Hqj2xqinz Sea Doo 1992 Shop Manual

SHOP
MANUAL
219 100 006

Page: 2 See Doo 1992 Shop Manual - http://~tfww.ReadManuals.com
Legal deposit :
National Library of Quebec

1 s t t,rimester 1992
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.
aBombardier Inc. 1992
Printed in Canada
^Registered trademarks of Bombardlier Inc.
LoctiteB is a trademark of Loctite Corporatiion

Snap-onm is a trademark of Snap-on Tools Corporation
Gelcote@is a trademark of Gelcote International Limited
Page: 3 See Doo 1992 Shop Manual - http://www.ReadManuals.com

TABLE OF CONTENTS
SECTION PAGE
01 SERVICE TOOLS
AND PRODUCTS
02 PERIODIC
INSPECTION CHART
04 COOLING SYSTEM
03 - Flushing and Care 04-03-1
05 FUEL SYSTEM
03 - Carburetors
06 OIL SYSTEM
07 ELECTRICAL
08 PROPULSION AND
DRIIVE SYSTEMS
Q 9 STEERING SYSTEM
12 TECHNICAL DATA

This rnanlulal has been prepared as a guide to service the SEA-DOO, models SPsao5, XPsssi,
- GTS 5812 and GTX 5860.
T1hisedition was primarily published to be used by watercraft mechanics who are already
fam~iliarwith all service procedures relating to Bombardier made watercraft.
Please note that the instructions will apply only if proper hand tools alnd special service tools
are used.
This Shop Manual uses technical terms which may be slightly different from the ones used
in Parts Catalog.
The content depicts parts andlor procedures appli~cablet o the particular prodluct at its
time of manufacture. It does not include dealer modifications, whether authorized or not
by Bombardier, after manufacturing the product.
In addition, the sole purpose of the illlustrations/photographs throughout the manual, is to
assist identification of the general configuration of the parts. They are not to be interpreted
as technical dralwings or exa~ctreplicas of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement
of any component. Dealer andlor distributor assistance should be sought in case of doubt.
Torque wrench tightening specifications must be strictllly adhered to. Locking devices (ex. :
locking disk, elastic stop 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 emph~asizesparticula~rinformation denoted by the wording and symbols;
Â WARNING : Identifies an instruction which, if not followed, could cause serious personal
injury includi~ngpossibility of death.
v CAUTION : Denotes an instruction which, if not fol~lowed,could severely damage vehicle

components.
01 NOTE : Indicates supplementary information needed t o fully complete an i~nstruction.
Althouglh the mere readling of such ilnformation does not eliminate the hazalrd, your under-
standing of the information will promote its correct use. Always use common shop safety
practice.
This info~rmationrelates to the prelparation and use of Bombardier watercraft and has been
utilized safely and effectively by Bombardier Inc.. However, Bombardier Inc. dlisclaims liabi-
lity for all damages and/or injuries resulting from the improper use of the contents. We strongly
recommend th~atany se~rvicesbe calrried out and/or verified by a highly skilled professional
rnechan~ic.It is undlerstood that certain modifications may render use of the watercraft illegal
under existing federal, provincial and state regulations.

BOMBARDIER WATERCRAFT SHOP MANUAL
INTRODUCTION HULL IDENTIFICATION NUMBER (H.I.N.)

This Shop Manual covers BOMBARDIIER made SEA- Can be found at right hand rear side of hull, and inside it.
DOO@ watercraft models SP5805, XP5851, GTS5812 and
GTX 5860
WATERCRAFT MODEL NUMIBER

Can be found on U.S. Coast Guard approved label locat-
ed on left hand side of stern (rear) eyelet.
-^J^Ãˆ
Hull Identification
I FOCI o n 001 Number (H I M I
The five digits after ZZN are the watercraft serial number.
ZZNI 2 3 4 5 X X X X
T Serial number

BOMBARDIER WATERCRAFT SHOP MANUAL
-
ENGINE IDENTIFICATION NUMBER ARRANGEMENT OF THIS MANUAL
(E.I.N.) The rnalnual is divided into 13 majioir sections :
It is located on the upper side of the magneto housing. 01 Service Tools and Products
02 Periodic Inspection Chart
rT^3 p r En~iineIdentification 03 Engine
04 Cooling System
05 Fuel System
06 Oil System
07 Electrical
08 Pro~pulsionand Drive Systems
09 Steerin~gSystem
10 HullIBody
11 Storage
12 Teclhnical Data
13 Troubleshooting
Each section is divided in various sub-sections, and again,
each sub-section has one or mlore division.
DEFINITION OF NUMBERING SYSTEM EX. : 03 ENGINE
-, OF THIS MANUAL
01 Water-Flooded Eng~ineCare
Sectio~nsand Sub-sections System 02 Removal and Installation
The manual makes uses of a 2-part digital numbering 03 Top End
system (e.g. : 01-011, in which the first two-digits repre- 04 Flywheel and Ma~gneto
sents the section, the second two-digits the sub-section. 05 Bottom End
06 Rotary Valve and Reservoir
07 Exhaust System
The use of RIGHT and LEFT indications in the text, al-
ways refers to driving position (when sitting on vehicle).
Section Sub-section
Pages System
The nu~merotationat the bottom of each page assists the
user in page location RlIGHT
+
(starboard)
section Sub-section Page

-
BOMBARDIER WATIERCRAFT SHOIP MANUAL
GENERAL
The information and camponentisystem descriptions
contained in this manual are correct at time of publica-
tion Bombardier Inc however, malintains a pollicy of con-
tinuous improvement of its products without imposing
upon itself any obligation to install them on products pre-
viously manufactured.
Bombardier Inc. reserves the right at any time to discon-
tinue or change specifications, designs, features, mod-
els or equipment without incurring obligation
ILLUSTRATIONS AND PROCEDURES

An exploded view is conveniently located at the begin-
ning of each section and is meant to assist the user in
identifying parts and components.
This Shop Manual uses technical terms which may be
different from the ones of the parts catalog.
When orderling parts always refer t o the specific
model, parts catalog.
The illustrations show the typical construction of the dif-
ferent assemblies alnd, in all cases, may not reproduce
the full detail or exact shape of the parts shown, how-
ever, they represent parts which have the same or a sirni-
lar function
When something special applies (such as adjustment,
inspection, etc.), boldface numbers in exploded views are
used for sspeci~ficparts and referred to in the text
v CAUTION : Pay attention to torque specification~s.

Some of these are in lbf*in instead of Ibf'ft. Use
appropriate torque wrench.
v CAUTION : Components of this watercraft are

built w i t h parts dimensioned i n the metric sys-
tem. Fasteners are metric and must not be replaced
by customary SAE fasteners or vice versa. Misrnatch-
ed or incorrect fasteners could cause damage t o the
waltercraft or possible personal injury.
As many of the procedures in this manual are interrelated,
we suggest, that before undertaking any task, you read
and thoroughly understand the entire section or sub-
section in which the procedure is contained.
A number of procedures throughout the book require the
use of special tools. Where a special tool is indicated,
refer to section 01. Before commencing any procedure,
be sure that you have on hand all the tools required, or
approved equivalents.
Bombardier Ilnc.
SEA-DO0 Watercraft After Sales Service
Valcourt, (Quebec), Canada

Section 01 SERVICE TOOLS AND PRODUCTS
Sub-section 01 (SERVICE TOOLS)
SERVICE TOOLS
ENGINE (h andatory Tools)
Some of the tools are mand~atory,refer tothe title of each sections
Mandatory tool kit is available: P I N 295 000 0187.
SERVICE TOOL PURPOSE APPLICATION
Degree wheel 11mandatory) To mark timing position of rotary valve, to All models.
P I N 295 000 007 check crankshaft alignment.
A 0 0 0 001 111
Bombardier ignition tester (mandatory) To test engine electrical components. All models.
P / N 295 000 008

Sectlion 01 SERVICE TOOLS ANiD PRODUCTS
SERVICE TOOL PURPOSE
Rubber pad (mandatory) To avoid needles of connecting rod bearing All models.
P/N 295 000 079 from falling in crainkcase.
- --
Piston pin puller (mandatory) To remove and install piston pin. All models.
P I N 290 877 090
Locating sleeve
I P / N 290 877 1801
Expansion sleeve
f P / N 290 877 040)
Extractin~gnut
I P ' N 290 877 1551
Piston circlip installer (rnandaltory) To install circlips on pistons.

PI N 295 000 077
01-01-2 Page: 10 See Doo 1992 Shop Manual - http://www.ReadManuals.com

Section 01 SERVICE TOOLS AND PRODUICTS
Sub-Section 01 (SERVIICE TOOLS)
SERVICE TOOL I PURPOSE APPLIICATION
Puller plate (mandatory) PI Used with extension handle to retain 411 models.
:rankshaft. When removing / installing PTO
P I N 290 876 080
Screw flywheel and loosen /tighten MAG flywheel
[P/N290 841 591) nut
Extension
handle
Extension handle
P 1 N 295 000 003
Sleeve
( P I N 290 847 220)
"^-'sssas,
F001 003 151 F001 003 152
Puller plate
Impeller/PTO flywheel remover / installer Used to loosen 1 tighten PTO flywheel and All models
(mandatory) rnpeller Must be used in conjonction with
P I N 295 000 001 puller plate [PIN 290 876 080) and exten-
sion handle ( P I N 295 000 003)
I
1 F001 009 029
Puller (mandatory1 Used with puller plate ( P / N 290 876 080) All models.
P I N 290 876 065 and extension handle ( P I N 295 000 003)
t o remove MAG flywheel

Sub-Section 01 (SERVICE TOOILS)
PURPOSE APPLICATION
Pulller with screws (mandatory) To remove crankshaft bearing;^. All rnodel,~.

PIN 290 876 298
Protective cap {both ends) (mandatory)

PIN 290 876 557
Ring (both ends) 4mandatory)

P / N 290 977 490
'---'
MAG side
Ring halves (PTO) (mandatory)

PIN 290 977 475
Distance ring (MAG) (mandatory)

P I N 290 876 569
Ring halves (MAG) (mandatory)

P I N 290 276 025
PTO side

APPLICATION
To position outer crankshaft bearing on All models.

PTO side. except 5801.
To remove rotary valve shaft from crank- All models.

case.
To install end bearing of rotary valve shaft

in crankcase.
To install rotary valve shaft in crankcase

Alignment tool (mandatory) To align engineljet pum~pwhenever either All models.

P I N 295 000 089 one is removed and reinstalled.
Housing
( F I N 295 000 0901

Sectioln 01 SERVICE TOOLS AND PRODUCTS
ENGINE (recommended tools)
I SERVICE TOOL
I PURPOSE APPLICATION
1 Dial indicator fTDC gauge) ,recommended)

I To find TDC position. For ignition timing
and rotary valve timing. To check cranks-
haft alignment.
I Stroboscopic timing llight 4recomrnended)

P I N 295 000 078
To verify ignition timing. All rnodells.
Ring compressor (recommended) To compress piston ring when inserting All models.
P / N 290 876 972 piston in cylinder.

Su b-Section 01 (SIERVICE TOOLS)
SERVICE TOOL PUIRPOSE APPILICATION

--
Dig~ital/induction type tachometer To verify engine RPM. All models.

(recommended)
P / N 295 000 100
To cool engine when watercraft is out of All models.

water. To clean cooling system
Timing mark pointer Align mark on PTO flywheel with pointer All models.
P I N 295 000 102 to verify engine timing.
Spark tester To verify spark at spark plug cap outlet All models.
Purchase locally
Superex Canada Ltd
NO. 15-785
01-01-8
Sub-section 01 (SERVIICE TOOLS)
Aligning tool (recommended1 To align cylinders by exhaust flanges at MI models.

assern bly
P / N 290 876 902
Centering tool (recomm~ended) To position coils on armature plate at as- All models.
P I N 290 876 922 sembly.
Nippondenso CDI tester (recommended! To test engine ignition system components. All models.
P / N 295 000 080
0 NOTE: This high quality tester use
power source of 115 Volts AC/60 Hz

I SERVICE TOOL
Hexagonal bit socket 1114" drive) b ease Alllien screw removal and installa- funed pipe
I (recommended)
ion.
Not sold by Bombardier
Purchase locally
Bearing separator (recommended1 'ull out bearing. Crankshaft.

Purchase locally
Bearing
separator
F001 003 061
Bearing separator (recommended) Pull out bearing. Bearing beside dis-

Not sold by Bombardier tance sleeve on ro-
Purchase locally tary valve shaft.
Bearing separator
Snap-on CJ-950

SERVICE TOOL PURPOSE APIPLICATION
Slide hammer puller (recomrnendedl Pull out bearing. Rotary valve shaft
Not sold by Bombardier end bearing /crank-
Purchase locally case.
Impeller shaft seal.
Snap-on Handle CJ193-1
Hammer CJ125-6
Claws CJ93-4
Lighted adjustable mirror (recommended) See in dark area Oil injection pump
NIot sold by Bombardier adjustment.
Purchase locally
Cable luber (recommended) Power inject Sea-Doo Lube in throttle cable. All models
Purchase locally
See a motorcycle
Terminal remover (recommended) Remove terminals from connector housing All models
Not sold by Bombardier in electrical circuit.
Purchase locally

I SERVICE TOOL PURPOSE APPLICATION
Engine lifting device (recommended) Lift engine out of watercraft. All watercraft engines.
Do it yourself
Refer to shop manual section 03-02
Weld lock washer

h
I Old spark plug

Sulb-Section 01 (SERVICE TOOLS)
COOLIlNG /FUEL/OIL SYSTEMS (Mandatory Tools)

Hiose pincher (mandatory1 To avoid leaks while working on oil/fuel All rnodeils.
PIN 295 000 076
A001 001 090
Pliers (mandatory) To securelcut ear clamps on oil/fuel lines All models.

P/ N 295 000 070 and coolant hoses.
Cutting cllarnp
+' u
Securing clamp
Securing clamp in limited access \/^

Gear holder (mandatory) To remove1install retaining nut of oil injec- All models.
PIN 290 277 905 tion plum gear.

- -

COOLING/FUEL/OIL SYSTEMS (Recommended Tools)
Pump gauge tester (recommended) To verify release pressure and leak at car- All models.
P i N 295 000 083 auretor.
Pump gauge tester (recommended) To make sure there is no leak by pressuriz- All models
PIN 295 000 085 ing the fuel system.
0 NOTE : Must maintain a pressure of 34

kPa ( 5 PSI1 during 10 minutes Never
pressurize over 34 kPa ( 5 PSI)
v CAUTION : Lubricate air pump piston1

seal using mild soap. Hydrocarbon lu-
bricant destroys rubber seal.

Sectlion 01 SERVICE TOOLS AND PRODUCTS
PROPULSIION SYSTEIM (Mandatory Tools)
SERVICE TOOL P'URPOSE APPLICATION
Pliers (mandatory) To remove / install drive shaft boot reusa- All models.
P l N 295 000 069 ble stepless clamps.
IF001 003 044
Impeller1PTO flywheel remover / installer Used to loosen4tighten impeller on shaft. All models.
(mandatory)
P / N 295 000 001
Impeller shaft holder (mandatory) Used to loosen/tighten impeller on shaft, All models.
P4N 295 000 082

APPLICATION
To install impeller shaft needle bearings All models.

and seal.
To protect seal lip when installing impeller MI models.

shaft in its housing.
To align eng1ine/jetpump whenever either 411 models.

m e is removed and reinstalled

PROPULSION SYSTEM (Recommendled Too~ls)

-- -
SERVICE TOOL APPLICATION
Fitting (recommended) To pressurize pump assembly before ins- All models.

P I N 295 000 086 tallation, to verify if any leak
0 NOTE : Must maintain a pressure of 70

kPa (10 PSI) during 10 minutes Never
pressurize over 70 kPa 110 PSI)
Slide hammer puller (recommended) Pull out bearing Rotary valve shaft
Not sold by Bombardier end bearing /crank-
Purchase locally case.
Impeller shaft seal
Snap-on Handle CJ93-1

Hammer CJ125-6
Claws CJ93-4
Seal puller (recommended) Pull out seal Impeller shaft seal.

Purchase locally

PURPOSE APPLICATION
Remove silicone. mpeller housing.

Cut wear ring. All models.

Machinist's square (recommended) Adjust reverse gate. Models equipped

Not sold by Bombardier with reverse.

SERVICE TOOL PURPOSE APPLIlCATIQN
Impeller housing remover (recommended1 Remove impeller housing All models.

Do it yourself
1 FOCI 011 096
Ride shoe remover (recommended) Remove ride shoe All modellls.

Do it yourself

Fitting remover (recommended) Remove impeller housing fittings All models.

Do it yourself
Refer to s h o p manual section 08-01
Roll pin
2 40 mm
(3132 in)
Bearing remover (recommended) Remove impeller housing bearings All models.

Do it yourself
Refer to shoo manual section 08-01
345 mrn (13-112 in)

S,ERVICE TOOL PURPOSE APPLICATION
Steeringljet pump alignment tool Ease steeringtjet pump alignment. All models,
(recommended1
Do it yourself

WATERCRAFT HANDLING (Recommended Tools)

--
Solley (recommended) To handle watercraft in shop or on beach. All models.

PIN 295 000 004
Beach wheels (recommended)

='IN 295 000 005
=001 001 007
Shop lamp ire~o~mmended) To facilitate repair when working inside the All models.
P I N 295 000 081 hull / body.
Â WARNING : Never use electric poweredl

tools on watercraft unless first verifying
no gasoline leaks/furnes are present.

- -
SERVICE TOOL APIPLICATIOIN
Lift kit (recommended) To handle watercraft in shop. All models.

P i N 298 760 000

Sectio~n01 SERVIICE TOOLS AND PRODUCTS
Sub-section 02 (SERVICE PRODUCTS)
SERVICE PRODUCTS
-
SERVIICE PRODUICT APPLICATION
Pipe sealant To seal pipe fittings Prevents leakage alnd Set screw on impeller
vibrational loosening housing cover
P / N 293 800 018
Plastic fitting (tool
P / N 295 000 0861
on impeller housing
Removable threadlocker A medium-strength adhesive for thread- Cylinder head cover

locking and threadsealing Vibration-proof screws
P I N 293 800 015
nuts, bolts and screws. Exhaust manifold
studs and screws
Engine rubber mount
screws
Ignition housing1
crankcase screws
Armature plate
screws
Magneto flywheel/
crankshaft
Carburetor mount
nuts
Magneto cod screws
Impeller housing
cover screws
Ventur~/ impeller
housing screws
Grill screws
Engine support
screws
Impeller housing/ hulll
nuts
Steering nozzle
screws
Reverse gate screws
Hig~hstrength threadlocker Hi-strength threadlocking threadsealing Sta~rter screws; en-

P/ N 293 800 005 adhesive Apply heat to ease disassembly gine
Impeller shaft thread
Loclite 271 (red! Steering column
(10 rnL) screw

SERVICE PRODUCT PURPOSE APPLICATION
High temperature threadlocker Hi-strength threadlocking threadsealing Crankcase 1 plug at

adhesive that resists high temperature. end of rotary vallve
P I N 290 899 788
shaft
Ring gear1MAG fly-
Loctite 648 (green)
15 g) wheel.
A000 001 ni
Primer for gasket eliminator General pulrpose primer Primer N assures Crankcase halves
fixtur~ingof parts in 15-30 minutes and full mating surface.
cure in 12 hours or less. On part life is 30 Impeller shaft thread.
days, but it \s recommended that parts be
Ventur~/ impeller
joined within 10 minutes after adhesive is
housing mating sur-
applied over primer
face.
Loctite
Locquic Primer N
( 4 021
Clean and prepare surface before assem- Impeller shaft thread

bly. and splines
Drive shaft splines
Impeller thread.
Loctite Safety Solvent

755
-
Sealant for gasketling. Ride shoe1hull,
pump / h,ull.

--
Section 01 SERVICE TOOLS AND PRODIUCTS

SERVICE PRODUCT APPLICATION
'aste gasket Makes, dresses and repairs gaskets of sizes Zylindler sleeve/0-ring
and shapes. groove.
'/ N 293 800 007
Crankcase halves
mating surface.
Impellller housing
cover.
Impeller shaft seal
Venturi / impeller
h~ausing
Seal outer diameter
in seal carrier.
Gasket eliminator
Loctite 51 5
150 rnL)
Glue Glue. Handlebar grip.
"r^ ^
1"-./-' ,
.-
^-2
'A?.
Gelcoat kit Gelcoat repair. Body.

P / N 295 500 009 Hulll.
Sea-Doo
Gelcote
Repair
kit
Gelcoat paste (white) Gelcoat repair Body.

P / N 293 500 016 Hull,

Section 01 SERVICE TOO1LSAND PROIDUCTS
Sub-section 02 (SERVIICE PRODUCTS)
SERVIICE PRODUCT PURPOSE
Gelcoat repair. Body

Hull.
1 liter white P I N 293 500 033
1 liter mauve P I N 293 500 034
1 liter grey P I N 293 500 035
1 Synthetic grease Lubricate and provide great wear protec-

tion and water resistance.
Under screw head of
cylinder
Carburetor linkage
Impeller shaft seal
lips
Both sides of impeller
shaft th~rustwasher.
Drive shaft / impeller
splines
Seal carrier seals and
bearing.
Bombardier PTO fllywheel rubber
Sea-Do0 boot
Penetrating lubricant Prevents corrosion and sticking Protects In carburetor intake

P / N 293 600 006 metallic parts when engine IS water
flooded and before
storage
Th~rottlecable
Wear ring (when
Sea-Doo
new)
lube Corroded Darts
1 FOCI 001 028

Synthetic oil Lubricate Jet pump
P I N 293 600 011

SERVICE PRODUCT PURPOSE APPLICATION
Injection oil Lubricate engine. All models.

1 liter P / N 293 600 005
4 liters P I N 293 600 004
Anti-seize lubricant Protects moving and stationary parts Crankshaft thread/

P i N 293 550 001 against high temperature seizing Prevents PTO flywheel.
rust and corrosion on parts exposed to Crankshaft bearing
high heat seat
Spark plug thread
Drive shaft splines

Section 01 SERVICE TOOLS AND PRaDIUICKS
I SERVICE PRODUCT PURPOSE APPLICATION
732 1MuIt1-purpose sealant To seal joints. 3ide shoe screws

:inside hulll.
P I N 2 9 3 800 006
Electricall insulating compound Prevents moisture and colrroslon build-up Battery p o s t s a n d

~ f electric
l connecl~~ns cable con~nectors.
P / N 2 9 3 550 004
Thermosensor con-
nectors.
Dow Corning
Clean amd plrepare surfalce for applicat~on Watertanktraplbody

of sealant (PIN1 2 9 3 5 3 0 0111. surface.
Rear baffle / body sur-
face
S~ka~flex
Primer 449
Fool Wl 050
Sealant Seal fiberg~lassand plast~cparts. Far best Water tank trap/ body
-esult use prllmer {PIN 2 9 3 5 3 0 012). surface.
P I N 2 9 3 530 011
Rear baffle /body slur-
face.
Slkaflex
Sealant 221
01-02-6 Page: 38 See Do0 1992 Shop Manual - http:llwww.ReadManuals.com

Section 01 SERVlCE TOOLS AND PRODUCTS
I SERVICE PRODUCT PURPOSE APPLICATION
Pain1 Protect~onof metallic parts.

P I N 2913 500 029 wh11te
I F I N 2913 500 030 clharcoal
P / N 293 500 020 mauve
11 Cleaner I Clem easily. i3ody and lhull.
sea-000
cleaner j
Fool 001 040
~ Lubr~cant
Not sold by Bombardle~
Provide excellelnt lubrication over long
interval of no main~tenance.
%ding surface of
startelr armature shaft
I Purchase locally s~line.
or
Esso Beacon 325
I
'Epoxy glue Glue IKnurIed surface 01

Not sold bv Bombardier aluminum hull inseri
( P I N 292 000 075)
Page: 39 See Do0 1992 Shop Manual - http://~.ReadManuals.com

Sectlion 01 SERVICE TOOLS AND PRODUCTS
Sub-section 02 (SERVICE PRODUCTS]
SERVICE PRODUCT PURPOSE 1 APPLICATION
F ~ epreservative
l Prevent fuel deterioration during storage. Fuel tank at storage
Not sold by Bombard~er
Purchase locally
Sta-Bil
Vinyl protectant clean and protect vinyl. Seat

Purcha~selocally
Armor-All

Section 0 2 PERMlDlC INSPECTIOIW CHART
PERIODIC INSPECTION CHART

0 NOTE : Shade area shows the m m t e n ~ a n c efrequency.
FREQUENCY 1
@ IEvery month in1 salt water use.

@ These Items have to be ~ n ~ t ~ achecked
lly after three months. Thereafte~~
serwcing to be made as spec~f~ed
lln th11schart.
@ Dwly flushlng~ln salt water use
Page: 41 See Do0 1992 Shop Manual - http:ll~.ReadManuals.com 02-00-I

Section 03 ENGINE
587 ENGINE TYPE
Page: 42 See Do0 1992 Shop Manual - http://~.ReadManuals.com 03-00-11

Section 03 ENGINE
Sub-section 01 (WATER-FLOODED ENGINE)
d
WATER-FLOODED ENGINE
ENGINE DESCRIPTION
Spark plug
The two stroke ROTAX engine rotates counterclockwise
seen from the rear (PTO flywheel) ilt has a rotary valve
to control fuel mixture intake Lubrication is provided by Grounding
a variable oil injection pump It is cooled by water sup- device
plied from the jet pump. It has a NIPPONDENSO Capa-
citor Discharge Ignition System with single coil and an
integrated electronic module. The fuel is provided by dill-
aphragm carburetor having an integrated fuel pump.
General
If engine is water-flooded, it must be serviced within a
few hours after the event Otherwise engine will have
to be overhauled
v CAUTION : A water-flooded engine must be prop-

erly lubricated, operated theln lubricated again,
otherwise palrts will be seriously damaged.
Remove spark plugs and dry with a clean dry cloth. A
contact cleaner spray can be used, it may be preferable
to replace spark plugs. Do NOT install spark plugs on
Procedure engine.
Check fuel and oil reservoirs for water contamination Crank engine to drain crankcase.
If necessary, siphon and refill with fresh fluids
Turn fuel valve to OFF position then drain fuel filter bowl
Drain bilge if water is present
0 NOTE : Whenever the engine is stopped more than
20 seconds with tether cord installed, the electri-
cal system has to be reactivated by touching starter
button.
Remove engine crankcase drain plugs located under-
neath oil injection pump
v CAUTION : Be careful when cranking engine, wa-
ter will spray out from spark plug holes.
Reinstall crankcase drain plugs.
Oil injection
oumD CAUTION : Cirankcase dralin plugs should have
Loctite PST 567 (PIN 293 800 013) appliied t o
threads before reinstalling.
Crank engine again to allow any remaining water to es-
cape from spark plug holes.
Spray SEA-DO0 LUBE ( P I N 293 600 006) into spark
plug holes.
Crank engine again.
Reinstall spark plugs and spark plug cables then tether
cord cap on switch
Turn fuel valve to ON positionl
Drain plugs
FOOI 003 DO8 Press starting button to start engine It may be neces-
sa~ryto use the choke If engine does not start, repeat
Remove spark plug cables and connect thlem on the previous steps as necessary
grounding device.

- - - -
Section 03 ENGINIE
Sub-section 01 (WATER-FLOODED ENGINE)
CAUTION : To avoid starting motor overheating,

tlhe cranking period should not exceed 5-10 se-
conds and a rest period of 30 seconds should be ob-
served between cranking cycles. Never depress the
starting button when the engine is run~ning.
0 NOTE : If engine does not start after several at-

tempts, check ignition system for spark occurence.
Refer to CDI AND CHARGING SYSTEMS 07-06 then
refer to ignition system testing procedure. Also a spark
tester tool no 15-785 from Superex Canada Ltd can be
used Check crankshaft if needed, it can become mis-
aligned or deflected
Refer to BOTTOM END 03-05 then refer to crankshaft
alignment
Â WARNING : Ventilate bilge at least two minutes

prior t o checking spark.
After engine has started, spray SEA-DO0 lube through
carburetor intake while engine is running.
Run engine until it reaches its normal operating tern-
perature.
Make sure to supply water to cool engine.
CAUTION :Water must be supplied t o cool en-
gine w i t h flush kit (P/N 295 000 038).

Section 03 ENGINE
Sub-section 02 (REMOVAL AIND INSTALLATION)
Engine Support, Tuned Pipe and Muffler
Page: 45 See Doo 1992 Shop Manual - http://www.ReadManuals.com 03-02- 1

-
Section 03 ENGINE
Sub-section 02 (REMOVAL AND INSTALLATION) -
COMPONENTS
1 Hexagonal nut M8 t4f 18 Hexagonal screw M8 x 20 (41
2 Lock washer M8 14) 19 Hexagonal screw M8 x 30 (8)
3 Tuned pipe 20 Flat washer 10 mrn f41
4 SwdM8x26f41 2 1 Elastic stop nut M 10 (4f
5 Gasket 22 Formed hose
6 Exaust manifold 23 Trtdon clamp W
7 Gasket /2i 24 Exhaust outlet
8 Rotax engine 587 25 Flat washer 6 mrn (4)
9 Engine support 26 Allen screw M6 x 20 (41
10 Lock washer M8 (81 27 Muffler
7 7 Lock washer f4! 28 Muffler strap
72 Lock washer M8 110) 29 Exhaust hose
13 Alien screw M8 x 75 (81 30 Strap clip i2)
74 Shim 0 4 0 m m 10016in) 31 Rival 3/16 14)
Shim 7 40 mrn 10 055 in1 32 Locr~te242
75 Shim 0 40 m m 10 016 ml 33 Sealant Locwe 587 "Ultra Blue"
Shim 7 3Qmm 10 051 in1 34 Exhaust collar
16 Rubber mount (4) 35 Rubber strip
7 7 F/ar washer 8 mrn W 36 Exhaust cone
GENERAL Cooling and Exhaust Systems
It is not necessary to remove engine from watercraft for

TOP END nor PTO FLYWHEEL AND MAGNETO servic-
0 NOTE :To release a clamp from cooling hose/fuel
line, use pliers ( P l N 295 0 0 0 070)
ing However engine removal is necessary to repair BOT-
TOM END AND ROTARY VALVE.
REMOVAL FROM WATERCRAFT

In order to remove engine from watercraft proceed as
follows.
Propulsion System
To withdraw jet pump unit ass'y, refer to PROPULSION
AND DRIVE SYSTEMS, 08-01 then refer to removal and
overhaul
Electrical Connections
Â WARNING : Always disconnect starter or bat-

tery cables exactly in the specified order, black
negative cable first. Electrolyte or fuel vapors can be Disconnect hose from water outlet socket on engine DIS-
present in the engine compartment and a spark might connect inlet hose, injection hose and bleed tube from
ignite them and possibly cause personal injuries. It tuned pipe.
is recommended t o disconnect electrical connections
prior t o disconnecting fuel lines.
First, remove bl~acknegative cable from battery, then red
0 NOTE : On some models the exhaust collar holld-
ing exhaust cone and tuned pipe has to be re-
moved first
positive cable
Remove battery holding straps then withdraw battery
Disconnect thermosensor wire and spark plug cables

Section 03 ENGINE
Sub-section 02 (REMOVAL AND INSTALLATION)
To prevent excessive oil spillage, use a hose pincher (PIN

Bleed tube Injection hose
295 000 0761.
removed Ã‘Ã‘Ã‘Ã‘Ã‘Ã‘^ removed
^ hose gear
0 NOTE :The tuned pipe is held on exhaust manifold

side by one or two retaining screws.
Remove tuned pipe retaining screws from exhaust Install hose pincher on oil pump suppily line then discon-
manifold nect hose.
Remove tuned pipe mounting nuts, slightlly lift it to re- Remove engine support mount screws
lease nuts as necessary. Withdraw tuned pipe in a for-
ward and rotating movement. Be careful not to drop
gaskets located on exhaust manifold. 0 NOTE : Be careful when removing engine support
mount screws, shims could have been installed
between engine support and rubber mounts.
Disconnect hose on exhaust manifold fitting. Remove
fasteners taking care not to drop any part then withdraw
manifold. 2
Intake and Fuel Systems
Loosen clamp of intake silencer hose on carburetor side
Pivot intake silencer to rear of watercraft
Remove both retaining screws of carburetor support from
engine cover.
Remove screws holding flame arrester cover, then with-
draw cover.
Turn fuel valve to OFF position
Disconnect fuel supply line from carburetor.
Disconnect fuel return line from carburetor
Disconnect throttle and choke cables from carburetor. I FOOT 003 1W
Remove screws from flame arrester base then withdraw
base. CAUTION : Be sure t o indicate shims location for
reinstallation. If shims are interchanged engine
Disconnect impulse line. and jet pump alignment will be altered.
Pull out electrical box then open electrical box and dis-
connect wires coming from magneto housing.
Unscrew cable cap Slide cap and compression gram-
met away then pull cable out of electrical box.
-/

Section 03 ENGINE
Sub-section 02 (REMOVAL AND INSTALLATION)
Engine can be easily lifted using the following suggest-

ed tools.
- Cut porcelain from two old spark plugs
- Weld a lock washer approximately 20 m m diameter
on each spark plug as shown
Weld a lock washer

here
\
O l d spark plug T CAUTION : Be careful not t o scratch body with

engine support or t o hit any component.
15,116, S1himand Rubber Moulnt

Remove spark plugs and replace by special tools
Do not remove engine rubber mounts needlessly. They
Hook a sling into holes of special tools then using a sit on shims which control enginleijet pump alignment.
chain block, a hoist or other suitable equipment, slowly Alignment has been set at the factory. Always remove
lift engine rubber mounts one at a time and reinstall each shim to
Lift it until rotary valve supply line is reachablle Install its origin~allocation.
a hose pinchler on hose, then disconnect.
Instaillhose pincher on rotary valve oil return line (on top
of starter then disconnect.
Disconnect red positive cable from starter polst.
Hose pincher
FOCI 003 013
I
v
installed
CAUTION : If shims with differenit tlhickness are
Rotary valve interchanged, engine and jet pump will be dis-
suppily line aligned.
0 NOTE : If shims location have been mixed up or

whenever removing the engine always use engine/
jet pump alignment tool ( P I N 295 000 089) to check
alignment
Cdrry on engine h f u r ~ guntil engine suppon reaches body
opening then tilt engine so that it can cornpl~etelyleave
watercraft

Section 03 ENGINE
Sub-section 02 ( R E M O V A L AND INSTALLATION)
/
CLEANING
Wipe off any spillag~ein bilge. Clean with a bilge cleaner
Discard all gaskets and O-rings.
Clean external parts of engine.
INSTALLATION
Installation of engine in watercraft is essentially the re-
verse of removal procedures However pay particular at-
tention to the following.
16,19, Rubber Mlount an~dScrew

Check tightness and condition of rubber mounts. If they
halve been removed, apply Loctite 242 (bluet (PIN 293 Housing
I P / N 295 000 0901
800 015) on screw threads. Torque screws to 25 Nern
(18 Ibfmft)
v CAUTION : Strict adherence t o this torque is im-

portant t o avoid damaging threads of aluminum
insert i~nbilge.
CAUTION : Some watercraft have a shim be-
tween hull and pump, if shim has been removed
ensure t o reinlstall it. If not install, engine anld jet pump
9,21,Engine Support and Nlut alignment will be altered.
Properly install support on crankcase so that rounded To verify allignment proceed as follows
portion of support matches with MAG side of crank- - Install housing on hull with four nuts.
case Apply Loctite 242 Iblue) (PIN 293 800 015) on
threads then torque nluts in a criss-cross sequence to - Slide shaft slowly thru housing Pay attention not to
35 N*m (26 lbfeft) hit PTO flywheel.
Rotary Vallve Supply Line
Make sure to reinstall lines before compfetely loweriing
engine in bilge
0 NOTE: If fuel line ends are damaged, cut dam-

aged ends before reinstallatioln For fuel line clamp-
ing, use special pliers ( P I N 295 000 070)
EngineiJet Pump Alignment

Alignment is necessary to eliminate possible vibration
and/or damagle to components The engineljet pump
alignment tool ( P / N 295 000 089) includes a housing
( P i N 295 000 0901 and a shaft [ P I N 295 000 093)

Section 03 ENGINE
Subsection 02 (REMOVAL ANID INSTALLATION)
- ~lnsertshaft end into PTO flywh~eel. 18'32, Screw and Loctite 242
nNOTE :The shaft should slide easily in flywheel Apply Loctite 242 ( P I N 293 800 015) on screw threads
\^^ splines if the alignment is correct.
Retorque engine support screws to 25 N*m (18 Ibfmft)
when procedure is completed.
0 NOTE : Whenever alignment tool is not utilized, ap-

ply SEA-DO0 LUBE on its shaft and inside the
housing to eliminate possible corrosion.
Electrical Connection~s
First, install red positive cable on starter post and tor-
que nut to 7 N*rn (62 lbf*in) Install black negative ca-
ble on starter mounting bolt apply Loctite 271 on threads
torque to 22 N*m (16 Ilbf*ft) if removed Apply Neopren
Grease on connectors then cover with boot.
Shaft
0 NOTE ; Install red positive cable with a tie rap lo-
cated on hull night side.
Â WARNING : Always connect red positive cable

first then black ground cable last. Whenever con-
necting the red positive cable t o the starter motor
make sure the battery cables are disconnected t o pre-
vent electric shock.
If the alignment is incorrect loosen engine support screws Install cable coming from ign~itionhousing, into electri-
to enable to align PTO flywheel with shaft end cal box Connect wires making sure to match wire colors.
Install compression grommet and cap It is strongly re-
0 NOTE : Use shim(s) ( P I N 270 000 024) ( P / N 270
000 0251 between engine support and rubber
mounts to correct alignment.
commended to use a flare nut wrench to properly tight-
en cap
Firmly tighten cap. To ensure water-tight mounting, pull
cable, it must not slide through grommet. Retighten as
necessary.
6,13, Exhaust Manifold, Screw

Apply Loctite 242 (PIN 293 800 015) on screw threads
Torq~uescrews in a criss-cross sequence to 24 N*m (17
Ibf*ft).
All Models
1,3,4,19, Nut, Tuned Pipe, Gasket and Screw
Make sure that gasket is properly located on exhaust
manifold prior to finalizing pipe installation
Apply Loctite 242 on stud and retaining screw threads.
Hand-tighten nuts only and assure that tuned pipe sup-
CAUTION : Whenever shims are used t o correct p o r t ( ~rests
) against manifold.
alignment, never install more then 6 rnm (0.240 CAUTION : If a gap is left, stress will1 eventually
in) shim thickness. If alignment cannot be obtained occur on tuned pipe and may cause cracking.
verify for en~ginesupport bending.

Section 03 ENGINE
Sub-section 02 (REMOVAL AND INSTALLATJOIN)
Pre-torque nuts in a criss-cross sequen~ceto about 20 All Models

N*m (15 Ibf*ft)
Final Inspection
Torque side retaining screwts) to 25 N*m (18 Ibf-ftJ and
then torque nuts in a criss-cross sequence to 25 N-rn Check throttle cable condition and lubricate cable with
(18 Ibfaft) SEA-DO0 LUBE. After its installation, properly adjust and
v CAIUTION: Make sure that a sufficient gap is

present between hull and tuned pipe.
synchronize oil injection pump as specified in OIL SYS-
TEM, 06-02
Bleed oil injection pump.
5851 and 5860 Models Pressure test fuel system, refer to FUEL SYSTEM 05-03
and look for fuel system pressurization Secure vent
34,36,Exhaust Cone and Exhaust Colllar tube to the battery Ensure vent tube is not kinked or
obstructed. Verify all connections and hoses condition.
Install exhaust cone to tuned pipe with exhaust collar
Position exhaust collar as illustrated. Do not tighten col- Run engine and ensure there is no leakage.
lar yet. CAUTIION : Water must be supplied t o cool en-
gine w i t h flush kit (P/N 295 000 038).
1
With hose removed, align cone outlet with muffler inlet.
0 NOTE : Due to exhaust cone angle,

be rotated to obtain alignment.
it may have to
Push cone until it touches tuned pipe, then tighten ex-

halust collar clamps and torque to 5 5 N*m (49 Ibf-in1
v CAUTION : There must be no gap between ex-

haust cone and tuned pipe.
0 NOTE : Exhaust collar clamps should be tighten al-

ternatively to assure no leakage and to obtain spec-
if led toraue

- - - -
Section 03 ENGINE
Sub-section 03 (TOP END)
TOP END

Section 03 ENGINE
COMPONENTS
1 Alien screw M6 x 3 5 (2) 17 Hexagonal screw M 8 x 70 (8)
2 Lock washer ( T 7) 18 Synthetic grease
3 Sensor switch 19 Cylinder with sleeve (2)
4 Alien screw M 6 x 2 5 f91 20 Cylinder gasket
5 Hose nipple 21 Semi-frapez ring t2)
6 Cylinder head cover 22 Rectangular ring (29
7 0-rtng 23 Piston (21
8 Hexagonal screw M8 x 55 (12} 24 Piston pin (2)
9 Sealing ring 25 Circltp (4)
10 Loctire 515 26 Needle bearing f2)
11 0-rtng (2i 27 Locme 242
12 0-rmg 28 Gasket set
13 Cylinder head 29 Locate PST 567
14 Hose nipple W 30 Sealant PL-32
75 0-nng f2) 37 Locate primer N
16 0-nng f2i
GENERAL
When repairing a seized engine, connecting rods should
be checked for straightness and crankshaft for deftec-
tion / misallignment. Refer to BOTTOM END for proce-
dures
DISASSEMBLY
In order to repair engine top end proceed as follows :
Exhaust System
To withdraw tuned pipe, refer to ENGINE REMOVAL AND
INSTALLATION 03-02 then look for cooling and exhaust
systems
Intake System
Disconnect therm~osensorwire
Loosen clamp of intake silencer hose on carburetor side.
Remove cylinder head cover.
Pivot intake silencer to rear of watercraft
If shells, sand, salt or any other particles a~represent in
Remove both retaining screws of carburetor support from
cylinder head, clea~nwith a vacuum cleaner.
engine cover.
Remove screws then cylinder head.
Remove screws holding fla~mearrester cover, then with-
draw cover. If shellls, sand, salt water or any other particles are present
in cylinder cooling jacket, clean with a vacuum cleaner
Remove throttle and choke cables from flame arrester
base. Remove screws th~enpull cylinder up, being careful that
connecting rod does not hit crankcase edge.
Remove screws from flame arrester base, then withdraw
base.
Remove spark plug cables and connect them on the Â WARNING : \i screws need to be heated for re-
moval when engine is in watercraft, fuel system
pressurization must be done first. Do not use open
grounding device.
flame ; use a heat gun. A n explosion rnilght occur since
vapors can be present in engine compartment.
0 NOTE : Even if only one cylinder needs repair, both

cylinders should be lifted to allow one-piece cvlin-
der base gasket replacement.

Section 03 ENGINE
23,24,25,26,piston^, Piston Pin, Circlip and To remove circllip, insert a pointed tool in piston notch
Needle Bearing (cageless) then pry it out and disca~rd
v CAUTION : This engine design features cageless

piston pin bearing. At piston disassembly, rollers
Â WARNING :Always wealr sa~fetyglasses whenl
removing piston c~irclips.
may fall out, use rubber pad t o prevent rol~lersfrom
dropping in crankcase.
Bring piston to Top Dead Center and install! rubber pad
tP/N 295 000 079) over crankcase openinq. Secure
with screws. Lower piston until it sits on pad.
Rubber
To extract piston pin, use piston pin puller (PIIN 290

877 090) as follows :
- Fully thread on puller handle.
It other cylinder has been removed, completely cover - Insert extractor spindle into the piston pin.
its opening with a clean rag. - Slide the expansion sleeve ( P I Nl 290 877 040) onto
As an additional precautionary measure, a magnet can the spindle.
be installed under piston to catch rollers for removal. -Screw in extractor nut ( P / N 290 877 1551 with the
movable extracting ring towards spindle.
Locating sleeve PISTON PIN PULLER

P f N 290.877 180) ( P i N 290 877 0901
/ Expansion sleeve
{P'N 290 877 0401
Extractor sleeve
I
Extracting nut Extractor spindle W
IP/N 290 877 1551

Section 03 ENGINE
- Firmly hold puller and rotate handle clockwise to pull REMOVAL OF NEEDLE BEARING
piston pin.
To remove needles with the thrust washers from the
connecting rod bore, push them together with the ex-
1 Clrclip at this side not to be removed 1 pansion sleeve into the locating sleeve ( P / N 290 877
1801 using any suitable pusher 21 mlm ( 826 in) dia.
CAUTION : Recover rollers, make sure that 31
rollers are found tor each piston.
Discard all gaskets and O-rings

Clean all metal components in a solvent
Clean water passages and make sure thley are not clogged.
Grease expansion sleeve
Remove carbon deposits from cylinder exhaust port, cyl-
F001 003 104 under head and piston dome.
Clean piston ring grooves with a groove cleaner tool,
- By turning the spindle, pull out piston pin until it aligns or a piece of broken ringl.
with the reference mark 587 on the extractor sleeve-
INSPECTION
1
Visually inspect all parts for corrosion damage
Inspect piston for damage. Light scratches can be sanded
with a fine sand paper
Inspect plane surfaces for warpage Small deformation
can be corrected by grinding surface with a fine sand
paper. Install sand paper on a surface plate and rub part
against oiled sand paper.
F001 003 105
I The inspection of engine top end should include the fol-
lowing measurements
- Rotate spindle counterclockwise until extracting nut
can be removed
1 1 TOLERANCES
- Remove spindle and extractor sleeve from piston pin
- Carefully remove the piston.
1 MEASUREMENTS 1 NEW PARTS I WEAR
I Cylinder
Taper
I Cylinder Out
of Round
Cylinder / Piston 0 05 mm 0 07 mm 0 20 mm
Clearance 002 in) ( 0028 ml ( 008 in1
I
Ring'Piston 0 05 mrr 0 08 mrn 0 20 mrn
Groove 1
.0021n) (003in) (0081nl
Clearance
Ring End 1 ~ z c i m q0 4 0 m m
( 010 in) ( 016 ml
1 (
10nr-n
039 in)
1
- The needles, thrust washers and the exDansion sleeve
remain in the connecting rod bore and may be used
again

Section 03 ENGINE
Sub-section 03 (TOP ENDS
0 NOTE : Replacement cylinder sleeves are available

if necessary. Consult a specialized shop for instal-
lation.
0 NOTE : 0.25 and 0.5 mrn oversize piston and rings

are available if necessary.
Cylinder Taper
Using a cylinder bore gauge, mealsure cylinder diameter
16 mrn (5/8 in) from top of cylinder to just below aux-
iliary transfer port, facing exhaust port. If the difference
between readings exceed specification, cylinder shlould
be rebored and honed or replaced.
Cyllinder /Piston Clearance

(90') to piston Clearance can be quickly checked with a long feeler
gauge. Insert feeler gauge in cylinder then slide piston
(without piston rings installed! into cylinder as shown
in the following illustration
Feeler
Cylinder Out of Round

Using a cylinder bore gauge, measure cylinder diameter
16 mrn (518 in) from top of cylinder. Measure diameter
in piston pin axis direction then perpendicularly (90')
to it. If the difference between readings exceed spec- 003 022
ification, cylinder should be rebored and honed or re-
placed

Section 03 ENGINE
Or, to accurately determine piston to cylinder wall clear-

ance. Measure piston 25 rnm (1 in1 below skirt end per-
penchcularly ( 9 0 O ) to piston pin.
0 NOTE : Ring/ piston groove clearaince can be cor-
rectly measured only on rectangular ring which is
bottom ring.
Measure cylinder 16 mrn (518 in) below its top edge.
Feeler Rectangular ring

(bottom)
Ring End Gap

Position ring just above transfer ports, un relation with
top of cylinder.
0 NOTE : In order to correctly position rung in cylin-

der, use piston as a pusher
Using a feeler gauge, check ring end gap. If gap ex-
ceeds specified tolerance, rings should be replaced.
Measuring perpendicularly
(90') to piston pin axis
F001 003 023
The difference between these two measurements should

be within specified tolerance.
Ring /Piston Groove Clearance

Using a feeler gauge, check clearance between rectan-
gular ring and groove. If clearance exceeds specified tol-
erance, replace piston
cylinder end gap
:001 003 024

Section 03 ENGIINE
-
ASSEMBLY
Assembly is essentially the reverse of disassembly pro-
cedures. However pay particular attention to the follow-
ing.
23,24,26,Piston, Piston Pin anld Roll~er

Bearing
At assembly, locate piston so that intake hole is on ro-
tary valve side.
Carefully cover crankcase opening as for disassembly
Installation of roller bearing and piston pin using proper
service too! piston pin puller (PIN 290 877 0901, pro-
ceed as follows :
- Insert piston pin into piston until it comes flush with
- Replacement bearings are held in place by a locating
inward edge of piston hub.
sleeve outside and two plastic cage halves inside.
- Warm piston to approximately 50-6O0C (122-140Â°F
- Push the inner halves out of the bearing as per fol- a~ndinstall it over connecting rod.
lowing illustration.
- Insert extractor spindle into the piston pin, screw on
extracting nut.
- Rotate handle counterclockwise to pull piston pin care-
Grease expansion sleeve
fully into the piston.
Locating sleeve
Circlip installation sleeve

F001 003 107 Plastic Mountilng Device Method
As an alternate method when no service tool is avail-
- Push needle bearing together with expansion sleeve able proceed as follows:
out of the locating sleeve into the connecting rod bore, Replacement roller bearings are delivered in a conve-
- Use any suitable pusher 21 mrn (.a26 in1 dia. as a merit plastic mounting device. For installation, proceed
tool Make sure thrust washers are present each side as follows ,
of rollers. - Align replacement roller bearing with connecting rod
bore.

Section 03 ENGINE
- Carefully push inn~erplastic sleeve into connectingl - Place piston over connecting rod and align bores,
rod bore ; outer plastic ring will release rollers. then gently tap piston pin with a fiber hammer to
push out inner plastic rtng on opposite side. Support
Outer ring removal after inner piston from opposite side.
sleeve insertion into bore
Gently tap
- Make sure thrust washers are present each side of

rollers
- Insert piston pin into piston until it comes flush with - As necessary, pulll halves of inner sleeve with llong
inward edge of piston h u h nose pliers.

Section 03 ENGINE
Sub-Section 03 (TOP END)
25, Circlip - Reinstall pusher into tool and push until circlip comes
in end of tool.
Secure remaining circlip taking into consideration the
following. - Position end of tool against piston pin opening
v CAUTION : To minimize the stress on the circlips,

install them so that their openings are located
at 6 o'clock (at bottom).
- Firmly hold piston against tool and push tool pusher
to insert circlip into its groove
1 Piston hole on
Circlip opening
at 6 o'clock -
F001 003 032

(at bottom)
19, Cylinder
Â WARNING : Always wear safety glasses wh~en

installing piston ci~rclips.
CAUTION ;Always use new circl~ips.A t instal-
To easily slide cylinder over piston, install ring cornpres-
sor (PIN 290 876 972) over rings
lation, take calre not to defo~rrnthem. Overstress-

ed circlips will come loose and will darnagle e~ngine.
Circlips must not move freely after installation, re-
place if circlip rotates after installation.
To easily insert circlip into piston, use circlip installer
( P I N 295 000 077).
Circlip slidethis
installer I
AOOI 001 065 edge
0 NOTE : Ring compressor will not fit on oversize

piston /rings.
- Remove pusher from tool then insert circlip into its

bore

Section 03 ENGINE
Make sure to align ring end gap with piston locating

pin Slide tool over rings.
Ring end gap aligned

with piston locating pin
~ x h a u s flange
t
aligning tool
Install cylinder gasket and slide cylinder over piston. ~linders

manifold
When reassembling cylinders to crankcase, it is important

to have them properly aligned so that exhaust flanges
properly match up with exhaust manifold. Use alignling
0 NOTE : If manifold has been used for exhaust
flanges alignment, remove it for engine installation
in watercraft.
tool ( P / N 290 876 902) or exhaust manifold itself

Section 03 ENGINE
17,18,19,Screw, Glrease and Cylinder Make sure to install1 large O-rings around spark plugs
holes and small O-ring where shown.
Apply synthetic grease (PIN 293 550 010 ) below screw
head Apply Loctite 242 ( P I N 293 800 01 5) on screw
Large
threads. Install and torque screws in a criss-cross se- O-rings
quence for each cylinder to 2 4 N*m (17 lbf-ft)
Torque screws to
24 N*rn (17 Ibf*ftl
1,4,6, Screw and C y l i n d e ~ rHead Cover

Installl cover over cylinder head. Apply Loctite 242 (PIN
Torque screws to
24 N*m (17 Ibf*%t) 293 800 015) on screw threads. The two longer screws
F001 003 113 must be installed on oval-shaped housing. Make sure to
install flame arrester support.
5,Screw, O - r i n g and Cylind~erHead
8,lI1l2,l~,l
Apply synthetic grease ( P I N 293 550 010) below screw
head
0 NOTE : Hand-tighten screws only Final torque
should be carried on after flame arresterlcarbu-
retor installation, once engin~eis un the watercraft
Torque cylinder head cover screws to 9 N m (80 lbf*in)
Apply Loctite 515 Gasket Eliminator ( P I N 293 800 007)
as per following illustrated sequence
un cylinder sleeve 0-ring groove Apply Loctite 242 ( P I N
293 800 015) on screw threads Install and torque screws
Torque to
to 2 4 N-rn (17 Ibf-ft) as per following illustrated se- 9 N m I80 Ibf-in)
quence
Torque to
24 N*m [I7 IbMtl
, Longer
screws

Section 03 ENGINE
Sub-section 04 (PTO FLYWHEEL AND MAGNETO)
PTO FLYWHEEL AND MAGNETO
Page: 63 See Doo 1992 Shop Manual - http://www.ReadManuals.com 03-04-1

Secti~on03 ENGINE
Sub-section 04 (PT0 FLYWHEEL AND MAGNETO)
COMPONENTS
1 Gasket 25 Phillips screw M5 x 22 (2)
2. ignition housing 2 6 Battery charging coil
3 Lock washer M8 (8) 27 Screw M 6 x 2 5 (2)
4 Alien screw M 8 x 25 f 8 i 2 8 Harness assembly
5 Armature plate assembly 2 9 Terminal clip (41
6 Magneto flywheel assembly 30 Shrink tube 30 m m f41
7 Ring gear 77 teeth 3 1 Female connector
8 Harness assembly 32 Ring terminal
9 Grommet f21 33 Female terminal
10 Cap (2) 34 Male Teftninal
11 Washer M5 5 f3i 35 Insulation sheath
12 Lock washer M5 (3) 3 6 insulation sheath
73 Alien screw MS x 18 0) 37 Locine 2 4 2
14 Retainer plate 38 Locl!te 648
15 Tapme screw M5 x8 (21 39 Ground plate
16 Lock washer M22 40 Protection cap
77 Hexagonal nut M22 4 1 Insulator f2i
J8 Woodruff k e y 42 Star washer M5
19 Protection mat 43 Spark plug 12)
20 0-nng 44 Diejecvtc grease
21 Ignition housing cover 45. Ignition coil
22 Self tapping screw MS x 2 5 f12l 4 6 Ann-seize lubricant
23 Armature plate 47 PTO flywheel
24 Generating coil 48 Tie rap (2)
GENERAL For removal1 of both flywh~eels,MAG flywh~eelis locked

with puller plllate ( P / N 290 876 0801, sleeves (Pi N 290
The folllowing procedures can be performed without re- 847 220) and extension handle ( P I N 295 000 003).
moving engine from watercraft. However, battery removal
will be required For only PTO flywheel removal withdraw
jet pump unit ass'y, refer to PROPULSION AND DRIVE
SYSTEMS 08-01 then refer to removal and overhaul
To ease the removal of PTO flywheel heat center of fly-
wheel with a heat gun to break bond Always pressurize
fuel system first.
Â WARNING : Never use a torch in the engine corn-

partrnent. Electrolyte or fuel vapors can be pre-
sent it may ignite.
REMOVAL date
21,22, Ignition Cover and Screw

Remove screws and spark plug grounding device then
h' Sleeve
withdraw cover.
0 NOTE : PTO side flywheel must be removed prior

to removing MAG side flywheel since puller has
to be installed on MAG flywheel.
CAUTION : Never lock crankshaft by inserting any
tool through connecting rod bores nor through
impulse fitting.

Section 03 ENGINE
47, PTO Flywheel Insert special tool in PTO flywheel splines

Using three M8 x 35 mrn screws ( P I N 290 841 591),
install screws three puller plate and slide sleeves on
screws then secure puller plate on MAG flywheel so that
Impeller remover used
sleeves are against flywheel. for PTO flywheel removal
Ilnstall extension handle on end of puller plate.
-
6 Sleeves on
opposite s~de
Using a suitable wrench or socket, unscrew PTO fly-

wheel COUNTERCLOCKWISE when facing it.
Extension handle
lockhg crankshaft
Rotate MAG flywheel so that extension handle end can

be held easily before PTO flywheel ioose~ning.
PTO flywh~eelis loosen using impeller remover ( P I N 295

Section 03 ENGIINIE
As an alternate method to remove PTO flywheel when Using a suitable socket, unscrew retaining nut COUN-
PTO flywheel splines are worn out and PTO flywheel TERCLOCKWISE when facing it
remover cannot be used.
Use a pipe wrench and install it on PTO flywheel as illus-
trated.
0 NOTE : If socket is found too large to be inserted
in puller plate, machine or grind its outside diam-
eter as necessary.
Remove nut and lock washer from MAG flywheel.
Extension handle MAG flywheel is easily freed from crankshaft with puller
locking crankshaft (PIN 290 876 065)
6, Magneto Fl~ywheel
With puller plate properly secured as for PTO flywheel Fully thread on puller in puller plate.
removal, rotate MAG flywheel so that extension handle Tighten puller bolt and at the same time, tap on bolt
end can be held easily before loosening head using a hammer to release MAG flywheel from its
taper.
Puller
plate
Extension
Puller handle
Fool 003 156

-
Section 03 ENGINE
.-
7, Ring Gear
Crankcase
Lay MAG flywheel on a steel pla~te,then to ease remov- locating lug Mark armature
al heat ring gear with a propane torch to alpproximately A d a t e at the
1 50Â° (300aF) to break thle Loctite bond. Tap lightlly
on ring gear using a hammer to release it from MAG
flywheel.
5,13, Screw and Armature Plate Ass'y

To ease reassembly and further ignition timing, index- - A t assembly, align armature plate mark (previously
in~gmarks should be made on armature plate and crank- punched) with the end of the same locating tug on
case. the new crankcase.
Remove three retaining screws and withdraw armature Lug end
pilate of crankcase
Cran~kcaseReplacement
Since replacement crankcases do not have timing mark
for armature plate location, indexing marks should be
made on armature plate and crankcase to ease reas-
sembly and further ignition timi~ng.
The following procedure is to find a common reference
point on both crankcases (old and new1 to position ar-
mature plate
Proceed as follows
- Find a crankcase locating lug (the top one in this ex-
ample)
- Place a cold chisel at the end of choosen lug, then
punch a mark on armature plate at this point

- - - -
Section 03 ENGINE
Sub-section 04 (PTO FLYWHEEL ANlD MAGNIETO) .,
- Find manufacturer's mark on armature plate. In 'line 2,4,Ignition Housing and Screw
with this mark, punch another mark on adjacent crank-
case lug. To remove ignition housing, starter has to be removed
Refer to ELECTRICAL 07-04 under electric starter for
procedures.
Unscrew retaining screws, then withdraw housing
CLEANING1
v CAIUTION : Clean armature coils and magneto

magnets using only a clean cloth.
Clean crankshaft taper and threads.
Pun~cha mark
on crankcase lug
aliened with
INSTALLATION
mark / Installation is essentially the reverse of removal proce-
Manufacturer's dures. However pay particular attention to the following
mark on
armature plate
2,4, Ignition Housing and Screw
Install gasket on housing /crankcase mating surfaces
Apply Loctite 242 (blue) I P / N 293 800 015) on screw
threads then torque them in a criss-cross sequence to
10 N*m 189 !bf*in). -
FOOT 003 159 After housing installation, make sure before reinstalling
electric starter, that oil outlet fitting is installed on crank-
From now on, these marks will be used for further as- case.
sembly positioning as a pre-timing posi,tion
5,13, Screw and Armature Plate Ass'y
Position armature plate on cra~nkcase,aligning previous-
ly traced marks on both parts
Apply a drop of Loctite 242 (blue) ( P / N 293 800 015)
on screw threads and torque to 6 N*m (53 lbf*in)

Section 03 ENGINE
7, Ring Gear 47,PTO Flywheel

Apply b c t i t e 648 ( P I N 290 899 788) to MAG flywheel1 Apply Loctite 767 Anti-Seize (PIN 293 550 001 1 on
mating surface Lay ring gear on a steel plllate, then heat crankshaft threads then screw on PTO flywheel
with a propane torch in order to install it on MAG fly-
Using same tool as for removal, torque PTO flywheel to
wh~eel
110 N*m (81 Ibfaft).
Pay particular attention to position ring gear teeth cham-
fer side as per folllowing illustration
v CAUTIION : Never use any type of impact wrench
at PTO flywheel installa~tion.
Ig~nitionTiming
For procedures, refer to ELECTRICAL 07-02 under igni-
tion timing
21,22,Ignition Housing Cover and Screw
Properly install O-ring in ignition housing Install cover
and spark plug grounding device then torque screws in
a criss-cross seouence to 5 Nem (44 lbf*in)
Teeth chamfer
0 NOTE : Ensure that ring gear contacts MAG fly-

wheel flange. Scribe a new mark on ring gear for
further ignition tinning
v CAUTION : A t MAG flywheel installation, ring

gear teeth chamfer and starter clutch should be
facing each other.
MAG Flywheel and Nut

6,l17,
Apply b c t i t e 242 (blue) ( P / N 293 800 015) on crank-
shaft taper
Position Woodruff key, MAG flywheel, apply Loctite 242
on nut threads and install fasteners on crankshaft
Torque nut to 105 Nmm (77 Ibfeftl.
CAUTION : Never use any type of impact wrench
at MAG flywheel installation.

Section 03 ENGINE
Sub-section 05 (BOTTOM END)
BOTTOM END

Section 03 ENGINE
Su~b-Section05 (BOTTOM END)
7 Crankcase assy 76 O - ~ n g(21

2 Lock washer 8 mm 16) 77 Crankshaft
3 Alien screw M8 x 45 (6) 78 Distance ring
4 Hexagonal head screw MJO x 75 (2) 79 Ball bearing 6206 (29
5 Hexagonal head screw !vt8 x 70 (6) 20 Oil seal
6 Stud MW x 2 5 / 1 8 W 21 Shim 3 0 4 / 5 7 / 7
7 Retaining ring 22 0-ring <2J
8 Retaining shim 23 Drain plug (2)
9 Labyrinth sleeve 24 Oil outlet fitting i2i
70 O-ring 25 Locute 5 15
1 1 Locme 271 26 Locote 242
12 Oil seat 27 Primer "N"
13 Ball bearing 6207 i2i 28 h c v w PST 567
14 Anti-seae lubricant 29 Synthetic grease
15 Distance ring
CRANKSHAFT MISALIGNMENT
AND DEFL~ECTION
S~nceit is an assembled crankshaft it can become mis-
aligned or deflected Crankshaft can be twisted on cen-
ter main journal, changing timing of one cylinder in re-
lation with the other.
Connecting rod
journal alignment here
F001 003 059
7
Crankshaft Alignment at Center Mlain

Journal
Main journal
alignment here
0
gine
NOTE :The following checks can be performed
with engine in watercraft without overhauling en-
To quickly check, without accuracy, if cranksh~aftis twist-

ed on center main journal, proceed as follows
Counterweights can also be twisted on connecting rod
journal on any or both cylinder(s). - Remove PTO flywheel guard
- Remove spark plugs
- Insert a screwdriver in one spark plug hole
- Insert a longer screwdriver in the other hole
- Lay a forearm over both screwdriver handles to feel
piston displacements

Section 03 ENGINE
Sub-section 05 ( B O T T O M END)
- With the other hand, slowly rotate engine by PTO fly-

wheel.
TDC gauge
Lay forearm
over screwdrivers Degree
to feel movement wheel
Screwdrivers
in spark plug Hand
holes tighten nut Needle
pointer
- Remove TDC gauge and install on PTO side,

- Bring PTO piston at Top Dead Center
As soon as one piston starts going up, the other must Interval between cylinders must be exactly 180' there-
mmediately go down. Any interval between strokes in- fore, needle pointer must indicate 18Q0on degree wheel
- dicates a misaligned crankshaft (360'- 180' = 180').
Or, to accurately check cranksha~ftalignment, proceed Any other reading indicates a misaligned crankshaft
as follows.
- Remove ignition housing cover.
Crankshaft Alignment a t Connecting Rod
Journal
- Remove MAG flywheel nut Refer to PTO FLYWHEEL
AND MAGNETO 03-04 for procedures. Such misalllignment may cause a crankshaft hard to be
- Install Bombardier degree wheel (PIN 295 000 007) manually turned. Verification can be done by measuring
on crankshaft end. Handl-tighten nut only deflection each end of crankshaft. Refer to INSPECTIION
paragraph.
- Remove both spark plugs
If deflection is found greater than specified tolerance,
- Install a TDC gauge ( P I N 295 000 0651 in spark plug1 this indicates worn bearing(s1, bent and/or disaligned
hole on MAG side. crankshaft.
- Bring MAG piston at Top Dead Center.
- As a needle pointer, secure a wire with a cover screw
GENERAL
and a washer. Engine has to be removed from watercraft to open bot-
- Rotate degree wheel (NOT crankshaft) so that needlle tom end.
pointer reads 360'. If crankshaft end sealts) haslhave to be replaced, bot-
tom end-must be opened.

Section 03 ENGIINE
Sulb-Section 05 (BOTTOM END)
DISASSEMBLY
Remove the following parts :
- ignition housing and PTO flywheel on opposite side
Separating ignition
housing /armature plate
from crankcase
by prying a t
provided lugs
12,13,19,20, Seal and Bearing
0 NOTE : Do not needllessly remove crankshaft bear-

ings.
Remove end seals.
- rotary valve cover and valve To remove end bearings from crankshaft, use crankshaft
- engine support end protective cap ( P / N 290 876 557) and puller ( P I N
- crankcase retaining screws 290 876 298).
Insert screwdrivers between crankcase lugs and pry to On PTO side, use ring ( P i N 290 977 490) with ring
separate halves being careful not to damage precision halves ( P / N 290 977 475).
machined surfaces On MAG side, use distance ring (PIN 290 876 5691
and ring ( P I N 290 977 490) with ring halves ( P I N 290
276 025).
0 NOTE : To facilitate ring or distance ring installation

lubricate their inside diameters
Puller MAG side ring halves

( P / N 290 876 298) ( P / N 290 276 025)
\
Distance ring,
MAG side
(PIN 290 876 5691
srsn /
Separate halves
by prying at
provided lugs
/
Ring (both side!
( P / N 290 977 4901
~rotectivecap PTO side ring halves

4P/N 290 876 557) i P / N 290 977 475)

Section 03 ENGINE
INSPECTION
Visually inspect parts for corrosion damage.
Inspect plane surfaces for warpage Small deformation
can be corrected by grinding surface with a fine sand
paper Install sand paper on a surface plate and rub part
against oiled sand paper.
Inspect crankshaft bearings. Check for scoring, pitting,
chipping or other evidence of wear Make sure plastic
cage is not melted Rotate an~dmake sure they turn
smoothly.
If crankshaft and/or components are found defective,
it must be repaired by a specialized shop or replaced
The inspection of engine bottom end should include the
following measurements :
Or, use a bearing extractor such as Proto #4332 and TOLERANCES I

a press to remove two bearings at a time.
I MEASUREMENTS I NEW PARTS WEAR
1
I
(min.1 4rnax.l LIMIT ,
I I I
Crankshaft
deflection
Connecting rod 0 39 mm 737 mrn 1 2 mm

big end axial play ( 015 in) I 029 in) ( 047 ml
Connecting Rod Straightness

Align a steel ruler on edge of small end connecting rod
bore. Check if ruller 11sperfectly aligned with edge of big
end.
L I/ extractor Ruler must be

aligned with edge
F001 003 061 of connectina rod here
7NOTE : If bearings are to be replaced, they can be

/quickly removed using an air hammer.
CLEANING
Discard all oil seals, gaskets, 0-nngs and sealing rings.
Clean water and oil passages and make sure thley are
not clogged
Clean all metal components in a solvent.
Remove old Loctite from crankcase mating surfaces with
stripper #I57 (P/N 295 000 040). Align ruler here
-
v CAUTION : Never use a sharp olbject t o scrape
away old sealant as score marks incurred are
detrimental t o crankcase sealing.
F001 003 062

Section 03 ENGINIE
Crankshaft Alignment
A quick check can be made as follows Measulring MAG side
- Insert a finger in each connecting rod deflection in crankcase
- Lift crankshaft and apply a rotation movement to

crankshaft with fingers
Remove crankshaft bearings and check deflection again

on V-shaped blocks as illustrated.
Measuring MAG side

A twisted crankshaft will turn irregularly in an out of deflection on V-shaped blocks
round motion
Crankshaft Deflection1
Crankshaft deflection is measured each end with a dial
indicator
First, check deflection with cranckshaft in crankcase
If deflection exceeds the specified tolerance, it can be
either ball bearings wear, bent or twisted cranlkshaft at
connecting rod journal
FOOI 003 066
Measuring PTO side

deflection in crankcase
0 NOTE : Crankshaft deflection can not be correctly

measured between centers of a lathe.

Section 03 ENGINE
Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between thrust
washer and crankshaft counterweight.
Measuring big end

axial play
To properly locate outer PTO bearing, temporariii~lyinstall

distance gauge ( P I N 290 876 826) against inner bear-
n g . Slide outer bearing until stopped by gauge then re-
move gauge.
ASSEMBLY
Assembly is essentially the reverse of disassembly pro-
I
- , cedures. However pay particular attention to the follow-
ing.
13,19, Bearing
Apply Loctite 767 Anti-Seize (PIN 293 550 001 1 on
bearing sea~ts.
Prior to installation, place bearings into a container filled
with oil, previously heated to 75OC (167OF) This will
expand bearing and ease installation.
Or, as an alternate method, apply heat with a propan~e
torch. Lay bearing on a steel plate, then heat plate
through bearing bore until smoke is noticed from bear-
ing. Install bearing carefully on crankshaft.
CAUTIION : Immediately stop heating as soon as
s~mokeis noticed. Overheating bearing will melt
plastic cage. Practice w i t h used bearings on first try.
PTO side
outer bearing

Section 03 EINGINE
9, Labyrinth Sleeve Install bearings so that their peripherical grooves be lo-

(5851 and 5860 models) cated as shown in following illustration. -
To properlly locate outer PTO bearing, install labyrinth

sleeve against inner bearing side. 1 Penphencal grooves
on inner side
Penphencal grooves
on inner side
Ilnner
bearing
Labyrinth
sleeve
12,20, Seal
- - -
At seal assembly, apply a ligh~tcoat of lithium grease

nNOTE : Be sure to install labyrinth sleeve with its on seal lips.
u hollow side facing PTO side outer bearing.
1, Crankcase
PTO side
outer bearing - Crankcase halves are factory matched and therefore,
are not interchangeable or ava~ilableas singlie halves.
Prior to joining crankcase halves, apply a light coat of
Loctite 51 5 Gasket Eliminator ( P I N 293 800 0071 on
mating surfaces. Do not apply in excess as it will spread
out inside crankcase.
0 NOTE : On aluminum material it is recommended

to use Loctite Primer N (PIN 293 600 012) to re-
duce curing time and increase gap filling capability. Re-
fer to manufacturer's instructions.
FOCI 0 0 3 1 7 3
Hollow
side
v CAUTIION : Rotary valve shaft must be installed
i~ncrankcase before closing halves. Before join-
ing crankcase ha~lves,make sure that crankshaft gear
is well engaged w i t h rotary valve shaft gear.
Slide outer bearing until it touches sleeve
Position crankcase halves together and hand-tighten
bolts.
v CAUTION : Temporarily install1 armature plate to

align crankcase halves with each other.

-
Sectlion 03 ENGINE
3,4,5,Screw
Apply Lnctite 242 (P/ N 293 800 015) on screw threads.
Torqiue crankcase screws to 24 Nmrn (17 llbf*ftI as per
following illustrated sequence.
6, Stud
At assembly in crankcase, apply Loctite 271 ( P I N 293
800 005) on stud threads
Finalizing Assembly
24, Oil Outlet Fitting
Iif oil outlet fitting has been removed from crankcase, re-
install it with its end pointing towards ignition housing.
Apply Loctite PST 567 ( P I N 293 800 013) on fitting
threads
For rotary valve timing and assembly, refer to ROTARY
VALVE AND RESERVOIR 03-06 procedures.
If engine support is installed on crankcase before igni-
tion housing, electric starter must be installed before
engine support.
I iglnition housing
End lawards 1
Install before
wnoinp support nr
ignition housing
F001 003 164

Section 03 ENGINE
Sub-section 06 (ROTARY VALVE AND RESERVOIR)
ROTARY VALVE

Section 03 ENGINE
COMIPONENTS
7 Ball bearing 6201 1 1 Oil seal
2 Circl1p (2) 12 Rotary valve shaft
3 Spring seat 13 Snap ring
4 Spring 14 Rotary valve
5 Sprocket 14 teeth 15 0-rtng
6 0-nng 16 Rotary valve cover
7 Distance sleeve 24 5 rnm 17 Dowe/pin
8 Snap ring 18 Lock washer 8 mm (4)
9 Shim 19 Hexagonal head screw MB x 20 (4)
10 Bat! bearing 6203 20 Rubber ring

Section 03 ENGINE
Sub-section 06 ('ROTAIRYVAILVE AND RESERVOIR)
RESERVOIR

Section 03 ENGINE
Sub-Section 06 (ROTARY VALVE AND RESERVOIR) .
COMPON'ENTS
7 Oil level indicator cap 75 Filter
2 0-r/ng 16 Hose 8 mm
3 Adaptor 17 Hose 12 mm
4 R;ver (4) 18 Hose 6 mm
5 Jndon clamp (2) 19 One way check valve
6 Gasket 20 Strap
7 Tridon clamp (2) 21 Tie rap
8 Hose 22 Tie rap
9 Oil tank 23 Tie-mount
70 Grommet (21 24 Oetiker clamp
77 Grommet t2i 25 Oil level sensor
72 90 Elbow (2) 26 Float
73 90' Elbow 27 Gromme!
14 9 O D Elbow 28 Hose fitting
GENERAL CAUTION : Bottom end must be opened to re-

move rotary valve shaft.
The following verification procedures such as clearance To remove rotary valve shaft, use a remover (PIN 290
between rotary valve and rotary valve cover or crankshaft 876 487).
and rotary valve shaft gear backlash can be performed
without removing engin~efrom watercraft. Refer to IN-
SPECTION further in this section
However engine must be removed from watercraft to
work on rotary valve shaft/cornponents. Refer to REMO-
VAL AND INSTALLATION 03-02 for procedures.
Bottom end must be opened to remove rotary valve
shaft.
DISASSEMBLY
16,19, Rotary Valve Cover and Screw Place puller over rotary valve shaft end and screw on
Unscrew four retaining screws and withdraw rotary valve puller boll into shaft. While retaining bollt with a wrench,
cover and valve. turn puller nut CLOCKWISE until shaft comes out.
12,13, Rotary Valve Shaft and Snap Ring

To remove rotary valve shaft assembly from crankcase,
first remove snap ring from crankcase.
Removing
snap ring
/
Hold bolt
-
Section 03 ENGINE
Bearing extractor
Snap-on CJ-950
2,3,Circlip and Spring Seat
If it is necessary to disassemble components of rotary
CAUTION : Ensure that rotary valve shaft is per-
valve shaft assembly, compress spring by seat to remove
fectly perpendicular with press tip or damage
circlips.
will occur,
1, Bearing
seat
0 NIOTE:Do not remove plug against bearing in

crankcase half
Remove
Fool 003 077
circlips
8,10, Snap Ring and Bearing

To remove bearing use a bearing extractor such as Snap-
on #CJ-950 as illustrated. Slide off distance sleeve, re- Do not remove
move snap ring and press shaft out. this plug

Section 03 ENGlBNE
Sub-section 06 (ROTAIRY VALVE AND RESERVOIR) - d
End bearing can be easily removed using the following

suggested tool.
Snap-on hammer puller including : Handle CJ93-1 Inspect rotary valve cover for warpage. Small deforma-
Hammer CJ125-6 tion can be corrected by surfacing with fine sand paper
Claws CJ93-4 on a surface plate Surface part algainst oiled sand pa-
per.
Inspect bearings. Check for scoring, pitting, chipping
or other evidence of wear. Make sure plastic cage (on
bigger bearing) is not melted. Rotate them and make
sure they turn smoothly.
Check for presence of brass filings in gear housing
Visually check gear wear pattern. It should be even on
tooth lenght all around. Otherwise it could indicate a
bent shaft, check deflection. Replace gear if damaged.
The inspection of rotary valve system should include
the following measurements.
Close puller claws so that they can be inserted in end
bearing Holding claws, turn puller shaft clockwise so
that claws open and become firmly tight against bear-
MEASUREMENTS
'nQ
Slide puller sleeve outwards and tap puller end Retight-
NEW 1
PARTS WEAR LIMIT
en claws as necessary to always ma~intainthem tight
Rotary Valve Cover 0.22-0.34 mrn
against bearing. Continue this way until bearing com- 1N.A.
and Valve Gap ,009 - .013 in)
pletely comes out.
Rotary Valve Shaft 0.08 mrn
N.A.
Deflection . 0 1 0 3in)
End bearing
0 NOTE : The following verifications can be per-

formed with engine in watercraft without oveir-
hauling engine.
Rotary Valve and Rotary Valve Cover

Clearance
There is a choice of two measuring methods.
One with solder, the other one with a depth micrometer
The clearance between the rotary valve and the rotary
valve cover must be 0.28 Â 0.06 mm (0.011 Â 0.002 in).
0 NOTE : If the clearance is below 0 22 mrn (0 009

in) this could create an overheating situation and
if the clearance is over 0-34 rnm <0.013in) this could
CLEANING create a hard starting situation.
Discard all seals and 0-rings
Clean oil passages and make sure they are not clogged.
Clean rotary valve shaft and inside of distance sleeve.

Section 03 ENGINE
Solder Method Depth M~icrorneterMlethod

Remove rotary valve cover and its O-ring. Remove rotary valve cover.
Use the following type of solder: Usinq a d e ~ t h
micrometer measure the distance from the
- rosin core crankcaserib to the valve surface of the crankcase.
- diameter : 0.8 mrn (0.032 in) Measure alt four different places.
- electronic application (availablle at electronic stores)
Install two short pieces (13 mum 4112 in) long) of solder
directly on rotary va~lve,one above and one below rotary
vailve gear. Apply grease to hold solder in position.
Reinstall cover in place WITHOUT its O-ring and torque
screws to 20 N*m (15 lbf*ft).
Remove cover then clean and rneasulre compressed
solder thickness, it must be within the specified toler-
Valve
surface
Add the four measurements and divide by 4 to obtain

an average. A typical reading should be around 3.5 mrn
(0.138 in).
Solder
FD01 003 133

Section 03 ENGINE
Sub-section 06 (ROTARY VALVE AND RESERVOIIR)
Using the depth micrometer again, measure the distance EXAMPLE :

between the rotarv valve cover seating surface and the Crankcase rib depth ,138 in
valve surface of the cover. Depth of cover seating surface - ,104 in
0 3 4 in
Rotary valve thickness - ,023 in
2 6 7 Â 0 2 5 mrn 10 Â 0 3 m m Clearance between rotary valve and cover .011 in
,106 Â 001 in) 039 Â -001 in)
Your result must be within the specified tolerance 0.28
Â 0.06 rnm (0.011 Â .002 mm).
Cover seating
surface Ilf rotary valvelrotary valve cover clearance is out of
specification, machine rotary valve cover seating surface
or replace the cover.
Machining Information
The amount of mrn fin) over tolerance must be removed
from the rotary valve cover seating surface.
Allso cut the O-ring groove and equal amount to obtain
10 Â .03 mrn (.a39 Â ,001 in) between the bottom
of the groove and the seating surface.
Remove burrs on the edges of the seating surface and
O-ring groove.
r'
Reverify the clearance.
At assembly the rotary valve timing must remain as per
origina~llsetting.
Crankshaft and rotary valve shaft gear

backlash
Remove PTO flywheel guard.
Remove spark plugs, rotary valve cover and valve.
ie surface Manually feel backlash at one position, then turn crank-
shalft about 118 turn and recheck. Continue this way to
complete one revolution.
Backllash must be even a t all positions. Otherwise over-
haul enginle to find which part is faulty (gear, rotary valve
shaft or crankshaft with excessive deflection)
Measure at four different places around the cover.

Add the four measurements and divide by 4 to obtain
an average. A typical reading should be around 2.67 m m
( 105 in) Knowing that the thickness of the rotary valve
IS .58 mrn I 0 2 3 in) the clearance between rotary valve
and rotary valve cover can be found using the following
formula.

-
Section 03 ENGIINE
Rotalry Valve Cover and Valve Gap Rotary Vallve Shaft Deflection
A gap must be maintained between rotary valve and Deflection is measured with a dial gauge. Installll rotary
crankcase. valve shaft in crankcase half, without its gear.
To measure this gap, use a feeler gauge inserted be-
tween rotary valve and upper half cra~nkcasewith rotary
valve cover in place WITHOUT its O-ring.
0 NOTE : End bearing must be in crankcase half.
Measure shaft deflection near gear mounting area.

Check as much surface as possible. Follow the same
procedure for lower half crankcase.
\ \ Measuring gap on
crankcase too haif
Deflection must not exceed specified value. Replace

shaft as necessary.
ASSEMBLY
Measuring gap on
crankcase bottom half Assembly is essentially the reverse of disassembly pro-
cedures. However pay particular attention to the follow-
ing.
To install end bearing in crankcase, use a pusher ( P / N

290 876 500)
Pusher

Section 03 ENGINE
Position ball bearing shielded side towards rotary valve. If plug has been removed, clean plug and crankcase hole
with Loctite Safety Primer ( P / N 293 800 019)
Apply Loctite Primer 'IT" and Loctite 648 (green) 4Pl N
290 899 788) insidle crankcase hole, then press plug into
crankcase.
11,12, Seal, Rotary Valve Shaft

Apply lithium grease on seal lips. IPosition seal with shield-
ed portion against shaft splines
8,10,12, Snap Ring Bearing and Rotary Valve

Shaft
Install ball bearing as illustrated.
Shielded side here
(towards gear)
Push bearing until it stops on its seat.
Bearing extractor
1013 002 015 1 r"lli
Install shim, snap ring and slide distance sleeve on shaft.
0 NOTE : Do not remove plug against bearin~gin

crankcase hallf.
Rotary
valve shaft
03-06-1
0 Page: 88 See Doo 1992 Shop Manual - http://www.ReadManuals.com
Section 03 ENGINE
Sub-Sectilon 06 (ROTARY VALVE AND RESERVOIR)
12,13, Rotary Valve Shaft Ass'y and Identificaltion of the rotary valves
S~napRing
CAUTIOlN : Crankcase halves must be separated
and clrankshaft rnu~stnot be present t o install
rotary valve shaft ass'y in crankcase.
To install rotary valve shaft in crankcase, use a pusher
( P / N 290 876 605).
There is no identification code on the valve. To find out

Push shaft until its stops on bearing seat. which is which, place an alngle finder on the valve alnd
measure the valve cut-out angle or use the following tem-
plates.
Rotary valve
shaft ass'y
Push shaft
until it stoos
At snap ring installation, position it so that its sharp edge

faces outwards.
ROTARY VALVE
The rotary valve controls the opening and closing of the
inllet ports Therefore its efficien~cywill depend on the pre-
cision of its installation.

p p p p p
Section 03 ENGIINE
Templates
290 924 504

actual size
290 924 508

actual size
Sectioln 03 ENGINE
Rotary Valve Cover and Valve Clearance For the following instructions, let's use these specifica-
tions as example :
The clearance between rotary vallve cover and valve must
be 0.28 Â 0.06 mrn (0.011 Â 0.002 in]. OPENING : 115' BTDC
CLOSING : 80' ATDC
0. NOTE : If clearance is below 0.22 mrn (0.009 in)
rt could create an overheating situation and i f clear-
ance is over 0.34 mrn (0.013 in) it could create a hard
Proceed as follows :
- Turning crankshaft, bring MAG side piston to Top
starting situation. Dead Center using a TDC gauge
Rotary Valve Timing
v CAUTION : Never use the ridge molded in crank-

case as a timing mark.
The following tools are required to measure rotary valve
TDC gauge
on MAG side
Bring piston
to TDC
opening and closing angles in relation with MAG side
piston.
Degree wheel
( P I N 295 000 0071
- For opening mark, first align 360' line of degree

wheel with BOTTOM of MAG side inlet port. Then,
find 115' line on degree wheel and mark cralnkcase
at this point.
Rotary valve must be set so that timing occurs as follows 1 on d,egree

2 O Find 115'
wheel Opening mark
and mark here
1 WATERCRAFT 1 1
1 MODEL NO. 1- TIMING
align 360' line

of degree wheel here
Page: 91 See Doo 1992 Shop Manual -

Section 03 ENGIINE
0 NOTE : Do not rotate the crankshaft.
- For cllosing mark, first align 360' line of degree wheel

with TOP of MAG side inlet port. Then, find 8 0 O line
on degree wheel and mark crankcase at this point.
2Â°Find80 \
on dlegree wheel
F0011 003 122
and mark here
- Remove degree wheel.

- Position rotary valve on shaft splines to have edges
as close as possible to these marks with the MAG
piston at TDC.
0 NOTE ; Rotary valve is asymmetrical. Therefore,

try flipping it over then reinstall on splines to ob-
tain best installation position.
Apply SEA-DO0 injection oil on rotary valve before reas-
sembling rotary valve cover
- Remove TDC gauge.
16,19, Rotary Valve Colver anld Screw
Install O-ring and cover then torque screws to 20 Nam
I15 Ibfaft) in a criss-cross sequence.

Section 03 ENGINE
Sub-section 07 (EXHAUST SYSTEM)
EXHAUST SYSTEM
Section 03 ENGINE
Sub-section 07 (EXHAUST SYSTEM)
COMPONENTS
7 Hexagonal nui M8 14) W . Formed hose
2 Lock washer M8 (41 7 7 Exhawsf outlet
3. Tuned pipe 12 Flat washer 6 rnm (4)
4 Exhaust clamp 13 AI6en screw MB x 20 14)
5 Rubber collar 14. S v a p clip (2)
6 Trrdon clamp (4) 15 Rivet 3/16 (4)
7 Exhaust hose 16 Locme 587 "Uiwa Blue"
8 Muffler strap 17 Exhaust cone
9 Muff/er
TUNED PIPE REPAIR Test :

- Use compressed air at 124 kPa (18 PSI) to pressurize
This procedure is given to repair tuned pipe cracks using tuned pipe
T.1.G welding process.
0 NOTE : Prior to verify leaks plug alll holes and pres-

sunze tuned pipe while immerging it in water.
- Sand the cracked area t o obtain bare metal

- Perform a 1 50 mm (1116 in) depth chamfer over crack.
v CAUTION : Always ensure water passages are
not blocked partially or completely while weld-
ing tuned pipe.
- Use pure argon gas with 5.55 rnm (3132 \n} tungsten
electrode (puretung "green", zirtung "brown") and
AC current
- Use aluminum welding rod 5-55 (3/32 in) (#4043),
to fill crack
- Sand welding slightly to remove material surplus.

Section 04 COOLING SYSTEM
COOLING SYSTEM

Sub-section 01 (COMPONENTS)
COMPONENTS

Section 04 COOLIING SYSTEM
Sub-section 01 (COMPONENTS1
COMPONENTS
1 Tuned pipe 13 Hose 6 mrn
2 Hose 12 5 m m 14 Bleed fitting (2)
3. Hose 8 mrn J5 T-fmmg
4 Elbow fitting 90 O 16 Tie rap
5 Male connector 17 Tie rap mount
6 Elbow fitting 90Â 78 Tie rap
7 Locme 'PST 567 19 Male connector
8 Male connector 20 Looms 592
9 Elbow fining 90Â 2 1 Hose 8 mm
70 Tndon clamp fW 22. Tie rap mount f2i
17 Oetiker clamp 23 Rivet
12 Oetiker clamp 131 24 Elbow firt~ng90Â

SEA-DOO@WATERCRAFT COOLING SYSTEM
Uppermost point of circuit Fresh water flows through tuned pipe

allows trapped air t o escape water jackets and manifold
POINTS TO REMEMBER
TECHNICAL DATA
Uppermost point of When servicina hull Iiet ourno. dwavs rotate watercraft
engine allows trapped countar-clock~se1-n fromthe rear). Rotating watercraft
Type TLCS (Total Loss Cooling clockwise could allow residual water in tuned pipe to enter
System) Temperature sensor monitors the engine and cause engine damage.
Coolant pressure Pressure build-up at impeller engine temperature and turn
housing (no water pump1 on an overheating beeper when
. ... ..... . temperature is over 96-9SÂ°
o w1 Calibrated outlet filling at
. . . (205-21O0F)
exhaust outlet and drain line
.... . . ......
/
(no thermostat)
.......... . ..............
System bleeding Self-bleed type (hose at
.. . .. ...
...
uppermost point of circuit
and a t cylinder head cover1
. . . . . . ..... .....
System draining Self-drain type (hose at
lowest point of circuit) .- -,.-, I
System flushing
Overheat beeper
A flush kit is available
Turns on at 96-99OC
2 Check joints for leaks to avoid water accumulation in the
bilge.
1205-2lO'FI
3 Flush cooling system after each operation i n salt water or
unclean water.
Do not modify hose or socket size as coolant flow could

4 be altered.
5A small stream of water must flow from the rear bleed

outletlsl. This indicates that coolant is circulating.
Water injected directly into

exhaust gas for noise reduction
and performance improvement
- Ootional flush kit to be used with a
1 calibrated Drain line
I fitting
minimize loss of cooling water)

Sub-section 03 (FLUSHIING AND CARE)
CAUTION : All hoses and fittings o f t h e cooling FLUSHING

system have calilbrated inside diarnete~rst o as-
sure proper cooling of the enginle. Always replace using When the watercraft is operated in uncllean water and/or
appropriate Bombardier part number. particularly i n salt water, flushing of cooling system is
necessary.
6,Elbow Fitting
Water injection used on exhaust system cools the ex-
haust gases to obtain maximum performance from the
v CAUTION : Fail~u~ret o perform cooling system
flushing, when watercraft is used in salt water,
will result in damage t o watercraft components.
tuned pipe. The water inta~keelbow fitting has a calibrated Since the watercraft uses the same water where it sails,
inside diameter to optimize water flow in each model. for propulsion and cooling systems, this water flows ev-
The water injection also helps in reducing noise level and erywhere in water jackets. If the watercraft is being ulsed
cools components of the exhaust system. in salt water and cooling system is not regularly flushed,
v CAUTION :The water intake elbow fittings are

cal~ibratedfor each model and can n o t be inter-
change with one of a different size as severe engine
salt will corrode components
Infiltration in cooling system of any particle present in
the water is unavoidable. Deposit accumulation can clog
cooling system and lead to severe engine damage
dam~agecould result.
The elbow fitting can be identified by using the two digits Flushing is necessary when the watercraft is operated
number stamped onto the fitting or by measuring its in- in :
side diameter. Refer to the following illustration and chart. - salt water
- debris filled water
- shallow water where the bottom is sandy andlor shell
covered.
Flushing the cooling system w i t h fresh water is essen-
tial to neutralize corroding effects of salt or other chem-
ical products present in water. It will help to clear sand,
sallt, shells or other particles in water jackets (engine, ex-
haust manifold, tuned pipe) and/or hoses.
Flushing should be performed when the watercraft is
not expected to be used further the same day or when
the watercraft is stored for any extended time.
T CAUTION :Failure t o flush cooling system, when

necessary, will severely damage engine and /or
exhaust system. Never flush a hot engine. Malke sure
engine operates during entire procedure.
Â WARNING : Do not touch any electrical part when

engine is running.
1 ~~i~~~
1 1 1 1
A convenient flush kit (PIN 295 000 0681 can perma-
Stamped Fitting nently be installled on the watercraft to ease flushing
imnibei Fitting
,,,N inside
on fitting diameter
For flush kit installation and flushing procedure refer to
instruction sheet included with the kit
I 1
"'"fl' 22 I 283 TOO 022 I ,lln,
46mm I

Sub-Section 03 (FLUSHING AND CARE)
0 NOTE : If a flush kit is not installed on watercraft,

disconnect outllet hose at exhaust socket. Insert
garden hose nozzle into hose end for flushing
CARE
1. When servicing hull /jet pump, always rotate water-
Proceed as follows. cralft counterclockwise (seen from the rear) Rotat-
ing watercraft clockwise could allow residual water
1 Remove seat to alllow access of cooling system. in tuned pipe to enter the engine and cause damage.
2 Disconnect outlet hose at exhaust socket and insert
garden hose nozzle in~tohose end. Do not open wa-
ter tap yet.
F001 004 Oil

Ground /
3 Start the engine then immediately open the water
ta P
v CAUTION : Allways start the engine before open-

ing the watelr tap, Otherwise, water will back
flow through the tuned pipe into the engine and may
cause darna~get o internal parts. Open water tap im-
mediately after engine is started t o prevent overheat-
ing. Folllow this procedure exactly.
4 Run the engine about five minutes at a fast idle around
3500 RPM.
v CAUTION : Never run engine longer than five mi-

nutes. Drive line seal has n o cooling whe~nwa-
tercraft is out of water.
5 Close the water tap then stop the engine
v CAUTION :Always close the water tap before

stopping the engine. Follow this procedure ex-
actly otherwise severe engine damage could occur. Ground
Fool on 001
6 Disconnect garden hose from outlet hose and con-
nect hose to exhaust socket.
2. Check joints for leaks to avoid water accumulation
7 Wipe off any residual water on the eng~ine,
in the bilge.
8 Reinstall seat and properly latch.
3 Do not modify hose or socket size as coolant flow
could be alltered.
4. When engine is running, water must flow from bleed
outlet indicating that water circulates.

-

Sub-section 03 (FLUSHING AND CARE)
5. For hose clamp installation, use special pliers ( P / N

295 000 0701.
6. Wh~eninstalling hoses onto fittings or when
troubleshootingfor water intake in the bilge area, con-
firm that all hoses are properly /tigh~tlysecured to the
fittings.
7. Check overheating beeper operation by jumping ter-
minal of thermosensor wire to ground Beeper must
operate.
0 NOTE: Engine has to be started to test beeper

operation.
At every verification of overheating beeper always ap-
ply dielectric grea~se(PIN 293 550 004) on thermosen-
sor connector.
Verify wire terminal on connector for tightness. If too
loose, squeeze terminal slightly at installation.
CAUTION : When investigating for no water flow
in the cooling system, check alll elbows and
straight fittings as well as all hoses for blockage.

Section 0 5 FUEL SYSTEM
FUEL SYSTEM
05-00-1
Section 05 FUEL SYSTEM
Sub-section 01 (FUEL CIRCUIT)
FUEL CIRCUIT

Sub-section 01 (FUEL CIRCUlIT)
Countersunk Phillips screw M4 x 8 30 Filler neck hose

Flat washer M4 31 Gasket
Fuel valve knob 32 Filler neck
Nur M22 33 Chain
Gasket 34 Cylindrical h i l i p s screw M3 9 x 9 5
Fuel valve 35 Gasket
Elastic slop nut M6 !3) 36 Hexagonal screw M 5 x 2 5 XP f585V GTX i5860)
Clamp XP (5857) GTX (5860) 37 Ha F washer MB XP (5851) GTX (5860)
Valve gasket 38 Fuel tank cap
Fuel sensor XP (5851) GTX (58601 39 Check valve !21
Hose 6 mm 40 Elbow fitting 90 (2)
Fuel sensor adaptor XP (585V GTX f58GO1 47 Grommet i2i
Oetiker clamp 42 Strap clip <61
Flat washer M 6 43 Rivet 3/16 x 565 (12)
Fuel filter housing 44 Tie rap
Fuel filter 45 Tie rnounr (67
O-ring 46 Washer
Fuel tank strap (2) 47 "Tee" firttng
Fuel tank 48 Pick up tube (21
Baffle 49 Oetiker clamp
Fuei filler screen 121 50 Inner filler neck hose
Oetiker clamp 141 51 0-rmg (8)
Tie rap 52 Rivet 1/8 x 690 181
Hose 6 mm 53 Flat washer M3 12)
Tr~donclamp 54 Rivet 1/8 x 502 12S
Tube adapter 55 Hexagonal screw M 6 x 16 (2)
Pick up rube (31 56 Filter support
Tr~donclamp 57 Locme 242
Tridon clamp !2i 58 Washer 18)

Sub-section 02 (AIR INTAKE)
AIR INTAKE
10 IN-m
(88Ibfwinl
CHOKE
CABLE
ACCELERATOR

Sub-section 02 (AIR INTAKE)
AIR INTAKiE
1 Alien screw M6 x 2 5 (2i 14 Inlet tube (2)
2 Cover adaptor 15 Synthetic grease
3 Flame arrester cover 76 Screw M4 x 6
4 Flame arrester foam 17 Performed hose
5 Isolator 18 Clamp f2)
6 Base 19 Hexagonal Screw M 6 x 2 0
7 Support 20 Fiat washer M6
8 Loctite 515 21 Hexagonal nut M6
9 Locme 242 22 Silicone 732 RJV
10 Alien screw M6 x 16 i6> 23 Flat washer M6 f81
Alien screw M6 x 30 f31 24 Alien screw M 6 x 12 f21
7 7 A/ten screw Mt3 x 80 i2i 25 Alien screw M 6 x 3 0 except SF (5805) GTS 15812) {41
12 Carburetor linkage 26 Nut M 6 (2>
13 Air intake silencer 27 Rubber plug

Sub-section 03 (CARB'URETORS)
CARBURETORS

Sub-section 03 (CARBURETORS)
CARBURETORS
Sealing ring (2f 37 Pilot jet
S/eeve 32 0-nng
Spring 33 Washer (2)
Throttle lever 34 Spring
Throttle /ever stopper 35 Low speed mixure screw
Lock washer 36 Screw (2)
Nut 37 Check valve housing
Ring 38 Pin
Washer 39 Plate
Lock washer 40 Needle valve
Screw 41 0-mg
Choke valve 42 Needle valve lever
0-nng 43 C/ip
Gasket 44 Spring
O-ring 45 Gasket
Pump body 46 Diaphragm
Diaphragm 47 Cover
Gasket 48 Screw 141
Pump cover 49 Screw 121
Screw (4) 50 Spring (2)
Throttle valve 51 Washer (2)
Screw and spring washer (5) 52 Screw
Sealing ring (2) 53 Washer (41
Sleeve 54 O-ring
Spring 55 Cap
Main pi screw flocked! 56 Locate 242
Ring 57 Carburetor linkage
Filter 58 Synthetic grease
Screw and spring washer 59 Bracket (twin carburetor only)
Main jet
REMOVAL FROM ENGINIE Remove two nuts, lock washers from carburetor base and
withdraw carburetor.
To remove carburetors from engine, proceed as follows :
Intake and Fuel Systems 0 NOTE : For easier access to right carburetor base
nut, throttle rope lever should be removed from
throttle shaft.
(Single Carburetor)
Loosen clamp of air intake silencer hose on flame arrester Intake and Fuel Systems
cover (Twin Carburetors)
Move air intake silencer hose to rear of watercraft. Re- Loosen clamp of air intake silencer hose on flame arrester
move screws holding flame arrester cover to engline, then cover.
remove screws from cover and withdraw cover. Remove
Move air intake silencer hose to rear of watercraft. Re-
throttle cable from flame arrester base and unhook ca-
move screws holding flame arrester cover to engine, th~en
ble from throttle rope lever. Unscrew Alien screw hold-
remove screws from cover and flame arrester adaptor.
ing choke cable rod to choke shaft fever then remove
Remove cover and adaptor from watercraft. Remove
cable rod
throttle cable from flame arrester base and unhook ca-
0 NOTE : Choke cable does not need to be removed

from flame arrester base.
Unscrew base retaining screws then remove base from
ble from throttle rope lever. Unscrew Allen screws hold-
ung choke cable rod to choke shaft lever then remove
cable rod.
carburetor and move it to front of watercraft
Turn fuel valve to OFF position 0 NOTE : Choke cable does not need to be removed
from flame arrester base.
Unscrew base retaining screws then remove base from
Disconnect impulse line, fuel supply line and fuel return
line from fulei pump. carburetors and move it to front of watercraft

Sub-Section 03 (CARBURETORS)
Turn fuel valve to OFF position. PUMP VERIFICATION

Disconnect impulse lline from fuel pump
Install a hose pincher (P/N 295 000 076) on fuel sup-
Disconnect fuel supply line from fuel pump. ply line close to pump inlet. Disconnect fuel inlet line.
Disconnect fuel return line from PTO side carburetor.
Remove oil injection cable bracket from fuel pump cover.
Remove four bolts, lock washers from rotary valve cover
then move carburetors and rotary valve cover together
on top of engine.
0 NOTE : Oil lines from oil pump don't need to be re-

moved and don't disconnect oil injection cable from
oil pump lever.
CLEAN IING
The entire carburetor should be cleaned with a general
solvent and dried with compressed air before disas-
sembty.
v CAUTION : Be careful at carburetor cleaning not

t o remove paint. Paint removal will cause carbu-
retor t o rust very rapidly. Repaint if necessary.
--
Carburetor body a~ndjets should be cleaned in a carbu- Disconnect fuel outlet tine.
retor cleaner following manufacturer's instruction. Disconnect impulse line.
.-.
Â WARNIING : Solvent with a l o w flash point such
as gasolline, naphtha, benzol, etc., should not
be used as they are flammablle and explosive.
b
v CAUTION : Heavy duty carburetor cleaner may

be harmful t o the rubber parts, O-ring, etc. There-
fore, it is recolm~mendedt o remove those parts prior
t o cleaning.
Discard O-rings, dia~phragmsand gaskets.
INSPECTION
Inspect parts for corrosion damage (shaft, butterfly,
spring, screw, check valve housing, etc).
40, Needle Valve

I Fuel inlei
Inspect needle valve tip for a grooved condition If worn,
needle and seat must be replaced as a matched set.
35, Low-Speed Mixture Screw

Check tip for a grooved condition. Replace if necessary

Check fuel pump valves operation as follows : 28, Filter

Connect a clean plastic tubing to the inlet nipple and all- To verify filter condition proceed as follows :
ternately apply pressure and vacuum with the mouth. The
inlet valve should release with pressure and hold under Remove pump cover, gasket, d~aph~ragrn
and then pump
vacuum body and gasket.
Repeat the same procedure at the outlet nipple. This time Remove filter from carburetor body then clean filter and
the outlet valve should hold with pressure and release blow carefully with compressed air (low pressure).
under vacuum. Replace filter if damaged.
Â WARNING : So~m~e fuel may be present in fuel

pump. Be careful not t o swallow fuel when under
vacuum.
r
Pump Diaphragm Leak Test

Using a suitable pump gauge tester, perform the follow-
ing 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).
Pump gauge
ASSEMBLY
When assembling pump, ensure to properly position
components together. Refer to previous illustration if
necessa~ry.
12,21, Choke Valve and Throttle Valve

When installling butterfly into sha~ft,close butterfly so
that it centers into carburetor bore. Firmly tighten screws.
CAUTION : Always apply Loctite 242 (blue) on
screw threads prior t o installling screws.
Ins,tall on
pulse nipple
42, Needle Valve Lever
Inlet Control Lever
Diaphragm must stand pressure for 10 seconds. If pres- Rounded end of needle valve llever must be flush with
sure drops, replace diaphragm. surrounding metering chamber floor and n~otwith body
assembly Place the end of a ruler over lever to check
16, Pump Body adjustment.
Inspect valves. The pumping area should be free of holes,
tears or imperfections. Replace as needed.

Sub-section 03 (CARBURETOIRS)
Pressure Test
Proceed as follows.
- Install pump gauge tester on carburetor inlet nipple.
- Obstruct outlet nipple with a finger
- Pumlp tester until inlet release pressure is reached
(seen by a sudden pressure drop) This must occur
within 150-225 kPa (21-32 PSI) then pressure will
drop.
end
The pressure drop will vary, but it should not go less then
Metering 100 kPa (15 PSI)
chamber
floor
0 NOTE : Pressure test should be performed three
times to obtain a valid reading.
Obstruct outlet
nipple
Pump gaugle
tester
To adjust, bend lever very slightly to change its height.

CAUTION :When adjusting lever, do not pry it
so that it applies pressulre o n needle. Thi~scould
damage valve seatineedle.
Install on
n i e t nipple
then push tab down F M 1 ( M B 036
Depress here
If release pressure is not within specification, check con-

trol lever adjustment. Replace spring as n~ecessary
HIGH
LEVER CAUTION : Do not stretch or cut spring.
Leak Test
Needle valve must stand a pressure of 69 kPa (10 PSI)
Depress here then p r y up here
for 30 seconds Otherwise, hold carburetor upside down,
pour oil over needle valve and apply pressure.
LOW Check for bubbles. If they come from seat O-ring, bub-
LEVER
bles will exit around seat. Retighten as necessary
If it still leaks remove needle and seat and replace O-ring
If bubbles come from needle, replace needle and seat.

Sub-section 0 3 (CARBURETORS)
30,31. Main Jet and Pilot Jet

Pilot jet and main jet are replaceable. Different jet sizes Check valve
are available to suit temperature and altitude conditions.
Always inspect spa~rkplug tip condition when dealinlg
with pilot jet and main jet Spark plug tip condition gives
a good indication of carburetor mixture setting.
v CAUTION :Adjustments vary with temperature

and altitude. Always observe spark plug condi-
tion for proper jetting.
0 NOTE : To have access to pilot jet or main jet, check

valve housing must be removed.
Prior to check valve housing installation, remember to

set gasket.
416~47,
Diaphragm and Cover
Install diaphragm with its integrated O-ring into car1bu-
retor groove. Make sure that the tab of cover is inserted
into carburetor notch.
32,54, O-ring
When installing O-rings of low-speed mixture screw and
main jet screw, apply some SEA-DO0 LUBE (FIN 293
600 006) to prevent sticking.
Carburetor Mount Nuts

Install lock washers and apply Loctite 242 (PIN 293 800
Check valve 015) on threads then torque nuts to 25 N e r n (18 lbfeftl.
housing
Fuel lines and Hlose Clamps
FOU1 OOS 037
If fuel line ends are damaged, cut damaged end before
reinstallation.
37,45, Check Valve, Gasket and Check Properly tighten clamps with special pliers {PIN 295 000
Valve Housing
The check valve is needed if a back pressure occurs into
carburetor. It will prevent fuel from flowing back into car-
buretor lower portion.
+
0701.
WARNIING : Make sure there is n o leak in fuel sys-
tem.
Refer to fuel system pressurization.
Inspect check valve, it should be free of holes, tears or Flame Arrester
imperfections. Replace as needed
Always verify if flame arrester is dirty or restricted.
Â WARNING :Never operate watercraft without

flame arrester.
The following illustration shows which part of the car-
buretor begins to function at different throttle valve
openings

Section 05 FUELSYSTEM
VIEW FROM AIR INTAKE OPENING ASSEMBLY

(Carburetor Synchronization)
At assembly, paiy attention to the followin~g.
MAG Carburetor and PTO Carburetor

When installing carburetors pay attention on which side
of oil pulmp mounting flange carburetors are to be locat-
ed. To ensure proper installation, carburetors are identi-
fied on the side with MAG or PTO. Refer to following
illustration.
mixture screw
Malin jet and

high-speed screw
Wide Throttle valve

openings
open
DISASSEMBLY
(Twin Carlbuiretor)
pro MAG
57, Carburetor Linkage Po01 005 041
Disconnect fuel return line between carburetors and dis-

connect linkage from carburetor. Unscrew carburetor 4,52,Thlrottle Levers and Idle Speed Screw
mount nuts and remove carburetor.
With idle speed screw not touching stopper on PTO car-
buretor, both throttle levers are in closed position
Loosen Allen screws on MAG carburetor throttle lever
/^\ NOTE : Ensure throttle lever is released Paint could
\^ possibly hold lever.
Idle speed
Fuel return line

Linkage
F001 005 040
Alien sciew

S u b - S e c t i o n 03 (CARBURETORS)
0 NOTE : Grease carburetor linkage at both ends with

synthetic grease (PIN 293 550 010).
10,12, Fuel Sensor and Fuel Sensor Aldapter
Connect linkage between both carburetors and fully tight-

en Allen screws on carburetor throttle llever MAG side
Â WARNING :Always disconnect battery cables
exactly in the specified order, black negative
cable first. Electrolyte or fuel vapors can be present
Be careful not to rotate lever while tightening i t in the engine compartment and a spark might ignite
v CAUTION :This set-up is done t o ensure good

synchronization between carburetor throttle le-
vers when throttle lever is pushed at handlebar grip.
them and possibly cause personal ilnjuries.
Disconnect the red positive calble last.
Empty fuel tank.
Â WARNING : Fuel is flammable and explosive un-

der certain conditions. Always work in a well ven-
tilated area. Do not smoke or allow open fla~mesor
sparks in the vicinity. Always wipe off fuel spillage
from th~ewatercraft.
Remove storage basket from watercraft
GTX Model (5860)o n l y

Unhook fuel ta~nkstrap slide it off through tie rap behind
vent tube.
Press on vent tube upper part to enable to withdraw tube
from body.
Throttle lever i
MAG side
F001 005 041
CAUTION : Throttle valves must open simultane-

ou~sly,Otherwise this will cause engine t o vibrate
and /or back fire.
Return Line Orifice

strap
The fuel return line orifice of carburetor MAG side is 3.0
rnm (.I18 in) and the one on carburetor PTO side is 0.5
rnm (.020 in).
v CAUITION: If ca~rburetorsare installed on wrong

side, the carburetor PTO silde will run very lean
because of low fuel fllow.
Â WARNING : Always ver~ifytightness of clamps

and hoses.
Carbluretor Mount Nuts

Install llock washers and apply Loctite 242 ( P / N 293 800
015) on threads thlen torque nuts to 25 N*m (18 lbf-ft). Â WARNING : Vent tube mu1stbe in place to pro-
vide proper bilge ventilation.
Disconnect filler neck hose from fuel tank.
Rotary Valve Cover and Screws Remove strap retaining fuel tank and move tank forward.
Install 0-r~ngand cover then torque screws to 20 N-rn
(15 Ibf-ft) in a criss-cross sequence.

Sub-section 03 ( C A R B U I R E T O R S )
XP Model (5851) GTX Model (5860)

Disconnect and remove fuel sensor from fuel tank.
Remove fuel sensor adapter from fuel sensor.
Make sure there IS no obstruction~sin threaded holes of
fuel sensor adapter.
Slide fuel sensor adapter on fuel sensor.
Align sensor holes with adapter holies.
Â WARNING : A good hole alignment is necessary.
Apply some Loctite 242 (bluet on the five screws, in~stall

washers and hand tighten to eliminate play between sen- Torque sequence
sor and adapter
Â
to.
WARNING : Do not over torque, Torque wrench
tightening specifications must be strictly adhere
Torque screws in a criss-cross sequence to 1.5 N*m (14 NOTE : It is normal to have a small and even defor-
lbfein) using an appropriate torque wrench such as mation all around fuel sensor adapter.
Snap-On TER 3A
Small and even

Su b-Section 03 (CARBURETORS)
Torque alpplied to m~aterialssuch as rubber, plastic and CAUTIIOIN : Improper cable full throttle adjust-
fiberglass will decrease automatically. The torque reduc-
tion is ca~usedby material creeping. This situ~ationis nor-
Tment will cause strain on cable andlor da~mage
cable bracket or throttle lever at handlebar.
mal and should not cause any installation problem. To adjust, loosen jam nut then turn adjustment nut as
v CAUTION : D o not retorque after a while, this

could lead t o an excessive deformation and/or
components damages.
necessary.
Adjustment nut
(not shown)
ADJUSTMENTS
(Single Carburetor)
T1hrottleCable
CAUTION : Make sure engine is turned off before
aldjusting throttle cable.
Lubricate cable with SEA-DO0 LUBE
Throttlle lever must reach handlebar grip without caus-
ing strain to cable or carburetor cable bracket.
Jam nut
FOOT 005 029
Tighten jam nut and recheck adjustment.

\
I F001 010 008
Must touch
handlebar grip Â WARNING : Make sure idle speed screw contacts
stopper when throttle lever is fully released at
handlebar.
Insure carburetor butterfly is fully open at full throttle po-
sition. At this position throttle stop lever is almost in con-
tact (0 5 mm (1164 in)) with carburetor body.
0 NOTE : Ilnsure lock tab on throttle handle is installed

over cable barrel opening.
' '
I with stopper
After throttle cable adjustment, allways proceed with oil

injection pump adjustment.
v CAUTION : Improper oil injection pump synchro-

nization w i t h carburetor can cause serious en-
g~inedamage.

Sub-Section 03 (CARBURETORS)
35, Low-Speed Mixture Screw
Low-speed CAUTION : Do n~otattempt t o adjust rna~injet

mixture screw
screw. Severe engine damage can occur.
52, Idle Speed Screw

v CAUTION :Do not attempt t o set engine idle
speed w i t h low-speed mixture screw. Severe
engine damage can occur.
- As a preliminary set-up, tighten screw in until a sli~ght
resistance is felt then back off 3i4 to 1-114 tulrn.
Start and warm engine.
v CAUTION :Water must be supplied t o cool en-

gine with flush kit (PIN 295 000 038).
Turning screw clockwise leans mixture and turning screw
counterclockwise enriches mixture.
Turn low-speed mixture screw so that engine reaches the
most suitable idle and runs smoothly. Make sure engine
reacts quickly to throttle lever depression.
26, Main Jet Screw

The main jet screw is sealed with a plastic cap that al-
lows an adjustment of 114 turn.
0 NOTE : Turning screw 114 turn counterclockwise

enriches mixture and turning screw clockwise leans
mixture.
Turning screw clockwise increases engine idle speed and
turning screw counterclockwise decreases engine idle
speed.
Connect an induction-type tachometer ( P / N 295 000
100) on spark plug wire of magneto side to measure en-
gine speed.
Start engine and bring to normal operating temperature.

Section 05 FUElL SYSTEM
Sub-section 03 (CARBURETORS1
CAUTION : Water must be supplied t o cool en- CAUTION : Improper cable full throttle adjust-
gine w i t h flush kit (P/N 295 000 038). ment will cause strain an cable and f or damage
Turn, screw so that engine idles between 1300 to 1500 cable bracket or th~rottlelever alt handlebar.
RPM {in water) or 2400 to 2600 RPM (out of waterl. To adjust, loosen jam nut then turn adjustment nut as
Stop en~glneand recheck 011 injectIan lpump alig~lning necessary.
marks and readjust as necessary
CAUTiON : Oil injection pump adjustment must Adjustment nut
Inot shown1
be checked each time carburetor is adjusted. Im-
proper oil pump adjustment can cause severe engine
damage.
ADJUSTMENTS
(Twinl Carhuretors)~
T h ~ t t l eCable
CAUTION : Make sure engine is turned off before
adjusting throttle cable.
Lubrl~catecable wtlh SEA-DO0 LUBE
Throttle lever must reach handlebar grip without caus-
ing straln to cable or carburetor cable bracket.
Tighten jam1 nut and recheck adjustment.

WARNING : Make sure idle set screw contacts --
stopper when throttle lever ~isfully relleased at

handlebar-
0 NOTIE : Thelre is only one idle set screw for both ca1r-
buretors. It IS located an the PTO slde carburetor.
Must touch
handlebar grip Idle set screw
in contact w ~ t hstopper
lnsure carburetor butterfhes are flully open at full throttle

p o s ~ t ~ oAt
n thls posltlon throttle stop lever IS almost
contact (0 5 mm (1164 In)) with carburetor body.
0 NOTE : Insure lock tab on throttle handlle IS installed

over cable barrel opening.
05-03-12
Page: 118 See Do0 1992 Shop Manual - http://www.ReadManuals.com
-- - -
Section 05 FIUEL SYSTEM

Sub-section 03 (CARBURETORSI
35, Low-speed Mixture Screw
Low-speed
mixture screw
015
CAUTION :Do not attempt to set engine idle CAUTION : Do not attempt t o adjust main jet
speed with low-speed mixture screw. Severe en- screw. Severe engine damage can occur.
gine damage cart occulr,
As a prellmlnary set-up tighten screw in ulntil a slight 52, Idle Speed Screw
resistance IS felt then back off I l o 1-112 turn (on PTO side carburetor on~lly)
Start amd warm engine.
CAUTION :Water must be supplied t o cool en- Idle speed
gine with flush kit (PIN 295 000 038). .. screw
Turning screw clockwise leans mixture and turnlng screw

c ~ u n t e r c l ~ c k w ~enriches
se mixture"
Turn low-speed mixture screw so that englne reaches the
most su~tableIdle and runs smoothly Make suve engine
reacts qu~cklyto thlrottle Ievw depression
2Gf Mai~nJet Screw

The main jet screw IS sealed ~ 1 1 tahplastic cap that al-
lows an adpstment of I14 turn
0
ture.
NOTE : Turning screw 1/4 turn counte~~c~ockwlse
enr~ch~es
mixture anld tur~nlngclockwise leans mix-
Turning screw clockw~seIncreases engine Idle speed and

turning screw c o u n t e ~ c l o c k w ~decreases
s~ e n g m Idle
speed
Connect an lnductlon tachometer ( P I N 2% 000 1001
an spark plug wlre of magneto s111de
to measure englne
speed.
Page: 119 See Do0 1992 Shop Manual - http:ll~.ReadManuals.com

-

Su b-Section 03 (CARBUIRETORS)
-.
Start engine and bring to normal operating temperature.

CAUTION :Water must be supplied t o GQOI
gine w~ithflush kit P / N 295 000 0381,
en- 0 NOTE : To minimize time of fuel system pressuriza-
tion the fuel tank should be quite full. The system
must maintain a pressure of 34 kPa ( 5 PSI) during 10
minutes. Never pressurize over 34 kPa (5PSI).
Turin screw so that engin~eidles bletwee~n1300 to 1500
RPM [in water) or 2800 to 3000 RPM (out of water)"
Stolp engine and recheck oil injection pump aligning marks
a~ndreadjust as necessary.
CAUTION : Oil injection pump adjulstrnent must
be checked each time carburetors are adjusted*
Improper ail pump adjustment can cause severe en-
gine damage.
FUEL SYSTEM PRESSURIZATIlON

WARINING :Whenever doing any type of repair
on watercraft or if alny cornponen~tsof the fu~el
system are disconnected, a pressure test must be
done before starting engine and/or releasing water-
Inlet hose of
craft t o customer. fuel tank vent
v CAUTION: Ensure t o verify fuel lline ends for

damage. Always cut damaged end before rein-
stallation.
FWl 005 016
WAIRNING : If any leak is found, do not start the

engine and wipe off any fuel leakage. Failure t o
Pressure Test correct a leak could lead t o an explosion. Do not use
electric powered tools on watercraft unless system
Proceed as fallows : has been verified for no leaks.
- Fill up fuel tank.
- Remove inlet hose of fuel tank vent from body.
- hstall a hose pincher ( P I N 295 000 0761 an outlet
hose of fuel tank vent.
- Connect pump gauge tester ( P I N 295 QOO 0851 to
111nle1
hose
- Turn fuel valllve to OFF and pressurize fuel system to
34 kPa [ 5 PSI), If no [leaks are found, tu~rnfuel va~lve
to ON and pressurize once more
- If pressure 15not maintamed locate leak and repair /
replace component leaking. To ease leak search spray
a solut~~onof soapy water on components, bubbles will
~~ndncateleak locat~~on
Page: 120 See Do0 1992 Shop Manual - http://~~~.ReadManuals.com

Section 06 OIL SYSTEM
OIL SYSTEM
I
086-00-
S e c t h 06 01L SYSTEM
Subsection 01 (OIL INJECTION RESERVOIR)
OIL IRIJECTION RESERVOIR
Page: 122 See Do0 1992 Shop Manual - http:ll~.ReadManuals.com 06-01-1

Section 06 OIL SYSTEM1
Sub-section 01 (OIL INJECTION RESERVOIR)
COMPONENTS
7 Oil gauge 15 Oil filter
2 0-nng 16 Hose 8 m m
3 Filler neck 77 Hose 12 mm
4 Rivet 1/8 x 640 I 18 Hose 6 mm
5 Clamp f2f 19 Check valve
6 Gasket 20. Strap
7 Clamp f21 21 Tie rap
8 Filler neck hose 22 Tie rap
9 Oil tank 23 Tie mount 121
10 Grommet (2) 24 Oetiker clamp
?7 Grommet 12! 25 Oil level sender (585 7, 5860 models)
12 Elbow fitting (21 26 Float (5851, 5860 models1
13 E h w fitting 2 7 Gramme: (5851, 5860 models)
14 Elbow fitting 28 Hose fining
GEN'ERAL
Whenever repairing the oil injection system, always verify
for water infiltration in reservoir.
7,8,Clamp and Hose

Verify oil filler neck hose for damage. Always ensure that
cla~mpsare well positioned and tightened.
19, Check Valve

Black side of check valve is the valve outlet.

Section 06 OIL SYSTlEM
Sub-section 02 (OIL INJECTION PUMP, REPAIR AND ADJUSTMENT)
OIL INJECTION PUMP, REPAIR AND ADJUSTMENT
006 013
~001 PARTS IN ILLUSTRATION MARKED WITH X ARE NOT AVAILABLE AS SPARE PARTS.

Sub-section 0 2 (OIL INJECTION PIUMP, REPAIR AND ADJUSTMENIT)
COMIPONENTS
1 Oil pump flange 21 0-nng
2 O-ring 22 Upper plate
3 Oil pump 23 Screw with lock washer M4 x 8 (8)
4 Washer (21 24 Stop pin
5 Oil pump gear 4 1 teeth 25 Gasket
6 Lock nut M6 26 Pump lower plate
7 Lock washer (21 27 Gasket
8 Mien screw M5 x 16 (21 28 Hexagonal screw M6 x 8
9 Lock washer M6 (6) 29 Spring
70 Alien screw M6 x 20 (6) 30 Fiat washer M6
71 Oil banjo gasker (41 31 Lever
12 Check valve (2) 32. Lock washer M6
13 Valve bolt M6 x W (2) 33. Nut M6
14 Oil line 34 Seal
15 Clamp W 35 Gasket set
16 Gaskef 36 Locrfte "242'"
17 S r u d M S x 19f2) 37 NutM6
18 Lock washer M8 f2) 38 Nection cable
15 N u W 2 1 39 Cable guide
20 Retainer 40 Circlip
Parts in illustration marked with X are not available as spare parts.
CLEANING ASSEMBLY
Discard all seals and 0-rings Clean metal components 10, Screw
in a solvent.
Torque to 10 N*m (89 lbfÃ§in)
DISASSEMBLY
0 NOTE : Some oil pump parts are not available in

single parts.
5,6,Oil Pump Gear and Lock Nult

To remove retaining nut, lock gear using gear holder (P/N
290 277 905).
WOO 002 043

Sub-section 02 (OIL INJECTION PUMP, REPAIR AND ADJUSTMENT)
6, Lock Nut
Apply Lnctite 242 f P / N 293 800 01511 on nut threads and
torque to 6 N*m 453 lbfein).
CAUTION :Whenever oil injection lines are re-
moved, always make the routing as shown.
Oil injection lines
Aligned marks
F001 003 172
ADJUSTMENTS
Synchronization
CAUTION : As oil injection pump adjustment is
dependant on throttle cable position, make sure
t o perfo~rrnthrottle cable adjustment first.
Eliminate throttle cable free-play by depressing throttle
lever until a slight resistance is felt. In this position, marks
on pump body and llever must ali~gn. Aligned
marks
0 NOTE : A mirror may be used to fa~cilitatethis verifi-

cation.
~lfnecessary, turn cable adjustment screw to obtain pump
PO02 003 006
Tighten nut and recheck alignment marks.

mark alignment. CAUTION :Proper oil injection pump adjustment
is very important. Any delay in tlhe opening of
pump can result in serious engine damage.

Sub-Section 02 (OIL INJECTION PUMP, REPAIR AIND ADJUSTMENT)
Bleeding CHECKING OPERATION

CAUTION : Oil injection system must be bled and
adjustment checked before operating engine.
On Watercraft
Ensure oil injection reservoir is sufficently filled
Install a dry rag below oil injection pump 0 NOTE : Main oil line must be full of oil. See bleed-
ing procedure above.
Unscrew banjo fittings from pump. Start engine and stop
Remove bleed screw to allow oil to flow
it as soon as it fires.
Ensure that oil level in small oil lines is passed banjo fit-
Must be
ting by about 25 m m (1 in1 (oil lines are clear tube, there-
full of 011 fore the verification can be done easily). Repeat the
procedure until this condition is attained
Reconnect banjo fittings with a washer on each side, start
engine and run at idle whille holding the pump lever in
fully open position. Oil column~smust advance into small
oil tines.
u
Bleed screw
F001 003 171
Keep bleeding until all air has escaped from line. Make
sure no air bubbles remain in oil feed line.
Reinstall and tighten blleed screw.
Wipe any oil spillage,
Check small oil lines between pump and intake manifold.
They must be full of oil. Fully open
Fa01 006 014
position
If not, run engine a~tidle speed while manually holding
pump lever in fully open position Do not activate throt-
tie lever. If not remove pump assembly and check the pump gear
and drive shaft lif applicable) for defects, replace as
CAUTION :Water must be supplied t o cool en- necessary. Test pump as describes below :
gine w i t h flush kit (PIN 295 000 038).
0 NOTE : Through normal use, oil level must not drop

in small tubes- If oil drops, verify check valve oper-
ation in banjo fittings. Replace as necessary.

Sub-section 02 (OIL INJECTION PUMP, REPAIR AND ADJUSTIMENT)
-'
Bench Test
The oil pump must be removed out of watercraft.
Connect a hose filllled with injection oil to main fine fit-
ting. Insert other hose end in an injection oil container.
Using a counterclockwise (reverse position) rotating drill1
rotate pump shaft. Oil must drip from outer holes while
holding lever in a fully open position. If not replace pump.
Main oil line to Counterclockwise

an oil container (reverse) rotating drill
Oil must
=001006 002
drrp here

Section 07 ELECTRICAL
ELECTRICAL

a Sub-section 01 (WIRING DIAGRAM)
WIRING DIAGRAM
WIRING COLOR CODES
First color of a wire is the main color. Second color is
the tracer color.
Ex. : YELLOWIBLACK is a YELLOW wire with a BLACK
tracer.
Some wires have a colored-identification tube near wire
terminal. On wires having such a tube, tube color (NOT
wire color) will be used.
Ex. : A BLUE wire with a yellow identification tube is
referred as a YELLOW wire.
Color Codes
YL = YELLOW
BK = BLACK
BR = BROWN
BL = BLUE
GN = GREEN
GY = GREY
PU = PURPLE
RD = RED
TA = TAN
WH = WHITE
Â WARNING : Ensure all terminals are properly

crimped on wires and connector housings are
properly fastened. Ensure electrical box is watertight.
WIRE TERMINAL REMOVAL

To remove terminal from connector housing use Snap-on
TT600-4 tool.

Sub-section 01 (WIRING DIAGRAM)
WIRING DIAGRAM FOR 5805, 5812, 5851 AND 5 8 6 0 MODELS
STOP SWITCH
INORMALY CLOSED)
I
Tlâ‚¬R Sâ‚¬N SWITCH
i
I
(NORMALY
TETHER CORD
CLOSED
SWITCH
BY CAP)
I Pu
MULTI-PURPOSE
ELECTRONIC MODULE
1
COLOR CODE
GY - GREY RD - RED
WARNING : Ensure all connections are secured and coun-
tertight. Chafed or damaged wire must be replaced. 0 NOTE : On some watercrafts, oil /fuel gauge wire colors have
been modified as a running change. The purple wire change
to PURPLEIWHITE and green to LIGHT GREEN.
WH- WHITE
BR - BROWN
BL - BLUE
TA
PU
YL
- TAN
- PURPLE
- YELLOW
BK - BLACK GN - GREEN
07-01-2
Sactiam 07 ELECTRICAL
Sub-section 02 (IGNITION TIMING)
IGNiTIQN TIMING
ELECTRONIC IGNITION SYSTEM 4. Install and a d w t a TDC Qa~uge( P I N 295 000 0651
in spark ulug-hole as follbw.s-:
This section IS mainly divided in two parts, the first one
using a top dead center gauge to verify PTO flywheei
timing mark pasition. The second one usmg a strobo-
scopic tming light to check ignition timing.
Flywheel timing mark position verification is required,to :
7 . Troubleshoot a missing or broken magneto flywheel
woodruff key.
2. Troublesh~ota magneto flywheel corresponding to a
different engme type.
3. Scribe the timing1 mark on a new service IPTO flywheel,
Always verify PTO flywheel timing mark position before
checking ign~tiontiming
Verifying PTO Flywheel Timin~gMark Position

I , Disconnect MAG side spark plug wire and connect
wire to grounding device then remove spark plug,
2 Remove PTO flywheel guard.
3. Install timing malrktool ( P I N 295 000 1021on engine
right side using wing nut prev~ouslyremoved.
Rotate PTO flywheel counter~lackwise(when facing it1

until p~stanIS just before top dead center.
O'uter ring
Adaptor
lock nut
Page: 132 See Do0 1992 Shop Manual - http:llwww.ReadManuals.com

Sub-section 02 (IGNITION TIIMINGI
- Loosen adaptor lock nut then holding gauge with dial

facing toward PTO, screw adaptor in1 spark plug hole.
- Slide gaugle far enough into adaptor to obtain a iread-
0 NOTE : T h ~ sliming lllght is balttery powered (two
batteiries, tyipe Cl and therefore needs no auxil~ary
power source.
lng then finger tighten adaptor lock nut. The ignition components are affected by temperature
- Rotate PTO $lywheel coun~erclockwiseuntil piston is
miatton, therefore, t~rnlngmust be checked when en-
at Top Dead Center gine is cold, after MAXIMUM 20 seconds idl~ng.
- Unlock outelr ring of d~ialand turn it until zero {01on 1. Connect timing light p~ck-upto MAG sidle spark plug
dtal aligns with pointer. lead.
- Lock outer ring in position.
5. From this point, rotate flywheel back 114 turn then ro-
tate it coun~erclockw~se to reach 2.65 mm 4.104 in1
BTDC (Before Top Dead Center).
6 Uslng timing tool slot as reference rnarlk, scribe in mid-
dle 0 f tool i l a t a mark onto PTO flywheel.
Tool slot
mark
2. Connect an indluction-type tachometer to spark plug

wire.
3 Start engine and lpoint timing light stra~ghtin line with
timiiing tool slot. Bring engine to 6000 RPM for a brief
instaint.
This mark becomes the reference when using strobo-
scopic timing l ~ g h t
CAUTION : Xrning mark position verification can-
0 MOTE : On t h NIPPONDENSO
~ system, timing
advance decreases as engine speed Increases.
When marks are aligned at 6000 RPM, spark occurence
not be used as a timing procedurer therefore, IS st111beiore top dead center.
always check the timing with a stroboscopic timiing 4. Check if PTO flywheel mark (or reference olne previ-
light at 6000 WPM after the marks have been checked. ously scribed] aligns with timing tool slot.
v CAUTION : If engine is to be run more than a few

minutes, connect flush kit (P/N 295 000 0381
0 NIOTE:To perform this procedure it 11srecommend-

ed to use a stroboscopic timing light ra~tedto work
uIp to 6000 RPM
to prolperly cool engine,
If t ~ r n ~ nmarks
g alignp timing is correct.
g , a timing hght {lP/N 295 000

To check lgnitioln t ~ m ~ n use
078)

Section 07 ELECTRlCAL
SkJb-&cti~rI 02 (IGNITION TIMING)
CAUTION : Always verify timing marks with TDC

gauge before checking the timing- Particularly if
PTO flywheel has been replaced, it could possibly
move slightly.
IGNITION TIMING ADJUSTMENT

Tim~lngis performed by moving arlmature plate, clock-
wise to retard soark accurence or counterclockwise to
To retard
In this case, turn armature plate cloclkwise.
To adjust, loosen three armature plate retaining screws

and slightly rotate armature plate in proper direction,
When PTO flywheel mark IS m left s~deof tuning tool

slot, 11indicates retarded t~irn~lng.
screw
h025 004 03?
When PTO flywheel mark is an right s ~ d eof tlrntrag tool

slot, ~t ~ndlcatesadvanced tming

Sub-section 02 (IIGNITIQN T I M I N G l )
Retarded t m n g
001 007 1111
In this case, turn armature plate c ~ u n t e r c ~ ~ c k w i s e .
Turn c~unterclackwise
After adjustment, t~ghte~n

armature plate retailni~ngsclrews
CAUTION : Make sure a~rmatureplate sc~rewsare
well secured. Armature plate screws must have
Loctite 242 (blue11(PIN 293 800 0151 applied before
tightening.
Reinstall rlemoved parts
Recheck ign1110nl i n i n g (make sure engine is cold)

Sub-section 03 (BATTIERY)
BATTERY
TROUBLESHOOTING
Cause Baking sc
1. Battery posts andfor cable

terminaloxidized
2. Loose or bad coMiGCtiuis
3. Faulty h
aw (sulfated,
doesn'tkeniafullchm,
damaged casing, loose post)
*4. Faulty rectifier or relay firstduckdwEinfcol.IF
It is in food condition
Â¥epiacsrgctifierofrela
Remove corrosion from battery cablle terminals and bat-
-5. Faulty charging col
tery posts using a firm wire brush.
* To test charging system, refer to CDI AND CHARG- INSPECTION

ING SYSTEMS 07-06 then look for current test.
Visuallly inspect battery casing for cracks or other possi-
* To test charging coil, refer to CDI AND CHARGING ble damage. If casting is damaged, replace battery and
SYSTEMS 07-06 then look for battery charging coil, thoroughly clean battery tray and close area with water
and baking soda.
REMOVAL
Â WARNING :Battery black negative cable must al-

ways be disconnected first and connected last.
Â WARNING : Should the battery casing be dam-
aged, wear a suitable pair of non-absorbent gloves
when removing the battery by hand.
Never charge or boost battery while i~nstalledon vehi- Inspect battery posts for security of mounting.
cle. Electrolyte or fuel vapors can be present in en-
gine compartment and a spark might ignite them and Inspect for cracked or damaged battery caps, replace
possibly cause personal ilnjuries. defective caps.
Withdraw battery from vehicle being careful not lean it
so t h a t electrolyte flows out of vent tube. Â WARNING : Battery caps do not have vent holes.
Make sulre that venlt tube is not obstructed.
v CAUTION : Sh~ouldany electrolyte spillage occur,

immediately wash off with a solution of baking
soda and water t o prevent damage to vehicle com-
HYDROMETER TEST
ponents.
CLEANING
Clea~nthe battery casing, caps, cables and battery posts
using a solution of baking soda and water
v CAUTION : Do not allow cleaning solution to

enter battery interior since it will destroy the elec-
tlrolyte,

Sub-section 03 (BATTERY1
A hydrometer measures the charge of a battery in terms Clean battery casing and caps using a solution of bak-
of specific gravity of thle electrolyte. Most hydrometers ing soda and water. (Do not allow cleaning solution to
glive a true reading at 27'C 4801Â°F) enter battery, otherwise it will destroy the electrolyte).
In order to obtain correct readings, adjust the initial read- Rinse battery with clear water and dry well using a clean
ing by adding ,004 points to the hydrometer readings cloth.
for each 5.5'C 410'F) above 27'C (80Â°Fand by sub- Store battery on a wooden shelf in a cool dry place. Such
tracting .004 point for every 5.5'C (1Q0F1below 27'C conditions reduce self-discharging and keep fluid evapo-
(80Â°F1 ration to a minimum.
This chart will be useful to find the correct reading. During the storage period, recheck electrolyte level and
specific gravity readings at least every 40 days. As neces-
ELECTROLYTE sary, keep the battery at its upper level line and near full
TEMPERATURE OPERATiION TO PERFORM charge as possible (trickle charge).
oc I OF
ACTIVATION OF NEW BATTERY
Â WARNING : Never charge or boost battery while

iinstalled o n vehicle.
A new battery is factory fresh dry charged. For storage
pulrposes, it is fitted with a temporary sealing tube.
Do not remove the sealing tube or loosen battery caps
unless activation is desired.
CAUTION : Do not leave a new battery standing
on a shelf without its sealing tube,
-
In case of accidental premature removal of caps or seal-
ing tube, battery should be given a full charge.
Perform the folllowing operations anytime a new battery is
EXAMPLE NO 1 EXAMPLE NO 2
to be installed.
Temperature below 27% I8QoFI : Temperature above 27@Ct80ÃˆF :
Hydrometer reading 1 250 Hvdromeler reading 1235 1. Remove the sealing tu~befrom the vent elbow. Install
Electrolyte temperature -7OC (2UÂ°F Electrolyte temperature 38-C I1OOÂ°F vent tube, included in the battery kit, to battery elbow.
Subtract 024 Sp Gr Add 008 Sp Gr
Â
Corrected Sp Gr is 1226 Corrected So Gr is 1 2 4 3
WARNING :Failure t o remove thie sealing tulbe
could result in an explosion.
BATTERY STORAGE
Disconnect and remove battery from the vehicle.
Check electrolyte level in each cell, add distilled water
up to upper level line.
CAUlTION : Do not overfill.
T
The battery must always be stored in fully charged con-
dition. If required, charge until specific gravity of 1.260
is obtained.
CAUTIION : Battery electrolyte tempe~raturemust
not exceed 50Â° (122Â¡F) The casing should not
feel hot.
Clean battery terminals and cable connections using a
wire brush Apply a light coat of dielectric grease (P 1 IN
293 550 004) or petroleum jelly on terminals.
2. Remove caps anid fill battery to UPPER LEVEL line with

electrolyte (specific gravity : 1.260 at 27'C (80Â°F)

Sub-section 03 (BATTERY)
3. Allow the battery to stand for 30 minutes MINIMUM 6. Connect a 2 A battery chlarger for 10 to 20 hours.
so that electrolyte soak through battery cells.
CAUTION : If charging rate raises higher than

4. Allow gas bubbles to escape by lightly shaking bat- 2.4 A reduce it imlmediately. If cell temperature
telry by hand. rises higher than 50Â° (12ZÂ°F or if the casing feels
hot, discontinue charqing temporarily or reduce the
charging rate.
Â WARNING : G~asesgiven off by a battery being

charged are highly explosive. Always charge in
a well ventilated area. Keep battery away from ciga-
rettes or open flames. Always turn battery charger off
prior to disconnecting cables. Otherwise a spark will
occur and battery might explode.
7. Disconnect battery charger.
5. Readjust the electrolyte level to the UPPER LEVEL line.
Battery
electrolyte

Sub-Sectio~n03 (BATTERY 1
8. Test battery state of charge. Use a hydrometer 11. Readjust electrolyte level.
Battery
electrolyte
12. Reinstall caps and clean any electrolyte spillage us-

ing a solution of baking soda and water.
9. Let battery settles for one hour.
Baking
CAUTION : Do not allow cleaning solution to en-

10. Allow gas bubbles to escape by lightly shake battery. ter battery interior since it will destroy the elec-
trolyte.
13. Reinstall1 battery. Hook up battery cables observing
correct polarity and coat terminals with silicone die-
lectric grease (PIN 293 550 0041 or petroleum jelly.
Install vent tube.

Sub-section 03 (BATTERY 1
CAUTION : Negative battlery terminal should al- - Type of charger : Battery chargers vary in the amount
ways be disconnected FIRST and reconnected of voltage and current that they can supply. Therefore,
LAST. the time required for the battery to begin accepting
measurable current will also vary.
Â WARNING :Vent tube must be free and open. A
kinked olr bent tube will restrict ventilation and
create gas accumulation that might result in an ex-
Charging a Very Flat or CornplletelyDischarged
pllosion. Battery :
0
tery.
NOTE: It is recommended to verify the battery
charge once a month. If necessary, fully charge bat-
Unless this procedure is properly followed, a good battery
may be needlessly replaced.
- Measure the voltage at the battery posts with an ac-
curate voltmeter. If it is bellow 10 volts, the battery will
SERVICING accept current at very low rate, in term of miliamperes,
because electrolyte is nearly pure water as explain-
Electrolyte Level ed above. It could be some time before the charging
Since a battery has been activated (see above), add dis- rate increases. Such low current flow may not be de-
tilled water to top up electrolyte tectable on some charger ammeters and the battery
will seem nlot to accept any charge
TIPS FOR CHARGING A USED - Exceptionnally for this particular case, set the charger
BATTERY to a high rate.
v CAUTION : Prior t o charging the battery, always

remove it from the vehicle t o prevent electrolyte
spillage.
0 NOTE : Some chargers have a polarity protection
feature which prevents charging unless the charg-
er leads are connected to the correct battery terminals.
A completely discharged battery may not have enough
For best results, ba~tteryshould be charged when the elec- voltage to activate this circuitry, even though the leads
trolyte and the plates are at room temperature. A bat- are connected properly. This will make it appear that the
tery that is cold may not accept current for several hours battery will not accept a charge. Follow the charger
after charging begun. manufacturer's instruction telling how to bypass or over-
Do not charge frozen battery. If the battery charge is very ride this circuitry so tha~tthe charger will turn on and
low, the battery may freeze. If it is suspected to be frozen, charge a low-voltage battery
keep it in a heated area for about two hours before - Since the battery chargers vary in the amount of volt-
charging. age and current they provide, the time required for the
battery to accept measurable charger current migh~t
Â WARNING : Do not place batte~rynear open flame.
The time required to charge a battery will vary depending

be up to approximatively 10 hours or more.
- If the charging current is not up to a measurable
some factors such as : amount at the end of about 10 hours, the battery
should be replaced.
- Battery temperature : The charging time is increased
as the temperature goes down The curren~taccepted - If the charging current is measurable before the end
by a cold battery will remain low As the battery warm or at the end of about 10 hours, the battery is good
up, it will accept a higher rate of charge. and charg~ingshould be completed in the normal man-
ner as specified in Activation of a new battery.
- State of charge . Because the electrolyte is nearly pure
water in a completely discharged battery, it cannot - It is recommended that any battery recharged by this
accept current as well as electrolyte This is the rea- procedure be load tested prior to returning it to service.
son the battery will not accept current when the charg-
ing cycle first beams. As the battery remains on the
charger, the current from the charger causes the elec-
trolytic acid content to rise which makes the electro-
lyte a better conductor and then, the battery will
accept a higher charging rate.

Subsection 03 (BATTERY)
BATTERY CHARGING EQUIPMENT

The battery charger should have an adjustable charging
rate. Variable adjustment is preferred, but a unit which
can be adjusted in small increments is acceptable.
The battery charger must be equipped with an ammeter
capable of accurately measuring current of less than one
ampere.
Charging Two olr More Batteries at a Time

Connect all positives together and use a charger with a
capacities (rated) equal t o : number of ba~tteryto be
charged multiply by 2 A.
For example : Charging five baltteries at a time requires
a 110A rated charger (5 x 2 A = 10 At.
(TYPICAL)
Two batteries = 4 A
INSTALLATION OF BATTERY
Install battery, connect red positive cable then black nega-
tive cable.
Â WARNING : Battery black negative cable must al-

ways be disconnected first and connected last.
Apply silllicone dielectric grease (P/Nl 293 550 0041 or
petroleum jelly on battery posts and connectors.
Ensure vent tube is properly installed on battery elbow
and that it is nlot kinked or blocked.
Â WARNING :Vent tube must be free and open. If

not, it willl restrict ventilation and create a gas ac-
cumulation that could result in an explosion. Gases
given off by a battery being charged are highly explo-
sive. Allways charge in a well ventilated area. Keep bat-
tery away from cigarettes or open flames. Avoid slkin
contact with electrollyte.

Sub-Section 04 (ELECTRIC STARTER)
ELECTRIC STARTER

- - -
Sub-Section 04 (ELECTRIC STARTER)
7 Starter clutch assembly 15. 0-rtng 0

2 CircJip 16. Through bolt (2)
3. Spring 17. Gasket
4 Pinion stop collar 18. External tooth lock washer 8 mm
5 Starter clutch housing 79. Hexagonal head screw MB x 30 (2)
6. 0-nng (2i 20 Lock washer 5 mm (2)
7 Washer 2 1. Starrer support
8 Armature 22 Elastic stop nut MS 129
9 Thrust washer 23. Hexagonal head screw MB x 16
10 Yoke assembly 24. Grease dielectric
11 Brush holder 25 Washer 8 mm f3)
12 Commutator end frame 26. Locme 271 /red)
73 Brush kit 27. Smarter
14 Spacer 28. Locttre 242 (blue)
STARTER SPECIFICATION
Nominal output I 0.6 kW
Voltage 12 V
Rated time 30 seconds

1
Rotation
Weight
Counterclockwise (viewed from pinion side)
Approx. 2 kg (4.4 Ib)

I
Performance Test condition
No load 11.5V 20Arnax. 5500RPM

Spec.
at 20Â° (68OFI Load 8.5 V 170 A max. 2200 RPM 2 Nem (18 lbfein)
Stall 5V 350 A max. 0 RPM 3 N*m (27 Ibfminl
Battery
I 19 Ah
TROUBLESHOOTING
Causes of troublles are not necessarily related to starter
but may be due to a faulty battery, switches, electrical
cables and /or connections. Consult the following trou-
bleshooting table.
Â WARNING : Short circuitinlg electric starter is

allways a danger, therefore disconnect the bat-
tery ground cable before carlrying out any kind of
mlaintenance on starting system. Do not place tools
on battery.

Sub-section 04 (ELECTRIC STARTER)
STARTING SYSTEM TROUBLESHOOTING TABLE

SYMPTOM CAUSE
Starter does not turn. Burnt fuse. :heck wiring condition and replace
fuse.
Weak battery. Recharge battery.
Poor con~tactof starter switch Repair or replace switch.
contact points.
Open circuit between starter switch Repair.
and solenoid switch.
Starter turns ; but does Burnt or poor contact of solenoid Replace solenoid switch.
not crank the engine. switch contact disc.
Poor contact of brush. Straighten commutator and brush
Burnt commutator. Turn commutator in lathe.
Worn commutator segments. Undercut mica.
Shorted armature. Repair or replace armature.
Weak brush spring tension. Replace spring.
Weak magnet Replace yoke assembly
Worn bushings. Replace bushings
Weak battery. Recharge battery
Shorted battery celKsl. Replace battery
Poor contact of battery terminalls). Clean and tighten terminallsl
Poor battery ground cable Clean a~ndtighten.
connection.
Starter turns, but Worn clutch pinion gear. Replace clutch.

overrunning clutch pinion
does not mesh with ring Defective clutch. Replace clutch.
gear. Poor movement of clutch on splines. Clean and correct.
Worn clutch bushing. Replace clutch.
Worn starter bushingls). Replace bushingls).
Worn ring gear. Replace ring gear
Starter motor keeps Shorted solenoid switch winding Replace solenoid switch
running.
Melted solenoid switch contacts. replace solenoid switch
Starter switch returns poorly. replace starter switch
Sticking or detective starter clutch ~ubricateor replace

REMOVAL 2,3,4, Circlip, Spring and Pinion Stop Collar

Disconnect black cable ground connection from battery. Tap the pinion stop collar using a screwdriver. Remove
circlip. Disassemble pinion stop collar and spring.
Â WARNING : Always disco~nnectground cable first
and reconnect last.
Disconnect red cable connection from battery a Pinion stop
Remove the following parts. collar
- cables from starter

- screw of starter rear support litern #23)
- starter mount screws (item #19)
DISASSEMBLY
10,11,12,16,22, Yoke, Brush Holder,
End Frame, Through Bolt and Nut
Before disassembling, trace index marks on yoke and
clutch housing to ease further assembly.
1,5,6,8, Clutclh Assfy, Housing, O-ring and
Armature
Trace indexing
rnzrks here Turn assembly counterclockwise to remove it from arma-
ture assembly.
Pull housing from arm~ature.
CLEANING
CAIUTION :Yoke ass'y and drive ulnit assembly
must not be immersed in cleaning solvent.
Discard all O-rings and gasket.
Clean brushes and holders with a clean cloth soaked in
sollvent. Brushlesmust be dried thoroughly with a clean
cloth.
Remove starter support nuts then through bolts. Separate Blow brush holders clean using compressed air
end frame from yoke assembly Withdraw yoke assem-
bly from armature.
Brush holder can be removed from end frame by un-
Â WARINING : Always wear safety glasses when
using compressed air.
Remove dirt, oil or grease from commutator using a
screwing nut retaining terminal. clean cloth soaked in suitable solvent. Dry well using a
Check that the radial play between the armature shaft clean, dry cloth^.
and end frame is not greater than 0.20 mm t.008 in). Clean engine ring gear teeth and drive unit (clutch).
Replace end frame if so.
0 NOTE : Bushings must not be cleaned with grease
dissolving agents.
Immerse all metal components in cleaning solution. Dry
using a clean, dry cloth.

INSPECTION Brush Holder

Check brush hol~derfor insulation using an ohmmeter.
Armature Place one test probe on insulated brush holder alnd the
0 NOTE : An ohmmeter may be used for the follow-

ing testing procedures, except for the one con-
cerning shorted windings in armature
other test probe on brush holder plate. If continuity is
found, brush holder has to be repaired or replaced.
Check commutator for roughness, burnt or scored sur- Brush Length

face, If necessary, turn commutator on a llathe, enough Measure brush length. If less th,an 8.5 mrn (.335 in),
to resurface only. replace them.
Check commutator for mica depth. If depth is less than
0.20 rnm 1.008 in), undercut mica. Be sure that no burrs
are left and no copper dust remains between segments
0 NOTE: New brush length is 12 mrn 4.472 in).
after undercutting operation is completed.
Commutator undercut
0.20 m m t.008 in) 1
Overrunning Clutch
Check commutator out of round condition with V-shaped Pinion of overrunning clutch should turn smoothly in
blocks and an indicator. If commutator out of round is clockwise direction, and should not slip in a counter-
more than 0.40 mm (.016 in), commutator should be clockwise direction. If defective, replace.
turned on a lathe.
Check pinion teeth for wear and damage If defective,
Check commutator outer diameter. If less than 27 mm~ replalce.
(1.063 in).,replace.
0 NOTE: Always check engine ring gear teeth for
wear and damage. If defective replace ring gear
Refer to ENGINE 03-04 then refer to ring gear.
Starter Switch
Switch condition can be checked with an ohmmeter
Install test probes on both BLACKlWHITE wires of
switch^. Measure resistance, it should be high when but-
ton is released and must be close to zero (0) ohm when
activated.

- -
Section 0 7 EILECTRICAL
-
Solenoid Switch 5,10, Housi~ngand Yoke Assty

Inspect connections and clean as necessary. Solenoid Align previously traced indexing marks.
switch condition can be checked with an ohmmeter. In-
stall test probes on larg~econnectors of solenoid. Mea-
sure resistance when current is applied to small con- Align marks
nectors ; +12 V on YELLOW/RED wire and negative ( - 1
on BLACKIWHITE wire. If it is more than a few ohms.
replace solenoid switch.
IMPORTANT: No current must be present on large
cables when using ohmmeter, otherwise meter could
be damaged.
ASSEMBLY
Reverse the order of disassembly to reassemble starter.
However, attention should be paid to the following oper-
ations.
Prior to assembling, coat sliding surfaces on armature
shaft splines, overrunning clutch and bushing with 6.E. 10,12,16, Yoke Ass'y, End Frame and Through
Versilube G 341 M or ESSO Beacon 325 lubricant or Bolt
equivalent.
Open brushes and slide over commutator.
Apply motor oil on metal bushings.
Align end frame locating notch with yoke locating pro-
trusion and properly sit brush holder into yoke.
2,4,Circlip and Pinion Stop Collar
After placing stop collar on armature shaft, fit circlip into Locating protrusion
armature shaft, then make sure that it is properly secured.
Slide stop collllar over circlip and secure in place by punch-
ing it at two or three plalces.
Armature sh8aft
Ci~clilp
FOOI 007 028
Brush holder
/ locating notch

- - .end frame installation, retain brush holder with

To- ease
a small screwdriver while installing end frame
Align end frame notch with brush holder notchiyoke

protrusion
CAUTION: Make sure end frame fits perfectly
on yoke.
INSTALLATION
Make sure that starter and engine mating surfaces are
free of debris. Serious trouble may arise if starter is not
properly aligned.
0 NOTE: Make sure to install stater screws in their

proper holes of ignition housing. install upper screw
in lower hole and tower screw in upper hole.
Install starter apply Loctite 242 on starter support screw
threads and torque screw to 22 N*rn 416 Ibf'ft).
Connect the red battery cable to the starter and torque
nut to 8 Nmm (71 lbf*in5. Apply Neopren grease on ter-
minal and nut
Then connect black cable to starter using a flat washer,
a tooth washer and a screw with Loctite 271 on threads
Torque screws to 22 Nmm (16 lbf*ft>.Apply Neopren
grease on terminal and screw
Â WARNING : Always connect red positive cable

first then black ground cable last. Whenever con-
necting the red positive cable to the starter motor
make sure the battery cables are disconnected to pre-
vent electric shock.

Sub-section 05 (MAGNETO SYSTEM)
MAGNETO SYSTEM, REPAIR

Sub-section 05 (MAGNETO SYSTEM)
COMPONENTS
1 Gasket 24 Generating coil
2 Ignition housing 25 Philhps screw M5 x 22 12)
3 Lock washer M8 (8i 26 Battery charging coil
4 Alien screw M8 x 2 5 f8) 27 Screw M6 x 25 12)
5 Armature plate assembly 28. Harness assembly
6 Magneto flywheel assembly 29. Terminal chp W
7 Ring Gear 77 teeth 30. Shrink tube 30 mm W
8 Harness assembly 31 Female connector
9 Grommer (21 32 Ring terminal
70 Cap (2i 33 Female terminal
7 1 Washer M 5 5 f3i 34 Male terminal
12 Lock washer M 5 (31 35 Insulation sheath
13 Alien screw MBx 18 /3J 36 Insulation sheath
14 Retainer plate 37 Lome 242
15 Taptite screw M5 x 8 (21 38 Loct~re6 4 8
16 Lock washer M22 39 Ground plate
1 7 Hexagonal nut M22 40. Protection cap
?5 Woodruff key 4 1. Insulator (2)
19 Protection mat 42 Star washer M5 12)
20 0-nng 43 Spark plug (21
2 1 Ignmon housing cover 44 Dielectric grease
22 Self tapping screw M5 x 25 (10) 45 Ignition coil
23 Armature plate 46 Tie rap 12)
REMOVAL - Remove screws.

- Uncrimo and unsolder BLACKIRED wire from coil
Refer to ENGINE section 03-04 then look for PTO terminal.
flywheel and magneto for parts removal.
DISASSEMBLY
24, Generating Coil
To replace generating coil :
- Hea~tthe armature plate to Q3OC (20O0F1around the
screw holes to break the threadlocker bond.
Un~cnmp
and unsolder~ \
Heat
Protect
from
CAUTION : Protect harn~essfrom filarne. - Strip end of old wire then crimp and solder on new
coil
07-05-2
Sub-Section 05 (MAGNETO SYSTEM)
24,25, Generating Coil and Screw - Uncrimp and insolder YELLOW and YELLOWIBLACK
wires from coil terminalls
Apply Loctite 242 (blue, medium strength! to screws and
install the new coil on armature plate. - Uncrimp and unsolder ground wire (BLACK)from coil
core.
Use magneto coil centering tool (P/N 290 876 922)
and install so that it fits around armature pilate before
tighteninig screws.
Magneto coil centering tool

( P / N 290 876 922)
. -
CAUTION : Before reinstalling the magneto, re- Uncrtmp
move the loose elpoxy from harness. and unsolder YELLOW and
YELLOW/ BLACK wires here
26, Battery Charging Coil
- Position new coil, crimp and solder all wires.
To replace battery charging coil :
- Heat the armature plate to 93'C (200Â°Faround the 26,27,Battery Charging Coil and Screw
screw holes to break the threadlocker bond
Prior to assembly, apply Loctite 242 (blue, medium
strength).
Use magneto coil centennq tool ( P / N 290 876 922)
and install it so that it fits around armature plate before
harness tightening screws
flame
Magneto coil centering tool

UP/N 290 876 9221
Heat
I
CAUTION : Protect harness from flame.
-.
/
- Remove screws.
Page: 151 See Doo 1992 Shop Manual

--
Sub-section 0 5 (MAGNETO SYSTEM)
-
ASSEMBLY SIX-WIRE SYSTEM 032000-7001
0 NOTE : Always apply dielectric grease on all elec-

trical connections
13,224, Screw and Armature Plate

Position the armature plate on the crankcase, aligning the
marks on both parts.
Apply a drop of Loctite 242 on screw threads and tighten.
45, Ignition Coil

Connect BLACKIRED wire to coil terminal.
Identification of Magneto Flywheels

There are two ways to differentiate the two magneto Keyway
flywheels :
1. Nippondenso part number stamped on flywheel is
different for each system :
Four-wire system flywheel : ( P f N 290 995 119) - Nip-
pon~densoPIN is 032000-7091 ; Ãˆ02 004 Ola
Six-wire system fllywheel : CP/N 290 995 1114) - Nip-

pondenso P/ N is 032000-7001 ; INSTALLATION
2 The glued-in magnets have a different angl~etowards Refer to ENGINE section 03-04 then look for PTO fly-
the keyway. wheel and magneto for installation.
FOUR-WIRE SYSTEM 032000-7091
Perform ignition timing.

Sub-section 06 (CDI AND CHARGING SYSTEMS)
CDI AND CHARGING SYSTEMS; TESTING PROCEDURES

Sub-Section 06 (CDI AND CHARGING SYSTEMS)
COMPONENTS
1 Stop switch assembly 32 Mate tab housing (3 ways)
2 Buzzer assembly 33 Female tab housing (3 waysi
3 Tether cord switch 34 Rivet
4 ignition starter switch 35 Spark plug cap (21
5 Red battery cable (positive! 36 Buzzer/stop switch harness assembly
6 Battery 37 Electrical box support
7 Strap 35 Starter cable
8 Screw M 6 x 16 f2f 39 Four wires support 12)
9 Washer MB (2) 40 Three wires support
70 Nut M6 f2) 4 1 Temperature sensor
17 Harness {3 waysi assembly 42 Locfite 515
12 Harness (4 waysl assembly 43. Oil'/fuel gauge
13 Battery lower pad 44 Tachometer
14 Battery support 45 Sheath (2)
15 Tie rap 46 Female terminal (21
16 Tie rap 47 Female tab housing (2 waysl (5!
77 Protector cap 131 48 Wire seal f2>
78 Tie mount 49 Male tab housing (2 ways9 i51
79 Rivet 1/8" x 640'" 50 Female terminal
20 Switch nut 51 Wire seal
21 Tether cord 52 Mate tab housing (6 ways)
22 Cap 53 Tab housing (6 ways/
23 Battery ground cable 54 0-nng HI
24 Spark plug (2) 55. Gauge support (7)
25 Lock nut M6 56 Plastic nut (21
26 External tooth lock washer M8 57 Male terminal
27 Dielectric grease 58 Male tab housing f! way1
28 Hexagonal screw M8 x 16 (2) 55 Tab housing t 1 way)
29 Tie rap 50 Flat washer M8
30 Locme 2 77 61 Gauge support
37 Washer

Section 07 ELECTRIICAL
Sub-section 06 {CD1 AND CHARGING SYSTEMS)
ELECTRICAL BOX
07-06-3
- -- - - - -- -
Section 0 7 ELECTRICAL
Sub-Section 06 (CDI AND CHARGING SYSTEMS)
COMPONENTS
1 Ignition coil 18 Grommet
2 Spacer I9 Grommet f21
3 Lock washer M6 20 G m e t (61
4 NutM6 2 1 Grommel l2l
5 Tapping screw M6 3 x 25 22 N u t M6
6 Fuse 15 Amp 23. Loci; washer M6
7 E/astic stop nut M6 24 Self tapping screw M6 3 x 73
8 Gasket 25. Cap f9i
9 Rubber bumper !4! 26 Support plate
70 Cover 27 Flat washer M5 f2i
71 Electric box base 2 8 Elastic stop nut 10-32 (2)
12 Relay t2i 29 Elastic nut 1/4-20 <ZI
73 Rectifier 30 Nut M6
14 Solenoid 3 1 Mounting plate
15 Mutv-purpose electronic module 32 Washer M6 12)
16 Fuse holder assembly 33 "Y" wire
77 Fuse 5 Amp 34 Dielelectric grease
GENERAL Magneto
The Capacitor Discharge Ignition system includes the fol- It is the primary source of electrical energy. It transforms
lowing components : magnetic field into electric current through a generating
coil.
CDI SYSTEM
1
MAGNETO
MULTI-PURPOSE
ELECTRONIC MODULE

- -
Ignition Coil Engline Speed Limiter

It receives its energy from generating coil via a BLACK/ It has three functions :
RED wire. The generating coil a~llowsa current flow - Keeps high voltage away from tether cord switch
through ignition coil with its integrated CDI module and
through primary windings - Provides engine stop by grounding the primary coil.
I~gnitioncoil induces voltage to a high level in secondary - Limits engine RPM to prevent over-reving.
windings to produce a spark at spark plug
0 :It is integrated in the multi-purpose elec-
tronic module.
A defective speed limiter may cause the folllowingl
problems :
- No spark.
- Uninterruption of spark when engine stopltether cord
switch is used.
- Incorrectly controlled engine max. RPM.
- Misfiringiblack fouled spark plugs.
To check engine speed limitation function, run engine and
check its maximum speed, it should be around 6550 Â
100 RPM.
IGNITION SYSTEM TESTING

PROCEDURE
When dealing with ignition problems, the following items
Multi-purpose Electronic Module should be verified in this order.
It receives its current from the battery. It includes two 1. Spark occurence/spark plug condition.
relays, one is used for the ignition system and the other 2. Battery condition.
one for charging system. Also integrated in the module
3. Electrical conn~ections.
a 20 second timer delay and the engine speed limiter.
4. Engine stopitether cord switches.
5. Ignition relay.
6. Multi- purpose electronic module (MPEMI.
7. Magneto output.
8. Ignition coil output.
v CAUTION : Whenever replacing a component in

ignition system, check ignition ti~ming,
0 NOTE : Spark occurence can be chleckedwith tester

from Superex Canada Ltd part number 15-785.
The first three items can be checked with known automo-
tive equipment and other items as follows :

- -
Subsection 06 (CDI AND CHARGING SYSTEMS)
Engine StopJTeth~erCord Switchles

Verification 0 NOTE : The relays can be interchanged wi~theach
other, because they are identical in construction.
If the relays exchanging brings ignition again then sim-
Engine Stop Switch ply replace the "faulty one.
Disconnect the BLACK and BLACK/YELLOW wires in the Voltage test
electricall box. Using an ohmmeter, connect test probes
to switch BLACK and BLACKIYELLOW wires. Remove ignition relay. Using a multimeter, con~nectone
test probe to terminal #30 and the other one to ground.
Measure resistance, it must be close to zero ohm in its Reading from terminal #30 should be battery power
operating position and an open circuit when depressed. source.
Tether Cord Switch
Disconnect tlhe BLACKtYELLOW wires in the electrical Ground
box. Using an ohmmeter, connect test probes to switch
BLACKIYELLOW wires
Measulre resistance, it must be close to zero ohm when
cap is over switch and an open circuit when removed.
Ignition Relay Verification

The relays which are installed on MPEM are identical, but
they are different in function The one located near the
module center is the one for the ignition system.
The ignition relay is working off a 20 second timer delay
and could be the problem of some faulty ignition situ-
ations.
Charging
system relay
(relay #I) Ignition
system relay Reinstall ignition relay to verify if current goes through
\ the relay.
Connect multirneter test probes, one into PURPLE wire
and the other to ground.
Install tether cord and touch starter button. A reading
should be supplied to multimeter through the PURPLE
wire from relay power source (battery voltage).
v CAUTION :To measure voltage at PURPLE wire,

BLACKlWHITE wire must be connected t o sole-
noid negative and YELLOW/RED wire connected to
solenoid positive.
A voltage test ca be performed to verify if power is going

to the relay and through the relay
Alllways confirm first that the fuses are in good condition.

- -
Ground Purple wire
0 NOTE ;To confirm the relay function, it should stay

on for about 20 seconds and then turn off.
KO01 007 099
Yellllow/ red
Multi-Purpose Electronic Module (MPEM)

Verification Most of circuit can be tested with an ohmmeter but a
The multi-purpose electronic module testing must be 100% test doesn't mean the MPEM is in perfect con-
done with all wires disconnected from circuit. Otherwise dition-
testing equipment (ohmmeter) could be damaged.
v CAUIONI: When disconnecting wires, BLACK/ 0 NOTE : Sometimes only parts replacement can
solve the problem.
RED wire must never touch solenoid positive ter-
minal.
MPEM testing equipment
v CAUTION :Whenever connecting MPEM, always
have battery disconnected from circuit. If MPEM
must be connected when circuit is activated, always
connect BLACK /RED wire first to ignition coil ICDI
Use an ohmmeter with an input impedance up to 10 module to prevent wire from touchi~ngsolenoid posi-
mega ohm (1 000 0010 ohm). tive terminal.
Refer to the following chart for MIPEM testing. Always
respect polarity in chart T CAUTION :Whenever connecting wires, never
connect RED /PURPLE and RED wilres together.
Damage could occur to multi-purpose electronic mo-
dule.
1 1 1 1
Back
Black
Black
Black
\ Blackhed
Blacklwhite
Blacklyellow
YelW red
I 87 kn 1
Mi
MPEMlfEngine speed tirn~ler
Solenoid
Stop switchlTether cord switch
Solenoid
1
1
m ,
I
Black
H I ~
Red / W hile
C(5 A ~ 1 1
Buzzer
met (+I
11
1
I a 0
Black 1 Red 1 00 Rectifier

Purple ) BlackIred 1 150 kfl 1 GD1 module 1
BOMBARDIER IGNITION TESTER 2. Follow test procedure sequence.

3. Install cap over tether cord switch and depress start-
The remaining items can be easily checked with Bom- ing button until light turns on, or otherwise, for a maxi-
bardier ignition tester ( P I N 295 000 008). mum of five seconds.
4. If engine starts when performing some test, allow it
to ildle while observing indicator. Then, shut engine
off.
5. After every test that lights the indicator lamp, RESET
the indicaltor circuit by depressing the reset button.
Analysis of Test Results

Indicator Lamp Lights at Specific Setting
Output is as specified. Test results should repeat three
times. If readings do not repeat, output is erratic and
cause should be investigated (loose connections or com-
ponents, e t ~ . ) .
Indicator Lamp Lights at Lower Setting
For more information concerning operation and main- This indicates that the output is less than that designed
tenance of the tester, refer to its instruction manual. to operate in a saltisfactory manner. However, before
coming to the conclusion of a faulty condition be cer-
Use of Bombardier Ignition Tester tain that correct engine cranking conditions were met
before condemning the tested part.
This tester can verify generating coil, ignition coil and -
battery charging coil. Indicator Lamp Does Not Light

Always make sure that tester batteries are in good con- Onle component is defective. Proceed as instructed to
dition. find defective component.
Test Condition Inte~rmittentIgnition Problems

In dealing with inltermittent problems there is no easy
All tests are performed on watercraft at cranking speed
diagnosis. For example, problems that occur only at
with spark plugs installed. normal engine operating temperature have to be tested
Always proceed in the following order : under similar conditions.
1. Connect tester P and N clip leads as indicated for each In most cases of temperature and/or vibration failure,
specific test. only parts replacement caln solve the problem as most
of these failures return to normal when engine is not
running.
Multiple Problems
There is always the possibility of more than one faulty
part. If after a component has been replaced, the problem
still persists, carefully repeat the complete test proce-
dure to find the other faulty part.
Safety Precautions
Â WARNINlG : To prevent powerful electlric shocks

while crankin~gengine, neither touch any elec-
tronic ignition components (ignition coil, high tension
wire, wire harn~ess,etc.1 nor tester lead clips. Also
rna~kesure that tester leads do not touch any metallic
object. Ventilate bilge at least two minutes prior to per-
forming any test.

TESTS Ignition Coil Output

A paper clip of approximately 20 mm (3/4 in) will be used
Magneto and Generating Coil Output as a test adapter for the following test.
1. Disconnect BLACKiRED wire between ignition coil/ 1. Install the test adapter to spark plug cable close to
CD1 module and magneto. Disconnect BLACK ground MAG side spark plug.
wire. 2. Connect tester wires then set switch and dial as
2. Connect tester wires then set switch and dial as fol- follows :
lows :
0 NOTE : BLACK wire must be connected to ground

in order to start engine. Cornpon~ent
wires
Tester
switch
1 1 1
position
s t Tester
Taster Component Tester adapter
switch dIid
wires wires position position (paper clip) on
spark plug cable 1 LOW
BLACK/ RED
of magneto harness 1 P I Engine Ground 1I
BLACK
of magneto harness
FOOI 007 101
3 Start engine and observe indicator.

to GROUND
4 Push reset button and repeat step 3 twice. 007 102 Fnni nn7
Results : 3. Start engine and observe indicator.

a) Indicator lamp lights : llgnition generating coil out-
put is up to specifications.
b) indicator lamp does n~otlight : The problem is a
0 NOTE : If engine starts, allow it to idle while observ-
ing indicator. Then, shut engine off.
4. Push1 reset button and repeat step 3 twice.
faulty ignition generating coil Replace it
Results :
a) Indicator lamp lights: Ignition coil is OK
bl Indicator lamp does not light on one or both
cylinders) , Ig~nitioncoil is faulty. Replace it

--
SUNMMARY TABLE Resistor cap
Component wires
BLACK1RED
of magneto harness
Generating
LOW
coil ouput
BLACK
of magneto harness
Tesi adapter on
Ignition
coil
output Engine ground
IGNITION COMPONENTS
RESISTANCE MEASUIREMENT
As an alternate method, ignition components can be
checked with an ohmmeter (preferably a digital one).
Proceeding by elimination, check magneto generating
coil then ignition coil4ignition module.
Disconnect connectors at ignition coil and magneto junc-
tion Check resistance between each terminal with a
high-sensitivity ohmmeter Refer to the following table
for values and wire collors.
0 NOTE : An ignition coil with good resistance mea-

surement can still be faulty. Voltage leak can occur
at high voltage level which is not detectable with an
ohmmeter.
MIAG NETO
WIRE COLOR 1 RESISTANCE

(OHMI (Ql
Generating
coil
I
BLACK with
BLACKIRED
1
I
40 - 76
IGNITION COIL
End of each spark

plug cable, sipark 9 - 115 K
winding
plug caps removed
0 NOTE : A short circuit will read zero 40 ohm) (or

close to) on ohmmeter.
The spark plug caps must be removed from high tension
cables, because they are resistor caps. The can resis-
tance is 4.48 K ohms.

Subsection 06 (CDl AND CHARGING SYSTEMS)
BATTERY CHARGING SYSTEM
GENERAL
Magneto
It is the primary source of electrical energy. It transforms
magnetic field into electric current through a three-pole Jumper
wire
coil. It outputs Alternating Current AC.
Rectifier / Regulator
A full-wave rectifier receives magneto AC current and
transforms it into Direct Current DC to allow battery
charging. Battery is the DC soulrce for electric starter,
multi-purpose electronic module/engine speed limiter,
engine overheat beeper and accessories.
Included in the same unit, a regulator keeps voltage at I I terminal
a steady level to prevent any damage to components.
TESTING PROCEDURE
0 NOTE : First, ensure that battery is in good condi-

tion prior to performing the following test.
- Disconnect positive cable from battery.
Current Test
- Start engine.
0 NOTE : Start engine before connecting cables.

Otherwise ammeter may be damaged as current
flow is much h~igherat starting.
- Connect jumper wire between battery positive post
and ammeter.
- Connect a second jumper wire between ammeter and
positive cable terminal. 1 1 ~ositivecable
- Bring engine to approximately 5500 RPM.

Depending on battery charge, current reading should be
approximately 5 A (amperes).If not, check magneto out-
put prior to concluding that rectifier is faulty

Voltage Test
Ground'
- Start engine.
- Connect a voltmeter (set on DC volt scale) on battery
posts.
- Bring en~gineto approximately 5500 RPM.
If voltmeter reads over 15 volts, regulator is defective.
Replace it.
0 NOTE : Whatever the voltmeter type used (peak

voltage or RMSI, the voltage must not exceed 15 V.
A faulty regulator will allow voltage to exceed 15 V as
engine speed is increased.
CAUTION : D~uringthis test the battery cables
must be reconnected t o the battery.
Charging System Relay

The relay is located on multi-pu~~rpose
electronic module Magneto, Battery Charging Coil
near the side.
If the system is not charging the battery, the relay could With Bom~bardierIg~nitionTester
be the problem. Operate it as for ignition system verifications.
1. Disconnect wires coming from magneto wiring
harness.
2. Connect tester wires then set switch and dial as fol-
Charging system relay
(relay #I)
lows :
\ Ignition system relay

Tester Component
Tester
switc~h
Tester
d~ial
wires wires position
position
YELLOW
of maglneto harness
LOW 70
of magneto harness
A voltage test can be performed to verify if power is

going to the relay. Always confirm first that the fuses are
in good condition-
Volta~geTest
Remove charging relay. Using a multimeter connect one
test probe to terminal #30 and the other one to ground.
Reading from terminal #30 should be battery power
source.

Sub-Section 06 (CDf AND CHARGING SYSTEMS)
3. Start engine and observe indicator

4. Push reset button and repeat step 3 twice.
Results :
a] Indicator lamp lights : Battery charging coil output
is up t o specifications.
b) Indicator lamp does not light : Battery charging
coil is faulty. Replace it.
Resistance Measurement
As an alternate method, battery charging coil can be
checked with an ohmmeterlpreferably a digital one).
Use the followi~ngtable :
MAGNETO
1 PART NAME 1 WIRE COLOR 1 IRESISTANCE

iQl
charging YELLOW1BLACK of 0.05 - 0.6

magneto harness
0 NOTE : A short circuit will read zero (0 ohm) (or

close to) on ohmmeter.

Sub-section 07 (SPARK PLUGS)
DESIGN SYMBOLS USED ON NGK SPARK PLUGS

First letter prefix for thread Second and third letter prefix Heat rating number First letter suffix for thread Second letter suffix for
and hexagon size for construction feature, reach construction feature, etc.
except single prefix
T h W un Constructionfuture 2
Honer Type
wr I Thread reach Latter ConBtructmn feature. ate.
118 rnm -1exagon size 20 6 mm 12.0 mm A specials

lthreadi dia I8 mmli
114 mm -1exagor size 16.0 mrn 4
I
B Special plug tor Hoflda vehicles
9 5 mm C ~ o m p e t ~ i otype
n
Hexagon size 23 8 mm (thread dia 14 mml
10 mm
5 G Racing plugs, center electrode
of nickel alloy
12 mm 2ompac1 type (SHORTY) 6 None 22.5 rnm
(thread dia W1/2 in-14 mm) GV Racing plugs center electrode
71S in 1B :ompact Type (BANTAM; off precious metal
16.0 nwi
N Racing plugs nickel
W1/2 in 14 electrode
7 thread d i a 718 m.18 mml
^esimoir type
8
Siwided w e
Surface discharge type 12 7 mm

9' facing type 112 5 mm}
I
I
19.0 mm
10 fraicing type 180 mimt
1 Conical seat type
A - F 109mm
11
B - F 112mm
12 EM - F 78mm
BE-F 175mrn M 2 Q 4
13 Others Except for above lenefs, there
are special pllugs of J, L. Z,
14 Colder type
"Standard regulation IS
drawn here There also
exist a few extraordinary
symbols.
I I

DISASSEMBLY FOULING
First unscrew the spark plug one turn. Fouling of the spark plug is indicated by irregullar run-
Clean the spark plug and cylmder head with pressurize ning of the engine, decreased engine speed due to mis-
air then completely unscrew. firing, reduced performance, and increased fuel
consumption. This is due to a loss of compressi~on.Other
HEAT RANlGE possible causes are : prolonged idling, or running on a
too rich mixture due to a faulty carburetor adjustment
The proper operating temperature or heat range of the or incorrect fuel and/or fuel mixing~.The plulg face of a
spark plugs is determined by the spark plug ability to dis- fouled spark plug h~aseither a dry coating of soot or an
sipate the heat generated by combustion. oily, glossy coating given by an excess either of oil or of
The longer the heat path between the electrode tip to oil with soot. Such coatings form a conductive connec-
the plug shell, the hotter the spark plug operating tem- tion between the center electrode and ground
perature will be - and inversely, the shorter the heat
path, the colder the operating temperature will be. SPARK PLUG ANALYSIS
A "cold" type pl~ugh~asa relatively short insulator nose
and transfers healt very rapidly into the cylinder hea~d.
Such a plug is used in heavy duty or continu~oushigh
speed operation to avoid overheating.
The "hot" type plug has a longer insulator nose and
transfers heat more slowly away from its firing end. It runs
hotter and burns off combustion deposits which might
tend to foul the plug during prolonged idle or low speed
operation.
Overheated Normal Fouled
{light grey) Ibrownish) (black)
Cold A Hot
The plug face (and piston dome) reveals the condition
of the engine, operating condition, method of driving and
fuel mixture. For this reason it is advisable to inspect the
spark plug at regular intervals, examining the plug face
i.e the part of the plug projecting into the combustion
chamber) an~dthe piston dome.
CAUTION : Severe engine damage might occur

if a wrong heat range pllug is used.
A too "hot" plug wnli result in overheating and pre-
ignition, etc
A too "cold" plug will result in foulling (shorting the spairk
plug) or may create carbon build up which can heat up
red-hot and cause pre-ignition or detonation

Sectio~n07 ELECTRICAL
SPARK PLUG INSTALLATION

Prior to installation make sure that contact surfaces of
the cylinder head and spark plug are free of grime.
1. Using a wire feeler gauge, set electrode gap accordl-
ing to chart below.
2. Apply antiseize lubricant (PIN 293 550 001) over the
spark plug threads to prevent possible seizure.
3. Hand screw spark plug into cylinder head and tighten
with a torque wrench and a proper socket.
Proper socket Improper socket
SPARIK PLIUG CHART
Models

Section 08 PROPULSION AND DRIVE SYSTEMS
PROPULSION AND DRIVE SYSTEMS
08-00-1
Subsection 01 (PROPULSION AND DRIVE SYSTEMS)
JET PUMP UNIT

-
Section 08 PROPIULSION ANID DRIVE SYSTEMS

Sub-section 01 (PROPULSION AND DRIVE SYSTEMS)
DIRIVE SHAFT ANID SEAL CARRIER

Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS)
COMPONENTS
1 Flat washer M 6 (41 35 0-nng (2i
2 Fining (bailer) f2f 36 Lock washer M10 141
3 Seat Idouble hp> 37 Ride shoe
4 Needle bearing (2f 38 Comersunk phi/lips screw M 6 x 35 (6)
5 Flay washer M 10 (4) 39 Hexagonal head screw MB x 16 !2i
6 Nut M10 (41 40 Hexagonal head screw M6 x 20 !2i
7 Impeller housing 47 Grill
8 Thrust washer 42 tactile PST 592
9 Thrust bearing 43 PTO flywheel
10 Impeller shaft 44 Grease fitting (2)
77 0-rtng 45 Clamp
72 Plug 46 Rubber boot
13 Housing cover 47 Clamp
74 Hexagonal head screw M5 x 20 (3) 48 Seal earner assembly
15 Fitting (pumpi 49 Seal (single hpl
16 Hexagonal head screw M8 x 30 (11 50 Seal carrier
77 Ventun 51 Needle bearing
18 Locate 515 52 Seal (double h d
79 Flat washer M8 (4) 53 Damper
20 Hexagonal head screw M8 x 35 W 54 Drive shaft
27 Hexagonal head screw M8 x 2 5 !1J 55 Wing nut MB t21
22 Sleeve (21 56 Flat washer M8 /8)
23 Bushing (2) 57 Flywheel guard
24 Nozzle 58 Locme 4 14 super bonder
25 Stud M70 x 45 (4J 59 O w e shaft assembly
26 Impeller 60 Protective hose
27 Boor 6 1 Gear clamp {2)
28 Wear ring 6 2 Locking disk (2i
29 Locttte 516 63 Shim
30 Loctite 242 (blue) 64. Stud M 8 x 15
37 Loctite 587 superflex ultra blue 6 5 Hull insert
32 Locate primer N 66 Lacrite 732 RTV silicone
33 Loctire 271 (red) 67 Lock washer M8 (41
34 Synthetic grease
Disconnect battery.
Â WARNING : Battery black negative cable must al-

ways be d~isconnectedfirst and connected last.
JET PUMP SERVICING
0 NOTE ;This portion outlines some routine proce-

dures. To obtain complete information concerning
these procedures, inspection, parts, illustrations, sealing 1
thread locking products, tightening torques etc, refer to
REMOVAL AND OVERHAUL and following portion.
To work on watercraft, securely install it on a stand. Thus,
Work stand
if access is needed to water inlet area, it will be easy to
F001 009 077
slide underneath watercraft. Working on the ride shoe, I
etc, can be done by simply bllocking the rear of vehicle

above work stand Impelller Condition and Impeller/Wear Ring1
A lift kit (PIN 298 760 0001) can be use to install water- Clearance
craft on a stand.
0 NOTE : These verifications can be performed with-
out removing impeller housing and thus, avoiding
cleaning and sealing pump to hull.

-- -
Section 08 PROPULSION ANID DRIVE SYSTEMS

Measuring from
Impeller and boot condition can be quickly checked from ventun side
underside of the watercraft. Remove drill - and look
through water inlet opening.
Using a long feeler gauge 30 cm (12 in) blades, mea-

sure clearance between impeller blade tip and wear ring.
Measure each blade at its center. Clearance shoud not
exceed .5 mrn 1.020 in). If clearance is greater, disas-
semble jet pump anld inspect impeller a~ndwear ring.
ImpellerJWear Ring Clearance Renew worn parts.
This clearance IS critical for jet pump performance.
Clearance can be checked from water inlet opening,
after inlet grill removal, or from venturi side, after Detach ball joint of steering cable from nozzle.
venturiinozzle assembly removal, however this may be Remove four retaining screws from venturi.
more difficult.
Pull venturi and nozzle assembly apart.
Remove hou~singcover plug.
Measuring from water
inlet side Check oil leveil, it should be to bottom of hole threads.
If oil level is low, check impeller shaft housina
- for leaks.
Feeler gauge Drain oil and use the following tools.

Section 08 PROPIULSIONAND DRIVE SYSTEMS
Pressurize to a maximum of 70 kPa (10 PSI) during 10

minutes. If there is no pressure drop impeller housing
does not leak.
If there is a pressulre drop spray soapy water around Flywt
housing cover. If bubbles are noticed, replace housing
cover 0-r~ngand/or housing cover. ~lfthere are no bub-
bles, impeller shaft, impeller shaft seall, bushing or im-
peller housing is leaking thlrough porosity and has to be
replaced. Jet pump unit has to be overhauled.
If everything is correct, add proper amount of oil.
To check oil condition, insert a wire through opening
then withdraw. A whitish oil inldicates water contami-
n~ation.
This may involve defective impeller shaft seal andlor Two wing
nuts
O-ring of housing cover. Jet pump unit should be over-
hauled to repair boot or seal.
To replace oil, remove housing cover. Unfasten small clamp on drive shaft boot as follows :
Thoroughly clean reservoir and inside of cover with a - Use pliers (PIN 295 000 069).
solvent.
Reinstall cover witlh its O-ring and Loctite 515 and remove
plug from cover.
1
Pour approximately 65 mL (2.2 oz) of oil through hole
-
until oil reaches the bottom of hole threads Use SEA-
DO0 JET PUMP SYNTHETIC OIL ( P / N 293 600 011)
only. Oil will penetrate slowly in housing, wait a few
minutes and readjust oil level.
CAUTION :This is a synthetic oil. Do not mlix
with mlineral based oil. Do not mix oil brands.
Properly rein~stallremoved parts - Insert pointed tips of pliers in closing hooks.
REMOVAL AND OVERHAUL
0 NOTE : Whenever removing a part, visually check

for damage such as : corrosion, crack, split, break,
porosity, cavitation, deformation, distortion, heating dis-
coloration, wear pattern, missing plating, missing or
broken needle on needle bearing, water damage diag-
nosed by black-colored spots, etc. Renew any damaged
part. As a quick check, manually feel cllearance and end
play, where applicable, to detect excessive wear.
Remove flywheel guard.

--
Sectilon 08 PROPULSION AND DRIVE SYSTEMS

Sub-section 01 (PIROPULSION AND DRIVE SYSTEMS)
- Squeeze pliers TO draw hooks together and disengage 6,7,Nut and Impeller Housing
windows from locking hooks.
Remove nuts retaining impeller housing to hull.
Make the following tool to easily separate impeller hous-
ing from hull.
Locking hooks
FOOI 009 081
- Keep clamlp for later use

From inside bilge, disconnect coolant inlet hose and both
bailer tubes from impeller housing.
- Use rectangular tube 38 x 19 x 1.5 mrn (1-112 x 314
x 1/16 in) thick. Five pieces of recta~ngulartube are
Bailer tubes needed. One piece 330 rnm (13 in) long, two pieces
160 m m (6-114 in) long and1 two other pieces 150 rnrn
( 6 in! long.
- Drill one 16 m m ( 5 / 8 in) diameter hole in center of
the 330 mrn (13 in) tube.
- Weld rectangular tubes together as shown in the fol-
lowing illustration.
~ o o l a i inlet
t
hose
Tubes
welded
Remove ball joint fasteners to release steering cable from together
nozzle.
21,22,23,24,62, Screw, Sleeve, Bushing,

Nolzzle and Locking Disk (if applicable)
Remove two retaining screws, locking disks 41f applica-
ble) and withdraw nozzle
Push sleeves and bushings out of nozzle.

Section 08 PROPULSION AND DRIVIE SYSTEMS
- Use threaded rod 13 x 170 rnm (1/2 N.C. x 6-1/2 in) Drill 16 rnm (51% m l
long. On one end install a 13 mm (1/2 in) diameter dia hole
nut flush with the end and weld it.
- Weld two cold rolled rods 10 x 180 mrn (3/8x 7 in)
long on the nut as shown in the following illustration.
(112 m l
n u welded I
38 mm 8 mrn (21164 m l 6 mm
(1-112 in) dia hole (1/4 m l
- Ilnstall two 16 mrn (518 in1 washers on threaded rod

before final assembly
- Glue a rubber mat or similar protective material on sup-
port to prevent scratching hull rear section.
,
- Use one steel flat bar 38 x 13 rnm (1-1/2 x 1/2 in) thick
- x 115 mm (4-112 in) long or two flat bars 6 mrn I114
in) thick welded together.
- Drill one 16 mm (518 in) diameter hole in center of
flat bar
- Align a 13 mm (1/2 in N C ) diameter nut over the hole 16 rnm
already drillled in flat bar and weld it in place 1518 m l
washers
- Use two steel flat bars 38 x 6 mrn (1-112 x 1/4 in) thick
x 70 mrn ( 2 - 3 4 in) long
- Weld two pieces of cold rolled steel 22 mrn (718 in)
diameter x 10 mm (318 in) thick on each flalt bar at
the center end.
- Drill one 8 mrn (21/64 in1 diameter hole in center of
each cold rolled bushing thru flat bar
- Weld flat bars together as shown in the following il- ~ u b b e rmat
F001 011 096
lustration

- - --

Sub-section 01 (PROPULSION AND DRIIVE SYSTEMS)
-
Using screws previously removed from nozzle, install1

pump remover on venturi. Use ball end mill for ra~dius.
This section of the slot should
be 38 mm (1-15132 in) deep
remove ma~terial f f
Venturt
FOCI on 097
Rotate handle clockwise to remove jet pump. Withdraw

pump unit and drive shaft together.
v CAUTION :When removing pump unit a shim

could have been installed between hull and pump
housing be careful n o t t o damage shim. If shim is not
(11132 in) holle
reinstalled engine and jet pump alignment will be
altered.
Drill and tap

6 rnrn 1114 in) holes
A) 305 mrn ( 1 2 in) F 1 22 rnm (718 in)

8 ) 105 mm (4-1/8 m l GI 17 mm (11116 m l
0 16 mrn (5/8 in) HI 19 mm (3/4 in)
D) 51 rnm ( 2 in) I 1 35 mm (1-3/8 in)
E) 36 rnm (1-25164 in)
Mount on pump unit remover drive shaft puller, then in-

Pump unit wit!h stall assembly on drive shaft using screws.
drive shaft
Fa01 011 098
If the drive shaft is jammed into PTO fllywheel or if bear-

ing is seized on shaft at seal carrier level, make the foi-
lowing tool and use it in conjunction with pump remover
to withdraw drive shaft
Raw material ;
- 1 aluminum alloy square 51 m m ( 2 in) x 305 mrn
(12 in).
- 2 aluminum rod 28.5 mm (1-1/8in1 dia. x 30 m m
(1-3116 in). Screws
POOH DOS 006

CAUTION : Be careful not to damage hull rea~r

section or engine rubber mounts. 0 NOTE : An impact screwdriver can be used to loos-
en tight screws
Remove four retaining screws of grill then withdraw it.
Remove six retalining screws of ride shoe then withdraw
it.
Ride shoes screws

Grill screws
17,20,35,Venturi, Screw and 0- ring

Remove four retaining screws and withdraw ventun Make the following tool to easily separate ride shoe from
hull.
Keep O-ring for future use.
CAUTION : Prying ride shoe is likely to be dam-
ageable. Use special tool when ride shoe needs
to be removed without damage.
- Use two steel angle bars 25 x 25 x 3 rnm (1 x 1 x 118
in) thick x 225 mrn (9 in) long.
- A kind of turnbucklie is needed to apply extension force
between ride shoe and hull. Use a 25 mm (1 in) square
tube by approximately 125 mm (5 in) long so that, with
all parts welded, its overall length will1not exceed 190
mrn (7-112 in).
- On one end, weld a 10 m m (3/8in) dia. nut
- Weld the head of a 10 x 100 mrn (318 x 4 in) screw
on top of one angle bar then screw in square tube.
- ~lnserta 10 x 15 mrn (318 x 1/2 in) screw through a
large and thick washer or a suitable sleeve
- Install a
nut on screw Do not fullly tighten, ensure
Ride Shoe, Screw anld Glrill
37,38,39,40,41, screw can easily rotate into washer Weld the top of
other angle bar to nut.
0 NOTE : Grill must be removed prior to removing ride

shoe. Impelller housing must be removed to allow
ride shoe removal.

-- - - -
Section 08 PROPIULSION AND DRIVE SYSTEMS

- Weld the washer to the remaining end of square tube. 48,160,Seal CalrrierAss'y and Protective H o s e
Max. overall leng~th

190 mrn (7-112 in)
, 0 NOTE : Drive shaft / pump housing or engine must
be removed to allow removal of seal carrier ass'y.
Pi
Since it is sealed to prevent water coming inside bilge,
seal carrier ass'y should not be removed needlessly-
Square tube Loosen gear clamp holding seal carrier protective hose,
then carefully pull hose and seal carrier from hull insert.
DISASSEMBLY
\
Angle bar 27, Boot
Nut welded on tswivell
extendable! CAUTION :Do not pull drive shaft to release it
I welded on \ from impeller, this cou~lddamage boot. Boot must
Head of 100 mrn sauare tube be slipped out of impeller before removing drive shaft.
screw. welded
against angle Nut welded against
Insert a screwdriver blade between irnpelller and flange
bar peak angle bar peak of boot. Carefully pry boot all around to release from im-
peller. To ease this operation, apply liquid soap between
boot and impeller, as they begin to separate.
Insert special tool between ride shoe ribs and hull as
shown.
v CAUTION : Ensure lower part of tool sits at least

on outer ribs in order t o reduce applied pressure
for removal. Ensure that tool is instal1ledvertically.
Usinq a wrench, turn tool bodv so that it extends to un-
stickand release ride shoe from hull.
FOOT 009 027
Withdraw drive shaft.

0 NOTE : A jammed drive shaft can be removed by

holding pump unit by drive shaft, slightly raised
above a smooth surface, then striking all around of im-
13,14, Holusing Cover and Screw
Starting with pump assembly in horizontal position, re-
peller housing with a fiber hammer. Corroded parts can move three retaining screws.
be loosened by applying penetrating oil such as SEA-DO0 Place container under cover to catch oil.
LUBE ( P i N 293 600 0061.
Using a fiber hammer, gently tap cover to release from
impelller housing.
Insert impeller shaft holder (Pf N 295 000 082) on flat
end of impelller shaft.
Using two screws previously removed from venturi, se-
cure shaft holder to housing. To ease removal heat im-
Hold raised peller center with a propane torch to approxima~tely
with drive shaft 150Â° (300QRto break the Loctite bond.
while striking
Impeller is l~oosenusing impeller remover (P/N 295 000
- 2,15, Fitting
Fittings can be removed with deep socket or vise grip.
Do not contact hose mou~ntingarea.
Fitting can be removed from pump housing with follow- Ilnstall shaft holder in a vice.
ing suggested tool . Insert special tool in impeller splines.
- Use a deep socket 14 mrn (9/16 in). Rotate counterclockwise and completely unscrew im-
- Drill deep socket with a 14 rnm (9/16 in1 drill bit, start-
ing at hexagone head end as shown in following illus-
tration
1,mpeIler remover
- Drill one 2.40 rnm (3f32 inF hole in center of deep (PIN 295 000 001)
socket as shown in following illustration.
- Install 2 40 mrn (3132 in) roll pin in the center hole
Impeller shaft holder

i P / N 295 000 082)
F001 009 009
CAUTION : Never use any impact wrench to loos-

Roll pin en impeller.
z 4~ rnm
(3132 m i
F001 009 099

To remove impeller, apply a rotation movement and pull After cutting rin~g,insert a screwdriver blade between im-
at same time. Slide impeller out of housing and remove peller housing and one end of ring.
tool from impeller. Lift ring end so that both ends overlap each other.
Remove two screws holding impeller housing to shaft Pull ring out
h~older.
Lift impeller housing away from impeller shaft. 3, Seal
Slide thrust washer and thrust bearing off of shaft.
28,Wear Ring
0 NOTE : If bearings and seal need to be renewed,
the special pusher described in bearing removal
(the following item), can be used to push the three parts
at same time Simply insert pusher from the rear and push
Place impeller housing in a brass jaw vise so that it is towards the front
firmly retained by a lug.
Cut wear ring.
0 NOTE : Wear ring can be cut using a jigsaw, a small

buffer or a low clearance hacksaw such as Snap-
On HS3 or equivalent.
Pushing seal and
CAUTION :When cutting ring, be careful not to bearings out from real
damage impeller housing.
Same tool
as for bearing
removal
If only seal needs to be renewed, proceed as follows.

CAUTION : It is not recommended to push seal
out with a punch. Housing and/or bearingk)
could be damaged.
Seal should be removed using the folllowing suggested
tool.
Seal puller, Snap-on #S6129

Sub-section 01 (PROPULSION ANID DRIVE SYSTEMS)
4, Needlie Bearing
Pulling seal
out of housing
0 NOTE: It is always recommended to renew both
bearings, even if only one needs to be replaced.
Bearings can be easiily removed with the following sug-
gested pusher.
Use a 30 mm dia. x 345 mm long (1-118 dia. x 13-112 in)
steel shaft. Machine shaft as per the following drawing.
22 rnm ( 865 in) dia 28 mm 11 115 in) dia
Or, use a Snap-on hammer puller including :

Handle CJ93-1
Hammer CJ125-6
(p-
--
-
(3-1/2 in1
345 rnm (13-112 in)

-
Claws CJ93-4
Insert pusher into one bearing then push tool using a ar-
bor press until bea~ringsare out. However, care should
be taken not to damage bearing journals.
- - -
Close puller claws so that they can be inserted between

seal and bearing. Holding claws, turn pulller shaft clock-
Push bearings
wise so that claws open an~dtighten against seal. ut
Slide puller sleeve outwards and gently tap pulller end.
Work with small strikes otherwise claws will slip out. As
soon as seal begins to slide out, retighten claws to al-
wa~ysmaintallin them tight against seal. Continue pulling
until seal is out.
0 NOTE : If seal is to be renewed at same time, sim-

ply insert pusher from the side opposite of seal then
pu~shseal and bearings out.
Fa01 009 036

out of housing

Sub-section 01 (IPROPULSIONANID DRIVE SYSTEMS)
49,50,51,52, Seal, Seal Carrier and Needlle INSPECTION

Bea~ring
26,43,54, Impeller, PTO Flywheel and Drive
Seals and bearing can be removed using same suggest-
ed tools as for pump unit.
Shaft
Properly support seal carrier when removing seals and Visually inspect splines of drive shaft, impeller and PTQ
bearing. flywheel. Check for wear or dleforrnation. Renew a~ny
damaged part.
CLEANING
0 NOTE : If PTO flywheel splines are very worn, a pipe
wrench can be used to remove PTO flywheel in-
0 : Bailer tube fittings and cooling supply fit-
tinlg can be removed to ease cleaning of impeller
housing mating surface.
stead of tool ( P I N 295 000 001). Refer to ENGINE 03-04
then look for PTO flywheel and magneto.
Most silicone can be removed out with a scraper such 51,53,54, Needle Bearing, Damper and Drive
as Snap-on #CS-M2. Shaft
Remlaining silicone can be removed with a steel brush
(disc) mounted on a drill motor Wear
Bombardier stripper #I57 ( P I N 295 000 040) can be Visually inspect shape of dampers for deformation or
used to remove remaining silicone. Carefully apply on other damage. Ensure they are firmly retainled.
mating surfaces talking care not to extend outside of this Inspect needle bearing of seal carrier and its contact sur-
area because paint will be damaged. Let product dissolve face. Check for scoring, pitting, chipping or other evi-
silicone then scrape it. dence of wear.
Properly clean all threads. With a finger tip, feel contact surfaces of bearing and
Discard all O-rings and clean parts in a solvent. seals. If any i~rregularsurface is found, renew drive shaft.
Carefully check water passages (bailer, cooling system)
and oil passages. Blow low pressure compressed air
Needle bearing
through them and make sure they are not clogged. conta~ctsurface Splines condition
Seal contact
surface
F001 009 040
Deflection
Oil passages
Excessive deflection could cause vibration and damage
splines of drive shaft, impeller, flywheel or seal carrier.
Install drive shaft in V-blocks and set a dial gauge in
center of shaft. Slowly rotate shaft ; difference between
highest and lowest dial gauge reading is deflection. Refer
to the following illustration.

Maximum permissible deflection is 0.5 mm 0220 in), Place impeller on a flat surface and using a precision ruler
measure at each end of the same blade. Measurement
D minus measurement C equals 5.
4 1
Measuring drive
shaft deflection
e i s i
ruler
Dial gauge
26, Impeller
Identification Refer to the following chart to identify impellers.
To identify the impellers refer to the following illustrations
and chart. VEHICLE MEASUREMENTS
Measure distance A and B. NO.
Use a
192 mrn 58 rnm

17-9/16") (2-9132")
l o
5'm1
5812
1 271 000
052 1 Stainless
steel 1 170
steel
5860 I 271 000

123 1 Stainless
steel 1 18"'
1
models 271 000 1 Polished 1
Stainless steel impeller can also be identified with a

stamped code.

Refer to following illustration and chart.

Replace if blunted
round or damaged
VEHICLE
MODEL NO.
IMPELLER
PIN
1
MATERIAL 1 DEGREE 1 CODE Check impeller for cavitation damage, deep scratches or
any other dalmage.
5810
I
Check for cavitation.

deep scratches or other da~mage
5850 271 000 Stainless

19'
115 steel
5851 9 or 115
5860
271 000
123
1 Stainless
steel 1 1 8 . 3 4 83
Alt models
except
04 6
5850 (optional!
5851
26,28,Impel~lerand Wear Ring

Examine impeller in wear ring for distortion.
Check wear ring for deep scratches, irregular surface or
Check if tips of blades are blu~ntedround, chipped or any apparent damage.
broken. Such impeller is unbalanced and wili vibrate and
damage wear ring, impeller shaft, shaft seal or bearings If irnpeller/wear ring clearance is too large and impeller
Renew if damaged. is in good shape, renew wear ring.
4,10, Needle Bearing and Impeller W a f t

Wear
Inspect needle bearings and their contact surface. Check
for scoring, pitting, chipping or other evidence of wear
With a finger tip, feel contact surface of seal If any ir-
reglular surface is found, renew impeller shaft.
With impeller shaft installed with bearings, rotate it and
make sure it turns smoothly.

Section 08 PROIPULSION AND DRIVE SYSTEMS
Radiail Play Excessive play can come either from worn bearings or
Radial play is critical for jet pump unit life span mpeller shaft or damaged impeller housing bearing sur-
faces.
Radial play of impeller shaft is checked with shaft in hous-
ing, without impelller Measuring shaft diameters wiill determine defective part
Retain housing in a brass jaw vise making sure not to Using a micrometer, measure diameters on bearing con-
damage housing lug tact surfaces. Minimum shaft diameter sh~ouldbe 22 24
mrn (.a76 in). A shaft within tolerance indicates worn
Set a dial gauge and position its tip onto end of shaft, bearings. Replace both bearings
close to end of threads.
Move shaft end up and down Difference between
highest and lowest dial gauge reading is radial play Mea~suringshaft diameter
at bearing contact surface
Maximum permissible radial play is 0.05 rnm (.a02 in).
Measuring irnpetler shaft radial play
Dial gauge / [[
Measure close to threadis at shaft end

0 NOTE : If shaft is to be replaced, it is recommend-
ed to replace both bearings at same time In addi-
tion, it is suggested to replace thrust bearing and thrust
washer
To check both bearings, proceed the same way with other
end of shaft Position tip of gauge on diameter, close to
8,9,Thrust Washer and Thrust Bearing
flats on shaft Visually inspect thrust waisher, thrust bearing and their
contact surface. Check for scoring, pitting, chipping or
Measuring impeller shaft radial play other evidence of wear
Dial aauae
Very close inspection
will show wear in circled
area of bearing if bad
Measure close to fliats at shaft end

PO01 009 045

-
Sectlion 08 PROPULSION AND DRIVE SYSTEMS

Measure thrust bearing thickness. If roller diameter I Excessive play come from worn protrusion inside hous-
found smaller than 1.93 mrn (.076 in11,renew it. ing cover.
Visually inspect protrusion inside cover. If worn, a small
peak in center will be apparent.
I
Measuring thrust
bearing thickness
F001 009 0 4 7
0 NOTE : When replacing either washer or bearing,

is recommended to renew both.
it
3,49,52, Seal
Carefully inspect seal lips. Make sure that lips are not
13, Housing Cover worn, distorted, cracked or present any other damages.
Renew as necessary.
End Play
End play of impeller shaft is checked with shaft in hous- ASSEMBLY
ing, without impeller and with housing cover installed.
Retain housing in a brass jalw vise making sure not to
28,Wear Ring
damage housing lug Set a dial gauge and position its If wear ring features a lip on one edge, position lip out-
tip on the end of shaft Move shaft end by pulling and wards of housing.
pushing Difference between highest and lowest dial
To ease insertion into housing, apply SEA-DO0 LUBE
gauge reading is end play Maximum permissible end play
(P/N 293 600 006) onto outside circumference of wear
(new) is 012 - 0.54 mrn t.005 - .021 in).
ring.
To install ring in housing, use a square steel plate approx
180 x 180 m m x 6 rnm thick (7 x 7 in x 114 in) and a
press.

Section 08 PROPULSIOIN AND DRIVE SYSTEMS
Manually engage ring in housing making sure it is equally 3,4, Seal and Needle Bearing
inserted all around. Press ring until it seats into bottom
of housing. Bearings and seal will be properly installed in housing
using bearing installer tool ( P I N 295 000 0141.
Stamped end of bearings (showing identification mark-

ings) must be located toward outside of housing
Properly insert bearing on tool Using an arbor press only,
r e /
wear ring
7, push tool until tool flange contacts housing^. Proceed the
same for both bearings.
If a press is not readily available, a piece of wood such

as a 2 x 4 x 12 in long, can be used.
Manually engage ring in housing making sure it is equally
inserted all around. Place wood piece over nng. Using
a hammer, strike on wood to push ring. Strike one side
then rotate wood piece about 90' and strike again. Work
this way, frequently rotating wood piece so that ring slides
eqlually all around until it seats into bottom of housing
CAUTION: Never hammer the bearing into its

housing.
Press on tool
until it stops

Section 08 PROPULSION AN1DDRIVE SYSTEM~S
Sub-section 01 (PROPULSION AND DRIVE S Y S T E I M S )
-
CAUTION : This tool has been designed t o prop- CAUTION : Take care that no sealan~tcontacts
erly position bearings and seal, thus providing any roller of bearin~g.
space for lubrication pulrposes. The tool flanges alllow Push on tool en~dwith a press until tool flange contacts
this. If a different pusher type is being used, compo- housing.
nents must be properly positioned as follows.
Bearing on impeller side must be 1.5 to 2.5 mm t.060 Push on tool
- 100 in) inside reservoir measured from seal seat. Bear- until it stops
ing on ventun side must be 2 to 3 mm (.080 - .I20in1
inside reservoir measured from thrust washer seat. Refer
to following illustration.
2-3mm
15-25mm 0 8 0 - 120 ml
Thrust
washer seat
Stamped end
of bearing
Apply syntlhetic grease (PIN 293 550 010) between seal
lips.
Loctite 515 all

around and behind
Same tool will be used to install seal in housing.

Seal must be installed so tlhat raised edges of llips are
toward outside of housing (toward impeller)
Apply Loctite 515 (PIN 293 800 007)in seal housing,
all around outer diameter and on seal seat
Properly insert seal on tool.
Raised edge of
0 NOTE : Be careful when installing seals to pack seal
with grease before inserting bearinglseal installer
tool Properly insert tool in seal with a rotating movement.
seal lip this side
7,8,9,10,26, Impeller Housi~n~g,

Thrust Washer,
Thrust Bearing, Impeller Shaft and Impeller
Ilnsert flat edgles of impeller shaft in a vise so that shaft
is vertical.
Apply synthetic grease ( P / N 293 550 010) both sides
of thrust bearing then insert onto shaft followed by thrust
washer. Properly center washer and bearing with shaft
flange. Grease will prevent parts from sliding at installa-
Raised edge tion and thus possibly wedging thrust bearing into shaft
of seal here
groove.
08-01 -20 Page: 190 See Doo 1992 Shop Manual - http://www.ReadManuals.com
Section 08 PROPIULSION AND DlRIVE SYSTEMS
Brush a~ndclean impeller shaft threads and impeller

splines with Loctite Safety solvent 755 ( P I N 293 800
0191 or equivalent. Free threads and splines from any
residue. Allow solvent to dry thoroughly
Apply grease on faces
of parts to prevent them
to slide and wedge
into sh~aftgroove
v CAUTION : Be careful not to damage impeller
shaft diameter.
Apply Loctite primer N ( P I N 293 600 012) on impeller
shaft threads. Allow to dry for two minutes.
0 NOTE : Loctite primer is used to reduce Loctite 271

curing time and to activate stainless steel and alu-
minum surfaces for better bonding action If applied,
complete curing time is six hou~rs,if not, 24 hours is
needed.
Apply Loctite 271 red ( P / N 293 800 0051 to shaft
threads.
To prevent seal lllip damage when inserting impeller shaft,

use impeller shaft guide ( P I N 295 000 002).
Insert tool onto shaft end then carefully slide housing over
shaft. 1 FOOT 009 062
Carefully insert
housing onto shaft v CAUTION : Make su~rethrust washer a~ndbear-
ing have not slipped in shaft groove.
Using two screws previously removed from venturi, se-
cure impeller shaft holder (PIN 295 000 0821 to hous-
t ing. Install shaft holder in a vice
0 NOTE : Pump pressurization should be performed

at this time. If it leaks, it is easier to determine
where. Refer to pump pressurization further in this
section.
To ease impeller installation, apply lliquid soap or Sea-
Doo lube ( P / N 293 600 006) on wear ring
Insert impeller into wear ring Manually rotate impeller
and push so that it slides on impeller shaft threads. Care-
fulily engalge threads making sure they are well aligned.
Install impeller remover (P/ N 295 000 001) into impeller
splines and tighten.
CAUTION : Make sure thrust washer and bear-
Remove special tool. T ing are n o t wedged in shaft groove. To check,
manually pull and push impeller housing, an axial play
must be felt.
Page: 191 See Doo 1992 Shop Manual - http://www.ReadManuals.com 08-01 -21
Sub-section 01 (lPROPULSION AND DRIVE SYSTEMS)
-
Torque impeller to 70 N*m (52 lbf*ft) then remove tools. PUMP PRESSURIZATION
CAUTION :Never use a~nyimpact wrench to
tighten impeller. Whenever doing any type of repair on the pump, pres-
sure test should be done to check for any leakage.
l~mpellerremover Pressure Test
[PIN 295 000 001)
- Remove plug from housing cover. Drain oil.
- Apply Loctite PST 592 ( P I N 293 800 0118) on threads
fitting (PIN 295 000 086) then secure on cover.
- Connect pump gauge tester ( P I N 295 000 083) to
Impeller h a f t holder fitting.
i P / N 295 000 0821
- Pressurize pump to a maximum of 70 kPa (10 PSI).
Pump must maintain this pressure for 10 minutes.
11,13,18, O-ring, Housing Cover, Loctite 515

Apply Loctite 515 ( P I IN 293 800 007) on 101-ringand in-
stall on housing cover then carefully insert cover on im-
peller housing making sure to properly position plug on
top side.
v
nents.
CAUTION : Repair any leak, failure t o correct a
leak will lead t o premature wear of pump compo-
If there is a pressure drop spray soapy water around hous-

ing cover If there are no bubbles, impeller shaft, impeller
shaft seal, bushing or impeller housing is leaking through
porosity and has to be repllaced. Jet pump unit has to
Filler plug toward
top side of pump housing be overhauled.
Place housing horizontally as in its operating position
so that fitting in cover is l~ocatedin top. Remove fitting
from cover. Pour SEA-DO0 JET PUMP SYNTHETIC OIL
Apply Loctite 242 (blue) (P/N 293 800 0151 on screw ( P I N 293 600 011) in reservoir until oil comes level with
threads and evenly tighten cover screws. Torque to 7 bottom of hole. Let oil penetrates in housing and after
N*m (62 Ibfainl. a few minutes pour oil again until it is level with bottom
of hole. Oil capacity is 65 mL (2.2 oz).

Section 08 PROPULSIOIN AND DRIVE SYSTEMS
.
-
CAUTION : This is a synthetic oil. Do not mix 2,15, Fitting

with mineral based oil,. Do not mix oil brands.
Apply Loctite PST 592 ( P i N 293 800 018) on plastic fit-
/^\ NOTE : When filling, oil must be poured into cover ting threads. Then thread fittings into pump housing un-
\^^ quite slowly to allow complete housing fill til threads are bottomed.
27, Boot
Pour oil slowly until
it flows out of hole Slide a new boot on drive shaft. To ease installation, ap-
ply some liquid soap on outer circumference of boot.
Clean drive shaft splines with Loctite solvent 755 ( P I N

293 800 019). Free splines from any residue Allow sol-
Apply Loctite PST 592 ( P I N 293 800 018) on plug then
vent to dry thoroughly.
secure on cover.
Generously apply synthetic grease ( P I N 293 550 0101
17,20,35, Venturi, Screw and O-ring on drive shaft splines and impeller splines
Install new O-rings around bailer passages Position ven- Make sure rubber damper is on drive shaft end
tun with bailer passages on top Apply Lactite 515 Gasket Insert drive shaft in impeller then carefully insert boot in
Eliminator ( P / N 293 800 0071 on mating surface impeller Use blade of a screwdriver to push on boot
Apply Loctite 242 (blue) ( P / N 293 800 01151 on threads
and install screws and wa~shersthen torque to 25 N*m
(18 !bf*ft) in a criss-cross sequence
Bailer
passages
aligned
Loctiie 242 Loctite 515

(blue) on mating surface
0 NOTE : On aluminum material it is recommended

to use Loctite primer N ( P I N 293 600 0121 to
reduce curing time and to increase gap filling capability
Refer to manufacturer's instructions.

Section 08 PROPiULSIONAND DRIVE SYSTEMS
Screw and Grill1

Ride Sh~o~e,
37,38,39,40,41,
Apply Loctite 587 Superflex Ultra Blue (PIN 293 800 Push bearing centered
in its housing
0161 on ride shoe as shown in the following illustration.
Ultra Blue
as indicated Ultra Blue
49,50,52, Seal and Seal Carrier
by shaded area on left and
naht ribs Install double-tip seal toward impeller side and single lip
seal toward engine side.
On both seals, raised edge of lip must be located out-
Carefully install ride shoe on hull. Apply Loctite 242
wards of seal carrier.
(blue) { P I N 2913 800 015) on screw threads, insta~lland
tighten in a criss-cross sequlence. Torque to 10 Nrrn (88
Ibfeinl.
Doublle-lip
From inside of bilge, apply Loctite 732 RTV Silicone IFIN seal toward
293 800 006) on end of screws to completely seal hull.
Apply Loctite 242 (bluet ( P / N 293 800 015) on threads
of grill screws, instalif and tighten. Torque screws to 8
N*m 171 lbf*iln)
50,51,Seal Carrier and Needle Bearling

Properly support seal cairrier when installing seals and
bearing.
Push bearing with same pusher used at disassembly.
Center bearing in longitudinal axis of housing.
CAUTION : Never hammer the bearing into its
housing.
' Seal carrier
of lip outwards
Apply Loctite 5115 ( P / N 293 800 007) all around outside

diameter of sea~ls.
Single-lip seal can be carefully inserted, using special tool
( P l N 295 000 014) to avoid seal damage. Push seal un-
til it comes flush with its housing

Apply Loctite 515

all around
FOOT 009 072
It is recommended to use a special tool ( P i N 295 000

014) to avoid lip damage on double-lip seal.
Push seal until it comes flush with its housing.
0 NOTE : Seal carrier gear clamps should not be tight-
ened ulntil pump is installed, to insure perfect
alignment.
0 NOTE : Whenever replacing the double lip seal, an

hydrodynamic seal should be installed. Always in-
stall seal with the protector facing the impeller.
INSTALLATION
65,Hull Insert
Cut pllastic hull insert flush with hull using a saw.
Inserting
double-lips
seal
Hull
Apply 1
sealant
FOOT 009 071
Plastic hull insert

Pack seals and bearing with synthetic grease ( P I N 293 FOCI OW 102
550 010)
Mix epoxy glue (3M-059001, follow manufacturer in-
Install seal carrier and protective hose to hull insert with
structions
gear clamps.
Apply epoxy glue on aluminum insert (PIN 292 000 075)
knurled surface and on plastic insert inner bore

Sub-section 01 (PROPULSION AND DlRIVE SYSTEMS)
CAUTION : A clearance between plastic inse~rt Pump Unit

and aluminum insert coulld possibly be noticed.
If so, en~suret o fill gap with epoxy glue to obtain alu- Apply Loctite 587 Superflex Ultra Blue PI'NI 293 800 0161
minum insert adhesion. onpump as shown in tlhe following illustration.
FO~Hws 073 Wear nnq lip
Install insert into plastic hull insert.

0 NOTE : If wear ring does not feature a lip on its
edge, apply additional silicone all around housing
0 NOTE : Align aluminum insert as much as possible
with PTO flywheel.
as shown.
CAUTION : Seal the wear ring t o ride shoe con-
tact area with Loctite 587 Suoerflex (P / N 293
Apply silicone
where indicated
by shaded area
No lip on
wear ring
0 NOTE : The epoxy glue curing time is 30 minutes.

Make sure rubber damper is on drive shaft end. - Insert pointed tilps of pliers first in closing hooks.
v CAUTIOIN:Some watercraft have a shim be-

tween hull a~ndpump, if shim has been removed
ensure t o reinstall it. If not install, engine and jet pump
t
alignment will be altered.

Insert drive shaft end through hull tunnel. Slide throu~gh
seal carrier being careful not to damage seals. Push on
pump until shaft comes close to PTO flywheel.
v CAUTION :When sliding the drive sha~ftthrough

seal carrier, the double tip seal (P/N 293 200
0091 could be folded over. This could cause a seal car-
rier bearing failure.
While holding pump, guide and engage shaft splines in
PTO flywheel. Rotate shaft to properly index splines.
Make sure boot is well positioned over shaft end.
If necessary, tap pump end with a rubber hammer until
retaining nuts and washers can be installed. Apply Inctite
Closing hooks
242 (blue) ( P / N 293 800 015) on threads and equally F001 009 083
tighten nuts in a criss-cross sequence and torque to 35
N*m (26 lbf*ftÃˆ
- Squeeze pliers to draw closing hooks toglether. When
Secure boot clamp as foliows both large and small windows are directly over the two
- Use pliers ( P / N 295 000 069) as for removal. locking hooks, press those windows down to engage
and sea! clamp.
- Manually engage holding hook in large window. This
is a pre-clamping position only.
PRE-CLAMPING POSITION
Holding hook
Large window
F001 009 075
Push windows
Using a grease gun, carefully lubrica~te,with synthetic

grease ( P I N 293 550 010), at grease fitting until boot
is just beginning to expand. From this point, immediately
stop.

Secure seal carrier protective hose to hull insert with gear

clamps. Lubricate at seal carrier grease fitting until grease
is jlust coming out on engine side. From this point im-
mediately stop.
-; , 1 Locking disks
115 Ibfafti locked togethe
FOOT OOS 001

Â WARNINIG : Whenever removing screw always
renew both locking disks. The recommended
Loctite must be applied on screw threads and screw
Secure filywheel guard to engine studs with washers and
must be torqued as specified.
wing nults.
Reinstall steering cable ball joint on nozzle and check
Secure coolant inlet hose and both bailer tubes to im- handlebarlnozzle alignment.
pelller housing.
Manually turn nozzle from side to side; it must pivot
21,22,23,24, Screw, Sleeve, Bushing ealsiily.
and Nozzle
Insert bushings in nozzle, positioning their flanges from
0 NOTE : To ease steering operation, inside of nyllon
bushings can be sllightly enlarged with a 13 mrn
(112 in) round file (rat tail type).
inside of nozzle. Apply SEA-DO0 LUBE ( P I N 293 600
006) on outer circumference of sleeve then insert in ny- Slightly lubricating wear ring with SEA-DO0 LUBE ( P i N
lon bushings. 293 600 006) before starting insulres no friction during
initial start.
Install nozzle on venturl, positioning its steering arm on
RH side. Apply Loctrte 242 (blue) on threads. Ilnstall To allow impeller seats into wear ring, start engine so that
screws position bottom screw in one of the holes with impeller rotates for a moment.
locking disks (if applicable) then torque to 20 Nmrn (15 CAUTION :Water must be suppllied to cool en-
!bf*ft). gilne with fllush kit (PIN 295 000 038).

Sub-Section 02 (REVERSE SYSTEM)
REVERSE SYSTEM

Sub-Section 0 2 (REVERSE SYSTEM)
COMPONENTS
1 Reverse support plate 16 Plastic washer M W
2 Guide plate 17 Reverse cable
3. Alien screw M6 x 2 0 <21 18 Hexagonal head screw M6 x 40
4 Elastic stop nut M6 (7) 19 Adjustment nut (2)
5 Fiat washer M6 fGf 20 Washer 129
6 Hexagonal head screw MS x 20 2 1 Hexagonal head screw M6 x 4 6
7. Flat washer M6 (2) 22. Flat washer MB (2i
8 Triangular lever 23 Hexagonal head screw M8 x 35 121
9 Bushing (2) 24 Reverse gate
10. Hexagonal head screw M6 x 2 5 25 Locsne 587 Superflex Ultra Blue
7 1 Sliding block 26. Loctite 242
12. Flat washer M6 27. Reverse gate spring (2)
13 Locking lever 28. Sleeve {21
14 Spring 29 Protector
15 Reverse handle
GENERAIL
It is not necessary to remove reverse system from water-
Â WARNING :Vent tube must be in place to pro-
vide proper bilge ventilation.
craft for servicing. However reverse system removal is ne- 11,13,14,15, Sliding Block, Locking Lever,
cessary to replace reverse support plate. Spring and Reverse Handle
DISASSEMBLY To remove reverse handle, unhook spring from sliding
block and pull spring from reverse handle stem.
Remove storage basket from watercraft.
Unhook fuel tank strap, slide it off through tie rap behind
vent tube.
Press on vent tube upper part to enable to withdraw tube
from body.
Press on
vent tube
Withdraw reverse handle stem and locking lever from

sliding block, then slide off locking lever from stem.

Sectio~n08 PROPULSION AND DRIVE SYSTEMS
Sub-section 02 (REVERSE SYSTEM!
Remove two Alien screws, lock nut and washer holding

guide plate and support plate.
Guide
plate
Alien
/
/
,A+/-@-
-
Locking
lever
Screw and washer

8,11, Triangu'lar Lever and Sliding Block F002 009 OUT
Remove screw, lock nut, washers and bushing holding

reverse cable to triangular lever. 24, Reverse Gate
Remove lock nut and washer holding sliding block to
Unhook reverse ga~tesprings and remove reverse cable
triangular lever and to support pla~te. from left side of reverse gate.
Remove screw, lock nut, qasher and bushing holding
- triangular lever to reverse support plate.
Reverse
cable
~riangular \ gate spring

lever Reverse
cable F002 008 008
1, Reverse Support Plate

In order to have access to screw holding lower part of
reverse support plate, remove front seat by pulling on
each side to release rt from body,
Remove screw, lock nut and washers holding support
plate lower part.

Sub-section 02 (REVERSE SYSTEM)
Unscrew from both sides of venturi housing reverse gate 1, Reverse Sulpport Plate
retaining screws, then remove g~ate.
For reverse support plate installation torque screw to 8
N*m (71 Ibfmin) and Allen screws to 2 N*m (18 lbfein).
8,11, Triangullar Lever and Sliding Block

Insert bushing to triangular lever and then install lever to
reverse support. Install reverse cable to triangular lever
with bushing and plastic washer which is installed to
opposite side of reverse cable on reverse support.
Torque cable screw to 7 N*m (62lbf*in).
Torque lower screw of tria~ngularlever to 8 N*m (71
lbfein).
Install sliding block to lever and torque nut to 8 N*m (71
Ibfeinl.
ASSEMBLY
Assembly IS essentially the reverse of disassembly pro-
cedures. However pay pa~rticularatten~tionto the fol-
lowing.
24, Reverse Glate

Install reverse gate with sleeve and washer. Apply Loc-
tite 242 ( P i N 293 800 015) on threads and torque to
20 N*rn (15 lbf-ft).
CAUTION :Always hook reverse gate springs in
order to ease reverse gate operatio~n.
13,14,15, Locking Lever, Spring and Reverse

Handle
-
Insert tocking lever end in sulDDort date hole then alian
llever and slilding block holes-'

Section 08 PIROPULSION AND DRIVE SYSTEMIS
Su~b-Section02 (REVERSE SYSTEM)
0 NOTE : Always install reverse handle with open end

facing left side of watercraft, then push handle stem
through lever and sliding block holes.
plate
FW2 003 003
ADJUSTMENITS
15, Reverse Handle
Insert spring in handle stem hole and then install curved Pull reverse handle to REVERSE position.
end in sliding block groove.
groove
F002 009 020
Reverse Handle System Lubrication

Lubricate support plate sliding area of sliding block and
triangular lever, also lubricate sliding washer and reverse
handle stem

Sub-section 02 (REVERSE SYSTEM)
24, Reverse Gate If reverse gate needs to be readjusted, it can be done

at support plate with adjustment nuts. Turn cable nuts
Position handlebar in a straight ahead position, nozzle to obtain position.
should be parallel to rear of watercraft.
Using a square set it to 125 Â 2 mrn (4-59164 Â 5/64
in), then pasiltion square end at the top middle of nozzle.
Adjustment
nuts
Tighten adjustment nuts and recheck gate position.
With the gate down to REVERSE position it should be

0 NOTE : If reverse gate adjustment is not done ade-
quately, performance and steering control will be
reduced at reverse position.
at the specification.
0 NOTE : Push slightly on the gate in order to reco-

ver spring tension and to obtain proper position of
the gate.

Section 08 PROPULSION AIND DRIVE SYSTEMS
Sub-section 03 (VARIABLE TRIM SYSTEM (VTS))
VARIABLE TRIIM SYSTEM

1 Housing 19 Trimming knob

2 Gasket 20 Snap cap
3 Hexagonal screw M6 x 30 21 Hexagonal screw M6 3 x 20
4 Elastic s o p nut M6 22 Spring washer M20 i4i
5 Trim cable 23 Flat washer M 10
6 Small boot 24 Rivet V8 f81
7 Large boor 25 Washer 1/8f8f
8 Jamnuti2l 26 Phdlfps (2)
9 Washer 27 Retaining
70 Flat washer 28 Arm (2)
7 1 Locme 5 8 7 sealant U-blue 29 Spring pin t2)
12 Ball joint 30 M e n screw M8 x 2 0 f2i
73 Worm 37 Alien screw M8 x 8 (2)
74 Synthetic grease 32 Plastic bushing (41
15 Set screw M 3 x 2 0 (21 33 Trimming ring
76 Sliding collar 34 M e n screw M8 x 10 (21
? 7 Nur ('3; 35 L o m e 242
18 Flat washer M5 t2)
GENERAL Remove ball joint from trim ring then unscrew ball joint
from cabl~e.Remove jam nut and flat washer from cable
It is not necessary to remove variable trim system (VTSI at the outside of hull. Pull1 out cable from inside the hull.
from watercraft for servicing. However variable trim sys-
tem removal is necessary to replace either worm, sliding
collar, housing gasket and housing. Jam nut
DISASSEMBLY
In order obtain a~neasy access to either trim cable or to
worm spring washers, remove storage basket from wal-
tercraft.
5, Tri~rncable
To replace trim cable, remove nut from the end of cable
at sliding collar Untighten screws from retaining plate
and slide off cable from housing.
FOCI 009 132

Section 08 PROPULSION AND DRIVE SYSTElMS
Sub-section 03 ( V A R I A B L E TRIM SYSTEM (VTS))
15,22, Set Screw and Spring Washer ASSEMBLY

Remove set screw from the end of worm then slide off Assembly is essentially the reverse of disassembly proce-
fla~twasher and spring washers dures. However pay particular attention to the following.
13,16, Worm and Sliding Collalr

Whenever replacing either worm or sliding collar, install
set screw which acts as a stopper for the sliding collar
0 NOTE : Always lubricate worm with synthetic

grease (PIIN 293 550 0101
22, Spring washer

Installll middle spring washers the way their inside dl-
arneters are touching each other Install outside spring
washers the way their outside diameters are contacting
// screw
\
housing and flat washer
Spring
washers
Outside
diameter
1,2,Il9,Housing Ass'y, Gasket and Trimming

Knolb
To remove housing assembly, withdraw t r m cable from
sliding collar and from housing
Remove snap cap from trimming knob center, remove
screw then pull knob from worm.
Drill rivets then pull out housing assembly from body
13,16, Worm and Sliding Collar

Remove both set screws from worm then slide off fiat
washer and spring washers. Housing Inside washer
diameter
Unscrew worm and remove sliding collar from housing.
screws \ Sliding
Worm collar
- FOCI 009 133

5, Trim cable Ensure ball joint is on top of steering arm

Install cable from inside the hull, apply Loctite 587 Ultra Make sure screw is installed on top of ball joint and that
Blue <PIN293 800 016) all around cable hole to ensure ball joint is parallel to steering a r m
no leakage Install flat washers and torque nuts to W
N * m (88 lbfein).
b c t i t e 587 Ultra Bllue
5, Trim Cable
Install ball joint and screw it in completely.
Secu~reball joint on right side of trim arm using screw
and nut. Make sure screw is installed on r ~ a l hside
t of trim
ADJUSTMENTS arm and that ball joint is parallel to trimarm
33, Trim Ring Torque screw to 13 N*m (10 lbfoft).
Make sure steering arm of jet pump nozzle is on right

Parallel
side and that trim arm is above venturi housing.
Trim arm
Torque lock nut of ball joint to 2.5 N*rn (23 Ibf*in~i

CAUTION :Ball joints must be in~stalledface t o
Steering arm
face. Damage to cables could result if not done
properly.

Su~b-Sectioln03 (VARIABLE TRIM S Y S T E M (VTS1)l
16, Sliding Collar When the trim knob is turned counterclockwise the noz-
zle must be down (10') and it must not interfere with
Turn trim knob counterclockwise until sliding collar ven~turihousing
touches the set screw. Make sure the nozzle is in down
position.
Turn knob
counterclockwise
Turn knob
cou~nterclockwise
No interference
IF001 0 0 9 124 F001 009 127
If trim ring needs to be readjusted, it can be done at slid-

ing collar with adjustment nuts
Install cable in sliding collar with washer and nut on each
side. Torque nuts to 5 N*m (44 Ibfain). Install retaining
plate over cable housing Adjustments
nuts
0 NOTE : Push cable as far as possible in sliding col-

lar without moving trim ring from its down position.
Verify if when turning trim knob cloclkwise to the end the
nozzle i s up (10') without interfering with ventun
housing
Turn knob No interference

clockwise I
CAUTION : Trim ring and/or nozzle must not in-

terfer. Damage to cables andlor venturi housing
will occur if adjustments are not done adequately.

Section 09 STEERING SYSTEM
09-800-
1
Sub-section 01 (STEERING SYSTEM)
5805 and 5851 1

44 models
-1
09-0'1
Sub-section 01 (STEERING SYSTEM)
COMPONENTS
1 Cover 33 Throttle handle
2 Foam (top) 34 Throttle handle housing
3 Foam (bottom! 35 Adapter
4 Elastic stop nut MB f5l 36. Retaining washer (21
5 Steering clamp 12) 37 Ball pint (2)
6 Phfips screw 14) 38 Nut TO-32 (21
7 Adapter 39 Jam nut 7/16 (41
8 Set screw (2) 40 Washer 7116 (31
9 Left handle housing 41 Cable
10 Large flat washer 42 Locme U blue
11 Stem steering 43. Cap
12 Washer (shim) 44 Hexagonal screw M6 x 20 (2)
13 Bushing (2} 45 Glue
74 Hexagonal head screw M8 x 25 W 46 Fiat washer M8
15 Plastic washer i2i 47 Hexagonal head screw M6 x 30 (21
16 Collar 48 Hexagonal head screw M8 x 55 f4f
17 Elastic stop nu! M6 i2t 49 Snap cap 121
18 Washer 50 Cable support
19 Steering stern arm 51 Small boot
20 Hexagonal screw M8 x 35 52 Large boot
21 Handle bar 53 Hexagonal screw M8 x 16 (2t
22 Grip S2! 54. Lock washer M8 12)
23 Stopper bushing 55 Tie rap
24 Steering support 56 Locking tab
25 Hexagonal head screw M8 x 25 57 Tie m o m
26 Washer 8 rnm f4) 58 Hexagonal nut M6 t21
27 Gromrner 59 Fiat washer MB (21
28 Throttle cable 60 Loctite 242
29 Circhp 61 Locvte 277
30 Ordip 62 Flat washer M6 (4)
31 Washer 63 Flat washer 7/76
32 Pin
ASSEMBLY
1, Cover (1st Run)
Prior to installation, soak handlebar cover in hot Walter.
This allows even heating of cover and makes installation
much easier
0 NOTE : During installation the cover might have to

be warmed again using a heat gun.
CAUITION : Overheating could damage vinyl
cover.
Slide cover over the left side handlebar until it reaches
the middle of foam. ' Middle of foam
V CAUlTtON : Never pull on vinyl cover seamiless

area.

Section 09 STEERIING SYSTEM
Sub-Section 01 (STEERING SYSTEM)
Pull cover over the right sidle handllebar takiln~gcare to grab Zip cover talking care to bring both sides together. Refer
it as illustrated. to following illustration.
t
--
Pull both sides of cover together before trying to zip it. I, Cover (ZndRun)
To replace the cover, just remove and reinstall four screws
and washers.
Both sides together

F001 011 076
T CAUTION: Never pull on cover around beeper

hole.
Thermoplastic
c * ^
22,43,Grip and Cap
Remove adhesive left on handlebar by pealing off old
Beeper glue.
hole
Apply glue (P 1 N 293 530 0321 inside handlebar grip and
install cap and grip. Rotate grip to evenly spread glue
CAUTION : Allow at least 30 minutes for glue to
T cure.

Sectlion 09 STEERING SYSTEM
Sub-section 0 1 (STEERING SYSTEM)
19,211, Steering Stem Arm and Handlebar Hand-tighten nut. Refer to Sh~irnAdjustment further in
this section for adjustment procedures.
Insert throttle cable through dashboard hole and slide
grommet on cable. Properly position steering stem arm on steering stem as
shown. Make sure to insert stem tenon into arm mortise.
Insert grommet in dashboard hole and pull it from inside
bilge.
0 NOTE : To ease installation, apply water on grom-

met~
Insert wires of engine overheating beeperlengine stop
switch through grommet.
Insert one of the two shims (0.8 mrn (0.030 in1 or 1l.3
rnm (0.050 in) onto steering stem.
Steering column not
Insert handlebar ass'y into steering column support. shown for more clarity
^^^\ One shim
Large flat
washers
fOOl 010 031
Temporarily install large fla~twasher and screw then

tighten.
0 NOTE ; Do not install locking disks yet since they

can be used only once.
CAUTION : Alwa~ysinstall large flat washer with
th~eX stamped side facing the locking disks.
Install steering cable in its bracket with one washer and

one nut each side of bracket.
Nut and washers

each side

-
Sectio~n09 STEERING SYSTEM

Shim Adjustment Weld steel angles A, B, C and bushing as per illustration

and pay attention to the following :
Check steering column axial play. It should be between
0.25-0.75 mrn (.010-,030 in) Replace shim as required. - Dimension 260 rnm (10-114 in1 must be respected on
both side.
Remove screw and apply Loctite 271 (red! ( P i N 293 800
005) on screw threads, reinstall large flat washer, locking - Steel angles A and 8 and hole center of bushing must
disks and screw. Torque to 40 Nmm (30 lbfmftl. be parallel.
- Weld bushing on steel angle C and drill steel angle.
260 rnrn
10-1/4 m l
Tape to protect both ends
with A and B
Locking disks face to face
Â WARNING : The recommended torque and Loc-

tite must be applied on screw. Ensure locking
disks are locked together (face to face).
Weld bushing on
steel angle C
ADJUSTMENT
Steering and Jet Pump Nozzle
Make the following tool to ease alignment Drill four 6 mm (114 in) holes in steel a~ngleD.
Raw Material : Weld steel a~ngleD with the 12 7 rnm (112 in) rod making
sure both parts are at 90'
- 2 steel angle 19 mm x 254 rnrn (314 x 10 in)
- 2 steel angle : 19 rnrn x 356 rnrn (314 x 14 in).
- 1 bushing : 13 rnm ( 510 in1 inside diameter, 19 mrn
(314 in) long
- 1 rod 12 7 mrn x 230 rnrn ( 500 x 9 in)
- 1 spring pin. 19 rnrn (314 in) l~ong.
- 2 rods for hooks (bolt with head removed) . 152 mrn
( 6 m l x 6 mrn (1/4 in) with a threaded portion of at
least 65 mrn (2-1/2 in)
- 2 bushings. 7 mrn (9132 in) inside diameter, 10 mm
(3/8 in1 outside diameter, 19 mrn (3/4 in) long.
- 2 wing nuts : 6 rnrn (1/4 in)

Assemble tool as per illustration.
Spring pin
--0;
-^\
Spring pin 19 mrn
(314 in) long
12 7 x 230 mrn rod

1112 x 9 in)
Hook tool on jet pump nozzle and slide it until both ends
touch hull.
Heat the unthreaded end of the 6 rnm (1/4 in) rod and
bend it as per following illustration. Ends touch hull
Hook
Hook
Verify handlebar position by measuring each side the dis-

tance from handlebar grip end to floorboard. They have
to be equal.

Measuring handlebar
grip end /floorboard
Steering alignment adjustment should be performed on

outer ca~bleadystment nuts on steering cable bracket
near steering stem.
Adjustment
nuts
Remove alignment tool and verify the following before

tightening nuts.
Adjust nuts so that nozzle pivots from side to side but
does not contact venturi housing on either side To verify,
insert a paper sheet or a feeler gauge 0.13 mrn 4.005 in)
between nozzle and ventun at indicated area
After adjustment, properly tighten nuts.
Â WARNING : Ensure handlebar and jet pump noz-

zle operate freely from side to side and that jet
pump nozzle does not contact the side of venturi
housin~g.

SECTION 10 HULLfBODY
Page: 218 See Doo 1992 Shop Manual - http://www.ReadManuals.com 1

1'0-00-
Section 10 HULL/BOlDY
Sub-section 01 (HULLfBODY)
FOOT 011 134

10-01-1
Section 10 HULL/BODY
Sub-Section 01 (HULLfBODY 1
COMPONENTS
7 "Sea-Doo " sticker 27 Elastic stop nut M8 (2)
2 Latch (2) 28 Rate
3 Silicone 732 RTV 29 Washer M8 12}
5 Sea/ 30 Tow hook
6 Storage basket 37 Neopren pad
7 Lock pin 32 "Sea-Doo" sticker 12)
8 Grill 33 "Fuel" sticker
9 Rivet (2) 34 1ocrtte 271
70 Grommet 35 Spring clip (2)
71 Clamp (41 36 Rivet 14)
12 Hose 37 Lock washer 12)
13 Rear baffle 38 Storage cover
15 Grommet 47 Elbow Wing 90'
16 Gasket i2i 42 Tie rap
17 Fitting (2) 43 Water tank trap
78 Bailer (2) 44 Tie mount
19 Tie rap 45 Hinge
20 Hose 46 Rivet (5)
2 1 Elbow fitting 90 47 Rear bracket (29
2 3 Tie rap 12) 48 Front bracket
2 4 Rear vent hose 49 Seat
25 Gear damp (2! 50 Cap
26 Floater (2i
0 NOTE : Some reference numbers are deliberately

missing

Section 10 HULLIBODY
\/
Sub-Section 01 (HULLIBODY)
Water Ta~nkTrap 13,24, Rear Baffle and Vent Hose

Remove air silencer, exhaust formled hose, rear vent hose
GENERAL and then the rear baffle.
In the situation when the water tank trap could possibly
move from its position, the following procedures can be 0 NOTE : Verify if glue remains on rear baffle, it none
install a new baffle
performed without removing jet pump unit ass'y and en-
gine from watercraft. However rf water tank trap is broken
these assemblies will have to be removed from watercraft.
v CAUTIOIN :Verify if glue remaining on rear baf-
fle comes off easily. If it does install a new bafflle.
If not install the same baffle. Disregarding the instal-
lation of a now baffle when required will result into
REMOVAL the same situation shortly,
30,43, Tow Hook a~ndWater Tank Trap CLEANING
Drill storage cover rivets and remove cover.
Clean glue left on water tank trap, rear baffle ( i f applica-
Remove fuel tank from watercraft and pull water talnk trap ble) and body surfaces.
from its position.
Â WARNING : The fuel valve must be set t o OFF.

Remove fuel cap slowl~y.Fuel may be under pres-
0 NOTE :It IS not necessary to remove all the glue
but it is important to have smooth surfaces in order
to get a good adherence
sure and might spray out when removing cap. Fuel is
flam~mableand explosive under certain conditions. Al-
ways work in a well ventilated area. Do not smoke or
allow open flames or sparks in the vicinity. Always Installation is essentialllythe reverse procedures. However
wipe off any fuel spillage from the watercraft. pay particular attention to the following.
-
Remove tow hook n~uts.
30,43,47,48, Tow Hook, Water Tank Trap,
0 NOTE : From this point if water tank trap is broken
the jet pump ulnit alnd engine removal will be re-
quired. Withdraw jet pump unit assry, refer to PRO1PUL-
Rear Bracket and Front Bracket
Install bracket A ( P I N 291 000 2141 on tow hook and
SIION AND DRIVE SYSTEMS 08-01 then look for apply Indite 271 (PIIN 293 800 005) on treads then re-
removal. install nuts
Withdraw engine, refer to ENGINE 03-02 then look for Apply Sikaflex primer 449 (PIN 293 530 0121 on water
removal. tank trap and body surfaces
16,17, Gasket and Fitting

This procedure can be used to repair the water tank trap
fittings.
Remove the air intake grill then remove gear clamp hold-
ing drain hose to fitt~ng.
Remove frtting from water tank

Section 10 HULL/BODY
Sub-section 01 (HULL/BODY 1 -
CAUTION :Allow at beast 30 minutes for primer Install brackets B (P/N 291 000 2131 to support the rear
t o cure. section of tank and secure them with M6 stainless screws
Apply Sikaflex sealant 221 [ P i N 293 530 011) oln water (PIN 210 000 004) and lock nuts ( P / N 212 000 0011.
tank trap and slide it back to its position.
Brackets 3
Sikaflex primer 449 A iÃ‘Ãˆ
an~dSikaflex sealant 221
Bracket A
Tow hook
Install fuel tank and storage cover.

To install engine, refer to ENGINE 03-02 then llook for
installation.
Install jet pump unit ass'y, refer to PROPULS!ON AND
DRIVE SYSTEMS 08-01 then look for installation.
Verify tightness of all fuel lines and clamps and pressu-
rize fuel system^. For pressurization procedure refer to
Drill a 6 mrn O f 4 in) hole each side storage cover hinge FUEL SYSTEM 05-03.
position as illustrated.
I Â WARNING : If any leak is found do not start the
engine and correct the leak. Failure t o correct a
leak could lead t o an explosion. If any fuel spilllage
and/or leak had occurred the bilge should be cleaned
with hot water and detergent or bilge cleaner t o re-
move fuel dleposits.
Before using watercraft wait three days for Sikaflex cur-
ing time.
1 F001 O i l 081
I

Section 10 HULLjBODY
Sub-section 01 (HULL/BODY)
16,17, Gas,ket and Fitting Sikafllex primer 449

and Sikaftex sealant 221
Slide g~asket(P/N 293 250 006)on fitting (PIN 293 710
015). Install through air intake hole the fitting in water
tank trap.
Install outside the tan~ka second gasket on the fitting,
install the nut and then tighten until the gaskets are com-
pressed.
Install drain hose on the fitting and tighten with gear
clamp.
Install rear baffle on body, align properly rear inlet grill

openin~gsand hold in position with a light pressure. Rein-
stall rear vent hose, exhaust formed hose and air silencer.
Before ulsing the watercraft wait three days for Sikaflex
curing time.
7,49, Lock Pin and Seat

Adjust front and rear hooks so that when seat is latched,
seal is compressed to insure a water-tight fit.
- -
To adjust untighten lock pin nuts.

Rear Baffle
-
Screw in or out lock pin
13,24, Realr Baffle and Vent Hose

Apply Sikaflex primer 449 (PIN 293 530 012) on rear Lock pin
baffle and body sections to be sealedl.
- Loctite 271
/
CAUTION :AHow at least 30 minutes for primer
to cure. Nuts
Apply Sikaflex sealant 221 ( P / N 293 530 0111 on rear 5 Nrm
144 Ib~f*in)
baffle section to be sealed.
Install seat and verify if seal is compressed.

Remove seat
Torque nuts to 5 N*m (44 lbf*in)

Section 10 HULL/BOlDY
Sub-section 01 (HULL/BODY)
Hull and Body Repair How to use liquid gelcoat (1 liter) for large repair
Upper body is mad~eof fiberglass. Hull is made of fiber- Clean damaged area making sure rt is free of any dirt,
gla~ssfeaturing aluminum inserts to allow strong struc- grease etc.
tural attachment points. Before spraying, all fiberglass su~rfacerepairs shoulld be
Fiberglass finish is made of Gelcote layer which gives its done with Bornhardier Small Repair Gelcote (P/ N 293
color and smooth finish. 500 016 or 295 500 009) to mask cracks.
Fiberglass repair kit is available through automotive or Mixing of spray Gelcote :
marine suppliers. Mix fou~rdrops of catalyst per teaspoon of Gelcote. This
Gelcoat repair kits are a~vailablethrough regular channel wilt allow you 15 minutes of working time at 21'C (7Q0F1.
Gelcoat kit (small repair) : P / N 295 500 009. To mix one liter of Gellcote, 14 mL (112 oz) to 21 mL (314
ozl of catalyst is required.
G~elcoatpaste (white, 300 mL (10 ozl) : P/ N 293 500
016. This paste is included in kit PIN 295 500 009 but Adding too much catalyst may change Gelcote color.
can be ordered separately. Spray the work area with the mix.
Gelcoat, liquid (1 liter) : white : PIN 293 500 033 To ease spraying add acetone (10% is sufficient) to the
mauve : P / N 293 500 034 mix.
grey : P / N 293 500 035 Allow to cure completely overnight.
How to use geicoat kit for small repair : Hand sand using a 400 - 600 grit paper.
Clean damaged area free of wax, dirt, grease etc Finish the repair area by rubbing or buffing with a fine
Enough paste should be mixed to make all repairs. Mix rubbing compound. When using a power buffer, be sure
approximately 1 part pigment to 20 parts paste. not to cut through surface and do not keep buffer on the
Place enough of the already matched pigmented paste same area for a prolonged time, this prevents heat build-
on a piece of wood or cardboard. Mix four drops of up and discoloration
hardener in 1 teaspoon of paste, mix thoroughlly. This will
give approximately 15 minutes of working time at 70Â°
or 2I0C.
Apply mix to damaged area, working it into the area with
a wooden or plastic spatulla, squeeze off excess paste
to the contour of the surrounding area. Care should be
taken not to have excess paste on surrounding un-
damaged surface.
For higher gloss and greater smoothnless, the repair
should be covered with a piece of clear plastic release
film and let to cure.
After approximately 2 hours remove the plastic film. Deep
damage may require several applications. For a quality
repair job you can sand repair area with 600 Grit Wet
sand paper, then buff with a fime rubbing coumpound
and wax.

Section I 0 HULUBODY
Sub-section 01 (HULLIBQDY)
-
Painting
0 NOTE :When using gelcoat it is not necessary to paint over it.
The fo!iowing was prepared ln conjunction w ~ t hPPG Industries fnc. It contains a list of SEA-DO0 pa~rtsw ~ t hthe~r
respective PPG color codes a~ndtwo pmntlng procedures, CONCEPTtmthe mast commonly used and DELTAtm(with
low VOC] mainly used in California.
PPCi Industries lnc sells paint and relaTed products and these are not available through Bombardier lnc. network.
To find your nearest PPG dealer dial one of the following numbers.
AMERICA PACIFIC, RIM

CANADA JAPAN
Phone : 1 -800-363-28Il6 Phone : 8 1-3-3280-285 I
U.S.A. KOREA
Phone : (216)572-6100 Phone : $2-32-529-8141
(This phone number IS also good for all coun- 82-32-523-8600
mes. Cammunicat~onsare available in engl~sh, 82-51-624-822 I
french and spanish) 82-2-792-2477
--
EUROPE
DEINMARK PORTUGAL
Phone : 45-3 1-54-92I I Phone : 351-230-17-43
FRANCE SPAIN
Phone : 33-1-48-35-7777 Phone : 34-3-588-2000
33-27-14-9700 34-3-71 1-51-54
33-27-14-4600 34-6- I54-7035
34-83-54-0400104
GERMAINY
SWEDEN
P h ~ t i ~: 49-202-788-
e 1
Phone : 46-479-7 4-445
ITALY
Phone : 39-81-831-1222
UNiTED KINGDOM
39-2-37-701 Pholne 44-21-455-9866
39-131-7701 44-926-41 0-255
PPG paint for Sea-Doo is not available in spray can. b r best result it must be apphed by a professional painter.
For fast touch up on metallic parts only refer to the appropriate Bombalrdier Sea-Do0 parts catalog, it contains a
few spray can part numbers.

Section 9 0 HULLIBODY
Sub-Section 01 (HULL/BODYl
PARTS THAT CAN BE PAINTED
1 Upper body 10 Ignition housing cover

2 Lower body I 1 Flame arrester covelr
3 Storage cover 12. Flame arrester support
4 Engine 13 Flame arrester base
5 Tuned p p e 14. Shoe
6 Muffler 15. Impeller housing
7 Exhaust manifold I 6. Ventur~
8 Engine support 17 Steer~ngn~ozzle
9 l g n ~ t ~ ohousing
n
10-0'1-8 Page: 226 See Do0 1992 Shop Manual - http:ll~.ReadManuals.com
PPG COLOR
CHART
Medurn
White Mauve White
Dark Grey
PPG no. 98208 59962 98208
38248
3.Storage cover COLOR Not Lavender Not Magenta
PPG no. applicable 59974 applicable 59973
4. Engine C0LOlR Wh~te White Wh~te White
PPG no. 98209 98209 98209 98209

Section 110 HlJLLjBODY
Sub-Section 01 ( H U L L / BODY]
CONCEPTTM PAlNTING PROCEDURE

INSTRUCTIONS FOR SPOT!PANEL AND OVERALL JIOBS
For additional information refer to PPG P-Buiietin no. 168.
FULL PAINEL AND OVERALL REPAIRS

,Prepare and clean surface consistent with good paint- Application
ing practices. Apply one medium wet coat and glve 5-10 minultes flash*
Primer followed by two wet coats with 15 minutes fllash time
between each coat. Adjust metallic on the last full wet
DP Epoxy Primer/ DIP 401 Catalyst; DX 1791 / 1792 coat, If necessary, apply a mist coat. For medium solids
(Prime before topcoating). opt~onlapply two full wet coats.
'Primer Surfacer Air Pressure
K36IK201, K2001K201 or IQZ KONQARm Primer Sur- 40-50 lbs. alt-the-gun
facers.
NCITE : KONDAR must be sealed before applying Dry T~ime
CONCEPT color. - Dust free : 30 minutes.
Sealer - Tac~kfree : two to three hours.
KTS30 2K Sealer, DP Epoxy Primer reduced as a sealer - Tape print f~ree: six hours.
or DAS 1980 or DAS 1987. - Dry to handle : six to eight hours at 70Â° (2l0C.I.
- Force dry : 40 minutes at 140Â° (60Â°C1
Direct Gloss Color
Faster dry times may be oblailned by using 1/2 oz 415 mL1
How to Mix of DXR $1 Accelerator per sprayable quart, however, the
Standard Air Dry : MIXCONCEPT Color 2:ll:l - two parts pot life is reduced to two hours.
color with one part DT Reducer best suited to shop tem-
peratures and olne palrt DU 4 (below 85OF (2gQC)1or SPOT/PANEL REPAIRS
DU 5 (above 85OF 429Â°C1 Hardener. Application
Standard Force Dry : Mix CONCEPT Color 2,1:1 - Appli- Spray medium wet coat of color on the repalm area an~d
cation temperatures below 85OF (2gÂ°C use DU 5 allow 5-10 minutes flash tme. Apply two addit~onalfull
Hardener, above 85OF (2gÂ°Cuse DU 6.
coats until hiding IS achievedpextending each coat be-
lM~ediumSolids (MS)Application : For faster filml budd, yond the previous coat. Flash 15 minutes between each
when usinlg solid colors, mix two parts CONCEPT color coat For medium solids option apply two full[ wet coats.
with half part DT Reducer and one part DLJ 5 or DU 6
Hardener. Select the IDT Reducer appropriate for shop BleInlding
temperatulre. Add DT 95 Reducer to a second gun cup. Reduce the
f\wd feed of the gun and lower the air pressure to 30 PSI.
Pot Life
Dust the dry edge until a slight wet look appears, then
Pot life of ready-to-spray CONCEPT color is six to eight stop. Or mix reduced1and catalyzed color with equal parts
hours at 70Â° (2l0C1. Medium solids option IS two to of reduced and catalyzed CONCEPT DCU 2020 Clear.
four hours at 70Â° (21Â°C1

Section1 10 HIULL/BODY
Sub-Sectkm 01 ( H U L L t B Q D Y )
DELTATM PAINTING PROCEDURE

(with1 low VOCt lmainly in California)
iNSTRUCTIQNS FOR SIPOT/PAINEL ANID OVERALL REFINISHING1
For add~t~onal
information refer $0 PPG P-Bulletm no" 157
SURFACE PREPARATION
Primer : DELTATMP1RIMEDPU 166.
DELTATM 2800,COLOR
How to Mix
Mix DELTATM2800 2 1 , two parts Colors to olne DU 6 Catalyst.
Applicatilo~n
Apply two coats of DELTATMPolyurethane Color. Apply the first coat at 1.5-1.8 wet mils. Atlow a m~nimum~of 15
m~nutesflash time prior applicati~nof the second coat. Apply a second coat of DELTATMu~singthe same techniq~ue
as the first applicat~on,paying strict attention1 to glun set up and proper eq~uip~ment
choices,
RECOMMENIQEDSPRAY EQUIPMENT
1 Gun Manufacturer 1 DeVilbiss 1 Binks 1 Gram 1 HVLP 1

1 Gun Model
1 JGA 1 62 1 1 Can A I ~
Model 900
--- - -
1
Fluid Tip Size
Air Cap 797 / 264 I 63PW 02 103 C9062

Gun D~stancle 10"-I 2 ' ? 10"-12'* 1 On'-12" 10"-12"
Fluid Delivery 02. / min. 8-12 8-12 8-12 8-1 2
Air Pressure (At-the-Gun) 60-75# 60-75# 60-75# 9#
Dry Time tat 7O0F ~ 2 l Q C l 1

- Dust free : 25-35 minutes
- Tack free Two and a half - t h e e lhours
- Tape 1 Sand Overmght
Farce Dry
Allow 20 minutes purge time at 80-90Â°(27-32'CI before bake. Bake 75 minutes at 150Â°(65OC)OK 40 minutes
at 180Â° 482'CI Allow to cool after force dry4 before sand~~ng
or tap~ing~

Section 110 HULLIBODY
Sub-section 01 (HULL/BODY 1
Decals
Clean surface with a good solvent such as ACRYLI-
Removal CLEAN DX 330 from PPG or equivalent (refer to manu-
facturer instructions).
Using a heat gun warm up one end of decal for a few
seconds (until decal can roll off when rubbing with your For best result apply an activator t P / N 293 530 036)
finger). to prepare the surface using a clean cloth After a few
seconds, when the activator evaporates, the surface is
Pull decal slowly and when necessary apply more heat
ready
to ease removal on the area that ha~sto be peeled off.
Using1a pencil and the decall as a template mark the area
To know when decal has enough heat: if decal tears
where decal will be located.
while pulling off it needs to be heated for a few seconds
longer. If decal tends to stretch while pulling off stop For better adhesion a dry application is recommended,
heating and wait a few seconds to let it cool, then peel however, t o ease decal installation a mild solution of
off. soapy water can be sprayed over surface where decal
will be installled.
Installation Remove ba~ckprotective film from decal and allign decal
with marks. When well alig~nedsqueegee decal begin-
There are two types of decals used on watercraft. One
ning at center and working outward using, firm, short,
having a protective film on back side and the other one
overlapping strokes.
a protective film on both sidles. They are used on three
types of materials; ptastw, gelcoat and metal. Remove front protective film once decal has adhered to
hull.
INSTALLATION OF DECALS HAVING A PROTECTIVE
FILM ON BACK SIDE OlNLY Installation on plastic (storage cover)
These decals usually contain written information (ex : Clean surface with isopropyi alcohol.
warning) and are used on gelcoat or metal. Using a pencil and the decal as a template, mark the area
Clean surface with a good solvent such as ACIRYLI- where decal will be located.
CLEAN DX 330 from PPG or equivalent (refer to manu- Apply an activator [Pf N 293 530 036) to prepare the
facturer instructions) surface using a clean cloth. After a few seconds, when
Using a pencil and the decal as a template, mark the alrea the activator evaporates, the surface is ready.
where decal will be located.
Remove from decal one half of its back protective film
and align decal with marks Start sticking it from center
v CAUTION : Do not use soa~pywater t o locate
decal on plastic parts.
Remove back protective film from decal and carefully
and remove the other half of the film to stick it completely. align dlecal with marks. When well aligned squeegee de-
Carefully squeegee decal beginning at center and work- cal beginning at cen~terand working outward using, firm,
ing outward using, firm, short, overlapping strokes short, overlapping strokes.
INSTALLATION OF DECALS HAVING A PROTECTIVE Remove front protective film once decal has adhlered
FILM ON BOTH SIDES
These decals usually contain graphics and are used on
gelcoat or plastic.

Section 11 STORAGE
STORAGE
STORAGE Fuel System
It is during winter or when the watercraft is not to be A fuel stabilizer, such as Sta-Bil@(or equivalent), can be
in use for a prolonged time that a proper storage is a added in fuel tank to prevent fuel deterioration and car-
necessity Storage during long periods of inactivity con- buretor(~) gumming. Follow rnan~ufacturer'sinstructions
sists of checking and replacing missing, broken or worn for proper use
parts and protecting cooling system against freezing and
corrosion
Proper lubrication and treatment should be performed
v CAUTION : Fuel stabilizer should be added prior
engine lubrication to ensure carburetor(s1protec-
tion against varnish deposit.
to insure that parts do not become corroded and in
general, preparing the watercraft so that when the time
comes to use it again, it will be in top condition
4 WARNING : Fuel is flammable and explosive un-
der certain conditions. Always work in a well ven-
tilated area. Do not smoke or allow open flames or
sparks in the vicinity. Always wipe off any fuel spil-
Engine Draining lage from the watercraft.
Ch~eckengine drain tube running from engine manifold
socket to exhalust outlet socket. Make sure there is no Cooling System Flushing and
sand or other particles in it and that it is not obstru~cted Engine Internal Lubrication
so that water can leave the engine. Clean tu~beand fit- Cooling system ha~sto be flushed with fresh water to
ting (on exhaust outlet) as necessary. prevent salt, sand or dirt accumulation which will clog
v CAUTION :Water in engine drain tube must be

free t o flow out, otherwise water could be trapped
in engine. Should water freeze in engine, severe dam-
water passages. This will be achieved with the flush kit
( P / N 295 500 008)
Engine must be lubricated to prevent corrosion on inter-
age will occulr. C1heckengine drain tube for obstruc- nal parts. This will be achieved by spraying SEA-DO0
tions. LUBE ( P I N 293 600 006) through air intake opening.
Â WARNING : Perform this operation in a well ven-

tilated area.
1. Clean jet pump by spraying water in its inlet and out-
let and then SEA-DO0 LUBE.
Â WARNING : Always remove tether cord cap from

switch t o prevent accidental engine starting be-
fore cleaning the jet pump area. Engine must not be
running for this operation.
2. Remove seat to allow access of cooling system.
3. Disconnect outlet hose at exhaust socket and insert
garden hose nozzle into hose end

- - -
Section 11 STORAGE
Or if equipped with a flush kit, remove dust cap from tee

fitting spigot of flush kit and attach coupler hose Make
sure coupler hose is properily locked to tee fitting spigot
. CAUTION : Never flush a hot engine. Always start
the engine before opening the water tap. Other-
wise, water will back flow through the tuned pipe into
the engine and may cause damage to internal parts.
Open water tap immediately after engine is started to
prevent overheating. Follow this procedure exactly.
5. Run the engine about five minutes at a fast idle around
3500 RPM.
CAUTION : Never run engine longer than five
minutes. Drive line seal has no cooling when wa-
tercraft is out of water.
Tee fitting spigot I 6. Remove plug from flame arrester cover.
Flame arrester
ve r
Attach other end of flush kit coupler hose to a garden

hose Do not open water tap yet.
0 NOTE : To allow a more efficient flushing on water-

craft equipped with a flush kit, install a hose pincer
(FIN 295 000 076) between T-fitting and exhaust sock-
et This prevents water from exiting through exhaulst
socket. Remove
plug
T-fittina Hose pin~cer

7. Sorav SEA-DO0 LUBE (PIN 293 600 0061 throuah -
flame arrester cover keeping engine at fast idle
Flame arrestel
w
4. Start the engine then immediately open the water tap. \
Spray SEA-DOC! LUBE here
Â WARNING : Do not touch any electrical part

when e~ngineis running.

Section 11 STOIRAGE
--,
Lubrication of engine should be done at least for one 13. Reinstall plug on flame arrester cover.
minute. After approximately half a minute, close fuel tank
valve to run engine out of fuel while lubricating. v CAUTION :Do not run the engine during the
storage period.
v CAUTION : When engine begin~st o run irreg~u~lar-

ly because of fuel starvation, immediately stop
water flow before engine dies. Severe engine damage
Watercraft Rinsing
Thoroughly rinse the watercraft hull, bilge, engine com-
coulld result if not done in this order.
partment, with fresh water
8. Close the water tap then stop the engine.
v CAUTION : Always close the water tap before

stopping the engine. Follow this procedure exact-
ly otherwise severe engine damage could occur.
Propulsion System
Lubricant in impelller shaft reservoir should be drained and
reservoir cleaned refilled with 65 mL (2.2 U.S. 021 of SEA-
9. Disconnect garden hose from outlet hose and con- DO0 synthetic 011 polyolester ( P i N 293 600 0111 75W
nect hose to exhaust socket. 90 GL5 type "C" gear lube. Refer to an authorized dealer
OR if equipped with a flush kit, press unlocking button for this operation.
to remove coupler hose. Reinstall dust ca~pover tee fitting.
10. Wipe up any residual water on the engine.
11. Remove spark plug cables and connect them on the
v CAUTION : Use only SEA-DO0 jet pump oil or
equivalent synthetic gear oil, otherwise compo-
nent se~rvicelife could be reduced. Do not mix oil
brands or types.
grounding device.
Lubricate drive sha~ftsplines through grease fitting at PTO
flywheel end with synthetic grease (PIIN 293 550 0101
CAUTION : Do not lubricate excessively. Immedi-
Spark plug ately stop when a slight movement is noticed on
\I
cables rubber boot.
Grounding
device Lubricate at seal earner grease fitting until grease IS just
coming out on engine side
Magneto h~ousing
cover v CAUTION :As soon as grease comes out the seal
immediately stop lubricating t o prevent seal dam-
age and overheating.
Remove both spark plugs and spray SEA-DO0 LUBE into

ea~chcylinder.
Crank the engine a few turns to distribute the oil onto
cylinder wall.
12 Apply anti-seize lubrica~nton spark plug threads then
reinstall them.
v CAUTION : Never leave any clothin~g,tool or other

objects near PTO flywheel and seal carrier.

Battery Disconnect hoses where shown.
Refer to BATTERY 07-03 then look for removal to remove
and clean the battery. Apply some dielectric grease (PIN
293 550 004) or petroleum jellly on battery posts and Disconnect
all exposed cable connectors.
Add distilled water if necessary then give the battery a
full charge at a maximum rate of two amperes.
Refer to BATTERY 07-03 then look for charging.
Store the battery on a wood shelf in a warm dry place
away from direct sunlight.
To prevent battery sulphatin~gand discharging, have it
charged every month.
Anticorrosion Treat~ment
Wipe off a~nyresidual water in the engine compartmenlt.
Spray SEA-DO0 LUBE over all metallic components in pincher here \
engine compartment. Water
FWI 004 013 inlet hose
Additional Recommended Protection1 .1.
Cooling system may be filled with a 50/ 50 water /anti- Raise all hoses above the highest point of tuned pipe and
freeze solution. temporarilly tie them together.
v CAUTIION : Always use ethylene-gllycol antifreeze

containin~gcorrosion inhibitors specifically re-
commended for aluminum engines.
Insert a funnel into inlet hose going to the water inlet
socket at tuned pipe. Pour about 2 liters (112 gal) of an-
tifreeze solution through the funnel.
.
0 NOTE : The engine will not have to run during this

operation.
Three hoses have to be disconnected to allow air to es-
Tie up all hoses higher than tuned pipe.
nNOTE : If hoses are not attached higher
\^ pipe, coolant will1 drain out.
- than tuned
cape and antifreeze solution to completely fill cooling sys-
tern water jackets Hold hoses
Water inlet hose
Install a hose pincher on water injection hose
to01 004 024

Section 11 STORAGE
.-
The following steps should be performed to provide the If the watercraft is to be stored outside, cover it with an
watercraft enhanced protection. opaque tarpaulin to prevent sun rays and grime from af-
Remove muffler and drain out as much water as possi- fecting the plastic components, watercraft finish as well
ble. Reinstall muffler. as preventing dust accumulation.
OR : Disconnect one hose from muffler and pour some CAUTION :The watercraft must never be left in
antifreeze liquid inside muffler. Reconnect hose. water for storage.
Lubricate the throttle cable with SEA-DO0 LUBE. The seat should be partially left opened during storage.
This will avoid engine compartment condensation and
0 NOTE : A cable hber can be used on throttle cal-

ble end to inject SEA-DO0 LUBE. Refer to a mo-
possible corrosion.
torcycle parts supplier for availlability.
0 NOTE : If the watercraft is stored outside with seat
partially opened and without a tarpaulin, remove
the rear drain plug in order to avoid water build up in the
bilge during rainfall. Tilt the watercraft to the rear so that
Cable lube6 water can flow out of floorboard.
Clea~nthe bilge with hot water and mild detergent or with

bilge cleaner. Rinse thoroughly. Lift front end of water-
craft to completely drain bilge If any repairs are needed
to body or to the hull, touch up paint such as ma~uvepaint
[ P I N 293 500 0201 and Gelcote@repair kit (P/N 295
500 009) are available. Replace damaged labels/decals.
0 NOTE : Bilge cleaning should be done prior anticor-

rosion treatment.
Wash the body with SEA-DO0 CLEANER 1lPiN 298 850
000) or soap and water solution (only use mild deter-
gent) Rinse thoroughly with fresh water. Remove ma-
rine organisms from the hull. Apply a nonabrasive wax
such as silicon wax.
CAUTION : Never clean apparent fibergllass and
plastic parts with strong detergent, degreasing
agent, paint thinner, acetone, etc.

-- -
Section 12 TECHNICAL DATA
TECHNICAL DATA
S F METRIC INFORMATION W I D E
I LEGEND BASE UNITS
ATDC : After top dead center DESCRIPTION UNIT SYMBOL
length meter
mass kilogram
force newton
ignition liquid liter
temperature Celsius
N.A. : Not available pressure kilopascat
torque newton-meter
RIPM: Revolutions per minute land velocity kilometer per hour
navigation velocity knot
STD : Standard
PREFIXES
VR01 : Variable ralte oil injection
P1REFIX SYMBOL MEANING VALUE
kilo k one thousand 1000
centi c one hundredth of 0 01
milli rn one thousandth of 0.001
micro one millionth of 0 000001
rp p CONVERSION FACTOlRS
TO CONVERT TO 0 MULTIPLY BY
in mrn 25 4
in cm 2 54
In2 cm* 6 45
in3 c rn3 16 39
ft m 03
02 g 28 35
Ib kg 0 45
Ibf N 44
Ibf-in N-rn 0 11
Ibfaft N-rn 1 36
Ibfeft Ibf-in 12
FSI kPa 6 89
imp oz U.S. 02 0 96
imp oz mL 28 41
imp. gal U.S gal 12
imp gal L 4 55
U.S 02 mL 29 57
U.S. gal L 3 79
knot MPH 1 15
MPH krn/h 1 61
Fahrenheit Celsius ( O F - 32) x 5/9
Celsius Fah~renheit O C x 9/51 + 32
T h e international system of units abbreviates Sl in all languages

@ To obtain the reverse sequence, divide by the given factor To convert miliimeters to
inches, divide by 2 5 4
0 NOTE : Conversion factors are rounded off to two decimals for easier use

Sub-section 01 (SP 5805, XP 5851 MODELS)
SP 5805, XP 5851 MODELS

ENGINE S? (5805) XP (5851)
Engine type Bombardier-Rotax 587, water cooled
Indluction type Rotary valve
Exhaust system TYpe Water cooled, water injected
Water injection fitting size 1 5.5 mrn (01.217 in) 4.6 mrn l.181 in)
Starting system Electric start
Lubrication Fuel 1 Oil mixture VROI (Variable rate oil injection)
Oil injection pump Gear
Oil type SEA-DO0 infection oil
Number of cylinders 2
Bore Standard 76 0 mrn ( 2 992 in)
First oversize 76.25 rnm (3.002 in)
Second oversize I 76.50 rnm (3.012 in1
Stroke 64 mm (2.520 in)
Displacement 580.7 cm3 (35.4 in3)
compression ratio (uncorrectedl 11.5: 1
(corrected) 5.9: 1
Engine maximum torque
I Ring / piston groove

clearance
Piston/cylinder wall
1 New
Wear limit
1 New
0.05 - 0.08 mrn (.a02 - ,003 in)
0.2 mrn (.OD8 in)
0.05 - 0.07 mm f.00'2 - ,003 in1
clearance Wear iimit 0.2 rnm (.a08 in)
Cylinder taper (maximum) 0 08 mrn (.003 in)
Cylinder out of round llmaximum) 0.05 mrn ( 002 in)
Connecting rod big New 0 39 - 0.74 mrn ( 015 - ,029 in)
end axial play Wear limit 1.2 rnrn ( 047 in)
Crankshaft deflection 0.08 mrn (.003 in1
Rotary valve timing
I Opening
1 80Â ATDC 1
I
65' 'Â¥
- 3
BTDC 1
1 Rotary valve plate opening
I I
147O
Crankcasecretary value gap 0 2 2 - 0.35 mrn (.DO9- .014 in)
Connecting rod radial New 0.0201 - 0.033 mrn (.0008 - ,0013 in)
clearance Wear limit 0.050 mrn (.002 in1
12-01-1
Sub-Section 01 (SP 5805, XP 5851 MODELS)
1 ELECTRICAL (engine)
-
I
I
SP (5805) i
XP (5851)
Magneto generaltor output , 160 W @ 6000 RPM
1 Ignition system, type I CD'I, 415 p
Spark plug Make and type 1 NGK BR7ES
1 Gap 1 0.5 mrn (.020 in)
Ignition timiing 1 BTDC 1 2.65 rnm <.104.in)(21O Â 1)
1
3
Engine
- speed (cold1 1
a
6000 RPM
Generatina coil 1 4 0 - 76 12
Battery charging coil 0 5 - .6 (1
Hiqh tension coil 1 Secondary 9 - 15KO
1 Engine RPM limiter operation
- - -
1 6550 Â 100
ADDITIONAL INFORMATION .
CARBURAT10N SP (5805) XP (5851)

Carburetor Type Diaphragm
Quantity 1 2
Main jet 125 107.5
Pilot jet 67.5 62.5
Low-speed mixture 1 turn Â 114 1-1/4 turn Â 114
Ad[ustment screw 11
High-speed screw 0
Idle speed (in water) 1400 RPM
Idle speed (out of water) 2400 RPM 3000 RPM
Fuel Type Regular unleaded
Octane no. 87 (Ron + Monlf2
Fuel return line orifice 0.5 mrn (0.020 in) 10.5 mrn (0 020 in) (PTO side
Leak test (pop off pressure) 150-200 kPa (22-29 PSI)
, ADDITIONAL INFORMATION :
COOLING SP (5805) XP (5851)

Tvoe Open circuit - Direct flow from jet propulsion unit
1 Thermostat 1
I
None
Overheatina beeper settina 96-99 OC (205-211O a F)
- - --
1 2-01-2 Page: 238 See Doo 1992 Shop Manual - http://www.ReadManuals.com

Sub-section 01 (SP 5805, XP 5851 MODELS)
PROPULSION SP 45805) XP (5851)

Propulsion system Bombardlier Formula pump ,
1 Jet pump type Axial flow single stage
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
1 Coupling type ! Crown splines 1
Oil type SEA-DO0 JET PUMP SYNTHETIC OIL
Polyolester 75W90 GL5 (PIN 293 600 01 1)
Steering nozzle pivoting angle 26'
1
- 1
Trim nozzle pivotinlg angile
Minimum required water level 1
N.A.
60 cml 424 in)
Â 1O0
1
Drive shaft deflection maximum 0.5 mrn ( - 0 2 0 in)
Impeller outside diameter 139.5 mm (5.490 in)
N
'
I Impeller/wear ring
clearance
Wear limit (performance)
Wear limit
0.5 t.020 in)
1.02 mrn (.040 in)
Impeller shaft end play (new) 0.12 - 0.54 mrn ("005 - ,021 in1
"
N Impeller shaft side play 0.05 mm t.002 in)
I
T Impeller pitch / material 1 8 O /aluminum 19Q/stainlesssteel
ADDITIONAL INFORMATION . Do not mix different trademarks or type of oil.
1
I
DIMENSIONS 11
SP (5805) I
XP (5851)
- (driver incl.)
Number of oassaqer u
2
Lenath,
" . overall 244 crn (96 in) 1
I
I
Width, overall 105 crn (41.5 in)

1 Heiahf, overall I
I
92 cm (36.2 inl
Mass 166 kg (365 Ibl
Load limit 1 160 kg (352 Ib)
Hull Composite
Air intake silencer Thermoplastic
M
Multi-layer wire screen
- Flame arrester
A
T
E Exhaulst muffler Aluminum
R
I Steering paddin~g Thermoplastic elastomer with polystyrene foam
A
L Fuel tank I
Polyethylene
Injection oil tank I Polyethylene
Seat- -
1 Polyurethane foam
ADDITIONAL INFORMATION :
12-01-3
Sub-section 01 [SP 5805, XP 5851 MODELS)
PERFORMANCE SP (5805) XP (5851)

Pump static thrust 170 kg (375 lbÃ
I 200 kg (441 Ib)
Max. fuel consumption at wide open throttle 20.8 U h (5.5 U.S. gallhl 1 22.7 L l h 16 U.S. gallhi
Cruising time at Fuel tank without reverse 1 hour 45 minutes 1 hour 20 minutes
full throttle Fuel tank reserve 20 minutes 13 minutes
ELECTRICAL (vehicle) 1 SP (5805) 1 XP (5851)

Battery j 12 V, 19 Aeh
Starti~ngsystem fuse 5A
Charging system fuse 15 A
CAPACITIES SP (5805) XP (58511

Fuel tank 33 L (8.7 U.S. galit
Impeller shaft reservoir Capacity 65 mL (2.2 U.S. ozl
I
Oil level height
- , To bottom of cover hole
Injection oil tank 2.8 L (95 U.S. fl ozt
STANDARD EQUIIPMENT SP (5805) XP (5851)

Tether cord STD
Tool kit STD
Fuel tank reserve STD
Overheating warning device STD
Electric fuel level gauge N.A. STD
Injection oil low level warning device N.A. STD
Tachometer N.A. STD
Variable trim system 4VTS) N.A. STD
Reverse N A.
Storage compartment STD
Rear grab handle N .A STD
Extinguisher holder STD
12-01-4
-- -

Slub-Section 01 (SP5805, XP 5851 MODELS)
TIGHTENING TORQUES SP (5805)and XP (5851)

Exhaust manifold, screws (8) 24 N*m (18 lbf*ftl
Magneto ring nut 105 N*m (77 Ibf*ftl
1 Flywheel (PTO side) 1 110 N * m (81 lbf*ftl 1
1- crankcase screws 1 M6
I
9 N*m (80 Ibfain) I

1 M8 2 4 N*m (18 lbf*ft)
Clrankcaselenqine support nuts 35 N*m (26 Ibfeft)
I Engine support/ hull 25 N*m (18 ilbf*ft) ( 11 I
Cylinder head screws 24 N*m (18 lbf*ft) (3)
Crankcase1cylinder screws I
Tuned oioe flanue nuts 1 25 N I * ~(18 lbf-ft) 1

Tuned fixation screws
Cylinder head cover screws
Steering cable nuts 10 N*m ( 8 8 lbf*in)

Steering support screws 15N.m (11Ibf*fti (1)
I Steering collar screws 5 N*m (44 lbfein) (1
I Steerina stem screw 40 N*m (29 lbf*ft) (2)
I
1 Handlebar saddle screws, nuts
Reverse gate 1 Venturi N .A. I
Cable / Reverse glate N .A.
E Ignition housing cover 4 N*m (35 Ibf*in)

L Starter mounting screws 22 N*m ( 1 6 1IbWt1 (21
7 N*m (62 tbfmin)
c . Starter lock nuts
T Spa~rkplug 2 4 lN*m ( 1 8 lbfaft)
R
ADDITIONAL INFORMATION : Apply where indicated ( 11 Loctite 242 I

,
(2) Loctite 271
(3) Loctite 515
12-01- 5
Sub-section 02 (GTS 5812, GTX 5860 MODELS)
GTS 5812, GTX 5860 MODELS

1 ENGINE I GTS (5812) GTX (58601 1
Engine type Bombardier-Rotax 587, water cooled
Induction type Rotary valve
Exhaust system Type Water cooled, water injected
Water injection fitting size 1 4.6 mrn (0.181 m l
Starting system Electric start
Lubrication FuelIOil mixture VROI (Variable rate oil injection)
Oil inlection pump i Gear
Oil type SEA-DO0 injection oil
Number of cylinders 2
Bore Standard 76.0 rnm (2.992 m l
First oversize 76.25 mrn (3.002 in)
Second oversize 76.50 mrn (3,012 in1
Stroke 6 4 rnm (2.520 in)
Displacement 580.7 cm3 (35.4 in3)
Compression ratio (uncorrected) 11.5: 1
(corrected) 5.9 : 1
Engine maximum torque 64 N*m 447 lbfeft) 65 Nern (48 Ibf*ftl
@ 5500 RPM @ 5750 RPM
Cylinder head warpage N.A.
Piston ring type and quantity 1 Semi-Trapez - 1 Rectangular
Ring end gap New 0.25 - 0.40 rnm (.010 - ,016 in)
Wear limit 1 .OO mm (.039 in)
Ring / piston groove New 0.05 - 0.08 rnm (.a02 - ,003 in)
clearance Wear limit 0.2 mm (.OD8 in)
Piston 4 cylinder wall New 0.05 - 0.07 rnm (.002 - ,003 in)
clearance Wear limit 0.2 mm (.Of38 in)
Cylinder taper (maximum) 0.08 rnm (.003 in)
Cylinder out of round (maximum1 0.05 rnm (.a02 in)
Connecting rod big New 0 39 - 0 74 rnm (.a15 - ,029 in)
end axial play Wear limit 1 . 2 mrn ( 047 in)
Crankshaft deflection 0.08 mrn (.a03 in)
Rotary valve timing
1 Opening
1 Rotary valve date opening 1 147' 1

Crankcase/rotary valve gap 0.22 - 0.35 n u n (.009 - 014 in)
Connecting rod radial New 0.020 - 0.033 mrn (.0008 - 001 3 in)
clearance Wear limit 0 050 rnm (.002 in)
Page: 242 See Doo 1992 Shop Manual - http://www.ReadManuals.com 1 2-02-11

--

Slub-Section 02 {GTS 5812, GTX 5860 MODELS)
1 ELECTRICAL (engine)
- , GTS (5812) ,I GTX (5860)
Maqneto generator output 160 W @ 6000 RPM
Ignition system, type I CDI, 415 p
Spark plug 1 Make an~dtype I NGK BR7ES
1
I1 Ignition timing
Generatinq coil
1
BTDC
Engine speed (cold) 1
I
2.65 mrn 1.104 in) (21' Â 1)
6000 RPM
40 - 76 0
I
Battery charging coil .05- - 6 Q

Hiqh tension coif 1 Secondlary 9-15KQ
1 Enqine RPM limiter operation1 1 6550 Â 100
CARBURATIOlN GTS (58l12) GTX (5860)

Carburetor 1 Tvoe Diaohraarn
- --
[ Quantity 1 2
Main jet I 125 107.5
Pilot jet 67.5 62.5
I
Adjustment Low-speed mixture 1 turn Â 114 1-1114 turn Â 1/4
screw
1 Hiahi-soeed screw
- -
Idle speed (in water) 1400 RPM

Idle speed (out of water) 2500 RPM 2800 RPM
Fuel Type Regular unleaded
Octane no. 87 (Ron + Monl/2
Fuel return line orifice 0.5 mm (0.020 in) 10.5 rnm (0.020 in) (PTO side
Leak test (pop off pressure) 150-200 kPa (22-29 PSI!
ADDITIONAL INFORMATION 1
1 COOLING I
GTS (58121 GTX (5860)
Open circuit - Direct flow from jet propulsion unit.
Thermostat None
1 Overheatinq beeper setting 1 96-99OC 4205-21OÂ°F
12-02-2
Sub-Section 02 ( G T S 5812, GTX 5 8 6 0 M O D E L S )
PROPULSION GTS (58121 GTX (5860)

Propulsion system Bombardier Formula pump
Jet pump type Axial flow single stage
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
Coup l i n ~
type 1 Crown spli,nes
Oil type SEA-DO0 JET PUMP SYNTHETIC OIL
Polyolester 75W90 GL5 ( P i N 293 600 01 1 )
Steering nozzle pivoting angle 26'
Trim nozzle pivoting angle N .A
Minimum required water level 90 cm (36 in1
Drive shaft deflection maximum 1 0.5 mm 1.020 in)
Impeller outside diameter 1 139.5 mrn (5.490 in)
Impeller/wear ring Wear limit (performance) 0.5 (.a20 in)
clearance Wear limit 1.02 rnm (.040 in)
~lmpellershaft end play (new) 0.1 2 - 0.54 mrn (-005 - ,021 in)
Impeller shaft side play 0.05 mm (.002 in)
Impeller pitch / material 18.3' /aluminum 17' /stainless steel
ADDITIONAL INFORMATION : Do not mix different trademarks or type of oil.
DIMENSIONS I
GTS (5812) I
GTX (5860)
Number of oassaaer (driver inclI.1 3
Lenath. overall 1 303 cm (1 19.3 in)
Width. overall1 1 121 crn (47.6 in)
Height, overall 95 cm (37.4 in)
Mass 209 kg (461 Ib)
Load limit 225 kg (496 Ib)
1 Hull Composite
1 Air intake silencer 1 Thermoplastic
Miulti-layer wire screen
Exhaust muffler Aluminum
Steerina oaddina Thermoplastic elastomer with polystyrene foam
1 Fuel tank 1 Polyethy lene
1 Injection oil tank 1 Polyethylene
I Seat
12-02-3
Sub-Section 02 (GTS 5812, GTX 5860 MODELS)
PERFORMANCE GTS (5812) I GTX ( 5 8 6 0 )

Pump static thrust
Max. fuel consumption at wide open th~rottle
Cruising time at Fuel tank without reverse
full throttle Fuel tank reserve
ADDITIONAL INFORMATION
ELECTRICAL (vehicle) 1
I
GTS (5812) 1
I
GTX (5860)
Battery 12 V, 19 Aeh
Starting system fuse 1 5A
Charging system fuse 1 15 A
CAPACITIES GTS ( 5 8 1 2 ) GTX (5860)

Fuel tank 33 L ( 8 7 U.S. gal)
Impeller shaft reservoir Capacity 65 mL (2.2 U.S. 02)
Oil level height To bottom of cover hole
Injection oil tank 2.8 L (95 U.S. fl oz)
ADDITIIIONAL INFORMATION ,
STANDARD EQUIPMENT 1 GTS (5812) 1 GTX (5860)

Tether cord 1 STD
Tool kit 1 STD
Fuel tank reserve 1 STD
Overheating warning device 1 STD
Electric fuel level gauge 1 OPT. 1 STD
Iniection oil low level warning device 1 OPT, 1 STD
Tachometer 1 N .A. 1 STD
Variable trim system N T S t 1 N .A.
Reverse 1 STD
Storage compartment ST D
Rear grab handle ST D
Extinguisher holder STD
12-02-4
Sub-Section 0 2 (GTS 5812, GTX 5860 MODELS)
TIGHTENING TORQUES GTS (5812) alnd GTX (5860)

Exhaust manifold, screws 181 24 N*rn ( 1 8 lbf.ft1
Magneto flywheel nut 105 Nmm (77 lbfoft)
Flywheel (PTO side) 110 N*m (81 Ibf*ft)
9 N.m (80 Ibf-in)
E M8 24 N*m (18 Ibfoft)
N
Q Cra~nkcaselenginesupport nuts 35 Nmrn (26 Ibfoft)
'
E I
Engine support1 hull
Cylinder head screws
25 N*m
24 N.m
(18 lbfoft)
(18 Ibf*ftl
(1)
(31
1 Crankcase1cylinder screws 24 N*m (18 lbfmftt (3)
1 Tuned pipe fllanqe nuts
I Tuned pipe fixation screws I
Cylinder head cover screws 1
1 Flame arrester screws 1 10N.m (88Ibf.in) (11
Impeller on shaft 70 N*m (52 I b f W (21
P u ~ Dhull
/ 35 Nmrn (26 Ibf*ft) (1)
1
I
I
- Venturi 1 housino 25 N*m (18 lbfeftt (1)
I
11
I 20 N*m (15 lbf-ftl (1 l

1 ~ o u s i n acover
w J,
M 1 7 Norm (62 Ibfmin) (1)
I
1 Steerina cable lock nuts
I
10 INmm (88 llbf*in) 1
Steering support screws 15 Nmrn ( 1 1 Ibf-fti (1) I
Steering collar screws 5 N*m ( 4 4 lbf*in) ( 1)
I
Steerina" stem screw 40 N*m (29 Ibfnft) (2)
1 Handlebar saddle screws, nuts
I
26 N m (19 Ibf*ftl
Reverse gate / Venturi 20 N.m I15 lbf*ftl
N
6 Cable1 Reverse gate 7 N*rn (62 lbfoin)
E Ignition housing cover 4 N*rn (35 lbf*in)
'
L
c
Starter mounting screws
- Starter lock nuts

22 N*m
7 N*rn
(16 Ibf*fti
(62 Ibf-in)
(21
T Spark plug 24Nwrn (18lbfmftl

R
ADDITIONAL INFORMATION . Apply where indicated < I Loctite 242 >

I ( 2 ) Loctite 271
( 3 ) Loctite 51 5
---

Section 13 TROUBLESHOOTING
-1
TROUBLESHOOTING
The following chart is provided to help in diagnosing the probable source of troubles.
ENGINE WILL NOT START

-- -
OTHER OBSERVATION POSSIBLE CAUSE REMEDY

Engine does not turn over Tether cord removed Reinstall
Fuse open 0 Check wiring then replace fuse
Discharged battery Check / recharge
Battery connections 0 Checklcleanl tighten
0 Water 1fuel hydrolock 0 Check, refer to section 03-01
Starter or solenoid Check, refer to section 07-04
Seized engine 0 Checkjrepair as needed
0 Seized jet pump Check, refer to section 08-01
Jammed pump Checkjclean out debris
Engine slowly turns Discharched / weak battery 0 Check/charge/replace
0 Restriction in jet pump Checklclean pump
0 Seizure in jet pump 0 Inspect, refer to section 08-01
Seal carrier seizure 0 Check, refer to section 08-01
* Partial en~ginehydrolock 0 Check, refer to section 03-01
* Partial engine seizure 0 Check compression, refer to
section 03-03
Engine turns over * Fuel tank empty 0 Refill
0 Fuel water-contami~nated 0 Renew supply
* Dirty fuel filter 0 Clean /replace
0 Fouled spark plugs 0 Replace
* Water in engine Check, refer to section 03-01
* Misuse of choke (fuel flooded) 0 Use only with cold engine
Carburation 0 Check, refer to section 05-03
0 Ignition 0 Check, refer to section 07-02
and 07-06
* Engine flooded 0 Check, refer to section 05-03
- Needle valve stuck open

E N G I N E MISFIRES, RUNS IRREGUILARLY

I OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Weak spark * Fouled, defective, worn spark plugs Checktverify heat rangelreplace
* Faulty RPM limiter * Check, refer to section 07-06
* Faulty ignition * Check, refer to section 07-06
Lean fuel mixture * Fuel level low * Checklrefill
Stale or water fouled fuel Checkisiphon and refill
e Fuel filter dirty or restricted * Checklclean 1replace
* Carburation dirty or out of * Check/clean/adjust, refer to
adjustment section 05-03
e Leaking cranksha~ftseal, * Check4 test1 replace, refer to
magneto or PTO engine section 03-05
* Fuel valve restricted Check/repilace
Filter in fuel tank restricted Checklreplace
* Loose carburetor * Tighten carburetor
Partially closed choke * Checkiadjust choke cable
* Flame arrester dirty or restricted Check/ clean /replace
Carburetor adjustment or setting Checklcleanladjust, refer to
section 05-03
* Main jet loose * Check, refer to section 05-03
Main jet O-ring damage * Checklreplace, refer to section
05-03
Rotary valve shaft seal leaking Checklreplace, refer to section
03-06
* Oil pump adjustment Checkladjust, refer to section
06-02
Watercraft transportation * Turn fuel valve to OFF
Difficult to start * Incorrect rotary valve timing * Checkiadjust, refer to section
03-06

--
ENGINE OVERHEATS
Overheat beeper sounds Restricted jet pump water intake 0 Check/clean
Cooling system restriction Check/flush, refer to section
04-03
1 0 Carburetor adjustment Checklclean /adjust, refer to
section 05-03
Grounded temperature sensor or 0 Check/replace/repair
sensor wire
ENGINE CONTINUALLY BACKFIRES

OTHER OBSERVATION
Weak spark
Ignition timing
POSSIBLE CAUSE
Fouled, defective spark plugs
RPM hmiter malfunction
Incorrect setting
Flywheel key sheared

I
REMEDY
*
0
0
Clean / replace
Checklreplace, refer to section
07-06
Check/ reset, refer to section
07-02
Check/replace
I Rotary disc valve
Carburetor 0
Timing incorrect
Carburation too lean

0 Check/ reset, refer to section
03-06
05-03
ENGINE DETONATION OR PINGING

OTHER OBSERVATION 1 POSSIBLE CAUSE
r I
REMEDY
I
I Ignition 0
*
Timing too far advanced
Spark plug heat range too high to correct range
r Engine temperature 0 Engine overheating
Poor quallity fuel

Check, refer t o section 03-01
and 04-01
Use good quality fuel
1
I

-- -
ENGINIE LACKS ACCELERATION OR POWER

* Weak spark 0 Check/replace, refer to section
07-06
Carburation, jetting too rich /lea~n * Check /reset / rejet, refer to section
05-03
Throttle does not reach full open * Check readjust
0 Low compression * Check repair, refer to section
03-03
0 Exhaust system restriction * Check clean
Water in glas or oil * Check siphon / replace
* Debris in needle valve 0 Check clean, refer to section
05-03
E N G I N E RUNS TOO FAST

OTHIER OBSERVATION 1 POSSIBLE CAUSE 1 REMEDY
Faulty RPM limiter 0 Check, refer to section 07-06
Jet pump cavitation 1 0 Damaged leading edge of impeller 1 * Check/replace
0 NOTE : Leading edge damage
contributes t o poor perfor-
mance from start. Training edge dam-
age contributes to poor top perfolr-
mance and stator vane erosion.
Jet pump ventilation 0 Pump housing or ride shoe air * Checklreseal, refer to section
Ileak 08-01
ABNORMAL NOISE FROM PROFUSION SYSTEM

OTHER OBSERVATION 1 POSSIBLE CAUSE 1 REMEDY
* Weeds/debris caught in pump
intake or impeller
* Low oil level in pump housing * Check/troubleshoot source of
leakirefill supply, refer to section
08-01
* Damaged or bent driveshaft Checkireplace, refer to section
08-01
Broken motor mounts 0 Check/replace, refer to section
03-02

INDEX
PAGE
ALIGNING TOOL .................................................................................................01-0 1-9
ALIGNMENT TOOL ........................................................................................... . 0 1-014
ANTICORROSION TREATMENT ........................,................................................... 1 1-00-4
ARMATURE PLATE ............................................................................................ 03-04-5
BATTERY ........................................................................................................ .07-03-1

BATTERY CHARGING COIL .............................................................................. 07-%-l2
BEACH WHEELS .............................................................................................. 01-01-23
BEARING ......................................................................................................... . 0 3 45-4

BEARING REMOVER ......................................... ,................................................. 01-01-4
BEARING ROTARY SHAFT ........- ....................................................................... .Oi-O6-5
BEARING SEPARATOR ..................................................................................... 01-QIIO

BEARINGISEAL INSTALLER .............................................................................. 01-01-17
BODY REPAIR ..........................................................................................,.........I041-6
BOMBARDIER IGNITION TESTER ........................................................................O1-0 1-1

BOTTOM END ...................................................................................................OW -1
BRUSH HOLDER ...............................................................................................
.O7-0 4-5
CARBURETOR SYNCHRONIZATION .....................................................................0543.7
CARBURETORS ................................................................................................ .05-03 8-1

CARE ..............................................................................................................
.O4-03-2
CDI .................................................................................................................
.O7.O 6.1
CENTERING TOOL .............................................................................................01-Ol9.
CHARGING COIL ..............................................................................................

.O7.0 5.3
.......................................... 0746-l7
CHARGING SYSTEM RELAY ...................................
CHARGING SYSTEMS ........................................................................................ . 0 7 46.1
CHECK VALVE ..................................................................................................

05434
Page: 251 See Doo 1992 Shop Manual . http://www.ReadManuals.com

INDEX
PAGI
CHOKE VALVE .................................................................................................. 05-03-4
CIRCLIP ............................................................................................................0343.9
CIRCLIP INSTALLER ......................................................................................... . 0 3 43.9
CONNECTING ROD ............................................................................................0345-5
COOLING SYSTEM ............................................................................................. 04-02-1
COOLING SYSTEM FLUSHING.............................................................................04.0 3. 1
COOLING SYSTEM PROTECTION .........................................................................

11-00-4
CRANKCASE .....................................................................................................
.03-04-5
CRANKSHAFT ..................................................................................................
. 0 1 45.2
CRANKSHAFT ALIGNMENT ................................................................................03845-6
CRANKSHAFT DEFLECTION ............................................................................. .03.0 5.6
CYLINDER .......................................................................................................
. 03-03
CYLINDER HEAD ............................................................................................03-03- 11

CYLINDER HEAD COVER .................................................................................03-03-1 1
DEGREE WHEEL .............................................................................................. .01.0 1.1
DIAL INDICATOR .............................................................................................-01-01-7
DISTANCE GAUGE ............................................................................................-01-01-5
DISTANCE SLEEVE ...........................................................................................

.03.0^
DOLLEY .........................................................................................................
0 1-01-23
DRIVE SHAFT ..................................................................................................

08-01-14
ELBOW FITTING ...............................................................................................-04-03-1
ELECTRICAL....................................................................................................
.07.0 0.1
ELECTRICAL STARTER .....................................................................................

. 0 7 44.1

INDEX
PAGE
ELECTRONIC IGNITION .....................................................................................
. 0 7 42.1
ENGINE DRAINING ............................................................................................11-00-1
ENGINE INTERNAL LUBRICATION ......................................................................11-00-1
ENGINE LIFTING DEVICE .................................................................................Ol-01-12
ENGINE SPEED LIMITER ...................................................................................-0746-5
ENGINE S'TOP SWITCH ......................................................................................

017-06-6
FILTER .............................................................................................................
05-03.4
FITTING REMOVER...........................................................
.................,..............01-01-21
FLUSH KIT .......................................................................................................
-01-01-8
FUEL LEVEL SENSOR .......................................................................................

-07-08-1
FUEL SENSOR ..................................................................................................

-05-03-8
FUEL STABILIZER ............................................................................................. 1 1-00-1
FUEL SYSTEM ...........................,.......................................................................
.OS-OO -1
FUEL SYSTEM PRESSURIZATION ......................................................................

105-03-14
GEAR HOLDER ................................................................................................

01-01-14
GELCOAT REPAIR .............................................................................................

1041-6
.,......................................
GENERATING COIL.................................................... .Q745-2
HACKSAW ......................................................................................................
01-01-19
HANDLEBAR.....................................................................................................O9-O 1-4
HOSE/PINCHER ...............................................................................................
01-01-13
HULL INSERT................................................................................................ 0&-01-25

.,.............................................................................
HULL/BODY ........................ 10-00-1
IDLE SPEED SCREW .........................................................................................

105-03-11
IGNITION ........................................................................................................
07-06- 10
IGNITION COIL.-. .............................................................................................

(37-06-5

INDEX
PAGE
IGNITION COIL OUTPUT ................................................................................... -07-06-0

IGNITION COVER ............................................................................................. -03-04-2
IGNITION HOUSING .................................................,......................................... .03-04-6
IGNITION HOUSING COVER ............................................................................... .O3-04-7
IGNITION RELAY ........................................................... ,....................................07-06-6

IGNITION SYSTEM VERIFICATION ................................. .,................................... .07-O6-5
IGNITION TESTER ............................................................................................ .O7* -8
IGNITION TIMING ........................................................................................... .07-02.1

IMPELLER ...................................................................................................... 08-01-15
IMPELLER HOUSING.......................................................................................... 08-01-6
IMPELLER HOUSING REMOVER ........................................................................ 01 -01-20
IMPELLER REMOVER ....................................................................................... .03-04 -38
IMPELLER SHAFT............................................................................................ 08-011-116
IMPELLER SHAFT GUIDE .................................,................................................ 01 -01-17
IMPELLER SHAFT HOLDER ..............................................................................01-01-1 6

,
IMPELLER/PTO FLYWHEEL REMOVER/INSTALLER .............................................. 0 1-0 1-3

INSTRUMENTS ..................................................................................................07-08. 1
INTAKE .................................................................................................. ..........0543.2

JET PUMP .........................................................................................................08-01-1
JET PUMP NOZZLE .............................................................................................09-01-5
LABYRINTH SLEEVE ........................................................................................ -03-05-8

........................................................
LIFT KIT .................................................. 01-01-24
LOW SPEED MIXTURE SCREW ..........................................................................

05-03-1 1
MACHINIST'S SQUARE ............................................... ...................................... 01-01-19
MAG FLYWHEEL ...............................................................................................
03-04-4

1rn'EX
PAGE
MAGNETO ......................................................................................................
0746-1 1
MAGNETO FLYWHEEL ...................................................................................... 0 3 4 4-4
MAGNETO FLYWHEELS IDENTIFICATION ...............*.................,..........................07-05-4
MAGNETO SYSTEM ...........................................................................................07-05-1

MAIN JET ................................................................................ ............
., ,....-.....a . 0 5 43-6
MAIN JET SCREW ............................................................................................ 0543-1 1
MXRQR ....................... ...............,......,..............................................................0'1-01-11
MPEM TESTING .................................................................................................07-06-7
MULTI PURPOSE ELECTRONIC MODULE ............................................................ -07-06-5
NEEDLE BEARING............................................................................................. 0343-4
NEEDLE VALVE.. ..............................................................................................05-03-3
NEED'LEVALVE LEVER .................................................................................... .05-03-4
NOZZLE ..........................,............................................................................... 08-01-28

OIL INJElCTION PUMP .................,....................................................................... 0642- 1
OIL LEVEL SENS'OR........................................................................................... 0 7 48-1
'OIL PUMP GEAR ................................................................................................ M-02-2

OIL SYSTEM..................................................................................................... .Q6-OQ-1
PAINTING ......................................................................................................... 10-01-7
PILOT JET ......................................................................................................... 0.5-03-6

PISTON CIRCLIP INSTALLER ... ......................................................................... .0141-2
,.
PjSTON PIN PULLER .........................................................................................-03-03-3

PISTON, PISTON PIN, ROLLER BEARINlG ..............................................................03-03-7
PISTON,PISTON PIN,,CJRCLIP, NEEDLE BEARING ................................................-03-03-3
PLIERS .......................................................................................... ................ 01-01-13

,.
-~-.'
PRESSURE TEST ............................................................................................... .(I543-5
Page: 255 See Do0 1992 Shop Manual . http://www.ReadManuals.com

PAGE
PROPULSION ................................................................................................... .O$-M.I
PROPULSION SYSTEM ........................................................................................ 11-00-3
PTO FLYWHEEL ............................................................................................... -03-04-3

PULLER PLATE .................................................................................................Ol-O 1-3
PUMP VERIFICATION........................................................................................
.05-Q3-3
PlJMP GAUGE TESTER ............................. ....................................................... 01-Q1-15

.,
PUMP PRES'SURIZATION...................................................................................08-01-22
PUSHER ...........................................................................................................
-01-01-5
REAR BAFFLE .................................................................................................. .lo-0 1-3
RECTIFIER/REGULATOR .................................................................................. 07-M-11
RESISTANCE MEASUREMENT ........................................................................... 07-06-13
REVERSE GATE ..................,..............................................................................

-08-02-3
REVERSE HANDLE ...............,............................................................................

.08-02-2
REVERSE SUPPORT PLATE .................................................................................

08-02-3
REVERSE SYSTEM .............................................................................................08-02-1
RIDE SHOE .......................................................................................................0841-9

RIDE SHOE REMOVER......................................................................................
0 1-0 1-20
RING COMPRES'SQR..................................................................................,.........01-OJ -7
RlNG GEAR .......................................................................................................

0344-5
ROTARY VALVE ................................................................................................

03-06-1
ROTARY VALVE AND ROTARY VALVE COVER CLEARANCE................................. 03-06-6
ROTARY VALVE C W E R ....................................................................................03-06-4

ROTARY VALVE IDENTIFICATION ....................................................................
03-06-11
ROTARY VALVE SHAFT .....................................................................................

03-06-4
ROTARY VALVE TEMPLATE ............................................................................03-0612
Page: 256 See Do0 1992 Shop Manual . http://www.ReadManuals.com

PAGE
RUBBER PAD ..................................................... ............................................. .'OI-O 1-2

.,
SCRAPER ........................................................................................................ 01-01-19

SEAL CARRIER ................................................................................................ 08-011-24
SEAL PULLER ................................................................................................. O 1-01- 188
SEAT ................................................................................................................ 1041-5
SHOP LAMP ........................................,........m.....................................b.............
01-01-23
SINGLE CARBURETOR .....................................................................................05-03-10

SLIDE HAMMER ..............................................................................................0141-1 1
SOLENOID SWITCH ............................................................................................07-04-6
SPARK PLUG CAPS .......................................................................................... 07-06-10
SPARK PLUGS ................................................................... .,.......*...................... 7-1
SPARK TESTER .................................................................................................-01-01-8

STEERING SY S'TEM............................................................................................
094 1-1
STEERINGIJET PUMP ALIGNMENT TOOL ...........................................................Ql-QJ

-22
STORAGE ................................................................................,.........................11-00-1
STROBOS,CClPIC TIMlNG LIGHT ...........................................................................01-01-7
TACHOMETER ..................................................................................................0 1-01-8
TDC GAUlGE....................................................................................................
03-06-13
TECH.NICALDATA ............................................................................................12-W-1
TERMINAL REMOVER ......................................................................................0141-1 1
TETHER CORD SWITCH......................................................................................07-06-6
THROTTLE CABLE ..........................................................................................05-03-10

THROTTLE LEVERS .........................................................
,.................................
.05-03-7
THROTTLE VALVE ........................................................................................... 3-4

THRUST BEARING ...........................................................................................
08-01-17
Page: 257 See Do0 1992 Shop Manual . http:ll~.ReadManuals.com

PAGE
THRUST WASHER ............................................................................................ '0841-17

TIMING MARK POINTER. ................................................................................... .Ola1-8
TlMING MARK TOOL ......................................................................................... 07-02-1
TQP END ..........................................................................................................03-03-1
TOW HOOK ....................................................................................................... 1041-3
TRIM CABLE ....................................................................................................

. 0 8 43-2
TRIM RING .......................................................................................................
-08-03-4
TROUBLESHOQTJNG ..........................................................................................
13840-1
TUNED PIPE REPAIR.......................................................................................... 0 3 47-2

TWlN CARBURETORS ...................................................................................... 05-03-12
VARIABLE 'TRIM SYSTEM .................................................................................. . 0 8 43-1
VENTURJ .........................................................................................................-08-01- 9
WATER TANK TRAP .......................................................................................... 10-01-3

,
WATER'CRAF'TRINSING ......................................................................................11-00-3
WEBARRING ....................................................................................................
08-01-12
WIRIN'G DIAGRAM ............................................................................................. 0 7 4 1-2
Page: 258 See Do0 1992 Shop Manual . http:llwww.ReadManuals.com

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LoctiteB is a trademark of Loctite Corporatiion

Page: 3 See Doo 1992 Shop Manual - http://www.ReadManuals.com

03 - Flushing and Care 04-03-1

Page: 4 See Doo 1992 Shop Manual - http://www.ReadManuals.com

v CAUTION : Denotes an instruction which, if not fol~lowed,could severely damage vehicle

01 NOTE : Indicates supplementary information needed t o fully complete an i~nstruction.

Page: 5 See Doo 1992 Shop Manual - http://www.ReadManuals.com

INTRODUCTION HULL IDENTIFICATION NUMBER (H.I.N.)

WATERCRAFT MODEL NUMIBER

Page: 6 See Doo 1992 Shop Manual - http://www.ReadManuals.com

section Sub-section Page

Page: 7 See Doo 1992 Shop Manual - http://www.ReadManuals.com

BOMBARDIER WATIERCRAFT SHOIP MANUAL

ILLUSTRATIONS AND PROCEDURES

v CAUTION : Pay attention to torque specification~s.

v CAUTION : Components of this watercraft are

Page: 8 See Doo 1992 Shop Manual - http://www.ReadManuals.com

SERVICE TOOL PURPOSE APPLICATION

Page: 9 See Doo 1992 Shop Manual - http://www.ReadManuals.com

SERVICE TOOL PURPOSE

Piston circlip installer (rnandaltory) To install circlips on pistons.

01-01-2 Page: 10 See Doo 1992 Shop Manual - http://www.ReadManuals.com

SERVICE TOOL I PURPOSE APPLIICATION

Page: 11 See Doo 1992 Shop Manual - http://www.ReadManuals.com

Pulller with screws (mandatory) To remove crankshaft bearing;^. All rnodel,~.

Protective cap {both ends) (mandatory)

Ring (both ends) 4mandatory)

Ring halves (PTO) (mandatory)

Distance ring (MAG) (mandatory)

Ring halves (MAG) (mandatory)

01-01-4 Page: 12 See Doo 1992 Shop Manual - http://www.ReadManuals.com

To position outer crankshaft bearing on All models.

To remove rotary valve shaft from crank- All models.

To install end bearing of rotary valve shaft

To install rotary valve shaft in crankcase

Page: 13 See Doo 1992 Shop Manual - http://www.ReadManuals.com

SERVICE TOOL PURPOSE APPLICATION

Alignment tool (mandatory) To align engineljet pum~pwhenever either All models.

Page: 14 See Doo 1992 Shop Manual - http://www.ReadManuals.com

ENGINE (recommended tools)

1 Dial indicator fTDC gauge) ,recommended)

I Stroboscopic timing llight 4recomrnended)

Page: 15 See Doo 1992 Shop Manual - http://www.ReadManuals.com

SERVICE TOOL PUIRPOSE APPILICATION

Dig~ital/induction type tachometer To verify engine RPM. All models.

To cool engine when watercraft is out of All models.

SERVICE TOOL PURPOSE APPLICATION

Aligning tool (recommended1 To align cylinders by exhaust flanges at MI models.

Page: 17 See Doo 1992 Shop Manual - http://www.ReadManuals.com

Bearing separator (recommended1 'ull out bearing. Crankshaft.

Bearing separator (recommended) Pull out bearing. Bearing beside dis-

01-01-10 Page: 18 See Doo 1992 Shop Manual - http://www.ReadManuals.com

SERVICE TOOL PURPOSE APIPLICATION

Page: 19 See Doo 1992 Shop Manual - http://www.ReadManuals.com

I SERVICE TOOL PURPOSE APPLICATION

Weld lock washer

I Old spark plug

Page: 20 See Doo 1992 Shop Manual - http://www.ReadManuals.com

COOLIlNG /FUEL/OIL SYSTEMS (Mandatory Tools)