2010 Sea-Doo 210 Challenger, 210 Challenger SE Personal Watercrafts OEM Service & Repair Manual
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150, 180,200,210 and 230 SERIES
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TABLE OF CONTENTS
SAFETY NOTiCE....................................................................................................... IX
INTRODUCTION......................................................................................................... X
GENERAL INFORMATION................ ........... ... .. . ... .. ......... ...... ... ... ... ..... ... ......... . ....... . ... X
BOAT INFORMATION............................................................................................... XI
ENGINE EMISSIONS INFORMATION. . ... .. .... .. . .. . ........ . ....... ... ... .. . ... ...... . .... .. ....... ... .. . ...... XI
MANUAL INFORMATION .............. .. ................................... ..... ........ ... ........................ XII
FASTENER INFORMATION ..... ... ........................ . ...... . ........................... . .... . ...... .... .... XVII
01 MAINTENANCE
01 - MAINTENANCE SCHEDULE.................................................................................... 7
02 - PRESEASON PREPARATION................................................................................. 19
03 - STORAGE PROCEDURE ....................................................................................... 21
PROCEDURES....... .. .... . .. ... .... ..... ..... .. . ... ..... ...... .. ...... .. ... .... ........ ....... .. ........... 21
PROPULSION SySTEM....... ........... .. . .......... ....... ... .... ...... .. .... ..... ......... ... ... ..... . 21
FUE L SySTEM ............................... . .............. . ....... ... ........... .. ............... . ...... 21
ENGINE .... ...... . ...... .. ... .............. .... ....... .... . .............. ............ ... ...... .. ... ... .... 21
ELE CTRICAL SySTEM.. ........ ... .. .......... . .......................................................... 23
ENGINE COMPARTM ENT. .. . .. .. .. ... ............... .............. ..... ... ... ..... .... ........ ... ... .... 23
BODY AND HULL......................................................................................... 23
04 - SPECIAL PROCEDURES ........................................ . ... . ... ... . .. .. . ......................... .. ... 25
GENERAL .................................................................................................... 25
PROCEDURES.. .. .. .. .......................... ...... ............ ...... ...... ... ..... ............... ........ 25
TOWING THE BOAT IN WATER ....... ...... ..... .. ..................................... .... ..... . ....... 25
SUBMERGED BOAT........................................................ . .......... ... ................ 25
WATER-FLOOD ED ENGINE ................................ ;... .-. ;-.-.-;;-;~ .- ........ ~ ........ . ............ . ... 25
02 ENGINE
01 - ENGINE REMOVAL AND INSTALLATION ... . ......... . .. . .... . .......... .. .... . .... ... ........ ............ 29
GENERAL .................................................................................................... 31
ENGINE ACCESS ....... . ...................................... .. ...... ................................ ... 31
PROCEDURES ............................................................................................... 31
ENGINE .. .. ..... . ... .... ... .... ...................... . ...................................... .... .... . ..... 31
ENGINE RUBBER MOUNTS .............................................................................. 34
02 - AIR INTAKE SySTEM................. . ........ . ....... . ...................... . ................. . .... . ........ . 37
GENERAL ...... . .... ........... . .... .. ..... . ....... ... ........... . ....... . ................. .... .............. 41
PROCEDURES ...... .. .. .. .......... . .... . ..... ..... ..... . ....... .......... ... ..... ...... . ................... 41
AIR FILTER (A LL E XC EPT 210 S ERIES) ................. ... .. .... ... . .. .... ..... .... . ..................... 41
AIR INTAKE TUBE (A LL E XC EPT 210 S ERIES ) ........................................................... 41
AIR INTAKE SI LE NC ER COV ER (210 SERIES) ............................................................ 42
AIR INTAKE SI LE NC ER BAFFLE (2 10 SERIES) . ........................................... . ..... .. ... .... 42
AIR INTAKE TUBE (210 S ERIE S) .......................................................................... 42
AIR INTAK E SI LENCER (210 SERIES) . .... . ....... . ....... .. ...... . ..... .. ... ' ............................ 43
03 -INTAKE MANIFOLD AND INTERCOOLER (215 ENGINE) .......... .... ..................... . .......... .. 45
GENERAL ............ .... .. . .............. . ................. .. ................ . .... . .... . .................. .. 50
PROCEDURES.......................................... ............. .. . . ..... ... .. . .... ........ ..... .... .... 50
INTAKE MAN IF OLD...... ........... ... ... ....... .... .. . .............. ..... .... . .... ... . .... ... ... ..... ... 50
FLAME ARREST ER... ... ..... . ........................................................................... 57
INTERCOOLER (215 ENGINE ) . ..................... . ......................................... . ........... 57
04 - SUPERCHARGER (215 AND 255 ENGINES) ............................................................... 61
GENERAL .. .. . ... .................................... ....... ... .. ..... ..... .. ................................ 63
INSPECTION ... .. ... . ......................................... .. .......... ... .............................. .. 63
SUPERCHARG ER INLET CLE ANLINESS ....... ... .. ................. . ................................. .. 63
S UPER CH ARG ER CL UTCH SLIPPING MOMENT (ON ENGINE) ...................................... ... 63
S UPER CH ARG ER CLUTCH SLIPPING MOMENT (BENCH TEST) ..................................... ... 64
TABLE OF CONTENTS
02 ENGINE (cant' d)
II
04 - SUPERCHARGER (215 AND 255 ENGINES) (cant' d)
TROUBLESHOOTING ...................................................................................... 65
PROCEDURES ............................................................................................... 65
SUPERCHARGER......................................................................................... 65
05 - INTERCOOLER (255 ENGINE) ................ . ...................................... . ........................ 77
GENERAL .................................................................................................... 80
MAINTENANCE ............... ... .... . ...................................................................... 80
INTERCOOLER FLUSHING............................................................................... 80
PROCEDURES ............................................................................................... 80
INTERCOOLER........................................................................................... 80
06 - EXHAUST SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
GENERAL .................................................................................................... 87
SYSTEM DESCRiPTION.................................................................................. 87
MAINTENANCE............................................................................................. 88
EXHAUST SYSTEM FLUSHING ........................................................................... 88
PROCEDURES ............................................................................................... 88
MUFFLER ................................................................................................. 88
EXHAUST PiPE........................................................................................... 91
EXHAUST MANIFOLD .................................................................................... 92
RESONATOR ................................................................ . ............................. 94
07 - PTO HOUSING AND MAGNETO............................................................................ 95
GENERAL .......... , ......................................................................................... 97
PROCEDURES ............................ . .................................................................. 97
PTO HOUSiNG............................................................................................ 97
PTO SEAL .. ....... ............................. . ........... ... ........................................... 101
P.TO COUPLiNG ......................................................................................... '102
STARTER DRIVE BEARINGS ............................................................................. 103
STATOR .................................................................................................. 104
ROTOR AND TRIGGER WHEEL ......................................................................... 106
RING GEAR .............................................................................................. 108
STARTER DRiVE ......................................................................................... 108
08 - LUBRICATION SySTEM.................................................. .................................... 111
GENERAL ................................................................................................... 116
MAINTENANCE ............................................................................................ 116
ENGINE OIL .............................................................................................. 116
OIL FILTER............................................................................................... 117
INSPECTION ................................................................................................ 118
ENGINE OIL PRESSURE ................................................................................. 118
TROUBLESHOOTING ..................................................................................... 119
PROCEDURES .............................................................................................. 120
OIL PRESSURE SWITCH (OPS) .......................................................................... 120
PTO OIL STRAINER ...................................................................................... 122
SUCTION PUMP OIL STRAINER ........................................................................ 122
ENGINE OIL PRESSURE REGULATOR .................................................................. 124
OIL PRESSURE PUMP ................................................................................... 124
OIL SUCTION PUMP .................................................................................... 127
SUPERCHARGER OIL SPRAY NOZZLE .................................................................. 130
PISTON OIL SPRAY NOZZLES ........................................................................... 131
OIL SEPARATOR COVER ................... .... ......................................................... 132
BLOW-BY VALVE ........................................................................................ 133
TOPS SWITCH(210 SERIES) ............................................................................. 135
OIL COOLER ............................................................................................. 137
TABLE OF CONTENTS
02 ENGINE (cont'd)
09 - COOLING SYSTEM. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. .. . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . .. 139
GENERAL................................................................................................... 145
SYSTEM DESCRiPTION............................................................... .. ........... . .... 145
MAINTENANCE............................................................................................ 145
ENGINE COOLANT...................................................................................... 145
INSPECTION . ................................................................................... . ........... 147
COOLING SYSTEM LEAK TEST...................... ..... ........... . ..... ........ ............ . ........ 147
TROUBLESHOOTING..................................................................................... 148
PROCEDURES ........... ................................................................................... 148
PRESSURE CAP ......................................................................................... 148
CLAMPS ................................................................................................. 148
WATER PUMP HOUSiNG ................................................................................ 149
WATER PUMP IMPELLER ............................................................................... 150
THERMOSTAT ........................................................................................... 151
ROTARY SEAL ........... ........ . ........ . ..................... .. .......... .. .... .. ............ ..... .... 151
HEAT E XCHANG ER (200, 210 AND 230 SERIES) ....................................................... 153
10 - CYLINDER HEAD . .. . ..................................... ... ......... .. ...... .... ...... ....... ............ .. .. 155
GENERAL ...... .... . ..... . .............................. .... .............. ..... .................. . ........ .. 157
INSPECTION . ...... ... ... .... .. .......... ... ..... . ............. ... ........ . ... . ............................. 157
ENGINE LEAK TEST..................................................................................... 157
TROUBLESHOOTING ...... ............................................................................... 159
PROCEDURES .......... .................................................................................... 160
CYLINDER HEAD COVER................................................................................ 160
SPARK PLUG TUBES...... . ............ . ... ... ............... ... ...... ... ... .................. .. ......... 161
ROCKER ARMS .............. ............ ....... . ................................... ; .. . .. : ............... 161
CAMSHAFT TIMING GEAR .............................................................................. 163
CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
CYLINDER HEAD.................. .. ............................................... . ...... .. ............ 166
VA LVE SPRINGS ......................................................................................... 168
VALVES ................................................................................................... 170
VA LVE GUiDE .... . ... .. .................... ... ................................. . ...... .. .............. ... 173
11 - CYLINDER BLOCK .. .................... .. ... . ...................................... . ................... .. ..... 175
GENERAL................................................................................................... 178
TROUBLESHOOTING ... ............ . .............................. . .................. . ....... ... .... . .. .. 178
PROCEDURES ....... ....................................................................................... 178
TIMING CHAIN ... .............. ..... ............... . .... . ............... ... .......................... . ... 178
CHAIN TENSIONER...... .. .. .. ... .......................................................... ... . ... ...... 179
PISTONS AND CONNECTING RODS.......... ... ........ . ... . .... . .... ..... ....... . .................... 179
PISTON RINGS ........................................................................................... 184
CRANKSHAFT........................................................................ ...... . ............. 185
BALANCER SHAFT...................................................................................... 190
CYLINDER BLOCK....................................................................................... 193
03 ELECTRONIC MANAGEMENT SYSTEMS
01 - ENGINE MANAGEMENT SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 199
GENERAL . .............................................. . ................................................... 199
ENGINE MANAGEMENT SCHEMATIC(150, 180,200 AND 230 SERIES) ............................... 199
ENGINE MANAGEMENT SCHEMATIC(210 SERIES) .................................................... 200
SYSTEM DESCRiPTION............................................................................ . .... 201
02 - COMMUNICATION TOOLS AND B.U.D.S. . ................ ... ....................................... ..... 205
GENERAL........ . .......... . ............. . ................................................................ . 205
TROUBLESHOOTING..................................................................................... 205
DIAGNOSTIC TiPS.... .. .................................. . .............................................. 205
III
TABLE OF CONTENTS
03 ELECTRONIC MANAGEMENT SYSTEMS (cant' d)
02 - COMMUNICATION TOOLS AND B.U.D.S. (cant' d)
PROCEDURES .............................................................................................. 207
MPI-2 ........ ..... .................... . ........................................ .. ......................... 207
B.U.D.S. SOFTWARE .................................................................................... 210
03 - MONITORING SYSTEM AND FAULT CODES .............................. ~ ............................. 213
GENERAL ........................................... . ........ ... ...................... ........ ....... ...... . 213
MONITORING SYSTEM ... .. ...... .. ....................... . .......................... ........ .. ..... ... 213
FAULT CODES ........................................................................................... 217
SPECIFIC FAULT CODES ........ ... . .... . .............. . ...... .. .... ..... .......... . .................... 219
FAULT CODE TABLE ... .... . ......... . ...................... . ... .. .. ........ ... . ......................... 220
04 FUEL SYSTEM
IV
01 - INTELLIGENT THROTTLE CONTROL (iTC) (210 SERIES) ............................................... 241
GENERAL ................................................................................................... 243
SYSTEM DESCRiPTION ................................................................................. 243
PROCEDURES ... ................................................... ... ........ . ................... ......... 243
TAS (THROTILE ACCELERATOR SENSOR) ............................................. . ..... ...... .. .. 243
02 - ELECTRONIC FUEL INJECTION (EFI) ................... .... ..................................... ...... .... 247
GENERAL................................................................................................... 247
SYSTEM DESCRiPTION................................................. .... ...... . ..................... 247
ADJUSTMENT ............................................................................ . ................ 249
IDLE SPEED ..... .... ...... . .......... .... ..... .... ............ . ......... .. ......... . ... .. ........ ...... . 249
CLOS ED THROTILE RESET ...... .. ........ . .... ... ................................ . ............. ...... . 250
TROUBLESHOOTING ....... .. .. ... . ....... . ............................... ... ......................... ... 250
DIAGNOSTIC TIPS ........................ . ............................... ... ......................... .. . 250
PROCEDURES ....................... ... ............ ...... ........ ... ...... ..... ....... ...... . .... .. . ....... 251
ECM (ENGINE CONTROL MODULE)(210 SERIES) .. .. ...... ... ....... . ........ .. ... .. ... . .......... .... 251
ECM (ENGINE CONTROL MODULE)(EXCEPT 210 SERIES) ............................................ 257
FUEL RAIL ................... ..... . ...................................................................... 259
FUEL INJECTOR .................. . ....... . ... . ..... . .............. ... .............................. .... . 261
THROTILE BODY(210 SERIES) . . ................. . .................... . ................... .. ......... . .. 264
THROTILE BODY (EXCEPT 210 SERIES) ............................................................... 267
ETA (ELECTRIC THROTILE ACTUATOR) ................................................................ 269
TPS (THROTILE POSITION SENSOR)(210 SERIES) .... .... ... .. ....... .... ............................. 269
TPS (THROTILE POSITION SENSOR) (EXC EPT 210 SERIES) . ............. . .... ... . ... ............. . ... 271
IBV (IDLE BYPASS VALVE)(21 0 SERIES) ................................................................. 272
CPS (CRANKS HAFT POSITION SENSOR) . . ..................... . .................. .... . .... ....... . .. .. 273
CAPS (CAMSHAFT POSITION SENSOR) . . . ....... . ......... . ....... . ................ ......... ..... ..... 275
MATS (MANIFOLD AIR TEMPERATURE SENSOR) ..................... . ........................ .. . .... 278
CTS (COOLANT TE M PERATURE SENSOR) ....... . ..... . .... . ...... . ... .... ....... . ................ . .. . 279
MAPS (MAN IFOLD ABSOLUTE PRESSURE SENSOR) .................................................. 280
EGTS (EXHAUST GAS TEMPERATURE SENSOR) .... . .. .. ............ .. . .......... .. ................. .. 282
KS (KNOCK SENSOR) ................ . ........................ ..... ..... . ............ ...... ... . ... .. .. ... 283
03 - FUEL TANK AND FUEL PUMP.............................................................................. 285
GENERAL ............. . ........ . .......... . .. . .... . .......... . ..................... . .... .. ........ . ...... . .. 288
SYSTEM DESCRiPTION...... . ................................................. . ..................... . .. 288
INSPECTION ......................... . ................. . ..... . ...... .. ...... .... ... ....... ............ . .... . 289
FUEL SYSTEM LEAK TEST ............ . ............ . .. ........ . .. .............................. .. ....... 289
FUEL PUMP PRESSURE TEST ........................... . .. . ... .... .. .. .. ........ . ..... .. ..... .. ....... 290
PROCEDURES .. .. ... . ...... . ........ . ........... . ................ ... ....... . .......... . .. ....... .. . ... .. . .. 291
FUEL HOSES AN D HOSE CLAMPS ... . .................................... . ............... . ........ .... 291
FUEL FILTER .. ............. .. ............... ... ........................................ .. ........... . .... 291
FUEL TANK......... . ...... ... .... . ........................................ . .............. . .............. 292
FUEL PUMP.................................................... .. ....... .. .. .. ... . ... . .. ...... ... ...... . 293
04 FUEL SYSTEM (cont'd)
03 - FUEL TANK AND FUEL PUMP (cont'd)
PROCEDURES (cont'd)
TABLE OF CONTENTS
FUEL LEVEL SENDER................................................................................... 297
05 ELECTRICAL SYSTEM
01 - POWER DiSTRIBUTION......... . ........ . ............................. . ..................................... 299
GENERAL........................................................................ . ... . ...................... 303
ELECTRICAL SYSTEM ACTiVATION .................... . .......... . ........ .' ... . ... . ........ . ..... . ..... 303
PROCEDURES .............................................................................................. 303
MAIN CUT-OFF SWITCH ................................................................................ 303
MAIN GROUNDS ................................................... . ....... :: ............................ 304
FUSES ................................................................................ . .................. 304
BATIERY POWER BUS-BAR(230 SERIES) .......................... : ........................ . .. . ....... 308
CIRCUIT BREAKER PANEL(210 AND 230 SERIES) .................. : ........................ .. ......... 308
MAIN BREAKER(180, 210 AND 230 SERIES) ........................................................... 308
MAIN RELAY(150, 180, AND 210 SERIES) .............................................................. 309
ECM (ENGINE CONTROL MODULE) .................................................................... 309
VCM(VEHICLE CONTROL MODULE)(200 AND 230 SERIES) ........................................... 310
EFB (ENGINE FUSE BLOCK)(200 AND 230 SERIES) .................................................... 312
02 - CONTROLLER AREA NETWORK (CAN) ................................................................... 315
GENERAL .......................... . ................................................................. . ...... 318
SYSTEM DESCRiPTION ................................................................................. 318
TROUBLESHOOTING .............. . ...................................................................... 318
DIAGNOSTIC TiPS ........................................................... . ............... . .......... . 318
03 - IGNITION SYSTEM ....................................................................... ; ~ . . . . . . . . . . . . . . . . .. 321
GENERAL ................. . ....... . ................................... : ..... . ...... ... ...... . ............. .. 321
SYSTEM DESCRiPTION ........................................... .. ........ .. .......................... 321
TROUBLESHOOTING .... ... . ........................ . ............. :' ....... . . , ........... . ............. . .. 322
IGNITION SYSTEM TESTING ...................................................... . .................. . ,. 322
DIAGNOSTIC GUiDELINES ....................... . ................................................... . .. 322
PROCE DU RES ................. ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 ' 23
ENGINE CUT-OFF SWITCH (150, 180, 200 AND 230 SERIES) .......................................... 323
ENGINE CUT-OFF SWITCH (210 SERIES) ............................................................... 324
IGNITION SWiTCH ....... . ............. . ........................... . ........................... ... .. , .... '" 324
IGNITION COILS....................................................................... . ................. 325
SPARK PLUGS ............................. . ... ' ................... . ....... . .............................. 328
04 - CHARGING SYSTEM . .................... .... ................................. . .................. . .... . .. , . .. 331
GENERAL .................................. . ............................................... .. ............... . 331
SYSTEM DESCRiPTION ............................................. . ;': ........................ , ......... ' 331
INSPECTION ..................... . ........................ . ............... . .................. . .............. 331
CHARGING SYSTEM OUTPUT .............................................................. .. .......... 331
TROUBLESHOOTING .......................... '" .............................. . ......................... 332
PROCEDURES .................................... , ........................... , ............................. 333
VOLTAGE REGULATOR/RECTIFIER..................................................................... 333
BATIERY ............................................. . ................................ . .................. 333
05 - STARTING SySTEM.......... . ............................................................................. .. 335
GENERAL..................................................... . .......................................... . .. 342
TROUBLESHOOTING ..................................................................................... 342
DIAGNOSTIC TiPS ....................................................................................... 342
DIAGNOSTIC GUiDELINES .............................................................................. 342
PROCEDURES .................................................................... . ............ . ............ 343
STARTER SOLENOID FUSE ............................................................................. 343
ENGINE START/STOP SWiTCH............................................ . ............................. 343
NEUTRAL SWiTCH ................. . ........................... . ........................................ 345
v
TABLE OF CONTENTS
05 ELECTRICAL SYSTEM (cant' d)
05 - STARTING SYSTEM (cant' d)
PROCEDURES (cant'd)
STARTER SOLENOID.................. . ..... ... ......................................................... 347
STARTER.................................... .. ......... .. ........ .. ..... .. ................... .. .......... 348
06 - DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) ........... .... ................................... 351
GENERAL ....... . ................. . ............ . ...... .. .. ... ..... . ... ..... ........ .. ....................... 351
SYSTEM DESCRiPTION ................. . ...... . ........... . .......... . .............. .. ............ . .... 351
PROCEDURES ......... ........ . ..................................................................... ... .... 351
D.E.S.S. KEy .... . .... . .......................... . ..... . .................. . ................... . ... . ....... 351
BEEPER ......... . ................ ... .......... .. .. .. . .. .... ... .... ........ . .. . ....... . ............. ... ... 354
07 - INSTRUMENTS AND ACCESSORIES...... . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 355
GENERAL .............................................................. . ................................... . 355
TROUBLESHOOTING .. ............................................................................... .... 355
DIAGNOSTIC TiPS .. .. ................................................ . .................................. 355
PROCEDURES ..... ............................... . .................................... . ........... . ........ 355
INFORMATION CENTER (150 AND 180 SERIES) .................................. . .................... 355
INFORMATION CENTER (210 SERIES) .......... . ....................................................... 356
SPEEDOMETER (210 SERIES) ................... . ............... . ....................................... 356
SPEEDOMETER (200 AND 230 SERIES) ................................................................ 357
SPEED SENSOR (ALL EXCEPT 210 SERIES) ............................................................ 358
TACHOMETER (200 AND 230 SERIES) .................................................................. 359
ANALOG FUEL GAUGE (210 SERIES) ................................................................... 359
ANALOG FUEL GAUGE (200 AND 230 SERIES) .................................................. .. .... 360
MONITORING GAUGE (200 AND 230 SERIES ONLy) ............... .... ............................ .. .. 360
BEEPER (200 AND 230 SERIES) ......................................................................... 361
RADIO ................................................................................................ .. . 362
RADIO AMPLIFIER (210 AND 230 WAKE ONLy) ............................................ ............ 362
DEPTH SOUNDER (150, 180 AND 210 SERIES) ............................................. .. ......... 363
DEPTH SOUNDER (200 AND 230 SERIES) .................................................... ..... ..... 363
HEATER UNIT (210 AND 230 WAKE ONLY) .... ...... ................................................... 364
ELECTRIC BILGE PUMP ................................................ .. .. ... .......................... 366
BILGE BLOWER ............................. . ............ . ..................... . ........................ 367
06 PROPULSION
01 - REVERSE SYSTEM ............................................................................... . ........... 369
GENERAL ..................................... ... ..................... . ..................................... 370
PROCEDURES .. ............................................................................................ 370
REVERSE GATE...................................... .. ........................................ . ......... 370
REVERSE GATE LEVER ............................. . .............................................. . ..... 371
REVERSE GATE SUPPORT .............................................................................. 372
REVERSE CABLE ........................................................................................ 373
02 - JET PUMP............. . ...................... .................................................................. 375
GENERAL ................................................................................................... 377
JET PUMP MAIN COMPONENTS ............................. .. ...... ... .............. .. ............... 377
INSPECTION ...... ................ . ......................................................................... 377
IMPELLER CONDITION ................................................................ . ................. 377
IMPELLERM'EAR RING CLEARANCE ................................................................... 377
IMPELLER SHAFT RADIAL PLAy .................................. .... .................................. 377
LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 378
PROCEDURES .... ......................... . .............. . ................................................. 379
VENTURI ........................ . .......... .. ......... .... ... . .................... . ...................... 379
JET PUMP HOUSiNG .................................................................................... 380
IMPELLER COVER ....................................................................................... 382
IMPELLER . .............................. ..... .................... . .......... .. .......................... 384
VI
06 PROPULSION (cant'd)
02 - JET PUMP (cant' d)
PROCEDURES (cant'd)
TABLE OF CONTENTS
WEAR RING............................................................................................. 386
IMPELLER SHAFT AND BEARING...................................................................... 387
03 - DRIVE SHAFT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 395
GENERAL ................................................ . .................................................. 397
MAINTENANCE ........................................................... . .................. . ............. 397
CORROSION PROTECTION............................................................... . ............. 397
PROCEDURES . ................................................................. . ........................... 397
DRIVE SHAFT............ . ......................... . ...................... . .............................. 397
DRI VE SHAFT BOOT..................................................................................... 403
CARBON RING ............................... . .. . ...... . ................................................. 404
DRIVE SHAFT PROTECTOR............................................. . ............................... 404
07 CONTROLS
01 - STEERING SySTEM......... ... ......... . ............................................................... . .... 405
GENERAL ..... . ........................ . ........ ... ............................................. . ........... 408
ADJUSTMENT ......................................... . ................................................... 408
STEERING ALIGNMENT................................................................................. 408
TROUBLESHOOTING . .................... . ....... . .................. . ................................ . ... 409
ABNORMAL PLAY IN STEERING ................................ . ......... . ............................. 409
PROCEDURES ....... ...... . ..... . .......................................................................... 410
NOZZLE LINK ROD ................... . ..... . ... . ..... . .................................... . .... . ........ 410
NOZZLE ........................ . .............. . ....... . ... .. ............................................. 411
STEERING CABLE ....................................................................................... 412
STEERING WHEEL .............. . .... . ............................................................. . .... 414
TILT MECHANISM ....................................................................................... 414
STEERING HELM ........................................................................................ 415
STEERING PiNION ................ . ... ... .......... .. .. .... . ............................... . ............. 415
02 - THROTTLE/SHIFTER CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 417
GENERAL ................................................................................................... 422
PROCEDURES . .... .. . .................................................................................. . ... 422
THROTILE/SHIFTER CONTROL (EXCEPT 210 SERIES) ........................................ . ........ 422
THROTILE/SHIFTER CONTROl(210 SERIES) ........................................................... 423
THROTILE ACCELERATOR SENSOR (TAS) CABLE(21 0 SERIES) ....................................... 425
THROTILE CABLE (EXCEPT 210 SERIES) .............................................................. 427
REVERSE CABLE ........................................................................................ 428
08 BODY AND HULL
01 - BODy. . ... .... . ............................ . ..................................................................... 433
GENERAL . ................................................................... . ...... .. ...................... 493
PROCEDURES . ...... ..... ............................................................................ .. .... 493
RIVETS . ....... . .......... . ......... . ........ . ............................................................ 493
LOCKS .. . ....................... . .. . .... .. ... . ... .. ....... . .... . ......................................... 493
DECALS .................................................................................................. 493
SHOCKS .................................................. . ............. . ................................ 494
ENGINE COVER LATCH ................................................................................. 494
BUMPER ..................................................... . ..... . ..................... . ............... 495
SLIDING DOOR (230 SERIES) ........................................................................... 496
WINDSHIELD TRIM (230 SERIES) ....................................................................... 500
WINDSHIELD (180 AND 210 SERIES) ................................................................... 500
WINDSHIELD (230 SERIES) ............................................................................. 502
RETRACTABLE WINDSHIELD MOTOR (230 SERIES) ................................................... 505
BODY . . ... . ..... . ........ . .................. . ............................................................ 509
VII
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2010 Sea-Doo 210 Challenger, 210 Challenger SE Personal Watercrafts OEM Service & Repair Manual
Models covered:
- 58AE
- 58AA
- 58AB
- 58AC
- 58AD
- 59AA
- 59AB
- 59AC
- 59AD
The 2010 Sea-Doo 210 Challenger and 210 Challenger SE OEM Service & Repair Manual is the factory-issued reference for models 58AE, 58AA, 58AB, 58AC, 58AD, 59AA, 59AB, 59AC, and 59AD. Written for both professional marine technicians and DIY owners, it lays out step-by-step repair procedures, maintenance intervals, and precise specifications.
Inside, you’ll find detailed coverage of all key systems, including engine service, cylinder head and block repair, supercharger and intercooler maintenance, PTO housing, cooling system troubleshooting, and fuel injection servicing. The manual also includes guidance on propulsion components such as jet pumps, impellers, reverse systems, and driveshaft repairs, ensuring thorough coverage of the drivetrain.
Content overview:
- Safety information and general specifications
- Complete maintenance schedules, preseason checks, and storage procedures
- Engine removal, installation, and detailed repair procedures
- Air intake system, intake manifold, supercharger, and intercooler servicing
- Exhaust system inspection, muffler, manifold, and resonator repairs
- PTO housing, magneto, and lubrication system troubleshooting
- Cooling system service including impellers, thermostats, and heat exchangers
- Cylinder head and cylinder block overhauls with valve and piston service
- Electronic management systems with B.U.D.S. diagnostic tools and fault codes
- Fuel system service including ITC, EFI, injectors, pumps, and sensors
- Electrical system coverage: power distribution, CAN network, ignition, charging, starting, and D.E.S.S. key security system
- Instruments, gauges, radios, depth sounders, and accessories
- Propulsion system with jet pump, reverse system, impeller, driveshaft, and wear ring service
- Controls including steering system, throttle, and shifter adjustments
- Body and hull repair, bilge system, ride plate, ballast, and windshield servicing
- Complete technical specifications for all 210 Challenger models
- Full wiring diagrams, connectors, and electrical schematics
Additional sections cover steering and throttle controls, hull and body maintenance, exhaust repairs, bilge systems, and onboard electronics such as gauges, radios, and accessories. With factory-approved service data and diagnostic procedures, this OEM manual is a complete guide to keeping the 210 Challenger lineup operating safely and reliably on the water.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
