SeaDoo-ShopManual.pdf

2000Shop Manual

VOLUME 1

GS/GTI/GTS/GTX/XPGSX RFI/GTX RFI

Legal deposit:

National Library of Quebec2nd trimester 2000National Library of Canada

All rights reserved. No parts of this manual may be reproduced in anyform without the prior written permission of Bombardier Inc.©Bombardier Inc. 2000

Technical PublicationsBombardier Inc.Valcourt (Quebec) Canada

Printed in Canada®*Registered trademarks of Bombardier Inc.

Loctite® is a trademark of Loctite CorporationSnap-on® is a trademark of Snap-on Tools CorporationGelcote® is a trademark of Gelcote International Limited

SMR2000_001_00A2.FM I

‘

SECTION SUBSECTION PAGE

SAFETY NOTICE.................................................................................................................................. III

WHAT’S NEW ....................................................................................................................................... IV

INTRODUCTION ................................................................................................................................... VI

01 SERVICE TOOLSAND PRODUCTS

01 - Table of contents ...................................................................... 01-01-102 - Mandatory service tools............................................................ 01-02-103 - Optional service tools................................................................ 01-03-104 - Service products ....................................................................... 01-04-1

02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-102 - Periodic inspection chart ........................................................... 02-02-103 - Flushing and lubrication............................................................. 02-03-104 - Water-flooded engine................................................................ 02-04-105 - Storage...................................................................................... 02-05-1

03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1

04 ENGINE 01 - Table of contents ...................................................................... 04-01-102 - Leak test ................................................................................... 04-02-103 - Removal and installation ........................................................... 04-03-104 - Magneto system....................................................................... 04-04-105 - Top end ..................................................................................... 04-05-106 - Bottom end ............................................................................... 04-06-107 - Rotary valve............................................................................... 04-07-108 - Exhaust system......................................................................... 04-08-1

05 COOLING SYSTEM 01 - Table of contents ...................................................................... 05-01-102 - Circuit, components and care ................................................... 05-02-1

06 FUEL SYSTEM 01 - Table of contents ...................................................................... 06-01-102 - Fuel circuit................................................................................. 06-02-103 - Air intake ................................................................................... 06-03-104 - Carburetor ................................................................................. 06-04-105 - Fuel injection ............................................................................. 06-05-1

07 LUBRICATIONSYSTEM

01 - Table of contents ...................................................................... 07-01-102 - Oil injection system................................................................... 07-02-103 - Oil injection pump ..................................................................... 07-03-1

08 ELECTRICALSYSTEM

01 - Table of contents ...................................................................... 08-01-102 - Ignition system.......................................................................... 08-02-103 - Charging system ....................................................................... 08-03-104 - Starting system......................................................................... 08-04-105 - Instruments and accessories .................................................... 08-05-106 - Digitally encoded security system ............................................ 08-06-1

09 PROPULSIONSYSTEM

01 - Table of contents ...................................................................... 09-01-102 - Jet pump................................................................................... 09-02-103 - Drive system............................................................................. 09-03-104 - Reverse system ........................................................................ 09-04-105 - Variable trim system ................................................................. 09-05-1

TABLE OF CONTENTS

II SMR2000_001_00A2.FM

10 STEERING SYSTEM 01 - Table of contents ...................................................................... 10-01-102 - Steering system........................................................................ 10-02-103 - Adjustable steering ................................................................... 10-03-104 - Alignment ................................................................................. 10-04-1

11 SUSPENSION 01 - Table of contents ...................................................................... 11-01-102 - Direct action suspension .......................................................... 11-02-1

12 HULL/BODY 01 - Table of contents ...................................................................... 12-01-102 - Adjustment and repair .............................................................. 12-02-1

13 TECHNICAL DATA 01 - GS............................................................................................. 13-01-102 - XP ............................................................................................. 13-02-103 - GTS........................................................................................... 13-03-104 - GTI and GTX.............................................................................. 13-04-105 - GTX RFI and GSX RFI ............................................................... 13-05-1

14 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 14-01-1

TABLE OF CONTENTS

SMR2000_001_00A2.FM III

SAFETY NOTICE 0This 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 alreadyfamiliar with all service procedures relating to Bombardier made watercraft. Mechanic technicians shouldintent 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 PartsCatalog.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. Serviceand Warranty Bulletins may be published to update the content of this manual. Make sure to read andunderstand these.In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of thegeneral configuration of the parts. They are not to be interpreted as technical drawings or exact replicasof 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 onproduct(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 lockingdevice 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 compo-nents.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 theinformation 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 thecontents. We strongly recommend that any services be carried out and/or verified by a highly skilledprofessional mechanic. It is understood that certain modifications may render use of the vehicle illegalunder existing federal, provincial and state regulations.

� WARNING

Identifies an instruction which, if not followed, could cause serious personal injury includingpossibility of death.

SAFETY NOTICE

IV SMR2000_001_00A2.FM

WHAT’S NEW 0THIS 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

SMR2000_001_00A2.FM V

TECHNICAL DATA• Updated specifications for each model.

WIRING DIAGRAMS• Updated wiring diagrams for each model.

WHAT’S NEW

VI SMR2000_001_00A2.FM

INTRODUCTION 0This 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 water-craft.

TYPICAL1. Hull Identification Number (H.I.N.)

All Models

The Hull Identification Number is composed of 12digits:

MODELS MODELNUMBER

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

SMR2000_001_00A2.FM VII

ENGINE IDENTIFICATION NUMBER (E.I.N.)717 Engine

The Engine Identification Number is located on theupper side of the magneto housing.

TYPICAL1. Engine Identification Number (E.I.N.)

787 RFI Engine

The Engine Identification Number is located on theupper crankcase on PTO side.

1. Engine Identification Number (E.I.N.)

947 Engine

The Engine Identification Number is located on theupper crankcase on MAGNETO side.

1. Engine Identification Number (E.I.N.)

ARRANGEMENT OF THIS MANUALThe manual is divided into 14 major sections:01 SERVICE TOOLS AND PRODUCTS02 MAINTENANCE03 TROUBLESHOOTING04 ENGINE05 COOLING SYSTEM06 FUEL SYSTEM07 LUBRICATION SYSTEM08 ELECTRICAL SYSTEM09 PROPULSION SYSTEM10 STEERING SYSTEM11 SUSPENSION12 HULL/BODY13 TECHNICAL DATA14 WIRING DIAGRAMSSeveral sections are divided in various subsections.There is a table of contents at the beginning ofmany sections.

1

F01D01A

��*�+� �

��,*��

INTRODUCTION

VIII SMR2000_001_00A2.FM

��'�%!�� -��./01�&�0/�2

��3� 3�

��* 4�

��%!�!��

��%!�!��

��%!�!��

��%!�!��

��%!�!��

��%!�!�, �

� �5�-��+��#5#!2

��!�3'��6��%��!

��

��

��

� ��

0&78��7�./

��

��

��

��

� ��

��

��

�� !"�!�� #��$%"!�&'��(�&�$�� )��*��

��+��

��

�� ,��

��- ��.# ��

/ ��

��

INTRODUCTION

SMR2000_001_00A2.FM IX

).

�� '�%!��-��9 :9/019�2

�,3��3

*��$"��(�

��

��9 :9/0199/�1;�� 0��1��1��1��2�� 1��3�

7:�7*8�7<9�.��/�=0/�0

��

& �� 1�� +� ��4�� 5� 2�� 2��4�� 2�� 4�� 5�� &�� '**��

10/>* �� 1��0�6!�.78��8#3�

�� 9�� 1�� 2��

4�� ),�� 2��)+��

�� 4�� #�� )�� 2��)��

10/>:�� 1�� 1� ��+��

4�� 2�� 0�� 3�4�� 0�3��

*8��/� �&�*8�7/�081

5��1�� +� �� +��0�6!�.78��; 3� ��+��.;�2��0#��3�

�� )�� 1��

��

�

�

�

� �

0&78��7�./

��+��0�3��

<&(��=%-<��

��+��+�� >��1�� 1��

��

&��

��

&�� + ��

��+��+��1��9��

��

��

��

!�� ,��

��

!��

-��

/ ��

��

INTRODUCTION

X SMR2000_001_00A2.FM

LIST OF ABBREVIATIONS USED IN THIS MANUAL

GENERAL INFORMATIONThe use of RIGHT and LEFT indications in the text,always refers to driving position (when sitting onwatercraft).

1. Left (port)2. Right (starboard)

The information and component/system descrip-tions contained in this manual are correct at timeof publication. Bombardier Inc. however, main-tains a policy of continuous improvement of itsproducts without imposing upon itself any obliga-tion to install them on products previously manu-factured.Bombardier Inc. reserves the right at any time todiscontinue or change specifications, designs,features, models or equipment without incurringobligation.This Shop Manual uses technical terms whichmay be different from the ones of the Parts Cata-logs.When ordering parts always refer to the specificmodel Parts Catalogs.

DESCRIPTIONAC Alternate Current

APS Air Pressure SensorATS Air Temperature SensorCDI Capacitor Discharge IgnitionCPS Crankshaft Position SensorCSI Cooling System IndicatorDC Direct Current

DESS Digitally Encoded Security SystemE.I.N. Engine Identification NumberECU Electronic Control UnitHP Horse PowerLED Light Emitting DiodeMAG Magneto

MPEM Multi-Purpose Electronic ModuleMPH Mile Per HourN.A. Not ApplicableOPT OptionalP/N Part NumberPFD Personal Flotation DevicePSI Pound Per Square InchPTO Power Take Off

RAVE Rotax Adjustable Variable ExhaustRFI Rotax Fuel Injection

RPM Revolution Per MinuteSTD StandardTPS Throttle Position SensorVDC Volt Direct CurrentVROI Variable Rate Oil InjectionVTS Variable Trim SystemWTS Water Temperature Sensor

F01L45B

1 2

INTRODUCTION

SMR2000_001_00A2.FM XI

ILLUSTRATIONS AND PROCEDURESThe illustrations show the typical construction ofthe different assemblies and, in all cases, may notreproduce the full detail or exact shape of the partsshown, however, they represent parts which havethe same or a similar function.CAUTION: These watercraft are designed withparts dimensioned in both the metric and theimperial systems. When replacing fasteners,make sure to use only those recommended byBombardier.As many of the procedures in this manual are in-terrelated, we suggest, that before undertakingany task, you read and thoroughly understand theentire section or subsection in which the proce-dure is contained.A number of procedures throughout the book re-quire the use of special tools. Before undertakingany procedure, be sure that you have on hand allthe tools required, or approved equivalents.

SELF-LOCKING FASTENERS PROCEDUREThe following describes the most common appli-cation procedures when working with self-lockingfasteners.Use a metal brush or a screwtap to clean the holeproperly then use a solvent (Methyl-Chloride), letact during 30 minutes and wipe off. The solventutilization is to ensure the adhesive works properly.

LOCTITE APPLICATION PROCEDUREThe following describes the most common appli-cation procedures when working with Loctiteproducts.NOTE: Always use proper strength Loctite prod-uct as recommended in this Shop Manual.

THREADLOCKER

Uncovered Holes (bolts and nuts)

1. Apply here2. Do not apply

1. Clean threads (bolt and nut) with solvent.2. Apply Loctite Primer N (P/N 293 800 041) on

threads and allow to dry.3. Choose proper strength Loctite threadlocker.4. Fit bolt in the hole.5. Apply a few drops of threadlocker at proposed

tightened nut engagement area.6. Position nut and tighten as required.

Blind Holes

1. On threads2. On threads and at the bottom of hole

A00A3LA

1

2

��

�

�

INTRODUCTION

XII SMR2000_001_00A2.FM

1. Clean threads (bolt and hole) with solvent.2. Apply Loctite Primer N (P/N 293 800 041) on

threads (bolt and nut) and allow to dry for 30seconds.

3. Choose proper strength Loctite threadlocker.4. Apply several drops along the threaded hole and

at the bottom of the hole.5. Apply several drops on bolt threads.6. Tighten as required.

Stud in Blind Holes

1. On threads2. On threads and in the hole3. Onto nut threads

1. Clean threads (stud and hole) with solvent.2. Apply Loctite Primer N (P/N 293 800 041) on

threads and allow to dry.3. Put several drops of proper strength Loctite

threadlocker on female threads and in hole.4. Apply several drops of proper strength Loctite

on stud threads.5. Install stud.6. Install cover, etc.7. Apply drops of proper strength Loctite on un-

covered threads.8. Tighten nuts as required.

Preassembled Parts

1. Apply here2. Do not apply

1. Clean bolts and nuts with solvent.2. Assemble components.3. Tighten nuts.4. Apply drops of proper strength Loctite on bolt/nut

contact surfaces.5. Avoid touching metal with tip of flask.NOTE: For preventive maintenance on existingequipment, retighten nuts and apply properstrength Loctite on bolt/nut contact surfaces.

Adjusting Screw

1. Apply here2. Plunger

1. Adjust screw to proper setting.2. Apply drops of proper strength Loctite thread-

locker on screw/body contact surfaces.3. Avoid touching metal with tip of flask.

��9�

�

� �A00A3OA

1

2

��7�

��

INTRODUCTION

INTRODUCTION

SMR2000_001_00A2.FM XIII

NOTE: If it is difficult to readjust, heat screw witha soldering iron (232°C (450°F)).

STRIPPED THREAD REPAIR

Stripped Threads

1. Release agent2. Stripped threads3. Form-A-Thread4. Tape5. Cleaned bolt6. Plate7. New threads8. Threadlocker

Standard Thread Repair1. Follow instructions on Loctite FORM-A-THREAD

(P/N 413 708 600) package.2. If a plate is used to align bolt:

a. Apply release agent on mating surfaces.b. Put waxed paper or similar film on the surfaces.

3. Twist bolt when inserting it to improve threadconformation.

NOTE: NOT intended for engine stud repairs.

Repair of Small Holes/Fine ThreadsOption 1: Enlarge damaged hole, then followStandard Thread Repair procedure.Option 2: Apply FORM-A-THREAD on the screwand insert in damaged hole.

Permanent Stud Installation (light duty)1. Use a stud or thread on desired length.2. DO NOT apply release agent on stud.3. Do a Standard Thread Repair.4. Allow to cure for 30 minutes.5. Assemble.

GASKET COMPOUND

All Parts

1. Proper strength Loctite2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator 515

(P/N 413 702 700) on both sides of gasket3. Loctite Primer N only

1. Remove old gasket and other contaminantswith Loctite Chisel remover (P/N 413 708 500).Use a mechanical mean if necessary.

NOTE: Avoid grinding.2. Clean both mating surfaces with solvent.3. Spray Loctite Primer N on both mating surfaces

and on both sides of gasket. Allow to dry 1 or 2minutes.

4. Apply GASKET ELIMINATOR 515 (P/N 413 702700) on both sides of gasket, using a clean ap-plicator.

5. Place gasket on mating surfaces and assembleimmediately.

NOTE: If the cover is bolted to blind holes (above),apply proper strength Loctite in the hole and onthreads. Tighten.If holes are sunken, apply proper strength Loctiteon bolt threads.6. Tighten as usual.

��?�

�

�,

+

�

�

�

A00A3SA

21

1 3

1

INTRODUCTION

XIV SMR2000_001_00A2.FM

MOUNTING ON SHAFT

Mounting with a Press

1. Bearing2. Proper strength Loctite3. Shaft

Standard1. Clean shaft external part and element internal

part.2. Apply a strip of proper strength Loctite on shaft

circumference at insert or engagement point.NOTE: Retaining compound is always forced outwhen applied on shaft.3. DO NOT use anti-seize Loctite or any similar

product.4. No curing period is required.

Mounting in Tandem1. Apply retaining compound on internal element

bore.2. Continue to assemble as shown above.

CASE-IN COMPONENTS

Metallic Gaskets

1. Proper strength Loctite

1. Clean inner housing diameter and outer gasketdiameter.

2. Spray housing and gasket with Loctite Primer N(P/N 293 800 041).

3. Apply a strip of proper strength Loctite on lead-ing edge of outer metallic gasket diameter.

NOTE: Any Loctite product can be used here. Alow strength liquid is recommended as normalstrength and gap are required.4. Install according to standard procedure.5. Wipe off surplus.6. Allow it to cure for 30 minutes.NOTE: Normally used on worn-out housings toprevent leaking or sliding.It is generally not necessary to remove gasketcompound applied on outer gasket diameter.

A00A3UA

1

2

3

A00A3VA 1

INTRODUCTION

SMR2000_001_00A2.FM XV

TIGHTENING TORQUESTighten fasteners to torque mentioned in explod-ed views and text. When they are not specifiedrefer to following table.The table also gives themetric conversion.

N•m FASTENER SIZE (8.8) Lbf•in1 92 M4 183 274 M5 355 446 537 628 719 8010 M6 8911 9712 10613 11514 12415 13316 14217 15018 15919 168

N•m FASTENER SIZE (8.8) Lbf•ft20 1521 1522 1623 M8 1724 1825 1826 1927 2028 2129 2130 2231 2332 2433 2434 2535 2636 2737 27

38 2839 2940 3041 3042 3143 3244 3245 3346 3447 3548 M10 3549 3650 3751 3852 3853 3954 4055 4156 4157 4258 4359 4460 4461 4562 4663 4664 4765 4866 4967 4968 5069 5170 5271 5272 5373 5474 5575 5576 5677 5778 5879 5880 M12 5981 6082 60

N•m FASTENER SIZE (8.8) Lbf•ft

INTRODUCTION

XVI SMR2000_001_00A2.FM

TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS

Technical PublicationsBombardier Inc.Valcourt (Quebec), Canada

N•m FASTENER SIZE (8.8) Lbf•ft83 6184 6285 6386 6387 6488 6589 6690 6691 6792 6893 6994 6995 7096 7197 7298 7299 73

100 74101 74102 75103 76104 77105 77106 78107 79108 80109 80110 81111 82112 83113 83114 84115 85116 86117 86

N•m FASTENER SIZE (8.8) Lbf•ft118 87119 88120 89121 89122 90123 91124 91125 92126 93127 94128 94129 95130 96131 97132 97133 98134 99135 M14 100136 100137 101138 102139 103140 103141 104142 105143 105144 106145 107146 108147 108148 109149 110150 111

SeaDoo-ShopManual.pdf

Documents

Transcript of SeaDoo-ShopManual.pdf