Beruflich Dokumente
Kultur Dokumente
Legal deposit: National Library of Quebec 1st trimester 1998 National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. Bombardier Inc. 1998 Printed in Canada *Registered trademarks of Bombardier Inc.
Loctite is a trademark of Corporation. Snap-on is a trademark of Snap-on Tools Corporation. Gelcote is a trademark of Gelcote International Limited.
TABLE OF CONTENTS
SECTION
SUBSECTION
PAGE III IV VI 01-01-1 01-02-1 01-03-1 01-04-1 02-01-1 02-02-1 02-03-1 02-04-1 02-05-1
SAFETY NOTICE .................................................................................................................................. WHATS NEW ....................................................................................................................................... INTRODUCTION ................................................................................................................................... 01 SERVICE TOOLS AND PRODUCTS 01 Table of Contents ..................................................................... 02 Mandatory Tools....................................................................... 03 Optional Tools .......................................................................... 04 Service Products ...................................................................... 01 Table of Contents ..................................................................... 02 Periodic Inspection Chart ......................................................... 03 Flushing and Lubrication........................................................... 04 Water-Flooded Engine.............................................................. 05 Storage .....................................................................................
02
MAINTENANCE
03 04
TROUBLESHOOTING ENGINE
01 Troubleshooting........................................................................ 03-01-1 01 Table of Contents ..................................................................... 02 Leak Test ................................................................................. 03 Removal and Installation .......................................................... 04 Magneto System...................................................................... 05 Top End .................................................................................... 06 Bottom End .............................................................................. 07 Rotary Valve ............................................................................. 08 Exhaust System ....................................................................... 04-01-1 04-02-1 04-03-1 04-04-1 04-05-1 04-06-1 04-07-1 04-08-1
05
COOLING SYSTEM
01 Table of Contents ..................................................................... 05-01-1 02 Components............................................................................. 05-02-1 03 Circuit ....................................................................................... 05-03-1 01 Table of Contents ..................................................................... 02 Fuel Circuit ............................................................................... 03 Air Intake .................................................................................. 04 Carburetors............................................................................... 06-01-1 06-02-1 06-03-1 06-04-1
06
FUEL SYSTEM
07
LUBRICATION SYSTEM
01 Table of Contents ..................................................................... 07-01-1 02 Oil Injection Reservoir .............................................................. 07-02-1 03 Oil Injection Pump .................................................................... 07-03-1 01 Table of Contents ..................................................................... 02 Overview .................................................................................. 03 Ignition System ........................................................................ 04 Spark Plugs............................................................................... 05 The DESS (Digitally Encoded Security System) ....................... 06 MPEM (Multi-Purpose Electronic Module)............................... 07 Charging System ...................................................................... 08 Starting System........................................................................ 09 Instruments and Accessories................................................... 08-01-1 08-02-1 08-03-1 08-04-1 08-05-1 08-06-1 08-07-1 08-08-1 08-09-1
08
ELECTRICAL
TABLE OF CONTENTS
SECTION
09 PROPULSION SYSTEM
SUBSECTION
01 Table of Contents...................................................................... 02 Jet Pump................................................................................... 03 Drive System ............................................................................ 04 Reverse System........................................................................ 05 Weedless System..................................................................... 01 Table of Contents...................................................................... 02 Steering System ....................................................................... 03 Alignment.................................................................................. 04 Throttle/Shifter Controller ......................................................... 01 Table of Contents...................................................................... 02 Components ............................................................................. 03 Repair........................................................................................ 04 Painting .....................................................................................
PAGE
09-01-1 09-02-1 09-03-1 09-04-1 09-05-1 10-01-1 10-02-1 10-03-1 10-04-1 11-01-1 11-02-1 11-03-1 11-04-1
10
STEERING SYSTEM
11
HULL/DECK
12 13
II
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:
x
-
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death.
CAUTION
Denotes an instruction which, if not followed, could severely damage boat components. NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier jet boat and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional technician. It is understood that certain modifications may render use of the boat illegal under existing federal, provincial and state regulations.
III
WHATS NEW
WHATS NEW
This section is introduced this year to indicate the major changes brought in this shop manual.
INTRODUCTION
Addition of a list of abbreviations used in this manual.
MAINTENANCE
Revised periodic inspection chart. Revised storage procedure.
TROUBLESHOOTING
Revised items.
ENGINE
Top end: Revised procedure with the use of the new piston pin puller. Bottom end: New distance gauge part numbers for positioning of bearings on crankshaft. Bottom end: PTO flywheel removal/installation procedure has been added (was in DRIVE SYSTEM).
COOLING SYSTEM
Procedure to adjust the water flow regulator valve removed. Photographs added to improve clarity.
FUEL SYSTEM
Revamped section to improve usability. New external fuel pump. New procedure to adjust throttle cable including the low-speed steering control system.
IV
WHATS NEW
LUBRICATION SYSTEM
No major changes.
ELECTRICAL
Bombardier ignition tester is not available anymore. New procedure to test magneto system with a voltmeter. Addition of important information pertaining to flywheel loosening when performing ignition timing. Improved procedure to make the voltage test for the rectifier/regulator. Improved procedure to test the battery (load and unload test). New procedure for battery removal/installation for Challenger model.
PROPULSION SYSTEM
New sealing pattern of ride shoe and jet pump support. The Right Stuff Gasket replaces the Ultra Black silicone. On twin-pump models, the ride shoe is now mounted to the hull with bolts instead of screws. PTO flywheel removal/installation procedure has been transferred to BOTTOM END in ENGINE section.
STEERING SYSTEM
Procedure to adjust low-speed steering control system transferred to CARBURETORS section.
HULL/DECK
New color on the 717 engine (off-white). New color on the 787 engine (silver reflection).
TECHNICAL DATA
Updated specifications for 1998.
WIRING DIAGRAMS
Updated for 1998.
INTRODUCTION
INTRODUCTION
This Shop Manual covers the following BOMBARDIER made SEA-DOO jet boats.
MODEL Sportster Sportster 1800 Challenger Challenger 1800 MODEL NUMBER 5614/5619/5634 5613/5618/5633 5612/5617/5632 5611/5616/5631
0
HULL IDENTIFICATION NUMBER (H.I.N.)
The Hull Identification Number (H.I.N.) is located at right hand rear side of hull.
15
10
30 70 45
90
km/h
60
MPH Bombardier
Serial number*
MAXIMUM CAPACITIES
.
F00A0CA
THIS BOAT COMPLIES WITH U.S. AND CANADIAN COAST GUARD SAFETY STANDARDS IN EFFECT ON THE DATE OF CERTIFICATION
F04L8WA
Some boats may have a serial number beginning with CEC. CEC boats are manufactured in USA and ZZN boats are manufactured in Canada.
VI
INTRODUCTION
F01D01A
F01D87A
VII
INTRODUCTION
TYPICAL PAGE
Page heading indicates section and subsection detailed.
MAGNETO SYSTEM
Drop represents a liquid product to be applied to a surface. In this case Loctite 242 to screw threads.
717 Engine
12 11 5 Nm (44 lbfin)
4 7
Anti-seize lubricant
F01D4WS
2 9 Nm (80 lbfin)
Tightening torque nearby fastener. In this case, nut must be torqued to 145 Nm (107 lbfft).
w CAUTION
Pay attention to torque specifications. Some of these are in lbfin instead of lbfft. Use appropriate torque wrench.
F04A09S
Page numbering system: 03: ENGINE section 04: MAGNETO SYSTEM subsection 1: First page of this subsection
VIII
INTRODUCTION
TYPICAL PAGE
CARBURETOR REMOVAL
To remove carburetors from engine, proceed as follows: Remove air vent tube support. Unlock retaining slides holding air intake silencer base. Remove air intake silencer base from watercraft. Remove screws holding flame arrester base support to cylinder head cover. Unscrew base retaining screws then remove base from carburetors and move to front of watercraft. Turn the valve to OFF position. NOTE: For fuel line removal, use pliers (P/N 295 000 054). Disconnect pulse line from fuel pump. Disconnect fuel fuel supply line from fuel pump. Disconnect fuel return line. Disconnect oil injection pump cable, throttle cable and choke cable.
Diaphragm
Pump Diaphragm Leak Test Using a suitable pump gauge tester, perform the following test proceeding as follows: - Install pump gauge tester (P/N 295 000 083) on pulse nipple. - Pump tester until it reaches 28 kPa (4 PSI).
Italic bold face setting indicates a particular procedure concerning a model. Italic bold face setting in this case indicates that particular procedure for Challenger is finished, so from this point, all others models are concerned.
Challenger Model Only Remove screws and lock washers retaining carburetors. Remove carburetors from intake manifold. All Others Models Remove 4 bolts and lock washers from rotary valve cover then move carburetors and rotary valve cover on top of engine.
NOTE: When removing rotary valve cover , pay attention that the rotary valve stay in place, otherwise it must be timed. Remove carburetors from intake manifold. Disconnect fuel bypass line between carburetors (twin carburetors). Remove carburetor(s) from rotary valve cover.
2
F01F0XB
TYPICAL Step 1 : Install pump gauge tester to pulse nipple Step 2 : Pump tester until it reaches the desired pressure 1. Fuel outlet nipple 2. Fuel inlet nipple A. 28 kPa (4 PSI)
''TYPICAL'' caption indicates a general view which does not represent full detail.
Diaphragm no. 3 must stand pressure for 10 seconds. If pressure drops, replace diaphragm.
Numbers in a frame are used to give a sequence to be perfomed for above illustration.
06-03-4
F04A08S
IX
INTRODUCTION
INTRODUCTION
GENERAL INFORMATION
In marine industry, PORT, STARBOARD, BOW and STERN are used to refer to LEFT, RIGHT, FRONT and REAR respectively. They always refer to the operators position sitting in boat.
1
CAUTION
These boats are designed with parts dimensioned in both the metric and the imperial systems. When replacing fasteners, make sure to use only those recommended by Bombardier. Mismatched or incorrect fasteners could cause damage to the boat or possible personal injury. As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. Technical Publications Bombardier Inc. Valcourt (Quebec), Canada
F04L03C
1. 2. 3. 4.
The information and component/system descriptions contained in this manual are correct at time of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This Shop Manual uses technical terms which may be different from the ones of the Parts Catalogs. When ordering parts always refer to the specific model Parts Catalogs.
XI
Section 01
TABLE OF CONTENTS
MANDATORY TOOLS ........................................................................................................... ENGINE .............................................................................................................................. OPTIONAL TOOLS ................................................................................................................ ENGINE .............................................................................................................................. SERVICE PRODUCTS ............................................................................................................
0
01-02-1 01-02-1 01-03-1 01-03-1 01-04-1
01-01-1
Section 01
MANDATORY TOOLS
ENGINE
Degree wheel P/N 295 000 007
33
32
31
NOTE: The numbers outlined in black (example: 1 ) are reference numbers to tools from other divisions (Ski-Doo Snowmobiles and/or Sea-Doo Watercraft). Matching reference numbers indicate the same tool is being used on both products, even if the part numbers are different.
Piston circlip installer A) P/N 295 000 077 B) P/N 290 877 016
50
202 548
1
40
32
50
290
5 2 4 3 6 4
A01B1P4
60
60
31
30
70
300
70
80
290
80
110 100 90
280
270
250
Piston circlip
260
130
120
12 0 13 250 0 24 1 0 2
24
14
A00B334
APPLICATION All models. Rubber pad P/N 295 000 101 547
F01B0J4
A00B2J4
40
30
15
22
0 23
PTO side
1) Puller P/N 290 876 298 2) Protective cap (both ends) P/N 290 876 557 3) Ring (both ends) P/N 290 977 490 4) Ring halves (PTO) P/N 290 977 475 (2) 5) Distance ring (MAG) P/N 290 876 569 6) Ring halves (MAG) P/N 290 276 025 (2) 7) Screw M8 x 40 P/N 290 840 681 (2) 8) Screw M8 x 70 P/N 290 841 201 (2) APPLICATION All models.
200
229
554
A00C0Y4
555
APPLICATION All engines except 787. Bearing pusher P/N 290 876 501
556
557
558
F00B074
559
560
01-02-1
242
553
F01J0T4 A00C1A4
549
APPLICATION All engines except 787. NOTE: This tool is also used for the impeller. Puller P/N 290 876 488 562
F01B1O4 A00C1R4
550
2
F01B0I4
F01D164
551
APPLICATION All engines. Replacement parts: 1) Hex. screw (M6 x 60) P/N 290 240 860 2) Nut (M6) P/N 290 242 210
F00A094
552
F00A0A4
01-02-2
Section 01
Alignment support plate kit P/N 529 035 506 1) Alignment plates P/N 529 035 507 2) Support P/N 529 035 511 3) Screw (2) P/N 222 082 565 Lock washer (2) P/N 213 000 001 Flat washer (2) P/N 217 081 410
NEW
778
F00B0U4
F01B2Q5
APPLICATION All models. 567 Ring gear puller tool P/N 420 976 235 569
F00B0F4
APPLICATION Boats equipped with the DESS. Flywheel extractor P/N 295 000 156 777
APPLICATION 787 engine. Ring gear blocking tool P/N 295 000 155 568
F00B0G4
APPLICATION All models. Piston pin puller P/N 529 035 503
NEW
F01B264
F00B0T4
COOLING/FUEL/OIL SYSTEMS
Hose pincher P/N 295 000 076 2 Pliers P/N 295 000 054
Caillau
606
F01B1T4
A01B2I4
APPLICATION All models. Gear holder P/N 290 277 905 235
APPLICATION All models. NOTE: This tool is also used for the propulsion system. Coupler hose P/N 295 500 258
41 cm (16 in)
752
F01E0Z4
A00C164
APPLICATION All engines except 787. Pliers P/N 295 000 070
Oetiker 1099
601
F01D174
01-02-4
Section 01
PROPULSION SYSTEM
Impeller remover/installer P/N 295 000 001 553 Bearing/seal installer P/N 295 000 107 604
F01J0T4
APPLICATION All models. NOTE: This tool is also used for the PTO flywheel. Pliers P/N 295 000 069
Oetiker 1090
F01J4K4
602
APPLICATION All models. Impeller shaft guide P/N 295 000 002 605
F01D184
F01J1O4
APPLICATION All models. Impeller shaft holder P/N 295 000 082 603
606
F01B0W4
F01B1T4
APPLICATION All models. NOTE: This tool is also used for the fuel system.
01-02-5
Section 01
OPTIONAL TOOLS
ENGINE
Ring compressor A) P/N 290 876 979 (82 mm) B) P/N 295 000 112 (78 mm) C) P/N 290 876 972 (76 mm) 766 751 207 Stroboscopic timing light P/N 529 031 900 225 Digital/induction type tachometer P/N 295 000 100
0
237
A00B4F4
F01B1G4
APPLICATION All models. 230 Timing mark pointer P/N 295 000 130 774
APPLICATION A) 717 and 787 engines. B) 657 engine. C) 587 engine. Coil centering tool P/N 290 876 922 209
A00B4E4
APPLICATION All models. Distance gauge A) P/N 529 034 800 B) P/N 529 034 900 C) P/N 290 876 826
NEW
F01B2O4
APPLICATION All engines except 787. 561 Timing mark pointer P/N 295 000 135 754
A01B1V4
APPLICATION All engines except 787. Cylinder aligning tool P/N 290 876 904 220
01-03-1
Engine lifting device Not sold by Bombardier Do it yourself Refer to engine removal and installation section
F01J0Z4
F00B0E4
NOTE: This tool is also used to pull out impeller shaft seal.
Protective mat P/N 295 000 129 890
759
APPLICATION All engines except 787. Feeler gauge 45 Not sold by Bombardier
Snap-on FB 300 A
F04L1V4 F01B2C4
APPLICATION 787 engine. Ring halves and ring P/N 290 876 330 (halves) (2) P/N 290 977 480 (ring)
761 762
775
F01B2D4
F01B1J4
F01B244
01-03-2
Section 01
A) Four-pin magneto harness 763 P/N 295 000 131 B) Six-pin magneto harness 755 P/N 295 000 136
831
F01B2A4 F01B284
APPLICATION A) 587, 657 and 717, 1995 and newer. B) 787 engine. Rotary valve shaft pusher P/N 290 876 609 757
APPLICATION Exhaust nut on transom. Gear/bearing puller P/N 290 877 665 765
F04B034 F01B2B4
APPLICATION 787 engine. Crankshaft protector P/N 420 876 552 764
F00B034
A00C3V4
01-03-3
COOLING/FUEL/OIL SYSTEMS
Pump gauge tester (carburetor) P/N 295 000 114
30
826
773
20
40
2 15 1
25 3 35
50
60
10
5 4
F01B234
834
F04B044
F01B1I4
01-03-4
Section 01
PROPULSION SYSTEM
Fitting P/N 295 000 086 828 Machinists square Not sold by Bombardier
Snap-on PMF 122
829
F01B0Z4 F02B064
APPLICATION Explorer. Fitting remover Not sold by Bombardier Do it yourself Refer to Shop Manual
Deep socket 14 mm (9/16 in)
F01L2O4
F01J0Z4
NOTE: This tool is also used to remove rotary valve shaft bearing.
Hacksaw Not sold by Bombardier
Snap-on HS3
F01J2R4
APPLICATION Models without a jet pump support. Pump bearing remover P/N 295 000 144 781
F01B1M4
F01J114
01-03-5
BOAT HANDLING
Valve wrench P/N 204 000 048 887 Foot pump kit P/N 204 000 047 883
APPLICATION Explorer tube. Pressure check valve P/N 204 000 043 964
F03P014
APPLICATION Explorer tube. Tie-down with ratchet 3.60 m (12 ft) long P/N 295 100 011 885
P/N 295 100 014 (nickel plated) P/N 295 100 015 (stainless steel)
881 882
F04B054
F03B044
APPLICATION Explorer.
01-03-6
Section 01
SERVICE PRODUCTS
NOTE: The numbers outlined in black (example: 1 ) are reference to product numbers from other divisions (Ski-Doo Snowmobiles and/or Sea-Doo Watercraft). Matching reference numbers indicate the same product is being used, even if the part numbers are different. Loctite is a trademark of LoctiteTM Corporation. Dow Corning is a trademark of Dow Corning Corporation.
Medium strength threadlocker P/N 293 800 015
Loctite 242 (blue) (10 mL)
154
359
151
LOCTITE
RC/609
LOCTITE
REMOVABLE
THREADLOCKER 242
155
959
373
A00B2V4
LOCTITE
LOCTITE
271
Adhesive Sealant
SURE AS
RETAINING COMPOUND 642 NET 1.69 FL .OZ. (50 ml)
935
A00B2U4
F00B024
BOM BARDIER
GASK ET STRIPPER
295 000 110
500 ml
WARNING
F01B1W4
01-04-1
157
Pipe sealant A) P/N 293 800 018 B) P/N 293 800 013
A) Loctite 592 A(50 mL) B) Loctite 567 (250 mL)
358 960
961
A00B2W4
NEW
F00B0W4
350
376
F01B164
518
F01B124
01-04-2
Section 01
(200 mL)
912
SYNTHETIC GREASE
F01B154
F00B0X4
362
A02B054
375
A00B2L4
932
F01B174
NEW
FUEL STABILIZER
Super Lube
R
PERMATEX INDUSTRIAL
913
A00B3V4
LUBE
REPLA CES SEA-DOO LUBE
ANTICO T RROSIVE LUBRICAN Excellent and for high humiditysalt water nts environme
BOMBARDIER
915
340 g
A00B474
DANGER
FLAMMABLE CONTA D. INER MAY EXPLODE IF HEATE DIRECT INHALATION OF SPRAY MAY BE HARMFUL.
Sea-Doo Valcourt, / Ski-Doo Division2LO Qubec, Canada J0E
BOMBARDIER INC.
BOMBARDIER
F01B0S4
Two-stroke
Injection Oil
1 U.S. quart
F01B184
01-04-3
ADCHEM
BOMBARDIER-ROTAX injection oil 916 P/N 413 803 000 (3 x 4 L) 962 P/N 413 803 200 (205 L)
914 Jet pump oil P/N 293 600 011 (12 x 6 oz)
Sea-Doo synthetic jet pump oil
934
ADS E AL
PREMIUM SEALANT ADHESIVE
F01B1S4
936
F01B0P4
F01B2H4
BOMBARDIER-ROTAX Formula XP-S synthetic injection oil P/N 413 711 000 (3 x 4 L) P/N 413 710 700 (205 L)
931
969 970
ACTIVEUR D'ADHSIF
250 mL
POUR L'APPLICATION DE MOULURE PRESSION ET VINYLES SENSIBLES LA LORSQU'UNE MEILLEURE . ADHRENCE EST NCESSAIRE
DANGER
BOMBARDIER
4 U.S. quart
AVEC LA PEAU -VITER TOUT CONTACT PROLONG CONTACT. CAS DE LAVER L'EAU FROIDE EN BIEN AR. -UTILISER DANS UN ENDROIT FERM. -TENIR LE CONTENANT BIEN DES ENFANTS. -GARDEZ HORS DE LA PORTE . -CONTIENT DU TRICHLORETYLNE DE CE PRODUIT -AVERTISSEMENT ! L'INHALATION EST NOCIF. N/P 293 530 036
FABRIQU AU
F01B1Z4 F01B354
BOMBARDIER-ROTAX Formula XP-S synthetic injection oil P/N 413 710 500 (12 x 1 L)
937
F00B0V4
Sea-Doo Cleaner P/N 293 110 001 (400 g) P/N 293 110 002 (4 L) 917
BOMBARDIER
946 947
CLEANER
400 g
BOMBARDIER BOMBARDIER
BOMBARDIER
DANGER
DANGER
4L
F01B1C4
1 liter (1.05 U.S. qt)
F01B2J4 F01B2G4
01-04-4
Section 01
Spray paint for metallic parts only 926 A) White (140 g) P/N 293 500 029 930 B) Purple (140 g) P/N 293 500 020 928 C) Grey (140 g) P/N 293 500 009
Sea-Doo paint
923
F03P024
966
Sea-Doo spray paint for gelcoat 956 A) Super white (140 g) P/N 293 500 082 933 B) Super white (140 g) P/N 293 500 076 921 C) White (140 g) P/N 293 500 041 D) Dark green (140 g) P/N 293 500 101
F03P064
VERTICAL FANSPRAY PATTERN ROTATE VALVE NOZZLE 1/4 TURN TO CHANGE SPRAY PATTERN HORIZONTAL FANSPRAY PATTERN
GELCOAT
T PAIN
965
DA NGE R
R DANGE
F01B1Q4
967
Gelcoat (liquid) A) Super white (1 L) P/N 293 500 075 B) White (1 L) P/N 293 500 033 C) Dark green (1 L) P/N 293 500 100
01-04-5
TABLE OF CONTENTS
PERIODIC INSPECTION CHART ........................................................................................... FLUSHING AND LUBRICATION ........................................................................................... GENERAL ........................................................................................................................... PROCEDURE ...................................................................................................................... WATER-FLOODED ENGINE .................................................................................................. GENERAL ........................................................................................................................... PROCEDURE ...................................................................................................................... STORAGE...............................................................................................................................
0
02-02-1 02-03-1 02-03-1 02-03-1 02-04-1 02-04-1 02-04-2 02-05-1
02-01-1
0
Every 50 hours Every 100 hours or seasonally
Every 10 hours
Every 25 hours
Replace
Every 10 hours in salt water use. These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in this chart. Daily flushing when used in salt or foul water use. Inspect anti-rattle pusher.
02-02-1
F00E01A
CAUTION
Sportster Model
Failure to flush cooling system, when necessary, will severely damage engine and/or exhaust system. Never flush a hot engine. Make sure engine operates during entire procedure.
PROCEDURE
Perform this operation in a well-ventilated area. Do not touch any electrical parts or jet pump area when engine is running. NOTE: On twin-engine models, perform the operation on each engine. 1. Clean jet pump by spraying water in its inlet and outlet and then spray a soapy solution.
WARNING
F04L8SB
Challenger Model
Always remove safety lanyard cap from DESS post to prevent accidental engine starting, before cleaning the jet pump area. Engine must not be running for this operation. 2. Open rear storage compartment and remove storage tray. 3. Connect a garden hose directly to the flushing connector. To prevent water leak, ensure the rubber washer is in the boat connector. NOTE: A quick hose connector can be used to ease garden hose installation.
F04L8RA
WARNING
TYPICAL 1. Flushing connector for port engine (LH side) on transom 2. Flushing connector for starboard engine (RH side) on transom
02-03-1
F10L06A
F04E1AA
1. Flushing connector for port engine 2. Flushing connector for starboard engine
TYPICAL SPORTSTER AND CHALLENGER MODELS 1. Flushing connector in engine compartment area with its cap (starboard engine for Challenger model)
F04L5LA
2
F04E1BA
1. Flushing connector for port engine 2. Flushing connector for starboard engine
The engine can also be flushed from the flushing connector that is located on the edge of the engine compartment. See illustrations.
CHALLENGER MODEL ONLY 1. Flushing connector in engine compartment area with its cap (port engine on Challenger model only)
02-03-2
717 Engine
1
F04E12A
F04E14A
787 Engine
F04E1GA
1
F04E15A
All Models For proper flushing from this location, it is necessary to prevent water from going out directly by the flushing connector on the transom. Install a hose pincher (P/N 529 032 500) on the hose between the transom and the T-fitting as shown.
CAUTION
Do not open water tap yet. 4. Start the engine then immediately open the water tap.
CAUTION
Always start the engine before opening the water tap to prevent engine flooding. Open water tap immediately after engine is started to prevent overheating.
02-03-3
5. Run the engine about 3 minutes at a fast idle around 3500 RPM. 6. Pull plug from air intake silencer cover.
2 1
8. If the lubrication is done for the storage, close fuel valve (if so equipped) to run engine out of fuel after approximately half a minute of lubrication.
CAUTION
If the lubrication is done for the storage, immediately stop water flow before engine dies when engine begins to run irregularly. 9. Close the water tap then stop the engine.
F01F25B
CAUTION
Always close the water tap before stopping the engine. 10. Remove garden hose. Ensure the rubber washer remains in the boat hose connector.
7. Spray BOMBARDIER LUBE lubricant through air intake silencer cover keeping engine at fast idle. NOTE: If the lubrication is done for the storage, use BOMBARDIER storage oil (P/N 413 711 600) instead.
CAUTION
If used, remove the quick hose connector from boat. 11. Remove hose pincher from water outlet hose.
CAUTION
Serious engine damage can occur if hose pincher is not removed. 12. Wipe up any residual water from the engine. 13. Remove spark plug cables and connect them on the appropriate grounding device.
Always use spark plug cable grounding device when removing spark plugs.
F00M01A
WARNING
TYPICAL 1. Spray BOMBARDIER LUBE (storage oil when performing storage lubrication)
02-03-4
14. Remove both spark plugs and spray BOMBARDIER LUBE lubricant into each cylinder. 15. Crank the engine a few turns to distribute the oil onto cylinder wall. 16. Apply anti-seize lubricant on spark plug threads then reinstall them. 17. Properly reconnect spark plug cables to spark plugs. 18. Reinstall plug on air intake silencer cover. NOTE: Engine fogging should be done with BOMBARDIER storage oil (P/N 413 711 600) whenever the boat is to be stored for a few days or a long period.
F04H5ZA
CAUTION
Never leave rags or tools in the engine compartment or in the bilge. 19. Reinstall tray and close storage compartment cover.
1
F09H01A
02-03-5
WATER-FLOODED ENGINE
GENERAL
If engine is water-flooded, it must be serviced within a few hours after the event. Otherwise engine will have to be overhauled.
0
CAUTION
CAUTION
Failure to do this may result in damage to the engine. If you must tow a stranded boat in water and do not have a hose pincher be sure to stay well below the maximum towing speed of 24 km/h (15 MPH). Snugly install the hose pincher on the hose as shown in the following illustration.
1
A water-flooded engine must be properly lubricated, operated then lubricated again, otherwise parts will be seriously damaged.
F10E01A
NOTE: If for some reason, you operate the jet boat over 24 km/h (15 MPH) with only one engine running, the non-running engine should have its water supply hose plugged. This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system. Without the engine running there isnt any exhaust pressure to carry the water out the exhaust outlet.
F04E0QA
02-04-1
CAUTION
1
When finished towing the boat you must remove the hose pincher before operating it. Failure to do so will result in damage to the engine.
PROCEDURE
Check fuel and oil reservoirs for water contamination. If necessary, siphon and refill with fresh fluids. Turn fuel valve(s) to OFF position (if so equipped) then drain fuel filter bowl(s). Refer to FUEL SYSTEM, 06-02. Drain bilge if water is present. Remove spark plug cables and connect them on the appropriate grounding device.
F09H01A
Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device.
2 1
WARNING
Remove spark plugs and dry them with a clean cloth. A contact cleaner spray can be used. It may be preferable to replace spark plugs. Do NOT install spark plugs on engine. Crank engine(s) to drain crankcase.
CAUTION
Be careful when cranking engine(s), water will spray out from spark plug holes. Spray BOMBARDIER LUBE lubricant (P/N 293 600 006) into spark plug holes. Crank engine(s) again.
F04H5ZA
Challenger 1800 Model There is an oil passage from the crankcase toward the balance shaft gear and bearing. Therefore, water that enters the engine, can flow through this passage and be trapped in a cavity. Proper draining of this water is required. Refer to STORAGE 02-05 and look for Engine Draining.
02-04-2
All Models Reinstall spark plugs and spark plug cables then safety lanyard cap on DESS post. Turn fuel valve(s) to ON position (if so equipped). Start engine(s). It may be necessary to use the choke. If engine(s) do not start, repeat previous steps as necessary.
CAUTION
To avoid starting motor overheating, the cranking period should not exceed 5-10 seconds and a rest period of 30 seconds should be observed between cranking cycles. NOTE: If engine(s) do not start after several attempts, check ignition system for spark occurrence. Refer to ELECTRICAL SYSTEM 08-03. Check crankshaft if needed, it can become misaligned or deflected. Refer to ENGINE 04-06. After engine has started, spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running.
F00M01A
CAUTION
Water must be supplied to cool engine(s) through the boat flushing connector(s).
02-04-3
STORAGE
NOTE: On twin-engine models, perform the operation on each engine.
0
787 Engine
Engine Draining
Check engine drain tube running from engine manifold fitting to outlet socket. Make sure it contains no sand or other particles and that it is not obstructed, so that water can leave the engine. Clean tube and outlet socket as necessary.
CAUTION
Water in engine drain tube must be free to flow out, otherwise water could be trapped in engine. Should water freeze in engine, severe damage will occur. Check engine drain tube for obstructions.
F04E0VA
717 Engine
787 Engine Only In the event water entered the engine during the season (water flood), water may have been trapped in the oil cavity of the balance shaft gear and bearing. Draining is required to prevent any potential damage. Proceed as follows.
CAUTION
Failure to properly drain this cavity may result in freezing inside engine leading to damage of cylinder base gasket.
F04E16A
Remove the filler plug of the counterbalance shaft on the engine crankcase.
02-05-1
CAUTION
Fuel stabilizer should be added prior to engine lubrication to ensure carburetor protection against varnish deposit.
Fuel is flammable and explosive under certain conditions. Always work in a well-ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the boat.
F07D06A
WARNING
Always turn the fuel valve to OFF position (if so equipped) when storing the boat.
Insert a wire through oil level hole to check oil condition. A whitish oil indicates water contamination and must be replaced. In order to replace the oil, remove the drain plug of the counterbalance shaft located on the PTO side of the lower crankcase.
Propulsion System
Lubricant in impeller shaft reservoir should be drained. Reservoir should be cleaned and refilled with 70 mL (2.4 U.S. oz) of BOMBARDIER synthetic 75W 90 GL5 polyolester oil (P/N 293 600 011). Refer to PROPULSION SYSTEM 09-03.
F06D2CA
1. Drain plug
CAUTION
Drain completely the crankcase oil of the counterbalance shaft. Reinstall drain plug with Loctite 515. Add 30 mL (1 oz) of SAE 30 motor oil. Reinstall filler plug.
Use only BOMBARDIER jet pump oil or equivalent synthetic gear oil, otherwise component service life could be reduced. Do not mix oil brands or types. Lubricate PTO flywheel at grease fitting with synthetic grease (P/N 293 550 010).
Fuel System
All Engines Sea-Doo Fuel Stabilizer (P/N 413 408 600) should be added in fuel tank to prevent fuel deterioration and carburetor gumming. Follow manufacturers instructions for proper use. NOTE: Fuel stabilizer should be added prior engine lubrication to ensure carburetor protection against varnish deposit.
02-05-2
CAUTION
Do not lubricate excessively. Immediately stop when a slight movement is noticed on rubber boot.
Antifreezing Protection
In cool regions (where freezing point temperature may be encountered), cooling system must be filled with water and antifreeze solution. (40% water, 60% antifreeze).
CAUTION
Antifreeze mix must be fed in cooling system. Otherwise water will freeze in engines/exhaust system causing severe damage. NOTE: When available, it is recommended to use biodegradable antifreeze compatible with internal combustion aluminum engines.This will contribute to protect the environment.
F01I0BA
Boat Cleaning
CAUTION
CAUTION
Always use ethylene-glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines. NOTE: The engine will not have to run during this operation but should have been ran before to exhaust water from cooling system components. Some hoses have to be plugged to prevent draining, before filling cooling system jackets with the antifreeze. Use hose pinchers (P/N 529 030 400).
Clean the bilge with hot water and mild detergent or with bilge cleaner. Rinse thoroughly. Lift front end of boat to completely drain bilge. If any repairs are needed to the body or to the hull, touch up paint and Gelcote repair kit are available. Replace damaged labels/decals. Wash the body and the trailer with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull. Apply a nonabrasive wax.
CAUTION
Never clean apparent fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc. Stains may be removed from seats and fiberglass with Knights Spray-Nine* from Korkay System Ltd or the equivalent.
F01B23A
02-05-3
717 Engine Install a hose pincher and firmly tighten on: water injection hose at tuned pipe
2
F04E17A
1. 2. 3. 4.
Hose pincher right after T-fitting T-fitting Hose pincher on this hose Hose pincher on drain tube
787 Engine Install a hose pincher and firmly tighten on: engine drain tube coming from cylinder base before T-fitting hose right after T-fitting hose on cylinder head
4 2 1 3
F04E0YA
engine drain tube coming from exhaust manifold before T-fitting hose right after T-fitting hose on cylinder head
F04E0TC
TYPICAL 1. Hose pincher right after T-fitting 2. T-fitting 3. Hose pincher on this hose 4. Hose pincher on drain tube
02-05-4
All Engines NOTE: Hose pinchers must be firmly tightened so that no antifreeze can flow through the blocked hoses. If you hear the liquid flowing in the muffler immediately after starting pouring antifreeze, it indicates that antifreeze is bypassing the engine/ tuned pipe water jackets. To correct this, firmly retighten hose pinchers. Unscrew cap from flushing fitting on the edge of engine compartment and insert a funnel into flushing fitting. Pour about 2 liters (1/2 gal) of antifreeze solution through the funnel. Let the antifreeze enough time to flow. Moving the hose with the T-fitting should accelerate the flow.
787 Engine
F04E0TA
717 Engine Remove hose pincher from injection hose at tuned pipe and continue to pour approximately 200 mL (7 oz). This will allow antifreeze to flow inside muffler to protect it.
F04E0SA
Pour antifreeze until you see it flowing out of tuned pipe bleed hose. At this time only, the entire circuit is filled with antifreeze.
717 Engine
1
F04E0WA
F04E10A
02-05-5
787 Engine At this time, remove hose pincher hose at engine head and continue to pour approximately 200 mL (7 oz). This will allow antifreeze to flow through water regulator valve toward muffler in order to protect it.
Battery
For battery removal, cleaning and storage, refer to ELECTRICAL 08-07.
Anticorrosion Treatment
Wipe off any residual water in the engine compartment. Spray BOMBARDIER LUBE lubricant over all metallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant.
Finalizing Storage
The engine storage cover should be left opened during storage (disconnect gas shocks from cover to prevent full opening). Remove storage tray. Place it on deck. This will avoid engine compartment condensation and possible corrosion. If the boat is to be stored outside, cover it with a vented opaque tarpaulin to prevent sun rays and grime from affecting the plastic components or boat finish as well as to prevent dust accumulation. Unscrew the drain plugs for the storage. Lift the boat so that the bow is higher then the stern to allow draining of the bilge. Safely block it in this position.
F04E0TB
All Engines When finished, remove all remaining hose pinchers. Most of the antifreeze will drain out from flushing fitting and jet pump nozzle when removing hose pinchers. Use a suitable container to recover it. Dispose antifreeze as per your local laws and regulations. NOTE: Although most antifreeze will drain out, it has flowed to mix with water that was possibly trapped in cooling system cavities thus preventing freezing problems. NOTE: For pre-season preparation, drain antifreeze from cooling system prior to launching boat in water as explained above.
CAUTION
The boat must never be Ieft in water for storage. Never leave the boat stored in direct sunlight. UV radiation will dull finishes. Make sure to turn OFF bilge pump and blower.
02-05-6
TROUBLESHOOTING
NOTHING IS WORKING IN THE ELECTRICAL SYSTEM
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
The following chart is provided to help in diagnosing the probable source of troubles. It is a guideline only and does not detail all causes for all problems.
No beeps are heard when installing Main disconnect switch is turned Verify and turn ON. safety lanyard on DESS post OFF.
Start/stop button defective. Burnt main fuse(s). Burnt MPEM supply fuse. MPEM supply fuse keeps on burning. Discharged battery. Battery connections. Water/fuel hydrolock. Starter or solenoid. Seized engine. Seized jet pump. Jammed jet pump. Engine turns slowly Discharged/weak battery. Battery connections. Restriction in jet pump. Seizure in jet pump. Partial engine hydrolock. Partial engine seizure. Worn starter.
Wear ring of jet pump improperly Check/replace, refer to section installed. 09-02.
03-01-1
Excessive rotary valve clearance. Check, refer to section 04-07. Internal engine damage. Sheared flywheel key. Incorrect rotary valve timing. No spark at spark plugs Grounded BLACK/RED/GREEN wire (additional BLACK/RED wire on twin-engine models) connecting to MPEM on 717 engine only. Unproperly grounded MPEM BLACK wire. Defective MPEM. Faulty magneto system. Check, refer to section 04-06 and 04-07. Check timing mark, refer to section 04-04. Check, refer to section 04-07. Repair.
Repair. Check, refer to section 08-04. Check wiring and ignition system, refer to section 04-04.
03-01-2
Faulty MPEM or start/stop switch. Check, refer to section 08-04. Faulty ignition. Sheared flywheel key. Lean fuel mixture Dry spark plug (except when water fouled) Fuel level low. Stale or water fouled fuel. Fuel filter dirty or restricted. Carburetion dirty or out of adjustment. Leaking crankshaft seal(s), rotary valve cover O-ring(s). Fuel valve restricted or partially opened. Loose carburetor. Rich fuel mixture Fouled spark plug Partially closed choke. Flame arrester dirty or restricted. Carburetor adjustment. Check, refer to section 04-04. Check timing mark, refer to section 04-04. Check/refill. Check/siphon and refill. Check/clean/replace. Check/clean/adjust, refer to section 07-03. Check/test/replace, refer to engine section 03-02. Check/replace/turn fully ON. Tighten carburetor(s). Check/adjust choke cable. Check/replace. Check/adjust, refer to section 06-04.
Leaking check valve at injector of Check, refer to section 06-04. accelerator pump. Main jet loose. Rotary valve shaft seal leaking. Oil pump adjustment. Boat transportation. Worn needle(s) and seat(s). Excessive rotary valve clearance. Difficult to start Incorrect rotary valve timing. Excessive rotary valve clearance. Check, refer to section 06-04. Check/replace, refer to section 06-04. Check/adjust, refer to section 07-03. Turn fuel valve to OFF (if so equipped). Check, refer to section 06-04. Check, refer to section 04-07. Check/adjust, refer to section 04-07. Check, refer to section 04-07.
03-01-3
ENGINE OVERHEATS
OTHER OBSERVATION Monitoring beeper continuously sounds POSSIBLE CAUSE REMEDY
Restricted jet pump water intake. Check/clean. Cooling system restriction. Check/flush, refer to section 02-03.
Intake leak/crankshaft seal failure. Pressure check engine, refer to section 04-03.
03-01-4
Twisted crankshaft. Cooling system water flow regulator valve (787 engine). Engine revs lower than its maximum RAVE valve does not open. operational RPM (787 engine) Peak performance is delayed until higher RPM range is reached (787 engine) RAVE valve is stuck open.
03-01-5
Jet pump improperly sealed to Check/reseal/install a new ride shoe; insufficient sealant on neoprene seal. the ride shoe or missing neoprene seal (or sealing in this area). Check/replace.
Engine RPM is high and boat is slow Through-hull seal around drive to accelerate shaft; air comes from inside the boat. OR engine does not react quickly when pushing on throttle lever (assuming that engine is correct) OR engine does not keep a steady top RPM (assuming that engine is correct) Other problem with jet pump (related to performance): Boat does not reach its top speed A wear ring (jet pump) with excessive clearance. A damaged or worn jet pump. A damaged impeller. An impeller with the wrong pitch (too low). Missing or damaged impeller boot. Weeds or debris in intake grate, jet pump intake or impeller. Retaining screws of ride shoe or sealing of weedless system cable/housing; air comes from inside the boat. Retaining screws of intake grate; air comes from inside the boat.
Check/reseal.
Check/reseal.
03-01-6
Drive shaft protector rubbing against drive shaft or impeller boot. Damaged or bent drive shaft. Broken motor mounts.
03-01-7
Subsection 01
TABLE OF CONTENTS
LEAK TEST............................................................................................................................. GENERAL ........................................................................................................................... PREPARATION ................................................................................................................... TESTING PROCEDURE ..................................................................................................... ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................ REMOVAL AND INSTALLATION .......................................................................................... GENERAL ........................................................................................................................... REMOVAL FROM JET BOAT ............................................................................................. CLEANING ......................................................................................................................... INSTALLATION.................................................................................................................. MAGNETO SYSTEM ............................................................................................................. GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... ASSEMBLY......................................................................................................................... INSTALLATION ..................................................................................................................
0
04-02-1 04-02-1 04-02-1 04-02-1 04-02-5 04-03-1 04-03-1 04-03-1 04-03-5 04-03-5 04-04-1 04-04-3 04-04-3 04-04-6 04-04-8 04-04-8 04-04-9
TOP END ................................................................................................................................ 04-05-1 ENGINE DESCRIPTION ..................................................................................................... 04-05-3 GENERAL ........................................................................................................................... 04-05-3 DISASSEMBLY................................................................................................................... 04-05-5 CLEANING ......................................................................................................................... 04-05-8 INSPECTION ...................................................................................................................... 04-05-8 ASSEMBLY......................................................................................................................... 04-05-12 ADJUSTMENT ................................................................................................................... 04-05-18 BOTTOM END........................................................................................................................ 04-06-1 DISASSEMBLY................................................................................................................... 04-06-3 CLEANING ......................................................................................................................... 04-06-7 INSPECTION ...................................................................................................................... 04-06-8 ASSEMBLY......................................................................................................................... 04-06-11 ROTARY VALVE ..................................................................................................................... GENERAL ........................................................................................................................... INSPECTION ON BOAT..................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... 04-07-1 04-07-2 04-07-2 04-07-4 04-07-6 04-07-6 04-07-6
04-01-1
EXHAUST SYSTEM ............................................................................................................... TUNED PIPE REMOVAL ..................................................................................................... EXHAUST MANIFOLD REMOVAL..................................................................................... MUFFLER AND OTHER COMPONENTS REMOVAL ........................................................ TUNED PIPE REPAIR .......................................................................................................... INSTALLATION ...................................................................................................................
04-01-2
LEAK TEST
GENERAL
A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) is available to help diagnose engine problems such as engine seizure, poor performance, oil leakage, etc. Before disassembling any components of the engine, it is important to perform a leakage test to determine which part is defective. It is also very important after servicing the engine, even for a complete engine rebuilt, to perform another leakage test; at this stage, it may avoid further engine problems and minimizing the risk of having to remove and reinstall the engine again. Static bench testing is the most effective way to conduct a leakage test. Inboard testing does not allow complete access to, and observation of all engine surfaces and should be avoided whenever possible. On 717 and 787 engines, cylinders cannot be verified individually due to leakage from one cylinder to another through a common intake manifold. When installing hoses of the Engine Leak Test Kit, use the collars provided in the kit to ensure a proper sealing. When pressurizing the engine, first confirm that the components of the Engine Leak Test Kit are not leaking by spraying a solution of soapy water on all hoses, connections, fittings, plates, etc. If there is a leak, bubbles will indicate leak location. Three areas of the engine will be tested in sequence as per the diagnostic flow chart (see the end of this subsection). 1. Engine Cooling System 2. Bottom End and Top End 3. Rotary Valve Shaft NOTE: If a leak is found, it is important to continue testing as there is the possibility of having more than one leak. Continue pumping to compensate for the air lost to find another leak.
0
PREPARATION
Verify fuel system for leaks.
WARNING
If any fuel leak is found, do not start the engine. Correct the leak and wipe off any fuel spillage. Do not use electric powered tools unless fuel system has passed pressure test. Disconnect battery BLACK negative cable.
WARNING
Always disconnect battery cables in the specified order, BLACK negative cable first. Disconnect battery RED positive cable.
TESTING PROCEDURE
Engine Cooling System
Remove the tuned pipe. Remove the exhaust manifold gasket and ensure the surface is clean. Disconnect engine cooling hoses. Install the appropriate exhaust manifold plate (no. 1 for the 787 engine and no. 2 for 717 engine) from the Engine Leak Test Kit. Tighten plate using fasteners provided in the kit. Use hoses provided in the kit and install them on the engine. Install pump using reducer and appropriate tube(s) as necessary.
04-02-1
4 3
F01B2UB
2
F01B2WA
717 ENGINE REAR VIEW 1. Engine drain hose blocked with a hose pincher
2 1
787 ENGINE 1. Loop hose and use clamps 2. Hose with clamps. Plug end with a screw 3. Block engine drain hose with a hose pincher 4. Use 2 washers with exhaust manifold stud
F01B2VA
NOTE: Water is not required for testing. Activate pump and pressurize engine cooling system to 5 PSI (34 kPa). Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking and pressure drops, verify all external jointed surfaces, temperature sensor and the O-ring between the spark plug area and the engine cylinder head cover. If none of these components are leaking, there is an internal leak and it can be detected with Bottom End and Top End testing.
717 ENGINE FRONT VIEW 1. Loop hose and use clamps 2. Use 2 washers with exhaust manifold stud 3. Hose with adapter and nipple
04-02-2
NOTE: Do not block the rotary valve shaft hoses. Install pump to the exhaust plate fitting.
3
2
F01B2ZA
717 ENGINE 1. Intake plates 2. Pulse hose blocked with a hose pincher 3. Exhaust plate
cylinder head gasket cylinder base gasket crankcase halves rotary valve cover engine plugs exhaust manifold intake manifold (717 engine) oil injection pump (717 engine) Check also small oil injection pump lines and fittings; check for air bubbles or oil column going toward pump, which indicate a defective check valve. If the above mentioned components are not leaking, block both oil hoses of the rotary valve shaft using hose pinchers. NOTE: If leakage stops at this point, proceed with rotary valve shaft testing. If there is still some leakage, remove the PTO flywheel and verify crankshaft outer seal. If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft outer seal. Proceed with the rotary valve shaft testing if the crankshaft outer seals are not leaking.
4 1
3
F01B30A
787 ENGINE 1. Intake plates 2. RAVE valve plates 3. Pulse hose blocked with a hose pincher 4. Exhaust plate
CAUTION
Do not exceed this pressure. Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking, verify engine jointed surfaces as per following areas: spark plugs
F01B31A
F01B32A
F01B34A
Install pump with reducer and nipple to the oil supply hose of the rotary valve shaft.
F01B33A
Activate pump and pressurize to 5 PSI (34 kPa). Check plug of the rotary valve shaft in crankcase. Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal. Remove MAG side spark plug. If pressure drops, it indicates a defective MAG side crankshaft inner seal. If the above mentioned components are not leaking and there is a pressure drops, remove the rotary valve cover. Check the seal of the rotary valve shaft. If the rotary valve shaft is not leaking, it could indicates a defective engine casting. Disassemble engine and carefully check for defects in castings. Pay attention to tapped holes which may go through sealed areas of engine and thus lead to leakage.
04-02-4
NO
CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. YES
YES
BLOCK LARGE HOSES OF ROTARY VALVE GEAR LUBRICATION SYSTEM NO IS ENGINE STILL LEAKING?
UNSEAL PTO CYLINDER AND MAG CYLINDER SEPARATELY BY REMOVING THE APPROPRIATE SPARK PLUG
IS RESERVOIR LEAKING? NO CHECK TESTING KIT CHECK FOR LEAKAGE AT ROTARY VALVE SHAFT CRANKCASE PLUG
YES
ANY LEAK FOUND? NO REMOVE ROTARY VALVE COVER, CHECK SEAL OF ROTARY VALVE SHAFT
YES
NO
YES
F00D07S
04-02-5
Subsection 03
Twin-engine Models Although basically the same engines are used for port and starboard, there are differences in hardware, such as throttle/choke cable length, fuel/oil lines, electrical wiring etc. Properly identify engines prior to removal.
First, remove BLACK negative cable from battery(ies), then RED positive cable. Disconnect thermosensor wire and spark plug cables. Disconnect magneto wires at connector of engine. Disconnect rectifier/voltage regulator wires.
F01D8RA
CAUTION
Whenever removing engine from jet boat, engine/jet pump alignment must be performed at installation.
Electrical Connections
WARNING
1
Always disconnect starter or battery cables exactly in the specified order, BLACK negative cable first. Electrolyte or fuel vapors can be present in the engine compartment and a spark might ignite them and possibly cause personal injuries. It is recommended to disconnect electrical connections prior to disconnecting fuel lines. Unfasten battery top brace (retaining strap and remove battery box cover on Sportster).
F06D0FA
04-03-1
3 2
F04D0ZA
1
F01D8PA
Cooling System
Disconnect cooling system hoses from engine head.
717 Engine Disconnect bleed hose at T-fitting close to engine. NOTE: The bleed hose of the 787 engine will be disconnected later. All Engines
Lifting Engine
717 Engine Engine can be easily lifted using the following suggested tools. Cut porcelain from 2 old spark plugs. Weld a lock washer approximately 20 mm diameter on each spark plug as shown.
04-03-2
Subsection 03
To prevent excessive oil spillage, use a hose pincher (P/N 295 000 076).
F01D0AA
Remove spark plugs and replace by special tools. Hook a sling into holes of special tools then using a chain block, a hoist or other suitable equipment, slowly lift engine.
A01B2JA
TYPICAL
787 Engine Engine can be easily lifted by inserting a hook into exhaust manifold eyelet.
Lift engine until oil injection pump supply line, rotary valve oil lines (supply and return) are reachable. Install a hose pincher on each line then disconnect. NOTE: When disconnecting oil tube, a salvaged tube with a plugged end can be used to plug the engine nipple to prevent oil spillage.
F04D11A
F04D0YA
All Models Using a chain block, a hoist or other suitable equipment, slightly lift engine to ease the removal of remaining components.
Disconnect RED positive cable from starter post and ground cable (where applicable).
CAUTION
Take care not to damage oil pump cable or oil injection hoses.
04-03-3
2 1
F01D3ZA F04D10A
TYPICAL 717 ENGINE 1. Rotary valve supply line 2. Hose pincher installed
TYPICAL 787 ENGINE 1. Rotary valve supply line 2. Hose pincher installed 3. Disconnect RED positive cable
1
F01H1JB
1
F04D12A
2 3
TYPICAL 787 ENGINE 1. Disconnect injection pump cable 2. Oil injection pump supply line 3. Hose pincher installed
04-03-4
Subsection 03
CAUTION
Strict adherence to this torque is important to avoid damaging threads of aluminum insert in bilge.
Engine Support
2
3
F04D13A
717 Engine Properly install support on crankcase so that rounded portion of support matches with MAG side of crankcase. Apply Loctite 242 (blue) on threads then torque nuts in a criss-cross sequence to 43 Nm (32 lbfft).
TYPICAL UNDERNEATH VIEW OF 787 ENGINE 1. Disconnect bleed hose 2. Oil injection pump return line 3. Hose pincher installed
Tuned Pipe
CAUTION
Be careful not to scratch body with engine support or to hit any component.
Loctite 242
F00D0BA
CLEANING
Wipe off any spillage in bilge. Clean with a bilge cleaner. Clean external parts of engine.
All Engines
INSTALLATION
Installation of engine in boat is essentially the reverse of removal procedures. However, pay particular attention to the following.
04-03-5
F00B0HA
TYPICAL
Insert shaft end into PTO flywheel. NOTE: Ensure the protective boot and carbon ring are removed to check engine alignment. If the alignment is correct, the shaft will slide easily without any deflection in PTO flywheel.
1
F00B0FA
1. Plate (P/N 529 035 507) 2. Support (P/N 529 035 511)
F07D05A
1
F00B0GA
To verify alignment proceed as follows: Install the appropriate plate with the support to hull with 4 nuts. Carefully slide shaft through support.
If the alignment is incorrect, loosen engine support screws to enable to align PTO flywheel with shaft end. NOTE: Use shim(s) (P/N 270 000 024) or (P/N 270 000 025) as necessary between engine support and rubber mounts to correct alignment.
04-03-6
Subsection 03
Final Inspection
Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. After its installation, properly adjust and bleed oil injection pump as specified in LUBRICATION SYSTEM 07-03.
Sportster 1800 and Challenger 1800 Properly reconnect hoses on fuel pump. All Models Check hose condition and pressure test fuel system, refer to FUEL SYSTEM 06-04.
F00D0CA
TYPICAL 1. Shim
CAUTION
Whenever doing any type of repair on craft or if any components of the fuel system are disconnected, a pressure test must be done before starting engine. Verify all electrical connections. Run engine and ensure there is no leakage.
WARNING
Whenever shims are used to correct alignment, never install more than 1.3 mm (.051 in) shim thickness. If alignment cannot be obtained verify for engine support bending.
CAUTION
04-03-7
MAGNETO SYSTEM
717 Engine
8 7 5 Nm (44 lbfin)
9 Loctite 242
9 Nm (80 lbfin)
11 10
13
Loctite 242 6 Nm (53 lbfin) 15 Loctite 242 4 16 Loctite 242 3 1 14 6 Nm (53 lbfin)
2 9 Nm (80 lbfin)
PARTS
FLAT RATE
04-04-1
787 Engine
7 10 Loctite 242 9 Lithium grease 10 Nm (88 lbfin)
4 Loctite 648 10 Nm 11 (88 lbfin) Loctite 648 Loctite 242 5 105 Nm 6 (77 lbfft) 4.5 Nm (40 lbfin) 16
13 10 Nm (88 lbfin)
Anti-seize lubricant
3 1
F01D7TS
Synthetic grease
6 Nm (53 lbfin)
04-04-2
PARTS
FLAT RATE
GENERAL
The following procedures can be performed without removing engine from jet boat.
1
REMOVAL
717 Engine
F01D48A
Using a suitable socket, unscrew retaining nut no. 6 COUNTERCLOCKWISE when facing it. NOTE: If socket is found too large to be inserted in puller plate, machine or grind its outside diameter as necessary.
3
1
4
F01D47A
1. 2. 3. 4.
Using 3 M8 x 35 screws (P/N 290 841 591), install screws through puller plate and slide sleeves on screws then secure puller plate on magneto flywheel so that sleeves are against flywheel. Install extension handle on end of puller plate.
F01D4BA
Remove nut and lock washer from magneto flywheel. Magneto flywheel is easily freed from crankshaft with puller (P/N 295 000 106).
04-04-3
A00C1AA
Fully thread bolt on puller in puller plate. Tighten puller bolt and at the same time, tap on bolt head using a hammer to release magneto flywheel from its taper.
3
F01D4CA
7, Magneto Housing
To remove magneto housing, starter has to be removed. Refer to ELECTRICAL SYSTEM 08-07. Unscrew retaining screws no. 9, then withdraw housing.
At assembly, align armature plate mark (previously punched) with the end of the same locating lug on the new crankcase.
04-04-4
The new mark on crankcase will be used for further assembly positioning as a pre-timing position.
F01D4GA F01D4EA
TYPICAL 1. Lug end of crankcase 2. Align mark and lug end here
787 Engine
Find manufacturers mark on armature plate. In line with this mark, punch another mark on adjacent crankcase lug.
F01B26A
F01D4FA
TYPICAL 1. Manufacturers mark on armature plate 2. Punch a mark on crankcase lug aligned with plate mark
04-04-5
F01D85A
F01D7YA
1. Puller
If desired, magneto rotor can be removed without the engine flywheel. Remove the 6 screws no. 11.
Tighten puller screw and at the same time, tap on screw head using a hammer to release engine flywheel from its taper.
DISASSEMBLY
717 Engine
F01D7XA
1. Screw
Using a suitable socket, unscrew retaining nut of engine flywheel COUNTERCLOCKWISE when facing it. Remove special tool locking ring gear. Engine flywheel is easily freed from crankshaft with puller (P/N 420 976 235) and crankshaft protective cap (P/N 290 876 557). Insert crankshaft protector to outer end of crankshaft and fully thread puller in engine flywheel.
F01D3AA
1. Magneto flywheel
04-04-6
1
F00D08A F00D09A
1
1. Heat the armature plate
CAUTION
CAUTION
Protect harness from flame. Remove screws. Uncrimp and unsolder BLACK/RED wire from coil.
Protect harness from flame. Remove screws. Uncrimp and unsolder YELLOW and YELLOW/ BLACK wires from coil. Uncrimp and unsolder ground wire (BLACK) from coil core.
A25E0QA
1. Uncrimp and unsolder ground wire (BLACK) 2. Uncrimp and unsolder YELLOW and YELLOW/BLACK wires
04-04-7
CLEANING
All Engines Clean all metal components in a solvent.
1
CAUTION
Clean coils and magnets using only a clean cloth. Clean crankshaft taper and threads.
ASSEMBLY
717 Engine
F00D0AA
F01D3BA
1. Teeth chamfer
F00D0AA
CAUTION
Before reinstalling the magneto, remove the loose epoxy from harness.
NOTE: Ensure that ring gear contacts magneto flywheel flange. Whenever replacing either ring gear or magneto flywheel, Gun Kote (available from Kal-Gard Coating & Mfg. Corp.) must be applied to prevent possible corrosion.
CAUTION
Always assemble magneto flywheel and ring gear prior to applying Gun Kote. If not done correctly, ring gear wont contact magneto flywheel flange.
To apply Gun Kote proceed as follows: 1. Clean thoroughly and degrease replacement part using a non oil base solvent. 2. Apply coating in light thin coats using a spray gun. NOTE: Do not spray Gun Kote into magneto flywheel threaded holes. 3. Bake parts in oven at 175 (350F) for one hour to cure Gun Kote.
CAUTION
Do not eliminate Gun Kote heat curing time because it will lose all its resistance and not give any protection.
CAUTION
F06D0DA
At installation of magneto, ring gear teeth chamfer and starter clutch should be facing each other.
1. Trigger coil
787 Engine
INSTALLATION
717 Engine
12, Stator
Install the stator in magneto housing cover no. 1 and torque screws no. 13 to 10 Nm (88 lbfin). Replace wiring harness bracket no. 16 of stator and torque screws to 4.5 Nm (40 lbfin).
1 2
7, Magneto Housing
Install gasket no. 8 between magneto housing and engine crankcase. Install magneto housing and torque screws no. 9 to 9 Nm (80 lbfin).
4, Magneto Flywheel
Apply Loctite 242 (blue) on crankshaft taper. Position Woodruff key no. 16 and magneto flywheel. Apply Loctite 242 (blue) on nut no. 6. Install nut with lock washer and torque to 145 Nm (107 lbfft).
F06D0CA
CAUTION
04-04-9
Ignition Timing
For ignition timing procedures, refer to ELECTRICAL SYSTEM 08-03.
787 Engine
7, Magneto Housing
To install oil seal no. 10 of magneto housing, use pusher (P/N 290 877 740) and handle (P/N 290 877 650).
F01D83A
1. Protuberance 2. Hole
F01B2NA
1. Pusher 2. Handle
Apply Loctite 648 (green) on screws no. 11 and torque to 10 Nm (88 lbfin). Apply Loctite 242 (blue) on crankshaft taper. Apply Loctite 242 (blue) on nut no. 6. Install nut with lock washer and torque to 105 Nm (77 lbfft).
All Engines
CAUTION
F04D0CA
Install gasket no. 8 between magneto housing and engine crankcase. Install magneto housing and torque screws no. 9 to 9 Nm (80 lbfin).
04-04-10
TOP END
717 Engine
Synthetic grease 8 24 Nm 11 (17 lbfft) Loctite PST 592 8 Loctite 242 24 Nm 11 (17 lbfft) Synthetic grease Loctite 242 10 10 25 1
4 34 rollers 3 4 5 6
Synthetic grease
F04D0UT
PARTS
FLAT RATE
04-05-1
787 Engine
Loctite 242 Synthetic grease 1 24 Nm 11 (17 lbfft)
25
10
2 24
16 14 13 22 23 17 Synthetic grease
7 Loctite 515 9
15
21
20 19
18
34 rollers
6 5 4
12 4 5 Synthetic grease
F01D7DV
04-05-2
PARTS
FLAT RATE
ENGINE DESCRIPTION
The 2-stroke ROTAX engine rotates counterclockwise seen from the rear (PTO flywheel). It has a rotary valve to control fuel mixture intake. Lubrication is provided by a variable oil injection pump. It is cooled by water supplied from the jet pump. It has a NIPPONDENSO Capacitor Discharge Ignition System. The fuel is provided by diaphragm MIKUNI carburetor having an integrated fuel pump.
GENERAL
CAUTION
When repairing a seized engine, connecting rods should be checked for straightness and crankshaft for deflection/misalignment. Refer to BOTTOM END for procedures.
787 Engine This engine is canted at a 30 degree angle, lowering the center of gravity of the craft. Cylinder exhaust ports are located on the same side of the intake, allowing a high volume tuned pipe design. This engine also features the RAVE system (Rotax Adjustable Variable Exhaust). The RAVE system, working in combination with the high volume tuned pipe, offers a broader power band.
When an engine of this design is run at a medium speed, efficiency falls off quickly. The relatively high exhaust port effectively shortens the useful power stroke, and because the exhaust system is tuned for maximum power, there is a large increase of fresh charge losses. As a result, the torque decreases along with a dramatic increase of the specific fuel consumption. Higher torque along with lower fuel consumption can be obtained at lower engine speeds if the time the exhaust port is open is shortened. BOMBARDIER-ROTAX has patented a remarkably simple system to automatically change the exhaust port height based on pressure in the exhaust system. Located above the exhaust port is a guillotinetype slide valve. This rectangular valve is connected by a shaft to a diaphragm which is working against the return spring. One small passage in the cylinder just outside the exhaust port allows exhaust gas pressure to reach the diaphragm. To the outside of the return spring is a red plastic adjustment knob. Turning the adjustment in or out changes the preload on the return spring which, in turn, will change the RPM at which the RAVE valve opens and closes.
1 5 3 2
RAVE System
THEORY For a 2-stroke-cycle engine to have high power capacity at high crankshaft speeds, a high volumetric 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.
4
A18C01A
As the throttle is opened and the engine begins producing more power, the pressure against the diaphragm will overcome the pressure of the return spring and the RAVE valve will open.
04-05-3
F01D7GA
Item P1 in figure is the force of the return spring against the diaphragm. The exhaust pressure must be high enough to overcome this force before the valve begins opening. Item P2 is the pressure required to completely open the RAVE valve. Between P1 and P2, the usable power curve of the engine is moving from power curve 1 to power curve 2. This transition takes place very rapidly at full throttle and from a practical standpoint can be considered to be instantaneous at item 7. Gradual application of the throttle, however, will result in the RAVE valve opening much later. If the RAVE valve opens too late, the engine will bog or hesitate momentarily as the RPM increases. Full peak performance (item 6) is still available. From a functional point of view, it is better to have the valve open a bit early than a bit late.
P2 1 4 7 6
P1
POWER
F01D7HA
The RAVE valve does not allow an engine to make higher peak horsepower than an engine not so equipped; however, it can make moving the peak horsepower higher practical because of its effect on the rest of the power curve. Item 2 in the following figure is the power curve of an engine with the RAVE valve held fully open through its entire RPM range. Item 6 notes the peak power produced. That peak would not change if the exhaust port timing of a similar engine without a RAVE valve were the same (with all other features equal). Item 1 is the power curve of the engine with the RAVE valve closed through its entire RPM range. The shaded area (item 3) is the improvement in power at lower engine speeds that is gained because of the lower exhaust port. If the port were to remain at this height; however, the power would peak as noted in item 5. Raising the exhaust port at the proper RPM (item 7) will allow the engine peak power to continue to rise (item 6).
A18C02A
RPM
MAINTENANCE There are no wear parts anywhere in the system and there are no adjustments to be periodically checked. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide. Cleaning intervals would depend upon the users riding style and the quality of the oil used. Using BOMBARDIER-ROTAX injection oil, we would suggest annual cleaning of the valve. If a customer uses a lower quality oil, more frequent cleaning may be required. No special solvents or cleaners are required when cleaning the valve.
04-05-4
BORING PRECAUTION In its stock configuration the RAVE valve guillotine has a minimum of 0.5 mm (.020 in) clearance to the cylinder bore measured at the center line of the cylinder. This is the minimum production clearance. There is only a first oversize piston available for the 787 engine. That piston is 0.25 mm (.010 in) larger in diameter than the stock piston. When the oversize is installed, the guillotine will have a minimum clearance of 0.375 mm (.015 in) with the cylinder bore. This is the minimum operating clearance the guillotine should be used with. Clearance less than 0.375 mm (.015 in) will require reworking of the guillotine to achieve the proper clearance and radius.
F01D8IA
DISASSEMBLY
787 Engine
1. Allen screws
Remove bellow no. 17 from valve piston no. 16. Unscrew valve piston no. 16 from sliding valve no. 18. NOTE: Hold the sliding valve to prevent it from turning.
1
WARNING
Firmly hold cover to valve base. The spring inside the valve is applying a pressure against the cover.
2
F01D8MA
All Engines Top end can be serviced while engine is in the boat, proceed as follow.
Electrical Connections
F01D8HA
1. Spring
Disconnect thermosensor wire and spark plug cables. Disconnect spark plug cables and connect on grounding device.
04-05-5
Exhaust System
To withdraw tuned pipe and exhaust manifold, refer to ENGINE 04-08.
Bring piston to Top Dead Center and install rubber pad (P/N 295 000 101) over crankcase opening. Secure with screws. Lower piston until it sits on pad.
1
F01B0JA
1. Rubber pad
If other cylinder has been removed, completely cover its opening with a clean rag.
WARNING
If screws need to be heated for removal when engine is in jet boat, fuel system pressurization must be done first. Do not use open flame; use a heat gun. An explosion might occur since vapors can be present in engine compartment. NOTE: Even if only one cylinder needs repair, both cylinders should be lifted to allow 1-piece cylinder base gasket replacement.
F01D43A
To remove circlip, insert a pointed tool in piston notch then pry it out and discard.
CAUTION
WARNING
Never use a magnet to catch rollers of bearing. This magnetizes the rollers that will catch dust. NOTE: These engines feature cageless piston pin bearing.
04-05-6
2 3 4
F00B0JA
F01D0PA
1. Piston notch
To extract piston pin, use piston pin puller (P/N 529 035 503) with a set of sleeves (P/N 529 035 542).
2 3
1. 2. 3. 4.
NOTE: The tool cutout must be positioned toward the bottom of the piston.
1
F00B0IA
F00B0KA
Fully thread on puller handle. Insert extractor spindle into the piston pin. Slide the sleeve and shoulder sleeve onto the spindle. Screw in extracting nut with the movable extracting ring towards spindle.
Firmly hold puller and rotate handle to pull piston pin. Rotate spindle until the shoulder sleeve is flushed with the piston recess.
04-05-7
F00B0LA
F00B0NA
Loosen the extracting nut and remove puller. Remove the shoulder sleeve from piston.
CLEANING
Discard all gaskets and O-rings. Clean all metal components in a solvent. Clean water passages and make sure they are not clogged. Remove carbon deposits from cylinder exhaust port, RAVE valve (787 engine), cylinder head and piston dome. Clean piston ring grooves with a groove cleaner tool, or a piece of broken ring. Piston pin may be cleaned with a fine steel whool.
F00B0MA
INSPECTION
787 Engine Check RAVE valve bellow no. 17 for cracks. Check if passages of valve housing no. 21 and cylinder no. 9 are not obstructed.
Carefully remove the piston no. 3. The needles, thrust washers and the sleeve remain in the connecting rod bore and may be used again.
04-05-8
NOTE: Replacement cylinder sleeves are available if necessary. Also, oversize pistons of 0.25 mm (.010 in) are available for all engines and additional oversize pistons of 0.5 mm (.020 in) are available for 717 engines.
Cylinder Taper
Using a cylinder bore gauge, measure cylinder diameter 16 mm (5/8 in) from top of cylinder to just below auxiliary transfer port, facing exhaust port. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced.
F01D8JA
All Engines 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 deformation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper. The inspection of engine top end should include the following measurements. All Engines
TOLERANCES (ALL ENGINES) NEW PARTS (min.) (max.) N.A. N.A. N.A. N.A. WEAR LIMIT 0.1 mm (.004 in) 0.08 mm (.003 in) 0.2 mm (.008 in)
1 A
ENGINE MEASUREMENT
F01D8AA
1. Measuring perpendicularly (90) to piston pin axis 2. Auxiliary transfer port A. 16 mm (5/8 in)
Cylinder taper Cylinder out of round Piston/cylinder clearance Ring/piston groove clearance Ring end gap
0.025 mm 0.07 mm 0.20 mm (.001 in) (.0028 in) (.008 in) 0.25 mm (.010 in) 0.40 mm (.016 in) 1.0 mm (.039 in)
04-05-9
A 2
F01D8BA
1. Measuring in piston pin axis 2. Measuring perpendicularly (90) to piston pin axis A. 16 mm (5/8 in)
F00D0EA
Adjust and lock a micrometer to the specified value on the piston dome.
1
F00B08A
F01D0NA
PISTON/CYLINDER WALL CLEARANCE MEASUREMENT Used and New Pistons With the micrometer set to the piston dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to zero.
The measured dimension should be the same as the one scribed on piston dome. If not, install a new piston.
04-05-10
1 2
Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.
F00B09A
1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge
1
F01D0XA
1
F00B0AA
Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge.
1 A
F01D0KA
GASKET THICKNESS 0.3 mm (0.012 in) 0.4 mm (0.016 in) 0.5 mm (0.020 in) 0.6 mm (0.024 in) 0.8 mm (0.031 in)
IDENTIFICATION HOLES 3 4 5 6 8
ASSEMBLY
Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following.
F01D0OA
787 Engine
3
F01D8KA
Install a new gasket no. 20. It must be installed at the same time as the sliding valve no. 18. Position the valve housing no. 21 onto the cylinder so that its opening is toward the bottom.
F01D67A
1. Identification holes
04-05-12
1
AUS
A01C01A
1. Exhaust side
F01D8JB
When the valve is mounted onto the cylinder, move the valve piston no. 16 to ensure the sliding valve no. 18 moves easily and doesnt stick.
F01D7EA
F01D8LA
All Engines
3, Piston
At assembly, place the pistons over the connecting rods with the letters AUS (over an arrow on the piston dome) facing in direction of the exhaust port. NOTE: On the 787 engine, the exhaust ports are located on the same side as the intake.
04-05-13
F00B0OA
F01D0Q A
Insert extractor spindle into the piston pin, screw on extracting nut.
2 1
F00B0PA
F01D0VA
1. Puller installed on the opposite side of the piston pin 2. Tighten extracting nut
Rotate handle to pull piston pin carefully into the piston. PLASTIC MOUNTING DEVICE METHOD As an alternate method when no service tool is available proceed as follows: Replacement roller bearings are delivered in a convenient plastic mounting device. For installation, proceed as follows: Align replacement roller bearing with connecting rod bore. Carefully push inner plastic sleeve into connecting rod bore; outer plastic ring will release rollers.
Insert piston pin into piston until it comes flush with inward edge of piston hub.
F01D0RA
Place piston over connecting rod and align bores, then gently tap piston pin with a fiber hammer to push out inner plastic ring on opposite side. Support piston from opposite side.
F06D18A
F01D0SA
To easily insert circlip into piston, use circlip installer (P/N 290 877 016).
F06B01A
1. Circlip installer
Remove sleeve from pusher then insert circlip into its bore. Reinstall sleeve onto pusher and push until circlip comes in end of tool.
F01D0TA
5, Circlip
Secure circlip with its opening located at the bottom of the piston.
CAUTION
F00B0QA
04-05-15
Position end of tool against piston pin opening. Firmly hold piston against tool and tap tool with a plastic tip hammer to insert circlip into its groove.
F01D0ZA
CAUTION
The forearm retaining the piston should absorb the energy to protect the connecting rod. Circlips must not move freely after installation.
7, Cylinder
To easily slide cylinder over piston, install ring compressor (P/N 295 000 112) over rings.
F01D10A
A01B1TA
When reassembling cylinders to crankcase, it is important to have them properly aligned so that exhaust flanges properly match up with exhaust manifold. Use aligning tool (P/N 290 876 902) or exhaust manifold itself.
NOTE: Ring compressor will not fit on oversize piston/rings. Make sure to align ring end gap with piston locating pin. Slide tool over rings.
04-05-16
717 Engine
F01D44A
F00D0FA
F01D45A
3
F01D35A
04-05-17
787 Engine Prior installation, apply synthetic grease below screw head and Loctite 518 on screw threads. Install M10 x 105 screws on exhaust side and the M10 x 73.5 on opposite side. Torque screws in a criss-cross sequence for each cylinder to 20 Nm (15 lbfft). Repeat the procedure, retightening all cylinder screws to 40 Nm (30 lbfft).
2 3 3 2
Apply Loctite 518 in cylinder sleeve O-ring groove. Install cylinder head.
F01D7FA
4 9 7 3 1 5 11
All Engines
F01D46A
TORQUING SEQUENCE
Finalizing Assembly
Reconnect electric wires/cables. To properly reinstall tuned pipe and exhaust manifold, refer to ENGINE 04-08. To properly reinstall air intake silencer, refer to FUEL SYSTEM 06-03.
ADJUSTMENT
RAVE Valve
787 Engine Turn the red plastic knob no. 22 until it is fully tightened.
1
F01D5AA
1. O-ring
04-05-18
NOTE: When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposit and cylinder head must be leveled. 1. Remove both spark plugs and bring one piston to Top Dead Center using TDC gauge.
F00D0WA
This will ensure the correct preload on the return spring no. 23 in order to open and close the RAVE valve at the proper RPM.
All Engines NOTE: This procedure is required to determine gasket thickness if you do not know the gasket thickness that was installed, if a crank repair has involved replacement of connecting rods or if you are experiencing repetitive engine seizure. The combustion chamber volume is the region in the cylinder head above the piston at Top Dead Center. It is measured with the cylinder head installed on the engine.
2. Use a graduated burette (capacity 0-50 cc) and fill with an equal part (50/50) of gasoline and injection oil.
F00B0BA
F01D5VA
1. Combustion chamber
04-05-19
3. Open burette valve to fill its tip. Add liquid in burette until level reaches 0 cc. 4. Inject the burette content through the spark plug hole until liquid touches the top spark plug hole.
F00D0HA
NOTE: The liquid level in cylinder must not drop for a few seconds after filling. If so, there is a leak between piston and cylinder. The recorded volume would be false. 5. Let burette stand upward for about 10 minutes, until liquid level is stabilized. 6. Read the burette scale to obtain the quantity of liquid injected in the combustion chamber. Compare the obtained value with the table below. The volume should be in the allowable range. If the volume is not as per specification, change cylinder base gasket thickness as follows. A higher volume dictates a thinner gasket. A lower volume dictates a thicker gasket. NOTE: When the combustion chamber is filled to top of spark plug hole, it includes an amount of 2.25 cc corresponding to the spark plug tip. The following table of combustion chamber volume includes this value.
ENGINE 717 787 COMBUSTION CHAMBER VOLUME 31.2 34.0 cc 34.7 37.9 cc
04-05-20
BOTTOM END
717 Engine
Loctite 515 12
19 1
Anti-seize lubricant 7 2 2 18
18
4 Primer "N" and Loctite 515 Loctite 242 5 3 5 3 Lithium grease 10 24 Nm (17 lbfft) Loctite 515 Synthetic grease 12 9 24 Nm (17 lbfft) Loctite 515 Loctite 515 8 Loctite 515 40 Nm (30 lbfft)
F04D1HS
PARTS
FLAT RATE
04-06-1
787 Engine
30 ml (1 oz) SAE 30 motor oil
19 1 13 2
Loctite 515
16 17
14 7 2 5 18 13
6 Anti-seize lubricant Anti-seize lubricant 15 Lithium grease Loctite 515 Anti-seize lubricant Loctite 515 40 Nm (30 lbfft) 8 9 12 Loctite 515 Loctite 515 40 Nm (30 lbfft) Synthetic grease Loctite 515 24 Nm (17 lbfft) Synthetic grease
Anti-seize lubricant
Loctite 242 5
3 Anti-seize lubricant
Synthetic grease
NOTE: Some numbers are missing. They are used on the previous illustration.
04-06-2
PARTS
FLAT RATE
DISASSEMBLY
Engine has to be removed from boat to open bottom end.
1
F00D0ZA
NOTE: When splines of PTO flywheel are worn out and special tool can not be used, proceed with the following alternate method. Use a pipe wrench and install it on PTO flywheel as illustrated.
F01J0TA
F00D10A
F01D1AA
787 Engine Only PTO flywheel can be loosen using either PTO flywheel remover as explained above or the one described below (P/N 295 000 156).
Using a suitable wrench or socket with a breaker bar, unscrew PTO flywheel COUNTERCLOCKWISE when facing it and hold extension handle locking the magneto flywheel.
04-06-3
ignition housing
F00B04A F01D4JA
rotary valve cover and valve crankcase retaining screws Put engine on a trestle. Loosen crankcase screws. Put engine back on a support. Insert a pry bar between crankcase lugs to separate halves.
CAUTION
F06I02A
Install the extension handle (P/N 295 000 125) on the PTO flywheel remover. Loosen PTO flywheel COUNTERCLOCKWISE when facing it.
All Engines
Crankshaft Seal(s)
If a crankshaft end seal has to be replaced, bottom end must be opened (except for the MAG side seal on the 787 engine, which is mounted on the magneto housing).
F01D1KA
Crankcase
Remove the following parts: engine support (717 engine) magneto flywheel, refer to MAGNETO SYSTEM 04-04 starter
04-06-4
8
1
F01D1LA
7
F01B09A
717 ENGINE 1. Puller (P/N 290 876 298) 2. Protective cap (P/N 290 876 557) 3. Distance ring, MAG side only (P/N 290 876 569) 4. Ring (both side) (P/N 290 977 490) 5. AG side ring halves (P/N 290 276 025) 6. PTO side ring halves (P/N 290 977 475) 7. Screw M8 x 40 (P/N 290 840 681) 8. Screw M8 x 70 (P/N 290 841 201)
787 Engine To remove end bearings from crankshaft, use the following tools. NOTE: The outer PTO bearing and crankshaft gear can be removed in one step using another puller. See Crankshaft Gear no. 17.
1 2 3 4 5
7
F06D1GA
F01B2MA
To remove end bearings from crankshaft, use the following tools. Use grease to hold protective cap on crankshaft end.
787 ENGINE 1. Puller (P/N 290 876 298) 2. Protective cap (P/N 290 876 557) 3. Distance ring (P/N 290 876 569) 4. Ring (P/N 290 977 490) 5. Ring halves (P/N 290 977 475) 6. Screw M8 x 40 (P/N 290 840 681) 7. Screw M8 x 70 (P/N 290 841 201)
717 Engine NOTE: To facilitate ring or distance ring installation lubricate their inside diameters.
NOTE: To facilitate ring or distance ring installation lubricate their inside diameters.
04-06-5
All Engines
F04B03A
Or, use a bearing extractor such as Proto no. 4332 and a press to remove 2 bearings at a time (except on PTO side for the 787 engine).
F00D0IA
787 Engine
F00D0JA
04-06-6
NOTE: If the inner PTO bearing needs to be replaced, remove the Woodruff key on the crankshaft.
F00D0SA
1. Index mark
5
F00B0CA
Use a press to remove the gear no. 16 from the counterbalance shaft.
1. 2. 3. 4. 5.
Puller (P/N 290 876 298) Protective cap (P/N 290 876 557) Ring (P/N 290 977 480) Ring halves (P/N 290 876 330) Screw M8 x 40 (P/N 290 840 681)
F00D0TA
F00D0KA
1. Tool installed
CLEANING
All Engines Discard all oil seals, gaskets, O-rings and sealing rings. Clean water and oil passages and make sure they are not clogged. Clean all metal components in a solvent.
To remove gear no. 16, first trace an index mark on the gear and counterbalance shaft. NOTE: There is no Woodruff key to position the gear on the counterbalance shaft. An index mark must be traced to ease assembly procedure.
04-06-7
Remove old Loctite from crankcase mating surfaces with stripper (P/N 295 500 110).
CAUTION
Be careful not to spray cleaner on the painted surface of the engine. Never use a sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing.
INSPECTION
Assembled Engine
The following verifications can be performed with the crankshaft installed in the engine. Crankshaft Alignment at Center Main Journal Since it is an assembled crankshaft it can become misaligned or deflected. Crankshaft can be twisted on center main journal, changing timing of one cylinder in relation with the other.
1
F01D1NB
Crankshaft Alignment at Center Main Journal NOTE: The following checks can be performed with engine in boat without overhauling engine. To quickly check, without accuracy, if crankshaft is twisted on center main journal, proceed as follows: Remove PTO flywheel guard. Remove spark plugs. Insert a screwdriver in one spark plug hole. Insert a longer screwdriver in the other hole. Lay a forearm over both screwdriver handles to feel piston displacements. With the other hand, slowly rotate engine by PTO flywheel.
1
1
F01D1NA
Counterweights can also be twisted on connecting rod journal on any or both cylinder(s).
F01D1IA
1. Lay 1 hand over screwdrivers to feel movement 2. Screwdrivers in spark plug holes
04-06-8
As soon as one piston starts going up, the other must immediately go down. Any interval between strokes indicates a misaligned crankshaft. Or, to accurately check crankshaft alignment, proceed as follows: Remove ignition housing cover. Remove MAG flywheel nut (and magneto rotor for the 787 engine). Refer to ENGINE 04-04 for procedures. Install Bombardier degree wheel (P/N 295 000 007) on crankshaft end. Hand-tighten nut only. Remove both spark plugs. Install a TDC gauge (P/N 295 000 065) in spark plug hole on MAG side. Bring MAG piston at Top Dead Center. As a needle pointer, secure a wire with a cover screw and a washer. Rotate degree wheel (NOT crankshaft) so that needle pointer reads 360.
Interval between cylinders must be exactly 180; therefore, needle pointer must indicate 180 on degree wheel (360 - 180 = 180). Any other reading indicates a misaligned crankshaft. Crankshaft Alignment at Connecting Rod Journal Such misalignment may cause a crankshaft hard to be manually turned. Verification can be done by measuring deflection each end of crankshaft. If deflection is found greater than specified tolerance, this indicates worn bearing(s), bent and/or disaligned crankshaft. Proceed with the disassembly of the engine.
Disassembled Engine
The following verifications can be performed with the engine component removed.
7, Crankcase
Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper.
2,3, Bearing
Inspect crankshaft bearings. Check for corrosion, scoring, pitting, chipping or other evidence of wear. Make sure plastic cage is not melted. Rotate and make sure they turn smoothly.
3 4
6, Crankshaft
NOTE: If crankshaft and/or components are found defective, they must be repaired by a specialized shop or replaced. The inspection of engine bottom end should include the following measurements: Connecting Rod Straightness Align a steel ruler on edge of small end connecting rod bore. Check if ruler is perfectly aligned with edge of big end.
F01D4IA
TYPICAL 1. TDC gauge 2. Degree wheel 3. Hand tighten nut 4. Needle pointer
Remove TDC gauge and install on PTO side. Bring PTO piston at Top Dead Center.
04-06-9
F01D1QA
F01D1TA
1. Ruler must be aligned with edge of connecting rod here 2. Align ruler here
Crankshaft Deflection NOTE: Crankshaft deflection cannot be correctly measured between centers of a lathe.
TOLERANCES MEASUREMENT Connecting rod big end axial play NEW PARTS (min.) 0.39 mm (.015 in) (max.) .74 mm (.029 in) WEAR LIMIT 1.2 mm (.047 in)
Remove crankshaft bearings and check deflection again on V-shaped blocks as illustrated.
Crankshaft deflection is measured at each end with a dial indicator. First, check deflection with crankshaft in crankcase. If deflection exceeds the specified tolerance, it can be either ball bearings wear or bent/twisted crankshaft at connecting rod journal.
1
F01D1UA
F01D1VA
F01D1SA
If the deflection exceeds the specified tolerance, crankshaft should be repaired or replaced.
04-06-10
Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight.
TOLERANCES MEASUREMENT Crankshaft deflection center MAG side PTO side NEW PARTS (min.) N.A. N.A. N.A. (max.) N.A. N.A. N.A. WEAR LIMIT 0.08 mm (.0031 in) 0.05 mm (.002 in) 0.03 mm (.001 in)
Install bearing carefully on crankshaft. To properly position the outer PTO bearing on 717 engine or the outer MAG side bearing on the 787 engine, a distance gauge must be temporarily installed against the inner bearing. Slide the outer bearing until stopped by the distance gauge, then remove it.
ENGINE 717 787 DISTANCE GAUGE P/N 529 034 800 (PTO) P/N 529 034 900 (MAG)
1
F01B0HA
1. Distance gauge
2
F01D1WA
ASSEMBLY
Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following.
F01D1YA
04-06-11
787 Engine
F00D0NA
All Engines
5, Drive Pin
F00D0LA
Make sure drive pins of bearings are properly installed in crankcase recesses at assembly.
1 1
2
F00D0MA
F00D0OA
1. Drive pin
787 Engine
1,4, Seal
At seal assembly, apply a light coat of lithium grease on seal lips.
787 Engine Position PTO seal no. 1 against the retaining shim; the gap between the seal and bearing will ensure proper lubrication of the bearing.
CAUTION
Counterbalance shaft must be properly assembled, otherwise engine will vibrate and premature wear will occur.
04-06-12
Proceed as follows to check if the gear no. 16 is properly positioned on the counterbalance shaft: Temporarily install the counterbalance shaft in the crankcase. Rotate the counterbalance shaft to align the notch of the gear with the crankcase.
Install crankshaft first in crankcase. After crankshaft installation, install counterbalance shaft. Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears.
CAUTION
Marks on the crankshaft and counterbalance shaft must be aligned, otherwise engine will vibrate and premature wear will occur.
F00D0UA
The notch of the couterweight on the opposite end of the counterbalance shaft must also be aligned with the cranckcase.
1
F00D0PA
Turn by hand the crankshaft and counterbalance shaft. Make sure they do not interfere with the crankcase.
F00D0VA
7, Crankcase
Crankcase halves are factory matched and therefore, are not interchangeable or available as single halves. Prior to joining crankcase halves, apply a light coat of Loctite 515 on mating surfaces. Do not apply in excess as it will spread out inside crankcase.
If notches are not aligned with the crankcase, remove the gear and repeat the procedure until the notches are properly aligned.
04-06-13
NOTE: On aluminum material it is recommended to use Loctite Primer N to reduce curing time and increase gap filling capability. Refer to manufacturers instructions.
717 Engines
8,9, Screw
Apply Loctite 515 on screw threads and synthetic grease below head screws.
CAUTION
Rotary valve shaft must be installed in crankcase before closing halves. Before joining crankcase halves, make sure that crankshaft gear is well-engaged with rotary valve shaft gear. Position crankcase halves together and handtighten bolts.
11 7 1 3
9 5 13
CAUTION
8 12
F01D20A
Temporarily install armature plate to align crankcase halves with each other (except 787 engine).
2 10
6 14
12, Fitting
All Engines If inlet and outlet oil fittings of rotary valve shaft have been removed from crankcase, reinstall them with their ends pointing toward ignition housing. Apply Loctite 515 on threads of fittings. 787 Engine
F01D20B
787 Engine
1
F00D0QA
04-06-14
11
21
22
12
8 13
2 14
10
F01D84A
19
F01D81A
17
15
16
18
20
1. O-ring
As a final step, torque only M10 screws no. 9 of crankcase to 40 Nm (30 lbfft) as per following sequence.
11 7 1 3 5 9
All Engines Apply Loctite anti-seize lubricant (P/N 293 800 023) to crankshaft threads. Using the same tools as for disassembly procedure, torque PTO flywheel to 110 Nm (81 lbfft).
Final Assembly
12 8 4 2 6 10
717 Engine If engine support is installed on crankcase before ignition housing, electric starter must be installed before engine support.
1
F01D81B
04-06-15
ROTARY VALVE
9 5 6 10 14 15 8 11 3 13 1 12 Lithium grease 4 7
1 12 2 20 Nm (15 lbfft)
787 Engine
717 Engine
2 20 Nm (15 lbfft)
F01D7SS
PARTS
FLAT RATE
04-07-1
GENERAL
The following verification procedures such as clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without removing engine from boat. Refer to INSPECTION further in this section. However, engine must be removed from boat to work on rotary valve shaft/components. Refer to REMOVAL AND INSTALLATION 04-03 for procedures. Bottom end must be opened to remove rotary valve shaft. Refer to ENGINE 03-07.
1
INSPECTION ON BOAT
Remove carburetors. Refer to FUEL SYSTEM 0604.
F01D53A
1. 45 feeler gauge
If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface or replace the cover. SOLDER METHOD Remove O-ring from rotary valve cover. Use the following type of solder: rosin core diameter: 0.8 mm (.032 in) electronic application (available at electronic stores) Install two solder pieces of 13 mm (1/2 in) long directly on rotary valve, one above and one below rotary valve gear. Apply grease to hold solder in position. Reinstall cover in place WITHOUT its O-ring and torque screws to 20 Nm (15 lbfft). Remove cover then clean and measure compressed solder thickness, it must be within the specified tolerance 0.30 0.05 mm (.012 .002 in).
04-07-2
1
F01D3PA
TYPICAL 1. Solder
If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface or replace the cover. MACHINING INFORMATION The amount of material over tolerance must be removed from the rotary valve cover seating surface. Also cut the O-ring groove the same amount to keep the 1.0 0.03 mm (.039 .001 in) depth between the bottom of the groove and the seating surface. Remove burrs on the edges of the seating surface and O-ring groove.
F01D3OA
SAME AMOUNT REMOVED FROM COVER SEATING SURFACE AND O-RING GROOVE BASE 1. Cover seating surface 2. O-ring groove depth must be 1.0 0.03 mm (.039 .001 in)
Reverify the clearance. At assembly the rotary valve timing must remain as per original setting. NOTE: If rotary valve crankcase surface is worn, it is possible to have it reworked at the factory. Contact your dealer or distributor.
04-07-3
DISASSEMBLY
1,2, Rotary Valve Cover and Screw
Unscrew 4 retaining screws and withdraw rotary valve cover and valve. NOTE: It is necessary to withdraw carburetors prior to removing rotary valve cover. Refer to FUEL SYSTEM 06-04 then refer to Carburetor Removal.
Place puller over rotary valve shaft end and screw on puller bolt into shaft. While retaining bolt with a wrench, turn puller nut CLOCKWISE until shaft comes out.
F01D61A
F01D22A
CAUTION
F01D27A
Bottom end must be opened to remove rotary valve shaft. To remove rotary valve shaft, use puller (P/N 290 876 488).
1
TYPICAL
F01D23C
04-07-4
9, Bearing
1
CAUTION
F01D25A
End bearing can be easily removed using the following suggested tool. Snap-on hammer puller including: Handle CJ93-1, hammer CJ125-6 or claws CJ93-4.
1
F01J0ZA F01D4NA
CAUTION
Ensure that rotary valve shaft is perfectly perpendicular with press tip or damage will occur.
Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing. Slide puller sleeve outwards and tap puller end. Retighten claws as necessary to always maintain them tight against bearing. Continue this way until bearing completely comes out.
04-07-5
F01D28A
1. End bearing
CLEANING
Discard all seals and O-rings. Clean all metal components in a solvent. Clean oil passages and make sure they are not clogged. Clean rotary valve shaft and inside of distance sleeve no. 14.
1
F01D2CA
INSPECTION
1, Rotary Valve Cover
Inspect rotary valve cover for warpage. Small deformation can be corrected by surfacing with fine sand paper on a surface plate. Surface part against oiled sand paper.
Deflection must not exceed 0.08 mm (.003 in). Replace shaft as necessary.
ASSEMBLY
Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following.
8,9, Bearing
Inspect bearings. Check for scoring, pitting, chipping or other evidence of wear. Make sure plastic cage (on bigger bearing) is not melted. Rotate them and make sure they turn smoothly.
8,9, Bearing
To install end bearing in crankcase, use the appropriate pusher according to the engine.
ENGINE 717 787 PUSHER P/N 290 876 500 P/N 290 876 501
Gear
Visually check gear wear pattern. It should be even on tooth length all around. Otherwise it could indicate a bent shaft, check deflection. Replace gear if damaged. Check for presence of brass filings in gear housing.
04-07-6
1 1
A00B2JA
F01D33A
1
F00B07A
1
1
F01D2DA
04-07-7
Install shim no. 15, snap ring no. 7, and slide distance sleeve no. 14 on shaft.
1 2 3 4
F01D2FA
6
F01D34A
1. 2. 3. 4. 5. 6.
Seal Ball bearing Snap ring Distance sleeve Shim 0.5 mm (.020 in) Rotary valve shaft
787 Engine To install rotary valve shaft in crankcase, use a pusher (P/N 290 876 609) and handle (P/N 290 877 650).
CAUTION
2 1
Crankcase halves must be separated and crankshaft must not be present to install rotary valve shaft assy in crankcase.
717 Engine To install rotary valve shaft in crankcase, use a pusher (P/N 290 876 605).
1
F01B2FA
1. Pusher 2. Handle
A00C0YA
1. Pusher
04-07-8
All Engines
4, Snap Ring
Position snap ring so that its sharp edge faces outwards.
717/787
There is no identification code on the valves. To find out the duration, place an angle finder on the valve and measure the valve cut-out angle or use the following template.
A
F01D73T
04-07-9
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.
33
50
60
0
32
31
40
30
30 33
40
32
50
31
60
30
70
300
70
290
80
290
110 100 90
80
280
260
270
250
130
120
250
120
24
F01D2IA
24
14
0
2
13
For the following instructions, use these specifications as example: OPENING: 147 BTDC CLOSING: 65 ATDC Proceed as follows: Turning crankshaft, bring MAG side piston to Top Dead Center using a TDC gauge.
04-07-10
40
30
15
22
23
For opening mark, first align 360 line of degree wheel with BOTTOM of MAG side inlet port. Then, find 147 line on degree wheel and mark crankcase at this point.
2 147
1
F01D3DC
OPENING MARK Step 1 : Bottom of MAG inlet port. Align 360 line of degree wheel Step 2 : Find 147 on degree wheel and mark here
For closing mark, first align 360 line of degree wheel with TOP of MAG side inlet port. Then, find 65 line on degree wheel and mark crankcase at this point.
1
65
F01D3EB
CLOSING MARK Step 1 : Top of MAG inlet port Align 360 line of degree wheel Step 2 : Find 65 on degree wheel and mark here
Remove degree wheel. Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC. NOTE: Rotary valve is asymmetrical. Therefore, try flipping it over, then reinstall on splines to obtain best installation position. Apply BOMBARDIER-ROTAX injection oil on rotary valve before reassembling rotary valve cover. Remove TDC gauge.
04-07-11
EXHAUST SYSTEM
Sportster and Starboard Side of Challenger
25 Nm (18 lbfft) 8 25 Nm (18 lbfft) 7 Loctite 242 9 20 17 25 Nm (18 lbfft) 14 15 9
Loctite 242
30 19 18 4 Nm (35 lbfin) 1 3
4 Nm (35 lbfin)
31
4 Nm (35 lbfin)
7 Nm (62 lbfin) 22
F04D1AS
PARTS
FLAT RATE
04-08-1
4 Nm (35 lbfin)
27
28
30
31
4 Nm (35 lbfin)
4 Nm (35 lbfin)
F04D1BS
04-08-2
PARTS
FLAT RATE
4 Nm (35 lbfin) 1
4 Nm (35 lbfin)
3 25 13 Sealant 732
26 30 Nm (22 lbfft)
F10D01S
PARTS
FLAT RATE
04-08-3
4 Nm (35 lbfin) 1
Sealant 732
4 Nm (35 lbfin)
25 30 Nm (22 lbfft) 26
13
F10D02S
04-08-4
PARTS
FLAT RATE
12
Loctite 648
25
Sealant 732 13
F10D03S
PARTS
FLAT RATE
04-08-5
Challenger 1800 Disconnect water supply hose and water injection hose at tuned pipe head.
F01D8NA
TYPICAL 1. Bleed hose removed 2. Injection hose removed 3. Inlet hose removed
Cut tie rap retaining together engine and tuned pipe bleed hoses (if applicable).
F01D3YA
1, Collar
Loosen exhaust hose collar at tuned pipe outlet.
3, Hose
Remove exhaust hose from tuned pipe by pulling muffler.
Loosen exhaust hose collar no. 1 at tuned pipe cone outlet. Remove clamp no. 4 securing tuned pipe cone to tuned pipe head. Remove screws no. 7 and nut no. 8 with flat washers no. 9 at tuned pipe head flange.
22, Clamp
Remove clamp from tuned pipe.
6, Screw
Remove tuned pipe retaining screw from exhaust manifold side.
F01D7IA
04-08-6
All Models
Muffler
All Models Disconnect hoses from muffler no. 13. Disconnect retaining strap(s) no. 2 from muffler.
1
1. Screw
Remove tuned pipe head no. 10. Remove both screws no. 6 retaining tuned pipe cone to engine.
F01D7KA
F04D1CA
Sportster and Challenger While lifting T-tube no. 30, pull muffler no. 13 out of bilge.
F01D7LA
Sportster 1800 Pull muffler out of bilge. Challenger 1800 While lifting resonnator no. 29, pull muffler no. 13 out of bilge.
04-08-7
Resonnator
Challenger 1800 NOTE: Resonnator can be removed without removing muffler. From outside of bilge, pull rubber lip to expose clamp and loosen clamp.
2
Disconnect resonnator tube no. 28 from expansion chamber no. 27. From inside of bilge, carefully pull expansion chamber out.
2
F04D15A
1
F04D1DA
Expansion Chamber
Sportster NOTE: Expansion chamber can be removed without removing muffler. From outside of bilge, pull rubber lip to expose clamp and loosen clamp.
2
Challenger NOTE: Expansion chamber can be removed without removing muffler. Loosen clamp of exhaust outlet as for Sportster model.
Port Side Remove battery to allow removal of expansion chamber. Refer to STARTING SYSTEM 08-08 for proper procedure. Pull resonnator tube of starboard side engine to make room then disconnect resonnator tube of port side engine as explained above for Sportster model. Starboard Side Follow the same procedure as above for Sportster model.
F04D15A
Exhaust Outlet
Sportster 1800 and Challenger 1800 To unscrew/screw the nut no. 26 of exhaust outlet no. 25, use the exhaust outlet tool (P/N 295 000 132).
F04D1FA
F01B2AA
Sportster and Challenger If nobody can help to hold nuts from inside of bilge, proceed as follows. Insert a closed wrench from the outside opening of exhaust outlet to the inside of bilge. Position wrench over a nut. While holding wrench, use a ratchet and socket from the outside. Loosen nut.
1
Repeat for each nut being careful not to drop nut inside bilge.
Procedure
Sand the cracked area to obtain bare metal. Perform a 1.50 mm (1/16 in) depth chamfer over crack. Use pure argon gas with 5.55 mm (3/32 in) tungsten electrode (puretung green, zirtung brown) and AC current. Use a 5.55 mm (3/32 in) aluminum welding rod (no. 4043), to fill crack. Sand welding slightly to remove material surplus.
F04D1EA
INSIDE VIEW TO SHOW POSITION OF WRENCH INSERTED FROM THE OUTSIDE 1. Closed wrench holding nut
04-08-9
Test
Use compressed air at 124 kPa (18 PSI) to pressurize tuned pipe. NOTE: Prior to verifying leaks, plug all holes and pressurize tuned pipe while immerging it in water.
787 Engine Apply Loctite 515 on two screws no. 14. On the other screws no. 14, apply synthetic grease on threads. Install screws. Refer to the following illustration for proper position of screws on the exhaust manifold.
1 2 1 2
CAUTION
Always ensure water passages are not blocked partially or completely while welding tuned pipe.
INSTALLATION
Installation is essentially the reverse of removal procedures. However, pay particular attention to the following.
717 Engine Apply synthetic grease on threads of screws no. 14. Install and torque screws no. 14 to 24 Nm (17 lbfft) as per following illustrated sequence.
F01D82B
Torque exhaust manifold screws to 24 Nm (17 lbfft) as per following illustrated sequence. Repeat the procedure, retightening screws to 40 Nm (30 lbfft).
1 7 6 4
3 2 5 8
5
F01D82A F01D59A
04-08-10
717 Engine Install tuned pipe cone no. 5 with collar no. 26 and clamp no. 22. Position clamp no. 22 as illustrated. Do not tighten clamp yet.
F01D69A F01D41A
Apply a thin layer of heat resistant sealant (P/N 413 709 200) all around sealing ring.
All Models Ensure rubber bushings no. 19 and sleeve no. 18 are not damaged and are properly installed into tuned pipe support.
With hose removed, align cone outlet with muffler inlet. NOTE: Due to exhaust cone angle, it may have to be rotated to obtain alignment. Push cone no. 4 until it touches tuned pipe, then tighten exhaust clamp no. 18 and torque to 10 Nm (88 lbfin).
CAUTION
Damage to bushings and/or sleeve will eventually cause stress to tuned pipe and may cause cracking. Make sure that gasket no. 20 is properly located on exhaust manifold prior to finalizing pipe installation.
CAUTION
There must be no gap between tuned pipe cone and tuned pipe head. NOTE: Exhaust clamp nuts should be tightened alternately to ensure no leakage and to obtain specified torque.
04-08-11
F04D1GA
04-08-12
TABLE OF CONTENTS
COMPONENTS ...................................................................................................................... GENERAL ........................................................................................................................... CIRCUIT.................................................................................................................................. GENERAL ........................................................................................................................... COOLING SYSTEM ARRANGEMENT ..............................................................................
0
05-02-1 05-02-3 05-03-1 05-03-1 05-03-2
05-01-1
COMPONENTS
Sportster/1800 and Challenger
Loctite 592 1 3 2
Sportster
Loctite 592 1
Loctite 592
Sportster 1800
Challenger
Loctite 592
Loctite 592
Loctite 592
F04E0RS
PARTS
FLAT RATE
05-02-1
Challenger 1800
Loctite 592
Loctite 592
1 1 2
4 7 0.11 Nm (1 lbfin) 8
Loctite 592
6 5 Loctite 592
05-02-2
PARTS
FLAT RATE
GENERAL
CAUTION
The water injection also helps in reducing noise level and cools components of the exhaust system.
All hoses and fittings of the cooling system have calibrated inside diameters to ensure proper cooling of the engine. Always replace using appropriate Bombardier part number.
CAUTION
1, Clamp
To cut or secure non-reusable Oetiker clamps of cooling system hoses, use pliers (P/N 295 000 070).
The elbow fittings are calibrated for each engine model and cannot be interchanged with one of a different size as severe engine damage could result. The elbow fitting can be identified by using the 2 digits number stamped onto the fitting or by measuring its inside diameter. Refer to the following illustration and chart.
16
1
1
2
3
F00E04A
2
F01B2KA
FITTING P/N
INLET DIAMETER
OULET DIAMETER
2, Flushing Connector
The flushing connector is used to flush cooling system. Refer to MAINTENANCE 02-02.
16 48 293 700 016 293 710 048
3, Elbow Fitting
Water injection used on exhaust system cools the exhaust gases to obtain maximum performance from the tuned pipe. The elbow fitting has a calibrated inside diameter to optimize water flow.
05-02-3
3
F01E2BA
LOW SPEED OPERATION 1. Water entering regulator valve 2. Water exiting regulator valve 3. Water injected in the muffler
F01E1FA
TYPICAL 1. Water supply hose of regulator valve 2. Regulated water to injection fitting at tuned pipe head 3. Water injected into the muffler
NOTE: The water injected into the muffler is not regulated by the valve. A calibrated water injection fitting of 3.0 mm (.118 in) inside diameter limits water flow into the muffler. The water flow regulator valve has a calibrated spring and a tapered needle which regulate the injected water in the tuned pipe.
CAUTION
F01E1HA
Do not change the calibration of the spring, otherwise serious engine damage can occur. At low speed, water pressure in the supply hose of the regulator valve is not sufficient to overcome the spring of the regulator valve; more water is being delivered to the injection fitting at the tuned pipe.
At higher speed, water pressure increases in the supply hose of the regulator valve and gradually overcomes the return spring of the regulator valve. Less water is being delivered to the injection fitting at the tuned pipe.
05-02-4
Disassembly
Firmly hold cover to valve base. The spring inside the valve is applying a pressure against the cover.
WARNING
3
F01E2CA
HIGH SPEED OPERATION 1. Water entering regulator valve 2. Water exiting regulator valve 3. Water injected in the muffler
F01E1RA
1. Spring 2. Cover
5, Fitting
1
F01E1IA
Adjustment The water flow regulator valve has been calibrated at the factory and should not be modified. NOTE: Water flow regulator valves ordered from the parts channel are also calibrated. If the maximum engine speed cannot be attained or if the engine has poor performance, the water flow regulator valve should be considered in the troubleshooting of the problem.
F01E1SA
1. Fitting
05-02-5
6, Tapered Needle
Unscrew the tapered needle. NOTE: Hold the valve to prevent it from turning.
F01E21A
1. Tapered needle
F01E24A
1. Clamp
Inspection Inspect parts for damage. Verify especially bellows for cracks.
F01E20A
05-02-6
CIRCUIT
GENERAL
TECHNICAL DATA TYPE: TLCS (Total Loss Cooling System). COOLANT FLOW: Pressure build-up at impeller housing (no water pump). TEMPERATURE CONTROL: Calibrated outlet fittings (no thermostat). SYSTEM BLEEDING: Self-bleed type (hose at uppermost point of circuit and at tuned pipe). SYSTEM DRAINING: Self-drain type (hose at lowest point of circuit). SYSTEM FLUSHING: Flushing connector on boat transom and in engine compartment area. MONITORING BEEPER: Turns on at 96-99C (205-210F).
F01B23A
The cooling system is equipped with flushing connectors for flushing purposes. For flushing operation, a garden hose is to be connected to flush the whole system by backwash. For flushing procedure, refer to MAINTENANCE 02-03. For winterization of cooling system, refer to MAINTENANCE 02-05.
NOTE: If for some reason, you operate a twinengine model over 24 km/h (15 MPH) with only one engine running, the non-running engine should have its water supply hose plugged. This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system. Without the engine running there isnt any exhaust pressure to carry the water out the exhaust outlet.
CAUTION
Failure to do this may result in damage to the engine. If you must tow a stranded boat and do not have a hose pincher be sure to stay well below the maximum towing speed of 24 km/h (15 MPH). Snugly install the hose pincher on the hose as shown in the following illustration.
1
F04J0YB
CAUTION
When finished towing the boat you must remove the hose pincher before operating it. Failure to do so will result in damage to the engine.
F01D7HB
1. Water passages
No water enters crankcase. When engine is running, water must flow from bleed outlet indicating that water circulates.
CAUTION
When investigating for no water flow in the cooling system, check all elbows and straight fittings as well as all hoses for blockage. For a minimum of back pressure in the exhaust, engine water outlet hose is not connected to the exhaust. It has its own fitting at the transom (the same used for flushing the cooling system).
F01E1LA
1. Cylinder head cover 2. Fresh water from jet pump 3. Water exiting head assembly to tuned pipe, exhaust manifold and cylinders 4. Water from cylinder water jackets exiting engine
Sportster Model
The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation. Water is pre-heated by the exhaust system before entering the cylinder cooling jackets. Water enters cylinder cooling jacket through passages located below exhaust ports from tuned pipe.
F04L8SB
05-03-2
Challenger Model
717 Engine Draining of the system is accomplished by a fitting to the bottom of exhaust manifold. Refer to illustration below.
F04L8RA
787 engine Draining of the system is accomplished by a fitting at the bottom of each cylinder. Fittings are linked to a common line. The line is connected to the exhaust outlet at the stern of the craft.
F10L06A
F01E1MA
For a complete view of cooling system arrangement, refer to the next pages for each engine model.
1 2
F04L5LA
CAUTION
Never modify cooling system arrangement, otherwise serious engine damage could occur.
05-03-3
Water injected directly into exhaust gases for noise reduction and performance improvement
Tuned pipe bleed hose injects water into muffler to cool exhaust components Lowest point of circuit allows Calibrated outlet draining whenever fitting limits engine is stopped water flow
Pressure zone Cooling System Indicator (CSI): Small stream of water flows out of bleed outlet located behind stern ring
F04E0HT
TYPICAL
05-03-4
Water regulated by the valve is injected directly into exhaust gases for noise reduction and performance improvement Pressure zone
Water flow regulator valve: At low speed, water is injected in tuned pipe Injects water directly (not regulated by the valve) into resonator through a calibrated hole. This cool exhaust components At higher speed, no water is injected in tuned pipe Calibrated outlet fitting limits water flow
F04E0IS
TYPICAL
05-03-5
TABLE OF CONTENTS
FUEL CIRCUIT........................................................................................................................ GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... FUEL SYSTEM PRESSURIZATION ................................................................................... AIR INTAKE............................................................................................................................ REMOVAL........................................................................................................................... ASSEMBLY.........................................................................................................................
0
06-02-1 06-02-5 06-02-6 06-02-7 06-02-8 06-02-8 06-03-1 06-03-2 06-03-2
CARBURETORS ..................................................................................................................... 06-04-1 GENERAL ........................................................................................................................... 06-04-4 REMOVAL........................................................................................................................... 06-04-4 CLEANING ......................................................................................................................... 06-04-5 DISASSEMBLY AND INSPECTION ................................................................................... 06-04-5 ASSEMBLY......................................................................................................................... 06-04-7 CARBURETOR INSTALLATION......................................................................................... 06-04-10 THROTTLE CABLE ADJUSTMENTS ................................................................................ 06-04-11 CARBURETOR ADJUSTMENTS ....................................................................................... 06-04-16
06-01-1
FUEL CIRCUIT
Sportster
To engine
VEN RET Use wires as reference point RES RET RES Loctite 242 ON ON
VEN
ON 7
RES
6 3
F04F0RS
TYPICAL
PARTS
FLAT RATE
06-02-1
Challenger
Left engine
Right engine
To left engine
To right engine
RET
RE
ON
Loctite 242
VEN
VEN
ON 7
Loctite 242 ON 5
RES OUT 1 2
F04F1BS
TYPICAL
06-02-2
PARTS
FLAT RATE
Sportster 1800
Left engine
Right engine
RET
ON RE
To left engine
VEN
5 To right engine
1 2
F10F01S
TYPICAL
PARTS
FLAT RATE
06-02-3
Challenger 1800
Left engine
Right engine
RET
ON RE
To left engine
VEN
5 To right engine
1 2
F10F02S
TYPICAL
06-02-4
PARTS
FLAT RATE
GENERAL
Whenever repairing the fuel system, always verify for water infiltration in reservoir. When replacing fuel lines on SEA-DOO JET BOATS be sure to use A1 hoses as available from the BOMBARDIER parts department. This will ensure continued proper and safe operation.
WARNING
Use of improper fuel lines could compromise fuel system integrity. To open or secure reusable clamps on fuel lines, use pliers (P/N 295 000 054). To open clamp, place flat side of plier on clamp embossment, squeeze and twist plier.
WARNING
F01B1UA
WARNING
Replace any damaged, leaking or deteriorated fuel lines. To secure or cut Oetiker clamps on fuel lines, use pliers (P/N 295 000 070).
1
F01B1VA
F01B03A
To secure clamp, place notch side of plier on clamp embossment and squeeze plier.
1. Cutting clamp
F01B04A
1. Securing clamp
06-02-5
F01B05A
1
F01F04A
REMOVAL
Fuel Filter and Bowl
Turn the fuel valve to OFF position (if so equipped).
TYPICAL
3, Baffle Pick Up
NOTE: The baffle pick up has an integrated fuel sensor.
1
WARNING
The engine must not be running and fuel valve must be set to OFF position. Fuel is flammable and explosive under certain conditions. Always work in a well-ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Unscrew the fuel filter bowl counterclockwise then pull toward the bottom.
3
F01F20A
WARNING
F01F01A
TYPICAL
Always disconnect battery cables exactly in the specified order, BLACK negative cable first. Electrolyte or fuel vapors can be present in the engine compartment and a spark might ignite them and possibly cause personal injuries.
06-02-6
Fuel Tank
WARNING
Fuel is inflammable and explosive under certain conditions. Always work in a wellventilated area. Do not smoke or allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the boat.
Some Models Only Remove ski post braces and fuel filter bracket. All Models Remove hoses from baffle pick up and disconnect fuel sensor wiring harness. Remove lower clamp from baffle pick up adapter and pull out baffle from fuel tank.
Remove the following parts to allow fuel tank removal: battery and its box rack (if applicable) jet pump(s) engine(s) MPEM (if applicable) fuel tank ground (some international models) fuel filler hose fuel vent line baffle pick up port side insulating foam (if applicable)
INSPECTION
Fuel Filter and Bowl
Check filter bowl for water contamination. Inspect fuel filter condition. Carefully use low pressure compressed air to clean fuel filter. Replace filter if permanently clogged or damaged.
Remove upper clamp from adapter and slide adapter from baffle.
1. Gasket in bowl
WARNING
06-02-7
3, Baffle Pick Up
Slide adapter onto baffle pick up until it stops on rib. Install clamp. Install baffle pick up into fuel tank and push it until it sits on fuel tank neck. Install clamp and torque both clamps to 3 Nm (27 lbfin).
6, Fuel Tank
Visually inspect the inside and outside of the fuel tank necks for crack(s). If crack(s) are existing, replace fuel tank. Check with your finger to feel the inside and outside surfaces of fuel tank. Flex fuel tank necks to ensure there are no hidden cracks.
4 2
WARNING
Whenever doing any type of repair on jet boat or if any components of the fuel system are disconnected, a pressure test must be done before starting engine and/or releasing jet boat to customer.
CAUTION
Ensure to verify fuel line ends for damage. Always cut damaged end before reinstallation.
Pressure Test
F07F06A
1. 2. 3. 4. 5. A.
Tank upper surface Inspect outside, above upper surface Normal molding seam Inspect inside, above upper surface Base of the neck Approximately 4 mm (5/32 in)
NOTE: A fuel tank is comprised of 3 components: the tank, the fuel pick up neck and the filler neck. The necks are injection molded and the tank is then blow molded over the necks. During the molding process, a small molding seam may appear on the inner side of the necks at approximately 4 mm (5/32 in) from the base of the neck. It is a normal situation to have a molding seam and it should not be confused with a crack.
ASSEMBLY
Assembly is essentially the reverse of disassembly procedures. However, pay particular attention to the following.
Proceed as follows: Fill up fuel tank. Ensure to firmly tighten fuel tank cap. Remove vent hose from boat body. Install an adapter on pump gauge tester to match vent hose (1/4 to 5/8 in). Connect pump gauge tester (P/N 295 500 352 from kit P/N 295 000 085) to vent hose. Turn fuel valve(s) to OFF and pressurize fuel system to 34 kPa (5 PSI). If no leaks are found, turn fuel valves to ON (one at a time on twinengine models) and pressurize once more. If pressure is not maintained locate leak and repair/replace component leaking. To ease leak search spray a solution of soapy water on components, bubbles will indicate leak location. Ensure the leak does not come from vent hose that could not be sealed completely.
06-02-8
NOTE: To minimize time of fuel system pressurization, the fuel tank should be quite full. The system must maintain a pressure of 34 kPa (5 PSI) during 10 minutes. Never pressurize over 34 kPa (5 PSI).
WARNING
If any leak is found, do not start the engine and wipe off any fuel leakage. Failure to correct a leak could lead to an explosion. Do not use electric powered tools on boat unless system has been verified for no leaks. Reconnect vent hose of fuel tank vent on body.
06-02-9
AIR INTAKE
1
11
9 10 Nm (88 lbfin)
Loctite 242
Loctite 518
F04F04T
PARTS
FLAT RATE
06-03-1
REMOVAL
1, Air Intake Silencer Cover
Unlock retaining slides no. 11 holding air intake silencer cover and remove cover.
F01F2OA
F00F03A
Remove screws no. 10 from flame arrester base then withdraw base.
ASSEMBLY
Assembly is essentially the reverse of removal procedures. However, pay particular attention to the following.
CAUTION
F00F02A
06-03-2
5, Flame Arrester
Inspect condition of flame arrester. Replace or clean as necessary.
WARNING
787 Engine Position the flame arrester with its embossment toward TOP.
F00F04A
9, Gasket
Inspect condition of gasket. Make sure to properly install gasket.
06-03-3
CARBURETORS
Sportster and Challenger
Loctite 242
13
Synthetic grease
F04F1CS
TYPICAL
PARTS
FLAT RATE
06-04-1
Sportster 1800
Loctite 242
13
Synthetic grease
F10F03S
TYPICAL
06-04-2
PARTS
FLAT RATE
Challenger 1800
Loctite 242
13
F10F04S
TYPICAL
PARTS
FLAT RATE
06-04-3
GENERAL
Some carburetor components and/or settings can be changed to improve boat performance in high altitude regions between 1500-3000 m (500010000 ft). Refer to the service department for the latest specifications.
The carburetor(s) is (are) equipped with a fuel accelerator pump. The fuel accelerator pump is linked to the throttle valve via a linkage. A metering jet in the fuel inlet hose controls fuel supply to the pump. A check valve on the fuel outlet hose prevents air from entering in the system.
CAUTION
Such modifications should only be performed by experienced mechanics since they can greatly affect boat performance and can cause severe damage to engine. Use only recommended settings. The following illustration shows which part of the carburetor begins to function at different throttle valve openings.
REMOVAL
To remove carburetors from engine, proceed as follows: Remove air intake silencer. Refer to FUEL SYSTEM 06-03. Turn fuel valve(s) to OFF position (if applicable). NOTE: For fuel line removal, use pliers (P/N 295 000 054). Disconnect pulse line(s) from fuel pump(s).
2 4 5 6
F00F05A
3
F01F13A
VIEW FROM AIR INTAKE OPENING 1. Throttle plate openings 2. Close 3. Wide open 4. Low-speed screw 5. Pilot jet 6. Main jet and high-speed screw
Disconnect fuel supply line(s) from fuel pump(s). Disconnect fuel return line(s). Disconnect oil injection pump cable(s), throttle cable(s) and choke cable(s). Remove screws and lock washers retaining carburetor(s).
06-04-4
1, Needle Valve
Inspect needle valve tip for a grooved condition. If worn, needle and seat must be replaced as a matched set.
TYPICAL 1. Screw
CLEANING
The entire carburetor should be cleaned with a general solvent and dried with compressed air before disassembly.
CAUTION
Be careful at carburetor cleaning not to remove paint. Paint removal will cause carburetor to rust very rapidly. Repaint if necessary. Carburetor body and jets should be cleaned in a carburetor cleaner following manufacturers instruction.
x x
WARNING
F04F0HA
Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as they are flammable and explosive.
WARNING
Heavy duty carburetor cleaner may be harmful to the rubber parts, O-ring, etc. Therefore, it is recommended to remove those parts prior to cleaning. Discard O-rings, diaphragms and gaskets.
TYPICAL 1. Pump gauge tester 2. Install on inlet nipple 3. Obstruct outlet nipple
Diaphragm must stand pressure for 10 seconds. If pressure drops, replace diaphragm. Verify accelerator pump check valves operation as follows:
06-04-5
Connect a clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with the mouth. The check valve should release with pressure and hold under vacuum.
12, Diaphragm
Fuel Pump Diaphragm Leak Test Using a suitable pump gauge tester, perform the following test proceeding as follows: Install pump gauge tester (P/N 295 000 083) on pulse nipple. Pump tester until it reaches 28 kPa (4 PSI).
1
WARNING
Some fuel may be present in fuel pump. Be careful not to swallow fuel when under vacuum.
F01F0XA
Diaphragm must stand pressure for 10 seconds. If pressure drops, replace diaphragm.
Pressure: 28 kPa (4 PSI) for 10 seconds
4, Pump Body
FUEL PUMP VERIFICATION
Some fuel may be present in fuel pump. Be careful not to swallow fuel when under vacuum.
WARNING
06-04-6
5, Filter
1
All Models To verify filter condition proceed as follows: Remove pump cover and gasket (diaphragm and then pump body and gasket on Sportster/Challenger). Remove filter from carburetor body then clean filter and blow carefully with compressed air (low pressure). Replace filter if damaged.
F01F0WA
Repeat the same procedure at the outlet nipple. This time the outlet valve should hold with pressure and release under vacuum. Inspect valves. The pumping area should be free of holes, tears or imperfections. Replace as needed.
F01F0YA
TYPICAL 1. Filter
ASSEMBLY
When assembling pump, ensure to properly position components together. Refer to previous illustrations if necessary.
WARNING
Wiping fuel spillage and ventilation of bilge is very important prior to starting engine. Take care that no fuel spills in engine compartment. Start engine and ensure the fuel pump is properly pumping gas into container. Otherwise, replace fuel pump.
CAUTION
Always apply Loctite 242 (blue) on screw threads prior to installing screws.
06-04-7
F01F34A
F01F0ZA
Pressure Test Proceed as follows: Install pump gauge tester on carburetor inlet nipple. Obstruct outlet nipple with a finger. Pump tester until inlet release pressure is reached (seen by a sudden pressure drop).
3 1
CAUTION
When adjusting lever, do not pry it. This will apply pressure on needle and damage valve seat/needle.
1 2
F01F10A
2
TYPICAL 1. Pump gauge tester 2. Install on inlet nipple 3. Obstruct outlet nipple
06-04-8
If release pressure is not within specification, check control lever adjustment. Replace spring as necessary.
2 1
CAUTION
Do not stretch or cut spring. Leak Test Needle valve must stand a pressure of 69 kPa (10 PSI) for 30 seconds. Otherwise, hold carburetor upside down, pour oil over needle valve and apply pressure. Check for bubbles. If they come from seat O-ring, bubbles will exit around seat. Retighten as necessary. If it still leaks remove needle and seat and replace O-ring. If bubbles come from needle, replace needle and seat.
3
F01F11A
CAUTION
Adjustments vary with temperature and altitude. Always observe spark plug condition for proper jetting.
CAUTION
F01F12A
Such modifications should only be performed by experienced mechanics since they can greatly affect boat performance and can cause severe damage to engine. Use only recommended settings. NOTE: To have access to pilot jet or main jet, check valve housing must be removed.
1. Check valve
06-04-9
14,15, O-ring
When installing O-rings of low-speed and highspeed screws, apply some BOMBARDIER LUBE (P/N 293 600 006) to prevent sticking.
CARBURETOR INSTALLATION
At installation, pay attention to the following: Install carburetor(s) with gasket(s) to intake manifold (rotary valve cover for the 787 engine). If applicable, synchronize carburetors before installation. Refer to Carburetor Synchronization. Apply Loctite 577 on screw threads. Then, install screws with lock washers and torque to 20 Nm (15 lbfft). This will prevent screws to jam to ease further removal.
Accelerator Pump
Lubricate pump plunger, roller and cam with synthetic grease (P/N 293 550 010) and roller shaft with BOMBARDIER LUBE.
CAUTION
Failure to apply Loctite 577 might lead you to damage carburetor to allow its removal if screws are jammed.
2
x
F04F0NB
WARNING
Make sure there is no leak in fuel system. For fuel system pressurization, refer to FUEL SYSTEM 06-02.
Carburetor Synchronization
Challenger 1800 With idle speed screw not touching throttle lever stopper on MAG carburetor, both throttle plates are in closed position.
1 2
F04F0OA
1
F01F1XA
Loosen jam nuts on carburetor linkage and adjust linkage with adjustment nut. Make sure threads length is the same on each side of linkage and flat surfaces of both ends are parallel with each other.
CAUTION
Throttle plates must open simultaneously, otherwise this will cause engine to vibrate and/or back-fire.
2 3
F01F1YA
CAUTION
Make sure engine is turned off before adjusting cable(s), except otherwise specified. As a preliminary adjustment, turn idle speed screw until it contacts throttle lever stopper. Then, turn 2 additional turns. The throttle cable adjustments imply the following steps which must be followed in this order. Full throttle adjustment for proper cable slack. Idle speed adjustment. Full throttle check for maximum RPM with proper cable slack. Throttle levers synchronization Accelerator pump adjustment. Injection oil pump cable adjustment. Low-speed steering control system cable adjustment. Final cable adjustment.
Tighten jam nuts and torque to 3 Nm (27 lbfin). NOTE: Grease carburetor linkage at both ends with synthetic grease (P/N 293 550 010). Connect linkage between both carburetor levers. Ensure both throttle plates are still in closed position. NOTE: The linkage installation is done with the marks located near PTO carburetor throttle lever to ease adjustment when performed in the boat.
1
F01F1ZD
CAUTION
Always perform cable adjustments in the specified order, as described in the following instructions.
2
Lubricate cable(s) with BOMBARDIER LUBE lubricant (P/N 293 600 016).
06-04-11
NOTE: Do not activate throttle lever(s) unnecessarily. Carburetor(s) is(are) equipped with fuel accelerator pump. This(these) pump(s) deliver(s) fuel to the engine(s) each time throttle lever(s) is(are) moved forward. Ensure throttle cable(s) has(ve) sufficient slack to allow 0.4 mm (1/64 in) gap between throttle lever and throttle stop, at carburetor.
If not, readjust cable threaded end at throttle/ shifter controller bracket location, then perform previous throttle cable tension validation.
CAUTION
Use a protective mat in throttle/shifter controller area when withdrawing it for adjustment.
F01G0YC
1
1 2
F04L0GB
F01F07A
TYPICAL 787 ENGINE SHOWN 1. Throttle lever stoppers (behind levers) 2. Adjustment nut
If throttle lever stop cannot be adjusted at throttle/ shifter controller, readjust throttle cable end on carburetor bracket. Repeat this procedure until gap is 0.4 mm (1/64 in). NOTE: When checking gap, ensure that throttle/ shifter controller is properly positioned into deck cutaway. If throttle lever stop cannot be adjusted with proper free play, replace cable with a new one.
CAUTION
06-04-12
Challenger 1800 There is only one idle speed screw for both carburetors. It is located on the MAG side carburetor. All Models Connect an induction-type tachometer (P/N 295 000 100) on spark plug cable of magneto side to measure engine speed. NOTE: To adjust idle speed, ensure flame arrester and air intake silencer are installed. Start engine and bring to normal operating temperature. Adjust idle speed to 3000 RPM (out of water) by using carburetor idle speed screws.
1
F01F1XA
CAUTION
Water must be supplied to cool engine with a garden hose at flushing connector.
Stop engine. If it is not possible to properly adjust idle speed, readjust throttle cable end on carburetor bracket. NOTE: Carburetor lever must rest on idle screw when control lever is at idle position. If carburetor lever does not rest on idle screw with control lever at idle position and when cable threaded end on carburetor bracket is at limit position, readjust cable threaded end on throttle/ shifter controller bracket. If idle speed cannot be properly adjusted. Replace cable with a new one.
Full Throttle Check for Maximum RPM with Proper Cable Slack
1
F01G0YD
Start engine. Set shifter control lever to forward or reverse position. Push throttle lever(s) forward momentarily to full position and check that engine revving is according to the following specifications:
ENGINE TYPE 717 787 RPM 7000 50 7200 50
Stop engine. Ensure again that throttle cable(s) has(ve) sufficient slack to allow 0.4 mm (1/64 in) gap between throttle lever and throttle stop.
06-04-13
Retighten locking nut. Accelerator Pump Verification With engine stopped, remove intake silencer cover and flame arrester then activate throttle lever to ensure accelerator pump is injecting fuel in carburetor(s). Reinstall removed parts. NOTE: Activate throttle only a few times to prevent engine flooding.
CAUTION
2 1
F04F18A
F04K12A
06-04-14
Twin-engine Models Fully turn steering in one direction. Adjust cable housing in bracket so that throttle moves slightly.
1
F04K13A
F04K0SC
Tighten adjustment screws. Turn steering in the other direction and repeat procedure on the other cable. When engine(s) RPM are the same for the two extreme steering positions, proceed with procedure FINAL ADJUSTMENT as described later.
Once engine RPM are the same for the two extreme steering positions, proceed with FINAL ADJUSTMENT procedure.
Single-engine Model Fully turn steering in one direction. Adjust cable housing in bracket so that throttle just starts moving. Turn steering to center position and ensure that idle speed is 1500 RPM (in water) or 3000 RPM (out of water). Perform final adjustment with adjuster knob of rotating end as described in the FINAL ADJUSTMENT procedure. If engine RPM are not the same when steering is turned left then right, adjust with the two following screws as shown in the next photo.
If testing on open water, ensure to accelerate slowly, boat may veer suddenly to left or right. With boat in water and helm arm fixed on, set throttle lever to idle speed (1500 RPM (in water)). Fully turn steering left and right, then turn adjuster knob of rotating end so that engine revolution reaches 2800 RPM (in water) on single-engine model and 3000 RPM (in water) on twin-engine models.
WARNING
CAUTION
Both screws must be adjusted at the same time. When tightening the first one, the other one must be loosened. Same for reverse procedure. When adjustment is completed, ensure there is no slack with screws.
06-04-15
F04K0OA
F01F07B
Seal rotating ends with heat shrink tubing. NOTE: Ensure that right side engine will speed up when steering is turned right. Left side engine will speed up when steering is turned left. If not, reposition cables accordingly, at helm bracket and/or control lever bracket.
787 ENGINE 1. PTO low-speed mixture screw 2. MAG low-speed mixture screw (not shown)
CAUTION
CARBURETOR ADJUSTMENTS
2, Low-speed Mixture Screw
Do not attempt to set engine idle speed with low-speed mixture screw. Severe engine damage can occur. Tighten screw in until a slight resistance is felt then back off to the specification as per following chart.
ENGINE TYPE LOW SPEED SCREW 1.25 turns 1.5 turns
717 787
F06F0GA
Start and warm up engine. NOTE: Turning screw clockwise leans mixture and turning screw counterclockwise enriches mixture. Check that engine idles and runs smoothly. Make sure engine reacts quickly to throttle lever. If necessary, readjust low-speed screw ( 1/4 turn). NOTE: Both low-speed screws must be adjusted exactly the same way. Never adjust screws more than 1/4 turn at a time.
06-04-16
CAUTION
When adjusting high-speed mixture screw, always inspect spark plug tip color and readjust screw accordingly. Otherwise, severe engine damage can occur.
F06F0IA
F01F2QA
ROT
1
06-04-17
TABLE OF CONTENTS
OIL INJECTION RESERVOIR................................................................................................. GENERAL ........................................................................................................................... OIL SYSTEM PRESSURIZATION ...................................................................................... OIL INJECTION PUMP .......................................................................................................... REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... ASSEMBLY......................................................................................................................... ADJUSTMENTS ................................................................................................................ CHECKING OPERATION....................................................................................................
0
07-02-1 07-02-3 07-02-3 07-03-1 07-03-3 07-03-3 07-03-3 07-03-3 07-03-4 07-03-6
07-01-1
1 2
F04G0IS
TYPICAL
PARTS
FLAT RATE
07-02-1
Twin-engine Models
3 1 2 Loctite 242 1
Left engine
F04G0JS
Right engine
07-02-2
PARTS
FLAT RATE
GENERAL
Whenever repairing the oil injection system, always verify for water infiltration in reservoir. Perform also a pressure test of the oil injection system.
3, Check Valve
White side of the one-way check valve is the valve outlet. It allows air to get in reservoir.
F01G0IA
Oil Filter
Oil filter should be replaced annually.
Whenever oil system components are disconnected or replaced, a pressure test must be done before starting engine. Ensure to verify oil line ends for damage. Always cut damaged end before reinstallation.
WARNING
Pressurize oil system to 21 kPa (3 PSI). If pressure is not maintained, locate leak and repair/ replace component leaking. To ease leak search, spray a solution of soapy water on components, bubbles will indicate leak location. NOTE: The system must maintain a pressure of 21 kPa (3 PSI) for at least 10 minutes. Never pressurize over 21 kPa (3 PSI).
CAUTION
If any leak is found, do not start the engine and wipe off any oil leakage. Disconnect pump gauge tester and remove hose pinchers.
Pressure Test
Proceed as follows: Fill up oil reservoir. Install hose pinchers to oil supply outlet hoses close to reservoir fitting. Install a hose pincher to rotary valve shaft oil return hose close to reservoir. Connect pump gauge tester to check valve of oil injection reservoir vent.
07-02-3
1 10 Nm 3 (89 lbfin)
Loctite 242
Loctite 242
F04G0KS
PARTS
FLAT RATE
07-03-1
787 Engine
6 Nm (53 lbfin)
8 6 1 3 Nm (27 lbfin)
F01G0TT
07-03-2
PARTS
FLAT RATE
REMOVAL
717 Engine Remove air intake silencer (refer to FUEL SYSTEM 06-03). Remove rotary valve cover (refer to ENGINE 0407). Remove Allen screws retaining intake manifold to rotary valve cover. Separate intake manifold from rotary valve cover.
DISASSEMBLY
NOTE: Some oil pump parts are not available in single parts. A gasket set is available for the pump. If the pump is found defective, it should be replaced by a new one.
CLEANING
Discard all seals and O-rings. Clean metal components in a solvent.
ASSEMBLY
717 Engine
CAUTION
Whenever oil injection lines are removed, always make the routing as shown.
A00C17B
1. Gear holder
Oil Pump
Remove 2 Allen screws with flat washers retaining oil injection pump to intake manifold. Remove pump.
787 Engine
Oil Pump
Disconnect oil injection pump cable. Remove 2 Allen screws with flat washers retaining oil injection pump to magneto housing cover. Pull pump. Disconnect oil hoses from fittings of oil injection pump.
1
F01D4SA
07-03-3
Intake Manifold
Install intake manifold to rotary valve cover and torque screws to 10 Nm (89 lbfin). NOTE: Make sure a new gasket is installed to rotary valve cover.
Turn idle speed screw until it contacts stopper. Turn idle speed screw 2 turns. Turn cable adjustment nut to align marks on pump. NOTE: A mirror may be used to facilitate this verification.
717 Engine
1 2
F01D4RC
A
F01D4RE
787 Engine
Pump
Make sure shaft is installed in crankshaft end. Install pump. Secure with flat washers and screws. Torque to 6 Nm (53 lbfin). Install oil injection pump cable.
787 Engine
ADJUSTMENTS
CAUTION
As oil injection pump adjustment is dependent on throttle cable position, make sure to perform throttle cable adjustment first.
Preliminary Synchronization
NOTE: To check synchronization of pump as a routine maintenance, refer to Final Synchronization. Make sure idle speed of engine is properly adjusted. Ensure carburetor butterflies are in closed position. NOTE: Make sure carburetors are properly synchronized. If necessary, refer to FUEL SYSTEM 06-04.
07-03-4
F07G02B
1. Aligned marks
NOTE: The adjustment nut and jam nut for the oil injection pump cable are located at the cable support on PTO side carburetor.
Bleeding
CAUTION
Oil injection system must be bled and adjustment checked before operating engine. Ensure oil injection reservoir is sufficiently filled. Install a dry rag below oil injection pump. Loosen bleed screw to allow oil to flow.
1 2
F01F32G
717 Engine
CAUTION
Water must be supplied to cool engine. Adjust idle speed to specification. Refer to FUEL SYSTEM 06-04. Stop engine.
F01D4SC
Final Synchronization
Eliminate throttle cable free-play by depressing throttle lever until a slight resistance is felt. In this position, marks on pump body and lever must align. NOTE: A mirror may be used to facilitate this verification. If necessary, turn cable adjustment screw to obtain pump mark alignment. Refer to above illustrations. Tighten jam nut and recheck alignment marks.
787 Engine
1
CAUTION
Proper oil injection pump adjustment is very important. Any delay in the opening of pump can result in serious engine damage.
F07G02A
1. Bleed screw
07-03-5
All Engines Keep bleeding until all air has escaped from line. Make sure no air bubbles remain in oil supply line. Tighten bleed screw. Wipe any oil spillage. Check small oil lines between pump and intake manifold. They must be full of oil. If not, run engine at idle speed while manually holding pump lever in fully open position. Do not activate throttle lever.
717 Engine
CAUTION
F02D05B
CHECKING OPERATION
On Boat
NOTE: Oil line supply must be full of oil. See bleeding procedure above. Start engine and run at idle while holding the pump lever in fully open position. Oil must advance into small oil lines. NOTE: The engine should have a rich mixture, idling irregularly and emitting smoke at exhaust outlet. If not, remove pump assembly and check the pump gear (717 engine) or shaft (787 engine) for defects, replace as necessary. Test pump as described below: NOTE: Through normal use, oil level must not drop in small tubes. If oil drops, verify check valve operation. Replace as necessary.
1. Check valves
787 Engine
1
F01G0QA
1. Check valves
07-03-6
Bench Test
The oil pump must be removed from boat. Connect a hose filled with injection oil to main line fitting. Insert other hose end in an injection oil container. Using a counterclockwise (reverse position) rotating drill, rotate pump shaft. Oil must drip from fittings in parts of rotary valve cover while holding lever in a fully open position.
2
4 3
F01G02A
TYPICAL 1. Supply oil line to an oil container 2. Hold lever in fully open position 3. Counterclockwise (reverse) rotating drill 4. Oil must drip here
For an accurate test, each port should be checked separately to ensure equal delivery on both ports. To obtain a precise result of the oil pump delivery rate, rotate it counterclockwise at 1500 RPM for a total time of 30 seconds. NOTE: To ensure accuracy of test, oil lines should be completely filled before starting test. Compare the results with the chart below. If oil pump is out of specification, replace it.
ENGINE 717 787 OIL PUMP FLOW RATE AT 1500 RPM (30 SECONDS) 1.24 1.51 mL (each port) 0.71 0.87mL (each port)
NOTE: Test can also be done at 3000 RPM. Double quantities in chart.
07-03-7
TABLE OF CONTENTS
OVERVIEW............................................................................................................................. 717 ENGINE ....................................................................................................................... MAGNETO SYSTEM ......................................................................................................... IGNITION SYSTEM (single generator coil)...................................................................... MPEM (Multi-Purpose Electronic Module) ................................................................................ CHARGING SYSTEM......................................................................................................... STARTING SYSTEM .......................................................................................................... GAUGES/ACCESSORIES .................................................................................................. 787 ENGINE ....................................................................................................................... MAGNETO SYSTEM ......................................................................................................... CHARGING SYSTEM......................................................................................................... CHARGING CIRCUIT SCHEMATIC.................................................................................... IGNITION SYSTEM............................................................................................................ STARTING SYSTEM AND GAUGES/ACCESSORIES ......................................................
0
08-02-1 08-02-1 08-02-1 08-02-1 08-02-2 08-02-2 08-02-2 08-02-2 08-02-3 08-02-3 08-02-3 08-02-3 08-02-4 08-02-4
IGNITION SYSTEM................................................................................................................ 08-03-1 IGNITION SYSTEM TESTING PROCEDURE, 717 ENGINE ............................................. 08-03-1 GENERAL ........................................................................................................................... 08-03-1 IGNITION TIMING, 717 ENGINE....................................................................................... 08-03-3 IGNITION TIMING ADJUSTMENT ................................................................................... 08-03-7 IGNITION SYSTEM TESTING PROCEDURE, 787 ENGINE ............................................. 08-03-8 GENERAL ........................................................................................................................... 08-03-8 IGNITION TIMING, 787 ENGINE....................................................................................... 08-03-10 SPARK PLUGS....................................................................................................................... NGK SPARK PLUG SYMBOL EXPLANATION.................................................................. DISASSEMBLY................................................................................................................... HEAT RANGE ..................................................................................................................... FOULING ............................................................................................................................ SPARK PLUG ANALYSIS................................................................................................... SPARK PLUG INSTALLATION........................................................................................... SPARK PLUG CHART......................................................................................................... THE DESS (DIGITALLY ENCODED SECURITY SYSTEM) ................................................... MPEM (MULTI-PURPOSE ELECTRONIC MODULE)............................................................ 08-04-1 08-04-1 08-04-2 08-04-2 08-04-2 08-04-2 08-04-3 08-04-3 08-05-1 08-06-1
08-01-1
CHARGING SYSTEM ............................................................................................................. 08-07-1 TESTING PROCEDURE ...................................................................................................... 08-07-1 STARTING SYSTEM .............................................................................................................. ELECTRIC STARTER ........................................................................................................... GENERAL............................................................................................................................ STARTING SYSTEM TROUBLESHOOTING...................................................................... REMOVAL ........................................................................................................................... DISASSEMBLY ................................................................................................................... CLEANING .......................................................................................................................... INSPECTION ....................................................................................................................... ASSEMBLY ......................................................................................................................... STARTER INSTALLATION .................................................................................................. STARTER SPECIFICATION ................................................................................................. BATTERY............................................................................................................................. TROUBLESHOOTING......................................................................................................... SPECIFICATIONS ............................................................................................................... ACTIVATION OF NEW BATTERY ....................................................................................... REMOVAL ........................................................................................................................... CLEANING .......................................................................................................................... INSPECTION ....................................................................................................................... BATTERY TESTING ............................................................................................................ BATTERY STORAGE .......................................................................................................... TIPS FOR CHARGING A USED BATTERY......................................................................... CHARGING 2 OR MORE BATTERIES AT A TIME ............................................................. INSTALLATION ................................................................................................................... 08-08-1 08-08-1 08-08-2 08-08-3 08-08-4 08-08-4 08-08-4 08-08-5 08-08-5 08-08-7 08-08-8 08-08-9 08-08-9 08-08-9 08-08-9 08-08-9 08-08-10 08-08-10 08-08-10 08-08-11 08-08-11 08-08-12 08-08-12
08-01-2
OVERVIEW
717 ENGINE
The electrical system consist of different subsystems where some are inter-related. The magneto is coupled to the engine and produces electrical energy for the ignition system and the charging system. Its outputs are directed toward the ignition coil as well as the charging system and some circuits through the MPEM (MultiPurpose Electronic Module). In the charging system, the battery supplies the MPEM, the starting system and the accessories. The following gives an outline of each components. There are different voltage types (AC (alternative current) and DC (direct current)) and voltage levels (0 to 40 000 Vac, 5 Vdc and 12 Vdc). There is unregulated AC from magneto for the charging system and the ignition system. For the charging system, the AC current is rectified to DC and regulated to 12 Vdc for MPEM, gauges, accessories and electrical system. The MPEM lowers the voltage level to 5 Vdc for its internal circuitry and some external components (neutral switch and low-fuel warning system on some models). For the ignition system, the AC voltage from the magneto is stepped up to 40 000 V. Keep that in mind when dealing with voltages in the electrical system.
0
IGNITION SYSTEM (single generator coil)
IGNITION COIL AND SPARK PLUGS (with integrated ignition module) The ignition coil integrates the electronic circuitry of the CDI (ignition module). The CDI circuitry receives its primary electric current from magneto via 2 wires which charges its capacitor. The CDI circuitry controls the ignition timing and generates the spark occurrence by discharging the current stored in its capacitor to ignition coil. The primary windings of ignition coil (connected to CDI circuitry internally) receives the electrical energy from the CDI circuitry. The ignition coil jumps this voltage to a high level in secondary windings to produce a spark at spark plug.
3
MAGNETO SYSTEM
It is the primary source of electrical energy. It transforms magnetic field into electric current through generator coil for the ignition system and through another separate 3-pole generator coil for the charging system.
1 2
F04H0VA
TYPICAL 1. Spark plugs 2. Ignition coil with integrated ignition module 3. Magneto system 4. MPEM (Multi-Purpose Electronic Module)
F04H0UA
TYPICAL 1. Ignition system generator coil 2. Magneto flywheel 3. Charging system generator coil
08-02-1
STARTING SYSTEM
The battery supplies the DC current to the electric starter via a solenoid to start the engine.
CHARGING SYSTEM
It receives its primary electric current from magneto via 2 wires which charges the battery. The magneto supplies unregulated AC current to a voltage regulator/rectifier. The half-wave rectifier receives the AC current and changes it to DC current to allow battery charging. This regulated DC current then supplies the MPEM, starting system and the accessories.
3
3 1
F04H0XA
GAUGES/ACCESSORIES
2
The battery supplies the DC current through the MPEM to the gauges and accessories.
2
F04H0WA
F04H0YA
08-02-2
787 ENGINE
The electrical system consist of different subsystems where some are inter-related. The magneto is coupled to the engine and produces electrical energy for the charging system. Its outputs are directed toward the charging system and some circuits through the MPEM (MultiPurpose Electronic Module). In the charging system, the battery supplies the MPEM, the starting system and the accessories. The following gives an outline of each components. There are different voltage types (AC (alternative current) and DC (direct current)) and voltage levels (0 to 40 000 Vac, 5 Vdc and 12 Vdc). There is unregulated AC from magneto for the charging system. For the charging system, the AC current is rectified to DC and regulated to 12 Vdc for the MPEM, gauges, accessories and electrical system. The MPEM lowers the voltage level to 5 Vdc for its internal circuitry and some external components (neutral switch). For the ignition system, the DC voltage from the battery is stepped up to 40 000 V. Keep that in mind when dealing with voltages in the electrical system.
CHARGING SYSTEM
It receives its primary electric current from magneto via 3 wires which charges the battery. The magneto supplies unregulated AC current to a voltage regulator/rectifier.
1 2
F04H24A
Rectifier/Regulator
A dual 1/2 wave series rectifier/regulator receives the AC voltage and rectifies it into DC. The system is regulated to a maximum of 14.5 - 14.8 volts (DC).
MAGNETO SYSTEM
It is the source of electrical energy to charge the battery and keep it at a full state of charge. It transforms magnetic field into electric current through a 3 phase, Y wound stator on 18 poles.
Battery
The battery is the DC source for the electric starter, multi-purpose electronic module (MPEM) and all accessories.
CONTROL CIRCUIT
AC 1 (YE)
F04H23A
AC 2 (YE)
AC 3 (YE)
08-02-3
IGNITION SYSTEM
A Digital DC-CDI (Direct Current-Capacitor Discharge Ignition) system is utilized on the 787 engine. The ignition system is made up of the following components:
4
3 6 1 5 N 2 2 S 1
1 6 2 3 5
1. 2. 3. 4. 5. 6. 7.
N S
A00E4JA
4
F04H3JA
Coil Magnet Protrusion Magnetic field outside of coil Magnetic field crossing coil Current to CDI module Magneto flywheel
TYPICAL 1. Battery 2. MPEM module 3. Flywheel/rotor 4. Trigger coil 5. Ignition coil 6. Spark plugs
Ignition Coil
The ignition coil steps up the voltage input from the DC-CDI system and the end result is firing of the spark plugs. The coil is housed in the electrical box.
08-02-4
IGNITION SYSTEM
IGNITION SYSTEM TESTING PROCEDURE, 717 ENGINE GENERAL
NOTE: On occasion a component will statically test good but in fact be defective. In this instance, removing the original part and replacing it with a known good part is the most accurate procedure. The MPEM (Multi-Purpose Electronic Module) is part of the ignition system as well as part of the electrical system. This section gives testing procedure for ignition-related problems. For other type of problems, refer to MPEM section.
0
MPEM (Multi-Purpose Electronic Module)
IGNITION AND RPM CONTROL PROBLEMS NOTE: There is one RPM limiter for each engine in the MPEM. A defective RPM limiter may cause the following problems: no spark misfiring/black fouled spark plugs uninterrupted spark when engine stop/safety lanyard is used incorrectly controlled engine maximum speed of 7000 RPM at forward/reverse and 3500 RPM at neutral sudden engine stop while riding at maximum RPM To diagnose spark problems that may come from the MPEM, first check that its BLACK wire is perfectly grounded, then if there is no spark, temporarily bypass the RPM limiter by disconnecting the BLACK/RED/GREEN for starboard (RH) side and BLACK/RED for port (LH) side wire coming from engine magneto system. If everything now works normally, the RPM limiter is defective and the MPEM must be replaced. If engine does not stop when using stop/safety lanyard, ensure that BLACK /RED/GREEN wire for starboard (RH) side and BLACK/RED for port (LH) side are well-connected to MPEM. For additional testing, refer to section 08-06, MPEM.
CAUTION
Whenever replacing a component of ignition system, check ignition timing. Spark occurrence can be checked with a tester from Superex Canada Ltd P/N 15-785. To perform verifications, a good quality multimeter such as Fluke 73 (P/N 529 022 000) can be used. When dealing with ignition problems, the following items should be checked in this order: 1. Spark occurrence/spark plug condition. 2. Battery condition. 3. MPEM supply fuse condition. 4. Electrical connections. 5. Engine stop/safety lanyard post. 6. MPEM. 7. Magneto output. 8. Ignition coil output. The first 4 items can be checked with common automotive equipment. For item 5 and 6, refer to section 08-06 MPEM. For items 7 and 8, refer to the following procedures.
08-03-1
Multiple Problems
There is always the possibility of more than one faulty part. If after a component has been replaced, the problem still persists, carefully repeat the complete test procedure to find the other faulty part.
Safety Precautions
WARNING
To prevent powerful electric shocks while cranking engine, neither touch any electronic ignition components (ignition coil, high tension wire, wire harness, etc.) nor tester lead clips. Also make sure that tester leads do not touch any metallic object. Ventilate bilge at least 5 minutes prior to performing any test.
F01H5WA
TYPICAL 1. Multimeter 2. Four-pin magneto harness adapter 3. RED/BLACK wire 4. BLACK wire
F01B28A
TYPICAL
Check resistance with a high-sensitivity ohmmeter. Refer to the following table for values and wire colors.
PART NAME Generating coil ADAPTER WIRE Black with RED/BLACK RESISTANCE 40-76
DYNAMIC TEST 1. Connect spark plug cables to grounding device. 2. Disconnect magneto wiring harness connector. 3. Install the 4-pin magneto harness adapter (P/N 295 000 131). 4. Connect positive test probe of the multimeter to the RED/BLACK wire of the 4-pin magneto harness adapter. 5. Connect negative test probe of the multimeter to BLACK wire of the 4-pin magneto harness adapter. 6. Set multimeter to Vac scale. 7. Crank engine and note result. The obtained value should be between 18 and 25 Vac. If the generating coil is out of specification, replace it. NOTE: If the generating coil tests good, disconnect the primary wires of the ignition coil. Crank engine and check voltage at primary wires. It should be at least 20 Vdc. If there is insufficient or no voltage, either the MPEM or wiring harness is defective.
STATIC TEST NOTE: An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an ohmmeter. Primary Winding Due to the integrated CDI module, it is not possible to take any resistance measurement. Secondary Winding The spark plug caps must be removed from high tension cables, because they are resistor caps. The cap resistance is 10 k.
1
1. With ignition coil removed from craft, disconnect spark plug caps from high tension cables. 2. Hook high tension leads from tester to ignition coil high tension cables. 3. Connect 2 smaller tester leads to primary of ignition coil.
1
ON OFF 12 V 6V
2 2
F01H55A A00E0QA
IGNITION COIL PART NAME Secondary winding WIRE End of each spark plug cable, spark plug caps removed RESISTANCE 8.4 - 15.6 k
4. Turn power switch to 12 volts and you should observe spark jumping at a predetermined gap of 7 to 8 mm (.276 to .311 in). If there is no spark, if it is weak or intermittent, the coil is defective and should be replaced.
NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter. DYNAMIC TEST Use an ignition coil tester, available from aftermarket tool/equipment suppliers.
CAUTION
Do NOT use coil tester on metal work bench. Follow manufacturer instructions.
08-03-3
CAUTION
The relation between the PTO flywheel mark position and crankshaft position may change as the PTO flywheel might tighten/loosen on the crankshaft. As an example, when the engine is accelerated out of water, PTO flywheel may tighten and then loosen when the engine is decelerated. This will result in a false ignition timing reading since the PTO flywheel has moved relatively to crankshaft. It is suggested to strongly accelerate engine in a water basin (or test run) and then slowly decelerate the engine to avoid PTO flywheel loosening. Always verify PTO flywheel mark position before checking ignition timing with an appropriate timing light. If mark does not align with tool, repeat static test to ensure flywheel has not loosen before changing the ignition timing. Flywheel timing mark position verification is required to: 1. Troubleshoot a missing or broken magneto flywheel Woodruff key. 2. Troubleshoot a magneto flywheel corresponding to a different engine type. 3. Scribe the timing mark on a new service PTO flywheel. 4. Ensure that an accurate mark will be used to check ignition timing.
F01H5SA
4. Install and adjust a TDC gauge (P/N 295 000 143) in spark plug hole as follows:
1
1. Disconnect MAG side spark plug wire and connect wire to grounding device then remove spark plug. 2. Remove PTO flywheel guard. 3. Install timing mark tool (P/N 295 000 130) on engine using wing nuts previously removed.
Rotate PTO flywheel counterclockwise (when facing it) until piston is just before top dead center.
08-03-4
90
80
10
70 30
20
40
50
60
F01H5SB
This mark becomes the reference when using stroboscopic timing light.
F01H4LA
CAUTION
Loosen adapter lock nut then, holding gauge with dial facing toward PTO, screw adapter in spark plug hole. Slide gauge far enough into adapter to obtain a reading then, finger tighten adapter lock nut. Rotate PTO flywheel counterclockwise until piston is at Top Dead Center. Unlock outer ring of dial and turn it until zero (0) on dial aligns with pointer. Lock outer ring in position. 5. From this point, rotate flywheel back 1/4 turn then rotate it counterclockwise to reach 2.59 mm (.102 in). 6. Using timing tool slot as reference mark, scribe in middle of tool slot a mark onto PTO flywheel.
Timing mark position verification cannot be used as a timing procedure, therefore, always check the timing with a stroboscopic timing light at 6000 RPM after the marks have been checked.
A00B4FA
08-03-5
NOTE: This timing light is battery powered (2 batteries, type C) and therefore needs no auxiliary power source.
3. Start engine and point timing light straight in line with timing tool slot. Bring engine to 6000 RPM for a brief instant.
1
CAUTION
Always verify timing marks with TDC gauge before checking the timing. The ignition components are affected by temperature variation, therefore, timing must be checked when engine is cold, after idling for a MAXIMUM of 20 seconds. 1. Connect an induction-type tachometer to spark plug wire.
1
F00H0IA
IMPORTANT: Place shifter in forward or reverse position to allow engine reaching 6000 RPM. NOTE: On this NIPPONDENSO system, timing advance decreases as engine speed increases. When marks are aligned at 6000 RPM, spark occurrence is still Before Top Dead Center. 4. Check if PTO flywheel mark (or reference one previously scribed) aligns with timing tool slot.
F06H06A
1. Tachometer pick-up
CAUTION
If engine is to be run more than a few seconds, connect a garden hose and supply water to the engine to properly cool it. If timing marks align, timing is correct. If mark does not align, recheck PTO flywheel mark before adjusting ignition timing to ensure PTO flywheel has not loosen.
F00H0HA
08-03-6
F01H5UA
2
A25E0RA
In this case, turn armature plate clockwise. When PTO flywheel mark is on left side of timing tool slot, it indicates retarded timing.
To adjust, loosen 3 armature plate retaining screws and slightly rotate armature plate in proper direction.
F01H5VA
1. Retarded timing
1 1
A25E0VA
In this case, turn armature plate counterclockwise. After adjustment, tighten armature plate retaining screws.
CAUTION
When PTO flywheel mark is on right side of timing tool slot, it indicates advanced timing.
Armature plate screws must have Loctite 242 (blue) applied before tightening. Make sure armature plate screws are well secured. Reinstall removed parts. Recheck ignition timing (make sure engine is cold).
08-03-7
CAUTION
Whenever replacing a component of ignition system, check ignition timing. Spark occurrence can be checked with a tester from Superex Canada Ltd P/N 15-785. To perform verifications, a good quality multimeter such as Fluke 73 (P/N 529 022 000) can be used. When dealing with ignition problems, the following items should be checked in this order: 1. Spark occurrence/spark plug condition. 2. Battery condition. 3. MPEM supply fuse condition. 4. Electrical connections. 5. Engine stop/safety lanyard. 6. MPEM. 7. Magneto output. 8. Ignition coil output. The first 4 items can be checked with common automotive equipment. For items 5 and 6, refer to MPEM section. For items 7 and 8, refer to the following procedures.
Multiple Problems
There is always the possibility of more than one faulty part. If after a component has been replaced, the problem still persists, carefully repeat the complete test procedure to find the other faulty part.
Safety Precautions
WARNING
To prevent powerful electric shocks while cranking engine, neither touch any electronic ignition components (ignition coil, high tension wire, wire harness, etc.) nor tester lead clips. Also make sure that tester leads do not touch any metallic object. Ventilate bilge at least 5 minutes prior to performing any test.
08-03-8
Trigger Coil
STATIC TEST: CONTINUITY Check resistance with a high-sensitivity ohmmeter. 1. Disconnect magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136).
4. Connect the other multimeter lead to the BLACK/ YELLOW wire of the 6-pin magneto harness adapter. 5. Crank engine and note result. The obtained value should be between 0.2 and 0.5 Vac. 6. If the trigger coil is out of specification, replace it.
Ignition Coil
Before conducting any testing on the ignition coil, make sure there is at least 20 Vdc at the primary wires. If there is insufficient voltage, the ignition problem is occurring before the ignition coil. STATIC TEST: CONTINUITY NOTE: An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an ohmmeter. Primary Winding 1. Remove the 2 female spade connectors from the primary side of the ignition coil. 2. With the multimeter set on the resistance scale, connect the meter leads to the primary terminals of the coil. 3. Resistance should be approximately .6 . Secondary Winding The spark plug caps must be removed from high tension cables, because they are resistor caps. The cap resistance is 10 k.
1
F01B28A
3. Connect one of the multimeter leads to the WHITE wire of the 6-pin magneto harness adapter. 4. Connect the other multimeter lead to the BLACK/ YELLOW wire of the 6-pin magneto harness adapter. 5. Measure resistance; it should be between 190300 ohms.
F01H5YA
1
A00E0QA
1. 2. 3. 4.
DYNAMIC TEST 1. Disconnect magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Connect one of the multimeter leads to the WHITE wire of the 6-pin magneto harness adapter.
End of each Secondary spark plug cable, winding spark plug caps (all other models) removed
8.4 - 15.6 k
08-03-9
NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter. DYNAMIC TEST Use an ignition coil tester, available from aftermarket tool/equipment suppliers.
CAUTION
Do NOT use coil tester on metal work bench. Follow manufacturer instructions. 1. With ignition coil removed from craft, disconnect spark plug caps from high tension cables. 2. Hook high tension leads from tester to ignition coil high tension cables. 3. Connect 2 smaller tester leads to primary of ignition coil.
1
ON OFF 12 V 6V
2
F01H55A
4. Turn power switch to 12 volts and you should observe spark jumping at a predetermined gap of 7 to 8 mm (.276 to .311 in). If there is no spark, if it is weak or intermittent, the coil is defective and should be replaced.
08-03-10
CAUTION
The relation between the PTO flywheel mark position and crankshaft position may change as the PTO flywheel might tighten/loosen on the crankshaft. As an example, when the engine is accelerated out of water, PTO flywheel may tighten and then loosen when the engine is decelerated. This will result in a false ignition timing reading since the PTO flywheel has moved relatively to crankshaft. It is suggested to strongly accelerate engine in a water basin (or test run) and then slowly decelerate the engine to avoid PTO flywheel loosening. Always verify PTO flywheel mark position before checking ignition timing with an appropriate timing light. If mark does not align with tool, repeat static test to ensure flywheel has not loosen before changing the ignition timing. STATIC TEST 1. To install the timing mark pointer tool, first remove PTO flywheel guard. Then remove middle screw securing the engine to the rear crossover motor mount. Reinstall screw with timing mark pointer tool attached.
F06H05A
F01H5TA
08-03-11
1. Connect an induction-type tachometer (P/N 295 000 100) to spark plug wire.
90
80
10
1
50
60
20
30
40
70
F06H06A
1. Tachometer pick-up
F01H4LA
2. Check ignition timing using the stroboscopic timing light connected to the MAG side spark plug cable.
1
4. From this point, rotate flywheel clockwise (when facing it) until piston is at 3.38 mm (.133 in) before top dead center. 5. Scribe a mark on PTO flywheel aligned with timing mark pointer tool. 6. Remove TDC gauge, reinstall spark plug and connect wire. DYNAMIC TEST To check ignition timing, use a timing light (P/N 529 031 900).
F00H0HA
3. Rev the engine to 3500 RPM and point beam of timing light straight in line with timing mark pointer.
A00B4FA
08-03-12
Through the MPEM programmer, the ignition timing can be advanced up to 3 or retarded up to 4. If the timing is too retarded, a performance decrease of the engine will be noticed. If the timing is too advanced, serious engine damage will occur.
CAUTION
If the ignition timing is too advanced, this will cause serious damage to the engine.
CAUTION
If engine is to be ran more than a few seconds, connect a garden hose and supply water to the engine to properly cool it. NOTE: If mark on PTO flywheel is perfectly aligned with timing mark pointer, no adjustment is required. If mark does not align with pointer, recheck PTO flywheel mark before adjusting ignition timing to ensure PTO flywheel has not loosen.
The timing marks refer to the physical component position when the spark must occur. The DC-CDI system must be synchronized with these marks. The timing correction does just that. For instance, on a particular engine, the timing correction may need to be advanced to 2 so that the marks align. This is not the real spark advance, just a correction for the tolerances of the mechanical components. A timing light is used to check the marks alignment. If the marks are found aligned, the ignition timing is correct and no further action is required. If the marks are found misaligned, the ignition timing must be corrected. When using the programmer, it will give you the actual correction number that is programmed inside the MPEM. Referring to the chart below, find the corresponding degree and if the correction was made to advance or retard the timing. Knowing that, you select the higher or lower number to advance or retard the actual timing correction by referring to the chart.
RETARDED 4 1 1 0 5 -1 6 -2 7 -3 8 -4
Simply put, you just have to change the number the programmer gave to have the timing marks aligned. If the flywheel mark goes in the bad direction after you tried the next value given by the programmer, try the other value to move the mark in the opposite direction. E.g.: the programmer gave no. 3. You tried no. 4 and the flywheel mark moved in the wrong direction, try no. 2.
08-03-13
Examples: a. You found the flywheel mark advanced. You must retard the timing. The programmer gives you number 3. Referring to the chart, number 3 returns 2. The timing correction is actually set at 2 (advanced) and this is too much. You estimate the correction should be set to 1 (advanced) to retard flywheel mark so that the timing marks align. Back in the chart, look to find 1 (advanced). This gives number 4. Enter this number with the programmer. You recheck the marks with the timing light and they are now aligned. The adjustment is finished. b. You found the flywheel mark advanced. You must retard the timing. The programmer gives you number 3. Referring to the chart, number 3 returns 2. The timing correction is actually set at 2 (advanced) and this is too much. You estimate the correction should be set to 1 (advanced) to retard flywheel mark so that the timing marks align. Back in the chart, look to find 1 (advanced). This gives number 4. Enter this number with the programmer. You recheck the marks with the timing light and found that the flywheel mark is still too advanced. You know now that the correction made previously was not enough and you estimate the correction should be set to 2 (retarded) to retard flywheel mark more. Back in the chart, look to find 2 (retarded). This gives number 6. Enter this number with the programmer. You recheck the marks with the timing light and they are now aligned. The adjustment is finished. c. You found the flywheel mark retarded. You must advance the timing. The programmer gives you number 4. Referring to the chart, number 4 returns 1. The timing correction is actually set at 1 (advanced) and this is too much. You estimate the correction should be set to 2 (advanced) to advance flywheel mark so that the timing marks align. Back in the chart, look to find 2 (advanced). This gives number 3. Enter this number with the programmer. You recheck the marks with the timing light and they are now aligned. The adjustment is finished.
08-03-14
SPARK PLUGS
NGK SPARK PLUG SYMBOL EXPLANATION
PREFIX SUFFIX WIDE GAP
10: 1.0 mm (.040") 11: 1.1 mm (.044") 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080")
B P 5 E S
Thread diameter Heat rating numbers
2
14 mm 10 mm 12 mm 8 mm 12 mm x 19 mm Reach
15
Reach
A: B: C: D: E: J:
18 mm
Hot
E: F:
A: B: C: G: GV: L: S:
Special Desing Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V-Type Half Heat Range Standard Center Electrode Fine Wire Center Electrode Booster Gap V-Grooved Center Electrode
H:
5
L: Z:
Construction
M: P: R: U: Z:
F02H08S
Compact Type Projected Insulator Type Resistor Type Surface Discharge Inductive Supressor Type
Blank
8
V:
18 mm 12 mm (31/64") 14 mm 9.5 mm (3/8")
X: Y:
10
Cold
A01E1PS
Standard Type
V-Type
08-04-1
DISASSEMBLY
First unscrew the spark plug one turn. Clean the spark plug and cylinder head with pressurized air then completely unscrew.
HEAT RANGE
The proper heat range of the spark plugs is determined by the spark plugs ability to dissipate the heat generated by combustion. The longer the heat path between the electrode tip to the plug shell, the hotter the spark plug operating temperature will be and inversely, the shorter the heat path, the colder the operating temperature will be. A cold type plug has a relatively short insulator nose and transfers heat very rapidly into the cylinder head. Such a plug is used in heavy duty or continuous high speed operation to avoid overheating. The hot type plug has a longer insulator nose and transfers heat more slowly away from its firing end. It runs hotter and burns off combustion deposits which might tend to foul the plug during prolonged idle or low speed operation.
A too hot plug will result in overheating preignition, etc. A too cold plug will result in fouling (shorting the spark plug) or may create carbon build up which can heat up red-hot and cause pre-ignition or detonation.
FOULING
Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible causes are: prolonged idling, or running on a too rich mixture due to a faulty carburetor adjustment or incorrect fuel. The plug face of a fouled spark plug has either a dry coating of soot or an oily, glossy coating given by an excess either of oil or of oil with soot. Such coatings form a conductive connection between the center electrode and ground.
1
A00E0AA
A00E09A
1. Cold 2. Hot
CAUTION
The plug face (and piston dome) reveals the condition of the engine, operating condition, method of driving and fuel mixture. For this reason it is advisable to inspect the spark plug at regular intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber) and the piston dome.
Severe engine damage might occur if a wrong heat range plug is used.
08-04-2
A00E0BA
08-04-3
SUPPLEMENT
08-05-1
Subsection 06
SUPPLEMENT
08-06-1
CHARGING SYSTEM
TESTING PROCEDURE
NOTE: First, ensure that battery is in good condition prior to performing the following test using current inductive ammeter such as Snap-on MT 110. If the battery is regularly discharged, check charging system fuse condition on MPEM. The rectifier/regulator could be the culprit of a blown fuse. To check, simply disconnect the rectifier/regulator from the circuit. If the fuse still burns, check for a defective wire.
0
Voltage Test Proceed as follows: Start engine. Connect a multimeter to battery posts. Set multimeter to Vdc scale. Bring engine to approximately 5500 RPM. If multimeter reads over 15 volts, regulator is defective. Replace it. NOTE: Whatever the voltmeter type used (peak voltage or RMS), the voltage must not exceed 15 V. A faulty regulator will allow voltage to exceed 15 V as engine speed is increased. NOTE: If it is continually necessary to add distilled water to the battery, this indicates an over voltage situation, requiring replacement of the rectifier/regulator. If, on the other hand, the battery will not stay charged, the problem can be any of the charging circuit components. If these all check good, you would be accurate in assuming the problem to be in the rectifier/regulator. If there is no charging at the battery with the preceding voltage test, the following test can also be performed. Disconnect the connector housing of the rectifier/ regulator. Using an appropriate terminal remover (Snap-on TT600-4), remove the RED and BLACK wires from the tab housing of the rectifier/regulator. Reconnect the connector housing. Connect the positive probe of a multimeter to the RED wire and the negative probe to the BLACK wire. Set multimeter to Vdc scale. Start and rev engine to 3500 RPM. The obtained value should be between 12 and 25 Vdc. NOTE: If the rectifier/regulator is within the specification, either the MPEM or wiring harness between the rectifier and battery is defective. If the rectifier/regulator is out of specification and the battery charging coil (or stator) test good, the rectifier/ regulator is defective.
CAUTION
Rectifier/Regulator
NOTE: There is one rectifier/regulator for each engine on twin-engine models. Perform the tests on each rectifier/regulator. STATIC TEST: CONTINUITY 1. Due to internal circuitry, there is no static test available. DYNAMIC TEST Current Test Proceed as follows: Start engine. Lay an inductive ammeter on positive cable of battery. Bring engine to approximately 5500 RPM. Depending on battery charge, current reading should be approximately 4 amperes for the 717 engine or 5 amperes for the 787 engine. If not, check magneto output prior to concluding that rectifier is faulty.
08-07-1
YL YL YL BK BK-YL YL-WH
TYPICAL
2. Place either meter test probe into the remaining stator lead (AC-3) and note the resistance (same as step no. 1). If the readings are out of specification, the stator will need to be replaced.
NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter. 1. Unplug magneto connector at engine. 2. Connect the 4-pin magneto test harness (P/N 295 000 131) between the unplugged connectors. 3. Connect test probes of the multimeter to the YELLOW and YELLOW/BLACK wires of the 4-pin magneto harness adapter. 4. Set multimeter to Vac scale. 5. Start and rev engine to 3500 RPM. The obtained value should be between 25 and 40 Vac. 6. If the battery charging coil is out of specification, replace it.
YL YL YL BK BK-YL YL-WH
F01H4XA
TYPICAL
Stator
787 Engine
STATIC TEST: CONTINUITY 1. Disconnect the magneto wiring harness connector. Connect the 6-pin magneto test harness (P/N 295 000 136) on the engine connector only. With a good multimeter (preferably a digital one), place the 2 meter test probes onto the stator wire leads AC-1 and AC-2 of the stator. The resistance should be 0.8 .
STATIC TEST: INSULATION With the stator leads disconnected, insert either meter test probe onto AC-1 and ground the other meter test probe to the engine or the stator iron core and note the reading. There should be no continuity (infinity) between the stator insulated coils and ground. If there is a reading, the stator coils and/or the wiring from the coils is grounded and needs to be replaced/repaired respectively.
08-07-2
YL YL YL BK BK-YL YL-WH
F01H4YA
TYPICAL
DYNAMIC TEST 1. Unplug magneto connector at engine. 2. Connect the 6-pin magneto test harness (P/N 295 000 136) between the unplugged connectors. 3. Connect test probes of the multimeter to two of the YELLOW wires of the 6-pin magneto harness adapter. 4. Set multimeter to Vac scale. 5. Start and rev engine to 3500 RPM. The obtained value should be between 45 and 70 Vac. 6. If the stator is out of specification, replace it.
08-07-3
STARTING SYSTEM
ELECTRIC STARTER
10
11 15 6 7 8
18
14 22 Nm (16 lbfft)
PARTS
FLAT RATE
08-08-1
GENERAL
Causes of troubles are not necessarily related to starter but may be due to a burnt fuse, faulty battery, MPEM, start/stop switch, safety lanyard post, solenoid, electrical cables or connections. Check these components before removing starter. Consult also the Starting System Troubleshooting table on next page for a general view of possible problems.
WARNING
Short circuiting electric starter is always a danger, therefore disconnect the battery ground cable before carrying out any kind of maintenance on starting system. Do not place tools on battery.
Battery
To check battery condition, refer to ELECTRICAL SYSTEM 08-07.
Solenoid
NOTE: Solenoid(s) is(are) located in electrical box. Prior to performing the following test, ensure the solenoid receives electric current from the MPEM. Refer to section 08-06, MPEM. Disconnect large cables from solenoid. Inspect connections and clean as necessary. Solenoid condition can be checked with an ohmmeter. Install test probes on large connectors of solenoid. Measure resistance when current is applied to small connectors; if it is more than a few ohms, replace solenoid.
08-08-2
08-08-3
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) starter mount screws (no. 19)
DISASSEMBLY
A03E04A
1,2,3,4,5, Yoke, Brush Holder, End Frame, Through Bolt and Nut
Before disassembling, trace index marks on yoke and clutch housing to ease further assembly.
1
CLEANING
CAUTION
Yoke assy and drive unit assembly must not be immersed in cleaning solvent. Discard all O-rings and gasket. Clean brushes and holders with a clean cloth soaked in solvent. Brushes must be dried thoroughly with a clean cloth. Blow brush holders clean using compressed air.
F01H0PA
Remove starter support nuts then through bolts. Separate end frame from yoke assembly. Withdraw yoke assembly from armature. Brush holder can be removed from end frame by unscrewing nut retaining terminal. Check that the radial play between the armature shaft and end frame is not greater than 0.20 mm (.008 in). Replace end frame if so.
WARNING
Always wear safety glasses when using compressed air. Remove dirt, oil or grease from commutator using a clean cloth soaked in suitable solvent. Dry well using a clean, dry cloth. NOTE: Bushings (717 engine) or bearings (787 engine) must not be cleaned with grease dissolving agents.
08-08-4
Clean engine ring gear teeth and drive unit (clutch). NOTE: Bushings must not be cleaned with grease dissolving agents. Immerse all metal components in cleaning solution. Dry using a clean, dry cloth.
Brush Holder
Check brush holder for insulation using an ohmmeter. Place one test probe on insulated brush holder and the other test probe on brush holder plate. If continuity is found, brush holder has to be repaired or replaced.
INSPECTION
Armature
NOTE: An ohmmeter may be used for the following testing procedures, except for the one concerning shorted windings in armature. 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.
1
Brush Length
Measure brush length. If less than 8.5 mm (.335 in), replace it. NOTE: New brush length is 12 mm (.472 in).
2 1
A03E05A
Overrunning Clutch
F01H0RA
Check commutator out of round condition with Vshaped blocks and an indicator. If commutator out of round is more than 0.40 mm (.016 in), commutator should be turned on a lathe. Check commutator outer diameter. If less than 27 mm (1.063 in), replace.
Pinion of overrunning clutch should turn smoothly in clockwise direction, and should not slip in a counterclockwise direction. If defective, replace. Check pinion teeth for wear and damage. If defective, replace. NOTE: Always check engine ring gear teeth for wear and damage. If defective replace ring gear. Refer to ENGINE 04-04 then refer to Ring Gear.
ASSEMBLY
Reverse the order of disassembly to reassemble starter. However, attention should be paid to the following operations. Prior to assembling, coat sliding surfaces on armature shaft splines, overrunning clutch and bushing (717 engine) with G.E. Versilube G 341 M or ESSO Beacon 325 lubricant or equivalent. Apply motor oil on metal bushings.
A03E06A
08-08-5
4 1 2 3
F01H0SA A03E0EA
1. 2. 3. 4.
F01H0TA
To ease end frame installation, retain brush holder with a small screwdriver while installing end frame.
F01H0QA
08-08-6
12, Nut
Connect the RED battery cable to the starter and torque nut to 6 Nm (53 lbfin). Apply dielectric grease on terminal and nut.
x
1
WARNING
Always connect RED positive cable first then BLACK negative cable last. Whenever connecting the RED positive cable to the starter motor make sure the battery cables are disconnected to prevent electric shock.
F01H0UA
Align end frame notch with brush holder notch/ yoke protrusion.
CAUTION
STARTER INSTALLATION
Installation is essentially the reverse of removal procedure. However, pay particular attention to the following. Make sure that starter and engine mating surfaces are free of debris. Serious trouble may arise if starter is not properly aligned.
3-4 2
F01H1JA
TYPICAL 1. Torque to 6 Nm (53 lbfin) 2. Loctite 271 3. Torque to 22 Nm (16 lbfft) 4. Dielectric grease
13,17, Screw
Torque starter screws to 22 Nm (16 lbfft).
08-08-7
STARTER SPECIFICATION
Nominal output Voltage Rated time Rotation Weight Performance specification at 20C (68F) No load Load 0.6 kW 12 V 30 seconds Counterclockwise (viewed from pinion side) Approx. 2 kg (4.4 lb) 11.5 V 20 A max. 5500 RPM 2200 RPM 2200 RPM 0 RPM 0 RPM 2 Nm (18 lbfin) 2.2 Nm (20 lbfin) 3 Nm (27 lbfin) 3.2 Nm (29 lbfin)
717 engine: 8.5 V 170 A max. 787 engine: 8.5 V 170 A max.
Stall
08-08-8
BATTERY TROUBLESHOOTING
SYMPTOM: DISCHARGED OR WEAK BATTERY CAUSE 1. Battery posts and/or cable terminal oxidized. 2. Loose or bad connections. 3. Faulty battery (sulfated, doesnt keep a full charge, damaged casing, loose rectifier). REMEDY Clean and coat with dielectric grease. Check wiring and connector cleanliness, damaged or short circuit. Replace.
A
F04H15A
4. Charging system fuse First check charging burnt or faulty rectifier.* system generator coil. If it is in good condition replace fuse or rectifier. 5. Faulty charging system generator coil.** Replace.
*To test charging system, refer to CHARGING SYSTEM 08-07 then look for Current Test. **To test charging system generator coil, refer to CHARGING SYSTEM 08-07 then look for Charging System Generator Coil.
WARNING
Never charge or boost battery while installed in boat. Properly follow manufacturers instructions for the activation of a new battery.
SPECIFICATIONS
Exyde RV24-130, 25 Ah (130 minutes reserve minimum or RV24-160 (160 minutes) or equivalent.
REMOVAL
Unfasten top brace (retaining strap and remove battery box cover on Sportster).
WARNING
Never use automotive type battery. Its mechanical construction does not allow to meet the shock conditions where boats operate. Only use the type of battery recommended. The battery has to be purchased locally. Refer to following illustration for MAXIMUM allowed size.
WARNING
Battery BLACK negative cable must always be disconnected first and connected last. Never charge or boost battery while installed in boat. Electrolyte or fuel vapors can be present in engine compartment and a spark might ignite them and possibly cause personal injuries. Pivot retaining rods toward front and lay down (N/A to Sportster). Disconnect the BLACK negative cable first. Then disconnect the RED cable last.
08-08-9
Inspect for cracked or damaged battery caps (if applicable), replace defective caps.
WARNING
BATTERY TESTING
There are 2 types of battery tests: unloaded and loaded. An unloaded test is made on a battery without discharging current. It is the simplest and commonly used. A loaded test gives more accuracy of the battery condition.
Ensure to electrically isolate battery posts. This will prevent possible sparks when pulling battery out. Carefully pull battery out while leaning it as necessary. Take care not to touch tuned pipe with battery post.
Unload Test
Check charge condition using either a hydrometer or a multimeter. With a multimeter, voltage readings appear instantly to show the state of charge. Always respect polarity. A fully charged battery will have a reading of 12.6 Vdc. A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte. A fully charged battery will have a specific gravity between 1.265 to 1.280.
CLEANING
WARNING
Electrolyte is poisonous, dangerous and explosive. It contains sulfuric acid and can cause severe burns. Avoid contact with eyes, skin and clothing. Clean the battery casing, caps, cables and battery posts using a solution of baking soda and water. Remove corrosion from battery cable terminals and battery posts using a firm wire brush. Rinse with clear water and dry well.
INSPECTION
Visually inspect battery casing for cracks or other possible damage. If casing is damaged, replace battery and thoroughly clean battery rack (box on Sportster) with water and baking soda.
A17E0JA
WARNING
Should the battery casing be damaged, wear a suitable pair of non-absorbent gloves when removing the battery by hand. Inspect battery rack (box on Sportster) mounting and retaining rods (strap on Sportster) condition. Inspect battery posts for security of mounting.
A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte. Most hydrometers give a true reading at 21C (70F). In order to obtain correct readings, adjust the initial reading by adding .004 points to the hydrometer readings for each 5.5C (10F) above 21C (70F) and by subtracting .004 point for every 5.5C (10F) below 21C (70F).
08-08-10
OPERATION TO PERFORM .012 add .008 .004 correct reading .004 .008 subtract .012 .016
EXAMPLE NO. 2
Temperature above 21C (70F): Hydrometer reading: 1.235 Electrolyte temperature: 38C (100F) Add .012 Sp. Gr. Corrected Sp. Gr. is 1.247
Clean battery terminals and cable connections using a wire brush. Apply a light coat of dielectric grease on terminals. Clean battery casing and caps using a solution of baking soda and water. Rinse battery with clear water and dry well using a clean cloth. Store battery on a wooden shelf in a cool dry place. Such conditions reduce self-discharging and keep fluid evaporation to a minimum. Keep battery away from dew, high moisture and direct sunlight. During the storage period, recheck electrolyte level and specific gravity readings at least every month. If applicable, keep the battery at its upper level line. Keep near full charge as possible (trickle charge).
Load Test
This is the best test of battery condition under a starting load. Use a load testing device that has an adjustable load. Apply a load of 3 times the ampere-hour rating of the battery. At 14 seconds into the test, check battery voltage; if battery is in good condition, it will have at least 10.5 Vdc.
WARNING
Prior to charging the battery, always remove it from jet boat. For best results, battery should be charged when the electrolyte and the plates are at room temperature. A battery that is cold may not accept current for several hours after charging has begun. Do not charge a frozen battery. If the battery charge is very low, the battery may freeze. If it is suspected to be frozen, keep it in a heated area for about 2 hours before charging.
BATTERY STORAGE
Disconnect and remove battery from boat. Check electrolyte level in each cell, add distilled water up to upper level line (if applicable).
WARNING
Do not overfill.
CAUTION
Do not place battery near open flame. The time required to charge a battery will vary depending on some factors such as: Battery temperature: The charging time is increased as the temperature goes down. The current accepted by a cold battery will remain low. As the battery warms up, it will accept a higher rate of charge.
The battery must always be stored in fully charged condition. If required, charge until specific gravity of 1.265 is obtained.
CAUTION
Battery electrolyte temperature must not exceed 50C (122F). The casing should not feel hot.
08-08-11
State of charge: Because the electrolyte is nearly pure water in a completely discharged battery, it cannot accept current as well as electrolyte. This is the reason the battery will not accept current when the charging cycle first begins. As the battery remains on the charger, the current from the charger causes the electrolytic acid content to rise which makes the electrolyte a better conductor and then, the battery will accept a higher charging rate. Type of charger: Battery chargers vary in the amount of voltage and current that they can supply. Therefore, the time required for the battery to begin accepting measurable current will also vary.
If the charging current is measurable before the end or at the end of about 10 hours, the battery is good and charging should be completed in the normal manner. It is recommended that any battery recharged by this procedure be load tested prior to returning it to service.
A17E0PA
INSTALLATION
Challenger Model Apply electrical tape on battery posts.
WARNING
Ensure to electrically isolate battery posts. This will prevent possible sparks when installing battery. Carefully move battery in while leaning it as necessary. Take care not to touch tuned pipe with battery post.
08-08-12
All Models Position charged battery in rack (box on Sportster) so that the positive post is toward bow (front).
Properly route cables toward battery posts, between case and insulating foam. It may be necessary to re-route engine ground cable so that it is long enough to reach battery post.
All Models Apply dielectric grease on battery posts. Secure brace (box cover on Sportster).
1 2
Challenger Model Remove electrical tape from battery posts. All Models Connect RED positive (+) cable first then connect BLACK negative (-) cable last.
WARNING
F04H3IB
Battery positioning and cable routing will keep RED positive (+) cable away from tuned pipe. Connect RED positive (+) cable first then connect BLACK negative (-) cable last.
Sportster Ensure to position cables on battery so that they will properly fit with cover embosses. Firmly tighten post fasteners.
1 2 3 4
WARNING
Never secure electrical wires cables with fuel lines. Keep wires away from any rotating, moving, heating, vibrating or sharp edge. Use proper locking ties.
F04H16A
TYPICAL 1. Position cables to fit embosses of cover 2. Route cables between case and insulating foam 3. RED positive (+) cable here 4. Secure cables with locking tie here
08-08-13
Subsection 09
SUPPLEMENT
08-09-1
TABLE OF CONTENTS
JET PUMP .............................................................................................................................. GENERAL ........................................................................................................................... INSPECTION ON JET BOAT.............................................................................................. REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... PUMP PRESSURIZATION ................................................................................................. INSTALLATION .................................................................................................................. RIDE SHOE REMOVAL AND INSTALLATION.................................................................. REMOVAL FOR SINGLE-PUMP MODEL .......................................................................... CLEANING ......................................................................................................................... INSTALLATION.................................................................................................................. REMOVAL FOR TWIN-PUMP MODELS............................................................................ CLEANING ......................................................................................................................... INSTALLATION.................................................................................................................. JET PUMP SUPPORT REMOVAL AND INSTALLATION ................................................. DRIVE SYSTEM ..................................................................................................................... GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... LUBRICATION.................................................................................................................... REVERSE SYSTEM................................................................................................................ INSPECTION ...................................................................................................................... DISASSEMBLY................................................................................................................... ASSEMBLY......................................................................................................................... WEEDLESS SYSTEM ............................................................................................................
0
09-02-1 09-02-3 09-02-3 09-02-6 09-02-8 09-02-10 09-02-10 09-02-14 09-02-19 09-02-20 09-02-24 09-02-24 09-02-25 09-02-26 09-02-26 09-02-27 09-02-27 09-02-28 09-03-1 09-03-2 09-03-2 09-03-3 09-03-4 09-03-7 09-04-1 09-04-3 09-04-3 09-04-5 09-05-1
09-01-1
JET PUMP
Single-pump Model
The Right Stuff Gasket
17 Loctite 518
8 Nm (71 lbfin) 10
Loctite 271
3 4 Loctite 518
20 21 22 25 Loctite 271
F04J3TS
23
25 Nm (18 lbfft) 8
4 Nm (35 lbfin) 15
Loctite 242
Loctite 242
2 1 20 Nm (15 lbfft)
TYPICAL
PARTS
FLAT RATE
09-02-1
Twin-pump Models
The Right Stuff Gasket
Adchem sealant clear 10 Nm (89 lbfin) 10 The Right Stuff Gasket 9 14 13 Loctite 518 Synthetic grease Loctite PST 592 The Right Stuff Gasket 19 20 18
10 Nm (89 lbfin) Adchem sealant clear Loctite 271 Loctite 242 6 5 33 Nm (24 lbfft) Loctite 518 7 3
24
20
70 Nm (52 lbfft) Loctite 518 25 Nm 23 8 (18 lbfft) Loctite 242 20 Nm 1 (15 lbfft) 15 4 Nm 16 (35 lbfin)
13 Nm (115 lbfin)
F04J3US
TYPICAL
09-02-2
PARTS
FLAT RATE
GENERAL
Some pump components can be changed to improve boat performance in high altitude regions between 1500 - 3000 m (5000 - 10 000 ft). Refer to the service department for the latest specifications.
Always remove safety lanyard from DESS post to prevent unattended engine starting prior to working on the jet pump/ride shoe.
WARNING
CAUTION
Such modifications should only be performed by experienced mechanics since they can greatly affect vehicle performance. The jet pump housing and venturi are made of plastic.
Impeller Identification
To identify the impellers refer to the following illustration and chart.
Sacrificial Anode
Check sacrificial zinc anode for oxidation and replace if required (some models only).
1
Impeller Condition
Condition of impeller, boot and ring can be quickly checked from underneath of the jet boat. Lower grill and look through water inlet opening.
F02J0VA
1
BOAT MODEL Sportster Challenger IMPELLER MATERIAL P/N 271 000 416 271 000 821 PITCH
Stainless Progressive steel pitch Stainless Progressive steel pitch Stainless Progressive steel pitch Stainless Progressive steel pitch
F01J0DA
Sportster 1800 271 000 885 Challenger 1800 204 160 039
09-02-3
Using a long feeler gauge 30 cm (12 in) blades, measure clearance between impeller blade tip and wear ring. Measure each blade at its center. Clearance should not exceed 1.02 mm (.040 in). If clearance is greater, disassemble jet pump and inspect impeller and wear ring. Renew worn parts.
Oil Inspection
Venturi Removal Detach adjuster of steering cable from nozzle (required only if removal is for RH side of twin-pump models). Detach ball joint of shifter cable from reverse gate (required only if removal is for RH side of twinpump models). Remove speedometer sensor (if necessary) from ride shoe. Detach steering link rod from nozzle (twin-pump models only). Detach reverse gate link rod from RH reverse gate (required even if you are working on LH side on twin-pump models only).
F01J0EA
F04J2NA
1. Detach
F01J0FA
Remove reverse gate support (with gate), venturi and nozzle assembly from impeller housing. NOTE: If you are removing parts on LH side, the reverse gate link rod may be kept with the reverse gate.
09-02-4
F02J0TB
1. Screws
F01J5IA
1. Remove plug
Check oil level, it should be at bottom of hole threads. If oil level is low, check impeller shaft housing for leaks. A pressure test must be performed. Refer to Pump Pressurization in this section. To check oil condition, insert a wire through opening then withdraw. A whitish oil indicates water contamination. This may involve defective impeller shaft seal and/or O-ring of housing cover. Jet pump unit should be overhauled to replace seal. If everything is correct, apply Loctite PST 592 on plug and reinstall it on cover. Properly reinstall removed parts.
Using a fiber hammer, gently tap cover to release it from housing. Be careful as cover is spring loaded. Thoroughly clean reservoir and inside of cover with a solvent. Check O-ring condition. Replace as necessary. Apply a thin layer of Loctite 518 on mating surface of cover and reinstall it with its O-ring. Torque screws to 4 Nm (35 lbfin). Remove plug from cover. Pour 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 center area of housing, wait a few minutes and readjust oil level.
Oil Replacement
Remove parts as described in Oil Inspection. Remove 3 screws retaining cover.
CAUTION
This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands. Apply Loctite PST 592 on plug and reinstall it on cover. Properly reinstall removed parts.
09-02-5
REMOVAL
Disconnect adjuster of steering cable from nozzle (refer to Oil Level Inspection above for more details pertaining to twin-pump models).
F04H2XA
NOTE: At this point, impeller housing can be removed as an assembly with nozzle and venturi/ reverse gate support. Refer to Impeller Housing below.
F04K0MA
TYPICAL
4, Nozzle
Remove 2 retaining screws and withdraw nozzle (refer to Oil Level Inspection above for more details pertaining to twin-pump models). Push sleeves and bushings out of nozzle.
Remove ball joint fasteners to release reverse cable from reverse gate.
7, Venturi
Remove nozzle no. 4 prior to removing venturi (refer to Oil Level Inspection above for more details pertaining to twin-pump models). Remove 4 retaining screws and withdraw venturi.
F04K0KA
TYPICAL
F04J2OA
1. Remove screws
09-02-6
6, Impeller Housing
NOTE: In the following procedure, impeller housing is removed as an assembly with nozzle and venturi/reverse gate support.
If pump is hard to remove, use a curved pry bar, apply electrical tape around the curved end in order to protect hull and pry to remove pump.
Single-pump Model From inside bilge, disconnect coolant inlet hose from impeller housing.
F04P0LA
F04E0NA
All Models Disconnect adjuster of steering cable from nozzle (refer to Oil Level Inspection above for more details pertaining to twin-pump models). Remove ball joint fasteners to release reverse cable from reverse gate. Remove nuts retaining impeller housing to hull.
CAUTION
Some boats may be equipped with shims. Ensure to note location of these shims at removal for reinstallation purposes.
F04L52A
F04J2PA
NOTE: If jet pump cannot be removed, the drive shaft may be seized in the impeller splines. Refer to PROPULSION SYSTEM 09-04 to remove drive shaft at the same time. If ride shoe needs to be removed, refer to Ride Shoe Removal and Installation at the end of this section.
09-02-7
Single-pump Model Remove spacer ring from ride shoe only if leakage is suspected (ventilation problem).
15, Cover
With pump assembly in horizontal position, remove 3 retaining screws. Place container under cover to catch oil. Using a fiber hammer, gently tap cover to release it from impeller housing. Be careful as cover is spring loaded.
DISASSEMBLY
All Models NOTE: Whenever removing a part, visually check for damage such as: corrosion, crack, split, break, porosity, cavitation, deformation, distortion, heating discoloration, wear pattern, missing plating, missing or broken needle on needle bearing, water damage diagnosed by black-colored spots, etc. Renew any damaged part. As a quick check, manually feel clearance and end play, where applicable, to detect excessive wear.
17, Impeller
Insert impeller shaft holder (P/N 295 000 082) on impeller shaft flat end. Using 2 screws previously removed from venturi, secure shaft holder to housing.
24, Fitting
Fitting can be removed with deep socket or vise grip (not required on twin-pump models). Do not touch hose mounting area. Fitting can be removed from pump housing with following suggested tool: Use a 14 mm (9/16 in) deep socket. Drill deep socket with a 14 mm (9/16 in) drill bit, starting at hexagon head end as shown in following illustration. Drill a 2.40 mm (3/32 in) hole in center of deep socket as shown in following illustration. Install 2.40 mm (3/32 in) roll pin in the center hole.
F00J07A
1. Shaft holder
A 1
To ease removal heat impeller center with a propane torch to approximately 150C (300F) to break the Loctite bond. Impeller is loosened using impeller remover tool (P/N 295 000 001). Install shaft holder in a vice.
B 2
F01J2RA
1. 2. A. B.
Deep socket 14 mm (9/16 in) Roll pin 2.40 mm (3/32 in) 42.50 mm (1-43/64 in) 36.80 mm (1-29/64 in)
09-02-8
NOTE: Wear ring can be cut using a jigsaw, a small buffer or a low clearance hacksaw such as Snap-on HS3 or equivalent.
CAUTION
F00J0HA
Impeller is loosened using impeller remover tool (P/N 295 000 001).
1
F01J0VA
TYPICAL
F00J08A
CAUTION
F01J0WA
Never use any impact wrench to loosen impeller. To remove impeller, apply a rotating movement and pull at same time. Slide impeller out of housing and remove tool from impeller.
1. Snap-on HS3
After cutting ring, insert a screwdriver blade between impeller housing and ring outside diameter. Push ring so that it can collapse internally. Pull ring out.
F01J11A
Insert bearing remover then press tool using a arbor press until seal and bearings are out. However, care should be taken not to damage bearing journals.
F01J13B
Brush and clean impeller shaft threads, impeller and drive shaft splines with Loctite Safety solvent 755 (P/N 293 800 019) or equivalent. Free threads and splines from any residue.
CAUTION
Single-pump Model If the spacer ring has been removed from ride shoe, clean spacer ring and ride shoe area with acetone.
F00J0MA
INSPECTION
All Models
NOTE: It is always recommended to renew both bearings, even if only one bearing needs to be replaced.
17, Impeller
Visually inspect impeller splines. Check for wear or deformation. Renew parts if damaged. NOTE: Check also PTO flywheel and drive shaft condition. Refer to PROPULSION SYSTEM 09-04. Examine impeller in wear ring for distortion. Check if blade tips are blunted round, chipped or broken. Such impeller is unbalanced and will vibrate and damage wear ring, impeller shaft, shaft seal or bearings. Renew if damaged.
CLEANING
Sealant can be removed with a wire brush (disc) mounted on a drill or a scraper (not required on twin-pump models). Properly clean all threads. Remove 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 clear.
09-02-10
F02J0VB
Check impeller for cavitation damage, deep scratches or any other damage.
F02J0UA
F01J18A
MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to threads at shaft end
09-02-11
To check both bearings, proceed the same way with other shaft end. Position gauge tip on diameter, close to flats on shaft.
1
NOTE: If shaft is to be replaced, it is recommended to replace both bearings at the same time. In addition, it is suggested to replace thrust bearing and thrust washer.
F01J19A
MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to flats at shaft end
Excessive play can come either from worn bearings or impeller shaft or damaged impeller housing bearing surfaces. Measuring shaft diameter will determine defective part. Using a micrometer, measure diameter on bearing contact surfaces. Minimum shaft diameter should be 22.24 mm (.876 in).
1
F01J52A
TYPICAL 1. Worn roller (trunnion worn on end of roller) 2. Good roller (cylindrical shape) 3. Look for scoring on retainer
F01J1AA
09-02-12
1
F00J0QA
Excessive play comes from worn protrusion inside housing cover and wear of impeller shaft nose. Using pliers, remove anti-knock pusher and spring from cover.
Pusher should be replaced if it is not within specification. Be sure to check end play after installing a new pusher. Inspect impeller shaft nose for wear.
F00J09A
F00J0AA
19, Seal
Carefully inspect seal lips. Make sure that lips are not worn, distorted, cracked or present any other damages. Renew as necessary.
Inspect pusher for any damage or deterioration. Refer to the following illustration to determine the wear limit of the pusher.
09-02-13
ASSEMBLY
The jet pump and all its components are the same on port and starboard (LH/RH).
2 1
F01J5EA
2
F01J4KA F01J5DA
If a press is not readily available, a piece of wood, such as a 2 x 4 x 12 in long, can be used. Manually engage ring in housing making sure it is equally inserted all around. Place wood piece over ring. Using a hammer, strike on wood to push ring. Strike one side then rotate wood piece about 90 and strike again. Frequently rotate wood piece so that ring slides equally all around until it seats into bottom of housing.
Stamped end of bearings (showing identification marks) must be located toward outside of housing. Properly insert bearing on tool. Using an arbor press only, push tool until tool flange contacts housing. Proceed the same way for both bearings.
09-02-14
Bearing on impeller side must be 1.5 to 2.5 mm (.060 - .100 in) inside reservoir measured from seal seat. Bearing on venturi side must be 2 to 3 mm (.080 - .120 in) inside reservoir measured from thrust washer seat. Refer to following illustration.
A 1 2
B 3 4
F01J1HA
CAUTION
F01J1JA
Seal must be installed so that lips raised edges are toward outside of housing (toward impeller). Apply Loctite 518 in seal housing, 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 bearing/seal installer tool. Properly insert tool in seal with a rotating movement.
F00J0BA
CAUTION
This tool has been designed to properly position bearings and seal, thus providing space for lubrication purposes. The tool flanges allow this. If a different pusher type is being used, components must be properly positioned as follows.
1
F01J1KA
09-02-15
CAUTION
Prevent sealant from contacting any needle of bearing. Push on tool end with a press until tool flange contacts housing.
F00J0DA
Apply synthetic grease (P/N 293 550 010) between seal lips.
1
F00J0EA
F01J1MA
1. Loctite 518 all around and behind 2. Raised edge of seal lip this side
09-02-16
Insert tool onto shaft end then carefully install shaft in impeller housing.
Using 2 screws previously removed from venturi, secure impeller shaft holder tool to housing. Install shaft holder tool in a vice.
F00J0FA
NOTE: If jet impeller housing rests against a table, raise it slightly to allow complete shaft insertion with the shaft guide. Remove shaft guide.
F00J0HA
17, Impeller
Apply Loctite primer N (P/N 293 600 012) on impeller shaft threads. Allow to dry for 2 minutes. NOTE: Loctite primer is used to reduce Loctite 271 curing time and to activate stainless steel and aluminum surfaces for better bonding action. If applied, complete curing time is 6 hours, if primer is not used, allow 24 hours for curing time. Apply Loctite 271 (red) to shaft threads.
To ease impeller installation, apply liquid soap on wear ring. Insert impeller into wear ring. Manually rotate impeller and push so that it slides on impeller shaft threads. Carefully engage threads making sure they are well-aligned. Install impeller remover/installer tool into impeller splines and tighten.
1
F00J08A
F00J0GA
09-02-17
CAUTION
Make sure thrust washer and bearing are not wedged in shaft groove. To check, manually pull and push impeller housing, some axial play must be felt. Torque impeller to 70 Nm (52 lbfft) then remove tools.
CAUTION
Never use any impact wrench to tighten impeller. Apply synthetic grease (P/N 293 550 010) on impeller splines. Insert a new boot no. 13 and ring no. 14 to impeller.
2 1
F00J0PA
Install cover to impeller housing making sure to properly position filler plug on top side.
F00J0IA
1
F01J5IA
1. Boot and ring 1. Filler plug toward top side of pump housing
15, Cover
Install O-ring no. 23 to cover. Apply Loctite 518 on O-ring. Make sure spring and anti-knock pusher are in place.
Apply Loctite 242 (blue) on screw threads and evenly tighten cover screws. Torque to 4 Nm (35 lbfin).
09-02-18
Oil Fill NOTE: It is highly recommended to perform a leakage test prior to adding the oil. Refer to PUMP PRESSURIZATION in this subsection. Place housing horizontally as in its operating position so that filler plug is located on top. Remove filler plug from cover. Pour SEA-DOO JET PUMP SYNTHETIC OIL (P/N 293 600 011) in reservoir until oil comes level with bottom of hole. Let oil drain into housing and after a few minutes add more oil until it is level with bottom of filler hole.
CAUTION
F04J2OA
This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands. NOTE: When filling reservoir, oil must be poured into cover quite slowly to allow complete housing fill.
24, Fitting
Apply Loctite PST 592 on plastic fitting threads. Then thread fitting into pump housing until threads are bottomed.
PUMP PRESSURIZATION
Whenever doing any type of repair on the pump, pressure test should be done to check for any leakage. Proceed as follows: Remove drain plug from housing cover. Apply Loctite PST 592 on threads fitting tool (P/N 295 000 086) then secure on cover. Connect pump gauge tester (P/N 295 000 083) to fitting. Pressurize pump to a maximum of 70 kPa (10 PSI).
F00J0JA
TYPICAL 1. Pour oil slowly until it is level with bottom of filler hole
7, Venturi
Apply Loctite 518 on mating surface. Position venturi with bailer passages on top. Install reverse gate support (with gate). Apply Loctite 242 (blue) on threads of screws no. 8. Install screws no. 8, lock washers and flat washers then torque to 21 Nm (16 lbfft).
F00J0LA
09-02-19
CAUTION
Repair any leak, failure to correct a leak will lead to premature wear of pump components. NOTE: If there is a pressure drop, spray soapy water around housing cover. If there are no bubbles, impeller shaft, impeller shaft seal, or impeller housing is leaking through porosity and has to be replaced. Jet pump unit has to be disassembled if jet pump has been overhauled, the impeller shaft seal no. 19 may be leaking; add a small quantity of Sea-Doo jet pump synthetic oil to wet the oil seal. Let soak and recheck. Disconnect pump gauge tester and remove fitting. Check oil level. Refill as necessary. Apply Loctite PST 592 on plug threads then secure it on cover.
F04L58A
Install spacer ring on ride shoe (side coated with the Right Stuff Gasket against ride shoe).
INSTALLATION
NOTE: It is recommended to apply the Right Stuff Gasket at a temperature within 5-27C (40-80F).
Single-pump Model NOTE: If a repetitive ventilation problem is experienced on a craft, follow the procedure titled Special Installation Procedure for a Repetitive Ventilation Problem. Otherwise, follow the procedure titled Regular Installation Procedure.
F04L59A
09-02-20
All Models
Miscellaneous
Generously apply synthetic grease (P/N 293 550 010) on drive shaft splines. Make sure rubber damper is on drive shaft end. Apply the Right Stuff Gasket on pump as shown in the following illustration.
1
CAUTION
Some boats may have a shim between hull and pump, if shim has been removed ensure to reinstall it. If not installed, engine and jet pump alignment will be altered.
F04J0CB
F01J50A
Ensure drive shaft protector tube is properly installed. While holding pump, guide and engage drive shaft splines in impeller. Wiggle pump if necessary. NOTE: As an alternative method if you experience difficulties, you may release the small clamp on PTO flywheel to withdraw drive shaft. Refer to DRIVE SYSTEM 09-03. Insert drive shaft in impeller splines then insert drive shaft (with the pump) in PTO flywheel. Properly reinstall components. If necessary, carefully tap pump end with a rubber hammer until retaining nuts and washers can be installed. Apply Loctite 242 (blue) on threads and equally tighten nuts in a criss-cross sequence and torque to 33 Nm (24 lbfft).
09-02-21
Single-pump Model From inside of bilge, secure water supply hose to impeller housing.
1
All Models Apply BOMBARDIER LUBE lubricant (P/N 293 600 006) on bushings. Insert bushings in nozzle, positioning their flanges from inside of nozzle (when applicable). Install nozzle on venturi, position its steering arm on RH side. Apply Loctite 242 (blue) on threads. Install screws then torque to 25 Nm (18 lbfft). Reinstall adjuster of steering cable and ball joint of reverse cable. Torque bolts to 7 Nm (63 lbfin).
F04J0YA
1. Reconnect
F04J04B
F04J2NB
TYPICAL 1. Embossment
F04J0DA
09-02-22
NOTE: Ball joint must be parallel with cable lever. If not, loosen jam nut and adjust ball joint. Torque jam nut to 2.5 Nm (23 lbfin). Reinstall speedometer sensor (if removed) to ride shoe. Attach speedometer sensor cable to hook on starboard side (right) of pump. Secure using a small locking tie.
Slightly lubricate wear ring with a soapy solution before starting to minimize friction during initial start. Manually rotate the PTO flywheel to ensure impeller rotates freely. If flywheel does not rotate, perform the following procedure. Loosen the 4 nuts retaining impeller housing enough to remove pressure, (approximately 1 turn). Generously apply BOMBARDIER LUBE lubricant (P/N 293 600 016) in impeller housing to minimize friction during initial start. Start engine. Run engine for a few seconds to allow impeller to make its way into the wear ring.
F04L5AA
CAUTION
1. Locking tie
Reinstall reverse gate link rod to RH reverse gate (twin-pump models only). Reinstall steering link rod to nozzle (twin-pump models only). Check steering alignment. Refer to STEERING SYSTEM 10-03.
Run engine at idle speed only. If engine is to be ran more than a few seconds, engine must be water cooled with a garden hose through the flushing fitting. Gradually tighten nuts of impeller housing in a criss-cross sequence and torque to 33 Nm (24 lbfft). NOTE: Repeat procedure for both impellers if such is the case. Test run boat.
09-02-23
CAUTION
Removing ride shoe will possibly damage it. Remove only when it is absolutely necessary. NOTE: If ride shoe is removed for a ventilation problem, ensure it is not a cavitation problem. Also make sure the ventilation does not come from the jet pump sealing, a leakage of the through-hull fitting/drive shaft boot, weedless cable/housing or ride shoe fasteners. Refer to TROUBLESHOOTING 03-01 for more information. To provide access for removing ride shoe, lift bow and partially move boat off back of trailer. Use a lift kit, see table below. Refer to the kit instruction sheets for proper use.
BOAT MODEL 14 feet 18 feet KIT P/N 205 000 160 205 100 045
Tools Required
bottle jack 2 heat guns 2 high x 3 wide x 24 long wood board 2 high x 6 wide x 10 long wood board Remove six screws retaining ride shoe to boat. Ensure to position the end closest to the front of the boat beneath the through-hull fitting and above the intake grate. Install the bottle jack on the wood board, then insert the other wood board above the jack, beneath the boarding deck.
F04L2DB
1
F04P0MA
Always remove safety lanyard from DESS post to prevent unattended engine starting, prior to working on the jet pump/ride shoe.
WARNING
Always work in a well-ventilated area. Electrolyte or fuel vapors may be present in the vicinity.
WARNING
09-02-24
Using heat guns, warm the entire ride shoe surface evenly while slowly pumping the jack.
F04P0NA
NOTE: It may take anywhere from 15 to 30 minutes for the ride shoe to separate from hull.
F04L56A
TYPICAL
CAUTION
It is imperative not to rush this procedure. Do not pump jack too quickly in order to avoid damaging ride shoe. Allow time for sealant bond to unstick. Once the ride shoe separates from hull, its surface will be very hot. Allow sufficient time for it to cool down prior to cleaning.
Clean ride shoe and hull using acetone. Ensure to eliminate grease, dust and any remaining loose sealant.
Handle ride shoe with care, its temperature will be excessively hot.
WARNING
CLEANING
Scrape all excess of sealant from ride shoe and hull.
F04L57A
Apply paint to any unpainted/scraped surfaces using PPG paint, black 9551 (aluminum ride shoe only). This will prevent corrosion.
09-02-25
INSTALLATION
NOTE: It is recommended to apply the Right Stuff Gasket at a temperature within 5-27C (40-80F). Apply a 6 mm (1/4 in) thick seam of the Right Stuff Gasket (P/N 293 800 053) on ride shoe while paying close attention to the routing shown on the following illustration.
Tools Required
2 pry bars, approx. 46 cm (19 in) in length phillips head screwdriver hammer scraper NOTE: Jet pump and intake grill do not need to be removed. Lower intake grill with the weedless system lever. Remove six bolts that are retaining ride shoe to hull. The ride shoe is assembled to the hull with bolts instead of screws. You will need a person to hold the nuts from the bilge while removing the bolts under the hull. The nuts are located each side of the water channel at the back.
F04J3VA
Install ride shoe on boat within 3-4 minutes after having applied the Right Stuff Gasket. Apply Loctite 242 (blue) to ride shoe screw threads. Install screws and torque to 10 Nm (88 lbfin). Remove remaining sealant from intake. Reinstall jet pump as described earlier in this section.
CAUTION
F04L4UA
Allow sealant to cure 12 hours when using the Right Stuff Gasket before putting boat in water.
NOTE: It may be necessary to heat ride shoe in order to remove it. Insert pry bars between hull and ride shoe. Tap ends of pry bars gently and alternately until the sealant bond breaks.
09-02-26
F04L4VA
F04L4XA
Apply a slight downward pressure on pry bars until sealant releases and ride shoe separates from boat.
INSTALLATION
NOTE: It is recommended to apply the Right Stuff Gasket at a temperature within 5-27C (40-80F). Apply a 6 mm (1/4 in) thick seam of the Right Stuff Gasket (P/N 293 800 053) on ride shoe while paying close attention to the routing shown on the following illustrations.
CLEANING
Scrape all excess of sealant from ride shoe, hull and pump support.
F04J3WA
F04L56A
TYPICAL
Clean hull using acetone. Clean plastic ride shoe and pump support using isopropyl alcohol. Let the cleaner evaporate completely. Ensure to eliminate grease, dust and any remaining loose sealant.
09-02-27
Insert arm up through intake opening from beneath boat and using a finger, spread excess sealant that is lodged between the hull and ride shoe. Apply the Right Stuff Gasket around screw holes on flat surface of intake grate.
CAUTION
Allow sealant to cure 12 hours when using the Right Stuff Gasket before putting boat in water.
F04J3XA
F04L50A
Install within 3-4 minutes after having applied the Right Stuff Gasket. Apply the Right Stuff Gasket around screws and on the taper of the screw head. Torque screws to 10 Nm (88 lbfin) in a criss-cross sequence while someone is holding the nuts from inside the bilge. Apply clear silicone on nuts inside bilge to have a water tight seal.
09-02-28
Installation NOTE: It is recommended to apply the Right Stuff Gasket at a temperature within 5-27C (40-80F). Apply the Right Stuff Gasket onto jet pump support as per the following illustrations.
F10J01A
F10J02A
09-02-29
DRIVE SYSTEM
Synthetic grease 10 13
F04J3YS
PARTS
FLAT RATE
09-03-1
GENERAL
Jet pump must be removed to replace any components of the drive system. Refer to PROPULSION SYSTEM 09-02 for jet pump removal procedure.
REMOVAL
Remove PTO flywheel guard.
1, Large Clamp
Unfasten large clamp of PTO flywheel boot as follows: Use pliers (P/N 295 000 069).
1
F01J29A
2, Small Clamp
F01J0GA
Unfasten small clamp of PTO flywheel boot as follows: Use pliers (P/N 295 000 054).
F01B1TA
To open clamp, place flat side of plier on clamp embossment, squeeze and twist plier.
F01J2AA
Squeeze pliers to draw hooks together and disengage windows from locking hooks.
F02J0PA
09-03-2
8, Carbon Ring
Loosen gear clamp no. 12 then pull carbon ring from protective boot.
INSPECTION
All Models
3, Drive Shaft
Inspect condition of drive shaft and PTO flywheel splines. Inspect condition of groove. With your finger nail, feel machined surface of drive shaft. If any irregular surface is found, renew drive shaft.
F04I02A
1 2
F01I0FA
3, Drive Shaft
Pull out drive shaft. NOTE: If the drive shaft is jammed into PTO flywheel, a hammer puller can be used to withdraw drive shaft.
7, Protective Boot
Loosen gear clamp no. 6 holding protective boot, then carefully pull hose and carbon ring no. 8 from hull insert.
Excessive deflection could cause vibration and damage to drive shaft splines, impeller, flywheel or floating ring. Place drive shaft on V-blocks and set-up a dial gauge in center of shaft. Slowly rotate shaft; difference between highest and lowest dial gauge reading is deflection. Refer to the following illustration.
09-03-3
10, Damper
Install damper no. 10 on drive shaft no. 3. NOTE: Make sure dampers were not left in PTO flywheel or impeller.
1
F01J15A
CAUTION
10, Damper
Visually inspect shape of dampers for deformation or other damage.
Grease on the carbon seal, floating ring or O-ring may cause O-ring to dislodge from the groove and slide on the drive shaft which may allow water leakage. Always wipe off any grease.
3, Drive Shaft
Insert drive shaft in through-hull fitting but temporarily keep a gap between shaft end and PTO flywheel.
CAUTION
Do not apply grease on drive shaft splines. Lubrication will be done later from the PTO flywheel grease fitting. Insert floating ring no. 4 on drive shaft. Engage drive shaft splines in PTO flywheel. NOTE: If shaft is difficult to insert into flywheel boot, a small quantity of grease can be applied INSIDE the boot. Rotate shaft to properly index splines. Make sure boot is well-positioned over shaft end.
F01I0GA
ASSEMBLY
Assembly is essentially the reverse of disassembly procedure. However, pay particular attention to the following.
09-03-4
If the difference is less than 8 mm (5/16 in), a spacer is required (see next paragraph). Otherwise, continue with the installation of clamps (see below). Unlock and pull out drive shaft to install one spacer between protective boot and hull on throughhull fitting.
1
1
F00J03A
TYPICAL DO NOT READ THE RULER FROM THE PHOTOGRAPH 1. Measuring free length of protective boot A. Measure between carbon ring and through-hull fitting
F00J04B
CAUTION
TYPICAL 1. Spacer
Take care not to break the O-rings in the floating ring while inserting the drive shaft. Insert circlip no. 5 in groove of shaft.
1 2
Reinstall parts and verify compressed length of boot another time. If everything is within the specification, continue with the installation of clamps (see below). Otherwise, call your service representative.
1, Large Clamp
Secure large clamp no. 1 as follows: Use pliers (P/N 295 000 069) as for removal. Manually engage holding hook in large window. This is a pre-clamping position only.
1
F06I06A
Measure the compressed length (installed parts) of the protective boot (between carbon ring and through-hull fitting). Note the measurement. Subtract the compressed length from the free length.
2
F01J23A
2
F01J23B
2, Small Clamp
F01J2BA
To secure small clamp no. 2, place notch side of plier on clamp embossment and squeeze plier.
1
Squeeze pliers. When both large and small windows are directly over the 2 locking hooks, press those windows down to engage hooks in windows.
1
F02J0PB
1. Squeeze plier
F02J0IA
09-03-6
LUBRICATION
Using a grease gun, carefully lubricate PTO flywheel with synthetic grease (P/N 293 550 010), until boot is just beginning to expand. At this point, immediately stop greasing.
F01I0BB
09-03-7
REVERSE SYSTEM
Single-pump Model
Loctite 242
Loctite 242
Loctite 242
Loctite 242 1
F04J3ZS
Loctite 242
TYPICAL
PARTS
FLAT RATE
09-04-1
Twin-pump Models
Loctite 242
Loctite 242
Loctite 242
Loctite 242
Loctite 242
F04J40S
TYPICAL
09-04-2
PARTS
FLAT RATE
INSPECTION
Check all moving parts and bushings for wear, straightness, corrosion and free movement. Replace parts as required.
DISASSEMBLY
1, Reverse Gate Support
For additional information, refer to JET PUMP 0902. Detach steering/shifter cables. Detach steering link rod from nozzle (twin-pump models only). Detach reverse gate link rod from RH reverse gate (required even if you are working on LH side on twin-pump models).
F04J1WA
F04J1XA
F04J2NA
1. Detach
Remove reverse gate support (with gate), venturi and nozzle assembly from impeller housing. NOTE: If you are removing parts on LH side (twin-pump models), the reverse gate link rod may be kept with the reverse gate.
Remove reverse gate to give access to the remaining screw of link rod.
Latching Mechanism
All Models Note that the latching mechanism is installed on RH reverse gate on twin-pump models. Remove screw to detach lever.
09-04-3
For installation, install lever in a vise and apply some BOMBARDIER LUBE in lever hole. Properly position reverse gate and carefully insert roll pin with a hammer.
CAUTION
Failure to properly hold lever in a vise may lead to damages to the reverse gate or the lever.
F04J1YA
Carefully install reverse gate in a vise with a socket underneath tab holding roll pin.
CAUTION
1 2
Failure to properly support tab of roller pin will lead to damages to the reverse gate. Remove lever using a small punch and carefully pushing roll pin out.
F04J20A
If the pawl-stop needs to be replaced, drill rivets out with a 4.8 mm (3/16 in) drill bit.
2 1
F04J1ZA
1. Socket to support tab of roll pin 2. Carefully punch roller pin out
F04J21A
NOTE: If roll pin cannot be removed this way, a small cutting disk can be used.
09-04-4
F04J22A
Fully push shifter in forward position. A latching sound should be heard. Try pulling reverse gate down manually. It must be locked by the latching mechanism.
F04J23A
ASSEMBLY
All Models Prior to assembling moving parts, lubricate with synthetic grease. Reinstall steering link rod and reverse link rod (twin-pump models only) steering and shifter cables. Refer to STEERING SYSTEM 10-03 then look for Alignment. Ensure that steering cable ball joints are parallel with cable lever.
2
F04J06A
TYPICAL IN FORWARD POSITION 1. Must be locked when manually pulling downward 2. Latching mechanism
09-04-5
CAUTION
Use a protective mat (P/N 295 000 129) in shifter area when withdrawing it for adjustment.
F04L7KA
09-04-6
WEEDLESS SYSTEM
14-foot boats
Loctite 242 Synthetic grease Loctite 242 8 Nm (71 lbfin) Loctite 242
Synthetic grease
7 Nm (62 lbfin)
18-foot boats
10 Nm (89 lbfin)
PARTS
FLAT RATE
09-05-1
Intake Grill
Lower the grill and grab it with a hand to feel the play. If excessive, replace bushings. Detach cable adjuster. Remove retaining screws to withdraw grill.
Pull lever out while holding locking block so that it does not fall. Detach weedless mechanism from body by removing retaining screws.
2 1
F04J27A
At assembly, ensure to apply the Right Stuff Gasket between hull and grill base as well as inside screw holes. Torque screws to 6 Nm (53 lbfin). Apply Loctite 242 on fasteners as shown in exploded view. Torque screw to 7 Nm (62 lbfin).
Detach cable(s) from weedless system support. NOTE: Be careful not to drop parts when disassembling fasteners. There are spacers and washers in the mechanism.
F04J29A
F04J28A
09-05-2
F04J2AA
F04J2CA
All Models Inspect parts for wear, bending or other damage. Replace parts as necessary. Inspect locking block for wear/damage where shown.
Ensure plate pivots easily after tightening nut. Slightly loosen nut as necessary.
1
F04J2DA
4 3
F04J2BA
Assembly is essentially the reverse of disassembly. However, pay attention to the following. Apply synthetic grease to all moving parts. Apply Loctite 242 on threads of fasteners as shown in exploded view.
CABLE ATTACHMENT (LH CABLE ON TWIN-PUMP MODELS) 1. Cable end 2. Steel washer 3. Nylon washer 4. Spacer
09-05-3
Twin-pump Models
F04J2GA
3 2 1
Reinstall weedless system support to body. Install lever with its open end as shown.
F04J2FA
F04J26B
1. Detach cable
09-05-4
Remove cable adjuster from cable. From inside of bilge, unscrew nut.
F04J2HB
1. Position of housing
F04J2HA
1. Unscrew nut
Pull cable out. From front storage compartment (RH side on Challenger 1800 models), detach cable from weedless system support.
Twin-pump Models It is necessary to detach support plate from body to allow removal of RH cable. All Models Tape the rear end of the old cable to the end of the new cable. Pull the old cable from the front to allow the installation of the new one. NOTE: If necessary, the RH cup holder may be removed to reach the cable. Do not remove the cable housing from the hull needlessly. If removal has been done, proceed with the following procedure. Scrape sealant from hull and cable housing. Sand hull surface using a sand paper to completely remove the sealant. Clean surfaces with acetone or oil-free cleaner (use isopropyl alcohol on plastic parts). Apply the Right Stuff Gasket on the hull surface taking care to seal around holes and inside holes. Reinstall cable housing to hull as shown.
Generously apply the Right Stuff Gasket around screws and particularly on the taper of the screw heads. Secure screws making sure the Right Stuff Gasket makes a water tight seal around the screws. Assembly is essentially the reverse of disassembly. However, pay attention to the following. Apply sealant and Loctite 242 on parts and torque fasteners as shown in exploded view.
1
F04J2IA
PARTS INSTALLATION IN CABLE HOUSING 1. Nut 2. Half-rings 3. Grommet 4. The Right Stuff Gasket 5. Apply synthetic grease on the sliding portion of cable (into grommet)
Hand-tighten nut until it bottoms then give an additional half a turn. When installing cable adjuster, position it half-way of the threaded length. When installing cable to weedless system support (in front), position cable housing half-way of the threaded length. Perform cable adjustment as described below.
09-05-5
Cable Adjustment
Adjustment at Intake Grill A small adjustment can be made here. If it cannot be reached here, perform it at the lever mechanism as explained below. When weedless lever is fully pushed in, the water intake grill must be fully lifted. Ensure there is no gap. At this point, the weedless system lever must be locked when pulling lever WITHOUT TURNING (contrarily to its normal use). This will validate the operation of the locking mechanism.
If adjustment is required, unscrew cable adjuster, loosen lock nut and turn adjuster as necessary. After adjustment, ensure to apply Loctite 242 and torque fasteners as shown in exploded view. Adjustment at Weedless Lever Mechanism When a proper adjustment cannot be reached at intake grill level, adjust cable housing at the weedless lever mechanism as necessary.
F04J29B
F04J2JA
09-05-6
TABLE OF CONTENTS
STEERING SYSTEM .............................................................................................................. STEERING SYSTEM INSPECTION ................................................................................... STEERING CABLE REPLACEMENT .................................................................................. LOW-SPEED STEERING CONTROL SYSTEM CABLE REPLACEMENT ......................... STEERING HELM REPLACEMENT ................................................................................... ALIGNMENT .......................................................................................................................... THROTTLE/SHIFTER CONTROLLER .................................................................................... REMOVAL........................................................................................................................... INSPECTION ...................................................................................................................... LUBRICATION .................................................................................................................... ADJUSTMENTS ................................................................................................................ ASSEMBLY.........................................................................................................................
0
10-02-1 10-02-2 10-02-2 10-02-3 10-02-4 10-03-1 10-04-1 10-04-1 10-04-1 10-04-1 10-04-1 10-04-2
10-01-1
STEERING SYSTEM
All Models
10
10 Nm (89 lbfin)
Loctite 242
Sportster only
12
11
Loctite 242
Silicone sealant
Loctite 242
F04K16S
TYPICAL
PARTS
FLAT RATE
10-02-1
Check cable movement. Replace as necessary. Turn steering from side to side, if rotation movement is abnormal or if end play is excessive, replace steering helm as an assembly.
WARNING
Disassembly of the steering helm can lead to steering failure. Replace complete assembly. For cable assembly, use supplied hardware only. Do not use substitutes.
F04K0PA
TYPICAL 1. Remove nut and detach from arm (underneath) 2. Loosen this nut to allow moving cable
F04K0QA
HELM REMOVED FOR CLARITY PURPOSE ONLY (REMOVAL IS NOT REQUIRED FOR THE VERIFICATION) 1. Check for wear (particularly brass bushing wear) or oxidation in this area
10-02-2
F04K0RA
Installation
Reinstall removed parts and pay attention to the following: Pass cable through transom. Screw external nut no. 3 and keep 1-2 threads protruding out of nut. Tighten internal nut no. 4. Position adjuster half way on threaded length of cable end. Secure adjuster on nozzle. Secure steering cable to helm and the throttle cable(s) bracket. Install throttle cable end to pivoting plate. Refer to Low-speed Steering Control System Cable Replacement below. On twin-pump models, reinstall helm. Refer to Steering Helm Replacement below. Proceed with steering adjustment. Refer to ALIGNMENT 10-03. From inside of hull, apply sealant adhesive (P/N 293 800 033) on cable and nut area to seal hull. Check cable/hull watertightness.
F04K0QB
10-02-3
Twin-pump Models
1
F04B0FA F04K0SA
1. Cable end of LH engine at this position 2. Cable end of RH engine at this position 3. Retighten this nut
Install steering wheel puller, hold steering wheel firmly and tighten puller screw to detach wheel from the shaft.
NOTE: To find which cable matches which engine, pull one cable and ask an helper to look on which engine the throttle cable is activated. Reinstall helm, refer to Steering Helm Replacement below.
CAUTION
All Models Proceed with low-speed steering control system cable adjustment as specified in CARBURETORS 06-04.
F04B0GA
Be careful to keep Woodruff key for reinstallation. Remove steering collar no. 8. Disconnect steering cable and low-speed steering control system cable(s) as described above. Remove screws no. 9 and withdraw steering helm no. 10. Pay attention, spacer(s) may be present.
10-02-4
Installation
Reinstall removed parts and pay attention to the following: Prior to installing steering helm to boat, position helm arm as shown.
F04K06A
2 1
F04K0TA
When installing steering helm to boat, reinstall spacer(s) if some were present then position screws no. 9 as required in slots on mounting plate to keep space between helm/cable and body. Centering screws in slots is a good starting point.
Torque screws as indicated in exploded view. Ensure to install Woodruff key. Apply anti-seize on helm shaft. Install steering wheel. Install lock nut and torque steering wheel nut as indicated in exploded view. Proceed with steering alignment. Refer to ALIGNMENT 10-03.
10-02-5
ALIGNMENT
Position steering in straight ahead position.
0
Twin-pump Models Check jet pump nozzle alignment and steering centering by placing a straight edge across nozzle ends. Straight edge must lean on both edges of each nozzle.
F04K01A
Single-pump Model Check jet pump nozzle alignment and steering centering by placing a straight edge on nozzle end. Straight edge must be parallel with transom.
F04K0UA
1
F04J0GA
TYPICAL 1. Parallel with transom 2. Measure distance between transom and straight edge
F04K0VA
TYPICAL 1. Remove nut, unlock adjuster and rotate adjuster to adjust 2. Adjuster
After the adjustment, ensure to install rod end so that it is parallel with nozzle arm.
10-03-1
Twin-pump Models Loosen lock nut of steering link rod. While holding rod end, turn link rod to adjust.
All Models If not enough adjustment is available here, adjust cable end on steering helm arm.
CAUTION
F04K0WA
When finished, apply Loctite 242 on lock nut threads and retighten it. After the adjustment, ensure to install rod ends so that they are parallel each other.
F04K0QC
F04K0XA
10-03-2
THROTTLE/SHIFTER CONTROLLER
REMOVAL
Unscrew retaining screws.
0
1
Single-engine Model
INSPECTION
CAUTION
Use a protective mat (P/N 295 000 129) in shifter area when withdrawing controller.
Check all moving parts for free movement and for excessive play. Pay attention to pivot plate nos. 11-12. Check cables for wear and oxidation. Replace parts as required.
LUBRICATION
Lubricate moving parts with synthetic grease. Where not possible, apply BOMBARDIER LUBE.
F04K05A
ADJUSTMENTS
Throttle and shifter cable adjustment are covered in FUEL SYSTEM, Carburetors section 06-04, PROPULSION SYSTEM, and Reverse System section 09-04 respectively.
To adjust shifter friction, turn set screw that is on the same side as shifter lever. For throttle, turn set screw on the same side as its lever.
10-04-1
Twin-engine Models
2
F04K07A
1. Set screw of port throttle (inner lever) 2. Set screw (1 screw each side for each lever)
To adjust shifter friction, turn set screw that is on the same side as shifter lever. To adjust starboard throttle lever (outer lever), turn set screw on the same side as its lever. To adjust port throttle lever (inner lever), turn set screw on center of pivot point of lever. Ensure that both throttle levers have the same friction. To adjust shifter friction, turn set screw that is on the same side as shifter lever. For throttle, turn set screw on the same side as its lever.
3 2
F04K05B
ASSEMBLY
When reinstalling throttle/shifter controller to boat, be careful not to bend cables. Ensure everything works properly.
10-04-2
TABLE OF CONTENTS
COMPONENTS ...................................................................................................................... DECK MOUNTING BOLTS ................................................................................................ BUMPER REPLACEMENT ................................................................................................. DECAL REPLACEMENT..................................................................................................... REAR STORAGE COMPARTMENT COVER GAS SHOCKS ............................................. LATCH ADJUSTMENT (ROUND PIN TYPE)..................................................................... LATCH ADJUSTMENT (HOOK TYPE) .............................................................................. BILGE PUMP/COOLING SYSTEM OUTLETS LOCATION................................................ DRAIN TUBES REPLACEMENT ........................................................................................ SEAT REMOVAL/INSTALLATION...................................................................................... WINDSHIELD CLEANING.................................................................................................. LUBRICATION OF LOCKS ................................................................................................. REPAIR.................................................................................................................................... GENERAL ........................................................................................................................... AIR BUBBLES .................................................................................................................... BLISTERS ........................................................................................................................... MINOR GELCOAT FRACTURES........................................................................................ COMPOUND FRACTURES ................................................................................................ TOOLS AND MATERIALS LIST......................................................................................... HULL INSERT REPAIR ....................................................................................................... PAINTING ............................................................................................................................... PARTS THAT CAN BE PAINTED........................................................................................ NEW R-M PAINT CODE ..................................................................................................... CONCEPTTM PAINTING PROCEDURE .............................................................................. SURFACE PREPARATION.................................................................................................. FULL PANEL AND OVERALL REPAIRS ............................................................................ SPOT/PANEL REPAIRS ...................................................................................................... DELTATM PAINTING PROCEDURE..................................................................................... SURFACE PREPARATION.................................................................................................. DELTATM 2800, COLOR ...................................................................................................... RECOMMENDED SPRAY EQUIPMENT............................................................................
0
11-02-1 11-02-8 11-02-8 11-02-9 11-02-10 11-02-10 11-02-10 11-02-11 11-02-11 11-02-12 11-02-18 11-02-18 11-03-1 11-03-1 11-03-1 11-03-2 11-03-2 11-03-3 11-03-4 11-03-4 11-04-1 11-04-2 11-04-3 11-04-4 11-04-4 11-04-4 11-04-4 11-04-5 11-04-5 11-04-5 11-04-5
11-01-1
COMPONENTS
All Models
Some models
Loctite 242
Challenger 1800
Loctite 271
F04L9HS
TYPICAL
PARTS
FLAT RATE
11-02-1
14-Foot Models
Synthetic grease
Synthetic grease
Loctite 271
Loctite 242
5 Nm (44 lbfin)
F04L9IS
TYPICAL
11-02-2
PARTS
FLAT RATE
14-Foot Models
Loctite 271
Challenger
F04L9JS
TYPICAL
PARTS
FLAT RATE
11-02-3
All Models
Loctite 271
Loctite 242
Some models
Loctite 242
F04L9KS
TYPICAL
11-02-4
PARTS
FLAT RATE
All Models
Loctite 242
Some models
Loctite 271
F04L9LS
PARTS
FLAT RATE
11-02-5
Challenger 1800
Loctite 242
Loctite 242
Loctite 242
F10L1JS
TYPICAL
11-02-6
PARTS
FLAT RATE
Challenger 1800
Loctite 242 Loctite 242
Loctite 242
Loctite 242
Loctite 242
Loctite 242
F10L1KS
TYPICAL
PARTS
FLAT RATE
11-02-7
F04L6PA
BUMPER REPLACEMENT
F04L6OA
F04L6TA
CAUTION
When drilling, be careful not to damage bumper rail and/or hull. NOTE: Check condition of silicone joint between hull and body. Reseal as necessary with sealant adhesive (293 800 033) or equivalent without acetic acid vapors. 6. Position bumper rail properly onto body all around coming back to other rear end and cut excess length if necessary. NOTE: Masking tape may be used to temporarily retain bumper rail ahead of your work. NOTE: Prior to installing trim in bumper rail for rear corners, apply silicone sealant inside bumper rail as shown. This is required so that trim properly remains attached to rail.
11-02-8
1 2
Decals Having a Protective Film on Back Side Only These decals usually contain written information (ex.: warning) and are used on gelcoat or metal. Clean surface with a good solvent such as ACRYLICLEAN DX 330 from PPG or equivalent (refer to manufacturers instructions). Using a pencil and the new decal as a template, mark the area where decal will be located. Remove half of the decal back protective film and align decal with marks. Start sticking it from center and remove the other half of the film to stick it completely. Carefully squeegee decal beginning at center and working outward using, firm, short, overlapping strokes. Decals Having a Protective Film on Both Sides These decals usually contain graphics and are used on gelcoat or plastic. Installation on Gelcoat Clean surface with a good solvent such as ACRYLICLEAN DX 330 from PPG or equivalent (refer to manufacturers instructions). For best result apply an activator (P/N 293 530 036) to prepare the surface using a clean cloth. After a few seconds, when the activator evaporates, the surface is ready. Using a pencil and the new decal as a template, mark the area where decal will be located. For better adhesion a dry application is recommended; however, to ease decal installation a mild solution of soapy water can be sprayed over surface where decal will be installed. Remove back protective film from decal and align decal with marks. When well-aligned squeegee decal beginning at center and working outward using, firm, short, overlapping strokes. Remove protective film once decal has adhered to hull. Installation on Plastic Front (front storage cover, if applicable) Clean surface with isopropyl alcohol. Using a pencil and the decal as a template, mark the area where decal will be located.
F04L9OA
7. Install trim using soapy water. Gently tapping trim with a rubber hammer will help to fit trim in rail. 8. Reinstall bumper cover. 9. Check fit between bumper and body. Fill gaps with silicone sealant as necessary.
DECAL REPLACEMENT
Removal
Using a heat gun, warm up one end of decal for a few seconds until decal can roll off when rubbing decal edge with your finger. Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off. If decal tears while pulling off, it has to be heated for a few seconds longer. If decal tends to stretch while pulling off, stop heating and wait a few seconds to let it cool, then peel it off.
Installation
There are 2 types of decals used on jet boat. One has a protective film on back side and the other has a protective film on both sides. They are used on 3 types of materials; plastic, gelcoat and metal.
11-02-9
Apply an activator (P/N 293 530 036) to prepare the surface using a clean cloth. After a few seconds, when the activator evaporates, the surface is ready.
CAUTION
2
Do not use soapy water as a cleaner to prepare the surface or to locate decal on cover. Remove back protective film from decal and carefully align decal with marks. Apply pressure to center of decal using a squeegee then slide outward using a firm, short overlapping stroke. Repeat as necessary. Remove protective film from front of decal after application.
F02L25B
TYPICAL MOUNTED UPSIDE DOWN ON CHALLENGER 1800 1. Locking pin 2. Adjustment nut 3. Lock nut. Torque to 5 Nm (44 lbfin)
F04L7IA
Try closing cover and readjust hook height as necessary. Properly retighten nuts.
11-02-10
F04L8SC
1. Engine cooling system outlet/flushing connector 2. Bilge pump outlet 3. Deck drain outlet
Challenger
Deck Drain
Disconnect drain tube from transom fitting. Cut locking ties all along drain tube from transom toward deck storage compartment. Remove throttle/shifter controller to gain access (not necessary on Sportster 1800/Challenger 1800). From the controller opening, disconnect drain tube from deck fitting. Cut new tube to proper length. Reconnect tube at each end and resecure with locking ties. Ensure tube does not leak in bilge.
F04L8RB
1. Engine cooling system outlets/flushing connectors 2. Bilge pump outlet 3. Deck drain outlet
Scupper Valve
Blow with your mouth inside scupper valve, the slits in rubber should collapse. Otherwise, remove retaining screws, cover, tube then valve and inspect valve.
F10L06B
1. Engine cooling system outlets/flushing connectors 2. Bilge pump outlet 3. Deck drain outlet
11-02-11
NOTE: To facilitate installation and ensure proper sealing of scupper valve inside plastic fitting, apply soap on the edge of scupper valve. When installing valve cover, position groove of cover against valve housing.
F04L6QA
F04L6VA
1. Groove here
SEAT REMOVAL/INSTALLATION
NOTE: A screwdriver may be used carefully to pry seat/backrest out.
F04L6RA
CAUTION
When reinstalling valve, ensure to position tapered end first inside valve housing.
Whenever removing seat/backrest and other removable component, always replace darts prior to reinstalling.
Rear Seat
The 4 retaining screws can be reached from engine compartment underneath seat.
Rear Backrest
Sportster/1800, Challenger Carefully pry sides of seat to release the darts. The starboard (RH) retaining screw can be reached by removing throttle/shifter controller. The port (LH) retaining screw can be reached by removing the cup holder. Apply Loctite 242 (blue) on screw threads at assembly.
F04L9PA
11-02-12
Challenger 1800 Firmly pull armrest from bottom while lifting at the same time to release locking plate.
2 1
F04L6OA F04L6VA
Sportster/1800, Challenger The 4 rear retaining screws can be reached from engine compartment. Remove electrical box to reach starboard retaining screw.
Side Seats Darts can be accessed after front seat has been removed.
Front Seat
Challenger Carefully pry seat up to release the darts.
F04L6TB
F04L77A
11-02-13
Front Backrest
All Models except Challenger 1800 Firmly pull panel while lifting at the same time to release locking plate.
2 1
F04L79A
1. Retaining screws
Seat
F04L78A
Challenger 1800 Firmly pull while lifting one corner of backrest at a time to remove it.
2 1
F04L7AA
F04L6WA
Spotter Seat
Sportster/1800, Challenger
Backrest The backrest is retained by 3 screws which can be accessed by lifting the cooler cover or opening storage compartment on back of backrest on some models.
F04L7BA
11-02-14
F04L7CA
F04L6ZA
Captain Seat
Challenger 1800 Refer to the following illustrations.
F04L70A
F04L6XA
F04L71A
1. Remove darts
11-02-15
F04L72A
F04L74A
1. Screw is reached from front storage compartment 2. Screw is reached by removing speaker
To reinstall panels, it may be easier to remove seat from deck. Remove locking knob then slide seat out toward front.
F04L75A F04L73A
Side handle fasteners can be reached from front storage compartment and by removing speaker.
Remove old tape and clean surface prior to installing new double sided adhesive tape.
11-02-16
F04L7GA
Remove latch mechanism from body and open it by removing the plate underneath. Detach cable end from the rod.
F04L76A
F04L7HA
Tape the end of the new cable to the end of the old cable. Detach front portion of cable in front storage compartment and pull cable toward front thus pulling the new cable at the same time. Complete parts assembling in the reverse order of disassembly.
F04L7DA
Lift pad to see the latch access hole. Insert a flat screwdriver into slot of latch pin end and hold while loosening locking nut with a key.
11-02-17
WINDSHIELD CLEANING
First rinse with fresh water to remove dried salt water. Wash with Bombardier cleaner (P/N 293 110 001). Clean only with flannel clothes or Kimtowels wipers no. 58-380 from Kimberly-Clark.
CAUTION
It is necessary to use flannel cloths or Kimtowels wipers on windshield to avoid damaging further surfaces to clean. To remove scratches on windshield: Start with Slip Streamer Motorcycle Windshield Heavy Duty Scratch, Remover. Finish with Slip Streamer Motorcycle Cleaner and Polish. NOTE: The later product may be used alone if only light scratches are noticeable.
CAUTION
Never clean windshield with strong detergent, degreasing agent, paint thinner, acetone, products containing chlorine, etc.
LUBRICATION OF LOCKS
Locks should be lubricated with BOMBARDIER LUBE lubricant to keep them working properly. This will help dissolving dried salt water.
11-02-18
REPAIR
GENERAL
Gelcoat is the smooth and durable cosmetic finish which coats the fiberglass hull and body of a SeaDoo jet boat. It also provides a protective barrier against water and sun. It consists of a mixture of resin, pigment (coloring), fillers, monomers and catalyst which is sprayed into the mold. The body and hull of the Sea-Doo jet boat are constructed of chopped fiberglass, saturated with resin. It is sprayed on the layer of gelcoat along with pieces of fiberglass mat, cloth and woven rowing which are added at required areas. This type of construction is very accommodating for high quality repairs. With patience, the proper techniques and materials, a damaged area can be restored to an original finish. The content presented here is not intended to replace the use of a complete fiberglass and gelcoat repair manual. Its main purpose is to help you understand what factors are involved when making a damage assessment or estimate. NOTE: Fiberglass repair kit is available through automotive or marine suppliers. Gelcote repair kits are available through regular channel.
0
AIR BUBBLES
Possible Cause
Air pocket trapped between layers of laminate and gelcoat.
1) Preparation of Surface
Remove all of the damaged gelcoat surrounding the air bubble with a putty knife or preferably a carbide grinding tip. Make sure all loose and weak areas are completely removed. Sand a small area of the gelcoat surface with 220-grit sandpaper. If needed, sand the cavity itself. These areas must have a rough surface to allow the gelcoat putty to bond properly.
Protect skin, wear gloves when in contact with resin, hardeners and gelcoat. A barrier skin cream may also be used. Do not expose area to open flame or lit cigarette. Some of the materials are flammable. Protect eyes, wear safety glasses when grinding, sanding or spraying. Use a dust mask when sanding or grinding. When spraying wear a respirator or paint mask. Always read warning labels on products.
WARNING
3) Sanding
Begin block sanding the patch with 320-grit sandpaper until you come close to the original surface. Remove dust with a water soaked cloth and continue sanding with a 400-grit wet paper. Finish wet sanding with a 600-grit to remove deeper scratches. If needed you can wet sand with finer grit paper such as 1000-grit.
BLISTERS
Possible Causes
Inert catalyst. Improper catalyst/gelcoat ratio. A blister is a visible bump on the Sea-Doo jet boat surface that may not necessarily come right through the gelcoat layer. In the case of only a few blisters, you may follow the same repair procedure as for air bubbles. If they are numerous and in close concentration, you may have to spray liquid gelcoat to achieve proper repair. This procedure is covered in the next problem.
CAUTION
3) Sanding
Wash the polyvinyl alcohol off with water. Depending on the size of the area repaired, you can either block sand as per previous procedure or you may use an air sander. Sand the surface down with progressively finer grits of sandpaper until the desired finish is achieved.
11-03-2
COMPOUND FRACTURES
Possible Causes
Thickness of fiberglass laminate. Direct result of impact. Compound fractures are those that have gone past the gelcoated surface and in through the layers of fiberglass laminate. Two types of repairs have to be performed. The first is to restore the structural integrity of the damaged area. Fracture types can vary from a simple crack to a large hole. Usually, fiberglass reinforcement becomes necessary, especially if the fracture can be attributed to weakness. The final part of the repair is the gelcoating, which cannot be done until the interior and exterior laminate surfaces have been repaired. Outside Remove the damaged gelcoat and fiberglass with a 24-grit disk using a power sander. Grind outward at least 2 inches from the fracture to allow the patch to bond to strong material. Cut enough pieces of fiberglass mat necessary to build up the area. The pieces should be cut so they overlap each other by at least half an inch. For a smoother finish, the last layer should be fiberglass cloth. If the fracture is small enough all you may have to do is fill the area with an epoxy filler. Inside For the interior repair, you can grind more. This will allow for more fiberglass material which will strengthen the area. If the fracture opening is too large after surface preparation, you may need a backing support to cover the opening. Cut alternating pieces of fiberglass mat and cloth in overlapping sizes.
Using a clean paintbrush, brush the mixed resin on the surface. Place the smallest piece of mat over the fracture and then wet out the mat. Follow with the remaining pieces of mat and final layer of cloth. While wetting the pieces make sure you work the air bubbles out and saturate all the pieces evenly. Try to work quickly, you may only have 15 or 20 minutes. You may clean the brush with acetone. Wait until the repair has hardened before moving on to the interior repair. If the size of the opening is too large for the pieces to maintain the proper shape, you will have to use a backing support. It is a shaped piece of cardboard that fits flush to the interior surface and has a plastic layer on the repair side. It is held in place by tape or a support. Inside Wipe down the area with acetone on a cloth. Apply the same procedure as for outside repair when laminating the alternating pieces of fiberglass material. If a backing support was used, remove it before starting the repair. After the area has hardened, remove sharp edges of material from surface. If required paint the surface.
Sanding
Outside This surface will have to be prepared for application of gelcoat. The size of the area will determine the gelcoating procedure to be used. Refer to the repair procedure for minor gelcoat fractures.
11-03-3
F01L2UA
Materials
fiberglass mat fiberglass cloth polyester resin cardboard masking tape sandpaper (100-grit, 220-grit, 220-grit, 320-grit, 400-grit, 600-grit, 1000-grit) 24-grit sanding disks Bombardier gelcoat putty Bombardier liquid gelcoat acetone cabosil epoxy filler medium compound (white) fine compound (white) wax
Mix epoxy glue (3M-05900), follow manufacturers instructions. Apply epoxy glue on replacement insert (P/N 292 000 075) knurled surface and on plastic insert inner bore.
CAUTION
A clearance between plastic insert and aluminum insert could possibly be noticed. If so, ensure to fill gap with epoxy glue to obtain aluminum insert adhesion.
2
F01L2VA
11-03-4
Install insert into plastic hull insert. NOTE: Align aluminum insert as much as possible with PTO flywheel.
2
F01L2WB
NOTE: The epoxy glue curing time is 30 minutes. Do not reinstall drive shaft protector as the replacement insert does not allow its installation.
11-03-5
PAINTING
The following was prepared in conjunction with PPG Industries Inc. It contains a list of SEA-DOO jet boat parts with their respective PPG color codes and 2 painting procedures; CONCEPTTM the most commonly used and DELTATM (with low VOC) mainly used in California. PPG Industries Inc. sells paint and related products and these are not available from Bombardier Inc. To find your nearest PPG dealer, dial one of the following numbers.
NORTH AMERICA CANADA Quebec Phone: 1-800-363-2816 All Other Provinces Phone: 1-905-855-5802 Communications are available in English and French.
U.S.A.
Phone: (216) 572-6100 This phone number is also good for all countries. Communications are available in English, French and Spanish. Phone: Phone: 45-31-54-9211 33-1-48-35-7777 33-27-14-9700 33-27-14-4600 49-202-788-1 39-81-831-1222 39-2-37-701 39-131-7701 81-3-3280-2851 PORTUGAL SPAIN Phone: Phone: 351-230-17-43 34-3-588-2000 34-3-711-51-54 34-6-154-7035 34-83-54-0400/04 46-479-14-445 44-21-455-9866 44-926-410-255 82-32-529-8141 82-32-523-8600 82-51-624-8221 82-2-792-2477
EUROPE
DENMARK FRANCE
GERMANY ITALY
Phone: Phone:
Phone: Phone:
PACIFIC RIM
JAPAN
Phone:
Phone:
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.
11-04-1
12
11 1 2 13 5 3 9 15 4
10
14
8 6
F04L7JS
TYPICAL 1. Body 2. Hull 3. Rear Storage Cover 4. Engine 5. Tuned Pipe 6. Muffler 7. Exhaust Manifold 8. Engine Support
Ignition Housing Ignition Housing Cover Deck Storage Compartment Cover Flame Arrester Support Flame Arrester Base Ride Shoe Rear Storage Compartment Tray
11-04-2
PART 1. Body 2. Hull 3. Rear Storage Cover 4. Engine 5. Tuned Pipe 6. Muffler 7. Exhaust 8. Engine Support 9. Ignition Housing 10. Ignition Housing Cover 11. Deck Storage Compartment Cover 12. Flame Arrester Support 13. Flame Arrester Base 14. Ride Shoe1 15. Rear Storage Compartment Tray
PPG COLOR Nos. FOR SEA-DOO JET BOATS ALL MODELS Super White 98260 Super White 98260 Forest Green M512 (Challenger 1800)
Super White 98260 717: Off-white 5812-92-08 787: Silver reflection M529 717: Off-white 5812-92-08 787: Silver reflection M529 717: Off-white 5812-92-08 787: Silver reflection M529 717: Off-white 5812-92-08 787: Silver reflection M529 Black 9551 717: Off-white 5812-92-08 787: Silver reflection M529 717: Off-white 5812-92-08 787: Silver reflection M529 Super White 98260
NOTE: Due to natural discoloration it may be necessary to completely repaint the part. 1 Aluminum parts only.
11-04-3
SURFACE PREPARATION
Prepare and clean surface consistent with good painting practices. Primer DP Epoxy Primer/DP 401 Catalyst; DX 1791/1792 (Prime before topcoating). Primer Surfacer K36/K201, K200/K201 or DZ KONDAR Primer Surfacers. NOTE: KONDAR must be sealed before applying CONCEPTTM color. Sealer KTS30 2K Sealer, DP Epoxy Primer reduced as a sealer or DAS 1980 or DAS 1987.
SPOT/PANEL REPAIRS
Application Spray medium wet coat of color on the repair area and allow 5-10 minutes flash time. Apply 2 additional full coats until hiding is achieved, extending each coat beyond the previous coat. Flash 15 minutes between each coat. For medium solids option apply 2 full wet coats. Blending Add DT 95 Reducer to a second gun cup. Reduce the fluid feed of the gun and lower the air pressure to 207 kPa (30 PSI). Dust the dry edge until a slight wet look appears, then stop. Or mix reduced and catalyzed color with equal parts of reduced and catalyzed CONCEPT TM DCU 2020 Clear.
11-04-4
SURFACE PREPARATION
Primer: DELTATM PRIME DPU 166.
Dry Time at 21C (70F) Dust free: 25-35 minutes. Tack free: 2-1/2 to 3 hours. Tape/sand: Overnight. Force Dry Allow 20 minutes purge time at 27-32C (80-90F) before bake. Bake 75 minutes at 65C (150F) or 40 minutes at 82C (180F). Allow to cool after force dry, before sanding or taping.
11-04-5
TECHNICAL DATA
ENGINE Number of engine Engine type Induction type Exhaust type Starting system Lubrication Fuel/oil mixture Oil injection pump Oil type Number of cylinders Bore Standard First oversize Second oversize Stroke Displacement Compression ratio Engine maximum torque Cylinder head warpage (maximum) Piston ring type and quantity Ring end gap Ring/piston groove clearance Piston/cylinder wall clearance Cylinder taper (maximum) Cylinder out of round Connecting rod big end axial play Crankshaft deflection (center) Rotary valve timing Rotary valve duration Crankcase/rotary valve gap Connecting rod/crankshaft pin radial clearance Connecting rod/piston pin radial clearance ADDITIONAL INFORMATION: MAG side: 0.05 mm (.002 in). PTO side: 0.03 mm (.001 in). New Wear limit New New limit Opening Closing New Wear limit New Wear limit New Wear limit New Wear limit Uncorrected Corrected 91 Nm (67 lbfft) @ 6250 RPM Type Water injection fittings N.A. SPORTSTER 1 Rotary valve Water cooled, water injected 3.5 mm (.139 in) Electric start VROI (Variable Rate Oil Injection) Gear driven BOMBARDIER-ROTAX injection oil 2 82.00 mm (3.228 in) 82.25 mm (3.238 in) 82.50 mm (3.248 in) 68 mm (2.68 in) 718.2 cm (43.81 in) 12 : 1 6.2: 1 2 x 91 Nm (67 lbfft) @ 6250 RPM 0.05 mm (.002 in) 1 Semi-trapez 1 Rectangular 0.25 - 0.40 mm (.010 - .016 in) 1.00 mm (.039 in) 0.025 - 0.070 mm (.001 - .003 in) 0.2 mm (.008 in) 0.09 - 0.11 mm (.0037 - .0044 in) 0.20 mm (.008 in) 0.10 mm (.004 in) 0.08 mm (.003 in) 0.39 - 0.74 mm (.015 - .029 in) 1.2 mm (.047 in) 0.08 mm (.003 in) 147 5 BTDC 65 5 ATDC 158 0.25 - 0.35 mm (.010 - .014 in) 0.01 - 0.02 mm (.0004 - .0008 in) 0.05 mm (.002 in) 0.003 - 0.012 mm (.00012 - .00047 in) 0.015 mm (.00059 in) SPORTSTER 1800 2 BOMBARDIER-ROTAX 717, water cooled CHALLENGER
12-01-1
ELECTRICAL Magneto generator output Ignition system type Spark plug Ignition timing (BTDC) Generating coil Trigger coil Battery charging coil Ignition coil Engine RPM limiter setting Battery Fuse Main MPEM (Multi-Purpose Electronic Module) supply Charging system Blower Bilge pump Lighting system Gauges Additional accessories Horn fuse 12 V connector Radio/courtesy lights ADDITIONAL INFORMATION: Primary Secondary Make and type Gap mm (in) Degrees
SPORTSTER 1800
CHALLENGER
CDI (Capacitor Discharge Ignition) NGK BR8ES 0.55 mm (.021 in) 2.59 (.102) 20 1 40 - 76 N.A. .05 - .6 .34 - .62 (not measurable) 9 - 15 k 7000 ( 50) RPM Not supplied 2 x 20 A 5A 15 A 7.5 A 3A 3A 5A 10 A N.A. N.A. N.A. 5A 10 A 10 A 3 x 20 A 5 A (2) 2 x 15 A
Engine cold @ 6000 RPM with shifter in forward or reverse position. Recommended: Exide RV24-130, 12 V, 25 Ah (130 minutes reserve) or RV24-160 (160 minutes) or equivalent. Battery pot: On top. Round taper type. Battery maximum allowed size: 285 mm (11-1/4) long x 190 mm (7-1/2) wide x 238 mm (9-3/8) high.
Never use automotive type battery. Its mechanical construction does not allow to meet the shock conditions where boats operate. Only use the type of battery recommended.
.
WARNING
12-01-2
CARBURETION Carburetor Main jet Pilot jet Adjustment Low-speed High-speed screw Idle speed (in water) Idle speed (out of water) Low-speed steering control system speed (in water) Fuel Fuel return line ADDITIONAL INFORMATION: Type Octane no. Type Quantity
SPORTSTER
SPORTSTER 1800 1 (per engine) 167.5 72.5 1-1/4 turn 1/4 0 (closed) / 1500 RPM 3000 RPM
CHALLENGER
3000 RPM
2800 RPM Regular unleaded gasoline 87 (Ron + Mon)/2 0.6 mm (.024 in)
3000 RPM
SPORTSTER
CHALLENGER
PROPULSION Propulsion system Number of pump Jet pump type Impeller rotation (seen from rear) Transmission Coupling type Oil type Steering nozzle pivoting angle Minimum required water level Drive shaft deflection (maximum) Impeller outside diameter Impeller/wear ring clearance Impeller shaft end play (new) Impeller shaft side play Impeller pitch/material ADDITIONAL INFORMATION: Do not mix different brands or oil types. New Wear limit
SPORTSTER 1
SPORTSTER 1800 Bombardier Formula pump 2 Axial flow single stage Counterclockwise Direct drive Crown splines
CHALLENGER
SEA-DOO JET PUMP SYNTHETIC OIL Polyolester 75W90 GL5 26 90 cm (35 in) 0.5 mm (.020 in) 139.5 mm (5.490 in) 0.18 - 0.44 mm (.007 - .017 in) 1.02 mm (.040 in) 0.12 - 0.54 mm (.005 - .021 in) 0.05 mm (.002 in) Progressive pitch stainless steel
12-01-3
DIMENSIONS Draft Dead rise Overall length Overall width (beam) Overall height Dry weight Load limit (passengers and 10 kg (22 lb) luggage)
SPORTSTER 30 cm (12 in) 20 442 cm (14 ft 6 in) 216 cm (85 in) 107 cm (42 in) 530 kg (1165 lb)
SPORTSTER 1800 27 cm (10.5 in) 19.5 546 cm (17 ft 11 in) 229 cm (90 in) 135 cm (53 in) 850 kg (1870 lb)
CHALLENGER 30 cm (12 in) 20 442 cm (14 ft 6 in) 216 cm (85 in) 107 cm (42 in) 560 kg (1235 lb)
4 passengers OR 7 passengers OR 4 passengers OR 300 kg (660 lb) 525 kg (1150 lb) 300 kg (660 lb) based on calm water operation 1 2
CAPACITIES Fuel tank (including reserve) Fuel tank reserve Impeller shaft reservoir Oil injection reservoir ADDITIONAL INFORMATION: Capacity Oil level height
SPORTSTER 1800 151 L (40 U.S. gal) 15 L (4 U.S. gal) 70 mL (2.4 U.S. oz) To bottom of cover hole 9 L (2.4 U.S. gal)
MATERIAL Hull Air intake silencer Flame arrester Exhaust muffler Fuel tank Oil injection reservoir Seat Ride shoe Jet pump Front storage cover ADDITIONAL INFORMATION:
SPORTSTER
CHALLENGER
Polyethylene (aluminum for some international models) Polyethylene Base: polyethylene Foam: polyurethane Aluminum Plastic Polystyrene Plastic
12-01-4
STANDARD EQUIPMENT DESS (Digitally Encoded Security System) Fuel tank reserve Electric fuel level gauge Oil injection low-level/warning device Overheating warning device and CSI (Cooling System Indicator) Speedometer Tachometer Stern light and navigation lights Courtesy lights Shifter controller (forward/neutral/reverse) Electric bilge pump (manual switch + auto) Blower Storage compartment Grab handles Extinguisher holder Cup holders Mirrors Retractable ski pole Bow filler cushion Sun deck cushion Rear cover pad Platform pad Radio AM/FM Horn Bimini top Slide/swivel bucket seats Windshield Rack for ski/wakeboard Lift kit Ski door lock Engine cover lock Storage cover lock Cooler door lock Ski rope locker lock Glove box Low-speed steering control system Depth sounder provision Mooring cover Weedless system Ladder Deck carpet ADDITIONAL INFORMATION:
SPORTSTER
SPORTSTER 1800 Standard Standard (low-fuel warning system) Standard Standard Standard Standard
CHALLENGER
Standard (manual)
Standard (manual)
Standard Standard N.A. Standard Standard Standard Standard Standard Standard Standard Standard N.A. Optional N.A. N.A. Optional Optional Optional Optional Optional Optional Standard Standard Standard N.A. Standard Optional Optional Optional Optional Optional N.A. Standard Standard Standard Standard N.A. N.A. Standard N.A. Optional Optional Standard Optional Standard Optional Optional Optional Standard
Standard (2) Standard N.A. N.A. Standard Standard Optional Optional Optional Optional
N.A.
Optional
12-01-5
PERFORMANCE Estimated pump power Maximum fuel consumption at wide open throttle Cruising time at full throttle ADDITIONAL INFORMATION: Fuel tank without reserve Fuel tank reserve
SPORTSTER 23.5 kW (32 hp) 31.5 L/h (8.5 U.S. gal/h) 2 h 40 min 20 min
SPORTSTER 1800
CHALLENGER
12-01-6
TIGHTENING TORQUE Exhaust manifold screw Magneto flywheel nut Flywheel (PTO side) Crankcase screws Crankcase/engine support nuts Engine support/hull Cylinder head screws Cylinder head cover screws Crankcase/cylinder screws Tuned pipe nut/manifold stud, screws and nuts Tuned pipe fixation screws Flame arrester screws Carburetor on intake manifold nuts Impeller shaft Pump/hull nuts Venturi/pump housing screws PUMP Nozzle/venturi screws Pump housing cover screws Reverse gate/venturi screws Intake grill screws Ride shoe screws Steering wheel nut Steering support screws STEERING Steering cable retaining block bolts Steering cable/helm arm screw and nut Steering cable/nozzle screw and nut Steering collar screw Steering cable/hull nut ELECTRICAL Ignition housing cover screws Starter mounting screws Starter lock nuts Spark plugs M6 M8 ENGINE
SPORTSTER
SPORTSTER 1800 24 Nm (17 lbfft) 105 Nm (77 lbfft) 110 Nm (81 lbfft) 9 Nm (80 lbfin) 24 Nm (17 lbfft) 35 Nm (26 lbfft) 25 Nm (18 lbfft) 24 Nm (17 lbfft) N.A. 24 Nm (17 lbfft) 25 Nm (18 lbfft) 25 Nm (18 lbfft) 10 Nm (88 lbfin) 25 Nm (18 lbfft) 70 Nm (52 lbfft) 35 Nm (26 lbfft) 25 Nm (18 lbfft) 20 Nm (15 lbfft) 7 Nm (62 lbfin) 25 Nm (18 lbfft) 8 Nm (71 lbfin) 10 Nm (88 lbfin) 32 Nm (24 lbfft) 10 Nm (88 lbfin) 6 Nm (53 lbfin) 20 Nm (15 lbfft) 20 Nm (15 lbfft) 5 Nm (44 lbfin) 40 Nm (30 lbfft) 8 Nm (71 lbfin) 22 Nm (16 lbfft) 7 Nm (62 lbfin) 24 Nm (17 lbfft)
CHALLENGER
PRODUCT TO APPLY (1) (1) (1) (1) (1) (1) (3) (1) (3) (1) (1) (1) (1) (2) (1) (1) (1) (1) (1) (1) (1) (1)
(1)
(2)
ADDITIONAL INFORMATION: Apply where indicated; (1) Loctite 242 (blue) (2) Loctite 271 (red) (3) Loctite 515 (4) Synthetic grease (5) Anti-seize lubricant N.A.: Not Applicable
12-01-7
ENGINE Number of engine Engine type Induction type Exhaust type Starting system Lubrication Fuel/oil mixture Oil injection pump Oil type Number of cylinders Bore Standard First oversize Second oversize Stroke Displacement Compression ratio Engine maximum torque Cylinder head warpage (maximum) Piston ring type and quantity Ring end gap Ring/piston groove clearance Piston/cylinder wall clearance Cylinder taper (maximum) Cylinder out of round Connecting rod big end axial play Crankshaft deflection (center) Rotary valve timing Rotary valve duration Crankcase/rotary valve gap Connecting rod/crankshaft pin radial New clearance Wear limit Connecting rod/piston pin radial clearance ADDITIONAL INFORMATION: MAG side: 0.05 mm (.002 in). PTO side: 0.03 mm (.001 in). New New limit Opening Closing New Wear limit New Wear limit New Wear limit New Wear limit Uncorrected Corrected Type Water injection fittings
CHALLENGER 1800 2 BOMBARDIER-ROTAX 787, water cooled Rotary valve Water cooled, water injected 3.5 mm (.139 in) Electric start VROI (Variable Rate Oil Injection) Gear driven BOMBARDIER-ROTAX injection oil 2 82.00 mm (3.228 in) 82.25 mm (3.238 in) N.A. 74 mm (2.91 in) 781.6 cm (47.68 in) 11.75: 1 5.9: 1 2 x 110 Nm (81 lbfft) @ 6250 RPM 0.05 mm (.002 in) 1 Semi-trapez 1 Rectangular 0.25 - 0.40 mm (.010 - .016 in) 1.00 mm (.039 in) 0.025 - 0.070 mm (.001 - .003 in) 0.2 mm (.008 in) 0.09 - 0.11 mm (.0037 - .0044 in) 0.20 mm (.008 in) 0.10 mm (.004 in) 0.08 mm (.003 in) 0.39 - 0.74 mm (.015 - .029 in) 1.2 mm (.047 in) 0.08 mm (.003 in) 147 5 BTDC 63.5 5 ATDC 158 0.25 - 0.35 mm (.010 - .014 in) 0.01 - 0.02 mm (.0004 - .0008 in) 0.05 mm (.002 in) 0.003 - 0.012 mm (.00012 - .00047 in) 0.015 mm (.00059 in)
12-01-8
ELECTRICAL Magneto generator output Ignition system type Spark plug Ignition timing (BTDC) Generating coil Battery charging coil Trigger coil Ignition coil Engigne RPM limiter setting Battery Fuse Main MPEM (Multi-Purpose Electronic Module) supply Charging system Blower Bilge pump Lighting system Gauges Additional accessories Horn fuse Jack system Radio/courtesy lights ADDITIONAL INFORMATION: Primary Secondary Make and type Gap mm (in) Degrees
CHALLENGER 1800 2 x 180 W @ 6000 RPM or 5 A @ 2000 RPM DC-CDI (Direct-Current Capacitor Discharge Ignition) NGK BR8ES 0.55 mm (.021 in) 3.38 (.133) 22 1 N.A. .8 242 .6 (not measurable) 11.4 - 14 k 7200 ( 50) RPM Not supplied 3 x 20 A 2x5A 2 x 15 A 7.5 A 3A 3A 5A 10 A 5A 10 A 10 A
@ 3500 RPM with shifter in forward or reverse position. Recommended: Exide RV24-130, 12 V, 25 Ah (130 minutes reserve) or RV24-160 (160 minutes) or equivalent. Battery pot: On top. Round taper type. Battery maximum allowed size: 285 mm (11-1/4) long x 190 mm (7-1/2) wide x 238 mm (9-3/8) high.
Never use automotive type battery. Its mechanical construction does not allow to meet the shock conditions where boats operate. Only use the type of battery recommended.
.
WARNING
12-01-9
CARBURETION Carburetor Main jet Pilot jet Adjustment Low-speed High-speed screw Idle speed (in water) Idle speed (out of water) Low-speed steering control system speed (in water) Fuel Fuel return line ADDITIONAL INFORMATION: Type Octane no. Type Quantity
CHALLENGER 1800 Mikuni Diaphragm BN-40i-38 with accelerator pump 2 (per engine) MAG: 142.5 PTO: 145 67.5 1-1/2 turn 1/4 0 1500 RPM 3000 RPM 2800 RPM Regular unleaded gasoline 87 (Ron + Mon)/2 0.8 mm (.031 in)
CHALLENGER 1800 Open circuit Direct water flow None 96 - 99C (205 - 210F)
PROPULSION Propulsion system Number of pump Jet pump type Impeller rotation (seen from rear) Transmission Coupling type Oil type Steering nozzle pivoting angle Minimum required water level Drive shaft deflection (maximum) Impeller outside diameter Impeller/wear ring clearance Impeller shaft end play (new) Impeller shaft side play Impeller pitch/material ADDITIONAL INFORMATION: Do not mix different brands or oil types. New Wear limit
CHALLENGER 1800 Bombardier Formula pump 2 Axial flow single stage Counterclockwise Direct drive Crown splines SEA-DOO JET PUMP SYNTHETIC OIL Polyolester 75W90 GL5 23 90 cm (35 in) 0.5 mm (.020 in) 139.5 mm (5.490 in) 0.18 - 0.44 mm (.007 - .017 in) 1.02 mm (.040 in) 0.12 - 0.54 mm (.005 - .021 in) 0.05 mm (.002 in) Progressive pitch stainless steel
12-01-10
DIMENSIONS Draft Dead rise Overall length Overall width (beam) Overall height Dry weight Load limit (passengers and 10 kg (22 lb) luggage) Maximum water skiers on tow ADDITIONAL INFORMATION:
CHALLENGER 1800 27 cm (10.5 in) 19.5 546 cm (17 ft 11 in) 229 cm (90 in) 135 cm (53 in) 850 kg (1870 lb) 7 passengers OR 525 kg (1150 lb) (based on calm water operation) 2
CAPACITIES Fuel tank (total capacity) Fuel tank reserve (after low-fuel warning signal on some models) Impeller shaft reservoir Oil injection reservoir ADDITIONAL INFORMATION: Capacity Oil level height
CHALLENGER 1800 151 L (40 U.S. gal) 15 L (4 U.S. gal) 70 mL (2.4 U.S. oz) To bottom of cover hole 9 L (2.4 U.S. gal)
MATERIAL Hull Air intake silencer Flame arrester Exhaust muffler Fuel tank Oil injection reservoir Seat Ride shoe Jet pump Front storage cover ADDITIONAL INFORMATION:
CHALLENGER 1800 Composite (fiberglass and wood) Thermoplastic Multi-layer wire screen Aluminum Polyethylene (aluminum for some international models) Polyethylene Base: polyethylene Foam: polyurethane Plastic Plastic Polyurethane
12-01-11
STANDARD EQUIPMENT DESS (Digitally Encoded Security System) Tool kit Fuel tank reserve Electric fuel level gauge Oil injection low level/warning device Overheating warning device and CSI (Cooling System Indicator) Speedometer Tachometer Stern light and navigation lights Courtesy lights Shifter controller (forward/neutral/reverse) Electric bilge pump (manual switch + auto) Blower Storage compartment Grab handles Extinguisher holder Cup holders Mirrors Retractable ski pole Bow filler cushion Sun deck cushion Rear cover pad Platform pad Radio AM/FM Horn Bimini top Slide/swivel bucket seats Windshield Rack for ski/wakeboard Lift kit Ski door lock Engine cover lock Storage cover lock Cooler door lock Ski rope locker lock Glove box Low-speed steering control system Depth sounder provision Mooring cover Weedless system Ladder Deck carpet ADDITIONAL INFORMATION:
CHALLENGER 1800 Standard Standard Standard (low-fuel warning system) Standard Standard Standard Standard Standard (2) Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard (1) Standard N.A. Standard N.A. Optional Standard Standard Optional Standard Standard (2) Optional Optional Standard Standard Standard N.A. Standard Standard Standard Optional Optional Standard Standard Optional
12-01-12
PERFORMANCE Estimated pump power Maximum fuel consumption at wide open throttle Cruising time at full throttle Fuel tank without low-fuel warning system Low-fuel warning system ADDITIONAL INFORMATION:
CHALLENGER 1800 2 x 28.2 kW (38 hp) 92 L/h (24.4 U.S. gal/h) 1 h 25 min 15 min
12-01-13
TIGHTENING TORQUE Exhaust manifold screw Magneto flywheel nut Flywheel (PTO side) Crankcase screws M6 M8 ENGINE Crankcase/engine support nuts Engine support/hull Cylinder head screws Cylinder head cover screws Crankcase/cylinder screws Tuned pipe nut/manifold stud, screws and nuts Tuned pipe fixation screws Flame arrester screws Carburetor on intake manifold nuts Impeller shaft Pump/hull nuts Venturi/pump housing screws PUMP Nozzle/venturi screws Pump housing cover screws Reverse gate/venturi screws Intake grill screws Ride shoe screws Steering wheel nut Steering support screws STEERING Steering cable retaining block bolts Steering cable/helm arm screw and nut Steering cable/nozzle screw and nut Steering collar screw Steering cable/hull nut ELECTRICAL Ignition housing cover screws Starter mounting screws Starter lock nuts Spark plugs (1) Loctite 242 (blue) (2) Loctite 271 (red) (3) Loctite 515 (4) Synthetic grease (5) Anti-seize lubricant
CHALLENGER 1800 24 Nm (17 lbfft) 105 Nm (77 lbfft) 110 Nm (81 lbfft) 9 Nm (80 lbfin) 24 Nm (17 lbfft) 35 Nm (26 lbfft) 25 Nm (18 lbfft) 24 Nm (17 lbfft) N.A. 24 Nm (17 lbfft) 25 Nm (18 lbfft) 25 Nm (18 lbfft) 10 Nm (80 lbfin) 25 Nm (18 lbfft) 70 Nm (52 lbfft) 35 Nm (26 lbfft) 25 Nm (18 lbfft) 20 Nm (15 lbfft) 7 Nm (62 lbfin) 25 Nm (18 lbfft) 8 Nm (71 lbfin) 10 Nm (88 lbfin) 32 Nm (24 lbfft) 10 Nm (88 lbfin) 6 Nm (53 lbfin) 20 Nm (15 lbfft) 20 Nm (15 lbfft) 5 Nm (44 lbfin) 40 Nm (30 lbfft) 8 Nm (71 lbfin) 22 Nm (16 lbfft) 7 Nm (62 lbfin) 24 Nm (17 lbfft)
PRODUCT TO APPLY (1) (1) (1) (1) (1) (1) (3) (1) (3) (1) (1) (1) (1) (2) (1) (1) (1) (1) (1) (1) (1) (1)
(1)
(2)
12-01-14
WIRING DIAGRAMS
The information was not available at print time. To be published later.
SUPPLEMENT
13-01-1