Datasheet | SeaDoo GTI LE Technical data

2003

Shop Manual

GTI, GTI LE, GTI LE RFI, GTX DI,

XP DI, RX DI, LRV DI, GTX 4-TEC SERIES

Legal deposit:

National Library of Quebec

2 nd trimester 2003

National Library of Canada

All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc.

© Bombardier Inc. 2003

Technical Publications

Bombardier Inc.

Valcourt (Quebec) Canada

Printed in Canada

® *Registered trademarks of Bombardier Inc.

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

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

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

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

SEA-DOO ®

BOMBARDIER-ROTAX ®

BOMBARDIER LUBE ®

BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil

BOMBARDIER Formula XP-S DI Synthetic Injection Oil

BOMBARDIER-ROTAX Injection Oil

Sea-Doo Synthetic Grease

Sea-Doo LK TM

DESS TM

Rotax ®

O.P.A.S.

TM

TOPS TM

TABLE OF CONTENTS

SECTION SUBSECTION PAGE

SAFETY NOTICE ..................................................................................................................................

INTRODUCTION ...................................................................................................................................

01 SERVICE TOOLS

AND PRODUCTS

02

03

MAINTENANCE

TROUBLESHOOTING

01 - Table of contents ......................................................................

02 - Mandatory service tools............................................................

III

IV

01-01-1

01-02-1

03 - Optional service tools................................................................

01-03-1

04 - Service products .......................................................................

01-04-1


02-01-1

02 - Periodic inspection chart ...........................................................

02-02-1

03 - Flushing and lubrication.............................................................

02-03-1

04 - Water-flooded engine................................................................

02-04-1

05 - Storage......................................................................................

02-05-1

01 - Troubleshooting chart ...............................................................

03-01-1

04 ENGINE (2-stroke)

05

06

07

08

09

ENGINE (4-TEC)

ENGINE

MANAGEMENT (RFI)

ENGINE

MANAGEMENT (DI)

ENGINE

MANAGEMENT

(4-TEC)

COOLING SYSTEM


04-01-1

02 - Leak test ...................................................................................

04-02-1

03 - Removal and installation ...........................................................

04-03-1

04 - Magneto system .......................................................................

04-04-1

05 - Top end .....................................................................................

04-05-1

06 - Bottom end ...............................................................................

04-06-1

07 - Rotary valve...............................................................................

04-07-1

08 - Exhaust system.........................................................................

04-08-1


05-01-1

02 - Leak test ...................................................................................

05-02-1

03 - Intake system............................................................................

05-03-1

04 - Exhaust system.........................................................................

05-04-1


05-05-1

06 - PTO housing/magneto ..............................................................

05-06-1

07 - Lubrication system....................................................................

05-07-1

08 - Cylinder head and valves...........................................................

05-08-1

09 - Engine block..............................................................................

05-09-1


06-01-1

02 - Overview...................................................................................

06-02-1

03 - Diagnostic procedures ..............................................................

06-03-1

04 - Component inspection ..............................................................

06-04-1

05 - Troubleshooting summary ........................................................

06-05-1

06 - Adjustment................................................................................

06-06-1


06-07-1


07-01-1

02 - Overview...................................................................................

07-02-1

03 - Component inspection and adjustment ....................................

07-03-1


07-04-1


08-01-1

02 - Overview...................................................................................

08-02-1

03 - Component inspection and adjustment ....................................

08-03-1


08-04-1


09-01-1

02 - Circuit, components and care ...................................................

09-02-1

SMR2003_001_00_00A2.FM

I

II

TABLE OF CONTENTS

SECTION

10

11

12

13

14

15

FUEL SYSTEM

LUBRICATION

SYSTEM (2-stroke)

ELECTRICAL

SYSTEM

PROPULSION

SYSTEM

STEERING SYSTEM

SUSPENSION

16 HULL/BODY

17 TECHNICAL DATA

18 WIRING DIAGRAMS

SUBSECTION PAGE


10-01-1

02 - Fuel circuit ................................................................................

10-02-1

03 - Air intake (2-stroke)...................................................................

10-03-1

04 - Carburetor.................................................................................

10-04-1


11-01-1

02 - Oil injection system ..................................................................

11-02-1

03 - Oil injection pump.....................................................................

11-03-1


12-01-1

02 - Ignition system (carbureted engines) .......................................

12-02-1

03 - Charging system.......................................................................

12-03-1

04 - Starting system.........................................................................

12-04-1

05 - Instruments and accessories....................................................

12-05-1

06 - DESS (carbureted and RFI engines)..........................................

12-06-1


13-01-1

02 - Jet pump...................................................................................

13-02-1

03 - Drive system.............................................................................

13-03-1

04 - Reverse system........................................................................

13-04-1

05 - Variable trim system .................................................................

13-05-1


14-01-1

02 - Steering system........................................................................

14-02-1

03 - Alignment .................................................................................

14-03-1


15-01-1

02 - Direct action suspension ..........................................................

15-02-1


16-01-1

02 - Adjustment and repair ..............................................................

16-02-1

01 - GTI and GTI LE models.............................................................

17-01-1

02 - GTI LE RFI models....................................................................

17-02-1

03 - GTX DI, RX DI and XP DI models..............................................

17-03-1

04 - LRV DI models..........................................................................

17-04-1

05 - GTX 4-TEC models....................................................................

17-05-1

01 - Wiring diagrams........................................................................

18-01-1

SMR2003_001_00_00A2.FM

SAFETY NOTICE

SAFETY NOTICE

0

This manual has been prepared as a guide to correctly service and repair all 2003 SEA-DOO watercraft.

See model list below.

This edition was primarily published to be used by watercraft mechanical technicians who are already familiar with all service procedures relating to Bombardier made watercraft. Mechanical technicians should attend training courses given by Bombardier Training Dept.

Please note that the instructions will apply only if proper hand tools and special service tools are used.

This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts

Catalog.

It is understood that this manual may be translated into another language. In the event of any discrepancy, the English version shall prevail.

The content depicts parts and/or procedures applicable to the particular product at time of writing. Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these.

In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts.

The use of Bombardier parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt.

The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document.

Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab, self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking device is impaired, it must be renewed.

This manual emphasizes particular information denoted by the wording and symbols:



WARNING

Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death.

CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.

NOTE: Indicates supplementary information needed to fully complete an instruction.

Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice.

Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations.

III

SMR2003_001_00_00A2.FM

INTRODUCTION

IV

INTRODUCTION

T h i s S h o p M a n u a l c o v e r s t h e f o l l o w i n g

BOMBARDIER made SEA-DOO ® 2003 watercraft models.

MODELS

XP DI

XP DI International

GTI (blue) International

GTI (ultraviolet)

GTI California

(ultraviolet)

GTI International

(ultraviolet)

GTI LE (earthen clay)

GTI LE International

(earthen clay)

GTI LE RFI

GTI LE RFI International

GTX DI

GTX DI International

RX DI

RX DI International

LRV DI

GTX 4-TEC

GTX 4-TEC International

GTX 4-TEC Vans Triple

Crown Edition

GTX 4-TEC Vans Triple

Crown Edition

International

GTX 4-TEC Supercharged

(viper red)


International (viper red)


(yellow)


International (yellow)


Limited


Limited International

ENGINE

TYPE

947 DI

947 DI

717

717

MODEL

NUMBER

6131

6130

5568

5598

717 5567

717

717

717

787 RFI

787 RFI

947 DI

947 DI

947 DI

947 DI

947 DI

1503

1503

1503

1503

1503

1503

1503

1503

1503

1503

6125

6129

6128

6106

6105

6108

6107

5597

6102

6101

6104

6103

6119

6118

6123

6122

5771

6112

6111

6126

0

HULL IDENTIFICATION NUMBER

(H.I.N.)

It is located on footboard at the rear of watercraft.

F00L2EA

1. Hull Identification Number (H.I.N.)

F08L0QA

1

TYPICAL

1. Hull Identification Number (H.I.N.)

1

SMR2003_001_00_00A2.FM

INTRODUCTION

All Models

The Hull Identification Number is composed of 12 digits:

Z Z N 1 2 3 4 5 L 4 9 5

Serial number*

Model year

Year of production

Month of production

Manufacturer

F00A0CB

*A letter may also be used as a digit.

ENGINE IDENTIFICATION

NUMBER (E.I.N.)

717 Engines

The Engine Identification Number is located on the upper side of the magneto housing.

F01D87A

1

1. Engine Identification Number (E.I.N.)

947 DI Engines

The Engine Identification Number is located on the upper crankcase on MAGNETO side.

1

F01D01A

TYPICAL


787 RFI Engines

The Engine Identification Number is located on the upper crankcase on PTO side.

F06D15A


1

ARRANGEMENT OF THIS

MANUAL

The manual is divided into many major sections as you can see in the main table of contents at the beginning of the manual.

Several sections are divided in various subsections.

There is a table of contents at the beginning of many sections.

SMR2003_001_00_00A2.FM

V

INTRODUCTION

VI

F01A0CS

TYPICAL PAGE

Page heading indicates section and subsection detailed.

Subsection title indicates beginning of the subsection.

Italic sub-title above exploded view indicate pertaining models.

Drop represents a liquid product to be applied to a surface. In this case

Loctite 243 to screw threads.

Subsection 04 (MAGNETO SYSTEM)

Loctite

243

Exploded view assits you in identifying parts and related positions.

Bold face number indicates special procedure concerning this part.

F01D4WS

Loctite

648

145 Nm

(107 lbfft)

Illustration number for publishing process.

Loctite

243

Loctite

243

Loctite

243

Loctite

243

Dotted box contains parts of a particular model or an exploded view.

Anti-seize lubricant

03-04-1

Page numbering system:

03: ENGINE section

04: MAGNETO SYSTEM subsection

1: First page of this subsection

SMR2003_001_00_00A2.FM

INTRODUCTION

TYPICAL PAGE

Sub-title with part name(s) from exploded view.

Title indicates main procedure to be carried-out.

Service tool to be used to perform a certain procedure.

Title in italic indicates a particular procedure concerning a model.

Sub-sub-title in this case indicates that particular procedure for XP is finished, so from this point, all others models are concerned.

Section 06 FUEL SYSTEM

Subsection 03 (CARBURETORS)

CARBURETOR REMOVAL

To remove carburetors from engine, proceed as follows:

Remove air vent tube support.

Unlock retaining slides holding air intake silencer base.

Remove air intake silencer base from watercraft.

Remove screws holding flame arrester base support to cylinder head cover.

Unscrew base retaining screws then remove base from carburetors and move to front of watercraft.

Turn the valve to OFF position.

NOTE: For fuel line removal, use pliers (P/N 295

000 054).

Disconnect pulse line from fuel pump.

Disconnect fuel fuel supply line from fuel pump.

Disconnect fuel return line.

Disconnect oil injection pump cable, throttle cable and choke cable.

XP Model Only

Remove screws no. 6 and lock washers no. 7 retaining carburetors.

All Others Models

Remove 4 bolts no. 8 and lock washers no. 12 from rotary valve cover then move carburetors and rotary valve cover on top of engine.

NOTE: When removing rotary valve cover , pay attention that the rotary valve stay in place, other-wise it must be timed.

Remove carburetors from intake manifold.

Disconnect fuel bypass line between carburetors (twin carburetors).

Remove carburetor(s) from rotary valve cover.

DISASSEMBLY AND INSPECTION

Inspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.).

Diaphragm

PUMP DIAPHRAGM LEAK TEST

Using a suitable pump gauge tester, perform the following test proceeding as follows:

- Install pump gauge tester (P/N 295 000 083) on pulse

nipple.

- Pump tester until it reaches 28 kPa (4 PSI).

F01F0XB

TYPICAL

1

2

2 1

1

2

A

Diaphragm must stand pressure for 10 seconds. If pressure drops, replace diaphragm.

Sub-sub-title in capital indicates a particular testing, adjustment or repair procedure.

Illustration always follows text it is pertained to.

TYPICAL mention indicates a general view which does not represent full detail.

Numbers in a frame are used to give a sequence to be perfomed.

Letters are used for any measures.

06-03-4

Bold numbers in the text refer to the parts shown in the exploded view at the beginning of the subsection.

Numbers are used for description of components.

F01A0BS

SMR2003_001_00_00A2.FM

VII

INTRODUCTION

ADC

AC

APS

ATS

B.U.D.S.

TPS

VDC

VCK

VDC

VTS

WTS

N.A.

OPT

P/N

PFD

PSI

PTO

RAVE

RFI

RPM

STD

TBD

TDC

CDI

CPS

CSI

DC

DESS

DI

E.I.N.

ECM

ECU

EPA

HP

LED

MAG

MPEM

MPH

MPI

LIST OF ABBREVIATIONS USED

IN THIS MANUAL

DESCRIPTION

Analog to Digital Conversion

Alternate Current

Air Pressure Sensor

Air Temperature Sensor

Bombardier Utility and Diagnostic

Software

Capacitor Discharge Ignition

Crankshaft Position Sensor

Cooling System Indicator

Direct Current

Digitally Encoded Security System

Direct Injection

Engine Identification Number

Engine Control Module

Electronic Control Unit

Environmental Protection Agency (USA)

Horse Power

Light Emitting Diode

Magneto

Multi-Purpose Electronic Module

Mile Per Hour

Multi Protocol Interface

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

To Be Determined

Top Dead Center

Throttle Position Sensor

Volt Direct Current

Vehicle Communication Kit

Volt Direct Current

Variable Trim System

Water Temperature Sensor

GENERAL INFORMATION

The use of RIGHT (starboard) and LEFT (port) indications in the text, always refers to driving position

(when sitting on watercraft).

Besides, in the marine industry, FRONT is called

BOW and REAR is called STERN.

1 2

F01L45B

1. Left (port)

2. Right (starboard)

The information and component/system descriptions contained in this manual are correct at time of writing. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured.

Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation.

This Shop Manual uses technical terms which may be different from the ones of the Parts Catalogs.

When ordering parts always refer to the specific model Parts Catalogs.

ILLUSTRATIONS AND

PROCEDURES

The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function.

CAUTION: These watercraft are designed with parts dimensioned mostly in the metric system.

However some components may be from the imperial system. When replacing fasteners, make sure to use only those recommended by Bombardier.

VIII

SMR2003_001_00_00A2.FM

INTRODUCTION

As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained.

A number of procedures throughout the book require the use of special tools. Before undertaking any procedure, be sure that you have on hand all the tools required, or approved equivalents.

ENGINE EMISSIONS

INFORMATION

Manufacturer’s Responsibility

Beginning with 1999 model year engines, PWC manufacturers of marine engines must determine the exhaust emission levels for each engine horsepower family and certify these engines with the

United States of America Environmental Protection Agency (EPA). An emissions control information label, showing emission levels and engine specifications, must be placed on each vehicle at the time of manufacture.

Dealer Responsibility

When performing service on all 1999 and more recent Sea-Doo watercrafts that carry an emissions control information label, adjustments must be kept within published factory specifications.

Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards.

Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications.

Exceptions include manufacturer’s prescribed changes, such as altitude adjustments for example.

Owner Responsibility

The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed certification standards.

The owner/operator is not to, and should not allow anyone to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.

SMR2003_001_00_00A2.FM

EPA Emission Regulations

All new 1999 and more recent Sea-Doo watercrafts manufactured by Bombardier are certified to the

EPA as conforming to the requirements of the regulations for the control of air pollution from new watercraft engines. This certification is contingent on certain adjustments being set to factory standards.

For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practicable, returned to the original intent of the design.

The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations:

VIA U.S. POSTAL SERVICE:

Office of Mobile Sources

Engine Programs and Compliance Division

Engine Compliance Programs Group (6403J)

401 M St. NW

Washington, DC 20460

VIA EXPRESS or COURIER MAIL:

Office of Mobile Sources

Engine Programs and Compliance Division

Engine Compliance Programs Group (6403J)

501 3 rd St. NW

Washington, DC 20001

EPA INTERNET WEB SITE: http:/www.epa.gov/omswww

SELF-LOCKING FASTENERS

PROCEDURE

The following describes the most common application procedures when working with self-locking fasteners.

Use a metal brush or a screwtap to clean the hole properly then use a solvent (Methyl-Chloride), let act during 30 minutes and wipe off. The solvent utilization is to ensure the adhesive works properly.

IX

INTRODUCTION

LOCTITE APPLICATION

PROCEDURE

The following describes the most common application procedures when working with Loctite products.

NOTE: Always use proper strength Loctite product as recommended in this Shop Manual.

THREADLOCKER

Uncovered Holes (bolts and nuts)

Blind Holes

2

1

1

2

A00A3LA

1. Apply here

2. Do not apply

1. Clean threads (bolt and nut) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry.

3. Choose proper strength Loctite threadlocker.

4. Fit bolt in the hole.

5. Apply a few drops of threadlocker at proposed tightened nut engagement area.

6. Position nut and tighten as required.

A00A3MA

1. On threads

2. On threads and at the bottom of hole

1. Clean threads (bolt and hole) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on threads (bolt and nut) and allow to dry for 30 seconds.

3. Choose proper strength Loctite threadlocker.

4. Apply several drops along the threaded hole and at the bottom of the hole.

5. Apply several drops on bolt threads.

6. Tighten as required.

Stud in Blind Holes

2

1 3

A00A5RA

1. On threads

2. On threads and in the hole

3. Onto nut threads

X

SMR2003_001_00_00A2.FM

INTRODUCTION

1. Clean threads (stud and hole) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry.

3. Put several drops of proper strength Loctite threadlocker on female threads and in hole.

4. Apply several drops of proper strength Loctite on stud threads.

5. Install stud.

6. Install cover, etc.

7. Apply drops of proper strength Loctite on uncovered threads.

8. Tighten nuts as required.

Preassembled Parts

Adjusting Screw

1

2

1

2

A00A3OA

1. Apply here

2. Do not apply

1. Clean bolts and nuts with solvent.

2. Assemble components.

3. Tighten nuts.

4. Apply drops of proper strength Loctite on bolt/nut contact surfaces.

5. Avoid touching metal with tip of flask.

NOTE: For preventive maintenance on existing equipment, retighten nuts and apply proper strength

Loctite on bolt/nut contact surfaces.

A00A3PA

1. Apply here

2. Plunger

1. Adjust screw to proper setting.

2. Apply drops of proper strength Loctite threadlocker on screw/body contact surfaces.

3. Avoid touching metal with tip of flask.

NOTE: If it is difficult to readjust, heat screw with a soldering iron (232°C (450°F)).

STRIPPED THREAD REPAIR

Stripped Threads

5

2

1

3

A00A3QA

1. Release agent

2. Stripped threads

3. Form-A-Thread

4. Tape

5. Cleaned bolt

6. Plate

7. New threads

8. Threadlocker

4

8

7

6

SMR2003_001_00_00A2.FM

XI

INTRODUCTION

Standard Thread Repair

1. Follow instructions on Loctite FORM-A-THREAD

81668 package.

2. If a plate is used to align bolt: a. Apply release agent on mating surfaces.

b. Put waxed paper or similar film on the surfaces.

3. Twist bolt when inserting it to improve thread conformation.

NOTE: NOT intended for engine stud repairs.

Repair of Small Holes/Fine Threads

Option 1: Enlarge damaged hole, then follow Standard Thread Repair procedure.

Option 2: Apply FORM-A-THREAD on the screw and insert in damaged hole.

Permanent Stud Installation (light duty)

1. Use a stud or thread on desired length.

2. DO NOT apply release agent on stud.

3. Do a Standard Thread Repair.

4. Allow to cure for 30 minutes.

5. Assemble.

GASKET COMPOUND

All Parts

1 2

NOTE: Avoid grinding.

2. Clean both mating surfaces with solvent.

3. Spray Loctite Primer N on both mating surfaces and on both sides of gasket. Allow to dry 1 or 2 minutes.

4. Apply GASKET ELIMINATOR 518 (P/N 293 800

038) on both sides of gasket, using a clean applicator.

5. Place gasket on mating surfaces and assemble immediately.

NOTE: If the cover is bolted to blind holes (above), apply proper strength Loctite in the hole and on threads. Tighten.

If holes are sunken, apply proper strength Loctite on bolt threads.

6. Tighten as usual.

MOUNTING ON SHAFT

Mounting with a Press

1

A00A3SA

1 3

1. Proper strength Loctite

2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518

(P/N 293 800 038) on both sides of gasket

3. Loctite Primer N only

1. Remove old gasket and other contaminants with Loctite Chisel remover (P/N 413 708 500).

Use a mechanical mean if necessary.

XII

3

2

1

A00A3UA

1. Bearing


3. Shaft

Standard

1. Clean shaft external part and element internal part.

2. Apply a strip of proper strength Loctite on shaft circumference at insert or engagement point.

NOTE: Retaining compound is always forced out when applied on shaft.

3. DO NOT use anti-seize Loctite or any similar product.

4. No curing period is required.

SMR2003_001_00_00A2.FM

INTRODUCTION

Mounting in Tandem

1. Apply retaining compound on internal element bore.

2. Continue to assemble as shown above.

CASE-IN COMPONENTS

Metallic Gaskets

A00A3VA

1


1. Clean inner housing diameter and outer gasket diameter.

2. Spray housing and gasket with Loctite Primer N

(P/N 293 800 041).

3. Apply a strip of proper strength Loctite on leading edge of outer metallic gasket diameter.

NOTE: Any Loctite product can be used here. A low strength liquid is recommended as normal strength and gap are required.

4. Install according to standard procedure.

5. Wipe off surplus.

6. Allow it to cure for 30 minutes.

NOTE: Normally used on worn-out housings to prevent leaking or sliding.

It is generally not necessary to remove gasket compound applied on outer gasket diameter.

SMR2003_001_00_00A2.FM

31

32

33

34

27

28

29

30

N•m

20

21

22

23

24

25

26

35

36

37

TIGHTENING TORQUES

Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to following table.The table also gives the metric conversion.

6

7

8

9

4

5

N•m

1

2

3

16

17

18

19

10

11

12

13

14

15

FASTENER SIZE (8.8)

M4

M5

M6

Lbf•in

9

18

27

35

44

53

62

71

80

89

97

106

115

124

133

142

150

159

168

FASTENER SIZE (8.8)

M8

23

24

24

25

20

21

21

22

Lbf•ft

15

15

16

17

18

18

19

26

27

27

XIII

INTRODUCTION

XIV

64

65

66

67

60

61

62

63

56

57

58

59

52

53

54

55

48

49

50

51

44

45

46

47

N•m

38

39

40

41

42

43

76

77

78

79

80

81

82

72

73

74

75

68

69

70

71

FASTENER SIZE (8.8)

M10

M12

47

48

49

49

44

45

46

46

41

42

43

44

38

39

40

41

35

36

37

38

32

33

34

35

Lbf•ft

28

29

30

30

31

32

56

57

58

58

59

60

60

53

54

55

55

50

51

52

52

106

107

108

109

110

111

112

113

98

99

100

101

102

103

104

105

94

95

96

97

90

91

92

93

N•m

83

84

85

86

87

88

89

122

123

124

125

126

127

114

115

116

117

118

119

120

121

FASTENER SIZE (8.8)

81

82

83

83

78

79

80

80

75

76

77

77

72

73

74

74

69

70

71

72

66

67

68

69

Lbf•ft

61

62

63

63

64

65

66

90

91

91

92

93

94

87

88

89

89

84

85

86

86

SMR2003_001_00_00A2.FM

135

136

137

138

139

140

141

142

N•m

128

129

130

131

132

133

134

143

144

145

146

147

148

149

150

FASTENER SIZE (8.8)

M14

TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS

100

100

101

102

103

103

104

105

Lbf•ft

94

95

96

97

97

98

99

105

106

107

108

108

109

110

111

INTRODUCTION

Technical Publications

Bombardier Inc.

Valcourt (Quebec), Canada

SMR2003_001_00_00A2.FM

XV

Datasheet | SeaDoo GTI LE Technical data

2003

Shop Manual

GTI, GTI LE, GTI LE RFI, GTX DI,

XP DI, RX DI, LRV DI, GTX 4-TEC SERIES

SAFETY NOTICE

WARNING

INTRODUCTION

HULL IDENTIFICATION NUMBER

(H.I.N.)

ENGINE IDENTIFICATION

NUMBER (E.I.N.)

ARRANGEMENT OF THIS

MANUAL

TYPICAL PAGE

TYPICAL PAGE

LIST OF ABBREVIATIONS USED

IN THIS MANUAL

GENERAL INFORMATION

ILLUSTRATIONS AND

PROCEDURES

ENGINE EMISSIONS

INFORMATION

Manufacturer’s Responsibility

Dealer Responsibility

Owner Responsibility

EPA Emission Regulations

SELF-LOCKING FASTENERS

PROCEDURE

LOCTITE APPLICATION

PROCEDURE

THREADLOCKER

Uncovered Holes (bolts and nuts)

Blind Holes

Stud in Blind Holes

Preassembled Parts

Adjusting Screw

STRIPPED THREAD REPAIR

Stripped Threads

GASKET COMPOUND

All Parts

MOUNTING ON SHAFT

Mounting with a Press

CASE-IN COMPONENTS

Metallic Gaskets

TIGHTENING TORQUES

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