Sea doo 180 Challenger 2008 2009 Workshop Service Manual
FILE DETAILS:
- LANGUAGE:ENGLISH
- PAGES:780
- FILE TYPE:PDF
- DOWNLOADABLE:YES
DESCRIPTION:
- This manual has been prepared as a guide to correctly service and repair 2008 SEA-DOO® watercraft as describe in the model list in the INTRODUCTION. This edition was primarily published to be used by watercraft mechanical technicians who are already familiar with all service procedures re lating to BRP made watercraft.
- Mechanical technicians should attend training courses given by BRPTI. Please note that the instructions will apply only if proper hand tools and special service tools are used. This Shop Manual uses technical terms which may be slightly different from the ones used in the PARTS CATALOG.
- It is understood that this manual may be translated into another language. In the event of any discrepancy, the Engl ish version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. SER~ VICE and WARRANTY BULLETINS may be published to Jpdate the content of this manual.
- Make sure to read and understand these. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts.
- The use of BRP parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. The engines and the corresponding components identifed in this document should not be utilized on product(s) other than those mentioned in this document
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TABLE OF CONTENTS:
Sea doo 180 Challenger 2008 2009 Workshop Service Manual
INTRODUCTION IX
GENERAL INFORMATION JX
VEHICLE INFORMATION X
WORKING ON WATERCRAFT X
ENGINE EMISSIONS INFORMATION XI
TIGHTENING TORQUE XII
SELF-LOCKING FASTEl\IERS PROCEDURE XIII
LOCTITE® APPLICATION PROCEDURE XIII
MANUAL INFORMATION XVI
01 MAINTENANCE
01 – MAINTENANCE CHART 1
02 – PRESEASON PREPARATION 3
03 – STORAGE PROCEDURE 5
PROCEDURES 5
PROPULSION SYSTEM 5
FUEL SYSTEM 5
ENGINE 6
ELECTRICAL SYSTEM 7
VEHICLE 7
04 – SPECIAL PROCEDURES 9
TOWING THE WATERCRAFT IN WATER 9
SUBMERGED WATERCRAFT 9
WATER-FLOODED ENGINE 9
CAPSIZED WATERCRAFT 12
02 TROUBLESHOOTING
01 – TECHNICAL GUIDELINES 13
ENGINE 13
ELECTRICAL SYSTEM 19
PROPULSION 20
STEERING SYSTEM 20
02 – DIAGNOSTIC FLOW CHART 23
FUEL SYSTEM 23
03 ENGINE
01 – ENGINE REMOVAL/INSTALLATION 25
GENERAL 25
PROCEDURES 25
ENGINE 25
02 – AIR INTAKE SYSTEM 33
GENERAL 35
PROCEDURES 35
AIR INTAKE SILENCER 35
03 – INTAKE MANIFOLD/INTERCOOLER 37
GENERAL 41
PROCEDURES 41
INTAKE MANIFOLD 41
INTERCOOLER 46
04 – INTERCOOLER (255 ENGINE) 49
GENERAL 51
MAINTENANCE 51
PROCEDURES 51
INTERCOOLER 51
TABLE OF CONTENTS
II
INTERCOOLER SUPPORT 54
05 – SUPERCHARGER 55
GENERAL 57
INSPECTION 57
SUPERCHARGER INLET CLEANLI NESS 57
SUPERCHARGER CLUTCH SLIPPING MOMENT (ON ENGINE) 58
SUPERCHARGER CLUTCH SLI PPING MOMENT (BENCH TEST) 59
PROCEDURES 60
SUPERCHARGER 60
06 – EXHAUST SYSTEM 71
EXHAUST COOLING SYSTEM 73
GENERAL 75
SYSTEM DESCRIPTION 75
MAINTENANCE 76
EXHAUST SYSTEM FLUSH ING 76
PROCEDURES 77
MUFFLER 77
EXHAUST PIPE 80
EXHAUST MANIFOLD 81
RESONATOR 83
EXHAUST OUTLET 85
EXHAUST GAS TEMPERATURE SENSOR (EGTSJ 85
07 – PTO HOUSING/MAGNETO 87
GENERAL 89
PROCEDURES 89
PTO HOUSING 89
PTO SEAL 95
PTO COUPLING 95
STARTER DRIVE BEARING 96
STATOR 97
ROTOR AND TRIGG ER WHEEL 100
RING GEAR 101
STARTE R DRIVE 102
08- LUBRICATION SYSTEM 105
GENERAL 109
MAINTENANCE 109
ENGINE OIL 109
OIL FILTER 111
INSPECTION 112
ENGINE OIL PRESSURE 112
PROCEDURES 113
PTO OIL STRAINER 113
SUCTION PUMP OIL STRAINER 114
ENGINE OIL PRESSURE REGULATOR 116
OIL PRESSURE PUMP 117
OIL SUCTION PUMP 120
OIL SPRAY JET 123
OIL SEPARATOR COVER 124
TOPS VALVE 125
OIL COOLER 126
09 – COOLING SYSTEM , 129
GENERAL 134
CIRCUIT 134
TECHNICAL SPECIFICATIONS 134
INSPECTION 134
PRESSURE CAP 134
TABLE OF CONTENTS
HOSES AND CLAMPS 134
COOLING SYSTEM LEAK TEST 135
MAINTENANCE 135
COOLANT REPLACEMENT 135
PROCEDURES 137
CLAMPS 137
WATER PUMP HOUSING 138
WATER PUMP IMPEL L E~ 139
THERMOSTAT 140
ROTARY SEAL 140
10 – CYLINDER HEAD 143
GENERAL 145
PROCEDURES 145
EXHAUST MANIFOLD 145
CYLINDER HEAD COVER 146
SPARK PLUG TUBES 146
ROCKER ARMS 147
CAMSHAFT TIMING GEAR 149
CYLINDER HEAD 151
CAMSHAFT 152
VALVE SPRINGS 153
VALVES 1 55
VALVE GUIDES 158
11 – CYLINDER BLOCK 161
GENERAL 164
PROCEDURES 164
TIMING CHAIN 164
CHAIN TENSIONER 164
PISTONS/CONNECTING RODS 165
PISTON RINGS 170
CRANKSHAFT 171
BALANCER SHAFT 175
CYLINDER BLOCK 178
04 ENGINE MANAGEMENT SYSTEM
01 – OVERVIEW 183
SYSTEM DESCRIPTION 185
CONTROLLER AREA NETWORK (CAN) 185
ENGINE CONTROL MODULE (ECM) 185
POWER DISTRIBUTION 186
02- COMMUNICATION TOOLS/B U D S SOFTWARE 189
COMMUNICATION TOOLS 189
MPI 189
MPl-2 191
B U D S SOFTWA RE 194
03 – MONITORING SYSTEM/FAULT CODES 197
MONITORING SYSTEM 197
FAULT CODES 199
SPECIFIC FAULT CODES 199
FAULT CODE TABLE 201
05 FUEL SYSTEM
01 – ELECTRONIC FUEL INJECTION (EFI) 215
GENERAL 215
SYSTEM DESCRIPTION 215
DEUTSCH CONNECTOR INFORMATION 218
Ill
TABLE OF CONTENTS
KOSTAL CONNECTOR (ECM) INFORMATION 220
GENERAL RECOMMENDATIONS 224
BASIC ADJUSTIVIENTS 228
IDLE SPEED 228
CLOSED THROTTLE AND IDLE ACTUATOR RESET 228
IGNITION TIMING 229
REPAIR PROCEDURES 229
ENGINE CONTROL M ODULE IECM) 229
FUEL INJECTOR 232
THROTTLE BODY 235
THROTTLE POSITION SENSOR (TPS) 237
IDLE AIR CONTROL VALVE (IACV) 239
CRANKSHAFT POSITION SENSOR (CPS) 240
CAMSHAFT POSITION SENSOR (CAPS) 242
MANIFOLD AIR TEMPERATURE SENSOR (MATS) 244
COOLANT TEMPERATURE SENSOR (CTS) 245
MANIFOLD AIR PRESSURE SENSOR (MAPS) 246
EXHAUST GAS TEMPERATURE SENSOR IEGTS) 247
KNOCK SENSOR (KS) 248
OIL PRESSURE SENSOR (OPSl 249
TOPS SWITCH 250
02 – FUEL TANK/FUEL PUMP 255
GENERAL 257
SYSTEM DESCRIPTION 257
INSPECTION 260
FUEL TANK LEAK TEST 260
FUEL SYSTEM HIGH PRESSURE LEAK TEST 262
FUEL PUMP PRESSURE TEST 263
PROCEDURES 264
FUEL HOSES AND OETIKER CLAMPS 264
FUEL FILTER 265
FUEL TANK 265
FUEL PUMP 268
FUEL LEVEL SENSOR 272
06 ELECTRICAL SYSTEM
IV
01 – IGNITION SYSTEM 277
GENERAL 277
IGNITION SYSTEM DESCRIPTION 277
TROUBLESHOOTING 277
IGNITION SYSTEM TESTING 277
PROCEDURES 278
IGNITION COILS 278
SPARK PLUGS 282
02 – CHARGING SYSTEM 285
GENERAL 285
SYSTEM DESCRIPTION 285
PROCEDURES : 286
VOLTAGE REGULATOR/RECTIFIER 286
BATTERY 289
03 – STARTING SYSTEM 297
GENERAL •• 297
TROUBLESHOOTING 297
PROCEDURES 298
STARTER SOLENOID FUSE 298
ENGINE START/STOP SWITCH 298
TABLE OF CONTENTS
STARTER SOLENOID 301
STARTER 305
04- DIGITALLY ENCODED SECURITY SYSTEM (DESS) 309
GENERAL 309
PROCEDURES 310
DESS KEY 310
BEEPER 311
DESS POST 311
05 – GAUGE/FUSES 317
GENERAL 317
PROCEDURES 318
FUSES 318
MAIN RELAY , 321
INFORMATION CENTER 323
PROCEDURES 326
INFORMATION CENTER 326
FUEL LEVEL SENSOR 334
WATER TEMPERATURE SENSOR 337
COMPASS 338
SPEED SENSOR 339
DEPTH GAUGE 341
BEEPER 342
07 PROPULSION
01 – JET PUMP 347
GENERAL 350
INSPECTION 350
IMPELLER CONDITION
IMPELLER/WEAR RING CLEARANCE
LEAK TEST
PROCEDURES
SACRIFICIAL ANODE
VENTURI
JET PUMP HOUSING
IMPELLER COVER
IMPELLER
WEAR RING
IMPELLER SHAFT AND BEARING
02 – DRIVE SYSTEM
GENERAL
MAINTENANCE
CORROSION PROTECTION
PROCEDURES
DRIVE SHAFT 366
DRIVE SHAFT BOOT 373
CARBON RING 373
03 – REVERSE SYSTEM 375
GENERAL 377
PROCEDURES 377
REVERSE CABLE 377
REVERSE CABLE LEVER 378
SHIFT LEVER 380
REVERSE CABLE SUPPORT 380
SHIFT LEVER HOUSING 381
REVERSE GATE 381
PIVOT SUPPORT 382
TABLE OF CONTENTS
LINK ROD
PIVOT TRIANGLE
PIVOT ARM 383
04 – VARIABLE TRIM SYSTEM (VTS) 385
GENERAL 387
TEST 387
VTS SWITCH
VTS MOTOR
VTS CONTROL MODULE 387
PROCEDURES 388
VTS UNIT 388
VTS RING
08 STEERING SYSTEM
01 – STEERING 393
GENERAL 396
ADJUSTMENT 396
STEERING ALIGNMENT 396
PROCEDURES 397
NOZZLE
HANDLEBAR GRIP
MULTIFUNCTION SWITCH
THROTTLE LEVER
THROTTLE CABLE 401
STEERING COVER 404
STEERING PADDING 406
HANDLEBAR EXTENSION 407
HANDLEBAR 407
STEERING CABLE SUPPORT 409
STEER ING SUPPORT 410
STEERING STEM 411
STEERING SUPPORT BEA RING
HANDLEBAR SUPPORT
STEERING CABLE
02 – OFF-POWER ASSISTED STEERING (0 P A S )
GENERAL
PROCEDURES
PLASTIC ELBOW
T-FITTING 421
WATER HOSE 422
SIDE VANE 422
CYLINDER 423
TIE ROD 426
SEALED TUBE 426
CROSS SUPPORT PLATE 427
09 BODY/HULL
VI
01 – BODY 429
GENERA L 450
PROCEDURES 450
DECALS
GLOVE BOX
SEAT 452
SEAT LATCH 454
ENGINE COVER 455
STORAGE COMPARTMENT COVER 456
TABLE OF CONTENTS
STORAGE COMPARTMENT COVER HINGE 457
STORAGE COMPARTMENT COVER SHOCK 457
STORAGE COMPARTMENT COVER INNER SHELL 458
FRONT GRILLE (STORAGE COMPARTMENT COVER) 461
BASKET LATCH 462
WIND DEFLECTOR
ACCESS COVER
CONSOLE
M IRROR
BUMPER
WAKE PYLON (MOULDED)
WAKE PYLON (ALUMINUM)
CARPET
02- HULL
GENERAL
PROCEDURES
INLET GRATE 477
RIDING PLATE 478
JET PUMP SUPPORT 479
TH RU-HULL FITIING 481
FRONT INNER CONTAINER 481
SPONSON 482
SPONSON ADAPTER 482
DRAIN PLUG 482
BOARDING STEP 483
BOW EYELET
STERN EYELETS
GELCOAT
10 TECHNICAL SPECIFICATIONS
01 – 1503 ENGINE 1130 HP) 489
02 – 1503 ENGINE (155 HP} 495
03 – 1503 ENGINE (215 HP) 501
04 – 1503 ENGINE 1255 HP) 507
11 ELECTRICAL CONNECTORS/WIRING DIAGRAM
01 – ELECTRICAL CONNECTORS 513
PROCEDURES 515
DEUTSCH CONNECTOR
PACKARD CONNECTOR
KOSTAL CONNECTOR (ECM)
BATIE RY AND STARTER CAB LE TERMINALS
02 – WIRING DIAGRAM
WIRE COLOR CODES
WIRE DIGIT CODES
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
