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BOMBARDIER Sea-Doo SPORTSTER LE Shop Manual Supplement

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Summary of Contents for BOMBARDIER Sea-Doo SPORTSTER LE

  • Page 1 219 100 097...
  • Page 2 Shop Manual Supplement SPORTSTER LE Use in conjunction with Shop Manual Volume 1 (P/N 219 100 097)
  • Page 3 National Library of Quebec trimester 2000 National Library of Canada 2000 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2000 Printed in Canada ®...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE ............................ INTRODUCTION ............................. SERVICE TOOLS 01 – Table of Contents ................. 01-01-1 02 – Mandatory Service Tools.............. 01-02-1 03 – Optional Service Tools..............01-03-1 MAINTENANCE 01 – Table of Contents ................. 02-01-1 02 –...

  • Page 5: Section Subsection Page

    TABLE OF CONTENTS SECTION SUBSECTION PAGE PROPULSION 01 – Table of Contents................. 09-01-1 SYSTEM 02 – Jet Pump..................09-02-1 03 – Drive System ................09-03-1 04 – Reverse System............See Shop Manual * 05 – Weedless System............See Shop Manual * STEERING SYSTEM 01 –...

  • Page 6: Safety Notice

    Always use common shop safety practice. This information relates to the preparation and use of Bombardier sport 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.

  • Page 7: Introduction

    INTRODUCTION INTRODUCTION This Shop Manual Supplement covers the Sports- ter LE BOMBARDIER made SEA-DOO ® sport boat. This Supplement contains information specifically applicable to the Sportster LE and should always be used in conjunction with 1999 Sport Boat Shop Manual, Volume 1 (P/N 219 100 097).

  • Page 8: Service Tools

    Section 01 SERVICE TOOLS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS MANDATORY SERVICE TOOLS ................... 01-02-1 ENGINE ..........................01-02-1 OPTIONAL SERVICE TOOLS ....................01-03-1 ENGINE ..........................01-03-1 COOLING/FUEL/OIL SYSTEMS ..................01-03-2 01-01-1 LMR2000_043_01_01ATOC.FM...

  • Page 9: Mandatory Service Tools

    Section 01 SERVICE TOOLS Subsection 02 (MANDATORY SERVICE TOOLS) MANDATORY SERVICE TOOLS ENGINE Piston circlip installer Puller Polygonal wrench P/N 529 035 563 (947 engine) P/N 529 035 547 P/N 529 035 505 APPLICATION Piston circlip installation. Starter drive bearing pusher A00C1A4 F00B0Y4 APPLICATION...

  • Page 10: Optional Service Tools

    Section 01 SERVICE TOOLS Subsection 03 (OPTIONAL SERVICE TOOLS) OPTIONAL SERVICE TOOLS ENGINE Distance gauge A) P/N 529 035 100 (11.5 mm) B) P/N 529 035 000 (7.5 mm) F01B0H4 APPLICATION A) 947 engine (MAG). B) 947 engine (PTO). Rubber pad P/N 290 877 032 F06B064 APPLICATION...

  • Page 11: System

    Section 01 SERVICE TOOLS Subsection 03 (OPTIONAL SERVICE TOOLS) COOLING/FUEL/OIL SYSTEMS Pump gauge tester P/N 295 000 114 F01B0X4 APPLICATION All models. 01-03-2 LMR2000_044_01_03A.FM...

  • Page 12: Maintenance

    Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS PERIODIC INSPECTION CHART ................... 02-02-1 FLUSHING AND LUBRICATION ................... 02-03-1 GENERAL ........................... 02-03-1 PROCEDURE ........................02-03-1 WATER-FLOODED ENGINE ....................02-04-1 PROCEDURE ........................02-04-1 STORAGE..........................02-05-1 02-01-1 LMR2000_046_02_01ATOC.FM...

  • Page 13: Periodic Inspection Chart

    Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART FREQUENCY Every Every Every To be DESCRIPTION First performed 10 hours hours or hours hours pre-season Fire extinguisher condition/mounting ➃ ✔ ✔➁ GENERAL ➀ ✔ ✔ Lubrication/corrosion protection ✔ ✔...

  • Page 14: System

    Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) FREQUENCY Every Every Every To be DESCRIPTION First performed 10 hours hours or hours hours pre-season STEERING Inspection and cable adjustment ➃ ✔ ✔ ✔ SYSTEM LOW-SPEED Inspection and throttle cable adjustment ➃ ✔...

  • Page 15: Flushing And Lubrication

    Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) FLUSHING AND LUBRICATION GENERAL Flushing 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.
  • Page 16 Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) 3. Start the engine then immediately open the wa- 1. With engine cover opened, remove storage ter tap. tray. CAUTION: Always start the engine before 2. Install a hose pincher (P/N 529 032 500) on the opening the water tap to prevent engine flood- hose between both T-fittings as shown in the ing.
  • Page 17 Always use spark plug cable grounding de- vice when removing spark plugs. TYPICAL 1. Air intake silencer 2. Spray BOMBARDIER LUBE here (storage oil when performing F07H07A storage lubrication) 1. Grounding device NOTE: If the lubrication is done for the storage,...

  • Page 18: Water-Flooded Engine

    Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) WATER-FLOODED ENGINE PROCEDURE Spray BOMBARDIER LUBE lubricant (P/N 293 600 016) into spark plug holes. Check fuel and oil reservoirs for water contamina- Crank engine again. tion. If necessary, siphon and refill with fresh fluids.

  • Page 19: Storage

    Section 02 MAINTENANCE Subsection 05 (STORAGE) STORAGE Engine Draining Cooling System Flushing and Engine Internal Lubrication Check engine drain hose (lowest hose of engine). Make sure there is no sand or other particles in it Cooling system has to be flushed with fresh water and that it is not obstructed so that water can to prevent salt, sand or dirt accumulation which leave the engine.

  • Page 20: System

    Knight’s Spay-Nine* from Korkay System Ltd or the equivalent. Anticorrosion Treatment Wipe off any residual water in the engine compart- ment. Spray BOMBARDIER LUBE lubricant over all me- tallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant. Additional Recommended Protection...

  • Page 21: System

    Section 02 MAINTENANCE Subsection 05 (STORAGE) Insert a funnel into hose and pour antifreeze mixed with water (40% water, 60% antifreeze) in engine until the colored solution appears in the engine drain hose. TYPICAL 1. Hose and funnel installed at water outlet on cylinder head 2.

  • Page 22: Engine

    Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS LEAK TEST..........................04-02-1 TESTING PROCEDURE ..................... 04-02-1 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............04-02-3 REMOVAL AND INSTALLATION ..................04-03-1 GENERAL ........................... 04-03-1 REMOVAL FROM SPORT BOAT ..................04-03-1 CLEANING ......................... 04-03-3 INSTALLATION........................

  • Page 23: Leak Test

    Section 04 ENGINE Subsection 02 (LEAK TEST) LEAK TEST TESTING PROCEDURE Make sure the spark plugs are installed and tight- Engine Cooling System Block pulse hose using a hose pincher. Remove the tuned pipe. Install pump to the exhaust plate fitting. Remove the exhaust manifold gasket and ensure the surface is clean.
  • Page 24 Section 04 ENGINE Subsection 02 (LEAK TEST) Check also small oil injection pump lines and fit- tings; check for air bubbles or oil column going to- ward pump, which indicate a defective check valve. If there is still some leakage, remove the PTO fly- wheel to verify outer seals.

  • Page 25: System

    Section 04 ENGINE Subsection 02 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART PRESSURIZE ENGINE COOLING SYSTEM CHECK TESTING KIT IS SYSTEM LEAKING? REPLACE O-RING OF CYLINDER HEAD PRESSURIZE ENGINE AND/OR CYLINDER BASE GASKET IS ENGINE LEAKING? RECHECK ENGINE SEALING CHECK TESTING KIT CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS.

  • Page 26: Removal And Installation

    Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL Unfasten battery top brace. First, remove BLACK negative cable from battery, It is not necessary to remove engine from sport then RED positive cable. boat for TOP END or PTO FLYWHEEL AND MAG- NETO servicing.

  • Page 27: System

    Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Cooling System Engine can be easily lifted by inserting a hook into exhaust manifold eyelet. Disconnect cooling system hoses from engine head. NOTE: Engine will have to be raised inside bilge to disconnect drain hose before removing from bilge.

  • Page 28: Cleaning

    Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Removal of Remaining Components CAUTION: Strict adherence to this torque is im- portant to avoid damaging threads of alumi- To prevent excessive oil spillage, use a hose pinch- num insert in bilge. er (P/N 295 000 076).
  • Page 29 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) TYPICAL 1. Plate (P/N 529 035 507) 1. Sliding shaft through support 2. Support (P/N 529 035 511) 2. Alignment plate properly secured to pump support Alignment shaft (P/N 295 000 141). –...

  • Page 30: System

    NOTE: Whenever alignment tool is not utilized, apply BOMBARDIER LUBE (P/N 293 600 016) lu- bricant on its shaft and inside the housing to elim- inate possible corrosion. Final Inspection...

  • Page 31: Magneto

    Section 04 ENGINE Subsection 04 (MAGNETO) MAGNETO 04-04-1 LMR2000_052_04_04A.FM...

  • Page 32: Disassembly

    Section 04 ENGINE Subsection 04 (MAGNETO) DISASSEMBLY Rotor and Flywheel To remove the rotor no. 4 or the flywheel no. 5, the Cover crankshaft must be locked. For procedure, refer to BOTTOM END. Loosen screws no. 2. Remove engine magneto cover no.

  • Page 33: Cleaning

    Section 04 ENGINE Subsection 04 (MAGNETO) CLEANING The flywheel is easily freed from crankshaft with puller (P/N 420 976 325). Clean all metal components in a solvent. Install protective cap (P/N 290 877 414) to crank- CAUTION: Clean coils and magnets using only shaft.
  • Page 34 Section 04 ENGINE Subsection 04 (MAGNETO) Rotor and Flywheel Install flywheel and make sure to align keyway with the crankshaft Woodruff key. Apply Loctite 648 on mating surface of the rotor Apply Loctite 243 on nut no. 6. Install nut with lock no.

  • Page 35: Top End

    Section 04 ENGINE Subsection 05 (TOP END) TOP END 13 14 23 04-05-1 LMR2000_053_04_05A.FM...

  • Page 36: General

    Section 04 ENGINE Subsection 05 (TOP END) GENERAL The 2-stroke ROTAX engine rotates counterclock- wise seen from the rear (PTO flywheel). The 947 engine uses reed valves in the crankcase. The 947 engines are also equipped with the RAVE system (Rotax Adjustable Variable Exhaust). CAUTION: No engine components can be inter- changed between engines.
  • Page 37 Section 04 ENGINE Subsection 05 (TOP END) F06D16S RAVE VALVE OPENED 1. Pulse from crankcase 2. Check valve 3. Positive pressure to solenoid 4. Solenoid activated 5. Positive crankcase pressure to RAVE valves 04-05-3 LMR2000_053_04_05A.FM...
  • Page 38 Section 04 ENGINE Subsection 05 (TOP END) F06D16T RAVE VALVE CLOSED 1. Pulse from crankcase 2. Check valve 3. Positive pressure blocked by the solenoid 4. Solenoid deactivated 5. RAVE valves are opened to atmosphere 04-05-4 LMR2000_053_04_05A.FM...

  • Page 39: Disassembly

    Section 04 ENGINE Subsection 05 (TOP END) The RAVE valve does not allow an engine to make MAINTENANCE higher peak horsepower than an engine not so There are no wear parts anywhere in the system equipped, it can make moving the peak horsepow- and there are no adjustments to be periodically er higher practical because of its effect on the rest checked.
  • Page 40 Section 04 ENGINE Subsection 05 (TOP END) Remove RAVE valve. Remove spring no. 9 retaining bellows no. 10 to valve piston no. 11. Remove the cover no. 6 of the valve by releasing the spring no. 7. WARNING Firmly hold cover to valve base. The com- pression spring inside the valve is applying pressure against the cover.
  • Page 41 Section 04 ENGINE Subsection 05 (TOP END) Unscrew valve piston no. 11 from sliding valve Remove supporting ring no. 14. no. 12. NOTE: Hold the sliding valve to prevent it from turning. F06D27A 1. Remove supporting ring F06D0TB Remove O-ring no. 15. 1.
  • Page 42 Section 04 ENGINE Subsection 05 (TOP END) Cylinder Head Remove sliding valve no. 12. Disconnect temperature sensor wire and spark plug cables. Connect spark plug cables on grounding device. Disconnect hose of RAVE valves. Loosen cylinder head bolts no. 16 following the sequence shown in the next photo.
  • Page 43 Section 04 ENGINE Subsection 05 (TOP END) Remove cylinder head no. 2. Remove cylinder block. Remove cylinder head gasket no. 18. F06D0ZA F06D0YA 1. Remove cylinder block 1. Remove gasket NOTE: To ease removal, a plastic tip hammer can be used. Cylinder Remove cylinder base gasket no.
  • Page 44 Section 04 ENGINE Subsection 05 (TOP END) To remove circlip no. 21, insert a pointed tool in – Fully thread on puller handle. piston notch then pry it out and discard. – Insert extractor spindle into the piston pin. – Slide the sleeve and shoulder sleeve onto the WARNING spindle.

  • Page 45: Cleaning

    Section 04 ENGINE Subsection 05 (TOP END) 1. Needles and thrust washer 2. Sleeve 1. Shoulder sleeve flush with piston recess CLEANING – Loosen the extracting nut and remove puller. Discard all gaskets and O-rings. – Remove the shoulder sleeve from piston. Clean all metal components in a solvent.

  • Page 46: Assembly

    Section 04 ENGINE Subsection 05 (TOP END) Cylinder Base Gasket The inspection of engine top end should include the following measurements. Different thicknesses of cylinder base gaskets are TOLERANCES used for a precise adjustment of the combustion 947 ENGINE chamber volume. NEW PARTS WEAR MEASUREMENT...
  • Page 47 Section 04 ENGINE Subsection 05 (TOP END) RAVE Valve Piston Install the supporting ring no. 14 with the bevel At assembly, place the pistons with the letters side facing the O-ring no. 23. “AUS” (over an arrow on the piston dome) facing in direction of the exhaust port.
  • Page 48 Section 04 ENGINE Subsection 05 (TOP END) – Install the shoulder sleeve tool on the opposite Plastic Mounting Device Method side of the piston pin. This is an alternate method when no service tool is available. Replacement roller bearings are delivered in a con- venient plastic mounting device.
  • Page 49 Section 04 ENGINE Subsection 05 (TOP END) – Insert piston pin into piston until it comes flush with inward edge of piston hub. F01D0TA TYPICAL 1. Pulling inner sleeve half F01D0RA TYPICAL Circlip 1. Piston pin flush here 2. Thrust washers Always use new circlips.
  • Page 50 Section 04 ENGINE Subsection 05 (TOP END) To easily insert circlip into piston, use circlip installer. CAUTION: The hand retaining the piston should absorb the energy to protect the connecting rod. ENGINE TOOL P/N Cylinder Base Gasket 290 877 517 Install new base gasket.

  • Page 51: Adjustment

    Section 04 ENGINE Subsection 05 (TOP END) ADJUSTMENT To easily slide cylinder block over pistons, use ring compressor (P/N 290 876 965). RAVE Valve Turn the red plastic knob no. 29 until it is fully tight- ened. 1. Slide this edge NOTE: For each ring, make sure to align ring end gap with piston locating pin.
  • Page 52 Section 04 ENGINE Subsection 05 (TOP END) NOTE: When checking the combustion chamber 4. Inject the burette content through the spark volume, engine must be cold, piston must be free plug hole until liquid touches the top spark plug of carbon deposit and cylinder head must be lev- hole.

  • Page 53: Bottom End

    Section 04 ENGINE Subsection 06 (BOTTOM END) BOTTOM END 04-06-1 LMR2000_054_04_06A.FM...

  • Page 54: Disassembly

    Section 04 ENGINE Subsection 06 (BOTTOM END) DISASSEMBLY Loosen bolt no. 10 retaining the PTO flywheel to the crankshaft using a suitable socket and breaker Engine has to be removed from boat and top end bar. has to be disassembled to open bottom end. Refer to REMOVAL AND INSTALLATION and TOP END.

  • Page 55: System

    Section 04 ENGINE Subsection 06 (BOTTOM END) Starter Drive Assembly Reed Valve Loosen 2 Allen screws no. 11 retaining starter Remove both carburetor flanges. drive cover no. 12. 1. Carburetor flange F06D1CA Remove reed valves no. 3 from crankcase. 1. Cover 2.
  • Page 56 Section 04 ENGINE Subsection 06 (BOTTOM END) Put engine back on a support. Insert a pry bar be- tween crankcase lugs to separate halves. CAUTION: Be careful to precision machined surfaces. F06D1GA TYPICAL TYPICAL 1. Separate halves by prying at provided lugs 1.

  • Page 57: Cleaning

    Section 04 ENGINE Subsection 06 (BOTTOM END) CLEANING Or, use a bearing extractor such as Proto no. 4332 and a press to remove two bearings at a time. Discard all oil seals, gaskets, O-rings and sealing rings. Clean oil passages and make sure they are not clogged.
  • Page 58 Section 04 ENGINE Subsection 06 (BOTTOM END) Crankshaft Alignment at Connecting – Install Bombardier degree wheel (P/N 295 000 007) on crankshaft end. Hand-tighten nut only. Rod Journal – Remove both spark plugs. Counterweights can also be twisted on connect- ing rod journal on any or both cylinder(s).
  • Page 59 Section 04 ENGINE Subsection 06 (BOTTOM END) Crankshaft NOTE: If crankshaft and/or components are found defective, it must be repaired by a specialized shop or replaced. Connecting Rod Straightness Align a steel ruler on edge of small end connecting rod bore. Check if ruler is perfectly aligned with edge of big end.
  • Page 60 Section 04 ENGINE Subsection 06 (BOTTOM END) Connecting Rod Big End Axial Play Reed Valve Check reed valve petals no. 22 for cracks or other CONNECTING ROD BIG END AXIAL PLAY defects. The reed petals must lie completely flat NEW PARTS WEAR against the reed valve body no.

  • Page 61: Assembly

    ASSEMBLY Assembly is essentially the reverse of disassem- bly procedures. However pay particular attention to the following. NOTE: It is recommended to spray BOMBARDIER- ROTAX injection oil on all moving parts when re- assembling the engine. Crankshaft and Bearing Apply Loctite 767 anti-seize on part of crankshaft where bearing fits.
  • Page 62 Section 04 ENGINE Subsection 06 (BOTTOM END) Drive Pin CAUTION: Marks on the crankshaft and coun- terbalance shaft must be aligned, otherwise Make sure drive pins no. 24 of bearings are prop- engine will vibrate and premature wear will oc- erly installed in crankcase recesses at assembly.
  • Page 63 Section 04 ENGINE Subsection 06 (BOTTOM END) Crankcase Screws Place seals no. 17 in their respective positions. Apply synthetic grease below head of screws and Loctite 518 on threads. Torque crankcase screws no. 25 and no. 26 to 12 N•m (9 lbf•ft) as per following sequence. Repeat procedure, retightening all screws to 27 N•m (20 lbf•ft).
  • Page 64 Section 04 ENGINE Subsection 06 (BOTTOM END) Starter Drive Bearing To install bearing no. 21 of starter drive assembly, use pusher (P/N 290 876 502) and handle (P/N 420 877 650). 1. Handle 2. Pusher PTO Flywheel Apply Loctite 243 on bolt no. 10. Using the same tools as for disassembly proce- dure, torque bolt to 115 N•m (85 lbf•ft).

  • Page 65: Exhaust System

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) EXHAUST SYSTEM 13-14 04-08-1 LMR2000_055_04_08A.FM...

  • Page 66: Removal

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) REMOVAL Tuned Pipe Disconnect water return hose at tuned pipe head no. 4. F06E0AA 1. Water injection hose Disconnect the water bleed hose. 1. Water return hose Disconnect small hose from water outlet fitting at the tuned pipe head.

  • Page 67: System

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Loosen and remove clamp no. 8 retaining tuned Loosen Allen screws no. 9 and nut no. 10 at tuned pipe head no. 4 to tuned pipe cone no. 7. pipe flange. NOTE: To loosen nut, use polygonal wrench (P/N 529 035 505).

  • Page 68: System

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Loosen bolt no. 12 of tuned pipe cone beside the Pull resonator out of bilge. engine water return hose. Muffler Disconnect hoses from muffler no. 3. Disconnect hoses of the water flow regulator valve. F06D1VA 1.

  • Page 69: Installation

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) INSTALLATION Tuned Pipe Make sure to install the sealing ring no. 16 on Installation is essentially the reverse of removal tuned pipe cone if it was removed. procedures. However, pay particular attention to the following.

  • Page 70: System

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Apply Loctite 243 on nut no. 10 and screws no. 12 Torque bolt of tuned pipe cone beside the engine and no. 9. water return hose to 25 N•m (18 lbf•ft). Hand tighten all fasteners before torquing any of them.

  • Page 71: System

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 1. Torque Allen screws and nut (not shown) to 40 N•m (30 lbf•ft) Torque exhaust hose clamp no. 5 of tuned pipe cone to 4 N•m (35 lbf•in). F06D14A 1. Torque clamp to 4 N•m (35 lbf•in) 04-08-7 LMR2000_055_04_08A.FM...

  • Page 72: System

    Section 05 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS CIRCUIT, COMPONENTS AND CARE................... 05-02-1 CIRCUIT ..........................05-02-2 COMPONENTS ........................05-02-4 05-01-1 LMR2000_056_05_01ATOC.FM...

  • Page 73: System

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT, COMPONENTS AND CARE 05-02-1 LMR2000_056_05_02A.FM...

  • Page 74: System

    Always replace using appropriate Bombardier part number. The 947 engine has a conventional cooling sys- tem. The water is entering the engine by the water inlet fitting at the cylinder head.

  • Page 75: System

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Draining of the cooling system is accomplished by The water supply of the water flow regulator is the drain hose connected to a fitting at the bottom provided by the water supply hose coming from of the cylinder-block, on tuned pipe side.

  • Page 76: System

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) COMPONENTS Regulated water is injected in the tuned pipe by a calibrated fitting. Clamp To remove non-reusable Oetiker clamps (where applicable) of cooling system hoses, use screw- driver. F06E0AA 1. Injection fitting CAUTION: Never modify cooling system ar- rangement, otherwise serious engine damage could occur.

  • Page 77: System

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Water Flow Regulator Valve A water flow regulator valve is mounted on the muffler so it can produce the maximum horse- power output and yet maintain the necessary di- ameter of the injection fitting at the tuned pipe head for unobstructed water flow.

  • Page 78: System

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Adjustment The water flow regulator valve has been calibrated at the factory and should not be modified. NOTE: Water flow regulator valves ordered from the parts channel are also calibrated. If the maximum engine speed cannot be attained or if the engine has poor performance, the water flow regulator valve should be considered in the...

  • Page 79: System

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Pull the valve slightly. Using pliers, release the clamp which retains the bellows no. 8. Remove valve no. 9 and bellows. F01B23A This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system.

  • Page 80: System

    Section 06 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS AIR INTAKE ..........................06-03-1 REMOVAL........................... 06-03-2 ASSEMBLY......................... 06-03-2 CARBURETOR ........................06-04-1 ASSEMBLY......................... 06-04-2 ADJUSTMENTS ........................ 06-04-2 06-01-1 LMR2000_059_06_01ATOC.FM...

  • Page 81: Air Intake

    Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) AIR INTAKE 06-03-1 LMR2000_059_06_03A.FM...

  • Page 82: Removal

    Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) REMOVAL Pull air ducts out. Air Intake Silencer Unlock the clip no. 2 on top of air intake silencer no. 1. F06D34A 1. Air duct 1. Clip Push the air intake silencer out of the carburetor Remove bolts retaining both air ducts to engine adapter no.

  • Page 83: Carburetor

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) CARBURETOR Mikuni BN-46i PTO/MAG 06-04-1 LMR2000_060_06_04A.FM...

  • Page 84: Assembly

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) ASSEMBLY If it still leaks remove needle and seat and replace O-ring. POP-OFF PRESSURE TEST If bubbles come from needle, replace needle and Proceed as follows: seat. – Install pump gauge tester on carburetor fuel in- ADJUSTMENTS let nipple.

  • Page 85: System

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) Unscrew idle adjustment screw no. 2 to obtain a Adjust oil pump cable. Refer to OIL INJECTION small gap between stopper and screw. PUMP. NOTE: It is important to adjust oil pump cable prior to finalize adjustment of throttle cable.

  • Page 86: System

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) Idle Speed Screw Tighten low speed no. 1 screw until a slight resis- tance is felt. Then, back it off to the specification Turning screw no. 2 clockwise increases engine as per following chart. idle speed and turning screw counterclockwise decreases engine idle speed.

  • Page 87: System

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) F02F1QA TYPICAL 1. Adjustment screw 2. Small gap NOTE: Turning the adjustment screw clockwise will increase the gap. 06-04-5 LMR2000_060_06_04A.FM...

  • Page 88: System

    Section 07 LUBRICATION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM ...................... 07-02-1 GENERAL ........................... 07-02-2 OIL SYSTEM PRESSURIZATION ..................07-02-2 OIL INJECTION PUMP ......................07-03-1 REMOVAL........................... 07-03-2 DISASSEMBLY ........................07-03-2 CLEANING ......................... 07-03-2 ASSEMBLY ........................07-03-2 ADJUSTMENT ........................

  • Page 89: Oil Injection System

    Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM 27 N•m (20 lbf•ft) 3.5 N•m (31 lbf•in) Dielectric grease 3.5 N•m (31 lbf•in) F07G03S 07-02-1 LMR2000_061_07_02A.FM...

  • Page 90: General

    Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GENERAL Pressure Test Proceed as follows: Whenever repairing the oil injection system, al- ways verify for water infiltration in reservoir. – Fill up oil reservoir. Perform also a pressure test of the oil injection –...

  • Page 91: System

    Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) OIL INJECTION PUMP 07-03-1 LMR2000_062_07_03A.FM...

  • Page 92: Oil Injection Pump

    Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) REMOVAL Turn oil pump cable adjustment nut to align refer- ence marks on pump. Oil Injection Pump NOTE: A mirror may be used to facilitate this ver- ification. Remove tuned pipe head. Refer to EXHAUST SYS- TEM.

  • Page 93: Checking Operation

    Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) Bleeding NOTE: Through normal use, oil level must not drop in small tubes. If oil drops, verify check valve CAUTION: Oil injection system must be bled and operation. Replace as necessary. adjustment checked before operating engine.

  • Page 94: System

    Section 08 ELECTRICAL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION SYSTEM........................ 08-03-1 GENERAL ........................... 08-03-1 IGNITION TIMING ......................08-03-2 IGNITION SYSTEM TESTING PROCEDURE ..............08-03-6 CHARGING SYSTEM......................08-07-1 GENERAL ........................... 08-07-1 TESTING PROCEDURE ..................... 08-07-1 STARTING SYSTEM ......................08-08-1 GENERAL ...........................

  • Page 95: Ignition System

    Section 08 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) IGNITION SYSTEM GENERAL Its purpose is to signal the engine position to the Multi-Purpose Electronic Module. The rotor has two The ignition system consist of different sub-systems protrusions (180 degrees apart) that, when coupled where some are interrelated.

  • Page 96: Ignition Timing

    Section 08 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) Both coils are located inside the electrical box. Compared to the magneto system, the DC-CDI system offers a more powerful and stable ignition at low RPM. Electrical Box The high amperage/voltage components are locat- ed into the electrical box.

  • Page 97: System

    Section 08 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) Normally ignition timing adjustment should not be 4. Install and adjust a TDC gauge (P/N 295 000 143) required. It has been set at factory and it should in MAG side spark plug hole. remain correctly adjusted since every part is fixed and not adjustable.

  • Page 98: System

    8. Remove TDC gauge. 9. Reinstall spark plug and connect wire. Dynamic Test To check ignition timing, use Bombardier timing light (P/N 529 031 900). 1. Timing light pick-up 08-03-4 LMR2000_066_08_03A.FM...

  • Page 99: System

    Section 08 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) 3. Start engine and rev the engine to 3500 RPM The timing mark on the PTO flywheel refers to the and point beam of timing light straight in line physical component position when the spark must with timing mark pointer.

  • Page 100: Ignition System Testing Procedure

    Section 08 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) b. You found the flywheel mark advanced. You 6. The programmer display a number that is must retard the ignition timing. stored in the MPEM. 7. Press ↔ to choose yes for modify then press –...

  • Page 101: System

    Section 08 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) Rev Limiter Verification NOTE: To perform verification, a good quality mul- timeter such as Fluke 73 (P/N 529 022 000) should To check engine rev limiter, connect an induction be used. tachometer (P/N 295 000 100), start engine and check its maximum speed.

  • Page 102: System

    Section 08 ELECTRICAL SYSTEM Subsection 03 (IGNITION SYSTEM) DYNAMIC TEST IGNITION COIL SECONDARY WINDING 1. Disconnect magneto wiring harness connector. MODEL WIRE RESISTANCE 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). End of each spark Sportster LE plug cable, spark 8.4 - 15.6 kΩ...

  • Page 103: Charging System

    Section 08 ELECTRICAL SYSTEM Subsection 07 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL TESTING PROCEDURE NOTE: First, ensure that battery is in good condi- Magneto tion prior to performing the following tests. The purpose of the charging system is to keep the battery at a full state of charge.

  • Page 104: System

    Section 08 ELECTRICAL SYSTEM Subsection 07 (CHARGING SYSTEM) Stator 4. Ground the multimeter negative (-) probe to the engine or the stator iron core and note the read- STATIC TEST: CONTINUITY ing. 1. Disconnect the magneto wiring harness con- nector. 2.

  • Page 105: Starting System

    Section 08 ELECTRICAL SYSTEM Subsection 08 (STARTING SYSTEM) STARTING SYSTEM Sportster LE 08-08-1 LMR2000_069_08_08.FM...

  • Page 106: General

    Section 08 ELECTRICAL SYSTEM Subsection 08 (STARTING SYSTEM) GENERAL Dynamic Test Depress start/stop button and measure the volt- Causes of troubles are not necessarily related to age on the solenoid positive posts with a multim- starter but may be due to a burnt fuse, faulty bat- eter.

  • Page 107: Starter Disassembly

    Section 08 ELECTRICAL SYSTEM Subsection 08 (STARTING SYSTEM) STARTER DISASSEMBLY Locate index marks on yoke no. 1 and end covers no. 3 and no. 10. 1. Thrust washers Remove the other end cover no. 10 and gasket. 1. Index marks Remove the 3 washers no.

  • Page 108: Cleaning

    Section 08 ELECTRICAL SYSTEM Subsection 08 (STARTING SYSTEM) Release brush wires of yoke from brush holder Remove brushes. no. 2. To remove bearing and seal in end cover, release Remove brush holder. tabs of retainer. F06H1KA 1. Retainer 1. Remove brush holder CLEANING To remove brushes from yoke no.

  • Page 109: Parts Inspection

    Section 08 ELECTRICAL SYSTEM Subsection 08 (STARTING SYSTEM) PARTS INSPECTION Brush Holder Check brush holder for insulation using an ohm- Armature meter. Place one test probe on insulated brush holder and the other test probe on brush holder NOTE: An ohmmeter may be used for the follow- plate.

  • Page 110: Starter Assembly

    Section 08 ELECTRICAL SYSTEM Subsection 08 (STARTING SYSTEM) STARTER ASSEMBLY Screw Apply Loctite 243 to Allen screws no. 16 of starter Reverse the order of disassembly to reassemble bracket and torque to 10 N•m (89 lbf•in). starter. However, attention should be paid to the following operations.

  • Page 111: Starter Specification

    Section 08 ELECTRICAL SYSTEM Subsection 08 (STARTING SYSTEM) STARTER SPECIFICATION 947 Engine Nominal output 0.8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise (viewed from pinion side) Weight 1.7 kg (3.7 lb) No load 10.9 V 45 A max. 8600 RPM Performance specification at 20°C (68°F) Load...

  • Page 112: System

    Section 09 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ..........................09-02-1 GENERAL ........................... 09-02-2 INSPECTION ON SPORT BOAT ..................09-02-2 ASSEMBLY......................... 09-02-2 DRIVE SYSTEM ........................09-03-1 GENERAL ........................... 09-03-2 REMOVAL........................... 09-03-2 09-01-1 LMR2000_63_09_01ATOC.FM...

  • Page 113: Jet Pump

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) JET PUMP TYPICAL 09-02-1 LMR2000_63_09_02A.FM...

  • Page 114: General

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) GENERAL BOAT IMPELLER MATERIAL PITCH MODEL Use procedures described in 1999 Shop Manual, Volume 1, however pay attention to the following. Stainless Progressive Sportster LE 204 160 136 steel pitch The jet pump housing is made of plastic and has a stator made of brass which offers greater strength.

  • Page 115: Drive System

    Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) DRIVE SYSTEM 09-03-1 LMR2000_064_09_03A.FM...

  • Page 116: General

    Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GENERAL Mount on drive shaft puller the jet pump housing remover; then, install assembly on drive shaft us- Use procedures described in 1999 Shop Manual, ing screws. Volume 1, however pay attention to the following points.

  • Page 117: System

    Fuel/oil mixture VROI (Variable Rate Oil Injection) Oil injection pump Direct driven Lubrication Synthetic oil injection Oil type BOMBARDIER Formula XP-S (or equivalent) Number of cylinders Standard 88.00 mm (3.465 in) Bore First oversize 88.25 mm (3.474 in) Second oversize N.A.

  • Page 118: Mpem (Multi-Purpose Electronic

    Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) ELECTRICAL SPORTSTER LE Magneto generator output 180 W or 5 A @ 6000 RPM Ignition system type Digital DC-CDI (Direct-Current Capacitor Discharge Ignition) Make and type NGK BR8ES Spark plug 0.55 mm (.021 in) mm (in) 2.99 (.118) Ignition timing (BTDC)

  • Page 119: Propulsion

    None Overheating beeper setting 86 - 94°C (187 - 201°F) ADDITIONAL INFORMATION: PROPULSION SPORTSTER LE Propulsion system Bombardier Formula sea pump (big hub) Number of pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission...
  • Page 120 Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) DIMENSIONS SPORTSTER LE Draft 30 cm (12 in) Dead rise 20° Overall length 4.42 m (14 ft 6 in) Overall width (beam) 2.16 m (7 ft 1 in) Overall height 1.07 m (3 ft 6 in) Dry weight 560 kg (1235 lb) Load limit (passengers and 10 kg (22 lb) luggage)

  • Page 121: Weedless System

    Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) STANDARD EQUIPMENT SPORTSTER LE DESS (Digitally Encoded Security System) Standard Tool kit Optional Fuel tank reserve Standard Electric fuel level gauge Standard Oil injection low level/warning device Standard Overheating warning device and CSI (Cooling System Indicator) Standard Speedometer Standard...

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