Sea-doo SPORTSTER 4-TEC Shop Manual

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Shop Manual SPORTSTER 4-TEC ...

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Legal deposit: National Library of Quebec 2 nd trimester 2003 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. 2003 Techn...

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LMR2003-001_002A.FM I SECTION SUBSECTION PAGE SAFETY NOTICE.................................................................................................................................. II INTRODUCTION ..............................................

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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 a...

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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 Numbe...

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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. Exp...

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LMR2003-001_002A.FM V 1 2 Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS) 06-03-4 Diaphragm XP Model Only CARBURETOR REMOVAL Inspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.). PUMP DIAPHRAGM LEAK ...

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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 ...

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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...

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VIII LMR2003-001_002A.FM Exceptions include manufacturer’s prescribed changes, such as altitude adjustments for example. Owner Responsibility The owner/operator is required to have engine maintenance performed to maintain emission lev- els within p...

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LMR2003-001_002A.FM IX Blind Holes 1. On threads 2. On threads and at the bottom of hole 1. Clean threads (bolt and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on threads (bolt and nut) and allow to dry for 30 seconds. 3. Choose p...

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X LMR2003-001_002A.FM Adjusting Screw 1. Apply here 2. Plunger 1. Adjust screw to proper setting. 2. Apply drops of proper strength Loctite thread- locker on screw/body contact surfaces. 3. Avoid touching metal with tip of flask. NOTE: If it is diffi...

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LMR2003-001_002A.FM XI 1. Remove old gasket and other contaminants with Loctite Chisel remover (P/N 413 708 500). Use mechanical means if necessary. NOTE: Avoid grinding. 2. Clean both mating surfaces with solvent. 3. Spray Loctite Primer N on both m...

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XII LMR2003-001_002A.FM TIGHTENING TORQUES Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table.The table also gives the metric conversion. N•m FASTENER SIZE (8.8 grade) Lbf•in 1...

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LMR2003-001_002A.FM XIII TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS Technical Publications Bombardier Inc. Valcourt (Quebec), Canada 81 60 82 60 83 61 84 62 85 63 86 63 87 64 88 65 89 66 90 66 91 67 92 68 93 69 94 69 95 70 96 71 97 72 98 72 99 7...