2003 SeaDoo GTI, GTI LE, GTI LE RFI, GTX DI, XP DI Manual
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2003
Shop Manual
GTI, GTI LE, GTI LE RFI, GTX DI,
XP DI, RX DI, LRV DI, GTX 4-TEC SERIES
www.SeaDooManuals.net
Legal deposit:
National Library of Quebec
2
nd
trimester 2003
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. 2003
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®
*Registered trademarks of Bombardier Inc.
Knight’s Spray-Nine
†
is a trademark of Korkay System Ltd
GTX
†
is a trademark of Castrol Ltd. Used under license
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
The following trademarks are the property of Bombardier Inc. or its subsidiaries:
SEA-DOO
®
BOMBARDIER-ROTAX
®
BOMBARDIER LUBE
®
BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil
BOMBARDIER Formula XP-S DI Synthetic Injection Oil
BOMBARDIER-ROTAX Injection Oil
Sea-Doo Synthetic Grease
Sea-Doo LK
TM
DESS
TM
Rotax
®
O.P.A.S.
TM
TOPS
TM
www.SeaDooManuals.net
SMR2003_001_00_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 (2-stroke) 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 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 system.................................................................... 05-07-1
08 - Cylinder head and valves........................................................... 05-08-1
09 - Engine block .............................................................................. 05-09-1
06 ENGINE
MANAGEMENT (RFI)
01 - Table of contents ...................................................................... 06-01-1
02 - Overview................................................................................... 06-02-1
03 - Diagnostic procedures .............................................................. 06-03-1
04 - Component inspection .............................................................. 06-04-1
05 - Troubleshooting summary ........................................................ 06-05-1
06 - Adjustment................................................................................ 06-06-1
07 - Removal and installation ........................................................... 06-07-1
07 ENGINE
MANAGEMENT (DI)
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 ENGINE
MANAGEMENT
(4-TEC)
01 - Table of contents ...................................................................... 08-01-1
02 - Overview................................................................................... 08-02-1
03 - Component inspection and adjustment .................................... 08-03-1
04 - Diagnostic procedures .............................................................. 08-04-1
09 COOLING SYSTEM 01 - Table of contents ...................................................................... 09-01-1
02 - Circuit, components and care ................................................... 09-02-1
TABLE OF CONTENTS
www.SeaDooManuals.net
II SMR2003_001_00_00A2.FM
SECTION SUBSECTION
PAGE
10 FUEL SYSTEM 01 - Table of contents ...................................................................... 10-01-1
02 - Fuel circuit ................................................................................ 10-02-1
03 - Air intake (2-stroke) ................................................................... 10-03-1
04 - Carburetor ................................................................................. 10-04-1
11 LUBRICATION
SYSTEM (2-stroke)
01 - Table of contents ...................................................................... 11-01-1
02 - Oil injection system .................................................................. 11-02-1
03 - Oil injection pump ..................................................................... 11-03-1
12 ELECTRICAL
SYSTEM
01 - Table of contents ...................................................................... 12-01-1
02 - Ignition system (carbureted engines) ....................................... 12-02-1
03 - Charging system....................................................................... 12-03-1
04 - Starting system......................................................................... 12-04-1
05 - Instruments and accessories .................................................... 12-05-1
06 - DESS (carbureted and RFI engines).......................................... 12-06-1
13 PROPULSION
SYSTEM
01 - Table of contents ...................................................................... 13-01-1
02 - Jet pump................................................................................... 13-02-1
03 - Drive system............................................................................. 13-03-1
04 - Reverse system........................................................................ 13-04-1
05 - Variable trim system ................................................................. 13-05-1
14 STEERING SYSTEM 01 - Table of contents ...................................................................... 14-01-1
02 - Steering system........................................................................ 14-02-1
03 - Alignment ................................................................................. 14-03-1
15 SUSPENSION 01 - Table of contents ...................................................................... 15-01-1
02 - Direct action suspension .......................................................... 15-02-1
16 HULL/BODY 01 - Table of contents ...................................................................... 16-01-1
02 - Adjustment and repair .............................................................. 16-02-1
17 TECHNICAL DATA 01 - GTI and GTI LE models ............................................................. 17-01-1
02 - GTI LE RFI models .................................................................... 17-02-1
03 - GTX DI, RX DI and XP DI models.............................................. 17-03-1
04 - LRV DI models .......................................................................... 17-04-1
05 - GTX 4-TEC models.................................................................... 17-05-1
18 WIRING DIAGRAMS 01 - Wiring diagrams ........................................................................ 18-01-1
TABLE OF CONTENTS
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SMR2003_001_00_00A2.FM III
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair all 2003 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
www.SeaDooManuals.net
IV SMR2003_001_00_00A2.FM
INTRODUCTION 0
This Shop Manual covers the following
BOMBARDIER made SEA-DOO
®
2003 watercraft
models.
HULL IDENTIFICATION NUMBER
(H.I.N.)
It is located on footboard at the rear of watercraft.
1. Hull Identification Number (H.I.N.)
TYPICAL
1. Hull Identification Number (H.I.N.)
MODELS
ENGINE
TYPE
MODEL
NUMBER
XP DI 947 DI 6131
XP DI International 947 DI 6130
GTI (blue) International 717 5568
GTI (ultraviolet) 717 5598
GTI California
(ultraviolet)
717 5567
GTI International
(ultraviolet)
717 5597
GTI LE (earthen clay) 717 6102
GTI LE International
(earthen clay)
717 6101
GTI LE RFI 787 RFI 6104
GTI LE RFI International 787 RFI 6103
GTX DI 947 DI 6119
GTX DI International 947 DI 6118
RX DI 947 DI 6123
RX DI International 947 DI 6122
LRV DI 947 DI 5771
GTX 4-TEC 1503 6112
GTX 4-TEC International 1503 6111
GTX 4-TEC Vans Triple
Crown Edition
1503 6126
GTX 4-TEC Vans Triple
Crown Edition
International
1503 6125
GTX 4-TEC Supercharged
(viper red)
1503 6129
GTX 4-TEC Supercharged
International (viper red)
1503 6128
GTX 4-TEC Supercharged
(yellow)
1503 6106
GTX 4-TEC Supercharged
International (yellow)
1503 6105
GTX 4-TEC Supercharged
Limited
1503 6108
GTX 4-TEC Supercharged
Limited International
1503 6107
F08L0QA 1
INTRODUCTION
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SMR2003_001_00_00A2.FM V
All Models
The Hull Identification Number is composed of 12
digits:
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
717 Engines
The Engine Identification Number is located on the
upper side of the magneto housing.
TYPICAL
1. Engine Identification Number (E.I.N.)
787 RFI Engines
The Engine Identification Number is located on the
upper crankcase on PTO side.
1. Engine Identification Number (E.I.N.)
947 DI Engines
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 many major sections as
you can see in the main table of contents at the
beginning of the manual.
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 SMR2003_001_00_00A2.FM
INTRODUCTION
www.SeaDooManuals.net
SMR2003_001_00_00A2.FM VII
INTRODUCTION
www.SeaDooManuals.net
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If you own a 2003 SeaDoo GTI, GTI LE, GTI LE RFI, GTX DI, XP DI, RX DI, LRV DI, GTX 4-TEC (6131/6130/5568/5567/5597/6102/6101/6104/6103/6119/6118/6123/6122/5771/6112/6111/6126//6129/6128/6106/6105/6108/6107), this complete service/repair manual is for you. It contains detailed instructions and step-by-step diagrams for all workshop procedures, making it useful for both professional mechanics and DIY enthusiasts.
This manual is in .PDF format, making it easy to print and read the information and notes. It covers the following models:
- 2003 SeaDoo GTI
- GTI LE
- GTI LE RFI
- GTX DI
- XP DI
- RX DI
- LRV DI
- GTX 4-TEC (6131/6130/5568/5567/5597/6102/6101/6104/6103/6119/6118/6123/6122/5771/6112/6111/6126//6129/6128/6106/6105/6108/6107)
The service repair manual covers the following:
- INTRODUCTION
- 01 SERVICE TOOLS AND PRODUCTS
- 02 MAINTENANCE
- 03 TROUBLESHOOTING
- 04 ENGINE (2-STROKE)
- 05 ENGINE (4-TEC)
- 06 ENGINE MANAGEMENT (RFI)
- 07 ENGINE MANAGEMENT (DI)
- 08 ENGINE MANAGEMENT (4-TEC)
- 09 COOLING SYSTEM
- 10 FUEL SYSTEM
- 11 LUBRICATION SYSTEM
- 12 ELECTRICAL SYSTEM
- 13 PROPULSION SYSTEM
- 14 STEERING SYSTEM
- 15 SUSPENSION
- 16 HULL/BODY
- 17 TECHNICAL DATA
- 18 WIRING DIAGRAMS
Product Details:
- File Format: .PDF
- Compatible: All Versions of Windows & Mac
- Language: English
- Printable: without any restriction
- Delivery: link will appear on the checkout page after payment is complete
- Requirements: Adobe Reader
How to get it?
After you click the BUY NOW button to complete this purchase, you can instantly download it. With it, you can save much money. Besides, you don't need to pay the extra cost and wait for the delivery.
