Sea-Doo Challenger 1997 Workshop Service Manual for Repair

1997 Shop Manual Volume 2 Speedster, Challenger/1800 R 219 100 059

Legal deposit: National Library of Quebec 1 st trimester 1997 National Library of Canada All rights reserved. No parts of this manual may be repro- duced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1997 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.

I SECTION SUB-SECTION PAGE SAFETY NOTICE .................................................................................................................................. III INTRODUCTION ................................................................................................................................... IV 01 MAINTENANCE 01 – Table of Contents ..................................................................... 01-01-1 02 – Periodic Inspection Chart ......................................................... 01-02-1 03 – Flushing and Care ..................................................................... 01-03-1 04 – Water-Flooded Engine .............................................................. 01-04-1 05 – Storage ..................................................................................... 01-05-1 02 TROUBLESHOOTING ................................................................................................................ 02-01-1 03 ENGINE 01 – Table of Contents ..................................................................... 03-01-1 02 – Leak Test .................................................................................. 03-02-1 03 – Removal and Installation .......................................................... 03-03-1 04 – Magneto System...................................................................... 03-04-1 05 – Top End .................................................................................... 03-05-1 06 – Bottom End .............................................................................. 03-06-1 07 – Rotary Valve ............................................................................. 03-07-1 08 – Exhaust System ....................................................................... 03-08-1 04 COOLING SYSTEM 01 – Table of Contents ..................................................................... 04-01-1 02 – Components ............................................................................. 04-02-1 03 – Circuit ....................................................................................... 04-03-1 05 FUEL SYSTEM 01 – Table of Contents ..................................................................... 05-01-1 02 – Fuel Circuit ............................................................................... 05-02-1 03 – Air Intake .................................................................................. 05-03-1 04 – Carburetors............................................................................... 05-04-1 06 LUBRICATION SYSTEM 01 – Table of Contents ..................................................................... 06-01-1 02 – Oil Injection Reservoir .............................................................. 06-02-1 03 – Oil Injection Pump .................................................................... 06-03-1 07 ELECTRICAL 01 – Table of Contents ..................................................................... 07-01-1 02 – Overview .................................................................................. 07-02-1 03 – Ignition System ........................................................................ 07-03-1 04 – Spark Plugs............................................................................... 07-04-1 05 – The DESS (Digitally Encoded Security System) ....................... 07-05-1 06 – MPEM (Multi-Purpose Electronic Module) ............................... 07-06-1 07 – Charging System ...................................................................... 07-07-1 08 – Starting System........................................................................ 07-08-1 09 – Instruments and Accessories ................................................... 07-09-1 TABLE OF CONTENTS

II SECTION SUB-SECTION PAGE 08 PROPULSION AND DRIVE SYSTEMS 01 – Table of Contents..................................................................... 08-01-1 02 – Jet Pump.................................................................................. 08-02-1 03 – Drive System ........................................................................... 08-03-1 04 – Reverse System....................................................................... 08-04-1 05 – Weedless System.................................................................... 08-05-1 06 – Variable Trim System (VTS)...................................................... 08-06-1 09 STEERING SYSTEM 01 – Table of Contents..................................................................... 09-01-1 02 – Steering System ...................................................................... 09-02-1 03 – Alignment................................................................................. 09-03-1 04 – Throttle/Shifter/VTS Controller ................................................. 09-04-1 10 HULL/DECK 01 – Table of Contents..................................................................... 10-01-1 02 – Components ............................................................................ 10-02-1 03 – Hull and Deck Repair................................................................ 10-03-1 04 – Painting .................................................................................... 10-04-1 11 TECHNICAL DATA ..................................................................................................................... 11-01-1 12 WIRING DIAGRAMS.................................................................................................................. 12-01-1 TABLE OF CONTENTS

III 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 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 its time of manufac- ture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufac- turing the product. The use of Bombardier parts is most strongly recommended when considering replacement of any com- ponent. 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: 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. ◆ 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. SAFETY NOTICE

IV INTRODUCTION This Shop Manual covers the following BOMBAR- DIER made SEA-DOO ® jet boats. BOAT MODEL NUMBER The jet boat model number can be found on RH side of operator position. TYPICAL 1. Model number 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 illustration for a description of the serial number. Some boats may have a serial number beginning with CEC. CEC boats are manufactured in USA and ZZN boats are manufactured in Canada. MODEL MODEL NUMBER SPEEDSTER 5602/5608 CHALLENGER 5603/5606 CHALLENGER 1800 5600/5601 F04L2SB 1 Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number* *A letter may also be used as a digit. F00A0CA Month of production Year of production *A letter may also be used as a digit. 1997 BOMBARDIER JET BOAT SHOP MANUAL

V ENGINE IDENTIFICATION NUMBER (E.I.N.) It is located on the upper side of the magneto housing. TYPICAL — 717 ENGINE 1. Engine Identification Number (E.I.N.) 787 ENGINE 1. Engine Identification Number (E.I.N.) ARRANGEMENT OF THIS MANUAL The manual is divided into 12 major sections: 01 MAINTENANCE 02 TROUBLESHOOTING 03 ENGINE 04 COOLING SYSTEM 05 FUEL SYSTEM 06 LUBRICATION SYSTEM 07 ELECTRICAL 08 PROPULSION SYSTEM 09 STEERING SYSTEM 10 HULL/DECK 11 TECHNICAL DATA 12 WIRING DIAGRAMS Each section is divided in various sub-sections, and again, each sub-section has one or more divi- sion. A table of contents is included at the beginning of most sections. 1 F01D01A F01D87A 1 1997 BOMBARDIER JET BOAT SHOP MANUAL

VI Section 03 ENGINE Sub-Section 04 (MAGNETO SYSTEM) MAGNETO SYSTEM 717 Engine 03-04-1 F01D4WS 12 11 5 N•m (44 lbf•in) 13 9 N•m (80 lbf•in) Loctite 242 4 6 8 Loctite 242 7 6 N•m (53 lbf•in) Loctite 242 6 N•m (53 lbf•in) 9 Loctite 242 5 6 N•m (53 lbf•in) 3 14 Loctite 242 4 Loctite 648 10 15 145 N•m (107 lbf•ft) Anti-seize lubricant 2 9 N•m (80 lbf•in) 1 Page heading indicates section and sub-section detailed. Tightening torque nearby fastener. In this case, nut must be torqued to 145 N•m (107 lbf•ft). Exploded view assists you in identifying parts and related positions. TYPICAL PAGE F04A09S Illustration number for publishing process. Sub-section title indicates beginning of the sub-section. Dotted box contains parts of a particular model or an exploded view. Page numbering system: 03: ENGINE section 04: MAGNETO SYSTEM sub-section 1: First page of this sub-section Italic sub-title above exploded view indicate pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 242 to screw threads. Bold face number indicates special procedure concerning this part. Pay attention to torque specifications. Some of these are in lbf•in instead of lbf•ft. Use appro- priate torque wrench. CAUTION ▼ 1997 BOMBARDIER JET BOAT SHOP MANUAL

VII 1 2 Section 06 FUEL SYSTEM Sub-Section 03 (CARBURETORS) 06-03-4 Step : Install pump gauge tester to pulse nipple Step : Pump tester until it reaches the desired pressure 1. Fuel outlet nipple 2. Fuel inlet nipple A. 28 kPa (4 PSI) Diaphragm Challenger Model Only CARBURETOR REMOVAL Inspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.). Pump Diaphragm Leak Test TYPICAL 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. 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. DISASSEMBLY AND INSPECTION 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). Diaphragm no. 3 must stand pressure for 10 seconds. If pressure drops, replace diaphragm. TYPICAL PAGE Sub-title indicates a particular procedure for the named part. ''TYPICAL'' caption indicates a general view which does not represent full detail. Italic bold face setting in this case indicates that particular procedure for Challenger is finished, so from this point, all others models are concerned. Italic bold face setting indicates a particular procedure concerning a model. Service tool to be used to perform a certain procedure. Title indicates main procedure to be carried-out. F04A08S Sub-sub-title indicates a particular testing, adjustment or repair procedure. Illustration always follows text it is pertained to. Numbers in a frame are used to give a sequence to be perfomed for above illustration. Numbers are used for description of components for above illustration. Letters are used for any measures for above illustration. F01F0XB A 2 1 1 2 Number: following part name refers to exploded view at beginning of sub-section. 1997 BOMBARDIER JET BOAT SHOP MANUAL

Sea-Doo Challenger 1997 Workshop Service Manual for Repair

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