2004 SeaDoo GTI, LE, RFI, 4-TEC, Supercharged , Wakeboard, International, RXP shop manual

Product Information

Table of Contents

SAFETY NOTICE

INTRODUCTION

1. Hull Identification Number (H.I.N.)
2. Engine Identification Number (E.I.N.)
3. Arrangement of This Manual
4. Get Acquainted
5. Illustrations and Procedures
6. Shop/Dealer Information
7. Engine Emissions Information
8. Technician Information
9. Shop/Dealer Operations
10. Breaking-In Procedure
11. Special Tools
12. Standard Torque Specifications
13. Loctite Application Chart
14. Coatings and Sealants
15. Calibrations
16. Service Components
17. Tightening Torques

01 SERVICE TOOLS AND PRODUCTS

1. Mandatory Service Tools
   • Mandatory Tools List
   • Basic Procedures
2. Optional Service Tools
   • Optional Tools List
   • Special Tools
3. Technical Systems
   • Diagnostic Tools
   • Electronic Systems
4. Service Products
   • Recommended Products

02 MAINTENANCE

1. Maintenance
   • Recommended Maintenance Schedule
   • Periodic Maintenance Chart
2. Flushing and Lubrication
   • Flushing Procedures
   • Lubrication Points
   • Recommended Lubricants
3. Water-Flooded Engine
   • Emergency Treatment
   • Cleaning Procedures
4. Storage
   • Storage Procedures
   • Engine Oil and Filter
   • Fuel System
   • Battery Maintenance
   • Coolant System
   • Hull Cleaning
   • Drive System
   • General Lubrication
   • Additional Recommended Protection
   • Decals

03 TROUBLESHOOTING

1. Troubleshooting Chart
   • Engine Will Not Start
   • Engine Starts But Does Not Idle
   • Engine Misfires, Runs Irregularly
   • Engine Continuously Backfires
   • Engine Lacks Acceleration or Power
   • Engine Overheats
   • Engine Knocks or Pings
   • Engine Continuously Overheats
   • Engine Does Not Reach Maximum RPM
   • Engine Continuously Idles
   • Engine Does Not Maintain Idle Speed
   • Engine Vibrates Excessively
   • Oil Pressure Problems
   • Fuel Delivery Problems
   • Electrical System Issues
   • Cooling System Problems
   • Drive System Problems
   • Diagnostics Procedure for the TEC Series
   • Jet Pump/Propulsion System Issues

04 ENGINE (2-STROKE)

1. Leak Test
   • Test Procedure
   • Leakage Diagnosis
2. Removal and Installation
   • Engine Removal
   • Engine Installation
3. Lubrication System
   • Lubrication Points
   • Lubrication Procedures
4. Top End
   • Cylinder Head
   • Cylinder Block
   • Piston and Rings
   • Compression Measurement
5. Bottom End
   • Crankshaft
   • Connecting Rods
   • Bearings
   • Seals

05 ENGINE (4-TEC)

1. Engine Management System (EMS)
   • EMS Overview
   • Diagnostics
2. Fuel System
   • Fuel Pump
   • Fuel Injector
3. Cooling System
   • Radiator
   • Thermostat
4. Lubrication System
   • Oil Pump
   • Oil Filter
5. Turbocharging System (if applicable)
   • Turbocharger
   • Intercooler

06 ELECTRICAL SYSTEM

1. Battery and Charging System
   • Battery Maintenance
   • Charging Procedures
2. Ignition System
   • Spark Plugs
   • Ignition Coil
3. Starting System
   • Starter Motor
   • Relay
4. Lighting and Accessories
   • Bulb Replacement
   • Accessory Installation
5. Wiring Diagrams
   • Complete Electrical Schematic
   • Component Locations

07 JET PUMP/PROPULSION SYSTEM

1. Jet Pump
   • Impeller Inspection
   • Impeller Replacement
2. Drive System
   • Drive Shaft
   • Bearings
3. Steering System
   • Steering Cable
   • Handlebar Adjustment

APPENDIX

1. Service Data
2. Conversion Tables
3. Special Tools
4. Index

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