Sea-Doo Explorer 1995 Operator Guide

% SAFETY WARNING Disregarding any of the safety precautions and instructions contained in this Operator's Guide, the Safety Handbook and on yVarning Labels could cause injury, including the possibility of death. This Operator's Guide and the Safety Handbook should remain with the jet boat at the time of resale. AFTER SALES SERVICE The following trademarks are property of BOMBARDIER INC. VALCOURT (QUEBEC) Bombardier Inc. : CANADA JOE 210 SEA-DOO® Sea-Doo Lube® Sea-Doo Jet Pump Synthetic Oil Sea-Doo Synthetic Grease Gelcote® is a trademark of Gelcote International Litho'd in Canada All rights reserved © 1994 Bombardier Inc. Doin'it on your new Sea-Doo Explorer Jet Boat Congratulations, you are now the proud owner of a jet boat. Whether you are an experienced boater or are new to the sport of boating, we ask you to take the time to read this Operator Guide ana familiarize yourself with its contents. The Guide contains pertinent information which, if followed, will provide you with the necessary knowledge to help you fully enjoy the pleasures of this craft. We strongly recommend that any boat operator complete a safety boating course. Check with your local Coast Guard or Power and Sail Squadron in your area for course availability. More serious boaters may want to obtain "Chapman Piloting’ by Elbert $. Maloney, available at most book stores. When introducing your family or friends to the sport, be sure they fully under- stand the controls and operation of the jet boat and the importance of courteous, responsible riding. Each jet boat operator has a responsibility to ensure the safety of its passengers and other water users. Please follow all safety instruction and drive with care. Finally, we invite you to visit your dealer for regular safety maintenance as well as any boating accessories you may require. Have fun and .....Bon Voyage. TABLE OF CONTENTS FOREWORD. ....uuussssensnansnnonsnunnunsnnnnnnennnununnsuonanssnnunnnannnnnnnnensnennnnnnsenanerensansnunnnnrrenn 4 © SAFETY WARNING oui... ccccccsccssccccccccccesseececscereeeeseeesnaanuenenaeeessennesceassesssssvensaas 5 LIST OF DISTRIBUTORS .............sss2nunnunnnnenonunnuennnnnnnnnnunnnnanenenennnnnnnnnnnnnonsnnennnnnen 8 THE 1995 BOMBARDIER JET BOAT LIMITED WARRANTY ......... „+. 9 WARRANTY QUESTIONS AND ANSWERS ...0onccccooconcconnnnnnncornrocaninonanononnacannnnas 11 REGISTRATION NUMBER LOCATION ...........::.::00 неона rro non rr non ran rrrrrnanianias 13 LOCATION OF THE IMPORTANT LABELS o.00rcccccnnccccccnncnnoccccnnncacacoconnnanacoscononns 14 JET BOAT IDENTIFICATION .........u200r0s@n0nnennnunnenonnnnnnnnnnnnnonnnnnnsnnanensonssunnnnnasannaenn 15 Hull Identification Number... sise 15 Tube Identification Number Ses 15 Jet Boat Model Number issue 15 Engine Identification Number ss 15 COMPONENT FUNCTIONS .......ccccccsssecsscsserecsceenessssseeeesceneesaasessnpenreunaanenenpeseeeoes 16 FUEL AND LUBRICATION .....ssuosannnnnennennonnnnnnnnnnnnennonnnenunanennonnnnennnnnnnennnanununnernen 25 Fueling Procedure ини 25 Recommended Fuel SE 25 Recommended О! ........... ини 25 Oil Injection System esse 25 BREAK-IN PERIOD .................00220s00000n00nn0nnununnen non nnnnnnnnnunsnnnnnen unsre nnnannennnnnnnnnssnnnnnn 26 Engine ...... нии 26 10-Hour INSPECTION .......... линии 26 PRE-OPERATION CHECKS ........... ини нити ини нниннннни 28 HULL ООО 28 Jet Pump Water Intake seen 29 OS 29 Battery ........... ини нина нии 29 Fuel and Oil Reservoirs sise 29 Engine Compartment иене 29 Fire Extinguisher Sierre 29 Steering and Throttle Systems... 29 Reverse System iii 29 Safety Lanyard and Engine Start / Stop Button oer renee 29 Inflatable Tube ss EE EE ERE IEEE EE nee 29 AA 30 OPERATING INSTRUCTIONS _..........usrsssnnnnnnnnnnnsoonunnnnnnnnnnnnnnnuennnnsansannannnensnnannuren 31 Principle of Operation ss 31 Boarding from a Dock or in Shallow Water ee 32 SE 32 Obstacles ree 33 Boarding in Deep Water ss 33 Rough Water Operation iii 34 Crossing Waves / Wakes sisi 34 Stopping / Docking ........ ceecccccccccssccuvececccecuseaanvessecseuaaaavesseseeeuaaersesssuaaaaaeesess 34 [51-12191 ВТ Го ЗО nennen 35 Shutting Off the Engine... нии ини een 35 Night Time Operation ааа 35 POST-OPERATION CARE ,.........cccccccessescessesvssueeesuseaucessenseuseccesnvevseeusueneeueesseseuags 36 CINCO oo. cecccccccccccesceeesevssssusuuuseesecerseesececesssseueenaaaneeseeecereesevuueauanenees 36 Additional Care for Foul Water or Salt Water ............. нии ннннннннииьнинии, 36 Anticorrosion Тгеатейт.......... ии ини ннншнии 38 SPECIAL PROCEDURES 0... ...ccscccccssssssuesecnecsscsseeuuueessenaccensearusecensnes ceveneeusnnauevrenss 39 Engine OvVerhe@at ..oconocccconnnncnnnnnncararinnnnononininss rr 39 Jet Pump Water Intake and Impeller Cleaning .............nnnnonicnininicinininininnnnnanons 39 Capsized (0 )- | ee 39 Submerged Boat oo. ини иинии нии наши ниининининии 39 Towing the Воа!............. ere 40 Low-Charge Battery Condition LR 40 MAINTENANCE ...........ccc:scccccevsrnssusecccnssuseuscensuuusepsuuuuusseceuseeuveseonsesanaasscetsnesssenenes 41 Lubrication coe нина шин иинши линь 43 Periodic Inspection ee 44 Periodic Inspection Chart... iii 45 Throttle and Choke Cable пзресНоп........... нии иининнини 45 Carburetor Adjustment ......... нина nennen 45 Fuel and Oil Filters .....ooooooncocicccnnnnnconcnononicononononioraconononoronnnnn nor sco nono rro nn nar icracnanons 45 Steering А!оптейт........... ии ннннннниин и re 45 Reverse Gate Adjustment ............ ини авиа ннььвнинннниниьи 45 Vacuum Bailer Pick-Ups and Deck Drain Holes нии нннинньннннии 46 FUSES ...... нина ини ии 46 Air В|о\\МегГ....... нии нина, 47 Zinc Anode A 4] Light Bulb Replacement ............. ини нннннннни 47 Tube Inflation... canino rocn nr nono nennen нии 48 Order of Inflation ........... ини нии нии ини nennen 50 Tube Deflation ............. ина анна nnenenneennenennenn 50 Tube Minor Repairs ............. нина, 50 General Inspection and Care .............. линии нии ннннинини нии ниннннннннии, 51 TRANSPORTATION, STORAGE AND PRE-SEASON PREPARATION ............. 52 ICA 52 STOLAGES ooo eeccccccccsssevvecceceeuaveceeveseeseuaeeveessssrssseaecesserseeeeseeeessresereceesseanersteseteses 52 Pre-Season Preparation oo... cicccccccccssscccccsscceceecveveeeeesseettersereeseceeeeeeeeeeeeeneenees 54 TROUBLESHOOTING ou... ccccsssssssssscuuseuuunuccusssuuusecceecseceeceseeeeeeeeeeusaececeeeveneeeeness 56 SPECIFICATIONS. ......... инете ии ииииииининнннннния 58 SI METRIC INFORMATION GUIDE ......uuuneeenessnansennnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnneennene 60 ACCESSORIES AND SERVICE PRODUCTS nn nono no nono nnnnccncoconononnos 61 OTHER PUBLICATIONS AVAILABLE o.00...ccccccccccncononnoconanaonananononcncononnnnroncorcanoncos 65 FOREWORD The Operator's Guide has been prepared to acquaint the owner / operator or passenger of this jet boat with the various jet boat controls, maintenance and safe riding instructions. It is indis- pensable for the proper use of the product, and should be kept in a wa- terproof bag in the jet boat at all times. For any questions pertaining to the warranty and its application, please consult the WARRANTY QUESTIONS AND ANSWERS section in this guide, or an authorized SEA-DOO jet boat dealer. This guide uses the following symbols to emphasize particular information. WARNING: Identifies an instruction which, if not followed, might cause serious personal injuries including the possibility of death. CAUTION : Denotes an instruction which, if not followed, might severely damage the jet boat and / or components. NOTE : Indicates supplementary information needed to fully complete an. instruction. Although the mere reading of such information does not eliminate the haz- ard, the understanding and application of the information will promote its correct use. The information and components / system descriptions contained in this guide are correct at the time of publication. Bombardier Inc. however, main- tains a policy of continuous improve- ment of its products without imposing upon itself any obligation to install them on products previously manufactured. The illustrations show the typical con- struction of the different assemblies and may not represent the full detail or exact shape of the parts which have the same or a similar function. Specifications are given in the SI metric system with the SAE U.S. equivalent in parenthesis. Where precise accuracy is not required, some con- versions are rounded off for easier use. A Shop Manual can be obtained for complete service, maintenance and repair information. WARNING: The engine and the corresponding components identified in this guide should not be utilized on product(s) other than those they were designed for. Main- tenance procedures and specified tightening torques must be strictly adhered to. Never attempt repairs unless the appropriate tools are available. This jet boat is designed with parts dimensioned in both the metric and the imperial systems. When replacing fasteners, make sure to use only those recommended by Bombardier. Mismatched or incorrect fasteners could cause damage to the jet boat or possible personal injury. NOTE : The following list gives the equivalent of terms commonly used to designate boat references. Port : LH side Starboard : RH side Bow : Front Stern : Rear @ SAFETY WARNING To fully appreciate the pleasures, en- joyment and excitement of boating there are some basic rules that MUST be observed and followed by any boater. Some rules may be new to you while others may be common sense or obvious, nevertheless, we ask that you please take a few minutes of your time to read these safety instructions completely before you operate your craft. Failure to follow this safety information and safe boating rules could result in injury, including the possibility of death to you, your passenger(s), or other water users. Information in this Guide is limited. It is strongly recommended that you obtain further boating information from the local Coast Guard or Power Squad- ron. We further recommend you take a boating safety course. Check local and federal boating laws applicable to the waterways where you intend to use the craft. Learn the local rules of the road. Always carry all required safety equipement. Verify it regularly. Become completely familiar with the controls and operation of the craft before taking on a passenger(s) or em- barking on a trip. If you have not had the opportunity to do so with your dealer, practice driving solo in a suitable area. Be fully familar with all controls before fully applying the throttle. Observe and follow all on-product warning labels and the content of this Guide. Operator and passenger(s) should wear suitable eye and body protection from wind and water as well as deck shoes or booties. Coast Guard approved personal floata- tion devices (PFD) should be worn by all aboard. Operation of this craft by a minor or disabled person is NOT recommended. Do not operate the craft after consum- ing alcohol or drugs. Store or tie-down any loose articles or necessary boating equipment before operating the craft. Always perform the pre-operational checks as specified in this Guide. This includes : - Attaching the safety lanyard. — Verification of throttle lever and steering movement. — Verification of start/stop button operation. — Oil and fuel levels. — Use of blower. ~ Adequate water depth. — Functional navigation lights. - Required boating equipment. (Know how to use each). The operator and passenger(s) must be properly seated in the designated seats before starting or moving the craft. Allow no one to jump into the boat at anytime, or move during boat operation. The risk of an accidental fall or slip Is always present. Ensure operator all-round visibility is unrestricted. Wave or wake jumping is dangerous and in many regions illegal. Most boating accidents result from the failure of the operator to keep a look- out for other water users or other po- tential hazards. Keep a safe distance from other boat or water. Do not attempt to splash others with your wake. Do not ride surf line. This craft is equipped with bow and stern navigation lights which should be used as required. Lower speed and do not operate the craft in reduced visibility. To prevent accidental starting or unau- thorized use, always detach the safety lanyard from the boat during maintenance, cleaning of the intake grate, or when swimmers are nearby. Ensure that all passengers know how to reboard the craft from the water. Always have an observer while towing a skier. Know the waters In which the craft is to be operated. Current, tides, rapids, shallow water, hidden obstacles etc., can affect safe operation. When boating, apply the principle of 1/3 fuel to destination, 1/3 back and 1/3 reserve fuel supply. Maintain the craft-and equipment in top condition at all times. Adhere to the prescribed maintenance schedules. Use a protective cover when not in use. After salt or foul water use, the craft should be thoroughly rinsed and protected from corrosion. If you sus- pect water ingestion into the engine, contact your dealer for proper servic- Ing. The bilge must be kept clean of oil, water or other foreign materials. Do not carry spare fuel and inflammable liquids in any of the storage or engine compartments. Avoid adding on accessories, carrying equipment or passengers which may alter the craft's configuration or bal- ance. Only perform servicing procedures which are detailed in this Guide. Further assistance or information can be obtained from your dealer. In many instances proper tools and training 1$ required for certain servicing or repair procedures. Gasoline fumes are flammable and explosive. Always adhere to the fueling procedures contained in this Guide and those given to you by the marina. Always keep in mind that as the throttle lever is released to idle position, less directional control is available. To turn the craft, both steering and throttle are necessary. This craft has the capability of turning more sharply than other boats, however, unless in an emergency, do not negotiate sharp, high speed turns. Like any other boat, this craft has no brake. Stopping distance will vary depending on initial soeed, load, wind, and water conditions. Practice stopping and docking in a safe area to have an idea of how long it will take stop the craft under varying conditions. Prolonged exposure to the sun, wind etc., causes fatigue and may affect your reaction time. Do not overload the craft or take on more passengers than designated for the intended type of boating. Load and altitude will also affect boat performance. Proceed with caution and at very low speeds on shallow water. Grounding or abrupt stops may result, or debris may be picked up and be jettisoned rearward to people or property. The impeller is turning even when the selector lever is at neutral. As the "skipper" of a boat you are responsible for damage to other boats caused by the wake of your craft. Re- spect no wake zones. Respect the rights of other water users and the environment. Allow no one to throw refuse overboard. Do not operate the craft in inclement weather. Constant attention and control of the boat is required by the operator for safe operation. Use of the bilge blower should never replace "smelling" for gasoline fumes. Blower must be off during boat operation. Lifting the craft requires special equipment and experience. Do not attempt to lift the craft without such experience or equipment. Respect the safety and comfort of your passenger(s) and persons being towed on skis. Drive prudently and have fun. LIST OF DISTRIBUTORS NORTH AMERICA U.S.A.: (Continental U.S.A. except Alaska, Hawaii and Puerto Rico) BOMBARDIER CORPORATION 7575 BOMBARDIER COURT P.O. BOX 8035 WAUSAU, WI 54402-8035 Phone : (715) 842-8886 Alaska THE BRYANT CORPORATION 19011 Woodinville Snow Road P.O. BOX 389 WOODINVILLE, WA 98072 Phone : (206) 483-0110 CANADA: BOMBARDIER INC. Alberta SEA-DOO SERVICE DEPARTMENT British Columbia VALCOURT, QUEBEC Manitoba CANADA — JOE 210 North West Territories Phone: (514) 532-2211 Ontario Quebec Saskatchewan Yukon New-Brunswick Newfoundland Nova Scotia Prince Edward Island BELL-CHARLES R. P.O. BOX 1050 RIVERSIDE DRIVE CORNER BROOKE, NFLD A2H 6J3 Phone : (709) 634-3533 If your SEA-DOO jet boat requires warranty service, you must take it to any authorized SEA-DOO jet boat dealer. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the service manager or owner of the SEA- DOO jet boat dealership. To find the nearest authorized Sea-Doo jet boat dealer, dial: 1-800-882-2900. THE 1995 BOMBARDIER JET BOAT LIMITED WARRANTY 1 - WARRANTY COVERAGE PERIOD BOMBARDIER INC. (“Bombardier”), as manufacturer warrants FROM THE DATE OF DELIVERY TO THE FIRST CONSUMER every 1995 SEA-DOO® jet boat, sold as NEW AND UNUSED and PREDELIVERED by an authorized dealer for a period of : a) For private use: ~ twelve (12) consecutive months, with the exception for the body and hull fiberglass structure. — sixty (60) consecutive months against any defect in material and workmanship for the body and hull fiberglass structure. b) For commercial use: ~ four (4) consecutive months, with the exception for the body and hull fiberglass structure. — twelve (12) consecutive months against any defect in material and workmanship for the body and hull fiberglass structure. The warranty coverage period on all genuine Bombardier accessories installed by an authorized Bombardier dealer at the time of delivery of the new and unused SEA-DOO jet boat, carry the same warranty coverage period as the SEA-DOO jet boat. 2 - WHAT BOMBARDIER WILL DO Bombardier will repair and / or replace, as ¡ts option, all genuine Bombardier components found defective in material and / or workmanship, under normal use, maintenance and service, with a genuine Bombardier component without charge for parts and labor, at any authorized SEA-DOO jet boat dealer during said warranty coverage period. 3 - CONDITION TO HAVE WARRANTY WORK VALIDATED Present to the servicing authorized SEA-DOO jet boat dealer the SEA-DOO Warranty Registration card or a proof of purchase of the NEW AND UNUSED 1995 SEA-DOO jet boat. The SEA-DOO jet boat customer must upon completion of all warranty work sign the Bombardier warranty claim form. All parts replaced under warranty become the property of Bombardier. 4 - EXCLUSIONS - АВЕ NOT WARRANTED e Normal wear and tear items. e Damages related to gel coat finish including but not limited to cosmetic gel coat finish, blisters or fiberglass delamination caused by blisters, crazing, spyder or hairline cracks. e Labor, parts and lubricant costs of all maintenance services. + Damage caused by failure to provide proper maintenance and/or storage, as described in the 1995 Sea-Doo Jet Boat Operator's Guide. e Damage resulting from improper repairs, modification or use of non-approved parts. e Damage resulting from abuse, misuse, neglect, racing. e Damage resulting from accident, fire, theft, vandalism or any act of God. e Damages resulting from losses incurred as consequential damages, incidental, or damages of any kind such as but not limited to towing, telephone calls or taxis. e Water damage caused by water ingestion and improper service or maintenance. 5- EXPRESSED OR IMPLIED WARRANTIES This warranty gives you specific rights and you may also have other legal rights which may vary from state to state, or province to province. Where applicable this warranty is expressly in lieu of all other expressed or implied warranties of Bombar- dier, its distributors and the selling dealer, including any warranty of merchantability or fitness for any particular purpose ; otherwise the implied warranty is limited to the duration of this warranty. However, some states or provinces do not allow imitation on how long an implied warranty lasts, so the above limitation may not apply. Neither the distributor, the selling dealer, nor any other person has been authorized to make any affirmation, representation or warranty other than those contained in this warranty, and if made, such affirmation, representation or warranty shall not be enforceable against Bombardier or any other person. Bombardier reserves the right to modify its warranty policy at any time, being understood that such modification will not alter the warranty conditions applicable to SEA-DOO jet boat sold while this warranty is in effect. Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply. 6-CONSUMER ASSISTANCE A) In the event of a controversy or a servicing problem arising in connection with this 1995 Bombardier Jet Boat Limited Warranty, Bombardier suggests that you try to resolve the issue at the dealership level. We recommend discussing the issue with the dealer's service manager or owner. B) If further assistance is required, the distributor's service department should be con- tacted in order to resolve the matter. С) If the issue has still not been resolved, please submit in writing your complaint to : Bombardier Inc. Sea-Doo / Ski-Doo Division, Customer Relations Center, Valcourt, Qc, Canada JOE 2LO August 1994 Bombardier Inc. Valcourt, Quebec, Canada ® Trademarks of Bombardier Inc. 10 WARRANTY QUESTIONS AND ANSWERS Q.Why must my jet boat be registered at the factory ? After all | do have my original invoice as proof of when | purchased my jet boat. A. Your warranty is valid at any authorized dealer of the product. Your registration is the key element in providing the servicing dealer with the necessary data to complete warranty claim forms. The federal government requires each manufacturer and dealer to maintain a complete up-to-date list of all first purchasers in case of a safety-related defect and recall. This list is compiled from the warranty registrations sent to BOMBARDIER INC. by the selling dealer at the time of your purchase. If you have a change of address after the purchase of your new SEA-DOO, please advise us of your new address by sending the Change of Address Card in this book or, a postcard listing your model number, dealer number (or dealer’s name) as it is shown on your warranty card, your name and new mailing address. Q.What costs are my responsibility during the warranty period ? А. The customer's responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damage. Q. What is cavitation ? A. This phenomenon is caused by a part travelling at high speed in a fluid (ex. : an impeller in water). The heat / bubbles generated in some areas are enough to draw microscopic particles from the material. Cavitation will increase if there are scratches or dents in the housing / impeller or if the wear ring is worn. Q. Does warranty cover the jet drive system components ? A. Yes, if components replacement is not due to cavitation or normal wear. Ex. : The impeller has to be considered a wear item since tiny particles and sand contained in the water will eventually cause some wear. This situation occurs most often when the watercraft is driven in shallow water where rocks and debris can be drawn into the pump. In order to extend the service life of the impeller housing, we have devel- oped a replaceable wear ring around the impeller. It is made of plastic, therefore it may wear with use and should be replaced. This is a convenient feature and inexpensive to replace. This replacement is considered normal maintenance and not covered by warranty. О. What are some examples of neglect or abuse ? A. These terms are general and overlap each other in areas. Specific examples include ; the engine running out of oil, operating the jet boat with a broken or damaged part, which causes another part to fail and so on. If you have any specific questions on operation or maintenance, please contact your SEA-DOO jet boat dealer for advice. 11 Q.Does the warranty cover incidental costs sucn as transportation due to a failure ? A. No. The warranty is limited to the repair of the SEA-DOO jet boat itself. OQ. May | perform any or all of the recommended maintenance shown in the Operator's Guide instead of having the dealer do them ? A. Yes, if you are a qualified mechanic and follow the procedures specified in the Operator's Guide and Shop Manual. We do recommend however that the critical adjustments to timing and carburetion be done by a SEA-DOO dealer. Q. Will the warranty be voided or cancelled if | do not operate or maintain my new SEA-DOO jet boat exactly as specified in the Operator’s Guide ? A. No. The warranty on a new SEA-DOO jet boat cannot be “voided” or “cancelled”. However, if a particular failure is caused by operation or maintenance other than as shown т the Operator's Guide, that failure may not be covered under warranty. Q.What responsibility does my dealer have under this warranty ? 1. Completely set up every new SEA-DOO jet boat before sale ; 2. Explain the operation, maintenance and warranty requirements to your satisfaction at the time of sale. In addition, each SEA-DOO dealer is responsible for set-up, service and warranty repair work. 12 REGISTRATION NUMBER LOCATION All jet boats are required by federal law to be registered and legally numbered. Due to space availability for proper display of registration number, refer to the following illustration for location. The registration number must appear on each side of jet boat. am) 9 LA (7 _ BE Е Registration number location F003 011 007 13 LOCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operating this jet boat. F003 011 007 3-4 “THIS BOAT 15 NOT REQUIRED TO COMPLY WITH THE FOLLOWING U,S. COAST GUARD SAFETY STANDARDS IN EFFECT ON THE DATE OF CERTIFICATION: « Fuel System © Sate Leading * Display of Capacity © Flotation Information * Powered Ventllation EXEMPTION (CGB 88-001)." Bombardler Corp. 7575 Bombardier Court, Wausau, WI 54401 | I E E 1 1 | AS AUTHORIZED BY U.S, COAST GUARD GRANT OF 1 1 1 1 É made in Canada Bombardier inc. fabriqué au Canada | Rd./Enr., 1988 | XXXX | F003 011 064 mm mm mm WARNING 2 | WHILE FUELING, STOP ENGINE, FUEL TANK MAY BE PRESSURIZED, SLOWLY TURN CAP WHEN OPENING. KEEP WATERCRAFT LEVEL. DO NOT OVERFILL. CHECK OIL LEVEL. PERIODICALLY, VERIFY FUEL SYSTEM. F001 011 247 F003 011 065 % WARNING N Meeting head on: KEEP RIGHT. Te”. starboard Crossing: GIVE RIGHT OF WAY to boats ahead and to our nght (see Yield one). Never cross in front of a boat. other boat and K Passing: Give vont ol e N Read & follow all Warning Labels & Operator Guide/Safety Handbook before operation. Severe injury or death can result from ignoring warnings or through improper use of watercraft. Carrying capacily: 1 operator and 4 passengers (1050 Ibs). Check throttle € steering operation before starting engine. Directional control Is lost when throttle is released or engine shut off, Remove debris from Jet intake only when engine Is turned OFF. Operator and passengers should always wear life vast. Securaly attach stop switch tather to your life vest. This watercraft Is not dastgned for night-time operation. Check all Federal & local boating regulations. Do not stunt or jump watercraft. Do nat ride on tube. Check tube pressure before riding (3 Psi}. Minimum recommended age: 14. Gasollne vapors can explode. Before starting engine operate blower for 4 minutes and check englne compartment bilge for gasoline vapors. D. F002 011 088 г" O WARNING eNOT A GRAB HANDLE «USE REVERSE ONLY AT VERY LOW SPEED 1 Y | REVERSE | $WARNING DO NOT BOOST BATTERY. SERVICING OF ELECTRICAL COMPONENTS SHOULD BE DONE BY DEALER ONLY. F002 011 084 14 JET BOAT IDENTIFICATION The main components of the Explorer (engine, hull and tube) are identified by different serial numbers. It may sometimes become necessary to lo- cate these numbers for warranty pur- poses or to trace the jet boat in the event of theft. Hull Identification Number The Hull Identification Number (H.!.N.) is located at right hand rear side of hull. Hull Identification Number (H.I.N.) 2003 011 004,2 Tube Identification Number The Tube Identification Number (T.1.N.) is located on right hand plastic cone. Tube Identification Number (Т.1.М.} F003 011 004.1 Jet Boat Model Number The jet boat model number can be found on U.S. Coast Guard approved label located on left hand side of front storage compartment cover. A III IDEE En tT "THIS BOAT IS NOT REQUIRED TO COMPLY WITH THE , „| FOLLOWING 4,5. COAST GUARD SAFETY STANDARDS |: D IN EFFECT ON THE DATE OF CERTIFICATION: + я m * Sab Leading et = Display cf Capacity blo , iihermaden | Powered Venti 11 AS AUTHORIZED BY U.S. COAST GUAAD GRANT OF tp EXEMPTION (CGB 88-001} 11 Bombardier Corp. n Them her Geer Ma М GA El 1 | made in Canada fabriqué au Canada mad number F003 011 008 F003 011 064 Engine Identification Number The Engine Identification Number (E.1.N.) is located on the upper side of the magneto housing. (TYPICAL) Engine Identification Number (E.!.N.) F001 003 001.1 15 COMPONENT FUNCTIONS TOP VIEW 16 SIDE VIEW 25 UNDERNEATH VIEW 32 | | CO — © F003 011 010 F003 011 006 17 1) Safety Lanyard Switch Pulling the safety lanyard from the switch stops the engine operation. WARNING : Should the engine be stopped, boat directional control is not available. Attach the safety lanyard to the operator's PFD and snap the cap to the switch to be able to start the engine. CAUTION: Always remove safety lanyard when leaving the boat. Leaving the safety lanyard on switch will eventually drain the battery. secured on operator's PFD F003 011 011 [002 011 009 2) Handlebar The handlebar controls the direction of the jet boat. Turning the handlebar to the right steers the jet boat to the right and inversely. WARNING: Check handlebar and corresponding steering nozzle operation before starting. 18 3) Throttle Lever It controls the speed of the engine and therefore, the speed of the boat. When squeezed, the jet boat accelerates. When fully released, engine automatically returns to idle speed and boat is gradually stopped by water drag. WARNING : Check throttle lever operation before starting the engine. 4) Choke Lever The choke is provided to supply a richer fuel / air mixture when starting a cold engine. When the lever is completely pulled, the choke is fully applied. The use of the choke is not recommended with a warm engine. ¡END a, ( Fully pulied a à F003 011 012 5) Light Switch A 3-position switch. NOTE : The safety lanyard must be snapped to the switch to have navigation lights working. ANC: Turns on the anchorage light when boat is anchored. Only the stern light is lit. OFF: Turns off ail lights. NAV: Turns on both bow and stern lights. 6) Engine Cover Latch The engine cover latch is located at the rear end of cover. To remove engine cover, pull the latch lever upward. With the operator seat integrated handle, lift and pull the engine cover rearward. (TYPICAL) Engine cover Seat integrated handle Latch F003 011 013 When reinstalling the engine cover, insert engine cover front tab into body hook and install rear latch lever. (TYPICAL) Insert this tab in hook F002 011 011 WARNING : Periodically verify the seat hook upper nuts and lock nuts, tighten if needed. Make sure engine cover is securely latched. 7) Boarding Platform Provides a large surface for easy boarding from rear of jet boat. 8) Cooling System Bleed Outlet (TYPICAL) Bleed outlet F003 011 004,3 When engine is running, water must flow from this hole. This allows air in engine water jacket to escape. lt also indicates that water is circulating in the cooling system. CAUTION: Should water not flow from this outlet a few seconds after engine starts, immediately stop engine and refer to POST- OPERATION CARE and look for cooling system flushing or refer to an authorized dealer for servicing. 9) Bilge Drain Plugs should water be found in the bilge, it can be easily drained by unscrewing these plugs. 19 CAUTION : Remove boat from water prior to unscrew drain plugs. Unscrew "> Tighten F002 011 087 Tilt the boat slightly to the rear so that the water can completely flow out of the bilge. It is suggested to drain bilge on a ramp. WARNING : Always make sure bilge drain plugs are properly tighten. 10) Jet Pump Nozzle It is turned from side to side via rider input at the handlebar. This provides jet boat directional control when engine Is running. 11) Air Intake Openings This is where air enters to supply the engine and ventilate the engine compartment. 12) Fuel Tank Cap Unscrew the cap counterclockwise to allow fuel tank filling. Fully tighten when finished. WARNING : Never use a lit match or open flame to check fuel level. 13) Reverse Gate It moves from upward to downward position to get forward, neutral, reverse and inversely. These positions are obtained with the selector lever. 20 CAUTION : Never use reverse gate as a supporting point to board the jet boat, it may damage reverse system components. 14) Rear Vent Grills Allows air to get in or out depending on engine operation. 15) Stern Eyelet Eyelet can be used for mooring, towing and as a tie-down point during transportation. 16) Deck It is an antiskid surface. User's feet should rest on the deck when riding. 17) Grab Handles Provides a handhold for the passengers. CAUTION : Never use the grab handles to pull anything or to lift the jet boat. 18) Fuel Valve A 3-position rotating valve, OFF, ON and RESERVE : FOO3 011 017 OFF : Stop fuel supply to carburetors. CAUTION : Turn valve to OFF position when boat is not operated. ON: Allows fuel to flow to carburetors. This is the normal position for boat operation. RES : Use when the jet boat has run out of fuel in the ON position. WARNING: Always refill the fuel tank at the first opportunity. After refueling, turn the fuel valve to the ON position for further operation. 19) Selector Lever When pushed in, the boat is in forward. To obtain neutral, unlock lever by turning it counterclockwise, then oull lever until neutral mark appears on rod. To engage reverse, repeat same procedure as for neutral, but pull lever until reverse mark appears on rod. Lever locks in forward and in neutral positions only. WARNING: Selector lever should only be used when the engine is idling. Engaging the reverse at any other speed may damage reverse system components and possibly cause personal injuries. Ensure lever is pushed in and locked. Do not use as a grab handle. 20) Engine Overheating Beeper In the event the engine overheats, a beeper (coutinuous sond) will warn the operator. Stop the engine and refer to SPECIAL PROCEDURES. 21) Engine Start / Stop Button Dual function push type switch. To start engine, depress and hold tne button. Release immediately after engine is started. To stop engine, fully release throttle lever then depress the button. WARNING: When the engine is stopped, jet boat directional control is not available. Engine start / stop button Fo01 011 219 22) Rear Storage Compartment Cover To access storage compartment, lift both toggle latches and gently lift cover. When completely lifted, the cover stays open with the help of a wire. Push on cover to close it. Secure cover latcn after closing. 23) Rear Storage Compartment A convenient watertight, compartment to carry the tool kit, Operator’s Guide and personal articles. Ideal location for spare spark plugs, tow rope, first aid kit, tube repair kit, foot pump, etc. WARNING: Never leave any heavy or breakable object in the storage compartment. This area is the preferred location to store an approved extinguisher. The fire extinguisher holder is installed in the top right portion of the compartment. This holder contains tool kit, Op- erator's Guide and it has a compartment to carry personal articles. Fire extinguisher should not be left loose in the storage compartment. 24) Tool Kit Contains tools needed to perform basic jet boat maintenance. 21 25) Navigation Lights Lights should always be used between sunset and sunrise or when visibility is reduced. WARNING : Proceed with caution and reduce your speed. REMOVABLE STERN LIGHT It is recommended to keep it in rear storage compartment at all time except when needed. To remove from storage, pull it out. Resnap to store again. Installation — Lift connector cap. — Insert post in commector hole. En- sure to align hole keyway with post screw head. — Firmly push downward to engage terminals. — Push lock ring downward. Turn until locked. It may be necessary to slightly turn it to allow its insertion in the hole. — Check light operation. 22 Align screw in groove 2° Turn to lock F004 011 021 26) Front Storage Cover Latch Pull the latch lever downward and lift in order to open the storage compartment cover. Always relatch. 27) Front Storage Compart- ment A convenient watertight compartment to carry fishing seat, anchor, additional PFD, etc. 28) Fuel Gauge / Low Oil Warning Light Located on dashboard, the analog gauge indicates the amount of fuel in the fuel tank and a light turns on when level is low in oil reservoir. Low oil warning > light _ Bombardier F001 006 007 NOTE : To check fuel level when engine is not running, remove safety lanyard and briefly depress engine start / stop button; the gauge will be activated for approximately 30 seconds. 29) Oil Injection Reservoir Cap NOTE: Engine cover has to be removed to access oil cap. Verify oil level through oil reservoir. Unscrew the cap counterclockwise and add appropriate amount of oil. (TYPICAL) Cap \ NN YVES Sn Oil injection yo ITA reservoir 30) Engine Compartment NOTE : Engine cover has to be removed to access engine compartment. This is where the mechanical, electrical and fuel / oil systems are located. WARNING: When starting or operating the engine, do not touch any electrical part. Never leave any object, rag, tool, etc., in the engine compartment or in the bilge. F003 006 001 31) Access Covers NOTE: Covers have to be removed to access bilge. This is where vacuum bailer pick-ups, cooling inlet and outlet, seal carrier and exhaust system are located. 32) Jet Pump Water Intake The water is drawn up by the impeller through this opening. The impeller and the drive shaft are protected by a grate. 33) Deck Drain Holes These 2 holes are located on each side of the deck at the rear. They provide drainage for rain, deck washing or water splashing. 23 34) Bow Eyelet Eyelet can be used for mooring, towing and as a tie-down point during transportation. 35) Deck Eyelets Eyelets should be used as material tie- down or for lifting the jet boat. WARNING : Ensure all loose equipment or material is securely tied down on board. 36) Inflatable Tube Inflatable tube is composed of 3 air- tight compartments, separated by par- titions, inflated through recessed valves. It is equipped with 6 grab han- es. Refer to MAINTENANCE for proper care of the tube. WARNING : Never inflate tube more than 21 kPa (3 PSI). 37) inflatable Tube Valves Three valves are installed on the tube for each compartment. They are used to inflate or deflate tube as necessary. Refer to MAINTENANCE for proper inflation of the tube. 24 38) Air Blower Switch To start air blower, activate toggle switch. The air blower must be started 4 minutes prior starting the engine. WARNING : Blower must be turned off during jet boat operation. F003 007 003 FUEL AND LUBRICATION Fueling Procedure WARNING : Follow these safe boating fueling instructions explicitly. Make sure the fet boat Is tied securely to the fueling pier. Use bilge blower for a minimum of 4 minutes. Turn off engine, bilge blower and any other devices that could produce a Spark. Disembark all people. Do not smoke or allow open flames in the vicinity. Have a fire extinguisher close at hand. Do not enter the spout too far in filler neck. Pour fuel slowly so that air can escape from the reservoir and prevent fuel flowback. Fill fuel tank to bottom of filler neck. Do not overfill. Fully tighten fuel tank cap and wipe off any fuel spillage. Ensure there are no fuel fumes in the angine compartment, ventilate using the blower as necessary. Recommended Fuel Use regular unleaded gasoline with 87 octane ((R + M) / 2) specification. NOTE : Look on service station pump sticker for octane specification. Do not mix oil with fuel except at engine break-in. Refer to BREAK-IN PERIOD. Always check injection oil reservoir level when refueling. The use of good quality fuel is necessary. A well known fuel brand is highly recommended. CAUTION : The use of a poor quality fuel can result in jet boat performance deterioration and damage to fuel system and engine components. Never experiment with other fuels or fuel ratios. Never use fuel containing alcohol, methanol or similar products including naphtha. The use of unrecommended fuel can result in jet boat performance deterioration and damage to critical parts in the fuel system and engine components. Never top off the fuel tank and leave jet boat in the sun. As temperature increases, fuel expands and might overflow. Always wipe off any fuel spillage from the jet boat. Recommended Oil Use only BOMBARDIER ROTAX INJECTION OIL which is available from authorized dealers. It is a blend of spe- clally selected base oils and additives which provides outstanding lubrication, engine cleanliness and minimum spark plug fouling. NOTE : High quality low ash API TC injection oil for 2-cycle en- gines can be used if BOMBARDIER ROTAX INJECTION OIL is not available. CAUTION: Never use 4-cycle petroleum or synthetic motor oil and never mix these with outboard motor oil. Do not use NMMA TC-W, TC-W2 or TC-W3 outboard motor oils or other ashless type 2- cycle oil. Avoid mixing different brands of API TC oil as resulting chemical reaction may cause severe engine damage. Oil Injection System This jet boat features an oil injection system which does not require manual! fuel / oil mixing. 25 Oil level in reservoir should be main- tained almost full. To check, remove seat to expose oil reservoir. Verify through oil reservoir. Unscrew cap to add oil as necessary. Use a flexible funnel to pour oil into reservoir. Wipe off any oil spillage. NOTE: Always carry 500 mL of BOMBARDIER ROTAX INJEC- TION OIL. BREAK-IN PERIOD CAUTION : Always maintain a sufficient amount of injection oil in the oil reservoir. Check and refill every time you refuel. Do not overfill. If the engine runs out of oil, severe engine damage will occur. If the oil reservoir is found almost empty, air can enter in the system and it must be bled. Immediately refer to an authorized dealer to have the oil injection system inspected. With Bombardier-Rotax® jet boat en- gines, a break-in period is required before operating the engine at full throttle. Engine manufacturer recom- mendation is about 10 operating hours. During this period, maximum throttle should not exceed 3/4, however, brief acceleration and speed variations con- tribute to a good break-in. Continued wide open throttle accelerations, prolonged cruising speeds and overload- ing the engine are detrimental during the break-in period. To assure additional protection during the initial engine break-in, 1L (34 oz) of BOMBARDIER ROTAX INJECTION OIL should be added in the fuel tank for the first full fuel tank filling only. CAUTION : Remove and clean spark plugs after engine break- in. 26 10-Hour Inspection It is highly recommended that after the first 10 hours of operation, the jet boat be checked by an authorized dealer. This inspection will also provide the opportunity to discuss the unanswered questions you may have encountered during the first hours of operation. The 10-hour inspection is at the ex- pense of the jet boat owner. 10-HOUR INSPECTION CHECK LIST "4 Engine ignition timing (if required) Spark plug inspection, cleaning and adjustment Fuel system lines and fasteners / pressurization test Carburetor adjustment including throttle / choke cables (if required) Oil lines and filter Oil injection pump adjustment (if required) Engine support and engine rubber mounts Muffler, battery and reservoir fastening devices Exhaust system hose clamp torque Carburetor flange nuts and flame arrester bracket Steering stem arm torque Steering cable adjustment (if required) Reverse cable adjustment (if required) Cooling system hose condition and fasteners Bailer pick-ups, check for obstructions Safety lanyard switch Engine overheating beeper Lighting system Electrical connections (starter, battery, etc.) Rev limiter operation Impeller shaft reservoir oil replacement Impeller boot condition, impeller / wear ring clearance PTO flywheel lubrication Seal carrier lubrication Water intake grate / hull condition Inspection of fasteners for tightness Inspect / clean engine drain tube Front and rear storage gasket condition Inflatable tube condition Sacrificial anode condition We recommend that this inspection chart be signed by an authorized ealer Date of 10-hour inspection Authorized dealer signature 27 PRE-OPERATION CHECKS some of the following items may not have been previously covered in this guide, however they will be described in the MAINTENANCE or SPECIAL PROCE- DURES section. Please refer to these portions to have more detailed information. Prior to your daily ride, verify the following : WARNING : Safety lanyard must always be removed from switch prior to verify any of the following. ITEM OPERATION Hull Inspect. Jet pump water intake inspect / clean. Bilge Drain. Ensure plugs are secured. Battery Inspect tightness of cables and retaining straps. Fuel and oil reservoirs Refill. Engine compartment Verify for any fuel leak/odor Fire extinguisher Inspect condition / mounting. steering and throttle systems Check operation. Reverse system Check operation. Inflatable tube Visually inspect / verify air pressure. safety lanyard, engine start / stop button Check operation. Hull Inspect hull for cracks or damage. Jet Pump Water Intake Remove weeds, shells, debris or anything else that could restrict the flow of water and damage cooling system or propulsion unit. Clean as necessary. If any obstruction can not be removed, refer to an authorized dealer for servicing. 28 (TYPICAL) Inspect this area F002 009 001 Inspect leading edges of the impeller, if they have nicks or bends performance will be greatly reduced. Bilge Should water be present in the bilge, have the jet boat tilted to the rear and unscrew drain plugs to completely empty the bilge. WARNING : Make sure to take the jet boat out of water prior to unscrew the drain plugs. Reinstall bilge drain plugs. Battery WARNING : Verify tightness of battery cables and retaining straps. Fuel and Oil Reservoirs With the jet boat horizontal, fill the fuel tank to specified level with fuel. Check the oil level and refill reservoir as necessary. Engine Compartment WARNING : Should any leak or gasoline odors be present, do not start the engine or operate the jet boat. Immediately refer to an authorized dealer. Fire Extinguisher Make sure it is full, in good condition and well secured. Steering and Throttle Systems Assisted by another person, check steering operation for free movement. When the handlebar is horizontal, the jet pump nozzle should be in the straight ahead position. Ensure the Jet pump nozzle pivots easily while handlebar is turned. Check throttle lever several times for free and smooth operation. lt must return to its initial position immediately after released. Reverse System Check reverse gate operation for free movement. With the selector lever pushed in and locked, the gate should be in upward position. Ensure the reverse gate moves easily while selector lever is pulled out. WARNING : Verify the reverse gate locking operation before starting the engine. Safety Lanyard and Engine Start / Stop Button Ensure that both switches operate properly. Start engine and stop it using each switch individually. WARNING : If engine does not shut-off when pushing engine start/stop button or by discon- necting the safety lanyard, stop the engine by applying the choke and turning fuel valve to OFF position. Do not operate the boat further, see an authorized dealer. Inflatable Tube Inspect tube for scratches and / or damage. Verify air pressure using valve adapter and pressure gauge. The air a” should always be at 21 kPa (3 PSI). NOTE : The valve adapter is part of the tube repair kit. A low pressure gauge can be used. CAUTION : An incorrect pressure will reduce the tube service life. 29 WARNING : Never inflate tube more than 21 kPa (3 PSI). Inflat- ing tube more than specified pressure may damage tube and cause personal injury. Never use high pressure to inflate tube. Clothing WARNING : Always wear a Coast Guard approved PFD. It is also recommended that gloves, wet suit, deck shoes / booties and protective glasses be worn when operating the boat. 30 OPERATING INSTRUCTIONS WARNING : Always perform the PRE-OPERATION CHECKS before operating the jet boat. Be- come thoroughly familiar with all controls and the function of each. Should any control or instruction be not fully understood, refer to an authorized dealer. Principle of Operation Propulsion The engine is directly coupled to a drive shaft which, in turn, rotates an impeller. This impeller is accurately adjusted in a housing where the water is drawn up from underneath the jet boat. Then the water flows through the impeller to a venturi. The venturi accelerates the water and produces thrust to move the jet boat. Depress- ing the throttle lever increases engine speed and therefore jet boat speed. The selector lever is used for either driving the jet boat forward or back- ward. With lever pushed in, the watercraft is in forward position, with the lever fully pulled out reverse position is obtained. The lever middle position is neutral. These 3 functions are pro- duced by the mean of a gate, which is installed on jet pump venturi housing. This gate directs the water flow to get the proper function. F003 011 020 WARNING : Whenever the engine is to be started, the operator should always be sitting on the jet boat with the selector lever in neutral position. Selector lever should only be used when the engine is idling. Engaging the reverse at any other speed may damage reverse system components and possibly cause personal injuries. Ensure lever is pushed in and locked. Turning (TYPICAL) F003 011 021 Turning the handlebar pivots the jet pump nozzle which controls the jet boat direction. Turning the handlebar to the right will turn the jet boat to the right and inversely. The throttle must be applied to turn the jet boat. WARNING : Directional control is lost when the throttle is released. Throttle must be applied and handlebar turned to change the direction of the jet boat. Steering effi- ciency will differ depending on number of passengers, load and water condition. The more the throttle is applied while turning the handlebar, the sharper the turn will be. The jet boat behaves differently with passengers and requires greater skill. The passengers should always grip the grab handles. Reduce speed and avoid sharp turns. Avoid choppy water conditions when carrying passengers. 31 Boarding from a Dock or in Shallow Water As with any craft, getting aboard should be done carefully. When boarding from a dock, slowly place one foot on the jet boat deck nearest the dock and then move the other foot over inflatable tube. Never use the inflatable tube as a boarding support. Push the jet boat away from the dock. (TYPICAL) F003 011 022 CAUTION : The engine should be started with at least 90 cm (3 ft) of water below the hull. (TYPICAL) = ~~ в AS 1 rH a RB TE JE oe eae VIA PEPR ВИ In shallow water, board the jet boat either from the side or the rear. WARNING : An inexperienced operator should practice how to get aboard close to the shore to simulate deep water boarding. Re- fer to Boarding in Deep Water in this section. 32 F003 011 025 Starting the Engine Before unloading the jet boat from the trailer, it can be started for about 10 seconds to verify proper operation. WARNING : Do not touch electrical parts or jet pump area when engine is running. Always activate air blower 4 minutes before starting the engine. WARNING: Blower must be turned off during jet boat operation. Attach the safety lanyard to the operator's PFD and snap the cap to the switch. Cold Engine Operator and passengers should be sitting on seats prior to starting the engine. Turn the fuel valve to ON position. Firmly grip handlebar with your left hand and place both feet on the floorboard. Turn off air blower switch. Fully pull the choke lever with your right hand and depress the engine start / stop button. FOO1 011 219,1 Immediately after engine is started, release start / stop button and release choke lever half way. NOTE : Do not depress the throttle lever while starting a cold engine. CAUTION: To avoid starter motor overheating, the cranking period should not exceed 5-10 seconds and a rest period should be observed between cranking cycles to let the starter cool down and its mechanism disengage. A few seconds after, completely release the choke lever and, if necessary, slightly apply throttle to keep engine running. Slowly accelerate to reach deeper water. Do not apply full throttle until the engine is warm. WARNING: In shallow water, shells, sand, pebbles or other objects could be drawn up by the jet pump and damage impeller, components or clog the cooling system. Also, debris could be thrown rearward into bystanders. Warm Engine The same procedure as a cold engine applies, except the choke does not need to be applied and throttle lever has to be slightly depressed. Obstacles Verify that the path ahead of the jet boat is clear of other craft or obstacles. Avoid riding close to swimmers. Check local boating laws for safe operation. WARNING: Only start the jet boat once all items have been checked and operate properly. (TYPICAL) F003 011 019 Boarding in Deep Water WARNING : Inexperienced rid- ers should practice how to get aboard close to shore first before venturing into deep water. Operator Alone Swim to the rear of the jet boat. (TYPICAL) F003 011 026 Grip the grab handle and pull yourself upward until your knee can reach the platform. 33 CAUTION : Never use reverse gate as a supporting point to board the jet boat, it may damage reverse system components. (TYPICAL) F003 011 027 (TYPICAL) F003 011 028 (TYPICAL) F003 011 029 Always activate air blower 4 minutes before starting the engine. Attach the safety lanyard to the operator's PFD and snap the cap to the switch. Turn off air blower switch. Start the engine. 34 Operator with Passengers The operator climbs on the Jet boat the same way as explained previously. The passenger then climbs on the jet boat while the operator may help him in climbing aboard. WARNING : It is not recommended to climb aboard from tube area using grab handle. Always activate air blower 4 minutes before starting the engine. Attach the safety lanyard cap to the switch. Turn off air blower switch. WARNING : Do not start engine until the passengers are properly seated. Rough Water Operation Avoid operation in these conditions. If you must do so, proceed with caution using minimum speed. Crossing Waves / Wakes Reduce speed and cross the wave at an angle. Always be prepared to steer and bal- ance as necessary. When crossing wakes, always keep a safe distance of boat ahead. WARNING: When crossing waves, operator and passenger(s) should always brace them- selves by posting. Do not attempt to jump a wake or wave at high speed. Stopping / Docking The jet boat is slowed by water drag. The stopping distance will vary depending on weight, water surface condition, presence and direction of wind and current. The operator should familiarize him- self with the stopping distance under different conditions. Release the throttle at a sufficient distance of the expected landing area, water resistance will slow down the jet boat. Reduce speed when approaching a dock then shut off the engine just before coming alongside. WARNING : No directional control is available when the throttle is closed or engine is shut off. Never use the reverse system for stopping the jet boat. Beaching CAUTION: It is not recommended to run the jet boat to the beach. Proceed the same way as for docking except for the following : Come slowly to the beach and shut off the engine when reaching about 90 cm (3 ft) of water under the hull. CAUTION : Avoid docking or beaching where sharp objects are present. Tube perforation may occur. (TYPICAL) 90 cm (3ft) of water under the hull A ET Le BREE CE SRR 4 EE LE SE SIRE ЗИ EEG ee eed SES F003 011 023.1 CAUTION: In shallow water, shells, sand, pebbles or other objects could be drawn up by the jet pump and damage impeller, components or clog cooling system. Get off jet boat and pull it on the beach. Shutting Off the Engine To keep jet boat directional control, the engine should be running until the jet boat is stopped assuming at least 90 cm (3 ft) of water is present underneath the hull. To shut off the engine, completely release throttle lever and press the engine start / stop button. Remove safety lanyard from jet boat. WARNING : Should the engine be shut off, jet boat directional! control is not available. Never leave the safety lanyard on an unattended watercraft. Night Time Operation WARNING: Proceed with caution and reduce your speed. Be extremely cautious when operating at night. All day time hazards exist but are hidden by darkness. The boat is not equipped with head or search lights. 35 POST-OPERATION CARE General Care Should any water be present in the hull, unscrew the drain plugs and tilt the jet boat to the rear in order to allow water to flow out. Wipe up any remaining liquid in the engine compartment (bilge, engine, battery, etc.) with clean dry rags (this is particularly important in salt water use). Remove the jet boat from the water every day to prevent marine organisms growth. Leave the engine cover partially opened. This will avoid engine compartment condensation and possible corrosion. NOTE: When the jet boat 1$ stored with engine cover partially opened and without a tarpaulin, unscrew the drain plugs in order to avoid water build up in the bilge during rain- all. Additional Care for Foul Water or Salt Water When the jet boat is operated in foul water and particularly in salt water, additional care must be taken to protect the jet boat and its components. Rinse bilge area with fresh water. CAUTION : Failure to perform proper care such as: jet boat rinsing, cooling system flushing and anticorrosion treatment, when jet boat is used in salt water, will result in damage to the jet boat and its components. 36 Cooling System Flushing and Engine Internal Lubrication Flushing the cooling system with fresh water is essential to neutralize corrod- ing effects of salt or other chemical products present in water. It will help to clean up sand, salt, shells or other particles in water jackets (engine, exhaust manifold, tuned pipe) and/or hoses. Engine lubrication and flushing should be performed when the jet boat is not expected to be used further the same day or when it is stored for any ex- tended time. An optional coupler hose can be in- Stalled on the jet boat to ease flushing. Proceed as follows: WARNING: Perform this operation in a well ventilated area. 1. Clean jet pump by spraying water in its inlet and outlet and then SEA- DOO LUBE lubricant. 2. Remove seat to allow access of cooling system. 3. Remove dust cap from fitting spigot and attach coupler hose. Make sure coupler hose is properly locked to fitting spigot. 4. Install a hose pincher on water outlet hose. NOTE: This prevents water from directly exiting cooling system. F001 004 042.1 5. Attach other end of coupler hose to a garden hose. Do not open water tap yet. 6. Start the engine then immediately open the water tap. WARNING: Do not touch any electrical part or jet pump area when engine Is running. CAUTION: Never flush a hot engine. Always start the engine before opening the water tap. Oth- erwise, water will back flow through the tuned pipe into the engine and may cause damage to internal parts. Open water tap immediately after engine is started to prevent overheating. 7. Run the engine about 3 minutes at a fast idle around 3500 RPM. CAUTION: Never run engine longer than 5 minutes. Drive line seal has no cooling when jet boat is out of water. 8. Pull plug from air intake silencer cover. 9. Spray SEA-DOO LUBE lubricant through air intake silencer cover keeping engine at fast idle. Pull plug Air intake Spray silencer cover SEADOO Lube srl) FO01 005 077 NOTE : Lubrication of engine should be done at least for 1 minute. After approximately half a minute, close fuel valve to run engine out of fuel while lubricating. CAUTION: When engine be- gins to run irregularly because of fuel starvation, immediately stop water flow before engine dies. Se- vere engine damage could result if not done in this order. 10. Close the water tap then stop the engine. CAUTION: Always close the water tap before stopping the engine, otherwise severe engine damage could occur. 11. Unlock and remove coupler hose. Reinstall dust cap over fitting spigot. 12. Remove hose pincher from water outler hose. 13. Wipe up any residual water from the engine. 14. Remove spark plug cables and connect them on the grounding device. 37 Grounding PT plug device cables Magneto housing cover FOO1 007 079 15. Remove both spark plugs and spray SEA-DOO LUBE lubricant into each cylinder. 16. Crank the engine a few turns to distribute the oil onto cylinder wall. 17. Apply antiseize lubricant on spark plug threads then reinstall them. 18. Reinstall plug on air intake silencer cover. Anticorrosion Treatment To prevent corrosion, spray a corrosion inhibitor (salt water resistant) such as SEA-DOO LUBE lubricant or equivalent over metallic components in engine compartment. NOTE: Engine fogging should be done with SEA-DOO LUBE lubricant whenever the jet boat is to be stored for few days or a long period. Apply dielectric grease (salt water resistant) on battery posts and cable con- nectors. CAUTION : Never leave rags or tools in the engine compartment or in the bilge. 38 SPECIAL PROCEDURES Engine Overheat If the engine overheating beeper sounds continuously, stop engine immediately. Perform the Jet Pump Water Intake and Impeller Cleaning procedure in this section. Flush cooling system, refer to POST- OPERATION CARE. № engine still overheats, refer to an authorized dealer for servicing. Jet Pump Water Intake and Impeller Cleaning Weeds, shells or debris can get caught on the intake grate, drive shaft and / or impeller. A clogged water intake may cause troubles such as : 1- Cavitation: Engine speed is high but jet boat moves slowly due to reduced jet thrust ; jet pump components may be damaged. 2- Overheating : Since the jet pump operation controls the flow of water to cool the engine, a clogged intake will cause the engine to overheat and damage engine internal components. The clogged area can be cleaned as follows : Shut off the engine and let the boat stop by itself then walt approximately 10 seconds before restarting engine. This waiting period may allow weeds to fall free from grate. WARNING: When the engine is shut off, jet boat directional control is not available. If system is still clogged, proceed with following procedure: With the engine running, put selector lever in reverse position and vary throttle quickly several times. Retry boat. If still clogged, restop boat and rock several times while repeatedly pressing start /stop button for short period without starting engine. If the jet pump can not be cleared of debris, the jet boat should be returnea to the trailer or to a boat lift. Clean the water intake area. If the system Is still clogged, refer to an authorized dealer for servicing. CAUTION : Avoid jet boat operation in weed areas. If una- voidable, vary jet boat speed. Weeds tend to entangle more at steady speed and at slow speed. Inspect water intake grate for damage. Re- fer to an authorized dealer for repair as necessary. Capsized Boat The jet boat is designed so that it should not turn over easily, due to its longer and larger dimensions and its inflated tubes. If it turns over, it will remain capsized. To return the jet boat upright proceed as follows : — Deflate the right tube (seen from rear) — Rotate jet boat clockwise (seen from rear) by pushing on the right side — Handhold the side of water intake hole and use your welght to complete the jet boat rotation. WARNING: In the event it is impossible to upright the boat, remain with it, you will be more easily located by a search plane or boat. Submerged Boat If the jet boat is submerged and engine Is water-flooded, it is strongly recommended that the jet boat be serviced by an authorized dealer immediately. 39 In the event the engine cannot be serviced within a few hours, remove spark plug cables and connect them on the grounding device. WARNING : Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device. Grounding device Spark plug cables F001 007 079.1 Remove spark plugs and dry them with a clean cloth. Cover spark plug holes with a rag. Crank engine to allow water to escape from spark plug holes. Spray SEA-DOO LUBE lubricant into spark plug holes. Crank engine again. Reinstall spark plugs. 40 Towing the Boat In the event the jet boat becomes in- operative, tie a tow rope to the bow (front) eyelet and have the jet boat towed to the shore at moderate speed. Low-Charge Battery Condition See your dealer to have it charged or replaced. WARNING: Do not charge or boost the battery in the jet boat. Connecting cables could produce a spark and possibly cause an explosion if fuel or electrolyte vapors are present. MAINTENANCE WARNING: Only perform procedures as detailed in this guide. It is recommended that the assistance of an authorized dealer be periodically obtained on other components / systems not covered in this guide. Unless otherwise specified, engine must not be running and the safety lanyard must be removed for all maintenance procedures. NOTE : Servicing period is given in hours. Lubrication PTO Flywheel and Seal Carrier Use SEA-DOO synthetic grease and lubricate every 10 hours. Proceed as follows : Remove engine cover to access engine compartment. Remove the wing nuts, washers and pull out PTO flywheel guard. WARNING: Always remove safety lanyard cap from its re- ceptacle to prevent accidental engine starting before removing the PTO flywheel guard. (TYPICAL) SZ À Wing nuts O O Flywheel Ш guard F001 011 221 Using a grease gun, carefully lubricate PTO flywheel at grease fitting until drive shaft boot is just beginning to expand. CAUTION: Immediately stop lubricating as soon as boot be- gins to expand to prevent boot damage or slipping. Lubricate seal carrier at grease fitting until grease Is just coming out. 2001 008 001 41 CAUTION : As soon as grease comes out the seal immediately stop lubricating. Never leave any clothing, tool or other objects near PTO flywheel and seal carrier. Secure PTO flywheel guard. Anticorrosion Protection Throttle / Choke Cables Lubricate the throttle and choke cables with SEA-DOO LUBE lubricant every 25 hours and every 10 hours in salt water use. Electrical Connections As necessary, apply anticorrosion product such as a dielectric grease on battery posts and all exposed cable con- nectors. Additional Lubrication SEA-DOO LUBE lubricant will help to prevent corrosion and keep proper operation of moving mechanisms. Lubrication of the following Items should be performed every 50 hours in fresh water use but every 10 hours in salt water use. Choke Lever Fully pull choke lever and lubricate the metallic portion. sa | . \ Va] “Y F003 011 012.2 42 Engine Cover Attachment, Tab and Hook (TYPICAL) Tab 2002 011 011.1 Carburetors and Oil Injection Pump Lubricate springs, shafts and exposed portion of cables. NOTE: Grease carburetor link- age at both ends with synthetic grease. (TYPICAL) [2002 005 015 Reverse System Lubricate support plate sliding area of sliding block, triangular lever, sliding washer and selector lever stem with synthetic grease. Periodic Inspection Routine maintenance is necessary for all mechanized products. A periodic inspection contributes to the products life span. The following maintenance chart gives guidelines for regular jet boat servicing schedule to be performed by you and/or by an authorized dealer. The schedule can be adjusted according to operating conditions and use. 43 Periodic Inspection Chart FREQUENCY DESCRIPTION every every | every | soo hours Tobe h 10 25 50 or performed by ours hours hours seasonally Lubrication / corrosion protection ® у ОРЕНАТОН Engine ignition timing Y DEALER Spark plug replacement и DEALER Throttle / choke cables, inspection / lubrication ® у OPERATOR Fiame arrester inspection Y DEALER cable adjustments and inkage v DEALER Dil injection pump adjustment v DEALER Fuel filter and oil filter inspection Y DEALER Oil filter and fuel filter replacement Y DEALER Engine head screws, retorque у DEALER Steering system и DEALER Reverse system / reverse cable adjustment Y DEALER Fastener tightening (flame arrester mount screws, carburetor mount nuts, engine mount screws, и DEALER exhaust system, etc.) Muffler, battery and reservoir fastening devices и OPERATOR fuel aster pressutvation Sherten и DEALER Inspect / clean engine drain tube O Y DEALER Bilge system / deck drain holes, inspection и OPERATOR Battery condition и DEALER Battery and starter cables Y DEALER Engine overheating beeper / electrical connections и DEALER Impeller shaft reservoir oil level / oil condition Y Replace DEALER Impe’ler condition and impeller / wear ring ® v DEALER Drive shaft boot and spline condition (both ends) ® и DEALER PTO flywheel lubrication и ОРЕВАТОВ Seal carrier lubrication и ОРЕВАТОВ Water intake grate condition @ и DEALER Hull condition у DEALER Cooling system flushing ® v OPERATOR Lights condition и DEALER Inflatable tube condition и ® DEALER Zinc anode и ОРЕНАТОВ Air blower inspection Y DEALER NOTE : Some items are included in the PRE-OPERATION CHECKS and are not necessarily repeated in this chart. O Every 10 hours in salt water use. @ These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in this chart. 44 G Daily flushing in salt water or foul water use. O Inflatable tube should be removed and cleaned. Also verify tube attachment condition. Throttle and Choke Cable Inspection Throttle Cable Depress and release the throttle lever several times. lt must operate smoothly and return to its initial position without any hesitation. Refer to an authorized dealer if necessary. WARNING: If throttle lever does not automatically return, do not operate jet boat and see your dealer. jh Must move F001 010 001 freely Choke Cable Inspection Ensure it operates smoothly and without any hesitation from fully open to fully close. When the choke lever is fully pulled, choke must be fully applied. Refer to an authorized dealer if necessary. Carburetor Adjustment Carburetor adjustment is very important to allow good engine operation and therefore jet boat performance. Carburetor adjustment requires technical knowledge and experience to have the correct mixture supplied to the engine. This critical adjustment must be performed by an authorized dealer once a year or more often if necessary. CAUTION: Serious engine damage can occur with improper carburetor adjustment. Fuel and Oil Filters These filters should be replaced by an authorized dealer annually. Fuel system pressurization should be con- ducted at the same time. CAUTION: An obstructed oil filter will cause oil starvation resulting in serious engine damage. Steering Alignment When the handlebar is aimed in straight ahead position, the jet pump nozzle should be in the same direction allow- ing the jet boat to run in a straight line. Refer to an authorized dealer if an adjustment is necessary. WARNING : Ensure the handlebar/jet pump nozzle operate freely from side to side and are not stressing the steering cable and / or bracket. Steering system wear should be inspected every 50 hours by an authorized dealer. Reverse Gate Adjustment When selector lever is pushed in and locked, reverse gate should be in upward position. With the lever half way out and locked, reverse gate should be in middle position. When lever is fully pulled out, reverse gate should be in downward position. Re- fer to an authorized dealer if adjustment is necessary. WARNING : Ensure the selector lever / reverse gate operate freely and are not stressing the reverse cable. Always make sure selector lever locks in forward. 45 Vacuum Bailer Pick-Ups and Deck Drain Holes Vacuum Bailer Pick-Ups Remove access covers. Bailers are located each side of the drive shaft tunnel. Vacuum bailer pick-up 7/ LZ Drive shaft tunnel F003 011 031 This jet boat features a vaccum activated syphon. Two pick-ups use a low pressure area in the jet pump to syphon the water out of the bilge. Inspect each pick-up screen for obstructions, clean as necessary. Make sure hose routing is not changed. Deck Drain Holes Remove any possible obstructions at drain inlets and outlets. Deck drain Inlets F003 011 032 46 Deck drain outiets F003 011 004.5 Fuses Electrical system is protected with 4 fuses. One fuse protects the charging circuit, the second fuse protects the accessories and controls. If starter does not operate or If battery is regularly discharged, check fuse condition. The lighting system and blower are protected with 2 fuses. М one of the system doesn't work, check fuse condition. The fuse caps are in the electrical box cated on port side (left) and hold spare uses. To access fuse caps unclip electrical box from its seat. Bring It over magneto housing and remove cover. (TYPICAL) Remove cover Fuse caps [001 007 125 Replace the fuse by one of the same rating. Make sure to properly close the fuse cap. CAUTION : Do not use a higher rated fuse as this can cause severe damage. Refer to SPECIFI- CATIONS section for recommended fuse rating. Wires in electrical box cover must hang freely. Do not pack wires in cover. WARNING : If any water is found in the electrical box, immediately refer to an authorized dealer before operating the jet boat. Properly close electrical box cover mak- ing sure its seal is well positioned. Replace electrical box in its support. Air Blower Verify air blower for proper operation. WARNING : If air blower does not operate properly, immediately refer to an authorized dealer before operating the jet boat. Zinc Anode This is a sacrifice anode to help reduce propulsion system corrosion in salt water use. Zinc anode is located on ride shoe. Verify anode. Replace it as necessary. Light Bulb Replacement Bow Light Remove screw. (TYPICAL) 7 2004 007 001.1 Pull out cover. Turn lens counterclockwise and pull it out. F003 007 008 Push and turn bulb counterclockwise to remove it. 47 F004 007 003 The assembly is essentially the reverse of removal procedures. However, pay particular attention to the following : Apply dielectric grease on bulb contact surface. CAUTION : Avoid finger contact or grease on bulb. Properly position lens: green on starboard side, red on port side. Stern Light Turn lens a quarter turn counterclockwise ans pull it out. F004 007 004 48 Push and turn bulb counterclockwise to remove it. 2004 007 005 Apply dielectric grease on new bulb contact surface. CAUTION : Avoid finger contact or grease on bulb. The assembly is essentially the reverse of removal procedure. Tube Inflation Proceed as follows: Remove valve cap of a rear section by unscrewing it a quarter of a turn counterclockwise. Check that the center plunger is in the upright position. Valve cap removed Center plunger upright F003 011 042 Insert foot pump hose end with proper adapter into the valve opening. Foot pump hose N Valve cap F003 011 033 Inflate with one foot by pressing down on the foot pump. CAUTION : Always inflate rear sections FIRST. Inflate front section LAST. Never use high pressure to inflate tube, moisture will damaged tube seams. FR: 13 eet see.) + ra > à + es —__ F003 011 034 oot pump NOTE : Inflation is sufficient when you can no longer put air into the tube section using one foot. When inflation is finished, remove foot pump hose end from valve. Verify pressure using valve adapter (included in tube repair kit) and a low pressure gauge (70 kPa (10 PSI)). NOTE : Seat valve adapter as quickly as possible onto valve opening ana firmly maintain in position to avoid air loss. Pressure must be set at 21 kPa (3 PSI). If pressure is too high, reduce it by slightly pushing the center plunger. WARNING : Never inflate tube more than 21 kPa (3 PSI). Inflat- ing tube more than specified pressure may damage tube and possibly cause personal injury. When pressure is set, screw valve cap. NOTE : It is ver, ‘portant to seal the valve with this cap in order to increase air tightness and to keep out unwanted dirt and water. Proceed with the same procedure for the remaining tube sections. 49 Order of Inflation The tubes must be inflated to the recommended pressure at all times. NOTE : When you cannot depress the tube with the pressure of your finger, you have reached approximate working pressure, Air pressure in tube sections should be rechecked while the jet boat is afloat ; adjust if necessary, as the temperature of the water may be different from that of the air, which could result in changes in air pressure. NOTE : Exterior air temperature / aifects tube air pressure; always adjust. Tube Deflation Remove valve cap of any tube sections by unscrewing it a quarter of a turn counterclockwise. Push and twist the center plunger in either direction to lock it into the open position. Valve button F003 011 035 The tube section will now automatically deflate. Reinstall valve cap. Proceed with the same procedure for the remaining tube sections. 50 Tube Minor Repairs Tear Repair of Less than 5 cm (2 in) For best results, repairs should be performed in temperatures of 18° to 25°C (64° to 77°F). Avoid carrying out repairs in direct sunlight, rain or in conditions of high humidity. NOTE : For any major repair, refer to an authorized dealer. Deflate completely tube section to be repaired. Cut a patch about 75 cm (3 in) larger than the tear in every direction. Al ways round corners. Using only a pencil, trace the position of the patch on the tube. CAUTION : Do not use pen or felt-tip pen as ink will perma- nently mark tube. sand thoroughly the area of the tube with a 80 grit sandpaper. NOTE : Protect tube surface in vicinity with masking tape. NOTE : Supplied materials included in repair kit do not need to be sanded. Remove masking tape. Clean the patch and tube areas with a solvent such as methyl! ethyl ketone, toluene or acetone. Allow solvent to completely evaporate. Apply a thin layer of adhesive (included in repair kit) to the patch and the tube. Allow to dry so that adhesive is dry to the touch. Apply a second thin layer of adhesive on both parts. Allow the second coat to dry until tacky to the touch ; then, apply the patch. Smooth out the patch with a spoon- shaped tool working from the center to the outside to remove all excess glue and air bubbles. Allow 24 hours to dry before inflating. Clean any excess of glue. General Inspection and Care Inspection Check engine compartment for any damage and fuel / oil injection systems for leaks. Aiso check battery vent tube for electrolyte leaks. Ensure all hose clamps are properly secured and no hose is cracked, kinked or presenting any other damage. enews : If any gasoline leak or odor is found, do not start the engine. Have the jet boat serviced by an authorized dealer. Failure to correct a leak could lead to an explosion. Inspect muffler, battery and reservoir fastening devices. Check electrical connections for corrosion and tightness. Cleaning Twice a year, the bilge should be cleaned with hot water and detergent or bilge cleaner to remove any possible fuel / oil / electrolyte deposits and mildew. Occasionally, wash the body with hot water and soap (only use mild detergent). Remove any marine organisms from engine and /or hull. Apply nonabrasive wax such as silicone wax. CAUTION : Never clean appar- ent fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc. When the jet boat is operated in foul water and particularly in salt water, tube must be rinsed frequently with fresh water. Occasionally, wash the tube with warm water and soap (only use mild detergent). Stubborn stains and scuff marks may be removed using methy! ethyl ketone, toluene or acetone. CAUTION : Never clean decals with strong detergent, methyl ethyl ketone, toluene or acetone. Limit application of these solvents on tube seams to avoid glue dilu- tion. 51 TRANSPORTATION, STORAGE AND PRE-SEASON PREPARATION Transportation WARNING : Always turn the fuel valve to OFF position when transporting or storing the jet boat. Tie the jet boat to both bow and stern (front / rear) eyelets so that it is firmly retained on the trailer. Use additional cables if necessary. CAUTION : Do not route ropes or tie-downs over the seats or tubes as they could produce perma- nent damage. Wrap ropes or tie- downs with rags or similar protec- tors where they can touch the jet boat body. Ensure engine and storage covers are properly latched. A SEA-DOO cover should protect the jet boat, particularly before driving on dirt roads. Observe trailering safety precautions. Storage lt is recommended that the jet boat be serviced by an authorized dealer for storage but the following operations can be performed by you with a minimum of tools. CAUTION : Do not run the engine during the storage period. Engine Draining Check engine drain tube running from bulkhead fitting to outlet socket. Make sure there is no sand or other particles in it and that it is not obstructed so that water can leave the engine. Clean tube and fitting (on outlet) as necessary. CAUTION: Water in engine drain tube must be free to flow out, otherwise water could be trapped in engine. Should water freeze in engine, severe damage will occur. Check engine drain tube for obstructions. 52 FOO3 004 001 Boat Rinsing Thoroughly rinse the hull, bilge and engine compartment with fresh water. Propulsion System Lubricant in impeller shaft reservoir should be drained and reservoir cleaned. Refill with 65 mL (2.2 oz) of SEA-DOO synthetic polyolester oil 79W/90 GL5 type Cgearlube. Referto an authorized dealer for this operation. CAUTION : Use only SEA-DOO jet pump oil or equivalent synthetic gear oil, otherwise component service life could be reduced. Do not mix oil brands or types. Lubricate PTO flywheel and seal carrier. Refer to procedure discussed in MAINTENANCE. Fuel System SEA-DOO fuel stabilizer (or equivalent), can be added in fuel tank to prevent fuel deterioration and carburetor gumming. Follow manufacturer's instructions for proper use. CAUTION: Fuel stabilizer should be added prior engine lubrication to ensure carburetor protection against varnish deposit. WARNING: Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Always wipe off any fuel spillage from the jet boat. Always turn the fuel valve to OFF position when storing the jet boat. Cooling System Flushing and Engine Internal Lubrication Refer to procedure discussed in POST- OPERATION CARE. Battery Contact your authorized dealer or refer to the appropriate Shop Manual for proper storage procedure. Anticorrosion Treatment Wipe off any residual water in the engine compartment. spray SEA-DOO LUBE lubricant over metallic components in engine compartment. Additional Recommended Protection Cooling system may be filled with an equal part of water and antifreeze solution. CAUTION : Always use ethyl- ene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum en- gines. NOTE: The engine does not have to run during this operation. Three hoses have to be disconnected to allow air to escape and antifreeze solution to completely fill cooling system water jackets. Install a hose pincher on tuned pipe water injection hose. Disconnect engine water inlet hose, drain hose and water outlet hose. Disconnect Install a hose pincher on water injection hose | | Water inlet F003 004 001.1 hose Raise all hoses above the highest point of tuned pipe and temporarily tie them together. Insert a funnel into inlet hose going to the water inlet socket at tuned pipe. Pour about 2 liters (1/2 gal) of antifreeze solution through the funnel. Tie up all hoses higher than tuned pipe. NOTE : If hoses are not attached higher than tuned pipe, coolant will drain out. . Water inlet Hold hoses higher hose than tuned pipe F003 004 003 The following steps should be performed to provide the jet boat enhanced protection. 53 Remove muffler and drain out as much water as possible. Reinstall muffler. OR: Disconnect one hose from muffler and pour some antifreeze liquid inside muffler. Reconnect hose. Lubricate the throttle cable with SEA- DOO LUBE lubricant. Clean the bilge with hot water and detergent or with bilge cleaner. Rinse thoroughly. Lift front end of jet boat to completely drain bilge. If any repairs are needed to body or to the hull, contact your dealer. For paint touch up to mechanical parts use Bombardier spray paint. For small gelcoat repairs, a Bom- bardier repair kit is available. See Ac- cessories and Service Products section. Replace damaged labels /decals. NOTE : Bilge cleaning shouid be done prior to anticorrosion treatment. Wash the body with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull. Apply a nonabrasive wax such as silicone wax. CAUTION : Never clean appar- ent fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc. | the jet boat is to be stored outside, cover it with an opaque tarpaulin to prevent sun rays and grime from affect- ing the plastic componenis, Jet boat finish as well as preventing dust accu- mulation. For storage period, tube should be cleaned and dried. If possible, store the jet boat with the tube sections 90% inflated. If it is not possible, fold the tube into the hull and tie it loosely into this position. 54 CAUTION: Never leave the jet boat stored in direct sunlight. UV radiation will decrease tube life and dull finish. The jet boat must never be left in water for storage. Keep away from rodents. The engine cover should be partially left opened during storage. This will avoid engine compartment condensation and possible corrosion. NOTE: If the jet boat is stored outside with engine cover partially opened and without a tarpaulin, unscrew the rear drain plugs in order to avoid water build up in the bilge during rainfall. Tilt the jet boat to the rear so that water can flow out of floorboard. Pre-Season Preparation Use the following chart. Since technical skills and special tools are required, some operations should be performed by an authorized dealer. WARNING: Observe WARN- INGS and CAUTIONS men- tioned throughout this guide which are pertinent to the item being checked. When component conditions seem less than satisfactory, replace with genuine BOMBARDIER parts or approved equivalents. Pre-Season Preparation Chart NOTE : It is highly recommended that the dealer perform at the same time the annual safety inspection in addition to the pre-season preparation. OPERATIONS To be performed by Lubrication / corrosion protection OPERATOR Battery condition / charging and reinstallation DEALER Battery, starter connections and routing ® DEALER Spark plug replacement O OPERATOR Impeller shaft reservoir oil inspection DEALER Propulsion system inspection DEALER Oil filter replacement DEALER Oil injection reservoir filling OPERATOR Flame arrester cleaning / inspection ® DEALER Fuel filter replacement DEALER Fuel line condition ® DEALER Filler neck, fuel tank and fuel cap condition @ DEALER Check valves, fasteners, fuel system pressurization O DEALER Throttle © / choke cable inspection / adjustment DEALER Oil injection pump adjustment and bleeding DEALER Engine ignition timing DEALER Carburetor adjustment DEALER Steering system alignment / inspection O DEALER Reverse cable adjustment DEALER baie tickaps drain holes / DEALER Inspection of cooling system inlet / outlet hoses O DEALER Engine overheating beeper DEALER Fire extinguisher condition / mounting O OPERATOR Tube and tube attachment condition DEALER ® Before installing new spark plugs, it is suggested to burn the excess SEA-DOO LUBE lubricant by starting the engine using the old spark plugs. ® Safety item covered in the annual safety inspection. Q AUS Only perform this operation in a well ventilated area. Coupler hose must be installed or jet boat must be in water to cool engine. Running the engine without cooling water will damage exhaust hose interior and may damage engine. 55 TROUBLESHOOTING The following chart is provided to help in diagnosing the probable source of simple troubles. You may be able to solve many of these problems rather quickly, but others may require the skills of a mechanical technician. In such a case, consult an authorized dealer for servicing. ENGINE WILL NOT START OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine does not turn over e Safety lanyard removed + Burnt fuse e Discharged battery e Battery connections, corroded or loose e Water-flooded engine Install cap over switch. Check wiring then replace fuse. Refer to an authorized dealer. Refer to an authorized dealer. Refer to Submerged Boat in SPECIAL PROCEDURES. Engine slowly turns e Discharged or weak battery Refer to an authorized dealer. Engine turns over e Fuel tank empty or water-contaminated e Fuel filter clogged or water-contaminated e Fuel-flooded engine : — Fouled / defective spark plugs — Misuse of choke -- Fuel valve closed Refill. Syphon and fill with fresh fuel. Clean, check fuel tank for water. Replace. Use only with cold engine. Replace spark plugs. Turn fuel valve to ON position. ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark e Fouled / defective / worn spark plugs e Faulty rev limiter e Too much oil supplied to engine Replace. Refer to an authorized dealer. Improper oil pump adjustment, refer to an authorized dealer. Lean fuel mixture e Fue! : Level too low, stale or water-contaminated e Fuel filter, clogged or water-contaminated Syphon and / or refill. Refer to an authorized dealer, Rich fuel mixture (high fuel consumption) e Flame arrester dirty / clogged e Partially closed choke Clean or replace. Refer to an authorized dealer. ENGINE OVERHEATS OTHER OBSERVATION POSSIBLE CAUSE REMEDY Overheating beeper sounds e Clogged jet pump water intake e Incorrect type of fuel or oil e Clogged coolant system Clean. Syphon and refill. Flush cooling system with coupler hose. 56 ENGINE CONTINUALLY BACKFIRES OTHER OBSERVATION POSSIBLE CAUSE REMEDY e Faulty rev limiter Refer to an authorized dealer. Weak spark + Fouled / defective / Replace. worn spark plugs Overheated engine e See ENGINE OVERHEATS ENGINE PINGING OR KNOCKING OTHER OBSERVATION POSSIBLE CAUSE REMEDY + Poor quality gasoline / low octane e Spark plug heat range too high e Ignition timing Use well known quality and recommended gasoline. Use recommended spark plugs. Refer to an authorized dealer. ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION POSSIBLE CAUSE REMEDY e Weak spark / incorrect fuel mixture + Water in fuel or injection oil Refer to ENGINE MISFIRES... Syphon and replace. Overheated engine e See ENGINE OVERHEATS JET BOAT CAN NOT REACH TOP SPEED OTHER OBSERVATION POSSIBLE CAUSE REMEDY Cavitation ® Jet pump water intake clogged + Damaged impeller or boot Clean. Replace. Refer to an authorized dealer. ABNORMAL NOISE FROM PROPULSION SYSTEM OTHER OBSERVATION POSSIBLE CAUSE REMEDY Cavitation e Weeds or debris jammed around impeller Clean and check for damage. e Damaged impeller shaft or drive shaft Refer to an authorized dealer. 57 SPECIFICATIONS ENGINE EXPLORER (5821) Engine type Bombardier-Rotax 657, 2-stroke Induction type Rotary valve Exhaust system Water cooled / water injected Lubrication Type Oil injection Oil type BOMBARDIER ROTAX INJECTION OIL Number of cylinders 2 Displacement 650 cm? (39.66 in?) Rev limiter setting 7000 RPM (+100, - 50) COOLING Type Water cooled, total loss type. Direct flow from propulsion unit. ELECTRICAL Magneto generator output 160 W @ 6000 RPM Ignition system type Capacitor discharge ignition (CDI) Spark plug Make and type NGK, BR8ES Gap 0.5 - 0.6 mm (.020 - .024 in) Starting system Electric starter Battery 12V,19A Fuse Starting system BA Charging system 15A Lighting system 7.5 À Blower system 7,5 À CARBURETION Fuel type Regular unleaded gasoline Carburetor Diaphragm type, quantity : 2 58 PROPULSION EXPLORER (5821) Propulsion system Bombardier Formula Jet Pump Jet pump type Axial flow, single stage Transmission Direct drive Impeller shaft reservoir SEA-DOO synthetic polyolester oil oil type 75W90 gear lube Pivoting angle of direction (nozzle) ~26° Minimum required water level 90 em (3 ft) for jet pump PERFORMANCE Cruising time at Fuel tank full throttle without reserve 1:05 В Fuel tank reserve DIMENSIONS Number of passengers © 1 operator and 4 passengers Overall length 396 cm (155.9 in) Overall width 206 cm (81.1 in) Overall height 132 cm (52 in) Weight (dry) 322 kg (710 lb) Load limit (passengers + luggage) 474 kg (1045 Ib) Hull material Composite (Fiberglass) Tube material Neoprene, hypalon, polyester reintorced CAPACITIES Fuel tank 48 L (12.6 U.S. gal) Impeller shaft reservoir Capacity 65 mL (2.2 U.S. oz) Oil level Up to plug Injection oil reservoir 4.5 L (153 U.S. fl. oz) Ф Refer to load limits. BOMBARDIER INC. reserves the right to make changes in design and specifications and / or to make additions to, or improvements in its products without imposing any obligation upon itself to install them on its products previously manufactured. 59 Si* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length meter m mass kilogram kg force newton N liquid liter L temperature Celsius °C pressure kilopascal kPa torque newton-meter Nem land velocity kilometer per hour km/h navigation velocity Knot kn PREFIXES PREFIX SYMBOL MEANING VALUE kilo k one thousand 1000 centi С one hundredth of 0.01 milli m one thousandth of 0.001 micro u one millionth of 0.000001 CONVERSION FACTORS TO CONVERT TO? MULTIPLY BY in mm 25.4 in cm 2.54 in? cm? 6.45 in? cm? 16.39 ft m 0.3 07 9 28.35 lb kg 0.45 Ibf N 4.4 Ibfein Nem 0.11 Ibfeft Nem 1.36 Ibfeft ibfein 12 PSI kPa 6.89 Imp. OZ U.S. oz 0.96 imp. 02 mL 28.41 imp. gal U.S. gal 1.2 imp. gal L 4.55 U.S. oz mL 29.57 U.S. gal L 3.79 knot MPH 1.15 MPH km/h 1.61 Fahrenheit Celsius (°F - 32) + 1.8 Celsius Fahrenheit (°C x 1.8) + 32 hp kW 75 * O) 60 The international system of units abbreviates Sl in all languages. To obtain the reverse sequence, divide by the given factor. Example: to convert “millimeters” to “inches”, divide by 25.4. O NOTE : Conversion factors are rounded off to 2 decimals for easier use. ACCESSORIES AND SERVICE PRODUCTS These accessories and other fine Sea-Doo products are available at your dealer. ACCESSORIES ACCESSORIES Coupler Hose Extinguisher P/N 295 500 099 P/N 298 770 000 (US) P/N 298 777 000 (CAN) [001 004 035 Hose Pincher | P/N 295 000 076 FOOT 001 023 Sea-Doo Cover P/N 298 350 009 A001 001 091 Bimini Top P/N 295 500 163 impeller See your authorized Sea-Doo dealer for appropriate choice of impeller \ F001 001 022 61 ACCESSORIES ACCESSORIES Tachometer Kit P/N 295 500 238 2002 001 004 Tie-Down (purple) Up to 1.50 m (5 ft) long P/N 298 752 040 Up to 3.60 m (12 ft) long with ratchet P/N 298 753 040 Speedometer Kit P/N 295 500 237 F002 001 005 Fishing Seat Sleeve P/N 204 000 101 Lift Kit P/N 298 780 090 (Nickel-plated) P/N 298 790 040 (Stainless steel) First Aid Kit P/N 298 296 001 Survival Kit P/N 298 295 040 Telescopic Paddle P/N 295 500 218 62 Mooring Line P/N 298 309 000 sand Bag Anchoir P/N 295 500 213 PRODUCTS PRODUCTS synthetic Grease P/N 293 550 010 Wiz A Nabe F001 001 041 Jet Pump Synthetic Oil P/N 293 600 011 F001 001 025 Antiseize Lubricant P/N 293 800 023 mz 549 fuss tor о ne F091 001 043 Spray Paint for Metallic Parts Only Mauve P/N 293 500 020 White P/N 293 500 029 FOO1 001 026 Sea-Doo Lube Lubricant P/N 293 600 006 F001 001 028 Dielectric Grease P/N 293 550 004 F001 001 042 Gelcote® Repair Kit P/N 295 500 216 oii \ Завд 06 GELCOTE® REPALA KIT NÉCESSAIRE DE MÉPARATION GELCOTE® sm Me “he du: EH ENS м Нан 34+ St el = > ~ Ba Re u 4 F001 001 027 63 Injection Oil 1 liter P/N 293 600 005 4 liters P/N 293 600 004 F001 001 044 Gelcoat Spray Paint P/N 293 500 076 (Super White) Sea-Doo Cleaner 400 gr P/N 293 110 001 AL P/N 293 110 002 RSE ORE RES ‘| CLEANER F001 001 040 2001 001 074 Tube Repair Kit P/N 204 000 046 F003 015 002 Fuel Stabilizer P/N 413 408 600 A000 001 139 64 OTHER PUBLICATIONS AVAILABLE PUBLICATION P/N Shop Manual 219 100 022 sea-Doo Racing Handbook 219 000 019 65 JET BOAT MODEL NO. HULL IDENTIFICATION NUMBER (H.I.N.) ENGINE IDENTIFICATION NUMBER (E.I.N.) Purchase Date | | | | Warranty Expiry Date | | | | year month day To be completed by the dealer at the time of the sale DEALER IMPRINT AREA Please verify with your selling dealer to ensure your SEA-DOO jet boat has been registered with Bombardier. 66 CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you If correction to your jet boat becomes necessary. O NOTE : This card is strictly for change of address only. CHANGE OF ADDRESS STOLEN UNITS In the event that your jet boat is stolen, you should notify your area's distributor warranty department of such. Please provide your name, address, phone number, hull identification number and date it was stolen. Bombardier will provide a list of stolen units to all jet boat dealers on a monthly basis to aid in recovery of such units to their owners. A 1 | CHANGE OF ADDRESS m | | JET BOAT | | IDENTIFICATION NUMBERS | | | | | | | | | | | | | | | | | | | | Model Number Hull Identification Number (H.I.N.) | | | | OLD ADDRESS : | | NAME | | | | | | NO. STREET APT | | | | CITY STATE / PROVINCE ZIP / POSTAL CODE | | NEW ADDRESS: | | NAME | | | | NO. STREET APT | | | | CITY STATE / PROVINCE ZIP / POSTAL CODE | | | | | | | | | | | | | | | | | 4 STAMP > O Q << M 5 ers N E ASE eota D toga mA <¢ = < Z < = Ow < am an > oO a ae iach > ee ee 2 He oo ee. P219000023 er

Sea-Doo Explorer 1995 Operator Guide

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BOMBARDIER

SeaDoo Speedster 200

Sea-doo

1997 HX