1995 Bombardier Sea-Doo SP (5873), SPX (5874), SPI (5875), GTS (5815), GTX (5863), XP (5857) Shop Manual (P/N 219 100 013)

• Exact 1995 model coverage: Sea-Doo SP (5873), SPI (5875), SPX (5874), GTS (5815), GTX (5863), and XP (5857), with model-group technical data and model-specific wiring diagrams.
• Engine repair coverage: Details engine removal and alignment, top-end service, bottom-end teardown and inspection, crankshaft checks, rotary-valve service and timing, and tuned-pipe removal and repair for the covered Rotax engines.
• Fuel, cooling, and lubrication procedures: Includes cooling-system flushing and storage preparation, water-flooded engine recovery, fuel- and oil-system pressure testing, Mikuni carburetor inspection and synchronization, and oil-injection pump adjustment, bleeding, and testing.
• Electrical diagnosis: Covers magneto service, CDI/MPEM ignition timing and testing, charging-system checks, starter diagnosis and overhaul, gauge and sensor tests, and electrical testing of the SPX and XP variable trim systems.
• Propulsion and control systems: Documents aluminum and plastic jet-pump overhaul, impeller and wear-ring inspection, pump leak testing, drive-shaft and seal-carrier repair, GTS/GTX reverse service, SPX/XP VTS work, and steering alignment.
• Factory reference data: The 271-page PDF contains mandatory and recommended service-tool listings, component-specific torque tables, inspection limits, clearances, pressure-test data, capacities, electrical test values, exploded views, and troubleshooting charts.

Factory Scope and Model Differences

Bombardier published this shop manual primarily for manufacturer-trained watercraft technicians already familiar with Sea-Doo service and maintenance procedures, and the work assumes access to the specified hand tools and special service tools.

Coverage follows the actual hardware fitted to each model. The SP, SPI, and GTS use the Bombardier-Rotax 587 engine; the SPX and GTX use the 657 X; and the XP uses the 717. The manual also separates the single-carburetor 587 installations from the twin-carburetor 657 X and 717 setups, with model-group tables for engine, carburetion, cooling, electrical, propulsion, capacity, equipment, and torque data. Reverse-system repair is specific to the GTS and GTX, while the mechanical and electrical VTS sections provide separate procedures for the SPX and XP designs.

Bombardier warns that engine components cannot be interchanged between the three engine families. This is a repair manual, not a parts catalog; parts ordering is directed to the separate model-specific catalogs.

Repair and Diagnostic Depth

The engine chapters document inspection and reassembly work, not just routine maintenance. They cover cylinder and piston inspection, ring and bore limits, crankshaft alignment and deflection, connecting-rod checks, 657 X/717 squish setup, rotary-valve cover clearance and gear backlash, valve identification and timing, and tuned-pipe crack repair with leak testing. Engine-to-jet-pump alignment is included after engine removal.

Fuel-system sections cover tank and vent components, pressure-relief and check valves, leak testing, carburetor pump and metering-circuit inspection, needle-and-seat tests, jetting data, and distinct synchronization methods for the XP and the SPX/GTX twin-carburetor arrangements. The oil-injection chapters add reservoir pressure testing, pump synchronization, bleeding, on-watercraft operation checks, and bench delivery testing.

Electrical diagnosis includes the generating and charging coils, integrated CDI ignition coil, MPEM timer and rev-limiter circuits, cold-engine ignition timing, Bombardier ignition-tester checks, regulator and battery tests, starter fault isolation and internal inspection, and fuel, oil, speed, multifunction-gauge, and VTS sensor circuits.

Propulsion, Steering, and Body Work

The jet-pump section distinguishes aluminum and plastic pump assemblies and covers removal, complete disassembly, bearings and seals, shaft play, impeller and wear-ring condition, oil service, reassembly, pressure testing, and installation. Drive-system coverage extends to the PTO flywheel, drive-shaft deflection, seal carrier, and hull-insert repair. Steering procedures are divided by hull family and finish with nozzle alignment checks.

Hull/body material includes seat and storage-cover adjustment, bumper and sponson replacement, GTS/GTX rear-baffle sealing, decals, fiberglass and gelcoat damage assessment, and PPG Concept and Delta paint procedures with model color codes. The fiberglass/gelcoat section supports common damage repair and estimating, but the manual explicitly says it does not replace a full fiberglass-repair manual.

Tools, Diagrams, and Repair Cautions

The tool index identifies factory equipment by part number, including the degree wheel P/N 295 000 007, engine/pump alignment tool P/N 295 000 089, Bombardier ignition tester P/N 295 000 008, impeller remover/installer P/N 295 000 001, and bearing/seal installer P/N 295 000 107. Visual references include 587/657 X/717 cooling-circuit schematics, the CDI/MPEM ignition diagram, rotary-valve timing templates, aluminum and plastic jet-pump exploded views, SPX/XP VTS views, and individual wiring diagrams for all six models.

The manual warns that mixing engine-mount shims changes engine-to-pump alignment, which can cause vibration or component damage. It also shows how incorrect VTS cable orientation or trim adjustment can damage the cables or venturi. Fuel, battery, ignition, and running-engine checks include specific bilge-ventilation, leak-test, electrical-isolation, cooling, and rotating-component precautions.