1996 SEADOO SP SPX SPI GTS GTI XP HX JETSKI Service Manual

www.SeaDooManuals.net

0 SHOP MANUAL 0 ® 219 100 031 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 writ- ten permission of Bombardier Inc. cBombardier Inc. 1995 Printed in Canada r*Registered trademarks of Bombardier Inc. Loctiter is a trademark of Loctite Corporation Snap-onr is a trademark of Snap-on Tools Corpo- ration Gelcoter is a trademark of Gelcote International Limited www.SeaDooManuals.net

i TABLE OF CONTENTS SECTION SUBJECT PAGE SAFETY NOTICE .............................................................................................................. II INTRODUCTION ............................................................................................................... III 01 SERVICE TOOLS AND PRODUCTS 01 - Mandatory Tools .............................................................................................. 01-01-1 02 - Recommended Tools ....................................................................................... 01-02-1 03 - Service Products .............................................................................................. 01-03-1 02 MAINTENANCE 00 - Table of Contents ............................................................................................. 02-00-1 01 - Periodic Inspection Chart ................................................................................. 02-01-1 02 - Flushing and Lubrication .................................................................................. 02-02-1 03 - Water-Flooded Engine ..................................................................................... 02-03-1 04 - Storage ............................................................................................................ 02-04-1 03 TROUBLESHOOTING ..................................................................................................................................... 03-00-1 04 ENGINE 00 - Table of Contents ............................................................................................. 04-00-1 01 - Removal and Installation .................................................................................. 04-01-1 02 - Top End ............................................................................................................ 04-02-1 03 - Bottom End...................................................................................................... 04-03-1 04 - Rotary Valve ..................................................................................................... 04-04-1 05 - Exhaust System............................................................................................... 04-05-1 05 COOLING SYSTEM 00 - Table of Contents ............................................................................................. 05-00-1 01 - Components .................................................................................................... 05-01-1 02 - Circuit............................................................................................................... 05-02-1 06 FUEL SYSTEM 00 - Table of Contents ............................................................................................. 06-00-1 01 - Fuel Circuit ....................................................................................................... 06-01-1 02 - Air Intake.......................................................................................................... 06-02-1 03 - Carburetors ...................................................................................................... 06-03-1 07 LUBRICATION SYSTEM 00 - Table of Contents ............................................................................................. 07-00-1 01 - Oil Injection System......................................................................................... 07-01-1 02 - Oil Injection Pump ........................................................................................... 07-02-1 08 ELECTRICAL SYSTEM 00 - Table of Contents ............................................................................................. 08-00-1 01 - Magneto System ............................................................................................. 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 00 - Table of Contents ............................................................................................. 09-00-1 01 - Jet Pump ......................................................................................................... 09-01-1 02 - Drive System ................................................................................................... 09-02-1 03 - Reverse System .............................................................................................. 09-03-1 04 - Variable Trim System ....................................................................................... 09-04-1 10 STEERING SYSTEM 00 - Table of Contents ............................................................................................. 10-00-1 01 - SP and XP Series ............................................................................................. 10-01-1 02 - GTS and GTI Models........................................................................................ 10-02-1 03 - HX Model ......................................................................................................... 10-03-1 04 - Alignment ........................................................................................................ 10-04-1 11 SUSPENSION 00 - Table of Contents ............................................................................................. 11-00-1 01 - Direct Action Suspension ................................................................................ 11-01-1 12 HULL / BODY 00 - Table of Contents ............................................................................................. 12-00-1 01 - Adjustment and Repair .................................................................................... 12-01-1 02 - Painting ............................................................................................................ 12-02-1 13 TECHNICAL DATA 01 - SP and SPI Models .......................................................................................... 13-01-1 02 - SPX and XP Models ......................................................................................... 13-02-1 03 - GTS and GTI Models........................................................................................ 13-03-1 04 - HX Model ......................................................................................................... 13-04-1 14 WIRING DIAGRAMS..........................................................................................................................................14-00-1 www.SeaDooManuals.net

00-0-2 SAFETY NOTICE SAFETY NOTICE 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 component. Dealer and / or distributor assistance should be sought in case of doubt. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.þ: 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 symbolsþ; 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. NOTE : þIndicates 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. ; - www.SeaDooManuals.net

00-0-3 1996 BOMBARDIER WATERCRAFT SHOP MANUAL INTRODUCTION This Shop Manual covers BOMBARDIER made SEA-DOO® watercraft models SPþ5876, SPX 5877, SPI 5878, XPþ5858, HX 5881, GTSþ5817 and GTIþ5865þ/þ5866. HULL IDENTIFICATION NUMBER (H.I.N.) It is located at right rear side of hull. 1. Hull Identification Number (H.I.N.) The Hull Identification Number is composed of 9 digitsþ: ENGINE IDENTIFICATION NUMBER (E.I.N.) All Engines Except the 787 The Engine Identification Number is located on the upper side of the magneto housing. 1. Engine Identification Number (E.I.N.) 787 Engine Only The Engine Identification Number is located on the upper side of the crankcase on PTO side. 1. Engine Identification Number (E.I.N.) F01L45A 1 Z Z N 1* 2 3 4 5 L 4 9 5 Model year Serial number *This digit may be a number or a letter. F00A0CA Month of production Year of production 1 F01D01A F01D87A 1 www.SeaDooManuals.net

00-0-4 1996 BOMBARDIER WATERCRAFT SHOP MANUAL ARRANGEMENT OF THIS MANUAL The manual is divided into 14 major sectionsþ: 01SERVICE TOOLS AND PRODUCTS 02MAINTENANCE 03TROUBLESHOOTING 04ENGINE 05COOLING SYSTEM 06FUEL SYSTEM 07LUBRICATION SYSTEM 08ELECTRICAL SYSTEM 09PROPULSION SYSTEM 10STEERING SYSTEM 11SUSPENSION 12HULL / BODY 13TECHNICAL DATA 14WIRING DIAGRAMS Several sections are divided in various sub-sections. There is a table of contents at the beginning of many sections. www.SeaDooManuals.net

00-0-5 1996 BOMBARDIER WATERCRAFT SHOP MANUAL Section 08 ELECTRICAL Sub-Section 01 (MAGNETO SYSTEM) MAGNETO SYSTEM 587 and 717 Engines 08-01-1 F01D4WS 12 11 5 N•m (44 lbf•in) 13 9 N•m (80 lbf•in) Loctite 242 4 6 8 Loctite 242 7 6 N•m (53 lbf•in) Loctite 242 6 N•m (53 lbf•in) 9 Loctite 242 5 6 N•m (53 lbf•in) 3 14 Loctite 242 4 Loctite 648 10 15 145 N•m (107 lbf•ft) Anti-seize lubricant 2 9 N•m (80 lbf•in) 1 Page heading indicates section and sub-section detailed. Tightening torque nearby fastener. In this case, nut must be torqued to 145 N•m (107 lbf•ft). Exploded view assits you in identifying parts and related positions. TYPICAL PAGE F01A09S Illustration number for publishing process. ▼ CAUTION : Pay attention to torque specifications. Some of these are in lbf•in instead of lbf•ft. Use appropriate torque wrench. Sub-section title indicates beginning of the sub-section. Dotted box contains parts of a particular model or an exploded view. Page numbering system : 08 : ELECTRICAL SYSTEM section 01 : MAGNETO SYSTEM sub-section 1 : First page of this sub-section Italic sub-tiltle above exploded view indicate pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 242 to screw threads. Bold face number indicates special procedure concerning this part. www.SeaDooManuals.net

00-0-6 1996 BOMBARDIER WATERCRAFT SHOP MANUAL 1 2 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 06-03-4 Step : Install pump gauge tester to pulse nipple Step : Pump tester until it reaches the desired pressure 1. Fuel outlet nipple 2. Fuel inlet nipple A. 28 kPa (4 PSI) 3, Diaphragm XP Model Only CARBURETOR REMOVAL Inspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.). PUMP DIAPHRAGM LEAK TEST TYPICAL To remove carburetors from engine, proceed as follows : Remove air vent tube support. Unlock retaining slides holding air intake silencer base. Remove air intake silencer base from watercraft. Remove screws holding flame arrester base support to cylinder head cover. Unscrew base retaining screws then remove base from carburetors and move to front of watercraft. Turn the valve to OFF position. O NOTE : For fuel line removal, use pliers (P / N 295 000 054). Disconnect pulse line from fuel pump. Disconnect fuel fuel supply line from fuel pump. Disconnect fuel return line. Disconnect oil injection pump cable, throttle cable and choke cable. Remove screws and lock washers retaining carburetors. Remove carburetors from intake manifold. All Others Models Remove 4 bolts and lock washers from rotary valve cover then move carburetors and rotary valve cover on top of engine. O NOTE : When removing rotary valve cover , pay attention that the rotary valve stay in place, other- wise it must be timed. Remove carburetors from intake manifold. Disconnect fuel bypass line between carburetors (twin carburetors). Remove carburetor(s) from rotary valve cover. DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester, perform the following test proceeding as follows : - Install pump gauge tester (P / N 295 000 083) on pulse nipple. - Pump tester until it reaches 28 kPa (4 PSI). Diaphragm must stand pressure for 10 seconds. If pressure drops, replace diaphragm. TYPICAL PAGE Sub-title beginning with part number(s) of above exploded view following by part name(s). ''TYPICAL''mention indicates a general view which does not represent full detail. Sub-sub-title in this case indicates that particular procedure for XP is finished, so from this point, all others models are concerned. Sub-sub title in italic indicates a particular procedure concerning a model. Service tool to be used to perform a certain procedure. Title indicates main procedure to be carried-out. F01A0AS Sub-sub-title in capital indicates a particular testing, adjustment or repair procedure. Illustration always follows text it is pertained to. Numbers in a frame are used to give a sequence to be perfomed. Numbers are used for desciption of components. Letters are used for any measures. F01F0XB A 2 1 1 2 www.SeaDooManuals.net

00-0-7 1996 BOMBARDIER WATERCRAFT SHOP MANUAL GENERAL INFORMATION The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on watercraft). 1. Left (port) 2. Right (starboard) The information and component / system descrip- tions contained in this manual are correct at time of publication. Bombardier Inc. however, main- tains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manu- factured. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This Shop Manual uses technical terms which may be different from the ones of the Parts Cata- logs. When ordering parts always refer to the specif- ic model Parts Catalogs. ILLUSTRATIONS AND PROCEDURES The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function. CAUTION : These watercraft are designed with parts dimensioned in both the metric and the imperial systems. When replacing fasteners, make sure to use only those recommended by Bombardier. Mismatched or incorrect fasteners could cause damage to the watercraft or possible personal injury. As many of the procedures in this manual are in- terrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or sub-section in which the procedure is contained. A number of procedures throughout the book re- quire the use of special tools. Before undertaking any procedure, be sure that you have on hand all the tools required, or approved equivalents. Technical Publications Bombardier Inc. Valcourt (Quebec), Canada PARTS CATALOGS MODELS P/N SP (5876) SPX (5877) SPI (5878) 219 300 180 GTS (5817) GTI (5865/5866) 219 300 210 XP (5858) 219 300 200 HX (5881) 219 300190 F01L45B 1 2 - www.SeaDooManuals.net

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1996 SEADOO SP SPX SPI GTS GTI XP HX JETSKI Service Manual

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