GSX Limited www.SeaDooManuals.
Legal deposit: National Library of Quebec 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. 1997 Printed in Canada *Registered trademarks of Bombardier Inc. ® Loctite® is a trademark of Loctite Corporation Snap-on® is a trademark of Snap-on Tools Corporation Gelcote® is a trademark of Gelcote International Limited www.SeaDooManuals.
TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE ....................................................................................................................................... II 01 ENGINE 01 - Magneto System................................................................ 02 - Top End .............................................................................. 03 - Bottom End ........................................................................ 04 - Exhaust System ..............
SAFETY NOTICE SAFETY NOTICE This manual was primarily published to be used by watercraft technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made SeaDoo watercraft. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into another language. In the event of any discrepancy, the English version shall prevail.
Section 01 ENGINE Subsection 01 (MAGNETO SYSTEM) MAGNETO SYSTEM 0 947 Engine 9 N•m (80 lbf•in) 2 8 Loctite 242 Anti-seize lubricant 1 10 13 N•m (115 lbf•in) 3 12 11 Loctite 242 13 9 N•m (80 lbf•in) 9 Loctite 242 Loctite 648 115 N•m 6 (85 lbf•ft) 7 13 N•m (115 lbf•in) Loctite 648 4 5 F06D0IS PARTS www.SeaDooManuals.
Section 01 ENGINE Subsection 01 (MAGNETO SYSTEM) DISASSEMBLY 1, Cover Loosen screws no. 2. Remove engine magneto cover. F06D0KA 1 1. Remove pulse fitting Turn engine manually until slot in crankshaft counterweight is aligned with the crankcase hole. Insert a M8 x 50 fixation screw to lock crankshaft. F06D1RA 1 2 1. Cover 2. Screw Remove oil pump shaft from flywheel nut. F06B04A CRANKSHAFT FIXATION SCREW (P/N 290 240 882) F06D23A 1 1.
Section 01 ENGINE Subsection 01 (MAGNETO SYSTEM) If necessary, the magneto rotor can be removed without the engine flywheel. Remove the 6 screws no. 7. 1 F06D0PA F06D0LA 1 1. Puller 1. Screw 8,9, Stator and Trigger Coil To remove the flywheel/rotor assembly, unscrew nut no. 6 counterclockwise when facing it. F06D0MA Loosen screws no. 10 and no. 11 to remove the stator and trigger coil from the engine magneto cover. 1 1.
Section 01 ENGINE Subsection 01 (MAGNETO SYSTEM) ASSEMBLY 8,9, Stator and Trigger Coil Install the stator and trigger coil in engine magneto cover. Torque screws to 9 N•m (80 lbf•in). Reinstall wiring harness bracket no. 12 using taptite screws no. 13. Torque trigger coil screws no. 11 to 9 N•m (80 lbf•in). Torque stator screws no. 10 to 13 N•m (115 lbf•in). Apply Loctite 648 (green) on screws no. 7 retaining rotor to flywheel and torque screws in a crisscross sequence to 13 N•m (115 lbf•in).
Section 01 ENGINE Subsection 02 (TOP END) TOP END 0 947 Engine 34 N•m (25 lbf•ft) 3 Loctite 242 Synthetic grease 34 N•m (25 lbf•ft) 4 1 5 16 Synthetic grease 11 15 18 13 17 14 26 Loctite 242 22 23 24 3 N•m (26 lbf•in) 12 Loctite 9 N•m 242 (80 lbf•in) 21 20 19 2 36 rollers 10 8 Synthetic grease 7 9 8 6 F06D17S PARTS www.SeaDooManuals.
Section 01 ENGINE Subsection 02 (TOP END) THEORY OF OPERATION RAVE Valve System On this engine, the RAVE valves are controlled by the Multi-Purpose Electronic Module (MPEM). The MPEM measures 2 factors to control the RAVE valves: engine speed (RPM) and its rate of acceleration. To open the RAVE valves, the MPEM activates a solenoid which directs the positive pressure from engine crankcase to the valves. NOTE: A check valve on the pressure line eliminates the negative pressure from the crankcase.
Section 01 ENGINE Subsection 02 (TOP END) To close the RAVE valves, the MPEM deactivates the solenoid which blocks the crankcase positive pressure. The RAVE valves are opened to the atmosphere. 4 3 2 5 1 F06D16T RAVE VALVE CLOSED 1. Pulse from crankcase 2. Check valve 3. Positive pressure blocked by the solenoid 4. Solenoid deactivated 5. RAVE valves are opened to atmosphere 01-02-3 www.SeaDooManuals.
Section 01 ENGINE Subsection 02 (TOP END) DISASSEMBLY Remove the compression spring no. 15. 11, RAVE Valve Loosen Allen screws no. 12 each side of RAVE valve. F06D25A 1 1. Remove spring Remove spring no. 16 retaining bellows no. 17 to valve piston no. 18. 1 F06D0QA 1. Remove screws Remove RAVE valve no. 11. Remove the cover no. 13 of the valve by releasing the spring no. 14. ; WARNING Firmly hold cover to valve base.
Section 01 ENGINE Subsection 02 (TOP END) Remove bellows from valve piston. Remove compression spring no. 22. 1 F06D0TA 1 A06D26A 1. Bellows removed from piston Unscrew valve piston no. 18 from sliding valve no. 19. NOTE: Hold the sliding valve to prevent it from turning. 1. Remove spring Remove supporting ring no. 23. 1 F06D27A F06D0TB 1 2 1. Remove supporting ring 1. Unscrew piston 2. Hold sliding valve 01-02-5 www.SeaDooManuals.
Section 01 ENGINE Subsection 02 (TOP END) Remove O-ring no. 24. Remove bellows no. 17. 1 F06D28A 1 F06D0VA 1. Remove O-ring 1. Remove bellows Remove sliding valve no. 19. 1,2, Cylinder Head and Cylinder Block Loosen cylinder head bolts no. 3 following the sequence shown in the next photo. F06D0UA 6 4 F06D0WA 5 2 1 1. Remove sliding valve 1 3 7 UNTORQUING SEQUENCE FOR THE CYLINDER HEAD BOLTS 01-02-6 www.SeaDooManuals.
Section 01 ENGINE Subsection 02 (TOP END) Loosen nuts no. 4 following the sequence shown in the next photo. 5 2 4 7 F06D2BA 1 1. Remove studs Remove cylinder block no. 2. F06D29A 6 3 1 8 UNTORQUING SEQUENCE FOR THE NUTS Remove cylinder head no. 1. Remove cylinder head gasket no. 5. 1 F06D0ZA 1. Remove cylinder block F06D0YA NOTE: To ease removal, a plastic tip hammer can be used. Remove cylinder base gasket no. 6. 1 1. Remove gasket 7, Piston Remove studs no. 25.
Section 01 ENGINE Subsection 02 (TOP END) 11, RAVE Valve Install the supporting ring no. 23 with the bevel side facing the O-ring no. 24. 1 F06D10A 1 1. Piston notch F06D11A To extract piston pin no. 9, use puller. Refer to the 1997 Sea-Doo Shop Manual for procedure. NOTE: Piston pin features cageless bearing (36 rollers). 1. Bevel facing the O-ring There is only one way to insert the sliding valve no. 19 in valve housing no. 21. INSPECTION ENGINE MEASUREMENT TOLERANCES NEW PARTS (min.) (max.
Section 01 ENGINE Subsection 02 (TOP END) To easily insert circlip no. 8, use circlip installer (P/N 290 877 517). 1 AUS A01C01A TYPICAL — PISTON DOME SHOWN 1. Exhaust side 9,10, Piston Pin and Roller Bearing To install roller bearing and piston pin, use piston pin puller (P/N 290 877 094) used at removal. For installation procedure, refer to the 1997 Sea-Doo Shop Manual. 8, Circlip Secure circlips no. 8 taking into consideration the following.
Section 01 ENGINE Subsection 02 (TOP END) Torque bolts and nuts to 15 N•m (11 lbf•ft) as per following sequence in the next photo. Repeat the torquing sequence by retightening to 34 N•m (25 lbf•ft). 7 12 F06D0WB 13 1 4 10 8 9 5 11 3 2 14 6 15 TORQUING SEQUENCE 01-02-10 www.SeaDooManuals.
Section 01 ENGINE Subsection 03 (BOTTOM END) BOTTOM END 0 947 Engine 30 mL (1 oz) Formula XP-S synthetic oil 26 11 17 16 18 19 22 1 Synthetic grease Synthetic grease Loctite 242 20 21 Loctite 242 19 24 18 14 17 15 Loctite 242 15 Anti-seize lubricant 9 N•m 7 (80 lbf•in) 8 Anti-seize lubricant 9 Loctite 242 15 Loctite 242 9 N•m Synthetic (80 lbf•in) grease Loctite 648 Loctite 242 Synthetic grease Loctite 242 Loctite 518 6 11 23 15 1 Synthetic grease 2 Loctite 518 Synthetic grease 1
Section 01 ENGINE Subsection 03 (BOTTOM END) DISASSEMBLY The following components should be removed prior to opening bottom end: – magneto cover – magneto flywheel – starter Loosen bolt no. 5 retaining the PTO flywheel to the crankshaft. 1, Seal If a crankshaft end seal has to be replaced, bottom end must be opened. 2, PTO Flywheel Lock the crankshaft using the same procedure for the magneto flywheel removal. Refer to ENGINE 01-01. Loosen the 6 Allen screws no. 4 retaining the coupling flange no.
Section 01 ENGINE Subsection 03 (BOTTOM END) 6, Starter Drive Assembly 10, Reed Valve Loosen 2 Allen screws no. 7 retaining starter drive cover no. 8. Remove both carburetor flanges. F06D0JA 1 1. Carburetor flange F06D1CA 2 1 Remove reed valves from crankcase. 1. Cover 2. Allen screw 11, Crankcase Remove starter drive cover no. 8 and spring no. 9. Remove starter drive assembly no. 6. Place engine upright on crankcase magneto side. F06D1DA 1.
Section 01 ENGINE Subsection 03 (BOTTOM END) 6 1 3 5 4 2 F06B03A 1. 2. 3. 4. 5. 6. F06D1FA 1 6 Puller (P/N 420 877 635) Protective cap (P/N 290 877 414) Distance ring (P/N 290 876 569) Ring (P/N 290 977 480) Ring halves (P/N 290 876 330) Screw (P/N 290 940 755) NOTE: To facilitate ring or distance ring installation, lubricate their inside diameters. Or, use a bearing extractor such as Proto no. 4332 and a press to remove 2 bearings at a time. 1.
Section 01 ENGINE Subsection 03 (BOTTOM END) 10, Reed Valve Check reed valve petals no. 24 for cracks or other defects. The reed petals must lie completely flat against the reed valve body no. 25. To check, hold against light. F06D1HA 1 1. Trace an index mark Remove seals no. 19. Remove bearing no. 20 and washer no. 21. Use a press to remove gear no. 22. INSPECTION 1 F06D1JA Visually inspect parts for corrosion damage. Inspect plane surfaces for warpage.
Section 01 ENGINE Subsection 03 (BOTTOM END) Bent stopper as required to obtain the proper distance. 2 14, Crankshaft Refer to the 1997 Sea-Doo Shop Manual for complete procedure of crankshaft inspection. ASSEMBLY 15, Bearing Apply Loctite 767 anti-seize on part of crankshaft where bearings fit. Prior to installation, place bearings into a container filled with oil, previously heated to 75°C (167°F). This will expand bearings and ease their installations.
Section 01 ENGINE Subsection 03 (BOTTOM END) Install the counterbalance shaft in crankcase lower half. Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears. 1 F06D1OA 1. Seal in place 11, Crankcase F06D1MA 1 1. Marks must be aligned Properly position bearing no. 20 and washer no. 21. F06D1NA Crankcase halves are factory matched and therefore, are not interchangeable or available as single halves. Make sure all locating dowels are in place. 1 2 F06D1PA 1 1.
Section 01 ENGINE Subsection 03 (BOTTOM END) Apply synthetic grease below head of bolts no. 12 and no. 13. Apply also Loctite 518 on threads of bolts no. 12 and no. 13. Torque crankcase bolts to 12 N•m (9 lbf•ft) as per following sequence. Repeat procedure, retightening all bolts to 23 N•m (17 lbf•ft). 9 7 14 3 1 16 5 18 11 20 10 21 8 19 2 F06D32A 13 2 1. Handle 2. Pusher 17 6 2, PTO Flywheel Apply Loctite 242 (blue) on bolt no. 5. Torque bolt no. 5 to 115 N•m (85 lbf•ft).
Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) EXHAUST SYSTEM 0 GENERAL To enhance performance and reduce noise level, the GSX Limited is equipped with a new plastic made resonator. 1 1 F06E08A 1. Water inlet hose Disconnect at the tuned pipe head the water supply hose of the water flow regulator valve. F06D13A 1. Resonator REMOVAL Tuned Pipe Remove seat. Remove air vent tube support from body opening. Disconnect water inlet hose at tuned pipe head. F06E09A 1 1.
Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Disconnect the water injection hose at tuned pipe head. Loosen clamp retaining exhaust hose to tuned pipe cone. 1 1 F06E0AA F06D14A 1. Water injection hose 1. Loosen clamp Disconnect the water bleed hose. Loosen and remove clamp retaining tuned pipe head to tuned pipe cone. F06E0BA 1 1. Water bleed hose F06D1SA 1 1. Loosen and remove clamp 01-04-2 www.SeaDooManuals.
Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Loosen Allen screw of carburetor bracket. F06D2DA Loosen bolt of tuned pipe head above the engine magneto. 1 1 F06D1UA 1. Loosen Allen screw Loosen Allen screws and nut at tuned pipe flange. 1. Remove bolt Remove tuned pipe head. Loosen bolt of tuned pipe cone beside the engine water outlet hose. F06D1TA 1 1. Tuned pipe flange F06D1VA 1 1. Loosen bolt Remove tuned pipe cone. Exhaust Manifold Remove tuned pipe head (if not removed).
Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Muffler INSTALLATION Disconnect front exhaust hose (if tuned pipe is not removed). Disconnect top exhaust hose from muffler. Disconnect hoses of the water flow regulator valve (if tuned pipe is not removed). Disconnect retaining strap. Installation is essentially the reverse of removal procedures. However, pay particular attention to the following.
Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Tuned Pipe Make sure to install the sealing ring on tuned pipe cone if it was removed. Apply a thin layer of heat resistant sealant (P/N 413 709 200) all around sealing ring. Ensure rubber bushings and sleeves are not damaged and are properly installed into tuned pipe supports. - Torque bolt of tuned pipe head above the engine magneto to 25 N•m (18 lbf•ft).
Section 01 ENGINE Subsection 04 (EXHAUST SYSTEM) Torque clamp of tuned pipe head to 14 N•m (10 lbf•ft). Torque exhaust hose clamp of tuned pipe cone to 4 N•m (35 lbf•in). 1 F06D1SA 1 F06D14A 1. Torque clamp to 14 N•m (10 lbf•ft) 1. Torque clamp to 4 N•m (35 lbf•in) As a final step, torque Allen screws and nut at tuned pipe head flange to 40 N•m (30 lbf•ft). Muffler Torque exhaust hose clamps of muffler to 4 N•m (35 lbf•in). Resonator Torque exhaust hose clamps of resonator to 3 N•m (27 lbf•in).
Section 02 COOLING SYSTEM Subsection 01 (CIRCUIT) CIRCUIT 0 947 Engine Cooling System As with other models, the water supply is provided by a pressurized area in the jet pump between the impeller and venturi. Water is directed to the water jacket of the tuned pipe head. After water has circulated in the cylinder-block water jackets, it is directed in the 1 piece cylinder head which features improved combustion chamber and spark plug cooling.
Section 02 COOLING SYSTEM Subsection 01 (CIRCUIT) Bleeding of the cooling system is accomplished by the bleed hose located at the uppermost point of the circuit at the tuned pipe. The bleed hose also serves as the Cooling System Indicator (CSI). Water Flow Regulator Valve The water supply of the water flow regulator is provided by the water jacket of the tuned pipe head. 1 F06E0BA 1 F06E09A 1. Bleed hose 1.
Section 02 COOLING SYSTEM Subsection 01 (CIRCUIT) Regulated water is injected in the tuned pipe by a calibrated fitting. F06E0AA 1 1. Injection fitting 02-01-3 www.SeaDooManuals.
Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) CARBURETION 0 AIR INTAKE SILENCER The air intake silencer is a molded piece and it can not be opened. It contains a new flame arrester, which can not be removed. 1 F06F06A 2 1. Fuel inlet hose 2. Fuel outlet hose F06D22A 1 1. Air intake silencer FUEL ACCELERATOR PUMP General The carburetors are equipped with a fuel accelerator pump. The fuel accelerator pump is mounted on the magneto side carburetor.
Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) Verify accelerator pump check valves operation as follows: Connect a clean plastic tubing to the valve inlet nipple and alternately apply pressure and vacuum. The check valve should release with pressure and hold under vacuum. ◆ WARNING Some fuel may be present in fuel pump. NOTE: Injectors are also equipped with check valves. Adjustment Ensure throttle cable is properly adjusted and idle speed is set at 1500 RPM in water.
Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) 1 F06F06B 2 1 TYPICAL 1. Apply synthetic grease to plunger 2. Apply BOMBARDIER LUBE on roller shaft F06F09A 1. Throttle position switch BN-46I CARBURETORS On these carburetors, diaphragms are either opened to the atmosphere or to the air intake silencer, depending upon throttle position. The advantage of this system is to keep the right air/fuel ratio on the entire RPM’s range of the engine.
Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) The solenoid is responsible for changing the venting position of the carburetors. The solenoid is located on the body, on left side. 1 3 2 1 F06F0BB SOLENOID ACTIVATED 1. Inlet (carburetor diaphragms) 2. Outlet to atmosphere blocked 3. Outlet to air intake silencer opened F06F0BA TYPICAL 1. Solenoid Up to 80% throttle opening, the solenoid is not activated and the diaphragms of the carburetors are opened to atmosphere.
Section 03 FUEL SYSTEM Subsection 01 (CARBURETION) Disconnect the wiring harness of the solenoid. Using a voltmeter, connect the positive probe to the PURPLE/BLUE wire and the negative probe to the BLACK/BLUE wire. With the safety lanyard removed, depress start/stop button to activate the MPEM timer. The voltmeter should indicate 0 Volt. Depress the throttle lever progressively. At 80% to full throttle opening, the voltmeter should indicate the battery voltage. If not, replace the amplifier.
Section 04 ELECTRICAL SYSTEM Subsection 01 (IGNITION AND CHARGING SYSTEMS) IGNITION AND CHARGING SYSTEMS 0 The ignition and charging systems of the 947 engine are of the same type as the 787 engine. The high amperage/voltage components (ignition coil and solenoid) are located into a rear electrical box. To access the rear electrical box, remove seat and vent tube support. 1 Digitally Encoded Security System F06E06A 1.
Section 04 ELECTRICAL SYSTEM Subsection 02 (STARTER) STARTER 0 GENERAL DISASSEMBLY The 947 engine is equipped with a MITSUBA 12 V starter. The starter is coupled to the drive assembly, which contains the overrunning clutch and gear reduction. To remove the drive assembly, the engine magneto cover must be removed. Locate index marks on yoke and end covers. 1 REMOVAL Remove seat. Remove air vent tube support. Remove air intake silencer. Disconnect the BLACK negative battery cable. ; F06H1FA 1.
Section 04 ELECTRICAL SYSTEM Subsection 02 (STARTER) Remove thrust washer from armature shaft. Release brush wires of yoke from brush holder. Remove brush holder. 1 1 F06H1HA 1. Thrust washer F06H1KA Remove the other end cover and gasket. Remove the 3 washers from armature shaft. 1. Remove brush holder To remove brushes from yoke, loosen nut and remove washers. 1 1 F06H1IA 1. Washers Remove armature. F06H1LA 1. Loosen nut and remove washers Remove brushes. F06H1JA 1 1.
Section 04 ELECTRICAL SYSTEM Subsection 02 (STARTER) To remove bearing and seal in end cover, release tabs of retainer. Install the 3 washers onto armature shaft, with the thicker one in the middle. 1 1 F06H1MA 1. Retainer F06H1NA INSPECTION 1. Thick washer in the middle For parts inspection, refer to the 1997 Sea-Doo Shop Manual, ELECTRICAL SYSTEM 07-04. ASSEMBLY Reverse the order of disassembly to reassemble starter. However, pay particular attention to the following.
Section 04 ELECTRICAL SYSTEM Subsection 02 (STARTER) STARTER SPECIFICATION Nominal output 0.8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise (viewed from pinion side) Weight 1.7 kg (3.7 lb) Performance specification at 20°C (68°F) Battery No load 10.9 V 45 A max. 8600 RPM Load 9V 120 A max. 5350 RPM Stall 2.25 V 390 A max. 0 RPM 12 V, 19 Ah 04-02-4 www.SeaDooManuals.
Section 05 PROPULSION SYSTEM Subsection 01 (DRIVE SYSTEM AND JET PUMP) DRIVE SYSTEM AND JET PUMP 0 DRIVE SYSTEM JET PUMP Seal Carrier and Bearing For performance improvement, the GSX Limited features a new jet pump with an impeller diameter of 155.6 mm (6-1/8 in). The jet pump housing and venturi are made of aluminum. Servicing the jet pump is identical as with the other models. For disassembly, inspection and assembly procedures, refer to the 1997 Sea-Doo Shop Manual, section 08-02.
Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) GSX LIMITED 0 ENGINE GSX Limited (5625) Engine type Bombardier-Rotax 947 Induction type Exhaust system Reed valve Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Water injection fitting (cone) N.A. Water injection fitting (muffler) 3.5 mm (.
Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) ELECTRICAL GSX Limited (5625) Magneto generator output 180 W @ 6000 RPM or 5.0 A @ 6000 RPM Ignition system type Spark plug Digital DC-CDI Make and type Gap Ignition timing (BTDC) NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) mm (in) 3.60 (.142) Degrees 22° ± 1 @ 3500 RPM Generating coil N.A. 0.1 - 1 Ω Battery charging coil 190 - 300 Ω Trigger coil Ignition coil Primary 0.33 - 0.62 Ω Secondary 8.4 - 15.
Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) COOLING GSX Limited (5625) Type Open circuit — Direct flow from jet propulsion unit Thermostat None Monitoring beeper setting 86-94°C (187-201°F) ADDITIONAL INFORMATION: Do not mix different brands or oil types.
Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) CAPACITIES GSX Limited (5625) Fuel tank 56.5 L (15 U.S. gal) Oil injection reservoir Impeller shaft reservoir 6 L (1.6 U.S. gal) Capacity 70 mL (2.4 U.S.
Section 06 TECHNICAL DATA Subsection 01 (GSX LIMITED) PERFORMANCE GSX Limited (5625) Estimated pump power 40.5 kW (54 hp) Maximum fuel consumption at wide open throttle 55 L/h (14.5 U.S.
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