BRP Sea-Doo GTX 2008 Series Manual

Date: January 11, 2008 Subject: Predelivery Inspection (4-TEC™)
(Canada / U.S. / Other country)
No. 2008-1
REVISION 1, May 7, 2008 <=
2008
MODEL PACKAGE
MODEL
NUMBER ENGINE (hp) PREDELIVERY
KIT P/N
SERIAL
NUMBER
STD 148A 294 000 824
STD inter. 148B
1503NA
(155) 294 000 821
STD 338A 294 000 824
STD inter. 338B
1503BVIC
(215) 294 000 821
WAKE 158A 294 000 824
WAKE inter. 158B
1503NA
(155) 294 000 821
WAKE 268A 294 000 824
WAKE inter. 268B
1503BVIC
(215) 294 000 821
LTD 188A 294 000 825
GTX†
LTD inter. 188B
1503BVIC
(215) 294 000 820
STD 178A / 178C 294 000 824
STD inter. 178B / 178D
1503BVIC
(215) 294 000 822
X 318A 294 000 827
RXT™
X inter. 318B
1503BVIC HO
(255) 294 000 828
STD 238A 294 000 824
STD inter. 238B
1503DT
(130) 294 000 819
SE 248A 294 000 824
SE inter. 248B
1503DT
(130) 294 000 817
SE 308A / 308C 294 000 824
SE inter. 308B / 308D
1503NA
(155) 294 000 817
STD R 258A 294 000 826
GTI™
STD R inter. 258B
1503DT
(130) 294 000 818
STD 288A 294 000 824
STD inter. 288B
1503NA
(155) 294 000 823
STD 218A 294 000 824
STD inter. 218B
1503BVIC
(215)294 000 823
X 328A 294 000 827
RXP™
X inter. 328B
1503BVIC HO
(255) 294 000 829
ALL
GTX†is a trademark of Castrol Ltd. Used under license
DUnderlined text(s) between arrows is (are) added element(s) to the original publication.A
Printed in Canada. (sbl2008-002 JPM) 1/29
©2008 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

TABLE OF CONTENTS
Page Page
IMPORTANT NOTICE.......................... 3
UNCRATING..................................... 4
Crate Cover......................................... 4
Lifting the Watercraft ............................. 4
Engine Foam Protector ........................... 4
Shipping Bracket................................... 4
SET-UP............................................ 5
Venturi .............................................. 5
Battery Preparation and Installation............. 5
Activation of a New Battery...................... 5
Installation.......................................... 6
Sealed VRLA Battery Routine Charging ........ 7
Rear View Mirrors Installation ................... 8
Reverse Handle....................................10
Handlebar Assembly / Handlebar Cover........10
Handlebar Assembly..............................12
Throttle Cable......................................16
Steering Harness ..................................17
Steering Rubber Boot.............................17
Storage Cover Installation........................17
Storage Cover Shock Installation On GTX
STD,LTD and Wake ...............................19
FINAL PREPARATION..........................19
Steering Alignment................................19
O.P.A.S.TM System Alignment ...................20
Fuel..................................................20
Fuel System Pressurization ......................20
Coolant Level ......................................20
Watercraft Identification .. .. .. .. ..... .. .. .. ..... ..21
Programming Keys With B.U.D.S. ..............21
Cluster Language / Scale Settings ..............22
Ending a B.U.D.S. Session .......................22
Recommended Engine Oil .......................22
Engine Oil Level ...................................23
Throttle Cable......................................23
FINAL INSPECTION............................24
General Instructions...............................24
Decal Protective Films............................24
Cleaning the Watercraft ..........................24
Accessories ........................................24
Delivery to Purchaser .............................24
SPECIFICATIONS ...............................25
Technical Specifications ..........................25
2 / 29 2008-1 Predelivery

IMPORTANT NOTICE
IMPORTANT NOTICE
This bulletin must be used in conjunction with the PRE-DELIVERY CHECK LIST enclosed in the shrink pack.
WARNING
To obtain limited warranty coverage, pre-delivery procedures must be performed by an authorized
Sea-Doo watercraft dealer/distributor. Apply all necessary torques as indicated.
— The information and components/system descriptions contained in this document are correct at the
time of publication. However, BRP maintains a policy of continuous improvement of its products without
imposing upon itself any obligation to install them on products previously manufactured.
— Due to late changes, there might be some differences between the manufactured product and the
descriptions and/or specifications in this document. BRP reserves the right at any time to discontinue or
change specifications, designs, features, models or equipment without incurring obligation.
— The illustrations in this document show the typical construction of the different assemblies and
may not reproduce the full detail or exact shape of the parts; however, they represent parts that have
the same or similar function.
— The content of this bulletin is designed as a guideline only. All mechanics performing predelivery
procedures should have attended the current model year service training.
— Further information or inquiries should be directed to your distributor service representative and/or
specific SHOP MANUAL sections.
— Please complete the PREDELIVERY CHECK LIST for each watercraft and retain a purchaser signed copy.
— Make sure the purchaser receives the OPERATORS GUIDE,PREDELIVERY CHECK LIST signed copy
and SAFETY VIDEO.
WARNING
Torque wrench tightening specifications must be strictly adhered to. Where specified, install new
locking devices (e.g. lock tabs, elastic stop nuts). If the efficiency of a locking device is impaired,
it must be renewed.
Predelivery 2008-1 3 / 29

UNCRATING
UNCRATING
Crate Cover
Model(s): All
22
1
F00A2A6
Carefully lay crate on its bottom.
CAUTION: Allowing crate to drop may cause
serious damage to watercraft.
Remove all screws [1]retaining crate cover to
crate base.
NOTE: Screws that are used are Robertson†#2
type that require the use of an appropriate bit
(Scrulox #2 from Snap-on†† Tools or ECAR.1 from
Facom††† Tools).
Assisted by another person, lift up crate cover [2].
NOTE: Do not tip cover toward front or back of
watercraft. Raise cover vertically [2]from both
ends at the same time.
Remove watercraft protective bag.
Remove parts from watercraft's storage
compartments and from crate.
Lifting the Watercraft
Model(s): All
Cut strapping at watercraft front eyelet.
Release shipping bracket at rear of watercraft from
cratebase.
Lift watercraft using appropriate lift kit and install
it on a proper support.
Engine Foam Protector
Model(s): International
Remove seat(s).
1
F18P016
Remove the foam protector [1]supporting engine.
Shipping Bracket
Model(s): All
1 32
F08A066
Remove shipping bracket [1]from venturi.
Discard shipping bracket and hexagonal bolts [2].
Keep the flat washers [3]located between bracket
and pump.
† Robertson is a registered trademark of Robertson Inc.
†† Snap-on is a trademark of Snap-on Inc.
††† FACOM is a brand of International tools Group, subsidiary of FIMALAC.
4 / 29 2008-1 Predelivery

SET-UP
SET-UP
Venturi
Model(s): All
1
F08A076
Secure lower portion of the venturi [1]with:
– 2 hexagonal bolts (with scotch grip) from
predelivery kit (refer to table below).
– 2 M8 flat washers (previously removed).
Models Bolt Torque
148A / 148B / 158A /
158B / 238A / 238B /
248A / 248B / 288A /
288B / 308A / 308B /
308C / 308D
M8 x 50
with
scotch-grip
338A / 338B / 268A /
268B / 188A / 188B /
178A / 178B / 178C /
178D / 318A / 318B /
258A / 258B / 218A /
218B / 328A / 328B
M8 x 40
with
scotch-grip
21 N•m
(15 lbf•ft)
Battery Preparation and
Installation
NOTE: GTI rental vehicle is equipped with a dry
type battery that is already activated and requires
no maintenance. The state of charge needs to be
checked as per the instruction later in the battery
section of this bulletin.
Model(s): All except GTI rental
Activation of a New Battery
WARNING
Never charge or boost battery while installed
in watercraft.
Remove battery from watercraft.
A17E0FB
2
1
3
Remove the sealing tube [1]from the vent elbow
(removed on picture).
WARNING
Failure to remove the sealing tube could result
in an explosion.
Remove caps and fill battery to UPPER LEVEL line
[3]with electrolyte [2](specific gravity: 1.265 at
21°C (70°F)).
NOTE: This battery may fill slower than others
due to the anti-spill check ball design.
Allow the battery to stand for 30 minutes
MINIMUM so that electrolyte soak through battery
cells.
Readjust the electrolyte level to the UPPER LEVEL
line.
Connect a 2 A battery charger for 3 to 5 hours.
WARNING
Gases given off by a battery being charged
are highly explosive. Always charge in a
well ventilated area. Keep battery away
from cigarettes or open flames. Always turn
battery charger off prior to disconnecting
cables. Otherwise a spark will occur and
battery might explode.
Predelivery 2008-1 5 / 29

SET-UP
CAUTION: If charging rate raises higher than
2.4 A reduce it immediately. If cell temperature
rises higher than 50°C (122°F) or if the casing
feels hot, discontinue charging temporarily or
reduce the charging rate.
A17E0JA
1
Test battery state of charge. Use a hydrometer
[1]. Specific gravity must be 1.265.
If electrolyte level has dropped after charging, fill
with distilled water to UPPER LEVEL line. After
water is added, continue charging for 1 to 2 hours
to mix water with electrolyte.
Reinstall caps and clean any electrolyte spillage
using a solution of baking soda and water.
NOTE: Hand tighten caps then tighten an
additional 1/4 turn using a 20 mm (3/4 in) socket.
Using other tool could damage the plastic battery
caps.
WARNING
Battery electrolyte is caustic. To prevent
spillage, battery cell cap should be sufficiently
tight to properly seal.
Installation
Model(s): All
Secure RED positive cable to battery positive post
with:
– 1 hexagonal bolt,
– 1 flat washer and
– 1 nut, all from predelivery kit
(P/N 250 000 282).
Apply dielectric grease (P/N 293 550 004) on
positive battery post.
Cover positive battery post with rubber boot.
sbl2006-002-100_a
NOTE: On RXP models, RED positive cable [1]
must be installed at a 45° angle while BLACK
negative cable [2]is still accepted at a 90° angle;
refer to photo.
Model(s): All
Secure BLACK negative cable to negative battery
post with:
– 1 hexagonal bolt,
– 1 flat washer and
– 1 nut, all from predelivery kit
(P/N 250 000 282).
Apply dielectric grease (P/N 293 550 004) on
negative battery post.
WARNING
Always connect battery cables exactly in this
specific order. Connect RED positive cable
first, then BLACK negative ground cable.
Secure battery with previously removed
– bracket,
– 2 flat washers and
– 2 nuts.
Install battery vent tube.
NOTE: GTI rental models comes with a sealed
battery. No vent tube installation is needed.
WARNING
Ensure vent tube is not kinked or obstructed.
Battery vent tube must be properly installed
Dand secured with a locking tie A.
6 / 29 2008-1 Predelivery

SET-UP
Sealed VRLA Battery Routine
Charging
Model(s): GTI rental
This vehicle is equipped with a dry type battery that
is already activated and requires no maintenance.
Place the battery on a leveled surface. Battery
must be out of the vehicle.
CAUTION: Remember that unlike a conventional
battery, the sealed VRLA battery won’t be
topped off during its life. Never pry off sealing
caps: it is dangerous and damaging.
The single most important thing to maintaining a
VRLA battery is to not let it sit discharged: keep
it fully charged. A sealed VRLA battery should be
kept to near fully charged for peak performance.
In fact, it can need charging more often than a car
battery because it’s probably not used routinely
and, therefore, not “automatically” charged.
Use the following guidelines for boost charge.
Always verify battery condition before charging,
and 30 minutes after charging.
A fully charged battery should read 12.8V or
higher after battery has been off the charger 1 -
2 hours.
CAUTION: Overcharging can harm the battery
beyond recovery.
It is not recommended to overcharge sealed VRLA
batteries. Because of their characteristics, too
much of a boost charge will decrease the volume
of electrolyte. The longer the overcharge time, the
greater the drop in electrolyte – and starting power.
Stage of charge Voltage Action Charging time*
100% 12.8 – 13.0 None
Check at 3 months
from date of
manufacture
None required
75% – 100% 12.5 – 12.8 May need slight
charge, if no charge
given, check in
3months
3–6hours
50% – 75% 12 – 12.5 Need charge 5 – 11 hours
25% – 50% 11.5 – 12 Need charge At least 13 hours
verify state of
charge
0% – 25% 11.5 or less
(see instructions
below)
Need charge 20 hours
* Using a constant current charger at standard amps specified on the battery. Charging times
can vary depending on type of charger. Follow the charger's instructions.
CAUTION: Water cannot be added to the
sealed VRLA battery to make up the difference.
Overcharging can warp plates, making future
charging difficult or impossible. Watch
charging times carefully, or ideally, use a Yuasa
Automatic Charger. Always stop charging if the
battery becomes really warm to the touch. Let
it cool down 6 - 12 hours and resume charging.
WARNING
Always wear protective goggles and charge in
a ventilated area. If battery gets really warm
to the touch, discontinue charging and allow
battery to cool down. No sparks, flames or
smoking when charging.
Predelivery 2008-1 7 / 29

SET-UP
Charging Instructions for Sealed VRLA
Batteries with Voltage of 11.5 or Less
Batteries with voltage below 11.5 V may require
special equipment and procedures to recharge.
In charging an over discharged battery having a
terminal voltage of 11.5 V or lower, its internal
resistance may be too high to charge at a normal
charge voltage.
Therefore, it may be necessary to raise the voltage
of the battery initially (25 V as a maximum),
and charge for approximately 5 minutes. If the
ampmeter shows no change in current after 5
minutes, you need a new battery. Current flowing
into the battery at high voltage can become
excessive. Monitor amperage and adjust voltage
as necessary to keep current at the battery’s
standard amp rating. Charge for approximately 20
hours.
Rear View Mirrors Installation
Model(s): RXT and RXT-X
(International)
sbl2006-002-101_a
— Models WITHOUT the cluster bezel already
installed —
Remove and keep both screws [1]retaining
instrument cluster. Unplug and set cluster aside
for now.
sbl2006-002-101_b
NOTE: At 2 places at bottom of cluster, rubber
shims [1]are folded on body for a tight fit; care
should be taken not to lose those shims so they
are reused when reinstalling cluster.
— Models WITH the cluster bezel already
installed —
CAUTION: Cluster's locking tabs may break
when removing cluster bezel; extreme care
must be taken while performing bezel removing
procedure.
sbl2006-002-103_a
Take a small wooden stick (coffee stirrer type) and
chamfer its end; refer to photo.
8 / 29 2008-1 Predelivery

SET-UP
sbl2006-002-104_a
sbl2006-002-102_a
Slide chamfered end between bezel and cluster,
in line with each side locking tab, pushing out
smoothly while lifting out bezel; repeat procedure
with lower locking tab and then, gently lift bezel
upward, out of its upper locking tabs.
Remove and keep both screws retaining
instrument cluster. Unplug and set cluster aside
for now.
sbl2006-002-101_b
NOTE:At 2 places at bottom of cluster, rubber
shims [1]are folded on body for a tight fit; care
should be taken not to lose those shims so they
are reused when reinstalling cluster.
F19L236
On some models, it is required to cut the locking
tie retaining support plate to front storage cover
or to mirror.
Install rear view mirrors on both sides.
NOTE: Install left and right mirrors so that
inscription “OBJECTS IN MIRROR ARE CLOSER
THAN THEY APPEAR” is in upright position.
Secure each mirror with:
– 2 M8 x 120 hexagonal bolts (P/N 230 062 060)
and
– 2 M8 stainless steel flat washers
(P/N 234 062 500), all from predelivery
kit .
Torque to 5 N•m (44 lbf•in).
NOTE: To ensure a correct installation, torque rear
bolts (closest to mirror) before front ones.
Reconnect instrument cluster and secure back in
place using same screws.
TorquescrewstoaMAXIMUM of 1.5 N•m
(13 lbf•in).
— Models WITH the cluster bezel already
installed —
Reinstall instrument cluster bezel simply by
pushing it in so it snaps back in place.
—Mod
els WITHOUT the cluster bezel already
installed —
Bezel is in mirror bag; install instrument cluster
bezel simply by pushing it in so it snaps in place.
Model(s): GTI SE
(International Only)
Pull out temporary plastic fasteners, 2 retaining
pod and 2 retaining glove box.
Set glove box aside.
Align mirror support inside pod to install each side
mirror.
Predelivery 2008-1 9 / 29

SET-UP
Secure each mirror with:
– 2 M8 x 120 socket head bolts and
– 2 M8 stainless steel flat washers , all from
predelivery kit .
Insert rearward screw through mirror support hole
andinmirrorand tighten manually.
NOTE: Install left and right mirror so that the
inscription “OBJECTS IN MIRROR ARE CLOSER
THAN THEY APPEAR” is in upright position.
Insert forward screw and tighten manually.
Without touching mirrors, complete tightening
both mirrors in the following sequence:
– left rear screw then right rear;
– left front screw then right front.
Torqueto5N•m(44lbf•in).
Reinstall pod in place and insert 6 new rivets
(P/N 293 150 123) (from predelivery kit ) in their
respective holes; do not pop yet.
Reinstall box in place and insert 4 new rivets
(P/N 293 150 123) (from predelivery kit ) in their
respective holes; do not pop yet.
Secure mirror support using M10 stainless steel
flat washer (P/N 234 002 600) and M10 x 40 socket
head screw (P/N 205 004 060) from predelivery
kit ; start screwing only to grab threads; do not
torque yet.
Pop all rivets, box's and pod's and then, tighten
mirror support screw. Torque to 8 N•m (71 lbf•in).
Model(s): GTI std and GTI std R International
Only
Insert 6 new rivets (from predelivery kit ) in their
respective holes, in pod; do not pop yet.
Insert 4 new rivets (from predelivery kit ) in their
respective holes, in box; do not pop yet.
Now that all rivets are in position, pop them from
left to right and front to rear.
Reverse Handle
Model(s): GTI std, GTI std R, GTI SE
International Only
sbl2006-002-105_a
Install reverse handle (from glove box) using guide
[1](P/N 268 000 023), pop rivet (P/N 204 000 081),
and2Phil
lips†M5 x 12 (P/N 250 000 319) screws
from predelivery kit .
Handlebar Assembly / Handlebar
Cover
Model(s): International models except X
– Handlebar assembly is located on the deck
at the rear of vehicle or Din the engine
compartment for the RXP XA. To install it,
refer to HANDLEBAR ASSEMBLY further in this
bulletin.
Model(s): North American models except X
– Upper handlebar cover with padding is located
inside front luggage compartment, underneath
storage box. To install it, follow this procedure:
† Phillips is a registered trademark of Phillips Screw Co.
10 / 29 2008-1 Predelivery

SET-UP
sbl2007-001-001_a
Pull out right side handle grip and unscrew M6 x 16
throttle lever housing socket set screw. Discard
screw as there are new ones in the PDI kit.
sbl2007-001-002_a
Push out throttle lever housing just enough to gain
a little room on the inside approximately 12.7 mm
(1/2 in).
sbl2007-001-003_a
Align and slide upper handlebar cover under left
side engine stop switch housing [1]and then,
close it down slowly toward right side making sure
to align all 5 male/female tabs along the way.
sbl2007-001-004_a
Press upper and lower handlebar covers together
so tabs clip in position.
Secure upper and lower covers using three K40
x16screws(
P/N 241 141 660) and washers
(P/N 234 051 600) included in the predelivery kit.
sbl2007-001-005_a
Push throttle lever housing back in position and
secure in place using an M6 x 16 (P/N 250 000 036)
socket head screw (with scotch grip — from
predelivery kit).
F02K0KA
1
24
53
Place an insert [1](P/N 277 000 554) (from
predelivery kit) into notch in handlebar.
Slidehandlegrip[2]back in place making sure it
bottoms at proper place.
Predelivery 2008-1 11 / 29

SET-UP
Secure with an M6 x 30 hexagonal bolt [4]
(P/N 250 000 002) (with scotch grip — from
predelivery kit) and an M6 stainless steel flat
washer [3](P/N 240 062 600) (from predelivery kit).
CAUTION: Ensure to install flat washer
otherwise screw will damage grip end.
Torque bolt to 7 N•m (62 lbf•in).
Cover bolt by inserting rubber cap [5]
(P/N 277 000 203) (from predelivery kit).
Repeat steps for other side.
Handlebar Assembly
Model(s): International Only except X
1
2
Install cable support [1]on steering support [2]
and secure with:
– 3 M6 x 20 hexagonal bolts (P/N 207 162 060)
and
– 3 M6 flat washers (P/N 234 061 600) from
predelivery kit .
Apply Loctite†† 243 (blue – threadlocker) on bolt
threads.
Torqueto5N•m(44lbf•in).
Remove both wing nuts from threaded studs on
console.
Open front storage cover and remove storage tray
(if so equipped).
F02K0M6
Insert throttle cable and steering harness through
console hole and position steering assembly.
2
1
F02K0N6
Attach steering cable end [2]to steering stem arm
[1]and secure with the M6 x 30 hexagonal bolt
(P/N 211 000 061) from predelivery kit .
Apply Loctite 243 (blue – threadlocker) on bolt
threads.
Torqueto5N•m(44lbf•in).
NOTE: Ensure threads protrude through elastic
nuts
†† Loctite is a registered trademark of Loctite Corp.
12 / 29 2008-1 Predelivery

SET-UP
212
F18K066
Secure steering assembly [1]with 4 M8 flat
washers [2](P/N 234 081 600) and 4 M8 elastic
nuts (P/N 232 581 200) from predelivery kit .
Apply Loctite 243 (blue – threadlocker) on bolt
threads.
Torque to 12 N•m (9 lbf•ft).
1
F07K0H6
Install bearing support [1](P/N 277 001 528) from
predelivery kit to cable support using 2 M6 x 50
(P/N 207 065 060) hexagonal bolts and 2 M6 flat
washers (P/N 234 061 600) from predelivery kit.
Do not torque yet.
DSteering alignment procedure, described
further in this bulletin, must be performed prior to
torque bolts. A
sbl2008-002-001_a
Secure vent tube [1]to steering support [2]and
steering cable [3]using 2 locking tie,[4](not
provided )as show on the picture.
Model(s): DInternational only RXP-X model
sbl2008-002-550_a
NOTE: Handlebar is now packaged into engine
compartment.
Unwrap handlebar
Predelivery 2008-1 13 / 29

SET-UP
sbl2008-002-004_a
Unscrew the 8 M8 bolts and collapse “X” riser
block.
sbl2008-002-551_a
Install handlebar on “X” riser block with throttle
lever on right side.
NOTE: Hole for DESS key must be toward rear of
watercraft. It also must be toward handlebar [1].
Install DESS key [2]on “X” riser block as shown.
Torque nut to 1.8 N•m (16 lbf•in).
sbl2008-002-552_a
Insert buzzer [1]through direction support / trim
and install on bracket at right of direction support
[2]. Apply Loctite 425 (P/N 293 800 040) on nut [3]
and torque nut to 3.3 N•m (29 lbf•in).
sbl2008-002-553_a
Insert wire harness [1]into direction support / trim
[3]and grommet [2], toward storage compartment.
Insert throttle cable [4]from storage compartment
into grommet and direction support / trim, toward
handlebar.
NOTE: Throttle cable must pass over X riser.
sbl2008-002-554_a
Plug-in connectors into storage compartment.
14 / 29 2008-1 Predelivery

SET-UP
NOTE: Connectors cannot be switched up.
sbl2008-002-555_a
Connect throttle cable to throttle lever as follow:
– Hook cable end barrel [2]to throttle lever
– Pull throttle cable sheath [1]and install throttle
cable adjustment screw [4]into its housing [3]
– Adjust as per procedure further in this bulletin.
Model(s): North American X and RXT-X
interational models
On North American X models, the handlebar is
already installed on watercraft but has been tilt
down for shipping. A
sbl2008-002-004_a
Loosen the 8 bolts shown on picture enough to
move assembly freely.
Model(s): All X models
sbl2008-002-005
Align handlebar and X riser in order to be straight
with steering stem.
sbl2008-002-009_a
Make sure handlebar and stem is well centered in
the X riser [1].
NOTE: DThrottle cable A[2]must pass over
Xriser.
Torque the 8 bolts first at 2 - 3 N•m (18 - 26 lbf•in),
then at 19 N•m (14 lbf•ft) into the following
sequence.
Predelivery 2008-1 15 / 29

SET-UP
sbl2008-002-003_a
Model(s): International only X models
sbl2008-002-007_a
Loosen 2 screws that secure housing.
Move housing toward end of handle about 13 MM
(1/2”).
sbl2008-002-008_a
Wrap padding on handlebar, secure it with
velcro™.
NOTE: Tabs must be around handlebar [1].
Put back housing at is original location and retorque
boltsat2-3N•m(18-27lbf•in).
Model(s): All X models
Install handle grip following same process as
others watercrafts described previously.
Throttle Cable
Model(s): International except X
1
F18F026
Insert end of throttle cable into plastic tube [1]
leading out from steering assembly.
16 / 29 2008-1 Predelivery

SET-UP
12
F18F036
Unscrew [1]and lift throttle housing cover [2].
1
2
F18F046
From handlebar side, pull hose/cable and install
throttle cable [2]in throttle housing [1].
Reinstall throttle housing cover.
F18F056
Install throttle cable into throttle lever.
Steering Harness
Model(s): International except X
1
F16F026
Connect [1]steering harness connectors to main
harness connectors.
Secure with locking tie from predelivery kit or, in
some cases, use existing locking tie attached to
vent tube bracket.
Steering Rubber Boot
Model(s): International except X
sbl2006-002-107
Position rubber boot.
Storage Cover Installation
Model(s): All GTX, RXP and RXP-X International
Remove plastic wrapping over storage cover
assembly.
Remove access cover and storage basket from
storage cover assembly.
Predelivery 2008-1 17 / 29

SET-UP
F19L0J6 43
61
5
2
Secure rear arm of storage cover assembly [1]to
deck pivot support [2]using:
– 2 M6 x 25 hexagonal bolts [3](P/N 211 000 022),
– 2 M6 flat washers [4](P/N 234 061 600) and
– 2 M6 elastic nuts [5](P/N 232 561 200), all from
predelivery kit .
Apply Loctite 243 (blue – threadlocker) on bolt
threads.
Torque nuts to 4 N•m (35 lbf•in).
Cover bolt heads with pressure caps [6]
(P/N 414 136 900) from predelivery kit .
F19L0M6
2
1
43
Secure front arm of deck pivot support [1]to
storage cover assembly [2]with the M6 x 60
hexagonal bolt [3](P/N 207 066 080) from
predelivery kit .
Apply Loctite 243 (blue – threadlocker) on bolt
threads.
Torqueto4N•m(35lbf•in).
Cover bolt head with a pressure cap [4]
(P/N 414 136 900) from predelivery kit .
Model(s): All RXP and RXP-X International
F19L0N6
31
2
Cut locking ties [1]holding storage cover rod [2]
to shock assembly [3].
F19L0O6
1
3
2
5
4
Insert storage cover rod [1]through deck rubber
grommet [2].
Clip shock female receptacle onto bracket ball.
Secure storage cover rod to storage cover [3]
using:
– anM6flatwasher[4](P/N 234 061 600) and
– a circlip [5](P/N 293 370 005) from predelivery
kit .
18 / 29 2008-1 Predelivery

SET-UP
F19L216
NOTE: It may be necessary to compress shock to
insert storage cover rod into storage cover, using
a1/2inchd
rive ratchet.
F19L0P6
2
1
3
Insert storage cover harness [1]in oval hole of
rubber grommet [2](P/N 293 720 070), from
predelivery kit .
Secure rubber grommet on left side of storage
cover rod using locking tie [3], from predelivery kit .
Storage Cover Shock Installation
On GTX STD,LTD and Wake
smr2007-034-008_a
Snap the top of shock (body side) in inner shell
socket.
Place the bottom of shock [3](rod side) against
the bump [2]on the shock support [1]and close
storage compartment cover. The bottom of the
shock will be inserted in its place automatically.
FINAL PREPARATION
Steering Alignment
Model(s): DAll
F01K07A
1
Position handlebar in straight ahead position by
measuring each side the distance from handlebar
grip end to floorboard [1].
F01J5ZA
1
Check jet pump nozzle position by placing a
straight edge on nozzle outer end. Measure the
distance on each side of the straight edge [1]. It
must be equalled.
If necessary, steering alignment adjustment should
be performed at steering cable support.
Model(s): All Models except GTI Series
Open storage compartment cover and remove
basket.
Predelivery 2008-1 19 / 29

FINAL PREPARATION
Model(s): RXP
Remove front vent tube to allow room.
Model(s): GTI Series
Remove the glove box.
Model(s): All Models
smr2007-032-002_a
Loosen bolts [3]securing the retaining block [1]at
the bottom of cable support.
Turn adjustment nut [2]as required.
After adjustment, torque retaining block bolts to
6 N•m (53 lbf•in).
CAUTION: Verify when the handlebar is turned
completely to the left or right side, that there is
no interference with venturi, O.P.A.S. or VTS
ring. A
O.P.A.S.TM System Alignment
Model(s): All
All adjustments have already been performed
at factory. If readjustments are needed,
check O.P.A.S. system alignment procedure in
appropriate SHOP MANUAL.
Fuel
Model(s): All
At predelivery, we suggest dealers to fill fuel tank
with recommended fuel type as described in
SPECIFICATIONS TABLE.
NOTE:Never add oil in fuel.
CAUTION: Never use fuel containing more than
10% alcohol (ethanol or methanol).
WARNING
Fuel is flammable and explosive under certain
conditions. Always work in a well ventilated
area.
It might be necessary to remove and install safety
lanyard 2 or 3 times to initially feed fuel system.
NOTE: This procedure should be explained to
purchaser at delivery.
NOTE: Verify fuel line connectors prior to
powering-up ECM. This verification must be done
visually as well as manually by physically checking
each connection.
WARNING
Never install safety lanyard prior to checking
fuel line connector tightness.
Fuel System Pressurization
Model(s): All
WARNING
At PDI, or whenever doing any type of repair
on watercraft or if any components of fuel
system are disconnected, a pressure test must
be done before starting engine. Ensure to
verify fuel line ends for damage. Always cut
damaged end before reinstallation.
For fuel system pressure test procedure, refer to
appropriate SHOP MANUAL.
Coolant Level
Model(s): All
WARNING
Check coolant level with engine cold. Never
add coolant in cooling system when engine
is hot.
1
F18E0M6
Remove seat or seat extension to expose cooling
system expansion tank [1].
20 / 29 2008-1 Predelivery