003 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 2nd 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.
TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE .................................................................................................................................. III INTRODUCTION ................................................................................................................................... IV 01 SERVICE TOOLS AND PRODUCTS 01 - Table of contents ...................................................................... 02 - Mandatory service tools...........
TABLE OF CONTENTS II PAGE SECTION SUBSECTION 10 FUEL SYSTEM 01 - Table of contents ...................................................................... 02 - Fuel circuit ................................................................................ 03 - Air intake (2-stroke)................................................................... 04 - Carburetor.................................................................................
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.
INTRODUCTION INTRODUCTION This Shop Manual covers the following BOMBARDIER made SEA-DOO® 2003 watercraft models.
INTRODUCTION All Models The Hull Identification Number is composed of 12 digits: ZZN12345L495 Serial number* F00A0CB Manufacturer Model year Year of production Month of production *A letter may also be used as a digit. ENGINE IDENTIFICATION NUMBER (E.I.N.) F01D87A 717 Engines The Engine Identification Number is located on the upper side of the magneto housing. 1 1. Engine Identification Number (E.I.N.
INTRODUCTION TYPICAL PAGE Page heading indicates section and subsection detailed. Subsection title indicates beginning of the subsection. Subsection 04 (MAGNETO SYSTEM) 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. Loctite 243 Loctite 243 Dotted box contains parts of a particular model or an exploded view.
INTRODUCTION TYPICAL PAGE Sub-title with part name(s) from exploded view. Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS) 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.
INTRODUCTION LIST OF ABBREVIATIONS USED IN THIS MANUAL ADC AC APS ATS B.U.D.S. CDI CPS CSI DC DESS DI E.I.N. ECM ECU EPA HP LED MAG MPEM MPH MPI N.A.
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.
INTRODUCTION LOCTITE APPLICATION PROCEDURE Blind Holes 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. 1 2 THREADLOCKER Uncovered Holes (bolts and nuts) A00A3MA 1. On threads 2. On threads and at the bottom of hole 1 2 A00A3LA 1. Apply here 2. Do not apply 1. Clean threads (bolt and nut) with solvent. 2.
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. Adjusting Screw 2 1 A00A3PA Preassembled Parts 1. Apply here 2. Plunger 1 1.
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.
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. Proper strength Loctite 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.
INTRODUCTION N•m 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 XIV FASTENER SIZE (8.
INTRODUCTION N•m 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 FASTENER SIZE (8.8) M14 Lbf•ft 94 95 96 97 97 98 99 100 100 101 102 103 103 104 105 105 106 107 108 108 109 110 111 TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS Technical Publications Bombardier Inc. Valcourt (Quebec), Canada SMR2003_001_00_00A2.
