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1999 sea doo speedster sk service repair manual
- 1. 219 100 099 Volume 2 SPEEDSTER/SK JB99C.FH7 03/07/98 PHOTO X:FINAUX1999JET_BOATCOVER99LMR JBFR99.EPS
- 3. Legal deposit: National Library of Quebec 1st trimester 1999 National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1999 Printed in Canada ® *Registered trademarks of Bombardier Inc. Loctite® is a trademark of Corporation. Snap-on® is a trademark of Snap-on Tools Corporation. Gelcote® is a trademark of Gelcote International Limited.
- 4. I SECTION SUBSECTION PAGE SAFETY NOTICE .................................................................................................................................. III WHAT’S NEW ....................................................................................................................................... IV INTRODUCTION ................................................................................................................................... VI 01 SERVICE TOOLS AND PRODUCTS 01 – Table of Contents..................................................................... 01-01-1 02 – Service Tools............................................................................ 01-02-1 03 – Service Products ...................................................................... 01-03-1 02 MAINTENANCE 01 – Table of Contents..................................................................... 02-01-1 02 – Periodic Inspection Chart ......................................................... 02-02-1 03 – Flushing and Lubrication........................................................... 02-03-1 04 – Water-Flooded Engine.............................................................. 02-04-1 05 – Storage..................................................................................... 02-05-1 03 TROUBLESHOOTING 01 – Table of contents...................................................................... 03-01-1 02 – Troubleshooting........................................................................ 03-02-1 03 – Flow Chart................................................................................ 03-03-1 04 ENGINE 01 – Table of Contents..................................................................... 04-01-1 02 – Leak Test ................................................................................. 04-02-1 03 – Removal and Installation .......................................................... 04-03-1 04 – Magneto System...................................................................... 04-04-1 05 – Top End .................................................................................... 04-05-1 06 – Bottom End .............................................................................. 04-06-1 07 – Rotary Valve ............................................................................. 04-07-1 08 – Exhaust System ....................................................................... 04-08-1 05 COOLING SYSTEM 01 – Table of Contents..................................................................... 05-01-1 02 – Components............................................................................. 05-02-1 03 – Circuit ....................................................................................... 05-03-1 06 FUEL SYSTEM 01 – Table of Contents..................................................................... 06-01-1 02 – Fuel Circuit ............................................................................... 06-02-1 03 – Air Intake .................................................................................. 06-03-1 04 – Carburetors............................................................................... 06-04-1 07 LUBRICATION SYSTEM 01 – Table of Contents..................................................................... 07-01-1 02 – Oil Injection Reservoir .............................................................. 07-02-1 03 – Oil Injection Pump.................................................................... 07-03-1 08 ELECTRICAL 01 – Table of Contents..................................................................... 08-01-1 02 – Overview.................................................................................. 08-02-1 03 – Ignition System ........................................................................ 08-03-1 04 – Spark Plugs............................................................................... 08-04-1 05 – The DESS (Digitally Encoded Security System) ....................... 08-05-1 06 – MPEM (Multi-Purpose Electronic Module)............................... 08-06-1 07 – Charging System...................................................................... 08-07-1 08 – Starting System........................................................................ 08-08-1 09 – Instruments and Accessories................................................... 08-09-1 TABLE OF CONTENTS
- 5. II SECTION SUBSECTION PAGE 09 PROPULSION SYSTEM 01 – Table of Contents...................................................................... 09-01-1 02 – Jet Pump................................................................................... 09-02-1 03 – Drive System ............................................................................ 09-03-1 04 – Reverse System........................................................................ 09-04-1 05 – Weedless System..................................................................... 09-05-1 10 STEERING SYSTEM 01 – Table of Contents...................................................................... 10-01-1 02 – Steering System ....................................................................... 10-02-1 03 – Alignment.................................................................................. 10-03-1 04 – Throttle/Shifter Controller ......................................................... 10-04-1 11 HULL/DECK 01 – Table of Contents...................................................................... 11-01-1 02 – Components ............................................................................. 11-02-1 03 – Repair........................................................................................ 11-03-1 04 – Painting ..................................................................................... 11-04-1 12 TECHNICAL DATA...................................................................................................................... 12-01-1 13 WIRING DIAGRAMS................................................................................................................... 13-01-1 TABLE OF CONTENTS
- 6. III SAFETY NOTICE 0 This manual was primarily published to be used by jet boat technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made Sea-Doo jet boat. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into local language upon certain conditions and fur- thermore agreed that in the event of any discrepancy among the two versions, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at its time of manufac- ture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufac- turing the product. The use of Bombardier parts is most strongly recommended when considering replacement of any com- ponent. Dealer and/or distributor assistance should be sought in case of doubt. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking disk, lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols: NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier jet boat and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional technician. It is understood that certain modifi- cations may render use of the boat illegal under existing federal, provincial and state regulations. x WARNING Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. - CAUTION Denotes an instruction which, if not followed, could severely damage boat components. SAFETY NOTICE
- 7. IV WHAT’S NEW 0 This section indicates this year is major changes brought to this shop manual including 717 engine pro- cedures applicable to the new Speedster SK model. SERVICE TOOLS AND SERVICE PRODUCTS • Revised tool part numbers. Tool are identical to last year, only part numbers have been modified. • The following tools are new: • Radio installation tool (P/N 295 100 106). • Tool board (P/N 295 500 608). • Tie-down (P/N 295 100 088). • Lift kit: –14 foot (P/N 295 000 160). –16 foot (P/N 295 100 085). –18 foot (P/N 295 100 045). • The following products are new: • Loctite Chisel (P/N 413 708 500) replaces Gasket stripper (P/N 295 000 110). • Parts cleaner (P/N 413 711 809) replaces Loctite safety solvent (P/N 293 800 019). MAINTENANCE • Revised periodic inspection chart with aluminum anode inspection. • Revised flushing procedure. • New photographs. • New flow chart. ENGINE • Revised engine cover removal procedure + photographs. • New main battery cut-off switch. • New wire color codes on generating and charging coils. FUEL SYSTEM • Revised procedure for clamp removal. LUBRICATION SYSTEM • Oil reservoir removal procedure. WHAT’S NEW
- 8. V ELECTRICAL • Standardized wire color codes. • Main battery cut-off switch on all boats. • New aluminium anode system on all boats. • Identified ground blocks to ease troubleshoot. • Connector location table moved to WIRING DIAGRAM 13-01. PROPULSION SYSTEM • Revamped weedless rod and cables replacement. HULL/DECK • New paint colors for 1999. • New swivel base removal procedure. • New ski post removal/disassembly/installation procedure for Speedster SK model. • New bow cover removal/installation/alignment procedure for Speedster SK model. • Lock pin adjustment and step removal procedures for Speedster SK model. TECHNICAL DATA • Updated specifications for 1999. WIRING DIAGRAMS • Updated for 1999. WHAT’S NEW
- 9. VI INTRODUCTION 0 This Shop Manual covers the following BOMBAR- DIER made SEA-DOO® Jet Boat. MAXIMUM BOAT CAPACITY The jet boat maximum capacity can be found on RH side of operator position. TYPICAL HULL IDENTIFICATION NUMBER (H.I.N.) The Hull Identification Number (H.I.N.) is located at right hand rear side of hull. TYPICAL 1. Hull Identification Number (H.I.N.) Refer to the next illustration for a description of the serial number. CEC indicates that boats are manufactured in USA. MODEL MODEL NUMBER Speedster 5678 Speedster SK 5677/5681 MAXIMUM CAPACITIES U.S. COAST GUARD 7 THIS BOAT COMPLIES WITH U.S. AND CANADIAN COAST GUARD SAFETY STANDARDS IN EFFECT ON THE DATE OF CERTIFICATION BOAT DESIGN CATEGORY: C PERSONS OR 565 KG/1245 LBS. MADE IN U.S.A., BOMBARDIER CORPORATION OF AMERICA 565 KG/1245 LBS. PERSONS, GEAR 60 4515 0 30 10 30 70 Bombardier MPH km/h 90 N R F10L1YA F09L03B 1 CEC 1 2 3 4 5 L 4 9 5 Model year Serial number* *A letter may also be used as a digit. F00A0YA Month of production Year of production *A letter may also be used as a digit. INTRODUCTION
- 10. VII ENGINE IDENTIFICATION NUMBER (E.I.N.) 717 Engine E.I.N. is located on the upper side of the magneto housing. TYPICAL — 717 ENGINE 1. Engine Identification Number (E.I.N.) 787 Engine E.I.N is located on crankcase PTO side. TYPICAL — 787 ENGINE 1. Engine Identification Number (E.I.N.) ARRANGEMENT OF THIS MANUAL The manual is divided into 13 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 HULL/DECK 12 TECHNICAL DATA 13 WIRING DIAGRAMS Each section is divided in various subsections, and again, each subsection has one or more divi- sion. A table of contents is included at the begin- ning of most sections. 1 F01D01A F01D87A 1 INTRODUCTION
- 11. VIII Section 03 ENGINE Subsection 04 (MAGNETO SYSTEM) MAGNETO SYSTEM 717 Engine 03-04-1 F01D4WS 12 11 5 N•m (44 lbf•in) 13 9 N•m (80 lbf•in) Loctite 242 4 6 8 Loctite 242 7 6 N•m (53 lbf•in) Loctite 242 6 N•m (53 lbf•in) 9 Loctite 242 5 6 N•m (53 lbf•in) 3 14 Loctite 242 4 Loctite 648 10 15 145 N•m (107 lbf•ft) Anti-seize lubricant 2 9 N•m (80 lbf•in) 1 Page heading indicates section and subsection detailed. Tightening torque nearby fastener. In this case, nut must be torqued to 145 N•m (107 lbf•ft). Exploded view assists you in identifying parts and related positions. TYPICAL PAGE F04A09S Illustration number for publishing process. Subsection title indicates beginning of the subsection. Dotted box contains parts of a particular model or an exploded view. Page numbering system: 03: ENGINE section 04: MAGNETO SYSTEM subsection 1: First page of this subsection Italic sub-title above exploded view indicate pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 242 to screw threads. Bold face number indicates special procedure concerning this part. Pay attention to torque specifi- cations. Some of these are in lbf•in instead of lbf•ft. Use appro- priate torque wrench. CAUTION INTRODUCTION
- 12. IX 1 2 Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS) 06-03-4 Step : Install pump gauge tester to pulse nipple Step : Pump tester until it reaches the desired pressure 1. Fuel outlet nipple 2. Fuel inlet nipple A. 28 kPa (4 PSI) Diaphragm Challenger Model Only CARBURETOR REMOVAL Inspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.). Pump Diaphragm Leak Test TYPICAL To remove carburetors from engine, proceed as fol- lows: Remove air vent tube support. Unlock retaining slides holding air intake silencer base. Remove air intake silencer base from watercraft. Remove screws holding flame arrester base support to cylinder head cover. Unscrew base retaining screws then remove base from carburetors and move to front of watercraft. Turn the valve to OFF position. NOTE: For fuel line removal, use pliers (P/N 295 000 054). Disconnect pulse line from fuel pump. Disconnect fuel fuel supply line from fuel pump. Disconnect fuel return line. Disconnect oil injection pump cable, throttle cable and choke cable. Remove screws and lock washers retaining carburetors. Remove carburetors from intake manifold. All Others Models Remove 4 bolts and lock washers from rotary valve cover then move carburetors and rotary valve cover on top of engine. NOTE: When removing rotary valve cover , pay attention that the rotary valve stay in place, otherwise it must be timed. Remove carburetors from intake manifold. Disconnect fuel bypass line between carburetors (twin carburetors). Remove carburetor(s) from rotary valve cover. DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester, perform the fol- lowing 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). Diaphragm no. 3 must stand pressure for 10 seconds. If pressure drops, replace diaphragm. TYPICAL PAGE Sub-title indicates a particular procedure for the named part. ''TYPICAL'' caption indicates a general view which does not represent full detail. Italic bold face setting in this case indicates that particular procedure for Challenger is finished, so from this point, all others models are concerned. Italic bold face setting indicates a particular procedure concerning a model. Service tool to be used to perform a certain procedure. Title indicates main procedure to be carried-out. F04A08S Sub-sub-title indicates a particular testing, adjustment or repair procedure. Illustration always follows text it is pertained to. Numbers in a frame are used to give a sequence to be perfomed for above illustration. Numbers are used for description of components for above illustration. Letters are used for any measures for above illustration. F01F0XB A 2 1 1 2 Number: following part name refers to exploded view at beginning of subsection. F01F0XB A 2 1 1 2 INTRODUCTION
- 13. X LIST OF ABBREVIATIONS USED IN THIS MANUAL GENERAL INFORMATION In marine industry, PORT, STARBOARD, BOW and STERN are used to refer to LEFT, RIGHT, FRONT and REAR respectively. They always refer to the operator’s position sitting in boat. 1. BOW (front) 2. STARBOARD (RH) 3. STERN (rear) 4. PORT (LH) The information and component/system descrip- tions contained in this manual are correct at time of publication. Bombardier Inc. however, main- tains a policy of continuous improvement of its products without imposing upon itself any obliga- tion to install them on products previously manu- factured. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This Shop Manual uses technical terms which may be different from the ones of the Parts Cata- logs. When ordering parts always refer to the spe- cific model Parts Catalogs. AC Alternative Current Ass’y Assembly ATDC After Top Dead Center BTDC Before Top Dead Center CDI Capacitor Discharge Ignition CSI Cooling System Indicator DC Direct Current DC-CDI Direct-Current Capacitor Discharge Ignition DESS Digitally Encoded Security System E.I.N Engine Identification Number H.I.N. Hull Identification Number HP Horsepower LH Left Hand side (port) MAG Magneto MPEM Multi-Purpose Electronic Module N.A. or N/A Not Applicable P/N Part Number PTO Power Take Off RAVE Rotax Adjustable Variable Exhaust RFI Radio-Frequency Interference RH Right Hand side (starboard) RMS Root Mean Square ROM Read-Only Memory RPM Revolution Per Minute SAE Society of Automotive Engineering TDC Top Dead Center T.I.G. Tungsten Inert Gas TLCS Total Loss Cooling System Vac Volt, Alternative Current Vdc Volt, Direct Current VROI Variable Rate Oil Injection 24 1 3F04L03C INTRODUCTION
- 14. XI ILLUSTRATIONS AND PROCEDURES The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown; however, they represent parts which have the same or a similar function. As many of the procedures in this manual are in- terrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the proce- dure is contained. A number of procedures throughout the book re- quire the use of special tools. Before commenc- ing any procedure, be sure that you have on hand all the tools required, or approved equivalents. Technical Publications Bombardier Inc. Valcourt (Quebec), Canada - CAUTION These boats are designed with parts dimen- sioned in both the metric and the imperial systems. When replacing fasteners, make sure to use only those recommended by Bombardier. Mismatched or incorrect fas- teners could cause damage to the boat or possible personal injury. INTRODUCTION
- 15. Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) 12-01-1 TECHNICAL DATA 0 ENGINE SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Number of engine 2 2 Engine type BOMBARDIER-ROTAX 787, water cooled BOMBARDIER-ROTAX 717, water cooled Induction type Rotary valve Exhaust type Type Water cooled, water injected Water injection fittings 3.5 mm (.139 in) Starting system Electric start Lubrication Fuel/oil mixture VROI (Variable Rate Oil Injection) Oil injection pump MIKUNI (gear driven) Oil type Bombardier-Rotax injection oil P/N 413 802 900 (12 x 1 L) P/N 413 803 000 (3 x 4 L) P/N 413 803 200 (205 L) Number of cylinders 2 x 2 Bore Standard 82.00 mm (3.228 in) First oversize 82.25 mm (3.238 in) Second oversize N.A. 82.50 mm (3.248 in) Stroke 74 mm (2.91 in) 68 mm (2.68 in) Displacement 781.0 cm3 (47.65 in3) 718.2 cm³ (43.81 in³) Compression ratio Uncorrected 11.75: 1 12:1 Corrected 5.9: 1 6.2:1 Engine maximum torque 2 x 110 N•m (81 lbf•ft) @ 6500 RPM 2 x 91 N•m (67 lbf•ft) @ 6250 RPM Cylinder head warpage (maximum) 0.05 mm (.002 in) Piston ring type and quantity 1 semi-trapez — 1 rectangular Ring end gap New 0.25 - 0.40 mm (.010 - .016 in) Wear limit 1.00 mm (.039 in) Ring/piston groove clearance New 0.025 - 0.070 mm (.001 - .003 in) Wear limit 0.20 mm (.008 in) Piston/cylinder wall clearance New 0.09 - 0.11 mm (.003 - .004 in) Wear limit 0.20 mm (.008 in) Cylinder taper (maximum) 0.10 mm (.004 in) Cylinder out of round 0.08 mm (.003 in) Connecting rod big end axial play New 0.39 - 0.74 mm (.015 - .029 in) Wear limit 1.2 mm (.047 in) Crankshaft deflection (center) 0.08 mm (.003 in) Œ Rotary valve timing Opening 147° ± 5° BTDC Closing 63.5° ± 5° ATDC Rotary valve duration 158° Crankcase/rotary valve gap 0.25 - 0.35 mm (.010 - .014 in) Connecting rod/crankshaft pin radial clearance New 0.01 - 0.02 mm (.0004 - .0008 in) Wear limit 0.050 mm (.002 in) Connecting rod/piston pin radial clearance New 0.003 - 0.012 mm (.00012 - .00047 in) Wear limit 0.015 mm (.00059 in) ADDITIONAL INFORMATION: Œ MAG side: 0.05 mm (.002 in) PTO side: 0.03 mm (.001 in) N.A.: Not Applicable
- 16. Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) 12-01-2 ELECTRICAL SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Magneto generator output 2 x 180 W @ 6000 RPM or 5 A @ 2000 RPM 2 x 160 W @ 6000 RPM or 4 A @ 2000 RPM Ignition system type DC-CDI (Direct Current-Capacitor Discharge Ignition) CDI (Capacitor Discharge Ignition) Spark plug Make and type NGK BR8ES Gap 0.55 mm (.021 in) Ignition timing (BTDC) mm (in) 3.38 (.133) 2.59 (.102) Degrees 22° @ 3500 RPM Œ 20° ± 1 @ 6000 RPM Œ Generating coil N.A. 40 - 76 Ω Trigger coil 242 Ω N.A. Battery charging coil 0.8 Ω 0.05 - 0.6 Ω Ignition coil Primary 0.6 Ω (not measurable) .34 - .62 Ω (not measurable) Secondary 11.4 - 14 kΩ 9 - 15 kΩ Engine RPM limiter setting 7200 (± 50) RPM 7000 (± 50) RPM Battery Not supplied Fuse MPEM (Multi-Purpose Electronic Module) supply 5 A Fuse block supply 3 x 20 A Charging system 2 x 15 A Blower 7.5 A Bilge pump 3 A Lighting system 3 A Gauges 5 A Additional accessories 10 A Horn fuse 5 A Jack system 10 A Radio/courtesy lights 10.0 A N.A. ADDITIONAL INFORMATION: Œ With shifter in forward or reverse position. Recommended: Exide RV24-130, 12 V, 25 A•h (130 minutes reserve) or RV24-160 (160 minutes) or equivalent. Battery posts: On top. Round taper type. Battery maximum allowed size: 285 mm (11-1/4 in) long x 190 mm (7-1/2 in) wide x 238 mm (9-3/8 in) high. N.A.: Not Applicable . ; WARNING Never use automotive type battery. Its mechanical construction does not allow to meet the shock conditions where boats operate. Only use the type of battery recommended.
- 17. Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) 12-01-3 CARBURETION SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Carburetor Type Mikuni twin diaphragm with acceleration pump Mikuni single diaphragm with acceleration pump Model (MAG side) (PTO side) BN 40i-38-49 BN 40i-38-50 BN 40i-38-28 Quantity 2 per engine 1 per engine Main jet MAG: 142.5, PTO: 145 167.5 Pilot jet 67.5 70.0 Adjustment Low-speed screw 1-1/2 turn 1-1/4 turn High speed screw 0 Idle speed (in water) 1500 RPM Idle speed (out of water) 3000 RPM Docking assistance speed (in water) 2800 RPM 2500 RPM Fuel Type Regular unleaded gasoline Octane no. 87 (R + M)/2 Fuel return line orifice (MAG) 8 mm (.316 in) — (PTO) 6 mm (.237 in) (PTO) 6 mm (.237 in) ADDITIONAL INFORMATION: COOLING SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Type Open circuit — Direct water flow Thermostat None Overheating beeper setting 96 - 99°C (205 - 210°F) ADDITIONAL INFORMATION: PROPULSION SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Propulsion system Bombardier Formula Pump (big hub) Number of pump 2 Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crowned splines Oil type SEA-DOO JET PUMP SYNTHETIC OIL Polyolester 75W90 GL5 Œ (P/N 293 600 011 - 12 x 6 oz) Steering nozzle pivoting angle 26° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in) Impeller outside diameter 139.5 mm (5.492 in) Impeller/wear ring clearance New 0.18 - 0.44 mm (.007 - .017 in) Wear limit 1.02 mm (.040 in) Impeller shaft end play (new) 0.12 - 0.54 mm (.005 -.021 in) Impeller shaft side play 0.05 mm (.002 in) Impeller pitch/material Progressive pitch/stainless steel ADDITIONAL INFORMATION: Œ Do not mix different brands or oil types.
- 18. Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) 12-01-4 DIMENSIONS SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Dead rise 20° Draft 30.5 cm (12 in) Overall length 503 cm (164 ft 6 in) Overall width (beam) 231 cm (91 in) Overall height 127 cm (50 in) Dry weight 777 kg (1710 lb) Load limit (passengers and 10 kg (22 lb) luggage) 5 passengers OR 410 kg (905 lb) Maximum water skiers on tow 2 ADDITIONAL INFORMATION: CAPACITIES SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Fuel tank (including reserve) 151 L (40 U.S. gal) Fuel tank reserve 15 L (4 U.S. gal) Impeller shaft reservoir Capacity 100 mL (3.4 U.S. oz) Oil level height To bottom of cover hole Oil injection reservoir 9 L (2.4 U.S. gal) ADDITIONAL INFORMATION: MATERIAL SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Hull Composite (fiberglass and wood) Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Base: polyethylene, Foam: polyurethane Ride shoe Plastic Jet pump Plastic Front storage cover Polystyrene ADDITIONAL INFORMATION: PERFORMANCE SPEEDSTER (5678) SPEEDSTER SK (5677/5681) Estimated pump power 2 x 33.0 kW (44.2 hp) 2 x 25.4 kW (34 hp) Maximum fuel consumption at wide open throttle 92 L/h (24.4 U.S. gal/h) 63 L/h (16.7 U.S. gal/h) Cruising time at full throttle Fuel tank without reserve 1 h 25 min 2 h 10 min Fuel tank reserve 15 min 15 min ADDITIONAL INFORMATION:
- 19. Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) 12-01-5 STANDARD EQUIPMENT SPEEDSTER (5678) SPEEDSTER SK (5677/5681) DESS (Digitally Encoded Security System) Standard Spark plug wrench Standard Fuel tank reserve Standard Electric fuel level gauge Standard Oil injection low level/warning device Standard Overheating warning device and CSI (Cooling System Indicator) Standard Speedometer Standard Tachometer Standard (2) Variable Trim System (VTS) N.A. Stern light and navigation lights Standard Courtesy lights Standard Shifter control (forward/neutral/reverse) Standard Electric bilge pump (manual switch + auto) Standard Blower Standard Storage compartment (front/console/rear/deck) std/std/std/std Grab handles Standard Extinguisher holder Standard Cup holders Standard Mirrors Standard (1) Retractable ski pole Standard Standard (+ extension) Bow filler cushion N.A. Sun deck cushion N.A. Rear cover pad Standard Platform pad Optional Standard Radio AM-FM Optional Horn Standard Bimini Top Optional Swivel bucket seats Standard Windshield Standard (2) Rack for ski/knee/wakeboard N.A. Lift kit Optional Ski door lock Standard Engine cover lock Standard Storage cover lock Standard Cooler door lock Standard Ski rope locker lock N.A. Glove box N.A. Low-speed steering control system Standard Depth sounder provision Standard Mooring cover Optional Weedless (system) Standard Ladder Standard Deck carpet Optional ADDITIONAL INFORMATION: N.A.: Not Applicable
- 20. Section 12 TECHNICAL DATA Subsection 01 (TECHNICAL DATA) 12-01-6 TIGHTENING TORQUES SPEEDSTER (5678) SPEEDSTER SK (5677/5681) PRODUCT TO APPLY ENGINE Exhaust manifold screw 24 N•m (17 lbf•ft) (1) Magneto flywheel nut (787 engine) 110 N•m (81 lbf•ft) (1) Magneto flywheel nut (717 engine) 145 N•m (107 lbf•ft) (1) Flywheel (PTO side) 105 N•m (77 lbf•ft) (5) Crankcase screws M6 9 N•m (80 lbf•in) (1) M8 24 N•m (17 lbf•ft) (1) Crankcase/engine support nuts 25 N•m (18 lbf•ft) (1) Engine support/hull 25 N•m (18 lbf•ft) (1) Cylinder head cover screws 24 N•m (17 lbf•ft) (3) Crankcase/cylinder screws 24 N•m (17 lbf•ft) (3) Tuned pipe nut/manifold stud, screws and nuts 40 N•m (30 lbf•ft) (1) and (2) Tuned pipe fixation screws 25 N•m (18 lbf•ft) (1) Flame arrester screws 10 N•m (88 lbf•in) (1) Carburetor on intake manifold nuts 25 N•m (18 lbf•ft) (1) PUMP Impeller shaft 70 N•m (52 lbf•ft) (2) Pump/hull nuts (inside bilge) 31 N•m (23 lbf•ft) (2) Pump/hull nuts (outside bilge) 28 N•m (21 lbf•ft) Venturi/pump housings screws 21 N•m (15 lbf•ft) Nozzle/venturi screws 20 N•m (15 lbf•ft) Pump housing cover screws 4 N•m (35 lbf•in) (1) Reverse gate support/venturi screws 21 N•m (15 lbf•ft) (1) Intake grate/hull screws 6 N•m (53 lbf•in) (1) Ride shoe screws/nuts 10 N•m (88 lbf•in) (6) STEERING Steering wheel nut 30 N•m (22 lbf•ft) Steering support/deck screws 6 N•m (53 lbf•in) Steering support/helm screws 4.5 N•m (40 lbf•in) Steering cable retaining block bolts 14 N•m (124 lbf•in) Steering cable/rotating arm screw and nut 3 N•m (27 lbf•in) (1) Steering cable/nozzle screw and nut 3 N•m (27 lbf•in) (4) on bushing Dashboard screws 1.5 N•m (14 lbf•in) Steering cable/hull nut 8 N•m (71 lbf•in) (1) and (6) ELECTRICAL Ignition housing cover screws 8 N•m (71 lbf•in) (5) Starter mountion screws 25 N•m (16 lbf•ft) (1) Starter lock nuts 7 N•m (62 lbf•in) Spark plugs 24 N•m (17 lbf•ft) Anode 5.7 N•m (50 lbf•in) (6) ADDITIONAL INFORMATION: Apply where indicated; (1) Add Loctite 242 (P/N 293 800 015) (2) Add Loctite 271 (P/N 293 800 005) (3) Add Loctite 518 (P/N 293 800 038) (4) Syhthetic grease (P/N 293 550 010) (5) Anti-seize lubricant (P/N 293 800 023) (6) Adseal 4511 (P/N 293 800 033) N.A.: Not Applicable ; WARNING Correct torques and use of Loctite® must be strictly followed.
- 21. 01-01-1 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 0 SERVICE TOOLS.................................................................................................................... 01-02-1 SERVICE PRODUCTS ............................................................................................................ 01-03-1
- 22. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS) 01-02-1 SERVICE TOOLS 0 This is a list of tools to properly service Sea-Doo jet boats. The list includes both the mandatory tools and the optional tools that are ordered separately. Service Products are not part of any kit and must all be ordered separately. If you need to replace or add to your tool inventory these items can be ordered through the regular parts channel. Following mention points out new tool: WORKSHOP — MANDATORY SERVICE TOOLS NEW Tool board P/N 295 500 608 F00A0S4 APPLICATION All models. NEW 01®
- 23. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS) 01-02-2 WORKSHOP — RECOMMENDED SERVICE TOOLS Radio removal tool P/N 295 100 106 F10P094 APPLICATION Boats equipped with radio. Protective mat P/N 295 000 129 F04L1V4 APPLICATION All models except Explorer. NEW
- 24. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS) 01-02-3 ENGINE — MANDATORY SERVICE TOOLS Degree wheel P/N 295 000 007 A00B334 APPLICATION All models. Rubber pad P/N 295 000 101 F01B0J4 APPLICATION All models. PTO flywheel remover/installer P/N 295 000 001 F01J0T4 APPLICATION All engines except 787. NOTE: This tool is also used for the impeller. 360 350 340 330 320 310 300 290280270260250 240 2 30 220 210200190180170 160 150 140 130 1201101009080 70 60 50 40 30 20 10 10 20 30 40 50 60 70 8090100110 120 130 1 40 150 160 170180190200 210 220 230 240 250260270280290 300 310 320 330 340 350 360 F01D884 1) Puller P/N 420 877 635 2) Protective cap (both ends) P/N 420 876 557 3) Ring (both ends) P/N 420 977 490 4) Ring halves (PTO) P/N 420 977 475 (2) 5) Distance ring (MAG) P/N 420 876 569 6) Ring halves (MAG) P/N 420 276 025 (2) 7) Screw M8 x 40 P/N 420 840 681 (2) 8) Screw M8 x 70 P/N 420 841 201 (2) APPLICATION All models. MAG side PTO side 8 1 5 2 3 4 46 8 7 7 Piston circlip installer P/N 529 035 562 A01B1P4 APPLICATION 717 and 787 engines. Pusher P/N 420 876 605 A00C0Y4 APPLICATION All engines except 787. Bearing pusher P/N 420 876 501 F00B074 APPLICATION 717 and 787 engines. Piston circlip
- 25. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS) 01-02-4 ENGINE (continued) — MANDATORY SERVICE TOOLS Digital multimeter P/N 529 022 000 F01B1O4 APPLICATION All models. Puller P/N 290 876 488 F01B0I4 APPLICATION All engines. Replacement parts: 1) Hex. screw (M6 x 60) P/N 290 240 860 2) Nut (M6) P/N 232 061 414 2 1 Puller P/N 529 035 547 A00C1A4 Puller plate P/N 420 876 080 A00C1R4 Extension handle P/N 295 000 125 F01D164 Screw M8 x 35 (3) P/N 420 841 591 F00A094 Sleeve (3) P/N 290 847 220 F00A0A4 APPLICATION All engines except 787. Alignment support plate kit P/N 529 035 506 1) Alignment plates P/N 529 035 507 2) Support P/N 529 035 511 3) Screw (2) P/N 207 182 544 Lock washer (2) P/N 234 181 601 Flat washer (2) P/N 234 081 410 F00B0F4 APPLICATION Engine alignment. Alignment shaft P/N 295 000 141 F00B0G4 APPLICATION Engine alignment. Ring gear blocking tool P/N 295 000 155 F01B264 APPLICATION 787 engine.
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- 27. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS) 01-02-5 ENGINE (continued) — MANDATORY SERVICE TOOLS Piston pin puller P/N 529 035 503 F00B0T4 APPLICATION All engines. Sleeve set P/N 529 035 542 (20 mm sleeve) F00B0U4 APPLICATION All models. MPEM programmer P/N 529 035 589 A01B5B4 APPLICATION Boats equipped with the DESS. Flywheel extractor P/N 295 000 156 F00B044 APPLICATION 787 engine. Engine leak tester kit P/N 295 500 352 F01B2Q5 APPLICATION All models. Ring gear puller tool P/N 529 035 547 F01B294 APPLICATION 787 engine.
- 28. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS) 01-02-6 ENGINE — RECOMMENDED SERVICE TOOLS Ring compressor P/N 290 876 979 (82 mm) A01B1T4 APPLICATION 717 and 787 engines. Coil centering tool P/N 420 876 922 A01B1V4 APPLICATION All engines except 787. Cylinder aligning tool P/N 420 876 904 A00B084 APPLICATION All engines except 787. Stroboscopic timing light P/N 529 031 900 A00B4F4 APPLICATION All models. Dial indicator (TDC gauge) P/N 295 000 143 A00B4E4 APPLICATION All models. Distance gauge A) P/N 529 034 800 B) P/N 529 034 900 F01B0H4 APPLICATION A) 717 engine. B) 787 engine. Digital/induction type tachometer P/N 529 014 500 F01B1G4 APPLICATION All models. Timing mark pointer P/N 295 000 130 F01B2O4 APPLICATION All engines except 787. Timing mark pointer P/N 295 000 135 F01H544 APPLICATION 787 engine.
- 29. Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE TOOLS) 01-02-7 ENGINE (continued) — RECOMMENDED SERVICE TOOLS Crimping tool P/N 295 100 164 F00B0E4 APPLICATION Contacts in AMP connectors on MPEM. Oil seal pusher P/N 290 877 740 F01B2C4 APPLICATION 787 engine. Ring halves and ring P/N 420 876 330 (halves) (2) P/N 420 977 480 (ring) F01B2D4 APPLICATION 787 engine. Engine lifting device Not sold by Bombardier Do it yourself Refer to ENGINE REMOVAL AND INSTALLATION section F01D0A4 APPLICATION All engines except 787. Feeler gauge 45° Not sold by Bombardier F01B1K4 APPLICATION All models. Terminal remover Not sold by Bombardier Snap-on TT 600-4 F01B1J4 APPLICATION All models. Snap-on FB 300 A Slide hammer puller Not sold by Bombardier Snap-on: Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4 F01J0Z4 APPLICATION All models. NOTE: This tool is also used to pull out impeller shaft seal. Safety lanyard switch tool P/N 529 034 600 F01B244 APPLICATION Boats equipped with the DESS. A) Four-pin magneto harness P/N 295 000 131 B) Six-pin magneto harness P/N 295 000 136 F01B284 APPLICATION A) 717, 1995 and newer. B) 787 engine.