Seadoo 180 Challenger 2011 Shop Service Repair Manual Downlo

2011 Sea-Doo@ Boats Shop Manual 150, 180, 200, 210 and 230 SERIES

Legal deposit: National Library of Quebec National Library of Canada 2011 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) 2011 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. 4-TECTM Rotax® Challenger* Sea-Doo® D.E.S.S.TM Sea-Doo Learning KeyTM D-SEA-BELTM Speedster™ Fold'n Stow™ 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 GUNK® is a trademark of Radiator Specialty Company 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 Zerex® is a trademark of Ashland Inc. TOPSTM Transat™ WAKETM XPSTM

TABLE OF CONTENTS SAFETY NOTiCE....................................................................................................... IX INTRODUCTION......................................................................................................... X BOAT INFORMATION ....... .. ...... ......... .......... ......... ...... .... ... ..... ..... ..... ... ....... ....... ... .... XI MANUAL INFORMATION ........................................................................................... XII FASTENER INFORMATION ... ............................. .......... .............................................. XVI 01 MAINTENANCE 01 - BREAK-IN INSPECTION......................................................................................... 7 02 - PERIODIC MAINTENANCE SCHEDULE....................................................................... 9 03 - PRESEASON PREPARATION................................................................................. 13 04 - STORAGE PROCEDURE....................................................................................... 15 PROCEDURES...... ............... ......... ... ..... ..... ....... ..... ..... ..... ..... ... .............. ... ..... 15 PROPULSION SySTEM. . .... ...... .... ............ ..... ..... ..... ..... ..... ..... ..... ....... ..... ... ..... 15 FUEL SYSTEM... ....... ... ..... ..... .... . ... .... ..... ... .... ..... ........ ..... ........ ....... ..... ....... 15 ENGINE ........ ... ......... .......... .......... ....... ..... ....... ........ .......... ...... .... ..... ....... 15 ELECTRICAL SySTEM................. .............. . ....... ......... .................................... 17 ENGINE COMPARTMENT .... ... ..... ............ ..... ..... ..... ..... ....... ........ ..... ..... ...... ..... 17 BODY AND HULL... ....................... .. ............................. ...... ....... ..... .............. 17 05 - SPECIAL PROCEDURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 GENERAL ... ..... ..... ... .............. ....... .. . ................. ..... ... ..... ....... .......... ........ ..... 19 PROCEDURES... ....... ..... .......... ....... ..... ..... ....... ... ........ ................. ..... ........ ..... 19 TOWING THE BOAT IN WATER.. ......... ..... ....... ..... ..... ... ....... ........ ..... ..... ........ .. . .. 19 SUBMERGED BOAT ..... ............. ............... ..... ................................................ 19 WATER-FLOODED ENGINE ...... ......... ... ..... ....... ..... ... ..... ..... ..... ..... .......... ...... .... 19 02 ENGINE 01 - ENGINE REMOVAL AND INSTALLATION .................................................................. 23 GENERAL .................................................................................................... 25 ENGINE ACCESS ......................................................................................... 25 PROCEDURES ............................................................................................... 25 ENGINE ................................................................................................... 25 ENGINE RUBBER MOUNTS............................... ... ....... ... .... .............................. 28 02 - AIR INTAKE SySTEM ........................................... . .............................................. 31 GENERAL ......................................................................... . .......................... 36 PROCEDURES ............................................................................................... 36 AIR FILTER (ALL EXCEPT 210 SERIES) .......... ... ....... . .... .... ...... . .... .... .... .............. ..... 36 AIR INTAKE TUBE (ALL EXCEPT 210 SERIES) ........................................................... 36 AIR INTAKE SILENCER COVER (210 SERIES) ............. ................ ......... ...................... 37 AIR INTAKE SILENCER BAFFLE (210 SERIES) ........................................................... 37 AIR INTAKE TUBE (2 10 SERIES) .............. ............................................................ 37 AIR INTAKE SILENCER (210 SERIES) .................................................................... 38 03 - INTAKE MANIFOLD............................................................................................ 39 GENERAL .................................................................................................... 43 PROCEDURES ................................................... ................................... ......... 43 INTAKE MANIFOLD ....................................................................................... 43 FLAME ARRESTER....................................................................................... 46 04 - SUPERCHARGER (215,255 AND 260 ENGINES) ......................................................... 47 GENERAL .................................................................................................... 49 INSPECTION ................................................................................................. 49 SUPERCHARGER INLET CLEANLINESS........................ ......................................... 49 SUPERCHARGER CLUTCH SLIPPING MOMENT (ON ENGINE) ......................................... 49 SUPERCHARGER CLUTCH SLIPPING MOMENT (BENCH TEST) ............... ......................... 50 TROUBLESHOOTING ...................................................................................... 51

TABLE OF CONTENTS 02 ENGINE (cont'd) II 04 - SUPERCHARGER (215,255 AND 260 ENGINES) (cont'd) PROCEDURES..... ..... ... ....... ..... ... ............ ..... ................. ... ....... ..... ..... ..... ... ..... 51 SUPERCHARGER......................................................................................... 51 05 -INTERCOOLER (215 ENGINE) ...................................................... ... ....................... 61 GENERAL .......................................... . ......................................... . ............... 62 PROCEDURES ...................................................... .... .................................... . 62 I NTERCOOLER................................................ . .......................................... 62 06 - INTERCOOLER (255 AND 260 ENGINES) ........................ . ......................................... 65 GENERAL ........... .. ....................................................................................... 67 MAINTENANCE.................................. . .......................................................... 67 I NTERCOOLER FL USHING........................ . ...................................................... 67 PROCEDURES ..... . .............. . .......................................................................... 67 I NTERCOOLER............................ . .............................................................. 67 07 - EXHAUST SySTEM ............................. . .............................................................. 71 GENERAL ........ ... ......................................................................................... 77 SYSTEM DESCRiPTION....... . .............. . ........................................................... 77 MAINTENANCE.................................................................... . ................... . .... 78 EXHAUST SYSTEM FLUSHING ..................................................... . ................... .. 78 PROCEDURES ............................................................................................... 79 MUFFLER ....... . ......................................................................................... 79 E XHAUST PiPE........................ ... .. . ................ . ............................................ 81 E XHAUST MANIFO LD .................................................................................... 82 RESONATOR ............................................................... . .. ... ......................... 83 08 - PTO HOUSING AND MAGNETO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 GENERAL .......... ... ............................. . ................................................ ... ...... 87 PROCEDURES ......................... . ...... . ..................... . ....................................... . 87 PTO HOUS iNG.................... . ............. ... ................. . ............ . ......... . ...... . ....... 87 PTO SEAL ..... . ...... .. .............. . ......... . ........................................... . .............. 91 PTO COUPLiNG . ............................................ . ............................................ 92 STARTER DRIVE BEAR I NGS .............................................................................. 93 STATOR .......................................................... . ........................................ 93 ROTOR AND TR I GGER WHEEL............................................. . .. . ......................... 96 RING GEAR............................................................................................... 97 STARTER DRiVE...................... . ................................................................... 98 09 - LUBRICATION SySTEM ...................................................................................... 101 GENERAL ......................... . ................................. .. ...................................... 106 MAINTENANCE ... . ................. . ............. . ................... . .................................... 106 ENGINE OIL ... . ............................................................... . .. . ....................... 106 OIL FI LTER ............................................................................................... 107 INSPECTION ................................................................................................ 108 ENGINE OIL PRESSURE ............ . .................................................................... 108 TROUBLESHOOTING ....................... . ..................... . ....................................... 109 PROCEDURES ..... . ....... . ................................................................................ 110 OIL PRESSURE SWITCH (OPS) .......................................................................... 110 PTO OIL STRAINER...................................................................................... 111 SUCTION PUMP OIL STRAINER ........................................................................ 112 ENGINE OI L PRESSURE REGULATOR .................................................................. 113 OIL PRESSURE PUMP ......................................... . ......................................... 114 ROTARY SEAL ........................................ .. ............. . .... . .............. . ............... 116 OIL SUCTION PUMP ................................................................... . ................ 117 SUPERCHARGER OIL SPRAY NOZZ LE .................................................................. 120 PISTON OIL SPRAY NOZZLES ........................................................................... 121 OIL SEPARA TOR COVER ................................................................................ 122 BL OW-BY VALVE ......................... . ......................................... .. ................... 123

02 ENGINE (cant' d) 09 - LUBRICATION SYSTEM (cant'd) PROCEDURES (cant'd) TABLE OF CONTENTS TOPS SWITCH (210 AND 230 SERIES) .................................................................. 125 OIL COOLER ............................................................................................. 127 10 - COOLING SYSTEM ........................................................................................... 129 GENERAL................................................................................................... 135 SYSTEM DESCRiPTION.. ............................................................................... 135 MAINTENANCE............................................................................................ 135 ENGINE COOLANT ...................................................................................... 135 INSPECTION ................................................................................................ 137 COOLING SYSTEM LEAK TEST ......................................................................... 137 TROUBLESHOOTING ..................................................................................... 138 PROCEDURES .............................................................................................. 138 PRESSURE CAP ......................................................................................... 138 CLAMPS ................................................................................................. 138 WATER PUMP HOUSiNG................................. ............................................... 139 WATER PUMP IMPELLER......................................... ...................................... 140 THERMOSTAT ........................................................................................... 141 ROTARY SEAL ........................................................................................... 141 HEAT EXCHANGER (200, 210 AND 230 SERIES) ....................................................... 141 11 - CYLINDER HEAD..................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 GENERAL................................................................................................... 145 INSPECTION ................................................................................................ 145 ENGINE LEAK TEST..................................................................................... 145 TROUBLESHOOTING ..................................................................................... 147 PROCEDURES .............................................................................................. 148 CYLINDER HEAD COVER ................................................................................ 148 SPARK PLUG TUBES .................................................................................... 149 ROCKER ARMS .......................................................................................... 149 CAMSHAFT TIMING GEAR .............................................................................. 151 CAMSHAFT. . . . . . . . . .. .. . . . . . . . . . . . . .. . . . .. . .. .. . . . .. . . . .. . . . . . .. .. . .. . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . 152 CYLINDER HEAD ........................................................................................ 154 VALVE SPRINGS ......................................................................................... 156 VALVES ................................................................................................... 157 VALVE GUiDE ............................................................................................ 161 12 - CYLINDER BLOCK .... ................ ........................ ........ ......................................... 163 GENERAL ................................................................................................... 166 TROUBLESHOOTING ..................................................................................... 166 PROCEDURES .............................................................................................. 166 TIMING CHAIN ........................................................................................... 166 CHAIN TENSIONER ...................................................................................... 167 PISTONS AND CONNECTING RODS .................................................................... 167 PISTON RINGS ........................................................................................... 172 CRANKSHAFT.... .................................................................................... .... 174 BALANCER SHAFT...................................................................................... 178 CYLINDER BLOCK ....................................................................................... 181 03 ELECTRONIC MANAGEMENT SYSTEMS 01 - ENGINE MANAGEMENT SySTEM........................ . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 GENERAL ................................................................................................... 187 ENGINE MANAGEMENT SCHEMATIC (150,180 AND 200 SERIES) .............. ...................... 187 ENGINE MANAGEMENT SCHEMATIC (210 AND 230 SERIES) ......................................... 188 SYSTEM DESCRiPTION ................................................................................. 189 III

TABLE OF CONTENTS 03 ELECTRONIC MANAGEMENT SYSTEMS (cont'd) 02 - CONTROLLER AREA NETWORK (CAN) ............ : ..... .. ............................................... 193 GENERAL................................................................................................... 197 SYSTEM DESCRiPTION ........ . .. .. .................................................................... 197 TROUBLESHOOTING..................................................................................... 197 DIAGNOSTIC TiPS ....................................................................................... 197 03 - COMMUNICATION TOOLS AND S.U.D.S . . ... ... ... . ... . .... ............................................. 199 GENERAL ................................... . ... . ...... ...... ........ ... ...... . ............. ... ............ . 199 REQUIRED TOOLS ...................................... • ............... •..• .............. • ......... •... 199 DIAGNOSTIC CONNECTOR LOCATION ..... . ............. . ............................................. 199 TROUBLESHOOTING ..... ............................ .. ............ . .. . .......... . ...... . .............. . . 200 DIAGNOSTIC TIPS ........ . ...... .. ................ ..... ................................................. 200 PROCEDURES ..... ... .. . .. . ...... ........ .......... .. .................. . .... .. .......................... ... 202 MPI-2 .............. . ...................................................................................... 202 B.U.D.S. SOFTWARE ....................................................................... •• ........... 203 04 - DIAGNOSTIC AND FAULT CODES......................................................................... 207 GENERAL................................................................................................... 207 MONITORING SySTEM................................................................................. 207 FAULT CODES........................................................................................... 211 SPECIFIC FAULT CODES ............... . ................................................................ 213 FAULT CODE TABLE . . .. . .... . ......... . ........ . .. ... ...... ... ...... . .................... ... ... . ........ 214 04 FUEL SYSTEM IV 01 -INTELLIGENT THROTTLE CONTROL (iTC) (210 AND 230 SERIES). ... ............................... 235 GENERAL ... . ... .... ....... .. ......... . ............. . .... . .......................................... .. ...... 237 SYSTEM DESCRiPTION. .. . ... .... . .. .. ..... ..... ... .... . ........... . .... ... .. . ... .... . ... ...... . ....... 237 PROCEDURES . ............................ .... .... .. ....................................................... 237 TAS (THROTILE ACCELERATOR SENSOR) ... ..... . ............. ... ..... . .... . ...• ...... .. ............ . 237 02 - ELECTRONIC FUEL INJECTION (EFI) ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . .. 241 GENERAL........ . ............. ... .... . . .. .. .............................. . ...... . ............. . ............ 241 SYSTEM DESCRiPTION ................ •. ...... . ...... . ...... . ........... . .............................. 242 ADJUSTMENT ..... ... ...... ... ..... . ...... . .................................................. . ............ 243 IDLE SPEED.. . ......... . .............. ... ............ ... .. .............................................. 243 CLOSED THROTILE RESET ............................................................................. 244 TROUBLESHOOTING . .................................................................................... 244 DIAGNOSTIC TiPS ...... ..... ............... ..... .. ...... .. .............................................. 244 PROCEDURES .. ... . .... . ....................................... . ... . .......................... ..... ..... ... 245 ECM (ENGINE CONTROL MODULE) (210 AND 230 SERIES) ........................................... 245 ECM (ENGINE CONTROL MODULE) (150, 180 AND 200 SERIES) ...... . .............................. 250 FUEL RAIL............... . ............. . ....................................................... .... ...... 252 FUEL INJECTOR..... . ................. . .. ... ........................................ . ..... ..... ......... 254 THROTILE BODY (210 AND 230 SERIES) ............ ... ....................... . ....................... 259 THROTILE BODY (150, 180 AND 200 SERIES) ...... . .................................................. 261 THROTILE POSITION SENSOR (TPS) (210 AND 230 SERIES) .......... . .......... . .......... .. ........ 263 THROTILE POSITION SENSOR (TPS) (150, 180 AND 200 SERIES) .................................... 264 IDLE BYPASS VALVE (IBV) (150,180 AND 200 SERIES) . .. ...................... . ............ .. ........ 266 CPS (CRANKSHAFT POSITION SENSOR) .. . .......... .. ............... . .... . ........................... 267 CAMSHAFT POSITION SENSOR (CAPS) ................................................................ 269 MANIFOLD AIR TEMPERATURE SENSOR (MATS) ..................................................... 272 COOLANT TEMPERATURE SENSOR (CTS) ............ ... ............. .. ................... •. .......... 274 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS) .................................................. 275 EXHAUST GAS TEMPERATURE SENSOR (EGTS) ....................................................... 277 KNOCK SENSOR (KS) .................................................................................... 278

TABLE OF CONTENTS 04 FUEL SYSTEM (cont'd) 03 - FUEL TANK AND FUEL PUMP ................... ..................... ............. ........ ...... ........... 281 GENERAL ................................................................................................... 285 SYSTEM DESCRiPTION ................................................................................. 285 INSPECTION ............................ ........................................................... ... ...... 286 FUEL SYSTEM LEAK TEST .............................................................................. 286 FUEL PUMP PRESSURE TEST................................ .......................................... 286 PROCEDURES ....................... ................. ...................................................... 287 FUEL HOSES AND HOSE CLAMPS..................................................................... 287 FUEL PUMP................................................................ . ............................ 288 FUEL FILTER.............. ............................................................................... 291 FUEL LEVEL SENDER....................... . ........................................................... 291 FUEL TANK........ ........ ...... ......... ...... ......................................................... 292 05 ELECTRICAL SYSTEM 01 - POWER DISTRIBUTION. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 295 GENERAL................................................................................................... 299 ELECTRICAL SYSTEM ACTiVATION..................................................................... 299 MAIN CUT-OFF SWiTCH................................................................................ 299 MAIN CIRCUIT BREAKER (180/210/230 SERIES) ....................................................... 299 FUSES (150/180 SERIES) ................................................................................ 299 FUSES (200 SPEEDSTER) ............................................................................... 301 FUSES (210 SERIES) ....... ........................... ..... .............................................. 302 CIRCUIT BREAKERS (210 SERIES) ...................................................................... 303 FUSES (230 SERIES) ................................................ . ............................ . ....... 304 CIRCUIT BREAKERS (230 SERIES) ...................................................................... 304 MAIN RELAY (150/180/210 SERIES) ..................................................................... 305 MAIN GROUNDS........................................................................................ 305 PROCEDURES .............................................................................................. 306 VCM (VEHICLE CONTROL MODULE) (200 SPEEDSTER) ........................... . ................... 306 EFB (ENGINE FUSE BLOCK) (200 SPEEDSTER) ................................................. . ...... 307 02 - IGNITION SYSTEM ........................................................................................... 311 GENERAL................................................................................................... 311 SYSTEM DESCRiPTION ................................................................................. 311 TROUBLESHOOTING ........................................................................... . ......... 312 IGNITION SYSTEM TESTING .................................................................. . ......... 312 DIAGNOSTIC GUiDELINES .............................................. . ............................... 312 PROCEDURES .............................................................................................. 313 ENGINE CUT-OFF SWITCH (150,180 AND 200 SERIES) ............................................... 313 ENGINE CUT-OFF SWITCH (210 AND 230 SERIES) ..................................................... 314 IGNITION SWiTCH ................................................................... . ................... 314 IGNITION COILS ............................................................... . ......................... 314 ·SPARK PLUGS ........................................................................................... 318 03 - CHARGING SySTEM................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 321 GENERAL ........................ . .......................................................................... 321 SYSTEM DESCRiPTION ................................................... . ............................. 321 INSPECTION ................................................................................................ 321 CHARGING SYSTEM OUTPUT .......................................................................... 321 TROUBLESHOOTING ............................................................. . ....................... 323 TROUBLESHOOTING GUiDELINES ..................................................................... 323 PROCEDURES .............................................................................................. 324 VOLTAGE REGULATOR/RECTIFIER ................ . ............................ . ....................... 324 BATIERY ................................................................................................. 324 v

TABLE OF CONTENTS 05 ELECTRICAL SYSTEM (cont'd) 04 - STARTING SySTEM.......................................................................................... 327 GENERAL................................................................................................... 334 ENGINE CRANKING CONDITIONS ...................................................................... 334 TROUBLESHOOTING..................................................................................... 334 DIAGNOSTIC TiPS....................................................................................... 334 DIAGNOSTIC GUiDELINES .............................................................................. 334 PROCEDURES .............................................................................................. 335 ENGINE START/STOP SWiTCH .......................................................................... 335 NEUTRAL SWITCH .......................................................................... . ........... 337 STARTER SOLENOID .................................................................................... 338 STARTER................................................................................................. 340 05 - DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) .................................................. 343 GENERAL ................................................................................................... 343 SYSTEM DESCRiPTION................................................................................. 343 PROCEDURES .............................................................................................. 343 D.E.S.S. KEy ............................................................................................. 343 BEEPER .................................................................................................. 346 06 - INSTRUMENTS AND ACCESSORIES...................................................................... 347 GENERAL ................................................................................................... 348 INFORMATION CENTER DESCRIPTION (150 AND 180 SERIES) ....................................... 348 INFORMATION CENTER DESCRIPTION (210 AND 230 SERIES) ....................................... 349 TROUBLESHOOTING ..................................................................................... 355 DIAGNOSTIC TiPS....................................................................................... 355 PROCEDURES .............................................................................................. 355 INFORMATION CENTER (150 AND 180 SERIES) ....................................................... 355 INFORMATION CENTER (210 AND 230 SERIES) ....................................................... 356 SPEEDOMETER (210 AND 230 SERIES) ................................................................ 356 SPEEDOMETER (200 SERIES) ........................................................................... 357 SPEED SENSOR (ALL EXCEPT 210 AND 230 SERIES) ................................................. 358 TACHOMETER (200 SERIES) ............................................................................ 359 ANALOG FUEL GAUGE (210 AND 230 SERIES) ........................................................ 359 ANALOG FUEL GAUGE (200 SERIES) ................................................................... 360 MONITORING GAUGE (200 SERIES ONLY) ............................................................. 361 BEEPER (200 SERIES) ................................................................................... 361 RADIO ................................................................................................... 362 RADIO AMPLIFIER (210 AND 230 WAKE ONLy) ........................................................ 362 DEPTH SOUNDER (ALL EXCEPT 200 SERIES) .......................................................... 363 DEPTH SOUNDER (200 SERIES) ........................................................................ 363 HEATER UNIT (210 AND 230 WAKE ONLY) ............................................................. 364 ELECTRIC BILGE PUMP..................................................................... . ........... 365 BILGE BLOWER ......................................................................................... 367 BOW LIGHT.............................................................................................. 367 STERN LIGHT ............................................................................................ 369 COURTESY LIGHT ....................................................................................... 370 EXTINGUISHER PRESSURE SWITCH (CE MODELS) ................................................... 371 EXTINGUISHER INDICATOR LAMP (CE MODELS) ...................................................... 372 06 PROPULSION 01 - REVERSE SYSTEM ........................................................................................... 373 GENERAL ................................................................................................... 374 PROCEDURES .............................................................................................. 374 REVERSE CABLE ....................................................................................... . 374 REVERSE GATE .......................................................................................... 374 REVERSE GATE LEVER............................................................... . .................. 375 VI

06 PROPULSION (cant' d) 01 - REVERSE SYSTEM (cant' d) PROCEDURES (cant' d) TABLE OF CONTENTS REVERSE GATE SUPPORT ............................................. • ................................ 376 02 - JET PUMP.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 379 GENERAL ................ . .................................................................. . ........... . ... 381 JET PUMP MAIN COMPONENTS .................. .... ................................................. 381 INSPECTION .. ..................... . ... .... .................................... . ............................ 381 IMPELLER CONDITION ..................................................... . ............................ 381 IMPELLER/WEAR RING CLEARANCE ...................................... .... ......... . ............... 381 IMPELLER SHAFT RADIAL PLAy ................................................... . ................... . 381 LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 382 PROCEDURES .. .................................... . ........................ . .............. . ............... 383 VENTURI ................................................................................................. 383 JET PUMP HOUSiNG ............... .. .. ................................................................. 384 IMPELLER COVER ........... . ......... . ................................................................. 385 IMPELLER ............................. . ................................................................. 387 WEAR RING ........................... . ................................................................. 389 IMPELLER SHAFT AND BEARING ...... . ......................... . .... . ................................ 390 03 - DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 397 GENERAL......................................... . .... . .................................................... 399 MAINTENANCE......................................... . .................................................. 399 CORROSION PROTECTION ............................................................................. 399 PROCEDURES .. ............................................................................................ 399 DRIVE SHAFT ............. .... ........................................................................... 399 DRIVE SHAFT BOOT ............................................................. . ........... . ........... 405 CARBON RING ........................................................................................... 406 DRIVE SHAFT PROTECTOR ......................... .. .. ........................ . ........... . ......... .. 406 07 CONTROLS 01 - STEERING SYSTEM. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 407 GENERAL .. ................. . ........................................... ...... ....... . ...................... 410 ADJUSTMENT . .......................... . ................................................................. 410 STEERING ALIGNMENT ................................................................................. 410 TROUBLESHOOTING ......... . .......................... . ................................................ 411 ABNORMAL PLAY IN STEERING ........................................ .. ............... . .............. 411 PROCEDURES ........ . ................... ... .............................................. . ................ 412 NOZZLELINKROD ....... . .................................. .......................... .. .. .............. 412 NOZZLE ........ . ...... . ........... ...... ..................... .. ...... .. . ................................. 413 STEERING CABLE ......... . ............................ . ................................................ 414 STEERING WHEEL ...................................................................................... 416 TILT MECHANISM .................................................................... . .................. 416 STEERING HELM ..... . ...................................... . ........................................... 417 STEERING PiNION . . ....................... . ......... .. .................. ... .. . .......................... 417 02 - THROTTLE/SHIFTER CONTROL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 419 GENERAL ............................................. .. .................................................... 424 PROCEDURES ... .................................... . ......... . ....................................... . .... 424 THROTILE/SHIFTER CONTROL (EXCEPT 210 SERIES) .............. . ......... . ...... . .............. ... 424 THROTILE/SHIFTER CONTROL (210 SERIES) ................ . ...... .... ............................... 425 THROTILE ACCELERATOR SENSOR (TAS) CABLE (210 AND 230 SERIES) ............ . .............. 427 THROTILE CABLE (EXCEPT 210 AN D 230 SERIES) ... ................................................. 430 REVERSE CABLE ....................................... . .... . ..................... . ............... . ..... 431 VII

Seadoo 180 Challenger 2011 Shop Service Repair Manual Downlo

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