1996 Sea Doo Sportster 5895 Service Repair Manual

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219 100 044 0 0 0 1996 Shop Manual 0 R Legal deposit : National Library of Quebec 4th trimester 1995 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. 1995 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 TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE .................................................................................................................................. II INTRODUCTION ................................................................................................................................... III 01 SERVICE TOOLS AND PRODUCTS 01 – Mandatory Tools....................................................................... 01-01-1 02 – Recommended Tools ............................................................... 01-02-1 03 – Service Products ...................................................................... 01-03-1 02 MAINTENANCE 00 – Table of contents...................................................................... 02-00-1 01 – Periodic Inspection Chart ......................................................... 02-01-1 02 – Flushing and Care..................................................................... 02-02-1 03 – Water-Flooded Engine.............................................................. 02-03-1 04 – Storage..................................................................................... 02-04-1 03 TROUBLESHOOTING 00 – Troubleshooting........................................................................ 03-00-1 04 ENGINE 00 – Table of contents...................................................................... 04-00-1 01 – Removal and Installation .......................................................... 04-01-1 02 –Top End ..................................................................................... 04-02-1 03 – PTO Flywheel and Magneto..................................................... 04-03-1 04 – Bottom End .............................................................................. 04-04-1 05 – Rotary Valve ............................................................................. 04-05-1 05 COOLING SYSTEM 00 – Table of contents...................................................................... 05-00-1 01 – Components............................................................................. 05-01-1 02 – Circuit ....................................................................................... 05-02-1 06 FUEL SYSTEM 00 – Table of contents...................................................................... 06-00-1 01 – Fuel Circuit ............................................................................... 06-01-1 02 – Air Intake .................................................................................. 06-02-1 03 –Carburetors................................................................................ 06-03-1 07 LUBRIFICATION SYSTEM 00 – Table of contents...................................................................... 07-00-1 01 – Oil Injection Reservoir .............................................................. 07-01-1 02 – Oil Injection Pump.................................................................... 07-02-1 08 ELECTRICAL 00 – Table of contents...................................................................... 08-00-1 01 – Overview.................................................................................. 08-01-1 02 – Magneto System...................................................................... 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 10 –Wiring Diagram.......................................................................... 08-10-1 II TABLE OF CONTENTS SECTION SUB-SECTION PAGE 09 PROPULSION AND DRIVE SYSTEMS 00 – Table of contents ..................................................................... 09-00-1 01 – Propulsion and Drive Systems................................................. 09-01-1 02 – Reverse System....................................................................... 09-02-1 03 – Variable Trim System (VTS)...................................................... 09-03-1 10 STEERING SYSTEM 00 – Table of contents ..................................................................... 10-00-1 01 – Steering System ...................................................................... 10-01-1 02 – Alignment................................................................................. 10-02-1 03 – Throttle / Shifter / VTS Controller ............................................. 10-03-1 11 HULL / DECK 00 – Table of contents ..................................................................... 11-00-1 01 – Components ............................................................................ 11-01-1 02 – Repair....................................................................................... 11-02-1 03 – Painting .................................................................................... 11-03-1 12 TECHNICAL DATA 01 – All Models ................................................................................ 12-01-1 III SAFETY NOTICE SAFETY NOTINCE 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 ; 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 watercraft 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. 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 modi- fications may render use of the boat illegal under existing federal, provincial and state regulations. ; - ' IV 1996 BOMBARDIER JET BOAT SHOP MANUAL INTRODUCTION This Shop Manual covers the following BOMBAR- DIER made SEA-DOOr jet boats. BOAT MODEL NUMBER The jet boat model number can be found on RH side of operator position. 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 (H.I.N.) The 5 digits after ZZN are the boat serial number. MODEL MODEL NUMBER SPORTSTER 5895 SPEEDSTER 5894 CHALLENGER 5896 Bombardier 1 / min x 1000 0 2 1 3 4 5 6 7 8 Bombardier 1 / min x 1000 0 2 1 3 4 5 6 7 8 60 45 15 0 30 Bombardier MPH km/h Bombardier ON OFF WARNING XXXX MADE IN CANADA BOMBARDIER INC. F04L3QA 1 F04L2SB 1 F004A07A Z Z N 1 2 3 4 5 X X X X Serial number V 1996 BOMBARDIER JET BOAT SHOP MANUAL 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 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL 09 PROPULSION AND DRIVE SYSTEMS 10 STEERING SYSTEM 11 HULL / DECK 12 TECHNICAL DATA 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 begin- ning of most sections. 1 F01D01A F01D87A 1 VI 1996 BOMBARDIER JET BOAT SHOP MANUAL Section 08 ELECTRICAL Sub-Section 01 (MAGNETO SYSTEM) MAGNETO SYSTEM 657 Engine 08-01-1 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 SPORTSTER Model Only 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 assits you in identifying parts and related positions. TYPICAL PAGE F04A04S Illustration number for publishing process. ▼CAUTION : Pay attention to torque specifications. Some of these are in lbf•in instead of lbf•ft. Use appropriate torque wrench. Sub-section title indicates beginning of the sub-section. Dotted box contains parts of a particular model (in this case, the Sporster model ) or an exploded view. Page numbering system : 08 : ELECTRICAL SYSTEM section 01 : MAGNETO SYSTEM sub-section 1 : First page of this sub-section Italic sub-tiltle 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. Number indicates special procedure concerning this part. This Shop Manual uses technical terms which may be slightly different from the ones in the Parts Catalog. VI 1996 BOMBARDIER JET BOAT SHOP MANUAL Section 08 ELECTRICAL Sub-Section 01 (MAGNETO SYSTEM) MAGNETO SYSTEM 657 Engine 08-01-1 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 SPORTSTER Model Only 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 assits you in identifying parts and related positions. TYPICAL PAGE F04A04S Illustration number for publishing process. ▼CAUTION : Pay attention to torque specifications. Some of these are in lbf•in instead of lbf•ft. Use appropriate torque wrench. Sub-section title indicates beginning of the sub-section. Dotted box contains parts of a particular model (in this case, the Sporster model ) or an exploded view. Page numbering system : 08 : ELECTRICAL SYSTEM section 01 : MAGNETO SYSTEM sub-section 1 : First page of this sub-section Italic sub-tiltle 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. Number indicates special procedure concerning this part. This Shop Manual uses technical terms which may be slightly different from the ones in the Parts Catalog. VIII 1996 BOMBARDIER JET BOAT SHOP MANUAL GENERAL INFORMATION 1. BOW (front) 2. STARBOARD (RH) 3. STERN (rear) 4. PORT (LH) 5. In marine insdustry, 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. The information and component / system descrip- tions contained in this manual are correct at time of publication. Bombardier Inc. however, main- tains a policy of continuous improvement of its products without imposing upon itself any obliga- tion to install them on products previously manu- factured. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment 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. ILLUSTRATIONS AND PROCEDURES The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function. CAUTION : These boats are designed with parts dimensioned in both the metric and the imperial systems. When replacing fas- teners, make sure to use only those recom- mended by Bombardier. Mismatched or incorrect fasteners could cause damage to the boat or possible personal injury. As many of the procedures in this manual are in- terrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or sub-section in which the proce- dure is contained. A number of procedures throughout the book re- quire the use of special tools. Before commenc- ing any procedure, be sure that you have on hand all the tools required, or approved equivalents. Technical Publications Bombardier Inc. Valcourt (Quebec), Canada 2 5 4 1 3 F04L03B - Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) 01-01-1 MANDATORY TOOLS O NOTE : The numbers outlined in black (example : 1 ) are reference numbers to tools from other divisions (Sea-Doo and / or Sea-Doo Jet Boats). Matching numbers are the same tool even if the part numbers are different. ENGINE MAG side PTO side 8 1 5 2 3 4 4 6 8 7 7 F01D884 1) Puller 200 P / N 290 876 298 2) Protective cap 554 (both ends) P / N 290 876 557 3) Ring (both ends) 555 P / N 290 977 490 4) Ring halves (PTO) 556 P / N 290 977 475 (2) 5) Distance ring (MAG) 557 P / N 290 876 569 6) Ring halves (MAG) 558 P / N 290 276 025 (2) 7) Screw M8 x 40 559 P / N 290 840 681 (2) 8) Screw M8 x 70 560 P / N 290 841 201 (2) APPLICATION All models. Degree wheel 1 P / N 295 000 007 360 350 340 330 320 31030029028027026025024023 0 2 2 0 2 1 0 2 0 0 1 9 0 1 8 0 1 7 0 1 6 0 1 5 0 1401301201101009080706050 40 30 20 1 0 1 0 20 30 40 506070809010011012013014 0 1 5 0 1 6 0 1 7 0 1 8 0 1 9 0 2 0 0 2 1 0 2 2 0 23024025026027028029030031032 0 330 340 35 0 3 6 0 A00B334 APPLICATION All models. Puller 5 P / N 295 000 106 A00C1A4 APPLICATION All models. Pusher 12 P / N 290 876 500 A00B2J4 APPLICATION All models. Piston circlip installer A) P / N 295 000 077 202 B) P / N 290 877 016 548 Piston circlip A01B1P4 APPLICATION A) 587 engine. B) 657 and 717 engines. Pusher 229 P / N 290 876 605 A00C0Y4 APPLICATION All models. Bombardier ignition 236 tester P / N 295 000 008 0 10 20 30 40 50 90 80 70 60 100 Low High Indicator IGNITION TESTER Reset A00C1K4 APPLICATION All models. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) 01-01-2 Rubber pad 547 P / N 295 000 101 F01B0J4 Puller plate 549 P / N 290 876 080 A00C1R4 Extension handle 550 P / N 295 000 125 F01D164 Screw M8 x 35 (3) 551 P / N 290 841 591 F00A094 Sleeve (3) 552 P / N 290 847 220 F00A0A4 APPLICATION All models. PTO flywheel remover / 553 installer P / N 295 000 001 F01J0T4 APPLICATION All models. ONOTE : This tool is also used for the impeller. Puller 562 P / N 290 876 488 F01B0I4 APPLICATION All models. A) Alignment tool support P / N 295 000 090 563 B) Alignment shaft P / N 295 000 093 571 F01L2R4 APPLICATION All models. Piston pin puller 566 P / N 295 000 092 1 2 3 Replacement parts : 1. Locating sleeve P / N 290 877 181 772 2. Expansion sleeve P / N 290 877 041 771 3. Extracting nut P / N 290 877 155 770 F01B0V4 APPLICATION All engines. MPEM programmer 567 P / N 295 000 127 F01B254 APPLICATION 787 engine. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) 01-01-3 Ring gear blocking tool 568 P / N 295 000 134 F01B264 APPLICATION 787 engine. Ring gear puller tool 569 P / N 420 976 235 F01B294 APPLICATION 787 engine. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) 01-01-4 COOLING / FUEL / OIL SYSTEMS Hose pincher 2 P / N 295 000 076 A01B2I4 APPLICATION All models. Gear holder 235 P / N 290 277 905 A00C164 APPLICATION 717 engine. Pliers 601 P / N 295 000 070 F01D174 APPLICATION All models. Pliers 606 P / N 295 000 054 F01B1T4 APPLICATION All models. ONOTE : This tool is also used for the propulsion system. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 01 (MANDATORY TOOLS) 01-01-5 PROPULSION SYSTEM Impeller remover / 553 installer P / N 295 000 001 F01J0T4 APPLICATION All models. O NOTE : This tool is also used for the PTO flywheel. Pliers 602 P / N 295 000 069 F01D184 APPLICATION All models. Impeller shaft holder 603 P / N 295 000 082 F01B0W4 APPLICATION All models. Bearing / seal installer 604 P / N 295 000 107 F01J4K4 APPLICATION All models. Impeller shaft guide 605 P / N 295 000 002 F01J1O4 APPLICATION All models. Pliers 606 P / N 295 000 054 F01B1T4 APPLICATION All models. ONOTE : This tool is also used for the fuel system. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) 01-02-1 RECOMMENDED TOOLS O NOTE : The numbers outlined in black (example : 1 ) are reference numbers to tools from other divisions (Sea-Doo and / or Sea-Doo Jet Boats). Matching numbers are the same tool even if the part numbers are different. ENGINE Ring compressor 766 P / N 290 876 979 A01B1T4 APPLICATION All engines. Coil centering tool 209 P / N 290 876 922 A01B1V4 APPLICATION 717 engine. Cylinder aligning tool 220 P / N 290 876 904 A00B084 APPLICATION All models. Stroboscopic timing light 225 P / N 295 000 078 A01B2K4 APPLICATION All models. Dial indicator 230 (TDC gauge) P / N 295 000 143 A00B2E4 APPLICATION All models. Distance gauge A) P / N 290 876 827 561 B) P / N 290 876 828 760 F01B0H4 APPLICATION A) 717 engine. B) 787 engine. Digital / induction type 237 tachometer P / N 295 000 100 F01B1G4 APPLICATION All models. Digital multimeter 242 P / N 529 022 000 COM VAC VDC MkΩ VΩ 10 A FUSED 1000 V 750 V 300 mV V V OFF 0 10 20 30 A A Ω 0000 _ + F01B1O4 APPLICATION All models. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) 01-02-2 Timing mark pointer 774 P / N 295 000 130 F01B2O4 APPLICATION 717 engine. Timing mark pointer 754 P / N 295 000 135 F01H544 APPLICATION 787 engine. Oil seal pusher 759 P / N 290 877 740 F01B2C4 APPLICATION 787 engine. Spark tester Not sold by Bombardier Superex Canada Ltd No. 15-785 F01B1H4 APPLICATION All models. Terminal remover Not sold by Bombardier Snap-on TT 600-4 F01B1J4 APPLICATION All models. Slide hammer puller Not sold by Bombardier Snap-on : Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4 ONOTE : This tool is also used to pull out impeller shaft seal. F01J0Z4 APPLICATION All models. Ring halves and ring P / N 290 876 330 (halves) 761 P / N 290 876 480 (ring)0 762 F01B2D4 APPLICATION 787 engine. Engine lifting device Not sold by Bombardier Do it yourself Refer to Shop Manual section 04-01 F01D0A4 APPLICATION All models. Feeler gauge 45° Not sold by Bombardier Snap-on FB 300 A F01B1K4 APPLICATION All models. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) 01-02-3 Protective mat 890 P / N 295 000 129 F04L1V4 APPLICATION All models. Safety lanyard switch tool 775 P / N 295 000 121 F01B244 APPLICATION All models. A) Four-pin magneto 763 harness P / N 295 000 131 B) Six-pin magneto 755 harness P / N 295 000 136 F01B284 APPLICATION A) 717 engine. B) 787 engine. Exhaust outlet tool 831 P / N 295 000 132 F01B2A4 APPLICATION Sportster and Speedster. Gear / bearing puller 765 P / N 290 877 665 F04B034 APPLICATION 787 engine. Rotary valve shaft 757 pusher P / N 290 876 609 F01B2B4 APPLICATION 787 engine. Handle 758 P / N 290 877 650 A00C3V4 APPLICATION 787 engine. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) 01-02-4 COOLING / FUEL / OIL SYSTEMS Pump gauge tester 826 (carburetor) P / N 295 000 114 35 4 3 25 2 15 1 5 605040 30 20 10F01B0X4 APPLICATION All models. Pump gauge tester 827 (fuel / oil reservoirs) P / N 295 000 085 F01B0Y4 APPLICATION All models. Screwdriver Not sold by Bombardier Snap-on SDD-143 F01B1P4 APPLICATION All models. Lighted adjustable mirror Not sold by Bombardier Snap-on 50101 F01B1I4 APPLICATION All models. Hose pincher 773 P / N 529 030 400 F01B234 APPLICATION All engines. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 02 (RECOMMENDED TOOLS) 01-02-5 PROPULSION SYSTEM Machinist’s square Not sold by Bombardier Snap-on PMF 122 F02B064 APPLICATION Models equipped with reverse. Fitting remover Not sold by Bombardier Do it yourself Refer to Shop Manual section 09-01 Deep socket 14 mm (9/16 in) F01J2RA APPLICATION All models. Bearing remover Not sold by Bombardier Do it yourself Refer to Shop Manual section 09-01 F01J114 APPLICATION All models. Flexible spout (oil) 834 P / N 414 8373 00 APPLICATION All models. Fitting 828 P / N 295 000 086 F01B0Z4 APPLICATION All models. Slide hammer puller Not sold by Bombardier Snap-on : Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4 ONOTE : This tool is also used to remove rotary valve shaft bearing. F01J0Z4 APPLICATION All models. Hacksaw Not sold by Bombardier Snap-on HS3 F01B1M4 APPLICATION All models. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) 01-03-1 SERVICE PRODUCTS O NOTE : The numbers outlined in black (example : 1 ) are reference numbers to tools from other divisions (Sea-Doo and / or Sea-Doo Jet Boats). Matching numbers are the same tool even if the part numbers are different. Medium strength 154 threadlocker P / N 293 800 015 Loctite 242 (blue) (10 mL) LOCTITE® REMOVABLE THREADLOCKER 242 A00B324 APPLICATION Cylinder head screws (All engines). Tuned pipe nut and screws. Engine rubber mount screws. Armature plate screws. Magneto flywheel / crankshaft. Carburetor mount nuts / screws. Magneto coil screws. Impeller housing cover screws (except for plastic pumps). Venturi / impeller housing screws. Intake grate screws. Engine support screws. Impeller housing / hull nuts. Steering nozzle screws. Reverse gate screws. High strength 155 threadlocker P / N 293 800 005 Loctite 271 (red) (10 mL) LOCTITE® 271 Adhesive Sealant A00B2U4 APPLICATION Impeller shaft thread. High temperature 359 threadlocker P / N 290 899 788 Loctite 648 (green) (5 g) A00B3D4 APPLICATION Crankcase / plug at end of rotary valve shaft. Magneto / ring gear. Paste gasket 152 P / N 293 800 007 Loctite 515 (50 mL) A00B2T4 APPLICATION Cylinder sleeve / O-ring groove. Crankcase halves mating surface. Crankcase screws. Paste gasket 376 P / N 293 800 038 518 Loctite 518 (50 mL) F01B124 APPLICATION Impeller housing cover. Venturi / impeller housing. Impeller shaft seal. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) 01-03-2 Solvent 157 P / N 293 800 019 Loctite Safety Solvent 755 A00B3M4 APPLICATION Impeller shaft threads. Drive shaft splines. Impeller threads and splines. Primer for paste gasket 158 P / N 293 600 013 Loctite Locquic Primer N 170 g (6 oz) A00B3N4 APPLICATION Crankcase halves mating surface. Impeller shaft thread. Venturi / impeller housing mating surface. Heat resistant sealant 374 P / N 413 709 200 Dow Corning 736 DOW CORNING ® RTV Sealant 736 Heat R esista nt Sea lant A00B3U4 APPLICATION Tuned pipe. Dielectric grease 350 P / N 293 550 004 Dow Corning F01B164 APPLICATION Battery posts and cable con- nectors. Thermosensor switch. Grease 924 P / N 293 550 005 (400 g) A00B2L4 APPLICATION PTO flywheel. Gasket stripper 935 N / P 295 500 110 AVERTISSEMENT EXTRÊMEMENT INFLAMMA BLE VAPEUR NOCIVE POISON DÉCAPANT À JOINT D'ÉTAN CHÉ ITÉ 295 000 110 500 ml BOMBARDIER F01B1W4 APPLICATION Mating surfaces of cylinders and crankcase. Crankcase halves. Pipe sealant 358 P / N 293 800 018 Loctite 592 (50 mL) A00B2W4 APPLICATION Plug on impeller housing cover. Plastic fitting tool (P / N 295 000 086) on impeller housing cover. Cooling system fittings. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) 01-03-3 Sea-Doo fuel stabilizer 375 P / N 413 408 600 STABILISANT D'ESSENCE NOUVEA U ® ® A00B3V4 APPLICATION Fuel system. Bombardier-Rotax 915 injection oil P / N 413 802 900 12 x 1 L ® ® Two-stroke Injection Oil ® BOMBARDIER 1 U.S. quart F01B184 APPLICATION All models. Synthetic grease 912 P / N 293 550 010 SYNTHETIC GREASE Sea-Doo (400 g) F01B154 APPLICATION Cylinder and cylinder head screws. Carburetor linkage. Impeller shaft seal lips. Drive shaft / impeller splines. PTO flywheel Lubricant 000 Not sold by Bombardier G.E. Versilube G341M or Esso Beacon 325 A00B1T4 APPLICATION Sliding surface of starter arma- ture shaft splines. Anti-seize lubricant 362 P / N 293 800 023 Loctite anti-seize lubricant 12 oz (454 g) F01B174 APPLICATION Crankshaft thread / PTO flywheel. Crankshaft bearing seat. Spark plug threads. Ignition housing cover screws. Penetrating lubricant 913 P / N 293 600 016 Bombardier Lube REMPLACE SEA-DOO LUB E BOMBARDIER LUBE ou humide LUBRIFIANT ANTICORROS IF Excellent en milieu salin 340 g DANGER INFLAMMABLE CE CONTENANT PEUT EXPLOS ER S'IL EST CHAUFFÉ. L'INHALATION DIRECTE DE CE PRO DUIT PEUT ÊTRE NOCIVE. BOMBARDIER INC. Sea-Doo / Ski-Doo Division Valcourt, Québec, Canada J0E 2LO NO UV EAU ! Pulv éris e m ême inv ersé ! F01B0S4 APPLICATION Throttle cable. Wear ring (when new). Corroded parts. Water flooded engine. Storage. Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) 01-03-4 732 Multi-purpose sealant 917 P / N 293 800 006 Dow Corning (Clear) F01B1C4 APPLICATION Ride shoe screws. Sealant adhesive 934 P / N 293 800 033 (Clear) L A E S D A ADCHEMSCELLANT ADHÉSIF PREMIÈRE QUALITÉ PREMIUM SEALANT ADHESIVE F01B1S4 APPLICATION Ride shoe screws. Sponson. General purpose instant 373 adhesive P / N 293 800 021 Loctite 495 LOCTITESUPER BOUNDERbfh nhhfkkgeruer rijggla jwjetw rjjwetwmwjttmvdiwpe ejfwf fwfksmcskgeruer rijggla jwjetwrjjwetwm wjttmvdiwpe ejfwf fwfksmcsmvdiwpe ejfwf fwfksmcsbfh nhhfkmvdiwpe ejfwf fwfksmcskgeruer rijggla jwjetw rjjwetwmwjttA00B2V4 APPLICATION Rubber to metal bonding and most hard plastic. Adhesive activator 931 P / N 293 530 036 ACTIVEUR D'ADHÉSIF 250 mL POUR L'APPLICATION DE MOULU RE ET VINYLES SENSIBLES À LA PRE SSION LORSQU'UNE MEILLEURE ADHÉRENCE EST NÉCESSAIRE. DANGER -ÉVITER TOUT CONTACT PROLON GÉ AVEC LA PEAU LAVER À L'EAU FROIDE EN CAS D E CONTACT. -UTILISER DANS UN ENDROIT BIE N AÉRÉ. -TENIR LE CONTENANT BIEN FERM É. -GARDEZ HORS DE LA PORTÉE DE S ENFANTS. -CONTIENT DU TRICHLORETYLÈN E. -AVERTISSEMENT ! L'INHALATION DE CE PRODUIT EST NOCIF. N/P 293 530 036 FABRIQUÉ AU F01B1Z4 APPLICATION Decals. Sea-Doo Cleaner 000 P / N 293 110 001 400 g 946 P / N 293 110 002 4 L 947 BOMBARDIER CLEANER DANGER 400 g EXTREMELY FLAMMABLE. HARMFUL OR FATAL IF SWALLOWED. VAPOUR HARMFUL. 293 110 002 DANGER 4 L BOMBARDIER I F01B2J4 APPLICATION All models. Bombardier-Rotax injection oil P / N 413 803 000 3 x 4 L 916 P / N 413 803 200 205 L 962 ® Injection Oil 4 U.S. quart ® ® BOMBARDIER Two-stroke F01B2H4 APPLICATION All models. Jet pump oil 914 P / N 293 600 011 Sea-Doo jet pump synthetic oil ® HUILE SYNTHÉTIQUE À TURBINE F01B0P4 APPLICATION All models. A) Silicone «Ultra Black» 901 P / N 293 800 030 B) Silicone 902 «Ultra Black HB» P / N 293 800 028 (300 mL) F01B1A4 APPLICATION Ride shoe. Jet pump fittings. Section 01 SERVICE TOOLS AND PRODUCTS Sub-Section 03 (SERVICE PRODUCTS) 01-03-5 Gelcoat spray paint Super white 933 P / N 293 500 076 Sea-Doo paint VERTICAL FANSPRAY PATTERN HORIZONTAL FANSPRAY PATTERN ROTATE VALVE NOZZLE 1/4 TURN TO CHANGE SPRAY PATTERN Danvern Fanspray® - A Sprayon Exclusive Featu re DANGE R DANGER GELCOAT PAIN T POUR PEINTURE F01B1Q4 APPLICATION All models. Spray paint for metallic parts only A) White 926 P / N 293 500 029 B) Purple 930 P / N 293 500 020 Sea-Doo paint F01B0Q4 APPLICATION A) Engine assembly. B) Tuned pipe and muffler. Gun Kote 000 Not sold by Bombardier Kal-Gard Coating & Mfg. Corp. F000 000 000 APPLICATION Magneto and armature plate. Gelcoat (liquid) 1 liter super white 943 P / N 293 500 075 F000 000 000 APPLICATION All models. Epoxy glue Not sold by Bombardier 3M-05900 F000 000 000 APPLICATION All models. Gelcoat repair kit 945 P / N 295 500 216 F000 000 000 APPLICATION All models. Loctite sealant 961 P / N 413 7103 00 F000 000 000 APPLICATION Exhaust system 787 engine. Sub-Section 00 (TABLE OF CONTENTS) 02-00-1 Section 02 MAINTENANCE TABLE OF CONTENTS PERIODIC INSPECTION CHART............................................................................................................. 02-01-1 FLUSHING AND CARE ........................................................................................................................... 02-02-1 FLUSHING........................................................................................................................................... 02-02-1 PROCEDURE ....................................................................................................................................... 02-02-1 CARE ................................................................................................................................................... 02-02-3 WATER-FLOODED ENGINE.................................................................................................................... 02-03-1 STORAGE................................................................................................................................................ 02-04-1

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