Sea-doo XP DI 2003 Manual

SAFETY WARNING
Disregarding any of the safety precautions and instructions contained in this
Operator’s Guide, the Safety Handbook, the Safety Videocassette and on the
on-product warning labels could cause injury, including the possibility of
death. The operator has the responsibility to inform passenger(s) of safety
precautions.
This Operator’s Guide, the Safety Handbook and Safety Videocassette
should remain with the craft at the time of resale.
2003 PWC Electro Magnetic Compatibility (EMC)
Compliance with 93/68 EC Directive.
The 2003 Sea-Doo Personal Watercraft do comply with the above men-
tioned directive and with 89/336 EC directive in order to match the current
European requirements on Personal Watercraft (PWC).
Knight’s Spray-Nine†is a trademark of Korkay System Ltd
GTX†is a trademark of Castrol Ltd. Used under license
The following trademarks are the property of Bombardier Inc. or its
subsidiaries:
SEA-DOO®
BOMBARDIER-ROTAX®
BOMBARDIER LUBE®
BOMBARDIER Formula XP-S II Synthetic Injection Oil
Sea-Doo LKTM
Rotax®
Printed in Canada (smo2003-004a.fm SH)
®*Trademarks of Bombardier Inc. and/or its subsidiaries.
©2002 Bombardier Inc. All rights reserved.
DECLARATION OF CONFORMITY
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1
NOTE
Dear 2003 XP DI watercraft owner. Use the information pertaining to the RX
DI model in the 2003 Operator’s Guide (P/N 219 000 290) and then use this
supplement to complete the specific information that applies to your XP DI
model.
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2
TABLE OF CONTENTS
LOCATION OF THE IMPORTANT LABELS ................................... 3
LOCATION OF CONTROLS, COMPONENTS AND INSTRUMENTS . 6
FUNCTIONS OF CONTROLS, COMPONENTS AND
INSTRUMENTS ........................................................................... 8
15) Oil Injection Reservoir Cap................................................................ 8
16) Front Storage Compartment Cover ................................................... 8
26) Mooring Cleats .................................................................................. 9
37) Fuses ................................................................................................. 9
38) Battery ............................................................................................... 9
41) Storage Compartment/Engine Cover Latches ................................... 9
42) Rear Access Cover ............................................................................ 9
43) Automatic Bilge Pump....................................................................... 9
OPERATING INSTRUCTIONS ...................................................... 10
SPECIAL PROCEDURES.............................................................. 12
Towing the Watercraft in Water .............................................................. 12
MAINTENANCE .......................................................................... 13
Lubrication ............................................................................................... 13
Periodic Inspection Chart......................................................................... 13
Fuses ....................................................................................................... 14
TRAILERING, STORAGE AND PRE-SEASON PREPARATION....... 16
Storage .................................................................................................... 16
SPECIFICATIONS........................................................................ 21
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LOCATION OF THE IMPORTANT LABELS
XP DI Models
TYPICAL
F08L1UL
84
2
9
12
3-5
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4
Label 1
F08A04L
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5
XP DI Model Only
The location of these labels differ on
the XP DI model.
Label 2
Label 3
Label 4
Label 5
Label 8
Label 9
Label 12
F00A22Y
F02L2D0
F00L29Y
F00L2XY
F00A23Y
F00A27Y
F00A1AY
F08G04Y
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6
LOCATION OF CONTROLS, COMPONENTS AND
INSTRUMENTS
XP DI Model
TYPICAL
NOTE: Components not shown here are the same as on the RX DI models in
the 2003 Sea-Doo Operator’s Guide.
F08L1WL
16
19
42
23
26
18
41
43
15
37
38
26
14
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14) Fuel Tank Cap
15) Oil Injection Reservoir Cap
16) Front Storage Compartment Cover
18) Tool Kit
19) Air Intake Opening
23) Rear Grab Handle
26) Mooring Cleats
37) Fuses
38) Battery
41) Storage Compartment/Engine Cover Latches
42) Rear Access Cover
43) Automatic Bilge Pump
NOTE: Some components shown in the 2003 Sea-Doo Operator’s Guide do not
apply to this watercraft. Refer to the following list:
7) Shift Lever
8) Fuel Gauge/Low Oil Warning Light
10) Tachometer
13) Fuel Tank Valve
17) Front Storage Compartment Cover Latch
20) Seat Strap
21) Seat Latch
22) Seat Extension Latch
24) Rear Storage Basket
30) Boarding Step
35) Reverse Gate
39) Side Vanes
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FUNCTIONS OF CONTROLS, COMPONENTS
AND INSTRUMENTS
The following components have the
same operation as explained in the
2003 Operator’s Guide, only their loca-
tion differ. To know where they are lo-
cated, refer to the LOCATION OF
CONTROLS, COMPONENTS AND IN-
STRUMENTS section in the previous
pages.
14) Fuel Tank Cap
18) Tool Kit
19) Air Intake Opening
23) Rear Grab Handle
The following components are specific
to the XP DI models. Refer to the fol-
lowing updated texts and/or illustrations.
15) Oil Injection Reservoir
Cap
Open engine cover and remove storage
tray.
TYPICAL
1. Oil injection reservoir cap
To add injection oil in the reservoir, un-
screw the cap counterclockwise.
Do not overfill. Make sure oil level
does not exceed the level shown on
the following drawing. Otherwise, si-
phon out the extra oil. Do not operate
the engine when oil level exceeds the
recommendation.
Reinstall cap and fully tighten it.
16) Front Storage
Compartment Cover
It gives access to the front storage com-
partment. Always relatch cover after
closing.
The tray is provided with separate
compartments.
1. Fire extinguisher (sold separately)
2. Retaining strap
F08L0VZ
1
WARNING
Do not overfill. Never exceed the
MAX. oil level line. Reinstall cap
and fully tighten. Oil is inflamma-
ble. Always wipe off any oil spill-
age from the bilge.
F08G04Y
F08L0UY
1
2
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26) Mooring Cleats
All Models
These cleats can be temporarily used for
docking, while refueling for example.
CAUTION: Never use mooring cleats
to pull or lift the watercraft.
1. Mooring cleats
37) Fuses
Fuses are located in engine compart-
ment. Refer to MAINTENANCE for
more details.
38) Battery
Battery is located in bilge under seat.
Refer to SPECIAL PROCEDURES.
41) Storage Compartment/
Engine Cover Latches
Pull both latch levers upward in order to
open the storage compartment/engine
cover. Always relatch cover on both
sides.
NOTE: Verify periodically the lock pins
tightness. Tighten if needed and make
sure storage compartment/engine cov-
er latches properly.
42) Rear Access Cover
It gives access to the battery, drive
system, suspension, exhaust system
and bailer pick-ups. Always relatch
cover.
43) Automatic Bilge Pump
Bilge pump evacuates water from the
bilge.
When safety lanyard cap is installed on
its post, bilge pump automatically
turns on. It will remain on until all water
is evacuated, if any, then it will shut
down automatically.
When engine is running, bilge pump
will automatically start periodically to
evacuate water.
WARNING
Ensure to properly secure extin-
guisher with the supplied retaining
straps.
F08L0TZ 1
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OPERATING INSTRUCTIONS
Variable Trim System
The variable trim system (VTS) chang-
es the angle of the jet pump nozzle to
provide the operator with a fast, effec-
tive system to compensate for load,
thrust, riding position and water condi-
tions. Correctly adjusted, it can im-
prove handling, reduce porpoising, and
position the watercraft at its best riding
angle to attain maximum performance.
When first using the watercraft, the
operator should become familiar with
the use of the variable trim system
(VTS) at varying speeds and water con-
ditions. A mid-range trim is generally
used when cruising. Experience alone
will dictate the best trim for the condi-
tions. During the watercraft break-in
period, when lower speeds are recom-
mended, it is an excellent opportunity
to gain familiarity of trim adjustment
and its effects.
When the nozzle is positioned in an up-
ward angle, the water thrust directs the
bow of the watercraft upward. This po-
sition is used to optimize high speed.
TYPICAL
1. Push on arrow pointing upward on VTS
button
2. Bow up
3. Nozzle up
F08J0AY
1
2
3
8°
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TYPICAL
1. Push on arrow pointing downward on VTS
button
2. Bow down
3. Nozzle down
F08J0BY
2
1
3
8°
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SPECIAL PROCEDURES
Towing the Watercraft in
Water
It is the same as explained in the 2003
Operator’s Guide. The hose location
and routing differs. Refer to the follow-
ing updated text and illustration.
Remove rear access cover.
Install pincher as shown.
1. Hose pincher on water supply hose
Properly relatch cover.
CAUTION: When finished towing the
watercraft, hose pincher should be
removed before operating it. Failure
to do so will result in damage to the
engine.
F08E08Y
1
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MAINTENANCE
Lubrication
Seal Carrier
Using a grease gun, carefully lubricate
seal carrier of mid bearing until grease
is just coming out of seal.
1. Grease seal carrier of mid bearing
Periodic Inspection Chart
The following is to be added for the XP DI models.
F08E0BY
1
DESCRIPTION
I: Inspect, verify, clean, adjust, lubricate,
replace if necessary
C: Clean
L: Lubricate
R: Replace
FREQUENCY
FIRST 10 HOURS EVERY 25 HOURS OR 3 MONTHS EVERY 50 HOURS OR 6 MONTHS EVERY 100 HOURS OR 1 YEAR TO BE PERFORMED BY
PROPULSION
SYSTEM
PTO flywheel and seal carrier L L
OPERATOR
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Fuses
Refer to this updated text and illustra-
tions.
Fuses can be found at 2 locations; on
the MPEM and in the electrical box.
MPEM
To access fuses on the MPEM, open
front storage compartment cover and
remove storage tray.
Locate MPEM on the left side of wa-
tercraft.
1. MPEM
Fuses are identified, look above and
besides the fuse holder.
FUSE IDENTIFICATION
1. Fuse identification
2. Fuse description
Fuse identification: The fuses (F) are
identified from 1 to 6.
Fuse description: The fuses are de-
scribed with abbreviation as follows:
FP: Fuel pump
ACC: Accessories (information center)
REG: Regulator (charging system)
VTS: Variable Trim System
BAT: Battery
INJ: Injection system
The fuse description is followed by the
ampere rating (A).
Reinstall storage tray and properly
relatch storage compartment cover.
Electrical Box
To access fuses in the electrical box,
open front storage compartment cover.
Locate electrical box on the right side
of watercraft.
F08H0JY
1
F1 : FP 15A
F2 : ACC 2A
F3 : REG 25A
F4 : VTS 7.5A
F5 : BAT 25A
F6 : INJ 15A
F1 F2 F3 F4 F5 F6
F18H06Y
21
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15
1. Electrical box
Unclip and remove cover of the electri-
cal box to expose the holder of the
main fuse.
TYPICAL
1. Fuse holder
Electric bilge pump fuse is located at the
bottom of the electrical box.
1. Electric bilge pump fuse
Properly reinstall removed components.
Properly relatch storage compartment
cover.
F08H0KY
1
1°
1
F18H1BY
2°
F12H02Y
1
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TRAILERING, STORAGE
AND PRE-SEASON PREPARATION
The information pertaining to traile-
ring, storage and pre-season prepara-
tion is similar to the one explained in
the 2003 Operator’s Guide, except for
the following updated text and illustra-
tions.
Storage
Engine Draining
Remove rear access panel.
Check engine drain hose (the lowest
one connected to the crankcase cool-
ing outlet). Make sure there is no sand
or other particles in it and that it is not
obstructed so that water can exit the
engine. Clean hose and fitting as nec-
essary.
CAUTION: Water in engine drain hose
should be free to flow out, otherwise
water could be trapped in engine.
Should water freeze in engine, severe
damage will occur. Check engine drain
hose for obstructions.
Disconnect the quick connect fitting.
Press both tabs and pull fitting.
1. Disconnect engine drain hose (crankcase
cooling outlet)
2. Air compressor drain line
Lower hose as necessary so that drain-
ing can take place.
Reconnect fitting when done.
Also ensure air compressor drain line
is not obstructed. Clean as necessary.
See illustration above.
Antifreezing Protection
NOTE: This procedure requires approx-
imately 2.8 L (3 U.S. qt.) of antifreeze.
In cool regions where freezing point
may be encountered, cooling system
should be filled with an equal part of
water and antifreeze solution.
F08E0FY
1
2
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CAUTION: Antifreeze mix must be
fed in cooling system. Otherwise re-
maining water will freeze. This opera-
tion requires a good technical knowl-
edge of the cooling system path. If
antifreezing is not performed ade-
quately engine/exhaust system may
freeze and cause severe engine dam-
age. We strongly recommend this op-
eration be performed by an autho-
rized SEA-DOO dealer.
CAUTION: Always use ethylene gly-
col antifreeze containing corrosion
inhibitors specifically recommended
for aluminum engines.
NOTE: When available, it is recom-
mended to use biodegradable anti-
freeze compatible with internal com-
bustion aluminum engines. This will
contribute to protect the environment.
NOTE: The engine will not have to run
during this operation but should have
been ran before, to exhaust as much
water as possible, from cooling sys-
tem components.
Hose Pinchers Installation
Some hoses have to be plugged to
prevent draining, before filling cooling
system jackets with the antifreeze.
Install hose pinchers at the following
location:
1. Water inlet hose
2. Engine cylinder drain hose (coming from
underneath engine)
1. Water outlet hose underneath tuned pipe
F08E0GY
2
1
F08E0PY
1
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Hose Disconnection
Disconnect the bottom hose at the wa-
ter regulator valve on muffler.
1. Disconnect the bottom hose from water
regulator valve
Temporarily install a hose of approxi-
mately 1 m (3 ft) in length with a
12.7 mm (1/2 in) internal diameter over
the previously disconnected hose.
Antifreeze
Insert a funnel into the temporary
hose.
Ensure to hold the funnel approximate-
ly 1 m (3 ft) above the deck when pour-
ing the antifreeze to create enough
pressure so that it flows properly.
A. 1 m (3 ft) to ease antifreeze flow
Pour antifreeze mix in engine until the
colored solution appears at cooling
system bleed outlet.
At this point, install a hose pincher on
bleed outlet hose.
1. Bleed outlet hose
Continue to pour until antifreeze ap-
pears at the engine drain hose (crank-
case cooling outlet). Then, install a
hose pincher on this hose.
F08E0SY 1
F08E0TY
A
F08E0 Y
1
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