BOMBARDIER SEA-DOO GTX RFI 5666 1998 User manual

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 written
permission of Bombardier Inc.
©Bombardier Inc. 1998
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

I
SECTION SUBSECTION PAGE
SAFETY NOTICE.................................................................................................................................. II
01 MAINTENANCE 01 - Table of contents ...................................................................... 01-01-1
02 - Periodic inspection chart........................................................... 01-02-1
03 - Flushing and lubrication............................................................. 01-03-1
04 - Storage...................................................................................... 01-04-1
02 ENGINE 01 - Table of contents ...................................................................... 02-01-1
02 - Magneto system....................................................................... 02-02-1
03 - Crankcase.................................................................................. 02-03-1
03 COOLING SYSTEM 01 - Table of contents ...................................................................... 03-01-1
02 - Circuit........................................................................................ 03-02-1
04 FUEL SYSTEM 01 - Table of contents ...................................................................... 04-01-1
02 - Fuel injection............................................................................. 04-02-1
05 ELECTRICAL
SYSTEM
01 - Table of contents ...................................................................... 05-01-1
02 - Ignition system.......................................................................... 05-02-1
03 - Charging system....................................................................... 05-03-1
06 TECHNICAL DATA 01 - GTX RFI Model.......................................................................... 06-01-1
07 WIRING DIAGRAM 01 - GTX RFI Model.......................................................................... 07-01-1
TABLE OF CONTENTS
VOLUME 2
VOLUME 1 1998

II
SAFETY NOTICE 0
This manual was primarily published to be used by watercraft technicians trained by the manufactur-
er 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 com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: 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 symbols:
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 modifi-
cations may render use of the watercraft 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.
-CAUTION
Denotes an instruction which, if not followed, could severely damage watercraft components.
SAFETY NOTICE

01-01-1
Section 01 MAINTENANCE
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS 0
PERIODIC INSPECTION CHART............................................................................................ 01-02-1
FLUSHING AND LUBRICATION............................................................................................ 01-03-1
GENERAL ........................................................................................................................... 01-03-1
PROCEDURE ...................................................................................................................... 01-03-1
STORAGE............................................................................................................................... 01-04-1
VOLUME 2
VOLUME 1 1998

Section 01 MAINTENANCE
Subsection 02 (PERIODIC INSPECTION CHART)
01-02-1
PERIODIC INSPECTION CHART 0
NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency.
➀Every 10 hours in salt water use.
➁These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified
in this chart.
➂Daily flushing in salt water or foul water use.
DESCRIPTION
FREQUENCY
Every
10 hours Every 25 hours Every 50 hours
Every
100 hours or
seasonally
Lubrication/corrosion protection of metallic components ➀
Engine ignition timing
Spark plug replacement
Fuel injector cleaning
Fuel injection sensors verification
Throttle cable, inspection/lubrication ➀
Flame arrester inspection
Throttle cable adjustment
RAVE valve cleaning
Engine counterbalance shaft oil level
Water flow regulator valve inspection
Oil injection pump adjustment
Oil filter inspection
Oil filter replacement
Engine head bolts, retorque
Steering system inspection
Reverse system/reverse cable adjustment
Fastener tightening (flame arrester support, throttle body, engine mount, exhaust
system, etc.)
Muffler, battery and reservoir fastening devices
Fuel/oil lines, check valve and hose inspection, fuel system pressurization
Fuel/vent line pressure relief valve inspection
Bailer pick up inspection
Battery condition
Ground connections (starter, battery, etc.)
Monitoring beeper
Jet pump reservoir oil level/oil condition
Jet pump oil replacement
Jet pump cover pusher inspection
Impeller condition and impeller/wear ring clearance ➁
Drive shaft boot/spline condition (both ends) ➁
PTO flywheel lubrication
Floating ring and boot inspection
Water intake grate condition ➁
Hull condition
Cooling system flushing ➂

Section 01 MAINTENANCE
Subsection 03 (FLUSHING AND LUBRICATION)
01-03-1
FLUSHING AND LUBRICATION 0
GENERAL
Flushing the cooling system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
help to clean up sand, salt, shells or other particles
in water jackets (engine, exhaust manifold, tuned
pipe) and/or hoses.
Flushing and engine lubrication should be per-
formed when the watercraft is not expected to be
used further the same day or when the watercraft
is stored for any extended time.
PROCEDURE
Clean jet pump by spraying water in its inlet and
outlet and then spray BOMBARDIER LUBE lubri-
cant.
To flush engine, connect a garden hose to the wa-
ter outlet located at the rear of the watercraft.
1. Water outlet
NOTE: A quick connect adapter is supplied with
the watercraft and can be used to ease garden
hose installation.
1. Quick connect adapter
1. Garden hose installed with quick connect adapter
-CAUTION
Failure to flush cooling system, when neces-
sary, will severely damage engine and/or ex-
haust system. Never flush a hot engine. Make
sure engine operates during entire procedure.
◆WARNING
Perform this operation in a well ventilated
area. Do not touch any electrical parts or jet
pump area when engine is running.
◆WARNING
Always remove safety lanyard cap from
switch to prevent accidental engine starting
before cleaning the jet pump area. Engine
must not be running for this operation.
F06E01A
1
F00E01A
1
F07E01A
1

Section 01 MAINTENANCE
Subsection 03 (FLUSHING AND LUBRICATION)
01-03-2
Start the engine then immediately open the water
tap.
Run the engine about 3 minutes at a fast idle
around 3500 RPM.
Spray BOMBARDIER LUBE lubricant through air
intake silencer keeping engine at fast idle.
1. Air intake silencer
2. Pull plug
3. Spray BOMBARDIER LUBE here
NOTE: Lubrication of engine should be done at
least for 1 minute.
Close the water tap then stop the engine.
Disconnect the garden hose.
Wipe up any residual water from the engine.
Remove spark plug cables and connect them on
the grounding device near the tuned pipe.
1. Grounding device
Remove both spark plugs and spray BOMBAR-
DIER LUBE lubricant into each cylinder.
NOTE: For the storage period, use Bombardier
storage oil (P/N 413 711 600).
Fully apply the throttle lever then depress the
start/stop button to crank the engine a few turns
to distribute the oil onto cylinder wall.
Apply anti-seize lubricant on spark plug threads
then reinstall them.
Reinstall plug on air intake silencer cover.
NOTE: Engine fogging should be done whenever
the watercraft is to be stored for a few days or a
long period.
;WARNING
Do not touch any electrical parts or jet pump
area when engine is running.
-CAUTION
Never flush a hot engine. Always start the
engine before opening the water tap. Open
water tap immediately after engine is start-
ed to prevent overheating.
-CAUTION
Always close the water tap before stopping
the engine.
-CAUTION
Remove quick connect adapter after flush-
ing operation (if used).
F01F25A
1
2
3
;WARNING
Always use spark plug cable grounding de-
vice when removing spark plugs.
-CAUTION
Never leave rags or tools in the engine com-
partment or in the bilge.
F07H0AA
1

Section 01 MAINTENANCE
Subsection 04 (STORAGE)
01-04-1
STORAGE 0
Engine Draining
Disconnect the water supply hose used to cool
the magneto. It features a quick connect fitting.
Press both tabs and pull fitting in order to discon-
nect hose.
This hose is located at the bottom of the magneto
cover beside the engine support.
1. Disconnect this hose
Water should flow out of the fitting (magneto cool-
ing circuit) and hose (crankcase heat exchanger).
1. Make sure water flows out of fitting and hose
Fuel System
Sea-Doo Fuel Stabilizer (P/N 413 408 600) should
be added in fuel tank to prevent fuel deterioration.
Follow manufacturer’s instructions for proper use.
NOTE: Fuel stabilizer should be added prior en-
gine lubrication.
Cooling System Flushing and Engine
Internal Lubrication
Cooling system has to be flushed with fresh wa-
ter to prevent salt, sand or dirt accumulation
which will clog water passages.
Engine must be lubricated to prevent corrosion on
internal parts.
For proper procedure, refer to FLUSHING AND
LUBRICATION 01-03.
Propulsion System
JET PUMP
Lubricant in impeller shaft reservoir should be
drained. Reservoir should be cleaned and refilled
with SEA-DOO synthetic 75W90 GL5 polyolester
oil. Refer to the
1998 Sea-Doo Shop Manual
for
proper procedure.
F07E05A
1
F07E06A
11
-CAUTION
Water in engine must be free to flow out.
Should water freeze in engine, severe dam-
age will occur.
◆WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well venti-
lated area.

Section 01 MAINTENANCE
Subsection 04 (STORAGE)
01-04-2
PTO FLYWHEEL
Lubricate PTO flywheel at grease fitting with syn-
thetic grease (P/N 293 550 010).
1. Grease PTO flywheel
Battery
For battery removal, cleaning and storage, refer to
the
1998 Sea-Doo Shop Manual
.
Watercraft Cleaning
Clean the bilge with hot water and mild detergent
or with bilge cleaner. Rinse thoroughly. Lift front
end of watercraft to completely drain bilge. If any
repairs are needed to body or to the hull, touch up
paint and Gelcote®repair kit are available. Replace
damaged labels/decals.
Wash the body with soap and water solution (only
use mild detergent). Rinse thoroughly with fresh
water. Remove marine organisms from the hull.
Apply a nonabrasive wax.
If the watercraft is to be stored outside, cover it
with an opaque tarpaulin to prevent sun rays and
grime from affecting the plastic components, wa-
tercraft finish as well as preventing dust accumu-
lation.
Anticorrosion Treatment
Wipe off any residual water in the engine com-
partment.
Spray BOMBARDIER LUBE lubricant over all me-
tallic components in engine compartment.
Lubricate the throttle cable with BOMBARDIER
LUBE lubricant.
The front seat should be partially left opened dur-
ing storage. This will avoid engine compartment
condensation and possible corrosion.
Additional Recommended Protection
In cool regions (where freezing point may be en-
countered), cooling system should be filled with
water and antifreeze solution.
-CAUTION
Do not lubricate excessively. Immediately
stop when a slight movement is noticed on
rubber boot.
-CAUTION
Never leave any clothing, tool or other ob-
jects near PTO flywheel and drive shaft.
F01I0BA
1
-CAUTION
Never clean fiberglass and plastic parts with
strong detergent, degreasing agent, paint
thinner, acetone, etc.
-CAUTION
The watercraft must never be Ieft in water for
storage. Never leave the watercraft stored in
direct sunlight.
-CAUTION
Always use ethylene-glycol antifreeze con-
taining corrosion inhibitors specifically rec-
ommended for aluminum engines.

Section 01 MAINTENANCE
Subsection 04 (STORAGE)
01-04-3
Install a hose pincher to water return hose of the
magneto cooling circuit.
1. Hose pincher to water return hose
Disconnect engine water return hose.
TYPICAL
1. Disconnect engine water return hose
Install a hose pincher to engine water supply
hose.
TYPICAL
1. Hose pincher installed on the engine water supply hose
Temporarily install a short piece of hose to engine
water outlet at cylinder head.
Insert a funnel into hose and pour antifreeze mixed
with water in engine until the colored solution ap-
pears in the water return hose of the magneto cool-
ing circuit.
Remove temporary hose and reconnect engine
water return hose.
Remove hose pinchers.
Most of the antifreeze will drain out from the fit-
ting near the exhaust outlet when removing the
hose pinchers. Use a container to recover it. Dis-
pose of antifreeze as per your local laws and reg-
ulations.
NOTE: Although antifreeze will mainly drain out,
the antifreeze has mixed with the water that was
possibly trapped in the cylinder water jackets and
thus preventing freezing problems.
At pre-season preparation, drain the remaining an-
tifreeze from cooling system prior using the wa-
tercraft.
F07E07Y
1
F06E0EA
1
F06E0FA
1

02-01-1
Section 02 ENGINE
Subsection 01 (TABLE OF CONTENT)
TABLE OF CONTENT 0
MAGNETO SYSTEM ............................................................................................................. 02-02-1
CRANKCASE.......................................................................................................................... 02-03-1
VOLUME 2
VOLUME 1 1998

Section 02 ENGINE
Subsection 02 (MAGNETO SYSTEM)
02-02-1
MAGNETO SYSTEM 0
9 N•m
(80 lbf•in)
F07D0BS
Loctite 242
Loctite 242
9 N•m
(80 lbf•in)
9 N•m
(80 lbf•in)
Synthetic
grease
105 N•m
(77 lbf•ft)
6 N•m
(53 lbf•in)
9 N•m
(80 lbf•in)
9 N•m
(80 lbf•in)
4 N•m
(35 lbf•in)
Anti-seize
lubricant
Synthetic
grease
PARTS

Section 02 ENGINE
Subsection 03 (CRANKCASE)
02-03-1
CRANKCASE 0
Synthetic
grease
Loctite
518
F07D0CS
Loctite
518
Synthetic
grease
Loctite
518
Loctite
518
24 N•m
(17 lbf•ft)
20 N•m
(15 lbf•ft) Synthetic
grease
30 mL (1 oz)
BOMBARDIER-ROTAX
Injection oil
9 N•m
(80 lbf•in)
40 N•m
(30 lbf•ft)
Loctite
518
24 N•m
(17 lbf•ft)
Synthetic grease
40 N•m
(30 lbf•ft)
9 N•m
(80 lbf•in)
PARTS

03-01-1
Section 03 COOLING SYSTEM
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS 0
CIRCUIT.................................................................................................................................. 03-02-1
VOLUME 2
VOLUME 1 1998

Section 03 COOLING SYSTEM
Subsection 02 (CIRCUIT)
03-02-1
CIRCUIT 0
F07E08S
Cooling
System
Indicator
(CSI) at
stern eyelet
Water
injected
into muffler
to cool
exhaust
components
Water supply
hose of the
regulator
valve
Engine
water
return
hose
(from
cylinder
water
jacket)
Bleed
hose
(upper
point
of circuit)
Water injected
in the tuned
pipe controlled
by the water
flow regulator
valve for noise
reduction and
performance
improvement
Water flows
through the
tuned pipe
and manifold
water jackets,
then to the
cylinder
water jackets
Engine
water
supply
hose
Magneto heat
exchanger
water outlet
hose exits
at the exhaust
outlet for
noise reduction
Serial cooling
system:
cylinder head
combustion
chambers are
cooled with
the water from
the jet pump
Engine
heat
exchanger
inlet
Engine
drain
hose
supplies
crankcase
heat
exchanger
Engine heat
exchanger
outlet
supplies
water to the
magneto heat
exchanger
Magneto
heat
exchanger
water
supply
hose
Quick
connect
hose
fitting
for easy
engine
draining
Water
from
cylinder
head to
tuned
pipe
water
jacket

04-01-1
Section 04 FUEL SYSTEM
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS 0
FUEL INJECTION................................................................................................................... 04-02-1
INTRODUCTION ................................................................................................................ 04-02-1
AIR INDUCTION................................................................................................................. 04-02-2
FUEL DELIVERY................................................................................................................. 04-02-2
ELECTRONIC MANAGEMENT.......................................................................................... 04-02-3
DIAGNOSTIC PROCEDURES ............................................................................................ 04-02-6
FAULT CODE TABLES....................................................................................................... 04-02-7
COMPONENT INSPECTION.............................................................................................. 04-02-8
AIR INDUCTION SYSTEM................................................................................................. 04-02-8
FUEL DELIVERY................................................................................................................. 04-02-8
ELECTRONIC MANAGEMENT.......................................................................................... 04-02-9
TROUBLESHOOTING SUMMARY.................................................................................... 04-02-13
ENGINE DOES NOT START.............................................................................................. 04-02-13
ENGINE STARTS BUT RUNS POORLY............................................................................ 04-02-13
ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS..................... 04-02-14
ENGINE CANNOT REACH MAXIMUM REVOLUTIONS.................................................. 04-02-14
ADJUSTMENT................................................................................................................... 04-02-15
THROTTLE POSITION SENSOR (TPS) ............................................................................. 04-02-15
REMOVAL AND INSTALLATION...................................................................................... 04-02-16
THROTTLE POSITION SENSOR (TPS) ............................................................................. 04-02-16
AIR TEMPERATURE SENSOR (ATS)................................................................................ 04-02-16
AIR PRESSURE SENSOR (APS) ....................................................................................... 04-02-16
WATER TEMPERATURE SENSOR (WTS)........................................................................ 04-02-16
CRANKSHAFT POSITION SENSOR (CPS) ....................................................................... 04-02-16
FUEL PUMP ASSEMBLY................................................................................................... 04-02-16
FUEL INJECTOR ................................................................................................................ 04-02-17
VOLUME 2
VOLUME 1 1998

Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
04-02-1
FUEL INJECTION 0
INTRODUCTION
DESCRIPTION OF THE FUEL INJECTION SYSTEM
1. Fuel tank
2. Fuel filter
3. Fuel pump
4. Regulator
5. Fuel rail
6. Fuel injector
7. Electronic Control Unit (ECU)
8. Multi-Purpose Electronic Module (MPEM)
9. Throttle plate
10.Throttle Position Sensor (TPS)
11.Air Pressure Sensor (APS)
12.Air Temperature Sensor (ATS)
13.Crankshaft Position Sensor (CPS)
14.Water Temperature Sensor (WTS)
15.Battery
F07F0OS
1
3
2
4
5
6
15
7
8
9
11
12
10
14
13

Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
04-02-2
The Rotax Fuel Injection (RFI) is a semi-direct
electronic fuel injection system.
Fuel is injected into each cylinder through the rear
transfer port. With this design, the injector is not
exposed to high combustion pressure, tempera-
ture and contaminants. The injector should run
cleaner and longer service intervals.
This system delivers the following benefits:
– easier cold engine starting (no choke)
– easier hot engine starting
– better throttle response
– better fuel economy
– no fuel valve
This system has the advantage of optimizing the
engine power, fuel economy and emission con-
trols under all engine operating conditions by
managing both the fuel injection duration and igni-
tion timing.
The Rotax Fuel Injection (RFI) is composed of the
3 following basic systems: Air Induction, Fuel De-
livery and Electronic Management.
AIR INDUCTION
A single throttle body (56 mm) breath through the
air intake silencer to provide a sufficient amount
of air for the engine operation.
THROTTLE BODY
FUEL DELIVERY
An electric fuel pump supplies the fuel to the fuel
rail and injectors.
FUEL PUMP
A regulator maintains a constant fuel pressure of
400-414 kPa (58-60 PSI).
REGULATOR
A dual piece fuel filter protects the fuel pump, reg-
ulator and injectors.
1. Fuel pump assembly
2. External fuel filter
F07F08A
F07F0JA
F07F0IA
F07F0KA
1
2

Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
04-02-3
1. End cap of fuel pump assembly removed
2. Internal fuel filter
All these components are comprised in a single
module mounted in the fuel tank. The fuel gauge
sender is also mounted on this module.
FUEL PUMP ASSEMBLY
The injectors inject a metered quantity of fuel in
the cylinder rear transfer port in accordance with
the signal from the Electronic Control Unit (ECU).
INJECTOR
ELECTRONIC MANAGEMENT
Electronic Control Unit (ECU)
The electronic fuel injection is equipped with a
Bosch Electronic Control Unit (ECU).
ELECTRONIC CONTROL UNIT (ECU)
The ECU is mounted behind the MPEM in the
front of the watercraft, in a watertight box.
The ECU controls the following functions:
1. Electronic fuel injection
The ECU receives the signals from 5 sensors
which indicate engine operating conditions at
milli-second intervals.
– Throttle Position Sensor (TPS)
– Crankshaft Position Sensor (CPS)
– Air Temperature Sensor (ATS)
– Water Temperature Sensor (WTS)
– Air Pressure Sensor (APS)
These signals are used by the ECU to determine
the injection duration required for optimum air-
fuel ratio.
2. Ignition timing
The ECU is programmed with data for optimum
ignition timing under all operating conditions. Us-
ing data provided by the sensors, the ECU con-
trols the ignition timing for best engine operation.
3. Maximum engine speed
The ECU limits the maximum allowable engine
speed. The rev limiter is set at 7080 ± 50 RPM.
4. Fail-Safe Function
In the event of a sensor malfunction, the ECU will
use a default operating mode to ensure driveabili-
ty to shore. A message may be displayed on the
Info Center to inform the operator.
F07F0LA
2
1
F07F09A
F07F0AA
F07F0BA