smo2003-001a.fm Page 0 Wednesday, October 30, 2002 8:28 AM SAFETY WARNING Disregarding any of the safety precautions and instructions contained in this Operator’s Guide, the Safety Handbook, the Safety Videocassette and on the on-product warning labels could cause injury, including the possibility of death. The operator has the responsibility to inform passenger(s) of safety precautions. This Operator’s Guide, the Safety Handbook and Safety Videocassette should remain with the craft at the time of resale.
smo2003-001a.book Page 1 Monday, July 22, 2002 11:50 AM Doin’it on your new SEA-DOO watercraft Congratulations, you are now the proud owner of a SEA-DOO personal watercraft. Whether you are an experienced boater or are new to the sport of boating, we ask you to take the time to view the safety videocassette provided with the watercraft, to read this Operator’s Guide, the Safety Handbook and on-product warning/caution labels and familiarize yourself with the contents.
smo2003-001a.book Page 2 Monday, July 22, 2002 11:50 AM TABLE OF CONTENTS FOREWORD ................................................................................ SAFETY MEASURES............................................................... General .................................................................................................... Operation................................................................................................. Maintenance.......................................
smo2003-001a.book Page 3 Monday, July 22, 2002 11:50 AM 21) Seat Latch ......................................................................................... 22) Seat Extension Latch (if so equipped)............................................... 23) Rear Grab Handle.............................................................................. 24) Rear Storage Basket (if so equipped)................................................ 25) Bow and Stern Eyelets ...............................................
smo2003-001a.book Page 4 Monday, July 22, 2002 11:50 AM Stopping/Docking .................................................................................... 64 Beaching.................................................................................................. 64 Shutting Off the Engine........................................................................... 64 POST-OPERATION CARE ............................................................ 65 General Care..........................................
smo2003-001a.book Page 5 Monday, July 22, 2002 11:50 AM FOREWORD The Operator’s Guide and Safety Handbook have been prepared to acquaint the owner/operator or passenger with this personal watercraft and its various controls, maintenance and safe riding instructions. Each 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 and Safety Handbook.
smo2003-001a.book Page 6 Monday, July 22, 2002 11:50 AM SAFETY MEASURES General Operation To fully appreciate the pleasures, enjoyment and excitement of boating there are some basic rules that should be observed and followed by any rider.
smo2003-001a.book Page 7 Monday, July 22, 2002 11:50 AM Do not start or operate the watercraft if someone is seated on the sun deck (if so equipped) or swim platform, or is nearby in the water. The watercraft’s jet thrust can cause injury. Always accelerate slowly. To prevent accidental starting or unauthorized use, always detach the safety lanyard from the watercraft especially when swimmers are boarding or nearby, or during removal of any weeds or debris from the intake grate.
smo2003-001a.book Page 8 Monday, July 22, 2002 11:50 AM Maintenance Only perform servicing procedures which are detailed in this guide. 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.
smo2003-001a.book Page 9 Monday, July 22, 2002 11:50 AM LIST OF DISTRIBUTORS 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.bombardier.com BOMBARDIER INC. RECREATIONAL PRODUCTS 75 J. A. BOMBARDIER ST. SHERBROOKE, QC J1L 1W3 Phone: (819) 566-3366 Fax: (819) 566-3062 www.bombardier.
smo2003-001a.book Page 10 Monday, July 22, 2002 11:50 AM BOMBARDIER LIMITED WARRANTY NORTH AMERICA: SEA-DOO® WATERCRAFT 1. SCOPE OF THE LIMITED WARRANTY In Canada, BOMBARDIER INC. (hereinafter “BOMBARDIER”), and in the USA, Bombardier on behalf of BOMBARDIER MOTOR CORPORATION OF AMERICA (BMCA) warrants its SEA-DOO watercraft from defects in material or workmanship for the period described below.
smo2003-001a.book Page 11 Monday, July 22, 2002 11:50 AM 4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE The customer must notify an authorized servicing BOMBARDIER 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.
smo2003-001a.book Page 12 Monday, July 22, 2002 11:50 AM Neither the distributor, any BOMBARDIER dealer nor any other person has been authorized to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against BOMBARDIER.
smo2003-001a.book Page 13 Monday, July 22, 2002 11:50 AM ONLY FOR 2003 SEA-DOO RX™ DI, SEA-DOO GTX† DI, SEA-DOO CALIFORNIA GTI (model 5567) AND REGISTERED IN CALIFORNIA CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your SEA-DOO watercraft has a special environmental label required by the California Air Resources Board (CARB). The label has 1, 2, or 3 stars. A hangtag, provided with your personal watercraft, describes the meaning of the star rating system.
smo2003-001a.book Page 14 Monday, July 22, 2002 11:50 AM The California Air Resources Board and BOMBARDIER on behalf of BOMBARDIER MOTOR CORPORATION OF AMERICA (BMCA) are pleased to explain the emission control system warranty on your 2003 SEA-DOO RX™ DI,SEA-DOO GTX† DI, SEA-DOO California GTI (model 5567) personal watercraft engine. In California, new personal watercraft engines must be designed, built and equipped to meet the State’s stringent anti-smog standards.
smo2003-001a.book Page 15 Monday, July 22, 2002 11:50 AM The emission warranty covers damage to other engine components that is caused by the failure of a warranted part. The Bombardier Operator’s Guide provided contains written instructions for the proper maintenance and use of your personal watercraft. All emission warranty parts are warranted by Bombardier for the entire warranty period of the watercraft, unless the part is scheduled for replacement as required maintenance in the Operator’s Guide.
smo2003-001a.book Page 16 Monday, July 22, 2002 11:50 AM BOMBARDIER LIMITED WARRANTY INTERNATIONAL: SEA-DOO® WATERCRAFT 1. SCOPE OF THE LIMITED WARRANTY BOMBARDIER INC. (hereinafter “BOMBARDIER” warrants its SEA-DOO personal watercraft from defects in material or workmanship for the period described below.
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smo2003-001a.book Page 18 Monday, July 22, 2002 11:50 AM 9. CONSUMER ASSISTANCE (a) In the event of a controversy or a dispute in connection with this BOMBARDIER LIMITED WARRANTY, BOMBARDIER suggests that you try to resolve the issue at the distributorship/dealership level. We recommend discussing the issue with the authorized dealer’s service manager or owner. (b) If further assistance is required, the distributor’s service department should be contacted in order to resolve the matter.
smo2003-001a.book Page 19 Monday, July 22, 2002 11:50 AM 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. On applicable models install registration number to the left of the star label. F18L03O 1 TYPICAL 1.
smo2003-001a.book Page 20 Monday, July 22, 2002 11:50 AM 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.
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smo2003-001a.book Page 27 Monday, July 22, 2002 11:50 AM 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. Hull The Hull Identification Number (H.I.N.) is located on footboard at the rear of watercraft. Engine NOTE: Refer to SPECIFICATIONS section to find what engine is used on each model.
smo2003-001a.book Page 28 Monday, July 22, 2002 11:50 AM 947 DI Engine The Engine Identification Number (E.I.N.) is located on the upper crankcase on MAGNETO side. F06D15Y 1 TYPICAL 1. Engine Identification Number (E.I.N.
smo2003-001a.book Page 29 Monday, July 22, 2002 11:50 AM CONTROLS, COMPONENTS AND INSTRUMENTS LOCATION NOTE: Some components do not apply or are optional on some models.
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smo2003-001a.book Page 33 Monday, July 22, 2002 11:50 AM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Safety Lanyard Handlebar Throttle Lever Engine Start/Stop Button Variable Trim System (VTS) Button Choke Lever Shift Lever Fuel Gauge/Low Oil Warning Light Speedometer Tachometer Information Center Gauge/Buttons Glove Box Fuel Tank Valve Fuel Tank Cap Oil Injection Reservoir Cap Front Storage Compartment Cover Front Storage Compartment Cover Latch 18. Tool Kit 19. Air Intake Opening 20. 21.
smo2003-001a.book Page 34 Monday, July 22, 2002 11:50 AM CONTROLS, COMPONENTS AND INSTRUMENTS FUNCTIONS 1) Safety Lanyard (engine cut-off cord) The safety lanyard cap should be securely snapped onto its post to be fully operational. Pulling the safety lanyard cap from its post stops the engine operation. Attach the safety lanyard to the operator’s Personal Flotation Device (PFD) and snap the cap to the post to be able to start the engine.
smo2003-001a.book Page 35 Monday, July 22, 2002 11:50 AM The DI models also offers a special safety lanyard — the SEA-DOO LKTM (SEA-DOO Learning KeyTM) — which electronically limits the speed of the watercraft to approximately 55 km/h (35 MPH) therefore enabling first time users and less experienced operators to learn how to operate the watercraft while gaining the necessary confidence and control. 3) Throttle Lever When the throttle lever is squeezed, the watercraft accelerates.
smo2003-001a.book Page 36 Monday, July 22, 2002 11:50 AM All Models except GTX DI 6) Choke Lever Carburetor-Equipped Models The choke is provided to supply a richer fuel/air mixture when starting a cold engine. Choke lever should be pulled and held to operate. Lever will automatically return to its normal position when released. 1 F01L63Y 1. Engine start/stop button 1 GTX DI Models 1 F17L0GY 1. Choke lever 7) Shift Lever F18L09Y 1.
smo2003-001a.book Page 37 Monday, July 22, 2002 11:50 AM From the forward position, pull the lever to reverse. Push back to go to forward. Always set in forward when finished. To find the neutral, set in reverse then push back until the watercraft stops moving backwards. 8) Fuel Gauge/Low Oil Warning Light (if so equipped) Analog gauge indicates the amount of fuel in the fuel tank and a warning light turns on when level is low in oil reservoir. 1 0 F17L0AY FORWARD POSITION 1 F01G07Y 1.
smo2003-001a.book Page 38 Monday, July 22, 2002 11:50 AM 11) Information Center Gauge/Buttons (if so equipped) 2 1 5 This is a LCD multifunction gauge. Different displays and functions can be activated using 2 buttons — MODE and SET — following specific sequences as described below. 1 F00L2BY 2 1. To change display mode 2. To set or reset a function NOTE: Some models have the MODE and SET buttons at a different location and differ in appearance. However, the functionality is the same.
smo2003-001a.book Page 39 Monday, July 22, 2002 11:50 AM Compass (if so equipped): Displays the cardinal points to indicate the orientation of the watercraft. WARNING Use the compass as a guide only. Not to be used for navigation purposes. Tachometer: Indicates the revolutions per minute (RPM) of the engine. Speedometer: Indicates the speed of watercraft in kilometers per hour (KPH) or miles per hour (MPH).
smo2003-001a.book Page 40 Monday, July 22, 2002 11:50 AM Display Priorities As a self test, all LCD segments and the LED will turn on for 3 seconds each time the information center is activated (when safety lanyard is installed). When the information center is activated, the last function set will be displayed if it was the tachometer, speedometer or chronometer. If another function was set, the compass will be displayed. On models without the compass function, the word “SeaDoo” will be displayed.
smo2003-001a.book Page 41 Monday, July 22, 2002 11:50 AM Maintenance Information When the watercraft is due for a maintenance inspection, the message MAINT will blink. To clear the warning message while it is blinking: 1 F00L2B0 1. Press and hold for 2 seconds to reset ON: Allows fuel to flow to carburetor(s). This is the normal position for operation of watercraft. CAUTION: Improper opening of fuel valve may restrict flow of fuel and may lead to engine damage.
smo2003-001a.book Page 42 Monday, July 22, 2002 11:50 AM 15) Oil Injection Reservoir Cap Refer to the vehicle illustration for oil injection reservoir cap location. To add injection oil in the reservoir, unscrew the cap counterclockwise. Do not overfill. Reinstall cap and fully tighten it. WARNING Do not overfill. Reinstall cap and fully tighten. Oil is inflammable. Always wipe off any oil spillage from the bilge. Open the front storage compartment cover to expose reservoir cap. F17L0VY 1 1.
smo2003-001a.book Page 43 Monday, July 22, 2002 11:50 AM GTX DI Models The front storage area includes a latch to hold an approved fire extinguisher (sold separately). 1 CAUTION: If the air intake opening is kept under water, such as turning constantly in tight circles, water will get inside bilge, which may cause severe damage to internal parts of the engine. 20) Seat Strap The seat strap provides a handhold to assist boarding and is used as a handhold for the passenger. 21) Seat Latch 2 F18L0LY 1.
smo2003-001a.book Page 44 Monday, July 22, 2002 11:50 AM All Models To remove seat, pull the latch lever upward and hold. Lift and pull the seat rearward. NOTE: On the 3-up seat models, it is necessary to remove the seat extension first and repeat the same procedure to remove the seat. Engine Compartment This is where the mechanical, electrical and fuel/oil systems are located. WARNING Components inside engine compartment may be hot.
smo2003-001a.book Page 45 Monday, July 22, 2002 11:50 AM All Models To latch seat, align latch hole with pin then, firmly push downward on rear of the seat. 23) Rear Grab Handle Provides a handhold for boarding when needed and a handhold for the passenger or the spotter on 3-up seat models. See illustration above. CAUTION: Never use the grab handle to tow anything or to lift the watercraft. 24) Rear Storage Basket (if so equipped) A convenient watertight, removable basket to carry personal articles.
smo2003-001a.book Page 46 Monday, July 22, 2002 11:50 AM F18L0HY Stern Eyelet Some Models This eyelet allows a rope with a hook, a closed end or an open end to be attached. 1 2 3 1. Storage basket 2. Spare spark plug holder cap 3. Spark plug holder 1 F07L0YY NOTE: Adjust spare spark plug gap according to SPECIFICATIONS before installation. NOTE: Spare spark plugs are not supplied with the watercraft.
smo2003-001a.book Page 47 Monday, July 22, 2002 11:50 AM 28) Boarding Pads Provide a cushioned surface for the knees when boarding from rear of watercraft. 31) Cooling System Bleed Outlet All Models All Models 29) Boarding Platform Provides a large surface for easier boarding from rear of watercraft. 30) Boarding Step (if so equipped) A convenient step to help reboarding the watercraft. 1 F12L05Y 1 TYPICAL 1. Bleed outlet F18L0IY 1.
smo2003-001a.book Page 48 Monday, July 22, 2002 11:50 AM 32) Flushing Connector (if so equipped) A convenient connector is provided to allow easy installation of a garden hose to flush the cooling system. 1 1 2 3 F18L14Y TYPICAL 1. Drain plugs 2. Tighten 3. Unscrew F18L0TY TYPICAL Refer to POST-OPERATION CARE section for proper use. 33) 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 water.
smo2003-001a.book Page 49 Monday, July 22, 2002 11:50 AM 35) Reverse Gate When selecting the neutral or reverse position with the shift lever, the reverse gate moves up or down to obtain the desired position. 1 F18J04Y 1 F18J05Y 2 1. Water intake 2. Ride plate TYPICAL 1. Reverse gate 37) Fuses 36) Jet Pump Water Intake Fuses are located under seat in bilge. Refer to MAINTENANCE for more details. The water is drawn up by the impeller through this opening.
smo2003-001a.book Page 50 Monday, July 22, 2002 11:50 AM FUEL AND LUBRICATION CAUTION: Scrupulously follow the instructions of this section. Failure to do so may reduce the engine’s life and/or performance. Fueling Procedure WARNING 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. Do not insert the spout too far in filler neck.
smo2003-001a.book Page 51 Monday, July 22, 2002 11:50 AM Recommended Oil WARNING Do not overfill. Reinstall cap and fully tighten. Oil is inflammable. Always wipe off any oil spillage from the bilge. Use only two-stroke engine injection oil sold by authorized SEA-DOO dealers.
smo2003-001a.book Page 52 Monday, July 22, 2002 11:50 AM 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.
smo2003-001a.book Page 53 Monday, July 22, 2002 11:50 AM 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.
smo2003-001a.book Page 54 Monday, July 22, 2002 11:50 AM Hull Battery 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. WARNING Verify tightness of battery cables to their posts and condition of battery retaining strap(s)/fasteners.
smo2003-001a.book Page 55 Monday, July 22, 2002 11:50 AM Throttle System Check throttle lever for free and smooth operation. It should return to its initial position immediately after it is released. WARNING Check throttle lever operation before starting the engine. All Models except RFI and DI CAUTION: Engine can be flooded if throttle lever is applied several times when engine is not running. If engine is flooded, it will not start.
smo2003-001a.book Page 56 Monday, July 22, 2002 11:50 AM 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. Principle of Operation Propulsion The engine is directly coupled to a drive shaft which, in turn, rotates an impeller.
smo2003-001a.book Page 57 Monday, July 22, 2002 11:50 AM F17J02Y F17L0BZ 1 1 1. Reverse gate in downward position 1. Shift lever in neutral position 1 F17J01Y NOTE: To obtain maximum efficiency and control from the reverse, increase engine speed to slightly above idle. Too much RPM will create water turbulence and reduce reverse efficiency. In reverse position, turn the handlebar in the same direction that you want to move the rear of the watercraft.
smo2003-001a.book Page 58 Monday, July 22, 2002 11:50 AM WARNING 1 Shift lever should only be used when the engine is idling and watercraft is completely stopped. Do not use reverse to stop the watercraft. Variable Trim System (if so equipped) The variable trim system (VTS) changes the angle of the jet pump nozzle to provide the operator with a fast, effective system to compensate for load, thrust, riding position and water conditions.
smo2003-001a.book Page 59 Monday, July 22, 2002 11:50 AM Turning the handlebar pivots the jet pump nozzle which controls the watercraft direction. Turning the handlebar to the right will turn the watercraft to the right and inversely. The throttle should be applied to turn the watercraft. WARNING 1 2 Throttle should be applied and handlebar turned to change the direction of the watercraft.
smo2003-001a.book Page 60 Monday, July 22, 2002 11:50 AM Models with Off-Power Assisted Steering System (O.P.A.S.) Two side vanes on the rear sides of the hull, turn as the steering is turned to assist the watercraft turning. At first, carefully experiment turning with this system. 1 F17K02Y 1. Side vane in lower position Boarding the Watercraft F17K03Y General As with any watercraft, boarding should be done carefully and engine should not be running. 1 1.
smo2003-001a.book Page 61 Monday, July 22, 2002 11:50 AM Boarding from a Dock or in Shallow Water When boarding from a dock, slowly place one foot on the watercraft footboard nearest the dock and, at the same time, transfer the body weight to the other side in order to balance the watercraft while holding the handlebar. Then, bring the other foot over the seat and put it on the other footboard. Push the watercraft away from the dock.
smo2003-001a.book Page 62 Monday, July 22, 2002 11:50 AM Operator with a Passenger The operator climbs on the watercraft the same way as explained previously. In choppy water, the passenger, while in the water, may hold the watercraft to help the operator in climbing aboard. F01L4MY The passenger then climbs on the watercraft while the operator maintains balance by sitting as close as possible to the console.
smo2003-001a.book Page 63 Monday, July 22, 2002 11:50 AM Carburetor-Equipped Models Cold Engine The choke is provided to supply a richer fuel/air mixture when starting a cold engine. Fully pull the choke lever and hold while starting the engine. All Models Riding Slowly accelerate to reach deeper water. Do not apply full throttle until the engine is warm. F18A02Y F12L07Y 1 TYPICAL 1. Fully pull After engine is started, release choke lever.
smo2003-001a.book Page 64 Monday, July 22, 2002 11:50 AM Stopping/Docking Beaching The watercraft is slowed by water drag. The stopping distance will vary depending on the watercraft size, weight, speed, water surface condition, presence and direction of wind and current. CAUTION: It is not recommended to run the watercraft to the beach. Come slowly to the beach and shut off the using the safety lanyard when water depth is 90 cm (3 ft) under the hull, then pull the watercraft to the beach.
smo2003-001a.book Page 65 Monday, July 22, 2002 11:50 AM POST-OPERATION CARE WARNING Allow engine to cool before performing any maintenance. Engine lubrication and flushing 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 General Care Remove the watercraft from the water every day to prevent marine organisms growth.
smo2003-001a.book Page 66 Monday, July 22, 2002 11:50 AM Flushing To flush cooling system, start the engine then immediately open the water tap. WARNING 947 DI Engines Spray BOMBARDIER LUBE lubricant or equivalent, through hole of air intake silencer keeping engine at fast idle during one minute. Components inside engine compartment may be hot. Do not touch any electrical parts or jet pump area when engine is running. CAUTION: Never flush a hot engine.
smo2003-001a.book Page 67 Monday, July 22, 2002 11:50 AM NOTE: A 1 second beep every second indicates the drowned mode is active. Crank the engine a few turns to distribute the oil on cylinder wall. F01H7DY 1 RX DI, GTI LE RFI AND GTX DI MODELS 1. Grounding device Remove both spark plugs and spray BOMBARDIER LUBE lubricant or equivalent into each cylinder. Carburetor-Equipped Models Crank the engine a few turns to distribute the oil on cylinder wall. RFI Models Remove safety lanyard from its post.
smo2003-001a.book Page 68 Monday, July 22, 2002 11:50 AM SPECIAL PROCEDURES Monitoring System All Models except DI Models To assist you when using the watercraft, a system monitors some component of the watercraft and sends audible signals through a beeper to inform you of a particular condition. Refer to the TROUBLESHOOTING section for the coded signals chart.
smo2003-001a.book Page 69 Monday, July 22, 2002 11:50 AM A weed clogged area can be cleaned as follows: In-Water Cleaning Rock the watercraft several times while repeatedly pressing engine start/stop button for short period without starting engine. Most of the time, this will remove the blockage. Start engine and make sure water flows out from bleed outlet and watercraft operates properly. If system is still blocked, move the watercraft out of the water and remove blockage manually.
smo2003-001a.book Page 70 Monday, July 22, 2002 11:50 AM Capsized Watercraft Submerged Watercraft The watercraft is designed so that it should not turn over easily. Also two sponsons mounted on the side of the hull assist watercraft stability. If it turns over, it will remain capsized. If the watercraft is submerged and engine is water-flooded, it is strongly recommended that the watercraft be serviced by an authorized SEA-DOO dealer.
smo2003-001a.book Page 71 Monday, July 22, 2002 11:50 AM All Models Crank engine several times to allow water to escape from spark plug openings. Release throttle lever. DI Models If water does not completely go out, it may be necessary to remove the air intake silencer then to lean the vehicle so that water can flow out from throttle bodies. All Models Spray BOMBARDIER LUBE lubricant or equivalent into spark plug holes. Crank engine again. Reinstall spark plugs. Install clean dry spark plugs if possible.
smo2003-001a.book Page 72 Monday, July 22, 2002 11:50 AM DI Models WARNING Always reconnect spark plug cables at the same spark plugs where they come from. The cable coming out the edge of the electrical box must be connected to the MAG side spark plug. When towing your watercraft in water, pinch the water supply hose from the impeller housing to the engine with a large hose pincher (P/N 529 032 500). 1 F01B23Y F16H01Y TYPICAL 1. PTO side spark plug cable All Models Start engine as explained above.
smo2003-001a.book Page 73 Monday, July 22, 2002 11:50 AM 1 F18E01Y GTX DI MODELS 1. Hose pincher on water supply hose on this side of the T-fitting 1 F12E01Y 1 TYPICAL — RX DI MODELS 1. Hose pincher on water supply hose on this side of the T-fitting CAUTION: When finished towing the watercraft, hose pincher should be removed before operating it. Failure to do so will result in damage to the engine. Low-Charge Battery Condition See an authorized SEA-DOO dealer to have it charged or replaced.
smo2003-001a.book Page 74 Monday, July 22, 2002 11:50 AM MAINTENANCE 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.
smo2003-001a.book Page 75 Monday, July 22, 2002 11:50 AM 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.
smo2003-001a.book Page 76 Monday, July 22, 2002 11:50 AM CAUTION: Do not lubricate connectors of the Multi-Purpose Electronic Module. START STOP Additional Lubrication BOMBARDIER LUBE lubricant or equivalent will help prevent corrosion of metallic parts and maintain proper operation of moving mechanisms. WARNING Do not lubricate the safety lanyard post. F01L51Y TYPICAL Carburetor-Equipped Models Choke Lever Fully pull choke lever and lubricate the metallic portion.
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smo2003-001a.book Page 78 Monday, July 22, 2002 11:50 AM HULL AND BODY PROPULSION SYSTEM O.P.A.S.
smo2003-001a.book Page 79 Monday, July 22, 2002 11:50 AM Throttle and Choke Cable Inspection Throttle Cable Depress and release the throttle lever. It should operate smoothly and return to its initial position without any hesitation. Refer to an authorized SEA-DOO dealer if necessary. Carburetor-Equipped Models Do not activate throttle lever unnecessarily, when engine is not running. Carburetors are equipped with fuel accelerator pumps.
smo2003-001a.book Page 80 Monday, July 22, 2002 11:50 AM Steering Alignment When the handlebar is directed in straight ahead position, the jet pump nozzle should be in the same direction allowing the watercraft to run in a straight line. The rear edge of side vanes (if so equipped) should be pointing out side by approximately 20° when the handlebar is pointing straight ahead. Refer to an authorized SEA-DOO dealer if an adjustment is necessary.
smo2003-001a.book Page 81 Monday, July 22, 2002 11:50 AM Fuses If an electrical problem occurs, check the fuses. If a fuse is burnt, replace by one of the same rating. Follow procedures below. WARNING Do not use a higher rated fuse as this can cause severe damage. If a fuse has burnt out, source of malfunction should be determined and corrected before restarting. See an authorized SEA-DOO dealer for servicing. Fuses can be found on the MPEM.
smo2003-001a.book Page 82 Monday, July 22, 2002 11:50 AM Fuses are identified, look above and besides the fuse holder. 2 F1 : FP F2 : ACC F3 : REG F4 : VTS F5 : BAT F6 : INJ 1 2 1 15A 2A 25A 7.5A 25A 15A F1 F2 F3 F4 F5 F6 3 F18H06Y FUSE IDENTIFICATION 1. Fuse identification 2. Fuse description F17H05Y 1. Battery 2. MPEM 3. Fuel pump SPR means spare (fuse). RX DI Models To access fuses on the MPEM, open front storage compartment cover and remove storage basket.
smo2003-001a.book Page 83 Monday, July 22, 2002 11:50 AM All Models Remove fuse cover from the MPEM. 1 F06H1SY 2 F12H01Y TYPICAL 1. MPEM 2. Fuse cover F06H1TY Rear Electrical Box Remove seat. 2 1 TYPICAL 1. Rear electrical box 2. Remove vent tubes Use the tabs of the fuse cover to remove and reinstall fuses. 1. Fuse cover 2. Fuse tabs GTI, GTI LE and RX DI Models Remove darts retaining tubes then pull out both vent tubes each side of electrical box at rear of hull.
smo2003-001a.book Page 84 Monday, July 22, 2002 11:50 AM Some Models Unclip and remove cover of the electrical box to expose the holder of the main fuse. Unclip and remove cover of the electrical box. 1 1 F12H02Y TYPICAL 1. Fuse holder All Models Properly reinstall removed components. 2° 1° O.P.A.S. System (if so equipped) The O.P.A.S. system operation and condition should be checked by an authorized SEA-DOO dealer. General Inspection and Cleaning F18H1BY TYPICAL 1.
smo2003-001a.book Page 85 Monday, July 22, 2002 11:50 AM Inspect hull and jet pump water intake grate for damage. Replace or have damaged parts repaired. WARNING Periodically verify the seat lock pin and tighten if needed. Make sure seat securely latches. Cleaning The bilge should be cleaned by an authorized SEA-DOO dealer to remove any fuel/oil/electrolyte deposits and mildew. Occasionally, wash the body with water and soap (only use mild detergent). Remove any marine organisms from engine and/or hull.
smo2003-001a.book Page 86 Monday, July 22, 2002 11:50 AM TRAILERING, STORAGE AND PRE-SEASON PREPARATION Trailering All Models Models with O.P.A.S. System CAUTION : To avoid damaging O.P.A.S. side vanes, the maximum trailer wood bunks span including bunk width should not exceed 71 cm (28 in). Ends of both trailer wood bunks should not be more than 2.59 m (102 in) away from watercraft bow attachment point. See following illustration.
smo2003-001a.book Page 87 Monday, July 22, 2002 11:50 AM WARNING Make sure seat is securely latched before prior to trailering. A SEA-DOO cover can protect the watercraft, particularly before driving on dirt roads, to prevent dirt entry through the air intake opening(s). Observe trailering safety precautions. Launching/Loading CAUTION: Before launching the watercraft, ensure the bilge plugs are fully screwed. After loading the watercraft, ensure they are removed to drain bilge.
smo2003-001a.book Page 88 Monday, July 22, 2002 11:50 AM This hose is located at the bottom of the magneto cover beside the engine support. RX DI Models Disconnect the quick connect fitting. Press both tabs and pull fitting. 1 F07E0HY DISCONNECT THIS HOSE F17E0AY TYPICAL 1. Press tabs here and disconnect hose GTX DI Models Water should flow out of the fitting (magneto cooling circuit) and hose (crankcase heat exchanger). Push and hold hose against bilge so that draining can take place.
smo2003-001a.book Page 89 Monday, July 22, 2002 11:50 AM All Models Lower hose as necessary so that draining can take place. Reconnect fitting when done. Also ensure air compressor drain line is not obstructed. Clean as necessary. All Models Body Rinsing/Repair Wash the body with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull.
smo2003-001a.book Page 90 Monday, July 22, 2002 11:50 AM CAUTION: Antifreeze mix must be fed in cooling system. Otherwise remaining water will freeze. This operation requires a good technical knowledge of the cooling system path. If antifreezing is not performed adequately engine/exhaust system may freeze and cause severe engine damage. We strongly recommend this operation be performed by an authorized SEA-DOO dealer.
smo2003-001a.book Page 91 Monday, July 22, 2002 11:50 AM Make sure the fitting is properly connected to the magneto cover. 1 F17E01Y TYPICAL — GTI, GTI LE (717 AND 787 RFI ENGINES) 1. Engine water outlet hose 1 F17E0AZ Hose Disconnection Some hoses have to be disconnected. Disconnect hoses at the following location: 1. Fitting properly connected F06E0EZ F17E03Y 1 GTI, GTI LE MODELS (717 ENGINES) 1. Hose pincher on injection hose going to tuned pipe 1 717 AND 787 RFI ENGINES 1.
smo2003-001a.book Page 92 Monday, July 22, 2002 11:50 AM Insert a funnel into hose and pour antifreeze mixed with water in engine until the colored solution appears at the cooling system bleed outlet. F15E03Y 1 TYPICAL 1. Hose pincher below T-fitting F07E0LY 787 RFI Engines Disconnect hose just above T-fitting from as shown. F15E02Y 1 2 TYPICAL 1. Hose connecting to inlet fitting of cylinder head 2.
smo2003-001a.book Page 93 Monday, July 22, 2002 11:50 AM 1 1 F18E0FY GTX DI MODELS 1. Crankcase cooling cover outlet hose F18E05Y GTX DI MODELS 1. Water outlet hose F07E0JY 1 RX DI MODELS 1. Engine cylinder drain hose F12E0AY 1 RX DI MODELS 1.
smo2003-001a.book Page 94 Monday, July 22, 2002 11:50 AM 1 1 F18E0BY F18E08Y GTX DI MODELS 1. Engine cylinder drain hose Hose Disconnection Disconnect water INLET hose at engine between T-fitting and cylinder head fitting. F12E0BY Temporarily install a short piece of hose to replace the one removed. Antifreeze Insert a funnel into the temporary hose and pour antifreeze mix in engine until the colored solution appears at cooling system bleed outlet. 1 RX DI MODELS 1.
smo2003-001a.book Page 95 Monday, July 22, 2002 11:50 AM At this point, install a hose pincher on bleed outlet hose. 1 F07E0NX 1 RX DI MODELS 1. Air compressor water outlet hose F07E0OY RX DI MODELS 1. Bleed outlet hose F18E01Y 1 GTX DI MODELS 1. Air compressor water outlet hose F18E0EY 1 GTX DI MODELS 1. Bleed outlet hose Continue to pour until antifreeze flows in air compressor water outlet hose. Remove pinchers in this order to allow proper flow of antifreeze. 1. Bleed outlet hose. 2.
smo2003-001a.book Page 96 Monday, July 22, 2002 11:50 AM All Models Most of the antifreeze will drain out when removing the hose pinchers. Use a container to recover it. DISPOSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS. NOTE: Although antifreeze will mainly drain out, the antifreeze has mixed with the water that was possibly trapped in the water jackets and thus preventing freezing problems.
smo2003-001a.book Page 97 Monday, July 22, 2002 11:50 AM Pre-Season 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 pre-season preparation all at the same time. OPERATIONS GENERAL ENGINE COOLING SYSTEM FUEL SYSTEM Lubrication/corrosion protection TO BE PERFORMED BY Operator Spark plug replacement ➀ Dealer Exhaust system condition (fasteners, hoses etc.
smo2003-001a.book Page 98 Monday, July 22, 2002 11:50 AM 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 2 short beeps (while installing safety lanyard on post).
smo2003-001a.book Page 99 Monday, July 22, 2002 11:50 AM Engine Will Not Start OTHER OBSERVATION Engine does not turn over. Engine turns slowly. Engine turns normally. POSSIBLE CAUSE • Safety lanyard removed. REMEDY • Discharged or weak battery. Refer to an authorized SEA-DOO dealer. • Worn starter. Refer to an authorized SEA-DOO dealer. • Closed fuel tank valve (carburetor-equipped models). Turn fuel tank valve to ON position. • Fuel tank empty or watercontaminated. Refill.
smo2003-001a.book Page 100 Monday, July 22, 2002 11:50 AM Engine Misfires, Runs Irregularly OTHER OBSERVATION Weak spark. POSSIBLE CAUSE • Fouled/defective/worn spark plugs. • Faulty MPEM. • Too much oil supplied to engine. Lean fuel mixture. Rich fuel mixture (high fuel consumption). REMEDY Replace. Refer to an authorized SEA-DOO dealer. Improper oil pump adjustment, refer to an authorized SEA-DOO dealer. • Fuel: Level too low, stale or watercontaminated.
smo2003-001a.book Page 101 Monday, July 22, 2002 11:50 AM Engine Lacks Acceleration or Power OTHER OBSERVATION POSSIBLE CAUSE • Weak spark. REMEDY Refer to engine MISFIRES, RUNS IRREGULARLY. • Incorrect fuel mixture (carburetor-equipped models). Refer to engine MISFIRES, RUNS IRREGULARLY. • Water in fuel or injection oil. Siphon and replace. • Clogged injectors (RFI and DI models). Refer to an authorized SEA-DOO dealer. • Low fuel pressure (RFI and DI models).
smo2003-001a.book Page 102 Monday, July 22, 2002 11:50 AM O.P.A.S. System Faults OTHER OBSERVATION POSSIBLE CAUSE • Side vanes do not go up while watercraft is at speed. REMEDY Watercraft pulls on one side. • One side vane does not go up while watercraft is at speed. Refer to an authorized SEA-DOO dealer. O.P.A.S. side vanes do not go up while watercraft is at speed. • Clogged filter, square rings damaged, leakage in hoses or mechanical malfunction. Refer to an authorized SEA-DOO dealer. O.P.A.S.
smo2003-001a.book Page 103 Monday, July 22, 2002 11:50 AM SPECIFICATIONS MODELS ENGINE Engine type Induction type GTI, GTI LE (5567/5597/5598/ 6101/6102) GTI LE RFI (6103/6104) Rotax® 717, 2-stroke Rotax® 787, 2-stroke Rotary valve Water cooled/water Water cooled/water injected injected with regulator Exhaust system Exhaust valve Rotax Adjustable Variable Exhaust (RAVE) Oil injection N.A.
smo2003-001a.book Page 104 Monday, July 22, 2002 11:50 AM MODELS FUEL SYSTEM Fuel type Carburetor Fuel injection PROPULSION Propulsion system Jet pump type Transmission GTI, GTI LE (5567/5597/5598/ 6101/6102) GTI LE RFI (6103/6104) Regular unleaded gasoline BN 40i (diaphragm). Fuel accelerator pump. Quantity: 1 N.A. N.A. Rotax Fuel Injection (semi direct), single throttle body (56 mm (2.
smo2003-001a.book Page 105 Monday, July 22, 2002 11:50 AM RX DI (6122/6123) MODELS ENGINE Engine type Rotax® 947, 2-stroke Induction type Exhaust system Reed valve Water cooled/water injected with regulator Exhaust valve Type Lubrication Oil type Number of cylinders Rotax Adjustable Variable Exhaust (RAVE) Oil injection BOMBARDIER Formula XP-S II synthetic injection oil 2 951.2 cm3 (58 in3) 7300 ± 50 RPM Displacement Rev limiter setting COOLING SYSTEM Type Open circuit.
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smo2003-001a.book Page 107 Monday, July 22, 2002 11:50 AM SI* METRIC INFORMATION BASE UNITS DESCRIPTION length.................................................. mass ................................................... force.................................................... liquid ................................................... temperature ........................................ pressure.............................................. torque .................................................
smo2003-001a.book Page 108 Monday, July 22, 2002 11:50 AM ABBREVIATIONS USED IN THIS MANUAL DESCRIPTION AC API Alternate current American petroleum institute CARB DC California air resource board Direct current DESS EMS Digitally encoded security system Engine management system ECU E.I.N.
smo2003-001a.book Page 109 Monday, July 22, 2002 11:50 AM CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary. NOTE: This card is strictly for change of address only.
smo2003-001a.book Page 110 Monday, July 22, 2002 11:50 AM CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary. NOTE: This card is strictly for change of address only.
smo2003-001a.book Page 111 Monday, July 22, 2002 11:50 AM CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary. NOTE: This card is strictly for change of address only.
smo2003-001a.book Page 112 Monday, July 22, 2002 11:50 AM CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary. NOTE: This card is strictly for change of address only.
smo2003-001a.book Page 113 Monday, July 22, 2002 11:50 AM WATERCRAFT MODEL No. HULL IDENTIFICATION NUMBER (H.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Owner: NAME No. CITY STREET APT STATE/PROVINCE ZIP/POSTAL CODE Purchase Date YEAR MONTH DAY YEAR MONTH DAY Warranty Expiry Date To be completed by the authorized Sea-Doo dealer at the time of the sale. DEALER IMPRINT AREA Please verify with your selling dealer to ensure your SEA-DOO watercraft has been registered with Bombardier.
