Sea-doo GSX Limited Install guide

GSX Limited

www.SeaDooManuals.net

Legal deposit:

National Library of Quebec

National Library of Canada

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 Corpo-

ration

Gelcote®is a trademark of Gelcote International

Limited

www.SeaDooManuals.net

SECTION SUBSECTION PAGE

SAFETY NOTICE....................................................................................................................................... II

01 ENGINE 01 - Magneto System................................................................ 01-01-1

02 - Top End .............................................................................. 01-02-1

03 - Bottom End ........................................................................ 01-03-1

04 - Exhaust System ................................................................. 01-04-1

02 COOLING SYSTEM 01 - Circuit ................................................................................. 02-01-1

03 FUEL SYSTEM 01 - Carburetion ........................................................................ 03-01-1

04 ELECTRICAL SYSTEM 01 - Ignition and Charging Systems........................................... 04-01-1

02 - Starter................................................................................. 04-02-1

05 PROPULSION SYSTEM 01 - Drive System and Jet Pump............................................... 05-01-1

06 TECHNICAL DATA 01 - GSX Limited ....................................................................... 06-01-1

07 WIRING DIAGRAM ........................................................................................................................ 07-01-1

TABLE OF CONTENTS

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VOLUME 2

VOLUME 1 1997

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 Sea-

Doo 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 discrepan-

cy, the English version shall prevail.

The content depicts parts and/or procedures applicable to the particular product at its time of manufac-

ture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufac-

turing the product.

The use of Bombardier parts is most strongly recommended when considering replacement of any com-

ponent. Dealer and/or distributor assistance should be sought in case of doubt.

Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking disk,

lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking

device is impaired, it must be renewed.

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

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

Although the mere reading of such information does not eliminate the hazard, your understanding of the

information will promote its correct use. Always use common shop safety practice.

This information relates to the preparation and use of Bombardier watercraft and has been utilized safely

and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or

injuries resulting from the improper use of the contents. We strongly recommend that any services be

carried out and/or verified by a highly skilled professional technician. It is understood that certain modifi-

cations may render use of the watercraft illegal under existing federal, provincial and state regulations.

◆WARNING

Identifies an instruction which, if not followed, could cause serious personal injury including

possibility of death.

-CAUTION

Denotes an instruction which, if not followed, could severely damage watercraft components.

SAFETY NOTICE

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Section 01 ENGINE

Subsection 01 (MAGNETO SYSTEM)

01-01-1

MAGNETO SYSTEM 0

947 Engine

F06D0IS

Loctite 242

Loctite 648

Loctite

648

Anti-seize

lubricant

9 N•m

(80 lbf•in)

13 N•m

(115 lbf•in)

115 N•m

(85 lbf•ft)

9 N•m

(80 lbf•in)

13 11

13 N•m

(115 lbf•in)

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FLAT RATE

PARTS

Section 01 ENGINE

Subsection 01 (MAGNETO SYSTEM)

01-01-2

DISASSEMBLY

1, Cover

Loosen screws no. 2. Remove engine magneto

cover.

1. Cover

2. Screw

Remove oil pump shaft from flywheel nut.

1. Remove oil pump shaft

4,5, Rotor and Flywheel

To remove the rotor or the flywheel, the crank-

shaft must be locked.

Remove the pulse fitting beside the starter bracket

on the lower crankcase half.

1. Remove pulse fitting

Turn engine manually until slot in crankshaft coun-

terweight is aligned with the crankcase hole. In-

sert a M8 x 50 fixation screw to lock crankshaft.

CRANKSHAFT FIXATION SCREW (P/N 290 240 882)

1. Crankshaft locked

F06D1RA

F06D23A

F06D0KA

F06B04A

F06D2AA 1

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Section 01 ENGINE

Subsection 01 (MAGNETO SYSTEM)

01-01-3

If necessary, the magneto rotor can be removed

without the engine flywheel. Remove the 6

screws no. 7.

1. Screw

To remove the flywheel/rotor assembly, unscrew

nut no. 6 counterclockwise when facing it.

1. Nut

The flywheel is easily freed from crankshaft with

puller (P/N 420 976 235).

Install protective cap (P/N 290 877 414) to crank-

shaft.

Fully thread puller in engine flywheel.

1. Puller

8,9, Stator and Trigger Coil

Loosen screws no. 10 and no. 11 to remove the

stator and trigger coil from the engine magneto

cover.

1. Screws

CLEANING

Clean all metal components in a solvent.

Clean crankshaft taper and threads.

F06D0LA

F06D0MA

-CAUTION

Clean coils and magnet using only a clean

cloth.

F06D0PA 1

F06D0NA

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Section 01 ENGINE

Subsection 01 (MAGNETO SYSTEM)

01-01-4

ASSEMBLY

8,9, Stator and Trigger Coil

Install the stator and trigger coil in engine magne-

to cover. Torque screws to 9 N•m (80 lbf•in).

Reinstall wiring harness bracket no. 12 using tap-

tite screws no. 13.

Torque trigger coil screws no. 11to 9 N•m (80 lbf•in).

Torque stator screws no. 10 to 13 N•m (115 lbf•in).

1. Torque to 9 N•m (80 lbf•in)

2. Taptite screws

3. Torque to 13 N•m (115 lbf•in)

4,5, Rotor and Flywheel

Apply Loctite 648 (green) on mating surface of the

rotor no. 4.

When reinstalling rotor to flywheel, one of the

protrusion end of rotor must be aligned with hole

in flywheel.

1. Protrusion

2. Hole

Apply Loctite 648 (green) on screws no. 7 retain-

ing rotor to flywheel and torque screws in a criss-

cross sequence to 13 N•m (115 lbf•in).

Apply Loctite 242 (blue) on crankshaft taper.

1. Loctite 242 (blue) on crankshaft taper

Install flywheel and make sure to align keyway

with the crankshaft Woodruff key.

Apply Loctite 242 (blue) on nut no. 6. Install nut

with lock washer and torque to 115 N•m (85

lbf•ft).

Unlock crankshaft. Reinstall pulse fitting with

washer and torque to 23 N•m (17 lbf•ft).

1, Cover

Before installation, properly install O-ring no. 3 in

engine magneto cover.

Apply Loctite 767 anti-seize compound on screws

no. 2. Torque screws in a criss-cross sequence to

9 N•m (80 lbf•in).

F06D0NB

1 2 3

F06D0OA

1 2

-CAUTION

Never use any type of impact wrench.

F06D24A

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Section 01 ENGINE

Subsection 02 (TOP END)

01-02-1

TOP END 0

947 Engine

F06D17S

Loctite

242

Loctite

242

Synthetic

grease

rollers

Synthetic

grease

34 N•m

(25 lbf•ft)

3 N•m

(26 lbf•in)

34 N•m

(25 lbf•ft)

1920

Loctite

242

13 18

16 Synthetic

grease

15 17

9 N•m

(80 lbf•in)

22 23 24

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FLAT RATE

PARTS

Section 01 ENGINE

Subsection 02 (TOP END)

01-02-2

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 acceler-

ation.

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.

RAVE VALVE OPENED

1. Pulse from crankcase

2. Check valve

3. Positive pressure to solenoid

4. Solenoid activated

5. Positive crankcase pressure to RAVE valves

F06D16S

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