[Kevin Leclair]

040022T CEC BOMBARDIER RECREATIONAL PROD SPORTSTER - SPEEDSTER STEERING CABLES
030010T CEC BOMBARDIER MOTOR CORP OF AMER SPORTSTER-4 TEC FUEL SYSTEM
030125T CEC BOMBARDIER MOTOR CORP OF AMER SEA-DOO SPORTSTER 4-TEC IGNTION PROTECTION
040017S CEC BOMBARDIER RECREATIONAL PROD SPORTBOATS FUEL SYSTEM

Campaign(s) No. 2004–0008
Date: August 27, 2004
Subject: Penetrated Air Intake Hose No. 2004-7

YEAR MODEL MODEL NUMBER SERIAL NUMBER
2004 Sportster 4–TEC 5150/5151 All

PROBLEM
Starboard aft seat dart in center seat cushion may have penetrated the air intake hose during assembly. On affected boats, water could enter the air intake hose and engine if stored outside, resulting in serious engine damage.

SOLUTION
Inspect and/or replace the intake hose and remove water from both intake manifold and engine if necessary.

PROCEDURE
Inspection. Open engine cover and remove panel.

The air intake hose exits the airbox [1] and loops forward between the fuel tank and deck before connecting to the throttle body bell mouth [2].

Inspect the top of the hose in the area between the deck and fuel tank. If the seat dart [1] has Printed in Canada. (LBGWC-2004-007 SB) 1 / 3 ©2004 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved. ®™Trademarks of Bombardier Recreational Products Inc. or its affiliates. * Trademark of Bombardier Inc. used under license. not penetrated the intake hose, loosen the hose clamp on the airbox end of the hose.

Rotate hose clockwise (viewed from above) until the hose contacts the fuel tank.

Rotate hose counterclockwise slightly so that it does not contact the fuel tank or dart [1]. Retighten clamp. Claim only flat rate time for inspection. Replacement Hoses penetrated by the dart must be replaced with 0.6m (24 in) of new hose (P/N 204 340 435*).

NOTE: * When ordering quantity 1 of this part number, dealer will receive 2m. If the boat has been stored outside, the intake manifold must be removed from the engine and any water in it must be removed. Remove only those components necessary to allow rotation of intake manifold to empty water from manifold. Refer to Shop Manual 219 100 172, section 04–03. If there is water in the intake hose or intake manifold, the engine cylinders must also be checked for water. Refer to section 02–04 for drowned engine procedure. Once all water has been removed from the engine and intake manifold, reinstall the intake manifold and install new hose.

NOTE: The engine oil will not need to be changed. However, the engine should be started and brought up to operating temperature with the boat in the water as soon as possible. Use the same technique as in the inspection procedure to ensure the new hose does not contact the dart or the fuel tank. Claim flat rate time for both inspection and repair. 2 / 3 2004-7 Warranty

WARRANTY
Submit a warranty claim using the following information:
Warranty Campaign Information
Campaign Number 2004–0008
Claim Type 07
Flat Rate Time Inspection 0.3
Flat Rate Time Replacement 0.8
Expiration Date 2005–08–27

NOTE: On BOSSWeb, put a check in the inspection box if only an inspection was performed, and both the inspection and repair boxes if a repair has been made. The dealer/distributor is required to return all
hoses to support their claims.

USA DEALERS
Shipping address is:
BRP
C/O Warranty Department
7575 Bombardier Court
Wausau, WI 54401

CANADIAN DEALERS
Shipping address is:
BRP
Warranty Parts Inspection Center
565 de la Montagne
Valcourt, QC J0E 2L0

INTERNATIONAL DEALERS
Contact your local distributor for return of parts.
Warranty 2004-7 3 / 3

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Source :: U.S. Coast Guard Office of Boating Safety