Sea-doo 2002 GTX 4-TEC Manual

SAFETY WARNING

Disregarding any of the safety precautions and instructions contained in

this Operator’s Guide, the Safety Handbook, the Safety Videocassette

and on the on-product warning labels could cause injury, including the

possibility of death. The operator has the responsibility to inform

passenger(s) of safety precautions.

This Operator’s Guide, the Safety Handbook and Safety Videocassette

should remain with the craft at the time of resale.

Knight’s Spray-Nine†is a trademark of Korkay System Ltd

GTX†is a trademark of Castrol Ltd. used under license

The following trademarks are the property of Bombardier Inc. or its

subsidiaries:

SEA-DOO®

BOMBARDIER-ROTAX®

BOMBARDIER LUBE®

BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil

BOMBARDIER Formula XP-S DI Synthetic Injection Oil

BOMBARDIER-ROTAX Injection Oil

Sea-Doo Synthetic Grease

Sea-Doo LKTM

Rotax®

O.P.A.S.TM

T.O.P.S.TM

Printed in Canada (smo2002-003_a.fm SG)

®™Trademarks of Bombardier Inc. or its subsidiaries.

smo2002-003_a.book Page 0 Friday, October 12, 2001 2:04 PM

Doin’it on your new SEA-DOO watercraft

Congratulations, you are now the proud owner of a SEA-DOO personal watercraft.

Whether you are an experienced boater or are new to the sport of boating, we ask

you to take the time to view the safety videocassette provided with the watercraft,

to read this Operator’s Guide, the Safety Handbook and on-product warning/caution

labels and familiarize yourself with the contents. These manuals contain pertinent

information which, if followed, will provide you with the necessary knowledge to

help you fully enjoy the pleasures of this watercraft.

We strongly recommend that all watercraft operators complete a safety boating

course. Check with your local Coast Guard or Power and Sail Squadron in your

area for course availability. More serious boaters may want to obtain Chapman

Piloting by Elbert S. Maloney, available at most book stores.

When introducing your family or friends to the sport, be sure they fully understand

the controls and operation of the watercraft and the importance of courteous,

responsible riding.

Each operator has a responsibility to ensure the safety of his/her passenger(s)

and of other water users. Please follow all safety instructions and operate your

craft with care.

We encourage you to have an Annual Safety Inspection of your watercraft. Please

contact your dealer for further details.

Finally, we urge you to visit your dealer regularly for regular and safety mainte-

nance as well as any watercraft accessories you may require.

Have fun and... Bon Voyage.

Please keep this guide and Safety Handbook on board at all times. These man-

uals along with the Safety Videocassette should remain with the watercraft

at time of resale.

smo2002-003_a.book Page 1 Friday, October 12, 2001 2:04 PM

TABLE OF CONTENTS

FOREWORD ..................................................................................... 5

 SAFETY MEASURES.................................................................... 7

General ......................................................................................................... 7

Operation ...................................................................................................... 7

Maintenance ................................................................................................. 9

LIST OF DISTRIBUTORS .................................................................. 10

BOMBARDIER LIMITED WARRANTY

NORTH AMERICA: SEA-DOO®WATERCRAFT .................................. 11

ONLY FOR 2002 SEA-DOO®RX™DI, SEA-DOO GTX DI,

SEA-DOO LRV™DI AND SEA-DOO GTX 4-TEC SOLD AND

REGISTERED IN CALIFORNIA.......................................................... 14

BOMBARDIER LIMITED WARRANTY INTERNATIONAL:

SEA-DOO®WATERCRAFT ................................................................ 17

REGISTRATION NUMBER LOCATION .............................................. 20

LOCATION OF THE IMPORTANT LABELS ........................................ 21

IDENTIFICATION NUMBERS ............................................................ 24

Hull................................................................................................................ 24

Engine........................................................................................................... 24

CONTROLS, COMPONENTS AND INSTRUMENTS LOCATION ........ 25

CONTROLS, COMPONENTS AND INSTRUMENTS FUNCTIONS ...... 27

1) Safety Lanyard (engine cut-off cord) ...................................................... 27

2) Handlebar............................................................................................... 28

3) Throttle Lever......................................................................................... 28

4) Engine Start/Stop Button ....................................................................... 28

5) Shift Lever.............................................................................................. 28

6) Speedometer ......................................................................................... 29

7) Tachometer............................................................................................ 29

8) Information Center Gauge/Buttons ........................................................ 29

9) Glove Box............................................................................................... 34

10) Fuel Tank Cap ........................................................................................ 34

11) Front Storage Compartment Cover........................................................ 35

12) Front Storage Compartment Cover Latch.............................................. 36

13) Tool Kit ................................................................................................... 36

14) Air Intake Opening ................................................................................. 36

15) Seat Strap .............................................................................................. 36

16) Seat Extension Latch ............................................................................. 36

17) Seat Latch .............................................................................................. 36

18) Rear Grab Handle ................................................................................... 37

19) Rear Storage Basket .............................................................................. 37

20) Front and Rear (bow/stern) Eyelets ....................................................... 38

21) Mooring Cleats....................................................................................... 38

22) Footboard............................................................................................... 38

23) Boarding Pads ........................................................................................ 38

24) Boarding Platform .................................................................................. 38

25) Boarding Step ........................................................................................ 38

26) Flushing Connector ................................................................................ 39

27) Bilge Drain Plugs .................................................................................... 39

smo2002-003_aTOC.fm Page 2 Wednesday, December 12, 2001 9:59 AM

28) Jet Pump Nozzle..................................................................................... 39

29) Reverse Gate .......................................................................................... 40

30) Jet Pump Water Intake and Ride Plate................................................... 40

31) Fuses ...................................................................................................... 40

32) Battery .................................................................................................... 41

33) Side Vanes .............................................................................................. 41

34) Engine Oil Dipstick.................................................................................. 41

35) Engine Oil Filling Cap .............................................................................. 42

36) Cooling System Expansion Tank Cap ..................................................... 42

LIQUIDS .......................................................................................... 43

Fueling Procedure.......................................................................................... 43

Recommended Fuel ...................................................................................... 43

Engine Oil ...................................................................................................... 43

Engine Coolant .............................................................................................. 45

BREAK-IN PERIOD ........................................................................... 46

10-Hour Inspection ........................................................................................ 46

PRE-OPERATION CHECKS ............................................................... 47

Hull ................................................................................................................ 48

Jet Pump Water Intake.................................................................................. 48

Bilge............................................................................................................... 48

Battery ........................................................................................................... 48

Fuel Tank......................................................................................................... 48

Engine Compartment .................................................................................... 48

Engine Oil Level............................................................................................. 48

Engine Coolant Level..................................................................................... 49

Steering System ............................................................................................ 49

Throttle System ............................................................................................. 49

Shifter System ............................................................................................... 49

Storage Compartment Covers and Seat........................................................ 49

Safety Lanyard and Engine Start/Stop Button ............................................... 49

OPERATING INSTRUCTIONS ........................................................... 50

Principle of Operation .................................................................................... 50

Boarding the Watercraft ................................................................................ 53

Starting .......................................................................................................... 55

Rough Water or Poor Visibility Operation ...................................................... 55

Crossing Waves............................................................................................. 56

Stopping/Docking .......................................................................................... 56

Beaching ........................................................................................................ 56

Shutting Off the Engine ................................................................................. 56

POST-OPERATION CARE ................................................................. 57

General Care.................................................................................................. 57

Additional Care for Foul Water or Salt Water ................................................ 57

Exhaust Cooling System Flushing ................................................................. 57

Anticorrosion Treatment................................................................................ 58

SPECIAL PROCEDURES .................................................................. 59

Monitoring System ........................................................................................ 59

Engine Overheating ....................................................................................... 59

Engine Low Oil Pressure ............................................................................... 59

Jet Pump Water Intake and Impeller Cleaning .............................................. 60

smo2002-003_aTOC.fm Page 3 Wednesday, December 12, 2001 9:59 AM

Capsized Watercraft ..................................................................................... 61

Submerged Watercraft ................................................................................. 61

Water-Flooded Engine .................................................................................. 61

Fuel-Flooded Engine ..................................................................................... 62

Towing the Watercraft in Water ................................................................... 63

Low-Charge Battery Condition...................................................................... 64

MAINTENANCE ............................................................................... 65

Engine Emissions Information ...................................................................... 65

Lubrication .................................................................................................... 66

Periodic Inspection ....................................................................................... 66

Periodic Inspection Chart .............................................................................. 67

Throttle Cable Inspection .............................................................................. 69

Engine Oil Change and Oil Filter Replacement............................................. 69

Valve Adjustment.......................................................................................... 69

Coolant Replacement ................................................................................... 69

Fuel Injection System ................................................................................... 69

Steering Alignment ....................................................................................... 69

Vacuum Bailer Pick-Ups ................................................................................ 70

Fuses ............................................................................................................ 70

General Inspection and Cleaning .................................................................. 74

TRAILERING, STORAGE AND PRE-SEASON PREPARATION ........... 75

Trailering ....................................................................................................... 75

Launching/Loading........................................................................................ 76

Storage ......................................................................................................... 76

Body Rinsing/Repair...................................................................................... 76

Fuel System .................................................................................................. 76

Engine Oil and Filter Replacement ............................................................... 76

Exhaust Cooling System Flushing and Engine Internal Lubrication...................... 76

Battery .......................................................................................................... 77

Engine Cooling System..................................................................................... 77

Bilge Cleaning ................................................................................................... 77

Anticorrosion Treatment ............................................................................... 77

Pre-Season Preparation ................................................................................ 78

TROUBLESHOOTING ....................................................................... 80

SPECIFICATIONS............................................................................. 86

SI METRIC INFORMATION ............................................................... 88

ABBREVIATIONS USED IN THIS MANUAL ...................................... 89

PRIVACY INFORMATION ................................................................. 90

CHANGE OF ADDRESS ................................................................... 91

smo2002-003_aTOC.fm Page 4 Wednesday, December 12, 2001 9:59 AM

FOREWORD

The Operator’s Guide and Safety Hand-

book have been prepared to acquaint

the owner/operator or passenger with

this personal watercraft and its various

controls, maintenance and safe riding

instructions. Each is indispensable for

the proper use of the product, and

should be kept in a waterproof bag with

the watercraft at all times.

Make sure you read and understand the

content of the Operator’s Guide and

Safety Handbook.

For any questions pertaining to the

warranty and its application, consult

the WARRANTY section in this guide,

and/or an authorized Sea-Doo dealer.

This guide uses the following safety

alert symbol in conjunction with signal

words to indicate a potential personal

injury hazard.

NOTE: Indicates supplementary infor-

mation needed to fully complete an in-

struction.

Although the mere reading of such in-

formation does not eliminate the haz-

ard, the understanding and application

of the information will promote the cor-

rect use of the watercraft.

The information and components/

system descriptions contained in this

guide are correct at the time of writing.

Bombardier Inc. however, maintains a

policy of continuous improvement of

its products without imposing upon it-

self any obligation to install them on

products previously manufactured.

Because of its ongoing commitment

to product quality and innovation,

Bombardier reserves the right at any

time to discontinue or change specifica-

tions, designs, features, models or

equipment without incurring obligation.

The illustrations in this document show

the typical construction of the different

assemblies and may not represent the

full detail or exact shape of the parts.

However, they represent parts that

have the same or similar function.

It is understood that this guide may be

translated into another language. In

the event of any discrepancy, the En-

glish version shall prevail.

Specifications are given in the SI met-

ric system with the SAE U.S. equiva-

lent in parenthesis. Where precise accu-

racy is not required, some conversions

are rounded off for easier use.

A Shop Manual can be obtained for

complete service, maintenance and

more repair information.

WARNING

Indicates a potentially hazardous sit-

uation which, if not avoided, could

result in death or serious injury.

 CAUTION

Indicates a potentially hazardous

situation which, if not avoided,

may result in minor or moderate in-

jury. When used without the safety

alert symbol , potential hazard

exists for property damage only.

smo2002-003_a.book Page 5 Friday, October 12, 2001 2:04 PM

The use of LEFT (port) and RIGHT (star-

board) indications in the text, always

refers to driving position (when sitting

on watercraft).

Furthermore, in the marine industry,

FRONT is referred to BOW and REAR

as STERN.

1. Left (port)

2. Right (starboard)

F01L451

smo2002-003_a.book Page 6 Friday, October 12, 2001 2:04 PM

SAFETY MEASURES

General

To fully appreciate the pleasures,

enjoyment and excitement of boat-

ing there are some basic rules that

should be observed and followed by

any rider. Some rules may be new

to you or covered in the Sea-Doo

Safety Handbook or Safety Video-

cassette, others may be common

sense or obvious… irrespective, we

ask that you please take a few min-

utes of your time to read these safe-

ty instructions completely together

with your Safety Handbook before

you operate your watercraft. Fail-

ure to follow this safety informa-

tion and safe boating rules could

result in injury, including the pos-

sibility of death to you, your pas-

senger(s), or other water users.

Bombardier recommends not to op-

erate a watercraft under the age of

16.

Become completely familiar with the

controls and operation of the water-

craft before embarking on your first

trip or taking on a passenger(s). If you

have not had the opportunity to do so

with your authorized Sea-Doo dealer,

practice driving solo in a suitable area

and feel the response of each con-

trol. Be fully familiar with all controls

before applying throttle above idle

speed. As its operator, you control

and are responsible for the water-

craft’s safe operation.

Always carry the regulatory required

safety items on board. Check the lo-

cal regulations or consult your au-

thorized Sea-Doo dealer.

Make sure that all users of the wa-

tercraft read and understand all on-

product warnings.

Operation

Always perform the pre-operation

checks as specified in this guide.

Operator and passenger(s) should at

all times wear a coast guard approved

personal flotation device (PFD) that is

suitable for personal watercraft.

Operator and passenger(s) should

wear protective clothing. Severe in-

ternal injuries can occur if water is

forced into body cavities of males or

females as a result of falling into wa-

ter or being near jet thrust nozzle.

Wet suit bottom (or thick, tightly wo-

ven, snug fitting clothing that pro-

vides equivalent protection. Thin bike

shorts for example would not be

appropriate), footwear, gloves and

goggles/glasses are recommended.

Always keep in mind that as the

throttle lever is released to idle posi-

tion, less directional control is avail-

able. To turn the watercraft, both

steering and throttle are neces-

sary.

Like any other craft, this watercraft

has no brake. Stopping distance will

vary depending on initial speed, load,

wind, and water conditions. Practice

stopping and docking in a safe, traffic

free area to have an idea of how long

it will take to stop the watercraft un-

der varying conditions. Do not re-

lease throttle when trying to steer

away from objects. You need throttle

to steer. Do not use the watercraft’s

reverse, if so equipped, to stop.

Ensure that all passengers know

how to swim and how to reboard

the watercraft from the water.

The operator and passenger(s) should

be properly seated before starting

or moving the watercraft, and at all

times when watercraft is in motion.

smo2002-003_a.book Page 7 Friday, October 12, 2001 2:04 PM

Do not start or operate the water-

craft if someone is seated on the sun

deck (if so equipped) or swim plat-

form, or is nearby in the water. The

watercraft’s jet thrust can cause in-

jury. Always accelerate slowly.

To prevent accidental starting or un-

authorized use, always detach the

safety lanyard from the watercraft es-

pecially when swimmers are board-

ing or nearby, or during removal of

any weeds or debris from the intake

grate.

Never turn handlebar while someone

is nearby rear of watercraft. Keep

away from steering moving parts

(nozzle, side vanes, linkage, etc.).

Keep away from intake grate while

engine is on. Items such as long hair,

loose clothing, or PFD straps can be-

come entangled in moving parts re-

sulting in severe injury or drowning.

Ride within your limits and avoid ag-

gressive maneuvers to reduce the

risk of loss of control, ejection and

collision.

Riding with a passenger(s) or pulling

other crafts, tubes, skies or wake-

boards makes the watercraft handle

differently and requires greater skill.

Do not overload the watercraft or

take on more passengers than des-

ignated for the particular watercraft.

Overloading can affect maneuver-

ability, stability and performance.

Avoid adding on accessories, or

equipment which may alter the con-

figuration, balance or control of the

watercraft. The watercraft maybe

fitted with tow eyelets which can be

used to attach a ski rope. However,

do not use these eyelets or the wa-

tercraft’s cleats to tow a parasail. Se-

vere injury or watercraft damage

may occur.

In shallow water, proceed with cau-

tion and at very low speeds. Ground-

ing or abrupt stops may result in in-

jury. Debris may also be picked up

and be thrown rearward by the jet

pump onto people or property.

Respect no wake zones, the rights

ofother water users and the environ-

ment. As the “skipper”and owner

of a watercraft you are responsible

for damage to other crafts caused by

the wake of your watercraft. Allow

no one to throw refuse overboard.

Remember that a watercraft is not

designed for night time operation.

Remember, gasoline fumes are

flammable and explosive. Always

adhere to the fueling procedure

contained in this guide and those

given to you by the marina. Always

verify fuel level before use and dur-

ing the ride. Apply the principle of

1/3 fuel to destination, 1/3 back and

1/3 reserve fuel supply. Do not carry

spare fuel or flammable liquids in

any of the storage or engine com-

partments.

Combustion engine needs air to op-

erate; consequently this watercraft

can not be totally watertight. Any

maneuvers such as figure eights

etc., that cause the upper deck to be

under water may cause severe en-

gine problems due to water ingestion.

Refer to SPECIAL PROCEDURES and

Limited Warranty contained in this

guide.

Due to the close proximity of other

racers, it is recommended that an

approved personal watercraft hel-

met be used during racing events.

Read and follow all instructions and

warnings provided with the helmet.

Never ride after consuming drugs or

alcohol or if you feel tired or ill. Op-

erate your watercraft prudently and

have fun.

Don’t forget that all persons must

assist other boaters in an emergency.

smo2002-003_a.book Page 8 Friday, October 12, 2001 2:04 PM

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