1999 Sea-Doo Speedster Service & Repair Manual

219 100 099 Volume 2 SPEEDSTER/SK

1999 Shop Manual VOLUME 2 SPEEDSTER SPEEDSTER SK

Legal deposit: National Library of Quebec 1 st trimester 1999 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. 1999 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 – 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 – Water-Flooded Engine .............................................................. 02-04-1 05 – Storage ..................................................................................... 02-05-1 03 TROUBLESHOOTING 01 – Table of contents...................................................................... 03-01-1 02 – Troubleshooting........................................................................ 03-02-1 03 – Flow Chart ................................................................................ 03-03-1 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 indicates this year is major changes brought to this shop manual including 717 engine procedures applicable to the new Speedster SK model. SERVICE TOOLS AND SERVICE PRODUCTS • Revised tool part numbers. Tool are identical to last year, only part numbers have been modified. • The following tools are new: • Radio installation tool (P/N 295 100 106). • Tool board (P/N 295 500 608). • Tie-down (P/N 295 100 088). • Lift kit: –14 foot (P/N 295 000 160). –16 foot (P/N 295 100 085). –18 foot (P/N 295 100 045). • The following products are new: • Loctite Chisel (P/N 413 708 500) replaces Gasket stripper (P/N 295 000 110). • Parts cleaner (P/N 413 711 809) replaces Loctite safety solvent (P/N 293 800 019). MAINTENANCE • Revised periodic inspection chart with aluminum anode inspection. • Revised flushing procedure. • New photographs. • New flow chart. ENGINE • Revised engine cover removal procedure + photographs. • New main battery cut-off switch. • New wire color codes on generating and charging coils. FUEL SYSTEM • Revised procedure for clamp removal. LUBRICATION SYSTEM • Oil reservoir removal procedure. WHAT’S NEW

V ELECTRICAL • Standardized wire color codes. • Main battery cut-off switch on all boats. • New aluminium anode system on all boats. • Identified ground blocks to ease troubleshoot. • Connector location table moved to WIRING DIAGRAM 13-01. PROPULSION SYSTEM • Revamped weedless rod and cables replacement. HULL/DECK • New paint colors for 1999. • New swivel base removal procedure. • New ski post removal/disassembly/installation procedure for Speedster SK model. • New bow cover removal/installation/alignment procedure for Speedster SK model. • Lock pin adjustment and step removal procedures for Speedster SK model. TECHNICAL DATA • Updated specifications for 1999. WIRING DIAGRAMS • Updated for 1999. WHAT’S NEW

VI INTRODUCTION 0 This Shop Manual covers the following BOMBAR- DIER made SEA-DOO ® Jet Boat. MAXIMUM BOAT CAPACITY The jet boat maximum capacity can be found on RH side of operator position. TYPICAL 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. MODEL MODEL NUMBER Speedster 5678 Speedster SK 5677/5681 MAXIMUM CAPACITIES U.S. COAST GUARD 7 THIS BOAT COMPLIES WITH U.S. AND CANADIAN COAST GUARD SAFETY STANDARDS IN EFFECT ON THE DATE OF CERTIFICATION BOAT DESIGN CATEGORY: C PERSONS OR 565 KG/1245 LBS. MADE IN U.S.A., BOMBARDIER CORPORATION OF AMERICA 565 KG/1245 LBS. PERSONS, GEAR N R F10L1YA F09L03B 1 CEC 1 2 3 4 5 L 4 9 5 Model year Serial number* *A letter may also be used as a digit. F00A0YA Month of production Year of production *A letter may also be used as a digit. INTRODUCTION

VII ENGINE IDENTIFICATION NUMBER (E.I.N.) 717 Engine E.I.N. is located on the upper side of the magneto housing. TYPICAL — 717 ENGINE 1. Engine Identification Number (E.I.N.) 787 Engine E.I.N is located on crankcase PTO side. TYPICAL — 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 begin- ning of most sections. 1 F01D01A F01D87A 1 INTRODUCTION

1999 Sea-Doo Speedster Service & Repair Manual

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