After the water is pumped out, the pump shuts-off automatically. Turn to bilge position when a manual operation is required after cleaning, storage, etc. Turn it to OFF when finished. The bilge pump may be operated without the safety lanyard on its switch. Bilge pump will then switch to automatic mode.
When turned on, the blower ventilates the engine compartment. Using the bilge blower for a prolonged time when the engine s is are not running will discharge the battery. Blower should be turned off during boat operation.
The gauge is illuminated whenever the navigation lights are used. The fuel level can also be verified without having engine s running. Fill reservoir as soon as possible, if lamp remains ON contact an authorized dealer.
Serious engine damage will occur. Multiply reading by to obtain actual RPM. The gauges are illuminated whenever the navigation lights are used.
Port engine tachometer 2. Starboard engine tachometer. A speed sensor mounted on the left ride shoe sends the signal to the speedometer. Should water be left in the bilge, it can be easily drained by unscrewing the plug.
Tilt the sport boat slightly to the rear so that the water can completely flow out of the bilge. Keep away from jet s or intake grate s. No passenger should use the most forward seat in the bow area if it faces backwards except at low speed in calm water or when the sport boat is stopped. Provide a handhold for the passengers. Refer to components location illustrations at the beginning of this section for grab handles location. Do not keep bottles, cans etc.
A convenient watertight, lockable storage compartment with a removable basket to carry personal articles. The basket is the ideal location for spare spark plugs, first aid kit, etc. Never operate the craft with the storage compartment cover open. Pull the latch lever upward to unlock storage compartment cover. Lift cover until stopped by the retaining device. The cover will hold in this position on calm water. Push cover down to release mechanism then move down slowly. When bottomed on latch, firmly push cover to lock.
Periodically verify the lock pin tightness of storage cover. Tighten if needed and make sure storage cover latches properly. The basket is provided with a holder to store an approved fire extinguisher. The fire extinguisher sold separately should not be loose in the storage compartment.
Lift the latch ring and open cover gently until stopped by retaining spring. When completely opened, the cover remains in that position on calm water. To close, gently push on the side of the spring to release it and lower the cover. Pull the latch lever upward and open engine cover gently until stopped. The gas assist cylinder will complete the opening and hold cover open. The storage tray is removable to give access to the engine compartment. Grab the handle and lift in a rearward movement until opposite holders release.
Never leave any object, rag, tool, etc. Never operate the craft with the rear storage compartment cover open. Ski Rope Storage Compartment. When reinstalling storage tray, ensure to properly locate it just below holders, gently lower tray then push it downward to lock. Convenient storage compartment located on engine cover.
This compartment is ideal for ski rope storage. It minimizes entry of foreign objects into the propulsion system. It is recommended to keep it in rear storage compartment at all times except when needed.
To remove from storage cover, pull it out. Snap in place to store again. Keep away from intake grate while engine is on. Items such as long hair, loose clothing or personal flotation device straps can become entangled in moving parts resulting in severe injury or drowning.
Installation — Lift connector cap. Ensure to align hole keyway with post screw head. Turn until locked. It may be necessary to slightly turn it to allow its insertion in the hole. See Light Switch as mentioned earlier in this section. The use of dock lines with sealed air fenders is recommended to protect your boat.
Always stop the engine before refueling. Fuel is inflammable and explosive under certain conditions. Always work in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Fuel tank may be pressurized, slowly turn cap when opening.
Keep craft level. Do not overfill or top off the fuel tank and leave craft in the sun. As temperature increases, fuel expands and might overflow. Always wipe off any fuel spillage from the craft. Never use an open flame to check fuel level. It provides drainage of water from rain, deck washing, water splashing, etc.
Keep clean to avoid clogging. NOTE: Each engine is provided with a flushing connector onto jet pump support. Port connector is for port engine and starboard connector is for starboard engine. For your convenience, there are additional flushing connectors under the rear storage compartment cover.
Lift cover, the flushing connectors are on each side of the storage compartment. Unscrew cap by turning counterclockwise and firmly tighten by turning clockwise. Close cover. You may use the flushing connectors at the location that you find more practical. NOTE: When using upper flushing connectors, hose pincher s must be installed in engine compartment. They should never be obstructed. Turns side to side via input from the steering wheel.
This provides directional control when engine is running. Shift lever should only be used when the engine is idling and craft is completely stopped. Push lever 2. Always have one person other than the operator as an observer. Unless absolutely necessary, do not make tight, sharp turns.
Keep a safe distance from the docks, other swimmers, craft or objects. Be advised that serious injury can result if the tow rope become slack during a tight turn or when circling. The rope could become wrapped around the neck or limbs of a person. This allows air in engine water jacket to escape. Valve for starboard engine 2. Valve for port engine 3. OFF 5. Turn to align notch with desired position 6. OFF: Stops fuel supply to carburetors.
ON: Allows fuel to flow to carburetors. This is the normal position for operation of the sport boat. Make sure valve s is are fully opened while running. On Challenger model, start one engine and check water flow at bleed outlet. Stop engine then start the other one and check water flow. If everything is correct, restart the first engine. It is provided to allow a complete cut-out of the electrical system.
It must be in the ON position to allow the use of electrical components and to start the engine s. It is recommended to set in the OFF position whenever performing maintenance in the engine compartment, on the electrical system, when transportation or during short term storage.
Turn off engine s. Tie craft securely to the fueling pier. Use bilge blower for a minimum of 5 minutes. Turn off bilge air blower, bilge pump and any other devices that could produce a spark. Ensure engine cover is closed to prevent fumes from entering the engine compartment. Disembark all people. Do not smoke or allow open flames in the vicinity.
Have a fire extinguisher close at hand. Do not insert the spout too far in filler neck. Pour fuel slowly so that air can escape from the reservoir and prevent fuel flowback. Fill fuel tank to bottom of filler neck.
Do not overfill. Fully tighten fuel tank cap and wipe off any fuel spillage. Before starting, ensure there are no fuel fumes in the engine compartment, ventilate using the blower as necessary. Fuel tank may be pressurized.
Slowly turn cap when opening. Do not mix oil with fuel except at engine break-in. Always check oil injection reservoir level when refueling. CAUTION: The use of a fuel other than regular unleaded fuel can result in craft performance deterioration and damage to fuel system and engine components. Never experiment with other fuels or fuel ratios.
Never use fuel containing alcohol, methanol or similar products including naphtha. Reinstall cap and fully tighten. Use only two-stroke engine injection oil sold by authorized Sea-Doo sport boats dealers. Use of any other brand of twostroke oil may void the limited warranty. Avoid mixing different brands of API TC oil as resulting chemical reaction may cause severe engine damage. Oil Injection System A sufficient amount of injection oil should be maintained in the reservoir.
To check, open rear storage cover then lift and hold the tray. Oil level is visible through the translucent reservoir. The use of a funnel is recommended to pour the oil into the reservoir. Wipe off any oil spillage. NOTE: Always carry a spare 1 liter of injection oil. Check and refill every time you refuel.
If the engines run out of oil, severe engine damage will occur. If the oil reservoir is allowed to almost empty, air can enter into the system and it must be bled. Immediately refer to an authorized dealer to have the oil injection system inspected.
We recommend about 10 operating hours. Continued wide open throttle accelerations, prolonged cruising speeds and overloading the engine s is are detrimental during the break-in period. The oil should be added for the first full fuel tank filling only. To add injection oil in the fuel tank, proceed as follows: Fill fuel tank with approximately 50 liters 12 gal of gasoline; then, add the required quantity of injection oil in the fuel tank.
NOTE: It is important to proceed in this order to allow a proper mixing of the oil in the gasoline. If oil is added first in an empty fuel tank, fuel lines will be filled up with injection oil leading in a no start condition of the engine s.
This inspection will also provide the opportunity to discuss any unanswered questions you may have encountered during the first hours of operation. The hour inspection is at the expense of the sport boat owner. NOTE: Inspection applies for both engine systems where applicable. We recommend that this inspection chart be signed by an authorized dealer. Date of hour inspection. Always check the proper operation of critical controls, safety features and mechanical components before starting.
If not done as specified here, severe injury or death might occur. Bring all safety equipment required by local laws. Please refer to these portions to have more detailed information.
Only start craft once all items have been checked and operate properly. With the craft horizontal, fill the fuel tank. Check the oil level and refill reservoir as necessary. Jet Pump Water Intake s Remove weeds, shells, debris or anything else that could restrict the flow of water and damage the cooling system or propulsion units.
Clean as necessary. If any obstruction can not be removed, refer to an authorized dealer for servicing. Consult an authorized dealer. Inspect leading edges of the impellers, if they have nicks or bends, performance will be greatly reduced. Do not boost battery while installed. Steering System Assisted by another person, check steering operation for free movement.
When the steering is centered, the jet pump nozzles should be in the straight ahead position. Ensure the jet pump nozzles pivot easily while steering is turned. Throttle System Check throttle lever s once for free and smooth operation. These pumps deliver fuel to the engine s each time throttle lever s is are moved forward.
Shifter System Check reverse gate s operation for free movement. With shift lever in forward position, the gate s must be in upward position. With the shift lever in neutral position, gate s must be in middle position. With shift lever in reverse position, gate s must be in downward position. On twin-engine models, start engines and stop them using each switch individually. Do not operate the sport boat further, see an authorized dealer.
Only start the sport boat once all items have been checked and operate properly. Become thoroughly familiar with all controls and the function of each. Should any control or instruction be not fully understood, refer to an authorized Sea-Doo dealer. Ensure the bilge plug is fully screwed and the main battery cut-off switch is turned ON. This will allow the water intake grates to be in upper position, eliminating the possibility to come in contact with the trailer.
When finished with loading the boat on trailer, it is suggested to turn the main battery cut-off switch to OFF. After loading the craft, ensure the main battery cut-off switch is turned OFF and the bilge plugs are remove to drain bilge.
Trailering Refer to the trailer instructions for proper capacity, operation, maintenance, accessories and warranty. Check the regulations in your area concerning towing a trailer, especially the following rules: — brake system — tow vehicle weight — mirrors. Use additional tie-downs if necessary.
Observe trailering safety precautions. Principle of Operation Propulsion Each engine is directly coupled to a drive shaft which, in turn, rotates an impeller.
This impeller is accurately adjusted in a housing where the water is drawn up from underneath the sport boat. Then, the water flows through the impeller to a venturi. The venturi accelerates the water and produces thrust to move the sport boat. Pushing the throttle lever s forward increase engine speed and therefore sport boat speed. With shift lever pushed forward, the sport boat moves forward.
In pulled back position, the sport boat moves backward. The middle position is neutral and the sport boat is at the minimum thrust for most conditions. Neutral and reverse are achieved by means of a gate, which is installed on jet pump venturi housing. This gate directs the water flow to obtain the desired direction.
Steering Turning the steering pivots the jet pump nozzle s which control the sport boat direction. Turning the steering clockwise will turn the sport boat to the right and inversely. Steering efficiency will differ depending on the number of passengers, load and water conditions.
A craft needs some throttle to turn. Practice in a safe area applying the throttle and turning away from an imaginary object. This is a good collision avoidance practice. Turning when Using the Reverse The sport boat behaves differently when using the reverse. The steering response is the opposite of forward operation.
So, turning the steering clockwise will turn the sport boat to the left and inversely. Use throttle moderately. Too much RPM will create water turbulence and reduce reverse efficiency. At first outing, carefully practice this maneuver away from anything you might collide. Low-Speed Steering Control System Whenever the throttle lever is in IDLE position AND the steering wheel is approaching the end of its rotation, the engine speed will be slightly accelerated to increase the jet pump thrust.
NOTE: On twin-engine models, each engine must be running so that the lowspeed control properly works. Boarding from a Dock As with any boat, boarding should be done carefully and engine s must not be running. When boarding from a dock, slowly place one foot on the sport boat deck nearest to the dock and then move the other foot inside the boat. Push the sport boat away from the dock. Disconnect cooling system hoses from engine head.
NOTE: Engine will have to be raised inside bilge to disconnect drain hose before removing from bilge. Sliding shaft through support 2. Final Inspection Loosen screws no. Remove engine magneto cover no.
Clean all metal components in a solvent. Apply Loctite on mating surface of the rotor Apply Loctite on nut no. Install nut with lock no. The engine uses reed valves in the crankcase. Pulse from crankcase 2. Check valve 3. Positive pressure to solenoid 4. Solenoid activated 5. Positive pressure blocked by the solenoid 4. Solenoid deactivated 5. Remove spring no. Remove the cover no. The com- pression spring inside the valve is applying pressure against the cover.
NOTE: Hold the sliding valve to prevent it from turning. F06D27A 1. 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. Remove cylinder block. Remove cylinder head gasket no. Remove cylinder block 1. Cylinder Remove cylinder base gasket no. Needles and thrust washer 2. Sleeve 1. Discard all gaskets and O-rings. This is an alternate method when no service tool is available.
Replacement roller bearings are delivered in a con- venient plastic mounting device. Piston pin flush here 2. Thrust washers Always use new circlips. Inject the burette content through the spark volume, engine must be cold, piston must be free plug hole until liquid touches the top spark plug of carbon deposit and cylinder head must be lev- hole. Cover 2. Insert a pry bar be- tween crankcase lugs to separate halves. Separate halves by prying at provided lugs 1. Discard all oil seals, gaskets, O-rings and sealing rings.
Clean oil passages and make sure they are not clogged. Hand-tighten nut only. Rod Journal — Remove both spark plugs. Counterweights can also be twisted on connect- ing rod journal on any or both cylinder s.
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