Sea-doo GTI California 6116 Install guide

www.SeaDooManuals.net

2002
Shop Manual
Volume 1
GTI, GTI LE, GTX, GTX RFI,
XP, RX, RX DI, LRV DI
www.SeaDooManuals.net

Legal deposit:
National Library of Quebec
2nd trimester 2002
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. 2002
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®*Registered trademarks of Bombardier Inc.
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
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SMR2002_015_00A2.FM I
SECTION SUBSECTION PAGE
SAFETY NOTICE .................................................................................................................................. III
INTRODUCTION ................................................................................................................................... IV
01 SERVICE TOOLS
AND PRODUCTS
01 - Table of contents ...................................................................... 01-01-1
02 - Mandatory service tools............................................................ 01-02-1
03 - Optional service tools................................................................ 01-03-1
04 - Service products ....................................................................... 01-04-1
02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1
02 - Periodic inspection chart........................................................... 02-02-1
03 - Flushing and lubrication............................................................. 02-03-1
04 - Water-flooded engine................................................................ 02-04-1
05 - Storage...................................................................................... 02-05-1
03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1
04 ENGINE 01 - Table of contents ...................................................................... 04-01-1
02 - Leak test ................................................................................... 04-02-1
03 - Removal and installation ........................................................... 04-03-1
04 - Magneto system ....................................................................... 04-04-1
05 - Top end ..................................................................................... 04-05-1
06 - Bottom end ............................................................................... 04-06-1
07 - Rotary valve............................................................................... 04-07-1
08 - Exhaust system......................................................................... 04-08-1
05 ENGINE
MANAGEMENT (RFI)
01 - Table of contents ...................................................................... 05-01-1
02 - Overview................................................................................... 05-02-1
03 - Diagnostic procedures .............................................................. 05-03-1
04 - Component inspection.............................................................. 05-04-1
05 - Troubleshooting summary ........................................................ 05-05-1
06 - Adjustment................................................................................ 05-06-1
07 - Removal and installation ........................................................... 05-07-1
06 ENGINE
MANAGEMENT (DI)
01 - Table of contents ...................................................................... 06-01-1
02 - Overview................................................................................... 06-02-1
03 - Component inspection and adjustment .................................... 06-03-1
04 - Diagnostic procedures .............................................................. 06-04-1
07 COOLING SYSTEM 01 - Table of contents ...................................................................... 07-01-1
02 - Circuit, components and care ................................................... 07-02-1
08 FUEL SYSTEM 01 - Table of contents ...................................................................... 08-01-1
02 - Fuel circuit................................................................................. 08-02-1
03 - Air intake ................................................................................... 08-03-1
04 - Carburetor ................................................................................. 08-04-1
09 LUBRICATION
SYSTEM
01 - Table of contents ...................................................................... 09-01-1
02 - Oil injection system................................................................... 09-02-1
03 - Oil injection pump ..................................................................... 09-03-1
10 ELECTRICAL
SYSTEM
01 - Table of contents ...................................................................... 10-01-1
02 - Ignition system.......................................................................... 10-02-1
03 - Charging system ....................................................................... 10-03-1
04 - Starting system......................................................................... 10-04-1
05 - Instruments and accessories .................................................... 10-05-1
06 - Digitally encoded security system (DESS) ................................ 10-06-1
TABLE OF CONTENTS
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II SMR2002_015_00A2.FM
11 PROPULSION
SYSTEM
01 - Table of contents...................................................................... 11-01-1
02 - Jet pump................................................................................... 11-02-1
03 - Drive system............................................................................. 11-03-1
04 - Reverse system........................................................................ 11-04-1
05 - Variable trim system................................................................. 11-05-1
12 STEERING SYSTEM 01 - Table of contents...................................................................... 12-01-1
02 - Steering system........................................................................ 12-02-1
03 - Alignment ................................................................................. 12-03-1
13 SUSPENSION 01 - Table of contents...................................................................... 13-01-1
02 - Direct action suspension .......................................................... 13-02-1
14 HULL/BODY 01 - Table of contents...................................................................... 14-01-1
02 - Adjustment and repair .............................................................. 14-02-1
15 TECHNICAL DATA 01 - GTI and GTI LE models............................................................. 15-01-1
02 - GTX RFI model.......................................................................... 15-02-1
03 - XP model .................................................................................. 15-03-1
04 - RX DI model.............................................................................. 15-04-1
05 - LRV DI models.......................................................................... 15-05-1
06 - GTX and RX models.................................................................. 15-06-1
16 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 16-01-1
TABLE OF CONTENTS
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SMR2002_015_00A2.FM III
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair all 2002 SEA-DOO watercraft.
See model list below.
This edition was primarily published to be used by watercraft mechanical technicians who are already
familiar 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 discrepancy,
the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
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.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking 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.
This manual emphasizes particular information denoted by the wording and symbols:
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.
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.
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
SAFETY NOTICE
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IV SMR2002_015_00A2.FM
INTRODUCTION 0
This Shop Manual covers the following BOMBAR-
DIER made SEA-DOO®2002 watercraft models. HULL IDENTIFICATION NUMBER
(H.I.N.)
It is located on footboard at the rear of watercraft.
GTS, GTI and RX Series
1. Hull Identification Number (H.I.N.)
All Other Models
TYPICAL
1. Hull Identification Number (H.I.N.)
MODELS ENGINE
TYPE
MODEL
NUMBER
XP 947 5578
XP International 947 5577
GTI (ultraviolet) 717 5559
GTI International
(ultraviolet) 717 5558
GTI LE International
(earthen clay) 717 5560
GTI LE (earthen clay) 717 5561
GTI California (ultraviolet) 717 6116
GTI LE California
(earthen clay) 717 6117
GTX (yellow) 947 5588
GTX International (yellow) 947 5587
GTX RFI (blue) 787 5566
GTX RFI International
(blue) 787 5565
RX (blue) 947 5580
RX International (blue) 947 5579
RX (yellow) 947 5582
RX International (yellow) 947 5581
RX DI (blue) 947 DI 5584
RX DI International
(blue) 947 DI 5583
RX DI (yellow) 947 DI 5586
RX DI International
(yellow) 947 DI 5585
RX DI International (blue) 947 DI 5591
RX DI International
(yellow) 947 DI 5592
LRV DI 947 DI 5460
F00L2EA 1
F08L0QA 1
INTRODUCTION
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SMR2002_015_00A2.FM V
All Models
The Hull Identification Number is composed of 12
digits:
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
717 Engine
The Engine Identification Number is located on the
upper side of the magneto housing.
TYPICAL
1. Engine Identification Number (E.I.N.)
787 RFI Engine
The Engine Identification Number is located on the
upper crankcase on PTO side.
1. Engine Identification Number (E.I.N.)
947 Engine
The Engine Identification Number is located on the
upper crankcase on MAGNETO side.
1. Engine Identification Number (E.I.N.)
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
1
F01D01A
F01D87A 1
F06D15A 1
INTRODUCTION
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VI SMR2002_015_00A2.FM
ARRANGEMENT OF THIS
MANUAL
The manual is divided into 16 major sections:
01 SERVICE TOOLS AND PRODUCTS
02 MAINTENANCE
03 TROUBLESHOOTING
04 ENGINE
05 ENGINE MANAGEMENT (RFI)
06 ENGINE MANAGEMENT (DI)
07 COOLING SYSTEM
08 FUEL SYSTEM
09 LUBRICATION SYSTEM
10 ELECTRICAL SYSTEM
11 PROPULSION SYSTEM
12 STEERING SYSTEM
13 SUSPENSION
14 HULL/BODY
15 TECHNICAL DATA
16 WIRING DIAGRAM
Several sections are divided in various subsections.
There is a table of contents at the beginning of
many sections.
INTRODUCTION
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SMR2002_015_00A2.FM VII
Subsec ion 04 (MAGNETO SYSTEM)
03-04-1
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 assits
you in identifying
parts and related
positions.
TYPICAL PAGE
F01A0CS
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 numbering system:
0 : ENGINE section
04: MAGNETO SYSTEM subsection
1: First page of this subsection
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents
a liquid product
to be applied to a
surface. In this case
Loctite 24 to
screw threads.
Bold face number
indicates special
procedure
concerning this part.
INTRODUCTION
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