Professional Documents
Culture Documents
SPORTSTER 4-TEC
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®*Registered trademarks of Bombardier Inc.
LMR2003-001_002A.FM I
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the SEA-DOO Sportster™
4-TEC™ sport boat.
This edition was primarily published to be used by sport boat mechanical technicians who are already
familiar with all service procedures relating to Bombardier made sport boats. Mechanical technicians
should attend training courses given by the Bombardier Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts
Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand these.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
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.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. 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 vehicle compo-
nents.
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.
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 mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.
II LMR2003-001_002A.FM
INTRODUCTION
This Shop Manual covers the following BOMBARDIER ENGINE IDENTIFICATION
made SEA-DOO® sport boat models.
NUMBER (E.I.N.)
ENGINE MODEL 1503 Engine
MODELS
TYPE NUMBER
The Engine Identification Number is located at
1503 front of engine.
Sportster™ 4-TEC™ 5770
4-TEC™
Sportster™ 4-TEC™ 1503
5768
with tower 4-TEC™
F09D0UA 1
1. Engine Identification Number (E.I.N.)
ARRANGEMENT OF THIS
MANUAL
The manual is divided into 13 major sections:
F09L4HA 1 01 SERVICE TOOLS AND PRODUCTS
1. Hull Identification Number (H.I.N.) 02 MAINTENANCE
Refer to the next illustration for a description of the 03 TROUBLESHOOTING
Serial Number. 04 ENGINE (4-TEC)
05 ENGINE MANAGEMENT (4-TEC)
CECH 1 2 3 4 5 L 4 9 5 06 COOLING SYSTEM
Model year 07 FUEL SYSTEM
Serial
number* Year of production 08 ELECTRICAL SYSTEM
Model Month of production 09 PROPULSION SYSTEM
10 STEERING SYSTEM
F00A11A
11 HULL/DECK
*A letter may also be used as a digit.
12 TECHNICAL DATA
13 WIRING DIAGRAMS
Several sections are divided in various subsec-
tions. There is a table of contents at the beginning
of many sections.
LMR2003-001_002A.FM III
TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
indicates
beginning of the
subsection. Subsection 04 (MAGNETO SYSTEM)
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents
a liquid product
to be applied to a
surface. In this case
Loctite 243 to
screw threads.
Loctite
243
Loctite
243
Dotted box
contains parts of
a particular
Exploded view assits Loctite model or an
243
you in identifying exploded view.
parts and related
positions. Loctite
243
Loctite
243
F01D4WS
Illustration number
for publishing
process.
03-04-1
F01A0CS
IV LMR2003-001_002A.FM
TYPICAL PAGE
indicates a general
for XP is finished, so NOTE: When removing rotary valve cover , pay
TYPICAL
view which does not
from this point, all
1
attention that the rotary valve stay in place, other-wise
represent full detail.
2
it must be timed.
others models are
Remove carburetors from intake manifold.
concerned. Diaphragm must stand pressure for 10 seconds. If
Disconnect fuel bypass line between carburetors (twin
carburetors). pressure drops, replace diaphragm. Numbers in a frame
Remove carburetor(s) from rotary valve cover. are used to give a
sequence to be
perfomed.
06-03-4
F01A0BS
LMR2003-001_002A.FM V
VI LMR2003-001_002A.FM
ENGINE EMISSIONS
3
F04L03C
INFORMATION
TYPICAL
1. BOW (front)
2. STARBOARD (RH)
Manufacturer’s Responsibility
3. STERN (rear) Beginning with 1999 model year engines, sport
4. PORT (LH)
boat manufacturers of marine engines must deter-
The information and component/system descrip- mine the exhaust emission levels for each engine
tions contained in this manual are correct at time horsepower family and certify these engines with
of writing. Bombardier Inc. however, maintains a the United States of America Environmental Pro-
policy of continuous improvement of its products tection Agency (EPA). An emissions control infor-
without imposing upon itself any obligation to in- mation label, showing emission levels and engine
stall them on products previously manufactured. specifications, must be placed on each vehicle at
Because of our ongoing commitment to product the time of manufacture.
quality and innovation, Bombardier Inc. reserves
the right at any time to discontinue or change Dealer Responsibility
specifications, designs, features, models or equip- When performing service on any 1999 and newer
ment without incurring obligation. Sea-Doo sport boat carrying an emissions control
This Shop Manual uses technical terms which information label, adjustments must be kept with-
may be different from the ones in the Parts Cata- in published factory specifications.
logs. Replacement or repair of any emission related
When ordering parts always refer to the specif- component must be executed in a manner that
ic model Parts Catalogs. maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
LMR2003-001_002A.FM VII
1. Apply here
2. Do not apply
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources 1. Clean threads (bolt and nut) with solvent.
Engine Programs and Compliance Division 2. Apply Loctite Primer N (P/N 293 800 041) on
Engine Compliance Programs Group (6403J) threads and allow to dry.
501 3rd St. NW 3. Choose proper strength Loctite threadlocker.
Washington, DC 20001
4. Fit bolt in the hole.
EPA INTERNET WEB SITE:
http:/www.epa.gov/omswww 5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
VIII LMR2003-001_002A.FM
1. On threads
Preassembled Parts
2. On threads and at the bottom of hole
1. Apply here
2. Do not apply
1 3
1. Clean bolts and nuts with solvent.
2. Assemble components.
2
3. Tighten nuts.
4. Apply drops of proper strength Loctite on bolt/
nut contact surfaces.
5. Avoid touching metal with tip of flask.
A00A5RA NOTE: For preventive maintenance on existing
1. On threads
equipment, retighten nuts and apply proper
2. On threads and in the hole strength Loctite on bolt/nut contact surfaces.
3. Onto nut threads
LMR2003-001_002A.FM IX
3
1
A00A3QA 4 7
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker A00A3SA 1 3
1. Proper strength Loctite
2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
(P/N 293 800 038) on both sides of gasket
3. Loctite Primer N only
X LMR2003-001_002A.FM
1. Remove old gasket and other contaminants 3. DO NOT use anti-seize Loctite or any similar
with Loctite Chisel remover (P/N 413 708 500). product.
Use mechanical means if necessary. 4. No curing period is required.
NOTE: Avoid grinding.
Mounting in Tandem
2. Clean both mating surfaces with solvent.
1. Apply retaining compound on internal element
3. Spray Loctite Primer N on both mating surfaces bore.
and on both sides of gasket. Allow to dry 1 or 2
2. Continue to assemble as shown above.
minutes.
4. Apply GASKET ELIMINATOR 518 (P/N 293 800 CASE-IN COMPONENTS
038) on both sides of gasket, using a clean ap-
plicator. Metallic Gaskets
5. Place gasket on mating surfaces and assemble
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
If holes are sunken, apply proper strength Loctite
on bolt threads.
6. Tighten as usual.
MOUNTING ON SHAFT
Mounting with a Press
A00A3VA 1
1. Proper strength Loctite
LMR2003-001_002A.FM XI
XII LMR2003-001_002A.FM
Technical Publications
Bombardier Inc.
Valcourt (Quebec), Canada
LMR2003-001_002A.FM XIII