1991 Sea-Doo SP 5804, GT 5811, XP 5850 PWC Shop Manual (P/N 219100004)

This Bombardier Shop Manual, 219 100 004, covers the 1991 Sea-Doo 5804 SP, 5811 GT, and 5850 XP personal watercraft with the Rotax 587 engine.

Text navigation and wiring detail: Text search and embedded PDF bookmarks are not available. Small wire-color codes in the wiring diagrams are readable with magnification.

• Engine repair: Water-flooded engine care, removal and installation, top- and bottom-end overhaul, PTO flywheel and magneto service, and rotary-valve and reservoir work.

• Fuel and oil systems: Single- and twin-carburetor service, fuel-system pressure tests, throttle adjustment, and oil-injection pump synchronization, bleeding, and bench testing.

• Cooling and storage: Total loss cooling-system circuit, flushing procedures, overheating checks, off-season preparation, and internal engine corrosion protection.

• Electrical diagnosis: Ignition timing, electric starter repair, magneto and CDI testing, charging-system checks, and separate SP/GT and XP wiring diagrams.

• Propulsion and steering: Jet-pump overhaul, impeller and wear-ring inspection, engine-to-pump alignment, steering-cable adjustment, and GT reverse-system service.

• Hull and body: Water-tank trap and drain-fitting repair, rear-baffle installation, and seat-latch adjustment for proper sealing.

• Service references: Periodic inspection chart, model-specific torque tables, component wear limits, exploded assembly views, and symptom-based troubleshooting charts.

Written for watercraft mechanics already familiar with Bombardier service procedures and equipped with the specified hand tools and special service tools.

Rotax 587 Repair and Production Variants

Engine-support, tuned-pipe, and muffler layouts distinguish first-run GT assemblies from the later GT and SP/XP arrangements. Coverage follows the original factory configurations; later dealer modifications are outside its scope.

Crankshaft alignment and deflection views accompany bottom-end inspection. Rotary-valve timing uses a degree wheel and TDC gauge, while top-end inspection covers rings, pistons, cylinder taper, and out-of-round measurements.

The manual distinguishes top-end and PTO flywheel/magneto work that can be performed with the engine installed from bottom-end and rotary-valve shaft repairs requiring engine removal. Its piston-pin circlip warnings explain how overstressed circlips can loosen and damage the engine.

Carburetors, Oil Injection, and Cooling

The SP uses a single carburetor, while the GT and XP use separate MAG- and PTO-side carburetors with different return-line arrangements. Their identification and synchronization instructions help match components and adjustments to the correct configuration before reassembly.

Fuel-circuit routing and carburetor exploded views cover the air intake and flame arrester. Oil-pump diagrams also identify internal parts that are unavailable separately.

The cooling-circuit illustration traces the jet-pump water supply, calibrated outlets, self-bleeding path, and drainage connections. Flushing and storage sections address contamination, corrosion, and freeze protection.

Ignition Tests and Fault Isolation

Diagnostic procedures cover the Bombardier ignition tester P/N 295 000 008 and Nippondenso CDI tester P/N 295 000 080, including ignition-module diode checks and electrical resistance measurements.

The starting-system troubleshooting table distinguishes battery, solenoid, starter-motor, and overrunning-clutch faults. Timing-mark illustrations separate TDC-gauge verification of the flywheel mark from the stroboscopic ignition-timing check.

Follow the factory precautions for fuel vapors, high-voltage ignition testing, and rotating drive components.

Jet Pump, Reverse, and Hull Service

Jet-pump repair covers bearing and seal replacement, thrust components, shaft radial and end-play checks, and leak testing. Engine-to-pump alignment procedures specify alignment tool P/N 295 000 089.

The installation cautions explain how a folded drive-shaft seal can cause seal-carrier bearing failure. Impeller identification charts distinguish the model-specific versions before replacement.

GT reverse-system coverage includes cable, gate, and neutral-position adjustment. The hull/body section details water-tank trap repairs, rear-baffle bonding, and seat sealing; fiberglass and Gelcote repair kits are referenced.

Engine Clearances and Ignition-Coil Resistance

New piston-to-cylinder clearance for the Rotax 587 is listed at 0.06–0.07 mm. The rotary-valve/crankcase gap is 0.2–0.3 mm, checked with the cover installed without its O-ring.

The ignition-coil secondary winding specification is 5.85–6.50 kΩ, measured between the spark-plug leads with the plug protectors removed. The text also explains why a normal resistance reading does not rule out a high-voltage leak.

Printable PDF and Included Pages

This English-language download contains one printable, 247-page PDF. The total includes one cover page, one title page, and 24 blank pages; these are already included in the page count.