OPERATOR’S GUIDE XP DI

This supplement must be used in conjunction with the

Sea-Doo 2003 Operator’s Guide

WARNING

Read this guide thoroughly.

It contains important safety information.

® TM TRADEMARKS OF BOMBARDIER IN. OR ITS SUBSIDIARIES.

©2003 BOMBARDIER INC. ALL RIGHTS RESERVED. PRINTED IN THE EU.

219 000 294

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 onproduct 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.

DECLARATION OF CONFORMITY

2003 PWC Electro Magnetic Compatibility (EMC)

Compliance with 93/68 EC Directive.

The 2003 Sea-Doo Personal Watercraft do comply with the above mentioned directive and with 89/336 EC directive in order to match the current European requirements on

Personal Watercraft (PWC).

Knight’s Spray-Nine † is a trademark of Korkay System Ltd

GTX † is a trademark of Castrol Ltd. Used under license

The following trademarks are the property of Bombardier Inc. or its subsidiaries:

SEA-DOO ®

BOMBARDIER-ROTAX ®

BOMBARDIER LUBE ®

BOMBARDIER Formula XP-S II Synthetic Injection Oil

Sea-Doo LK TM

Rotax ®

Printed in the E.C. (smo2003-004a.fm SH)

®*Trademarks of Bombardier Inc. and/or its subsidiaries.

©2003 Bombardier Inc. All rights reserved.

NOTE

Dear 2003 XP DI watercraft owner. Use the information pertaining to the RX DI model in the 2003 Operator’s Guide (P/N 219 000 290) and then use this supplement to complete the specific information that applies to your XP DI model.

1

TABLE OF CONTENTS

NOTE.......................................................................................................

1

LOCATION OF THE IMPORTANT LABELS ........................................

3

LOCATION OF CONTROLS, COMPONENTS AND INSTRUMENTS ...

6

FUNCTIONS OF CONTROLS, COMPONENTS AND INSTRUMENTS .

8

15) Oil Injection Reservoir Cap................................................................

8

16) Front Storage Compartment Cover ...................................................

8

26) Mooring Cleats ..................................................................................

9

1. 37) Fuses ..........................................................................................

9

1. 38) Battery ........................................................................................

9

1. 41) Storage Compartment/ Engine Cover Latches............................

9

1. 42) Rear Access Cover......................................................................

9

1. 43) Automatic Bilge Pump ................................................................

9

OPERATING INSTRUCTIONS...........................................................

10

SPECIAL PROCEDURES ..................................................................

12

Towing the Watercraft in Water ..............................................................

12

MAINTENANCE ...............................................................................

13

Lubrication ...............................................................................................

13

Periodic Inspection Chart.........................................................................

13

Fuses .......................................................................................................

14

TRAILERING, STORAGE AND PRE-SEASON PREPARATION ...........

16

Storage ....................................................................................................

16

SPECIFICATIONS.............................................................................

21

2

LOCATION OF THE IMPORTANT LABELS

XP DI Models

F08L1UL

TYPICAL

3-5

8 4

2

9

12

3

4

F08A04L

Label 1

XP DI Model Only

The location of these labels differ on the

XP

DI model

.

Label 2

F00A23Y

F00A22Y

Label 3

Label 5

Label 8

F02L2D0

Label 4

F00A27Y

Label 9

F00A1AY

Label 12

F00L29Y

F08G04Y

F00L2XY

5

LOCATION OF CONTROLS, COMPONENTS AND

INSTRUMENTS

XP DI Model

16

19

23

42

26

26

43

41

18 15

37

38

14

F08L1WL

TYPICAL

6

NOTE: Components not shown here are the same as on the RX DI models in the 2003 Sea-

Doo Operator’s Guide .

14) Fuel Tank Cap

15) Oil Injection Reservoir Cap

16) Front Storage Compartment Cover

18) Tool Kit

19) Air Intake Opening

23) Rear Grab Handle

26) Mooring Cleats

37) Fuses

38) Battery

41) Storage Compartment/Engine Cover Latches

42) Rear Access Cover

43) Automatic Bilge Pump

NOTE: Some components shown in the 2003 Sea-Doo Operator’s Guide do not apply to this watercraft. Refer to the following list:

7) Shift Lever

8) Fuel Gauge/Low Oil Warning Light

10) Tachometer

13) Fuel Tank Valve

17) Front Storage Compartment Cover Latch

20) Seat Strap

21) Seat Latch

22) Seat Extension Latch

24) Rear Storage Basket

30) Boarding Step

35) Reverse Gate

39) Side Vanes

7

8

FUNCTIONS OF CONTROLS, COMPONENTS AND

INSTRUMENTS

The following components have the same operation as explained in the 2003 Operator’s

Guide, only their location differ. To know where they are located, refer to the LOCA-

TION OF CONTROLS, COMPONENTS AND

INSTRUMENTS section in the previous pages.

14) Fuel Tank Cap

18) Tool Kit

19) Air Intake Opening

23) Rear Grab Handle

The following components are specific to the

XP DI models

. Refer to the following updated texts and/or illustrations.

15) Oil Injection Reservoir Cap

Open engine cover and remove storage tray.

F08G04Y

Reinstall cap and fully tighten it.

MAXIMUM

OIL LEVEL

MAXIMUM

OIL LEVEL



WARNING

Do not overfill. Never exceed the MAX.

oil level line. Reinstall cap and fully tighten. Oil is inflammable. Always wipe off any oil spillage from the bilge.

1

16) Front Storage Compartment

Cover

It gives access to the front storage compartment. Always relatch cover after closing.

The tray is provided with separate compartments.

1

2

F08L0VZ

TYPICAL

1. Oil injection reservoir cap

To add injection oil in the reservoir, unscrew the cap counterclockwise.

Do not overfill. Make sure oil level does not exceed the level shown on the following drawing. Otherwise, siphon out the extra oil.

Do not operate the engine when oil level exceeds the recommendation.

F08L0UY

1. Fire extinguisher (sold separately)

2. Retaining strap



WARNING

Ensure to properly secure extinguisher with the supplied retaining straps.

26) Mooring Cleats

All Models

These cleats can be temporarily used for docking, while refueling for example.

CAUTION:

Never use mooring cleats to pull or lift the watercraft.

42) Rear Access Cover

It gives access to the battery, drive system, suspension, exhaust system and bailer pickups. Always relatch cover.

43) Automatic Bilge Pump

Bilge pump evacuates water from the bilge.

When safety lanyard cap is installed on its post, bilge pump automatically turns on. It will remain on until all water is evacuated, if any, then it will shut down automatically.

When engine is running, bilge pump will automatically start periodically to evacuate water.

F08L0TZ

1. Mooring cleats

1

37) Fuses

Fuses are located in engine compartment.

Refer to MAINTENANCE for more details.

38) Battery

Battery is located in bilge under seat. Refer to

SPECIAL PROCEDURES.

41) Storage Compartment/

Engine Cover Latches

Pull both latch levers upward in order to open the storage compartment/engine cover. Always relatch cover on both sides.

NOTE:

Verify periodically the lock pins tightness. Tighten if needed and make sure storage compartment/engine cover latches properly.

9

OPERATING INSTRUCTIONS

Variable Trim System

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. Correctly adjusted, it can improve handling, reduce porpoising, and position the watercraft at its best riding angle to attain maximum performance.

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.

When the nozzle is positioned in an upward angle, the water thrust directs the bow of the watercraft upward. This position is used to optimize high speed.

2

1

8°

F08J0AY

3

TYPICAL

1. Push on arrow pointing upward on VTS button

2. Bow up

3. Nozzle up

10

1

2

8°

F08J0BY

3

TYPICAL

1. Push on arrow pointing downward on VTS button

2. Bow down

3. Nozzle down

11

SPECIAL PROCEDURES

Towing the Watercraft in

Water

It is the same as explained in the 2003

Operator’s Guide . The hose location and routing differs. Refer to the following updated text and illustration.

Remove rear access cover.

Install pincher as shown.

1

F08E08Y

1. Hose pincher on water supply hose

Properly relatch cover.

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.

12

MAINTENANCE

Lubrication

Seal Carrier

Using a grease gun, carefully lubricate seal carrier of mid bearing until grease is just coming out of seal.

F08E0BY

1. Grease seal carrier of mid bearing

Periodic Inspection Chart

The following is to be added for the

XP DI models.

DESCRIPTION

I

: Inspect, verify, clean, adjust, lubricate, replace if necessary

C

: Clean

L

: Lubricate

R

: Replace

FREQUENCY

1

PTO flywheel and seal carrier L L

13

Fuses

Refer to this updated text and illustrations.

Fuses can be found at 2 locations; on the

MPEM and in the electrical box.

MPEM

To access fuses on the MPEM, open front storage compartment cover and remove storage tray.

Locate MPEM on the left side of watercraft.

1

2

F1 : FP 15A

F2 : ACC 2A

F3 : REG 25A

F4 : VTS 7.5A

F5 : BAT 25A

F6 : INJ 15A

1

F1 F2 F3 F4 F5 F6

F08H0JY

1. MPEM

Fuses are identified, look above and besides the fuse holder.

F18H06Y

FUSE IDENTIFICATION

1. Fuse identification

2. Fuse description

Fuse identification:

The fuses (F) are identified from 1 to 6.

Fuse description:

The fuses are described with abbreviation as follows:

FP:

Fuel pump

ACC:

Accessories (information center)

REG: Regulator (charging system)

VTS:

Variable Trim System

BAT:

Battery

INJ:

Injection system

The fuse description is followed by the ampere rating (A).

Reinstall storage tray and properly relatch storage compartment cover.

Electrical Box

To access fuses in the electrical box, open front storage compartment cover.

Locate electrical box on the right side of watercraft.

14

1

Electric bilge pump fuse is located at the bottom of the electrical box.

F08H0KY

1. Electrical box

Unclip and remove cover of the electrical box to expose the holder of the main fuse.

1

F12H02Y

1

1. Electric bilge pump fuse

Properly reinstall removed components.

Properly relatch storage compartment cover.

1°

F18H1BY

TYPICAL

1. Fuse holder

2°

15

TRAILERING, STORAGE

AND PRE-SEASON PREPARATION

The information pertaining to trailering, storage and pre-season preparation is similar to the one explained in the 2003 Operator’s

Guide, except for the following updated text and illustrations.

Storage

Engine Draining

Remove rear access panel.

Check engine drain hose (the lowest one connected to the crankcase cooling outlet). Make sure there is no sand or other particles in it and that it is not obstructed so that water can exit the engine. Clean hose and fitting as necessary.

CAUTION:

Water in engine drain hose should be free to flow out, otherwise water could be trapped in engine. Should water freeze in engine, severe damage will occur. Check engine drain hose for obstructions.

Disconnect the quick connect fitting. Press both tabs and pull fitting.

1

2

F08E0FY

1. Disconnect engine drain hose (crankcase cooling outlet)

2. Air compressor drain line

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. See illustration above.

Antifreezing Protection

NOTE :

This procedure requires approximately 2.8 L (3 U.S. qt.) of antifreeze.

In cool regions where freezing point may be encountered, cooling system should be filled with an equal part of water and antifreeze solution.

16

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.

CAUTION:

Always use ethylene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines.

NOTE:

When available, it is recommended to use biodegradable antifreeze compatible with internal combustion aluminum engines.

This will contribute to protect the environment.

NOTE:

The engine will not have to run during this operation but should have been ran before, to exhaust as much water as possible, from cooling system components.

Hose Pinchers Installation

Some hoses have to be plugged to prevent draining, before filling cooling system jackets with the antifreeze.

Install hose pinchers at the following location:

1

2

F08E0GY

1. Water inlet hose

2. Engine cylinder drain hose (coming from underneath engine)

1

F08E0PY

1. Water outlet hose underneath tuned pipe

17

Hose Disconnection

Disconnect the bottom hose at the water regulator valve on muffler.

Pour antifreeze mix in engine until the colored solution appears at cooling system bleed outlet.

At this point, install a hose pincher on bleed outlet hose.

1

F08E0SY

1

1. Disconnect the bottom hose from water regulator valve

Temporarily install a hose of approximately

1 m (3 ft) in length with a 12.7 mm (1/2 in) internal diameter over the previously disconnected hose.

Antifreeze

Insert a funnel into the temporary hose.

Ensure to hold the funnel approximately 1 m

(3 ft) above the deck when pouring the antifreeze to create enough pressure so that it flows properly.

F08E0MY

1. Bleed outlet hose

Continue to pour until antifreeze appears at the engine drain hose (crankcase cooling outlet). Then, install a hose pincher on this hose.

A

F08E0TY

A. 1 m (3 ft) to ease antifreeze flow

18

1

F08E0JY

1. Engine drain hose (crankcase cooling outlet)

Continue to pour until antifreeze flows in air compressor water outlet hose.

1

NOTE: Most of the antifreeze will drain out when removing the hose pinchers. Use a container to recover it. DISPOSE ANTI-

FREEZE AS PER YOUR LOCAL LAWS AND

REGULATIONS.

1. Bleed outlet hose.

2. Engine drain hose (crankcase cooling cover outlet).

3. Engine cylinder drain hose.

4. Water outlet hose.

5. Water inlet hose.

Install a temporary hose on the open fitting of the water regulator valve.

Pour approximately 200 mL (7 oz) of antifreeze in the temporary hose to allow antifreeze flowing through the water regulator valve and into muffler to protect it.

Remove temporary hoses and reconnect the factory hose to water regulator valve.

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.

At pre-season preparation, drain the remaining antifreeze from cooling system prior to using the watercraft. Ensure no hose pincher was forgotten at storage.

The following steps should be performed to provide the watercraft enhanced protection.

F08E0EY

1. Air compressor water outlet hose

The pouring operation is over.

Remove pinchers in this order to allow proper flow of antifreeze.

19

Clean the bilge with hot water and detergent or with bilge cleaner. Rinse thoroughly. Lift front end of watercraft to completely drain bilge. If any repairs are needed to body or to the hull contact your authorized SEA-DOO dealer. For paint touch up to mechanical parts use Bombardier spray paint.

Final Steps

Refer to this updated text.

Apply a good quality marine wax to the body.

The seat should be partially left opened and the rear access cover and storage tray should be removed during storage. This will avoid engine compartment condensation and possible corrosion.

If the watercraft is to be stored outside, cover it with an opaque tarpaulin to prevent sun rays and grime from affecting the plastic components, watercraft finish as well as preventing dust accumulation.

CAUTION:

The watercraft should never be left in water for storage. Never leave the watercraft stored in direct sunlight.

20

SPECIFICATIONS

ENGINE

Engine type

Induction type

Exhaust system

Exhaust valve

Lubrication

Type

Oil type

Number of cylinders

Displacement

Rev limiter setting

COOLING

Type

ELECTRICAL

Magneto generator output

Ignition system type

Spark plug

Make and type

Gap

Starting system

Battery

Battery

Fuse

Charging system

(REG)

VTS system

Information center

(ACC)

Injection system

(INJ)

Fuel pump (FP)

Bilge pump

FUEL SYSTEM

Fuel type

Fuel injection

XP DI

(6130/6131)

Rotax 947, 2-stroke

Reed valve

Water cooled/water injected with regulator

Rotax Adjustable Variable Exhaust (RAVE)

Oil injection

BOMBARDIER Formula XP-S II synthetic injection oil

2

951.2 cm 3

Open circuit.

Direct flow from propulsion unit

270 W @ 6000 RPM

Digital inductive

NGK, ZFR4F

1.1 mm (.043 in)

Electric starter with reduction gear

12 V, 19 A•h

25 A

25 A

7.5 A

2 A

15 A

15 A

3 A

(58 in

7300 ± 50 RPM

3 )

Regular unleaded gasoline with 87 octane minimum (R+M)/2

Orbital direct fuel injection, twin throttle body

(46 mm (1.81 in))

21

PROPULSION

Propulsion system

Jet pump type

Transmission

Reverse system

Jet pump oil type

Pivoting angle of direction (nozzle)

Minimum required water level for jet pump

DIMENSIONS

Number of passengers

!

Overall length

Overall width

Overall height

Weight

Load limit (passengers + luggage)

CAPACITIES

Fuel tank

Fuel tank reserve (from low level signal

Oil injection tank

Impeller shaft reservoir

Capacity

Oil level

XP DI

(6130/6131)

Bombardier Formula pump

Axial flow, single stage

Direct drive/split front and rear

No

SEA-DOO synthetic polyolester oil SAE 75W90 GL5

~ 20°

90 cm (3 ft)

2

272 cm (107 in)

112 cm (44.1 in)

104 cm (40.6 in)

274 kg (605 lb)

181 kg (400 lb)

51 L (13.5 U.S. gal)

9.8 L (2.6 U.S. gal)

4 L (1.1 U.S. gal)

100 mL (3.4 U.S. oz)

Up to plug

!

Refer to load limit.

BOMBARDIER INC. reserves the right to make changes in design and specifications and/or to make additions to, or improvements in its products without imposing any obligation upon itself to install them on its products previously manufactured.

22

OPERATOR’S GUIDE XP DI

This supplement must be used in conjunction with the

Sea-Doo 2003 Operator’s Guide

WARNING

Read this guide thoroughly.

It contains important safety information.

® TM TRADEMARKS OF BOMBARDIER IN. OR ITS SUBSIDIARIES.

©2003 BOMBARDIER INC. ALL RIGHTS RESERVED. PRINTED IN THE EU.

219 000 294