Sea-doo 230 Challenger 2008 Manual

SAFETY WARNING
Disregarding any of the safety precautions and instructions contained in
this Operator's Guide, the SAFETY VIDEO and the on-product warning
labels could cause injury, including the possibility of death. The operator
has the responsibility to inform passenger(s) of safety precautions.
This Operator's Guide and SAFETY VIDEO should remain with the boat at
the time of resale.
The following trademarks are the property of Bombardier Recreational Prod-
ucts Inc. or its affiliates.
Sea-Doo®
ROTAX™
Challenger™
Perfect Pass®
LMO2008-006 DR
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2007 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.

DOIN'IT ON YOUR NEW SEA-DOO SPORT BOAT
Congratulations, you are now the proud owner of a Sea-Doo Sport Boat. Whether
you are an experienced boater or are new to the sport of boating, we ask you to
take the time to view the SAFETY VIDEO provided with the boat, to read this
Operator's Guide on-product warning/caution labels and familiarize yourself with
the contents. This guide contains pertinent information which, if followed, will
provide you with the necessary knowledge to help you fully enjoy the pleasures
of this boat.
We strongly recommend that any boat operator complete a safety boating
course. Check with your local Coast Guard or Power and Sail Squadron in your
area for course 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 under-
stand the controls and operation of the boat and the importance of courteous,
responsible riding.
Each boat operator has a responsibility to ensure the safety of his/her passen-
ger(s) and of other water users. Please follow all safety instructions and operate
your boat with care.
We encourage you to have an Annual Safety Inspection of your boat. Please
contact your authorized Sea-Doo Sport Boat dealer for further details.
Finally, we invite you to visit your authorized Sea-Doo Sport Boat dealer for regular
safety maintenance as well as any boating accessories you may require.
Have fun and... Bon Voyage.
Please keep this guide on board. This guide should remain with the boat at
time of resale.
If you want to view and/or print an extra copy of your Operator's Guide, simply
visit the following website www.operatorsguide.brp.com. Alsonotethatthe
guide is available in several languages.
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TABLE OF CONTENTS
FOREWORD .......................................................................... 7
SAFETY INFORMATION
GENERAL............................................................................ 10
TRAILERING......................................................................... 11
SAFE BOATING CHECKLIST...................................................... 12
SAFETY EQUIPMENT.............................................................. 15
CARBON MONOXIDE AND BOATING .......................................... 21
SAFETY LANYARD................................................................. 25
SAFE BOATING PRACTICES...................................................... 26
PASSENGER SAFETY.............................................................. 27
RULES OF THE ROAD ............................................................. 28
FUELING PROCEDURE ............................................................ 31
VOLUNTARY INSPECTIONS...................................................... 32
SAFE BOATING COURSES ....................................................... 33
WATER SPORTS.................................................................... 34
VEHICLE INFORMATION
REGISTRATION NUMBER LOCATION .......................................... 38
LOCATION OF THE IMPORTANT LABELS...................................... 39
IDENTIFICATION NUMBERS ..................................................... 44
CONTROLS, COMPONENTS AND INSTRUMENTS .......................... 45
1) DESS Post (engine cut-out switch) ........................................ 51
2) Steering Wheel............................................................... 52
3) Throttle/Shifter Lever........................................................ 52
4) Start/Stop Switches ......................................................... 53
5) Bilge Air Blower Switch..................................................... 54
6) Bilge Pump Switch .......................................................... 54
7) Navigation Lights Switch.................................................... 55
8) Deck Lights/Switch.......................................................... 55
9) Horn Switch .................................................................. 55
10) Fuel Gauge.................................................................. 56
11) Tachometers ................................................................ 56
12) Speedometer ............................................................... 56
13) Monitoring Gauges......................................................... 57
14) Bilge Drain Plug............................................................. 58
15) Grab Handles ............................................................... 58
16) Rear Grab Handles ......................................................... 58
17) Ladder ....................................................................... 58
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18) Swim Platform.............................................................. 59
19) Passenger Seats............................................................ 59
20) Bow Seats................................................................... 61
21) Driver/Passenger Seat ..................................................... 62
22) Sun Deck.................................................................... 63
23) Cup Holders................................................................. 63
24) Glove Box/Storage Compartment ........................................ 64
25) AM/FM Radio/CD Player................................................... 64
26) 12-Volt Accessory Jacks ................................................... 65
27) Bow Storage Compartment............................................... 65
28) Deck Storage Compartment .............................................. 66
29) Rear Storage Compartment (engine cover). ............................. 66
30) Jet Pump Water Intakes................................................... 67
31) Bow Lights Socket ......................................................... 67
32) Stern Light Socket.......................................................... 68
33) Mooring Cleats ............................................................. 69
34) Deck ......................................................................... 69
35) Fuel Tank Cap............................................................... 69
36) Deck Drain .................................................................. 70
37) Flushing Connectors ....................................................... 70
38) Ventilation Ducts ........................................................... 70
39) Bow/Stern Eyelets ......................................................... 70
40) Jet Pump Nozzles .......................................................... 70
41) Reverse Gates.............................................................. 71
42) Scupper Valve............................................................... 71
43) Fuel Tank Vent .............................................................. 71
44) Water Sport Towing Attachments........................................ 71
45) Ballast System/Switch..................................................... 72
46) Main Battery Cut-Off Switch.............................................. 75
47) Fuses ........................................................................ 76
48) Bimini Top (not shown) .................................................... 76
49) Storage Nets................................................................ 78
50) Cockpit Table................................................................ 78
51) Windshield/Switch ......................................................... 79
52) Walk-Thru Door/Windshield ............................................... 79
53) Depth Finder ................................................................ 80
54) AM/FM Radio/CD Player Remote Control ............................... 80
55) Speaker System/P.A........................................................ 80
56) Wakeboard Storage Rack. ................................................. 81
57) Heating System/Switch.................................................... 81
LIQUIDS.............................................................................. 83
Recommended Fuel ............................................................ 83
Recommended Engine Oil . .................................................... 83
Engine Oil Level................................................................. 84
Engine Coolant.................................................................. 85
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BREAK-IN PERIOD.................................................................. 87
PRE-OPERATION CHECKS ........................................................ 88
Hull ............................................................................... 89
Jet Pump Water Intakes ....................................................... 89
Bilge.............................................................................. 90
Battery ........................................................................... 90
Fuel Tank and Engine Oil Levels . . ............................................ 90
Engine Compartment........................................................... 90
Fire Extinguisher ................................................................ 90
Steering System ................................................................ 90
Throttle System................................................................. 90
Shifter Lever..................................................................... 90
DESS Post and Engine Start/Stop Switches................................. 91
Storage Compartment Covers................................................. 91
OPERATING INSTRUCTIONS..................................................... 92
Launching/Loading.............................................................. 92
Principle of Operation .......................................................... 92
Boarding from a Dock .......................................................... 94
Boarding from the Water....................................................... 94
Starting........................................................................... 95
Rough Water or Poor Visibility Operation .................................... 96
Crossing Waves................................................................. 96
Stopping/Docking............................................................... 96
Beaching......................................................................... 96
Shutting Off the Engines....................................................... 96
Post-Operation Care............................................................ 97
Additional Care for Foul Water or Salt Water Use........................... 97
SPECIAL PROCEDURES........................................................... 98
Jet Pump Water Intake and Impeller Cleaning .............................. 98
Capsized Boat................................................................... 98
Submerged Boat/Water-Flooded Engine ..................................... 98
Fuel-Flooded Engines .......................................................... 99
Towing the Boat in Water.................................................... 100
TROUBLESHOOTING............................................................ 102
SPECIFICATIONS ................................................................. 107
MAINTENANCE INFORMATION
10-HOUR INSPECTION .......................................................... 112
PERIODIC INSPECTION CHART................................................ 113
MAINTENANCE PROCEDURES................................................ 116
General......................................................................... 116
Engine Emissions Information............................................... 116
Lubrication ..................................................................... 117
Throttle Lever Cables......................................................... 119
Engine Oil Change and Oil Filter Replacement ............................ 119
4_______________________

Coolant Replacement ........................................................ 119
Fuel Injection System . ....................................................... 120
Steering Alignment ........................................................... 120
Shifter Lever................................................................... 120
Deck Drain..................................................................... 120
Fuses........................................................................... 120
Bilge Air Blower............................................................... 123
Navigation Light Bulb Replacement ........................................ 123
Sacrificial Anodes ............................................................. 124
General Inspection and Cleaning ............................................ 125
STORAGE AND PRESEASON PREPARATION ............................... 126
WARRANTY INFORMATION
BRP LIMITED WARRANTY FOR MODEL YEAR 2008 SEA-DOO®SPORT
BOATS SOLD IN THE UNITED STATES AND CANADA.................... 134
CALIFORNIA AND NEW YORK EMISSION CONTROL WARRANTY
STATEMENT FOR MODEL-YEAR 2008 SEA-DOO®SPORT BOATS
WITH 4-TEC™ 1503 NORMALLY ASPIRATED (NA) AND 4-TEC™ 1503
SUPERCHARGED INTERCOOLED (SCIC) ENGINE(S) ...................... 139
BRP INTERNATIONAL LIMITED WARRANTY FOR MODEL YEAR 2008
SEA-DOO®SPORT BOATS...................................................... 143
BRP EUROPEAN UNION MEMBER STATES LIMITED WARRANTY FOR
MODEL YEAR 2008 SEA-DOO®SPORT BOATS............................. 147
DECLARATION CE OF CONFORMITY......................................... 151
PRIVACY OBLIGATION/DISCLAIMER......................................... 153
CHANGE OF ADDRESS/OWNERSHIP ........................................ 155
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6_______________________

FOREWORD
This Operator's Guide has been pre-
pared to acquaint the owner/operator
or passenger of this boat with the var-
ious controls, maintenance and safe
riding instructions. It is indispensable
for the proper use of the product, and
should be kept in a waterproof bag in
the boat at all times. Make sure you
read and understand the content of
this document.
For any questions pertaining to the
warranty and its application, please
consult an authorized Sea-Doo Sport
Boat dealer.
Hazard Statements
As you read this Operator's Guide,
please note the hazard warnings
which alert you to safety precautions
related to unsafe conditions or operat-
ing procedures.
This guide uses the following symbols
to emphasize particular information.

The safety alert symbol is recognized
around the world. In this manual, it
means read this information careful-
ly! Be sure you understand the con-
sequences of the hazards and how to
avoid them. Failure to follow the rec-
ommendations in a hazard communi-
cation statement may result in proper-
ty damage, personal injury, or death.
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 like-
ly effect of a hazard (minor injury,
severe injury, death).
WARNING
Identifies a potentially or immi-
nently hazardous situation which,
if not avoided, COULD result in
serious personal injuries including
the possibility of death or substan-
tial property damage.
CAUTION: This signal word indi-
cates a potentially hazardous sit-
uation which, if not avoided, may
resultinminorormoderateper-
sonal injury or property damage. It
mayalsobeusedtoalertagainst
unsafe practices.
NOTE: Indicates supplementary infor-
mation needed to fully complete an in-
struction relating to equipment opera-
tion and/or maintenance procedures.
Although the mere reading of such in-
formation does not eliminate the haz-
ard, the understanding and application
of the information will promote correct
and safe use of the boat.
The warnings in this supplement do
not and cannot address every conceiv-
able situation. Always use common
sense! If a procedure, method, tool,
or part is not specifically recommend-
ed, you must satisfy yourself that it is
safe for you and others and that your
boat will not be damaged or made un-
safe as a result of your decision.
Advisory Statements
Advisory statements alert you to con-
ditions that affect equipment opera-
tion, maintenance, and servicing prac-
tices.
An IMPORTANT statement indicates
a procedure intended to prevent dam-
age to equipment or associated com-
ponents.
______________________ 7

The information and components/
system descriptions contained in this
supplement are correct at the time of
publication. Bombardier Recreational
Products (BRP) however, maintains a
policy of continuous improvement of
its products without imposing upon
itself any obligation to install them on
products previously manufactured.
Because of our ongoing commitment
to product quality and innovation, BRP
reserves the right at any time to dis-
continue or change specifications, de-
signs, features, models or equipment
without incurring obligation.
The illustrations in this document
show the typical construction of the
different assemblies and may not re-
produce the full detail or exact shape
of the parts. However, they represent
parts that have the same or similar
function.
It is understood that this guide may
be translated into another language.
In the event of any discrepancy, the
English version shall prevail.
Specifications are given in the SI met-
ric system with the SAE U.S. equiva-
lent in parenthesis. Where precise ac-
curacy is not required, some conver-
sions are rounded off for easier use.
ASHOP MANUAL can be obtained for
complete service, maintenance and
more repair information.
8_______________________