2006 Sea-Doo 4-TEC Service & Repair Manual: GTX/RXP/RXT/GTI

Complete 4-TEC engine service documentation: fuel injection diagnostics, cylinder head/block rebuild, cooling system maintenance. Includes ECM/MPEM adjustment procedures and torque specifications.

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Document Details

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Document Number / Seller:
24370 / Christopher Johnson
File Size:
32.89 MB
File Type:
PDF
Language:
English
Pages:
428
Printable:
Yes
Category:
Personal Watercraft (PWC)
Last updated / verified
Sep 6, 2025

Models Covered & Key Technical Specifications

Sea-Doo GTX, GTI, RXP and RXT 4-TEC — 2006 Functional Technical Sourcebook | 4-TEC Series Section.

  • Factory Charge Quantity: Engine coolant capacity reaches 5.0 L (1.32 US gal) is specified as the closed-loop system requirement Benchmarks.
  • Certified Alignment Specs: For optimal fuel delivery, 290–310 kPa (42–45 PSI) defines the naturally-aspirated injection pressure Range.
  • Engineered Power Framework: 155 hp maximum engine output at 6500 RPM indicates peak crankshaft horsepower Sequences.
  • Primary Throughput Data: The supercharged intercooled fuel system requires 386–414 kPa (56–60 PSI) for operational baseline Baseline.
  • General Gross Dimensions: Engine block displacement measures 1503 cc (92 cu in) represents three-cylinder total capacity Requirements.
  • Integral Capacity Limits: Oil reservoir volume supports 8.5 L (2.25 US gal) operational fill level Threshold.

Professional Workshop Service Manual & Technical Specifications

Technical Configuration Training Manual: Personal Watercraft (PWC) Sea-Doo GTX 4-TEC (STD, SC, LTD, WAKE), RXP, RXT and GTI (STD, SE, Rental) - Official 4-TEC Service & Repair Manual (2006) Engineering-Archive

Operational-Framework: Sea-Doo GTX 4-TEC (STD, SC, LTD, WAKE), RXP, RXT, GTI (STD, SE, Rental) // Architecture-Focus: Multi-system propulsion and engine control / Fuel injection, electrical distribution, cooling topology // Engine-Type: ROTAX 1503 4-TEC naturally aspirated and supercharged intercooled configurations.

Assessment-Element Baseline Framework
Engine systems coverage Complete 4-TEC series specifications Chapters covering removal, installation, component servicing
Propulsion architecture Jet pump and variable trim documentation Drive system, reverse mechanism, impeller assembly procedures
Electronic management ECM and MPEM diagnostic reference Engine control module interactions, sensor inputs, fuel mapping

Documentation sections include the engine and propulsion systems, then examines cooling system topology, and covers electrical management protocols. The manual provides reference material for fuel system pressurization, includes guidance on ignition timing and spark plug specifications, and addresses maintenance procedures for storage and preseason operations. Comprehensive troubleshooting data accompanies sections on starting system faults, electrical distribution anomalies, steering alignment, and hull assembly operations.

Diagnostic Standard

The document encompasses detailed procedural sequences for engine disassembly and reassembly. Transmission service information covers reverse cable routing, shift lever housing installation, and pivot arm configurations. The manual catalogs specifications for timing chain tension, camshaft lobe dimensions, and crankshaft bearing clearance tolerance bands. Technical data includes cylinder bore taper measurement protocols, piston ring end gap verification, and crankshaft axial clearance documentation.

Engineered Methodology

The reference material outlines water pump impeller replacement, cooling system pressure cap testing, and thermostat operational range specifications. Procedures document the intercooler inspection sequence, exhaust system flushing protocols, and bleed valve positioning guidance. The manual provides instructions for supercharger clutch slipping moment verification, including bearing replacement and drive gear component assembly. Valve spring free length specifications, cylinder head warpage tolerance limits, and rocker arm bore diameter measurements are comprehensively cataloged.

Operational Topology

Electrical system documentation covers battery removal and charging circuit testing. The reference material includes ignition coil primary and secondary winding resistance parameters, spark plug gap settings, and magneto stator output verification methods. Sensor circuit continuity checks, MPEM connector pin identification, and ECM terminal mapping appear throughout diagnostic sections. The manual documents fuel injector electrical testing procedures, throttle position sensor voltage readings, and crankshaft position sensor signal validation approaches.

Operational Logic-Path

The propulsion system reference incorporates jet pump housing removal sequences, impeller wear ring clearance measurement, and sacrificial anode replacement guidance. Hull and body documentation addresses seat latch mechanisms, storage compartment cover shock absorber installation, and drain plug sealing procedures. The manual documents torque specifications for the fuel rail assembly, includes cooling hose clamp tightening values, and references bolt tension parameters for engine mounting brackets throughout multiple system sections.

The manual documents torque specifications for the fuel injector retaining fasteners to ensure proper mechanical engagement and system integrity.

FAQ

Check the **standard** torque specification for connecting rod screws? keyboard_arrow_down

45 N·m (33 lbf·ft) applied first, then finished with an additional 90° rotation using an angle torque wrench for proper clamping force on the crankshaft journals.

What does the **necessary** fuel pressure requirement measure? keyboard_arrow_down

290-310 kPa (42-45 PSI) for naturally aspirated and supercharged 4-TEC engines, or 386-414 kPa (56-60 PSI) for supercharged intercooled models when the safety lanyard is installed.

Reference the **recommended** oil pressure reading for engine protection? keyboard_arrow_down

228 kPa (33 PSI) minimum at idle when engine reaches 50°C (176°F) operating temperature to activate warning systems and protect internal components from inadequate lubrication.

What are the **calibrated** connecting rod big end clearance specifications? keyboard_arrow_down

0.09 mm (0.0035 in) service limit maximum between the connecting rod bore and crankshaft pin diameter to maintain proper bearing preload and engine reliability.

Specify the **applicable** spark plug gap setting for all 1503 4-TEC engines? keyboard_arrow_down

0.75 mm (0.030 in) gap using NGK DCPRSE spark plugs, torqued by hand plus 1/4 additional turn with proper socket to prevent fouling and ensure consistent ignition.

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This manual has been a game changer for my Sea-Doo maintenance. The diagrams are clear and easy to follow, making repairs much simpler. I also appreciated the quick email response when I had a question about downloading the manual. Highly recommend!