Sea-doo Challenger*180 Operator's Manual
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Sea-doo Challenger*180 Operator's Manual

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  • Page 2 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™...
  • Page 3 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS FOREWORD ................Hazard Statements .................. Advisory Statements ................SAFETY INFORMATION SAFETY ..................10 Safe Boating Checklist................Safety Equipment ..................Carbon Monoxide and Boating ..............Lanyard Stop Switch/DESS............... Safe Boating Practices................Passenger Safety..................Rules of the Road ..................Voluntary Inspections ................
  • Page 5 17) 12-Volt Jack..................18) Fuses ....................19) Seats ....................20) Bow Seats..................21) Bow Seat Storage Compartments ............ 22) Bow Filler Cushion (if so equipped) ..........23) Deck....................24) Deck Storage Compartment ............. 25) Rear Seat Storage Compartments ............ 26) Passenger Storage Area ..............27) Starboard Rear Storage Compartment..........
  • Page 6 Bilge......................Battery ..................... Fuel Tank and Oil Level ................Engine Compartment ................Fire Extinguisher..................Steering System ..................Throttle System ..................Shifter System..................Safety Lanyard and Engine Start/Stop Button ......... Storage Compartment Covers..............OPERATING INSTRUCTIONS ............67 Launching/Loading................... Trailering ....................Principle of Operation ................Boarding from a Dock................
  • Page 7 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 ROTAX ENGINE(S) .... 104 Your Emission Control Warranty Rights and Obligations ......105 Manufacturer’s Limited Warranty Coverage ........... 105 Owner’s Warranty Responsibilities ............

  • Page 8: Foreword

    For any questions pertaining to the warranty and its application, please which, if not avoided, may result in minor or moderate personal injury or consult an authorized Sea-Doo sport property damage. It may also be used boat dealer. to alert against unsafe practices.

  • Page 9: Advisory Statements

    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.

  • Page 10: Safety Information

    SAFETY INFORMATION SAFETY INFORMATION...

  • Page 11: Safe Boating Checklist

    SAFETY Your safety and that of your passengers – Like any other boat, this boat has no and fellow boaters is YOUR responsibil- brake. Stopping distance will vary de- ity. Before launching your boat, you pending on initial speed, load, wind, should completely read and understand and water conditions.
  • Page 12 – Engine exhaust contains carbon Before Getting Underway... monoxide (CO), which can cause in- – Always perform the pre-operation jury or death if inhaled in sufficient checks as specified in this Opera- quantities. Do not operate the boat tor's Guide. in a confined area or allow CO to ac- –...

  • Page 13: Safety Equipment

    Operators and Passengers... – Know the capacity of the fuel tank. Avoid fueling at night except under – Never operate a boat while under well-lit conditions. Gas spills are not the influence of drugs or alcohol. It noticeable in the dark. Do not carry is a Federal offense.
  • Page 14 Personal Flotation Devices (PFDs) Federal regulations require that you have at least one Coast Guard ap- proved personal flotation device (PFD) for each person in a recreational boat and require that all children under 13 years of age wear a PFD at all times when the boat is underway, except when below deck or in an enclosed cabin.
  • Page 15 F00A2GY F00A2EY TYPE V — WEARABLE TYPE III — WEARABLE PFD Pointers PFD Type IV, Throwable is required in addition to the PFDs previously dis- The purpose of a PFD is to help save cussed. The most common Type IV your life.
  • Page 16 – If a PFD contains kapok, the kapok 4. Always wear your PFD. It won't fibers may become waterlogged help you fight off the effects of hy- and lose their buoyancy after the vi- pothermia if you don't have it on nyl inserts are punctured.
  • Page 17 Careful selection and proper stowage Navigation Lights of visual distress equipment is very im- Navigation lights are intended to keep portant if children are aboard. other vessels informed of your pres- ence and course. If you are out on the WARNING water between sunset and sunrise, you are required to display appropriate...

  • Page 18: Carbon Monoxide And Boating

    TOOLS CO reacts with the blood to reduce the ability of the blood to carry oxygen. – spark plug wrench The reduced oxygen supply to body – hammer tissues results in death of the tissue. Prolonged exposure can cause brain –...
  • Page 19 Carbon Monoxide Accumulation Following are examples of possible situations where CO may accumulate within your boat while docked, anchored, or underway. Become familiar with these ex- amples and their precautions to prevent personal injury or death. WARNING Exhaust Fumes! Generator or hull exhaust from other vessels while either docked or anchored can emit poisonous CO gas and cause excessive ac- cumulation within cabin and cockpit areas.
  • Page 20 While underway, CO concentrations can increase by backdrafting or “the station wagon effect.” Backdrafting is caused by factors such as relative wind direction, speed, or the bow being too high. To prevent this, open canvas whenever possible to provide positive airflow through the hull. Boat houses, seawalls, and other boats in close proximity or confined areas can contribute to increased CO levels.

  • Page 21: Lanyard Stop Switch/Dess

    Do NOT Operate your Boat The DESS post incorporates a shutoff without Performing the switch, lanyard cap, lanyard, and lan- Following Checklist: yard clip. The lanyard clip must be se- curely attached to the operator's PFD, Each Boating Day clothing, arm, or leg. Be sure to attach the lanyard clip to a place where it is ✔...

  • Page 22: Passenger Safety

    Drugs and Alcohol – Be sure at least one other passenger is familiar with the operation and Do not use drugs or drink alcohol while safety aspects of the boat in case of operating a boat. Like driving a car, an emergency.

  • Page 23: Rules Of The Road

    Operation by Minors CROSSING Minors should always be supervised Give right of way to craft ahead and to by an adult whenever operating a boat. your right. Never cross in front of anoth- Many states have laws regarding the er craft. minimum age and licensing require- RED light (give way to the other craft).
  • Page 24 – Respect the rights of other recre- – Do not use the boat's reverse, to ationists and/or bystanders and al- stop. You or your passenger(s) ways keep a safe distance from all could be violently ejected forward other craft, people and objects. or even off the boat onto the hazard.

  • Page 25: Voluntary Inspections

    Water Sports – Always carry an observer when pull- ing a tube, skier or wakeboarder, proceed with only as much speed WARNING as required and follow the observ- Avoid Personal Injury! Your boat is er's instructions. Unless absolutely not designed for and should not necessary, do not make tight, sharp be used for pulling parasails, kites, turns.
  • Page 26 Everyone participating in a water sport 8. Turn off engine and anchor the boat should observe these guidelines: before swimming. 1. Allow only capable swimmers to 9. Participate in water sports only in take part in any water sport. safe areas. Stay away from other boats, channels, beaches, restrict- 2.
  • Page 27 14. Stay at least 45 m (150 ft) away from areas marked by a diver down float. F00A2MY DIVER DOWN FLOAT WARNING Avoid Personal Injury! Do not al- low anyone near the jet pump or intake grate, even when the en- gine is off.
  • Page 28 FASTER - SLOWER - SPEEK OK - Palm of one hand pointing Palm pointing down. Arm upraised with thumb and upward. finger joined to form circle. RIGHT TURN - LEFT TURN - RETURN TO DROP-OFF AREA - Arm outstretched pointing Arm outstretched pointing Arm at 45 degree from body to the right.

  • Page 29: Vehicle Information

    VEHICLE INFORMATION...

  • Page 30: Registration Number Location

    REGISTRATION NUMBER LOCATION All boats are required by federal law to be registered and legally numbered. Due 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 boat.

  • Page 31: Location Of The Important Labels

    LOCATION OF THE IMPORTANT LABELS The following labels are on your boat. If missing or damaged, they can be replaced free of charge. See an authorized Sea-Doo sport boat dealer. Please read the following labels carefully before operating your boat.
  • Page 32 Label 2 Label 5 WARNING F13L1SY F13L0DY Label 6 Label 3 WARNING F13L1NY F23L0RY TYPICAL — REFER TO ACTUAL LABEL ON Label 7 BOAT WARNING Label 4 Avoid Serious Or Fatal Injury. WARNING Do Not Occupy Seat When Speed Exceeds 5 M.P.H. F00L3BY Label 8 WARNING...
  • Page 33 D485,526; D483,315; D482,649; D469,053; D468,254; D467,860; D467,859; D465,446; D465,194; D464,601; D459,693; D409,555; D400,844. SEA-DOO, ISLANDIA, UTOPIA, SPEEDSTER, SPORTSTER, ROTAX, 4-TEC and their associated graphic designs are trademarks of Bombardier Recreational Products Inc. or their affiliates. BOMBARDIER, CHALLENGER are trademarks of Bombardier Inc. used under license.

  • Page 34: Identification Numbers

    IDENTIFICATION NUMBERS The main components of the boat (hull and engine) are identified by different serial numbers. It may sometimes be- come necessary to locate these num- bers for warranty purposes or to trace the boat in the event of theft. Hull The Hull Identification Number (H.I.N.) is located on the right side of the tran-...

  • Page 35: Controls, Components And Instruments Location

    CONTROLS, COMPONENTS AND INSTRUMENTS LOCATION Cockpit F23L03L COCKPIT VIEW...

  • Page 36: Overview

    Overview 30 18-40 36 28 32 19 37 37 15 16-17 20-21 32 25-50 36 18 20-21 32 36 F23L02M TYPICAL 36 30 34 42 45 47 46 F23L05L TYPICAL...
  • Page 37 1. Safety Lanyard/DESS Post 25. Rear Seat Storage Compartments (engine cut-out switch) 26. Passenger Storage Compartment 2. Steering Wheel 27. Starboard Rear Storage 3. Throttle/Shifter Levers compartment 4. Start-Stop Button/Ignition Switch 28. Fuel Tank Cap/Vent 5. Inlet Clearance System 29. Oil Fill Cap (on engine) (ICS) Switch 30.

  • Page 38: Controls, Components And Instruments Functions

    CONTROLS, COMPONENTS AND INSTRUMENTS FUNCTIONS 1) Safety Lanyard/ DESS Post ™ (engine cut-out switch) WARNING Always use safety lanyard when operating your boat to help pre- vent a runaway boat and reduce the risk of personal injury or death. Disconnect the safety lanyard when stopped to help prevent ac- F09L06Y cidental starting.

  • Page 39: Steering Wheel

    The steering wheel controls the direc- your boat. To have additional safety tion of the boat. Turning the steering lanyards programmed, refer to an au- wheel clockwise steers the boat to the thorized Sea-Doo sport boat dealer. right and inversely.

  • Page 40: Throttle/Shifter Levers

    3) Throttle/Shifter Levers CAUTION: Do not force lever. Insure throttle lever is in idle position. Throttle NOTE: To ease shifter use, line up the When pushed forward, the boat accel- shifter arrow with the appropriate dot erates. When fully pulled back, engine (Forward/Neutral/Reverse).

  • Page 41: Start/Stop Button

    4) Start/Stop Button Stopping Dual function push switch, used to WARNING start as well as to stop engine. While engine can be stopped by pressing the stop button, we strong- ly re comm end the e ngine be stopped by removing the safety lan- yard.

  • Page 42: Horn Switch

    Inspect wa- The clogged area can be cleaned as ter intake grate for damage. Refer to follows: an authorized Sea-Doo sport boat Inlet Clearance System (ICS): Place dealer for repair as necessary. shifter in neutral position. Let the...

  • Page 43: Bilge Pump Switch

    7) Bilge Pump Switch 8) Bilge Air Blower Switch F23L090 F23L091 1. Bilge pump switch 1. Bilge blower switch A 2-position OFF/ON switch. A 2-position OFF/ON switch. When turned on, the blower ventilates the en- Turn to ON position when manual op- gine compartment.

  • Page 44: Deck Light Switch

    Turn engine off. Wait one (1) minute. Re- start engine. If light remains lit, take Press switch to OFF position to turn boat to nearest authorized Sea-Doo off the deck lights. sport boat dealer for servicing. Using the deck lights for a prolonged...

  • Page 45: Tachometer

    Restart the engine. If this does not cor- F23L0BY rect the situation, do not run the en- TYPICAL — TACHOMETER gine further. Refer to an authorized Sea-Doo sport boat dealer for servic- 13) Fuel Gauge ing. Located in dashboard, this gauge con- CAUTION: Running engine with low...

  • Page 46: Glovebox

    15) Glovebox 17) 12-Volt Jack Located on the port console, the A 12-Volt jack is located in the glove- glovebox provides a convenient, lock- box to power temporary accessories able storage space for keys, wallet, such as a cellular phone or other 12- etc.

  • Page 47: Bow Seats

    20) Bow Seats Located at the front of the boat, they are provided as a sun seat. WARNING No passenger should use the most forward seat in the bow area if it faces backwards unless the boat is stopped or under idle speed. F23L0HY 1.

  • Page 48: Deck

    23) Deck Flat surface of boat, should be kept clean and clear. 24) Deck Storage Compartment The deck storage compartment is a convenient location for water-skis, paddles, anchor and rope, etc. WARNING Never leave any heavy or loose breakable objects in the storage bas- F23L0LY ket.

  • Page 49: Passenger Storage Area

    26) Passenger Storage 28) Fuel Tank Cap/Vent Area F23L0PY 1. Fuel tank cap F23L0NY The fuel tank cap is located on the port 1. Passenger storage area outside gunwale. Unscrew the cap counterclockwise to Located at the port side of the boat allow fuel tank filling.

  • Page 50: Oil Fill Cap (On Engine)

    WARNING Always stop the engine before refu- eling. Fuel is flammable and explo- sive under certain conditions. Al- ways work in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Fuel tank may be pressurized, slowly turn cap when opening.

  • Page 51: Grab Handles

    CAUTION: Never use the grab han- dles to pull anything or to lift the boat. Refer to components location illustra- tions at the beginning of this section for grab handle locations. 33) Rear Grab Handles Provide a handhold for boarding when needed.
  • Page 52 Ski Tow This boat comes equipped with a ski tow hook to pull a tube, water skier or wake- boarder. WARNING When pulling a tube, skier or wake- boarder, always have an observer, proceed with only as much speed as required, and follow the observ- er’s instructions.
  • Page 53 Installation (from off boat) NOTE: Only install tower with support arms in position. Carefully lift tower assembly and posi- tion on boat with help from another person. Apply Loctite 243 (P/N 293 800 059) to threads of bolts and install bolts into attachment points.

  • Page 54: Bow/Stern Eyelets

    35) Bow/Stern Eyelets 39) Engine Cover Eyelets can be used for mooring, tow- Pull upwards on the latch below the ing and as a tie-down point during rear center seat cushion and lift engine transportation. cover lid. F23L0UY TYPICAL 1. Bow eyelet 2.

  • Page 55: Bow Light

    F23L0XY 1. Latch F23L0WY TYPICAL The gas assist cylinder will hold the 1. Battery cut-off switch in ON position storage cover open. It is recommended to set this switch to WARNING the OFF position whenever performing maintenance in the engine compart- Always close cover before getting ment, on the electrical system, for trans- underway.

  • Page 56: Bilge Drain Plugs

    Pull latches to unlock the ladder. F23L0YY F23L05Z TYPICAL TYPICAL 1. Retractable ladder 2. Latch 1. Drain plugs 2. Loosen Slide ladder toward rear, then push 3. Tighten down. 46) Jet Pump Nozzle The jet pump nozzle provides direc- tional control when engine is running, turning side to side via input from the steering wheel.

  • Page 57: Flushing Connector

    48) Flushing Connector Refer to POST-OPERATION CARE sec- tion for proper use. NOTE: Engine is provided with a flush- ing connector on jet pump support. F23L11Y TYPICAL 1. Flushing connector 49) Scupper Valve This is where water from the deck drains out of the boat.

  • Page 58: Fuel And Lubrication

    FUEL AND LUBRICATION CAUTION: Carefully follow the in- Recommended Fuel structions of this section. Failure to do Naturally-Aspirated Engine Models so may reduce the engine’s life and/or (155 NA) performance. Use regular unleaded gasoline with Fueling Procedure the following recommended minimum octane number.

  • Page 59: Engine Oil

    NA Engines Oil Level Sea-Doo sport boats featuring a 4-stroke engine without a supercharger require CAUTION: Check level frequently and 4-stroke motor oil meeting the require- refill if necessary. Do not overfill. Op-...
  • Page 60 Check the oil level as follows: NOTE: Before checking the oil level on this engine, it is necessary to let it idle for 30 seconds before shutting it off. Then it is necessary to wait 30 sec- onds before the oil can be checked. F18D05Y This is required to allow the oil to prop- erly level out in the different oil cham-...

  • Page 61: Engine Coolant

    Use a funnel to is completely flushed and refilled. Refer avoid spillage. Do not overfill. to an authorized Sea-Doo sport boat Properly reinstall and tighten filler cap. dealer. NOTE: A cooling system that frequent-...

  • Page 62: Break-In Period

    CAUTION: Carefully follow the in- structions of this section. Failure to do so may reduce the engine’s life and/or performance. With Sea-Doo sport boats powered by Rotax engines, a break-in period of 10 hours is required before continuous operation at full throttle.
  • Page 63 10-HOUR INSPECTION CHECK LIST Pressure test fuel system and inspect lines and fasteners Check cooling system coolant level (refill as needed) Check oil level in engine (refill as needed) Inspect ride shoe/coolant leaks Inspect fuel tank straps Inspect fuel injection system sensors Inspect ski tow/wakeboard tower (if so equipped) and fasteners Inspect hull Inspect drive shaft/hull seal...

  • Page 64: Pre-Operation Checks

    PRE-OPERATION CHECKS WARNING The pre-operation check is very important before operating the boat. Al- ways check the proper operation of critical controls, safety features and mechanical components before starting. If not done as specified here, se- vere injury or death might occur. Bring all safety equipment required by local laws.

  • Page 65: Hull

    Clean as nec- Engine Compartment essary. If any obstruction cannot be re- moved, refer to an authorized Sea-Doo WARNING sport boat dealer for servicing. If any leaks or gasoline odors are present, do not start the engine.

  • Page 66: Shifter System

    CAUTION: If the reverse gate does not stay in the up position when the shifter is at FORWARD, do not oper- ate the boat further, see an autho- rized Sea-Doo sport boat dealer. Safety Lanyard and Engine Start/Stop Button Ensure that switch operates properly.

  • Page 67: Operating Instructions

    – Ensure all storage compartment cov- all controls and the function of ers are properly latched. each. Should any control or instruc- – A Sea-Doo cover can protect the tion be not fully understood, refer boat, particularly before driving on to an authorized Sea-Doo sport dirt roads, to prevent dirt entry boat dealer.

  • Page 68: Boarding From A Dock

    Above idle speed, throttle must be ap- WARNING plied to turn the boat. When the boat is in neutral posi- WARNING tion, the impeller is turning. Throttle must be applied and steer- ing turned to change the direction of WARNING the boat at speed.

  • Page 69: Boarding From The Water

    Swim to the rear of the boat. Release the rubber stays on one-step ladder pulling ladder out and down into boarding position. Grip the grab handle and pull yourself up until your knee can reach the swim platform. WARNING F04L06Y Never leave ladder in down posi- tion when engine is running or TYPICAL...

  • Page 70: Starting

    NOTE: If you hear some beeper sig- nals other than 2 short beeps, it indi- cates a particular condition that must be corrected. Refer to chart in the TROUBLESHOOTING section for the meaning of the coded signal. Grip steering wheel with your right hand and place both feet on the floorboard.

  • Page 71: Crossing Waves

    Crossing Waves Reduce speed when crossing waves. Always be prepared to steer and bal- ance as necessary. When crossing wakes, always keep a safe distance from boat ahead. WARNING F04L07Y When crossing wakes, slow down. A. 90 cm (3 ft) of water under the hull Operator and passenger(s) can brace themselves by posting.

  • Page 72: Post-Operation Care

    POST-OPERATION CARE Flushing should be performed when the WARNING boat is not expected to be used further the same day or when the boat is stored Allow engine to cool before per- for any extended time. forming any maintenance. WARNING General Care Perform this operation in a well- Once boat is on trailer, unscrew the...

  • Page 73: Flushing

    Ensure water flows out of jet pump CAUTION: Never leave rags or tools while flushing. Otherwise, refer to an in the engine compartment or in the authorized Sea-Doo sport boat dealer bilge. for servicing.

  • Page 74: Special Procedure

    OPERATION CARE. od does not work, the following can be If engine still overheats, refer to an au- performed: thorized Sea-Doo sport boat dealer for – With engine running, put shift lever servicing. in reverse position and vary throttle setting quickly several times.

  • Page 75: Capsized Boat

    Bring the boat to be serviced by an au- Reinstall spark plugs and ignition coils. thorized Sea-Doo sport boat dealer as Reconnect ignition coil connector. soon as possible. NOTE: After installation, ensure the seal...

  • Page 76: Towing The Boat In Water

    Towing the Boat in Water Snugly install the hose pincher on the water supply hose as shown. Special precautions should be taken when towing a Sea-Doo sport boat in water. Maximum recommended towing speed is 24 km/h (15 MPH). When towing your sport boat in water,...

  • Page 77: Maintenance Information

    MAINTENANCE INFORMATION...

  • Page 78: Maintenance

    An emissions control information la- be obtained from your authorized bel, showing emission levels and en- Sea-Doo sport boat dealer. In many gine specifications, must be placed on instances proper tools and training each boat at the time of manufacture.

  • Page 79: Lubrication

    EPA Emission Regulations tems not covered in this guide. Un- less otherwise specified, engine All new 1999 and more recent Sea-Doo must not be running, the safety lan- sport boats manufactured by BRP are yard must be removed from the...

  • Page 80: Periodic Inspection

    It must operate smooth- operation of moving mechanisms. ly. Refer to an authorized Sea-Doo sport boat dealer if adjustment is necessary. Lubrication of the following items should be performed every 50 hours in...

  • Page 81: Reverse Gate

    See an authorized Sea-Doo sport When shift lever is in reverse position, boat dealer for servicing. reverse gate should be in downward position.
  • Page 82 Squeeze cover locking tabs and pull cover out to access fuses. Use the cover tabs to remove the fuse. F23H03Y 1. Solenoid 2. Engine fuse block 3. Engine electrical system fuses F04H63Y NOTE: There are spare fuses inside TYPICAL the covers of the engine fuse block 1.

  • Page 83: Bilge Air Blower

    Fuses for the charging system are lo- cated near the starter relay in the en- gine compartment. Bilge Air Blower Verify bilge air blower for proper oper- ation. It is located beneath starboard ventilation duct in engine compart- ment. F04H2RY TYPICAL 1.

  • Page 84: Sacrificial Anode System

    Sacrificial Anode System Apply dielectric grease on bulb contact surface. Corrosion of metal parts, especially When installing the bulb under the up- those exposed to saltwater, is com- per terminal plate, it is possible that mon for boats. Corrosion can be the bulb remains loose.

  • Page 85: General Inspection And Cleaning

    Have the boat serviced by an au- thorized Sea-Doo sport boat dealer. Stains may be removed from seats and fiberglass with Knight’s Spray- Inspect mufflers, battery and fuel tank †...

  • Page 86: Storage And Preseason Preparation

    It is recommended that the boat be and leave boat in the sun. As tem- taken to an authorized Sea-Doo sport perature increases, fuel expands boat dealer for proper storage, howev- and might overflow. Always wipe er you can perform the following oper- off any fuel spillage from the boat.
  • Page 87 NOTE: It is recommended to fog the en- Remove ignition coils. gine valves with BOMBARDIER LUBE lu- bricant. Contact your authorized Sea-Doo CAUTION: Ensure there is no dirt in sport boat dealer. coil holes before removing the spark plugs.

  • Page 88: Preseason Preparation

    Since technical skills and special tools Using a flat screwdriver, lift tab as are required, some operations should shown below. be performed by an authorized Sea-Doo sport boat dealer. WARNING Observe all WARNINGS and CAU- TIONS mentioned throughout this guide which are pertinent to the item being checked.

  • Page 89: Preseason Preparation Chart

    Since technical skills and special tools are required, some operations should be performed by an authorized Sea- Doo sport boat dealer. WARNING Only perform procedure 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.

  • Page 90: Troubleshooting

    You may be able to solve many of these problems rather quickly, but others may require the skills of a mechanical technician. In such a case, consult an authorized Sea-Doo sport boat dealer for servicing. Nothing is Working in the Electrical System...
  • Page 91 POSSIBLE CAUSE REMEDY Weak spark. • Fouled worn spark plugs. • Replace. • Faulty ignition component. • Refer to an authorized Sea-Doo sport boat dealer. • Too much oil supplied to • Improper oil pump engine. adjustment, refer to an authorized Sea-Doo sport boat dealer.
  • Page 92 Engine Continually Backfires OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Faulty ignition component. • Refer to an authorized Sea-Doo sport boat dealer. Weak spark. • Fouled, worn spark plugs. • Replace. Overheated engine. • See ENGINE OVERHEATS. Engine Pinging or Knocking...

  • Page 93: Periodic Inspection Chart

    PERIODIC INSPECTION CHART FREQUENCY DESCRIPTION Check fire extinguisher condition/ ✔ ✔➁ mounting ➂ GENERAL ➀ ✔ ✔ Verify lubrication/corrosion protection Inspect condition and tightness of engine ✔ ✔ supports and rubber mounts Inspect exhaust system fasteners/ ✔ ✔ ✔ ENGINE hoses ➂...
  • Page 94 FREQUENCY DESCRIPTION Test main battery cut-off switch ➂ ✔ ✔ ✔ ✔ ✔ ✔➁ Verify operation and condition of lights Inspect bilge blower and bilge pump ➂ ✔ ✔ ✔➁ Inspect electrical connections ✔ ✔ ✔ (ignition system, electrical box(es), starting system, etc.) ➂...

  • Page 95: Specifications

    SPECIFICATIONS CHALLENGER 180 CHALLENGER 180 MODEL BVIC ENGINE ® Rotax 1503 4-TEC, 4-stroke, Single Over Head Engine type Camshaft (SOHC), liquid cooled Number of cylinders Number of valves 12 valves with hydraulic lifters (no adjustment) Displacement 1493.8 cc (91 cu. in) Compression ratio 10.6:1 8.5:1...
  • Page 96 BOMBARDIER Formula pump Jet pump type Axial flow, single stage. Greased bearings Transmission Direct drive Grease type Sea-Doo grease (P/N 293 550 032) Steering nozzle pivoting angle 26° Minimum required water level 90 cm (3 ft) for jet pump Additional information: Do not mix different brands or oil types.
  • Page 97 CHALLENGER 180 CHALLENGER 180 MODEL BVIC DIMENSIONS Number of passengers (driver included) 5.36 m (17 ft 7 in)/ Overall length/(on trailer) (6.2 m (20 ft 4 in)) Overall width 2.49 m (8 ft 2 in) 1.85 m (6 ft 1 in) w/o tower Overall height on trailer 2.01 m (6 ft 7 in) w/tower down 2.56 m (8 ft 5 in) w/tower up...

  • Page 98: Si Metric Information

    SI* METRIC INFORMATION BASE UNITS DESCRIPTION UNIT SYMBOL length meter mass kilogram force newton liquid liter temperature Celsius °C pressure kilopascal torque newton-meter N•m land velocity kilometer per hour km/h navigation velocity knot PREFIXES PREFIX SYMBOL MEANING VALUE kilo one thousand 1000 centi one hundredth of...

  • Page 99: Warranty Information

    WARRANTY INFORMATION...

  • Page 100: Brp Limited Warranty For Model Year 2005 Sea-Doo Sport Boats Sold In The United States And Canada

    The emission-related components included in the chart below, that are installed on EPA certified Sea-Doo sport boats (see list below) registered in the USA are covered for TWENTY-FOUR (24) CONSECUTIVE MONTHS OR 200 HOURS OF ENGINE USE, whichever occurs first. If the 200 hours of engine use are reached...
  • Page 101 All genuine sport boat accessories installed by an authorized BRP Dealer at the time of delivery carry the same warranty as the sport boat. The repair or replace- ment of parts or the performance of service to a sport boat under this warranty does not extend the life of this limited warranty beyond its original expiration date.
  • Page 102 • Damage caused by improper or lack of maintenance or storage, or failure to follow the procedures and recommendations in the Operator's Guide; • Damage resulting from removal of parts, improper repairs, service, mainte- nance, or modification, or use of parts or accessories not manufactured or approved by BRP, which in its reasonable judgement, are either incompatible with sport boats or adversely affect its operation, performance, or durability, or resulting from repairs done by a person that is not an authorized BRP Dealer;...
  • Page 103 If the issue has not yet been resolved, please submit your complaint in writing or call the appropriate number below: In Canada: In USA: BOMBARDIER BRP US Inc. RECREATIONAL PRODUCTS INC. SEA-DOO SEA-DOO CONSUMER SERVICES GROUP CONSUMER SERVICES GROUP 7575 BOMBARDIER COURT VALCOURT QC J0E 2L0 WAUSAU WI 54401...

  • Page 104: California Emission Control Warranty Statement For Model Year 2005 Sea-Doo Sport Boats Equipped With A Rotax Engine(S)

    SPORT BOATS EQUIPPED WITH A ROTAX ENGINE(S) If your Sea-Doo sport boat has an engine other than a Rotax engine, the warranty issued by that engine manufacturer will apply. Your Model Year 2005 Sea-Doo sport boat (’’sport boat’’) equipped with a Rotax engine(s) has a special environmental label required by the California Air Resourc- es Board.

  • Page 105: Your Emission Control Warranty Rights And Obligations

    California to a California resident or subsequently warranty registered to a California resident. The BRP limited warranty conditions for Sea-Doo sport boats are still applicable to these models with the necessary modifications. Select emission control parts of your 2005 Sea-Doo sport boat equipped with Rotax engines(s) are warranted from the date of delivery to the first retail con- sumer for a period of 4 years, or for 250 hours of use, whichever occurs first.
  • Page 106 Parts covered for a Model Year 2005 Sea-Doo sport boat equipped with 947 DI engines: Air Lines Exhaust Manifold Fuel Rail Coolant Temp. Sensor Rave Valve Throttle Position Sensors Reed Valve Ignition Coil Tuned Pipe Manifold Temp. Sensor High-Tension Ignition Wires Manifold Air Press.

  • Page 107: Owner's Warranty Responsibilities

    Owner's Warranty Responsibilities As the owner of a Sea-Doo sport boat equipped with a Rotax engine(s), you are responsible for the performance of the required maintenance listed in your Oper- ator's Guide. BRP recommends that you retain all receipts covering maintenance on your Rotax engine, but BRP cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

  • Page 108: Brp International Limited Warranty For Model Year 2005 Sea-Doo Sport Boats

    SPORT BOATS 1. SCOPE BRP US Inc. (’’BRP’’)* warrants its new and unused Model Year 2005 Sea-Doo sport boats (’’Sport Boat’’) sold by authorized BRP Distributors/Dealers outside of the fifty United States and Canada (’’Distributor/Dealer’’) will be free from defects in material and workmanship for the period and under the conditions below.
  • Page 109 4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE The owner must notify an authorized BRP Distributor/Dealer within two (2) days of the appearance of the defect and must promptly bring the Sport Boat, including any defective part, to Distributor/Dealer (in any event, within the warranty period) and must provide Distributor/Dealer with reasonable opportunity to repair the defect.
  • Page 110 • Operation with fuel, oils or lubricants that are not suitable for the Sport Boat (see Operator's Guide); • Damage from rust, corrosion or exposure to the elements; • Damage from cooling system or jet pump blockage by foreign material; •...
  • Page 111 If the matter still remains unresolved then contact BRP by writing to us at the address listed below. BOMBARDIER RECREATIONAL PRODUCTS INC. SEA-DOO CONSUMER SERVICES GROUP VALCOURT QC J0E 2L0 Tel: 01 819-566-3366 * For the territory covered by this limited warranty, products are distributed and serviced by Bombardier Recreational Products Inc.

  • Page 112: Web Sites

    WEB SITES BRP Sea-Doo Website: www.sea-doo.com Canadian Coast www.ccg-gcc.gc.ca/ Guard United States www.uscgboating.org/regulations/boating_laws.htm Coast Guard Alabama www.boat-ed.com Alaska www.dnr.state.ak.us/parks/boating Arizona www.azgfd.com Arkansas www.boat-ed.com California www.dbw.ca.gov Colorado http://parks.state.co.us/boating/ Connecticut http://dep.state.ct.us/rec/prgactiv.htm Delaware www.boat-ed.com Florida www.boat-ed.com (freshwater) Florida www.boat-ed.com (saltwater) Georgia www.boat-ed.com Hawaii www.hawaii.gov/dlnr/dbor/dbor...
  • Page 113 Nebraska www.ngpc.state.ne.us/boating Nevada www.boat-ed.com New Hampshire www.boat-ed.com New Jersey www.state.nj.us/mvs/boats.htm New Mexico www.emnrd.state.nm.us/nmparks/pages/boating/boating.htm New York www.nysparks.com North Carolina www.boat-ed.com North Dakota http://www.state.nd.us/gnf/boating/ Ohio www.boat-ed.com Oklahoma www.boat-ed.com Oregon www.boat-ed.com Pennsylvania www.boat-ed.com Rhode Island www.boat-ed.com South Carolina www.boat-ed.com South Dakota www.state.sd.us/gfp/divisionwildlife/boating/index.htm Tennessee www.boat-ed.com Texas www.boat-ed.com...

  • Page 114: List Of Distributors

    Nunavut Newfoundland If your Sea-Doo sport boat requires warranty service, you must take it to any au- thorized Sea-Doo sport boat dealer. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the service manager or owner of the Sea-Doo sport boat dealership.

  • Page 115: Declaration Ce Of Conformity

    I, the undersigned, hereby declare that the equipment specified above conforms to the above Directives and Standards. Name of signatory: Fernando Garcia Title of signatory on behalf of BRP US Inc.: Director - Public and Regulatory Affairs — Sea-Doo sport boats...

  • Page 116: Homologation And Certification

    Homologation and Certification These boats comply with the following standards: STANDARD TYPE OF CERTIFICATION United States Coast Guard Self certification Canadian Coast Guard Self certification Russian Maritime Register of Shipping Certify by Russian Maritime Register of Shipping 8, Dvortsovaya Nab., 191186 St.

  • Page 117: Operator's Guide Confirmation Of Receipt

    I understand and agree to be bound with. I am also satisfied with the predelivery set-up and inspection of my Sea-Doo sport boat. I have also received a copy of the Operator’s Guide and Safety Videocassette for my Sea-Doo sport boat.

  • Page 118: Privacy Information

    PRIVACY INFORMATION We wish to inform you that your coordinates will be used for safety and warranty purposes. Sometimes, we also use the coordinates of our clients to inform them about our products and to present them offers. Should you prefer not to receive information on our products, services and offers, please let us know by writing to the address below.

  • Page 119: Change Of Address

    Please provide your name, address, phone number, Hull Identification Number and date it was stolen. BRP will provide a list of stolen units to all authorized Sea-Doo sport boat dealers on a monthly basis to aid in recovery of such units to their owners.

  • Page 120: Change Of Address

    CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary.
  • Page 121 Please provide your name, address, phone number, Hull Identification Number and date it was stolen. BRP will provide a list of stolen units to all authorized Sea-Doo sport boat dealers on a monthly basis to aid in recovery of such units to their owners.
  • Page 122 CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary.
  • Page 123 Please provide your name, address, phone number, Hull Identification Number and date it was stolen. BRP will provide a list of stolen units to all authorized Sea-Doo sport boat dealers on a monthly basis to aid in recovery of such units to their owners.
  • Page 124 CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary.
  • Page 125 Please provide your name, address, phone number, Hull Identification Number and date it was stolen. BRP will provide a list of stolen units to all authorized Sea-Doo sport boat dealers on a monthly basis to aid in recovery of such units to their owners.
  • Page 126 CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary.
  • Page 127 Please provide your name, address, phone number, Hull Identification Number and date it was stolen. BRP will provide a list of stolen units to all authorized Sea-Doo sport boat dealers on a monthly basis to aid in recovery of such units to their owners.
  • Page 128 CHANGE OF ADDRESS If your address has changed, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your watercraft becomes necessary.
  • Page 129 Purchase Date YEAR MONTH Warranty Expiry Date YEAR MONTH To be completed by the dealer at the time of the sale. DEALER IMPRINT AREA Please verify with your selling dealer to ensure your SEA-DOO sport boat has been registered with BRP.

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