Description

Sea-Doo Service Manual – 1996

This comprehensive service manual provides complete maintenance, diagnostic, and repair information for the 1996 Sea-Doo XP featuring the Rotax 787 twin-cylinder engine. This professional-grade manual contains detailed procedures and specifications required for proper service and maintenance of all major systems.

Technical Coverage

• Rotax 787cc twin-cylinder engine (110HP) service procedures, including RAVE valve timing, 36mm Mikuni carburetors, and Digital CDI ignition system calibration
• Multi-layer SMC composite hull construction maintenance, with specific focus on bond line inspection and high-stress area reinforcement
• MPEM (Multi-Purpose Electronic Module) diagnostics with complete 12V DC electrical system schematics
• Direct-drive axial flow single-stage jet pump system (155.5mm diameter impeller) maintenance
• Variable trim nozzle system with 24° total range adjustment specifications
• Closed-loop cooling system with thermostat (143°F/62°C) and aluminum heat exchanger service
• Direct-access engine compartment with quick-release seat system
• Dual automatic bilge pump system (400 GPH capacity) maintenance

Professional Features

This factory-authorized manual includes detailed specifications, torque values (including 21 N⋅m for cylinder head bolts), and specialized tool requirements (P/N MAF-52000 alignment tools) for all service procedures. Clear diagrams and exploded views accompany step-by-step instructions, ensuring accurate repairs and maintenance.

Essential Resource For:

• Professional marine technicians and Sea-Doo certified mechanics
• Watercraft service centers and dealership service departments
• Marina maintenance facilities with PWC certification
• Experienced DIY enthusiasts with marine repair background

All procedures meet or exceed USCG and ABYC standards for personal watercraft maintenance. This manual is an indispensable tool for maintaining peak performance and reliability of your 1996 Sea-Doo XP watercraft. Includes complete troubleshooting guides and maintenance schedules for 10/25/50/100-hour service intervals.

Technical Specifications

Features factory-correct specifications including 6.8:1 compression ratio, 5500-7000 RPM operating range, and 15.9 US gal (60 L) fuel capacity. Includes detailed marine-grade electrical connections, sacrificial anode locations, and comprehensive system diagnostics for the MPEM-controlled systems. All content is organized for efficient reference and practical application in a marine service environment.