SeaDoo GSX Wartungshandbuch

GSX Limitedwww.SeaDooManuals.net

Section 01 ENGINESubsection 02 (TOP END)01-02-2THEORY OF OPERATIONRAVE Valve SystemOn this engine, the RAVE valves are controlled by the Multi-Purpose

Section 01 ENGINESubsection 02 (TOP END)01-02-3To close the RAVE valves, the MPEM deactivates the solenoid which blocks the crankcase positive pres-su

Section 01 ENGINESubsection 02 (TOP END)01-02-4DISASSEMBLY11, RAVE ValveLoosen Allen screws no. 12 each side of RAVEvalve.1. Remove screwsRemove RAVE

Section 01 ENGINESubsection 02 (TOP END)01-02-5Remove bellows from valve piston.1. Bellows removed from pistonUnscrew valve piston no. 18 from sliding

Section 01 ENGINESubsection 02 (TOP END)01-02-6Remove O-ring no. 24.1. Remove O-ringRemove sliding valve no. 19.1. Remove sliding valveRemove bellows

Section 01 ENGINESubsection 02 (TOP END)01-02-7Loosen nuts no. 4 following the sequence shownin the next photo.UNTORQUING SEQUENCE FOR THE NUTSRemove

Section 01 ENGINESubsection 02 (TOP END)01-02-81. Piston notchTo extract piston pin no. 9, use puller. Refer to the1997 Sea-Doo Shop Manual for proced

Section 01 ENGINESubsection 02 (TOP END)01-02-9TYPICAL — PISTON DOME SHOWN1. Exhaust side9,10, Piston Pin and Roller BearingTo install roller bearing

Section 01 ENGINESubsection 02 (TOP END)01-02-10Torque bolts and nuts to 15 N•m (11 lbf•ft) as per fol-lowing sequence in the next photo. Repeat the t

Section 01 ENGINESubsection 03 (BOTTOM END)01-03-1BOTTOM END 0947 EngineF06D19S11Loctite 242102425Loctite2429 N•m(80 lbf•in)18161719222021181719Synthe

Legal deposit:National Library of QuebecNational Library of CanadaAll rights reserved. No parts of this manual may bereproduced in any form without th

Section 01 ENGINESubsection 03 (BOTTOM END)01-03-2DISASSEMBLYThe following components should be removedprior to opening bottom end:– magneto cover– ma

Section 01 ENGINESubsection 03 (BOTTOM END)01-03-36, Starter Drive AssemblyLoosen 2 Allen screws no. 7 retaining starterdrive cover no. 8.1. Cover2. A

Section 01 ENGINESubsection 03 (BOTTOM END)01-03-41. Separate halves by prying at provided lugs (both sides)Remove crankshaft and counterbalance shaft

Section 01 ENGINESubsection 03 (BOTTOM END)01-03-51. Trace an index markRemove seals no. 19.Remove bearing no. 20 and washer no. 21.Use a press to rem

Section 01 ENGINESubsection 03 (BOTTOM END)01-03-6Bent stopper as required to obtain the proper dis-tance.14, CrankshaftRefer to the 1997 Sea-Doo Shop

Section 01 ENGINESubsection 03 (BOTTOM END)01-03-7Install the counterbalance shaft in crankcase low-er half. Make sure to properly index crankshaftand

Section 01 ENGINESubsection 03 (BOTTOM END)01-03-8Apply synthetic grease below head of boltsno. 12 and no. 13.Apply also Loctite 518 on threads of bol

Section 01 ENGINESubsection 04 (EXHAUST SYSTEM)01-04-1EXHAUST SYSTEM 0GENERALTo enhance performance and reduce noise level,the GSX Limited is equipped

Section 01 ENGINESubsection 04 (EXHAUST SYSTEM)01-04-2Disconnect the water injection hose at tuned pipehead.1. Water injection hoseDisconnect the wate

Section 01 ENGINESubsection 04 (EXHAUST SYSTEM)01-04-3Loosen Allen screw of carburetor bracket.1. Loosen Allen screwLoosen Allen screws and nut at tun

ISECTION SUBSECTION PAGESAFETY NOTICE...

Section 01 ENGINESubsection 04 (EXHAUST SYSTEM)01-04-4MufflerDisconnect front exhaust hose (if tuned pipe isnot removed).Disconnect top exhaust hose f

Section 01 ENGINESubsection 04 (EXHAUST SYSTEM)01-04-5Tuned PipeMake sure to install the sealing ring on tuned pipecone if it was removed.Apply a thin

Section 01 ENGINESubsection 04 (EXHAUST SYSTEM)01-04-6Torque clamp of tuned pipe head to 14 N•m(10 lbf•ft).1. Torque clamp to 14 N•m (10 lbf•ft)As a f

Section 02 COOLING SYSTEMSubsection 01 (CIRCUIT)02-01-1CIRCUIT 0947 Engine Cooling SystemAs with other models, the water supply is provid-ed by a pres

Section 02 COOLING SYSTEMSubsection 01 (CIRCUIT)02-01-2Bleeding of the cooling system is accomplishedby the bleed hose located at the uppermost pointo

Section 02 COOLING SYSTEMSubsection 01 (CIRCUIT)02-01-3Regulated water is injected in the tuned pipe by acalibrated fitting.1. Injection fitting1F06E0

Section 03 FUEL SYSTEMSubsection 01 (CARBURETION)03-01-1CARBURETION 0AIR INTAKE SILENCERThe air intake silencer is a molded piece and it cannot be ope

Section 03 FUEL SYSTEMSubsection 01 (CARBURETION)03-01-2Verify accelerator pump check valves operation asfollows:Connect a clean plastic tubing to the

Section 03 FUEL SYSTEMSubsection 01(CARBURETION)03-01-3TYPICAL1. Apply synthetic grease to plunger2. Apply BOMBARDIER LUBE on roller shaftBN-46I CARBU

Section 03 FUEL SYSTEMSubsection 01 (CARBURETION)03-01-4The solenoid is responsible for changing the vent-ing position of the carburetors. The solenoi

IISAFETY NOTICEThis manual was primarily published to be used by watercraft technicians trained by the manufacturerwho are already familiar with all s

Section 03 FUEL SYSTEMSubsection 01 (CARBURETION)03-01-5Disconnect the wiring harness of the solenoid.Using a voltmeter, connect the positive probe to

Section 04 ELECTRICAL SYSTEMSubsection 01 (IGNITION AND CHARGING SYSTEMS)04-01-1IGNITION AND CHARGING SYSTEMS 0The ignition and charging systems of th

Section 04 ELECTRICAL SYSTEMSubsection 02 (STARTER)04-02-1STARTER 0GENERALThe 947 engine is equipped with a MITSUBA 12 Vstarter.The starter is coupled

Section 04 ELECTRICAL SYSTEMSubsection 02 (STARTER)04-02-2Remove thrust washer from armature shaft.1. Thrust washerRemove the other end cover and gask

Section 04 ELECTRICAL SYSTEMSubsection 02 (STARTER)04-02-3To remove bearing and seal in end cover, releasetabs of retainer.1. RetainerINSPECTIONFor pa

Section 04 ELECTRICAL SYSTEMSubsection 02 (STARTER)04-02-4STARTER SPECIFICATIONNominal output 0.8 kWVoltage 12 VRated time 30 secondsRotation Counterc

Section 05 PROPULSION SYSTEMSubsection 01 (DRIVE SYSTEM AND JET PUMP)05-01-1DRIVE SYSTEM AND JET PUMP 0DRIVE SYSTEMSeal Carrier and BearingThe drive s

Section 06 TECHNICAL DATASubsection 01 (GSX LIMITED)06-01-1GSX LIMITED 0ENGINE GSX Limited (5625)Engine type Bombardier-Rotax 947Induction type Reed v

Section 06 TECHNICAL DATASubsection 01 (GSX LIMITED)06-01-2ELECTRICAL GSX Limited (5625)Magneto generator output 180 W @ 6000 RPMor 5.0 A @ 6000 RPMIg

Section 06 TECHNICAL DATASubsection 01 (GSX LIMITED)06-01-3COOLING GSX Limited (5625)Type Open circuit — Direct flow from jet propulsion unitThermosta

Section 01 ENGINESubsection 01 (MAGNETO SYSTEM)01-01-1MAGNETO SYSTEM 0947 EngineF06D0ISLoctite 242Loctite 242Loctite 242Loctite 648Loctite648Anti-seiz

Section 06 TECHNICAL DATASubsection 01 (GSX LIMITED)06-01-4CAPACITIES GSX Limited (5625)Fuel tank 56.5 L (15 U.S. gal)Oil injection reservoir 6 L (1.6

Section 06 TECHNICAL DATASubsection 01 (GSX LIMITED)06-01-5PERFORMANCE GSX Limited (5625)Estimated pump power 40.5 kW (54 hp)Maximum fuel consumption

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Section 01 ENGINESubsection 01 (MAGNETO SYSTEM)01-01-2DISASSEMBLY1, CoverLoosen screws no. 2. Remove engine magnetocover.1. Cover2. ScrewRemove oil pu

Section 01 ENGINESubsection 01 (MAGNETO SYSTEM)01-01-3If necessary, the magneto rotor can be removedwithout the engine flywheel. Remove the 6screws no

Section 01 ENGINESubsection 01 (MAGNETO SYSTEM)01-01-4ASSEMBLY8,9, Stator and Trigger CoilInstall the stator and trigger coil in engine magne-to cover

Section 01 ENGINESubsection 02 (TOP END)01-02-1TOP END 0947 EngineF06D17SLoctite242Loctite242Syntheticgrease121036rollers8978Syntheticgrease35634 N•m(