2010 SeaDoo Challenger 180 Service & Repair Manual
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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.
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This document contains the trademarks of the following companies:
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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
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$39.99
Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your SeaDoo Challenger 180 2010.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it offers instructions for diagnosing and fixing any issue, from routine maintenance like an oil change to more complex tasks such as a transmission swap. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual is designed to walk you through the fundamentals of maintenance and repair, providing step-by-step instructions to empower you with the knowledge that factory-trained technicians possess. By utilizing the insights in this service repair manual, any owner can confidently make informed decisions about maintaining and repairing their machine.
Our commitment extends beyond providing a high-quality service manual; we also ensure excellent customer service, guaranteeing your satisfaction.
