1999

Shop Manual

Legal deposit:
National Library of Quebec
1st 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

TABLE OF CONTENTS

SECTION

SUBSECTION

PAGE

SAFETY NOTICE ..................................................................................................................................

III

WHATS NEW .......................................................................................................................................

IV

INTRODUCTION ...................................................................................................................................

VI

01

SERVICE TOOLS
AND PRODUCTS

01 - Table of contents ......................................................................

02 - Mandatory service tools............................................................
03 - Optional service tools................................................................
04 - Service products .......................................................................

01-01-1
01-02-1
01-03-1
01-04-1

02

MAINTENANCE

01 - Table of contents ......................................................................

02 - Periodic inspection chart ...........................................................
03 - Flushing and lubrication.............................................................
04 - Water-flooded engine................................................................
05 - Storage......................................................................................

02-01-1
02-02-1
02-03-1
02-04-1
02-05-1

03

TROUBLESHOOTING

01 - Troubleshooting chart ...............................................................

03-01-1

04

ENGINE

01 - Table of contents ......................................................................

02 - Leak test ...................................................................................
03 - Removal and installation ...........................................................
04 - Magneto system .......................................................................
05 - Top end .....................................................................................
06 - Bottom end ...............................................................................
07 - Rotary valve...............................................................................
08 - Exhaust system.........................................................................

04-01-1
04-02-1
04-03-1
04-04-1
04-05-1
04-06-1
04-07-1
04-08-1

05

COOLING SYSTEM

01 - Table of contents ......................................................................

02 - Circuit, components and care ...................................................

05-01-1
05-02-1

06

FUEL SYSTEM

01 - Table of contents ......................................................................

02 - Fuel circuit.................................................................................
03 - Air intake ...................................................................................
04 - Carburetor .................................................................................
05 - Fuel injection .............................................................................

06-01-1
06-02-1
06-03-1
06-04-1
06-05-1

07

LUBRICATION
SYSTEM

01 - Table of contents ......................................................................

02 - Oil injection system...................................................................
03 - Oil injection pump .....................................................................

07-01-1
07-02-1
07-03-1

08

ELECTRICAL
SYSTEM

01 - Table of contents ......................................................................

02 - Ignition system..........................................................................
03 - Charging system .......................................................................
04 - Starting system .........................................................................
05 - Instruments and accessories ....................................................
06 - Digitally encoded security system ............................................

08-01-1
08-02-1
08-03-1
08-04-1
08-05-1
08-06-1

TABLE OF CONTENTS

II

09

PROPULSION
SYSTEM

01 - Table of contents ......................................................................

02 - Jet pump...................................................................................
03 - Drive system.............................................................................
04 - Reverse system........................................................................
05 - Variable trim system .................................................................

09-01-1
09-02-1
09-03-1
09-04-1
09-05-1

10

STEERING SYSTEM

01 - Table of contents ......................................................................

02 - Steering system........................................................................
03 - Adjustable steering ...................................................................
04 - Alignment .................................................................................

10-01-1
10-02-1
10-03-1
10-04-1

11

SUSPENSION

01 - Table of contents ......................................................................

02 - Direct action suspension ..........................................................

11-01-1
11-02-1

12

HULL/BODY

01 - Table of contents ......................................................................

02 - Adjustment and repair ..............................................................

12-01-1
12-02-1

13

TECHNICAL DATA

01 - SPX model ................................................................................

02 - GS and GSX Limited .................................................................
03 - XP Limited ................................................................................
04 - GTS model ................................................................................
05 - GTI and GTX Limited.................................................................
06 - GTX RFI and GSX RFI ...............................................................

13-01-1
13-02-1
13-03-1
13-04-1
13-05-1
13-06-1

14

WIRING DIAGRAMS

01 - Wiring diagrams........................................................................

14-01-1

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 discrepancy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at its time of manufacture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing 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 (e.g. lock tabs, selflocking 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:

WARNING

CAUTION

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

Denotes an instruction which, if not followed, could severely damage watercraft 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.
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.

III

WHATS NEW

WHATS NEW

THIS SECTION INDICATES PROCEDURES THAT WERE MODIFIED OR NEWLY ADDED IN THIS MANUAL.

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.

IV

WHATS NEW

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.

INTRODUCTION

INTRODUCTION
This Shop Manual covers the following BOMBARDIER made SEA-DOO 1999 watercraft models.
MODELS

MODEL
NUMBER

0
HULL IDENTIFICATION NUMBER
(H.I.N.)
SPX and GTS Models
It is located at right hand rear side of hull.

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

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

GTS ..................................................

5883

GTI International .............................

5884

GTI....................................................

5885

All Other Models

It is located on floorboard at the rear of the watercraft.

GTX RFI International .....................

5886

GTX RFI............................................

5887

GTX Limited International..............

5888

GTX Limited ....................................

5889

F01L8XA

F08L0QA

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

VI

INTRODUCTION

All Models
The Hull Identification Number is composed of 9
digits:

787 Engine
The Engine Identification Number is located on
the upper crankcase on PTO side.

ZZN12345L495
Serial
number*
F00A0CA

Model year
Year of production
Month of production

*A letter may also be used as a digit.

ENGINE IDENTIFICATION
NUMBER (E.I.N.)
717 Engine
The Engine Identification Number is located on
the upper side of the magneto housing.
F01D87A

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

947 Engine
The Engine Identification Number is located on
the upper crankcase on MAGNETO side.

F01D01A

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

F06D15A

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

VII

INTRODUCTION

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

VIII

INTRODUCTION

TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
indicates
beginning of the
subsection.

Subsection 04

(MAGNETO SYSTEM)

Italic sub-title
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.
Loctite
242

Loctite
242

Dotted box
contains parts of
a particular
model or an
exploded view.

Loctite
242

Exploded view assits

you in identifying
parts and related
positions.

Loctite
242
Loctite
242

Bold face number

indicates special
procedure
concerning this part.

Loctite
648
145 Nm
(107 lbfft)
Anti-seize
lubricant
F01D4WS

Illustration number
for publishing
process.

03-04-1

Page numbering system:

03: ENGINE section
04: MAGNETO SYSTEM subsection
1: First page of this subsection

F01A09S

IX

INTRODUCTION

TYPICAL PAGE
Sub-title with part
name(s) from
exploded view.

Section 06 FUEL SYSTEM

Subsection 03 (CARBURETORS)

Title indicates main

procedure to be
carried-out.

Service tool to be
used to perform a
certain procedure.

Title in italic indicates a

particular procedure
concerning a model.
Sub-sub-title in this
case indicates that
particular procedure
for XP is finished, so
from this point, all
others models are
concerned.

CARBURETOR REMOVAL

DISASSEMBLY AND INSPECTION

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.

Inspect parts for corrosion dammage (shaft, butterfly,

spring screw, check valve housing, etc.).

Diaphragm
PUMP DIAPHRAGM LEAK TEST
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).

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.

Illustration
always follows
text it is
pertained to.

XP Model Only
Remove screws no. 6 and lock washers no. 7 retaining
carburetors.
All Others Models
Remove 4 bolts no. 8 and lock washers no. 12 from
rotary valve cover then move carburetors and rotary
valve cover on top of engine.
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.

Sub-sub-title in
capital indicates a
particular testing,
adjustment or
repair procedure.

F01F0XB

"TYPICAL" mention
indicates a general
view which does not
represent full detail.

TYPICAL
1
2

Diaphragm must stand pressure for 10 seconds. If

pressure drops, replace diaphragm.

Numbers in a frame
are used to give a
sequence to be
perfomed.
Letters are used for
any measures.

06-03-4

Bold numbers in the

text refer to the parts
shown in the exploded
view at the beginning
of the subsection.

F01A0BS

Numbers are used

for description of
components.

INTRODUCTION

LIST OF ABBREVIATIONS USED

IN THIS MANUAL
AC
APS
ATS
CDI
CPS
CSI
DC
DESS
E.I.N.
ECU
HP
LED
MAG
MPEM
MPH
N.A.
OPT
P/N
PFD
PSI
PTO
RAVE
RFI
RPM
STD
TPS
VDC
VROI
VTS
WTS

DESCRIPTION
Alternate Current
Air Pressure Sensor
Air Temperature Sensor
Capacitor Discharge Ignition
Crankshaft Position Sensor
Cooling System Indicator
Direct Current
Digitally Encoded Security System
Engine Identification Number
Electronic Control Unit
Horse Power
Light Emitting Diode
Magneto
Multi-Purpose Electronic Module
Mile Per Hour
Not Applicable
Optional
Part Number
Personal Flotation Device
Pound Per Square Inch
Power Take Off
Rotax Adjustable Variable Exhaust
Rotax Fuel Injection
Revolution Per Minute
Standard
Throttle Position Sensor
Volt Direct Current
Variable Rate Oil Injection
Variable Trim System
Water Temperature Sensor

GENERAL INFORMATION
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
watercraft).

F01L45B

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

The information and component/system descriptions contained in this manual are correct at time
of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its
products without imposing upon itself any obligation to install them on products previously manufactured.
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 Catalogs.
When ordering parts always refer to the specific model Parts Catalogs.

XI

INTRODUCTION

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.
As many of the procedures in this manual are interrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the procedure is contained.
A number of procedures throughout the book require 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

XII