SeaDoo GTI LE RFI User manual

SeaDoo GTI LE RFI User manual
Date: November 16 , 2004
Subject: Storage Procedure (2-stroke
No.
2004-19
engine units)
YEAR
MODEL
MODEL NUMBER
3D™ RFI
6157/6158
GTI™ / GTI RFI
6133/6134/6137/6138
GTI LE / GTI LE RFI
6135/6136/6139/6140
XP® DI
6151/6152
SERIAL NUMBER
2004
All
N O T E : Refer to appropriate Sea-Doo Shop Manual
when servicing a Sea-Doo watercraft.
ENGINE DRAINING
Model(s): All Carburetor-Equipped Engines
Check engine drain hose [ 1]] (lowest hose of
engine). 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 must
be free to flow out, otherwise water could
be trapped in engine. Should water freeze in
engine, severe damage will occur. Check engine
drain hose for obstructions.
F07E0MA
Printed in Canada. (sbs2004-020 MD)
©2004 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
®™Trademarks of Bombardier Recreational Products Inc. or its affiliates.
* Trademark of Bombardier Inc. used under license.
1
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Model(s): RFI
Disconnect the water supply hose used to cool the
magneto. It features a quick connect fitting. Press
both tabs [ 1]] and pull fitting in order to disconnect
hose. This hose is located at the bottom of the
magneto cover beside the engine support.
1
F17E0AA
Model(s): 3D RFI
N O T E : It may be necessary to position the end
of the hose in a lower area of the bilge to allow
proper drainage.
1
F22E02A
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Water should flow out of the fitting [ 1]] (magneto
cooling circuit) and hose [ 2]] (crankcase heat
exchanger).
2
Push and hold hose against bilge so that draining
can take place.
CAUTION: Water in heat exchanger system must
be free to flow out. Should water freeze in
engine, severe damage will occur.
Reconnect hose when done.
F17E0BA
1
Model(s): XP DI
Disconnect the quick connect fitting [ 1]] ; press
both tabs and pull fitting.
N O T E : Photo also shows the air compressor
drain line [ 2]] .
Lower hose as necessary so that draining can
take place.
Reconnect fitting when done.
N O T E : Ensure air compressor drain line is not
obstructed. Clean as necessary.
2
1
F08E0FA
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PROPULSION SYSTEM
Model(s): All
Jet Pump
Lubricant in impeller shaft reservoir should be
drained. Reservoir should be cleaned and refilled
with SEA-DOO synthetic 75W90 GL5 polyolester
oil. Refer to JET PUMP in Shop Manual for proper
procedure.
CAUTION: Use only SEA-DOO jet pump oil
or equivalent synthetic gear oil, otherwise
component service life could be reduced. Do
not mix oil brands or types.
PTO Flywheel
Model(s): All except XP DI
Remove PTO flywheel guard.
Lubricate PTO flywheel at grease fitting [ 1]] with
synthetic grease (P/N 293 550 010).
CAUTION: Do not lubricate excessively. Stop
immediately when a slight movement is noticed
on rubber boot.
CAUTION: Never leave any clothing, tool or
other objects near PTO flywheel and driveshaft.
F01I0BA
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Service
Seal Carrier
Model(s): XP DI and 3D
Lubricate seal carrier [ 1]] of driveshaft support with
synthetic grease. Stop lubricating when grease
starts coming out of seal.
1
F08E0BA
FUEL SYSTEM
Model(s): All
Verify fuel system.
Check fuel hoses and carburetor(s), if so
equipped, for leaks.
Replace damaged hoses or clamps if necessary.
N O T E : Sea-Doo Fuel Stabilizer (P/N 413 408 600)
or equivalent should be added in fuel tank to
prevent fuel deterioration and, if so equipped,
carburetor(s) gumming. Follow manufacturer’s
instructions for proper use.
On RFI and DI models, fill up fuel tank completely.
Ensure there is no water inside fuel tank.
CAUTION: Should any water be trapped inside
fuel tank, severe internal damage will occur to
the fuel injection system (if so equipped).
CAUTION: Fuel stabilizer should be added prior
to engine lubrication to ensure fuel system
components protection against varnish deposits.
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 WARNING
Fuel is flammable and explosive under certain
conditions. Always work in a well ventilated
area. Do not smoke or allow open flames
or sparks in the vicinity. Fuel tank may be
pressurized, turn cap slowly when opening.
When fueling, keep watercraft level. Do not
overfill or top off the fuel tank and leave
watercraft in the sun. As temperature increases,
fuel expands and might overflow. Always
wipe off any fuel spillage from the watercraft.
Periodically inspect fuel system. Always turn the
fuel tank valve (if so equipped) to OFF position
when storing the watercraft.
Model(s): Carburetor-Equipped
Always turn the fuel valve to OFF position when
storing the watercraft.
COOLING SYSTEM
FLUSHING AND ENGINE
INTERNAL LUBRICATION
Cooling system has to be flushed with fresh water
to prevent salt, sand or dirt accumulation which will
clog water passages.
Engine must be lubricated to prevent corrosion on
internal parts.
For proper procedure, refer to FLUSHING AND
LUBRICATION in Shop Manual.
N O T E : On the 3D RFI, the hose adapter [ 1]] is
located on the right hand side on the jet pump
support.
1
F22J01A
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BATTERY
Model(s): All
For battery removal, cleaning and storage, refer to
CHARGING SYSTEM in Shop Manual.
Model(s): 3D RFI
Refer to STORAGE in Shop Manual Supplement
(P/N 219 100 199) and to CHARGING SYSTEM in
Shop Manual.
WATERCRAFT CLEANING
Clean the bilge with hot water and mild detergent
or with bilge cleaner. Rinse thoroughly. Lift front
end of watercraft to completely drain bilge. If any
repairs are needed to body or to the hull, touch
up paint and Gelcote† repair kits are available.
Replace damaged labels/decals.
Wash the body with soap and water solution (use
mild detergent only). Rinse thoroughly with fresh
water. Remove marine organisms from the hull.
Apply a nonabrasive wax.
CAUTION: Never clean fiberglass and plastic
parts with strong detergent, degreasing agent,
paint thinner, acetone, etc.
If the watercraft is to be stored outside, cover it with
an opaque tarpaulin to prevent sun rays and grime
from affecting the plastic components, watercraft
finish as well as preventing dust accumulation.
CAUTION: The watercraft must never be Ieft in
water for storage. Never leave the watercraft
stored in direct sunlight.
† Gelcote is a registered trademark of Gelcote International.
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ADDITIONAL
RECOMMENDED
PROTECTION
Model(s): All
In cool regions (where freezing point may be
encountered), cooling system should be filled with
pure undiluted antifreeze.
CAUTION: Antifreeze must be fed in cooling
system, otherwise remaining water will freeze.
If antifreezing is not performed adequately,
engine/exhaust system may freeze and cause
severe damage. Always use ethylene glycol
antifreeze containing corrosion inhibitors
specifically recommended for aluminum
engines.
CAUTION: Use only undiluted antifreeze (100%
concentration). The pre-mixed antifreeze
available from Bombardier Recreational
Products Inc. is not suitable for this particular
application. Its concentration will be reduced
when mixed with remaining water trapped in
water jackets. Never use antifreeze for RVs
(recreational vehicles).
N O T E : When available, it is recommended to use
biodegradable antifreeze compatible with internal
combustion aluminum engines. This will contribute
to protect the environment.
N O T E : 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.
Model(s): All GTI's
N O T E : This procedure requires approximately 2.5 L
(2.6 U.S. qt) of antifreeze.
Hose Pinchers Installation
Some hoses have to be plugged to prevent
draining, before filling cooling system jackets
with the antifreeze.
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Install hose pinchers where indicated.
Photo shows engine drain hose [ 1]] on GTI and GTI
LE models, 717 engine.
1
F17E05A
Install hose pinchers where indicated.
Photo shows engine drain hose [ 1]] on RFI models,
787 engine.
F15E01A
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N O T E : On RFI models, make sure the hose [ 1]] is
properly connected to the magneto cover.
1
F17E0AB
Install a hose pincher on injection hose [ 1]] going
to tuned pipe.
Photo shows hose pincher on injection hose
going to tuned pipe on GTI and GTI LE models,
717 engine.
F17E03A
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Photo shows engine water outlet hose [ 1]] , 717
and 787 RFI engines.
1
F17E01A
Hose Disconnection
Some hoses have to be disconnected. Disconnect
hoses at the following location.
Photo shows water inlet hose [ 1]] (to be
disconnected), 717 and 787 RFI engines.
Model(s): 717 Engines
Temporarily install a short piece of hose to engine
water inlet at cylinder head.
F06E0EB
1
Model(s): All GTI's
Insert a funnel into hose and pour antifreeze in
engine until the colored solution appears at the
cooling system bleed outlet.
F07E0LA
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Model(s): 787 RFI Engines
Disconnect hose [ 2]] just above T-fitting [ 1]]
as shown.
1
F15E02A
2
Install a hose pincher [ 1]] just below T-fitting.
Pour approximately 300 mL (10 oz) of antifreeze in
the water regulator valve supply hose to allow
antifreeze flowing through the valve and into
muffler to protect them.
Reconnect hose to T-fitting and remove hose
pincher (if applicable).
Model(s): All GTI's
Remove temporary hose on 717 engines and
reconnect engine water outlet hose.
Remove hose pinchers.
F15E03A
1
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.
N O T E : 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 preseason preparation, drain the remaining
antifreeze from cooling system prior to using
the watercraft. Ensure no hose pinchers were
forgotten at storage.
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Model(s): 3D
Engine and Tuned Pipe
N O T E : This procedure requires approximately 2.5 L
(2.6 U.S. qt) of antifreeze.
Remove rear access panel and engine cover. Lock
steering pole in upright position with the holder.
 WARNING
Always install steering pole holder while
working in the engine compartment.
Install hose pinchers and disconnect hoses at the
locations shown in photo, where [ 1]] indicates
the engine cylinder drain hose and [ 2]] the heat
exchanger drain hose.
2
1
F22E03A
Disconnect water supply hose [ 1]] .
2
Pinch water outlet hose [ 2]] .
1
Install a temporary hose to engine fitting [ 3]] .
3
F22E04A
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TYPICAL
F07E0LA
Insert a funnel into the temporary hose and pour
antifreeze in engine until the colored solution
appears at the cooling system bleed outlet [ 1]] . Use
a container to recover the water/antifreeze.
Place a container at rear of watercraft to recover
the water/antifreeze from the vehicle hose adapter.
Remove the 2 hose pinchers from the engine
drain hoses.
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.
1
F22L0HA
Expansion Pipe and Muffler
Disconnect the tuned pipe water supply hose
[ 1]] at T-fitting.
Insert a funnel into the hose.
Raise the hose as high as possible and pour 1.2 L
(1.3 U.S. qt) of antifreeze.
1
CAUTION: It is important to keep the hose as
high as possible so the antifreeze can reach the
end of the expansion pipe.
Reconnect hose to the T-fitting.
14 / 20
F22E06A
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Complete Cooling System
N O T E : For the above engine and exhaust system
procedures, although antifreeze will mainly drain
out, it has mixed with the water that was possibly
trapped in the water jackets and thus preventing
freezing problems.
At preseason preparation, drain the remaining
antifreeze from cooling system prior to using
the watercraft. Ensure no hose pinchers were
forgotten at storage.
Model(s): XP DI
N O T E : This procedure requires approximately 2.8 L
(3 U.S. qt) of antifreeze.
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:
Photo shows water inlet hose [ 1]] and engine
cylinder drain hose [ 2]] (coming from underneath
engine).
1
2
F08E0GA
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Photo shows water outlet hose [ 1]] underneath
tuned pipe.
1
F08E0PA
Hose Disconnection
Disconnect the bottom hose [ 1]] at the water
regulator valve on muffler.
Temporarily install a hose of approximately
1 m (3 ft) with an internal diameter of
12.7 mm (1/2 in) over the previously disconnected
hose.
F08E0SA
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Service
Antifreeze
Insert a funnel into the temporary hose. Ensure to
hold the funnel approximately 1 m (3 ft) [ A]] above
the deck when pouring the antifreeze to create
enough pressure so that it flows properly.
Pour antifreeze mix in engine until the colored
solution appears at cooling system bleed outlet.
A
F08E0TA
At this point, install a hose pincher [ 1]] on bleed
outlet hose.
1
F08E0MA
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Continue to pour until antifreeze appears at the
engine drain hose [ 1]] (crankcase cooling outlet).
Then, install a hose pincher on this hose.
1
F08E0JA
Continue to pour until antifreeze flows in air
compressor water outlet hose [ 1]] .
1
The pouring operation is over.
Remove pinchers in the following order to allow
proper flow of antifreeze:
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.
N O T E : 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.
F08E0EA
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 them.
Remove temporary hoses and reinstall the factory
hose to water regulator valve.
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N O T E : 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.
N O T E : At preseason preparation, drain the
remaining antifreeze from cooling system prior to
using the watercraft. Ensure no hose pinchers
were forgotten at storage.
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.
ANTICORROSION
TREATMENT
Model(s): All
Wipe off any residual water in the engine
compartment.
Spray BOMBARDIER LUBE lubricant over all
metallic components in engine compartment.
Lubricate the throttle cable with BOMBARDIER
LUBE lubricant.
N O T E : The seat should be partially left opened
during storage (the engine cover for the XP DI
models). This will avoid engine compartment
condensation and possible corrosion.
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CHECK LIST
O P E RAT I O N
✔
Check engine drain hose(s).
Drain and clean impeller shaft reservoir.
Lubricate PTO flywheel or seal carrier.
Verify fuel system.
Add Sea-Doo fuel stabilizer.
Flush cooling system.
Lubricate the engine.
Remove, clean and store the battery.
Clean the bilge.
Wash the body.
Add antifreeze solution to the cooling
system (in cool regions).
Spray BOMBARDIER LUBE over
all metallic components in engine
compartment and in throttle cable.
Spray BOMBARDIER LUBE in oil
injection pump cable .
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