smo2004-001a.book Page 2 Monday, March 31, 2003 12:17 PM TABLE OF CONTENTS FOREWORD ................................................................................ SAFETY MEASURES ............................................................... General .................................................................................................... Operation................................................................................................. Maintenance......................................
smo2004-001a.book Page 3 Monday, March 31, 2003 12:17 PM 20) Front and Rear (bow/stern) Eyelets .................................................. 21) Mooring Cleats.................................................................................. 22) Footboard.......................................................................................... 23) Boarding Pads ................................................................................... 24) Boarding Platform ...................................
smo2004-001a.book Page 4 Monday, March 31, 2003 12:17 PM Crossing Waves ...................................................................................... Stopping/Docking .................................................................................... Beaching.................................................................................................. Shutting Off the Engine........................................................................... POST-OPERATION CARE.........................
smo2004-001a.book Page 5 Monday, March 31, 2003 12:17 PM FOREWORD The Operator’s Guide and Safety Handbook have been prepared to acquaint the owner/operator or passenger with this personal watercraft and its various controls, maintenance and safe riding instructions. Each is indispensable for the proper use of the product and should be kept in a waterproof bag with the watercraft at all times. Make sure you read and understand the content of the Operator’s Guide and Safety Handbook.
smo2004-001a.book Page 6 Monday, March 31, 2003 12:17 PM The use of LEFT (port) and RIGHT (starboard) indications in the text, always refers to driving position (when sitting on watercraft). Furthermore, in the marine industry, FRONT is referred to BOW and REAR as STERN. 1 2 F01L451 1. Left (port) 2.
smo2004-001a.book Page 7 Monday, March 31, 2003 12:17 PM SAFETY MEASURES General Operation To fully appreciate the pleasures, enjoyment and excitement of boating there are some basic rules that should be observed and followed by any rider.
smo2004-001a.book Page 8 Monday, March 31, 2003 12:17 PM Do not start or operate the watercraft if someone is seated on the sun deck (if so equipped) or swim platform, or is nearby in the water. The watercraft’s jet thrust can cause injury. Always accelerate slowly. To prevent accidental starting or unauthorized use, always detach the safety lanyard from the watercraft especially when swimmers are boarding or nearby, or during removal of any weeds or debris from the intake grate.
smo2004-001a.book Page 9 Monday, March 31, 2003 12:17 PM Maintenance Only perform servicing procedures which are detailed in this guide. Further assistance or information can be obtained from your authorized Sea-Doo dealer. In many instances proper tools and training is required for certain servicing or repair procedures. Maintain the watercraft and equipment in top condition at all times. Adhere to the prescribed maintenance schedules.
smo2004-001a.book Page 20 Monday, March 31, 2003 12:17 PM REGISTRATION NUMBER LOCATION All personal watercraft are required by federal law to be registered and legally numbered. Due to space availability for proper display of registration number, refer to following illustration for location. The registration number should appear on each side of the watercraft. On applicable models install registration number to the left of the star label. F18L01L 1 1.
smo2004-001a.book Page 21 Monday, March 31, 2003 12:17 PM LOCATION OF THE IMPORTANT LABELS The following labels are on your watercraft. If missing or damaged, they can be replaced free of charge. See an authorized Sea-Doo dealer. Please read the following labels carefully before operating this watercraft.
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smo2004-001a.
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smo2004-001a.book Page 25 Monday, March 31, 2003 12:17 PM IDENTIFICATION NUMBERS The main components of the watercraft (engine and hull) are identified by different serial numbers. It may sometimes become necessary to locate these numbers for warranty purposes or to trace the watercraft in the event of theft. Engine NOTE: Refer to SPECIFICATIONS section to find what engine is used on each model. The Engine Identification Number (E.I.N.) is located on the front end of the engine.
smo2004-001a.book Page 26 Monday, March 31, 2003 12:17 PM CONTROLS, COMPONENTS AND INSTRUMENTS LOCATION NOTE: Some components do not apply or are optional on some models.
smo2004-001a.book Page 27 Monday, March 31, 2003 12:17 PM 1. Safety Lanyard (engine cut-off cord) 2. Handlebar 3. Throttle Lever 4. Engine Start/Stop Button 5. Shift Lever 6. Speedometer 7. Tachometer 8. Information Center Gauge/Buttons 9. Glove Box 10. Fuel Tank Cap 11. Front Storage Compartment Cover 12. Front Storage Compartment Cover Latch 13. Tool Kit 14. Air Intake Opening 15. Seat Strap 16. Seat Extension Latch 17. Seat Latch 18. Rear Grab Handle 19. Rear Storage Basket 20.
smo2004-001a.book Page 28 Monday, March 31, 2003 12:17 PM CONTROLS, COMPONENTS AND INSTRUMENTS FUNCTIONS 1) Safety Lanyard (engine cut-off cord) The safety lanyard cap should be securely snapped onto its post to be fully operational. Pulling the safety lanyard cap from its post stops the engine operation. WARNING While engine can be stopped using the engine start/stop button, good habits recommend that the safety lanyard also be disconnected when stopping.
smo2004-001a.book Page 29 Monday, March 31, 2003 12:17 PM Limited-Speed Operation The 4-TEC models also offers a special safety lanyard — the SEA-DOO Learning KeyTM — which electronically limits the speed of the watercraft to approximately 55 km/h (35 MPH) therefore enabling first time users and less experienced operators to learn how to operate the watercraft while gaining the necessary confidence and control. Adjustment (if so equipped) The handlebar height can be adjusted to suit rider preferences.
smo2004-001a.book Page 30 Monday, March 31, 2003 12:17 PM 1 F18J01Y 1 1. Forward position F18L09Y 1. Engine start/stop button 5) Shift Lever A push-pull lever: – forward – neutral – reverse. WARNING Shift lever should only be used when the engine is idling and craft is completely stopped. Do not use as a grab handle. F18J02Y 1 1. Neutral position WARNING Only use reverse at slow speed and for the shortest time possible.
smo2004-001a.book Page 31 Monday, March 31, 2003 12:17 PM The speed sensor mounted on the transom sends the signal to the MPEM and the MPEM send it to the gauge. 7) Tachometer An analog tachometer indicates the revolutions per minute (RPM) of the engine. Multiply by 1000 to obtain the actual revolutions. In addition, a digital tachometer can be displayed in the information center. See INFORMATION CENTER GAUGE/ BUTTONS below.
smo2004-001a.book Page 32 Monday, March 31, 2003 12:17 PM Units and Messages Section This section shows the units related to the numbers displayed. Units such as KMH (MPH), HOUR etc. are displayed. This section also display navigational and system fault informations. See the gauge functions and message lists below for more details. Gauge Functions Digital Tachometer: Indicates the revolution per minute (RPM) of the engine.
smo2004-001a.book Page 33 Monday, March 31, 2003 12:17 PM Display Selection Repeatedly pressing the MODE button scrolls the following displays: Compass, tachometer, speedometer, average speed, distance, hourmeter, water temperature, exterior temperature, depth gauge (if so equipped), and trip hour meter. Language Option While in the compass mode: 1 F18L092 1. Press and hold for 2 seconds F18L091 1 1.
smo2004-001a.book Page 34 Monday, March 31, 2003 12:17 PM English/Metric System Allows to display the units in the metric system or in the SAE English system. NOTE: This function is not available when information center displays the compass, hourmeter or trip hour meter. F18L092 1 1. Press and hold for 2 seconds to reset Trip hour meter is reset every time engine is turned off. F18L090 1 1. Press TOGETHER and hold for 2 seconds Trip Hour Meter While in the trip hour meter mode: F18L092 1 1.
smo2004-001a.book Page 35 Monday, March 31, 2003 12:17 PM NOTE: If a fault occurs, this system generates numbered fault codes (P-XXXX) that can be displayed through the information center using a special procedure. In case of a failure, you may call your authorized Sea-Doo dealer and he would be able to assist you to have the codes displayed to help troubleshooting. Warning Light The red warning LED (Light-Emitting Diode) blinks along with the beeper to catch your attention.
smo2004-001a.book Page 36 Monday, March 31, 2003 12:17 PM If there is water in the storage area, pull out the drain plug to let water go out. Reinstall the plug when done. F18L2YY 1 F18L0KY 1 TYPICAL 1. Removable basket 1. Drain plug NOTE: The water will flow to the bilge. If there is an important quantity of water, ensure to drain the bilge (out of water) prior to using the watercraft. The front storage area includes a latch to hold an approved fire extinguisher (sold separately).
smo2004-001a.book Page 37 Monday, March 31, 2003 12:17 PM 14) Air Intake Opening This is where air enters to supply the engine and to ventilate the engine compartment. If the air intake opening is kept under water, water will get inside bilge. CAUTION: If the air intake opening is kept under water, such as turning constantly in tight circles, water will get inside bilge, which may cause severe damage to internal parts of the engine.
smo2004-001a.book Page 38 Monday, March 31, 2003 12:17 PM To latch seat, align latch hole with pin then, firmly push downward on rear of the seat. To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them, a holder is provided. Unscrew cap counterclockwise to expose the holder and insert spark plug in their holes. Reinstall cap. 1 2 F00L2TY 1 2 1. Latch hole 2. Pin F18L0HY 3 18) Rear Grab Handle 1. Storage basket 2. Spare spark plug holder cap 3.
smo2004-001a.book Page 39 Monday, March 31, 2003 12:17 PM Rear (stern) Eyelet This eyelet allows a rope with a hook, a closed end or an open end to be attached. 25) Boarding Step A convenient step to help reboarding the watercraft. 1 1 F18L0RY 1. Rear (stern) eyelet F18L0IY 21) Mooring Cleats 1. Boarding step These cleats can be temporarily used for docking, while refueling for example. Pull down the step with your hand and hold until a foot or a knee is put on the step. F18L0SY 1 1.
smo2004-001a.book Page 40 Monday, March 31, 2003 12:17 PM Tilt the watercraft slightly to the rear so that the water can completely flow out of the bilge. It is suggested to drain bilge on a ramp. CAUTION: Make sure drain plugs are properly secured prior to launching the watercraft in water. 28) Jet Pump Nozzle Jet pump nozzle turns side to side via rider input at the handlebar. This provides directional control when engine is running. F18L0TY Refer to POST-OPERATION CARE section for proper use.
smo2004-001a.book Page 41 Monday, March 31, 2003 12:17 PM 30) Jet Pump Water Intake and Ride Plate The water is drawn up by the impeller through this opening. The water intake grate minimizes the entry of foreign objects into the propulsion system. NOTE: The ride plate is the heat exchanger for the ENGINE cooling system. 31) Fuses Fuses are located under seat in bilge. Refer to MAINTENANCE for more details. WARNING Keep away from intake grate while engine is on.
smo2004-001a.book Page 42 Monday, March 31, 2003 12:17 PM 33) Side Vanes Side vanes are part of the Off-Power Assisted Steering (O.P.A.S.™) system. When engine RPM is reduced, the side vanes are lowered to assist the steering system. Refer to PRINCIPLE OF OPERATION in OPERATING INSTRUCTIONS section for the description of the system. WARNING Check handlebar and corresponding side vanes operation before starting. Never use side vanes as a supporting point to board the watercraft or to lift it.
smo2004-001a.book Page 43 Monday, March 31, 2003 12:17 PM Remove seat extension and storage basket to expose expansion tank. F18E0MY 2 1 1. Expansion tank 2. Cap Refer to LIQUIDS for more details. 1 F18D09Y TYPICAL 1. Oil filling cap Refer to LIQUIDS for more details. 36) Cooling System Expansion Tank Cap Located in engine compartment. It provides access to the expansion tank filling neck. Ski/Wake Board Post (if so equipped) Pull up the post to allow hooking a ski or wake board rope.
smo2004-001a.book Page 44 Monday, March 31, 2003 12:17 PM 1 2 F18L30Y 1. Ski/wake board post lifted 2. Ensure it is locked WARNING Make sure ski/wake board post is fully extended and locked before use. Completely retract when not used. Use caution with skier/wake boarder in tow as tow rope may backlash to watercraft when released. Never perform a sharp turn when towing a skier, wake boarder or any toy. Always have one person other than the operator as an observer.
smo2004-001a.book Page 45 Monday, March 31, 2003 12:17 PM LIQUIDS CAUTION: Scrupulously follow the instructions of this section. Failure to do so may reduce the engine’s life and/or performance. Fueling Procedure WARNING Follow these safe boating fueling instructions explicitly. Turn off engine. Do not allow anyone to remain on the watercraft. Tie watercraft securely to the fueling pier. Have a fire extinguisher close at hand. Do not insert the spout too far in filler neck.
smo2004-001a.book Page 46 Monday, March 31, 2003 12:17 PM Engine Oil Recommended Oil This watercraft features a 4-stroke engine that requires 4-stroke motor oil for internal engine lubrication. Ensure to respect the following requirements. Use 4-stroke engine oil that meets or exceeds the requirements for API service classification SG, SH or SJ. Always check the API service label on the oil container to be sure it includes those letters. Only use high-quality high-detergent oil.
smo2004-001a.book Page 47 Monday, March 31, 2003 12:17 PM 7. Remove dipstick and read oil level. It should be between marks. 1 1 3 2 F18D2MY 1. Full 2. Add 3. Operating range 8. Otherwise, add oil up to have the level between marks as required. 9. To add oil, unscrew oil cap. Place a funnel into the opening and add the recommended oil to the proper level. Do not overfill.
smo2004-001a.book Page 48 Monday, March 31, 2003 12:17 PM Coolant Level WARNING Check coolant level with engine cold. Never add coolant in cooling system when engine is hot. 1 Remove seat extension to expose cooling system expansion tank. F18E0NY 1. Level between marks when engine is cold F18E0MZ 1 1. Expansion tank With vehicle on a level surface, liquid should be between MIN. and MAX. level marks of coolant reservoir when engine is cold. NOTE: The watercraft is level when it is in water.
smo2004-001a.book Page 49 Monday, March 31, 2003 12:17 PM BREAK-IN PERIOD CAUTION: Scrupulously follow the instructions of this section. Failure to do so may reduce the engine’s life and/or performance. With SEA-DOO watercraft powered by Rotax® engines, a break-in period of 10 hours is required before continuous operation at full throttle. To achieve a good break-in, throttle lever should not be depressed more than 3/4, however, brief acceleration and speed variations contribute to a good break-in.
smo2004-001a.book Page 50 Monday, March 31, 2003 12:17 PM PRE-OPERATION CHECKS WARNING The pre-operation check is very important prior to operating the watercraft. Always check the proper operation of critical controls, safety features and mechanical components, before starting as listed hereinafter. If not done as specified here, severe injury or death might occur. Bring all safety equipment required by local laws.
smo2004-001a.book Page 51 Monday, March 31, 2003 12:17 PM Hull Bilge Inspect hull for cracks or damage. Should water be present in the bilge, tilt the watercraft to the rear and unscrew drain plugs to completely empty the bilge. Secure bilge drain plugs. Jet Pump Water Intake Remove weeds, shells, debris or anything else that could restrict the flow of water and damage exhaust cooling system or propulsion unit. Clean as necessary.
smo2004-001a.book Page 52 Monday, March 31, 2003 12:17 PM Engine Coolant Level Shifter System Ensure coolant level is appropriate as specified in LIQUIDS section. Check for coolant leaks on engine, in bilge and from ride plate. Check reverse gate operation for free movement. With shift lever in forward position, the gate should be in upward position; and offering a resistance to go downward. With the shift lever in neutral position, gate should be in middle position.
smo2004-001a.book Page 53 Monday, March 31, 2003 12:17 PM Water Flow in Exhaust Manifold (only when temperature is below or close to freezing point) In Northern areas, if watercraft is to be used when temperature is below or close to freezing point (0°C (32°F)) or if watercraft was left unused while temperature was below or close to freezing point, water may be frozen in the supply hose going to the exhaust manifold. This could cause exhaust cooling system overheating.
smo2004-001a.book Page 54 Monday, March 31, 2003 12:17 PM OPERATING INSTRUCTIONS WARNING Always perform the PRE-OPERATION CHECKS before operating the watercraft. Become thoroughly familiar with all controls and the function of each. Should any control or instruction not be fully understood, refer to an authorized Sea-Doo dealer. Principle of Operation Propulsion The engine is directly coupled to a drive shaft which, in turn, rotates an impeller.
smo2004-001a.book Page 55 Monday, March 31, 2003 12:17 PM F18J02Y 1 F18J07Y 1. Shift lever in neutral position 1 1. Reverse gate in downward position NOTE: To obtain maximum efficiency and control from the reverse, increase engine speed to slightly above idle. Too much RPM will create water turbulence and reduce reverse efficiency. In reverse position, turn the handlebar in the same direction that you want to move the rear of the watercraft.
smo2004-001a.book Page 56 Monday, March 31, 2003 12:17 PM WARNING Shift lever should only be used when the engine is idling and watercraft is completely stopped. Do not use reverse to stop the watercraft. Steering The watercraft behaves differently with a passenger and requires greater skill. The passenger should always grip the seat strap or grab handle. Reduce speed and avoid sharp turns. Avoid choppy water conditions when carrying a passenger. Off-Power Assisted Steering System (O.P.A.S.
smo2004-001a.book Page 57 Monday, March 31, 2003 12:17 PM WARNING Engine should be OFF when boarding the watercraft or when using boarding step. Keep limbs away from jet or intake grate. Stay on center of the step. Only one person at a time on the step. Never use the step for pulling, towing, diving or jumping, boarding a watercraft that is out of water or any other purpose other than a boarding step. 1 F18K02Y Boarding is facilitated by using a step. WARNING 1.
smo2004-001a.book Page 58 Monday, March 31, 2003 12:17 PM In shallow water, board the watercraft either from the side or the rear. Ensure there is at least 90 cm (3 ft) of water underneath the lowest rear portion of the hull. Take into account that the hull will lower in water when all passengers are aboard. Be certain to maintain the specified depth so sand, pebbles and rocks will not be drawn up in the jet pump.
smo2004-001a.book Page 59 Monday, March 31, 2003 12:17 PM The passenger then climbs on the watercraft while the operator maintains balance by sitting as close as possible to the console. NOTE: If you hear anything else than 2 short beeps from DESS system, it indicates a particular condition that should be corrected. Refer to the TROUBLESHOOTING section for the meaning of the coded signal. WARNING Before starting the engine, the operator and passengers should always be properly seated.
smo2004-001a.book Page 60 Monday, March 31, 2003 12:17 PM Riding Gradually accelerate to reach deeper water. Do not apply full throttle until the engine is warm. Stopping/Docking The watercraft is slowed by water drag. The stopping distance will vary depending on the watercraft size, weight, speed, water surface condition, presence and direction of wind and current. F18A02Y CAUTION: Avoid watercraft operation in weeded areas. If unavoidable, vary watercraft speed.
smo2004-001a.book Page 61 Monday, March 31, 2003 12:17 PM CAUTION: Riding the watercraft in shallower water might damage the impeller or other jet pump components. F18A03Y CAUTION: Pay attention, when leaving the watercraft on the beach, so that the side vanes do not rub or hit the ground due to the rocking movement. It might eventually damage components of the O.P.A.S. system. Shutting Off the Engine To keep watercraft directional control, the engine should be running until the watercraft is at idle.
smo2004-001a.book Page 62 Monday, March 31, 2003 12:17 PM POST-OPERATION CARE WARNING Allow engine to cool before performing any maintenance. General Care Remove the watercraft from the water every day to prevent marine organisms growth. Should any water be present in the hull, unscrew the drain plugs and tilt the watercraft to the rear in order to allow water to flow out. Wipe up any remaining fluid in the engine compartment (bilge, engine, battery, etc.
smo2004-001a.book Page 63 Monday, March 31, 2003 12:17 PM Flushing To flush the exhaust cooling system, start the engine then immediately open the water tap. WARNING Certain components in the engine compartment may be very hot. Direct contact may result in skin burn. Do not touch any electrical parts or jet pump area when engine is running. CAUTION: Never flush a hot engine. Always start the engine before opening the water tap. Open water tap immediately after engine is started to prevent overheating.
smo2004-001a.book Page 64 Monday, March 31, 2003 12:17 PM SPECIAL PROCEDURES Monitoring System To assist you when using the watercraft, a system monitors the electronic components of the EMS (engine management system) and other components of the electrical system. When a fault occurs, it sends visual messages through the information center and/or audible signals through a beeper to inform you of a particular condition.
smo2004-001a.book Page 65 Monday, March 31, 2003 12:17 PM Jet Pump Water Intake and Impeller Cleaning WARNING Keep away from intake grate while engine is on. Items such as long hair, loose clothing or personal flotation device straps can become entangled in moving parts resulting in severe injury or drowning. Weeds, shells or debris can get caught on the intake grate, drive shaft and/or impeller. A clogged water intake may cause troubles such as: 1.
smo2004-001a.book Page 66 Monday, March 31, 2003 12:17 PM WARNING When watercraft is capsized, do not attempt to restart the engine. Operator and passengers should always wear approved personal flotation devices. To return the watercraft upright, ensure the engine is off and the safety lanyard is NOT on its post then grab the inlet grate, step on bumper rail and use your weight to rotate the watercraft in any direction. The 4-TEC engine features a tip-over protection system (TOPS™).
smo2004-001a.book Page 67 Monday, March 31, 2003 12:17 PM Disconnect ignition coil connectors. WARNING When disconnecting coil from spark plug, always disconnect coil from main harness first. Never check for engine ignition spark from an open coil and/or spark plug in the engine compartment as spark may cause fuel vapor to ignite. Remove ignition coils. CAUTION: Ensure there is no dirt in coil holes prior to removing the spark plugs.
smo2004-001a.book Page 68 Monday, March 31, 2003 12:17 PM To ease access to the hose, the vent tube can be temporarily removed. Snugly install the hose pincher on the water supply hose as shown. 1 F18E0OY 1. Vent tube Lift lock tab and holding the tab, pull the tube to release it. 1 1 F18E0RY TYPICAL 1. Hose pincher F18E0PY 1. Lift lock tab Then proceed with the tab under the tube. Refer to the following illustration to see it.
smo2004-001a.book Page 69 Monday, March 31, 2003 12:17 PM MAINTENANCE Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine SI (spark ignition) engine repair establishments or individual.
smo2004-001a.book Page 70 Monday, March 31, 2003 12:17 PM WARNING Only perform procedures as detailed in this guide. It is recommended that the assistance of an authorized Sea-Doo dealer be periodically obtained on other components/ systems not covered in this guide. Unless otherwise specified, engine must not be running and the safety lanyard must be removed from its post for all maintenance procedures. Never use jet pump components or side vanes to lift the watercraft.
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smo2004-001a.book Page 72 Monday, March 31, 2003 12:17 PM HULL AND BODY PROPULSION SYSTEM O.P.A.S. STEERING SYSTEM SYSTEM Steering cable I O.P.A.S.
smo2004-001a.book Page 73 Monday, March 31, 2003 12:17 PM Throttle Cable Inspection Throttle Cable Depress and release the throttle lever. It should operate smoothly and return to its initial position without any hesitation. There must be a small amount of free-play when throttle lever is released. Refer to an authorized Sea-Doo dealer if necessary. CAUTION: Never attempt to adjust the idle speed through the throttle body tamper proof screw. If so, it would impair the idle speed stability.
smo2004-001a.book Page 74 Monday, March 31, 2003 12:17 PM Refer to an authorized Sea-Doo dealer if an adjustment is necessary. WARNING Fuses If an electrical problem occurs, check the fuses. If a fuse is burnt, replace by one of the same rating. Ensure the handlebar and jet pump nozzle operate freely from side to side and are not stressing the steering cable or brackets. Never turn handlebar while someone is nearby rear of watercraft.
smo2004-001a.book Page 75 Monday, March 31, 2003 12:17 PM MPEM To access fuses on the MPEM, remove seat. Locate MPEM besides engine. 1 F18H0JY TYPICAL 1. Fuses Fuses rating are identified, look beside the fuse holders. T.O.P.S. Depth gauge (if so equipped) or spare fuse Cylinder 3 ignition coil and injection Information center Cylinder 2 ignition coil and injection Cylinder 1 ignition coil and injection 10A 2A 10A 1A 10A 10A 3A 5A 10A 2A 7.
smo2004-001a.book Page 76 Monday, March 31, 2003 12:17 PM Squeeze locking tabs together, hold and pull fuse cover from the MPEM. 1 2 1 1 F18H0BY 1 1. Rubber protector F18H0CY 2 1 TYPICAL 1. MPEM 2. Fuse cover 2 Use the tabs of the fuse cover to remove and reinstall fuses. Slide cover tabs along fuse top. F18H0DY 1. Rubber protector 2. Spare fuses F06H1TY 1 2 1. Fuse cover 2. Fuse tabs One cover contains spare fuses.
smo2004-001a.book Page 77 Monday, March 31, 2003 12:17 PM Main Fuse besides MPEM 2 1 O.P.A.S. System (if so equipped) The O.P.A.S. system operation and condition should be checked by an authorized SEA-DOO dealer. Ski/Wake Board Post (if so equipped) Check ski/wake board post operation. Ensure it slides up and down easily. Check locking mechanism operation. Check fasteners tightness. If something is found defective, don’t use ski/wake board post and see an authorized Sea-Doo dealer for repair.
smo2004-001a.book Page 78 Monday, March 31, 2003 12:17 PM Cleaning The bilge should be cleaned by an authorized Sea-Doo dealer to remove any fuel/oil/electrolyte deposits and mildew. Occasionally, wash the body with water and soap (only use mild detergent). Remove any marine organisms from engine and/or hull. Apply non-abrasive wax such as silicone wax. CAUTION: Never clean fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc.
smo2004-001a.book Page 79 Monday, March 31, 2003 12:17 PM TRAILERING, STORAGE AND PRESEASON PREPARATION Trailering CAUTIO N: To avoid damaging O.P.A.S. side vanes, the maximum trailer wood bunks span including bunk width should not exceed 71 cm (28 in). Ends of both trailer wood bunks should not be more than 2.59 m (102 in) away from watercraft bow attachment point. See following illustration.
smo2004-001a.book Page 80 Monday, March 31, 2003 12:17 PM Storage WARNING Because fuel and oil are flammable, have an authorized Sea-Doo dealer inspect the fuel system integrity as specified in the periodic inspection chart. It is recommended that the watercraft be serviced by an authorized Sea-Doo dealer for storage but the following operations can be performed by you with a minimum of tools. CAUTION: Do not run the engine during the storage period.
smo2004-001a.book Page 81 Monday, March 31, 2003 12:17 PM Disconnect ignition coil connectors. WARNING When disconnecting coil from spark plug, always disconnect coil from main harness first. Never check for engine ignition spark from an open coil and/or spark plug in the engine compartment as spark may cause fuel vapor to ignite. IMPORTANT: Never cut the locking ties of ignition coil connectors. This would allow mixing the wires between cylinders. Remove ignition coils.
smo2004-001a.book Page 82 Monday, March 31, 2003 12:17 PM Lubricate the throttle cable with BOMBARDIER LUBE lubricant or equivalent. Final Steps If any repairs are needed to body or to the hull, contact your authorized Sea-Doo dealer. For paint touch up of mechanical parts use Bombardier spray paint. Apply a good quality marine wax to the body. The seat and the seat extension should be partially left opened. This will prevent engine compartment condensation and possible corrosion.
smo2004-001a.book Page 83 Monday, March 31, 2003 12:17 PM Preseason Preparation Chart NOTE: It is highly recommended that an authorized Sea-Doo dealer perform the annual safety inspection and factory campaigns in addition to the preseason preparation all at the same time.
smo2004-001a.book Page 84 Monday, March 31, 2003 12:17 PM TROUBLESHOOTING The following chart is provided to help in diagnosing the probable source of simple troubles. You may be able to solve many of these problems rather quickly, but others may require the skills of a mechanical technician. In such cases, consult an authorized Sea-Doo dealer for servicing. NOTE: For the definition of abbreviations used here, refer to ABBREVIATIONS USED IN THIS MANUAL section below.
smo2004-001a.book Page 85 Monday, March 31, 2003 12:17 PM CODED SIGNALS POSSIBLE CAUSE REMEDY A 2 seconds beep every 15 minutes interval. • Watercraft is upside down. Turn watercraft upright. Refer to SPECIAL PROCEDURES. • Engine coolant temperature Refer to an authorized Sea-Doo sensor or circuit malfunction. dealer. Continuously beeps. • Fuel level sensor or circuit malfunction. Refer to an authorized Sea-Doo dealer. • Exhaust temperature sensor or circuit malfunction.
smo2004-001a.book Page 86 Monday, March 31, 2003 12:17 PM Engine Will Not Start OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine does not turn over. • Safety lanyard removed. Install cap over post. • EMS ECU does not recognize Refer to an authorized Sea-Doo the safety lanyard. dealer. • Turned over watercraft. Refer to CAPSIZED WATERCRAFT in SPECIAL PROCEDURES. • Burnt fuse: main, electric starter, MPEM or EMS ECU. Check wiring then replace fuse(s). • Discharged battery.
smo2004-001a.book Page 87 Monday, March 31, 2003 12:17 PM Engine Misfires, Misinjects, Runs Irregularly OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark. • Fouled/defective/worn spark plugs. Replace. • Faulty ignition coil(s) or EMS ECU. Refer to an authorized Sea-Doo dealer. • Fuel: Level too low, stale or water-contaminated. Siphon and/or refill. • Clogged injectors. Refer to an authorized Sea-Doo dealer. • Defective sensor or EMS ECU. Refer to an authorized Sea-Doo dealer.
smo2004-001a.book Page 88 Monday, March 31, 2003 12:17 PM Engine Pinging or Knocking OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Knock sensor malfunction. Refer to an authorized Sea-Doo dealer. Engine Lacks Acceleration or Power OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Engine oil level too high. Refer to an authorized Sea-Doo dealer. • Weak spark. Refer to ENGINE MISFIRES, RUNS IRREGULARLY. • The monitoring system put the watercraft in limp home mode due to a component malfunction.
smo2004-001a.book Page 89 Monday, March 31, 2003 12:17 PM Engine RPM Gradually Decreases and Engine Stops OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Out of fuel. Refill. • CPS sensor malfunction. Refer to an authorized Sea-Doo dealer. • TOPS malfunction. Refer to an authorized Sea-Doo dealer. O.P.A.S. System Faults OTHER OBSERVATION POSSIBLE CAUSE REMEDY Watercraft is more responsive than usual while turning. • Side vanes do not go up while watercraft is at speed.
smo2004-001a.book Page 90 Monday, March 31, 2003 12:17 PM SPECIFICATIONS GTX 4-TEC SUPERCHARGED (6159/6160) MODELS ENGINE BOMBARDIER-ROTAX 1503, 4 stroke. Single Over Head Camshaft (SOHC), liquid cooled Type Number of cylinder Number of valve 3 in line 12 valves (4 per cylinder) with hydraulic lifters (no adjustment) Displacement 1494 cc (91.2 cu. in) Induction type Mechanically-driven supercharger Bore 100 mm (3.9 in) Stroke 63.
smo2004-001a.book Page 91 Monday, March 31, 2003 12:17 PM GTX 4-TEC SUPERCHARGED (6159/6160) MODELS ELECTRICAL SYSTEM Magneto generator output 360 W @ 6000 RPM Ignition system type Digital inductive type Ignition timing Not adjustable Make and type Spark plug Gap Quantity Starting system Battery Fuse NGK, DCPR8ES 0.75 mm (.030 in) 3 Electric starter 12 V, 30 A•h. Electrolyte type.
smo2004-001a.book Page 92 Monday, March 31, 2003 12:17 PM MODELS GTX 4-TEC SUPERCHARGED (6159/6160) PROPULSION Propulsion system Jet pump type Transmission Bombardier Formula pump Axial flow, single stage. Greased bearings Direct drive Reverse system Yes O.P.A.S.
smo2004-001a.book Page 93 Monday, March 31, 2003 12:17 PM SI* METRIC INFORMATION BASE UNITS DESCRIPTION length.................................................. mass ................................................... force.................................................... liquid ................................................... temperature ........................................ pressure.............................................. torque .................................................
smo2004-001a.book Page 94 Monday, March 31, 2003 12:17 PM ABBREVIATIONS USED IN THIS MANUAL DESCRIPTION AC API Alternate current American petroleum institute CARB DC California air resource board Direct current DESS Digitally encoded security system Engine management system EMS EMS ECU EMS Electronic control unit E.I.N.
