Campaign no.: 2010 0007 June 29, 2010 Subject:Neutral Switch Malfunction 210 Series No. 2010-5 YEAR MODEL MODEL NUMBER SERIAL NUMBER 2010 210 Challenger 58AE 210 Challenger SE 210 WAKE 58AA, 58AB, 58AC, 58AD, 58AF, 58AG 59AA, 59AB, 59AC, 59AD, 59AG 58AW 59AW See list attached NOTE: Inspect boat at PDI. If boat is already delivered to customer, inspect boat at next service. PROBLEM The throttle/shifter control cam may interfere with the neutral switch lever and cause the neutral switch to be inoperative and not allow the boat to start. PROCEDURES Neutral Switch Inspection Throttle/Shifter Control Removal 1. Remove the lever and the bezel. 1.1 Remove both chromed trims and lever cap. SOLUTION Inspect the neutral switch and if required, replace the cam into the throttle/shifter control, the bezel and hardware kit as per the following procedure. PARTS REQUIRED Order the following parts through the regular channels. PART PART NUMBER QTY Cam (if required) 204 390 609 1 Bezel (if required) 204 390 603 1 Hardware kit (if required) 1/4 washers (mandatory) 204 390 604 1 204 100 089 2 lmr2010-034-010_a 1. Lever cap 2. Chromed trims Trademark of Bombardier inc. used under license. Printed in Canada. (lbg2010-006 en AP) 2010 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved. and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates. 1/6
1.2 Remove lever and bezel. 3.2 Slide the front portion of panel down. lmr2010-034-011_a 1. Lever bolt 2. Bezel screws 2. Remove the console lateral pad. lmr2010-034-014_a Step 2: Slide 3.3 Place the panel aside to make room. NOTE: Take care not to damage the engine cut-off switch wires. lmr2010-034-012_a Step 1: Pull Step 2: Slide 3. Remove the shifter panel. 3.1 Pull the rear portion of panel to unsnap it. lbg2010-006-001 4. Detach throttle/shifter control support from upper deck. lmr2010-034-013_a Step 1: Pull lmr2010-034-015_b 1. Support screws 5. Remove throttle/shifter control from upper deck. 5.1 Protect the seating surface of driver's seat. 2 / 6 2010-5 WARRANTY CAMPAIGN
5.2 Pull out the throttle/shifter control being careful not to damage wires and cables. 5.3 Place the throttle/shifter control upside down on the seat. 6. Check neutral switch lever. If the lever is straight, the mechanism is in good condition. Reinstall the throttle/shifter control. Refer to THROTTLE/SHIFTER CONTROL IN- STALLATION. 2. Remove screw and nut from the throttle cable retainer arm. lbg2010-006-010_a 1. Remove this screw 2. Throttle cable retainer arm 3. Cam 3. Separate the throttle cable actuator from the throttle/shifter control. lbg2010-006-014_a GOOD STRAIGHT LEVER 1. Straight lever If the lever bent, install the new cam. Refer to CAM REPLACEMENT. lbs2010-004-003_a 1. Throttle cable actuator 2. Retaining screw 4. Remove the cam lever screw. lbg2010-006-013_a REPLACE BENT LEVER 1. Bent lever NOTE: If the neutral switch lever is broke, call your service representative. Cam Replacement Cam Replacement 1. Temporarily assemble the lever to the throttle/shifter control and shift the mechanism to forward position to relieve spring tension. lbg2010-006-004_a 1. Cam lever screw WARRANTY CAMPAIGN 2010-5 3 / 6
5. Remove the cam lever screw from the throttle/shifter control. lbg2010-006-012_a 1. Throttle cable retainer arm tab 2. Actuator channel TORQUE lbg2010-006-005_a 1. Cam lever 6. Remove the cam. lbg2010-006-006_a 1. Cam 7. Install the new cam by reversing steps 2 to 4. Cam lever screw Cover system screw 2.8 N m (25 lbf in) 2.8 N m (25 lbf in) Throttle/Shifter Control Installation The installation is the reverse of the removal procedure. However, pay attention to the following. When reinstalling throttle/shifter control, be careful not to bend cables. If the bezel is broken, order a bezel, a hardware kit and two 1/4 washers to replace it. Refer to PARTS REQUIRED for part numbers. During the installation, add both washers behind the bezel. Before tightening the throttle/shifter control lever bolt, make sure that the reverse system is in the neutral position. TORQUE Throttle/shifter control support screws Bezel screws Chromed trims screws Throttle/shifter control lever bolt 8N m (71lbf in) 3 N m (27 lbf in) Finger-tight compression 30 N m (22 lbf ft) lbg2010-006-011_a 1. New cam Ensure everything works properly before operating craft. 8. Install the throttle cable actuator. Make sure throttle cable retainer arm tab is inserted in the actuator channel. 4 / 6 2010-5 WARRANTY CAMPAIGN
WARRANTY For claiming procedure, refer to the DEALER/DIS- TRIBUTOR WARRANTY GUIDE. Neutral Switch Inspection If this action has been completed (this action must be performed on all vehicles), submit a warranty claim using the following information: CAMPAIGN NUMBER 2010-0007 Claim Type Action Flat Rate Time Campaign Claim Inspection 0.6 hours Click in the INSPECT BOX while completing your claim on BOSSWeb. INSPECT NOTE: This will pay for neutral switch inspection, not for cam replacement. Cam Replacement If cam replacement has been performed, submit a warranty claim using the following information: CAMPAIGN NUMBER 2010-0007 Claim Type Action Flat Rate Time Campaign Claim Repair 0.1 hours Click in the INSPECT BOX and in the REPAIR BOX while completing your claim on BOSSWeb. INSPECT REPAIR If repair is performed, you need to click in the IN- SPECT BOX and in the REPAIR BOX to be paid accordingly. NOTE: This will pay for inspection and repair flat rate. Parts required will be automatically included and paid separately on the claim. WARRANTY CAMPAIGN 2010-5 5 / 6
SERIAL NUMBERS LISTING OF INVOLVED VEHICLES Model: 58AA From 025500 to 025526 From 025572 to 025579 From 025581 to 025584 From 025586 to 025592 From 025640 to 025651 From 025668 to 025675 From 025690 to 025692 From 025694 to 025696 025714 Model: 58AB From 026000 to 026003 From 026020 to 026024 From 026026 to 026027 From 026050 to 026053 Model: 58AC From 025527 to 025553 From 025593 to 025609 From 025612 to 025622 From 025652 to 025659 From 025661 to 025662 From 025677 to 025681 From 025697 to 025703 Model: 58AD From 026004 to 026011 From 026028 to 026033 From 026042 to 026043 026056 Model: 58AE From 025000 to 025026 From 025028 to 025044 From 025046 to 025065 025069 Model: 58AF From 025554 to 025571 From 025624 to 025639 From 025663 to 025667 From 025682 to 025689 From 025707 to 025712 Model: 58AG From 026012 to 026019 From 026034 to 026041 From 026044 to 026049 From 026054 to 026055 From 026057 to 026060 Model: 58AW From 026500 to 026511 From 026513 to 026554 Model: 59AA From 027000 to 027007 Model: 59AA (cont d) From 027017 to 027019 From 027021 to 027044 From 027112 to 027119 027147 027151 From 027164 to 027170 From 027189 to 027195 Model: 59AB From 027501 to 027505 From 027510 to 027522 From 027573 to 027574 From 027576 to 027577 From 027582 to 027583 Model: 59AC From 027008 to 027016 From 027045 to 027079 From 027081 to 027097 From 027120 to 027127 From 027129 to 027130 From 027148 to 027150 From 027152 to 027158 From 027171 to 027186 From 027198 to 027216 027219 Model: 59AD 027500 From 027506 to 027509 From 027523 to 027527 From 027529 to 027530 From 027532 to 027555 027562 From 027564 to 027565 From 027578 to 027579 Model: 59AG From 027556 to 027561 From 027567 to 027572 From 027580 to 027581 Model: 59AW From 028001 to 028064 From 028066 to 028144 From 028146 to 028147 From 028149 to 028154 028156 From 028158 to 028159 6 / 6 2010-5 WARRANTY CAMPAIGN