1989 Sea-Doo 5802 Personal Watercraft Shop Manual (P/N 295000060)

Bombardier’s 1989 Sea-Doo shop manual, P/N 295 000 060, covers model 5802 and its ROTAX 587 engine. It documents the original configuration and excludes dealer modifications made after manufacture.

PDF Access and Wiring Detail

Search, navigation and diagram labels: PDF text search and embedded bookmarks are not available. Small wire-color labels on the sideways wiring diagram are readable with rotation and zoom.

One printable PDF in English contains 173 pages: 144 section pages, eight cover and introductory pages, and 21 blank pages, all included in that total.

587 Engine, Ignition and Jet Pump Service

The selected service topics below are not a complete table of contents. Other examples include seat-latch adjustment and electrical-box sealing checks.

• Engine repair: Step-by-step procedures for water-flooded engine care, removal and installation, top-end inspection, crankcase disassembly, and crankshaft bearing replacement.

• Rotary valve system: Cover-clearance checks, shaft and gear inspection, and timing methods for original and replacement crankcases.

• Fuel and oil systems: Carburetor inspection, pressure and leak tests, throttle adjustment, and oil injection pump synchronization, bleeding, and operational checks.

• Electrical diagnosis: Model-specific wiring diagram, ignition timing, starter overhaul, magneto repair, and CDI and charging-system testing.

• Jet pump and drive shaft: Impeller and wear-ring inspection, pump overhaul, bearing and seal installation, and drive-shaft checks.

• Cooling and storage: Cooling-circuit information, freshwater flushing, engine preservation, and freeze and corrosion protection.

• Steering and body reference: Handlebar/nozzle alignment and exploded component views for the steering assembly, hull, body, and seat.

This manual was written primarily for watercraft mechanics already familiar with Bombardier service procedures and assumes access to the specified hand tools and special service tools.

Engine Repair and Internal Inspection

Factory inspection limits provide a reference for assessing wear during a rebuild, including piston-to-cylinder clearance, ring end gap, and connecting-rod axial play. Crankshaft alignment drawings and rotary valve timing views explain the use of a TDC gauge and degree wheel.

Top-end and flywheel/magneto servicing can be performed with the engine installed; bottom-end and rotary valve shaft repairs require engine removal. Defective crankshaft assemblies are referred to a specialized repair shop or replacement.

Engine-mount shims control engine/jet pump alignment. The manual states that this factory-set alignment cannot be performed in the workshop.

The manual warns that overheating crankshaft bearings can melt their plastic cages. The torque summary and component assembly instructions differ for crankcase screws, crankcase-to-engine-support nuts, and cylinder-head-cover screws.

Carburetor and Oil Injection Adjustments

The fuel chapter covers the diaphragm carburetor identified in the technical data as BN-38-34. Carburetor exploded views accompany needle-valve inspection, inlet-control-lever adjustment, Welch-plug leak testing, and separate low-speed mixture and idle-speed adjustments.

Oil-system coverage explains the relationship between throttle adjustment and pump synchronization. Pump alignment illustrations, bleeding instructions, on-watercraft checks, and a bench test support inspection of oil delivery.

Nippondenso Ignition and Starting Diagnosis

Electrical coverage includes the 5802 wiring diagram, wire-color codes, starter troubleshooting table, and commutator, brush, and overrunning-clutch inspection. The wiring diagram distinguishes first- and second-version wire colors at the ignition-module harness.

Ignition timing uses a TDC gauge and stroboscopic timing light. CDI and charging tests describe use of Bombardier Ignition Tester 295 000 008, with resistance checks as an alternative.

Charging-system diagnosis also includes current and voltage tests and magneto-output checks to distinguish charging-coil, rectifier, and regulator faults. The manual notes that acceptable ignition-coil resistance does not rule out a high-voltage leakage fault.

Symptom charts connect no-start, misfire, overheating, and propulsion-noise complaints with likely causes and relevant service sections, helping mechanics select the appropriate checks. Follow the manual’s bilge-ventilation and electrical-isolation precautions around fuel vapors and ignition components.

Jet Pump, Steering and Seasonal Care

Pump overhaul extends to wear-ring replacement, impeller-shaft radial-play checks, thrust-bearing inspection, and seal-carrier assembly. Dimensioned drawings describe shop-made removal tools. Pulling on the drive shaft while its impeller boot remains seated can damage the boot.

Steering adjustment addresses handlebar/nozzle alignment and clearance at the venturi housing. Hull/body coverage provides component identification and a short materials overview rather than detailed fiberglass repair procedures.

The cooling-circuit diagram explains the total-loss system supplied by the jet pump. Flushing and storage sections address water-passage contamination, engine internal lubrication, battery care, and protection against freezing and corrosion.

Examples of Fastener Torques and Carburetor Test Data

The flywheel installation procedure specifies 110 N·m (81 lbf·ft) for the PTO flywheel; the cylinder-head assembly procedure lists 20 N·m (15 lbf·ft) for the head screws.

The carburetor pressure test gives an inlet release pressure of 11.5–12.5 psi. Its separate needle-valve leak test specifies holding 3 psi for 30 seconds.