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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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-3
To close the RAVE valves, the MPEM deactivates the solenoid which blocks the crankcase positive pres-
sure. The RAVE valves are opened to the atmosphere.
RAVE VALVE CLOSED
1. Pulse from crankcase
2. Check valve
3. Positive pressure blocked by the solenoid
4. Solenoid deactivated
5. RAVE valves are opened to atmosphere
F06D16T
4
3
5
2
1
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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-4
DISASSEMBLY
11, RAVE Valve
Loosen Allen screws no. 12 each side of RAVE
valve.
1. Remove screws
Remove RAVE valve no. 11.
Remove the cover no. 13of the valve by releasing
the spring no. 14.
1. Spring
Remove the compression spring no. 15.
1. Remove spring
Remove spring no. 16 retaining bellows no. 17 to
valve piston no. 18.
1. Spring
;WARNING
Firmly hold cover to valve base. The com-
pression spring inside the valve is applying
pressure against the cover.
F06D0QA 1
F06D0RA
1
F06D25A
1
F06D0SA 1
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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-5
Remove bellows from valve piston.
1. Bellows removed from piston
Unscrew valve piston no. 18 from sliding valve
no. 19.
NOTE: Hold the sliding valve to prevent it from
turning.
1. Unscrew piston
2. Hold sliding valve
Remove compression spring no. 22.
1. Remove spring
Remove supporting ring no. 23.
1. Remove supporting ring
F06D0TA
1
F06D0TB
2
1
A06D26A
1
F06D27A
1
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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-6
Remove O-ring no. 24.
1. Remove O-ring
Remove sliding valve no. 19.
1. Remove sliding valve
Remove bellows no. 17.
1. Remove bellows
1,2, Cylinder Head and Cylinder Block
Loosen cylinder head bolts no. 3 following the se-
quence shown in the next photo.
UNTORQUING SEQUENCE FOR THE CYLINDER HEAD BOLTS
F06D28A 1
F06D0UA
1
F06D0VA
1
F06D0WA
24
6
51 3 7
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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-7
Loosen nuts no. 4 following the sequence shown
in the next photo.
UNTORQUING SEQUENCE FOR THE NUTS
Remove cylinder head no. 1.
Remove cylinder head gasket no. 5.
1. Remove gasket
Remove studs no. 25.
NOTE: Studs must be removed prior cylinder
block.
1. Remove studs
Remove cylinder block no. 2.
1. Remove cylinder block
NOTE: To ease removal, a plastic tip hammer can
be used.
Remove cylinder base gasket no. 6.
7, Piston
To remove piston circlip no. 8, insert a pointed
tool in piston notch then pry it out and discard.
F06D29A
5 2 4 7
8136
F06D0YA
1
;WARNING
Always wear safety glasses when removing
piston circlips.
F06D2BA
1
1
F06D0ZA
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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-8
1. Piston notch
To extract piston pin no. 9, use puller. Refer to the
1997 Sea-Doo Shop Manual
for procedure.
NOTE: Piston pin features cageless bearing
(36 rollers).
INSPECTION
N.A.: Not Applicable
Refer to the
1997 Sea-Doo Shop Manual
for prop-
er measurement procedures.
ASSEMBLY
Assembly is essentially the reverse of disassem-
bly procedures. However pay particular attention
to the following.
11, RAVE Valve
Install the supporting ring no. 23 with the bevel
side facing the O-ring no. 24.
1. Bevel facing the O-ring
There is only one way to insert the sliding valve
no. 19 in valve housing no. 21.
1. Sliding valve ridge toward housing groove
7, Piston
Install the pistons to the crankshaft connecting
rods with the letters “AUS” (over an arrow on the
piston dome) facing in direction of the exhaust
port.
ENGINE
MEASUREMENT
TOLERANCES
NEW PARTS
(min.) (max.) WEAR LIMIT
Cylinder Taper N.A. 0.05 mm
(.002 in) 0.1 mm (.004 in)
Cylinder Out
of Round N.A. 0.008 mm (.0003 in) 0.08 mm (.003 in)
Piston/Cylinder Wall
Clearance 0.10 mm (.004 in) 0.12 mm (.005 in) 0.20 mm (.008 in)
Ring/Piston Groove
Clearance 0.03 mm (.001 in) 0.07 mm (.003 in) 0.20 mm (.008 in)
Ring End Gap 0.25 mm
(.010 in) 0.40 mm (.016 in) 1.0 mm (.039 in)
F06D10A 1
F06D11A
1
F06D12A
1
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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-9
TYPICAL — PISTON DOME SHOWN
1. Exhaust side
9,10, Piston Pin and Roller Bearing
To install roller bearing and piston pin, use piston
pin puller (P/N 290 877 094) used at removal. For
installation procedure, refer to the
1997 Sea-Doo
Shop Manual
.
8, Circlip
Secure circlips no. 8 taking into consideration the
following.
1. Circlip opening at 6 o’clock (at bottom)
To easily insert circlip no. 8, use circlip installer
(P/N 290 877 517).
1. Circlip installer
1,2, Cylinder Head and Cylinder Block
Both the cylinder head and cylinder block are po-
sitioned with locating dowels.
There is only one way to install cylinder base gas-
ket no. 6 and cylinder head gasket no. 5. They are
also properly positioned by locating dowels.
To easily slide cylinder block no. 2 over pistons
no. 7, install on piston ring compressor (P/N 290
876 965).
1. Ring compressor
NOTE: For each ring, make sure to align ring end
gap with piston locating pin.
Install studs no. 25.
Install cylinder block no. 2.
Install O-rings no. 26.
NOTE: The O-rings must be installed and properly
positioned in the cylinder block. The O-rings are
meant to dampen stud vibration.
Apply Loctite 242 (blue) on the threads of the cyl-
inder block studs no. 25.
Apply Loctite 242 (blue) below head of cylinder
head bolts no. 3.
Apply synthetic grease on threads of cylinder
head bolts no. 3.
-CAUTION
To minimize the stress on the circlips, install
them so that their openings are located at 6
o’clock (at bottom). Always use new circlips.
At installation, take care not todeform them.
◆WARNING
Always wear safety glasses when installing
piston circlips.
A01C01A
AUS
1
F06D18A
1
F06B01A
1
A01B1TA
1
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Section 01 ENGINE
Subsection 02 (TOP END)
01-02-10
Torque bolts and nuts to 15 N•m (11 lbf•ft) as per fol-
lowing sequence in the next photo. Repeat the torqu-
ing sequence by retightening to 34 N•m (25 lbf•ft).
TORQUING SEQUENCE
F06D0WB
31
12
45 15
7 10 8 14 6
11913 2
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Section 01 ENGINE
Subsection 03 (BOTTOM END)
01-03-1
BOTTOM END 0
947 Engine
F06D19S
11
Loctite 242
10
24
25
Loctite
242
9 N•m
(80 lbf•in)
18 16
17
19
22
2021
18 17
19
Synthetic
grease
15
1
15
Synthetic
grease
Loctite
242
14
Loctite
242
15
1
Synthetic
grease
25
115 N•m
(85 lbf•ft)
3
Loctite
648
Loctite
242
Synthetic
grease
23 N•m
(17 lbf•ft)
Loctite
242
4
15
11
Loctite
518
79 N•m
(80 lbf•in)
Loctite
242
8
96
23
Synthetic
grease
Loctite 518
Synthetic grease
Loctite
518
13
Synthetic
grease
23 N•m
(17 lbf•ft)
13 23 N•m
(17 lbf•ft)
Loctite
518
12
Synthetic grease
12
Loctite 518
Synthetic grease
13 23 N•m
(17 lbf•ft)
40 N•m
(30 lbf•ft)
Anti-seize
lubricant
Anti-seize
lubricant
26 30 mL
(1 oz)
Formula
XP-S
synthetic
oil
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FLAT RATE
PARTS

Section 01 ENGINE
Subsection 03 (BOTTOM END)
01-03-2
DISASSEMBLY
The following components should be removed
prior to opening bottom end:
– magneto cover
– magneto flywheel
– starter
1, Seal
If a crankshaft end seal has to be replaced, bot-
tom end must be opened.
2, PTO Flywheel
Lock the crankshaft using the same procedure for
the magneto flywheel removal. Refer to ENGINE
01-01.
Loosen the 6 Allen screws no. 4 retaining the
coupling flange no. 3 to the PTO flywheel.
1. Allen screw (6)
Remove the coupling flange no. 3.
Loosen bolt no. 5 retaining the PTO flywheel to
the crankshaft.
1. Bolt
Remove the PTO flywheel no. 2 using puller
(P/N 290 976 237).
Install puller to PTO flywheel. Insert 6 M8 x 30
screws (P/N 290 940 481) through puller holes
and tighten screws in PTO flywheel to extract it
from crankshaft.
F06D1AA 1
F06D1BA 1
F06B02A
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