1995
Shop Manual
219 100025
TABLE OF CONTENTS
SECTION
SUBJECT
PAGE
SAFETY NOTICE ........................................................................................................................................................
II
INTRODUCTION ........................................................................................................................................................
III
01
SERVICE TOOLS AND PRODUCTS
01 - Mandatory Tools .............................................................................. . 02 - Recommended Tools ...................................................................... .. 03 - Service Products ............................................................................. ..
01-01-1 01-02-1 01-03-1
02
MAINTENANCE
00 01 02 03 04
- Table of Contents ............................................................................. . - Periodic Inspection Chart ................................................................ . - Flushing and Care .......................................................................... .. - Water-Flooded Engine ..................................................................... . - Storage ............................................................................................. .
02··00·1 02-01-1 02-02-1 02-03-1 02-04-1
03 04
TROUBLESHOOTING
00 - Troubleshooting .............................................................................. ..
03-00-1
ENGINE
00 - Table of Contents ............................................................................. . 01 - Removal and Installation ................................................................. .. 02 - Top End ........................................................................................... .. 03 - PTO Flywheel and Magneto ............................................................ . 04 - Bottom End ..................................................................................... .. 05 - Rotary Valve .................................................................................... ..
04-00-1 04-01-1 04-02-1 04-03-1 04-04-1 04-05-1
05
COOLING SYSTEM
00 - Table of Contents ............................................................................ .. 01 - Components .................................................................................... . 02 - Circuit ............................................................................................... .
05-00-1 05-01-1 05-02-1
06
FUEL SYSTEM
00 01 02 03
- Table of Contents ............................................................................. . - Fuel Circuit ...................................................................................... .. - Air Intake .......................................................................................... . - Carburetors ...................................................................................... .
06-00-1 06-01-1 06-02-1 06-03-1
07
LUBRICATION SYSTEM
00 - Table of Contents ............................................................................. . 01 - Oil Injection Reservoir ..................................................................... .. 02 - Oil Injection Pump ........................................................................... ..
07-00-1 07-01-1 07-02-1
08
ELECTRICAL
00 01 02 03 04 05 06 07 08 09
- Table of Contents ............................................................................. . - Overview ......................................................................................... .. - Magneto System ............................................................................ .. - Ignition System ................................................................................ . - Spark Plugs ..................................................................................... .. - MPEM (Multi-Purpose Electronic Module) ...................................... . - Charging System ............................................................................. .. - Starting System .............................................................................. . - Instruments and Accessories ......................................................... .. - Wiring Diagram (see Annexes at the end of this manual) ............... .
08-00-1 08-01-1 08-02-1 08-03-1 08-04-1 08-05-1 08-06-1 08-07-1 08-08-1 08-09-1
09
PROPULSION AND DRIVE SYSTEMS
00 - Table of Contents ............................................................................. . 01 - Propulsion and Drive Systems ........................................................ .. 02 - Reverse System .............................................................................. ..
09-00-1 09-01-1 09-02-1
10
STEERING SYSTEM
00 - Table of Contents ............................................................................ .. 01 - Steering System ............................................................................. .. 02 - Alignment ......................................................................................... . 03 - Throttle / Shifter Controller ............................................................. ..
10-00-1 10-01-1 10-02-1 10-03-1
11
HULL / BODY
00 - Table of Contents ............................................................................ .. 01 - Components .................................................................................... . 02 - Repair ............................................................................................... . 03 - Painting ............................................................................................ .
11-00-1 11-01-1 11-02-1 11-03-1
12
TECHNICAL DATA
01 - Sportster and Speedster Models .................................................... ..
12-01-1
ANNEXES OF WIRING DIAGRAMS
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SAFETY NOTICE
SAFETY NOTICE This manual was primarily published to be used by jet boat technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made Sea-Doo jet boat. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into local language upon certain conditions and furthermore agreed that in the event of any discrepancy among the two versions, the English version shall prevail. The content depicts parts and / or procedures applicable to the particular product at its time of manufacture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing the product. The use of Bombardier parts is most strongly recommended when considering replacement of any component. Dealer and / or distributor assistance should be sought in case of doubt. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex. : locking disk, lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols; WARNING : Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death . . , . CAUTION: Denotes an instruction which, if not followed, could severely damage T watercraft components. NOTE: Indicates supplementary information needed to fully complete an instruction.
+
o
Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier jet boat and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and / or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and / or verified by a highly skilled professional technician. It is understood that certain modifications may render use of the boat illegal under existing federal, provincial and state regulations.
II
1995 BOMBARDIER JET BOAT SHOP MANUAL
INTRODUCTION This Shop Manual covers the following BOMBARDIER made SEA-DOO® jet boats. MODEL
MODEL NUMBER
SPORTSTER
5892
SPEEDSTER
5891
HULL IDENTIFICATION NUMBER (H.I.N.) The Hull Identification Number (H.iN.l is located at nght hand rear side of hulL
BOAT MODEL NUMBER The jet boat model number can be found on RH side of operator position.
Hull IdentificatIOn Number (!-liN)
FOO' 011 001.6
The 5 digits after ZZN are the boat serial number. ZZN
1 2 3 4 5 X X X X
Serial number
ENGINE IDENTIFICATION NUMBER (E.I.N.) It is located on the upper side of the magneto housing. (TYPICAL) Ergire laentlflcatlon Number {EI.N)
Model number FD04 011 004.5
F004 011 035
FOOl 003001.2
III
1995 BOMBARDIER JET BOAT SHOP MANUAL
ARRANGEMENT OF THIS MANUAL The manual is divided into 12 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL 09 PROPULSION AND DRIVE SYSTEMS 10 STEERING SYSTEM 11 HULL I BODY 12 TECHNICAL DATA Each section is divided in various sub-sections, and again. each sub-section has one or more division. A table of contents is included at the beginning of most sections.
IV
1995 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 beginniC1g of the sub-section.
11
Drop represents a liquid, lubricant or paste product to be applied to a surface, In this case Loctite 242 to screw threads.
Exploded view assits you in identifying parts and related positions.
Sub-title at too right corner of exploded view pertaining models,
Dotted box contains parts of a particular model (in thiS case, the Sportster model) or an exploded view,
-+--l"...
I
Bold face number indicates special I I ~'.• procedure ~ . concerning this part,
11I~~~~t~~n
for publishing process,
~:1 • ""''!:'.:.'''!!'''i:::!'~~'_ _ _ _ _;f.-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _---l
I
~------------/---------------------------------lightening torque nearby fastener, In this case, nut must be torqued to 145 N.m (107Ibt·ft).
Page numbering system : 08 : ELECTRICAL SYSTEM section 01 . MAGNETO SYSTEM sub-section 1 : First page of thiS sub-section
. . . CAUTION: Pay attention to torque specifica'Y tions. Some of these are in Ibf.in instead of Ibf·ft. Use appropriate torque wrench.
v
1995 BOMBARDIER JET BOAT SHOP MANUAL
TYPICAL PAGE
Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS)
litle indicates main procedure to be carried-out
DISASSEMBLY AND INSPECTION To ;t)move cetburators: frOM engine proceed as 101, lOWS
Raf'"love a:r ~Iert wbe support U~ ock ret3ln:no shdes held fig: and rGm::ve cover
em ~:1tai<e sde"'cer Cover
Re'T'love SC'6WS r,oldlr'lg rel!rner and alf :~tao(e sdencer base Remove air Irltllke silencer base from watercraft
Remove screws raiding flarne arrester case support to cyllncer need cover
Service used to a certain
Sub-sub-tltle indicates a particular procedure concerning a model.
Inspeel p.~s lor con05,on damage (sheft. bUrI.r! Y
,.,!,o~rIJ:n~g\~..sJc~r.~w~.~c!l~ri·ilc~,k~v,.!'v,;.,..h0E-"_'_n_g_,e_,_c_,-------H~-:~
Inspect needle vaive lip for a grooved COndi~jOn, If wQrr'i, r"eedle and seat must 09 replaced: as a malched
.e'
31,33, Low Speed Screw Cr.eck tiP for & grooved c:mdltior R.eplace If nacessal'{
PUMP VERIFICATION
D,sconnect fuel supply ::'18 from fuel p"FTlP D.sconnect fuel return ilr,e
Remove screws end rock washers ret3lnir,9
Illustration always follows text It is pertained to.
cal'bu~e·
:or5.
Rerr·ove 4 colts en:::' lock washers from rotary va,ve ::.over !r.en move carb.,lretofs and rotary valve cover on
top of eng.lie
O
NOTE: When removing atten:ion that the rotary o\herv.tlse It muSt be timeD
vs've covar, pay will stay in place
Remove carburetors ftor ir'itake manifold D;sconnect fuel bYDassline betwae'1 carb\,Jrewrs (twin carburetors) Remove carourel10r{sl froIT' rotary va:ve cover
VI
'Typical" mention at top left corner indicates a general view which does not represent full detail.
Dlscornec: oi; il'ljecw:m pump cable, throttle cable ar'lO ct'oke cable
Reenove camuretors frofT": Intake Manlfo:c
Sub-sub-title in this case indicates that particular procedure for Sportster is finished, so from this pOint. all models are concerned,
Sub-title beginning with part number(s) of above exploded view following by part name(s).
Creck fuei pump vaives operatlo,,,, as foHows Connect o!J clean oluttC tub:r"g to the )nle~ niPple and alternately apply pressure and ve;cv;,Jm wltr, the r"louih,
ihe irllet valva should release with pressure end hold unde~ vacuum, Repes! the same p'oceoure at outlet n:pple. ThiS time tne outlet valve shot.;!d w'th pressure end release under vacuum WARNING: Some fuel may be present in fuel • pump, Be careful not to swallow fuel when under vacuum,
1995 BOMBARDIER JET BOAT SHOP MANUAL
ILLUSTRATIONS AND PROCEDURES
GENERAL INFORMATION
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.
BOW (front)
-,.r CAUTION: These boats are designed with T parts dimensioned in both the metric and the
PORT (LH)
STARBOARD (RH)
imperial systems. When replacing fasteners, make sure to use only those recommended by Bombardier. Mismatched or incorrect fasteners could cause damage to the boat or possible personal injury. As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or sub-section in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents.
STERN (rear)
Technical Publications Bombardier Inc. Valcourt (Quebec), Canada
In manne industry, PORT, STARBOARD. BOW and STERN are used to refer to LEFT, RIGHT. FRONT and REAR respectively, They always refer to the operator's position sitting In boat. F004 011 003,1
The information and component / system descriptions contained in this manual are correct at time of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This Shop Manual uses technical terms which may be different from the ones of the Parts Catalogs. When ordering parts always refer to the specific model Parts Catalogs.
VII
Section 01
SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
MANDATORY TOOLS ENGINE Mandatory tool kit: PIN 295 000 123. SERVICE TOOL
Degree wheel PIN 295 000 007
..
PURPOSE
To mark timing position of rotary valve, to check crankshaft alignment.
AooOOOll"
FOOl 003093
Puller
Used with puller plate (P I N 290 876 080) and extension handle (P I N 295 000 111) to remove MAG flywheel.
PIN 295 000 106
AOOO 002 046
All models.
All models.
FOOl 003 156
Pusher
lEI
PIN 290 876 500
To install end bearing of rotary valve shaft in crankcase.
() AOOO 00' 09'
APPLICATION
FOO' 003085
All models.
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
SERVICE TOOL
APPLICATION
PURPOSE
EIml
Puller
All models.
To remove crankshaft bearings.
P / N 290 876 298
FOO' GOl 010
Protective cap (both ends)
P / N 290 876 557
, ~ ~ , , , ' , '.' ,.'
.. / ...•. •...............•
-.:;.
•......
...•... ..•..
••.....
...•.......•..
•.......•..•..
;....
FOOl 001 011
Ring (both ends)
P / N 290 977 490
FOO' 00' 013
§
MAG side
,
Ring halves (PTO)
P / N 290 977 475
FOOl 001 015
Distance ring (MAG)
P / N 290 876 569
FOOl 001 012
@j
Ring halves (MAG) P / N 290 276 025
F001 00' 014
@~
Screws
(M8 x40)
P / N 290840681
@):lmD
PIN 290841 201
(l)
PTa side
mm1
mmm
mm
IM8 x 70) FOOl 001 072
01-01-2
FOOl 003 094
FOOl 003095
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
SERVICE TOOL
Piston circlip installer
PURPOSE
ma
To install circiips on pistons.
APPLICATION
Ali models.
PIN 290 877 016
AOOl 001 061
Pusher
FOOl 003034
ml
To install rotary valve shaft in crankcase.
All models.
PIN 290 876 605
AOOO 002 034
Bombardier ignition tester
FOOl C03 06S
fin)
To test engine ignition system.
All models.
PIN 295 000 008
AOOO 002 066
FOOl 007 100
01-01-3
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
SERVICE TOOL
Puller plate
APPLICATION
PURPOSE
Used with extension handle to retain crankshaft. When removing I installing PTO flywheel and loosen I tighten MAG flywheel nut.
PIN 290876080
All models.
Extension handle
Extension handle I N 295 000 111)
(p
Screw M8 x 35 (3)
IP IN 290 84 1 591)
Sleeve (3)
(P IN 2908472201
i
Puller plate
@
U
FOOl 003 151
FOOl 003 152
PTO flywheel remover / installer
Used to loosen / tighten PTO flywheel. Must be used in conjunction with puller plate (P / N 290 876 080) and extension handle (P / N 295 000 111).
P / N 295 000 001
O
NOTE: This tool is also used for the impeller.
<001009029
01-01-4
FOOl 003046
All models.
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
PURPOSE
SERVICE TOOL Puller
Imf) To remove rotary valve shaft from crank-
FOOl 001 018
FOOl 011 099
All models.
case.
P / N 290 876 487
Alignment tool P / N 295 000 089
APPLICATION
FOOl 003217
mil
To properly align engine with jet pump.
All models.
Foo1011101
01-01-5
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
COOLING / FUEL / OIL SYSTEMS SERVICE TOOL
PURPOSE
Hose pincher
To avoid leaks while working on oil/fuel lines.
P / N 295000076
APPLICATION All models.
AOOl 001 090
AOOl 001 091
Hose pincher
To plug cooling system outlet hose when flushing engine.
All models.
To remove / install lock nut of oil injection pump gear.
All models.
P / N 529 030 400
FOOl 001 075
f!m
Gear holder P / N 290 277 905
)
AOOO 002 042
01-01-6
AOOO 002 043
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
SERVICE TOOL
Pliers
PIN 295 000 070
APPLICATION
PURPOSE
To secure I cut non-reusable clamps of coolant hoses.
All models.
Cutting clamp
Securing clamp
FOOl 003043
FOOl 00' 003
FOO' 001 004
01·01·7
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
SERVICE TOOL
Pliers
APPLICATION
PURPOSE
m::mJ
To secure or open clamps on fuel lines.
P / N 295 000 054
To secure clamp, place notch side of pliers on clamp embossment and squeeze r p.!ers.
To open clamp, place flat side of pliers on clamp embossment, squeeze and twist pliers.
FOOt 001 065
01-01-8
FOOt OOt 066
FOOt 001 067
All models.
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
PROPULSION SYSTEM SERVICE TOOL Impeller remover / installer
PURPOSE
1m!]
Used to loosen / tighten impelier on shaft.
APPLICATION All mode!s.
P / N 295 000 001
O
NOTE: This tool is also used for the PTO flywheel.
FOOl 009029
Pliers P / N 295 000 069
FOCl 009030
l'm.EI
To remove / install drive shaft boot reusable stepless clamps.
FOOl 003044
F001 009017
Impeller shaft holder
Used to hold shaft when removing / installing impeller.
P / N 295 000 082
F001 001032
All models.
All models.
FOO' 009089
01-01-9
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS)
SERVICE TOOL
Bearing / seal installer
PIN 295 000 107
PURPOSE
To install impeller shaft needle bearings and seal.
FOO' 009 '64
FOO' 009054
Impeller shaft guide
To protect seal lip when installing impeller shaft in its housing.
P / N 295 000 002
FOO' 009060
FOO, 00906'
Protective mat
To protect boat's body and seats when servicing. Mats can be used together or separately can be used with and without engine cover installed.
PIN 295 000 1 29
F004 0" 067
01-01-10
APPLICATION
All models.
All models.
All models.
Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS)
RECOMMENDED TOOLS ENGINE SERVICE TOOL
Ring compressor
PIN 295 000 11 2
PURPOSE
To compress piston ring when inserting piston in cylinder.
AOO, 00' 065
FOO'003035
Centering tool
To position coils on armature plate at assembly.
P / N 290 876 922
MO, 001 067
APPLICATION
All models.
All models.
Aoe, 004003
01-02-1
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