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Technical Update Book - Sea

1. TECHNICAL UPDATE BOOR c UU ZEQNZDO X Gn Sport Boats Index 2004 Technical Update Book Bombardier Recreational Products Inc is proud to introduce the 2004 BOMBARDIER SPORT BOAT Technical Update Book Again this year you are given the opportunity to test on the B R P T l web site www brpti brp com General Information What s New Troubleshooting and Tech Tips Special Tools Specifications Annexes Section 1 Section 2 Section 3 Section 4 Section 5 STEP BY STEP TO DO THE EXAM Go to the the B R P T l web site www brpti brp com If you are not registered click on New to B R P T I CLICK HERE If you are already registered to B R P T I you need to enroll to 2004 Sport Boat Technical Update 1 2 Use your B R P T I login name and password to enter the B R P T I web site In the Favorites box click on Courses Check English click on GO Choose 2004 Sport Boat Technical Update course by clicking on the yellow folder next to it Click on Enroll at the bottom of the screen Click on learning environment in white You are now back to your learning environment click on 2004 Sport Boat Technical Update to begin the exam The passing grade is 75 Notes You always have three 3 opportunities to take an exam If you do not pass after three attempts you will be restricted from taking the exam for a period of 30 days During the 30 days y
2. Dealer Development Training DVDs English amp French Introduction to Dealer Development Training DVD1 219 700 256 Dealer Development Training CSI DVD2 219 700 325 Dealer Development Training Service Department Operation DVD3 219 700 329 xE QOO 200 Sport Boats 2004 Technical Update page 1 17 SECTION General Information 3 AM went Sea Doo Sport Boat Shop Manual Quick Reference Please use this chart to determine the correct Shop Manual for the following boats Ver Model 9 English French Speedster Speedster SK Sportster 1800 219 100 107 219 100 106 and Challenger 1800 2000 2000 200 1 2002 Sportster LE supplement 219 100 119 219 100 120 Utopia 185 205 219 100 135 219 100 134 Explorer supplement 219 100 137 219 100 136 Speedster and 219 100 162 219 100 163 Challenger 1800 2000 X Speedster and 219 100 162 219 100 163 Challenger 1800 2000 X 219100115 219 100 116 Sportster 4 TEC 219100172 219 100 173 Sportster LE supplement 219 100 119 219 100 120 Utopia 185 205 219100135 219 100 134 Speedster 200 219 100 185 219 100 184 NOTE Some boats use a previous year Shop Manual Every Supplement must be used with its corresponding complete Shop Manual xE 200 Sport Boats 2004 Technical Update page 1 18 2 SECTION z General Information Accident Procedure Since BRP wants to monitor all aspects of accidents involving any BRP
3. S E E ap 1 HIR Ss JU if d 100 108 24 ow i i E P Deia ae Ga fA x E ww Le 312551600 234 051 600 M4 204 130 070 178000235 gt TO SHIFTER 3 e FIBER d T TO SHIFTER 1314 051 600 207 154 560 This system is similar to the rev limiter we have used in previous PWC s prior to digital ignition in that it controls RPM by momentarily grounding the ignition primary lead The biggest difference is that it senses HPM from the tachometer AC battery charging circuit rather than the ignition charge coil The module compares the AC voltage coming from the stator tach signal versus the switch on the throttle lever So if voltage engine RPM remains too high and the throttle switch opens throttle lever is returned to the idle position the engine should be limited to 3500 RPM maximum x 200 2004 Technical Update Page 3 18 OO Sport Boats SECTION Troubleshooting and Tech Tips Here is a rundown of the wires on the module e BLACK Engine ground All grounds should attach to it but for the module to function properly it needs at least a good engine ground e PURPLE Switched power battery voltage Like every Sea Doo since 1992 e GRAY Tachometer signal This is AC voltage taken from the stator but connected inside yellow to gray the top regulator rectifier The stator contains 2 single phase coils 2 x 2 yellow wires that each c
4. NC eS O s uc 2 ow BO 75 SS IL os ue 2 mmm emm NO 421000612 mac ue 2 aem H O ONLY AAA 421000613 793 2001 2003 This shortblock is assy With a 2004 HO crank and Crankcase 421000614 693 Hue a 2001 2004 ENGINES UPDATE 2004 421000615 seng uc 2 2009 2004 H O ONLY EE 421000616 53 uo 2 2001200 ENGINES UPDATE 2004 PA 421000617 493 L C 2001 2003 ALL 2004 UPDATED SHORTBLOCKS WILL BE IDENTIFIED ON CRANKCASE 2004 MODEL NMIN IN Bombardier Rebuilt Center Rebuilt Center 3 COOLING PRODUCT REBUILT PART PART ENGINE SYSTEM AMOUNT YEAR DESCRIPTION Original Part TYPE F C L C CYL 421000071 587 L C 2 1988 to 1993 Labyrinthe Seal 290886797 421000052 587 1989 to 1991 Yellow 290913286 O om S CH ui 1995 O 421000057 787 421000058 gt 87 uo 2 190199 NoRFkGreyseenoie2 29099350 ef 421000813 O AE E E AM ur OE 421000093 587 L C 1989 to 1991 Yellow 290881440 1993 XP White 421000095 Y 290881448 O 1994 SPX XPI GTX White O 1994 XP White 421000096 657X 290881449 E Em White SPX GTX 421000097 is 717 2 199500200 8900731708 421000098 tc 787 E 1995 USE 421 000 100 290 958 057 290881527 290881528 421000100 O 787 UC 2 1996 to 1999 Non RFI Grey SEE NOTE 1 290078704 421000913 7 SS i ve hee l 1998 to 2003 RFI Grey 290078703 421000562 947 LUC 2 1998 to 2002 Except DL replace 912 290094703 421000572 947 E 2 2001 IM 290094705 421000416 94
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6. YL 0R B SP5 N V NC SWITCH BL YL BK U BK BK YL ico gt OIL SENSOR Da ico START STOP EP RE b BK e T WH GY T BUZZER E SAFETY SWITCH DESS CG BK 23 Leg BK 24 un Ui e Di 219 700 398 CA SEA DOO SPORT BOATS TECHN UPDATE BOOK 2004 ENGLISH SEA DOO BATEAUX SPORT MISE A JOUR TECHN 2004 ANGLAIS FAIT AU MADE IN CANADA U M P C OF BOMBARDIER RECREATIONAL PRODUCTS INC OR ITS AFFILIATES TRADEMARK OF BOMBARDIER INC USED UNDER LICENSE JIER RECREATIONAL PRODUCTS INC ALL RIGHTS RESERVED PRINTED IN CANADA
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9. 4 15 RAVE 4 20 UE 12 21 2 B B 2 AIR INJ 2 4 21 FUEL PUMP 4 26 ol GAUGE MONITOR 1 7 ga 55 55 Er Eg ER FR 571 Bee nc ks X LK 55 ma SS mau Knorr BRE SA MPO d LI dE ty ty dE OL GL OH NA PH didis oa EN z qe A es deny T E A nens o o o o lt lt Yoox o LL at IL COMMUNICATION PORT ij 1 2 1 6 SPEEDOMETER Pam 3 26 YL OR PU 1 24 BK 1 25 3 10 PU BW PU YL 1 26 3 14 BK BW 1 3 3 5 WH BW RE 3 3 PU BL 3 7 BK WH STARTER 26 25 24 3 6 WH BL 23 1 3 24 BK 15 Nodo dig 9 TACHOMETER 8 33 3932 5 1 8 LN d PER 1 ycc 1 17 H Y UE H LI mE GND CONNECTOR 4 CONNECTOR 3 be BK 9 RPM ENGINE GROUND Le 3 25 RE PU ir NEUTRAL SWITCH 20 29 M 3 19 BK dE 15 ee bg 3 22 WH GR 1 g r 3 21 RE GR FUEL GAUGE Ree im 3 20 RE BL E OIL LEVEL 3 11 PU YL FUEL LEVEL 3 8 BK OR IIT I mE aa eh P7 dme P7 TIT CN CN CN CN CN NN NN NN NNN B A e e eee LE YT dE LL TA d s T LJ A x LJ x lt gt y REAR ME d T Jo qul CP Lo e cd ELECTRICAL iUe EFFE DD s a m0m SPARK PLUGS BOX SPEEDO SENSOR ENSURE ALL TERMINALS ARE PROPERLY W N H NI N 5 o CRIMPED ON THE WIRES AND ALL CONNECTOR HOUSINGS ARE PROPERLY FASTENED 32 PK BK 33 PK WIRE COLOR CODE TABLE STERN BOW REGULATOR OR ORANGE LIGHT LIGHT RECTIFIER F04Z06S 17 DBL C i O 28
10. 4 TEC Gauge Interface The gauge interface is located in the helm of the boat and serves several functions the ECU sends a CAN signal to the gauges of a PWC and to the gauge interface on a Sea Doo sport boat This allows the use of two wires for many functions where many more would normally be required Typically a boat owner would rather see instruments with needles moving back and forth analog rather than LCD bar graphs digital so the gauge interface converts the CAN to an analog signal Secondly the gauge interface contains an amplifier to strengthen the D E S S signal to the ECU and lastly to the fuses for the various functions in the helm The gauge interface functions are basically the same for single and twin engine applications but they use different components There is one interface per boat regardless if the boat is equipped with single or twin engines xE Q9 200 S port Boats 2004 Technical Update Page 3 17 SECTION Troubleshooting and Tech Tips d Y M N e gt F ty Mercury Throttle Adjustment Module Here are some explanations about the Mercury throttle adjustment module included in kits P N 295 500 989 and P N 295 500 991 aie er Je a D wl E IAS ws ev o Sl S amp A er i e d k qe af e A a E d 3 te e e AN An A E e d ail a e A 8 e E za fT ST MY Aet Se Oe CC F eh g lt Ze AE E vdd j ax a SS m WAV A 204 130 071 ato P Ful E KA xr el r G
11. Product O Yes O No O O Were all scheduled maintenance procedures performed by an LJ Yes LJ No Insured Yes No f Authorized BRP dealer Was Routine Lubrification and Maintenance Given DW Yes L No to the Products as Specified by the Manufacturer Policy No Expiracy Date Name of Ins Company May 2004 Bombardier Recreational Products Inc 2 Witnesses Name if more than one please add a page Witnesses Address Did the operator perform a pre start check of the product before the accident LJ Yes LJ No LJ Yes LJ No Was the operator familiar with the area being traveled Did the operator complete any appropriate safety training courses relative to product i e SVIA LJ Yes LJ No If so what type Did the operator review the product safety video or DVD supplied with the vehicle O Yes O No PROPERTY DAMAGE Vehicle Components ESTIMATED COST OF REPAIR Vehicle Environment Private Property Total ACCIDENT INCIDENT DATA Type of Terrrain oo D Type of Topography AN dct Estimated Speed Vehicle 1 Location of Accident Vehicle 2 O F May 2004 Bombardier Recreational Products Inc 3 INJURY DATA Person Injured Exposure Bruise Bums TYPE OF INJURY Address Fracture Sprain Lacerations Internal PART OF BODY INJURED Face Neck Chest Upper Limp Other If more than one person was injured please join another page per person Was the person inj
12. Sales Department Go to BOSSWeb www bossweb brp com From the home page select the What s News links 3 Siebel eDealer Microsoft Inmemet Explorer provided by Bombardier Recreational Products OE X De Eck View Favores Took Help EJ gt 9 003 19 a All 3 M Sko Rekeh Home Pret Search Favores History Mad 3 Siebel eDealer Microsoft Intemet Explorer provided by Bombardies Recreational Products AE Ele Edi Yew Det Took Heb EJ e gt 0 NANA a die 3 M Back Stop Rekeh Home Search Favores History Mad Pret Address ii https Aeren bostweb bep com EN start swe S WE Cm s Start Back BOSS RESULTS NOW Home Show Homepage Queries BOSS R SULTATS INSTANTANES ComCenter Show Message Alerts Gr ary market better 2004 Metals ia the geed peti Attention Please read this important letter from Matt HA concerning the Gray Market 1 Message Alerts Cross Border issue d Messi Alerts a ww am ous ves COD 410010 Gi ERP Lat Addis hangs This is to inform you that Bombardier Recreational Products inc BRP has updated all It s how much ou can save with the Category From Subject Activation Date y Expiration Date t s employees amp departmental e mail addresses in ceder to comp Ma a y E g E ER S Promotion Text After Sales Services What s New Wednsday May 26 5 26 2004 9 31 AM 6 2 2004 931 AM Rebuilt Shortblock PRICE BUSTER Sales Sa
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14. and filed Was it signed by the customer Legal protection e The PDI provides documented proof that you have reviewed the operation and maintenance procedures for the boat with the customer Sell Value for the money e The PDI gives the customer assurance that a proper pre delivery inspection has been performed on the boat as well as the ability to show all the steps required to justify the expense of set up charges Professionalism e n today s marketplace customers have come to expect nothing but the best from a well trained service department With the PDI sheet completed and signatures from each person involved you can show your commitment to excellence When a customer leaves your dealership he should be aware of and have the operator s guide and safety videocassette as well as his sales information PDI sheet and proof of registration Where do I find this document e It is included with every BRP boat would like to know more about it e There is an easy way to learn more about the delivery process you may want to view the DVD Introduction to Dealer Development Training DVD Volume 1 P N 219 700 256 From the B R P T I Bombardier Hecreational Products Training Institute DVD series s 200 Ge Sport Boats an BOMBARDIER SA BOMBARDIER RECREATIONAL PRODUCTS MODEL NUMBER SEAac400 IND Sport Boats HULL IDENTIFICATION NUMBER H I N PREDELIVERY CHECK LIST THIS CHECK
15. is part number 420 256 885 When updating BUDS software to the latest letter it metnecessary to call in for a new verificati D 4 TEC Idle code BUDS will detect your previous profile on Remember the idle RPM on all 4 TEC models is PC and use this information to set up thg updat 1800 50 and is not adjustable version The verification code is necessary onl installing BUDS for the first time on a HC Big changes for RFI in 2004 Please make sure your technicians realizg that there have been many upgrades to the RFI powergd boats this year The closed TPS procedure has dhanged the cylinders are new and the engine idles on one cylinder Out of the water the new RFI s will idle at approximately 3000 RPM This is normal nqw Please read more about it on pages 2 4 and 2 5 of the 2004 Technical Update Book BombardierRecreationaProductsInc www bossweb brp xE 200 Sport Boats 2004 Technical Update page 1 16 ECTION SECTIO General Information Book and DVD Quick P N Heference Technical Book English French BRP Guide to Service Fundamentals and Principles 484 800 168 484 800 167 Sea Doo sport boat video English amp French 2004 Sea Doo sport boat Competitive Edge video 297 000 870 297 000 878 Technical DVDs English amp French DVD Series Training Kit includes a DVD player Tech DVDs Vol 1 to 5 amp Intro to B R P T I DVD EPUM EDS Intro to B R P T I DVD 219 700 196 DVD1 Engines 219 700 197
16. product please call our toll free hotline to report the accident and communicate to us any relevant information In general If you are aware that a BRP product is involved in an accident which has the potential to be related to product quality or you or BRP are being accused as being responsible listen and report all the facts names addresses serial numbers circumstances etc In the event of fatality or serious accident If a fatality or serious injury occurs in your area involving any BRP product we ask dealers to adhere to the following procedure Immediately contact one of the following Nancy Larsen English SS 800 366 6992 B 715 847 6879 Legal Coordinator ext 4967 Rich Klein English 800 366 6992 amp 715 847 6879 Manager Technical Support ext 6836 Ghislain Cossette French 450 532 2211 amp 450 532 6313 After Sales Services Manager e The accident report should be completed and signed by the owner operator then sent to the BRP Wausau office fax 715 847 6879 Mail 7575 Bombardier Court Wausau WI 54401 Ensure the date of the narrative is filled in Call a Service Representative to open a file you will be advised what to do next Report facts only Do not investigate or commit yourself BRP or others The owner should bring the vehicle to you in order to facilitate the investigation Isolate and cover the vehicle Do not make any repairs pending further investigation Take photogr
17. resistor plugs e Partial continuity in key switch or lanyard switch Erratic engagement e No tach signal Find out why it is not charging Mercury manual P N 90 877837 has all the charging info e No battery voltage to the purple wire Blown fuse in fuseblock e idle too high Goes into rev limit mode without holding throttle open Engine idle should be checked with the boat in the water 1000 1100 rpm x 200 Sport Boats 2004 Technical Update Page 3 19 SECTION Troubleshooting and Tech Tips Vinyl Cleaning Recommendations For general purpose cleaning use Vinyl Finish Vinyl Cleaner Fantastik or warm water with a mild dish soap such as Dawn or Ivory Gently scrub with a small soft bristle brush For dirt build up use Vinyl Finish Vinyl Cleaner or equivalent Let soak for approximately 10 minutes then gently scrub with a soft bristle brush For specific stain removal refer to your cleaning and care card Do not use 409 the bottle states not to use on vinyl kerosene gasoline or acetone They will remove the protective marine top coat Do not use any silicone based protectants They will extract the plasticizers leaving the vinyl hard and brittle and eventually cracking will occur Recommended Not Recommended Vinyl Finish Vinyl Cleaner 409 states not for use on vinyl Dish Soap Dawn lvory Fantastik 3M Citrus Cleaner 303 Protectant Murphy s Soap Simple Green DC Plus Armor All
18. will the ECU be bad Again this problem can be hard to duplicate If everything checks out replace the OTPS 4 TEC Engine Oil Pressure Check The procedure for checking the oil pressure in the 2003 Shop Manual is not correct It states to remove the plug next to the oil filter but FS that plug is no longer there on MY 2003 and above ES engines x There are two options The Oil Pressure Switch can be removed to allow the use of that hole Note also that the Oil Pressure Switch connector must be grounded after B the engine is started to allow the engine to rev above 2500 RPM s The oil pressure can be also checked on the head of the engine The pressure values will be the same when the engine is cold however the values will be reduced as the engine heats up because the clearance of the camshaft bearings aluminum head expands much more then the steel camshaft which leads to higher oil flow Hot idle 20 30 PSI Hot 4000 to 6000 RPM s 25 35 PSI Note At either location a 1 8 npt pipe extension may have to be used in order to connect the pressure gauge s 200 Sport Boats 2004 Technical Update Page 3 6 SECTION Troubleshooting and Tech Tips 4 TEC Engine Checking Oil amp Oil Accumulating in the PTO Cover In the past 2 years we have had some confusion regarding checking the oil and oil accumulating in the PTO cover While we have had some failures regarding the scavenge pump and some oil galley blocka
19. 209307 O 421000554 50 LC 2 1998202 X 420023435 420923497 421000121 643 LC 2 1948192 J J 420913077 O 421000123 670 421000124 670 421000568 43 LC 2 20110203 Z3 420923855 420613600 421000578 593 421000550 670 421000125 79 LC 3 19411996 o l 420913339 Co Bombardier Rebuilt Center Rebuilt Center 2 COOLING PRODUCT REBUILT PART PART ENGINE SYSTEM AMOUNT YEAR DESCRIPTION M Part TYPE F C UC CYL 421000558 UC 2 2010202 420923694 420923692 421000065 UC 2 1958196 42099170 Q 421000610 UC 2 1978198 4209917 421000066 2 UC 8 1 9 J J J 4209910 Q 421000067 O LC 3 199090199 42092332 CH 421000555 m UC 2 0200 SANDCAST 4209236909 421000064 2 UC 8 1970200 420929420 SE 421000068 U UC 8 1970208 J 420924800 NY 421000566 t 421000579 C uc 2 2001204 WITHOUT DEKO SLOTS 420928811 420928817 N 21000507 Lue p p me eneen 8 421000605 cL A A A 421000604 2003 to 2004 H O ONLY 420613852 421000175 377 F C 1995 to 2002 421000173 494 NO 421000181 494 ele 1997 n 421000412 44 uc 2 t998102000 All models except Skandic Mu 421000410 503 CN RE ON 1994001999 NA NO PO O 421000418 O se u 2 eame OOOO NA C 421000180 O Leiwe erte CH SC B alan Eege 12100058 m uc 2 eme eee
20. 6S sdl OU HU peol uosied 8 Ayoedeo Jabuessed By Z356 sdI ouer Ap 3uBIeA Sssipesaq LD Sg O AZcL 94 ul vt 2 0 8 urmeeg ul 9S8 S 8L uiBuel 121940 SNOISNAWIG 39VHOLS MOG eiqeiieAv Bujoueul4 Siet eine s soyeuedo LUODEIOL LUSO Fels uoyMws duung eb ony s1467 reuoneBiAeN JUNOW USNI UJOH seipueH qelo dils uoN Dupoegd PMS UON uome1ueuunaJjsul INA do 413409 BULIOOIN peuo1elNA uj01sn2 4ejar uenem peur Moe HOA ZL jueunadedulo2 sAo H NACO SSAIUIEIS XIS tue s s Bulisa s 1017U09 Duinees pa191s 09 Pp9PPEd Eig A RE EI EP ere 8 ALSAVS IVNOLLICGOV OTAIHSONIM HINOHAHL ITVM EAN ENS daaddav vM INHOd3AV 1d INIMS 1dO MER Melo o NINE ANNAL NI C3HOLS CALS dOL INIIAIS NOIHSN9 1930 NNS 3J95WVHOLS MS NOLLVNIS8INOO JV3S AdONA GNV LANG d3AV Id 09 M O3831S W V SLHDIT ASALHNOSD LIAADOD QI3IHSONIAA TINA 395VHOLS OIHVOS8 NO LNVONNAV Eg ERE ADA 681 VIdO LN Q E E 5 8 3 Se 3 S N Ge Sport Boats SEQ I00 Specifications SECTION G V S ey ui pejuug Pamesa syuBu y Boueurng jo uongJod40o2 10310JN Jeipaequiog EQOZO seueipisqns sy Jo ouj Jeipuequuog jo sxXeurepe4 pejJejsiDe1 pue sxeulepeJ4 GIE O wi uong4odao2 Yyomsurnig SU JO SAJBLISPEn p916 51D91 ese Xe yndo pue eat jer ziN ANAAL HOA SL eneg dwe 09 xewndo du osz dwe ov 143 du ovz dwe 09 xenmnmdo du ooz uwe s s Bubieyo 911498913 13118 1S TVIMBLOST ssa paam oDung oJpAH 21816 out
21. 7 NE 2002 2003 420094706 SEA DOO BALSHAFT se uc 2 meam sumomoswr 2er N JININ NO Bombardier Rebuilt Center Rebuilt Center 4 COOLING PRODUCT REBUILT PART PART ENGINE SYSTEM AMOUNT YEAR DESCRIPTION Original Part PE F C L C CYL 421000577 E 654 L C 1 2001 DS650 711295192 gt 421000157 lt 511 UC 1999 2002 420295893 i p quu E x z c E E BEE IO E oc KH NOTE 1 Running change from white to grey Note Old core will be completely refunded only if LEGEND Core is returned within 30 days with the filled out rebuilt confirmation form CR CRANKSHAFT Core is same model as the one shipped CY CYLINDER Core casting is not broken CYN CYLINDER NICASIL Core is complete and fully assembled REP REPAIR ONLY Core is shipped prepaid to Bombardier SB SHORT BLOCK Core is returned in original packaging to avoid freight damages Not respecting those requirements could result in a refused or reduced core credit Bombardier Rebuilt Center Rebuilt Center 5 RETURN AUTHORIZATION PROSPEC ELECTRONICS OF SOUTH CAROLINA 3325 HIGHWAY 17 NORTH MOUNT PLEASANT SC 29466 PH 843 849 9037 FAX 843 849 9054 All information below must be completed to be accepted Customer Name Address Contact Fax Pore Radio Manufacturer Radio Model Hull Identification Number Boat Model Manufacturer Purchase Date Year Customer Complaint DAG RC Prospect use Store Number QuickFax Servi
22. A N A Ski Sea Doo 421000062 Ski Sea Doo 421000063 Rotary valve cover refacing repair only Oversized cylinder repair only 1993102004 199210 1996 Ski Sea Doo 421000050 F C Resleeve cylinder repair only N A 421000031 277 F C 1993 to 2004 420995301 421000009 377 443 F C 1992 to 1996 420887245 420996332 421000154 377 443 F C 420889630 421000150 454 L C 420887962 420887966 421000574 693 L C 27 mm 420888286 421000573 793 L C 420888402 421000019 467 L C 420995205 1996 to 2000 421000151 494 L C 420886933 421000567 493 F C 2000 420888462 421000011 503 F C 1990 to 1996 Keyway at 3 o clock 420996445 421000155 E 503 F C 1997 to 2003 420888390 420888391 O 421 000 601 m 562 2008 to 2004 420 689 062 532 536 1985 to 1996 Q 421000021 S 937 582 L C 420996628 77 583 1990 to 1993 C 421000044 Y 583 1994 to 1999 420 887 355 1 421000563 Z 593 2000 to 2002 420888252 420888751 4 421000553 et 593 L C 1999 420888250 421000023 CC 643 1991 amp 1992 420996625 UN 421000025 O 670 1993 amp 1994 Order needle bearing 420 832 425 420886425 420887987 1995 8 1996 i 421000046 670 L C 2 Order needle bearing 420 832 425 1997 to 1999 421000312 670 L C Summit X amp MXZ H O 420887986 421000047 599 420886903 421000152 599 420887970 421000310 cos L C New modified part for 1999 2000 420888030 420888034 421000153 699 L C 420887605 421000026 779 L C 420886485 1995 amp 1996 1997 to 2003 New modified p
23. AINM H3 LN3O JONIINIANOSO 13 UNO L M INOOH DNIONVHO MOS NI 100d mila 39VHOLS GHYVO8 NO LNVONNAV WALSAS SNIH33IS TOH LNOO dadav vA NtyHOJ1W1d DNICUVOS LNOdS SaHnlvid AMA uVIGNV TSI NOILVLS ONIONVHO2 2 E E 5 8 3 Se 3 S N Ge Sport Boats SEQ I00 SECTION SEN Specifications s E09 200 Sport Boats 2004 Technical Update page 5 10 Annexes 2004 Technical Update REPORT ON PEFORMANCE QUALITY FROM DEALER N B If fields with grey headings are not completed the report can not be processed O SPORT BOAT DATE YEAR MONTH DAY REPORTED BY DEALER S NUMBER 999999 CONTACT First Name First Name Last Name Last Name CIRCLE THE APPLICABLE CONDITION CIRCLE THE APPLICABLE SYSTEM ENVIRONEMENT TYPE OF USAGE TYPE OF USAGE WATER THROTTLE N A if not applicable 1 1 During PDI 1 5 River Channel 2 1 Fresh Water 3 1 Personal CONDITION OPENING 01 Engine 07 Steering System 1 2 Freight Damage 1 6 During Storage 22 Salt Water 3 2 Rental 4 1 High Waves 1 4 02 Fuel System and Fuel Tank 08 Suspension 1 3 High Sea NA NA 33 Commercial 4 2 Shallow Water 1 2 Oil System 09 Body 1 4 Lake 3 4 Racing 4 3 Calm Water 3 4 03 Exhaust System ces NA N A 4 4 04 Electrical System Electrical Special Tools n Starter Engine Ignition 11NA 05 Propulsion 118 Multiple Svst OUTSIDE TEMPERATURE Unit de mesure WATER TEMPERATURE Select Measure SPEED Select Measure TUS Or Oc Or Oc O km h CI MPH MO
24. CR E record 2stroke models 1 Check engine oll TEC models Purge coolant system s of air and check coolant levels 4 TEC models ADJUSTMENTS Y Steering alignment aM Throttle cable s Controller throttle shifter select or lever cables Weedless system Idle speed aM Trailer refer to trailer Owner s Guide Printed in Canada LBL2004 001A FM SB TMTrademarks of Bombardier Inc or its subsidiaries 02003 Bombardier Inc All rights reserved 2004 Technical Update 204 630 307 GENERAL INSTRUCTIONS inspect movement and operation of Theowtelevers Oi Gs Safety lanyard DESS and engine start stop button s All gauges Navigation lights Bilge blower Bilge pump Controller throttle shifter selector lever Main battery cut off switch Pressurize fuel system and lubrication system apply proper pressure Water test sport boat Wash trailer with fresh water Clean sport boat thoroughly and polish Check all items on Mercury Predelivery Inspection Sheet where applicable Verify trailer wheel lug nuts torque refer to traller Owner s Guide AT SALE EXPLAIN TO OWNER Bombardier documentation Operator s Guide and warranty and Mercury documentation where applicable AT DELIVERY Complete and retum Bombardier warranty registration signed by owner and Mercury warranty registration where applicable ATDELIVERY 0 Jv PREPARED BY DATE day month year DEALER NO INSPECT
25. DEL NUMBER 9999 SERIAL NUMBER Ozzy O cec TOTAL HOURS USED mi PART NUMBER 999 999 999 PROBLEM DESCRIPTION CORRECTIVE ACTION TAKEN COMMENTS OTHER OBSERVATIONS FO419 SAV 01 05 99 N A Infos Unavailable 219 600 003 Bombardier Oils amp Lubricants This is only a partial listing to use as a quick reference sheet Product Description us Notes seanoa Bombardier Synthetic Same as 293 600 011 413408600 Bombardier Fuel Stabilizer B ml E OZ ITE 293600016 Bombardier Lube e CH i x x 16 oz Bombardier 2 stroke 1 liter e Injection Oil 33 8 oz Exc Models that require Bombardier 2 stroke 4 liter FORMULA XP S ME Injection Oil 135 oz or FORMULA XP S DI 413803200 Bombardier 2 stroke Drum 205 L ATV Mini DS 2 stroke only Injection Oil 54 gallons NEW FORMULA XP S II 1 liter Meu o and NEW FORMULA XP S Il 4 liter He MEI BOUN OIL Synthetic 2 stroke Oil 135 oz ATV Mini DS 2 stroke onl 293600047 NEW FORMULA XP S II Drum 205 L y Synthetic 2 stroke Oil 54 gallons 413803100 Bombardier Premix oil 500 ml 17 oz 2 stroke Bombardier Synthetic 1 liter Bombardier Synthetic 1 liter REBUILT PARTS LIST SEA DOO SKI DOO ATV COOLING PRODUCT REBUILT PART PART ENGINE SYSTEM AMOUNT YEAR DESCRIPTION Original Part TYPE F C L C CYL L C Ski Sea Doo 421000051 REP Ski Sea Doo 421000060 REP Resleeve cylinder repair only N A Crankcase brass plate insert repair only N A N
26. ED BY DATE day month year DEALER SIGNATURE The dealer named on this document has instructed me on the operation maintenance safety features and warranty policy all of which understand am also satisfied with the predelivery set up and inspec tion of my sport boat have also received a copy of the Operator s Guide for my craft OWNER SIGNATURE DATE day month year x PRINT NOTE File this document in sport boat file Give a copy to owner Page 1 of 1 page 1 13 SECTION A 130009 General Information The BRP ELECTRONIC PARTS CATALOG is here e FAST parts look up e ACCURATE up to date information e INTEGRATED into BOSSWeb and many Dealer Management Systems Ordering your parts has just become that much easier The BRP ATV Sea Doo Watercraft Sport Boat Electronic and Ski Doo Parts Catalogs are now available on the Web or on the PartSmart CD The Web version of Electronic Parts Catalog is included in the monthly fee so there is NO extra billing Here are some of the Electronic Parts Catalog highlights Web Version PartSmart CD Parts look up 8 ordering Hotspotting for easy part identification Updates for error reduction Weekly e en eege weg a corrections Print Part images and Part lists Part Print Part images and Part lists and Part lists e Can be installed on a single workstation or on a network Web Example PartSmart CD Example o ns po Ge ze game FIT GUE SVAN IN TAKE
27. IOOW PSYUSJEW WOISND Jet uoneljolY4 UIeBoyY MOEf HOA SL Jueuimnadeduoz2 aaron sieal9 99158 SSSJUJE S XIS uua s s Duioeo s Jo41uo2 Dunees pe4e1siog D9pped SA ET E re i EF ere 8 AL3dvS IVNOILIGOV 39VHOLS LV3S HV3H Hadav M IWHOdlVv 1d IWIMS ANNAEL NI CIdHOLS OLS dOL INIWIa CLdO 13 1IOL M WOO 9NIONVHO NOIHSN9 De eai J9VHOLS IMS Cals 318VL LldX49202 Egi ieu El ydIAV Id 09 M O3831S NJ NW NOLLVNIB8NO9O Mb E Adana ANY LVAS 1349N8 SLHDIT ASALHNOD re ere CQ T3IHSONIAA TINA 395VHOLS GHVOE NO LNVONNAV SAHNnLVAad AJM S0 VIdOLN WH JONVWHOAnAd 2 2004 Technical Update Ge Sport Boats SEQ I00 Specifications SECTION d Keck Ul payd penesel syyBu y BoLeury jo uomngJodao z AGO JSIPIEGUIOG EQOZO seugipisqns SY JO ou JSIPIEQUIOS JO SAIBLUSPE N pele siDel pue sxeuieped eJe wi UOQBIOdIOD AOIMSUNAG ey jo sxeulepe4 peJejsiDea 81 XEAGO pue eut 19 zig UNN HOA SL Aieyeg due 09 xenndo du osz dwe or 143 du OpZ uuo s s BuiDaeu 91119913 191181S Bi ell HE TA sseipeeM eB InS oJp H 2 e16 exe1ul d un eiqeisn pe jenueljA ua s s uu Loes ssejuig1s youd Te GITT ET D M Ez 001 1 o WA ETE TO H N 4 Simuede ulm 1snau1 uBIH ege euonsoaJ 11g euunjoA uBiu MOL pexilN ad 1 dund jer LINN INHA sepoue IEDULIOES Bunured dejys ninw wnujune O9 MX u0 1193101d BU o eR Bele os9 s xewndo dy osz 000 9 143 du ovz
28. LIST MUST BE USED IN CONJUNC TION WITH THE PREDELIVERY BULLETIN OF THE APPLICABLE SPORT BOAT POTABLE WATER SYSTEM if so equipped Potable water system should always be disinfect ed and flushed before delivery to customer Refer to the Operator s Guide for complete de tailed procedure DESS Digitally Encoded Security System if so equipped The sport boat cannot be started and used without programming the safety lanyard The use of the following tool is mandatory for pro gramming VCK Vehicle Communication Kit and the B U D S Bombardier Utility and Diagnostic Software P N 529 035 844 OR MPEM programmer P N 529 035 878 with ver sion 3 3 and up except on 4 TEC models For detailed information pertaining to the use of the VCK use the help menu inside the B U D S software or if using the MPEM programmer refer to the guide that is shipped with it When programming first start by erasing the pre viously programmed keys at factory THEN pro gram the safety lanyard that is shipped with the sport boat NOTE Some parts or accessories may apply to a particular model only To find out specific parts or accessories of a sport boat refer to appropriate Predelivery Bulletin PARTS INSTALLATION Battery Trailer wheels if necessary refer to trailer Owner s Guide French labels if applicable For sport boats used in Canada Apply the Canadian Coast Guard Compliance Label Bewe essecrdye
29. RP Closed End Financing Program Please cick on tfe attached for all t s URL addresses Internet addresses in order to comply with Subject What s New Wednsday May 26 Bombardier ATV Serateh and Win Succetttuly complete te 2004 ATV Competitive Edge Training Plus Sel any new and unused AGA Bomberder ATV excluding the Sarasota and you wil Message Body What s News Information for AM Dealers US Bombardier ATV Financing Dealer Contest Reminder Reiner Put yourself in the picture Vin a Caribbean Cruise with the Bombardier Recrestional Products Financing Program Literature TO Po Ja 1 195 Literature Type Mame Alert Administration jer Sa What s New Wednesday May 26 14 968 pdt 1 LJ 14 Description Sire File Type Bombardier ATY 2 Up ATY Safety Training Program Letter to al US Bombardier ATV Dealers Sales Bulletin 07 05 SM 2005 Summt X Packege Salesman SPFF Your Sales Staff wil receive a 100 Salesman SP for every new and unused 2 300 H O unt sold jevescrpt c_dic_O new Ana 1 3LGS26 s 2 2 11 1 SWERowdOs1 3LG825 c 1 c 3 A e eret e preasciptc dic 48 new Anay 1 3LCXUP st 2 8 0 SWERowldOs1 3LGS26 SWERowldT 1 3LCXUF c 43 c 50 WHAT S N Latest Bulletins HELPFUL WARRANTY HINTS Sea Doo Warranty Bulletin 2004 2 When removing the hinge there may be some SEA DOO storage covers that are showing minor styess Warranty 2004 4RXP A Recal
30. S ORDER STATUS Tip Click on the right hand Order status to see posted ETA information Search Results Bombardier Order Number Order Date Tour Order Number Terms Order Type Order Status 1003336481 2004 15 26 4304 Met 30 Days Regular Partially Delivered PARTS BACK ORDER LIST X Parts Order Status Bombardier Order Number 1003336481 Ex Item Part Humber Req Qty BrO Alloc x Alloc Shipped UD Del UOM x Description Memo Ship Date Ship Item Ho Last Ship Ho Expected Availability Date LUISE 10 420250250 z z PC PC wv BELT STOCK mE ZU 715900024 z PC PC COURROIE ENTRAIN BELT i Son0o0321705 30 420256188 3 i PC PC r FILTER GIL STOCK ETA WEEK OF JUNE 4 2004 IZ Parts Back Order List Search Results Order 6 0 Bombardier Your Order Order Cancel Qty Qty Order Number Item Order Humber Type Date Miri item Expected Availability Date 4202556188 FILTER OIL 3 1003336481 30 4304 Regular 2004 05 26 stack D ETA WEEK GF JUNE 4 2004 07800072 FIELTER AIR 2 1003332312 20 4292 Regular 2004 05 24 stack D SeEac400 Sport Boats 2004 Technical Update page 1 15 Part Number Description ECTION SECTIO General Information What s News Letter Hot Tips and Tricks From Your After Sales Group Posted Weekley Once a week the What s News letter is published on BOSSWeb It provides the latest news from the After
31. SIHOdS Op HILSLIHOdS DAILY ATLSLIOAS ATAH JONVNHOJHIJd Q E E 5 8 3 Se 3 S N SEQ I00 Sport Boats Specifications SECTION wem ey ui peyuud peneses syyBu Iv Eoueury jo UOIPBIOdIOD 1040W Jeiprequiog OOZO seueipisqns sy JO out JSIPIEQUIOS JO sxreuiepse g peuejsiDeg pue sxeuieped eJe O wi ipoeq DULLISAA unmoeg ebneBb Io lenJj xz Woe 4e1euiou2g1 IK bie Jajaulopesds Saaonwvo DO TUVUNV y91IMsS JJOMO lSYeq Um TVIINVHIJIAN HOA cl ianeg M O8 duly of 1018 9495 MOT pepooug AUESUDIOU S S q d uim 91119913 FNAC WIIHLDAT xg uw SSL OL S Jajaewejp dund LUSISAS SOUBIBSID Re Ez L8 31816 exe1ul youd eaisseuBoud 1981S ssajulels Jallad H N 4 39126 S4194A9 1 1SN1U U IH a21eB euonoada 2be s a Duis Mol II le dund jer LINN 3AIHG au bue 3b Fo 0 o SHBeyoA mo o MO Jeu Id Snap Bujulem jesyiero sula s s uonoa 01d su bBuy sJeuyniwN rend 1sneux3 euiBuoe ued g 9 sJepul o 2MOMS v edAL au bua Je SSL du OLE 4JamodesioH sulibuse ued g6r L 99 966 Z juavusoeldsia m0O31 y XeJoH UML I POIN EL IDE au bua 1ad 1 S E yoedeo lO 1 SIEB sn Ob yoedeo any uno og LArno or Auge a5e 101S DX SE9 SAI COOL yu peo7 uosiad 2 AT Ee LE Jabuessed BA 9sz L sdi 0ZZ z Ap 3513M Bet esiipesaa A yea WD vv 2 00 8 wesg ul ZO 9 6 6L u1Buel 21950 SNOISNAWIG ES ESA E NNS El eiqeieAv Duroueut4 118104 Aug USA pay
32. SYSTEMI of 2G 99 BRE aces 4 i e la la ke Nx 1 DLIDDLLCDIDLDUULDDULDDULULL 202215 r ow ow a mt e CO E m op dE Ss CEETEEEEHLEEREEEKEETER S Ho Dlacumnent Solecod Please note that PartSmart does not interface with Lightspeed Bell amp Howell ProQuest Dealer Management Systems If you are a user of FicheFinder integrated to Lightspeed you will remain supported through this supplier Visit the web version at www bossweb BHP com ComCenter Parts Catalogs For assistance do not hesitate to contact the BOSSWeb Help Desk amp 800 366 6992 USA ZS 800 361 9980 Canada xE Q9 200 Sport Boats 2004 Technical Update page 1 14 SECTION A 130909 General Information BOSSWeb Tips and Tricks E T A You can now see on various BOSSWeb screens Estimated Time of Arrival E T A s for some our your critical back ordered items PARTS PARTS AVAILABILITY SCREEN Tip You must choose a product line while consulting this screen to avoid error messages such as Error 14 Profiuct Line Arv x Material not saleable Search Type Look for all parts matching Parts Parts Availability Ex Part Humber Description Tear BO Avail Qty Retail Cost Markup Sales Unit Price Unit Sck h Results z 72800072 FILTER AIR 2003 1 D 17 474 10 24 41 DC DC 420256155 FILTER 2IL 2001 1 10 474 6 241 40 Pc DC ETA WEEK OF JUNE 4 2004 PART
33. Top Kote Sealant Son Of A Gun Orange 88 Degreaser Roll Off Bleach Baking Soda Turtle Wax Tar Removal states not for use on vinyl APCO Tannery St oc o5 Iw x zech wesch 0 0 D d o Oo EF WD zk kK O N Harbor Master k Ql Equivalent Or Similar Products x 200 Sport Boats 2004 Technical Update Page 3 20 7 Rh SECTION Troubleshooting and Tech Tips Vinvl Cleaning Recommendations Ballpoint ink E B A A Medium soft i brush warm Chewing gum D A spy water crayon D 8B B Vinyl Finish Vinyl Household soil A B Ketchup A B Jj COne l tablespoon of ammonia one Latex paint LA 4 O bo US Lipstick a a buds peroxide Mildew or wet leaves C B A three fourths ot e OHmeidm 0 8 0 0 mme B O EE Tarasp D B Yellow mustard A C E Denatured alcohol rinse dry All cleaning methods must be followed by a thorough rinse with warm water 22255 Suntan lotion tree pollen wet leaves and some other products can contain dyes that stain permanently Certain household cleaners powdered abrasives steel wool and industrial cleaners can cause damage and discoloration and are not recommended Dry cleaning fluids and lacquer solvents should not be used as they will remove printed pattern and gloss Waxes should be used with caution as many contain dyes or solvents that can permane
34. and Tech Tips Mercury Exhaust Hoses If a Mercury powered boat is found to have exhaust hoses melted through near the expansion chamber outlets it is recommended that the hoses be updated with the new sleeves that are currently being used in production For the Islandia the hoses will need to be replaced with kit P N 295 500 992 or use component parts from the 2004 Islandia parts catalog For all other Mercury powered boats use kit P N 295 500 990 Depending on the condition of the hoses it may not be necessary to replace the entire hose Follow the instructions in bulletins 2003 4 or 2003 5 for kit installation It is important to try to find what caused the hoses to melt The cooling system could have been restricted by debris prior to hose failure x 200 Sport Boats 2004 Technical Update Page 3 23 Efe QD Troubleshooting and Tech Tips x 200 S port Boats 2004 Technical Update Page 3 24 SECTION 4 SEN I300 ED Sport Boats 2004 Technical Update Special Tools In Section 4 you will find the most current special tools information to efficiently service BRP Products New Special Tools Page 4 3 SECTION Special Tools New tool for the 2004 4 TEC models Bearing pusher MANDATORY P N 529 035 955 Application For impeller shaft removal and bearing installation New tool for the 2003 4 4 TEC models DESS adapter OPTIONAL P N 278 001 978 Application To comm
35. aphs of the damaged product as verification of the damages and to avoid any potential claim that the product was destroyed modified or the evidence was lost e Incase of PERSONAL INJURIES DO NOT REPAIR THE PRODUCT Contact one of the above contact persons e Make no admissions or assumptions on the cause e Keep BRP informed of any further developments The BRP Accident Report Form is available from BOSSWeb or in the Annexes Section of this book xE 200 Sport Boats 2004 Technical Update page 1 19 SECTION z General Information xE 200 Sport Boats 2004 Technical Update page 1 20 SECTION 2 SENIO AEN Sport Boats 2004 Technical Update What s New The objective of Section 2 is to give the opportunity to dealers and technicians to learn General Page 2 3 and understand the differences between the 2003 and 2004 models 4 Tec Engine Page 2 3 REGHION What s New IN ALL SEA DOO SPORT BOAT What s New SEDIDOOD p Sport Boats Safety guide has been integrated into the OPERATOR S GUIDE Operator s Guides ence gece cence SPORTSTER YeTEC Why Standardization ease of use What s New An anode was added to the ride shoe cooling plate For extreme conditions there is also a similar location to add a second anode on the other side left side of the ride shoe Why For improved resistance to corrosion The new ride shoe fits on previous models but th
36. art for 1999 2002 420887590 420887667 420887668 420887662 421000048 779 L C 421000156 809 L C Bombardier Rebuilt Center Rebuilt Center COOLING PRODUCT REBUILT PART PART ENGINE SYSTEM AMOUNT YEAR DESCRIPTION Original Part TYPE F C L C CYL O 421000606 t 793SDI L C 2 2003 2004 SDI ONLY 420889106 O 421000607 lt 793HO LIC A 421000608 T 793 NC 693 x 421000611 oc 53 LC 2 209204 420880757 H 421000599 o 43 LC 2 ao TI NN 421000101 277 FIC 1 19091196 ETA 421000200 277 FIC f 1 190710200 4209013218 420913219 421000102 377 421000103 377 421000201 377 421000104 377 421000105 377 421000202 377 Mag 421000106 443 421000107 443 421000203 443 FIC 2 421000204 443 FIC 421000559 377 Q 421000560 377 421000114 an 467 Q 421000113 LL 4607 LC f 2 198010195 0823699 O 421000115 O 494 C 421000551 gt 494 l 421000552 494 421000109 500 Fe f 2 190300199 o 420828645 O NY 421000110 2 5095 FC 2 198101997 JJ 4209340 O 421000500 O 503 FIC 1908102008 SC V 421000600 552 FC 2 2030204 OTE 421000116 582 LC 2 o JI 4 J9 40349 O 421000117 582 LC 2 19401960 A4 J J 420919460 421000118 583 LC 2 19801199 Z X 420913078 421000119 583 Uc 2 14 JJ 9 y 42093670 421000120 583 LC f 2 190101999 Z3 4
37. cal Ski Doo Dial the same numbers Technical Technical Sea Doo Service Technical ATV Enter your BRP dealer number to access your support Technical Sport Boat Services Warranty Listen to the first menu and choose the service by Clothing Warranty pressing the number key on your telephone BOSSWeb BOSSWeb and technology ame 4 Support Including BUDS Listen to the second menu tone and choose the Technology i PACPro amp EPC appropriate subject category Support If you know your Regional Sales Coordinator extension These phone numbers are for dealer use only Do Coordinator amp not give these phone numbers to customers as Vehicle Canadian Dealer this will have a serious impact on your ability to Shipping deele 2 Abs SEQ I00 Sport Boats 2004 Technical Update page 1 3 2 SECTION z General Information Before You Call the Service Department Be prepared The BRP Service Department values your call In fact you are the reason that we are here Your input and information are vital to our department and accuracy is critical In an effort to provide the best service to you we ask you to observe the following guidelines Review the service material that you already have Check your service library for any publications that may assist you with your problem Often the answer is already in your hands in the form of manuals bulletins spec books etc Check BOSSWeb All bulletins and campaigns can be found
38. ce Fax Form Mercury Mariner Force MerCruiser Service Canada Service USA Service USA Miss FAX 905 270 8334 QuickFax 800 842 4550 QuickFax 800 245 8794 QuickFax 800 663 8334 Please use this convenient form to request service assistance Information bellow is re quired to help us respond to your request Number of Pages Being Faxed Dealer OEM Name Dealer OEM Phone No Fax No Contact Person Serial No Model No Horsepower Liters Owner s Name Date of Purchase Hours Used Boat Manufacturer Boat Length Prop Size W O T RPM Description of Problem WHen does problem occur What RPM How often Tests Performed Readings Ignition DVA Pressures Engine RPM etc Suspected Cause of Problem Disassemble if this is an Internal Engine or Lower Unit problem List Any Repairs Already Performed and Parts Replaced Action Requested Warranty QGuard Preauthorization Advice Information Only Other DDT DATA WORKSHEET 90 858879 OptiMax __ MERCURY DDT Data Worksheet Total Run Time 0000 0999 1000 1499 1500 2999 5000 3999 6000 SSES RPMUIMCNT o BREALUNMR OVERTMPSec Tenio te f f OH E Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6 njector Err Cyl 1 Cyl 2 Cyl 3 Oi SIE Lp ore f Pump Err D OlPMp o es pe MM pM EE MEN MEE NN LM E Lum a TPR WE worm Propeller Type Pro
39. creational Products Inc 896 Kersfield Circle Heathrow FL 32746 Address TBD Canada East Charles Bedard Bombardier Recreational Products Inc 2 5 Des Mouettes Beloeil QC J3G 5A2 Canada West Wade McDonald Bombardier Recreational Products Inc 2497 Pinewood Drive Winnipeg Manitoba R3J 0C3 qu X Gb BD X GD BD X ib X HR General Information Regional After Sales Manager 603 293 8454 603 293 8224 jean pierre foucault brp com 715 848 8800 715 848 2371 perry white brp com TBD TBD TBD 407 833 8862TBD 407 833 8862TBD rodney thompson O brp com 450 467 8950 450 467 9009 charles bedard 9 brp com 204 837 3094 204 837 2765 wade mcdonald O brp com Who s Who Legal Coordinator Nancy Larsen s 200 Ge Sport Boats 715 842 8886 2004 Technical Update C 715 847 6879 page 1 6 SECTION General Information Who s Who International Distributor After Sales Support Ronald Hurner Senior Coordinator International After Sales amp Service Australia Paul Dawson Gary Nixon Bruce O Dowd 1 819 566 3086 ron hurner O brp com 612 9794 6615 paul dawson brp com 612 9794 6600 gary nixon O brp com 612 9794 6600 bruce o dowd O brp com Europe Middle East 8 Africa Russia Oliver Leitner Karel Bogaerts Latin America David Rummel Rene Morales all except Brazil Alfredo Padron all except Brazil Edni
40. dOd M NIIYISONIM 39VHO1S OIHVOS8 NO HOHHIIN 3 18vlsnrav 3T19NV 301M SAHNLVAA ADA X wAAINAITIVHI Q E E 5 8 3 Se 3 S N OO Sport Boats SEQ I00 Specifications SECTION w S n eu ut peyuug Pamesa syuBu Iv BOLIGLUIY jo UOIT2IOCLIO JOOP Jeipaequuog EQOZO seueipisqns sy 40 ouj JS PIEQUIOS JO sxreuiepe g peuejsiDe1 pue sxeuieped eJe 0 wi uonBaoda4oz 4oiwsunag SU jo sxeuepe4j Diese sue XENO pue eang yer lA ANN HOA cL iayeg due Ob 143 du ord dure 09 xewndo dy ooz uea s s Bubieyo 91119913 1911818 WIIHLDA 1 sseipeem e64NS OUDAH eg ID exe1ul ajeld unn eiqeisnipe enuen LUSISAS ul jee 1s ssojulels yoyud SsiIqeeA epelq p Je eweIpP SZ Jaadu Y N 4 euynniede umy 1snau1 uBIiH a1e5 euono aa euunjoA uBiu MOLL pexiw ed A dund jer LINN SAIBO sapoue elo 11oes Bunured dejs ninuu uunuiunpe O9 MX uo ooejoud uoiso4402 000 9 143 du ove os9 s xelamdo du oog Widi XEN Aleyeg moj tuonosajo d A9J I9AO GA9 IO MO Yeeylenro aubuy sula s s uonoa oJd ou ujosug ubnoauug Sewn enp paun 19MOd wf e ueAlp 1eebD uonoefuli 10 one4 SIQBLIBA UOUSOLIOTT uo oeful JUIOd I INW 43 du 0bz uonosfu up aSbels 2 xewndo du ooz METER IST EEN MO A ESTA om oog 1 S 2 9A Jlamodeas oy jueusoedsip ad L ANIONA aptum Eu ae 143 du OZ an 1ef ZW ANJAN xeiundo du oog suo ndo E V o 8 ps 1 by LL 1eB sn e A yoedes IIO 7151 18 sn ob Ayoedeo jeng Dx 6
41. e anode only will not fit alone on previous ride shoe versions ON ALL 4 TEC EQUIPPED MODELS What s New New noise canceling system Part of D SEA BEL This polymer resonator replaces tuned components and the resonator that were use in the previous versions Why Simpler exhaust system lighter component less exhaust restriction and reduced sound level SEQ I00 Sport Boats 2004 Technical Update PAGE 2 3 SECTION WHAT S NEW New larger bearing pump Why Standardization WHAT S NEW A larger bearing is now used in the composite impeller housing Why Stronger component WHAT S NEW A through hull fitting has been developed for servicing e 4 TEC EQUIPPED BOATS P N 292 000 975 Why New part for service Retrofits the previous 4 TEC models SeEace400 What s New CERTAIN 4 TEC MODELS CERTAIN 4 TEC MODELS ON ALL 4 TEC MODELS Sport Boats 2004 Technical Update PAGE 2 4 SECTION What s New WHAT S NEW 4 TEC MODELS The anchoring tabs on the impeller housing to the venturi are now machined flush with the pump housing Why For improved fit between the impeller housing and the venturi The venturi remains the same Fits on previous models SEQ I00 Sport Boats 2004 Technical Update PAGE 2 5 SEA LON What s New SEQ 100 Sport Boats 2004 Technical Update PAGE 2 6 SECTION 3 Z3 EN 2DU D Spo
42. e in the shortest period of time possible Please refer to Administration Bulletin 2000 02 for more details Below is a sample of the main RPQ screen each Service Representative must fill out with your help By compiling data we can evaluate any trends development in the field Please be prepared to provide all pertinent information Mandatory fields e Dealer e Model and serial number e Description of concern e Mileage hour temperature any special condition etc Call Entry 1 File Edit Options Mt Help APO Report submission fans Reg d Status Po s EA Gel Part H SUE pal ar aper j w La o m MA NR e Outside Temp Unt gt Water Temp Unit e Speed Unit y waf E Fase ae Outside Temp C m Water Temp CJ Speed Km H reueg Be f a Detail Dutside Temp Fl Water Temp Fl E Speed MFH rer NEN A Corrective Action Throttle l APM Total Hrs Used Water Type ES Notes Date Reported Date Linked beme Im Engine Sena Number Feel free to contact your Service Representative to report any issue A form is also available in the Annexes Section it can be filled out and faxed to a Service Representative History a s 200 X Sport Boats 2004 Technical Update page 1 12 7 BX SECTION e o NET Aene Importance of PDI General Information Was the PDI Check List properly filled out
43. entatives e US 800 366 6992 a U S 715 847 6879 Canada 800 361 9980 Canada 819 566 3062 Alain Doucet English French Mike Carter English Claude Beaudoin English French Patrick Eppolite Sr English Dennis Sawyer English French Paul Literski English lan McAuliffe English Richard Cossette English French Jeff Downs English Rosaire Goudreau English French John Lofy English Simon Belzile English French Who s Who Performance and Quality of Product US 800 366 6992 or 618 439 9444 Canada 800 361 9980 2 618 439 8724 kurt otteson O brp com Kurt Otteson Field Product Quality Specialist Who s Who B R P T I Bombardier Recreational Products Training Institute Call for questions concerning B R P T I web training DVD s exams or for the Dealer Certification Georgie Johns English Christian Larose English amp French 2 U S 800 366 6992 a U S 715 847 6879 Canada 800 361 9980 Canada 819 566 3062 Dx brpti brp com s 200 Sport Boats 2004 Technical Update page 1 5 SECTION Who s Who RAM US North East Region Jean Pierre Foucault Bombardier Recreational Products Inc 31 Henderson Rd Unit 10 Gilford N H 03249 US Central Region Perry White Bombardier Recreational Products Inc 2604 Merganser Way Wausau Wi 54401 US West Region To be determined US South East Region Rodney Rod Thompson Bombardier Re
44. ergized the 2 blow by valves lift to uncover ports and allow the crankcase to vent It energizes with an audible dck when the lanyard is installed on the DESS post The power relay in the rear fuseblock supplies the voltage the ECU provides and controls the ground Initially the blow by solenoid is energized by approx 7 5V After a few seconds the voltage drops to around 3V enough to keep it energized xE QOO 200 S port Boats 2004 Technical Update Page 3 4 SECTION If the ECU loses it s ground from the OTPS it thinks that the blow by solenoid is not energized because there is crankcase pressure The ECU will then try to re energize the blow by solenoid by controling the ground to the blow by solenoid to allow a cycling of 7 5V down to 3V back up to 7 5V and so on for 3 to 5 minutes If after that time the OTPS does not provide a ground to the ECU fault code 1202 will activate and the engine will go into the 5000 RPM limp home mode Troubleshooting and Tech Tips In order to measure the voltage as described us Sl above the 2 pin connector must be connected to the blow by soleniod and probed from the back side If the connector is probed from the front side of the solenoid when it s disconnected battery voltage will be read The low voltage requires less amps and allows the solenoid to run cooler 1 PA ma Pa ST ce ULARLY SCT AAA MA A To recap if the blow by solenoid is not working c
45. ers 819 566 3062 Mailing address for Retail Customers Customer Assistance Center Bombardier Recreational Products Inc 565 de la Montagne Street Valcourt Qu bec Canada JOE 2LO Warranty Parts Return tor dealers only Canadian Dealers U S A Dealers Bombardier Recreational Products Inc Bombardier Motor Corporation of America C O Warranty Parts Center C O Warranty Department 565 De La Montagne 7575 Bombardier Court Valcourt Qc JOE 2LO Wausau WI 54401 Make sure that the correct copy of the BOSSWeb claim or paper claim is included with the exact part returned and properly tagged otherwise this may cause a delay in processing your claim Dealers dealing with North West Co Inc must forward the parts warranty claim and documents to their respective distributor s office For complete details concerning returning warranty parts clothing etc please refer to the Warranty Guide on BOSSWeb xE QOO 200 Sport Boats 2004 Technical Update page 1 8 2 SECTION z General Information Radio Warranty and Repair In the US Prospec Electronics In Canada L F Burgess and Associates E 800 394 1914 E 519 647 3222 E 843 849 9037 519 647 3226 843 849 9054 DX E mail info Olfobugess com e JVC and Seaworthy radios are covered by a Prospec Burgess warranty e Areturn authorization is required from Prospec Burgess prior to return unit e Prospec Burgess will repair or exchange at their discretion e For
46. ges in most cases there is nothing wrong It states in the owner s guide to check the oil when the engine is warm That s important as cold oil does not return to the oil tank as fast Experience has told us the best way to check the oil is when the engine has reached operating temperature 10 15 minutes riding That may be a little inconvenient but unless there is an obvious problem you may consider checking the oil at operating temps before you start troubleshooting oil accumulation in the PTO cover Also consider draining all the oil out of the engine and adding the correct amount to be sure you have the correct amount in the engine With that said in the 2003 Sea Doo Technical Update Book 219 700 266 we had a section on oil accumulating in the PTO cover Refer to pages 3 5 through 3 7 It mentions reasons why oil may accumulate there and over the past year we came across a couple more areas to check There is an insert pressed into the counterbalancer that drives the scavenge pump shaft assy 420 837 542 that must be checked so it does not spin inside the counterbalancer and the gear on the pump shaft assy itself must be checked so it doesn t spin on the shaft Even though these items must be checked it must be noted that there was only a couple failures on each last year Also pictured in the 2003 Sea Doo Technical Update Book page 3 15 is a cam cover tab that was on all MY 2002 4 TEC and MY 2003 4 TEC s that may break off a
47. he first thing that should be done is watch Technical DVD 1 P N 219 700 197 which covers the 4 TEC engine It is also very important to read through the Shop Manual before starting your project Get yourself familiar with what your about to do Disassembly Get a stand to mount the engine on It is much easier to work on when it s stable Ensure you have any special tools you need on hand Note the first production of crankshaft locking tools 529035821 were made to the exact size of the hole then a zinc coating was f added Use some emery cloth and remove this coating so it will fit in the crankcase hole i x 200 Sport Boats 2004 Technical Update Page 3 9 SECTION Troubleshooting and Tech Tips As stated before if the head does not need to be disassembled for repairs it can be removed as an assembly Before removing it stake the crankshaft and the camshaft This makes reassembly much easier The 8 M30 x 1 5 plug screws used to cover the main bolts are TORX T 55 These plug screws have Scotchgrip on them and are sometimes hard to remove Ensure to use a high quality T 55 Heat may have to be used to ease removal Take special care when removing the encoder wheel If the teeth are bent or damaged there will be a CPS fault code and or a running problem when put back together Re assembly New rod stretch bolts must be used New rocker arm stretch bolts must be used if they were remo
48. ibration cracking DO NOT REPLACE THESE COVERS Sensor Update B Storage Cover Stud The replacement brackets will reinforce and cov the area ATV SKI DOO SPORT BOAT Warranty 2002 4 Re ektain 2000 2002 Challenger and X 20 Models with 240 EFI Hngines Warranty 2003 4 ReXx ertain 2000 2003 Islandia PAC Tips Models with 240 EFI Engines Wake Pylon Kit Warranty 2003 5 ReWektain 2002 2003 Drop 29510025Wake Pylon kit will fit all GTX h TEC 205 Models with 240 EFI Engines modelsNOTE The following exhaust hose may need to be ordered for model listed 2002 GTX 4 TEC 274 001 036 This is an example of the May 26 2004 qc oe e SEQ 400 TECH TIPS 2003 GTX 4 TEC N A use stock hose b 2004 GTX 4 TEC ALL use stock hose ats New letter m LI The 4 TEC Oil Tank Pressure Switch is on back order We are expediting more from the supplier soon but it is obvious that many are being replaced needlessly Please review pages 3 8 and 1 22 of 2003 Technical Update book and pages 3 4 and 3 of the 2004 Technical Update book for a full NEW B U D S VERSION understanding of this switch and the assdciated 1202 Fault Replace the OTPS only if needed to The latest version for the RXP Update is us control the switch inventory Also please H BOSSWeb Version 2 1 3 is available for BOSSWeb is the only place you will find this Rue siad EE page 3 4 of the book are reversed The QTPS sw BOSSWeb ComCenter B U D S MPEM B U D S
49. ical to what is used on PWC Therefore they have the same running parameters as the PWC line When using B U D S to access an engine s ECU the system will tell you if it is a Sea Doo sport boat engine or a Sea Doo PWO engine The majority of 2004 engines are designated as sport boat engines but there some engines in both models that could be designated as Sea Doo PWC There is no difference in calibration or performance with these components The only issue is if you encounter one of these and do not have Sea Doo PWC access you will need to call the service department to obtain the access All engine management sensors are monitored by the ECU except the T O P S which is bypassed The idea is that a Sea Doo sport boat is not likely to capsize so that function is not required xE Q9 200 S port Boats 2004 Technical Update Page 3 16 SECTON Troubleshooting and Tech Tips Speedster 200 and Sportster 4 TEC Fuseblock Relay When the D E S S cap is installed on the post the magnetic switch in the post closes and energizes the relay in the fuseblock located on the seat back on the Sportster 4 TEC and on the stringers of the Speedster 200 This brings the entire system to life The fuseblocks are identical in single and twin engine applications with the twin engine models using two of them There are no electronic components in this unit only a relay and fuses Sportster 4 TEC Speedster 200 Speedster 200 and Sportster
50. ive to product i e SVIA LJ Yes LJ No Insured If so what type Did the operator review the product safety video or DVD supplied with the vehicle O Yes O No VEHICLE NO 2 Owner s Address Completed State Prov Product Safety Course O Yes O No O N A Town City State Prov Year Taken Certificat No Operator s Address Passenger s Name Driver s Licence No Coded Restrictions Zip Postal Code Date of Birth Age Sex O Male O Female Age Sex O Male O Female Product Experience Hours O 0 50 O 50 100 O 100 150 O 150 200 O 200 Make Model Safety Devices Present O Yes O No IfYes specify Year Serial No Safety Device in Use O Yes O No If Yes specify O Owned O Borrowed O Rent Warning or Caution Statement Present O Yes O No IfYes specify Date of Pre Delivery Date of 1 Recommended Inspection Proper Operating Instructions Present O Yes O No If Yes specify Date of Recent Service Mileage Hours Had Product Undergone Modification Recall Approved by Manufacturer O Yes O No Dealer s Name Had Product Undergone Modification by Former Owner O Yes O No Dealer s Address Were All Components on Product Original Yes NO Town City State Prov If no what was changed Zip Postal Code Tel No Were Replacement Components Sold by Product Manufacturer or Representative O Yes O No Product Registration No Year of Registration Were All Components on Any Security Item Fastened to the
51. kcase it curves around as shown in the drawing below If the cam cover tab or other obstruction is in the oil galley it will be stuck in one of the corners and that is why we need to snake the hose through to blow it out The blockage may exit the passage shown here with great F force Use adequate safety protection To ensure the oil galley is clear put the crankcase on end and insert a 10 to 11 mm steel ball into it If the oil galley is clear the steel ball will roll right through it The picture here is for clarity purposes The crankcase does not have to be separated to perform this task xE QOO 200 Sport Boats 2004 Technical Update Page 3 8 SECTION Troubleshooting and Tech Tips Rebuilding a 4 TEC Engine Now that the 4 TEC engines are getting older the opportunity to rebuild them will start to increase Do not be afraid of this engine as it is very easy to work on For example E There are no pressed fit bearings in the crankcases with the exception of the starter drive bearing Insert bearings are used on the rod main and counterbalancer Each has a different configuration but each of the configurations only has one size e No special tools are required to remove the flywheel e he head can be removed as an assembly no need to remove the cam and rocker arms Our service dept has rebuilt several engines and we would like to give you some helpful tips when performing this procedure T
52. les Department Gray market letter 05 2004 5 21 2004 4 58 PM 6 21 2004 4 58 PM Hew Core Return Policy With GORP s New Return and Credit Policy winning free cash is a sure bet and chis play to the core Promotion Banner PAC Communications Rebull Sea Doo Short Block 5 21 2004 1 45 PM 644 2004 1 46 PM GM Principal Technology Support BRP E mail Address change 5021 2004 12 02 FM 614 2004 12 03 PM Click here for more Safety Recall Sport Boats 2003 4 Rev 1 Please reter to the attached fie ParisiAcc Cotino PAC Departeent New Core Return Policy 502102004 6 55 AM 621 2004 6 56 AM Service Techracal Publications Safety Recal Sport Boats 2003 4 Rev 1 5 20 2004 10 53 AM 6 10 2004 10 53 AM fety Recall Sport Boats 2002 4 Rev 1 Service Techrecal Publications Safety Recal Sport Boats 2002 4 Rev 1 5 20 2004 10 44 AM 60 2004 10 44 AM Please reter to the attached fie US Watercraft Summer Closed End Promotion 000 tor S0 Days PLUS as Low as 5 9 for 72 Months Please see attached Safety Recall Sport Boats 200 Rev 1 Please eier to the attached fie What s lew Wednsday M What s News Information for Alert Detail From BOSSWeb News After Sales Services special Bulletin 07 04 GE URL Addre change for BRP Web site Closed End Add on increase to 25 PLUS Important Processing This is to inform you that Bombardier Recreational Products inc GRP has updated al Reminders B
53. letin 97 4 SENADO Sport Boats 2004 Technical Update page 1 9 2 SECTION z General Information Trailer Warranty and Repair For 2002 all Sea Doo trailers are made by Karavan BHP does not stock any parts or administer warranty for these trailers To help identify the trailer manufacturer the first characters of serial for each brand we have used are listed with the manufacturer s information Karavan Karavan Trailers 100 Karavan Dr Fox Lake Wl 53933 Serial 5KTB 920 928 6200 fx 920 928 6201 128 Leo Merkes karavan powerweb net Rivalair Out of business For parts Call Karavan Serial 2RV Trailer warranty was 1 year administered by Bombardier Recreational Products Inc Shorelander Midwest Industries Hwy 594 175 Ida Grove IA 51445 Serial 1MD 712 364 3365 fx 712 364 3361 Explorer Tube Warranty and Repair e Tubes are covered under warranty by BRP for 1 year e Hypalon material is covered by the manufacturer for 5 years For repair Dockside Inflatable Service Gary Carman 519 S E 32 CT Fort Lauderdale FL 33316 954 527 1399 fx 954 527 5146 Cel 954 270 8457 docksideis 9 aol com Georgian Bay Inflatables Brad Ansell 79 Chanplain Road Penetang ON Canada L9M 2G2 705 549 6643 Fiberglass Warranty and Repair There is a 60 month hull structural warranty on all 14 and longer Sea Doo sport boats To claim use system 12 You need to get an authorization from a Service Representati
54. lson Beneli Brazil only Carlos Parra Brazil only Japan Makoto Numajiri Asia John Koh Scandinavia Pekka Tiuraniemi Jorma Kukkola s 200 Ge Sport Boats E 32 9 272 63 62 oliver leitner 9 brp com 32 9 272 63 63 karel bogaerts brp com 1 954 846 1434 david rummel brp com 1 954 846 1424 rene morales brp com 1 954 846 1407 alfredo padron O brp com 55 19 3716 8605 ednilson beneli brp com 55 19 3716 8616 carlos parra O brp com 81 44 200 1431 makoto numajiri brp com 65 622 767 55 ext 103 john koh O brp com 358 16 3208 128 pekka tiuraniemi O brp com 358 16 3208 132 jorma kukkola O brp com 2004 Technical Update amp 1 819 566 3457 amp 612 9794 6651 amp 612 9794 6651 amp 612 9794 6651 B 32 9 272 63 49 amp 32 9 272 63 49 amp 1 954 846 1476 amp 1 954 846 1476 B 1 954 846 1476 B 55 19 3246 3800 amp 55 19 3246 3800 amp 81 44 200 1432 amp 65 622 629 32 amp 358 16 3420 316 amp 358 16 3420 316 page 1 7 ECTION SECTIO General Information Who s Who Customer Assistance Center CAC Representatives respond to customers and dealers who call write or e mail the Customer Assistance Center by giving information investigating complaints or referring callers writers to the appropriate department within BRP For Retail Customers In Canada 819 566 3366 E For Retail Custom
55. nd get lodged in the return oil galley If you are satisfied that there is indeed a problem of oil accumulating in the PTO cover and the scavenge pump is ok we have successfully found a way to check the oil galley between the PTO cover and the scavenge pump and remove a blockage This procedure will require e an8to 10 mm o d fuel line 72 cm long e anair gun e a10to 11 mm steel ball Cut the fuel line at an angle to allow it to slide easily into the galley xE QOO 200 S port Boats 2004 Technical Update Page 3 7 SECTON Troubleshooting and Tech Tips With these tools we will probe the oil passage and push any blockage out You will have to remove the engine PTO cover and scavenge pump Locate the lower oil galley hole going to the scavenge pump on the bottom half of the crankcase on the front of the engine Introduce the fuel line into that oil galley while blowing high pressure air through the line at the same time a The air pressure will push the piece that may be blocking the galley b The movement of the fuel line from side to side caused by the air pressure that passes through it assists in dislodging the rubber tab or other obstruction which may be blocking the passage c If your air gun can not be inserted into the hose then work the hose in as far as you can then apply pressure D It is important to understand that the oil galley is not straight through the lower part of the cran
56. new radio immediately need credit card 5 fee e BHP will cover labor please get an authorization from a Service Representative Warranty Period e CD player 1 year limited warranty from purchase date e Cassette Player 2 year limited warranty from purchase date Handling Procedure 1 When calling Prospec Burgess make sure to have the following information available e Radio model amp serial number found on chassis e Date boat was sold copies to be included in return This information is mandatory to determine the warranty coverage period 2 Make sure to write the return authorization number outside of the box Include also the dealer s name complete address and key contact at dealership 3 Send the complete radio face plate etc via UPS prepaid to the following address In the US Prospec Electronics In Canada L F Burgess and Associates 3325 Highway 17 North 177 Lynden Rd Mount Pleasant SC 29466 Lynden ON LOR 1T0 4 Prospec Burgess upon receipt of the product will repair and return the product to the dealer within 72 hours typically unless during the peak season at which times may vary 5 Should Prospec Burgess find a reason to charge a dealer out of warranty neglect abuse or missing parts the dealer would be called and told of the situation about the charges and would be asked for a valid credit card number for billing purposes Note For Clarion radios please refer to the Administrative Bul
57. ntly damage the protective coating Please contact G amp T Industries Marine Specialties Group hot line at 800 318 2887 for any cleaning and care questions SEQ I00 Sport Boats 2004 Technical Update Page 3 21 SECTON Troubleshooting and Tech Tips Past Years Technical Update Book P N s We currently have in stock the 2002 and 2003 Sea Doo Technical Update Books Since we refer you back to them several times in this update book if you need to order them here are the part numbers 2002 Technical Update Book P N 219 700 170 2003 Technical Update Book P N 219 700 266 B U D S USB Adaptor Some new computers no longer have com ports yet that is what connection is required when connecting the B U D S V C K to your computer We have successfully found an adapter that will plug into the USB port F5U109 BELKINS It is the only one we can recommend As usual if there are any questions with this or any other computer related problem regarding our F5U109 BELKINS systems please call the BOSSWeb help desk DI amp 4 TEC Fuel Filters We now stock the fuel filter that is on the bottom of the DI and 4 TEC fuel pumps A This filter is the same for both pumps The old filter is easily pried off and the new one can be pressed back on by hand Ensure it is fully seated for complete fuel filtering e P N 219 700 368 x 200 S port Boats 2004 Technical Update Page 3 22 SECTION Troubleshooting
58. of soapy water on components Bubbles will indicate leak location Check that leak does not come from improperly sealed hoses WARNING If any leak is found do not start the engine Remove any fuel leakage Failure to correct a leak could lead to an explosion Do not use electric powered tools on boat unless system has been verified for no leaks Hemove pressure test cap and retrieve chainfrom filler neck Reconnect fuel cap to chain and firmly tighten fuel cap into filler neck xE Q9 200 S port Boats 2004 Technical Update Page 3 14 bie HN Troubleshooting and Tech Tips DI and DI LE Engines Cylinders and Air Injectors Now that the 947 DI engine has been around awhile and was updated in 2002 there s seems to be a little confusion on what parts to use The engines updated in 2002 were called the DI LE However some international MY 2002 s produced did not have the new LE engine version in them Refer to the 2002 Technical Update Book Section 3 What s New P N 219 700 170 for this information and all the details concerning the differences between the two engines Note that the 2003 blue book rebuilt part numbers are incorrect for cylinders and shortblocks The correct numbers are DI DI LE e Rebuilt cylinders 421 000 570 e Rebuilt cylinder 421 000 205 e Rebuilt shortblock 421 000 572 e Rebuilt shortblock 421 000 416 The main difference between these cylinders are e DI cylinders have 6 ports DI LE cylinder
59. on BOSSWeb Verify the unit history on each vehicle to see if there are any pending campaigns Have vital information close at hand You will always be asked for your dealer number the vehicle model serial number and the vehicle mileage hours You will also be asked if there is already a call identification number logged on the vehicle or customer in question Not having this information readily available is very common and slows the system down for everybody Verify the customer s complaint If you are contacting your Service Representative for assistance you should be able to describe the problem accurately with factual information Verify the warranty status Is the unit in warranty out of warranty or covered by a BEST contract If it is covered by BEST have the contract number available as well as maintenance history if available Take names and Call ID Every BRP representative will identify themselves when answering your call Do not complete the call without noting who you spoke with Your call will also be logged in the computer system Make sure you ask for the call I D number and put it on the repair order SeEac400 Sport Boats 2004 Technical Update page 1 4 2 SECTION z General Information Who s Who Dealer Technical Support Call the Service Reps to get technical assistance and to get a Warranty authorization number Rich Klein Manager 2 715 842 8886 amp 715 847 6879 Service Repres
60. onnect to their own regulator rectifier on the port side of the engine The two long yellow wires connect to the bottom reg rect and the two short yellow wires to the top reg rect Each reg rect has a gray wire coming out of it One has a rubber plug in the connector and the other has the tachometer lead from the wiring harness connected to it Either gray wire could provide a signal to the tach If the module they have just installed receives no signal from the charging system tach it will run for 1 3 seconds and shut the ignition down It is possible for the tach to work even though the battery is not being charged e BLACK YELLOW Ignition circuit This is the circuit that the module intermittently grounds and opens to regulate rpm If there is some continuity in the key switch or lanyard switch when it should be an open circuit it could affect function of the module e BLUE Throttle sensor circuit This wire connects to the magnetic switch on the throttle control which is open when near the magnet at idle position and connected to ground through the black wire when away from the magnet If the blue wire is connected to the black wire at all times the rev limiter should not function Troubleshooting Tips e Poor wire connections Mainly grounds ex Battery ground cable connection to engine e Magnet is installed backwards Look at the picture in bulletins 2003 4 or 2003 5 Rev limit function does not work e Wrong spark plugs Non
61. ou should study the course review the material then re test SECTION 1 SEQ IODO AEN Sport Boats 2004 Technical Update General Information f One Toll Free Number Page 1 3 The objective of Section 1 is to make contacts between dealers and BRP as easy as possible Before You Call Page 1 4 Who s Who Page 1 5 In Section 1 you will find the most important Wel ad ic asis phone numbers key contact names and the latest updated procedures to help you be more efficient Trailers Warranty and Repair Page 1 Radio Warranty and Repair Page 1 9 Explorer Tube Warranty and Repair Page 1 Fiberglass Warranty and Repair Page 1 Boat Information Page 1 11 RPO Reporting Page 1 12 PDI Page 1 13 Electronic Parts Catalog Page 1 BOSSWeb Tips amp Tricks Page 1 What s News Letter Page 1 Book DVD and Shop Manual Quick P N Reference Page 1 ECTION SECTIO General Information IT S EASY TO REACH US The Dealer Network Support Group has a consolidated structure that combines all of our core services thus allowing you easy access to eleven services with ONE TOLL FREE NUMBER Just dial One Toll Free Number rom U S z 1 800 366 6992 For Dealer use only son Canada 1 800 361 9980 For Dealer use only It s Quick and Easy BRP Network Support Serice Shortcut path using phone keys PAC Analysts This is the new phoning procedure for contacting PAG ELE EM Sales Se Information Techni
62. peller Size Boat Type BoatLength f Weather Condon Description of Problem 90 858879 DDT DATA WORKSHEET 90 858879 MERCURY q MERCURY LA TI RM A V Ga UM A OptiMax DDT Data Worksheet Dealer Name Technician Name Dealer Number Engine S N 1 Data Monitor NOW ENGINE RPM TPI 1 VOLTS TPI 2 VOLTS BATTERY VOLTS PWR 1 VOLTS PWR 2 VOLTS COOL TMP STB COOL TMP PRT MAP PSI AIR TMP TRIGGER ERR TIME TO OIL OIL INJ CNT AIR COMP TMP BLOCK PSI p 2 Data Monitor ENGINE RPM TPI 1 VOLTS TPI 2 VOLTS BATTERY VOLTS PWR 1 VOLTS PWR 2 VOLTS COOL TMP STB COOL TMP PRT MAP PSI AIR TMP TRIGGER ERR TIME TO OIL OIL INJ CNT AIR COMP TMP BLOCK PSI 90 858879 3 12 99 Bombardier Recreational Products inc BRP ACCIDENT INCIDENT REPORT DATE OF ACCIDENT INCIDENT Year DEALER NUMBER NAME OF DEALER DISTRIBUTOR Contact person at dealership Town City Date of Report State Prov PLEASE REPRESENT SITUATION BY DRAWING AND IDENTIFYING VEHICLE 1 AND VEHICLE 2 Owner s Name Sind ce Hours Ol os Cl 50 100 Ll 100 150 Ll 150 200 Ll 200 Owner s Address Completed State Prov Product Safety Course Yes NO O N A Town City State Prov Year Taken Certificat No Zip Postal Code Member of Product Club Association L Yes L No If Yes name Town City State Prov Passenger s Address Sex O Male O Female Product Experience Hou
63. r Cap There was a running change on the oil filter cap It has been updated from plastic to aluminum There are no more plastic caps in stock therefore when a cap is ordered an aluminum cap will be received There are now two O rings used on the cap instead of one Parts Numbers e aluminum cap 420 610 328 e O ring 420 230 920 same one as used on plastic cap e O ring 420 850 500 xE CO 200 S port Boats 2004 Technical Update Page 3 13 SECTION Troubleshooting and Tech Tips Speedster 200 Fuel System Pressurization Pressure Test Fill up fuel tank Remove fuel cap from chain at fuel cap end 1 only Place chain in filler neck for later retrieval Thread pressure test cap P N 529 035 870 into filler neck NOTE It will be necessary to install the fuel system pressurization retainer P N 529 035 978 as shown 1 before performing the fuel system pressurization test This retaining bracket prevents the fuel pump modules from being dislodged from their respective pockets during the pressure test NOTE To minimize time of fuel system pressurization the fuel tank should be quite full The system must maintain a pressure of 34 kPa 5 PSI for 10 minutes Never pressurize over 34 kPa 5 PSI Connect pump gauge tester to pressure test cap Pressurize fuel system to 34 kPa 5 PSI If pressure is not maintained locate leak and repair replace leaking component To ease leak search spray a solution
64. rankcase pressure builds the OTPS will open and the ECU will lose it s ground If after 3 to 5 minutes the ECU does not get it s ground back from the OTPS Fault Code 1202 will be activated and the engine will go into the 5000 RPM limp home mode The same thing will happen if there is a problem with the wiring connectors or the OTPS itself that would cause the ECU to lose the ground from the OTPS circuit SEQ I00 Sport Boats 2004 Technical Update Page 3 5 SECTION 130909 Troubleshooting and Tech Tips If Fault Code 1202 is Active or Occurred check the following Check for Battery Voltage at the PURPLE GREY wire going to the blow by solenoid Inspect wiring and connectors related to that circuit Verify the Blow By Solenoid is good and that the blow by valves are lifting to uncover the ports You can fool the system by disconnecting the OTPS connector and manually grounding it If the problem 1202 code goes away there is an issue with the connector or the OTPS itself if you know for a fact no crankcase pressure is present If the problem remains the wiring Kostal connector or the ECU which is rare is the problem If you can duplicate the problem and the 1202 code becomes active carefully unthread the oil filler cap and listen for pressure to escape If pressure is present there is a problem with the vent system If no pressure if present then the wiring connectors or the OTPS is at fault rarely
65. regarding these switches If after properly troubleshooting the respective switch and circuit and nothing was found that could lead to the above described issues replace the switch causing the problem Many parts were needlessly replaced last year and hours of troubleshooting were wasted because tech s were mistakenly troubleshooting the wrong switch and respective circuits Below are the facts and troubleshooting tips on these 2 switches OPS Oil Pressure Switch The OPS is located on the right hand side of the y Ns E js Ze y engine just forward of the oil filter i Q A A normally open switch that will switch to ground and ae y provide that ground to the ECU if there is sufficient oil pressure 26 32 PSI and higher and the RPM s are greater than 3250 If oil pressure is below spec the switch will not activate and the ECU will not receive a ground As a result OIL will be displayed on the cluster gauge the LED will illuminate and the buzzer will continuously sound It will also be in the 2500 RPM limp home mode No fault codes will be recorded The same thing will happen if the switch is bad and does not provide a ground to the ECU xE QOO 200 Sport Boats 2004 Technical Update Page 3 3 SECTION 130909 Troubleshooting and Tech Tips Troubleshooting the OPS Verify Oil Pressure Verify continuity between the OPS connector and the ECU connector Ensure OPS connector is making good contact
66. rive ass y CAI ITIMAN Enrmiira tha nka akan AN When installing the PTO cover ensure that the gasket is positioned correctly especially around the oil and coolant passageway areas The cam chain sprocket is slotted giving you 2 possible ways of installing it due to manufacturing tolerances and chain stretch Both ways can be correct Refer to page 3 11 in the 2003 technical update book P N 219 700 266 for a thorough explanation Be sure to follow all torque and sealant recommendations SEQ 200 S port Boats 2004 Technical Update Page 3 12 SECTION Troubleshooting and Tech Tips Other information If for any reason there are any light scuffs or scratches on the cylinder wall don t automatically think it has to be replaced The minimum piston cylinder clearance is e 4 TEC 0 024 0 056 mm 0 001 0 0022 in The service limit is 0 1 mm 0 0039 in that means approx 0 05 mm 0 002 in can be honed off the cylinder wall and still be below the service limit A good quality rigid hone with the recommended finish stone will do the job If your shop does not have one most machine shops do Valve guides are also available so there is no need to replace the entire head if one or more guides are damaged or worn There is a procedure in the 2003 Shop Manual on checking and or replacing valve guides Again if your shop does not have the facilities to perform this job most machine shops do 4 TEC Engine Oil Filte
67. rs O 0 50 O 50 100 O 100 150 O 150 200 O 200 Safety Devices Present O Yes O No Safety Device in Use O Yes O No O Owned O Borrowed O Rent Warning or Caution Statement Present O Yes O No Date of Pre Delivery Proper Operating Instructions Present O Yes O No Date of Recent Service Had Product Undergone Modification Recall Approved by Manufacturer O Yes O No Had Product Undergone Modification by Former Owner O Yes O No Dealer s Name Dealer s Address Were All Components on Product Original O Yes O No Town City State Prov If no what was changed Zip Postal Code Were Replacement Components Sold by Product Manufacturer or Representative O Yes O No Product Registration No Year of Registration Were All Components on Any Security Item Fastened to the Product O Yes O No May 2004 Bombardier Recreational Products Inc 1 O O Were all scheduled maintenance procedures performed by an LJ Yes LJ No Yes No Authorized BRP dealer e Was Routine Lubrification and Maintenance Given LJ Yes LJ No Policy No Expiracy Date to the Products as Specified by the Manufacturer Name of Ins Company Witnesses Name if more than one please join another page witness Witnesses Address Did the operator perform a pre start check of the product before the accident L Yes LJ No Was the operator familiar with the area being traveled LJ Yes LJ No Did the operator complete any appropriate safety training courses relat
68. rson injured at time injury consider wearing glasses handicapped or disabled influenced by alcohol or drugs mentally ill chronically ill Had the operating literature been read and understood by the person injured Had victim ever been involved in another accident other than with this product LJ Yes LJ No i Marine Occupational Recreation Other If so When Was the person injured informed of proper driving position techniques before LJ Yes LJ No riding the product Was passenger wearing adequate clothing helmet lifejacket LJ Yes LJ No May 2004 Bombardier Recreational Products Inc 4 NARRATION REPORT BY PERSON INJURED If narration is done by someone else than the person injured please identify yourself and sign the Narration report LJ Attach Police or Fire Department reports Include photographs of Ll Vehicle Ll Scene LJ Injuries Signature Narration date May 2004 Bombardier Recreational Products Inc 5 PUMP 12 VOLTS DISTRIBUTION ACCESSORY 4 22 VIS 3 26 2004 SPORTSTER LE DI 75 AMP VTS N a 5 5 DB E E N ka E o o gt e 5 3 BUZZER 2 16 2 2 5 5 d ne CRANK RELAY 3 19 3 u a a 2 2 5 E zz IGN COIL 2 3 20 gt EA LJ L LA ER ER LA lt x IGN COIL 1 3 21 p TPS PTO _ FUEL WI 4 13 25 AMP BAT BLOWER FUEL INJ 2 4 14 BAT 4 3 25 AIR NI
69. rt Boats 2004 Technical Update Troubleshooting Tech Tips In this section you will find the most current 4 TEC Engine Page 3 3 tips and solutions concerning situations that occured during last season as well as the latest updated procedures General Page 3 18 2 Stroke Engine Page 3 17 Vinyl cleaning Page 3 20 Note All troubleshooting procedures should be used in conjunction with the Shop Manual and other BRP service publications SECTION Troubleshooting and Tech Tips 4 TEC Engine OPS and OTPS We heard many times last year from customers bringing their Sea Doo 4 TEC equipped boat to the shop saying that it would only go so fast that the OIL warning or Check Engine would be displayed on the cluster gauge the buzzer would go off the LED would flash on the cluster gauge etc The problem was hard to duplicate and at times no fault codes were recorded We had some issues with both the OPS and OTPS in that they did not provide a proper ground to the ECU Many times the above mentioned problems were the end result of a faulty OPS or OTPS It is important to understand that these switches ARE NOT related They have entirely separate circuits The confusion comes because they are both related to oil and they are both pressure switches e OPS Oil Pressure Switch OLD P N 420 256 777 NEW P N 420 856 530 e OTPS Oil Tank Pressure Switch OLD P N 420256 880 NEW P N 420 256 885 We issued Service Bulletin 2003 13
70. s have 5 ports e the volumetric efficiency is increased and the fuel mapping is different on DI LE engines Interchanging cylinders would have an adverse effect in the way the engine performs It is important to note that although the air injectors would both physically fit on either of the engines types it is not a good idea to interchange them The opening and closing times on the DI LE injectors are different because of their ability to react The injecting mapping is different and if used on DI engines they will run richer This could foul plugs and could also cause non compliance with the EPA pa aea S r j A y DI DI LE SEQ 200 Sport Boats 2004 Technical Update Page 3 15 SECTION Troubleshooting and Tech Tips Electrical Systems Explained Sportster LE DI The Sportster LE DI electrical system is identical to the 2003 LRV DI electrical system with the exception of the inclusion of a neutral switch and analog gauges versus the LRV s info center The MPEM is identical in both models The wiring diagram is included in the appendixes at the back of this book Speedster 200 and Sportster 4 TEC ECU Both the Speedster 200 and Sportster 4 TEC e AQ models are equipped with Rotax 1503 NA normally M OMNES aspirated engines The Sportster in a single engine Pr m configuration and the Speedster with twin engines Each engine regardless of application has its own ECU mounted to it This ECU is ident
71. u aping s 1ojelado y9oyms dund eDiig ou do 1ed e2 ydy909 1dO 13409 BuooN ido dor uug QUNOWN ysni uJoH s146 reuoneBIAeN seipueH qe19 dils uoN A9er HOA ZL Dupioed ppIS uoN uonejusaun asul In Cdo peziueAreo peuojelA uiojsn2 WILL jueumnadedulo2 SAOID ajosuoy JeDuesseg 4eAug SIE 1 S sso uieis xis TO mog EZ 1881S ESSI Dunees pa19 s 098 PpSPped ua s s SOUBIESID Io uonoj euo SI1 YUNLVI33 ADNAINSANOD 2 ALSAAVS IVNOILIGOV ASVHOLS INS dadav VM IWHOdlV Id WIMS LNAWLYVdANOS IDVHOLS dv3d SSI99V vna avd 1930 NNS NOTAd MS SIH9MN ASALHNOD LIdADOD J39VWHOLS MS A9Vr 1104 eb SH3 V4ddS v M O3431S 09 IAa INV 39VWyHO1S WISH ANY 4019313430 ANIM dN dOd M N33HOSCNIM 1S3H9 391 NINA SII1ONVH KG 395VHOLS QHVOS8 NO SIYNLVI ADA UNA EPRTIE ES E WAH JONVWHOJHAd Q E E 5 8 3 Se 3 S N Ge Sport Boats SEQ I00 Specifications SECTION G YSN ey ul payd peneses syuBl iry Boueuiy jo uong4oduJoz JOJOJA ASIPAEQUIOS EQOZO seueipisqns SY Jo ouj jJeipuequuog jo sxreuiepeg peuejsiDe1 pue sxJgeuleped eJe O wi uogB4od4jo2 AOIMSUNAIG SU JO SAJBLLIS PEA peJejsiDe4 eue ENIGO pue oni 1er zi ANDAN HOA SL ianeg dwe 09 xelindo du osz ue s s Bubieyo 91419913 EISE nice 8 Ro i sso peo oDuns oJp H ep JD axejul awed un siqeysnipe enuen WISI CHUTE ESTRES youd S GeLeA apelq py LISIaLUEID GA ETE To H N 3 eanuiede um 1snau1 uDIH a eb euonsaJIg e
72. unicate with the BUDS system without using the DESS post xE 0200 Sport Boats 2004 Technical Update page 4 3 SECTION Special Tools New tool for various models Fuel system pressure test cap MANDATORY P N 529 035 870 Application To allow pressurization of most fuel systems tool will be autoshipped when available New tool for the 2003 4 Speedster 200 models Fuel system pressure retaining bracket MANDATORY P N 529 035 978 Application To retain fuel pump modules in their tank pockets during fuel system pressurization tool has been autoshipped SEQ I00 Sport Boats 2004 Technical Update page 4 4 SECTION 9 2004 Technical Update Specifications Vehicle Spec Sheets Z3 EN Z2DU QD Sport Boats In Section 5 you will find the most important specifications concerning the 2004 line up Specifications SECTION G w s n eu ur Pew Pamesa syu jy amp eoueurng jo uong4ocuoz2 JOJOW 4eipauequiog EQOZO esueoi Jepun pesn ouj seiBojouuoe pini ERGO Jo NABLUSPE pe4ejsiBeu E S IOC SOLIBIPISQNS SY JO ouj JIPIEQUIOS jo sxXeurepeag pe4ejsiDe1 pue sxeulepeJ eJe O wi HOA cL ieneg MOE ES et 13 a S S F7 a UUM 2112593 NU WIIHLDA TA yeys y paaMm a 1e16 exe1ul youd eAisse4Doad jeejs ssajule s ENTES 88 H N 4J 3126 95185914 1snuu1 ubiH ef IEuUOnOe Im 2bBe s a Du s mol II ed 1 duund jer LINN SANG sapoue OU IEIOULIOEe
73. ured in O Vehicle 1 O Operators O Passenger O Other Please specify O Vehicle 2 O Other Please specify CLOTHING Boots Deck Shoes Visor Goggles O Doctor s Name Doctor s Address Length of Stay Hospital Accident Reported to Was the person injured aware that what he was doing might result in injury LJ Yes LJ No Was there anything to distract the injured person s attention from what he was LJ Yes LJ No What doing Had anything happened to upset the person injured that day or at the time of LJ Yes LJ No What accident Was the person injured unusually tired or fatigued that day or at the time of LJ Yes LJ No accident Was the person injured ejected from product LJ Yes LJ No If so How Was the person injured entraped by product LJ Yes LJ No If so by What Was the person injured in a hurry at the time of the accident LJ Yes LJ No Has the person injured or any member of his family had LJ Yes LJ No If so What inj accident or close call from this previous activity Had the person injured taken any precautions to prevent an accident LJ Yes LJ N If so What Was the person injured familiar with the proper operation of the product LJ Yes LJ No Was the person injured informed of proper driving position techniques before LJ Yes LJ No riding the product LJ Yes LJ No Was passenger wearing adequate clothing helmet lifejacket Describe activities of person injured leading up to and at time of injury Describe physical condition of pe
74. uunjoA uBiu MO PSXIIAN ed 1 dund r LINN IMUA S poue IESULIES unured dejs ninuu uinui une 09 MX u0 1199101d Mele e Flere os9 s xewndo du osz Ndy xeW leyeg mo uonoa o d A9J 18AO lAa WO MO YeESeuyseAO uug sula s s uonosajold euiDuz vuwosue n yBbnoly Uanw enp peuni 19MOd JSNeYUXS usAUp 7eeB uonosful 110 OMe SsIqeUeA uopeaan uonoslul up SBe1s 2 xewndo du osz waj s s any xelando du osz 1 0 9A Jamodeas oy juevveoedsip ad L ANIDNA SAU 19 AN BuU aes EIS vd fue Le du osz au Buy 1 pb 11 18 sn e yoedeo IIO 7 151 1185 sn ob yoedeo Ierd Dx S9 SQl Obb L yu peo1 uosaed o Ayoedeo ET CET Dx 866 sal OOZ Z Ap 1uBISM o02 esiipesq AA 94a W PbSAO8 ueg ul 00 9 8 6L u1Buel I219A0 SNOISNAWIG HAMOL J 1SISdVT1IOD eiqeieAv Bujoueul4 gien ALUS LUISA Dau aping s joyesedo Fels uouAs duung eDig oinv s46 reuoneBIAeN UNO Usni UOH izle Size qe1o dI lS UON GIE Ge PMS UON uomne1ueuunJjsul m4 do 1350 Bulioow PpeyoyeW WoOIsNyD WIE uonejoi4 Wweoy A9Er HOA cL jueurnuedulo2 s109 NACO sso ureis XIS MOCOS A ete Duinees pe4eisiog Depped E i ig A RE EI EP ere ALSAVS IVNOILIGOV dANd M IVS LVJ 871 009 aile eE AOS J39VHOLS UH VOg NO NOIHSN9 1930 NNS diNNd M OVS 1V3 dIHS AIIN 81 009 LNIOd MOL Z H3MO L IEVOSIAVM 3SV37138 A9INO LEVA OML SLHDIT ASALHNOD Lld3 02 iE Nar 09 M OJy31S WANY H3 1002 NI L1IIn8 EI 42 03 0M Min ONV 4019313430 ANIM dN
75. ve Use these part numbers on your Warranty Claims e Hull p n 999999000 e Deck p n 999999001 e Assy p n 999999002 xE 200 Sport Boats 2004 Technical Update page 1 10 2 SECTION z General Information FishHawk Boat Parts Information for dealers only NOTE When a FishHawk supply part is shown as depleted in BOSSWeb dealers should then contact GenMar Holdings Inc http iwww genmar com Johnson Evinrude For dealer only Technical Support US CA 800 888 4662 Customer Assistance US CA 847 689 7090 IMercury For dealer only Dealer Technical Support US 920 929 5884 or fax 800 842 4550 CA 905 567 8515 or fax 800 663 8334 Technical Training US 920 929 5552 or fax 800 842 5929 CA 905 567 8515 or fax 800 663 8334 For faster service fill out a Quick Fax or OptiMax DDT Worksheet and fax it to Mercury Customer Assistance US 920 929 5040 CA 905 567 6372 Gelcote International For dealer only Phone US and Canada 613 225 2177 Toll free US and Canada 877 GEL COTE 435 2683 Email info gelcote com SEQ 200 Sport Boats 2004 Technical Update page 1 11 SECTION z General Information RPQ Reporting Reports on Performance and Quality RPQ reporting is necessary in order to relay all information to the Engineering Department This process ensures that any network concern will be well documented to provide an accurate respons
76. ved Cylinder head screws can be re used if they are with in the service limit of 148 5 mm If the crankcases are to be replaced ensure to order a new starter drive assembly bearing P N 420 232 480 as it is very difficult to remove without damaging it s 200 am Sport Boats 2004 Technical Update Page 3 10 SECTION Be sure to install the cam chain tension guide on the crankcase and the cam chain around the crank gear before assembling the crankcases If not you will be taking them apart again Cleanliness is vital when installing insert bearings as well as for the entire re assembly procedure When installing the flywheel ensure the balance holes are not lined up with the encoder wheel gap Be sure to align the encoder wheel with the drive pin on the crank gear SeEac400 Troubleshooting and Tech Tips S port Boats 2004 Technical Update Page 3 11 SECTON Troubleshooting and Tech Tips Ensure the encoder teeth are not bent If in doubt insert a feeler gauge between the flywheel and the encoder teeth The flywheel and encoder wheel teeth must be within 0 006 of one another 3 o e f e j 7 PT l EX amp gt 3 je ex n i z e m LM e Install the washers correctly on the starter ele Position the disc springs no 6 and washer no 7 as per the following illustration Refer to the Shop Manual l Washer 2 Disc spring 3 Flange washer 4 Starter d
77. with the OPS Ensure the ECU Kostal connector is making good contact with the ECU You can fool the system by starting the engine then grounding the OPS connector If the problem goes away and of course the oil pressure is within specs then the wiring from the connector to the ECU is OK and the switch connection or the switch itself is most likely the cause If the connector is grounded prior to starting the engine the ECU sees a ground that is not supposed to be there and Fault Code P0520 will be tripped Again at times the problem may be hard to duplicate So if after troubleshooting and no discrepancies are found replace the OPS OTPS Oil Tank Pressure Switch or as it is called in the Service Manual OSPS Oil Separator Pressure Switch On the 4 TEC engine the OTPS Oil Tank Pressure Switch is actually a crankcase pressure switch and is located at the front of the engine on the oil air separator assembly This switch is normally closed to ground so in normal operation the switch provides a ground to the ECU If the crankcase pressure exceeds approx 4 psi the switch opens the ECU loses the ground and activates fault code P 1202 after 3 to 5 minutes of running CHK ENG will displayed on the cluster gauge and the engine will go into the 5000 RPM limp home mode The same thing will happen if the OTPS is bad The blow by solenoid located on the oil air separator has 2 blow by valves attached to it When it is en

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