---------- ------------
t t
I
230 Chailenger*
230 Wake
®
Legal deposit:
National Library of Quebec
National Library of Canada 2007
All rights reserved. No parts this manual may be reproduced In any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP)
© Bombardier Recreational Products Inc. (BRP) 2007
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada
®Trvl Trademarks of Bombardier Recreational Pmducts Inc. (BRP) or its affiliates.
* Trademarks of Bombardier Inc., used under license.
Challenger* DESSTrvl D-SEA-BELTM
Rotax®
TOPSTrvl
SEA-DOO®
XP-STM
SEA-DOO® Learning KeyTM
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Snap-on® is a trademark of Snap-on Tools Corporation
Spray-Nine® is a trademark of Korkay System Ltd
TABLE OF CONTENTS
SAFETY NOTiCE .................................................................................. VIII
INTRODUCTION ................................................................................... IX
GENERAL INFORMATION......... .... ....... .... ..... ....... ..... .... ........ ............... .... ........... ...... IX
BOAT IDENTIFiCATION............................................................................................ IX
ENGINE EMISSIONS INFORMATION ..... ....................................................................... X
SELF-LOCKING FASTENERS PROCEDURE .............. ...... ............ ............... ............ ... ...... XI
LOCTITE® APPLICATION PROCEDURE. .... ...... ........ .................. ........ ...... ......... ..... ........ XI
TIGHTENING TORQUES ......................................................................................... XIV
MANUAL INFORMATION ... ............ ...... ...... ...... .................... ........ ....... ............... ..... XV
01 MAINTENANCE
01 - MAINTENANCE CHART....................................................................................... 1
02 - PRESEASON PREPARATION................................................................................. 5
03 - STORAGE PROCEDURES ..................................................................................... 7
PROPULSION SySTEM............................................................................................... 7
FUEL SySTEM......................................................................................................... 7
ENGINE ................................................................................................................ 8
ELECTRICAL SySTEM................................................................................................ 9
VEHICLE ............................................................................................................... 9
CHECKLIST. . ..................... . ................ ............................ ......... . .. ............... ............ 10
04 - SPECIAL PROCEDURES ..................................................................................... 11
TOWING THE BOAT IN WATER ..................................................................................... 11
SUBMERGED BOAT................................................................................................. 11
WATER-FLOODED ENGINE......................................................................................... 11
02 TROUBLESHOOTING
01 - TROUBLESHOOTING CHART.............................................................................. 15
ENGINE ............................................................................................................... 15
ELECTRIC SySTEM.................................................................................................. 21
PROPULSiON........................................................................................................ 25
STEERING SySTEM.................................................................................................. 26
03 ENGINE
01 - ENGINE REMOVAL AND INSTALLATION................................................................ 27
GENERAL ...................................................................................................... 27
PROCEDURES................................................................................................ 27
ENGINE ............................................................................................................... 27
ENGINE RUBBER MOUNTS........................................................................................ 33
02 - ENGINE LEAK TEST......................................................................................... 35
PREPARATION ....................................................................................................... 35
PROCEDURE......................................................................................................... 36
03 - AIR INTAKE SySTEM........................................................................................ 39
GENERAL ...................................................................................................... 41
PROCEDURES................................................................................................ 41
AIR FILTER....................................... ...................... ..... .. . ....... ................... . .. ... ....... 41
AIR INTAKE TUBE.................................................................................................... 41
TOPS HOSE................................... ........................ ....... . .. ........ .... ................. ... .. ... 42
04 - INTAKE MANIFOLD AND INTERCOOLER................................................................ 43
PROCEDURES................................................................................................ 46
INTAKE MANIFOLD......................... .. .. .................................. ............... ................. . .. 46
INTERCOOLER....................................................................................................... 51
05 - SUPERCHARGER............................................................................................. 55
GENERAL ............................................................................................................. 57
SUPERCHARGER INSPECTION (INSTALLED) ..................................................................... 57
SUPERCHARGER REMOVAL....................................................................................... 58
TABLE OF CONTENTS
II
SUPERCHARGER DiSASSEMBLy .................................................................................. 59
SUPERCHARGER INSPECTION..................................................................................... 62
SUPERCHARGER ASSEMBLy ...................................................................................... 62
SUPERCHARGER INSTALLATION.................................................................................. 67
06 - EXHAUST SySTEM.......................................................................................... 69
COMPONENTS ............................................................................................... 70
GENERAL. ..... ........... ..... ...... ...... ....... .... ..... .... ....... .... .... ............... ..... .... .... ..... 71
EXHAUST SYSTEM COOLING....... ........ ................... ... ..... ....... ..... ............... .... .......... . .. 71
MAINTENANCE.............................................................................................. 73
EXHAUST SYSTEM FLUSHING ..................................................................................... 73
PROCEDURES................................................................................................ 74
EXHAUST PiPE ....................................................................................................... 74
MUFFLER ............................................................................................................. 77
RESONATOR......................................................................................................... 78
EXHAUST OUTLET ................................................................................................... 78
07 - PTO HOUSING AND MAGNETO.......................................................................... 81
GENERAL ...................................................................................................... 83
PROCEDURES................................................................................................ 83
PTO HOUSiNG....................................................................................................... 83
PTO SEAL ............................................................................................................. 85
COUPLiNG............................................................................................................ 86
STATOR ............................................................................................................... 86
ROTOR AND TRIGGER WHEEL .................................................................................... 88
RING GEAR........................................................................................................... 88
STARTER DRiVE...................................................................................................... 89
08 - LUBRICATION SySTEM..................................................................................... 91
GENERAL ...................................................................................................... 95
MAINTENANCE.............................................................................................. 95
OIL LEVEL VERIFiCATION ........................................................................................... 95
OIL CHANGE......................................................................................................... 96
OIL FILTER............................................................................................................ 96
INSPECTION.................................................................................................. 98
ENGINE OIL PRESSURE............................................................................................. 98
PROCEDURES ........... ......... .......... ...... ....... ..... .... ........ ....... ........ ................. .... 99
PTO OIL STRAINER .................................................................................................. 99
ENGINE OIL PRESSURE REGULATOR ............................................................................. 99
OIL PRESSURE PUMP....... .................................... .................................................. 100
OIL SUCTION PUMP............................................................................................... 103
SUCTION PUMP OIL STRAINER.................................................................................. 106
OIL SEPARATOR COVER.......................................................................................... 107
TOPS VALVE........................... . .. .......... ..... ......... ... .......... .. .......... .......... .... . ..... .. ... 108
OIL COOLER....................................................................................................... 109
09 - COOLING SySTEM......... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .. .. . . .. . . .. . . .. . . .. . . . . . 111
OVERVIEW - CLOSED LOOP COOLING SYSTEM .................................................... 112
-GENERAL ..................................................................................................... 115
CiRCUiT ............................................................................................................. 115
TECHNICAL SPECiFiCATIONS.................................................................................... 115
INSPECTION ................................................................................................. 115
COOLING SYSTEM LEAK TEST................................. ......................... ......................... 115
MAINTENANCE ............................................................................................. 116
COOLANT REPLACEMENT....................................................................................... 116
PROCEDURES ............................................................................................... 118
CLAMPS ............................................................................................................ 118
PRESSURE CAP.................................................................................................... 118
WATER PUMP HOUSING ........................................................... .............................. 118
WATER PUMP IMPELLER......................................................................................... 120
TABLE OF CONTENTS
THERMOSTAT. ........................ ........ .............. ......................... ..... ............... .......... 120
ROTARY SEAL...................................................................................................... 120
HEAT EXCHANGER ................................................................................................ 122
10 - CYLINDER HEAD............................................................................................ 123
GENERAL ..................................................................................................... 125
PROCEDURES ............................................................................................... 125
EXHAUSTMANIFOLD ............................................................................................. 125
CYLINDER HEAD COVER......................................................................................... 125
SPARK PLUG TUBE...................... .................... ........... ..... . ................... .. ................ 126
ROCKER ARM........ ............ . .......... ......... ....... .......... ....... .................... ............. ..... 127
CAMSHAFT TIMING GEAR....... ................. ......... .......... ....... .................... ............ ...... 130
TIMING CHAIN ....................................................... , ............................................. 131
CYLINDER HEAD................................................................................................... 131
CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
VALVE SPRING....................................... ....... ............... ......................... ............ ... 134
VALVE ............................................ ............ ............ ... ..... .................... .......... ..... 135
11 - CYLINDER BLOCK ........................................................................................... 141
GENERAL ..................................................................................................... 144
PROCEDURES ............................................................................................... 144
TIMING CHAIN....... .......... ... ........................................... ...................................... 144
CHAIN TENS lONER ............................................................................................... , 144
PISTON AND CONNECTING ROD.... .................................... ....... .................. ............... 145
PISTON RINGS..................................................................................................... 149
CRANKSHAFT...................................................................................................... 151
BALANCER SHAFT............................ .............. . ........................ ..... .. .......... .. . .. ....... . 155
CYLINDER BLOCK................................................................................................. 157
04 FUEL SYSTEM
01 - FUEL TANK AND FUEL PUMP ............................................................................ 163
GENERAL ..................................................................................................... 165
INSPECTION ................................................................................................. 165
FUEL SYSTEM LEAK TEST......... ....... ............... ................... .................. .............. ...... 165
FUEL PUMP PRESSURE TEST.................................................................................... 166
PROCEDURES ................................................................................................ 167
FUEL HOSES AND OETIKER CLAMPS........................................................................... 167
FUELFILTER ........................................................................................................ 168
FUEL TANK......................................................................................................... 168
FUEL PUMP........................................................................................................ 169
05 ENGINE MANAGEMENT
01 - OVERViEW .............................. ..................................................................... 175
OPERATING PRINCIPLE .................................................................................... 176
AIR INDUCTION.................................................................................................... 176
FUEL SySTEM...................................................................................................... 177
ELECTRICAL SySTEM..................... ................................ ..... ............................. . .. ... 178
ENGINE MANAGEMENT SySTEM ....................................................................... 178
ELECTRONIC FUEL INJECTION.................................................................................. 178
IGNITION SySTEM ..................... " ....................................... .. ............... .. ............. ... 178
ENGINE MODES OF OPERATION................................................................................ 179
MONITORING SYSTEM ................... ...................... ............ ........ ....... .......... ... .......... 180
DIAGNOSTIC MODE............................................................................................... 180
ENGINE MANAGEMENT SYSTEM FLOW CHART.............................................................. 181
02 - EMS DIAGNOSTIC .......................................................................................... 183
GENERAL ..................................................................................................... 183
DIAGNOSTiC ................................................................................................. 184
MONITORING SYSTEM ................... ............ .................... ........ ..................... ........... 184
III
TABLE OF CONTENTS
FAULT CODES ............................................................ " ................. ............... ... ..... 185
03 - ADJUSTMENT AND REPAIR PROCEDURES........................................................... 187
GENERAL ..................................................................................................... 187
FUEL SySTEM...................................................................................................... 187
ELECTRICAL SySTEM............................................................................................. 188
BASIC ADJUSTMENTS .................................................................................... 193
IDLE SPEED........ .............. ........ ..... .......................... .............................. ..... ........ 193
THROTILE CABLE................................. .................................. .............................. 193
CLOSED THROTILE AND IDLE ACTUATOR RESET............................................................ 193
IGNITION TIMING.................................................................................................. 194
REPAIR PROCEDURES ..................................................................................... 194
ENGINE CONTROL MODULE (ECM) ............................................................................. 194
FUEL INJECTOR................................................................................................... 196
THROTILE BODy .................................................................................................. 198
THROTILE POSITION SENSOR (TPS) ............................................................................ 200
IDLE BYPASS VALVE (lBV) ......................................................................................... 201
CRANKSHAFT POSITION SENSOR (CPS) ........................................................................ 202
CAMSHAFT POSITION SENSOR (CAPS) ......................................................................... 204
MANIFOLD AIR TEMPERATURE SENSOR (MATS) ............................................................. 205
COOLANT TEMPERATURE SENSOR (CTS) ...................................................................... 206
MANIFOLD AIR PRESSURE SENSOR (MAPS) .................................................................. 207
EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................................................... 208
KNOCK SENSOR (KS) ............ .................. .. ........ ..................... ...... ...... . ....... .......... ... 209
OIL PRESSURE SENSOR (OPS) .................................................................................. 210
06 ELECTRICAL SYSTEM
01 - OVERViEW ................................................................................................... 213
COMMUNICATION LINK (CAN LINES) ........................................................................... 213
MODULES FUNCTIONS ........................................................................................... 214
MODULES POWER SUPPLy ...................................................................................... 215
MAIN GROUNDS ................................................................................................... 217
POWER BUS....................................................................................................... 217
02 - COMMUNICATION TOOLS AND S.U.D.S. SOFTWARE............................................... 219
COMMUNICATION TOOLS ................................................................................ 219
MPI .......... ........................................................................................................ 219
MPI-2................................................................................................................ 221
B.U.D.S. SOFTWARE ....................................................................................... 222
03 - IGNITION SySTEM......................................................................................... 225
GENERAL ..................................................................................................... 225
PROCEDURES............................................................................................... 226
IGNITION COIL..................................................................................................... 226
SPARK PLUGS...................................................................................................... 228
04 - CHARGING SySTEM.......... . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . . . . .. . . .. . . ... 231
GENERAL ..................................................................................................... 231
PROCEDURES............................................................................................... 232
RECTIFIER/REGULATOR.......................................................................................... 232
STATOR............................................................................................................. 233
BATIERY ............................................................................................................ 235
05 - STARTING SySTEM........................................................................................ 237
GENERAL ..................................................................................................... 239
TROUBLESHOOTING ....................................................................................... 239
HIGH CURRENT CIRCUIT TEST................................................................................... 239
PROCEDURES ............................................................................................... 240
FUSE................................................................................................................ 240
ENGINE START/STOP SWiTCH................................................................................... 240
NEUTRAL SWiTCH................................................................................................. 241
IV
TABLE OF CONTENTS
SOLENOID ... . . .. . .... .. . .. . ..... . .. .. . . ......... ... ... . .......... ... ....... ..... .. . . ... .. ..... .... . .... ... . .. . . . . 242
STARTER ..... ........ ... ... . ... . .. ... ...... .... ...... ... ..... ... . .. . . . 244
STARTER GEAR....... .......... ...... ... ....... .... . ... ......... .. . ......... . .. .. .. .. ....... ..... . .. 245
06 - FUSES, GAUGES AND ACCESSORIES ........................ . ........ . ................... .. .... . ...... 247
GENERAL .. . ..... ... ............... ....... ................ ... . ... .............. . ...... .. ............ .... .... .. 247
PROCEDURES ...................... .. ... ................... .. ................... ... .................. . ...... 248
MAIN CU T-OFF SWiTCH .... ...... . .. ..... ... ... ....... ... .. .... ........ ... .. ...... .. . .. . .... ... ...... .. 248
FUSES ....... .......... ....... . ...... ........ ...... ................... . ....... .. .... ....... .. . ........... . ..... . .. 249
VEHICLE CO NTROL MODULE (VCM) ..... ...... ... ... .. . ... ... .. .. . .... ... .... ... .... ........ .. .... .. .... .... .. 251
ENGINE FUSE BLOCK (EFB) ..... ......... . .. .... .. ... . .. . .... ........ .. .. .... ... ..... . .. . .... .......... .. 252
SPE EDOMETER ....... ... ... . 253
TACHOMETER ..... .... ... .... .. .. . .... .. . ............. .. .. .. .. ... . .. ...... .. ... ......... .. .. ...... ... 255
FUEL GAUGE ..... . ....... ... . ....... . .. . ...... . .. . .... . .. ....... ....... . ..... ...... . .. . .. .. 255
MONITORING GAUGE... ... ........ . .. . .. . .. ..... ... ... . .. . . ... . . . .. .. .. ........ .. .... .. .. . .. ..... ... . 257
BEEPER.............. .... ... .. ... .. ..... . .. . ...... . .. ........... ...... .. ............ .... ... . 258
RADIO .. ............ .. 259
RADIO POWER AMPLIFIER ... .. .. ..... ...... .. . . .... ......... .. .............. ... .. .. .. ... ... . ....... .... .. ... . 260
DEPTH SO UNDER .... ...... 260
HEATING UNIT............. ... .... ..... .. ................ ... ... . .... ........ .... . ............. ..... . .. . .. .. 261
ELECTRIC BILGE PUMP ......... . ..... . .. ........ . .. . ....... .. ....... ........ . ........ ........ .... . .. ..... .. 263
OTHER ELECTRIC DEViCES......... ................... ..... .. . ... .... .. ..... .. . .. . .. .. ...... .... ..... .. .... . 264
07 - DIGITALLY ENCODED SECURITY SYSTEM (DESS) ....... . ... . ................ . ...................... 265
GEN ERAL .. ................. ... .... ............ ..... .... . .. . .. . ..... .. ...... ...... .. .. .. . . . . ........ ... ... 265
DESS KEY PROGRAMMING.... . .......................... .. . .............. . .. . ....... . ..... ... .......... ... .. 265
TROUBLESHOOTING .... 267
07 PROPULSION
01 - JET PUMP........... .. ... .................. ... ....................... . ............ . .......................... 269
GENERAL ............... . ................... . ... .................. .. .................... . ..................... 271
INSPECTION ......................... .... ..... .. .................... .... ............ ...... .... . ........... ... 271
IMPELLER CONDITION ......... . .... ..... . .... ... . ......... ... ... .. ...... .. .... ... .. .. .. .. . ..... ....... . . 271
IMPELLER/WEAR RING CLEARAN CE ... . .... .. .. . .. . .... .......... .... . .. ........ .............................. 271
LEAK TE ST .... ............ .... .. ........... .. ..... . ... ............. ......... .. . .. .. ... ...... . 271
PROCEDURES . ..... ...... ........... . ....... ... .......... .... ...... ... ..... ... . ... ......... .. ... .. ..... ..... 272
SACRIFICIAL ANOD E .. .. .. ..... ... . .......... .... .... ... ..... . . . 272
VENTURI .... 272
JETPUMPHOUSING ............. " . .. "" ............. . " .. .. .... " ............. . 274
IM PELLER COVER. .. .... .. ... ...... ........ .... .... ..... . .. ... . ..... .... .. . ... . .. . . .. ..... .... .. ... . . ... ...... . 276
IM PELLER. . .. ........... . . . .. . .. .. ... . ..... .... .. .. .. . . .. . ....... ..... . .. . . ... ... ....... . . 277
WEAR RING. 279
IMPELLER SHAFT AND BEARING .... . .. . .... .. . .. ... . ... .. .... .. .. .. ..... .... .. . .. ..... .... ... ... ... ...... ... . . . 280
02 - DRIVE SySTEM ... .. ................. .... ............... .. ..... ................ .... . .. ............. .. ....... . 285
GENERAL. ..... ....... ... ...... .. ........... . ........... . ....... .. ............... ........ ............... .... . . 287
MAINTENANCE ......... . ................... . ....... . ....... ..... . ......................................... . 287
CORROSION PROTECTION ...... ..... ..... .. ...... . .... ........ ..... .. ... .. ..... . .. ... .. .. . .... .. . .... . .. .. . ..... 287
PROCEDURES .. .. ...... ...... .. .......... .... .... ..... ...... .. ... ....... ... .............. .. .. ............... 287
DRIVE SHAFT ......... .. .. ... .. .. . .... . .. ....... .. .. ... ... ..... .. . .... . ...... . ..... .. .......... .......... .... ..... . 287
DRIVE SHAFT BOOT .............. ........ . .... ..... ... ....... . ... .. .... .. . . . 293
CARBON RING ....... 294
DRIVE SHAFT PROTECTOR ... .. .. ..... .... . ...... ... . ... .. ........ . . ............ .... . .. . .. . .. 294
03 - REVERSE SySTEM .... ... ...................... .. .............. ... ... .... .................... ... .......... . 295
GENERAL ..................... . ............. . ......................... . .. ................. . .................. . 297
PROCEDURES ... . ......... ....... .. ... ... ......... ............. ....... . .................... .... ...... . ..... . 297
SACRIFICIAL ANODE ..... . .... ... . ........ . ........ ...... . .. . ...... .... ... . ....... . ... .. .. .. .. ... .. .. ..... .. ... . 297
REVERSE GATE .... .......... .. . . ....... .. ......... ..... .. ..... ....... .. ..... .... . ... ........ .. .... .. ..... . .... . 297
REVER SE GATE LEVER . ....... .... ... ... . .. . .. .. ... . .... ...... .. .. .. .. .... . ........ .. ..... ... . ... .. . ... . .. . .. .. . 298
V
TABLE OF CONTENTS
RE VER SE GATE SUPPO RT 299
RE V ERSE CABLE .... 300
08 CONTROLS
01 - STEERING SySTEM............................... ... ........ .. ......... ... ................. .... ........ ... 303
GENERAL ........ ...... .... . ............ ... ................ ..... ......... .. ....... ... ....... . .......... . ...... 305
ADJUST MENT ........... ... ......... . ..................... . .... ....... .......... . ...... .... ........... . .... . 305
ST EE RING ALl Gt\IMENT ....... . .... .... . .. .. ... ... ... ........ .. . .. .. .. .. .. . .. ....... . .. .. ............. .. .... ... 305
INSPECTION .. ... .. ... .. ......... ......... ... ......... .. ... . ................ .... .................. .... ....... 306
PROCEDURES ..... .... .. ...... . .......... .. ......... .. ........ .. ............ . .... ....... ............... ... .. 307
NOZZ LE ....... . . 307
NOZZLE LIN K RO D ..... ............. .. ... .... ...... .. . ..... .. . ... ... .. ... .. .. ... . .. ... ... .. ...... .. . ... .... .. . . . 308
STEERING CABLE ..... . .. . . . . .. .. ..... .. .... .. .. .. . . ... ...... .. .. ... ... .. ... . ....... .. ...... ... ... .... .... .. ... . . . 308
STEERING WHEEL .... . .... ..... .. .. .... ............. .... .. ... .. .. . .. .. . .... .. ..... ... . .... . ..... . .. .... . .. . ..... 3 10
TILT MECHANiSM.. .. ......... ... . .. .. . . ..... ......... .. . .... .... . .. .. . .. .. ....... .... ... ... .. .. .. .. .. .. . . .. . .... . 3 11
STEERIN G HELM ... ... ..... ... ..... .. ....... ..... .. . .. .... .. ..... ..... . .. ...... .. ... .... ...... .. .. .... ... 3 11
02 - THROTTLE/SHIFTER CONTROL ...... . ........... . ... ............................................... .. ... 313
GENERAL .......... . ........ .. .......... . .......... .. .......... ... .. ... ... .. ......... .. .. .... .. .... ........ ... 315
PROCEDURES .. .. . .................... . ............... . .............. .. ......... . .......... ...... ..... .. .... 315
THROTTLE/SHIFTER CONTROL ..... .. ..... . .. .. . .... . ... .... ... .. .. ....... .. .. .. .. .. .... ...... .. . .. .... .. .. .... . 31 5
THR OTT LE CABLE .... ... ... .... . . .. .... ..... .... ........... ... .... .. . . .. ..... .... . ... ...... . .. . . ..... .. 3 17
RE VERS E CA BLE .. .... .. .. .. .. .. .. ... ..... .. ... .. ... . .. . ... .. ..... .................. ... ... .. . ... .... .. . . .. . ... . .. . 318
09 BODY AND HULL
01 - BODY . .. .. .................. ... ... ..... . .......... .... ........ . .......... . .................... . ................ 319
GENERAL .... ..... ....... .. ....... ... .......... . .... ..... ............. . ..... . .... ... ....... .... ....... .... .... 330
PROCEDURES .. ... .. .. ................ . ..... .. ......... .. .... .. . ... .. ......... ... .. ...... . .......... ... .. ... 330
LOCKS .. .... ..... .... .. . .. ....... .. ..... .... ............... .... ..... . ... .. ... .. .... ... ... . . .. . . .... .. .. .. . .. .. . 330
DECALS ... 330
BUC KET SEAT .. .. ... ... . .. ...... .. ... ....... .... ......... . .. . .. .. .. .. . ... . . 331
BU CK ET SEAT PO ST . .. 331
SEAT AND BACKREST ..... . .. ... .. . .. .. .. .... . ... .......... ... ... .. .. 331
ARMREST ..... . ....... . ... . .. . .. . . .... ....... ........ ...... .... .. . ... ... .... . ... .. . .. . .... .. .... .. .. .. .. . .. ... ... . 332
SU N DEC K CUSHION ... . ... . .. ..... .. .... .... .. .. .. .. ..... ..... .. .. .. .. . . .. . .. .... .. .. ... . .. .. 332
ENGINE AC CES S PANEL ..... ... .. .... .. .. .... .. ..... .. .... . .. . ..... . .. ......... ... .... ... ... ... .... . 333
SHO CKS .... . .. .... .... . . .. . ....... .. . .. .. . .. ... . ... ....... .. .. .. .... . .. ... .... .. .......... ................ . 333
ENGINE COVER 333
ENGINE COVER LATCH AND CABLE .... 334
STORAGE CO VER (BOW AND CENTRA l) ...... . .. .. . .. ... .. ... ... .. .. . . .. ..... ... ........... .. . .. . 334
BUMPER. 334
SLIDING DOO R 335
WINDSHIELD TRIM .. 339
WIND SHIELD (S TARBOA RD AND PORT) ... ..... .. . ... ... . .. .... .......... . . .. ..... . .. .. ...... ... .. . .. ... ... 340
WINDSHIELD MOTO R (IF SO EQUIPPED) .. .. ..... .. .. . .. .. ... ... .... ....... ... .. ..... ... . .. . ........... . .. . . .. 343
M OORING CLEATS. .. .. .. .. .. . .. .... .... .. .... ... .. . ... .. . . .... ... .... ... .. 347
GRA B HANDLES ... . 34 7
RETR AC TA BLE SK I POST 347
SKI TOW .... .. 348
BODY .. .... ... ....... .. . ..... . .. . .. . .. . .... .. .... ... . .... ........ ... ... . .. . . ..... ..... .. . . 348
02- HULL ....... ... ................. ... .. . ............... . .................. .. ........ . ........... . ............... . 351
GENERAL .... ...... .... .. .......... .. ... ....... . ....... . .. .. ......... . ....... .. ... .......... . ....... . ......... . 355
PROCEDURES ... . .. . . ... ...... . ... . ... .. ... ......... ... .... ... . ... ............. . .. .. .. .. ........ ........ ... . 355
LADDER. .... ..... .. .... .. .. ......... ..... . ...... .. .. .... .. .. . .. .. . 3 55
DRAI N PLUG . 3 55
BILGE PUMP DRAIN ...... .. .. .. . .... ...... .. ... .. .. . ....... .. ...... .. . . .. .. . .. ............ . .. .. . .... ... .. 356
DECK DRAIN ..... .. . 356
VI
TABLE OF CONTENTS
SCUPPER VALVE................................................................................................... 356
SACRIFICIAL ANODE........ ..... ..... .... ..... .......... .. .......... ..... .. ... .................... .... . .......... 357
INLET GRATE............ .................... ............................ ........................................... 357
RIDE PLATE ........... '" ....... .......... ... ............................ ...... ....... .............................. 357
JET PUMP SUPPORT.............................................................................................. 358
DRIVE SHAFT THRU-HULL FiniNG.............................................................................. 359
BALLAST BAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
BALLAST PUMP.................................................................................................... 361
BOW/STERN EYELETS. .............. ... ....... ........................ ........................................ ... 363
GELCOAT ........................................................................................................... 364
10 TECHNICAL SPECIFICATIONS
01 - MODELS EQUIPPED WITH2 X 155 HP ENGINES ...................................................... 367
02 - MODELS EQUIPPED WITH2 X 215 HP ENGINES ...................................................... 373
11 ELECTRICAL CONNECTORS AND WIRING DIAGRAM
01 - ELECTRICAL CONNECTORS.............................................................................. 379
DEUTSCH CONNECTORS......................................................................................... 379
PACKARD CONNECTOR........ ...... ..... ................................. ............. ..... .... ..... ........... 381
ECM CONNECTORS........................ ................... ............ .. ........................... ........... 381
EFB AND VCM CONNECTORS................................................................................... 384
BAnERY AND STARTER CABLE TERMINALS.................................................................. 386
02 - WIRING DIAGRAM.......................................................................................... 389
WIRE COLOR CODES.................................. ........ ..................... .............................. 389
WIRE AND CONNECTOR CODES................................................................................ 389
VII
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2007 Sea-Doo Sport Boats Service & Repair Manual
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$31.99
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What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
2007 Sea-Doo Sport Boats Service & Repair Manual
Models covered:
- 230 Wake
- 230 Challenger
Whether you are a professional mechanic or a DIY enthusiast, this repair manual provides comprehensive troubleshooting and replacement procedures recommended by the manufacturer. It includes step-by-step instructions, clear images, and exploded-view illustrations to assist you in fixing problems with your boat.
Regular maintenance is essential for your boat, and over time, certain parts will wear out and require replacement. A reliable repair manual is invaluable as it offers the manufacturer's recommended troubleshooting charts and replacement procedures, enabling you to effectively address issues and ensure minimal downtime.
This digital manual contains all the service and repair procedures provided by the manufacturer, presented in an easy-to-use format with step-by-step instructions, clear images, and exploded-view illustrations.
Digital repair manuals are highly convenient, compatible with various electronic devices such as smartphones, tablets, iPads, PCs, and Macs. They eliminate the hassle of searching through numerous pages and the risk of damage or loss associated with traditional bound manuals.
Furthermore, you have the option to print a physical copy if preferred.
Printable: Yes
Language: English
Compatibility: Compatible with various electronic devices including PC, Mac, Android, and Apple smartphones and tablets.
Requirements: Adobe Reader (free)
