1999 Sea-Doo GSX Limited Service & Repair Manual

www.SeaDooManuals.net

1999 Shop Manual www.SeaDooManuals.net

Legal deposit: National Library of Quebec 1 st trimester 1999 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. 1999 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

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 TABLE OF CONTENTS www.SeaDooManuals.net

II 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 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 - SPX model ................................................................................ 13-01-1 02 - GS and GSX Limited ................................................................. 13-02-1 03 - XP Limited ................................................................................ 13-03-1 04 - GTS model ................................................................................ 13-04-1 05 - GTI and GTX Limited................................................................. 13-05-1 06 - GTX RFI and GSX RFI ............................................................... 13-06-1 14 WIRING DIAGRAMS 01 - Wiring diagrams ........................................................................ 14-01-1 TABLE OF CONTENTS www.SeaDooManuals.net

III SAFETY NOTICE 0 This manual was primarily published to be used by watercraft technicians trained by the manufactur- er 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 (e.g. lock tabs, self- locking fasteners, etc.) 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

IV WHAT’S NEW 0 THIS SECTION INDICATES PROCEDURES THAT WERE MODIFIED OR NEWLY ADDED IN THIS MAN- UAL. ALL SECTIONS • All sections, were applicable, are updated to include specifications and procedures regarding the GSX RFI and GTX RFI models (787 RFI engine). INTRODUCTION • List of 1999 Sea-Doo models with their corresponding model number. • A list of abbreviations used in the manual is added in this section. SERVICE TOOLS AND PRODUCTS • New tools for servicing RFI engine. • No more reference numbers to tools from other divisions (Ski-doo and/or Jet-boats). Part numbers are the same for all divisions. STORAGE 02-05 • Updated flushing procedure for the 947 engine according to the modification of the cooling water flow. ENGINE LEAK TEST 04-02 • Section updated to include leak test procedure for 947 engine. • Testing procedure for RFI engine added. EXHAUST SYSTEM 04-08 • New resonators added for noise reduction. Identification and procedure for removal and installation. COOLING SYSTEM 05-02 • Cooling system on the 947 engine has been modified. The cooling water flow through tuned pipe and engine is circulating the opposite direction. PRESSURE TEST 06-02 • Testing procedure for pressurized fuel system on the 787 RFI engine. AIR INTAKE 06-03 • Removal and installation procedure for new air intake silencer on 947 engine. CARBURETOR 06-04 • New throttle cable with sensor and new procedure for throttle cable adjustment. WHAT’S NEW www.SeaDooManuals.net

V FUEL INJECTION 06-05 • New section added to properly service and troubleshoot fuel injection system on GSX RFI and GTX RFI models. OIL INJECTION PUMP 07-03 • New oil injection pump cable adjustment procedure for the 947 engine. IGNITION SYSTEM 08-02 • This subsection has been rearranged and updated. • Explanation of the MPEM functions were added. • The timing correction chart is different from previous year. ADJUSTABLE STEERING SYSTEM 10-03 • New subsection added for removal, inspection and installation of the adjustable steering mechanism used on the GTX RFI. TECHNICAL DATA 13-01 • Updated specifications for each models including GTX RFI and GSX RFI. WIRING DIAGRAMS 14-01 • Information added regarding Deutsch connectors and Packard connectors. WHAT’S NEW www.SeaDooManuals.net

VI INTRODUCTION 0 This Shop Manual covers the following BOMBAR- DIER made SEA-DOO ® 1999 watercraft models. HULL IDENTIFICATION NUMBER (H.I.N.) SPX and GTS Models 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. 1. Hull Identification Number (H.I.N.) MODELS MODEL NUMBER SPX International ............................ 5636 GSX RFI (yellow) ............................. 5637 GSX RFI (Aztec) ............................... 5638 SPX .................................................. 5828 GSX RFI (yellow) International ...... 5652 GSX RFI (Aztec) International ........ 5829 GS International .............................. 5846 GS .................................................... 5847 GSX Limited International.............. 5848 GSX Limited ................................... 5849 XP Limited International................. 5868 XP Limited ....................................... 5869 GTS .................................................. 5883 GTI International ............................. 5884 GTI .................................................... 5885 GTX RFI International ..................... 5886 GTX RFI ............................................ 5887 GTX Limited International .............. 5888 GTX Limited .................................... 5889 F01L8XA 1 F08L0QA 1 INTRODUCTION www.SeaDooManuals.net

VII All Models The Hull Identification Number is composed of 9 digits: 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 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.) Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number* F00A0CA Month of production Year of production *A letter may also be used as a digit. 1 F01D01A F01D87A 1 F06D15A 1 INTRODUCTION www.SeaDooManuals.net

1999 Sea-Doo GSX Limited Service & Repair Manual

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