Sea-doo SPORTSTER 4-TEC Installationsanleitung

Shop Manual

SPORTSTER 4-TEC

Legal deposit:

National Library of Quebec

2nd trimester 2003

National Library of Canada

form without the prior written permission of Bombardier Inc.

©Bombardier Inc. 2003

Technical Publications

Bombardier Inc.

Valcourt (Quebec) Canada

Printed in Canada

®*Registered trademarks of Bombardier Inc.

Loctite®is a trademark of Loctite Corporation

Snap-on®is a trademark of Snap-on Tools Corporation

Gelcote®is a trademark of Gelcote International Limited

LMR2003-001_002A.FM I

SECTION SUBSECTION PAGE

SAFETY NOTICE .................................................................................................................................. II

INTRODUCTION ................................................................................................................................... III

01 SERVICE TOOLS

AND PRODUCTS

01 - Table of contents ...................................................................... 01-01-1

02 - Mandatory service tools............................................................ 01-02-1

03 - Optional service tools................................................................ 01-03-1

04 - Service products ....................................................................... 01-04-1

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 - Troubleshooting chart ............................................................... 03-01-1

04 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 04-01-1

02 - Leak test ................................................................................... 04-02-1

03 - Intake system............................................................................ 04-03-1

04 - Exhaust system......................................................................... 04-04-1

05 - Removal and installation ........................................................... 04-05-1

06 - PTO housing/Magneto .............................................................. 04-06-1

07 - Lubrication system.................................................................... 04-07-1

08 - Cylinder head and valves........................................................... 04-08-1

09 - Engine block.............................................................................. 04-09-1

05 ENGINE

MANAGEMENT

(4-TEC)

01 - Table of contents ...................................................................... 05-01-1

02 - Overview................................................................................... 05-02-1

03 - Component inspection and adjustment .................................... 05-03-1

04 - Diagnostic procedures .............................................................. 05-04-1

06 COOLING SYSTEM 01 - Table of contents ...................................................................... 06-01-1

02 - Circuit, components and care ................................................... 06-02-1

07 FUEL SYSTEM 01 - Table of contents ...................................................................... 07-01-1

02 - Fuel circuit................................................................................. 07-02-1

03 - Air intake ................................................................................... 07-03-1

08 ELECTRICAL

SYSTEM

01 - Table of contents ...................................................................... 08-01-1

02 - Charging system ....................................................................... 08-02-1

03 - Starting system ......................................................................... 08-03-1

04 - Instruments and accessories .................................................... 08-04-1

09 PROPULSION

SYSTEM

01 - Table of contents ...................................................................... 09-01-1

02 - Jet pump ................................................................................... 09-02-1

03 - Drive system ............................................................................. 09-03-1

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

12 TECHNICAL DATA 01 - Sportster 4-TEC......................................................................... 12-01-1

13 WIRING DIAGRAMS 01 - Wiring diagrams ........................................................................ 13-01-1

TABLE OF CONTENTS

II LMR2003-001_002A.FM

SAFETY NOTICE

This manual has been prepared as a guide to correctly service and repair the SEA-DOO Sportster™

4-TEC™ sport boat.

This edition was primarily published to be used by sport boat mechanical technicians who are already

familiar with all service procedures relating to Bombardier made sport boats. Mechanical technicians

should attend training courses given by the Bombardier Training Dept.

Please note that the instructions will apply only if proper hand tools and special service tools are used.

This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts

Catalog.

It is understood that this manual may be translated into another language. In the event of any discrepancy,

the English version shall prevail.

The content depicts parts and/or procedures applicable to the particular product at time of writing. Service

and Warranty Bulletins may be published to update the content of this manual. Make sure to read and

understand these.

In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the

general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas

of the parts.

The use of Bombardier parts is most strongly recommended when considering replacement of any com-

ponent. Dealer and/or distributor assistance should be sought in case of doubt.

The engines and the corresponding components identified in this document should not be utilized on

product(s) other than those mentioned in this document.

Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,

self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking

device is impaired, it must be renewed.

This manual emphasizes particular information denoted by the wording and symbols:

CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-

nents.

NOTE: Indicates supplementary information needed to fully complete an instruction.

Although the mere reading of such information does not eliminate the hazard, your understanding of the

information will promote its correct use. Always use common shop safety practice.

Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the

contents. We strongly recommend that any services be carried out and/or verified by a highly skilled

professional mechanic. It is understood that certain modifications may render use of the vehicle illegal

under existing federal, provincial and state regulations.

WARNING

Identifies an instruction which, if not followed, could cause serious personal injury including

possibility of death.

SAFETY NOTICE

LMR2003-001_002A.FM III

INTRODUCTION

This Shop Manual covers the following BOMBARDIER

made SEA-DOO®sport boat models.

HULL IDENTIFICATION NUMBER

(H.I.N.)

It is located at the rear of sport boat.

Sportster™ 4-TEC™

1. Hull Identification Number (H.I.N.)

Refer to the next illustration for a description of the

Serial Number.

ENGINE IDENTIFICATION

NUMBER (E.I.N.)

1503 Engine

The Engine Identification Number is located at

front of 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 (4-TEC)

05 ENGINE MANAGEMENT (4-TEC)

06 COOLING SYSTEM

07 FUEL SYSTEM

08 ELECTRICAL SYSTEM

09 PROPULSION SYSTEM

10 STEERING SYSTEM

11 HULL/DECK

12 TECHNICAL DATA

13 WIRING DIAGRAMS

Several sections are divided in various subsec-

tions. There is a table of contents at the beginning

of many sections.

MODELS ENGINE

TYPE

MODEL

NUMBER

Sportster™4-TEC™1503

4-TEC™5770

Sportster™4-TEC™

with tower

1503

4-TEC™5768

F09L4HA

CECH 1 2 3 4 5 L 4 9 5

Model year

Serial

number*

A letter may also be used as a di it.

F00A11A

Month of production

Year of production

Model

F09D0UA

INTRODUCTION

IV LMR2003-001_002A.FM

Subsection 04 (MAGNETO SYSTEM)

03-04-1

F01D4WS

Loctite

243

Loctite

243

Loctite

243

Loctite

243

Loctite

243

Loctite

648

145 Nm

(107 lbfft)

Anti-seize

lubricant

Page heading

indicates section

and subsection

detailed.

Exploded view assits

you in identifying

parts and related

positions.

TYPICAL PAGE

F01A0CS

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:

0 : 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 24 to

screw threads.

Bold face number

indicates special

procedure

concerning this part.

INTRODUCTION

LMR2003-001_002A.FM V

Section 06 FUEL SYSTEM

Subsection 03 (CARBURETORS)

06-03-4

Diaphra m

XP 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 no. 6 and lock washers no. 7 retaining

carburetors.

All Others Models

Remove 4 bolts no. 8 and lock washers no. 12 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, other-wise

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 08 ) on pulse

nipple.

- Pump tester until it reaches 28 kPa (4 PSI).

Diaphragm must stand pressure for 10 seconds. If

pressure drops, replace diaphragm.

F01F0XB

1 2

TYPICAL PAGE

Sub-title with part

name(s) from

exploded view.

TYPICAL mention

indicates a general

view which does not

represent full detail.

Sub-sub-title in this

case indicates that

particular procedure

for XP is finished, so

from this point, all

others models are

concerned.

Title in italic 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.

Sub-sub-title in

capital 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.

Numbers are used

for description of

components.

Letters are used for

any measures.

Bold numbers in the

text refer to the parts

shown in the exploded

view at the beginning

of the subsection.

F01A0BS

INTRODUCTION

VI LMR2003-001_002A.FM

LIST OF ABBREVIATIONS USED

IN THIS MANUAL

DESCRIPTION

AC Alternate Current

ADC Analog to Digital Conversion

APS Air Pressure Sensor

ATS Air Temperature Sensor

B.U.D.S. Bombardier Utility and Diagnostic

Software

CAPS Camshaft Position Sensor

CDI Capacitor Discharge Ignition

CPS Crankshaft Position Sensor

CSI Cooling System Indicator

CTS Coolant Temperature Sensor

DC Direct Current

DESS Digitally Encoded Security System

DLA Digital Linear Actuator

E.I.N. Engine Identification Number

ECU Electronic Control Unit

EGT Exhaust Gas Temperature

EMS Engine Management System

EPA Environmental Protection Agency (USA)

HP Horse Power

KS Knock Sensor

MAG Magneto

MAPS Manifold Air Pressure Sensor

MATS Manifold Air Temperature Sensor

MPH Mile Per Hour

MPI Multi Protocol Interface

N.A. Not Applicable

OPS Oil Pressure Sensor

OPT Optional

OSPS Oil Separator Pressure Sensor

P/N Part Number

PFD Personal Flotation Device

PSI Pound Per Square Inch

PTO Power Take Off

RPM Revolution Per Minute

STD Standard

TBD To Be Determined

TDC Top Dead Center

TOPS Tip-Over Protection System

TPS Throttle Position Sensor

VCK Vehicle Communication Kit

VDC Volt Direct Current

WTS Water Temperature Sensor

DESCRIPTION

INTRODUCTION

LMR2003-001_002A.FM VII

GENERAL INFORMATION

In the 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.

TYPICAL

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 writing. Bombardier Inc. however, maintains a

policy of continuous improvement of its products

without imposing upon itself any obligation to in-

stall them on products previously manufactured.

Because of our ongoing commitment to product

quality and innovation, Bombardier Inc. reserves

the right at any time to discontinue or change

specifications, designs, features, models or equip-

ment without incurring obligation.

This Shop Manual uses technical terms which

may be different from the ones in the Parts Cata-

logs.

When ordering parts always refer to the specif-

ic model Parts Catalogs.

ILLUSTRATIONS AND

PROCEDURES

The illustrations show the typical construction of

the different assemblies and, in all cases, may not

reproduce the full detail or exact shape of the parts

shown, however, they represent parts which have

the same or a similar function.

CAUTION: These sport boat are designed with

parts dimensioned mostly in the metric sys-

tem. However some components may be from

the imperial system. When replacing fasteners,

make sure to use only those recommended by

Bombardier.

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 undertaking

any procedure, be sure that you have on hand all

the tools required, or approved equivalents.

ENGINE EMISSIONS

INFORMATION

Manufacturer’s Responsibility

Beginning with 1999 model year engines, sport

boat manufacturers of marine engines must deter-

mine the exhaust emission levels for each engine

horsepower family and certify these engines with

the United States of America Environmental Pro-

tection Agency (EPA). An emissions control infor-

mation label, showing emission levels and engine

specifications, must be placed on each vehicle at

the time of manufacture.

Dealer Responsibility

When performing service on any 1999 and newer

Sea-Doo sport boat carrying an emissions control

information label, adjustments must be kept with-

in published factory specifications.

Replacement or repair of any emission related

component must be executed in a manner that

maintains emission levels within the prescribed

certification standards.

Dealers are not to modify the engine in any man-

ner that would alter the horsepower or allow emis-

sion levels to exceed their predetermined factory

specifications.

F04L03C

INTRODUCTION

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