smo2003-003a.fm Page 0 Tuesday, August 27, 2002 9:41 AM SAFETY WARNING Disregarding any of the safety precautions and instructions contained in this Operator’s Guide, the Safety Handbook, the Safety Videocassette and on the on-product warning labels could cause injury, including the possibility of death. The operator has the responsibility to inform passenger(s) of safety precautions. This Operator’s Guide, the Safety Handbook and Safety Videocassette should remain with the craft at the time of resale.
smo2003-003a.book Page 1 Tuesday, August 27, 2002 9:23 AM Doin’it on your new SEA-DOO watercraft Congratulations, you are now the proud owner of a SEA-DOO personal watercraft. Whether you are an experienced boater or are new to the sport of boating, we ask you to take the time to view the safety videocassette provided with the watercraft, to read this Operator’s Guide, the Safety Handbook and on-product warning/caution labels and familiarize yourself with the contents.
smo2003-003a.book Page 2 Tuesday, August 27, 2002 9:23 AM TABLE OF CONTENTS FOREWORD ................................................................................ SAFETY MEASURES ............................................................... General .................................................................................................... Operation ................................................................................................. Maintenance ..................................
smo2003-003a.book Page 3 Tuesday, August 27, 2002 9:23 AM 25) Boarding Step ................................................................................... 26) Flushing Connector ........................................................................... 27) Bilge Drain Plugs............................................................................... 28) Jet Pump Nozzle ............................................................................... 29) Reverse Gate ..................................
smo2003-003a.book Page 4 Tuesday, August 27, 2002 9:23 AM POST-OPERATION CARE ............................................................ General Care ............................................................................................ Additional Care for Foul Water or Salt Water .......................................... Exhaust Cooling System Flushing ........................................................... Anticorrosion Treatment...............................................................
smo2003-003a.book Page 5 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 6 Tuesday, August 27, 2002 9:23 AM 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 F01L451 1. Left (port) 2.
smo2003-003a.book Page 7 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 8 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 9 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 10 Tuesday, August 27, 2002 9:23 AM LIST OF DISTRIBUTORS NORTH AMERICA USA (Except Puerto Rico) CANADA BOMBARDIER MOTOR CORPORATION OF AMERICA 7575 Bombardier Court WAUSAU, WI. 54401 Phone: (715) 848-4957 Fax: (715) 847-6879 www.bombardier.com BOMBARDIER INC. RECREATIONAL PRODUCTS 75 J. A. BOMBARDIER ST. SHERBROOKE, QC J1L 1W3 Phone: (819) 566-3366 Fax: (819) 566-3062 www.bombardier.
smo2003-003a.book Page 11 Tuesday, August 27, 2002 9:23 AM BOMBARDIER LIMITED WARRANTY NORTH AMERICA: SEA-DOO® WATERCRAFT 1. SCOPE OF THE LIMITED WARRANTY In Canada, BOMBARDIER INC. (hereinafter “BOMBARDIER”), and in the USA, Bombardier on behalf of BOMBARDIER MOTOR CORPORATION OF AMERICA (BMCA) warrants its SEA-DOO watercraft from defects in material or workmanship for the period described below.
smo2003-003a.book Page 12 Tuesday, August 27, 2002 9:23 AM 4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE The customer must notify an authorized servicing BOMBARDIER dealer within two (2) days of the appearance of a defect, and provide it with reasonable access to the product and reasonable opportunity to repair it.
smo2003-003a.book Page 13 Tuesday, August 27, 2002 9:23 AM 7. LIMITATIONS OF LIABILITY THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY.
smo2003-003a.book Page 14 Tuesday, August 27, 2002 9:23 AM ONLY FOR 2003 SEA-DOO GTX† 4-TEC, SEA-DOO GTX† 4-TEC VANS TRIPLE CROWN EDITION, SEA-DOO GTX† 4-TEC SUPERCHARGED AND SEA-DOO GTX† 4-TEC SUPERCHARGED LIMITED SOLD AND REGISTERED IN CALIFORNIA CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your SEA-DOO watercraft has a special environmental label required by the California Air Resources Board (CARB). The label has 1, 2, or 3 stars.
smo2003-003a.book Page 15 Tuesday, August 27, 2002 9:23 AM The California Air Resources Board and BOMBARDIER on behalf of BOMBARDIER MOTOR CORPORATION OF AMERICA (BMCA) are pleased to explain the emission control system warranty on your 2003 SEA-DOO GTX † 4-TEC, SEA-DOO GTX † 4-TEC VANS TRIPLE CROWN EDITION, SEA-DOO GTX† 4-TEC SUPERCHARGED and SEA-DOO GTX† 4-TEC SUPERCHARGED LIMITED personal watercraft engine.
smo2003-003a.book Page 16 Tuesday, August 27, 2002 9:23 AM Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted by Bombardier for the period of time before the first scheduled replacement date for that part. Emission warranty parts that are scheduled for regular inspection, but not regular replacement, are warranted by Bombardier for the entire warranty period of the watercraft.
smo2003-003a.book Page 17 Tuesday, August 27, 2002 9:23 AM BOMBARDIER LIMITED WARRANTY INTERNATIONAL: SEA-DOO® WATERCRAFT 1. SCOPE OF THE LIMITED WARRANTY BOMBARDIER INC. (hereinafter “BOMBARDIER” warrants its SEA-DOO personal watercraft from defects in material or workmanship for the period described below.
smo2003-003a.book Page 18 Tuesday, August 27, 2002 9:23 AM 6.
smo2003-003a.book Page 19 Tuesday, August 27, 2002 9:23 AM 9. CONSUMER ASSISTANCE (a) In the event of a controversy or a dispute in connection with this BOMBARDIER LIMITED WARRANTY, BOMBARDIER suggests that you try to resolve the issue at the distributorship/dealership level. We recommend discussing the issue with the authorized dealer’s service manager or owner. (b) If further assistance is required, the distributor’s service department should be contacted in order to resolve the matter.
smo2003-003a.book Page 20 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003b.fm Page 21 Monday, September 16, 2002 8:38 AM 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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smo2003-003a.book Page 25 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 26 Tuesday, August 27, 2002 9:23 AM CONTROLS, COMPONENTS AND INSTRUMENTS LOCATION NOTE: Some components do not apply or are optional on some models.
smo2003-003a.book Page 27 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 28 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 29 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 30 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 31 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 32 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 33 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 34 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 35 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 36 Tuesday, August 27, 2002 9:23 AM 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).
smo2003-003a.book Page 37 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 38 Tuesday, August 27, 2002 9:23 AM 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. 2 F00L2TY 1 1 2 1. Latch hole 2. Pin F18L0HY 3 18) Rear Grab Handle 1. Storage basket 2. Spare spark plug holder cap 3.
smo2003-003a.book Page 39 Tuesday, August 27, 2002 9:23 AM 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 21) Mooring Cleats These cleats can be temporarily used for docking, while refueling for example. F18L0SY 1 F18L0IY 1. Boarding step Pull down the step with your hand and hold until a foot or a knee is put on the step. F18L0JY 1.
smo2003-003a.book Page 40 Tuesday, August 27, 2002 9:23 AM Refer to POST-OPERATION CARE section for proper use. 27) Bilge Drain Plugs Should water be found in the bilge, it can be easily drained by unscrewing the drain plugs when engine is off and watercraft is out of water. CAUTION: Remove boat from water prior to unscrewing drain plugs.
smo2003-003a.book Page 41 Tuesday, August 27, 2002 9:23 AM NOTE: The ride plate is the heat exchanger for the ENGINE cooling system. 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. F18J05Z 1 1.
smo2003-003a.book Page 42 Tuesday, August 27, 2002 9:23 AM 31) Fuses 33) Side Vanes Fuses are located under seat in bilge. Refer to MAINTENANCE for more details. 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.
smo2003-003a.book Page 43 Tuesday, August 27, 2002 9:23 AM 1 F18D04Y 1 F18D09Y TYPICAL 1. Oil dipstick TYPICAL 1. Oil filling cap Refer to LIQUIDS for more details. Refer to LIQUIDS for more details. 35) Engine Oil Filling Cap 36) Cooling System Expansion Tank Cap Located in engine compartment, on the engine. It allows adding oil in the engine when required. Located in engine compartment. It provides access to the expansion tank filling neck.
smo2003-003a.book Page 44 Tuesday, August 27, 2002 9:23 AM Remove seat extension and storage basket to expose expansion tank. F18E0MY 2 1 1. Ski/wake board post lifted 2. Ensure it is locked Refer to LIQUIDS for more details. Ski/Wake Board Post (if so equipped) Pull up the post to allow hooking a ski or wake board rope. Push down when finished and properly relock. To lift post, unlock by pulling the locking pin then lift post. Ensure it is properly locked.
smo2003-003b.fm Page 45 Monday, September 16, 2002 11:42 AM 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.
smo2003-003a.book Page 46 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 47 Tuesday, August 27, 2002 9:23 AM 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. NOTE: Every time oil is added in engine, the complete procedure explained above must be done (engine restarted, idling for 30 seconds, 30 seconds waiting time and then, rechecking the oil level).
smo2003-003a.book Page 48 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 49 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 50 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 51 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 52 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 53 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 54 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 55 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 56 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 57 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003b.fm Page 58 Monday, September 16, 2002 8:39 AM 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.
smo2003-003a.book Page 59 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003b.fm Page 60 Monday, September 16, 2002 8:40 AM Riding Slowly 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.
smo2003-003a.book Page 61 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 62 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 63 Tuesday, August 27, 2002 9:23 AM Models without a Flushing Connector in Engine Compartment Connect a garden hose to connector located at the rear of watercraft on jet pump support. Do not open water tap yet. NOTE: An optional quick connect adapter can be used (P/N 295 500 473). No hose pincher is required to flush engine. 2 1 F07E01Y 3 2 1 TYPICAL 1. Hose adapter 2. Quick connect adapter (optional, not mandatory) 3.
smo2003-003a.book Page 64 Tuesday, August 27, 2002 9:23 AM Attach other end of coupler hose to a garden hose. Do not open water tap yet. Flushing All Models 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.
smo2003-003a.book Page 65 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 66 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 67 Tuesday, August 27, 2002 9:23 AM 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 (T.O.P.S.™).
smo2003-003a.book Page 68 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 69 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 70 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 71 Tuesday, August 27, 2002 9:23 AM 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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smo2003-003a.book Page 73 Tuesday, August 27, 2002 9:23 AM HULL AND BODY PROPULSION SYSTEM O.P.A.S. STEERING SYSTEM SYSTEM Steering cable I O.P.A.S.
smo2003-003a.book Page 74 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 75 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 76 Tuesday, August 27, 2002 9:23 AM MPEM To access fuses on the MPEM, remove seat. Locate MPEM besides engine. 1 F18H0JY TYPICAL 1. Fuses Fuses rating are identified, look besides 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 F18H07M FUSE IDENTIFICATION 76 10A 2A 10A 1A 10A 10A 3A 5A 10A 2A 7.
smo2003-003a.book Page 77 Tuesday, August 27, 2002 9:23 AM Squeeze locking tabs together, hold and pull fuse cover from the MPEM. 1 2 1 F18H0CY To gain access to spare fuses, remove the cover identified “SPARE FUSES INSIDE”. Look inside cover and pull the rubber protector with a finger. Take care not to drop the fuses. 1 2 TYPICAL 1. MPEM 2. Fuse cover F18H0BY 1 1. Rubber protector Use the tabs of the fuse cover to remove and reinstall fuses. Slide cover tabs along fuse top.
smo2003-003a.book Page 78 Tuesday, August 27, 2002 9:23 AM Main Fuses They are located besides the MPEM. See below for details. 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.
smo2003-003a.book Page 79 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 80 Tuesday, August 27, 2002 9:23 AM TRAILERING, STORAGE AND PRE-SEASON PREPARATION Trailering CA U T IO N : T o a v oi d da m a g ing 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.
smo2003-003a.book Page 81 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 82 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 83 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 84 Tuesday, August 27, 2002 9:23 AM Pre-Season 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 pre-season preparation all at the same time.
smo2003-003a.book Page 85 Tuesday, August 27, 2002 9:23 AM 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.
smo2003-003a.book Page 86 Tuesday, August 27, 2002 9:23 AM 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 sensor or circuit malfunction. Refer to an authorized Sea-Doo dealer. • Fuel level sensor or circuit malfunction. Refer to an authorized Sea-Doo dealer. • Exhaust temperature sensor or circuit malfunction. Refer to an authorized Sea-Doo dealer.
smo2003-003a.book Page 87 Tuesday, August 27, 2002 9:23 AM 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 the safety lanyard. Refer to an authorized Sea-Doo 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.
smo2003-003a.book Page 88 Tuesday, August 27, 2002 9:23 AM 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 watercontaminated. 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.
smo2003-003a.book Page 89 Tuesday, August 27, 2002 9:23 AM 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. Refer to MONITORING SYSTEM in SPECIAL PROCEDURES. • Engine damaged by water ingestion. Refer to an authorized Sea-Doo dealer. • Clogged injectors.
smo2003-003a.book Page 90 Tuesday, August 27, 2002 9:23 AM 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. Refer to an authorized Sea-Doo dealer. Watercraft pulls on one side. • One side vane does not go up while watercraft is at speed. Refer to an authorized Sea-Doo dealer. O.P.A.S. side vanes do not go up while watercraft is at speed.
smo2003-003a.book Page 91 Tuesday, August 27, 2002 9:23 AM SPECIFICATIONS GTX 4-TEC SERIES (6105/6106/6107/6108/6111/6112/ 6125/6126/6128/6129) 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.
smo2003-003b.fm Page 92 Monday, September 16, 2002 11:42 AM ELECTRICAL SYSTEM GTX 4-TEC SERIES (6105/6106/6107/6108/6111/6112/ 6125/6126/6128/6129) 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.
smo2003-003b.fm Page 93 Monday, September 16, 2002 8:41 AM PROPULSION Propulsion system Jet pump type Transmission Reverse system O.P.A.S. system Pivoting angle of direction (nozzle) Minimum required water level for jet pump GTX 4-TEC SERIES (6105/6106/6107/6108/6111/6112/ 6125/6126/6128/6129) Bombardier Formula pump Axial flow, single stage.
smo2003-003a.book Page 94 Tuesday, August 27, 2002 9:23 AM SI* METRIC INFORMATION BASE UNITS DESCRIPTION length .................................................. mass.................................................... force .................................................... liquid .................................................... temperature......................................... pressure .............................................. torque ..................................................
smo2003-003a.book Page 95 Tuesday, August 27, 2002 9:23 AM ABBREVIATIONS USED IN THIS MANUAL DESCRIPTION AC Alternate current API American petroleum institute CARB California air resource board DC Direct current DESS Digitally encoded security system EMS Engine management system EMS ECU EMS Electronic control unit E.I.N.
smo2003-003a.book Page 96 Tuesday, August 27, 2002 9:23 AM PRIVACY INFORMATION We wish to inform you that your coordinates will be used for safety and warranty purposes. Sometimes, we also use the coordinates of our clients to inform them about our products and to present them offers. Should you prefer not to receive information on our products, services and offers, please let us know by writing to the address below.
smo2003-003a.book Page 97 Tuesday, August 27, 2002 9:23 AM CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary. NOTE: This card is strictly for change of address only.
smo2003-003a.book Page 98 Tuesday, August 27, 2002 9:23 AM CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary. NOTE: This card is strictly for change of address only.
smo2003-003a.book Page 99 Tuesday, August 27, 2002 9:23 AM CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary. NOTE: This card is strictly for change of address only.
smo2003-003a.book Page 100 Tuesday, August 27, 2002 9:23 AM CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary. NOTE: This card is strictly for change of address only.
smo2003-003a.book Page 101 Tuesday, August 27, 2002 9:23 AM WATERCRAFT MODEL No. HULL IDENTIFICATION NUMBER (H.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Owner: NAME No. CITY STREET APT STATE/PROVINCE ZIP/POSTAL CODE Purchase Date Warranty Expiry Date YEAR MONTH DAY YEAR MONTH DAY To be completed by the authorized Sea-Doo dealer at the time of the sale. DEALER IMPRINT AREA Please verify with your selling dealer to ensure your SEA-DOO watercraft has been registered with Bombardier.
