Sea-doo Racino Owner's Handbook Manual
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Sea-doo Racino Owner's Handbook Manual

Sea-doo Racino Owner's Handbook Manual

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  • Page 2 SEA-DOO RACING HANDBOOK WARNING This information relates to the preparation and use of watercraft in competitive events. Bombar- dier inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that these modifications be carried out and/or verified by a highly-skilled professional watercraft racing mechanic.

  • Page 3: Introduction

    INTRODUCTION INTRODUCTION Welcome to the world of SEA-DOO watercraft racing. The information in this manual contains the theory and operating principals of the SEA-DOO watercraft systems. It provides the foundation needed for set- ting up the watercraft for racing purposes. All racers should obtain a copy of the model year Shop Manual and necessary tools before attempting any mechanical work.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION ........................ SAFETY ..........................RACE SANCTIONING ASSOCIATIONS ................SECTION 01 - GENERAL RACING INFORMATION PREPARING FOR RACE DAY ACTIVITIES ................ 01-2 PREPARING FOR A SAFETY INSPECTION ..............01-5 PRERACE MAINTENANCE....................01-6 MAINTENANCE BETWEEN RACES.................. 01-7 EQUIPMENT AND SPARE PARTS TO BRING TO THE RACE..........
  • Page 5 TABLE OF CONTENTS SECTION 03 - ENGINE PREPARATION ENGINE TUNING CAUTIONS.................... 03-2 BASIC ENGINE TERMINOLOGY ..................03-2 BASIC ENGINE COMPONENTS ..................03-3 ENGINE CONFIGURATION ....................03-7 BASIC ENGINE THEORY....................03-8 COMBUSTION PROCESS ....................03-10 SQUISH AREA ........................03-13 COMBUSTION CHAMBER VOLUME MEASUREMENT........... 03-14 CALCULATING THE COMPRESSION RATIO..............
  • Page 6 TABLE OF CONTENTS SECTION 04 - PROPULSION SYSTEM BASIC FUNCTIONS OF THE SYSTEM ................04-2 PROPULSION SYSTEM ANALYSIS .................. 04-2 VENTILATION (AIR LEAK) ....................04-3 CAVITATION ........................04-4 IMPELLER........................... 04-4 IMPELLER APPLICATION CHART ..................04-7 IMPELLER SPECIFICATIONS AND BOOT APPLICATIONS..........04-9 IMPELLER PITCH CHART ....................

  • Page 7: Safety

    SAFETY AND RACE SANCTIONING ASSOCIATION SAFETY RACE SANCTIONING ASSOCIATIONS PLEASE READ AND UNDERSTAND ALL WARN- INGS AND CAUTIONS IN THIS HANDBOOK. This handbook was written to help in the prepara- tion of a Sea-Doo watercraft for competitive events. This handbook uses the following symbols. Carefully study the association rule book and WARNING class of racing you intend to compete in before...

  • Page 8: Section 01 - General Racing Information

    SECTION 01 - GENERAL RACING INFORMATION TABLE OF CONTENTS PREPARING FOR RACE DAY ACTIVITIES ..................01-2 PREPARING FOR A SAFETY INSPECTION ..................01-5 PRERACE MAINTENANCE......................01-6 MAINTENANCE BETWEEN RACES ....................01-7 EQUIPMENT AND SPARE PARTS TO BRING TO THE RACE............01-7 PIT AREA PRESENTATION......................

  • Page 9: Preparing For Race Day Activities

    SECTION 01 - GENERAL RACING INFORMATION PREPARING FOR RACE DAY 3. Pit Area Setup ACTIVITIES At the race site you will be allowed to setup your pit area the morning of the event at approximately 1. Joining the Sanctioning Body 6:00 a.m.
  • Page 10 SECTION 01 - GENERAL RACING INFORMATION 6. Practice 9. Starting Practice is for the purpose of learning the course. Once in position on the line you will be allowed 1 Red buoys signify left turns while yellow buoys or 2 holders to keep your boat in position safely. are for right turns.
  • Page 11 SECTION 01 - GENERAL RACING INFORMATION Be sure you race to the checkered flag. Many rac- After your hull number is recorded, the inspector es have been lost because the rider thought the may make a series of visual inspections inside and white flag was waved then stopped on the next outside the hull to verify class legality or to see if lap.

  • Page 12: Preparing For A Safety Inspection

    SECTION 01 - GENERAL RACING INFORMATION Always make sure that you have all your emer- Your boat numbers must be at minimum 18 cm gency information written down. Designate a (7 in) high and must be spaced 13 mm (0.5 in) member of your team to get this information to apart.

  • Page 13: Prerace Maintenance

    SECTION 01 - GENERAL RACING INFORMATION 15. All fuel lines must be secured to the carbure- 6. Check the fuel filter for debris or water, if any tor and fuel tank with clamps or zip ties. Fuel abnormality is noticed, remove and clean the injected engines must have approved high fuel tank, fuel filter, fuel lines, and carburetors.

  • Page 14: Maintenance Between Races

    SECTION 01 - GENERAL RACING INFORMATION MAINTENANCE BETWEEN All racers should be equipped with the Shop Man- ual for their watercraft. They should have at mini- RACES mum the necessary tools to accomplish the service procedures that they are capable of per- The following items should be checked between forming themselves.

  • Page 15: Interaction With Race Officials

    SECTION 01 - GENERAL RACING INFORMATION 1. You need to set up where you will receive the Keep your pit area clean, bring a small waste can greatest amount of exposure to the spectators, for your pit, (it’s another place to put decals) it media, and well financed race teams.

  • Page 16: Sponsorship And Solicitation

    SECTION 01 - GENERAL RACING INFORMATION The most common problems which arise be- If your complaint concerns the legality of a given tween racers and officials occur at the start of the watercraft’s modification, go to the Technical In- race. Racers jump the start, and then the race is spector.
  • Page 17 SECTION 01 - GENERAL RACING INFORMATION Recognition is what sponsorship is all about. Rac- The complexity of your sponsorship proposal will ers seek sponsorship to help offset the cost of vary, quite noticeably, depending upon the level of racing, while sponsors support you for one pur- racing at which you are competing.

  • Page 18: The Professionals Point Of View

    SECTION 01 - GENERAL RACING INFORMATION Racers competing on the National Tour, that are Next, a successful rider always has inner drive. ranked in the top five in the world in their respec- This is required to push through those tough tive classes, seek an entirely different level of times.
  • Page 19 SECTION 01 - GENERAL RACING INFORMATION Our sport is now, in what I think to be, still in the My commitment and conditioning to be a Pro developmental stage. Because of this, testing Runabout racer has put me up front in my class. A your PWC is very, very important if you want to class that many people dare not adventure, for win.

  • Page 20: Section 02 - Hull Preparation

    SECTION 02 - HULL PREPARATION TABLE OF CONTENTS PREPARING THE HULL FOR INSPECTION ..................02-2 MEASURING THE HULL ......................... 02-2 TRUING THE HULL.......................... 02-2 PAINTING ............................02-3 CONCEPT PAINTING PROCEDURE .................... 02-3 DELTA PAINTING PROCEDURE....................02-4 SEA-DOO PAINT CODES......................... 02-5 STORAGE COVER PAINT CODES....................

  • Page 21: Preparing The Hull For Inspection

    SECTION 02 - HULL PREPARATION PREPARING THE HULL FOR TRUING THE HULL INSPECTION Truing the hull means to make the hull as straight as possible. This will help you gain maximum per- The production hulls produced by Sea-Doo are formance and top speed. Follow these steps and manufactured to fine tolerances.

  • Page 22: Painting

    SECTION 02 - HULL PREPARATION ® e. Measure the low area and mix up enough filler NOTE: KONDAR must be sealed before apply- material to fill the area in. Follow the manufac- ing CONCEPT color. turers mixing instructions. Fill low area and Sealer blend in evenly with bondo spreader.

  • Page 23: Delta Tm Painting Procedure

    SECTION 02 - HULL PREPARATION Spot/Panel Repairs Application Spray medium wet coat of color on the repair area and allow 5-10 minutes flash time. Apply 2 additional full coats until hiding is achieved, extending each coat beyond the previous coat. Flash 15 minutes be- tween each coat.

  • Page 24: Sea-Doo Paint Codes

    SECTION 02 - HULL PREPARATION SEA-DOO PAINT CODES SPRAY PAINT BOMBARDIER B.A.S.F. R-M B-176 VIPER RED 74790 M-506 BRIGHT YELLOW (HULL) RM-88152-9 88243 293 500 078 M-506 BRIGHT YELLOW (BODY) RM-88152 88245 293 500 078 M-510 METALLIC FOREST GREEN RM-88270 48023 M-511 MARINE GREEN...

  • Page 25: Storage Cover Paint Codes

    SECTION 02 - HULL PREPARATION STORAGE COVER PAINT CODES MODELS WITH CORRESPONDING BODY/HULL PAINT CODES BRIGHT YELLOW M-506 Body/Hull METALLIC FOREST GREEN M-510 Model Name Model Bombardier 1997 Number Paint Code BRIGHT METALLIC PURPLE M-521 5879 5801-88-01 BLUE 5804-91-01 5834/5661 5801-88-01/M-506 LAVENDER 5804-92-02...
  • Page 26 SECTION 02 - HULL PREPARATION Model Name Model Body/Hull Model Name Model Body/Hull 1994 Number Bombardier 1991 Number Bombardier Paint Code Paint Code 5870 5801-88-01 5804 5801-88-01/ 5810-90-02 5871 5801-88-01/ 5870-94-01 5850 5801-88-01/ 5804-91-01 5872 5801-88-01 5811 5801-88-01 5854/5855 5801-88-01/ 5810-90-02 5852-93-01 5814...

  • Page 27: Sealing Of Body Components

    SECTION 02 - HULL PREPARATION SEALING OF BODY Available Kits: COMPONENTS Short Concave Sponsons Important areas to check: hull, storage compart- 295 500 248 BLUE/PURPLE ment cover, water trap tank, drain hoses, seat 295 500 194 GREEN seal and rear baffle. Reseal all leaks (refer to ap- propriate Shop Manual ).
  • Page 28 SECTION 02 - HULL PREPARATION Hole Location in Hull (Short Sponsons) The vertical measurement must start from under the top edge of the hull. This will avoid mounting the sponson too low. F01L61A 1. Urethane foam Start cutting the urethane foam by carefully pull- ing hole saw into the foam and operating the drill in reverse position.
  • Page 29 SECTION 02 - HULL PREPARATION F01P09A Install lock nuts by using the 4-claw pick-up tool or a 10 mm deep socket. Torque nuts to 14 N•m (10 lbf•ft). Urethane Foam Reinstallation When sponsons installation is completed, you can reinstall the first removed urethane foam core into each hole.
  • Page 30 SECTION 03 - ENGINE PREPARATION TABLE OF CONTENTS ENGINE TUNING CAUTIONS....................... 03-2 BASIC ENGINE TERMINOLOGY....................03-2 BASIC ENGINE COMPONENTS ....................03-3 ENGINE CONFIGURATION ......................03-7 BASIC ENGINE THEORY ....................... 03-8 COMBUSTION PROCESS ......................03-10 SQUISH AREA ..........................03-13 COMBUSTION CHAMBER VOLUME MEASUREMENT.............. 03-14 CALCULATING THE COMPRESSION RATIO ................

  • Page 31: Engine Tuning Cautions

    SECTION 03 - ENGINE PREPARATION ENGINE TUNING CAUTIONS BASIC ENGINE TERMINOLOGY A few items to keep in mind when preparing your Cycle In a combustion engine, a cycle is engine: accomplished when the 4 phases; intake, compression, combustion and – There are specific set of rules for racing, know exhaust are complete.

  • Page 32: Basic Engine Components

    SECTION 03 - ENGINE PREPARATION BASIC ENGINE COMPONENTS F01D5DS 1. Rings 9.Wrist pin 2. Cylinder 10. Rotary valve 3. Cylinder head 11. Intake port 4. Cylinder head cover 12. Oil injection pump 5. Spark plug 13. Crankcase 6. Combustion chamber 14.
  • Page 33 SECTION 03 - ENGINE PREPARATION Cylinder Head A shaped aluminum alloy casting bolted to the top of cylinder. It contains the combustion chamber and is designed with a threaded hole to accom- modate a spark plug. F01D5QA TWO CYLINDERS SHOWN Piston A shaped cast aluminum alloy “plug”...
  • Page 34 SECTION 03 - ENGINE PREPARATION F01D6CA The piston is manufactured out-of-round, the rea- son being that wrist pin bosses have a greater vol- ume of metal than the other sections of the F01D6EA piston, and consequently, will absorb more heat. RECTANGULAR RING SHOWN ON LEFT SIDE —...
  • Page 35 SECTION 03 - ENGINE PREPARATION Crankshaft F01D1ND CRANKSHAFT SHOWN WITH CONNECTING RODS The engine crankshaft is the backbone of the en- gine. It converts the reciprocating movement of the piston into rotary movement. The crankshaft is supported by ball bearings mounted inside the crankcase.

  • Page 36: Engine Configuration

    SECTION 03 - ENGINE PREPARATION Less expensive engines have the crankshaft and connecting rods mounted on sleeve bearings rather than roller or needle bearings. The advan- tage of roller or needle bearings is less friction and longer life. Wrist Pin Provides support for the piston.

  • Page 37: Basic Engine Theory

    SECTION 03 - ENGINE PREPARATION 1. Intake and Secondary Compression By doing this, the large volume of air/fuel mixture taken into the engine during intake is wholly re- Port Condition: tained inside the engine, and not partially expelled Intake port: Partially opened with the exhaust.
  • Page 38 SECTION 03 - ENGINE PREPARATION As the piston approaches the top of the cylinder (TDC), the compressed air/fuel mixture inside the combustion chamber is ignited by the spark plug. The burning gases expand and push the piston downward, thus causing a power stroke. F01D6HA 1.

  • Page 39: Combustion Process

    SECTION 03 - ENGINE PREPARATION Spark occurs as piston approches Top Dead Center F01D5GA F01D6IA 1. Exhaust 2. Burnt gases 3. Fresh charge 4. Transfer port 5. Intake 6. Fresh charge COMBUSTION PROCESS Normal Combustion Flame front Since the beginning of this study we have spoken begins...
  • Page 40 SECTION 03 - ENGINE PREPARATION ...heat and pressure rapidly build up..until mixture is completely burnt F01D5JA F01D5KA With all operating parameters correct, normal combustion will take place. However, if for some reason the temperature inside the cylinder is in- creased during combustion, abnormal combus- tion will occur and lead to serious engine damage.
  • Page 41 SECTION 03 - ENGINE PREPARATION Pre-ignition Pre-ignition is the ignition of the mixture inside the combustion chamber before the timed spark. Pre- ignition sources are generally an overheated spark plug tip or a glowing carbon deposit on the piston head. Since ignition occurs earlier than the timed spark, the hot gases stay longer in the combus- tion chamber, thus increasing cylinder head and ...timed spark...

  • Page 42: Squish Area

    SECTION 03 - ENGINE PREPARATION Usually the piston is subject to damage. It may seize or the aluminum on the exhaust side of the piston dome may melt. Pre-ignition is always pre- ceded by detonation. Causes of Detonation 1. Octane of the fuel is too low for compression ratio.

  • Page 43: Combustion Chamber Volume Measurement

    SECTION 03 - ENGINE PREPARATION Squish Area of Prepared Engines Uncorrected compression ratio: up to 14.5: 1 • 1.00 mm – 1.60 mm (.039 in – .063 in) engine type 587 • 0.80 mm – 1.40 mm (.031 in – .055 in) engine type 657 •...
  • Page 44 SECTION 03 - ENGINE PREPARATION F00D0HA 1. Top of spark plug hole F01D2IA NOTE: The liquid level in cylinder must not de- 1. Bring piston to TDC crease after filling. If so, there is a leak between 2. Obtain a graduated burette (capacity 0-50 cc) piston and cylinder.

  • Page 45: Calculating The Compression Ratio

    SECTION 03 - ENGINE PREPARATION CALCULATING THE 290.3 cc 27.6 cc C.R. = - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - COMPRESSION RATIO 27.6 cc Uncorrected Compression Ratio...

  • Page 46: Calculating Machining Cylinder Head Height Versus Combustion Chamber Volume

    SECTION 03 - ENGINE PREPARATION CALCULATING MACHINING OCTANE REQUIREMENTS FOR CYLINDER HEAD HEIGHT ROTAX ENGINES VERSUS COMBUSTION Following is a set of guidelines for a suggested CHAMBER VOLUME relationship between uncorrected compression ratio, combustion chamber squish band clear- – ance, and octane requirements for an engine built - - - - - - - - - - - - - - - - - - - - - to compete in racing.
  • Page 47 SECTION 03 - ENGINE PREPARATION When an engine of this design is run at a high speed, efficiency falls off quickly. The relatively high exhaust port effectively shortens the useful power stroke and because the exhaust system is tuned for maximum power, there is a large in- crease of fresh charge losses at lower speeds.
  • Page 48 SECTION 03 - ENGINE PREPARATION All Engines The RAVE valve does not allow an engine to make higher peak horsepower than an engine not so equipped, it can however make moving the peak horsepower higher practical, because of its effect on the rest of the power curve.

  • Page 49: Function Of The Rotary Valve Intake System

    SECTION 03 - ENGINE PREPARATION Cylinder Boring Precaution Engine Operation In its stock configuration the RAVE valve guillotine Basically, the rotary valve engine performs the has a minimum of 0.5 mm (.020 in) clearance to same operation as the piston port 2-stroke en- the cylinder bore measured at the center line of gine.
  • Page 50 SECTION 03 - ENGINE PREPARATION Ignition and Combustion Transfer F01D6UA F01D6WA 1. Fresh charge for the other cylinder 1. Fresh charge 2. Fresh charge 3. Intake port covered As the piston nears the top of the cylinder (TDC), the compressed air/fuel mixture in the combus- Near the bottom of the downward stroke, the tion chamber is ignited by the spark plug.
  • Page 51 SECTION 03 - ENGINE PREPARATION As shown for the rotary valve engine, the total du- ration of the intake is greater and the opening starts earlier. This results in a better volumetric efficiency. In the rotary valve engine, the intake closes earlier to avoid fresh charge spitback.
  • Page 52 SECTION 03 - ENGINE PREPARATION Inspection of the Rotary Valve Inspect rotary valve cover for warpage. Small de- formation can be corrected by surfacing with a fine sandpaper on a surface plate. Surface part against oiled sandpaper. Inspect bearings. Check for scoring, pitting, chip- ping or other evidence of wear.
  • Page 53 SECTION 03 - ENGINE PREPARATION F01D3PA TYPICAL 1. Solder If rotary valve cover clearance is out of specifica- F01D3OA tion, machine rotary valve cover seating surface SAME AMOUNT REMOVED FROM COVER SEATING SURFACE or replace the cover. AND O-RING GROOVE BASE 1.

  • Page 54: Rotary Valve Timing

    SECTION 03 - ENGINE PREPARATION ROTARY VALVE TIMING For opening mark, first align 360° line of degree wheel with BOTTOM of MAG side inlet port. Then, find line 147° on degree wheel and mark CAUTION crankcase at this point. Never use the ridge molded in crankcase as a timing mark.
  • Page 55 SECTION 03 - ENGINE PREPARATION Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC. NOTE: When checking the timing with the MAG side piston at Top Dead Center, the rotary valve shaft should be lightly held in a clockwise position to take up any gear lash that may be present.

  • Page 56: Rotary Valve Identification

    SECTION 03 - ENGINE PREPARATION ROTARY VALVE IDENTIFICATION TEMPLATE 147° (cut-out angle) 290 924 508 actual size A00A0YS 03-27...
  • Page 57 SECTION 03 - ENGINE PREPARATION 159° TEMPLATE 159° (cut-out angle) (cut-out angle) 290 924 502 actual size 132° (cut-out angle) 290 924 504 actual size F01D8SS 03-28...

  • Page 58: Cylinder Porting Maps

    SECTION 03 - ENGINE PREPARATION CYLINDER PORTING MAPS NOTE: See tables on next pages for porting map specifications. Refer to the following illustration for measurement references. F01D7CS 03-29...
  • Page 59 SECTION 03 - ENGINE PREPARATION Porting Map for Engines Prior to 1995 SEA-DOO ENGINE SPECIFICATIONS Exhaust port height 34.0 mm 34.5 mm Exhaust port width 50.0 mm 53.0 mm Exhaust port height bottom to top 34.0 mm 35.0 mm Rear transfer height 52.0 mm 55.5 mm Rear transfer width...
  • Page 60 SECTION 03 - ENGINE PREPARATION Porting Map for the 1995 Engines ENGINE TYPE/MODEL YEAR 657X Exhaust port height 35.0 mm 36.0 mm 34.1 mm 34.2 mm 35.2 mm Exhaust port width 47.8 mm 50.9 mm 50.9 mm 51.1 mm 54.4 mm Exhaust port height bottom to top 30.1 mm 33.1 mm...
  • Page 61 SECTION 03 - ENGINE PREPARATION Porting Map for the 1996 and 1997 Engines ENGINE TYPE/MODEL YEAR Exhaust port height 33.4 mm 32.4 mm 34.6 mm 38.70 mm Exhaust port width 50.0 mm 51.3 mm 54.4 mm 69.30 mm Exhaust port height bottom to top 32.3 mm 34.7 mm 38.4 mm...

  • Page 62: Engine Leakage Test

    SECTION 03 - ENGINE PREPARATION ENGINE LEAKAGE TEST Install the appropriate exhaust manifold plate (no. 1 for the 787 engine and no. 2 for other en- gines except the 947) from the Engine Leak Test General Kit. Tighten plate using fasteners provided in the A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) kit.
  • Page 63 SECTION 03 - ENGINE PREPARATION F01B2TA F01B2VA 657 ENGINE 717 ENGINE — FRONT VIEW 1. Insert small hose inside large hole. Secure with clamps 1. Loop hose and use clamps 2. Plug exhaust manifold drain hose with a pincher 2. Use 2 washers with exhaust manifold stud 3.
  • Page 64 SECTION 03 - ENGINE PREPARATION Bottom End and Top End Remove the carburetor(s) and gasket(s). Make sure the surface of the intake manifold (587, 657 and 717 engines) or rotary valve cover (787 en- gine) are clean. Install the intake plate(s) no. 3 with fasteners from the kit and tighten adequately.
  • Page 65 SECTION 03 - ENGINE PREPARATION If there is still some leakage, remove the PTO fly- wheel to verify outer seal. If no leak is found on the PTO side outer seal, re- move magneto flywheel and verify crankshaft outer seals. Proceed with the Rotary Valve Shaft testing if the crankshaft outer seals are not leaking.
  • Page 66 SECTION 03 - ENGINE PREPARATION Install pump with reducer and nipple to the oil Activate pump and pressurize to 5 PSI (34 kPa). supply hose of the rotary valve shaft. 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.

  • Page 67: Engine Leakage Diagnostic Flow Chart

    SECTION 03 - ENGINE PREPARATION ENGINE LEAKAGE DIAGNOSTIC FLOW CHART PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING? CHECK TESTING KIT 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 68: Crankshaft Inspection

    SECTION 03 - ENGINE PREPARATION CRANKSHAFT INSPECTION – Remove MAG flywheel nut (and also the mag- neto rotor for the 787 engine). Crankshaft Misalignment – Install Bombardier degree wheel (P/N 295 000 and Deflection 007) on crankshaft end. Hand-tighten nut only. –...
  • Page 69 SECTION 03 - ENGINE PREPARATION Crankshaft Alignment at Connecting Rod Journal Crankshaft misalignment at connecting rod jour- nal may cause the crankshaft to be hard to manu- ally turn. Verification can be done by measuring deflection at each end of crankshaft. Refer to IN- SPECTION in this section.
  • Page 70 SECTION 03 - ENGINE PREPARATION Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. F01D1TA 1. Measuring MAG side deflection in crankcase Remove crankshaft bearings and check deflection again on V-shaped blocks as illustrated. F01D1WA 1.

  • Page 71: Engine Break-In Procedure

    SECTION 03 - ENGINE PREPARATION NOTE: Be sure to install labyrinth sleeve with its To obtain the most benefit from your labor and hollow side facing PTO side outer bearing. money, a proper break-in is essential. The proper break-in procedure allows all of the “rough”...

  • Page 72: Function Of An Exhaust System

    SECTION 03 - ENGINE PREPARATION FUNCTION OF AN EXHAUST SYSTEM Volumetric efficiency (V.E.) of an engine is the ra- tio of the actual amount of air drawn into an en- gine versus the capacity of the engine. The natural V.E. of a 2-stroke is about 65%. This means a 250 cc cylinder only draws in about 160 cc of air.

  • Page 73: Water Flow Regulator Valve

    SECTION 03 - ENGINE PREPARATION WATER FLOW REGULATOR Maximum efficiency is generally obtained by hav- ing 1 pipe for each cylinder. But, this maximum VALVE point may be across a narrow and/or high RPM range, causing difficulties in driveability. All watercraft equipped with a 787 or 947 engines use a water flow regulator valve located on top of The 2 into 1 tuned pipes used on Sea-Doo water- the muffler to control the amount of water inject-...
  • Page 74 SECTION 03 - ENGINE PREPARATION 2. At the exhaust tuned head pipe there is a 1/4 in fitting already in use that was used to accept the regulated water supply from the now dis- carded water flow regulator valve. Remove the hose from the fitting at the head pipe and thread the fitting to accept a Mikuni main jet.
  • Page 75 SECTION 03 - ENGINE PREPARATION F01E23S 1. Original fitting threaded to accept a Mikuni main jet size 150 2. New 1/4 in T-fitting 3. New fitting threaded to accept a Mikuni jet size 200 IMPORTANT: It is necessary to readjust the exhaust hard jetting for maximum performance when racing in different water temperatures.

  • Page 76: Function Of The Cooling System

    SECTION 03 - ENGINE PREPARATION FUNCTION OF THE COOLING Some aftermarket companies may suggest that the cooling system be re-routed to feed cold wa- SYSTEM ter directly to the engine instead of allowing the exhaust system to warm it first. This change All Sea-Doo watercraft are equipped with a total should be approached with caution as random loss cooling system.
  • Page 77 SECTION 03 - ENGINE PREPARATION 03-48...
  • Page 78 SECTION 03 - ENGINE PREPARATION 1. Uppermost point of engine (cylinder head) allows bleeding 9.Pressure zone 2. Temperature sensor activates monitoring beeper when 10. Engine water inlet hose temperature exceeds 96-99°C (205-210°F) 11. Tuned pipe bleed hose injects water into muffler to cool exhaust 3.
  • Page 79 SECTION 03 - ENGINE PREPARATION 03-50...

  • Page 80: Engine Cooling System

    SECTION 03 - ENGINE PREPARATION 787 ENGINE COOLING SYSTEM Temperature Calibrated sensor activates Uppermost point of cylinder monitoring circuit (tuned pipe) Water regulated head limits beeper when allows bleeding by the water flow water flow temperature regulator valve exceeds 96-99°C and injected (205-210°F) directly into...

  • Page 81: Ignition Systems

    SECTION 03 - ENGINE PREPARATION IGNITION SYSTEMS All Systems Maximum power from a given engine configura- Two stroke engines in watercraft rely on an elec- tion is produced when peak combustion chamber tric spark to initiate combustion of the air/fuel pressure (about 750 PSI) takes place at about 15°...
  • Page 82 SECTION 03 - ENGINE PREPARATION NOTE: For initial tuning it is recommended that Before checking ignition timing with a strobo- you test using 1 heat range colder spark plug than scopic timing light (dynamic test), it is mandatory stock. If upon completion of tuning the center in- to scribe a timing mark on the PTO flywheel (stat- sulator shows excessive carbon deposits go back ic test) corresponding to the specific engine.
  • Page 83 SECTION 03 - ENGINE PREPARATION Static Test All Engines 4. Install and adjust a TDC gauge in MAG side All Engines spark plug hole. 1. Disconnect MAG side spark plug wire and con- nect wire to grounding device then remove spark plug.
  • Page 84 SECTION 03 - ENGINE PREPARATION 7. Scribe a thin mark on PTO flywheel in the mid- dle of tool slot (587, 657, 657X, 717D and 717 engines) or aligned with timing mark pointer tool (787, 787X and 947 engines). A00B4FA 587, 657, 657X, 717D and 717 Engines NOTE: To perform this procedure, make sure to use a stroboscopic timing light rated up to 6000...
  • Page 85 SECTION 03 - ENGINE PREPARATION 787, 787X and 947 Engines 1. Connect an induction-type tachometer (P/N 295 000 100) to spark plug wire. F00H0HA 1. Timing light pick-up 3. Start engine and point timing light straight in line with timing tool slot. Bring engine to the F06H06A specified RPM.
  • Page 86 SECTION 03 - ENGINE PREPARATION A25E0RA F06H07A 1. Timing light straight in line with tool slot TYPICAL 1. To retard 2. To advance CAUTION To adjust, loosen 3 armature plate retaining If engine is to be run more than a few sec- screws and slightly rotate armature plate in prop- onds, engine must be cooled using the flush er direction.
  • Page 87 SECTION 03 - ENGINE PREPARATION Recheck ignition timing (make sure engine is cold). Repeat armature plate positioning procedure if timing mark position is not adequate. 787, 787X and 947 Engines To correct the ignition timing, the data of the MPEM is changed using the MPEM programmer. Through the MPEM programmer, the ignition tim- ing can be advanced up to 3°...
  • Page 88 SECTION 03 - ENGINE PREPARATION Examples: – You recheck the timing with the timing light and if the mark is aligned, the ignition timing a. You found the flywheel mark advanced. You is properly set. must retard the ignition timing. Proceed as follows to adjust the ignition timing –...

  • Page 89: Spark Plug Information

    SECTION 03 - ENGINE PREPARATION SPARK PLUG INFORMATION A cold type plug has a relatively short insulator nose and transfers heat very rapidly into the cylin- Spark plug heat ranges are selected by measuring der head. actual combustion chamber temperatures. A cold- Such a plug is used in heavy duty or continuous er spark plug, one that dissipates heat more rapid- high speed operation to avoid overheating.
  • Page 90 SECTION 03 - ENGINE PREPARATION Design Symbols Used on NGK Spark Plugs WIDE GAP PREFIX SUFFIX 10: 1.0 mm (.040") 11: 1.1 mm (.044") B R 8 E S 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...

  • Page 91: Mikuni Bn Carburetors

    SECTION 03 - ENGINE PREPARATION MIKUNI BN CARBURETORS Carburetor Installation REPRINTED WITH THE AUTHORIZATION OF MIKUNI CORP. Introduction of the Super BN Carburetor F01F29A F01F0WB MIKUNI SUPER BN38 DUAL CARBURETOR SET FOR HIGH PERFORMANCE APPLICATIONS The Super BN carburetor is the latest in a series of watercraft carburetors from Mikuni.
  • Page 92 SECTION 03 - ENGINE PREPARATION Basic Instructions External Components 1. Use a new gasket between the carburetor(s) and intake manifold. 2. Use flat washers and lock nuts to secure the carburetor(s). 3. Be sure that the fuel lines are of the correct di- ameter for the carb fittings.
  • Page 93 SECTION 03 - ENGINE PREPARATION Viewing the high speed circuit, notice that fuel is NOTE: It is important to NOT select a needle divided at the high speed jet, so that even if the valve that is too small for your application due to high speed screw was fully closed, fuel would still the fact that the needle valve can be a limiting fac- pass through the jet.
  • Page 94 SECTION 03 - ENGINE PREPARATION Standard Needle Valve Size for Various Sea-Doo Carburetors NEEDLE VALVE CARBURETOR MODEL SIZE BN38I-37-17/BN38I-37-18 BN38I-37-25/BN38I-37-26 BN40I-38-9/BN40I-38-10 BN40I-38-15 BN40I-38-11/BN40I-38-12 BN38I-37BI BN38-34-45B BN38-34-58/BN38-34-59 BN-38-34-64/BN-38-34-65 BN38-34-73/BN38-34-74 BN38-34-92/BN38-34-93 BN38-34-110/BN38-34-111 BN38-34-147 BN46I-42-2/BN46I-42-3 03-65...
  • Page 95 SECTION 03 - ENGINE PREPARATION F01F2CS 1.Low speed outlet 12. High speed screw 2.Bypass holes 13. Main jet 3.Throttle plate 14. Anti-siphon valve 4.Fuel inlet 15. Pilot jet 5.Pulse 16. Needle valve assembly 6.Check valves 17. Regulator diaphragm 7.Pump diaphragm 18.
  • Page 96 SECTION 03 - ENGINE PREPARATION Loctite 20 N•m (15 lbf•ft) Loctite Loctite 242 Anti-seize lubricant Synthetic grease Synthetic grease F01F05S 1.Needle valve 12. Choke valve 2.Low speed screw 13. O-ring 3.Diaphragm 14. High speed screw 4.Pump body 15. Idle speed screw 5.Filter 16.
  • Page 97 SECTION 03 - ENGINE PREPARATION Carburetor Tuning Freer Air Intake Systems Free flowing (unrestricted) air intakes increase air Tuning the Super BN carburetor(s) can be a fairly flow, but once again, at low throttle openings may simple matter if you look at it with a logical per- reduce manifold pressure.
  • Page 98 SECTION 03 - ENGINE PREPARATION Low Speed Screw High Speed Screw Low speed screw is used in conjunction with the High speed screw adjusts the air/fuel mixture, in idle stop screw to maintain idle speed and conjunction with the main jet, for maximum full smoothness.
  • Page 99 SECTION 03 - ENGINE PREPARATION Now you can see the importance of the transition 5. Pressurize the carb with the pump until the circuit; it is there to aid in the transition from high needle valve pops-off. Check at what pressure manifold pressure to high air velocity.
  • Page 100 SECTION 03 - ENGINE PREPARATION Pop-off Pressure Chart High Speed Circuit High speed circuit controls the fuel flow in addi- Needle Valve tion to the low speed and transition circuits. The Arm Spring Size high speed screw can control up to as much as 1/2 of the fuel delivered by the high speed circuit, de- 115 g 95 g...

  • Page 101: Racing Engine Preparation Summary

    SECTION 03 - ENGINE PREPARATION Pilot Jets for Mikuni Super BN Carburetors PILOT JET SIZE PART NUMBER 270 500 202 57.5 270 500 201 270 500 180 62.5 270 500 164 270 500 117 67.5 370 500 165 F01E1AA 270 500 175 1.
  • Page 102 SECTION 03 - ENGINE PREPARATION 6. Assemble the engine using the correct seal- ants where specified. Rotary valve timing should be correctly set for your application. Re- fer to FUNCTION OF THE ROTARY VALVE IN- TAKE SYSTEM in this section. For maximum power output, a dual carburetor setup should be used.
  • Page 103 SECTION 03 - ENGINE PREPARATION 10. Synchronize the carburetors and set the idle according to the appropriate model year Shop Manual ; then, synchronize the oil pump arm. At wide open throttle, the fuel/oil ratio deliv- ered by the oil pump is 40: 1. If additional oil is desired, pre-mix a quantity of oil with the fuel to achieve the desired fuel/oil ratio.
  • Page 104 SECTION 04 - PROPULSION SYSTEM TABLE OF CONTENTS BASIC FUNCTIONS OF THE SYSTEM ................... 04-2 PROPULSION SYSTEM ANALYSIS....................04-2 VENTILATION (AIR LEAK)....................... 04-3 CAVITATION ............................. 04-4 IMPELLER............................04-4 IMPELLER APPLICATION CHART ....................04-7 IMPELLER SPECIFICATIONS AND BOOT APPLICATIONS ............04-9 IMPELLER PITCH CHART ......................

  • Page 105: Section 04 - Propulsion System

    SECTION 04 - PROPULSION SYSTEM BASIC FUNCTIONS OF Water Inlet THE SYSTEM The function of the inlet is to carry the water to the jet pump with minimum loss. Another very im- The following is a brief explanation of some of the portant function is to assist the jet pump in trans- principals behind a water jet drive system.

  • Page 106: Ventilation (Air Leak)

    SECTION 04 - PROPULSION SYSTEM Nozzle The handlebar pivots the jet pump nozzle which controls the watercraft direction. These 2 items, the handlebar and nozzle, must be adjusted properly to obtain optimum control of the watercraft. The steering system alignment is most important to ensure the adequate control of the watercraft.

  • Page 107: Cavitation

    SECTION 04 - PROPULSION SYSTEM If everything is in good order but the watercraft does not accelerate quickly when depressing the throttle lever and a good top speed cannot be ob- tained, the pump is probably ventilating; then, the ride shoe must be removed and resealed to the hull.
  • Page 108 SECTION 04 - PROPULSION SYSTEM Regular Fixed Pitch 15° The impeller pitch remains constant on all the blades. The blades are straight with the same an- gle from leading to trailing edges. 15° 19° F01J4NB 1. Leading edge 2. Trailing edge 19°...
  • Page 109 SECTION 04 - PROPULSION SYSTEM Impeller/Wear Ring Clearance This clearance is critical for jet pump perfor- mance. Excessive clearance will result in de- creased performance. Clearance can be checked from water inlet open- ing, after inlet grate removal, or from venturi side after venturi/nozzle assembly removal.

  • Page 110: Impeller Application Chart

    SECTION 04 - PROPULSION SYSTEM IMPELLER APPLICATION CHART MODEL MODEL YEAR PITCH ANGLE MATERIAL NUMBER 5802 1989 18.8 aluminum 271 000 016 5803 1990 18.8 aluminum 271 000 016 5804 1991 18.8 aluminum 271 000 016 5805 1992 18.8 aluminum 271 000 016 5806 1993...
  • Page 111 SECTION 04 - PROPULSION SYSTEM IMPELLER APPLICATION CHART MODEL MODEL YEAR PITCH ANGLE MATERIAL NUMBER 5865/5866/5867 1996 11-24 stainless 271 000 470 5641 1997 11-22 stainless 271 000 470 5860 1992 18.3 stainless 271 000 123 5861 1993 18.3 stainless 271 000 123 5862 1994...

  • Page 112: Impeller Specifications And Boot Applications

    SECTION 04 - PROPULSION SYSTEM IMPELLER SPECIFICATIONS AND BOOT APPLICATIONS IMPELLER P/N IMPELLER SPECIFICATION BOOT P/N 271 000 015 271 000 028 18° cast aluminum 293 300 015 (O-ring) 271 000 086 18° die-cast aluminum 271 000 114 271 000 235 18°...

  • Page 113: Impeller Pitch Chart

    SECTION 04 - PROPULSION SYSTEM IMPELLER PITCH CHART NOTE: The following chart could be used as a guide to help optimize pitch for your application. 7000 TIME (seconds) 15 PITCH 4500 1400 BOAT SPEED MPH F01D72S 04-10...

  • Page 114: Engine/Jet Pump Alignment

    SECTION 04 - PROPULSION SYSTEM ENGINE/JET PUMP ALIGNMENT Alignment is necessary to minimize power loss and eliminate possible vibration and/or damage to components. Check alignment of your engine/jet pump using the following special alignment tools: NOTE: The alignment tool is available through your dealer.

  • Page 115: Functions Of The Variable Trim System (Vts)

    SECTION 04 - PROPULSION SYSTEM F01J5CB 1. Bow up 2. Push on VTS button UP position F00D0CA 3. Nozzle up TYPICAL When the nozzle is down, the bow comes down. 1. Shim CAUTION Whenever shims are used to correct align- ment, never install more than 1.3 mm (0.051 in) shim thickness.

  • Page 116: Propulsion System Maintenance

    SECTION 04 - PROPULSION SYSTEM PROPULSION SYSTEM – Verify impeller shaft end play. For racing pur- poses, maximum permissible end play (new) is MAINTENANCE 0.12 – 0.54 mm (.005 – .021 in). Excessive play comes from worn protrusion (end stop) inside To obtain optimum efficiency of jet pump and to housing cover.
  • Page 117 SECTION 05 - MISCELLANEOUS TABLE OF CONTENTS EQUIVALENT WEIGHTS AND MEASURES CHART ................ 05-2 GLOSSARY OF TERMS IN PERSONNAL WATERCRAFT RACING ..........05-3 RACER’S LOG ............................ 05-4 AFTERMARKET MANUFACTURERS ....................05-5 USE AT YOUR OWN RISK ........................ 05-6 05-1...

  • Page 118: Section 05 - Miscellaneous

    SECTION 05 - MISCELLANEOUS EQUIVALENT WEIGHTS AND MEASURES CHART LINEAR MEASURE 1 Inch = 25.4 Millimeters (mm) 1 Millimeter = .03937 Inch 1 Inch = 2.54 Centimeters (cm) 1 Centimeter = .3937 Inch 1 Foot = .3048 Meter (m) 1 Meter = 3.2808 Feet 1 Yard = .914 Meter (m) 1 Meter = 1.093 Yards AREA...

  • Page 119: Glossary Of Terms In Personnal Watercraft Racing

    SECTION 05 - MISCELLANEOUS GLOSSARY OF TERMS IN PERSONNAL WATERCRAFT RACING Bail: To wipe out, to fall. The bond flange is the overlapping/mating section where the deck (upper) and hull Bond Flange: (lower) portions are joined. Buoy: Floating object anchored in the water designating race course. An official located on the race course to help control the race as well as to assist Course Marshall: downed riders.

  • Page 120: Racer's Log

    SECTION 05 - MISCELLANEOUS RACER’S LOG Event: Date: Sheet Number: Association: Race Director: Temperature: Barometric Pressure: Humidity: Water Temperature: WATERCRAFT NOTES: Model Number: Hull Identification Number: Engine Identification Number: Weight: CARBURETION NOTES: Main Jet: Pilot Jet: Needle Valve: Low Speed Screw: High Speed Screw: Pop-off Pressure/Needle Valve Spring: Fuel Type:...

  • Page 121: Aftermarket Manufacturers

    SECTION 05 - MISCELLANEOUS AFTERMARKET MANUFACTURERS Aftermarket manufacturers produce products that can be used to replace the original Sea-Doo part on your watercraft. Some of these parts are designed to simply give the operator a choice of color or styling while others are intended to improve the performance characteristics of the watercraft.

  • Page 122: Use At Your Own Risk

    SECTION 05 - MISCELLANEOUS USE AT YOUR OWN RISK Beach House Express Bullett Engineering (Racing Parts and Sponsons) (Racing Parts) Brian Bevins 2422 East Huntington 301 North Gulf Dr. Duarte, CA91010 Bradenton, FL34217 Phone: (818) 357-6310 Phone: (941) 779-1151 Fax: (818) 357-4544 Fax: (941) 778-1886 Evolution Marine Factory Pipe...
  • Page 123 SECTION 05 - MISCELLANEOUS Race Pak Competition Systems Odyssey Racing (Racing Parts and Engine Modifications) (Data Acquisition) Dale Vranckx 26806 Vista Terrace R. R. 2 Courtland Lake Forest, CA92630 Ontario, Canada, N0J 1E0 Phone: (714) 580-6898 Phone: (519) 688-6818 Fax: (714) 580-6897 Fax: (519) 688-3099 R &...

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