SeaDoo Challenger Mercury M2 240 HP Jet Drive Won't Go Over 2500, 3500, 4500 RPM and Won't Start.

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

[@rockwellpaintingstaging8051]

I'll be happy to walk you through it when you're ready..

[@liammoore8287]

Dude this is one of the coolest videos I've ever watched especially because there's no content on these engines at all. I've always been interested in getting a sea doo boat and I like the idea of getting the mercury V6 because it seemed more reliable than the sea-doo engines. Now you definitely have me second guessing myself this sounds like an absolute nightmare to keep running. maybe i'll buy one if i'm feeling masochistic. But regardless thank you for this video, very rare to find content on this engine.

[@golferdmr]

I'm glad you liked the video. I will tell you now I would absolutely recommend this motor. It is really easy to work on and ever since I got it working, I have had zero problems.

[@isaacgarcia3390]

Thank you Bro 4 the heads up, with all intell you posted and passed on in this video with all the advice. Through your trial and area, thank you Bro I have been in the dark for so long much respect 👌

[@golferdmr]

Yes Sir, I was actually out dragging the kids around on a Tube this morning. The darn thing is working great.

[@krishoffman1516]

Your a big help thank you!!!

[@golferdmr]

Glad it helped.

[@rockwellpaintingstaging8051]

It was a little hard I had to modify a few things when you pull the old cable out and match it up I ran mine through the drive linkage it's hard to make that turn make sure you take some pics for reference.

[@rockwellpaintingstaging8051]

What's going on David good video I have an 02 Sportster 1800 same motor I just finished replacing steering cable..

[@golferdmr]

How did that go? I have a cable waiting in the garage but, the snow is just melting where I live.

[@ericandthesibs2203]

Where did you get the manual from? I just bought a Seadoo Challenger with a Merc 240. This will be helpful info for me to go ahead and take care of the common problems/maintenance with these engines.

[@golferdmr]

So the first manual I bought was for the Challenger but, it’s worthless. You need to buy the manual for the Mercury motor. I got mine on eBay for like $10.

[@rockwellpaintingstaging8051]

It's not starting good crank but not firing up any suggestions before I get into it..

[@golferdmr]

I would start by chasing the fuel from the tank to the high pressure out put. You are probably going to need to purchase a pressure Guage. They are $25 on Amazon. The first pump is low pressure and there is a couple filters.

[@rockwellpaintingstaging8051]

@@golferdmr I'm going to check later today if I can hear that first pump running also was thinking about shooting a tiny bit of starting fluid in each carb just a small spray

[@rockwellpaintingstaging8051]

@@golferdmr I noticed that square pump I'm going to check to see if it's even making a sound I should hear something before I Crank goon work on it Saturday

[@rockwellpaintingstaging8051]

@@golferdmr where would the filters be located?

[@espinoza313ae]

Hey man So mine isn't going over 4000 .. My question is what the the trigger do? Some machanic said its a fuel problem but i have 40 psi and that it has 3 fuel pumps and that it would me $2000 to start working on it and keep going up after that if thats not the problem.

[@golferdmr]

I could definitely see it costing that much as mechanics in my area are now $180/Hr. To answer your question, I think the trigger is like a distributor. It sends a signal as the fly wheel and stator spin around it. It is what your are advancing (turning counter clockwise) as you engage the throttle or mess with the timing screws. WARNING, after I messed with my stator, it must have got pinned in the advanced position and when I started it if for the first time it took off at full speed. Luckily, I was pointed in a safe direction. I yanked the throttle back and fourth and it never happened again but, it really scared me. I think of it this way, you can try to replace it. It’s under $100 on Amazon and you will need a flywheel puller (under $20). It is a very easy job. I would also disconnect the fuel line coming from the water separator (looks like oil filter) to the Vapor separator (looks like a oblong aluminum tank). If there is good flow when you turn the key to “on”, not start, you have eliminated 2 of the 3 fuel pumps. I would also get a fuel gauge, remove the valve stem from that bicycle stem looking thing on the top of the vapor separator and install the fuel pressure gauge and just don’t remove it until you figure this out. It’s is weird that yours is a 40 pounds, the book says 34 and mine never moved from 34 after if got the fuel issue fixed. There is a pressure regulator that should keep it at 34 pounds. I think the high pressure pump can go to 60. Finally, there is a procedure in the manual where you can see the injectors fire by taking off the cover. You can do all this without removing the engine and it wouldn’t take very much time. I would go that route if its not the trigger and your low and high pressure pumps are working. In the end, all my problems were caused by one bad injector. The boat will do 4500 RPMs on 4 of 6 cylinders.

[@espinoza313ae]

Hey do you have the info where you bought the lift pump .. did you get an aftermarket or original? And do you know how much psi it should have