122 N•m(16 lbf•ft)22 N•m(16 lbf•ft)Loctite 242161722 N•m(16 lbf•ft)Loc

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-3GENERALJet pump must be removed to replace any com-ponents of the drive system. Refer

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 03 (SERVICE PRODUCTS)General purpose instantmadhesiveP i N 293800021~octlte 495AOOB2VAAPPLICATIONRubb

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-43, Drive ShaftIf the drive shaft is jammed into PTO flywheel,make the following tool a

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-57, Front Drive ShaftRemove bolt, lock nut and sleeve from support.1. Bolt2. Lock nut3.

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-6Lock ring gear using special tool (P / N 295 000134).1. Ring gear blocking toolAll Mod

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-7HX Model OnlyPTO flywheel is loosen using flywheel remover.1. PTO flywheel removerDISA

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-8Place drive shaft on V-blocks and set-up a dialgauge in center of shaft. Slowly rotate

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-9NOTE : Bearing can also be installed withthe same driver used at disassembly. Cen-ter

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-10Install alignment tool at rear of watercraft.1. Housing (P / N 295 000 090)2. Alignme

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-11PRE-CLAMPING POSITION1. Holding hook2. Large window– Insert pointed tips of pliers fi

Section 09 PROLPUSION SYSTEMSub-Section 02 (DRIVE SYSTEM)09-02-121. Squeeze plier1F02J0PBwww.SeaDooManuals.net

Section 09 PROPULSION SYSTEMSub-Section 03 (REVERSE SYSTEM)09-03-1REVERSE SYSTEM 3GTS and GTI ModelsF02J0NS2Syntheticgrease648 N•m(71 lbf•in)7 N•m(62

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 03 (SERVICE PRODUCTS)Hylomar sealantm● .P / N 293800001DL32‘ 100 g)AOOB3F4APPLICATIONSealantm. .P / N

Section 09 PROPULSION SYSTEMSub-Section 03 (REVERSE SYSTEM)09-03-2GENERALIt is not necessary to remove reverse systemfrom watercraft for servicing. Ho

Section 09 PROPULSION SYSTEMSub-Section 03 (REVERSE SYSTEM)09-03-3TYPICAL1. Reverse support2. Reverse cable3. Triangular lever6, Reverse SupportIn ord

Section 09 PROPULSION SYSTEMSub-Section 03 (REVERSE SYSTEM)09-03-4CAUTION : Always hook reverse gatesprings in order to ease reverse gate oper-ation.1

Section 09 PROPULSION SYSTEMSub-Section 03 (REVERSE SYSTEM)09-03-52, SpringInsert spring in lever stem hole and then installcurved end in sliding bloc

Section 09 PROPULSION SYSTEMSub-Section 03 (REVERSE SYSTEM)09-03-61. REVERSE positionIf reverse gate needs to be readjusted, it can bedone at support

Section 09 PROPULSION SYSTEMSub-Section 04 (VARIABLE TRIM SYSTEM)09-04-1VARIABLE TRIM SYSTEM 4SPI and HX ModelsF05J07S78621 N•m(16 lbf•ft)1Loctite2421

Section 09 PROPULSION SYSTEMSub-Section 04 (VARIABLE TRIM SYSTEM)09-04-2REMOVAL1,2,3, Screw, Bolt and Lock NutLoosen venturi screw, bolt and nut retai

Section 09 PROPULSION SYSTEMSub-Section 04 (VARIABLE TRIM SYSTEM)09-04-3SPX and XP ModelsF01J56S77 N•m(62 lbf•in)896546 N•m(53 lbf•in)1022310 N•m(88 l

Section 09 PROPULSION SYSTEMSub-Section 04 (VARIABLE TRIM SYSTEM)09-04-4GENERALTo test VTS control module, motor or switch, referto ELECTRICAL SYSTEM

Section 09 PROPULSION SYSTEMSub-Section 04 (VARIABLE TRIM SYSTEM)09-04-59, WormInspect threads and splines of worm for wear. Ifworm replacement is nec

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 03 (SERVICE PRODUCTS)LubricantNot sold by BombardierG E. VersllubeG341 M=ej (Esso Be;;on 325AOOB1T4A

Section 09 PROPULSION SYSTEMSub-Section 04 (VARIABLE TRIM SYSTEM)09-04-61, Ball JointInstall ball joint on right side of sliding shaft.Torque fastener

10-00-1Section 10 STEERING SYSTEMSub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSSPÞ/ÞXP SERIES...

Section 10 STEERING SYSTEMSub-Section 01 (SP /XP SERIES)10-01-1SP /XP SERIES 1F01K19S8 N•m(72 lbf•in)15 N•m(11 lbf•ft)SyntheticgreaseSyntheticgrease7

Section 10 STEERING SYSTEMSub-Section 01 (SP /XP SERIES)10-01-2REMOVAL AND ASSEMBLY1,2,3, Cover, Screw and WasherTo replace the cover, just remove and

Section 10 STEERING SYSTEMSub-Section 01 (SP /XP SERIES)10-01-31. Grip insert2. Grip3. Flat washer4. Loctite 242 (blue)5. Torque bolt to 6 N•m (53 lbf

Section 10 STEERING SYSTEMSub-Section 01 (SP /XP SERIES)10-01-49,10,11,12, Steering Stem, Arm, Support and HandlebarInstall support to steering stem a

Section 10 STEERING SYSTEMSub-Section 01 (SP /XP SERIES)10-01-51. Steering stem2. Steering stem arm3. Support4. Torque to 6þN•m (53þlbf•in)5. Integrat

Section 10 STEERING SYSTEMSub-Section 02 (GTS AND GTI MODELS)10-02-1GTS AND GTI MODELS 2F02K0BS26 N•m(19 lbf•ft)3.5 N•m(30 lbf•in)546 N•m(53 lbf•in)An

Section 10 STEERING SYSTEMSub-Section 02 (GTS AND GTI MODELS)10-02-2REMOVAL AND ASSEMBLY1,2,3, Cover, Screw and WasherTo replace the cover, just remov

Section 10 STEERING SYSTEMSub-Section 02 (GTS AND GTI MODELS)10-02-3TO INSTALL HANDLEBAR ASSEMBLY:14, GrommetInsert throttle cable through dashboard h

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 03 (SERVICE PRODUCTS)Bombard ier-Rotaxinjection oilP / N 413803000m.e(3x 4 L)P / N 413803200m● *(205

Section 10 STEERING SYSTEMSub-Section 02 (GTS AND GTI MODELS)10-02-4TYPICAL21,22,23, Steering Cable, Ball Joint and Retaining BlockTo replace steering

Section 10 STEERING SYSTEMSub-Section 03 (HX MODEL)10-03-1HX MODEL 3F05K03S5766 N•m(53 lbf•in)48132323 N•m(27 lbf•in)6 N•m(53 lbf•in)7 N•m(62 lbf•in)7

Section 10 STEERING SYSTEMSub-Section 03 (HX MODEL)10-03-2REMOVAL1,2,3, Cover, Screw and WasherTo remove the cover, just remove 4 screws andwashers.1.

Section 10 STEERING SYSTEMSub-Section 03 (HX MODEL)10-03-31. Boot12,13,14, Steering Support, Bolts and NutsLoosen bolts and nuts of steering support.1

Section 10 STEERING SYSTEMSub-Section 03 (HX MODEL)10-03-4WARNING : Make sure integrated flatkeys of steering stem arm and support areproperly seated

Section 10 STEERING SYSTEMSub-Section 04 (ALIGNMENT)10-04-1ALIGNMENT 4Position handlebar in straight ahead position bymeasuring each side the distance

Section 00 STEERING SYSTEMSub-Section 04 (ALIGNMENT)10-04-2GTS / GTI Models1. Retaining block2. Adjustment nut3. BoltsAll ModelsAfter adjustment, torq

Sub-Section 00 (TABLE OF CONTENTS)11-00-1Section 11 SUSPENSIONTABLE OF CONTENTSDIRECT ACTION SUSPENSION...

Section 11 SUSPENSIONSub-Section 01 (DIRECT ACTION SUSPENSION)11-01-1DIRECT ACTION SUSPENSION 1HX ModelF05L0GS235 N•m(44 lbf•in)5 N•m(44 lbf•in)95461

Section 11 SUSPENSIONSub-Section 01 (DIRECT ACTION SUSPENSION)11-01-2COIL OVER SHOCK REMOVALRemove bottom cover of seat with grab handle.1. Grab handl

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 03 (SERVICE PRODUCTS)Sealantm.eP / N 293800029Tremco clear~300 mL)APPLICATIONAdhesive activator ●mP

Section 11 SUSPENSIONSub-Section 01 (DIRECT ACTION SUSPENSION)11-01-33,7, Inner Boot and CollarLoosen upper collar of coil over shock inner boot ;then

Sub-Section 00 (TABLE OF CONTENTS)12-00-1Section 12 HULL / BODYTABLE OF CONTENTSADJUSTMENT AND REPAIR...

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-1ADJUSTMENT AND REPAIR 1SP / XP SeriesF01L6HS3Loctite2715 N•m(44 lbf•in)Loctite271Lo

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-2F01L6ISLoctite 2426 N•m(53 lbf•in)15 N•m(11 lbf•ft)Sealant 732Loctite271SPX / XPmod

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-3GTS / GTI ModelsF02L26S3Loctite2715 N•m(44 lbf•in)8 N•m(71 lbf•in)Loctite242Loctite

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-4F02L27SLoctite 2427 N•m(62 lbf•in)41215 N•m(11 lbf•ft)Loctite271Sealant732451241212

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-5HX ModelF05L0PSBody5 N•m(44 lbf•in)Loctite 27135 N•m(44 lbf•in)BodyBody1.5 N•m(13 l

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-6F05L0QSBody4 N•m(35 lbf•in)4 N•m(35 lbf•in)4 N•m(35 lbf•in)Loctite2424 N•m(35 lbf•i

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-7F05L0RS4 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 l

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-8F05L0SS6 N•m(53 lbf•po)15 N•m(11 lbf•pi)6 N•m(53 lbf•po)Loctite24213www.SeaDooManua

Section 01 SERVICE TOOLS AND PRODUCTSSub-Section 03 (SERVICE PRODUCTS)Sea-Doo spray paint for gelcoatmA) Super white (140 g) ●P / N 293500076B) Tealm

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-9SEAT ADJUSTMENTAll Models Except HX1, Front HookAdjust front hook as per following

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-10STORAGE COMPARTMENT COVERADJUSTMENTAll Models Except HX3, Lock PinAdjust lock pin

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-11DRAIN PLUG INSTALLATION14, Drain PlugRefer to the following illustration for drain

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-12Remove bolt and lock nut from shock absorberupper support.1. Bolt2. Lock nutTilt s

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-134. Slide bumper rail under front bumper.5. Using a 4.80 mm (3/16 in) drill bit, dr

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-14If decal tears while pulling off, it has to be heatedfor a few seconds longer. If

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-15WARNING : Protect skin, wear gloveswhen in contact with resin, hardeners andgelcoa

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-16FILLING THE REPAIR AREASmall Fractures :Refer to the same procedure as in the air

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-17Wait until the repair has hardened before movingon to the interior repair. If the

Section 12 HULL / BODYSub-Section 01 (ADJUSTMENT AND REPAIR)12-01-18CAUTION : If you notice any clearance be-tween plastic insert and aluminum insert,

02-00-1Section 02 MAINTENANCESub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSPERIODIC INSPECTION CHART...

Section 12HULL/BODYSub-Section 02(PAINTING)12-02-1PAINTING 0GENERALThe following was prepared in conjunction with PPG Industries Inc. It contains a li

Section 12 HULL/BODYSub-Section 02(PAINTING)12-02-2PARTS THAT CAN BE PAINTED1. Body2. Hull3. Storage Cover (if applicable)4. Engine5. Tuned Pipe6. Muf

Section 12 HULL/BODYSub-Section 02(PAINTING)12-02-3➀Except for plastic partsNOTE:Due to natural discoloration, it may be necessary to completely repai

Section 12 HULL/BODYSub-Section 02(PAINTING)12-02-4CONCEPTTM PAINTING PROCEDUREFor additional information refer to PPG P-Bulletin no. 168.SURFACE PREP

Section 12HULL/BODYSub-Section 02(PAINTING)12-02-5DELTATM PAINTING PROCEDURE(with low VOC, mainly in California)For additional information refer to PP

13-00-1Section 13TECHNICAL DATASub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSSP AND SPI MODELS...

Section 13 TECHNICAL DATASub-Section 01 (SP AND SPI MODELS)13-01-1SP AND SPI MODELS 1ENGINE SP (5876) SPI (5878)Engine type Bombardier-Rotax 587Induct

Section 13 TECHNICAL DATASub-Section 01 (SP AND SPI MODELS)13-01-2ELECTRICAL SP (5876) SPI ( 5878)Magneto generator output 160 W @ 6000 RPM or 4.0 A @

Section 13 TECHNICAL DATASub-Section 01 (SP AND SPI MODELS)13-01-3PROPULSION SP (5876) SPI (5878)Propulsion system Bombardier Formula PumpJet pump typ

Section 13 TECHNICAL DATASub-Section 01 (SP AND SPI MODELS)13-01-4MATERIALS SP (5876) SPI (5878)Hull CompositeAir intake silencer ThermoplasticFlame a

Legal deposit :National Library of QuebecNational Library of CanadaAll rights reserved. No parts of this manual maybe reproduced in any form without t

Section 02 MAINTENANCESub-Section 01 (PERIODIC INSPECTION CHART)02-01-1PERIODIC INSPECTION CHART 1NOTE : Servicing period is given in hours. Shaded ar

Section 13 TECHNICAL DATASub-Section 01 (SP AND SPI MODELS)13-01-5TIGHTENING TORQUES SP (5876) SPI (5878)Exhaust manifold screw 24 N•m (17 lbf•ft) (4)

Section 13 TECHNICAL DATASub-Section 02 (SPX AND XP MODELS)13-02-1SPX AND XP MODELS 2ENGINE SPX (5877) XP (5858 / 5859)Engine type Bombardier-Rotax 71

Section 13 TECHNICAL DATASub-Section 02 (SPX AND XP MODELS)13-02-2ELECTRICAL SPX (5877) XP (5858 / 5859)Magneto generator output 160 W @ 6000 RPMor 4.

Section 13 TECHNICAL DATASub-Section 02 (SPX AND XP MODELS)13-02-3PROPULSION SPX (5877) XP (5858 / 5859)Propulsion system Bombardier Formula PumpJet p

Section 13 TECHNICAL DATASub-Section 02 (SPX AND XP MODELS)13-02-4MATERIALS SPX (5877) XP (5858 / 5859)Hull CompositeInlet grate PlasticImpeller housi

Section 13 TECHNICAL DATASub-Section 02 (SPX AND XP MODELS)13-02-5TIGHTENING TORQUES SPX (5877) XP (5858 / 5859)ENGINEExhaust manifold screw 24 N•m (

Section 13 TECHNICAL DATASub-Section 03 (GTS AND GTI MODELS)13-03-1GTS AND GTI MODELS 3ENGINE GTS (5817) GTI (5865 / 5866)Engine type Bombardier-Rotax

Section 13 TECHNICAL DATASub-Section 03 (GTS AND GTI MODELS)13-03-2ELECTRICAL GTS (5817) GTI ( 5865 / 5866)Magneto generator output 160 W @ 6000 RPM o

Section 13 TECHNICAL DATASub-Section 03 (GTS AND GTI MODELS)13-03-3PROPULSIONGTS (5817) GTI (5865 / 5866)Propulsion system Bombardier Formula PumpJet

Section 13 TECHNICAL DATASub-Section 03 (GTS AND GTI MODELS)13-03-4MATERIALS GTS (5817) GTI (5865 / 5866)Hull CompositeInlet grate PlasticAir intake s

Section 02 MAINTENANCESub-Section 02 (FLUSHING AND LUBRICATION)02-02-1FLUSHING AND LUBRICATION 2GENERALFlushing the cooling system with fresh water is

Section 13 TECHNICAL DATASub-Section 03 (GTS AND GTI MODELS)13-03-5TIGHTENING TORQUESGTS (5817) GTI (5865 / 5866)ENGINEExhaust manifold screws 24 N•m

Section 13 TECHNICAL DATASub-Section 04 (HX MODEL)13-04-1HX MODEL 4ENGINE HX (5881)Engine type Bombardier-Rotax 717Induction type Rotary valveExhaust

Section 13 TECHNICAL DATASub-Section 04 (HX MODEL)13-04-2ELECTRICAL HX ( 5881)Magneto generator output 160 W @ 6000 RPM or 4.0 A @ 2000 RPMIgnition sy

Section 13 TECHNICAL DATASub-Section 04 (HX MODEL)13-04-3PROPULSION HX (5881)Propulsion system Bombardier Formula PumpJet pump type Axial flow single

Section 13 TECHNICAL DATASub-Section 00 (TABLE OF CONTENTS)13-04-4MATERIALS HX (5881)Hull CompositeInlet grate AluminumImpeller housing PlasticAir int

Section 13 TECHNICAL DATASub-Section 04 (HX MODEL)13-04-5TIGHTENING TORQUES HX (5881)ENGINEExhaust manifold screw 24 N•m (17 lbf•ft) (4)Magneto flywhe

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Section 02 MAINTENANCESub-Section 02 (FLUSHING AND LUBRICATION)02-02-2787 ENGINE1. Coupler hose2. Fitting spigot3. Install a hose pincher hereAttach o

Section 02 MAINTENANCESub-Section 02 (FLUSHING AND LUBRICATION)02-02-3All ModelsWipe up any residual water from the engine.Remove spark plug cables an

Section 02 MAINTENANCESub-Section 03 (WATER-FLOODED ENGINE)02-03-1WATER-FLOODED ENGINE 3GeneralIf engine is water-flooded, it must be servicedwithin a

Section 02 MAINTENANCESub-Section 03 (WATER-FLOODED ENGINE)02-03-2NOTE : If engine does not start after sever-al attempts, check ignition system for

Section 02 MAINTENANCESub-Section 04 (STORAGE)02-04-1STORAGE 4Engine DrainingCheck engine drain hose. Make sure there is nosand or other particles in

Section 02 MAINTENANCESub-Section 04 (STORAGE)02-04-21. Grease PTO flywheelCAUTION : Never leave any clothing, toolor other objects near PTO flywheel

Section 02 MAINTENANCESub-Section 04 (STORAGE)02-04-3All Models Except the HXInstall coupler hose to fitting spigot.Install a hose pincher to engine w

03-00-1Section 03 TROUBLESHOOTINGTROUBLESHOOTING 0The following is provided to help in diagnosing the probable source of troubles. It is a guideline a

iTABLE OF CONTENTSSECTION SUBJECT PAGESAFETY NOTICE...

03-00-2Section 03 TROUBLESHOOTINGENGINE MISFIRES, RUNS IRREGULARLYENGINE OVERHEATSENGINE CONTINUALLY BACKFIRESOTHER OBSERVATION POSSIBLE CAUSE REMEDYW

03-00-3Section 03 TROUBLESHOOTINGENGINE DETONATION OR PINGINGENGINE LACKS ACCELERATION OR POWERENGINE RUNS TOO FASTABNORMAL NOISE FROM PROPULSION SYST

04-00-1Section 04 ENGINESub-Section 00 (TABLE OF CONTENTS)TABLE OF CONTENTSREMOVAL AND INSTALLATION ...

Section 04 ENGINESub-Section 00 (TABLE OF CONTENTS)04-00-2EXHAUST MANIFOLD, TUNED PIPE AND MUFFLER INSTALLATION ... 04-05-7ww

Section 04 ENGINESous-section 01 (REMOVAL AND INSTALLATION)04-01-1REMOVAL AND INSTALLATION 1GENERALIt is not necessary to remove engine from water-cra

Section 04 ENGINESous-section 01 (REMOVAL AND INSTALLATION)04-01-2Disconnect magneto wiring harness.ALL MODELS EXCEPT XP1. Unplug connectorXP MODEL1.

Section 04 ENGINESous-section 01 (REMOVAL AND INSTALLATION)04-01-3HX ModelLoosen screws of engine rubber mount adapters.NOTE : Rubber mount adapters s

Section 04 ENGINESous-section 01 (REMOVAL AND INSTALLATION)04-01-4All ModelsInstall a hose pincher to oil supply hoses of oilinjection pump and rotary

Section 04 ENGINESous-section 01 (REMOVAL AND INSTALLATION)04-01-5CAUTION : Strict adherence to this torqueis important to avoid damaging threads ofal

Section 04 ENGINESous-section 01 (REMOVAL AND INSTALLATION)04-01-6TYPICAL - ALL MODELS EXCEPT THE XP1. ShimXP MODEL1. Rear support2. Front support3. S

00-0-2SAFETY NOTICESAFETY NOTICEThis manual was primarily published to be used by watercraft technicians trained by the manufacturerwho are already fa

Section 04 ENGINESub-Section 02 (TOP END)040-02-1TOP END 2587 and 717 EnginesF01D42SLoctite 242Syntheticgrease1524 N•m(17 lbf•ft)717 Engine1122Synthet

Section 04 ENGINESub-Section 02 (TOP END)040-02-2787 EngineF01D7DS24 N•m(17 lbf•ft)15Synthetic greaseLoctite 242Syntheticgrease40 N•m(30 lbf•ft)18Loct

Section 04 ENGINESub-Section 02 (TOP END)040-02-3ENGINE DESCRIPTION587, 717 and 787 EnginesThe 2-stroke ROTAX engine rotates counterclock-wise seen fr

Section 04 ENGINESub-Section 02 (TOP END)040-02-4If the other cylinder has been removed, complete-ly cover its opening with a clean rag.1. Openings co

Section 04 ENGINESub-Section 02 (TOP END)040-02-5– The needles, thrust washers and the expansionsleeve remain in the connecting rod bore andmay be use

Section 04 ENGINESub-Section 02 (TOP END)040-02-6NOTE : Replacement cylinder sleeves areavailable if necessary. Also, oversize pistonsof 0.25 mm (.010

Section 04 ENGINESub-Section 02 (TOP END)040-02-7Measure cylinder at 16 mm (5/8 in) below its topedge.1. Measuring perpendicularly (90°) to piston pin

Section 04 ENGINESub-Section 02 (TOP END)040-02-8NOTE : Squish gap measurement is dis-cussedfurther in this sub-section.ASSEMBLYAssembly is essentiall

Section 04 ENGINESub-Section 02 (TOP END)040-02-9– Warm piston to approximately 50-60°C (122-140°F) and install it over connecting rod.– Insert extrac

Section 04 ENGINESub-Section 02 (TOP END)040-02-10– As necessary, pull halves of inner sleeve withlong nose pliers.1. Pulling inner sleeve halfAll Eng

00-0-31996 BOMBARDIER WATERCRAFT SHOP MANUALINTRODUCTIONThis Shop Manual covers BOMBARDIER madeSEA-DOO® watercraft models SPþ5876, SPX5877, SPI 5878,

Section 04 ENGINESub-Section 02 (TOP END)040-02-113,7,8,9, Piston, Ring and CylinderTo easily slide cylinder over piston, install on pis-ton ring comp

Section 04 ENGINESub-Section 02 (TOP END)040-02-12ALL ENGINES EXCEPT THE 7871. Exhaust flange aligning toolALL ENGINES1. Aligning cylinders using exha

Section 04 ENGINESub-Section 02 (TOP END)040-02-13Apply Loctite 515 in O-ring groove of cylindersleeves.Make sure to install large O-rings around spar

Section 04 ENGINESub-Section 02 (TOP END)040-02-14Torque cylinder head screws to 12 N•m (9 lbf•ft)as per following illustrated sequence. Repeat thepro

Section 04 ENGINESub-Section 02 (TOP END)040-02-151. Measure hereCAUTION : Do not use acid core solder ;the acid can damage the piston and cylin-der.–

Section 04 ENGINESub-Section 02 (TOP END)040-02-16VALVE FULLY OPENEDVALVE FULLY CLOSEDThe RAVE valve does not allow an engine to makehigher peak horse

Section 04 ENGINESub-Section 02 (TOP END)040-02-17Boring PrecautionIn its stock configuration the RAVE valve guillotinehas a minimum of 0.5 mm (.020 i

Section 04 ENGINESub-Section 02 (TOP END)040-02-18InspectionCheck bellow for cracks.Check if passages of valve housing and cylinderare not obstructed.

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-1BOTTOM END 3587 Engine3Loctite515Loctite515SyntheticgreaseLoctite515Loctite515Loctite515Syntheticgr

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-2717 EngineF01D06S11Loctite51532Loctite64214265Anti-seizelubricantLoctite242Anti-seizelubricantLithi

00-0-41996 BOMBARDIER WATERCRAFT SHOP MANUALARRANGEMENT OF THIS MANUALThe manual is divided into 14 major sectionsþ:01SERVICE TOOLS AND PRODUCTS02MAIN

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-3787 EngineLoctite515Anti-seizelubricant13LithiumgreaseAnti-seizelubricant1LithiumgreaseF01D8GS3Anti

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-4CRANKSHAFT MISALIGNMENT AND DEFLECTIONSince it is an assembled crankshaft it can becomemisaligned o

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-51. TDC gauge2. Degree wheel3. Hand tighten nut4. Needle pointer– Remove TDC gauge and install on PT

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-61. Separate halves by prying at provided lugs1. Separate halves by prying at provided lugsRemove cr

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-7All Engines1. Removing crankshaft bearingOr, use a bearing extractor such as Proto no. 4332and a pr

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-81. Ruler must be aligned with edge of connecting rod here2. Align ruler hereCrankshaft DeflectionCr

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-9Connecting Rod Big End Axial PlayUsing a feeler gauge, measure distance betweenthrust washer and cr

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-10TYPICAL1. Distance gauge2. PTO side outer bearing15, Distance RingWhen installing the distance rin

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-11587 and 717 Engines7,8,9, Crankcase ScrewTorque crankcase screws to 24 N•m (17 lbf•ft) asper follo

Section 04 ENGINESub-Section 03 (BOTTOM END)04-03-121. Install starter before engine support787 EngineAdd 30 mL (1 oz) of FORMULA XP-S synthetic in-je

00-0-51996 BOMBARDIER WATERCRAFT SHOP MANUALSection 08 ELECTRICALSub-Section 01 (MAGNETO SYSTEM)MAGNETO SYSTEM587 and 717 Engines08-01-1F01D4WS1

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-1ROTARY VALVE 4F01D7SS8220 N•m(15 lbf•ft)Lithiumgrease17106951134131214151787 Engine717 Engines213

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-2GENERALThe following verification procedures such asclearance of rotary valve cover or rotary val

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-3TYPICAL1. SolderIf rotary valve cover clearance is out of specifica-tion, machine rotary valve co

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-4DISASSEMBLY3,4, Rotary Valve Shaft and Snap RingTo remove rotary valve shaft assembly, first re-m

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-57,8, Snap Ring and BearingTo remove bearing use a bearing extractor suchas Snap-on no CJ-950 as i

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-68,9 BearingInspect bearings. Check for scoring, pitting, chip-ping or other evidence of wear. Mak

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-73,11, Rotary Valve Shaft and SealApply lithium grease on seal lips. Position sealwith shielded po

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-8787 EngineTo install rotary valve shaft in crankcase, use apusher (P / N 290 876 609) and handle

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-9F01D89S290 924 502actual size290 924 508actual sizeTEMPLATE147 °(cut-out angle)159 °(cut-out angl

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-10ROTARY VALVE TIMINGCAUTION : Never use the ridge moldedin crankcase as a timing mark.The follow

00-0-61996 BOMBARDIER WATERCRAFT SHOP MANUAL12Section 06 FUEL SYSTEMSub-Section 03 (CARBURETORS)06-03-4Step : Install pump gauge tester to pul

Section 04 ENGINESub-Section 04 (ROTARY VALVE)04-04-11CLOSING MARKStep : Top of MAG inlet port.Align 360° line of degree wheelStep : Find 65° on degre

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-1EXHAUST SYSTEM 5SP Series, GTS and GTI ModelsF01D4QS20151717241424 N•m(17 lbf•ft)Syntheticgreas

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-2HX ModelF05D08S25 N•m(18 lbf•ft)8Loctite 2429725 N•m (18 lbf•ft)Loctite 2429191010 N•m(88 lbf•i

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-3XP ModelF01D7WS25 N•m (18 lbf•ft)25 N•m(18 lbf•ft)Loctite24261219191440 N•m(30 lbf•ft)241517Loc

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-4TUNED PIPE REMOVALAll Models Except HX and XPNOTE : For SP series, remove air vent tubesupport

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-5Disconnect water supply hose and water injectionhose at tuned pipe head.1. Water supply hose2.

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-612, Tuned Pipe ConeMove tuned pipe cone in front of bilge betweenbody and fuel tank.Open storag

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-7Te st :– Use compressed air at 124 kPa (18 PSI) to pres-surize tuned pipe.NOTE : Prior to ver

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-816, Sealing RingHX and XP Model OnlyMake sure to install the sealing ring on tuned pipecone if

Section 04 ENGINESub-Section 05 (EXHAUST SYSTEM)04-05-9SPI, SPX, GTS and GTI Models5,21,22, Tuned Pipe Cone, Collar and ClampInstall tuned pipe cone w