1996 Sea-Doo GTS, GTI & GTX Shop Manual Set, Parts Catalogs & Racing Handbooks (P/N 219 100 031 / 219 100 034)
2,973 Pages • ZIP Download: 61 Printable PDFs • 171.89 MB
Bombardier Models Covered & Key Technical Specifications
Models & Model Codes: GTS (5817), GTI (5865, 5866, 5867), GTX (5640)
Sub-models / Variants: GTS 5817 – Rotax 587; GTI 5865, 5866 and 5867 – Rotax 717; GTX 5640 – Rotax 787
Model Year: 1996
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Engine type: Water-cooled, two-stroke Rotax twin-cylinder engines with rotary-valve induction; 787 engine with RAVE exhaust valves
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Carburetor types: GTS 5817 – single Mikuni; GTI 5865/5866 – twin Mikuni; GTI 5867 – single Morgenroth; GTX 5640 – twin Mikuni
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Drive system: Direct-drive, single-stage axial-flow jet pump with reverse
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Fuel system: Carbureted fuel delivery with fuel tank, filter and selector valve; separate variable-rate oil injection
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Service coverage: GTI 5865/5866 are covered by the main shop manual; GTI 5867 has parts-catalog coverage. GTX 5640 service uses the main shop manual together with the included GSX/GTX supplement.
Bombardier Manual Features & Selected Content Preview
| Publication | Pages |
|---|---|
| 1996 Shop Manual — SP, SPI, SPX, XP, HX, GTS 5817 and GTI 5865/5866; P/N 219 100 031 | 315 |
| 1996 GSX 5620 / GTX 5640 Shop Manual Supplement; P/N 219 100 034 | 39 |
| 1997 Shop Manual — SP, SPX, GS, GSI, GSX, HX, XP, GTS 5818, GTI 5641 and GTX 5642; P/N 219 100 048 | 371 |
| 1996 GTS 5817 / GTI 5865, 5866, 5867 Parts Catalog; P/N 219 300 210 (02/96) | 95 |
| 1996 GTX 5640 Parts Catalog; P/N 219 300 230 (03/96) | 77 |
| 1996 GSX 5620 Parts Catalog; P/N 219 300 220 | 77 |
| 1996 HX 5881 Parts Catalog; P/N 219 300 190 | 75 |
| 1996 SP 5876 / SPI 5878 / SPX 5877 Parts Catalog; P/N 219 300 180 | 89 |
| 1996 XP 5858/5859 Parts Catalog; P/N 219 300 200 | 76 |
| 1997 SP 5879 / SPX 5661/5834 Parts Catalog; P/N 219 300 290 | 134 |
| 1997 HX 5882 Parts Catalog; P/N 219 300 300 | 99 |
| 1997 GS 5621 / GSI 5622 Parts Catalog; P/N 219 300 310 | 101 |
| 1997 XP 5662 Parts Catalog; P/N 219 300 330 | 103 |
| 1997 GTS 5818 / GTI 5641 Parts Catalog; P/N 219 300 340 | 134 |
| 1997 GSX 5624 Parts Catalog; P/N 219 300 370 | 89 |
| 1997 GTX 5642 Parts Catalog; P/N 219 300 390 | 108 |
| 1996 Racing Handbook; P/N 219 000 048 | 168 |
| 1997 Racing Handbook; P/N 219 000 060 | 123 |
| 1988–1996 Specification Booklet; P/N 219 100 039 | 184 |
| 1988–1997 Specification Booklet; P/N 219 100 049 | 107 |
| 1997 Operator’s Guide — SP, SPX, HX, GTS, GS, GSI, GSX, XP, GTI and GTX; P/N 219 000 059 | 105 |
| 1997 XP 5662 Operator’s Guide Supplement; P/N 219 000 075 | 7 |
| MPEM Programmer Guide; P/N 219 700 090 | 23 |
| Tool Booklet; P/N 219 200 106 | 21 |
| Mandatory Tool Kit and optional service tools — SSI-9601 | 16 |
| Engine Leak Test Kit instructions — SSI-9602 | 9 |
| Speedometer Gauge Kit instructions — SSI-9603 | 16 |
| Bilge Pump Kit instructions — SSI-9604 | 10 |
| Handlebar grip installation instructions — SSI-9605 | 1 |
| HX DESS Kit instructions — SSI-9607 | 5 |
| DESS Kit instructions — SSI-9608 | 4 |
| Rear Grab Handle Kit instructions — SSI-9609 | 3 |
| Mirror Kit instructions — SSI-9610 | 3 |
| Handlebar grip installation instructions — SSI-9611 | 1 |
| Optional Seat instructions — SSI-9612 | 1 |
| Stabilizer Plate Kit instructions — SSI-9613 | 3 |
| Choke Knob Kit instructions — SSI-9614 | 2 |
| Fuel Baffle Float Kit instructions — SSI-9615 | 4 |
| Speedometer Kit instructions — SSI-9616 | 4 |
| Programmer Updating Kit instructions — SSI-9617 | 3 |
| Mirror Kit instructions, Revision 1 — SSI-9618 | 3 |
| Anti-Rattle Device instructions — SSI-9619 | 4 |
| Speedometer Gauge Kit instructions — SSI-9702 | 8 |
| SP Fuel/Oil Gauge instructions — SSI-9703 | 7 |
| LCD Gauge Kit instructions — SSI-9704 | 7 |
| Speedometer Kit instructions — SSI-9705 | 6 |
| Manual VTS Kit instructions — SSI-9706 | 5 |
| Bilge Pump Kit instructions — SSI-9708 | 12 |
| Speedometer/Temperature Gauge Kit instructions — SSI-9709 | 6 |
| Mirror Kit instructions — SSI-9711 | 4 |
| Tachometer Kit instructions — SSI-9713 | 16 |
| LCD Gauge Kit instructions — SSI-9714 | 9 |
| Bilge Pump Kit instructions — SSI-9715 | 18 |
| Speedometer Kit instructions — SSI-9716 | 9 |
| XP Tachometer Kit instructions — SSI-9719 | 5 |
| Speedometer Kit instructions, update — SSI-9722 | 6 |
| HX Boarding Platform instructions — SSI-9723 | 4 |
| Steering Cable Kit instructions — SSI-9724 | 5 |
| 1996 accessory and kit index | 10 |
| 1997 accessory and kit index | 10 |
| Archive navigation menus | 14 |
The GSX/GTX supplement supplies model-specific differences and directs you to the main 1996 shop manual for systems it does not repeat. The racing handbooks add competition setup and operating theory alongside the model-specific service information.
Coverage limits: GTI 5867 has parts-catalog coverage; the 1996 main shop manual identifies GTI 5865/5866 as its service applications. The main PDF omits its listed Wiring Diagrams chapter, so 1996 GTS/GTI wiring diagrams are not included.
PDF Search, Bookmarks and Wiring Detail
Search and diagram detail: Service text and parts lists are searchable, while some covers and wiring sheets are not. Embedded bookmarks provide chapter or contents navigation; some legacy links target French files outside this ZIP. Small labels in the checked GSX/GTX and 1997 GTS/GTX wiring diagrams are readable when enlarged.
The ZIP contains 61 printable PDFs totaling 2,973 pages, including document covers, blank pages, supplements and 34 pages of archive menus and accessory indexes. Shop manuals are in English; parts catalogs and specification booklets also include French text.
Rotax Engine, Jet Pump and Electrical Work
The following selected topics highlight the repair coverage. Other sections include variable trim system checks and HX suspension service.
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Engine repair: Step-by-step removal and installation, top- and bottom-end inspection, crankshaft checks, rotary-valve timing and 787 RAVE service.
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Fuel and oil injection: Mikuni carburetor overhaul, twin-carburetor synchronization, fuel-circuit pressure testing, and oil-pump adjustment and bleeding.
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Cooling and exhaust: Cooling-circuit illustrations, tuned-pipe and muffler service, water-flow regulator inspection and engine-flushing procedures.
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Electrical diagnosis: Ignition, charging and starting-system tests, instrument checks, DESS troubleshooting and model-specific wiring diagrams.
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Jet pump and steering: Pump disassembly, impeller and wear-ring inspection, pump pressurization, driveline alignment, reverse-system service and steering adjustment.
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Maintenance and hull repair: Periodic inspection charts, water-flooded engine procedures, storage preparation, hull/body adjustment, fiberglass repair and painting information.
The shop manuals were written for manufacturer-trained watercraft technicians already familiar with Sea-Doo service and maintenance procedures and equipped with the specified service tools.
Engine Inspection and Parts Identification
Exploded views identify the crankcase, crankshaft, piston sets and hull components by illustration reference and OEM part number. Engine inspection material includes cylinder taper and out-of-round checks, piston clearance and crankshaft deflection limits.
GTI carburetor differences: The parts catalog separates the twin-Mikuni 5865/5866 configurations from the single-Morgenroth 5867. That distinction helps you match carburetor and fuel-system parts before ordering.
The 1997 shop manual separates engine leakage testing into cooling-system, top- and bottom-end, and rotary-valve-shaft checks. Its diagnostic sequence helps distinguish external leaks from internal leakage before engine disassembly.
Fuel, Cooling and Lubrication
Cooling-circuit illustrations show the water routing associated with the different engine and exhaust layouts. The lubrication chapter covers oil-injection pump testing and synchronization; it warns that delayed pump opening can cause serious engine damage.
Follow factory torque specifications and keep fuel-system work in a well-ventilated area away from ignition sources.
Electrical Diagnosis and Wiring Coverage
Battery installation, electrical-box components and harness layouts accompany electrical test specifications. The separate MPEM Programmer Guide covers key registration and basic and advanced diagnostic modes; programming functions require the appropriate programmer.
Model-specific diagrams: The supplement includes GSX 5620 and GTX 5640 wiring diagrams spread across adjacent pages. The 1997 volume provides separate diagrams for its own model codes; those diagrams should not be substituted for 1996 GTS/GTI wiring.
Jet Pump and Hull Repairs
Jet-pump repair material includes shaft and bearing inspection, seal installation and leak testing. The assembly cautions explain how a misplaced thrust bearing can become wedged in the shaft groove.
Hull repair sections address composite damage, fittings and surface refinishing. Steering and reverse sections provide the associated disassembly, installation and adjustment information.
Racing Setup and Factory References
The racing handbooks add Cylinder Porting Maps, RAVE operating explanations and propulsion-system analysis. The Engine Leakage Diagnostic Flow Chart appears in both the 1997 shop manual and the 1997 racing handbook.
Competition preparation is covered separately from stock repair, with racing modifications directed to skilled watercraft racing mechanics. Factory reference tables provide torque specifications, wear limits, clearances, electrical test values and fluid capacities.
Selected Carburetor Tests and Drive-Shaft Limits
The 1996 Mikuni carburetor section specifies 28 kPa (4 psi) for the pump-diaphragm leak test and 69 kPa (10 psi) for a 30-second needle-valve leak test.
For GTS 5817 and GTI 5865/5866, the propulsion data list a maximum drive-shaft deflection of 0.5 mm (.020 in), together with shaft-play and impeller wear specifications.
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