Sea-doo Spark Operating instructions

Polytec Surface
Care and Repair
Hull and Deck
Technical Service Procedures
IMPORTANT
BRP strongly recommends providing a copy of this
document to your local body shop before it performs
any repairs on a Polytec hull or deck.
Version Date: September 30, 2019
2 1 9 1 0 1 0 2 9

All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP)
© Bombardier Recreational Products Inc. (BRP) 2019
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada
® ™ Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
219101029 - Polytec Surface - Care and Repair online booklet en AP
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2019 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
ACE™ GTS™ WAKE™
FISH PRO™ RXT™ X™
GTI™ Sea-Doo® XPS™
GTR™ SPARK™
This document contains the trademarks of the following companies:
3M is a trademark of 3M.
Fabuloso is a trademark of Colgate-Palmolive Company.
Fantastik is a trademark of S.C. Johnson & Son, Inc.
Kleen-Flo is a trademark of Kleen-Flo Tumbler Industries Limited.
WD-40 is a trademark of WD-40 Manufacturing Company.
R-M is a trademark of BASF Corporation.
Meguiar’s Gold Class is a trademark of Meguiar’s Inc.

1
Table of Contents
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Aesthetic Damage - Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Structural Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Location of Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HULL AND DECK IDENTIFICATION
IDENTIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
CARE AND PRODUCTS
SPECIAL CARE OF POLYTEC SURFACES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fuel Spillage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Aggressive Liquids and Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heat Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Flame Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Storage Shrink Wrap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PRODUCTS SAFE FOR USE ON POLYTEC SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
PRODUCTS TO BE USED WITH CAUTION ON POLYTEC SURFACES. . . . . . . . . . . . . . . . . . . .10
PRODUCTS PROHIBITED FROM USE ON POLYTEC SURFACES . . . . . . . . . . . . . . . . . . . . . . . 11
REPAIR PROCEDURES
QUICK REFERENCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PLASTIC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
POLYTEC RESURFACING TECHNIQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2
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3
OVERVIEW
The Polytec deck and hull are made of a single
thick skin of polypropylene reinforced with
fiberglass.
Aesthetic Damage - Scratches
An external scratch is the result of the hull or
deck surfaces rubbing against a rough or sharp
object.
This type of damage does not cause any
operational problems. This type of damage is
exclusively aesthetic.
In most cases, this damage can be removed or
diminished by buffing over the scratch using the
Polytec Resurfacing Technique. Refer to REPAIR
PROCEDURES at the end of this document.
The results may vary, depending on the affected
area.
Structural Damage
IMPORTANT
BRP strongly recommends providing a copy
of this document to your local body shop
before it performs any repairs on a
Polytec hull or deck.
Structural damage is usually the result of
impact. The component is cracked or pierced.
The size and location of the damage are
deciding factors when evaluating if the
component should be repaired. For example,
repairing a large area of complex damage under
the engine might require as much labor as a
hull replacement. An estimate of the labor cost
should be used to guide the decision.
The decision to repair or replace should be
based on the customer’s expectations regarding
cost, aesthetics, resale value, and how quickly
the job must be completed.
Cracks
This is the most common type of damage after
scratches.
A crack is a fracture which penetrates the
material of a component. The opening is
visible from the inside and the outside of the
component.
Holes
The second type of structural damage is a hole,
usually the result of an impact with an external
object. A piece of the damaged component may
be missing.
A hole can be repaired using the original piece
if it is not bent or damaged. A new piece of
Polytec material, cut to size, can also be used.
NOTICE
Failure to follow the recommendations presented
in this bulletin may result in a poor quality repair
or damage to the Polytec surface.

4
Location of Damage
Certain areas of the hull are critically sensitive to dimensional precision and should not be repaired by
plastic welding.
It is not recommended to repair structural damage at the bow and transom tow hooks as well as in the
following areas:
Ribbing
Pump support and ride plate mating surfaces
Intake grate mating surface
Keel line

5
HULL AND DECK
IDENTIFICATION

6
IDENTIFICATION CHART
YEAR MODEL MODEL MODEL HULL DECK
Up to 2016 Spark All Polytec Polytec
2017
GTS 25HC, 25HD Polytec Acrylic/ABS
GTI (900 ACE) 37HC, 37HD
Spark All Polytec Polytec
2018
GTI (900 ACE)
GTI SE (900 ACE)
GTS WAKE 155
All Polytec
Gelcoat (black and white)
Acrylic/ABS (other colors)
Spark All Polytec Polytec
2019 GTS WAKE 155 All Polytec Acrylic/ABS
Spark All Polytec Polytec
2020
GTI Pro
RXP-X All Gelcoat Acrylic/ABS
GTI
WAKE 155
GTI SE
GTR
All Polytec Acrylic/ABS
GTX
RXT
Fish Pro
Wake Pro
All Acrylic/ABS Acrylic/ABS

7
CARE AND PRODUCTS

8
SPECIAL CARE OF POLYTEC SURFACES
Fuel Spillage
NOTICE
Wipe up spilled fuel immediately. Failure to
clean fuel spillage may weaken the surface and
cause damage.
Washing
Wash the vehicle with a solution of mild soap or
detergent and lukewarm water.
Use a clean, soft cloth, applying only light
pressure.
Rinse with clean water and dry with a damp
cloth or chamois.
Aggressive Liquids and
Solvents
If a cleaning liquid or organic solvent is used, it
should be removed as soon as possible to avoid
a chemical attack on the surface.
The time required for a chemical attack to occur
can be surprisingly short.
Damage can be minimized and/or eliminated if
no aggressive liquids or solvents are used.
Heat Gun
NOTICE
Do not use a heat gun to perform the following:
– Decal removal
– Carpet replacement
– Pump support removal
– Ride plate removal
If heat is applied to the same area for too long,
the high temperature can damage the surface.
Flame Treatment
Flame treatment:
– Is a quick movement over an area or
component with a blow torch.
– Should never be too intense. The part should
never melt to the point that it looks polished.
– Will burn any excess plastic around a
scratch.
Storage Shrink Wrap
When shrink wrapping a vehicle, several
precautions must be followed to avoid damage
to the finish.
1. Wash the vehicle with a mixture of water and
light detergent.
NOTICE
Do not use a no-rinse, wash-and-shine product
on any acrylic components. This type of product
may contain agents not compatible with the
surface finish, which could lead to acrylic
crazing during storage.
2. Dry the vehicle thoroughly.
3. Install the shrink wrap.
NOTICE
Avoid touching the vehicle surface with the
torch flame during the shrinking process or
heating a particular area for an extended period
of time.
4. Install vents to allow proper ventilation under
the shrink wrap.

9
PRODUCTS SAFE FOR USE ON POLYTEC SURFACES
While it is impossible to test every product used in every region of the world, some common ones are
know to be compatible with Polytec.
NOTICE
If using other products, always test on a hidden area before use.
BRP recommends the use of the following care products on Polytec hulls and decks:
XPS Care Products:
– SEA-DOO® HULL CLEANER
– WASH & WAX
– CLEANER & DEGREASER ALL PURPOSE
– MULTI-SURFACE & GLASS CLEANER
– UV PROTECTANT VINYL & PLASTIC
XPS PRO Products:
– C1 - Cleaner and Degreaser (Canada and USA only - not for retail)
– C2 - Cleaner Surface (Canada and USA only - not for retail)
– C4 - Cleaner Extra Foaming (Canada and USA only - not for retail)

10
PRODUCTS TO BE USED WITH CAUTION ON POLYTEC
SURFACES
While it is impossible to test every product used in every region of the world, some common ones are
known to be compatible with Polytec.
These products are safe when used under controlled conditions, as per manufacturer’s instructions.
NOTICE
– Always follow the manufacturer’s instructions.
– Do not leave raw product on surfaces for an extended period of time. Wipe up immediately after
application.
– If using other products, always test on a hidden area before use.
Be careful when using the following care products on Polytec hulls and decks:
– 3M™ Marine Cleaner and Wax
– Meguiar’s® Gold Class™ Carnauba Wax
– Dish soap
– Fabuloso® All-Purpose Cleaner Liquid Solution
– Fantastik® Original All Purpose Cleaner
– Kleen-Flo Glass Kleen
– R-M® 900 Pre-Kleano
– WD-40®

11
PRODUCTS PROHIBITED FROM USE ON POLYTEC
SURFACES
While it is impossible to test every product used in every region of the world, some common ones are
known to cause damage.
NOTICE
NEVER use cleaners or products containing the following:
– Acetone or other ketones
– Alcohol
– Ammonia
– Chlorinated solvents
– Mineral spirits
– Paint thinners
– Petroleum-based products
– Toluene or other aromatic solvents

12
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13
REPAIR PROCEDURES

Type
Tools & Products Where to Buy
Rotary Wire Brush
PP + GF 30% 8-9 mm (1/3”) Shape: flat or triangle
Crimped Cup Brush 2” (5 cm), coarse or medium, SS
PlasticSolutionsUK.com
***
Hot Air Plastic
Welding Tool
Auto Supply Store or Renovation
Center
0 5mm (1/2”) 15°
Leister Triac ST * Leister.com/en/Plastic-Welding/
Products/Hot-Air-Hand-Tools
**
Tubular Nozzle
Belt Sander & Band Finger Sander 40 to 150 grit bands
Burr bits: plastic or wood types
Plastic Welding Rods
Flaw Repair Coating for Plastic Parts Suggested: Per-Fix Black #7500AAA, PP TPO
Infrared Thermometer
Rotary Tool & Burr Bit Set
*Leister Triac AT is an upgraded option and can be used with this procedure.
** You can also contact your local Leister Sales and Service Center for purchase and tell them BRP Sea-Doo sent you.
Leister.com/en/Plastic-Welding/Distributors.
*** BRP part no. to come; stay up to date with service publications for the latest information.
Sheet Metal Snips
Auto Supply Store
Requirements
1. Inside (not visible)
2. Outside (visible)
3. Wall thickness
4. ~ 1/3 of the thickness
5. ~ 2/3 of the thickness
6. Inner weld joint thickness = wall
thickness
7. Inner weld joint ≥ 6x groove width
(TYP. 2.25” + 5.625+ cm)
Plastic Welding
Plastic welding is the process of creating a bond between two compatible polymers.
There are two major stages.
Heating allows a bond to form between the
welding rod and the faying surface of the
repaired component (melt-mixing).
Cooling, layer by layer, is necessary to solidify
the newly-formed bond; this stage can have a
significant effect on strength of the finished weld.
1
2
3
4
5
6
7
45.0°
Replace the
component.
Resurface
NoYes
No
Yes
Deep ≥ 1/2
thickness
Minor < 1/2
thickness
Is there material
available to fill
the hole?
Based on your customer's needs (time, cost, and
desired aesthetic), the location, and accessibility of
the damage, is it realistic to repair rather than to
replace?
What sort
of scratch?
Crack HoleScratch
What kind of damage is it?
This procedure was developed
to be used for Polytec products
using the specified materials,
settings, and techniques. The
use of tools, products, settings,
or techniques other than those
recommended may cause
results to vary.
Weld
Replace
Repair Time
Days 5 10 15
Get back on the water sooner!

Welding
TECH TIPS
The material is hot enough when both the surface of the weld rod and the faying surface
become glossy. As the rod is laid or pushed into the groove, a small weld puddle should
appear.
A rod can be cut to half width using a good pair of metal snips, and used to
precisely fill the groove on the first pass or for touch-ups.
1) Groove the crack from the inside surface, about 1/3 of the materi-
al thickness. This groove can be made as wide as you need to work
comfortably, up to 45°. Groove should extend past crack by 1” (2.5
cm). Refer to the repair diagram above.
2) Remove all excess material from in or around the groove.
3) Cut the end of the rod at an angle to start with a clean tip. Scrape
the rod with a blade to remove any dirt or oil.
4) Place the rod end slightly beyond the beginning of the groove and
apply heat to both surfaces simultaneously. The tip of the heat
source should be within 1” (2.5 cm) of the weld joint.
5) While moving the heat source along the length of the rod, press
the rod into the groove to fill it. Lay down the rod until slightly past the
end of the groove.
6) Continue to fill the groove by adding layers. Each layer should
overlap the edges of the previous one. Overlap edges of the groove
as well. Wait for the material to become cool to the touch before
proceeding with the next layer. The material cannot become “over
cooled” if left a long time.
On the outside surface ONLY: Fill the groove until it is slightly beyond
flush with the original surface.
On the inside surface ONLY: Continue until the welding joint covers
3x the groove width on each side of the crack and is the same
thickness as the material itself. When in doubt, go wider.
7) Sand the weld to remove excess material. Using a fingernail,
check the joint between the weld and the hull for defects. If neces-
sary, groove the defect and apply another layer.
DO NOT MELT THROUGH THE ROD OR REPAIR SURFACE MATERIAL!
Overheating changes the material mechanical properties.
Step 1-3
4-5
1
6
The complete Official Sea-Doo Polytec Hull and Deck Repair instructional
video can be viewed at www.youtube.com/watch?v=eZpD0wrB_rk&t=1s ,
or scan the QR codes to jump to select parts of the video.
Step 4-6
Surface
Preparation 1) Use a mild detergent to remove dirt or grease from
both the inside and outside surfaces of the repair area.
Use a belt sander to remove the reinforcement matting
from the repair area when applicable. Weld directly on
Polytec surface to avoid possible delamination.
2) Sand the repair area on the inside surface only.
Surface Prep
Full Video
Preparation
Hot Air Plastic Welding Tool
• Install the appropriate nozzle on the tool.
• Adjust the hot air welding tool to 300°C (572°F) and let it run for at least 10 minutes. If
using a tool without a built-in temperature display, use an infrared thermometer gun to
verify air temperature at the tip of the nozzle.
*This temperature setting has been validated for the use of the recommended hot air
welding tool and welding rods.

Using a crimped cup wire brush in a circular pattern, buff away the scuff or apparent
scratch. This should be done locally at first, at a lower speed while applying some pressure.
Once the scuff or scratch appears to be filled in, buff outward in a circular pattern, applying
less pressure at a higher speed. A reasonably smooth transition zone should become
apparent. Continue the process while increasing speed, decreasing pressure and switching
from c.w. to c.c.w. until the texture of the buffed area is acceptable. Optionally, blur away
the transition area with a flaw repair coating for plastics, or with spray paint for polypropyl-
ene. Spray sparingly from 12 inches (30 cm) away onto the affected area.
Polytec Resurfacing Technique
This technique is useful to repair a minor scuff or scratch as well as to improve the color,
texture, and transition following a repair. Practice on nonvisible areas before attempting.
Finishing On the outside surface, perform the Polytec Resurfacing technique on
the repair and surrounding area. The result should be a flush surface.
1) Groove the crack from the inside surface, about 1/3 of the materi-
al thickness. This groove can be made as wide as you need to work
comfortably, up to 45°. Groove should extend past crack by 1” (2.5
cm). Refer to the repair diagram above.
2) Remove all excess material from in or around the groove.
3) Cut the end of the rod at an angle to start with a clean tip. Scrape
the rod with a blade to remove any dirt or oil.
4) Place the rod end slightly beyond the beginning of the groove and
apply heat to both surfaces simultaneously. The tip of the heat
source should be within 1” (2.5 cm) of the weld joint.
5) While moving the heat source along the length of the rod, press
the rod into the groove to fill it. Lay down the rod until slightly past the
end of the groove.
6) Continue to fill the groove by adding layers. Each layer should
overlap the edges of the previous one. Overlap edges of the groove
as well. Wait for the material to become cool to the touch before
proceeding with the next layer. The material cannot become “over
cooled” if left a long time.
On the outside surface ONLY: Fill the groove until it is slightly beyond
flush with the original surface.
On the inside surface ONLY: Continue until the welding joint covers
3x the groove width on each side of the crack and is the same
thickness as the material itself. When in doubt, go wider.
7) Sand the weld to remove excess material. Using a fingernail,
check the joint between the weld and the hull for defects. If neces-
sary, groove the defect and apply another layer.
Step 7
7
7
TECH TIP
A common defect is the formation of an air pocket somewhere in the joint. Check for these bubbles
or waves between layers as you go along. When in doubt, sand away a small amount of the area
in question to verify.
Note: A hole can be repaired using the technique described
above. Use a piece of Polytec to block the hole; the hole and/ or
the piece may need to be trimmed to fit. A piece of Polytec left
over from a scrap part may be used if needed. Temporarily
secure the piece in place using aluminum tape. Follow the
procedure for Plastic Welding on a crack; treat the junction
between the two parts as the crack.
Transition area in work.

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©2019 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED.