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Sea-doo Challenger 1800 Operator'S Manual Download Page 96

94

1. Hose pincher right after T-fitting
2. T-fitting
3. Hose pincher on this hose
4. Hose pincher on drain tube

Challenger 1800

Install a hose pincher and firmly tighten
on:

– engine drain tube coming from cyl-

inder base before T-fitting

– hose right after T-fitting

– hose on cylinder head

1. Hose pincher right after T-fitting
2. T-fitting
3. Hose pincher on this hose
4. Hose pincher on drain tube

All Models

NOTE:

Hose pinchers must be firmly

tightened so that no antifreeze can
flow through the blocked hoses. If you
hear the liquid flowing in the muffler
immediately after starting pouring an-
tifreeze, it indicates that antifreeze is
bypassing the engine/tuned pipe wa-
ter jackets. To correct this, firmly re-
tighten hose pinchers.

Unscrew cap from flushing fitting on
the edge of engine compartment and
insert a funnel into flushing fitting.
Pour about 2 liters (1/2 gal) of anti-
freeze solution through the funnel. Let
the antifreeze enough time to flow.
Moving the hose with the T-fitting
should accelerate the flow.

Pour antifreeze until you see it flowing
out of tuned pipe bleed hose. At this
time only, the entire circuit is filled
with antifreeze.

F04E1CY

1

3

4

2

F04E0T0

1

3

2

4

F04E1DY

lmo9802a.bk : lmo9802a.fm5  Page 94  Monday, September 8, 1997  9:16 AM

Summary of Contents for Challenger 1800

Page 1: ......

Page 2: ...t the time of resale AFTER SALES SERVICE BOMBARDIER INC VALCOURT QUÉBEC CANADA J0E 2L0 The following trademarks are property of Bombardier Inc SEA DOO Sea Doo Lube Sea Doo Jet Pump Synthetic Oil Sea Doo Synthetic Grease Gelcote is a trademark of Gelcote International Knight s Spray Nine is a trademark of Korkay System Ltd Litho d in Canada LMO 9802 SH Trademarks of Bombardier Inc All rights reserv...

Page 3: ...e 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 under stand the controls and operation of the jet boat and the importance of courteous responsible riding Each jet boat operator has a responsibility to ensure the safety of its passengers and other water users Please follow...

Page 4: ...hoke Levers 30 7 Navigation Light Switch 30 8 Bilge Pump Switch 31 9 Bilge Air Blower Switch 31 10 Horn Switch 31 11 Deck Light Switch 32 12 Low Fuel Warning System Switch 32 13 Fuel Gauge Low Injection Oil Level Pilot Lamp 32 14 Tachometers 33 15 Speedometer 33 16 Wind Deflector if so equipped 34 17 Bilge Drain Plug 34 18 Grab Handles 34 19 Rear Grab Handle 35 20 Swim Platform 35 21 Seats 35 22 S...

Page 5: ...dder 48 47 Scupper Valve 49 48 Weedless System Lever 49 49 Fuel Tank Vent 52 50 Bimini Top if so equipped 52 51 Ski Post 55 Fuses 56 FUEL AND LUBRICATION 57 Fueling Procedure 57 Recommended Fuel 57 Recommended Oil 57 Oil Injection System 58 BREAK IN PERIOD 59 Engines 59 10 Hour Inspection 59 PRE OPERATION CHECKS 61 Hull 62 Jet Pump Water Intakes 62 Bilge 62 Battery 62 Fuel Oil Reservoirs 62 Engine...

Page 6: ...d Boat 75 Towing the Boat in Water 75 Operating the Boat with Only One Engine 76 Low Charge Battery Condition 76 MAINTENANCE 77 Lubrication 77 Periodic Inspection 79 Periodic Inspection Chart 80 Throttle and Choke Cables 81 Fuel and Oil Filters 81 Steering Jet Pump Nozzle Adjustment 81 Reverse Gates 82 Fuses 82 Bilge Air Blower 85 Navigation Light Bulb Replacement 85 Bimini Top if so equipped 86 G...

Page 7: ...ctured Due to late changes it may have some differences between the manufactured product and the de scriptions and or specifications in this document Bombardier Inc reserves the right at any time to discontinue or change specifications designs fea tures models or equipment without incurring obligation The illustrations in this document show the typical construction of the different assemblies and ...

Page 8: ...G The engines and the correspond ing components identified in this guide should not be utilized on products other than those they were designed for Maintenance procedures and specified tight ening torques must be strictly ad hered to Never attempt repairs unless the appropriate tools are available This jet boat is de signed with parts dimensioned in both the metric and the imperial systems When re...

Page 9: ...you may have operated There fore use of this jet boat by a novice or inexperienced operator is not recom mended Observe and follow all on product warning labels and the content of this guide An operator and passenger s should wear suitable eye and body protection as well as deck shoes or booties Coast Guard approved personal flota tion devices PFD should be worn by all aboard Operation of this boa...

Page 10: ... engine compartments Avoid adding on accessories carrying equipment or passengers which may alter the boat s configuration or bal ance Only perform servicing procedures which are detailed in this guide Fur ther assistance or information can be obtained from your dealer In many in stances proper tools and training is re quired for certain servicing or repair procedures Gasoline fumes are flammable ...

Page 11: ...ne fumes Blower and bilge pump must be off during boat operation The ski tow universal eyelet can be used to attach a ski rope Do not use this ring for para sailing or other uses which may overstress the transom Lifting the boat requires special equip ment and experience Do not attempt to lift the boat without such experi ence or equipment Respect the safety and comfort of your passenger s and per...

Page 12: ...hout charge for parts and labor at any authorized SEA DOO jet boat dealer during the Warranty Coverage Period 3 CONDITION TO HAVE WARRANTY WORK VALIDATED The customer must notify an authorized SEA DOO jet boat dealer within two 2 days of the appearance of the defect in material and or workmanship and present to the servicing authorized SEA DOO jet boat dealer the SEA DOO Warranty Registration Card...

Page 13: ...consequential damages or limita tions on how long an implied warranty lasts so the above limitation or exclusion may not apply BOMBARDIER reserves the right to modify this warranty at any time being understood that such modification will not alter the warranty conditions applicable to the SEA DOO jet boat sold while this warranty is in effect 6 CONSUMER ASSISTANCE a In the event of a controversy o...

Page 14: ...in material and or workmanship under normal use maintenance and ser vice with a genuine BOMBARDIER part without charge for parts and labor at any local authorized SEA DOO jet boat dealer 3 CONDITION TO HAVE WARRANTY WORK VALIDATED The customer must notify a local authorized SEA DOO jet boat dealer within two 2 days of the appearance of the defect in material and or workmanship and present to the s...

Page 15: ...glish version of this warranty A specific SEA DOO International Distributor may elect to translate this warranty into local language it is then understood and agreed that in the event of any discrepancies or inconsistencies between the two versions the English version shall prevail It is the customer s responsibility to ensure that the SEA DOO jet boat complies with all boating regulations and sta...

Page 16: ...ial 1 800 882 2900 NOTE If outside Canada and U S A consult the local distributor U S A Continental U S A Except Puerto Rico BOMBARDIER MOTOR CORPORATION OF AMERICA 7575 BOMBARDIER COURT P O BOX 8035 WAUSAU WI 54402 8035 Phone 715 842 8886 CANADA Alberta British Columbia Manitoba North West Territories Ontario Quebec Saskatchewan Yukon New Brunswick Nova Scotia Prince Edward Island BOMBARDIER INC ...

Page 17: ...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 jet boat TYPICAL CHALLENGER 1800 SHOWN 1 Registration number location F04L5HL 1 lmo9802a bk lmo9802a fm5 Page 15 Monday September 8 1997 9 16 AM ...

Page 18: ...rs is not recommended Check throttle shifter controls and steering position before starting engines Directional control is lost when throttle or engines are off Do not splash others or jump waves or wakes with this jet boat Operator and passengers should always wear approved life vests and recommended clothing Do not operate if passengers are not properly seated and using handgrips or if visibilit...

Page 19: ...lons Use Bombardier Rotax oil when refilling Do not use ashless NMMA oils OIL ONLY F04L8NY 10 WARNING Gasoline vapors can explode Before starting engine operate blower for compartment bilge for gasoline vapors minutes and check engine 5 WARNING While fueling stop engine s Fuel tank may be pressurized Slowly turn cap when opening Keep watercraft level Do not overfill Use regular unleaded gasoline C...

Page 20: ...SPORTSTER 1800 SHOWN 1 Hull Identification Number H I N The jet boat model number can be found on RH side of operator position TYPICAL CHALLENGER 1800 SHOWN REFER TO ACTUAL LABEL ON BOAT 1 Model number F10L06Y 1 MAXIMUM CAPACITIES MADE IN U S A BOMBARDIER CORPORATION OF AMERICA XXXX U S COAST GUARD 4PERSONS OR 660 LBS 660 LBS PERSONS GEAR THIS BOAT COMPLIES WITH U S AND CANADIAN COAST GUARD SAFETY...

Page 21: ...ber E I N is located on the crankcase on PTO side SPORTSTER 1800 ENGINE 1 Engine Identification Number CHALLENGER 1800 ENGINE 1 Engine identification number F01D01Y 1 F01D87Y 1 lmo9802a bk lmo9802a fm5 Page 19 Monday September 8 1997 9 16 AM ...

Page 22: ...20 CONTROLS AND COMPONENTS LOCATION COCKPIT VIEW SPORTSTER 1800 F10L04L 10 32 48 33 1 5 6 13 14 15 14 16 9 8 12 11 7 4 3 2 lmo9802a bk lmo9802a fm5 Page 20 Monday September 8 1997 9 16 AM ...

Page 23: ...21 COCKPIT VIEW CHALLENGER 1800 F10L09L 10 5 11 12 4 3 7 8 9 6 13 14 15 14 2 48 1 lmo9802a fm5 Page 21 Monday September 22 1997 10 41 AM ...

Page 24: ... 1800 F10L05L 20 52 26 21 24 39 16 25 31 37 18 22 18 36 34 50 38 36 31 35 36 24 31 36 24 18 36 36 18 F10L08L 23 20 36 38 21 39 18 24 21 24 25 37 18 36 36 18 24 21 28 32 33 29 18 36 34 26 35 22 49 31 lmo9802a fm5 Page 22 Monday September 22 1997 1 35 PM ...

Page 25: ...23 TYPICAL SIDE VIEW SPORTSTER 1800 AND CHALLENGER 1800 REAR VIEW SPORTSTER 1800 F04L5HN 43 30 40 41 27 35 F10L06L 42 44 45 41 46 19 41 42 43 47 43 lmo9802a fm5 Page 23 Monday September 22 1997 11 13 AM ...

Page 26: ...24 REAR VIEW CHALLENGER 1800 F04L9CL 42 45 19 31 46 42 45 43 41 44 17 44 41 47 43 lmo9802a fm5 Page 24 Monday September 22 1997 10 48 AM ...

Page 27: ...uipped 24 Cup Holders 25 Right Front Storage Compartment 26 Deck Storage Compartment 27 Rear Storage Compartment 28 Glove Box if so equipped 29 Left Front Storage Compartment if so equipped 30 Jet Pump Water Intakes 31 Tow Hook 32 Radio 33 12 Volts Accessory Jack 34 Bow Light 35 Removable Stern Light 36 Mooring Cleats 37 Deck 38 Fuel Tank Cap 39 Deck Drain Hole 40 Oil Injection Tank Cap 41 Flushin...

Page 28: ...s delay it is necessary to apply a slight pressure of the safety lanyard on the DESS post Two short beeps should be heard which indicate the system is ready again to allow engine starting Monitoring System To assist you when using the boat a system monitors some components of the boat and sends audible signals through a beeper to inform you of a par ticular condition The following chart gives the ...

Page 29: ...increase the jet pump thrust and thus improving the steering control for low speed operation and when ap proaching leaving a dock Refer to OP ERATING INSTRUCTIONS for more details 3 Throttle Levers They control the speed of the engines and therefore the speed of the jet boat When pushed forward the jet boat accelerates When fully pulled back engines return to idle speed and the jet boat is gradual...

Page 30: ...e fully pulled back to idle speed Shifter must be in neutral position to allow engine starting NOTE 4 short beeps will signal that shifter is not in neutral with the safety lanyard on the DESS post while press ing one of the start stop button There after 1 short beep will confirm the neutral position while shifting SHIFT LEVER CHALLENGER 1800 SHOWN 1 Throttle levers must be fully pulled back idle ...

Page 31: ... one engine at a time can be started 1 Start when engine is NOT running Stopping Pressing buttons when engines are running will stop the engines 1 STOP when engine IS running WARNING Only use reverse at slow speed and for the shortest time possi ble Always ensure the path be hind is clear of obstacles swim mers and children playing in shallow water If stopping the en gines is required pull safety ...

Page 32: ...2 For starboard engine 7 Navigation Light Switch A 3 position NAV OFF ANC push type switch NOTE The navigation lights may be operated without the safety lanyard on DESS post Press switch to first position to turn on the stern light anchorage position Press switch to second position to turn on the bow and stern lights Press to OFF position to turn off navi gation lights Navigation lights should alw...

Page 33: ... 9 Bilge Air Blower Switch A 2 position push type switch When ON it ventilates the engine compart ment Press switch to ON position to turn on the blower The blower must be started 5 minutes prior to starting the engines Press the switch to OFF to turn off the bilge blower Using the bilge blower for a prolonged time when the engines are not run ning will discharge the battery 10 Horn Switch A 2 pos...

Page 34: ...nalog gauge continuously indicates the amount of fuel in fuel tank when en gines are running The gauge is illuminated whenever the navigation lights are used NOTE The fuel level can also be veri fied without having engines running With the safety lanyard removed from the DESS post push a start stop but ton the gauge will be activated for ap proximately 30 seconds Low Injection Oil Level Pilot Lamp...

Page 35: ...board engine tachometer CHALLENGER 1800 1 Port engine tachometer 2 Starboard engine tachometer 15 Speedometer The analog speedometer indicates the speed of the jet boat in miles per hour MPH and kilometers per hour km h The gauge is illuminated whenever the navigation lights are used A speed sensor mounted on the left ride shoe sends the signal to the speed ometer SPORTSTER 1800 1 Speedometer F04G...

Page 36: ...ug while on the trailer Tilt the jet boat slightly to the rear so that the water can completely flow out of the bilge It is suggested to drain bilge when trailer is on a ramp 1 Drain plug 2 Loosen 3 Tighten 18 Grab Handles Provides a handhold for the passen gers F04H3DZ 1 F10L0EY F10L0FY CAUTION Remove jet boat from water prior unscrewing the drain plug WARNING Always make sure bilge drain plug is...

Page 37: ... Challenger 1800 Both front seats are swivels and ad justable fore and aft For the fore and aft adjustment lift le ver to unlock seat Move seat at the desired position Release lever after adjustment is completed 1 Fore and aft control lever To unlock swivel pull lever toward front in a rotating movement Turn seat at the desired position The seat can be locked in steps of 45 To lock swivel release ...

Page 38: ... to expose storage com partment Pay attention to the retain ing strap when laying down seat 1 Lift seat When reinstalling seat slide it so that its base goes under the two stoppers then push down seat to properly latch 1 Slide seat under stoppers WARNING Always ensure swivel is locked before riding Seat must also face steering wheel WARNING No passenger should use this seat except at low speed in ...

Page 39: ...e Seat Backrest Pull backrest a small amount to un latch then gently rotate clockwise Step Pull a small amount to unlatch Step Gently rotate clockwise When finished rotate backrest to cov er storage compartment opening then push backrest to properly latch All Models 23 Sun Deck if so equipped A convenient space to rest or take some sun while anchored F10L0JY F10L1IY 1 WARNING No passenger should u...

Page 40: ...extinguisher The fire extinguisher sold separately should not be loose in the storage compartment A second holder contains the Opera tor s Guide and can be used to carry personal articles The Operator s Guide should be kept in a waterproof bag and remain with the jet boat at all times Step Turn covers counterclockwise to unlock Step Lift 1 Extinguisher holder The basket can be pulled out to have a...

Page 41: ...ooler The storage area below the cooler can be used to carry large personal arti cles Ideal location for sleeping bags blanket duffle bags etc Reinstall cooler as shown TYPICAL COOLER INSTALLATION All Models Push down the storage compartment cover to close NOTE Always relatch and lock stor age compartment cover using the key F04L5TY 1 WARNING Never leave any heavy or loose breakable objects in the...

Page 42: ...ing and open cover gent ly until stopped by retaining spring When completely opened the cover remains in that position on calm water To close gently push on the side of the spring to release it and lower the cover 1 Gently push here to release the spring Models with a Retaining Rod Fully open cover until stopped by the retaining rod Pull back cover until the slider locks the cover open F04L0QZ 1 1...

Page 43: ...Models Always relock latch after closing by lowering the latch ring 27 Rear Storage Compartment Convenient rear storage location to be used to carry large personal articles Ideal location for spare Personal Flota tion Device PFD towels lunch etc Sportster 1800 Model Unhook retaining straps of Bimini top from body before opening rear stor age compartment F04L95Y 1 1 2 1 2 WARNING Never operate the ...

Page 44: ...y when the right front storage compartment cover is locked The storage tray is removable to give access to the engine compartment Grab the handle and lift in a rearward movement until opposite holders re lease CHALLENGER 1800 SHOWN When reinstalling storage tray ensure to properly locate it just below hold ers gently lower tray then push it downward to lock F10L0TY 1 F10L0UY 1 F04L5VY 1 WARNING Wh...

Page 45: ... lease button using the provided key and press button NOTE Always relatch and lock glove box 29 Left Front Storage Compartment if so equipped Challenger 1800 A convenient watertight lockable stor age compartment with a removable cooler The cooler is the ideal location to keep a lunch or beverages WARNING Never operate the boat with the rear storage compartment cover open CAUTION If the rear storag...

Page 46: ...a hook a closed end or an open end to be attached 32 Radio Refer to its guide for a complete expla nation of the features and controls Using the radio for a prolonged time without engines running may dis charge the battery Sportster 1800 Lift protection flap and push in when completely lifted Close protection flap when radio is not in use to protect against weather in clemency Challenger 1800 Loca...

Page 47: ...1800 Close protection cap when jack is not in use to protect against weather in clemency All Models 34 Bow Light Mandatory red green light See Navi gation Light Switch as mentioned earlier in this section 35 Removable Stern Light Mandatory stern white light It is recommended to keep it in rear storage compartment at all times ex cept when needed To remove from storage cover pull it out Snap in pla...

Page 48: ...rn 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 TYPICAL 1 Lift 2 Align screw in groove 3 Push downward 4 Turn to lock WARNING The jet boat is not equipped with headlights or spotlights 1 2 3 4 F04L0LY lmo9802a bk lmo9802a fm5 Page 46 Monday September 8 1997 9 16 AM ...

Page 49: ...DER REAR STORAGE COMPARTMENT COVER 1 Oil injection tank cap Unscrew cap by turning counterclock wise and when finished firmly tighten by turning clockwise Close cover Re fer to FUEL AND LUBRICATION for in jection oil specification 41 Flushing Connectors Refer to POST OPERATION CARE sec tion for proper use NOTE Each engine is provided with a flushing connector Port connector is for port engine and ...

Page 50: ...sed for mooring tow ing and as a tie down point during transportation 44 Jet Pump Nozzles They are turned from side to side via operator input from the steering wheel This provides jet boat direc tional control when engines are run ning 45 Reverse Gates Moves from upward to downward po sition to get Forward Neutral Re verse and inversely These positions are obtained by moving shift lever 46 Retrac...

Page 51: ...uld clean the water intake grates from any weeds Completely push le ver when finished Refer to SPECIAL PROCEDURE section for details Before launching or loading the boat from the trailer ensure that the weed less system lever is completely pushed in CAUTION Do not leave ladder hanging when operating the boat Always lock the ladder using the latch F04L61Y 1 CAUTION Loading launching the boat on fro...

Page 52: ...50 1 Turn lever counterclockwise then pull 2 Water intake grate lowered to release weeds F04J1JL 1 2 lmo9802a bk lmo9802a fm5 Page 50 Monday September 8 1997 9 16 AM ...

Page 53: ...51 1 Push lever 2 Position of water intake grate while riding on water and loading launching on from trailer F04J1KL 1 2 lmo9802a bk lmo9802a fm5 Page 51 Monday September 8 1997 9 16 AM ...

Page 54: ...the Bimini top to hit the mirror while pivoting Pivot Bimini top forward and lay down 1 Bimini top here Detach struts from structural tube sup port by pulling the ring of the locking pin WARNING Never use a lit match or open flame close to vent Follow the Fueling Procedure instructions in the FUEL AND LUBRICATION sec tion WARNING Avoid body contact with Bimi ni top Operate this craft at a very low...

Page 55: ... to body Fully push lock ing pin until its small ball passes through the bracket hole 1 Strut 2 Ball of locking pin out of bracket Hook the front straps to the body Ad just if necessary to obtain a slight ten sion in the strap Readjust mirror properly F10L10Y 1 2 3 F10L0VY F10L0YY 1 F10L11Y 1 2 lmo9802a bk lmo9802a fm5 Page 53 Monday September 8 1997 9 16 AM ...

Page 56: ...e top tube 1 Retain top tube 2 Pull the second tube toward the top tube Hold both tubes together and lower over the other ones 1 Hold both tubes together and lower 1 Lower both tubes together over the other ones Secure struts to structural tubes Lay down Bimini top cover on rear storage compartment cover approxi mately at the location where the Bimi ni top will rest Position the cover so that the ...

Page 57: ...nhook retaining straps Remove fasteners at pivot point 1 Remove fastener at pivot point 2 Strut below structural tubes With the assistance of someone care fully lift Bimini top and withdraw to ward rear Reinstall fasteners to boat to prevent losing them Installation is the reverse procedure however pay attention to position Bimi ni top so that struts are below struc tural tubes 51 Ski Post Pull up...

Page 58: ...rt the engines TYPICAL 1 Battery 2 Main disconnect switch It is recommended to set in the OFF position whenever performing mainte nance in the engine compartment on the electrical system for transporta tion and for short term storage on the trailer CAUTION Never use the ski post to tow oth er boats WARNING Use caution with skier in tow as tow rope may backlash into cock pit when released Never per...

Page 59: ...s check oil injection res ervoir level when refueling The use of good quality fuel is neces sary A well known fuel brand is highly recommended Recommended Oil Use only BOMBARDIER ROTAX injec tion oil The oil is available from authorized dealers It is a blend of specially se lected base oils and additives which provides outstanding lubrication en gine cleanliness and minimum spark plug fouling NOTE...

Page 60: ...ervoir Do not overfill Wipe off any oil spillage NOTE Always carry a spare 1 liter of BOMBARDIER ROTAX injection oil CAUTION Always maintain a sufficient amount of injection oil in the oil reservoir Check and refill every time you refuel Do not overfill If the engines run out of oil severe engine damage will occur If the oil reservoir is allowed to almost empty air can enter into the sys tem and i...

Page 61: ...uel tank pro ceed as follows Fill fuel tank with approximately 50 li ters 12 gal of gasoline then add the required quantity of injection oil in the fuel tank Continue to fill until tank is full Do not overfill NOTE It is important to proceed in this order to allow a proper mixing of the oil in the gasoline If oil is added first in an empty fuel tank fuel lines will be filled up with injection oil ...

Page 62: ... Steering system and low speed steering control system Steering cable adjustment if required Shifter cable adjustment if required Ensure that throttle levers keep the selected position Adjust levers friction as necessary Hose condition and fasteners Bilge pump and bilge blower DESS system and start stop buttons operation Monitoring beeper Electrical connections starter battery etc Lighting system ...

Page 63: ...ghtness of cables and retaining straps Main disconnect switch Ensure it is in the ON position Navigation lights Check operation Fuel oil reservoirs Refill Engine compartment Verify fuel oil system components Fire extinguisher Inspect condition mounting Steering Check operation Throttle shifter system Check operation Weedless system Ensure it is not activated Bilge blower and bilge pump Check opera...

Page 64: ...teering operation for free movement When the steering is centered the jet pump nozzles should be in the straight ahead position Ensure the jet pump nozzles pivot easily while steering is turned Throttle System Check throttle levers once for free and smooth operation NOTE Do not activate throttle levers unnecessarily Carburetors are equip ped with fuel accelerator pumps This these pumps deliver fue...

Page 65: ...in use or properly secured struts and straps if in use CAUTION Operating the jet boat with the wa ter intake grate in lower position will cause damage to the weed less system WARNING If engine does not shut off when pushing engine start stop button or by disconnecting the safety lanyard stop the engine by apply ing the choke Do not operate the jet boat further see an authorized dealer Only start t...

Page 66: ...ec tion Turning Turning the steering pivots the jet pump nozzles which control the jet boat direction Turning the steering clockwise will turn the jet boat to the right and inversely Above idle speed the throttles must be applied to turn the jet boat WARNING Always perform PRE OPERATION CHECKS before operating the jet boat Become thoroughly famil iar with all controls and the func tion of each Sho...

Page 67: ...d of its rotation the engine speed will be slightly accel erated to increase the jet pump thrust and thus improving the steering con trol for low speed navigation or when approaching leaving a dock For dock ing tips refer to Stopping Docking section below NOTE On twin engine boats each engine must be running so that the low speed control properly works Boarding from a Dock or in Shallow Water As w...

Page 68: ...le position First Engine Fully pull one choke lever and depress the starting button just below it NOTE Either engine can be started first TYPICAL CHALLENGER 1800 SHOWN Step Fully pull and hold choke lever Step Press the start stop button Immediately after engine is started release starting button and release choke lever half way NOTE Do not push the throttle lever forward while starting a cold eng...

Page 69: ...path ahead of the jet boat is clear of other craft or obsta cles Avoid riding close to swimmers Check local boating laws for safe oper ational areas Boarding in Deep Water Swim to the rear of the jet boat Unlatch and slide the ladder toward rear Use both steps to reach the grab han dle and pull yourself upward to place one of your foot on the swim platform WARNING In shallow water shells sand pebb...

Page 70: ...g the Reverse The jet boat behave differently when using the reverse The steering re sponse is the opposite of forward op eration So turning the steering clock wise will turn the jet boat to the left and inversely At first outing carefully practice this maneuver away from anything you might collide Low Speed Steering Control System Reduce speed reduce RPM to IDLE and use the low speed steering con...

Page 71: ...To keep jet boat directional control the engines should be running until the jet boat is stopped assuming at least 90 cm 3 ft of water is present underneath the hull To shut off the engines completely pull back throttle levers then remove safety lanyard or press the engine start stop buttons Always remove safety lanyard from jet boat WARNING Become familiar with this feature during your first ride...

Page 72: ...lize 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 en gine exhaust manifold tuned pipe and or hoses Engine lubrication and flushing should be performed when the jet boat is not expected to be used further the same day or when the jet boat is stored for any extended time Proceed as follows for both e...

Page 73: ... compartment area Use of the Upper Flushing Connectors 1 Flushing connector with its cap When using the upper connector it is necessary to prevent water going out directly by the connector on the tran som Install a hose pincher not sup plied P N 529 030 400 on the hose between the transom and the T fitting as shown SPORTSTER 1800 1 T fitting 2 Hose pincher right after the T fitting F10L06Z 2 1 F04...

Page 74: ...ut of fuel while lubricating by turning the fuel valve to OFF position WARNING Do not touch any electrical parts or jet pump area when engine is running CAUTION Never flush a hot engine Always start the engine before opening the water tap Otherwise water will back flow through the tuned pipe into the engine and may cause damage to internal parts Open water tap immediately af ter engine is started ...

Page 75: ...t spark plug ca bles to spark plugs 17 Wipe up any residual water from the engine NOTE Repeat the same procedure for the other engine Anticorrosion Treatment To prevent corrosion spray a corro sion inhibitor salt water resistant such as BOMBARDIER LUBE lubri cant or equivalent over metallic com ponents in engine compartment NOTE Engine fogging should be done with BOMBARDIER LUBE lubricant whenever...

Page 76: ...ll lower the water in take grates Wait a while to allow weeds or other debris to escape from grates Thereafter fully push whee dles system lever and start engines It may be necessary to repeat the proce dure In severe conditions if the above meth od does not work the following can be performed With engines running put shift le ver in reverse position and vary throttles quickly several times Retry ...

Page 77: ... engine running the non running engine should have its water supply hose plugged This will prevent the cooling system from filling which may lead to water being injected into and filling the ex haust system Without the engine run ning there isn t any exhaust pressure to carry the water out the exhaust out let Snugly install the hose pincher on the hose as shown in the following illus tration CAUTI...

Page 78: ... care must be taken See above in Towing the Boat in Water for com plete procedure Low Charge Battery Condition See your dealer to have it charged or replaced F10E01Y 1 F04E0QY 1 CAUTION When finished towing the boat you must remove the hose pinch er before operating it Failure to do so will result in damage to the engine WARNING Do not charge or boost a battery in the boat lmo9802a fm5 Page 76 Mon...

Page 79: ...R 1800 1 Loosen wing nuts CHALLENGER 1800 1 Flywheel guard 2 Loosen wing nuts WARNING Only perform procedures as de tailed in this guide It is recom mended that the assistance of an authorized dealer be periodically obtained on other components systems not covered in this guide Unless otherwise specified en gines must not be running and the main disconnect switch must be turned OFF for all mainten...

Page 80: ...ery posts and all exposed cable connectors including stern light con nectors on mat and boat Additional Lubrication BOMBARDIER LUBE lubricant will help to prevent corrosion and keep proper operation of moving mecha nisms Lubrication of the following items should be performed every 50 hours in fresh water use but every 10 hours in salt water use Choke Levers Fully pull choke levers and lubricate th...

Page 81: ... grease TYPICAL Reverse Gates Lubricate pivoting points and mecha nism of each side Weedless System From underneath of hull lubricate wa ter intake grates at pivoting points and cable rods Rear Storage Compartment Cover Cylinders Lubricate rod of cylinders Periodic Inspection Routine maintenance is necessary for all mechanized products A periodic in spection contributes to the products life span T...

Page 82: ...ent DEALER Fuel filter and oil filter inspection DEALER Oil filter and fuel filter replacement DEALER Engine head screws torque DEALER Steering system and low speed steering control system DEALER Throttle and shifter systems DEALER Fastener tightening flame arrester carburetors engine exhaust system etc DEALER Muffler battery and reservoir fastening devices DEALER Fuel oil line check valve and hos...

Page 83: ...ect mixture supplied to the engine These critical adjustments must be performed by an authorized dealer once a year or more often if necessary Fuel and Oil Filters These filters must be replaced by an authorized dealer annually Fuel sys tem pressurization should be conduct ed at the same time Steering Jet Pump Nozzle Adjustment When the steering is aimed in straight ahead position the jet pump noz...

Page 84: ...nt NOTE There are spare fuses in rub ber holders attached to the top of MPEM TYPICAL 1 Battery 2 Main fuses If an accessory engine or gauge is not working check its fuse condition Fuses for the accessories the electri cal system of the engine s and the gauge s are mounted on the Multi Purpose Electronic Module MPEM which is located in the engine com partment 1 MPEM 2 Spare fuse holders 3 Top fuse ...

Page 85: ... these tabs as a fuse puller 1 Slide cover tabs each side of fuse then pull fuse out FUSEIDENTIFICATIONINTOPFUSE BLOCK SPORTSTER 1800 1 MPEM supply 2 Gauges supply 3 Bilge pump FUSE IDENTIFICATION IN TOP FUSE BLOCK CHALLENGER 1800 1 MPEM supply 2 Gauges supply 3 Ignition system 4 Bilge pump F04H62Y 1 2 F04H63Y 1 F04H64Y 1 2 3 F10H02Y 1 2 3 4 lmo9802a bk lmo9802a fm5 Page 83 Monday September 8 1997...

Page 86: ...n fuse block then firmly push until you hear a snap ping sound for each locking tab Charging System If the battery is regularly discharged check this fuse condition Fuse s for the charging system s are located in the small electrical box es in the engine compartment On twin engine model the port side box is for the port engine and the starboard side box is for the starboard engine Pull tabs outsid...

Page 87: ...ioned Bilge Air Blower Verify bilge air blower for proper oper ation It is located in starboard ventila tion duct beneath rear storage com partment cover 1 Blower Navigation Light Bulb Replacement Bow Light 1 Gently pry here with a screwdriver F04H67Y 1 F04H68Y 1 2 2 1 1 2 F04H69Y 1 WARNING If bilge blower does not operate properly immediately refer to an authorized dealer before operat ing the je...

Page 88: ...ill compress the terminal plate against the bulb at reinstallation Stern Light Unscrew lens counterclockwise and pull it out 1 Unscrew then pull Pull bulb to remove it 1 Pull bulb out Apply dielectric grease on new bulb contact surface The assembly is the reverse of remov al procedure Bimini Top if so equipped Verify tightness of fasteners and con dition of straps Tighten fasteners as necessary Re...

Page 89: ... electrolyte deposits and mildew Occasionally wash the body with hot water and soap only use mild deter gent Remove any marine organisms from engine and or hull Apply non abrasive wax 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 lucite polycarbonate and simi lar materials Stains may be removed fr...

Page 90: ...oat particularly before driving on dirt roads Loading Launching Before launching the boat ensure the bilge plug is fully screwed and the main disconnect switch is turned ON When finished with loading the boat on trailer it is suggested to turn the main disconnect switch to OFF This will allow the water intake grates to be in upper position eliminating the possibility to come in contact with the tr...

Page 91: ...down hook is passed through trailer bracket hole as shown The hook open end must be toward ground so that if it would loosen it would remain hooked on trailer bracket TYPICAL 1 Hook open end must be positioned toward ground Bimini Top if so equipped Always close Bimini top and hook re taining straps to boat for transporta tion F04J2ZY 2 1 WARNING Observe trailering safety precau tions F04L12Y 1 ce...

Page 92: ...it and that it is not obstructed so that water can exit the engine Clean hose and fitting as necessary Refer to POST OPERATION CARE SPORTSTER 1800 1 Drain tube must be clean CHALLENGER 1800 1 Drain tube must be clean CAUTION Do not run the engines during the storage period CAUTION Water in engine drain tube must be free to flow out otherwise wa ter could be trapped in engine Should water freeze in...

Page 93: ...ive shaft boot CAUTION Fuel stabilizer should be added prior to engine lubrication to en sure carburetor protection against varnish deposit WARNING Fuel is flammable and explosive under certain conditions Always work in a well ventilated area Do not smoke or allow open flames or sparks in the vicinity Always wipe off any fuel spillage from the jet boat Always turn the fuel valves to OFF position w...

Page 94: ...eze NOTE When available it is recom mended to use biodegradable anti freeze compatible with internal com bustion aluminum engines This will contribute to protect the environment NOTE The engines will not have to run during this operation but should have been run before to exhaust wa ter from cooling system components Some hoses have to be plugged to prevent draining before filling cooling system j...

Page 95: ...injection hose going to tuned pipe engine drain tube coming from exhaust manifold before T fitting hose right after T fitting hose on cylinder head F04E0YL 1 lmo9802a bk lmo9802a fm5 Page 93 Monday September 8 1997 9 16 AM ...

Page 96: ...uid flowing in the muffler immediately after starting pouring an tifreeze it indicates that antifreeze is bypassing the engine tuned pipe wa ter jackets To correct this firmly re tighten hose pinchers Unscrew cap from flushing fitting on the edge of engine compartment and insert a funnel into flushing fitting Pour about 2 liters 1 2 gal of anti freeze solution through the funnel Let the antifreeze...

Page 97: ...pincher hose at engine head and continue to pour approximately 200 mL 7 oz This will allow antifreeze to flow through water regulator valve toward muffler to protect them 1 Remove hose pincher All Models When finished remove all remaining hose pinchers Most of the antifreeze will drain out from flushing fitting and jet pump noz zle when removing hose pinchers Use a suitable container to recover it...

Page 98: ...orage disconnect the gas shocks from the cover to prevent full opening Re move storage tray Place it on deck This will avoid engine compartment condensation and possible corrosion For the storage period it is necessary to lift the bow up and safely block in this position so drainage can take place Ensure the drain plug is un screwed Pre Season Preparation Use the following chart Since technical sk...

Page 99: ...ction DEALER Fuel filter replacement DEALER Fuel line condition DEALER Filler neck fuel tank and fuel cap condition DEALER Check valves fasteners fuel system pressurization DEALER Choke cable inspection adjustment DEALER Oil injection pump adjustment and bleeding DEALER Engine ignition timing DEALER Carburetor adjustment DEALER Steering system and low speed steering control system inspection DEALE...

Page 100: ...ses Bad connection between safety lanyard cap and DESS post Remove and reinstall the safety lanyard on the DESS post Two short beeps should be heard which indicates the system is ready again to allow engine starting Wrong safety lanyard Use the safety lanyard that has been programmed for the boat If it does not work refer to an authorized dealer Dried salt water or oil in safety lanyard cap Clean ...

Page 101: ...f choke Use only with cold engine Replace spark plugs Engine Misfires Runs Irregularly OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark Fouled worn spark plugs Replace Faulty RPM limiter Refer to an authorized dealer Too much oil supplied to engine Improper oil pump adjustment refer to an authorized dealer Lean fuel mixture Fuel Level too low stale or water contaminated Siphon and or refill Fuel...

Page 102: ...Power OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark incorrect fuel mixture Refer to ENGINE MISFIRES Water in fuel or injection oil Siphon and replace Overheated engine See ENGINE OVERHEATS Jet Boat can not Reach Top Speed OTHER OBSERVATION POSSIBLE CAUSE REMEDY Jet pump water intakes clogged Clean Damaged impellers Replace Refer to an authorized dealer Abnormal Noise from Propulsion System OT...

Page 103: ...Magneto generator output 160 W 6000 RPM 180 W 6000 RPM Ignition system type CDI Capacitor Discharge Ignition breakerless DC CDI Direct Current Capacitor Discharge Ignition breakerless Spark plug Make and type NGK BR8ES resistor type Gap 0 5 0 6 mm 020 024 in Starting system Electric starter Battery Not supplied Fuses Main 20 A 3 20 A 3 MPEM supply 5 A 1 5 A 2 Charging system 15 A 2 15 A 2 Bilge ai...

Page 104: ...rive Impeller shaft reservoir oil type Sea Doo Synthetic polyolester 75W90 GL5 gear oil Pivoting angle of direction nozzle 26 Minimum required water level for jet pumps 90 cm 3 ft DIMENSIONS Overall length 546 cm 215 in Overall length on trailer 617 cm 243 in Beam 229 cm 90 in Draft 27 cm 10 5 in Dead rise 19 5 Overall height 135 cm 53 in Overall height on trailer 178 cm 70 in Weight dry 850 kg 18...

Page 105: ... 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 cm cm cm m g kg N N m N m lbf i...

Page 106: ...CATION NUMBER H I N ________________________________ ENGINES IDENTIFICATION NUMBER E I N _________________________________ IDENTIFICATION NUMBER E I N _________________________________ 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 lmo9802a bk lmo9802a fm5 Page 104 Monday September 8 1997 9 16 AM ...

Page 107: ...105 NOTES lmo9802a bk lmo9802a fm5 Page 105 Monday September 8 1997 9 16 AM ...

Page 108: ...106 NOTES lmo9802a bk lmo9802a fm5 Page 106 Monday September 8 1997 9 16 AM ...

Page 109: ...___________________________ CITY STATE PROVINCE ZIP POSTAL CODE ______________________________________________ COUNTRY NEW ADDRESS ______________________________________________ NAME ______________________________________________ NO STREET APT ______________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE ______________________________________________ COUNTRY STOLEN UNITS In th...

Page 110: ...BOMBARDIER INC SEA DOO WARRANTY VALCOURT QUEBEC CANADA J0E 2L0 STAMP lmo9802a bk lmo9802b fm5 Page 108 Monday September 8 1997 9 16 AM ...

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