Sea-doo 2006 GTI Install guide

Smr-2004 ang.FH8 Thu Jun 03 14:42:10 2004 Page 1
www.SeaDooManuals.net

2004
Shop Manual
GTI, GTI LE, GTI RFI, GTI LE RFI, XP DI
GTX 4-TEC /Supercharged /Limited Supercharged /Wakeboard Edition
RXP 4-TEC Supercharged
BOMBARDIER RECREATIONAL PRODUCTS INC.
www.SeaDooManuals.net

Legal deposit:
National Library of Quebec
National Library of Canada 2004
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc.
©Bombardier Recreational Products Inc. 2004
Technical Publications
Bombardier Recreational Products Inc.
Valcourt (Quebec) Canada
PrintedinCanada
®TMRegistered trademarks of Bombardier Recreational Products Inc. or its affiliates.
†Bombardier and sprocket design are trademarks of Bombardier Inc, used under license.
SEA-DOO®
BOMBARDIER-ROTAX®
BOMBARDIER LUBE®
BOMBARDIER-ROTAX Formula XP-S Synthetic Injection
Oil BOMBARDIER Formula XP-S DI Synthetic Injection Oil
BOMBARDIER-ROTAX Injection Oil
Sea-Doo Synthetic Grease
Sea-Doo LKTM
DESSTM
Rotax®
O.P.A.S.TM
TOPSTM
This document contains the trademarks of the following companies:
Knight’s Spray-Nine†is a trademark of Korkay System Ltd
GTX†is a trademark of Castrol Ltd. Used under license
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
Molykote©is a trademark of Dow Corning Corporation
Snap-on©is a trademark of Snap-on Tools Corporation
AMP©is a trademark of Tyco Electronics Corporation
www.SeaDooManuals.net

TABLE OF CONTENTS
SAFETY NOTICE .................................................................................. XII
INTRODUCTION .................................................................................. XIII
HULL IDENTIFICATION NUMBER (H.I.N.) ..................................................................... XIII
ENGINE IDENTIFICATION NUMBER (E.I.N.) .................................................................. XIV
ARRANGEMENT OF THIS MANUAL........................................................................... XV
LIST OF ABBREVIATIONS USED IN THIS MANUAL....................................................... XVIII
GENERAL INFORMATION...................................................................................... XVIII
ILLUSTRATIONS AND PROCEDURES ......................................................................... XIX
ENGINE EMISSIONS INFORMATION .......................................................................... XIX
SELF-LOCKING FASTENERS PROCEDURE ................................................................... XX
LOCTITE APPLICATION PROCEDURE.......................................................................... XX
THREADLOCKER .................................................................................................. XX
STRIPPED THREAD REPAIR ..................................................................................... XXI
GASKET COMPOUND........................................................................................... XXII
MOUNTING ON SHAFT ......................................................................................... XXII
CASE-IN COMPONENTS....................................................................................... XXIII
TIGHTENING TORQUES ....................................................................................... XXIV
01 SERVICE TOOLS AND PRODUCTS
01 – MANDATORY SERVICE TOOLS ............................................................................. 1
ENGINE ................................................................................................................ 1
COOLING/FUEL/OIL SYSTEMS...................................................................................... 5
PROPULSION SYSTEM............................................................................................... 6
STEERING SYSTEM................................................................................................... 8
02 – OPTIONAL SERVICE TOOLS ................................................................................ 9
ENGINE ................................................................................................................ 9
COOLING/FUEL/OIL SYSTEMS..................................................................................... 14
PROPULSION SYSTEM.............................................................................................. 14
BODY.................................................................................................................. 15
WATERCRAFT HANDLING .......................................................................................... 15
03 – SERVICE PRODUCTS ....................................................................................... 17
02 MAINTENANCE
01 – PERIODIC INSPECTION CHART............................................................................ 21
02 – FLUSHING AND LUBRICATION............................................................................ 27
GENERAL............................................................................................................. 27
PROCEDURE......................................................................................................... 27
ANTICORROSION TREATMENT.................................................................................... 32
03 – WATER-FLOODED ENGINE................................................................................. 33
GENERAL............................................................................................................. 33
PROCEDURE......................................................................................................... 33
04 – STORAGE ..................................................................................................... 39
ENGINE DRAINING .................................................................................................. 39
PROPULSION SYSTEM.............................................................................................. 40
FUEL SYSTEM........................................................................................................ 41
ENGINE OIL CHANGE AND FILTER ................................................................................ 41
COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION ...................................... 41
ENGINE LUBRICATION.............................................................................................. 41
BATTERY.............................................................................................................. 42
WATERCRAFT CLEANING........................................................................................... 42
ADDITIONAL RECOMMENDED PROTECTION ................................................................... 42
I
www.SeaDooManuals.net

TABLE OF CONTENTS
ANTICORROSION TREATMENT.................................................................................... 48
CHECKLIST........................................................................................................... 48
03 TROUBLESHOOTING
01 – TROUBLESHOOTING CHART.............................................................................. 49
ENGINE WILL NOT START.......................................................................................... 49
ENGINE HARD TO START........................................................................................... 52
ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED.............................................................. 52
ENGINE MISFIRES, RUNS IRREGULARLY......................................................................... 53
ENGINE CONTINUALLY BACKFIRES............................................................................... 55
ENGINE DETONATION OR PINGING............................................................................... 55
ENGINE LACKS ACCELERATION OR POWER .................................................................... 56
ENGINE STOPS RUNNING . ... ....... ..... ..... ... .... ... ....... ..... ....... ..... ... ............ ....... ..... ... ..... 57
ENGINE CANNOT REACH MAXIMUM RPM ...................................................................... 57
ENGINE RUNS TOO FAST (VEHICLE CANNOT REACH ITS TOP SPEED)....................................... 58
ENGINE OVERHEATS................................................................................................ 58
O.P.A.S. SYSTEM FAULTS (GTX 4-TEC MODELS)................................................................. 59
ENGINE SMOKE IN THE EXHAUST (4-TEC SERIES).............................................................. 59
LOW OR NO ENGINE OIL PRESSURE (4-TEC SERIES) .......................................................... 60
ENGINE OIL CONTAMINATION (MILKY) (4-TEC SERIES) ........................................................ 60
UNUSUAL ENGINE NOISE AND/OR VIBRATION (4-TEC SERIES) ............................................... 61
ABNORMAL NOISE FROM PROPULSION SYSTEM.............................................................. 61
04 ENGINE (2-STROKE)
01 – LEAK TEST .................................................................................................... 63
GENERAL............................................................................................................. 63
PREPARATION ....................................................................................................... 63
TESTING PROCEDURE.............................................................................................. 63
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART.................................................................. 69
02 – REMOVAL AND INSTALLATION........................................................................... 71
GENERAL............................................................................................................. 71
ENGINE REMOVAL .................................................................................................. 71
CLEANING............................................................................................................ 76
INSTALLATION ....................................................................................................... 76
03 – MAGNETO SYSTEM......................................................................................... 83
DISASSEMBLY ....................................................................................................... 86
CLEANING............................................................................................................ 93
ASSEMBLY ........................................................................................................... 93
04 – TOP END....................................................................................................... 99
GENERAL........................................................................................................... 102
DISASSEMBLY ..................................................................................................... 104
CLEANING.......................................................................................................... 111
INSPECTION........................................................................................................ 112
USED PISTON MEASUREMENT.................................................................................. 113
ASSEMBLY ......................................................................................................... 116
ADJUSTMENT...................................................................................................... 125
05 – BOTTOM END ............................................................................................... 129
DISASSEMBLY ..................................................................................................... 132
CLEANING.......................................................................................................... 139
INSPECTION........................................................................................................ 140
ASSEMBLY ......................................................................................................... 144
II
www.SeaDooManuals.net

TABLE OF CONTENTS
06 – ROTARY VALVE ............................................................................................. 153
GENERAL........................................................................................................... 154
INSPECTION ON WATERCRAFT.................................................................................. 154
DISASSEMBLY ..................................................................................................... 155
CLEANING.......................................................................................................... 157
INSPECTION........................................................................................................ 157
ASSEMBLY ......................................................................................................... 158
ROTARY VALVE TIMING........................................................................................... 162
07 – EXHAUST SYSTEM......................................................................................... 165
REMOVAL .......................................................................................................... 168
TUNED PIPE REPAIR .............................................................................................. 174
INSTALLATION ..................................................................................................... 174
05 ENGINE (4-TEC)
01 – LEAK TEST ................................................................................................... 181
LEAK TEST PROCEDURE .................................................................................. 181
PREPARATION ..................................................................................................... 181
PROCEDURE....................................................................................................... 182
INSTALLATION ..................................................................................................... 183
LEAK TEST PROCEDURE FOR INTERCOOLER......................................................... 184
02 – INTAKE SYSTEM............................................................................................ 185
INSPECTION........................................................................................................ 189
REMOVAL .......................................................................................................... 191
DISASSEMBLY ..................................................................................................... 198
ASSEMBLY ......................................................................................................... 201
INSTALLATION ..................................................................................................... 205
03 – EXHAUST SYSTEM......................................................................................... 209
EXHAUST PIPE..................................................................................................... 210
EXHAUST MANIFOLD............................................................................................. 213
MUFFLER........................................................................................................... 214
RESONATOR ....................................................................................................... 214
EXHAUST OUTLET................................................................................................. 215
04 – REMOVAL AND INSTALLATION.......................................................................... 217
GENERAL........................................................................................................... 217
ENGINE REMOVAL ................................................................................................ 217
CLEANING.......................................................................................................... 221
INSTALLATION ..................................................................................................... 221
05 – PTO HOUSING/MAGNETO................................................................................ 225
GENERAL........................................................................................................... 226
PTO HOUSING ..................................................................................................... 226
PTO SEAL........................................................................................................... 229
COUPLING.......................................................................................................... 229
STATOR ............................................................................................................. 230
ROTOR AND ENCODER WHEEL................................................................................. 231
RING GEAR......................................................................................................... 231
STARTER DRIVE ASS'Y............................................................................................ 232
OIL SPRAY NOZZLE ............................................................................................... 233
06 – LUBRICATION SYSTEM.................................................................................... 235
GENERAL........................................................................................................... 237
OIL LEVEL VERIFICATION......................................................................................... 237
ENGINE OIL PRESSURE TEST.................................................................................... 238
OIL FILTER.......................................................................................................... 240
III
www.SeaDooManuals.net

TABLE OF CONTENTS
OIL STRAINERS.................................................................................................... 241
ENGINE OIL PRESSURE REGULATOR........................................................................... 244
OIL PRESSURE PUMP............................................................................................. 245
OIL SUCTION PUMP............................................................................................... 248
OIL COOLER ....................................................................................................... 251
OIL SEPARATOR ................................................................................................... 252
07 – CYLINDER HEAD AND VALVES........................................................................... 255
GENERAL........................................................................................................... 256
SPARK PLUG ....................................................................................................... 256
VALVE COVER...................................................................................................... 256
ROCKER ARM...................................................................................................... 257
CAMSHAFT TIMING GEAR........................................................................................ 260
TIMING CHAIN..................................................................................................... 262
CYLINDER HEAD................................................................................................... 262
CAMSHAFT......................................................................................................... 263
VALVE SPRING ..................................................................................................... 265
VALVE ............................................................................................................... 266
08 – ENGINE BLOCK.............................................................................................. 273
GENERAL........................................................................................................... 275
CRANKSHAFT LOCKING .......................................................................................... 275
CRANKSHAFT...................................................................................................... 275
TIMING CHAIN..................................................................................................... 279
CHAIN TENSIONER................................................................................................ 280
BALANCER SHAFT................................................................................................. 280
ENGINE BLOCK.................................................................................................... 283
PISTON/CONNECTING ROD...................................................................................... 288
PISTON RINGS ..................................................................................................... 294
06 ENGINE MANAGEMENT (RFI)
01 – OVERVIEW ................................................................................................... 297
AIR INDUCTION............................................................................................. 298
FUEL DELIVERY ............................................................................................. 298
FUEL PUMP ........................................................................................................ 298
FUEL PRESSURE REGULATOR................................................................................... 298
FUEL FILTERS...................................................................................................... 298
FUEL PUMP MODULE ............................................................................................ 299
FUEL INJECTORS.................................................................................................. 299
ELECTRONIC MANAGEMENT ............................................................................ 299
ELECTRONIC CONTROL UNIT (ECU) ............................................................................ 299
MPEM (MULTI-PURPOSE ELECTRONIC MODULE) ............................................................ 300
02 – DIAGNOSTIC PROCEDURES ............................................................................. 303
INTRODUCTION.................................................................................................... 303
SELF-DIAGNOSTIC MODE........................................................................................ 303
ADVANCED DIAGNOSTIC......................................................................................... 303
FAULT CODE TABLES ............................................................................................. 305
03 – COMPONENT INSPECTION .............................................................................. 307
GENERAL..................................................................................................... 307
AIR INDUCTION SYSTEM ................................................................................. 309
THROTTLE BODY.................................................................................................. 309
FUEL DELIVERY ............................................................................................. 309
FUEL FILTER........................................................................................................ 309
FUEL PUMP ........................................................................................................ 309
IV
www.SeaDooManuals.net

TABLE OF CONTENTS
REGULATOR........................................................................................................ 309
FUEL INJECTOR ................................................................................................... 310
LEAK TEST (SUPPLY AND VENTILATION CIRCUITS) ........................................................... 311
HIGH PRESSURE TEST (FUEL PUMP CIRCUIT)................................................................. 311
ELECTRONIC MANAGEMENT ............................................................................ 312
THROTTLE POSITION SENSOR (TPS)............................................................................ 312
CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 313
AIR TEMPERATURE SENSOR (ATS).............................................................................. 314
WATER TEMPERATURE SENSOR (WTS) ........................................................................ 314
AIR PRESSURE SENSOR (APS)................................................................................... 315
RAVE SOLENOID................................................................................................... 316
RFI SENSORS RESISTANCE VALUES............................................................................ 317
04 – TROUBLESHOOTING SUMMARY........................................................................ 319
ENGINE DOES NOT START ............................................................................... 319
FLOODED ENGINE FEATURE ............................................................................. 319
SPARK PLUG INSPECTION................................................................................ 319
ECU FAULT CODES......................................................................................... 319
ENGINE STARTS BUT RUNS POORLY .................................................................. 319
ENGINE RUNS ONLY ON ONE CYLINDER.............................................................. 319
ENGINE CANNOT REACH MAXIMUM REVOLUTIONS............................................... 320
05 – ADJUSTMENT............................................................................................... 321
THROTTLE CABLE ADJUSTMENT....................................................................... 321
THROTTLE POSITION SENSOR (TPS)................................................................... 321
CLOSED TPS ....................................................................................................... 321
IDLE SPEED ........................................................................................................ 321
06 – REMOVAL AND INSTALLATION ......................................................................... 323
MPEM/ECU................................................................................................... 323
THROTTLE POSITION SENSOR (TPS)................................................................... 323
AIR TEMPERATURE SENSOR (ATS) ..................................................................... 323
AIR PRESSURE SENSOR (APS)........................................................................... 323
WATER TEMPERATURE SENSOR (WTS) ............................................................... 323
CRANKSHAFT POSITION SENSOR (CPS) .............................................................. 323
FUEL PUMP ASSEMBLY................................................................................... 323
REGULATOR........................................................................................................ 324
FUEL FILTER........................................................................................................ 324
FUEL INJECTORS........................................................................................... 324
07 ENGINE MANAGEMENT (DI)
01 – OVERVIEW ................................................................................................... 327
OPERATING PRINCIPLE.................................................................................... 327
AIR INDUCTION............................................................................................. 327
AIR COMPRESSOR SYSTEM.............................................................................. 327
FUEL DELIVERY SYSTEM.................................................................................. 327
BASIC OPERATION ................................................................................................ 327
AIR/FUEL RAIL ASSEMBLY ....................................................................................... 328
FUEL PUMP MODULE ............................................................................................ 328
ELECTRONIC MANAGEMENT ............................................................................ 329
MPEM (MULTI-PURPOSE ELECTRONIC MODULE) ............................................................ 329
MPEM —ENGINE MANAGEMENT FUNCTIONS............................................................... 332
IGNITION SYSTEM................................................................................................. 334
02 – COMPONENT INSPECTION AND ADJUSTMENT ..................................................... 335
GENERAL..................................................................................................... 335
V
www.SeaDooManuals.net

TABLE OF CONTENTS
FUEL SYSTEM...................................................................................................... 335
ELECTRICAL SYSTEM............................................................................................. 336
AMP CONNECTOR PIN-OUT...................................................................................... 337
QUICK FUEL PRESSURE TEST ........................................................................... 337
AIR INDUCTION SYSTEM ................................................................................. 339
THROTTLE BODY.................................................................................................. 339
AIR COMPRESSOR ......................................................................................... 342
PRESSURE TEST................................................................................................... 342
REPAIR.............................................................................................................. 343
FUEL DELIVERY ............................................................................................. 346
FUEL PRESSURE REGULATOR................................................................................... 346
FUEL INJECTOR ................................................................................................... 348
AIR/FUEL RAIL ..................................................................................................... 349
DIRECT INJECTOR................................................................................................. 350
FUEL PUMP ........................................................................................................ 352
FUEL FILTERS ..................................................................................................... 354
ELECTRONIC MANAGEMENT ............................................................................ 357
MPEM REPLACEMENT ........................................................................................... 357
THROTTLE POSITION SENSOR (TPS)............................................................................ 358
CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 360
MANIFOLD AIR TEMPERATURE SENSOR (MATS) ............................................................. 362
WATER TEMPERATURE SENSOR (WTS) ........................................................................ 362
MANIFOLD AIR PRESSURE SENSOR (MAPS) .................................................................. 363
EXHAUST GAS TEMPERATURE SENSOR (EGTS)............................................................... 364
KNOCK SENSOR (KS).............................................................................................. 364
RAVE SOLENOID................................................................................................... 365
IGNITION COIL..................................................................................................... 366
IGNITION TIMING.................................................................................................. 368
SPARK PLUGS...................................................................................................... 372
CRANKING SYSTEM............................................................................................... 373
DI SYSTEM TEST SUMMARY..................................................................................... 373
03 – DIAGNOSTIC PROCEDURES.............................................................................. 377
GENERAL..................................................................................................... 377
FAULT DETECTION AND COMPENSATORY ACTIONS............................................... 379
COMPONENT FAILURE WARNING SYSTEM.................................................................... 379
VCK (VEHICLE COMMUNICATION KIT) ................................................................. 381
DI SYSTEM FAULT CODES ................................................................................ 382
08 ENGINE MANAGEMENT (4-TEC)
01 – OVERVIEW ................................................................................................... 391
COMPLETE ELECTRICAL SYSTEM OVERVIEW ........................................................ 391
MAGNETO SYSTEM AND POWER SUPPLY............................................................ 393
OPERATING PRINCIPLE OF ENGINE MANAGEMENT ................................................ 393
AIR INDUCTION............................................................................................. 393
FUEL DELIVERY SYSTEM.................................................................................. 394
BASIC OPERATION ................................................................................................ 394
FUEL PUMP MODULE ............................................................................................ 396
ELECTRONIC MANAGEMENT ............................................................................ 396
EMS (ENGINE MANAGEMENT SYSTEM)........................................................................ 396
EMS —GENERAL FUNCTIONS .................................................................................. 397
EMS —ENGINE MANAGEMENT FUNCTIONS ................................................................. 399
MPEM —MULTI-PURPOSE ELECTRONIC MODULE .......................................................... 402
VI
www.SeaDooManuals.net

TABLE OF CONTENTS
02 – COMPONENT INSPECTION AND ADJUSTMENT ..................................................... 403
GENERAL..................................................................................................... 403
FUEL SYSTEM...................................................................................................... 403
ELECTRICAL SYSTEM............................................................................................. 404
ENGINE CONNECTOR PIN-OUT.................................................................................. 405
CONNECTORS ON ENGINE....................................................................................... 406
AIR INDUCTION SYSTEM ................................................................................. 407
THROTTLE BODY.................................................................................................. 407
FUEL DELIVERY ............................................................................................. 411
FUEL PUMP ........................................................................................................ 412
FUEL FILTER ....................................................................................................... 414
FUEL RAIL .......................................................................................................... 414
FUEL INJECTOR ................................................................................................... 415
ELECTRONIC MANAGEMENT ............................................................................ 417
ECM AND MPEM REPLACEMENT .............................................................................. 417
ENGINE WIRING HARNESS....................................................................................... 419
THROTTLE POSITION SENSOR (TPS)............................................................................ 421
IDLE BYPASS VALVE............................................................................................... 423
CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 424
CAMSHAFT POSITION SENSOR (CAPS)......................................................................... 425
MANIFOLD AIR TEMPERATURE SENSOR (MATS) ............................................................. 426
COOLANT TEMPERATURE SENSOR (CTS)...................................................................... 427
MANIFOLD AIR PRESSURE SENSOR (MAPS) .................................................................. 428
EXHAUST GAS TEMPERATURE SENSOR (EGTS)............................................................... 429
KNOCK SENSOR (KS).............................................................................................. 429
OIL PRESSURE SENSOR (OPS) .................................................................................. 431
OIL SEPARATOR PRESSURE SENSOR (OSPS) ................................................................. 431
TOPS VALVE (BLOW-BY).......................................................................................... 433
IGNITION COILS ................................................................................................... 436
IGNITION TIMING.................................................................................................. 437
ENGINE START/STOP SWITCH VERIFICATION ................................................................. 437
SAFETY LANYARD SWITCH VERIFICATION..................................................................... 437
SPARK PLUGS...................................................................................................... 438
CRANKING SYSTEM............................................................................................... 438
03 – DIAGNOSTIC PROCEDURES.............................................................................. 439
GENERAL........................................................................................................... 439
SELF-DIAGNOSTIC MODE................................................................................. 441
VCK (VEHICLE COMMUNICATION KIT) ................................................................. 443
4-TEC SYSTEM FAULT CODES ........................................................................... 444
4-TEC SYSTEM FAULT CODES CHART .......................................................................... 447
BURNT FUSE AND RELATED FAULT CODE..................................................................... 465
09 COOLING SYSTEM
01 – CIRCUIT, COMPONENTS AND CARE .................................................................... 467
CIRCUIT............................................................................................................. 473
COMPONENTS..................................................................................................... 476
CARE................................................................................................................ 480
CIRCUIT............................................................................................................. 488
COOLING SYSTEM LEAK TEST................................................................................... 488
INSPECTION........................................................................................................ 490
DRAINING THE SYSTEM.......................................................................................... 490
CLEANING.......................................................................................................... 490
VII
www.SeaDooManuals.net

TABLE OF CONTENTS
COOLANT REPLACEMENT ....................................................................................... 491
COOLANT PUMP HOUSING...................................................................................... 492
THERMOSTAT...................................................................................................... 493
COOLANT PUMP IMPELLER ..................................................................................... 494
ROTARY SEAL...................................................................................................... 494
CARE................................................................................................................ 496
10 FUEL SYSTEM
01 – FUEL CIRCUIT ............................................................................................... 499
GENERAL........................................................................................................... 505
REMOVAL .......................................................................................................... 506
INSPECTION........................................................................................................ 508
ASSEMBLY ......................................................................................................... 509
FUEL SYSTEM PRESSURIZATION................................................................................ 509
02 – AIR INTAKE (2-STROKE)................................................................................... 511
GENERAL........................................................................................................... 513
REMOVAL .......................................................................................................... 513
ASSEMBLY ......................................................................................................... 514
REMOVAL .......................................................................................................... 516
ASSEMBLY ......................................................................................................... 517
03 – CARBURETOR ............................................................................................... 519
GENERAL........................................................................................................... 520
REMOVAL .......................................................................................................... 520
CLEANING.......................................................................................................... 520
DISASSEMBLY AND INSPECTION ............................................................................... 521
ASSEMBLY ......................................................................................................... 523
INSTALLATION ..................................................................................................... 525
ADJUSTMENTS.................................................................................................... 525
11 LUBRICATION SYSTEM (2-STROKE)
01 – OIL INJECTION SYSTEM .................................................................................. 529
GENERAL........................................................................................................... 531
OIL SYSTEM PRESSURIZATION.................................................................................. 531
02 – OIL INJECTION PUMP...................................................................................... 533
OIL PUMP IDENTIFICATION ...................................................................................... 536
REMOVAL .......................................................................................................... 536
DISASSEMBLY ..................................................................................................... 536
CLEANING.......................................................................................................... 536
ASSEMBLY ......................................................................................................... 536
ADJUSTMENT...................................................................................................... 538
CHECKING OPERATION........................................................................................... 541
12 ELECTRICAL SYSTEM
01 – IGNITION SYSTEM ......................................................................................... 543
GENERAL........................................................................................................... 543
MULTI-PURPOSE ELECTRONIC MODULE (MPEM) ............................................................ 544
IGNITION TIMING ................................................................................................. 544
PROCEDURE....................................................................................................... 552
SPARK PLUGS...................................................................................................... 555
02 – CHARGING SYSTEM ....................................................................................... 559
GENERAL........................................................................................................... 559
TESTING PROCEDURE............................................................................................ 562
VIII
www.SeaDooManuals.net

TABLE OF CONTENTS
BATTERY............................................................................................................ 566
CABLE TERMINAL INSTALLATION .............................................................................. 572
03 – STARTING SYSTEM ........................................................................................ 575
GENERAL........................................................................................................... 578
STARTING SYSTEM TROUBLESHOOTING ...................................................................... 579
STARTER REMOVAL............................................................................................... 580
STARTER DISASSEMBLY.......................................................................................... 580
CLEANING.......................................................................................................... 584
PARTS INSPECTION ............................................................................................... 584
STARTER ASSEMBLY.............................................................................................. 585
STARTER INSTALLATION ......................................................................................... 587
STARTER SPECIFICATION ........................................................................................ 589
04 – INSTRUMENTS AND ACCESSORIES.................................................................... 591
GENERAL........................................................................................................... 591
POWER SUPPLY CUT-OFF RELAY VERIFICATION.............................................................. 591
MULTI-PURPOSE ELECTRONIC MODULE (MPEM) ............................................................ 591
INFORMATION CENTER .......................................................................................... 592
ADDITION OF ELECTRICAL ACCESSORIES..................................................................... 600
INSPECTION........................................................................................................ 600
05 – DESS (CARBURETED AND RFI ENGINES).............................................................. 609
GENERAL........................................................................................................... 609
DESS KEY PROGRAMMING............................................................................... 611
13 PROPULSION
01 – JET PUMP.................................................................................................... 615
GENERAL........................................................................................................... 616
JET PUMP INSPECTION ON WATERCRAFT..................................................................... 616
REMOVAL .......................................................................................................... 618
DISASSEMBLY ..................................................................................................... 620
CLEANING.......................................................................................................... 622
PARTS INSPECTION ............................................................................................... 623
ASSEMBLY ......................................................................................................... 625
PUMP PRESSURIZATION ......................................................................................... 633
INSTALLATION ..................................................................................................... 633
GENERAL........................................................................................................... 637
JET PUMP INSPECTION ON WATERCRAFT..................................................................... 637
REMOVAL .......................................................................................................... 638
DISASSEMBLY ..................................................................................................... 641
CLEANING.......................................................................................................... 644
PARTS INSPECTION ............................................................................................... 644
ASSEMBLY ......................................................................................................... 646
PUMP PRESSURIZATION ......................................................................................... 649
INSTALLATION ..................................................................................................... 650
02 – DRIVE SYSTEM.............................................................................................. 653
GENERAL........................................................................................................... 656
REMOVAL .......................................................................................................... 656
INSPECTION........................................................................................................ 663
ASSEMBLY ......................................................................................................... 665
INSTALLATION ..................................................................................................... 666
LUBRICATION...................................................................................................... 673
03 – REVERSE SYSTEM ......................................................................................... 675
DISASSEMBLY .................................................................................................... 676
IX
www.SeaDooManuals.net

TABLE OF CONTENTS
INSPECTION........................................................................................................ 678
ASSEMBLY ......................................................................................................... 678
ADJUSTMENT...................................................................................................... 678
04 – VARIABLE TRIM SYSTEM ................................................................................. 679
GENERAL........................................................................................................... 681
REMOVAL .......................................................................................................... 681
DISASSEMBLY ..................................................................................................... 681
INSPECTION........................................................................................................ 682
ASSEMBLY ......................................................................................................... 682
INSTALLATION ..................................................................................................... 683
ADJUSTMENT...................................................................................................... 683
14 STEERING SYSTEM
01 – STEERING SYSTEM ........................................................................................ 685
DISASSEMBLY ..................................................................................................... 687
ASSEMBLY ......................................................................................................... 692
DISASSEMBLY ..................................................................................................... 697
ASSEMBLY ......................................................................................................... 700
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.).............................................. 702
GENERAL........................................................................................................... 703
SIDE VANE.......................................................................................................... 703
CYLINDER SUPPORT.............................................................................................. 704
TIE ROD............................................................................................................. 705
SEALED TUBE...................................................................................................... 706
FILTER............................................................................................................... 706
VALVE ............................................................................................................... 707
WATER HOSE ...................................................................................................... 707
CROSS SUPPORT PLATE ......................................................................................... 708
02 – ALIGNMENT ................................................................................................. 709
15 SUSPENSION
01 – DIRECT ACTION SUSPENSION........................................................................... 711
REMOVAL .......................................................................................................... 712
INSPECTION........................................................................................................ 713
ASSEMBLY ......................................................................................................... 714
16 HULL/BODY
01 – ADJUSTMENT AND REPAIR .............................................................................. 715
GENERAL........................................................................................................... 733
GLOVE BOX ........................................................................................................ 733
ENGINE COVER.................................................................................................... 735
SEAT ADJUSTMENT............................................................................................... 736
STORAGE COMPARTMENT INNER SHELL ..................................................................... 737
STORAGE COVER SHOCK........................................................................................ 744
STORAGE COMPARTMENT COVER ADJUSTMENT ........................................................... 745
ACCESS PANEL ADJUSTMENT .................................................................................. 746
MIRROR ............................................................................................................ 746
INFO CENTER (LCD GAUGE) ..................................................................................... 747
DEFLECTOR AND/OR UPPER GRID.............................................................................. 747
FINITION PLATE.................................................................................................... 748
INLET GRATE....................................................................................................... 748
RIDING PLATE...................................................................................................... 749
X
www.SeaDooManuals.net

TABLE OF CONTENTS
JET PUMP SUPPORT.............................................................................................. 750
DRAIN PLUG INSTALLATION..................................................................................... 751
SEAT REMOVAL.................................................................................................... 752
SEAT COVER REPLACEMENT.................................................................................... 753
BUMPER REPLACEMENT......................................................................................... 753
WAKE PYLON ...................................................................................................... 754
SPONSON REPLACEMENT....................................................................................... 756
ENGINE COMPARTMENT COVER REMOVAL................................................................... 756
DECALS REPLACEMENT.......................................................................................... 757
HULL AND BODY REPAIR......................................................................................... 758
TOOLS AND MATERIALS LIST ................................................................................... 760
THRU-HULL FITTING INSTALLATION ............................................................................ 761
17 TECHNICAL DATA
01 – GTI AND GTI LE MODELS ................................................................................. 763
02 – GTI RFI AND GTI LE RFI MODELS........................................................................ 767
03 – XP DI MODEL................................................................................................ 771
04 – RXP 4-TEC MODELS........................................................................................ 775
05 – GTX 4-TEC MODELS ....................................................................................... 781
18 WIRING DIAGRAM
01 – WIRING DIAGRAMS........................................................................................ 787
WIRE COLOR CODES............................................................................................. 787
WIRE DIGIT CODES ............................................................................................... 787
DEUTSCH CONNECTORS......................................................................................... 787
PACKARD CONNECTOR .......................................................................................... 790
AMP PLUG CONNECTOR......................................................................................... 790
IDENTIFICATION OF CONNECTOR PINS........................................................................ 793
ECM CONNECTORS............................................................................................... 794
MAIN FUSE HOLDER JOINT CONNECTOR ..................................................................... 797
XI
www.SeaDooManuals.net

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair all 2004 SEA-DOO watercraft.
See model list below.
This edition was primarily published to be used by watercraft mechanical technicians who are already fa-
miliar with all service procedures relating to Bombardier made watercraft. Mechanical technicians should
attend 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 Parts
Catalog.
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 time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of 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 on
product(s) other than those mentioned in this document.
WARNING
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: lock-
ing tab, self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency
of a locking device is impaired, it must be renewed.
WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
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 the
information 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 the
contents. We strongly recommend that any services be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.
XII
www.SeaDooManuals.net

INTRODUCTION
INTRODUCTION
This Shop Manual covers the following BOM-
BARDIER made SEA-DOO®2004 watercraft
models.
MODEL ENGINE
TYPE MODEL NUMBER
GTI (blue jay) 717 6133
GTI International (blue jay) 717 6134
GTI LE (Sonora sand) 717 6135
GTI LE International
(Sonora sand) 717 6136
GTI RFI (blue jay) 787 RFI 6137
GTI RFI International
(blue jay) 787 RFI 6138
GTI RFI LE (Sonora sand) 787 RFI 6139
GTI RFI LE International
(Sonora sand) 787 RFI 6140
GTX 4-TEC NA 1503 6147
GTX 4-TEC NA International 1503 6148
GTX 4-TEC Supercharged
Limited International
(blue pearl) 1503 6142
GTX 4-TEC Supercharged
Limited (blue pearl) 1503 6141
GTX 4-TEC Supercharged
(yellow) 1503 6143
GTX 4-TEC Supercharged
International (yellow) 1503 6144
GTX 4-TEC Wakeboard
Edition (viper red) 1503 6149
GTX 4-TEC Wakeboard
Edition International
(viper red) 1503 6150
RXP (apple green) 1503 6115
RXP International
(apple green) 1503 5599
RXP (yellow) 1503 6162
RXP International (yellow) 1503 6163
XP DI (viper red) 947 DI 6151
XP DI International (viper red) 947 DI 6152
HULL IDENTIFICATION NUMBER
(H.I.N.)
It is located on footboard at the rear of watercraft.
F00L2EA 1
1. Hull Identification Number (H.I.N.)
F08L0QA 1
TYPICAL
1. Hull Identification Number (H.I.N.)
All Models
The Hull Identification Number is composed of 12
digits:
XIII
www.SeaDooManuals.net

INTRODUCTION
Z Z N 1 2 3 4 5 L 4 9 5
Model year
Serial
number*
F00A0CB
Mon h of produc ion
Year of produc ion
* A le er may also be used as a digi .
Manufac urer
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
717 Engines
The Engine Identification Number is located on the
upper side of the magneto housing.
1
F01D01A
TYPICAL
1. Engine Identification Number (E.I.N.)
787 RFI Engines
The Engine Identification Number is located on the
upper crankcase on PTO side.
F01D87A 1
1. Engine Identification Number (E.I.N.)
947 DI Engines
The Engine Identification Number is located on the
upper crankcase on MAGNETO side.
F06D15A 1
1. Engine Identification Number (E.I.N.)
1503 Engines
The Engine Identification Number is located on
front end of the engine.
XIV
www.SeaDooManuals.net

INTRODUCTION
F18D03A
1
1. Engine Identification Number (E.I.N.)
ARRANGEMENT OF THIS
MANUAL
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Several sections are divided in various subsec-
tions. There is a table of contents at the beginning
of many sections.
XV
www.SeaDooManuals.net

INTRODUCTION
Subsec ion 04 (MAGNETO SYSTEM)
30
F01D4WS
Loc i e
243
Loc i e
243
Loc i e
243
Loc i e
243
Loc i e
243
Loc i e
648
145 Nm
(107 lbff )
An i-seize
lubrican
Page heading
indicates section
and subsection
detailed.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
F01A0CT
Illustration number
for publishing
process.
Subsection title
indicates
beginning of the
subsection.
Dotted box
contains parts of
a particular
model or an
exploded view.
Page number
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents
a liquid product
to be applied to a
surface. In this case
octite 243 to
screw threads.
Bold face number
indicates special
procedure
concerning this part.
XVI
www.SeaDooManuals.net

INTRODUCTION
1
2
Section 06 FUEL SYSTEM
Subsec ion 03 (CARBURETORS)
31
Diaphragm
XP Model Only
CARBURETOR REMOVAL
Inspect parts for corrosion dammage (shaft, butterfly,
spring screw, check valve housing, etc.).
PUMP DIAPHRAGM LEAK TEST
TYPICAL
To remove carburetors from engine, proceed as fol-
lows:
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.
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.
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.
DISASSEMBLY AND INSPECTION
Using a suitable pump gauge tester, perform the fol-
lowing 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).
Diaphragm must stand pressure for 10 seconds. If
pressure drops, replace diaphragm.
F01F0XB
A
2
1
1 2
TYPICAL PAGE
Sub-title with part
name(s) from
exploded view.
TYPICA  mention
indicates a general
view which does not
represent full detail.
Sub-sub-title in this
case indicates that
particular procedure
for XP is finished, so
from this point, all
others models are
concerned.
Title in italic indicates a
particular procedure
concerning a model.
Service tool to be
used to perform a
certain procedure.
Title indicates main
procedure to be
carried-out.
Sub-sub-title in
capital indicates a
particular testing,
adjustment or
repair procedure.
Illustration
always follows
text it is
pertained to.
Numbered step are
used to give a
sequence to be
perfomed.
Numbers are used
for description of
components.
etters are used for
any measures.
Bold numbers in the
text refer to the parts
shown in the exploded
view at the beginning
of the subsection.
F01A0BT
XVII
www.SeaDooManuals.net