Sea-doo 2001 UTOPIA 185 Guide d'installation

Shop Manual

2001 UTOPIA 185

(5444/5451/5452/5453/5454/5456/5457/5458/5496/5497/5498/5499)

2002 UTOPIA 185

(5462/5464/5466/5475/5476/5477/5478/5479/5480)

2002 UTOPIA 205

(5745/5746/5747/5748/5749/5750)

Legal deposit:

National Library of Quebec

2nd trimester 2002

National Library of Canada

reproduced in any form without the prior written

permission of Bombardier Inc.

©Bombardier Inc. 2002

Printed in Canada

®™Registered trademarks of Bombardier Inc.

Loctite®is a trademark of Loctite Corporation.

Snap-on®is a trademark of Snap-on Tools Corporation.

Gelcote®is a trademark of Gelcote International Limited.

LMR2002-001_00-02A.FM I

SECTION SUBSECTION PAGE

SAFETY NOTICE .................................................................................................................................. II

INTRODUCTION ................................................................................................................................... III

01 SERVICE TOOLS AND

PRODUCTS

01 – Table of Contents ..................................................................... 01-01-1

02 – Service Tools............................................................................ 01-02-1

03 – Service Products ...................................................................... 01-03-1

02 MAINTENANCE 01 – Table of Contents ..................................................................... 02-01-1

02 – Periodic Inspection Chart ......................................................... 02-02-1

03 – Flushing and Lubrication........................................................... 02-03-1

04 – Storage ..................................................................................... 02-04-1

03 ENGINE 01 – Table of Contents ..................................................................... 03-01-1

02 – Exhaust System ....................................................................... 03-02-1

04 FUEL SYSTEM 01 – Table of Contents ..................................................................... 04-01-1

02 – Fuel Circuit ............................................................................... 04-02-1

05 ELECTRICAL SYSTEM 01 – Table of Contents ..................................................................... 05-01-1

02 – Battery...................................................................................... 05-02-1

03 – Instruments and Accessories................................................... 05-03-1

06 STEERING SYSTEM 01 – Table of Contents ..................................................................... 06-01-1

02 – Steering System....................................................................... 06-02-1

03 – Throttle/Shifter Controller......................................................... 06-03-1

07 HULL/DECK 01 – Table of Contents ..................................................................... 07-01-1

02 – Components............................................................................. 07-02-1

03 – Repair ....................................................................................... 07-03-1

08 TECHNICAL DATA ...................................................................................................................... 08-01-1

09 WIRING DIAGRAM ..................................................................................................................... 09-01-1

TABLE OF CONTENTS

II LMR2002-001_00-02A.FM

SAFETY NOTICE 0

This manual was primarily published to be used by sport boat mechanic technicians trained by the man-

ufacturer who are already familiar with all service and maintenance procedures relating to Bombardier

made Sea-Doo sport boats. Mechanic technicians should attend continuing training courses given by

Bombardier Training Dept.

Please note that the instructions will apply only if proper hand tools and special service tools are used.

It is understood that this manual may be translated into local language upon certain conditions and fur-

thermore agreed that in the event of any discrepancy among the two versions, the English version shall

prevail.

The content depicts parts and/or procedures applicable to the particular product at time of writing. Service

and Warranty Bulletins may be published to update the content of this manual. Make sure to read and

understand these.

The use of Bombardier parts is most strongly recommended when considering replacement of any com-

ponent. Dealer and/or distributor assistance should be sought in case of doubt.

Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,

self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking

device is impaired, it must be renewed.

This manual emphasizes particular information denoted by the following wording and symbols:

CAUTION: Denotes an instruction which, if not followed, could severely damage boat components.

NOTE: Indicates supplementary information needed to fully complete an instruction.

Although the mere reading of such information does not eliminate the hazard, your understanding of the

information will promote its correct use. Always use common shop safety practice.

Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the

contents. We strongly recommend that any services be carried out and/or verified by a highly skilled

professional technician. It is understood that certain modifications may render use of the boat illegal under

existing federal, provincial and state regulations.

WARNING

Identifies an instruction which, if not followed, could cause serious personal injury including

possibility of death.

SAFETY NOTICE

LMR2002-001_00-02A.FM III

INTRODUCTION 0

This Shop Manual covers the following BOMBARDIER

made SEA-DOO®sport boat:

–2001/2002 Utopia 185

–2002 Utopia 205

MAXIMUM BOAT CAPACITY

Depending on model, the sport boat maximum ca-

pacity label can be found on RH or LH side of op-

erator position.

UTOPIA 185 CAPACITY LABEL LOCATION

UTOPIA 205 CAPACITY LABEL LOCATION

HULL IDENTIFICATION NUMBER

(H.I.N.)

The Hull Identification Number (H.I.N.) is located

at right hand rear side of hull.

TYPICAL

1. Hull Identification Number (H.I.N.)

Refer to the next illustration for a description of

the serial number.

CEC indicates that boats are manufactured in USA.

F10A0CA

F10A0DA

F10A0EA

CECH 1 2 3 4 5 L 4 9 5

Model year

Serial

number*

A letter may al o be u ed a a digit.

F00A11A

Month of production

Year of production

Model

INTRODUCTION

IV LMR2002-001_00-02A.FM

ENGINE IDENTIFICATION

NUMBER (E.I.N.)

Refer to Mercury Marine (M2) Jet Drive Operator’s

Guide.

ARRANGEMENT OF THIS

MANUAL

The manual is divided into 9 major sections:

Each section may be divided in various subsections,

and again, each subsection have one or more divi-

sion.

01 SERVICE TOOLS AND PRODUCTS

02 MAINTENANCE

03 ENGINE

04 FUEL SYSTEM

05 ELECTRICAL SYSTEM

06 STEERING SYSTEM

07 HULL/DECK

08 TECHNICAL DATA

09 WIRING DIAGRAMS

INTRODUCTION

LMR2002-001_00-02A.FM V

Section 03 ENGINE

Sub ection 04 (MAGNETO SYSTEM)

MAGNETO SYSTEM

717 Engine

03-04-1

F01D4WS

12 11

5 Nm

(44 lbfin)

13 9 Nm

(80 lbfin)

Loctite

242

Loctite

242

6 Nm

(53 lbfin)

Loctite

242

6 Nm

(53 lbfin)

Loctite

242

6 Nm

(53 lbfin)

Loctite

242

Loctite

648

145 Nm

(107 lbfft)

Anti- eize

lubricant 2

9 Nm

(80 lbfin)

LMR2001_005_03-04A.FM

Page heading

indicates section

and subsection

detailed.

Tightening torque nearby fastener.

In this case, nut must be torqued to

145 Nm (1 7 lbfft).

Exploded view assists

you in identifying

parts and related

positions.

TYPICAL PAGE

F00A1WS

Illustration number

for publishing

process.

Subsection title

indicates

beginning of the

subsection.

Dotted box

contains parts of

a particular

model or an

exploded view.

Page numbering system:

3: ENGINE section

4: MAGNETO SYSTEM subsection

1: First page of this subsection

Italic sub-title

above exploded

view indicate

pertaining models.

Drop represents a

liquid product to be

applied to a surface.

In this case Loctite

242 to screw

threads.

Bold face number

indicates special

procedure

concerning this part.

CAUTION: Pay attention to torque

pecification . Some of the e are in

lbfin in tead of lbfft. U e appro-

priate torque wrench.

Document

number for

publishing

process.

INTRODUCTION

VI LMR2002-001_00-02A.FM

Section 06 FUEL SYSTEM

Sub ection 03 (CARBURETORS)

06-03-4

Step : Install pump gauge tester to pulse nipple

Step : Pump tester until it reaches the desired pressure

1. Fuel outlet nipple

2. Fuel inlet nipple

A. 28 kPa (4 PSI)

Diaphragm

Challenger Model Only

CARBURETOR REMOVAL

Inspect parts for corrosion dammage (shaft, butterfly,

spring screw, check valve housing, etc.).

Pump Diaphragm Leak Te t

TYPICAL

To remove carburetors from engine, proceed as fol-

lows:

Remove air vent tube support.

Unlock retaining slides holding air intake silencer base.

Remove air intake silencer base from watercraft.

Remove screws holding flame arrester base support

to cylinder head cover.

Unscrew base retaining screws then remove base from

carburetors and move to front of watercraft.

Turn the valve to OFF position.

NOTE: For fuel line removal, use pliers (P/N 295

54).

Disconnect pulse line from fuel pump.

Disconnect fuel fuel supply line from fuel pump.

Disconnect fuel return line.

Disconnect oil injection pump cable, throttle cable and

choke cable.

Remove screws and lock washers retaining carburetors.

Remove carburetors from intake manifold.

All Others Models

Remove 4 bolts and lock washers from rotary valve

cover then move carburetors and rotary valve cover on

top of engine.

NOTE: When removing rotary valve cover , pay attention

that the rotary valve stay in place, otherwise it must be

timed.

Remove carburetors from intake manifold.

Disconnect fuel bypass line between carburetors (twin

carburetors).

Remove carburetor(s) from rotary valve cover.

DISASSEMBLY AND INSPECTION

Using a suitable pump gauge tester, perform the fol-

lowing test proceeding as follows:

- Install pump gauge tester (P/N 295 83) on pulse

nipple.

- Pump tester until it reaches 28 kPa (4 PSI).

Diaphragm no. 3 must stand pressure for 1 seconds.

If pressure drops, replace diaphragm.

TYPICAL PAGE

Sub-title indicates a

particular procedure for

the named part.

TYPICAL caption

indicates a general

view which does not

represent full detail.

Italic bold face

setting in this case

indicates that

particular procedure

for Challenger is

finished, so from this

point, all others

models are

concerned.

Italic bold face setting

indicates a particular

procedure concerning

a model.

Service tool to be

used to perform a

certain procedure.

Title indicates main

procedure to be

carried-out.

F00A1XS

Sub-sub-title

indicates a

particular testing,

adjustment or

repair procedure.

Illustration

always follows

text it is

pertained to.

Numbers in a frame

are used to give a

sequence to be

perfomed for above

illustration.

Numbers are used

for description of

components for

above illustration.

Letters are used for

any measures for

above illustration.

F01F0XB

1 2

Number: following

part name refers to

exploded view at

beginning of

subsection.

F01F0XB

1 2

LMR2001_006 _06-03A.FM

INTRODUCTION

LMR2002-001_00-02A.FM VII

LIST OF ABBREVIATIONS USED

IN THIS MANUAL

GENERAL INFORMATION

In marine industry, PORT, STARBOARD, BOW and

STERN are used to refer to LEFT, RIGHT, FRONT

and REAR respectively. They always refer to the

operator’s position sitting in boat.

TYPICAL

1. BOW (front)

2. STARBOARD (RH)

3. STERN (rear)

4. PORT (LH)

The information and component/system descrip-

tions contained in this manual are correct at time

of publication. Bombardier Motor Corporation of

America (B.M.C.A.), however, maintains a policy

of continuous improvement of its products with-

out imposing upon itself any obligation to install

them on products previously manufactured.

Because of our ongoing commitment to product

quality and innovation, Bombardier Inc. reserves

the right at any time to discontinue or change

specifications, designs, features, models or equip-

ment without incurring obligation.

This Shop Manual uses technical terms which

may be different from the ones of the Parts Cata-

logs.

When ordering parts always refer to the specif-

ic model Parts Catalogs.

AC Alternative Current

Ass’y Assembly

CDI Capacitor Discharge Ignition

DC Direct Current

E.I.N Engine Identification Number

H.I.N. Hull Identification Number

HP Horsepower

LH Left Hand side (port)

MAG Magneto

N.A. Not Applicable

P/N Part Number

PTO Power Take Off

RFI Radio-Frequency Interference

RH Right Hand side (starboard)

RPM Revolution Per Minute

SAE Society of Automotive Engineering

T.I.G. Tungsten Inert Gas

Vac Volt, Alternative Current

Vdc Volt, Direct Current

F04L03C

INTRODUCTION

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