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2001 Sea Doo Challenger with Mercury M2 240 HP Jet Drive.
This video is my victory lap to finally getting a SeaDoo Challenger with a Mercury M2 240 HP Jet Drive working.
I purchased the boat and the guy said, “it was running last year”. I can tell you it is not possible it was running correctly last year. This is the saga of me getting the boat running. I have around 100 hours in the boat, mainly because I used the incorrect strategy, I was unfamiliar with the systems, and the boat had way more than normal flaws.
This is the steps I took
Replaced high pressure fuel pump (inside Vapor Separator). Went from 0 - 2500 RPM
Replaced Trigger. Went from 2500 - 3500
Fixed timing. Went from 3500 to 4500
Replaced 1 fuel injector, replaced piston, rings and honed Cylinders #3 and #5. 4500 to 0 RPM
Started from scratch with the sequence I would recommend now.
Check low pressure fuel delivery to the Vapor Separator
Check high pressure fuel delivery with gauge hooked to valve stem at top of Vapor Separator (Needs to be 34 pounds)
Pull all plugs and ground spark plug wires. Check compression and spark with gap tester at same time.
Check timing using procedure in manual.
There are many more tests in the manual but remember, f it has fuel, compression and spark at the correct time it will run.
Good luck
I kind of just ramble most of the video. It is a stupid video but I sure wish I had it to watch before I started. This should help skip around.
Introduction :01
Tools 2:00
Comments 2:30
Serial Number 3:06
Jet drive serial number 3:50
Not starting 4:30
Fuel System explained 4:35
High pressure fuel pump 5:40
2500 Max RPM 6:42
Trigger 7:06
3500 Max RPM 7:58
Timing 8:40
4500 Max RPM 9:53
Compression Check 10:30
Ground plug Wires 10:55
Compression Tester Tool 10:38
2 Stroke Injector bad and problem with that 13:06
Bad piston 13:44
Hone tool 14:08
Won’t start 4500 - 0 RPM
Correct trouble shooting procedure 15:30
Spark Test 15:45
Compression test 16:06
Compression, Fuel, Spark 16:19
Lift pump 16:37
Timing each cylinder 16:50
Bleed System Leak 17:30
Fuel, Compression, spark 18:40
Fuel, spark, timing 19:25
I searched each of the below searches and got nearly nothing on KZbin so I thought I would do this video.
SeaDoo Mercury M2 240HP Jet drive won’t start
SeaDoo Mercury M2 240HP Jet drive won’t go over 2500 RPM
SeaDoo Mercury M2 240HP Jet drive won’t go over 3500 RPM
SeaDoo Mercury M2 240HP Jet drive won’t go over 4500 RPM
SeaDoo Mercury M2 240HP Jet drive cuts out at 2500 RPM
SeaDoo Mercury M2 240HP Jet drive cuts out at 3500 RPM
SeaDoo Mercury M2 240HP Jet drive cuts out at 4500 RPM