2007-2008 Seadoo 150 Speedster, 180-230 Challenger, 230 Wake Boats Service & Repair Manual

t t I 150 SpeedsterTM Series 180 hallenge Series ® I

Legal deposit: National Library of Quebec National Library of Canada 2007 All rights reserved. No parts of this manual may be reproduced In any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) © Bombardier Recreational Products Inc. (BRP) 2007 Printed in Canada Technical Publications Bombardier Recreational Products Inc. (BRP) Valcourt (Quebec) Canada @TM Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates. * Trademarks of Bombardier Inc., used under license. Challenger* DESSTM D-SEA-BELTM Rotax® SEA-DOO® SEA-DOO® Learning KeyTM Speedster™ TOPSTM XP-STM 4-TECTM This document contains the trademarks of the following companies: AMp® is a trademark of Tyco Electronics Corporation Gelcote® is a trademark of Gelcote International Limited Loctite® is a trademark of Henkel Corporation Molykote® is a trademark of Dow Corning Corporation Snap-on® is a trademark of Snap-on Tools Corporation Spray-Nine® is a trademark of Korkay System Ltd I

TABLE OF CONTENTS SAFETY NOTiCE .................................................................................. VIII INTRODU CTION ................................................................................... IX GENERAL INFORMATION............ ..... ............ ........... .... ........ ..... .... ....... ......... ....... ..... IX ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES ............................. X ENGINE EMISSIONS INFORMATION .......................................................................... XIV SELF-LOCKING FASTENERS PROCEDURE................................................................... XIV LOCTITE® APPLICATION PROCEDURE ........................................................................ XIV TIGHTENING TORQUES. ................. ........ .... ............ .... ... ..... ............ ....... ......... ..... XVIII 01 MAINTENANCE 01 - MAINTENANCE CHART..... .. . . .. . . .. . . . . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . . . 1 02 - PRESEASON PREPARATION................................................................................. 5 03 - STORAGE PROCEDURES ..................................................................................... 7 PROPULSION SySTEM............................................................................................... 7 FUEL SySTEM......................................................................................................... 7 ENGINE ................................................................................................................ 8 ELECTRICAL SYSTEM.. ..... .. ............. ....... .. ....... ........................... . ....... ....... ............ . ... 9 VEHiCLE............................................................................................................... 9 CHECKLIST........................................................................................................... 10 04 - SPECIAL PROCEDURES........ . .. . . . . . . .. . . .. . . .. . . .. . . .. . . . . . .. .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 11 TOWING THE BOAT IN WATER..................................................................................... 11 SUBMERGED BOAT................................................................................................. 11 WATER-FLOODED ENGINE......................................................................................... 11 02 TROUBLESHOOTING 01 - TROUBLESHOOTING CHART.............................................................................. 15 ENGINE ............................................................................................................... 15 ELECTRIC SySTEM.................................................................................................. 22 PROPULSION... . .. ..... ............ ... ........... .......... . ................ . ....... ....... ........ ................. 25 STEERING SySTEM .................................................................................................. 26 03 ENGINE 01 - ENGINE REMOVAL AND INSTALLATION................................................................ 27 GENERAL ...................................................................................................... 27 PROCEDURES................................................................................................ 27 ENGINE REMOVAL.................................................................................................. 27 CLEANING............................................................................................................ 31 ENGINE INSTALLATION............................................................................................. 31 ENGINE ALiGNMENT................................................................................................ 31 02 - ENGINE LEAK TEST. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . . . . .. . ... . . .. . . 35 PREPARATION......... ...... ..................... . .. ... ...................... ....... ................. ............... 35 PROCEDURE....... .... ...... ...................... .. ... ...................... ......... ....... ........ ............... 36 03 - AIR INTAKE SYSTEM.. . . .. . . .. . . .. . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . . . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 39 PROCEDURES ................................................................................................ 42 AIR INTAKE SiLENCER .............................................................................................. 42 04 - INTAKE MANIFOLD AND INTERCOOLER................................................................ 43 PROCEDURES ................................................................................................ 46 INTAKE MANIFOLD.................................................................................................. 46 INTERCOOLER..... .......... .................................. .. ............ . ....... ........ ......... ............... 50 05 - SUPERCHARGER ............................................................................................. 53 SUPERCHARGER INSPECTION (INSTALLED) ..................................................................... 55 SUPERCHARGER REMOVAL .............................................. ,. .. ........ ......... ............. .... ... 56 SUPERCHARGER DiSASSEMBLy .................................................................................. 57 SUPERCHARGER INSPECTION..................................................................................... 59 SUPERCHARGER ASSEMBLy ...................................................................................... 60

TABLE OF CONTENTS II SUPERCHARGER INSTALLATION.................................................................................. 64 06 - EXHAUST SySTEM.......................................................................................... 67 GENERAL ...................................................................................................... 69 EXHAUST SYSTEM COOLING...................................................................................... 69 MAINTENANCE .............................................................................................. 71 EXHAUST SYSTEM FLUSHING ..................................................................................... 71 PROCEDURES ................................................................................................ 72 EXHAUST PiPE ......................................... '" ...................... '" .... .......... .. .................. 72 MUFFLER ............................................................................................................. 76 RESONATOR.. ..... ......... ..... ... ..... ................. ..... ... ........... . .. ....... .......... .................... 76 EXHAUST OUTLET ................................................................................................... 77 07 - PTO HOUSING AND MAGNETO.......................................................................... 79 GENERAL ...................................................................................................... 81 PROCEDURES ................................................................................................ 81 PTO HOUSiNG....................................................................................................... 81 PTO SEAL ............................................................................................................. 83 COUPLiNG ............................................................................................................ 84 STATOR ............................................................................................................... 85 ROTOR AND TRIGGER WHEEL .................................................................................... 86 RING GEAR................ ....... . .. ..... ... ...... ..... ...................... .......... ..... ... .. .. .................. 86 STARTER DRiVE........ ............. ....... . ...... ..... ..... ... ................. ....... . .. .. ... .... . .. ............... 87 08 - LUBRICATION SySTEM..................................................................................... 89 GENERAL ...................................................................................................... 93 MAINTENANCE.............................................................................................. 93 OIL LEVEL VERIFICATION ........................................................................................... 93 OIL CHANGE......................................................................................................... 94 OIL FILTER............................................................................................................ 95 INSPECTION.................................................................................................. 96 ENGINE OIL PRESSURE............................................................................................. 96 PROCEDURES ................................................................................................ 97 PTO OIL STRAINER .................................................................................................. 97 ENGINE OIL PRESSURE REGULATOR ............................................................................. 97 OIL PRESSURE PUMP............................................................................................... 98 OIL SUCTION PUMP............................................................................................... 101 SUCTION PUMP OIL STRAINER... ..... .......... ....... ............................. ....... ... ............... ... 104 OIL SEPARATOR COVER ..................................................... , .... ,. ......... ............. .. . .... . 105 TOPS VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 OIL COOLER ....................................................................... ,. ........ .... .................. 107 09 - COOLING SYSTEM ......................................................................................... 109 GENERAL..................................................................................................... 113 CiRCUiT ............................................................................................................. 113 TECHNICAL SPECiFiCATIONS.................................................................................... 113 INSPECTION ................................................................................................. 113 PRESSURECAP .................................................................................................... 113 HOSES AND CLAMPS............................................................................................. 113 COOLING SYSTEM LEAK TEST................................................................................... 113 MAINTENANCE ............................................................................................. 114 COOLANT REPLACEMENT....................................................................................... 114 PROCEDURES ................. , ............................................................................. 116 CLAMPS ............................................................................................................ 116 WATER PUMP HOUSiNG......................................................................................... 116 WATER PUMP IMPELLER......................................................................................... 118 THERMOSTAT............... .......... ............. ......... ... ..... ....... ................. ..... ............... ... 118 ROTARY SEAL...................................................................................................... 118 10 - CYLINDER HEAD............................................................................................ 121 GENERAL ..................................................................................................... 123

TABLE OF CONTENTS PROCEDURES ............................................................................................... 123 EXHAUST MANIFOLD............................................................................................. 123 CYLINDER HEAD COVER .................................................................................. 123 SPARK PLUG TUBE.................................................................... ................... 124 ROCKER ARM................ ........................................... .......... .......... ................. 124 CAMSHAFT TIMING GEAR........................................................................................ 127 TIMING CHAIN ..................................................................................................... 128 CYLINDER HEAD..... .................................................... .......................................... 128 CAMSHAFT. . .. .. . .. .... . .. ....... . .. ..... .. . .... .. . .. .. . .. .. ..... ..... .. . .. .. . .... . .... . .. .. . .. .... . .. .. . .. .. . .. .. . 130 VALVE SPRING..................................................................................................... 131 VALVE............................................................................................................... 133 11 - CYLINDER BLOCK........................................................................................... 139 GENERAL ..................................................................................................... 142 PROCEDURES ............................................................................................... 142 TIMING CHAIN............................................................................................... 142 CHAIN TENS lONER .... .......... ......................................................................... 142 PISTON AND CONNECTING ROD.......................................................................... 143 PISTON RINGS....................................................................................... ............. 147 CRANKSHAFT .................................................................................................... 149 BALANCERSHAFT ................................................................................................. 153 CYLINDER BLOCI( .......... ................ ........................................................ ............ 155 04 ENGINE MANAGEMENT 01 - OVERViEW ................................................................................................... 161 OPERATING PRINCiPLE .................................................................................... 162 AIR INDUCTION............................................................................. ....................... 162 FUELSYSTEM ...................................................................................................... 163 ELECTRICAL SySTEM........................................... .................................................. 163 ENGINE MANAGEMENT SySTEM ....................................................................... 167 ELECTRONIC FUEL INJECTION................................................. ......................... 167 IGNITION SYSTEM... ............ ........................................ ................... ....................... 167 ENGINE MODES OF OPERATION.................................................... ............................ 167 MONITORING SySTEM........................................................................................... 168 DIAGNOSTIC MODE.... ........................................................................................... 168 ENGINE MANAGEMENT SYSTEM FLOW CHART.............................................................. 169 02 - DiAGNOSTIC ................................................................................................. 111 GENERAL ..................................................................................................... 171 DIAGNOSTiC ................................................................................................. 172 MONITORiNG SySTEM..... ..... ...................... .............. ............................................ 172 FAULT CODES ..................................................................................................... 173 03 - ADJUSTMENT AND REPAIR PROCEDURES........................................................... 115 GENERAL ..................................................................................................... 175 FUEL SYSTEM .......................................................... . 175 ELECTRICAL SySTEM............................................................................................. 176 BASIC ADJUSTMENTS .................................................................................... 183 IDLE SPEED................................................................................................. 183 THROTTLE CABLE ............................................................................................... . CLOSED THROTTLE AND IDLE ACTUATOR RESET ............................................. . 183 183 IGNITION TIMING..................... ............................................ .................. ............... 184 REPAIR PROCEDURES ..................................................................................... 184 ENGINE FUSE BLOCK (EFB) ................... .................................................................. 184 VEHICLE CONTROL MODULE (VCM)..... ................. ............................... ....................... 184 ENGINE CONTROL MODULE (ECM) ............................................................................. 186 FUEL INJECTOR......................................................... ......................................... 188 THROTTLE BODy .................................................................................................. 190 THROTTLE POSITION SENSOR (TPS) ........................................................ ................... 191 III

TABLE OF CONTENTS IDLE BYPASS VALVE (lBV).. ........ ..... ..... .... ............. ....... ....... ........ .. ..... ....... . ....... .. . ..... 193 CRANKSHAFT POSITION SENSOR (CPS) ........................................................................ 194 CAMSHAFT POSITION SENSOR (CAPS) ......................................................................... 195 MANIFOLD AIR TEMPERATURE SENSOR (MATS) ............................................................. 197 COOLANT TEMPERATURE SENSOR (CTS) ............. ..... ............ ..... ....... ....... ........... .......... 198 MANIFOLD AIR PRESSURE SENSOR (MAPS) ...... ........ ............ ..... ....... .......... ....... ........... 199 EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................................................... 200 KNOCK SENSOR (KS) ............ ................. ............. ..... ......... . .... . .. ..... ............ .......... .. . 201 OIL PRESSURE SENSOR (OPS) .................................................................................. 202 05 FUEL SYSTEM 01 - FUEL TANK AND FUEL PUMP............................................................................ 205 GENERAL ..................................................................................................... 208 INSPECTION................................................................................................. 208 FUEL SYSTEM LEAK TEST........................................................................................ 208 FUEL PUMP PRESSURE TEST.................................................................................... 210 PROCEDURES ............................................................................................... 211 FUEL HOSES AND OETIKER CLAMPS........................................................................... 211 FUEL VENT ANTI-SURGE.......................................................................................... 211 FUELFILTER ........................................................................................................ 212 FUEL TANK......................................................................................................... 213 FUEL PUMP........................................................................................................ 213 06 ELECTRICAL SYSTEM IV 01 - COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE............................................... 219 COMMUNICATION TOOLS ................................................................................ 219 MPI .................................................................................................................. 219 MPI-2................................................................................................................ 221 B.U.D.S. SOFTWARE ....................................................................................... 223 02 - IGNITION SySTEM......................................................................................... 225 GENERAL ..................................................................................................... 225 PROCEDURES ............. : ................................................................................. 226 IGNITION COIL..................................................................................................... 226 SPARK PLUGS...................................................................................................... 228 03 - CHARGING SySTEM....................................................................................... 231 GENERAL ..................................................................................................... 231 TESTING PROCEDURE ..................................................................................... 232 RECTIFIER/REGULATOR.......................................................................................... 232 STATOR............................................................................................................. 233 BATTERy ............................................................................................................ 235 04 - STARTING SySTEM........................................................................................ 237 GENERAL ..................................................................................................... 239 TROUBLESHOOTING ....................................................................................... 239 HIGH CURRENT CIRCUIT TEST................................................................................... 239 PROCEDURES ............................................................................................... 240 FUSE................................................................................................................ 240 ENGINE START/STOP SWiTCH................................................................................... 240 NEUTRAL SWiTCH................................................................................................. 241 SOLENOID.......................................................................................................... 242 STARTER.. .. . .......................... . ....... ......... ................. ... .......... ................. ............. 244 STARTER GEAR. ............ ... ............... .. .. ............. ..... .... . .... ........ ....... ............. .. ..... .. . 245 05 - FUSES, GAUGE AND ACCESSORIES................................................................... 247 GENERAL ..................................................................................................... 247 CHECKING FOR SHORTS BETWEEN 2 WiRES................................................................. 248 MAIN CUT-OFF SWiTCH.......................................................................................... 248 FUSES............................................................................................................... 249

TABLE Of CONTENTS EFB POWER SUPPLY AND GROUND............................................................................ 250 VCM POWER SUPPLY AND GROUND........ ............ .............................. .... ..................... 250 COMMUNICATION LINK (CAN LINES) .......................................................................... 251 INFORMATION CENTER.......................................................................................... 251 TESTING PROCEDURES ................................................................................... 253 INFORMATION CENTER ....................................................................................... . 253 FUEL LEVEL SENDER................................................... .... ...................................... 255 WATER TEMPERATURE SENSOR .............................................................................. . 257 COMPASS......................................................................................... ................ 257 SPEED SENSOR.......................................................... .......................................... 258 BEEPER............................................................................................................. 259 ELECTRIC BILGE PUMP ........................................................................................... 260 DEPTH SOUNDER.................................................. ....... ....... ...... ........................... 263 OTHER ELECTRIC DEViCES...................................................................................... 263 06 - DIGITAllY ENCODED SECURITY SYSTEM (OESS) ................................................... 265 GENERAL ........................................................................................................... 265 DESS KEY PROGRAMMING...................................................................................... 265 TROUBLESHOOTING.............................................................................................. 267 07 PROPULSION 01- JET PUMP .................................................................................................... 271 GENERAL ..................................................................................................... 273 INSPECTION ...................................... "" ......................................................... 273 IMPELLER CONDITION........................................................................................... 273 IMPELLER/WEAR RING CLEARANCE........................................................................... 273 LEAK TEST.......................................................................................................... 273 PROCEDURES .................................................................... " ......................... 274 SACRIFICIAL ANODE.............................................................................................. 274 VENTURI ............................................................................................................ 274 JET PUMP HOUSiNG.............................................................................................. 275 IMPELLER COVER................................................................................................. 277 IMPELLER.......................................................................................................... 278 WEAR RING ...................................................................................................... . 280 IMPELLER SHAFT AND BEARING................................................................................ 281 102 - DRIVE SySTEM.............................................................................................. 285 GENERAL .......... " ......................................................................................... 287 MAINTENANCE ......................................................................................... " .. 287 CORROSION PROTECTION........................................................ .............................. 287 PROCEDURES ................................ , ............. , ................................................ 287 DRIVE SHAFT..................................................................................................... 287 DRIVE SHAFT BOOT............................................................................................... 293 CARBON RING..................................................................................................... 294 DRIVE SHAFT PROTECTOR........ ....................... .............................................. 294 03 - REVERSE SySTEM......................................................................................... 295 GENERAL ..................................................................................................... 297 PROCEDURES ............................................................................................... 297 SACRIFICIAL ANODE.............................................................................................. 297 REVERSE GATE.................................................................................................... 297 REVERSE GATE LEVER......... .................................................................................. 297 REVERSE GATE SUPPORT........................................................................................ 298 REVERSE CABLE ................................................................................................. . 299 08 CONTROL SYSTEMS 01 - STEERING SySTEM........................................................................................ 303 GENERAL .................................................................. " ................................. 305 INSPECTION ................................................................................................. 305 v

TABLE OF CONTENTS PARTS REPLACEMENT..................................................................................... 305 NOZZLE............................................................................................................. 305 STEERING CABLE.................................................................................................. 306 STEERING WHEEL................................................................................................. 308 STEERING HELM.................................................................................................. 309 ADJUSTMENT ............................................................................................... 309 STEERING ALIGNMENT........................................................................................... 309 02 - THROTTLE/SHIFTER CONTROL.......................................................................... 311 GENERAL ..................................................................................................... 313 PROCEDURES ............................................................................................... 313 THROTILE/SHIFTER CONTROL.................................................................................. 313 THROTILE CABLE................................................................................................. 315 REVERSE CABLE................................................................................................... 316 09 BODY AND HULL VI 01 - BODy .......................................................................................................... 319 GENERAL ..................................................................................................... 335 LUBRiCATION............................................................................................... 335 LOCKS.............................................................................................................. 335 PARTS REPLACEMENT..................................................................................... 335 DECALS............................................................................................................. 335 SEATS............................................................................................................... 336 ARMREST........................................................................................................... 337 WEDGE PAD............................................................................ ............................ 338 SUN PAD ............................................................................................................ 338 FRONT STORAGE COVER SHOCK............................................................................... 339 FRONT STORAGE COVER....... .. ....... . ...... ........ ........ ...... ........... ....... .............. . ......... . 339 FRONT STORAGE COVER LATCH........ . ...... . ..................... ...... ..... ....... ............ ... ......... . 339 ENGINE COVER.................................................................................................... 339 ENGINE COVER LATCH........................................................................................... 340 ENGINE COVER CABLE........................................................................................... 340 COVER SHOCK......................................... ........ .................................................... 341 REAR STORAGE COMPARTMENT COVER...................................................................... 341 BUMPER............................................................................................................ 341 SKI POST............................................................................................................ 342 CLEANING .................................................................................................... 343 WiNDSCREEN...................................................................................................... 343 ViNyL ................................................................................................................ 343 BODy ................................................................................................................ 343 CARPET ............................................................................................................. 344 BODY REPAIR ................................................................................................ 344 02 - HULL.......................................................................................................... 345 GENERAL ..................................................................................................... 354 LUBRiCATION............................................................................................... 354 LOCKS .............................................................................................................. 354 PARTS REPLACEMENT ..................................................................................... 354 LADDER ............................................................................................................. 354 DRAIN PLUG....................................................................................................... 354 BILGE PUMP TUBE................................................................................................ 355 DECK DRAIN....................................................................................................... 355 SCUPPER VALVE................................................................................................... 355 INLET GRATE................ . ..................... ........ ..... ................. ....... ... .. .......... ............. 356 RIDE PLATE......................................................................................................... 356 JET PUMP SUPPORT.............................................................................................. 357 CLEANING .................................................................................................... 358 HULL................................................................................................................ 358

TABLE OF CONTENTS HULL REPAIR ................................................................................................ 358 GENERAL ........................................................................................................ . 358 TOOLS AND MATERIALS LIST................................. .................................................. 358 GELCOAT DAMAGES ............................................................................................ . 359 10 TECHNICAL SPECIFICATIONS 01 - MODEL EQUIPPED WITH A 1503 ENGINE (155 HPJ ................................................... 363 02 - MODELS EQUIPPED WITH A 1503 ENGINE (215 HP) ................................................. 369 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS 01 - ELECTRICAL CONNECTORS .............................................................................. 375 DEUTSCH CONNECTORS......................................................................................... 375 PACKARD CONNECTOR.................................................. ........................................ 377 ECM CONNECTORS ............................................................................................. . 377 EFB AND VCM CONNECTORS........................................ ........................................... 380 BATTERY AND STARTER CABLE TERMINALS........................................ .......................... 382 02 - WIRING DIAGRAMS........................................................................................ 385 WIRE COLOR CODES ........................................................................................... . 385 CONNECTOR CODES............................................................................................. 385 VII

2007-2008 Seadoo 150 Speedster, 180-230 Challenger, 230 Wake Boats Service & Repair Manual

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