2003 SeaDoo XP DI Operator's Guide...

SAFETY WARNING

Disregarding any of the safety precautions and instructions contained in thisOperator’s Guide, the Safety Handbook, the Safety Videocassette and on theon-product warning labels could cause injury, including the possibility ofdeath. The operator has the responsibility to inform passenger(s) of safetyprecautions.

This Operator’s Guide, the Safety Handbook and Safety Videocassetteshould remain with the craft at the time of resale.

2003 PWC Electro Magnetic Compatibility (EMC) Compliance with 93/68 EC Directive.

The 2003 Sea-Doo Personal Watercraft do comply with the above men-tioned directive and with 89/336 EC directive in order to match the currentEuropean requirements on Personal Watercraft (PWC).

Knight’s Spray-Nine† is a trademark of Korkay System LtdGTX† is a trademark of Castrol Ltd. Used under license

The following trademarks are the property of Bombardier Inc. or its subsidiaries:

SEA-DOO®

BOMBARDIER-ROTAX®

BOMBARDIER LUBE®

BOMBARDIER Formula XP-S II Synthetic Injection OilSea-Doo LKTM

Rotax®

Printed in Canada (smo2003-004a.fm SH)®*Trademarks of Bombardier Inc. and/or its subsidiaries.©2002 Bombardier Inc. All rights reserved.

DECLARATION OF CONFORMITY

smo2003-004a.fm Page 0 Wednesday, January 22, 2003 1:09 PM

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NOTE

Dear 2003 XP DI watercraft owner. Use the information pertaining to the RXDI model in the 2003 Operator’s Guide (P/N 219 000 290) and then use thissupplement to complete the specific information that applies to your XP DImodel.


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TABLE OF CONTENTS

LOCATION OF THE IMPORTANT LABELS ................................... 3LOCATION OF CONTROLS, COMPONENTS AND INSTRUMENTS . 6FUNCTIONS OF CONTROLS, COMPONENTS ANDINSTRUMENTS ........................................................................... 8

15) Oil Injection Reservoir Cap................................................................ 816) Front Storage Compartment Cover ................................................... 826) Mooring Cleats .................................................................................. 937) Fuses ................................................................................................. 938) Battery ............................................................................................... 941) Storage Compartment/Engine Cover Latches ................................... 942) Rear Access Cover ............................................................................ 943) Automatic Bilge Pump....................................................................... 9

OPERATING INSTRUCTIONS...................................................... 10SPECIAL PROCEDURES.............................................................. 12

Towing the Watercraft in Water .............................................................. 12MAINTENANCE .......................................................................... 13

Lubrication ............................................................................................... 13Periodic Inspection Chart......................................................................... 13Fuses ....................................................................................................... 14

TRAILERING, STORAGE AND PRE-SEASON PREPARATION....... 16Storage .................................................................................................... 16

SPECIFICATIONS........................................................................ 21


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LOCATION OF THE IMPORTANT LABELS

XP DI Models

TYPICAL

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Label 1

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XP DI Model Only

The location of these labels differ onthe XP DI model.

Label 2

Label 3

Label 4

Label 5

Label 8

Label 9

Label 12

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LOCATION OF CONTROLS, COMPONENTS AND INSTRUMENTS

XP DI Model

TYPICAL

NOTE: Components not shown here are the same as on the RX DI models inthe 2003 Sea-Doo Operator’s Guide.

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14) Fuel Tank Cap15) Oil Injection Reservoir Cap16) Front Storage Compartment Cover18) Tool Kit19) Air Intake Opening23) Rear Grab Handle26) Mooring Cleats37) Fuses38) Battery41) Storage Compartment/Engine Cover Latches42) Rear Access Cover43) Automatic Bilge PumpNOTE: Some components shown in the 2003 Sea-Doo Operator’s Guide do notapply to this watercraft. Refer to the following list:7) Shift Lever8) Fuel Gauge/Low Oil Warning Light

10) Tachometer13) Fuel Tank Valve17) Front Storage Compartment Cover Latch20) Seat Strap21) Seat Latch22) Seat Extension Latch24) Rear Storage Basket30) Boarding Step35) Reverse Gate39) Side Vanes


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FUNCTIONS OF CONTROLS, COMPONENTS AND INSTRUMENTS

The following components have thesame operation as explained in the2003 Operator’s Guide, only their loca-tion differ. To know where they are lo-cated, refer to the LOCATION OFCONTROLS, COMPONENTS AND IN-STRUMENTS section in the previouspages.14) Fuel Tank Cap18) Tool Kit19) Air Intake Opening23) Rear Grab HandleThe following components are specificto the XP DI models. Refer to the fol-lowing updated texts and/or illustrations.

15) Oil Injection Reservoir Cap

Open engine cover and remove storagetray.

TYPICAL1. Oil injection reservoir cap

To add injection oil in the reservoir, un-screw the cap counterclockwise. Do not overfill. Make sure oil leveldoes not exceed the level shown onthe following drawing. Otherwise, si-phon out the extra oil. Do not operatethe engine when oil level exceeds therecommendation.

Reinstall cap and fully tighten it.

16) Front Storage Compartment Cover

It gives access to the front storage com-partment. Always relatch cover afterclosing.The tray is provided with separatecompartments.

1. Fire extinguisher (sold separately)2. Retaining strap

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Do not overfill. Never exceed theMAX. oil level line. Reinstall capand fully tighten. Oil is inflamma-ble. Always wipe off any oil spill-age from the bilge.

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26) Mooring CleatsAll Models

These cleats can be temporarily used fordocking, while refueling for example.CAUTION: Never use mooring cleatsto pull or lift the watercraft.

1. Mooring cleats

37) FusesFuses are located in engine compart-ment. Refer to MAINTENANCE formore details.

38) BatteryBattery is located in bilge under seat.Refer to SPECIAL PROCEDURES.

41) Storage Compartment/Engine Cover Latches

Pull both latch levers upward in order toopen the storage compartment/enginecover. Always relatch cover on bothsides.NOTE: Verify periodically the lock pinstightness. Tighten if needed and makesure storage compartment/engine cov-er latches properly.

42) Rear Access CoverIt gives access to the battery, drivesystem, suspension, exhaust systemand bailer pick-ups. Always relatchcover.

43) Automatic Bilge PumpBilge pump evacuates water from thebilge.When safety lanyard cap is installed onits post, bilge pump automaticallyturns on. It will remain on until all wateris evacuated, if any, then it will shutdown automatically.When engine is running, bilge pumpwill automatically start periodically toevacuate water.

� WARNING

Ensure to properly secure extin-guisher with the supplied retainingstraps.

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OPERATING INSTRUCTIONS

Variable Trim SystemThe variable trim system (VTS) chang-es the angle of the jet pump nozzle toprovide the operator with a fast, effec-tive system to compensate for load,thrust, riding position and water condi-tions. Correctly adjusted, it can im-prove handling, reduce porpoising, andposition the watercraft at its best ridingangle to attain maximum performance.When first using the watercraft, theoperator should become familiar withthe use of the variable trim system(VTS) at varying speeds and water con-ditions. A mid-range trim is generallyused when cruising. Experience alonewill dictate the best trim for the condi-tions. During the watercraft break-inperiod, when lower speeds are recom-mended, it is an excellent opportunityto gain familiarity of trim adjustmentand its effects.When the nozzle is positioned in an up-ward angle, the water thrust directs thebow of the watercraft upward. This po-sition is used to optimize high speed.

TYPICAL1. Push on arrow pointing upward on VTS

button2. Bow up3. Nozzle up

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TYPICAL1. Push on arrow pointing downward on VTS

button2. Bow down3. Nozzle down

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SPECIAL PROCEDURES

Towing the Watercraft in WaterIt is the same as explained in the 2003Operator’s Guide. The hose locationand routing differs. Refer to the follow-ing updated text and illustration.Remove rear access cover.Install pincher as shown.

1. Hose pincher on water supply hose

Properly relatch cover.CAUTION: When finished towing thewatercraft, hose pincher should beremoved before operating it. Failureto do so will result in damage to theengine.

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MAINTENANCE

Lubrication

Seal CarrierUsing a grease gun, carefully lubricateseal carrier of mid bearing until greaseis just coming out of seal.

1. Grease seal carrier of mid bearing

Periodic Inspection ChartThe following is to be added for the XP DI models.

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DESCRIPTION

I: Inspect, verify, clean, adjust, lubricate, replace if necessary

C: CleanL: LubricateR: Replace

FREQUENCY

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FusesRefer to this updated text and illustra-tions.Fuses can be found at 2 locations; onthe MPEM and in the electrical box.

MPEMTo access fuses on the MPEM, openfront storage compartment cover andremove storage tray. Locate MPEM on the left side of wa-tercraft.

1. MPEM

Fuses are identified, look above andbesides the fuse holder.

FUSE IDENTIFICATION1. Fuse identification2. Fuse description

Fuse identification: The fuses (F) areidentified from 1 to 6.Fuse description: The fuses are de-scribed with abbreviation as follows:FP: Fuel pumpACC: Accessories (information center)REG: Regulator (charging system)VTS: Variable Trim System BAT: BatteryINJ: Injection systemThe fuse description is followed by theampere rating (A).Reinstall storage tray and properlyrelatch storage compartment cover.

Electrical BoxTo access fuses in the electrical box,open front storage compartment cover. Locate electrical box on the right sideof watercraft.

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1. Electrical box

Unclip and remove cover of the electri-cal box to expose the holder of themain fuse.

TYPICAL1. Fuse holder

Electric bilge pump fuse is located at thebottom of the electrical box.

1. Electric bilge pump fuse

Properly reinstall removed components.Properly relatch storage compartmentcover.

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TRAILERING, STORAGEAND PRE-SEASON PREPARATION

The information pertaining to traile-ring, storage and pre-season prepara-tion is similar to the one explained inthe 2003 Operator’s Guide, except forthe following updated text and illustra-tions.

StorageEngine DrainingRemove rear access panel.Check engine drain hose (the lowestone connected to the crankcase cool-ing outlet). Make sure there is no sandor other particles in it and that it is notobstructed so that water can exit theengine. Clean hose and fitting as nec-essary.CAUTION: Water in engine drain hoseshould be free to flow out, otherwisewater could be trapped in engine.Should water freeze in engine, severedamage will occur. Check engine drainhose for obstructions.Disconnect the quick connect fitting.Press both tabs and pull fitting.

1. Disconnect engine drain hose (crankcase cooling outlet)

2. Air compressor drain line

Lower hose as necessary so that drain-ing can take place.Reconnect fitting when done.Also ensure air compressor drain lineis not obstructed. Clean as necessary.See illustration above.

Antifreezing ProtectionNOTE: This procedure requires approx-imately 2.8 L (3 U.S. qt.) of antifreeze.In cool regions where freezing pointmay be encountered, cooling systemshould be filled with an equal part ofwater and antifreeze solution.

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CAUTION: Antifreeze mix must befed in cooling system. Otherwise re-maining water will freeze. This opera-tion requires a good technical knowl-edge of the cooling system path. Ifantifreezing is not performed ade-quately engine/exhaust system mayfreeze and cause severe engine dam-age. We strongly recommend this op-eration be performed by an autho-rized SEA-DOO dealer.CAUTION: Always use ethylene gly-col antifreeze containing corrosioninhibitors specifically recommendedfor aluminum engines.NOTE: When available, it is recom-mended to use biodegradable anti-freeze compatible with internal com-bustion aluminum engines. This willcontribute to protect the environment.NOTE: The engine will not have to runduring this operation but should havebeen ran before, to exhaust as muchwater as possible, from cooling sys-tem components.

Hose Pinchers InstallationSome hoses have to be plugged toprevent draining, before filling coolingsystem jackets with the antifreeze.Install hose pinchers at the followinglocation:

1. Water inlet hose2. Engine cylinder drain hose (coming from

underneath engine)

1. Water outlet hose underneath tuned pipe

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Hose DisconnectionDisconnect the bottom hose at the wa-ter regulator valve on muffler.

1. Disconnect the bottom hose from water regulator valve

Temporarily install a hose of approxi-mately 1 m (3 ft) in length with a12.7 mm (1/2 in) internal diameter overthe previously disconnected hose.

AntifreezeInsert a funnel into the temporaryhose. Ensure to hold the funnel approximate-ly 1 m (3 ft) above the deck when pour-ing the antifreeze to create enoughpressure so that it flows properly.

A. 1 m (3 ft) to ease antifreeze flow

Pour antifreeze mix in engine until thecolored solution appears at coolingsystem bleed outlet.At this point, install a hose pincher onbleed outlet hose.

1. Bleed outlet hose

Continue to pour until antifreeze ap-pears at the engine drain hose (crank-case cooling outlet). Then, install ahose pincher on this hose.

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1. Engine drain hose (crankcase cooling outlet)

Continue to pour until antifreeze flowsin air compressor water outlet hose.

1. Air compressor water outlet hose

The pouring operation is over.Remove pinchers in this order to allowproper flow of antifreeze.

NOTE: Most of the antifreeze will drainout when removing the hose pinchers.Use a container to recover it. DISPOSEANTIFREEZE AS PER YOUR LOCALLAWS AND REGULATIONS.1. Bleed outlet hose.2. Engine drain hose (crankcase cool-

ing cover outlet).3. Engine cylinder drain hose.4. Water outlet hose.5. Water inlet hose.Install a temporary hose on the openfitting of the water regulator valve.Pour approximately 200 mL (7 oz) ofantifreeze in the temporary hose to al-low antifreeze flowing through the wa-ter regulator valve and into muffler toprotect it. Remove temporary hoses and recon-nect the factory hose to water regula-tor valve.NOTE: Although antifreeze will mainlydrain out, the antifreeze has mixed withthe water that was possibly trapped inthe water jackets and thus preventingfreezing problems.At pre-season preparation, drain theremaining antifreeze from cooling sys-tem prior to using the watercraft. En-sure no hose pincher was forgotten atstorage.The following steps should be per-formed to provide the watercraft en-hanced protection.

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Clean the bilge with hot water and de-tergent or with bilge cleaner. Rinsethoroughly. Lift front end of watercraftto completely drain bilge. If any repairsare needed to body or to the hull con-tact your authorized SEA-DOO dealer.For paint touch up to mechanical partsuse Bombardier spray paint.

Final StepsRefer to this updated text.Apply a good quality marine wax to thebody.The seat should be partially leftopened and the rear access cover andstorage tray should be removed duringstorage. This will avoid engine com-partment condensation and possiblecorrosion.If the watercraft is to be stored out-side, cover it with an opaque tarpaulinto prevent sun rays and grime from af-fecting the plastic components, water-craft finish as well as preventing dustaccumulation.CAUTION: The watercraft shouldnever be left in water for storage.Never leave the watercraft stored indirect sunlight.


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SPECIFICATIONS

ENGINEXP DI

(6130/6131)

Engine type Rotax 947, 2-strokeInduction type Reed valveExhaust system Water cooled/water injected with regulatorExhaust valve Rotax Adjustable Variable Exhaust (RAVE)

Lubrication Type Oil injection

Oil type BOMBARDIER Formula XP-S II synthetic injection oil

Number of cylinders 2Displacement 951.2 cm3 (58 in3)Rev limiter setting 7300 ± 50 RPMCOOLING

Type Open circuit.Direct flow from propulsion unit

ELECTRICAL

Magneto generator output 270 W @ 6000 RPMIgnition system type Digital inductive

Spark plugMake and type NGK, ZFR4FGap 1.1 mm (.043 in)

Starting system Electric starter with reduction gearBattery 12 V, 19 A•h

Fuse

Battery 25 AMain 30 ACharging system (REG) 25 A

VTS system 7.5 AInformation center (ACC) 2 A

Injection system (INJ) 15 A

Fuel pump (FP) 15 ABilge pump 3 A

FUEL SYSTEM

Fuel type Regular unleaded gasoline with 87 octane minimum (R+M)/2

Fuel injection Orbital direct fuel injection, twin throttle body(46 mm (1.81 in))


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➀ Refer to load limit.BOMBARDIER INC. reserves the right to make changes in design and specifica-tions and/or to make additions to, or improvements in its products without im-posing any obligation upon itself to install them on its products previously manu-factured.

PROPULSIONXP DI

(6130/6131)

Propulsion system Bombardier Formula pumpJet pump type Axial flow, single stageTransmission Direct drive/split front and rearReverse system No

Jet pump oil type SEA-DOO synthetic polyolester oil SAE 75W90 GL5

Pivoting angle of direction (nozzle) ~ 20°Minimum required water level for jet pump 90 cm (3 ft)DIMENSIONS

Number of passengers ➀ 2Overall length 272 cm (107 in)Overall width 112 cm (44.1 in)Overall height 104 cm (40.6 in)Weight 274 kg (605 lb)Load limit (passengers + luggage) 181 kg (400 lb)CAPACITIES

Fuel tank 51 L (13.5 U.S. gal)Fuel tank reserve (from low level signal 9.8 L (2.6 U.S. gal)Oil injection tank 4 L (1.1 U.S. gal)

Impeller shaft reservoirCapacity 100 mL (3.4 U.S. oz)Oil level Up to plug


2003 SeaDoo XP DI Operator's Guide...

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