1995 Sea-Doo SP, SPI, SPX, GTS, GTX & XP OEM Shop Manual (P/N 219 100 013, 219 300 130)

This 618-page PDF set brings together Bombardier's 1995 Sea-Doo shop manual and four factory parts catalogs. Shop-manual repair coverage applies to SP 5873, SPI 5875, SPX 5874, GTS 5815, GTX 5863, and XP 5857. The engine sections cover the Rotax 587 used in the SP, SPI, and GTS; the 657 X used in the SPX and GTX; and the 717 used in the XP. Bombardier states that the manual was primarily published for manufacturer-trained watercraft technicians already familiar with Sea-Doo service and maintenance procedures, so it is best suited to experienced technicians with the specified hand and special tools.

• Engine repair: Covers engine removal and installation, top-end and bottom-end disassembly, cleaning, inspection and assembly, crankshaft misalignment and deflection checks, rotary-valve inspection and timing, squish-area verification, and tuned-pipe repair.
• Fuel, oil, and cooling systems: Documents fuel-circuit and oil-system pressure testing, carburetor teardown and pump verification, oil-pump adjustment and operational checks, plus separate cooling layouts for each covered engine family.
• Electrical diagnosis: Provides magneto service, ignition-timing and ignition-system tests, Bombardier ignition tester procedures, charging-system checks, starter troubleshooting and overhaul, instrument inspection, and model-specific electrical diagrams.
• Propulsion and controls: Details aluminum and plastic jet-pump inspection, removal, disassembly, reassembly and pressure testing, along with drive-system repair, GTS/GTX reverse adjustment, SPX/XP variable trim work, and steering alignment.
• Maintenance and fault isolation: Includes the periodic inspection chart, salt- and foul-water flushing guidance, water-flooded engine recovery, storage preparation, and symptom charts for starting, misfire, overheating, backfire, power loss, cavitation, and propulsion noise.
• Hull and body work: Covers seat and storage-cover adjustment, bumper and sponson replacement, GTS/GTX baffle sealing, fiberglass and gelcoat repair, decal replacement, and Concept and Delta paint procedures.

Exact File Makeup and Coverage Limits

The 245-page shop manual is P/N 219 100 013. The balance consists of four illustrated parts catalogs: XP 5857, 90 pages, P/N 219 300 130; XP 800 5856, 92 pages, P/N 219 300 170; SP 5873 / SPX 5874 / SPI 5875, 102 pages, P/N 219 300 110; and HX 5880, 89 pages, P/N 219 300 120. Their assembly descriptions are presented in English and French.

XP 800 5856 and HX 5880 are parts-catalog coverage only; this file does not provide shop-manual repair procedures for those two models. Conversely, the shop manual covers GTS 5815 and GTX 5863 repair, but model-specific GTS/GTX parts catalogs are not included.

Factory Procedures, Tools, and Technical References

The shop manual is organized into 12 sections covering service tools, maintenance, troubleshooting, engine, cooling, fuel, lubrication, electrical, propulsion, steering, hull/body, and technical data. Technical data is separated into SP/SPI, SPX/XP, and GTS/GTX groups, with component torque tables, engine clearances and wear limits, rotary-valve and ignition settings, carburetor specifications, electrical test values, fluid capacities, and jet-pump inspection limits. A separate products section identifies the specified sealants, lubricants, threadlockers, and coatings by application.

The tooling pages identify required equipment by part number, including the degree wheel P/N 295 000 007, Bombardier ignition tester P/N 295 000 008, engine/jet-pump alignment tool P/N 295 000 089, carburetor pump gauge tester P/N 295 000 114, and impeller-housing remover P/N 295 000 113.

Representative visuals include the 587, 657 X, and 717 cooling-system schematics; aluminum and plastic jet-pump exploded views; rotary-valve timing illustrations; and separate SP, SPI, SPX, GTS, GTX, and XP wiring diagrams. The four parts catalogs add exploded assembly views with OEM part numbers and quantities for engine, electrical, fuel, drive, steering, trim, hull, and accessory assemblies.

Model-Specific Repair Cautions

The cooling section warns that its calibrated elbow fittings are engine-specific; interchanging fittings with a different restriction can cause severe engine damage. The care section also warns that turning the watercraft the wrong way while working on the hull or jet pump can allow residual water from the tuned pipe to enter the engine.

Battery connections, fuel vapors, a running engine, and the jet-pump area present serious hazards. Follow the manual's isolation, ventilation, tooling, and verification requirements before performing repair work.