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This Operator’s Guide utilizes the following symbols to emphasize particular information: The Safety Alert Symbol indicates a potential personal injury hazard. Indicates a potentially hazardous situation which, if not avoided, could WARNING result in serious injury or death. CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. NOTE: Indicates supplementary information needed to fully complete an instruction.
FOREWORD The Operator's Guide has been prepared to acquaint the owner/operator with this personal watercraft and its various controls, maintenance and safe riding instructions. It is indispensable for the proper use of the product and should be kept in a waterproof bag with the watercraft at all times. Make sure you read and understand the content of the Operator's Guide.
TABLE OF CONTENTS SAFETY INFORMATION INTRODUCTION .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . . 8 SAFETY CHECK LIST.. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . . 9 General. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. . 9 GETTING UNDERWAY . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . ..
16) Flushing Connector.. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . 17) Bilge Drain Plugs . . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . 18) Jet Pump Nozzle.. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . 19) VTS Adjuster . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . 20) Jet Pump Water Intake .. .. . .
POST-OPERATION CARE.. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . General Care .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . Additional Care for Foul Water or Salt Water .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . . Cooling System Flushing and Engine Internal Lubrication. . .. .. . .. . .. .. . .. . . Anticorrosion Treatment. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .
TROUBLESHOOTING . . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . 93 SPECIFICATIONS . . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . 97 INTERNATIONAL SYSTEM METRIC INFORMATION . .. .. . .. . .. .. . .. . .. .. . .. 100 ABBREVIATIONS USED IN THIS MANUAL . . .. .. . .. . .. .. . .. . .. .. . .. .. . .. . .. ..
SAFETY INFORMATION ____________ SAFETY INFORMATION www.SeaDooManuals.
INTRODUCTION Congratulations, you are now the proud owner of a Sea-Doo personal watercraft. You have selected one of the most popular craft on water. Your Sea-Doo® personal watercraft (PWC) can provide you and your family or friends the opportunity to fully enjoy the natural beauty and excitement of the world’s waterways. Welcome to fun on water! With this new enjoyment and freedom however comes the responsibility of safety for yourself, the people you lend your craft to, and other water users.
SAFETY CHECK LIST To fully appreciate the pleasures, enjoyment and excitement of boating there are some basic rules that should be observed and followed by any boater. Failure to follow this safety information and safe boating rules could result in injury, including the possibility of death to you, the people you lend your watercraft to, or other water users. General BRP recommends a minimum operator age of 16 years old. A boating safety course is recommended and may be required in your province or state.
GETTING UNDERWAY To Wear The operator must wear a Coast Guard approved Personal Flotation Device (PFD) that is suitable for PWC use. An operator should have ready access to shatterproof glasses should riding conditions or personal preference warrant. Wind, water spray and speed may cause a person’s eyes to water and create blurred vision. The operator of PWCs must wear protective clothing, including: – a wet suit bottom or thick, tightly woven, snug fitting clothing that provides equivalent protection.
Eye protection Vest-type personal flotation device Gloves Wet suit or wet suit bottom Foot protection F00A12L ____________ SAFETY INFORMATION ___________ www.SeaDooManuals.
Helmets Some Important Considerations Helmets are designed to offer some degree of protection in case of impact to the head. In most motorized sports, the benefits of wearing a helmet clearly outweigh the drawbacks. However, in the case of motorized watersports such as riding personal watercraft, this is not necessarily true as there are some particular risks associated with the water.
To Do Read and understand all warning/caution labels on your Sea-Doo PWC, your Operator’s Guide, all other safety documents, and watch properly your safety videocassette, before operating. Always keep in mind that the ““ symbol, the Warning symbol, identifies an instruction which, if not followed, may cause serious personal injuries including the possibility of death. Check local and federal boating laws applicable to the waterways where you intend to use your watercraft. Learn the local rules of the road.
OPERATION Collision Avoidance Do not release throttle when trying to steer away from objects. You need throttle to steer. Always keep a constant lookout for other water users, other boats or objects, especially when turning. Be alert for conditions that may limit your visibility or block your vision of others. Respect the rights of other recreationists and/or bystanders and always keep a safe distance from all other craft, people and objects.
In shallow water, proceed with caution and at very low speeds. Grounding or abrupt stops may result in injury. Debris may also be picked up and be thrown rearward by the jet pump onto people or property. PWCs are not designed for night-time operation. Never turn handlebar while someone is nearby rear of watercraft. Keep away from steering moving parts (nozzle, linkage, etc.). Never operate this watercraft with a passenger onboard. This watercraft is for one (1) operator only. No passenger.
OPERATING RULES Operating a watercraft can be compared with driving unmarked highways and roads. To prevent collisions or avoid other boaters, a system of operating rules must be followed. It’s not only common sense... it’s the law! Remember these Rules of the Road Know the Right of Way Rules Generally keep to your right and safely avoid other craft by keeping a safe distance from other craft, people and objects. Meeting Head-On Keep right.
WEB SITES Sea-Doo website: www.sea-doo.com Alabama www.ccg-gcc.gc.ca/obs-bsn/sbg-gsn/ main_e.htm www.uscgboating.org/regulations/ boating_laws.htm www.dcnr.state.al.us/mp/menu.htm Alaska www.dnr.state.ak.us/parks/boating Arizona www.azgfd.com Arkansas www.agfc.state.ar.us/ California www.dbw.ca.gov Colorado http://parks.state.co.us/boating/ Connecticut http://dep.state.ct.us/rec/prgactiv.htm Delaware www.dnrec.state.de.us/fw/index.htm Florida (freshwater) http://floridaconservation.
New Hampshire www.state.nh.us/safety/ss/links.html New Jersey North Dakota www.state.nj.us/mvs/boats.htm www.emnrd.state.nm.us/nmparks/pages/ question/regulate/rules/nmac172.pdf www.ncwildlife.org/ fs_index_02_regulations.htm http://www.state.nd.us/gnf/boating/ Ohio www.dnr.state.oh.us/odnr/watercraft Oregon www.osmb.state.or.us Pennsylvania www.fish.state.pa.us Rhode Island www.state.ri.us/dem/topics/boating.htm South Carolina Tennessee www.dnr.state.sc.us/etc/boating.html www.state.sd.
LOCATION OF THE IMPORTANT LABELS The following labels are on your watercraft. If missing or damaged, they can be replaced free of charge. See an authorized Sea-Doo dealer. Please read the following labels carefully before operating this watercraft. 13 1-6-10 3 14 2-5-7-9 4 8 F22L02L 11 F22L03L “MOTO“ CONFIGURATION ____________ SAFETY INFORMATION ___________ www.SeaDooManuals.
12 F22L04L KART SEAT CONFIGURATION (IF SO EQUIPPED) Label 1 To reduce the risk of SEVERE INJURY or DEATH: WEAR A PERSONAL FLOTATION DEVICE (PFD). All riders must wear a Coast Guard approved PFD that is suitable for personal watercraft (PWC) use. WEAR PROTECTIVE CLOTHING. Severe internal injuries can occur if water is forced into body cavities as a result of falling into water or being near jet thrust nozzle.
Label 2 Label 4 F00A22Y Label 3 F22A02Y Label 5 F02L2D0 F00A23Y Label 6 F22A03L ____________ SAFETY INFORMATION ___________ www.SeaDooManuals.
Label 7 F22A09L Label 8 Label 10 WARNING / AVERTISSEMENT PRESSURIZED FUEL Do not unscrew protective cap. Must be used only by Bombardier certified technician. Do not operate the watercraft without cap properly installed. F00A2QY ESSENCE SOUS PRESSION Ne pas dévisser le capuchon protecteur. Réservé seulement à lusage dun technicien certifié par Bombardier. Ne pas opérer la motomarine sans le capuchon bien installé.
Label 12 F22A06Y Label 13 F22A07Y Label 14 F22A08Y ____________ SAFETY INFORMATION ___________ www.SeaDooManuals.
VEHICLE INFORMATION _____________________ www.SeaDooManuals.
REGISTRATION NUMBER LOCATION All personal watercraft are required by federal law to be registered and legally numbered. Due to space availability for proper display of registration number, refer to following illustration for location. The registration number should appear on each side of the watercraft. F22L0BL 1 1. Registration number location NOTE: The registration number must be above the water line. Ensure also that the numbers are of the correct size and color.
IDENTIFICATION NUMBERS The main components of the watercraft (engine and hull) are identified by different serial numbers. It may sometimes become necessary to locate these numbers for warranty purposes or to trace the watercraft in the event of theft. Engine The Engine Identification Number (E.I.N.) is located on the upper crankcase on PTO (Power Take-Off) side. Hull The Hull Identification Number (H.I.N.) is located on platform at the rear of watercraft. F01D87Y 1 1. Engine Identification Number (E.
CONTROLS/INSTRUMENTS/EQUIPMENTS NOTE: Some components do not apply or are optional on some models. 7 9 12 8 13 12-16 10 15 17 11 24 20 6 2 5 21 4 25 1 3 F22L07L “VERT” CONFIGURATION 28 18-19 14 23 ______________________ www.SeaDooManuals.
27 26 F22L03N “MOTO” CONFIGURATION 29 28 F22L04M KART CONFIGURATION (IF SO EQUIPPED) 1. Safety Lanyard (engine cut-off cord) 2. Handlebar 3. Handlebar Adjuster 4. Throttle Lever 5. Engine Start/Stop Button 6. Indicator Light Cluster 7. Steering Pole 8. Fuel Tank Cap 9. Engine Cover Latch 10. Oil Injection Reservoir Cap 11. Air Intake Opening 12. Bow and Stern Eyelets 13. Boarding Pad 14. Rear Platform 15. Cooling System Bleed Outlet 16. Flushing Connector 17. Bilge Drain Plugs 18.
CONTROLS/INSTRUMENTS/EQUIPMENTS FUNCTIONS 1) Safety Lanyard (engine cut-off cord) The safety lanyard cap should be securely snapped onto its post to be fully operational. 1 1 2 F22L1TY 1. Safety lanyard cap on the post 2. Safety lanyard secured on operator's PFD F22L0CY 1. Safety lanyard on its post Pulling the safety lanyard cap from its post stops the engine operation.
If engine is not started within 5 seconds after installing the safety lanyard on its post, 4 very short beeps every 3 second interval will sound for approximately 2 hours to remind you to start the engine or to remove safety lanyard. Afterwards, the beeps will stop. The same will occur when safety lanyard is left on its post 5 seconds after engine is stopped. Always ensure safety lanyard is not left on its post after engine is stopped.
C 1 3 5 B 1 1 3 A 2 3 4 F22K01Y A. B. C. 1. 2. 3. 4. 5. Rearward position Middle position Forward position Handlebar adjuster Handlebar Start/stop buttons Index finger position Thumb position 4) Throttle Lever When the throttle lever is squeezed, the watercraft accelerates. When fully released, engine automatically slows down to idle speed and watercraft is gradually stopped by water drag. Adjusting handlebar height changes the throttle lever position. Refer to HANDLEBAR ADJUSTER above.
1 F22K03Y 1. Engine start/stop buttons 6) Indicator Light Cluster 1 3 2 4 The warning light will turn on whenever there is a problem with the engine management system. It will blink when there is a problem with the O.T.A.S.TM system or the electric bilge pump. NOTE: When engine is not running and safety lanyard is on its post, the warning light will remain turned on until safety lanyard is removed.
Ensure to adjust handlebar to the desired position before use. Refer to HANDLEBAR ADJUSTER. 8) Fuel Tank Cap Unscrew the cap counterclockwise. After fueling, reinstall cap and fully tighten. First, stop the engine then raise and stabilize the steering pole at its highest position. Pull the latch lever upward to unlock the engine cover. Lift up the rear portion of engine cover, and pull rearward to remove. 1 WARNING Always stop the engine before refueling.
1 1 F22L16Y F22L0EY 1. Holder end here 1. Insert holder here WARNING Components inside engine compartment may be hot. When starting or operating the engine, do not touch any electrical part. Never leave any object, rag, tool, etc., in the engine compartment or in the bilge. 2 Ensure fire extinguisher is properly positioned in its location prior to reinstalling engine cover. When reinstalling engine cover, properly insert engine cover tab into C-hook of body.
10) Oil Injection Reservoir Cap 1 Remove engine cover to expose oil reservoir cap. Lock steering pole with the holder. WARNING 2 Always install steering pole holder immediately after engine cover removal to support the pole securely while working in the engine compartment. F22L0FY 1. Tab 2. C-hook 1 Ensure to relatch engine cover. If engine cover cannot be latched, check position of fire extinguisher and if objects on storage tray prevent engine cover to latch.
11) Air Intake Opening 13) Boarding Pads Allows air into the bilge for ventilation purposes and engine supply. If the air intake opening is kept under water, water will get inside the bilge under certain circumstances. Provide a cushioned surface for the knees when boarding. CAUTION: If the air intake opening is kept under water, such as when turning constantly in tight circles, water will get inside the bilge, which may cause severe damage to internal parts of the engine.
18) Jet Pump Nozzle Jet pump nozzle turns side to side via rider input at the handlebar. This provides directional control when engine is running. 1 1 F22J01Y 1. Flushing connector Refer to POST-OPERATION CARE section for proper use. 2 17) Bilge Drain Plugs Should water be found in the bilge, it can be easily drained by unscrewing the drain plugs when engine is off and watercraft is out of the water. CAUTION: Always take the watercraft out of the water prior to unscrewing drain plugs. 1 F22J02Y 1.
21) Fuses The fuses are located in the engine compartment. Refer to MAINTENANCE for more details. 8 6 4 2 0 2 4 6 8 2 1 22) Battery The battery is located in the engine compartment. Refer to SPECIAL PROCEDURES. F05J02Y 1. Trim knob 2. Reference numbers 23) Rear Access Cover 20) Jet Pump Water Intake stalled, stow it into steering pole. Refer to “MOTO” SEAT INSTALLATION/ STOWAGE. If the kart seat is installed, remove it. Refer to KART SEAT INSTALLATION/REMOVAL.
When safety lanyard cap is installed on its post, the bilge pump is automatically turned on. It will remain on until all water is evacuated,then it will shut down automatically. When engine is running, the bilge pump will automatically start periodically to evacuate water. 1 25) “Moto” Seat Release Button This button is used to unlatch the “moto“ seat stowed into the steering pole.
CAUTION: Ensure to maintain the seat high enough so as to have room to pull the seat post out without touching the body. Pull the red locking lever rearward and pull the post out of the seat. 1 1 2 F22L0NY 1. Post vertical 2. Receiver F22L0MY Lift the receiver cap and hold open while inserting the seat post in receiver. Ensure post knuckle is fully inserted into the receiver. 1. Lock lever 1 F22L0OY F22L0SZ 1.
1 2 1 F22L0PY F22L0QY 1. Slide seat rearward 2. Firmly push seat down 1. Hold steering pole Ensure the seat is properly locked by pulling up on it. Push the seat forward so that the seat post becomes vertical. Lift the seat to release the post from its receiver. WARNING To avoid loss of control, always ensure that the seat is properly locked in prior to operating the watercraft. Adjust steering to the desired position before use. Refer to HANDLEBAR ADJUSTER.
26) “Moto” Seat Post Receiver The receiver locks the seat post into position on the deck. For instructions, refer to “MOTO” SEAT INSTALLATION/STOWAGE above. 1 F22L0SY Firmly push the post in the seat until you hear a “clunk“. CAUTION: Make sure to maintain the seat high enough so that the post clears the body when rotated forward into the seat. Make sure that the post is latched properly. Keep steering pole high enough and rotate seat in steering pole.
Seat Installation WARNING Before installing or removing kart seat: Only install or remove the kart seat when the watercraft is out of the water or docked securely on calm water. With the seat slightly angled forward, insert the seat front tab into the anchor plate on the deck. Line up the pin located underneath the seat with the hole in the deck, then push down to latch the seat. The spacers have 2 steps to accommodate different rider heights. Use the one that best suits your leg size.
Continue lowering the steering pole down until the retainer can be inserted into the body hook. Then, push retainer to lock in position. 3 1 2 F22L0ZY 2 1. Lever 2. Push and hold 3. Lift seat CAUTION: To prevent permanent deformation of the foam shape, always store the seat right side up and never leave any object on it. F22L11Y 1 1. Position retainer in body hook 2.
LIQUIDS CAUTION: Scrupulously follow the instructions of this section. Failure to do so may reduce the engine’s life and/or performance. Fueling Procedure Use unleaded regular gasoline with the following recommended minimum octane number. LOCATION WARNING Inside North America Follow these safe boating fueling instructions explicitly. Turn off engine. Do not allow anyone to remain on the watercraft. Tie watercraft securely to the fueling pier. Have a fire extinguisher close at hand.
Oil Injection System MODELS OIL TYPE 3DTM RFITM BOMBARDIER* FORMULA XP-S II synthetic injection oil (1) CAUTION: (1) The BOMBARDIER Formula XP-S II oil is specially formulated and tested for the severe requirements of the 787 RFI engines. Use of any other brand two-stroke oil may void the limited warranty. Use only BOMBARDIER FORMULA XP-S II oil. There is no known equivalent on the market for the moment. If a high quality equivalent were available, it could be used.
BREAK-IN PERIOD CAUTION: Scrupulously follow the instructions of this section. Failure to do so may reduce the engine’s life and/or performance. With Sea-Doo watercraft powered by Rotax® engines, a break-in period of 10 hours is required before continuous operation at full throttle. To achieve a good break-in, throttle lever should not be depressed more than 3/4, however, brief acceleration and speed variations contribute to a good break-in.
PRE-OPERATION CHECKS WARNING The pre-operation check is very important prior to operating the watercraft. Always check the proper operation of critical controls, safety features and mechanical components, before starting as listed hereinafter. If not done as specified here, severe injury or death might occur. Bring all safety equipment required by local laws.
Hull Inspect hull for cracks or damage. Jet Pump Water Intake Remove weeds, shells, debris or anything else that could restrict the flow of water and damage cooling system or propulsion unit. Clean as necessary. If any obstruction can not be removed, refer to an authorized Sea-Doo dealer for servicing. Inspect leading edges of the impeller, if they have nicks or bends performance will be greatly reduced.
Battery Steering Pole WARNING Verify tightness of battery cables to their posts and condition of battery retaining bracket(s)/fasteners. Do not charge or boost battery while installed. Fuel Tank and Oil Reservoir With the watercraft horizontal, fill the fuel tank. Check the oil level and refill reservoir as necessary. Check fuel tank and oil reservoir retaining straps/fasteners. Check steering pole up and down movement for free and smooth operation. Pay attention to the weight feeling of the pole.
Optional Configurations Refer to CONTROLS/INSTRUMENTS/ EQUIPMENTS. WARNING To make sure you are in a riding position that allows you to be in control of the craft, always check that any optional seat or accessory that you are using are properly latched and stable before turning on the watercraft engine. 52 ______________________ www.SeaDooManuals.
OPERATING INSTRUCTIONS WARNING Always perform the PRE-OPERATION CHECKS before operating the watercraft. Become thoroughly familiar with all controls and the function of each. Should any control or instruction not be fully understood, refer to an authorized Sea-Doo dealer. This watercraft is designed for one person only. F22L1AY WARNING - Never allow a passenger onboard. This watercraft is for an operator only.
When first using the watercraft, the operator should become familiar with the use of the variable trim system (VTS) at varying speeds and water conditions. A mid-range trim is generally used when cruising. Experience alone will dictate the best trim for the conditions. During the watercraft break-in period, when lower speeds are recommended, it is an excellent opportunity to gain familiarity of trim adjustment and its effects.
WARNING Throttle should be applied and handlebar turned to change the direction of the watercraft. Steering efficiency will differ depending on load, water conditions and environmental factors such as the wind. Unlike a car, a watercraft needs some throttle to turn. Practice in a safe area applying the throttle and turning away from an imaginary object. This is a good collision avoidance technique.
We recommend that you familiarize yourself with this feature during your first ride. Boarding the Watercraft General As with any watercraft, boarding should be done carefully and engine should not be running. WARNING Engine should be OFF when boarding the watercraft. Keep limbs away from jet or intake grate. WARNING Inexperienced riders should practice how to get aboard (all methods explained here) close to shore first before venturing into deep water.
CAUTION: Starting the engine or operating the watercraft in shallow water can draw sand, pebbles, or rocks through the jet pump, which might damage the impeller or other pump components. Boarding in Deep Water Swim to the rear of the watercraft. F22L1IY F22L1FY Put your hands on the boarding platform and pull yourself up until your knee can reach the boarding platform, then get on. F22L1JY NOTE: When boarding a watercraft with the “moto“ seat configuration, you can find helpful to use the seat strap.
F22L1QY F22L1MY F22L1RY F22L1NY NOTE: When boarding a watercraft with the kart seat configuration (if so equipped), you can use the seat as an additional support point to keep your balance. F22L1SY Once aboard, take the appropriate riding position. Starting F22L1OY Preparation Before unloading the watercraft from the trailer, it can be started for about 10 seconds to verify proper operation. WARNING F22L1PY Components inside the engine compartment may be hot.
NOTE: If you hear anything other than 2 short beeps from DESS system, it indicates a particular condition that should be corrected. Refer to the TROUBLESHOOTING section for the meaning of the coded signal. WARNING Before starting the engine, the operator should always be properly seated or have a stable stance in the “vert“ configuration. Firmly grip the handlebar with your hands and properly place both feet on the floorboard.
WARNING CAUTION: Hanging to handlebar while falling might damage the steering pole or other components. The steering pole length multiply the effect of your weight and this creates an important stress on the watercraft components. WARNING In the “vert” configuration, the proper riding position is for the operator to be on the rear platform of the deck, behind the handlebar.
Rough Water or Poor Visibility Operation Avoid operation in these conditions. If you must do so, proceed with caution and prudence using minimum speed. Crossing Waves Reduce speed. Always be prepared to steer and balance as necessary. When crossing wakes, always keep a safe distance from watercraft ahead. WARNING When crossing wakes, slow down. Operator can brace himself by posting. Do not jump waves or wakes. Stopping/Docking The watercraft is slowed down by water drag.
Shutting Off the Engine To keep watercraft directional control, the engine should be running until the watercraft is at idle. To shut off the engine, completely release throttle lever and press the engine start/stop button. Remove safety lanyard from watercraft. WARNING Should the engine be shut off, watercraft directional control is lost.
POST-OPERATION CARE WARNING Allow engine to cool before performing any maintenance. General Care Take the watercraft out of the water every day to prevent marine organism growth. Should any water be present in the bilge, install safety lanyard on its post to start the electric bilge pump. If some water remains, unscrew the drain plugs and tilt the watercraft rearward in order to allow water to flow out. Wipe off any remaining fluid in the engine compartment (bilge, engine, battery, etc.
NOTE: The quick connect adapter has to be removed once the procedure is completed. Flushing and Lubrication To flush cooling system, start the engine then immediately open the water tap. WARNING Components inside the engine compartment may be hot. Keep away from electrical parts or jet pump area when engine is running. CAUTION: Never flush a hot engine. Always start the engine before opening the water tap. Open the water tap immediately after engine is started to prevent overheating.
Remove both spark plugs and spray BOMBARDIER LUBE or an equivalent lubricant into each cylinder. Remove safety lanyard from its post. Depress the throttle lever at full throttle position and hold. Reinstall the safety lanyard cap on its post. Crank the engine a few turns to distribute the oil on the cylinder walls. NOTE: Proceeding in this order, no fuel will be injected into the engine. Apply anti-seize lubricant on spark plug threads then reinstall them.
SPECIAL PROCEDURES Monitoring System To assist you when operating the watercraft, a system monitors some component of the watercraft and sends audible signals from a beeper or light up a warning light to inform you of a particular condition. Refer to the TROUBLESHOOTING section for the coded signals chart. Engine Overheating CAUTION: If the monitoring beeper continuously sounds, stop engine immediately. Perform JET PUMP WATER INTAKE AND IMPELLER CLEANING procedure described in this section.
CAUTION: The longer the delay before you have the engine serviced, the greater will be the risk and severity of the damage will be to the engine. Water-Flooded Engine In the event the engine cannot be serviced within a few hours, 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. Be careful when cranking engine, water will spray out from spark plug holes.
Remove safety lanyard from its post. Depress and hold the throttle lever to full throttle position. Wait 2 seconds then, reinstall the safety lanyard cap while keeping throttle lever fully depressed. Crank engine approximately 5 seconds. Release throttle lever and crank again to start engine. If this does not work: Remove spark plug cables and connect them on the grounding device. WARNING Always use spark plug cable grounding device whenever removing spark plugs.
CAUTION: When done towing the watercraft, the hose pincher must be removed before operation. Failure to do so will result in severe damage to the engine. Low-Charge Battery Condition See an authorized Sea-Doo dealer to recharge or replace the battery. WARNING Do not charge or boost the battery while installed in the watercraft. Electrolyte is poisonous and dangerous. Avoid contact with eyes, skin or clothing. _____________________ www.SeaDooManuals.
MAINTENANCE INFORMATION _____________________ www.SeaDooManuals.
Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine SI (spark ignition) engine repair establishments or individual. Engine Emissions Information Manufacturer's Responsibility Beginning with 1999 model year engines, PWC manufacturers of marine engines must determine the exhaust emission levels for each engine horsepower family and certify these engines with the United States of America Environmental Protection Agency (EPA).
General Only perform servicing procedures which are detailed in this safety section. Further assistance or information can be obtained from your authorized Sea-Doo dealer. In many instances proper tools and training is required for certain servicing or repair procedures. Maintain the watercraft and equipment in top condition at all times. Adhere to the prescribed maintenance schedules. An annual inspection of the watercraft is always a good recommendation that should be followed.
MAINTENANCE CHART Periodic Inspection Routine maintenance is necessary for all mechanical products. A periodic inspection contributes to the product’s life span. The following maintenance chart gives guidelines for regular watercraft servicing scheduled to be performed by you and/or by an authorized Sea-Doo dealer. The schedule should be adjusted according to operating conditions and use.
I: Inspect, verify, clean, adjust, lubricate or replace if necessary C: Clean EVERY First 10 h L: Lubricate R: Replace 25 h 50 h 100 h or or or 3 months 6 months 1 year To be performed by FUEL SYSTEM (1) Throttle cable I Customer Fuel filter Fuel injection system sensors (except throttle body) (5) I Fuel vent line pressure relief valve Fuel lines, connections, check-valve and fuel system pressurization (5) Throttle body, sensors, fuel lines, fuel rail and fittings (5) R Dealer I Dealer I De
I: Inspect, verify, clean, adjust, lubricate or replace if necessary C: Clean EVERY First 10 h L: Lubricate R: Replace 25 h 50 h 100 h or or or 3 months 6 months 1 year To be performed by O.T.A.S.TM SYSTEM O.T.A.S.
MAINTENANCE WARNING Only perform procedures as detailed in this guide. It is recommended that the assistance of an authorized Sea-Doo dealer be periodically obtained on other components/systems not covered in this guide. Unless otherwise specified, engine must not be running and the safety lanyard must be removed from its post for all maintenance procedures. Components inside engine compartment may be hot. Never use jet pump components or steering pole to lift the watercraft.
Throttle Cable Inspection Throttle Cable Depress and release the throttle lever. It should operate smoothly and return to its initial position without any hesitation. Repeat the test for each adjustable handlebar position. Refer to an authorized Sea-Doo dealer if necessary. WARNING CAUTION: An obstructed oil filter will cause oil starvation resulting in serious engine damage.
2 1 4 3 F22L0S0 1. 2. 3. 4. F22L061 WARNING If any of the above tests fail, do not operate the watercraft and refer to an authorized Sea-Doo dealer. Handlebar and Adjuster Operation Move handlebar to each position. It should move easily and lock in each position. Make sure there is no excessive play in the handlebar. WARNING If any of the above tests fail, do not operate the watercraft and refer to an authorized Sea-Doo dealer.
2 4 3 1 1 F22J020 2 F22L0YZ 1. Check seat tab and anchor plate 2. Check latch mechanism WARNING If any of the above tests fail, do not use the kart seat and refer to an authorized Sea-Doo dealer. All Models O.T.A.S.TM System This test is to be performed with the watercraft in the water. Make sure the path ahead is clear. Run the watercraft and bring it to a planing speed (above 4000 RPM) then release throttle lever. Turn handlebar all the way on one side within 3 seconds.
Fuses If an electrical problem occurs, check the fuses. If a fuse is burnt, replace by one of the same rating. Follow procedures below. 2 1 1 2 3 F22H03Y 1. Engine 2. MPEM Fuse ratings are identified on the MPEM. Look for them beside the fuse holder. SPR means spare (fuse). A15E0KZ 1. Fuse 2. Check if melted 3. Ampere rating WARNING Never use a higher rated fuse as this can cause severe damage.
1 2 1 F06H1TY 2 1. Fuse cover 2. Fuse tabs F22L0FY Main Fuse The main fuse is located beside the VCM. 2 1 1. Tab 2. C-hook NOTE: Verify periodically that the latch pin for the engine cover is tight in the body. Tighten if needed and make sure engine cover latches properly. Check engine compartment for any damage or leaks from the fuel/oil injection systems. Ensure all hose clamps are secure and no hose is cracked, kinked or shows any other damage. WARNING F22H02Y 1. VCM 2.
Occasionally, wash the body with water and soap (only use mild detergent). Remove any marine organisms from engine and/or hull. Apply non-abrasive wax such as silicone wax. CAUTION: Never clean fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc. To clean the engine cover and the steering pole nose and top pieces, use only flannel cloths or an equivalent. 1 F22L0H0 1.
TRAILERING, STORAGE AND PRESEASON PREPARATION Trailering Make sure that the oil reservoir and fuel tank caps are installed and tight. WARNING Never tip this vehicle on its end for transportation. We recommend that you carry the vehicle in its normal operating position. Check the laws and regulations in your area that apply, especially the rules pertaining to: – brake system – tow vehicle weight – mirrors.
1 Engine Draining Check engine drain hose (lowest hose of engine). Make sure it is free of sand or other particles and unobstructed so that water can drain out of the engine. Clean hose and fitting as necessary. CAUTION: Water in engine drain F22L15Y 1. Tie down steering pole here CAUTION: Trailering the watercraft without properly tying down steering pole might result in damage to the watercraft. All Models Always observe all trailering safety precautions.
NOTE: It may be necessary to position the end of the hose in a lower area of the bilge to allow proper drainage. 2 Fuel System Sea-Doo fuel stabilizer (or equivalent), can be added in fuel tank to prevent fuel deterioration and gumming. Follow manufacturer’s instructions for proper use. CAUTION: Fuel stabilizer should be added prior to engine lubrication to ensure fuel system components protection against varnish deposits. WARNING F17E0BY 1 TYPICAL 1. Fitting 2. Hose Reconnect hose when done.
CAUTION: Antifreeze must be fed in cooling system. Otherwise remaining water will freeze (approximately 500 mL (.5 U.S. qt) in tuned pipe water jackets). This operation requires a good technical knowledge of the cooling system path. If antifreezing is not performed adequately, any water left in the engine/exhaust system could freeze and cause severe damage. We strongly recommend this operation to be performed by an authorized Sea-Doo dealer. CAUTION: Use only undiluted antifreeze (100% concentration).
NOTE: Most of the antifreeze will drain out when removing the hose pinchers. ALWAYS DISPOSE OF ANTIFREEZE IN ACCORDANCE WITH YOUR LOCAL LAWS AND REGULATIONS. Remove the temporary hose from engine and reinstall the water supply hose to the cylinder head. Remove hose pincher from engine outlet hose. Procedure for Exhaust Pipe and Muffler Disconnect hose as shown. 1 F22E02Y 1. Hose properly connected Insert a funnel into the temporary hose and pour in 1.3L (1.4 U.S.
NOTE: It is important to use the entire quantity prescribed above to ensure a strong enough final antifreeze concentration in the system once the procedure is complete. During the draining process, some water always remain trapped in a few cooling passages, which tends to dilute the antifreeze and reduce the concentration. Circulating enough antifreeze gradually increases the mixture concentration to reach the appropriate level. CAUTION: Do not reuse water/antifreeze mixture that came out of the engine.
Preseason Preparation Use the following chart. Since technical skills and special tools are required, some operations should be performed by an authorized SeaDoo dealer. WARNING Only perform procedures as detailed in this guide. It is recommended that the assistance of an authorized Sea-Doo dealer be periodically obtained on other components/ systems not covered in this guide.
Preseason Preparation Chart NOTE: It is highly recommended that an authorized Sea-Doo dealer perform the annual safety inspection and factory campaigns in addition to the preseason preparation all at the same time. GENERAL ENGINE COOLING SYSTEM OPERATIONS TO BE PERFORMED BY Lubrication/corrosion protection Operator (1) Dealer Exhaust system condition (fasteners, hoses etc.
OPERATIONS TO BE PERFORMED BY O.T.A.S.TM SYSTEM Check O.T.A.S. system operation Dealer PROPULSION SYSTEM VTS (Variable Trim System) Dealer Propulsion system inspection Dealer Jet pump oil replacement Dealer Inspection of bailer pick-ups Dealer Kart seat (if so equipped) Dealer HULL AND BODY (1) Before installing new spark plugs, it is suggested to burn the excess BOMBARDIER LUBE lubricant or equivalent by starting the engine using the old spark plugs.
TROUBLESHOOTING The following chart is provided to help in diagnosing the probable source of simple troubles. You may be able to solve many of these problems rather quickly, but others may require the skills of a mechanical technician. In such cases, consult an authorized Sea-Doo dealer for servicing. Monitoring Beeper Coded Signals CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps (while installing safety lanyard on post). Confirms safety lanyard signal operation. Engine can be started.
Engine Will Not Start OTHER OBSERVATION Engine does not turn over. POSSIBLE CAUSE Safety lanyard removed. Install cap over post. Burnt fuse on MPEM: battery, or main fuse. Check wiring then replace fuse(s). Discharged battery. Refer to an authorized Sea-Doo dealer. Battery connections, corroded or loose. Refer to an authorized Sea-Doo dealer. Water-flooded engine. Refer to WATER-FLOODED ENGINE in SPECIAL PROCEDURES. Faulty sensor or MPEM. Refer to an authorized Sea-Doo dealer. Seized engine.
OTHER OBSERVATION Lean fuel mixture. Rich fuel mixture (high fuel consumption). POSSIBLE CAUSE REMEDY Fuel: Level too low, stale or water-contaminated. Siphon and/or refill. Fuel filter clogged. Refer to an authorized Sea-Doo dealer. Clogged injectors. Refer to an authorized Sea-Doo dealer. Defective sensor or MPEM. Refer to an authorized Sea-Doo dealer. Flame arrester dirty/clogged. Clean or replace. Defective sensor or MPEM. Refer to an authorized Sea-Doo dealer.
Engine Lacks Acceleration or Power OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark. Refer to engine MISFIRES, RUNS IRREGULARLY. Water in fuel or injection oil. Siphon and replace. Watercraft Can Not Reach Top Speed OTHER OBSERVATION POSSIBLE CAUSE VTS is adjusted to suit other riding conditions. Cavitation. REMEDY Readjust to try another setting. Jet pump water intake clogged. Clean. Damaged impeller. Replace. Refer to an authorized Sea-Doo dealer. Damaged wear ring. Replace.
SPECIFICATIONS 3DTM RFITM (6157/6158) VEHICLES ENGINE Rotax® 787 RFITM , 2-stroke Type Induction Type Rotary valve Exhaust system Water cooled Exhaust valve Rotax Adjustable Variable Exhaust (RAVE) Type Lubrication Oil injection BOMBARDIER FORMULA XP-S II synthetic injection oil Oil type Number of cylinders 2 Displacement 781.6 cc (47.7 cu. in) Bore 82 mm (3.228 in) Stroke 74 mm (2.91 in) 6.
3DTM RFITM (6157/6158) VEHICLES FUEL SYSTEM Fuel Type Regular unleaded gasoline Minimum octane number Fuel injection Inside North America: 87 (R + M) / 2 Outside North America: 91 RON Rotax fuel injection (RFITM) Single throttle body (56 mm (2.21 in)) PROPULSION Propulsion system Bombardier Formula pump Jet pump type Axial flow, single stage, needle bearing Transmission Direct drive Reverse system No O.T.A.S.
3DTM RFITM (6157/6158) VEHICLES CAPACITIES Fuel tank (including reserve) 32 L (8.5 U.S. gal) Fuel tank reserve (from low level signal) 5 L (1.3 U.S. gal) Oil injection reservoir Impeller shaft reservoir 4 L (1 U.S. gal) Capacity 100 mL (3.4 U.S. gal) Oil level Up to plug N.A.: Not applicable (1) Refer to load limit. Bombardier Recreational Products Inc.
INTERNATIONAL SYSTEM METRIC INFORMATION BASE UNITS DESCRIPTION UNIT length ................................................. meter ................................ mass .................................................. kilogram ............................ force................................................... newton.............................. liquid .................................................. liter .................................... temperature .......................................
ABBREVIATIONS USED IN THIS MANUAL ABBREVIATION DESCRIPTION AC Alternate current API American petroleum institute CARB California air resource board DC Direct current DESS Digitally encoded security system ECM Engine control module ECU Electronic control unit EMS Engine management system E.I.N.
WARRANTY _____________________ 103 www.SeaDooManuals.
NORTH AMERICA USA (Except Puerto Rico) CANADA BOMBARDIER MOTOR CORPORATION OF AMERICA 7575 Bombardier Court Wausau, WI. 54401 Phone: (715) 848-4957 Fax: (715) 847-6879 www.brp.com BOMBARDIER RECREATIONAL PRODUCTS INC. 75 J.A. Bombardier Sherbrooke, QC J1L 1W3 Phone: (819) 566–3366 Fax: (819) 566–3062 www.brp.com If your Sea-Doo watercraft requires warranty service, you should take it to any authorized Sea-Doo dealer.
BRP NORTH AMERICA LIMITED WARRANTY: 2004 SEA-DOO ® 3DTM RFITM PERSONAL WATERCRAFT 1. SCOPE Bombardier Recreational Products Inc. (“BRP”)* warrants its model-year 2004 Sea-Doo 3D RFI personal watercraft from defects in material or workmanship for the period and under the conditions described below.
Fuel Pump Airbox and Flame Arrester Cylinder Head All Emission Component Related Gaskets; Head, Base, Exhaust The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
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CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT FOR MODEL-YEAR 2004 SEA-DOO® PERSONAL WATERCRAFT WITH RFITM ENGINES. Your Sea-Doo personal watercraft may have a special environmental label required by the California Air Resources Board. The label has 1, 2, 3 or 4 stars. A hangtag, provided with your personal watercraft, describes the meaning of the star rating system.
Three Stars - Ultra Low Emission The three-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star Low Emission engines.
Select emission control parts of your 2004 Sea-Doo personal watercraft equipped with RFI engine are warranted from the date of delivery to the first retail consumer for a period of 4 years, or for 250 hours of use, whichever occurs first. However, warranty coverage based on the hourly period is only permitted for personal watercraft equipped with the appropriate hour meters or their equivalent.
Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted by BRP for the period of time before the first scheduled replacement date for that part. Emission warranty parts that are scheduled for regular inspection, but not regular replacement, are warranted by BRP for the entire warranty period of the personal watercraft.
BRP INTERNATIONAL LIMITED WARRANTY: 2004 SEA-DOO ® 3DTM RFITM PERSONAL WATERCRAFT 1. SCOPE Bombardier Recreational Products Inc. (“BRP”) warrants its model-year 2004 Sea-Doo 3D RFI personal watercraft from defects in material or workmanship for the period described below. All genuine Sea-Doo parts and accessories, installed by an authorized BRP distributor/dealer (as hereinafter defined) at the time of delivery of the Sea-Doo personal watercraft, carry the same warranty as that of the personal watercraft.
4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE The customer must notify a servicing BRP distributor/dealer within two (2) days of the appearance of a defect, and provide it with reasonable access to the product and reasonable opportunity to repair it. The customer must also present to the authorized BRP distributor/dealer, proof of purchase of the product and must sign the repair/work order prior to the start of the repair in order to validate the warranty repair.
7. LIMITATIONS OF LIABILITY THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY.
PRIVACY INFORMATION We wish to inform you that your coordinates will be used for safety and warranty purposes. Sometimes, we also use the coordinates of our clients to inform them about our products and to present them offers. Should you prefer not to receive information on our products, services and offers, please let us know by writing to the address below.
CHANGE OF ADDRESS/OWNERSHIP If your address has changed or if you are the new owner of the personal watercraft, be sure to notify Bombardier Recreational Products Inc. (BRP) by either: – mailing the card below; – calling at (715) 848-4957 (USA) or (819) 566-3366 (Canada) or – notifying an authorized Sea-Doo dealer. In case of change of ownership, please join a proof that the former owner agreed to the transfer.
AFFIX PROPER POSTAGE Bombardier Recreational Products Inc. WARRANTY DEPARTMENT 75, J.A. Bombardier Sherbrooke, QC Canada J1L 1W3 V00A2G 118 _____________________ www.SeaDooManuals.
WATERCRAFT MODEL No. HULL IDENTIFICATION NUMBER (H.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Owner: NAME No. CITY Purchase Date Warranty Expiry Date STREET APT STATE/PROVINCE ZIP/POSTAL CODE YEAR MONTH DAY YEAR MONTH DAY To be completed by the authorized Sea-Doo dealer at the time of the sale. DEALER IMPRINT AREA F00A30L Please verify with your selling dealer to ensure your SEA-DOO watercraft has been registered with BRP. _____________________ 119 www.SeaDooManuals.
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