BRP SEA-DOO GTX LTD iS 255 Manual

April 2, 2009 Subject:GTX†LTD iS 255 and RXT™ iS 255
Predelivery Inspection (All countries)
No. 2009-3
MODEL PACKAGE MODEL NUMBER ENGINE (HP) PREDELIVERY KIT SERIAL NUMBER
189A
GTX†LTD iS 189B (Int'l)1503 HO (255) 294 000 815 ALL
349A
RXT™ iS 349B (Int'l) 1503 HO (255) 294 000 815 ALL
GTX†is a trademark of Castrol Ltd. Used under license
TABLE OF CONTENTS
Page Page
IMPORTANT NOTICE ........................ 2
UNCRATING................................... 3
Crate Cover Removal ........................... 3
Vehicle Preparation.............................. 3
Releasing Moving Deck ........................ 4
PARTS TO BE INSTALLED.................. 6
Battery ............................................ 6
Boarding Step.................................... 8
Steering Column Installation ................... 8
Steering Cable .................................. 11
Storage Cover................................... 12
Compliance Label............................... 12
Vehicle Decal.................................... 12
Accessories ..................................... 12
FLUIDS......................................... 12
General Guidelines ............................. 12
Fuel............................................... 12
Engine Oil........................................ 12
Engine Coolant.................................. 14
B.U.D.S. PROGRAMMING................. 15
Connecting a PC to Vehicle ................... 15
B.U.D.S. Software.............................. 16
D.E.S.S. Key Programming.................... 17
Information Center Setup ..................... 19
Unlock iS Suspension .. ............ ............ 19
Ending a B.U.D.S. Session .................... 19
ADJUSTMENTS ............................. 20
Steering Alignment............................. 20
FUEL SYSTEM PRESSURIZATION ...... 21
Fuel System Pressurization Procedure ...... 21
FINAL INSPECTION ......................... 21
Vehicle Test Run................................ 21
Protective Films Removal ..................... 21
Vehicle Cleaning ................................ 21
Delivery to Customer .......................... 21
TECHNICAL DATA........................... 22
Printed in Canada. (sbl2009-004 en DM/AP)
©2009 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved. 1/23
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

IMPORTANT NOTICE
IMPORTANT NOTICE
This bulletin must be used in conjunction with the PREDELIVERY CHECK LIST enclosed in the shrink
pack.
WARNING
To obtain limited warranty coverage, predelivery procedures must be performed by an autho-
rized 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 pro-
cedures 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 DVD .
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.
2 / 23 2009-3 PREDELIVERY

UNCRATING
UNCRATING
Crate Cover Removal
1. Carefully lay crate on its bottom.
NOTICE Allowing crate to drop may cause se-
rious damage to vehicle.
2. Remove all screws retaining crate cover to
crate base.
NOTE: Screws that are used are Robertson†#2
type that require the use of an appropriate bit.
3. Assisted by another person, lift up crate cover.
4. Raise cover vertically from both ends at the
same time.
NOTICE Never tip cover toward the front or
rear of the vehicle while lifting it.
22
1
F00A2A6
TYPICAL
1. Remove screws
2. Raise cover vertically
Vehicle Preparation
1. Remove rear retaining screws from crate base.
sbl2009-004-001_a
1. Rear retaining screws
2. Cut front retaining strap.
sbl2009-004-002_a
1. Front retaining strap
3. Remove protective wrapping from vehicle.
NOTICE While manipulating to cut, take care
not to damage trim components with blade.
4. Lift vehicle using the LIFTING STRAP (P/N 529 036
171).
NOTICE Using any other lifting strap kit than
the recommended one will cause damages to
the vehicle. Bumpers will be tear off and their
replacement will be required.
sbl2009-004-003
5. Place the vehicle on a proper support.
6. Remove rear retaining bracket from vehicle.
6.1 Discard brackets and screws.
6.2 Keep washers for boarding step installa-
tion.
† Robertson is a registered trademark of Robertson Inc.
PREDELIVERY 2009-3 3 / 23

UNCRATING
NOTE: If washers are not present, you will
need 6 stainless steel flat washer (P/N 234
061 600).
sbl2009-004-004_a
1. Rear retaining brackets
USA and Canadian models
7. Remove boarding step from vehicle by cutting
locking ties.
sbl2009-004-005_a
1. Lockingties
International Models
Remove the gauge support cover then cut locking
ties to release the boarding step.
sbl2009-004-101_a
1. Gauge support cover
All Models
8. Ensure that the predelivery kit in the storage
compartment includes the following items.
sbl2009-004-051_a
ITEM DESCRIPTION (P/N ) QTY
M8 x 25 screw (P/N 207 382 560)
1Refer to
RELEASING MOVING DECK
subsection.
2
M8 washer (P/N 250 200 011)
2Refer to
RELEASING MOVING DECK
subsection.
2
Plastic cap (P/N 291 002 950)
3Refer to
RELEASING MOVING DECK
subsection.
2
Battery hardware (P/N 250 000 282)
4Refer to
BATTERY subsection. 1
M6 x 45 bolt (P/N 207 164 560)
5Refer to
BATTERY subsection. 2
M6 washer (P/N 234 062 600)
6Refer to
BATTERY subsection. 2
M6 nut (P/N 232 561 200)
7Refer to
BATTERY subsection. 2
M6 x 25 screw (P/N 250 000 076)
8Refer to
BOARDING STEP
subsection.
6
Releasing Moving Deck
NOTE: For transportation purpose, the moving
deck suspension has been completely com-
pressed and secured at the factory using cable.
Make sure to release tension and remove secur-
ing cable from moving deck suspension prior to
working on the vehicle.
4 / 23 2009-3 PREDELIVERY

UNCRATING
WARNING
The moving deck suspension is attached un-
der tension (spring-loaded). Before releasing
tension:
– Clean moving deck of any objects and
tools.
– Do not use pneumatic or electric tools for
removing moving deck retaining screws.
– Adhere strictly to following procedure.
1. Lift seat by pressing the rear latch and moving
seat to the rear and them upwards.
sbl2009-004-006_a
1. Rear latch
2. Remove cable free end from hole.
3. Put a knot at the end of the cable to prevent it
from going into the hole.
sbl2009-004-007_a
1. Cable free end
2. Hole
4. Slowly unscrew rear retaining screw (Do not
use pneumatic or electric tools).
sbl2009-004-008_a
1. Rear retaining screw
5. Carefully lift rear tab upwards using a flat
screwdriver.
sbl2009-004-009_a
1. Rear tab
NOTE: After lifting the rear tab, the cable will slide
into the hole and the moving deck will move up-
wards. Ensure that the cable is free of tension be-
fore removing the front screw.
6. Remove front retaining screw.
sbl2009-004-010_a
1. Knot
2. Front retaining screw
PREDELIVERY 2009-3 5 / 23

PARTS TO BE INSTALLED
7. Completely remove and discard the following
items from moving deck.
–Cable
– Retaining screws
– Washers
–Plate.
8. Install plastic caps on moving deck (from prede-
livery kit).
sbl2009-004-011_a
1. Plastic caps
9. Install M8 x 25 screws and M8 washers on
moving deck (from predelivery kit).
sbl2009-004-012_a
1. M8 washers
2. M8 x 25 screws
10. Tighten screws to 25 N•m (18 lbf•ft).
PARTS TO BE INSTALLED
Battery
WARNING
Never charge or boost battery while installed
in watercraft.
NOTICE Always charge battery before its in-
stallation on the vehicle.
NOTICE Make sure not to squeeze battery ca-
bles between vehicle components.
Battery Removal
1. Open the boarding platform.
ssi2009-002-002_a
1. Boarding platform
2. Remove the RH (starboard) storage bin.
NOTE: The storage bin is secured using two plas-
tic rivets
ssi2009-002-003_a
1. RH (starboard) storage bin
3. Disconnect the diagnostic connector.
ssi2009-002-004_a
1. Diagnostic connector
4. Lift and push the top of electrical component
support forward to unlock it from battery holder.
6 / 23 2009-3 PREDELIVERY

PARTSTOBEINSTALLED
5. Move support aside to make room.
ssi2009-002-008_a
1. Electrical component support
6. Remove and discard screws securing battery
holder to battery holder base (one on each side).
ssi2009-002-009_a
PARTS REMOVED FOR CLARITY
1. Retaining screws
2. Battery holder
7. Unplug vent hose from battery.
8. Remove battery holder from vehicle.
9. Remove battery from battery holder.
sbl2009-004-013_a
Battery Activation and Charging
1. Activate and charge the battery.
Refer to the latest edition of
Sea-Doo BATTERIES
ACTIVATION, CHARGING AND MAINTENANCE
BULLETIN
and to instructions notice attached to
battery for proper activating, charging and main-
tenance procedure.
Battery Installation
WARNING
Always connect battery cables exactly in this
specific order. Connect RED positive cable
first, then BLACK negative ground cable.
1. Install charged battery into battery holder.
2. Secure battery on battery holder using the fol-
lowing hardware from predelivery kit:
– M6 x 45 bolts
–M6flatwas
hers
– M6 nuts.
sbl2009-004-050_a
1. M6 x 45 bolt
2. M6 flat washer
3. M6 nut
3. Tighten bolts to 5 N•m (44 lbf•in).
4. Position battery holder on vehicle.
5. Plug vent hose on the top of battery.
6. Make sure vent hose is not pinched or bent.
7. Reinstall screws securing battery holder to bat-
tery holder base (one on each side).
8. Tighten battery holder screws to 14 N•m
(124 lbf•in).
9. Attach the electrical component support to bat-
tery holder.
10. Insert diagnostic connector into its housing.
11. Apply DIELECTRIC GREASE (P/N 293 550 004) on
battery posts.
12. Connect RED (+) battery cable then BLACK (-)
cable using the battery hardware (from prede-
livery kit).
PREDELIVERY 2009-3 7 / 23

PARTS TO BE INSTALLED
ssi2009-002-005_a
1. BLACK (-) cable
2. RED (+) cable
13. Cover positive battery post with rubber boot.
Do not install the storage bin yet. It's removal is
necessary to connect B.U.D.S..
WARNING
Ensure vent tube is not kinked or obstructed.
Battery vent tube must be properly installed
and secured with a locking tie.
Boarding Step
1. Position boarding step on fixation holes.
sbl2009-004-014_a
1. Boardingstepfixationholes
2. Install M6 washers (previously removed from
retaining brackets).
3. Install M6 x 25 screws (from predelivery kit).
4. Torque M6 screws to 10 N•m (89 lbf•in).
NOTE: For an easier installation, place small shafts
into the housing cavities to lock the boarding step
downwards.
sbl2009-004-015_a
1. Small shaft
Steering Column Installation
International Models
1. Cut retaining strap that holds front storage
cover to vehicle.
NOTICE
– Properly hold the front storage cover with
hand while cutting the retaining strap.
– Be careful not to damage vehicle compo-
nents while cutting.
sbl2009-004-102_a
1. Front storage cover
2. Retaining strap
2. Cut locking tie securing front storage cover to
vehicle.
3. Carefully remove the cover from vehicle.
8 / 23 2009-3 PREDELIVERY

PARTSTOBEINSTALLED
sbl2009-004-103_a
1. Locking tie
4. Remove foam from storage cover.
5. Cut locking tie that holds gas shock to storage
cover.
sbl2009-004-104_a
1. Foam
2. Gas shock
6. Remove retaining collar from hood.
sbl2009-004-105_a
1. Retaining collar
7. Disconnect gauge connector.
8. Disconnect steering connectors from vehicle
harness.
sbl2009-004-106_a
1. Gauge connector
2. Steering connectors
9. Remove gauge support by lifting it upwards us-
ing a screwdriver.
sbl2009-004-107_a
10. Cut retaining strap that holds steering column.
11. Carefully remove steering column from foam.
sbl2009-004-108
12. Remove foam from vehicle.
13. Remove front storage bin from vehicle.
PREDELIVERY 2009-3 9 / 23

PARTS TO BE INSTALLED
sbl2009-004-109_a
1. Steering column foam
2. Front storage bin
14. By the front storage compartment opening,
pull vehicle harness connectors through front
module opening to locate them between the
fixed deck and the moving deck.
15. Remove screws and washers from the steer-
ing column arm. Keep them for reuse.
16. Remove tape retaining the steering column
arm.
sbl2009-004-111_a
1. Steering column retaining screw
2. Washer
3. Steering column arm
4. Tape
17. Ensure upper and lower wear bushings are
properly inserted into steering support.
smr2009-037-028_a
1. Upper bushing
2. Steering column support
3. Lower bushing
18. Carefully, drive steering column through steer-
ing column support. Ensure to not hit the
O.T.A.S. magnet during steering column in-
stallation.
19. Insert steering harness through the front mod-
ule opening.
NOTE: Do NOT insert gauge connector into front
module opening.
sbl2009-004-112_a
1. Steering harness
2. Front module opening
3. Steering support
20. Complete insertion of the steering column into
its support.
21. Install steering retaining screws and washers
(previously removed) onto bracket holes.
22. Tighten steering column screws to 6 N•m
(53 lbf•in).
10 / 23 2009-3 PREDELIVERY