sportster 1800

R

1998 Shop ManualVOLUME 1 SPORTSTER/1800 CHALLENGER/1800

Legal deposit: National Library of Quebec 1st trimester 1998 National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. Bombardier Inc. 1998 Printed in Canada *Registered trademarks of Bombardier Inc.

Loctite is a trademark of Corporation. Snap-on is a trademark of Snap-on Tools Corporation. Gelcote is a trademark of Gelcote International Limited.

TABLE OF CONTENTS

SECTION

SUBSECTION

PAGE III IV VI 01-01-1 01-02-1 01-03-1 01-04-1 02-01-1 02-02-1 02-03-1 02-04-1 02-05-1

SAFETY NOTICE .................................................................................................................................. WHATS NEW ....................................................................................................................................... INTRODUCTION ................................................................................................................................... 01 SERVICE TOOLS AND PRODUCTS 01 Table of Contents ..................................................................... 02 Mandatory Tools....................................................................... 03 Optional Tools .......................................................................... 04 Service Products ...................................................................... 01 Table of Contents ..................................................................... 02 Periodic Inspection Chart ......................................................... 03 Flushing and Lubrication........................................................... 04 Water-Flooded Engine.............................................................. 05 Storage .....................................................................................

02

MAINTENANCE

03 04

TROUBLESHOOTING ENGINE

01 Troubleshooting........................................................................ 03-01-1 01 Table of Contents ..................................................................... 02 Leak Test ................................................................................. 03 Removal and Installation .......................................................... 04 Magneto System...................................................................... 05 Top End .................................................................................... 06 Bottom End .............................................................................. 07 Rotary Valve ............................................................................. 08 Exhaust System ....................................................................... 04-01-1 04-02-1 04-03-1 04-04-1 04-05-1 04-06-1 04-07-1 04-08-1

05

COOLING SYSTEM

01 Table of Contents ..................................................................... 05-01-1 02 Components............................................................................. 05-02-1 03 Circuit ....................................................................................... 05-03-1 01 Table of Contents ..................................................................... 02 Fuel Circuit ............................................................................... 03 Air Intake .................................................................................. 04 Carburetors............................................................................... 06-01-1 06-02-1 06-03-1 06-04-1

06

FUEL SYSTEM

07

LUBRICATION SYSTEM

01 Table of Contents ..................................................................... 07-01-1 02 Oil Injection Reservoir .............................................................. 07-02-1 03 Oil Injection Pump .................................................................... 07-03-1 01 Table of Contents ..................................................................... 02 Overview .................................................................................. 03 Ignition System ........................................................................ 04 Spark Plugs............................................................................... 05 The DESS (Digitally Encoded Security System) ....................... 06 MPEM (Multi-Purpose Electronic Module)............................... 07 Charging System ...................................................................... 08 Starting System........................................................................ 09 Instruments and Accessories................................................... 08-01-1 08-02-1 08-03-1 08-04-1 08-05-1 08-06-1 08-07-1 08-08-1 08-09-1

08

ELECTRICAL

I

TABLE OF CONTENTS

SECTION09 PROPULSION SYSTEM

SUBSECTION01 Table of Contents...................................................................... 02 Jet Pump................................................................................... 03 Drive System ............................................................................ 04 Reverse System........................................................................ 05 Weedless System..................................................................... 01 Table of Contents...................................................................... 02 Steering System ....................................................................... 03 Alignment.................................................................................. 04 Throttle/Shifter Controller ......................................................... 01 Table of Contents...................................................................... 02 Components ............................................................................. 03 Repair........................................................................................ 04 Painting .....................................................................................

PAGE09-01-1 09-02-1 09-03-1 09-04-1 09-05-1 10-01-1 10-02-1 10-03-1 10-04-1 11-01-1 11-02-1 11-03-1 11-04-1

10

STEERING SYSTEM

11

HULL/DECK

12 13

TECHNICAL DATA...................................................................................................................... 12-01-1 WIRING DIAGRAMS................................................................................................................... 13-01-1

II

SAFETY NOTICE

SAFETY NOTICE

0

This manual was primarily published to be used by jet boat technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made Sea-Doo jet boat. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into local language upon certain conditions and furthermore agreed that in the event of any discrepancy among the two versions, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at its time of manufacture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing the product. The use of Bombardier parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking disk, lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols:

x-

WARNING

Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death.

CAUTION

Denotes an instruction which, if not followed, could severely damage boat components. NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier jet boat and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional technician. It is understood that certain modifications may render use of the boat illegal under existing federal, provincial and state regulations.

III

WHATS NEW

WHATS NEWThis section is introduced this year to indicate the major changes brought in this shop manual.

0

INTRODUCTION Addition of a list of abbreviations used in this manual.

SERVICE TOOLS AND SERVICE PRODUCTS Complete new section. The following tools are new: Distance gauge for positioning of bearings on crankshaft. Piston pin puller with interchangeable sleeves. Crimping tool for AMP connectors. New P/N for MPEM programmer. Engine alignment tool with replaceable plates. The following products are new: Thread sealant, Loctite 577. Deoxit contact lubricant. The Right Stuff Gasket replaces the Ultra Black silicone. Bombardier storage oil.

MAINTENANCE Revised periodic inspection chart. Revised storage procedure.

TROUBLESHOOTING Revised items.

ENGINE Top end: Revised procedure with the use of the new piston pin puller. Bottom end: New distance gauge part numbers for positioning of bearings on crankshaft. Bottom end: PTO flywheel removal/installation procedure has been added (was in DRIVE SYSTEM).

COOLING SYSTEM Procedure to adjust the water flow regulator valve removed. Photographs added to improve clarity.

FUEL SYSTEM Revamped section to improve usability. New external fuel pump. New procedure to adjust throttle cable including the low-speed steering control system.

IV

WHATS NEW

LUBRICATION SYSTEM No major changes.

ELECTRICAL Bombardier ignition tester is not available anymore. New procedure to test magneto system with a voltmeter. Addition of important information pertaining to flywheel loosening when performing ignition timing. Improved procedure to make the voltage test for the rectifier/regulator. Improved procedure to test the battery (load and unload test). New procedure for battery removal/installation for Challenger model.

PROPULSION SYSTEM New sealing pattern of ride shoe and jet pump support. The Right Stuff Gasket replaces the Ultra Black silicone. On twin-pump models, the ride shoe is now mounted to the hull with bolts instead of screws. PTO flywheel removal/installation procedure has been transferred to BOTTOM END in ENGINE section.

STEERING SYSTEM Procedure to adjust low-speed steering control system transferred to CARBURETORS section.

HULL/DECK New color on the 717 engine (off-white). New color on the 787 engine (silver reflection).

TECHNICAL DATA Updated specifications for 1998.

WIRING DIAGRAMS Updated for 1998.

V

INTRODUCTION

INTRODUCTIONThis Shop Manual covers the following BOMBARDIER made SEA-DOO jet boats.MODEL Sportster Sportster 1800 Challenger Challenger 1800 MODEL NUMBER 5614/5619/5634 5613/5618/5633 5612/5617/5632 5611/5616/5631

0HULL IDENTIFICATION NUMBER (H.I.N.)The Hull Identification Number (H.I.N.) is located at right hand rear side of hull.

BOAT MODEL NUMBERThe jet boat model number can be found on RH side of operator position.F04L8SA

1

TYPICAL 1. Hull Identification Number (H.I.N.)30

1510

30 70 4590km/h

0

60

MPH Bombardier

Refer to the illustration for a description of the serial number.N

R

ZZN12345L495 Model yearMADE IN U.S.A. BOMBARDIER CORPORATION OF AMERICA XXXX U.S. COAST GUARD

1

Serial number*

Year of production Month of production

MAXIMUM CAPACITIES

4 PERSONS OR 660 LBS660 LBS. PERSONS, GEAR BOAT DESIGN CATEGORY:

.F00A0CA

THIS BOAT COMPLIES WITH U.S. AND CANADIAN COAST GUARD SAFETY STANDARDS IN EFFECT ON THE DATE OF CERTIFICATION

C

*A letter may also be used as a digit.

F04L8WA

TYPICAL 1. Model number

Some boats may have a serial number beginning with CEC. CEC boats are manufactured in USA and ZZN boats are manufactured in Canada.

VI

INTRODUCTION

ENGINE IDENTIFICATION NUMBER (E.I.N.)It is located on the upper side of the magneto housing.

ARRANGEMENT OF THIS MANUALThe manual is divided into 13 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 HULL/DECK 12 TECHNICAL DATA 13 WIRING DIAGRAMS Each section is divided in various subsections, and again, each subsection has one or more division. A table of contents is included at the beginning of most sections.

1

F01D01A

TYPICAL 717 ENGINE 1. Engine Identification Number (E.I.N.)

F01D87A

1

787 ENGINE 1. Engine Identification Number (E.I.N.)

VII

INTRODUCTION

TYPICAL PAGEPage heading indicates section and subsection detailed.

Section 03 ENGINE Subsection 04 (MAGNETO SYSTEM)

Subsection title indicates beginning of the subsection.

MAGNETO SYSTEMDrop represents a liquid product to be applied to a surface. In this case Loctite 242 to screw threads.717 Engine12 11 5 Nm (44 lbfin)

Italic sub-title above exploded view indicate pertaining models.

9 Nm 13 (80 lbfin) Loctite 242

6

8 Loctite 242 6 Nm (53 lbfin)

Exploded view assists you in identifying parts and related positions.6 Nm (53 lbfin) 5

4 7

Dotted box contains parts of a particular model or an exploded view.

Loctite 242 9 6 Nm (53 lbfin)

Loctite 242 3 14 Loctite 242 1

Bold face number indicates special procedure concerning this part.4 Loctite 648 10 15 145 Nm (107 lbfft)

Anti-seize lubricantF01D4WS

2 9 Nm (80 lbfin)

Illustration number for publishing process.03-04-1

Tightening torque nearby fastener. In this case, nut must be torqued to 145 Nm (107 lbfft).

w CAUTIONPay attention to torque specifications. Some of these are in lbfin instead of lbfft. Use appropriate torque wrench.F04A09S

Page numbering system: 03: ENGINE section 04: MAGNETO SYSTEM subsection 1: First page of this subsection

VIII

INTRODUCTION

TYPICAL PAGE

Sub-title indicates a particular procedure for the named part.

Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS)

Title indicates main procedure to be carried-out.

CARBURETOR REMOVALTo remove carburetors from engine, proceed as follows: Remove air vent tube support. Unlock retaining slides holding air intake silencer base. Remove air intake silencer base from watercraft. Remove screws holding flame arrester base support to cylinder head cover. Unscrew base retaining screws then remove base from carburetors and move to front of watercraft. Turn the valve to OFF position. NOTE: For fuel line removal, use pliers (P/N 295 000 054). Disconnect pulse line from fuel pump. Disconnect fuel fuel supply line from fuel pump. Disconnect fuel return line. Disconnect oil injection pump cable, throttle cable and choke cable.

DISASSEMBLY AND INSPECTIONInspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.).

Sub-sub-title indicates a particular testing, adjustment or repair procedure.

DiaphragmPump Diaphragm Leak Test Using a suitable pump gauge tester, perform the following test proceeding as follows: - Install pump gauge tester (P/N 295 000 083) on pulse nipple. - Pump tester until it reaches 28 kPa (4 PSI).

Service tool to be used to perform a certain procedure.

1

A

Italic bold face setting indicates a particular procedure concerning a model. Italic bold face setting in this case indicates that particular procedure for Challenger is finished, so from this point, all others models are concerned.

Illustration always follows text it is pertained to.

Challenger Model Only Remove screws and lock washers retaining carburetors. Remove carburetors from intake manifold. All Others Models Remove 4 bolts and lock washers from rotary valve cover then move carburetors and rotary valve cover on top of engine.NOTE: When removing rotary valve cover , pay attention that the rotary valve stay in place, otherwise it must be timed. Remove carburetors from intake manifold. Disconnect fuel bypass line between carburetors (twin carburetors). Remove carburetor(s) from rotary valve cover.

2F01F0XB

1

2

TYPICAL Step 1 : Install pump gauge tester to pulse nipple Step 2 : Pump tester until it reaches the desired pressure 1. Fuel outlet nipple 2. Fuel inlet nipple A. 28 kPa (4 PSI)

''TYPICAL'' caption indicates a general view which does not represent full detail.

Diaphragm no. 3 must stand pressure for 10 seconds. If pressure drops, replace diaphragm.

Numbers in a frame are used to give a sequence to be perfomed for above illustration.

Number: following part name refers to exploded view at beginning of subsection.

06-03-4

Letters are used for any measures for above illustration.

Numbers are used for description of components for above illustration.

F04A08S

IX

INTRODUCTION

LIST OF ABBREVIATIONS USED IN THIS MANUALAC Assy ATDC BTDC CDI CSI DC DC-CDI DESS E.I.N H.I.N. HP LH MAG MPEM N.A. or N/A P/N PTO RAVE RFI RH RMS ROM RPM SAE TDC T.I.G. TLCS Vac Vdc VROI Alternative Current Assembly After Top Dead Center Before Top Dead Center Capacitor Discharge Ignition Cooling System Indicator Direct Current Direct-Current Capacitor Discharge Ignition Digitally Encoded Security System Engine Identification Number Hull Identification Number Horsepower Left Hand side (port) Magneto Multi-Purpose Electronic Module Not Applicable Part Number Power Take Off Rotax Adjustable Variable Exhaust Radio-Frequency Interference Right Hand side (starboard) Root Mean Square Read-Only Memory Revolution Per Minute Society of Automotive Engineering Top Dead Center Tungsten Inert Gas Total Loss Cooling System Volt, Alternative Current Volt, Direct Current Variable Rate Oil Injection

X

INTRODUCTION

GENERAL INFORMATIONIn marine industry, PORT, STARBOARD, BOW and STERN are used to refer to LEFT, RIGHT, FRONT and REAR respectively. They always refer to the operators position sitting in boat.1

ILLUSTRATIONS AND PROCEDURESThe illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown; however, they represent parts which have the same or a similar function.

-

CAUTION

4

2

These boats are designed with parts dimensioned in both the metric and the imperial systems. When replacing fasteners, make sure to use only those recommended by Bombardier. Mismatched or incorrect fasteners could cause damage to the boat or possible personal injury. As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. Technical Publications Bombardier Inc. Valcourt (Quebec), Canada

F04L03C

3

1. 2. 3. 4.

BOW (front) STARBOARD (RH) STERN (rear) PORT (LH)

The information and component/system descriptions contained in this manual are correct at time of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This Shop Manual uses technical terms which may be different from the ones of the Parts Catalogs. When ordering parts always refer to the specific model Parts Catalogs.

XI

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTSMANDATORY TOOLS ........................................................................................................... ENGINE .............................................................................................................................. OPTIONAL TOOLS ................................................................................................................ ENGINE .............................................................................................................................. SERVICE PRODUCTS ............................................................................................................

001-02-1 01-02-1 01-03-1 01-03-1 01-04-1

01-01-1

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY TOOLS)

MANDATORY TOOLSENGINEDegree wheel P/N 295 000 007333231

0

NOTE: The numbers outlined in black (example: 1 ) are reference numbers to tools from other divisions (Ski-Doo Snowmobiles and/or Sea-Doo Watercraft). Matching reference numbers indicate the same tool is being used on both products, even if the part numbers are different.

1

8

8

7

7

Piston circlip installer A) P/N 295 000 077 B) P/N 290 877 016

0

50

350 360 10 20 340 30 10 360 350 3 20 40 30 33 0 400

202 548

140

32

50

0

0

290

5 2 4 3 6 4A01B1P4

60

60

31

0

0

30

70

300

70

80

290

80

110 100 90

280

90 100 11 0 280 270 26 0

270

250

Piston circlip

260

130

120

12 0 13 250 0 24 1 0 2

0

24

14

0

A00B334

APPLICATION All models. Rubber pad P/N 295 000 101 547

F01B0J4

APPLICATION All models. Bearing pusher P/N 290 876 500 12

A00B2J4

APPLICATION All engines except 787.

40

3015

0

22

0

180 190 2 170 00 21 160 0 200 190 180 17 22 0 210 0 16 0 15 0

0 23

APPLICATION A) 587 engine. B) 657, 717 and 787 engines.MAG sideF01D884

PTO side

1) Puller P/N 290 876 298 2) Protective cap (both ends) P/N 290 876 557 3) Ring (both ends) P/N 290 977 490 4) Ring halves (PTO) P/N 290 977 475 (2) 5) Distance ring (MAG) P/N 290 876 569 6) Ring halves (MAG) P/N 290 276 025 (2) 7) Screw M8 x 40 P/N 290 840 681 (2) 8) Screw M8 x 70 P/N 290 841 201 (2) APPLICATION All models.

200

Pusher P/N 290 876 605

229

554

A00C0Y4

555

APPLICATION All engines except 787. Bearing pusher P/N 290 876 501

556

557

558F00B074

559

APPLICATION 787 engine.

560

01-02-1

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY TOOLS)

Digital multimeter P/N 529 022 000

242

Puller P/N 295 000 106

5

PTO flywheel remover/ installer P/N 295 000 001

553

F01J0T4 A00C1A4

Puller plate P/N 290 876 080

549

APPLICATION All engines except 787. NOTE: This tool is also used for the impeller. Puller P/N 290 876 488 562

F01B1O4 A00C1R4

APPLICATION All models.

Extension handle P/N 295 000 125

5502F01B0I4

1

F01D164

Screw M8 x 35 (3) P/N 290 841 591

551

APPLICATION All engines. Replacement parts: 1) Hex. screw (M6 x 60) P/N 290 240 860 2) Nut (M6) P/N 290 242 210

F00A094

Sleeve (3) P/N 290 847 220

552

F00A0A4


01-02-2

Section 01


Alignment support plate kit P/N 529 035 506 1) Alignment plates P/N 529 035 507 2) Support P/N 529 035 511 3) Screw (2) P/N 222 082 565 Lock washer (2) P/N 213 000 001 Flat washer (2) P/N 217 081 410NEW

Sleeve set P/N 529 035 542 (20 mm sleeve)NEW

Engine leak tester kit P/N 295 500 352

778

F00B0U4

APPLICATION All models. MPEM programmer P/N 529 035 502NEW

F01B2Q5

APPLICATION All models. 567 Ring gear puller tool P/N 420 976 235 569

F00B0F4

APPLICATION All models.F01B294 A01B5B4

Alignment shaft P/N 295 000 141

APPLICATION Boats equipped with the DESS. Flywheel extractor P/N 295 000 156 777

APPLICATION 787 engine. Ring gear blocking tool P/N 295 000 155 568

F00B0G4

APPLICATION All models. Piston pin puller P/N 529 035 503NEW

F01B264

APPLICATION 787 engine.F00B044


F00B0T4

APPLICATION All engines.01-02-3

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY TOOLS)

COOLING/FUEL/OIL SYSTEMSHose pincher P/N 295 000 076 2 Pliers P/N 295 000 054Caillau

606

F01B1T4

A01B2I4

APPLICATION All models. Gear holder P/N 290 277 905 235

APPLICATION All models. NOTE: This tool is also used for the propulsion system. Coupler hose P/N 295 500 25841 cm (16 in)

752

F01E0Z4

A00C164


APPLICATION All engines except 787. Pliers P/N 295 000 070Oetiker 1099

601

F01D174


01-02-4

Section 01


PROPULSION SYSTEMImpeller remover/installer P/N 295 000 001 553 Bearing/seal installer P/N 295 000 107 604

F01J0T4

APPLICATION All models. NOTE: This tool is also used for the PTO flywheel. Pliers P/N 295 000 069Oetiker 1090F01J4K4

602

APPLICATION All models. Impeller shaft guide P/N 295 000 002 605

F01D184

F01J1O4

APPLICATION All models. Impeller shaft holder P/N 295 000 082 603

APPLICATION All models. Pliers P/N 295 000 054Caillau

606

F01B0W4

F01B1T4


APPLICATION All models. NOTE: This tool is also used for the fuel system.

01-02-5

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL TOOLS)

OPTIONAL TOOLSENGINERing compressor A) P/N 290 876 979 (82 mm) B) P/N 295 000 112 (78 mm) C) P/N 290 876 972 (76 mm) 766 751 207 Stroboscopic timing light P/N 529 031 900 225 Digital/induction type tachometer P/N 295 000 100

0237

A00B4F4

APPLICATION All models.A01B1T4

F01B1G4

APPLICATION All models. 230 Timing mark pointer P/N 295 000 130 774

APPLICATION A) 717 and 787 engines. B) 657 engine. C) 587 engine. Coil centering tool P/N 290 876 922 209

Dial indicator (TDC gauge) P/N 295 000 143

A00B4E4

APPLICATION All models. Distance gauge A) P/N 529 034 800 B) P/N 529 034 900 C) P/N 290 876 826NEWF01B2O4

APPLICATION All engines except 787. 561 Timing mark pointer P/N 295 000 135 754

A01B1V4

APPLICATION All engines except 787. Cylinder aligning tool P/N 290 876 904 220

F01B0H4 F01H544 A00B084

APPLICATION A) 717 engine. B) 787 engine. C) 587 and 657 engines.



01-03-1

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL TOOLS)

Crimping tool P/N 295 100 164

Engine lifting device Not sold by Bombardier Do it yourself Refer to engine removal and installation section

Slide hammer puller Not sold by BombardierSnap-on: Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4

F01J0Z4

F00B0E4


APPLICATION Contacts in AMP connectors on MPEM.F01D0A4

NOTE: This tool is also used to pull out impeller shaft seal.Protective mat P/N 295 000 129 890

Oil seal pusher P/N 290 877 740

759

APPLICATION All engines except 787. Feeler gauge 45 Not sold by BombardierSnap-on FB 300 A

F04L1V4 F01B2C4

APPLICATION 787 engine. Ring halves and ring P/N 290 876 330 (halves) (2) P/N 290 977 480 (ring)

APPLICATION All models except Explorer.F01B1K4

761 762

APPLICATION All models. Terminal remover Not sold by BombardierSnap-on TT 600-4

Safety lanyard switch tool P/N 295 000 121

775

F01B2D4

F01B1J4

F01B244



APPLICATION Boats equipped with the DESS.

01-03-2

Section 01


A) Four-pin magneto harness 763 P/N 295 000 131 B) Six-pin magneto harness 755 P/N 295 000 136

Exhaust outlet tool P/N 295 000 132

831

F01B2A4 F01B284

APPLICATION A) 587, 657 and 717, 1995 and newer. B) 787 engine. Rotary valve shaft pusher P/N 290 876 609 757

APPLICATION Exhaust nut on transom. Gear/bearing puller P/N 290 877 665 765

F04B034 F01B2B4

APPLICATION 787 engine. Handle P/N 290 877 650 758

APPLICATION 787 engine. Crankshaft protector P/N 420 876 552 764

F00B034

APPLICATION For use with pullers.

A00C3V4


01-03-3


COOLING/FUEL/OIL SYSTEMSPump gauge tester (carburetor) P/N 295 000 11430

826

Hose pincher P/N 529 032 500TYPICAL

773

20

40

2 15 1

25 3 3550

60

10

5 4

F01B234

APPLICATION All engines.F01B0X4

APPLICATION All models. Screwdriver Not sold by BombardierSnap-on SDD-143

Flexible spout (oil) P/N 414 837 300

834

F04B044

APPLICATION All models.F01B1P4

APPLICATION All models. Lighted adjustable mirror Not sold by BombardierSnap-on 50101

F01B1I4


01-03-4

Section 01


PROPULSION SYSTEMFitting P/N 295 000 086 828 Machinists square Not sold by BombardierSnap-on PMF 122

Impeller housing remover P/N 295 000 113

829

F01B0Z4 F02B064

APPLICATION All models. Slide hammer puller Not sold by BombardierSnap-on: Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4

APPLICATION Explorer. Fitting remover Not sold by Bombardier Do it yourself Refer to Shop ManualDeep socket 14 mm (9/16 in)

F01L2O4

APPLICATION Models without a jet pump support.

F01J0Z4


NOTE: This tool is also used to remove rotary valve shaft bearing.Hacksaw Not sold by BombardierSnap-on HS3

F01J2R4

APPLICATION Models without a jet pump support. Pump bearing remover P/N 295 000 144 781

F01B1M4


F01J114


01-03-5


BOAT HANDLINGValve wrench P/N 204 000 048 887 Foot pump kit P/N 204 000 047 883

APPLICATION Explorer tube. Pressure check valve P/N 204 000 043 964

F03P014

APPLICATION Explorer tube. Tie-down with ratchet 3.60 m (12 ft) long P/N 295 100 011 885

APPLICATION Explorer tube. Lift kit

P/N 295 100 014 (nickel plated) P/N 295 100 015 (stainless steel)

881 882

F04B054


F03B044

APPLICATION Explorer.

01-03-6

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS)

SERVICE PRODUCTS

0

NOTE: The numbers outlined in black (example: 1 ) are reference to product numbers from other divisions (Ski-Doo Snowmobiles and/or Sea-Doo Watercraft). Matching reference numbers indicate the same product is being used, even if the part numbers are different. Loctite is a trademark of LoctiteTM Corporation. Dow Corning is a trademark of Dow Corning Corporation.Medium strength threadlocker P/N 293 800 015Loctite 242 (blue) (10 mL)

154

High temperature threadlocker P/N 290 899 788Loctite 648 (green) (5 g)

359

Retaining compound P/N 413 703 100Loctite RC/609 (green) (10 mL)

151

LOCTITERC/609

LOCTITEREMOVABLETHREADLOCKER 242

A00B2S4 A00B324 A00B3D4

High strength threadlocker P/N 293 800 005Loctite 271 (red) (10 mL)

155

High temperature retaining compound P/N 293 800 039Loctite 642 (50 mL)

959

General purpose instant adhesive P/N 293 800 021Loctite 495

373

A00B2V4

LOCTITELOCTITE271Adhesive Sealant

SURE ASRETAINING COMPOUND 642 NET 1.69 FL .OZ. (50 ml)

Gasket stripper P/N 295 000 110(500 mL)

935

A00B2U4

F00B024

BOM BARDIERGASK ET STRIPPER295 000 110500 ml

EXTRE MELY FLAMMABLE VAPOR HARMFUL POISON

WARNING

F01B1W4

01-04-1

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS)

Solvent P/N 293 800 019Loctite Safety Solvent 755 (12 oz)

157

Pipe sealant A) P/N 293 800 018 B) P/N 293 800 013A) Loctite 592 A(50 mL) B) Loctite 567 (250 mL)

358 960

Sealant P/N 413 710 300Loctite 179 (80 mL)

961

A00B2W4

Thread sealant P/N 293 800 050A00B3M4

NEW

Primer for gasket eliminator 158 P/N 293 800 041Loctite 764

Loctite 577 (250 mL)A02B044

F00B0W4

Epoxy glue Not sold by Bombardier 3M-05900 369

Hylomar sealant P/N 293 800 001PL-32 (100 g)A00B3N4

Gun Kote Not sold by Bombardier 152A00B3F4

Gasket eliminator P/N 293 800 007Loctite 515 (50 mL)

Kal-Gard Coating & Mfg. Corp.

Dielectric grease P/N 293 550 004A00B2T4

350

Dow Corning (150 g)

Gasket eliminator P/N 293 800 038Loctite 518 (50 mL)

376

F01B164

518

F01B124

01-04-2

Section 01


Deoxit contact lubricant P/N 293 550 015NEW

Lubricant Not sold by BombardierG.E. Versilube G341M

Bombardier storage oil P/N 413 711 600NEW

(200 mL)

350 g spray can (12 x 350 g)

or Esso Beacon 325A00B1T4

Synthetic grease P/N 293 550 010(400 g)

912

SYNTHETIC GREASEF01B154

F00B0X4

Anti-seize lubricant P/N 293 800 023 924Loctite anti-seize lubricant 12 oz (454 g)

362

A02B054

Grease P/N 293 550 005(400 g)

Sea-Doo fuel stabilizer P/N 413 408 600(8 oz)

375

A00B2L4

Super lube grease P/N 293 550 014

932F01B174

NEW

FUEL STABILIZER

Super LubeR

PERMATEX INDUSTRIAL

R

BOMBARDIER LUBE P/N 293 600 016(12 x 14 oz)

913A00B3V4

M Syn ulti-Purpose the tic Lubrica nt Wi th Teflon RNe tW t. 14.5 Oz. (41 1g )s ray ! Spwn! NEWe do upsid

LUBEREPLA CES SEA-DOO LUBEANTICO T RROSIVE LUBRICAN Excellent and for high humiditysalt water nts environme

BOMBARDIER

BOMBARDIER-ROTAX injection oil P/N 413 802 900 (12 x 1 L)

915

340 g

A00B474

DANGERFLAMMABLE CONTA D. INER MAY EXPLODE IF HEATE DIRECT INHALATION OF SPRAY MAY BE HARMFUL.Sea-Doo Valcourt, / Ski-Doo Division2LO Qubec, Canada J0E

BOMBARDIER INC.

BOMBARDIER

F01B0S4

Two-stroke

Injection Oil

1 U.S. quart

F01B184

01-04-3

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS)

ADCHEM

BOMBARDIER-ROTAX injection oil 916 P/N 413 803 000 (3 x 4 L) 962 P/N 413 803 200 (205 L)

914 Jet pump oil P/N 293 600 011 (12 x 6 oz)Sea-Doo synthetic jet pump oil

Sealant adhesive P/N 293 800 033Adchem 4511 (clear)

934

SCELLANT ADHSIF PREMIRE QUALIT

ADS E ALPREMIUM SEALANT ADHESIVE

F01B1S4

JET PUMP SYNTHETIC OIL

Sealant P/N 293 800 029

936

F01B0P4

F01B2H4

The Right Stuff Gasket P/N 293 800 053NEW

Tremco clear (300 mL)

BOMBARDIER-ROTAX Formula XP-S synthetic injection oil P/N 413 711 000 (3 x 4 L) P/N 413 710 700 (205 L)

Permatex (198 g) (300 mL)

Adhesive activator P/N 293 530 036(250 mL)

931

969 970

ACTIVEUR D'ADHSIF

250 mLPOUR L'APPLICATION DE MOULURE PRESSION ET VINYLES SENSIBLES LA LORSQU'UNE MEILLEURE . ADHRENCE EST NCESSAIRE

DANGERBOMBARDIER

Two-stroke FORMULA XP-S

4 U.S. quart

SYNTHETIQUE Injection OilTwo-Stroke Oil

AVEC LA PEAU -VITER TOUT CONTACT PROLONG CONTACT. CAS DE LAVER L'EAU FROIDE EN BIEN AR. -UTILISER DANS UN ENDROIT FERM. -TENIR LE CONTENANT BIEN DES ENFANTS. -GARDEZ HORS DE LA PORTE . -CONTIENT DU TRICHLORETYLNE DE CE PRODUIT -AVERTISSEMENT ! L'INHALATION EST NOCIF. N/P 293 530 036

FABRIQU AU

F01B1Z4 F01B354

BOMBARDIER-ROTAX Formula XP-S synthetic injection oil P/N 413 710 500 (12 x 1 L)

937F00B0V4

Sea-Doo Cleaner P/N 293 110 001 (400 g) P/N 293 110 002 (4 L) 917BOMBARDIER

946 947

732 Multi-purpose sealant P/N 293 800 006Dow Corning (90 mL) (clear)

CLEANER400 g

BOMBARDIER BOMBARDIER

BOMBARDIER

FORMULA XP-S SyntheticTwo-Stroke Oil

DANGER

293 110 002

EXTREMELY FLAMMABLE. HARMFUL OR FATAL IF SWALLOWED. VAPOUR HARMFUL.

DANGER

4L

F01B1C41 liter (1.05 U.S. qt)

F01B2J4 F01B2G4

01-04-4

Section 01


Spray paint for metallic parts only 926 A) White (140 g) P/N 293 500 029 930 B) Purple (140 g) P/N 293 500 020 928 C) Grey (140 g) P/N 293 500 009Sea-Doo paint

Tube repair kit P/N 204 000 046

923

F03P024

Barge glue P/N 204 000 045(22 mL)F01B0Q4

966

Sea-Doo spray paint for gelcoat 956 A) Super white (140 g) P/N 293 500 082 933 B) Super white (140 g) P/N 293 500 076 921 C) White (140 g) P/N 293 500 041 D) Dark green (140 g) P/N 293 500 101F03P064VERTICAL FANSPRAY PATTERN ROTATE VALVE NOZZLE 1/4 TURN TO CHANGE SPRAY PATTERN HORIZONTAL FANSPRAY PATTERN

Danvern Fanspray - A Sprayon Exclusive Feature

PEIN TURE POUR

GELCOAT

T PAIN

Hypalon fabric strip P/N 204 000 042 24 x 36 in

965

DA NGE R

R DANGE

F01B1Q4

Glue for P.V.C. P/N 204 000 044 943 906

967

Gelcoat (liquid) A) Super white (1 L) P/N 293 500 075 B) White (1 L) P/N 293 500 033 C) Dark green (1 L) P/N 293 500 100

01-04-5

Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTSPERIODIC INSPECTION CHART ........................................................................................... FLUSHING AND LUBRICATION ........................................................................................... GENERAL ........................................................................................................................... PROCEDURE ...................................................................................................................... WATER-FLOODED ENGINE .................................................................................................. GENERAL ........................................................................................................................... PROCEDURE ...................................................................................................................... STORAGE...............................................................................................................................

002-02-1 02-03-1 02-03-1 02-03-1 02-04-1 02-04-1 02-04-2 02-05-1

02-01-1

Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART)

PERIODIC INSPECTION CHARTNOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency.FREQUENCY DESCRIPTIONLubrication/corrosion protection of metallic components Lubrication of locks of storage compartments covers DESS operation/DESS post and safety lanyard cap terminal condition Engine ignition timing Spark plug replacement Throttle/choke cables/accelerator pump mechanism and plunger, inspection/lubrication Flame arrester inspection Carburetor adjustment including choke/throttle cable adjustment and linkage RAVE valve (if so equipped) Water flow regulator valve (if so equipped) Oil injection pump adjustment Fuel filter and oil filter inspection Fuel filter and oil filter replacement Engine head screws, retorque Steering system and low-speed steering control system Throttle/shifter inspection/adjustment Reverse system/reverse cable adjustment Fastener tightening (flame arrester(s), carburetor(s), engine(s), exhaust system(s), etc.) Muffler(s), battery and reservoir fastening devices Fuel/oil lines, inspection, fuel system pressurization Inspect/clean engine drain hose(s) Bilge pump/deck drain hole/scupper valve inspection Battery condition MPEM connector condition Battery and starter cables Monitoring beeper/electrical connections Impeller shaft reservoir oil level/condition Impeller condition and impeller/wear ring and clearance Drive shaft boot/spline condition (both ends) Drive shaft floating seal circlip position PTO flywheel lubrication Water intake grate and weedless system lubrication/condition Hull/ride shoe condition/deck mounting bolts tightening (if applicable) Cooling system flushing Zinc anode(s) (if applicable) Bilge air blower inspection

0Every 50 hours Every 100 hours or seasonally

Every 10 hours

Every 25 hours

Replace

Every 10 hours in salt water use. These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in this chart. Daily flushing when used in salt or foul water use. Inspect anti-rattle pusher.02-02-1

Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION)

FLUSHING AND LUBRICATIONGENERALFlushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. It will help to clear sand, salt, shells or other particles in water jackets (engine, exhaust manifold, tuned pipe) and/or hoses. Flushing should be performed when the boat is not expected to be used further the same day or when the boat is stored for any extended time.

0

F00E01A

1

-

CAUTION

1. Quick hose connector

Sportster Model

Failure to flush cooling system, when necessary, will severely damage engine and/or exhaust system. Never flush a hot engine. Make sure engine operates during entire procedure.

PROCEDURE

Perform this operation in a well-ventilated area. Do not touch any electrical parts or jet pump area when engine is running. NOTE: On twin-engine models, perform the operation on each engine. 1. Clean jet pump by spraying water in its inlet and outlet and then spray a soapy solution.

;

WARNINGF04L8SB

1

TYPICAL 1. Flushing connector on transom

Challenger Model

Always remove safety lanyard cap from DESS post to prevent accidental engine starting, before cleaning the jet pump area. Engine must not be running for this operation. 2. Open rear storage compartment and remove storage tray. 3. Connect a garden hose directly to the flushing connector. To prevent water leak, ensure the rubber washer is in the boat connector. NOTE: A quick hose connector can be used to ease garden hose installation.F04L8RA

;

WARNING

1

2

TYPICAL 1. Flushing connector for port engine (LH side) on transom 2. Flushing connector for starboard engine (RH side) on transom

02-03-1


Sportster 1800 Model

Speedster and Challenger Models

F10L06A

1

2

F04E1AA

1

1. Flushing connector for port engine 2. Flushing connector for starboard engine

Challenger 1800 Model

TYPICAL SPORTSTER AND CHALLENGER MODELS 1. Flushing connector in engine compartment area with its cap (starboard engine for Challenger model)

F04L5LA

1

2F04E1BA

1

1. Flushing connector for port engine 2. Flushing connector for starboard engine

The engine can also be flushed from the flushing connector that is located on the edge of the engine compartment. See illustrations.

CHALLENGER MODEL ONLY 1. Flushing connector in engine compartment area with its cap (port engine on Challenger model only)

02-03-2


Challenger 1800 Model

717 Engine1

F04E12A

1

F04E14A

2

1. Flushing connector for port engine (LH side)

1. T-fitting 2. Hose pincher right after the T-fitting

787 Engine

F04E1GA

1F04E15A

1. Flushing connector for starboard engine (RH side)

2

1

All Models For proper flushing from this location, it is necessary to prevent water from going out directly by the flushing connector on the transom. Install a hose pincher (P/N 529 032 500) on the hose between the transom and the T-fitting as shown.

1. T-fitting 2. Hose pincher right after the T-fitting

-

CAUTION

Do not open water tap yet. 4. Start the engine then immediately open the water tap.

-

CAUTION

Always start the engine before opening the water tap to prevent engine flooding. Open water tap immediately after engine is started to prevent overheating.

02-03-3


5. Run the engine about 3 minutes at a fast idle around 3500 RPM. 6. Pull plug from air intake silencer cover.2 1

8. If the lubrication is done for the storage, close fuel valve (if so equipped) to run engine out of fuel after approximately half a minute of lubrication.

-

CAUTION

If the lubrication is done for the storage, immediately stop water flow before engine dies when engine begins to run irregularly. 9. Close the water tap then stop the engine.

F01F25B

CAUTION

Always close the water tap before stopping the engine. 10. Remove garden hose. Ensure the rubber washer remains in the boat hose connector.

1. Air intake silencer cover 2. Pull plug

7. Spray BOMBARDIER LUBE lubricant through air intake silencer cover keeping engine at fast idle. NOTE: If the lubrication is done for the storage, use BOMBARDIER storage oil (P/N 413 711 600) instead.

-

CAUTION

If used, remove the quick hose connector from boat. 11. Remove hose pincher from water outlet hose.

-

CAUTION

Serious engine damage can occur if hose pincher is not removed. 12. Wipe up any residual water from the engine. 13. Remove spark plug cables and connect them on the appropriate grounding device.

Always use spark plug cable grounding device when removing spark plugs.F00M01A

;

WARNING

1

TYPICAL 1. Spray BOMBARDIER LUBE (storage oil when performing storage lubrication)

NOTE: Lubrication of engine should be done at least for one minute.

02-03-4


2

1

14. Remove both spark plugs and spray BOMBARDIER LUBE lubricant into each cylinder. 15. Crank the engine a few turns to distribute the oil onto cylinder wall. 16. Apply anti-seize lubricant on spark plug threads then reinstall them. 17. Properly reconnect spark plug cables to spark plugs. 18. Reinstall plug on air intake silencer cover. NOTE: Engine fogging should be done with BOMBARDIER storage oil (P/N 413 711 600) whenever the boat is to be stored for a few days or a long period.

F04H5ZA

-

CAUTION

TYPICAL 1. Electrical box 2. Connect spark plug cables to grounding device

Never leave rags or tools in the engine compartment or in the bilge. 19. Reinstall tray and close storage compartment cover.1

F09H01A

TYPICAL 1. Connect spark plug cables on engine grounding device

02-03-5

Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE)

WATER-FLOODED ENGINEGENERALIf engine is water-flooded, it must be serviced within a few hours after the event. Otherwise engine will have to be overhauled.

0CAUTION

-

CAUTION

Failure to do this may result in damage to the engine. If you must tow a stranded boat in water and do not have a hose pincher be sure to stay well below the maximum towing speed of 24 km/h (15 MPH). Snugly install the hose pincher on the hose as shown in the following illustration.1

A water-flooded engine must be properly lubricated, operated then lubricated again, otherwise parts will be seriously damaged.

Towing the Boat in WaterThe maximum recommended towing speed is 24 km/h (15 MPH). When towing your boat in water, pinch the water supply hose from the jet pump housing to the engine with a hose pincher (not supplied) (P/N 529 030 400) shown in the following illustration.

F10E01A

717 ENGINE 1. Install hose pincher on this hoseF01B23A

1

NOTE: If for some reason, you operate the jet boat over 24 km/h (15 MPH) with only one engine running, the non-running engine should have its water supply hose plugged. This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system. Without the engine running there isnt any exhaust pressure to carry the water out the exhaust outlet.

F04E0QA

787 ENGINE 1. Install hose pincher on this hose

02-04-1


-

CAUTION1

When finished towing the boat you must remove the hose pincher before operating it. Failure to do so will result in damage to the engine.

Operating the Boat with Only One EngineIf in an emergency situation the jet boat is operated with only one engine, special care must be taken. See above in Towing the Boat in Water for complete procedure.

PROCEDURECheck fuel and oil reservoirs for water contamination. If necessary, siphon and refill with fresh fluids. Turn fuel valve(s) to OFF position (if so equipped) then drain fuel filter bowl(s). Refer to FUEL SYSTEM, 06-02. Drain bilge if water is present. Remove spark plug cables and connect them on the appropriate grounding device.

F09H01A

Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device.2 1

;

WARNING

TYPICAL 1. Connect spark plug cables on engine grounding device

Remove spark plugs and dry them with a clean cloth. A contact cleaner spray can be used. It may be preferable to replace spark plugs. Do NOT install spark plugs on engine. Crank engine(s) to drain crankcase.

-

CAUTION

Be careful when cranking engine(s), water will spray out from spark plug holes. Spray BOMBARDIER LUBE lubricant (P/N 293 600 006) into spark plug holes. Crank engine(s) again.

F04H5ZA

Challenger 1800 Model There is an oil passage from the crankcase toward the balance shaft gear and bearing. Therefore, water that enters the engine, can flow through this passage and be trapped in a cavity. Proper draining of this water is required. Refer to STORAGE 02-05 and look for Engine Draining.

TYPICAL 1. Electrical box 2. Connect spark plug cables to grounding device

02-04-2


All Models Reinstall spark plugs and spark plug cables then safety lanyard cap on DESS post. Turn fuel valve(s) to ON position (if so equipped). Start engine(s). It may be necessary to use the choke. If engine(s) do not start, repeat previous steps as necessary.

-

CAUTION

To avoid starting motor overheating, the cranking period should not exceed 5-10 seconds and a rest period of 30 seconds should be observed between cranking cycles. NOTE: If engine(s) do not start after several attempts, check ignition system for spark occurrence. Refer to ELECTRICAL SYSTEM 08-03. Check crankshaft if needed, it can become misaligned or deflected. Refer to ENGINE 04-06. After engine has started, spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running.

F00M01A

1

1. Spray BOMBARDIER LUBE

Run engine until it reaches its normal operating temperature.

-

CAUTION

Water must be supplied to cool engine(s) through the boat flushing connector(s).

02-04-3

Section 02 MAINTENANCE Subsection 05 (STORAGE)

STORAGENOTE: On twin-engine models, perform the operation on each engine.

0787 Engine

Engine DrainingCheck engine drain tube running from engine manifold fitting to outlet socket. Make sure it contains no sand or other particles and that it is not obstructed, so that water can leave the engine. Clean tube and outlet socket as necessary.

-

CAUTION

Water in engine drain tube must be free to flow out, otherwise water could be trapped in engine. Should water freeze in engine, severe damage will occur. Check engine drain tube for obstructions.F04E0VA

1

717 Engine

TYPICAL 1. Drain tube must be clean

787 Engine Only In the event water entered the engine during the season (water flood), water may have been trapped in the oil cavity of the balance shaft gear and bearing. Draining is required to prevent any potential damage. Proceed as follows.

1

CAUTION

Failure to properly drain this cavity may result in freezing inside engine leading to damage of cylinder base gasket.F04E16A

1. Drain tube must be clean

Remove the filler plug of the counterbalance shaft on the engine crankcase.

02-05-1


-

CAUTION

Fuel stabilizer should be added prior to engine lubrication to ensure carburetor protection against varnish deposit.

Fuel is flammable and explosive under certain conditions. Always work in a well-ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the boat.F07D06A

;

WARNING

1

1. Remove filler plug

Always turn the fuel valve to OFF position (if so equipped) when storing the boat.

Insert a wire through oil level hole to check oil condition. A whitish oil indicates water contamination and must be replaced. In order to replace the oil, remove the drain plug of the counterbalance shaft located on the PTO side of the lower crankcase.

Cooling System Flushing and Engine Internal LubricationCooling system has to be flushed with fresh water to prevent salt, sand or dirt accumulation which will clog water passages. Engine must be lubricated to prevent corrosion on internal parts. For proper procedure, refer to MAINTENANCE 02-03.

Propulsion SystemLubricant in impeller shaft reservoir should be drained. Reservoir should be cleaned and refilled with 70 mL (2.4 U.S. oz) of BOMBARDIER synthetic 75W 90 GL5 polyolester oil (P/N 293 600 011). Refer to PROPULSION SYSTEM 09-03.F06D2CA

1

1. Drain plug

-

CAUTION

Drain completely the crankcase oil of the counterbalance shaft. Reinstall drain plug with Loctite 515. Add 30 mL (1 oz) of SAE 30 motor oil. Reinstall filler plug.

Use only BOMBARDIER jet pump oil or equivalent synthetic gear oil, otherwise component service life could be reduced. Do not mix oil brands or types. Lubricate PTO flywheel at grease fitting with synthetic grease (P/N 293 550 010).

Fuel SystemAll Engines Sea-Doo Fuel Stabilizer (P/N 413 408 600) should be added in fuel tank to prevent fuel deterioration and carburetor gumming. Follow manufacturers instructions for proper use. NOTE: Fuel stabilizer should be added prior engine lubrication to ensure carburetor protection against varnish deposit.02-05-2

-

CAUTION

Do not lubricate excessively. Immediately stop when a slight movement is noticed on rubber boot.


Antifreezing ProtectionIn cool regions (where freezing point temperature may be encountered), cooling system must be filled with water and antifreeze solution. (40% water, 60% antifreeze).

-

CAUTION

Antifreeze mix must be fed in cooling system. Otherwise water will freeze in engines/exhaust system causing severe damage. NOTE: When available, it is recommended to use biodegradable antifreeze compatible with internal combustion aluminum engines.This will contribute to protect the environment.

F01I0BA

1

1. Grease PTO flywheel

Boat Cleaning

CAUTION

-

CAUTION

Never leave any clothing, tool or other objects in engine compartment.

Always use ethylene-glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines. NOTE: The engine will not have to run during this operation but should have been ran before to exhaust water from cooling system components. Some hoses have to be plugged to prevent draining, before filling cooling system jackets with the antifreeze. Use hose pinchers (P/N 529 030 400).

Clean the bilge with hot water and mild detergent or with bilge cleaner. Rinse thoroughly. Lift front end of boat to completely drain bilge. If any repairs are needed to the body or to the hull, touch up paint and Gelcote repair kit are available. Replace damaged labels/decals. Wash the body and the trailer with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull. Apply a nonabrasive wax.

-

CAUTION

Never clean apparent fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc. Stains may be removed from seats and fiberglass with Knights Spray-Nine* from Korkay System Ltd or the equivalent.

F01B23A

Air will escape from bleed hose on tuned pipe.

02-05-3


717 Engine Install a hose pincher and firmly tighten on: water injection hose at tuned pipe

1

3

4

2F04E17A

1. 2. 3. 4.

Hose pincher right after T-fitting T-fitting Hose pincher on this hose Hose pincher on drain tube

1

787 Engine Install a hose pincher and firmly tighten on: engine drain tube coming from cylinder base before T-fitting hose right after T-fitting hose on cylinder head4 2 1 3

F04E0YA

1. Hose pincher on injection hose going to tuned pipe

engine drain tube coming from exhaust manifold before T-fitting hose right after T-fitting hose on cylinder head

F04E0TC

TYPICAL 1. Hose pincher right after T-fitting 2. T-fitting 3. Hose pincher on this hose 4. Hose pincher on drain tube

02-05-4


All Engines NOTE: Hose pinchers must be firmly tightened so that no antifreeze can flow through the blocked hoses. If you hear the liquid flowing in the muffler immediately after starting pouring antifreeze, it indicates that antifreeze is bypassing the engine/ tuned pipe water jackets. To correct this, firmly retighten hose pinchers. Unscrew cap from flushing fitting on the edge of engine compartment and insert a funnel into flushing fitting. Pour about 2 liters (1/2 gal) of antifreeze solution through the funnel. Let the antifreeze enough time to flow. Moving the hose with the T-fitting should accelerate the flow.

787 Engine

F04E0TA

1

TYPICAL 1. Pour antifreeze until it flows out here

717 Engine Remove hose pincher from injection hose at tuned pipe and continue to pour approximately 200 mL (7 oz). This will allow antifreeze to flow inside muffler to protect it.F04E0SA

Pour antifreeze until you see it flowing out of tuned pipe bleed hose. At this time only, the entire circuit is filled with antifreeze.

717 Engine1

F04E0WA

1

1. Remove hose pincher

F04E10A

1. Pour antifreeze until it flows out here

02-05-5


787 Engine At this time, remove hose pincher hose at engine head and continue to pour approximately 200 mL (7 oz). This will allow antifreeze to flow through water regulator valve toward muffler in order to protect it.

BatteryFor battery removal, cleaning and storage, refer to ELECTRICAL 08-07.

Anticorrosion TreatmentWipe off any residual water in the engine compartment. Spray BOMBARDIER LUBE lubricant over all metallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant.

Finalizing StorageThe engine storage cover should be left opened during storage (disconnect gas shocks from cover to prevent full opening). Remove storage tray. Place it on deck. This will avoid engine compartment condensation and possible corrosion. If the boat is to be stored outside, cover it with a vented opaque tarpaulin to prevent sun rays and grime from affecting the plastic components or boat finish as well as to prevent dust accumulation. Unscrew the drain plugs for the storage. Lift the boat so that the bow is higher then the stern to allow draining of the bilge. Safely block it in this position.

F04E0TB

1

TYPICAL 1. Remove hose pincher

All Engines When finished, remove all remaining hose pinchers. Most of the antifreeze will drain out from flushing fitting and jet pump nozzle when removing hose pinchers. Use a suitable container to recover it. Dispose antifreeze as per your local laws and regulations. NOTE: Although most antifreeze will drain out, it has flowed to mix with water that was possibly trapped in cooling system cavities thus preventing freezing problems. NOTE: For pre-season preparation, drain antifreeze from cooling system prior to launching boat in water as explained above.

-

CAUTION

The boat must never be Ieft in water for storage. Never leave the boat stored in direct sunlight. UV radiation will dull finishes. Make sure to turn OFF bilge pump and blower.

02-05-6

Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING)

TROUBLESHOOTINGNOTHING IS WORKING IN THE ELECTRICAL SYSTEMOTHER OBSERVATION POSSIBLE CAUSE REMEDY

0

The following chart is provided to help in diagnosing the probable source of troubles. It is a guideline only and does not detail all causes for all problems.

No beeps are heard when installing Main disconnect switch is turned Verify and turn ON. safety lanyard on DESS post OFF.

ENGINE WILL NOT STARTOTHER OBSERVATION Engine does not turn over POSSIBLE CAUSE Safety lanyard cap worn or removed. DESS operation non functional. REMEDY Replace/reinstall. If 2 short beeps are not heard when installing safety lanyard, refer to section 08-06. Check, refer to section 08-06. Check wiring then replace fuse. Check wiring then replace fuse. Check wiring and MPEM refer to section 08-06 Replace fuse. Check/recharge. Check/clean/tighten. Check, refer to section 02-04. Check, refer to section 08-06. Check/repair as needed. Check, refer to section 09-02. Check/clean out debris. Check/charge/replace. Check/tighten connections. Check/clean pump. Inspect, refer to section 09-02. Check, refer to section 02-04. Check compression, refer to section 04-06. Check, refer to section 08-06.

Start/stop button defective. Burnt main fuse(s). Burnt MPEM supply fuse. MPEM supply fuse keeps on burning. Discharged battery. Battery connections. Water/fuel hydrolock. Starter or solenoid. Seized engine. Seized jet pump. Jammed jet pump. Engine turns slowly Discharged/weak battery. Battery connections. Restriction in jet pump. Seizure in jet pump. Partial engine hydrolock. Partial engine seizure. Worn starter.

Wear ring of jet pump improperly Check/replace, refer to section installed. 09-02.03-01-1


ENGINE WILL NOT START (CONTD)OTHER OBSERVATION Engine turns over POSSIBLE CAUSE Fuel tank empty. Fuel water-contaminated. Dirty fuel filter. Fouled spark plugs. Water in engine. Misuse of throttle lever(s) (fuel flooded). Misuse of choke (fuel flooded). Carburetion. Ignition. Engine flooded. Refill. Renew supply. Clean/replace. Replace. Check, refer to section 02-04. Avoid moving throttle lever(s) several times when engine(s) is (are) not running. Use only with cold engine. Check, refer to section 06-04. Check, refer to section 04-04 and 08-04. Check, refer to section 06-04. REMEDY

Needle valve stuck open. Choke(s) not closing completely. Adjust for complete closure.

Excessive rotary valve clearance. Check, refer to section 04-07. Internal engine damage. Sheared flywheel key. Incorrect rotary valve timing. No spark at spark plugs Grounded BLACK/RED/GREEN wire (additional BLACK/RED wire on twin-engine models) connecting to MPEM on 717 engine only. Unproperly grounded MPEM BLACK wire. Defective MPEM. Faulty magneto system. Check, refer to section 04-06 and 04-07. Check timing mark, refer to section 04-04. Check, refer to section 04-07. Repair.

Repair. Check, refer to section 08-04. Check wiring and ignition system, refer to section 04-04.

03-01-2


ENGINE MISFIRES, RUNS IRREGULARLYOTHER OBSERVATION Weak spark POSSIBLE CAUSE Fouled, defective, worn spark plugs. REMEDY Check/verify heat range/gap/ replace.

Faulty MPEM or start/stop switch. Check, refer to section 08-04. Faulty ignition. Sheared flywheel key. Lean fuel mixture Dry spark plug (except when water fouled) Fuel level low. Stale or water fouled fuel. Fuel filter dirty or restricted. Carburetion dirty or out of adjustment. Leaking crankshaft seal(s), rotary valve cover O-ring(s). Fuel valve restricted or partially opened. Loose carburetor. Rich fuel mixture Fouled spark plug Partially closed choke. Flame arrester dirty or restricted. Carburetor adjustment. Check, refer to section 04-04. Check timing mark, refer to section 04-04. Check/refill. Check/siphon and refill. Check/clean/replace. Check/clean/adjust, refer to section 07-03. Check/test/replace, refer to engine section 03-02. Check/replace/turn fully ON. Tighten carburetor(s). Check/adjust choke cable. Check/replace. Check/adjust, refer to section 06-04.

Leaking check valve at injector of Check, refer to section 06-04. accelerator pump. Main jet loose. Rotary valve shaft seal leaking. Oil pump adjustment. Boat transportation. Worn needle(s) and seat(s). Excessive rotary valve clearance. Difficult to start Incorrect rotary valve timing. Excessive rotary valve clearance. Check, refer to section 06-04. Check/replace, refer to section 06-04. Check/adjust, refer to section 07-03. Turn fuel valve to OFF (if so equipped). Check, refer to section 06-04. Check, refer to section 04-07. Check/adjust, refer to section 04-07. Check, refer to section 04-07.

03-01-3


ENGINE OVERHEATSOTHER OBSERVATION Monitoring beeper continuously sounds POSSIBLE CAUSE REMEDY

Restricted jet pump water intake. Check/clean. Cooling system restriction. Check/flush, refer to section 02-03.

Grounded temperature sensor or Check/repair/replace. sensor wire.

ENGINE CONTINUALLY BACKFIRESOTHER OBSERVATION Weak spark POSSIBLE CAUSE Fouled, defective spark plugs. MPEM malfunction. Ignition timing Incorrect setting. Flywheel key sheared. Rotary valve Carburetor Engine Timing incorrect. Carburetion too lean. REMEDY Clean/replace. Check, refer to section 08-04. Check/reset, refer to section 04-04. Check/replace. Check/reset, refer to section 04-07. Check/adjust, refer to section 06-04.

Intake leak/crankshaft seal failure. Pressure check engine, refer to section 04-03.

ENGINE DETONATION OR PINGINGOTHER OBSERVATION Ignition POSSIBLE CAUSE Timing too far advanced. Spark plug heat range too high. Engine temperature Engine overheating. Poor quality fuel. REMEDY Check/reset. Check/change to correct range. Check, refer to section 02-04 and 05-02 or to engine overheat. Use good quality fuel.

03-01-4


ENGINE LACKS ACCELERATION OR POWEROTHER OBSERVATION POSSIBLE CAUSE Weak spark. Carburetion, jetting too rich/lean/ accelerator pump not working properly. Throttle does not open fully. Low compression. Exhaust system restriction. Water in gas or oil. Debris in needle valve. Jet pump related problem. REMEDY Check/replace, refer to section 04-04. Check/adjust, refer to section 06-04. Check/readjust. Check/repair, refer to section 04-06. Check/clean. Check/siphon/replace. Check/clean, refer to section 06-04. Refer to POOR START, ACCELERATION OR PERFORMANCE OF BOAT below. Check, refer to section 04-07. Check/adjust, refer to section 05-02. Check, refer to section 04-06. Check, refer to section 04-06.

Twisted crankshaft. Cooling system water flow regulator valve (787 engine). Engine revs lower than its maximum RAVE valve does not open. operational RPM (787 engine) Peak performance is delayed until higher RPM range is reached (787 engine) RAVE valve is stuck open.

03-01-5


POOR START, ACCELERATION OR PERFORMANCE OF BOATOTHER OBSERVATION Jet pump cavitation: Poor start/acceleration of boat Poor top performance of boat and/or stator vanes erosion Jet pump ventilation: Trailing edge of impeller is damaged. Leading edge of impeller is damaged. Check/replace. Check/replace. POSSIBLE CAUSE REMEDY

Jet pump improperly sealed to Check/reseal/install a new ride shoe; insufficient sealant on neoprene seal. the ride shoe or missing neoprene seal (or sealing in this area). Check/replace.

Engine RPM is high and boat is slow Through-hull seal around drive to accelerate shaft; air comes from inside the boat. OR engine does not react quickly when pushing on throttle lever (assuming that engine is correct) OR engine does not keep a steady top RPM (assuming that engine is correct) Other problem with jet pump (related to performance): Boat does not reach its top speed A wear ring (jet pump) with excessive clearance. A damaged or worn jet pump. A damaged impeller. An impeller with the wrong pitch (too low). Missing or damaged impeller boot. Weeds or debris in intake grate, jet pump intake or impeller. Retaining screws of ride shoe or sealing of weedless system cable/housing; air comes from inside the boat. Retaining screws of intake grate; air comes from inside the boat.

Check/reseal.

Check/reseal.

Check/replace. Check/replace. Check/replace. Check/replace. Check/install. Check/clean.

03-01-6


ABNORMAL NOISE FROM PROPULSION SYSTEMOTHER OBSERVATION POSSIBLE CAUSE Low oil level in jet pump. REMEDY Check/troubleshoot source of leak/refill supply, refer to section 09-02. Check/replace, refer to section 09-03. Check/replace, refer to section 09-03. Check/replace, refer to section 04-05.

Drive shaft protector rubbing against drive shaft or impeller boot. Damaged or bent drive shaft. Broken motor mounts.

03-01-7

Subsection 01

Section 04 ENGINE (TABLE OF CONTENTS)

TABLE OF CONTENTSLEAK TEST............................................................................................................................. GENERAL ........................................................................................................................... PREPARATION ................................................................................................................... TESTING PROCEDURE ..................................................................................................... ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................ REMOVAL AND INSTALLATION .......................................................................................... GENERAL ........................................................................................................................... REMOVAL FROM JET BOAT ............................................................................................. CLEANING ......................................................................................................................... INSTALLATION.................................................................................................................. MAGNETO SYSTEM ............................................................................................................. GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... ASSEMBLY......................................................................................................................... INSTALLATION ..................................................................................................................

004-02-1 04-02-1 04-02-1 04-02-1 04-02-5 04-03-1 04-03-1 04-03-1 04-03-5 04-03-5 04-04-1 04-04-3 04-04-3 04-04-6 04-04-8 04-04-8 04-04-9

TOP END ................................................................................................................................ 04-05-1 ENGINE DESCRIPTION ..................................................................................................... 04-05-3 GENERAL ........................................................................................................................... 04-05-3 DISASSEMBLY................................................................................................................... 04-05-5 CLEANING ......................................................................................................................... 04-05-8 INSPECTION ...................................................................................................................... 04-05-8 ASSEMBLY......................................................................................................................... 04-05-12 ADJUSTMENT ................................................................................................................... 04-05-18 BOTTOM END........................................................................................................................ 04-06-1 DISASSEMBLY................................................................................................................... 04-06-3 CLEANING ......................................................................................................................... 04-06-7 INSPECTION ...................................................................................................................... 04-06-8 ASSEMBLY......................................................................................................................... 04-06-11 ROTARY VALVE ..................................................................................................................... GENERAL ........................................................................................................................... INSPECTION ON BOAT..................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... 04-07-1 04-07-2 04-07-2 04-07-4 04-07-6 04-07-6 04-07-604-01-1

Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS)

EXHAUST SYSTEM ............................................................................................................... TUNED PIPE REMOVAL ..................................................................................................... EXHAUST MANIFOLD REMOVAL..................................................................................... MUFFLER AND OTHER COMPONENTS REMOVAL ........................................................ TUNED PIPE REPAIR .......................................................................................................... INSTALLATION ...................................................................................................................

04-08-1 04-08-6 04-08-7 04-08-7 04-08-9 04-08-10

04-01-2

Section 04 ENGINE Subsection 02 (LEAK TEST)

LEAK TESTGENERALA Sea-Doo Engine Leak Test Kit (P/N 295 500 352) is available to help diagnose engine problems such as engine seizure, poor performance, oil leakage, etc. Before disassembling any components of the engine, it is important to perform a leakage test to determine which part is defective. It is also very important after servicing the engine, even for a complete engine rebuilt, to perform another leakage test; at this stage, it may avoid further engine problems and minimizing the risk of having to remove and reinstall the engine again. Static bench testing is the most effective way to conduct a leakage test. Inboard testing does not allow complete access to, and observation of all engine surfaces and should be avoided whenever possible. On 717 and 787 engines, cylinders cannot be verified individually due to leakage from one cylinder to another through a common intake manifold. When installing hoses of the Engine Leak Test Kit, use the collars provided in the kit to ensure a proper sealing. When pressurizing the engine, first confirm that the components of the Engine Leak Test Kit are not leaking by spraying a solution of soapy water on all hoses, connections, fittings, plates, etc. If there is a leak, bubbles will indicate leak location. Three areas of the engine will be tested in sequence as per the diagnostic flow chart (see the end of this subsection). 1. Engine Cooling System 2. Bottom End and Top End 3. Rotary Valve Shaft NOTE: If a leak is found, it is important to continue testing as there is the possibility of having more than one leak. Continue pumping to compensate for the air lost to find another leak.

0PREPARATIONVerify fuel system for leaks.

x

WARNING

If any fuel leak is found, do not start the engine. Correct the leak and wipe off any fuel spillage. Do not use electric powered tools unless fuel system has passed pressure test. Disconnect battery BLACK negative cable.

x

WARNING

Always disconnect battery cables in the specified order, BLACK negative cable first. Disconnect battery RED positive cable.

TESTING PROCEDUREEngine Cooling SystemRemove the tuned pipe. Remove the exhaust manifold gasket and ensure the surface is clean. Disconnect engine cooling hoses. Install the appropriate exhaust manifold plate (no. 1 for the 787 engine and no. 2 for 717 engine) from the Engine Leak Test Kit. Tighten plate using fasteners provided in the kit. Use hoses provided in the kit and install them on the engine. Install pump using reducer and appropriate tube(s) as necessary.

04-02-1


1

4 3

F01B2UB

1

2F01B2WA

717 ENGINE REAR VIEW 1. Engine drain hose blocked with a hose pincher

2 1

787 ENGINE 1. Loop hose and use clamps 2. Hose with clamps. Plug end with a screw 3. Block engine drain hose with a hose pincher 4. Use 2 washers with exhaust manifold stud

F01B2VA

3

NOTE: Water is not required for testing. Activate pump and pressurize engine cooling system to 5 PSI (34 kPa). Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking and pressure drops, verify all external jointed surfaces, temperature sensor and the O-ring between the spark plug area and the engine cylinder head cover. If none of these components are leaking, there is an internal leak and it can be detected with Bottom End and Top End testing.

717 ENGINE FRONT VIEW 1. Loop hose and use clamps 2. Use 2 washers with exhaust manifold stud 3. Hose with adapter and nipple

Bottom End and Top EndRemove the carburetor(s) and gasket(s). Make sure the surface of the intake manifold (717 engine) or rotary valve cover (787 engine) are clean. Install the intake plate(s) no. 3 with fasteners from the kit and tighten adequately. On engines with the RAVE system, remove the RAVE valves and gaskets. Install plates no. 4 with fasteners from the kit and tighten adequately. NOTE: On engines with the RAVE system, the boot and O-ring can be checked for leakage with the valve in place. Simply remove the cover to expose the boot. Make sure the spark plugs are installed and tightened. Block pulse hose using a hose pincher.

04-02-2


NOTE: Do not block the rotary valve shaft hoses. Install pump to the exhaust plate fitting.3

1

2F01B2ZA

717 ENGINE 1. Intake plates 2. Pulse hose blocked with a hose pincher 3. Exhaust plate

2

cylinder head gasket cylinder base gasket crankcase halves rotary valve cover engine plugs exhaust manifold intake manifold (717 engine) oil injection pump (717 engine) Check also small oil injection pump lines and fittings; check for air bubbles or oil column going toward pump, which indicate a defective check valve. If the above mentioned components are not leaking, block both oil hoses of the rotary valve shaft using hose pinchers. NOTE: If leakage stops at this point, proceed with rotary valve shaft testing. If there is still some leakage, remove the PTO flywheel and verify crankshaft outer seal. If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft outer seal. Proceed with the rotary valve shaft testing if the crankshaft outer seals are not leaking.

4 1

Rotary Valve ShaftNOTE: It is preferable to drain the injection oil from the rotary valve shaft, but it is not mandatory. Block oil return hose of the rotary valve shaft with a hose pincher.

3F01B30A

787 ENGINE 1. Intake plates 2. RAVE valve plates 3. Pulse hose blocked with a hose pincher 4. Exhaust plate

Activate pump and pressurize engine to 5 PSI (34 kPa).

-

CAUTION

Do not exceed this pressure. Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking, verify engine jointed surfaces as per following areas: spark plugs

F01B31A

1

717 ENGINE 1. Oil return hose blocked with hose pincher04-02-3


1

1

F01B32A

F01B34A

787 ENGINE 1. Oil return hose blocked with hose pincher

787 ENGINE 1. Pump with reducer and nipple

Install pump with reducer and nipple to the oil supply hose of the rotary valve shaft.

F01B33A

1

717 ENGINE 1. Pump with reducer and nipple

Activate pump and pressurize to 5 PSI (34 kPa). Check plug of the rotary valve shaft in crankcase. Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal. Remove MAG side spark plug. If pressure drops, it indicates a defective MAG side crankshaft inner seal. If the above mentioned components are not leaking and there is a pressure drops, remove the rotary valve cover. Check the seal of the rotary valve shaft. If the rotary valve shaft is not leaking, it could indicates a defective engine casting. Disassemble engine and carefully check for defects in castings. Pay attention to tapped holes which may go through sealed areas of engine and thus lead to leakage.

04-02-4


ENGINE LEAKAGE DIAGNOSTIC FLOW CHARTPRESSURIZE ENGINE COOLING SYSTEM YES

IS SYSTEM LEAKING? NO PRESSURIZE ENGINE

CHECK TESTING KIT

REPLACE O-RING OF CYLINDER HEAD AND/OR CYLINDER BASE GASKET

NO

IS ENGINE LEAKING? YES CHECK TESTING KIT

RECHECK ENGINE SEALING

CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. YES

ANY LEAK FOUND?

REPLACE GASKET OR O-RING, RE-SEAL LEAKING AREA

CHECK SMALL OIL LINES OF INJECTION PUMP

AIR BUBBLES FOUND OR OIL MOVING TOWARD PUMP?

YES

REPLACE CHECK VALVE(S) / LINE(S)

BLOCK LARGE HOSES OF ROTARY VALVE GEAR LUBRICATION SYSTEM NO IS ENGINE STILL LEAKING?

CHECK TESTING KIT

CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES YES

PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE

ARE SEALS LEAKING? NO PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE

REPLACE DEFECTIVE SEAL(S)

YES IS RESERVOIR LEAKING?

RECHECK ENGINE SEALING

UNSEAL PTO CYLINDER AND MAG CYLINDER SEPARATELY BY REMOVING THE APPROPRIATE SPARK PLUG

IS RESERVOIR LEAKING? NO CHECK TESTING KIT CHECK FOR LEAKAGE AT ROTARY VALVE SHAFT CRANKCASE PLUG

YES

REPLACE DEFECTIVE SEAL(S)

YES IS RESERVOIR LEAKING?

ANY LEAK FOUND? NO REMOVE ROTARY VALVE COVER, CHECK SEAL OF ROTARY VALVE SHAFT

YES

REPLACE OIL SEAL OF ROTARY VALVE SHAFT END, OR REPLACE CAP

NO

YES IS SEAL LEAKING?

REPLACE DEFECTIVE SEAL

CAREFULLY INSPECT ENGINE CASTINGS, PARTICULARLY THE THREADED HOLE AREAS

ANY LEAK FOUND?

YES

REPLACE DEFECTIVE PARTS

ENGINE IS PERFECTLY SEALED INTERNALLY

F00D07S

04-02-5

Subsection 03

Section 04 ENGINE (REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATIONGENERALIt is not necessary to remove engine from jet boat for TOP END or PTO FLYWHEEL AND MAGNETO servicing. However, engine removal is necessary to repair BOTTOM END AND ROTARY VALVE.

0

Twin-engine Models Although basically the same engines are used for port and starboard, there are differences in hardware, such as throttle/choke cable length, fuel/oil lines, electrical wiring etc. Properly identify engines prior to removal.

First, remove BLACK negative cable from battery(ies), then RED positive cable. Disconnect thermosensor wire and spark plug cables. Disconnect magneto wires at connector of engine. Disconnect rectifier/voltage regulator wires.

REMOVAL FROM JET BOATNOTE: To ease working in engine compartment, it is suggested to remove rear storage compartment cover from boat (some models features a removable pin on the hinge). In order to remove engine from jet boat proceed as follows.

-

F01D8RA

1

CAUTION

Whenever removing engine from jet boat, engine/jet pump alignment must be performed at installation.

TYPICAL 717 ENGINE 1. Unplug connector

Jet Pump RemovalTo withdraw jet pump unit assy, refer to PROPULSION, 09-02.

Electrical Connections

x

WARNING1

Always disconnect starter or battery cables exactly in the specified order, BLACK negative cable first. Electrolyte or fuel vapors can be present in the engine compartment and a spark might ignite them and possibly cause personal injuries. It is recommended to disconnect electrical connections prior to disconnecting fuel lines. Unfasten battery top brace (retaining strap and remove battery box cover on Sportster).

F06D0FA

TYPICAL 787 ENGINE 1. Unplug connector

Air Intake SilencerTo remove air intake silencer, refer to FUEL SYSTEM 06-03.

04-03-1

Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION)

Carburetors and Fuel PumpSportster 1800 and Challenger 1800 Properly identify hoses on fuel pump then disconnect hoses. All Models To remove carburetors, refer to FUEL SYSTEM 06-04. Do not disconnect throttle cable. It will save time for reassembly.Move carburetors away from engine.F01D32A

1

TYPICAL 717 ENGINE 1. Shim

1

3

3 2

F04D0ZA

1F01D8PA

TYPICAL 787 ENGINE SHOWN 1. Move carburetors away

Cooling SystemDisconnect cooling syst

sportster 1800

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