BOMBARDIER SEA-DOO GTX RFI 5666 1998, Manual

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Page 2: ...y be reproduced in any form without the prior written permission of Bombardier Inc Bombardier Inc 1998 Printed in Canada Registered trademarks of Bombardier Inc Loctite is a trademark of Loctite Corpo...

Page 3: ...1 02 Magneto system 02 02 1 03 Crankcase 02 03 1 03 COOLING SYSTEM 01 Table of contents 03 01 1 02 Circuit 03 02 1 04 FUEL SYSTEM 01 Table of contents 04 01 1 02 Fuel injection 04 02 1 05 ELECTRICAL S...

Page 4: ...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 Ind...

Page 5: ...tion 01 MAINTENANCE Subsection 01 TABLE OF CONTENTS TABLE OF CONTENTS 0 PERIODIC INSPECTION CHART 01 02 1 FLUSHING AND LUBRICATION 01 03 1 GENERAL 01 03 1 PROCEDURE 01 03 1 STORAGE 01 04 1 VOLUME 2 VO...

Page 6: ...cleaning Engine counterbalance shaft oil level Water flow regulator valve inspection Oil injection pump adjustment Oil filter inspection Oil filter replacement Engine head bolts retorque Steering syst...

Page 7: ...BARDIER LUBE lubri cant To flush engine connect a garden hose to the wa ter outlet located at the rear of the watercraft 1 Water outlet NOTE A quick connect adapter is supplied with the watercraft and...

Page 8: ...orage oil P N 413 711 600 Fully apply the throttle lever then depress the start stop button to crank the engine a few turns to distribute the oil onto cylinder wall Apply anti seize lubricant on spark...

Page 9: ...r use NOTE Fuel stabilizer should be added prior en gine lubrication Cooling System Flushing and Engine Internal Lubrication Cooling system has to be flushed with fresh wa ter to prevent salt sand or...

Page 10: ...ng dust accumu lation Anticorrosion Treatment Wipe off any residual water in the engine com partment Spray BOMBARDIER LUBE lubricant over all me tallic components in engine compartment Lubricate the t...

Page 11: ...in engine until the colored solution ap pears in the water return hose of the magneto cool ing circuit Remove temporary hose and reconnect engine water return hose Remove hose pinchers Most of the ant...

Page 12: ...02 01 1 Section 02 ENGINE Subsection 01 TABLE OF CONTENT TABLE OF CONTENT 0 MAGNETO SYSTEM 02 02 1 CRANKCASE 02 03 1 VOLUME 2 VOLUME 1 1998...

Page 13: ...02 02 1 MAGNETO SYSTEM 0 9 N m 80 lbf in F07D0BS Loctite 242 Loctite 242 9 N m 80 lbf in 9 N m 80 lbf in Synthetic grease 105 N m 77 lbf ft 6 N m 53 lbf in 9 N m 80 lbf in 9 N m 80 lbf in 4 N m 35 lbf...

Page 14: ...ctite 518 F07D0CS Loctite 518 Synthetic grease Loctite 518 Loctite 518 24 N m 17 lbf ft 20 N m 15 lbf ft Synthetic grease 30 mL 1 oz BOMBARDIER ROTAX Injection oil 9 N m 80 lbf in 40 N m 30 lbf ft Loc...

Page 15: ...03 01 1 Section 03 COOLING SYSTEM Subsection 01 TABLE OF CONTENTS TABLE OF CONTENTS 0 CIRCUIT 03 02 1 VOLUME 2 VOLUME 1 1998...

Page 16: ...rovement Water flows through the tuned pipe and manifold water jackets then to the cylinder water jackets Engine water supply hose Magneto heat exchanger water outlet hose exits at the exhaust outlet...

Page 17: ...TROUBLESHOOTING SUMMARY 04 02 13 ENGINE DOES NOT START 04 02 13 ENGINE STARTS BUT RUNS POORLY 04 02 13 ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS 04 02 14 ENGINE CANNOT REACH MAXIMUM REVO...

Page 18: ...lter 3 Fuel pump 4 Regulator 5 Fuel rail 6 Fuel injector 7 Electronic Control Unit ECU 8 Multi Purpose Electronic Module MPEM 9 Throttle plate 10 Throttle Position Sensor TPS 11 Air Pressure Sensor AP...

Page 19: ...ng the engine power fuel economy and emission con trols under all engine operating conditions by managing both the fuel injection duration and igni tion timing The Rotax Fuel Injection RFI is composed...

Page 20: ...fuel injection The ECU receives the signals from 5 sensors which indicate engine operating conditions at milli second intervals Throttle Position Sensor TPS Crankshaft Position Sensor CPS Air Tempera...

Page 21: ...jec tion system MPEM It is responsible of the following electrical func tions interpreting information distributing information start stop function timer vehicle hours Digitally Encoded Security Syste...

Page 22: ...tion Idle to wide open throttle Engine temperature Intake air temperature Battery voltage Start stop signal Air Pressure Sensor APS Water Temperature Sensor WTS Air Temperature Sensor ATS Fuel tank Fu...

Page 23: ...NOSIS 2 START VEHICLE By selecting DIAGNOSIS the following message INITIALIZING IN PROCESS will be displayed a few seconds then a new menu will appear on the screen Select READ FAULT and press ENTER 1...

Page 24: ...t circuit to ground 1C short circuit to battery Crankshaft Position Sensor CPS 02 1F 23 do not indicate 06 signal too large Crankshaft Position Sensor CPS 02 01 03 no signal provisional after ignition...

Page 25: ...ump The fuel pump operation can be checked as fol lows Install the safety lanyard cap on the switch The fuel pump should run for approximately 1 second If not check the 7 5 A fuse on the MPEM module R...

Page 26: ...he injectors and fuel rail have to be removed See REMOVAL in this sub section for the procedure Reinstall both injectors to the fuel rail Reconnect the wire connector of the injector Place each inject...

Page 27: ...sistance between the PURPLE BROWN wire position 3 and the BLACK BROWN wire posi tion 4 in the AMP plug connector no 4 Deduct the total resistance value of the wires The resistance should be between 1...

Page 28: ...the WHITE GREY wire between the AMP plug connector position 13 and the air temperature sensor connector ter minal 2 If there is an open circuit repair the defective wire or terminal If not proceed as...

Page 29: ...1 2 Terminal 2 3 Terminal 3 The resistance should be between 3 4 k and 8 2 k Check also the resistance between the terminals 2 and 3 of the air pressure sensor The resistance should be between 2 4 k a...

Page 30: ...ght to the high tension lead while turning the en gine with the starter Reversed high tension cables will not allow the RFI to run Unlike other Sea Doo models the spark plugs spark independently on ea...

Page 31: ...OXIMATELY 30 SECONDS The RPM signal GREY wire is short circuit to the ground Check wire condition If the wire test good either the tachometer or Info Center is de fective ENGINE CANNOT REACH MAXIMUM R...

Page 32: ...e stopper Selecting YES will instantly readjust the close throttle position adjustment to the new setting NOTE If the ECU is replaced the TPS must be readjusted Idle Speed Turn idle speed screw until...

Page 33: ...the WTS Loosen the WTS from the cylinder head At installation apply Loctite 518 on threads of the WTS CRANKSHAFT POSITION SENSOR CPS Disconnect the connector of the CPS Loosen Allen screw retaining th...

Page 34: ...fitting of the fuel rail with a shop towel Press on both tabs and disconnect the quick con nect fitting Disconnect the wire connectors of both fuel injec tors 1 Press retaining clip to unlock the con...

Page 35: ...SYSTEM Subsection 01 TABLE OF CONTENTS TABLE OF CONTENTS 0 IGNITION SYSTEM 05 02 1 GENERAL 05 02 1 INSPECTION 05 02 1 IGNITION TIMING 05 02 1 CHARGING SYSTEM 05 03 1 GENERAL 05 03 1 TESTING PROCEDURE...

Page 36: ...be 12 Vdc between the RED and WHITE BLUE wires or between the RED and WHITE GREEN wires while starting the engine If there is no voltage either the MPEM or the wir ing harness is defective Secondary W...

Page 37: ...tests Rectifier Regulator STATIC TEST CONTINUITY 1 Due to internal circuitry there is no static test available DYNAMIC TEST Voltage Test Proceed as follows Start engine Connect a multimeter to battery...

Page 38: ...ontinuity infinity be tween the stator insulated coils and ground If there is a reading the stator coils and or the wir ing from the coils is grounded and needs to be replaced or repaired DYNAMIC TEST...

Page 39: ...Combustion chamber volume 36 3 1 6 cc Cylinder head warpage maximum 0 05 mm 002 in Piston ring type and quantity 1 Semi trapez 1 Rectangular Ring end gap New 0 40 0 55 mm 016 022 in Wear limit 1 00 mm...

Page 40: ...MPEM 5 A ADDITIONAL INFORMATION FUEL SYSTEM GTX RFI 5666 5843 Fuel injection type Rotax Fuel Injection semi direct single throttle body 56 mm Idle speed in water 1400 50 RPM Throttle Position Sensor T...

Page 41: ...0 0 0 4 mm 000 016 in Wear limit 1 00 mm 040 in Impeller shaft end play new 0 12 0 54 mm 005 021 in Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch 12 25 stainless...

Page 42: ...ane foam ADDITIONAL INFORMATION STANDARD EQUIPMENT GTX RFI 5666 5843 Safety lanyard Standard Digitally Encoded Security System Standard Fuel tank reserve Not applicable Monitoring beeper Standard Spee...

Page 43: ...0 lbf in 5 Starter mounting screws 22 N m 16 lbf ft 1 Spark plugs 24 N m 17 lbf ft 5 JET PUMP Impeller 70 N m 52 lbf ft 2 Pump hull nuts 31 N m 23 lbf ft 1 Venturi pump housing screws 21 N m 16 lbf ft...

Page 44: ...GTX RFI MODEL 5666 5843...

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