2004 BOMBARDIER SEA-DOO SPORTSER 4-TEC Factory Service & Work Shop Manual

Printed in Canada (lbg2004-001a.fmSB) ® TM Trademarks of Bombardier Inc. or its subsidiaries. ©2003 Bombardier Inc. All rights reserved. 2004-1 Page 1 of 4 PROBLEM The inner lining of the air intake hose(s) may col- lapse, preventing proper air flow to engine(s). SOLUTION Replace air intake hose(s). PARTS REQUIRED PROCEDURE Sportster 4-TEC Each Sportster 4-TEC will need 610 mm (24 in) of air intake hose cut to replace the existing air intake hose. Open engine compartment cover. Remove engine access cover tray. Loosen clamps and remove air intake hose from engine and air box fitting. Save clamps for reinstallation. TYPICAL — SPORTSTER 4-TEC 1. Loosen this clamp and remove hose from air box Campaign no. 2003-0004 and 2004-0001 No. 2004-1 Date: September 26, 2003 SUBJECT: Intake Hose Replacement YEAR MODEL MODEL NUMBER SERIAL NUMBER 2003 Sportster™ 4-TEC™ 5768/5770 All 2004 Speedster™ 200 5773 See Attachment Schedule “A”

of 4 2004-1 TYPICAL — SPORTSTER 4-TEC 1. Loosen this clamp and remove air intake hose from engine fitting Remove original hose from engine compartment. Put retained clamps onto and install new intake hose. Tighten clamps until hose is firmly secured. Reinstall engine access cover tray and close engine compartment cover. Speedster 200 The Speedster 200 will require two pieces cut, one each to replace the existing port and starboard air intake hoses. Cut the port hose to 1020 mm (40.2 in). Cut the starboard hose to 930 mm (36.6 in). Open engine compartment cover. Remove engine access cover tray. Lift and remove rear seat cushions. Remove two screws from each storage tub and remove both storage tubs. Loosen clamps and remove air intake hoses from each engine and air box fitting. Save clamps for reinstallation. TYPICAL — SPEEDSTER 200 1. Loosen this clamp and remove hose from starboard engine fitting 2. Loosen this clamp and remove hose from port engine fitting TYPICAL — PORT AIR BOX 1. Loosen this clamp and remove hose from port air box TYPICAL — STARBOARD AIR BOX 1. Loosen this clamp and remove hose from starboard air box         

2004-1 Page 3 of 4 Remove original hoses from engine compartment. Put clamps onto new 1020 mm (40.2 in) port intake hose and install. Put clamps onto new 930 mm (36.6 in) starboard intake hose and install. Tighten clamps until each hose end is firmly secured. Reinstall storage tubs and replace cushions. Reinstall engine access cover tray. Close engine compartment cover. WARRANTY Submit a warranty claim using the following infor- mation: For models 5768 and 5770 Sportster 4-TEC For model 5773 Speedster 200 For claiming procedure, refer to the Dealer/Distributor Warranty Guide. Do not return parts. Retain per Warranty Guide. Submit a warranty claim on the BOSSWeb™ web- site or on a Campaign Claim Form (P/N 484 070 300). If a paper warranty claim is used, send claim to: USA DEALERS Shipping address is: Bombardier Recreational Products 7575 Bombardier Court Wausau, WI 54401 ATTN: WARRANTY CANADIAN DEALERS Shipping address is: Bombardier Warranty Parts Center 565 de la Montagne Valcourt, QC J0E 2L0 Campaign Number 2003-0004 Claim Type 07 Flat Rate Time 0.3 hour Expiration Date September 20, 2004 Campaign Number 2004-0001 Claim Type 07 Flat Rate Time 0.4 hour Expiration Date September 20, 2004

of 4 2004-1 Schedule “A” Serial Number Listing of Involved Vehicles Model 5773 US-CEC60000D304 US-CEC60001E304 US-CEC60002E304 US-CEC60003E304 US-CEC60004E304 US-CEC60005E304 US-CEC60006E304 US-CEC60008E304 US-CEC60009E304 US-CEC60010E304 US-CEC60011E304 US-CEC60012E304 US-CEC60013E304 US-CEC60014E304 US-CEC60015E304 US-CEC60016E304 US-CEC60017E304 US-CEC60018E304 US-CEC60019E304 US-CEC60020E304 US-CEC60021E304 US-CEC60022E304 US-CEC60023E304 US-CEC60024E304 US-CEC60025E304 US-CEC60026E304 US-CEC60027E304 US-CEC60028E304 US-CEC60029E304 US-CEC60030E304 US-CEC60031E304 US-CEC60032E304 US-CEC60033F304 US-CEC60034F304 US-CEC60035F304 US-CEC60036F304 US-CEC60037F304 US-CEC60038F304 US-CEC60039F304 US-CEC60040F304 US-CEC60041F304 US-CEC60042F304 US-CEC60043F304 US-CEC60044F304 US-CEC60045F304 US-CEC60046F304 US-CEC60048F304 US-CEC60049F304 US-CEC60050F304 US-CEC60051F304 US-CEC60052F304 US-CEC60053F304 US-CEC60054F304 US-CEC60055F304 US-CEC60056F304 US-CEC60057F304 US-CEC60058F304 US-CEC60059F304 US-CEC60060F304 US-CEC60061F304 US-CEC60062F304 US-CEC60063F304 US-CEC60064F304 US-CEC60065F304 US-CEC60066F304 US-CEC60067F304 US-CEC60068F304 US-CEC60069F304 US-CEC60070F304 US-CEC60071F304 US-CEC60072F304 US-CEC60073F304 US-CEC60074F304 US-CEC60075F304 US-CEC60076F304 US-CEC60077F304 US-CEC60078F304 US-CEC60079F304 US-CEC60080F304 US-CEC60081F304 US-CEC60082F304 US-CEC60083F304 US-CEC60084F304 US-CEC60085F304 US-CEC60086F304 US-CEC60087F304 US-CEC60088F304 US-CEC60089F304 US-CEC60090F304 US-CEC60091F304 US-CEC60092F304 US-CEC60093F304 US-CEC60094F304 US-CEC60095F304 US-CEC60096F304 US-CEC60097F304 US-CEC60098F304 US-CEC60099F304 US-CEC60100F304 US-CEC60101F304 US-CEC60102F304 US-CEC60103F304 US-CEC60104F304 US-CEC60105F304 US-CEC60106G304 US-CEC60107G304 US-CEC60108G304

Printed in Canada (LBG-2004-002a.fm SB) ® TM Trademarks of Bombardier Inc. or its subsidiaries. ©2003 Bombardier Inc. All rights reserved. 2004-2 Page 1 of 9 PROBLEM Fuel hose clamps in certain Sportster 4-TEC and Speedster 200 boats could be improperly positioned on end of fuel supply line(s). This could allow the fuel hose to become loose or dislodged causing a leak and creating a risk of explosion and serious personal injury. SOLUTION Inspect fuel supply line clamps as per the following procedure and replace as necessary. PARTS REQUIRED ➀ When ordering quantity 1 of this part number, dealer receives 5 clamps. ➁ When ordering quantity 1 of this part number, dealer receives 10 darts. PROCEDURE Sportster 4-TEC Open engine compartment cover and remove engine compartment storage tray. Turn battery switch to OFF position. Remove center seat bottom cushion by pulling back sides upwards to release darts. Pull cushion to- wards front of boat to release cushion from S-clips. PULL UPWARDS FROM SIDES Campaign no. 2003-0005 and no. 2004-0003 No. 2004-2 Date: November 26, 2003 SUBJECT: Fuel Hose Clamps YEAR MODEL MODEL NUMBER SERIAL NUMBER 2003 Sportster™ 4-TEC™ 5768/5770 All 2004 Sportster™ 4-TEC™ 5150/5151 See Attachment Schedule “A” 2004 Speedster ® 200 5160/5773

of 9 2004-2 1. S-clip Remove access cover and inspect clamp at fuel pump module. TYPICAL 1. Inspect this clamp Remove dipstick and fuel rail cover from engine. Reinstall dipstick. From inside engine compartment, inspect clamp on fitting at fuel rail. TYPICAL 1. Inspect this clamp Fuel Line Clamp Inspection Inspect clamps on both ends of fuel supply line. Each clamp must be positioned 3 - 7 mm (0.12 - 0.28 in) from the end of the hose. Clamps either too close or too far from the ends must be replaced. TYPICAL A. 3 - 7 mm (0.12 - 0.28 in)        

2004-2 Page 3 of 9 Clamp Replacement Release clamp(s) using cutters. TYPICAL — USE CUTTERS AS SHOWN NOTE: Before attempting to remove hose from nipple, remove fitting from fuel rail or fuel pump module to prevent damage to nipple or fitting. Remove fitting from hose and slide on new clamp(s). Reinstall fitting into hose and position and tighten clamp(s) as described above. TYPICAL — INSTALL CLAMP NOTE: Oetiker pliers (P/N 295 000 070) must be used for proper installation. Reattach fitting to fuel rail or fuel pump (whichever was removed). Turn battery switch to ON position. Install lanyard to allow fuel pump to pressurize fuel line. Check for leaks around hose ends and fittings. Remove and install lanyard several times while looking for leaks. Repair all leaks and re-test as necessary. Install access cover. Add new darts (P/N 293 730 021) to seat cushion and slide cushion rearward onto S-clips. Push rear sides of cushion down to engage darts in holes. Remove dipstick and reinstall fuel rail cover. Reinstall dipstick. Reinstall engine compartment storage tray and close engine cover to complete procedure. Speedster 200 Open engine compartment cover and remove engine compartment storage tray. Remove dipstick and fuel rail cover from each engine. Reinstall dipsticks. Turn battery switch to OFF position. Unsnap, lift and remove rear seat cushions. Remove two screws from each rear storage tub and remove both tubs. Fuel Line Clamp Inspection From rear storage tub openings, inspect clamps on both ends of fuel supply line for each engine. All clamps must be positioned 3 - 7 mm (0.12 - 0.28 in) from the end of hose. Clamps either too close or too far from the ends must be replaced. TYPICAL A. 3 - 7 mm (0.12 - 0.28 in)    

of 9 2004-2 TYPICAL — SPEEDSTER 200 1. Inspect this clamp at port engine fuel pump 2. Inspect this clamp at starboard engine fuel pump TYPICAL — SPEEDSTER 200 1. Inspect these clamps on fuel rail fuel hose assembly at each engine Clamp Replacement Release clamp(s) using cutter. TYPICAL — USE CUTTERS AS SHOWN NOTE: Before attempting to remove hose from nipple, remove fitting from fuel rail or fuel pump module to prevent damage to nipple or fitting. Remove fitting from hose and slide on new clamp(s). Reinstall fitting into hose and position and tighten clamp(s) as described above. TYPICAL — INSTALL CLAMP NOTE: Oetiker pliers (P/N 295 000 070) must be used for proper installation. Reattach fitting to fuel rail(s) or fuel pump(s). Turn battery switch to ON position. Install lanyard to allow fuel pumps to pressurize fuel lines. Check for leaks around hose ends and fittings. Remove and install lanyard several times while looking for leaks. Repair all leaks and re-test as necessary. Reinstall storage tubs with retaining screws and slide cushions into position and snap in place. Remove dipsticks and reinstall fuel rail covers. Reinstall dipsticks. Reinstall engine compartment storage tray and close engine cover to complete procedure.       

2004-2 Page 5 of 9 WARRANTY Submit a warranty claim using the following infor- mation: For 2003 Sportster 4-TEC For 2004 Sportster 4-TEC For 2004 Speedster 200 NOTE: Reimbursement for two darts (P/N 293 730 021) is included in labor time for all Sportster 4-TEC inspections. NOTE: For replacement of clamps, both Inspect and Repair boxes must be checked on the claim. Flat rate times will be added together. For claiming procedure, refer to the Dealer War- ranty Guide. NOTE: No part return is required for this campaign. Campaign Number 2003-0005 Claim Type 07 Flat Rate Time – Inspection 0.3 Flat Rate Time – Replacement 0.1 Campaign Number 2004-0003 Claim Type 07 Flat Rate Time – Inspection 0.3 Flat Rate Time – Replacement 0.1 Campaign Number 2004-0003 Claim Type 07 Flat Rate Time – Inspection 0.3 Flat Rate Time – Replacement 0.2

2004 BOMBARDIER SEA-DOO SPORTSER 4-TEC Factory Service & Work Shop Manual

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