Sea-doo GSX Limited Install guide

GSX Limited
www.SeaDooManuals.net

Legal deposit:
National Library of Quebec
National Library of Canada
All rights reserved. No parts of this manual may be
reproduced in any form without the prior written
permission of Bombardier Inc.
©Bombardier Inc. 1997
Printed in Canada
®*Registered trademarks of Bombardier Inc.
Loctite®is a trademark of Loctite Corporation
Snap-on®is a trademark of Snap-on Tools Corpo-
ration
Gelcote®is a trademark of Gelcote International
Limited
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I
SECTION SUBSECTION PAGE
SAFETY NOTICE....................................................................................................................................... II
01 ENGINE 01 - Magneto System................................................................ 01-01-1
02 - Top End .............................................................................. 01-02-1
03 - Bottom End ........................................................................ 01-03-1
04 - Exhaust System ................................................................. 01-04-1
02 COOLING SYSTEM 01 - Circuit ................................................................................. 02-01-1
03 FUEL SYSTEM 01 - Carburetion ........................................................................ 03-01-1
04 ELECTRICAL SYSTEM 01 - Ignition and Charging Systems........................................... 04-01-1
02 - Starter................................................................................. 04-02-1
05 PROPULSION SYSTEM 01 - Drive System and Jet Pump............................................... 05-01-1
06 TECHNICAL DATA 01 - GSX Limited ....................................................................... 06-01-1
07 WIRING DIAGRAM ........................................................................................................................ 07-01-1
TABLE OF CONTENTS
www.SeaDooManuals.net
VOLUME 2
VOLUME 1 1997

II
SAFETY NOTICE
This manual was primarily published to be used by watercraft technicians trained by the manufacturer
who are already familiar with all service and maintenance procedures relating to Bombardier made Sea-
Doo watercraft.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at its time of manufac-
ture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufac-
turing the product.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking disk,
lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols;
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
This information relates to the preparation and use of Bombardier watercraft and has been utilized safely
and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or
injuries resulting from the improper use of the contents. We strongly recommend that any services be
carried out and/or verified by a highly skilled professional technician. It is understood that certain modifi-
cations may render use of the watercraft illegal under existing federal, provincial and state regulations.
◆WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
-CAUTION
Denotes an instruction which, if not followed, could severely damage watercraft components.
SAFETY NOTICE
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Section 01 ENGINE
Subsection 01 (MAGNETO SYSTEM)
01-01-1
MAGNETO SYSTEM 0
947 Engine
F06D0IS
Loctite 242
Loctite 242
Loctite 242
Loctite 648
Loctite
648
Anti-seize
lubricant
9 N•m
(80 lbf•in)
13 N•m
(115 lbf•in)
115 N•m
(85 lbf•ft)
9 N•m
(80 lbf•in)
6
4
5
1
7
12
13 11
8
10
3
2
9
13 N•m
(115 lbf•in)
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FLAT RATE
PARTS

Section 01 ENGINE
Subsection 01 (MAGNETO SYSTEM)
01-01-2
DISASSEMBLY
1, Cover
Loosen screws no. 2. Remove engine magneto
cover.
1. Cover
2. Screw
Remove oil pump shaft from flywheel nut.
1. Remove oil pump shaft
4,5, Rotor and Flywheel
To remove the rotor or the flywheel, the crank-
shaft must be locked.
Remove the pulse fitting beside the starter bracket
on the lower crankcase half.
1. Remove pulse fitting
Turn engine manually until slot in crankshaft coun-
terweight is aligned with the crankcase hole. In-
sert a M8 x 50 fixation screw to lock crankshaft.
CRANKSHAFT FIXATION SCREW (P/N 290 240 882)
1. Crankshaft locked
F06D1RA
12
F06D23A
1
F06D0KA
1
F06B04A
F06D2AA 1
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Section 01 ENGINE
Subsection 01 (MAGNETO SYSTEM)
01-01-3
If necessary, the magneto rotor can be removed
without the engine flywheel. Remove the 6
screws no. 7.
1. Screw
To remove the flywheel/rotor assembly, unscrew
nut no. 6 counterclockwise when facing it.
1. Nut
The flywheel is easily freed from crankshaft with
puller (P/N 420 976 235).
Install protective cap (P/N 290 877 414) to crank-
shaft.
Fully thread puller in engine flywheel.
1. Puller
8,9, Stator and Trigger Coil
Loosen screws no. 10 and no. 11 to remove the
stator and trigger coil from the engine magneto
cover.
1. Screws
CLEANING
Clean all metal components in a solvent.
Clean crankshaft taper and threads.
F06D0LA
1
F06D0MA
1
-CAUTION
Clean coils and magnet using only a clean
cloth.
F06D0PA 1
F06D0NA
1
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Section 01 ENGINE
Subsection 01 (MAGNETO SYSTEM)
01-01-4
ASSEMBLY
8,9, Stator and Trigger Coil
Install the stator and trigger coil in engine magne-
to cover. Torque screws to 9 N•m (80 lbf•in).
Reinstall wiring harness bracket no. 12 using tap-
tite screws no. 13.
Torque trigger coil screws no. 11to 9 N•m (80 lbf•in).
Torque stator screws no. 10 to 13 N•m (115 lbf•in).
1. Torque to 9 N•m (80 lbf•in)
2. Taptite screws
3. Torque to 13 N•m (115 lbf•in)
4,5, Rotor and Flywheel
Apply Loctite 648 (green) on mating surface of the
rotor no. 4.
When reinstalling rotor to flywheel, one of the
protrusion end of rotor must be aligned with hole
in flywheel.
1. Protrusion
2. Hole
Apply Loctite 648 (green) on screws no. 7 retain-
ing rotor to flywheel and torque screws in a criss-
cross sequence to 13 N•m (115 lbf•in).
Apply Loctite 242 (blue) on crankshaft taper.
1. Loctite 242 (blue) on crankshaft taper
Install flywheel and make sure to align keyway
with the crankshaft Woodruff key.
Apply Loctite 242 (blue) on nut no. 6. Install nut
with lock washer and torque to 115 N•m (85
lbf•ft).
Unlock crankshaft. Reinstall pulse fitting with
washer and torque to 23 N•m (17 lbf•ft).
1, Cover
Before installation, properly install O-ring no. 3 in
engine magneto cover.
Apply Loctite 767 anti-seize compound on screws
no. 2. Torque screws in a criss-cross sequence to
9 N•m (80 lbf•in).
F06D0NB
1 2 3
F06D0OA
1 2
-CAUTION
Never use any type of impact wrench.
F06D24A
1
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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-1
TOP END 0
947 Engine
F06D17S
Loctite
242
Loctite
242
Synthetic
grease
1
2
10
36
rollers
8
9
7
8
Synthetic
grease
3
5
6
34 N•m
(25 lbf•ft)
3 N•m
(26 lbf•in)
34 N•m
(25 lbf•ft)
26
4
1920
21
Loctite
242
12
14
13 18
16 Synthetic
grease
11
15 17
9 N•m
(80 lbf•in)
22 23 24
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FLAT RATE
PARTS

Section 01 ENGINE
Subsection 02 (TOP END)
01-02-2
THEORY OF OPERATION
RAVE Valve System
On this engine, the RAVE valves are controlled by the Multi-Purpose Electronic Module (MPEM).
The MPEM measures 2 factors to control the RAVE valves: engine speed (RPM) and its rate of acceler-
ation.
To open the RAVE valves, the MPEM activates a solenoid which directs the positive pressure from engine
crankcase to the valves.
NOTE: A check valve on the pressure line eliminates the negative pressure from the crankcase.
RAVE VALVE OPENED
1. Pulse from crankcase
2. Check valve
3. Positive pressure to solenoid
4. Solenoid activated
5. Positive crankcase pressure to RAVE valves
F06D16S
4
35
2
1
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