Sea-doo SP 5873 Install guide

MANUAL
SP 5873, SPI 5875, SPX 5874, GTS 5815, GTX 5863, XP 5857
Lifho'd in Canada
www.SeaDooManuals.net

SHOP
MANUAL
www.SeaDooManuals.net

1 Legaldeposit :
I
i National Library of Quebec
I
National Library of Canada
All rights reserved. No parts of this manual may be repro-
duced in any form without the prior written permission of
Bombardier Inc.
OBombardier Inc.
1995
I
Printed inCanada
@*Registeredtrademarks of Bombardier Inc.
1
Loctitemis atrademark of Loctite Corporation
I
Snap-on@ is atrademark of Snap-on Tools Corporation
GelcoteQD
is atrademark of Gelcote International Limited
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TABLE OF CONTENTS
-
00-Table of Contents .....................................................................
0500-1
. Components .................................................................................... 0501-1
02
. Circuit .......................................................................................... 0502-1
SECTION SUBJECT PAGE
SAFETY NOTICE ........................ .. ........................................................................................................................... I I
INTRODUCTION
.......................................................................................................................................................... 111
0 1 SERVICE TOOLS
AND PRODUCTS
02 MAINTENANCE
03 TROUBLESHOOTING
04 ENGINE
.............................................................................
01 . MandatoryTools 01-01-1
02
. RecommendedTools ..................................................................... 01-02-1
03
. ServiceProducts .......................................................................... 01-03-1
00 -Table of Contents
......................... .. ........................................... 02-00-1
01
. Periodic InspectionChart ................................................................ 02-01-1
02
. Flushingand Care ...................... ... ............................................. 02-02-1
............................ ............................ 03 -Water Flooded Engine ............ 02-03-1
04
- Storage .......................................................................................... 02-04-1
00
- Troubleshooting ........................ ... .............................................. 03-00-1
............................................................................ 00-Table of Contents 04-00-1
01
- Removaland Installation ........................... .. .............................. 04-01-1
02
- Top End ...................................................................................... 04-02-1
03
- Bottom End .................................................................................... 04-03-1
04
- RotaryValve .................................................................................. 04-04-1
05
- Exhaust System .......................... .. .............................................. 04-05-1
06 FUEL SYSTEM
07 LUBRICATIONSYSTEM
08 ELECTRICAL SYSTEM
........................................................................... 00 . Table of Contents 06-00-1
01
. Fuel Circuit ................................................................................... 06-01-1
02
. Air Intake ...................................................................................
06-02-1
03
. Carburetors ..................................................................................... 06-03-1
00-Table of Contents ......................................................................... 07-00-1
01
. Oil InjectionSystem .................................................................... 07-01-1
02
. Oil InjectionPump ........................................................................... 07-02-1
00
. Table of Contents ............................................................................ 0840-1
01
. Magneto System .......................................................................... 08-01-1
02
. IgnitionSystem ........................................................................... 08-02-1
03
. Charging System ......................................................................... 08-03-1
04
. Starting System .......................................................................... 08-04-1
05
. Instrumentsand Accessories ..................................................... 08-05-1
09 PROPULSIONSYSTEM
10 STEERING SYSTEM
1 HULLIBODY
1 2 TECHNICAL DATA
00
. Table of Contents ........................................................................
09-00-1
01
. Jet Pump ....................... ... ......................................................... 09-01-1
02
. DriveSystem ............................................................................. 0902-1
03
. Reverse System .......................................................................... 0903-1
04-VariableTrim System
...................................................................... 09-04-1
00
- Table of Contents ........................................................................... 10-00-1
01
- SP andXP Series ............................................................................. 10-01-1
02
- GTS and GTX Models ................... .. ............................................. 10-02-1
03
- Alignment ................................................................................... 10-03-1
00 - Table of Contents ............................................................................ 11-00-1
01
- Adjustment and Repair .................................................................... 11-01-1
02
- Painting ........................................................................................... 11-02-1
01
- SP and SPI Models ...................................................................... 12-01-1
02
- SPX and XP Models ................................................................... 12-02-1
03
- GTS and.GTX Models ...................................................................... 12-03-1
ANNEXES (ElectricalWiring Diagrams)
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SAFETY NOTICE
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 relatingto
BombardiermadeSea-Doo watercraft.
Please notethatthe instructionswill applyonly if proper handtools and specialservicetools are
used.
It is understoodthat this manual may be translated into local language upon certain conditions
andfurthermoreagreed that inthe event of any discrepancyamong the
2 versions, the English
version shall prevail.
The contentdepicts parts and
/ or procedures applicable to the particular product at its time of
manufacture. Itdoes not includedealer modifications,whether authorizedor notby Bombardier,
after manufacturingthe product.
The use of Bombardierparts is most strongly recommendedwhen considering replacementof
any component. Dealer and I or distributorassistanceshouldbe sought incase 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
efficiencyof a lockingdevice is impaired,
it must be renewed.
This manual emphasizes particular informationdenoted bythe wording and symbols
;
WARNING : Identifies an instruction which, if not followed, could cause serious
personal injury including possibility of death.
v
CAUTION : Denotes an instruction which, if not followed, could severely damage
watercraft components.
0
NOTE : Indicatessupplementaryinformationneededtofully completean instruction.
Althoughthe mere reading of such informationdoes not eliminatethe hazard, your understand-
ingof the informationwill promoteitscorrect use. Always use common shop safety practice,
This information relates to the preparation and use of Bombardier watercraft and has been
utilizedsafelyand effectivelyby BombardierInc. However,Bombardier Inc.disclaimsliabilityfor
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 understoodthat certain modifications may render use of the watercraft illegal
under existingfederal, provincialand state regulations.
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1995 BOMBARDIER WATERCRAFT SHOP MANUAL
lNTRODUCTlON
The 5 digits after ZZN are the watercraft serial number.
This
Shop Manualcovers BOMBARDIER made SEA-
DOO" watercraft models SP
5873, SPX 5874, SPI 5875.
XP 5857, GTS 5815 and GTX 5863.
ZZN 12345.XXXX
w Serial number
WATERCRAFT MODEL NUMBER
Itis located on U.S. Coast Guardapproved labelon left
ENGINE lDENTlFlCATlON NUMBER
hand side of stern (rear)eyelet.
(E.I.N.)
HULLIDENTIFICATIONNUMBER
(H.I.N.)
It is locatedat right hand rear side of hull.
It is located on the upper side of the magneto housing.
ARRANGEMENT OF THIS MANUAL
The manual is divided into 12 major sections :
01 SERVICETOOLS AND PRODUCTS
02 MAINTENANCE
03TROUBLESHOOTING
04 ENGINE
05 COOLING SYSTEM
06 FUELSYSTEM
07 LUBRIFICATION SYSTEM
08 ELECTRICAL SYSTEM
09 PROPULSION SYSTEM
10 STEERING SYSTEM
11 HULL 1 BODY
12TECHNICAL DATA
Each section is divided in various sub-sections, and
again, eachsub-section hasone or moredivision. There
is a table of contents at the beginning of each section.
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1995 BOMBARDIERWATERCRAFT SHOP MANUAL
This Shop Manual usestechnicalterms which may be
slightlydifferent from the ones inthe
Parts Catalog.
TYPICAL PAGE
Page headingindicates
sectionand sub-section
detailed.
Sub-sectiontitle
to screw threads.
Inthis case, nutmust betorqued Page numberingsystem
: 08 : ELECTRICALSYSTEM section
to 145Nmm
(107 Ibfeft). 01
: MAGNETOSYSTEM sub-sect~on
1 : First page of this sub-section
v
CAUTION : Pay attentiontotorque specifica-
tions. Some of these are in Ibf-ininstead of
Ibf-fl. Use appropriate torque wrench.
-
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1995 BOMBARDIERWATERCRAFT SHOP MANUAL
TYPICAL PAGE
Smetion W FUEL SYSTEM
Sub-Section 03 (CARBURETORS)
DISASSEMBLYAND INSPECTION
Sub-title beginning
Removeair vent tubs sumn.
with part number(s1
Unlock retainingsbdas holdingairintskealencef Cwer
of aboveexploded
and removemvsr. Inspect needle valve tip
~ci a grooved condion. 11
view following by
R~OVO scr- holnoretalnerend air intakesaencer needleand replsced
Or a
part narne(s).
base. R-e airintakesilencer bass fromwatercnft.
set'
Removescrewsholdingflameanesterbasesuwonlo 31.33. Low Speed Screw
cylinderheadcovef.
"Typical" mention
Servicetool to be at top leftcorner
indicates ageneral
view which does
not represent full
detail.
Illustration always
followstext it
is
pertainedto.
Remove carburetorsfrom intake manifold. Repeat the same procedure st the outlet n~ppleThis
are concerned.
II~B the out~etvalve should hold with pressure and
WARNING : Somefuel may bs present infuel
Remove csrburetor(slfromrotary wlvs cover. pump. Be caroful not to
sw.llow fuel when
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1995 BOMBARDIER WATERCRAFT SHOP MANUAL
GENERAL INFORMATION
The use of RIGHT and LEFT indications in the text,
always refers to driving position (whensitting on wa-
tercraft).
The information and component
1 system descriptions
contained inthis manual are correctat time of publica-
tion. Bombardier Inc. however, maintains a policy of
continuous improvement of its products without im-
posing upon itself any obligation to install them on
productspreviouslymanufactured.
Bombardier Inc. reserves the right at any time to dis-
continue or change specifications, designs, features,
modelsor equipment without incurringobligation.
This
Shop Manual uses technicaltermswhich may be
differentfrom the ones of the
Parts Catalogs.
When ordering parts always refer to the specific
model
Parts Catalogs.
ILLUSTRATIONSAND PROCEDURES
The illustrations show the typical construction of the
different assemblies and, in all cases, may not repro-
duce the full detail or exact shape of the parts shown,
however, they representpartswhich havethe same or
asimilar function.
v
CAUTION : Thesewatercraftaredesignedwith
parts dimensioned in boththe metric and the
imperial systems. When replacing fasteners, make
sure to use only those recommended by Bombar-
dier. Mismatchedorincorrectfastenerscould cause
damage to the watercraft or possible personal in-
jury.
As many of the proceduresinthis manualare interrela-
ted, wesuggest, that beforeundertakingany task, you
read and thoroughly understand the entire section or
sub-section inwhich the procedureis contained.
A number of procedures throughout the book require
the use of special tools. Before commencing any pro-
cedure, be sure that you have on hand all the tools
required, or approvedequivalents.
Technical Publications
Bombardier Inc.
Valcourt (Quebec),Canada
PARTS CATALOGS
MODELS
SP (5873)
SPX (5874)
SPI (5875)
GTS (5815)
GTX (5863)
XP (5857)
PIN
219 800 016
219 800 018
219800017
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Section 01 SERVICE TOOLS AND PRODUCTS
Su b-Section 01 (MANDATORY TOOLS)
MANDATORY TOOLS
0 NOTE : Reversalnumbers (example : I correspondto those of the Sea-Doo Service Tools Order Form.
ENGINE
Degreewheel
P / N 295 000 007
A000001111
APPLICATION
All models.
Puller
P 1 N 295 000 106
H
A000002 046
APPLICATION
All models.
Pusher
P / N 290 876 500
m
(ux
M)M)001091
APPLICATION
All models.
P / N 290 876 298
P / N 290 876 557
P / N 290 977 490
--------
) Ring halves (PTO)
P 1 N 290977475
--------
I Distance ring (MAG)
P / N 290 276 025
--------
) Screw M8 x 40
P / N 290840681
Pistoncirclip installer
A) P / N 295 000 077
B)P/N290877016
Q==QCD
A001 001061
APPLICATION
A) 587 engine.
B)
657 X and 71 7 engines.
Pusher
P / N 290 876 605
m
a
AWP 002 034
APPLICATION
All models.
Bombardier ignition
tester
rn
P / N 295 000 008
[Zi
0 -@Z,
AWO 002 066
APPLICATION
All models.
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Section 01
SERVICE TOOLS AND PRODUCTS
Sub-section 01 (MANDATORY TOOLS)
Rubber pad
P / N 295 000 101
m
Fool 001 019
Puller plate
P
1 N 290 876 080
m
loo?2E - - - - - - - - -
Extension handle Ha
PIN 295000 111
-
Fool 003 042
-------I----
Screw M8 x 35 (3)
P / N 290 841 591
rn
fizMw -- - -- - - - -
Sleeve (3)
P 1 N 290 847 220
m
PTO flywheel remover I
installer
P 1 N 295 000 001
0
NOTE : This tool is also
used for the impeller.
F001008 023
APPLICATION
All models.
Distancegauge
P
1 N 290 876 826
m
WI APPI-ICATION MI 017 9
587 and 717 engines.
Puller
P / N 290 876487
rn
(T(@-
MO1001 018
APPLICATION
All models.
Alignment tool
P I N 295 000 089
m
MOl011099
APPLICATION
All models.
Piston pin puller
PIN 295 000 105
ma
Replacement pans :
1- Locatingsleeve
IP I N 290 877 180)
2- Expansion sleeve
IP I N 290 877 0401
3- Extraclngnut
(PIN290877 1151
Fool001031
APPLICATION
71 7 engine.
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Section 01
SERVICE TOOLS AND PRODUCTS
Sub-section 01 (MANDATORY TOOLS)
COOLING / FUEL / OIL SYSTEMS
Hosepincher
P
/ N 295 000 076
I
A001 001 090
APPLICATION
All models.
Fool 001 076
657 X engine.
--
I Gear holder
A000 002 042
All models.
Pliers
rn
P / N 295 000 070
>
FGQ1003043
APPLICATION
All models.
Pliers
P / N 295 000054
F001001086
APPLICATION
All models.
0
NOTE : This toolisalso used
for the propulsionsystem.
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Section 01
SERVICE TOOLS AND PRODUCTS
Su b-Section 01 (MANDATORYTOOLS)
PROPULSION SYSTEM
Impellerremover /
installer
m
P / N 295 000 001
0
NOTE : This tool is also
used for the PTO flywheel.
Fa01 WS 029
APPLICATION
All models.
Pliers
P
/ IV 295 000 069
m
FW1003 044
APPLICATION
All models.
Impeller shaft holder
P / N 295 000 082
0
Fool Wl032
APPLICATION
All models.
Bearing
/ seal installer
PI
N 295 000 107
APPLICATION
All models.
Impellershaft guide
P
1 N 295 000 002
ma
aB
miooam
APPLICATION
All models.
Pliers
rn
P 1 N 295 000 054
Fool 001 Mu
APPLICATION
All models.
0
NOTE : Thistool is also used
for the fuel system.
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Section 01 SERVICE TOOLS AND PRODUCTS
Su'b-Section 02 (RECOMMENDEDTOOLS)
RECOMMENDED TOOLS
0 NOTE : Reversalnumbers(example : ) correspondto those of the SeaDooService Tools Order Form.
ENGINE
Ring compressor
A) P / N 290 876 972
B)P/N295000112
A001 001 085
APPLICATION
A)
587 engine.
B)657 X engine.
Coil centeringtool
P 1 N 290 876 922
m
A001001 Ocn
APPLICATION
All models.
Cylinder aligningtool
P / N290 876 902
0 0 0 0
0
0 0 0
AOWOO1008
APPLICATION
All models.
Stroboscopictiming light
P 1 N 295 000 078
A001001 C92
APPLICATION
All models.
Dial indicator
(TDCgauge)
m
P / N 295 000 065
A000 001 ow
APPLICATION
All models.
Digital
/ inductiontype
tachometer
PIN295000 100
FODl001062
APPLICATION
All models.
Digitalmultimeter
P / N 529 022 000
m
FcQl001Oo
APPLICATION
All models.
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Section 01
SERVICE TOOLS AND PRODUCTS
Sub-section 02 (RECOMMENDEDTOOLS)
Coupler hose
P 1 N 295 500 258
rn
Fool 004 036
APPLICATION
All models.
Timing mark pointer
P 1 N 295 000 102
€m
Fool 007 127
APPLICATION
All models.
Engine liftingdevice
Not sold by Bombardier
Do
it yourself
Referto
Shop Manual section
04-0
1
FW1W3 010
APPLICATION
All models.
Feeler gauge
45"
Not sold by Bombardier
FW1W1066
APPLICATION
All models.
Spark tester
Not sold by Bombardier
Superex Canada Ltd
NO.
15-785
FWl Wl063
APPLICATION
All models.
Slide hammer puller
Not sold by Bombardier
Snap-on : Handle CJ93-1
Hammer CJ125-6
Claws CJ93-4
0
NOTE,: This tool is also
used to pull out impeller
shaft seal.
FWl008036
APPLICATION
All models.
Protective mat
PIN295000
128
APPLICATION
All models.
Terminal remover
Not sold by Bombardier
Snapon
FWlWl 066
APPLICATION
All models.
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Section 01 SERVICE TOOLS AND PRODUCTS
Sub-section
02 (RECOMMENDED TOOLS)
COOLING / FUEL / OIL SYSTEMS
Pump gauge tester
(carburetor)
PIN
295000 114
FWl001033
APPLICATION
All models.
Pump gauge tester
(fuel
1 oil reservoirs)
m
P 1 N 295 000 085
FW1001034
APPLICATION
All models.
Screwdriver
Not sold
by Bombardier
Snapon
SDD143
FW1WlOBI
APPLICATION
All models.
Lighted adjustable mirror
Not sold
by Bombardier
Snapon
50101
m
1
Fool 001 061
APPLICATION
All models.
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Section 01
SERVICE TOOLS AND PRODUCTS
Sub-section 02 (RECOMMENDED TOOLS)
PROPULSION SYSTEM
Fitting
P 1 N295 000 086
&$59
FM)l 001036
APPLICATION
All models.
Impeller housing
remover
PIN295 000
113
FOOl 01 1096
APPLICATION
All models.
Slide hammer puller
Not sold by Bombardier
Snapon : Handle CJ93-1
Hammer CJ125-6
Claws CJ93d
0
NOTE : This tool is also
usedto remove rotaryvalve
shaft bearing.
Fool 00903s
APPLICATIOIV
All models.
Ride shoe remover
Not sold by Bombardier
Do ityourself
Refer to
Shop Manualsection
09-0
1
FWlW9025
APPLICATION
All models.
Hacksaw
Not sold by Bombardier
Sna -on
H !3
P-
FOOl W1068
APPLICATION
All models.
Machinist's square
Not sold by Bombardier
F002 w1006
APPLICATION
Models equippedwith reverse.
Fitting remover
Not sold by Bombardier
Do ityourself
Refer to
Shop Manualsection
09-0
1
Deep socket 14 mm(911 6 in)
Deep socket
14 mrn
(9116 in1
Q
Fool 009 099
APPLICATION
All models.
Bearing remover
Not sold by Bombardier
Do
it yourself
Referto
Shop Manualsection
09-0
1
-
--
M01009037
APPLICATION
All models.
Drive shaft puller
Not sold by Bombardier
Do
it yourself
Refer to
Shop Manualsection
09-02
%
FWl W8006
APPLICATION
All models.
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Section 01
SERVICE TOOLS AND PRODUCTS
Sub-section 02 (RECOMMENDEDTOOLS)
WATERCRAFT HANDING
Dolley(withoutwheels)
P / N 295 000004
F001001001
APPLICATION
All models.
Beachwheels
P / N 295 000 005
m
Fool 001 007
APPLICATION
All models.
Lift kit
A)
PIN295 100012
B)P/N295100013
FW1 001069
APPLICKI'ION
A) SP and
XP series.
B) GTS and GTX models.
Tie-down
1.50 m (5 ft) long
PIN295 100010
APPLICATION
All models.
Tie-downwith ratchet
3.60 m (1 2 ft) long
PIN 295 100011
APPLICATION
All models.
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Section 01
SERVICE TOOLS AND PRODUCTS
Sub-section 03 (SERVICE PRODUCTS)
SERVICE PRODUCTS
0 NOTE : Reversal numbers (example : 1 correspond to those of the Sea-Doo Service Tools Order Form.
Mediumstrength
threadlocker
m
PIN 293 800015
Loctite 242 (blue)
(10 mL)
AOM)Ool~lO
APPLICATION
Cylinderhead screws
(657 X / 71 7 engines).
Tuned pipe nut and screws.
Engine rubber mount screws.
Armature platescrews.
Magnetoflywheel
/ crankshaft.
Carburetormount nuts
/ screws.
Magneto coil screws.
lmpeller housing cover screws
(exceptfor plastic pumps).
Venturi
/ impeller housing
screws.
Intakegrate screws.
Engine support screws.
lmpeller housing
I hullnuts.
Steeringnozzle screws.
Reversegate screws.
Highstrength
threadlocker
m
P / N 293 800 005
Loctite 271 (red)
(10 mL)
AOOO Wl 102
APPLICATION
lmpeller shaftthread.
Steeringstem
1 stemarm screw
(GTS I GTX).
Hightemperature
threadlocker
m
P 1 N 290 899 788
Loctite 648 (green)
(5 g)
AOOO 001 121
APPLICATION
Crankcase
/ plug at end of rotary
valve shaft.
Magneto
/ ringgear.
Paste gasket
P / N 293 800 007
m
Loctite 51 5
(50mL)
AOOO w1101
APPLICATION
Cylindersleeve
1 O-ring groove.
Crankcasehalvesmatingsurface.
Crankcasescrews.
Paste gasket
P
1 N 293 800 038
Loctite 518
(60 mL)
H)01 001038
APPLICATION
lmpeller housingcover.
Venturi
1 impeller housing.
lmpeller shaft seal.
Seal carrier.
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Section 01
SERVICETOOLS AND PRODUCTS
Su b-Section 03 (SERVICE PRODUCTS)
Solvent
P
/ IN 293 800 01 9
ma
Loctite Safety Solvent
755
AMW) 001 130
APPLICATION
Impellershaft threads.
Drive shaft splines.
Impellerthreads and splines.
Primerfor paste gasket
PIN
293 600 013
Loctite
Locquic Primer
N
170 g (6 oz)
AWO001131
APPLICATION
Crankcasehalves matingsurface.
Impellershaftthread.
Venturi
1 impellerhousingmating
surface.
Gasket stripper
PIN
295 500 110
m
MOl 001 068
APPLICATION
Matingsurfaces of cylindersand
crankcase.
Crankcasehalves.
Pipe sealant
PI
N 293 800 018
Em
Loctite 592
AOW 001 104
APPLICATION
Plugon impeller housingcover.
Plasticfitting tool
(P I N 295 000
086)
on impeller housing cover.
Coolingsystemfittings.
Heat resistantsealant
PIN
413 709 200
DowCorning 736
AGm00113a
APPLICATION
Tuned pipe of XP and
GTX
models.
Dielectricgrease
P I N 293 550 004
m
Dow Corning
Fool001 042
APPLICATION
Battery posts and cable connec-
tors.
Thermosensorswitch.
Grease
P / N 293 550 005
m
(400 g)
AOOD 001083
APPLICATION
Seal carrier.
PTO flywheel.
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