Sea-doo Challenger*180 Manual

Lmo2005 challenger 180 ang.FH8 Thu Sep 09 11:43:03 2004 Page 1
C M Y CM MY CY CMY K

SAFETY WARNING
Disregarding any of the safety precautions and instructions contained in
this Operator’s Guide, the Safety Videocassette 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 Videocassette should remain with the
boat at the time of resale.
The following trademarks are the property of Bombardier Recreational
Products Inc. or its affiliates.
SEA-DOO®
ROTAX™
BOMBARDIER* LUBE
SPORTSTER™
4-TEC™
Printed in Canada (lmo2005-007a.fm SB)
®TM Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
©2004 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
*Trademark of Bombardier Inc. used under license.
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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 Videocassette 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 plea-
sures 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 understand
the controls and operation of the boat and the importance of courteous, respon-
sible riding.
Each boat operator has a responsibility to ensure the safety of his/her passen-
ger(s) and of other 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 con-
tact 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.
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TABLE OF CONTENTS
FOREWORD ................................................................................ 7
Hazard Statements .................................................................................. 7
Advisory Statements ............................................................................... 8
SAFETY INFORMATION
SAFETY ...................................................................................... 10
Safe Boating Checklist............................................................................. 10
Safety Equipment.................................................................................... 12
Carbon Monoxide and Boating ................................................................ 17
Lanyard Stop Switch/DESS ....................................................................... 20
Safe Boating Practices............................................................................. 20
Passenger Safety..................................................................................... 21
Rules of the Road.................................................................................... 22
Voluntary Inspections .............................................................................. 24
Safe Boating Courses .............................................................................. 24
Water Sports ........................................................................................... 24
VEHICLE INFORMATION
REGISTRATION NUMBER LOCATION ......................................... 30
LOCATION OF THE IMPORTANT LABELS ................................... 31
IDENTIFICATION NUMBERS ....................................................... 34
Hull .......................................................................................................... 34
4-TEC Engine ........................................................................................... 34
CONTROLS, COMPONENTS AND INSTRUMENTS LOCATION .... 35
Overview ................................................................................................. 36
CONTROLS, COMPONENTS AND INSTRUMENTS FUNCTIONS.. 38
1) Safety Lanyard/DESS™ Post (engine cut-out switch)....................... 38
2) Steering Wheel ................................................................................. 39
3) Throttle/Shifter Levers ...................................................................... 40
4) Start/Stop Button .............................................................................. 41
5) Inlet Clearance System (ICS) Switch ........................................................ 41
6) Horn Switch................................................................................................ 42
7) Bilge Pump Switch..................................................................................... 43
8) Bilge Air Blower Switch............................................................................. 43
9) Navigation Light Switch............................................................................. 43
10) Deck Light Switch ............................................................................. 44
11) Warning Gauge ................................................................................. 44
12) Tachometer....................................................................................... 45
13) Fuel Gauge ........................................................................................ 45
14) Speedometer .................................................................................... 45
15) Glovebox ........................................................................................... 46
16) AM/FM CD Stereo ............................................................................ 46
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17) 12-Volt Jack....................................................................................... 46
18) Fuses ................................................................................................ 46
19) Seats ................................................................................................. 46
20) Bow Seats......................................................................................... 47
21) Bow Seat Storage Compartments .................................................... 47
22) Bow Filler Cushion (if so equipped) .................................................. 47
23) Deck.................................................................................................. 48
24) Deck Storage Compartment ............................................................. 48
25) Rear Seat Storage Compartments .................................................... 48
26) Passenger Storage Area ................................................................... 49
27) Starboard Rear Storage Compartment.............................................. 49
28) Fuel Tank Cap/Vent ........................................................................... 49
29) Oil Fill Cap (on engine) ...................................................................... 50
30) Ventilation Ducts............................................................................... 50
31) Deck Drain ........................................................................................ 50
32) Grab Handles .................................................................................... 51
33) Rear Grab Handles ............................................................................ 51
34) Water Sport Towing Attachment ...................................................... 51
35) Bow/Stern Eyelets ............................................................................ 54
36) Mooring Cleats.................................................................................. 54
37) Cup Holders ...................................................................................... 54
38) Swim Platform .................................................................................. 54
39) Engine Cover..................................................................................... 54
40) Main Battery Cut-Off Switch............................................................. 54
41) Bow Light.......................................................................................... 55
42) Stern Light Socket ............................................................................ 55
43) Port Bilge Access.............................................................................. 55
44) Ladder ............................................................................................... 55
45) Bilge Drain Plugs............................................................................... 56
46) Jet Pump Nozzle............................................................................... 56
47) Reverse Gate .................................................................................... 56
48) Flushing Connector ........................................................................... 57
49) Scupper Valve ................................................................................... 57
50) Removable Cooler............................................................................. 57
FUEL AND LUBRICATION ........................................................... 58
Fueling Procedure ................................................................................... 58
Recommended Fuel ................................................................................ 58
Engine Oil ................................................................................................ 59
Engine Coolant ........................................................................................ 61
BREAK-IN PERIOD ...................................................................... 62
10-Hour Inspection .................................................................................. 62
PRE-OPERATION CHECKS .......................................................... 64
Hull .......................................................................................................... 65
Jet Pump Water Intake ........................................................................... 65
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Bilge......................................................................................................... 65
Battery ..................................................................................................... 65
Fuel Tank and Oil Level ........................................................................... 65
Engine Compartment .............................................................................. 65
Fire Extinguisher...................................................................................... 65
Steering System ...................................................................................... 65
Throttle System ....................................................................................... 65
Shifter System......................................................................................... 66
Safety Lanyard and Engine Start/Stop Button ......................................... 66
Storage Compartment Covers................................................................. 66
OPERATING INSTRUCTIONS ...................................................... 67
Launching/Loading................................................................................... 67
Trailering.................................................................................................. 67
Principle of Operation .............................................................................. 67
Boarding from a Dock.............................................................................. 68
Boarding from the Water......................................................................... 69
Starting ................................................................................................... 70
Rough Water or Poor Visibility Operation ................................................ 70
Crossing Waves....................................................................................... 71
Stopping/Docking .................................................................................... 71
Beaching.................................................................................................. 71
POST-OPERATION CARE ............................................................ 72
General Care............................................................................................ 72
Additional Care for Foul Water or Salt Water .......................................... 72
Exhaust Cooling System Flushing ........................................................... 72
SPECIAL PROCEDURE................................................................ 74
Engine Overheating ................................................................................. 74
Jet Pump Water Intake and Impeller Cleaning ........................................ 74
Capsized Boat.......................................................................................... 75
Submerged Boat/Water-Flooded Engine ................................................. 75
Fuel-Flooded Engine ................................................................................ 75
Towing the Boat in Water........................................................................ 76
Low-Charge Battery Condition ................................................................ 76
MAINTENANCE INFORMATION
MAINTENANCE .......................................................................... 78
Emission Component Maintenance ........................................................ 78
Engine Emissions Information................................................................. 78
Lubrication ............................................................................................... 79
Periodic Inspection .................................................................................. 80
Throttle Cable .......................................................................................... 80
Fuel and Oil Filters................................................................................... 80
Steering/Jet Pump Nozzle Adjustment.................................................... 80
Reverse Gate........................................................................................... 81
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Deck Drain............................................................................................... 81
Fuses....................................................................................................... 81
Bilge Air Blower....................................................................................... 83
Navigation Light Bulb Replacement ........................................................ 83
Sacrificial Anode System ......................................................................... 84
General Inspection and Cleaning............................................................. 85
STORAGE AND PRESEASON PREPARATION ............................. 86
Storage .................................................................................................... 86
Fuel System ............................................................................................ 86
Engine Oil and Filter Replacement .......................................................... 86
Exhaust Cooling System Flushing and Engine Internal Lubrication ............... 86
Preseason Preparation ............................................................................ 88
Preseason Preparation Chart................................................................... 89
TROUBLESHOOTING................................................................... 90
PERIODIC INSPECTION CHART .................................................. 93
SPECIFICATIONS ........................................................................ 95
SI METRIC INFORMATION .......................................................... 98
WARRANTY INFORMATION
BRP LIMITED WARRANTY FOR
MODEL YEAR 2005 SEA-DOO®SPORT BOATS
SOLD IN THE UNITED STATES AND CANADA........................... 100
CALIFORNIA EMISSION CONTROL WARRANTY
STATEMENT FOR MODEL YEAR 2005 SEA-DOO®
SPORT BOATS EQUIPPED WITH A ROTAXTM ENGINE(S) ............ 104
Your Emission Control Warranty Rights and Obligations ........................ 105
Manufacturer’s Limited Warranty Coverage ........................................... 105
Owner’s Warranty Responsibilities ......................................................... 107
BRP INTERNATIONAL LIMITED WARRANTY
FOR MODEL YEAR 2005 SEA-DOO®SPORT BOATS ................... 108
WEB SITES.................................................................................. 112
LIST OF DISTRIBUTORS.............................................................. 114
DECLARATION CE OF CONFORMITY.......................................... 115
Homologation and Certification ............................................................... 116
Operator’s Guide Confirmation of Receipt .............................................. 117
PRIVACY INFORMATION ............................................................ 118
CHANGE OF ADDRESS............................................................... 119
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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 carefully!
Be sure you understand the conse-
quences 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 likely ef-
fect of a hazard (minor injury, severe
injury, death).
CAUTION: This signal word indicates
a potentially hazardous situation
which, if not avoided, may result in
minor or moderate personal injury or
property damage. It may also be used
to alert against unsafe 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 recommended,
you must satisfy yourself that it is safe
for you and others and that your boat
will not be damaged or made unsafe
as a result of your decision.
WARNING
Identifies a potentially or immi-
nently hazardous situation which,
if not avoided, COULD result in se-
rious personal injuries including
the possibility of death or substan-
tial property damage.
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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.
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 it-
self 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
discontinue or change specifications,
designs, features, models or equip-
ment without incurring obligation.
The illustrations in this document show
the typical construction of the different
assemblies and may not reproduce the
full detail or exact shape of the parts.
However, they represent parts that
have the same or similar function.
It is understood that this guide may be
translated into another language. In
the event of any discrepancy, the En-
glish version shall prevail.
Specifications are given in the SI metric
system with the SAE U.S. equivalent in
parenthesis. Where precise accuracy
is not required, some conversions are
rounded off for easier use.
A Shop Manual can be obtained for
complete service, maintenance and
more repair information.
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SAFETY INFORMATION 9
SAFETY
INFORMATION
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