1997 SeaDoo Shop Manual

0
SHOP
MANUAL
0
219 100 048
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. 1996

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
TABLE OF CONTENTS
SECTION
SUB-SECTION
PAGE
SAFETY NOTICE .............................................................................................................
II
INTRODUCTION ..............................................................................................................
III
01
MAINTENANCE
02
03
TROUBLESHOOTING ........................................................................................................................................ 02-01-1

ENGINE
01 - Table of Contents...........................................................................................
02 - Engine Leak Test............................................................................................
03 - Removal and Installation ................................................................................
04 - Magneto System ...........................................................................................
05 - Top End ..........................................................................................................
06 - Bottom End....................................................................................................
07 - Rotary Valve ...................................................................................................
08 - Exhaust System .............................................................................................
04
COOLING SYSTEM
01 - Table of Contents........................................................................................... 04-01-1

02 - Components .................................................................................................. 04-02-1
03 - Circuit............................................................................................................. 04-03-1
05
FUEL SYSTEM
02 - Fuel Circuit.....................................................................................................
03 - Air Intake........................................................................................................
04 - Carburetors ....................................................................................................
06
LUBRICATION SYSTEM

02 - Oil Injection System....................................................................................... 06-02-1
03 - Oil Injection Pump ......................................................................................... 06-03-1
07
ELECTRICAL SYSTEM
02 - Ignition System..............................................................................................
03 - Charging System ...........................................................................................
04 - Starting System .............................................................................................
05 - Instruments and Accessories ........................................................................
06 - Digitally Encoded Security System ................................................................
07-01-1
07-02-1
07-03-1
07-04-1
07-05-1
07-06-1
08
PROPULSION SYSTEM
02 - Jet Pump .......................................................................................................
03 - Drive System .................................................................................................
04 - Reverse System ............................................................................................
05 - Variable Trim System .....................................................................................
08-01-1
08-02-1
08-03-1
08-04-1
08-05-1
09
STEERING SYSTEM
02 - SP and SPX Models .......................................................................................
03 - GTS Model.....................................................................................................
04 - GS, GSI, GSX, GTI and GTX Models ..............................................................
05 - XP and HX Models .........................................................................................
06 - Alignment ......................................................................................................
09-01-1
09-02-1
09-03-1
09-04-1
09-05-1
09-06-1
10
SUSPENSION

02 - Direct Action Suspension .............................................................................. 10-02-1
11
HULL/BODY

02 - Adjustment and Repair .................................................................................. 11-02-1
12
TECHNICAL DATA
01 - SP and SPX Models .......................................................................................

02 - GS and GSI Models .......................................................................................
03 - GSX Model.....................................................................................................
04 - GTS Model.....................................................................................................
05 - GTI and GTX Models......................................................................................
06 - HX and XP Models .........................................................................................
13
WIRING DIAGRAMS.......................................................................................................................................... 13-01-1
02 - Periodic Inspection Chart...............................................................................
03 - Flushing and Lubrication ................................................................................
04 - Water-Flooded Engine ...................................................................................
05 - Storage ..........................................................................................................
01-01-1
01-02-1
01-03-1
01-04-1
01-05-1
03-01-1
03-02-1
03-03-1
03-04-1
03-05-1
03-06-1
03-07-1
03-08-1
05-01-1
05-02-1
05-03-1
05-04-1
12-01-1
12-02-1
12-03-1
12-04-1
12-05-1
12-06-1
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 relating to Bombardier made SeaDoo 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 discrepancy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at its time of manufacture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing the product.
The use of Bombardier parts is most strongly recommended when considering replacement of any component. 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;
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.
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 modifications may render use of the watercraft illegal under existing federal, provincial and state regulations.
II
1997 BOMBARDIER WATERCRAFT SHOP MANUAL
INTRODUCTION
This Shop Manual covers BOMBARDIER made
SEA-DOO watercraft models SP 5879, SPX
5834/5661, XP 5662, GS 5621, GSI 5622, GSX
5624, GTS 5818, GTI 5641, GTX 5642 and HX
5882.
All Models
The Hull Identification Number is composed of 9 digits:
ZZN12345L495
Model year
HULL IDENTIFICATION NUMBER

(H.I.N.)
Serial
number*
Year of production
Month of production
SP, SPX, GTS and HX Models

It is located at right rear side of hull.
F00A0CA
*A letter may also be used as a digit.
ENGINE IDENTIFICATION
NUMBER (H.I.N.)
717 Engines
The Engine Identification Number is located on
the upper side of the magneto housing.
F01L45A
1. Hull Identification Number (H.I.N.)
XP, GS, GSI, GSX, GTI and GTX Models

It is located on floorboard at the rear of the watercraft.
F01D01A
TYPICAL
1. Engine Identification Number (E.I.N.)
F07A01A
1. Hull Identification Number (H.I.N.)
III
787 Engine
The Engine Identification Number is located on
the crankcase on PTO side.
F01D87A
1. Engine Identification Number (E.I.N.)
IV
ARRANGEMENT OF THIS
MANUAL
The manual is divided into 13 major sections:
01 MAINTENANCE
02 TROUBLESHOOTING
03 ENGINE
04 COOLING SYSTEM
05 FUEL SYSTEM
06 LUBRICATION SYSTEM
07 ELECTRICAL SYSTEM
08 PROPULSION SYSTEM
09 STEERING SYSTEM
10 SUSPENSION
11 HULL/BODY
12 TECHNICAL DATA
13 WIRING DIAGRAMS
Several sections are divided in various sub-sections.
There is a table of contents at the beginning of
many sections.
TYPICAL PAGE
Page heading
indicates section
and sub-section
detailed.
Section 03 ENGINE
Sub-Section 04 (MAGNETO SYSTEM)
Sub-section title
indicates
beginning of the
sub-section.
MAGNETO SYSTEM
717 Engine
Italic sub-tiltle
above exploded
view indicate
pertaining models.
11
12
5 Nm
(44 lbfin)
Drop represents a
liquid product to be
applied to a surface.
In this case Loctite
242 to screw
threads.
9 Nm
13 (80 lbfin)
Loctite
242
8
Loctite
242
4
7
Dotted box
contains parts of
a particular
model or an
exploded view.
6 Nm
(53 lbfin)
Loctite
242
Exploded view assits

you in identifying
parts and related
positions.
6 Nm
(53 lbfin)
5
3
14
Bold face number

indicates special
procedure
concerning this part.
9
6 Nm
(53 lbfin)
Loctite
242
Loctite
242
4
Loctite
648
10
15
145 Nm
(107 lbfft)
Anti-seize
lubricant
F01D4WS
2
9 Nm
(80 lbfin)
Illustration number
for publishing
process.
03-04-1
Tightening torque nearby fastener.

In this case, nut must be torqued to
145 Nm (107 lbfft).
CAUTION
Page numbering system:

03: ENGINE section
04: MAGNETO SYSTEM sub-section
1: First page of this sub-section
Pay attention to torque specifications. Some of these are in

lbfin instead of lbfft. Use appropriate torque wrench.
F01A09S
TYPICAL PAGE
Sub-title with part
number(s) from exploded
view followed by part
name(s).
Section 06 FUEL SYSTEM

Sub-Section 03 (CARBURETORS)
Title indicates main

procedure to be
carried-out.
Service tool to be
used to perform a
certain procedure.
Title in italic indicates a

particular procedure
concerning a model.
Sub-sub-title in this
case indicates that
particular procedure
for XP is finished, so
from this point, all
others models are
concerned.
CARBURETOR REMOVAL
DISASSEMBLY AND INSPECTION
To remove carburetors from engine, proceed as follows:

Remove air vent tube support.
Unlock retaining slides holding air intake silencer base.
Remove air intake silencer base from watercraft.
Remove screws holding flame arrester base support
to cylinder head cover.
Unscrew base retaining screws then remove base from
carburetors and move to front of watercraft.
Turn the valve to OFF position.
Inspect parts for corrosion dammage (shaft, butterfly,

spring screw, check valve housing, etc.).
3, Diaphragm
PUMP DIAPHRAGM LEAK TEST
Using a suitable pump gauge tester, perform the following test proceeding as follows:
- Install pump gauge tester (P/N 295 000 083) on pulse
nipple.
- Pump tester until it reaches 28 kPa (4 PSI).
NOTE: For fuel line removal, use pliers (P/N 295

000 054).
Disconnect pulse line from fuel pump.

Disconnect fuel fuel supply line from fuel pump.
Disconnect fuel return line.
Disconnect oil injection pump cable, throttle cable and
choke cable.
Illustration
always follows
text it is
pertained to.
XP Model Only
Remove screws no. 6 and lock washers no. 7 retaining
carburetors.
All Others Models
Remove 4 bolts no. 8 and lock washers no. 12 from
rotary valve cover then move carburetors and rotary
valve cover on top of engine.
NOTE: When removing rotary valve cover , pay
attention that the rotary valve stay in place, other-wise
it must be timed.
Remove carburetors from intake manifold.
Disconnect fuel bypass line between carburetors (twin
carburetors).
Remove carburetor(s) from rotary valve cover.
Sub-sub-title in
capital indicates a
particular testing,
adjustment or
repair procedure.
F01F0XB
''TYPICAL'' mention
indicates a general
view which does not
represent full detail.
TYPICAL
Step 1 : Install pump gauge tester to pulse nipple
Step 2 : Pump tester until it reaches the desired pressure
1. Fuel outlet nipple
2. Fuel inlet nipple
A. 28 kPa (4 PSI)
Diaphragm must stand pressure for 10 seconds. If

pressure drops, replace diaphragm.
Numbers in a frame
are used to give a
sequence to be
perfomed.
Letters are used for

any measures.
06-03-4
Bold numbers in the

text refer to the parts
shown in the exploded
view at the beginning
of the sub-section.
F01A0AS
VI
Numbers are used

for desciption of
components.
GENERAL INFORMATION
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
watercraft).
ILLUSTRATIONS AND
PROCEDURES
The illustrations show the typical construction of
the different assemblies and, in all cases, may not
reproduce the full detail or exact shape of the
parts shown, however, they represent parts
which have the same or a similar function.
CAUTION
These watercraft are designed with parts dimensioned in both the metric and the imperial systems. When replacing fasteners,
make sure to use only those recommended
by Bombardier.
F01L45B
1. Left (port)
2. Right (starboard)
The information and component/system descriptions contained in this manual are correct at time
of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its
products without imposing upon itself any obligation to install them on products previously manufactured.
Bombardier Inc. reserves the right at any time to
discontinue or change specifications, designs,
features, models or equipment without incurring
obligation.
This Shop Manual uses technical terms which
may be different from the ones of the Parts Catalogs.
When ordering parts always refer to the specific model Parts Catalogs.
As many of the procedures in this manual are interrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or sub-section in which the procedure is contained.
A number of procedures throughout the book require the use of special tools. Before undertaking
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.
Technical Publications
Bombardier Inc.
Valcourt (Quebec), Canada
VII
Section 01 MAINTENANCE
Sub-Section 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
PERIODIC INSPECTION CHART............................................................................................
01-02-1
FLUSHING AND LUBRICATION............................................................................................

GENERAL ...........................................................................................................................
PROCEDURE ......................................................................................................................
01-03-1
01-03-1
01-03-1
WATER-FLOODED ENGINE...................................................................................................
GENERAL ...........................................................................................................................
PROCEDURE ......................................................................................................................
01-04-1
01-04-1
01-04-1
STORAGE...............................................................................................................................
01-05-1
01-01-1
Sub-Section 02
(PERIODIC INSPECTION CHART)
PERIODIC INSPECTION CHART
NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency.
FREQUENCY
DESCRIPTION
Lubrication/corrosion protection of metallic components
Engine ignition timing
Spark plug replacement
Throttle/choke cables, inspection/lubrication
Flame arrester inspection
Carburetor adjustment including choke/throttle cable adjustments and linkage
RAVE valve cleaning (787 engine)
Water flow regulator valve inspection (787 engine)
Oil injection pump adjustment
Fuel filter and oil filter inspection
Fuel filter and oil filter replacement
Engine head bolts, retorque
Steering system inspection
Reverse system/reverse cable adjustment (if applicable)
Variable trim system (if applicable)
Fastener tightening (flame arrester support, carburetor(s), engine mount, exhaust
system, etc).
Muffler, battery and reservoir fastening devices
Fuel/oil lines, check valve and hose inspection, fuel system pressurization
Fuel/vent line pressure relief valve inspection
Inspect/clean engine drain hose
Water tank trap drain inspection (GTS)
Bailer pick up inspection
Battery condition
Electrical connections (starter, battery, etc.)
Monitoring beeper
Impeller shaft reservoir oil level/oil condition
Impeller condition and impeller/wear ring clearance
Drive shaft boot/spline condition (both ends)
PTO flywheel and mid bearing (HX/XP models only) lubrication
Water intake grate condition
Hull condition
Cooling system flushing
Every
10 hours
Every
25 hours
Every
50 hours
Every 100
hours or
seasonally
Replace
Every 10 hours in salt water use.

These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified
in this chart.
Daily flushing in salt water or foul water use.
01-02-1
Sub-Section 03
(FLUSHING AND LUBRICATION)
FLUSHING AND LUBRICATION

GENERAL
Flushing the cooling system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
help to clean up sand, salt, shells or other particles
in water jackets (engine, exhaust manifold, tuned
pipe) and/or hoses.
Flushing and engine lubrication should be performed when the watercraft is not expected to be
used further the same day or when the watercraft
is stored for any extended time.
SP, SPX, GTS and XP Models

Remove dust cap from fitting spigot and attach
coupler hose (P/N 295 500 258). Make sure coupler hose is properly locked to fitting spigot.
Install a hose pincher on water outlet hose.
CAUTION
This prevents water from exiting through

outlet socket. Remove hose pincher after
flushing operation.
CAUTION
Failure to flush cooling system, when necessary, will severely damage engine and/or exhaust system. Never flush a hot engine.
Make sure engine operates during entire
procedure.
PROCEDURE
WARNING
Perform this operation in a well ventilated

area. Do not touch any electrical parts or jet
pump area when engine is running.
F01E1EA
Clean jet pump by spraying water in its inlet and

outlet and then spray BOMBARDIER LUBE lubricant.
WARNING
Always remove safety lanyard cap from

switch to prevent accidental engine starting
before cleaning the jet pump area. Engine
must not be running for this operation.
SP, SPX and GTS Models

Remove seat to allow access of cooling system.
TYPICAL
1. Coupler hose
2. Fitting spigot
3. Hose pincher
Attach other end of coupler hose to a garden hose.
CAUTION
Do not open water tap yet.
GS Series, GTI and GTX Models

Connect a garden hose to the water outlet located
at the rear of the watercraft.
XP Model
Remove rear access cover.
01-03-1
Sub-Section 03 (FLUSHING AND LUBRICATION)
All Models
Start the engine then immediately open the water
tap.
CAUTION
Always start the engine before opening the

water tap. Open water tap immediately after
engine is started to prevent overheating.
Run the engine about 3 minutes at a fast idle
around 3500 RPM.
Pull plug from air intake silencer cover.
1
F06E01A
1. Water outlet
NOTE: A quick hose connector can be used to

ease garden hose installation.
F01F25B
F00E01A
1. Quick hose connector
F07E01A
1. Air intake silencer cover

2. Pull plug
Spray BOMBARDIER LUBE lubricant through air

intake silencer cover keeping engine at fast idle.
1. Garden hose installed
F00M01A
1. Spray Bombardier Lube
NOTE: Lubrication of engine should be done at

least for one minute.
01-03-2
Sub-Section 03
(FLUSHING AND LUBRICATION)
After approximately half a minute, close fuel valve

to run engine out of fuel while lubricating.
CAUTION
When engine begins to run irregularly, immediately close the water tap to stop water
flow before engine dies.
Disconnect the garden hose.
CAUTION
If used, remove the quick hose connector

from watercraft.
SP, SPX, GTS and XP Models

Unlock and remove coupler hose. Reinstall dust
cap over fitting spigot.
Remove hose pincher from water outlet hose.
F00H0DA
SPX, GS, GSI, GSX, GTI AND GTX MODELS

1. Spark plug cables on grounding device
All Models
Wipe up any residual water from the engine.
Remove spark plug cables and connect them on
the grounding device.
F00H0AA
XP MODEL
1. Grounding device
F01H64A
SP, GTS AND HX MODELS

Remove both spark plugs and spray BOMBARDIER LUBE lubricant into each cylinder.
Crank the engine a few turns to distribute the oil
onto cylinder wall.
Apply anti-seize lubricant on spark plug threads
then reinstall them.
Reinstall plug on air intake silencer cover.
01-03-3
Sub-Section 03 (FLUSHING AND LUBRICATION)
NOTE: Engine fogging should be done with

BOMBARDIER LUBE lubricant whenever the watercraft is to be stored for a few days or a long
period.
CAUTION
Never leave rags or tools in the engine compartment or in the bilge.
01-03-4
Sub-Section 04 (WATER-FLOODED ENGINE)
WATER-FLOODED ENGINE
SPX, GS, GSI, GSX, GTI and GTX
GENERAL
If engine is water-flooded, it must be serviced
within a few hours after the event. Otherwise engine will have to be overhauled.
CAUTION
A water-flooded engine must be properly lubricated, operated then lubricated again,

otherwise parts will be seriously damaged.
PROCEDURE
Check fuel and oil reservoirs for water contamination. If necessary, siphon and refill with fresh fluids.
Turn fuel valve to OFF position then drain fuel filter
bowl. Refer to FUEL SYSTEM 05-02.
Drain bilge if water is present.
Remove spark plug cables and connect them on
the grounding device.
F00H0DA
XP Model
1
WARNING
Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device.
SP, GTS and HX Models
F00H0AA
1. Grounding device
All Models
Remove spark plugs and dry them with a clean
cloth. A contact cleaner spray can be used. It may
be preferable to replace spark plugs. Do NOT install spark plugs on engine.
Crank engine to drain crankcase.
F01H64A
CAUTION
Be careful when cranking engine, water will

spray out from spark plug holes.
01-04-1
Sub-Section 04 (WATER-FLOODED ENGINE)
Spray BOMBARDIER LUBE lubricant (P/N 293

600 016) into spark plug holes.
Crank engine again.
Reinstall spark plugs and spark plug cables.
SPX, GSX, GTX and XP Models

On the 787 engine, remove the drain plug of the
counterbalance shaft located on the PTO side of
the lower crankcase.
Drain completely the crankcase oil of the counterbalance shaft. Reinstall drain plug.
Remove the filling plug located on the upper
crankcase.
Add 30 mL (1 oz) of SAE 30 motor oil.
Reinstall filling plug.
All Models
Turn fuel valve to ON position.
Start engine; It may be necessary to use the
choke. If engine does not start, repeat previous
steps as necessary.
CAUTION
To avoid starting motor overheating, the

cranking period should not exceed 5-10 seconds and a rest period of 30 seconds should
be observed between cranking cycles.
NOTE: If engine does not start after several attempts, check ignition system for spark occurrence. Refer to ELECTRICAL SYSTEM 07-02.
Check crankshaft if needed, it may be misaligned
or deflected. Refer to ENGINE 03-06.
After engine has started, spray BOMBARDIER
LUBE lubricant through air intake silencer while
engine is running.
01-04-2
F00M01A
1. Spray Bombardier Lube
Run engine until it reaches its normal operating

temperature.
CAUTION
Engine must be cooled using the flush kit.
Sub-Section 05 (STORAGE)
STORAGE
0
XP and HX Models
Engine Draining
Check engine drain hose. Make sure there is no
sand or other particles in it and that it is not obstructed so that water can leave the engine. Clean
hose and fitting as necessary.
CAUTION
Water in engine drain hose must 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.
All Models Except XP and HX
F05J04A
TYPICAL
1. Engine drain hose
Fuel System
Sea-Doo Fuel Stabilizer (P/N 413 408 600) should
be added in fuel tank to prevent fuel deterioration
and carburetor gumming. Follow manufacturers
instructions for proper use.
NOTE: Fuel stabilizer should be added prior engine lubrication to ensure carburetor protection
against varnish deposit.
WARNING
Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area.
F02E02A
TYPICAL
1. Engine drain hose
2. Exhaust outlet
Always turn the fuel valve to OFF position when

storing the watercraft.
Cooling System Flushing and Engine

Internal Lubrication
Cooling system has to be flushed with fresh water to prevent salt, sand or dirt accumulation
which will clog water passages.
Engine must be lubricated to prevent corrosion on
internal parts.
For proper procedure, refer to MAINTENANCE
01-03.
01-05-1
Propulsion System
Lubricant in impeller shaft reservoir should be
drained. Reservoir should be cleaned and refilled
with SEA-DOO synthetic 75W90 GL5 polyolester
oil. Refer to PROPULSION SYSTEM 08-02.
CAUTION
Use only SEA-DOO jet pump oil or equivalent synthetic gear oil, otherwise component
life span could be reduced. Do not mix oil
brands or types.

Lubricate PTO flywheel at grease fitting with synthetic grease (P/N 293 550 010).
F05I09A
1. Grease fitting
Battery
CAUTION
Do not lubricate excessively. Immediately

stop when a slight movement is noticed on
rubber boot.
For battery removal, cleaning and storage, refer to

ELECTRICAL 07-03.
Watercraft Cleaning
Clean the bilge with hot water and mild detergent
or with bilge cleaner. Rinse thoroughly. Lift front
end of watercraft to completely drain bilge. If any
repairs are needed to body or to the hull, touch up
paint and Gelcote repair kit are available. Replace damaged labels/decals.
Wash the body with soap and water solution (only
use mild detergent). Rinse thoroughly with fresh
water. Remove marine organisms from the hull.
Apply a nonabrasive wax.
F01I0BA
Never clean apparent fiberglass and plastic

parts with strong detergent, degreasing
agent, paint thinner, acetone, etc.
1. Grease PTO flywheel
CAUTION
Never leave any clothing, tool or other objects near PTO flywheel and drive shaft.
XP and HX Models
Lubricate mid bearing of drive system at seal carrier grease fitting with synthetic grease.
01-05-2
CAUTION
If the watercraft is to be stored outside, cover it

with an opaque tarpaulin to prevent sun rays and
grime from affecting the plastic components, watercraft finish as well as preventing dust accumulation.
CAUTION
The watercraft must never be Ieft in water

for storage. Never leave the watercraft
stored in direct sunlight.
Anticorrosion Treatment
Wipe off any residual water in the engine compartment.
Spray BOMBARDIER LUBE lubricant over all metallic components in engine compartment.
Lubricate the throttle cable with BOMBARDIER
LUBE lubricant.
NOTE: A cable luber can be used on throttle cable
end to inject BOMBARDIER LUBE lubricant.
The seat should be partially left opened during
storage (the engine cover for the XP and HX models). This will avoid engine compartment condensation and possible corrosion.
NOTE: If the watercraft is stored outside with
seat (or the engine cover for the XP and HX models) partially opened and without a tarpaulin, unscrew the rear drain plug(s) in order to avoid water
build up in the bilge during rainfall. Tilt the watercraft to the rear so that water can flow out.
F02E02B
Additional Recommended Protection
TYPICAL
1. Drain hose
In cool regions (where freezing point temperature

may be encountered), cooling system should be
filled with water and antifreeze solution.
Disconnect engine water supply hose and engine

water return hose.
CAUTION
Always use ethylene-glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines.
NOTE: The engine will not have to run during this
operation.

Three hoses have to be disconnected to allow air
to escape and antifreeze solution to completely fill
cooling system water jackets.
Disconnect drain hose.
F07E02A
TYPICAL
1. Engine water supply hose
2. Engine water return hose
Raise all hoses above the highest point of tuned

pipe and tie them together.
Insert a funnel into the engine water supply hose.
Pour about 1 liter (1 quart) of antifreeze mixed
with water in the engine.
01-05-3
F05E03A
TYPICAL
1. Engine water supply hose
2. Engine water return hose
F00E03A
TYPICAL
1. Hold hoses higher than tuned pipe
2. Insert funnel into engine water supply hose
NOTE: If hoses are not attached higher than

tuned pipe, coolant will drain out.
XP and HX Models
Install a hose pincher to engine drain hose.
F05E02A
TYPICAL
1. Hose pincher
2. Drain hose
3. Magneto housing cover
Disconnect engine water supply hose and engine

water return hose.
01-05-4
Install temporarily one hose to engine water inlet

at cylinder head.
Insert a funnel into hose and pour about 1 liter (1 qt)
of antifreeze mixed with water in engine.
Remove temporary hose and reconnect engine
water supply hose and engine water return hose.
Remove hose pincher.
All Models
Most of the antifreeze will drain out when removing hose pinchers. Use a container to recover it.
Dispose antifreeze as per your local laws and regulations.
NOTE: Although antifreeze will mainly drain out,
the antifreeze has flowed to mix with water that
was possibly trapped in cooling system cavities
and thus preventing freezing problems.
NOTE: For pre-season preparation, drain antifreeze from cooling system prior to launching
boat in water as explained above.
Section 02 TROUBLESHOOTING
Sub-Section 01 (TROUBLESHOOTING CHART)
TROUBLESHOOTING CHART
The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should
not be assumed to have all causes for all problems.
ENGINE WILL NOT START
OTHER OBSERVATION
POSSIBLE CAUSE
Engine does not turn over
Safety lanyard cap worn or removed
Replace/reinstall
Safety lanyard switch or harness

damaged
Replace
Engine turns slowly
Engine turns over
REMEDY
Burnt 5 A fuse
Check wiring then replace fuse
5 A fuse keeps on burning
Check wiring, solenoid and MPEM
Discharged battery
Check/clean/tighten
Battery connections
Check/recharge
Water/fuel hydrolock
Check, refer to section 01-04
Starter
Seized engine
Check/repair as needed
Seized jet pump
Discharged/weak battery
Check/charge/replace
Restriction in jet pump
Check/clean pump
Seizure in jet pump
Inspect, refer to section 08-02
Partial engine hydrolock
Partial engine seizure
Check compression, refer to section 03-05
Worn starter
Fuel water-contaminated
Check/siphon and refill
Dirty fuel filter
Clean/replace
Fouled spark plugs
Replace
Water in engine
Carburetion
Ignition
Flooded engine
Carburetor needle valve stuck open
No spark at spark plugs
Excessive rotary valve clearance
Internal engine damage
Check, refer to section 03-05 and 03-06
Sheared flywheel key
Check timing mark, refer to section 07-02
Incorrect rotary valve timing
Faulty rev limiter
Replace M.P.E.M.
Faulty ignition module
Replace M.P.E.M. or ignition module

depending upon the model
NOTE: Watercraft equipped with the Digitally Encoded Security System, refer to ELECTRICAL SYSTEM
07-06 for troubleshooting of problems related with this system.
02-01-1
ENGINE MISFIRES, RUNS IRREGULARLY

OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Weak spark
Fouled, defective, worn spark plugs
Check/verify heat range/gap/replace
Faulty rev limiter or ignition module
Lean fuel mixture

Dry spark plug (except when
water fouled)
Check timing mark, refer to section 07-02
Low fuel level
Check/refill
Stale or water fouled fuel
Check/siphon and refill
Fuel filter dirty or restricted
Check/clean/replace
Carburetion dirty or out of adjustment
Check/clean/adjust, refer to section 05-04
Leaking crankshaft seal(s), intake or rotary

valve cover O-ring
Pressure check engine, refer to 03-02
Restricted fuel valve
Check/replace
Loose carburetor
Tighten carburetor(s)
Partially closed choke
Check/adjust choke cable
Flame arrester dirty or restricted
Check/clean/replace
Carburetor adjustment or setting
Check/clean/adjust, refer to section 05-04
Loose main jet (if applicable)
Rotary valve shaft seal leaking
Check/replace, refer to section 03-07
Oil pump adjustment
Check/adjust, refer to section 06-03
Worn needle(s) and seal(s)
Incorrect rotary valve timing
OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Monitoring beeper sounds

continuously
Restricted jet pump water intake
Check/clean
Cooling system restriction
Check/flush, refer to section 01-03
Rich fuel mixture

Fouled spark plug
Difficult to start
ENGINE OVERHEATS
Grounded temperature sensor or sensor Check/repair/replace

wire
ENGINE CONTINUALLY BACKFIRES

OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Weak spark
Fouled, defective spark plugs
Clean/replace
Malfunction of rev limiter
Clean/replace, refer to section 07-02
Incorrect setting
Check/reset, refer to section 07-02

and 03-04
Rotary valve
Incorrect timing
Check/reset, refer to section 03-07
Carburetor
Carburetion to lean
Engine
Intake leak/crankshaft seal failure
Pressure check engine, refer to 03-02
Ignition timing
02-01-2
ENGINE DETONATION OR PINGING

OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Ignition
Timing too far advanced
Check/reset
Spark plug heat range too high
Check/change to correct range
Defective ignition module
Engine overheats
Check, refer to engine overheats
Fuel of poor quality
Use good quality fuel
Engine temperature
ENGINE LACKS ACCELERATION OR POWER

OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Weak spark
Carburetion, jetting too rich/lean
Throttle does not open fully
Check/readjust, refer to section 05-04
Low compression
Check/repair, refer to section 03-05
Exhaust system restriction
Check/clean
Water in fuel or oil
Check/siphon/replace
Debris in carburetor needle valve
Check/clean, refer to section 05-04
Impeller leading edge damaged
Twisted crankshaft
Engine revs lower than its

maximum operational RPM
(787 engine)
RAVE valve does not open
Peak performance is delayed

until higher RPM range is
reached (787 engine)
RAVE valve is stuck opened
ENGINE RUNS TOO FAST

OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Engine RPM too high
Faulty rev limiter
Improper impeller pitch (too low)
Damaged leading or trailing edge of

impeller
Check/replace
NOTE: Leading edge damage contributes to
poor performance from start. Trailing edge
damage contributes to poor top performance
and stator vanes erosion.
Sealing of ride shoe or jet pump support/jet pump
Check/reseal, refer to section 08-02

or 11-02
Jet pump cavitation
ABNORMAL NOISE FROM PROPULSION SYSTEM

OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Weeds/debris caught in intake grate or

impeller
Check/clean
Low oil level in pump housing
Check/troubleshoot source of leak/refill

supply, refer to section 08-02
Worn anti-knocking system
Check/replace pusher in cover, refer to

section 08-02
Damaged or bent drive shaft
Broken motor mounts
02-01-3
Sub-Section 01
Section 03 ENGINE
(TABLE OF CONTENTS)
TABLE OF CONTENTS
LEAK TEST.............................................................................................................................
GENERAL ...........................................................................................................................
PREPARATION ...................................................................................................................
TESTING PROCEDURE .....................................................................................................
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................
03-02-1
03-02-1
03-02-1
03-02-1
03-02-6
REMOVAL AND INSTALLATION..........................................................................................

GENERAL ...........................................................................................................................
ENGINE REMOVAL ............................................................................................................
CLEANING .........................................................................................................................
INSTALLATION ..................................................................................................................
03-03-1
03-03-1
03-03-1
03-03-4
03-03-4
MAGNETO SYSTEM .............................................................................................................

GENERAL ...........................................................................................................................
REMOVAL...........................................................................................................................
CLEANING .........................................................................................................................
DISASSEMBLY...................................................................................................................
ASSEMBLY.........................................................................................................................
INSTALLATION ..................................................................................................................
03-04-1
03-04-3
03-04-3
03-04-6
03-04-6
03-04-8
03-04-9
TOP END ................................................................................................................................ 03-05-1

GENERAL ........................................................................................................................... 03-05-3
DISASSEMBLY................................................................................................................... 03-05-5
CLEANING ......................................................................................................................... 03-05-7
INSPECTION ...................................................................................................................... 03-05-8
ASSEMBLY......................................................................................................................... 03-05-11
ADJUSTMENT ................................................................................................................... 03-05-18
BOTTOM END........................................................................................................................
CRANKSHAFT MISALIGNMENT AND DEFLECTION ......................................................
DISASSEMBLY...................................................................................................................
CLEANING .........................................................................................................................
INSPECTION ......................................................................................................................
ASSEMBLY.........................................................................................................................
03-06-1
03-06-3
03-06-4
03-06-7
03-06-7
03-06-9
ROTARY VALVE .....................................................................................................................

GENERAL ...........................................................................................................................
INSPECTION ON WATERCRAFT .......................................................................................
DISASSEMBLY...................................................................................................................
CLEANING .........................................................................................................................
INSPECTION ......................................................................................................................
ASSEMBLY.........................................................................................................................
03-07-1
03-07-2
03-07-2
03-07-4
03-07-5
03-07-6
03-07-6
03-01-1
Section 03 ENGINE
EXHAUST SYSTEM ...............................................................................................................

TUNED PIPE REMOVAL .....................................................................................................
EXHAUST MANIFOLD REMOVAL.....................................................................................
MUFFLER REMOVAL..........................................................................................................
TUNED PIPE REPAIR ..........................................................................................................
INSTALLATION ...................................................................................................................
03-01-2
03-08-1
03-08-4
03-08-6
03-08-6
03-08-6
03-08-7
Section 03 ENGINE
Sub-Section 02 (LEAK TEST)
LEAK TEST
GENERAL
PREPARATION
A Sea-Doo Engine Leak Test Kit (P/N 295 500 352)

is available to help diagnose engine problems
such as engine seizure, poor performance, oil
leakage, etc.
Before disassembling any components of the engine, it is important to perform a leakage test to
determine which part is defective.
It is also very important after servicing the engine,
even for a complete engine rebuilt, to perform another leakage test; at this stage, it may avoid further engine problems and minimizing the risk of
having to remove and reinstall the engine again.
Static bench testing is the most effective way to
conduct a leakage test. Inboard testing does not
allow complete access to, and observation of all
engine surfaces and should be avoided whenever
possible.
On 717 engines, cylinders can not be verified individually due to leakage from one cylinder to another through a common intake manifold.
When installing hoses of the Engine Leak Test Kit,
use the collars provided in the kit to ensure a proper sealing.
When pressurizing the engine, first confirm that
the components of the Engine Leak Test Kit are
not leaking by spraying a solution of soapy water
on all hoses, connections, fittings, plates, etc. If
there is a leak, bubbles will indicate leak location.
Three areas of the engine will be tested in sequence as per the diagnostic flow chart (see the
end of this sub-section).
1. Engine Cooling System
2. Bottom End and Top End
3. Rotary Valve Shaft
NOTE: If a leak is found, it is important to continue testing as there is the possibility of having
more than one leak. Continue pumping to compensate for the air lost to find another leak.
Verify fuel system for leaks.
WARNING
If any fuel leak is found, do not start the engine. Correct the leak and wipe off any fuel
spillage. Do not use electric powered tools
unless fuel system has passed pressure test.
Disconnect battery BLACK negative cable.
WARNING
Always disconnect battery cables in the

specified order, BLACK negative cable first.
Disconnect battery RED positive cable.
TESTING PROCEDURE
Engine Cooling System
Remove the tuned pipe.
Remove the exhaust manifold gasket and ensure
the surface is cleaned.
Disconnect engine cooling hoses.
Install the appropriate exhaust manifold plate
(no. 1 for the 787 engine and no. 2 for 717 engines) from the Engine Leak Test Kit. Tighten plate
using fasteners provided in the kit.
Use hoses provided in the kit and install them on
the engine.
Install pump using reducer and appropriate
tube(s) as necessary.
03-02-1
Section 03 ENGINE
4
3
F01B2UB
F01B2WA
717 ENGINES REAR VIEW

1. Engine drain hose blocked with a hose pincher
2
1
F01B2VA
717 ENGINES FRONT VIEW

1. Loop hose and use clamps
2. Use 2 washers with exhaust manifold stud
3. Hose with adapter and nipple
03-02-2
787 ENGINE
1. Loop hose and use clamps
2. Hose with clamps. Plug end with a screw
3. Block engine drain hose with a hose pincher
4. Use 2 washers with exhaust manifold stud
NOTE: Water is not required for testing.

Activate pump and pressurize engine cooling system to 34 kPa (5 PSI).
Wait 3 minutes and check if pressure drops; if so,
verify all testing components.
If kit components are not leaking and pressure
drops, verify all external jointed surfaces, temperature sensor and the O-ring between the
spark plug area and the engine cylinder head
cover. If none of these components are leaking,
there is an internal leak and it can be detected
with Bottom End and Top End testing.
Bottom End and Top End

Remove the carburetor(s) and gasket(s). Make
sure the surface of the intake manifold (717 engines) or rotary valve cover (787 engine) are clean.
NOTE: With the BN-38 carburetor, intake manifold must be removed first to withdraw carburetor; Then, reinstall intake manifold to proceed
with testing.
Install the intake plate(s) no. 3 with fasteners
from the kit and tighten adequately.
On engines with the RAVE system, remove the
RAVE valves and gaskets.
Section 03 ENGINE
Install plates no. 4 with fasteners from the kit and

tighten adequately.
NOTE: On engines with the RAVE system, the
boot and O-ring can be checked for leakage with
the valve in place. Simply remove the cover to expose the boot.
Make sure the spark plugs are installed and tighten.
Block pulse hose using a hose pincher.
NOTE: Do not block the rotary valve shaft hoses.
Install pump to the exhaust plate fitting.
3
2
F01B2ZA
717 ENGINES
1. Intake plates
2. Pulse hose blocked with a hose pincher
3. Exhaust plate
Activate pump and pressurize engine to 34 kPa (5 PSI).
CAUTION
Do not exceed this pressure.

Wait 3 minutes and check if pressure drops; if so,
verify all testing components.
If kit components are not leaking, verify engine
jointed surfaces as per following areas:
spark plugs
cylinder head gasket
cylinder base gasket
crankcase halves
rotary valve cover
engine plugs
exhaust manifold
intake manifold (717 engines)
oil injection pump (717 engines)
Check also small oil injection pump lines and fittings; check for air bubbles or oil column going toward pump, which indicate a defective check
valve.
If the above mentioned components are not leaking, block both oil hoses of the rotary valve shaft
using hose pinchers.
NOTE: If leakage stops at this point, proceed with
Rotary Valve Shaft testing.
If there is still some leakage, remove the PTO flywheel to verify outer seal.
If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft
outer seals.
Proceed with the Rotary Valve Shaft testing if
the crankshaft outer seals are not leaking.
3
F01B30A
787 ENGINE
1. Intake plates
2. RAVE valve plates
3. Pulse hose blocked with a hose pincher
4. Exhaust plate
03-02-3
Section 03 ENGINE
Rotary Valve Shaft

NOTE: It is preferable to drain the injection oil
from the rotary valve shaft, but it is not mandatory.
Block oil return hose of the rotary valve shaft with
a hose pincher.
F01B32A
717 ENGINES
1. Pump with reducer and nipple
F01B31A
717 ENGINES
1. Oil return hose blocked with hose pincher
F01B34A
787 ENGINE
1. Pump with reducer and nipple
F01B33A
787 ENGINE
1. Oil return hose blocked with hose pincher
Install pump with reducer and nipple to the oil

supply hose of the rotary valve shaft.
03-02-4
Activate pump and pressurize to 5 PSI (34 kPa).

Check plug of the rotary valve shaft in crankcase.
Remove PTO side spark plug. If pressure drops, it
indicates a defective PTO side crankshaft inner
seal.
Remove MAG side spark plug. If pressure drops,
it indicates a defective MAG side crankshaft inner
seal.
Section 03 ENGINE
If the above mentioned components are not leaking and there is a pressure drops, remove the rotary valve cover. Check the seal of the rotary valve
shaft.
If the rotary valve shaft is not leaking, it could indicates a defective engine casting. Disassemble engine and carefully check for defects in castings.
Pay attention to tapped holes which may go
through sealed areas of engine and thus lead to
leakage.
03-02-5
Section 03 ENGINE
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

PRESSURIZE ENGINE
COOLING SYSTEM
IS SYSTEM LEAKING?
YES
CHECK TESTING KIT
NO
REPLACE O-RING OF CYLINDER HEAD
AND/OR CYLINDER BASE GASKET
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
RECHECK ENGINE SEALING
YES
CHECK TESTING KIT
CHECK ALL JOINTED SURFACES,

SCREW/STUD THREADS. MOUNTING
FLANGES ETC.
ANY LEAK FOUND?
YES
REPLACE GASKET OR O-RING,

RE-SEAL LEAKING AREA
CHECK SMALL OIL LINES OF

INJECTION PUMP
AIR BUBBLES FOUND

OR OIL MOVING
TOWARD PUMP?
YES
REPLACE CHECK VALVE(S) / LINE(S)
BLOCK LARGE HOSES OF

ROTARY VALVE GEAR
LUBRICATION SYSTEM
NO
IS ENGINE STILL LEAKING?
CHECK TESTING KIT
CHECK CRANKSHAFT OUTER

SEAL OF PTO AND
MAG SIDES
ARE SEALS LEAKING?
PRESSURIZE ROTARY VALVE GEAR

RESERVOIR IN CRANKCASE
YES
REPLACE DEFECTIVE SEAL(S)
NO
PRESSURIZE ROTARY VALVE GEAR
RESERVOIR IN CRANKCASE
YES
RECHECK ENGINE SEALING
IS RESERVOIR LEAKING?
UNSEAL PTO CYLINDER AND MAG CYLINDER

SEPARATELY BY REMOVING THE
APPROPRIATE SPARK PLUG
YES
REPLACE DEFECTIVE SEAL(S)
YES
REPLACE OIL SEAL OF ROTARY

VALVE SHAFT END, OR
REPLACE CAP
NO
CHECK TESTING KIT
YES
NO
CHECK FOR LEAKAGE AT ROTARY

VALVE SHAFT CRANKCASE PLUG
ANY LEAK FOUND?

NO
REMOVE ROTARY VALVE COVER, CHECK
SEAL OF ROTARY VALVE SHAFT
YES
IS SEAL LEAKING?
REPLACE DEFECTIVE SEAL
CAREFULLY INSPECT ENGINE CASTINGS,

PARTICULARLY THE THREADED HOLE AREAS
ANY LEAK FOUND?
ENGINE IS PERFECTLY SEALED

INTERNALLY
F00D07S
03-02-6
YES
REPLACE DEFECTIVE PARTS
Sub-Section 03
Section 03 ENGINE
(REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION

GENERAL
Disconnect magneto wiring harness.
It is not necessary to remove engine from watercraft for TOP END nor PTO FLYWHEEL AND
MAGNETO servicing. However engine removal is
necessary to repair BOTTOM END.
ENGINE REMOVAL
In order to remove engine from watercraft proceed as follows.
CAUTION
Whenever removing engine from watercraft, engine/jet pump alignment must be

performed.
Jet Pump Removal
F01D8RA
TYPICAL 717 ENGINES

1. Unplug connector
To withdraw jet pump, refer to PROPULSION

SYSTEM 08-02.
Drive System
To withdraw driveshaft(s), refer to PROPULSION
SYSTEM 08-03.
All Models
Electrical Connections
First, remove BLACK negative cable from battery,
then RED positive cable.
WARNING
Always disconnect starter or battery cables

exactly in the specified order, BLACK negative cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines.
SP and GTS Models

Remove battery holding straps and disconnect
vent tube from battery.
Remove battery.
All Models
Disconnect temperature switch wire and spark
plug cables.
F06D0FA
787 ENGINE
1. Unplug connector
Tuned Pipe
To remove tuned pipe, refer to ENGINE 03-08.
Air Intake Silencer

To remove air intake silencer, refer to FUEL SYSTEM 05-03.
Carburetor(s)
All Models Except the XP and HX
To remove carburetor(s), refer to FUEL SYSTEM
05-04.
03-03-1
Section 03 ENGINE
Sub-Section 03 (REMOVAL AND INSTALLATION)
XP and HX Models Only

Disconnect choke and throttle cables from carburetor linkage.
Disconnect fuel supply and fuel return hoses.
Engine Support(s)
NOTE: Be careful when removing engine support(s) or rubber mount adapters, shims could
have been installed underneath. Shims control engine/jet pump alignment. Always note position of
shims for reinstallation, to avoid altering engine
alignment.
Remove engine support mount screws.
F01D0AA
1. Weld a lock washer

2. Old spark plug
Remove spark plugs and replace by special tools.

Hook a sling into holes of special tools.
Using a chain block, a hoist or other suitable
equipment, slightly lift engine to ease the remaining component removal.
CAUTION
Take care not to damage cable or oil injection hoses.
F06D0HA
TYPICAL
1. Remove screws
787 Engine
Engine can be easily lifted by inserting a hook into
exhaust manifold eyelet.
Lifting Engine
717 Engines
Engine can be easily lifted using the following
suggested tools:
Cut porcelain from 2 old spark plugs.
Weld a lock washer approximately 20 mm diameter on each spark plug as shown.
F01D7OA
TYPICAL
Using a chain block, a hoist or other suitable

equipment, slightly lift engine to ease the remaining component removal.
03-03-2
Sub-Section 03
Section 03 ENGINE
CAUTION
Take care not to damage cable or oil injection hoses.

Remove rear engine support.
F01H1JB
TYPICAL
1. Disconnect RED positive cable
Carry on engine lifting then tilt engine so that it

can be removed from the body opening.
F01D7PA
1. Rear support
All Engines
Install a hose pincher to oil supply hoses of oil injection pump and rotary valve shaft; then, disconnect hoses.
CAUTION
Be careful not to scratch body or to hit any

component.
F01D40A
A01B2JB
TYPICAL
1. Hose pincher (P/N 295 000 076)
TYPICAL ALL ENGINES EXCEPT THE 787
Install a hose pincher to oil return hose of rotary

valve shaft; then, disconnect hose.
Disconnect RED positive cable from starter post.
03-03-3
Section 03 ENGINE
Loctite
242
F00D0BA
F01D7RA
TYPICAL 787 ENGINE
TYPICAL
1. Torque to 35 Nm (26 lbfft)
CLEANING
Wipe off any spillage in bilge. Clean with a bilge
cleaner.
Clean external parts of engine.
Four-Piece Engine Support

Torque front and rear engine supports as shown in
the following illustration.
INSTALLATION
Installation of engine in watercraft is essentially

the reverse of removal procedures. However pay
particular attention to the following.
Rubber Mount, Shim and Screw

Check tightness and condition of rubber mounts.
If they have been removed, apply Loctite 242
(blue) on screw threads. Torque screws to
25 Nm (18 lbfft).
CAUTION
Strict adherence to this torque is important

to avoid damaging threads of aluminum insert in bilge.
Loctite
242
F02D09A
Loctite
242
1. Torque screws to 22 Nm (16 lbfft)

2. Torque nuts to 39 Nm (29 lbfft)
Oil Injection Hoses
Engine Support(s)
Make sure to reinstall hoses before completely

lowering engine in bilge.
717 Engines
Positive Starter Cable
One-Piece Engine Support

Properly install support on crankcase so that
rounded portion of support matches with MAG
side of crankcase. Apply Loctite 242 (blue) on
threads then torque nuts in a criss-cross sequence to 35 Nm (26 lbfft).
Torque nut of positive starter cable to 6 Nm

(53 lbfin). Apply dielectric grease on nut.
03-03-4
Engine/Jet Pump Alignment

Alignment is necessary to eliminate possible vibration and/or damage to components. Check
alignment of engine using the following alignment
tools.
Sub-Section 03
Section 03 ENGINE
1
2
F01L2RC
1. Housing (P/N 295 000 090)

2. Alignment shaft (P/N 295 000 093) or (P/N 295 000 141) for the
HX and XP models
F00B06A
TYPICAL
HX and XP Models
On these models, the PTO flywheel adapter (P/N
295 000 157) must be used in conjunction with
the alignment shaft.
F00B05A
Insert shaft end into PTO flywheel.

NOTE: Ensure the protective hose and carbon
ring is removed to check engine alignment. If the
alignment is correct, the shaft will slide easily
without any deflection in PTO flywheel.
1. Adapter P/N 295 000 157
NOTE: Ensure the mid bearing is removed to

check engine alignment.
All Models
To verify alignment proceed as follows:
Install housing on hull with 4 nuts.
Carefully slide shaft through housing.
F07D05A
TYPICAL
1. Alignment shaft
2. PTO flywheel
If the alignment is incorrect loosen engine support screws to enable to align PTO flywheel with
shaft end.
NOTE: Use shim(s) (P/N 270 000 024) or (P/N 270
000 025) as necessary between engine support
and rubber mounts to correct alignment.
03-03-5
Section 03 ENGINE
F00D0CA
TYPICAL
1. Shim
CAUTION
Whenever shims are used to correct alignment, never install more than 6 mm
(0.240 in) shim thickness. If alignment cannot be obtained verify for engine support
bending.
Engine Support Screws
Apply Loctite 242 (blue) on screw threads.
Torque engine support screws to 25 Nm
(18 lbfft) when procedure is completed.
NOTE: Whenever alignment tool is not utilized,
apply BOMBARDIER LUBE lubricant on its shaft
and inside the housing to eliminate possible corrosion.
Final Inspection
Check throttle cable condition and lubricate cable
with BOMBARDIER LUBE lubricant. After its installation, properly adjust and bleed oil injection
pump as specified in LUBRICATION SYSTEM
06-03.
Check hose condition and pressure test fuel system, refer to FUEL SYSTEM 05-02.
Verify all electrical connections.
Run engine and ensure there is no leakage.
CAUTION
If watercraft is out of water, engine must be

cooled using the flush kit.
03-03-6
Sub-Section 04
Section 03 ENGINE
(MAGNETO SYSTEM)
MAGNETO SYSTEM
717 Engines
8
7
5 Nm
(44 lbfin)
9
Loctite
242
11
9 Nm
(80 lbfin)
12
Loctite
242
10
13
6 Nm
(53 lbfin)
Loctite
242
14
6 Nm
(53 lbfin)
6 Nm
(53 lbfin)
15
Loctite 242
3
4
16
Loctite
242
SP, GTS and

HX models
4 Nm
(35 lbfin)
18
17
Loctite
648
5
6
145 Nm
(107 lbfft)
Anti-seize
lubricant
F00D04S
PARTS
2
9 Nm
(80 lbfin)
FLAT RATE
03-04-1
Section 03 ENGINE
787 Engine
7
10
Loctite 242
9
Lithium
grease
10 Nm
(88 lbfin)
4
Loctite 648
10
Nm
11
(88 lbfin)
Loctite 648
Loctite 242
5
105 Nm 6
(77 lbfft)
4.5 Nm
(40 lbfin)
16
13 10 Nm
(88 lbfin)
10 Nm
(88 lbfin) 15
14
2
9 Nm
(80 lbfin)
12
Anti-seize
lubricant
3
1
F01D7TS
03-04-2
PARTS
FLAT RATE
Synthetic
grease
6 Nm
(53 lbfin)
Sub-Section 04
Section 03 ENGINE
(MAGNETO SYSTEM)
GENERAL
The following procedures can be performed without removing engine from watercraft. However,
battery removal will be required on SP and GTS
models.
REMOVAL
717 Engines
1, Magneto Housing Cover

Remove screws no. 2, wire supports no. 17 and
no. 18, then withdraw cover.
4,5, Magneto Flywheel and Ring Gear

Magneto flywheel is locked with puller plate (P/N
290 876 080), sleeves (P/N 290 847 220) and extension handle (P/N 295 000 111).
1
F01D48A
TYPICAL
1. Sleeves on opposite side
Using a suitable socket, unscrew retaining nut

no. 6 COUNTERCLOCKWISE when facing it.
NOTE: If socket is found too large to be inserted
in puller plate, machine or grind its outside diameter as necessary.
2
1
3
4
F01D47A
1.
2.
3.
4.
Screw
Extension handle
Puller plate
Sleeve
Using 3 M8 x 35 screws (P/N 290 841 591), install

screws through puller plate and slide sleeves on
screws then secure puller plate on magneto flywheel so that sleeves are against flywheel.
Install extension handle on end of puller plate.
F01D4BA
TYPICAL
1. Extension handle locking crankshaft
Remove nut and lock washer from magneto flywheel.

Magneto flywheel is easily freed from crankshaft
with puller (P/N 295 000 106).
03-04-3
Section 03 ENGINE
Engine Crankcase Replacement
A00C1AA
Fully thread on puller in puller plate.

Tighten puller bolt and at the same time, tap on
bolt head using a hammer to release magneto flywheel from its taper.
717 Engines
Since replacement crankcases do not have timing
mark for armature plate location, indexing marks
should be made on armature plate and crankcase
to ease reassembly and further ignition timing.
The following procedure is to find a common reference point on both crankcases (old and new) to
position armature plate.
Proceed as follows:
Find a crankcase locating lug (the top one in this
example).
Place a cold chisel at the end of chosen lug,
then punch a mark on armature plate at this
point.
1
2
3
F01D4CA
1. Puller plate
2. Puller
3. Extension handle
10, Armature Plate

F01D4DA
Remove 3 retaining screws no. 15 and withdraw

armature plate.
7, Magneto Housing
To remove magneto housing, starter has to be removed. Refer to ELECTRICAL SYSTEM 07-04.
Unscrew retaining screws no. 9, then withdraw
housing.
03-04-4
1. Crankcase locating lug

2. Mark armature plate at the end of lug
At assembly, align armature plate mark (previously punched) with the end of the same locating lug on the new crankcase.
Sub-Section 04
Section 03 ENGINE
(MAGNETO SYSTEM)
The new mark on crankcase will be used for further assembly positioning as a pre-timing position.
F01D4GA
F01D4EA
TYPICAL
1. For further assembly, use these marks
TYPICAL
1. Lug end of crankcase
2. Align mark and lug end here
Find manufacturers mark on armature plate. In

line with this mark, punch another mark on adjacent crankcase lug.
787 Engine

Loosen screws no. 2. Remove engine magneto
cover.
4,5, Rotor and Flywheel

Remove starter. Refer to ELECTRICAL SYSTEM
07-04.
Lock ring gear using special tool.
1
2
1
F01B26A
1. Ring gear blocking tool (P/N 295 000 134)

2. Retaining plate (P/N 295 000 154)
F01D4FA
TYPICAL
1. Manufacturers mark on armature plate
2. Punch a mark on crankcase lug aligned with plate mark
03-04-5
Section 03 ENGINE
F01D85A
F01D7YA
1. Ring gear blocking tool with retaining plate
1. Puller
If desired, magneto rotor can be removed without

the engine flywheel. Remove the 6 screws
no. 11.
Tighten puller screw and at the same time, tap on

screw head using a hammer to release engine flywheel from its taper.
CLEANING
Clean all metal components in a solvent.
CAUTION
Clean coils and magnets using only a clean

cloth.
Clean crankshaft taper and threads.
DISASSEMBLY
F01D7XA
1. Screw
Using a suitable socket, unscrew retaining nut of

engine flywheel COUNTERCLOCKWISE when
facing it.
Remove special tool locking ring gear.
Engine flywheel is easily freed from crankshaft
with puller (P/N 420 976 235) and crankshaft protective cap (P/N 290 876 557).
Insert crankshaft protector to outer end of crankshaft and fully thread puller in engine flywheel.
03-04-6
717 Engines

Lay magneto flywheel on a steel plate. Tap lightly
on ring gear using a hammer to release it from
magneto flywheel.
Sub-Section 04
Section 03 ENGINE
(MAGNETO SYSTEM)
F01D3AA
1. Magneto flywheel
11, Generating Coil

To replace generating coil:
Heat the armature plate to 93C (200F) around
the screw holes to break the threadlocker
bond.
A25E0QA
1. Uncrimp and unsolder wire here
13, Battery Charging Coil

To replace battery charging coil:
Heat the armature plate to 93C (200F) around
the screw holes to break the threadlocker
bond.
1
F00D08A
1. Heat the armature plate
CAUTION
1
Protect harness from flame.

F00D09A
Remove screws.
Uncrimp and unsolder BLACK/RED wire from
coil.
1. Heat the armature plate
CAUTION
Protect harness from flame.

Remove screws.
Uncrimp and unsolder YELLOW and YELLOW/BLACK wires from coil.
03-04-7
Section 03 ENGINE
Uncrimp and unsolder ground wire (BLACK)

from coil core.
CAUTION
Before reinstalling the magneto, remove the

loose epoxy from harness.
1
13, Battery Charging Coil

Position new coil, crimp and solder all wires.
Prior to assembly, apply Loctite 242 (blue).
Use magneto coil centering tool (P/N 290 876
922) and install it so that it fits around armature
plate before tightening screws no. 14.
1
A25E0SA
1. Uncrimp and unsolder ground wire (BLACK)

2. Uncrimp and unsolder YELLOW and YELLOW/BLACK wires
F00D0AA
ASSEMBLY
1. Magneto coil centering tool (P/N 290 876 922)
717 Engines
11, Generating Coil
Apply Loctite 648 (green) to magneto flywheel

mating surface. Lay ring gear on a steel plate,
then heat with a propane torch in order to install it
on magneto flywheel.
Pay particular attention to position ring gear teeth
chamfer side as per following illustration.
Strip end of old wire then crimp and solder on

new coil.
Apply Loctite 242 (blue) to screws no. 12 and install the new coil on armature plate.
Use magneto coil centering tool (P/N 290 876
922) and install so that it fits around armature
plate before tightening screws.
1
F01D3BA
1. Teeth chamfer
F00D0AA
1. Magneto coil centering tool (P/N 290 876 922)
03-04-8
NOTE: Ensure that ring gear contacts magneto

flywheel flange.
Sub-Section 04
Whenever replacing either ring gear or magneto

flywheel, Gun Kote must be applied to prevent
possible corrosion.
CAUTION
Section 03 ENGINE
(MAGNETO SYSTEM)
14, Trigger Coil

Install the trigger coil in magneto housing cover
no. 1 and torque screws no. 15 to 10 Nm (88
lbfin).
NOTE: The trigger coil is not adjustable.
Always assemble magneto flywheel and

ring gear prior to apply Gun Kote. If not done
correctly, ring gear wont contact magneto
flywheel flange.
To apply Gun Kote proceed as follows:
1. Clean thoroughly and degrease replacement
part using a non oil base solvent.
2. Apply coating in light thin coats using a spray
gun.
NOTE: Do not spray Gun Kote into magneto flywheel threaded holes.
3. Bake parts in oven at 175 (350F) for one hour
to cure Gun Kote.
CAUTION
Do not eliminate Gun Kote heat curing time

because it will lose all its resistance and it
will not give any protection.
787 Engine
12, Stator
Install the stator in magneto housing cover no. 1
and torque screws no. 13 to 10 Nm (88 lbfin).
Replace wiring harness bracket no. 16 of stator
and torque screws to 4.5 Nm (40 lbfin).
1
F06D0DA
1. Trigger coil
INSTALLATION
717 Engines
7, Magneto Housing
Install gasket no. 8 between magneto housing
and engine crankcase.
Install magneto housing and torque screws no. 9
to 9 Nm (80 lbfin).
10, Armature Plate

Position the armature plate on the crankcase,
aligning the marks on both parts.
Apply a drop of Loctite 242 (blue) on threads of
screws no. 15 and torque to 6 Nm (53 lbfin).
4, Magneto Flywheel
Apply Loctite 242 (blue) on crankshaft taper.
Position Woodruff key no. 16 and magneto flywheel. Apply Loctite 242 (blue) on nut no. 6. Install nut with lock washer and torque to 145 Nm
(107 lbfft).
F06D0CA
1. Stator screws
2. Bracket
CAUTION
Never use any type of impact wrench at

magneto installation.
03-04-9
Section 03 ENGINE
Ignition Timing
4,5, Rotor and Flywheel
For ignition timing procedures of 717 engines, refer to ELECTRICAL SYSTEM 07-02.
When reinstalling magneto rotor to engine flywheel, apply Loctite 648 to mating surfaces.
One of the protuberance end of magneto rotor
must align with hole of engine flywheel.
787 Engine
7, Magneto Housing
To install oil seal no. 10 of magneto housing, use

pusher (P/N 290 877 740) and handle (P/N 290
877 650).
F01D83A
1. Protuberance
2. Hole
F01B2NA
1. Pusher
2. Handle
Apply Loctite 648 (green) on screws no. 11 and

torque to 10 Nm (88 lbfin).
Apply Loctite 242 (blue) on crankshaft taper.
Apply Loctite 242 (blue) on nut no. 6. Install nut
with lock washer and torque to 105 Nm (77
lbfft).
CAUTION
Never use any type of impact wrench at

magneto installation.
All Engines
F04D0CA
Install gasket no. 8 between magneto housing

and engine crankcase.
Install magneto housing and torque screws no. 9
to 9 Nm (80 lbfin).
03-04-10
Properly install O-ring no. 3 in magneto housing.

Apply Loctite 767 anti-seize on screws no. 2, install cover, wire supports no. 17 and no. 18 (717
engines) then torque screws no. 2 in a criss-cross
sequence to 9 Nm (80 lbfin).
Section 03 ENGINE
Sub-Section 05 (TOP END)
TOP END
717 Engines
24 Nm 15
(17 lbfft)
Loctite 242
Synthetic grease
1
28
12
Synthetic
grease
24 Nm
(17 lbfft) 17
Loctite
515
Loctite
242
9
34
rollers
6
16
7
5
8
3
Synthetic
grease
7
8
4
4
5
6
34
rollers
Synthetic
grease
F00D0DS
PARTS
FLAT RATE
03-05-1
Section 03 ENGINE
787 Engine
Loctite 242
24 Nm
15 (17 lbfft)
Synthetic grease
1
31
12
2
30
22
20
19
28
Synthetic
grease
23
Synthetic
grease
29
18 40 Nm
(30 lbfft)
Loctite
515
21
27
26 25
34 rollers
Loctite
515
24
9
6 5
4
7
8
7
8
4 5
Synthetic
grease
3
F01D7DS
03-05-2
PARTS
FLAT RATE
16
Synthetic
grease
6
34 rollers
Section 03 ENGINE
GENERAL
The 2-stroke ROTAX engine rotates counterclockwise seen from the rear (PTO flywheel). It has a
rotary valve to control opening and closing of intake.
CAUTION
No engine components can be interchanged

between engines.
Located above the exhaust port is a guillotinetype slide valve. This rectangular valve is connected by a shaft to a diaphragm which is working
against the return spring. One small passage in
the cylinder just outside the exhaust port allows
exhaust gas pressure to reach the diaphragm.
To the outside of the return spring is a red plastic
adjustment knob. Turning the adjustment in or out
changes the preload on the return spring which, in
turn, will change the RPM at which the RAVE
valve opens and closes.
787 Engine Only

This engine is canted at a 30 degree angle, lowering the center of gravity of the watercraft. Cylinder exhaust ports are located on the same side of
the intake, allowing a high volume tuned pipe design. This engine also features the RAVE system
(Rotax Adjustable Variable Exhaust). The RAVE
system working in combination with the high volume tuned pipe offers a broader power band.
5
3
2
RAVE System
THEORY
For a 2-stroke-cycle engine to have high power capacity at high crankshaft speeds, a high volumetric or breathing efficiency is required and the fresh
charge losses must be minimized. The result is
achieved by opening the exhaust port early and
utilizing the resonant effects of the tuned exhaust
system to control fresh charge losses.
When an engine of this design is run at a medium
speed, efficiency falls off quickly. The relatively
high exhaust port effectively shortens the useful
power stroke and because the exhaust system is
tuned for maximum power, there is a large increase of fresh charge losses. As a result, the
torque decreases along with a dramatic increase
of the specific fuel consumption. Higher torque
along with lower fuel consumption can be obtained at lower engine speeds if the time the exhaust port is open is shortened.
Bombardier-Rotax has patented a remarkably simple system to automatically change the exhaust
port height based on pressure in the exhaust system.
A18C01A
TYPICAL
1. Sliding valve
2. Diaphragm
3. Spring
4. Exhaust port
5. Adjustment knob
As the throttle is opened and the engine begins

producing more power, the pressure against the
diaphragm will overcome the pressure of the return spring and the RAVE valve will open.
F01D7GA
VALVE FULLY OPENED
03-05-3
Section 03 ENGINE
P1
P2
POWER
F01D7HA
VALVE FULLY CLOSED

A18C02A
The RAVE valve does not allow an engine to make

higher peak horsepower than an engine not so
equipped, it can make moving the peak higher
practical because of its effect on the rest of the
power curve. Item 2 in the following figure is the
power curve of an engine with the RAVE valve
held fully open through its entire RPM range. Item
6 notes the peak power produced. That peak will
not change if the exhaust port time of a similar
engine without a RAVE valve was the same (with
all other features equal).
Item 1 is the power curve of the engine with the
RAVE valve closed through its entire RPM range.
The shaded area (item 3) is the improvement in
power at lower engine speeds that is gained because of the lower exhaust port. If the port remains at this height, however, the power would
peak as noted in item 5. Raising the exhaust port
at the proper RPM (item 7) will allow the engine
peak power to continue to rise (item 6).
Item P1 in figure is the force of the return spring
against the diaphragm. The exhaust pressure
must be high enough to overcome this force before the valve begins opening. Item P2 is the pressure required to completely open the RAVE valve.
Between P1 and P2, the usable power curve of
the engine is moving from power curve 1 to power curve 2. This transition takes place very rapidly
at full throttle and from a practical standpoint can
be considered to be instantaneous at item 7.
Gradual application of the throttle, however, will
result in the RAVE valve opening much later.
If the RAVE valve opens too late, the engine will
bog or hesitate momentarily as the RPM increases. Full peak performance (item 6) is still available.
From a functional point of view. It is better to have
the valve open a bit early than a bit late.
03-05-4
RPM
MAINTENANCE
There are no wear parts anywhere in the system
and there are no adjustments to be periodically
checked. The only possible maintenance required
would be cleaning of carbon deposits from the
guillotine slide. Cleaning intervals would depend
upon the users riding style and the quality of the
oil used. Using FORMULA XP-S synthetic injection oil, we would suggest annual cleaning of the
valve. If a customer uses a lower quality oil, more
frequent cleaning may be required.
No special solvents or cleaners are required when
cleaning the valve.
BORING PRECAUTION
In its stock configuration the RAVE valve guillotine
has a minimum of 0.5 mm (.020 in) clearance to
the cylinder bore measured at the center line of
the cylinder. This is the minimum production
clearance.
There is only a first oversize piston available for
the 787 engine. That piston is 0.25 mm (.010 in)
larger in diameter than the stock piston. When the
oversize is installed, the guillotine will have a minimum clearance of 0.375 mm (.015 in) with the
cylinder bore. This is the minimum operating
clearance the guillotine should be used with.
Clearance less than 0.375 mm (.015 in) will require reworking of the guillotine to achieve the
proper clearance and radius.
Section 03 ENGINE
DISASSEMBLY
787 Engine
30, RAVE Valve

Remove the cover no. 20 of the valve by releasing
the spring no. 19.
Remove bellow no. 23 from valve piston no. 22.

Unscrew valve piston no. 22 from sliding valve
no. 24.
NOTE: Hold the sliding valve to prevent it from
turning.
1
WARNING
Firmly hold cover to valve base. The spring

inside the valve is applying a pressure
against the cover.
2
F01D8MA
1. Unscrew piston
2. Hold sliding valve
All Engines
1,2, Cylinder Head Cover and Cylinder

Head
Disconnect temperature sensor wire and spark

plug cables.
Connect spark plug cables on grounding device.
F01D8HA
1. Spring
Loosen Allen screws no. 21 and remove RAVE

valve.
717 Engines
Remove air intake silencer and support, refer to
FUEL SYSTEM 05-03.
All Engines
Remove screws no. 15.
Remove cylinder head cover no. 1.
If shells, sand, salt or any other particles are
present in cylinder head, clean with a vacuum
cleaner.
Remove cylinder head no. 2.
If shells, sand, salt water or any other particles are
present in cylinder cooling jacket, clean with a
vacuum cleaner.
9, Cylinder
F01D8IA
1. Allen screws
787 Engine
Remove air intake silencer and support, refer to
FUEL SYSTEM 05-03.
03-05-5
Section 03 ENGINE
All Engines
Remove tuned pipe and exhaust manifold, refer
to ENGINE 03-08.
Remove screws no. 17.
Remove cylinders, being careful that connecting
rods do not hit crankcase edge.
WARNING
If screws need to be heated for removal

when engine is in watercraft, fuel system
pressurization must be done first. Do not use
open flame; use a heat gun.
F01D43A
NOTE: Even if only one cylinder needs repair,

both cylinders should be lifted to allow 1-piece cylinder base gasket replacement.
1. Openings covered with rag and rubber pad
To remove circlip no. 5, insert a pointed tool in piston notch then pry it out and discard.
3, Piston
NOTE: The 717 and 787 engines feature cageless
piston pin bearings.
Bring piston to Top Dead Center and install rubber
pad (P/N 295 000 101) over crankcase opening. Secure with screws. Lower piston until it sits on pad.
WARNING
Always wear safety glasses when removing

piston circlips.
F01B0JA
1. Rubber pad
If the other cylinder has been removed, completely cover its opening with a clean rag.
03-05-6
F01D0PA
TYPICAL
1. Piston notch
To extract piston pin no. 4, use piston pin puller

(P/N 290 877 092) as follows:
Fully thread on puller handle.
Insert extractor spindle into the piston pin.
Slide the expansion sleeve (P/N 290 877 041)
onto the spindle.
Screw in extracting nut (P/N 290 877 155) with
the movable extracting ring towards spindle.
Section 03 ENGINE
1
2
3
5
4
F01D2YA
F01B0VA
PISTON PIN PULLER (P/N 290 877 092)

1. Bushing (P/N 290 877 181)
2. Expansion sleeve (P/N 290 877 041)
3. Extractor sleeve
4. Extractor spindle
5. Extracting nut (P/N 290 877 155)
Firmly hold puller and rotate handle to pull piston pin no. 4.
The needles, thrust washers and the expansion

sleeve remain in the connecting rod bore and
may be used again.
To remove rollers with the thrust washers from
the connecting rod bore, push them together with
the expansion sleeve into the bushing (P/N 290
877 181) using any suitable 23 mm (.905 in) diameter pusher.
CAUTION
Recover rollers, make sure that 34 rollers are

found for each piston.
1
2
F01D2WA
1. Circlip at this side not to be removed

2. Grease expansion sleeve
By turning the spindle, pull out piston pin until

it is completely removed from bearing.
A21C04A
1. Pusher 23 mm (.905 in)
CLEANING
F01D2XA
Rotate spindle until extracting nut can be removed.

Remove spindle and extractor sleeve from piston pin no. 4.
Carefully remove the piston no. 3.
Discard all gaskets and O-rings.

Clean water passages and make sure they are not
clogged.
Remove carbon deposits from cylinder exhaust
port, RAVE valve (787 engine), cylinder head and
piston dome.
03-05-7
Section 03 ENGINE
Clean piston ring grooves with a groove cleaner

tool, or a piece of broken ring.
INSPECTION
787 Engine
Check RAVE valve bellow no. 23 for cracks.
Check if passages of valve housing no. 27 and cylinder no. 9 are not obstructed.
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 for
717 Engines
0.06 mm
(.0024 in)
0.11 mm
(.004 in)
0.20 mm
(.008 in)
Piston/Cylinder Wall
Clearance for the
787 Engine
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)
N.A.: Not Applicable
F01D8JA
1. Passage of valve housing
All Engines
Visually inspect all parts for corrosion damage.
Inspect piston for damage. Light scratches can be
sanded with a fine sand paper.
NOTE: When repairing a seized engine, connecting rods should be checked for straightness and
crankshaft for deflection/misalignment. Refer to
ENGINE 03-06 for procedures.
Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a surface
plate and rub part against oiled sand paper.
The inspection of engine top end should include
the following measurements.
03-05-8
NOTE: Replacement cylinder sleeves are available if necessary. Also, oversize pistons of 0.25
mm (.010 in) are available for all engines and oversize pistons of 0.5 mm (.020 in) are available for
717 engines.
Cylinder Taper
Using a cylinder bore gauge, measure cylinder diameter at 16 mm (5/8 in) from top of cylinder just below
auxiliary transfer port, facing exhaust port. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced.
Section 03 ENGINE
Piston/Cylinder Wall Clearance

PISTON MEASUREMENT
Used Piston
Using a micrometer, measure piston at 25 mm (1 in)
from skirt end perpendicularly (90) to piston pin.
1
A
F01D8AA
1. Measuring perpendicularly (90 ) to piston pin axis

2. Auxiliary transfer port
A. 16 mm (5/8 in)
F01D0NA
Cylinder Out of Round
1. Measuring perpendicularly (90) to piston pin axis

A. 25 mm (1 in)
Using a cylinder bore gauge, measure cylinder diameter at 16 mm (5/8 in) from top of cylinder.
Measure diameter in piston pin axis direction then
perpendicularly (90) to it. If the difference between readings exceed specification, cylinder
should be rebored and honed or replaced.
Lock the micrometer to the obtained value.

New Piston
To determine the piston dimension, take the measurement on the piston dome.
2
F00D0EA
1. Piston dome
2. Piston measurement
Adjust and lock a micrometer to the specified value on the piston dome.
F01D8BA
1. Measuring in piston pin axis

2. Measuring perpendicularly (90 ) to piston pin axis
A. 16 mm (5/8 in)
03-05-9
Section 03 ENGINE
F00B08A
1. Micrometer set to the piston dimension

F00B0AA
PISTON/CYLINDER WALL CLEARANCE

MEASUREMENT
1. Indicator set to zero
Used and New Pistons

With the micrometer set to the piston dimension,
adjust a cylinder bore gauge to the micrometer dimension and set the indicator to zero.
Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge.
2
A
F01D0KA
1. Measuring perpendicularly (90) to piston pin axis

A. 16 mm (5/8 in)
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
Read the measurement on the cylinder bore

gauge. The result is the exact piston/cylinder wall
clearance.
NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Ring/Piston Groove Clearance

Using a feeler gauge, check clearance between
rectangular ring and groove. If clearance exceeds
specified tolerance, replace piston.
NOTE: Ring/piston groove clearance can be correctly measured only on rectangular ring which is
bottom ring.
03-05-10
Section 03 ENGINE
F01D0XA
1. Feeler gauge
2. Rectangular ring (bottom)
F01D67A
1. Identification holes
Ring End Gap

Position ring halfway between exhaust port and
top of cylinder.
NOTE: In order to correctly position ring in cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. If gap
exceeds specified tolerance, rings should be replaced.
GASKET
THICKNESS
IDENTIFICATION
HOLES
0.3 mm
(.012 in)
0.4 mm
(.016 in)
0.5 mm
(.020 in)
0.6 mm
(.024 in)
0.8 mm
(.031 in)
ASSEMBLY
2
F01D0OA
1. Top of cylinder
2. Ring end gap
16, Cylinder Base Gasket

Five thicknesses of cylinder base gaskets are
available for a precise adjustment of the combustion chamber volume.
To determine gasket thickness, refer to the identification holes on the gasket.
Assembly is essentially the reverse of disassembly procedures. However pay particular attention
to the following.
787 Engine
30, RAVE Valve

Make sure to insert O-ring no. 25 onto rod of sliding valve no. 24.
The TOP position of the sliding valve no. 24 is indicated on one side.
03-05-11
Section 03 ENGINE
3
F01D8KA
1. Sliding valve
2. O-ring
3. TOP
Install a new gasket no. 26. It must be installed at

the same time as the sliding valve no. 24.
Position the valve housing no. 27 onto the cylinder so that its opening is toward the bottom.
F01D8LA
All Engines
3, Piston
At assembly, place the pistons over the connecting rods with the letters AUS (over an arrow on
the piston dome) facing in direction of the exhaust
port.
1
AUS
A01C01A
F01D8JB
1. Bottom of valve housing
When the valve is mounted onto the cylinder,

move the valve piston no. 22 to ensure the sliding
valve no. 24 moves easily and doesnt stick.
03-05-12
1. Exhaust side
NOTE: On the 787 engine, the exhaust ports are

located on the same side as the intake.
Section 03 ENGINE
Insert extractor spindle into the piston pin,

screw on extracting nut.
Rotate handle to pull piston pin carefully into
the piston.
F01D31A
F01D7EA
787 ENGINE SHOWN

1. AUS
Carefully cover crankcase opening as for disassembly.
4,6, Piston Pin and Roller Bearing

To install roller bearing and piston pin use piston
pin puller (P/N 290 877 092), proceed as follows:
Replacement bearings are held in place by a locating sleeve outside and 2 plastic cage halves
inside.
Push needle bearing together with inner halves
out of the locating sleeve into the connecting
rod bore.
Use any suitable 23 mm (.905 in) diameter
pusher as a tool. Make sure thrust washers are
present each side of needles.
Plastic Mounting Device Method

This is an alternate method when no service tool
is available.
Replacement roller bearings are delivered in a
convenient plastic mounting device. For installation, proceed as follows:
Align replacement roller bearing with connecting rod bore.
Carefully push inner plastic sleeve into connecting rod bore; outer plastic ring will release
rollers.
1
F01D0Q A
1. Outer ring removal after inner sleeve insertion into bore
Make sure thrust washers are present each

side of rollers.
F01D30A
1. Pusher
Insert piston pin into piston until it comes flush

with inward edge of piston hub.
Warm piston to approximately 50-60C (122140F) and install it over connecting rod.
03-05-13
Section 03 ENGINE
F01D0VA
1. Thrust washer each side

F01D0SA
Insert piston pin into piston until it comes flush

with inward edge of piston hub.
As necessary, pull halves of inner sleeve with

long nose pliers.
1
2
F01D0RA
1. Piston pin flush here

2. Thrust washers
Place piston over connecting rod and align

bores, then gently tap piston pin with a fiber
hammer to push out inner plastic ring on opposite side. Support piston from opposite side.
F01D0TA
1. Pulling inner sleeve half
5, Circlip
Secure remaining circlip no. 5 taking into consideration the following.
CAUTION
To minimize the stress on the circlips, install

them so that their openings are located at 6
oclock (at bottom). Always use new circlips.
At installation, take care not to deform them.
03-05-14
Section 03 ENGINE
F01D0WA
F01D0YA
1. Circlip opening at 6 oclock (at bottom)
WARNING
Always wear safety glasses when installing

piston circlips.
To easily insert circlip no. 5 into piston no. 3, use
circlip installer P/N 290 877 016.
CAUTION
Circlips must not move freely after installation.
9, Cylinder
To easily slide cylinder no. 9 over piston no. 3, install on piston ring compressor P/N 290 876 979.
F01B0KA
1. Circlip installer
Remove pusher from tool then insert circlip into

its bore.
Reinstall pusher into tool and push until circlip
comes in end of tool.
Position end of tool against piston pin opening.
Firmly hold piston against tool and push tool
pusher to insert circlip into its groove.
A01B1TA
1. Slide this edge
NOTE: Ring compressor will not fit on oversize

parts.
Make sure to align ring end gap with piston locating pin. Slide tool over rings.
03-05-15
Section 03 ENGINE
717 Engines
The aligning tool (P/N 290 876 902) or the exhaust
manifold can be used to align cylinders.
F01D0ZA
1. Ring end gap aligned with piston locating pin
Slide cylinder no. 9 over piston no. 3.

F01D44A
717 ENGINES
1. Exhaust flange aligning tool
F01D10A
When reassembling cylinders no. 9 to crankcase,

it is important to have them properly aligned so
that exhaust flanges properly match up with exhaust manifold.
F01D45A
717 ENGINES
1. Aligning cylinders using exhaust manifold
03-05-16
Section 03 ENGINE
787 Engine
The exhaust manifold is used to align cylinders.
787 Engine
Prior installation, apply synthetic grease below
screw head and Loctite 515 on screw threads.
Install M10 x 105 screws on exhaust side and the
M10 x 73,5 on opposite side.
Torque screws in a criss-cross sequence for each
cylinder to 20 Nm (15 lbfft). Repeat the procedure, retightening all cylinder screws to 40 Nm
(30 lbfft).
2
F00D0FA
787 ENGINE
1. Aligning cylinders using exhaust manifold
17,18, Cylinder Screw

717 Engines
Apply synthetic grease below the screw head.
Apply also Loctite 242 (blue) on screw threads.
Install and torque screws in a criss-cross sequence for each cylinder to 24 Nm (17 lbfft). Refer to the following illustration.
1
F01D7FA
2, Cylinder Head
Make sure to install O-rings no. 12 around spark
plug holes and O-ring no. 31 of cylinder head as
shown in the following illustration.
1
F01D35A
F01D5AA
1. O-rings
Apply Loctite 515 in O-ring groove of cylinder

sleeves.
Install cylinder head.
03-05-17
Section 03 ENGINE
1, Cylinder Head Cover

Install cylinder head cover.
Apply Loctite 242 (blue) below head of screws
no. 15.
Apply also synthetic grease on threads of screws
no. 15.
Torque cylinder head screws no. 15 to 12 Nm (9
lbfft) as per following illustrated sequence. Repeat the procedure, retightening all screws no. 15
to 24 Nm (17 lbfft).
10
12
This will ensure the correct preload on the return

spring no. 29 in order to open and close the RAVE
valve at the proper RPM.
Combustion Chamber Volume

Measurement
The combustion chamber volume is the region in
the cylinder head above the piston at Top Dead
Center. It is measured with the cylinder head installed on the engine.
F01D5VA
1. Combustion chamber
F01D46A
11
ADJUSTMENT
RAVE Valve
NOTE: When checking the combustion chamber

volume, engine must be cold, piston must be free
of carbon deposit and cylinder head must be leveled.
1. Remove both spark plugs and bring one piston
to Top Dead Center a using a TDC gauge.
Turn the red plastic knob no. 28 until it is equal to

the valve cover.
1
F00D0GA
1. Knob equal with the cover
F01D2IA
1. Bring piston to TDC
03-05-18
Section 03 ENGINE
2. Obtain a graduated burette (capacity 0-50 cc)

and fill with an equal part (50/50) of gasoline
and injection oil.
NOTE: The liquid level in cylinder must not drop

for a few seconds after filling. If so, there is a leak
between piston and cylinder. The recorded volume would be false.
5. Let burette stand upward for about 10 minutes,
until liquid level is stabilized.
6. Read the burette scale to obtain the quantity of
liquid injected in the combustion chamber.
NOTE: When the combustion chamber is filled to
top of spark plug hole, it includes an amount of
2.25 cc for this space (BR7ES or BR8ES have a 19
mm reach head).
7. Repeat the procedure for the other cylinder.
F00B0BA
1. Graduated burette (0-50 cc)
3. Open burette valve to fill its tip. Add liquid in

burette until level reaches 0 cc.
4. Inject the burette content through the spark
plug hole until liquid touches the top spark plug
hole.
F00D0HA
1. Top of spark plug hole
03-05-19
Section 03 ENGINE
Sub-Section 06 (BOTTOM END)
BOTTOM END
717 Engines
Loctite
515
11
Lithium
grease
Anti-seize
lubricant
2
15
1
6
14
5
3
Loctite
642
6
Anti-seize
lubricant
15
Loctite
515
Anti-seize
lubricant
Loctite
242
6
24 Nm
(17 lbfft)
9
6
11
1
Lithium
grease
Loctite
515
Synthetic
grease
Loctite
515
7
24 Nm
(17 lbfft)
F01D06S
10
10 Nm
(88 lbfin)
Synthetic
grease
8
40 Nm
(30 lbfft)
PARTS
FLAT RATE
03-06-1
Section 03 ENGINE
787 Engine
30 mL (1 oz)
SAE 30
motor oil
Loctite
515
Anti-seize
lubricant
12
Lithium
grease
1
5
13
16
18
Lithium
grease
6
15
14
12
Anti-seize
lubricant
Loctite
642
Anti-seize
lubricant
Anti-seize
lubricant
15
17
Lithium
grease
Loctite
515
Loctite
242
Loctite
515
Synthetic
grease
8
40 Nm
(30 lbfft)
Synthetic
grease
Loctite
515
Synthetic
grease
7
24 Nm
(17 lbfft)
F01D8GS
03-06-2
PARTS
FLAT RATE
Loctite
515
Synthetic
grease
8 40 Nm
(30 lbfft)
7 24 Nm
(17 lbfft)
Anti-seize
lubricant
Section 03 ENGINE
CRANKSHAFT MISALIGNMENT
AND DEFLECTION
Since it is an assembled crankshaft it can become
misaligned or deflected. Crankshaft can be twisted on center main journal, changing timing of one
cylinder in relation with the other.
Remove flywheel nut (and magneto rotor for

the 787 engine). Refer to ENGINE 03-04 for
procedures.
Install Bombardier degree wheel (P/N 295 000
007) on crankshaft end. Hand-tighten nut only.
Remove both spark plugs.
Install a TDC gauge in spark plug hole on MAG
side.
Bring MAG piston at Top Dead Center.
As a needle pointer, secure a wire with a cover
screw and a washer.
Rotate degree wheel (NOT crankshaft) so that
needle pointer reads 360.
F01D1NA
1. Main journal alignment here
Counterweights can also be twisted on connecting rod journal on any or both cylinder(s).
3
4
F01D4IA
1.
2.
3.
4.
1
F01D1NB
1. Connecting rod journal alignment here
Crankshaft Alignment at Center Main

Journal
NOTE: The following checks can be performed
with engine in watercraft without overhauling engine.
To accurately check if crankshaft is twisted on
center main journal, proceed as follows:
Remove magneto housing cover.
TDC gauge
Degree wheel
Hand tighten nut
Needle pointer
Remove TDC gauge and install on PTO side.

Bring PTO piston at Top Dead Center.
Interval between cylinders must be exactly 180
therefore, needle pointer must indicate 180 on
degree wheel (360 - 180 = 180).
Any other reading indicates a misaligned crankshaft.
03-06-3
Section 03 ENGINE
Crankshaft Alignment at Connecting

Rod Journal
Such misalignment may cause a crankshaft hard
to be manually turned. Verification can be done by
measuring deflection each end of crankshaft. Refer to Inspection paragraph.
If deflection is found greater than specified tolerance, this indicates worn bearing(s), bent and/or
disaligned crankshaft.
1
DISASSEMBLY
Engine has to be removed from watercraft to
open bottom end. Refer to ENGINE 03-03.
F01D1KA
1. Separate halves by prying at provided lugs
1, Seal
If a crankshaft end seal has to be replaced, bottom end must be opened (except for the MAG
side seal on the 787 engine, which is mounted on
the magneto housing).
3, Crankcase
Remove the following parts:
engine support (except for the 787 engine)
PTO flywheel, refer to PROPULSION SYSTEM
08-03
NOTE: PTO flywheel must be removed prior removing MAG flywheel.
magneto flywheel, refer to ENGINE 03-04
starter
magneto housing
rotary valve cover and valve
crankcase retaining screws
Insert screwdrivers between crankcase lugs and
pry to separate halves being careful not to damage precision machined surfaces.
1
F01D1LA
1. Separate halves by prying at provided lugs
Remove crankshaft and counterbalance shaft

(787 engine).
1,2,4,5, Seal and Bearing

NOTE: Do not needlessly remove crankshaft
bearings.
Remove end seal(s).
To remove end bearings from crankshaft, use protective cap (P/N 290 876 557) and puller (P/N 290
876 298).
717 Engines
On PTO side, use ring (P/N 290 977 490) with ring
halves (P/N 290 977 475).
On MAG side, use distance ring (P/N 290 876
569), ring (P/N 290 977 490) with ring halves (P/N
290 276 025).
03-06-4
Section 03 ENGINE
NOTE: To facilitate ring or distance ring installation lubricate their inside diameters.
2
All Engines
6
1
8
7
F01B09A
1.
2.
3.
4.
5.
6.
7.
8.
F01D1OA
Puller (P/N 290 876 298)

Protective cap (P/N 290 876 557)
Distance ring, MAG side (P/N 290 876 569)
Ring (both side) (P/N 290 977 490)
MAG side ring halves (P/N 290 276 025)
PTO side ring halves (P/N 290 977 475)
Screw M8 x 40 (P/N 290 840 681)
Screw M8 x 70 (P/N 290 841 201)
TYPICAL
1. Removing crankshaft bearing
787 Engine
For MAG and PTO sides, use distance ring (P/N
290 876 569), ring (P/N 290 977 490) and ring
halves (P/N 290 977 475).
NOTE: The outer PTO bearing and crankshaft
gear can be removed in one step using another
puller. See Crankshaft Gear no. 13.
1
Or, use a bearing extractor such as Proto no. 4332

and a press to remove two bearings at a time (except on PTO side for the 787 engine).
F01D1PA
1. Press bearings out

2. Bearing extractor
7
F01B2MA
1.
2.
3.
4.
5.
6.
7.
Puller (P/N 290 876 298)

Distance ring (P/N 290 876 569)
Ring (P/N 290 977 490)
Ring halves (P/N 290 977 475)
Screw M8 x 40 (P/N 290 840 681)
Screw M8 x 70 (P/N 290 841 201)
787 Engine
13, Crankshaft Gear

The crankshaft gear and bearing no. 5 can be removed in one step using the following puller:
NOTE: To facilitate ring or distance ring installation lubricate their inside diameters.
03-06-5
Section 03 ENGINE
NOTE: If the inner PTO bearing needs to be replaced, remove the Woodruff key on the crankshaft.
16, Counterbalance Shaft

Bearings no. 12 can be removed by using the following tools:
F04B03A
1. Puller (P/N 290 877 665)
Install the puller as per following illustration.

1
5
F00B0CA
1.
2.
3.
4.
5.
F00D0IA
Puller (P/N 290 876 298)

Ring (P/N 290 977 480)
Ring halves (P/N 290 876 330)
Screw M8 x 40 (P/N 290 840 681)
1. Puller
2. Protective cap
Secure puller in a vise and remove gear and bearing.
F00D0KA
1. Tool installed
To remove gear no. 18, first trace an index mark

on the gear and counterbalance shaft.
NOTE: There is no Woodruff key to position the
gear on the counterbalance shaft. An index mark
must be traced to ease assembly procedure.
F00D0JA
03-06-6
Section 03 ENGINE
INSPECTION
F00D0SA
1. Index mark
Use a press to remove the gear no. 18 from the

counterbalance shaft.
Visually inspect parts for corrosion damage.

Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a surface
plate and rub part against oiled sand paper.
Inspect crankshaft bearings. Check for scoring,
pitting, chipping or other evidence of wear. Make
sure plastic cage is not melted. Rotate and make
sure they turn smoothly.
If crankshaft and/or components are found defective, it must be repaired by a specialized shop or
replaced.
The inspection of engine bottom end should include the following measurements:
MEASUREMENT
NEW PARTS
(min.)
Connecting rod 0.390 mm

big end axial play (.015 in)
(max.)
WEAR
LIMIT
.737 mm
(.029 in)
1.2 mm
(.047 in)
MEASUREMENT
MAG SIDE
PTO SIDE
Crankshaft
deflection (max.)
0.050 mm
(.002 in)
0.030 mm
(.001 in)
Connecting Rod Straightness

Align a steel ruler on edge of small end connecting rod bore. Check if ruler is perfectly aligned
with edge of big end.
F00D0TA
CLEANING
Discard all oil seals, gaskets, O-rings and sealing
rings.
Clean oil passages and make sure they are not
clogged.
Remove old Loctite from crankcase mating surfaces with gasket remover (P/N 295 000 110).
CAUTION
Be careful not to spray cleaner on the painted surface of the engine. Never use a sharp
object to scrape away old sealant as score
marks incurred are detrimental to crankcase
sealing.
F01D1QA
1. Ruler must be aligned with edge of connecting rod here

2. Align ruler here
03-06-7
Section 03 ENGINE
Crankshaft Deflection
Crankshaft deflection is measured each end with
a dial indicator.
First, check deflection with crankshaft in crankcase. If deflection exceeds the specified tolerance, it can be either ball bearings wear, bent or
twisted crankshaft at connecting rod journal.
F01D1UA
1. Measuring MAG side deflection on V-shaped blocks
1
F01D1SA
1. Measuring PTO side deflection in crankcase
F01D1VA
1. Measuring PTO side deflection on V-shaped blocks
NOTE: Crankshaft deflection can not be correctly

measured between centers of a lathe.
F01D1TA
1. Measuring MAG side deflection in crankcase
Remove crankshaft bearings and check deflection

again on V-shaped blocks as illustrated.
03-06-8
Section 03 ENGINE
Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between
thrust washer and crankshaft counterweight.
1
F01B0HA
1. Distance gauge
2
F01D1WA
1. Measuring big end axial play

2. Feeler gauge
ASSEMBLY
to the following.
2,4,5,14, Bearing and Crankshaft

Apply Loctite 767 anti-seize on part of crankshaft
where bearing fits.
Prior to installation, place bearings into a container
filled with oil, previously heated to 75C (167F).
This will expand bearing and ease installation.
To properly position the outer PTO side bearing
no. 5 on 717 engines or the outer MAG side bearing no. 4 on the 787 engine, a distance gauge
must be temporarily installed against the inner
bearing. Slide the outer bearing until stopped by
the distance gauge, then remove it.
ENGINE
DISTANCE GAUGE
717
P/N 290 876 827
787
P/N 290 876 828
F01D1YA
TYPICAL
1. Distance gauge
2. Outer bearing
15, Distance Ring

When installing the distance ring, make sure to
position it with its chamfer toward the counterweight of the crankshaft.
787 Engine
13, Crankshaft Gear

Position the long flange of the gear toward the
counterweight of the crankshaft. Also, make sure
to align the gear keyway with the Woodruff key
on the crankshaft.
03-06-9
Section 03 ENGINE
F00D0LA
F00D0NA
1. Woodruff key on the crankshaft
1. Seal against the retaining shim
All Engines
6, Drive Pin
Make sure drive pins of bearings are properly installed in crankcase recesses at assembly.
1
2
F00D0MA
1. Keyway
2. Long flange toward the crankshaft counterweight
1, Seal
At seal assembly, apply a light coat of lithium
grease on seal lips.
F00D0OA
1. Drive pin
787 Engine
Position PTO seal no. 1 against the retaining
shim; the gap between the seal and bearing will
ensure proper lubrication of the bearing.
787 Engine
16,18, Counterbalance Shaft and Gear

Press gear no. 18 onto counterbalance shaft taking care to align both marks previously traced.
CAUTION
Counterbalance shaft must be properly assembled, otherwise engine will vibrates and
premature wear will occur.
03-06-10
Section 03 ENGINE
Proceed as follows to check if the gear no. 18 is

properly positioned on the counterbalance shaft:
Temporarily install the counterbalance shaft in
the crankcase.
Rotate the counterbalance shaft to align the
notch of the gear with the crankcase.
12,16, Bearing and Counterbalance

Shaft
Prior to installation, place bearings into a container
filled with oil, previously heated to 75C (167F).
This will expand bearings and ease their installation.
14,16, Crankshaft and Counterbalance

Shaft
1
Install crankshaft first in crankcase.

After crankshaft installation, install counterbalance shaft. Make sure to properly index crankshaft and counterbalance shaft by aligning marks
of gears.
CAUTION
Marks on the crankshaft and counterbalance

shaft must be aligned, otherwise engine will
vibrates and premature wear will occur.
F00D0UA
1. Gear notch aligned with the crankcase
The notch of the couterweight on the opposite

end of the counterbalance shaft must also be
aligned with the cranckcase.
1
F00D0PA
1. Marks must be aligned
Turn by hand the crankshaft and counterbalance

shaft. Make sure they do not interfere with the
crankcase.
F00D0VA
1. Counterweight notch aligned with the crankcase
If notches are not aligned with the crankcase, remove the gear and repeat the procedure until the
notches are properly aligned.
3, Crankcase
Crankcase halves are factory matched and therefore, are not interchangeable or available as single
halves.
Prior to joining crankcase halves, apply a light coat
of Loctite 515 on mating surfaces. Do not apply in
excess as it will spread out inside crankcase.
03-06-11
Section 03 ENGINE
NOTE: On aluminum material it is recommended

to use Loctite Primer N to reduce curing time and
increase gap filling capability. Refer to manufacturers instructions.
CAUTION
Rotary valve shaft must be installed in crankcase before closing halves. Before joining
crankcase halves, make sure that crankshaft
gear is well engaged with rotary valve shaft
gear.
717 Engines
7,8,9, Crankcase Screw

Apply Loctite 515 on screw threads and synthetic
grease below head screws.
Torque crankcase screws to 24 Nm (17 lbfft) as
per following illustrated sequence.
11
5 13
Position crankcase halves together and handtighten screws.
CAUTION
Temporarily install armature plate to align

crankcase halves with each other (except the
787 engine).
12
6 14
10
F01D20A
11, Fitting
8, Crankcase Screw
If inlet and outlet oil fittings of rotary valve shaft

have been removed from crankcase, reinstall
them with their ends pointing toward ignition
housing. Apply Loctite 515 on threads of fittings.
Torque 2 M10 crankcase screws to 40 Nm (30

lbfft).
1
787 Engine
17, Bearing Cover

Install the bearing cover with its hollow side toward the bearing.
F01D20B
1. Torque to 40 Nm (30 lbfft)
10, Stud
At assembly in crankcase, apply Loctite 515 on
stud threads. Torque to 10 Nm (88 lbfin).
787 Engine
7,8, Crankcase Screw

F00D0QA
1. Hollow side facing bearing
03-06-12
Apply Loctite 515 on screw threads and synthetic

grease below head screws.
Torque crankcase screws to 12 Nm (9 lbfft) as
per following sequence. Repeat procedure, retightening all screws to 24 Nm (17 lbfft).
Section 03 ENGINE
11
12
21
17
10
14
13
19
22
15
16
18
20
F01D4KA
F01D81A
As a final step, torque only M10 screws no. 8 of

crankcase to 40 Nm (30 lbfft) as per following
sequence.
11
12
1. Install starter before engine support
787 Engine
When engine assembly is completed, add 30 mL
(1oz) of motor oil SAE 30 to the counterbalance
shaft gear through the crankcase filler plug.
10
F01D81B
Final Assembly
For rotary valve timing and assembly procedures,
refer to ENGINE 03-07.
F00D0RA
1. Add oil here
717 Engines
ONE PIECE ENGINE SUPPORT
If engine support is installed on crankcase before
magneto housing, electric starter must be installed before engine support.
03-06-13
Section 03 ENGINE
Sub-Section 07 (ROTARY VALVE)
ROTARY VALVE
9
5
6
10
14
15
8
11
3
13
1
12
Lithium
grease
1
12
2
20 Nm
(15 lbfft)
787 Engine
717 Engines
2
20 Nm
(15 lbfft)
F01D7SS
PARTS
FLAT RATE
03-07-1
Section 03 ENGINE
GENERAL
1
The following verification procedures such as

clearance of rotary valve cover or rotary valve
shaft gear backlash can be performed without removing engine from watercraft.
However engine must be removed from watercraft to work on rotary valve shaft/components.
Refer to ENGINE 03-03 for engine removal procedure.
Bottom end must be opened to remove rotary
valve shaft. Refer to ENGINE 03-06.
INSPECTION ON WATERCRAFT
Remove carburetor(s). Refer to FUEL SYSTEM
05-04.
NOTE: On the 717D engine (SP model), rotary
valve cover and carburetor are removed as an assembly.
1, Rotary Valve Cover

Unscrew 4 screws no. 2 and withdraw rotary
valve cover and valve no. 13.
Rotary Valve/Cover Clearance

The clearance between the rotary valve and the
cover must be 0.30 0.05 mm (.012 .002 in).
NOTE: If the clearance is below 0.25 mm (.010 in)
this could create an overheating situation and if
the clearance is over 0.35 mm (.014 in) this could
create a hard starting situation.
There is two methods to verify rotary valve
/cover clearance. One with a 45 feeler gauge, the
other one with a solder.
45 FEELER GAUGE METHOD
Remove O-ring from rotary valve cover.
Remove intake manifold from rotary valve cover
(except 787 engine).
Reinstall cover in place WITHOUT its O-ring and
torque screws to 20 Nm (15 lbfft).
Feeler gauge blade from 0.25 mm (.010 in) to 0.35
mm (.014 in) thickness should fit between rotary
valve and cover.
Insert feeler gauge blade through cover inlet ports
to verify clearance. At least verify clearance at two
different places in each port.
03-07-2
F01D53A
1. 45 feeler gauge
If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface
or replace the cover.
SOLDER METHOD
Remove O-ring from rotary valve cover.
Use the following type of solder:
rosin core
diameter: 0.8 mm (.032 in)
electronic application (available at electronic
stores)
Install two solder pieces of 13 mm (1/2 in) long
directly on rotary valve, one above and one below
rotary valve gear. Apply grease to hold solder in
position.
Reinstall cover in place WITHOUT its O-ring and
torque screws to 20 Nm (15 lbfft).
Remove cover then clean and measure compressed
solder thickness, it must be within the specified tolerance 0.30 0.05 mm (.012 .002 in).
Section 03 ENGINE
1
F01D3PA
TYPICAL
1. Solder
If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface
or replace the cover.
MACHINING INFORMATION
The amount of material over tolerance must be
removed from the rotary valve cover seating surface.
Also cut the O-ring groove the same amount to
keep the 1.0 0.03 mm (.039 .001 in) depth between the bottom of the groove and the seating
surface.
Remove burrs on the edges of the seating surface
and O-ring groove.
F01D3OA
SAME AMOUNT REMOVED FROM COVER SEATING SURFACE

AND O-RING GROOVE BASE
1. Cover seating surface
2. O-ring groove depth must be 1.0 0.03 mm (.039 .001 in)
Reverify the clearance.

At assembly the rotary valve timing must remain
as per original setting.
NOTE: If rotary valve crankcase surface is worn,
it is possible to have it reworked at the factory.
Contact your dealer or distributor.
Rotary Valve Shaft Gear Backlash

Remove PTO flywheel guard.
Remove spark plugs, rotary valve cover and valve.
Manually feel backlash at one position, then turn
crankshaft about 1/8 turn and recheck. Continue
this way to complete one revolution.
Backlash must be even at all positions. Otherwise
overhaul engine to find which part is faulty (gear,
rotary valve shaft or crankshaft with excessive deflection).
03-07-3
Section 03 ENGINE
DISASSEMBLY
3, Rotary Valve Shaft
To remove the rotary valve shaft assembly, first
remove snap ring no. 4 from crankcase.
1
F01D61A
1. Hold bolt
F01D22A
1. Removing snap ring
CAUTION
Bottom end must be opened to remove rotary valve shaft.

To remove rotary valve shaft, use the appropriate
puller (P/N 290 876 488).
F01D27A
5,6, Circlip and Spring Seat

If it is necessary to disassemble components of
rotary valve shaft assembly, use seat to compress
spring and remove circlips.
1
F01D23B
Place puller over rotary valve shaft end and screw

on puller bolt into shaft. While retaining bolt with
a wrench, turn puller nut CLOCKWISE until shaft
comes out.
F01D25A
1. Compress seat
2. Remove circlips
03-07-4
Section 03 ENGINE
8, Bearing
To remove bearing use a bearing extractor such as
Snap-on no CJ-950 as illustrated. Slide off distance sleeve, remove snap ring no. 7 and press
shaft out.
Snap-on hammer puller including:

Handle
CJ93-1
Hammer CJ125-6
Claws
CJ93-4
F01J0ZA
Close puller claws so that they can be inserted in

end bearing. Holding claws, turn puller shaft
clockwise so that claws open and become firmly
tight against bearing.
Slide puller sleeve outwards and tap puller end.
Retighten claws as necessary to always maintain
them tight against bearing. Continue this way until bearing completely comes out.
F01D4NA
1. Bearing
2. Bearing extractor Snap-on CJ-950
CAUTION
Ensure that rotary valve shaft is perfectly

perpendicular with press tip.
9, Bearing
CAUTION
Do not remove plug against bearing in upper crankcase half.
F01D28A
1. End bearing
CLEANING
1
F01D4OA
1. Do not remove this plug
Discard all seals and O-rings.

Clean oil passages and make sure they are not
clogged.
Clean rotary valve shaft and inside of distance
sleeve no. 14.
End bearing can be easily removed using the following suggested tool.
03-07-5
Section 03 ENGINE
INSPECTION
Deflection must not exceed 0.08 mm (.003 in).

Replace shaft as necessary.

Inspect rotary valve cover for warpage. Small deformation can be corrected by surfacing with fine
sand paper on a surface plate. Surface part
against oiled sand paper.
8,9 Bearing
ASSEMBLY
to the following.
9, Bearing
Inspect bearings. Check for scoring, pitting, chipping or other evidence of wear. Make sure plastic
cage (on bigger bearing) is not melted. Rotate
them and make sure they turn smoothly.
To install end bearing in crankcase, use the appropriate pusher according to the engine.
10, Gear
Visually check gear wear pattern. It should be
even on tooth length all around. Otherwise it
could indicate a bent shaft, check deflection. Replace gear if damaged.
Check for presence of brass filings in gear housing.
ENGINE
PUSHER
717/717D
P/N 290 876 500
787
P/N 290 876 501
Rotary Valve Shaft Deflection

Deflection is measured with a dial gauge. Install
rotary valve shaft in crankcase half, without its
gear.
NOTE: End bearing must be in crankcase half.
Measure shaft deflection next to gear splines.
A00B2JA
1. Pusher (P/N 290 876 500)
1
F00B07A
1. Pusher (P/N 290 876 501)
Position ball bearing shielded side towards rotary

valve.
1
F01D2CA
1. Rotary valve shaft

2. End bearing in place
03-07-6
Section 03 ENGINE
1
2
1
F01D2DA
1. Shield side (toward gear)

A13C0FB
Push bearing until it stops on its seat.
1. Seal
2. Ball bearing
3. Bearing extractor Snap-on CJ-950
Install shim no. 15, snap ring no. 7 and slide distance sleeve no. 14 on shaft.
2
F01D33A
1. Bearing
2. Pusher
11, Seal
Apply lithium grease on seal lips. Position seal
with shielded portion against shaft splines.
8, Bearing
Install ball bearing as illustrated.
F01D2FA
1.
2.
3.
4.
5.
6.
Seal
Ball bearing
Snap ring
Distance sleeve
Shim 0.5 mm (.020 in)
Rotary valve shaft
3, Rotary Valve Shaft Assembly
CAUTION
Crankcase halves must be separated and

crankshaft must not be present to install rotary valve shaft assembly in crankcase.
03-07-7
Section 03 ENGINE
717 Engines
To install rotary valve shaft in crankcase, use a
pusher (P/N 290 876 605).
Push shaft until it stops on bearing seat.
A00C0YA
1. Pusher
Push shaft until its stops on bearing seat.

F01D8OA
All Engines
4, Snap Ring
Position snap ring so that its sharp edge faces outwards.
13, Rotary Valve

The rotary valve controls the opening and closing
of the inlet ports. Therefore its efficiency will depend on the precision of its installation.
IDENTIFICATION OF THE ROTARY VALVE
F01D34A
1. Rotary valve shaft

2. Push shaft until it stops
787 Engine
To install rotary valve shaft in crankcase, use a
pusher (P/N 290 876 609) and handle (P/N 290
877 650).
2
1
F01B2FA
1. Pusher
2. Handle
03-07-8
Engine
Rotary Valve
P/N
Valve
Duration
717D
290 924 504
132
717/787
290 924 502
159
There is no identification code on the valves. To

find out the duration, place an angle finder on the
valve and measure the valve cut-out angle or use
the following template.
Section 03 ENGINE
TEMPLATE
159
(cut-out angle)
290 924 502

actual size
132
(cut-out angle)
290 924 504

actual size
F01D8SS
03-07-9
Section 03 ENGINE
ROTARY VALVE TIMING
CAUTION
Never use the ridge molded in crankcase as

a timing mark.
The following tools are required to measure rotary
valve opening and closing angles in relation with
MAG side piston.
32
40
350 360 10
20
340
10 360 350 3
20
40
30
30
33
40
32
0
30
70
15
22
0
80 190 2
170 1
00
21
160
0
200 190 180 17
22
0
210
16
0
0
15
0
280
290
80
30
270
110 100 90
130
40
23
F01D2IA
13
14
24
250
120
250
120
90 100 11
0
280 270 26
0
80
290
24
70
300
260
60
295 000 007
31
60
50
50
31
33
1. Bring piston to TDC
For opening mark, first align 360 line of degree wheel with BOTTOM of MAG side inlet
port. Then, find 147 line on degree wheel and
mark crankcase at this point.
295 000 143
F00B0DA
Rotary valve must be set so that timing occurs as

follows:
2
147
TIMING
ENGINE
OPENING
BTDC
CLOSING
ATDC
717D
130 5
55 5
717
147 5
65.5 5
787
146.5 5
64 5
For the following instructions, lets use these

specifications as example:
OPENING: 147 BTDC
CLOSING: 65 ATDC
Proceed as follows:
Turning crankshaft, bring MAG side piston to
Top Dead Center using a TDC gauge.
03-07-10
1
F01D3DC
OPENING MARK
Step 1 : Bottom of MAG inlet port.
Align 360 line of degree wheel
Step 2 : Find 147 on degree wheel and mark here
NOTE: Do not rotate the crankshaft.

For closing mark, first align 360 line of degree
wheel with TOP of MAG side inlet port. Then,
find 65 line on degree wheel and mark crankcase at this point.
Section 03 ENGINE
65
F01D3EB
CLOSING MARK
Step 1 : Top of MAG inlet port.
Align 360 line of degree wheel
Step 2 : Find 65 on degree wheel and mark here
Remove degree wheel.

Position rotary valve on shaft splines to have
edges as close as possible to these marks with
the MAG piston at TDC.
NOTE: Rotary valve is asymmetrical. Therefore,
try flipping it over then reinstall on splines to obtain best installation position.
Apply BOMBARDIER-ROTAX injection oil on rotary valve before reassembling rotary valve cover.
Remove TDC gauge.

Install O-ring no. 12 and cover then torque
screws no. 2 to 20 Nm (15 lbfft) in a criss-cross
sequence.
NOTE: For the 717D engine (SP model), install
engine in watercraft first; then, install rotary valve
cover, intake manifold and carburetor as an assembly.
03-07-11
Sub-Section 08
Section 03 ENGINE
(EXHAUST SYSTEM)
EXHAUST SYSTEM
SP, GS, GSI, GTS and GTI Models
11
25 Nm
8 (18 lbfft)
Loctite
242
SP
model
25 Nm
7 (18 lbfft)
Loctite 242
9
19
18
19
18
20
17
17
19
19
Loctite 242
Loctite
242
6
25 Nm
(18 lbfft)
15
6 25 Nm
(18 lbfft)
Synthetic
grease
10 Nm
22 (88 lbfin)
21
24
14
24 Nm
(17 lbfft)
3
27 Nm
(20 lbfft)
Sealant
732
1
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
13
F00D05S
PARTS
FLAT RATE
03-08-1
Section 03 ENGINE
Sub-Section 08 (EXHAUST SYSTEM)
HX Model
10 Nm
(88 lbfin)
4
25 Nm 8
(18 lbfft)
10
Loctite 242
9
7 25 Nm (18 lbfft)
Loctite 242
9
16
Sealant
736
18 19
19
20
17
12
15
Loctite
242
24 Nm
(17 lbfft) 14
25 Nm
(18 lbfft)
4 Nm 1
(35 lbfin)
4 Nm
(35 lbfin)
Synthetic
grease
Loctite
592
25
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
13
F05D08S
03-08-2
PARTS
FLAT RATE
Sub-Section 08
Section 03 ENGINE
(EXHAUST SYSTEM)
SPX, XP, GSX and GTX Models

25 Nm
(18 lbfft)
23
Loctite
242
12
19
19
17
19
19
15
24
16
Loctite
515
40 Nm
(30 lbfft) 14
40 Nm
(30 lbfft) 14
Synthetic
grease
25 Nm (18 lbfft)
6
Loctite
242
Loctite
648
4
Sealant
736
24
10
20
9
2
4 Nm
(35 lbfin)
10 Nm
(88 lbfin)
Loctite 242
9
7
Loctite 40 Nm
242 (30 lbfft)
40 Nm
8 (30 lbfft)
SPX
GSX
GTX
4 Nm
(35 lbfin)
27 Nm
(20 lbfft)
4 Nm
(35 lbfin)
Sealant
732
7 Nm
(62 lbfin)
F00D06S
PARTS
Sealant
732
XP
FLAT RATE
03-08-3
Section 03 ENGINE
TUNED PIPE REMOVAL

SP, GS and GSI Models
Remove seat.
Remove air vent tube support from body opening.
GTS and GTI Models
Remove seat.
Remove seat support (GTI model).
Disconnect water inlet hose and water injection
hose.
Disconnect tuned pipe bleed hose.
1
F01D8NA
TYPICAL
1. Bleed hose removed
2. Injection hose removed
3. Inlet hose removed
Cut tie rap retaining together engine and tuned

pipe bleed hoses (if applicable).
Loosen exhaust hose collar no. 1 at tuned pipe
outlet.
Disconnect strap no. 2 retaining muffler no. 13.
Remove exhaust hose no. 3 from tuned pipe by
pulling muffler.
Remove clamp no. 22 from tuned pipe (except SP
model).
Remove tuned pipe cone no. 5 (except SP model).
Remove tuned pipe retaining screw(s) no. 6 from
exhaust manifold side.
Remove screws no. 7, nut no. 8 and flat washers
no. 9 from tuned pipe flange.
03-08-4
NOTE: Slightly lift tuned pipe to release nut as

necessary. Take care not drop nut and flat washer.
Withdraw tuned pipe head no. 11 in a forward and
rotating movement.
HX and XP Models Only

NOTE: It is possible to remove the tuned pipe
head and cone at the same time. If such is the
case, disconnect only the water outlet hose at cylinder head and do not remove the clamp retaining
tuned pipe head to tuned pipe cone.
Disconnect water inlet hose at tuned pipe head
no. 10.
Disconnect water injection hose at tuned pipe
cone no. 12.
Disconnect bleed hose on top of tuned pipe head
no. 10.
Remove clamp no. 4 retaining tuned pipe head
no. 10 to tuned pipe cone no. 12 (if desired).
Remove screws no. 7, nut no. 8 and flat washers
no. 9 from tuned pipe head flange.
Remove tuned pipe head no. 10.
cone outlet.
Remove two screws no. 6 retaining tuned pipe
cone from exhaust manifold.
SPX and GSX Models
Remove seat.
Remove air vent tube support from body opening.
SPX Model Only
Remove electrical box from watercraft. Refer to
ENGINE REMOVAL AND INSTALLATION 03-02.
Sub-Section 08
Section 03 ENGINE
(EXHAUST SYSTEM)

Disconnect water supply hose and water injection
hose at tuned pipe head.
F01D76A
1. Screw
F01D3YA
1. Water supply hose

2. Water injection hose
Remove tuned pipe head no. 10.

Remove both screws no. 6 retaining tuned pipe
cone to engine.

cone outlet.
Remove clamp no. 4 securing tuned pipe cone to
tuned pipe head.
Remove screws no. 7 and nut no. 8 with flat
washers no. 9 at tuned pipe head flange.
F01D7KA
F01D7IA
Remove retaining screw no. 23 of tuned pipe

head.
F01D7LA
03-08-5
Section 03 ENGINE
SPX Model Only

Move tuned pipe cone no. 12 in front of bilge between body and fuel tank.
Disconnect upper exhaust hose no. 25 in front of

muffler.
Disconnect both water injection hoses and both
water drain hoses from muffler.
Disconnect retaining strap no. 2 of muffler.
F01D7JA
Open storage cover and remove basket. Then,

pull out tuned pipe cone no. 12 through storage
compartment opening.
1. Strap
XP, GSX and GTX Models

Remove tuned pipe cone no. 12 from engine
compartment.
Pull muffler no. 13 out of bilge.

NOTE: Lower exhaust hose of muffler may be
disconnected or left with muffler.
EXHAUST MANIFOLD REMOVAL
TUNED PIPE REPAIR

Remove air intake silencer and carburetors. Refer
to FUEL SYSTEM 05-03 for proper procedure.
This procedure is given to repair tuned pipe cracks

using T.I.G. welding process.
All Models
Remove eight screws no. 14 and lock washers
no. 24 then withdraw exhaust manifold.
Sand the cracked area to obtain bare metal.

Perform a 1.50 mm (1/16 in) depth chamfer
over crack.
Use pure argon gas with 5.55 mm (3/32 in)
tungsten electrode (puretung green, zirtung
brown) and AC current.
Use a 5.55 mm (3/32 in) aluminum welding rod
(no. 4043), to fill crack.
Sand welding slightly to remove material surplus.
MUFFLER REMOVAL
All Models Except the HX and XP
Disconnect hoses from muffler.
Disconnect hoses of the water flow regulator
valve (787 engines).
Disconnect retaining strap no. 2 of muffler.
Pull muffler no. 13 out of bilge.
HX Model Only
cone outlet (only if tuned pipe cone is not removed).
Remove rear access cover from body.
03-08-6
F05D07A
Procedure
Test
Use compressed air at 124 kPa (18 PSI) to pressurize tuned pipe.
Sub-Section 08
NOTE: Prior to verify leaks, plug all holes and

pressurize tuned pipe while immerging it in water.
Section 03 ENGINE
(EXHAUST SYSTEM)
CAUTION
Always ensure water passages are not

blocked partially or completely while welding tuned pipe.
INSTALLATION
Installation is essentially the reverse of removal
procedures. However, pay particular attention to
the following.
15, Exhaust Manifold

Make sure gasket(s) no. 17 are properly positioned prior to finalizing manifold installation.
717 Engines
Apply synthetic grease on threads of screws
no. 14.
Install and torque screws no. 14 to 24 Nm (17
lbfft) as per following illustrated sequence.
F01D82B
1. Screw with Loctite 515

2. Screw with synthetic grease
Torque exhaust manifold screws to 24 Nm (17

lbfft) as per following illustrated sequence. Repeat the procedure, retightening screws to 40
Nm (30 lbfft).
4
7
7
6
5
8
F01D82A
10,11,12, Tuned Pipe

F01D59A
787 Engine
Apply Loctite 515 on two screws no. 14. On the
other screws no. 14, apply synthetic grease on
threads. Install screws. Refer to the following illustration for proper position of screws to the exhaust manifold.
HX, GSX and GTX Models

Make sure to install the sealing ring no. 16 on
tuned pipe cone if it was removed.
03-08-7
Section 03 ENGINE
F01D69A
2 3
TYPICAL
1. Sealing ring
F01D0IA
Apply a thin layer of heat resistant sealant (P/N

413 709 200) all around sealing ring.
All Models
Ensure rubber bushings no. 19 and sleeve no. 18
are not damaged and are properly installed into
tune pipe support(s).
CAUTION
Damage to bushings and/or sleeve will

eventually cause stress to tune pipe and
may cause cracking.
Make sure that gasket no. 20 is properly located
on exhaust manifold prior to finalizing pipe installation.
1 3
TYPICAL
Step 1 : Torque screw(s) of tuned pipe cone to 12 Nm (9 lbfft)
Step 2 : Torque nut and screws of tuned pipe flange in a criss-cross
sequence to 12 Nm (9 lbfft)
Step 3 : Repeat the torquing sequence by retightening all fasteners
to 25 Nm (18 lbfft)
Step 4 : Torque clamp to 10 Nm (88 lbfin) (if applicable)
787 Engines
Torque nut no. 8 and screws no. 7 of tuned pipe
head flange to 40 Nm (30 lbfft).
GS, GSI, GTS and GTI Models
Install tuned pipe cone no. 5 with collar no. 21
and clamp no. 22.
Position clamp no. 22 as illustrated. Do not tighten clamp yet.
4,6,7,8,23, Clamp, Screw and Nut

Apply Loctite 242 (blue) on nut no. 8 and screws
no. 6 and no. 7. Hand-tighten nut no. 8 and
screws no. 6 and no. 7 and assure that tuned
pipe bushing(s) no. 19 rests against manifold.
Refer to the following illustration for the torquing
sequence.
F01D41A
1. Clamp
2. Exhaust collar
With hose removed, align cone outlet with muffler inlet.

03-08-8
Sub-Section 08
Section 03 ENGINE
(EXHAUST SYSTEM)
NOTE: Due to exhaust cone angle, it may have to

be rotated to obtain alignment.
Push cone no. 5 until it touches tuned pipe, then
tighten exhaust clamp no. 22 and torque to 10
Nm (88 lbfin).
CAUTION
There must be no gap between tuned pipe

cone and tuned pipe head.
NOTE: Exhaust clamp nuts should be tightened
alternately to assure no leakage and to obtain
specified torque.
03-08-9
Section 04 COOLING SYSTEM

TABLE OF CONTENTS
COMPONENTS ......................................................................................................................
GENERAL ...........................................................................................................................
04-02-1
04-02-6
CIRCUIT..................................................................................................................................
GENERAL ...........................................................................................................................
717 ENGINE COOLING SYSTEM......................................................................................
787 ENGINE COOLING SYSTEM......................................................................................
04-03-1
04-03-1
04-03-4
04-03-5
04-01-1

Sub-Section 02 (COMPONENTS)
COMPONENTS
SP and GTS Models
Loctite
592
1.2 Nm
(11 lbfin)
Loctite
592
SP
model only
Loctite
592
1.2 Nm
(11 lbfin)
2
Loctite
592
1.2 Nm
(11 lbfin)
1
1.2 Nm
(11 lbfin)
2.5 Nm
(22 lbfin)
Loctite
592
F01E1PS
PARTS
FLAT RATE
04-02-1

SPX Model
Loctite 592
Loctite 592
Loctite
592
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
3
1
1
2 Nm
(18 lbfin)
1.2 Nm
(11 lbfin)
1
Loctite
592
Loctite
592
1.2 Nm
(11 lbfin)
6
9
0.11 Nm
(1 lbfin)
10
8 0.6 Nm
(5 lbfin)
5 Nm
7 (44 lbfin)
Loctite
592
F01E1QS
04-02-2
PARTS
FLAT RATE
4
Loctite
592
2.5 Nm
(22 lbfin)
Loctite
592

GS, GSI and GTI Models

Loctite
592
1.2 Nm
(11 lbfin)
1
Loctite
592
1 1.2 Nm
(11 lbfin)
Loctite
592
1.2 Nm
(11 lbfin)
Loctite
592
1.2 Nm
(11 lbfin)
Loctite
592
F00E02S
PARTS
FLAT RATE
04-02-3

XP, GSX and GTX Models

Loctite
592
Loctite 592
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
Loctite
592
1.2 Nm
(11 lbfin)
1
Loctite
592
Loctite
592
1.2 Nm
(11 lbfin)
6
9
0.11 Nm
(1 lbfin)
10
0.6 Nm
8 (5 lbfin)
5 Nm
7 (44 lbfin)
Loctite 592
F06E02S
04-02-4
PARTS
FLAT RATE
Loctite
592
0.11 Nm
(1 lbfin)
Loctite
592

HX Model
Loctite
592
Loctite 592
1.2 Nm
(11 lbfin)
Loctite 592
1
1.2 Nm
(11 lbfin)
Loctite
592
1.2 Nm
(11 lbfin)
Body
1
1.2 Nm
(11 lbfin)
Loctite
592
Engine
water outlet
1
Engine water outlet
F05E04S
PARTS
FLAT RATE
04-02-5

GENERAL
3, Elbow Fitting
CAUTION
All hoses and fittings of the cooling system

have calibrated inside diameters to assure
proper cooling of the engine. Always replace using appropriate Bombardier part
number.
A Serial Cooling System is utilized on 717 and 787
engines, which offers an efficient cooling of the
combustion chamber to prevent the possibilities
of detonation.
1, Clamp
To cut or secure non-reusable Oetiker clamps of
cooling system hoses, use pliers (P/N 295 000
070).
Water injection used on exhaust system cools the

exhaust gases to obtain maximum performance
from the tuned pipe. The elbow fitting has a calibrated inside diameter to optimize water flow in
tuned pipe.
The water injection also helps in reducing noise
level and cools components of the exhaust system.
CAUTION
The elbow fittings are calibrated and can not

be interchanged with one of a different size
as severe engine damage could result.
The elbow fitting can be identified by using the
number stamped onto the fitting or by measuring
its inside diameter. Refer to the following illustration and chart.
1
22
1
2
3
F01E0YA
2
F01B2KA
1. Cutting clamp
2. Securing clamp
2, Fitting Spigot
The fitting spigot is used on some models to flush
cooling system. Refer to MAINTENANCE 02-02.
04-02-6
TYPICAL
1. Outlet diameter = 4.6 mm (.181 in)
2. Stamped number
3. Inlet diameter = 5.5 mm (.219 in)
Stamped
Number
on Fitting
Fitting
P/N
Inlet
Diameter
Outlet
Diameter
22
293 700 022
5.5 mm
(.219 in)
4.6 mm
(.181 in)
24
293 700 024
5.5 mm
(.219 in)
3.5 mm
(.139 in)
48
293 710 048
4.0 mm
(.157 in)
3.5 mm
(.139 in)

4, Water Flow Regulator Valve

A water flow regulator valve has been developed
for the 787 engine so that it can produce the maximum horsepower output and yet maintain the
necessary diameter of the injection fitting at the
tuned pipe head for unobstructed water flow.
The water flow regulator valve is mounted directly
onto the muffler.
Adjustment
The water flow regulator valve has been calibrated at the factory and should not be modified.
NOTE: Water flow regulator valves ordered from
the parts channel are also calibrated.
If the maximum engine speed can not be attained
or if the engine has poor performance, the water
flow regulator valve should be considered in the
troubleshooting of the problem.
Mark the location of the red plastic adjustment
screw with paint dots for reference purposes.
Fully tighten screw (clockwise) in valve cap.
1
F01E1FA
1. Water supply hose of regulator valve

2. Regulated water to injection fitting at tuned pipe head
3. Water injected into the muffler
NOTE: The water injected into the muffler is not

regulated by the valve. A calibrated water injection fitting of 3.0 mm (.118 in) inside diameter limits water flow into the muffler.
The water flow regulator valve has a calibrated
spring and a tapered needle which regulate the
injected water in the tuned pipe.
CAUTION
Do not change the calibration of the spring,

otherwise serious engine damage can occur.
At low speed, water pressure in the supply hose
of the regulator valve is not sufficient to overcome
the spring of the regulator valve; more water is
being delivered to the injection fitting at the tuned
pipe.
At higher speed, water pressure increases in the
supply hose of the regulator valve and gradually
overcomes the return spring of the regulator
valve. Less water is being delivered to the injection fitting at the tuned pipe.
F01E1FC
1. Turn this screw

2. Valve cap
Turn the screw 3 turns counterclockwise (loosen).

The adjustment is now complete.
NOTE: The water flow regulator valve should deliver 0.4 gallon per minute at maximum engine
speed.
Disassembly
5,6, Spring and Cover

Remove the cover of the valve by releasing the
spring.
WARNING
Firmly hold cover to valve base. The spring

inside the valve is applying a pressure
against the cover.
04-02-7

1
1
F01E1RA
1. Spring
2. Cover
F01E1TA
1. Tapered needle
Remove the tapered needle from valve housing.
7, Fitting
1
Remove fitting from valve housing.

1
F01E20A
1. Remove tapered needle

F01E1SA
1. Fitting
8, Tapered Needle
Unscrew the tapered needle.
NOTE: Hold the valve to prevent it from turning.
04-02-8

9,10, Valve and Bellows

Pull the valve slightly. Using pliers, release the
clamp which retains the bellows.
Remove valve and bellows.
F01E21A
Loosen clamp to separate valve from bellows.
F01E24A
1. Clamp
Inspection
Inspect parts for damage. Verify especially bellows for cracks.
Assembly
Assembly is essentially the reverse of disassembly procedures.
04-02-9

Sub-Section 03 (CIRCUIT)
CIRCUIT
GENERAL
The cooling system is equipped with either a fitting spigot or a hose adapter depending upon the
model for flushing purposes.
For flushing operation, a coupler hose is available
(unnecessary for models with the hose adapter)
to connect to the fitting spigot. A garden hose is
used to flush the whole system by backwash. For
flushing procedure, refer to MAINTENANCE 0103.
For winterization of cooling system, refer to
MAINTENANCE 01-05.
CAUTION
Failure to do this may result in damage to

the engine. If you must tow a stranded watercraft in water and do not have a hose
pincher be sure to stay well below the maximum towing speed of 24 km/h (15 MPH).
Snugly install the hose pincher on the water supply hose as shown in the following illustrations.
Towing the Watercraft in Water

Special precautions should be taken when towing
a Sea-Doo watercraft in water.
Maximum recommended towing speed is 24
km/h (15 MPH).
When towing your watercraft, pinch the water
supply hose from the impeller housing to the engine with the Hose Pincher (large) P/N 529 030
400.
F01E1WA
1. Hose pincher
SPX, GSX and GTX Models
F01B23A
This will prevent the cooling system from filling

which may lead to water being injected into and
filling the exhaust system. Without the engine
running there isnt any exhaust pressure to carry
the water out the exhaust outlet.
F01E1XA
1. Hose pincher
04-03-1

XP and HX Models
Water is pre-heated by the exhaust system before

entering the cylinder cooling jackets.
Water enters cylinder cooling jacket through passages located below exhaust ports from tuned
pipe.
F01E1YA
1. Hose pincher
CAUTION
When finished towing the watercraft, the

hose pincher must be removed before operating it.
Cooling System Arrangement

The water supply is taken from a pressurized area
in the jet pump between the impeller and venturi.
Water enters the cylinder head assembly, cooling
the combustion chamber to prevent detonations.
Then, water exits cylinder head toward tuned
pipe.
2
F01D7HB
1. Water passages
No water enters crankcase.

When engine is running, water must flow from
bleed outlet indicating that water circulates.
CAUTION
When investigating for no water flow in the

cooling system, check all elbows and
straight fittings as well as all hoses for blockage.
When servicing the hull, always rotate watercraft
counterclockwise (seen from the rear). Rotating
watercraft clockwise could allow residual water in
tuned pipe to enter the engine and cause damage.
Max. 90
F01E1LA
1. Cylinder head cover

2. Fresh water from jet pump
3. Water exiting head assembly to tuned pipe, exhaust manifold and
cylinders
4. Water from cylinder water jackets exiting engine
The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation.
04-03-2
F01L45C

For a minimum back pressure in the exhaust, engine water outlet hose is not connected to the exhaust. It has its own outlet at the rear of the hull.
F01E1MA
787 ENGINE
1. Drain hose
F01E1GA
For a complete view of cooling system arrangement, refer to the next pages for each engine
model.
TYPICAL
1. Engine water outlet hose
Draining of the cooling system is accomplished by

a drain hose located at the lowest point of the circuit.
CAUTION
Never modify cooling system arrangement, otherwise serious engine damage could occur.
TECHNICAL DATA
TYPE:
TLCS (Total Loss Cooling System).
COOLANT FLOW:
Pressure build-up at impeller housing
(no water pump).
TEMPERATURE CONTROL:
Calibrated outlet fittings (no thermostat).
F01E0FB
717 ENGINES
1. Drain hose
SYSTEM BLEEDING:
Self-bleed type (hose at uppermost point of circuit).
SYSTEM DRAINING:
Self-drain type (hose at lowest point of circuit).
SYSTEM FLUSHING:
Fitting spigot or hose adapter.
MONITORING BEEPER:
SP, SPX and GTS models: turns on at 95-103C
(203-217C).
GS, GSI, GSX, GTI, GTX, HX and XP models: turns on
at 86-94C (187-201C).
04-03-3
04-03-4
F01E0JS
Tuned pipe bleed

hose injects water
into muffler to cool
exhaust components
Lowest point of circuit

allows draining whenever
engine is stopped
Water
injected
directly
into exhaust
gas for noise
reduction and
performance
improvement
Water flows
through tuned
pipe and
manifold
water jackets
Uppermost point
of circuit
(tuned pipe)
allows bleeding
717 ENGINE COOLING SYSTEM
Pressure zone
Engine water
outlet hose
Calibrated
Temperature
cylinder head.
sensor activates Serial cooling
monitoring beeper
allows the
when temperature cylinder head
exceeds 96-99C
to run cooler
(205-210F)
Calibrated outlet fittings

limit water flow
Cooling System
Indicator (CSI):
small stream of
water flows out of
bleed outlet located
near stern eyelet
Engine water
inlet hose



Water regulated
by the water flow
regulator valve
and injected
directly into
exhaust gas for
noise reduction
and performance
improvement
Calibrated
cylinder
head limits
water flow
Temperature
sensor activates
monitoring
beeper when
temperature
exceeds 96-99C
(205-210F)
Uppermost point of
circuit (tuned pipe)
allows bleeding
Cooling System
Indicator (CSI): small
stream of water
flows out of bleed
outlet located near
stern eyelet
Engine water
outlet hose
Calibrated
outlet fittings
limit water
flow
Water flows
through
tuned pipe
and manifold
water jackets
Pressure
zone
Water flow
regulator valve
Lowest point of
circuit allows
draining whenever
engine is stopped
Engine
water
inlet
hose
Water inlet
hose of
valve
Water directly
injected into muffler
to cool exhaust
components
F01E1US
04-03-5

TABLE OF CONTENTS
FUEL CIRCUIT........................................................................................................................ 05-02-1
GENERAL ........................................................................................................................... 05-02-6
REMOVAL........................................................................................................................... 05-02-7
INSPECTION ...................................................................................................................... 05-02-9
ASSEMBLY......................................................................................................................... 05-02-10
FUEL SYSTEM PRESSURIZATION ................................................................................... 05-02-10
AIR INTAKE ............................................................................................................................
REMOVAL...........................................................................................................................
ASSEMBLY.........................................................................................................................
05-03-1
05-03-2
05-03-2
CARBURETORS .....................................................................................................................
GENERAL ...........................................................................................................................
REMOVAL...........................................................................................................................
CLEANING .........................................................................................................................
DISASSEMBLY AND INSPECTION...................................................................................
ASSEMBLY.........................................................................................................................
INSTALLATION ..................................................................................................................
ADJUSTMENTS ................................................................................................................
05-04-1
05-04-3
05-04-3
05-04-4
05-04-4
05-04-5
05-04-8
05-04-9
05-01-1

Sub-Section 02 (FUEL CIRCUIT)
FUEL CIRCUIT
SP and GTS Models

2 Nm
(18 lbfin)
6 Nm
(53 lbfin)
6
7
22 Nm
(16 lbfft)
4 Nm 4
(35 lbfin)
1 Nm
(9 lbfin)
12
11
10
3 Nm
(27 lbfin)
4
4 Nm
(35 lbfin)
Loctite 242
3 Nm
(27 lbfin)
SP
model
9
1
3
13
F01F19S
PARTS
FLAT RATE
05-02-1

SPX Model
3 Nm
(27 lbfin)
Body
2 Nm
(18 lbfin)
6 Nm
(53 lbfin)
3
1
2
1 Nm
(9 lbfin)
22 Nm
(16 lbfft)
4 Nm
(35 lbfin) 4
12
3 Nm
(27 lbfin)
11
10
4 Nm
(35 lbfin) 4
13
Engine
F01F2ZS
05-02-2
PARTS
FLAT RATE


3 Nm
(27 lbfin)
2 Nm
(18 lbfin)
Body
6 Nm
(53 lbfin)
3
1
1 Nm
(9 lbfin)
22 Nm
(16 lbfft)
4 Nm
(35 lbfin) 4
12
3 Nm
(27 lbfin)
11
10
4 Nm
(35 lbfin) 4
8
9
Engine
F00F09S
PARTS
FLAT RATE
05-02-3

GSX and GTX Models

3 Nm
(27 lbfin)
2 Nm
(18 lbfin)
Body
6 Nm
(53 lbfin)
3
1
1 Nm
(9 lbfin)
22 Nm
(16 lbfin)
4 Nm
(35 lbfin) 4
12
3 Nm
(27 lbfin)
11
10
8
9
Engine
F06F03S
05-02-4
PARTS
FLAT RATE

HX and XP Models
7
Body
3 Nm
(27 lbfin)
6
2 Nm
(18 lbfin)
6 Nm
(53 lbfin)
1
3
Body
1 Nm
(9 lbfin)
22 Nm
(16 lbfin)
12
4 Nm
(35 lbfin) 4
3 Nm
(26 lbfin)
11
10
4
4 Nm
(35 lbfin)
Engine
8
9
F05F09S
PARTS
FLAT RATE
05-02-5

GENERAL
WARNING
Whenever repairing the fuel system, always

verify for water infiltration in reservoir.
To open or secure reusable clamps on fuel lines,
use pliers (P/N 295 000 054).
To open clamp, place flat side of plier on clamp
embossment, squeeze and twist plier.
1
F01B03A
1. Cutting clamp
F01B1VA
To secure clamp, place notch side of plier on

clamp embossment and squeeze plier.
F01B04A
1. Securing clamp
F01B05A
1. Securing clamp in limited access

F01B1UA
WARNING
Replace any damaged, leaking or deteriorated fuel lines.

To secure or cut Oetiker clamps on fuel lines, use
pliers (P/N 295 000 070).
05-02-6
When replacing fuel lines on SEA-DOO watercraft, be sure to use B1 hoses as available from
Bombardier parts department. This will ensure
continued proper and safe operation.
WARNING
Use of improper fuel lines could compromise fuel

system integrity.

REMOVAL
1, Fuel Filter
All Models Except HX and XP
Open storage compartment cover.
Remove basket.
HX and XP Models
Open engine cover.
GTS Model
Press on vent tube upper part to enable to withdraw tube from body.
F01F01A
TYPICAL
Step 1 : Loosen counterclockwise
Step 2 : Pull
Pull fuel filter no. 1 toward the bottom.

1
F02L1MA
TYPICAL
1. Press on vent tube
All Models
Turn the fuel valve to OFF position.
WARNING
The engine must not be running and fuel

valve must be set to OFF position. Gasoline
is flammable and explosive under certain
conditions. Always work in a well ventilated
area.
F01F04A
TYPICAL
8, Fuel Baffle Pick Up

NOTE: The baffle pick up has an integrated fuel
sensor on models which have a fuel gauge.
Unscrew fuel filler cap to remove any fuel pressure in system.

Unscrew the fuel filter bowl no. 2 counterclockwise then pull toward the bottom.
05-02-7

GTI and GTX Models

Remove glove box.
HX Model
Pull down left vent tube.
3
F01F20A
1. Pick up tube
2. Fuel sensor
3. Baffle pick up
Disconnect BLACK negative cable, then RED positive cable of battery.
WARNING
Always disconnect battery cables exactly in

the specified order, BLACK negative cable
first.
F05L14A
1. Vent tube
Cut tie rap retaining fuel hoses to tie-mount.

1
Empty fuel tank.
WARNING
Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. Always wipe off any fuel spillage
from the watercraft.

Remove storage basket from watercraft.
On GTS model, remove vent tube. Refer to fuel
filter removal procedure in this sub-section.
Disconnect filler neck hose no. 5 from fuel tank.
Remove retaining straps no. 13 from fuel tank
and move tank forward.
GS, GSI and GSX Models
Remove storage basket from watercraft.
Remove steering assembly. Refer to STEERING
SYSTEM 09-04.
05-02-8
F05F02A
1. Cut tie rap
XP Model
Tilt seat. Refer to HULL/BODY 11-02.
Remove access plug on body.
All Models
Remove hoses from baffle pick up and disconnect
wiring harness of fuel sensor (if applicable).

1
3
F01F21A
TYPICAL
1. Wiring harness
2. Baffle pick up adapter
3. Fuel hoses
F01F02A
1. Gasket in bowl
WARNING
Loosen lower clamp no. 10 of baffle pick up

adapter and pull out baffle no. 8 from fuel tank.
Remove upper clamp no. 12 from adapter no. 11
and slide adapter from baffle.
Push inward on the 3 clips at the base of the baffle in order to remove the filter. Pry base off using
a small slotted screwdriver (if necessary).
5, Filler Neck Hose
INSPECTION
6, Pressure Relief Valve
1, Fuel Filter
This valve will eliminate fuel spillage when the

watercraft is upside down. If pressure is built up
in fuel system the valve should open at 10 kPa
(1.5 PSI) to release the pressure.
Inspect fuel filter condition. Carefully use low

pressure compressed air to clean fuel filter. Replace filter if permanently clogged or damaged.
2, Fuel Filter Bowl

Check filter bowl for water contamination.
3, Gasket
Inspect gasket condition. Make sure gasket is
well positioned into the filter bowl no. 2.
Ensure that there is no leakage from the fuel

filter.
Verify fuel filler neck hose for damage. Always ensure that clamps no. 4 are well positioned and
tightened. Torque clamps to 4 Nm (35 lbfin).
WARNING
If pressure relief valve is stuck, the pressure

in fuel system will build up and it may cause
fuel leakage in engine compartment.
NOTE: It is a one-way valve with an arrow to indicate the air flow.
7, Check Valve
Black side of the one-way check valve is the valve
outlet. It allows air to get in reservoir.
9, Baffle Pick Up Filter

Inspect filter no. 9 of baffle pick up. Clean or replace as necessary.
05-02-9

ASSEMBLY
to the following.
8, Baffle Pick Up
Slide adapter no. 11 onto baffle pick up no. 8 until

it stops on rib. Install clamp no. 12.
Install baffle pick up no. 8 into fuel tank and
push it until it sits on fuel tank neck. Install
clamp no. 10 and torque both clamps to 3 Nm
(27 lbfin).
HX Model Only
Make sure to align notch of baffle pick up no. 8
with the mark on the fuel tank.
F02L14A
1. Install vent tube
FUEL SYSTEM PRESSURIZATION
WARNING
Whenever doing any type of repair on watercraft or if any components of the fuel system
are disconnected, a pressure test must be
done before starting engine. Ensure to verify
fuel line ends for damage. Always cut damaged end before reinstallation.
Pressure Test
F05F04A
1. Baffle pick up notch

2. Fuel tank mark
GTS Model Only

Insert vent tube in body and clip it in place.
WARNING
Vent tube must be in place to provide proper

bilge ventilation.
05-02-10
Proceed as follows:
Fill up fuel tank.
Disconnect air inlet hose of fuel tank from body.
Install a hose pincher (P/N 295 000 076) on fuel
tank vent hose.

RE
T
OU
F01F0KA
TYPICAL
1. Disconnect air inlet hose
2. Install a hose pincher to vent hose
Connect pump gauge tester (P/N 295 021 800)

to air inlet hose.
NOTE: This pump is included in the ENGINE
LEAK TESTER KIT (P/N 295 500 352).
Turn fuel valve to OFF position and pressurize
fuel system to 34 kPa (5 PSI). If no leaks are
found, turn fuel valve to ON position and pressurize once more.
If pressure is not maintained locate leak and repair/replace component leaking. To ease leak
search spray a solution of soapy water on components, bubbles will indicate leak location.
NOTE: The system must maintain a pressure of
34 kPa (5 PSI) during 10 minutes. Never pressurize over 34 kPa (5 PSI).
Reconnect air inlet hose of fuel tank to body.
WARNING
If any leak is found, do not start the engine

and wipe off any fuel leakage. Do not use
electric powered tools on watercraft unless
system has passed pressure test.
NOTE: Before removing the hose pincher, block
with your finger the outlet fitting to feel if air is
coming out when removing hose pincher. This will
indicate that pressure relief valve and the outlet
fitting are not blocked.
Remove hose pincher from fuel tank vent hose.
05-02-11

Sub-Section 03 (AIR INTAKE)
AIR INTAKE
9
10 Nm
(88 lbfin)
2
4
Loctite
242
10 Nm
(88 lbfin)
8
8
Loctite
242
Loctite
242
Twin carbs
10
Loctite 242
10 Nm
(88 lbfin)
Single carb
7
Loctite 515
Loctite 515
F01F1WS
PARTS
FLAT RATE
05-03-1

REMOVAL
7, Flame Arrester Base
1, Air Intake Silencer Cover
Remove flame arrester no. 5.

Remove screws no. 8 retaining support no. 6 of
flame arrester base to the cylinder head cover
(717 engines) or to the exhaust manifold (787 engine).
Unlock retaining slides holding air intake silencer

cover and remove cover.
F01F2OA
TYPICAL
1. Air intake silencer cover
2. Unlock
4, Air Intake Silencer Base

Remove screws no. 2 of retaining plate no. 3.
Pull out retaining plate no. 3 and air intake silencer
base no. 4.
1
F00F03A
1. Remove support
Remove screws no. 10 from flame arrester base

then withdraw base.
NOTE: On single Mikuni carburetor models, remove choke and throttle cables from flame arrester base.
ASSEMBLY
Assembly is essentially the reverse of removal
procedures. However pay particular attention to
the following.
CAUTION
Do not modify air intake system, otherwise

calibration will be affected.
7, Flame Arrester Base

F00F02A
1. Retaining plate
2. Remove screws
05-03-2
Apply Loctite 515 on mating surfaces of flame arrester base.

Apply Loctite 242 (blue) on screws no. 10 and
torque to 10 Nm (88 lbfin).

5, Flame Arrester
Inspect condition of flame arrester. Replace or
clean as necessary.
WARNING
Do not operate watercraft without flame arrester.
787 Engine
Position the flame arrester with its embossment
toward TOP.
F00F04A
9, Gasket
Inspect condition of gasket. Make sure to properly installed gasket.
05-03-3

CARBURETORS
Mikuni BN-38
12
3
14
13
8
9
7
Loctite
242
11
10
19
5
Loctite
242
15
6
13
Anti-seize
lubrifiant
18
17
16
F02F0KS
PARTS
FLAT RATE
05-04-1

Mikuni BN-38I, BN-40I

Loctite
242
12
6
20 Nm
(15 lbfft)
13
14
20
Loctite
242
21
11
Loctite 242
MAG
10
15
Anti-seize lubricant
19
5
13
2
Synthetic
grease
Synthetic
grease
PTO
18
17
16
F01F05S
05-04-2
PARTS
FLAT RATE

GENERAL
The following illustration shows which part of the
carburetor begins to function at different throttle
plate openings.
F00F05A
TYPICAL
1. Pulse line
Disconnect fuel supply line from fuel pump.

Disconnect fuel return line.
Disconnect oil injection pump cable, throttle cable
and choke cable.
F01F13A
VIEW FROM AIR INTAKE OPENING

1. Throttle plate openings
2. Throttle plate closed
3. Throttle plate wide opened
4. Low-speed screw
5. Pilot jet
6. Main jet and high-speed screw
BN-38 Carburetor
Remove 4 bolts and lock washers from rotary
valve cover then move carburetors and rotary
valve on top of engine.
NOTE: When removing rotary valve cover, pay attention that the rotary valve will stay in place, otherwise it must be timed.
REMOVAL
To remove carburetor(s) from engine, proceed as
follows:
Remove air vent tube support (SP, SPX, GS, GSI
and GSX models).
Remove air intake silencer. Refer to FUEL SYSTEM 05-03.
Turn fuel valve to OFF position.
Disconnect pulse line.
F01D4RF
1. Rotary valve cover bolt
Remove carburetor from intake manifold.
BN-38I and BN-40I Carburetors

Remove screws no. 20 and lock washers no. 21
retaining carburetors.
05-04-3

DISASSEMBLY AND INSPECTION
Inspect parts for corrosion damage (shaft, throttle

plate, spring, screw, check valve housing, etc.).
1, Needle Valve
Inspect needle valve tip for a grooved condition. If
worn, needle and seat must be replaced as a
matched set.
2, Low Speed Screw

Check tip for a grooved condition. Replace if necessary.
3, Diaphragm
F07F03A
1. Screw
Remove carburetors.
CLEANING
The entire carburetor should be cleaned with a
general solvent and dried with compressed air before disassembly.
PUMP DIAPHRAGM LEAK TEST

Using a suitable pump gauge tester, perform the
following test proceeding as follows:
Install pump gauge tester (P/N 295 000 114) on
pulse nipple.
Pump tester until it reaches 28 kPa (4 PSI).
1
CAUTION
Be careful at carburetor cleaning not to remove

paint. Paint removal will cause carburetor to
rust very rapidly. Repaint if necessary.
Carburetor body and jets should be cleaned with
a carburetor cleaner. Follow manufacturers instructions.
WARNING
Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be
used as they are flammable and explosive.
CAUTION
Heavy duty carburetor cleaner may be

harmful to the rubber parts, O-rings, etc.
Therefore, it is recommended to remove
these parts prior to cleaning.
Inspect O-rings, diaphragms and gaskets.
05-04-4
F01F0XA
TYPICAL
1. Pump gauge tester
2. Install on pulse nipple
Diaphragm must stand pressure for 10 seconds.

If pressure drops, replace diaphragm.
4, Pump Body
Check fuel pump valve operation as follows:
Connect a clean plastic tubing to the inlet nipple
and alternately apply pressure and vacuum with
the mouth. The inlet valve should release with
pressure and hold under vacuum.

WARNING
Some fuel may be present in fuel pump. Be

careful not to swallow fuel when under vacuum.
1
1
F01F0YA
TYPICAL
1. Filter
ASSEMBLY
F01F0WA
TYPICAL
1. Fuel outlet nipple
2. Pulse nipple
3. Inlet nipple
Repeat the same procedure at the outlet nipple.

This time the outlet valve should hold with pressure and release under vacuum.
Inspect valves. The pumping area should be free
of holes, tears or imperfections. Replace as needed.
5, Filter
To verify filter condition proceed as follows:
Remove pump cover no. 16, gasket no. 17, diaphragm no. 18 and then pump body no. 4 and diaphragm no. 19.
Remove filter from carburetor body then clean filter and blow carefully with compressed air (low
pressure).
Replace filter if damaged.
When assembling pump, ensure to properly position components together. Refer to previous illustrations if necessary.
6,7, Choke Plate and Throttle Plate

When installing plate onto shaft, close plate so
that it centers into carburetor bore. Firmly tighten
screws.
CAUTION
Always apply Loctite 242 (blue) on screw

threads prior to installing screws.
8, Needle Valve Lever

Rounded end of needle valve lever must be flush
with surrounding metering chamber floor and not
with body assembly. Place the end of a ruler over
lever to check adjustment.
05-04-5

F01F34A
LOW LEVER
Step 1 : Depress here
Step 2 : Pry up here
POP-OFF PRESSURE TEST

Proceed as follows:
Install pump gauge tester on carburetor fuel inlet nipple.
Obstruct fuel return nipple with a finger.
Pump tester until inlet release pressure is
reached (seen by a sudden pressure drop).
F01F0ZA
1. Metering chamber floor

2. Lever end
3. Flush
3
1
To adjust, bend lever very slightly to change its

height.
CAUTION
When adjusting lever, do not pry it so that it

applies pressure on needle. This could damage valve seat/needle.
1
2
2
F01F10A
TYPICAL
1. Pump gauge tester
2. Install on inlet nipple
3. Obstruct outlet nipple
F01F0HA
HIGH LEVER
Step 1 : Depress here
Step 2 : Push tab down
05-04-6
Refer to the following table for pop-off pressures

(PSI), from needle valve size and arm spring combinations:
Valve
Seat
Diameter
(mm)
Arm Spring Load (g)

51
65
80
115
1.2
29 8
38 10
48 12
76 15
1.5
17 5
27 8
33 10
42 12
2.0
11 4
16 5
21 7
29 8

NOTE: Pressure test should be performed three

times to obtain a valid reading.
If pop-off pressure is not within specification,
check control lever adjustment. Replace spring as
necessary.
2
1
CAUTION
Do not stretch or cut spring.

LEAK TEST
Needle valve must stand a pressure of 69 kPa
(10 PSI) for 30 seconds. Otherwise, hold carburetor upside down, pour oil over needle valve and
apply pressure.
Check for bubbles. If they come from seat or
O-ring, bubbles will exit around seat. Retighten as
necessary.
If it still leaks remove needle and seat and replace
O-ring.
If bubbles come from needle, replace needle and
seat.
9,10, Main Jet and Pilot Jet

Pilot jet and main jet are replaceable. Different jet
sizes are available to suit temperature and altitude
conditions. Always inspect spark plug tip condition when dealing with pilot jet and main jet. Spark
plug tip condition gives a good indication of carburetor mixture setting.
F01F11A
TYPICAL
1. Pilot jet
2. Gasket
3. Main jet
4. Check valve housing removed
11, Check Valve Assembly

The check valve is needed if a back pressure occurs into carburetor. It will prevent fuel from flowing back into carburetor lower portion.
Inspect check valve, it should be free of holes,
tears or imperfections. Replace as needed.
CAUTION
Adjustments vary with temperature and altitude. Always observe spark plug condition
for proper jetting.
NOTE: To have access to pilot jet or main jet,
check valve housing must be removed.
F01F12A
1. Check valve
NOTE: Prior to check valve assembly installation,

remember to set gasket.
3,12, Diaphragm and Cover

Install diaphragm with its integrated O-ring into
carburetor groove. Make sure that the tab of cover is inserted into carburetor notch.
05-04-7

13, O-ring
When installing O-rings of low speed and high
speed screws, apply some BOMBARDIER LUBE
(P/N 293 600 016) to prevent sticking.
INSTALLATION
At installation, pay attention to the following:
Install carburetor(s) with gasket(s) to intake manifold (rotary valve cover for the 787 engine).
2
3
BN-38 Carburetor
F01F1YA
Install lock washers and apply Loctite 242 (blue)

on threads then torque nuts to 25 Nm (18 lbfft).
BN-38I and BN-40I Carburetors

Apply Loctite 242 (blue) on screws no. 20. Then,
install screws no. 20 with lock washers no. 21
and torque to 20 Nm (15 lbfft).
Twin Carburetor Synchronization

With idle speed screw not touching throttle lever
stopper on MAG carburetor, both throttle plates
are in closed position.
1. Jam nuts
2. Adjustment nut
3. Flat surfaces
Tighten jam nuts and torque to 3 Nm (27 lbfin).

NOTE: Grease carburetor linkage at both ends
with synthetic grease (P/N 293 550 010).
Connect linkage between both carburetor levers.
Ensure both throttle plates are still in closed position.
NOTE: The linkage installation is done with the
marks located near PTO carburetor throttle lever
to ease adjustment if to be performed in the watercraft.
F01F31A
1. Stopper
2. Idle speed screw
Loosen jam nuts on carburetor linkage and adjust

linkage with adjustment nut.
Make sure threads length is the same on each
side of linkage and flat surfaces of both ends are
parallel with each other.
F01F32A
1. Throttle lever PTO side

2. Marks
CAUTION
Throttle plates must open simultaneously,

otherwise this will cause engine to vibrate
and/or back fire.
Fuel Lines and Hose Clamps

If fuel line ends are damaged, cut damaged end
before reinstallation.
05-04-8

Properly install clamps.
WARNING
1
Make sure there is no leak in fuel system.

For fuel system pressurization, refer to FUEL
SYSTEM 05-02.
ADJUSTMENTS
Throttle Cable
Lubricate cable with BOMBARDIER LUBE lubricant.
Throttle lever must reach handlebar grip without
causing strain to cable or carburetor cable bracket.
F01F0TF
SINGLE CARB
1. Adjustment nut
2. Throttle lever stopper
1
F01K08A
1. Must touch handlebar grip
Ensure carburetor throttle plate is fully open at full

throttle position. At this position throttle lever
stopper is almost in contact (0.5 mm (1/64 in))
with carburetor body.
CAUTION
Improper cable adjustment will cause strain

on cable and/or damage cable bracket or
throttle lever at handlebar.
To adjust, loosen jam nut then turn adjustment nut
as necessary.
F01F32B
TWIN CARBS
1. Throttle lever stoppers (behind levers)
2. Adjustment nut
Tighten jam nut and recheck adjustment.
WARNING
Make sure idle speed screw contacts stopper

when throttle lever is fully released at handlebar.
After throttle cable adjustment, always proceed
with oil injection pump adjustment. Refer to LUBRICATION SYSTEM 06-03.
CAUTION
Improper oil injection pump synchronization

with carburetor can cause serious engine
damage.
05-04-9

2, Low Speed Screw
Start and warm up engine.
CAUTION

F01F0TC
Check that engine idles and runs smoothly. Make

sure engine reacts quickly to throttle lever depression. If necessary, readjust low speed screw
( 1/4 turn).
NOTE: On twin carburetor engines, both low
speed screws must be adjusted exactly the same
way. Never adjust screws more than 1/4 turn at a
time.
14, High Speed Screw
TYPICAL SINGLE CARB

1. Low speed screw
The high speed screw is sealed with a plastic cap

that allows an adjustment of 1/4 turn.
NOTE: Turning screw 1/4 turn counterclockwise
enriches mixture and turning screw clockwise
leans mixture.
CAUTION
Do not attempt to adjust high speed screw

by removing plastic cap.
F01F33A
TWIN CARBS
1. Low speed screw (PTO)
2. Low speed screw (MAG)
CAUTION
Do not attempt to set engine idle speed with

low-speed screw.
Tighten low speed screw until a slight resistance
is felt. Then, back it off to the specification as per
following chart.
Watercraft
model
Low speed
screw (turn)
HX
SP/GS/GSI/
GTS/GTI
SPX/XP/
GSX/GTX
1-1/2
1-3/4
NOTE: Turning screw clockwise leans mixture

and turning screw counterclockwise enriches
mixture.
05-04-10
1
F01F0VA
TYPICAL SINGLE CARB

1. High speed screw

ROT
F01F2QA
F01F32C
TWIN CARBS
1. Idle speed screw
TYPICAL TWIN CARBS

1. High speed screws
15, Idle Speed Screw

Turning screw clockwise increases engine idle
speed and turning screw counterclockwise decreases engine idle speed.
NOTE: On twin carburetor engines, there is only

one idle speed screw.
Connect an induction-type tachometer (P/N 295
000 100) on spark plug cable of magneto side to
measure engine speed.
NOTE: To adjust idle speed, ensure flame arrester
and air intake silencer are installed.
Start engine and bring to normal operating temperature.
CAUTION

Turn screw so that engine idles at 1500 RPM in
water or 3000 RPM out of water.
F01F0TE
SINGLE CARB
1. Idle speed screw
05-04-11
Section 06 LUBRICATION SYSTEM

TABLE OF CONTENTS
OIL INJECTION SYSTEM ......................................................................................................
GENERAL ...........................................................................................................................
OIL SYSTEM PRESSURIZATION ......................................................................................
06-02-1
06-02-4
06-02-4
OIL INJECTION PUMP ..........................................................................................................

REMOVAL...........................................................................................................................
DISASSEMBLY...................................................................................................................
CLEANING .........................................................................................................................
ASSEMBLY.........................................................................................................................
ADJUSTMENTS ................................................................................................................
CHECKING OPERATION....................................................................................................
06-03-1
06-03-3
06-03-3
06-03-3
06-03-3
06-03-4
06-03-6
06-01-1

Sub-Section 02 (OIL INJECTION SYSTEM)
OIL INJECTION SYSTEM

3
27 Nm
(20 lbfft)
3
SP model only
1
2
3.5 Nm
(31 lbfin)
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
To engine
crankcase
(return)
To engine
crankcase
(supply)
To oil
injection
pump
F01G0VS
1.2 Nm
(11 lbfin)
PARTS
FLAT RATE
06-02-1

XP and HX Models
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
To engine
crankcase
(return)
F05G03S
06-02-2
PARTS
FLAT RATE
To engine
crankcase
(supply)
To oil
injection
pump

GS, GSI, GSX, GTI and GTX Models
To oil
injection
pump
To engine
crankcase
(return)
27 Nm
(20 lbfft)
1
3.5 Nm
(31 lbfin)
FR
AVON
AN T
T
To engine
crankcase
(supply)
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
2
1 3.5 Nm
(31 lbfin)
1.2 Nm
(11 lbfin)
3
F07G01S
PARTS
FLAT RATE
06-02-3

GENERAL
Whenever repairing the oil injection system, always verify for water infiltration in reservoir.
Perform also a pressure test of the oil injection
system.
1,2, Clamp and Hose

Verify oil filler neck hose for damage. Always ensure that clamps are well positioned and tightened. Torque clamps to 3.5 Nm (31 lbfin).
F01G0IA
All Models
TYPICAL
1. Connect pump to check valve
3, Check Valve
Black side of the one-way check valve is the valve
outlet. It allows air to get in reservoir.
4, Oil Filter
Oil filter should be replaced annually.
OIL SYSTEM PRESSURIZATION
WARNING
Whenever oil system components are disconnected or replaced, a pressure test must
be done before starting engine. Ensure to
verify oil line ends for damage. Always cut
damaged end before reinstallation.
Pressure Test
Proceed as follows:
Fill up oil reservoir.
Install a hose pincher to rotary valve shaft oil
supply hose.
Install a hose pincher to rotary valve shaft oil
return hose.
Install a hose pincher to oil injection pump supply hose.
to check valve of oil injection reservoir vent.
NOTE: Use the same pump included in the ENGINE LEAK TESTER KIT (P/N 295 500 352).
06-02-4
Pressurize oil system to 21 kPa (3 PSI). If pressure is not maintained, locate leak and repair/replace component leaking. To ease leak search
spray a solution of soapy water on components, bubbles will indicate leak location.
NOTE: The system must maintain a pressure of
21 kPa (3 PSI) for at least 10 minutes. Never pressurize over 21 kPa (3 PSI).
CAUTION
If any leak is found, do not start the engine

and wipe off any oil leakage.
Disconnect pump gauge tester and remove
hose pinchers.

Sub-Section 03 (OIL INJECTION PUMP)
OIL INJECTION PUMP
717 Engines
Twin carbs
6 Nm
(53 lbfin)
2
6
Loctite
242
Single carb
10 Nm
(89 lbfin)
Loctite
6 Nm 648
(53 lbfin)
1 2
SP/GTI
6 Nm
(53 lbfin)
5
6 Nm
(53 lbfin)
8 Nm
(71 lbfin)
4.5 Nm
(40 lbfin)
6
10 Nm
(89 lbfin)
Single carb
Loctite
242
5 Nm
(44 lbfin)
Twin carbs
4.5 Nm
(40 lbfin)
Loctite
242
F00G01S
PARTS
FLAT RATE
06-03-1

787 Engine
6 Nm
(53 lbfin)
11
9
8
10
4.5 Nm
(40 lbfin)
4.5 Nm
(40 lbfin)
Loctite
242
4.5 Nm
(40 lbfin)
F01G0TS
06-03-2
PARTS
FLAT RATE

REMOVAL
DISASSEMBLY
717 Engines
Remove air intake silencer (refer to FUEL SYSTEM 05-03).
Remove rotary valve cover (refer to ENGINE 0307).
Remove Allen screws no. 6 retaining intake manifold no. 4 to rotary valve cover.
Separate intake manifold from rotary valve cover.
NOTE: Some oil pump parts are not available in

single parts. A gasket set is available for the
pump.
If the pump is found defective, it should be replaced by a new one.
1, Oil Pump Gear

To separate oil pump from intake manifold, remove oil pump gear using gear holder (P/N 290
277 905) and unscrew lock nut no. 2.
CLEANING
Discard all seals and O-rings. Clean metal components in a solvent.
ASSEMBLY
717 Engines
3,4, Oil Injection Pump and Intake

Manifold
Install oil injection pump to intake manifold.
Torque screws no. 5 to 6 Nm (53 lbfin).
CAUTION
Whenever oil injection lines are removed, always make the routing as shown.
A00C17B
1. Gear holder
3, Oil Injection Pump

Remove 2 Allen screws no. 5 with flat washers
retaining oil injection pump to intake manifold.
Remove pump.
787 Engine
10, Oil Injection Pump

Disconnect oil injection pump cable no. 7.
Remove 2 Allen screws no. 8 with flat washers
no. 9 retaining oil injection pump to magneto
housing cover.
Pull pump and shaft no. 11.
Disconnect oil hoses from fittings of oil injection
pump.
1
F01D4SA
TYPICAL
1. Small oil line
1, Oil Pump Gear

Install gear to oil injection pump shaft. Torque lock
nut no. 2 to 6 Nm (53 lbfin).
NOTE: Make sure one washer is installed on each
side of gear.
06-03-3

4, Intake Manifold
Install intake manifold to rotary valve cover and
torque screws no. 6 to 10 Nm (89 lbfin).
Turn idle speed screw until it contacts stopper.

Turn idle speed screw 2 turns.
Turn cable adjustment nut to align marks on
pump.
NOTE: A mirror may be used to facilitate this verification.
717 Engines
1
2
A
F01D4RC
TYPICAL
A. 10 Nm (89 lbfin)
787 Engine
10,11, Oil Injection Pump and Shaft

Install shaft no. 11 in crankshaft end.
Install pump. Secure with flat washers no. 9 and
screws no. 8. Torque to 3 Nm (26 lbfin).
Install oil injection pump cable.
ADJUSTMENTS
F01D4RE
TYPICAL
1. Jam nut
2. Adjustment nut
3. Aligned marks
787 Engine
NOTE: The adjustment screw and jam nut for the
oil injection pump cable are located at PTO carburetor lever.
CAUTION
As oil injection pump adjustment is dependent on throttle cable position, make sure to
perform throttle cable adjustment first.
Preliminary Synchronization
NOTE: To check synchronization of pump as a
routine maintenance, refer to Final Synchronization. Make sure idle speed of engine is properly
adjusted.
Ensure carburetor butterfly(ies) is (are) in closed
position.
NOTE: On a twin carburetor engine, make sure
carburetors are properly synchronized. If necessary, refer to FUEL SYSTEM 05-04.
06-03-4
1
F01G0RA
TYPICAL
1. Aligned marks

All Engines
Start and bring engine to normal operating temperature.
717 Engines
CAUTION

cooled using the flush kit. If air bubbles are
present in the oil injection system, bleed
system before operating engine.
Adjust idle speed to specification. Refer to FUEL
SYSTEM 05-04.
Stop engine.
Final Synchronization
Eliminate throttle cable free-play by depressing
throttle lever until a slight resistance is felt. In this
position, marks on pump body and lever must
align.
NOTE: A mirror may be used to facilitate this verification.
If necessary, turn cable adjustment screw to obtain pump mark alignment. Refer to above illustrations.
Tighten jam nut and recheck alignment marks.
F01D4SC
TYPICAL
1. Bleed screw
787 Engine
1
CAUTION
Proper oil injection pump adjustment is very

important. Any delay in the opening of
pump can result in serious engine damage.
Bleeding
F07G02A
CAUTION
Oil injection system must be bled and adjustment checked before operating engine.
Ensure oil injection reservoir is sufficiently filled.
Install a dry rag below oil injection pump.
Loosen bleed screw to allow oil to flow.
1. Bleed screw
All Engines
Keep bleeding until all air has escaped from line.
Make sure no air bubbles remain in oil supply line.
Tighten bleed screw.
Wipe any oil spillage.
Check small oil lines between pump and intake
manifold. They must be full of oil.
06-03-5

If not, run engine at idle speed while manually

holding pump lever in fully open position. Do not
activate throttle lever.
CAUTION

CHECKING OPERATION
On Watercraft
NOTE: Oil line supply must be full of oil. See
bleeding procedure above.
Start engine and run at idle while holding the
pump lever in fully open position. Oil must advance into small oil lines.
NOTE: The engine should have a rich mixture,
idling irregularly and emitting smoke at exhaust
outlet.
If not, remove pump assembly and check the
pump gear (717 engines) or shaft (787 engine) for
defects, replace as necessary. Test pump as describes below:
NOTE: Through normal use, oil level must not
drop in small tubes. If oil drops, verify check valve
operation. Replace as necessary.
Bench Test
The oil pump must be removed out of watercraft.
Connect a hose filled with injection oil to main line
fitting. Insert other hose end in an injection oil
container. Using a counterclockwise (reverse position) rotating drill rotate pump shaft. Oil must
drip from fittings in parts of rotary valve cover
while holding lever in a fully open position.
4
3
F01G02A
TYPICAL
1. Supply oil line to an oil container
2. Hold lever in fully open position
3. Counterclockwise (reverse) rotating drill
4. Oil must drip here
For an accurate test, each port should be checked

separately to ensure equal delivery on both ports.
To obtain a precise result of the oil pump delivery
rate, rotate it counterclockwise at 1500 RPM for a
total time of 30 seconds.
NOTE: To ensure accuracy of test, oil lines should
be completely filled before starting test.
Compare the results with the chart below. If oil
pump is out of specification, replace it.
Engine
Oil Pump
Flow Rate at
1500 RPM
(30 seconds)
717/717D
787
1.24 1.51 mL
(each port)
0.71 0.87ml
(each port)
NOTE: Test can also be done at 3000 RPM. Double quantities in chart.
06-03-6
Section 07 ELECTRICAL SYSTEM

TABLE OF CONTENTS
IGNITION SYSTEM................................................................................................................ 07-02-1
GENERAL ........................................................................................................................... 07-02-1
IGNITION TIMING PROCEDURE ...................................................................................... 07-02-4
BOMBARDIER IGNITION TESTER .................................................................................... 07-02-11
IGNITION SYSTEM TESTING PROCEDURE .................................................................... 07-02-11
SPARK PLUGS ................................................................................................................... 07-02-16
CHARGING SYSTEM.............................................................................................................
GENERAL ...........................................................................................................................
TESTING PROCEDURE .....................................................................................................
BATTERY ............................................................................................................................
07-03-1
07-03-1
07-03-1
07-03-4
STARTING SYSTEM ..............................................................................................................

GENERAL ...........................................................................................................................
STARTING SYSTEM TROUBLESHOOTING .....................................................................
STARTER REMOVAL..........................................................................................................
STARTER DISASSEMBLY..................................................................................................
CLEANING .........................................................................................................................
PARTS INSPECTION ..........................................................................................................
STARTER ASSEMBLY........................................................................................................
STARTER INSTALLATION .................................................................................................
STARTER SPECIFICATION ................................................................................................
07-04-1
07-04-3
07-04-4
07-04-5
07-04-5
07-04-5
07-04-6
07-04-6
07-04-8
07-04-9
INSTRUMENTS AND ACCESSORIES ..................................................................................

GENERAL ...........................................................................................................................
INSPECTION ......................................................................................................................
07-05-1
07-05-1
07-05-1
DIGITALLY ENCODED SECURITY SYSTEM ........................................................................

GENERAL ...........................................................................................................................
07-06-1
07-06-1
07-01-1

Sub-Section 02 (IGNITION SYSTEM)
IGNITION SYSTEM
GENERAL
0
Ignition Coil
717 Engines
The digital Capacitor Discharge Ignition (CDI) system includes the following components:
Magneto
It is the primary source of electrical energy. It
transforms magnetic field into electric current.
The flywheel contains 4 permanent magnets and
spins around the generating coil. This electric current flows to the ignition coil (SP, GTS and HX
models) or the Multi-Purpose Electronic Module
(GS, GSI and GTI models).
F01H2NA
TYPICAL
F00H0EA
1. Flywheel
2. Generating coil

The ignition coil performs two functions:
It has an integrated capacitor discharged ignition
(CDI) module, which controls the spark occurrence (ignition timing curve).
Every half revolution of the flywheel, a critical
point occurs when the position of the magnets
changes the polarity of the current flowing from
the generating coil.
The CDI module detects the change of polarity
and signals at the right time the primary winding
of the ignition coil.
The secondary winding of the ignition coil steps
up the voltage input to high voltage current for
both spark plugs.
The ignition coil steps up the voltage input from
the Multi-Purpose Electronic Module to high voltage current for both spark plugs.
The ignition coil is located in the rear electrical
box, on right side of watercraft.
Multi-Purpose Electronic Module

(MPEM)
The MPEM is directly powered by the battery. It
has a micro-processor inside of its sealed case.
The MPEM is responsible of the following electrical functions:
interpreting information
distributing information
07-02-1

start/stop function
timer
Digitally Encoded Security System
ignition (GS, GSI and GTI models)
engine rev limiter
Fuses are directly mounted onto the MPEM.
787 Engine
The 787 engine has a digital Direct CurrentCapacitor Discharge Ignition (DC-CDI) system.
Compared to the magneto system, the DC-CDI
system offers a more powerful and stable ignition
at low RPM.
SPX, GSX and GTX Models
The high amperage/voltage components are located into a rear electrical box (next to the battery).
XP Model
The high amperage/voltage components are located into a front electrical box.
SPX and GTX Models
The other components are located in the conventional electrical box.
F01H2OA
TYPICAL
GS, GSI, and GTI Models

On these models, the MPEM is also used as a
junction box, eliminating the need of an electrical
box.
All electrical components or accessories are directly linked to the MPEM.
Wire position are identified with a series of number on the MPEM. AMP plug connectors are
used.
The regulator/rectifier is also mounted on the
MPEM.
GSX and XP Models

The other components are integrated to the MultiPurpose Electronic Module (MPEM).
All Models with a 787 Engine
The ignition system includes the following components:
Battery
The battery is the primary power source for this
system.
F00H0KA
F00H0FA
TYPICAL
07-02-2

Trigger Coil
The trigger coil is mounted outside the rotor (inside the magneto housing of the engine) and is
not adjustable.

(MPEM)
The MPEM is directly powered by the battery. It
has a micro-processor inside of its sealed case.
The MPEM is responsible of the following electrical functions:
interpreting information
distributing information
start/stop function
timer
ignition
engine rev limiter
Fuses are directly mounted onto the MPEM.
SPX and GTX Models

F06H04A
Its purpose is to signal the engine position to the

Multi-Purpose Electronic Module. The rotor has
two protrusions (180 degrees apart) that, when
coupled with the trigger coil, accomplish the signaling.
7
F00H0JA
6
1
1
N
N
2
S
A00E4JA
1.
2.
3.
4.
5.
6.
Coil
Magnet
Rotor protrusion
Magnetic field outside of coil
Magnetic field crossing coil
Current to MPEM
2
S
GSX and XP Models

On these models, the MPEM is also used as a
junction box, eliminating the need of an electrical
box.
All electrical components or accessories are directly linked to the MPEM.
Wire position are identified with a series of number on the MPEM. AMP plug connectors are
used.
The regulator/rectifier is also mounted on the
MPEM.
07-02-3

CAUTION
The relation between the PTO flywheel mark

position and crankshaft position may
change as the PTO flywheel is screwed on
the crankshaft. As an example, when the
PTO flywheel is reinstall on the crankshaft, it
can slightly turns on the crankshaft when the
engine is accelerated, even if it is properly
torqued. This is enough to obtain a false ignition timing reading. Always verify PTO flywheel mark position before checking
ignition timing with an appropriate timing
light.
F00H0FA
Ignition Coil
The ignition coil steps up the voltage input from
the Multi-Purpose Electronic Module to high voltage current for both spark plugs.
IGNITION TIMING PROCEDURE

Before checking ignition timing with a stroboscopic timing light (dynamic test), it is mandatory
to scribe a timing mark on the PTO flywheel (static test) corresponding to the specific engine.
Also, the timing mark scribed on the PTO flywheel
can be used to troubleshoot a broken magneto
woodruff key.
NOTE: Do not use the factory mark found on the
PTO flywheel to check ignition timing or troubleshoot any problems.
787 Engine
Normally ignition timing adjustment should not be
required. It has been set at factory and it should
remain correctly adjusted since every part is fixed
and not adjustable. The only time the ignition timing might have to be changed would be when replacing the crankshaft, the magneto rotor, the
trigger coil and the MPEM. If the ignition timing is
found incorrect, you should first check for proper
crankshaft alignment. This might be the indication
of a twisted crankshaft.
With this DC-CDI system, the ignition timing can
be checked with either the engine hot or cold. Also, the ignition timing is to be checked at 3500
RPM with the timing light.
Between 3000 and 4000 RPM, the spark advance
does not change. So when checking ignition timing at 3500 RPM, a change in engine speed within
500 RPM will not affect the timing mark when
checked with the timing light.
Static Test
All Engines
1. Disconnect MAG side spark plug wire and connect wire to grounding device then remove
spark plug.
2. Remove PTO flywheel guard.
07-02-4

717 Engines
3. Install timing mark pointer tool on engine using
wing nuts previously removed.
F01H5TA
F01H5SA
TYPICAL
1. TDC gauge on MAG side
1. Timing mark pointer tool (P/N 295 000 130)
70
60
40
30
20
50
10
80
5. Rotate PTO flywheel counterclockwise (when

facing it) until piston is at top dead center.
90
787 Engine
3. Remove middle screw securing the engine to
the rear engine mount. Reinstall screw with
timing mark pointer tool.
F06H05A
1. Timing mark pointer tool (P/N 295 000 135)
All Engines
4. Install and adjust a TDC gauge (P/N 295 000
143) in MAG side spark plug hole.
F01H4LA
TYPICAL
1. Adjust gauge dial at zero
6. From this point, rotate flywheel clockwise to

reach proper specification according to engine.
Refer to the following chart.
07-02-5

ENGINE
IGNITION TIMING
(BTDC)
717D/717
2.59 mm (.102 in)
787
3.38 mm (.133 in)
7. Scribe a thin mark on PTO flywheel in the middle of tool slot (717 engines) or aligned with
timing mark pointer tool (787 engine).
A00B4FA
F01H5SB
TYPICAL
1. Tool slot
2. Flywheel mark
717 Engines
NOTE: To perform this procedure, make sure to
use a stroboscopic timing light rated up to 6000
RPM. Otherwise, an inaccurate reading will be obtained.
The ignition components are affected by temperature variation, therefore, timing must be checked
when engine is cold, after idling for a MAXIMUM
of 20 seconds.
1. Connect an induction-type tachometer (P/N
295 000 100) to spark plug wire.
NOTE: This mark becomes the reference when

using the stroboscopic timing light.
CAUTION
The static test cannot be used as a timing

procedure, therefore, always check the timing with a stroboscopic timing light.
8. Remove TDC gauge.
9. Reinstall spark plug and connect wire.
Dynamic Test
To check ignition timing, use Bombardier timing
light (P/N 529 031 900).
F00H0GA
1. Tachometer pick-up
2. Connect timing light pick-up to MAG side spark

plug wire.
07-02-6

If timing mark aligns with tool slot, timing is properly set. If not, refer to Ignition Timing Adjustment in this sub-section.
787 Engine
1. Connect an induction-type tachometer (P/N
295 000 100) to spark plug wire.
1
F00H0HA
1. Timing light pick-up
3. Start engine and point timing light straight in

line with timing tool slot. Bring engine to the
specified RPM as per following table:
ENGINE
RPM
F06H06A
717D
5500
1. Tachometer pick-up
717
6000
2. Connect timing light pick-up to MAG side spark

plug wire.
F00H0IA
F00H0HA
1. Timing light straight in line with tool slot
CAUTION
If engine is to be run more than a few seconds, engine must be cooled using the flush
kit.
1. Timing light pick-up
3. Rev the engine to 3500 RPM and point beam of

timing light straight in line with timing mark
pointer.
4. Check if PTO flywheel mark aligns with timing

tool slot.
NOTE: On this system, timing advance decreases as engine speed increases.
07-02-7

2
A25E0RA
F06H07A
1. Timing light straight in line with tool slot
CAUTION
If engine is to be run more than a few seconds, engine must be cooled using the flush
kit.
NOTE: If mark on PTO flywheel is perfectly
aligned with timing mark pointer, no adjustment is
required. If it is not the case, refer to Ignition
Timing Adjustment in this sub-section.
TYPICAL
1. To retard
2. To advance
To adjust, loosen 3 armature plate retaining

screws and slightly rotate armature plate in proper direction.
NOTE: As a guideline, turn the armature plate the
same amount needed to align mark on PTO flywheel.
Ignition Timing Adjustment

717 Engines
Remove battery (SP and GTS models).
Remove magneto housing cover and wire support.
For removal of magneto, refer to ENGINE 03-04.
Timing is performed by moving armature plate;
clockwise to retard spark occurrence or counterclockwise to advance.
1
1
A25E0VA
TYPICAL
1. Retaining screw
Example 1
When PTO flywheel mark is on right side of timing
tool slot, it indicates advanced timing.
07-02-8

Recheck ignition timing (make sure engine is

cold).
Repeat armature plate positioning procedure if
timing mark position is not adequate.
787 Engine
To correct the ignition timing, the data of the
MPEM is changed using the MPEM programmer
(P/N 295 000 127).
NOTE: For more information on the programmer,
refer to its guide.
Through the MPEM programmer, the ignition timing can be advanced up to 3 or retarded up to 4.
1
F01H5UA
1. Too advanced timing
In this case, turn armature plate clockwise when

facing it.
Example 2
When PTO flywheel mark is on left side of timing
tool slot, it indicates retarded timing.
CAUTION
If the ignition timing is adjusted too advanced, this will cause serious damage to
the engine.
The timing mark refer to the physical component
position when the spark must occur. The MPEM
must be synchronized with the mark. For instance, on a particular engine, the timing correction may need to be advanced to 2 so that the
mark aligns with timing mark pointer tool. This is
not the real spark advance, just a correction for
the tolerances of the mechanical components.
Knowing that, you select with the programmer
the higher or lower number to advance or retard
the actual timing correction by referring to the following chart.
TIMING CORRECTION CHART
F01H5VA
1. Retarded timing
In this case, turn armature plate counterclockwise

when facing it.
After adjustment, tighten armature plate retaining
screws.
CAUTION
Armature plate screws must have Loctite

242 (blue) applied before tightening. Make
sure armature plate screws are well secured.
Programmer number
(MPEM)
Ignition Timing
Correction
-1
-2
-3
-4
Reinstall removed parts. Refer to ENGINE 03-04.
07-02-9

Examples:
a. You found the flywheel mark advanced. You
must retard the ignition timing.
The programmer gives you the number 3.
Referring to the chart, number 3 returns a
correction of 2 (advanced) and this is too
much in this case.
You estimate the correction should be set to
1 (advanced) to align flywheel mark. Back in
the chart, look to find 1 (advanced). This
gives number 4. Enter this number with the
programmer.
You recheck the timing with the timing light
and if the mark is aligned, ignition timing is
properly set.
b. You found the flywheel mark advanced. You
must retard the ignition timing.
correction of 2 (advanced) and this is too
much in this case.
programmer.
and found that the flywheel mark is still too
advanced. You know now that the correction
made previously was not enough and you estimate the correction should be set to - 2 (retarded) to align flywheel mark. Back in the
chart, look to find - 2 (retarded). This gives
number 6. Enter this number with the programmer.
and if the mark is aligned, ignition timing is
properly set.
c. You found the flywheel mark retarded. You
must advance the ignition timing.
correction of 1 (advanced) and this is not
enough in this case.
programmer.
07-02-10

and if the mark is aligned, the ignition timing
is properly set.
Proceed as follows to adjust the ignition timing
with the MPEM programmer:
1. Connect the communication cable to the
MPEM programmer and the other end to the
safety lanyard switch on the craft.
2. Press the ON/C button on programmer and
enter your password.
3. Press 3 to choose Vehicle info in programmer.
4. Press 4 to choose Engine param.
5. Press 2 to choose Timing adjust.
6. The programmer display a number that is
stored in the MPEM.
7. Press to choose yes for modify then press
Enter.
8. Now punch in the number that corresponds to
the degree you want for the ignition timing
then press Enter.
9. Press Menu to go back one level.
10. Press 8 to choose Save + Quit (even if item
no. 8 is not visible on the display, it is active
when you select it).
11. Press Enter to confirm yes you want to save
modifications to the MPEM.
12. You must see Operation successful. This
confirms that the new timing data has been
stored in the MPEM.
13. Unplug communication cable from safety lanyard switch on craft.
14. Press Off to close the programmer.
At this point, you can install the watercraft safety
lanyard and start the engine to check the effect of
the correction on the ignition timing. If further adjustment is required, repeat the procedure.
NOTE: The MPEM features a permanent (nonvolatile) memory and keeps the ignition timing
programmed even when the watercraft battery is
disconnected.

BOMBARDIER IGNITION TESTER

Use of Bombardier Ignition Tester
This tester (P/N 295 000 008) can verify generating coil (717 engines) and ignition coil of the ignition system.
INDICATOR LAMP LIGHTS AT LOWER

SETTING
This indicates that the output is less than that designed to operate in a satisfactory manner. However, before coming to the conclusion of a faulty
condition be certain that correct engine cranking
conditions were met before condemning the tested part.
INDICATOR LAMP DOES NOT LIGHT
One component is defective. Proceed as instructed to find defective component.
A00E0EA
Always make sure that tester batteries are in

good condition.
Test Condition
All tests are performed on watercraft at cranking
speed with spark plugs installed.
Always proceed in the following order:
1. Connect tester P and N clip leads as indicated
for each specific test.
2. Follow test procedure sequence.
3. Install cap over safety lanyard switch and crank
engine until light turns on, or otherwise, for a
maximum of 5 seconds.
4. After every test that lights the indicator lamp,
RESET the indicator circuit by depressing the
reset button.
Analysis of Test Results

INDICATOR LAMP LIGHTS AT SPECIFIC
SETTING
Output is as specified. Test results should repeat
3 times. If readings do not repeat, output is erratic
and cause should be investigated (loose connections or components, etc.).
INTERMITTENT IGNITION PROBLEMS

In dealing with intermittent problems there is no
easy diagnosis. For example, problems that occur
only at normal engine operating temperature have
to be tested under similar conditions.
In most cases of temperature and/or vibration failure, only parts replacement can solve the problem
as most of these failures return to normal when
engine is not running.
MULTIPLE PROBLEMS
There is always the possibility of more than one
faulty part. If after a component has been replaced, the problem still persists, carefully repeat
the complete test procedure to find the other
faulty part.
SAFETY PRECAUTIONS
WARNING
To prevent powerful electric shocks while

cranking engine, neither touch any electronic ignition components (ignition coil, high
tension wires, etc.) nor tester lead clips. Also
make sure that tester leads do not touch any
metallic object. Ventilate bilge at least two
minutes prior to performing any test.
IGNITION SYSTEM TESTING

PROCEDURE
When dealing with ignition problems, the following items should be verified in this order:
1. Spark occurrence/spark plug condition.
2. Battery condition.
3. Electrical connections.
4. Engine start/stop switch.
5. Safety lanyard switch.
07-02-11

6. Timer.
7. Multi-Purpose Electronic Module (MPEM).
8. Magneto output (717 engines).
9. Ignition coil output.
CAUTION
Whenever replacing a component in ignition

system, check ignition timing.
NOTE: To perform verification, a good quality multimeter such as Fluke 73 (P/N 529 022 000) should
be used.
Engine Start/Stop Switch Verification

Disconnect the YELLOW/RED wire of the
start/stop switch. Using an ohmmeter, connect
test probes to YELLOW/RED wire and to ground.
Measure resistance, it must be an open circuit
(switch is normally open). Depress and hold
switch, the ohmmeter should read close to 0
ohm.
Safety Lanyard Switch Verification

If 2 short beeps are not heard when installing the
safety lanyard, refer to ELECTRICAL SYSTEM 0706.
The following continuity tests can also be performed using an ohmmeter:
Disconnect switch wires.
Safety Lanyard Removed
Connect test probes to switch BLACK and
BLACK/YELLOW wires. Measure resistance,
there should be no continuity (open circuit).
Connect one test probe to the WHITE/GRAY wire
and the other test probe to the switch terminal.
Measure resistance, it must be close to 0 ohm.
Connect one test probe to the BLACK wire and
the other test probe to the switch ring. Measure
resistance, it must be close to 0 ohm.
Safety Lanyard on Switch
BLACK/YELLOW wires. Measure resistance, it
must be close to 0 ohm.
07-02-12
Timer Verification
The timer is integrated into the MPEM.
Always confirm first that the fuses are in good
condition.
To confirm operation of timer, remove safety lanyard from switch. After a 5 seconds delay, depress start/stop button once. The timer should
stay on for about 33 seconds (for example,
gauge(s) will be activated) and then turn off.
Rev Limiter Verification

To check engine rev limiter, connect an induction
tachometer (P/N 295 000 100), start engine and
check its maximum speed; it should be at 5900
50 RPM for a 717D engine, 7000 50 RPM for a
717 engine, and 7200 50 RPM for a 787 engine.

(MPEM) Verification
The multi-purpose electronic module testing must
be done with all wires disconnected from circuit.
Otherwise testing equipment (ohmmeter) could
be damaged.
CAUTION
When disconnecting wires, BLACK/RED wire

must never touch solenoid positive terminal. When replacing a MPEM, make sure to
replace it with the right model.
Refer to the following chart for MPEM testing. Always respect polarity in chart.

Meter (+) lead
Meter (-)
Value
Red
(ring terminal)
Red
(female terminal)
< 1
Red
(ring terminal)
Red/Purple
(female terminal)
< 1
Red
(ring terminal)
Black
(ring terminal)
> 20 k
Black/Red
Black
(ring terminal)
> 10 k
White/Grey
Black
(ring terminal)
> 100 k
Tan/Black
Black
(ring terminal)
> 200 k
PART NAME
ADAPTER
WIRE
RESISTANCE
Yellow/Red
(female terminal)
Black
(ring terminal)
> 10 k
Generating coil
Black with
RED/BLUE
40-76
Yellow/Red
(male terminal)
Black
(ring terminal)
> 50 k
Black
(ring terminal)
Red
(ring terminal)
> 10 k
F01B28A
TYPICAL
Check resistance with a high-sensitivity ohmmeter. Refer to the following table for values and
wire colors.
Most of circuit can be tested with an ohmmeter

but a 100% test doesnt mean the MPEM is in
perfect condition.
CAUTION
Whenever connecting MPEM, always have

battery disconnected from circuit. If MPEM
must be connected when circuit is activated,
always connect BLACK/RED wire first to ignition coil/CDI module to prevent wire from
touching solenoid positive terminal.
F01H5WA
717 Engines
Generating Coil Verification

STATIC TEST
Disconnect magneto wiring harness connector.
Install the four-pin magneto harness adapter (P/N
295 000 131).
1.
2.
3.
4.
Multimeter
Four-pin magneto harness adapter
RED/BLUE wire
BLACK wire
DYNAMIC TEST
1. Connect spark plug cables to grounding device.
2. Disconnect magneto wiring harness connector.
3. Install the four-pin magneto harness adapter (P/N
295 000 131).
4. Connect probe N of Bombardier Ignition
Tester to RED/BLUE wire of four-pin magneto
harness adapter.
5. Connect probe P of Bombardier Ignition
Tester to BLACK wire of four-pin magneto harness adapter.
07-02-13

6. Set Bombardier Ignition Tester as per following

table:
Tester
probe
Adapter
wire
RED/BLUE
BLACK
Tester
switch
position
Tester
dial
position
LOW
60
F01B28A
3. Connect one multimeter lead to the WHITE

wire of the six-pin magneto harness adapter.
4. Connect the other multimeter lead to the
BLACK/YELLOW wire of the six-pin magneto
harness adapter.
5. Measure resistance; it should be between 190300 ohms.
F01H5XA
1.
2.
3.
4.
Bombardier ignition tester

Four-pin magneto harness adapter
Probe N to RED/BLUE wire
Probe P to BLACK wire
7. Crank engine and observe indicator.

8. Push reset button and repeat test twice.
Results:
a. Indicator lamp lights: Generating coil output is
up to specifications.
b. Indicator lamp does not light: The problem is
a faulty generating coil. Replace it.
F01H5YA
1.
2.
3.
4.
Multimeter
Six-pin magneto harness adapter
WHITE wire
BLACK/YELLOW wire
All Engines
787 Engine
Trigger Coil Verification

STATIC TEST: CONTINUITY
1. Disconnect magneto wiring harness connector.
2. Install the six-pin magneto harness adapter
(P/N 295 000 136).
Ignition Coil Verification

STATIC TEST
NOTE: An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur
at high voltage level which is not detectable with
an ohmmeter.
Primary Winding

Due to the integrated CDI module, it is not possible to take any resistance measurement.
07-02-14

All Other Models

1. Remove the 2 female spade connectors from
the primary side of the ignition coil.
2. With the meter set on the resistance scale,
connect the meter leads to the primary terminals of the coil.
3. Resistance should be between 0.34 - 0.62
ohm.
Secondary Winding
The spark plug caps must be removed from high
tension cables, because they are resistor caps.
The cap resistance is 4.48 K ohms.
2. Connect Bombardier Ignition Tester probes

then set switch and dial as follows:
Tester
probe
Component
Tester adapter
(paper clip) on
spark plug cable
Tester
switch
position
Tester
dial
position
LOW
50
Grounding
device
2
IGNITION
TESTER
40 50 60
30
70
20
80
10
90
ELECTR
O-SPECIALT
A00E0QA
IES, INC
.
0
LOW
100
HIGH
1. Resistor cap
2. High-tension cable
IGNITION COIL
PART NAME
WIRE
Secondary
winding
(SP/GTS/HX)
End of each spark

plug cable, spark
plug caps removed
Secondary
winding
(all other
models)
End of each spark

plug cable, spark
plug caps removed
RESISTANCE
1
9 - 15 k
2
F01H5MA
8.4 - 15.6 k
NOTE: A short circuit will read 0 ohm (or close to)

on ohmmeter.
DYNAMIC TEST
A paper clip of approximately 20 mm (3/4 in) will
be used as a test adapter for the following test.
1. Install the test adapter to spark plug cable close
to MAG side spark plug.
TYPICAL
1. N lead on paper clip
2. P lead to grounding device
3. Start engine and observe indicator.

NOTE: If engine starts, allow it to idle while observing indicator. Then, shut engine off.
Results:
a. Indicator lamp lights: Ignition coil is OK.
b. Indicator lamp does not light: Ignition coil is
faulty. Replace it.
07-02-15

All Models Except SP, GTS and HX

As an alternate method, use KOWA ignition coil
tester (or equivalent), available from after-market
tool/equipment suppliers.
CAUTION
Do NOT use coil tester on metal work bench.

Follow manufacturer instructions.
1. With ignition coil removed from craft, disconnect spark plug caps from high tension cables.
2. Hook high tension leads from tester to ignition
coil high tension cables.
3. Connect 2 smaller tester leads to primary of ignition coil.
1
Heat Range
The proper heat range of the spark plugs is determined by the spark plugs ability to dissipate the
heat generated by combustion.
The longer the heat path between the electrode
tip to the plug shell, the hotter the spark plug operating temperature will be and inversely, the
shorter the heat path, the colder the operating
temperature will be.
A cold type plug has a relatively short insulator
nose and transfers heat very rapidly into the cylinder head.
Such a plug is used in heavy duty or continuous
high speed operation to avoid overheating.
The hot type plug has a longer insulator nose
and transfers heat more slowly away from its firing end. It runs hotter and burns off combustion
deposits which might tend to foul the plug during
prolonged idle or low speed operation.
ON
OFF
12 V
6V
2
F01H55A
TYPICAL
1. Leads to secondary
2. Leads to primary
4. Turn power switch to 12 volts and you should

observe spark jumping at a predetermined gap
of 7 to 8 mm (.276 to .311 in).
If there is no spark, if it is weak or intermittent, the
coil is defective and should be replaced.
SPARK PLUGS
Disassembly
First unscrew the spark plug one turn.
Clean the spark plug and cylinder head with pressurize air then completely unscrew.
07-02-16
A00E09A
1. Cold
2. Hot
CAUTION
Severe engine damage might occur if a

wrong heat range plug is used.
A too hot plug will result in overheating and preignition, etc.
A too cold plug will result in fouling or may create carbon build up which can heat up red-hot and
cause pre-ignition or detonation.

Fouling
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of
compression. Other possible causes are: prolonged idling, or running on a too rich mixture due
to a faulty carburetor adjustment or incorrect fuel.
The plug face of a fouled spark plug has either a
dry coating of soot or an oily, glossy coating given
by an excess either of oil or of oil with soot. Such
coatings form a conductive connection between
the center electrode and ground.
2. Apply anti-seize lubricant over the spark plug

threads to prevent possible seizure.
3. Hand screw spark plug into cylinder head and
tighten with a torque wrench and a proper
socket.
1
Spark Plug Analysis
A00E0BA
1. Proper socket
2. Improper socket
Spark Plug Chart

1
A00E0AA
1. Overheated (light grey)

2. Normal (brownish)
3. Fouled (black)
The plug face (and piston dome) reveals the condition of the engine, operating condition, method
of driving and fuel mixture. For this reason it is
advisable to inspect the spark plug at regular intervals, examining the plug face (i.e. the part of the
plug projecting into the combustion chamber) and
the piston dome.
Watercraft
model
Engine
Spark
plug
Torque
Nm (lbfft)
Gap
mm (inch)
SP
717D
NGK
BR7ES
24 (17)
0.5-0.6
(.020-.024)
GS/GSI/GTS/
GTI/HX
717
NGK
BR8ES
24 (17)
0.5-0.6
(.020-.024)
SPX/GSX/
GTX/XP
787
NGK
BR8ES
24 (17)
0.5-0.6
(.020-.024)
NOTE: Refer to next page for Spark Plug Symbol Explanation.
Spark Plug Installation

Prior to installation make sure that contact surfaces of the cylinder head and spark plug are free of
grime.
1. Using a wire feeler gauge, set electrode gap according to the following chart.
07-02-17

Spark Plug Symbol Explanation

WIDE GAP
SUFFIX
PREFIX
B R 8 E S
Thread
diameter
A:
18 mm
B:
C:
D:
E:
J:
14 mm
19 mm
(3/4")
A:
Special Design
F:
Taper
Seat
B:
Single Ground
Special Alloy
H:
12.7 mm
(1/2")
C:
Dual Ground
Special Alloy
L:
11.2 mm
(7/16")
G:
Racing Type
Z:
21 mm
(53/54")
Hot
12 mm
8 mm
12 mm x 19 mm
Reach
Construction
M:
P:
Projected
Insulator Type
R:
U:
Resistor Type
Z:
Inductive
Suppressor Type
Firing end
construction
Reach
E:
Compact Type
15
Heat rating
numbers
10 mm
10: 1.0 mm (.040")

11: 1.1 mm (.044")
13: 1.3 mm (.050")
14: 1.4 mm (.055")
15: 1.5 mm (.060")
20: 2.0 mm (.080")
GV:
Racing Version
of V-Type
L:
Half Heat Range
S:
Standard Center
Electrode
V:
Fine Wire Center

Electrode
X:
Booster Gap
Y:
V-Grooved Center
Electrode
Blank
8
18 mm 12 mm
(31/64")
14 mm 9.5 mm
(3/8")
Surface Discharge
10
Cold
F02H0MS
CROSSCUTS AND GAP STYLES OF SPARK PLUGS
A01E1PS
07-02-18
Standard
Type
Projected
Insulator Type
Taper
Seat Type
V-Type
Surface
Discharge Type

Sub-Section 03 (CHARGING SYSTEM)
CHARGING SYSTEM
GENERAL
Magneto
The purpose of the charging system is to keep the
battery at a full state of charge.
The magneto is the primary source of electrical
energy. It transforms magnetic field into electric
current (AC).
717 Engines
The magneto has a three-pole coil. Capacity is 160
watts.
787 Engine
The magneto has a 3 phase, Y wound stator on
18 poles. Capacity is 180 watts.
Rectifier/Regulator
717 Engines
A half-wave rectifier receives magneto AC current
and transforms it into direct current (DC) to allow
battery charging.
Included in the same unit, a regulator keeps voltage at a steady level (14.5 to 14.8 volts) to prevent
any damage to components.
787 Engine
A dual 1/2 wave series rectifier receives the magneto AC current and transforms it into direct current (DC) to allow battery charging.
Included in the same unit, a regulator keeps voltage at a steady level (14.5 to 14.8 volts) to prevent
any damage to components.
Battery
The battery is the DC source for the electric starter, the Multi-Purpose Electronic Module and all accessories.
Fuse
A 15 A fuse protects the charging system.
0
SPX, GS, GSI, GSX, GTI, GTX and XP Models
Two 15 A fuses protect the charging system. The
first one is located on the MPEM and the second
one is located between the solenoid and the
MPEM.
All Models
If the battery is regularly discharged, check fuse
condition.
The rectifier/regulator could be the culprit of a
blown fuse. To check, simply disconnect the rectifier/regulator from the circuit.
If the fuse still burns, check for a defective wire.
CAUTION
Do not use a higher rated fuse as this cause

severe damage.
TESTING PROCEDURE
NOTE: First, ensure that battery is in good condition prior to performing the following tests.
Rectifier/Regulator
1. Due to internal circuitry, there is no static test
available.
DYNAMIC TEST
Current Test
Proceed as follows:
Start engine.
Lay an inductive ammeter on positive cable of
battery.
Bring engine to approximately 5500 RPM.
Depending on battery charge, current reading
should be approximately 4 amperes for the 717
engines or 5 amperes for the 787 engine. If not,
check magneto output prior to concluding that
rectifier is faulty.
Voltage Test
Proceed as follows:
Start engine.
Connect a DC voltmeter on battery posts.
Bring engine to approximately 5500 RPM.
07-03-1

If voltmeter reads over 15 volts, regulator is defective. Replace it.

NOTE: If it is continually necessary to add distilled
water to the battery, this indicates an over voltage
situation, requiring replacement of the rectifier/regulator. If, on the other hand, the battery will
not stay charged, the problem can be any of the
charging circuit components. If these all check
good, you would be accurate in assuming the
problem to be in the rectifier/regulator.
DYNAMIC TEST
1. Disconnect the magneto wiring harness connector.
2. Install the four-pin magneto harness adapter
(P/N 295 000 131).
3. Connect and set Bombardier Ignition Tester as
per following table.
Tester
wires
Adapter
wire color
YELLOW
YELLOW/BLACK
Battery Charging Coil

717 Engines
2. Install the four-pin magneto harness adapter
(P/N 295 000 131).
3. Check resistance between the YELLOW and
YELLOW/BLACK wires of the magneto harness adapter. Refer to the following table.
PART NAME
ADAPTER
WIRE COLOR
RESISTANCE
()
Battery
charging coil
YELLOW with
YELLOW/BLACK
0.05-0.6
Tester
switch
position
Tester
dial
position
LOW
70
NOTE: A short circuit will read 0 ohm (or close to)

on ohmmeter.
F02H0LA
1.
2.
3.
4.
Bombardier Ignition tester

Magneto harness adapter
Probe N to YELLOW wire
Probe P to YELLOW/BLACK wire
4. Crank engine and observe indicator.

Results:
a. Indicator lamp lights: Battery charging coil
output is up to specifications.
b. Indicator lamp does not light: Battery charging coil is faulty. Replace it.
F02H0KA
1. Multimeter
2. Magneto harness adapter
3. YELLOW and YELLOW/BLACK wires
07-03-2

787 Engine
Stator

(P/N 295 000 136).
3. Check resistance between two of the YELLOW
wires. The resistance should be between 0.1 to
1.0 ohm.
3
F01H60A
1.
2.
3.
4.
Multimeter
Magneto harness adapter
+ lead to YELLOW wire
lead to ground
5. Repeat test with the other two YELLOW wires

of the six-pin magneto harness adapter.
NOTE: There should be no continuity (infinity) between the stator insulated coils and ground. If
there is a reading, the stator coils and/or the wiring from the coils is grounded and needs to be
replaced or repaired.
F01H5ZA
1. Multimeter
2. Magneto harness adapter
3. YELLOW wires
4. Place either meter lead into the remaining YELLOW wire and note the resistance (same as
step no. 3). If the readings are out of specification, the stator will need to be replaced.
STATIC TEST: INSULATION
(P/N 295 000 136).
3. Insert multimeter + lead to one of the YELLOW
wire of the six-pin magneto harness adapter.
4. Ground the multimeter lead to the engine or
the stator iron core and note the reading.
07-03-3

BATTERY
Troubleshooting
SYMPTOM: DISCHARGED OR WEAK BATTERY
CAUSE
Clean and coat with

dielectric grease.
2. Loose or bad
connections.
Check wiring and

connector cleanliness,
damaged or short circuit.
3. Faulty battery
(sulfated, doesnt
keep a full charge,
damaged casing,
loose post).
Replace.
4. 15 amp fuse(s) burnt

or faulty rectifier.
First check fuse.

If it is in good condition,
check rectifier/regulator.
5. Faulty battery
charging coil (or
stator).
Replace.
WARNING
Battery BLACK negative cable must always

be disconnected first and connected last.
Never charge or boost battery while installed in watercraft.
Proceed as follows:
1. Disconnect the BLACK negative cable first.
2. Disconnect the RED positive cable last.
3. Remove the vent line from the battery.
4. Remove the holding strap(s).
5. Withdraw battery from watercraft being careful
not lean it so that electrolyte flows out of vent
elbow.
Clean the battery casing, caps, cables and battery

posts using a solution of baking soda and water.
CAUTION
Do not allow cleaning solution to enter battery.
Inspection
Visually inspect battery casing for cracks or other
possible damage. If casing is damaged, replace
battery and thoroughly clean battery tray and
close area with water and baking soda.
Inspect battery posts for security of mounting.
Inspect for cracked or damaged battery caps, replace defective caps.
WARNING
Battery caps do not have vent holes. Make

sure that vent line is not obstructed.
Electrolyte Level
Check electrolyte level in each cell, add distilled
water up to upper level line.
CAUTION
Add only distilled water in an activated battery.
Hydrometer Test
WARNING
Electrolyte is poisonous and dangerous.

Avoid contact with eyes, skin and clothing.
Wear a suitable pair of non-absorbent
gloves when removing the battery by hand.
07-03-4
Cleaning
Remove corrosion from battery cable terminals

and battery posts using a firm wire brush. Rinse
with clear water and dry well.
Removal
Should any electrolyte spillage occur, immediately wash off with a solution of baking
soda and water.
REMEDY
1. Battery posts and/or

cable terminal oxidized.
CAUTION
A hydrometer measures the charge of a battery in

terms of specific gravity of the electrolyte. Most
hydrometers give a true reading at 21C (70F).

The battery must always be stored in fully

charged condition. If required, charge until specific gravity of 1.260 is obtained.
CAUTION
Battery electrolyte temperature must not exceed 50C (122F). The casing should not
feel hot.
A17E0JA
1. Specific gravity 1.260
In order to obtain correct readings, adjust the initial reading by adding .004 points to the hydrometer readings for each 5.5C (10F) above 21C
(70F) and by subtracting .004 point for every
5.5C (10F) below 21C (70F).
This chart will be useful to find the correct reading.
ELECTROLYTE
TEMPERATURE
C
38
32
27
100
90
80
21
70
16
10
4
1
60
50
40
30
OPERATION TO
PERFORM
.012
.008
.004
Add
to the
reading
correct reading
.004
.008
.012
.016
Subtract
from the
reading
EXAMPLE NO. 1
EXAMPLE NO. 2
Temperature above 21C (70F):

Hydrometer reading: 1.250
Electrolyte temperature: 1C (30F)
Subtract .016 Sp. Gr.
Corrected Sp. Gr. is 1.234
Temperature above 21C (70F):

Hydrometer reading: 1.235
Electrolyte temperature: 38C (100F)
Add .012 Sp. Gr.
Corrected Sp. Gr. is 1.247
Battery Storage
Disconnect and remove battery from watercraft
as explained in Removal.
Check electrolyte level in each cell, add distilled
water up to upper level line.
Do not overfill.
CAUTION
Clean battery terminals and cable connections using a wire brush. Apply a light coat of dielectric
grease on terminals.
Clean battery casing and caps using a solution of
baking soda and water.
CAUTION
Do not allow cleaning solution to enter battery.

Rinse battery with clear water and dry well using
a clean cloth.
Store battery on a wooden shelf in a cool dry
place. Such conditions reduce self-discharging
and keep fluid evaporation to a minimum. Keep
battery away from dew, high moisture and direct
sunlight.
During the storage period, recheck electrolyte level and specific gravity readings at least every
month. If necessary, keep the battery at its upper
level line and near full charge as possible (trickle
charge).
Activation of a New Battery
WARNING
Never charge or boost battery while installed in watercraft.

A new battery is factory fresh dry charged. For
storage purposes, it is fitted with a temporary
sealing tube.
CAUTION
Do not remove the sealing tube or loosen

battery caps unless activation is desired.
NOTE: In case of accidental premature removal
of caps or sealing tube, battery should be given a
full charge.
07-03-5

Perform the following operations anytime a new

battery is to be installed.
1. Remove the sealing tube from the vent elbow.
WARNING
Failure to remove the sealing tube could result in an explosion.

2. Remove caps and fill battery to UPPER LEVEL
line with electrolyte (specific gravity: 1.260 at
21C (70F)).
NOTE: This battery may fill slower than others
due to the anti-spill check ball design.
A17E0RB
1. Battery electrolyte
2. Upper level line
5. Connect a 2 A battery charger for 3 to 5 hours.

2
3
3
A17E0FB
A17E0IA
1. Sealing tube removed

2. Battery electrolyte
3. Upper level line
3. Allow the battery to stand for 30 minutes MINIMUM so that electrolyte soak through battery
cells.
Step 1 : Connect + lead to battery + post

Step 2 : Connect _ lead to battery _ post
Step 3 : Plug battery charger
CAUTION
If charging rate raises higher than 2.4 A reduce it immediately. If cell temperature rises
higher than 50C (122F) or if the casing feels
hot, discontinue charging temporarily or reduce the charging rate.
.
1
A17E0GA
1. 30 minutes
4. Readjust the electrolyte level to the UPPER

LEVEL line.
07-03-6
WARNING
Always charge in a well ventilated area. Always turn battery charger off prior to disconnecting cables.
6. Disconnect battery charger.

1
2
Do not charge a frozen battery. If the battery

charge is very low, the battery may freeze. If it is
suspected to be frozen, keep it in a heated area
for about 2 hours before charging.
WARNING
Always charge battery in a well ventilated

area.
A17E0IB
Step 1 : Unplug battery charger

Step 2 : Disconnect _ lead
Step 3 : Disconnect + lead
7. Test battery state of charge. Use a hydrometer.
A17E0JA
1. Specific gravity 1.260
8. If electrolyte level has dropped after charging,

fill with distilled water to UPPER LEVEL line. After water is added, continue charging for 1 to 2
hours to mix water with electrolyte.
9. Reinstall caps and clean any electrolyte spillage
using a solution of baking soda and water.
Charging a used battery
WARNING
Never charge battery while installed in watercraft.
The time required to charge a battery will vary depending on some factors such as:
Battery temperature: The charging time is increased as the temperature goes down. The
current accepted by a cold battery will remain
low. As the battery warms up, it will accept a
higher rate of charge.
State of charge: Because the electrolyte is
nearly pure water in a completely discharged
battery, it cannot accept current as well as electrolyte. This is the reason the battery will not
accept current when the charging cycle first begins. As the battery remains on the charger, the
current from the charger causes the electrolytic
acid content to rise which makes the electrolyte a better conductor and then, the battery
will accept a higher charging rate.
Type of charger: Battery chargers vary in the
amount of voltage and current that they can
supply. Therefore, the time required for the battery to begin accepting measurable current will
also vary.
Charging a very flat or completely discharged
battery
The battery charger should have an adjustable
charging rate. Variable adjustment is preferred,
but a unit which can be adjusted in small increments is acceptable.
The battery charger must be equipped with an
ammeter capable of accurately measuring current
of less than 1 ampere.
Unless this procedure is properly followed, a good
battery may be needlessly replaced.
For best results, battery should be charged when

the electrolyte and the plates are at room temperature. A battery that is cold may not accept current for several hours after charging begun.
07-03-7

Measure the voltage at the battery posts with

an accurate voltmeter. If it is below 10 volts, the
battery will accept current at very low rate, in
term of milliamperes, because electrolyte is
nearly pure water as explained above. It could
be some time before the charging rate increases. Such low current flow may not be detectable on some charger ammeters and the
battery will seem not to accept any charge.
Exceptionally for this particular case, set the
charger to a high rate.
NOTE: Some chargers have a polarity protection
feature which prevents charging unless the charger leads are connected to the correct battery terminals. A completely discharged battery may not
have enough voltage to activate this circuitry,
even though the leads are connected properly.
This will make it appear that the battery will not
accept a charge. Follow the charger manufacturers instruction on how to bypass or override this
circuitry so that the charger will turn on and
charge a low-voltage battery.
Since the battery chargers vary in the amount
of voltage and current they provide, the time
required for the battery to accept measurable
charger current might be up to approximately
10 hours or more.
If the charging current is not up to a measurable
amount at the end of about 10 hours, the battery should be replaced.
If the charging current is measurable before the
end or at the end of about 10 hours, the battery
is good and charging should be completed in
the normal manner as specified in Activation
of a new battery.
It is recommended that any battery recharged
by this procedure be load tested prior to returning it to service.
Charging Two or More Batteries at a

Time
Connect all positive battery posts together and
use a charger with a capacity (rated) equal to:
number of battery to be charged multiply by 2 A.
For example: Charging 5 batteries at a time requires a 10 A rated charger (5 x 2 A = 10 A).
07-03-8
A17E0PA
TYPICAL
1. Two batteries = 4 A
WARNING
Always charge battery(ies) in a well ventilated area.
Battery Installation
WARNING
Always connect battery cables exactly in the

specified order, RED positive cable first
BLACK negative cable last.
Proceed as follows:
1. Install battery in its emplacement.
2. Secure vent line to the battery and support. Ensure vent line is not kinked or obstructed.
WARNING
Vent line must be free and open. Avoid skin

contact with electrolyte.
3. First connect RED positive cable.
4. Connect BLACK negative cable last.
NOTE: On the SPX, GSX and GTX models, secure
the negative battery cable on top of the small
ground wire without using a washer.

F01H63A
SPX, GSX AND GTX MODELS

1. Negative battery cable on top of small ground wire
5. Apply dielectric grease on battery posts.

6. Verify cable routing and attachment.
SP and GTS Models

Secure RED positive battery cable using right
strap of battery.
F01H0AA
1. Strap retaining RED positive cable

2. Vent tube connected and secured in support
07-03-9

Sub-Section 04 (STARTING SYSTEM)
STARTING SYSTEM
717 Engines
8
9
10
11
12
3
13
1
2
3
5
4
22 Nm
(16 lbfft) 14
6
Loctite 242
5 Nm
(44 lbfin) 15
Dielectric grease
19
22 Nm
(16 lbfft) 16
Loctite 271
Ground cable
17
22 Nm
(16 lbfft) 18
Loctite 242
F00H0BS
PARTS
FLAT RATE
07-04-1

787 Engine
7
8
9
10
11
1
2
4
22 Nm
(16 lbfft) 14
Loctite 242
5 Nm 13
(44 lbfin)
Dielectric grease
17
22 Nm
(16 lbfft ) 14
Loctite 242
Loctite 271
16
Ground cable
15
Loctite 242
25 Nm
(18 lbfft) 19
Loctite 242
07-04-2
16
18
F00H0CS
PARTS
22 Nm
(16 lbfft)
FLAT RATE
22 Nm
(16 lbfft)

GENERAL
Safety Lanyard Switch
Causes of troubles are not necessarily related to

starter but may be due to a burnt fuse, faulty battery, start/stop switch, safety lanyard switch,
MPEM, solenoid, electrical cables or connections.
Check these components before removing starter. Consult also the starting system troubleshooting table on next page for a general view of
possible problems.
The following continuity tests can be performed

using an ohmmeter:
Disconnect switch wires.
WARNING
Short circuiting electric starter is always a

danger, therefore disconnect the battery
ground cable before carrying out any kind of
maintenance on starting system. Do not
place tools on battery.
Fuse
Make sure 5 A fuse on MPEM is in good condition.
The solenoid may be the cause of a burnt fuse. If
the solenoid checks good, one of the accessory
may be defective.
Battery
To check battery condition, refer to ELECTRICAL
SYSTEM 07-04.
MPEM
If 2 short beeps are not heard when installing the
safety lanyard, refer to ELECTRICAL SYSTEM 07-06.
Engine Start/Stop Switch

Switch condition can be checked with an ohmmeter.
Disconnect the switch YELLOW/RED wire. Connect test probes to YELLOW/RED wire and to
ground near solenoid.
Measure resistance, it must be an open circuit
(switch is normally open). Depress and hold
switch, the ohmmeter should read close to
0 ohm.
Safety Lanyard Removed

BLACK/YELLOW wires. Measure resistance,
there should be no continuity (open circuit).
Connect one test probe to the WHITE/GRAY wire
and the other test probe to the switch terminal.
Measure resistance, it must be close to 0 ohm.
Connect one test probe to the BLACK wire and
the other test probe to the switch ring. Measure
resistance, it must be close to 0 ohm.
Safety Lanyard on Switch
BLACK/YELLOW wires. Measure resistance, it
must be close to 0 ohm.
Solenoid
NOTE: Solenoid is located in the electrical box.
Inspect connections and clean as necessary.
Static Test: Continuity
With a multimeter, check primary winding resistance. It should be approximately 5 ohms.
There should be no continuity between the positive posts of the solenoid.
Dynamic Test
Depress start/stop button and measure the voltage on the solenoid positive posts with a multimeter.
If there is no voltage and battery is in good condition, replace the solenoid.
Electrical Cables or Connections

Check all connections, cables and wires. Tighten
any loose cables. Replace any chafe wires.
07-04-3

STARTING SYSTEM TROUBLESHOOTING

SYMPTOM
CAUSE
REMEDY
Starter does not turn.
Burnt 5A fuse.
Check wiring condition and replace

fuse.
Poor contact of battery terminal(s).
Clean and tighten terminal(s).
Poor battery ground cable connection.
Clean and tighten.
Weak battery.
Recharge or replace battery.
Poor contact of start/stop switch,

safety lanyard switch or solenoid.
Replace.
Open circuit: start/stop switch or

solenoid.
Replace.
Safety lanyard or MPEM.
Refer to ELECTRICAL SYSTEM 07-06.
Poor contact of brush.
Straighten commutator and brush.
Burnt commutator.
Turn commutator in lathe.
Worn commutator segments.
Undercut mica.
Shorted armature.
Repair or replace armature.
Weak brush spring tension.
Replace brush holder or spring.
Weak magnet.
Replace yoke assembly.
Worn bushings.
Replace clutch.
Weak battery.
Recharge or replace battery.
Worn clutch pinion gear.
Replace clutch.
Defective clutch.
Replace clutch.
Poor movement of clutch on splines.
Clean and correct.
Worn clutch bushing.
Replace clutch.
Worn ring gear.
Replace ring gear.
Shorted solenoid winding.
Replace solenoid.
Melted solenoid contacts.
Replace solenoid.
Sticking or defective starter clutch.
Lubricate or replace.
Presence of salt water in the electrical

box which gives continuity.
Verify electrical box watertightness.
Starter engages; but does

not crank the engine.
Starter engages; but does

not crank the engine.
Starter motor keeps

running.
07-04-4

STARTER REMOVAL
Disconnect BLACK cable ground connection from
battery.
WARNING
Always disconnect ground cable first and reconnect last.

Disconnect RED cable connection from battery.
Remove the following parts:
cables from starter
screw of starter rear support
starter mount screws
STARTER DISASSEMBLY
Before disassembling, trace index marks on yoke
no. 1 and clutch housing no. 10 to ease further
assembly.
1
A03E04A
1. Pinion stop collar
Turn clutch assembly no. 9 clockwise to remove

it from armature assembly no. 11.
Pull housing from armature.
CLEANING
CAUTION
Yoke assy and drive unit assembly must not

be immersed in cleaning solvent.
Discard all O-rings.
Clean brushes and holders with a clean cloth
soaked in solvent. Brushes must be dried thoroughly with a clean cloth.
Blow brush holders clean using compressed air.
WARNING
F01H0PA
TYPICAL
1. Trace indexing marks
Remove starter support nuts no. 13 then through

bolts no. 5. Separate end frame no. 3 from yoke
assembly no. 1. Withdraw yoke assembly from
armature no. 11.
Brush holder no. 2 can be removed from end
frame no. 3 by unscrewing nut retaining terminal.
Check that the radial play between the armature
shaft and end frame is not greater than 0.20 mm
(.008 in). Replace end frame if so.
Tap the pinion stop collar no. 7 using a screwdriver. Remove circlip no. 6. Disassemble pinion stop
collar no. 7 and spring no. 8.
Always wear safety glasses when using

compressed air.
Remove dirt, oil or grease from commutator using
a clean cloth soaked in suitable solvent. Dry well
using a clean, dry cloth.
Clean engine ring gear teeth and drive unit
(clutch).
NOTE: Bushings (717 engines) or bearings (787
engine) must not be cleaned with grease dissolving agents.
Immerse all metal components in cleaning solution. Dry using a clean, dry cloth.
07-04-5

PARTS INSPECTION
2, Brush Holder
11, Armature
NOTE: An ohmmeter may be used for the following testing procedures, except for the one concerning shorted windings in armature.
Check commutator for roughness, burnt or
scored surface. If necessary, turn commutator on
a lathe, enough to resurface only.
Check commutator for mica depth. If depth is less
than 0.20 mm (.008 in), undercut mica. Be sure
that no burrs are left and no copper dust remains
between segments after undercutting operation
is completed.
Check brush holder for insulation using an ohmmeter. Place one test probe on insulated brush
holder and the other test probe on brush holder
plate. If continuity is found, brush holder has to be
repaired or replaced.
4, Brush
Measure brush length. If less than 8.5 mm
(.335 in), replace them.
NOTE: New brush length is 12 mm (.472 in).
2
1
F01H0RA
A03E05A
1. Commutator undercut 0.20 mm (.008 in)
Check commutator out of round condition with Vshaped blocks and an indicator. If commutator out
of round is more than 0.40 mm (.016 in), commutator should be turned on a lathe.
Check commutator outer diameter. If less than
27 mm (1.063 in), replace.
1. New
2. Wear limit, 8.5 mm (.335 in)
9, Overrunning Clutch
Pinion of overrunning clutch should turn smoothly
in clockwise direction, and should not slip in a
counterclockwise direction. If defective, replace.
Check pinion teeth for wear and damage. If defective, replace.
NOTE: Always check engine ring gear teeth for
wear and damage. If defective replace ring gear.
Refer to ELECTRICAL SYSTEM 07-02.
STARTER ASSEMBLY
A03E06A
07-04-6
Reverse the order of disassembly to reassemble

starter. However, attention should be paid to the
following operations.
Prior to assembling, coat sliding surfaces on armature shaft splines, overrunning clutch and
bushing (717 engines) with G.E. Versilube
G 341 M or ESSO Beacon 325 lubricant or equivalent.
After placing pinion stop collar no. 7 on armature
shaft no. 11, fit circlip no. 6 into armature shaft,
then make sure that it is properly secured.

Slide stop collar no. 7 over circlip no. 6 and secure in place by punching it at 2 or 3 places.
4
1
2
F01H0SA
1. Locating protrusion is the higher one

A03E0EA
1.
2.
3.
4.
Armature shaft
Circlip
Pinion stop collar
Punch
1,10, Yoke Assembly and Clutch

Housing
Align previously traced indexing marks.
1
F01H0TA
1. Brush holder locating notch
To ease end frame installation, retain brush holder

with a small screwdriver while installing end
frame.
F01H0QA
TYPICAL
1. Align marks
Open brushes no. 4 and slide over commutator.

Align end frame locating notch with yoke locating
protrusion and properly sit brush holder no. 2 into
yoke no. 1.
07-04-7

17, Nut
Connect the RED battery cable to the starter and
torque nut to 6 Nm (53 lbfin). Apply dielectric
grease on terminal and nut.
14,15, Screw and Teeth Washer

Apply Loctite 271 (red) on screw.
Connect BLACK cable to starter using flat washer,
teeth washer and screw. Torque screw to 22 Nm
(16 lbfft). Apply dielectric grease on terminal and
screw.
F01H0UA
Step 1 : Retaining brush holder with a screwdriver

Step 2 : Align here
2
3
4
Align end frame notch with brush holder

notch/yoke protrusion.
CAUTION
Make sure end frame fits perfectly on yoke.
STARTER INSTALLATION
procedure. However, pay particular attention to
the following.
Make sure that starter and engine mating surfaces are free of debris. Serious trouble may arise if
starter is not properly aligned.
12,16, Screw
Apply Loctite 242 (blue) on threads and torque
starter screws to 22 Nm (16 lbfft).
07-04-8
F01H1JC
717 ENGINE SHOWN

Step
Step
Step
Step
1
2
3
4
: Torque nut to 6 Nm (53 lbfin)

: Apply Loctite 271 on screw
: Torque screw to 22 Nm (16 lbfft)
: Apply dielectric grease
WARNING
Always connect RED positive cable first then

BLACK negative cable last. Whenever connecting the RED positive cable to the starter
motor make sure the battery cables are disconnected to prevent electric shock.

787 Engine Only
18, Locking Collar

Install the locking collar of the fuel hose. Apply
Loctite 242 (blue) on nut no. 19 and torque to 25
Nm (18 lbfft).
F07H03A
1. Locking collar
2. Nut
STARTER SPECIFICATION
Nominal output
0.6 kW
Voltage
12 V
Rated time
30 seconds
Rotation
Counterclockwise (viewed from pinion side)
Weight
Approx. 2 kg (4.4 lb)
Performance specification at 20 C (68 F)
Battery
No load
11.5 V
20 A max.
5500 RPM
Load
8.5 V
170 A max.
2200 RPM
Stall
5V
350 A max.
0 RPM
19 Ah
07-04-9
Sub-Section 05

(INSTRUMENTS AND ACCESSORIES)
INSTRUMENTS AND ACCESSORIES
GENERAL
Lake Temperature Sensor
It is possible to activate the instruments when the

engine is not running.
Make sure the safety lanyard is removed, then depress the start/stop button.
The timer of the MPEM will maintain the gauge(s)
activated during a period of approximately 33 seconds.
GTX Model
The lake temperature sensor is integrated with
the speed sensor located on the ride plate.
To check if the lake temperature sensor is operational, activate the Info Center and select the lake
temperature mode.
With a garden hose, spray the speed sensor with
water. The lake temperature on the Info Center
should adjust to the water temperature.
If not, replace the speed sensor.
INSPECTION
Exterior Temperature Sensor
GTX Model
The temperature sensor is located in the storage
cover.
Remove the back panel of the storage cover to
access the temperature sensor.
F07H01A
1. Temperature sensor
To check if the temperature sensor is operational,

activate the Info Center and select the exterior
temperature mode.
Use a heat gun to warm up the sensor. The temperature should raise rapidly on the gauge.
If not, replace the temperature sensor.
Compass
GTX Model
The compass is located in the storage cover.
Remove the back panel of the storage cover to
access the compass.
F07H02A
1. Compass
Remove the compass from the support.

Activate the Info Center.
Change the direction of the compass and keep it
horizontal (10). There should be a change of direction on the Info Center.
NOTE: To check the accuracy of the compass,
you can use a portable compass and point it in the
same direction. Compare the given directions,
they should be the same.
07-05-1

Sub-Section 05 (INSTRUMENTS AND ACCESSORIES)
Tachometer
To check if the speed sensor is operational, disconnect the speed sensor connector housing
from inside bilge.
Using an appropriate terminal remover (Snap-on
TT600-4), remove the PURPLE/YELLOW and
BLACK/ORANGE wires from the tab housing of
the speed sensor.
Reconnect the PURPLE/YELLOW and
BLACK/ORANGE wires in the receptacle housing.
Connect the positive probe of a voltmeter to
speed sensor PURPLE/YELLOW wire and the
negative probe to speed sensor BLACK/ORANGE
wire.
Depress the start/stop button to activate the timer.
Spin the paddle wheel. There should be a voltage
fluctuation.
GTX Model
3
2
RPM
x 1000
6
7
1
0
Bombardier
F07H04A
The PURPLE wire is the 12 VDC power source of

the tachometer.
The BLACK wire is the ground.
The GRAY wire is the pulse signal from the multipurpose electronic module (MPEM).
Speedometer
GSX, GTI and GTX Models
Speed Sensor
30
GSX, GTI and GTX Models

The speedometer gives a reading through a
speed sensor. Speed sensor is installed on riding
plate. It works with the water flow which turns a
magnetic paddle wheel that triggers an electronic
pick-up that in turn sends a speed signal to the
speedometer.
The paddle wheel is protected by the pick-up
housing.
20
40
50
MPH
60
10
70
0
R
F07H05A

the speedometer.
The PURPLE/YELLOW wire is the pulse signal
from the speed sensor.
1
F01H3VA
1. Pick-up housing
2. Paddle wheel
07-05-2
Sub-Section 05

Info Center
Operation
GSI, GSX and GTX Models
SCROLLING FUNCTIONS
Press the MODE button until the desired function
is displayed on the Info Center.
Bombardier
F07H06A
This is a LCD multifunction gauge. It features the

following functions:
fuel level
low fuel level
low oil level
low voltage
overheating
hourmeter
clock
maintenance information
chronometer
tachometer
speedometer (GSX and GTX models)
peak speed (GSX and GTX models)
average speed (GSX and GTX models)
trip meter (GSX and GTX models)
VTS (GSI and GSX models)
compass (GTX model)
exterior temperature (GTX model)
lake temperature (GTX model)
The Info Center also features a red warning LED
which turns on if a particular condition such as low
fuel, low oil, low voltage or overheating occur.
As a self test, all LCD segments and the LED will
turn on for 3 seconds each time the watercraft is
started.
RESET
To reset a function such as the chronometer, peak
speed, trip meter, etc., select the desired function
using the MODE button then press and hold the
SET button for 2 seconds.
DISPLAY PRIORITIES
The clock (and compass for the GTX) is the basic
mode of the Info Center.
The chronometer, tachometer and speedometer
(if applicable) are the only other functions that
may be chosen to replace the clock mode.
If an another function is chosen, the clock mode
will be displayed again after 4 seconds.
In the event of a warning message such as low
fuel is displayed, the message will blink and override any other functions.
If more than one warning message is displayed,
the messages will blink and reappear every 4 seconds.
LANGUAGE OPTION
While in the clock mode, press and hold the SET
button for 2 seconds. Language option will be displayed.
Press the MODE button to scroll language (English, French and Spanish).
Press the SET button to confirm the selected language and return to the clock mode.
ENGLISH/METRIC OPTION
Press and hold both MODE and SET buttons for 2
seconds. The system will be automatically
changed.
CHRONOMETER
Select the chronometer mode and press the SET
button to start or stop the chronometer.
Press the SET button for 2 seconds to reset the
chronometer.
CLOCK SETTING
While in the clock mode, press and hold both
MODE and SET buttons for 2 seconds. The clock
will blink to confirm the setting mode.
07-05-3

Press the MODE button to adjust the hours and

the SET button to adjust the minutes.
Press again on both the MODE and SET buttons
to exit the setting mode (or the gauge will automatically exit the setting mode after 10 seconds).
RESISTANCE
()
FUEL LEVEL
LCD GRAPHIC
LOW FUEL
LEVEL RED
LIGHT
0 + 2.2
FULL
OFF
MAINTENANCE INFORMATION
When the watercraft is due for a maintenance inspection, the message MAINT will blink.
To clear the MAINT message, press the SET
button for 2 seconds during the message blinking.
17.8 2.2
7/8
OFF
27.8 2.2
3/4
OFF
37.8 2.2
5/8
OFF
47.8 2.2
1/2
OFF
Verification
the Info Center.
The RED/PURPLE wire is the 12 VDC from the
battery protected by a 5 A fuse on the MPEM.
57.8 2.2
3/8
OFF
67.8 2.2
1/4
OFF
77.8 2.2
1/8
ON
89.0 2.2
EMPTY
ON
The accuracy of some features of the Info Center

can be checked with a potentiometer.
FUEL LEVEL
Disconnect the 4-circuit connector housing of the
Info Center.
Using an appropriate terminal remover, remove
the PINK wire from the tab housing.
Reconnect the connector housing.
Disconnect the 2-circuit connector housing which
contains a PURPLE and BLACK wires.
Remove the BLACK wire from the receptacle
housing.
Reconnect the connector housing.
Connect potentiometer test probes to the PINK
and BLACK wires.
Adjust potentiometer to the resistance values as
per following chart to test the accuracy of the
gauge.
NOTE: The gauge must be activated to obtain a
reading.
07-05-4
VTS
GSI and GSX Models

Info Center.
Connect potentiometer test probes to the
BROWN/WHITE and BROWN/BLACK wires.
gauge.
reading.
RESISTANCE
()
VTS LEVEL LCD

GRAPHIC
167.3 2.2
11/11 (UP)
153.0 2.2
10/11
138.7 2.2
9/11
124.4 2.2
8/11
110.1 2.2
7/11
95.8 2.2
6/11
81.5 2.2
5/11
67.2 2.2
4/11
52.9 2.2
3/11
38.6 2.2
2/11
24.3 2.2
1/11 (DOWN)
Sub-Section 05
LAKE TEMPERATURE
Info Center which contains a BLACK/ORANGE
and TAN/ORANGE wires.
BLACK/ORANGE and TAN/ORANGE wires.
gauge.
reading.


reading.
RESISTANCE
()
DISPLAY
TEMPERATURE (C)
25590.1
52
20005.8
10 2
15761.7
15 2
12510.2
20 2
10000.0
25 2
RESISTANCE
()
DISPLAY
TEMPERATURE (C)
8047.8
30 2
25407.3
52
6518.7
35 2
19911.1
10 2
15718.0
15 2
RESISTANCE
()
DISPLAY
TEMPERATURE (F)
12495.0
20 2
22919.8
45 4
10000.0
25 2
17491.7
55 4
8054.9
30 2
13487.5
65 4
6528.3
35 2
10501.5
75 4
8252.0
85 4
RESISTANCE
()
DISPLAY
TEMPERATURE (F)
6518.7
95 4
22799.0
45 4
Fuel Gauge/Low Oil Warning Light
17262.0
55 4
13470.0
65 4
10496.3
75 4
8264.4
85 4
SPX, GS, GTS, GTI, HX and XP Models

The fuel gauge has a pointer which indicates fuel
level in the tank.
The low oil warning light is part of the gauge. It
will light when injection oil level is low.
6528.3
95 4
EXTERIOR TEMPERATURE
Info Center which contains a TAN/WHITE and
BLACK/WHITE wires.
TAN/WHITE and BLACK/WHITE wires.
gauge.
07-05-5

VTS
Bombardier
Bombardier
2
F01H4RA
F01G07A
SPX, GTS, HX AND XP MODELS

1. Low oil warning light
TYPICAL
1. Bow up
2. Bow down
Bombardier
Accuracy of gauge can be checked with a potentiometer.

Disconnect 2-circuit connector housing of
BROWN/BLACK and BROWN/WHITE wires of
gauge.
Con ne ct po te n tiom ete r te st pr ob es to
BROWN/BLACK and BROWN/WHITE wires of
gauge.
Adjust potentiometer to the resistance values
as per following chart to test accuracy of gauge.
NOTE: Gauge must be activated to obtain a reading.
F06H0DA
GS AND GTI MODELS

1. Low oil warning light
RESISTANCE ()
GAUGE NEEDLE
POSITION
10
45
95
180
+ 45
Variable Trim Gauge

SPX and XP Models
The trim gauge shows the riding angle of the watercraft.
+ 45
VTS
45
Bombardier
F01H0EA
If gauge is not within the specifications, replace it.

07-05-6
Sub-Section 05
Fuel Baffle Pick-Up Sensor

SPX, GS, GSI, GSX, GTS, GTI, GTX and HX
Models
The baffle pick-up has an integrated fuel sensor.
To verify fuel sensor, a resistance test should be
performed with an ohmmeter allowing the float to
move up through a sequence.
1

FUEL LEVEL AND RESISTANCE

(GTS)
FUEL LEVEL
(mm)
RESISTANCE
()
From 257.9 5 and more
0 + 2.2
From 234.4 to 257.8 5
17.8 2.2
From 200.9 to 234.3 5
27.8 2.2
From 167.4 to 200.8 5
37.8 2.2
From 134 to 167.3 5
47.8 2.2
From 100.5 to 133.9 5
57.8 2.2
From 67 to 100.4 5
67.8 2.2
From 40.1 to 66.9 5
77.8 2.2
From 0 to 40 5
89.8 2.2

(GS, GSI, GSX, HX, GTI and GTX)
3
F01F20A
1. Pick-up tube
2. Fuel sensor
3. Baffle pick-up
The resistance measured between PINK/BLACK

and PINK wires must be in accordance with fuel
level (measured from under the flange) as specified in the following charts.
(SPX)
FUEL LEVEL
(mm)
RESISTANCE
()
0 + 2.2
From 189.1 to 206 5
17.8 2.2
From 162.1 to 189 5
27.8 2.2
From 135.1 to 162 5
37.8 2.2
From 108.1 to 135 5
47.8 2.2
From 81.1 to 108 5
57.8 2.2
From 54.1 to 81 5
67.8 2.2
From 40.1 to 54 5
77.8 2.2
From 0 to 40 5
89.8 2.2
FUEL LEVEL
(mm)
RESISTANCE
()
0 + 2.2
From 234.4 to 248.8 5
17.8 2.2
From 200.9 to 234.3 5
27.8 2.2
From 167.4 to 200.8 5
37.8 2.2
From 134.0 to 167.3 5
47.8 2.2
From 100.5 to 133.9 5
57.8 2.2
From 67.0 to 100.4 5
67.8 2.2
From 40.1 to 66.9 5
77.8 2.2
From 0 to 40.0 5
89.8 2.2
Oil Sensor
All Models Except the SP
The sensor sends the signal to the low-oil level
light in the fuel gauge or the LED in the Info Center.
07-05-7

2
F03H0BA
F00H0LA
1. Measure resistance here

2. Sensor reservoir
1. Oil sensor
The bottom of the sensor has a small reservoir

with two small holes underneath to let the oil enter inside and one at the top to let the air enter
allowing the oil to flow out.
When there is enough oil inside the oil tank (and
therefore in the sensor reservoir), the sensor detects the liquid and the light DOES NOT turn on.
When the oil level goes at critical LOW level inside the oil tank (and therefore in sensor reservoir), the sensor detects the absence of liquid and
the light TURNS ON.
To check the oil sensor, unplug its connector and
pull sensor out of oil tank.
Using an ohmmeter, check the continuity between the BLUE and BLUE/BLACK terminals.
When sensor is out of oil tank and its reservoir is
empty, resistance must be infinite (open circuit).
NOTE: Wait about 15-20 seconds before taking
any reading to give the oil enough time to flow out
or inside sensor reservoir.
Soak sensor in oil so that its reservoir fills up.
Maximum resistance should be approximately
2 (closed circuit).
TEST CONDITION
READING ()
Sensor OUT of oil.
(open circuit)
Sensor soaked IN oil.
2 max. (closed circuit)
07-05-8
To reinstall sensor:
Remove rubber seal from sensor.
Install seal in oil tank hole.
Push sensor in seal.
Plug connector.
NOTE: This sensor turns the LED to ON if the
connector has been forgotten unconnected even
when there is enough oil in tank.
VTS Switch
SPX, GSI, GSX and XP Models
Always confirm first that the fuse is in good condition.
Disconnect BLACK wire, BLUE/WHITE wire and
GREEN/WHITE wire of VTS switch.
Using an ohmmeter, connect test probes to
switch BLACK and BLUE/WHITE wires; then,
connect test probes to switch BLACK and
GREEN/WHITE wires.
Measure resistance; in both test it should be high
when button is released and must be close to
zero when activated.
VTS Motor
Always confirm first that the fuse is in good condition.
Motor condition can be checked with an ohmmeter. Install test probes on both BLUE/ORANGE
and GREEN/ORANGE wires. Measure resistance,
it should be close to 1.5 ohm.
Sub-Section 05

If motor seems to jam and it has not reached the

end of its stroke, the following test could be performed.
First remove motor, refer to PROPULSION SYSTEM 08-05. Then manually rotate worm to verify
VTS system actuating mechanism for free operation.
Connect motor through a 15 A fuse directly to the
battery.
Connect wires one way then reverse polarities to
verify motor rotation in both ways.
If VTS actuating mechanism is correct and the
motor turns freely in both ways, VTS module
could be defective.
VTS Control Module

It receives its current from the battery. It is protected by its own 7.5 A fuse.
RESISTANCE TEST
Disconnect BROWN/BLACK wire and
BROWN/WHITE wire of VTS control module.
Con nect test probes of an ohmmeter to
BROWN/BLACK wire and BROWN/WHITE wire
of VTS control module.
NOTE: To permit VTS actuation when engine is
not running, remove safety lanyard from switch
and depress start/stop button to activate timer.
Push on VTS switch down position until motor
stops.
Read the resistance on the ohmmeter, it should
indicate a resistance of 24 ohms 1%.
Push on VTS switch up position until motor stops.
Read the resistance on the ohmmeter, it should
indicate a resistance of 167 ohms 1%.
RESISTANCE ()
NOZZLE
POSITION
167 1%
UP
24 1%
DOWN
NOTE: If the VTS control module passes this resistance test, it doesnt mean it is in perfect condition.
07-05-9

Sub-Section 06 (DIGITALLY ENCODED SECURITY SYSTEM)
DIGITALLY ENCODED SECURITY

SYSTEM
GENERAL
The Digitally Encoded Security System (DESS)
features an anti-start protection against unauthorized use of the watercraft.
The following components are specially designed
for this system: Multi-Purpose Electronic Module
(MPEM), safety lanyard cap and safety lanyard
switch.
The safety lanyard cap has a magnet and a ROM
chip. The chip has a unique digital code.
The DESS circuitry in the watercraft MPEM is activated at the factory. Therefore, a safety lanyard
must be programmed to start the engine.
NOTE: Actually, it is the memory of the MPEM
which is programmed to recognize the digital
code of the safety lanyard cap. This is achieved
with the MPEM programmer (P/N 295 000 127).
Refer to its guide to program a safety lanyard.
The system is quite flexible. Up to eight safety
lanyards may be programmed in the memory of
the watercraft MPEM. They can also be erased.
NOTE: If desired, a safety lanyard can be used on
any watercraft of the same model year equipped
with the DESS.
The memory of the MPEM is permanent. If the
battery is disconnected, no information is lost.
The memory of the MPEM has also two selfdiagnostic modes.
When ordering a new MPEM from the regular
parts channel, the DESS circuitry will be activated.
07-06-1

Basic Self-Diagnostic Mode

It is self-activated when the safety lanyard is being installed on the watercraft switch. It gives immediate
monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following
chart.
SIGNAL
CAUSE
REMEDY
2 short beeps
(while installing
safety lanyard on
watercraft switch)
Safety lanyard is
recognized by the MPEM.
Ignition is authorized, engine can start.
1 long beep
(while installing
safety lanyard on
watercraft switch or
when pressing
start/stop button in
some cases)
Bad connection between

safety lanyard cap and
switch.
Remove and replace the safety lanyard on the

switch until 2 short beeps are heard to indicate
the system is ready to allow engine starting.
Unprogrammed or
defective safety lanyard.
Use the safety lanyard that has been programmed

for the watercraft. If it does not work, check
safety lanyard condition with the programmer.
Replace safety lanyard if reported defective. If it
still does not work, enable more detail about the
failure.
Salt water in safety

lanyard cap.
Clean safety lanyard cap to remove salt water.
Improper operation of
MPEM or defective wiring
harness.
Enable advanced diagnostic mode to obtain more

detail about the failure.
8 short beeps
Defective MPEM
(memory).
Replace MPEM.
Continuous beep
Engine overheating.
Refer to TROUBLESHOOTING 02-01.
07-06-2

Advanced Self-Diagnostic Mode

It needs to be enabled manually. Proceed as follows:
1. Remove safety lanyard from watercraft switch.
2. Press 5 times on the watercraft start/stop button.
NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode.
3. Install safety lanyard on watercraft switch.
4. Press the watercraft start/stop button again.
NOTE: If everything is correct, engine will start. Otherwise, refer to the following chart.
SIGNAL
CAUSE
REMEDY
No beep
Engine actually starts.
Everything is correct.
1 long and
1 short beeps
No safety lanyard has ever been

programmed in watercraft MPEM.
Use programmer and program a

safety lanyard. This code can occur
only when you receive a new MPEM
from the factory and no key has ever
been programmed.
2 short beeps
MPEM can not read the digital code

of the safety lanyard cap or the
magnet is defective.
Check safety lanyard cap condition

with the MPEM programmer.
Replace safety lanyard if reported
defective.
Mixed wires at safety lanyard switch

connectors or bad connections.
Check switch wiring harness.
2 long beeps
Wrong safety lanyard or bad

connection of the DESS wires.
Use the safety lanyard that has been

programmed for the watercraft. If
the problem is not resolved, check
safety lanyard cap condition with the
MPEM programmer. Replace safety
lanyard if reported defective.
3 short beeps
Wiring harness of DESS switch is

grounded or there is a short circuit.
Check wiring harness and safety

lanyard switch.
If you need to listen again the coded beeps, remove safety lanyard and repeat the procedure to activate
the diagnostic mode.
If there is more than one problem, the MPEM will send only one error code. When the problem is solved,
the MPEM will send a second code and so on until all problems are resolved.
07-06-3
Section 08 PROPULSION SYSTEM

TABLE OF CONTENTS
JET PUMP .............................................................................................................................. 08-02-1
GENERAL ........................................................................................................................... 08-02-2
JET PUMP INSPECTION ON WATERCRAFT .................................................................... 08-02-2
REMOVAL........................................................................................................................... 08-02-4
DISASSEMBLY................................................................................................................... 08-02-6
CLEANING ......................................................................................................................... 08-02-8
PARTS INSPECTION .......................................................................................................... 08-02-9
ASSEMBLY......................................................................................................................... 08-02-11
PUMP PRESSURIZATION ................................................................................................. 08-02-18
INSTALLATION .................................................................................................................. 08-02-18
DRIVE SYSTEM ..................................................................................................................... 08-03-1
GENERAL ........................................................................................................................... 08-03-4
REMOVAL........................................................................................................................... 08-03-4
DISASSEMBLY................................................................................................................... 08-03-8
PARTS INSPECTION .......................................................................................................... 08-03-8
ASSEMBLY......................................................................................................................... 08-03-9
LUBRICATION.................................................................................................................... 08-03-14
REVERSE SYSTEM................................................................................................................ 08-04-1
GENERAL ........................................................................................................................... 08-04-2
DISASSEMBLY................................................................................................................... 08-04-2
ASSEMBLY......................................................................................................................... 08-04-3
ADJUSTMENTS ................................................................................................................ 08-04-5
DISASSEMBLY................................................................................................................... 08-04-8
INSPECTION ...................................................................................................................... 08-04-8
ASSEMBLY ........................................................................................................................ 08-04-9
ADJUSTMENT ................................................................................................................... 08-04-10
VARIABLE TRIM SYSTEM ....................................................................................................
MANUAL TRIM ..................................................................................................................
REMOVAL...........................................................................................................................
DISASSEMBLY...................................................................................................................
ASSEMBLY AND INSTALLATION .....................................................................................
ELECTRIC TRIM..................................................................................................................
GENERAL ...........................................................................................................................
REMOVAL...........................................................................................................................
DISASSEMBLY...................................................................................................................
INSPECTION ......................................................................................................................
ASSEMBLY.........................................................................................................................
INSTALLATION ..................................................................................................................
ADJUSTMENT ...................................................................................................................
08-05-1
08-05-1
08-05-2
08-05-2
08-05-2
08-05-3
08-05-4
08-05-4
08-05-4
08-05-4
08-05-5
08-05-5
08-05-6
08-01-1

Sub-Section 02 (JET PUMP)
JET PUMP
28
SP/SPX/GTS
15
20
21
17
Loctite
518
16
Synthetic
grease
29
SPX/GSI/GSX/HX/XP
17
22 23
10
29
Loctite
518
19
8
SP/GS/GTS/GTI/GTX
23
25 26
6
Loctite
271
20 Nm
1 (15 lbfft)
24
27
Loctite
242
18
4
2
Loctite
Synthetic
PST
oil
11
14
13
12
Loctite
242
3
5
4
1
20 Nm
(15 lbfft)
F00J05S
PARTS
FLAT RATE
Loctite
242
08-02-1

GENERAL
The jet pump housing and venturi are made of
plastic.
On the SP, GS and GSI models, the jet pump
housing is a one piece plastic unit, including the
stator.
On other models, the jet pump housing has a stator made of bronze which offers greater strength.
The nozzle is either made of plastic or aluminum,
depending upon the model of watercraft.
JET PUMP INSPECTION ON

WATERCRAFT
To work on watercraft, securely install it on a
stand. Thus, if access is needed to water inlet area, it will be easy to slide underneath watercraft.
A lift kit can be used to install watercraft on a
stand. Refer to the following chart.
LIFT KIT P/N
WATERCRAFT MODEL
295 100 012
SP/SPX/GS/GSI/GSX/HX
Impeller Identification
295 100 013
GTS/GTI/GTX
To identify the impellers refer to the following illustration and chart.
295 100 044
XP
1
1
F01J42A
1. Lift kit
2. Work stand
F02J0VA
Impeller Condition
1. Stamped part number
WATERCRAFT
MODEL
IMPELLER
P/N
MATERIAL
PITCH
SP
271 000 669
Aluminum
Progressive
pitch
16-35
SPX/GSX/XP
271 000 331
Stainless
steel
Progressive
pitch
16-23
GS/GSI/HX
271 000 497
Stainless
steel
Progressive
pitch
11-22
GTS/GTI
271 000 470
Stainless
steel
Progressive
pitch
11-22
GTX
271 000 660
Stainless
steel
Progressive
pitch
17-25
08-02-2
Condition of impeller no. 20, boot no. 15 and ring

no. 16 can be quickly checked from underneath
of the watercraft. Remove grate and look through
water inlet opening.

F01J0DA
TYPICAL
1. Inspect impeller and boot
Impeller/Wear Ring Clearance

This clearance is critical for jet pump performance.
Clearance can be checked from water inlet opening or from venturi side. However, the last method requires more work.
To check clearance from water inlet side, remove
inlet grate.
To check clearance from venturi side, remove
venturi/nozzle assembly as described in Oil Inspection in this section.
Using a feeler gauge with 30 cm (12 in) blades,
measure clearance between impeller blade tip
and wear ring. Measure each blade at its center.
Clearance should not exceed 1.0 mm (.040 in). If
clearance is greater, disassemble jet pump and inspect impeller and wear ring. Renew worn parts.
F01J0EA
TYPICAL MEASURING FROM WATER INLET SIDE

1. Feeler gauge
F01J0FA
TYPICAL MEASURING FROM VENTURI SIDE

1. Feeler gauge
Oil Inspection
Detach ball joint of steering cable from nozzle.
SPX, XP, GSI and GSX Models

Detach ball joint of VTS link rod.
GTS, GTI and GTX Models
Detach ball joint of reverse cable and springs from
reverse gate (GTS model only).
All Models
Remove 4 screws retaining venturi to jet pump
housing.
08-02-3

GTI and GTX Models

Remove reverse gate and support.
All Models
Pull nozzle and venturi from impeller housing.
NOTE: On the GTS model, the venturi and reverse gate are removed as an assembly.
Remove plug from cover.
F02J0TB
1. Screws
F01J5IA
TYPICAL
1. Remove plug
Check oil level, it should be at bottom of hole

threads.
If oil level is low, check impeller shaft housing for
leaks. A pressure test must be performed. Refer
to PUMP PRESSURIZATION in this section.
To check oil condition, insert a wire through oil level hole then withdraw. A whitish oil indicates water contamination.
This may involve defective impeller shaft seal
and/or O-ring of housing cover. Jet pump unit
should be overhauled to replace seal.
If everything is correct, apply Loctite PST 592 on
plug and reinstall it on cover. Properly reinstall removed parts.
Using a fiber hammer, gently tap cover to release

it from housing cover.
Thoroughly clean reservoir and inside of cover
with a solvent. Check O-ring condition. Replace as
necessary.
Apply a thin layer of Loctite 518 on mating surface
of cover and reinstall it with its O-ring. Torque
screws to 4 Nm (35 lbfin).
Remove plug from cover.
Pour approximately 70 mL (2.4 oz) of oil through
hole until oil reaches the bottom of hole threads.
Use SEA-DOO JET PUMP SYNTHETIC OIL (P/N
293 600 011) only. Oil will drain slowly into center
area of housing, wait a few minutes and readjust
oil level.
CAUTION
This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands.
Apply Loctite PST 592 on plug and reinstall it on
cover.
Properly reinstall removed parts.
Oil Replacement
REMOVAL
Remove venturi as described in Oil Inspection.

Remove 3 screws retaining cover.
5, Nozzle
Disconnect steering cable from jet pump nozzle.
SP, GS, GTS, GTI and GTX Models

Remove 2 retaining screws no. 1, 2 sleeves
no. 2, 4 locking disks no. 4.
08-02-4

Remove 4 retaining screws and withdraw venturi.
F01J3BE
TYPICAL
1. Screw
2. Locking disks
3. Sleeve
F02J0TA
1. Remove screws
9, Jet Pump Housing
Remove nozzle.

Disconnect ball joint of VTS link rod.
HX Model
Loosen fasteners retaining trim support to nozzle.
SPX, GSI, GSX, XP and HX Models
Loosen 2 screws each side of trim ring.
NOTE: In the following procedure, jet pump housing is removed with nozzle and reverse gate (if applicable).

Remove air vent tube support from body opening
(SP and SPX models).
Disconnect engine water inlet hose and both bailer pick-up tubes in bilge.
1
F01J5FA
1. Screws
Remove nozzle.
11, Venturi
Remove nozzle no. 5 prior removing venturi.
F01J0IA
TYPICAL
1. Bailer pick-up tubes
2. Engine water inlet hose
SPX, XP, GSI and GSX Models

Detach ball joint of VTS link rod.
08-02-5

GTS, GTI and GTX Models

Detach ball joint of reverse cable and springs (GTS
model) from reverse gate.
All Models
Disconnect steering cable from jet pump nozzle.
Loosen 4 hexagonal nuts no. 6 and remove flat
washers and lock washers from jet pump housing.
Remove jet pump with a wiggle movement.
NOTE: If jet pump can not be removed, the drive
shaft may be seized in the impeller splines. Refer
to PROPULSION SYSTEM 08-03 to remove drive
shaft at the same time.
CAUTION
When removing pump unit, a shim could

have been installed between hull and pump
housing. Be sure to reinstall it otherwise engine and jet pump alignment will be altered.
DISASSEMBLY
NOTE: Whenever removing a part, visually check
for damage such as: corrosion, crack, split, break,
porosity, cavitation, deformation, distortion, heating discoloration, wear pattern, missing plating,
missing or broken needles in needle bearing, water damage diagnosed by black-colored spots on
metal parts, etc. Renew any damaged part. As a
quick check, manually feel clearance and end play,
where applicable, to detect excessive wear.
A
1
B
2
F01J2RA
1.
2.
A.
B.
Deep socket 14 mm (9/16 in)

Roll pin 2.40 mm (3/32 in)
42.50 mm (1-43/64 in)
36.80 mm (1-29/64 in)
All Models
18, Cover
With pump assembly in horizontal position, remove 3 retaining screws no. 19.
Place container under cover to catch oil.
Using a fiber hammer, gently tap cover to release
it from impeller housing.
20, Impeller
Insert impeller shaft holder (P/N 295 000 082) on
impeller shaft flat end.
Using 2 screws previously removed from venturi,
secure shaft holder to housing.
17, Fitting
Fittings can be removed with deep socket or vise
grip. Do not contact hose mounting area.
Fittings can be removed from pump housing with
the following suggested tool:
Use a 14 mm (9/16 in) deep socket.
Drill deep socket with a 14 mm (9/16 in) drill bit,
starting at hexagon head end as shown in following illustration.
Drill a 2.40 mm (3/32 in) hole in center of deep
socket as shown in following illustration.
Install 2.40 mm (3/32 in) roll pin in the center
hole.
F00J07A
1. Shaft holder
08-02-6

Heat impeller center with a propane torch to approximately 150C (300F) to break the Loctite
bond.
Install shaft holder in a vice.
Rotate impeller remover tool counterclockwise

and unscrew completely impeller.
CAUTION
Never use any impact wrench to loosen impeller.

To remove impeller, apply a rotating movement
and pull at same time. Slide impeller out of housing. Remove tool from impeller.
21, Wear Ring

1
Place impeller housing in a vise with soft jaws. It

is best to clamp housing using a lower ear.
Cut wear ring at two places.
NOTE: Wear ring can be cut using a jigsaw, a
small grinder or a low clearance hacksaw such as
Snap-on HS3 or equivalent.
F00J0HA
1. Shaft holder
Impeller is loosened using impeller remover tool

(P/N 295 000 001).
CAUTION
When cutting ring, be careful not to damage

impeller housing.
F01J0TA
Insert special tool in impeller splines.

1
F01J0VA
TYPICAL
F00J08A
1. Impeller remover tool
08-02-7

F01J0WA
TYPICAL
1. Snap-on HS3
After cutting ring, insert a screwdriver blade between impeller housing and ring outside diameter.
Push ring so that it can collapse internally.
Pull ring out.
24, Impeller Shaft

Remove shaft holder tool.
Remove impeller shaft with thrust washer and
thrust bearing.
22,23, Seal and Needle Bearing

Remove seal and bearings at the same time using
bearing/seal remover tool (P/N 295 000 144).
F00J0MA
1. Bearing/seal remover tool
NOTE: It is always recommended to renew both

bearings, even if only one bearing needs to be replaced.
CLEANING
Sealant can be removed with a wire brush (disc)
mounted on a drill or a scraper.
Properly clean all threads.
Remove all O-rings and clean parts in a solvent.
Carefully check water passages and oil passages.
Blow low pressure compressed air through them
and make sure they are clear.
F01J11A
Insert bearing remover then press tool using a arbor press until seal and bearings are out. However, care should be taken not to damage bearing
journals.
F01J13A
TYPICAL
1. Water passages
2. Oil passages
08-02-8

Brush and clean impeller shaft threads, impeller

and drive shaft splines with Loctite Safety solvent
755 (P/N 293 800 019) or equivalent. Free threads
and splines from any residue.
CAUTION
Be careful not to damage impeller shaft diameter.
PARTS INSPECTION
20, Impeller
Visually inspect impeller splines. Check for wear
or deformation. Renew parts if damaged.
NOTE: Check also PTO flywheel and drive shaft
condition. Refer to PROPULSION SYSTEM 08-03.
Examine impeller in wear ring for distortion.
Check if blade tips are blunted round, chipped or
broken. Such impeller is unbalanced and will vibrate and damage wear ring, impeller shaft, shaft
seal or bearings. Renew if damaged.
1
F02J0UA
1. Check for cavitation, deep scratches or other damage
21, Wear Ring

Check wear ring for deep scratches, irregular surface or any apparent damage.
If impeller/wear ring clearance is too large and impeller is in good shape, renew wear ring.
22,24, Needle Bearing and Impeller

Shaft
WEAR
Inspect needle bearings and their contact surface.
Check for scoring, pitting, chipping or other evidence of wear.
With your finger nail, feel contact surface of seal.
If any irregular surface is found, renew impeller
shaft.
Install bearings, then install impeller shaft and rotate it. Make sure it turns smoothly.
F02J0VB
1. Replaced if blunted round or damaged
Check impeller for cavitation damage, deep

scratches or any other damage.
RADIAL PLAY
Radial play is critical for jet pump unit life span.
Radial play of impeller shaft is checked with shaft
in housing, without impeller.
Retain housing in a soft jaw vise making sure not
to damage housing lug.
Set a dial gauge and position its tip onto shaft end,
close to end of threads.
Move shaft end up and down. Difference between highest and lowest dial gauge reading is
radial play.
Maximum permissible radial play is 0.05 mm
(.002 in).
08-02-9

1
1
F01J18A
TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY

1. Dial gauge
2. Measure close to threads at shaft end
To check both bearings, proceed the same way

with other shaft end. Position gauge tip on diameter, close to flats on shaft.
F01J1AA
1. Inspect for wear at the bearing pilot

2. Radial bearing raceway
NOTE: If shaft is to be replaced, it is recommended to replace both bearings at the same time. In
addition, it is suggested to replace thrust bearing
and thrust washer.
25,26, Thrust Washer and Thrust

Bearing
Visually inspect thrust washer, thrust bearing and

their contact surface. Check for scoring, pitting,
flaking, discoloration or other evidence of wear.
For best inspection, use a 7X magnifying glass to
check wear pattern.
1
2
3
F01J19A
TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY

1. Dial gauge
2. Measure close to flats at shaft end
Excessive play can come either from worn bearings or impeller shaft or damaged impeller housing bearing surfaces.
Measuring shaft diameter will determine the defective parts.
Using a micrometer, measure diameter on bearing contact surfaces. Minimum shaft diameter
should be 22.24 mm (.876 in).
F01J52A
TYPICAL
1. Worn roller (trunnion worn on end roller)
2. Good roller (cylindrical shape)
3. Look for scoring on retainer
NOTE: When replacing either washer or bearing,

it is recommended to renew both.
08-02-10

18,24, Cover and Impeller Shaft

END PLAY
End play of impeller shaft is checked with shaft in
housing, without impeller and with cover installed.
Retain housing in a soft jaw vise making sure not
to damage housing lug. Set a dial gauge and position its tip on the end of shaft. Move shaft end by
pulling and pushing. Difference between highest
and lowest dial gauge reading is end play. Maximum permissible end play (new) is 0.12 0.54
mm (.005 .021 in). Make sure vise is secured
and not adding to your measurement as you move
impeller shaft.
F00J09A
TYPICAL
1. Pusher
If impeller shaft end play is excessive, pusher

should be replaced.
Use pliers to pull pusher and spring from cover.
Be sure to check end play after installing a new
pusher.
Inspect impeller shaft nose for wear.
1
F01J2SA
1. Tip on shaft end
Excessive play comes from a worn anti-knock

pusher inside cover and wear of impeller shaft
nose.
Visually inspect pusher inside cover.
F00J0AA
1. Impeller shaft nose
22, Seal
Carefully inspect seal lips. Make sure that lips are
not worn, distorted, cracked or show signs of any
other damage. Renew as necessary.
ASSEMBLY
21, Wear Ring
The wear ring features a lip on one edge; position
lip outwards of housing.
08-02-11

NOTE: To ease insertion into housing, apply

BOMBARDIER LUBE lubricant (P/N 293 600 016)
onto outside circumference of wear ring.
To install ring in housing, use a square steel plate
of approximately 180 180 mm 6 mm thick
(7 7 in 1/4 in) and a press.
Manually engage ring in housing making sure it is
equally inserted all around. Press ring until it seats
into bottom of housing.
2
1
F01J5EA
1. Piece of wood
2. Seal lip facing upward
3. Wear ring

2
Bearings and seal will be properly installed in

housing using bearing/seal installer tool (P/N 295
000 107).
1
F01J5DA
1. Seal lip
2. Press wear ring
If a press is not readily available, a piece of wood

such as a 2 4 12 in long, can be used.
Manually engage ring in housing making sure it is
equally inserted all around. Place wood piece over
ring. Using a hammer, strike on wood to push
ring. Strike one side then rotate wood piece about
90 and strike again. Frequently rotate wood
piece so that ring slides in evenly until it seats into
bottom of housing.
08-02-12
F01J4KA
BEARING/SEAL INSTALLER TOOL

1. Seal side
2. Bearing side
Stamped end of bearings (showing identification

markings) must be located toward outside of
housing.
Properly insert bearing on tool. Using an arbor
press only, push tool until tool flange contacts
housing. Proceed the same way for both bearings.

Bearing on impeller side must be 1.5 to 2.5 mm

(.060 .100 in) inside reservoir measured from
seal seat. Bearing on venturi side must be 2 to
3 mm (.080 .120 in) inside reservoir measured
from thrust washer seat. Refer to following illustration.
F01J1HA
1. Stamped end this side
B
3
4
CAUTION
Never hammer the bearing into its housing.

F01J1JA
1.
2.
3.
4.
A.
B.
Seal seat
Stamped end of bearing
Thrust washer seat
Stamped end of bearing
1.5 2.5 mm (.060 .100 in)
2 3 mm (.080 .120 in)
Seal must be installed so that lips raised edges

are toward outside of housing (toward impeller).
Apply Loctite 518 (P/N 293 800 038) to seal housing, all around outer diameter and on seal seat.
Properly insert seal on tool.
NOTE: It is important when installing seals to
pack seal lip with grease before inserting bearing/seal installer tool. Properly insert tool in seal
with a rotating movement.
F00J0BA
1. Press on tool until it stops
CAUTION
This tool have been designed to properly position bearings and seal, thus providing
space for lubrication purposes. The tool
flanges allow this. If a different pusher type
is being used, components must be properly
positioned as follows.
08-02-13

1
F01J1MA
F01J1KA
1. Raised edge of seal this side
CAUTION
Prevent sealant from contacting any needles

of bearing.
Push on tool end with a press until tool flange contacts housing.
1. Loctite 518 all around and behind

2. Raised edge of seal lip this side
25, Thrust Washer

Position jet pump housing no. 9 with the stator
vanes on top.
Insert thrust washer no. 25 in the stator seat.
F00J0DA
F00J0CA
1. Thrust washer properly installed in stator seat
1. Press on tool until it stops
26, Thrust Bearing
Apply synthetic grease (P/N 293 550 010) between seal lips.
Apply Sea-Doo jet pump synthetic oil (P/N 293

600 011) on both sides of thrust bearing.
Position thrust bearing no. 26 on thrust washer
no. 25.
08-02-14

NOTE: If jet pump housing rest against a table,

raise it slightly to allow complete shaft insertion
with the shaft guide.
Remove shaft guide.
20, Impeller
F00J0EA
Apply Loctite primer N (P/N 293 600 012) on

threads of impeller shaft no. 24. Allow to dry for 2
minutes.
NOTE: Loctite primer is used to reduce Loctite
271 curing time and to activate stainless steel and
aluminum surfaces for better bonding action. If
applied, complete curing time is 6 hours, if primer
is not used, allow 24 hours for curing time.
Apply Loctite 271 (red) to shaft threads.
1. Thrust bearing on top of thrust washer
24, Impeller Shaft

To prevent seal lip damage when inserting impeller shaft, use impeller shaft guide (P/N 295 000
002).
F01J1OA
F00J0GA
Insert tool onto shaft end then carefully install

shaft in impeller housing.
F00J0FA
1. Apply Loctite 271 (red) on threads
Using 2 screws previously removed from venturi,

secure impeller shaft holder tool to housing.
Install shaft holder tool in a vice.
1. Impeller shaft
2. Impeller shaft guide
08-02-15

Torque impeller to 70 Nm (52 lbfft) then remove

tools.
CAUTION
Never use any impact wrench to tighten impeller.

Apply synthetic grease (P/N 293 550 010) on impeller splines.
Insert a new boot no. 15 and ring no. 16 to impeller.
F00J0HA
1. Impeller shaft holder secured in a vice
To ease impeller installation, apply BOMBARDIER

LUBE lubricant on wear ring.
Insert impeller into wear ring. Manually rotate impeller and push so that it slides on impeller shaft
threads. Carefully engage threads making sure
they are well aligned.
Install impeller remover/installer tool into impeller
splines and tighten.
1
F00J0IA
1. Boot and ring
18, Cover
Install O-ring no. 27 to cover. Apply Loctite 518 on
O-ring. Install cover to impeller housing making
sure to properly position filler plug on top side.
F00J08A
1. Impeller remover/installer tool
CAUTION
Make sure thrust washer and bearing are

not wedged in shaft groove. To check, manually pull and push impeller housing, some
axial play must be felt (maximum 0.54 mm
(.021 in)).
F01J5IA
1. Filler plug toward top side of pump housing
08-02-16

Apply Loctite 242 (blue) on screw threads and

evenly tighten cover screws. Torque to 4 Nm
(35 lbfin).
Oil Fill
NOTE: It is highly recommended to perform a
leakage test prior adding the oil. Refer to PUMP
PRESSURIZATION in this sub-section.
Place housing horizontally as in its operating position so that filler plug is located on top. Remove
filler plug from cover. Pour SEA-DOO JET PUMP
SYNTHETIC OIL (P/N 293 600 011) in reservoir until oil comes level with bottom of hole. Let oil drain
into housing and after a few minutes add more oil
until it is level with bottom of filler hole. Oil capacity is 70 mL (2.4 oz).
CAUTION
This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands.
NOTE: When filling reservoir, oil must be poured
into cover quite slowly to allow complete housing
fill.
F00J0KA
1. O-rings
Apply Loctite 518 (Gasket Eliminator) on mating

surface.
Position venturi with bailer passages on top.
Apply Loctite 242 (blue) on threads of screws
no. 12.
NOTE: On the GTI and GTX models, install the reverse support with the venturi.
Install screws no. 12, lock washers no. 13 and
flat washers no. 14 then torque to 21 Nm
(16 lbfft).
1
F00J0JA
TYPICAL
1. Pour oil slowly until it is level with bottom of filler hole
11, Venturi
If needed, install new O-rings no. 10 around bailer
passages.
F02J0TA
17, Fitting
Apply Loctite PST 592 on plastic fitting threads.
Then thread fitting into pump housing until
threads are bottomed.
08-02-17

29, O-Rings
GS, GSI, GSX, GTI, GTX, HX and XP Models
Install O-rings no. 29 around bailer passages or
make sure they are in place if they were not removed.
PUMP PRESSURIZATION
Whenever doing any type of repair on jet pump, a
pressure test should be done to check for leakage.
Proceed as follows:
Remove drain plug from cover.
Apply Loctite PST 592 on threads of fitting tool
(P/N 295 000 086) then secure on cover.
to fitting.
Pressurize pump to a maximum of 70 kPa
(10 PSI).
NOTE: If there is a pressure drop spray soapy water around cover. If there are no bubbles, impeller
shaft, impeller shaft seal, or impeller housing is
leaking through porosity and has to be replaced.
Jet pump unit has to be disassembled. If jet pump
has been overhauled, the impeller shaft seal
no. 22 may be leaking; Add a small quantity of
Sea-Doo jet pump synthetic oil to wet the oil seal.
Let soak and recheck.
Disconnect pump gauge tester and remove fitting.
Check oil level. Refill as necessary.
Apply Loctite PST 592 to threads of filler plug
then secure it in cover.
INSTALLATION
28, Neoprene Seal
If neoprene seal is damaged, replace it with a new
one.
F00J0LA
Pump must maintain this pressure for at least

10 minutes.
CAUTION
Repair any leak, failure to correct a leak will

lead to premature wear of pump components.
08-02-18
F01J50A
TYPICAL
1. Neoprene seal
9, Jet Pump Housing

Apply Loctite 598 Ultra Black around bailer and
water supply fittings.

F01J0IA
1. Bailer tubes
2. Water inlet hose
F01J21A
1. Apply Loctite 598 Ultra Black where indicated
All Models
Generously apply synthetic grease on drive shaft
splines.
Make sure rubber damper is on drive shaft end.
Install jet pump. If necessary, wiggle jet pump to
engage drive shaft splines in impeller.
CAUTION
Some watercraft require a shim between

hull and pump; if shim has been removed at
pump removal, be sure to reinstall it, otherwise engine alignment will be altered.
Reinstall air vent tube support onto body (SP/SPX

models).
5, Nozzle
SP, GS, GTS, GTI and GTX Models
Insert bushings no. 3 in nozzle no. 5, positioning
their flanges from inside of nozzle.
Insert sleeves no. 2 in bushings no. 3.
Install nozzle no. 5 on venturi no. 11; position its
steering arm on RH side. Apply Loctite 242 (blue)
on screw threads (or use new screws with preapplied threadlocker). Install screws no. 1 and
locking disks no. 4 then torque to 20 Nm
(15 lbfft).
Apply Loctite 242 (blue) on stud threads of jet

pump housing.
Install flat washers no. 8, lock washers no. 7 and
nuts no. 6. Tighten nuts of impeller housing in
a criss-cross sequence and torque to 33 Nm
(24 lbfft).
NOTE: Slightly lubricate wear ring with BOMBARDIER LUBE lubricant to minimize friction during initial start.

Secure water supply hose and both bailer tubes to
impeller housing using tie raps.
08-02-19

Steering Cable
Refer to STEERING SYSTEM 09.
Trim System
Refer to PROPULSION SYSTEM 08-05.
Reverse Cable
2
1
F01J3BA
TYPICAL
1. Locking disks
WARNING
Whenever removing screw always renew

locking disks. Screw must be torqued as
specified.
SPX, GSI, GSX, HX and XP

Install nozzle/trim ring assembly.
Torque screws to 14 Nm (10 lbfft).
NOTE: Trim ring has a tight fit; to install, insert
both sides at the same time, taking care not to
break plastic bushings. Carefully use a plastic tip
hammer if necessary. Make sure steering arm of
jet pump is on right side and trim arm is above
venturi.
F01J5FA

08-02-20
Refer to PROPULSION SYSTEM 08-04.

Sub-Section 03 (DRIVE SYSTEM)
DRIVE SYSTEM
SP, SPX, GS, GSI, GTS and GTI Models
Loctite
271
11
2
6
5
18
10
2 Nm
(18 lbfin)
9
2 Nm
(18 lbfin)
8
15
Synthetic
grease
21
3
Synthetic
grease
15
F01I0ES
PARTS
FLAT RATE
08-03-1

GSX and GTX Models
11
1
2
6
5
18
2 Nm
(18 lbfin)
10
21
2 Nm
(18 lbfin)
8
15
Synthetic
grease
3
Synthetic
grease
15
F06I01S
08-03-2
PARTS
FLAT RATE

XP and HX Models
11
17
16
22 Nm
(16 lbfft)
Loctite 242
17
16
20
22 Nm
(16 lbfft)
Loctite 242
22 Nm
(16 lbfft)
Loctite 242
Loctite
515
Synthetic
grease
18
18
Loctite
271
10
6
7 Nm
(62 lbfin)
19
Loctite
515
13
Synthetic
grease
21
2 Nm
(18 lbfin)
12
4
8
2 Nm
(18 lbfin)
14
13
Synthetic
grease
15
F05I02S
PARTS
FLAT RATE
08-03-3

GENERAL
Jet pump must be removed to replace any components of the drive system. Refer to PROPULSION SYSTEM 08-02 for jet pump removal
procedure.
REMOVAL
Remove seat.
Remove PTO flywheel guard.
1, Large Clamp
Unfasten large clamp of PTO flywheel boot as follows:
Use pliers (P/N 295 000 069).
1
F01J29A
TYPICAL
1. Locking hooks
2, Small Clamp
Unfasten small clamp of PTO flywheel boot as follows:
Use pliers (P/N 295 000 054).
F01J0GA
Insert pointed tips of pliers in closing hooks.
F01B1TA
To open clamp, place flat side of plier on clamp

embossment, squeeze and twist plier.
F01J2AA
TYPICAL
1. Closing hooks
Squeeze pliers to draw hooks together and disengage windows from locking hooks.
F02J0PA
08-03-4

XP and HX Models
Remove rear access panel.
All Models
I
C
5,6, Floating Ring and O-ring

B
Hold floating ring no. 5 and compress boot no. 9;

then, pull out O-ring no. 6 from drive shaft groove.
D
E
3
H
D
4
F F
5
F01I05A
F05I03A
1. Floating ring
2. O-ring
3, Drive Shaft
Simply pull out drive shaft.
NOTE: If the drive shaft is jammed into PTO flywheel, make the following tool and use it in conjunction with the impeller housing remover (P/N
295 000 113) to withdraw drive shaft.
1. Use ball end mill for radius. This section of the slot should be
38 mm (1-15/32 in) deep
2. Drill 25 mm (1 in) hole in center to remove material
3. Weld all around
4. Drill 9 mm (11/32 in) hole
5. Drill through 9 mm (11/32 in)
6. Drill and tap 6 mm (1/4 in) holes
A. 305 mm (12 in)
B. 105 mm (4-1/8 in)
C. 16 mm (5/8 in)
D. 51 mm (2 in)
E. 36 mm (1-25/64 in)
F. 22 mm (7/8 in)
G. 17 mm (43/64)
H. 19 mm (3/4 in)
I. 35 mm (1-3/8 in)
J. 20.3 mm .18 (.800 in .007)
Mount on drive shaft puller the impeller housing

remover; then, install assembly on drive shaft using screws.
1
Raw Material:
1 aluminum alloy square of 51 mm (2 in)
305 mm (12 in).
2 aluminum rods of 28.5 mm (1-1/8 in) dia.
30 mm (1-3/16 in).
F01I06A
TYPICAL
1. Impeller housing remover
2. Drive shaft puller
3. Screws
08-03-5

CAUTION
Be careful not to damage hull rear section or

engine rubber mounts.
HX and XP Models
4, Rear Drive Shaft

Remove rear drive shaft.
NOTE: If the rear drive shaft is jammed, remove
the seal carrier no. 12 and front drive shaft no. 7
if necessary.
7, Front Drive Shaft

Remove shock absorber from lower support. Refer to SUSPENSION 10-02 for proper procedure.
Remove bolt, lock nut and sleeve from support.
3
F05I05A
1. Nut (6)
All Models
9, Boot
Loosen gear clamp no. 8 holding boot no. 9, then
carefully pull boot and carbon ring no. 10 from hull
insert.
10, Carbon Ring

Loosen gear clamp no. 21 then pull carbon ring
from boot no. 9.
11, PTO Flywheel

To remove PTO flywheel, the magneto flywheel
must be locked. Refer to ENGINE 03-04 and follow the procedure to lock the magneto flywheel.
NOTE: Do not remove the magneto flywheel.
F05I04A
1. Bolt
2. Lock nut
3. Sleeve

PTO flywheel is loosen using PTO flywheel remover (P/N 295 000 001).
Remove front drive shaft.
12, Seal Carrier

To remove the seal carrier from support, loosen
the 6 nuts no. 19.
F01J0TA
Insert special tool in PTO flywheel splines.
08-03-6

1
1
F01D4AA
TYPICAL
F01D1AA
TYPICAL
1. PTO flywheel remover (P/N 295 000 001)
Using a suitable wrench or socket, unscrew PTO

flywheel COUNTERCLOCKWISE when facing it
and hold extension handle locking the magneto
flywheel.
SPX, GSX, GTX, XP and HX Models

PTO flywheel is loosen using PTO flywheel remover (P/N 295 000 156).
F00B04A
F01D49A
TYPICAL
Install special tool.

1
NOTE: When splines of PTO flywheel are worn

out and special tool can not be used, proceed with
the following alternate method.
Use a pipe wrench and install it on PTO flywheel
as illustrated.
F00I01A
XP AND HX MODELS
1. PTO flywheel remover
08-03-7

1
2
3
F01I0FA
F06I02A
SPX, GSX AND GTX MODELS

1. PTO flywheel remover
Install the extension handle (P/N 295 000 125) on

the PTO flywheel remover. Loosen PTO flywheel
COUNTERCLOCKWISE when facing it.
DISASSEMBLY
HX and XP Models

Bearing and seals can be easily removed using
the bearing/seal remover tool (P/N 295 000 144).
1. Floating ring contact surface

2. Groove condition
3. Splines condition
Excessive deflection could cause vibration and

damage to drive shaft splines, impeller, flywheel
or floating ring.
Place drive shaft on V-blocks and set-up a dial
gauge in center of shaft. Slowly rotate shaft; difference between highest and lowest dial gauge
reading is deflection. Refer to the following illustration.
Maximum permissible deflection is 0.5 mm
(.020 in).
1
F01J11A
NOTE: The same tool is used for bearing and seal

removal of jet pump.
Properly support seal carrier when removing seals
and bearing.
F01J15A
PARTS INSPECTION
MEASURING DRIVE SHAFT DEFLECTION

1. Dial gauge
2. V-blocks
3, Drive Shaft
15, Damper
Inspect condition of splines.

Inspect condition of groove.
With your finger nail, feel contact surface of floating ring. If any irregular surface is found, renew
drive shaft.
Visually inspect shape of dampers for deformation

or other damage.
08-03-8

Inspect condition of O-rings and floating ring contact surface.
14, Needle Bearing
Properly support seal carrier when installing seals

and bearing.
CAUTION
Ensure to install stamped end of bearing

(showing identification markings) first on
tool. Never hammer the bearing into its
housing.
2
Install bearing with the bearing/seal installer tool

(P/N 295 000 107).
F01I0GA
1. O-rings
2. Floating ring contact surface
6, O-ring
Check also condition of drive shaft O-ring. Replace as necessary.
11, PTO Flywheel

Inspect spline condition of PTO flywheel.
F01J51A
1. Press bearing in its housing
4,14, Drive Shaft and Needle Bearing
NOTE: Bearing can also be installed with the

same driver used at disassembly. Center bearing
in longitudinal axis of housing.
Inspect seal carrier needle bearing and its contact

surface on drive shaft. Check parts for scoring, pitting, chipping or other evidence of wear.
ASSEMBLY
Assembly is essentially the reverse of disassembly procedure. However, pay particular attention
to the following.
F01J2TA
1. Push bearing centered in its housing
08-03-9

13, Seal
Install double-lip seal with protector toward jet
pump.
On both seals, raised edge of lip must be located
outwards of seal carrier.
Pack seals and bearing with synthetic grease (P/N

293 550 010).
12, Seal Carrier

Properly index flanges together.
Install seal carrier and hand tighten nuts only.
NOTE: Apply Loctite 242 (blue) on studs.
Install alignment tool at rear of watercraft.
2
1
1
2
3
3
F01J2FA
1.
2.
3.
4.
Double-lip seal toward engine

Double-lip seal with protector toward jet pump
Raised edge of lip outwards
Seal carrier
F01L2RC
1. Housing (P/N 295 000 090)

2. Alignment shaft (P/N 295 000 093)
Apply Loctite 518 all around seals outside diameter.

Seals can be carefully installed in housing using
bearing/seal installer tool (P/N 295 000 107).
Push seals until tool comes in contact with housing.
F05I07A
Carefully slide shaft through seal carrier.
F01J1YA
TYPICAL
08-03-10

F05I08A
F05I0FA
1. Alignment tool
2. Seal carrier
Torque seal carrier nuts no. 19 to 7 Nm (62 lbfin)

in a criss-cross sequence as per following illustration.
NOTE: It is very important to tighten nuts of seal
carrier in a criss-cross sequence to maintain its
alignment.
1
ENGINE SIDE SHOWN

1. Damper
2. Bushing
7,20, Front Drive Shaft and Coupler

Install front drive shaft no. 7 and coupler no. 20.
4,15, Rear Drive Shaft and Damper

Install damper no. 15 on rear drive shaft.
15, Damper
Install damper no. 15 on drive shaft no. 3.
NOTE: Make sure dampers were not left in PTO
flywheel or impeller.
3
F05I0EA
16,17, Damper and Bushing

Make sure to install dampers no. 16 and bushings
no. 17 on front drive shaft no. 8.
08-03-11

All Models
3, Drive Shaft
Position the O-ring no. 6 of the drive shaft in the

flange of the floating ring no. 5.
Install drive shaft.
CAUTION
Take care not to break the O-ring in the floating ring flange while inserting the drive
shaft.
Engage drive shaft splines in PTO flywheel. Rotate shaft to properly index splines. Make sure
boot is well positioned over shaft end.
4, Rear Drive Shaft

Install rear drive shaft.
CAUTION
Take care not to break the O-ring in the floating ring flange while inserting the drive
shaft.
F01I0DA
1. O-ring
2. Floating ring
Position the floating ring no. 5 between the carbon ring no. 10 and the PTO flywheel (seal carrier
for the HX and XP models).
Engage drive shaft splines in coupler no. 20. Rotate shaft to properly index splines.
All Models
Push the floating ring to compress the boot. Insert
the O-ring in the drive shaft groove.
F02I03A
TYPICAL
1. Floating ring
F02I04A
TYPICAL
Step 1 : Push floating ring
Step 2 : Insert O-ring in the groove
Slide the floating ring onto the O-ring.
08-03-12

1, Large Clamp
Secure large clamp no. 1 as follows:
Use pliers (P/N 295 000 069) as for removal.
Manually engage holding hook in large window.
This is a pre-clamping position only.
1
F02J0IA
1. Press to engage hooks in windows
NOTE: At installation, clamp tail should be in opposite direction of engine rotation.
2
F01J23A
PRE-CLAMPING POSITION
1. Holding hook
2. Large window
Insert pointed tips of pliers first in closing

hooks.
2
F01J23B
1. Engine rotation (counterclockwise)

2. Tail in opposite direction
F01J2BA
TYPICAL
1. Closing hooks
Squeeze pliers. When both large and small windows are directly over the 2 locking hooks,
press those windows down to engage hooks in
windows.
08-03-13

2, Small Clamp
To secure small clamp no. 2, place notch side of
plier on clamp embossment and squeeze plier.
XP and HX Models
Lubricate mid bearing with synthetic grease (P/N
293 550 010).
F05I09A
1. Grease fitting
F02J0PB
1. Squeeze plier
LUBRICATION
All Models Except the XP and HX Models
Using a grease gun, carefully lubricate PTO flywheel with synthetic grease (P/N 293 550 010),
until boot is just beginning to expand. At this
point, immediately stop greasing.
F01I0BB
08-03-14

Sub-Section 04 (REVERSE SYSTEM)
REVERSE SYSTEM
GTS Model
5
1
Synthetic
grease
2.5 Nm
(22 lbfin)
8 Nm
(71 lbfin)
7 Nm
(62 lbfin)
3 Nm
(27 lbfin)
10 Nm
(88 lbfin)
6 Nm
(53 lbfin)
8 Nm
(71 lbfin)
7
7 Nm
(62 lbfin)
10 Nm
(88 lbfin)
3 Nm
(27 lbfin)
Loctite
242
20 Nm
(15 lbfin)
F02J0NS
Loctite
242
PARTS
FLAT RATE
08-04-1

GENERAL
It is not necessary to remove reverse system
from watercraft for servicing. However reverse
system removal is necessary to replace reverse
support.
DISASSEMBLY
Remove storage tray from watercraft.
Press on vent tube upper part to enable to withdraw tube from body.
2
1
F02J04A
TYPICAL
1. Sliding block
2. Spring
Withdraw shift lever stem and locking lever no. 1

from sliding block no. 5, then slide off locking lever from stem.
F02L1MA
TYPICAL
1. Press on vent tube
3, Shift Lever
To remove shift lever, unhook spring no. 2 from
sliding block no. 5 and pull spring from shift lever
stem.
1
F02J05A
TYPICAL
1. Locking lever
4,5, Triangular Lever and Sliding Block

Remove screw, lock nut, washers and bushing
holding reverse cable to triangular lever.
Remove lock nut and washer holding sliding block
to triangular lever and to support.
Remove screw, lock nut, washer and bushing
holding triangular lever to reverse support.
08-04-2

7, Reverse Gate
1
Unhook reverse gate springs and remove ball joint

fasteners to release reverse cable from reverse
gate.
2
F02J06A
TYPICAL
1. Reverse support
2. Reverse cable
3. Triangular lever
6, Reverse Support
In order to have access to screw holding lower
part of reverse support, remove front seat by pulling on each side to release it from body.
Remove screw, lock nut and washers holding lower part of support.
Remove reverse cable from support.
Remove 2 Allen screws, lock nut and washer
holding guide plate and support.
F02J08A
1. Reverse cable
2. Reverse gate spring (each side)
Unscrew reverse gate retaining screws from venturi housing, then remove gate.
F02J09A
1. Screw (each side)
ASSEMBLY
3
F02J07A
TYPICAL
1. Guide plate
2. Allen screw
3. Screw and washer
to the following.
7, Reverse Gate
Install reverse gate with sleeve and washer. Apply
Loctite 242 (blue) on threads and torque to 20
Nm (15 lbfft).
08-04-3

CAUTION
Always hook reverse gate springs in order to

ease reverse gate operation.
Torque triangular lever screw to 8 Nm (71 lbfin).

Install sliding block to lever and torque nut to
8 Nm (71 lbfin).
1,5, Locking Lever and Sliding Block

Insert locking lever end in support hole then align
lever and sliding block holes.
F02J02B
1
1
1. Screws, washers and sleeves

F02J0DA
6, Reverse Support
For reverse support installation, torque screw to
8 Nm (71 lbfin) and Allen screws to 2 Nm
(18 lbfin).
4,5, Triangular Lever and Sliding Block

Insert bushing in triangular lever and then install
lever to reverse support.
TYPICAL
1. Support hole
3, Shift Lever
NOTE: Always install shift lever with its open end
facing left side of watercraft, then push shift lever
stem through locking lever no. 1 and sliding block
no. 5 holes.
F02J0CA
TYPICAL
1. Bushing
Install reverse cable to triangular lever with bushing, plastic washer(s) and flat washers.
Torque cable screw to 7 Nm (62 lbfin).
08-04-4
F02J0EA
TYPICAL
1. Install shift lever as shown

2, Spring
ADJUSTMENTS
Insert spring in lever stem hole and then install

curved end in sliding block groove.
7, Reverse Gate
Position handlebar in a straight ahead position,
nozzle should be parallel to rear of watercraft.
Using a square, set it to 129 3 mm (5-5/64
7/64 in), then position square end at the top middle of nozzle.
1
F02J0KA
TYPICAL
1. Sliding block groove
Shift Lever Lubrication

Lubricate sliding block support sliding area and triangular lever with synthetic grease. Also, lubricate sliding washer and shift lever stem.
F02J0HA
A. 129 3 mm (5-5/64 7/64 in)
Pull shift lever in REVERSE position.
F02D03A
3
F02J0GA
TYPICAL
1. Sliding washer
2. Sliding block
3. Support plate
TYPICAL
1. Shift lever in REVERSE position
With the gate down to REVERSE position it

should be at the specification.
NOTE: Push slightly on the gate in order to recover spring tension and to obtain proper position of
the gate.
08-04-5

Tighten adjustment nuts and recheck gate position.

Reinstall vent tube.
WARNING
Vent tube must be in place to provide proper

bilge ventilation.
F02J0FA
1
1
1. REVERSE position
If reverse gate needs to be readjusted, it can be

done at support with adjustment nuts. Turn cable
nuts to obtain position.
NOTE: If reverse gate adjustment is not done adequately, performance and steering control will be
reduced at reverse position.
F02L14A
1. Install vent tube
2
F02J06B
TYPICAL
1. Support
2. Adjustment nuts
08-04-6
Reinstall storage tray.

GTI and GTX Models

11
15
3 Nm
19 (27 lbfin)
Loctite 242
Synthetic
grease
16
Loctite
242
3.5 Nm
(31 lbfin)
13
20
2.5 Nm
(22 lbfin)
12
23
Sealant
732
18
17
6 Nm
(53 lbfin)
4 Nm
(35 lbfin)
3 Nm
(27 lbfin)
Loctite
242
14
2
7 Nm
(62 lbfin)
21
5
2.5 Nm
(22 lbfin)
10 Nm
(88 lbfin)
Loctite
242
6 Nm
6 (53 lbfin)
4
9 Nm
(80 lbfin)
7
10
8
9
1
4
22
9 Nm
(80 lbfin)
5 Nm
(44 lbfin)
F07J01S
PARTS
FLAT RATE
08-04-7

DISASSEMBLY
1, Reverse Gate
Put shift lever in reverse position.
Disconnect reverse cable by loosing bolt no. 2
and lock nut no. 3 from cable lever.
Loosen 2 Allen screws no. 4 and remove reverse
gate.
5, Cable Lever
Loosen Allen screw no. 6 and remove cable lever.
7,8, Pawl Lock and Spring

F07J03A
Remove roll pin no. 9.
1. Reverse cable
2. Interior lever
10, Reverse Gate Support

Loosen 4 bolts which retains reverse gate support
to venturi.
2
Loosen bolt no. 14 retaining the interior lever.

1
F07J04A
F07J02A
1. Bolt
2. Shift lever
1. Support
2. Bolt
Remove the interior lever and spring no. 15.
11, Interior Lever
16, Reverse Cable Support
Remove glove box.

Disconnect reverse cable by loosing bolt no. 12
and lock nut no. 13.
Remove retaining block no. 17 of reverse cable

support by loosing bolts no. 18.
Loosen 3 bolts no. 19 retaining reverse cable support to body.
Remove reverse cable support.
INSPECTION
Visually inspect parts for wear or cracks. Replace
parts as required.
08-04-8

ASSEMBLY
Assembly is essentially the reverse of disassembly procedures. However, pay particular attention
to the following.
CAUTION
Apply all specified torques and service products as per main illustration.
Make sure the shift lever action is smooth and

precise. Forward, neutral and reverse positions
should be easy to select with a detent position between each.
8, Spring
Make sure spring is properly installed. One end of
the spring is hooked in the pawl lock and the other
end is retained by the stopper lock nut.
15, Spring
Make sure to properly installed spring in reverse
cable support as per following illustration.
3
2
F07J06A
1. Pawl lock
2. Spring
3. Stopper lock nut
F07J05A
1, Reverse Gate
1. Spring
11,20, Interior Lever and Shift Lever
When installing the reverse gate, pay attention to

position its lever behind the reverse gate support
stopper.
1
Install the interior lever in a rotating movement.

Engage properly the interior lever tabs in the shift
lever slots.
1
F07J07A
1. Stopper
F07J04B
1. Shift lever
2. Interior lever tabs
08-04-9

21, Reverse Cable

Install reverse cable to cable lever as per following
illustration.
1
2
3
F07J09A
F07J08A
1.
2.
3.
4.
5.
5 4
4 2
Bolt
Ball joint
Cable lever
Flat washer
Lock nut
1. Reverse cable support

2. Loosen bolts
3. Adjustment nut
When adjustment is completed, there should be

gap of 2 to 3 mm (5/64 to 7/64 in) between handle
and left cover.
CAUTION
Ensure cable ball joint is parallel to cable lever (90 5) to minimize tension on cable.
Adjust as required.
ADJUSTMENT
Put shift lever in forward position.
Pull shift lever approximately 50 mm (2 in) and
push it back slowly in forward position.
The pawl lock no. 7 should be engaged in the anchor no. 22.
If not, adjust reverse cable. Loosen 2 bolts no. 18
at reverse cable support no. 16. Turn adjustment
nut no. 23 as required.
08-04-10
F07J0AA
A. 2 to 3 mm (5/64 to 7/64 in)

Sub-Section 05 (VARIABLE TRIM SYSTEM)
VARIABLE TRIM SYSTEM
MANUAL TRIM
6
7
8
21 Nm
(16 lbfft)
1
10
Loctite
242
13 Nm
(10 lbfft)
10 Nm 3
(89 lbfin)
Loctite 242
5
Loctite
242
13 Nm
(10 lbfft)
Loctite 242
13 Nm
(10 lbfft)
F05J07S
PARTS
FLAT RATE
08-05-1

REMOVAL
Loosen screw no. 1, bolt no. 2 and lock nut no. 3
retaining support from trim ring.
3
F05J08A
1. Screw
2. Bolt
3. Lock nut
Remove manual trim.
4, Trim Ring
To remove trim ring/nozzle assembly from venturi,
loosen side screws no. 5 of trim ring.
DISASSEMBLY
Loosen nut no. 6 from support; then, remove rubber washer no. 7 and half bushings no. 8.
Loosen adjustment screw no. 9 to remove
threaded pivot no. 10.
ASSEMBLY AND INSTALLATION

Assembly and installation are essentially the reverse of removal and disassembly procedures.
For torque specifications and service products to
be used, refer to the main illustration at the beginning of this sub-section.
08-05-2

ELECTRIC TRIM
7
12
7 Nm
(62 lbfin)
11
6
8
10
5
4
6 Nm
(53 lbfin)
3
2
10 Nm
(88 lbfin)
1
13 Nm
(10 lbfft)
2.5 Nm
(23 lbfin)
13 Nm
(10 lbfft)
Loctite
242
7 Nm
(62 lbfin)
Loctite
242
Loctite
242
13 Nm
(10 lbfft)
F01J56S
PARTS
FLAT RATE
08-05-3

GENERAL
To test VTS control module, motor or switch, refer

to ELECTRICAL SYSTEM 07-05.
REMOVAL
Disconnect ball joint no. 1.
Loosen gear clamps no. 2.
Remove boot no. 3.
To loosen nut no. 4, use VTS socket tool (P/N 295
000 133).
F01J1XA
1. Remove nuts
2. Disconnect wires
Pull on motor to remove it.
9,10, Worm and Sliding Shaft

F01B2PA
Pull out VTS assembly no. 6 from bilge.
Simply pull on worm and sliding shaft in order to

remove them.
INSPECTION
DISASSEMBLY
2, Boot
7, Cover
Remove VTS cover by pressing on tabs.
1
Make sure boot is in good condition. If it is

cracked or teared, replace boot.
9, Worm
Inspect threads and splines of worm for wear. If
worm replacement is necessary, renew also sliding shaft.
VTS
F01J1WA
1. Press tabs to remove cover
8, Motor
Disconnect wires of motor.
Remove retaining nuts.
F01J25A
1. Inspect threads and splines
08-05-4

ASSEMBLY
INSTALLATION
to the following.

procedures. However pay particular attention to
the following.
8,9,10, Motor, Worm and Sliding Shaft
4,5, Nut and Seal
Apply synthetic grease to worm.

Screw worm to sliding shaft.
Mesh worm splines to gear of motor.
Place seal on nut. Make sure seal lips are facing

toward hull.
1
F01J2PA
F01J2LA
1. Mesh worm spline to gear of motor
Install motor, worm and sliding shaft in VTS housing.
1. Seal lips facing hull

2. Nut
Install nut with seal and torque to 13 Nm (10

Ibfft) using the VTS socket tool.
1, Ball Joint
SPX and XP Models
Install ball joint on RIGHT side of sliding shaft.
Torque fasteners to 10 Nm (88 lbfin).
NOTE: Install boot on sliding shaft before securing ball joint.
GSI and GSX Models
Install ball joint on LEFT side of sliding shaft.
Torque fasteners to 10 Nm (88 lbfin).
NOTE: Install boot on sliding shaft before securing ball joint.
F01J2GA
Tighten nuts no. 11 of motor to 7 Nm (62 Ibfin).

Connect wires of motor.
CAUTION
Make sure wire color codes match.

Install cover no. 7.
NOTE: Make sure seal no. 12 is in place.
08-05-5

ADJUSTMENT
Push on VTS button up position until motor stops.
When the nozzle is up (8), nozzle edge must not
interfere with venturi (there should be a gap of 1
mm (.039 in)).
NOTE: Activate timer to be able to position VTS.
1
2
F01J3IA
1. No interference
2. Nozzle up
If an adjustment is necessary, loosen jam nut of

ball joint at link rod. Turn adjustment nut of ball
joint to obtain the desired gap between trim ring
and venturi.
1
F06J01A
TYPICAL GSX MODEL SHOWN

1. Turn adjustment nut of ball joint
Tighten jam nut of ball joint to 2.5 Nm (23 lbfin)

when adjustment is completed.
08-05-6
Section 09 STEERING SYSTEM

TABLE OF CONTENTS
SP AND SPX MODELS..........................................................................................................
REMOVAL AND INSTALLATION .......................................................................................
STEERING ALIGNMENT ...................................................................................................
09-02-1
09-02-2
09-02-5
GTS MODEL...........................................................................................................................
REMOVAL AND INSTALLATION .......................................................................................
09-03-1
09-03-2
09-03-5
GS, GSI, GSX, GTI AND GTX MODELS...............................................................................

DISASSEMBLY...................................................................................................................
ASSEMBLY.........................................................................................................................
09-04-1
09-04-2
09-04-4
09-04-5
HX AND XP MODELS............................................................................................................
REMOVAL ..........................................................................................................................
DISASSEMBLY...................................................................................................................
ASSEMBLY AND INSTALLATION .....................................................................................
09-05-1
09-05-2
09-05-3
09-05-3
09-05-5
ALIGNMENT ..........................................................................................................................
09-06-1
09-01-1

Sub-Section 02 (SP AND SPX MODELS)
SP AND SPX MODELS
1 Nm
(8.5 lbfin)
19
6
7
14 Nm
(10 lbfft)
1 Nm
(8.5 lbfin)
3
2
8
3
2
0.5 Nm
(4 lbfin)
12
26 Nm
(19 lbfft)
8 Nm
(72 lbfin)
15 Nm
(11 lbfft)
14
15 Nm
(11 lbfft)
Synthetic
grease
17
11
7 Nm
(63 lbfin)
13
10
2.5 Nm
(22 lbfin)
15
SPX
13
6 Nm 16
(53 lbfin)
2 Nm
(18 lbfin)
18
6 Nm
(53 lbfin)
2.5 Nm
(22 lbfin)
10 Nm
(88 lbfin)
SP
F01K19S
PARTS
FLAT RATE
09-02-1


1, Cover
To replace the cover, loosen set screws no. 19 of
handlebar housing.
1
When installing the grip insert in the handlebar

no. 12, ensure that its notch is properly inserted
in the hole beneath the handlebar.
Install grip no. 4 on handlebar no. 12 matching it
to the hex form on the grip insert.
Install flat washer no. 7 and screw no. 6.
Torque screw to 14 Nm (10 lbfft).
Install cap no. 5.
3 5
F00K01A
1. Set screw
F01K1PA
Remove and reinstall 4 screws no. 2 and washers

no. 3.
1
1.
2.
3.
4.
5.
Grip insert
Grip
Flat washer
Screw. Torque to 14 Nm (10 lbfft)
Cap
CAUTION
Ensure to install flat washer otherwise screw

will damage grip end.
9,12, Steering Stem and Handlebar
F00K02A
1. Cover
2. Screws
4,8, Grip and Grip Insert

To remove grip, just pull out cap no. 5 from grip
end and remove screw no. 6 and washer no. 7.
Pull out grip.
To verify grip insert for damage, remove it from
handlebar.
09-02-2
REMOVAL
Disconnect wiring harnesses leading out of steering stem no. 9.
Disconnect throttle cable at carburetor.
Remove throttle cable from tie-blocks.
Unscrew bolts no. 16 retaining support no. 11 to
steering stem arm no. 10.

F01K17A
1. Bolts
2. Steering stem arm
Remove support no. 11 and steering stem arm

no. 10 from steering stem.
NOTE: It is not necessary to remove steering cable from steering stem arm.
Pull out handlebar assembly.
F01K0HA
REAR SUPPORT
1. Apply synthetic grease
2. Thrust ring shown removed for more clarity
CAUTION
While performing this procedure, take precautions to avoid damaging throttle cable
and wiring harnesses.
INSTALLATION
procedures. However, pay particular attention to
the following.
F01K1FA
FRONT SUPPORT
1. Apply synthetic grease
2. Thrust ring
13, Thrust Ring
NOTE: Make sure thrust rings are properly installed.
Lubricate with synthetic grease thrust ring of rear

support no. 14 and front support no. 15.
10,11, Steering Stem Arm and Support

Install support to steering stem arm.
NOTE: Insert lock nuts no. 17 in support. Screw
only a few threads of the bolts no. 16.
09-02-3

F01K0AA
F01K09A
TYPICAL
1. Support
3. Insert lock nuts
4. Screw only a few threads of the bolts
1. Install handlebar assembly

2. Route throttle cable and wiring harnesses at the same time
Push handlebar assembly until steering stem

no. 9 is well seated into steering supports no. 14
and no. 15.
Install handlebar assembly into rear support

no. 14, taking care at the same time to insert
throttle cable and wiring harnesses.
From bilge, route throttle cable and wiring harnesses into support no. 11 and steering stem arm
no. 10, and finally in front steering support
no. 15.
CAUTION
While performing this procedure, take precautions to avoid damaging throttle cable
and wiring harnesses.
3
2
F01K1BA
1. Rear support (steering collar)

2. Front support
3. Steering stem
Position steering stem arm no. 10 and support

no. 11 onto steering stem.
WARNING
Make sure integrated flat key of steering

stem arm is properly seated in steering stem
keyway. Steering stem arm must be locked
in place before torquing the bolts.
09-02-4

Torque bolts of steering stem arm no. 10 to

6 Nm (53 lbfin).
1
3
F01K1NA
1.
2.
3.
4.
5.
F01K1OA
SP MODEL
1. One washer each side of arm
2. Torque nut to 2 Nm (18 lbfin)
Steering stem
Steering stem arm
Support
Torque to 6 Nm (53 lbfin)
Integrated flat key must be seated in keyway and steering stem
arm locked in place
NOTE: Once steering stem arm is properly tightened, look between body and front support to
make sure there is no gap between steering stem
arm and its support. If there is a gap, components
are not properly installed.
Connect wiring harnesses.
Route throttle cable alongside bilge. Insert cable
barrel into carburetor throttle lever.
Insert throttle cable alongside choke cable in tieblocks.
For throttle cable adjustment, refer to FUEL SYSTEM 05-04.
18, Ball Joint

Secure steering cable ball joint to nozzle as per
following illustrations.
F06K01A
SPX MODEL
1. Ball joint on top of arm
STEERING ALIGNMENT
For steering alignment, refer to STEERING SYSTEM 09-06.
CAUTION
Ensure the ball joint is parallel ( 5) to the

nozzle arm.
09-02-5

Sub-Section 03 (GTS MODEL)
GTS MODEL
0
1
3.5 Nm
(30 lbfin)
30
8
Loctite
242
5
26 Nm
(19 lbfft)
14 Nm
7 6 (10 lbfft)
3
2
29
3.5 Nm
(30 lbfin)
15 Nm
(11 lbfft)
Anti-seize
lubricant
15
Loctite
242
28
17
15 Nm
(11 lbfft)
14
15 Nm
(11 lbfft)
Loctite
242
16
Loctite
242
28
Loctite
271
19
18
20
40 Nm
13 (30 lbfft)
9
10
30
6 Nm
(53 lbfin)
7 Nm
11 (63 lbfin)
12
7 Nm
(63 lbfin)
22
10 Nm
24 (88 lbfin)
2 Nm
(18 lbfin)
23
21
2.5 Nm
(23 lbfin)
F02K0BS
22
20 Nm 12
(15 lbfft)
25 26
27
PARTS
FLAT RATE
09-03-1


1, Cover
To replace the cover, loosen set screws no. 30 of
handlebar housing.

Install cap no. 5.
3 5
F01K1PA
F00K01A
1. Set screw
Remove and reinstall 4 screws no. 2 and washers

no. 3.
1
1.
2.
3.
4.
5.
Grip insert
Grip
Flat washer
Cap
CAUTION

F00K02A
1. Cover
2. Screws

To remove grip, just pull out cap no. 5 from grip
end and remove screw no. 6 and washer no. 7.
Pull out grip.
handlebar.
When installing the grip insert in handlebar
09-03-2
REMOVAL
Disconnect wiring harnesses leading out of dashboard hole.
Disconnect throttle cable at carburetor.
Remove throttle cable from tie-block and clip.
Unscrew nut no. 11 retaining locking plate no. 9;
then remove locking plate and washers no. 12.
Unscrew screw no. 13 of steering stem arm
no. 10.
Pull out handlebar and steering stem.
NOTE: It is not necessary to disconnect steering
cable to remove handlebar and steering stem.
28, Bushing
Inspect bushings for wear, cracks, scoring, etc.
Replace as necessary.

INSTALLATION
14, Grommet
Insert throttle cable through dashboard hole and
slide grommet on cable.
Insert grommet in dashboard hole and pull it from
inside bilge.
NOTE: To ease installation, apply water on grommet.
Insert wires of monitoring beeper and start/stop
button.
WARNING
The recommended torque and Loctite must

be applied on screw. Steering arm mortise
must seat properly on steering stem tenon.
2
1
Insert spring washer no. 15 and the shim no. 16

onto steering stem.
Insert steering stem into support no. 18.
5
6
4
F01K0VA
TYPICAL
1. Steering stem tenon
3. Mortise
4. Large flat washer with X
5. Lock washer
6. Screw, apply Loctite 271 and torque to 40 Nm (30 Ibfft)
3
4
F02K05A
1.
2.
3.
4.
Steering stem
Grommet
Spring washer
Shim
Position 8 mm flat washer no. 12 on steering

stopper screw then install locking plate no. 9 over
steering stem head screw.
NOTE: Ensure locking plate slot is inserted in
steering stopper screw.
Install a second 8 mm flat washer no. 12 and secure locking plate using jam nut no. 11. Torque
nut to 7 Nm (62 Ibfin).
Properly position steering stem arm no. 10 on

steering stem. Make sure to insert stem tenon
into arm mortise.
Apply Loctite 271 (red) on threads of screw
no. 13.
Install large flat washer no. 19, lock washer
no. 20 and screw no. 13. Torque screw to 40
Nm (30 Ibfft).
CAUTION
Always install large flat washer with the X

stamped side facing the lock washer.
09-03-3

1
2
3
5
F01K10A
STEERING CABLE NOT SHOWN FOR MORE CLARITY

1. Steering stem head screw
2. Locking plate
3. Steering stopper screw
4. 8 mm flat washers
F02K0DE
TYPICAL
1. Ball joint
2. Steering cable
3. Retaining block
F02K0CA
TYPICAL
21, Steering Cable

To replace steering cable, proceed as follows:
Disconnect ball joint no. 22 at steering stem arm
no. 19.
Loosen nuts no. 30 and open retaining block
no. 23.
09-03-4
Disconnect ball joint no. 22 at jet pump nozzle;

then, remove ball joint.
From bilge, unscrew nut no. 24 retaining steering
cable to hull.
Remove half rings no. 25, rubber washer no. 26
and retaining ring no. 27.
NOTE: Move shift lever in reverse position to
lower reverse gate. It will ease parts removal.
Remove steering cable from tie-block and clips.
Pull out steering cable.
to the following.
22, Ball Joint

Inspect and reuse ball joints only if they are in
good condition.
Secure steering cable ball joint to nozzle as per
following illustration.

CAUTION

nozzle arm.
F02K0HA
1. One washer each side of arm

STEERING ALIGNMENT
For steering alignment procedure, refer to STEERING SYSTEM 09-06.
09-03-5
Sub-Section 04

(GS, GSI, GSX, GTI AND GTX MODELS)
GS, GSI, GSX, GTI AND GTX MODELS 0

14 Nm
(10 lbfft)
3 23
5
1
21
26 Nm
(19 lbfft)
Loctite 242
10 Nm
(89 lbfin)
22
4 Nm
(35 lbfin)
4
12
14 Nm 13
(10 lbfft)
Loctite 242
14
7
7
8
18
16
11
15
Loctite 242
6 Nm
(53 lbfin)
6 Nm
(53 lbfin)
Loctite 242
17
3 Nm
(26 lbfin)
2.5 Nm
(22 lbfin)
10
9
6 Nm Loctite
(53 lbfin) 242
19
2.5 Nm
(22 lbfin)
10 Nm
(88 lbfin)
F07K01S
PARTS
FLAT RATE
09-04-1

Sub-Section 04 (GS, GSI, GSX, GTI AND GTX MODELS)
DISASSEMBLY
8, Cable Support
Loosen bolts no. 9 and remove retaining block

no. 10.
To remove grip, pull out cap no. 2 and remove

screw no. 3.
Pull out grip.
handlebar no. 22.
4, Cover
Remove grips no. 1.
Loosen set screws no. 5 of handlebar housings
no. 6.
1
F01K18C
F00K01A
1. Set screw
1. Retaining block
Remove 4 screws no. 7.
Loosen bolts no. 11 each side of steering support

no. 12.
2
1
F00K02A
F07K02A
TYPICAL
1. Cover
2. Screws
Remove cover.
09-04-2
1. Steering support
2. Bolt
Sub-Section 04

F07K03A
F07K05A
1. Steering support
2. Bolts
TYPICAL
1. Tie rap
2. Connectors
Remove support.
12, Steering Support
Disconnect the steering cable from the steering

stem arm no. 15.
Cut tie rap securing wiring harness boot.
1
2
F07K04A
2
F07K06A
1. Boot
2. Tie rap
Disconnect the throttle and choke cables from

carburetor levers.
Disconnect the wiring harnesses leading out of
steering stem and cut tie rap.

2. Steering cable
Loosen bolts no. 11 retaining cable support to

steering support (refer to cable support no. 8).
Loosen bolts no. 13 and lock nuts no. 14.
09-04-3

Sub-Section 04 (GS, GSI, GSX, GTI AND GTX MODELS)
ASSEMBLY
Assembly is essentially the reverse of disassembly procedures. However, pay particular attention
to the following.
CAUTION
Apply all specified torques and service products as per main illustration at the beginning
of this sub-section.
3
2
3
F07K07A
1. Steering support
2. Bolt
3. Lock nut
Remove steering support with handlebar, wiring

harnesses and cables.

When installing the grip insert no. 21 in the handlebar no. 22, ensure that its notch is properly inserted in the hole beneath the handlebar.
Install cap no. 2.

Loosen bolts no. 17 retaining steering stem arm
to support.
3 5
1
F01K1PA
1.
2.
3.
4.
5.
F07K08A

2. Bolt
Remove steering stem arm and support.
09-04-4
Grip insert
Grip
Flat washer
Cap
CAUTION


Sub-Section 04
GSI and GSX Models
Position steering stem arm and support onto

steering stem.
WARNING
Make sure the integrated flat keys of the

steering stem arm and support are properly
seated in steering stem keyways. Steering
stem arm must be locked in place before
torquing the bolts.
F06K01A
1. Ball joint on top of steering arm

GS, GTI, and GTX Models

1
1
2
F07K09A
1. Keyways
2. Integrated flat key
Replace lock nuts no. 18 by new ones.

Torque bolts no. 17 of steering stem arm to
6 Nm (53 lbfin).
19, Ball joint
F00J01A
Secure the steering cable ball joint no. 19 to the

nozzle as per following illustrations.
CAUTION

nozzle arm.
TYPICAL
1. Bolt
2. Flat washers
3. Lock nut. Torque to 2 Nm (18 lbfin)
STEERING ALIGNMENT
09-04-5

Sub-Section 05 (HX AND XP MODELS)
HX AND XP MODELS
7
0
1
5
14 Nm
(10 lbfft) 6
4
29
3
2
20
7 Nm
(62 lbfin)
7 Nm
(62 lbfin)
3 Nm
(27 lbfin)
26 Nm
(19 lbfft)
21
6 Nm
(53 lbfin)
15
6 Nm
(53 lbfin)
18
16
17
6 Nm
(53 lbfin)
10
Synthetic
grease
22
Synthetic grease
12
11
13
6 Nm
(53 lbfin)
15 Nm
(11 lbfft)
14
19
7 Nm
(62 lbfin)
23
28
24
2.5 Nm
(22 lbfin)
25
10 Nm
(89 lbfin)
27 26
F05K03S
PARTS
FLAT RATE
09-05-1

REMOVAL
1, Cover
Remove the hood cover by loosening the 4 plastic

Phillips screws. They may need to be replaced after one use.
Disconnect steering cable no. 9 from lever no. 10
of steering stem arm.
To remove the cover, loosen set screws no. 29 of

handlebar housing.
1
2
1
F05K04A
F00K01A
1. Set screws
1. Lever
2. Disconnect cable
Remove 4 screws no. 2 and washers no. 3.
Remove retaining block no. 11 of cable support.
F00K02A
TYPICAL
1. Cover
2. Screws
4, Grip
To remove grip, pull out cap no. 5 from grip end

and remove screw no. 6 and washer no. 7.
Pull out grip.
8, Grip Insert
F01K18C

handlebar.
1. Retaining block
Disconnect wires of monitoring beeper and start/

stop switch.
09-05-2

Open hood.
Disconnect throttle cable from carburetor linkage.
Pull out boot from hood and remove throttle cable
from boot.
Disconnect ball joint no. 23 of steering cable

no. 9 from jet pump nozzle.
Remove ball joint no. 23, boots no. 24 and
no. 28, nut no. 25, half rings no. 26 and O-ring
no. 27 from steering cable.
Remove steering cable from watercraft.
DISASSEMBLY
Disconnect link rod no. 17 from steering stem
arm no. 15 and lever no. 10.
Slide the steering stem arm no. 15 and support
no. 16 rearward and rotate them 90.
Remove the 2 M6 25 screws no. 21 and nuts
no. 22.
Remove the steering stem arm no. 15.
F05L0FA
1. Boot
Loosen bolts no. 13 and nuts no. 14 of steering

support no. 12.
2
F05K06A
Pull out steering stem no. 18 from steering support no. 12.
Remove lever no. 10 from cable support no. 19.
F05K04B
1. Steering support
2. Bolts
Remove steering system assembly.
9, Steering Cable
Disconnect steering cable from steering stem
arm lever no. 10.
Remove retaining block no. 11 of cable support
no. 19.
Pull out boot of steering cable and throttle cable
from hood.
ASSEMBLY AND INSTALLATION

Assembly and installation are essentially the reverse of removal and disassembly procedures.
However, pay particular attention to the following.
10, Lever
Prior installing lever, apply synthetic grease to pivot.
18, Steering Stem

Apply synthetic grease to front and rear thrust
bearing surface.
09-05-3


Position steering stem arm and support onto
steering stem arm no. 18.
3 5
WARNING
Make sure integrated flat keys of steering

stem arm and support are properly seated in
steering stem keyways.
4
2
F01K1PA
1.
2.
3.
4.
5.
Grip insert
Grip
Flat washer
Screw. Torque screw to 14 Nm (10 lbfft)
Cap
CAUTION

23, Ball Joint

Secure the steering cable ball joint no. 23 to the
nozzle as per following illustration.
F05K08A
1.
2.
3.
4.
5.
CAUTION

nozzle arm.
Keyways
Synthetic grease
Torque to 15 Nm (11 lbfft)
WARNING
Correct torque must be strictly followed.

When installing the grip insert in the handlebar
to the hex form on the grip insert no. 8.
09-05-4
F06K01A
TYPICAL
1. Ball joint on top of steering arm

STEERING ALIGNMENT
09-05-5

Sub-Section 06 (ALIGNMENT)
ALIGNMENT

To position handlebar in straight ahead position,
insert a pin in the steering support and turn the
handlebar until the pin locks the steering stem.
1
F01J03A
TYPICAL
1. Measure the distance on each side of the straight edge
F07K0AA
1. Steering support
2. Hole
SP, SPX, XP, HX and GTS Models

Position handlebar in straight ahead position by
measuring each side the distance from handlebar
grip end to floorboard.
If necessary, steering alignment adjustment

should be performed at steering cable support
near steering stem.
Loosen retaining block at cable support.
Turn adjustment nut as required.
F01K07A
TYPICAL
1. Measuring handlebar grip end/floorboard distance
Check jet pump nozzle position by placing a

straight edge on nozzle outer end. Measure the
distance on each side of the straight edge. It must
be equalled.
09-06-1

Sub-Section 06 (ALIGNMENT)
All Models Except GTS
GTS Model
2
2
F01K18A
1. Retaining block
2. Adjustment nut
3. Bolts
F03K03A
1. Retaining block
2. Adjustment nut
3. Bolts
All Models
After adjustment, torque retaining block bolts to
6 Nm (53 Ibfin).
CAUTION
Verify when the handlebar is turned completely to the left or right side, that there is
no interference with venturi housing.
09-06-2
Section 10 SUSPENSION
TABLE OF CONTENTS
DIRECT ACTION SUSPENSION............................................................................................
DISASSEMBLY...................................................................................................................
INSPECTION ......................................................................................................................
ASSEMBLY.........................................................................................................................
10-02-1
10-02-2
10-02-3
10-02-3
10-01-1
Sub-Section 02
(DIRECT ACTION SUSPENSION)
DIRECT ACTION SUSPENSION
XP and HX Models
Loctite
242
11
10
34 Nm 2
(25 lbfft)
Loctite
242
5 Nm
(44 lbfin)
3
10 Nm
(88 lbfin)
12
1
5 Nm
(44 lbfin)
34 Nm 7
(25 lbfft)
5
4
5 Nm
(44 lbfin)
Loctite
242
10 Nm
(88 lbfin)
8
F05L0GS
PARTS
FLAT RATE
10-02-1
Sub-Section 02 (DIRECT ACTION SUSPENSION)
DISASSEMBLY
1, Shock Absorber
Remove bottom cover of seat with grab handle
(HX model).
F05L0JA
1. Collar
Remove bolt no. 6 and lock nut no. 7 from shock

absorber lower support no. 8.
1
F05L0HA
TYPICAL HX MODEL SHOWN

1. Grab handle
2. Cover
Loosen collar no. 2 of outer boot no. 3, then pull

outer boot downward.
F05L0KA
1. Bolt
2. Lock nut
Tilt seat upward.

Loosen upper collar no. 9 of inner boot no. 5;
then, pull inner boot.
F05L0IA
1. Collar
Remove rear access panel from body.

From bilge, loosen lower collar no. 4, then push
inner boot no. 5 upward.
10-02-2
Sub-Section 02
(DIRECT ACTION SUSPENSION)
F05L0LA
1. Collar
F05L0NA
Remove bolt no. 10 and lock nut no. 11 from

shock absorber upper support.
Compress spring and remove cup.

Unload tool and remove spring from shock absorber.
INSPECTION
3,5, Boot
Inspect condition of boots. If there is any tear, renew boot(s).
1, Shock Absorber
F05L0MA
1. Bolt
2. Lock nut
Remove shock absorber/coil spring assembly.
3, Outer Boot
Pull outer boot to remove it from body.
12, Coil Spring

Install spring compressor tool (P/N 529 027 100)
in a vise.
WARNING
Do not attempt to dismantle a spring without using the proper tool.

Install shock absorber/coil spring assembly in
spring compressor tool.
Inspect shock absorber for wear. Extend and compress the piston several times over its entire
stroke; it should moves smoothly and with uniform resistance.
Pay attention to the following conditions that will
denote a defective shock absorber:
A skip or a hang back when reversing stroke at
mid travel.
Seizing or binding condition except at extreme
end of either stroke.
Oil leakage.
A gurgling noise, after completing one full compression and extension stroke.
Renew if any defects are present.
ASSEMBLY
Assembly is essentially the reverse of disassembly procedure. Refer to the main illustration at the
beginning of this sub-section for torque specifications and service products to be used.
10-02-3
Section 11 HULL/BODY
TABLE OF CONTENTS
ADJUSTMENT AND REPAIR ................................................................................................
SEAT ADJUSTMENT.........................................................................................................
STORAGE COMPARTMENT COVER ADJUSTMENT ......................................................
ACCESS PANEL ADJUSTMENT .......................................................................................
INLET GRATE REMOVAL...................................................................................................
RIDING PLATE....................................................................................................................
JET PUMP SUPPORT ........................................................................................................
DEFLECTOR .......................................................................................................................
DRAIN PLUG INSTALLATION ...........................................................................................
SEAT REMOVAL.................................................................................................................
SEAT COVER REPLACEMENT ..........................................................................................
BUMPER REPLACEMENT .................................................................................................
SPONSON REPLACEMENT ..............................................................................................
BAFFLE SEALING (GTS MODEL) .....................................................................................
HOOD REMOVAL ...............................................................................................................
DECALS REPLACEMENT ..................................................................................................
HULL AND BODY REPAIR .................................................................................................
TOOLS AND MATERIALS LIST .........................................................................................
HULL INSERT REPAIR .......................................................................................................
11-02-1
11-02-15
11-02-17
11-02-17
11-02-18
11-02-18
11-02-19
11-02-21
11-02-21
11-02-21
11-02-22
11-02-23
11-02-23
11-02-24
11-02-24
11-02-24
11-02-25
11-02-27
11-02-28
11-01-1
Sub-Section 02
(ADJUSTMENT AND REPAIR)
ADJUSTMENT AND REPAIR
SP and SPX Models
3
Loctite
271
Loctite
271
Loctite
271
5 Nm
(44 lbfin)
8 Nm
(71 lbfin)
Sealant
732
5 Nm
(44 lbfin)
Loctite
242
5 Nm 10
(44 lbfin)
Sealant
732
7
9
8
Loctite
242
Loctite 271
Sealant 732
6
15 Nm
(11 lbfft)
Body
F01L6HS
PARTS
FLAT RATE
11-02-1
Sub-Section 02 (ADJUSTMENT AND REPAIR)
13
12
Loctite
242
6 Nm
(53 lbfin)
15 Nm
(11 lbfft)
Sealant
732
Loctite
271
Loctite
271
12
Sealant 732
Sealant
732
12
1.5 Nm
(13 lbfin)
5
12
14
4
15
5
F01L6IS
11-02-2
PARTS
FLAT RATE
Sub-Section 02
GTS Model
2
Loctite 271
1
Loctite
271
3
5 Nm
(44 lbfin)
Loctite
271
8 Nm
(71 lbfin)
Loctite
242
5 Nm
(44 lbfin)
Loctite
242
Sealant
732
9 10 5 Nm
7 8
(44 lbfin)
6
Sealant
732
11
15 Nm
(11 lbfft)
Loctite
271
F02L26S
PARTS
FLAT RATE
11-02-3
7 Nm
(62 lbfin)
Loctite 242
13
12
15 Nm
(11 lbfft)
Loctite
271
4
Sealant 732
5
4
12
12
1.5 Nm
(13 lbfin)
5
14
12
F02L27S
11-02-4
PARTS
FLAT RATE
Sealant
732
15
Sub-Section 02
GS, GSI and GSX Models
5 Nm
(44 lbfin)
Loctite
242
5 Nm
(44 lbfin)
Loctite
242
Loctite
242
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
Loctite
271
3
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
Loctite
271
8 Nm
(71 lbfin)
Loctite
271
Loctite
242
Sealant
732
7
10
5 Nm
(44 lbfin)
6
F06L01S
PARTS
FLAT RATE
11-02-5
Loctite
271
Loctite
242
8 Nm
(71 lbfin)
13
15 Nm
(11 lbfft)
Sealant
732
Loctite
271
Sealant
732
12
15
2.5 Nm
(22 lbfin)
Sealant
732
4
5
12
12
14
12
F06L02S
11-02-6
PARTS
FLAT RATE
Sub-Section 02
GTI and GTX Models

Loctite
271
5 Nm
(44 lbfin)
Loctite
271
5 Nm
(44 lbfin)
Loctite
242
8 Nm
(71 lbfin)
3
Loctite
271
Loctite
242
5 Nm
(44 lbfin)
10
8 Nm
(71 lbfin)
Loctite
271
Loctite
242
Sealant
732
10
5 Nm
9 (44 lbfin)
Body
Left
side
only
Loctite
271
Sealant
732
15 Nm
(11 lbfft)
F07L03S
PARTS
FLAT RATE
11-02-7
Loctite
271
Loctite
242
8 Nm
(71 lbfin)
13
12
15 Nm (11 lbfft)
Loctite
271
Loctite
271
8 Nm
(71 lbfin)
Sealant
732
Sealant
732
12
12
14
11-02-8
15
F07L04S
PARTS
12
FLAT RATE
1.5 Nm
(13 lbfft)
Sealant
732
Sub-Section 02
1.4 Nm
(12 lbfin)
8 Nm
(71 lbfin)
0.8 Nm
(7 lbfin)
Loctite
242
Loctite
242
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
8 Nm
(71 lbfin)
Loctite
242
3 Nm
(26 lbfin)
Loctite 242
5 Nm
(44 lbfin)
F07L05S
PARTS
FLAT RATE
11-02-9
Loctite 242
4 Nm
(35 lbfin)
5 Nm
(44 lbfin)
Loctite 242
Loctite 242
4 Nm
(35 lbfin)
Loctite 242
5 Nm (44 lbfin)
Loctite 242
F07L06S
11-02-10
5 Nm (44 lbfin)
PARTS
FLAT RATE
Sub-Section 02
HX Model
12
13
Loctite
271
Body
Body
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
4
5
12
Loctite
271
14
Body
12
4
F05L0PS
15 Nm
(11 lbfft)
2.5 Nm
(22 lbfin)
12
5
Sealant
732
PARTS
15
FLAT RATE
11-02-11
4 Nm
(35 lbfin)
Body
Loctite
242
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
8 Nm
(71 lbfin)
Loctite
242
8 Nm
(71 lbfin)
F05L0QS
11-02-12
PARTS
FLAT RATE
Body
Sub-Section 02
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
17
1.2 Nm
(11 lbfin)
4 Nm
(35 lbfin)
5 Nm 20
(44 lbfin)
Loctite
242
18
19
4 Nm
(35 lbfin)
5 Nm
(44 lbfin)
21
Body
13 Nm
(10 lbfin)
F05L0RS
PARTS
FLAT RATE
11-02-13
16
Loctite
242
6 Nm
(53 lbfin)
6 Nm
(53 lbfin)
22 Nm
(16 lbfft)
F05L0SS
11-02-14
PARTS
FLAT RATE
Sub-Section 02
SEAT ADJUSTMENT

Adjust seat retainer no. 1 as per following specifications:
2
A
1
2
A
3
F02L24A
GTS MODEL
1. Front hook
2. Adjustment nut (Loctite 271)
3. Nut (Loctite 242). Torque to 8 Nm (71 lbfin)
A. 22.5 (+1, 0) mm (51/64 (+1/32, 0) in)
Adjust lock pin no. 2 as per following specifications:
F02L24A
SP, SPX, GTI AND GTX MODELS

1. Seat retainer
3. Nut (Loctite 242). Torque to 8 Nm (71 lbfin)
A. 25 1 mm (63/64 3/64 in)
3
F02L25C
3
F02L24A
GS, GSI AND GSX MODELS

1. Seat retainer
2. Adjustment nut (apply Loctite 271)
3. Nut (apply Loctite 242 and torque to 8 Nm (71 lbfin)
A. 21 1 mm (53/64 3/64 in)
SP AND SPX MODELS

1. Lock pin
A. 37 1 mm (1-29/64 3/64 in)
11-02-15
1
2
A
A
F06L03A
F07L08A
GTI AND GTX MODELS FRONT SEAT

1. Lock pin
A. 39 1 mm (1-35/64 3/64 in)

1. Lock pin
A. 33.5 1 mm (1-5/16 3/64 in)
3
F02L25C
GTS MODEL
1. Lock pin
A. 38 1 mm (1-1/2 3/64 in)
11-02-16
F06L03A
GTI AND GTX MODELS REAR SEAT

1. Lock pin
A. 33.5 1 mm (1-5/16 3/64 in)
Sub-Section 02
STORAGE COMPARTMENT
COVER ADJUSTMENT

Adjust lock pin no. 3 as per following specifications:
A
3
A
F07L09A
GTI AND GTX MODELS

1. Lock pin (apply Loctite 242)
2. Rubber washer
3. Flat washers
A. 39.2 1 mm (1-35/64 3/64 in)
3
F02L25C
SP, SPX AND GTS MODELS

1. Lock pin
A. 37 1 mm (1-29/64 3/64 in)
NOTE: The GTI and GTX models have a floating

type lock pin. It is normal to have a front and aft
play of the lock pin. To adjust, tighten lock pin until
any vertical play is eliminated. Make sure a front
and aft play remains when pressing by hands.
ACCESS PANEL ADJUSTMENT

2
HX Model Only
Adjust lock pin no. 3 of access panel as per following specifications:
A
F06L04A

1. Lock pin (apply Loctite 271)
2. Adjustment nut
A. 34 1 mm (1-11/32 3/64 in)
3
F02L25C
1.
2.
3.
A.
Lock pin
Adjustment nut (Loctite 271)
Lock nut. Torque to 5 Nm (44 lbfin)
37 1 mm (1-29/64 3/64 in)
11-02-17
Adjust bolts no. 16 of access panel arms as per

following specifications:
1
F05L0VA
1. Lock nut. Torque to 22 Nm (16 lbfft)

A. 32 1 mm (1-17/64 3/64 in)
INLET GRATE REMOVAL

Loosen screws and remove inlet grate.
NOTE: An impact screwdriver should be used to
loosen tight screws.
F05J03A
TYPICAL
1. Hydraulic bottle jack
2. Steel plates
Installation
Apply Loctite 598 Ultra Black as indicated by the
shaded areas in the next illustrations. Follow also
the torquing sequence (if applicable) as shown in
the same illustrations.
RIDING PLATE
Removal
Remove inlet grate.
Remove jet pump. Refer to PROPULSION
SYSTEM 08-02.
Remove the speed sensor from the riding plate (if
applicable).
Loosen riding plate screws.
NOTE: An impact screwdriver should be used to
loosen tight screws.
Using a low height hydraulic bottle jack and 2
steel plates, pry out riding plate.
F01J1VA
SP, SPX AND GTS MODELS

1. Apply Loctite 598 Ultra Black as indicated by the shaded area
11-02-18
Sub-Section 02
82
71
F05K02A
F07L0DA
GS, GSI, GSX, GTI AND GTX MODELS
TYPICAL
1. Unscrew nut
Remove ball joint, boot, nut, half rings and O-rings

from reverse cable (GTI and GTX models).
Remove boot and nut from VTS sliding shaft (XP,
GSI and GSX models).
Disconnect water supply hose, water return hose
and bailer hoses.
F05J06A
HX MODEL
JET PUMP SUPPORT

GS, GSI, GSX, GTI, GTX, XP and HX Models
Removal
Remove jet pump. Refer to PROPULSION SYSTEM 08-02.
Remove inlet grate and riding plate.
Remove ball joint, boot, nut, half rings and O-rings
from steering cable.
F05J0DA
TYPICAL HX MODEL SHOWN
HX Model Only
Disconnect engine drain hose.
Disconnect engine exhaust hose.
11-02-19
NOTE: Shims may have been installed between

support and body. Do not remove these shims,
otherwise jet pump alignment will be altered.
Installation
shaded areas in the next illustrations. Follow also
the torquing sequence as shown in the same illustrations.
3
F05D04A
GS, GSI, GSX, GTI, GTX, XP and HX Models

Remove nuts, lock washers and flat washers retaining jet pump support.
1
F07L0CA
GS, GSI, GSX, GTI AND GTX MODELS
F07L0AA
TYPICAL GTX MODEL SHOWN

1. Remove nuts
Using a heat gun, heat jet pump support until it is

possible to pull it.
F05J0EA
HX MODEL
11-02-20
Sub-Section 02
DEFLECTOR
SEAT REMOVAL
HX Model Only
Remove seat bottom cover no. 17 and grab handle no. 18.
Removal
Using a heat gun, heat deflector and pry it using a
piece of wood.
Installation
shaded area in the following illustration.
F05L0HB
1. Handle
2. Cover
Loosen collar of coil over shock outer boot; then,

pull outer boot downward.
F07L0BA
DRAIN PLUG INSTALLATION

Refer to the following illustration to install drain
plug no. 15.
2
1
4
F05L0IA
1. Collar
3
4
F05L13A
1.
2.
3.
4.
Drain plug
Gasket and 732 sealant
Torque screws to 1.5 Nm (13 lbfin)
From inside bilge, apply 732 sealant on screws
11-02-21
Loosen upper collar of coil over shock inner boot;

then, pull boot downward.
Seat installation is essentially the reverse of removal procedure. Refer to the main illustration of
seat at the beginning of this sub-section for proper torque specifications and service products to
be used.
SEAT COVER REPLACEMENT

Install staples with an electric tacker such as Arrow tacker no. ETN-50 or with a manual tacker
such as Arrow tacker no. T-50.
NOTE: For an easier installation, its highly recommended to use an electric tacker.
Ensure that the seat rest firmly against a hard surface such as a piece of wood. This is done to get
the staples completely pushed in place.
F05L0LA
1. Collar
Remove bolt and lock nut from shock absorber

upper support.
F05L0MA
1. Bolt
2. Lock nut
Tilt seat.
Loosen side screws no. 19 retaining seat frame
to pivot blocks no. 21.
Lower seat.
Loosen upper screws no. 20 retaining seat frame
to pivot blocks no. 21.
Remove seat.
11-02-22
2
F01L3YA
TYPICAL
1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)
After cover installation cut all around the excess

of material.
Sub-Section 02
BUMPER REPLACEMENT
SPONSON REPLACEMENT
1. Remove trim no. 5 from side bumper rail

no. 4.
2. Drill pop rivets no. 12 to remove side bumper
rail no. 4.
3. Mark hole positions on body straight and bow
sections.
2
RES
F01L4GA
TYPICAL
1. Front bumper
2. Corner bumper
3. Straight section
4. Bow section
Remove seat (access cover for the XP model).

Remove air vent tube support (SP, SPX, GS, GSI
and GSX models).
Remove muffler.
From bilge, unscrew sponsons no. 6 using a 10
mm deep socket with an extension.
Remove sponsons no. 6. Clean any residues of
sealant adhesive on hull.
Install gaskets no. 7 on new sponsons no. 6.
Apply sealant 732 (P/N 293 800 006) or sealant
adhesive (P/N 293 800 033) around sponson
studs.
Apply Loctite 242 (blue) on sponson studs.
Install sponsons no. 6 on hull.
From bilge, first insert flat washers no. 8 over
sponson studs, then lock washers no. 9. Secure
with lock nuts no. 10. Tighten to 5 Nm (44
lbfin).
NOTE: To ease flat washer and lock washer installation, use a flexible 4-claw Snap-on pick-up
tool.
4. Slide bumper rail no. 4 under front bumper

no. 13.
5. Using a 4.80 mm (3/16 in) drill bit, drill first
hole through bumper rail no. 4 at front of bow
section. Use locating mark as a guide. Then
install a rivet no. 12.
CAUTION
When drilling, be careful not to damage

bumper rail and/or hull.
6. Position bumper rail no. 4 properly onto body
and cut excess length if necessary.
7. Slide bumper rail no. 4 in corner bumper
no. 14.
8. Using hole positions previously marked on
body, drill holes in bumper rail no. 4 and install
rivets no. 12.
9. Install trim no. 5 using soapy water.
10. Repeat procedure for the other side.
F01P09A
Reinstall muffler. Tighten hose clamps to 4 Nm

(35 lbfin).
Reinstall air vent tube support (SP, SPX, GS, GSI
and GSX models).
Reinstall seat.
Clean hull and sponsons of any sealant adhesive
surplus.
WARNING
Recommended torques and use of Loctite

must be strictly followed.
11-02-23
BAFFLE SEALING (GTS MODEL)
Installation
Apply Sikaflex primer 449 (P/N 293 530 012) on

rear baffle no. 11 and body sections to be sealed.
There are 2 types of decals used on watercraft.

One has a protective film on back side and the
other has a protective film on both sides. They are
used on 3 types of materials; plastic, gelcoat and
metal.
CAUTION
Allow at least 30 minutes for primer to cure.

Apply Sikaflex sealant 221 (P/N 293 530 011) on
rear baffle section to be sealed.
Before using the watercraft wait 3 days for Sikaflex curing time.
HOOD REMOVAL
HX and XP Models
Disconnect throttle and choke cables at carburetor linkage.
Disconnect wiring harnesses of start/stop button,
monitoring beeper, safety lanyard switch and
gauge(s).
Loosen bolts and nuts of hinge from watercraft
body.
Disconnect the gas assist cylinder (XP model).
Remove hood.
Hood installation is essentially the reverse of removal procedure. Refer to the main illustration of
hood at the beginning of this sub-section for proper torque specifications and service products to
be used.
DECALS REPLACEMENT
Removal
Using a heat gun warm up one end of decal for a
few seconds until decal can roll off when rubbing
with your finger.
Pull decal slowly and when necessary apply more
heat to ease removal on the area that has to be
peeled off.
If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch
while pulling off, stop heating and wait a few seconds to let it cool, then peel it off.
11-02-24
DECALS HAVING A PROTECTIVE FILM ON

BACK SIDE ONLY
These decals usually contain written information
(ex.: warning) and are used on gelcoat or metal.
Clean surface with a good solvent such as
ACRYLICLEAN DX 330 from PPG or equivalent
(refer to manufacturer instructions).
Using a pencil and the decal as a template, mark
the area where decal will be located.
Remove half of the decal back protective film and
align decal with marks. Start sticking it from center and remove the other half of the film to stick it
completely. Carefully squeegee decal beginning
at center and working outward using, firm, short,
overlapping strokes.
DECALS HAVING A PROTECTIVE FILM ON
BOTH SIDES
These decals usually contain graphics and are
used on gelcoat or plastic.
INSTALLATION ON GELCOAT
Clean surface with a good solvent such as ACRYLI-CLEAN DX 330 from PPG or equivalent (refer to
manufacturer instructions).
For best result apply an activator (P/N 293 530
036) to prepare the surface using a clean cloth.
After a few seconds, when the activator evaporates, the surface is ready.
Using a pencil and the decal as a template mark
For better adhesion a dry application is recommended, however, to ease decal installation a
mild solution of soapy water can be sprayed over
surface where decal will be installed.
Remove back protective film from decal and align
decal with marks. When well aligned squeegee
decal beginning at center and working outward
using firm, short, overlapping strokes.
Remove front protective film once decal has adhered to hull.
Sub-Section 02
INSTALLATION ON PLASTIC (STORAGE

COVER)
Clean surface with isopropyl alcohol.
Using a pencil and the decal as a template, mark
Apply an activator (P/N 293 530 036) to prepare
the surface using a clean cloth. After a few seconds, when the activator evaporates, the surface
is ready.
CAUTION
Do not use soapy water to locate decal on

plastic parts.
Remove back protective film from decal and carefully align decal with marks. When well aligned
squeegee decal beginning at center and working
outward using firm, short, overlapping strokes.
Remove front protective film once decal has adhered.
HULL AND BODY REPAIR

General
Gelcoat is the smooth and durable cosmetic finish
which coats the fiberglass hull and body of a SeaDoo watercraft. It also provides a protective barrier against water and sun. It consists of a mixture
of resin, pigment (coloring), fillers, monomers and
catalyst which is sprayed into the mold.
The body and hull of the Sea-Doo are constructed
of chopped fiberglass, saturated with resin. It is
sprayed on the layer of gelcoat along with pieces
of fiberglass mat, cloth and woven rowing which
are added at required areas. This type of construction is very accommodating for high quality repairs. With patience, the proper techniques and
materials, a damaged area can be restored to an
original finish.
NOTE: Fiberglass repair kit is available through

automotive or marine suppliers. Gelcoat repair
kits are available through regular channel.
WARNING
Protect skin, wear gloves when in contact

with resin, hardeners and gelcoat. A barrier
skin cream may also be used. Do not expose
area to open flame or lit cigarette. Some of
the materials are flammable. Protect eyes,
wear safety glasses when grinding, sanding
or spraying. Use a dust mask when sanding
or grinding. When spraying wear a respirator or paint mask. Always read warning labels on products.
Air Bubbles
Possible Cause:
Air pocket trapped between layers of laminate
and gelcoat.
PREPARATION OF SURFACE
Remove all of the damaged gelcoat surrounding
the air bubble with a putty knife or preferably a
carbide grinding tip. Make sure all loose and weak
areas are completely removed. Sand a small area
of the gelcoat surface with 220-grit sandpaper. If
needed, sand the cavity itself. These areas must
have a rough surface to allow the gelcoat putty to
bond properly.
FILLING THE CAVITY
The prepared surface must be cleaned with acetone on a cloth. Use the Bombardier gelcoat repair
kit (P/N 295 500 100). Follow the mixing instructions in the kit when preparing the gelcoat putty.
Carefully mix the required amount while making
sure there are no air bubbles in the mixture. With
a putty knife, fill the repair area and cover with
plastic film. Curing time may depend on temperature, amount of putty and percentage of catalyst.
After 2 hours, press lightly on the surface with fingers to test the hardness. When the area becomes hard, remove the plastic film.
11-02-25
SANDING
Begin block sanding the patch with 320-grit sandpaper until you come close to the original surface.
Remove dust with a water soaked cloth and continue sanding with a 400-grit wet paper. Finish
wet sanding with a 600-grit to remove deeper
scratches. If needed you can wet sand with finer
grit paper such as 1000-grit.
BUFFING AND WAXING
Buff the surface using a heavy duty polisher with
a buffing pad. Make sure the pad is free of dirt or
you may damage the gelcoat. Carefully begin
buffing with a white medium compound. Finish
off using a fine compound. While buffing, pay
close attention to avoid overheating the surface.
Blisters
Possible Causes:
Insert catalyst.
Improper catalyst/gelcoat ratio.
A blister is a visible bump on the watercraft surface that may not necessarily come right through
the gelcoat layer. In the case of only a few blisters,
follow the same repair procedure as for air bubbles. If they are numerous and in close concentration, spray liquid gelcoat to achieve proper repair.
This procedure is covered in Minor Gelcoat Fractures.
Minor Gelcoat Fractures

Possible Causes:
Flexing of fiberglass laminate.
Gelcoat thickness.
Direct result of impact.
In case of fractures which have not penetrated
past the gelcoat layer, the repair concerns the
gelcoat only. If flex cracking or impact are evident,
then additional reinforcement may be necessary.
This subject will be covered in Compound Fractures.
PREPARING THE SURFACES
Small Fractures
Open the cracks up with a sharp triangular can
opener or preferably a carbide tipped die grinder.
The V groove will provide a good bonding area for
the gelcoat. With 220-grit sandpaper, sand the
sides of the notched out areas.
11-02-26
Numerous Fractures
Using a grinder with a 24-grit disk, remove the
gelcoat. Sand the area edge with 220-grit sandpaper.
FILLING THE REPAIR AREA
Small Fractures
Refer to the same procedure as in the Air Bubbles.
Numerous Fractures Over Large Surface:
Prepare the area for spray application of liquid
gelcoat. Wipe down the surface with acetone.
Mask the area off to protect the watercraft from
overspray.
Mix the needed quantity of gelcoat and catalyst
according to suppliers recommendations. The
gelcoat can be thinned with acetone up to 10%. If
it needs more consistency you can add cabosil.
Make sure that the air supply is free of oil, dirt and
water.
Test spray the gelcoat mixture on paper to verify
its consistency and pattern. You may have to apply 5 or 6 coats to cover the area properly. Overlap
each coat further than the last, leaving at least 30
seconds between passes. Avoid trying to coat the
surface with only a few heavy coats, this will not
allow the gelcoat to dry properly.
Apply a coat of polyvinyl alcohol to seal off the air
and protect the gelcoat surface from dust. PVA
speeds up the curing process because gelcoat
will not cure properly when exposed to air.
SANDING
Wash the polyvinyl alcohol off with water. Depending on the size of the area repaired, you can
either block sand as per previous procedure or
you may use an air sander. Sand the surface down
with progressively finer grits of sandpaper until
the desired finish is achieved.
BUFFING AND WAXING
Buff the surface using a heavy duty polisher with
a buffing pad. Make sure the pad is free of dirt or
you may damage the gelcoat. Carefully begin
buffing with a white medium compound. Finish
off using a fine compound. While buffing, pay
close attention to avoid overheating the surface.
Sub-Section 02
Compound Fractures
Possible Causes:
Thickness of fiberglass laminate.
Direct result of impact.
Compound fractures are those that have gone
past the gelcoated surface and in through the layers of fiberglass laminate. Two types of repairs
have to be performed. The first is to restore the
structural integrity of the damaged area. Fracture
types can vary from a simple crack to a large hole.
Usually, fiberglass reinforcement becomes necessary, especially if the fracture can be attributed
to weakness. The final part of the repair is the
gelcoating, which cannot be done until the interior
and exterior laminate surfaces have been repaired.
Outside
Remove the damaged gelcoat and fiberglass with
a 24-grit disk using a power sander. Grind outward
at least 2 inches from the fracture to allow the
patch to bond to strong material. Cut enough pieces of fiberglass mat necessary to build up the area. The pieces should be cut so they overlap each
other by at least a half inch. For a smoother finish,
the last layer should be fiberglass cloth. If the fracture is small enough all you may have to do is fill
the area with an epoxy filler.
Inside
For the interior repair, you can grind more. This
will allow for more fiberglass material which will
strengthen the area. If the fracture opening is too
large after surface preparation, you may need a
backing support to cover the opening. Cut alternating pieces of fiberglass mat and cloth in overlapping sizes.
PATCHING THE REPAIR AREA
Outside
The outside should be done first. Wipe clean the
area with acetone on a cloth, then mask off area.
For a small crack use an epoxy filler in the same
way you would use Bombardiers gelcoat repair
putty. When laying up a larger area you will use
mat, cloth and fiberglass resin and hardener. Use
a clean container to mix the resin, mix only what
you will need. Follow the recommended catalyst
ratio.
Using a clean paintbrush, brush the mixed resin

on the surface. Place the smallest piece of mat
over the fracture and then wet out the mat. Follow with the remaining pieces of mat and final layer of cloth. While wetting the pieces make sure
you work the air bubbles out and saturate all the
pieces evenly. Try to work quickly, you may only
have 15 or 20 minutes. You may clean the brush
with acetone.
Wait until the repair has hardened before moving
on to the interior repair. If the size of the opening
is too large for the pieces to maintain the proper
shape, you will have to use a backing support. It is
a shaped piece of cardboard that fits flush to the
interior surface and has a plastic layer on the repair side. It is held in place by tape or a support.
Inside
Wipe down the area with acetone on a cloth. Apply the same procedure as for outside repair when
laminating the alternating pieces of fiberglass material. If a backing support was used, remove it
before starting the repair. After the area has hardened, remove sharp edges of material from surface. If required paint the surface.
SANDING
Outside
This surface will have to be prepared for application of gelcoat. The size of the area will determine
the gelcoating procedure to be used. Refer to the
repair procedure for minor gelcoat fractures.
BUFFING AND WAXING
Refer to the buffing and waxing for Minor
Gelcoat Fractures.
TOOLS AND MATERIALS LIST

Tools
safety glasses
air mask
white cloths
sanding block
putty knife
plastic film
stirring stick
cover sheets (for Sea-Doo)
scissors
buffing pad
11-02-27
heavy-duty polisher
power sander
paint brush
plastic container (mixing)
spray gun
plastic squeegee
Mix epoxy glue (3M-05900), follow manufacturer

instructions.
Apply epoxy glue on aluminum insert (P/N 292
000 075) knurled surface and on plastic insert inner bore.
Materials
fiberglass mat
fiberglass cloth
polyester resin
cardboard
masking tape
sandpaper
(100-grit, 220-grit, 320-grit, 400-grit, 600-grit,
1000-grit)
24-grit sanding disks
Bombardier gelcoat putty
Bombardier liquid gelcoat
acetone
cabosil
epoxy filler
medium compound (white)
fine compound (white)
wax
HULL INSERT REPAIR
CAUTION
If you notice any clearance between plastic

insert and aluminum insert, fill gap with epoxy glue to obtain good adhesion of aluminum insert.
2
F01L2VA
1. Knurled surface
2. Inner bore
Install aluminum insert into plastic hull insert.

NOTE: Align aluminum insert as much as possible with PTO flywheel.
For hull insert repair proceed as follows:

Cut plastic hull insert flush with hull using a saw.
1
1
F01L2WA
1. Aluminum insert
F01L2UA
1. Hull
2. Plastic hull insert
11-02-28
NOTE: The epoxy glue curing time is 30 minutes.
Section 12 TECHNICAL DATA

SP AND SPX MODELS

ENGINE
Engine type
Induction type
Exhaust system
SP (5879)
Type
Water injection fitting (head)
Water injection fitting (cone)
Water injection fitting (muffler)
Exhaust valve
Starting system
Lubrication
Number of cylinders
Bore
Fuel/oil mixture
Oil injection pump
Oil type
Standard
First oversize
Second oversize
Stroke
Displacement
Corrected compression ratio
Cylinder head warpage (maximum)
Piston ring type and quantity
Ring end gap
New
Wear limit
New
Ring/piston groove
clearance
Wear limit
New (minimum)
Piston/cylinder wall
clearance
Wear limit
Cylinder taper (maximum)
Cylinder out of round (maximum)
Connecting rod big
New
end axial play
Wear limit
Crankshaft deflection
Rotary valve timing
Opening
Closing
Rotary valve duration

Crankcase/rotary valve gap
Connecting
rod/crankshaft pin radial
clearance
Connecting rod/piston pin
radial clearance
New
Wear limit
New
Wear limit
ADDITIONAL INFORMATION:
SPX (5834/5661)
Bombardier-Rotax 717D
Bombardier-Rotax 787
Rotary valve
Water cooled, water injected Water cooled, water injected
with regulator
4.5 mm (.177 in)
3.5 mm (.139 in)
Not applicable
Not applicable
3.5 mm (.139 in)
Not applicable
Rotax Adjustable
Variable Exhaust (RAVE)
Electric start
VROI (Variable Rate Oil Injection)
Gear driven
Direct driven
BOMBARDIER-ROTAX injection oil
2
82 mm (3.228 in)
82.25 mm (3.238 in)
82.50 mm (3.248 in)
Not applicable
68 mm (2.68 in)
74 mm (2.99 in)
718.2 cm (43.81 in)
781.6 cm (47.7 in)
6.5: 1
6.0: 1
0.05 mm (.002 in)
1 Semi-trapez 1 Rectangular
0.25 - 0.40 mm (.010 - .016 in)
1.00 mm (.039 in)
0.025 - 0.070 mm (.001 - .003 in)
0.2 mm (.008 in)
0.100 mm (.0039 in)
0.110 mm (.0043 in)
0.200 mm (.008 in)
0.100 mm (.004 in)
0.080 mm (.003 in)
0.311 - 0.678 mm
0.230 - 0.617
(.012 - .027 in)
(.009 - .024 in)
1.2 mm (.047 in)
MAG side: 0.050 mm (.002 in)
PTO side: 0.030 mm (.001 in)
134 5 BTDC
146.5 5 BTDC
51.5 5 ATDC
64 5 ATDC
132
159
0.25 - 0.35 mm (.010 - .014 in)
0.020 - 0.033 mm
0.023 - 0.034 mm
(.0008 - .0013 in)
(.0009 - .0013 in)
0.050 mm (.002 in)
0.003 - 0.012 mm (.00012 - .00047 in)
0.015 mm (.00059 in)
12-01-1

ELECTRICAL
Magneto generator output
SP (5879)
SPX (5834/5661)
160 W @ 6000 RPM
180 W @ 6000 RPM
or 4.0 A @ 2000 RPM
or 5.0 A @ 6000 RPM
Ignition system type
Digital CDI
Digital DC-CDI
Spark plug
Make and type
NGK BR7ES
NGK BR8ES
Gap
0.5 - 0.6 mm (.020 - .024 in)
Ignition timing
mm (in)
2.59 (.102)
3.38 (.133)
(BTDC)
Degrees
20 1
22 1 @ 3500 RPM
Generating coil
40 - 76
Not applicable
Battery charging coil
0.05 - 0.6
0.1 - 1
Trigger coil
Not applicable
190 - 300
Ignition coil
Primary
Not applicable
0.33 - 0.62
Secondary
9 - 15 k
8.4 - 15.6 k
Engine rev limiter setting
5900 ( 50) RPM
7200 ( 50) RPM
Battery
(Yuasa/Exide) 12 V, 19 Ah
Fuse
Starting system
5A
Charging system
15 A
2 x 15 A
VTS system
Not applicable
7.5 A
ADDITIONAL INFORMATION: Engine cold @ 5500 RPM.
CARBURETION
Carburetor
Type
Quantity
Main jet
Pilot jet
Spring
Adjustment
Fuel
Low-speed screw
High-speed screw
Idle speed (in water)
Idle speed (out of water)
Type
Minimum octane no.
Fuel return line orifice
SP (5879)
Mikuni BN-38
(diaphragm)
1
135
57.5
115 g
1-3/4 turn 1/4
SPX (5834/5661)
Mikuni BN-40I
(diaphragm)
2
142.5
70
80 g
1 turn 1/4
0
1500 RPM
3000 RPM
Regular unleaded gasoline
87
MAG and PTO:
0.8 mm (.031 in)
0.8 mm (.031 in)
COOLING
Type
Thermostat
Monitoring beeper setting
12-01-2
SP (5879)
SPX (5834/5661)
Open circuit Direct flow from jet propulsion unit
None
95-103C (203-217F)

PROPULSION
Propulsion system
Jet pump type
Impeller rotation (seen from rear)
Transmission
Coupling type
Oil type
SP (5879)
SPX (5834/5661)
Bombardier Formula Pump
Axial flow single stage
Counterclockwise
Direct drive
Crown splines
SEA-DOO JET PUMP SYNTHETIC
POLYOLESTER OIL 75W90 GL5
Steering nozzle pivoting angle
26
Minimum required water level
90 cm (35 in)
Drive shaft deflection (maximum)
0.5 mm (.020 in)
Impeller outside diameter
139.5 mm (5.490 in)
Impeller/wear ring
New
0.0 - 0.4 mm (.000 - .016 in)
clearance
Wear limit
1.0 mm (.040 in)
Impeller shaft end play (new)
0.12 - 0.54 mm (.005 - .021 in)
Impeller shaft side play
0.05 mm (.002 in)
Impeller pitch/material
Progressive pitch
Progressive pitch
16 - 35/aluminum
16 - 23/stainless steel
ADDITIONAL INFORMATION: Do not mix different brands or oil types.
DIMENSIONS
Number of passenger (driver incl.)
Overall length
Overall width
Overall height
Dry weight
Load limit (passenger and 10 kg (22 lb) luggage)
CAPACITIES
Fuel tank
Impeller shaft reservoir
SP (5879)
SPX (5834/5661)
2
254 cm (100 in)
105 cm (41.3 in)
92 cm (36.2 in)
187 kg (412 lb)
197 kg (434 lb)
160 kg (352 lb)
SP (5879)
Capacity
Oil level height
Oil injection reservoir

SPX (5834/5661)
34 L (9 U.S. gal)
70 mL (2.4 U.S. oz)
Up to plug
4.5 L (1.2 U.S. gal)
12-01-3

MATERIALS
Hull
Inlet grate
Impeller housing/stator/venturi/nozzle
Air intake silencer
Flame arrester
Exhaust muffler
Steering padding
Fuel tank
Seat
STANDARD EQUIPMENT
Safety lanyard
Tool kit
Fuel tank reserve
Monitoring beeper
Speedometer
Fuel/oil gauge (analog)
Tachometer
Variable trim system (VTS)
Reverse
Storage compartment
Rear grab handle
Extinguisher holder
PERFORMANCE
Estimated pump power
Maximum fuel consumption at wide open throttle
Cruising time at full
throttle
Fuel tank without reserve

Fuel tank reserve
12-01-4
SP (5879)
SPX (5834/5661)
Composite
Plastic
Plastic/plastic/
Plastic/brass/plastic/
plastic/plastic
aluminum
Thermoplastic
Multi-layer wire screen
Aluminum
Thermoplastic elastomer with polystyrene foam
Polyethylene
Polyethylene
Polyurethane foam
SP (5879)
SPX (5834/5661)
Standard
Standard
Standard
Standard
Standard
Optional
Optional
Standard
Optional
Optional (manual)
Not applicable
Standard
Optional
Standard
SP (5879)
23.5 L/h
(6.2 U.S. gal/h)
1 hour 14 minutes
13 minutes
Standard
Standard
SPX (5834/5661)
42 kW (57 hp)
44.5 L/h
(11.7 U.S. gal/h)
39 minutes
7 minutes

TIGHTENING TORQUES
SP (5879)
Exhaust manifold screw

Magneto flywheel nut
145 Nm (107 lbfft) (1)
Flywheel (PTO side)
ENGINE
Crankcase screws
110 Nm
M8
24 Nm
M10
40 Nm
Crankcase/engine support nuts
35 Nm
Engine mount/hull
25 Nm
Cylinder head screws

Crankcase/cylinder screws
Tuned pipe flange screws/nut
24 Nm
24 Nm (17 lbfft) (1) (4)
25 Nm (18 lbfft) (1)
Tuned pipe fixation screws
25 Nm
Flame arrester screws
10 Nm
Magneto housing cover screws

Starter mounting screws
Starter lock nuts
JET PUMP
SPX (5834/5661)
24 Nm (17 lbfft) (4)
9 Nm
22 Nm
7 Nm
Spark plugs
24 Nm
Impeller
70 Nm
Pump/hull nuts
33 Nm
Venturi/pump housing screws
21 Nm
VTS ring screws
Not applicable
Pump housing cover screws
4 Nm
STEERING
Inlet grate screws

8 Nm
Riding plate screws
10 Nm
Cable retaining block bolts
6 Nm
Steering cable/stem arm bolt
3 Nm
Steering stem arm bolts
6 Nm
Handlebar clamp bolts
26 Nm
Steering cable ball joint (nozzle)
2 Nm (18 lbfin)
Front support bolts
15 Nm
Rear support/cable bracket bolts
15 Nm
ADDITIONAL INFORMATION: apply where indicated; (1) Loctite 242 (blue)
(2) Loctite 271 (red)
(3) Loctite 515
(4) Synthetic grease
(5) Anti-seize lubricant
40 Nm (30lbfft)
105 Nm (77 lbfft)
(81 lbfft)
(17 lbfft)
(30 lbfft)
(26 lbfft)
(18 lbfft)
(17 lbfft)
40 Nm (30 lbfft)
40 Nm (30 lbfft)
(18 lbfft)
(88 lbfin)
(80 lbfin)
(16 lbfft)
(62 lbfin)
(17 lbfft)
(52 lbfft)
(24 lbfft)
(16 lbfft)
14 Nm (10 lbfft)
(35 lbfin)
(71 lbfin)
(88 lbfin)
(53 lbfin)
(26 lbfin)
(53 lbfin)
(19 lbfft)
7 Nm (62 lbfin)
(11 lbfft)
(11 lbfft)
(3) (4)
(1)
(5)
(3) (4)
(3) (4)
(1)
(1)
(1) (4)
(3) (4)
(1)
(1)
(1)
(5)
(1)
(5)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
; WARNING: Correct torques and use of Loctite must be strictly followed.
12-01-5

Sub-Section 02 (GS AND GSI MODELS)
GS AND GSI MODELS

ENGINE
Engine type
Induction type
Exhaust system
Starting system
Lubrication
Number of cylinders
Bore
Type
Water injection fitting
(head)
(cone)
Fuel/oil mixture
Oil injection pump
Oil type
Standard
First oversize
Second oversize
Stroke
Displacement
Ring end gap
New
Wear limit
Ring/piston groove
New
clearance
Wear limit
New (minimum)
clearance
Wear limit
Connecting rod big end
New
axial play
Wear limit
Rotary valve timing
Connecting
rod/crankshaft pin radial
clearance
radial clearance
Opening
Closing
New
Wear limit
New
Wear limit
0
GS (5621)
GSI (5622)
Rotary valve
Water cooled, water injected
3.5 mm (.139 in)
3.5 mm (.139 in)
Electric start
VROI (Variable Rate Oil Injection
Gear driven
2
82 mm (3.228 in)
82.25 mm (3.238 in)
82.50 mm (3.248 in)
68 mm (2.677 in)
718.2 cm (43.81 in)
6.2: 1
0.05 mm (.002 in)
0.25 - 0.40 mm (.010 - .016 in)
1.00 mm (.039 in)
0.025 - 0.070 mm (.001 - .003 in)
0.2 mm (.008 in)
0.100 mm (.0039 in)
0.2 mm (.008 in)
0.100 mm (.004 in)
0.080 mm (.003 in)
0.311 - 0.678 mm (.012 - .027 in)
1.2 mm (.047 in)
MAG side: 0.050 mm (.002 in)
PTO side: 0.030 mm (.001 in)
147 5 BTDC
65.5 5 ATDC
159
0.25 - 0.35 mm (.010 - .014 in)
0.020 - 0.033 mm (.0008 - .0013 in)
0.050 mm (.002 in)
0.003 - 0.012 mm (.00012 - .00047 in)
0.015 mm (.00059 in)
12-02-1

ELECTRICAL
Spark plug
Make and type
Gap
Ignition timing
mm (in)
(BTDC)
Degrees
Generating coil
Ignition coil
Primary
Secondary
Battery
Fuse
Starting system
Charging system
CARBURETION
Carburetor
Main jet
Pilot jet
Spring
Adjustment
Fuel
Type
Quantity
Low-speed screw
High-speed screw
Type
Minimum octane no.

COOLING
Type
Thermostat
12-02-2
GS (5621)
GSI (5622)
160 W @ 6000 RPM or 4.0 A @ 2000 RPM
Digital CDI
NGK BR8ES
0.5 - 0.6 mm (.020 - .024 in)
2.59 (.102)
20 1
40 - 76
0.05 - 0.6
0.33 - 0.62
8.4 - 15.6 k
7000 50 RPM
5A
2 x 15 A
GS (5621)
GSI (5622)
Mikuni BN-40I (diaphragm)
1
175
70
80 g
1-3/4 turn 1/4
0
1500 RPM
3000 RPM
87
0.8 mm (.031 in)
GS (5621)
GSI (5622)
Open circuit Direct flow
from jet propulsion unit
None
86-94C (187-201F)

PROPULSION
Propulsion system
Jet pump type
Transmission
Coupling type
Oil type
GS (5621)
GSI (5622)
Counterclockwise
Direct drive
Crown splines
26
90 cm (35 in)
0.5 mm (.020 in)
139.5 mm (5.490 in)
Impeller/wear
New
0.0 - 0.4 mm (.000 - .016 in)
ring clearance
Wear limit
1.0 mm (.040 in)
0.12 - 0.54 mm (.005 - .021 in)
0.05 mm (.002 in)
Progressive pitch 10 Progressive pitch 11 Impeller pitch/material
25/aluminum
22/stainless steel
DIMENSIONS
Overall length
Overall width
Overall height
Dry weight
GS (5621)
CAPACITIES
Fuel tank
GS (5621)
GSI (5622)
56.5 L (15 U.S. gal)
70 mL (2.4 U.S. oz)
To bottom of cover hole
6 L (1.6 U.S. gal)
Capacity
Oil level height

GSI (5622)
2
267 cm (105 in)
116 cm (45.7 in)
94 cm (37 in)
217 kg (478 lb)
165 kg (364 lb)
12-02-3

MATERIALS
Hull
Inlet grate
Air intake silencer
Flame arrester
Exhaust muffler
Steering padding
Fuel tank
Seat
GS (5621)
GSI (5622)
Composite
Aluminum
Plastic/plastic/plastic/plastic
Thermoplastic
Aluminum
Thermoplastic with Polyethylene foam
Polyethylene
Polyethylene
Polyurethane foam
STANDARD EQUIPMENT
GS (5621)
GSI (5622)
Safety lanyard
Standard
Standard
Fuel tank reserve
Standard
Monitoring beeper
Standard
Standard
Not applicable
Info Center
Not applicable
Standard
Variable trim system
Optional
Standard
Storage compartment
Standard
Rear grab handle
Standard
Reverse
Not applicable
Extinguisher holder
Standard
Tool kit
Standard
ADDITIONAL INFORMATION: Info Center standard functions: Fuel level/low fuel level/low oil level/low
voltage/tachometer/high temperature/hour meter/clock/maintenance information/trim/chronometer
PERFORMANCE
Cruising time at
full throttle

Fuel tank reserve
12-02-4
GS (5621)
GSI (5622)
34.9 kW (46.8 hp)
33 L/h
(8.7 U.S. gal/h)
1 hour 21 minutes
21 minutes

STEERING
JET PUMP
ENGINE
TIGHTENING TORQUES
GS (5621)
24 Nm
145 Nm
Flywheel (PTO side)
110 Nm
Crankcase screws
M8
24 Nm
M10
40 Nm
35 Nm
Engine mount/hull
25 Nm
24 Nm
24 Nm
Tuned pipe nut
25 Nm
25 Nm
10 Nm
9 Nm
22 Nm
Starter lock nuts
7 Nm
Spark plugs
24 Nm
Impeller
70 Nm
Pump/hull nuts
31 Nm
21 Nm
VTS ring screws
Not applicable
4 Nm
Inlet grate screws
8 Nm
Riding plate screws
22 Nm
6 Nm
3 Nm
6 Nm
26 Nm
2 Nm
Steering support bolts
15 Nm
Handlebar grip screw
14 Nm
(3) Loctite 515
GSI (5622)
(17 lbfft)
(107 lbfft)
(81 lbfft)
(17 lbfft)
(30 lbfft)
(26 lbfft)
(18 lbfft)
(17 lbfft)
(17 lbfft)
(18 lbfft)
(18 lbfft)
(88 lbfin)
(80 lbfin)
(16 lbfft)
(62 lbfin)
(17 lbfft)
(52 lbfft)
(23 lbfft)
(16 lbfft)
14 Nm (10 lbfft)
(35 lbfin)
(71 lbfin)
(16 lbfft)
(53 lbfin)
(26 lbfin)
(53 lbfin)
(19 lbfft)
(18 lbfin)
(11 lbfft)
(10 lbfft)
(4)
(1)
(5)
(3) (4)
(3) (4)
(1)
(1)
(1) (4)
(1) (4)
(1)
(1)
(1)
(5)
(1)
(5)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
12-02-5

Sub-Section 03 (GSX MODEL)
GSX MODEL
ENGINE
Engine type
Induction type
Exhaust system
Exhaust valve
Starting system
Lubrication
Number of cylinders
Bore
0
GSX (5624)
Type
(muffler)
Fuel/oil mixture
Oil injection pump
Oil type
Standard
First oversize
Second oversize
Stroke
Displacement
Ring end gap
New
Wear limit
Ring piston groove
New
Wear limit
New (minimum)
clearance
Wear limit
Connecting rod big end axial
New
play
Wear limit
Rotary valve timing
Opening
Closing
Connecting rod/crankshaft
New
pin radial clearance
Wear limit
New
radial clearance
Wear limit
Rotary valve
Water cooled, water injected with regulator
3.5 mm (.139 in)
Not applicable
3.5 mm (.139 in)
Rotax Adjustable Variable Exhaust (RAVE)
Electric start
Direct driven
2
82 mm (3.228 in)
82.25 mm (3.238 in)
Not applicable
74 mm (2.99 in)
781.6 cm (47.7 in)
6.0: 1
0.05 mm (.002 in)
0.25 - 0.40 mm (.010 - .016 in)
1.00 mm (.039 in)
0.025 - 0.070 mm (.001 - .003 in)
0.2 mm (.008 in)
0.110 mm (.0043 in)
0.200 mm (.008 in)
0.100 mm (.004 in)
0.080 mm (.003 in)
0.230 - 0.617 mm (.009 - .024 in)
1.2 mm (.047 in)
MAG side: 0.050 mm (.002 in); PTO side: 0.030 mm (.001 in)
146.5 5 BTDC
64 5 ATDC
159
0.25 - 0.35 mm (.010 - .014 in)
0.023 - 0.034 mm (.0009 - .0013 in)
0.050 mm (.002 in)
0.003 - 0.012 mm (.00012 - .00047 in)
0.015 mm (.00059 in)
12-03-1

ELECTRICAL
GSX (5624)
180 W @ 6000 RPM

or 5.0 A @ 6000 RPM

Spark plug
Digital DC-CDI
Make and type
Gap
Ignition timing
(BTDC)
3.38 (.133)
Degrees
22 1 @ 3500 RPM
Not applicable
0.1 - 1
190 - 300
Trigger coil
Primary
Secondary
0.33 - 0.62
8.4 - 15.6 k
7200 ( 50) RPM
Battery
Fuse
0.5 - 0.6 mm (.020 - .024 in)
mm (in)
Generating coil
Ignition coil
NGK BR8ES
Starting system
5A
Charging system
2 x 15 A
VTS system
7.5 A
CARBURETION
Carburetor
GSX (5624)
Type
Quantity
Main jet
Mikuni BN-40I-38 (diaphragm)

2
142.5
Pilot jet
70
Spring
80 g
Adjustment
Low-speed screw
High-speed screw
Fuel
Type
Minimum octane no.
1 turn 1/4
0
1500 RPM
3000 RPM
87
MAG and PTO: 0.8 mm (.031 in)
COOLING
Type
Thermostat
12-03-2
GSX (5624)
None
86-94C (187-201F)

PROPULSION
Propulsion system
Jet pump type
Transmission
Coupling type
Oil type
GSX (5624)
Counterclockwise
Direct drive
Crown splines
26
90 cm (35 in)
0.5 mm (.020 in)
139.5 mm (5.490 in)
Impeller/wear ring
New
0.0 - 0.4 mm (.000 - .016 in)
clearance
Wear limit
1.00 mm (.040 in)
0.12 - 0.54 mm (.005 - .021 in)
0.05 mm (.002 in)
Progressive pitch 16 - 23/stainless steel
DIMENSIONS
Overall length
Overall width
Overall height
Dry weight
CAPACITIES
Fuel tank
Capacity
Oil level height

GSX (5624)
2
267 cm (105 in)
116 cm (45.7 in)
94 cm (37 in)
227 kg (500 lb)
165 kg (364 lb)
GSX (5624)
56.5 L (15 U.S. gal)
70 mL (2.4 U.S. oz)
Up to plug
6 L (1.6 U.S. gal)
12-03-3

MATERIALS
Hull
Inlet grate
Air intake silencer
Flame arrester
Exhaust muffler
Steering padding
Fuel tank
Seat
STANDARD EQUIPMENT
GSX (5624)
Composite
Aluminum
Plastic/brass/plastic/aluminum
Thermoplastic
Aluminum
Thermoplastic with polyethylene foam
Polyethylene
Polyethylene
Polyurethane foam
GSX (5624)
Safety lanyard
Standard
Standard
Fuel tank reserve
Standard
Monitoring beeper
Standard
Speedometer
Standard
Info Center gauge
Standard
Standard
Reverse
Not applicable
Storage compartment
Standard
Rear grab handle
Standard
Extinguisher holder
Standard
Tool kit
Standard
ADDITIONAL INFORMATION: Info Center standard functions: Fuel level/low fuel level/low oil level/low voltage/
high temperature/tachometer/hour meter/clock/maintenance information/speedometer/average speed/
peak speed/chronometer/trim
PERFORMANCE
Cruising time at full throttle

Fuel tank reserve
12-03-4
GSX (5624)
42 kW (56 hp)
44.5 L/h
(11.7 U.S. gal/h)
1 hour 1 minutes
15 minutes

TIGHTENING TORQUES
JET PUMP
ENGINE

Flywheel (PTO side)
Crankcase screws
M8
M10
Engine mount/hull
Starter lock nuts
Spark plugs
Impeller
Pump/hull nuts
VTS ring screws
STEERING

Inlet grate screws
Riding plate screws
Steering cable ball joint bolt (nozzle)
(3) Loctite 515
GSX (5624)
40 Nm
105 Nm
110 Nm
24 Nm
40 Nm
35 Nm
25 Nm
24 Nm
40 Nm
40 Nm
25 Nm
10 Nm
9 Nm
22 Nm
7 Nm
24 Nm
70 Nm
31 Nm
21 Nm
(30 lbfft)
(77 lbfft)
(81 lbfft)
(17 lbfft)
(30 lbfft)
(26 lbfft)
(18 lbfft)
(17 lbfft)
(30 lbfft)
(30 lbfft)
(18 lbfft)
(88 lbfin)
(80 lbfin)
(16 lbfft)
(62 lbfin)
(17 lbfft)
(52 lbfft)
(23 lbfft)
(16 lbfft)
14 Nm
(10 lbfft)
4 Nm
8 Nm
22 Nm
6 Nm
3 Nm
6 Nm
26 Nm
7 Nm
15 Nm
14 Nm
(35 lbfin)
(71 lbfin)
(16 lbfft)
(53 lbfin)
(26 lbfin)
(53 lbfin)
(19 lbfft)
(62 lbfin)
(11 lbfft)
(10 lbfft)
(3) (4)
(1)
(3) (4)
(3) (4)
(1)
(1)
(1) (4)
(3) (4)
(1)
(1)
(1)
(5)
(1)
(5)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
12-03-5

GTS MODEL
ENGINE
Engine type
Induction type
Exhaust system
Starting system
Lubrication
Number of cylinders
Bore
GTS (5818)
Type
Fuel/oil mixture
Oil injection pump
Oil type
Standard
First oversize
Second oversize
Stroke
Displacement
Ring end gap
New
Wear limit
Ring/piston groove
New
clearance
Wear limit
New (minimum)
clearance
Wear limit
Connecting rod big end axial
New
play
Wear limit
Rotary valve timing
Rotary valve/cover clearance
radial clearance
Opening
Closing
New
Wear limit
New
Wear limit
Rotary valve
3.5 mm (.139 in)
3.5 mm (.139 in)
Electric start
Gear driven
2
82 mm (3.228 in)
82.25 mm (3.238 in)
82.50 mm (3.248 in)
68 mm (2.68 in)
718.2 cm (43.81 in)
6.2: 1
0.05 mm (.002 in)
1 Semi-Trapez 1 Rectangular
0.25 - 0.40 mm (.010 - .016 in)
1.00 mm (.039 in)
0.025 - 0.070 mm (.001 - .003 in)
0.2 mm (.008 in)
0.100 mm (.0039 in)
0.200 mm (.008 in)
0.100 mm (.004 in)
0.080 mm (.003 in)
0.311 - 0.678 mm (.012 - .027 in)
1.2 mm (.047 in)
MAG side: 0.05 mm (.002 in)
PTO side: 0.03 mm (.001 in)
147 5 BTDC
65.5 5 ATDC
159
0.25 - 0.35 mm (.010 - .014 in)
0.020 - 0.033 mm (.0008 - .0013 in)
0.050 mm (.002 in)
0.003 - 0.012 mm (.00012 - .00047 in)
0.015 mm (.00059 in)
12-04-1

ELECTRICAL
Spark plug
Ignition timing
(BTDC)
Generating coil
Ignition coil
GTS (5818)
Make and type

Gap
mm (in)
Degrees
Primary
Secondary

Battery
Fuse
Starting system
Charging system
CARBURETION
Carburetor
Main jet
Pilot jet
Spring
Adjustment
Fuel
COOLING
Type
Thermostat
12-04-2
160 W @ 6000 RPM or 4.0 A @ 2000 RPM

Digital CDI
NGK BR8ES
0.5 - 0.6 mm (.020 - .024 in)
2.59 (.102)
20 1
40 - 76
0.05 - 0.6
Not applicable
9 - 15 k
7000 50 RPM
5A
15 A
GTS (5818)
Type
Quantity
Low-speed screw
High-speed screw
Type
Minimum octane no.

1
175
70
80 g
1-3/4 turn 1/4
0
1500 RPM
3000 RPM
87
0.8 mm (.031 in)
GTS (5818)
Open circuit Direct flow
from jet propulsion unit
None
95-103C (203-217F)

PROPULSION
Propulsion system
Jet pump type
Transmission
Coupling type
Oil type
GTS (5818)
Counterclockwise
Direct drive
Crown splines
26
90 cm (35 in)
0.5 mm (.020 in)
139.5 mm (5.490 in)
Impeller/wear ring
New
0.0 - 0.4 mm (.000 - .016 in)
clearance
Wear limit
1.00 mm(.040 in)
0.12 - 0.54 mm (.005 - .021 in)
0.05 mm (.002 in)
Progressive pitch, 11 - 22/stainless steel
DIMENSIONS
Overall length
Overall width
Overall height
Dry weight
CAPACITIES
Fuel tank
Capacity
Oil level height

GTS (5818)
3
302 cm (119.0 in)
119 cm (46.8 in)
95 cm (37.4 in)
210 kg (463 lb)
225 kg (496 lb)
GTS (5818)
47 L (12 U.S. gal)
70 mL (2.4 U.S. oz)
To bottom of cover hole
4.5 L (1.2 U.S. gal)
12-04-3

MATERIALS
Hull
Inlet grate
Air intake silencer
Flame arrester
Exhaust muffler
Steering padding
Fuel tank
Seat
STANDARD EQUIPMENT
Safety lanyard
Fuel tank reserve
Monitoring beeper
Fuel gauge/low oil warning light
Tachometer
Speedometer
Reverse
Storage compartment
Rear grab handle
Extinguisher holder
Tool kit
PERFORMANCE
throttle

Fuel tank reserve
12-04-4
GTS (5818)
Composite
Plastic
Plastic/brass/plastic/plastic
Thermoplastic
Aluminum
Thermoplastic elastomer with polystyrene foam
Polyethylene
Polyethylene
Polyurethane foam
GTS (5818)
Standard
Standard
Standard
Standard
Standard
Optional
Optional
Not applicable
Standard
Standard
Standard
Standard
Standard
GTS (5818)
34.9 kW (46.8 hp)
33.5 L/h
(8.8 U.S. gal/h)
1 hour
20 minutes

STEERING
JET PUMP
ENGINE
TIGHTENING TORQUES
GTS (5818)
Exhaust manifold screws
24 Nm (17 lbfft)
145 Nm (107 lbfft)
Flywheel (PTO side)
110 Nm (81 lbfft)
Crankcase screws
M8
24 Nm (17 lbfft)
M10
40 Nm (30 lbfft)
35 Nm (26 lbfft)
Engine support/hull
25 Nm (18 lbfft)
24 Nm (17 lbfft)
24 Nm (17 lbfft)
Tuned pipe nut
25 Nm (18 lbfft)
25 Nm (18 lbfft)
10 Nm (88 lbfin)
9 Nm (80 lbfin)
22 Nm (16 lbfft)
Starter lock nuts
7 Nm (62 lbfin)
Spark plugs
24 Nm (17 lbfft)
Impeller
70 Nm (52 lbfft)
Pump/hull nuts
33 Nm (24 lbfft)
21 Nm (16 lbfft)
Nozzle/venturi screws
20 Nm (15 lbfft)
4 Nm (35 lbfin)
Inlet grate screws
8 Nm (71 lbfin)
Riding plate screws
10 Nm (88 lbfin)
Steering cable jam nuts
10 Nm (88 lbfin)
Steering support/collar screws
15 Nm (11 lbfft)
Steering stem screw
40 Nm (30 lbfft)
Handlebar nuts
26 Nm (19 lbfft)
Reverse gate screws
20 Nm (15 lbfft)
2 Nm (18 lbfin)
Reverse cable ball joint nut
7 Nm 62 lbfin)
(3) Loctite 515
(4)
(1)
(5)
(3) (4)
(3) (4)
(1)
(1)
(1) (4)
(1) (4)
(1)
(1)
(1)
(5)
(1)
(5)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(2)
(1)
12-04-5

Sub-Section 05 (GTI AND GTX MODELS)
GTI AND GTX MODELS

ENGINE
Engine type
Induction type
Exhaust system
GTI (5641)
Type
(muffler)
Exhaust valve
Starting system
Lubrication
Number of cylinders
Bore

radial clearance
GTX (5642)
Rotary valve
with regulator
3.5 mm (.139 in)
3.5 mm (.139 in)
Not applicable
Not applicable
3.5 mm (.139 in)
Rotax Adjustable
Electric start
Gear driven
Direct driven
2
82 mm (3.228 in)
82.25 mm (3.238 in)
82.50 mm (3.248 in)
Not applicable
68 mm (2.68 in)
74 mm (2.99 in)
718.2 cm (43.81 in)
781.6 cm (47.7 in)
6.2: 1
6.0: 1
0.05 mm (.002 in)
0.25 - 0.40 mm (.010 - .016 in)
1.00 mm (.039 in)
0.025 - 0.070 mm (.001 - .003 in)
0.2 mm (.008 in)
0.100 mm (.0039 in)
0.110 mm (.0043 in)
0.200 mm (.008 in)
0.100 mm (.004 in)
0.080 mm (.003 in)
0.311 - 0.678 mm
0.230 - 0.617
(.012 - .027 in)
(.009 - .024 in)
1.2 mm (.047 in)
MAG side: 0.050 mm (.002 in)
PTO side: 0.030 mm (.001 in)
147 5 BTDC
146.5 5 BTDC
65.5 5 ATDC
64 5 ATDC
159
0.25 - 0.35 mm (.010 - .014 in)
0.020 - 0.033 mm
0.023 - 0.034 mm
(.0008 - .0013 in)
(.0009 - .0013 in)
0.050 mm (.002 in)
0.003 - 0.012 mm (.00012 - .00047 in)
0.015 mm (.00059 in)
Not applicable
Fuel/oil mixture
Oil injection pump
Oil type
Standard
First oversize
Second oversize
Stroke
Displacement
Ring end gap
New
Wear limit
New
Ring/piston groove
clearance
Wear limit
New (minimum)
clearance
Wear limit
Connecting rod big
New
end axial play
Wear limit
Rotary valve timing
Opening
Closing
New
Wear limit
New
Wear limit
12-05-1

ELECTRICAL
GTI (5641)
GTX (5642)
160 W @ 6000 RPM

or 4.0 A @ 2000 RPM
180 W @ 6000 RPM

or 5.0 A @ 6000 RPM
Digital CDI
Digital DC-CDI

Spark plug
Make and type

Gap
NGK BR8ES
0.5 - 0.6 mm (.020 - .024 in)
Ignition timing
(BTDC)
mm (in)
2.59 (.102)
3.38 (.133)
Degrees
20 1
40 - 76
22 1 @ 3500 RPM
Not applicable
Generating coil
Trigger coil
Ignition coil
0.1 - 1
190 - 300
Primary
0.33 - 0.62
Secondary
8.4 - 15.6 k

Battery
Fuse
0.05 - 0.6
Not applicable
7000 ( 50) RPM

7200 ( 50) RPM
Starting system
5A
Charging system
VTS system
2 x 15 A
Not applicable

CARBURETION
Carburetor
GTI (5641)
Type
Quantity
Main jet

1
175
142.5
Pilot jet
Spring
Adjustment
70
80 g
Low-speed screw
1-3/4 turn 1/4
High-speed screw
Type
Minimum octane no.
1 turn 1/4
0
1500 RPM

Fuel
GTX (5642)
3000 RPM
87
0.8 mm (.031 in)
MAG and PTO:

0.8 mm (.031 in)
GTI (5641)
GTX (5642)
COOLING
Type
Thermostat
12-05-2

None
86-94C (187-201F)

PROPULSION
Propulsion system
Jet pump type
Transmission
Coupling type
Oil type
GTI (5641)
GTX (5642)
Counterclockwise
Direct drive
Crown splines
23
90 cm (35 in)
0.5 mm (.020 in)
139.5 mm (5.490 in)
Impeller/wear ring
New
0.0 - 0.4 mm (.000 - .016 in)
clearance
Wear limit
1.0 mm (.040 in)
0.12 - 0.54 mm (.005 - .021 in)
0.05 mm (.002 in)
Progressive pitch
Progressive pitch
DIMENSIONS
Overall length
Overall width
Overall height
Dry weight
GTI (5641)
CAPACITIES
Fuel tank
GTI (5641)
GTX (5642)
56.5 L (15 U.S. gal)
70 mL (2.4 U.S. oz)
Up to plug
6 L (1.6 U.S. gal)
Capacity
Oil level height

GTX (5642)
3
312 cm (122.8 in)
119 cm (47 in)
94 cm (37 in)
262 kg (578 lb)
230 kg (507 lb)
12-05-3

MATERIALS
Hull
Inlet grate
Air intake silencer
Flame arrester
Exhaust muffler
Steering padding
Fuel tank
Seat
GTI (5641)
GTX (5642)
Composite
Aluminum
plastic
Thermoplastic
Aluminum
Thermoplastic with polyethylene foam
Polyethylene
Polyethylene
Polyurethane foam
STANDARD EQUIPMENT
GTI (5641)
GTX (5642)
Safety lanyard
Standard
Standard
Fuel tank reserve
Standard
Monitoring beeper
Standard
Speedometer
Standard
Standard
Not applicable
Tachometer
Not applicable
Standard
Info Center
Not applicable
Standard
Reverse
Standard
Storage compartment
Standard
Glove box
Standard
Rear grab handle
Standard
Extinguisher holder
Standard
Tool kit
Standard
ADDITIONAL INFORMATION: Info Center standard functions: Fuel level/low fuel level/low oil level/low
voltage/high temperature/tachometer/speedometer/average speed/peak speed/trip meter/hour
meter/clock/compass/exterior temperature/lake temperature/chronometer/maintenance information.
PERFORMANCE
throttle

Fuel tank reserve
12-05-4
GTI (5641)
34.9 kW (46.8 hp)
33.5 L/h
(8.8 U.S. gal/h)
1 hour 21 minutes
20 minutes
GTX (5642)
42 kW (56 hp)
44.5 L/h
(11.7 U.S. gal/h)
1 hour 1 minute
15 minutes

GTI (5641)
24 Nm (17 lbfft) (4)
145 Nm (107 lbfft) (1)
110 Nm
M8
24 Nm
M10
40 Nm
35 Nm
Engine mount/hull
25 Nm
24 Nm
24 Nm (17 lbfft) (1) (4)
25 Nm (18 lbfft) (1)
25 Nm
10 Nm
9 Nm
22 Nm
Starter lock nuts
7 Nm
Spark plugs
24 Nm
Impeller
70 Nm
Pump/hull nuts
31 Nm
21 Nm
4 Nm
Inlet grate screws
8 Nm
Riding plate screws
22 Nm
6 Nm
3 Nm
6 Nm
26 Nm
2 Nm
15 Nm
14 Nm
(3) Loctite 515
STEERING
JET PUMP
ENGINE
TIGHTENING TORQUES
Flywheel (PTO side)
Crankcase screws
GTX (5642)
40 Nm (30 lbfft)
105 Nm (77 lbfft)
(81 lbfft)
(17 lbfft)
(30 lbfft)
(26 lbfft)
(18 lbfft)
(17 lbfft)
40 Nm (30 lbfft)
40 Nm (30 lbfft)
(18 lbfft)
(88 lbfin)
(80 lbfin)
(16 lbfft)
(62 lbfin)
(17 lbfft)
(52 lbfft)
(23 lbfft)
(16 lbfft)
(35 lbfin)
(71 lbfin)
(16 lbfft)
(53 lbfin)
(26 lbfin)
(53 lbfin)
(19 lbfft)
(18 lbfin)
(11 lbfft)
(10 lbfft)
(3) (4)
(1)
(5)
(3) (4)
(3) (4)
(1)
(1)
(1) (4)
(3) (4)
(1)
(1)
(1)
(5)
(1)
(5)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
12-05-5

HX AND XP MODELS
ENGINE
Engine type
Induction type
Exhaust system
HX (5882)
Type
Water injection fitting (muffler)
Exhaust valve
Starting system
Lubrication
Number of cylinders
Bore
Fuel/oil mixture
Oil injection pump
Oil type
Standard
First oversize
Second oversize
Stroke
Displacement
Ring end gap
New
Wear limit
Ring/piston groove
New
clearance
Wear limit
New (minimum)
clearance
Wear limit
Connecting rod big
New
end axial play
Wear limit
Rotary valve timing
radial clearance
Opening
Closing
New
Wear limit
New
Wear limit
XP (5662)
Rotary valve
with regulator
3.5 mm (.139 in)
3.5 mm (.139 in)
Not applicable
Not applicable
3.5 mm (.139 in)
Rotax Adjustable
Not applicable
Electric start
Gear driven
Direct driven
2
82 mm (3.228 in)
82.25 mm (3.238 in)
82.50 mm (3.248 in)
Not applicable
68 mm (2.68 in)
74 mm (2.99 in)
718.2 cm (43.81 in)
781.6 cm (47.7 in)
6.2: 1
6.0: 1
0.05 mm (.002 in)
0.25 - 0.40 mm (.010 - .016 in)
1.00 mm (.039 in)
0.025 - 0.070 mm (.001 - .003 in)
0.2 mm (.008 in)
0.100 mm (.0039 in) 0.110 mm (.0043 in)
0.200 mm (.008 in)
0.100 mm (.004 in)
0.080 mm (.003 in)
0.311 - 0.678 mm
0.230 - 0.617
(.012 - .027 in)
(.009 - .024 in)
1.2 mm (.047 in)
MAG side: 0.050 mm (.002 in)
PTO side: 0.030 mm (.001 in)
147 5 BTDC
146.5 5 BTDC
65.5 5 ATDC
64 5 ATDC
159
0.25 - 0.35 mm (.010 - .014 in)
0.020 - 0.033 mm
0.023 - 0.034 mm
(.0008 - .0013 in)
(.0009 - .0013 in)
0.050 mm (.002 in)
0.003 - 0.012 mm (.00012 - .00047 in)
0.015 mm (.00059 in)
12-06-1

ELECTRICAL
HX (5882)
XP (5662)
160 W @ 6000 RPM

or 4.0 A @ 2000 RPM
180 W @ 6000 RPM

or 5.0 A @ 6000 RPM
Digital CDI
Digital DC-CDI

Spark plug
Make and type

Gap
NGK BR8ES
0.5 - 0.6 mm (.020 - .024 in)
Ignition timing
(BTDC)
mm (in)
2.59 (.102)
3.38 (.133)
Degrees
20 1
40 - 76
22 1 @ 3500 RPM
Not applicable
Generating coil
Trigger coil
Ignition coil
Primary
Secondary

Battery
Fuse
0.05 - 0.6
0.1 - 1
Not applicable
Not applicable
190 - 300
0.33 - 0.62
9 - 15 k
8.4 - 15.6 k
7000 ( 50) RPM

7200 ( 50) RPM
Starting system
5A
Charging system
VTS system
15 A
Not applicable
2 x 15 A
7.5 A
HX (5882)
XP (5662)
Mikuni BN-38I
(diaphragm)
Mikuni BN-40I
(diaphragm)

CARBURETION
Carburetor
Type
Quantity
Main jet
130
Pilot jet
75
Spring
Adjustment
142.5
70
80 g
Low-speed screw
1-1/2 turn 1/4
High-speed screw

Fuel
Type
Minimum octane no.
1 turn 1/4
1500 RPM
3000 RPM

87
MAG and PTO: 0.8 mm (.031 in)
COOLING
Type
Thermostat
12-06-2
HX (5882)
XP (5662)

None
86-94C (187-201F)

PROPULSION
Propulsion system
Jet pump type
Transmission
Coupling type
Oil type
HX (5882)
XP (5662)
Counterclockwise
Direct drive
Crown splines
26
90 cm (35 in)
0.5 mm (.020 in)
139.5 mm (5.490 in)
Impeller/wear ring
New
0.0 - 0.4 mm (.000 - .016 in)
clearance
Wear limit
1.0 mm (.040 in)
0.12 - 0.54 mm (.005 - .021 in)
0.05 mm (.002 in)
Progressive pitch
Progressive pitch
DIMENSIONS
Overall length
Overall width
Overall height
Dry weight
Load limit
CAPACITIES
Fuel tank
Capacity
Oil level height

HX (5882)
1
273 cm (107.5 in)
85 cm (33.5 in)
97 cm (38.2 in)
177 kg (390 lb)
110 kg (250 lb)
XP (5662)
2
272 cm (107 in)
111 cm (43.7 in)
103 cm (40.6 in)
238 kg (525 lb)
HX (5882)
XP (5662)
27 L (7 U.S. gal)
41.5 L (11 U.S. gal)
70 mL (2.4 U.S. oz)
Up to plug
4 L (1 U.S. gal)
12-06-3

MATERIALS
Hull
Inlet grate
Air intake silencer
Flame arrester
Exhaust muffler
Steering padding
Fuel tank
Seat
STANDARD EQUIPMENT
Safety lanyard
Fuel tank reserve
Monitoring beeper
Speedometer
Tachometer
VTS gauge
Info Center
Reverse
Storage compartment
Rear grab handle
Extinguisher holder
Tool kit
PERFORMANCE
throttle

Fuel tank reserve
12-06-4
HX (5882)
XP (5662)
Composite
Aluminum
plastic
Thermoplastic
Aluminum
Thermoplastic elastomer
Thermoplastic with
with polystyrene foam
polyethylene foam
Polyethylene
Polyethylene
Polyurethane foam
HX (5882)
XP (5662)
Standard
Standard
Standard
Standard
Not applicable
Standard
Optional
Standard
Not applicable
Standard
Not applicable
Standard (manual)
Not applicable
Not applicable
Standard
Standard
Standard
HX (5882)
34.9 kW (46.8 hp)
33.5 L/h
(8.8 U.S. gal/h)
35 minutes
10 minutes
Standard
XP (5662)
42 kW (56 hp)
44.5 L/h
(11.7 U.S. gal/h)

HX (5882)
24 Nm (17 lbfft) (4)
145 Nm (107 lbfft) (1)
110 Nm
M8
24 Nm
M10
40 Nm
35 Nm
Engine mount/hull
25 Nm
24 Nm
24 Nm (17 lbfft) (1) (4)
25 Nm (18 lbfft) (1)
25 Nm
10 Nm
9 Nm
22 Nm
Starter lock nuts
7 Nm
Spark plugs
24 Nm
Impeller
70 Nm
Pump/hull nuts
31 Nm
21 Nm
4 Nm
Inlet grate screws
8 Nm
Riding plate screws
10 Nm
6 Nm
Steering cable/lever
3 Nm
6 Nm
26 Nm
7 Nm
15 Nm
Lever pivot bolt
6 Nm
14 Nm
(3) Loctite 515
STEERING
JET PUMP
ENGINE
TIGHTENING TORQUES
Flywheel (PTO side)
Crankcase screws
XP (5662)
40 Nm (30 lbfft)
105 Nm (77 lbfft)
(81 lbfft)
(17 lbfft)
(30 lbfft)
(26 lbfft)
(18 lbfft)
(17 lbfft)
40 Nm (30 lbfft)
40 Nm (30 lbfft)
(18 lbfft)
(88 lbfin)
(80 lbfin)
(16 lbfft)
(62 lbfin)
(17 lbfft)
(52 lbfft)
(23 lbfft)
(16 lbfft)
(35 lbfin)
(71 lbfin)
(88 lbfin)
(53 lbfin)
(26 lbfin)
(53 lbfin)
(19 lbfft)
(62 lbfin)
(11 lbfft)
(53 lbfin)
(10 lbfft)
(3) (4)
(1)
(5)
(3) (4)
(3) (4)
(1)
(1)
(1) (4)
(3) (4)
(1)
(1)
(1)
(5)
(1)
(5)
(2)
(1)
(1)
(1)
(1)
(1)
12-06-5
Section 13 WIRING DIAGRAMS

Sub-Section 01 (WIRING DIAGRAMS)
WIRING DIAGRAMS
WIRE COLOR CODES
AMP CONNECTOR
First color of a wire is the main color. Second color

is the tracer.
Example: YELLOW/BLACK is a YELLOW wire
with a BLACK tracer.
GS, GSI, GSX, GTI and XP Models

These connectors are found on the MPEM of the
aforementioned watercraft.
Description
WIRE DIGIT CODES

GS, GSI, GSX, GTI and XP Models
First number indicates in which connector the
wire is plugged in.
Second number indicates the position of the wire
in the connector.
The letter at the end of the number (if applicable)
indicates a common circuit in the MPEM printed
circuit with another wire bearing the same letter.
Example: 2-18 (g)
The first number indicates that the wire is positioned in the connector no. 2 of the MPEM.
The second number indicates that the wire is positioned in the terminal no. 18.
The letter (g) indicates a common circuit with another wire(s) bearing the same letter (g) in the circuit.
WIRE TERMINAL REMOVAL

To remove terminal from connector housing, use
Snap-on TT600-4 tool.
F00H0MA
PLUG CONNECTOR
1. Housing
2. Wedge lock
3. Locking tab
Removal
To remove the plug connector from the header assembly, press both tabs and pull plug.
1
2
F01B1JA
WARNING
Ensure all terminals are properly crimped on

wires and connector housings are properly
fastened.
F00H0NA
Step 1 : Press tabs (both sides)

Step 2 : Pull plug
13-01-1

Contact Removal
Insert a screwdriver blade between the housing
and wedge lock on the lock tab side.
Pry the wedge lock to unlock the tab (open position).
1
1
2
F00H0QA
1. Rotate wire back and forth

2. Pull wire
F00H0OA
1. Screwdriver between wedge lock and housing

2. Locking tab
Repeat the same steps for the other locking tab

retaining the wedge lock.
The wedge lock is now in the open position.
CAUTION
The wedge lock should never be removed

from the housing for insertion or removal of
the contacts.
Contact Installation
Make sure the wedge lock is in the open position.
To insert a contact, push it straight into the appropriate circuit cavity as far as it will go.
1
1
2
F00H0PA
1. Wedge lock opened
While rotating the wire back and forth over a half

turn (1/4 turn in each direction), gently pull the
wire until the contact is removed.
F00H0PB
1. Wedge lock open

2. Push the wire
Pull back on the contact wire to be sure the retention fingers in the housing are holding the contact
properly.
After all required contacts have been inserted, the
wedge lock must be closed to its locked position.
13-01-2

Release the locking tabs by squeezing them inward.

1
F00H0RA
1. Squeeze locking tab (both sides)
Slide the wedge lock until it is flush with the housing.
13-01-3

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0

219 100 048

Bombardier Inc. 1996

Loctite is a trademark of Loctite Corporation

SAFETY NOTICE .............................................................................................................

TROUBLESHOOTING ........................................................................................................................................ 02-01-1

01 - Table of Contents........................................................................................... 04-01-1

01 - Table of Contents........................................................................................... 06-01-1

01 - Table of Contents........................................................................................... 10-01-1

01 - Table of Contents........................................................................................... 11-01-1

01 - SP and SPX Models .......................................................................................

WIRING DIAGRAMS.......................................................................................................................................... 13-01-1

1997 BOMBARDIER WATERCRAFT SHOP MANUAL

HULL IDENTIFICATION NUMBER

SP, SPX, GTS and HX Models

*A letter may also be used as a digit.

1. Hull Identification Number (H.I.N.)

XP, GS, GSI, GSX, GTI and GTX Models

1. Hull Identification Number (H.I.N.)

1997 BOMBARDIER WATERCRAFT SHOP MANUAL

1. Engine Identification Number (E.I.N.)

1997 BOMBARDIER WATERCRAFT SHOP MANUAL

Exploded view assits

Bold face number

Tightening torque nearby fastener.

Page numbering system:

Pay attention to torque specifications. Some of these are in

1997 BOMBARDIER WATERCRAFT SHOP MANUAL

Section 06 FUEL SYSTEM

Title indicates main

Title in italic indicates a

DISASSEMBLY AND INSPECTION

To remove carburetors from engine, proceed as follows:

Inspect parts for corrosion dammage (shaft, butterfly,

NOTE: For fuel line removal, use pliers (P/N 295

Disconnect pulse line from fuel pump.

Diaphragm must stand pressure for 10 seconds. If

Letters are used for

Bold numbers in the

Numbers are used

1997 BOMBARDIER WATERCRAFT SHOP MANUAL

FLUSHING AND LUBRICATION............................................................................................

PERIODIC INSPECTION CHART

Every 10 hours in salt water use.

FLUSHING AND LUBRICATION

SP, SPX, GTS and XP Models

This prevents water from exiting through

Perform this operation in a well ventilated

Clean jet pump by spraying water in its inlet and

Always remove safety lanyard cap from

SP, SPX and GTS Models

Attach other end of coupler hose to a garden hose.

Do not open water tap yet.

GS Series, GTI and GTX Models

Always start the engine before opening the

NOTE: A quick hose connector can be used to

1. Quick hose connector

1. Air intake silencer cover

Spray BOMBARDIER LUBE lubricant through air

1. Garden hose installed