Sea-doo Speedster 5894 manuals

Sea doo Speedster 5894 Service Manual (274 pages)

Brand: Sea-doo | Category: Engine | Size: 14.80 MB |

English

Table of contents

SAFETY NOTICE

7

SAFETY NOTINCE

7

Serial number

8

TYPICAL-717 ENGINE

9

1996 BOMBARDIER JET BOAT

10

SHOP MANUAL

10

GENERAL INFORMATION

12

ILLUSTRATIONS AND

12

PROCEDURES

12

MANDATORY TOOLS

13

COOLING / FUEL / OIL SYSTEMS

16

PROPULSION SYSTEM

17

RECOMMENDED TOOLS

18

Shop Manual

19

SERVICE PRODUCTS

23

DOW CORNING ®

24

RTV Sealant

24

SYNTHETIC GREASE

25

BOMBARDIER

26

PERIODIC INSPECTION CHART 1

29

FLUSHING

30

PROCEDURE

30

Sportster and Speedster

31

Section 02 MAINTENANCE

32

WATER-FLOODED ENGINE 3

33

Engine Draining

35

Fuel System

35

Internal Lubrication

35

Propulsion System

36

Boat Cleaning

37

Anticorrosion Treatment

37

Sub-Section 04 (STORAGE)

38

TROUBLESHOOTING 0

39

Section 03 TROUBLESHOOTING

40

REMOVAL FROM JET BOAT

47

Engine Support Mounts

48

Lifting Engine

48

1,2, Shim and Rubber Mount

48

Tuned Pipe Removal

49

15,16, Exhaust Outlet and Nut

50

2,3, Rubber Mount and Screw

53

4,5, Engine Support and Nut

53

Supply and Return Lines

53

Engine / Jet Pump Alignment

53

Electrical Connections

54

ENGINE DESCRIPTION

57

Sub-Section 02 (TOP END)

58

Cylinder Taper

60

Cylinder Out of Round

60

Piston / Cylinder Clearance

60

Ring End Gap

61

12, Cylinder Base Gasket

61

5, Circlip

64

7, Cylinder

65

RAVE SYSTEM

67

Maintenance

68

Boring Precaution

68

Troubleshooting

69

Squish Gap Measurement

69

1,2, Ignition Cover and Screw

73

3, PTO Flywheel

73

4, Magneto Flywheel

75

4,10, Magneto and Nut

79

Ignition Timing

79

CRANKSHAFT MISALIGNMENT

82

AND DEFLECTION

82

Rod Journal

83

1,2,3,4, Seal and Bearing

84

Crankshaft Deflection

86

2,3,6, Bearing and Crankshaft

87

1,4 Seal

88

5, Drive Pin

88

7, Crankcase

88

8,9, Screw

89

8,9,10, Screw

89

11, Stud

89

Finalizing Assembly

90

12, Oil Outlet Fitting

90

5,6, Circlip and Spring Seat

92

7,8, Snap Ring and Bearing

93

9, Bearing

93

Rotary Valve Shaft Deflection

95

1, Bearing

96

Snap Ring

97

ROTARY VALVE

98

290 924 502

99

295 000 007

100

295 000 065

100

Section 04 ENGINE

101

Sub-Section 05 (ROTARY VALVE)

101

TABLE OF CONTENTS

102

FLAT RATE

103

2, Flushing Connector

104

3, Elbow Fitting

104

1, Clamp

104

Challenger

105

Section 05 COOLING SYSTEM

106

Sub-Section 01 (COMPONENTS)

106

Sub-Section 02 (CIRCUIT)

107

3, Baffle Pick Up

115

Fuel Tank Removal

116

CARBURETOR REMOVAL

119

CLEANING

119

DISASSEMBLY AND INSPECTION

119

PUMP VERIFICATION

119

CARBURETOR ASSEMBLY

120

Section 06 FUEL SYSTEM

121

Sub-Section 03 (CARBURETORS)

121

CARBURETOR INSTALLATION

122

Carburetor Synchronization

123

Fuel Lines and Hose Clamps

123

Flame Arrester

123

Throttle Cable(s)

124

Speedster Only

124

All Models

124

2, Low-Speed Mixture Screw

125

16, High-Speed Mixture Screw

126

15, Idle Speed Screw

126

Pressure Test

127

1,2, Clamp and Hose

131

3, Check Valve

131

F01D4RC

134

Synchronization (All Models)

135

Bleeding

135

CHECKING OPERATION

136

TABLE OF CONTENT

138

Section 08 ELECTRICAL

139

OVERVIEW 1

141

MPEM (MULTI-PURPOSE

142

ELECTRONIC MODULE)

142

CHARGING SYSTEM

142

STARTING SYSTEM

142

GAUGES / ACCESSORIES

142

Sub-Section 01 (OVERVIEW)

143

787 ENGINE

144

MAGNETO SYSTEM

144

CHARGING CIRCUIT SCHEMATIC

144

IGNITION SYSTEM

145

STARTING SYSTEM AND

145

DISASSEMBLY

147

ASSEMBLY

148

INSTALLATION

148

MAGNETO ROTOR AND ENGINE

150

FLYWHEEL REMOVAL

150

ELECTRICAL SYSTEM

151

Sportster

152

Speedster

154

Ignition Coil Output

157

IGNITION TIMING, 717 ENGINE

158

Checking Ignition Timing

160

IGNITION TIMING ADJUSTMENT

161

717 ENGINE

161

Trigger Coil

162

DC-CDI Module

163

Ignition Coil

163

IGNITION TIMING, 787 ENGINE

165

Ignition Timing Adjustment

166

Programmer

167

SPARK PLUG SYMBOL EXPLANATION

168

HEAT RANGE

169

SPARK PLUG ANALYSIS

169

SPARK PLUG INSTALLATION

169

SPARK PLUG CHART

170

THE DESS (DIGITALLY ENCODED

171

SECURITY SYSTEM) 5

171

The Advanced Diagnostic Mode

173

OPERATION OF MPEM

175

RPM Limiter

176

DESS Post

176

Start / Stop Switch

177

Starting Solenoid Activation

177

Neutral Switch

177

Gauge Supply Outlet

178

Monitoring Beeper

178

Overheat Sensor

178

Accessories

178

Charging System

179

TESTING PROCEDURE 717

180

TESTING PROCEDURES

181

Rectifier / Regulator

182

All Engines

182

ELECTRIC STARTER

183

INSPECTION

186

1,7, Yoke Ass’y and Housing

188

Through Bolt

188

13,17, Screw

189

16,18, Screw and Teeth Washer

189

STARTER SPECIFICATION

190

TROUBLESHOOTING

191

HYDROMETER TEST

192

BATTERY STORAGE

192

ACTIVATION OF NEW BATTERY

192

Electrolyte Level

195

Discharged Battery

195

INSTALLATION OF BATTERY

196

FUEL / OIL GAUGE

199

WIRE COLOR

202

WIRE TERMINAL REMOVAL

202

ACCESSORIES INSTALLATION

202

FUSES LOCATION

202

JET PUMP UNIT

204

DRIVE SHAFT AND SEAL CARRIER

205

Ring Clearance

206

Oil Inspection

206

JET PUMP REMOVAL

207

7,8, Nut and Impeller Housing

209

31, Jet Pump Support

210

16, Boot

210

30, Fitting

211

19, Impeller

211

20, Wear Ring

212

21, Seal

212

22, Needle Bearing

213

PARTS INSPECTION

214

19,20, IMPELLER AND WEAR RING

216

09-01-14

217

JET PUMP ASSEMBLY

218

09-01-16

219

09-01-17

220

09-01-18

221

Loctite 518

222

Oil Fill

223

Jet Pump Support

224

JET PUMP INSTALLATION

225

Jet Pump Unit

226

PRE-CLAMPING POSITION

227

1. Holding hook

227

2. Large window

227

1. Closing hooks

227

1. Grease PTO flywheel

227

2. Latching mechanism

229

Shifter Cable Replacement

232

Trim Cable Replacement

234

Cable Adjustment

234

STEERING SYSTEM 1

237

Installation

239

Section 10 STEERING SYSTEM

241

Sub-Section 02 (ALIGNMENT)

241

Speedster model

242

Lever Friction Adjustment

243

Shifter Lock Adjustment

244

Bumper and Trim

252

REAR STORAGE COMPARTMENT

253

COVER GAS SHOCKS

253

LATCH ADJUSTMENT

253

DRAIN / COOLING OUTLET(S)

253

LOCATION

253

DRAIN REPLACEMENT

254

SEAT REMOVAL / INSTALLATION

254

HULL AND DECK REPAIR

255

AIR BUBBLES

255

BLISTERS

256

MINOR GELCOAT FRACTURES

256

COMPOUND FRACTURES

256

Patching the Repair Area

257

Buffing and Waxing

257

Materials

258

PAINTING 3

259

Sea-Doo Jet Boat

259

Parts Catalog

259

PARTS THAT CAN BE PAINTED

260

Section 11 HULL / DECK

261

Sub-Section 03 (PAINTING)

261

CONCEPTTM PAINTING PROCEDURE

262

SURFACE PREPARATION

262

FULL PANEL AND OVERALL

262

SPOT / PANEL REPAIRS

262

DELTATM PAINTING PROCEDURE

263

2800, COLOR

263

RECOMMENDED SPRAY EQUIPMENT

263

ALL MODELS 1

264

Section 12 TECHNICAL DATA

265

Sub-Section 01 (ALL MODELS)

265

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