2002 Sea-Doo Watercraft Service & Repair Manual
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2002
Shop Manual
Volume 2
GTX DI, GTX 4-TEC
www.SeaDooManuals.net
Legal deposit:
National Library of Quebec
2
nd
trimester 2002
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. 2002
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
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SMR2002-053_00A2.FM I
SECTION SUBSECTION
PAGE
SAFETY NOTICE .................................................................................................................................. III
INTRODUCTION ................................................................................................................................... IV
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 (DI) 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 - Exhaust system......................................................................... 04-07-1
05 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 05-01-1
02 - Leak test ................................................................................... 05-02-1
03 - Intake system............................................................................ 05-03-1
04 - Exhaust system......................................................................... 05-04-1
05 - Removal and installation ........................................................... 05-05-1
06 - PTO housing/Magneto .............................................................. 05-06-1
07 - Lubrication................................................................................. 05-07-1
08 - Cylinder head and valves........................................................... 05-08-1
09 - Engine block .............................................................................. 05-09-1
06 ENGINE
MANAGEMENT (DI)
01 - Table of contents ...................................................................... 06-01-1
02 - Overview................................................................................... 06-02-1
03 - Component inspection and adjustment .................................... 06-03-1
04 - Diagnostic procedures .............................................................. 06-04-1
07 ENGINE
MANAGEMENT
(4-TEC)
01 - Table of contents ...................................................................... 07-01-1
02 - Overview................................................................................... 07-02-1
03 - Component inspection and adjustment .................................... 07-03-1
04 - Diagnostic procedures .............................................................. 07-04-1
08 COOLING SYSTEM 01 - Table of contents ...................................................................... 08-01-1
02 - Circuit, components and care ................................................... 08-02-1
09 FUEL SYSTEM 01 - Table of contents ...................................................................... 09-01-1
02 - Fuel circuit ................................................................................. 09-02-1
03 - Air intake (DI)............................................................................. 09-03-1
10 LUBRICATION
SYSTEM (DI)
01 - Table of contents ...................................................................... 10-01-1
02 - Oil injection system................................................................... 10-02-1
03 - Oil injection pump ..................................................................... 10-03-1
TABLE OF CONTENTS
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II SMR2002-053_00A2.FM
11 ELECTRICAL
SYSTEM
01 - Table of contents ...................................................................... 11-01-1
02 - Charging system....................................................................... 11-02-1
03 - Starting system......................................................................... 11-03-1
04 - Instruments and accessories .................................................... 11-04-1
12 PROPULSION
SYSTEM
01 - Table of contents ...................................................................... 12-01-1
02 - Jet pump................................................................................... 12-02-1
03 - Drive system............................................................................. 12-03-1
04 - Reverse system........................................................................ 12-04-1
13 STEERING
SYSTEM
01 - Table of contents ...................................................................... 13-01-1
02 - Steering system........................................................................ 13-02-1
03 - Alignment ................................................................................. 13-03-1
14 HULL/BODY 01 - Table of contents ...................................................................... 14-01-1
02 - Adjustment and repair .............................................................. 14-02-1
15 TECHNICAL DATA 01 - GTX DI model ........................................................................... 15-01-1
02 - GTX 4-TEC model ..................................................................... 15-02-1
16 WIRING DIAGRAMS 01 - Wiring diagrams ........................................................................ 16-01-1
TABLE OF CONTENTS
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SMR2002-053_00A2.FM III
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair 2002 SEA-DOO watercraft. See
model list below.
This edition was primarily published to be used by watercraft mechanical technicians who are already
familiar with all service procedures relating to Bombardier made watercraft. Mechanical technicians
should attend 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
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IV SMR2002-053_00A2.FM
INTRODUCTION 0
This Shop Manual covers the following BOMBAR-
DIER made SEA-DOO
®
2002 watercraft models.
HULL IDENTIFICATION NUMBER
(H.I.N.)
It is located on footboard at the rear of watercraft.
GTX DI and GTX 4-TEC
1. Hull Identification Number (H.I.N.)
The Hull Identification Number is composed of 12
digits:
MODELS
ENGINE
TYPE
MODEL
NUMBER
GTX DI International
(green)
947 DI 5563
GTX DI (green) 947 DI 5564
GTX 4-TEC International
(red)
1503 5573
GTX 4-TEC (red) 1503 5574
GTX 4-TEC International
(blue)
1503 5593
GTX 4-TEC (blue) 1503 5594
GTX DI International
(blue)
947 DI 5595
GTX DI (blue) 947 DI 5596
INTRODUCTION
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SMR2002-053_00A2.FM V
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
947 DI Engine
The Engine Identification Number is located on the
upper side of the magneto housing.
TYPICAL
1. Engine Identification Number (E.I.N.)
1503 Engine
The Engine Identification Number is located be-
side the oil separator.
1. Engine Identification Number (E.I.N.)
ARRANGEMENT OF THIS
MANUAL
The manual is divided into 16 major sections:
01 SERVICE TOOLS AND PRODUCTS
02 MAINTENANCE
03 TROUBLESHOOTING
04 ENGINE (DI)
05 ENGINE (4-TEC)
06 ENGINE MANAGEMENT (DI)
07 ENGINE MANAGEMENT (4-TEC)
08 COOLING SYSTEM
09 FUEL SYSTEM
10 LUBRICATION SYSTEM (DI)
11 ELECTRICAL SYSTEM
12 PROPULSION SYSTEM
13 STEERING SYSTEM
14 HULL/BODY
15 TECHNICAL DATA
16 WIRING DIAGRAMS
Several sections are divided in various subsections.
There is a table of contents at the beginning of
many sections.
1
F01D01A
INTRODUCTION
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VI SMR2002-053_00A2.FM
INTRODUCTION
www.SeaDooManuals.net
SMR2002-053_00A2.FM VII
INTRODUCTION
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Lifetime Access
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Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$35.99
Enhance the performance and longevity of your 2002 Sea-Doo Watercraft with this comprehensive Service & Repair Manual. Ideal for personal watercraft owners and marine technicians, this manual provides extensive instructions for maintenance, troubleshooting, and repairs of various 2002 Sea-Doo models. It includes step-by-step procedures, clear illustrations, and detailed exploded-view diagrams.
The 2002 Sea-Doo lineup, known for its innovation and excitement on the water, requires precise maintenance and skilled repairs to maintain its optimal performance. This manual covers a wide range of Sea-Doo watercraft models, offering all the expert knowledge and procedures recommended by Sea-Doo.
From engine servicing and tuning to jet pump maintenance, electrical system diagnostics, and hull repairs, this manual addresses a broad spectrum of topics. The instructions are clear and easy to follow, supported by detailed visuals, making maintenance and repair tasks manageable for both professional technicians and DIY enthusiasts with a passion for water sports.
Presented in a digital format, this manual is accessible on various devices, including PCs, tablets, and smartphones. This format allows for quick information retrieval and efficient navigation, enhancing your repair and maintenance experience compared to traditional paper manuals. It's an essential tool for ensuring your 2002 Sea-Doo Watercraft continues to perform at its best on the water.
Printable: Yes
Language: English
Compatibility: Compatible across a wide range of devices including PCs, Macs, smartphones, and tablets.
Requirements: A PDF reader like Adobe Reader (free)
Models covered:
- GTI
- GTI
- GTI LE
- GTI LE
- GTX
- GTX RFI
- RX
- RX DI
- XP
- LRV DI
