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2000 Shop Manual VOLUME 1 GS/GTI/GTS/GTX/XP GSX RFI/GTX RFI .

Legal deposit: National Library of Quebec 2nd trimester 2000 National Library of Canada All rights reserved. ©Bombardier Inc. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. 2000 Technical Publications Bombardier Inc. Valcourt (Quebec) Canada Printed in Canada ®*Registered trademarks of Bombardier Inc. Loctite® is a trademark of Loctite Corporation Snap-on® is a trademark of Snap-on Tools Corporation Gelcote® is a trademark of Gelcote International Limited .

........................................................................................Table of contents .................... 01 ....................................Table of contents ........................ INTRODUCTION .................... 04 ..............................................Fuel injection ........................... 02 ....................................................Table of contents ....................Digitally encoded security system ........................................................................Ignition system............................ 06 ....... 02 .................................Table of contents ....................................................... 01 ........................................Carburetor ................................................ 02 ...Table of contents .......................................Oil injection pump ......................................................... 01 ................................... 05 ........ 05 ........................ 01 ......Leak test ...............................................................................................................Table of contents ....... 04 ......................................Drive system .............................. 08 ................................. 03 ...................................Top end ............... 01 ............................ 03 ..................Variable trim system ........................................................ 02 ...............................................................................................................................................Removal and installation ...................................................................................................... 02 ......................................... 05 ...................Flushing and lubrication....................................Optional service tools............... 05 ......................................................................Reverse system ......Starting system .......................................Periodic inspection chart ....... 02 .......................Jet pump ......................... 02 ............................ 04 ........................Charging system .................................... 07 ......................Table of contents ...............................................................FM I ..................................................................... 04 ................... components and care ..................... 06 .........................................................................................................................................Circuit....... 05 ............Water-flooded engine........ 01 .........Troubleshooting chart ................ 04 ..................................................................................................................Table of contents ............Oil injection system................................................. 02 MAINTENANCE 03 04 TROUBLESHOOTING ENGINE 05 06 COOLING SYSTEM FUEL SYSTEM 07 LUBRICATION SYSTEM ELECTRICAL SYSTEM 08 09 PROPULSION SYSTEM SMR2000_001_00A2.......Instruments and accessories ............. 01 .................................... 01 .........................................................................................................Exhaust system..............................................................................................Magneto system .....................................TABLE OF CONTENTS ‘ SECTION SUBSECTION PAGE III IV VI 01-01-1 01-02-1 01-03-1 01-04-1 02-01-1 02-02-1 02-03-1 02-04-1 02-05-1 03-01-1 04-01-1 04-02-1 04-03-1 04-04-1 04-05-1 04-06-1 04-07-1 04-08-1 05-01-1 05-02-1 06-01-1 06-02-1 06-03-1 06-04-1 06-05-1 07-01-1 07-02-1 07-03-1 08-01-1 08-02-1 08-03-1 08-04-1 08-05-1 08-06-1 09-01-1 09-02-1 09-03-1 09-04-1 09-05-1 SAFETY NOTICE ................. 03 ..............................................................................................Service products ...................................................................... WHAT’S NEW .................Fuel circuit.................................... 03 .................................................................................. 02 ............................. 03 ................Bottom end ...............................Storage........Air intake ............................................... 03 . 04 .................................................. 03 ..............Mandatory service tools..................... 01 SERVICE TOOLS AND PRODUCTS 01 .Rotary valve..................

.................... 02 ...................... 01 .....GTX RFI and GSX RFI ................................. 04 ......................................................Table of contents ............................................Table of contents ................ 02 ............................FM ................................TABLE OF CONTENTS 10 STEERING SYSTEM 01 ...................................................................................GTI and GTX.........................................................................................GS ........................................................................................................ 05 ......................................Adjustable steering ...........GTS .......................................................Alignment ... 10-01-1 10-02-1 10-03-1 10-04-1 11-01-1 11-02-1 12-01-1 12-02-1 13-01-1 13-02-1 13-03-1 13-04-1 13-05-1 14-01-1 11 12 13 SUSPENSION HULL/BODY TECHNICAL DATA 14 WIRING DIAGRAMS II SMR2000_001_00A2.............................................. 04 .................................Wiring diagrams................Adjustment and repair ........................... 01 ............... 01 ...........................................................................................................Direct action suspension . 02 ........Steering system.................................................................. 02 ....................... 01 .... 03 ..........................Table of contents ................ 03 .......XP ........................

The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document. If the efficiency of a locking device is impaired. Although the mere reading of such information does not eliminate the hazard. Dealer and/or distributor assistance should be sought in case of doubt. Mechanic technicians should intent to continuous training courses given by Bombardier Training Dept. if not followed. is to assist identification of the general configuration of the parts.) must be installed or replaced with new ones. It is understood that certain modifications may render use of the vehicle illegal under existing federal. Service and Warranty Bulletins may be published to update the content of this manual. NOTE: Indicates supplementary information needed to fully complete an instruction. provincial and state regulations.FM III . etc. Please note that the instructions will apply only if proper hand tools and special service tools are used. SMR2000_001_00A2. self-locking fasteners. Always use common shop safety practice. See model list below. In addition. This edition was primarily published to be used by watercraft mechanic technicians who are already familiar with all service procedures relating to Bombardier made watercraft. could cause serious personal injury including possibility of death. It is understood that this manual may be translated into another language. This manual emphasizes particular information denoted by the wording and symbols: ƽ WARNING Identifies an instruction which. the English version shall prevail. it must be renewed.: locking tab. The use of Bombardier parts is most strongly recommended when considering replacement of any component. Bombardier Inc. CAUTION: Denotes an instruction which. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. Locking devices (ex. your understanding of the information will promote its correct use. They are not to be interpreted as technical drawings or exact replicas of the parts. Make sure to read and understand these. Torque wrench tightening specifications must be strictly adhered to. In the event of any discrepancy. disclaims liability for all damages and/or injuries resulting from the improper use of the contents.SAFETY NOTICE SAFETY NOTICE 0 This manual has been prepared as a guide to correctly service and repair some 2000 SEA-DOO watercraft. could severely damage vehicle components. if not followed. The content depicts parts and/or procedures applicable to the particular product at time of writing. the sole purpose of the illustrations throughout the manual. This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts Catalog.

• Loctite application procedure. 0 THIS SECTION INDICATES PROCEDURES THAT WERE MODIFIED OR NEWLY ADDED IN THIS MANUAL. versus RFI). Added the following new products: • medium strength threadlocker Loctite 243 • Molykote 111.WHAT’S NEW WHAT’S NEW INTRODUCTION • Self-locking fasteners procedure.FM .D. COOLING SYSTEM • New diagram for the cooling system (all engines). IV SMR2000_001_00A2. FUEL SYSTEM • Procedure to remove fuel tank on all models.S. JET PUMP • New procedure for anti-rattle system.6 mm (6-1/8 in) pump • drive shaft alignment shaft for XP model. • New procedure to remove and install tuned pipe on 947 engine. EXHAUST SYSTEM • New procedure to install tuned pipe on 787 RFI engine. AIR INTAKE • New procedure to install air intake on 947 engine. FUEL INJECTION • Fault codes chart (B. SERVICE TOOLS AND PRODUCTS Added the following new tools: • VCK (Vehicle Communication Kit) for all models • bearing/seal installer tool for outlet end of 155. • Tightening torques chart. STORAGE • New procedure with air pressure to empty the cooling system.U. • New procedure for wear ring installation.

WHAT’S NEW TECHNICAL DATA • Updated specifications for each model.FM V . SMR2000_001_00A2. WIRING DIAGRAMS • Updated wiring diagrams for each model.

................) GTS Only It is located at right hand rear side of hull. XP International ...................................... GTI............................... GTX RFI....) VI SMR2000_001_00A2.............................. XP ....... GTI International ....................... GTX RFI International ........... Hull Identification Number (H......... GSX RFI International ......I................ GTX .......... GTX RFI International (green) ......... GTS International............................................ GS International ............... GSX RFI .......... 1 5653 5669 5648 5658 5515 5516 TYPICAL 1.......FM ......................N................................................N.................N................ MODELS GS ..........................INTRODUCTION INTRODUCTION This Shop Manual covers the following BOMBARDIER made SEA-DOO® 2000 watercraft models...... F00A0CB *A letter may also be used as a digit... GTX RFI (green) ...................I............. GTX International .............I................................. Hull Identification Number (H.....) All Models The Hull Identification Number is composed of 12 digits: ZZN12345L495 Serial number* Manufacturer Model year Year of production Month of production HULL IDENTIFICATION NUMBER (H................... F01L8XA 1 1.... MODEL NUMBER 5644 5827 5645 5654 5651 5655 5647 5657 5639 F08L0QA 0 All Other Models It is located on floorboard at the rear of the watercraft....

F01D87A 1 1.) SMR2000_001_00A2.I.N.FM VII .I. Engine Identification Number (E. 947 Engine The Engine Identification Number is located on the upper crankcase on MAGNETO side.INTRODUCTION ENGINE IDENTIFICATION NUMBER (E.I.) 717 Engine The Engine Identification Number is located on the upper side of the magneto housing. Engine Identification Number (E.) ARRANGEMENT OF THIS MANUAL The manual is divided into 14 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL SYSTEM 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 SUSPENSION 12 HULL/BODY 13 TECHNICAL DATA 14 WIRING DIAGRAMS Several sections are divided in various subsections.N.N. Engine Identification Number (E.I. 1 F06D15A 1 F01D01A 1.N. 787 RFI Engine The Engine Identification Number is located on the upper crankcase on PTO side. There is a table of contents at the beginning of many sections.) TYPICAL 1.

Drop represents a liquid product to be applied to a surface. 03-04-1 Page numbering system: 03: ENGINE section 04: MAGNETO SYSTEM subsection 1: First page of this subsection F01A0CS VIII SMR2000_001_00A2. Subsection title indicates beginning of the subsection. Loctite 648 145 N•m (107 lbf•ft) Anti-seize lubricant F01D4WS Illustration number for publishing process.FM .INTRODUCTION TYPICAL PAGE Page heading indicates section and subsection detailed. Bold face number indicates special procedure concerning this part. In this case Loctite 243 to screw threads. Loctite 243 Loctite 243 Exploded view assits you in identifying parts and related positions. Loctite 243 Loctite 243 Loctite 243 Dotted box contains parts of a particular model or an exploded view. Subsection 04 (MAGNETO SYSTEM) Italic sub-title above exploded view indicate pertaining models.

Disconnect oil injection pump cable. perform the following test proceeding as follows: . all others models are concerned. 06-03-4 Bold numbers in the text refer to the parts shown in the exploded view at the beginning of the subsection. NOTE: For fuel line removal. Service tool to be used to perform a certain procedure. Diaphragm PUMP DIAPHRAGM LEAK TEST Using a suitable pump gauge tester. so from this point. Numbers are used for description of components. adjustment or repair procedure. If pressure drops. Unscrew base retaining screws then remove base from carburetors and move to front of watercraft. other-wise it must be timed. Turn the valve to OFF position. butterfly. DISASSEMBLY AND INSPECTION Inspect parts for corrosion dammage (shaft. spring screw. Remove air intake silencer base from watercraft. Sub-sub-title in this case indicates that particular procedure for XP is finished. Disconnect fuel return line. replace diaphragm. Disconnect fuel fuel supply line from fuel pump. Remove screws holding flame arrester base support to cylinder head cover. Illustration always follows text it is pertained to.Pump tester until it reaches 28 kPa (4 PSI). XP Model Only Remove screws no. Numbers in a frame are used to give a sequence to be perfomed.INTRODUCTION TYPICAL PAGE Sub-title with part name(s) from exploded view. Diaphragm must stand pressure for 10 seconds. F01A0BS SMR2000_001_00A2. pay attention that the rotary valve stay in place. All Others Models Remove 4 bolts no. Unlock retaining slides holding air intake silencer base. Letters are used for any measures. 8 and lock washers no. 7 retaining carburetors. Remove carburetors from intake manifold. Disconnect fuel bypass line between carburetors (twin carburetors). F01F0XB 2 1 2 TYPICAL 1 2 "TYPICAL" mention indicates a general view which does not represent full detail. check valve housing. 6 and lock washers no. . 1 A Title in italic indicates a particular procedure concerning a model. throttle cable and choke cable.Install pump gauge tester (P/N 295 000 083) on pulse nipple. etc. CARBURETOR REMOVAL To remove carburetors from engine. NOTE: When removing rotary valve cover . Remove carburetor(s) from rotary valve cover.FM IX . 12 from rotary valve cover then move carburetors and rotary valve cover on top of engine. use pliers (P/N 295 000 054).). Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS) Title indicates main procedure to be carried-out. proceed as follows: Remove air vent tube support. Disconnect pulse line from fuel pump. Sub-sub-title in capital indicates a particular testing.

This Shop Manual uses technical terms which may be different from the ones of the Parts Catalogs. features. 1 2 F01L45B 1. maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured.FM .I. models or equipment without incurring obligation. ECU HP LED MAG MPEM MPH N.INTRODUCTION LIST OF ABBREVIATIONS USED IN THIS MANUAL AC APS ATS CDI CPS CSI DC DESS E. Left (port) 2.A. When ordering parts always refer to the specific model Parts Catalogs. Bombardier Inc. Bombardier Inc.N. reserves the right at any time to discontinue or change specifications. Right (starboard) The information and component/system descriptions contained in this manual are correct at time of publication. X SMR2000_001_00A2. always refers to driving position (when sitting on watercraft). OPT P/N PFD PSI PTO RAVE RFI RPM STD TPS VDC VROI VTS WTS DESCRIPTION Alternate Current Air Pressure Sensor Air Temperature Sensor Capacitor Discharge Ignition Crankshaft Position Sensor Cooling System Indicator Direct Current Digitally Encoded Security System Engine Identification Number Electronic Control Unit Horse Power Light Emitting Diode Magneto Multi-Purpose Electronic Module Mile Per Hour Not Applicable Optional Part Number Personal Flotation Device Pound Per Square Inch Power Take Off Rotax Adjustable Variable Exhaust Rotax Fuel Injection Revolution Per Minute Standard Throttle Position Sensor Volt Direct Current Variable Rate Oil Injection Variable Trim System Water Temperature Sensor GENERAL INFORMATION The use of RIGHT and LEFT indications in the text. however. designs.

Do not apply SELF-LOCKING FASTENERS PROCEDURE The following describes the most common application procedures when working with self-locking fasteners. be sure that you have on hand all the tools required. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. When replacing fasteners. Fit bolt in the hole. make sure to use only those recommended by Bombardier. let act during 30 minutes and wipe off. 4. THREADLOCKER Uncovered Holes (bolts and nuts) 1 2 A00A3LA 1. or approved equivalents. A number of procedures throughout the book require the use of special tools. 5. Choose proper strength Loctite threadlocker. may not reproduce the full detail or exact shape of the parts shown. we suggest. however. NOTE: Always use proper strength Loctite product as recommended in this Shop Manual. Position nut and tighten as required. Apply here 2. A00A3MA 1. Clean threads (bolt and nut) with solvent. The solvent utilization is to ensure the adhesive works properly. 2.INTRODUCTION ILLUSTRATIONS AND PROCEDURES The illustrations show the typical construction of the different assemblies and. you read and thoroughly understand the entire section or subsection in which the procedure is contained. Blind Holes 1 2 LOCTITE APPLICATION PROCEDURE The following describes the most common application procedures when working with Loctite products. On threads 2.FM XI . Use a metal brush or a screwtap to clean the hole properly then use a solvent (Methyl-Chloride). that before undertaking any task. they represent parts which have the same or a similar function. Apply a few drops of threadlocker at proposed tightened nut engagement area. 6. CAUTION: These watercraft are designed with parts dimensioned in both the metric and the imperial systems. As many of the procedures in this manual are interrelated. On threads and at the bottom of hole SMR2000_001_00A2. Before undertaking any procedure. in all cases. 1. 3.

3. Apply several drops of proper strength Loctite on stud threads. Clean threads (bolt and hole) with solvent. 3. Preassembled Parts 1 Stud in Blind Holes 2 1 2 3 A00A3OA 1. Apply drops of proper strength Loctite on uncovered threads. 5. Clean threads (stud and hole) with solvent. Onto nut threads 1. retighten nuts and apply proper strength Loctite on bolt/nut contact surfaces. XII SMR2000_001_00A2. 1. Choose proper strength Loctite threadlocker. 4.INTRODUCTION 1. 6. 5. Put several drops of proper strength Loctite threadlocker on female threads and in hole. Avoid touching metal with tip of flask. Apply here 2. Tighten nuts as required. Apply several drops on bolt threads. 3. Apply drops of proper strength Loctite on bolt/nut contact surfaces. Avoid touching metal with tip of flask. Tighten nuts. Tighten as required. Clean bolts and nuts with solvent. On threads and in the hole 3. 5. 6. Apply here 2. 2. 2. Plunger 1. 4. Install cover. 8. Apply drops of proper strength Loctite threadlocker on screw/body contact surfaces. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. etc. Adjust screw to proper setting. Do not apply A00A5RA 1.FM . 3. 2. Assemble components. 7. On threads 2. 4. Install stud. Apply several drops along the threaded hole and at the bottom of the hole. Adjusting Screw 2 1 A00A3PA 1. Apply Loctite Primer N (P/N 293 800 041) on threads (bolt and nut) and allow to dry for 30 seconds. 2. NOTE: For preventive maintenance on existing equipment.

2. Put waxed paper or similar film on the surfaces. 2. Use a mechanical mean if necessary.FM XIII . using a clean applicator. DO NOT apply release agent on stud. Repair of Small Holes/Fine Threads Option 1: Enlarge damaged hole. 5. 3. 5. heat screw with a soldering iron (232 °C (450°F)).INTRODUCTION NOTE: If it is difficult to readjust. 3. 1. If holes are sunken. GASKET COMPOUND All Parts 1 2 STRIPPED THREAD REPAIR Stripped Threads 5 1 8 2 6 1 3 4 7 A00A3SA A00A3QA 1. 3. Apply release agent on mating surfaces. 4. Permanent Stud Installation (light duty) 1. Option 2: Apply FORM-A-THREAD on the screw and insert in damaged hole. 7. 4. NOTE: Avoid grinding. Clean both mating surfaces with solvent. Proper strength Loctite 2. 5. Remove old gasket and other contaminants with Loctite Chisel remover (P/N 413 708 500). Tighten as usual. Use a stud or thread on desired length. SMR2000_001_00A2. Allow to cure for 30 minutes. Apply GASKET ELIMINATOR 515 (P/N 413 702 700) on both sides of gasket. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator 515 (P/N 413 702 700) on both sides of gasket 3. 4. Release agent Stripped threads Form-A-Thread Tape Cleaned bolt Plate New threads Threadlocker 1 3 1. 6. apply proper strength Loctite in the hole and on threads. Twist bolt when inserting it to improve thread conformation. apply proper strength Loctite on bolt threads. 8. 2. 6. Spray Loctite Primer N on both mating surfaces and on both sides of gasket. 2. then follow Standard Thread Repair procedure. Place gasket on mating surfaces and assemble immediately. 3. Tighten. NOTE: If the cover is bolted to blind holes (above). If a plate is used to align bolt: a. Loctite Primer N only Standard Thread Repair 1. Assemble. Follow instructions on Loctite FORM-A-THREAD (P/N 413 708 600) package. Allow to dry 1 or 2 minutes. b. NOTE: NOT intended for engine stud repairs. Do a Standard Thread Repair.

Clean inner housing diameter and outer gasket diameter. Apply a strip of proper strength Loctite on leading edge of outer metallic gasket diameter. Clean shaft external part and element internal part. 2. Proper strength Loctite Standard 1. Proper strength Loctite 3. Spray housing and gasket with Loctite Primer N (P/N 293 800 041). 2. 2. NOTE: Normally used on worn-out housings to prevent leaking or sliding. Apply retaining compound on internal element bore. 4. Mounting in Tandem 1. 3. 4. 5. Allow it to cure for 30 minutes.INTRODUCTION MOUNTING ON SHAFT Mounting with a Press CASE-IN COMPONENTS Metallic Gaskets 1 2 3 A00A3UA A00A3VA 1 1. Apply a strip of proper strength Loctite on shaft circumference at insert or engagement point. Wipe off surplus. 6. NOTE: Any Loctite product can be used here. Install according to standard procedure. Shaft 1.FM . No curing period is required. NOTE: Retaining compound is always forced out when applied on shaft. A low strength liquid is recommended as normal strength and gap are required. DO NOT use anti-seize Loctite or any similar product. 1. XIV SMR2000_001_00A2. It is generally not necessary to remove gasket compound applied on outer gasket diameter. Continue to assemble as shown above. Bearing 2. 3.

8) M10 M12 Lbf•ft 28 29 30 30 31 32 32 33 34 35 35 36 37 38 38 39 40 41 41 42 43 44 44 45 46 46 47 48 49 49 50 51 52 52 53 54 55 55 56 57 58 58 59 60 60 XV . N•m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 N•m 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 SMR2000_001_00A2.INTRODUCTION TIGHTENING TORQUES Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to following table.8) M4 M5 M6 Lbf•in 9 18 27 35 44 53 62 71 80 89 97 106 115 124 133 142 150 159 168 Lbf•ft 15 15 16 17 18 18 19 20 21 21 22 23 24 24 25 26 27 27 FASTENER SIZE (8.8) M8 N•m 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 FASTENER SIZE (8.The table also gives the metric conversion.FM FASTENER SIZE (8.

8) M14 Lbf•ft 87 88 89 89 90 91 91 92 93 94 94 95 96 97 97 98 99 100 100 101 102 103 103 104 105 105 106 107 108 108 109 110 111 TIGHTENING TORQUES FOR 8.INTRODUCTION N•m 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 FASTENER SIZE (8. Canada XVI SMR2000_001_00A2.FM . Valcourt (Quebec).8 GRADE BOLTS AND NUTS Technical Publications Bombardier Inc.8) Lbf•ft 61 62 63 63 64 65 66 66 67 68 69 69 70 71 72 72 73 74 74 75 76 77 77 78 79 80 80 81 82 83 83 84 85 86 86 N•m 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 FASTENER SIZE (8.