2001-2002 Seadoo Sport Boats Service Repair Workshop Manual 01 02

Shop Manual 2001 UTOPIA 185 (5444/5451/5452/5453/5454/5456/5457/5458/5496/5497/5498/5499) 2002 UTOPIA 185 (5462/5464/5466/5475/5476/5477/5478/5479/5480) 2002 UTOPIA 205 (5745/5746/5747/5748/5749/5750)

Legal deposit: National Library of Quebec 2 nd trimester 2002 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. 2002 Printed in Canada ® ™Registered trademarks of Bombardier Inc. Loctite ® is a trademark of Loctite Corporation. Snap-on ® is a trademark of Snap-on Tools Corporation. Gelcote ® is a trademark of Gelcote International Limited.

LMR2002-001_00-02A.FM I SECTION SUBSECTION PAGE SAFETY NOTICE .................................................................................................................................. II INTRODUCTION ................................................................................................................................... III 01 SERVICE TOOLS AND PRODUCTS 01 – Table of Contents ..................................................................... 01-01-1 02 – Service Tools ............................................................................ 01-02-1 03 – Service Products ...................................................................... 01-03-1 02 MAINTENANCE 01 – Table of Contents ..................................................................... 02-01-1 02 – Periodic Inspection Chart ......................................................... 02-02-1 03 – Flushing and Lubrication........................................................... 02-03-1 04 – Storage ..................................................................................... 02-04-1 03 ENGINE 01 – Table of Contents ..................................................................... 03-01-1 02 – Exhaust System ....................................................................... 03-02-1 04 FUEL SYSTEM 01 – Table of Contents ..................................................................... 04-01-1 02 – Fuel Circuit ............................................................................... 04-02-1 05 ELECTRICAL SYSTEM 01 – Table of Contents ..................................................................... 05-01-1 02 – Battery ...................................................................................... 05-02-1 03 – Instruments and Accessories ................................................... 05-03-1 06 STEERING SYSTEM 01 – Table of Contents ..................................................................... 06-01-1 02 – Steering System....................................................................... 06-02-1 03 – Throttle/Shifter Controller ......................................................... 06-03-1 07 HULL/DECK 01 – Table of Contents ..................................................................... 07-01-1 02 – Components ............................................................................. 07-02-1 03 – Repair ....................................................................................... 07-03-1 08 TECHNICAL DATA ...................................................................................................................... 08-01-1 09 WIRING DIAGRAM ..................................................................................................................... 09-01-1 TABLE OF CONTENTS

II LMR2002-001_00-02A.FM SAFETY NOTICE 0 This manual was primarily published to be used by sport boat mechanic technicians trained by the man- ufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made Sea-Doo sport boats. Mechanic technicians should attend continuing training courses given by Bombardier Training Dept. 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 fur- thermore 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 time of writing. Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. 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 tab, self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the following wording and symbols: 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. 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.  WARNING Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. SAFETY NOTICE

LMR2002-001_00-02A.FM III INTRODUCTION 0 This Shop Manual covers the following BOMBARDIER made SEA-DOO ® sport boat: – 2001/2002 Utopia 185 – 2002 Utopia 205 MAXIMUM BOAT CAPACITY Depending on model, the sport boat maximum capacity label can be found on RH or LH side of operator position. UTOPIA 185 CAPACITY LABEL LOCATION UTOPIA 205 CAPACITY LABEL LOCATION HULL IDENTIFICATION NUMBER (H.I.N.) The Hull Identification Number (H.I.N.) is located at right hand rear side of hull. TYPICAL 1. Hull Identification Number (H.I.N.) Refer to the next illustration for a description of the serial number. CEC indicates that boats are manufactured in USA.              INTRODUCTION

IV LMR2002-001_00-02A.FM ENGINE IDENTIFICATION NUMBER (E.I.N.) Refer to Mercury Marine (M2) Jet Drive Operator’s Guide. ARRANGEMENT OF THIS MANUAL The manual is divided into 9 major sections: Each section may be divided in various subsections, and again, each subsection have one or more divi- sion. 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 ENGINE 04 FUEL SYSTEM 05 ELECTRICAL SYSTEM 06 STEERING SYSTEM 07 HULL/DECK 08 TECHNICAL DATA 09 WIRING DIAGRAMS INTRODUCTION

LMR2002-001_00-02A.FM V                                                                                                        INTRODUCTION

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LMR2002-001_00-02A.FM VII LIST OF ABBREVIATIONS USED IN THIS MANUAL 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 operator’s position sitting in boat. TYPICAL 1. BOW (front) 2. STARBOARD (RH) 3. STERN (rear) 4. PORT (LH) The information and component/system descrip- tions contained in this manual are correct at time of publication. Bombardier Motor Corporation of America (B.M.C.A.), however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Because of our ongoing commitment to product quality and innovation, Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equip- ment without incurring obligation. This Shop Manual uses technical terms which may be different from the ones of the Parts Cata- logs. When ordering parts always refer to the specif- ic model Parts Catalogs. AC Alternative Current Ass’y Assembly CDI Capacitor Discharge Ignition DC Direct Current E.I.N Engine Identification Number H.I.N. Hull Identification Number HP Horsepower LH Left Hand side (port) MAG Magneto N.A. Not Applicable P/N Part Number PTO Power Take Off RFI Radio-Frequency Interference RH Right Hand side (starboard) RPM Revolution Per Minute SAE Society of Automotive Engineering T.I.G. Tungsten Inert Gas Vac Volt, Alternative Current Vdc Volt, Direct Current 2 4 1 3 F04L03C INTRODUCTION

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2001-2002 Seadoo Sport Boats Service Repair Workshop Manual 01 02

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