This is the Highly Detailed factory service repair manual for the1999 SEA DOO CHALLENGER 1800, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.1999 SEA DOO CHALLENGER 1800 Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Safe Notice
Introduction
Service Tools and Products
Maintenance
Troubleshooting
Engine
Cooling System
Lubrication System
Electrical
Propulsion System
Steering System
Hull / Deck
Technical Data
Wiring Diagrams
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
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6. III
SAFETY NOTICE 0
This manual was primarily published to be used by jet boat technicians trained by the manufacturer who
are already familiar with all service and maintenance procedures relating to Bombardier made Sea-Doo
jet boat.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
It is understood that this manual may be translated into local language upon certain conditions and fur-
thermore agreed that in the event of any discrepancy among the two versions, the English version shall
prevail.
The content depicts parts and/or procedures applicable to the particular product at its time of manufac-
ture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufac-
turing the product.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking disk,
lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
This information relates to the preparation and use of Bombardier jet boat and has been utilized safely
and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or
injuries resulting from the improper use of the contents. We strongly recommend that any services be
carried out and/or verified by a highly skilled professional technician. It is understood that certain modifi-
cations may render use of the boat illegal under existing federal, provincial and state regulations.
x WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
- CAUTION
Denotes an instruction which, if not followed, could severely damage boat components.
SAFETY NOTICE
7. IV
WHAT’S NEW 0
This section indicates this year major changes brought in this shop manual.
SERVICE TOOLS AND SERVICE PRODUCTS
• Revised tool part numbers. Tool are identical to last year, only part numbers have been modified.
• The following tools are new:
• Radio installation tool (P/N 295 100 106).
• Tool board (P/N 295 500 608).
• Tie-down (P/N 295 100 088).
• Lift kit:
– 14 foot (P/N 295 000 160).
– 16 foot (P/N 295 100 085).
– 18 foot (P/N 295 100 045).
• The following products are new:
• Loctite Chisel (P/N 413 708 500) replaces Gasket stripper (P/N 295 000 110).
• Parts cleaner (P/N 413 711 809) replaces Loctite safety solvent (P/N 293 800 019).
• Vinyl and plastic cleaner (P/N 413 711 200 - 6 x 1 L).
• Loctite 414 super bonder (P/N 413 705 800 - 30 mL).
• Loctite 425 (P/N 293 800 040).
• Molykote 111 (P/N 413 707 000).
MAINTENANCE
• Revised periodic inspection chart with aluminum anode inspection.
• Revised flushing procedure with flushing connectors mounted on pump support.
• New impeller shaft oil capacity.
• New photographs.
TROUBLESHOOTING
• Revised items according to main battery cut-off switch.
ENGINE
• Revised engine cover removal procedure + photographs.
• New main battery cut-off switch.
• Revamped Engine/Jet Pump Alignment section.
• New wire color codes on generating and charging coils.
COOLING SYSTEM
• Revised procedure for Oetiker clamp removal.
• Flushing connectors on pump support (except Sportster model).
WHAT’S NEW
8. V
FUEL SYSTEM
• Revised procedure for clamp removal.
ELECTRICAL
• Standardized wire color codes.
• Main battery cut-off switch on all boats.
• New aluminium anode system on all boats.
• Identified ground blocks to ease troubleshoot.
PROPULSION SYSTEM
• Revised drive shaft protector installation procedure.
STEERING SYSTEM
• Revised steering helm replacement procedure.
HULL/DECK
• New paint colors for 1999.
TECHNICAL DATA
• Updated specifications for 1999.
WIRING DIAGRAMS
• Updated for 1999.
WHAT’S NEW
9. VI
INTRODUCTION 0
This Shop Manual covers the following BOMBAR-
DIER made SEA-DOO® jet boats.
MAXIMUM BOAT CAPACITY
The jet boat maximum capacity can be found on
RH side of operator position.
TYPICAL
HULL IDENTIFICATION NUMBER
(H.I.N.)
The Hull Identification Number (H.I.N.) is located
at right hand rear side of hull.
TYPICAL
1. Hull Identification Number (H.I.N.)
Refer to the illustration for a description of the se-
rial number.
CEC indicates that boats are manufactured in USA.
MODEL MODEL NUMBER
Sportster 5673
Sportster 1800 5676/5680
Challenger 5672
Challenger 1800 5675/5679
MAXIMUM CAPACITIES
U.S. COAST GUARD
7
THIS BOAT COMPLIES WITH U.S. AND CANADIAN COAST GUARD
SAFETY STANDARDS IN EFFECT ON THE DATE OF CERTIFICATION
BOAT DESIGN CATEGORY: C
PERSONS OR 565 KG/1245 LBS.
MADE IN U.S.A., BOMBARDIER CORPORATION OF AMERICA
565 KG/1245 LBS. PERSONS, GEAR
60
4515
0
30
10
30 70
Bombardier
MPH
km/h
90
N
R
F10L1YA
F04L8SA 1
CEC 1 2 3 4 5 L 4 9 5
Model year
Serial
number*
*A letter may also be used as a digit.
F00A0YA
Month of production
Year of production
*A letter may also be used as a digit.
INTRODUCTION
10. VII
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
717 Engine
It is located on the upper side of the magneto hous-
ing.
TYPICAL
1. Engine Identification Number (E.I.N.)
787 Engine
E.I.N. is located on crankcase PTO side.
TYPICAL
1. Engine Identification Number (E.I.N.)
ARRANGEMENT OF THIS
MANUAL
The manual is divided into 13 major sections:
01 SERVICE TOOLS AND PRODUCTS
02 MAINTENANCE
03 TROUBLESHOOTING
04 ENGINE
05 COOLING SYSTEM
06 FUEL SYSTEM
07 LUBRICATION SYSTEM
08 ELECTRICAL
09 PROPULSION SYSTEM
10 STEERING SYSTEM
11 HULL/DECK
12 TECHNICAL DATA
13 WIRING DIAGRAMS
Each section is divided in various subsections,
and again, each subsection has one or more divi-
sion. A table of contents is included at the begin-
ning of most sections.
1
F01D01A
F01D87A 1
INTRODUCTION
11. VIII
Section 03 ENGINE
Subsection 04 (MAGNETO SYSTEM)
MAGNETO SYSTEM
717 Engine
03-04-1
F01D4WS
12 11
5 N•m
(44 lbf•in)
13
9 N•m
(80 lbf•in)
Loctite
242
4
6 8
Loctite
242
7
6 N•m
(53 lbf•in)
Loctite
242
6 N•m
(53 lbf•in)
9
Loctite
242
5
6 N•m
(53 lbf•in)
3
14
Loctite
242
4
Loctite
648
10
15
145 N•m
(107 lbf•ft)
Anti-seize
lubricant
2
9 N•m
(80 lbf•in)
1
Page heading
indicates section
and subsection
detailed.
Tightening torque nearby fastener.
In this case, nut must be torqued to
145 N•m (107 lbf•ft).
Exploded view assists
you in identifying
parts and related
positions.
TYPICAL PAGE
F04A09S
Illustration number
for publishing
process.
Subsection title
indicates
beginning of the
subsection.
Dotted box
contains parts of
a particular
model or an
exploded view.
Page numbering system:
03: ENGINE section
04: MAGNETO SYSTEM subsection
1: First page of this subsection
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents a
liquid product to be
applied to a surface.
In this case Loctite
242 to screw
threads.
Bold face number
indicates special
procedure
concerning this part.
Pay attention to torque specifi-
cations. Some of these are in
lbf•in instead of lbf•ft. Use appro-
priate torque wrench.
CAUTION
INTRODUCTION
12. IX
1
2
Section 06 FUEL SYSTEM
Subsection 03 (CARBURETORS)
06-03-4
Step : Install pump gauge tester to pulse nipple
Step : Pump tester until it reaches the desired pressure
1. Fuel outlet nipple
2. Fuel inlet nipple
A. 28 kPa (4 PSI)
Diaphragm
Challenger Model Only
CARBURETOR REMOVAL
Inspect parts for corrosion dammage (shaft, butterfly,
spring screw, check valve housing, etc.).
Pump Diaphragm Leak Test
TYPICAL
To remove carburetors from engine, proceed as fol-
lows:
Remove air vent tube support.
Unlock retaining slides holding air intake silencer base.
Remove air intake silencer base from watercraft.
Remove screws holding flame arrester base support
to cylinder head cover.
Unscrew base retaining screws then remove base from
carburetors and move to front of watercraft.
Turn the valve to OFF position.
NOTE: For fuel line removal, use pliers (P/N 295 000
054).
Disconnect pulse line from fuel pump.
Disconnect fuel fuel supply line from fuel pump.
Disconnect fuel return line.
Disconnect oil injection pump cable, throttle cable and
choke cable.
Remove screws and lock washers retaining carburetors.
Remove carburetors from intake manifold.
All Others Models
Remove 4 bolts and lock washers from rotary valve
cover then move carburetors and rotary valve cover on
top of engine.
NOTE: When removing rotary valve cover , pay attention
that the rotary valve stay in place, otherwise it must be
timed.
Remove carburetors from intake manifold.
Disconnect fuel bypass line between carburetors (twin
carburetors).
Remove carburetor(s) from rotary valve cover.
DISASSEMBLY AND INSPECTION
Using a suitable pump gauge tester, perform the fol-
lowing test proceeding as follows:
- Install pump gauge tester (P/N 295 000 083) on pulse
nipple.
- Pump tester until it reaches 28 kPa (4 PSI).
Diaphragm no. 3 must stand pressure for 10 seconds.
If pressure drops, replace diaphragm.
TYPICAL PAGE
Sub-title indicates a
particular procedure for
the named part.
''TYPICAL'' caption
indicates a general
view which does not
represent full detail.
Italic bold face
setting in this case
indicates that
particular procedure
for Challenger is
finished, so from this
point, all others
models are
concerned.
Italic bold face setting
indicates a particular
procedure concerning
a model.
Service tool to be
used to perform a
certain procedure.
Title indicates main
procedure to be
carried-out.
F04A08S
Sub-sub-title
indicates a
particular testing,
adjustment or
repair procedure.
Illustration
always follows
text it is
pertained to.
Numbers in a frame
are used to give a
sequence to be
perfomed for above
illustration.
Numbers are used
for description of
components for
above illustration.
Letters are used for
any measures for
above illustration.
F01F0XB
A
2
1
1 2
Number: following
part name refers to
exploded view at
beginning of
subsection.
F01F0XB
A
2
1
1 2
INTRODUCTION
13. X
LIST OF ABBREVIATIONS USED
IN THIS MANUAL
GENERAL INFORMATION
In marine industry, PORT, STARBOARD, BOW
and STERN are used to refer to LEFT, RIGHT,
FRONT and REAR respectively. They always refer
to the operator’s position sitting in boat.
1. BOW (front)
2. STARBOARD (RH)
3. STERN (rear)
4. PORT (LH)
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
products without imposing upon itself any obliga-
tion to install them on products previously manu-
factured.
Bombardier Inc. reserves the right at any time to
discontinue or change specifications, designs,
features, models or equipment without incurring
obligation.
This Shop Manual uses technical terms which
may be different from the ones of the Parts Cata-
logs.
When ordering parts always refer to the specif-
ic model Parts Catalogs.
AC Alternative Current
Ass’y Assembly
ATDC After Top Dead Center
BTDC Before Top Dead Center
CDI Capacitor Discharge Ignition
CSI Cooling System Indicator
DC Direct Current
DC-CDI
Direct-Current Capacitor Discharge
Ignition
DESS Digitally Encoded Security System
E.I.N Engine Identification Number
H.I.N. Hull Identification Number
HP Horsepower
LH Left Hand side (port)
MAG Magneto
MPEM Multi-Purpose Electronic Module
N.A. or
N/A
Not Applicable
P/N Part Number
PTO Power Take Off
RAVE Rotax Adjustable Variable Exhaust
RFI Radio-Frequency Interference
RH Right Hand side (starboard)
RMS Root Mean Square
ROM Read-Only Memory
RPM Revolution Per Minute
SAE Society of Automotive Engineering
TDC Top Dead Center
T.I.G. Tungsten Inert Gas
TLCS Total Loss Cooling System
Vac Volt, Alternative Current
Vdc Volt, Direct Current
VROI Variable Rate Oil Injection
24
1
3F04L03C
INTRODUCTION
14. XI
ILLUSTRATIONS AND
PROCEDURES
The illustrations show the typical construction of
the different assemblies and, in all cases, may not
reproduce the full detail or exact shape of the parts
shown; however, they represent parts which have
the same or a similar function.
As many of the procedures in this manual are in-
terrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before commenc-
ing any procedure, be sure that you have on hand
all the tools required, or approved equivalents.
Technical Publications
Bombardier Inc.
Valcourt (Quebec), Canada
- CAUTION
These boats are designed with parts dimen-
sioned in both the metric and the imperial
systems. When replacing fasteners, make
sure to use only those recommended by
Bombardier. Mismatched or incorrect fas-
teners could cause damage to the boat or
possible personal injury.
INTRODUCTION
15. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-1
TECHNICAL DATA 0
ENGINE SPORTSTER SPORTSTER 1800 CHALLENGER
Number of engine 1 2
Engine type BOMBARDIER-ROTAX 717, water cooled
Induction type Rotary valve
Exhaust type Type Water cooled, water injected
Water injection fittings 3.5 mm (.139 in)
Starting system Electric start
Lubrication Fuel/oil mixture VROI (Variable Rate Oil Injection)
Oil injection pump Gear driven
Oil type
BOMBARDIER-ROTAX injection oil
P/N 413 802 900 (12 x 1L)
P/N 413 803 000 (3 x 4L)
P/N 413 803 200 (205 L)
Number of cylinders 2
Bore Standard 82.00 mm (3.228 in)
First oversize 82.25 mm (3.238 in)
Second oversize 82.50 mm (3.248 in)
Stroke 68 mm (2.68 in)
Displacement 718.2 cm³ (43.81 in³)
Compression ratio Uncorrected 12: 1
Corrected 6.2: 1
Engine maximum torque 91 N•m (67 lbf•ft)
@ 6250 RPM
2 x 91 N•m (67 lbf•ft)
@ 6250 RPM
Cylinder head warpage (maximum) 0.05 mm (.002 in)
Piston ring type and quantity 1 semi-trapez — 1 rectangular
Ring end gap New 0.25 - 0.40 mm (.010 - .016 in)
Wear limit 1.00 mm (.039 in)
Ring/piston groove clearance New 0.025 - 0.070 mm (.001 - .003 in)
Wear limit 0.2 mm (.008 in)
Piston/cylinder wall clearance New 0.09 - 0.11 mm (.0037 - .0044 in)
Wear limit 0.20 mm (.008 in)
Cylinder taper (maximum) 0.10 mm (.004 in)
Cylinder out of round 0.08 mm (.003 in)
Connecting rod big end axial
play
New 0.39 - 0.74 mm (.015 - .029 in)
Wear limit 1.2 mm (.047 in)
Crankshaft deflection (center) 0.08 mm (.003 in) Œ
Rotary valve timing Opening 147° ± 5 BTDC
Closing 65.5° ± 5 ATDC
Rotary valve duration 158°
Crankcase/rotary valve gap 0.25 - 0.35 mm (.010 - .014 in)
Connecting rod/crankshaft pin
radial clearance
New 0.01 - 0.02 mm (.0004 - .0008 in)
Wear limit 0.05 mm (.002 in)
Connecting rod/piston pin
radial clearance
New 0.003 - 0.012 mm (.00012 - .00047 in)
New limit 0.015 mm (.00059 in)
ADDITIONAL INFORMATION:
ΠMAG side: 0.05 mm (.002 in).
PTO side: 0.03 mm (.001 in).
16. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-2
ELECTRICAL SPORTSTER SPORTSTER 1800 CHALLENGER
Magneto generator output 160 W @ 6000 RPM
or 4 A @ 2000 RPM
2 x 160 W @ 6000 RPM or 4 A @ 2000 RPM
Ignition system type CDI (Capacitor Discharge Ignition)
Spark plug Make and type NGK BR8ES
Gap 0.55 mm (.021 in)
Ignition timing (BTDC) mm (in) 2.59 (.102)
Degrees 20° ± 1 Œ
Generating coil 40 - 76 Ω
Trigger coil N.A.
Battery charging coil .05 - .6 Ω
Ignition coil Primary .34 - .62 Ω (not measurable)
Secondary 9 - 15 kΩ
Engine RPM limiter setting 7000 (± 50) RPM
Battery Not supplied
Fuse Main 2 x 20 A 3 x 20 A
MPEM (Multi-Purpose Electronic
Module) supply
5 A
Charging system 15 A 2 x 15 A
Blower 7.5 A
Bilge pump 3 A
Lighting system 3 A
Gauges 5 A
Additional accessories 10 A
Horn fuse N.A. 5 A N.A.
12 V connector N.A. 10 A N.A.
Radio/courtesy lights N.A. 10 A N.A.
ADDITIONAL INFORMATION:
ΠEngine cold @ 6000 RPM with shifter in forward or reverse position.
Recommended: Exide RV24-130, 12 V, 25 A•h (130 minutes reserve) or RV24-160 (160 minutes) or equivalent.
Battery pot: On top. Round taper type.
Battery maximum allowed size: 285 mm (11-1/4”) long x 190 mm (7-1/2”) wide x 238 mm (9-3/8”) high.
.
; WARNING
Never use automotive type battery. Its mechanical construction does not allow to meet the
shock conditions where boats operate. Only use the type of battery recommended.
17. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-3
CARBURETION SPORTSTER SPORTSTER 1800 CHALLENGER
Carburetor Type Mikuni single diaphragm with accelerator pump
Model BN-40i-38-25 BN-40i-38-28 BN-40i-38-25
Quantity 1 (per engine)
Main jet 167.5
Pilot jet 70
Adjustment Low-speed 1-1/4 turn ± 1/4
High-speed screw 0/ (closed)
Idle speed (in water) 1500 RPM
Idle speed (out of water) 3000 RPM
Low-speed steering control system
speed (in water)
2500 RPM 2500 RPM 2500 RPM
Fuel Type Regular unleaded gasoline
Octane no. 87 (R + M)/2
Fuel return line 6 mm (.237 in)
ADDITIONAL INFORMATION:
COOLING SPORTSTER SPORTSTER 1800 CHALLENGER
Type Open circuit — Direct water flow from jet pump
Thermostat None
Overheating beeper setting 96 - 99°C (205 - 210°F)
ADDITIONAL INFORMATION:
PROPULSION SPORTSTER SPORTSTER 1800 CHALLENGER
Propulsion system
Bombardier Formula
pump
Bombardier Formula
pump (big hub)
Bombardier Formula
pump
Number of pump 1 2
Jet pump type Axial flow single stage
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
Coupling type Crown splines
Oil type SEA-DOO JET PUMP SYNTHETIC OIL
Polyolester 75W90 GL5 Œ
Steering nozzle pivoting angle 26°
Minimum required water level 90 cm (35 in)
Drive shaft deflection (maximum) 0.5 mm (.020 in)
Impeller outside diameter 139.5 mm (5.490 in)
Impeller/wear ring clearance New 0.18 - 0.44 mm (.007 - .017 in)
Wear limit 1.02 mm (.040 in)
Impeller shaft end play (new) 0.12 - 0.54 mm (.005 - .021 in)
Impeller shaft side play 0.05 mm (.002 in)
Impeller pitch/material Progressive pitch stainless steel
ADDITIONAL INFORMATION:
ΠDo not mix different brands or oil types.
18. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-4
DIMENSIONS SPORTSTER SPORTSTER 1800 CHALLENGER
Draft 30 cm (12 in) 27 cm (10.5 in) 30 cm (12 in)
Dead rise 20° 19.5° 20°
Overall length 442 cm (14 ft 6 in) 546 cm (17 ft 11 in) 442 cm (14 ft 6 in)
Overall width (beam) 216 cm (85 in) 229 cm (90 in) 216 cm (85 in)
Overall height 107 cm (42 in) 135 cm (53 in) 107 cm (42 in)
Dry weight 530 kg (1165 lb) 800 kg (1760 lb) 560 kg (1235 lb)
Load limit (passengers and 10 kg (22 lb) luggage) 4 passengers OR
325 kg (715 lb)
7 passengers OR
565 kg (1245 lb)
4 passengers OR
325 kg (715 lb)
based on calm water operation
Maximum water skiers on tow 1 2
ADDITIONAL INFORMATION:
CAPACITIES SPORTSTER SPORTSTER 1800 CHALLENGER
Fuel tank (including reserve) 102 L (27 U.S. gal) 151 L (40 U.S. gal) 102 L (27 U.S. gal)
Fuel tank reserve 10 L (2.7 U.S. gal) 15 L (4 U.S. gal) 10 L (2.7 U.S. gal)
Impeller shaft reservoir Capacity 80 mL (2.7 U.S. oz) 100 mL (3.4 U.S. oz) 80 mL (2.7 U.S. oz)
Oil level height To bottom of cover hole
Oil injection reservoir 9 L (2.4 U.S. gal)
ADDITIONAL INFORMATION:
MATERIAL SPORTSTER SPORTSTER 1800 CHALLENGER
Hull Composite (fiberglass and wood)
Air intake silencer Thermoplastic
Flame arrester Multi-layer wire screen
Exhaust muffler Aluminum
Fuel tank Polyethylene
Oil injection reservoir Polyethylene
Seat Base: polyethylene
Foam: polyurethane
Ride shoe Aluminum Plastic
Jet pump Plastic
Front storage cover Polystyrene
ADDITIONAL INFORMATION:
19. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-5
STANDARD EQUIPMENT SPORTSTER SPORTSTER 1800 CHALLENGER
DESS (Digitally Encoded Security System) Standard
Tool kit Optional Optional Optional
Fuel tank reserve Standard (manual)
Standard (low-fuel
warning system)
Standard (manual)
Electric fuel level gauge Standard
Oil injection low-level/warning device Standard
Overheating warning device and CSI
(Cooling System Indicator)
Standard
Speedometer Optional Standard
Tachometer Optional Standard (2)
Stern light and navigation lights Standard
Courtesy lights N.A. Standard N.A.
Shifter controller (forward/neutral/reverse) Standard
Electric bilge pump (manual switch + auto) Standard
Blower Standard
Storage compartment Standard
Grab handles Standard
Extinguisher holder Standard
Cup holders Standard
Mirrors Optional Standard Standard (2)
Retractable ski pole ® Optional Standard
Bow filler cushion Optional
Sun deck cushion N.A.
Rear cover pad Optional Standard
Platform pad Optional Standard
Radio AM/FM N.A. Standard N.A.
Horn N.A. Standard N.A.
Bimini top Optional Standard Optional
Slide/swivel bucket seats N.A.
Windshield Optional Standard Optional
Rack for ski/wakeboard Optional
Lift kit Optional
Ski door lock Optional Standard Optional
Engine cover lock Optional Standard Optional
Storage cover lock Optional Standard Optional
Cooler door lock N.A. N.A. Optional
Ski rope locker lock N.A. N.A. Optional
Glove box N.A.
Low-speed steering control system Standard
Depth sounder provision N.A. Standard N.A.
Mooring cover Optional
Weedless system Standard
Ladder Optional Standard Optional
Deck carpet Optional
ADDITIONAL INFORMATION:
20. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-6
PERFORMANCE SPORTSTER SPORTSTER 1800 CHALLENGER
Estimated pump power 25.7 kW (34.4 hp) 2 x 24 kW (32.3 hp) 2 x 25.4 kW (34 hp)
Maximum fuel consumption at wide open throttle 31.5 L/h
(8.5 U.S. gal/h)
63 L/h
(17 U.S. gal/h)
Cruising time at full throttle Fuel tank without reserve 2 h 40 min 2 h 10 min 1 h 20 min
Fuel tank reserve 20 min 15 min
ADDITIONAL INFORMATION:
22. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-8
ENGINE CHALLENGER 1800
Number of engine 2
Engine type BOMBARDIER-ROTAX 787, water cooled
Induction type Rotary valve
Exhaust type Type Water cooled, water injected
Water injection fittings 3.5 mm (.139 in)
Starting system Electric start
Lubrication Fuel/oil mixture VROI (Variable Rate Oil Injection)
Oil injection pump Mikuni
Oil type
BOMBARDIER-ROTAX injection oil
P/N 413 802 900 (12 x 1L)
P/N 413 803 000 (3 x 4L)
P/N 413 803 200 (205 L)
Number of cylinders 2
Bore Standard 82.00 mm (3.228 in)
First oversize 82.25 mm (3.238 in)
Second oversize N.A.
Stroke 74 mm (2.91 in)
Displacement 781.6 cm³ (47.68 in³)
Compression ratio Uncorrected 11.75: 1
Corrected 5.9: 1
Engine maximum torque 2 x 110 N•m (81 lbf•ft)
@ 6500 RPM
Cylinder head warpage (maximum) 0.05 mm (.002 in)
Piston ring type and quantity 1 semi-trapez — 1 rectangular
Ring end gap New 0.25 - 0.40 mm (.010 - .016 in)
Wear limit 1.00 mm (.039 in)
Ring/piston groove clearance New 0.025 - 0.070 mm (.001 - .003 in)
Wear limit 0.2 mm (.008 in)
Piston/cylinder wall clearance New 0.09 - 0.11 mm (.0037 - .0044 in)
Wear limit 0.20 mm (.008 in)
Cylinder taper (maximum) 0.10 mm (.004 in)
Cylinder out of round 0.08 mm (.003 in)
Connecting rod big end axial play New 0.39 - 0.74 mm (.015 - .029 in)
Wear limit 1.2 mm (.047 in)
Crankshaft deflection (center) 0.08 mm (.003 in) Œ
Rotary valve timing Opening 147° ± 5 BTDC
Closing 63.5° ± 5 ATDC
Rotary valve duration 158°
Crankcase/rotary valve gap 0.25 - 0.35 mm (.010 - .014 in)
Connecting rod/crankshaft pin radial
clearance
New 0.01 - 0.02 mm (.0004 - .0008 in)
Wear limit 0.05 mm (.002 in)
Connecting rod/piston pin
radial clearance
New 0.003 - 0.012 mm (.00012 - .00047 in)
New limit 0.015 mm (.00059 in)
ADDITIONAL INFORMATION:
ΠMAG side: 0.05 mm (.002 in).
PTO side: 0.03 mm (.001 in).
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24. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-9
ELECTRICAL CHALLENGER 1800
Magneto generator output 2 x 180 W @ 6000 RPM or 5 A @ 2000 RPM
Ignition system type DC-CDI (Direct-Current Capacitor Discharge Ignition)
Spark plug Make and type NGK BR8ES
Gap 0.55 mm (.021 in)
Ignition timing (BTDC) mm (in) 3.38 (.133)
Degrees 22° ± 1 Œ
Generating coil N.A.
Battery charging coil .8 Ω
Trigger coil 242 Ω
Ignition coil Primary .6 Ω (not measurable)
Secondary 11.4 - 14 kΩ
Engigne RPM limiter setting 7200 (± 50) RPM
Battery Not supplied
Fuse Main 3 x 20 A
MPEM (Multi-Purpose Electronic
Module) supply
5 A
Charging system 2 x 15 A
Blower 7.5 A
Bilge pump 3 A
Lighting system 3 A
Gauges 5 A
Additional accessories 10 A
Horn fuse 5 A
Jack system 10 A
Radio/courtesy lights 10 A
ADDITIONAL INFORMATION:
Π@ 3500 RPM with shifter in forward or reverse position.
Recommended: Exide RV24-130, 12 V, 25 A•h (130 minutes reserve) or RV24-160 (160 minutes) or equivalent.
Battery pot: On top. Round taper type.
Battery maximum allowed size: 285 mm (11-1/4”) long x 190 mm (7-1/2”) wide x 238 mm (9-3/8”) high.
.
; WARNING
Never use automotive type battery. Its mechanical construction does not allow to meet the
shock conditions where boats operate. Only use the type of battery recommended.
25. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-10
CARBURETION CHALLENGER 1800
Carburetor Type Mikuni twin diaphragm with accelerator pump
Model MAG: BN-40i-38-49 PTO: BN-40i-38-50
Quantity 2 (per engine)
Main jet MAG: 142.5 PTO: 145
Pilot jet 67.5
Adjustment Low-speed 1-1/2 turn ± 1/4
High-speed screw 0
Idle speed (in water) 1500 RPM
Idle speed (out of water) 3000 RPM
Low-speed steering control system
speed (in water)
2800 RPM
Fuel Type Regular unleaded gasoline
Octane no. 87 (R + M)/2
Fuel lines
IN: 8 mm (.316 in)
RETURN: 6mm (.237 in)
ADDITIONAL INFORMATION:
COOLING CHALLENGER 1800
Type Open circuit — Direct water flow from jet pump
Thermostat None
Overheating beeper setting 96 - 99°C (205 - 210°F)
ADDITIONAL INFORMATION:
PROPULSION CHALLENGER 1800
Propulsion system Bombardier Formula sea pump (big hub)
Number of pump 2
Jet pump type Axial flow single stage
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
Coupling type Crown splines
Oil type SEA-DOO JET PUMP SYNTHETIC OIL
Polyolester 75W90 GL5 Œ
Steering nozzle pivoting angle 26°
Minimum required water level 90 cm (35 in)
Drive shaft deflection (maximum) 0.5 mm (.020 in)
Impeller outside diameter 139.5 mm (5.490 in)
Impeller/wear ring clearance New 0.18 - 0.44 mm (.007 - .017 in)
Wear limit 1.02 mm (.040 in)
Impeller shaft end play (new) 0.12 - 0.54 mm (.005 - .021 in)
Impeller shaft side play 0.05 mm (.002 in)
Impeller pitch/material Progressive pitch stainless steel
ADDITIONAL INFORMATION:
ΠDo not mix different brands or oil types.
26. Section 12 TECHNICAL DATA
Subsection 01 (TECHNICAL DATA)
12-01-11
DIMENSIONS CHALLENGER 1800
Draft 27 cm (10.5 in)
Dead rise 19.5°
Overall length 546 cm (17 ft 11 in)
Overall width (beam) 229 cm (90 in)
Overall height 135 cm (53 in)
Dry weight 848 kg (1865 lb)
Load limit (passengers and 10 kg (22 lb) luggage) 7 passengers OR 565 kg (1245 lb) (based on calm water operation)
Maximum water skiers on tow 2
ADDITIONAL INFORMATION:
CAPACITIES CHALLENGER 1800
Fuel tank (total capacity) 151 L (40 U.S. gal)
Fuel tank reserve (after low-fuel warning signal on some models) 15 L (4 U.S. gal)
Impeller shaft reservoir Capacity 100 mL (3.4 U.S. oz)
Oil level height To bottom of cover hole
Oil injection reservoir 9 L (2.4 U.S. gal)
ADDITIONAL INFORMATION:
MATERIAL CHALLENGER 1800
Hull Composite (fiberglass and wood)
Air intake silencer Thermoplastic
Flame arrester Multi-layer wire screen
Exhaust muffler Aluminum
Fuel tank Polyethylene
Oil injection reservoir Polyethylene
Seat Base: polyethylene
Foam: polyurethane
Ride shoe Plastic
Jet pump Plastic
Front storage cover Polyurethane
ADDITIONAL INFORMATION:
