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1996 SeaDoo Racing Handbook

1. nn adid asoy 1 EQ jo Jayem 501 802 2266 96 5 u ym 1409 peau Jedeeq jo 10 98 1 INALSAS 3NIDN3 289 03 40 www SeaDooManuals net SECTION ENGINE PREPARATION m gt o o o 2 gt lt LO 01 195 03 41 www SeaDooManuals net SECTION ENGINE PREPARATION Uppermost point of engine cylinder head allows bleeding Temperature sensor activates monitoring beeper when temperature exceeds 96 99 C 205 210 F Calibrated cylinder head limits water flow Engine water outlet hose SPX model Fitting spigot Cooling System Indicator s CSI Small stream of water flows out of bleed outlet s located near stern eyelet Calibrated outlet fittings limit water flow Pressure zone 10 Engine water inlet hose 11 Tuned pipe bleed hose injects water into muffler to cool exhaust components GTX model 12 Lowest point of circuit allows draining whenever engine is stopped 13 Water injected directly into exhaust gas for noise reduction and performance improvement 14 Fresh water flows through tuned pipe and manifold water jackets 15 Uppermost point of circuit tu
2. F01D1NS 1 Main journal alignment here Counterweights can also be twisted on connecting rod journal on any or both cylinders 03 62 www SeaDooManuals net SECTION ENGINE PREPARATION FO1D1NT 1 Connecting rod journal alignment here CRANKSHAFT ALIGNMENT AT CENTER MAIN JOURNAL To accurately check crankshaft alignment proceed as follows Remove ignition housing cover Remove MAG flywheel nut Install Bombardier degree wheel P N 295 000 007 on crankshaft end Hand tighten nut only Remove both spark plugs Install a TDC gauge P N 295 000 065 in spark plug hole on MAG cylinder side Bring MAG piston at Top Dead Center As a needle pointer secure a wire with a cover screw and a washer Rotate degree wheel NOT crankshaft so that needle pointer reads 360 Remove TDC gauge and install on PTO side Bring PTO piston at Top Dead Center 03 63 www SeaDooManuals net SECTION ENGINE PREPARATION 010415 Degree wheel Hand tighten nut Needle pointer Interval between cylinders must be exactly 180 therefore needle pointer must indicate 180 degree wheel 360 180 180 Any other reading indicates a misaligned crankshaft CRANKSHAFT ALIGNMENT AT CONNECTING ROD JOURNAL Crankshaft misalignment at connecting rod journal may cause the crankshaft to be hard to manually turn Verification can be done by measuring defle
3. seen tns 01 9 SPONSORSHIP AND SOLICITATION enne 01 11 THE PROFESSIONALS POINT OF VIEW cens 01 12 SECTION 02 HULL PREPARATION PREPARING THE HULL FOR INSPECTION etn 02 2 MEASURING THE HULL tette ttt tet ttt tet totns 02 2 TRUING THE HULL 2 02 3 NN e 02 4 PAINTING PROCEDURE ettet tenis 02 5 DELTA PAINTING PROCEDURE cte tete tents 02 7 SEALING OF BODY COMPONENTS cette tnnt tente tena 02 8 HULL AND BODY MAINTENANCE 02 8 LIGHT WEIGHT PARTS scene tnter tenet tete tet ta tet tet ta totis 02 8 SPONSOWN M EIU 02 8 INSTALLATION GUIDELINES ettet tette 02 9 PARTS THAT CAN BE PAINTED 1988 1991 WATERCRAFT MODELS 02 12 PPG COLOR CHART sette tette tette te tete setate ses n 02 13 PARTS THAT CAN BE PAINTED 1992 1993 WATERCRAFT MODELS 02 15 PPG COLOR CHART eet tentent tentent tette tette t tete tese sea setas 02 16 PARTS THAT CAN BE PAINTED 1994 WATERCRAFT MODELS 02 18 PPG COLOR CHART erepto 02 19 PARTS THAT CAN BE PAINTED 1995 WATERCRAFT MODELS 02 20 PPG COLOR CHART E ep E 02 21 PAR
4. vs 622 7 Low speed outlet 12 High Bypass holes 13 Main Throttle plate 14 Anti siphon valve Fuel inlet 15 Low speed jet Pulse 16 Needle valve assembly Check valves 17 Regulator diaphragm Pump diaphragm 18 ilter Restricter 10 Fuel return 11 Inner venturi speed adjuster jet Oo 3 19 Arm spring 20 Fuel chamber 21 Vent to atmosphere 22 Low speed adjuster 03 87 www SeaDooManuals net SECTION ENGINE PREPARATION NOTE It is important to NOT select a needle valve that is too small for your application due to the fact that the needle valve can be a limiting factor in maximum fuel flow In other words in some applications engines require more fuel than small needle valves can deliver The needle valve sizes in Mikuni special set carbs have been carefully selected and should not be decreased However in the case of watercraft with very high fuel demands it may be necessary to increase the needle valve size Keep in mind that when the needle valve size is changed it will affect the pop off pressure STANDARD NEEDLE VALVE SIZE FOR VARIOUS SEA DOO CARBURETORS BN38l 37Bl BN38 34 45B BN38 34 58 BN38 34 59 BN38 34 64 BN38 34 65 BN38 34 73 BN38 34 74 BN38 34 92 BN38 34 93 BN38 34 110 BN38 34 111 All use 2 0 needle valve CAUTION It is recommended that you select an arm spring that is the correct l
5. 04 18 STEERING SYSTEM ALIGNMENT eene 04 19 SECTION 05 MISCELLANEOUS EQUIVALENT WEIGHTS AND MEASURES CHART 05 2 GLOSSARY OF TERMS IN PERSONAL WATERCRAFT RACING 05 3 05 4 LISTING AFTERMARKET MANUFACTURERS AND SERVICES 05 5 V www SeaDooManuals net SAFETY PLEASE READ AND UNDERSTAND ALL WARNINGS AND CAUTIONS IN THIS HANDBOOK This handbook uses the following symbols WARNING Identifies an instruction which if not followed could cause serious personal injuries including possibility of death CAUTION Denotes an instruction which if not followed could severely damage water craft components O NOTE Indicates supplementary information needed to fully complete an instruction Prior to operating the watercraft thoroughly read and understand the Sea Doo Operator Guide and Safety Handbook it will give necessary knowledge required to adequately operate your watercraft Check local and federal boating laws and regulations in the area where the watercraft is to be used It is recommended to complete a boating safety course Never operate the watercraft after consuming alcohol and or drugs At race events always respect rules legislated by the organizer and sanctioning association KEEPING YOUR WATERC
6. HX watercraft must be removed prior to inspection and racing It is recommended that a length of nylon rope be used to replace the eyelet The rope will facilitate easy towing off the course by the Course Marshals in the event of a breakdown and prevent water entry into the hull When securing the rope ends inside the nose of the hull the eyelet retaining plate must continue to be used in order to prevent the rope from pulling through The pump intake grate must have at least one bar running the length of the inlet and must not protrude down more than 12 mm 473 inches below the flat plane of the intake portion of the pump housing The ride shoe pump plate must not contain any fin or rudder type protrusions and aftermarket plates must stay within required dimensions The rubber bumpers must be in place and securely attached The hull and deck must not have any sharp edges torn or improperly repaired fiberglass Steering must turn from lock to lock without binding The handle bar grips must be secure After market handle bars that have a cross bar must have padding on the cross bar The fuel cap must fit tightly The throttle lever must work freely The Safety Lanyard tether cord will be checked for proper operation The engine idle will be checked to determine that the engine will not idle in the event of lanyard failure Inside the hull the fuel tank oil tank and battery box will be checked for secure moun
7. 1 sss 02 2 MEASURING THE HULL 02 2 IRUING THE HULL rnnt treten ttr tette ett ttt 02 3 PAINTING 02 4 CONCEPT PAINTING PROCEDURE 22 22222222222 2 1 02 5 DELTA PAINTING PROCEDURE 22222222 222222221 02 7 SEALING OF BODY COMPONENTS 2 2 4 24 120020240 1523120 20000008005448 02 8 HULL AND BODY MAINTENANCE 02 8 HULL LIGHT WEIGHT PARTS 2222222 20222 02 8 SPONSON KIIS 02 8 INSTALLATION GUIDELINES sese tete tentnntntees 02 9 PARTS THAT CAN BE PAINTED 1988 1991 WATERCRAFT MODELS 02 12 PPG COLOR CHART eiecit ast priae e dieci e itane 02 13 PARTS THAT CAN BE PAINTED 1992 1993 WATERCRAFT MODELS 02 15 PPG COLOR CHART eee eee M Ee 02 16 PARTS THAT BE PAINTED 1994 WATERCRAFT MODELS 02 18 PPG COLOR CHART rae aere adiecto t eterne 02 19 PARTS THAT CAN BE PAINTED 1995 WATERCRAFT MODELS 02 20 PPG COLOR CHART ie n ti o deni 02 21 PARTS THAT BE PAINTED 1996 WATERCRAFT MODELS 02 22 PPG COLOR CHART i atio op ei eee dadas
8. 31 64 Resistor 14 mm 09 5 mm Surface Discharge 3 8 Inductive Suppressor Type F02H08S CROSSCUTS AND GAP STYLES OF SPARK PLUGS Ww u y Standard Projected Taper Insulator 03 82 www SeaDooManuals net Special Design Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V Type alf Heat Range andard Center ectrode Fine Wire Center Electrode Booster Gap V Grooved Center Electrode Surface Discharge Type SECTION ENGINE PREPARATION MIKUNI BN CARBURETORS REPRINTED WITH THE AUTHORIZATION OF MIKUNI CORP INTRODUCTION OF THE SUPER BN CARBURETOR FO1FOWS The Super BN carburetor is the latest in a series of watercraft carburetors from Mikuni The Super BN earns its name because of the increased performance it delivers over previous model Mikuni BN carburetors What differentiates the Super BN from its predecessors 1 The fuel pump and jet sections are separated for easier maintenance 2 It has an integral fuel filter 3 The fuel pump capacity is increased by almost 20 4 Air flow is increased by 9 5 It is easily tuneable with replaceable jets in a wide range of sizes and an array of other tuning components With the introduction of the Super BN Series of carburetors Mikuni American has made a renewed commitment to the watercraft industry b
9. 092 Sq Meter m 1m 10 8 Sq Feet WEIGHT 1 Ounce 28 35 Grams 9 1 Gram 03527 Ounce 1 Pound 4536 Kilogram kg 1 Kilogram 2 2046 Pounds VOLUME 1 FI U S Ounce 29 574 Milliliters 2957 Deciliter 0296 Liter 1 Fl U S Pint 473 18 Milliliters 4 7316 Deciliters 4732 Liter 1 FI U S Quart 946 35 Milliliters 9 4633 Deciliters 9463 Liter 1 U S Gallon 128 2 3 785 Liters 1 Cu Inch 16 387 Cu cm 1 Cu Centimeter 061 Cu Inch 1 Cu Foot 2 831 16 Cm 1 Cu Decimeter 0353 Cu Foot 1 Cu Yard 7646 Cu Meter 1 Dry Quart 32 oz 1 101 Liters TEMPERATURE 32 Fahrenheit 0 Celsius 0 Fahrenheit 17 8 Celsius F c x 1 8 32 C F 32 1 8 05 2 www SeaDooManuals net SECTION 5 MISCELLANEOUS GLOSSARY OF TERMS PERSONNAL WATERCRAFT RACING Bail Bond flange Buoy Course Marshall Deck Holder Holeshot Hull Log Jump Pit Area Porpoise Race Director Sponsor Staging Area Starter Starting Line Technical Inspector Wake To wipe out to fall The bond flange is the overlapping mating section where the deck upper and hull lower portions are joined Floating object anchored in the water designating race course An official located on the race course to help control the race as well as to assist downed riders The structural body of the watercraft located above the bond flange T
10. 2 1 9 0 0 0 0 4 8 www SeaDooManuals net SEA DOO RACING HANDBOOK WARNING This information relates to the preparation and use of watercraft in competitive events Bombardier Inc disclaims liability for all damages and or injuries resulting from the improper use of the contents We strongly recommend that these modifications be carried out and or verified by a highly skilled professional watercraft racing mechanic It is understood that racing or modifications of any Bombardier made watercraft voids the watercraft warranty Racing of any product including watercraft involves an assumption of risk by each competitor In watercraft racing these risks include drowning collision with other craft and falls onto the watercraft or into the water The danger and risk is multiplied as speed is increased Protective clothing or equipment including helmets cannot protect a racer in all conditions www SeaDooManuals net INTRODUCTION Welcome to the world of SEA DOO watercraft racing The information in this manual contains the theory and operating principals of the SEA DOO watercraft systems It provides the foundation needed for setting up the watercraft for racing purposes All racers should obtain a copy of the model year SHOP MANUAL and necessary tools before attempting any mechanical work Many aspects of watercraft Fine Tuning and Blueprinting which are contained in this handbook are critical to insure safe and proper watercraf
11. They were able to conquer their goals after major set backs such as equipment failure personal injuries or being knocked off your watercraft at the start of the race and battling your way back to the lead Being a Pro is a big responsibility You have a responsibility to your sponsors and to your sport As a professional racer you are a representative of your sponsors and all personal watercraft racers Everything you do on or off the track is reflected on those you represent If you are a budding Pro racer and wonder sometimes if it is all worth it personally know the feeling I ve been through the ups and downs of a Pro racing career more downs than ups and wondered myself sometimes also know the feeling of winning and winning World Champion ships There is nothing that can compare to the feeling of being number one feel the challenge is worth the effort Good luck Jeff Poison Prieur Pro Watercraft Racer As a Pro Runabout racer each day of training testing and racing has taught me more Conditioning has become a big part of my daily routine learned early on while racing in the Modified Division against the men that physical strength plays a major role in being competitive Each day include a weight training program with my personal trainer for strength and stamina Weight training has given me the strenght need to compete on a professional level use this training to my advantage to improve my endurance and cor
12. 03 93 www SeaDooManuals net SECTION ENGINE PREPARATION What we have been considering and learning is pop off pressure what it is and what affects it What effect does this have on your fuel system Pop off pressure controls throttle response from just off idle until approximately 1 2 throttle As a rule of thumb piston ported and rotary valve engines use generally higher pop off pressures as where reed valve engines require lower pop off pressures SPRING SELECTION When changing the pop off it is recommended that you select a spring from the chart that combines with your needle valve size to obtain the desired pressure If no spring size is appropri ate it is acceptable to take a spring of greater pressure and cut it shorter to achieve the correct pop off Use your gauge to verify the pop off Do not stretch lesser springs to increase pressure as the metal has a memory and will eventually shrink back to its original size POP OFF PRESSURE CHART Needle Valve Size Arm Springs FUEL FLOW CHART High speed screw of total Main jet fuel flow Transition circuit Low speed screw 1 2 F01D71Sa Throttle position NOTE This chart depicts the approximate amount of fuel that each circuit contributes to the total fuel flow of the Super BN S Fuel flow is in percentage Low speed circuit contributes fuel all the way to full throttle All fuel circuits within the carb work in this man
13. 219 100 010 1995 Shop Manual 219 100 013 1996 Shop Manual 219 100 031 Always use a laboratory blended fuel Do not add your own octane booster Doing so will result in unknown burning rates of the fuel Select a fuel with a given octane rating and tune your engine to maximum efficiency for that fuel REFER TO OCTANE REQUIREMENTS FOR ROTAX ENGINES Correct your carburetor s jetting to compensate for engine modifications Reconfirm correct jetting at the race site Atmospheric conditions ALTITUDE TEMPERATURE BAROMETRIC PRESSURE HUMIDITY may be quite different at the race site or during different times of the year Ignition timing may need to be altered from standard timing specifications to achieve maximum power output if modifications are made to the engine 03 2 www SeaDooManuals net SECTION ENGINE PREPARATION BASIC ENGINE THEORY TERMINOLOGY CYCLE In a combustion engine a cycle is accomplished when the 4 phases are completed intake compression ignition and exhaust TDC Top Dead Center The position of the piston when it reaches the upper limit of its travel inside the cylinder BTDC Before Top Dead Center ATDC After Top Dead Center BDC Bottom Dead Center The position of the piston when it reaches the lower limit of its travel inside the cylinder BBDC Before Bottom Dead Center ABDC After Bottom Dead Center BORE Diameter of the cylinder STROKE The maximum movement of the
14. Pilot and main jets are replaceable Different jet sizes are available to suit altitude and or temperature conditions Different jetting may be required as engine performance is increased Always inspect spark plug and piston dome color before selecting jetting options Spark plug or piston dome color is an indication of carburetion mixture conditions Dark brown or black coloration indicates a rich condition while light tan or white indicates a lean condition Medium brown coloration may indicate a correct jetting range Location to check spark plug coloration sF F01E1AS 1 Location to check spark plug coloration Refer to the appropriate Shop Manual of your watercraft for instructions on changing carburetor jetting 03 95 www SeaDooManuals net SECTION 03 ENGINE PREPARATION JETS FOR MIKUNI SUPER BN CARBURETORS SIZE PART NUMBER MAIN JETS 270 500 157 270 500 158 270 500 116 270 500 159 270 500 181 270 500 160 270 500 161 270 500 162 270 500 163 270 500 225 270 500 174 270 500 209 270 500 210 PILOT JETS 270 500 202 270 500 201 270 500 180 270 500 164 270 500 117 370 500 165 270 500 175 270 500 166 270 500 149 270 500 167 If in doubt with carburetion jetting always begin with a rich setting and work toward a lean adjustment NOTE It is recommended you always race with your fuel tank valve on the reserve position This should eliminate any possibility of air entering in the fuel sys
15. Primer DELTA PRIME PPU 166 DELTA 2800 COLOR HOW TO MIX Mix DELTA 2800 2 1 2 parts colors 1 DU 6 Catalyst APPLICATION Apply 2 coats of DELTA Polyurethane Color Apply the first coat at 1 5 1 8 wet mils Allow minimum of 15 minutes flash time prior to application of the second coat Apply a second coat of DELTA using the same technique as the first application paying strict attention to gun set up and proper equipment choices RECOMMENDED SPRAY EQUIPMENT Gun Model JGA 62 800N Can Am Model 900 Fluid Tip Size FF 63D 02N HT 9072 1 4 mm 055 in 1 5 mm 059 in 1 2 mm 047 in 2 5 mm 098 in Air Cap 791 264 63PW 02 03 9062 Gun Distance 26 30 cm 26 30 cm 26 30 cm 26 30 cm 10 12 in 10 12 in 10 12 in 10 12 in Fluid Delivery 221 340 mL min 221 340 mL min 221 340 mL min 221 340 mL min 8 12 oz min 8 12 oz min 8 12 oz min 8 12 oz min Air Pressure 42 51 kPa 42 51 kPa 42 51 kPa 62 kPa At the Gun 60 75 PSI 60 75 PSI 60 75 PSI 9 PSI DRY TIME AT 21 70 F dust free 25 35 minutes tack free 2 1 2 3 hours tape sand Overnight FORCE DRY Allow 20 minutes purge time at 27 32 C 80 90 F before bake Bake 75 minutes at 65 C 150 F or 40 minutes at 82 C 180 F Allow to cool after force dry before sanding or taping 02 7 www SeaDooManuals net SECTION 02 HULL PREPARATION SEALING OF BODY COMPONENTS Important areas to check
16. Those who choose late registration are charged a penalty fee for that privilege During registration you will have to indicate on the entry form the type of event and classes you have chosen to enter Also at that time your holder will need to sign a release form 3 PIT AREA SET UP At the race site you will be allowed to set up your pit area the morning of the event at approxi mately 6 00 AM Pit location is very important be there early You will have to place your watercraft close to the water line your equipment and tent if you have one must be placed little further away The promoter may not be on hand during your set up Look the site over the night before if possible talk to the promoter to find out where to set up by doing this you will avoid moving all your equipment later and you will be able to get a choice spot with easy access to the water as well as to your equipment You are also required to keep a fire extinguisher in your pit and store your fuel in a designated area 4 SAFETY INSPECTION Before your watercraft is allowed on the water the Safety Inspector or his assistant must perform a safety inspection The Inspector will check your full face helmet and your personal flotation device for compliance with sanctioning requirements At that time your watercraft will be checked for safety require ments which are defined in your rule book and then affix a sticker to your watercraft which signifies your compliance Aft
17. 02 18 www SeaDooManuals net SECTION 02 HULL PREPARATION PPG COLOR CHART 1994 5 000 MODELS COMPONENTS SP 5870 SPX XP 5854 GTS GTX EXPLORER SPI 5872 5871 5855 5814 5862 5821 1 Body White White White White White White 98223 98223 98223 98223 98223 98223 2 Hull White Teal Green White White White 98223 18923 49580 98223 98223 98223 3 Storage Cover Not Not Not Teal Green White Applicable Applicable Applicable 18923 49580 98223 White White White White White White 98209 98209 98209 98209 98209 98209 5 Tuned Pipe Gray Gray Purple Gray Purple Gray 38269 38269 59962 38269 59962 38269 6 Muffler Gray Gray Purple Gray Purple Gray 38269 38269 59962 38269 59962 38269 7 Exhaust Manifold White White White White White White 98209 98209 98209 98209 98209 98209 8 Engine Support Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 9 Ignition Housing White White White White White White 98209 98209 98209 98209 98209 98209 10 Ignition Housing Cover White hite hite White White White 98209 98209 98209 98209 98209 98209 11 Console Not Not Not Not Not White Applicable Applicable Applicable Applicable Applicable 98223 12 Fame Arrestor Support White White White White White White 98209 98209 98209 98209 98209 98209 13 Flame Arrestor Base Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 14 Ride Shoe Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 15 Impeller
18. 03 26 www SeaDooManuals net SECTION ENGINE PREPARATION 6 Exhaust system restrictions muffler plugged restricted tail pipe diameter too small incorrect design of expansion chamber 7 General overheating restriction in cooling system debris in water pick up 8 Water entering combustion chamber MEASURING COMPRESSION RATIO The minimum combustion chamber volume is the region in the head above the piston at Top Dead Center It is measured with the head installed on the engine 1 Remove spark plug and place piston at Top Dead Center 2 Obtain a cc graduated burette 0 50 cc and fill with 5096 gasoline and 50 oil NOTE Suggested burette Canlab 8 000 T equivalent F01D6MS 3 Inject the burette content through the spark plug hole until mixture touches the 2 bottom threads of the spark plug hole 4 Read the burette scale and obtain the number of cc injected into the cylinder example 21 5 cc 5 Record the volume which we will note as V 03 27 www SeaDooManuals net SECTION ENGINE PREPARATION FO1D5VS 1 Combustion chamber V 2 Liquid mixture 2 threads NOTE When the combustion chamber is full the level of fluid should not decrease If it does there may be leakage between the piston and cylinder Removing the head and measuring the head volume by laying a flat plate across the head will not give an accurate measurement of
19. 2 Check the ignition timing and ignition flywheel nut torque 3 Lubricate the electric starter gear and shaft Check the starter mounting bolts for tightness and the starter electrical cable for a clean corrosion free connection both on the starter and solenoid 4 Check all rotary valve housing intake manifold and carburetor mounting bolts for tightness 5 Check for correct oil injection pump adjustment if an injection pump is being used 6 Check the fuel filter for debris or water if any abnormality is noticed remove and clean the fuel tank fuel filter fuel lines and carburetors 7 Carburetor diaphragm screws should be checked and pop off pressure verified Now is a good time to check your low and high speed fuel mixture screws to make sure they have not backed out and are still set to the required setting Throttle cable operation should be checked to insure maximum throttle opening is being attained Lubricate the throttle cable at this time 8 Clean or replace the flame arrester as necessary 9 Engine bed plate bolts should be checked for tightness 10 Check all exhaust system components for cracks or signs of fatigue Pay close attention to rubber couplers exhaust pipe and exhaust manifold mounting bolts 11 Service the battery and check for clean corrosion free battery cable connections 12 Grease the PTO flywheel and the drive shaft seal carrier at their grease fittings If the seal is damaged replace it
20. 222 2220 44 0 03 81 5 03 83 CARBURET OR UNING 2 03 95 BREAK IN 03 97 SUMMARY ince datecode 03 97 SECTION 04 PROPULSION SYSTEM BASIC FUNCTIONS OF THE 5 22 1 04 2 AXIAL FLOW ga rcs erui d rer Dette 04 2 MAINTENANCE MMWP 04 3 PROPULSION SYSTEM 1 5 2 2 04 4 PROPULSION SYSTEM SPECIFICATIONS 04 4 ED 04 5 IMPELLER 2 PO 04 6 IMPELLER TYPES uid Isa Sica ad 04 6 IMPELLER IDENTIFICATION nnn 0 Rand 04 10 STATOR VANE 04 14 mhi pU re vice dina na EAE aiaa 04 14 ENGINE JET PUMP 04 14 FUNCTIONS OF THE VARIABLE TRIM SYSTEM 85 04 16 www SeaDooManuals net VENTILATION AIR LEAK a ed re tocaba eds 04 17 IP uie P
21. 271 000 104 271 000 313 ring 271 000 454 10 22 progressive pitch satin finish stainless steel 271 000 422 214 000 434 ring 271 000 458 10 22 progressive pitch satin finish stainless steel 271 000 104 271 000 313 ring 271 000 470 04 12 10 22 progressive pitch satin finish stainless steel www SeaDooManuals net 271 000 422 271 000 434 ring SECTION 04 PROPULSION SYSTEM The following chart could be used as a guide to help optimize pitch for your application IMPELLER PITCH CHART 15 PITCH 4 BOAT SPEED 010725 04 13 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM STATOR VANE The function of the stator is to transform the dynamic force created by the impeller into forward thrust The design principle is similar to the impeller although the stator vanes are in a fixed position VENTURI The venturi function is to increase the fluid velocity using static pressure to generate the thrust Without the venturi there would be very little thrust The venturi outlet diameter can be adjusted to compliment the engine tuning and impeller you have selected Generally speaking a slightly larger 1 2 mm outlet will improve acceleration and should give better performance for closed course competition ENGINE JET PUMP ALIGNMENT Alignment is necessary to minimize power loss and eliminate possible vibration and or damage to components
22. 95 657 95 657 95 717 95 787 95 SS SSO T2 48 1 mm 54 3 543mm 53 9 mm 58 6 mm 4 21 9 223 223mm 24 5 26 5 Rm T8 mm rh Brasstown atone omm ezomm 0mm 80mm Sau band 5mm imm Bvinder head volume twnourpison sre Combustion chamber volume with 012 base gasket 277 289 289 327 364 fte mm sm F01D7CS 03 71 www SeaDooManuals net SECTION ENGINE PREPARATION PORTING MAP FOR THE 96 MODELS ENGINE TYPE MODELYER 057796 707796 8 sto T2 49 5 mm 51 8mm 51 8mm 56 7 mm T4 21 0 mm 21 0mm 20 0mm 228 mm _ tin nem rasm t Bastoun m im did oe mec ee coburn canbe voume vit pner m m em m 03 72 www SeaDooManuals net SECTION ENGINE PREPARATION I
23. 9551 13 Impeller Housing COLOR Black Black Black Black Black Black PPG no 9551 9551 9551 9551 9551 9551 14 Venturi COLOR Black Black Black Black Black Black PPG no 9551 9551 9551 9551 9551 9551 15 Nozzle COLOR Black Black Black Black Black Black PPG no 9551 9551 9551 9551 9551 9551 Q NOTE Due to natural discoloration it may be necessary to completely repaint the part Except for plastic parts 02 23 www SeaDooManuals net SECTION ENGINE PREPARATION ENGINE TUNING CAUTIONS 03 2 03 3 MEASURING COMPRESSION 03 27 OCTANE REQUIREMENTS FOR ROTAX ENGINES 03 32 FUNCTION AN EXHAUST 5 5 03 33 XP 800 EXHAUST WATER REGULATOR OPERATION 5 errr eer S 03 35 FUNCTION OF THE COOLING SYSTEM 03 37 RAVE SYSTEM OPERATION nennen 03 44 FUNCTION OF THE ROTARY VALVE INTAKE SYSTEM 03 47 CRANKSHAFT INSPECTION 03 61 CYLINDER PORTING MAPS va Saec Snc dcus 03 70 PORTING MAP FOR THE 95
24. Housing Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 16 Venturi Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 17 Steering Nozzle Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 NOTE Due to natural discoloration it be necessary to completely repaint the 02 19 www SeaDooManuals net SECTION 02 HULL PREPARATION PARTS THAT CAN BE PAINTED 1995 WATERCRAFT MODELS F02B03S 1 Body 9 Ignition Housing 2 Hull 10 Ignition Housing Cover 3 Storage Cover Hood for the HX Model 11 Flame Arrester 4 Engine 12 Ride Shoe 5 Tuned Pipe 13 Impeller Housing 6 Muffler 14 Venturi 7 Exhaust Manifold 15 Nozzle 8 Engine Support Except for parts made of plastic 02 20 www SeaDooManuals net SECTION 02 HULL PREPARATION COLOR CHART SEKDOOMOBHS DOO MODELS COMPONENTS SP 5873 SPX i SPI 5875 5874 5816 Touring 5864 Touring 1 LU COLOR White White White White White PPG no 98260 98260 98260 98260 98260 2 LN COLOR White Teal Yellow White White PPG no 98260 18923 88243 98260 98260 3 Storage Cover COLOR Not Not Not Teal Green PPG no Applicable Applicable 18923 49521 COLOR White White White White White PPG no 98209 98209 98209 98209 98209 5 Tuned Pipe COLOR Purple Purple Purple Purple Purple PPG no 59962 59962 59962 59962 59962 6 Muffler COL
25. MODELS 03 71 PORTING MAP FOR THE 96 MODELS 03 72 IGNITION SYSTEM 03 73 SPARK PLUG 22 002 40 E pa hd 03 81 MIKUNI BN CARBURETORS aree Rn BE ae Sa tede ai Sa qaaa sucus 03 83 CARBURETOR TUNING Rudi uH uta Dacus 03 95 BREAK IN PROCEDURE paci ao Edda tna Reo 03 97 SUMMARY 03 97 03 1 www SeaDooManuals net SECTION ENGINE PREPARATION ENGINE TUNING CAUTIONS A few items to keep in mind when preparing your engine There are specific set of rules for racing know what those rules are If your engine is operating at higher than stock RPM the rev limiter must be changed accordingly Never operate the engine without a rev limiter Sloppy engine building will usually result in less power output Follow the assembly and disassembly procedures outlined in the appropriate model year Shop Manual 1989 Shop Manual 295 000 060 1990 Shop Manual 219 100 002 1991 Shop Manual 219 100 004 1992 Shop Manual 219 100 006 1993 Shop Manual 219 100 008 1994 Shop Manual
26. Not Applicable Applicable 9551 Applicable 20 Reverse Gate Right Plate Not Not Black Not Applicable Applicable 9551 Applicable 02 14 www SeaDooManuals net SECTION 02 HULL PREPARATION PARTS THAT CAN BE PAINTED 1992 1993 WATERCRAFT MODELS F02B07S 1 Body 10 Ignition Housing Cover 2 Hull 11 Flame Arrester Cover Except XP Model 3 Storage Cover GTS and GTX Models Only 12 Flame Arrester Support 4 Engine 13 Flame Arrester Base 5 Tuned Pipe 14 Ride Shoe 6 Muffler 15 Impeller Housing 7 Exhaust Manifold 16 Venturi 8 Engine Support 17 Steering Nozzle 9 Ignition Housing 02 15 www SeaDooManuals net SECTION 02 HULL PREPARATION PPG COLOR CHART 1992 5 000 MODELS COMPONENTS SP GTS XP GTX 5805 5812 5851 5860 1 Body White White White White 98208 98208 98208 98208 2 Hull Medium Gray White Purple White 38247 98208 59962 98208 3 Storage Cover Not Lavender Not Magenta Applicable 59974 Applicable 59973 White White White White 98209 98209 98209 98209 5 Tuned Pipe Gray Gray Purple Purple 38269 38269 59962 59962 6 Muffler Gray Gray Purple Purple 38269 38269 59962 59962 7 Exhaust Manifold White White White White 98209 98209 98209 98209 8 Engine Support Black Black Purple Purple 9551 9551 59962 59962 9 Ignition Housing White White White White 98209 98209 98209 98209 10 Ignition Housing Cover White White White White 98209 98209 98209 98209 11 Fl
27. Top Dead Center the rotary valve shaft should be lightly held in a clockwise position to take up any gear lash that may be present The valve is asymmetrical and can be flipped over to obtain a better timing position There is a possibility that exact timing cannot be reached by this method When this occurs the rotary valve shaft may have to be removed and the gear repositioned Refer to appropriate model year Shop Manual By removing the rotary valve shaft and re installing it with the drive gear in a different position with respect to the crankshaft gear and or valve shaft splines a different valve position may be established When a crankshaft rotary valve shaft or drive gear is removed or replaced it will be necessary to re verify the timing Apply Sea Doo injection oil on rotary valve surfaces before reassembling rotary valve cover Remove TDC gauge ROTARY VALVE COVER INSTALLATION Install O ring and cover When installing O ring do not roll O ring into groove Instead place O ring in groove until it becomes necessary to stretch it to fit about half way around diameter Now pull O ring beyond cover and lay it into groove without twisting or rolling O ring then torque screws to 20 Nem 15 Ibfeft in a criss cross sequence CAUTION Crankcase halves must be separated and crankshaft must not be present to install rotary valve shaft assembly in crankcase 03 57 www SeaDooManuals net SECTION ENGINE PREPARATION 010
28. closes and pushes the fresh charge that has escaped into the header pipe into the cylinder FO1D6RS FO1D6SS The pipe then bleeds down to approximately atmospheric pressure and the cycle is repeated The design of the pipe depends upon many factors including bore stroke and desired effective operating RPM Because the sonic wave speed is fairly constant the length of the pipe is a large factor in controlling the engine RPM at which the pipe will be efficient A shorter pipe will result in higher RPM s but not necessarily more horsepower the pipe must be compatible with the other flow characteristics of the engine carburetor size intake timing etc Maximum efficiency is generally obtained by having 1 pipe for each cylinder But this maximum point may be across a narrow and or high RPM range causing difficulties in driveability The 2 into 1 tuned pipes used on Sea Doo watercraft are very accurately tuned for the overall design of these particular engines NOTE Changing the tuned pipe for an aftermarket unit will usually change RPM and torque of the engine An impeller change to compliment your new tuned pipe will probably be necessary 03 34 www SeaDooManuals net SECTION ENGINE PREPARATION WATER INJECTED EXHAUST SYSTEM Several factors necessitate the use of a water cooled water injected tuned exhaust system One major concern is overall bilge temperature which is kept low by keeping the part of the tuned pipe clo
29. combustion chamber volume because the dome of the piston protrudes into the head on an assembled engine The uncorrected compression ratio of an engine is the volume of a cylinder plus the minimum volume of the combustion chamber divided by the minimum volume of the combustion chamber CR VV V 2 WHERE compression ratio 1 V volume ofa cylinder 2 5 1 4 V minimum combustion chamber volume 2314 B bore diameter cm S stroke 03 28 www SeaDooManuals net SECTION ENGINE PREPARATION o 1 FO1D6NS B D C T D C AKRON V Effective stroke EXAMPLE 76 V 7 6 cm X 6 4 cm X p 290 3 S 264mm 4 V 27 6 290 3 cc 27 6 27 6 cc C R 2 11 5 1 UNCORRECTED In a 2 stroke engine this is referred to as the uncorrected compression ratio Because of the exhaust port midway up the cylinder some designers believe that actual compression does not begin until termed corrected compression ratio and is measured with the piston just as it closes the exhaust port MEASURING CORRECTED COMPRESSION RATIO C C R V V V WHERE C C R corrected compression ratio volume of cylinder with piston just closing the exhaust port V minimum combustion chamber volume 2 www SeaDooManuals net 03 29 SECTION ENGINE PREPARATION 01 605 Exhaus
30. enters the cooling jackets of the cylinders From the cylinders the water flows upward through calculated holes to the outlet side of the cylinder head The outlet side of the cylinder head s cooling jacket also houses the engine temperature sensor where the now hot water escapes through the engine water outlet hose Some aftermarket companies may suggest that the cooling system be re routed to feed cold water directly to the engine instead of allowing the exhaust system to warm it first This change should be approached with caution as random changes without adequate testing and development could be detrimental to the engine Changing the routing of the cooling system could result in less power output and engine reliability On the 1988 91 engines the cooling water proceeds into the engine via a water distributor into the crankcase then up to the cylinders On the 1992 96 engines the cooling water proceeds from the exhaust manifold cooling jacket into the cylinder cooling jacket via the passages below the exhaust ports On all engines the water surrounds the cylinders and moves upward through calculated holes in the cylinder head exiting the engine at the intake side of the cylinder head 03 38 www SeaDooManuals net SECTION ENGINE PREPARATION Temperature Calibrated sensor activates Uppermost point of Water regulated ace monitoring circuit tuned pipe by the water flow ead limits beeper when allows bleeding regulator v
31. expert or first year pro the type of sponsorship support you can expect will normally be very limited unless you re the best in your class When you re national number one sponsors will be at your door step however in the mean time you must actively seek support in every possible way Many large companies have solicited marketing specialists to research and deter mine the feasibility of racer sponsorship while most smaller or local businesses have not On a regional level these smaller businesses may not even realize the potential for product recognition that watercraft racing can bring them Go after these sponsors invite them to a regional race so that they can experience first hand the advertising opportunities available to them When making initial contact with a potential sponsor attempt to set up an appointment to meet with them Try to avoid discussing your proposal over the phone or by mail Face to face meetings normally accomplish much more Major sponsors will have representatives at the national events in your area Call these people several weeks priorto the event and arrange a meeting with them during race week end In many instances personal meetings are impossible When this is the case contact the spon sor by phone and inform them that you will be sending your resume and sponsorship proposal to them for review Close your conversation by setting a date to call again to discuss your proposal Your resume should begin with your pe
32. in relation with magneto side piston 295 000 007 295 000 065 00 445 03 55 www SeaDooManuals net SECTION ENGINE PREPARATION For the following instructions let s use these specifications as example OPENING 130 BTDC CLOSING 65 ATDC Proceed as follows Turning crankshaft bring MAG side piston to Top Dead Center using a TDC gauge 010215 1 TDC gauge on MAG side For opening mark first align 360 line of degree wheel with BOTTOM of MAG side inlet port Then find line 130 on degree wheel and mark crankcase at this point OPENING MARK 010305 1 1 Bottom of MAG inlet port align 360 line of degree wheel here 2 2 Find 130 on degree wheel and mark here NOTE Do not rotate the crankshaft 03 56 www SeaDooManuals net SECTION ENGINE PREPARATION For closing mark first align 360 line of degree wheel with TOP of MAG side inlet port Then find 65 line on degree wheel and mark crankcase at this point CLOSING MARK WON 2 710 t os ore oye 086 ps Si 0 osz f on gu 09 FO1D3ES 1 1 Top of MAG inlet port 2 2 Find 65 on degree wheel and mark here 3 Align 360 line of degree wheel here Remove degree wheel Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC NOTE When checking the timing with the MAG side piston at
33. mark or reference one previously scribed aligns with timing tool slot CAUTION If engine is to be run more than a few minutes connect coupler hose P N 295 500 099 to properly cool engine If timing marks align timing is correct CAUTION Always verify timing marks with TDC gauge before checking the timing Particularly if PTO flywheel has been removed or replaced it could possibly move slightly 03 77 www SeaDooManuals net SECTION ENGINE PREPARATION IGNITION TIMING ADJUSTMENT Timing adjustment on all engines except the 787 model is performed by moving armature plate clockwise to retard spark or counterclockwise to advance A25E0RS 1 To retard 2 To advance To adjust loosen 3 armature plate retaining screws slightly and carefully rotate armature plate in proper direction A small amount of rotational movement will advance or retard timing A25E0VS 1 Retaining screw 03 78 www SeaDooManuals net SECTION ENGINE PREPARATION When PTO flywheel mark is on right side of timing tool slot it indicates advanced timing F01H32S 1 Too advanced timing In this case turn armature plate clockwise A25E0RT 1 Turn clockwise to retard 03 79 www SeaDooManuals net SECTION 03 ENGINE PREPARATION When PTO flywheel mark is on left side of timing tool slot it indicates retarded timing F01H33S 1 Retarded timing In this case turn arm
34. of cover seating surface 2 64 mm 0 86 mm Rotary valve tickness 58 Clearance between rotary valve and cover 0 28 mm Your result must be within the specified tolerance 0 18 0 30 mm 0 007 0 012 in If rotary valve rotary valve cover clearance is out of specification machine rotary valve cover seating surface and O ring groove 03 54 www SeaDooManuals net SECTION ENGINE PREPARATION MACHINING INFORMATION The amount of mm in over tolerance must be removed from the rotary valve cover seating surface Also cut the o ring groove an equal amount to obtain 1 0 03 mm 039 001 in between the bottom of the groove and the seating surface Remove burrs on the edges of the seating surface and O ring groove Reverify the clearance At assembly the rotary valve timing must remain as per original setting CRANKSHAFT AND ROTARY VALVE SHAFT DRIVE GEARS BACKLASH Remove PTO flywheel guard Remove spark plugs rotary valve cover and valve Manually feel backlash at one position then turn crankshaft about 1 8 turn and recheck Continue this way to complete one revolution Backlash must be even at all positions Otherwise disassemble engine to find which part is faulty drive gears or rotary valve shaft with excessive deflection ROTARY VALVE TIMING wv CAUTION Never use the ridge molded in crankcase as a timing mark The following tools are required to measure rotary valve opening and closing angles
35. opened and the engine begins producing more power the pressure against the diaphragm will overcome the pressure of the return spring and the RAVE valve will open 03 44 www SeaDooManuals net SECTION ENGINE PREPARATION F01D7GS Valve Fully Open FO1D7HS Valve Fully Closed The RAVE valve does not allow an engine to make higher peak horsepower than an engine not so equipped it can however make moving the peak horsepower higher practical because of its effect on the rest of the power curve Item 2 in the following figure is the power curve of an engine with the RAVE valve held fully open through its entire RPM range Item 6 notes the peak power produced That peak will not change if the exhaust port time of a similar engine without a RAVE valve was the same with all other features equal 03 45 www SeaDooManuals net SECTION ENGINE PREPARATION A18C02S Item 1 is the power curve of the engine with the RAVE valve closed through its entire RPM range The shaded area item 3 is the improvement in power at lower engine speeds that is gained because of the lower exhaust port If the port remains at this height however the power would peak as noted in item 5 Raising the exhaust port at the proper RPM item 7 will allow the engine peak power to continue to rise item 6 Item P1 in the figure is the pressure of the return spring against the diaphragm The exhaust pressure must be high enough to overcome this pr
36. supported by bosses and is locked in position with circlips ENGINE OPERATION Basically the 2 stroke engine performs the same operation as a 4 stroke However instead of completing the cycle in 4 strokes or 720 degrees crankshaft rotation the 2 stroke engine com pletes the cycle in only 360 degrees 2 strokes In other words the 2 stroke engine piston travels to Top Dead Center and back to Bottom Dead Center once to complete the intake compression combustion and exhaust phases NOTE On all Sea Doo engine types the intake is controlled by a rotary valve and not by the piston skirt as shown in the following illustrations The illustrations are provided just to demonstrate the principles of operation which are very similar whether the intake is controlled by piston movement or a rotary valve 03 10 www SeaDooManuals net SECTION ENGINE PREPARATION 1 INTAKE AND SECONDARY COMPRESSION Intake port Partially open Exhaust port Closed Transfer port Closed Boost port Closed FO1D6FS 1 Exhaust 2 Compressed charge 3 Intake 4 Fresh charge When the piston starts its upward stroke a vacuum is created inside the crankcase and an air fuel mixture is sucked in from the carburetor via the intake port At the same time the piston blocks the exhaust and transfer ports and compresses the fuel charge in the combustion chamber second ary compression 03 11 www SeaDooManuals net SECTION EN
37. the boost port opens and this allows the remaining air fuel mixture mixture trapped under piston crown to flow into the combustion chamber This assists in clearing the combustion chamber and cylinder of all burnt gases The boost port also aids in cooling the piston dome lubricating and cooling wrist pin bearing The cylinder head transfer port and exhaust pipe design limit the escape of the fresh incoming charge to a minimum 03 14 www SeaDooManuals net SECTION ENGINE PREPARATION ENGINE CONFIGURATION Two pistons are connected to a single crankshaft mounted in a horizontally split crankcase with 2 cylinders and a 1 piece head F01D6JS In operation while 1 piston is at TDC the other is at BDC therefore producing a simultaneous ignition and transfer Since there is both transfer and ignition occurring rubber center seals isolate the primary compression areas of the crankcase and thereby retains the equilibrium of crankcase and cylinder areas TRANSFER PORTS To achieve greater efficiency Rotax engineers have designed the engines with 2 extra transfer ports An engine with 4 transfer ports enhances the rapid escape of the air fuel mixture from the crankcase into the combustion chamber F01D6KS 1 Transfer ports 2 Intake port 03 15 www SeaDooManuals net SECTION ENGINE PREPARATION The configuration of the transfer ports is termed as being tangential type flow In other
38. the piston Unlike the transfer port the boost port does not connect to the crankcase via a passage in the cylinder wall On the 587 engine type the boost port communicates with the crankcase via a hole in the piston skirt On all 1994 and later Sea Doo engine types 587 657 717 787 the boost port is connected with the crankcase and functions much as a transfer port 03 16 www SeaDooManuals net SECTION ENGINE PREPARATION AIR TIGHTNESS Areas to verify for leakage are illustrated below F01D75S a b c d e SPARK PLUGS The results of thread stripping crossing or installing a spark plug without a gasket could result in loss of compression or serious spark plug and cylinder head damage EXHAUST SYSTEM If the gaskets O rings or hoses are damaged omitted or incorrectly installed engine damage or a drastic reduction in engine output will occur CYLINDER HEAD SEALING If there is damage to either the cylinder head mating surface or the cylinder top mating surface engine compression will be forced into the cooling jackets and damage the cylinder head o ring if the cylinder head o ring is omitted or damaged water may enter the combus tion chamber from the cooling jackets causing engine damage PISTONS AND RINGS If the pistons rings or cylinders are worn damaged or incorrectly installed engine damage or poor performance will occur INTAKE SYSTEM If there i
39. these shock waves can be detrimental to the mechanical integrity of the engine it is the generation of excessive heat that causes most problems in 2 strokes For many various reasons the piston may expand excessively causing a seizure or the piston dome may in fact melt The melting will occur at the hottest points which will be right below the spark plug and around the edge of the piston often at a ring locating pin If allowed to continue a hole may melt completely through the top of the piston PRE IGNITION Pre ignition is the ignition of the mixture inside the combustion chamber before the timed spark Pre ignition sources are generally an overheated spark plug tip or a glowing carbon deposit on the piston head Since ignition occurs earlier than the timed spark the hot gases stay longer in the combustion chamber thus increasing cylinder head and piston temperatures to a dangerous level 03 22 www SeaDooManuals net SECTION ENGINE PREPARATION Portion of the mixture is ignited by a hot spot before timed spark occurs 01 5 5 NOTE Detonation and pre ignition are conditions you need to be listening for as serious engine damage or complete failure may occur if this condition is allowed to continue These 2 conditions can be heard if you are listening carefully The engine will produce a sound similar to glass bottles rattling together or a noise which sounds like transmission gears growling These sound
40. www SeaDooManuals net SECTION ENGINE PREPARATION Sealing Ring 2 Sleeve Spring Throttle Lever Throttle Lever Stopper Lock Washer Nut Ring Washer 10 Lock Washer 11 Screw 12 Choke Valve 13 O Ring 14 Gasket 15 O Ring 16 Pump Body 17 Diaphragm 18 Gasket 19 Cover 20 Screw 4 21 Throttle Valve 22 Screw and Spring Washer 5 23 Sealing Ring 2 24 Sleeve 25 Spring 26 Main Jet Screw 27 Ring 28 Filter 29 Screw and Spring Washer 30 Main Jet Oo 03 90 31 Pilot Jet 32 O Ring 33 Washer 2 34 Spring 35 Low Speed Mixture Screw 36 Screw 2 37 Check Valve Housing 38 Pin 39 Plate 40 Needle Valve 41 O Ring 42 Needle Valve Lever 43 Clip 44 Spring 45 Gasket 46 Diaphragm 47 Cover 48 Screw 4 49 Screw 2 50 Spring 2 51 Washer 2 52 Screw 53 Washer 4 54 O Ring 55 Cap 56 Loctite 242 57 Carburetor Linkage 58 Synthetic Grease 59 Bracket twin carburetor only www SeaDooManuals net SECTION ENGINE PREPARATION TUNING Tuning the Super BN carburetor s can be a fairly simple matter if you look at it with a logical perspective As modern and technologically advanced as the Super BN is it is still a fuel regulator due to the fact that fuel entry into the carb and fuel delivery is regulated by a spring and diaphragm system Using the cut away drawing as reference you can see that
41. 02 23 02 1 www SeaDooManuals net SECTION 02 HULL PREPARATION PREPARING THE HULL FOR INSPECTION The production hulls produced by Sea Doo are manufactured to fine tolerances All riders can benefit from truing the hulls Hull truing becomes most beneficial on watercraft equipped with highly tuned modified engines Exacting tolerances are necessary to attain proper high speed stability The section of the hull where truing is most important is from the rear of the hull to a point approximately 1 5 meters 60 inches forward This is due to the fact that at high speeds only the rear section of the hull is in contact with the water You can not alter the hull configuration more than 2 mm 0 0797 in any direction if you are racing in Limited Class otherwise your modification will be illegal NOTE The hull bond flange can not be altered in length or width even in the modified classes Doing so is considered an illegal modification by all sanctioning bodies The following steps must be observed before turning the watercraft upside down remove seat remove battery remove engine and jet pump siphon fuel and oil from tanks NOTE Refer to appropriate model year Shop Manual for proper removal and installation procedures MEASURING THE HULL A straight edge should be used to measure the condition of the hull bottom surface Place straight edge on its most rigid side along the bottom of the hull Identify the low and high
42. 1 2 in from hull flat surface C 115 mm 4 17 32 in from center of radius Be sure to verify stud location on your particular sponsons and compare to dimensions on diagram Some minor adjustments may be necessary Mark center of holes in gelcoat with an awl or center punch When drilling holes in fiberglass start slowly with a light pressure on drill motor as it is easy to drift off your locating point 02 9 www SeaDooManuals net SECTION 02 HULL PREPARATION URETHANE FOAM CUTTING Cutting of the urethane foam can be accomplished by using a 35 mm 1 1 2 in hole saw O NOTE The center drill bit must be removed from the hole saw Insert a pilot wire through the urethane foam Then insert a 6 mm 1 4 in steel rod through the urethane foam by hand From inside bilge attach the hole saw to the steel rod Refer to the following illustration FO1L61S 1 Urethane foam Start cutting the urethane foam by carefully pulling hole saw into the foam and operating the drill in reverse position NOTE Depending on hole saw depth approximately 3 passes will be required to cut the urethane foam Keep the first foam core It will be reinstall once the job is completed CAUTION When cutting the last portion of urethane foam carefully listen to the sound of the hole saw making contact with the side of the hull Stop sawing immediately and remove the remaining foam by hand 02 10 www SeaDooManuals net SECTION 02 HULL PREP
43. 1 9551 9 Ignition Housing White White White White White White 98209 98209 98209 98209 98209 98209 10 Ignition Housing Cover White White White White White White 98209 98209 98209 98209 98209 98209 11 Flame Arrestor Cover Gray Gray Not Gray Purple Gray 38269 38269 Applicable 38269 59962 38269 12 Flame Arrestor Support Gray Gray White Gray Purple Gray 38269 38269 98209 38269 59962 38269 13 Flame Arrestor Base Gray Gray Purple Gray Purple Gray 38269 38269 59962 38269 59962 38269 14 Ride Shoe Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 15 Impeller Housing Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 16 Venturi Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 17 Steering Nozzle Black Black Black Black Black Black 9551 9551 9551 9551 9551 9551 18 Console Not Not Not Not Not White Applicable Applicable Applicable Applicable Applicable 98223 NOTE Due to natural discoloration it may be necessary to completely repaint the 02 17 www SeaDooManuals net SECTION 02 HULL PREPARATION PARTS THAT CAN BE PAINTED 1994 WATERCRAFT MODELS 02 095 1 9 Ignition Housing 2 Hull 10 Ignition Housing Cover 3 Storage Cover GTS and GTX Models Only 11 Flame Arrester Base 4 Engine 12 Ride Shoe 5 Tuned Pipe 13 Impeller Housing 6 Muffler 14 Venturi 7 Exhaust Manifold 15 Steering Nozzle 8 Engine Support
44. 13 Check the hull and deck for signs of cracking or damage If the bottom of the hull has been damaged or scraped repair should be made to restore the configuration to it s original shape 14 The impeller housing should be removed to allow for a close inspection of the jet pump and related parts Impeller clearance stator vane and general pump condition should also be checked Remove the drive shaft and inspect the splines Check for correct engine to pump alignment Grease all necessary components during reassembly Lubricate the steering stem steering support and cables Upon completion check for proper steering cable and trim cable adjustments NOTE Poor engine to jet pump alignment will cause excessive vibration and loss of horsepower 15 Check the pump intake grate for damage and tightness 16 Verify that all gauges are functioning correctly 17 Test ride the watercraft and perform any adjustments before leaving for the race site 18 Flush the cooling system to insure cleanliness and maximum cooling system efficiency The following items should be checked between races 1 Remove the spark plugs and check their condition change if necessary 2 Check the exhaust system for leaks and tightness 3 Check throttle operation make sure full throttle is being attained 4 Visually inspect all inner hull components for secure mounting and proper operation 01 7 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATIO
45. 605 TYPICAL 03 58 www SeaDooManuals net SECTION ENGINE PREPARATION TEMPLATE 147 cut out angle 290 924 508 actual size A00A0YS 03 59 www SeaDooManuals net SECTION ENGINE PREPARATION TEMPLATE 158 cut out angle 290 924 502 actual size F01D73S 03 60 www SeaDooManuals net SECTION ENGINE PREPARATION CRANKSHAFT INSPECTION Lithium rease 9 Anti seize lubricant Anti seize lubricant Anti seize lubricant Anti seize 6 lubricant Lithium 24Nem 9 SSX grease 17 2 X A Loctite Loctite i 515 515 g 40 Nem 06 30 Ibfeft Synthetic 17 Ibfeft grease Synthetic 4 grease 7 88 Ibf in FO1D4HS 03 61 www SeaDooManuals net SECTION ENGINE PREPARATION COMPONENTS Oil Seal Crankcase Assembly Ball Bearing Retaining Shim Retaining Ring Retaining pin Hexagonal Head Screw M8 x 70 Hexagonal Head Screw M10 x 75 Allen Screw x 45 10 Stud M10 x 25 18 11 Fitting 12 Distance Ring 13 0 Ring 14 Crankshaft 15 Shim CRANKSHAFT MISALIGNMENT AND DEFLECTION Since it is an assembled crankshaft it can become misaligned or deflected Crankshaft can be twisted on center main journal changing timing of 1 cylinder in relation with the other also changing the ignition timing for the PTO cylinder and the rotary valve timing for the MAG cylinder
46. ARATION SPONSON INSTALLATION Place a generous bead of silicone sealant along mating surface of sponson and around studs This will help keep water from entering through attachment holes Insert sponson locating studs into corresponding holes inside of hull Install flat washers onto sponson studs using a flexible 4 claw pick up tool Snap on YA837 Apply Loctite 242 to nuts prior to installation 01 095 Install lock nuts by using the 4 claw pick up tool 10 mm deep socket Torque nuts to 10 URETHANE FOAM REINSTALLATION When sponsons installation is completed you can reinstall the first removed urethane foam core into each hole Glue with RTV 128 sealant P N 293 800 027 02 11 www SeaDooManuals net SECTION 02 HULL PREPARATION PARTS THAT CAN BE PAINTED 1988 1991 WATERCRAFT MODELS 028025 1 6 Muffler 11 Ignition Housing Cover 16 Impeller Housing 2 Hull 7 Exhaust Manifold 12 Flame Arrester Cover 17 Venturi 3 Storage Cover 8 Engine Support 13 Flame Arrester Support 18 Steering Nozzle 4 Engine 9 Ignition Housing 14 Flame Arrester Base 19 Reverse Gate Left Plate 5 Tuned Pipe 10 Ignition Housing Support 15 Ride Shoe 20 Reverse Gate Right Plate 02 12 www SeaDooManuals net SECTION 02 HULL PREPARATION PPG COLOR CHART 1988 1991 SEA DOO MODELS COMPONENTS SP SP GT 5801 5802 5803 5804 5810 5811 5850 1 Body White White White W
47. Check alignment of your engine jet pump using special alignment tool P N 295 000 089 The alignment tool is available through your dealer FO1L2RS 1 Shaft P N 295 000 093 2 P N 295 000 089 3 Housing P N 295 000 090 CAUTION Some models require a shim between hull and pump if shim has been removed at time of pump disassembly be sure to reinstall it If this shim is required for your watercraft and not reinstalled engine and jet pump alignment will be altered 04 14 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM To verify alignment proceed as follows Install housing on hull with 4 nuts Carefully slide shaft through housing and seal carrier Pay attention not to hit PTO flywheel 011255 Insert shaft end into PTO flywheel NOTE The shaft should slide easily in flywheel splines if the alignment is correct Watch for any deflection of shaft as you slowly slide shaft into PTO flywheel splines Try to eliminate deflection by shimming engine FO1L2TS 1 Shaft end 2 PTO flywheel If the alignment is incorrect loosen engine support screws to enable alignment of PTO flywheel with shaft end NOTE Use shim s P N 270 000 024 or P N 270 000 025 between engine support and rubber mounts to correct alignment 04 15 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM F01D32S 1 Shim CAUTION Whenever shims are used to correct alignment never install more t
48. Flywheel timing mark position verification is required to 1 Troubleshoot a missing or broken magneto flywheel woodruff key 2 Troubleshoot a magneto flywheel corresponding to a different engine type 3 Scribe the timing mark on a new service PTO flywheel Always verify PTO flywheel timing mark position before checking ignition timing 03 74 www SeaDooManuals net SECTION ENGINE PREPARATION PROCEDURE Disconnect MAG side spark plug wire and connect wire to grounding device if applicable then remove spark plug Remove PTO flywheel guard Install timing mark tool P N 295 000 102 on engine right side using wing nut previously removed F01H2GS 1 Timing mark tool Install and adjust a TDC gauge P N 295 000 065 in spark plug hole as follows F01H2HS 1 TDC gauge on MAG side Rotate PTO flywheel counterclockwise when facing it until piston is just before Top Dead Center 03 75 www SeaDooManuals net SECTION ENGINE PREPARATION Loosen adaptor lock nut then holding gauge with dial facing toward PTO screw adaptor in spark plug hole Slide gauge far enough into adaptor to obtain a reading then finger tighten adaptor lock nut Rotate PTO flywheel counterclockwise until piston is at Top Dead Center Unlock outer ring of dial and turn it until zero on dial aligns with pointer Lock outer ring in position From this point rotate PTO flywheel 1 4 turn clockwise then rotate it co
49. GINE PREPARATION 2 IGNITION AND COMBUSTION Intake port Open Exhaust port Closed Transfer port Closed Boost port Closed F01D6GA Exhaust Combustion Intake Fresh charge RON gt As the piston nears the top of the cylinder TDC the compressed air fuel mixture inside the combustion chamber is ignited by the spark plug The burning gases expand and push the piston downward thus causing a power stroke 03 12 www SeaDooManuals net SECTION ENGINE PREPARATION 3 EXHAUST AND PRIMARY COMPRESSION Intake port Closed Exhaust port Partially open Transfer port Closed Boost port Closed F01D6HS 1 Exhaust 2 Burnt gases 3 Intake 4 Fresh charge As the piston descends the intake port is blocked and pressure begins to build inside the crankcase primary compression As the piston continues its course downward the exhaust port is uncovered and burnt gases are allowed to escape 03 13 www SeaDooManuals net SECTION ENGINE PREPARATION 4 TRANSFER Intake port Closed Transfer port Open Exhaust port Open Boost port Open FO1D6IS Exhaust Burnt gases Fresh charge Transfer port Intake Fresh charge Ooh Near the bottom of the downward stroke the transfer port is uncovered and the compressed air fuel mixture inside the crankcase rushes into the cylinder and combustion chamber Just after the opening of the transfer port
50. GNITION SYSTEM Two stroke engines in watercraft rely on an electric spark to initiate combustion of the air fuel charge which has been inducted into the combustion chamber For the engine to operate effi ciently the spark must be delivered at precisely the right moment in relation to the position of the piston in the cylinder and the rotation at speed of the crankshaft Additionally the spark must be of sufficient intensity to ignite the air fuel mixture even at high compression pressure and high RPM It is the function of the ignition system to generate this voltage and provide it to the spark plug at the correct time The Nippondenso capacitor discharge ignition CDI system has 4 magnets located on the crank shaft flywheel AC voltage is induced in the generating coil s as the poles of the magnets rotate past the poles of the coils Timing is controlled by the position of the coil poles relative to the magnet poles which are directly related to piston position The CD box or amplifier contains the electronic circuitry to store and control the initial voltage and deliver it to the ignition coil and then the spark plug at the correct moment The ignition coil is a transformer that steps up the relatively low voltage 150 300 V of the generating coil to the 20 000 40 000 volts necessary to jump the spark plug gap and initiate the burning of the air fuel mixture in the combustion chamber Maximum power from a given engine configuration
51. IL P N 293 600 005 1L or 293 600 004 4L which is available from authorized dealers It is a blend of specially selected base oils and additives which provides outstanding lubrication engine cleanliness and minimum spark plug fouling Sea Doo Formula XP S can also be used If SEA DOO INJECTION OIL is not available substitute with BOMBARDIER SNOWMOBILE INJEC TION OIL P N 496 013 300 1L BOMBARDIER BLIZZARD OIL P N 496 014 500 500 NOTE High quality low ash API TC injection oil for 2 cycle engines can be used if SEA DOO INJECTION OIL is not available CAUTION Never use petroleum or synthetic 4 cycle motor oil and never mix with outboard Do not use NUMA TC W TC W2 or TC W3 outboard oils or other ashless type 2 cycle oils Avoid mixing different brands of API TC oil as resulting chemical reaction may cause severe engine damage SUMMARY RACING ENGINE PREPARATION SUMMARY NOTE Most machining and or grinding is illegal in limited class racing Keep your machine legal check the rules 03 97 www SeaDooManuals net SECTION ENGINE PREPARATION 1 Remove and disassemble the engine according to appropriate model year Shop Manual procedures 2 With the crankshaft resting in the lower half of the crankcase set up a dial indicator and check the runout of the crankshaft at both ends You should see no more than 05 mm 002 in runout If you have the capability adjust the crankshaft as close to perfect
52. ION ENGINE PREPARATION NOTE Be sure to install labyrinth sleeve with its hollow side facing PTO side outer bearing FO1D4VS 1 side outer bearing 2 Hollow side Slide on outer bearing until it touches sleeve Install bearings so that their peripherical grooves will be located as shown in the following illustration Fo1D1ZS 1 Peripherical grooves on inner side if applicable 2 Peripherical grooves on inner side Not all engines are equipped with the labyrinth sleeve between the PTO crankshaft bearings For racing purposes it would be advantageous for models with dual carburetors to have the labyrinth sleeve installed to help displace crankcase volume thus increasing primary compression 03 69 www SeaDooManuals net SECTION ENGINE PREPARATION CYLINDER PORTING MAPS O NOTE See page 03 62 for the chart were these measurements are to be taken SEA DOO ENGINE SPECIFICATIONS __1 ___ 587 657 Exhaust port width Rear transfer length bottom to top Exhaust outlet width at Y pipe 490mm Bom Exhaust outlet height at Y pipe 320m 330mm Squish band clearance 15mm im Cylinder head volume without piston 42 Combustion chamber volume with 012 base gasket 29562 Uncorrected compression ratio pp 03 70 www SeaDooManuals net SECTION ENGINE PREPARATION PORTING MAP FOR THE 95 MODELS ENGINE TYPE MODELYEAR 587
53. N 5 Adjust fuel and oil levels as needed 6 Visually inspect the hull for external damage or punctures repair as necessary NOTE Irreparable hull damage which occurs during race is the only reason a racer is allowed to run a different boat in a race than that which they have already qualified for The Technical inspector must make the determination 7 Check the intake grate for damage and secure mounting 8 Inspect the pump for rocks or debris that may have been lodged inside 9 Check the operation of the steering components and adjust or tighten as necessary EQUIPMENT AND SPARE PARTS TO BRING TO THE RACE Racers must be prepared for any situations that may arise on race day However most racers do not have the resources required to attain or to transport all the equipment necessary to cover all possible situations You will have to determine what your capabilities are for the level of racing you are at Pro Expert Novice and just how important winning a race is to you Serious racers normally have two boats of equal capabilities If a problem is encountered on one boat before it is qualified for an event the backup boat is used If the boat has already been qualified for a race the parts are taken from the backup boat then used to repair the qualified boat These racers normally bring extra parts as well All racers should be equipped with the Service Manual for their watercraft They should have at minimum the necessary
54. OR Purple Purple Purple Purple Purple PPG no 59962 59962 59962 59962 59962 7 Exhaust Manifold COLOR White White White White White PPG no 98209 98209 98209 98209 98209 8 Engine Support COLOR Black Black Black Black Black PPG no 9551 9551 9551 9551 9551 9 Ignition Housing COLOR White White White White White PPG no 98209 98209 98209 98209 98209 10 Ignition Housing Cover COLOR White White White White White PPG no 98209 98209 98209 98209 98209 11 Flame Arrester Base COLOR Black Black Black Black Black PPG no 9551 9551 9551 9551 9551 12 Ride Shoe COLOR Black Black Black Black Black PPG no 9551 9551 9551 9551 9551 13 Impeller Housing COLOR Black Black Not Black Black PPG no 9551 9551 applicable 9551 9551 14 Venturi COLOR Black Black Not Black Black PPG no 9551 9551 applicable 9551 9551 15 Steering Nozzle COLOR Black Black Not Black Black PPG no 9551 9551 applicable 9551 9551 O NOTE Due to natural discoloration it may be necessary to completely repaint the part Except for plastic parts 02 21 www SeaDooManuals net SECTION 02 HULL PREPARATION PARTS THAT CAN BE PAINTED 1996 WATERCRAFT MODELS F02B03S 1 Body 9 Magneto Housing 2 Hull 10 Magneto Housing Cover 3 Storage Cover if applicable 11 Flame Arrester Base 4 Engine 12 Ride Shoe 5 Tuned Pipe 13 Impeller Housing 6 Muffler 14 Venturi 7 Exhaust Manifold 15 Steering Nozzle 8 Engine Support Exc
55. RAFT LEGAL AND WITHIN THE RULES IS YOUR RESPONSIBILITY VI www SeaDooManuals net RACE SANCTIONING ASSOCIATIONS This handbook was witten to help in the preparation of a Sea Doo watercraft for competitive events Carefully study the association rule book and class of racing you intend to compete in before making any modifications to your watercraft Your watercraft must conform to association specifications The IJSBA is the sanctioning association for the United States You can contact them at the address listed below The IJSBA will also be able to provide you with the contact information for the affiliate association in your country as well as promoters in your region A membership in the association sanctioning the event is mandatory before competing in race 5 INTERNATIONAL JET SPORTS BOATING ASSOCIATION 1239 EAST WARNER AVENUE SANTA ANA CA 92705 PHONE 714 751 4277 FAX 714 751 8418 VII www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION PREPARING FOR RACE DAY ACTIVITIES 01 2 PREPARING FOR A SAFETY INSPECTION 01 5 PRE RACE MAINTENANCE 16 22 2222 2 2 01 7 EQUIPMENT AND SPARE PARTS TO BRING TO THE 01 8 PIT AREA PRESENTATION sse tnnt 01 9 INTERACTION WITH RACE OFFICIALS see
56. TS THAT CAN BE PAINTED 1996 WATERCRAFT MODELS 02 22 PPG COLOR CHART entente tenete tnter tette tette tette te tette ta sea soos 02 23 www SeaDooManuals net SECTION 03 ENGINE PREPARATION ata anda ee nada utto 03 2 BASIC ENGINE THEORY ertt Ero tata 03 3 MEASURING COMPRESSION RATIO eene 03 27 OCTANE REQUIREMENTS FOR ROTAX ENGINES 03 32 FUNCTION OF AN EXHAUST SYSTEM 2 03 33 800 EXHAUST WATER REGULATOR OPERATION AND REMOVAL 03 35 FUNCTION OF THE COOLING SYSTEM 03 37 RAVE SYSTEM OPERATION 03 44 FUNCTION OF THE ROTARY VALVE INTAKE SYSTEM 03 47 CRANKSHAFT INSPECTION eene nennen 03 61 CYLINDER PORTING 5 2 0 03 70 PORTING FOR THE 1995 MODELS 03 71 PORTING MAP FOR THE 1996 MODELS 03 72 IGNITION Eli 03 73 SPARK PLUG INFORMATION 202222 2202
57. XHAUST WATER REGULATOR OPERATION AND REMOVAL The XP 800 models utilize a water regulator located on top of the muffler to control the amount of water injected into the exhaust system at the tuned pipe head and the muffler box The purpose of this is two fold 1 It effectively controls the exhaust wave speed thereby creating a more usefull or broader power curve 2 It cools the exhaust system and hoses which prevents heat damage The water regulator is calibrated for use on XP 800 s which have no engine modifications The regulators works quite well on the stock watercraft and provides a noticeable increase in perfor mance over models not so equipped If the watercraft is not being raced but modifications are made to the engine such as increased compression changes in port timing etc the water regulator will not deliver the correct amount of water for optimum performance Recalibrating the regulator water flow will require most users to experiment with different size holes being drilled into the regulator then threading and fitting the holes with jets Various size jets will then be tried until the best performance is found The water regulator has been disallowed for competition usage by the IJSBA Furthermore any valves used within the entire engine cooling system must be of the fixed type This rule was placed into affect during the mid 1995 racing season Due to this ruling the water regulator must be removed and the exhaust system must
58. ally come to the finish line slowed down and turned directly into the technical inspection area without crossing the finish line Others have been passed because they slowed down Race past the finish line continue around the course as not to interfere with slower riders still finishing the race Never turn and go against the flow of traffic after you have finished the race even if you are going to tech Continue around the course to get back 11 TECHNICAL INSPECTION After your qualifying race or moto you will be required to go to Technical Inspection if you have placed in a transfer position On your first trip to tech the Technical Inspector will record your hull number The hull number is located below the bond flange on the right rear of the hull The purpose of recording your hull number is to insure that you will be running the same boat in the final that you have qualified for or in your second moto On a Sea Doo the number is imprinted in the fiberglass or on a black tag with a series of dots forming letters and numbers This number can be extremely hard to read especially in the water To make reading easier paint over the numbers with white paint After the paint dries lightly use a little steel wool or very fine sandpaper to take the paint off of the hull This procedure will leave the paint in the dots which now can be easily read At some races the inspector will place a special sticker with a serial number on the rear of the hull fo
59. alve water flow temperature exceeds 96 99 and injected 205 210 F directly into exhaust gas for noise reduction and performance improvement Cooling System Indicator CSI small stream of water flows out of bleed outlet located near stern eyelet Calibrated outlet fittings Engine water limit water outlet hose flow PERN Water flows through tuned pipe and manifold water jackets Pressure zone Water flow regulator valve Lowest point of Water directly circuit allows injected into muffler draining whenever Water inlet to cool exhaust engine is stopped hose of components valve F01E1US 03 39 www SeaDooManuals net SECTION ENGINE PREPARATION 2 1 915 1 pa1e2o 51 1no SMO JO 4 5 JSD 1 5403104 eJnsseJg asoy peddojs si JUIOd 1990 asiou 10 526 15 yobids Gun 14918 sjoxyoef pue edid 1 45914
60. ame Arrester Cover Gray Gray Purple Purple 38269 38269 59962 59962 12 Flame Arrester Support Gray Gray Purple Purple 38269 38269 59962 59962 13 Flame Arrester Base Gray Gray Purple Purple 38269 38269 59962 59962 14 Ride Shoe Black Black Purple Purple 9551 9551 59962 59962 15 Impeller Housing Black Black Purple Purple 9551 9551 59962 59962 16 Venturi Black Black Purple Purple 9551 9551 59962 59962 17 Steering Nozzle Black Black Purple Purple 9551 9551 59962 59962 O NOTE Due to natural discoloration it may be necessary to completely repaint the part 02 16 www SeaDooManuals net SECTION 02 HULL PREPARATION PPG COLOR CHART 1993 SEA DOO MODELS COMPONENTS SP 5806 SPX XP GTS GTX EXPLORER SPI 5808 5807 5852 5813 5861 5820 1 Body White White White White White White 98223 98223 98223 98223 98223 98223 2 Hull Light Medium Lignt White White White Gray Blue Green 98223 98223 98223 38287 19518 49580 3 Storage Cover Not Not Not Lavender Magenta White Applicable Applicable Applicable 59974 59973 98223 White White White White White White 98209 98209 98209 98209 98209 98209 5 Tuned Pipe Gray Gray Purple Gray Purple Gray 38269 38269 59962 38269 59962 38269 6 Muffler Gray Gray Purple Gray Purple Gray 38269 38269 59962 38269 59962 38269 7 Exhaust Manifold White White White White White White 98209 98209 98209 98209 98209 98209 8 Engine Support Black Black Black Black Black Black 9551 9551 9551 9551 955
61. an be solved without bringing the Race Director into the conversation An example of this would be a scoring error When a discrepancy arises in scoring that places you further back in the race than you thought was correct see the Chief Scorer The Chief Scorer will recheck the lap charts to determine if an error was made If no error is found the Scorer can explain to you how they arrived at the decision If your complaint concerns the legality of a given watercraft s modification go to the Technical Inspector The Inspector knows the modification rules better than any other official it s their job If you believe that a boat is illegal tell the inspector If the item can be visually inspected without any tear down the Inspector will normally keep an eye open for the infraction If the infraction requires engine or pump tear down it would then be your responsibility to lodge a formal protest The protest must be in writing to the Race Director The protest must be specific not general in scope For example you may protest the fuel induction system ignition system or crankshaft but you could not protest the entire engine as a whole unit Each item protested must be accompanied with a protest and an additional fee to cover tear down The fee is determined by the Technical Director and Race Director You are allowed only a short time period to file the protest after the race concludes Check your rule book for specific details Remember offic
62. aping through the exhaust port This also assists in clearing the combustion chamber of all burnt gases ROTARY VALVE DRIVE GEARS Located in crankcase halves between the 2 cylinder bases These gears transmit crankshaft rotation to the 90 angled rotary valve shaft The helical gear mounted on the rotary valve shaft uses the crankshaft as a power source To prevent overheating and provide lubrication the gears operate in an oil bath To prevent pressurization of the system a vent tube from the top of the gear chamber returns to the oil reservoir which is vented to the atmosphere FO1D6XS 1 Pinion on rotary valve shaft 3 Gear crankshaft 2 Rotary valve 4 Gear on rotary valve shaft ADVANTAGES OF THE ROTARY VALVE ENGINE The major differences between a piston port engine and a rotary valve engine are 1 Intake port directly positioned in the crankcase 2 The opening and closing of the intake port is controlled by a rotary valve instead of the piston allowing asymmetrical timing The use of a rotary valve enables a very short inlet track The design introduces the mixture in a very suitable position without obstruction to the gas flow that would impair the volumetric efficiency This intake position also enhances the lubrication of the lower connecting rod bearings With rotary valves the opening duration of the intake port is specifically controlled by the valve Therefore it is possible to determine the maximu
63. art hold your line until the first turn buoy If you cut across in front of other riders you will be placed 1 lap down or black flagged This does not mean you can not change lines If you have a definite lead on another boat and you will not endanger them you can move in Getting around the first turn buoy in good position is very important If you are back of the pack you will have a lot of trouble getting around the other boats before you finish In many cases a rider has been 2nd or 3rd to the first turn buoy and lost position because of water spray blinding their vision Use race goggles at least for the first few buoys You can duct tape the strap to the back of your helmet so you don t lose them when you pull them off Race smart Stay close to your competitor and capitalize on their mistakes Know the course Many times the leader has taken the wrong path with other riders following just to have a slower rider negotiate the course correctly and win Be sure you race to the checkered flag Many races have been lost because the rider thought the white flag was waved then stopped on the next lap Flag men make mistakes Race to the checkered flag not 1 lap past the white Always race past the start finish line and between the two finish line buoys Many Expert and Pro racers on the IJSBA National Tour have gone outside the finish line buoy during the race or at the finish only to be penalized one lap Racers with big leads have actu
64. as fuel is drawn out of the fuel chamber atmospheric pressure pushes inward on the regulator diaphragm moving it against the spring pressure on the needle valve arm When the combined forces the suction within the carb the fuel pressure at the needle valve and the atmospheric pressure are great enough to overcome the arm spring pressure the needle valve will open allowing fuel under pressure from the pump to enter the fuel chamber This combined force is commonly referred to as pressure The force required to pop the needle valve off the seat NOTE As soon as the fuel chamber has been filled fuel flow into the chamber ceases and the carb returns excess fuel via a restriction to the fuel tank There are a number of factors that can modify or change the effectiveness of an engine to overcome this pop off pressure The engine s ability to create a strong suction signal within the carb and the outside air pressure are 2 variable factors Engines can be modified in many ways that can increase or in most instances decrease the suction generated Listed here are examples of changes and the effect on engine suction Modified porting from mild to wild can have the effect in most cases of reducing suction at lower throttle openings and with it hindering carburetion and clean running in the engine s lower RPM range Hopefully the porting is good and will increase air flow at higher RPM S for better carbur
65. as possible HIN irn m F01D1TS 1 Measuring MAG side deflection in crankcase 3 Set your cylinder base gaskets and cylinders on the upper half of the crankcase and lightly torque the cylinders to the half Be sure to install exhaust manifold on the cylinders before tightening them to the upper crankcase half to ensure the same position of the cylinders on final assembly Check the match of the gaskets and cylinders to the base match them perfectly with a die grinder in the areas of transfer port passages Also check for any overlap of the exhaust manifold gaskets where the exhaust manifold joins the cylinders Before reassembling make sure that parts are free of any dust or particles 4 Check ports alignment between the cylinder casting and the sleeve If the sleeve is off in 1 direction on all ports heat the cylinder in the oven at 176 C 350 F for 45 minutes Drop a rag that has been soaked in ice water into the sleeve and quickly align the sleeve with the cylinder casting Apply constant pressure with some type of heavy object not affected by extreme heat to the top of the sleeve while letting the sleeve and cylinder cool down at room temperature 5 Check piston to cylinder clearances ring end gap cylinder taper and out of round Check compression ratios and squish areas of both cylinders Make sure that they are equal to each other in both respects and that the proper fuel is used for the compression rati
66. ate The intake grill must be properly installed and blend in with the hull and ride shoe to eliminate possible inlet flow restrictions The water inlet and ride shoe must have surfaces sealed and blended Certain aftermarket intake grates will enhance the performance of your watercraft Selecting the correct intake grate will depend on your intended use and type of racing A carefull choice is highly suggested 04 5 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM IMPELLER The impeller is enclosed in the housing and it creates a dynamic force The thrust created by the impeller alone is minor but it has a high power absorption The stator vane and venturi are essential to create thrust and to straighten out twisted water coming of spinning impeller IMPELLER TYPES Two types of impellers can be installed in the jet pump the regular fixed pitch and the progressive pitch impellers The meaning of the term pitch is the angle between the edge of the blade and the surface on which the impeller is sitting on or the angle at which impeller moves the water 1 Angle 2 Flat surface REGULAR FIXED PITCH The impeller pitch remains constant on all the blades The blades are straight with the same angle from leading to trailing edges 04 6 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM F01JANT 1 Leading edge 2 Trailing edge F01J4SS 1 Leading edge 2 Straight blade 3 Tra
67. ating temperature will be and inversely the shorter the heat path the lower the operating temperature will be 00 095 1 Cold 2 Hot cold type plug has a relatively short insulator nose and transfers heat very rapidly into the cylinder head Such a plug is used in heavy duty or continuous high speed operation to avoid overheating The hot type plug has a longer insulator nose and transfers heat more slowly away from its firing end It runs hotter and burns off combustion deposits which might tend to foul the plug during prolonged idle or low speed operation Generally speaking if you have increased horsepower by 10 15 you will have to change to the next colder heat range spark plug Sea Doo watercraft are equipped stock with NGK BR7ES spark plugs in all 587 type engines and 5 in all 657 717 787 type engines The spark plug gap should be 0 5 0 6 mm 020 024 in for all models These are resistor type plugs which help reduce radio frequency interference 03 81 www SeaDooManuals net SECTION 03 ENGINE PREPARATION DESIGN SYMBOLS USED ON NGK SPARK PLUGS WIDE GAP 1 0 mm 040 1 1 mm 044 1 3 mm 050 1 4 mm 055 1 5 mm 060 2 0 mm 080 Thread diameter 18 mm 14mm 10mm 12mm 8mm 12mm x 19 mm Reach Compact Type Blank 53 54 Projected Insulator 18 mm 12 mm
68. ations to your engine hull jet pump or paint jobs for your boat and trailer 3 Cash for entry fees and other types of expenses 01 11 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION The services you can provide for this support is only limited to your imagination Innovative new ideas are what businesses are looking for The better job you do for the sponsor the more support you can count on in the future Types of services can include 1 Placing the product name on various racing equipment such as your boat truck trailer helmet wet suit or tent Different decal size or location can be dependent upon the amount of support received by the sponsor 2 News releases can be sent out to the magazines and newspapers detailing your wins and sponsor support 3 You can provide your sponsor with your trophy to be displayed in their place of business or office 4 You can make personal appearances at their business or fund raisers to sign autographs or to talk about the effectiveness of their products Your proposal must include a list of the races you will compete in for that season The listing of races should include the date of each event and detail the estimated rider and spectator turnout Racers competing on the National Tour that are ranked in the top five in the world in their respective classes seek an entirely different level of support than most racers These racers normally receive support from t
69. ature plate counterclockwise d S 0 t V A25E0RU 1 Turn counterclockwise to advance After adjustment tighten armature plate retaining screws CAUTION Make sure armature plate screws are well secured Armature plate screws must have Loctite 242 P N 293 800 015 applied before tightening If you are going to apply loctite to the screws remove one screw apply loctite and reinstall the screw This way you will retain the timing you just set Torque screws to 6 Nem 53 Reinstall removed parts Recheck ignition timing make sure engine is cold The timing adjustment for the DC CDI ignition used on the 787 engine types must be accomplished electronically The Sea Doo dealer in your area has an MPEM programmer necessary to perform the task If you are able to tell the dealer how many degrees you want the timing advanced or retarded the price of the adjustment will usually be reduced 03 80 www SeaDooManuals net SECTION ENGINE PREPARATION SPARK PLUG INFORMATION Spark plug heat ranges are selected by measuring actual combustion chamber temperatures A colder spark plug 1 that dissipates heat more rapidly is often required when engines are modified to produce more horsepower The proper heat range of the spark plugs is determined by the spark plugs ability to dissipate the heat generated by combustion The longer the heat path between the electrode tip to the plug shell the higher the spark plug oper
70. be Hard Jetted fitted with jets of the fixed type 03 35 www SeaDooManuals net SECTION ENGINE PREPARATION 01 1 5 1 Water supply hose of regulator valve 2 Regulated water to injection fitting at tuned pipe head 3 Water injected into the muffler CAUTION When Hard Jetting an exhaust system small jets are used to regulate water flow These jets are very prone to clogging by sand or debris The jets must be continually checked for blockage or system damage will occur THE PROCEDURE FOR HARD JETTING THE EXHAUST SYSTEM IS AS FOLLOWS 1 Remove the water regulator and replace the unit with a fitting that will thread into the waterbox in its place The fitting must have at least a three millimeter orifice through it and be threaded to accept a Mikuni main jet The fitting must also accept a one quarter inch I D hose At the exhaust tuned head pipe there is a one quarter inch fitting already in use that was used to accept the regulated water supply from the now discarded water regulator Remove the hose from the fitting at the head pipe and thread the fitting to accept a Mikuni main jet The engine is equipped with a one half inch water inlet hose coming from the jet jump Between the jet pump and the engine there is a one quarter inch O D T fitting and hose currently installed The fitting and hose was used to supply water to the now discarded water regulator Attach a one quarter inch T fitting to t
71. craft moves slowly due to reduced jet thrust Check jet pump components for damage Refer to appropriate model year Shop Manual STEERING SYSTEM ALIGNMENT The handlebar pivots the jet pump nozzle which controls the watercraft direction These 2 items handlebar and nozzle must be adjusted properly or centered to obtain optimum control of the watercraft The steering system alignment is most important to ensure the adequate control of the watercraft WARNING Ensure handlebar and jet pump nozzle operate freely from side to side and that jet pump nozzle does not contact the side of venturi housing For alignment procedures refer to appropriate model year Shop Manual 04 19 www SeaDooManuals net SECTION 05 MISCELLANEOUS EQUIVALENT WEIGHTS AND MEASURES CHART 05 2 GLOSSARY OF TERMS IN PERSONAL WATERCRAFT RACING 05 3 5 05 4 LISTING OF AFTERMARKET MANUFACTURERS AND SERVICES 05 5 05 1 www SeaDooManuals net SECTION 05 MISCELLANEOUS EQUIVALENT WEIGHTS AND MEASURES CHART LINEAR MEASURE 1 Inch 25 4 Millimeters mm 1 Millimeter 03937 Inch 1Inch 2 54 Centimeters cm 1 Centimeter 3937 Inch 1 Foot 3048 Meter m 1 Meter 3 2808 Feet 1 Yard 914 Meter m 1 Meter 1 093 Yards AREA 1 Sq Foot 144 Sq Inches 929 03 cm 1 Sq Inch 6 4516 cm 1cm 155 Sq Inch 1 Sq Foot
72. ction at each end of crankshaft Refer to INSPECTION in this section If deflection is found to be greater than specified tolerance this indicates worn bearing s bent and or misaligned crankshaft For engine disassembly procedure refer to appropriate model year Shop Manual INSPECTION Visually inspect parts for corrosion damage Inspect crankshaft bearings Check for scoring pitting chipping or other evidence of wear Make sure plastic bearing retainer cage is not melted Rotate and make sure bearings turn smoothly If crankshaft and or components are found worn or damaged it must be replaced or repaired by a shop specializing in this type of work 03 64 www SeaDooManuals net SECTION 03 ENGINE PREPARATION The inspection of engine crankshaft should include the following measurements MEASUREMENTS NEW WEAR min max LIMIT Crankshaft 0 05 mm 0 08 mm deflection 002 in 0031 in Connecting rod 0 39 mm 0 737 mm 1 2 mm big end axial play 015 in 029 in 047 in CONNECTING ROD STRAIGHTNESS Align a steel ruler on edge of small end connecting rod bore Check if ruler is perfectly aligned with edge of big end F01D10S 1 Ruler must be aligned with edge of connecting rod here 2 Align ruler here CRANKSHAFT DEFLECTION Crankshaft deflection is measured at each end with a dial indicator 03 65 www SeaDooManuals net SECTION 03 ENGINE PREPARATION First check deflection with cranksha
73. d in inches of mercury In the case of the Mikuni BN carburetor the main restriction is considered to be the throttle plate When the throttle plate is closed it offers the greatest amount of restriction and manifold pressure is high As the throttle plate is opened the restriction is reduced and manifold pressure decreases The carburetor sees manifold pressure as a potentially strong suction drawing on any exposed openings within the carb As the throttle is opened more internal openings are exposed to this suction To begin with only the low speed fuel outlet is exposed but as the throttle is opened further the bypass holes and the high speed fuel from the inner venturi are exposed to the suction At this point with the throttle wide open if there was no fuel in the carb the engine would not rev up and because the throttle plate was open fully the manifold pressure would be very low However we do have fuel and the engine does rev drawing an increasing amount of air velocity through the carb As the air velocity through the carb increases it replaces manifold pressure as the suction force within the carburetor What are the dynamics of manifold pressure and air velocity As the engine is idling we know that manifold pressure is high and there is good signal strength within the carb which makes adjustment easy As the throttle is opened quickly manifold pressure disappears and if the jetting within the carb is correct the engine re
74. delines and are not the only factors involved in the complete building of a reliable race ready engine All Rotax engines will perform best on unleaded regular gasoline of the proper octane There is no advantage of using a higher octane fuel if the compression ratio is not higher than production However if the compression ratio is higher it may become necessary to use a higher octane fuel or engine damage will result Do not use a compression gauge to determine compression ratio A compression gauge is useful in checking general condition of any engine but is useless when checking compression ratio Minimum octane requirement for production engines 87 RM Regular unleaded R Research octane number 90 M Motor octane number 84 R 87 octane 2 Minimum octane requirement for engines with higher compression ratio Premium unleaded Up to 14 1 108 112 motor octane Over 14 1 114 motor octane 03 32 www SeaDooManuals net SECTION ENGINE PREPARATION FUNCTION OF AN EXHAUST SYSTEM Volumetric efficiency V E of an engine is the ratio of the actual amount of air drawn into an engine versus the capacity of the engine The natural V E of a 2 stroke is about 65 This means a 250 cc cylinder only draws in about 160 cc of air The HP output of an engine can be raised by increasing the V E of the engine The most notable method of raising V E is the use of a correctly tuned expansion chamber or tuned pipe If the ex
75. dual action sander sand the low spots just enough to rough up the gelcoat These low spots are indicated where gelcoat hasn t been sanded with the long board This is done so that fairing compound will adhere 02 3 www SeaDooManuals net SECTION 02 HULL PREPARATION e Measure the low area and mix up enough filler material to fill the area in Follow the manufac turers mixing instructions Fill low area and blend in evenly with bondo spreader Try to leave your filler a little high so you have material to sand Allow proper curing time f Using the pneumatic long sander sand the area until you accomplish a flat surface Remember to finish edges radius and flat sections of strakes as well Using the straight edge check the area which was just finished Verify flatness and if the area still has a low spot start your filling steps again g At the rear of the watercraft where the transom meets the hull there is radiused edge approx 4 mm radius this radius should be covered with epoxy fairing compound and sanded to a square edge h For refinish we recommend using PPG products PPG high build K 36 primer can be used for fine finishing small hull irregularities after application of fairing compound PAINTING GENERAL The following was prepared in conjunction with PPG Industries Inc It contains 2 painting proce dures CONCEPT the most commonly used and DELTA with low VOC mainly used California If more informati
76. e cylinders armature plate coils etc CRANKSHAFT F01D1NU 1 Crankshaft shown with connecting rods The engine crankshaft is the backbone of the engine It converts the reciprocating movement of the piston into rotary movement The crankshaft is supported by ball bearings mounted inside the crankcase It is finely machined to obtain precision journals and perfect alignment Distortion or out of round will impair the neces sary free and smooth rotation 03 9 www SeaDooManuals net SECTION ENGINE PREPARATION CONNECTING ROD The connecting rod links the piston to the crankshaft Within each bored end of the rod is a needle bearing Rotax connecting rods are integral parts of the crankshaft assembly and therefore are not removable unless crankshaft is disassembled with special tooling If you are unsure about the condition of your crankshaft or if you know your crankshaft needs to be worked on it is highly suggested that you send the crankshaft to a machine shop specializing in this type of work 0105 5 Less expensive engines have the crankshaft and connecting rods mounted on sleeve bearings rather than roller or needle bearings The advantage of roller or needle bearings is less friction and longer life WRIST PIN Provides support for the piston It also links the piston to the connecting rod This machined pin is inserted through a needle bearing resting within the upper end of connecting rod It is
77. ength rather than cutting or stretching an existing spring the results are more consistent over the long run Cut or stretched springs tend to change in strength over time The anti siphon valve is located in the valve body assembly attached directly above the high speed jet It is responsible for retaining fuel in the fuel chamber when the engine is shut off When the engine is running suction will cause the anti siphon valve to flex allowing fuel to flow to the jet If the valve becomes worn or does not seal correctly the symptoms will appear as a rich condition from 1 half to full throttle The throttle plate butterfly valve is worth a closer look It s quite obvious that the throttle plate controls the entire operation of the carb At idle the throttle plate blocks off almost all air flow through the carb creating a very high amount of manifold pressure within the carb This high pressure is 1 reason that the low speed screw is as sensitive as it is small adjustments will make a big difference Notice that when the throttle plate is in the idle position the bypass holes are actually above the throttle plate with the carb in the down draft position The bypass holes are actually having air drawn through them in this position It isn t until the throttle plate opens over the bypass holes that fuel actually passes through them 03 88 www SeaDooManuals net SECTION ENGINE PREPARATION Anti seize lubricant 03 89
78. ept for parts made of plastic 02 22 www SeaDooManuals net SECTION 02 HULL PREPARATION PPG COLOR CHART SEA DOO MODELS 1 Body COLOR White White Yellow White White White PPG no 98260 98260 M506 98260 98260 98260 2 Hull COLOR White Yellow Yellow White White PPG no 98260 506 88243 98260 98260 3 Storage Cover Marine COLOR Yellow Yellow hood forthe HX model PPG applicable applicable applicable 88243 506 COLOR White White White White White White PPG no 98209 98209 98209 98209 98209 98209 5 Tuned Pipe COLOR Purple Purple Purple Purple Purple Purple PPG no 59962 59962 59962 59962 59962 59962 6 Muffler COLOR Purple Purple Purple Purple Purple Purple PPG no 59962 59962 59962 59962 59962 59962 7 Exhaust Manifold COLOR White White White White White White PPG no 98209 98209 98209 98209 98209 98209 8 Engine Support COLOR Black Black Black Black Black Black PPG no 9551 9551 9551 9551 9551 9551 9 Magneto Housing COLOR White White White White White White PPG no 98209 98209 98209 98209 98209 98209 10 Magneto Housing Cover COLOR White White White White White White PPG no 98209 98209 98209 98209 98209 98209 11 Flame Arrester Base COLOR Black Black Black Black Black Black PPG no 9551 9551 9551 9551 9551 9551 12 Ride Shoe COLOR Black Black Black Black Black Black PPG no 9551 9551 9551 9551 9551
79. er inspection you will be ready for practice but remember most promoters do not allow practice or free riding until after the rider s meeting Failure to comply can mean disqualification or a fine During safety inspection ask the Inspector what type of fuel tests are going to be made if any Have your fuel tested at this time Fuel from filling stations sometimes have alcohol added and may not test legal Now is the time to find out and change fuel if necessary www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION 5 RIDER S MEETING The rider s meeting is mandatory for racers In many cases a roll call is held to ensure attendance Failure to attend can be grounds for disqualification or a fine During rider meetings the Promoter will discuss particular requirements for the day s events including practice order course layout starting procedures number of laps emergency rescue technical inspections and award presen tation If you have any questions or concerns this is the time they should be discussed 6 PRACTICE Practice is for the purpose of learning the course Red buoys signify left turns while yellow buoys are for right turns Be on the line ready to go when your class is called Do not race during practice You may injure yourself or damage your boat Many racers have been taken out during practice because of stupidity Don t join their ranks Remember learn the course don t tune your water craft du
80. essure before the valve begins opening Item P2 is the pressure required to completely open the RAVE valve Between P1 and P2 the usable power curve of the engine is moving from curve 1 to power curve 2 This transition takes place very rapidly at full throttle and from a practical standpoint can be considered to be instantaneous at item 7 Gradual application of the throttle however will result in the RAVE valve opening much later If the RAVE valve opens too late the engine will bog or hesitate momentarily as the RPM increases Full peak performance item 6 is still available From a functional point of view It is better to have the valve open a bit early than a bit late RAVE VALVE ADJUSTMENT To adjust the RAVE valve turn the red adjustment knob all the way in clockwise Open the red knob 1 turn out counter clockwise and perform an acceleration run on the craft starting from zero and accelerating to full speed Repeat the procedure until you attain the best performance The use of a radar gun with acceleration recording capabilities is advised in order to obtain accurate data however rider observation will surface 03 46 www SeaDooManuals net SECTION ENGINE PREPARATION MAINTENANCE The RAVE components should be periodically checked The RAVE valve requires cleaning of carbon deposits Cleaning intervals would depend upon the user s riding style and the quality of the oil used Using FORMULA 5 synthetic injection
81. etor response and increased power Freer exhaust systems decrease suction Even though they flow more freely they reduce manifold pressure within the carb Manifold pressure is a way of measuring the strength of engine suction Although air flow is increased initially there isn t enough air flow until high engine speeds to replace manifold pressure Freer air intake systems Free flowing unrestricting air intakes increase air flow but once again at low throttle openings may reduce manifold pressure Increasing air flow is a good thing but be aware that adjustments have to be made in your carb to compensate for pressure changes Atmospheric pressure changes with altitude and temperature BN carbs adjust automatically to minor changes in either altitude or temperature in this way As air thins out for example less air is drawn through the engine which enrichens the air fuel mixture but there is also less pressure acting on the regulator diaphragm this tends to lean the air fuel mixture These 2 factors off set each other to a small degree but this effect must be taken into account when you consider readjustment for a large change in altitude or temperature Needle valve arm adjustment is from the top surface of the arm being level with the cast surface of the carb to a maximum of the surface of the arm raised 1 mm 040 above the carb surface The arm is a convenient way to make minor adjustments in pop off pressures Bending the arm u
82. ext to their tent The sponsors names have been placed on the billboard with custom paint or decals The billboard can also be arranged to prevent easy access to or through your pit Some sponsors may be providing you with very generous support You might want to design something special for them Again sponsors are always looking for new and innovative ways to advertise if you can provide that something different it will not only help you keep a sponsor but other sponsors will recognize your work and may throw support your way Keep your pit area clean bring a small waste can for your pit it s another place to put decals it adds to the professional look You are required to have a fire extinguisher in your pit Do not set it on the ground it will be hard to locate in the event of an emergency Attach a hanger to one tent post and place the extinguisher on it Your fuel container should be of high quality red in color a requirement not normally enforced by the promoter and stored away from smoking areas There should be no horse play in your pit area again your conduct and that of others with you is a direct reflection on your professionalism Do not loose your temper act like a child or allow yourself and those with you to use profane language under any circumstance INTERACTION WITH RACE OFFICIALS There are many officials that you will come in contact with during race day These officials have specific duties required of the
83. ft in crankcase If deflection exceeds the specified tolerance it can be either ball bearing wear bent or twisted crankshaft at connecting rod journal FO1D1SS F01D1TS 1 Measuring MAG side deflection in crankcase Remove crankshaft bearings and check deflection again on v shaped blocks as illustrated 03 66 www SeaDooManuals net SECTION ENGINE PREPARATION 1 Measuring MAG side deflection on V shaped blocks 1 Measuring PTO side deflection on V shaped blocks O NOTE Crankshaft deflection can not be accurately measured between centers of a lathe 03 67 www SeaDooManuals net SECTION ENGINE PREPARATION CONNECTING ROD BIG END AXIAL PLAY Using a feeler gauge measure distance between thrust washer and crankshaft counterweight FO1D1WS 1 Measuring big end axial play 2 Feeler gauge ASSEMBLY Assembly is essentially the reverse of disassembly procedures However pay particular attention to the following BEARING Apply Loctite 767 anti seize lubricant P N 293 550 001 on bearing seats Prior to installation place bearings into a container filled with oil previously heated to 75 C 167 F This will expand bearings and ease installation LABYRINTH SLEEVE DUAL CARB MODELS To properly locate outer PTO bearing install labyrinth sleeve against inner bearing side FO1D4US 1 Labyrinth sleeve 2 Inner bearing 3 O ring 03 68 www SeaDooManuals net SECT
84. g line This is called staging You will be lined up in 1 of 3 ways 1 You will draw for your position 2 The computer will line you up randomly as posted on the pit board 3 You will be lined up in order of your finish position from your previous qualifier or heat race 9 STARTING Once in position on the line you will be allowed 1 or 2 holders to keep your boat in position safely The holders will hold back your boat while the engine is running just before the rubber band is snapped It is important that you practice your starts with your holders Holders need to learn how to hold on to your boat while you increase the throttle Holders must be in sync with you and the Starter Many races are won or lost by your holders ability to get you off to a good start Holders must use gloves to do a good job Starting procedures at your event will be discussed during the riders meeting However the best way to get the edge is for you and your holders to watch the Flag Man and Starter on the races prior to yours Watching them will allow you to see the rhythm or pattern they are using for the start This can give you the edge 01 3 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION It is very important to remember that if you jump the start you will be severely penalized You will have to start with a dead engine your throttle hand on your head and only 1 holder or no holder to keep you in position 10 THE RACE Upon the st
85. gine Best V E s are obtained by asymmetrical intake timing opening and closing of intake port operates independently with regard to piston position Example 130 BTDC opening 65 ATDC closing While also allowing for an unobstructed intake tract to provide maximum airflow into the engine This is best accomplished by using a rotary valve type inlet The rotary valve engine is 1 of the most innovative concepts to be applied to 2 stroke watercraft engines Simply stated the design produces more horsepower out of the same size engine displacement at the same RPM Because the aperture size and degree of opening exceed that of a piston port engine a greater air fuel mixture supply can enter the engine and remain in the engine without spitback ENGINE OPERATION Basically the rotary valve engine performs the same operation as the piston port 2 stroke engine The only difference being the location and operation of intake 1 The intake port is positioned directly in the crankcase 2 The opening and closing of the intake port is controlled by a rotary valve instead of the piston 3 The rotary valve is driven by the crankshaft in a counterclockwise direction 03 47 www SeaDooManuals net SECTION ENGINE PREPARATION INTAKE AND SECONDARY COMPRESSION FO1D6TS 1 Fresh charge from carburator As the piston starts its upward stroke the air fuel mixture is drawn into the crankcase from the carburetor via the intake port the r
86. h the central rotary valve complete control of intake timing means greater torque at lower RPM s more peak power and easier starting INSPECTION Inspect rotary valve cover for warpage Small deformation can be corrected by surfacing with a fine sandpaper on a surface plate Surface part against oiled sandpaper Inspect bearings Check for scoring pitting chipping or other evidence of wear Make sure plastic cage on bigger bearing is not melted Rotate them and make sure they turn smoothly Check for presence of brass filings in gear housing Visually check gear wear pattern on gears It should be even on each tooth for the complete rotation of the gears Uneven wear could indicate a bent shaft check for deflection Replace gear if damaged There should be no deflection in the rotary valve shaft If there is the shaft must be replaced 03 51 www SeaDooManuals net SECTION ENGINE PREPARATION ROTARY VALVE COVER CLEARANCE There is a choice of 2 measuring methods 1 with solder the other 1 with a depth micrometer The clearance between the rotary valve and the cover must be 0 18 0 30 mm 0 007 0 012 in SOLDER METHOD Remove rotary valve cover and its O ring Use the following type of solder rosin core diameter 0 8 mm 0 032 electronic application available at electronic stores Install 2 short pieces 13 mm 1 2 in long of solder directly on rotary valve 1 above and 1 below rotary
87. han 6 mm 0 240 in shim thickness If alignment cannot be obtained verify for engine support bending FUNCTIONS OF THE VARIABLE TRIM SYSTEM VTS To obtain optimal performance push VTS button located on left side of handlebar or turn knob on left side of body depending on the model of watercraft This adjustment changes the jet pump steering nozzle position which compensates for load and thrust When the nozzle is up the bow of the watercraft comes up F01J5CS 1 Bow up 2 Push on VTS button UP position 3 Nozzle up 04 16 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM When the nozzle is down the bow comes down F01J5BS 1 Push on VTS button Down position 2 Bow down 3 Nozzle down According to boat load and water conditions the driver can trim the watercraft as desired CAUTION Trim ring and or nozzle must not interfer at any position Damage to cables and or venturi housing will occur if adjustments are not done properly For adjustment procedures refer to appropriate model year Shop Manual VENTILATION AIR LEAK Ventilation is caused by air being sucked through jet pump which will reduce performance of the pump Pump ventilation reduces acceleration and will be most noticeable during initial and low speed accelerations Engine RPM will increase tremendously with very little increase in watercraft speed This condition feels much the same as a slipping clutch in a car or motorcycle Jet
88. haust port is emptied into the open atmosphere much of the fresh air fuel charge rushing up the transfer ports is expelled out of the exhaust port and lost To prevent this charge from being lost a tuned chamber is attached to the exhaust port The tuned chamber uses sonic wave motion which is separate from the exhaust particles and fresh charge particles to move the particles around this is like waves in water moving a cork When the exhaust port is opened a sonic or sound wave is generated by the high pressure exhaust gases expanding into the header pipe The speed of sound at exhaust temperature is a b t 518 meters 1700 ft per second FO1D6PS 1 Sonic wave initiated as exhaust port opens 4 Diverging cone s 2 or stinger 5 Mid section 3 Head pipe 6 Converging cone s This wave travels down the header pipe and expands into the diverging cone causing a negative pressure of about 48 kPa 7 PSI This negative pressure helps pull the remaining exhaust particles out of the cylinder It also helps pull the fresh charge up the transfer ports and into the cylinder F01D60S A 48 KPa 7 PSI 03 33 www SeaDooManuals net SECTION ENGINE PREPARATION As the sonic wave hits the converging end of the pipe a positive pressure wave is reflected back towards the exhaust port If the length of the pipe is tuned correctly this positive pressure returns to the header pipe just before the exhaust port
89. he hose in place of the water regulator Attach two quarter inch hoses to the T fitting run one hose to the new fitting on the muffler which replaces the water regulator and one hose to the fitting on the tuned head pipe Start the hard jetting procedure by installing a 200 Mikuni main jet in the fitting on the muffler and a 150 Mikuni main jet in the fitting on the exhaust tuned head pipe After an initial test ride of no more than three minutes stop and check the exhaust hoses for excessive temperature If you believe the temperatures to be too high install a larger jet in both areas This is highly unlikely because the initial jet sizes stated should be more than sufficient After verifying that the exhaust hose temperature is not excessive you can start testing the watercraft with smaller or larger jets in order to attain the performance desired 03 36 www SeaDooManuals net SECTION ENGINE PREPARATION 01 235 1 Original fitting threaded to accept Mikuni main jet size 150 2 New 1 4 T Fitting 3 New fitting threaded to accept a Mikuni main jet size 200 IMPORTANT It is necessary to readjust the exhaust hard jetting for maximum performance when racing in different water temperatures Because of this it is recommended that you keep a record of the jet sizes chosen at given water temperatures 03 37 www SeaDooManuals net SECTION 03 ENGINE PREPARATION FUNCTION OF THE COOLING SYSTEM All Sea Doo watercraf
90. he manufacturer of the watercraft they race Some riders receive support directly from manufacturers race team directors while others receive support from the manufacturer through factory race centers These individuals have achieved the highest goals in racing through hard work and commitment to their racing program They started out just like you with the ambition to be the very best racer they could be With hard work preparation and a little luck you can do the same THE PROFESSIONALS POINT OF VIEW Westcoast Performance Products Racing Team Manager Ken Clark was asked what does a Team Manager look for in the Ideal Racer This was his response The ideal racer has a fierce desire to win and will work as hard as necessary to accomplish that goal Regardless of that old saying it s not whether you win or lose it s how you play the game the ideal racer will only understand the winning part of this For the ideal racer anything other than victory is only second best The ideal racer has a commitment to the sport they have chosen to compete in These racers are always searching for ways to improve their performance either by superior physical conditioning superior personal skills and coordination or a better understand ing of the dynamics of the vehicle involved This takes a dedication that is foreign to most competitors which combined with superior motor skills is what distinguishes champions from other competitors There i
91. he needle The size of the fuel passage hole in the valve seat contributes to the performance of the carb in a couple of different ways First and most important the hole size helps determine pop off pressure 4 things combine to create pop off 1 Suction within the carb manifold pressure 2 Atmospheric pressure 3 Arm spring pressure 4 Fuel pressure acting on the needle valve Hydraulic principles apply in this instance There is fuel pressure acting against the exposed end of the needle valve with this pressure being measured in PSI For example with a 2 0 size needle valve the fuel pressure pushes against the needle through the opening with a certain force If you increase the needle valve size to 2 5 and retain the same arm spring the fuel has a larger surface to push against and can move the needle more easily So increasing needle valve size effectively decreases pop off conversely decreasing the size of the needle valve will increase pop off The arm spring is also an adjustable component There are currently 4 springs available with different gram ratings You can refer to the pressure chart further along in this section to obtain approximate pop off pressures with spring pressure and needle valve combinations 03 86 www SeaDooManuals net SECTION ENGINE PREPARATION 5 4 reed piii 3 9 4 En s w f 7 m mi a lt gt 2 tan X ji 2 7 M t y i Aep j S
92. he person that holds your watercraft on the starting line prior to the start of the race The process of arriving at the first turn ahead of the competi tion in a race The structural portion of the boat below the bond flange An obstacle used in closed course racing that consists of a row of tires which riders must pass over Area used by riders and mechanics to make repairs store watercraft etc The act of a watercraft nose pitching up and down in the water Person responsible for organizing a race A person or group that provides support to a rider promoter or association usually in exchange for promotion Area near the starting line where riders and their watercraft wait for their scheduled race Person who officially gives the signal to begin the race A straight boundary that designates the beginning point of a race Person who checks competing watercraft for safety and technical eligibility The path created by a boat or watercraft in the water 05 3 www SeaDooManuals net SECTION 05 MISCELLANEOUS RACER S LOG Event Date Sheet number Association Race Director Temperature Barometric Pressure Humidity Water temperature WATERCRAFT NOTES Model Number Hull Identification Number Engine Identification Number Weight Main Jet Pilot Jet Needle Valve Low Speed Screw High Speed Screw Pop Off Pressure Needle Valve Spring Fuel T
93. he race is red flagged or the rider and their holders are unhappy because they feel a red flag should have been thrown but was not Because of these problems being most common it is recommended that you watch the start of the races preceding yours whenever possible Determine the type of calls the Starter is making and use the information to your advantage When problems arise and the call is made against you respond professionally If you believe that the call made by the Starting Official was incorrect talk to the Race Director The Race Director s decision is final in these matters The second most common problem occurs during a race because a racer misses a buoy and no officials witnessed the incident or the racer was called for a missed buoy and the racer believes they did not miss the buoy When missed buoys are not seen by a race official then the call against the racer in question cannot be made even when the error was captured on video tape Video tape evidence is not permissible by any sanctioning body If you feel that the call made against you was invalid consult the Race Director The Director will consult with the official making the call against you If that official wishes to retract the call on the buoy in question the decision will be reversed The Director will not reverse an officials call unless the Director witnessed the situation personally While there are many examples of differences between officials and racers most c
94. hite 98192 98192 98192 98192 2 Hull Medium Medium Gray Medium Gray Purple Dark Gray 59962 38248 3 Storage Cover Not Not Medium Blue Not Applicable Applicable 17861 Applicable Yellow Yellow Yellow Yellow 88207 88207 88207 88207 5 Tuned Pipe Black Blue Blue Purple 9551 17862 17862 59963 6 Muffler Black Blue Blue Purple 9551 17862 17862 59963 7 Exhaust Manifold Yellow Yellow Yellow Yellow 88207 88207 88207 88207 8 Engine Support Black Black Black Purple 9551 9551 9551 59963 9 Ignition Housing Yellow Yellow Yellow Yellow 88207 88207 88207 88207 10 Ignition Housing Support Yellow Yellow Yellow Yellow 88207 88207 88207 88207 11 Ignition Housing Cover Yellow Yellow Yellow Yellow 88207 88207 88207 88207 12 Flame Arrester Cover Black Blue Blue Purple 9551 17862 17862 59963 13 Fame Arrester Support Yellow Yellow Yellow Yellow 88207 88207 88207 88207 14 Flame Arrester Base Black Blue Blue Purple 9551 17862 17862 59963 15 Ride Shoe Medium Black Black Purple Dark Gray 9551 9551 59963 38248 16 Impeller Housing Medium Black Black Purple Dark Gray 9551 9551 59963 38248 17 Venturi Medium Black Black Purple Dark Gray 9551 9551 59963 38248 02 13 5 www SeaDooManuals net SECTION 02 HULL PREPARATION 1988 1991 SEA DOO MODELS COMPONENTS SP SP GT XP 5801 5802 5803 5804 5810 5811 5850 18 Steering Nozzle Medium Black Black Purple Dark Gray 9551 9551 59963 38248 19 Reverse Gate Left Plate Not Not Black
95. hull storage compartment cover water trap tank drain hoses seat seal and rear baffle Reseal all leaks Refer to appropriate Shop Manual HULL AND BODY MAINTENANCE TIPS To obtain a smooth hull after every use wash watercraft with soap and water This will remove residues which will slow your watercraft Wax the hull periodically When storing outdoors keep your watercraft covered LIGHT WEIGHT PARTS There are several aftermarket MFG which produce lighter weight and or stronger parts for racing purposes such as seats and storage covers These are worth considering Be sure the parts you are installing are within the rules SPONSON KITS Advantages of the sponson improved handling reduces spin out Holds better in corners more stability NOTE The sponsons on the Stock Sea Doo XP and GT models protrude beyond the width of the hull bond flange Because of this it is necessary that the sponsons be filed or ground down to fit within the bond flange in order to be race legal There are long type sponsons and short type sponsons available in kits They do work well when interchanged within the same type It is only a matter of preference AVAILABLE KITS Short Sponsons 295 500 168 GREY XP 93 295 500 194 195 GREEN MAGENTA respectively Long Sponsons 295 500 092 GREY 02 8 www SeaDooManuals net SECTION 02 HULL PREPARATION INSTALLATION GUIDELINES The following pertain to all types of sponsons The sp
96. ials can make mistakes but so can racers When problems arise conduct yourself in a professional manner Attempt to locate and deal with the official that handles that aspect of the race If you don t get satisfaction then it s time to take your problem to the Race Director The outcome may not always be to your liking but if you handle yourself professionally the Race Director will be more open to your comments and in the future will place more validity on your side of the argument 01 10 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION SPONSORSHIP AND SOLICITATION There are many levels of sponsorship available to racers The amount of sponsorship you receive is primarily dependent on your national ranking and experience level novice expert pro There are many novice and expert racers with much greater sponsorship support than some pro racers The reason is that they made a commitment to their racing program They practiced hard stayed in shape and made sure their machines were always race ready Because of this they won races received media coverage and gained recognition Recognition is what sponsorship is all about Racers seek sponsorship to help offset the cost of racing while sponsors support you for one purpose recognition of their product Your winning races promotes their products and exposes them to a large target population group The sponsor hopes this will enhance their image and sales As a novice
97. iling edge 04 7 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM PROGRESSIVE PITCH The impeller pitch changes progressively on each blade The blades are bent constantly or asymmetrically with different angles at leading and trailing edges The blade bending is done by using a special fixture F01J4TS Leading edge Constant bend Trailing edge Asymmetrical bend 04 8 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM A low pitch leading edge is important for good acceleration and a higher pitch on trailing edge will give better top speed IMPELLER EFFICIENCY The impeller efficiency is related to several parameters hydrodynamic blade design incidence angle turbulence created at the inlet pre rotation of water relative circulation eddy friction cavitation Impeller Wear Ring Clearance This clearance is critical for jet pump performance Excessive clearance will result in decreased performance Clearance can be checked from water inlet opening after inlet grill removal or from venturi side after venturi nozzle assembly removal This last method may be more difficult WARNING Prior to impeller wear ring clearance verification disconnect battery black negative cable F01JOFT 1 Feeler gauge 2 Measuring from venturi side Using a long feeler gauge 30 cm 12 in measure clearance between impeller blade tip and wea
98. ill transfer a designated volume of water each revolution through the pump The axial flow jet pump characteristics are low pressure high flow small size of pump high RPM FO1J4PS Oil reservoirs Impeller shaft end play Venturi Stator vanes Impeller OY 04 2 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM MAINTENANCE To obtain optimum efficiency of jet pump and to eliminate backlash in propulsion and drive system the following maintenance items must be checked regularly Verify oil condition and replace oil regularly A whitish oil indicates water contamination Use only SEA DOO JET PUMP SYNTHETIC OIL P N 293 600 011 Using a grease gun carefully lubricate PTO flywheel and seal carrier with synthetic grease P N 293 550 010 Stop greasing as soon as the first bit of grease comes out from under seals Verify impeller shaft end play For racing purposes maximum permissible end play new is 0 12 0 54 mm 005 021 in Excessive play comes from worn protrusion end stop inside housing cover Excessive end play will negatively affect performance Visually inspect protrusion end stop inside cover If worn a small peak in center will be apparent F01J1CS 1 Protrusion Lubricate drive shaft and impeller splines regularly using synthetic grease The jet pump must be disassembled and drive shaft removed to perform th
99. ing or if detonation is heard it is advisable to 1 Determine that the carburetion is not adjusted too lean 2 Try a higher octane fuel 3 Retard ignition timing to remedy the problem 4 Determine that the exhaust system is providing for adequate flow IGNITION TIMING SPECIFICATIONS Refer to appropriate model year Shop Manual IGNITION TIMING It is very important that timing specification is checked at 6000 RPM with a cold engine When preparing an engine for racing the flywheel should be checked for the correct phazing between the firing points of the MAG and PTO spark plugs The firing points should be exactly 180 apart if there is any deviation between the firing points the flywheel should be changed for a perfect unit to obtain maximum performance In order to check the flywheel for proper phazing the crankshaft itself must first be checked for the 180 phasing refer to crankshaft cautions and inspection Use the procedure for verifying PTO flywheel timing mark position and repeat the procedure that was done to the MAG side cylinder on the PTO cylinder There should be 2 marks on the PTO flywheel 180 apart The ignition fires every 180 of crankshaft rotation at TDC and BDC so the marks should line up exactly when viewed with a timing light If they do not line up exactly and the crankshaft is correctly phazed the flywheel magnets may not be phazed exactly 180 apart VERIFYING PTO FLYWHEEL TIMING MARK POSITION
100. is maintenance This is a good time to inspect spline condition of your drive shaft If excessive drive shaft wear is detected both PTO flywheel and impeller should be inspected 04 3 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM PROPULSION SYSTEM ANALYSIS 1 Nozzle 2 Venturi 3 Inlet PROPULSION SYSTEM SPECIFICATIONS SEA DOO JET PUMP SYNTHETIC OIL 75W90 GL5 P N 293 600 011 60 cm 24 in 139 5 mm 5 490 in Impeller wear ring clearance 0 5 mm 020 in Wear limit performance 1 02 mm 040 in Wear limit not suggested for high performance Impeller shaft end play new 0 12 0 54 mm 005 021 in Impeller shaft side play 0 025 0 05 mm 001 002 in Impeller material Aluminum or stainless steel ADDITIONAL INFORMATION Do not mix different brands or types of oil in the jet pump 04 4 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM NOTE The 95 and 96 XP models were equipped with the new composite pump housing Because of this pump housings of the aluminum type from previous models can not be interchanged and legally used for IJSBA competition INLET The function of the inlet is to carry the water to the jet pump with minimum loss Another very important function is to assist the jet pump in transforming water volume into thrust F01JARS Ride shoe and hull sealed and blended Sealed and blended Water flow inside of the inlet Sealed and blended intake gr
101. is produced when peak combustion chamber pressure about 750 PSI takes place at about 15 after crankshaft rotation ATDC Normal combus tion is the controlled burning of the air fuel mixture in the cylinder The flame is initiated at the spark plug and spreads to the unburned at the edges of the cylinder The flame front travels through the cylinder at about 30 m 100 ft per second In order to achieve maximum pressure at about 15 ATDC the spark must occur about 15 before TDC Complete combustion will finish at about 35 ATDC The actual amount of spark advance BTDC is dependent upon bore size combustion chamber shape operating RPM mixture turbulence and the actual flame speed Flame speed is directly proportional to piston speed in an almost linear fashion Though it is not completely understood why this relationship exists it is thought to be related to intake speed and mixture turbulence Hence flame speed increases as RPM increases It also increases as the air fuel ratio becomes leaner Because the flame speed is slower at lower RPM s more advance at low RPM is necessary for maximum performance Advancing the spark too much BTDC for the needs of the engine will cause the engine to detonate Ignition advance on Rotax engines is measured by a linear distance of piston travel BTDC A dimension taken through a straight spark plug hole in the center of the head is a direct measure ment A direct measurement can be converted to degree
102. is section and your engine will deliver more power longer 03 99 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM BASIC FUNCTIONS OF THE 04 2 AXIAL FLOW PUMP ei aas ne 04 2 Pippi eM 04 3 PROPULSION SYSTEM 5 04 4 PROPULSION SYSTEM SPECIFICATIONS 04 4 xp E a 04 5 ESIMPELEERH 04 6 IMPELLER 6 1 04 6 IMPELLER 2 2 2 2 2 2 04 10 STATOR VANE ascacicsncczsstasizsnccenscacdsssendncetadanctinacesseedansccctiaprianseicaataatnsecet 04 14 VENTURI 04 14 ENGINE JET PUMP ALIGNMENT 2 2 2 2 4 04 14 FUNCTIONS OF THE VARIABLE TRIM SYSTEM VTS 04 16 VENTILATION AIR 2222222 2222224 2 04 17 U 04 18 STEERING SYSTEM ALIGNMENT 222 22 04 19 04 1 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM BASIC FUNCTIONS OF THE SYSTEM The following is a brief explanation of some of the principals behind a
103. ling a new piston and or piston rings it is critically important that piston ring locating pin is matched or indexed with gap in piston ring This should be checked as the cylinders are being installed FO1D6DS 2 types of compression rings are used with Rotax pistons 1 Rectangular cast iron 2 L type trapezoid molybdenum FO1D6ES Selection of the appropriate type of piston ring is relative to the use of a particular engine For example rectangular rings provide adequate piston sealing for a normal medium revolution engine While performance engines with a higher revolution capacity require better than average sealing with L type trapezoid rings 03 7 www SeaDooManuals net SECTION ENGINE PREPARATION CRANKCASE Crankcases are fabricated as matched halves and are split horizontally 010555 1 Pulse nipple Material is of light weight alloy to reduce overall engine weight Incorporated into crankcase designs is a pulsation nipple a tube connects the pulsation nipple to the carburetor fuel pump to assist with the fuel pumping cycle 03 8 www SeaDooManuals net SECTION 03 ENGINE PREPARATION Torque crankcase screws 24 Nem 17 as per following illustrated sequence 010205 engine crankcase serves 3 main functions 1 Supports the crankshaft in perfect line bore 2 Serves as a primary compression chamber for incoming air fuel mixture 3 Supporting structure for th
104. lve WARNING Do not use gasoline due to the hazard of fire Protect your eyes from the spray when the needle valve pops off 5 Pressurize the carb with the pump until the needle valve pops off Check at what pressure the valve closes and seals This illustrates quality of valve sealing Test the valve at least 3 times to assure an accurate reading Be sure to keep the needle valve wet The reason for wetting the needle valve is to duplicate actual conditions during operation When the engine is running the needle valve has gasoline running through to wet it and engine vibrations to actually help the needle obtain a good seal As you adjust pop off pressure to tune your carb make changes in small increments only approximately 2 PSI because small changes in pop off can equate to big differences in engine performance Increasing or decreasing pop off dramatically affects how the low speed jet per forms Pop off enhances the fuel flow of the low speed jet Example The low speed jet is a 100 and the pop off is 16 PSI If the pop off is increased to 20 PSI the amount of fuel that passes through the jet decreases even though the jet size remains unchanged If the pop off was decreased to 13 PSI the 4100 jet would flow proportionally more fuel The low speed jet and pop off work together in the transition circuit As a rule of thumb adjusting pop off is for making big changes in the transition circuit the low speed jet is used for fine tuning
105. m all of which play a part in how efficiently the race is conducted Always treat the officials with respect Never raise your voice use profane language or make rude gestures to officials You can always discuss your differences without loosing your cool Being loud and obnoxious will not change the officials mind on a decision but it can sway his opinion on future matters normally against you Treat all officials courteously it will pay off in the long run 01 9 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION The person in charge of the officials is the Race Director The Race Director orchestrates all activities on race day If you have a problem with a judgement made by an official and you cannot come to an equitable solution see the Race Director The Race Director is in charge of settling disputes The Race Director s calls are final at the race site If you feel the wrong decision was made you can file a written protest to the Race Committee of the sanctioning body under which the race was conducted Normally the protest must be accompanied with a protest fee If it becomes necessary follow the procedures outlined in your rule book for filing an official protest There has been documented cases where the Race Committee has reversed the decision of the Race Director however it is rare The most common problems which arise between racers and officials occur at the start of the race Racers jump the start and then t
106. m possible intake with benefit to crankcase filling 03 50 www SeaDooManuals net SECTION 03 ENGINE PREPARATION The following chart indicates the intake phase differences between a piston port engine and a rotary valve engine ROTARY VALVE INTAKE PISTON PORT ENGINE ENGINE Total 6 Opening o o BTDC m Closing o o ATDC 73 ii As shown for the rotary valve engine the total duration of the intake is greater and the opening starts earlier This results in a better volumetric efficiency In the rotary valve engine the intake closes earlier to avoid fresh charge spitback Some watercraft manufacturers have adopted reed valve engines to increase overall performance However reed valve engines do have some disadvantages over the rotary valve engine These disadvantages are 1 The intake port is restricted by the reeds and cage 2 The reeds tend to separate air from fuel 3 Since the crankcase vacuum must first open the reed to permit intake this initial force is not fully applied to the intake operation Consequently there is a partial loss of intake potential 4 Athigh speeds the delay in closing the reed affects the reopening of the reed Again potential volumetric efficiency is affected 5 The continual rebounding of the reed causes further intake restrictions CONCLUSION With the central rotary valve duration of the intake is asymmetrical In piston port engines intake duration is symmetrical Wit
107. may need to be changed to either the pre 92 ignition or 93 XP 5852 dual magneto coil ignition If the engine maximum RPM has been increased due to impeller changes it would be advantageous to use the dual magneto coil because the advance curve of the ignition will be better suited to the higher RPM Ensure that the rev limiter is properly calibrated for the RPM range you wish to operate your engine When choosing a peak operating RPM it is very important to avoid operating an engine at certain RPM s for extended periods For the 587 type engine 6800 RPM is the maximum harmonic imbalance and 7400 RPM for the 657 type If the engines are run constantly at these RPM S serious engine damage may occur The 787 engine is equipped with a balancer shaft to prevent this occurrence Synchronize the carburetors and set the idle according to the appropriate model year Shop Manual then synchronize the oil pump arm At wide open throttle the fuel oil ratio delivered by the oil pump is 40 1 If additional oil is desired pre mix a quantity of oil with the fuel to achieve the desired fuel oil ratio Ensure that carburetors calibration is correct Refer to carburetor s tuning in this section as a tuning guide and reference for available jets Break in your freshly built engine All the meticulous work that you have done could be for little or no gain if the engine is not properly broken in Follow the directions for engine break in procedure as outlined in th
108. mixture is burned thus providing maximum piston thrust Spark occurs as piston approches Top Dead Center 03 18 www SeaDooManuals net SECTION ENGINE PREPARATION Flame front begins 03 19 www SeaDooManuals net SECTION ENGINE PREPARATION Iraverses combustion chamber rapidly 010515 until mixture is completely burnt With all operating parameters correct normal combustion will take place However if for some reason the temperature inside the cylinder is increased during combustion abnormal combustion will occur and lead to serious engine damage 03 20 www SeaDooManuals net SECTION ENGINE PREPARATION DETONATION In detonation the spark plug initiates burning and the air fuel mixture starts to burn in the usual manner but as combustion continues the heat generated affects the large portion of the yet unburnt air fuel mixture This unburnt mixture temperature becomes so high that it burns spontaneously creating high velocity pressure waves within the combustion chamber Regular spark ignites mixture FO1D5GT heat and pressure rapidly build up 03 21 www SeaDooManuals net SECTION ENGINE PREPARATION remaining unburned mixture burns spontaneously These shock waves can sometimes be heard as pinging This pinging is especially detrimental to engines with raised compression ratios While
109. n the modified class If you are using your boat in another racing class later that day inform the inspector he will have you come back after your last race Don t forget to come back The inspector keeps close notes and you will be disqualified if you do not return 12 EMERGENCY RESCUE During the race several Course Marshals will be riding the course watching for missed buoys and fallen riders In the event of an accident and you go down wave your arm over your head if you are OK Other riders can see you easier and the Course Marshal will pull you back to your boat If you are hurt the Course Marshal will be in the water as soon as they reach you At that time the race will be red flagged The Course Marshals will then determine if a backboard is needed Once they get you to shore the EMT will take over and transport if necessary Always make sure that you have all your emergency information written down Designate a member of your team to get this information to the EMT as soon as possible The information sheet must contain your 1 Full name Address and phone number Allergies Blood type Person to contact in an emergency and phone number Insurance company Social Security Number 8 Employer s name and phone number PREPARING FOR A SAFETY INSPECTION On race day you must have your watercraft safety inspected The Technical Inspector will thor oughly check the watercraft for safety requirements The requireme
110. n 01 9 SPONSORSHIP AND 2 2 2 2 2 01 11 THE PROFESSIONALS POINT OF VIEW 01 12 01 1 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION PREPARING FOR RACE DAY ACTIVITIES 1 JOINING THE SANCTIONING BODY All legitimate races are conducted under the guidance of a given sanctioning body The most common being the IJSBA The sanctioning body requires the promoter to meet safety standards and provide adequate insurance coverage for the event You should purchase a rule book from them or join the sanctioning body and receive a free rule book well before you go racing Study the rule book learn the procedures and requirements The rule book will give you strict guidelines as to what is allowed to be done to your vehicle for racing within a particular class The phone numbers to the various sanctioning bodies are located on page VI of this manual Call or write and they will send you an entry form You must however be 14 years old to join If you are under 18 you must request a parental release form that must be signed and notarized by your parent or guardian 2 REGISTRATION Registration for a race should be done by mail several weeks before the event This is the procedure preferred by the race promoter However most promoters not all will also hold late registration the night before or the morning of the race
111. n your mind and make the best possible choice given the circumstances 1 You need to set up where you will receive the greatest amount of exposure to the spectators media and well financed race teams You need to be recognized for your professional appear ance your attention to small details and your finishing position by all of these people Setting up next to large race teams will allow you to watch them and learn from them When people come to see these teams they will also see you 2 You must be able to get your boat to and from the pit area between races This will allow you to service the boat with easy access to your tools In some cases this is not possible because the race site will not allow for it 3 Set up where other racers do not have to go through your pit to get to their boat or the water Your pit area is a reflection on your sponsors as well as yourself You should invest in a tent for your pit as soon as you can afford one Always anchor your tent and do not leave it up over night unless it is very secure The tent should be attractive and of a light color to be cooler A section of indoor outdoor carpet to set your watercraft stand and tool box on can help add a professional appearance Many racers hang banners of sponsors on their tents to advertise their sponsors This can add appeal to your area assuming you don t clutter the tent with too many banners Some racers have designed a small billboard and placed it n
112. nd pop off pressure To adjust the transition circuit change the low speed jet or pop off pressure If a slight lean or rich condition exists while accelerating from just off idle to half throttle change the low speed jet Increasing the jet size will richen the mixture Make any jet changes in small increments of jet sizes If a severely lean or rich condition exists in transition it will be necessary to readjust the pop off pressure Refer to the pop off chart to determine how to change components for pop off adjustment NOTE To accurately check and adjust pop off pressure it will be necessary to use a pop off pump and gauge which are available through your dealer The pop off chart in this section is for approximating pressure only High speed screw adjusts the air fuel mixture in conjunction with the high speed jet for maximum full throttle performance The initial setting for the high speed screw is closed If your are uncertain that this setting will provide enough fuel do not hesitate to start with the screw out more turns Turning the screw clockwise inward will lean the mixture counterclockwise will richen the mixture The high speed screw is effective up to 3 full turns out The plastic cap must be removed for adjustments over 1 4 turn What is manifold pressure and how does it differ from air velocity Manifold pressure is the suction generated by the engine against a restriction the strength of this suction is measure
113. ned pipe allows bleeding fog NOU GN 03 42 www SeaDooManuals net SECTION ENGINE PREPARATION 19 2M sBumy 1 1945 pa1e2o 1916 10 ISD 40 e9 pu 1 002 9504 19 UI asoy 1 9102 91155914 191000 uni 01 peau au jenas JapuljAo 401 902 2966 96 Jedeeq 105095 ainjesodway pe1eaqije 5 03103 SjueuoduiJoo 1009 01 5129 esou edid peun peddois si JO JUIOd 1590 pue asiou 10 526 jsneuxe pe1oefur sjoxyoef pue edid peuni SM0 J 1878M Buipee q edid JO IN3LSAS 214 03 43 www SeaDooManuals net SECTION ENGINE PREPARATION RAVE SYSTEM OPERATION For a 2 stroke cycle engine to have high power capacity at high crankshaft speeds a high volumetric or breathing efficiency is required and the fresh charge losses mus
114. neering 2422 East Huntingdon Duarte CA 91010 Phone 818 357 6310 Fax 818 357 4544 Butchs Watersports 7357 Expressway Ct Suite A Grand Rapids MI 49548 Phone 616 281 7475 Fax 616 281 7515 Moto De Lile 31 Grand Blvd lle Perrot Canada J7V 4V9 Phone 514 453 9663 Fax 514 453 6784 Novi Performance Products 2 Rutledge Circle Fletcher NC 28732 Phone 704 687 7555 Fax 704 687 7556 Rossier Engineering 1340 Okray AV Plover WI 54467 Phone 715 341 8742 Fax 715 341 9875 Watercraft Magic 2264 East Alosta Glendora CA 91740 Phone 818 914 9509 Fax 818 914 6019 Westcoast Performance Products 3100 East Coronado Street Anaheim CA 92806 Phone 714 630 4411 714 630 7670 Contact WCPP for a complete listing of services 05 6 Services High Compression Heads Engine Modifications Racing Hulls and Hoods Carburetor Kits Engine Modifications High Performance Parts Lightweight Hulls Hoods Engine Modifications High Performance Parts Carburetor Kits Engine Modifications High Performance Parts Modified Engines High Performance Parts Carburetor Kits Carburetor Kits Engine Modifications Lightweight Hulls Big Bore Engine Kits Racing Cylinders High Performance Parts Carburetors amp manifolds Exhaust systems Ride Plates amp Grates www SeaDooManuals net
115. ner as the throttle opens each circuit in turn contributes to the total fuel requirements of the engine 03 94 www SeaDooManuals net SECTION ENGINE PREPARATION Transition circuit controls the fuel flow for a smooth transition to the high speed circuit If the transition circuit is far enough out of adjustment it may become difficult to get to the high speed circuit and the engine will not rev up High speed circuit controls the fuel flow in addition to the low speed and transition circuits The high speed screw can control up to as much as 1 2 of the fuel delivered by the high speed circuit depending on the relative size of the high speed jet This adjustability allows for a wide range of tuning without changing an internal jet CARBURETOR TUNING GENERAL The oxygen content of air varies with different atmospheric conditions Cool dry air at a high barometric pressure has more oxygen molecules per cubic foot than does hot moist air at low barometric pressure readings Hot air expands therefore there are less oxygen molecules per cubic foot At low barometric pressure also allows air to expand An increase in altitude results in a decrease in barometric pressure Air with high humidity has more water molecules which take up space so there is less room for oxygen molecules Since oxygen is what is needed to mix fuel to provide a burnable mixture changing atmospheric conditions will require a change in fuel flow JETTING
116. nering skills This type of conditioning has taught me dedication motivation responsibility and self control The lessons have learned have helped me sharpen the skills need to be a competitive racer Racing may not be for everyone because of the commitment involved But for me feel racing brings out the best in me and builds physical endurance knew at my first race as a novice when the rubberband snapped that my life would never be the same again It takes a special individual to pursue an avenue of contrast excitement and disappointment However that s what racings all about Being a Pro Runabout racer is a big responsibility Racing impacts every part of your life feel as does Sea Doo that the image project to others must be positive This includes safety responsi bility and attitude both on and off the race course You must always be a positive role model While racing fear can not be in your vocabulary and challenge you accept on a one to one basis Your striving each day to improve upon the talents that people may think comes naturally My commitment and conditioning to be a Pro Runabout racer has put me up front in my class A class that many people dare not adventure for fear of where it may or may not lead them Take the challenge it may bring out the best in you Kelly Kurpil Pro Woman Runabout Racer 01 13 www SeaDooManuals net SECTION 02 HULL PREPARATION PREPARING THE HULL FOR INSPECTION
117. nts vary slightly from one sanctioning body to another The IJSBA is the most stringent in their requirements The following is a list of items the inspector will evaluate if the race is IJSBA sanctioned 1 Boat numbers and backgrounds must be of the correct size color coordinated and placed in the correct location on the watercraft On Sea Doo watercraft the numbers are required to be on the upper portion of the front deck as close to the storage compartment as possible This allows ease of visibility for the scoring staff The background and boat number colors are determined by your experience level Novice White Numbers Medium Blue Background Expert Black Numbers Yellow Background Pro Black Numbers White Background 01 5 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION Your boat numbers must be at minimum 18 cm 7 inches high and must be spaced 13 mm 5 inches apart Backgrounds must be 20 cm 8 inches high and 15 36 cm 6 14 inches wide depending on the amount of numbers you run Boat numbers will be assigned to you by the IJSBA or in regional events you will be allowed to choose your own number providing the number has not already been selected by another rider Check with the IJSBA or your regional promoter prior to buying or painting numbers on your boat 2 14 15 16 17 18 19 20 The bow eyelet all models excluding the 1995 96
118. o and squish area of the engine 03 98 www SeaDooManuals net 6 SECTION ENGINE PREPARATION Assemble the engine using the correct sealants where specified Rotary valve timing should be correctly set for your application Refer to FUNCTION OF THE ROTARY VALVE INTAKE SYS TEM in this section For maximum power output a dual carburetor set up should be used When converting a single carburetor engine to a dual carburetor type some very important changes need to be made the rotary valve cover intake manifold intake manifold o ring flame arrester and housing throttle cable and other hardware must be changed Also a labyrinth sleave should be installed on the crankshaft PTO side The carburetor from a single type set up cannot be used in a dual carburetor application Check the match of mating surfaces through out entire engine exhaust system Smooth or blend in any mismatched mating surfaces if allowed by your racing association rules ROTARY VALVE TIMING ENGINE TYPE P N OPENING CLOSING DURATION 8 9 10 11 VALVE 657 X dual carb 290 924 502 149 158 717 290 924 502 147 158 787 290 924 502 147 158 The engine should be pressure tested for leakage It should hold 6 PSI for 6 minutes with no more than 1 PSI per minute loss Adjust ignition timing to the recommended advance before Top Dead Center All 92 and 93 engines except the 93 XP 5852 are equipped with a single magneto coil and
119. oil clean the valve periodically Check for clean passages between the exhaust port and diaphragm chamber If cleaning is necessary use solvent to remove the deposits Also check the diaphragm for punctures replace if damaged No special solvents or cleaners are required when cleaning the valve CYLINDER BORING PRECAUTION In its stock configuration the RAVE valve guillotine has a minimum of 0 5 mm 020 in clearance to the cylinder bore measured at the center line of the cylinder This is the minimum production clearance There is only a first oversize piston available It is 0 25 mm 010 in larger in diameter than the stock piston When the oversize is installed the guillotine will have a minimum clearance of 0 375 mm 015 in with the cylinder bore This is the minimum operating clearance the guillotine should be used with Clearance less than 0 375 mm 015 in will require reworking of the guillotine to acheive the proper clearance and radius NOTE When boring the cylinder on the XP 800 watercraft with the 787 model engine the engine displacement will be 785 76 cc s after boring and honing The engine will no longer be race legal for 785 cc class racing In order to maintain legality have your Sea Doo dealer re sleeve the cylinders and install stock diameter pistons FUNCTION OF THE ROTARY VALVE INTAKE SYSTEM Controlling the opening and closing of the intake port is also a critical factor in the volumetric efficiency of an en
120. om the aftermarket manifold manufacturer to help you with the installation and tuning of the BN carburetor system BASIC INSTRUCTIONS 1 Use a new gasket between the carburetor s and intake manifold 2 Use flat washers and lock nuts to secure the carburetor s 3 Be sure that the fuel lines are of the correct diameter for the carb fittings Secure all hose connections with cable ties and proper clamps 4 When installing the throttle cable be sure to securely tighten the jam nuts Allow a small amount of free play at the throttle lever Check to see if the throttle is opened as the handlebar is turned from side to side correct the cable routing if necessary CAUTION Be careful at carburetor cleaning not to remove paint Paint removal will cause carburetor to corrode very rapidly Repaint if necessary CAUTION Heavy duty carburetor cleaner may be harmful to rubber parts O rings etc Therefore it is recommended to remove those parts prior to cleaning 03 84 www SeaDooManuals net SECTION ENGINE PREPARATION EXTERNAL COMPONENTS a 2 E 010705 1 High speed adjuster 2 Fuel return 3 Fuel inlet 4 Pulse nipple 5 Outer venturi 6 Inner venturi 7 Fuel pump assembly 8 Idle stop screw 9 Low speed adjuster 10 Regulator diaphragm high and low speed jets needle valve assembly INTERNAL COMPONENTS At first look the cutaway d
121. on is needed contact a PPG dealer or a Sea Doo watercraft authorized dealer 02 4 www SeaDooManuals net SECTION 02 HULL PREPARATION CONCEPT PAINTING PROCEDURE For additional information refer to PPG P Bulletin no 168 SURFACE PREPARATION Prepare and clean surface consistent with good painting practices PRIMER DP Epoxy Primer DP 401 Catalyst DX 1791 1792 Prime before topcoating PRIMER SURFACER K36 K201 K200 K201 DZ KONDAR Primer Surfacers NOTE KONDAR must sealed before applying CONCEPT color SEALER KTS30 2K Sealer DP Epoxy Primer reduced as a sealer or DAS 1980 or DAS 1987 DIRECT GLOSS COLOR HOW TO MIX Standard Air Dry Mix CONCEPT Color 2 1 1 2 parts color with 1 part DT Reducer best suited to shop temperatures and 1 part DU 4 below 29 C 85 F or DU 5 above 29 C 85 F Hardener Standard Force Dry Mix CONCEPT Color 2 1 1 Application temperatures below 29 C 85 F use DU 5 Hardener above 29 C 85 F use DU 6 Medium Solids MS Application For faster film build when using solid colors mix 2 parts CONCEPT color with half part DT Reducer and 1 part DU 5 or DU 6 Hardener Select the DT Reducer appropriate for shop temperature POT LIFE Pot Life of ready to spray CONCEPT color is 6 to 8 hours at 21 C 70 F Medium solids option is 2 to 4 hours at 21 C 70 F FULL PANEL AND OVERALL REPAIRS APPLICATION Apply 1 medium wet coat and give 5 10 minutes flash foll
122. onson holes location are given for short type For long type it is recommended to experiment to obtain what you require Minor adjustments in angle or height location of the sponson can have a tremendous effect on handling and speed The position illustrated is a good starting point Pro riders experiment with sponson design and location many times before they choose a position or design which is best suited for their riding style Experimenting with location of sponsons is time consuming but necessary Sponsons that are angled with the front too far down will cause the rear of the watercraft to drag in the water Sponsons angled with the front too far up will cause the nose of the watercraft to plow You must find the position that works best for you The one sponson position that keeps the pump in the water in corners without sliding out while not creating excessive down force Sponsons when attached must not exceed the width or length of the bond flange The bond flange is considered the fiberglass joint under the rubber bumper not the bumper Most add on long sponsons will require sanding on the base before attachment to prevent this from occurring HOLE LOCATION IN HULL SHORT SPONSONS The vertical measurement must start from under the top edge of the hull This will avoid mounting the sponson too low FO1L5WS 1 Template on hull A 100 mm 3 15 16 in from hull flat surface B 89 mm 3
123. otary valve uncovers the intake port At the same time the piston blocks the exhaust and transfer ports and compresses the air fuel mixture in the combustion chamber Secondary compression IGNITION AND COMBUSTION FO1D6US 1 Fresh charge As the piston nears the top of the cylinder TDC the compressed air fuel mixture in the combustion chamber is ignited by the spark plug The burning gases expand and push the piston downward thus causing a power stroke 03 48 www SeaDooManuals net SECTION ENGINE PREPARATION EXHAUST AND PRIMARY COMPRESSION 0106 5 1 Fresh charge for the other cylinder 2 Intake port covered As the piston descends the intake port is blocked by the rotary valve and pressure begins to build inside the crankcase primary compression The exhaust port is uncovered as the piston contin ues its course downward and burnt gases are allowed to escape TRANSFER F01D6WS 1 Fresh charge for the other cylinder 2 Fresh charge 3 Intake port covered 03 49 www SeaDooManuals net SECTION 03 ENGINE PREPARATION Near the bottom of the downward stroke the transfer ports are uncovered by the piston and the compressed air fuel mixture in the crankcase rushes into the combustion chamber via the transfer ports Piston dome and combustion chamber configuration and exhaust back pressures prevent fresh charge air fuel mixture from esc
124. owed by 2 wet coats with 15 minutes flash time between each coat Adjust metallic on the last full wet coat If necessary apply a mist coat For medium solids option apply 2 full wet coats AIR PRESSURE 275 345 kPa 40 50 PSI at the gun 02 5 www SeaDooManuals net SECTION 02 HULL PREPARATION DRY TIME dust free 30 minutes tack free 2 to 3 hours tape print free 6 hours dry to handle 6 to 8 hours at 21 C 70 F force dry 40 minutes at 60 C 140 F Faster dry times may be obtained by using 15 mL 1 2 oz of DXR 81 Accelerator per sprayable 1 2 L quart however the pot life is reduced to 2 hours SPOT PANEL REPAIRS APPLICATION Spray medium wet coat of color on the repair area and allow 5 10 minutes flash time Apply 2 additional full coats until hiding is achieved extending each coat beyond the previous coat Flash 15 minutes between each coat For medium solids option apply 2 full wet coats BLENDING Add DT 95 Reducer to a second gun cup Reduce the fluid feed of the gun and lower the air pressure to 207 kPa 30 PSI Dust the dry edge until a slight wet look appears then stop Or mix reduced and catalyzed color with equal parts of reduced and catalyzed CONCEPT DCU 2020 Clear 02 6 www SeaDooManuals net SECTION 02 HULL PREPARATION DELTA PAINTING PROCEDURE with low VOC mainly in California For additional information refer to PPG P Bulletin no 157 SURFACE PREPARATION
125. piston from BDC to TDC It is characterized by a 180 crankshaft rotation COMBUSTION CHAMBER Space between cylinder head and piston dome at TDC DISPLACEMENT The space within the cylinder swept by the piston as it travels from TDC to BDC COMPRESSION Reduction in volume or squeezing of a gas 03 3 www SeaDooManuals net SECTION 03 ENGINE PREPARATION BASIC ENGINE COMPONENTS i FO1D5DS 1 Rings 5 Spark plug 9 Wrist pin 13 Crankcase 2 Cylinder 6 Combustion chamber 10 Rotary valve 14 Crankshaft 3 Cylinder head 7 Exhaust port 11 Intake port 15 Connecting rod 4 Cylinder head cover 8 Transfer port 12 Oil injection pump 16 Piston 03 4 www SeaDooManuals net SECTION ENGINE PREPARATION CYLINDER HEAD A shaped aluminum alloy casting bolted to the top of cylinder It contains the combustion chamber and is designed with a threaded hole to accommodate a spark plug FO1D5AS High performance engines use hemispherical heads with squish areas allowing a better disper sion when combustion occurs FO1D5FS CYLINDER Characterized by the presence of intake exhaust and transfer ports It directs the passage of the air fuel mixture from the crankcase to the combustion chamber A large hole bored through it accepts a piston Through the years Rotax engineers have designed many types of cylinder blocks to attain better engine efficiency 03 5 www SeaDooMan
126. pump ventilation is commonly traced to a poor seal between ride shoe and hull To determine if jet pump is ventilating first verify the following Verify if the watercraft accelerates quickly when depressing throttle lever Verify if the engine has a consistant top RPM Verify impeller impeller wear ring and pump housing for wear and or damage or if debris is caught in the grill or around drive shaft WARNING Before working on or cleaning propulsion system battery black negative cable must always be disconnected If everything is in good order but the watercraft does not accelerate quickly when depressing the throttle lever and a good top speed cannot be obtained the pump is probably ventilating then the ride shoe must be removed and resealed to the hull Refer to appropriate model year Shop Manual NOTE When resealing ride shoe ensure to eliminate any possible flow restriction excessive sealer build up NOTE When resealing ride shoe or pump to hull use Ultra Black Heavy Duty sealer P N 293 800 028 Curing time is greatly reduced with this type of sealer 04 17 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM CAVITATION Cavitation can be defined as a phenomenon where the water inside the inlet or pump becomes incapable of keeping up with the flow Therefore a negative pressure within the system occurs creating gas vapor and ultimately cavitation As these gas vapor bubbles implode they generate eno
127. pwards by the mentioned 1 mm 040 will noticeably decrease pop off pressure Idle stop screw adjusts the idle speed RPM by opening or closing the throttle plate butterfly Refer to your Operator s Guide for the correct idle speed for your watercraft As a rule of thumb adjust the idle to approximately 1100 RPM Low speed screw is used in conjunction with the idle stop screw to maintain idle speed and smoothness Use the low speed screw to adjust the smoothness of the idle Experiment turning the low speed screw in and out in small increments until a smooth idle is obtained As the idle stop screw is turned in or out to raise or lower idle speed the low speed mixture is also affected The 03 91 www SeaDooManuals net SECTION ENGINE PREPARATION low speed screw is very sensitive and adjustments should be made in small increments only For clarification if the idle stop screw is turned out to lower idle speed the low speed air fuel mixture will richen slightly and a small adjustment will need to be made with the low speed screw inward to compensate NOTE To get a good feel for the correct low speed adjustment experiment with the idle stop and low speed screws You will find that a small adjustment with 1 of the screws requires and equal readjustment of the other Correct low speed adjustment will result in improved throttle response Transition circuit is made up of the low speed screw low speed jet bypass holes a
128. r ring Measure each blade at its center Clearance should not exceed 5 mm 020 in If clearance is greater disassemble jet pump and inspect impeller and wear ring Replace worn parts Refer to appropriate model year Shop Manual Remember to stay out of shallow water avoid sand and rocks going through jet pump and damaging wear ring Scratches in wear ring reduce efficiency 04 9 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM IMPELLER IDENTIFICATION To identify the impellers refer to the following illustration and charts me XXXXXXX gt FO1J4LS 1 Stamped part number 04 10 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM IMPELLER APPLICATION CHART NUMBER in degrees NUMBER Lm 18 8 aluminum 271 000 016 7 a 18 3 stainless 271 000 123 Gr sme 1 7 s ___ w 7 Cex o 195 en 1996 O NOTE Impeller may be interchangeable to suit the required performance of the course type 04 11 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM IMPELLER SPECIFICATIONS AND BOOT APPLICATIONS IMPELLER P N IMPELLER SPECIFICATION BOOT P N 2 271 000 015 271 000 028 18 cast aluminum 293 300 015 O ring 271 000 086 18 die cast aluminum 271 000 114 271 000 235 18 die cast aluminum 271 000 114 271 000 052 17 satin finish stainless steel 271 000 055 271 000 215 17 satin finish stainless
129. r easier reading After your hull number is recorded the inspector may make a series of visual inspections inside and outside the hull to verify class legality or to see if safety requirements have been met The inspector may use a paint type seal on various areas of the engine to prevent a rider from going into the engine and removing illegal parts that may have been used for qualifying If after the race something goes wrong which requires you to break a seal to perform service take your boat to the inspector before breaking the seal You will then be able to perform repairs at tech This will allow the inspector to check the parts coming out for legality and he will be able to apply a new seal upon completion www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION After your final moto you will then return to tech for verification of hull and seal authenticity At this time the inspector may require the top 3 finishers to disassemble various parts of the engine for close inspection You and one mechanic will be allowed in tech to disassemble the required items You will not be reimbursed for any cost of gaskets etc If you refuse tear down you will be disqualified In limited classes usually the technical inspector has you remove the rotary valve housing in order to check for an illegal rotary valve Also the head may have to be removed to check for porting in limited classes or bore and stroke measurements for displacement limits i
130. rawing see next page appears somewhat straight forward but some interesting things appear as you study it Follow the fuel flow through the low speed circuit Fuel flows through the low speed jet and then is divided with part of the fuel being metered by the low speed screw An additional route the low speed fuel takes is through the by pass holes transition circuit Fuel is drawn through the by pass holes as the throttle is opened and the butterfly valve exposes them to the air flow The ability for fuel to pass through the low speed circuit and its transition is controlled first by pop off pressure then by the size of the low speed jet NOTE If the low speed jet size is changed it affects the mixture both at idle speed and off idle Viewing the high speed circuit notice that fuel is divided at the high speed jet so that even if the high speed screw was fully closed fuel would still pass through the jet The fuel flow chart illustrates the adjustability of total fuel flow with the high speed screw It is possible with the Super BN to adjust the desired fuel flow with the screw closed by changing the size of the jet alone In this way if the screw was used later the fuel mixture could not get lean enough to cause an engine seizure 03 85 www SeaDooManuals net SECTION ENGINE PREPARATION Trace to the needle valve and notice the relationship between the spring and the needle The spring exerts pressure through the arm onto t
131. ring practice If your boat needs tuning it is due to poor preparation on your part Go to a designated free riding area so that you can devote your thought to tuning and not negotiating the course or another rider 7 RACE AND RESULT POSTING The pit board will be posted before practice or shortly afterward Now is the time to make sure you have been placed in the correct class and that your boat number is listed correctly If you find any discrepancies see the Chief Scorer or Race Director immediately Write down the race number that you are in note the designated number of finishing boats that transfer to the final event All transfer positions must report to tech inspection after the race If you do not transfer during your heat race then you will be placed in the LCO Last Chance Qualifier race In the LCO only the top 1 or 2 riders will transfer Know what the cut off point is for transfer positions and what race number the is In some cases heat races will not be necessary due to a low rider turnout for your class In the event that this is the case you will normally run 2 races called motos You will be scored on each race and the combined totals will be your overall score After your race the official results for your race will be posted within 15 minutes If there is a mistake see the Chief Scorer or Race Director at this time 8 STAGING FOR THE RACE When you come to the line for your race you will be lined up on the startin
132. rsonal information such as name age address marital status schooling completed occupation etc Next you should list your future goals as a water craft racer This section should be concise and to the point It should outline your short term and long term goals After your statement of goals list all the races you have competed in complete with your finishing positions and overall titles Conclude your resume with a listing of your previous sponsors their product line and any major media coverage that you have received that would be advantageous for a sponsor to know The complexity of your sponsorship proposal will vary quite noticeably depending upon the level of racing at which you are competing Racers who are competing in regional events or are well back in the standings on the National Tour are not able to get the high dollar support that requires an exhaustive detailed proposal Most proposals should list the various levels of support that are available for the sponsor within your racing program Each level of support should be followed by a statement of the service you will provide for that support There are many ways a sponsor can support your racing program and there are many services you can provide for that support Types of support can include 1 Products such as racing equipment for your boat racing apparel safety equipment or transport equipment trailers totes 2 Services including repair work or modific
133. s a single mindedness evident in the racers that have seen become champions In nearly every case this factor was evident from the very first In conclusion the riders that am looking for have demonstrated a level of intensity and dedication that makes them noticeably different from the majority of other competitors These traits coupled with physical condition coordination and courage are the qualities that will take them to the top in whatever sport they chose to compete in Ken Clark Pro Racing Team Manager Westcoast Performance Products 01 12 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION Jeff Prieur and Kelly Kurpil are two of the top Professional Sea Doo racers in the world Each were asked to give their point of view concerning their racing careers Most people that race Personal Watercraft seem to share the same goal That goal is to be the fastest on the track and to someday become a Professional What does it take to be a Pro racer Is just being a fast racer enough to make you a candidate to be a Pro The answer No There are a lot of different aspects of being a Pro which include training diet and mind control To be at one with your craft to have a certain confidence not to be confused as cockiness and to be able to make everything you do look easy In my years of racing l ve seen many talented riders come and go The racers that prevailed had one thing in common PERSEVERANCE
134. s damage to any of the mating surfaces on the carburetors intake manifold rotary valve cover or damage to any of the gaskets or o rings a lean mixture condition will occur causing poor engine performance and serious engine damage 03 17 www SeaDooManuals net SECTION ENGINE PREPARATION f CYLINDER BASE GASKET If omitted or incorrectly installed could lean the air fuel mixture and result in poor engine performance and serious engine damage g CRANKSHAFT OIL SEALS If omitted cut or incorrectly installed could lean the air fuel mixture and result in poor engine performance and serious engine damage h CRANKCASE HALVES If sealed joined incorrectly could lean the air fuel mixture and result in poor engine performance and serious engine damage COMBUSTION PROCESS NORMAL COMBUSTION Since the beginning of this study we have spoken of air fuel mixture combustion rather than explosion This combustion is a slow then accelerated burning of the mixture within the combus tion chamber It is not an explosion Ignition occurs with the firing of the spark plug This initial process generates heat and pressure which in turn is transmitted by conduction to the contiguous portion of the unburned mixture When this portion has reached the point of self ignition it starts to burn releasing more pressure and heat This burning action called a flame front travels at a speed of approximately 30 m 100 feet per second until all
135. s of crankshaft rotation by the appropriate formulas Initial ignition timing procedures can be found in the appropriate model year Shop Manual When working with modified engines it may be necessary to alter ignition timing from stock specifications to achieve maximum power output or to prevent engine damage Select a fuel that meets the octane requirement for the compression ratio of your engine REFER TO OCTANE REQUIREMENTS FOR ROTAX ENGINES Once you have chosen the fuel you will be tuning the engine IGNITION TIMING for maximum efficiency for that fuel If you change to another brand of fuel or a different octane it will be necessary to re tune the engine Failure to do so may cause engine damage or power loss 03 73 www SeaDooManuals net SECTION 03 ENGINE PREPARATION NOTE For initial tuning it is recommended that you test using 1 heat range colder spark plug than stock If upon completion of tuning the center insulator shows excessive carbon deposits go back to the stock heat range spark plug If you have increased the engine compression the fuel mixture will normally burn at a faster rate Because of this effect combustion chamber pressure may peak sooner than desired If this occurs the engine will over heat leading to detonation and extreme engine damage Because of these possibilities it is recommended that you pay particular attention to your spark plug readings during your initial tuning If there are any signs of over heat
136. s will usually be more audible at specific throttle positions Do not hold the throttle at these positions for any longer than absolutely necessary i e just the amount of time required to identify verify that there is a problem 03 23 www SeaDooManuals net SECTION ENGINE PREPARATION timed spark occurs 03 24 www SeaDooManuals net SECTION 03 ENGINE PREPARATION flame front spreads and collides with pre ignited portion of mixture 010505 Please consult section Causes of detonation on the next page for possible causes and begin diagnostic process to correct this condition before serious damage occurs to your engine 03 25 www SeaDooManuals net SECTION ENGINE PREPARATION ll mixture is burned FO1D5PS Usually the piston is subject to damage It may seize or the aluminum on the exhaust side of the piston dome may melt Pre ignition is always preceded by detonation CAUSES OF DETONATION Octane of the fuel is too low for compression ratio 2 Air fuel mixture is too lean incorrect jetting air leaks varnish deposits in carburetor malfunction anywhere in fuel system 3 Spark plug heat range too hot Ignition timing too far advanced initial timing off ignition component failure 5 Compression ratio too high for fuel being used improperly modified engine deposit accumulation on piston dome or head
137. sest to the engine jacketed with water and the remainder of the exhaust system cool by injecting water directly into the exhaust stream Injecting water into the exhaust system not only helps keep the exhaust system cool but also changes the characteristics of the sonic wave in the tuned pipe The water injected exhaust system reduces exhaust gas temperature therefore increasing exhaust gas density in the tuned pipe The sonic wave moves slower in this cooled denser air so it takes longer to reflect back to the exhaust port The net effect is that the tuned pipe can be shorter yet achieving the same results as a longer dry tuned pipe By changing the amount of water injected into the exhaust stream the characteristics of the engine power band can be altered It is important that enough water is injected into the exhaust stream to keep the rubber hoses and muffler from damage due to excessive heat In Limited Class racing an aftermarket exhaust pipe and manifold are allowed The water box or muffler however must remain stock with no modifications When purchasing an aftermarket pipe consult the manufacturer of the pipe to determine if the pipe is race legal by your race sanctioning body IJSBA Some pipes will fit your craft but may not be race legal because of inadequate head pipe cooling or mounting of the pipe requires relocation of the waterbox Waterbox relocation is illegal by several sanctioning bodies for Limited Class racing XP 800 E
138. spots on the surface as shown below 051018 1 Place straight edge at difference locations as shown shadow areas 2 Not necessary to true beyond this point 02 2 www SeaDooManuals net SECTION 02 HULL PREPARATION TRUING THE HULL Truing the hull means to make the hull as straight as possible This will help you gain maximum performance and top speed Follow these steps and you will attain a good racing hull Special tools and materials may be required to perform this work REQUIRED TOOLS AND MATERIALS pneumatic long sander long flat sander long board dual action sander sandpaper epoxy fairing compound found at marine supply store NOTE It is not recommended to use bondo or auto body filler as it is less durable and can absorb water A compound with fiberglass particles in it will be very hard to sand flat and true if proper techniques are not observed PROCEDURE a Remove intake grate b Mask off body and ride shoe Accurately place masking tape down in seam where aluminum ride shoe meets relief in hull c Carefully sand each section by hand using the long board sander This will help to indicate the low high spots along the hull surface Be careful not to remove excess material 3 FO5L01T TYPICAL 1 Shadow areas indicate possible high spots 2 Strakes 3 Corner to be reinforced d Using the
139. steel 271 000 114 271 000 046 17 7 polished stainless steel 271 000 069 271 000 199 17 7 satin finish stainless steel 271 000 069 271 000 227 17 7 satin finish stainless steel 271 000 114 271 000 123 18 3 satin finish stainless steel 271 000 114 271 000 115 19 0 satin finish stainless steel 271 000 114 271 000 230 16 20 5 progressive pitch satin finish stainless steel 271 000 114 271 000 182 14 21 progressive pitch satin finish stainless steel 271 000 104 271 000 313 271 000 016 18 8 Cast aluminum 271 000 114 271 000 030 14 21 progressive pitch satin finish stainless steel 271 000 114 271 000 299 14 20 progressive pitch satin finish stainless steel 271 000 114 271 000 307 16 24 progressive pitch satin finish stainless steel 271 000 305 271 000 280 15 21 progressive pitch satin finish stainless steel 271 000 305 271 000 331 progressive pitch satin finish stainless steel 271 000 104 271 000 313 ring 271 000 367 11 21 progressive pitch satin finish stainless steel 271 000 104 271 000 313 ring 271 000 416 15 21 progressive pitch satin finish stainless steel 271 000 104 271 000 313 ring 271 000 417 10 22 progressive pitch satin finish stainless steel 271 000 422 271 000 434 ring 271 000 445 11 21 progressive pitch satin finish stainless steel
140. t are equipped with a total loss cooling system The water supply is taken from a pressurized area in the pump between the impeller and venturi The water passes through a tee where a small amount is diverted into the exhaust stream refer to WATER INJECTED EXHAUST SYSTEM in this section and the majority continues into the exhaust system cooling jacket to be warmed before entering the engine On the 1988 91 engines water enters at the bottom of the exhaust manifold and tuned pipe cooling jackets then to the engine On the 1992 96 engines excluding the 717 and 787 X engines the water enters the cooling jacket on the tuned pipe and travels into the cooling jacket around the exhaust manifold after which it enters the cooling jackets of the cylinders through small passages under the exhaust ports The flow of water through the exhaust system has changed slightly from the 1988 91 yellow engines to the 1992 96 white engines however the most important point is that on either type of engine the water is still pre heated by the exhaust system before entering the engine cooling jackets On the 1995 96 717 and 787 X engines the water first enters the cylinder head unlike previous models The cylinder head cooling jacket has been divided into 2 sections One side of the head s water jacket exhaust side has cool incoming water circulate around the combustion chambers then into the tuned pipe and exhaust manifold cooling jacket The preheated water then
141. t be minimized The result is achieved by opening the exhaust port early and utilizing the resonant effects of the tuned exhaust system to control fresh charge losses When an engine of this design is run at a high speed efficiency falls off quickly The relatively high exhaust port effectively shortens the useful power stroke and because the exhaust system is tuned for maximum power there is a large increase of fresh charge losses at lower speeds As a result the torque decreases along with a dramatic increase of the specific fuel consumption Higher torque along with lower fuel consumption can be obtained at lower engine speeds if the time the exhaust port is open is shortened Bombardier Rotax has patented a remarkably simple system to automatically change the exhaust port height based on pressure in the exhaust system Located above the exhaust port is a guillotine type slide valve This rectangular valve is connected by a shaft to a diaphragm which is working against a return spring Two small passages in the cylinder just outside the exhaust port allow exhaust gas pressure to reach the diaphragm To the outside of the return spring is a red plastic adjustment knob Turning the adjustment in or out changes the preload on the return spring which in turn will change the RPM at which the RAVE valve opens and closes A18C01S Sliding Valve Diaphragm Spring Exhaust Port Adjustment Knob ARON gt As the throttle is
142. t operation If you are not absolutely sure how to accomplish an adjustment or procedure outlined in your service manual please have your local authorized SEA DOO Dealer perform the task The handbook also provides information on race day activities rider presentation general racing practices sponsor solicitation and other useful tips to successful racing Some Sea Doo watercraft may need to be altered from their stock configuration even in the stock class in order to meet racing guidelines established by race sanctioning bodies It is important to refer to the racing rule book for direction When racing do so within the confines of the official race meet Do not disturb other boaters or others using the waterway Keep your SEA DOO watercraft legal Good Luck and success in your race Bombardier Inc www SeaDooManuals net TABLE CONTENTS PAGE cec VI RACE SANCTIONING ASSOCIATIONS eene VII SECTION 01 GENERAL RACING INFORMATION PREPARING FOR RACE DAY 5 2 0 22222241 01 2 PREPARING FOR A SAFETY INSPECTION eene 01 5 PRE RACE MAINTENANCE LIST ettet ttt tette 01 7 EQUIPMENT AND SPARE PARTS TO BRING TO THE RACE 01 8 PIT AREA PRESENTATION ettet tentent tet ttt tet ttn 01 9 INTERACTION WITH RACE OFFICIALS
143. t port just closed 5 T D C AKRON V Efficient stroke Following is a guideline for compression ratio and how it should relate to combustion chamber squish band clearance It is very important that the compression ratio and squish band clearance should be the same for both cylinders of any given engine PRODUCTION ENGINES Uncorrected compression ratio 11 5 1 engine type 587 12 2 1 engine type 657 12 25 1 engine type 717 11 75 1 engine type 787 Squish clearance 1 30 mm 1 70 mm 051 in 067 in engine type 587 1 00 mm 1 40 mm 039 in 055 in engine type 657 1 30 mm 1 70 mm 051 in 067 in engine type 717 1 30 mm 1 70 mm 051 in 067 in engine type 787 PREPARED ENGINES Uncorrected compression ratio up to 14 5 1 Squish clearance 1 00 mm 1 60 mm 039 in 063 in engine type 587 0 80 mm 1 40 mm 031 in 055 in engine type 657 1 00 mm 1 60 mm 039 in 063 in engine type 717 1 00 mm 1 60 mm 039 in 063 in engine type 787 CAUTION Reducing squish area may require using higher octane fuel as well as retarding ignition timing 03 30 www SeaDooManuals net SECTION ENGINE PREPARATION SQUISH AREA Rotax rotary valve cylinder heads incorporate a squish area This area is basically a ledge projecting beyond combustion chamber area In operation as the piston ascends and approaches the ledge a rapid squeezing action is applied to the air fuel mi
144. tem should the fuel tank level be lower than a quarter full 03 96 www SeaDooManuals net SECTION ENGINE PREPARATION BREAK IN PROCEDURE When preparing an engine for racing many details must be made exactly to specification to achieve the maximum performance To obtain the most benefit from your labor and money a proper break in is essential The proper break in procedure allows all of the rough metallic surfaces to slowly begin to fit each other resulting in minimum friction loss and maximum power output The importance of this procedure should not be underestimated With Bombardier Rotax watercraft engines a break in period is required before operating the engine at full throttle Engine manufacturer recommendation is about 10 operating hours During this period maximum throttle should not exceed 3 4 however brief full acceleration and speed variations contribute to a good break in Continued wide open throttle accelerations prolonged cruising speeds and overloading the engine are detrimental during the break in period To assure additional protection during the initial engine break in 250 ml of SEA DOO INJECTION OIL should be added in the fuel tank for the first full fuel tank filling only ve Replace spark plugs after engine break in RECOMMENDED OIL On the 95 and 96 Sea Doo XP and HX models use only SEA DOO FORMULA XP S SYNTHETIC INJECTION OIL All other Sea Doo watercraft can use SEA DOO INJECTION O
145. ting All fuel lines must be secured to the carburetor and fuel tank with clamps or zip ties Fuel injected engines must have approved high pressure fuel lines There can be no fuel leaks of any type Flame arresters must be USCG approved and not modified Electrical components must be properly wired insulated and routed away from high tempera ture components Decals that are required to be placed on the boat by the sanctioning body promoter or sponsor will also be checked You will be required to show your USCG approved floatation device and approved full face helmet without face shields at this time The sponsons on the Stock Sea Doo XP and GT models protrude beyond the width of the hull bond flange Because of this it is necessary that the sponsons be filed or ground down to fit within the bond flange in order to be race legal NOTE The inspector will place a small decal on your boat upon satisfactory completion of the inspection If you are competing in a multi day event the inspection will be valid for the entire event www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION PRE RACE MAINTENANCE LIST The following items should always be checked when preparing for an upcoming race 1 Check the engine compression If the compression is low or the variance between cylinders is greater than 10 psi determine the cause and remedy the problem Check the torque on the cylinder head bolts Put in new spark plugs
146. tools to accomplish the service procedures that they are capable of performing themselves The following is a list of parts and equipment that are recommended for you to have on hand for quick repair when needed 1 Spark plugs A complete gasket and o ring set Two sets of piston rings Two flywheel keys Extra exhaust couplers A roll of fuel and water line A throttle and steering cable A fuel filter A carburetor rebuild kit A starter motor An ignition coil and multi purpose electronic module A fully charged battery and jumper cables Quick drying epoxy or fiberglass repair kit Various size hose clamps Zip ties of assorted sizes Safety wire Duct tape and electrical tape Waterproof silicone sealer Assorted nuts and bolts 20 A grease gun with grease o 0 089 O ON Oo 5 C N 01 8 www SeaDooManuals net SECTION 01 GENERAL RACING INFORMATION PIT AREA PRESENTATION Your pit area is of major importance in many ways Race teams that are well financed actually pay the promoters to place large tents with sponsor names on them at the most advantageous locations on the beach This allows them greater media exposure by film crews and easy access to the water for their racers For these same reasons and more your pit location is just as important Your choice for pit location should be based on the following factors Weigh these factors i
147. uals net SECTION ENGINE PREPARATION 010505 PISTON A shaped cast aluminium alloy plug made to fit inside the cylinder bore It is attached to the crankshaft by a connecting rod and wrist pin FO1D5RS The piston serves 3 purposes 1 Transmits combustion expansion forces to the crankshaft 2 Acts as a valve for the opening and closing of exhaust and transfer ports 3 Retains piston rings which seal the bore Heat flows into piston bosses on normal circular piston center causes distortion to oval left If oval turned right distortion converts to circular shape FO1D6CS 03 6 www SeaDooManuals net SECTION ENGINE PREPARATION The piston is manufactured out of round the reason being that wrist pin bosses have a greater volume of metal than the other sections of the piston and consequently will absorb more heat The greater the absorption the greater the area will expand Under normal operating tempera tures the piston expands and assumes a more rounded shape PISTON RINGS Expanding rings are placed in the grooves immediately below the piston dome They seal the piston and cylinder wall Within each ring groove is a small pin that provides a locating point for the ring ends This pin prevents the ring from rotating around the ring land Without it rings would catch on the port edges and piston ring breakage would occur When instal
148. ugh force to remove microscopic particles of material within the pump assembly This usually can be seen in the form of discolored areas or trails within the pump assembly on the stator vanes or impeller These areas look as though they have been sand blasted A certain degree of cavitation is an accepted occurrence with a water jet propulsion system However some changes within the pump can reduce cavitation such as replacing a thick bladed aluminum impeller with a thin bladed stainless steel impeller removing any scratches or dents in the housing impeller or replacing wear ring if worn Chamfer and or radius leading edges of stator vanes Using a straight file break the square edge on both sides of stator vane to about 1 3 mm 050 in wide then use about a 2 foot strip of 1 inch wide sandpaper 100 grit min and drape sandpaper over stator vane area already filed by placing 1 end of sandpaper in 1 tunnel and the other end in the tunnel directly adjacent to the first and finish dressing the leading edge This procedure should be done to both the leading and trailing edges of stator vanes 04 18 www SeaDooManuals net SECTION 04 PROPULSION SYSTEM F01J4MS 1 Reworked vanes 2 Tunnel 3 Break these edges slightly 4 Be careful not to make a sharp or square corner in these areas It is important to realize that water conditions and repeated accelerations will increase cavitation Verify if engine speed is high but water
149. unterclockwise to reach the position listed in the chart Before Top Dead Center IGNITION TIMING CHART FO1H31S 1 Tool slot 2 Flywheel mark This mark becomes the reference when using stroboscopic timing light CAUTION Timing mark position verification cannot be used as a timing procedure therefore always check the timing with a stroboscopic timing light at 6000 RPM after the marks have been checked 03 76 www SeaDooManuals net SECTION ENGINE PREPARATION CHECKING IGNITION TIMING NOTE To perform this procedure it is recommended to use a stroboscopic timing light rated to work up to 6000 RPM To check ignition timing use a timing light P N 295 000 078 NOTE This timing light is battery powered and therefore needs no auxiliary power source The ignition components are affected by temperature variation therefore timing must be checked when engine is cold after MAXIMUM 20 seconds idling PROCEDURE Connect timing light pick up to MAG side spark plug lead FO1H2IS 1 Timing light pick up on MAG side Connect an induction type tachometer to spark plug wire Start engine and point timing light straight in line with timing tool slot Bring engine to 6000 RPM for a brief instant NOTE On this NIPPONDENSO system timing advance decreases as engine speed increases When marks are aligned at 6000 RPM spark occurrence is still before Top Dead Center Check if PTO flywheel
150. valve shaft Apply grease to hold solder in position Reinstall cover in place WITHOUT its o ring and torque screws 20 Nem 15 Remove cover then clean and measure compressed solder thickness it must be within the specified tolerance fe U FO1D3PS 1 Solder 03 52 www SeaDooManuals net SECTION ENGINE PREPARATION DEPTH MICROMETER METHOD Remove rotary valve cover Using a depth micrometer measure the distance from the crankcase rib to the valve surface of the crankcase Measure at 4 different places F01D30S 1 Valve surface 2 Rib Add the 4 measurements and divide by 4 to obtain an average A typical reading should be around 3 5 mm 0 138 in 03 53 www SeaDooManuals net SECTION ENGINE PREPARATION Using the depth micrometer again measure the distance between the rotary valve cover seating surface and the valve surface of the cover 010305 1 Valve surface 2 Cover seating surface 3 No burrs A 2 67 x 0 25 105 001 in B 1 0 03 mm 039 001 in Measure at 4 different places around the cover Add the 4 measurements and divide by 4 to obtain an average A typical reading should be around 2 67 mm 105 in Knowing that the tickness of the rotary valve is 58 mm 023 in the clearance between rotary valve and rotary valve cover can be found using the following formula EXAMPLE Crankcase rib depth 3 50 mm Depth
151. vs quickly and air velocity increases to accelerate you on your way Now you can see the importance of the transition circuit it is there to aid in the transition from high manifold pressure to high air velocity Correct adjustment of the transition circuit is vital to smooth acceleration and good performance 03 92 www SeaDooManuals net SECTION ENGINE PREPARATION TESTING POP OFF PRESSURE FO1BOXS Pop off Pump with gauge P N 295 000 114 Testing pop off pressure requires a small pump used in conjunction with an air pressure gauge such as the Bombardier Pop Off Gauge P N 295 000 114 The gauge should be calibrated in at least 1 2 PSI increments and read up to 30 PSI The readings taken from the gauge are used for comparison before and after changes so the actual accuracy of the gauge is not critical The pop off pressure chart in this section shows very accurate PSI values between needle valve sizes and spring pressures Before making any changes in pop off test your carb and see how it compares to the chart STEPS IN TESTING 1 Attach the pump hose to the fuel inlet on the carb 2 Cover or in some way completely plug the fuel return line 3 It is recommended that the regulator diaphragm and its cover be removed during testing 4 During testing it is important to obtain consistent readings To accomplish this it is necessary to keep the needle valve wet Use Sea Doo lube P N 293 600 006 to wet the needle va
152. water jet drive system As the impeller begins to turn with the rotation of the engine it will move a volume of water through the pump housing into the venturi section or venturi As the volume of water is forced through the smaller cross section it will be accelerated in flow thus creating thrust or forward propulsion However the volume in and volume out remain the same While the venturi section of the pump is not technically impressive or complicated in appearance its simple shape and diameter are very crucial to pump performance A small increase of the venturi outlet diameter will reduce watercraft top speed but improve acceleration at lower speeds Conversely a small decrease in venturi outlet diameter will reduce low speed acceleration but improve top speed After exiting the venturi the water passes through a steering nozzle where it can be directed right or left to turn the watercraft Understanding the basic function of a jet pump should make it easy to realize that steering control is only accomplished under thrust Steering control at lower speeds or idle is minimized Always keep in mind that as the throttle lever is released less directional control will be available To control or steer the watercraft throttle must be applied AXIAL FLOW PUMP The Bombardier Formula Jet pump is an axial flow single stage design This term axial flow is defined as a single impeller axially driven by a centrally located shaft The impeller w
153. words the indirect positioning of the transfer port openings in the cylinder creates an upward swirling movement of the air fuel mixture This swirling action is in general limited to the sides of the cylinder wall FO1D6LS Flushing action of transfer flow the fresh mixture staying close to the walls of the cylinder expels the burnt gases without mixing with them and or causing turbulence When this upward swirl reaches the cylinder head dome it attempts a downward inward move ment However since the piston is also ascending at the same time a vortex type of effect occurs This vortex retains the air fuel mixture in the upper part of the combustion area therefore burnt exhaust gases are completely expelled by the vortex pressure and upward movement of the piston By doing this the large volume of air fuel mixture taken into the engine during intake is wholly retained inside the engine and not partially expelled with the exhaust Combustion therefore is with a completely fresh charge BOOST PORT The boost port or finger port as occasionally referred to is a cavity in the wall of a cylinder The prime purpose of this port is to assist the clearing of burnt gases from the combustion chamber In doing so it allows a fresher charge for the next combustion phase and at the same time cools the piston dome This port comes into function after the third phase of engine operation or during the transfer stroke of
154. xture contained in the area immediately between the piston dome and the ledge This squishing action forces the entrapped mixture rapidly into the combustion chamber area creating a greater mixture turbulence Addi tionally the small volume and large surface area of the squish band allow a better cooling of the end gases to help prevent detonation F01D5WS 1 Squish area If the squish clearance is increased a loss in power will occur while too small a squish clearance will lead to detonation The squish clearance can be measured by inserting a piece of resin core solder into the combus tion chamber rotating the engine through Top Dead Center removing the solder and measuring the thickness of the compressed solder The solder should be inserted above and in line with the wrist pin 03 31 www SeaDooManuals net SECTION ENGINE PREPARATION 010645 1 Solder 2 Measure here not use acid core solder acid damage piston and cylinder NOTE If you are machining your cylinder head to increase compression ratio be sure to respect proper squish band tolerances in the machining process OCTANE REQUIREMENTS FOR ROTAX ENGINES Following is a set of guidelines for a suggested relationship between uncorrected full stroke compression ratio combustion chamber squish band clearance and octane requirements for an engine built to compete in racing These are only suggested gui
155. y researching carburetor tuning applications and dissemi nating this information to the consumer In the past jetting information was available through many different sources but unfortunately there were as many different recommendations as there were sources With this information we will be able to provide a reliable and consistent source of approved technical details 03 83 www SeaDooManuals net SECTION ENGINE PREPARATION CARBURETOR INSTALLATION FO1F29S Mikuni Super BN38 mm Dual Carburetor Set for high performance applications CAUTION Exercise caution when changing carburetion components and any time you work with the fuel system on your watercraft Work in a well ventilated area Do not turn the engine over while fuel lines are disconnected Immediately clean up any fuel spill that might occur during carb installation NOTE As when installing any performance product a degree of mechanical ability is required If after reviewing the parts and instructions you do not feel that you can properly complete this installation take your watercraft to a competent professional Proper installation and adjustment will save time money and aggravation NOTE In most cases your new Super BN Carburetor will be installed in conjunction with an aftermarket manifold and flame arrestor air filter system We recommend using this manual together with the appropriate model year Shop Manual for your watercraft and the instructions fr
156. ype LUBRICATION NOTES Fuel Mixture Oil Type Timing Spark Plug Rev Limiter Setting Impeller Pitch Material Intake Grate 05 4 www SeaDooManuals net SECTION 5 MISCELLANEOUS AFTERMARKET MANUFACTURERS AND SERVICES Aftermarket manufacturers produce products that can be used to replace the original Sea Doo part on your watercraft Some of these parts are designed to simply give the operator a choice of color or styling while others are intended to improve the performance characteristics of the vehicle Sea Doo has encountered many manufacturers of aftermarket parts that have made claims about their product that later could not be validated Some products actually had an adverse affect on performance over the production item or caused vehicle damage It must also be noted that Sea Doo can not verify every product claim made by manufacturers due to the constant development of new aftermarket products Sea Doo has found the following aftermarket manufacturers have proven their products to be reliable and of high quality We recommend these manufacturers based on their previous performance records Sea Doo takes no responsibility for products not installed as original equipment In fact most applications of aftermarket parts invalidates the vehicle warranty as provided for by law USE AT YOUR OWN RISK 05 5 www SeaDooManuals net SECTION 05 MISCELLANEOUS Manufacturer Bullett Engi

1996 SeaDoo Racing Handbook

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