PDF Workshop Service Manual Sea-Doo 180 Challenger 2008-2009 - 8 MB
This workshop service manual covers the 2008 and 2009 Sea-Doo 180 Challenger models.
It is the most comprehensive resource available for repair and maintenance, containing the same information used by certified technicians.
The manual includes detailed procedures for servicing the engine, jet pump, electrical systems, and hull.
It's the perfect guide for DIY enthusiasts and professional mechanics alike.
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--- Page 3 ---
INTRODUCTION
VEHICLE INFORMATION
Hull Identification Number (H.l.N.)
The hull identification number is composed of 12
digits:
YDV 12345 L 4 95
ivlodel veiir ·
Year of production
Month of production
..
.· . Serial number (a letter may also be used as a digit)
Manufacturer
It is located on footboard at the rear of watercraft.
1. Engine Identification Number (E./N)
WORKING ON WATERCRAFT
To work on watercraft, securely install it on a
stand. Thus, if access is needed to water inlet
area, it will be easy to slide underneath watercraft.
The lift kit (P/N 295 100 205) can be used to install
watercraft on a stand.
i:ist.O?A 1
TYPICAL
1. Hull Identification Number (H.l.N J
Engine Identification Number (E.l.N.)
The Engine Identification Number is located on
front end of the engine.
TYPICAL
1. Lift kit
2. Work stand
x
--- Page 4 ---
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
4-TEC MODELS
A: ADJUST FIRST 10 HOURS
C: CLEAN EVERY 25 HOURS OR 3 MONTHS
I: INSPECT EVERY 50 HOURS OR 6 MONTHS
L: LUBRICATE EVERY 100 HOURS OR 1 YEAR
R: REPLACE
PARTffASK
STEERING SYSTEM
Steering cable and connections
STEERING SYSTEM
Steering nozzle bushings
OFF-POWER ASSISTED STEERING
Off-power assisted steering {0.P.A.S.)
SYSTEM (0.PA.S.)
PROPULSION SYSTEM
Drive shaft I L11)
DRIVE SYSTEM
Carbon ring and rubber boot (drive shaft)
Reverse system. cable and connections REVERSE SYSTEM
VTS (Variable Trim System) {if so equipped) VARIABLE TRIM SYSTEM {VTS)
Drive shaft/impeller splines I. L JET PUMP and DRIVE SYSTEM
Impeller boot
Impeller shaft seal, sleeve and 0-ring
JET PUMP
Impeller and wear ring clearance I I
16)
Sacrificial anode
HULL/BODY
Ride plate and water intake grate
Drain plugs (inside bilge). check for obstructions
BODY/HULL
Hull
Ski/wakeboard post and fasteners
(1} In fresh water. perform for storage period or after 100 hours of use whichever comes first. In salt water use. lubricate drive shaft as
indicated to protect it from corrosion.
(2) Including intercooler on supercharged models.
{3) Daily flushing in salt water or foul water use.
{4) The supercharger requires replacement when the MAINTENANCE SUPERCHARGER message is displayed on the informa~ion center every
100 hours of operation or earlier depending on the riding style (speed. engine RPM's. water conditions) This is determined by the engine
management system. The supercharger will need to be replaced within 5 hours of the message display by an authorized Sea-doo dealer.
(5) llVIPORTANT: When use in salt water. the throttle body lubrication is highly recommended after every 1CI hours of use. Failure to
perform lubrication will result in damage to the throttle body
6) In salt water use.
2
--- Page 5 ---
CAUTION: Never clean fiberglass and plastic
parts with strong detergent, degreasing
agent, paint thinner, acetone, etc.
If the watercraft is to be stored outside,
cover it with an opaque tarpaulin to prevent
sun rays and grime from affecting the plastic
components, watercraft finish as well as
preventing dust accumulation.
CAUTION: The watercraft must never be
Ieft in water for storage. Never leave the
watercraft stored in direct sunlight.
ANTICORROSION
TREATMENT
Wipe off any residual water in the engine
compartment.
Spray BOMBARDIER LUBE lubricant over all
metallic components in engine compartment.
Lubricate the throttle cable with
BOMBARDIER LUBE lubricant.
Apply an anticorrosion product (P/N 219 700 304)
on drive shaft. Refer to PROPULSION is
appropriate SHOP MANUAL.
NOTE: The seat should be partially left
opened during storage. This will avoid engine
compartment condensation and possible corrosion.
CHECK LIST
OPERATION ✔
Propulsion System
Fuel System
Engine Oil and Filter Change
Exhaust Cooling System Flushing
Close Loop Cooling System (engine)
Engine Lubrication
Throttle Body Lubrication
Intercooler and Exhaust Manifold
Antifreeze Protection
Battery
Watercraft Cleaning
Anticorrosion Treatment
4/4 2006-15 Service
--- Page 6 ---
Section 02 TROUBLESHOOTING
Subsection 01 (TECHNICAL GUIDELINES)
Sym ptom: ENGINE SMOKE IN THE EXHAUST (BLUE SMOKE AT ENGI NE STARTING ) (cont'd)
2. Oil rings worn out
- Replace rings, refer to CYLINDER BLOCK.
Symptom: ENGINE SMOKE IN THE EXHAUST (BLUE SMOKE WITH ENGINE UNDER LOAD)
1. Oil rings
- Replace oil rings, refer to CYLINDER BL OCK.
Sym ptom: LOW OR NO ENGINE OIL PRESSURE
1. Oil level too low
- Refill. See LUBRICATI ON SYSTEM
2. leaking gasket
- Replace.
3. Oil leaking out of leak indicator hole (PTO housing)
- Replace oil seal on pump shaft.
4. Oil pressure sensor defective
- Check/replace.
5. Oil pump malfunctioning
- Clean rotor and check wear limits.
6. Oil regulator valve sticks open, or spring load too small
- Clean/replace.
7. Heavy wear on plain bearings
- Replace.
Symptom: ENGINE OIL CON TAMINATION (MILKY)
1. Oil seal and rotary seal on water pump s haft leaking
- Replace both seals. Refer to PTO HOUSING AND MAGNETO. Change oil.
2. Cylinder head gasket leaking
- Replace gasket. Refer to CYLINDER HEAD. Change oil.
3. loose screws on cylinder head, PTO housing or oil separator
- Retorque. Change oil.
4. Oil contamination due to metal or plastic particles
- Replace possibly damaged parts. Change oil.
5. Water ingestion
- Refer to SPECIAL PROCEDURES.
6. leak indicator hole plugged
- Check/clean leak indicator hole.
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION
1. Worn chain tensioner
- Replace.
2. Worn chain guide
- Replace.
18 smr2008-007
--- Page 7 ---
Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL/INSTALLATION)
F18Dt4A
REAR SUPPORT
1. Remove screws
1. Hook·up a steel rope/chain here
Using a chain block, a hoist or other suitable equip- Carefu lly lift engine by th e side w ith the steel
ment, slightly lift engine to ease the remaining
rope/chain and rotate engine so that it can be
component removal. pulled out of vehicle.
CAUTION: Take care not to damage cables.
1
F18Dl1A
TYPICAL
1. Lifting brackets 1. Lift steel rope/chain here to rotate engine
2. Us!Jal lifting brackets
RXP Models
All Models
Slightly move engine rearward to take advantage
Carry on engine lifting to remove from the body
of the larger opening.
opening.
The engine have to be hooked-up at an additional
location. See illustration. CAUTION: Be careful not to scratch body or to
hit any component.
Disconnect RED (+) cable from starter post.
28 S!';r2008-009
--- Page 8 ---
Section 03 ENGINE
Subsection 03 (INTAKE MANIFOLD/INTERCOOLER}
130/155 Naturally Aspirated Engines
10 N•m
(89 lbfoin)
10 N•m
(89 lbf.in)
.smr2005·033·200_aen
38 smr2008·01 1
--- Page 9 ---
Section 03 ENGINE
Subsection 03 (INTAKE MA~ll FOLD/11\JTERCOOLER)
1
t
F\900FA
1. Clamp
2. Plastic block between nipples
3. Plastic block
Reinstall collar.
Reinstall intake manifold.
48 s mr2008·01 l
--- Page 10 ---
Section 03 ENGINE
Subsection 05 (SUPERCHARGER)
sr
\
~ 008-0 1 2-002 _a
1. Coolant tank
2. Vent lube
3. Vent tube support
All RXP Supercharged Models
Disconnect intercooler air hoses.
Remove the exhaust inlet hose.
$Mr'l006-012·010_a
1. Dirt here
If dirt is found, proceed as fol lows.
Remove supercharger and perfo rm the clutch slip-
ping moment test. Inspect bearings and friction
clutch. Replace bearings/clutch components as
necessary.
Separate supercharger housing.
NOTE: Since supercharger is disassembled, it is
recommended to completely inspect it.
Clean internal housing and turbine using a brush
and cleaning solvent to get rid of oil deposits. 1. lntercoo/er air iniet /Jose
2. 'r:tercoo/er air outlet hose
Blow dry with compressed air. 3. Fxhaust iniet /lose
CAUTION: Do not let turbine spin when using
compressed air. All Supercharged Models
Complete usual assembly procedures as de- Remove air inlet hose from supercharger.
scribed in t his section.
SUPERCHARGER CLUTCH
SLIPPING MOMENT (ON ENGINE)
All RXP Supercharged Models
Remove the engine cover. Refer to BODY sec-
tion.
Move the coolant tan k aside.
All Supercharged Models (except RXP)
Detach the vent tube.
Move the coolant tank aside.
Remove the vent tube support.
R 1e.OJJro;r2240
1. Inlet hose
58 smrZOOB-012
--- Page 11 ---
Section 03 ENGINE
Subsection 05 (SUPERCHARGER)
CAUTION: No other grease can be used, other- Hold the lock wash er of the supercharger shaft
wise damage to bearings will occur. (engine side) using the retaining key (P/N 529 036
Install the 40 needle bearings on the compressor 027).
shaft.
NOTE: The 40 needle bearings comes in a wax
strip with an adhesive backing .
Remove the adhesive backing .
Install the drive gear over the needle bearings.
Install the second titanium shim.
Install the lock washer.
Apply engine oil to the spring washers. 529035949
Position the spring washers as per illustration. Tighten the cap nut to 30 N•m {22 lbf•ft).
CAUTION: When installing the spring washers, Apply Loctite 591 O (P/N 293 800 081 l on super-
take care of the exact installation direction of charger hou sing sealing surface.
the washers.
sn,r2C06·Cl 2·003_a
1. Spring washers
1. Apply Loctite 5910 on sealing surface
Install the L-ring on the compressor shaft.
Assemble supercharger housing halves. Apply
Apply Loctite 243 {blue) (P/N 293 800 060) on Loctite 243 (blue) (P/N 293 800 060) on retaining
the hexagonal nut threads. Torque to 30 N•m screws and torque to 11 N •m (97 lbf•in) accord-
(22 lbf•ft). ing to the following sequence.
7 6 4 3 2 1
So\'\r2C06·0•2-009_a
1. Nut
2. L·ring
3. Spring washers
4. Lock washer SUPERCHARGER TIGHTENING SEQUENCE
5. Tiranium shims
6. Drive gear
7. Needle bearings
Perform the clutch slipping moment test. Refer to
SUPERCHARGER CLUTCH SLIPPING MOMENT
NOTE: The L-ring will preload the spring washers. (BENCH TEST) in this section.
68
--- Page 12 ---
Section 03 !ENGINE
Subsection 06 (EXHAUST SYSTEM)
Turn intercooler support and VTS toward the l=iH
side to make room.
1. TOPS valve hose
2. TOPS valve
__ ,;
';\rr-.~?OO;J.-(11 :~ -u:m
All Models Unscrew exhaust clamp.
Cut locking tie securing TOPS valve hose and ex- CAUTION: Do not use pneumatic or electric
haust manifold water outlet hose. tools as seizure may occurs.
srr·~200 B-O 13-021. a
1. Exhaust clamp
1. TOPS valve hose
2. Exhaust manifold water outlet hose Move exhaust clamp on exhaust manifold.
Disconnect the upper water outlet hose from the
exhaust manifold.
r. mr2 00.9-0 12-022 .. a
1. Opened exhaust clamp on exhaust manifold
~fM200fi ·0~3-019 ..<1
1. Exhaust manifold water outlet hose Unplug the exhaust gas temperature sensor
2. Exhaust manifold fitting
(EGTS) from muffler.
Gently disconnect the TOPS valve hose from
TOPS valve.
78 srnr200il-013
--- Page 13 ---
Section 03 ENGINE
Subsectio n 07 (PTO HOUSING/ MAGNETO )
11 N•m
(97 !bf.in)
I Loctite
J_':,._ ~ 243
~'- . /
"""'"'tefJ .
(@- ~ lsofl ex grease
Topas NB 52
lsofl ex grease
Topas NB 52
15 N•m
(133 !bf.in)
+50°
250 N•m
(1 84 lbfoft)
88
smr?.OOB-014
--- Page 14 ---
Section 03 ENGINE
Subsectio n 07 (PTO HOUSING/MAGNETO)
Stator Insulation Test
Disconnect the magneto w iring ha rness con nec-
tor.
smrOS-01 G-008
TYPICAL - ENGINE COVER REMOVED FOR CLARITY OF
ILLUSTRA TION
Install the 3-pin magneto harness adapte r (P/N 529
smr05.01G·OOB
036 016) onto the magneto con nector.
TYPICAL - ENGINE COVER REMOVED FOR CLARITY OF
NOTE: Do not con nect the magneto harness ILL USTRATION
adapter to the ve hicle harness connector.
In sta ll the 3-pin mag neto harness adapter (P/N 529
Set m ultimeter to n.
036 016) onto the magneto conn ector.
Connect mul timet er between each pair of YEL-
NOTE: Do not conn ect t he magneto harness
LOW wires.
adapter to t he vehicle harness connector.
Set mu ltimeter to n.
Con nect multimeter between any YELLOW w ire
and engine ground.
smr 2000 -07.5-009_tl
STATOR CONTINUITY TEST (ENGINE COVER INS TA LL ED!
Read resistan ce.
STATOR CONTINUITY TEST
STATOR INSULATION TEST (ENGINE COVER INSTALLED)
RESISTANCE @
TERM INAL
20°c (69°F) Read resistance .
1 and 2
1 and 3 0.1 - 1 n
2 and 3
If any result is out of specif ication, replace stato r.
98 smr20 08·0 l 4
--- Page 15 ---
~GINE
Section 03 E
Subsection 08 UBRICATION SYSTEM)
ENGINE OIL FLOW
-, ®
···· ········ · ·········• ······+···············
'
sf!lr/00'/·01 S· U:.\O ..o ri
108 s w 2008-015
--- Page 16 ---
Section 03 ENGINE
Subsection 08 (LUBRICATION SYSTEM)
R1503mo11129A
1. Pittings on the teet/1
Using a f ee ler gauge, measure t he clearance be-
tween inner and outer rotors .
TYPICAL
CAUTION: Be careful not to damage the surface
of the rotary seal bore in PTO housing cover.
• Remove and disca rd the oi l sea l behind rotary
seal.
A1603moll130A 2 1
1. Outer rotor
2. Inner rotor
R1503mo1tl28A
OUTER AND INNER ROTOR CLEARANCE
1. Oil seal
SERVICE LIMIT
Oil Pressure Pump Inspection A
Inspect oi l pump shaft, hous ing and cover for
B 0.25 mm (.009 in)
marks or other damages.
Check in ner rotor for corrosion pin-holes or other c
damag es. If so, replace oil pump shaft. En sure to
also check oil pump housing and cover and replace If clearance between inner and outer rotors ex-
if damaged. ceeds the tolerance, replace water/oil pump shaft.
Ensure to also check oil pump housing and cover
and replace if damaged.
If cleara nce between oute r rotor and its bore in
oi l pump exceeds t he tolera nce, replace the com-
plete oil pump and the PTO housing.
Using a vernie r depth gauge, measu re side wear
as shown.
118 srr.r2008· 01 fi
--- Page 18 ---
Section 03 ENGINE
Subsectio n 09 (COOLING SYSTEM}
WATER PUMP HOUSING
,.,.
srrn 2008·016-00l_Ji
1. Ride plate inlet hose
1. Water pump ilovsing 2. Ride plate outlet /Jose
Disconnect t he cylinder head outlet hose and oi l
Water Pump Housing Removal cooler hoses.
2 75 and 255 Engines
On 255 engine models, remove both air hoses
from intercooler to reach supercharger.
Remove supe rcharger inlet and out let hoses to
make room.
1. Water pump housing
2. Cylinder head hose
3. Oil cooler inlet hose
4. Oil cooler outlet hose
Remove wate r pump housing screws.
FlBFOCI\ 2 3
1. Supercharger
2. Inlet hose
3. Outler hose
A ll Engines
Dra in cooling syste m and eng ine oi l.
Di scon ne ct the coolant expans ion tank hose from
water pu mp housing.
Disconnect ride plate hoses from water pump
housing.
:;.n\t2009-0! 6-00IO_Jli
Pull the w ater pump housing to remove it.
138 smr2007·0 16
--- Page 19 ---
Section 03 ENGINE
Subsection 10 (CYLINDER HEAD)
M easure rocker arm inside diam eter. If diameter Rocker Arms Installation
is out of specific ati on, change t he rocke r arm as- For installation, reve rse the removal procedure .
sembly. Pay attention to the following details.
ROCKER ARM INSIDE DIAMETER Apply engine oil on rocker arm shaft .
20.007 - 20.020 mm
IMPORTANT: The rocker arm shaft can only be in-
NEW stalled in one specif ic position. Therefore crank-
(.7877 - .7881 in}
shaft as well as cam shaft has to be positioned
SER VICE LIMIT 20.035 m m {. 7887 in) with their locking pins w hen the piston of cylin-
der no. 3 is on ignition TDC. Refer to CYLINDER
Press t he hydraulic lifter w ith your t humb. If t he BLOCK section for crankshaft and the foll owing
hydraulic lifter can be f ully pressed in, replace for the camshaft locking.
rocker arm. Lifter must turn freely in rocker arm
NOTE: Cylinder no. 3 is next to the oil filler tube .
bore. Otherwise, replace.
Rotate ca mshaft so that the camshaft locki ng tool
Rocke r Arm Shaft (P/N 529 035 839) can be pushed in camshaft hole
Check for scored friction surfac es, if so, replace and lock camshaft in place .
parts.
Measure rocker arm shaft diameter.
B 1 ~03m o tr90A A
A. Measure rocker arm sh,1f1 diameter here
ROCKER ARM SHAFT DIAMETER
19.980 - 19.993 mm
NEW
(.7866 - .7871 in)
SE RVICE LIM IT 19.965 m m (.7860 in)
Any area worn excessively w ill requ ire parts re- Rl503molr l11A
placement. 1. Camshaf t locking tool
Verify and clean oil passages to ensure a good
rocker arm shaft lubrication. Then, t he camshaft sprocket lines should be lined
up as shown in the fol lowing illustration.
R1G03mot1 85A
7. Oil supply from ril e cam slJaft to tile ro cke r arm sha ft, then ro t11e 7. Position lines
rocker arms and finally to tile valve adjustment
148 sm r2008-017
--- Page 20 ---
Section 03 ENGINE
Subsection 10 (CYLINDER HEAD}
VALVE GUIDES
Valve Guide Replacement
CAUTION: Do not heat cylinder head for this
procedure .
CAUTION: The sharp edge near the top of the
valve guide must be machined away. Othe r-
wise it will foul the valve guide hole in the cylin-
der head and destroy the cylinder head, as the
valve guide is removed.
Use a specia l reamer as far as the top of the notch.
R1 !l03111otr251lA
1. Valve stem seal
Apply eng ine oil on va lve stem and install va lve.
CAUTION: Be careful when valve stem is
passed through sealing lips of valve stem seal.
1
TYPICAL
1. Special reamer
2. Notch
Chase valve gu ide out of the cylinder head to-
n t503rnou2!>40
wards combustion chamber by using valve guide
remover (P/N 529 036 086).
7. Sealing li'ps of valve stem seal
To ease instal lation of cotters, apply oil or grease
on them so t hat they remain in place w hile releas-
ing the spring.
Af ter springs are installed, ensure valve springs
and va lve spring reta iner are properly locked by
tapping on valve stern end w ith a soft hammer so
that valve opens and closes a few times.
CAUTION: An improp erly locked valve spring
will cause engine damage.
158 smr2008·017
--- Page 21 ---
Section 03 ENGINE
Subsection 11 (CYLINDER BLOCK)
1 NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Position the dial bore gauge 62 mm (2.44 in) above
cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
FOO BO BA
PISTON/CYLINDER CLEARANCE mm (in}
0.024 - 0.056
1. Micrometer set to the piston dimension NEW NOMINAL
(.0009 - .0022)
NOTE: Make sure used piston is not worn. SERVICE UMIT 0.090 (.004)
With the micrometer set to the dimension, adjust
a cylinder bore gauge to the micrometer dimen- If clearance exceeds specified tolerance, re-hone
sion and set the indicator to 0 (zero). cylinder sleeve and replace piston by an oversize
one.
NOTE: It is not necessary to have all pistons re-
placed with an oversize if they are not all out of
specification. Mixed standard size and oversize
piston are allowed.
1
Pistons/Connecting Rods Assembly
For installation, reverse the rem ova I procedure.
Pay attention to the following details.
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
Use the piston circlip installer (P/N 529 035 765)
to assemble the piston circ!ip.
529 035 765
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
CAUTION: Secure piston pin with new piston
circlips.
NOTE: Take care that the hook of the piston circlip
is positioned properly.
FOOBOAA
TYPICAL
1. Indicator set to 0 (zero)
168 smr2008·018
--- Page 22 ---
Section 03 ENGINE
Subsection 11 (CYLINDER BLOCK)
1 1
R1 603motr 18A
1. Crankshaft locking tool Rl 503motr37A 2
1. Mark on balancer sl1aft bearings
2. Mark on crankshaft bearings
CYLINDER BLOCK Starter Drive Bearing
Cylinder Block Disassembly Check bearing no. 21 of starter drive assembly
Remove: no. 22 in cylinder block and replace it if damaged.
Engine oil (refer to LUBRICATION SYSTEM sec-
tion)
Engine from vehicle (refer to ENGINE
REMOVAUINSTALLAT!ON section)
- Cylinder head (refer to CYLINDER HEAD sec-
tion)
PTO housing (refer to PTO HOUSING AND ":"·.· ..
- -~,
MAGNETO section)
- Starter gear (refer to PTO HOUSING AND MAG-
'I~
NETO section)
- Starter drive
Oil suction pump (refer to LUBRICATION SYS-
TEM section)