Sea-doo Challenger*180 Operator'S Manual Download Page 106

Page: 106 / 130

106

Parts covered for a Model Year 2005 Sea-Doo sport boat equipped
with 947 DI engines:

Parts covered for a Model Year 2005 Sea-Doo sport boat equipped
with 4-TEC

engines, 4-TEC SC engines and 4-TEC IC engines:

Air Lines

Exhaust Manifold

Fuel Rail

Coolant Temp. Sensor

Rave Valve

Throttle Position Sensors

Reed Valve

Ignition Coil

Tuned Pipe

Manifold Temp. Sensor

High-Tension Ignition Wires

Manifold Air Press. Sensor

Electrical Harness

Crankshaft Posit. Sensor

Throttle Bodies

Air Pressure Regulator

Exhaust Hoses

Fuel Pressure Regulator

Fuel Lines

Fuel Injectors

Water Regulator

Electronic Control Module

Air Compressor

Fuel Pump

Cylinder Head

Air Injector

Detonation/Knock Sensor

Spark Plugs

Intake Manifold

All emission component related gaskets;
Head, Base, Exhaust

Digital Linear Actuator
(low idle control)

All Fuel System Components

Throttle Position Sensor

Spark Plugs

Intake Manifold Air Pressure Sensor

Ignition Coils

Intake Manifold Air Temperature
Sensor

Piston and Rings

Engine Temperature Sensor

Intake and Exhaust Valve Gear/Train

Knock Sensor

Valves, Valve Guides and Valve Guide Sealing

Emission Control Unit

Crankcase Ventilation Valve

Injectors

Wire Harness and Connectors

Fuel Pressure Regulator

Emission Related Seals, Gaskets and Hoses

Intake Manifold

Exhaust Manifold

lmo2005-007a_1.book Page 106 Wednesday, September 1, 2004 3:27 PM

Summary of Contents for Challenger*180

Page 1: ......

Page 2: ... precautions This Operator s Guide and Safety Videocassette should remain with the boat at the time of resale The following trademarks are the property of Bombardier Recreational Products Inc or its affiliates SEA DOO ROTAX BOMBARDIER LUBE SPORTSTER 4 TEC Printed in Canada lmo2005 007a fm SB TM Trademarks of Bombardier Recreational Products Inc BRP or its affiliates 2004 Bombardier Recreational Pr...

Page 3: ...urse availability More serious boaters may want to obtain Chapman Piloting by Elbert S Maloney available at most book stores When introducing your family or friends to the sport be sure they fully understand the controls and operation of the boat and the importance of courteous respon sible riding Each boat operator has a responsibility to ensure the safety of his her passen ger s and of other wat...

Page 4: ...0 LOCATION OF THE IMPORTANT LABELS 31 IDENTIFICATION NUMBERS 34 Hull 34 4 TEC Engine 34 CONTROLS COMPONENTS AND INSTRUMENTS LOCATION 35 Overview 36 CONTROLS COMPONENTS AND INSTRUMENTS FUNCTIONS 38 1 Safety Lanyard DESS Post engine cut out switch 38 2 Steering Wheel 39 3 Throttle Shifter Levers 40 4 Start Stop Button 41 5 Inlet Clearance System ICS Switch 41 6 Horn Switch 42 7 Bilge Pump Switch 43 ...

Page 5: ...33 Rear Grab Handles 51 34 Water Sport Towing Attachment 51 35 Bow Stern Eyelets 54 36 Mooring Cleats 54 37 Cup Holders 54 38 Swim Platform 54 39 Engine Cover 54 40 Main Battery Cut Off Switch 54 41 Bow Light 55 42 Stern Light Socket 55 43 Port Bilge Access 55 44 Ladder 55 45 Bilge Drain Plugs 56 46 Jet Pump Nozzle 56 47 Reverse Gate 56 48 Flushing Connector 57 49 Scupper Valve 57 50 Removable Coo...

Page 6: ...aves 71 Stopping Docking 71 Beaching 71 POST OPERATION CARE 72 General Care 72 Additional Care for Foul Water or Salt Water 72 Exhaust Cooling System Flushing 72 SPECIAL PROCEDURE 74 Engine Overheating 74 Jet Pump Water Intake and Impeller Cleaning 74 Capsized Boat 75 Submerged Boat Water Flooded Engine 75 Fuel Flooded Engine 75 Towing the Boat in Water 76 Low Charge Battery Condition 76 MAINTENAN...

Page 7: ...RRANTY INFORMATION BRP LIMITED WARRANTY FOR MODEL YEAR 2005 SEA DOO SPORT BOATS SOLD IN THE UNITED STATES AND CANADA 100 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT FOR MODEL YEAR 2005 SEA DOO SPORT BOATS EQUIPPED WITH A ROTAXTM ENGINE S 104 Your Emission Control Warranty Rights and Obligations 105 Manufacturer s Limited Warranty Coverage 105 Owner s Warranty Responsibilities 107 BRP INTERNATIO...

Page 8: ...h People often refer to a hazard state ment as a warning in a general sense This manual uses three kinds of warnings depending on the likely ef fect of a hazard minor injury severe injury death CAUTION This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate personal injury or property damage It may also be used to alert against unsafe pract...

Page 9: ...product quality and innovation BRP reserves the right at any time to discontinue or change specifications designs features models or equip ment without incurring obligation The illustrations in this document show the typical construction of the different assemblies and may not reproduce the full detail or exact shape of the parts However they represent parts that have the same or similar function ...

Page 10: ...SAFETY INFORMATION 9 SAFETY INFORMATION ...

Page 11: ...e lever is returned to the idle position less directional control is available To turn the boat both steering and throttle are necessary Like any other boat this boat has no brake Stopping distance will vary de pending on initial speed load wind and water conditions Practice stop ping and docking in a safe traffic free area to have an idea of how long it will take to stop the boat under vary ing c...

Page 12: ...or equipment that may adversely affect visibility or alter control of the boat The skipper should personally take the helm during storms Before Getting Underway Always perform the pre operation checks as specified in this Opera tor s Guide Do not exceed the payload or pas senger capacities for this boat which are listed on the capacity plate and in the specifications Overloading can affect maneuve...

Page 13: ...ree of gasoline vapors and inspect fuel lines for leaks and hose deterioration Do not smoke or allow open flames or sparks in the vicinity Know the capacity of the fuel tank Avoid fueling at night except under well lit conditions Gas spills are not noticeable in the dark Do not carry spare fuel or flammable liquids in any of the storage or engine com partments Safety Equipment An operator and the ...

Page 14: ...deral and local regulations and that your pas sengers know where they are and how to use them PFD Types Five types of PFDs have been ap proved by the U S Coast Guard PFD Type I Wearable has the greatest required buoyancy Its design allows for turning most unconscious persons in the water from face down position to a vertical or slightly backward face up po sition It can greatly increase the chanc ...

Page 15: ... in good condition Try the PFD on and adjust it until it fits comfortably in and out of the wa ter Mark your PFD if you are the only wearer To make sure the PFD works wear it in the water This will show you how it works and give you confidence when you use it Teach children how to put a PFD on and allow them to try it in the water That way they know what the PFD is for and how it works They will f...

Page 16: ...us increase the sur vival time 4 Always wear your PFD It won t help you fight off the effects of hy pothermia if you don t have it on when you go into the water Fire Extinguishers As the owner of the boat you are re sponsible for supplying a fire extinguish er approved by the U S 4 8 to less than 7 9 m 16 26 ft are required to carry one 1 B 1 type hand portable fire extin guisher unless the boat i...

Page 17: ...t on the water between sunset and sunrise you are required to display appropriate navigation lights Additional Recommended Equipment It is recommended that you acquire additional equipment for safe enjoy able cruising This list which is not all inclusive includes items you should consider acquiring BASIC GEAR flashlight mooring lines compass oar or paddle distress signals first aid kit dock fender...

Page 18: ...gen The reduced oxygen supply to body tissues results in death of the tissue Prolonged exposure can cause brain damage or death In high concentra tions CO can be fatal within minutes The effects of CO in lower concentra tions are cumulative and can be just as lethal over long periods of time Symptoms of CO poisoning include Itchy and watering eyes flushed ap pearance throbbing temples inability to...

Page 19: ...her docked or anchored can emit poisonous CO gas and cause excessive ac cumulation within cabin and cockpit areas Be alert for generator exhaust from your vessel or other vessels alongside Exhaust outlets near a pier dock seawall or outlets blocked by any other means can cause excessive accumulation of poisonous CO gas within cockpit area F00A2HL WARNING Engine exhaust fumes contain carbon monoxid...

Page 20: ...are of how exhaust from his boat will affect others Operation of the engines while moored may cause CO accumulation in your boat and those around you CONFINED AREAS Be sure to provide adequate ventilation If the windshield has vents open them before getting underway to increase positive air flow and decrease the chances of CO accumulation Even with the best boat design and construction CO may stil...

Page 21: ...because the lan yard cap was removed the cap must be reinstalled on the DESS post before the engine can be restarted TYPICAL IGNITION INTERRUPTER STOP SWITCH WITH LANYARD 1 DESS cap 2 Safety lanyard Safe Boating Practices YOU are responsible for your own safety the safety of your passengers and the safety of fellow boaters OPERATION Make sure you and your passengers know where exhaust outlets are ...

Page 22: ...re that passengers and gear do not obstruct the operator s view or ability to move Do not exceed the maximum en gine power rating stated on the cer tification plate attached to the boat Observe all safety signs and warn ings both inside the boat and in the immediate boating area Passenger Safety Before getting underway show all passengers where emergency and safety equipment is stowed and ex plain...

Page 23: ...ate the boat in rough or inclement weather Remember these Rules of the Road Know the Right of Way Rules Generally keep to your right and safely avoid other craft by keeping a safe dis tance from other craft people and ob jects CROSSING Give right of way to craft ahead and to your right Never cross in front of anoth er craft RED light give way to the other craft GREEN light you have the right of wa...

Page 24: ...skill and increases the risk of severe injuries In shallow water proceed with cau tion and at very low speeds Ground ing or abrupt stops may result in in jury Debris may also be picked up and be thrown rearward by the jet pump onto people or property Do not use the boat s reverse to stop You or your passenger s could be violently ejected forward or even off the boat onto the hazard Operator Passen...

Page 25: ...course is recommended and may be re quired in your province or state Water Sports Water skiing wakeboarding or riding a towed inflatable apparatus are some of the more popular water sports Tak ing part in any water sport requires in creased safety awareness by the par ticipant and the boat operator If you have never pulled someone behind your boat before it is a good idea to spend some hours as an...

Page 26: ...n result in CO poison ing personal injury and death 6 Give immediate attention to a per son who has fallen He or she is vul nerable in the water alone and may not be seen by other boaters 7 Approach a person in the water from the lee side opposite the direction of the wind Turn off the motor be fore coming close to the person 8 Turn off engine and anchor the boat before swimming 9 Participate in w...

Page 27: ... al low anyone near the jet pump or intake grate even when the en gine is off Items such as long hair loose clothing or personal flota tion device straps can become en tangled in moving parts resulting in serious injury or drowning In shallow water shells sand peb bles or other objects could be drawn up by the jet pump and be thrown rearward F00A2MY ...

Page 28: ...EK OK Arm upraised with thumb and finger joined to form circle RIGHT TURN Arm outstretched pointing to the right LEFT TURN Arm outstretched pointing to the left RETURN TO DROP OFF AREA Arm at 45 degree from body pointing down to water and swinging CUT MOTOR Finger drawn across throat STOP Hand up palm forward policeman style SKIER OK AFTER THE FALL Hands clenched together overhead PICK ME UP OR FA...

Page 29: ...29 VEHICLE INFORMATION ...

Page 30: ...law to be registered and legally numbered Due to space availability for proper display of registration number refer to the following illustration for location The registration number must appear on each side of the boat TYPICAL 1 Registration number location F23L01L 1 ...

Page 31: ...s are on your boat If missing or damaged they can be replaced free of charge See an authorized Sea Doo sport boat dealer Please read the following labels carefully before operating your boat Label 1 F23L02L 8 9 12 4 13 6 10 7 1 2 9 11 14 3 5 F13L1UL WARNING ...

Page 32: ...BEL ON BOAT Label 4 Label 5 Label 6 Label 7 Label 8 Label 9 F13L0DY F23L0RY WARNING F13L1MY F13L1SY WARNING F13L1NY WARNING Avoid Serious Or Fatal Injury Do Not Occupy Seat When Speed Exceeds 5 M P H F00L3BY WARNING F13L1OY WARNING F13L1QL WARNING ...

Page 33: ... 520 5 369 360 D490 766 D489 311 D485 798 D485 526 D483 315 D482 649 D469 053 D468 254 D467 860 D467 859 D465 446 D465 194 D464 601 D459 693 D409 555 D400 844 SEA DOO ISLANDIA UTOPIA SPEEDSTER SPORTSTER ROTAX 4 TEC and their associated graphic designs are trademarks of Bombardier Recreational Products Inc or their affiliates BOMBARDIER CHALLENGER are trademarks of Bombardier Inc used under license...

Page 34: ...se num bers for warranty purposes or to trace the boat in the event of theft Hull The Hull Identification Number H I N is located on the right side of the tran som TYPICAL 1 Hull Identification Number H I N 4 TEC Engine The Engine Identification Number E I N is located on the upper crank case on MAGNETO side 1 Engine Identification Number E I N F04L8SY 1 F09D0RY 1 ...

Page 35: ...35 CONTROLS COMPONENTS AND INSTRUMENTS LOCATION Cockpit COCKPIT VIEW F23L03L 11 12 4 13 5 6 7 8 9 10 14 3 1 2 ...

Page 36: ...23L02M 33 39 34 35 30 18 40 36 25 28 32 19 37 32 36 37 15 16 17 24 20 21 32 36 37 41 35 22 37 32 36 20 21 23 37 36 18 37 31 32 25 50 36 36 29 30 27 38 35 42 26 28 F23L05L 30 36 38 43 39 34 42 27 36 30 33 35 44 45 47 46 45 48 49 35 ...

Page 37: ...Compartments 22 Bow Filler Cushion if so equipped 23 Deck 24 Deck Storage Compartment 25 Rear Seat Storage Compartments 26 Passenger Storage Compartment 27 Starboard Rear Storage compartment 28 Fuel Tank Cap Vent 29 Oil Fill Cap on engine 30 Ventilation Ducts 31 Deck Drain 32 Grab Handles 33 Rear Grab Handles 34 Water Sport Towing Attachment 35 Bow Stern Eyelets 36 Mooring Cleats 37 Cup Holders 38...

Page 38: ...ARNING Always use safety lanyard when operating your boat to help pre vent a runaway boat and reduce the risk of personal injury or death Disconnect the safety lanyard when stopped to help prevent ac cidental starting WARNING Should the safety lanyard cap be come loose or fails to remain on the DESS post replace it immedi ately WARNING Directional control is reduced when throttle is decreased and ...

Page 39: ...elay it is necessary to re move and reinstall lanyard cap on the DESS post Two short beeps should sound indicating the system is ready again to allow engine starting 2 Steering Wheel The steering wheel controls the direc tion of the boat Turning the steering wheel clockwise steers the boat to the right and inversely NUMBER OF BEEPS POSSIBLE CAUSE REMEDY 2 short while installing safety lanyard on D...

Page 40: ...t be fully pulled back idle speed to shift 2 Forward 3 Neutral 4 Reverse CAUTION Do not force lever Insure throttle lever is in idle position NOTE To ease shifter use line up the shifter arrow with the appropriate dot Forward Neutral Reverse TYPICAL 1 Dots besides shifting position 2 Arrow on shifter CAUTION Never rev the engine at high RPM in reverse F23L06Y 2 3 1 4 F23L06Z 2 3 4 1 WARNING Shift ...

Page 41: ...the engine 1 STOP when engine IS running 5 Inlet Clearance System ICS Switch 1 Inlet Clearance System ICS switch WARNING Engine exhaust fumes contain car bon monoxide CO which can ac cumulate in and around the boat under Bimini top in cockpit etc CO can be harmful or fatal if in haled Assure there is adequate ventilation whenever running en gine s 1 F23L08Y F04H0AY 1 WARNING While engine can be st...

Page 42: ...pleting the cycle CAUTION Operating the boat with the water intake grate in lower posi tion will cause damage to the ICS In severe conditions if the above meth od does not work the following can be performed With engine running put shift lever in reverse position and vary throt tles quickly several times Try accelerating again Most of the time debris will escape from the propulsion system Out of w...

Page 43: ...hen the main battery cut off switch is turned OFF while boat is moored the automatic bilge pump will start if water comes up in the bilge 8 Bilge Air Blower Switch 1 Bilge blower switch A 2 position OFF ON switch When turned on the blower ventilates the en gine compartment Using the bilge blower for a prolonged time when the engine is not running will discharge the battery Blower should be turned ...

Page 44: ... light is on you should discontinue all use of electrical accessories immediately and start the engine in order to recharge the battery Check Engine Light When the ECM detects a fault code the check engine light will come on and a beep may sound Turn engine off Wait one 1 minute Re start engine If light remains lit take boat to nearest authorized Sea Doo sport boat dealer for servicing Engine Temp...

Page 45: ...tachometer indicates the revolu tions per minute RPM of the engine Multiply reading by 1000 to obtain ac tual RPM Gauge is illuminated whenever the navigation lights are used TYPICAL TACHOMETER 13 Fuel Gauge Located in dashboard this gauge con tinuously indicates the amount of fuel in fuel tank when engine is running The gauge is illuminated whenever the navigation lights are used TYPICAL FUEL GAU...

Page 46: ...essories such as a cellular phone or other 12 Volt portable devices 1 12 Volt jack Open glovebox cover Lift protective cap to expose jack CAUTION Using the accessory jack for a prolonged time without engine running may discharge the battery CAUTION Close protective cap when jack is not in use to protect against weather 18 Fuses Fuses are located in the gunwale near the driver s seat and in the por...

Page 47: ...t cushion Unsnap the front bow seat cushion and remove Pull the bow seat filler cushion from its storage position 1 Filler cushion Remove the support bars from their storage position beneath the bow seat filler cushion Unsnap the two side bow seat cush ions lift each cushion slightly to posi tion the support bars 1 Support bars installed Reposition front bow seat cushion and fasten with the snap P...

Page 48: ...ains in that position on calm water To close gently push on the side of the spring to release it and lower the cover TYPICAL 1 Gently push here to release the spring 25 Rear Seat Storage Compartments Located beneath the rear port and star board seat cushions these compart ments are convenient for storing a cooler or additional articles TYPICAL 1 Starboard side shown WARNING Never leave any heavy o...

Page 49: ... storage cover 1 Lift latch The gas assist cylinder will hold the storage cover open 28 Fuel Tank Cap Vent 1 Fuel tank cap The fuel tank cap is located on the port outside gunwale Unscrew the cap counterclockwise to allow fuel tank filling Fully tighten when finished The fuel tank vent is located on the starboard outside gunwale and allows fuel vapor and pressure release from fuel tank 1 Fuel tank...

Page 50: ...nward to engage terminals Push lock ring downward Turn until locked It may be necessary to slightly turn it to allow its insertion in the hole Check light operation See LIGHT SWITCH as mentioned earlier in this section WARNING Always stop the engine before refu eling Fuel is flammable and explo sive under certain conditions Al ways work in a well ventilated area Do not smoke or allow open flames o...

Page 51: ... CAUTION Never use the grab han dle to tow anything or to lift the boat Each passenger should be seated while underway 34 Water Sport Towing Attachment Please read and often refer to WATER SPORTS information in the SAFETY SECTION at the front of this guide 1 2 3 4 F04L0LY WARNING Allow no one to sit on edge of the boat or to stand up while in oper ation Seat grab handles should be used in rough wa...

Page 52: ...ve both knobs from each side lower sup port arms to the gunwale and carefully lower tower to rear of boat Remove bolts from each support arm using an 8 mm 5 16 in hexagonal tip PERFORM FOR EACH SIDE 1 Remove both knobs 2 Lower support arms to gunwale 3 Remove bolt Store support arms in the deck storage compartment Erection of tower is reverse of this pro cedure NOTE Apply Loctite 243 P N 293 800 0...

Page 53: ... 35 N m 25 8 lbf ft to complete in stallation of tower WARNING Pulling a tube skier or wakeboarder makes the boat handle differently and requires greater skill Unless ab solutely necessary do not make tight sharp turns Keep a safe dis tance from docks swimmers other craft or objects Be advised that seri ous injury can result if the tow rope becomes slack during a tight turn or when circling The ro...

Page 54: ...st cylinders will complete the opening and hold the cover open 40 Main Battery Cut Off Switch This switch is located in the port bilge access compartment It allows a com plete power cut out of the electrical system When in OFF position ALL electrical equipment and electronics will be OFF except the bilge pump The bilge pump will operate automatically with the battery switch in the OFF position Swi...

Page 55: ...s recommended to keep stern light in ski locker compartment at all times except when needed 43 Port Bilge Access Located at the port rear of the boat This area allows access to the battery the main battery cut off switch and various fuses Lift latch to open storage cover 1 Latch The gas assist cylinder will hold the storage cover open Also see MAINTENANCE section 44 Ladder Located under the swim p...

Page 56: ... 2 Loosen 3 Tighten 46 Jet Pump Nozzle The jet pump nozzle provides direc tional control when engine is running turning side to side via input from the steering wheel Refer to PROPULSION under PRINCI PLE OF OPERATION 47 Reverse Gate When selecting the neutral or reverse position with the shift lever the re verse gate moves up or down to the desired position F23L0YY 2 1 F23L0ZY WARNING Never use no...

Page 57: ...per Valve This is where water from the deck drains out of the boat Keep clean to avoid clogging TYPICAL 1 Scupper valve 50 Removable Cooler A 15 liter 16 quart removable cooler is provided for keeping sandwiches and non alcoholic beverages cold It is located in the starboard rear seat storage compartment and will also fit in the port rear seat storage compart ment F23L11Y 1 F23L11Z 1 ...

Page 58: ...ne number for optimum perfor mance As a minimum regular unleaded gaso line with the following minimum oc tane number may be used WARNING Follow these safe boating fueling instructions explicitly WARNING Always stop the engine before re fueling Fuel is flammable and ex plosive under certain conditions Always work in a well ventilated area Do not smoke or allow open flames or sparks in the vicinity ...

Page 59: ...d Supercharged Intercooled Engines Use Bombardier 4 stroke oil SAE 10W 40 P N 219 700 346 or an equivalent approved by BRP The same oil lubri cates both the engine and the super charger clutch Bombardier 4 stroke oil SAE 10W 40 P N 219 700 346 has been thoroughly tested to be free of any additives that could impair the functionality of the supercharger clutch CAUTION Do not add any additives to th...

Page 60: ... or exhaust sys tem 3 Warm up engine then let idle for 30 seconds before stopping 4 Stop engine 5 Wait at least 30 seconds then pull dipstick out and wipe clean CAUTION Never run engine longer than 5 minutes Drive line seal has no cooling when boat is out of water 6 Reinstall dipstick push in complete ly 7 Remove dipstick and read oil level It should be between marks 1 Full 2 Add 3 Operating range...

Page 61: ...Refer to an authorized Sea Doo sport boat dealer Coolant Level With boat on a level surface liquid should be between MIN and MAX level marks of coolant reservoir when engine is cold 1 Level between marks when engine is cold NOTE The boat is considered level when it is in water When on a trailer block the wheels and raise the bow slightly with the trailer jack if so equipped until the bumper rail i...

Page 62: ...d variations contribute to a good break in CAUTION Continued wide open throttle runs and prolonged cruising without speed variations should be avoided This can cause engine dam age during the break in period NOTE Never add oil in fuel tank 10 Hour Inspection It is highly recommended that after the first 10 hours of operation the boat be checked by an authorized Sea Doo sport boat dealer This inspe...

Page 63: ... Retighten exhaust system hose clamps Verify steering system Adjust steering cable if required Adjust shifter cable if required Ensure that throttle lever keeps the selected position Adjust lever tension as necessary Inspect condition of hoses and clamps Verify operation of bilge pump and bilge blower Verify operation of DESS system and start stop button Test monitoring beeper Inspect electrical c...

Page 64: ...e following Only start boat once all items have been checked and operate properly ITEM OPERATION Hull Inspect for damage Jet pump water intake Inspect clean Bilge Drain Ensure plugs are secured Battery Inspect tightness of cables and retaining straps Main battery cut off switch Ensure it is in the ON position Navigation lights Check operation Fuel reservoir Refill Engine compartment Verify fuel ex...

Page 65: ...Extinguisher Make sure fire extinguisher is full in good condition and well secured Steering System Have another person help check steer ing operation for free movement When the steering is centered the jet pump nozzle should be in the straight ahead position Ensure the jet pump nozzle pivots easily while steering is turned Throttle System Check throttle lever for free and smooth operation WARNING...

Page 66: ...s in the up position CAUTION If the reverse gate does not stay in the up position when the shifter is at FORWARD do not oper ate the boat further see an autho rized Sea Doo sport boat dealer Safety Lanyard and Engine Start Stop Button Ensure that switch operates properly Storage Compartment Covers Ensure they are closed and latched WARNING Verify the reverse gate lock WARNING If engine does not sh...

Page 67: ...ntry through the air intake openings Observe trailering safety precautions CAUTION Always ensure rear stor age compartment lid is closed and securely fastened before trailering Principle of Operation Propulsion The engine is directly coupled to a drive shaft which in turn rotates an impeller This impeller rotates within a housing drawing water in from be neath the boat Water is then forced by the ...

Page 68: ...practice this ma neuver away from anything with which you might collide Boarding from a Dock As with any boat boarding should be done carefully and engine must not be running When boarding from a dock slowly place one foot on the boat deck near est to the dock and then move the oth er foot inside the boat Push the boat away from the dock WARNING When the boat is in neutral posi tion the impeller i...

Page 69: ...e the rubber stays on one step ladder pulling ladder out and down into boarding position Grip the grab handle and pull yourself up until your knee can reach the swim platform TYPICAL TYPICAL WARNING Inexperienced riders shouldpractice how to get aboard close to shore first before venturing into deep water WARNING Engine should not be running while boarding Never use propul sion components as a sup...

Page 70: ...o not apply full throttle until the engine is warm Rough Water or Poor Visibility Operation Avoid operation in these conditions If you must do so proceed with caution and prudence using minimum speed Turn on navigation lights if necessary WARNING Do not start engine until all pas sengers are properly seated WARNING Engine exhaust fumes contain car bonmonoxide CO whichcan accu mulate in and around ...

Page 71: ...h Ensure that all accessories are OFF A 90 cm 3 ft of water under the hull As necessary the cooling system of the engine should be flushed before restart ing in order to remove sand or shell ac cumulation which may clog the water passages Refer to POST OPERATION CARE and look for COOLING SYSTEM FLUSHING Shutting Off the Engine To shut off the engine completely pull back throttle lever then remove ...

Page 72: ...shing the exhaust cooling system with fresh water is essential to neutral ize corroding effects of salt or other chemical products present in water It will help to remove sand salt shells or other particles in water jackets and or hoses Flushing should be performed when the boat is not expected to be used further the same day or when the boat is stored for any extended time Proceed as follows Clea...

Page 73: ...ng when boat is out of water Close the water tap then stop the en gine CAUTION Always close the water tap before stopping the engine Leave all compartments open to air dry Anticorrosion Treatment To prevent corrosion spray a corrosion inhibitor salt water resistant such as BOMBARDIER LUBE lubricant or equiv alent over metallic components in en gine compartment NOTE Engine fogging should be done wi...

Page 74: ... allow weeds or other debris to escape from grate It may be necessary to repeat the procedure In severe conditions if the above meth od does not work the following can be performed With engine running put shift lever in reverse position and vary throttle setting quickly several times Try accelerating again Most of the time debris will escape from the propulsion system Out of water cleaning If the ...

Page 75: ...as follows Crank engine several times If it does not work Disconnect ignition coil connectors CAUTION Ensure there is no dirt in coil holes before removing the spark plugs Otherwise dirt would fall into cylinder and will damage the internal components Remove ignition coils Remove spark plugs NOTE After loosening the spark plugs a coil may be used to pull the spark plugs out Simply bring the coil d...

Page 76: ...st outlet CAUTION Failure to do this may re sult in damage to the engine If your Sea Doo sport boat must be towed in water and you do not have a hose pincher be sure to stay well below the maximum towing speed of 24 km h 15 MPH Snugly install the hose pincher on the water supply hose as shown TYPICAL 1 Hose pincher CAUTION When finished towing the sport boat hose pincher must be re moved before op...

Page 77: ...77 MAINTENANCE INFORMATION ...

Page 78: ...d by BRP If required contact your authorized Sea Doo sport boat dealer for further servicing information Operate your boat prudently and have fun Don t forget that all per sons must assist other boaters in an emergency Engine Emissions Information Manufacturer s Responsibility Beginning with 1999 model year en gines manufacturers of marine en gines must determine the exhaust emission levels for ea...

Page 79: ...nue NW Washington DC 20004 EPA INTERNET WEB SITE http www epa gov otaq Lubrication IMPORTANT DO NOT lubricate DESS post This will prevent proper electrical contact Anticorrosion Protection Throttle Cable Lubricate the throttle cable with BOMBARDIER LUBE lubricant every 25 hours of use every 10 hours in salt water use Electrical Connections As necessary apply dielectric grease on battery posts and ...

Page 80: ... sport boat dealer The schedule should be adjusted according to operating condi tions and use Throttle Cable Move the throttle lever forward and rearward once It must operate smooth ly Refer to an authorized Sea Doo sport boat dealer if adjustment is necessary TYPICAL THROTTLE LEVER 1 Must move smoothly Fuel and Oil Filters These filters must be replaced by an authorized Sea Doo sport boat dealer ...

Page 81: ...e engine compartment is in the ON position Al so check main fuses connected to battery cut off switch inside port rear storage compartment 1 Main fuses 2 Automatic bilge pump fuse Fuses for the electrical system of the en gine are mounted in the fuse block which is located in the engine compart ment Fuses for the engine electrical system are located below the solenoid as shown below WARNING Ensure...

Page 82: ...cover tabs to remove the fuse TYPICAL 1 Slide cover tabs each side of fuse then pull fuse out TYPICAL GAUGE INTERFACE 1 Accessory 2 Radio 3 Blower 4 Bilge pump 5 Navigation lights 6 Courtesy lights If an accessory engine or gauge is not working check its fuse condition When finished ensure seal is properly placed in cover Carefully position cover on fuse block then firmly push until you hear a sna...

Page 83: ...vigation Light Bulb Replacement Bow Light TYPICAL 1 Gently pry here with a screwdriver TYPICAL 1 Remove this screw TYPICAL 1 Pull lens out TYPICAL 1 Lift and remove bulb The assembly is essentially the reverse of removal procedures However pay particular attention to the following WARNING If bilge blower does not operate properly refer to an authorized Sea Doo sport boat dealer before start ing th...

Page 84: ...s Corrosion can be caused by stray electric currents from shore power installations improperly grounded A C lines and circuits and poorly insulated D C powered equip ment from boats moored nearby Cor rosion is accelerated when electric current is present Sacrificial anodes are attached to cer tain parts of this boat to reduce corro sion The anode corrodes rather than the part to which the anode is...

Page 85: ...he body with hot water and soap only use mild deter gent Remove any marine organisms from engine and or hull Apply non abrasive wax CAUTION Never clean fiberglass and plastic parts with strong detergent degreasing agent paint thinner ace tone etc Wash windscreen with Bombardier cleaner P N 293 110 001 and water For fine scratches and scuff marks re moval use a windshield polisher for acrylic lucit...

Page 86: ...ubrication Connect a garden hose to cool the ex haust system as explained in FLUSH ING under POST OPERATION CARE Bring engine to normal operating tem perature CAUTION Properly follow the instruc tions given in the flushing procedure Close the water tap then stop the en gine Pull engine access panel upward to re move it WARNING Because fuel and oil are flammable have an authorized Sea Doo sport boa...

Page 87: ...p any residual water from the engine Disconnect the garden hose NOTE It is recommended to fog the en gine valves with BOMBARDIER LUBE lu bricant Contact your authorized Sea Doo sport boat dealer Battery Contact your authorized Sea Doo sport boat dealer Engine Cooling System Antifreeze is to be replaced every 100 hours or once per season to pre vent antifreeze deterioration The antifreeze replaceme...

Page 88: ... to prevent UV ultraviolet rays and grime from affecting the plastic compo nents boat finish as well as prevent ing dust accumulation CAUTION Never leave the boat stored in direct sunlight UV radia tion will dull finishes The boat must never be left in water for storage Make sure to turn off main battery cut off switch For the storage period it is necessary to make certain the drain plugs are un s...

Page 89: ...tance of an authorized dealer be periodically obtained on other components systems not covered in this guide Unless otherwise specified en gine must not be running and the main battery cut off switch must be turned OFF for all maintenance procedures OPERATIONS TO BE PERFORMED BY Verify lubrication corrosion protection OPERATOR Inspect condition of safety lanyard cap and post DEALER Verify battery ...

Page 90: ...afety lanyard on DESS post or when pressing start stop buttons in some cases Bad connection between safety lanyard cap and DESS post Remove and reinstall the safety lanyard on the DESS post Two short beepsshould be heard which indicates the system is ready again to allow engine starting Wrong safety lanyard Use the safety lanyard that has beenprogrammedfor the boat If it does not work refer to an ...

Page 91: ...or water contaminated Clean check fuel tank for water Fuel flooded engine Fouled defective spark plugs Replace Engine Misfires Runs Irregularly OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark Fouled worn spark plugs Replace Faulty ignition component Refer to anauthorizedSea Doo sport boat dealer Too much oil supplied to engine Improper oil pump adjustment refer to an authorized Sea Doo sport bo...

Page 92: ...k plugs Engine Lacks Acceleration or Power OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark incorrect fuel mixture Refer to ENGINE MISFIRES Water in fuel or oil Siphon and replace Overheated engine See ENGINE OVERHEATS Boat cannot Reach Top Speed OTHER OBSERVATION POSSIBLE CAUSE REMEDY Jet pump water intakes clogged Clean Damaged impeller Replace Refer to an authorized Sea Doo sport boat dealer ...

Page 93: ...cked charred or deteriorated exhaust hoses if found O D Inspect metal exhaust components for cracking rusting leaking or loosening Check cylinder head gasket exhaust manifold water injection elbow and the threaded adapter nipple between the manifold and the elbow D COOLING SYSTEM Flushing DAILY O Inspect hose and fastener condition D Inspect clean exhaust drain tube D Check coolant levels DAILY Re...

Page 94: ...erify battery cable tightness and hold down condition D Charge battery D Inspect sacrificial anodes O STEERING SYSTEM Inspect and adjust cable D PROPULSION SYSTEM Inspect drive shaft floating seal condition D Adjust shifter system cable D Inspect jet pump reservoir grease level condition D Impeller condition and impeller wear ring clearance D Inspect condition of water intake grate O HULL AND BODY...

Page 95: ...lectric start ELECTRICAL Magneto generator output 360 W 6000 RPM Ignition system type DI Digital Induction Ignition timing Not adjustable Spark plug Make and type NGK DCPR8E Gap 0 75 mm 030 in Battery charging coil 0 1 1 0 Ω Ignition coil Number of coils 3 Model type Stick coil Engine RPM limiter setting 7650 RPM 8000 RPM Battery 12 V 30 A h Fuse TOPS 10 A Battery fuse 30 A Cylinder 1 ignition coi...

Page 96: ...losed loop Coolant Ethylene glycol 50 50 antifreeze water coolant containing corrosion inhibitors for internal combustion aluminum engines Exhaust Water cooled open loop PROPULSION Propulsion system BOMBARDIER Formula pump Jet pump type Axial flow single stage Greased bearings Transmission Direct drive Grease type Sea Doo grease P N 293 550 032 Steering nozzle pivoting angle 26 Minimum required wa...

Page 97: ... 2 m 20 ft 4 in Overall width 2 49 m 8 ft 2 in Overall height on trailer 1 85 m 6 ft 1 in w o tower 2 01 m 6 ft 7 in w tower down 2 56 m 8 ft 5 in w tower up Dry Weight boat and trailer 941 2 kg 2075 lb 1156 6 kg 2550 lb w trailer Dead rise 20 Load limit passengers luggage 653 kg 1440 lb CAPACITIES Engine oil 3 L 3 2 U S qt oil change w filter 4 5 L 4 75 U S qt total Cooling system coolant 5 5 L 5...

Page 98: ...ilopascal newton meter kilometer per hour knot SYMBOL m kg N L C kPa N m km h kn PREFIXES PREFIX kilo centi milli micro SYMBOL k c m µ MEANING one thousand one hundredth of one thousandth of one millionth of VALUE 1000 0 01 0 001 0 000001 CONVERSION FACTORS TO CONVERT in in in in ft oz lb lbf lbf in lbf ft lbf ft PSI imp oz imp oz imp gal imp gal U S oz U S gal knot MPH Fahrenheit Celsius hp TO mm...

Page 99: ...99 WARRANTY INFORMATION ...

Page 100: ...berglass structure is covered for TWELVE 12 CONSECUTIVE MONTHS A sport boat is used commercially when it is used in connection with generating income or any work or employment during any part of the warranty period A sport boat is also used commercially when at any point during the warranty period it has commercial tags or is licensed for commercial use The emission related components included in ...

Page 101: ...o Dealer for warranty repairs Owner is required to sign the re pair work order prior to the start of the repair in order to validate the warranty repair All parts replaced under this warranty become the property of BRP 5 WHAT BRP WILL DO BRP s obligations under this warranty are limited to at its sole discretion repair ing or replacing parts of the sport boat found to be defective in material or w...

Page 102: ...s entirety and rendered null and void where The sport boat has been altered or modified in such a way so as to adversely affect its operation performance or durability or has been altered or modified to change its intended use or The sport boat is or has been used for racing at any point even by a prior owner 7 LIMITATIONS OF LIABILITY ALL WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMI TAT...

Page 103: ...he new owner or b BRP or an authorized BRP Dealer receives a proof that the former owner agreed to the transfer of ownership in addition to the coordinates of the new owner 9 CONSUMER ASSISTANCE a In the event of a controversy or a dispute in connection with this limited war ranty BRP suggests that you try to resolve the issue at the dealership level We recommend discussing the issue with the auth...

Page 104: ...ercent less gas and oil than conventional carbureted two stroke engines saving money and resources Longer Emission Warranty Protects consumer for worry free operation One Star Low Emission The one star label identifies personal watercraft outboard sterndrive and inboard engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2001 exhaust emission standards Engine...

Page 105: ...sted below provided there has been no abuse neglect or improper maintenance of your sport boat engine Your emission control system may include parts such as the fuel injection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists BRP will repair your sport boat s Rotax engine at no c...

Page 106: ...Lines Fuel Injectors Water Regulator Electronic Control Module Air Compressor Fuel Pump Cylinder Head Air Injector Detonation Knock Sensor Spark Plugs Intake Manifold All emission component related gaskets Head Base Exhaust Digital Linear Actuator low idle control All Fuel System Components Throttle Position Sensor Spark Plugs Intake Manifold Air Pressure Sensor Ignition Coils Intake Manifold Air ...

Page 107: ...ed to each subsequent owner of the sport boat Owner s Warranty Responsibilities As the owner of a Sea Doo sport boat equipped with a Rotax engine s you are responsible for the performance of the required maintenance listed in your Oper ator s Guide BRP recommends that you retain all receipts covering maintenance on your Rotax engine but BRP cannot deny warranty solely for the lack of receipts or y...

Page 108: ...E MONTHS A Sport Boat is used commercially when it is used in connection with generating income or any work or employment during any part of the warranty period A Sport Boat is also used commercially when at any point during the warranty period it has commercial tags or is licensed for commercial use All genuine Sport Boat accessories installed by an authorized BRP Distributor Dealer at the time o...

Page 109: ...rranty service is required outside of the country where the Sport Boat was purchased owner will bear responsibility for any additional charges due to local practices and conditions such as but not limited to freight insurance taxes license fees import duties and any and all other financial charges including those levied by governments states territories and their respective agencies BRP reserves t...

Page 110: ...RE EXCLUDED FROM COV ERAGE UNDER THIS WARRANTY INCLUDING BUT NOT LIMITED TO ex pense for gasoline expense for transporting Sport Boat to and from Distributor Dealer mechanic s travel time in and out of water charges slip or dock fees trailering or towing storage telephone cell phone fax or telegram charges rental of a like or replacement boat during warranty services or down time taxi travel lodgi...

Page 111: ... dispute in connection with this limited war ranty BRP suggests that you try to resolve the issue at the dealership level We recommend discussing the issue with the authorized distributor dealer s service manager or owner b If further assistance is required the distributor s service department should be contacted in order to resolve the matter c If the matter still remains unresolved then contact ...

Page 112: ...iv htm Delaware www boat ed com Florida freshwater www boat ed com Florida saltwater www boat ed com Georgia www boat ed com Hawaii www hawaii gov dlnr dbor dbor Idaho www boat ed com Illinois http dnr state il us Indiana www boat ed com Iowa www boat ed com Kansas www boat ed com Kentucky www boat ed com Louisiana www boat ed com Maine www state me us Maryland www dnr state md us boating Massachu...

Page 113: ...nysparks com North Carolina www boat ed com North Dakota http www state nd us gnf boating Ohio www boat ed com Oklahoma www boat ed com Oregon www boat ed com Pennsylvania www boat ed com Rhode Island www boat ed com South Carolina www boat ed com South Dakota www state sd us gfp divisionwildlife boating index htm Tennessee www boat ed com Texas www boat ed com Utah www boat ed com Vermont www boa...

Page 114: ...lership To find the nearest authorized Sea Doo sport boat dealer dial 1 800 882 2900 NOTE If outside Canada and USA consult the local distributor USA Except Puerto Rico BRP US INC 7575 Bombardier Court P O Box 8035 WAUSAU WI 54401 Phone 715 848 4957 Fax 715 847 6879 http www brp com CANADA Alberta British Columbia Manitoba North West Territories Ontario Quebec Saskatchewan Yukon New Brunswick Nova...

Page 115: ...ddress 2 rue du Nouveau Bercy 94220 Charenton Paris France Notified body for Directive 94 25 CE International Marine Certification Institute Trèves centre rue de Trèves 45 1040 Brussels Belgium Competent body for Directive 89 336 CEE UTAC Autodrome de Linas Montlhéry B P 212 91311 Montlhéry cedex France Type of equipment Sport boats inshore category C Model names and numbers ______________________...

Page 116: ...336 CEE of the council relating to electromagnetic compatibility Internal production control plus control carried out on the responsability of a competent body Competent body UTAC Autodrome de Linas Montlhéry B P 212 91311 Montlhéry cedex France Directive 94 25 EC of the European Parliament and of the council relating to recreational craft Internal production control plus control carried out on th...

Page 117: ... _ _ _ _ _ _ _ _ _ _ _ _ Cut here Name Address Receipt Name Address Owner of Sport Boat model No HIN to be completed by customer or selling dealer _____________________________________________ This warranty begins date The dealer named on this document has instructed me on the operation maintenance safety features and warranty policy all of which I understand and agree to be bound with I am also s...

Page 118: ...vices and offers please let us know by writing to the address below Also note that from time to time carefully selected and trustworthy organizations may be permitted to use the coordinates of our clients to promote quality prod ucts and services If you prefer not to have your name and address released please let us know by writing to the address below Bombardier Recreational Products Inc Warranty...

Page 119: ...________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOLEN UNITS In ...

Page 120: ...afety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS INC WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 ...

Page 121: ..._________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOLEN ...

Page 122: ...afety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS INC WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 ...

Page 123: ..._________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOLEN ...

Page 124: ...afety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS INC WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 ...

Page 125: ..._________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOLEN ...

Page 126: ...afety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS INC WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 ...

Page 127: ..._________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS ______________________________________________ NAME ________________________________________________________________ NO STREET APT ________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE STOLEN ...

Page 128: ...afety even after expiration of the original warranty since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary NOTE This card is strictly for change of address only CHANGE OF ADDRESS AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS INC WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 ...

Page 129: ...RP BOAT MODEL No HULL IDENTIFICATION NUMBER H I N MERCURY OR ROTAX ENGINE IDENTIFICATION NUMBER E I N Owner Purchase Date YEAR MONTH DAY Warranty Expiry Date YEAR MONTH DAY To be completed by the dealer at the time of the sale DEALER IMPRINT AREA NAME No STREET APT CITY STATE PROVINCE ZIP POSTAL CODE ...

Page 130: ......

Search results

Summary of Contents for Challenger*180

Reviews:

Related manuals for Challenger*180

Brands by name

Popular brands

Sea-doo Challenger*180, Operator'S Manual

Search results

Summary of Contents for Challenger*180

Reviews:

Related manuals for Challenger*180

Brands by name

Popular brands