1996 Seadoo Service Shop Manual

www.SeaDooManuals.
net
0
0
SHOP
MANUAL
0
www.SeaDooManuals.net
219 100 031
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.
cBombardier Inc. 1995
Printed in Canada
r*Registered trademarks of Bombardier Inc.
Loctiter is a trademark of Loctite Corporation
Snap-onr is a trademark of Snap-on Tools Corporation
Gelcoter is a trademark of Gelcote International
Limited
TABLE OF CONTENTS
SECTION
SUBJECT
PAGE
SAFETY NOTICE ..............................................................................................................
II
INTRODUCTION ...............................................................................................................
III
01
SERVICE TOOLS
AND PRODUCTS
01 - Mandatory Tools ..............................................................................................01-01-1

02 - Recommended Tools .......................................................................................01-02-1
03 - Service Products..............................................................................................01-03-1
02
MAINTENANCE
00 - Table of Contents .............................................................................................02-00-1

01 - Periodic Inspection Chart .................................................................................02-01-1
02 - Flushing and Lubrication ..................................................................................02-02-1
03 - Water-Flooded Engine .....................................................................................02-03-1
04 - Storage ............................................................................................................02-04-1
03
04
TROUBLESHOOTING ..................................................................................................................................... 03-00-1

ENGINE

01 - Removal and Installation ..................................................................................04-01-1
02 - Top End ............................................................................................................04-02-1
03 - Bottom End......................................................................................................04-03-1
04 - Rotary Valve .....................................................................................................04-04-1
05 - Exhaust System ...............................................................................................04-05-1
05
COOLING SYSTEM

01 - Components ....................................................................................................05-01-1
02 - Circuit...............................................................................................................05-02-1
06
FUEL SYSTEM

01 - Fuel Circuit .......................................................................................................06-01-1
02 - Air Intake..........................................................................................................06-02-1
03 - Carburetors ......................................................................................................06-03-1
07
LUBRICATION SYSTEM

01 - Oil Injection System.........................................................................................07-01-1
02 - Oil Injection Pump ...........................................................................................07-02-1
08
ELECTRICAL SYSTEM

01 - Magneto System .............................................................................................08-01-1
02 - Ignition System................................................................................................08-02-1
03 - Charging System .............................................................................................08-03-1
04 - Starting System ...............................................................................................08-04-1
05 - Instruments and Accessories ..........................................................................08-05-1
06 - Digitally Encoded Security System ..................................................................08-06-1
09
PROPULSION SYSTEM

01 - Jet Pump .........................................................................................................09-01-1
02 - Drive System ...................................................................................................09-02-1
03 - Reverse System ..............................................................................................09-03-1
04 - Variable Trim System .......................................................................................09-04-1
10
STEERING SYSTEM

01 - SP and XP Series .............................................................................................10-01-1
02 - GTS and GTI Models........................................................................................10-02-1
03 - HX Model .........................................................................................................10-03-1
04 - Alignment ........................................................................................................10-04-1
11
SUSPENSION

01 - Direct Action Suspension ................................................................................11-01-1
12
HULL / BODY

01 - Adjustment and Repair ....................................................................................12-01-1
02 - Painting ............................................................................................................12-02-1
13
TECHNICAL DATA
01 - SP and SPI Models ..........................................................................................13-01-1

02 - SPX and XP Models .........................................................................................13-02-1
03 - GTS and GTI Models........................................................................................13-03-1
04 - HX Model .........................................................................................................13-04-1
14
WIRING DIAGRAMS..........................................................................................................................................14-00-1
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.
00-0-2
1996 BOMBARDIER WATERCRAFT SHOP MANUAL
INTRODUCTION
This Shop Manual covers BOMBARDIER made
SEA-DOO watercraft models SP5876, SPX
5877, SPI 5878, XP5858, HX 5881, GTS5817
and GTI5865/5866.
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
All Engines Except the 787
The Engine Identification Number is located on
the upper side of the magneto housing.
HULL IDENTIFICATION NUMBER

(H.I.N.)
It is located at right rear side of hull.
F01D01A
1. Engine Identification Number (E.I.N.)
F01L45A
1. Hull Identification Number (H.I.N.)
The Hull Identification Number is composed of 9

digits:
787 Engine Only

The Engine Identification Number is located on
the upper side of the crankcase on PTO side.
Z Z N 1* 2 3 4 5 L 4 9 5
Model year
Serial
number
Year of production
Month of production
F00A0CA
*This digit may be a number or a letter.
F01D87A
1. Engine Identification Number (E.I.N.)
00-0-3
ARRANGEMENT OF THIS
MANUAL
The manual is divided into 14 major sections:
01SERVICE TOOLS AND PRODUCTS
02MAINTENANCE
03TROUBLESHOOTING
04ENGINE
05COOLING SYSTEM
06FUEL SYSTEM
07LUBRICATION SYSTEM
08ELECTRICAL SYSTEM
09PROPULSION SYSTEM
10STEERING SYSTEM
11SUSPENSION
12HULL / BODY
13TECHNICAL DATA
14WIRING DIAGRAMS
Several sections are divided in various sub-sections. There is a table of contents at the beginning
of many sections.
00-0-4
TYPICAL PAGE
Page heading
indicates section
and sub-section
detailed.
Section 08 ELECTRICAL
Sub-Section 01 (MAGNETO SYSTEM)
Sub-section title
indicates
beginning of the
sub-section.
MAGNETO SYSTEM
587 and 717 Engines
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.
13
9 Nm
(80 lbfin)
Loctite
242
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
Loctite
242
3
14
Bold face number

indicates special
procedure
concerning this part.
Loctite
242
9
6 Nm
(53 lbfin)
4
Loctite
648
10
15
145 Nm
(107 lbfft)
Anti-seize
lubricant
F01D4WS
2
9 Nm
(80 lbfin)
Illustration number
for publishing
process.
08-01-1
Tightening torque nearby

fastener. In this case, nut
must be torqued to
145 Nm (107 lbfft).
CAUTION : Pay attention to torque specifications.
Some
of these are in lbfin instead of lbfft. Use
Page numbering system :

08 : ELECTRICAL SYSTEM section
01 : MAGNETO SYSTEM sub-section
1 : First page of this sub-section
appropriate torque wrench.

F01A09S
00-0-5
TYPICAL PAGE
Sub-title
beginning with
part number(s) of
above exploded
view following 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.
Sub-sub 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 and lock washers retaining carburetors.
Remove carburetors from intake manifold.
All Others Models
Remove 4 bolts and lock washers 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, otherwise 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
Numbers are used

for desciption of
components.
F01A0AS
00-0-6
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. Mismatched or
incorrect fasteners could cause damage to the
watercraft or possible personal injury.
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.
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.
Technical Publications
Bombardier Inc.
Valcourt (Quebec), Canada
PARTS CATALOGS
MODELS
P/N
SP (5876)
SPX (5877)
SPI (5878)
219 300 180
GTS (5817)
GTI (5865/5866)
219 300 210
XP (5858)
219 300 200
HX (5881)
219 300190
00-0-7
Section 01 SERVICE TOOLS AND PRODUCTS

Sub-Section 01 (MANDATORY TOOLS)
MANDATORY TOOLS
NOTE : The numbers outlined in black (example : ) are reference numbers to tools from other dlvlslons
(Sea-Doo and/or Sea-Doo Jet Boats). Matchinq reference numbers indicate the same tool is being used on
both products, even if the part numbers are different:
ENGINE
Degree wheel
El
Piston circlip installer
o
m
.
m
A) P / N 295000077
P / N 295000007
II
B) P / N 290877016
1
5
2
.,.,.,,,.,.,,,.,
,., ,. ,., ,.,
,, Q :,
. :.,.,,.,.,,,.,.,,,.,.
,., ,,. ,,, ,., :.
pf~
4
,. ::,..., .,., ,..,,
9
3
::;;
. ,.,. . . . . . . :;.
...
J!?Sl!$
4
~
Plstor-1
clrclip
A01B1P4
APPLICATION
A) 587 engine.
B) 657, 717 and 787 engines.
AOOB334
NIAG side
APPLICATION
PTO side
01 D884
.
All models.
1 )
A
m
Rubber pad
P / N 295000101
Q
P / N 290876298
.
A
2) Protective cap
m
(both ends)
P / N 290876557
.
3) Ring (both ends)
m
P / N 290977475 (2)
~)~istance ring (MAG)

m
FOIBOJA
APPLICATION
P / N 290876569
. 6) Ring halves (MAG)
..
m
All models.
P / N 290876500
II
m
P / N 290977490
~)~ing halves (PTO)
m
=
0
e
m
Bearing pusher
Puller
P / N 290876605
/
AOOCOY4
APPLICATION
All engines except 787.
Bombardier ignition
tester
P / N 295000008
P / N 290276025 (2)
. .
7) Screw M8 x 40
m
P / N 290840681 (2)
-.6
8) Screw M8 x 70
m
0
TESTER
~ w~
70
R*1
@
20:
m
a
: @ : : :
:El
0
APPLICATION
All models.
(9
IGNITION
P/N 290841201 (2)
AOOB2J4
.
m
Pusher
AOOC1 K4
APPLICATION
APPLICATION
All models.
All models.
01-01-1

ENGINE (continued)
E.
Puller
P / N 295000106
PTO flywheel remover/

instal Ier
P / N 295000001
F01JOT4
AOOC1A4
-
,4
m
Pulier plate
P / N 290876080
B(
Extension handle
P / N 295000125
- FO1 D164
IZew M8 x 35 (3)
P / N 290841 591
295000105 m
=2
~
A) 657, 717 and 787 engines
NOTE : This tool is also

used for the impeller.
Replacement parts :
1. Locating sleeve
P / N 290877181
Puller
2. Expansion sleeve
P / N 290877041
3. Extracting nut
P / N 290877155
t
m
0o @
\
m
B) 587 engine
Replacement parts :
All engines.
A) Alignment tool support
P / N 295000090 m
.*
1. Locating sleeve
m
P / N 295000118
(2)
2. Expansion sleeve m
. :
P / N 295000117
(2)
3. Extracting nut (2)m
.
P / N 295000115
B) Alignment shaft
P / N 295000093
C) Alignment shaft
P / N 295000141
MPEM
t
m
/ N 295000127
,,,..P
,.., ,.,.,. ,,.. .,,. ., ,.,..,,.,. ,,...,,..,.,,..,, .,.,. .,,.. ,. ,,.,..,.,...,, ..,, ,,. .,...,.,. ,. ,.,..,, ., .,,.,..,. ,,. ,.,.,..,.,.,., ..,.,,.,. .,,...,,.,, .,., .,, ,.., ,,.,,..,,. .,,. .,, ,.,, ,.,. ,., ,,,.., ,.,,.,.,. ,,,.,,.., ,., ,, .,.,.,.,, .,,. .,,. ,.,.,., .,,., .,, .,., ,.,,,.. ,,. ,,..,, .,, .,. ,,.,., ., ,.
.:: .::. .::. ::. :.:.::..:.:.. :.:..::..:.:..::. .:.::..:..:. ::..:.:..: .:..::. .::..::...:.::..:..::. .:.:.:. .::..::..:.:.. :.:..::..::.. .::..:.:..::. ..:: . :. :.:.:..:. .::..:.:.:.:..:.:. :.:..::..::. .:.:. .: .::..:.:. . ::...::..::. ..::. .: .::..:..::. :..:.:.:..:.:..::..::..:..::..:.:..::..:..::..::..:.:..:.:.:..::..:.:.:..::...::..::..:,..::. ,..:..,. . .
,: : .:,.,:.,:.,
,, ,,..,,
,..,,..,,
,,..,,.,,..,,..,,.,
,,. ,,..,,
.::..::.,,.::...::...::...
:, :,.:,
,,,...,,,...,,,...,,,...,,,...
.,.,,..,,
,,..,,..,,..,,..,,..
,.,.,
,:,...:,,..:..,,:..,:,...,,,.. ,,, , .,,.,,,, ,,, ,., ,,, ,,, ,., ,., ,,, ,,, ,., ,,, ,,, ,,, ,,, ,,, ,,, ,,, ,.:.:. ,,..,, ,,
,.,,,,.,.,.,,,.,... ,,, ,., ,., .., ,,. ,.. ,.. ,,, ,,, .,..,,.,,.,,..,,,,,,,,.,,,,,,,,,,,,,,,,,.,.,,.,,
,. .,.,.,.,.,..,. ,. .,.,. ,.,.,..,.,. .,.,.,.,.,..,.,. .,.,.,.,.,..,.,..,.,.,.,.,.,.,..,.,. .,.,.,.,.,..,.. .,.,.,. .,.,..,.,. .,.,.,.,.,.,.,..,.,. .,.,.,.,.,..,.,. .,.,.,.,.,. .,. .,. . . .
:.,. ..,:...,,:..,:...,:..,,:...,:..,:. ..,,:...,:..,:...,:..,:...,:..,:. ..,:...,:..,:...,:.. ,:...,,:..,:...,:..,:. ..,:...,:..,:...,:..,:...,:..,:. ..,:...,:..,:...,:,. .,:...,,:..,:...,:..,:. ..,:...,:.. ,:...,:..,:.,..,:..,,:. ..,:...,:..,:...,:.. ,:...,:..,,:. ..,:.,.,.:..,,:...,:.. ,:...,,:..,:...,:..,:. ..,:...,:..,:...,:.. .:,,..:..,:. ..:.,,..:..,:. .. ,:.,..,:.. . .
,. .,. .,.,...,..,..,..,. .,...,.,...,.,..,..,. .,..., .,...,.,. .,..,..,. ,. .,...,.. ,...,.,. .,..,. .,...,.,...,.. ,...,..,..,. ,. .,...,. ,...,..,. .,..,. .,...,.,...,.,. .,.. ,. .,..,. .,...,.,...,..,..,. ,. .,...,.,.. .,.,. .,..,. .,. .,. .,. .,. .. ,. .. . .
F01L2R4
APPLICATION
programmer
F01B254
FOOAOA4
APPLICATION
All models
<a
APPLICATION
P / N 290847220
0
0
All models.
FOOA094
-
Sleeve (3)
P/N
.m
APPLICATION
6)
290877092
F01BOV4
APPLICATION
P/N
3 m
F01BO14
A)
I@
P / N 290876488
AOOC1R4
-
Piston pin puller
A) All models.
APPLICATION
B) All models except HX.
787 engine.
c) l-lx.
01-01-2
.
m

ENGINE (continued)
R i n g g e a r b l o c k i n g t o o lm
. :
P / N 295000134
F01B264
APPLICATION
787 engine.
Ring gear puller tool
P / N 420976235
F01B294
APPLICATION
787 engine.
Distance gauge
ml
P / N 290876826
FO1 BOH4
APPLICATION
587 and 657 engines.
01-01-3

COOLING / FUEL/ OIL SYSTEMS

Hose pincher
P / N 295000076
Pliers
m
8 0
P / N 295000054
Calllau
F01B1T4
APPLICATION
, AO1 B214
All models.
APPLICATION
All models.
Gear holder
NOTE : This tool is also used

for the propulsion system.
.4
m
Flush kit
P / N 290277 905
P / N 295500068
F01E014
AOOC164
APPLICATION
APPLICATION
587, 717 and 787 engines.
717
engine,
Coupler hose
Pliers
m
.0
p,/ N 29.5 000 07(,)
P / N 295500258
41 cm (16 in)
Oetlker 1099
F01EOZ4
APPLICATION
FO1 D174
All models.
APPLICATION
All models.
01-01-4

PROPULS1ON SYSTEM
Impeller remover /
i nsta I Ie r
Bearing / seal installer
o~
m
P / N 295000107
VTS tool
*O
m
P/ N 295000133
P / N 295000001
F01JOT4
F01B2P4
APPLICATION
APPLICATION
All models.

used for the PTO flywheel.
Pliers
XP 1995 and 1996 models.
F01J4K4
APPLICATION
XP 8001995 model.
All models.
SPX 1996 model.
P / N 295 000069
Impeller shaft guide
P / N 295000002
Oetiker 1090
~b
FO1J1O4
APPLICATION
FO1 D184
All models.
APPLICATION
All models.
Pliers
Impeller shaft holder
.8
m
I*
m
P / N 295000054
P / N 295000082
Calllau
F01B1T4
F01BOW4
APPLICATION
All models.
APPLICATION
All models.
NOTE : This tool is also used

for the fuel system.
01-01-5

Sub-Section 02 (RECOMMENDED TOOLS)
RECOMMENDED TOOLS
NOTE : The numbers outlined in black (example : ) are reference numbers to tools from other divisions
(Sea-Doo and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being used on
both products, even if the part numbers are different.
ENGINE
Ring compressor
Stroboscopic timing light ~

P / N 295000078
P / N 290876979
Dlgltal / induction type

tachometer
P / N 295000100
, AO1 B1T4
A01B2K4
APPLICATION
FO181G4
717 and 787 engines (82 mm).
APPLICATION
APPLICATION
All models.
All models.
Coil centering tool

Dial indicator
UDC gauge)
P / N 295000143
P / N 290876922
Dlgltal multlmeter
i
m
P / N 529022000
AOOB2E4
APPLICATION
All models.
A01B1V4
APPLICATION
Distance gauge
717 engine.
A) P / N 290876827
Cylinder aligning tool
t
m
B) P / N 290876828
.0
m
P / N 290876904
FO1B1O4
APPLICATION
All models.
AOOB084
APPLICATION
All models.
FOIBOH4
APPLICATION
A) 717 engine.
B) 787 engine.
01-02-1

ENGINE (continued)
Timing mark pointer
Ring halves and ring
P / N 295000130
P / N 290876330
(halves) (2)
Terminal remover
m
Not sold by Bombardier

Snap-on
TT 60@4
P/N 2 9 0 9 7 7 4 8 0 (ring) .
o
--
F01B1J4
G;
F01B2D4
, FO1 B204
APPLICATION
All engines except 787.
Timing mark pointer
P / N 295000135
APPLICATION
All models.
APPLICATION
787 engine
Slide hammer puller

Engine Ilftlng device

Do It yourself
Snap-on Handle
CJ93-I
Hammer CJ1 25-6
Claws
CJ93-4
Refer to Shop Manual sect[on

04-01
F01JOZ4
o
#
F01H544
APPLICATION
All models.

used to pull out impeller
shaft seal.
APPLICATION
v
787 engine.
FOIDOA4
Protective mat
P / N 295000128
Oil seai pusher
APPLICATION
P/ N 290877740
All models except 787

Feeler gauge 45
Snap-on
FB 300A
F04L1V4
APPLICATION
F01B2C4
All models.
APPLICATION
787 engine.
F01B1K4
APPLICATION
All models
01-02-2
.. .. .
m

ENGINE (continued)
..
m
Safety lanyard switch tool ~
Handle
P / N 295000121
P / N 290877650
Ring compressor
A) P / N 290876972
t
m
B) P / N 295000112
F01B244
A01B1T4
APPLICATION
APPLICATION
DESS switch.
A) 587 engine (76 mm).

AOOC3V4
A) Four-pin
magneto m
.
harness
P / N 295000131
APPLICATION
B) Six-pin magneto
harness
P / N 295000136
Exhaust
B) 657 engine (78 mm).
787 engine.
Crankshaft protector
outlet
tool
:
m
P / N 420876552
P / N 295000132
\,
p
F01B284
F01B2A4
APPLICATION
APPLICATION
APPLICATION
A) 587, 657 and 717, 1995 and

newer.
Exhaust nut on transom.
B) 787 engine.
Gear/
Rotary valve shaft

pusher
FOOB034
bearing
For use with pullers.
puller m
.
P / N 290877665
P / N 290876609
F04B034
F01B2B4
APPLICATION
APPLICATION
787 engine.
787 eng[ne.
01-02-3

COOLING / FUEL/ OIL SYSTEMS

Pump
gauge
tester : .
(carburetor
P / N 295000114
Screwdriver
Spring compressor
P / N 529027100
Snap-on
SDD-143
i--l
F01B1P4
APPLICATION
All models.
Lighted adjustable mirror
A01B404
APPLICATION
F01BOX4
Snap-on
50101
APPLICATION
Suspension adjustment m
:
wrench
All models.
Pump
gauge
tester
(fuel / oil reservoirs)
P / N 295000085
HX.
P / N 529012200
F01B114
APPLICATION
All models.
Hose pincher
P / N 529030400
A25A014
APPLICATION
HX seat suspension.
F01BOY4
APPLICATION
All models.
F01B234
APPLICATION
All engines.
01-02-4

PROPULSION SYSTEM
Fitting
Machinists square
Bearing remover
P / N 295000086
P / N 295000144
Snap-on
P~F I 22
~01 Jl14
APPLICATION
0
All models.
~!
II
.. -. . - J ; ~
-- - - $ --- - . - -&
;L:::j,,-.,,.
..7. !67 ,. h$,4. ,;. ,..+- ..,------.. ---=.k:4---u;:LJ;;;:::;...m;:J::::.
, FO1 BOZ4
APPLICATION
F02B064
All models.
APPLICATION
Flexible spout (oil)

P / N 414837300
Models equipped with reverse.

Slide hammer puller
.,
m
APPLICATION
All models.
Fitting remover
Snap-on Handle
CJ93-1
Hammer CJ1 25-6
Claws
CJ93-4
Do it yourself
Refer to Shop Manua/ section
09-01
Impeller housing
remover
: .
m
P / N 295000113
.)
Deep socket
14 mm
(9/1 6 In)
F01JOZ4
APPLICATION
All models.

used to remove rotary valve
shaft bearing.
F01J2RA
APPLICATION
Hacksaw
Q
G
All models.
Ff11L204
APPLICATION
All models.
Snap-on
HS3
FO1 B1 M4
APPLICATION
All models.
01-02-5

WATERC RAFT HANDING

Dolley
(with
wheels)
: .
m
Lift kit
Tie-down with ratchet :m

:
3.60 m (12 ft) long
A) P / N 295100012 m
: c
:: t
B) P / N 295100 0? 3
m
P / N 295000126
P / N 295100 0! 1
APPLICATION
AlI models.
F01B014
.
Beach wheels (2)
.
m
P / N 295000005
F01B1N4
APPLICATION
A) SP and XP series.
B) GTS and GTX models.
1
: :A
m
Tie-down
1.50 m (5 ft) long
F01B074
P / N 295100010
APPLICATION
All models.
FOOB014
APPLICATION
All models.
01-02-6

Sub-Section 03 (SERVICE PRODUCTS)
SERVICE PRODUCTS
NOTE : The numbers outlined in black. (example : ) are reference numbers to tools from other divisions
(Sea-Doo and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool iS being USe~ On
both products, even if the part numbers are differen~
Medium strength
thread locker
A
m
High strength
thread locker
P / N 293800005
P / N 293800015
Em
P / N 293800039
Loctlte 642
(50 mL)
Loctite 271 (red)

(1 O mL)
Loctlte 242 (blue)

(1 O mL)
. .
m
Assure
f@BTITE
@JRE
LJwl!m$
A..
,71
*...-!
kii%zz?
RETAININO COMPOUND \
642
T=ADLCCW7>42
~1
~
8
AOOB324
APPLICATION
Cylinder head screws
(All engines).
Tuned pipe nut and screws.
Engine rubber mount screws.
Armature plate screws.
Magneto f Iywheel / crankshaft.
N ET I rnFL 02 K4ml)
AOOB2U4
APPLICATION
Impeller shaft thread.
FOOB024
APPLICATION
High temperature
threadlocker
Press fit parts on crankshafts.
P / N 290899788
Retaining compound
Loctlte 648 (green)

(5 g)
P / N 413703100
Loctlte@ RC / 609 (green)
(1 O mL)
Carburetor mount nuts / screws.

Magneto coil screws.
Impeller housing cover screws
(except for plastic pumps).
Venturi / impeller housing
screws.
Intake grate screws.
Engine support screws.
Impeller housing / hull nuts.
Steering nozzle screws.
Reverse gate screws.
%P
=
-
APPLICATION
Crankcase / plug at end of rotary
valve shaft.
Magneto / ring gear.
i
AOOB2SA
APPLICATION
Used for retaining bushings, bearings in slightly worn housing or
on shaft.
01-03-1

General purpose instant

adhesive
Solvent
P / N 293800019
Gasket eliminator
P / N 293800007
P i N 293800021
~octlte 495
AOOB2VA
Loctlte Safety
Solvent 755
{ 12 Oz!
Loctite 515
!50 m i-;
@@/rr m.
*
a
AOOB2T4
APPLICATION
Rubber to metal bonding and

most hard plastlc.
*
B
~
APPLICATION
Cylinder sleeve / O-ring groove.
1400
I
Gasket stripper
m
P / N 295000110 (500 mL)
Crankcase halves mating surface.

Crankcase screws.
AOOB3M4
APPLICATION
Impeller shaft threads.
Gasket eliminator
Drive shaft splines.
P / N 293800038
Impeller threads and splines.
Loctlte 518
(50 mL)
:
m
Primer for gasket

eliminator
P / N 293600013
Loctke
Locquic Primer N
(170 mL)
F01B1W4
APPLICATION
F01B124
APPLICATION
Impeller housing cover.
Mating surfaces of cylinders and

crankcase.
Venturi / impeller housing.

Ulc
Crankcase halves.
y;
Impeller shaft seal.
PRIMERN
m
~
,!,. cnu-
Pipe sealant
A) P / N 293800018
o
AOOB3N4
APPLICATION
B) P / N 293800013
A) Loctlte 592
(50 mL)
.
m
91
m
B) Loctlte 567
(250 mL)
Crankcase halves mating

surface.
Plfn SdmtwlthTafkm*
Impeller shaft thread.

Venturi / impeller housing
mating surface.
AOOB2W4
APPLICATION
Plug on impeller housing cover.
Plastic fitting tool (P/ N 295000
086) on impeller housing cover.
Cooling system fittings.
01-03-2

.
m
Hylomar sealant
P / N 293800001
Heat resistant sealant
A
m
8
m
P / N 293550004
P / N 413709200
DL32
100 g)
Dielectric grease
Dow Cornlncj
( 150 g)
Dow Corning 736

(90 m L}
AOOB3F4
AOOB3U4
~01 B164
APPLICATION
APPLICATION
APPLICATION
Tuned pipe.
Battery posts and cable connectors.
. .
m
Sealant
8
m
Sealant
Thermosensor switch.
P / N 413710300
P / N 293530011
.,
m
Grease
Loctlte 179
(80 mL)
Slkaflex 221
(350 mL)
P / N 293550005
(400 g)
APPLICATION
Exhaust system 787 engine.
FO1 BI D4
APPLICATION
Slkaflex primer
Epoxy glue
449
APPLICATION
3M-05900
PTO flywheel.
:
m
P / N 293530012
(475 mL)
AOOB2L4
Superlube grease
APPLICATION
.
m
P / N 293550014
All models.
Gun Kote
INDUSTW!l
u e~
e
e
%?,;::,::,::;:..!
. !,,.!,...
\* ,. ,0, i, ,
===
~
+s+5=
II&
Kal-Gard
Coating & Mfg Corp
F01B1E4
APPLICATION
APPLICATION
Magneto and armature plate.
AOOB474
For use with SIkaflex 221

sealant.
APPLICATION
01-03-3

Anti-seize lubricant
Lubricant
Not sold
Em
(8 OZ)
Loctlte anti-seize
Iubrl cant
12 Oz (454 g)
G E. Versllube
G341 M
P / N 413408600
P / N 293800023
by B o m b a r d i e r
Sea-Doo fuel stabilizer
7
II
=ej
Esso Be;;on 325
.dflll
~~wbo~
FUEL
STABILIZER
AOOB1T4
j~
APPLICATION
Sliding surface of starter armature shaft splines.
F01B174
APPLICATION
AOOB3V4
Crankshaft thread / PTO flywheel.

Synthetic grease
P / N 293550010
(400 g)
Crankshaft bearing seat.
APPLICATION
Fuel system.
Spark plug threads.

Ignition housing cover screws.
Bombardier lube
DB
Bombard ier-Rotax
injection oil
P/N 413802900 (12 X 1 L)
P / N 293600016
F01B154
(12 x 14 Oz)
APPLICATION
Cylinder and cylinder head
screws.
#~MBARDIER
R O T A X .
ti . . . .
In].,?th
Carburetor linkage.
01/
Impeller shaft seal lips.

~
Drive shaft / impeller splines.
PTO flywheel.
F01B184
APPLICATION
All models.
F01BOS4
APPLICATION
Throttle cable.
Wear ring (when new).
Corroded parts.
Water flooded engine.
Storage.
01-03-4

Bombard ier-Rotax
injection oil
.e
m
P / N 413803000
(3x 4 L)
P / N 413803200
(205 L)
Bombardier-Rotax
Formula XP-S synthetic
Injection oIl
.
m
P/N 413710500 (12 X 1 L)
*
m
A ) S i l i c o n e U l t r a Black
t
m
P / N 293800030
o
B) Silicone
m
Ultra Black FIB
P / N 293800028
Loctlte 598
(300 n-l L!
a
MBARDIER
ROTAX.
u
~=K-~
;
c2Eiz3
on
F01B1A4
!I,,.,, ms a
OMBARDIER
ROTAX.
Ij.di.m
APPLICATION
W2
*oil
~Dfl
FO1 B2H4
FO1 B2GA
Ride shoe.
APPLICATION
Jet pump fittings.
All models.
APPLICATION
732 Multi-purpose sealant ~
All models.
,
m
Jet pump 011

Bombardier-Rotax Formula XP-S
synthetic injection oil
P / N 413711000 (3 X 4 L)
P / N 293800006
P/N 293600011 (12 X 6 OZ)
Dow Corning (90 mL)

(ciear)
Sea-Doo
synthetic jet pump 011
P / N 413710700 (205 L)
ES
smanaoo.
1
,
I
Jfl PUMP SYNIHEIEOtL
~::no,,,
a
b
,0.,nuux,.
I ~u Ty::,:,
JIz!qfl
FOI BOP4
APPLICATION
F01B354
F01B1C4
APPLICATION
Ride shoe screws.
.,
m
Sealant adhesive
P / N 293800033
All models.
Adchem 4511
(clear)
APPLICATION
All models.
t
,, . . ,., A. . I.I l. s. E
. . A. .n )
FO1 B1S4
APPLICATION
Ride shoe screws.
Sponson.
01-03-5

.e
m
Sealant
P / N 293800029
Tremco clear
~300 mL)
APPLICATION
Spray paint for metallic parts only

m
A) White (140 g)
m
P / N 293500029
A) Violet
P / N 293500068
A
m
B) Purple (140 g)
P / N 293500020
I
m
B) Yellow (140 g)
P / N 293500078
8A*
m
C) Yellow(140 g)
P / N 293500008
C)
Lavender (140
P / N 293500 05!3
g)m
~
g)m
D)
Magenta
(140
P / N 293500060
g)m
D)
Adhesive
activator
P / N 293530036
(250
mL)
\ RzF
x,,,D ADM6S1F
250mL
, ,,,::\~;.&~,.e~~uW~mL,~&
,.an.w.nc**:yw
.w,.mcr,m
Charcoal (140
P / N 293500030
E) Grey (140 g)
P / N 293500009
.*
m
F) Blue
P / N 293500014
9.
m
G) Green
P / N 293500061
H) White
P / N 293500082
*
m
1) Blue /Violet
P / N 293500077
.
m
SMC spray paint
E) Blue (140 g)
P / N 293500073
Sea-Doo paint for SMC
1[
a~~.~o
%UR:,:;lWJ
04N6@$
@
\
~1
B
-.
APPLICATION
Decals,
Sea-Doo Cleaner
APPLICATION
Storage cover.
a&&s~o
A) GTS 1994.
7UR:;;;1$
B) GTI 1996.
P / N 293110002 (4 L)m
~
*xi*
F01BOQ4
APPLICATION
A) Engine assembly 1995.
Ix%!
400Q
D)
E)
w
\
:
~
DAIIO-
B) Tuned pipe and muffler 1995.
c)
AI
F)
~1
!
F01B2J4
APPLICATION
C) GTS 1992-1993.
@wmEflg
\&mri.i
P/N 293110001 (400 g) ~
R
F01BOQ4
FO1 B1 Z4
i~
b*g-$
Sea-Doo
paint
i#wji+%k]
.. ..- ,-*..
G)
H)
1)
All models.
01-03-6
D) GTX 1992-1993.
E) GT 1991.
.
m

Sea-Doo spray paint for gelcoat

A) Super white (140 g) m
P / N 293500076
Gelcoat (liquid)
Gelcoat repair kit
A) Super white (1 L)
P / N 293500075
A) P / N 295500216
B) P / N 295500340
B) White (1 L)
P / N 293500033
C) P / N 295500100
C) Green (140 g)
P / N 293500062
. .
m
C) Mauve (1 L)
P / N 293500034
m
t
m
D) Turquoise
P / N 293500066
D) Grey (1 L)
P / N 293500035
E) Light grey
P / N 293500067
9A
m
E) Light grey
P / N 293500037
F) Grey (140 g)
P / N 293500040
. t
m
F) Green (1 L)
P / N 293500038
G) White (140 g)
P / N 293500041
G) Turquoise (1 L)
P / N 293500039
H) Purple (140 g)
P / N 293500042
.
m
H) Teal (1 L)
P / N 293500069
F01BOR4
*.
g)m
1) Yellow
P / N 293500081
A) All 1995 models
B) Teal
P/N
1)
293 !500 063
Rhodamine (140
P / N 293500083
D) P / N 295500009
9A
APPLICATION
B)
C) 1993 and 1994 moaels
APPLICATION
D) 1992 and prior models
A)
B)
Gelcoat paste (white)
c)
P / N 293500016
D)
o
m
(1 o Oz)
E)
F01B1Q4
F)
APPLICATION
A) All models 1995.
G)
H) SPX.
B) SPX 1995.
1)
d.
ff$tAlffE DE RIPhl@ti
c)
Geicotee
REPAIR KIT
B
D)
E)
F01BIF4
F)
APPLICATION
G)
H)
1)
01-03-7
Section 02 MAINTENANCE
Sub-Section 00 (TABLE OF CONTENTS)
TABLE OF CONTENTS
PERIODIC INSPECTION CHART.............................................................................................. 02-01-1
FLUSHING AND LUBRICATION.............................................................................................. 02-02-1
GENERAL ............................................................................................................................. 02-02-1
PROCEDURE ........................................................................................................................ 02-02-1
WATER-FLOODED ENGINE..................................................................................................... 02-03-1
STORAGE................................................................................................................................. 02-04-1
02-00-1
Sub-Section 01 (PERIODIC INSPECTION CHART)
PERIODIC INSPECTION CHART
NOTE : Servicing period is given in hours. Shaded area shows the maintenance frequency
.
FREQUENCY
DESCRIPTION
Every
10 hours
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
Oil injection pump adjustment
Fuel filter and oil filter inspection
Fuel filter and oil filter replacement
Engine head bolts, retorque
Steering system
Reverse system / reverse cable adjustment (GTS / GTI)
Variable trim system (SPX / XP)
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 / GTI)
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 model only) lubrication
Water intake grate condition
Hull condition
Cooling system flushing
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.
02-01-1
Sub-Section 02
(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.
WARNING : 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.
1
3
PROCEDURE
WARNING : Perform this operation in a

well ventilated area. Do not touch any
electrical parts or jet pump area when engine
is running.
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.
Remove seat to allow access of cooling system
(except for the HX model).
F01E0RA
587 ENGINE
1. Fitting spigot
2. Coupler hose
3. Hose pincher
All Models Except the HX

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.
NOTE : This prevents water from exiting
through outlet socket. Remove hose pincher after flushing operation.
717 ENGINE
1. Coupler hose
2. Fitting spigot
3. Hose pincher
02-02-1
Sub-Section 02 (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.
Spray BOMBARDIER LUBE lubricant through air
intake silencer cover keeping engine at fast idle.
2
F01E02A
2
1
787 ENGINE
1. Coupler hose
2. Fitting spigot
3. Install a hose pincher here
Attach other end of coupler hose to a garden hose.

CAUTION : Do not open water tap yet.
HX Model Only
Connect a garden hose directly to the adapter located at the rear of the watercraft.
F01F25A
1. 1Air intake silencer cover

2. Pull plug
3. Spray BOMBARDIER LUBE here
NOTE : Lubrication of engine should be

done ateast for one minute. After approximately half a minute, close fuel valve to run engine out of fuel while lubricating.
CAUTION : When engine begins to run irregularly because of fuel starvation, immediately stop water flow before engine dies.
Close the water tap then stop the engine.
CAUTION : Always close the water tap before stopping the engine.
Disconnect the garden hose.
F05E01A
1. Garden hose
NOTE : A quick connect hose adapter can

be fixed to ease garden hose installation to
watercraft adapter.

Unlock and remove coupler hose. Reinstall dust
cap over fitting spigot.
Remove hose pincher from water outlet hose.
02-02-2
Sub-Section 02
All Models
Wipe up any residual water from the engine.
Remove spark plug cables and connect them on
the grounding device.
3
(FLUSHING AND LUBRICATION)
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.
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.
F01H27B
ALL MODELS EXCEPT THE XP

1. .Magneto housing cover
2. Grounding device
3. Spark plug cables
F01H58A
XP MODEL ONLY
1. Grounding device
02-02-3
Sub-Section 03 (WATER-FLOODED ENGINE)
WATER-FLOODED ENGINE
XP Model Only
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, 06-01).
Drain bilge if water is present.
Remove spark plug cables and connect them on
the grounding device.
WARNING : Never crank engine with
spark plugs removed unless spark plug
cables are connected to the grounding device.
All Models Except XP

3
F01H27B
1. Magneto housing
2. Grounding device
F01H58A
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.
CAUTION : Be careful when cranking engine,
water will spray out from spark plug holes.
Spray BOMBARDIER LUBE lubricant (P / N 293
600 016) into spark plug holes.
Crank engine again.
Reinstall spark plugs and spark plug cables then
safety lanyard cap on switch.
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.
02-03-1
Sub-Section 03 (WATER-FLOODED ENGINE)
NOTE : If engine does not start after several attempts, check ignition system for spark
occurence. Refer to ELECTRICAL SYSTEM, 0802.
Check crankshaft if needed, it can become misaligned or deflected. Refer to ENGINE, 04-03.
After engine has started, spray BOMBARDIER
LUBE lubricant through air intake silencer while
engine is running.
2
1
F01F25A
1. Air intake silencer cover

2. Pull plug
3. Spray BOMBARDIER LUBE here
Run engine until it reaches its normal operating

temperature.
CAUTION : Water must be supplied to the
engine to avoid overheating.
02-03-2
Sub-Section 04 (STORAGE)
STORAGE
Engine Draining
Fuel System
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.
Sea-Doo Fuel Stabilizer (P / N 413 408 600) can 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. Do not smoke or
allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the watercraft. Always turn the fuel valve to OFF
position when storing the watercraft.
All Models Except HX
Cooling System Flushing and Engine

Internal Lubrication
F01E1JA
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
02-03.
Propulsion System
TYPICAL
1. Engine drain hose
2. Exhaust outlet
Lubricant in impeller shaft reservoir should be

drained. Reservoir should be cleaned and refilled with 90 mL (3.0 U.S. oz) of SEA-DOO synthetic 75W90 GL5 polyolester oil (P / N 293 600
011). Refer to PROPULSION SYSTEM 09-01.
CAUTION : Use only SEA-DOO jet pump
oil or equivalent synthetic gear oil, otherwise component service life could be reduced.
Do not mix oil brands or types.
HX Model

Lubricate PTO flywheel at grease fitting with synthetic grease (P / N 293 550 010).
CAUTION : Do not lubricate excessively.
Immediately stop when a slight movement is noticed on rubber boot.
F05J04A
1. Engine drain hose

02-04-1
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.
CAUTION : Never clean apparent fiberglass
and plastic parts with strong detergent,
degreasing agent, paint thinner, acetone, etc.
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.
F01I0BA
1. Grease PTO flywheel
: Never leave any clothing, tool

- CAUTION
or other objects near PTO flywheel and
seal carrier.
HX Model Only
Lubricate mid bearing of drive system at seal carrier grease fitting with synthetic grease.
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.
The seat should be partially left opened during
storage (the hood for the HX). This will avoid engine compartment condensation and possible corrosion.
NOTE : If the watercraft is stored outside
with seat (or the hood for the HX) partially
opened and without a tarpaulin, unscrew the rear
drain plug in order to avoid water build up in the
bilge during rainfall. Tilt the watercraft to the rear
so that water can flow out.
Additional Recommended Protection

F05I09A
1. Grease fitting
Battery
For battery removal, cleaning and storage, refer to
ELECTRICAL 08-03.
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. Refer
to SERVICE TOOLS AND PRODUCTS 01-02. Replace damaged labels / decals.
In cool regions (where freezing point temperature

may be encountered), cooling system should be
filled with water and antifreeze solution.
CAUTION : Always use ethylene-glycol
anti-freeze containing corrosion inhibitors
specifically recommended for aluminum engines.
NOTE : The engine will not have to run during this operation.
02-04-2

Install coupler hose to fitting spigot.
Install a hose pincher to engine water return hose
(beside fitting spigot).
1
Disconnect engine water supply hose and engine

water return hose.
F05E03A
1. Engine water supply hose

2. Engine water return hose
F01E1EA
1. Coupler hose
2. Fitting spigot
3. Hose pincher
Pour slowly the antifreeze mixed with water in

coupler hose until the colored solution appears in
the engine drain hose.
HX Model Only
Install a hose pincher to engine drain hose.
F05E02A
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
The following steps should be performed to provide the watercraft enhanced protection.
Remove muffler and drain out as much water as
possible. Reinstall muffler.
OR : Disconnect one hose from muffler and pour
some antifreeze solution inside muffler. Reconnect hose.
Lubricate the throttle cable with BOMBARDIER
LUBE lubricant.
NOTE : A cable luber can be used on throttle
cable end to inject BOMBARDIER LUBE lubricant.
1. Hose pincher
2. Drain hose
3. Magneto housing cover
02-04-3
Section 03
TROUBLESHOOTING
TROUBLESHOOTING
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
REMEDY
Engine does not turn over
Safety lanyard cap worn or removed
Replace / reinstall
Burnt 5 A fuse
Check wiring then replace fuse
5 A fuse keeps on burning
Check wiring, solenoid and MPEM
Discharged battery
Check / recharge
Battery connections
Check / clean / tighten
Water / fuel hydrolock)

Starter
Check, refer to section 02-03

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 09-01
Partial engine hydrolock

Partial engine seizure

Check compression, refer to section 04-02
Worn starter
Fuel water-contaminated
Renew supply
Dirty fuel filter
Clean / replace
Fouled spark plugs
Replace
Water in engine
Carburetion
Ignition
Flooded engine
Engine turns slowly
Engine turns over
Needle valve stuck open
No spark at spark plugs
Excessive rotary valve clearance
Internal engine damage
Check, refer to section 04-02 and 04-03
Sheared flywheel key
Check timing mark, refer to section 08-02
Incorrect rotary valve timing

Replace M.P.E.M. (587 and 717 engines) or
DC-CDI ignition module (787 engine)
Faulty rev limiter
' SYSTEM 08-06 for troubleshooting of problems related with this system.
NOTE : Watercraft equipped with the Digitally Encoded Security System, refer to ELECTRICAL
03-00-1
Section 03
TROUBLESHOOTING
ENGINE MISFIRES, RUNS IRREGULARLY

OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Weak spark
Fouled, defective, worn spark plugs

Faulty rev limiter or ignition
Check / verify heat range / gap / replace

Check timing mark, refer to section 08-02
Low fuel level

Stale or water fouled fuel
Check / refill
Check / siphon and refill
Fuel filter dirty or restricted
Check / clean / replace
Carburetion dirty or out of adjustment
Check / clean / adjust, refer to section

06-03
Lean fuel mixture

Dry spark plug (except when
water fouled)
Leaking crankshaft seal(s), intake or rotary Check / test / replace, refer to engine section 04-03 and 04-04
valve cover
Rich fuel mixture

Fouled spark plug
Restricted fuel valve

Loose carburetor
Check / replace
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 06-03
Tighten carburetor(s)

Loose main jet
Check / replace, refer to section 04-04
Rotary valve shaft seal leaking
Check / adjust, refer to section 07-02
Oil pump adjustment
Worn needle(s) and seal(s)

Difficult to start
Incorrect rotary valve timing


OTHER OBSERVATION
POSSIBLE CAUSE
REMEDY
Monitoring beeper sounds

continuously
Restricted jet pump water intake
Check / clean
Check / flush, refer to section 02-02
ENGINE OVERHEATS
Cooling system restriction

Grounded temperature sensor or sensor
wire
Check / repair / replace
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 08-02
Incorrect setting
Check / reset, refer to section 08-02

Rotary valve
Incorrect timing
Check / reset, refer to section 04-04
Carburetor
Carburetion to lean
Engine
Intake leak / crankshaft seal failure
Pressure check engine to 48 kPa (7 PSI)
Ignition timing
03-00-2
Section 03
TROUBLESHOOTING
ENGINE DETONATION OR PINGING

OTHER OBSERVATION
Ignition
Engine temperature
POSSIBLE CAUSE
REMEDY
Timing too far advanced
Check / reset
Spark plug heat range too high
Check / change to correct range
Engine overheats
Fuel of poor quality
Check, refer to engine overheats

Use good quality fuel
ENGINE LACKS ACCELERATION OR POWER

OTHER OBSERVATION
Engine revs lower than its

maximum operational RPM
(787 engine)
Peak performance is delayed
until higher RPM range is
reached (787 engine)
POSSIBLE CAUSE
REMEDY
Weak spark
Carburetion, jetting too rich / lean
Throttle does not open fully
Low compression
Exhaust system restriction
Water in fuel or oil
Debris in needle valve
Impeller leading edge damaged
Twisted crankshaft
RAVE valve does not open

Check / readjust, refer to section 06-03
Check / repair, refer to section 04-02
Check / clean
Check / siphon / replace
Check / clean, refer to section 06-03
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.
Air leak of pump housing or ride shoe
Check / reseal, refer to section 09-01
Jet pump cavitation
Jet pump ventilation
'
ABNORMAL NOISE FROM PROPULSION SYSTEM

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

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

supply, refer to section 09-01
Damaged or bent drive shaft
Broken motor mounts
03-00-3
Sub-Section 00
Section 04 ENGINE
(TABLE OF CONTENTS)
TABLE OF CONTENTS
REMOVAL AND INSTALLATION ............................................................................................
GENERAL .............................................................................................................................
REMOVAL FROM WATERCRAFT ........................................................................................
CLEANING ...........................................................................................................................
INSTALLATION ....................................................................................................................
04-01-1
04-01-1
04-01-1
04-01-4
04-01-4
TOP END .................................................................................................................................. 04-02-1

587 AND 717 ENGINES ....................................................................................................... 04-02-1
787 ENGINE ......................................................................................................................... 04-02-2
ENGINE DESCRIPTION ....................................................................................................... 04-02-3
GENERAL ............................................................................................................................. 04-02-3
DISASSEMBLY..................................................................................................................... 04-02-3
CLEANING ........................................................................................................................... 04-02-5
INSPECTION ........................................................................................................................ 04-02-5
SQUISH AREA ..................................................................................................................... 04-02-14
RAVE SYSTEM..................................................................................................................... 04-02-15
BOTTOM END..........................................................................................................................
587 ENGINE .........................................................................................................................
717 ENGINE .........................................................................................................................
787 ENGINE .........................................................................................................................
CRANKSHAFT MISALIGNMENT AND DEFLECTION ........................................................
DISASSEMBLY.....................................................................................................................
CLEANING ...........................................................................................................................
INSPECTION ........................................................................................................................
ASSEMBLY...........................................................................................................................
04-03-1
04-03-1
04-03-2
04-03-3
04-03-4
04-03-5
04-03-7
04-03-7
04-03-9
ROTARY VALVE .......................................................................................................................

GENERAL .............................................................................................................................
INSPECTION ON WATERCRAFT .........................................................................................
DISASSEMBLY.....................................................................................................................
CLEANING ...........................................................................................................................
INSPECTION ........................................................................................................................
ASSEMBLY...........................................................................................................................
04-04-1
04-04-2
04-04-2
04-04-3
04-04-5
04-04-5
04-04-5
EXHAUST SYSTEM.................................................................................................................
SP SERIES, GTS AND GTI MODELS ..................................................................................
HX MODEL ...........................................................................................................................
XP MODEL ...........................................................................................................................
TUNED PIPE REMOVAL ......................................................................................................
EXHAUST MANIFOLD REMOVAL ......................................................................................
MUFFLER REMOVAL ...........................................................................................................
TUNED PIPE REPAIR ...........................................................................................................
04-05-1
04-05-1
04-05-2
04-05-3
04-05-4
04-05-6
04-05-6
04-05-6
04-00-1
Section 04 ENGINE
EXHAUST MANIFOLD, TUNED PIPE AND MUFFLER INSTALLATION ............................ 04-05-7
04-00-2
Sous-section 01
Section 04 ENGINE
(REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION

GENERAL
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.
All Models
Disconnect thermosensor wire and spark plug
cables.
Connect spark plug cables onto grounding device.
3
HX Model Only
Engine can be removed with jet pump in place. It
is not necessary to perform engine alignment
when engine support is not loosen from rubber
mounts. Engine rubber mounts sit on adapters
which can be loosen prior lifting engine. If an
engine rubber mount must be replaced, jet pump,
driveshafts and seal carrier have to be removed
and engine alignment performed.
REMOVAL FROM WATERCRAFT

In order to remove engine from watercraft proceed as follows.
CAUTION : Whenever removing engine
from watercraft, engine / jet pump alignment must be performed.
F01H27B
ALL MODELS EXCEPT XP

1. Magneto housing cover
2. Grounding device
Jet Pump Removal

To withdraw jet pump unit assy, refer to PROPULSION SYSTEM 09-01.
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.
F01D7MA
XP MODEL
1. Grounding device
All Models Except HX and XP

Remove battery holding straps and disconnect
vent tube from battery.
Remove battery.
04-01-1
Section 04 ENGINE
Sous-section 01 (REMOVAL AND INSTALLATION)
HX Model Only
Disconnect choke and throttle cables from carburetors.
Disconnect fuel supply and fuel return hoses.
Disconnect magneto wiring harness.

1
Engine Support Mounts

Remove engine support mount screws.
NOTE : Be careful when removing engine
support mount screws, shims could have
been installed between engine support and rubber mounts. To ease engine / jet pump alignment,
indicate shim location for reinstallation.
F01H09A
ALL MODELS EXCEPT XP

1. Unplug connector
F01D32A
TYPICAL - ALL MODELS EXCEPT XP

1. Shim
F01D7NA
XP MODEL
1. Unplug connector
3
2
Tuned Pipe
To remove tuned pipe, refer to ENGINE 04-05.
Air Intake Silencer

To remove air intake silencer, refer to FUEL SYSTEM 06-02.
Carburetor(s)
To remove carburetor(s), refer to FUEL SYSTEM
06-03.
F01D8PA
XP MODEL
1. Rear support
2. Front support
3. Shim
04-01-2
Sous-section 01
HX Model
Loosen screws of engine rubber mount adapters.
NOTE : Rubber mount adapters sit on
shims which control engine / jet pump alignment. Always note position of shims for reinstallation, to avoid altering engine alignment.
F05D09A
Section 04 ENGINE
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.
XP Model
Engine can be easily lifted by inserting a hook into
exhaust manifold eyelet.
1. Adapter screw
F01D7OA
Lifting Engine
All Models Except the XP
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.
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.
Remove rear engine support.
F01D0AA
1. Weld a lock washer

2. Old spark plug
F01D7PA
1. Rear support
Remove spark plugs and replace by special tools.

Hook a sling into holes of special tools.
04-01-3
Section 04 ENGINE
All Models
Install a hose pincher to oil supply hoses of oil
injection pump and rotary valve shaft ; then, disconnect hoses.
F01D40A
TYPICAL - ALL MODELS EXCEPT THE XP

A01B2JB
TYPICAL
1. Hose pincher (P / N 295 000 076)
Install a hose pincher to oil return hose of rotary

valve shaft ; then, disconnect hoses.
Disconnect RED positive cable from starter post.
F01D7RA
XP MODEL
CLEANING
F01H1JB
Wipe off any spillage in bilge. Clean with a bilge

cleaner.
Clean external parts of engine.
1. Disconnect RED positive cable
Carry on engine lifting until engine support reaches body opening (except the XP) then tilt engine
so that it can be removed from the watercraft.
CAUTION : Be careful not to scratch body
with engine support or to hit any component.
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).
04-01-4
Sous-section 01
Section 04 ENGINE
: Strict adherence to this torque

- CAUTION
is important to avoid damaging threads of
aluminum insert in bilge.

NOTE : Always remove rubber mounts one
at a time and reinstall each shim to its original location.
Engine Support and Nut

All Models Except the XP
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).
Oil Injection Hoses

Make sure to reinstall hoses before completely
lowering engine in bilge.
F01J59A
TYPICAL
Insert shaft end into PTO flywheel.

NOTE : If the alignment is correct, the shaft
will slide easily without any deflection in
PTO flywheel splines.
Positive Starter Cable

2
Torque nut of positive starter cable to 6 Nm (53

lbfin). Apply dielectric grease on nut.
Engine / Jet Pump Alignment

Alignment is necessary to eliminate possible
vibration and / or damage to components. Check
alignment of engine using alignment tool.
NOTE : On the HX model, it is not necessary to perform engine alignment when the
engine support is not loosen from rubber mounts.
F01L2TA
1
TYPICAL
1. Shaft end
2. PTO flywheel
F01L2RA
1. Housing (P / N 295 000 090)

2. Alignment shaft (P / N 295 000 093) or (P / N 295 000 141) for the
HX
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.
To verify alignment proceed as follows :

Install housing on hull with 4 nuts.
Carefully slide shaft through housing.
04-01-5
Section 04 ENGINE
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 0702.
Pressure test fuel system, refer to FUEL SYSTEM
06-01.
Verify all connections and hoses condition.
Run engine and ensure there is no leakage.
CAUTION : Water must be supplied to
cool the engine.
F01D32A

1. Shim
3
2
F01D8PA
XP MODEL
1. Rear support
2. Front support
3. Shim
: Whenever shims are used to

- CAUTION
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.
Retorque 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.
04-01-6
Section 04 ENGINE
Sub-Section 02 (TOP END)
TOP END
587 and 717 Engines

24 Nm
(17 lbfft)
Loctite 242
15
Synthetic
grease
9 Nm
(80 lbfin)
14
717 Engine
9 Nm
(80 lbfin)
Loctite 515
13
587
Engine
1
12
Synthetic
grease
12
24 Nm
11 (17 lbfft)
Synthetic
grease
2
Loctite
PST 592
Synthetic
grease
24 Nm
(17 lbfft)
2
Synthetic
grease
17
Loctite
515
Loctite
242
10
24 Nm
(17 lbfft)
Loctite
515
9
34
rollers
6
16
7
8
717 Engine
Synthetic grease
587 3
Engine
7
8
3
34
rollers
5
6
717 Engine
Synthetic grease
587
Engine
F01D42S
PARTS
040-02-1
Section 04 ENGINE
787 Engine
15
Loctite 242
24 Nm
(17 lbfft)
Synthetic grease
12
2
19
Synthetic
grease
23
22
20
Synthetic
grease
40 Nm
(30 lbfft)
18
Loctite
515
21
27
26
34 rollers
25
Loctite
515
24
7
8
4
Synthetic
grease
7
8
F01D7DS
040-02-2
PARTS
Synthetic
grease
6
16
34 rollers
Section 04 ENGINE
ENGINE DESCRIPTION
587, 717 and 787 Engines
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. Lubrication is provided by a variable rate oil
injection pump. It is cooled by water supplied
from the jet pump. It has a NIPPONDENSO Capacitor Discharge Ignition System. The fuel is provided by diaphragm MIKUNI carburetor(s) having
an integrated fuel pump.
CAUTION : No engine components can be
interchanged between engines.
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 new 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.
1,2, Cylinder Head Cover and Cylinder

Head
Remove cylinder head cover.
NOTE : With the 717 and 787 engines, cylinder head screws secure also cylinder head
cover.
If shells, sand, salt or any other particles are
present in cylinder head, clean with a vacuum
cleaner.
Remove cylinder head.
If shells, sand, salt water or any other particles are
present in cylinder cooling jacket, clean with a
vacuum cleaner.
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.
NOTE : Even if only one cylinder needs repair, both cylinders should be lifted to allow
1-piece cylinder base gasket replacement.
3,4,5,6, Piston, Piston Pin, Circlip and

Roller Bearing
GENERAL
When repairing a seized engine, connecting rods
should be checked for straightness and crankshaft for deflection / misalignment. Refer to ENGINE 04-03 for procedures.
DISASSEMBLY
NOTE : The 717 and 787 engines feature

cageless piston pin bearing.
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.
In order to repair engine top end proceed as follows :
Electrical Connections
Disconnect thermosensor wire and spark plug cables.
Connect spark plug cables on grounding device.
Exhaust System
To withdraw tuned pipe, refer to ENGINE 04-05.
Air Intake Silencer
F01B0JA
To remove air intake silencer, refer to FUEL SYSTEM 06-02.
1. Rubber pad
040-02-3
Section 04 ENGINE
If the other cylinder has been removed, completely cover its opening with a clean rag.
1
2
3
5
4
1
F01B0VA
F01D43A
1. Openings covered with rag and rubber pad
To remove circlip, insert a pointed tool in piston

notch then pry it out and discard.
WARNING : Always wear safety glasses
when removing piston circlips.
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.

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.
F01D0PA
TYPICAL
1. Piston notch
717 and 787 Engines

To extract piston pin, 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.
F01D2XA
Rotate spindle until extracting nut can be removed.

Remove spindle and extractor sleeve from piston pin.
Carefully remove the piston.
040-02-4
Section 04 ENGINE
CLEANING
Discard all gaskets and O-rings.
Clean all metal components in a solvent.
Clean water passages and make sure they are not
clogged.
Remove carbon deposits from cylinder exhaust
port, cylinder head and piston dome.
Clean piston ring grooves with a groove cleaner
tool, or a piece of broken ring.
INSPECTION
F01D2YA
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.
Visually inspect all parts for corrosion damage.

Inspect piston for damage. Light scratches can be
sanded with a fine sand paper.
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.
ENGINE
MEASUREMENT
A21C04A
1. Pusher 23 mm (.905 in)
587 Engine
To extract piston pin, it is possible to use piston
pin puller (P / N 295 000 105) as follows :
Fully thread on puller handle.
Insert extractor spindle into the piston pin.
Screw extracting nut (P / N 290 877 115) with
the movable extracting ring towards spindle.
Hold puller firmly and rotate puller handle to pull
piston pin.
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
the 587 Engine
0.05 mm
(.002 in)
0.07 mm
(.0028 in)
0.20 mm
(.008 in)
Piston / Cylinder Wall

Clearance for the
717 Engine
0.06 mm
(.0024 in)
0.08 mm
(.0031 in.)
0.20 mm
(.008 in)
Piston / Cylinder Wall

Clearance for the
787 Engine
0.10 mm
(.004 in)
0.12 mm
(.005 in)
0.15 mm
(.006 in)
Ring / Piston Groove

Clearance for
the 587 Engine
0.05 mm
(.002 in)
0.08 mm
(.003 in)
(.003 in)
(.008 in)
Ring / Piston Groove

Clearance for the
717 and 787 Engines
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)
040-02-5
Section 04 ENGINE
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 the 587 and 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.
F01D8BA
1. Measuring in piston pin axis

2. Measuring perpendicularly (90) to piston pin axis
A. 16 mm (5/8 in)
Piston / Cylinder Wall Clearance
Clearance can be quickly checked with a long feeler gauge. Insert feeler gauge in cylinder then slide
piston (without piston rings installed) into cylinder
as shown in the following illustration.
2
F01D8AA

2. Auxiliary transfer port
A. 16 mm (5/8 in)
Cylinder Out of Round

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.
F01D0MA
1. Feeler gauge
2. Piston
Or, to accurately determine piston to cylinder wall

clearance, measure piston at 25 mm (1 in) below
skirt end perpendicularly (90) to piston pin.
040-02-6
Section 04 ENGINE
Measure cylinder at 16 mm (5/8 in) below its top

edge.
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.
A
1
F01D8CA

A. 16 mm (5/8 in)
B. 25 mm (1 in)
F01D0OA
1. Top of cylinder
2. Ring end gap
The difference between these two measurements should be within specified tolerance.
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.
16, Cylinder Base Gasket

717 and 787 Engines Only
For the 717 and 787 engines, five thicknesses of
cylinder base gaskets are available for a precise
adjustment of the squish gap.
To determine gasket thickness, refer to the identification holes on the gasket.
1
F01D0XA
1. Feeler gauge
2. Rectangular ring (bottom)
F01D67A
1. Identification holes
040-02-7
Section 04 ENGINE
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)
F01D7EA
NOTE : Squish gap measurement is discussedfurther in this sub-section.
ASSEMBLY
Assembly is essentially the reverse of disassembly procedures. However pay particular attention
to the following.
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
787 ENGINE SHOWN

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

717 and 787 Engines
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.
1
A01C01A
1. Exhaust side
NOTE : On the 787 engine, the exhaust

ports are located on the same side as the
intake.
F01D30A
1. Pusher
Insert piston pin into piston until it comes flush

with inward edge of piston hub.
040-02-8
Section 04 ENGINE
Warm piston to approximately 50-60C (122140F) and install it over connecting rod.
Insert extractor spindle into the piston pin,
screw on extracting nut.
Rotate handle to pull piston pin carefully into
the piston.
1
F01D0VA
1. Thrust washer each side
Insert piston pin into piston until it comes flush

with inward edge of piston hub.
F01D31A
PLACTIC MOUNTING DEVICE METHOD

As an alternate method when no service tool is
available proceed as follows :
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
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.
F01D0Q A
1. Outer ring removal after inner sleeve insertion into bore
Make sure thrust washers are present each

side of rollers.
040-02-9
Section 04 ENGINE
F01D0SA
F01D0WA
As necessary, pull halves of inner sleeve with

long nose pliers.
1. Circlip opening at 6 oclock (at bottom)
: Always wear safety glasses

; WARNING
when installing piston circlips.
: Always use new circlips. At in- CAUTION
stallation, take care not to deform them.
Overstressed circlips will come loose and will

damage engine. Circlips must not move freely
after installation.
To easily insert circlip into piston, use circlip installer P / N 295 000 077 for the 587 engine or P /
N 290 877 016 for the 717 and 787 engines.
F01D0TA
1. Pulling inner sleeve half
All Engines
F01B0KA
5, Circlip
1. Circlip installer
Secure remaining circlip 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).
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.
040-02-10
Section 04 ENGINE
F01D0YA
F01D0ZA
3,7,8,9, Piston, Ring and Cylinder

To easily slide cylinder over piston, install on piston ring compressor P / N 290 876 972 for the 587
engine or P / N 290 876 979 for the 717 and 787
engines.
A01B1TA
1. Ring end gap aligned with piston locating pin
Slide cylinder over piston.
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.
F01D10A
When reassembling cylinders to crankcase, it is

important to have them properly aligned so that
exhaust flanges properly match up with exhaust
manifold. The aligning tool (P / N 290 876 902) can
be used on the 587 and 717 engines, or the exhaust manifold can also be used for all engines.
040-02-11
Section 04 ENGINE
F01D44A
F01D35A
ALL ENGINES EXCEPT THE 787

1. Exhaust flange aligning tool
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).
F01D45A
ALL ENGINES
1. Aligning cylinders using exhaust manifold
10,17,18, Cylinder Screw

587 and 717 Engines
Apply synthetic grease below the screw head.
For the 717 engine, 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.
F01D7FA
2,11,12, Cylinder Head, Screw and O-ring

587 Engine
Apply synthetic grease below screw head and on
screw threads.
040-02-12
Section 04 ENGINE
Apply Loctite 515 in O-ring groove of cylinder

sleeves.
10
1
8
10
9
6
2
12
11
5
11
5
F01D15A
1. Longer screws
F01D14A
2,12, Cylinder Head and O-ring

Make sure to install large O-rings around spark
plug holes and small O-ring where shown.
1
717 and 787 Engines

Make sure to install O-rings around spark plug
holes and O-ring of cylinder head as shown in the
following illustration.
Apply Loctite 515 in O-ring groove of cylinder
sleeves.
1
F01D14B
1. Large O-rings
2. Small O-ring
1,13,14, Cylinder Head Cover and Screw

587 Engine
Install cover over cylinder head. The two longer
screws must be installed on oval-shaped housing.
Make sure to install flame arrester support.
Torque cylinder head cover screws to 9 Nm (80
lbfin) as per following illustrated sequence.
F01D5AA
1. O-ring
Install cylinder head.
1,15, Cylinder Head Cover and Screw

717 and 787 Engines
Install cylinder head cover.
Prior installation, apply Loctite 242 (blue) below
screw head and synthetic grease on screw
threads.
040-02-13
Section 04 ENGINE
Torque cylinder head screws to 12 Nm (9 lbfft)

as per following illustrated sequence. Repeat the
procedure, retightening all screws to 24 Nm (17
lbfft).
1
10
12
F01D5WA
1. Squish gap
F01D46A
If the squish gap is increased, a loss in power will

occur, while too small a squish gap will lead to
detonation.
11
SQUISH AREA
Squish Gap Measurement
Rotax rotary valve engines incorporate a combustion chamber which feature a squish area. This
area is basically a ledge projecting beyond combustion chamber area. In operation, as the piston
ascends and approaches the ledge, a rapid
squeezing action is applied to the air / fuel mixture
contained in the area immediately between the
piston dome and the ledge. This squishing action
forces the entrapped mixture rapidly into the combustion chamber area, creating a greater mixture
turbulence. Additionally, the small volume and
large surface area of the squish band allow a better cooling of the end gases to help prevent detonation.
CAUTION : When reassembling an engine, always measure squish gap to make
sure it is within the specified tolerance.
The squish gap can be measured by inserting a

piece of resin core solder into the combustion
chamber.
Insert solder in combustion chamber.
Rotate the engine through Top Dead Center ;
remove the solder and measure the thickness
of the compressed solder.
NOTE : The solder should be inserted above
and in line with the wrist pin.
1
F01D74A
1. Solder
040-02-14
Section 04 ENGINE
A18C0OA
1. Measure here
: Do not use acid core solder ;

- CAUTION
the acid can damage the piston and cylin-
der.
Take another measurement at the opposite
side of the piston.
Repeat procedure for the other cylinder.
The lowest and the highest values of both cylinders must be within the specified range.
Engine
Squish Gap
587
1.2 - 1.8 mm (.047 - .071 in)
717
1.3 - 1.7 mm (.051 - .067 in)
787
1.2 - 1.6 mm (.047 - .063 in)
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.
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.
1
5
3
2
If adjustment is required, replace cylinder base

gasket accordingly, using a thicker or thinner one.
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.
A18C01A
TYPICAL
1. Slding 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.
040-02-15
Section 04 ENGINE
Item P1 in figure is the pressure of the return

spring against the diaphragm. The exhaust pressure must be high enough to overcome this pressure 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.
F01D7GA
VALVE FULLY OPENED
P1
P2
POWER
F01D7HA
VALVE FULLY CLOSED
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).
A18C02A
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.
040-02-16
Section 04 ENGINE
Boring Precaution
21, Allen Screw
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.
Loosen Allen screws and remove RAVE valve.
Disassembly
F01D8IA
19,20, Spring and Cover
1. Allen screws
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.
P1
P2
22,23,24, Valve Piston, Bellow and

Sliding Valve
Remove bellow from valve piston.
Unscrew valve piston from sliding valve.
NOTE : Hold the sliding valve to prevent it
from turning.
1
1
POWER
A18C02A
RPM
2
1. Spring
F01D8MA
1. Unscrew piston
2. Hold sliding valve
040-02-17
Section 04 ENGINE
Inspection
27, Valve Housing
Check bellow for cracks.

Check if passages of valve housing and cylinder
are not obstructed.
Position the valve housing onto the cylinder so

that its opening is toward the bottom.
F01D8JB
F01D8JA
1. Bottom of valve housing
1. Passage of valve housing
22,24, Valve Piston and Sliding Valve
Assembly
When the valve is mounted onto the cylinder,

move the valve piston to ensure the sliding valve
moves easily and doesnt stick.
Assembly is essentially the reverse of disassembly procedure. However, pay particular attention
to the following.
24,25, Sliding Valve and O-ring

Make sure to insert O-ring onto rod of sliding
valve.
The TOP position of the sliding valve is indicated
on one side.
F01D8LA
3
F01D8KA
1. Sliding valve
2. O-ring
3. TOP
26, Gasket
Install a new gasket. It must be installed at the
same time as the sliding valve.
040-02-18
Section 04 ENGINE
Sub-Section 03 (BOTTOM END)
BOTTOM END
587 Engine
Loctite
515 11
1 Lithium
grease
Anti-seize
lubricant
2
14
5
Loctite
642
Anti-seize
lubricant
Anti-seize
lubricant
Loctite
242
15
2
6
4
6
1
Loctite
515
Anti-seize
lubricant
Anti-seize
lubricant
Lithium
grease
24 Nm 9
(17 lbfft)
Loctite
515
Synthetic
grease
Loctite
515
8 40 Nm
(30 lbfft)
Synthetic
grease
Loctite
11 515
Loctite
7
24 Nm 515
(17 lbfft)
10
10 Nm
(88 lbfin)
F01D4HS
PARTS
04-03-1
Section 04 ENGINE
717 Engine
Loctite
515
11
Lithium
grease
Anti-seize
lubricant
2
14
1
65
Loctite
642
6
Anti-seize
lubricant
2 Anti-seize
lubricant
3
Loctite
515
Loctite
242
6
24 Nm
(17 lbfft)
9
6
11
Synthetic
grease
Loctite
515
7
24 Nm
(17 lbfft)
10
10 Nm
(88 lbfin)
Loctite
515
Synthetic
grease
8
40 Nm
(30 lbfft)
F01D06S
04-03-2
PARTS
Lithium
grease
Section 04 ENGINE
787 Engine
30 mL (1 oz)
FORMULA XP-S
synthetic
injection oil
Loctite
515
Anti-seize
lubricant
12
Lithium
grease
1
5
13
2
Lithium
grease
14
12
Anti-seize
lubricant
Loctite
642
Anti-seize
lubricant
Anti-seize
lubricant
2
Lithium
grease
Loctite
515
8
40 Nm
(30 lbfft)
Loctite
242
Loctite
515
Synthetic
grease
Synthetic
grease
Loctite
515
Synthetic
grease
7
24 Nm
(17 lbfft)
F01D8GS
PARTS
Loctite
515
Synthetic
grease
7 24 Nm
(17 lbfft)
Anti-seize
lubricant
8 40 Nm
(30 lbfft)
04-03-3
Section 04 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 spark plugs.

Insert a screwdriver in one spark plug hole.
Insert a longer screwdriver in the other spark
plug hole.
Lay one hand over both screwdriver handles to
feel piston displacements.
With the other hand, slowly rotate engine by
PTO flywheel.
1
F01D1NA
1. Main journal alignment here
Counterweights can also be twisted on connecting rod journal on any or both cylinder(s).
F01D1IA
TYPICAL
1. Lay one hand over screwdrivers to feel movement
2. Screwdrivers in spark plug holes
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 quickly check, without accuracy, if crankshaft
is twisted on center main journal, proceed as follows :
Remove PTO flywheel guard.
As soon as one piston starts going up, the other

must immediately go down. Any interval between
strokes indicates a misaligned crankshaft.
Or, to accurately check crankshaft alignment, proceed as follows :
Remove ignition housing cover.
Remove flywheel nut (and magneto rotor for
the 787 engine). Refer to ELECTRICAL SYSTEM 08-01 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.
04-03-4
Section 04 ENGINE
1, Seal
If crankshaft end seal(s) has / have to be replaced,
bottom end must be opened (except for the MAG
side seal on the 787 engine, which is mounted on
the ignition housing).
3, Crankcase
3
4
Remove the following parts :

Engine support (except for the 787 engine).
PTO flywheel. Refer to PROPULSION SYSTEM
09-02.
NOTE : PTO side flywheel must be removed prior removing MAG side flywheel.
Magneto flywheel. Refer to ELECTRICAL SYSTEM 08-01.
Starter.
Ignition housing.
F01D4IA
1.
2.
3.
4.
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.
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.
F01D4JA
1. Separating ignition housing / armature plate from cranckcase
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.
DISASSEMBLY
Engine has to be removed from watercraft to
open bottom end. Refer to ENGINE 04-01.
04-03-5
Section 04 ENGINE
7
F01B09A
F01D1KA
1. Separate halves by prying at provided lugs
1.
2.
3.
4.
5.
6.
7.
8.
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)
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 290 276 025).
1
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).
F01B2MA
1.
2.
3.
4.
5.
6.
7.
Puller (P / N 290 876 298)

Protective cap (P / N 290 876 557)
Distance ring (P / N 290 876 569)
Ring (P / N 290 977 490)
Ring halves (P / N 290 276 025)
Screw M8 x 40 (P / N 290 840 681)
Screw M8 x 70 (P / N 290 841 201)
587 and 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 290276 025).
NOTE : To facilitate ring or distance ring installation lubricate their inside diameters.
04-03-6
Section 04 ENGINE
All Engines

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.
INSPECTION
F01D1OA
1. Removing crankshaft bearing
Or, use a bearing extractor such as Proto no. 4332

and a press to remove two bearings at a time.
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)
F01D1PA
1. Press bearings out

2. Bearing extractor
12,13, Bearing and Counterbalance Shaft

787 Engine
Bearings can be removed by using puller (P / N
290 876 298), ring halves (P / N 290 876 330) and
ring (P / N 290 977 480).
If gear or oil seals need servicing, counterbalance
shaft must be factory repaired.
(max.)
WEAR
LIMIT
.737 mm
(.029 in)
1.2 mm
(.047 in)
MEASUREMENT
MAG SIDE
PDM 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.
CLEANING
Discard all oil seals, gaskets, O-rings and sealing
rings.
Clean oil passages and make sure they are not
clogged.
04-03-7
Section 04 ENGINE
F01D1QA
F01D1TA
1. Ruler must be aligned with edge of connecting rod here

2. Align ruler here
1. Measuring MAG side deflection in crankcase
Remove crankshaft bearings and check deflection

again on V-shaped blocks as illustrated.
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
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.
04-03-8
Section 04 ENGINE
Connecting Rod Big End Axial Play

1
Using a feeler gauge, measure distance between

thrust washer and crankshaft counterweight.
1
2
3
F01D1XA
1. Bearing against a steel plate

2. Propane torch
3. Heat plate through bearing bore
2
F01D1WA
5, Outer PTO Bearing
1. Measuring big end axial play

2. Feeler gauge
ASSEMBLY
to the following.
To properly position the outer PTO bearing, 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
587
P/N 290 876 826
2,4,5,14, Bearing and Crankshaft
717
P/N 290 876 827
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.
Or, as an alternate method, apply heat with a propane torch. Lay bearing on a steel plate, then heat
plate through bearing bore until smoke is noticed
from bearing. Install bearing carefully on crankshaft.
CAUTION : Immediately stop heating as
soon as smoke is noticed. Overheating
bearing will melt plastic cage. Practice with
used bearings on first try.
787
P/N 290 876 828
F01B0HA
1. Distance gauge
04-03-9
Section 04 ENGINE
F01D1YA
F01D80A
TYPICAL
1. Distance gauge
2. PTO side outer bearing
1. Marks
15, Distance Ring
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.
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.
Position crankcase halves together and handtighten screws.
CAUTION : Temporarily install armature
plate to align crankcase halves with each
other (except the 787 engine).
3, Crankcase
When installing the distance ring on the magneto

side, make sure to position it with its chamfer toward the counterweight of the crankshaft.
1, Seal
At seal assembly, apply a light coat of lithium
grease on seal lips.
6, Drive Pin
Make sure drive pins of bearings (where applicable) are properly installed in crankcase recesses at
assembly.
13,14, Counterbalance Shaft and

Crankshaft
787 Engine
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.
11, Fitting
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.
7,8, Crankcase Screw

Apply Loctite 515 on screw threads and synthetic
grease below head screws.
04-03-10
Section 04 ENGINE
587 and 717 Engines
11
7,8,9, Crankcase Screw
21
22
Torque crankcase screws to 24 Nm (17 lbfft) as

per following illustrated sequence.
12
11
8
13
5 13
6 14
12
19
10
17
10
14
15
16
18
20
F01D81A
F01D20A
8, Crankcase Screw
8, Crankcase Screw
Torque 2 M10 crankcase screws to 40 Nm (30
lbfft).
As a final step, torque only M10 screws of crankcase to 40 Nm (30 lbfft) as per following sequence.
11
12
10
F01D20B
1. Torque to 40 Nm (30 lbfft)

F01D81B
10, Stud
At assembly in crankcase, apply Loctite 515 on
stud threads. Torque to 10 Nm (88 lbfin).
787 Engine
7,8, Crankcase Screw

Torque crankcase screws to 12 Nm (9 lbfft) as
per following sequence. Repeat procedure, retightening all screws to 24 Nm (17 lbfft).
Final Assembly
For rotary valve timing and assembly procedures,
refer to ENGINE 04-04.
587 and 717 Engines

If engine support is installed on crankcase before
ignition housing, electric starter must be installed
before engine support.
04-03-11
Section 04 ENGINE
F01D4KA
1. Install starter before engine support
787 Engine
Add 30 mL (1 oz) of FORMULA XP-S synthetic injection oil in the small hole near the transfer of the
PTO cylinder.
F01D86A
TYPICAL
1. Add 30 mL (1 oz) of injection oil
04-03-12
Section 04 ENGINE
Sub-Section 04 (ROTARY VALVE)
ROTARY VALVE
9
5
6
10
14
15
8
11
3
13
1
12
Lithium
grease
2
20 Nm
(15 lbfft)
787 Engine
717 Engines
2
20 Nm
(15 lbfft)
F01D7SS
PARTS
04-04-1
Section 04 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 04-01 for engine removal procedure.
Bottom end must be opened to remove rotary
valve shaft. Refer to ENGINE 04-03.
INSPECTION ON WATERCRAFT
F01D53A
Remove carburetor(s). Refer to FUEL SYSTEM

06-03.
NOTE : On the 587 engine, rotary valve cover and carburetor are removed as an assembly.
1,2, Rotary Valve Cover and Screw

Unscrew 4 retaining screws and withdraw rotary
valve cover and valve.
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.
1. 45 feeler gauge
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 short pieces (13 mm (1/2 in) long) of
solder 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).
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.
04-04-2
Section 04 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 rework at the
factory. Contact your dealer or distributor.
Rotary Valve Shaft Gear Backlash
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).
04-04-3
Section 04 ENGINE
DISASSEMBLY
3,4, Rotary Valve Shaft and Snap Ring
To remove rotary valve shaft assembly, first remove snap ring from crankcase.
1
F01D61A
1. Hold bolt
F01D22A
1. Removing snap ring
: Bottom end must be opened

- CAUTION
to remove rotary valve shaft.
To remove rotary valve shaft, use puller (P / N 290
876 487) for the 587 and 717 engines or puller (P / N
290 876 488) for the 787 engine.
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.
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
04-04-4
Section 04 ENGINE
7,8, Snap Ring and Bearing

To remove bearing use a bearing extractor such
as Snap-on no CJ-950 as illustrated. Slide off distance sleeve, remove snap ring and press shaft
out.
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
: Ensure that rotary valve shaft

- CAUTION
is perfectly perpendicular with press tip or
damage will occur.
9, Bearing
: Do not remove plug against
- CAUTION
bearing in upper crankcase half.
F01D28A
1. End bearing
CLEANING
1
F01D4OA
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.
1. Do not remove this plug
End bearing can be easily removed using the following suggested tool.
Snap-on hammer puller including :
Handle
CJ93-1
Hammer CJ125-6
Claws
CJ93-4
INSPECTION
1, Rotary Valve Cover
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 sandpaper.
04-04-5
Section 04 ENGINE
8,9 Bearing
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 a pusher

(P / N 290 876 500).
1
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.
A00B2JA
1. Pusher
Position ball bearing shielded side towards rotary

valve.
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 near gear mounting area.
1
F01D2DA
1. Shield side (toward gear)
Push bearing until it stops on its seat.

1
F01D2CA
1. Rotary valve shaft

2. End bearing in place
Deflection must not exceed specified value. Replace shaft as necessary.
ASSEMBLY
to the following.
F01D33A
1. Bearing
2. Pusher
04-04-6
Section 04 ENGINE
3,11, Rotary Valve Shaft and Seal

Apply lithium grease on seal lips. Position seal
with shielded portion against shaft splines.
3,4, Rotary Valve Shaft Assy and Snap

Ring
: Crankcase halves must be
- CAUTION
separated and crankshaft must not be
3,7,8, Rotary Valve Shaft, Snap Ring

and Bearing
present to install rotary valve shaft assy in

crankcase.
Install ball bearing as illustrated.
587 and 717 Engines

To install rotary valve shaft in crankcase, use a
pusher (P / N 290 876 605).
1
1
2
3
A00C0YA
Push shaft until its stops on bearing seat.
A13C0FB
1. Seal
2. Ball bearing
3. Bearing extractor Snap-on CJ-950
Install shim, snap ring and slide distance sleeve

on shaft.
1
2
3
F01D34A
1. Rotary valve shaft assy

2. Push shaft until it stops
F01D2FA
1.
2.
3.
4.
5.
6.
Seal
Ball bearing
Snap ring
.Distance sleeve
Shim 0.5 mm (.020 in)
Rotary valve shaft
04-04-7
Section 04 ENGINE
787 Engine
To install rotary valve shaft in crankcase, use a
pusher (P / N 290 876 609) and handle (P / N 290
877 650).
All Engines
At snap ring installation, position it so that its
sharp edge faces outwards.
13, Rotary Valve

2
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
F01B2FA
1. Pusher
2. Handle
Push shaft until it stops on bearing seat.
Engine
Rotary Valve
P/N
Valve
Duration
587
290 924 508
147
717 and 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 templates.
F01D8OA
04-04-8
Section 04 ENGINE
TEMPLATE
159
159
(cut-out angle)
290 924 502

actual size
147
147
(cut-out angle)
290 924 508

actual size
F01D89S
04-04-9
Section 04 ENGINE
ROTARY VALVE TIMING

: Never use the ridge molded
- CAUTION
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
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
0
0
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
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
40
50
31
33
F01D2IA
1. Bring piston to TDC
For opening mark, first align 360 line of degree wheel with BOTTOM of MAG side inlet
port. Then, find 130 line on degree wheel and
mark crankcase at this point.
295 000 065

A00B44A
Rotary valve must be set so that timing occurs as

follows :
2
TIMING
ENGINE
OPENING
BTDC
CLOSING
ATDC
587
130 5
65 5
717
147 5
65 5
787
146.5 5
64 5
130
For the following instructions, lets use these

specifications as example :
OPENING : 130 BTDC
CLOSING : 65 ATDC
Proceed as follows :
Turning crankshaft, bring MAG side piston to
Top Dead Center using a TDC gauge.
1
F01D3DA
OPENING MARK
Step 1 : Bottom of MAG inlet port.
Align 360 line of degree wheel
Step 2 : Find 130 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.
04-04-10
Section 04 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.
1,2,12, Rotary Valve Cover, Screw and

O-ring
Install O-ring and cover then torque screws to 20
Nm (15 lbfft) in a criss-cross sequence.
NOTE : For the 587 engine, install engine in
watercraft first ; then, install rotary valve
cover, intake manifold and carburetor as an assembly.
04-04-11
Section 04 ENGINE
Sub-Section 05 (EXHAUST SYSTEM)
EXHAUST SYSTEM
SP Series, GTS and GTI Models
SPI, SPX,
GTS and GTI
models
SP
model
11
Loctite
242
25 Nm
8 (18 lbfft)
9
20
25 Nm
7 (18 lbfft)
17
17
Loctite 242
15
9
Synthetic
grease
19
18
18
Loctite
242
6
25 Nm
(18 lbfft)
24
14
24 Nm
(17 lbfft)
19
Loctite
242
19
19
4 Nm
(35 lbfin)
5
6
25 Nm
(18 lbfft)
22 10 Nm
(88 lbfin)
21
Sealant
732
3
27 Nm
(20 lbfft)
4 Nm
(35 lbfin)
1
4 Nm
(35 lbfin)
SPX and GTI models
4 Nm
(35 lbfin)
13
7 Nm
(162 lbfin)
Silicone
"Ultra Black"
F01D4QS
PARTS
04-05-1
Section 04 ENGINE
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
20
19
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
PARTS
04-05-2
Section 04 ENGINE
XP Model
25 Nm
(18 lbfft)
23
25 Nm (18 lbfft)
12
Loctite
242 19
Loctite
242
19
17
19
19
Loctite
515
16
15
24
Loctite
648
40 Nm 14
(30 lbfft)
40 Nm 14
(30 lbfft)
Sealant
736
10 Nm
(88 lbfin)
24
10
Synthetic
grease
9
2
Loctite 242
4 Nm
(35 lbfin)
Loctite
242
7
40 Nm
(30 lbfft)
8 40 Nm
(30 lbfft)
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
Sealant
732
27 Nm
(20 lbfft)
F01D7WS
PARTS
04-05-3
Section 04 ENGINE
TUNED PIPE REMOVAL
6, Screw
All Models Except HX and XP

NOTE : For SP series, remove air vent tube
support from body opening.
Disconnect water inlet hose and water injection
hose.
Disconnect tuned pipe bleed hose.
Remove tuned pipe retaining screw(s) from exhaust manifold side.
7,8,9, Screw, Nut and Flat Washer

Remove screws, nut and flat washers from tuned
pipe flange.
NOTE : Slightly lift tuned pipe to release nut
as necessary. Take care not drop nut and flat
washer.
11, Tuned Pipe Head

Withdraw tuned pipe in a forward and rotating
movement.
F01D8NA
HX Model 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.
Disconnect water injection hose at tuned pipe
cone.
Disconnect bleed hose on top of tuned pipe head.
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).
1, Collar
4, Clamp
Remove clamp retaining tuned pipe head to tuned
pipe cone (if desired).
7,8,9, Screw Nut and Flat Washer
Loosen exhaust hose collar at tuned pipe outlet.
2,13, Strap and Muffler
Remove screws, nut and flat washers from tuned

pipe head flange.
Disconnect strap retaining muffler.
10, Tuned Pipe Head
3, Hose
Remove tuned pipe head.
Remove exhaust hose from tuned pipe by pulling

muffler.
1,3,6, Collar, Hose and Screw
4,22, Clamp
Remove clamp from tuned pipe (except SP model).
5, Tuned Pipe Cone.

Remove tuned pipe cone (except SP model).
Loosen exhaust hose collar at tuned pipe cone

outlet.
Remove two screws retaining tuned pipe cone
from exhaust manifold.
XP Model Only
Remove air vent tube support from body opening.
Remove electrical box from watercraft. Refer to
ENGINE REMOVAL AND INSTALLATION 04-01.
04-05-4
Section 04 ENGINE
Disconnect water supply hose and water injection

hose at tuned pipe head.
F01D76A
1. Screw
F01D3YA
Remove tuned pipe head.
1. Water supply hose

2. Water injection hose
6, Screw
1,3, Collar and Hose

Loosen exhaust hose collar at tuned pipe cone
outlet.
Remove two screws retaining tuned pipe cone to

engine.
4, Clamp
Remove clamp securing tuned pipe cone to tuned
pipe head.
7,8,9, Screw, Nut and Flat Washer

Remove screws and nut with flat washers at
tuned pipe head flange.
F01D7KA
F01D7IA
23, Screw
Remove retaining screw of tuned pipe head.
F01D7LA
04-05-5
Section 04 ENGINE
12, Tuned Pipe Cone
HX Model Only
Move tuned pipe cone in front of bilge between

body and fuel tank.
1, Collar
Loosen exhaust hose collar at tuned pipe
cone outlet (only if tuned pipe cone is not removed).
2, Strap
Remove rear access cover from body.
Disconnect upper exhaust hose in front of muffler.
Disconnect retaining strap of muffler.
1
F01D7JA
Open storage cover and remove basket. Then,

pull out tuned pipe cone through storage compartment opening.
EXHAUST MANIFOLD REMOVAL

XP Model Only
Remove air intake silencer and carburetors. Refer
to FUEL SYSTEM 06-02 for proper procedure.
F05D07A
1. Strap
All Models
13, Muffler
14,24, Screw and Lock Washer

Remove eight screws and washers then withdraw exhaust manifold.
Pull muffler out of bilge.

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

Disconnect hoses from muffler.
Disconnect hoses of the water flow regulator
valve (XP model only).
This procedure is given to repair tuned pipe cracks

using T.I.G. welding process.
2, Strap
Disconnect retaining strap of muffler.
13, Muffler
Pull muffler out of bilge.
Procedure
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.
04-05-6
Section 04 ENGINE
Test :
Use compressed air at 124 kPa (18 PSI) to pressurize tuned pipe.
NOTE : Prior to verify leaks, plug all holes
and pressurize tuned pipe while immerging
it in water.
CAUTION : Always ensure water passages are not blocked partially or completely
while welding tuned pipe.
XP Model Only
Except for two screws, apply synthetic grease on
screw threads. Apply Loctite 515 on the other two
screws. Install screws. Refer to the following illustration for position of screws.
1
EXHAUST MANIFOLD, TUNED

PIPE AND MUFFLER
INSTALLATION
Installation is essentially the reverse of removal
procedures. However, pay particular attention to
the following.
14,15,17,24, Screw, Exhaust Manifold,

Gasket and Lock Washer
Make sure gasket(s) are properly positioned prior
to finalizing manifold installation.

Apply synthetic grease on screw threads.
Install and torque screws to 24 Nm (17 lbfft) as
per following illustrated sequence.
1
4
Torque exhaust manifold screws to 24 Nm (17

lbfft) as per following illustrated sequence. Repeat the procedure, retightening screws to 40
Nm (30 lbfft).
7
6
F01D82B
1. Screw with Loctite 515

2. Screw with synthetic grease
5
8
F01D59A
04-05-7
Section 04 ENGINE
20, Gasket
Make sure that gasket is properly located on exhaust manifold prior to finalizing pipe installation.
4
7
4,6,7,8,23, Clamp, Screw and Nut
Apply Loctite 242 (blue) on stud and retaining

screw threads. Hand-tighten nut and screws and
assure that tuned pipe bushing(s) rests against
manifold.
Refer to the following illustration for the torquing
sequence.
F01D82A
16, Sealing Ring

HX and XP Model Only
Make sure to install the sealing ring on tuned pipe
cone if it was removed.
1
2 3
4
F01D0IA
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)
XP Model Only
F01D69A
TYPICAL
1. Sealing ring
7,9, Screw and Nut
Apply a thin layer of heat resistant sealant (P/N

413 709 200) all around sealing ring.
Torque nut and screws of tuned pipe head flange

to 40 Nm (30 lbfft).
All Models
18,19, Sleeve and Rubber Bushing

Ensure rubber bushings and sleeve 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.
04-05-8
Section 04 ENGINE
SPI, SPX, GTS and GTI Models
5,21,22, Tuned Pipe Cone, Collar and

Clamp
Install tuned pipe cone with collar and clamp.
Position clamp as illustrated. Do not tighten clamp
yet.
F01D41A
1. Clamp
2. Exhaust collar
With hose removed, align cone outlet with muffler inlet.

NOTE : Due to exhaust cone angle, it may
have to be rotated to obtain alignment.
Push cone until it touches tuned pipe, then tighten exhaust collar clamp and torque to 10 Nm (88
lbfin).
CAUTION : There must be no gap between tuned pipe cone and tuned pipe
head.
NOTE : Exhaust collar clamp nuts should be
tighten alternately to assure no leakage and
to obtain specified torque.
04-05-9
Section 05 COOLING SYSTEM

TABLE OF CONTENTS
COMPONENTS ........................................................................................................................
SP / SPI AND GTS MODELS ...............................................................................................
SPX AND GTI MODELS ......................................................................................................
HX MODEL ...........................................................................................................................
XP MODEL ...........................................................................................................................
GENERAL .............................................................................................................................
0-01-1
0-01-1
0-01-2
0-01-3
0-01-4
0-01-5
CIRCUIT....................................................................................................................................
GENERAL .............................................................................................................................
0-02-1
0-02-1
05-00-1

Sub-Section 01 (COMPONENTS)
COMPONENTS
SP / SPI and GTS Models

Loctite 592
Loctite
592
Loctite
592
Loctite
592
1
Loctite
592
Loctite
592
Loctite
592
F01E0SS
PARTS
05-01-1

SPX and GTI 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
05-01-2
PARTS

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
05-01-3

XP 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)
4
Loctite
592
10
8 0.6 Nm
(5 lbfin)
5 Nm
7 (44 lbfin)
F01E1QS
05-01-4
Loctite
592
PARTS
2.5 Nm
(22 lbfin)
Loctite
592

GENERAL
3, Elbow Fitting
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.
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.
The Serial Cooling System is utilized on the 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).
22
1
3
2
F01B2KA
F01E0YA
TYPICAL
1. Outlet diameter = 4.6 mm (.181 in)
2. Stamped number
3. Inlet diameter = 5.5 mm (.219 in)
1. Cutting clamp
2. Securing clamp
2, Fitting Spigot
The fitting spigot is used to flush cooling system.
Refer to MAINTENANCE 02-02.
NOTE : The HX model doesnt have a fitting
spigot. It has a hose adapter located at the
rear of the watercraft.
Stampe
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)
05-01-5

4, Water Flow Regulator Valve

XP Model
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.
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
F01E1FC
F01E1FA
1. Turn this screw

2. Valve cap
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 egulated 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.
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.
Adjustment
The water flow regulator valve has been calibrated at the factory and should not be modified.
05-01-6

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

1
F01E20A
1. Remove tapered needle

F01E1SA
9,10, Valve and Bellows
1. Fitting
8, Tapered Needle
Unscrew the tapered needle.
NOTE : Hold the valve to prevent it from
turning.
Pull the valve slightly. Using pliers, release the

clamp which retains the bellows.
Remove valve and bellows.
Inspection
Inspect parts for damage. Verify especially bellows for cracks.
Assembly
Assembly is essentially the reverse of disassembly procedures.
05-01-7

Sub-Section 02 (CIRCUIT)
CIRCUIT
GENERAL
The cooling system is equipped with a fitting spigot for flushing purposes (a hose adapter for the
HX model).
For flushing operation, a coupler hose is available
(unnecessary for the HX model) to connect to fitting spigot. The other end of coupler hose is to be
connected to a garden hose to flush the whole
system by backwash. For flushing procedure, refer to MAINTENANCE 02-02.
For winterization of cooling system, refer to
MAINTENANCE 02-04.
Special precautions should be taken when towing
a Sea-Doo watercraft.
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.
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.
CAUTION : Failure to do this may result in
damage to the engine. If you must tow a
stranded watercraft and do not have a hose
pincher be sure to stay well below the maximum towing speed of 24 km/h (15 MPH).
When finished towing the craft you must remove
the hose pincher before operating it. Failure to do
so will result in damage to the engine.
The water supply is taken from a pressurized area
in the jet pump between the impeller and venturi.
The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation.
Water is pre-heated by the exhaust system before entering the cylinder cooling jackets.
When engine is running, water must flow from
bleed outlet(s) indicating that water circulates.
Check monitoring beeper operation by jumping
terminal of thermosensor wire to ground. Beeper
must operate.
At every verification of monitoring beeper always
apply dielectric grease on thermosensor connector.
Verify wire terminal on connector for tightness. If

too loose, squeeze terminal slightly at installation.
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
F01L45C
717 and 787 Engines Only

These engines have a Serial Cooling System ;
fresh water enters the cylinder head assembly,
cooling the combustion chamber to prevent detonations. Then, water exits cylinder head toward
tuned pipe.
3
F01E1LA
1. Cylinder head cover

2. Fresh water from jet pump
3. Water exiting head assembly to tuned pipe, exhaust manifold and
cylinders
A. Water from cylinder water jackets exiting engine
05-02-1

For a minimum back pressure in the exhaust, engine water outlet hose is not connected to the exhaust. It has its own fitting at the rear of the hull.
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).
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 (except HX).
Hose adapter (HX).
F01E1GA
MONITORING BEEPER :
Turns on at 96-99C (205-210F).
1. Engine water outlet hose
All engines
Water enters cylinder cooling jacket through passages located below exhaust ports from tuned
pipe.
F01D7HA
1. Water passages
No water enters crankcase.

For a complete view of cooling system arrangement, refer to the next pages for each engine
model.
CAUTION : Never modify cooling system arrangement, otherwise serious engine damage could occur.
05-02-2
F01E0PS
Water
injected
directly
into exhaust
gas for noise
reduction and
performance
improvement
Fresh water
flows through
tuned pipe
and manifold
water jackets
Lowest point of circuit

allows draining whenever
engine is stopped
Uppermost point
of circuit
(tuned pipe)
allows bleeding
587 ENGINE COOLING SYSTEM
Engine water
inlet hose
Pressure zone
Temperature
sensor activates
Uppermost point
monitoring beeper
of engine
(cylinder head cover) when temperature
exceeds 96-99C
allows bleeding
(205-210F)
Engine water
outlet hose
Calibrated
outlet fittings
limit water flow
Cooling System
Indicator (CSI) :
small stream
of water flows
out of bleed
outlets located
near stern eyelet
Fitting spigot
Calibrated
cylinder
head limits
water flow

05-02-3
05-02-4
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

Temperature
sensor activates
monitoring beeper
when temperature
exceeds 96-99C
(205-210F)
Pressure zone
Calibrated
cylinder head.
Serial cooling
allows the
cylinder head
to run cooler
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
Engine water
outlet 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
05-02-5

TABLE OF CONTENTS
FUEL CIRCUIT..........................................................................................................................
SP, SPI AND GTS MODELS.................................................................................................
SPX, XP AND GTI MODELS................................................................................................
HX MODEL ...........................................................................................................................
GENERAL .............................................................................................................................
INSPECTION ........................................................................................................................
REMOVAL.............................................................................................................................
ASSEMBLY...........................................................................................................................
FUEL SYSTEM PRESSURIZATION .....................................................................................
06-01-1
06-01-1
06-01-2
06-01-3
06-01-4
06-01-6
06-01-6
06-01-7
06-01-8
AIR INTAKE .............................................................................................................................. 06-02-1

REMOVAL............................................................................................................................. 06-02-2
ASSEMBLY........................................................................................................................... 06-02-2
CARBURETORS .......................................................................................................................
587 ENGINE .........................................................................................................................
717 AND 787 ENGINES .......................................................................................................
GENERAL .............................................................................................................................
CARBURETOR REMOVAL ...................................................................................................
CLEANING ...........................................................................................................................
DISASSEMBLY AND INSPECTION.....................................................................................
PUMP VERIFICATION ..........................................................................................................
CARBURETOR ASSEMBLY .................................................................................................
CARBURETOR INSTALLATION...........................................................................................
ADJUSTMENTS ..................................................................................................................
06-03-1
06-03-1
06-03-2
06-03-3
06-03-3
06-03-3
06-03-3
06-03-4
06-03-5
06-03-7
06-03-8
06-00-1

Sub-Section 01 (FUEL CIRCUIT)
FUEL CIRCUIT
SP, SPI and GTS Models

2 Nm
(18 lbfin)
6 Nm
(53 lbfin)
6
7
22 Nm
(16 lbfft)
1 Nm
(9 lbfin)
4 Nm
(35 lbfin) 4
5
3 Nm
(27 lbfin)
4
4 Nm
(35 lbfin)
Loctite 242
3 Nm
(27 lbfin)
(SP)
1
3
2
F01F19S
PARTS
06-01-1

SPX, XP and GTI Models

Loctite 242
3 Nm
(27 lbfin)
Body
2 Nm
(18 lbfin)
6 Nm
(53 lbfin)
6
7
1
3
2
1 Nm
(9 lbfin)
22 Nm
(16 lbfft)
4 Nm 4
(35 lbfin)
5
3 Nm
(27 lbfin)
4
4 Nm
(35 lbfin)
Engine
F01F2ZS
06-01-2
PARTS

HX Model
Body
7
6
2 Nm
(18 lbfin)
3 Nm
(27 lbfin)
6 Nm
(53 lbfin)
Loctite
242
1
3
Body
1 Nm
(9 lbfin)
22 Nm
(16 lbfft)
4
3 Nm
(26 lbfin)
4 Nm
(35 lbfin)
5
4
4 Nm
(35 lbfin)
Engine
8
F05F09S
PARTS
06-01-3

GENERAL
: Whenever repairing the fuel
; WARNING
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
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).
1. Securing clamp in limited access
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.
06-01-4

1,2, Fuel Filter and Bowl

REMOVAL

Open storage compartment cover.
Remove basket.
HX Model Only
Open hood.
GTS and GTI Models Only

Press on vent tube upper part to enable to withdraw tube from body.
F01F01A
TYPICAL
Pull fuel filter toward the bottom.
F02L1MA
TYPICAL
1. Press on vent tube
F01F04A
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. Do not smoke or allow
open flames or sparks in the vicinity.
Unscrew fuel filler cap to remove any fuel pressure in system.
Unscrew the fuel filter bowl counterclockwise
then pull toward the bottom.
TYPICAL
INSPECTION
Check filter bowl for water contamination.
Inspect fuel filter condition. Carefully use low
pressure compressed air to clean fuel filter. Replace filter if permanently clogged or damaged.
ASSEMBLY
to the following.
2,3, Bowl and Gasket

Inspect gasket condition. Make sure gasket is
well positioned into the filter bowl.
06-01-5

6, Pressure Relief Valve

1
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.
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
F01F02A
Black side of the one-way check valve is the valve

outlet. It allows air to get in reservoir.
1. Gasket in bowl
: Ensure that there is no leakage

; WARNING
from the fuel filter.
GTS and GTI Models Only

Insert vent tube in body and clip it in place.
WARNING : Vent tube must be in place to
provide proper bilge ventilation.
REMOVAL
8, Baffle Pick Up
NOTE : The baffle pick up has an integrated
fuel sensor on models which have a fuel
gauge.
1
1
2
3
F01F20A
F02L14A
1. Pick up tube
2. Fuel sensor
3. Baffle pick up
1. Install vent tube
INSPECTION
4, 5, Gear Clamp and Filler Neck Hose
Verify fuel filler neck hose for damage. Always ensure that clamps are well positioned and tightened. Torque clamps to 4 Nm (35 lbfin).
Disconnect BLACK negative cable, then RED positive cable of battery.

WARNING : Always disconnect battery
cables exactly in the specified order,
BLACK negative cable first. Electrolyte or fuel
vapors can be present in the engine compartment and a spark might ignite them and possibly cause personal injuries.
Empty fuel tank.
06-01-6

: Fuel is flammable and explo; WARNING

sive under certain conditions. Always
work in a well ventilated area. Do not smoke or

allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the watercraft.

Remove storage basket from watercraft.
On GTS and GTI models, remove vent tube. Refer
to fuel filter removal procedure in this sub-section.
Disconnect filler neck hose from fuel tank.
Remove retaining straps from fuel tank and move
tank forward.
Remove hoses from baffle pick up and disconnect
wiring harness of fuel sensor (if applicable).
Remove lower clamp from baffle pick up adapter
and pull out baffle from fuel tank.
F05L14A
1. Vent tube
Cut tie rap retaining fuel hoses to tie-mount.

1
F05F02A
1
F01F21A
TYPICAL
1. Wiring harness
2. Baffle pick up adapter
HX Model Only
Pull down left vent tube.
1. Cut tie rap
All Models
Loosen lower clamp of baffle pick up adapter and
pull out baffle from fuel tank.
Remove upper clamp from adapter and slide
adapter from baffle.
Inspect filter of baffle pick up. Clean or replace as
necessary.
ASSEMBLY
to the following.
Slide adapter onto baffle pick up until it stops on
rib. Install clamp.
06-01-7

Install baffle pick up into fuel tank and push it until

it sits on fuel tank neck. Install clamp and torque
both clamps to 3 Nm (27 lbfin).
RE
S
OU
T
HX Model Only
Make sure to align notch of baffle pick up with the
mark on the fuel tank.
F01F0KA
TYPICAL
1. Disconnect air inlet hose
2. Install a hose pincher to vent hose
F05F04A
1. Baffle pick up notch

2. Fuel tank mark
FUEL SYSTEM PRESSURIZATION

: Whenever doing any type of
; WARNING
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 beforePressure Test
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.
Connect pump gauge tester (P / N 295 000 085)

to air inlet hose.
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 hole 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.
06-01-8

Sub-Section 02 (AIR INTAKE)
AIR INTAKE
9
10 Nm
(88 lbfin)
2
4
Loctite
242
10 Nm
(88 lbfin)
8
8
Loctite
242
Loctite
242
10
Twin carbs
Loctite 242
10 Nm
(88 lbfin)
7
Loctite 515
Single carb
Loctite 515
F01F1WS
PARTS
06-02-1

REMOVAL
5,6,7,8, Flame Arrester, Support, Base

and Screw
1, Air Intake Silencer Cover
Remove flame arrester.

Remove screws holding support of flame arrester
base to the cylinder head cover (587 and 717 engines) or to the tuned pipe (787 engine).
Remove screws from flame arrester base then
withdraw base.
NOTE : On single carburetor models, remove choke cable from flame arrester base.
Unlock retaining slides holding air intake silencer

cover and remove cover.
F01F2OA
TYPICAL
1. Air intake silencer cover
2. Unlock
2,3,4, Screw, Plate and Air Intake

Silencer Base
Remove screws of plate.
Pull out plate and air intake silencer base.
F01F03A
1. Remove support and 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.
7,10, Flame Arrester Base and Screw

2
Apply Loctite 515 on mating surfaces of flame arrester base.

Apply Loctite 242 (blue) on screws and torque to
10Nm (88lbfin).
F01F0AA
1. Air intake silencer base

2. Retaining plate
3. Remove screws
06-02-2

5, Flame Arrester
Inspect condition of flame arrester. Replace or
clean as necessary.
WARNING : Do not operate watercraft
without flame arrester.
9, Gasket
Inspect condition of gasket. Make sure to properly installed gasket.
06-02-3

CARBURETORS
587 Engine
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
06-03-1

717 and 787 Engines

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
06-03-2
PARTS

GENERAL
Twin Carburetor Models Only
The following illustration shows which part of the

carburetor begins to function at different throttle
plate openings.
16,17, Screw and Lock Washer

Remove screws and lock washers retaining carburetors.
Remove carburetors.
Single Carburetor Models Only
2
4
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.
Remove carburetor from intake manifold.
CLEANING
The entire carburetor should be cleaned with a

general solvent and dried with compressed air before disassembly.
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 in a
carburetor cleaner following manufacturers instruction.
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, Oring, etc. Therefore, it is recommended to remove those parts prior to cleaning.
Inspect O-rings, diaphragms and gaskets.
3
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
CARBURETOR REMOVAL
To remove carburetors from engine, proceed as
follows:
Remove air vent tube support (SP/XP series).
Remove air intake silencer. Refer to FUEL SYSTEM 06-02.
Turn fuel valve to OFF position.
Disconnect pulse line from fuel pump.
Disconnect fuel supply line from fuel pump.
Disconnect fuel return line.
Disconnect oil injection pump cable, throttle cable
and choke cable.
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.
06-03-3

2, Low Speed Screw
PUMP VERIFICATION
Check tip for a grooved condition. Replace if necessary.
Check fuel pump valves 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.
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.
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 295 000 114)
on pulse nipple.
Pump tester until it reaches 28 kPa (4 PSI).
06-03-4

CARBURETOR ASSEMBLY
1
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.
F01F0XA
8, Needle Valve Lever
TYPICAL
1. Pump gauge tester
2. Install on pulse nipple
Diaphragm must stand pressure for 10 seconds.

If pressure drops, replace diaphragm.
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.
4, Pump Body
Inspect valves. The pumping area should be free
of holes, tears or imperfections. Replace as needed.
3
5, Filter
To verify filter condition proceed as follows:
Remove pump cover, gasket, diaphragm and then
pump body and gasket.
Remove filter from carburetor body then clean filter and blow carefully with compressed air (low
pressure).
Replace filter if damaged.
F01F0ZA
F01F0YA
TYPICAL
1. Filter
1. Metering chamber floor

2. Lever end
3. Flush
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.
06-03-5

Refer to the following table for specifications of

the pop off pressure for each model.
MODELS
POP OFF
PRESSURE
(PSI)
MINIMUM
STABILIZED
PRESSURE
SP
21-37
14
SPX
40-56
24
SPI
21-37
14
GTS
21-37
14
GTI
40-56
24
XP
27-39
15
HX
40-56
24
F01F0HA
HIGH LEVER
Step 1 depress here
Step 2 push tab down
NOTE : Pressure test should be performed

three times to obtain a valid reading.
If release pressure is not within specification,
check control lever adjustment. Replace spring as
necessary.
CAUTION : Do not stretch or cut spring.
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 inlet
nipple.
Obstruct outlet nipple with a finger.
Pump tester until inlet release pressure is
reached (seen by a sudden pressure drop).
3
1
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 Oring, 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
2
F01F10A
TYPICAL
1. Pump gauge tester
2. Install on inlet nipple
3. Obstruct outlet nipple
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.
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.
06-03-6

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.
2
1
CARBURETOR INSTALLATION
3
At installation, pay attention to the following :

Install carburetor(s) with gasket(s) to intake manifold (rotary valve cover for the 787 engine).
Single Carburetor Models Only

Install lock washers and apply Loctite 242 (blue)
on threads then torque nuts to 25 Nm (18 lbfft).
Twin Carburetor Models Only

4
Apply Loctite 242 (blue) on screw threads. Then,

install screws with lock washers and torque to 20
Nm (15 lbfft).
F01F11A
SYNCHRONIZATION OF TWIN CARBURETORS

With idle speed screw not touching throttle lever
stopper on MAG carburetor, both throttle plates
are in closed position.
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.
1
F01F31A
1. Stopper
2. Idle speed screw
F01F12A
1. Check valve
NOTE : Prior to check valve assembly installation, remember to set gasket.
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.
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.
06-03-7

: Make sure there is no leak in

; WARNING
fuel system.
For fuel system pressurization, refer to FUEL
SYSTEM 06-01.
ADJUSTMENTS
Throttle Cable
Lubricate cable with BOMBARDIER LUBE lubricant.
Throttle lever must reach handlebar grip without
causing strain to cable or carburetor cable bracket.
2
3
F01F1YA
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.
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.
1
1
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.
Properly install clamps.
F01F0TF
587 ENGINE
1. Adjustment nut
2. Throttle lever stopper
06-03-8

F01F32B
F01F33A
717 AND 787 ENGINES

1. Throttle lever stoppers (behind levers)
2. Adjustment nut
717 AND 787 ENGINES

1. Low speed screw (PTO)
2. Low speed screw (MAG)
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 07-02.
CAUTION : Improper oil injection pump
synchronization with carburetor can
cause serious engine damage.
: Do not attempt to set engine

- CAUTION
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.
2, Low Speed Screw
Watercraft
model
SP
SPX
SPI
XP
HX
GTS
GTI
Low speed
screw (turn)
1-1/
4
1-1/
4
1-1/
4
1-3/
4
1-1/
4
1-1/
4
NOTE : Turning screw clockwise leans mixture and turning screw counterclockwise
enriches mixture.
Start and warm up engine.
cool engine.
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.
F01F0TC
587 ENGINE
1. Low speed screw
14, High 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.
06-03-9

15, Idle Speed Screw

Turning screw clockwise increases engine idle
speed and turning screw counterclockwise decreases engine idle speed.
1
F01F0VA
TYPICAL - 587 ENGINE

1. High speed screw
F01F0TE
587 ENGINE
1. Idle speed screw
F01F2QA
TYPICAL - 717 AND 787 ENGINES

1. High speed screws
F01F32C
717 AND 787 ENGINES

1. Idle speed screw
06-03-10

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 : If watercraft is out of water,
water must be supplied to cool engine.
Turn screw so that engine idles at 1500 RPM if
watercraft is in water.
If watercraft is out of water, refer to the following
chart to adjust idle speed to the specification.
Watercraft model
Idle speed
out of water (RPM)
SP
2400
SPX
3000
SPI
2500
XP
3000
HX
3000
GTS
2500
GTI
3000
06-03-11
Section 07 LUBRIFICATION SYSTEM

TABLE OF CONTENTS
OIL INJECTION SYSTEM ........................................................................................................
ALL MODELS EXCEPT HX ..................................................................................................
HX MODEL ...........................................................................................................................
0-01-1
0-01-1
0-01-2
OIL INJECTION PUMP ............................................................................................................

ALL MODELS EXCEPT XP ..................................................................................................
XP MODEL ...........................................................................................................................
REMOVAL.............................................................................................................................
CLEANING ...........................................................................................................................
ASSEMBLY...........................................................................................................................
ADJUSTMENTS ..................................................................................................................
CHECKING OPERATION......................................................................................................
0-02-1
0-02-1
0-02-2
07-02-3
07-02-3
07-02-3
0-02-4
07-02-5
07-00-1

Sub-Section 01 (OIL INJECTION SYSTEM)
OIL INJECTION SYSTEM
SP Model Only
3
2
4 Nm
(35 lbfin)
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
F01G0CS
PARTS
07-01-1

HX Model
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
F05G02S
07-01-2
PARTS

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 Nm (27 lbfin).
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

: Whenever oil system compo; WARNING
nents 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
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.
Connect pump gauge tester to check valve of
oil injection reservoir vent.
F01G0IA
TYPICAL
1. Connect pump to check valve
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.
07-01-3

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

Loctite
242
6 Nm 2
(53 lbfin)
4
Twin Carbs
Single Carb
6 Nm
(53 lbfin)
6
Loctite
242
1
3
10 Nm
(89 lbfin)
Loctite
242
5
6 Nm
(53 lbfin)
6
6 Nm
(53 lbfin)
8 Nm
(71 lbfin)
4
4.5 Nm
(40 lbfin)
Loctite
242
8 Nm
(71 lbfin)
5 Nm
(44 lbfin)
F01G0DS
PARTS
07-02-1

XP Model
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
07-02-2
PARTS

REMOVAL
CLEANING

Remove air intake silencer (refer to FUEL SYSTEM 06-02).
Remove rotary valve cover (refer to ENGINE 0405).
Remove 6 Allen screws retaining intake manifold
to rotary valve cover.
Separate intake manifold from rotary valve cover.
Discard all seals and O-rings. Clean metal components in a solvent.
1,2, Oil Pump Gear and Lock Nut

To separate oil pump from intake manifold, remove oil pump gear using gear holder (P / N 290
277 905) and unscrew lock nut.
ASSEMBLY
3,4,5, Oil Injection Pump, Intake

Manifold and Screw
Install oil injection pump to intake manifold.
Torque screws to 6 Nm (53 lbfin).
CAUTION : Whenever oil injection lines
are removed, always make the routing as
shown.
A00C17B
1. Gear holder
F01D4SA
XP Model Only
1. Small oil line
7,8,9, Cable, Screw and Flat Washer
1,2, Oil Pump Gear and Lock Nut
Disconnect oil injection pump cable.

Remove 2 Allen screws with flat washers retaining oil injection pump to ignition housing cover.
Install gear to oil injection pump shaft. Torque lock

nut to 6 Nm (53 lbfin).
NOTE : Make sure one washer is installed
on each side of gear.
10,11, Pump and Shaft

Pull pump and shaft.
Disconnect oil hoses from fittings of oil injection
pump.
DISASSEMBLY
4,6, Intake Manifold and Screw

Install intake manifold to rotary valve cover and
torque screw to 10 Nm (89 lbfin).
NOTE : Make sure a new gasket is installed
to 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.
07-02-3

587 and 717 Engines
1
2
F01D4RC
TYPICAL
A. 10 Nm (89 lbfin)
F01D4RE
TYPICAL
1. Jam nut
2. Adjustment nut
3. Aligned marks
XP Model Only
8,9,10,11, Screw, Flat Washer, Pump

and Shaft
Install shaft in crankshaft end.
Install pump. Secure with flat washers and
screws. Torque to 3 Nm (26 lbfin).
Install oil injection pump cable.
787 Engine
NOTE : The adjustment screw and jam nut
for the oil injection pump cable is located at
PTO carburetor lever.
ADJUSTMENTS
: As oil injection pump adjust- CAUTION
ment is dependant on throttle cable posi-
tion, 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 06-03.
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.
1
F01G0RA
1. Aligned marks
All Engines
Start and bring engine to normal operating temperature.
cool engine.
Adjust idle speed to specification. Refer to FUEL
SYSTEM 06-03.
Stop engine.
07-02-4

787 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.
CAUTION : Proper oil injection pump adjustment is very important. Any delay in
the opening of pump can result in serious engine damage.
F01G0RB
1. Bleed screw
Bleeding
: Oil injection system must be
- CAUTION
bled and adjustment checked before op-
erating engine.
Ensure oil injection reservoir is sufficiently filled.
Install a dry rag below oil injection pump.
Loosen bleed screw to allow oil to flow.
587 and 717 Engines
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.
If not, run engine at idle speed while manually
holding pump lever in fully open position. Do not
activate throttle lever.
cool engine.
CHECKING OPERATION
2
F01D4RB
TYPICAL
1. Bleed screw
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 a lot of
smoke from exhaust outlet.
If not, remove pump assembly and check the
pump gear (587 and 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.
07-02-5

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.
2
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)
587
717
787
0.83 - 1.00 mL
(each port)
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.
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
07-02-6
Section 08 ELECTRICAL SYSTEM

TABLE OF CONTENTS
MAGNETO SYSTEM ...............................................................................................................
587 AND 717 ENGINES .......................................................................................................
787 ENGINE .........................................................................................................................
GENERAL .............................................................................................................................
REMOVAL.............................................................................................................................
CLEANING ...........................................................................................................................
DISASSEMBLY.....................................................................................................................
ASSEMBLY...........................................................................................................................
INSTALLATION ....................................................................................................................
08-01-1
08-01-1
08-01-2
08-01-3
08-01-3
08-01-6
08-01-6
08-01-7
08-01-8
IGNITION SYSTEM.................................................................................................................. 08-02-1

GENERAL ............................................................................................................................. 08-02-1
IGNITION TIMING PROCEDURE ........................................................................................ 08-02-3
BOMBARDIER IGNITION TESTER ...................................................................................... 08-02-8
IGNITION SYSTEM TESTING PROCEDURE ...................................................................... 08-02-9
SPARK PLUGS ..................................................................................................................... 08-02-13
CHARGING SYSTEM...............................................................................................................
GENERAL .............................................................................................................................
TESTING PROCEDURE .......................................................................................................
BATTERY ..............................................................................................................................
08-03-1
08-03-1
08-03-1
08-03-3
STARTING SYSTEM ................................................................................................................

GENERAL .............................................................................................................................
STARTING SYSTEM TROUBLESHOOTING .......................................................................
STARTER REMOVAL............................................................................................................
STARTER DISASSEMBLY....................................................................................................
CLEANING ...........................................................................................................................
PARTS INSPECTION ............................................................................................................
STARTER ASSEMBLY..........................................................................................................
STARTER INSTALLATION ...................................................................................................
STARTER SPECIFICATION ..................................................................................................
08-04-1
08-04-2
08-04-3
08-04-4
08-04-4
08-04-4
08-04-4
08-04-5
08-04-7
08-04-8
INSTRUMENTS AND ACCESSORIES .................................................................................... 08-05-1

GENERAL ............................................................................................................................. 08-05-1
INSPECTION ........................................................................................................................ 08-05-1
DIGITALLY ENCODED SECURITY SYSTEM........................................................................... 08-06-1
GENERAL ............................................................................................................................. 08-06-1
08-00-1

MAGNETO SYSTEM
587 and 717 Engines

11
12
5 Nm
(44 lbfin)
13
9 Nm
(80 lbfin)
Loctite
242
Loctite
242
4
7
6 Nm
(53 lbfin)
Loctite
242
6 Nm
(53 lbfin)
5
Loctite
242
3
14
Loctite
242
9
6 Nm
(53 lbfin)
4
Loctite
648
10
15
145 Nm
(107 lbfft)
Anti-seize
lubricant
F01D4WS
PARTS
2
9 Nm
(80 lbfin)
08-01-1

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
Synthetic
grease
F01D7TS
08-01-2
PARTS
6 Nm
(53 lbfin)

GENERAL
The following procedures can be performed without removing engine from watercraft. However,
battery removal will be required (except for the XP
and HX).
REMOVAL
587 and 717 Engines
1,2, Magneto Housing Cover and Screw

Remove screws, wire support and spark plug
grounding device then withdraw cover.
F01D48A
3,10, MAG Flywheel and Ring Gear

MAG 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
TYPICAL
1. Sleeves on opposite side
Using a suitable socket, unscrew retaining nut

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 MAG 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 MAG flywheel.

MAG flywheel is easily freed from crankshaft with
puller (P / N 295 000 106).
08-01-3

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 MAG flywheel from its taper.
587 and 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.
Find a crankcase locating lug (the top one in this
example).
Place a cold chisel at the end of choosen lug,
then punch a mark on armature plate at this
point.
1
2
3
F01D4CA
1. Puller plate
2. Puller
3. Extension handle
4,5, Armature Plate and Screw

F01D4DA
Remove 3 retaining screws and withdraw armature plate.
11,13, Magneto Housing and Screw

To remove magneto housing, starter has to be removed. Refer to ELECTRICAL SYSTEM 08-04.
Unscrew retaining screw, then withdraw housing.
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.
08-01-4

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
787 Engine
Find manufacturers mark on armature plate. In

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

Remove engine magneto cover.
15,16, Rotor and Flywheel

Remove starter.
Lock ring gear using special tool (P / N 295 000
134).
2
1
F01D85A
F01D4FA
TYPICAL
1. Manufacturers mark on armature plate
2. Punch a mark on crankcase lug aligned with plate mark
1. Ring gear blocking tool
08-01-5

If desired, magneto rotor can be removed without

the engine flywheel. Remove the 6 screws.
: Clean coils and magnets us- CAUTION

ing only a clean cloth.
Clean crankshaft taper and threads.
DISASSEMBLY
587 and 717 Engines

Lay MAG flywheel on a steel plate. Tap lightly on
ring gear using a hammer to release it from MAG
flywheel.
1
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.
F01D3AA
1. Magneto flywheel
6, Generating Coil
To replace generating coil :
Heat the armature plate to 93C (200F) around
the screw holes to break the threadlocker
bond.
F01D7YA
1. Puller
Tighten puller screw and at the same time, tap on

screw head using a hammer to release engine flywheel from its taper.
A01C03A
1. Heat the armature plate
CLEANING
- CAUTION : Protect harness from flame.
08-01-6

Remove screws.
Uncrimp and unsolder BLACK / RED wire from
coil.
BLACK wires from coil.

Uncrimp and unsolder ground wire (BLACK) from
coil core.
A25E0SA
A25E0QA
1. .Uncrimp and unsolder ground wire (BLACK) here

2. Uncrimp and unsolder YELLOW and YELLOW / BLACK wires
here
1. Uncrimp and unsolder wire here
7, Battery Charging Coil

To replace battery charging coil :
Heat the armature plate to 93C (200F) around
the screw holes to break the threadlocker
bond.
ASSEMBLY
587 and 717 Engines
6,8, Generating Coil and Screw

Strip end of old wire then crimp and solder on
new coil.
Apply Loctite 242 (blue) to screws 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.
2
A01C2JA
1. Heat the armature plate
- CAUTION : Protect harness from flame.

Remove screws.
Uncrimp and unsolder YELLOW and YELLOW /
08-01-7

420 8769 22
F01D3BA
A25E0RD
1. Magneto coil centering tool (P / N 290 876 922)
1. Teeth chamfer
: Before reinstalling the magne- CAUTION

to, remove the loose epoxy from harness.
NOTE : Ensure that ring gear contacts MAG

flywheel flange.
Whenever replacing either ring gear or MAG flywheel, Gun Kote must be applied to prevent possible corrosion.
CAUTION : Always assemble MAG flywheel and ring gear prior to apply Gun
Kote. If not done correctly, ring gear wont contact MAG 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 MAG 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.
CAUTION : At installation of magneto,
ring gear teeth chamfer and starter clutch
should be facing each other.
7,9, Battery Charging Coil and Screw

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.
420 8769 22
A25E0RD
1. Magneto coil centering tool (P / N 290 876 922)

Apply Loctite 648 (green) to MAG flywheel mating surface. Lay ring gear on a steel plate, then
heat with a propane torch in order to install it on
MAG flywheel.
Pay particular attention to position ring gear teeth
chamfer side as per following illustration.
INSTALLATION
587 and 717 Engines
11,12,13, Magneto Housing, Gasket and

Screw
Install gasket between magneto housing and engine crankcase.
Install magneto housing and torque screws to 9
Nm (80 lbfin).
08-01-8

4,5, Armature Plate and Screw

Position the armature plate on the crankcase,
aligning the marks on both parts.
Apply a drop of Loctite 242 (blue) on screw
threads and torque to 6 Nm (53 lbfin).
3,14,15, Magneto Flywheel, Woodruff

Key and Nut
Apply Loctite 242 (blue) on crankshaft taper.
Position Woodruff key and magneto flywheel. Apply Loctite 242 (blue) on nut threads. Install nut
with lock washer and torque to 145 Nm (107
lbfft).
CAUTION : Never use any type of impact
wrench at magneto installation.
Ignition Timing
F04D0CA
11,12,13, Magneto Housing, Gasket and

Screw
787 Engine
Install gasket between magneto housing and engine crankcase.

Install magneto housing and torque screws to 9
Nm (80 lbfin).
11,18, Magneto Housing and Seal
15,16,17, Rotor Flywheel and Nut
To install oil seal of magneto housing, use pusher

(P / N 290 877 740) and handle (P / N 290 877
650).
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.
For procedures, refer to ELECTRICAL SYSTEM

08-02.
F01B2NA
1. Pusher
2. Handle
F01D83A
1. Protuberance
2. Hole
Apply Loctite 242 (blue) on crankshaft taper.

Apply Loctite 242 (blue) on nut threads. Install nut
with lock washer and torque to 105 Nm (77
lbfft).
08-01-9

: Never use any type of impact

- CAUTION
wrench at magneto installation.
All Engines

Properly install O-ring in magneto housing. Apply
Loctite 767 Anti-seize on screw threads, install
cover, wire support and spark plug grounding device (587 and 717 engines) then torque screws in
a criss-cross sequence to 9 Nm (80 lbfin).
08-01-10

Sub-Section 02 (IGNITION SYSTEM)
IGNITION SYSTEM
GENERAL
Ignition Coil
587 and 717 Engines

The Capacitor Discharge Ignition system includes
the following components :
It receives its energy from the generating coil via

a BLACK / RED wire. The generating coil allows a
current flow through ignition coil with its integrated CDI module and through primary windings.
Ignition coil induces voltage to a high level in secondary windings to produce a spark at spark plug.
1
2
F01H2NA
Multi-Purpose Electronic Module

It receives its current from the battery. It includes
the engine rev limiter and also an integrated delay
timer which cut off the electrical circuit after approximately 33 seconds of non-use when the
safety lanyard cap is on switch. Delay timer can
be activated by depressing start / stop button
when safety lanyard is removed.
F01H2LA
CDI SYSTEM
1. Magneto
2. Spark plugs
3. Ignition coil with integrated CDI module
4. Multi-purpose electronic module
Magneto
It is the primary source of electrical energy. It
transforms magnetic field into electric current
through a generating coil.
F01H2OA
TYPICAL
NOTE : The fuses are directly mounted onto

theMPEM.
F01H2MA
08-02-1

787 Engine
The 787 engine has a digital DC-CDI (Direct Current-Capacitor Discharge Ignition) system. The
high amperage / voltage components are located
into a rear electrical box (next to the battery). The
other components are located in the conventional
electrical box. The ignition system includes the
following components :
1
1
N
N
2
2
S
S
A00E4JA
1.
2.
3.
4.
5.
6.
Coil
Magnet
Rotor protrusion
Magnetic field outside of coil
Magnetic field crossing coil
Current to CDI module
DC-CDI Module
F01H4ZA
1.
2.
3.
4.
5.
6.
The DC-CDI module receives the input from the

trigger coil and signals the ignition coil when to
fire. It also has the rev limiter function built into its
circuitry, as well as the ignition timing curve. The
DC-CDI module is mounted in the cover of the
conventional electrical box.
Rotor
Trigger coil
MPEM
Digital DC-CDI module
Holder relay
Ignition coil
WIRE COLOR
Magneto Rotor / Trigger Coil

The trigger coil is mounted outside the rotor (inside the magneto housing of the engine) and is
not adjustable. Its purpose is to signal the DC-CDI
to be conductive at the proper number of degrees
before TDC (Top Dead Center). The rotor has two
protrusions (180 degrees apart) that, when coupled with the trigger coil, accomplish the signaling.
FUNCTION
RE/PU
CDI power source from MPEM

through holder relay
BK
Grounded in main electrical box
WH
To ignition coil
YL/WH
Impulse from trigger coil
BK/OR
Blanks-not used at this time
BK/GR
Blanks-not used at this time
BK
Ground between CDI and MPEM
GY/WH
RPM data to MPEM
WH/BL
Data to MPEM (low voltage)

(MPEM)
The MPEM has a micro processor inside of its
sealed case and basically is responsible for : interpreting information, distribution of information,
and as a timed /untimed power source. The
MPEM is mounted in the conventional electrical
box. Wire connections are as follows :
08-02-2

WIRE
WH/GY
FUNCTION
Communication for DESS lanyard
TA
Power to the monitoring beeper and

sensor
PU
Power
BK/YL
Safety lanyard switch (DESS)
YL/RE
Start/stop witch (handlebar)
WH/BL
Data transfer (low voltage)
GY/WH
RPM data to MPEM
BK
Ground between CDI and MPEM
BK
External ground
BK
Ground for safety lanyard
YL/RE
Starter relay
RE/PU
Power to instrument
(oil/fuel/etc.)
RE/BL
Power to holder relay
Holder Relay
The holder relay is used to prevent discharge of
the battery, through the ignition system, when
the craft is not running. The relay is in the conventional electrical box.
Ignition Coil
The ignition coil steps up the voltage input from
the DC-CDI module and the end result is firing of
the spark plugs. Output of this coil has been increased by 3KV. The coil is housed in the rear
electrical box.
All Engines
Engine Rev Limiter
It has 3 functions :
Keeps high voltage away from safety lanyard
switch.
Provides engine stop by grounding the primary
coil.
Limits engine RPM to prevent over-revving.
A defective rev limiter may cause the following
problems :
No spark.
Uninterruption of spark when engine start /
stop and safety lanyard switch is used.
Incorrectly controlled engine maximum RPM.
Misfiring / black fouled spark plugs.
To check engine rev limiter, connect an induction

tachometer (P / N 295 000 100), start engine and
check its maximum speed ; it should be around
6550 50 RPM for a 587 engine, 7000 50 RPM
for a 717 engine, and 7200 50 RPM for a 787
engine.
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 missing or broken
magneto woodruff key.
NOTE : Do not use the factory mark found
on the PTO flywheel to check ignition timing
or troubleshoot any problems.
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 (static test) before
checking ignition timing with an appropriate
timing light (dynamic test).
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 flywheel, the
trigger coil, the DC-CDI module or 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 new 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 timing at
3500 RPM, a change in engine speed within 500
RPM will not affect the timing mark when
checked with the timing light.
08-02-3

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.
587 and 717 Engines
3. Install timing mark pointer tool on engine using
wing nuts previously removed.
F01H5TA
TYPICAL
1. TDC gauge on MAG side
80
70
60
30
1. Timing mark pointer tool (P / N 295 000 102)
40
20
50
10
F01H5SA
90
5. Rotate PTO flywheel counterclockwise (when

facing it) until piston is at top dead center.
787 Engine
3. Remove middle screw securing the engine to
the rear engine mount. Reinstall screw with
timing mark pointer tool.
F01H4LA
TYPICAL
1. Adjust gauge dial at zero
F01H54A
1. Timing mark pointer tool (P / N 295 000 135)
All Engines
4. Install and adjust a TDC gauge (P / N 295 000
065) in MAG side spark plug hole.
6. From this point, rotate flywheel clockwise to

reach proper specification according to engine.
Refer to the following chart.
08-02-4

ENGINE
IGNITION TIMING (BTDC)
587
2.41 mm (.095 in)
717
2.59 mm (.102 in)
787
3.38 mm (.133 in)
1. Connect timing light pick-up to MAG side spark

plug wire.
2. Connect an induction-type tachometer (P / N
295 000 100) to spark plug wire.
7. Scribe a thin mark on PTO flywheel in the middle of tool slot (587 and 717 engines) or aligned
with timing mark pointer tool (787 engine).
F01H5SB
TYPICAL
1. Tool slot
2. Flywheel mark
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
587 and 717 Engines
To check ignition timing, use Bombardier timing
light (P / N 295 000 078).
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.
08-02-5

3. Start engine and point timing light straight in

line with timing tool slot. Bring engine to 6000
RPM .
00
60
Ignition Timing Adjustment

587 and 717 Engines
Remove battery (except HX).
Remove magneto housing cover and grounding
device.
For removaI of magneto, refer to ELECTRICAL
SYSTEM 08-01.
Timing is performed by moving armature plate ;
clockwise to retard spark occurrence or counterclockwise to advance.
1
F01H2IA
TYPICAL
1. Timing light pick-up on MAG side
: If engine is to be run more

- CAUTION
than a few seconds, water must be sup-
plied to the engine.

4. Check if PTO flywheel mark aligns with timing
tool slot.
NOTE : On this NIPPONDENSO system,
timing advance decreases as engine speed
increases.
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.
2. Check ignition timing using a stroboscopic timing light connected to the MAG side spark plug
cable. Rev the engine to 3500 RPM and point
beam of timing light straight in line with timing
mark pointer.
CAUTION : If engine is to be run more
than a few seconds, connect coupler hose
(P / N 295 500 258) and supply water to the engine to properly cool it.
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.
2
A25E0RA
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.
08-02-6

1
1
A25E0VA
F01H5VA
1. Retarded timing
TYPICAL
1. Retaining screw
Example 1
When PTO flywheel mark is on right side of timing
tool slot, it indicates advanced 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.
Reinstall removed parts. Refer to ELECTRICAL
SYSTEM 08-01.
Recheck ignition timing (make sure engine is
cold).
Repeat armature plate positioning procedure if
timing mark position is not adequate.
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.
787 Engine
Since the trigger coil on this engine is fixed and
not movable to correct the ignition timing, the
MPEM programmer (P / N 295 000 127) is now
used to set the timing when an adjustment is required. The programmer will act as if you were
moving the trigger coil to advance or retard the
ignition timing.
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.
If the timing is adjusted too retarded, a performance decrease of the engine will be noticed. If
the timing is adjusted too advanced, serious engine damage will occur.
CAUTION : If the ignition timing is adjusted too advanced, this will cause serious
damage to the engine.
08-02-7

The timing mark refer to the physical component

position when the spark must occur. The DC-CDI
module 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
Programmer number
(MPEM)
Ignition Timing
Correction
-1
-2
-3
-4
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.
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.

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.
The programmer gives you the number 4.
Referring to the chart, number 4 returns a
correction of 1 (advanced) and this is not
enough in this case.
programmer.
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 actually 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.
08-02-8

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 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 module features a permanent (non-volatile) 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 and ignition coil / CDI module of the ignition system.
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.).
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.
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.
A00E0EA
Always make sure that tester batteries are in

good condition.
Test Condition
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.
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.
08-02-9

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
Delay 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 and depress start / stop button
once. The timer should stay on for about 33 seconds (for example, fuel gauge will be activated)
and then turn off.
587 and 717 Engines
When dealing with ignition problems, the following items should be verified in this order.
1. Spark occurence / spark plug condition.
2. Battery condition.
3. Electrical connections.
4. Engine start / stop switch.
5. Safety lanyard switch.
6. Delay timer .
7. Multi-purpose electronic module (MPEM).
8. Magneto output.
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) can be used.
Engine Start / Stop Switch Verification

Disconnect the YELLOW / RED wire in the electrical box. Using an ohmmeter, 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 Switch Verification

Disconnect the BLACK and BLACK / YELLOW
wires in the electrical box. Using an ohmmeter,
connect test probes to switch wires.
Measure resistance, it must be close to 0 ohm
when cap is over switch and an open circuit when
removed.

(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
Yellow/Red
(female terminal)
Black
(ring terminal)
> 10 k
Yellow/Red
(male terminal)
Black
(ring terminal)
> 50 k
Black
(ring terminal)
Red
(ring terminal)
> 10 k
08-02-10

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.
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.
F01B28A
TYPICAL
Check resistance with a high-sensitivity ohmmeter. Refer to the following table for values and
wire colors.
PART NAME
ADAPTER
WIRE
RESISTANCE
()
Generating coil
Black with
RED/BLUE
40-76
F01H5WA
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.
6. Set Bombardier Ignition Tester as per following
table :
Tester
probe
Adapter
wire
RED/
BLUE
Tester
switch
position
Tester
dial
position
LOW
60
BLACK
08-02-11

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
F01H5YA
1.
2.
3.
4.
7. Crank engine and observe indicator.

8. Push reset button and repeat test twice.
Multimeter
Six-pin magneto harness adapter
WHITE wire
BLACK / YELLOW wire
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.
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).
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.
08-02-12

DC-CDI Module Verification

+ Meter Lead
- Meter Lead
Value
RE/PU
(male connector)
RE
<1
+ Meter Lead
- Meter Lead
Value
RE/PU
BK
2.6 k
YL/WH
BK
0.380 M
WH
BK
2.208 M
RE/PU
(male connector)
BK
(ring terminal)
> 20 k
BK/OR
BK
infinity
WH/GY
BK
(ring terminal)
> 100 k
BK/GR
BK
infinity
BK
BK
0.2
TA/BL
BK
(ring terminal)
> 10 k
WH/BL
BK
30.38 k
PU/WH
BK
RE/PU
2.690 k
BK
(ring terminal)
> 2 k
> 2.4
BK
YL/WH
0.390 M
YL/RE
(female connector)
BK
(ring terminal)
> 10 k
BK
WH
2.2 M
BK/OR
infinity
BK
(ring terminal)
> 50 k
BK
YL/RE
(male connector)
BK
BK/GR
infinity
GY/WH
BK
(ring terminal)
> 9 k
< 11
BK
BK
2.69 k
WH/BL
BK
(ring terminal)
> 4.3 k
< 4.9 k
WH/BL
PU/WH
> 2.2 k
< 2.6 k
BK
(ring terminal)
RE
(ring terminal)
> 10 k
BK
GY/WH
RE/PU
RE/PU
(male connector) (female connecto)
33.07 k

(MPEM) Verification
The multi-purpose electronic module testing must
be done with all wires disconnected from circuit.
Otherwise testing equipement (ohmmeter) could
be damaged.
NOTE : < = less than
> = greater than
<1
Holder Relay Verification

1. Disconnect the PURPLE / BLUE and BLACK
wires coming out from the holder relay.
2. Connect meter leads to above wires and resistance of holding coil should be 104 ohms
(10%).
DYNAMIC TEST
1. Disconnect all 4 wires to the holder relay.
2. Set meter to resistance scale, connect meter
leads to RED / BLUE and RED / PURPLE wires
(there should be no reading).
3. Jumper DC (battery) voltage : positive lead to
PURPLE / BLUE, negative to BLACK.
4. By energizing the coil, the switch should have
closed, the ohmmeter should read less than 0.5
ohm resistance.
08-02-13

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.
1. Install the test adapter to spark plug cable close

to MAG side spark plug.
2. Connect Bombardier Ignition Tester probes
then set switch and dial as follows :
Tester
probe
Component
Tester adapter
(paper clip) on
spark plug
cable
Primary Winding
587 and 717 Engines

Due to the integrated CDI module, it is not possible to take any resistance measurement.
787 Engine
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.
Tester
switch
position
Tester dial
position
LOW
50
Grounding
device
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.
IGNITION
TESTER
40 50 60
30
70
20
80
10
90
ELECTR
O-SPECIALT
IES, INC
.
0
LOW
100
HIGH
A00E0QA
F01H5MA
1. Resistor cap
2. High-tension cable
TYPICAL
1. N lead on paper clip
2. P lead to grounding device
IGNITION COIL
PART NAME
WIRE
RESISTANCE
()
Secondary
widing
End of each spark

plug cable, spark
plug caps removed
9-15 k
3. Start engine and observe indicator.

NOTE : If engine starts, allow it to idle while
observing indicator. Then, shut engine off.
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.
Results :
a. Indicator lamp lights : Ignition coil is OK.
b. Indicator lamp does not light : Ignition coil is
faulty. Replace it.
08-02-14

787 Engine Only

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.
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
A00E09A
1. Cold
2. Hot
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
: Severe engine damage might

- CAUTION
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.
Disassembly
First unscrew the spark plug one turn.
Clean the spark plug and cylinder head with pressurize air then completely unscrew.
Heat Range
The proper heat range of the spark plugs is determined by the spark plugs ability to dissipate the
heat generated by combustion.
08-02-15

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.
A00E0BA
Spark Plug Analysis
1. Proper socket
2. Improper socket
Spark Plug Chart
Watercraft
models
Engine
Spark
plugs
Torque Nm
(lbfft)
Gap
mm (inch)
SP
SPI
GTS
587
NGK
BR8ES
24 (17)
0.5-0.6
(.020-.024)
SPX
GTI
HX
717
NGK
BR8ES
24 (17)
0.5-0.6
(.020-.024)
XP
787
NGK
BR8ES
24 (170
0.5-0.6
(.020-.024)
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.
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.
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.
08-02-16

Spark Plug Symbol Explanation

WIDE GAP
SUFFIX
PREFIX
15
B P 5 E S
Thread
diameter
Heat rating
numbers
A : 18 mm
B : 14 mm
C : 10 mm
D : 12 mm
E : 8 mm
mm x 19 mm
J : 12
Reach
mm
E : 19
(3/4")
A : Special Design
F : Taper
Seat
Ground
B : Single
Special Alloy
mm
H : 12.7
(1/2")
Ground
C : Dual
Special Alloy
G : Racing Type
mm
L : 11.2
(7/16")
Z:
Construction
M:
Firing end
construction
Reach
Hot
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")
Version
GV : Racing
of V-Type
21 mm
(53/54")
L : Half Heat Range
Center
S : Standard
Electrode
Compact Type
Blank
P : Projected
Insulator Type
R : Resistor Type
U : Surface Discharge
Z : Inductive
Suppressor Type
10
Wire Center
V : Fine
Electrode
18 mm 12 mm
(31/64")
X : Booster Gap
Center
Y : V-Grooved
Electrode
14 mm 9.5 mm
(3/8")
Cold
F02H08S
CROSSCUTS AND GAP STYLES OF SPARK PLUGS
A01E1PS
Standard
Type
Projected
Insulator Type
Taper
Seat Type
V-Type
Surface
Discharge Type
08-02-17

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).
3
The rectifier / regulator is often 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
587 and 717 Engines

The magneto has a three-pole coil. Capacity is 160
watts.
NOTE : First, ensure that battery is in good

condition prior to performing the following
tests.
787 Engine
The magneto has a 3 phase, Y wound stator on
18 poles. Capacity is 180 watts.
Current Test
Rectifier / Regulator
587 and 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 - 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 - 14.8 volts) to prevent
any damage to components.
Battery
The battery is the DC source for electric starter,
multipurpose electronic module and all accessories.
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 587
and 717 engines or 5 amperes for the 787 engine.
If not, check magneto output prior to concluding
that rectifier is faulty.
Voltage Test
Start engine.
Connect a DC voltmeter on battery posts.
Bring engine to approximately 5500 RPM.
If voltmeter reads over 15 volts, regulator is defective. Replace it.
NOTE : Whatever the voltmeter type used
(peak voltage or RMS), the voltage must not
exceed 15 V. A faulty regulator will allow voltage
to exceed 15 V as engine speed is increased.
Rectifier / Regulator
Fuse
A 15 A fuse protects the charging system. If the
battery is regularly discharged, check fuse condition.
NOTE : On the XP model, there is two 15 A
fuses.

1. Due to internal circuitry, there is no static test
available.
DYNAMIC TEST
Refer to Voltage test above.
08-03-1

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.
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
Tester
switch
position
Tester
dial
position
LOW
70
587 and 717 Engines

1

1. Disconnect the magneto wiring harness connector.
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
NOTE : A short circuit will read 0 ohm (or

closeto) on ohmmeter.
1
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.
Stator
787 Engine
F02H0KA
1. Multimeter
2. Magneto harness adapter
3. YELLOW and YELLOW / BLACK wires
DYNAMIC TEST

N 295 000 136).
08-03-2

3. Check resistance between two of the YELLOW

wires. The resistance should be between 0.1 1.0 ohm.
3
F01H60A
F01H5ZA
1.
2.
3.
4.
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
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.
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.
08-03-3

BATTERY
Cleaning
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.
Remove corrosion from battery cable terminals
and battery posts using a firm wire brush. Rinse
with clear water and dry well.
Troubleshooting
SYMPTOM : DISCHARGED OR WEAK BATTERY

CAUSE
REMEDY
1. Battery posts and/

or cable terminal
oxidized.
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 burnt

or faulty rectifier.
First check fuse.

If it is in good condition,
regulator.
5. Faulty battery
charging coil (or
stator)
Replace.
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.
WARNING : Should the battery casing be
damaged, wear a suitable pair of non-absorbent gloves when removing the battery by
hand.
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.
Removal
Hydrometer Test
: Battery BLACK negative ca; WARNING

ble must always be disconnected first and
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).
connected last. Never charge or boost battery

while installed in watercraft.
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 straps.
5. Withdraw battery from watercraft being careful
not lean it so that electrolyte flows out of vent
elbow.
CAUTION : Should any electrolyte spillage occur, immediately wash off with a
solution of baking soda and water.
WARNING : Electrolyte is poisonous and
dangerous. Avoid contact with eyes, skin
and clothing.
A17E0JA
A. 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).
08-03-4

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
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

.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.
Check electrolyte level in each cell, add distilled
water up to upper level line.
CAUTION : Do not overfill.
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.
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.
: Never charge or boost bat; WARNING

tery 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.
In case of accidental premature removal of caps
or sealing tube, battery should be given a full
charge.
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
tub 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.
3
1
A17E0FB
1. Sealing tube removed

2. Battery electrolyte
3. Upper level line
08-03-5

3. Allow the battery to stand for 30 minutes MINIMUM so that electrolyte soak through battery
cells.
: If charging rate raises higher

- CAUTION
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.
WARNING : Always charge in a well ventilated area. Keep battery away from cigarettes or open flames. Always turn battery
charger off prior to disconnecting cables.
6. Disconnect battery charger.
A17E0GA
1. 30 minutes
4. Readjust the electrolyte level to the UPPER

LEVEL line.
A17E0IB
Step 1 Unplug battery charger

Step 2 Disconnect - lead
Step 3 Disconnect + lead
7. Test battery state of charge. Use a hydrometer.

2
A17E0RB
1. Battery electrolyte
2. Upper level line
5. Connect a 2 A battery charger for 3 to 5 hours.
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.
A17E0IA
Step 1 Connect + lead to battery + post

Step 2 Connect - lead to battery - post
Step 3 Plug battery charger
08-03-6

10.Reinstall battery. Hook up battery cables observing correct polarity and coat terminals with
dielectric grease.
Install vent line.
NOTE : A check valve is installed on vent
line to prevent water infiltration into battery.
CAUTION : Negative battery terminal
should always be disconnected FIRST and
reconnected LAST.
WARNING : Vent line must be free and
open.
NOTE : It is recommended to verify the battery charge once a month. If necessary, fully
charge battery.
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.
Servicing
CHARGING A VERY FLAT OR

COMPLETELY DISCHARGED BATTERY:
Electrolyte Level
Since a battery has been activated (see above),
add distilled water to top up electrolyte.
Tips for charging a used battery

: Prior to charging the battery,
- CAUTION
always remove it from watercraft to pre-
vent electrolyte spillage.

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.
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 : Do not place battery near
open flame. Always charge in a well ventilated area.
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.
Unless this procedure is properly followed, a good

battery may be needlessly replaced.
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.
08-03-7

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.
Battery Charging Equipment

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.
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. Keep battery away from cigarettes
or open flames. Avoid skin contact with electrolyte.
3. First connect RED positive cable.
4. Connect BLACK negative cable last.
5. Apply dielectric grease on battery posts.
6. Verify cable routing and attachment.
All Models Except XP and HX

Secure RED positive battery cable using right
strap of battery.
Charging TWO or More Batteries at a

Time
1
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).
2
1
F01H0AA
1. Strap retaining RED positive cable

2. Vent tube connected and secured in support
A17E0PA
TYPICAL
1. Two batteries = 4 A
: Always charge in a well ven; WARNING

tilated area.
Installation of Battery
: Always connect battery ca; WARNING
bles exactly in the specified order, RED
positive cable first BLACK negative cable last.
08-03-8

Sub-Section 04 (STARTING SYSTEM)
STARTING SYSTEM
8
7
9
10
11
12
1
2
3
13
4
5 Nm
(44 lbfin)
Dielectric
grease
15
16
Loctite 271
Ground cable
Dielectric grease
F01H1MT
17
14
22 Nm
(16 lbfft)
PARTS
08-04-1

GENERAL
Solenoid
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, 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.
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.
NOTE : Solenoid is located in the electrical

box.
Inspect connections and clean as necessary.
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.

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.
Battery
To check battery condition, refer to ELECTRICAL
SYSTEM 08-03.
Engine Start / Stop Switch

Switch condition can be checked with an ohmmeter.
Disconnect the YELLOW / RED wire in the electrical box. 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 Switch

Disconnect the BLACK and BLACK / YELLOW
wires in the electrical box. Using an ohmmeter,
connect test probes to switch wires.
Measure resistance, it must be close to 0 ohm
when cap is over switch and an open circuit when
removed.
08-04-2

STARTING SYSTEM TROUBLESHOOTING

SYMPTOM
CAUSE
REMEDY
Starter does not turn.
Burnt fuse 5A.
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,

safety lanyard switch or solenoid.
Replace.
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
08-04-3

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
A03E04A
1. Pinion stop collar
STARTER DISASSEMBLY
9,10,11,12, Clutch Assy, Housing,

O-ring and Armature
1,2,3,4,5, Yoke, Brush Holder, End

Frame, Through Bolt and Nut
Before disassembling, trace index marks on yoke
and clutch housing to ease further assembly.
Turn assembly clockwise to remove it from armature assembly.

Pull housing from armature.
CLEANING
: Yoke assy and drive unit as- CAUTION

sembly must not be immersed in cleaning
solvent.
Discard all O-rings and gasket.
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 : 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 must not be cleaned with
grease dissolving agents.
Immerse all metal components in cleaning solution. Dry using a clean, dry cloth.
F01H0PA
TYPICAL
1. Trace indexing marks
Remove starter support nuts then through bolts.

Separate end frame from yoke assembly. Withdraw yoke assembly from armature.
Brush holder can be removed from end frame 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.
6,7,8, Circlip, Spring and Pinion Stop

Collar
PARTS INSPECTION
Tap the pinion stop collar using a screwdriver. Remove circlip. Disassemble pinion stop collar and
spring.
Armature
NOTE : An ohmmeter may be used for the
following testing procedures, except for the
one concerning shorted windings in armature.
08-04-4

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.
2
1
A03E05A
1. New
2. Wear limit, 8.5 mm (.335 in)
Overrunning Clutch
F01H0RA
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.
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
08-01.
STARTER ASSEMBLY
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 with G.E. Versilube G 341 M or ESSO
Beacon 325 lubricant or equivalent.
Apply motor oil on metal bushings.
A03E06A
6,8, Circlip and Pinion Stop Collar

Brush Holder
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.
After placing stop collar on armature shaft, fit circlip into armature shaft, then make sure that it is
properly secured.
Slide stop collar over circlip and secure in place by
punching it at 2 or 3 places.
Brush Length
Measure brush length. If less than 8.5 mm (.335
in), replace them.
NOTE : .New brush length is 12 mm (.472
in).
08-04-5

1
4
1
2
F01H0SA
A03E0EA
1.
2.
3.
4.
Armature shaft
Circlip
Pinion stop collar
Punch
1. Locating protrusion is the higher one
1,10, Housing and Yoke Assy

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
1,3,4, Yoke Assy, End Frame and

Through Bolt
Open brushes and slide over commutator.
Align end frame locating notch with yoke locating
protrusion and properly sit brush holder into yoke.
08-04-6

15, Nut
Connect the RED battery cable to the starter and
torque nut to 6 Nm (53 lbfin). Apply dielectric
grease on terminal and nut.
16,17, 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
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.
2
3
4
F01HiJC
Step
Step
Step
Step
1
2
3
4
Torque nut to 6 Nm (53 lbfin)

Apply Loctite 271 on screw
orque screw to 22 Nm (16 lbfft)
Apply dielectric grease
: Always connect RED positive

; WARNING
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.
13,14, Screw
Torque starter screws to 22 Nm (16 lbfft).
08-04-7

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
08-04-8

Sub-Section 05 (INSTRUMENTS AND ACCESSORIES)
INSTRUMENTS AND ACCESSORIES

GENERAL
It is possible to activate the fuel gauge / low oil

warning light, multifunction gauge or VTS gauge
when the engine is not running.
Make sure the safety lanyard is removed, then depress the start / stop button.
The gauge(s) will be activated during 33 seconds
: the time the delay timer of the MPEM will stay
on.
INSPECTION
Bombardier
Fuel Gauge / Low Oil Warning Light

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.
F01G0LA
1.
2.
3.
4.
5.
Fuel level bar graph

Engine overheats
Low oil level
Low fuel level
Low voltage
Accuracy of gauge can be checked with a potentiometer.

Disconnect 6-circuit tab housing of gauge.
Using an appropriate terminal remover, remove
PINK / BLACK and PINK wires from tab housing.
Bombardier
A
B
C
F01G07A
1. Low oil warning light
Multifunction Gauge
3
4
5
6
7
8
A LCD gauge indicates the amount of fuel in the

tank. Warning lights will indicate a defective
charging system, an overheating engine, low fuel
level and low oil level.
F02H0CB
1.
2.
3.
4.
5.
6.
7.
8.
Remove wires
Tab housing
PURPLE
BLACK
PINK
PINK / BLACK
BLUE
BLUE / BLACK
Reconnect tab housing of gauge.

Connect potentiometer test probes to PINK /
BLACK and PINK wires of gauge.
08-05-1

Adjust potentiometer to the resistance values

as per following chart to test accuracy of
gauge.
NOTE : Gauge must be activated to obtain a
reading.
RESISTANCE
()
FUEL LEVEL
LCD GRAPHIC
LOW FUEL
LEVEL RED
LIGHT
0 2.2
0
FULL
OFF
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
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
Adjust potentiometer to the resistance values

as per following chart to test accuracy of gauge.
NOTE : Gauge must be activated to obtain a
reading.
RESISTANCE ()
GAUGE NEEDLE
POSITION
10
-45
95
180
+ 45
+ 45
VTS
- 45
If gauge is not within the specifications, replace it.
Bombardier
F01H0EA
Variable Trim Gauge
If gauge is not within the specifications, replace it.
The trim gauge shows the riding angle of the watercraft.
Fuel Baffle Pick-Up Sensor
VTS
The baffle pick-up has an integrated fuel sensor

(except SP and HX models).
To verify fuel sensor, a resistance test should be
performed with an ohmmeter allowing the float to
move up through a sequence.
1
Bombardier
F01H4RA
1. Bow up
2. Bow down
Accuracy of gauge can be checked with a potentiometer.

Disconnect 2-circuit connector housing of
BROWN / BLACK and BROWN / WHITE wires
of gauge.
Connect potentiometer test probes to BROWN
/ BLACK and BROWN / WHITE wires of gauge.
3
F01F20A
1. Pick-up tube
2. Fuel sensor
3. Baffle pick-up
08-05-2

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.
FUEL LEVEL AND RESISTANCE
(SPI, SPX, XP)
FUEL LEVEL
(mm)
RESISTANCE
()
From 206.1 5 and more
0 2.2
0
From 189.1 @ 206 5
17.8 2.2
From 162.1 @ 189 5
27.8 2.2
From 135.1 @ 162 5
37.8 2.2
From 108.1 @ 135 5
47.8 2.2
From 81.1 @ 108 5
57.8 2.2
From 54.1 @ 81 5
67.8 2.2
From 40.1 @ 54 5
77.8 2.2
From 0 @ 40 5
89.8 2.2
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).
FUEL LEVEL AND RESISTANCE

(GTS, GTI)
FUEL LEVEL
(mm)
RESISTANCE
()
From 257.9 5 and more
0 2.2
0
From 234.4 @ 257.8 5
17.8 2.2
From 200.9 @ 234.3 5
27.8 2.2
From 167.4 @ 200.8 5
37.8 2.2
From 134 @ 167.3 5
47.8 2.2
From 100.5 @ 133.9 5
57.8 2.2
From 67 @ 100.4 5
67.8 2.2
From 40.1 @ 66.9 5
77.8 2.2
From 0 @ 40 5
89.8 2.2
Oil Sensor
The sensor sends the signal to the low-oil level
light in the fuel gauge.
TEST CONDITION
READING ()
Sensor OUT of oil.
(open circuit)
Sensor soaked IN oil.
2 max. (closed circuit)
2
F03H0BA
1. Measure resistance here

2. Sensor reservoir
To reinstall sensor :
Remove rubber seal from sensor.
Install seal in oil tank hole.
Push sensor in seal.
Plug connector.
08-05-3

NOTE : This sensor turns the low-level oil

light to ON if the connector has been forgotten unconnected even when there is enough oil in
tank.
Speed Sensor
The speedometer gives a reading through a
speed sensor. Speed sensor is installed on ride
shoe. 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.
DYNAMIC TEST
To verify speed sensor, a dynamic test can also be
performed using a battery and a voltmeter.
Disconnect speed sensor wires from inside bilge.
With a 12 VDC battery, connect the positive (+) to
sensor PURPLE / YELLOW wire.
Connect the negative (-) to the sensor BLACK
wire.
Connect the voltmeter positive probe to sensor
BLUE / PURPLE wire and the negative probe to
sensor BLACK wire.
Turn the paddle wheel slowly. There should be a
voltage fluctuation.
BLACK
PURPLE /
YELLOW
BLUE /
PURPLE
F01H3VA
1. Pick-up housing
2. Paddle wheel
BAT
TER
Y
VOLTMETER
STATIC TEST
F04H20A
To verify speed sensor, a resistance test can be

performed with an ohmmeter. Disconnect speed
sensor wires from inside bilge.
Refer to the following chart for speed sensor testing. Always respect polarity in chart.
METER (-)
LEAD
METER (+)
LEAD
APPROX.
VALUE
Purple/Yellow
Black
Black
Purple/Yellow
21.8 M
Blue/Purple
Black
3.6 M
Black
Blue/Purple
Purple/Yellow
Blue/Purple
Blue/Purple
Purple/Yellow
3 M
VTS Switch
Always confirm first that the fuse is in good condition.
Disconnect BLACK wire, BLUE / WHITE wire and
GREEN / WHITE wire of VTS switch located in
front of bilge on left side.
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.
08-05-4

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.
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 09-04. 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.
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%.
For a complete resistance test from UP to DOWN
position, refer to the following chart.
NOTE : If the VTS control module passes
this resistance test, it doesnt mean it is in
perfect condition.
RESISTANCE ()
NOZZLE
POSITION
167.3 1 %
UP
153.0 4 %
138.7 1 %
124.4 1 %
110.1 1 %
VTS Control Module
95.8 1 %
It receives its current from the battery. It is protected by its own 7.5 A fuse.
81.5 1 %
67.2 1 %
RESISTANCE TEST
Disconnect BROWN / BLACK wire and BROWN /
WHITE wire of VTS control module located in
front of bilge on left side.
Connect 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 delay timer.
52.9 1 %
38.6 1 %
24.3 1 %
DOWN
08-05-5

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 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 self-diagnostic modes.
When ordering a new MPEM from the regular
parts channel, the DESS circuitry will not be activated. If desired, it can be activated with the
MPEM programmer.
NOTE : If the DESS circuitry of the watercraft MPEM is not activated, engine can be
started with any safety lanyard. Once the DESS
circuitry is activated, it is not possible to deactivate it. A safety lanyard must be programmed to
start the engine.
08-06-1

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)
Everything is correct
with the safety lanyard
(good contact and right
lanyard cap).
Engine can be started normally.
1 long beep
(while installing
safety lanyard on
watercraft switch
or when pressing
start/stop button
in some cases)
Bad connection
between saafety lanyard
cap and switch.
Push and turn the safety lanyard on the

switch until 2 short beeps are heard to
indicate the system is ready to allow
engine starting.
Wrong 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.
4 long beeps
(while installing
safety lanyard on
watercraft switch)
Watercraft MPEM can

not communicate with
the DC-CDI module
(XP model only)
Check fuse on relay located in the

conventional electrical box.
Check connector between MPEM and
DC-CDI modules.
8 short beeps
Defective MPEM
(memory)
Replace MPEM
Continuous beep
Engine overheating.
Refer to TROUBLESHOOTING 03-00.
08-06-2

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 lanyardcap 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
atercraft. 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.
08-06-3
Section 09 PROPULSION SYSTEM

TABLE OF CONTENTS
JET PUMP ................................................................................................................................
ALUMINUM PUMP..............................................................................................................
PLASTIC PUMP....................................................................................................................
GENERAL .............................................................................................................................
JET PUMP INSPECTION ON WATERCRAFT ......................................................................
JET PUMP REMOVAL..........................................................................................................
RIDE SHOE REMOVAL ........................................................................................................
JET PUMP SUPPORT REMOVAL........................................................................................
JET PUMP DISASSEMBLY..................................................................................................
CLEANING ...........................................................................................................................
JET PUMP ASSEMBLY........................................................................................................
PUMP PRESSURIZATION ...................................................................................................
JET PUMP SUPPORT INSTALLATION ...............................................................................
RIDE SHOE INSTALLATION ................................................................................................
JET PUMP INSTALLATION .................................................................................................
0-01-1
0-01-1
0-01-2
0-01-3
09-01-3
0-01-4
0-01-7
0-01-7
0-01-8
0-01-12
0-01-12
0-01-15
0-01-20
0-01-21
0-01-21
0-01-22
DRIVE SYSTEM .......................................................................................................................

ALL MODELS EXCEPT HX ..................................................................................................
GENERAL .............................................................................................................................
REMOVAL.............................................................................................................................
DISASSEMBLY.....................................................................................................................
ASSEMBLY...........................................................................................................................
09-02-1
09-02-1
09-02-2
09-02-2
09-02-6
09-02-6
09-02-7
REVERSE SYSTEM..................................................................................................................
GTS AND GTI MODELS ......................................................................................................
GENERAL .............................................................................................................................
DISASSEMBLY.....................................................................................................................
ASSEMBLY...........................................................................................................................
ADJUSTMENTS ..................................................................................................................
09-03-1
09-03-1
09-03-2
09-03-2
09-03-3
09-03-5
09-00-1

VARIABLE TRIM SYSTEM .......................................................................................................

SPI AND HX MODELS..........................................................................................................
REMOVAL .............................................................................................................................
DISASSEMBLY .....................................................................................................................
ASSEMBLY AND INSTALLATION........................................................................................
SPX AND XP MODELS ........................................................................................................
GENERAL..............................................................................................................................
REMOVAL .............................................................................................................................
DISASSEMBLY .....................................................................................................................
INSPECTION .........................................................................................................................
ASSEMBLY ...........................................................................................................................
INSTALLATION .....................................................................................................................
ADJUSTMENT......................................................................................................................
09-00-2
09-04-1
09-04-1
09-04-2
09-04-2
09-04-2
09-04-3
09-04-4
09-04-4
09-04-4
09-04-4
09-04-5
09-04-5
09-04-5

Sub-Section 01 (JET PUMP)
JET PUMP
ALUMINUM PUMP
Loctite 598
Ultra Black
12
Loctite 242
28
15
8 Nm 27
(71 lbfin)
14
70 Nm
(52 lbfft)
19
20
Loctite 242
10 Nm
(88 lbfin) 13
4.5 Nm
(40 lbfin) 16
11
Loctite
242
Loctite
PST
Loctite
518
21
4 Nm
(35 lbfin)
7
22
22
15 Nm Loctite
(11 lbfft) 271
24
25
(If required)
Loctite
271
23
Loctite
518
3 Nm
(27 lbfin)
35 Nm 6
(26 lbfft)
Loctite
PST
SP / GTS
Loctite
242
Loctite
518
1 20 Nm
(15 lbfft)
Loctite
242
17
4
3
18
4 Nm
(35 lbfin)
Loctite
242
SP / GTS
10
25 Nm
(18 lbfft)
SP / GTS
3
2
4
Loctite
242
1 20 Nm
(15 lbfft)
F01J5LS
PARTS
09-01-1

PLASTIC PUMP
Loctite 598
Ultra Black
Loctite
242
28
15
12
27
8 Nm
(71 lbfin)
14
19 70 Nm
(52 lbfft)
10 Nm
(88 lbfin)
13
20
Loctite
518
Loctite
PST
16
22
21
Loctite
242
16
Loctite
PST
11
Loctite
242
4 Nm
(35 lbfin)
15 Nm
(11 lbfft)
35 Nm
6 (26 lbfft)
Loctite
271
(If
required)
22
24
25
Loctite
271
23
GTI
Loctite
242
3
Loctite
518
Loctite
518
26
1 20 Nm
(15 lbfft)
3 Nm
(27 lbfin)
Loctite
PST
4
2
17
Loctite
242
GTI
5
Loctite
242
10
21 Nm
(16 lbfft)
3
2
Loctite
242
4
1 20 Nm
(15 lbfft)
F01J5MS
09-01-2
PARTS
18
4 Nm
(35 lbfin)

GENERAL
The impeller housing, venturi and nozzle are either made of aluminum or plastic, depending on
which model of watercraft.
Plastic is a light weight material and it is not affected by corrosion.
All watercraft powered by a 717 or 787 engines
have a stator made of bronze which offers greater
strength than aluminum.
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.
Working on the water intake grate, jet pump, ride
shoe, etc., can be done by simply blocking the
rear of watercraft above work stand.
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 / XP series and HX
295 100 013
GTS / GTI models
F01J0DA
1. Boot with ring
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.
F01J42A
1. Lift kit
2. Work stand
Impeller Condition and Impeller / Wear

Ring Clearance
Impeller Condition
Condition of impeller, boot and ring can be quickly
checked from underneath of the watercraft. Remove grate and look through water inlet opening.
09-01-3

Oil Check
Remove housing cover plug.
F01J0EA
F01J5IA
MEASURING FROM WATER INLET SIDE

1. Feeler gauge
F01J0FA
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.
MEASURING FROM VENTURI SIDE

1. Feeler gauge
Oil Replacement
Oil Inspection
Venturi Removal
Detach ball joint of steering cable from nozzle.
Detach ball joint of VTS from trim ring (SPX / XP
models).
Remove nut of manual trim from trim ring (SPI /
HX models)
Detach ball joint of reverse cable and springs from
reverse gate (GTS / GTI models).
Remove 4 retaining screws from venturi.
Pull venturi and nozzle assembly from impeller
housing.
Remove venturi / nozzle assembly as described in

Oil Inspection.
Remove 3 screws retaining cover.
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.
09-01-4

Pour approximately 90 mL (3 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.
JET PUMP REMOVAL

HX Model
Disconnect steering cable from jet pump nozzle.
Loosen 4 hexagonal nuts and remove flat washers and lock washers from jet pump housing.
Remove jet pump.
Remove air vent tube support from body opening
(SP / XP series).
F01I0AA
XP MODEL
1. PTO flywheel guard
2. Wing nuts
Using pliers (P / N 295 000 054), unfasten small

clamp on drive shaft boot.
NOTE : If necessary, refer to PROPULSION
SYSTEM 09-02.
1
F02J0PC
1. Unfasten small clamp

F01L1DA

1. PTO flywheel guard
2. Wing nuts
Hold floating ring and compress protective hose ;

then, pull out O-ring from drive shaft groove.
09-01-5

SP, GTS and GTI Models
1,2,4,5, Screw, Sleeve, Locking Disk

and Nozzle
Remove 2 retaining screws, 2 sleeves, 4 locking
disks and withdraw nozzle.
3
F01I0CA
2
1
1. Floating seal
2. O-ring
Disconnect engine water inlet hose and both bailer pick-up tubes from impeller housing.
1
F01J3BE
TYPICAL
1. Screw
2. Locking disks
3. Sleeve
SPI, SPX and XP Models
5, Nozzle
Withdraw nozzle / trim ring assembly by removing

2 retaining screws of trim ring.
F01J0IA
TYPICAL
1. Bailer pick-up tubes
2. Engine water inlet hose
Remove ball joint fasteners to release steering cable from nozzle.

Remove ball joint fasteners to release VTS (SPX /
XP models).
Remove nut of manual trim from trim ring (SPI
and HX models).
Remove ball joint fasteners to release reverse cable from reverse gate (GTS / GTI models).
F01J5FA
1. Remove screws
09-01-6

6,7, Nut and Impeller Housing
Remove nuts retaining impeller housing to hull.

Using screws previously removed from nozzle, install impeller housing remover tool (P / N 295 000
113) on venturi.
NOTE : It may be possible to remove jet
pump without using puller.
1
F01J0OA
TYPICAL
1. Ride shoe screws
2. Intake grate screws
Using a low height hydraulic bottle jack and two

steel plates, pry out ride shoe.
F01J5JA
Rotate handle clockwise to remove jet pump.

Withdraw pump unit and drive shaft together.
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.
NOTE : After jet pump removal, if drive
shaft remains in PTO flywheel, simply pull it
out. If drive shaft will not come out, it is probably
jammed into PTO flywheel. Refer to PROPULSION SYSTEM 09-02.
F05J03A
1. Hydraulic bottle jack

2. Steel plate
RIDE SHOE REMOVAL

11,12,13,27, Ride Shoe, Intake Grate
and Screws
NOTE : Intake grate and impeller housing
must be removed prior to ride shoe removal.
An impact screwdriver should be used to loosen
tight screws.
Remove intake grate.
Remove ride shoe screw.
09-01-7

JET PUMP SUPPORT REMOVAL

HX Model Only
Remove ball joint, boot, nut, half rings and O-rings
from steering cable.
F05D04A
F05K02A
Remove nuts, lock washers and flat washers retaining jet pump support.
Using a heat gun, heat jet pump support until it is
possible to pull it off.
1. Unscrew nut
JET PUMP DISASSEMBLY
Disconnect water supply and water return hoses,

drain hose and bailer hoses.
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.
9,10, Venturi and Screw

Remove 4 retaining screws and withdraw venturi.
1
F05J0DA
Disconnect exhaust hose.
F01J4ZB
1. Remove screws
09-01-8

14,15, Boot and Ring

Pull out ring from boot
1
1
F01J0SA
1. Hold raised with drive shaft while striking

F01J09A
16, Fitting
1. Pull out ring
Insert a screwdriver blade between impeller and

boot flange. Carefully pry boot all around to release from impeller.
Fittings can be removed with deep socket or vise

grip. Do not contact hose mounting area.
Fitting 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 hexagone 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.
A
1
F01J0RA
1. Pry boot out
Withdraw drive shaft.

NOTE : A jammed drive shaft can be removed by holding pump unit by drive shaft,
slightly raised unit above a soft surface, then
strike all around impeller housing with a fiber hammer. Corroded parts can be loosened by applying
BOMBARDIER LUBE lubricant (P / N 293 600
016).
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)
09-01-9

17,18, Housing Cover and Screw
20, Wear Ring
With pump assembly in horizontal position, remove 3 retaining screws of housing cover.
Place container under cover to catch oil.
Using a fiber hammer, gently tap cover to release
it from impeller housing.
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.
CAUTION : When cutting ring, be careful
not to damage impeller housing.
19, 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. Heat impeller center with a propane torch to approximately 150C
(300F) to break the Loctite bond.
Impeller is loosened using impeller remover tool
(P / N 295 000 001).
Install shaft holder in a vice.
Insert special tool in impeller splines.
Rotate impeller remover tool counterclockwise
and unscrew completely impeller.
1
F01J0VA
F01J2HA
1. Impeller remover / installer tool

2. Impeller shaft holder tool
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 and remove tool from impeller.
Remove 2 screws holding impeller housing to
shaft holder.
Lift impeller housing away from impeller shaft.
Slide thrust washer and thrust bearing off from
shaft.
F01J0WA
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.
09-01-10

21, Seal
To remove seal, proceed as follows :
CAUTION : It is not recommended to
push seal out with a punch. Housing and /
or bearing(s) could be damaged.
Seal should be removed using the following suggested tool.
Seal puller, Snap-on no. S6129.
Close puller claws so that they can be inserted between seal and bearing. Holding claws, turn puller
shaft clockwise so that claws open and tighten
against seal.
Slide puller sleeve outwards and gently tap puller
end. Work with small strikes otherwise claws will
slip out. As soon as seal begins to slide out, retighten claws to maintain contact with seal. Continue pulling until seal is out.
F01J0XA
F01J10A
1. Pulling seal out of housing
NOTE : If bearings and seal need to be replaced the special driver described further
on in bearing removal can be used. Simply insert
driver from the rear and press parts towards the
front.
F01J0YA
1. Pulling seal out of housing
Or, use a Snap-on hammer puller including :

Handle
CJ93-1
Hammer
CJ125-6
Claws
CJ93-4
2
1
F01J12A
F01J0ZA
1. Same tool for bearing removal

2. Removing seal and bearings out from rear
09-01-11

22, Needle Bearing
CLEANING
NOTE : It is always recommended to renew

both bearings, even if only one bearing
needs to be replaced.
Bearings can be easily removed with the following suggested driver.
Use a 30 mm dia. x 345 mm (1-1/8 dia. x 13-1/2 in)
long steel shaft. Machine shaft as per the following drawing.
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 (bailer pick-up,
cooling system) and oil passages. Blow low pressure compressed air through them and make sure
they are clear.
C
D
F01J11A
A.
B.
C.
D.
22 mm (.865 in) dia.

28 mm (1.115 in) dia.
90 mm (3-1/2 in)
345 mm (13-1/2 in)
F01J13A
Insert driver into one bearing then press tool using

a arbor press until bearings are out. However,
care should be taken not to damage bearing journals.
1. Water passages
2. Oil passages
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
19, Impeller
F01J12B
1. Press bearings out
Visually inspect impeller splines. Check for wear

or deformation. Renew parts if damaged.
NOTE : Check also flywheel and drive shaft
condition. Refer to PROPULSION SYSTEM
09-02.
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.
09-01-12

F01J16A
F02J0VA
1. Replaced if blunted round or damaged
1. Stamped part number
Check impeller for cavitation damage, deep

scratches or any other damage.
WATERCRAFT
MODEL
IMPELLER
MATERIAL
P/N
PITCH
SP
271 000 016 Aluminium
18.8
1
SPX
271 000 497
Stainless
steel
Progressive
pitch
11-24
SPI
271 000 182
Stainless
steel
Progressive
pitch
11-26
XP
271 000 331
Stainless
steel
Progressive
pitch
17-25
HX
271 000 497
Stainless
steel
Progressive
pitch
11-24
GTS
271 000 416
Stainless
steel
Progressive
pitch
10-25
GTI
271 000 470
Stainless
steel
Progressive
pitch
11-24
F02J0UA
1. Check for cavitation, deep scratches or other damage
Identification
To identify the impellers refer to the following illustration and chart.
09-01-13

20, 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.
To check both bearings, proceed the same way

with other shaft end. Position gauge tip on diameter, close to flats on shaft.
1
22,23, 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.
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).
F01J19A
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).
1
F01J1AA
1. Inspect for wear at the bearing pilot

2. Radial bearing raceway
F01J18A
MEASURING IMPELLER SHAFT RADIAL PLAY

1. Dial gauge
2. Measure close to threads at shaft end
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.
09-01-14

24,25, 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
F01J2SA
1. Tip on shaft end
Excessive play comes from worn end stop inside

housing cover and wear of impeller shaft nose.
Visually inspect end stop inside cover. If worn, a
small peak in center will be apparent.
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.
1
17,23, Housing Cover and Impeller

Shaft
End Play
End play of impeller shaft is checked with shaft in
housing, without impeller and with housing 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.
F01J5KA
TYPICAL
1. End stop
If impeller shaft end play is excessive, housing

cover should be replaced. Be sure to check end
play after installing a new housing cover.
Inspect impeller shaft nose for wear.
09-01-15

F01J53A
1. Impeller shaft nose

F01J5DA
21, Seal
Carefully inspect seal lips. Make sure that lips are
not worn, distorted, cracked or show signs of any
other damage. Renew as necessary.
JET PUMP ASSEMBLY

20, Wear Ring
The wear ring features a lip on one edge ; position
lip outwards of housing.
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
approx. 180 x 180 mm x 6 mm thick (7 x 7 in x 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.
1. Seal lip
2. Press wear ring
If a press is not readily available, a piece of wood

such as a 2 x 4 x 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.
2
1
F01J5EA
1. Piece of wood
2. Seal lip facing upward
3. Wear ring
09-01-16

21,22, Seal and Needle Bearing

Bearings and seal will be properly installed in
housing using bearing / seal installer tool (P / N
295 000 107).
1
F01J4KA
BEARING / SEAL INSTALLER TOOL

1. Seal side
2. Bearing side
F01J1IA
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.
1. Press on tool until it stops
: This tool have been designed

- CAUTION
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.
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.
A
1
F01J1HA
1. Stamped end this side
B
3
4
: Never hammer the bearing

- CAUTION
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).
09-01-17

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.
F01J1MA
1. Loctite 518 all around and behind

2. Raised edge of seal lip this side
7,19,23,24,25, Impeller Housing,

Impeller, Impeller Shaft, Thrust Washer
and Thrust Bearing
1
F01J1KA
1. Raised edge of seal this side
: Prevent sealant from contact- CAUTION

ing any needles of bearing.
Push on tool end with a press until tool flange contacts housing.
Insert impeller shaft flats in a vise so that shaft is

vertical.
Apply Sea-Doo jet pump synthetic oil (P / N 293
600 011) on both sides of thrust bearing then insert onto shaft followed by thrust washer. Make
sure bearing is leaning against shaft flange and
washer is properly centered. Oil will prevent parts
from sliding at installation and thus possibly
wedging thrust bearing into shaft groove.
CAUTION : It is critical to keep thrust bearing and washer properly centered on
shaft during assembly of pump.
F01J1LA
1. Press on tool until it stops
Apply synthetic grease (P / N 293 550 010) between seal lips.

F01J1NA
1. Apply oil on faces of parts to prevent them to slide and wedge

into shaft groove
09-01-18

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

housing over shaft.
F01J1Q A
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.
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.
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)).
Torque impeller to 70 Nm (52 lbfft) then remove
tools.
CAUTION : Never use any impact wrench
to tighten impeller.
F01J1PA
1. Carefully insert housing onto shaft

2. Impeller shaft guide tool
Remove special tool.

Apply Loctite primer N (P / N 293 600 012) on impeller shaft threads. 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.
09-01-19

: This is a synthetic oil. Do not

- CAUTION
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.
1
F01J2HA
1. Impeller remover / installer tool

2. Impeller shaft holder tool
17,26, Housing Cover and O-ring

Install O-ring to cover. Apply Loctite 518 on Oring. Install cover to impeller housing making sure
to properly position filler plug on top side.
F01J1SA
1. Pour oil slowly until it is level with bottom of filler hole
At this stage, a pressure test should be performed

to detect any leakage of the jet pump. Refer to
PUMP PRESSURIZATION in this sub-section.
8,9,10, O-ring, Venturi and Screw

If needed, install new O-rings around bailer passages.
Apply Loctite 518 (Gasket Eliminator) on mating
surface.
Position venturi with bailer passages on top.
F01J5IA
1. Filler plug toward top side of pump housing
Apply Loctite 242 (blue) on screw threads and

evenly tighten cover screws. Torque to 4 Nm (35
lbfin).
Oil Fill
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 90 mL (3 oz).
1
F01J1TA
1. Loctite 518 on mating surface

2. Bailer passages aligned
09-01-20

Aluminum Impeller Housing

Install screws and washers then torque to 25
Nm (18 lbfft) in a criss-cross sequence.
14,15,19, Boot, Ring and Impeller

Apply synthetic grease (P / N 293 550 010) on impeller splines.
Insert a new boot and ring to impeller.
F01J4ZB
F01J1UA
1. Torque screws to 25 Nm (18 lbfft)
1. Insert boot and ring
Plastic Impeller Housing

Install screws and washers then torque to 21
Nm (16 lbfft).
1
F02J0TA
PUMP PRESSURIZATION
Whenever doing any type of repair on jet pump, a
pressure test should be done to check for leakage.
NOTE : After complete rebuilding of the jet
pump, oil MUST be added to the housing
BEFORE performing the pressure test in order to
seat the new seal, otherwise it will leak.
Remove drain plug from housing cover.
Apply Loctite PST 592 on threads of fitting tool
(P / N 295 000 086) then secure on cover.
Connect pump gauge tester (P / N 295 000 083)
to fitting.
Pressurize pump to a maximum of 70 kPa (10
PSI).
16, Fitting
Apply Loctite PST 592 on plastic fitting threads.
Then thread fitting into pump housing until
threads are bottomed.
09-01-21

F05J05A
Installation of support is essentially the reverse of

removal procedure.
F01J2IA
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.
NOTE : If there is a pressure drop spray
soapy water around housing 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.
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.
RIDE SHOE INSTALLATION

Apply Loctite 598 Ultra Black on ride shoe as
shown in the following illustrations.
JET PUMP SUPPORT

INSTALLATION
F01J1VA
HX Model Only
Apply Loctite 598 Ultra Black on support as
shown in the following illustration.
ALL MODELS EXCEPT HX

1. Apply Loctite 598 Ultra Black as indicated by shaded area
09-01-22

Miscellaneous
Generously apply synthetic grease on drive shaft
splines.
Make sure rubber damper is on drive shaft ends.
Apply Loctite 598 Ultra Black around bailer and
water inlet supply fittings.
1
F05J06A
HX MODEL
1. Apply Loctite 598 Ultra Black as indicated by shaded area
Carefully install ride shoe on hull. Apply Loctite

242 (blue) on screw threads, install and tighten in
a criss-cross sequence. Torque to 10 Nm (88
lbfin).
From inside of bilge, apply 732 sealant (P / N 293
800 006 or P / N 293 800 003) on end of screws
to completely seal hull.
Apply Loctite 242 (blue) on intake grate screw
threads, install and tighten. Torque screws to 8
Nm (71 lbfin).
JET PUMP INSTALLATION
F01J21A
1. Apply Loctite 598 Ultra Black where indicated
Install drive shaft in impeller.
28, Neoprene Seal

If neoprene seal is damaged, replace it with a new
one.
F02J0LA
Position the O-ring of the drive shaft in the floating

ring flange.
F01J50A
TYPICAL
1. Neoprene seal
09-01-23

Apply Loctite 242 (blue) on stud threads of jet

pump housing.
Install flat washers, lock washers and nuts. Tighten nuts of impeller housing in a criss-cross sequence and torque to 35 Nm (26 lbfft).
Push the floating ring to compress the protective
hose. Insert the O-ring in the drive shaft groove.
F01I0DA
1. O-ring
2. Floating ring
Position the floating ring between the carbon ring

and the PTO flywheel boot.
F02I04A
Step 1 Push floating ring

Step 2 Insert O-ring in the groove
Slide the floating ring onto the O-ring.

Secure small clamp of PTO flywheel boot. Refer
to PROPULSION SYSTEM 09-02.
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.
F02I03A
1. Floating ring
Install jet pump with drive shaft.

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.
CAUTION : Take care not to break the Oring 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.
F01I0BB
Secure water inlet hose and both bailer tubes to

impeller housing using tie raps.
09-01-24

1
1
F01J0IA
1. Bailer tubes
2. Water inlet hose
F01J3BA
Secure flywheel guard to engine studs using 1 nut

and 1 washer on each side of guard.
Reinstall air vent tube support onto body (SP / XP
series).
TYPICAL
1. Locking disks
2. Torque to 20 Nm (15 lbfft)
HX Model Only
Make sure rear drive shaft is properly installed.
Install jet pump. If necessary, wiggle jet pump to
engage drive shaft splines in impeller.
Install flat washers, lock washers and nuts. Tighten nuts of impeller housing in a criss-cross sequence and torque to 31 Nm (23 lbfft).
be torqued as specified.
: Whenever removing screw

; WARNING
always renew locking disks. Screw must
Steering and Reverse Cables

Secure ball joints of steering cable and reverse cable (GTS and GTI models).
SP, GTS and GTI Models
1,2,3,4,5, Screw, Sleeve, Bushing,

Locking Disk and Nozzle
Insert bushings in nozzle, positioning their flanges
from inside of nozzle.
Insert sleeves in bushings.
Install nozzle on venturi ; position its steering arm
on RH side. Apply Loctite 242 (blue) on screw
threads (or use new screws with pre-applied Loctite). Install screws and locking disks then torque
to 20 Nm (15 lbfft).
F01J4YB
TYPICAL - ALUMINUM NOZZLE

1. Ball joint on top of arm
2. Torque nut to 7 Nm (62 lbfin)
09-01-25

Steering Cable
Secure ball joint of steering cable.
1
F02J02C
TYPICAL - PLASTIC NOZZLE

1. Torque nut of steering cable ball joint to 7 Nm (62 lbfin)
2. Torque nut of reverse cable ball joint to 7 Nm (62 lbfin)
(if applicable)
F01J58A
TYPICAL
1. Ball joint on top of arm
HX, SPI, SPX and XP Models
5, Nozzle
Trim Systems
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 housing.
SPX and XP Models

Secure ball joint of VTS link rod
1
F01J08C
F01J5FA
09-01-26

SPI and HX Models

Secure support of manual trim.
1
F05J08B
All Models
NOTE : Ball joint must be parallel. If not,
loosen jam nut and adjust ball joint. Torque
jam nut to 2.5 Nm (23 lbfin).
Check steering alignment. Refer to STEERING
SYSTEM 10-04.
Slightly lubricate wear ring with BOMBARDIER
LUBE lubricant before starting to minimize friction
during initial start.
09-01-27
Section 09 PROLPUSION SYSTEM

Sub-Section 02 (DRIVE SYSTEM)
DRIVE SYSTEM
Loctite
271
11
2
6
5
18
10
2 Nm
(18 lbfin)
9
2 Nm
(18 lbfin)
8
15
Synthetic
grease
3
Loctite
495
Synthetic
grease
Loctite 495
15
F01I0ES
PARTS
09-02-1

HX Model
11
17
16
22 Nm
(16 lbfft)
Loctite 242
17
16
22 Nm
(16 lbfft)
Loctite
242
Loctite 242
22 Nm
(16 lbfft)
Loctite
515 Synthetic
grease
13
18
2 Nm
(18 lbfin)
Loctite
271
14
13
2 Nm
(18 lbfin)
Loctite
242
Synthetic
grease
10
12
10 Nm
(89 lbfin)
9
Loctite
242
4
Loctite 598
Ultra Black
30 Nm
(22 lbfft)
F05I02S
09-02-2
PARTS
Synthetic
grease
15
Loctite
515

GENERAL
Jet pump must be removed to replace any components of the drive system. Refer to PROPULSION SYSTEM 09-01 for jet pump removal
procedure.
REMOVAL
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
09-02-3

3, Drive Shaft
1
If the drive shaft is jammed into PTO flywheel,

make the following tool and use it in conjunction
with impeller housing remover (P / N 295 000 113)
to withdraw drive shaft.
Raw Material :
1 aluminum alloy square of 51 mm (2 in) x 305
mm (12 in).
2 aluminum rods of 28.5 mm (1-1/8 in) dia. x 30
mm (1-3/16 in).
F01I06A
TYPICAL
1. Impeller housing remover
2. Drive shaft puller
3. Screws
I
C
: Be careful not to damage hull

- CAUTION
rear section or engine rubber mounts.
B
D
HX Model Only
4, Rear Drive Shaft

H
4
F01I05A
Remove rear access panel from body.

Remove muffler. Refer to ENGINE 04-05 for proper procedure.
Remove coil over shock. Refer to SUSPENSION
11-01 for proper procedure.
D
F F
5
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)
F. 22 mm (7/8 in)
B. 105 mm (4-1/8 in)
G. 17 mm (43/64 in)
C. 16 mm (5/8 in)
H. 19 mm (3/4 in)
D. 51 mm (2 in)
I. 35 mm (1-3/8 in)
E. 36 mm (1-25/64 in)
J. 20.3 .18 (.800 in .007)
5,6, Floating Ring and O-ring

Hold floating ring and compress protective hose ;
then, pull out O-ring from driveshaft groove.
Mount on drive shaft puller the impeller housing

remover ; then, install assembly on drive shaft using screws.
F05I03A
1. Floating ring
2. O-ring
Pull out rear drive shaft.
09-02-4

7, Front Drive Shaft
11, PTO Flywheel
Remove bolt, lock nut and sleeve from support.
Remove magneto housing cover. Refer to ELECTRICAL SYSTEM 08-01.

To remove PTO flywheel, magneto 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
2
F05I04A
1. Bolt
2. Lock nut
3. Sleeve
4
F01D47A
Remove front drive shaft.
1. Screw
2. Extension handle
12, Seal Carrier

To remove the seal carrier from support, loosen
the 6 nuts.
1
3. Puller plate
4. 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 so
that sleeves are against flywheel.
Install extension handle on end of puller plate.
F05I05A
1. Nut (6)
F01D48A
All Models
8,9,10, Clamp, Protective Hose and

Carbon Ring
Loosen gear clamp holding protective hose, then
carefully pull hose and carbon ring from hull insert.
TYPICAL
1. Sleeves on opposite side
XP Model Only
Remove starter. Refer to ELECTRICAL SYSTEM
08-04.
09-02-5

Lock ring gear using special tool (P / N 295 000

134).
F01D49A
TYPICAL
1. Ring gear blocking tool

PTO flywheel is loosen using PTO flywheel remover (P / N 295 000 001).
As an alternate method to remove PTO flywheel

when splines are worn out and PTO flywheel remover cannot be used.
Use a pipe wrench and install it on PTO flywheel
as illustrated.
F01J0TA
Insert special tool in PTO flywheel splines.

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.
09-02-6

HX Model Only
PTO flywheel is loosen using flywheel remover.
C
D
F01J11A
A.
B.
C.
D.
F05I0CA
22 mm (.865 in) dia.

28 mm (1.115 in) dia.
90 mm (3-1/2 in)
345 mm (13-1/2 in)
Properly support seal carrier when removing seals

and bearing.
1. PTO flywheel remover
PARTS INSPECTION
3, Drive Shaft
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.
F05I0DA
DISASSEMBLY
HX Model Only
1
2
13,14, Seal and Needle Bearing

To remove seals and bearing, use a 30 mm (1-1/8
in) diameter by 345 mm (13-1/2 in) long steel
shaft. Machine shaft as per the following drawing.
NOTE : The same tool is used for bearing
and seal removal of jet pump.
F01I0FA
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.
09-02-7

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).
6, O-ring
Check also condition of drive shaft O-ring. Replace as necessary.
All Model Except HX
11, PTO Flywheel

Inspect spline condition of PTO flywheel.
NOTE : There is a possibility that when
drive shaft was removed, the damper has
remained in PTO flywheel. Remove it if such is
the case.
HX Model Only
1
4,14, Drive Shaft and Needle Bearing

Inspect seal carrier needle bearing and its contact
surface on drive shaft. Check parts for scoring, pitting, chipping or other evidence of wear.
F01J15A
ASSEMBLY
MEASURING DRIVE SHAFT DEFLECTION

1. Dial gauge
2. V-blocks
HX Model Only
15, Damper
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.
Install bearing with the bearing / seal installer tool
(P / N 295 000 107).
14, Needle Bearing
Visually inspect shape of dampers for deformation or other damage.
5,18, Floating Ring and O-ring

Inspect condition of O-rings and floating ring contact surface.
1
2
F01I0GA
F01J51A
1. O-rings
2. Floating ring contact surface
1. Press bearing in its housing
09-02-8

NOTE : Bearing can also be installed with

the same driver used at disassembly. Center bearing in longitudinal axis of housing.
Push seals until tool comes in contact with housing.
F01J2TA
F01J1YA
1. Push bearing centered in its housing
TYPICAL
13, Seal
Install double-lip seal with protector toward impeller side.
On both seals, raised edge of lip must be located
outwards of seal carrier.
NOTE : Always install seal with its protector

facing the impeller.
Pack seals and bearing with synthetic grease (P /
N 293 550 010).
3,4,15, Drive Shaft and Damper

2
Install dampers on drive shaft.

NOTE : Make sure dampers were not left in
PTO wheel or impeller.
Refer to PROPULSION SYSTEM 09-01 for drive
shaft installation in impeller.
HX Model Only
12, Seal Carrier
5
3
F01J2FA
1.
2.
3.
4.
5.
Properly index flanges together.

Install seal carrier and hand tighten nuts only.
NOTE : Apply Loctite 242 (blue) on studs.
Double-lip seal toward engine

Double-lip seal with protector toward impeller
Raised edge of lip outwards
Seal carrier
Raised edge of lip outwards
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).
09-02-9

Install alignment tool at rear of watercraft.
Torque seal carrier nuts to 10 Nm (89 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.
F01L2RC
1. Housing (P / N 295 000 090)

2. Alignment shaft (P / N 295 000 093)
F05I0EA
4,7,16,17, Drive Shaft, Damper and

Bushing
Make sure to install damper and bushing on both
drive shafts.
F05I07A
Carefully slide shaft through seal carrier.
F05I0FA
1. Damper
2. Bushing
1, Large Clamp
F05I08A
1. Alignment tool
2. Seal carrier
Secure large clamp 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.
09-02-10

1
1
2
F01J23A
PRE-CLAMPING POSITION
1. Holding hook
2. Large window
F02J0IA
1. Press to engage hooks in windows
Insert pointed tips of pliers first in closing

hooks.
NOTE : At installation, clamp tail should be

in opposite direction of engine rotation.
1
2
F01J23B
1. Engine rotation (counterclockwise)

2. Tail in opposite direction
F01J2BA
2, Small Clamp
TYPICAL
1. Closing hooks
To secure small clamp, place notch side of plier on

clamp embossment and squeeze plier.
Squeeze pliers. When both large and small windows are directly over the 2 locking hooks,
press those windows down to engage hooks in
windows.
09-02-11

F02J0PB
1. Squeeze plier
09-02-12

Sub-Section 03 (REVERSE SYSTEM)
REVERSE SYSTEM
GTS and GTI Models
5
1
Synthetic
grease
2.5 Nm
(22 lbfin)
8 Nm
(71 lbfin)
7 Nm
(62 lbfin)
10 Nm
(88 lbfin)
3 Nm
(27 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)
Loctite
242
F02J0NS
PARTS
09-03-1

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 basket 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 selector lever stem and locking lever

from sliding block, then slide off locking lever
from stem.
F02L1MA
TYPICAL
1. Press on vent tube
1,2,3, Locking Lever, Spring and

Selector Lever
To remove selector lever, unhook spring from
sliding block and pull spring from selector 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.
09-03-2

7, Reverse Gate
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
F02J08A
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.
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).
09-03-3

: Always hook reverse gate

- CAUTION
springs in order to ease reverse gate oper-
Install sliding block to lever and torque nut to 8

Nm (71 lbfin).
ation.
1,5, Locking Lever and Sliding Block

Insert locking lever end in support hole then align
lever and sliding block holes.
F02J02B
1. Screws, washers and sleeves
6, Reverse Support
F02J0DA
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
1,3,5, Locking Lever, Selector Lever and

Sliding Block
NOTE : Always install selector lever with its
open end facing left side of watercraft, then
push selector lever stem through locking lever
and sliding block holes.
F02J0CA
TYPICAL
1. Bushing
F02J0EA
Install reverse cable to triangular lever with bushing, plastic washer(s) and flat washers.
Torque cable screw to 7 Nm (62 lbfin).
Torque triangular lever screw to 8 Nm (71
lbfin).
TYPICAL
1. Install lever as shown
09-03-4

2, Spring
Insert spring in lever stem hole and then install
curved end in sliding block groove.
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.
A
F02J0HA
F02J0KA
A. 129 3 mm (5-5/64 7/64 in)
TYPICAL
1. Sliding block groove
Pull selector lever to REVERSE position.
Selector Lever System Lubrication
Lubricate sliding block support sliding area and triangular lever with synthetic grease. Also, lubricate sliding washer and selector lever stem.
2
1
F02J0GA
TYPICAL
1. Lever to REVERSE position
F02D03A
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.
TYPICAL
1. Sliding washer
2. Sliding block
3. Support plate
ADJUSTMENTS
Reverse Gate
Position handlebar in a straight ahead position,
nozzle should be parallel to rear of watercraft.
09-03-5

Tighten adjustment nuts and recheck gate position.

Reinstall vent tube.
WARNING : Vent tube must be in place to
provide proper bilge ventilation.
1
F02J0FA
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
Reinstall storage basket.
2
F02J06B
TYPICAL
1. Support
2. Adjustment nuts
09-03-6

Sub-Section 04 (VARIABLE TRIM SYSTEM)
VARIABLE TRIM SYSTEM
SPI and HX Models
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
4
13 Nm
(10 lbfft)
Loctite 242
13 Nm
(10 lbfft)
F05J07S
PARTS
09-04-1

REMOVAL
1,2,3, Screw, Bolt and Lock Nut
Loosen venturi screw, bolt and nut retaining support from trim ring.
3
F05J08A
1. Screw
2. Bolt
3. Lock nut
Remove manual trim.
4,5, Trim Ring and Screws

To remove trim ring / nozzle assembly from venturi, loosen side screws of trim ring.
DISASSEMBLY
6,7,8, Nut, Rubber Washer and Half
Bushings
Loosen nut from support; then, remove rubber
washer and half bushings.
9,10, Screw and Threaded Pivot

Unscrew adjustment screw to remove threaded
pivot.
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.
09-04-2

SPX and XP Models

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
09-04-3

GENERAL
8, Motor
To test VTS control module, motor or switch, refer

to ELECTRICAL SYSTEM 08-05.
Disconnect wires of motor.

Remove retaining nuts.
REMOVAL
1,2,3, Ball Joint, Boot and Gear Clamp

Disconnect ball joint of link rod.
Loosen gear clamps of boot.
RRemove boot.
4,5, Nut and Seal

To loosen nut, 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

Simply pull on worm and sliding shaft in order to
remove them.
6, VTS Assembly
INSPECTION
From bilge, pull out VTS assembly.
2, Boot
DISASSEMBLY
Make sure boot is in good condition. If it is

cracked or teared, replace boot.
7, Cover
Remove VTS cover by pressing on tabs.
1
F01J1WA
1. Press tabs to remove cover
09-04-4

9, Worm
Inspect threads and splines of worm for wear. If
worm replacement is necessary, renew also sliding shaft.
F01J2GA
F01J25A
Tighten nuts of motor to 7 Nm (62 Ibfin).

Connect wires of motor.
CAUTION : Make sure wire color codes
match.
Install cover.
NOTE : Make sure seal is in place.
1. Inspect threads and splines

2. Nuts
ASSEMBLY
to the following.
INSTALLATION
8,9,10, Motor, Worm and Sliding Shaft

procedures. However pay particular attention to
the following.
Apply synthetic grease to worm.

Screw worm to sliding shaft.
Mesh worm splines to gear of motor.
4,5, Nut and Seal

Place seal on nut. Make sure seal lips are facing
toward hull.
1
F01J2PA
1. Mesh worm spline to gear of motor
Install motor, worm and sliding shaft in VTS housing.
F01J2LA
1. Seal lips facing hull
Install nut with seal and torque to 13 Nm (10

Ibfft) using the VTS socket tool.
09-04-5

1, Ball Joint
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.
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.
ADJUSTMENT
Push on VTS button up position until motor stops.
When the nozzle is up (8), nozzle edge must not
interfer with venturi (there should be a gap of 1
mm (.039 in)).
NOTE : Activate timer to be able to position
VTS.
1
1
F01J08B
1. Turn adjustment nut of ball joint
Tighten jam nut of ball joint to 2.5 Nm (23 lbfin)

when adjustment is completed.
2
F01J3IA
1. No interference
2. Nozzle up
09-04-6
Section 10 STEERING SYSTEM

TABLE OF CONTENTS
SP/XP SERIES ..................................................................................................................... 10-01-1
REMOVAL AND ASSEMBLY ............................................................................................... 10-01-2
GTS AND GTI MODELS .......................................................................................................... 10-02-1
REMOVAL AND ASSEMBLY ............................................................................................... 10-02-2
HX MODEL...............................................................................................................................
REMOVAL ............................................................................................................................
DISASSEMBLY.....................................................................................................................
STEERING CABLE REMOVAL .............................................................................................
ASSEMBLY AND INSTALLATION .......................................................................................
STEERING ALIGNMENT .....................................................................................................
10-03-1
10-03-2
10-03-3
10-03-3
10-03-3
10-03-4
ALIGNMENT ............................................................................................................................ 10-04-1
10-00-1

Sub-Section 01 (SP /XP SERIES)
SP /XP SERIES
Two types of
assembly
1
14 Nm
(10 lbfft)
5
5
7 4
7 4
6 Nm
(53 lbfin)
Loctite
242
12
26 Nm
(19 lbfft)
3
2
8 Nm
(72 lbfin)
15 Nm
(11 lbfft)
14
9
Loctite
242
15 Nm
(11 lbfft)
Synthetic
Synthetic grease
grease
11
2.5 Nm
(23 lbfin)
10
15
13
7 Nm
(63 lbfin)
Loctite
242
13
Only with
plastic
nozzle
6 Nm
(53 lbfin)
Synthetic
grease
6 Nm
(53 lbfin)
2.5 Nm
(23 lbfin)
10 Nm
(88 lbfin)
F01K19S
PARTS
10-01-1

REMOVAL AND ASSEMBLY

1,2,3, Cover, Screw and Washer
3 5
To replace the cover, just remove and reinstall 4

screws and washers.
F01K1PA
1.
2.
3.
4.
5.
: Ensure to install flat washer

- CAUTION
otherwise bolt will damage grip end.
F01K0WA
Grip insert
Grip
Flat washer
Torque bolt to 14 Nm (10 lbfft)
Cap
TYPE B
1. Screw
2. Cover
When installing the grip insert, ensure that its

notch is properly inserted in the hole beneath the
handlebar.
4,5,6,7,8, Grip, Cap, Bolt, Washer and

Grip Insert
To remove grip, just pull out cap from grip end and
remove bolt.
Pull out grip.
There is two possible assemblies for the grip insert.
TYPE A
To verify grip insert for damage, remove it from
handlebar.
notch is properly aligned with the hole beneath
the handlebar.
Install grip on handlebar matching it to the hex
form on the grip insert.
Install flat washer and bolt, torque bolt to 14 Nm
(10 lbfft).
F01K1RA
1. Notch inserted in handlebar hole
Install grip on handlebar matching it to the U form

on the handlebar.
Apply Loctite 242 (blue) on bolt threads.
Install flat washer and bolt, torque bolt to 6 Nm
(53 lbfin).
10-01-2

: While performing this proce- CAUTION

dure, take precautions to avoid damaging
throttle cable and wiring harnesses.
1
4
To install handlebar assembly:

procedures. However, pay particular attention to
the following.
6
Lubricate with synthetic grease thrust ring of rear

and front supports.
F01K1QA
1.
2.
3.
4.
5.
6.
13,14,15, Thrust Ring, Rear and Front

Supports
Grip insert
Grip
Flat washer
Loctite 242 (blue)
Torque bolt to 6 Nm (53 lbfin)
Cap
9,10,11,12, Steering Stem, Arm,

Support and Handlebar
To remove handlebar assembly:
Disconnect wiring harnesses leading out of steering stem.
Disconnect throttle cable at carburetor.
Remove throttle cable from tie-blocks.
Unscrew bolts retaining support to steering stem
arm.
F01K0HA
REAR SUPPORT SHOWN

1. Apply synthetic grease
2. Thrust ring shown removed for more clarity
F01K17A
1. Bolts
2. Steering stem arm
F01K1FA
Remove support and steering stem arm from

steering stem.
NOTE : It is not necessary to remove steering cable from steering stem arm.
Pull out handlebar assembly.
FRONT SUPPORT SHOWN

1. Apply synthetic grease
2. Thrust ring
NOTE : Make sure thrust rings are properly

installed.
10-01-3

9,10,11,12, Steering Stem, Arm,

Support and Handlebar
Install support to steering stem arm.

NOTE : Insert lock nuts in support. Screw
only a few threads of the bolts.
3
F01K0AA
1. Install handlebar assembly

2. Route throttle cable and wiring harnesses at the same time
Push handlebar assembly until steering stem is

well seated into steering supports.
4
F01K09A
TYPICAL
1. Support
3. Insert lock nuts
4. Screw only a few threads of the bolts
Install handlebar assembly into rear support, taking care at the same time to insert throttle cable
and wiring harnesses.
From bilge, route throttle cable and wiring harnesses into steering stem arm and front steering
support.
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 and support 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.
Torque bolts of steering stem arm to 6 Nm (53
lbfin).
10-01-4

1
3
5
F01K1NA
1.
2.
3.
4.
5.
Steering stem
Steering stem arm
Support
Torque to 6Nm (53lbfin)
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 05-03.
For steering alignment, refer to ALIGNMENT 1004.
10-01-5

Sub-Section 02 (GTS AND GTI MODELS)
GTS AND GTI MODELS
1
3.5 Nm
(30 lbfin)
4
Loctite
242 5
26 Nm
(19 lbfft)
7
3
2
3.5 Nm
(30 lbfin)
15 Nm
(11 lbfft)
6 Nm
(53 lbfin)
Anti-seize
lubricant
15
16 28
Loctite
242
17
15 Nm
(11 lbfft)
Loctite 242
14
15 Nm
(11 lbfft)
Loctite
242 18
28
19
20
10
20 Nm 12
(15 lbfft) 9
6 Nm
(53 lbfin)
22
13 40 Nm
(30 lbfft)
Loctite 271
11
7 Nm
(63 lbfin)
12
7 Nm
(63 lbfin)
22
24
10 Nm
(88 lbfin)
7 Nm
(63 lbfin)
21
2.5 Nm
(23 lbfin)
25
26
27
23
F02K0BS
PARTS
10-02-1

REMOVAL AND ASSEMBLY

To replace the cover, just remove and reinstall 4
screws and washers.

of the handlebar.
Install flat washer and bolt; torque to 6 Nm (53
lbfin).
1
4
1
2
F01K1QA
1.
2.
3.
4.
5.
6.
F01K0WA
1. Screw
2. Thermoplastic cover
4,5,6,7,8, Grip, Cap, Screw, Washer and

Grip Insert
To remove grip, just pull out cap from grip end and
remove screw.
Pull out grip.
handlebar.
Grip insert
Grip
Flat washer
Loctite 242 (blue)
Cap
Handlebar Assembly
TO REMOVE HANDLEBAR ASSEMBLY :
Disconnect wiring harnesses leading out of dashboard hole.
Disconnect throttle cable at carburetor.
Remove throttle cable from tie-block and clip.
9,10,11,12,13, Locking Plate, Steering

Stem Arm, Nut, Washer and Screw
Unscrew nut retaining locking plate, then remove
locking plate and washers.
Unscrew screw of steering stem arm.
Pull out handlebar assembly.
NOTE : It is not necessary to disconnect
steering cable to remove handlebar assembly.
28, Bushing
Inspect bushings for wear, cracks, scoring, etc.
Replace as necessary.
F01K1RA
10-02-2

TO INSTALL HANDLEBAR ASSEMBLY :

14, Grommet
2
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.
1
3
5
6
15,16,17,18, Spring Washer, Shim,

Steering Stem and Support
Insert spring washer and the shim onto steering
stem.
Insert steering stem into support.
4
F01K0VA
TYPICAL
2. 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)
Position 8 mm flat washer on steering stopper

screw then install locking plate over steering
stem head screw.
NOTE : Ensure locking plate slot is inserted
in steering stopper screw.
Install 8 mm flat washer and secure locking plate
using a jam nut. Torque to 7 Nm (62 Ibfin).
3
4
F02K05A
2
1.
2.
3.
4.
Steering stem
Grommet
Shim
Spring washer
10,13,19,20, Steering Stem Arm, Screw,

Large Washer and Lock Washer
Properly position steering stem arm on steering
stem. Make sure to insert stem tenon into arm
mortise. Apply Loctite 271 (red) on screw threads,
install large flat washer, lock washer and screw.
Torque to 40 Nm (30 Ibfft).
CAUTION : Always install large flat washer with the X stamped side facing the lock
washer.
WARNING : The recommended torque
and Loctite must be applied on screw.
Steering arm mortise must seat properly on
steering stem tenon.
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
10-02-3

24,25,26,27, Nut, Half Ring, Rubber

Washer and Retaining Ring
From bilge, unscrew nut retaining steering cable
to hull.
Remove half rings, rubber washer and retaining
ring.
NOTE : Move selector lever in reverse position to lower reverse gate. It will ease part
removal.
Remove steering cable from tie-block and clips.
Pull out steering cable.
to the following.
F02K0CA
22, Ball Joint
TYPICAL
21,22,23, Steering Cable, Ball Joint and

Retaining Block
Inspect and reuse ball joints only if they are in

good condition.
Steering Alignment
To replace steering cable, proceed as follows :

Disconnect ball joint at steering stem arm.
Remove nuts and open retaining block.
For steering alignment procedure, refer to

STEERING SYSTEM 10-04.
F02K0DE
TYPICAL
1. Ball joint
2. Steering cable
3. Retaining block
Disconnect ball joint at jet pump nozzle ; then, remove ball joint.
10-02-4

Sub-Section 03 (HX MODEL)
HX MODEL
7
5
6
6 Nm
(53 lbfin)
4
8
3
2
26 Nm
(19 lbfft)
7 Nm
(62 lbfin)
7 Nm
(62 lbfin)
3 Nm
(27 lbfin)
15
16
17
6 Nm
(53 lbfin)
6 Nm
(53 lbfin)
18
Synthetic grease
6 Nm
(53 lbfin)
10
Synthetic grease
Synthetic grease
12
11
13
7 Nm
(62 lbfin)
6 Nm
(53 lbfin)
15 Nm
(11 lbfft)
14
19
2.5 Nm
(22 lbfin)
10 Nm
(89 lbfin)
F05K03S
PARTS
10-03-1

REMOVAL
11, Retaining Block

Remove retaining block of cable support.

To remove the cover, just remove 4 screws and
washers.
2
F01K0WA
1. Screw
2. Thermoplastic cover
4,5,6,7,8, Grip, Cap, Bolt, Washer and

Grip Insert
To remove grip, pull out cap from grip end and remove bolt.
Pull out grip.
F01K18C
1. Retaining block
9,10, Steering Cable and Lever
Miscellaneous
Remove the hood cover by loosening the 4 plastic

Phillips screws. They may need to be replaced after one use.
Disconnect steering cable from lever of steering
stem arm.
Disconnect wires of monitoring beeper and start /

stop switch.
Open hood.
Disconnect throttle cable from carburetor linkage.
Pull out boot from hood and remove throttle cable
from boot.
2
1
F05K04A
1. Lever
2. Disconnect cable
10-03-2

F05L0FA
F05K06A
1. Boot
12,13,14, Steering Support, Bolts and

Nuts
12,18,19, Steering Support, Steering

Stem and Cable Support
Loosen bolts and nuts of steering support.
Pull out steering stem from steering support.

Remove lever from cable support.
STEERING CABLE REMOVAL

Disconnect steering cable from lever of steering
stem arm.
Remove retaining block of cable support.
Pull out boot of steering cable and throttle cable
from hood.
Disconnect ball joint of steering cable from jet
pump nozzle.
Remove ball joint, boot, nut, half rings and O-ring
from steering cable.
Remove cable from watercraft.
F05K04B
1. Steering support
2. Bolts
ASSEMBLY AND INSTALLATION
Remove steering system assembly.
Assembly and installation are essentially the reverse of removal and disassembly procedures.
However, pay particular attention to the following.
DISASSEMBLY
10,15,16,17, Lever, Steering Stem Arm,
Support and Ball Joint
Disconnect ball joints from steering stem arm and
lever.
Slide the steering stem arm and support rearward
and rotate it 90.
Remove the 2 M6 x 25 screws and nuts.
Remove the steering stem arm.
10,12,15,16,18, Lever, Steering

Support, Steering Stem Arm, Support
and Steering Stem
Prior installing lever, apply synthetic grease to pivot.
Apply synthetic grease in front and rear thrust
bearings of steering support.
10-03-3

: Make sure integrated flat

; WARNING
keys of steering stem arm and support are
properly seated in steering stem keyways.

4
3
F01K1RA
F05K08A
1.
2.
3.
4.
5.

of the handlebar.
Install flat washer and bolt ; torque to 6 Nm (53
lbfin).
Keyway
Torque to 6 Nm (53 lbfin)
Synthetic grease
Torque to 7 Nm (62 lbfin)
Torque to 15 Nm (11 lbfft)
1
4
Apply the proper torque specifications as given in

the previous illustration or the main illustration at
the beginning of this sub-section.
WARNING : Correct torque must be strictly followed.
4,5,6,7,8, Grip, Cap, Bolt, Flat Washer

and Grip Insert
F01K1QA

handlebar.
1.
2.
3.
4.
5.
6.
Grip insert
Grip
Flat washer
Loctite 242 (blue)
Cap
STEERING ALIGNMENT
For steering alignment procedure, refer to STEERING SYSTEM 10-04.
10-03-4

Sub-Section 04 (ALIGNMENT)
ALIGNMENT
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.
Slacken retaining block at cable support.
Turn adjustment nut as required.
SP / XP Series and HX Models

1
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.
F01K18A
1. Retaining block
2. Adjustment nut
3. Bolt
1
F01J03A
TYPICAL
1. Measure the distance on each side of the straight edge
10-04-1

Sub-Section 04 (ALIGNMENT)
GTS / GTI Models
2
3
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.
10-04-2
Section 11 SUSPENSION
TABLE OF CONTENTS
DIRECT ACTION SUSPENSION ............................................................................................................. 11-01-1
HX MODEL ..........................................................................................................................................
COIL OVER SHOCK REMOVAL ...........................................................................................................
OUTER BOOT REMOVAL ....................................................................................................................
COIL OVER SHOCK DISASSEMBLY....................................................................................................
ASSEMBLY ..........................................................................................................................................
11-01-1
11-01-2
11-01-3
11-01-3
11-01-3
11-00-1
Sub-Section 01 (DIRECT ACTION SUSPENSION)
DIRECT ACTION SUSPENSION
HX Model
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
11-01-1
COIL OVER SHOCK REMOVAL
Remove bottom cover of seat with grab handle.
F05L0JA
1. Collar
F05L0HA
5,6 Bolt and Lock Nut
1. Grab handle
2. Cover
Remove bolt and lock nut from shock absorber

lower support.
1,2, Outer Boot and Collar
Loosen collar of coil over shock outer boot ; then,

pull outer boot downward.
F05L0KA
1. Bolt
2. Lock nut
F05L0IA
Tilt seat upward.
1. Collar
3,4, Inner Boot and Collar

Remove rear access panel from body.
From bilge, loosen lower collar of coil over shock
inner boot ; then, push boot upward.
11-01-2
3,7, Inner Boot and Collar

Loosen upper collar of coil over shock inner boot ;
then, remove boot.
COIL OVER SHOCK

DISASSEMBLY
Remove boot.
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 coil over shock in spring compressor tool.
F05L0LA
1. Collar
8,9, Bolt and Lock Nut

upper support.
F05L0NA
Compress spring and remove cup.

Unload tool and remove spring from shock absorber.
ASSEMBLY
Assembly is essentially the reverse of assembly
procedure. Refer to the main illustration at the
beginning of this section for torque specifications
and service products to be used.
F05L0MA
1. Bolt
2. Lock nut
Remove coil over shock.
OUTER BOOT REMOVAL

Using long nose pliers, push out lower retaining
ring of outer boot.
Remove outer boot from body.
11-01-3
Section 12 HULL / BODY

TABLE OF CONTENTS
ADJUSTMENT AND REPAIR.................................................................................................................. 12-01-1
SP / XP SERIES ....................................................................................................................................
GTS / GTI MODELS .............................................................................................................................
HX MODEL ..........................................................................................................................................
SEAT ADJUSTMENT............................................................................................................................
STORAGE COMPARTMENT COVER ADJUSTMENT ..........................................................................
ACCESS PANEL ADJUSTMENT ..........................................................................................................
DRAIN PLUG INSTALLATION ..............................................................................................................
SEAT REMOVAL ..................................................................................................................................
SEAT COVER REPLACEMENT.............................................................................................................
BUMPER REPLACEMENT...................................................................................................................
SPONSON REPLACEMENT.................................................................................................................
BAFFLE SEALING (GTS / GTI MODELS) .............................................................................................
HOOD REMOVAL ................................................................................................................................
DECALS REPLACEMENT ....................................................................................................................
HULL AND BODY REPAIR ...................................................................................................................
HULL INSERT REPAIR .........................................................................................................................
12-01-1
12-01-3
12-01-5
12-01-9
12-01-10
12-01-10
12-01-11
12-01-11
12-01-12
12-01-12
12-01-13
12-01-13
12-01-13
12-01-13
12-01-14
12-01-17
PAINTING ................................................................................................................................................ 12-02-1

GENERAL ............................................................................................................................................ 12-02-1
PARTS THAT CAN BE PAINTED......................................................................................................... 12-02-2
CONCEPTTM PAINTING PROCEDURE ............................................................................................. 12-02-4
DELTATM PAINTING PROCEDURE.................................................................................................... 12-02-5
12-00-1
Sub-Section 01

(ADJUSTMENT AND REPAIR)
ADJUSTMENT AND REPAIR
SP / XP Series
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
(44 lbfin) 10
Sealant
732
7
9
8
Loctite
242
Loctite 271
Sealant 732
6
15 Nm
(11 lbfft)
Body
F01L6HS
PARTS
12-01-1

Sub-Section 01 (ADJUSTMENT AND REPAIR)
4
12
Loctite 242
6 Nm
(53 lbfin)
15 Nm
(11 lbfft)
Sealant 732
Loctite
271
SPX / XP
models
Loctite 271
12
Sealant
732
Sealant 732
4
5
4
12
1.5 Nm
(13 lbfin)
12
5
F01L6IS
12-01-2
PARTS
Sub-Section 01

GTS / GTI Models
2
1
Loctite 271
Loctite
271
3
Loctite
271
5 Nm
(44 lbfin)
8 Nm
(71 lbfin)
Loctite
242
5 Nm
(44 lbfin)
Loctite
242
Sealant
732
7
9 10 5 Nm
8
(44 lbfin)
Sealant
732
11
15 Nm
(11 lbfft)
Loctite
271
F02L26S
PARTS
12-01-3

7 Nm
(62 lbfin)
Loctite 242
4
12
15 Nm
(11 lbfft)
Loctite
271
Sealant
732
4
5
4
12
12
1.5 Nm
(13 lbfin)
4
5
12
F02L27S
12-01-4
PARTS
Sealant
732
Sub-Section 01

HX Model
3
Loctite 271
Body
Body
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
Loctite 271
Body
15 Nm
(11 lbfft)
1.5 Nm
(13 lbfin)
Sealant
732
F05L0PS
PARTS
12-01-5

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
12-01-6
PARTS
Body
Sub-Section 01

4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
1.2 Nm
(11 lbfin)
5 Nm
(44 lbfin)
Loctite
242
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
5 Nm
(44 lbfin)
Body
13 Nm
(10 lbfft)
F05L0RS
PARTS
12-01-7

13
Loctite
242
6 Nm
(53 lbfpo)
6 Nm
(53 lbfpo)
15 Nm
(11 lbfpi)
F05L0SS
12-01-8
PARTS
Sub-Section 01

SEAT ADJUSTMENT
2, Lock Pin
Adjust lock pin of seat as per following specifications.
1, Front Hook
1
Adjust front hook as per following specifications :

1
2
3
F02L25C
SP / XP SERIES
1. Lock pin
2. Adjustment nut (Loctite 271)
3. Lock nut. Torque to 5 Nm (44 lbfin)
A. 37 1 mm (1-29/64 3/64 in)
F02L24A
SP / XP SERIES
1. Front hook
3. Nut (Loctite 242). Torque to 8 Nm (71 lbfin)
A. 25 1 mm (63/64 3/64 in)
1
2
3
F02L25C
3
F02L24A
GTS / GTI MODELS

1. Front hook
3. Nut (Loctite 242). Torque to 8 Nm (71 lbfin)
A. 22.5 (+1, 0) mm (51/64 (+1/32, 0) in)
GTS / GTI MODELS

1. Lock pin
A. 38 1 mm (1-1/2 3/64 in)
NOTE : If watercraft is equipped with a optional storage tray, height of lock pin and
front hook must be raised by 2 mm (5/64 in).
12-01-9

STORAGE COMPARTMENT
COVER
ADJUSTMENT
ACCESS PANEL ADJUSTMENT

HX Model Only
3, Lock Pin
Adjust lock pin of access panel as per following

specifications.
3, Lock Pin
Adjust lock pin of storage compartment cover as
per following specifications.
1
2
2
3
F02L25C
3
F02L25C
SP / XP SERIES
1. Lock pin
A. 37 1 mm (1-29/64 3/64 in)
1.
2.
3.
A.
Lock pin
Adjustment nut (Loctite 271)
Lock nut. Torque to 5 Nm (44 lbfin)
47 1 mm (1-27/32 3/64 in)
13, Bolt
Adjust bolts of access panel arms as per following
specifications.
1
3
F02L25C
F05L0VA
1. Lock nut. Torque to 15 Nm (11 lbfft)

A. 25 1 mm (63/64 3/64 in)
GTS / GTI MODELS

1. Lock pin
A. 37 (+0.5, 1) mm (1-3/64 (+1/64, 1/32) in)
12-01-10
Sub-Section 01
DRAIN PLUG INSTALLATION

Loosen collar of coil over shock outer boot; then,

pull outer boot downward.
14, Drain Plug

Refer to the following illustration for drain plug installation.
2
1
4
F05L0IA
1. Collar
Loosen upper collar of coil over shock inner boot;

then, pull boot downward.
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
SEAT REMOVAL
HX Model Only
Remove bottom cover of seat with grab handle.
F05L0LA
1. Collar
F05L0HB
1. Cover
12-01-11


upper support.
F05L0MA
1. Bolt
2. Lock nut
Tilt seat.
Loosen side screws retaining seat frame to pivot
blocks.
Lower seat.
Loosen upper screws retaining seat frame to pivot blocks.
Remove seat.
Seat installation is essentially the reverse of removal procedure. Refer to the main illustration of
seat at the beginning of this section for proper
torque specifications and service products to be
used.
SEAT COVER REPLACEMENT
F01L3YA
TYPICAL
1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)
After cover installation cut all around the excess

of material.
BUMPER REPLACEMENT
4,5,12, Bumper, Trim and Rivet
1. Remove trim from side bumper rail.
2. Drill pop rivets to remove side bumper rail.
3. Mark hole positions on body straight and bow
sections.
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.
2
RES
4
F01L4GA
1.
2.
3.
4.
Front bumper
Corner bumper
Straight section
Bow section
12-01-12
Sub-Section 01
4. Slide bumper rail under front bumper.

5. Using a 4.80 mm (3/16 in) drill bit, drill first hole
through bumper rail at front of bow section.
Use locating mark as a guide. Then install a rivet.
CAUTION : When drilling, be careful not
to damage bumper rail and / or hull.
6. Position bumper rail properly onto body and cut
excess length if necessary.
7. Slide bumper rail in corner bumper.
8. Using hole positions previously marked on
body, drill holes in bumper rail and install rivets.
9. Install trim using soapy water.
10.Repeat procedure for the other side.
SPONSON REPLACEMENT
6,7,8,9,10, Sponson, Gasket, Washer,
Lock Washer and Nut
Remove seat.
Remove air vent tube support (SP / XP series).
Remove muffler.
From bilge, unscrew sponsons using a 10 mm
deep socket with an extension.
Remove sponsons. Clean any residus of sealant
adhesive on hull.
Install gaskets on new sponsons.
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 on hull.
From bilge, first insert flat washers over sponson
studs, then lock washers. Secure with lock nuts.
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.

Reinstall muffler. Tighten hose clamps to 4 Nm

(35 lbfin).
Reinstall air vent tube support (SP / XP series).
Reinstall seat.
Clean hull and sponsons of any sealant adhesive
surplus.
WARNING : Recommended torques and
use of Loctite must be strictly followed.
BAFFLE SEALING (GTS / GTI

MODELS)
11, Rear Baffle
Apply Sikaflex primer 449 (P / N 293 530 012) on
rear baffle and body sections to be sealed.
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 Model Only
Disconnect throttle and choke cables at carburetor linkage.
Disconnect wiring harnesses of start/stop button, monitoring beeper and safety lanyard switch.
Loosen bolts and nuts of hinge from watercraft
body.
Remove hood.
Hood installation is essentially the reverse of removal procedure. Refer to the main illustration of
hood at the beginning of this 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.
F01P09A
12-01-13

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.
Installation
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.
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.

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. Refer to SERVICE TOOLS AND PRODUCTS 01-03.
12-01-14
Sub-Section 01
: Protect skin, wear gloves

; WARNING
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.
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 (RM
856). Finish off using a fine compound (RM 852).
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 the next problem.
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 the next problem.
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.
Numerous Fractures :
Using a grinder with a 24-grit disk, remove the
gelcoat. Sand the area edge with 220-grit sandpaper.
12-01-15

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 (RM
856). Finish off using a fine compound (RM 852).
While buffing, pay close attention to avoid overheating the surface.
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.
12-01-16
Sub-Section 01
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. If painting the exterior is preferred, refer to HULL / BODY 11-02.
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
heavy-duty polisher
power sander
paint brush
plastic container (mixing)
spray gun
plastic squeegee

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

For hull insert repair proceed as follows :
Cut plastic hull insert flush with hull using a saw.
1
F01L2UA
1. Hull
2. Plastic hull insert
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.
12-01-17

: If you notice any clearance be- CAUTION

tween plastic insert and aluminum insert,
fill gap with epoxy glue to obtain good adhesion of aluminum insert.
1
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.
1
F01L2WA
1. Aluminum insert
NOTE : The epoxy glue curing time is 30

minutes.
12-01-18
Section 12 HULL/BODY
Sub-Section 02 (PAINTING)
PAINTING
GENERAL
The following was prepared in conjunction with PPG Industries Inc. It contains a list
of SEA-DOO parts with their respective PPG color codes and 2 painting procedures
; CONCEPT the most commonly used and DELTA (with low VOC) mainly used
in California.
PPG Industries Inc. sells paint and related products and these are not available through Bombardier Inc.
network. To find your nearest PPG dealer, dial one of the following numbers.
NORTH AMERICA
CANADA
Quebec
Phone : 1-800-363-2816
All Others Provinces

Phone : 1-905-855-5802
Communications are available in english and
french.
U.S.A
Phone : (216) 572-6100

This phone number is also good for all countries.
Communications are available in english, french and spanish.
EUROPE
PACIFIC RIM
DENMARK
Phone : 45-31-54-9211
PORTUGAL
Phone : 351-230-17-43
FRANCE
Phone : 33-1-48-35-7777
33-27-14-9700
33-27-14-4600
SPAIN
Phone : 34-3-588-2000
34-3-711-51-54
34-6-154-7035
34-83-54-0400 / 04
GERMANY
Phone : 49-202-788-1
SWEDEN
Phone : 46-479-14-445
ITALY
Phone : 39-81-831-1222
39-2-37-701
39-131-7701
UNITED
KINGDOM
Phone : 44-21-455-9866
44-926-410-255
JAPAN
Phone : 81-3-3280-2851
KOREA
Phone : 82-32-529-8141
82-32-523-8600
82-51-624-8221
82-2-792-2477
PPG paint for Sea-Doo watercraft is not available in spray can. For best result it must be applied by a
professional painter.
For fast touch up on metallic and gelcoat surfaces, refer to the appropriate Bombardier Sea-Doo Parts
Catalog to find the available products.
12-02-1
PARTS THAT CAN BE PAINTED
11
2
10
9
4
12
7
8
6
14
15
F02B03S
1.
2.
3.
4.
5.
6.
7.
8.
9.
Body
Hull
Storage Cover (if applicable)
Engine
Tuned Pipe
Muffler
Exhaust Manifold
Engine Support
Magneto Housing
10. Magneto Housing Cover

11. Flame Arrester Base
12. Ride Shoe
13. Impeller Housing*
14. Venturi*
15. Steering Nozzle*
*Except for parts made of plastic.
12-02-2
13
SEA-DOO MODELS
PPG COLOR CHART
SP
SPI
SPX
XP
HX
GTS
GTI
COLOR
PPG no.
White
98260
White
98260
Yellow
M506
White
98260
White
98260
White
98260
COLOR
PPG no.
White
98260
Marine
green
M511
Yellow
M506
Yellow
88243
White
98260
White
98260
COLOR
PPG no.
Not
applicable
Not
applicable
Not
applicable
Yellow
88243
Marine
green
M511
Yellow
M506
1.
Body
2.
Hull
3.
Storage cover
(hood for the HX
model)
4.
Engine
COLOR
PPG no.
White
98209
White
98209
White
98209
White
98209
White
98209
White
98209
5.
Tuned pipe
COLOR
PPG no.
Purple
59962
Purple
59962
Purple
59962
Purple
59962
Purple
59962
Purple
59962
6.
Muffler
COLOR
PPG no.
Purple
59962
Purple
59962
Purple
59962
Purple
59962
Purple
59962
Purple
59962
7.
Exhaust Manifold
COLOR
PPG no.
White
98209
White
98209
White
98209
White
98209
White
98209
White
98209
8.
Engine support
COLOR
PPG no.
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
9.
Magneto housing
COLOR
PPG no.
White
98209
White
98209
White
98209
White
98209
White
98209
White
98209
10.
Magneto housing
cover
COLOR
PPG no.
White
98209
White
98209
White
98209
White
98209
White
98209
White
98209
11.
Flame arrester
base
COLOR
PPG no.
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
12.
Ride shoe
COLOR
PPG no.
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
13.
Impeller housing
COLOR
PPG no.
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
14.
Venturi
COLOR
PPG no.
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
15.
Nozzle
COLOR
PPG no.
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
Black
9551
Except for plastic parts
NOTE : Due to natural discoloration, it may be necessary to completely repaint the part.
12-02-3
CONCEPTTM PAINTING PROCEDURE

For additional information refer to PPG P-Bulletin no. 168.
SURFACE PREPARATION
FULL PANEL AND OVERALL REPAIRS
Prepare and clean surface consistent with good

painting practices.
Primer
DP Epoxy Primer / DP 401 Catalyst; DX 1791 /
1792 (Prime before top coating).
Primer Surfacer
K36 / K201, K200 / K201 or DZ KONDAR Primer
Surfacers.
NOTE : KONDAR must be sealed before applying CONCEPT color.
Sealer
KTS30 2K Sealer, DP Epoxy Primer reduced as a
sealer or DAS 1980 or DAS 1987.
Application
Apply 1 medium wet coat and give 5-10 minutes
flash, followed by 2 wet coats with 15 minutes
flash time between each coat. Adjust metallic on
the last full wet coat. If necessary, apply a mist
coat. For medium solids option apply 2 full wet
coats.
Direct Gloss Color

How to Mix
Standard Air Dry : Mix CONCEPT Color 2:1:1 - 2
parts color with 1 part DT Reducer best suited to
shop temperatures and 1 part DU 4 Hardener below 29C (85F) or DU 5 Hardener above 29C
(85F).
Standard Force Dry : Mix CONCEPT Color 2:1:1 Application temperatures below 29C (85F) use
DU 5 Hardener, above 29C (85F) use DU 6.
Medium Solids (MS) Application : For faster film
build, when using solid colors, mix 2 parts CONCEPT color with half part DT Reducer and 1 part
DU 5 or DU 6 Hardener. Select the DT Reducer
appropriate for shop temperature.
Pot Life
Pot life of ready-to-spray CONCEPT color is 6 to 8
hours at 21C (70F). Medium solids option is 2 to
4 hours at 21C (70F).
Air Pressure
275-345 kPa (40-50 PSI) at the gun.
Dry Time
Dust free: 30 minutes.
Tack free: 2 to 3 hours.
Tape print free: 6 hours.
Dry to handle: 6 to 8 hours at 21C (70F).
Force dry: 40 minutes at 60C (140F).
Faster dry times may be obtained by using 15 mL
(1/2 oz) of DXR 81 Accelerator per sprayable
quart, however, the pot life is reduced to 2 hours.
SPOT / PANEL REPAIRS

Application
Spray medium wet coat of color on the repair area
and allow 5-10 minutes flash time. Apply 2 additional full coats until hiding is achieved, extending
each coat beyond the previous coat. Flash 15 minutes between each coat. For medium solids option apply 2 full wet coats.
Blending
Add DT 95 Reducer to a second gun cup. Reduce
the fluid feed of the gun and lower the air pressure to 207 kPa (30 PSI). Dust the dry edge until a
slight wet look appears, then stop. Or mix reduced and catalyzed color with equal parts of reduced and catalyzed CONCEPT DCU 2020 Clear.
12-02-4
DELTATM PAINTING PROCEDURE

(with low VOC, mainly in California)
For additional information refer to PPG P-Bulletin no. 157.
SURFACE PREPARATION
Primer: DELTATM PRIME DPU 166.
DELTATM 2800, COLOR

How to Mix
Mix DELTATM 2800 2:1, 2 parts Colors to 1 DU 6 Catalyst.
Application
Apply 2 coats of DELTATM Polyurethane Color. Apply the first coat at 1.5 -1.8 wet mils. Allow a minimum
of 15 minutes flash time prior application of the second coat. Apply a second coat of DELTATM using the
same technique as the first application, paying strict attention to gun set up and proper equipment choices.
RECOMMENDED SPRAY EQUIPMENT

Gun Manufacturer
De Vilbiss
Binks
Graco
HVLP
Gun Model
JGA
62
800N
Can Am Model 900
Fluid Type
FF
1.4 mm (0.055 in)
63D
1.5 mm (0.059)
02N
1.2 mm (0.047 in)
HT no. 9072
2.5 mm (0.098 in)
Air Cap
797 / 264
63 PW
02 / 03
C9062
Gun Distance
25 - 30 cm
(10 - 12 in)
25 - 30 cm
(10 - 12 in)
25 - 30 cm
(10 - 12 in)
25 - 30 cm
(10 - 12 in)
Fluid Delivery
227 - 340 mL / min.

(8 - 12 oz / min.)
227 - 340 mL / min.

(8 - 12 oz / min.)
227 - 340 mL / min.

(8 - 12 oz / min.)
227 - 340 mL / min.

(8 - 12 oz / min.)
Air Pressure
(At-the-Gun)
414 - 517 kPa

(60 - 75 PSI)
414 - 517 kPa

(60 - 75 PSI)
414 - 517 kPa

(60 - 75 PSI)
62 kPa
(9 PSI)
Dry Time at 21C (70F)

Dust free: 25-35 minutes.
Tack free: 2-1/2 to 3 hours.
Tape / Sand: Overnight.
Force Dry
Allow 20 minutes purge time at 27-32C (80-90F) before bake. Bake 75 minutes at 65C (150F) or 40
minutes at 82C (180F). Allow to cool after force dry, before sanding or taping.
12-02-5
Section 13 TECHNICAL DATA

TABLE OF CONTENTS
SP AND SPI MODELS ............................................................................................................. 13-01-1
SPX AND XP MODELS............................................................................................................ 13-02-1
GTS AND GTI MODELS .......................................................................................................... 13-03-1
HX MODEL............................................................................................................................... 13-04-1
13-00-1

Sub-Section 01 (SP AND SPI MODELS)
SP AND SPI MODELS
ENGINE
Engine type
Induction type
Exhaust system
SP (5876)
SPI (5878)
Bombardier-Rotax 587
Rotary valve
Type
Water cooled, water injected
Water injection fitting
4.6 mm (.181 in)
Starting system
Electric start
Lubrication
Fuel / oil mixture
VROI (Variable Rate Oil Injection
Oil injection pump
Gear driven
Oil type
BOMBARDIER-ROTAX injection oil
Number of cylinders
2
Bore
Standard
76.0 mm (2.992 in)
First oversize
76.25 mm (3.002 in)
Second oversize
76.50 mm (3.012 in)
Stroke
64 mm (2.520 in)
Displacement
580.7 cm (35.4 in)
Corrected compression ratio
6.5 : 1
Cylinder head warpage (maximum)
0.05 mm (.002 in)
Piston ring type and quantity
1 Semi-trapez 1 Rectangular
Ring end gap
New
0.25 - 0.40 mm (.010 - .016 in)
Wear limit
1.00 mm (.039 in)
Ring / piston groove
New
0.05 - 0.08 mm (.002 - .003 in)
clearance
Wear limit
0.2 mm (.008 in)
Piston / cylinder wall
New
0.05 - 0.07 mm (.002 - .003 in)
clearance
Wear limit
0.2 mm (.008 in)
Cylinder taper (maximum)
0.100 mm (.004 in)
Cylinder out of round (maximum)
0.080 mm (.003 in)
Connecting rod bigend
New
0.39 - 0.74 mm (.015 - .029 in)
axial play
Wear limit
1.2 mm (.047 in)
Crankshaft deflection
Rotary valve timing

Opening
130 5 BTDC
Closing
65 5 ATDC
Rotary valve duration
147
Crankcase / rotary valve gap
0.25 - 0.35 mm (.010 - .014 in)
Connecting rod / crankNew
0.02 - 0.03 mm (.0008 - .0013 in)
shaft pin radial clearance
Wear limit
0.050 mm (.002 in)
Connecting rod / piston
New
0.003 - 0.012 mm (.00012 - .00047 in)
pin radial clearance
Wear limit
0.015 mm (.00059 in)
ADDITIONAL INFORMATION : Squish gap : 1.2 - 1.8 mm (.047 - .071 in).
MAG side : 0.05 mm (.002 in)
PTO side : 0.03 mm (.001in)
13-01-1

ELECTRICAL
Magneto generator output
Ignition system type
Spark plug
Make and type
Gap
Ignition timing
mm (in)
(BTDC)
Degrees
Generating coil
Battery charging coil
Ignition coil
Primary
Secondary
Engine rev limiter setting
Battery
Fuse
Starting system
Charging system
ADDITIONAL INFORMATION : Engine cold @ 6000 RPM.
CARBURETION
Carburetor
Main jet
Pilot jet
Adjustment
Fuel
Type
Quantity
Low-speed screw
High-speed screw
Idle speed (in water)
Idle speed (out of water)
Type
Minimum octane no.
Fuel return line orifice
SP (5876)
SPI ( 5878)
160 W @ 6000 RPM or 4.0 A @ 2000 RPM
CDI
NGK BR7ES
0.5-0.6 mm (.020-.024 in)
2.41 (.095)
20 1
40 - 76
.05 - .6
Not applicable
9 - 15 k
6550 50 RPM
(Yuasa / Exide) 12 V, 19 Ah
5A
15 A
SP (5876)
SPI (5878)
Mikuni BN-38 (diaphragm)
1
142.5
147.5
65
1-1/4 turn 1/4
0
1500 RPM
2400 RPM
2500 RPM
Regular unleaded gasoline
87
0.8 mm
(.031 in)
ADDITIONAL INFORMATION :
COOLING
Type
Thermostat
Monitoring beeper setting
SP (5876)
Open circuit Direct flow
from jet propulsion unit
None
96-99C (205-210F)
13-01-2
SPI (5878)

PROPULSION
Propulsion system
Jet pump type
Impeller rotation (seen from rear)
Transmission
Coupling type
Oil type
SP (5876)
SPI (5878)
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
Trim nozzle pivoting angle
Not applicable
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
New
0.18 - 0.44 mm (.007 - .017 in)
ring clearance
Wear limit
1.02 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
18.8 /
Progressive pitch 11aluminum
26 / 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 (5876)
SPI (5878)
2
254 cm
105 cm
92 cm
176 kg (388 lb)
160 kg
(100 in)
(41.3 in)
(36.2 in)
178 kg (392 lb)
(352 lb)
SP (5876)
Capacity
Oil level height
Oil injection reservoir

SPI (5878)
34 L (9 U.S. gal)
90 mL (3 U.S. oz)
To bottom of cover hole
4.5 L (1.2 U.S. gal)
13-01-3

MATERIALS
Hull
Air intake silencer
Flame arrester
Exhaust muffler
Steering padding
Fuel tank
Seat
SP (5876)
SPI (5878)
Composite
Thermoplastic
Multi-layer wire screen
Aluminum
Thermoplastic elastomer with polystyrene foam
Polyethylene
Polyethylene
Polyurethane foam
STANDARD EQUIPMENT
Safety lanyard
Tool kit
Fuel tank reserve
Monitoring beeper
Electric fuel gauge / low oil warning light
Tachometer
Manual trim system
Reverse
Storage compartment
Rear grab handle
Extinguisher holder
SP (5876)
Optional
Standard
Optional
Optional
Standard
Not applicable
Standard
Optional
Standard
Standard
PERFORMANCE
Estimated pump power
Maximum fuel consumption at wide open throttle
Cruising time at full throttle
SPI (5878)
Standard
Standard
Standard
Standard
Fuel tank without reserve

Fuel tank reserve
SP (5876)
18.3 kW (24.5 hp)
20.4 L/h
(5.5 U.S. gal/h)
1 hour 20 minutes
15 minutes
13-01-4
SPI (5878)
21.7 kW (29.1 hp)
22.3 L/h
(6 U.S. gal/h)
1 hour 12 minutes
14 minutes

TIGHTENING TORQUES
SP (5876)
Exhaust manifold screw
24 Nm
Magneto flywheel nut
145 Nm
Flywheel (PTO side)
110 Nm
Crankcase screws
M8
24 Nm
M10
40 Nm
Crankcase / engine support nuts
35 Nm
Engine support / hull
25 Nm
24 Nm
Crankcase / cylinder screws
24 Nm
Tuned pipe nut
25 Nm
Tuned pipe fixation screws
25 Nm
Cylinder head cover screws
9 Nm
Flame arrester screws
10 Nm
Impeller
70 Nm
Pump / hull nuts
35 Nm
Venturi / pump housing screws
25 Nm
Nozzle / venturi screws
20 Nm
Pump housing cover screws
4 Nm
Inlet grate screws
8 Nm
Ride shoe 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
Ball joint bolt
7 Nm
Front support bolts
15 Nm
Rear support/cable bracket bolts
15 Nm
Magneto housing cover screws
9 Nm
Starter mounting screws
22 Nm
Starter lock nuts
7 Nm
Spark plugs
24 Nm
ADDITIONAL INFORMATION : Apply where indicated ; (1) Loctite 242 (blue)
(2) Loctite 271 (red)
(3) Loctite 515
(4) Synthetic grease
(5) Anti-seize lubricant
SPI (5878)
(17 lbfft)
(107 lbfft)
(81 lbfft)
(17 lbfft)
(30 lbfft)
(26 lbfft)
(18 lbfft)
(17 lbfft)
(17 lbfft)
(18 lbfft)
(18 lbfft)
(80 lbfin)
(88 lbfin)
(52 lbfft)
(26 lbfft)
(18 lbfft)
(15 lbfft)
(35 lbfin)
(71 lbfin)
(88 lbfin)
(53 lbfin)
(26 lbfin)
(53 lbfin)
(19 lbfft)
(62 lbfin)
(11 lbfft)
(11 lbfft)
(80 lbfin)
(16 lbfft)
(62 lbfin)
(17 lbfft)
(4)
(1)
(5)
(3) (4)
(3) (4)
(1)
(1)
(4)
(4)
(1)
(1)
(1)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(5)
(1)
(5)
; WARNING : Correct torques and use of Loctite must be strictly followed.
13-01-5

Sub-Section 02 (SPX AND XP MODELS)
SPX AND XP MODELS

ENGINE
Engine type
Induction type
Exhaust system
2
SPX (5877)
Type
Water injection fitting (head)
Water injection fitting (cone)
Water injection fitting (muffler)
XP (5858 / 5859)
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
Variable Exhaust (RAVE)
Starting system
Electric start
Lubrication
Fuel / oil mixture
VROI (Variable Rate Oil Injection)
Oil injection pump
Gear driven
Direct driven
BOMBARDIER-ROTAX
Formula XP-S synthetic
Oil type
injection oil
injection oil
Number of cylinders
2
Bore
Standard
82 mm (3.228 in)
First oversize
82.25 mm (3.238 in)
Second oversize
82.50 mm (3.248 in)
Not applicable
Stroke
68 mm (2.68 in)
74 mm (2.99 in)
Displacement
718 cm3 (43.81 in)
781.6 cm (47.7 in3)
6.2 : 1
5.9 : 1
0.05 mm (.002 in)
1 Semi-trapez 1 Rectangular
Ring end gap
New
0.25 - 0.40 mm (.010 - .016 in)
Wear limit
1.00 mm (.039 in)
New
0.025 - 0.070 mm (.001 - .003 in)
Wear limit
0.2 mm (.008 in)
New
0.060 - 0.108 mm (.0024 - .0043 in)
clearance
Wear limit
0.2 mm (.008 in)
0.100 mm (.004 in)
0.080 mm (.003 in)
Connecting rod big
New
0.39 - 0.74 mm (.015 - .029 in)
end axial play
Wear limit
1.2 mm (.047 in)
MAG side : 0.05 mm (.002 in) ; PTO side : 0.03 mm (.001 in)
Rotary valve timing
Opening
147 5 BTDC
146.5 5 BTDC
Closing
65.5 5 ATDC
64 5 ATDC
159
0.25 - 0.35 mm (.010 - .014 in)
Connecting rod / crankshaft
New
0.023 - 0.034 mm (.0009 - .0013 in)
Wear limit
0.050 mm (.002 in)
Connecting rod / piston pin
New
0.003 - 0.012 mm (.00012 - .00047 in)
radial clearance
Wear limit
0.015 mm (.00059 in)
ADDITIONAL INFORMATION : Squish gap : 717 engine : 1.3 - 1.7 mm (.051 - .067 in)
787 engine : 1.2 - 1.6 mm (.047 - .063 in)
Exhaust valve
Not applicable
13-02-1

ELECTRICAL
SPX (5877)
XP (5858 / 5859)
160 W @ 6000 RPM

or 4.0 A @ 2000 RPM
180 W @ 6000 RPM

or 5.0 A @ 2000 RPM
CDI
DC-CDI

Spark plug
Make and type
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
40 - 76
Not applicable
Generating coil
Trigger coil
Ignition coil
Primary
0.05 - 0.6
0.1 - 1
Not applicable
190 - 300
Not applicable
0.33 - 0.62
Secondary
9 - 15 k
7000 ( 50) RPM
Battery
Fuse
7200 ( 50) RPM
Starting system
5A
Charging system
15 A
15 A (2)
VTS system
7.5 A
Holder relay
Not applicable
5A
SPX (5877)
XP (5858 / 5859)
CARBURETION
Carburetor
Type
Mikuni BN-38I (diaphragm)
Quantity

2
Main jet
130
142.5
Pilot jet
67.5
70
Adjustment
Low-speed screw
1-1/4 turn 1/4
High-speed screw
Fuel
1 turn 1/4
0
1500 RPM
3000 RPM
Type
Minimum octane no.
87
MAG 0.8 mm (.031 in)

PTO 0.8 mm (.031 in)
COOLING
Type
SPX (5877)
XP (5858 / 5859)
Open circuit Direct flow from jet propulsion unit
Thermostat
None
96-99C (205-210F)
13-02-2

PROPULSION
SPX (5877)
Propulsion system
Jet pump type
XP (5858 / 5859)

Counterclockwise
Transmission
Coupling type
Direct drive
Crown splines
Oil type

26

8
90 cm (35 in)

Impeller / wear ring clearance
0.5 mm
139.5 mm
New
Wear limit

Impeller pitch / material
(.020 in)
(5.490 in)
0.18 - 0.44 mm
1.02 mm
(.007 - .017 in)

(.040 in)
0.12 - 0.54 mm
0.05 mm
(.005 - .021 in)

(.002 in)
Progressive pitch 11-24 /

stainless steel

stainless steel
ADDITIONAL INFORMATION : Do not mix different brands or oil types.
DIMENSIONS
SPX (5877)
XP (5858 / 5859)
Overall length
Overall width
254 cm
105 cm
Overall height
Dry weight
92 cm
(36.2 in)
197 kg (434 lb)
160 kg
(352 lb)
187 kg (412 lb)

CAPACITIES
Fuel tank
SPX (5877)
XP (5858 / 5859)
34 L
90 mL
Capacity
(100 in)
(41.3 in)
Oil level height
(9 U.S. gal)
(3.0 U.S. oz)
Up to plug
4.5 L (1.2 U.S. gal)

PERFORMANCE

Fuel tank reserve
SPX (5877)
XP (5858 / 5859)
34.9 kW (47.4 hp)
42 kW (57 hp)
35 L/h
(9.2 U.S. gal/h)
44.5 L/h
(11.7 U.S. gal/h)
45 minutes
9 minutes
36 minutes
7 minutes
13-02-3

MATERIALS
SPX (5877)
Hull
Inlet grate
Impeller housing / venturi / nozzle
XP (5858 / 5859)
Composite
Plastic
Plastic / Plastic / Aluminum
Air intake silencer

Flame arrester
Thermoplastic
Exhaust muffler
Steering padding
Aluminum
Fuel tank
Polyethylene
Polyethylene
Seat
STANDARD EQUIPMENT
Polyurethane foam
SPX (5877)
XP (5858 / 5859)
Safety lanyard
Tool kit
Standard
Standard
Fuel tank reserve

Monitoring beeper
Standard
Standard
Speedometer
Multifunction gauge
Optional
Standard
Standard
Tachometer
Variable trim system (VTS)
Optional
Standard
Reverse
Storage compartment
Not applicable
Standard
Rear grab handle

Extinguisher holder
Standard
Standard
13-02-4

TIGHTENING TORQUES
SPX (5877)

Flywheel (PTO side)
ENGINE
Crankcase screws
PUMP
STEERING
(3) (4)
(1)
(81 lbfft)
24 Nm
40 Nm
(17 lbfft)
(30 lbfft)
(3) (4)
(3) (4)
35 Nm
25 Nm
(26 lbfft)
(18 lbfft)
(1)
(1)
24 Nm
24 Nm (17 lbfft) (1) (4)
(17 lbfft)
40 Nm (30 lbfft)
(1) (4)
(3) (4)
25 Nm (18 lbfft) (1)

25 Nm
40 Nm (30 lbfft)
(18 lbfft)
(1)
(1)

Engine mount / hull
40 Nm (30 lbfft)
105 Nm (77 lbfft)
110 Nm
M8
M10
Tuned pipe flange screws / nut

ELECTRICAL
XP (5858 / 5859)
24 Nm (17 lbfft) (4)

145 Nm (107 lbfft) (1)

Impeller
10 Nm
70 Nm
(88 lbfin)
(52 lbfft)
(1)
(2)
Pump / hull nuts

35 Nm
21 Nm
(26 lbfft)
(16 lbfft)
(1)
(1)
VTS ring screws

14 Nm
4 Nm
(10 lbfft)
(35 lbfin)
(1)
(1)
Inlet grate screws

Ride shoe screws
8 Nm
10 Nm
(71 lbfin)
(88 lbfin)
(1)
(1)
6 Nm
3 Nm
(53 lbfin)
(26 lbfin)

6 Nm
26 Nm
(53 lbfin)
(19 lbfft)
Ball joint bolt

Front support bolts
7 Nm
15 Nm
(62 lbfin)
(11 lbfft)
(1)
Rear support / cable bracket bolts

15 Nm
9 Nm
(11 lbfft)
(80 lbfin)
(1)
(5)

Starter lock nuts
22 Nm
7 Nm
(16 lbfft)
(62 lbfin)
(1)
Spark plugs
24 Nm
(17 lbfft)
(5)

Steering cable / stem arm bolt
ADDITIONAL INFORMATION :Apply where indicated ;
(1) Loctite 242 (blue)

(3) Loctite 515
13-02-5

GTS AND GTI MODELS

ENGINE
GTS (5817)
Engine type
Induction type
Exhaust system
3
GTI (5865 / 5866)
Rotary valve
Type

4.6 mm (.181 in)
3.5 mm (.139 in)
Not applicable
Starting system
Lubrication
Fuel / oil mixture

Oil injection pump
Oil type

Gear driven
2
Number of cylinders
Bore
3.5 mm (.139 in)

Electric start
Standard
First oversize
76.0 mm (2.992 in)

76.25 mm (3.002 in)
82.0 mm (3.228 in)

82.25 mm (3.238 in)
Second oversize
Stroke
76.50 mm (3.012 in)

64 mm (2.520 in)
82.50 mm (3.248 in)

68 mm (2.68 in)
Displacement
580.7 cm3 (35.4 in3)

6.5 : 1
718 cm3 (43.81 in3)

6.2 : 1

0.05 mm (.002 in)

1 Semi-Trapez 1 Rectangular
Ring end gap
New
Wear limit
0.25 - 0.40 mm
1.00 mm
(.010 - .016 in)

(.039 in)
Ring / piston grooveclearance
New
Wear limit
0.05 - 0.08 mm
(.002 - .003 in)
0.2 mm
(.008 in)
Piston / cylinder wall clearance
New
0.05 - 0.07 mm
(.002 - .003 in)
Wear limit
0.2 mm
0.100 mm

Connecting rod big end axial
New
play
Wear limit
0.08 mm
0.39 - 0.74 mm
Connecting rod / piston pin

radial clearance
(.003 in)
(.015 - .029 in)
(.047 in)
Opening
Closing
130 5 BTDC
65 5 ATDC
147 5 BTDC
65.5 5 ATDC
147
0.25 - 0.35 mm
159
(.010 - .014 in)
New
0.20 - 0.033 mm
(.0008 - .0013 in)
0.01 - 0.02 mm
(.0004 - .0008 in)
Wear limit
New
0.050 mm
0.003 - 0.012 mm
(.002 in)
(.00012 - .00047 in)

Rotary valve / cover clearance
(.008 in)
(.004 in)
1.2 mm
Rotary valve timing
0.06 - 0.11 mm
(.002 - .004 in
Wear limit
0.015 mm
Squish gap :587 engine : 1.2 - 1.8 mm (.047 - .071 in)
717 engine : 1.3 - 1.7 mm (.051 - .067 in)
MAG side : 0.05 mm (.002 in)
PTO side : 0.03 mm (.001 in)
(.00059 in)
13-03-1

ELECTRICAL
GTS (5817)

GTI ( 5865 / 5866)
160 W @ 6000 RPM or 4.0 A @ 2000 RPM

CDI
Spark plug
Make and type
Ignition timing
Gap
mm (in)
0.5 - 0.6 mm (.020 - .024 in)

2.41 (.095)
2.59 (.102)
Degrees
20 1
40 - 76 W
(BTDC)
Generating coil
Ignition coil
NGK BR7ES
NGK BR8ES
.05 - .6 W
Not applicable
Primary
Secondary
9 - 15 kW

Battery
Fuse
6550 50 RPM
7000 50 RPM
5A
Starting system
Charging system
CARBURETION
Carburetor
Type
Quantity
Main jet
Pilot jet
Adjustment
GTS (5817)
GTI (5865 / 5866)
Mikuni BN-38 (diaphragm)

1

2
147.5
65
130
67.5
Low-speed screw
High-speed screw
Fuel
15 A
Type
Minimum octane no.
1-1/4 turn 1/4

0
1500 RPM
2500 RPM
3000 RPM

87
0.8 mm (.031 in)
MAG 0.8 mm (.031 in)

PTO 0.8 mm (.031 in)
GTS (5817)
GTI (5865 / 5866)
COOLING
Type
Open circuit Direct flow

Thermostat
None
96-99C (205-210F)
13-03-2

GTS (5817)
PROPULSION
Propulsion system
Jet pump type
GTI (5865 / 5866)

Counterclockwise
Transmission
Coupling type
Direct drive
Crown splines
Oil type

26

Not applicable
90 cm
(35 in)
0.5 mm
139.5 mm
(.020 in)
(5.490 in)
0.18 - 0.44 mm
1.02 mm
(.007 - .017 in)

(.040 in)
0.12 - 0.54 mm
0.05 mm
(.005 - .021 in)

(.002 in)

stainless steel

stainless steel

Impeller / wearring clearance
New
Wear limit

DIMENSIONS
GTS (5817)
GTI (5865 / 5866)
3 (5865) / 2 (5866)
Overall length
Overall width
302 cm
119 cm
(119.0 in)
(46.8 in)
Overall height
Dry weight
95 cm
210 kg (463 lb)
(37.4 in)
220 kg (485 lb)
225 kg
(496 lb)
GTS (5817)
GTI (5865 / 5866)
46 L
90 mL
(12 U.S. gal)

(3 U.S. oz)

CAPACITIES
Fuel tank
Capacity
Oil level height
4.5 L

(1.2 U.S. gal)
13-03-3

MATERIALS
GTS (5817)
GTI (5865 / 5866)
Hull
Inlet grate
Composite
Plastic
Air intake silencer
Thermoplastic
Flame arrester
Exhaust muffler

Aluminum
Steering padding
Fuel tank

Polyethylene

Seat
Polyethylene
Polyurethane foam
STANDARD EQUIPMENT
GTS (5817)
GTI (5865 / 5866)
Safety lanyard
Tool kit
Standard
Standard
Fuel tank reserve

Monitoring beeper
Standard
Standard
Electric fuel gauge / low oil warning light

Multifunction gauge
Standard
Optional
Digitally Encoded Security System (D.E.S.S.)

Tachometer
Optional
Speedometer
Variable trim system (VTS)
Optional
Not applicable
Standard
Standard
Optional
Standard
Not applicable
Reverse
Storage compartment
Standard
Standard
Rear grab handle

Extinguisher holder
Standard
Standard
PERFORMANCE

Fuel tank reserve
GTS (5817)
GTI (5865 / 5866)
21.7 kW (29 hp)

22.3 L/h
(5.9 U.S. gal/h)
1 hour 42 minutes
34.9 kW (46.8 hp)

35 L/h
(9.3 U.S. gal/h)
1 hour 5 minutes
14 minutes
9 minutes
13-03-4

GTS (5817)
TIGHTENING TORQUES
Exhaust manifold screws
Flywheel (PTO side)
ENGINE
PUMP
STEERING
(17 lbfft)
(107 lbfft)
(4)
(1)
110 Nm
(81 lbfft)
(5)
24 Nm
40 Nm
(17 lbfft)
(30 lbfft)
(3)* (4)
(3)* (4)

35 Nm
25 Nm
(26 lbfft)
(18 lbfft)
(1)
(1)

Cylinder head cover screws (GTS)
24 Nm
9 Nm
(17 lbfft)
(80 lbfin)
(1)* (4)

Tuned pipe nut
24 Nm
25 Nm
(17 lbfft)
(18 lbfft)
(1)** (4)
(1)

25 Nm
10 Nm
(18 lbfft)
(88 lbfin)
(1)
(1)
Impeller
Pump / hull nuts
70 Nm
35 Nm
(52 lbfft)
(26 lbfft)
(2)
(1)

Nozzle / venturi screws
21 Nm
20 Nm
(16 lbfft)
(15 lbfft)
(1)
(1)
4 Nm
8 Nm
(35 lbfin)
(71 lbfin)
(1)
(1)
Ride shoe screws

Steering cable jam nuts
10 Nm
10 Nm
(88 lbfin)
(88 lbfin)
(1)
Steering support / collar screws

Steering stem screw
15 Nm
40 Nm
(11 lbfft)
(30 lbfft)
(1)
(2)
Handlebar nuts
Reverse gate screws
26 Nm
20 Nm
(19 lbfft)
(15 lbfft)
(1)
7 Nm
7 Nm
62 lbfin)
62 lbfin)
9 Nm
22 Nm
(80 lbfin)
(16 lbfft)
7 Nm
(62 lbfin)
24 Nm
(17 lbfft)
Crankcase screws
ELECTRICAL
GTI (5865 / 5866)
24 Nm
145 Nm
M8
M10

Inlet grate screws
Steering / cable ball joint nut

Reverse cable ball joint nut
Starter lock nuts
Spark plugs
(5)
(1)
(5)
ADDITIONAL INFORMATION :Apply where indicated ; (1) Loctite 242 (blue)

(3) Loctite 515
* 717 engine only
WARNING : Correct torques and use of Loctite must be strictly followed.
13-03-5

HX MODEL
ENGINE
HX (5881)
Engine type
Induction type
Exhaust system
Rotary valve
Type

3.5 mm (.139 in)
3.5 mm (.139 in)

Electric start
Starting system
Lubrication
Fuel / oil mixture

Oil injection pump

Gear driven
Oil type

2
Number of cylinders
Bore
Standard
First oversize
82.00 mm
82.25 mm
(3.228 in)
(3.238 in)
Second oversize
82.50 mm
68 mm
(3.248 in)
(2.68 in)
Stroke
Displacement
718 cm (43.81 in)

6.2 : 1

Ring end gap
New
Wear limit

clearance
New

clearance
0.05 mm (.002 in)

1 Semi-trapez - 1 Rectangular
0.25 - 0.40 mm
1.00 mm
0.025 - 0.070 mm
(.001 - .003 in)
(.008 in)
Wear limit
0.2 mm
New
Wear limit
0.060 - 0.108 mm
0.2 mm

Connecting rod bigend axial
play
New
Wear limit
Rotary valve timing
Opening
0.100 mm
0.080 mm
New
Wear limit
New
(.015 - .029 in)

(.047 in)
147 5 BTDC
Closing

Connecting rod / piston
(.0024 - .0043 in)

(.008 in)
(.004 in)
(.003 in)
0.39 - 0.74 mm
1.2 mm
65.5 5 ATDC
159

(.010 - .016 in)

(.039 in)
0.25 - 0.35 mm
0.01 - 0.02 mm
0.050 mm
0.003 - 0.012 mm

Wear limit
ADDITIONAL INFORMATION : Squish gap : 1.3 - 1.7 mm (.051 - .067 in)
MAG side : 0.05 mm (.002 in)
PTO side : 0.03 mm (.001 in)
0.015 mm
(.010 - .014 in)

(.0004 - .0008 in)
(.002 in)
(.00012 - .00047 in)
(.00059 in)
13-04-1

ELECTRICAL
HX ( 5881)

Spark plug
Ignition timing
(BTDC)
160 W @ 6000 RPM or 4.0 A @ 2000 RPM

CDI
Make and type
NGK BR8ES
Gap
mm (in)
0.5 - 0.6 mm (.020 - .024 in)

2.59 (.102)
Degrees
20 1 ?
40 - 76 y
Generating coil
Ignition coil
.05 - .6 y
Not applicable
Primary
Secondary
9 - 15 ky
7000 ( 50) RPM

Battery
Fuse
Starting system
5A
Charging system
Trim system
15 A
Not applicable
ADDITIONAL INFORMATION : ? Engine cold @ 6000 RPM.
CARBURETION
Carburetor
HX (5881)
Type
Quantity
2
130
Main jet
Pilot jet
Adjustment
75
1-1/2 turn 1/4
Low-speed screw
High-speed screw
Fuel

Type
0
1500 RPM
3000 RPM
Minimum octane no.
87
MAG 0.8 mm (.031 in)
PTO 0.8 mm (.031 in)

COOLING
HX (5881)
Type
Open circuit - Direct flow

None
Thermostat
96-99C (205-210F)
13-04-2

PROPULSION
HX (5881)
Propulsion system
Jet pump type

Counterclockwise
Transmission
Coupling type
Direct drive / split FR and RR

Driving claw with rubber cushion
Oil type

26

10
90 cm

Impeller / wearring clearance
(35 in)
(.020 in)
0.5 mm
New
Wear limit

139.5 mm
0.18 - 0.44 mm
(5.490 in)
(.007 - .017 in)
1.02 mm
0.12 - 0.54 mm
(.040 in)
(.005 - .021 in)
0.05 mm (.002 in)

Progressive pitch 11-24 / stainless steel
DIMENSIONS
HX (5881)
Overall length
Overall width
273 cm
85 cm
(107.5 in)
(33.5 in)
Overall height
Dry weight
97 cm
177 kg
(38.2 in)
(390 lb)

110 kg
(250 lb)
CAPACITIES
HX (5881)
Fuel tank
27 L
Capacity
Oil level height
(7 U.S. gal)
90 mL
(3.0 U.S. oz)
4.0 L
(1.0 U.S. gal)

13-04-3

MATERIALS
HX (5881)
Hull
Inlet grate
Composite
Aluminum
Impeller housing
Plastic
Air intake silencer

Flame arrester
Thermoplastic
Exhaust muffler
Steering padding
Aluminum
Fuel tank
Polyethylene
Polyethylene
Seat
Polyurethane foam
STANDARD EQUIPMENT
HX (5881)
Safety lanyard
Tool kit
Standard
Standard
Fuel tank reserve

Monitoring beeper
Standard
Standard
Electric fuel gauge /low oil warning light

Multifunction gauge
Optional
Optional
Tachometer
Manual trim system
Optional
Standard
Reverse
Storage compartment
Not applicable
Not applicable
Rear grab handle

Extinguisher holder
Standard
Standard
PERFORMANCE
HX (5881)
34.9 kW (46.8 hp)

Cruising time at full
throttle
33 L/h
(8.7 U.S. gal/h)
35 minutes
Fuel tank reserve
10 minutes
13-04-4

TIGHTENING TORQUES
HX (5881)

24 Nm
145 Nm
(17 lbfft)
(107 lbfft)
110 Nm
(81 lbfft)
24 Nm
40 Nm
(17 lbfft)
(30 lbfft)
(3) (4)
(3) (4)

35 Nm
25 Nm
(26 lbfft)
(18 lbfft)
(1)
(1)

24 Nm
24 Nm
(17 lbfft)
(17 lbfft)
(1) (4)
(1) (4)
Tuned pipe nut

25 Nm
25 Nm
(18 lbfft)
(18 lbfft)
(1)
(1)

Impeller
10 Nm
70 Nm
(88 lbfin)
(52 lbfft)
(1)
(2)
Pump / hull nuts

31 Nm
21 Nm
(23 lbfft)
(16 lbfft)
(1)
(1)
VTS ring screws

14 Nm
4 Nm
(10 lbfft)
(35 lbfin)
(1)
Inlet grate screws

Ride shoe screws
8 Nm
10 Nm
(71 lbfin)
(88 lbfin)
(1)
(1)
6 Nm
3 Nm
(53 lbfin)
(26 lbfin)

6 Nm
26 Nm
(53 lbfin)
(19 lbfft)
Ball joint bolt

Steering support bolts
7 Nm
15 Nm
(62 lbfin)
(11 lbfft)
6 Nm
9 Nm
(53 lbfin)
(80 lbfin)

Starter lock nuts
22 Nm
7 Nm
(16 lbfft)
62 lbfin)
(1)
Spark plugs
24 Nm
(17 lbfft)
(5)
Flywheel (PTO side)
PUMP
ENGINE
Crankcase screws
M8
M10
ELECTRICAL
STEERING

Steering cable / lever
Lever pivot bolt

(4)
(1)
(5)
ADDITIONAL INFORMATION : Apply where indicated ;(1) Loctite 242 (blue)

(3) Loctite 515
13-04-5

1996 Seadoo Service Shop Manual

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219 100 031

SAFETY NOTICE ..............................................................................................................

01 - Mandatory Tools ..............................................................................................01-01-1

00 - Table of Contents .............................................................................................02-00-1

TROUBLESHOOTING ..................................................................................................................................... 03-00-1

00 - Table of Contents .............................................................................................04-00-1

00 - Table of Contents .............................................................................................05-00-1

00 - Table of Contents .............................................................................................06-00-1

00 - Table of Contents .............................................................................................07-00-1

00 - Table of Contents .............................................................................................08-00-1

00 - Table of Contents .............................................................................................09-00-1

00 - Table of Contents .............................................................................................10-00-1

00 - Table of Contents .............................................................................................11-00-1

00 - Table of Contents .............................................................................................12-00-1

01 - SP and SPI Models ..........................................................................................13-01-1

1996 BOMBARDIER WATERCRAFT SHOP MANUAL

HULL IDENTIFICATION NUMBER

It is located at right rear side of hull.

1. Engine Identification Number (E.I.N.)

1. Hull Identification Number (H.I.N.)

The Hull Identification Number is composed of 9

787 Engine Only

*This digit may be a number or a letter.

1. Engine Identification Number (E.I.N.)

1996 BOMBARDIER WATERCRAFT SHOP MANUAL

1996 BOMBARDIER WATERCRAFT SHOP MANUAL

Exploded view assits

Bold face number

Tightening torque nearby

Page numbering system :

appropriate torque wrench.

1996 BOMBARDIER WATERCRAFT SHOP MANUAL

Section 06 FUEL SYSTEM

Title indicates main

Sub-sub title in italic

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

NOTE : When removing rotary valve cover , pay

Diaphragm must stand pressure for 10 seconds. If

Letters are used for

Numbers are used

1996 BOMBARDIER WATERCRAFT SHOP MANUAL

219 300 180

219 300 210

219 300 200

Section 01 SERVICE TOOLS AND PRODUCTS

Piston circlip installer

~)~istance ring (MAG)

P/N 290841201 (2)

Section 01 SERVICE TOOLS AND PRODUCTS

PTO flywheel remover/

A) 657, 717 and 787 engines

NOTE : This tool is also