1992 Bombardier Sea-Doo SP5805 / XP5851 / GTS 5812 / GTX 5860 Watercraft Shop Manual (P/N 219-100-006)

This 1992 Bombardier Sea-Doo shop manual, P/N 219-100-006, covers SP 5805, XP 5851, GTS 5812, and GTX 5860 watercraft. Its 13 sections address the watercraft as a whole, including the Rotax 587 engine.

PDF Search, Navigation and Wiring Detail

Text search and diagram detail: PDF text search and embedded bookmarks are not available. The printed contents and index provide section references. Small wiring labels are legible when enlarged.

One printable English PDF contains 286 pages, including the original cover and preliminary material, eight index pages, and 28 blank pages.

Engine, Jet Pump and Watercraft Service

These selected topics show the manual’s repair and diagnostic coverage rather than its complete contents. Further examples include decal installation and model-specific paint references.

• Engine repair: Step-by-step removal and installation, top- and bottom-end service, rotary valve timing, and PTO flywheel and magneto work.

• Fuel and oil systems: Carburetor overhaul and synchronization, fuel-pump and leak tests, plus oil-injection pump repair, bleeding, adjustment, and bench testing.

• Cooling and exhaust: Cooling-circuit diagrams, flushing procedures, hose checks, overheat checks, and tuned-pipe repair.

• Electrical diagnosis: Wiring diagrams, ignition timing, starter overhaul, charging tests, battery service, instrument checks, and spark-plug analysis.

• Jet-pump service: Pump disassembly and reassembly, impeller and wear-ring inspection, drive-shaft and seal-carrier service, alignment, and pressure testing.

• Steering, reverse and trim: Steering alignment, reverse-gate adjustment, and mechanical Variable Trim System service.

• Hull care and storage: Fiberglass and gelcoat repair, refinishing, and storage preparation, supported by periodic inspection and symptom-based troubleshooting charts.

Written primarily for watercraft mechanics already familiar with Bombardier service procedures, this manual assumes access to the specified hand tools and special service tools.

Rotax Engine Inspection and Reassembly

The engine section follows service from water-flooded engine recovery through removal, alignment, teardown, inspection, and reassembly. Top-end and flywheel work can be performed with the engine installed; bottom-end and rotary-valve-shaft repairs require engine removal.

Cylinder and piston inspection includes ring-groove clearance and end-gap checks. Bottom-end pages cover crankshaft alignment and deflection, connecting-rod condition, bearing placement, and crankcase assembly. Rotary-valve clearance has dedicated measuring methods and timing illustrations.

Factory torque sequences, wear limits, sealant references, and tool applications support reassembly. Mechanics can use the inspection methods to assess parts for reuse, while the installation instructions explain how support shims affect engine-to-jet-pump alignment.

Carburetion, Oil Injection and Cooling

Single and twin carburetors: SP and GTS use a single carburetor; XP and GTX use twin carburetors. The twin-carburetor instructions distinguish MAG and PTO positions and explain synchronization. Fuel-pump diaphragm tests and needle-valve checks extend the coverage beyond mixture adjustment.

Oil-system pages cover reservoir service, injection-pump repair, cable synchronization, bleeding, and on-watercraft and bench checks.

The cooling-circuit drawing identifies calibrated fittings, bleed points, and drain paths. Flushing instructions warn that incorrect coordination of water flow and engine operation can send water through the tuned pipe into the engine and damage internal parts.

Fuel-system work also requires the manual’s leak checks and bilge-ventilation precautions because fuel vapors can ignite.

Ignition, Charging and Starting Faults

The electrical section separates flywheel timing-mark verification from ignition-timing checks with a stroboscopic light. Tests address the generating coil, ignition coil, charging coil, relays, and multi-purpose electronic module.

The wiring diagram includes relay terminal numbers, wire-color codes, and a running-change note for gauge wiring. The Starting System Troubleshooting Table connects starting symptoms with possible causes and remedies; the starter section adds armature, brush, commutator, and clutch inspection.

Battery charging and storage, fuel- and oil-level sensor checks, and Spark Plug Analysis provide additional diagnostic references.

Propulsion, Steering and Hull Repairs

Jet Pump Unit and Drive Shaft and Seal Carrier exploded views accompany internal inspection and assembly procedures. Coverage includes bearing and seal replacement, pump leak testing, and impeller identification.

Installation notes warn that a folded double-lip seal can lead to seal-carrier bearing failure. Dimensioned workshop-tool drawings support pump removal and steering alignment.

Equipment differences: Reverse-system procedures apply to GTS and GTX; Variable Trim System procedures apply to XP. Steering instructions cover cable adjustment, column shimming, and nozzle alignment.

Hull/body work includes water tank trap and rear-baffle repairs, seat-latch adjustment, fiberglass finishing, and painting. Storage instructions address drainage, internal lubrication, corrosion protection, and freeze protection.

Examples of Ring and Pump Inspection Limits

The top-end inspection table lists a new-part piston-ring end gap of 0.25–0.40 mm and a 1.0 mm wear limit. The same section explains the ring’s position in the cylinder for measurement.

For jet-pump inspection, maximum impeller-shaft radial play is 0.05 mm with the shaft installed in its housing and the impeller removed. Accompanying dial-gauge illustrations show the measuring positions at both shaft ends.