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Sea-doo Speedster 5894 Shop Manual

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  • Page 3 1996 Shop Manual 219 100 044...
  • Page 4 Legal deposit : National Library of Quebec trimester 1995 National Library of Canada All rights reserved. No parts of this manual may be repro- duced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1995 Printed in Canada ®...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE ..........................INTRODUCTION ........................... SERVICE TOOLS 01 – Mandatory Tools............... 01-01-1 AND PRODUCTS 02 – Recommended Tools ............... 01-02-1 03 – Service Products ..............01-03-1 MAINTENANCE 00 – Table of contents..............02-00-1 01 – Periodic Inspection Chart ............02-01-1 02 –...
  • Page 6 TABLE OF CONTENTS SECTION SUB-SECTION PAGE PROPULSION AND 00 – Table of contents ..............09-00-1 DRIVE SYSTEMS 01 – Propulsion and Drive Systems ..........09-01-1 02 – Reverse System............... 09-02-1 03 – Variable Trim System (VTS)............09-03-1 STEERING SYSTEM 00 – Table of contents ..............10-00-1 01 –...

  • Page 7: Safety Notice

    SAFETY NOTINCE 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.

  • Page 8: Introduction

    1996 BOMBARDIER JET BOAT SHOP MANUAL INTRODUCTION HULL IDENTIFICATION NUMBER (H.I.N.) This Shop Manual covers the following BOMBAR- DIER made SEA-DOOr jet boats. The Hull Identification Number (H.I.N.) is located at right hand rear side of hull. MODEL MODEL NUMBER SPORTSTER 5895 SPEEDSTER...

  • Page 9: 01 Service Tools And Products

    1996 BOMBARDIER JET BOAT SHOP MANUAL ENGINE IDENTIFICATION ARRANGEMENT OF THIS NUMBER (E.I.N.) MANUAL It is located on the upper side of the magneto The manual is divided into 12 major sections : housing. 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM...
  • Page 10 1996 BOMBARDIER JET BOAT SHOP MANUAL This Shop Manual uses technical terms which may be slightly different from the ones in the Parts Catalog. TYPICAL PAGE Page heading indicates section and sub-section detailed. Sub-section title indicates Section 08 ELECTRICAL beginning of the Sub-Section 01 (MAGNETO SYSTEM) sub-section.
  • Page 11 1996 BOMBARDIER JET BOAT SHOP MANUAL This Shop Manual uses technical terms which may be slightly different from the ones in the Parts Catalog. TYPICAL PAGE Page heading indicates section and sub-section detailed. Sub-section title indicates Section 08 ELECTRICAL beginning of the Sub-Section 01 (MAGNETO SYSTEM) sub-section.

  • Page 12: General Information

    1996 BOMBARDIER JET BOAT SHOP MANUAL GENERAL INFORMATION ILLUSTRATIONS AND PROCEDURES The 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.

  • Page 13: Mandatory Tools

    MANDATORY TOOLS NOTE : The numbers outlined in black (example : ) are reference numbers to tools from other divisions (Sea-Doo and / or Sea-Doo Jet Boats). Matching numbers are the same tool even if the part numbers are different. ENGINE...
  • Page 14 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) Rubber pad PTO flywheel remover / Piston pin puller installer P / N 295 000 101 P / N 295 000 092 P / N 295 000 001 Replacement parts : F01J0T4 1.
  • Page 15 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) Ring gear blocking tool P / N 295 000 134 F01B264 APPLICATION 787 engine. Ring gear puller tool P / N 420 976 235 F01B294 APPLICATION 787 engine. 01-01-3...
  • Page 16 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) COOLING / FUEL / OIL SYSTEMS Hose pincher Pliers P / N 295 000 076 P / N 295 000 070 F01D174 APPLICATION All models. A01B2I4 APPLICATION All models. Pliers P / N 295 000 054 Gear holder P / N 290 277 905...

  • Page 17: Propulsion System

    Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) PROPULSION SYSTEM Impeller remover / Bearing / seal installer installer P / N 295 000 107 P / N 295 000 001 F01J0T4 APPLICATION All models. F01J4K4 NOTE : This tool is also APPLICATION used for the PTO flywheel.

  • Page 18: Recommended Tools

    RECOMMENDED TOOLS NOTE : The numbers outlined in black (example : ) are reference numbers to tools from other divisions (Sea-Doo and / or Sea-Doo Jet Boats). Matching numbers are the same tool even if the part numbers are different. ENGINE...
  • Page 19 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) Timing mark pointer Spark tester Ring halves and ring P / N 295 000 130 Not sold by Bombardier P / N 290 876 330 (halves) Superex Canada Ltd P / N 290 876 480 (ring)0 No.
  • Page 20 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) Protective mat Rotary valve shaft Exhaust outlet tool pusher P / N 295 000 129 P / N 295 000 132 P / N 290 876 609 F04L1V4 F01B2A4 F01B2B4 APPLICATION APPLICATION APPLICATION...
  • Page 21 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) COOLING / FUEL / OIL SYSTEMS Pump gauge tester Screwdriver (carburetor) Not sold by Bombardier P / N 295 000 114 Snap-on SDD-143 F01B1P4 APPLICATION All models. Lighted adjustable mirror Not sold by Bombardier Snap-on F01B0X4...
  • Page 22 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) PROPULSION SYSTEM Fitting Machinist’s square Bearing remover P / N 295 000 086 Not sold by Bombardier Not sold by Bombardier Do it yourself Snap-on Refer to Shop Manual section PMF 122 09-01 F01J114...

  • Page 23: Service Products

    NOTE : The numbers outlined in black (example : ) are reference numbers to tools from other divisions (Sea-Doo and / or Sea-Doo Jet Boats). Matching numbers are the same tool even if the part numbers are different. Medium strength...
  • Page 24 Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) Solvent Gasket stripper Heat resistant sealant P / N 293 800 019 N / P 295 500 110 P / N 413 709 200 Loctite Safety Dow Corning 736 Solvent 755 DOW CORNING ®...
  • Page 25 B O M BARD IE R 1 U.S. quart L U B E Sliding surface of starter arma- R E M PL ACE SEA-DOO LU BE ture shaft splines. LU BR IFIA NT ANTICOR RO SI F Exc ellent en milieu salin...
  • Page 26 P / N 293 110 001 400 g SCELLANT ADHÉSIF PREMIÈRE QUALITÉ PREMIUM SEALANT ADHESIVE P / N 293 600 011 P / N 293 110 002 4 L F01B1S4 APPLICATION Sea-Doo jet pump synthetic oil Ride shoe screws. Sponson. BOMBARDIER CLEANER 400 g...
  • Page 27 Gun Kote Loctite sealant Super white Not sold by Bombardier P / N 413 7103 00 P / N 293 500 076 Kal-Gard Coating & Mfg. Corp. Sea-Doo F000 000 000 paint F000 000 000 APPLICATION VERTICAL FANSPRAY ROTATE APPLICATION...
  • Page 28 Section 02 MAINTENANCE Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS PERIODIC INSPECTION CHART......................02-01-1 FLUSHING AND CARE ........................... 02-02-1 FLUSHING............................02-02-1 PROCEDURE ............................02-02-1 CARE ..............................02-02-3 WATER-FLOODED ENGINE........................02-03-1 STORAGE..............................02-04-1 02-00-1...

  • Page 29: Maintenance

    Section 02 MAINTENANCE Sub-Section 01 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART NOTE : Servicing period is given in hours. Shaded area shows the maintenance frequency. FREQUENCY Every 100 DESCRIPTION Every 10 Every 25 Every 50 hours or hours hours hours seasonally Lubrification / corrosion protection of metallic components DESS operation / DESS post and safety lanyard cap terminal condition...

  • Page 30: Flushing And Care

    Section 02 MAINTENANCE Sub-Section 02 (FLUSHING AND CARE) FLUSHING AND CARE FLUSHING Sportster and Challenger Models 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 31 Section 02 MAINTENANCE Sub-Section 02 (FLUSHING AND CARE) Challenger F04E0JA 1. Flushing connector with its cap F04E0IA 1. Install a hose pincher in this section For proper flushing, it is necessary to prevent wa- ter going out directly by the flushing connector on CAUTION : Do not open water tap yet.

  • Page 32: Care

    Section 02 MAINTENANCE Sub-Section 02 (FLUSHING AND CARE) CARE 1. Check joints for leaks to avoid water accumula- tion in the bilge. 2. Do not modify hose or socket size as coolant flow could be altered. 3. When engine is running, water must flow from bleed outlet(s) indicating that water circulates.

  • Page 33: Water-Flooded Engine

    Section 02 MAINTENANCE Sub-Section 03 (WATER-FLOODED ENGINE) WATER-FLOODED ENGINE General CAUTION : Be careful when cranking en- gine(s), water will spray out from spark If engine is water-flooded, it must be serviced plug holes. within a few hours after the event. Otherwise en- Spray BOMBARDIER LUBE lubricant (P / N 293 gine will have to be overhauled.
  • Page 34 Section 02 MAINTENANCE Sub-Section 03 (WATER-FLOODED ENGINE) CAUTION : Water must be supplied to cool engine(s) through the boat’s flushing connector(s). 02-03-2...

  • Page 35: Storage

    Engine Draining Fuel System Check engine drain hose running from engine Sea-Doo Fuel Stabilizer (P / N 413 408 600) can be manifold fitting to outlet socket. Make sure there added in fuel tank to prevent fuel deterioration is no sand or other particles in it and that it is not and carburetor gumming.
  • Page 36 Section 02 MAINTENANCE Sub-Section 04 (STORAGE) 6. Remove both spark plugs and spray BOMBAR- DIER LUBE lubricant into each cylinder. 7. Crank the engine a few turns to distribute the oil onto cylinder wall. 8. Apply antiseize lubricant (P / N 293 550 001) on spark plug threads then reinstall them.
  • Page 37 Section 02 MAINTENANCE Sub-Section 04 (STORAGE) Boat Cleaning CAUTION : Always use ethylene-glycol anti-freeze containing corrosion inhibi- Clean the bilge with hot water and mild detergent tors specifically recommended for aluminum or with bilge cleaner. Rinse thoroughly. Lift front engines. end of boat to completely drain bilge.
  • Page 38 Section 02 MAINTENANCE Sub-Section 04 (STORAGE) Challenger Challenger Model F04E0IB TYPICAL F04E0LA 1. Install a hose pincher on water injection hose, CSI hose and outlet hose between T-fitting and transom TYPICAL 2. Disconnect here 1. Hold hoses higher than tuned pipe Raise all hoses above the highest point of tuned 2.

  • Page 39: Troubleshooting

    Section 03 TROUBLESHOOTING TROUBLESHOOTING The following chart is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to have all causes for all problems. ENGINE WILL NOT START OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine does not turn over...
  • Page 40 Section 03 TROUBLESHOOTING ENGINE WILL NOT START (CONT’D) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine turns over • Fuel tank empty • Refill • Fuel water-contaminated • Renew supply • Dirty fuel filter • Clean / replace • Fouled spark plugs •...
  • Page 41 Section 03 TROUBLESHOOTING ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark • Fouled, defective, worn spark plugs • Check / verify heat range / gap /replace • Faulty MPEM or start / stop switch • Check, refer to section 08-05 •...
  • Page 42 Section 03 TROUBLESHOOTING NGINE CONTINUALLY BACKFIRES OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark • Fouled, defective spark plugs • Clean / replace • MPEM malfunction • Check, refer to section 08-05 Ignition timing • Incorrect setting • Check / reset, refer to section 08-03 •...
  • Page 43 Section 03 TROUBLESHOOTING POOR START, ACCELERATION OR PERFORMANCE OF BOAT OTHER OBSERVATION POSSIBLE CAUSE REMEDY Jet pump cavitation : • Poor start / acceleration of boat • Trailing edge of impeller is damaged • Check / Replace • Poor top performance of boat and / or •...

  • Page 44: Engine

    Section 04 ENGINE Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS REMOVAL AND INSTALLATION......................04-01-1 717 ENGINE............................04-01-1 787 ENGINE............................04-01-2 GENERAL............................. 04-01-3 REMOVAL FROM JET BOAT ....................... 04-01-3 CLEANING ............................04-01-7 INSTALLATION ............................ 04-01-7 TOP END ..............................04-02-1 ENGINE DESCRIPTION ........................04-02-2 GENERAL.............................

  • Page 45: Removal And Installation

    Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION 717 Engine 25 N•m (18 lbf•ft) 25 N•m Loctite (18 lbf•ft) Loctite Loctite 25 N•m 25 N•m Loctite (18 lbf•ft) (18 lbf•ft) 25 N•m (18 lbf•ft) Loctite 35 N•m 25 N•m (26 lbf•ft) (18 lbf•ft)
  • Page 46 Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) 787 Engine 25 N•m 25 N•m (18 lbf•ft) Loctite (18 lbf•ft) 25 N•m (18 lbf•ft) Loctite 25 N•m Loctite (18 lbf•ft) Loctite 25 N•m 40 N•m (18 lbf•ft) (30 lbf•ft) Loctite 242 Loctite 648 Loctite 515 24 N•m...

  • Page 47: Engine

    Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) GENERAL It is not necessary to remove engine from jet boat for TOP END nor PTO FLYWHEEL AND MAGNE- TO servicing. However engine removal is neces- sary to repair BOTTOM END AND ROTARY VALVE.
  • Page 48 Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) Engine Support Mounts Hook a sling into holes of special tools then using a chain block, a hoist or other suitable equipment, Remove engine support mount screws. slowly lift engine. NOTE : Be careful when removing engine 787 Engine support mount screws, shims could have been installed between engine support and rub-...
  • Page 49 Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) Remove tuned pipe retaining screw from exhaust manifold side. Remove tuned pipe mounting screws and nut from top of exhaust manifold. NOTE : Slightly lift tuned pipe to release nut as necessary. Withdraw tuned pipe.
  • Page 50 Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) Remove retaining screw of tuned pipe head. Remove carburetors. Refer to FUEL SYSTEM, CARBURETORS 06-03 for proper procedure. Remove 8 screws and lock washers then with- draw exhaust manifold. 15,16, Exhaust Outlet and Nut Sportster / Speedster To unscrew / screw the nut, use the exhaust out- let tool (P / N 295 000 132).

  • Page 51: Cleaning

    Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) Air Intake Silencer Removal Install and torque exhaust manifold screws to 12 N•m (9 lbf•ft) as per following illustrated se- Unlock retaining slides holding air intake silencer quence. Repeat the procedure, retightening cover and remove cover.
  • Page 52 Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) Refer to the following illustration for the torquing sequence. F01D69A TYPICAL 1. Sealing ring Apply a thin layer of heat resistant sealant (P / N F01D0IB 413 709 200) all around sealing ring. TYPICAL Refer to the main illustration at the beginning of Step...
  • Page 53 Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) NOTE : Due to exhaust cone angle, it may have to be rotated to obtain alignment. Push cone until it touches tuned pipe, then tight- en exhaust collar clamp and torque to 10 N•m (88 lbf•in).
  • Page 54 Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) 6, Screw and Loctite 242 (Blue) Apply Loctite 242 (blue) on screw threads. Retorque engine support screws to 25 N•m (18 lbf•ft) when procedure is completed. NOTE : Whenever alignment tool is not uti- lized, apply BOMBARDIER LUBE lubricant on its shaft and inside the housing to eliminate possible corrosion.
  • Page 55 Section 04 ENGINE Sub-Section 01 (REMOVAL AND INSTALLATION) CAUTION : Water must be supplied to cool engine(s) with a garden hose. 04-01-11...

  • Page 56: Top End

    Section 04 ENGINE Sub-Section 02 (TOP END) TOP END Synthetic Loctite Synthetic grease grease PST 592 24 N•m 40 N•m 24 N•m (17 lbf•ft) (30 lbf•ft) (17 lbf•ft) on 717 engine on 787 engine Loctite 242 Loctite 242 Synthetic grease Synthetic grease 24 N•m...

  • Page 57: Engine Description

    Section 04 ENGINE Sub-Section 02 (TOP END) ENGINE DESCRIPTION Remove cylinders, being careful that connecting rods do not hit crankcase edge. The 2-stroke ROTAX engine rotates counterclock- WARNING : If screws need to be heated wise seen from the rear (PTO flywheel). It has a for removal when engine is in jet boat, rotary valve to control fuel mixture intake.
  • Page 58 Section 04 ENGINE Sub-Section 02 (TOP END) F01D43A F01B0VA 1. Openings covered with rag and rubber pad PISTON PIN PULLER (PÞ/ÞN 290 000 105) 1. Locating sleeve (P / N 290 877 181) To remove circlip, insert a pointed tool in piston 2.

  • Page 59: Cleaning

    Section 04 ENGINE Sub-Section 02 (TOP END) INSPECTION Visually inspect all parts for corrosion damage. Inspect piston for damage. Light scratches can be sanded with a fine sand paper. Inspect plane surfaces for warpage. Small defor- mation can be corrected by grinding surface with a fine sand paper.
  • Page 60 Section 04 ENGINE Sub-Section 02 (TOP END) Cylinder Taper Using a cylinder bore gauge, measure cylinder di- ameter 16 mm (5/8 in) from top of cylinder to just below auxiliary transfer port, facing exhaust port. If the difference between readings exceed speci- fication, cylinder should be rebored and honed or replaced.

  • Page 61: Ring End Gap

    Section 04 ENGINE Sub-Section 02 (TOP END) Ring End Gap Position ring halfway between exhaust port and top of cylinder. NOTE : þIn order to correctly position ring in cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. If gap exceeds specified tolerance, rings should be re- placed.

  • Page 62: Assembly

    Section 04 ENGINE Sub-Section 02 (TOP END) Carefully cover crankcase opening as for disas- GASKET IDENTIFICATION sembly. THICKNESS HOLES 4,6, Piston Pin and Roller Bearing 0.3 mm (0.012 in) To install roller bearing and piston pin use piston 0.4 mm (0.016 in) pin puller (P / N 290 877 092), proceed as fol- 0.5 mm (0.020 in) lowsþ:...
  • Page 63 Section 04 ENGINE Sub-Section 02 (TOP END) PLASTIC MOUNTING DEVICE METHOD As an alternate method when no service tool is available proceed as followsþ: Replacement roller bearings are delivered in a convenient plastic mounting device. For installa- tion, proceed as followsþ: –...
  • Page 64 Section 04 ENGINE Sub-Section 02 (TOP END) F01B0KA 1. Circlip installer – Remove pusher from tool then insert circlip into its bore. – Reinstall pusher into tool and push until circlip comes in end of tool. F01D0TA 1. Pulling inner sleeve half –...
  • Page 65 Section 04 ENGINE Sub-Section 02 (TOP END) F01D35A F01D0ZA 1. Ring end gap aligned with piston locating pin Install cylinder gasket and slide cylinder over pis- ton. F01D0YA 7, Cylinder F01D10A To easily slide cylinder over piston, install ring compressor (P / N 295 000 112) over rings. When reassembling cylinders to crankcase, it is important to have them properly aligned so that exhaust flanges properly match up with exhaust...
  • Page 66 Section 04 ENGINE Sub-Section 02 (TOP END) F01D5AA 1. O-ring F01D44A 1,11, Cylinder Head Cover and Screw 717 ENGINE SHOWN 1. Exhaust flange aligning tool Apply synthetic grease (P / N 293 550 010) below screw head. 787 Engine Type Install cover over cylinder head.

  • Page 67: Rave System

    Section 04 ENGINE Sub-Section 02 (TOP END) RAVE SYSTEM Theory For a 2-stroke-cycle engine to have high power ca- pacity at high crankshaft speeds, a high volumet- ric or breathing efficiency is required and the fresh charge losses must be minimized. The result is achieved by opening the exhaust port early and utilizing the resonant effects of the tuned exhaust system to control fresh charge losses.
  • Page 68 Section 04 ENGINE Sub-Section 02 (TOP END) The RAVE valve does not allow an engine to make higher peak horsepower than an engine not so equipped, it can make moving the peak higher practical because of its effect on the rest of the power curve.

  • Page 69: Squish Area

    Section 04 ENGINE Sub-Section 02 (TOP END) Troubleshooting SYMPTOM CAUSE REMEDY Engine revs 500 to 1. Bend valve rod Replace 1000 RPM lower 2. Stuck valve Clean than its maximum operational 3. Wrong spring Replace RPM ; RAVE valve tension (too does not open at high) all.
  • Page 70 Section 04 ENGINE Sub-Section 02 (TOP END) F01D64A 1. Solder 2. Measure here CAUTION : Do not use acid core solder ; the acid can damage the piston and cylinder. – Take another measurement at the opposite side of the piston. –...

  • Page 71: Pto Flywheel And Magneto

    Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) PTO FLYWHEEL AND MAGNETO 717 Engine Anti-seize lubricant 110 N•m (81 lbf•ft) Loctite Loctite 242 10 N•m (89 lbf•in) 5 N•m Loctite 242 (44 lbf•in) 6 N•m 4 N•m (53 lbf•in) (35 lbf•in) Loctite Anti-seize...
  • Page 72 Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) 787 Engine Anti-seize 110 N•m (81 lbf•ft) 3 lubricant Loctite 10 N•m (89 lbf•in) Synthetic grease Loctite 10 N•m (89 lbf•in) Loctite Loctite 242 105 N•m (77 lbf•ft) 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) Anti-seize...

  • Page 73: General

    Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) GENERAL 3, PTO Flywheel 717 Engine The following procedures can be performed with- out removing engine from jet boat. For only PTO Using 3 M8 x 35 screws (P / N 290 841 591), in- flywheel removal withdraw jet pump unit ass’y, stall screws through puller plate and slide sleeves refer to PROPULSION AND DRIVE SYSTEMS 09-...
  • Page 74 Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) F01D4AA TYPICAL F01D1AA 1. Extension handle locking crankshaft TYPICAL 787 Engine 1. PTO flywheel remover (P / N 295 000 001) Remove starter. Using a suitable wrench or socket, unscrew PTO Lock ring gear using special tool (Pþ/þN 295 000 flywheel COUNTERCLOCKWISE when facing it.

  • Page 75: Magneto Flywheel

    Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) A00C1AA Fully thread on puller in puller plate. F01D1AA Tighten puller bolt and at the same time, tap on TYPICAL bolt head using a hammer to release MAG fly- 1. PTO flywheel remover (P / N 295 000 001) wheel from its taper.
  • Page 76 Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) 4,5, MAG Flywheel and Ring Gear 717 Engine Lay MAG flywheel on a steel plate, then to ease removal heat ring gear with a propane torch to ap- proximately 150 °C (300 °F) to break the Loctite bond.
  • Page 77 Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) – Find manufacturer’s mark on armature plate. In line with this mark, punch another mark on ad- jacent crankcase lug. F01D4DA 1. Crankcase locating lug 2. Mark armature plate at the end of lug F01D4FA –...

  • Page 78: Cleaning

    Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) 8,9, Ignition Housing and Screw 4,5, MAG Flywheel and Ring Gear 717 Engine 717 Engine To remove ignition housing, starter has to be re- Apply Loctite 648 (green) to MAG flywheel mat- moved.
  • Page 79 Section 04 ENGINE Sub-Section 03 (PTO FLYWHEEL AND MAGNETO) 4,10, Magneto and Nut 3, PTO Flywheel Apply lubricant Anti-Seize on crankshaft threads 787 Engine then screw on PTO flywheel. When reinstalling magneto rotor to engine fly- Using same tool as for removal, torque PTO fly- wheel, one of the protuberance end of magneto wheel to 110 N•m (81 lbf•ft).

  • Page 80: Bottom End

    Section 04 ENGINE Sub-Section 04 (BOTTOM END) BOTTOM END 717 Engine Loctite Anti-seize lubricant Anti-seize Anti-seize lubricant lubricant Loctite Primer "N" and Loctite 515 Lithium grease 24 N•m (17 lbf•ft) Loctite Loctite 515 Loctite 515 40 N•m Synthetic (30 lbf•ft) grease 24 N•m Synthetic grease...
  • Page 81 Section 04 ENGINE Sub-Section 04 (BOTTOM END) 787 Engine 30 ml (1 oz) FORMULA XP-S Synthetic injection oil Loctite Anti-seize lubricant Synthetic grease Synthetic grease Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant Loctite 242 Synthetic grease Loctite 515 Anti-seize lubricant Loctite Anti-seize...

  • Page 82: Crankshaft Misalignment And Deflection

    Section 04 ENGINE Sub-Section 04 (BOTTOM END) CRANKSHAFT MISALIGNMENT – Remove spark plugs. AND DEFLECTION – Insert a screwdriver in one spark plug hole. – Insert a longer screwdriver in the other hole. Since it is an assembled crankshaft it can become –...

  • Page 83: General

    Section 04 ENGINE Sub-Section 04 (BOTTOM END) DISASSEMBLY Remove the following partsþ: – Ignition housing and PTO flywheel on opposite side. F01D4JA F01D4IA 1. Separating ignition housing / armature plate from crankcase 1. TDC gauge 2. Degree wheel – Rotary valve cover and valve. 3.
  • Page 84 Section 04 ENGINE Sub-Section 04 (BOTTOM END) F01B09A 1. Puller (P / N 290 876 298) 2. Protective cap (P / N 290 876 557) F01D1LA 3. Distance ring, MAG side (P / N 290 876 569) 1. Separate halves by prying at provided lugs 4.

  • Page 85: Cleaning

    Section 04 ENGINE Sub-Section 04 (BOTTOM END) If crankshaft and / or components are found de- fective, it must be repaired by a specialized shop or replaced. 787 Engine New oil seals do not necessitate the use of a cage. F01D1PA 1.
  • Page 86 Section 04 ENGINE Sub-Section 04 (BOTTOM END) F01D1QA F01D1TA 1. Ruler must be aligned with edge of connecting rod here 1. Measuring MAG side deflection in crankcase 2. Align ruler here Remove crankshaft bearings and check deflection Crankshaft Deflection again on V-shaped blocks as illustrated. NOTE : Crankshaft deflection can not be correctly measured between centers of a lathe.

  • Page 87: Assembly

    Section 04 ENGINE Sub-Section 04 (BOTTOM END) Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. F01D1XA 1. Bearing against a steel plate 2. Propane torch 3. Heat plate through bearing bore F01D1WA To properly locate outer PTO bearing, temporarily install distance gauge (P / N 290 876 827 for 717...
  • Page 88 Section 04 ENGINE Sub-Section 04 (BOTTOM END) 1,4 Seal 787 Engine At seal assembly, apply a light coat of lithium 5, Drive Pin grease on seal lips. Make sure drive pins of bearings are properly in- On 787 engine, use a pusher (P / N 290 877 740) stalled in crankcase recesses at assembly.
  • Page 89 Section 04 ENGINE Sub-Section 04 (BOTTOM END) CAUTION : On 717 engine, temporarily install armature plate to align crankcase halves with each other. 8,9, Screw Apply Loctite 515 on screw threads and synthetic grease below head screws. 717 Engine 8,9,10, Screw Torque crankcase screws to 24 N•m (17 lbf•ft) as per following illustrated sequence.
  • Page 90 Section 04 ENGINE Sub-Section 04 (BOTTOM END) F01D86A TYPICAL 1. Add 30 mL (1oz) of injection oil Finalizing Assembly 12, Oil Outlet Fitting All Engines If oil outlet fitting has been removed from crank- case, reinstall it with its end pointing towards igni- tion housing.

  • Page 91: Rotary Valve

    Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) ROTARY VALVE 20 N•m (15 lbf•ft) F01D4LS PARTS FLAT RATE 04-05-1...

  • Page 92: General

    Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) GENERAL The following verification procedures such as clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without re- moving engine from boat. Refer to INSPECTION further in this section. However engine must be removed from boat to work on rotary valve shaft / components.
  • Page 93 Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) F01D25A F01D4OA 1. Compress seat 1. Do not remove this plug 2. Remove circlips End bearing can be easily removed using the fol- 7,8, Snap Ring and Bearing lowing suggested tool. To remove bearing use a bearing extractor such as Snap-on hammer puller including : Handle CJ93-1, Snap-on no.

  • Page 94: Cleaning

    Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) CLEANING NOTE : If the clearance is below 0.25 mm (0.010 in) this could create an overheating Discard all seals and O-rings. situation and if the clearance is over 0.35 mm (0.014 in) this could create a hard starting situa- Clean all metal components in a solvent.
  • Page 95 Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) 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 96: Assembly

    Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) Measure shaft deflection near gear mounting ar- F01D2DA TYPICAL 1. Shielded side here (towards gear) Push bearing until it stops on its seat. F01D2CA TYPICAL 1. Rotary valve shaft 2. End bearing in place Deflection must not exceed specified value.
  • Page 97 Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) F01D4OA F01D2FA TYPICAL 1. Seal 2. Ball bearing 1. Plug 3. Snap ring 4. Distance sleeve If plug has been removed, clean plug and crank- 5. Shim 0.5 mm (.020 in) case hole with Loctite Safety Primer (P / N 293 6.
  • Page 98 Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) F01D34A F01D8OA 1. Rotary valve shaft ass’y 2. Push shaft until it stops All Engines 787 Engine At snap ring installation, position it so that its sharp edge faces outwards. To install rotary valve in crankcase, use a pusher (P / N 290 876 609) with an handle (P / N 420 877 ROTARY VALVE 650).
  • Page 99 Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) TEMPLATE 159° (cut-out-angle) 290 924 502 actual size F01D73S TEMPLATE 04-05-9...

  • Page 100: Rotary Valve Timing

    Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) Rotary Valve Timing CAUTION : Never use the ridge molded in crankcase as a timing mark. The following tools are required to measure rotary valve opening and closing angles in relation with MAG side piston. 295 000 007 F01D2IA 1.
  • Page 101 Section 04 ENGINE Sub-Section 05 (ROTARY VALVE) 65° F01D3EA EXAMPLE : Top of MAG inlet port. Align 360 ° line of degree wheel Step here : Find 65 ° on degree wheel and mark here Step 1. Closing mark – Remove degree wheel. –...

  • Page 102: Cooling System

    Section 05 COOLING SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS COMPONENTS ............................05-01-1 SPORTSTER AND SPEEDSTER......................05-01-1 GENERAL............................. 05-01-2 WATER FLOW REGULATOR VALVE....................05-01-3 CIRCUIT ..............................05-02-1 GENERAL............................. 05-02-1 717 ENGINE COOLING SYSTEM ......................05-02-4 787 ENGINE COOLING SYSTEM ......................05-02-5 05-00-1...

  • Page 103: Components

    Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) COMPONENTS Sportster and Speedster Loctite Loctite Loctite Loctite Loctite F04E0GS 05-01-1 PARTS FLAT RATE...

  • Page 104: General

    Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) GENERAL CAUTION : The elbow fittings are cali- brated for each engine model and can not All Models be interchanged with one of a different size as severe engine damage could result. CAUTION : All hoses and fittings of the cooling system have calibrated inside di- The elbow fitting can be identified by using the 2 ameters to assure proper cooling of the en-...

  • Page 105: Water Flow Regulator Valve

    Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) Challenger A water flow regulator valve has been developed so that the engine can produce the maximum horsepower output and yet maintain the neces- sary diameter of the injection fitting at the tuned pipe head for unobstructed water flow.
  • Page 106 Section 05 COOLING SYSTEM Sub-Section 01 (COMPONENTS) ADJUSTEMENT NOTE : The water flow regulator valve has been calibrated at the factory and should not be tampered with or modified in any way. CAUTION : Strictly adhere to the calibra- tion procedure below, otherwise serious engine damage can occur.

  • Page 107: Circuit

    Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) CIRCUIT GENERAL Challenger Only Prior to entering the engine, the main inlet hose TECHNICAL DATA from the jet pump has a T-fitting to supply the wa- TYPE : flow regulator valve which is mounted directly on TLCS (Total Loss Cooling System).
  • Page 108 Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) All Models Fresh water from the jet pump enters the head assembly, cooling the combustion chamber to prevent detonation. F01E0FA TYPICAL - SPORTSTER / SPEEDSTER 1. Water enters cylinder cooling jacket F01E1LA 2. Drain hose 1.
  • Page 109 Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) F04L2XB SPEEDSTER 1. Port engine water outlet 2. Starboard engine water outlet On Sportster / Speedster, draining of the system is accomplished by a fitting to the bottom of ex- haust manifold. Refer to illustration above. On Challenger, draining of the system is accom- plished by a fitting at the bottom of each cylinder.

  • Page 110: 717 Engine Cooling System

    Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) 717 Engine Cooling System Temperature sensor activates monitoring beeper when temperature exceeds 96-99° (205-210°F) Uppermost point of circuit (tuned pipe) allows bleeding Fresh water enters engine head to prevent Calibrated cylinder head detonation Calibrated outlet limits water flow fitting limits water...
  • Page 111 Section 05 COOLING SYSTEM Sub-Section 02 (CIRCUIT) 787 Engine Cooling System Ce tuyau de purge est situé au Cette sonde Indicateur du point de purge le plus élevé actionne Système de du moteur , soit au niveau du l'avertisseur refroidissement tuyau d'échappement calibré...

  • Page 112: Fuel System

    Section 06 FUEL SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT ............................06-01-1 SPORTSTER AND CHALLENGER......................06-01-1 SPEEDSTER............................06-01-2 GENERAL............................. 06-01-3 AIR INTAKE ............................. 06-02-1 CARBURETORS ............................06-03-1 GENERAL............................. 06-03-2 CARBURETOR REMOVAL ........................06-03-2 CLEANING ............................06-03-2 DISASSEMBLY AND INSPECTION ......................

  • Page 113: Fuel Circuit

    Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) FUEL CIRCUIT Sportster and Challenger To engine Loctite Loctite F04F05S PARTS FLAT RATE 06-01-1...

  • Page 114: Speedster

    Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) Speedster Left engine Right engine To engine To engine Loctite Loctite F04F06S PARTS 06-01-2 FLAT RATE...

  • Page 115: General

    Al- ways wipe off any fuel spillage from the boat. When replacing fuel lines on SEA-DOO JET BOATS be sure to use «B1» hoses as available Challenger Only from the BOMBARDIER parts department.
  • Page 116 Section 06 FUEL SYSTEM Sub-Section 01 (FUEL CIRCUIT) Fuel Tank Removal Remove the following parts to allow fuel tank removal : – jet pump(s) – engine(s) – electrical box (Speedster only) – battery and its case (when applicable) 06-01-4...

  • Page 117: Air Intake

    Section 06 FUEL SYSTEM Sub-Section 02 (AIR INTAKE) AIR INTAKE 10 N•m (88 lbf•in) 10 N•m (88 lbf•in) Loctite Loctite Loctite Loctite 242 10 N•m (88 lbf•in) Loctite 515 F04F04S PARTS FLAT RATE 06-02-1...

  • Page 118: Carburetors

    Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) CARBURETORS Loctite Loctite Loctite Synthetic grease Synthetic grease F04F07S PARTS FLAT RATE 06-03-1...

  • Page 119: General

    Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) GENERAL CAUTION : Be careful at carburetor clean- ing not to remove paint. Paint removal Some carburetor components and / or settings will cause carburetor to rust very rapidly. Re- can be changed to improve boat performance in paint if necessary.

  • Page 120: Carburetor Assembly

    Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) Check fuel pump valves operation as follows : Remove filter from carburetor body then clean fil- ter and blow carefully with compressed air (low Connect a clean plastic tubing to the inlet nipple pressure).
  • Page 121 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) F01F34A LOW LEVER Step : Depress here Step : Pry up here Pressure Test Proceed as follows : – Install pump gauge tester on carburetor inlet nipple. – Obstruct outlet nipple with a finger. –...

  • Page 122: Carburetor Installation

    Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) Leak Test 11, Check Valve Assembly Needle valve must stand a pressure of 69 kPa (10 The check valve is needed if a back pressure oc- PSI) for 30 seconds. Otherwise, hold carburetor curs into carburetor.
  • Page 123 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) Carburetor Synchronization NOTE : The linkage installation is done with the marks located near PTO carburetor throt- With idle speed screw not touching throttle lever tle lever to ease adjustment if to be performed in stopper on MAG carburetor, both throttle plates the boat.

  • Page 124: Adjustments

    Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) ADJUSTMENTS The following illustration shows which part of the carburetor begins to function at different throttle valve openings. F01F07A 717 ENGINE SHOWN 1. Throttle lever stoppers (behind levers) 2. Adjustment nut Speedster Only Ensure that at full throttle, both throttle levers (op- erator’s control) are synchronized at the same po- sition.
  • Page 125 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) F04H28A 1. Electrical box connector WARNING : Always connect RED positive cable first then BLACK negative cable last. After connecting the battery, reinstall the electri- cal box connector. F04L0GB TYPICAL-SPEEDSTER SHOWN 2, Low-Speed Mixture Screw 1.

  • Page 126: Fuel System Pressurization

    Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) CAUTION : If boat is out of water, water 15, Idle Speed Screw must be supplied to cool engine with a garden hose. Turning screw clockwise leans mixture and turn- ing screw counterclockwise enriches mixture. Turn low-speed mixture screw so that engine reaches the most suitable idle and runs smoothly.
  • Page 127 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) CAUTION : Ensure to verify fuel line ends for damage. Always cut damaged end be- fore reinstallation. Pressure Test Proceed as follows : – Fill up fuel tank. – Ensure to firmly tighten fuel tank cap. Remove vent hose from boat’s body.

  • Page 128: Table Of Contents

    Section 07 LUBRICATION SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION RESERVOIR ........................07-01-1 SPORTSTER AND CHALLENGER......................07-01-1 SPEEDSTER............................07-01-2 GENERAL............................. 07-01-3 OIL INJECTION PUMP..........................07-02-1 SPORTSTER AND SPEEDSTER......................07-02-1 CHALLENGER............................07-02-2 CLEANING ............................07-02-3 DISASSEMBLY ............................ 07-02-3 ASSEMBLY ............................

  • Page 129: Oil Injection Reservoir

    Section 07 LUBRICATION SYSTEM Sub-Section 01 (OIL INJECTION RESERVOIR) OIL INJECTION RESERVOIR Sportster and Challenger F04G0BS PARTS 07-01-1 FLAT RATE...

  • Page 130: Speedster

    Section 07 LUBRICATION SYSTEM Sub-Section 01 (OIL INJECTION RESERVOIR) Speedster Left engine Right engine F04G0CS 07-01-2 PARTS FLAT RATE...

  • Page 131: General

    Section 07 LUBRICATION SYSTEM Sub-Section 01 (OIL INJECTION RESERVOIR) GENERAL Whenever repairing the oil injection system, al- ways verify for water infiltration in reservoir. 1,2, Clamp and Hose Verify oil filler neck hose for damage. Always en- sure that clamps are well positioned and tight- ened.

  • Page 132: Oil Injection Pump

    Section 07 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) OIL INJECTION PUMP Sportster and Speedster 6 N•m (53 lbf•in) Loctite Loctite 10 N•m (89 lbf•in) 6 N•m (53 lbf•in) 8 N•m (71 lbf•in) 8 N•m (71 lbf•in) 4.5 N•m (40 lbf•in) Loctite 5 N•m (44 lbf•in)
  • Page 133 Section 07 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) Challenger 6 N•m (53 lbf•in) Loctite Loctite Loctite 4.5 N•m 4.5 N•m (40 lbf•in) (40 lbf•in) Loctite F04G0DS PARTS FLAT RATE 07-02-2...

  • Page 134: Sportster And Speedster

    Section 07 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) Challenger Only The oil injection pump is located on the magneto housing cover and is driven directly by the crank- shaft. Oil pump flow rate at 1500 RPM for 30 seconds is 0,71 - 0,87 mL for each port.

  • Page 135: Adjustments

    Section 07 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) F02D05A 1. Oil injection lines F01G0KA ADJUSTMENTS TYPICAL 1. Adjustment screw (not shown) 2. Aligned marks Synchronization (All Models) Tighten jam nut and recheck alignment marks. Ensure carburetor butterfly(ies) is(are) in closed position.

  • Page 136: Checking Operation

    Section 07 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) F04G0EA CHALLENGER F01G0EA 1. Must be full of oil 2. Bleed screw TYPICAL Keep bleeding until all air has escaped from line. 1. Engine at idle 2. Fully open position Make sure no air bubbles remain in oil feed line. 3.

  • Page 137: Oil System Pressurization

    Section 07 LUBRICATION SYSTEM Sub-Section 02 (OIL INJECTION PUMP) NOTE : To minimize time of oil system pres- surization the oil reservoir should be quite full. The system must maintain a pressure of 21 kPa (3 PSI) for at least 10 minutes. Never pressur- ize over 21 kPa (3 PSI).

  • Page 138: Electrical

    Section 08 ELECTRICAL Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENT OVERVIEW .............................. 08-01-1 717 ENGINE ............................08-01-1 MAGNETO SYSTEM..........................08-01-1 IGNITION SYSTEM (SINGLE GENERATOR COIL)................08-01-1 MPEM (MULTI-PURPOSE ELECTRONIC MODULE) ................08-01-2 CHARGING SYSTEM ........................... 08-01-2 STARTING SYSTEM ..........................08-01-2 GAUGES / ACCESSORIES ........................
  • Page 139 Section 08 ELECTRICAL Sub-Section 00 (TABLE OF CONTENTS) SPARK PLUGS ............................08-04-1 SPARK PLUG SYMBOL EXPLANATION ................... 08-04-1 DISASSEMBLY ............................ 08-04-2 HEAT RANGE ............................08-04-2 FOULING ............................. 08-04-2 SPARK PLUG ANALYSIS ........................08-04-2 SPARK PLUG INSTALLATION......................08-04-2 SPARK PLUG CHART .......................... 08-04-3 THE DESS (DIGITALLY ENCODED SECURITY SYSTEM)..............
  • Page 140 Section 08 ELECTRICAL Sub-Section 00 (TABLE OF CONTENTS) INSTRUMENTS AND ACCESSORIES....................08-09-1 SPORTSTER............................08-09-1 SPEEDSTER............................08-09-2 FUEL / OIL GAUGE ..........................08-09-3 WIRING DIAGRAM ..........................08-010-1 WIRE COLOR ............................08-010-1 WIRE TERMINAL REMOVAL....................... 08-010-1 ACCESSORIES INSTALLATION ......................08-010-1 FUSES LOCATION..........................08-010-1 08-0-3...

  • Page 141: Overview

    Section 08 ELECTRICAL Sub-Section 01 (OVERVIEW) OVERVIEW 717 ENGINE The electrical system consist of different sub-sys- tems where some are inter-related. The magneto is coupled to the engine and produc- es electrical energy for the ignition system and the charging system. Its outputs are directed to- ward the ignition coil as well as the charging sys- tem and some circuits through the MPEM (Multi- Purpose Electronic Module).

  • Page 142: Mpem (Multi-Purpose Electronic Module)

    Section 08 ELECTRICAL Sub-Section 01 (OVERVIEW) F04H0WA 1. Voltage regulator / rectifier 2. Battery F04H0VA 3. Magneto system 1. Spark plugs 2. Ignition coil with integreted ignition module STARTING SYSTEM 3. Magneto system 4. MPEM (Multi-purpose Electronic Module) The battery supplies the D.C. current to the elec- MPEM (MULTI-PURPOSE tric starter via a solenoid to start the engine.
  • Page 143 Section 08 ELECTRICAL Sub-Section 01 (OVERVIEW) F04H0YA 1. Battery 2. Fuse block 3. Accessories 08-01-3...

  • Page 144: 787 Engine

    Section 08 ELECTRICAL Sub-Section 01 (OVERVIEW) 787 ENGINE CHARGING SYSTEM The electrical system consist of different sub-sys- It receives its primary electric current from mag- tems where some are inter-related. neto via 3 wires which charges the battery. The magneto supplies unregulated AC current to a The magneto is coupled to the engine and produc- voltage regulator / rectifier.

  • Page 145: Ignition System

    Section 08 ELECTRICAL Sub-Section 01 (OVERVIEW) IGNITION SYSTEM A Digital DC-CDI (Direct Current-Capacitor Dis- charge Ignition) system is utilized on the 787 en- gine. The ignition system is made up of the following components: A00E4JA 1. Coil 4. Magnetic field outside of coil 2.

  • Page 146: Magneto System

    Section 08 ELECTRICAL Sub-Section 02 (MAGNETO SYSTEM) MAGNETO SYSTEM 717 Engine 24 N•m (17 lbf•ft) Dielectric grease Loctite 10 N•m (89 lbf•in) 5 N•m (44 lbf•in) Loctite Loctite 4 N•m (35 lbf•in) 6 N•m (53 lbf•in) Loctite Loctite Loctite 105 N•m (77 lbf•ft) 5 N•m (44 lbf•in)

  • Page 147: Removal

    Section 08 ELECTRICAL Sub-Section 02 (MAGNETO SYSTEM) REMOVAL Refer to ENGINE section 04-03 then look for PTO Flywheel and Magneto for parts removal. DISASSEMBLY 1, Ignition System Generator Coil (Single) To replace generator coil : – Heat the armature plate to 93°C (200°F) around the screw holes to break the threadlocker bond.

  • Page 148: Assembly

    Section 08 ELECTRICAL Sub-Section 02 (MAGNETO SYSTEM) 3, Charging System Generator Coil – Position new coil, crimp and solder all wires. To replace : 3,4, Charging System Generator Coil – Heat the armature plate to 93°C (200°F) around and Screw the screw holes to break the threadlocker Prior to assembly, apply Loctite 242 (blue).

  • Page 149: 787 Engine

    Section 08 ELECTRICAL Sub-Section 02 (MAGNETO SYSTEM) 787 Engine Loctite 242 Synthetic 10 N•m grease (88 lbf•in) Loctite 648 10 N•m (88 lbf•in) Loctite 242 105 N•m (77 lbf•ft) Loctite 648 10 N•m (88 lbf•in) 10 N•m (88 lbf•in) 9 N•m (80 lbf•in) Anti-seize lubricant...

  • Page 150: Magneto Rotor And Engine Flywheel Removal

    Section 08 ELECTRICAL Sub-Section 02 (MAGNETO SYSTEM) MAGNETO ROTOR AND ENGINE Engine flywheel is easily freed from crankshaft with puller (P / N 420 976 235) and crankshaft pro- FLYWHEEL REMOVAL tective cap (P / N 290 876 557). Remove starter. Insert crankshaft protector to outer end of crankshaft and fully thread puller in engine Lock ring gear using special tool (P / N 295 000...

  • Page 151: Ignition System

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) IGNITION SYSTEM ELECTRICAL SYSTEM Sportster See Electrical Accessories See Electric Box Dielectric grease Wires BLACK F04H10S PARTS FLAT RATE 08-03-1...

  • Page 152: Electrical Box

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) ELECTRICAL BOX Sportster F04H11S 08-03-2 PARTS FLAT RATE...

  • Page 153: Electrical System

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) ELECTRICAL SYSTEM Speedster See electrical accessories Dielectric grease Dielectric grease See electrical Dielectric grease Dielectric grease Dielectric grease Wires BLACK LEFT RIGHT engine engine F04H27S PARTS FLAT RATE 08-03-3...

  • Page 154: Electrical Box

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) ELECTRICAL BOX Speedster F04H26S 08-03-4 PARTS FLAT RATE...

  • Page 155: Ignition System Testing Procedure, 717 Engine

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) IGNITION SYSTEM TESTING PROCEDURE, 717 ENGINE General MPEM (Multi-Purpose Electronic Module) NOTE : The following section gives informa- tion for both Sportster and Speedster mod- ENGINE RPM LIMITER els. To make the section shorter, the Sportster is On Speedster model, there is one RPM limiter for actually described and the differences for the each engine in the MPEM.
  • Page 156 Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) Magneto / Ignition Coil Output Tests 3. Install cap over safety lanyard post and depress starting button until light turns on, or otherwise, These items can be easily checked with Bombar- for a maximum of 5 seconds. dier ignition tester (P / N 295 000 008) and the 4- 4.
  • Page 157 Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) Safety Precautions Ignition Coil Output WARNING : To prevent powerful electric A paper clip of approximately 20 mm (3/4 in) will shocks while cranking engine, neither be used as a test adapter for the following test. touch any electronic ignition components (ig- 1.

  • Page 158: Ignition Timing, 717 Engine

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) Summary Table for Bombardier IGNITION COIL Ignition Tester RESISTANCE PART NAME WIRE COLOR (OHM) (Ω) Test to Tester Component wires Switch Dial perform wires End of each spark plug BLACK / RED Ignition Secondary cable, spark 9-15 k...
  • Page 159 Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) 3. Install timing mark tool (P / N 295 000 130) on engine right side using wing nut previously re- moved. F01H2GA 1. Timing mark tool 4. Install and adjust a TDC gauge (P / N 295 000 F01H4LA 143) in spark plug hole as follows : TYPICAL...
  • Page 160 Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) F01H31A 1. Tool slot 2. Flywheel mark F01H2IA This mark becomes the reference when using TYPICAL 1. Timing light pick-up on MAG side stroboscopic timing light. 2. Connect an induction-type tachometer to spark CAUTION : Timing mark position verifica- plug wire.

  • Page 161: Ignition Timing Adjustment, 717 Engine

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) IGNITION TIMING ADJUSTMENT, 717 ENGINE Timing is performed by moving armature plate, clockwise to retard spark occurrence or counter- clockwise to advance. F01H32A 1. Too advanced timing In this case, turn armature plate clockwise. When PTO flywheel mark is on left side of timing tool slot, it indicates retarded timing.

  • Page 162: Ignition System Testing Procedure, 787 Engine

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) IGNITION SYSTEM TESTING PROCEDURE, 787 ENGINE General • Incorrectly controlled engine maximum RPM. To diagnose spark problems that might come NOTE : On occasion a component will stati- from the MPEM, first check that its BLACK wire cally check good but in fact be defective.
  • Page 163 Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) STATIC TEST : CONTINUITY + Meter Lead - Meter Lead Value RE / PU 2.6 KΩ YL / WH 0.380 MΩ 2.208 MΩ BK / OR infinity BK / GR infinity 0.2 Ω WH / BL 30.38 KΩ...
  • Page 164 Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) DYNAMIC TEST Test can be performed with either the Bombardier ignition tester (P / N 295 000 008) OR the KOWA ignition coil tester (typical), available from after market tool / equipment suppliers. Testing with the Bombardier Ignition Tester For more information how to perform the test and interpret the results, refer to ‘’USE OF BOMBAR-...

  • Page 165: Ignition Timing, 787 Engine

    Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) Ignition Timing Procedure STATIC TEST 1. To install the new timing mark pointer tool, first remove PTO flywheel guard. Then remove mid- dle screw securing the engine to the rear cross- over motor mount. Reinstall screw with timing mark pointer tool attached.
  • Page 166 Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) Ignition Timing Adjustment THE TIMING CORRECTION CHART The timing marks refer to the physical component Since the trigger coil on this engine is fixed and position when the spark must occur. The DC-CDI not movable to correct the ignition timing, the module must be synchronized with these marks.
  • Page 167 Section 08 ELECTRICAL Sub-Section 03 (IGNITION SYSTEM) – You recheck the marks with the timing light and 11. Press Enter to confirm yes you want to save found that the flywheel mark is still too ad- modifications to the MPEM. vanced.

  • Page 168: Spark Plugs

    Section 08 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUGS SPARK PLUG SYMBOL EXPLANATION WIDE GAP PREFIX SUFFIX 10 : 1.0 mm (.040") 11 : 1.1 mm (.044") B P 5 E S 13 : 1.3 mm (.050") 14 : 1.4 mm (.055") 15 : 1.5 mm (.060") 20 : 2.0 mm (.080") Thread...

  • Page 169: Disassembly

    Section 08 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DISASSEMBLY FOULING First unscrew the spark plug one turn. Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed Clean the spark plug and cylinder head with pres- due to misfiring, reduced performance, and in- surize air then completely unscrew.

  • Page 170: Spark Plug Chart

    Section 08 ELECTRICAL Sub-Section 04 (SPARK PLUGS) A00E0BA 1. Proper socket 2. Improper socket SPARK PLUG CHART Engine Spark Torque type plugs N•m (lbf•ft) mm (inch) 24 (17) 0.55 (.022) BR8ES 08-04-3...

  • Page 171: 05 -The Dess (Digitally Encoded Security System)

    Section 08 ELECTRICAL Sub-Section 05 (THE DESS (DIGITALLY ENCODED SECURITY SYSTEM)) THE DESS (DIGITALLY ENCODED SECURITY SYSTEM) SAFETY LANYARD NOTE : Technically, the boat’s MPEM is the component that is actually programmed to The basic operation of the DESS safety lanyard is recognize a safety lanyard.
  • Page 172 Section 08 ELECTRICAL Sub-Section 05 (THE DESS (DIGITALLY ENCODED SECURITY SYSTEM)) The boat MPEM features a permanent (non-vola- tile) memory and keeps programmed safety lan- yard(s) active even when the boat’s battery is disconnected. When replacing an MPEM, reprogramming safety lanyard(s) is required.

  • Page 173: Monitoring System

    Section 08 ELECTRICAL Sub-Section 05 (THE DESS (DIGITALLY ENCODED SECURITY SYSTEM)) MONITORING SYSTEM To assist you when using the boat, a system monitors the DESS and sends audible signals through a beeper to warn you of a particular condition. It is self-activated when the safety lanyard is being installed on the boat’s DESS post.
  • Page 174 Section 08 ELECTRICAL Sub-Section 05 (THE DESS (DIGITALLY ENCODED SECURITY SYSTEM)) 1. Remove safety lanyard from boat’s DESS post and set shifter in NEUTRAL. 2. Press 5 times on the boat starting button. • 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode.

  • Page 175: Mpem (Multi-Purpose Electronic Module)

    Section 08 ELECTRICAL Sub-Section 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE)) MPEM (multi-purpose electronic module) NOTE : The following section gives informa- To Start Engine tion for both Sportster and Speedster mod- Install safety lanyard on boat’s DESS post. The els. To make the section shorter, the Sportster is MPEM will be energized instantly and will check actually described and the differences for the the safety lanyard cap.

  • Page 176: Electrical Tests For The Mpem

    Section 08 ELECTRICAL Sub-Section 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE)) RPM Limiter Speedster Only – Both batteries must be properly connected. It has 4 functions : Never alter connections of batteries. They are • Keeps high voltage away from safety lanyard connected in parallel.
  • Page 177 Section 08 ELECTRICAL Sub-Section 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE)) If the DESS system is not working, you can check If the STOP function of the start / stop switch the DESS wire as follow. Disconnect the connec- does not work, it is necessary to check if engine tor behind dashboard.
  • Page 178 Section 08 ELECTRICAL Sub-Section 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE)) RPM Limiter Accessories If maximum engine’s speed is not limited to 7000 If an accessory does not work, first check acces- RPM, check the connection of BLACK / RED / sory fuse (on MPEM). It is also possible to check GREEN wire (additional BLACK / RED wire for port the operation of an accessory by connecting it di- (LH) side of Speedster).
  • Page 179 Section 08 ELECTRICAL Sub-Section 06 (MPEM (MULTI-PURPOSE ELECTRONIC MODULE)) ACCESSORY COUNTER TYPE CENTER CLOCKWISE SWITCH CLOCKWISE Blower On / Off NONE B1-L1 closed Bilge Pump On / Off NONE B1-L1 closed L2 : On / Off Nav / Anc B1-L2 B1-L1-L2 L1 &...

  • Page 180: 07 -Charging System

    Section 08 ELECTRICAL Sub-Section 07 (CHARGING SYSTEM) CHARGING SYSTEM TESTING PROCEDURE 717 Tester Tester Tester Component ENGINE switch dial wires wires position position NOTE : First, ensure that battery is in good YELLOW condition prior to performing the following of magneto harness test using current inductive ammeter such as Snap-on MT 110.
  • Page 181 Section 08 ELECTRICAL Sub-Section 07 (CHARGING SYSTEM) Use the following table : MAGNETO RESISTANCE PART NAME WIRE COLOR (OHM) (Ω) Charging YELLOW with system YELLOW / BLACK 0.05 - 0.6 generator coil of magneto harness TESTING PROCEDURES 787 ENGINE BK-YL YL-WH Stator F01H4XA...
  • Page 182 Section 08 ELECTRICAL Sub-Section 07 (CHARGING SYSTEM) Rectifier / Regulator STATIC TEST : CONTINUITY 1. Due to internal circuitry, there is no static test available. DYNAMIC TEST 1. Disconnect the RED lead coming out of the rectifier / regulator. 2. Connect the multimeter + lead to the rectifier / regulator RED wire and the - lead to ground.

  • Page 183: 08 -Starting System

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) STARTING SYSTEM ELECTRIC STARTER 5 N•m Dielectric (44 lbf•in) grease Loctite 271 Ground cable Dielectric grease 22 N•m (16 lbf•ft) F01H1MS PARTS FLAT RATE 08-08-1...
  • Page 184 Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) GENERAL Causes of troubles are not necessarily related to starter but may be due to a burnt fuse, faulty bat- tery, ignition switch, start / stop switch, safety lan- yard switch, solenoid, electrical cables or connections.

  • Page 185: Starting System Troubleshooting

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY Starter does not turn. Burnt MPEM supply fuse. Check wiring condition and replace fuse. Poor contact of battery terminal(s) or Clean and tighten terminal(s). ground cable connections. Weak battery.

  • Page 186: Removal

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) REMOVAL Disconnect BLACK cable ground connection from battery. WARNING : Always disconnect ground cable first and reconnect last. Disconnect RED cable connection from battery. Remove the following parts. – cables from starter – screw of starter rear support (no. 23) –...

  • Page 187: Assembly

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) Check commutator for roughness, burnt or scored surface. If necessary, turn commutator on a lathe, enough to resurface only. Check commutator for mica depth. If depth is less than 0.20 mm (.008 in), undercut mica. Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed.
  • Page 188 Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) A03E0EA F01H0SA 1. Armature shaft 1. Locating protrusion is the higher one 2. Circlip 3. Pinion stop collar 4. Punch 1,7, Yoke Ass’y and Housing Align previously traced indexing marks. F01H0TA 1. Brush holder locating notch To ease end frame installation, retain brush holder with a small screwdriver while installing end frame.

  • Page 189: Starter Installation

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) 12, Nut Connect the RED battery cable to the starter and torque nut to 6 N•m (53 lbf•in). Apply dielectric grease on terminal and nut. 16,18, Screw and Teeth Washer Apply Loctite 271 (red) on screw. Connect BLACK cable to starter using flat washer, teeth washer and screw.

  • Page 190: Starter Specification

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) STARTER SPECIFICATION Nominal output 0.6 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise (viewed from pinion side) Weight Approx. 2 kg (4.4 lb) Performance specification No load 11.5 V 20 A max. 5500 RPM at 20°C(68°F) Load...

  • Page 191: Battery

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) BATTERY CAUTION : Should any electrolyte spill- age occur, immediately wash off with a solution of baking soda and water to prevent TROUBLESHOOTING damage to boat components. WARNING : Electrolyte is poisonous, dan- SYMPTOM : DISCHARGED OR WEAK BATTERY gerous and explosive.

  • Page 192: Hydrometer Test

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) HYDROMETER TEST CAUTION : Do not overfill. The battery must always be stored in fully charged condition. If required, charge until specif- ic gravity of 1.260 is obtained. CAUTION : Battery electrolyte tempera- ture must not exceed 50°C (122°F).
  • Page 193 Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) 1. Remove the sealing tube from the vent elbow. WARNING : Failure to remove the sealing tube could result in an explosion. A17E0HA 5. Readjust the electrolyte level to the UPPER LEVEL line. A17E0FB 1.
  • Page 194 Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) WARNING : Gases given off by a battery being charged are highly explosive. Al- ways charge in a well ventilated area. Keep battery away from cigarettes or open flames. Always turn battery charger off prior to discon- necting cables.

  • Page 195: Servicing

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) SERVICING – Measure the voltage at the battery posts with an accurate voltmeter. If it is below 10 volts, the battery will accept current at very low rate, in Electrolyte Level term of milliamperes, because electrolyte is Since a battery has been activated (see above), nearly pure water as explained above.

  • Page 196: Installation Of Battery

    Section 08 ELECTRICAL Sub-Section 08 (STARTING SYSTEM) Charging 2 or More Batteries at a Time WARNING : To prevent any possible spark that may occur at the battery terminals Connect all positive battery posts together and while connecting the cables, unscrew and dis- use a charger with a capacity (rated) equal to : connect the connector at the electrical box PRI- number of battery to be charged multiply by 2 A.

  • Page 197: 09 -Instruments And Accessories

    Section 08 ELECTRICAL Sub-Section 09 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES Sportster Dielectric grease Dielectric grease Dielectric grease Dielectric grease Dielectric grease Dielectric grease Dielectric grease Electrical System Dielectric grease Dielectric grease Dielectric grease Dielectric grease F04H14S PARTS FLAT RATE 08-09-1...
  • Page 198 Section 08 ELECTRICAL Sub-Section 09 (INSTRUMENTS AND ACCESSORIES) Speedster Dielectric grease Dielectric Dielectric grease grease Dielectric grease Dielectric grease Dielectric grease Dielectric grease Dielectric grease Electrical System Dielectric grease Dielectric grease Dielectric grease Dielectric Dielectric grease grease F04H17S PARTS 08-09-2 FLAT RATE...

  • Page 199: Fuel / Oil Gauge

    Section 08 ELECTRICAL Sub-Section 09 (INSTRUMENTS AND ACCESSORIES) FUEL / OIL GAUGE Speedster The fuel / oil gauge has a pointer which indicates FUEL LEVEL AND RESISTANCE fuel level. To verify if fuel pointer works, first FUEL LEVEL RESISTANCE touch start /stop button (with safety lanyard re- moved) to activate electrical system for about 33 (in) (Ω)
  • Page 200 Section 08 ELECTRICAL Sub-Section 09 (INSTRUMENTS AND ACCESSORIES) When there is enough oil inside the oil tank (and therefore in the sensor reservoir), the sensor de- tects the liquid and the light DOES NOT turn on. When the oil level goes at a critical LOW level in- side the oil tank (and therefore in sensor reser- voir), the sensor detects the absence of liquid and the light turns on.
  • Page 201 Section 08 ELECTRICAL Sub-Section 09 (INSTRUMENTS AND ACCESSORIES) To verify speed sensor, use a voltmeter as follows : – Disconnect speed sensor from inside the bilge. – Provide a 12 Vdc to the sensor. Connect the + wire to the PURPLE / YELLOW wire and con- nect the - wire to the BLACK wire.

  • Page 202: 10 -Wiring Diagram

    Section 08 ELECTRICAL Sub-Section 10 (WIRING DIAGRAM) WIRING DIAGRAM WIRE COLOR FUSES LOCATION First color of a wire is the main color. Second color MPEM, Sportster / Challenger is the tracer color. Speedster Only In the electrical system, basically the same wire 20 A colors are used for starboard (RH) and port (LH) sides.
  • Page 203 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS PROPULSION AND DRIVE SYSTEMS....................09-01-1 JET PUMP UNIT ..........................09-01-1 ALL MODELS ............................09-01-1 DRIVE SHAFT AND SEAL CARRIER ....................09-01-2 GENERAL............................. 09-01-3 JET PUMP INSPECTION ON JET BOAT ....................09-01-3 JET PUMP REMOVAL .........................

  • Page 204: Propulsion And

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) PROPULSION AND DRIVE SYSTEMS JET PUMP UNIT All Models Loctite 598 Loctite Speedster only Sealant 732 Loctite 515 Loctite PST 592 If required 7 N•m (62 lbf•in) Loctite PST 592 35 N•m Loctite (26 lbf•ft)
  • Page 205 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) DRIVE SHAFT AND SEAL CARRIER Loctite Loctite Loctite 2 N•m (18 lbf•in) Synthetic grease Synthetic grease Loctite F04J0US PARTS FLAT RATE 09-01-2...

  • Page 206: Jet Pump Inspection On Jet Boat

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) GENERAL Some pump components can be changed to im- prove boat performance in high altitude regions between 1500 - 3000 m (5000 - 10 000 ft). Refer to the service department for the latest specifica- tions.

  • Page 207: Jet Pump Removal

    Pour approximately 90 mL (3 oz) of oil through hole until oil reaches the bottom of hole threads. Use SEA-DOO JET PUMP SYNTHETIC OIL (P / N 293 600 011) only. Oil will penetrate slowly in housing, wait a few minutes and readjust oil level.
  • Page 208 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) F01J0GA – Insert pointed tips of pliers in closing hooks. F02J0PC TYPICAL 1. Unfasten small clamp – Keep clamp for later use. Hold floating ring and compress protective boot ; then, pull out O-ring from driveshaft groove.
  • Page 209 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) From inside bilge, disconnect coolant inlet hose 7,8, Nut and Impeller Housing from impeller housing. Remove nuts retaining impeller housing to hull. Withdraw pump unit and drive shaft together. CAUTION : When removing pump unit, a shim could have been installed between hull and pump housing, be careful not to dam-...
  • Page 210 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) An hydraulic jack can be used to remove ride JET PUMP DISASSEMBLY shoe. NOTE :Whenever removing a part, visually Place a steel plate on ride shoe and a long piece check for damage such as : corrosion, crack, of wood underneath swim platform.
  • Page 211 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) – Drill deep socket with a 14 mm (9/16 in) drill bit, starting at hexagon head end as shown in fol- lowing illustration. – Drill a 2.40 mm (3/32 in) hole in center of deep socket as shown in following illustration.
  • Page 212 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) F01J2HA F01J0VA 1. Impeller remover installer tool TYPICAL 2. Impeller shaft holder tool CAUTION : Never use any impact wrench to loosen impeller. To remove impeller, apply a rotating movement and pull at same time.
  • Page 213 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) F01J0XA F01J0XA F01J10A 1. Pulling seal out of housing NOTE :If bearings and seal need to be re- newed, the special pusher described further on in bearing removal can be used. Simply insert pusher from the rear and push towards the front.

  • Page 214: Cleaning

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) Properly clean all threads. Discard all O-rings and clean parts in a solvent. Carefully check water passages (Cooling system) and oil passages. Blow low pressure compressed air through them and make sure they are not clogged.
  • Page 215 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) 24,25,34, Drive Shaft, Carbon Ring and Damper Wear Visually inspect shape of dampers for deforma- tion or other damage. Ensure they are firmly re- tained. Inspect carbon ring and its contact surface. Check for scoring, pitting, chipping or other evidence of wear.
  • Page 216 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) 19,20, IMPELLER AND WEAR RING 22,25, Needle Bearing and Impeller Shaft Examine impeller in wear ring for distortion. Wear Check if blade tips are blunted round, chipped or Inspect needle bearings and their contact surface.
  • Page 217 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) 26,27, Thrust Washer and Thrust Bearing Visually inspect thrust washer, thrust bearing and their contact surface. Check for scoring, pitting, flaking, discoloration or other evidence of wear. F01J19A MEASURING IMPELLER SHAFT RADIAL PLAY 1.

  • Page 218: Jet Pump Assembly

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) F01J2SA F01J53A 1. Tip on shaft end 1. Impeller shaft nose Excessive play comes from worn protrusion in- 21, Seal side housing cover and wear of impeller shaft Carefully inspect seal lips.
  • Page 219 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) 21,22, Seal and Needle Bearing Bearings and seal will be properly installed in housing using bearing / seal installer tool (P / N 295 000 107). F01J4KA BEARING / SEAL INSTALLER TOOL 1.
  • Page 220 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) Apply Loctite 515 (P / N 293 800 007) in seal hous- ing, all around outer diameter and on seal seat. Properly insert seal on tool. NOTE :Be careful when installing seals to pack seal with grease before inserting bear- ing / seal installer tool.
  • Page 221 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) F01J1OA Insert tool onto shaft end then carefully slide housing over shaft. F01J1MA 1. Loctite 518 all around and behind 2. Raised edge of seal lip this side 8,19,25,26,27, Impeller Housing, Impeller, Impeller Shaft, Thrust Washer and Thrust Bearing...
  • Page 222 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) F01J1QA F01J2HA TYPICAL 1. Impeller remover installer tool 2. Impeller shaft holder tool 1. Apply Loctite 271 (red) on threads 17,28,29, Housing Cover, O-ring and CAUTION : Make sure thrust washer and bearing have not slipped in shaft groove.

  • Page 223: Pump Pressurization

    Place housing horizontally as in its operating posi- tion so that fitting in cover is located in top. Re- move fitting from cover. Pour SEA-DOO JET PUMP SYNTHETIC OIL (P / N 293 600 011) in res- ervoir until oil comes level with bottom of hole.
  • Page 224 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) Insert drive shaft in impeller then carefully insert boot in impeller. Use screwdriver blade to push on boot. F01J1TA 1. Loctite 518 on mating surface 2. Loctite 242 (blue) 3.

  • Page 225: Jet Pump Installation

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) Apply epoxy glue on aluminum insert (P / N 292 000 075) knurled surface and on plastic insert in- ner bore. CAUTION : A clearance between plastic insert and aluminum insert could possibly be noticed.
  • Page 226 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) Incorrect stud installation may strip the threads in Jet Pump Unit the aluminum anchor plate that retains the stud or Apply Loctite 598 Ultra black on pump as shown the nut may not engage the stud properly.
  • Page 227 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) Reinstall drive shaft protector tube and protective boot w / carbon ring. Install the small O-rings (2) on drive shaft then slide the floating ring over O-rings. Temporarily install the remaining O-ring on drive shaft end.

  • Page 228: All Models

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) 1,2,3,4,5, Screw, Sleeve, Bushing and Nozzle Insert bushings in nozzle, positioning their flanges from inside of nozzle. Apply BOMBARDIER LUBE lubricant (P / N 293 600 006) on outer circumfer- ence of sleeve then insert in nylon bushings.
  • Page 229 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS) F04J0DA 1. Ball joint parallel with cable lever 2. Latching mechanism NOTE :Ball joint must be parallel with cable lever. If not, slacken jam nut and adjust ball joint.

  • Page 230: Reverse System

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 02 (REVERSE SYSTEM) REVERSE SYSTEM All Models Loctite 271 Loctite 242 Loctite 242 Loctite 242 Loctite Loctite 242 F04J0ES PARTS FLAT RATE 09-02-1...

  • Page 231: Disassembly

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 02 (REVERSE SYSTEM) DISASSEMBLY Fully push shifter in forward position. A latching sound should be heard. Try manually pulling re- Pay attention to the following : verse gate(s) down. They must be locked by the latching mechanism.
  • Page 232 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 02 (REVERSE SYSTEM) F04L0GA TYPICAL - SPEEDSTER MODEL SHOWN 1. Adjust reverse gates individually here Shifter Cable Replacement Detach cable ball joint from cable lever on reverse gate then unscrew ball joint from cable. From inside of hull, slacken lock nut.

  • Page 233: Variable Trim System (Vts)

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 03 (VARIABLE TRIM SYSTEM (VTS)) VARIABLE TRIM SYSTEM (VTS) Challenger 14 N•m (10 lbf•ft) Loctite Loctite Loctite 14 N•m (10 lbf•ft) 14 N•m (10 lbf•ft) F04J0WS PARTS FLAT RATE 09-03-1...

  • Page 234: Adjustments

    Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 03 (VARIABLE TRIM SYSTEM (VTS)) Trim Cable Replacement Detach cable adjuster from trim ring then un- screw adjuster from cable end. From inside of hull, slacken lock nut. From outside of hull, pull cable to allow half rings removal. For the other end of cable, remove the controller from the deck and detach cable from its mecha- nism.
  • Page 235 Section 09 PROPULSION AND DRIVE SYSTEMS Sub-Section 03 (VARIABLE TRIM SYSTEM (VTS)) F04K0BA TYPICAL 1. Adjust slider mechanism cable here while shifter is at FORWARD 2. Adjust cable so that blocks hold together with a tension in the cable 3. Ensure cable locking devices are properly installed 4.

  • Page 236: Steering System

    Section 10 STEERING SYSTEM Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ..........................10-01-1 SPORTSTER............................10-01-1 SPEEDSTER............................10-01-2 STEERING SYSTEM INSPECTION....................... 10-01-3 STEERING CABLE REPLACEMENT ....................10-01-3 STEERING HELM REPLACEMENT...................... 10-01-3 ALIGNMENT ............................10-02-1 THROTTLE / SHIFTER / VTS CONTROLLER ..................10-03-1 REMOVAL ............................

  • Page 237: Steering System

    Section 10 STEERING SYSTEM Sub-Section 01 (STEERING SYSTEM) STEERING SYSTEM Sportster 6 N•m (53 lbf•in) 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) Loctite 40 N•m (30 lbf•ft) Silicone sealant Loctite Loctite Loctite 242 40 N•m 20 N•m (30 lbf•ft) (15 lbf•ft) F04K0DS 10-01-1...

  • Page 238: Speedster

    Section 10 STEERING SYSTEM Sub-Section 01 (STEERING SYSTEM) Speedster 6 N•m (53 lbf•in) 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) Loctite 40 N•m (30 lbf•ft) Silicone sealant Loctite Loctite Loctite 242 20 N•m 40 N•m (15 lbf•ft) (30 lbf•ft) F04K0CS 10-01-2 PARTS...

  • Page 239: Steering System Inspection

    Section 10 STEERING SYSTEM Sub-Section 01 (STEERING SYSTEM) STEERING SYSTEM INSPECTION STEERING CABLE REPLACEMENT Check operation of steering. It must turn easily Removal and smoothly with a regular resistance from side – Remove nut no. 1 from adjuster no. 2, then to side.
  • Page 240 Section 10 STEERING SYSTEM Sub-Section 01 (STEERING SYSTEM) Installation Reinstall removed parts and pay attention to the following : Prior to installing steering helm to boat, position helm arm as shown. F04K09A 1. Correct position 2. Helm arm – When installing steering helm to boat, position screws no.

  • Page 241: Alignment

    Section 10 STEERING SYSTEM Sub-Section 02 (ALIGNMENT) ALIGNMENT Position steering in straight ahead position. F04K01A F04J03A Sportster and Challenger Models 1. Straight edge across nozzle ends Check jet pump nozzle alignment and steering All Models centering by placing a straight edge on nozzle A small adjustment can be made with adjuster on end.
  • Page 242 Section 10 STEERING SYSTEM Sub-Section 02 (ALIGNMENT) Sporster and Challenger Models F04K0AA Step : Remove nut Step : Slacken lock nuts Step Turn to adjust 1. Cable end must protude here Speedster model F04K02A 1. Adjust here 2. Cable end must protrude here Ensure to apply Loctite on parts as indicated on exploded view.

  • Page 243: Throttle / Shifter / Vts Controller

    Section 10 STEERING SYSTEM Sub-Section 03 (THROTTLE / SHIFTER / VTS CONTROLLER) THROTTLE / SHIFTER / VTS CONTROLLER3 REMOVAL Sportster Unscrew retaining screws. CAUTION : Use a protective mat (P / N 295 000 129) in shifter area when withdrawing controller.
  • Page 244 Section 10 STEERING SYSTEM Sub-Section 03 (THROTTLE / SHIFTER / VTS CONTROLLER) Speedster Challenger F04K07A F04K07B 1. Set screw of shifter and starboard throttle (outer lever) TYPICAL 2. Set screw of port throttle (inner lever) 1. Set screw of shifter and VTS 2.

  • Page 245: Assembly

    Section 10 STEERING SYSTEM Sub-Section 03 (THROTTLE / SHIFTER / VTS CONTROLLER) F04K05B 1. Shifter lever 2. Shifter plate 3. Set screw (shifter lock) ASSEMBLY F04K0BA When reinstalling throttle / shifter control to boat, TYPICAL be careful not to bend cables. 1.
  • Page 246 Section 11 HULL/DECK Sub-Section 00 (TABLE OF CONTENTS) TABLE OF CONTENTS COMPONENTS ............................11-01-1 BUMPER REPLACEMENT........................11-01-6 DECAL REPLACEMENT ........................11-01-6 REAR STORAGE COMPARTMENT COVER GAS SHOCKS ..............11-01-7 LATCH ADJUSTMENT ......................... 11-01-7 DRAIN / COOLING OUTLET(S) LOCATION..................11-01-7 DRAIN REPLACEMENT ........................11-01-8 SEAT REMOVAL / INSTALLATION .......................

  • Page 247: Hull / Deck

    Section 11 HULL / DECK Sub-Section 01 (COMPONENTS) COMPONENTS Loctite Loctite Loctite Loctite Some models only Loctite 5 N•m (44 lbf•in) F04L3FS PARTS FLAT RATE 11-01-1...
  • Page 248 Section 11 HULL / DECK Sub-Section 01 (COMPONENTS) SPEEDSTER and CHALLENGER models Synthetic grease Loctite SPORTSTER model only Loctite Silicone 5 N•m sealant (44 lbf•in) F04L3GS 11-01-2 PARTS FLAT RATE...
  • Page 249 Section 11 HULL / DECK Sub-Section 01 (COMPONENTS) SPEEDSTER model only Silicone sealant (clear) SPEEDSTER and SPORTSTER models only Silicone Loctite sealant (clear) F04L1QS PARTS FLAT RATE 11-01-3...
  • Page 250 Section 11 HULL / DECK Sub-Section 01 (COMPONENTS) Silicone sealant (clear) Loctite Loctite Silicone sealant (clear) CHALLENGER model only SPEEDSTER model only Some models only Sealant "Ultra-Black" F04L3HS 11-01-4 PARTS FLAT RATE...
  • Page 251 Section 11 HULL / DECK Sub-Section 01 (COMPONENTS) Loctite F04L3IS PARTS 11-01-5 FLAT RATE...

  • Page 252: Bumper Replacement

    Section 11 HULL / DECK Sub-Section 01 (COMPONENTS) BUMPER REPLACEMENT Installation There are 2 types of decals used on jet boat. One Bumper and Trim has a protective film on back side and the other NOTE : Prior to beginning job, place bumper has a protective film on both sides.

  • Page 253: Rear Storage Compartment Cover Gas Shocks

    Section 11 HULL / DECK Sub-Section 01 (COMPONENTS) Using a pencil and the decal as a template, mark the area where decal will be located. Gently heat the marked surface with a flame (a heat gun does not work). Heat until the material begins to change (color and texture).

  • Page 254: Drain Replacement

    Section 11 HULL / DECK Sub-Section 01 (COMPONENTS) DRAIN REPLACEMENT Rear Backrest The 4 rear retaining screws can be reached from Bilge Pump Drain engine compartment. Remove electrical box to • Disconnect drain tube from transom fitting. reach starboard retaining screw. •...

  • Page 255: Repair

    These areas must catalyst which is sprayed into the mold. have a rough surface to allow the gelcoat putty to The body and hull of the Sea-Doo jet boat are con- bond properly. structed of chopped fiberglass, saturated with resin.

  • Page 256: Blisters

    Make sure that the air supply is free of oil, dirt and – Improper catalyst / gelcoat ratio. water. A blister is a visible bump on the Sea-Doo jet boat Test spray the gelcoat mixture on paper to verify surface that may not necessarily come right its consistency and pattern.
  • Page 257 Section 11 HULL / DECK Sub-Section 02 (REPAIR) Compound fractures are those that have gone Using a clean paintbrush, brush the mixed resin past the gelcoated surface and in through the lay- on the surface. Place the smallest piece of mat ers of fiberglass laminate.

  • Page 258: Tools And Materials List

    – putty knife – masking tape – plastic film – sandpaper – stirring stick – (100-grit, 220-grit, 220-grit, 320-grit, 400-grit, – cover sheets (for Sea-Doo) – 600-grit, 1000-grit) – scissors – 24-grit sanding disks – buffing pad – Bombardier gelcoat putty –...

  • Page 259: Painting

    82-51-624-8221 82-2-792-2477 PPG paint for Sea-Doo jet boat is not available in spray can. For best result it must be applied by a professional painter. For fast touch up on metallic and gelcoat surfaces, refer to the appropriate Bombardier Sea-Doo Jet Boat Parts Catalog , it contains a few spray can part numbers.

  • Page 260: Parts That Can Be Painted

    Section 11 HULL / DECK Sub-Section 03 (PAINTING) PARTS THAT CAN BE PAINTED F04L3KS 1. Body 10. Ignition Housing Cover 2. Hull 11. Deck Storage Compartment Cover 3. Rear Storage Cover 12. Flame Arrester Support 4. Engine 13. Flame Arrester Base 5.
  • Page 261 Section 11 HULL / DECK Sub-Section 03 (PAINTING) PPG COLOR Nos. FOR SEA-DOO JET BOATS PART SPORSTER CHALLENGER SPEEDSTER 1.Body Super White Super White Super White 98260 98260 98260 2.Hull Super White Super White Super White 98260 98260 98260 3.Rear Storage Cover...

  • Page 262: Concepttm Painting Procedure

    Section 11 HULL / DECK Sub-Section 03 (PAINTING) CONCEPTTM PAINTING PROCEDURE For additional information refer to PPG P-Bulletin no. 168. SURFACE PREPARATION FULL PANEL AND OVERALL REPAIRS Prepare and clean surface consistent with good painting practices. Application Primer Apply 1 medium wet coat and give 5-10 minutes flash, followed by 2 wet coats with 15 minutes DP Epoxy Primer / DP 401 Catalyst ;...

  • Page 263: Deltatm Painting Procedure

    Section 11 HULL / DECK Sub-Section 03 (PAINTING) DELTATM PAINTING PROCEDURE (with low VOC, mainly in California) For additional information refer to PPG P-Bulletin no. 157. SURFACE PREPARATION Primer : DELTA PRIME DPU 166. DELTA 2800, COLOR How to Mix Mix DELTA 2800 2:1, 2 parts Colors to 1 DU 6 Catalyst.

  • Page 264: Technical Data

    Section 12 TECHNICAL DATA Sub-Section 01 (ALL MODELS) ALL MODELS ENGINE SPORSTER (5895) SPEEDSTER (5894) Number of engine Engine type Bombardier-Rotax 717, water cooled Induction type Rotary valve Exhaust type Type Water cooled, water injected Water injection fittings 3.5 mm (.139 in) Starting system Electric start Lubrication...
  • Page 265 Section 12 TECHNICAL DATA Sub-Section 01 (ALL MODELS) ELECTRICAL SPORTSTER (5895) SPEEDSTER (5894) Magneto generator output 160 W @ 6000 RPM or 4 A @ 2000 RPM (each engine on Speedster) Ignition system type CDI (Capacitor Discharge Ignition) Spark plug Make and type NGK BR8ES 0.55 mm (.021 in)
  • Page 266 Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines Oil type SEA-DOO JET PUMP SYNTHETIC OIL Polyolester 75W90 GL5 Steering nozzle pivoting angle 26° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in)
  • Page 267 Section 12 TECHNICAL DATA Sub-Section 01 (ALL MODELS) MATERIAL SPORTSTER (5895) SPEEDSTER (5894) Hull Composite (fiberglass) Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Base : Polyethylene Foam : Polyurethane Ride shoe Aluminum Jet pump...
  • Page 268 Section 12 TECHNICAL DATA Sub-Section 01 (ALL MODELS) TIGHTENING TORQUE SPORTSTER (5895) SPEEDSTER (5894) Exhaust manifold screw 24 N•m (17 lbf•ft) Magneto flywheel nut 105 N•m (77 lbf•ft) Flywheel (PTO side 110 N•m (81 lbf•ft) Crankcase screws 9 N•m (80 lbf•in) 24 N•m (17 lbf•ft) (3) (4)
  • Page 269 Section 12 TECHNICAL DATA Sub-Section 01 (ALL MODELS) ENGINE CHALLENGER (5896) Number of engine Engine type Bombardier-Rotax 787, water cooled Induction type Rotary valve Exhaust type Type Water cooled, water injected Water injection fittings 3.5 mm (.139 in) Starting system Electric start Lubrication Fuel / oil mixture...
  • Page 270 Section 12 TECHNICAL DATA Sub-Section 01 (ALL MODELS) ELECTRICAL CHALLENGER (5896) Magneto generator output 180 W @ 6000 RPM or 5 A @ 2000 RPM Ignition system type DC-CDI (Direct-Current Capacitor Discharge Ignition) Spark plug Make and type NGK BR8ES 0.55 mm (.021 in) Ignition timing mm (in)
  • Page 271 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC OIL Oil type Polyolester 75W90 GL5 Steering nozzle pivoting angle 26° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in)
  • Page 272 Section 12 TECHNICAL DATA Sub-Section 01 (ALL MODELS) MATERIAL CHALLENGER (5896) Hull Composite (fiberglass) Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Base : polyethylene, Foam : Polyurethane Ride shoe Aluminum Jet pump...
  • Page 273 Section 12 TECHNICAL DATA Sub-Section 01 (ALL MODELS) TIGHTENING TORQUES CHALLENGER (5896) Exhaust manifold screw 24 N•m (17 lbf•ft) Magneto flywheel nut 105 N•m (77 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) Crankcase screws 9 N•m (80 lbf•in) 24 N•m (17 lbf•ft) (3) (4) Crankcase / engine support nuts...

This manual is also suitable for:

Sportster 5895Challenger 5896

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