Sea-doo 2001 UTOPIA 185 Install guide

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
All rights reserved. No parts of this manual may be
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
1
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
4
68
Loctite
242
7
6 Nm
(53 lbfin)
Loctite
242
6 Nm
(53 lbfin)
9
Loctite
242
5
6 Nm
(53 lbfin)
3
14
Loctite
242
4
Loctite
648
10
15
145 Nm
(107 lbfft)
Anti- eize
lubricant 2
9 Nm
(80 lbfin)
1
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
1
2
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
A
2
1
1 2
Number: following
part name refers to
exploded view at
beginning of
subsection.
F01F0XB
A
2
1
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
24
1
3
F04L03C
INTRODUCTION

VIII LMR2002-001_00-02A.FM
ILLUSTRATIONS AND
PROCEDURES
The illustrations in this document show the typical
construction of the different assemblies and, in all
cases, may not reproduce the full detail or exact
shape of the parts shown. However, they represent
parts which have the same or a similar function.
CAUTION: These boats are 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 boat or possible personal injury.
As many of the procedures in this manual are in-
terrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before commencing
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.
Technical Publications
Bombardier Inc.
Valcourt (Quebec), Canada
INTRODUCTION