2012-2014 Seadoo Speedster, Challenger, Sportster, SP, Wake Boats Service & Repair Manual
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2012
Sea-Doo@ Boats
Shop Manual
150, 180, 200, 210 and 230 Series
Legal deposit:
National Library of Quebec
National Library of Canada 2012
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) 2012
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 Rota x®
Challenger* Sea-Doo®
D. E.S.S.TM Sea-Doo Learning KeyTM
D-SEA-BELTM Speedster™
Fold'n Stow™ ECOTM
TOPSTM
Transat™
WAKETM
XPSTM
This document contains the trademarks of the following companies:
M ade for
AMp® is a trademark of Tyco Electronics Corporation
Gelcote® is a trademark of Gelcote International Limited
GUN K® 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.
~ i Pod IJ iPhone
iPhone, iPod, iPod nano and iPod touch ar e trademarks of Apple Inc. registered in U.S .A.
and other countries.
"Made for iPod" and "Made for iPhone" mean that an electronic accessory has been
designed to connect specifically to iPod or iPhone, respectively, and has been certified
by the developer to meet Apple performance standards. Apple is not responsible for the
operation of this device or its compliance with safety and regulatory standards. Please
note that the use of this accessory with iPod or iPhone may affect wireless performance.
TABLE OF CONTENTS
SAFETY NOTiCE..................... . ................................... ...... ............................... . ........ IX
INTRODUCTION....... . ............. ........... .. .. .......................... .. ............ . ......... .. ................. X
BOAT INFORMATION ........................ . ... ,. ...... .. ..... .. .. . ..... ............. ... .............. .. . .... . . . .. XI
MANUAL INFORMATION ... . ............ . ....................... . ....... . ...................................... . ... XII
FASTENER INFORMATION ........................................ . ............ . .. . ........... . ........ . .......... XVI
01 MAINTENANCE
01 - PERIODIC MAINTENANCE SCHEDULE.. ... .. ....... . ....... . ................... . .... . .... . ..... . ....... . .... 7
02 - STORAGE PROCEDURE......... . ....... ... ....... ... .............. . ... . ...... . ............... . ........... . ... 11
PROCEDURES.... ..... ..... ....... ..... ... ....... ......... ........ ...... .. . ..... ............. . .... ..... ..... 11
PROPULSION SySTEM...... . ................................................ .. ...... ..... ... .. .......... 11
FUEL SySTEM............................................... ... ............... ... . .. .... ... .............. 11
ENGINE........ ... .. .. . .. . ....... .... ................................ . .... . ..... ... ....... . ............... 11
ELECTRICAL SySTEM............... . ............. ... ... . ............. . ... . .......................... . ... 13
ENGINE COMPARTMENT ....................................................... . ........... . .. , ... . ..... 13
BODY AND HULL.......... . ...... ... .. . ................. .... .. . .......... . ..... . ......... . ............... 13
03 - PRESEASON PREPARATION. . ..... .... ......... . ...................... ... ................ . .................. 15
04 - SPECIAL PROCEDURES .. . ................. ... ............ . .......... . .......... .... ... ... ....... ... .......... 17
GENERAL .................................................... . .......... . .... . ... .... ..... . .................. 17
PROCEDURES..... ..... ... ... ..... ..... ..... . .... ... ... ........ . ... .. .. . .. . .................. ............... 17
TOWING THE BOAT IN WATER .. .... ....... . .......... ........ ........ .... ... .... ... .. ....... ..... ...... 17
SUBMERGED BOAT...................................................................... . ...... ... .. .... 17
WATER-FLOODED ENG INE .... .... . .... ....... ......... .. ..... ... ... ....... ..... ..... .... .. . .... ........ 17
02 ENGINE
01 - ENGINE REMOVAL AND INSTALLATION ................. .. .... ... ......... . .............. . ............... 21
GENERAL ....... . ....................................................... . ......... . .............. . ............ 23
ENGINE ACCESS....................... . ............ . .............. . .............. . ......... ....... ...... 23
PROCEDURES ....................................................................................... . ....... 23
ENGINE..... . ... . ... ... ............... . ........................................... . ....................... 23
ENGINE RUBBER MOUNTS.............................. .. ........................ . ... .. .... ... .......... 26
02 - AIR INTAKE SySTEM........................ . ............. .. .................................................. 29
GENERAL ................................ .... ........ . .... .. .. .. ..... . .................................... . .. 35
PROCEDURES ..... . ............ ......... ... .... .... . ......... . .... . .......... . ............................. , 35
AIR FILTER ............................ . ........................................... . .... . ........ ......... 35
AIR INTAKE TUBE.. . .......... . ............................................. .... ........ . ................ 35
AIR INTAKE SILENCER COVER........................................................................... 36
AIR INTAKE SILENCER BAFFLE.............................. . ... . ... . ........................... .... .... 36
AIR INTAKE SiLENCER.......................... . ......... .... ................ . ............... ... .... .... 36
03 - INTAKE MANIFOLD..... . .................. . ...................... .. ...... . .................................... 39
PROCEDURES ............................................ . ....... . ............. . ............................ 42
INTAKE MANIFOLD ....... . ....... .. .. ....... . ... . ... . ..... . ............... . ..................... . ..... . .. 42
FLAME ARRESTER....................... .... ........ ... .. . ............ ... .. .................... . .... . ... 45
04 - SUPERCHARGER (215, 255 AND 260 ENGINES) .................. . ............ . ............... . ... . ..... 47
INSPECTION ....... . ................... .. ... ........ . ................ .... ..... . .... ... ................... . ... 49
SUPERCHARGER INLET CLEANLINESS........ . ......... . ....... ..... ................................. . 49
SUPERCHARGER CLUTCH SLIPPING MOMENT (ON ENGINE) ..... . ............................ . ...... 49
SUPERCHARGER CLUTCH SLIPP ING MOMENT (BENCH TEST)... . ......... .. .... .. . ... ............... 50
TROUBLESHOOTING ... .................. .. ..... . ... ... .. ..... . ... ........ . ....... ..... ... . ... .... ... ..... 51
PROCEDURES.. .......... ....... . ...... ...... .... .... ..... ...... .............. ...... .. . . .. .. ..... .... ....... 51
SUPERCHARGER............ . ...... .. ......... . ........................................................ .. 51
05 -INTERCOOLER (215 ENGINE) ............ . .. .. ....... . ............ . ........................ . ........ . .. . ..... 63
PROCEDURES ............................................................................................... 64
INTERCOOLER.............................................. . ................ . ... . ....................... 64
TABLE OF CONTENTS
02 ENGINE (cont'd)
06 - INTERCOOLER (255 AND 260 ENGINES) .... . ... .. .... .... ................... ... ................... . ...... 67
MAINTENANCE .. . ... . ........ ........ .............. . ....... .. ... . ... ... .............. .... ...... ......... ... 69
INTERCOOLER FLUSHING.... . ....... . ....... . .. .. ... ....... .. ........... . .......... . ................... 69
PROCEDURES.... ... .... ... .. ....... ... . ....... .... ....... . ...... .. ............. ................ ............ 69
INTERCOOLER............ .. .. .... . .... ..... ... .. ..... .. ... . ............................................. 69
07 - EXHAUST SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
MAINTENANCE. ... ... . ........ . ... . ...... ... ..... . ...... ......... .... . ..................................... 81
EXHAUST SYSTEM FLUSHING ......... . ................ .. ................. . ... .. ... . .... ... . ........... . 81
PROCEDURES ...................... . ......... . ........ . .... ... .................. .. ......... . ................ 82
MUFFLER ..... ... .. . ...... ... ....... .. .. . ... ... .. ... .... .... . ... .. ......... . ............ . .. . .............. 82
EXHAUST PiPE....................... . ....... . ...... .. ... . ....... ... ........ . .... . ... . ................... 84
EXHAUST MANIFOLD................................................... . ........... . .. ..... ........ . .. .. 85
RESONATOR ..... . ............. . ............... . .. . ....................................................... 86
HEATED OXYGE N SENSOR (H02S) . ....................................... ... . ...... .. ......... . .. . .. .. . 87
CATALYST (150 AND 180 SERIES WITH CATALyST) ..................................................... 87
08 - PTO HOUSING AND MAGNETO. . . . .. . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
PROCEDURES .................... . ................................ . ......................................... 91
PTO HOUSiNG................................ .. ................ . ......... . ............................... 91
PTO SEAL ..................... . .... . .. . .......... .. ..... . .... ... .................. .. ..... .... ............. 95
PTO COUPLiNG..................... . .... .......... ....... ........ . ... ........................ .. ...... .. . 96
STARTER DRIVE BEARINGS. ............ . .................... . .......... .. ............................... 97
STATOR .......... . .. ... ... ... ........................... ... .. ................... .. .. ... .. .. .... ........... 97
ROTOR, TRIGGER WHEEL AND RI NG GEAR ............ .. ............... . ............ . .... . ........ . .. 100
STARTER DRIVE ............... . ....... . ................................................... . ..... , ... , ... 101
09 - LUBRICATION SySTEM ... . ....................... .. ... ...................... . ............................... 105
MAINTENANCE ......................... . ........... .... ...... . ................................... . ... .. ... 110
ENGINE OIL . .............. ... ........ . .... .. ... . ........................... . ..... . ........ . .......... .. .. 110
II
OIL FILTER ... ............ . ... ... . .. .. ........................ .. ...................... . ..... ... ........... 111
INSPECTION . ... .. ..... ... ......................... . ....................... . .............. . .... . ............ 112
ENGINE OIL PRESSURE . ....... . ........... . ........................... . ................................ 112
TROUBLESHOOTING ............. . ..... . ... . ....... . ....... . ............................................. 113
PROCEDURES .............................................................................................. 114
OIL PRESSURE SWITCH (OPS) ................................ . ......................................... 114
PTO OIL STRAINER...................................................................................... 115
SUCTION PUMP OIL STRAINER ........................................................................ 116
ENGINE OIL PRESSURE REGULATOR .. . ......................................... . ................. .. .. 117
OIL PRESSURE PUMP . .... . ............ ..... ............ ..... .. ..... . ...... . ............................ 118
ROTARY SEAL ................................... . ...... . ........ . .... . ......... . .............. . .. . ..... . 120
OIL SUCT ION PUMP .................................................................................... 121
SUPERCHARGER OIL SPRAY NOZZLE ...... ... .. . ...................................................... 124
PI STON OIL SPRAY NOZZL ES . ............. .. .. . ... ... .. .. .. .. ... ..... ... . ................... . .. . ....... 125
OIL SEPARATOR COVER........... ... ........... ... . ........ .... ...... .. ............................... 126
BLOW-BY VALVE........................................................................................ 127
TOPS SWITCH (ALL MODELS EXCEPT SPEEDSTER 200) .... .. ............ . ............. .... .......... 129
OIL COOLER............................................................................................. 131
10 - COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 133
GENERAL . . ..... . ..... . ... ...... .............................. . .................................... . ........ 139
SYSTEM DESCRiPTION .......................... .... .......... .. ................ . ...................... 139
MAINTENANCE ... ... ........ . ... .... ..... ..... . ...... .... ... ... . ... . ............. . ............. .... ... . ... 139
ENGINE COOLANT .. . .............. .. ... ....... . ... ..... .. ... .................................... ...... . 139
INSPECTION ...................................................... . ................... ... ................... 141
COOLING SYSTEM LEA K TEST ................................ . ........................................ 141
TROUBLESHOOTING ..................................................................................... 142
TABLE OF CONTENTS
02 ENGINE (cont'd)
10 - COOLING SYSTEM (cont'd)
PROCEDURES ............... ... .. '" ........................... . ...... . .................................... 142
PRESSURE CAP ......................................................................................... 142
CLAMPS .......... . .............. . .......................... ... .. ... ..... . .. ... ... ... ....... . ........ .... 142
WATER PUMP HOUSING ......... .. . ' " ....... . ............... . ............. . .......... . ................ 142
WATER PUMP IMPELLER ............................................................................... 144
THERMOSTAT ....... . .... . .............. .. ............. .. ... . ................... . .............. . ........ 144
ROTARY SEAL ..... . .. ... ....... . ...................... . ........... ..... ........... ... ... ..... .. . .. . .. . .. 144
HEAT EXCHANGER (200, 210 AND 230 SER IE S) . ...................................................... 145
11 - CYLINDER HEAD ..... .. .......... . .............................. ... .. ..... ... ................ .. ............ ... 147
GENERAL ......... ... ....... .................. ... ....... ............................. .. ..................... 149
INSPECTION ....................... . ... . ... . ..................... . .......... . ............ .. .... .... ..... . ... 149
ENGINE LEAK TEST ... . ................................................................................. 149
TROUBLESHOOTING ...... . .......... . ............................. . .... ......... ... . ....... .. .. . .... . ... 151
PROCEDURES ......... ... ........ . .......... .... ........................................................... 152
CYLINDER HEAD COVER ...................... . .... .. ... .................................... . ........... 152
SPARK PLUG TUBES ......... .. .............. . ....... .. ...... . .... ... .............. . .. .. ..... .. ..... . ... 153
ROCKER ARMS .............. .. .. ......................................... . .................. . ........... 153
CAMSHAFT TIMING GEAR .................................... . ........... ... ....... .. ...... ... ..... . ... 155
CAMSHAFT .... . .... ..... ..... .. .. .. .. ...................................... . .................... . ..... .. 156
CYLINDER HEAD . .................. . .................................................................... 158
VALVE SPRINGS ...... ......................... . ..... . ................................................... 160
VALVES ....... . ....................................................... . ................................... 161
VALVE GUiDE ............ . ................................................................................. 165
12 - CYLINDER BLOCK . ................................................ . ..... . ... . ... ... ..... . ..................... 167
GENERAL ....................... ... ............................................ . ... ... ................. . .... 170
TROUBLESHOOTING .. .. ..... . ........... ... ..... . ........ . ........................................ . ..... 170
PROCEDURES .......... . ........... . ....................... : ............................................... 170
TIMING CHAIN .................................................. . ................ .. ...................... 170
CHAIN TENSIONER . . ... . ...... . ...... . .................................................................. 171
PISTONS AND CONNECTING RODS .................................................................... 171
PISTON RINGS.. . .... .... ........ . ... . ...... . .......... ..... ........................... ...... ... . ... .. ... 176
CRANKSHAFT ............................................................................................ 177
BALANCER SHAFT...................................................................................... 181
CYLINDER BLOCK .......................................................... . ......... . .................. 183
03 ELECTRONIC MANAGEMENT SYSTEMS
01 - ENGINE MANAGEMENT SySTEM..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 189
GENERAL ..................................... . ........................................ . .... . ....... .... ... . 189
ENGINE MANAGEMENT SCHEMATIC (200 SER IE S) ............................................ .. ..... 189
ENGINE MANAGEMENT SCHEMATIC (OTHER SERIES) ............................................... 190
SYSTEM DESCRiPTION ...... . .. .......................... . ........................................... .. 191
02 - COMMUNICATION PROTOCOLS ........................................................................... 195
GENERAL.................. . ............ . .................................... .... ..... . .................... . 195
CONTROLLER AREA NETWORK (CAN) ................................................................. 195
LOCAL INTERCONNECT NETWORK (LIN) .... .. .. ........ ............................ .... .............. 200
TROUBLESHOOTING .. . ................... . ........... ..... .......... .. ............ . ................. . ... 202
DIAGNOSTIC TiPS........................................... . ........................................... 202
03 - COMMUNICATION TOOLS AND B.U.D.S. .. ............................. . ................................ 203
GENERAL.......... . ...................................... .. .... ..... ... .............. .. . ................... 203
REQU IR ED TOOLS ..... . ........................... .... ... . ........................................ . .... 203
DIAGNOSTIC CONNECTOR LOCATION................ . ... . ........... . ................................ 203
TROUBLESHOOTING ..................................................................................... 204
DIAGNOSTIC TIPS ................................................... . ......... . ........... . ...... . ...... 204
III
TABLE OF CONTENTS
03 ELECTRONIC MANAGEMENT SYSTEMS (cant' d)
03 - COMMUNICATION TOOLS AND S.U.D.S. (cont'd)
PROCEDURES ..................................... ... .. ... .. ... .... .... . ... ... .... ... ..... . ................ 205
MPI-2 ..................................................................................................... 205
B.U.D.S . SOFTWARE ..................... .... ........................................................... 207
04 - DIAGNOSTIC AND FAULT CODES ........................ .. ............................................ ... 211
GENERAL ..... . ................................ .. .... .. ... ...... ..... .. ........... .. ....................... . 211
MON ITORING SYSTEM ................................................................................. 211
FAULT CODES ........... . .......... ..... ... ..... .... . .... . .... . ............... ... .............. . ........ 216
SPEC IFI C FAULT CODES . ............................... . ....... .. ............ . ....... ... .......... . .... 218
FAULT CODE TABLE ...... .. . .. .. .... ... ..... . ....... . ........ . ... . ..... . ............... . .... . ........... 219
04 FUEL SYSTEM
IV
01 - INTELLIGENT THROTTLE CONTROL (iTC) (ALL MODELS EXCEPT 200 SERIES) . ..... .... . ... .... 235
GENERAL. . ............ . .... . ......................... . ................................. .... .. .............. 238
SYSTEM DESCRiPTION .............. . ........ ... ....................................................... 238
OPERATING MODES............. .. .. ..................... . ................................... .. ........ 239
PROCEDURES .... . .................. .... ... . ..... .. ..... ... ...... .. .... . ...... ... .......................... 241
TAS (THROTILE ACCELERATOR SENSOR) ............................................................. 241
02 - ELECTRONIC FUEL INJECTION (EFI) ...................................................................... 245
GENERAL........... . ... .. ......... ...... . ....... . ........................ .. ............. ....... ............ 245
SYSTEM DESCRiPTION . ........................ . ..... .. .. ................. . ........... . ................ 246
ADJUSTMENT ...... . ........ . .... . .... . ................ .. ... . ............................................. 247
IDLE SPEED............. . .. . ........... . ................... . ...................... .. .. .. ............. . .. 247
CLOSED THROTILE RESET. .. ............................ . .................... . ...... . ................. 248
TROUBLESHOOTING..................... . ............ . ............. . ............. . ......... .. .... .. .... . 249
DIAGNOSTIC TiPS ....................................................................................... 249
PROCEDURES ..... .. .... . .... .. ~ ........................................................................... 249
ECM (ENGINE CONTROL MODULE) (150. 180,210 AND 230 SERIES) ......................... . ...... 249
ECM (ENGINE CONTROL MODULE) (200 SERIES) .............................................. .. ..... 254
FUEL RAIL ..... . ....... .... .. . ... ..... ... ....... . ................ . ....................................... 256
FUEL INJECTOR ... .. .. . .... . .......... .. ... . ......................... . .... ; ......................... .. .. 258
THROTILE BODY (150, 180, 210 AND 230 SERIES)... . ........................... . ....... . ....... ... .. 263
THROTILE BODY (200 SERIES) ......................................................................... 266
THROTILE POSITION SENSOR (TPS) (150, 180, 210 AND 230 SERIES) ................... . ..... ... ... 267
THROTILE POSITION SENSOR (TPS) (200 SERIES) .......... . .............. .. .. . ............... . ...... 269
IDLE BYPASS VALVE (IBV) (200 SERIES) . ......... .............. ... .. . ....... ... ....... . ................ 271
CRANKSHAFT POSITION SENSOR (CPS) ................................................ ... ............ 272
CAMSHAFT POSITION SENSOR (CAPS) ................................................................ 274
MANIFOLD AIR TEMPERATURE SENSOR (MATS) .. . ... . ....................... . ................ . .. ... 277
COOLANT TEMPERATURE SENSOR (CTS) ...... . .... .. .... . ..... . ... . .......... . ...................... 278
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS).. . .......... . ....... . ........ . .... .. .. ....... .... 280
EXHAUST GAS TEMPERATURE SENSOR (EG TS) ........ .. .......... . ...... . ... . ....... .. ...... . ....... 281
HEATED OXYGEN SENSOR (H02S). . ........ . .............. . ..... . ....... . ........... . ....... ... ... ... . 283
KNOCK SENSOR (KS) . .... .... ...... . ... . ..... . ................... . ... . ............................. . .... 285
03 - FUEL TANK AND FUEL PUMP .............................................................................. 287
GENERAL................. . ................................................... . ............... . ......... . ... 294
SYSTEM DESCRiPTION .. . .. .. . .. ..... . .............. . ........................... . ...................... 294
INSPECTION ........................................ . .......... . ........... . ..... . .......................... 295
FUEL TANK LEAK TE ST (180,200 AND 210 SINGLE-EN GINE MODELS) ........... .. ... .... .. ... . ..... 295
FUEL TANK LEAK TEST (150, 210 TWIN-ENGINE AND 230 MODELS) ....... . ......................... 296
FUEL TAN K VENT ......... . .......... . ... ... .. ........ . .. . .. ..... .. . .............. ... ................. . .. 297
FUEL TANK CAP VENT TEST.... .... .. ..... . ...... . ......... ... .... . ..................... ... ..... . ...... 297
FUEL CIRCUIT LEAK TEST (HIGH PRESSURE) ...... . ............ . ...................................... 298
FUEL PUMP PRESSURE TEST ........ . .............. . .................... ... ... .. .... .. .. ...... ... ..... 298
TABLE OF CONTENTS
04 FUEL SYSTEM (cont'd)
03 - FUEL TANK AND FUEL PUMP (cont'd)
TROUBLESHOOTING.................. . ..... .... ... . .......................................... . ....... .. . 299
PROCEDURES ......... . ...... .. ....... , . ..... . ................ .. ....... . ...... ... ... .. ........ . ... . ........ 299
FUEL HOSES AND HOSE CLAMPS............................. .. ...................................... 299
FUEL PUMP ...... . .. ... .................... . ...... . .. ... ..... . ..................................... . .... 299
FUEL FILTER .................... .. .. ..................... .. .. .. .... ... .. . .... ....... .. ................... 302
FUEL LEVEL SENDER .............. . .............. . .......... .. .............................. . .......... 303
FUEL TANK ........ .. .. ...... . .................... . ......... . ............ . ............................... 303
05 ELECTRICAL SYSTEM
01 - POWER DiSTRIBUTION... . ......... . .. . ......... . ....... ... ....................... . ..................... .... 305
GENERAL ........ ...... ............... . ..................................................................... 311
ELECTRICAL SYSTEM ACTiVATION ........................................ .. ... .. .. .. ........... . ..... . 311
MAIN CUT-OFF SWiTCH...................................................................... ...... . ... 311
MAIN CIRCUIT BREAKER (180, 210 AND 230 SERIES) ... ... ............................. ..... .... . .... 311
FUSES (150/180 SERIES) .............................. . ......................... .. ....... . ..... .. ....... 311
FUSES (200 SPEEDSTER) ......... . ... .. ... ......... ... ................... . ................. . ........... 313
FUSES (210 SERIES) .................. ... ................. . ................................. . ............ 313
CIRCUIT BREAKERS (210 SER IES) .... ... ... ... ................. .. ..................... . ................ 314
FUSES (230 SER IE S) ..................... . ..... . ........... . ............................................. 315
CIRCUIT BREAKERS (230 SERIES) .. ......... ... .................................. . ........ ..... .... .... 315
MAIN RELAY (150 , 180 AND 210 SERIES) ................. . .. . ............................. ...... .. .. .. 315
MAIN GROUNDS .............................. .. .. ................. : .............................. ...... 316
PROCEDURES ............... .. ......................................... .. .... .. .. ... ... . ... .... ..... . ...... 316
VCM (VEHICLE CONTROL MODULE) (200 SPEEDSTER) ....... . .................... .. .. .. ............. 316
EFB (ENGINE FUSE BLOCK) (200 SPEEDSTER) . ....... . .... ... ................................. ... .... 318
02 -IGNITION SYSTEM ................................... .. ......... . ... . .... . ......... . ... . ........ . ............ 321
GENERAL . . ...................................................................................... . .......... 321
SYSTEM DESCRiPTION ..... .. ........... . .............. .. .. ........... .... .... ... .. . ...... . .. . .. .. .. ... 321
TROUBLESHOOTING .......................... ....... ........... .. ... . ........ . ............. ... ........ .. 322
IGNITION SYSTEM TESTING ....................................................................... . .... 322
DIAGNOSTIC GUiDELINES ................ . ................................... .. ...... ... ............... 322
PROCEDURES ..... .... .. ... . .. . ... ......... . ......................................................... . ..... 323
ENGINE CUT-OFF SWITCH (200 SERIES) ........ . .............................. . ...... .. ............ . .. 323
ENGINE CUT-OFF SWITCH (150 180210 AND 230 SER IES) ........................................... 323
IGN ITION SWiTCH........ . ........................................................................ . ..... 324
IGNITION COILS.................................................................................... . .... 324
SPARK PLUGS............................. .. .... ........ ... .. .. .. .... .. ....... . ..... . .................. . 328
03 - CHARGING SYSTEM .... . ................... . ......................... . .......................... . ..... . ..... 331
GENERAL . . ........ . ....... .. .............. . ......... . ..... . ... .. ................ ....... ...... .............. 331
SYSTEM DESCRiPTION .................. .. .. . ............................. . ........ . ... .... ........... . 331
INSPECTION ............................................ . ....... . .... . .............................. . ....... 331
CHARGING SYSTEM OUTPUT .... . .................... . .............. . ........ . ........................ 331
TROUBLESHOOTING.... . ............... . ................... .... ...... . ....... . .............. . ........... 333
TROUBLESHOOTING GUiDELINES ......... . .......... . .. . ............... .. .. ..... .. . .... ... .. . .. . .. . .. 333
PROCEDURES ....... ... ... ......... . ... .. ................................. . ........ . ................ . ...... 334
VOLTAGE REGULATOR/RECTIFIER .... .. ............................................................... 334
BATIERY ..... . ............... .. . ........ ......... . ............. . ................................... . ..... 334
04 - STARTING SySTEM.......... . ............................................................................... 337
GENERAL...... . ....... . ............................... .. ............................ . .... ....... ....... .... 345
ENGINE CRANKING CONDITIONS................................. .. ... .................... . ........ . .. 345
TROUBLESHOOTING ....................... . ........ . ..... . ...... . .......................... . ............ 345
DIAGNOSTIC TiPS.... ... ....... . .... . ............................. ... .. ..... ..... . .............. . ... .. .. 345
DIAGNOSTIC GUiDELINES .. . ................. ... ............... .. .. ................... .. ............... 345
v
TABLE OF CONTENTS
05 ELECTRICAL SYSTEM (cont'd)
04 - STARTING SYSTEM (cont'd)
PROCEDURES .................................... . .............. ... ................... ... .............. . ... 346
ENGINE START/STOP SWiTCH.......................................................................... 346
NEUTRAL SWiTCH. .......... . ................... . ..................................... ... .............. 347
STARTER SOLENOID.......... . .................................. . ....................... . .............. 349
STARTER ................... ... ............................. . ............................................. 351
05 - DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.s.) ....... . ................................ . ... . ..... 355
GENERAL................................................... . ............................................... 355
SYSTEM DESCRiPTION......... . .................................................................. . .... 355
TROUBLESHOOTING ... . ................................................................................. 355
DIAGNOSTIC GUiDELINES ...................... . ..................... . ............ ;. ................... 355
PROCEDURES ...................... . ...... . ...................... . ......................................... 356
D.E.S.S. KEy .................................................. . .......................................... 356
06 - INSTRUMENTS AND ACCESSORIES..... . ......................... . ................................... ... 359
GENERAL.................. . ........................................................................ . ....... 360
INFORMATION CENTER DESCRIPTION (150 AND 180 SERIES) ....................................... 360
INFORMATION CENTER DESCRIPTION (210 AND 230 SERIES EXCEPT WAKE) ...................... 361
TOUCH SCREEN DISPLAY DESCRI PTION (210 AND 230 WAKE) ......... . .............. . .... . ........ 367
TROUBLESHOOTING ....................................... . .......................... . .......... . ... . ... 370
DIAGNOSTIC TIPS ................ ... ............................ • ....................................... 370
PROCEDURES .............. . ........... . ............ , ............................... ..... .................. 370
IN FORMATION CENTER (150 AND 180 SERIES) ....................................... .. ... ........... 370
INFORMATION CENTER (210 AND 230 CHALLENGER) ................................................ 371
TOUCH SCREEN DISPLAY (210 AND 230 WAKE) ....................................................... 372
RADIO MODULE (210 AND 230 WAKE) .............. . ...................................... . ........... 377
OVAL PAD CONTROL (210 AND 230 WAKE) .................... . .... . ..................... . ............ 378
GPS RECEIVER (210 AND 230 WAKE) .................................................................. 378
SPEEDOMETER (210 AND 230 SERIES) ........................................................... . .... 378
SPEEDOMETER (200 SERIES) ......................... . ................................................. 379
SPEED SENSOR (ALL EXCEPT 210 AND 230 SER IE S) ................. . ............................... 380
ANALOG TEMPERATURE GAUGE (CHALLENGER WITH SINGLE ENGINE) ............................ 381
TACHOMETER (200 SERIES) . . .......... . ............................................................... 381
ANALOG FUEL GAUGE (210 AND 230 SERIES) ........................................................ 381
ANALOG FUEL GAUGE (200 SERIES) .................. . ...... . ......................................... 382
MONITORING GAUGE (200 SERIES ONLY) ............................................................. 383
BEEPER (200 SERIES) ...................................... .. ........................................... 383
BEEPER (210 AND 230 WAKE) .......................................................................... 384
RADIO ................................................................................................... 384
RADIO AMP LIFIER (210 AND 230 WAKE ONLy) ........................................................ 386
DEPTH SOUNDER ........................................ . ..................................... . ....... 387
HEATER UNIT (210 AND 230 WAKE ONLY) ............................................................ . 388
ELECTRIC BILGE PUMP . . ............................................................................... 389
BILGE BLOWER............ . ........... . ......... . ................. . .............. . .. . ............. . .... 390
BOW LIGHT .... . ......... . ............................ . ............................. . ... .. ......... . ..... 391
STERN LIGHT ............................................................................................ 392
COURTESY LIGHT (ALL EXCEPT 150) .................................................... ...... .. . ...... 393
EXTINGUISHER PRESSURE SWITCH (CE MODELS) ................................................... 394
EXTINGUISHER INDICATOR LAMP (CE MODELS) ...................................................... 395
06 PROPULSION
VI
01 - WEEDLESS SySTEM .. ....... . .. . ........................ .... ...................... ... ..... . ................. 397
GENERAL..................................................................................... . .......... ... 400
SYSTEM DESCRiPTION ................................................................................. 400
TABLE OF CONTENTS
06 PROPULSION (cant' d)
01 - WEEDLESS SYSTEM (cant' d)
TROUBLESHOOTING ................ ..... ... ........................... .... .. .......................... .. 400
TROUBLESHOOTING GUiDELINES ...... . ................ . ..... .. .. ........... . ........................ 400
PROCEDURES ........... .... ... .................... ..... ............................ . ... ........ ........... 400
WEEDLESS SYSTEM MODULE (WSM) ............ . .............................. ... ..... . ......... ... . 400
WEEDLESS SYSTEM MODULE (WSM) SUPPORT ... .... ........................ . ......... . ... . ....... 401
INLET GRATE ....................... .. ......... . ............................. .. ...... ...... .............. 402
WEEDLESS SYSTEM (WS) ACTUATOR ......... .. .. . ....................................... . ......... .. 403
WS ACTUATOR CABLE S .... ... ...... . ................ . .......... .... ................................... 404
02 - REVERSE SYSTEM ..... . ..................... . ................ .... ...... . .................................... 405
PROCEDURES .......................... . ................................................................... 406
REVERSE CABLE ..... .............. .... ........................... . ............. . ....................... 406
REVERSE GATE........ .... ............. . .................. ... .... ... .............. . .......... .. ....... .. 406
REVERSE GATE LEVER. . ............ . ................. . ....................... . ......................... 407
REVERSE GATE SUPPORT .............. . ..................... . ......................................... 408
03 - JET PUMP . ................. . ............ . .... .. ...................................... ... .................... ... 411
GENERAL .................................................. ... ... .. ......................................... 413
JET PUMP MAIN COMPONENTS .................................... ...... ...................... . ...... 413
INSPECTION ................ . ......... ...... ................................ ...... .......................... 413
IMPELLER CONDITION ...... . ........... ... .. ................................ . ............ . ......... .... 413
IMPELLER/WEAR RING CLEARANCE . .. ......................................... .. ....... ... .. ..... .. .. 413
IMPELLER SHAFT RADIAL PLAy ............. ... .. ..... .. ..... .......................................... 413
LEAK TEST ................................... . ............... . .......... . ..... ......................... .. 414
PROCEDURES ....................................... .. ... ... .... . .... . .. .. ... .. .. .. ........ . ............... 4 14
VEN TURI ............................................. . ................................................... 414
JET PUMP HOUSiNG.................................... . ................................... . ........... 416
IMPELLER COVER ..... . ..... . ........................ .. .................... . ............................ 417
IMPELLER ................................ . ............. . ........ .. ... . ... .... ........ . .... .. ............ 419
WEAR RING.... .. .. .. ................. .. ............................... .. .... ....... ... .. .... .... ....... 421
IMPELLER SHAFT AND BEARING ............................. . ...... . ............. . .. ... . .. .... .. . .. .. 422
04 - DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . .. 429
MAINTENANCE ...................... . ......................................... . .. . ........ . ............... 431
CORROSION PROTECTION .......... .. ...................................... .. .. ... ... .. ...... ....... .. 431
PROCEDURES ... .. ..... ........... .... ................. . ....................... . .. . ..... .. ................. 431
DRIVE SHAFT ............................... . ............ .. ..... .... ............................ . .... . ... 431
DRIVE SHAFT BOOT................... ... .......................................................... . ... . 437
CARBON RING . ...................... . ........ .... ................................ .... .. . ... .. ... .. ..... . 438
DRIVE SHAFT PROTECTOR...................... .. ... .. ...... .. ......................... ... ............ 438
07 CONTROLS
01 - STEERING SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. 439
ADJUSTMENT ....... . ... . ........................ ... ......... ..... ... ... . ................................. 443
STEERING ALIGNMENT .. .. ........................... . .. . ......................... . .................... 443
TROUBLESHOOTING ... . ... ... ..................... . .............. . ......... . ....... . .................... 444
ABNORMAL PLAY IN STEER ING......... ............................................................... 444
PROCEDURES .... . .. .. ........... . .......................................................... ... ........ . ... 445
NOZZLE LINK ROD ............ . ......... . .................. . ............. .. ... .. . ....... ... ... ... .. ..... 445
NOZZLE .................................................................. ... ................. . ........... 445
STEERING CABLE.......................................................... .. .. ....... ..... .. . .. ........ 446
STEERING WHEEL .......................... . ............. ... ...... . .. . ........... . ..................... 448
TILT MECH ANiSM ............. . ..... . ... .. ... .. ...................... . ........................ . ......... 449
STEER ING HELM .............. . ............ . ......... .. .. ......... . ............................ . .. . ..... 449
STEERING PiNION .. . .................. . ... .. .............. ... .......... . ........................... . .... 450
VII
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