YEAR MODEL MODEL NUMBER SERIAL NUMBER 5175 Starting with US-CEC50000H304 through US-CEC50114A404 5176 Starting with US-CEC52000I304 through US-CEC52070A404 2004 Islandia™
PROBLEM Some 2004 Islandia boats have the oil lines from the external oil tank inverted as connected to the engine. When the engine is run with the lines connected improperly, the #6 cylinder can hydrolock with oil, causing severe engine damage, and no oil will be drawn from the external tank, activating the alarm and putting the engine in the limp home mode. The following hose connection information is true of all Mercury engines in use by BRP.
The oil supply line  (blue/black) should be connected to an in-line oil filter on the port side of the engine.
The pressure line  (black) should be connected to a connector and short piece of hose that is connected to the engine crankcase on the starboard side of the engine. If the lines are connected correctly at both the cap and the engine, no corrections are necessary.
If the lines are reversed at the engine, cut both tie wraps at the oil tank cap and move the lines to the opposite fittings on the cap. Mark them as shown with a paint pen (obtained locally). Refasten using 2 tie wraps (P/N 293 750 002) or equivalent.
NOTE: Mercury has always marked the oil line with a blue stripe. Marking the lines as shown will clarify any questions when future service is required.
Remove the lanyard cap to prevent spark at the spark plugs. Remove the #6 spark plug. Turn the engine over for several revolutions to purge the crankcase of oil that may have run into the cases during storage. Please check, and if necessary, correct all 2004 Islandia boats in stock prior to delivery. If you have delivered any of the models listed, please call your customers and arrange inspection of these oil lines as soon as possible. 2 / 3 2004-6 Warranty
WARRANTY Submit a warranty claim using the following information: Warranty Information Campaign Number 2004–0007 Claim Type 07 Flat Rate Time 0.5 Expiration Date June 21, 2005 For claiming procedure, refer to the Dealer/Distributor Warranty Guide. Warranty 2004-6 3 / 3
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  and loops forward between the fuel tank and deck before connecting to the throttle body bell mouth .
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 . 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