1998 SeaDoo Jet Boat - Sportster Challenger Speedster - Workshop Manual

1998 Shop Manual VOLUME 1 SPORTSTER/1800 CHALLENGER/1800 R

Legal deposit: National Library of Quebec 1 st trimester 1998 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. 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.

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

II SECTION SUBSECTION PAGE 09 PROPULSION SYSTEM 01 – Table of Contents...................................................................... 09-01-1 02 – Jet Pump................................................................................... 09-02-1 03 – Drive System ............................................................................ 09-03-1 04 – Reverse System........................................................................ 09-04-1 05 – Weedless System..................................................................... 09-05-1 10 STEERING SYSTEM 01 – Table of Contents...................................................................... 10-01-1 02 – Steering System ....................................................................... 10-02-1 03 – Alignment.................................................................................. 10-03-1 04 – Throttle/Shifter Controller ......................................................... 10-04-1 11 HULL/DECK 01 – Table of Contents...................................................................... 11-01-1 02 – Components ............................................................................. 11-02-1 03 – Repair ........................................................................................ 11-03-1 04 – Painting ..................................................................................... 11-04-1 12 TECHNICAL DATA...................................................................................................................... 12-01-1 13 WIRING DIAGRAMS................................................................................................................... 13-01-1 TABLE OF CONTENTS

III SAFETY NOTICE 0 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 WHAT’S NEW 0 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. SERVICE TOOLS AND SERVICE PRODUCTS • Complete new section. • The following tools are new: • Distance gauge for positioning of bearings on crankshaft. • Piston pin puller with interchangeable sleeves. • Crimping tool for AMP connectors. • New P/N for MPEM programmer. • Engine alignment tool with replaceable plates. • The following products are new: • Thread sealant, Loctite 577. • Deoxit contact lubricant. • The Right Stuff Gasket replaces the Ultra Black silicone. • Bombardier storage oil. 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. WHAT’S NEW

V 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. WHAT’S NEW

VI INTRODUCTION 0 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 Sportster 5614/5619/5634 Sportster 1800 5613/5618/5633 Challenger 5612/5617/5632 Challenger 1800 5611/5616/5631 MAXIMUM CAPACITIES MADE IN U.S.A. BOMBARDIER CORPORATION OF AMERICA XXXX U.S. COAST GUARD 4 PERSONS OR 660 LBS. 660 LBS. PERSONS, GEAR THIS BOAT COMPLIES WITH U.S. AND CANADIAN COAST GUARD SAFETY STANDARDS IN EFFECT ON THE DATE OF CERTIFICATION BOAT DESIGN CATEGORY: C N R 1 F04L8WA F04L8SA 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. INTRODUCTION

VII 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 13 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 HULL/DECK 12 TECHNICAL DATA 13 WIRING DIAGRAMS Each section is divided in various subsections, and again, each subsection has one or more divi- sion. A table of contents is included at the beginning of most sections. 1 F01D01A F01D87A 1 INTRODUCTION

1998 SeaDoo Jet Boat - Sportster Challenger Speedster - Workshop Manual

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