1998 Seadoo GTX RFI GS Service & Repair Manual

www.SeaDooManuals.net

Legal deposit: National Library of Quebec National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1998 Printed in Canada ® *Registered trademarks of Bombardier Inc. Loctite ® is a trademark of Loctite Corporation Snap-on ® is a trademark of Snap-on Tools Corporation Gelcote ® is a trademark of Gelcote International Limited www.SeaDooManuals.net

I SECTION SUBSECTION PAGE SAFETY NOTICE .................................................................................................................................. II 01 MAINTENANCE 01 - Table of contents ...................................................................... 01-01-1 02 - Periodic inspection chart ........................................................... 01-02-1 03 - Flushing and lubrication............................................................. 01-03-1 04 - Storage ...................................................................................... 01-04-1 02 ENGINE 01 - Table of contents ...................................................................... 02-01-1 02 - Magneto system ....................................................................... 02-02-1 03 - Crankcase.................................................................................. 02-03-1 03 COOLING SYSTEM 01 - Table of contents ...................................................................... 03-01-1 02 - Circuit ........................................................................................ 03-02-1 04 FUEL SYSTEM 01 - Table of contents ...................................................................... 04-01-1 02 - Fuel injection ............................................................................. 04-02-1 05 ELECTRICAL SYSTEM 01 - Table of contents ...................................................................... 05-01-1 02 - Ignition system.......................................................................... 05-02-1 03 - Charging system ....................................................................... 05-03-1 06 TECHNICAL DATA 01 - GTX RFI Model .......................................................................... 06-01-1 07 WIRING DIAGRAM 01 - GTX RFI Model .......................................................................... 07-01-1 TABLE OF CONTENTS www.SeaDooManuals.net

II SAFETY NOTICE 0 This manual was primarily published to be used by watercraft technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made Sea-Doo watercraft. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into another language. In the event of any discrepan- cy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at its time of manufac- ture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufac- turing the product. The use of Bombardier parts is most strongly recommended when considering replacement of any com- ponent. Dealer and/or distributor assistance should be sought in case of doubt. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking disk, lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols: NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier watercraft and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional technician. It is understood that certain modifications may render use of the watercraft illegal under existing federal, provincial and state regulations. ◆ WARNING Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. - CAUTION Denotes an instruction which, if not followed, could severely damage watercraft components. SAFETY NOTICE www.SeaDooManuals.net

01-01-1 Section 01 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 0 PERIODIC INSPECTION CHART............................................................................................ 01-02-1 FLUSHING AND LUBRICATION............................................................................................ 01-03-1 GENERAL ........................................................................................................................... 01-03-1 PROCEDURE ...................................................................................................................... 01-03-1 STORAGE............................................................................................................................... 01-04-1 www.SeaDooManuals.net

Section 01 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) 01-02-1 PERIODIC INSPECTION CHART 0 NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency. ➀ Every 10 hours in salt water use. ➁ These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in this chart. ➂ Daily flushing in salt water or foul water use. DESCRIPTION FREQUENCY Every 10 hours Every 25 hours Every 50 hours Every 100 hours or seasonally Lubrication/corrosion protection of metallic components ➀ Engine ignition timing Spark plug replacement Fuel injector cleaning Fuel injection sensors verification Throttle cable, inspection/lubrication ➀ Flame arrester inspection Throttle cable adjustment RAVE valve cleaning Engine counterbalance shaft oil level Water flow regulator valve inspection Oil injection pump adjustment Oil filter inspection Oil filter replacement Engine head bolts, retorque Steering system inspection Reverse system/reverse cable adjustment Fastener tightening (flame arrester support, throttle body, engine mount, exhaust system, etc.) Muffler, battery and reservoir fastening devices Fuel/oil lines, check valve and hose inspection, fuel system pressurization Fuel/vent line pressure relief valve inspection Bailer pick up inspection Battery condition Ground connections (starter, battery, etc.) Monitoring beeper Jet pump reservoir oil level/oil condition Jet pump oil replacement Jet pump cover pusher inspection Impeller condition and impeller/wear ring clearance ➁ Drive shaft boot/spline condition (both ends) ➁ PTO flywheel lubrication Floating ring and boot inspection Water intake grate condition ➁ Hull condition Cooling system flushing ➂ www.SeaDooManuals.net

Section 01 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) 01-03-1 FLUSHING AND LUBRICATION 0 GENERAL Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. It will help to clean up sand, salt, shells or other particles in water jackets (engine, exhaust manifold, tuned pipe) and/or hoses. Flushing and engine lubrication should be per- formed when the watercraft is not expected to be used further the same day or when the watercraft is stored for any extended time. PROCEDURE Clean jet pump by spraying water in its inlet and outlet and then spray BOMBARDIER LUBE lubricant. To flush engine, connect a garden hose to the water outlet located at the rear of the watercraft. 1. Water outlet NOTE: A quick connect adapter is supplied with the watercraft and can be used to ease garden hose installation. 1. Quick connect adapter 1. Garden hose installed with quick connect adapter - CAUTION Failure to flush cooling system, when neces- sary, will severely damage engine and/or exhaust system. Never flush a hot engine. Make sure engine operates during entire procedure. ◆ WARNING Perform this operation in a well ventilated area. Do not touch any electrical parts or jet pump area when engine is running. ◆ WARNING Always remove safety lanyard cap from switch to prevent accidental engine starting before cleaning the jet pump area. Engine must not be running for this operation. F06E01A 1 F00E01A 1 F07E01A 1 www.SeaDooManuals.net

Section 01 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) 01-03-2 Start the engine then immediately open the water tap. Run the engine about 3 minutes at a fast idle around 3500 RPM. Spray BOMBARDIER LUBE lubricant through air intake silencer keeping engine at fast idle. 1. Air intake silencer 2. Pull plug 3. Spray BOMBARDIER LUBE here NOTE: Lubrication of engine should be done at least for 1 minute. Close the water tap then stop the engine. Disconnect the garden hose. Wipe up any residual water from the engine. Remove spark plug cables and connect them on the grounding device near the tuned pipe. 1. Grounding device Remove both spark plugs and spray BOMBAR- DIER LUBE lubricant into each cylinder. NOTE: For the storage period, use Bombardier storage oil (P/N 413 711 600). Fully apply the throttle lever then depress the start/stop button to crank the engine a few turns to distribute the oil onto cylinder wall. Apply anti-seize lubricant on spark plug threads then reinstall them. Reinstall plug on air intake silencer cover. NOTE: Engine fogging should be done whenever the watercraft is to be stored for a few days or a long period. ; WARNING Do not touch any electrical parts or jet pump area when engine is running. - CAUTION Never flush a hot engine. Always start the engine before opening the water tap. Open water tap immediately after engine is start- ed to prevent overheating. - CAUTION Always close the water tap before stopping the engine. - CAUTION Remove quick connect adapter after flushing operation (if used). F01F25A 1 2 3 ; WARNING Always use spark plug cable grounding device when removing spark plugs. - CAUTION Never leave rags or tools in the engine compartment or in the bilge. F07H0AA 1 www.SeaDooManuals.net

Section 01 MAINTENANCE Subsection 04 (STORAGE) 01-04-1 STORAGE 0 Engine Draining Disconnect the water supply hose used to cool the magneto. It features a quick connect fitting. Press both tabs and pull fitting in order to disconnect hose. This hose is located at the bottom of the magneto cover beside the engine support. 1. Disconnect this hose Water should flow out of the fitting (magneto cooling circuit) and hose (crankcase heat exchanger). 1. Make sure water flows out of fitting and hose Fuel System Sea-Doo Fuel Stabilizer (P/N 413 408 600) should be added in fuel tank to prevent fuel deterioration. Follow manufacturer’s instructions for proper use. NOTE: Fuel stabilizer should be added prior engine lubrication. Cooling System Flushing and Engine Internal Lubrication Cooling system has to be flushed with fresh water to prevent salt, sand or dirt accumulation which will clog water passages. Engine must be lubricated to prevent corrosion on internal parts. For proper procedure, refer to FLUSHING AND LUBRICATION 01-03. Propulsion System JET PUMP Lubricant in impeller shaft reservoir should be drained. Reservoir should be cleaned and refilled with SEA-DOO synthetic 75W90 GL5 polyolester oil. Refer to the 1998 Sea-Doo Shop Manual for proper procedure. F07E05A 1 F07E06A 1 1 - CAUTION Water in engine must be free to flow out. Should water freeze in engine, severe damage will occur. ◆ WARNING Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. www.SeaDooManuals.net

Section 01 MAINTENANCE Subsection 04 (STORAGE) 01-04-2 PTO FLYWHEEL Lubricate PTO flywheel at grease fitting with synthetic grease (P/N 293 550 010). 1. Grease PTO flywheel Battery For battery removal, cleaning and storage, refer to the 1998 Sea-Doo Shop Manual. Watercraft Cleaning Clean the bilge with hot water and mild detergent or with bilge cleaner. Rinse thoroughly. Lift front end of watercraft to completely drain bilge. If any repairs are needed to body or to the hull, touch up paint and Gelcote ® repair kit are available. Replace damaged labels/decals. Wash the body with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull. Apply a nonabrasive wax. If the watercraft is to be stored outside, cover it with an opaque tarpaulin to prevent sun rays and grime from affecting the plastic components, watercraft finish as well as preventing dust accumulation. Anticorrosion Treatment Wipe off any residual water in the engine compartment. Spray BOMBARDIER LUBE lubricant over all metallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant. The front seat should be partially left opened during storage. This will avoid engine compartment condensation and possible corrosion. Additional Recommended Protection In cool regions (where freezing point may be en- countered), cooling system should be filled with water and antifreeze solution. - CAUTION Do not lubricate excessively. Immediately stop when a slight movement is noticed on rubber boot. - CAUTION Never leave any clothing, tool or other ob- jects near PTO flywheel and drive shaft. F01I0BA 1 - CAUTION Never clean fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc. - CAUTION The watercraft must never be Ieft in water for storage. Never leave the watercraft stored in direct sunlight. - CAUTION Always use ethylene-glycol antifreeze con- taining corrosion inhibitors specifically recommended for aluminum engines. www.SeaDooManuals.net

1998 Seadoo GTX RFI GS Service & Repair Manual

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