1988-1996 Clymer Sea-Doo Water Vehicles Service Manual

Description

This Sea-Doo Water Vehicles 1988 1989 1990 1991 1992 1993 1994 1995 1996 Shop Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1988-1996 Sea-Doo Standard, GT, GTS, GTX HX, SP, SPi, SPX, and XP water vehicles. Includes quick reference data, general information, troubleshooting, lubrication, maintenance, tune-up procedures, engine, drive system, fuel system, electrical system, oil injection system, cooling system, steering, storage and complete wiring diagrams. Features 592 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE/ GENERAL INFORMATION

Manual organization/ Notes, cautions and warnings/ Safety first/ Service hints/ Engine operation/ Model number/ Engine identification number/ Hull identification number/ Parts replacement/ Cleaning a submerged water vehicle/ Torque specifications/ Fasteners/ Lubricants/ RTV gasket sealant/ Threadlock/ Basic hand tools/ Precision measuring tools/ Special tools/ Mechanic’s tips/ Ball bearing replacement/ Oil seals

CHAPTER TWO/ TROUBLESHOOTING

Operating requirements/ Testing electrical components/ Emergency troubleshooting (engine turns over but will not start) / Engine starting/ Engine performance/ Electric box/ Starting system/ Charging system/ Ignition system/ Variable trim system/ Fuel system/ Engine/ Two-stroke pressure testing/ Steering/ Jet pump

CHAPTER THREE/ LUBRICATION, MAINTENANCE AND TUNE-UP

Operational checklist/ Break-in procedure/ 10-hour inspection/ Lubrication/ Periodic maintenance/ General inspection and maintenance/ Engine tune-up

CHAPTER FOUR/ ENGINE

Engine number identification/ Engine rotation/ Engine lubrication/ Service precautions/ Servicing engine in hull/ Special tools/ Engine removal/ Engine support and rubber mounts/ Engine installation/ Jet pump/engine alignment/ Exhaust pipe and manifold/ Engine top end/ Cylinders/ Rotax automatic variable exhaust (type 787 engines) / Piston, piston pin and piston rings/ Crankcase, crankshaft and rotary valve/ Rotary valve and shaft/ PTO flywheel

CHAPTER FIVE/ DRIVE SYSTEM

Service precautions/ Jet pump/ Seal carrier (1988-1989) / Seal carrier (1990-1994) / Seal assembly (1995-on) / Support bearing (1995-on HX models) / Variable trim system/ Reverse system

CHAPTER SIX/ FUEL SYSTEM

Fuel system identification/ Flame arrestor and air silencer/ Carburetor (1988-1990) / Carburetor (1991-on) / Carburetor pressure testing/ Remove fuel pump (1988-1990) / Fuel tank/ Fuel valve/ Fuel sensor/ Fuel system pressurization

CHAPTER SEVEN/ ELECTRICAL SYSTEM

Battery/ Charging system/ Flywheel and stator plate (587, 657 and 717 engine types) / Flywheel and stator plate (type 787 engine) / Ignition housing (1988-1991) / Ignition housing (type 587, 6587 and 717 engines 1992-on) / Engine front housing (type 787 engine) / Electric box (1988-1991) / Electrical box (type 587, 657 and 717 engines 1992-on) / Electrical boxes (type 787 engines) / Switches/ Fuel level sensor (1992-on) / LCD fuel gauge (1995-1996) / Oil level sensor/ Fuse/ Wiring diagrams

CHAPTER EIGHT/ OIL INJECTION SYSTEM

System components/ Oil pump service/ Component replacement/ Oil pump

CHAPTER NINE/ COOLING SYSTEM

Cooling system identification/ Hose and hose fitting replacement/ Factory hose clamps/ Engine drain hose/ Cooling system flushing/ Water flow regulator (type 787 engines)

CHAPTER TEN/ STEERING SYSTEMS

Handlebar cover/ Handlebar grips/ Steering stem (1988-1990) / Steering stem (all 1991-1993 except 1993 XP, 1994-1995 GTS and GTX, 1996 GTS and GTI) / Steering stem (1993 XP, 1994-on SP, SPI, SPX and XP) / Steering stem (1995-1996 HX) / Steering stem (1996 GSX and GTX) / Steering cable replacement/ Handlebar replacement

CHAPTER ELEVEN/ OFF-SEASON STORAGE

INDEX

WIRING DIAGRAMS