Printed in Canada (LBL2004-001A.FM SB)®TMTrademarks of Bombardier Inc. or its subsidiaries.©2003 Bombardier Inc. All rights reserved

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MODEL NUMBER HULL IDENTIFICATION NUMBER (H.I.N.)

PREDELIVERY CHECK LISTTHIS CHECK LIST MUST BE USED IN CONJUNC-TION WITH THE PREDELIVERY BULLETIN OFTHE APPLICABLE SPORT BOAT.

POTABLE WATER SYSTEM (if so equipped)Potable water system should always be disinfect-ed and flushed before delivery to customer.Refer to the Operator’s Guide for complete de-tailed procedure.

DESS (Digitally Encoded Security System) (if so equipped)The sport boat cannot be started and used withoutprogramming the safety lanyard.The use of the following tool is mandatory for pro-gramming:VCK (Vehicle Communication Kit) and the B.U.D.S.(Bombardier Utility and Diagnostic Software) (P/N529 035 844).ORMPEM programmer (P/N 529 035 878) with ver-sion 3.3 and up (except on 4-TEC models).For detailed information pertaining to the use ofthe VCK, use the help menu inside the B.U.D.S.software or if using the MPEM programmer, referto the guide that is shipped with it.When programming, first start by erasing the pre-viously programmed keys at factory THEN, pro-gram the safety lanyard that is shipped with thesport boat.NOTE: Some parts or accessories may apply to aparticular model only. To find out specific parts oraccessories of a sport boat, refer to appropriatePredelivery Bulletin.

GENERAL INSTRUCTIONS

NOTE: File this document in sport boat file. Givea copy to owner.

PARTS INSTALLATION

Battery

Trailer wheels (if necessary)(refer to trailer Owner‘s Guide)

French labels (if applicable)For sport boats used in Canada: Apply the Canadian Coast Guard Compliance Label

LIQUIDS

Battery(ies) electrolyte

Fuel

Injection oil (2-stroke models)Check engine oil (4-TEC models)

Purge coolant system(s) of air and check coolant levels (4-TEC models)

ADJUSTMENTS

Steering alignment

Throttle cable(s)Controller (throttle/shifter)/select or lever cables

Weedless system

Idle speedTrailer (refer to trailer Owner’s Guide)

FINAL INSPECTION

Inspect movement and operation of:Throttle lever(s)

Monitoring beeper(s)

Safety lanyard/DESS and engine start/stop button(s)

All gauges

Navigation lightsBilge blower

Bilge pump

Controller (throttle/shifter)/selector leverMain battery cut-off switch

Pressurize fuel system and lubrication system (apply proper pressure)

Water test sport boatWash trailer with fresh water

Clean sport boat thoroughly and polish

Check all items on Mercury Predelivery Inspection Sheet (where applicable)

Verify trailer wheel lug nuts torque(refer to trailer Owner’s Guide)

AT SALE, EXPLAIN TO OWNER

Bombardier documentation: Operator’s Guideand warranty (and Mercury documentationwhere applicable).

AT DELIVERY

Complete and return Bombardier warrantyregistration signed by owner (and Mercurywarranty registration where applicable).

PREPARED BY: DATE:day month year

DEALER NO.:

INSPECTED BY: DATE:day month year

DEALER SIGNATURE:

The dealer named on this document has instructedme on the operation, maintenance, safety featuresand warranty policy, all of which I understand. I amalso satisfied with the predelivery set-up and inspec-tion of my sport boat. I have also received a copy ofthe Operator’s Guide for my craft.

OWNER SIGNATURE:

DATE:day month year

PRINT:

Printed in Canada (lbl2004_002a.fm SB)®TMTrademarks of Bombardier Inc. or its subsidiaries.©2003 Bombardier Inc. All rights reserved.

2004-1 Page 1 of 12

GENERALThis bulletin must be used in conjunction with thecheck list enclosed in Operator’s Guide bag. Makesure that Predelivery Check List is completed andsigned.To obtain warranty coverage, predelivery proceduresmust be performed by an authorized Sea-Doo® sportboat dealer/distributor.

PREPARATION TIME: 1.5 hourNOTE: The information and components/systemdescriptions contained in this document are cor-rect at the time of publication. Bombardier MotorCorporation of America (B.M.C.A.) however, main-tains a policy of continuous improvement of itsproducts without imposing upon itself any obliga-tion to install them on products previously manu-factured.

Because of our ongoing commitment to productquality and innovation, Bombardier reserves theright at any time to discontinue or change specifi-cations, designs, features, models or equipmentwithout incurring obligation.The illustrations in this document show the typicalconstruction of the different assemblies and maynot represent the full detail or exact shape of theparts. However, they represent parts that have thesame or similar function.The content of this bulletin is designed as aguideline only. All mechanics performing pre-delivery procedures should have attended thecurrent model year service training. Further in-formation or inquiries should be directed toyour service representative and/or specific ShopManual sections.Please complete the Predelivery Check List foreach sport boat and return a customer signedcopy. Make sure the customer receives the Oper-ator’s Guide and Safety Videocassette.

No. 2004-1

Date: December 11, 2003 SUBJECT: Predelivery

YEAR MODEL MODEL NUMBER SERIAL NUMBER

2004 Speedster™ 200 5160/5773 All

WARNING

Torque wrench tightening specificationsmust be strictly adhered to.

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VEHICLE COMMUNICATION KIT (VCK)

SPORT BOAT IDENTIFICATIONRemove rear seats and storage tubs.Connect VCK components to port engine connec-tor and open the B.U.D.S. software.

TYPICAL1. Remove cover and connect VCK harness

Choose KW2000 Protocol from Choose Protocoloption in the MPI® drop-down menu.Read ECM using leftmost icon.

1. MPI® drop-down menu2. Read MPEM icon

Click on Vehicle tab.Enter customer name in the Customer zone.Click on the second icon of the toolbar (WriteMPEM) to register new informations from MPImemory to ECM.NOTE: Perform above steps for starboard engine.

NOTE PERTAINING TO THE DESS (Digitally Encoded Security System)The boats are shipped with the DESS activatedwhich enables the anti-start feature. The safetylanyard shipped with the boat has NOT been pro-grammed at factory. Therefore, THE SPORT BOATCAN NOT BE STARTED AND USED WITHOUTPROGRAMMING THE SAFETY LANYARD TOTHE BOAT. The use of the B.U.D.S. software ismandatory for programming. NOTE: The handheld programmer will not pro-gram a lanyard.For detailed information pertaining to the use ofthe VCK, refer to the guide that is shipped with theVCK.The lanyard must be programmed to each engine.

INTRODUCTION

NOTE: Dealers are requested to install the wheelson the trailer (if removed) as per Karavan instruc-tion sheet. Inspect and torque all wheel lug nutsto 108 N•m (80 lbf•ft).NOTE: To ease predelivery work, it is suggestedto raise trailer’s tongue in order to lower boat’sstern (rear). Safely block in this position.

WARNING

Torque wrench tightening specifications mustbe strictly adhered to. Locking devices (tie raps,lock nuts, etc.) must be installed or replaced bynew ones, where specified. If efficiency of alocking device is impaired, it must be renewed.

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UNWRAPPINGBefore unwrapping, clean the boat and trailer withfresh water to wash out any accumulation of dirtbuilt up during transportation. Corrosive agentsfrom the road may alter the appearance of boat hulland trailer.CAUTION: Whenever using a cutter to removeshrink wrap, use care not to damage boat.Carefully cut wrap and its rope at bow (front) andstern (rear) eyelets.

TYPICAL1. Carefully cut wrap and rope here

TYPICAL1. Carefully cut wrap and rope here

Raise wrap gently at stern then gently “roll” to-ward bow. Completely remove from boat.

BATTERY REQUIREMENTAND CHARGINGThe battery has to be purchased locally. Refer toTECHNICAL DATA for specifications. Refer to fol-lowing illustration for MAXIMUM allowed size.

A. 267 mm (10-1/2 in)B. 172 mm (6-3/4 in)C. 238 mm (9-3/8 in)

Activate and charge the new battery as per man-ufacturer’s instructions.

PARTS INSTALLATION

BATTERY

Two battery post adapters are supplied with theboat, inside battery case. Use them to fit cables tobattery if necessary. Install the post adapter iden-tified “P” on the positive post.Position charged battery in case so that the posi-tive post is toward bow (front).Properly route cables toward battery posts, be-tween case and insulating foam. It may be neces-sary to re-route engine ground cable so that it islong enough to reach battery post.Install red cable on positive (+) battery post/terminaland tighten nut.

WARNING

Never use automotive type battery. Its me-chanical construction does not allow to meetthe shock conditions where boats operate.Only use the type of battery recommended.

WARNING

Never secure electrical wires/cables with fuellines. Keep wires away from any rotating, mov-ing, heating, vibrating or sharp edged parts.Use proper locking ties.

WARNING

Verify starter cable connections for tightness.Always connect battery cables exactly inspecified order, RED positive cable first. Elec-trolyte or fuel vapors can be present in enginecompartment and a spark might ignite themproducing an explosion and possibly causingpersonal injuries. Do not charge a battery thatis installed.

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Install black cable on negative (-) battery post/terminaland tighten nut.NOTE: Ensure all connections are tight. Looseconnections or momentary contact could causefailure of electrical components.

LIQUIDSENGINE OILRecommended OilThis sport boat features dual 4-stroke engines thatrequire 4-stroke motor oil for internal engine lubri-cation.Only use a 4-stroke engine oil that meets or ex-ceeds the requirements for API service classifica-tion SG, SH or SJ. Always check the API servicelabel on the oil container to be sure it includesthose letters. Only use high-quality high-detergentoil.CAUTION: Never use any two-stroke engine oil.

Oil ViscositySAE 10W40 is recommended for all seasons.

Oil Level VerificationCAUTION: Check levels frequently and refill ifnecessary. Do not overfill - it would make theengine smoke and reduce its power. Operatingthe engine(s) with an improper level may se-verely damage engine(s). Wipe off any spill-age.

1. Dipstick

Check the oil level for each engine as follows:1. Sport boat must be level. Check oil level(s) ei-

ther with sport boat in water or out of water.Engines should be warm.

CAUTION: Never run engine(s) without supply-ing water to the exhaust cooling system(s)when sport boat is out of water.2. If out of water, raise trailer tongue and block in

position when bumper rail is level. Install a gar-den hose to the flushing connector. Refer toFLUSHING in MAINTENANCE and follow theprocedures.

CAUTION: Failure to flush exhaust cooling sys-tem(s) when engine(s) is out of water, may se-verely damage engine(s) and/or exhaust sys-tem(s).3. Warm-up engine(s) then let idle for 30 seconds

before stopping.4. Stop engine.5. Wait at least 30 seconds then pull dipstick out

and wipe clean.

CAUTION: Never run engine(s) longer than 5minutes. Drive line seals have no cooling whensport boat is out of water.6. Reinstall dipstick, push in completely.7. Remove dipstick and read oil level. It should be

between marks.

1. Full2. Add3. Operating range

8. Otherwise, add oil up to the level betweenmarks as required.

9. To add oil, unscrew oil cap. Place a funnel intothe opening and add the recommended oil tothe proper level. Do not overfill.

WARNING

Engine oil may be hot. Certain components inthe engine compartment may be very hot. Di-rect contact may result in skin burn.

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FUELWith ROTAX engines, use regular unleaded gaso-line with a minimum of 87 octane (Ron + Mon)/2specification.Outside North America use 90 RON.NOTE: Do not add oil into fuel.CAUTION: Never use fuel containing morethan 10% alcohol (ethanol or methanol).

NOTE: Please remember, always respect the en-vironment. Be careful while fueling.

COOLANT INSPECTION PROCEDURESport boat should be level and engines cold whenchecking coolant levels.Check the coolant level for each engine as follows:

1. Level between marks when engine is cold

Remove pressure cap.If needed, fill coolant expansion tank to levelsshown above.Start engines and run for 2 minutes. Stop enginesand wait 15 minutes to cool down. Refill tanks asneeded.Repeat this run-stop cycle 2-3 times until thermo-stat opens, then stop engines.When engines have completely cooled down, re-check coolant levels in expansion tanks and top upif necessary.Reinstall pressure cap.

ADJUSTMENTSAll adjustments have already been performed atthe factory. If an adjustment is required, refer toShop Manual (P/N 219 100 185) for procedures.

STEERING SYSTEM

AlignmentPosition steering wheel in straight ahead position.Move shifter to FOREWARD position.

TYPICAL

Check alignment of jet pump nozzles and steeringcentering by placing a straight edge across nozzleends. Straight edge must be parallel with transomand contact both edges of each nozzle with steer-ing wheel in straight position.

WARNING

Fuel is flammable and explosive under certainconditions. Always work in a well ventilated ar-ea. Do not smoke or allow open flames orsparks in vicinity. Never experiment with otherfuels or fuel ratios. Never use fuel containingalcohol, methanol or similar products includingnaphta. The use of non-recommended fuel canresult in sport boat performance deteriorationand damage to critical parts in fuel system andengine components. Never top off fuel tankthen allow boat to remain under hot weatherand/or direct sun rays. As temperature increas-es, fuel expands and might overflow. Alwaysremove any fuel spillage from boat.

F04K01A

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TYPICAL1. Parallel with transom

AdjustmentLoosen lock nut of steering link rod. While holdingrod end, turn link rod to adjust.

TYPICAL1. Lock nut2. Link rod

When finished, apply Loctite 243 (P/N 293 800060) on link rod threads and retighten lock nut.After adjustment, ensure rod ends are parallel toeach other to prevent binding of link rod.If not enough adjustment is available, adjust cableend on steering helm arm.CAUTION: Cable end must remain protrudingthrough helm mounting block.

1. Adjust here. Cable end must remain protruding

GENERAL INSTRUCTIONSFINAL INSPECTIONPerform and complete all items of final inspectionspecified in predelivery check list.Verify tightness of all fuel and oil line clamps, thenpressurize fuel system as described below.

Pressure TestProceed as follows:NOTE: It will be necessary to install the fuel sys-tem pressurization retainer (P/N 529 035 978 asshown in the photo below before performing thefuel system pressurization test.

1. Fuel system pressurization retaining bracket in position

2004-1 Page 7 of 12

This retaining bracket prevents the fuel pumpmodules from being dislodged from their respec-tive tank detents during the pressure test.– Fill up fuel tank.– Remove fuel cap from chain. Ensure to remove

chain at fuel cap end only.

TYPICAL1. Remove chain at fuel cap end only

– Place chain in filler neck for later retrieval.– Thread pressure test cap (P/N 529 035 870) into

filler neck.– Connect pump gauge tester (P/N 529 021 800)

from kit (P/N 295 500 352) to pressure test cap.– Pressurize fuel system to 34 kPa (5 PSI).

TYPICAL1. pressurized to 34 kPa (5 PSI)2. Pressure test cap

– If pressure is not maintained locate leak andrepair/replace leaking component. To ease leaksearch, spray a solution of soapy water on com-ponents. Bubbles will indicate leak location.Check that leaks do not come from improperlysealed hoses.

NOTE: To minimize time of fuel system pressur-ization, the fuel tank should be quite full. The sys-tem must maintain a pressure of 34 kPa (5 PSI) for10 minutes. Never pressurize over 34 kPA (5 PSI).

Remove pressure test cap and retrieve chain fromfiller neck.Reconnect chain to fuel cap and firmly tighten fuelcap into filler neck to finish procedure.CAUTION: Clean apparent fiberglass and plasticparts with a clean cloth and soapy water or iso-propyl alcohol. Never use strong detergent, de-greasing agent, paint thinner, acetone, etc. Donot apply isopropyl alcohol directly on decals.EXPLAIN OPERATOR’S GUIDE, BOAT OPERA-TION, MAINTENANCE, SAFETY FEATURES ANDWARRANTY TO CUSTOMER. WHERE POSSI-BLE, GIVE TO CUSTOMER A BRIEF DEMO RIDEAND EXPLAIN ITS OPERATION.Give Operator’s Guide and Safety Videocassetteto customer.Explain, complete and return WARRANTY REGIS-TRATION CARD (Legal requirement).Give safety lanyard to customer (located in frontstorage compartment).Take this opportunity to explain to customer theDESS operation and benefits. Show customerhow to properly secure boat to trailer.TO ENSURE TOTAL CUSTOMER SATISFACTION,WE STRONGLY RECOMMEND THAT ALL SPORTBOATS BE WATER TESTED BEFORE DELIVERYTO CUSTOMER. THIS PROCEDURE IS STAN-DARD TO THE BOATING INDUSTRY AND WILLREFLECT IN CUSTOMER SATISFACTION.

WARNING

If any leak is found, do not start the engines.Remove any fuel leakage. Failure to correct aleak could lead to an explosion. Do not useelectric-powered tools on boat unless systemhas been verified for no leaks.

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TECHNICAL DATA

ENGINE SPEEDSTER 200Number of engines 2

Engine type BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke,Over Head Camshaft (OHC), liquid cooled (x2)

Number of cylinders 3 (x2)Number of valves 12 valves with hydraulic lifters (no adjustment)Bore Standard 100 mm (3.9 in)Stroke 63.4 mm (2.49 in)Displacement 1498 cm³ (91.41 in³)Compression ratio 10.6 ± 0.4:1Rev limiter setting 7650 ± 50 RPM

LubricationDry sump with replaceable oil filter 4-stroke engine oil

(P/N 293 600 039) SAE 10W40(API service classification SG, SH or SJ)

Oil filter Rotax (P/N 420 956 741)Exhaust system Type Water cooled, water injected with regulator

Piston ring type and quantity1st Rectangular2nd Taper-face3rd Oil scraper ring

ADDITIONAL INFORMATION:

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ELECTRICAL SPEEDSTER 200Magneto generator output 380 W @ 6000 RPMIgnition system type DI (Digital Induction)Ignition timing Not adjustable

Spark plugMake and type NGK DCPR8EGap 0.75 mm (.030 in)

Generating coil N.A.Battery charging coil 0.1 - 1.0 Ω

Ignition coilPrimary 0.45 - 0.55 ΩSecondary 6.8 - 10.2 kΩ

Engine RPM limiter setting 7650 RPM

Battery

Recommended: Exide RV24-130, 12 V, 25 A•h(130 minutes reserve)

or RV24-160 (160 minutes)or equivalent.

Battery posts: On top. Round taper type.

Battery maximum allowed size: 267 mm (10-1/2 in) long x 172 mm (6-3/4 in) wide

x 238 mm (9-3/8 in) high.

Fuses

TOPS 10 ABattery fuse 30 ACylinder 1,ignition coil and injection 10 A

Cylinder 2, ignition coil and injection 10 A

Cylinder 3, ignition coil and injection 10 A

Electric bilge pump 3 AStarting system, electric fuel pump 10 A

EMS, start/stop circuit 5 AMain 20 A (3)MPEM 5 ACharging System 15 A (2)Single bilge air blower (if so equipped) 5 A

Twin bilge air blower (if so equipped) 10 A

Navigation lights 3 AGauges supply 5 AAuxiliary system 10 A

ADDITIONAL INFORMATION:

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FUEL SYSTEM SPEEDSTER 200

Fuel injection typeRotax EMS (engine management system).

Multipoint fuel injection.Single throttle body (52 mm (2.05 in))

Fuel pressure 42 PSI - 45 PSIIdle speed (in water/out of water) 1800 ± 50 RPMThrottle Position Sensor (TPS) 1.6 kΩ - 2.4 kΩCrankshaft Position Sensor (CPS) 5 voltsCamshaft Position Sensor (CAPS) 12 voltsCamshaft Position Sensor (CAPS) 1.2 kΩManifold Air Temperature Sensor (MATS) 2.28 kΩ - 2.74 kΩCoolant Temperature Sensor (CTS) 2.28 kΩ - 2.74 kΩExhaust Gas Temperature Sensor (EGT) 2.28 kΩ - 2.74 kΩManifold Air Pressure Sensor (MAPS) 0 Ω (continuity between terminals 3 and 1)Knock Sensor (KS) 5 MΩ Oil Pressure Switch (OPS) 0 Ω , if oil pressure is greater than 26 - 32 PSIOil Separator Pressure Switch (OSPS) 0 Ω , if blow-by pressure is less than 6 PSITOPS valve 1.27 Ω - 2.47 ΩFuel injector 11.4 Ω - 12.6 Ω

Fuel Type

Regular unleaded gasoline with 87 octane(Ron + Mon)/2 specification.

Outside North America 90 RON.Never use fuel containing more than 10% alcohol

(ethanol or methanol)

ADDITIONAL INFORMATION:

COOLING SPEEDSTER 200

Type Liquid cooled. Closed loop for engine - open loop for exhaust system

CoolantEthylene-glycol 50%/50% antifreeze/water coolant (P/N 293 600 044) containing corrosion inhibitors for

internal combustion aluminum enginesThermostat 87°C (188°F)Monitoring beeper setting 110°C (230°F)ADDITIONAL INFORMATION:

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PROPULSION SPEEDSTER 200Propulsion system BOMBARDIER Formula pumpNumber of jet pumps 2Jet pump type Axial flow single stage. Greased bearingsImpeller rotation (seen from rear) CounterclockwiseTransmission Direct driveCoupling type Crown splinesReverse system Yes

Grease typeJet pump bearing grease (P/N 293 550 032),10 mL front bearing, 50 mL rear of bearing,

50 mL in pump capSteering nozzle pivoting angle 26°Minimum required water level for jet pumps 90 cm (3 ft)Drive shaft deflection (maximum) 0.5 mm (.020 in)Impeller outside diameter 155.3 ± 0.3 mm (6.122 ± .0118 in)

Impeller/wear ring clearanceNew 0.0 - 0.4 mm (.000 - .016 in)Wear limit 1.0 mm (.040 in)

Impeller shaft end play (new) 0Impeller shaft side play 0.75 mm (.029 in)Impeller material Stainless steel

DIMENSIONS SPEEDSTER 200Number of passenger (driver incl.) 7Overall length 6.02 m (237 in)Overall width 2.44 m (96 in)Overall height 1.42 m (56 in)Dry weight 1256.5 kg (2770 lb)Draft 30 cm (12 in)Dead rise 20 °Load limit (passenger and luggage) 619 kg (1365 lb)ADDITIONAL INFORMATION:

CAPACITIES SPEEDSTER 200

Engine oil (per engine) 3 L (3.2 U.S. qt) oil changew/filter 4.5 L (4.8 U.S. qt) total

Cooling system (coolant) (per engine) 6.65 L (7.03 U.S. qt) totalFuel tank 151 L (40 U.S. gal)Jet pump bearing grease reservoir capacity (per pump) 100 cc (3.4 oz) (P/N 293 550 032)ADDITIONAL INFORMATION:

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N.A.: Not Available

MATERIALS SPEEDSTER 200Hull CompositeInlet grate AluminumSteering cover ThermoplasticImpeller housing/stator/venturi/nozzle Plastic/stainless steel/aluminum/aluminumAir intake silencer N.A.Flame arrester Tubular wire screenFuel tank PolyethyleneSeat Polyurethane foamADDITIONAL INFORMATION:

PERFORMANCE SPEEDSTER 200Estimated pump power 57 kW (76.44 HP) (x2)Maximum fuel consumption at wide open throttle 83.3 L/h (22 U.S. gal/h)Cruising time at full throttle 96 minutesADDITIONAL INFORMATION: