BOMBARDIER Sea-Doo SPORTSTER LE Shop Manual Supplement Download

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Section 04

ENGINE

Subsection 05

(TOP END)

04-05-8

LMR2000_053_04_05A.FM

Remove sliding valve

no. 12

1. Remove sliding valve

Remove bellows

no. 10

1. Remove bellows

Cylinder Head

Disconnect temperature sensor wire and spark
plug cables.

Connect spark plug cables on grounding device.

Disconnect hose of RAVE valves.

Loosen cylinder head bolts

no. 16

following the

sequence shown in the next photo.

UNTORQUING SEQUENCE FOR THE CYLINDER HEAD BOLTS

Loosen nuts

no. 17

following the sequence shown

in the next photo.

UNTORQUING SEQUENCE FOR THE NUTS

F06D0UA

F06D0VA

F06D0WA

F06D29A

Summary of Contents for Sea-Doo SPORTSTER LE

Page 1: ...219 100 097...

Page 2: ...Shop Manual Supplement SPORTSTER LE Use in conjunction with Shop Manual Volume 1 P N 219 100 097...

Page 3: ...this manual may be reproduced in any form without the prior written permission of Bombardier Inc Bombardier Inc 2000 Printed in Canada Registered trademarks of Bombardier Inc Loctite is a trademark of...

Page 4: ...04 03 1 04 Magneto 04 04 1 05 Top End 04 05 1 06 Bottom End 04 06 1 07 Rotary Valve NOT APPLICABLE 08 Exhaust System 04 08 1 05 COOLING SYSTEM 01 Table of Contents 05 01 1 02 Circuit Components and Ca...

Page 5: ...al 05 Weedless System See Shop Manual 10 STEERING SYSTEM 01 Table of Contents See Shop Manual 02 Steering System See Shop Manual 03 Alignment See Shop Manual 04 Throttle Shifter Controller See Shop Ma...

Page 6: ...g 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 in...

Page 7: ...s information specifically applicable to the Sportster LE and should always be used in conjunction with 1999 Sport Boat Shop Manual Volume 1 P N 219 100 097 ENGINE IDENTIFICATION NUMBER E I N 947 Engi...

Page 8: ...TOOLS Subsection 01 TABLE OF CONTENTS LMR2000_043_01_01ATOC FM 01 01 1 TABLE OF CONTENTS 0 MANDATORY SERVICE TOOLS 01 02 1 ENGINE 01 02 1 OPTIONAL SERVICE TOOLS 01 03 1 ENGINE 01 03 1 COOLING FUEL OI...

Page 9: ...ton pin removal and installa tion Use with puller P N 529 035 503 Puller P N 529 035 547 A00C1A4 APPLICATION PTO flywheel removal Ring gear puller tool P N 420 976 235 947 engine puller ass y P N 529...

Page 10: ...1 OPTIONAL SERVICE TOOLS 0 ENGINE Distance gauge A P N 529 035 100 11 5 mm B P N 529 035 000 7 5 mm F01B0H4 APPLICATION A 947 engine MAG B 947 engine PTO Rubber pad P N 290 877 032 F06B064 APPLICATION...

Page 11: ...SERVICE TOOLS Subsection 03 OPTIONAL SERVICE TOOLS 01 03 2 LMR2000_044_01_03A FM COOLING FUEL OIL SYSTEMS Pump gauge tester P N 295 000 114 F01B0X4 APPLICATION All models 35 4 3 25 2 15 1 5 60 50 4 0...

Page 12: ...TABLE OF CONTENTS LMR2000_046_02_01ATOC FM 02 01 1 TABLE OF CONTENTS 0 PERIODIC INSPECTION CHART 02 02 1 FLUSHING AND LUBRICATION 02 03 1 GENERAL 02 03 1 PROCEDURE 02 03 1 WATER FLOODED ENGINE 02 04...

Page 13: ...w regulator valve inspection D FUEL SYSTEM Carburetor adjustment including choke throttle cable adjustments D Throttle choke cables inspection lubrication D Fuel filter and lines inspection D Fuel fil...

Page 14: ...season To be performed by STEERING SYSTEM Inspection and cable adjustment D LOW SPEED STEERING SYSTEM Inspection and throttle cable adjustment D PROPULSION SYSTEM Drive shaft boot and spline conditio...

Page 15: ...ine compartment lo cation choose one of both method 2 Engine lubrication 3 After flushing procedure 4 Cylinder wall lubrication Flushing Procedure Use of the Lower Flushing Connector 1 Clean jet pump...

Page 16: ...dge of the en gine compartment as shown in the next photo 1 Upper flushing connector For proper flushing from this location it is neces sary to prevent water from going out directly by the flushing co...

Page 17: ...ter tap before stopping the engine Remove garden hose Ensure the rubber washer remains in the boat hose connector Remove hose pincher from water outlet hose CAUTION Serious engine damage can occur if...

Page 18: ...plug holes Spray BOMBARDIER LUBE lubricant P N 293 600 016 into spark plug holes Crank engine again Reinstall spark plugs and spark plug cables Turn fuel valve to ON position Start engine It may be ne...

Page 19: ...boat Cooling System Flushing and Engine Internal Lubrication Cooling system has to be flushed with fresh water to prevent salt sand or dirt accumulation which will clog water passages Engine must be...

Page 20: ...Korkay System Ltd or the equivalent Anticorrosion Treatment Wipe off any residual water in the engine compart ment Spray BOMBARDIER LUBE lubricant over all me tallic components in engine compartment...

Page 21: ...y hose Remove temporary hose and reconnect engine water return hose Remove hose pinchers Most of the antifreeze will drain out when remov ing hose pincher s Use a container to recover it Dispose of an...

Page 22: ...AL 04 03 1 REMOVAL FROM SPORT BOAT 04 03 1 CLEANING 04 03 3 INSTALLATION 04 03 3 MAGNETO 04 04 1 DISASSEMBLY 04 04 2 CLEANING 04 04 3 ASSEMBLY 04 04 3 TOP END 04 05 1 GENERAL 04 05 2 DISASSEMBLY 04 05...

Page 23: ...ith Bottom End and Top End testing Bottom End and Top End Remove the carburetor s and gasket s Make sure the surface of the exhaust manifold is clean Install the intake plates P N 296 000 025 with fas...

Page 24: ...ction pump lines and fit tings check for air bubbles or oil column going to ward pump which indicate a defective check valve If there is still some leakage remove the PTO fly wheel to verify outer sea...

Page 25: ...MOVING TOWARD PUMP YES REPLACE CHECK VALVE S LINE S CHECK TESTING KIT CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES ARE SEALS LEAKING REPLACE DEFECTIVE SEAL S YES NO UNSEAL PTO CYLINDER AND MAG CYL...

Page 26: ...PRO PULSION Electrical Connections TYPICAL TURN OFF MAIN BATTERY CUT OFF SWITCH Unfasten battery top brace First remove BLACK negative cable from battery then RED positive cable Disconnect thermosens...

Page 27: ...engine support mount screws shims could have been installed underneath Shims control engine jet pump align ment Always note position of shims for reinstal lation to avoid altering engine alignment 1 R...

Page 28: ...r Mount Shim and Screw Check tightness and condition of rubber mounts If rubber mounts have been removed apply Loctite 243 on screw threads Torque screws to 25 N m 18 lbf ft CAUTION Strict adherence t...

Page 29: ...jet pump support Secure alignment plate using existing jet pump nuts Carefully slide shaft through support as shown in the next photo TYPICAL 1 Sliding shaft through support 2 Alignment plate properly...

Page 30: ...rews to 25 N m 18 lbf ft once procedure is complete NOTE Whenever alignment tool is not utilized apply BOMBARDIER LUBE P N 293 600 016 lu bricant on its shaft and inside the housing to elim inate poss...

Page 31: ...R2000_052_04_04A FM 04 04 1 MAGNETO 0 F06D0IT Loctite 243 Loctite 243 Loctite 243 Loctite 648 Loctite 648 Anti seize lubricant 9 N m 80 lbf in 13 N m 115 lbf in 115 N m 85 lbf ft 9 N m 80 lbf in 6 4 5...

Page 32: ...1 Remove oil pump shaft Rotor and Flywheel To remove the rotor no 4or the flywheel no 5 the crankshaft must be locked For procedure refer to BOTTOM END If necessary the magneto rotor can be removed w...

Page 33: ...igger coil no 9 from the engine magneto cover 1 Remove screws CLEANING Clean all metal components in a solvent CAUTION Clean coils and magnets using only a clean cloth Clean crankshaft taper and threa...

Page 34: ...lbf in Apply Loctite 243 on crankshaft taper 1 Loctite 243 on crankshaft taper Install flywheel and make sure to align keyway with the crankshaft Woodruff key Apply Loctite 243 on nut no 6 Install nut...

Page 35: ...P END 0 F06D17U Loctite 243 Loctite 243 Synthetic grease 2 3 25 36 rollers 21 22 4 21 Synthetic grease 16 18 20 34 N m 25 lbf ft 5 N m 44 lbf in 34 N m 25 lbf ft 28 17 12 15 24 Loctite 243 5 7 6 11 9...

Page 36: ...controlled by the Multi Purpose Electronic Module MPEM The MPEM measures 2 factors to control the RAVE valves engine speed RPM and its rate of accel eration To open the RAVE valves the MPEM activates...

Page 37: ...bsection 05 TOP END LMR2000_053_04_05A FM 04 05 3 RAVE VALVE OPENED 1 Pulse from crankcase 2 Check valve 3 Positive pressure to solenoid 4 Solenoid activated 5 Positive crankcase pressure to RAVE valv...

Page 38: ...tion 05 TOP END 04 05 4 LMR2000_053_04_05A FM RAVE VALVE CLOSED 1 Pulse from crankcase 2 Check valve 3 Positive pressure blocked by the solenoid 4 Solenoid deactivated 5 RAVE valves are opened to atmo...

Page 39: ...ery rapidly at full throttle and from a practical standpoint can be considered to be instantaneous at item 7 Gradual application of the throttle however will result in the RAVE valve opening much late...

Page 40: ...g Remove the compression spring no 8 1 Remove spring Remove spring no 9 retaining bellows no 10 to valve piston no 11 1 Spring Free bellows no 10 from valve piston no 11 1 Bellows removed from piston...

Page 41: ...from sliding valve no 12 NOTE Hold the sliding valve to prevent it from turning 1 Unscrew piston 2 Hold sliding valve Remove compression spring no 13 1 Remove spring Remove supporting ring no 14 1 Rem...

Page 42: ...or wire and spark plug cables Connect spark plug cables on grounding device Disconnect hose of RAVE valves Loosen cylinder head bolts no 16 following the sequence shown in the next photo UNTORQUING SE...

Page 43: ...er block no 3 1 Remove studs Remove cylinder block 1 Remove cylinder block NOTE To ease removal a plastic tip hammer can be used Remove cylinder base gasket no 20 Piston NOTE All engines feature cagel...

Page 44: ...ton pin Slide the sleeve and shoulder sleeve onto the spindle Screw in extracting nut with the movable ex tracting ring towards spindle 1 Puller 2 Sleeve 3 Shoulder sleeve 4 Extracting nut NOTE The to...

Page 45: ...are not clogged Remove carbon deposits from cylinder exhaust port RAVE valve cylinder head and piston dome Clean piston ring grooves with a groove cleaner tool or a piece of broken ring INSPECTION Vis...

Page 46: ...er Base Gasket Different thicknesses of cylinder base gaskets are used for a precise adjustment of the combustion chamber volume To identify gasket thickness refer to the identifi cation holes on the...

Page 47: ...kcase opening as for disas sembly Piston Pin and Roller Bearing To install roller bearing no 25 and piston pin no 22 use piston pin puller P N 529 035 503 with the appropriate set of sleeves as for di...

Page 48: ...Plastic Mounting Device Method This is an alternate method when no service tool is available Replacement roller bearings are delivered in a con venient plastic mounting device For installation procee...

Page 49: ...on oppo site side Support piston from opposite side TYPICAL As necessary pull halves of inner sleeve with long nose pliers TYPICAL 1 Pulling inner sleeve half Circlip Always use new circlips CAUTION A...

Page 50: ...to install a new gasket of the same thickness However if you do not know the gasket thickness that was installed or if a crankshaft and or crankcase repair or re placement was involved refer to the CO...

Page 51: ...sequence in the next picture Re peat the torquing sequence by retightening to 34 N m 25 lbf ft TORQUING SEQUENCE ADJUSTMENT RAVE Valve Turn the red plastic knob no 29 until it is fully tight ened TYP...

Page 52: ...filling If so there is a leak between piston and cylinder The recorded vol ume would be false 5 Let burette stand upward for about 10 minutes until liquid level is stabilized 6 Read the burette scale...

Page 53: ...tite 648 Loctite 243 Synthetic grease 23 N m 17 lbf ft Loctite 243 8 5 4 Loctite 518 11 9 N m 80 lbf in Loctite 243 12 13 2 21 Synthetic grease Loctite 518 Synthetic grease Loctite 518 25 Synthetic gr...

Page 54: ...len screws 2 Breaker bar locking crankshaft Remove the coupler Install puller plate P N 529 035 533 and extension handle P N 295 000 125 to PTO flywheel NOTE Puller plate can be used without the exten...

Page 55: ...no 2 1 Starter drive assembly Reed Valve Remove both carburetor flanges 1 Carburetor flange Remove reed valves no 3 from crankcase Crankcase Before opening the bottom end remove the fol lowing parts m...

Page 56: ...nterbalance shaft no 7 Crankshaft Bearing and Seal If a crankshaft end seal no 6 has to be replaced bottom end must be opened NOTE Do not needlessly remove crankshaft bear ings no 5 Remove end seals T...

Page 57: ...l metal components in a solvent Remove old Loctite from crankcase mating surfac es with gasket remover P N 413 708 500 CAUTION Be careful not to spray cleaner on the painted surface of the engine Neve...

Page 58: ...ng Rod Journal Counterweights can also be twisted on connect ing rod journal on any or both cylinder s 1 Connecting rod journal alignment here Such misalignment may cause a crankshaft hard to be manua...

Page 59: ...cator First check deflection with crankshaft in crank case If deflection exceeds the specified toler ance it can be either ball bearings wear bent or twisted crankshaft at connecting rod journal 1 Mea...

Page 60: ...s The reed petals must lie completely flat against the reed valve body no 23 To check hold against light 1 No play In case of a play turn reed petals upside down and recheck If there is still a play r...

Page 61: ...l expand bearing and ease instal lation To properly position the outer bearing s a dis tance gauge must be temporarily installed against the inner bearing Slide the outer bearing until stopped by the...

Page 62: ...counterweights no 15 using a press and take care to align index marks previously traced Crankshaft and Counterbalance Shaft Install crankshaft no 14 first in crankcase After crankshaft installation in...

Page 63: ...mended to use Loctite Primer N to reduce curing time and increase gap filling capability Refer to manufactur er s instructions Make sure all locating dowels are in place 1 Dowel Crankcase Screws Apply...

Page 64: ...olt no 10 Using the same tools as for disassembly proce dure torque bolt to 115 N m 85 lbf ft Apply Loctite 648 on mating surface of PTO fly wheel and coupler Apply Loctite 243 to Allen screws no 8 of...

Page 65: ...35 lbf in 5 6 7 16 8 14 N m 10 lbf ft 40 N m 30 lbf ft Loctite 243 Loctite 243 10 4 9 19 1 13 14 Loctite 271 17 18 17 11 Loctite 243 25 N m 18 lbf ft 25 N m 18 lbf ft Loctite 243 25 N m 18 lbf ft 17 1...

Page 66: ...sconnect small hose from water outlet fitting at the tuned pipe head 1 Disconnect hose from outlet fitting Disconnect the water injection hose at tuned pipe head 1 Water injection hose Disconnect the...

Page 67: ...ove clamp Loosen Allen screw retaining carburetor bracket to tuned pipe head 1 Loosen Allen screw Loosen Allen screws no 9 and nut no 10 at tuned pipe flange NOTE To loosen nut use polygonal wrench P...

Page 68: ...from resonator no 2 to muffler Loosen clamps retaining exhaust hose to exhaust outlet Detach holding strap retaining resonator inside bilge Pull resonator out of bilge Muffler Disconnect hoses from mu...

Page 69: ...ake sure to install the sealing ring no 16 on tuned pipe cone if it was removed TYPICAL 1 Sealing ring Apply a thin layer of Ultra Copper heat resistant sealant P N 413 710 300 all around sealing ring...

Page 70: ...9 035 505 1 Torque Allen screws and nut not shown to 25 N m 18 lbf ft Torque bolt of tuned pipe head above the engine magneto to 25 N m 18 lbf ft 1 Torque bolt to 25 N m 18 lbf ft Torque bolt of tuned...

Page 71: ...EXHAUST SYSTEM LMR2000_055_04_08A FM 04 08 7 1 Torque Allen screws and nut not shown to 40 N m 30 lbf ft Torque exhaust hose clamp no 5 of tuned pipe cone to 4 N m 35 lbf in 1 Torque clamp to 4 N m 3...

Page 72: ...Section 05 COOLING SYSTEM Subsection 01 TABLE OF CONTENTS LMR2000_056_05_01ATOC FM 05 01 1 TABLE OF CONTENTS 0 CIRCUIT COMPONENTS AND CARE 05 02 1 CIRCUIT 05 02 2 COMPONENTS 05 02 4...

Page 73: ...S AND CARE LMR2000_056_05_02A FM 05 02 1 CIRCUIT COMPONENTS AND CARE 0 11 N m 1 lbf in 5 N m 44 lbf in Loctite 592 Loctite 567 Loctite 567 Loctite 592 Loctite 567 Loctite 567 1 2 N m 11 lbf in 1 2 N m...

Page 74: ...the impeller and venturi Water is directed to the water inlet fitting at cylin der head 1 Water supply hose Water circulates through the one piece cylinder head which features improved combustion cham...

Page 75: ...ated at the uppermost point of the circuit at the tuned pipe The bleed hose also serves as the Cooling System Indicator CSI 1 Bleed hose The water supply of the water flow regulator is provided by the...

Page 76: ...tab NOTE If clamp cannot be removed using screw driver cut clamp To cut or secure non reusable Oetiker clamps use pliers P N 295 000 070 1 Cutting clamp 2 Securing clamp TECHNICAL DATA TYPE TLCS Tota...

Page 77: ...r valve has a calibrated spring and a tapered needle which regulate the injected water in the tuned pipe CAUTION Do not change the calibration of the spring otherwise serious engine damage can occur A...

Page 78: ...performance the water flow regulator valve should be considered in the troubleshooting of the problem Disassembly Remove the cover no 2 of the valve by releasing the spring no 3 1 Spring 2 Cover Remov...

Page 79: ...upply hose from the jet pump housing to the engine with a large hose pincher P N 529 030 400 This will prevent the cooling system from filling which may lead to water being injected into and filling t...

Page 80: ...06 FUEL SYSTEM Subsection 01 TABLE OF CONTENTS LMR2000_059_06_01ATOC FM 06 01 1 TABLE OF CONTENTS 0 AIR INTAKE 06 03 1 REMOVAL 06 03 2 ASSEMBLY 06 03 2 CARBURETOR 06 04 1 ASSEMBLY 06 04 2 ADJUSTMENTS...

Page 81: ...Section 06 FUEL SYSTEM Subsection 03 AIR INTAKE LMR2000_059_06_03A FM 06 03 1 AIR INTAKE 0 F08F07T Loctite 243 2 3 Loctite 243 4 Super Lube 1...

Page 82: ...arward to remove it from the lower bracket no 4 and remove it in a rotating movement The air intake silencer is a molded piece and it can not be opened It has an integrated flame arrester ASSEMBLY Ass...

Page 83: ...FUEL SYSTEM Subsection 04 CARBURETOR LMR2000_060_06_04A FM 06 04 1 CARBURETOR 0 Mikuni BN 46i F02F1ZU Loctite 243 3 2 1 Loctite 577 Loctite 243 20 N m 15 lbf ft Anti seize lubricant Synthetic grease P...

Page 84: ...herwise hold carbure tor upside down pour oil over needle valve and apply pressure Check for bubbles If they come from seat or O ring bubbles will exit around seat Retighten as necessary If it still l...

Page 85: ...ith stopper Adjust as follows Adjust oil pump cable Refer to OIL INJECTION PUMP NOTE It is important to adjust oil pump cable prior to finalize adjustment of throttle cable CAUTION Improper oil inject...

Page 86: ...pt to adjust high speed screw by removing plastic cap 1 High speed screw PTO side shown Idle Speed Screw Turning screw no 2 clockwise increases engine idle speed and turning screw counterclockwise dec...

Page 87: ...Section 06 FUEL SYSTEM Subsection 04 CARBURETOR LMR2000_060_06_04A FM 06 04 5 TYPICAL 1 Adjustment screw 2 Small gap NOTE Turning the adjustment screw clockwise will increase the gap F02F1QA 1 2...

Page 88: ...0_061_07_01ATOC FM 07 01 1 TABLE OF CONTENTS 0 OIL INJECTION SYSTEM 07 02 1 GENERAL 07 02 2 OIL SYSTEM PRESSURIZATION 07 02 2 OIL INJECTION PUMP 07 03 1 REMOVAL 07 03 2 DISASSEMBLY 07 03 2 CLEANING 07...

Page 89: ...ion 07 LUBRICATION SYSTEM Subsection 02 OIL INJECTION SYSTEM LMR2000_061_07_02A FM 07 02 1 OIL INJECTION SYSTEM 0 F07G03S Dielectric grease 27 N m 20 lbf ft 3 5 N m 31 lbf in 3 5 N m 31 lbf in 1 3 2 1...

Page 90: ...Install a hose pincher to oil injection pump sup ply hose Connect pump gauge tester P N 529 021 800 to check valve of oil injection reservoir vent NOTE Use the same pump included in the EN GINE LEAK...

Page 91: ...LUBRICATION SYSTEM Subsection 03 OIL INJECTION PUMP LMR2000_062_07_03A FM 07 03 1 OIL INJECTION PUMP 0 F07G07T 4 5 N m 40 lbf in Loctite 243 3 4 5 N m 40 lbf in 3 1 4 2 To MPEM To carburetor 4 5 N m...

Page 92: ...see Final Synchronization Make sure idle speed screw on carburetor is prop erly set Refer to CARBURETOR for throttle cable adjust ment procedure NOTE Make sure carburetors are properly syn chronized...

Page 93: ...f not remove pump assembly and check the pump gear or shaft for defects replace as neces sary Test pump as describes below NOTE Through normal use oil level must not drop in small tubes If oil drops v...

Page 94: ...1 IGNITION TIMING 08 03 2 IGNITION SYSTEM TESTING PROCEDURE 08 03 6 CHARGING SYSTEM 08 07 1 GENERAL 08 07 1 TESTING PROCEDURE 08 07 1 STARTING SYSTEM 08 08 1 GENERAL 08 08 2 STARTER REMOVAL 08 08 2 ST...

Page 95: ...rigger Coil The trigger coil is mounted outside the rotor in side the magneto housing of the engine and is not adjustable 1 Trigger coil Its purpose is to signal the engine position to the Multi Purpo...

Page 96: ...hen to fire Compared to the magneto system the DC CDI system offers a more powerful and stable ignition at low RPM Electrical Box The high amperage voltage components are locat ed into the electrical...

Page 97: ...NOTE Between 3000 and 4000 RPM the spark advance does not change So when checking igni tion timing at 3500 RPM a change in engine speed within 500 RPM will not affect the timing mark when checked with...

Page 98: ...e when using the stroboscopic timing light CAUTION The static test cannot be used as a timing procedure therefore always check the timing with a stroboscopic timing light 8 Remove TDC gauge 9 Reinstal...

Page 99: ...ming is adjusted too advanced this will cause serious damage to the engine The timing mark on the PTO flywheel refers to the physical component position when the spark must occurs The MPEM must be syn...

Page 100: ...M programmer and the other end to the safety lanyard switch on the craft 2 Press the ON C button on programmer and en ter your password 3 Press 3 to choose Vehicle info in programmer 4 Press 4 to choo...

Page 101: ...wire and the other test probe to the switch ring Measure resis tance it must be close to 0 ohm Safety Lanyard on Switch Connect test probes to switch BLACK and BLACK YELLOW wires Measure resistance it...

Page 102: ...coil 2 With the multimeter set on the resistance scale connect the meter probes to the primary termi nals of the coil 3 Resistance should be between 0 34 0 62 ohm Secondary Winding The spark plug cap...

Page 103: ...this cause severe damage Two 15 A fuses protect the charging system The first one is mounted on the MPEM and the other one is located in the rear electrical box TESTING PROCEDURE NOTE First ensure th...

Page 104: ...f the 6 pin magneto harness adapter 4 Ground the multimeter negative probe to the engine or the stator iron core and note the read ing 1 Multimeter 2 Magneto harness adapter 3 Positive probe to YELLOW...

Page 105: ...YSTEM Subsection 08 STARTING SYSTEM LMR2000_069_08_08 FM 08 08 1 STARTING SYSTEM 0 Sportster LE F07H0TS Dielectric grease 17 Loctite 243 16 10 N m 89 lbf in Synthetic grease Synthetic grease 18 10 11...

Page 106: ...check primary winding resis tance It should be approximately 5 ohms There should be no continuity between the posi tive posts of the solenoid Dynamic Test Depress start stop button and measure the vol...

Page 107: ...Index marks Loosen through bolts no 5 1 Through bolts Remove end cover no 3 and gasket on armature shaft side Remove thrust washers no 19 from armature shaft 1 Thrust washers Remove the other end cov...

Page 108: ...immersed in cleaning solvent Discard all O rings Clean brushes and holders with a clean cloth soaked in solvent Brushes must be dried thor oughly with a clean cloth Blow brush holders clean using comp...

Page 109: ...tator out of round is more than 0 40 mm 016 in commu tator should be turned on a lathe Check commutator outer diameter If less than 27 mm 1 063 in replace Brush Holder Check brush holder for insulatio...

Page 110: ...ticular attention to the following Make sure that starter and engine mating surfaces are free of debris Serious trouble may arise if starter is not properly aligned Screw Apply Loctite 243 to Allen sc...

Page 111: ...ECIFICATION 947 Engine Nominal output 0 8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight 1 7 kg 3 7 lb Performance specification at 20 C 68 F No load 10...

Page 112: ...STEM Subsection 01 TABLE OF CONTENTS LMR2000_63_09_01ATOC FM 09 01 1 TABLE OF CONTENTS 0 JET PUMP 09 02 1 GENERAL 09 02 2 INSPECTION ON SPORT BOAT 09 02 2 ASSEMBLY 09 02 2 DRIVE SYSTEM 09 03 1 GENERAL...

Page 113: ...0 TYPICAL F00J0RT Loctite 518 Right Stuff sealant Loctite 518 Silicone sealant Loctite 518 Loctite 262 Loctite 518 Pipe sealant Loctite 243 Loctite 243 Loctite 243 Loctite 243 20 N m 15 lbf ft 20 N m...

Page 114: ...securely install it on a stand Thus if access is needed to water inlet area it will be easy to slide underneath boat A lift kit can be used to install boat on a stand See table below Refer to the kit...

Page 115: ...Section 09 PROPULSION SYSTEM Subsection 03 DRIVE SYSTEM LMR2000_064_09_03A FM 09 03 1 DRIVE SYSTEM 0 1 8 N m 16 lbf in Synthetic grease Synthetic grease F04J47T Loctite 271 Right Stuff sealant...

Page 116: ...3 16 in 1 Use ball end mill for radius This section of the slot should be 38 mm 1 15 32 in deep 2 Drill 25 mm 1 in hole in center to remove material 3 Weld all around 4 Drill 9 mm 11 32 in hole 5 Dri...

Page 117: ...ed 6 1 1 Cylinder head warpage maximum 0 10 mm 004 in Piston ring type and quantity 2 semi trapez Ring end gap New 0 45 0 60 mm 018 024 in Wear limit 1 00 mm 039 in Ring piston groove clearance New 0...

Page 118: ...upplied Fuse Main 3 x 20 A MPEM Multi Purpose Electronic Module supply 5 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...

Page 119: ...tat None Overheating beeper setting 86 94 C 187 201 F ADDITIONAL INFORMATION PROPULSION SPORTSTER LE Propulsion system Bombardier Formula sea pump big hub Number of pump 1 Jet pump type Axial flow sin...

Page 120: ...ORMATION CAPACITIES SPORTSTER LE Fuel tank total capacity 83 L 22 U S gal Fuel tank reserve 15 L 4 U S gal Impeller shaft reservoir Capacity 115 mL 3 9 U S oz Oil level height To bottom of cover hole...

Page 121: ...tandard Storage compartment Standard Grab handles Standard Cup holders Standard Mirrors Standard Retractable ski pole Standard Platform pad Standard Radio AM FM N A Bimini top Optional Windshield Opti...

Page 122: ......

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