2000 SEADOO GS-GTI-GTS-GTX-XP-GSX-RFI-GTX-RFI-RX-RX-DI-GTX-DI Service Manual

www.SeaDooManuals.net

2000 Shop Manual VOLUME 1 GS/GTI/GTS/GTX/XP GSX RFI/GTX RFI www.SeaDooManuals.net

Legal deposit: National Library of Quebec 2 nd trimester 2000 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. 2000 Technical Publications Bombardier Inc. Valcourt (Quebec) Canada 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

SMR2000_001_00A2.FM I ‘ SECTION SUBSECTION PAGE SAFETY NOTICE .................................................................................................................................. III WHAT’S NEW ....................................................................................................................................... IV INTRODUCTION ................................................................................................................................... VI 01 SERVICE TOOLS AND PRODUCTS 01 - Table of contents ...................................................................... 01-01-1 02 - Mandatory service tools ............................................................ 01-02-1 03 - Optional service tools................................................................ 01-03-1 04 - Service products ....................................................................... 01-04-1 02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1 02 - Periodic inspection chart ........................................................... 02-02-1 03 - Flushing and lubrication............................................................. 02-03-1 04 - Water-flooded engine................................................................ 02-04-1 05 - Storage ...................................................................................... 02-05-1 03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1 04 ENGINE 01 - Table of contents ...................................................................... 04-01-1 02 - Leak test ................................................................................... 04-02-1 03 - Removal and installation ........................................................... 04-03-1 04 - Magneto system ....................................................................... 04-04-1 05 - Top end ..................................................................................... 04-05-1 06 - Bottom end ............................................................................... 04-06-1 07 - Rotary valve............................................................................... 04-07-1 08 - Exhaust system......................................................................... 04-08-1 05 COOLING SYSTEM 01 - Table of contents ...................................................................... 05-01-1 02 - Circuit, components and care ................................................... 05-02-1 06 FUEL SYSTEM 01 - Table of contents ...................................................................... 06-01-1 02 - Fuel circuit ................................................................................. 06-02-1 03 - Air intake ................................................................................... 06-03-1 04 - Carburetor ................................................................................. 06-04-1 05 - Fuel injection ............................................................................. 06-05-1 07 LUBRICATION SYSTEM 01 - Table of contents ...................................................................... 07-01-1 02 - Oil injection system................................................................... 07-02-1 03 - Oil injection pump ..................................................................... 07-03-1 08 ELECTRICAL SYSTEM 01 - Table of contents ...................................................................... 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 01 - Table of contents ...................................................................... 09-01-1 02 - Jet pump ................................................................................... 09-02-1 03 - Drive system ............................................................................. 09-03-1 04 - Reverse system ........................................................................ 09-04-1 05 - Variable trim system ................................................................. 09-05-1 TABLE OF CONTENTS www.SeaDooManuals.net

II SMR2000_001_00A2.FM 10 STEERING SYSTEM 01 - Table of contents ...................................................................... 10-01-1 02 - Steering system........................................................................ 10-02-1 03 - Adjustable steering ................................................................... 10-03-1 04 - Alignment ................................................................................. 10-04-1 11 SUSPENSION 01 - Table of contents ...................................................................... 11-01-1 02 - Direct action suspension .......................................................... 11-02-1 12 HULL/BODY 01 - Table of contents ...................................................................... 12-01-1 02 - Adjustment and repair .............................................................. 12-02-1 13 TECHNICAL DATA 01 - GS ............................................................................................. 13-01-1 02 - XP ............................................................................................. 13-02-1 03 - GTS ........................................................................................... 13-03-1 04 - GTI and GTX.............................................................................. 13-04-1 05 - GTX RFI and GSX RFI ............................................................... 13-05-1 14 WIRING DIAGRAMS 01 - Wiring diagrams ........................................................................ 14-01-1 TABLE OF CONTENTS www.SeaDooManuals.net

SMR2000_001_00A2.FM III SAFETY NOTICE 0 This manual has been prepared as a guide to correctly service and repair some 2000 SEA-DOO watercraft. See model list below. This edition was primarily published to be used by watercraft mechanic technicians who are already familiar with all service procedures relating to Bombardier made watercraft. Mechanic technicians should intent to continuous training courses given by Bombardier Training Dept. Please note that the instructions will apply only if proper hand tools and special service tools are used. This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts Catalog. It is understood that this manual may be translated into another language. In the event of any discrepancy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts. 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. The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab, self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols: CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. 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. 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 mechanic. It is understood that certain modifications may render use of the vehicle 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. SAFETY NOTICE www.SeaDooManuals.net

IV SMR2000_001_00A2.FM WHAT’S NEW 0 THIS SECTION INDICATES PROCEDURES THAT WERE MODIFIED OR NEWLY ADDED IN THIS MANUAL. INTRODUCTION • Self-locking fasteners procedure. • Loctite application procedure. • Tightening torques chart. SERVICE TOOLS AND PRODUCTS Added the following new tools: • VCK (Vehicle Communication Kit) for all models • bearing/seal installer tool for outlet end of 155.6 mm (6-1/8 in) pump • drive shaft alignment shaft for XP model. Added the following new products: • medium strength threadlocker Loctite 243 • Molykote 111. STORAGE • New procedure with air pressure to empty the cooling system. EXHAUST SYSTEM • New procedure to install tuned pipe on 787 RFI engine. • New procedure to remove and install tuned pipe on 947 engine. COOLING SYSTEM • New diagram for the cooling system (all engines). FUEL SYSTEM • Procedure to remove fuel tank on all models. AIR INTAKE • New procedure to install air intake on 947 engine. FUEL INJECTION • Fault codes chart (B.U.D.S. versus RFI). JET PUMP • New procedure for anti-rattle system. • New procedure for wear ring installation. WHAT’S NEW www.SeaDooManuals.net

SMR2000_001_00A2.FM V TECHNICAL DATA • Updated specifications for each model. WIRING DIAGRAMS • Updated wiring diagrams for each model. WHAT’S NEW www.SeaDooManuals.net

VI SMR2000_001_00A2.FM INTRODUCTION 0 This Shop Manual covers the following BOMBAR- DIER made SEA-DOO ® 2000 watercraft models. HULL IDENTIFICATION NUMBER (H.I.N.) GTS Only It is located at right hand rear side of hull. 1. Hull Identification Number (H.I.N.) All Other Models It is located on floorboard at the rear of the watercraft. TYPICAL 1. Hull Identification Number (H.I.N.) All Models The Hull Identification Number is composed of 12 digits: MODELS MODEL NUMBER GS .................................................... 5644 GS International .............................. 5827 GSX RFI ........................................... 5645 GSX RFI International ..................... 5654 XP ..................................................... 5651 XP International .............................. 5655 GTI .................................................... 5647 GTI International ............................. 5657 GTS International ............................ 5639 GTX .................................................. 5653 GTX International ........................... 5669 GTX RFI ............................................ 5648 GTX RFI International ..................... 5658 GTX RFI (green) .............................. 5515 GTX RFI International (green) ........ 5516   F08L0QA 1          INTRODUCTION www.SeaDooManuals.net

SMR2000_001_00A2.FM VII ENGINE IDENTIFICATION NUMBER (E.I.N.) 717 Engine The Engine Identification Number is located on the upper side of the magneto housing. TYPICAL 1. Engine Identification Number (E.I.N.) 787 RFI Engine The Engine Identification Number is located on the upper crankcase on PTO side. 1. Engine Identification Number (E.I.N.) 947 Engine The Engine Identification Number is located on the upper crankcase on MAGNETO side. 1. Engine Identification Number (E.I.N.) ARRANGEMENT OF THIS MANUAL The manual is divided into 14 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL SYSTEM 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 SUSPENSION 12 HULL/BODY 13 TECHNICAL DATA 14 WIRING DIAGRAMS Several sections are divided in various subsections. There is a table of contents at the beginning of many sections. 1 F01D01A     INTRODUCTION www.SeaDooManuals.net

2000 SEADOO GS-GTI-GTS-GTX-XP-GSX-RFI-GTX-RFI-RX-RX-DI-GTX-DI Service Manual

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