1996 Sea-Doo SP/SPI/SPX/XP/HX/GTS/GTI PWC Shop Manual

1996 Sea-Doo PWC Technical Documentation

• Covers 1996 Sea-Doo SP, SPI, SPX, XP, HX, GTS, and GTI watercraft models equipped with Rotax 587, 717, and 787 powerplants
• Official Bombardier publication P/N 219 100 031, 1996 edition
• Contains 43 exploded-view assembly diagrams, 12 electrical wiring schematics, and 14 major system maintenance chapters
• File link appears in your order confirmation straight away
• OCR text layer lets you jump to a torque spec by keyword
• Laid out for standard letter and A4 printing
• This 315-page factory publication provides the precise torque-to-spec values and clearance thresholds necessary for seasonal maintenance and internal engine rebuilding of the 1996 Sea-Doo watercraft fleet

Procedural and Diagnostic Scope

This factory manual outlines service procedures for the full range of 1996 Sea-Doo personal watercraft, including the SP, SPI, SPX, XP, HX, GTS, and GTI models. Documentation spans complete engine teardown and assembly, detailing the removal, cleaning, and inspection of the top end, bottom end, and rotary valve assemblies. It covers essential system maintenance for the cooling circuit, lubrication injection, and fuel delivery, including carburetor tuning and the RAVE exhaust power-valve system. Owners will find clear guidance on propulsion system service, jet pump rebuilds, and hull maintenance, supported by exploded-view parts positioning.

Technical Specification Highlights

Technical data provided includes critical clearances such as piston-to-cylinder wall tolerances, ring end gaps, and squish gap measurements specific to the 587, 717, and 787 engine series. Crankshaft deflection limits and big-end axial play thresholds are documented for precision engine overhaul work. Jet pump oil capacity is set at 90 mL using synthetic 75W90 GL5 polyolester oil. Engine RPM limits for the 587 engine are 6550 ± 50 RPM, while the 717 engine is rated at 7000 ± 50 RPM. Reference values for the rotary valve timing are explicitly listed for all engines, with 587 timing set at 130° ± 5° BTDC opening.

Reference only — always consult a certified technician before performing service on this equipment. An official 315-page Bombardier OEM workshop manual covering the 1996 Sea-Doo SP, SPI, SPX, XP, HX, GTS, and GTI, documenting engine, chassis, propulsion, and electrical specifications for the entire 587/717/787 engine series.