1997 Challenger Starter (starboard) - How To help needed

[jmille15]

I am a newbie to this forum. I am not sure how I went 6 years as a SeaDoo Challenger owner without it, but anyway, I find myself in need of some help.

I have a 1997 Challenger 1800. I sucked up a tow rope into the starboard prop shaft (DOH!) and unfortunately the driver at the time did not realize it and tried to start the boat several times before burning up the starter. I was able to remove all the rope (had to pull the pump assy from the back of the boat to do it) but after freeing up the shaft, the starter doesn't have the torque to turn over the motor. It will with the plugs out, but it still struggles.

I am trying to pull the starter. I removed the airbox and flame arrestor assy to get access to the starter, but it is still a tight spot. I can get to two of the hex screws (the one at the rear, and top) but the hex on the bottom of the starter is in an area where it is almost impossible to reach. I can get an allen wrench to it, but cannot get enough torque angle on it to loosen it up. Has anyone experienced this fun yet?

I would rather not have to pull the engine to get it out, but that may be my last hope. Could use some of your collective experience with this one please!

 

[dbracela]

I forgot to put that bottom bolt in when I installed an engine in my 98 challenger. I was able to get a socket wrench with the Allen head on it in there but it was tight. Would one of those knuckle adapters help?

 

[Guest_User]

you can get in there with an allen socket. The only hex bolt should be the ground cable, and the only hex nut would be the clamp for the return fuel line. The 2 front allen head socket bolts, and the one allen socket head on the rear bracket...

remember to clean these and use loctite and torque properly...

 

[Coastiejoe]

Extensions, allen with a 3/8 drive and knuckle adapters.

 

[jmille15]

Ok. I don't have any of these tools. I guess this is a good excuse to head to the tool store. I am half tempted to pull the motors just to do some cleaning. I followed Pale Rider's threads and really dug what he did with his, and I could stand to replace some lines. Anyone know how difficult it would be to pull the motors? Looks like I would need to disconnect the pipe, some hoses, throttle, and drive shaft. Am I missing anything? How does one disconnect the drive shaft?

 

[jmille15]

By the way.. Do you know what the torque setting is for the starter allen head socket bolts?

 

[Guest_User]

download a manual for your model/year

all the info will be in there...:thumbsup:

http://www.sea-doo.net/SHOPMANUALS/JETBOATS/1996-1997/WELCOME.PDF

 

[jmille15]

Thanks Pale Rider. You rock!

 

[Guest_User]

:cheers:

the service manual in PDF is a must have. anytime you need a reference, it`s right there on your laptop.

Good luck...

 

[jmille15]

Headed to the store to get some tools today. I also need to pick up some bilge cleaner. Anyone have something that they swear by? I was hoping to find something I can spray on the bottom and power wash the gunk out.

 

[jmille15]

One other thing.. there 'was' a plastic sleeve that went around the drive shaft between the hull and the impeller. It got crushed when the tow rope got wound around the shaft. Is this something that need to be replaced. What purpose does it serve?

 

[Guest_User]

I personally use Marine spray9, and simple green in a pinch. others have sworn by Purple power degreaser.

But you have to watch with some of these industrial type cleaners, they don`t like aluminum, painted surfaces or rubber. so if you use a purple type cleaner don`t let it soak or hang for to long...

If you can find Marine Spray 9

then try that.

also Homo depot sells ZEP products, treat these the same as the purple stuff and rinse generously...

However the Marine Spray 9 also gets rid of the mold...

good luck...

note* some have even poured liquid laundry soap in the bilges of ski`s and boats and road around the block to swoosh the soap around, then drain and rinse. I don`t particularly care for doing this with all the electrical and engines still in the boat.

 

[USAF_Pride]

One other thing.. there 'was' a plastic sleeve that went around the drive shaft between the hull and the impeller. It got crushed when the tow rope got wound around the shaft. Is this something that need to be replaced. What purpose does it serve?

That protector is not required and most people toss them after the first time they eat a rope.

 

[jmille15]

Quick update.. After some tool shopping at the local Sears store, I was able to acquire all the items necessary to get the old starter allen screws out. I must say that this is a bugger of a project due to the location of the starter. My ribs are still sore from hanging over the rear seats into the bilge while disassembling and reassembling the parts.

I picked up a new non-OEM starter on eBay for $52. The only difference that I could see was the new starter is a 9 tooth vs. the original 8 tooth. I did some research before hand and it sounds like that is not a major deal. Long story short, I was able to install the new starter with minimal issue and it fired right up.

I picked up some bilge cleaner and powerwashed the gunk out. Next project that I am in the middle of is removing all seats and cleaning mildew off undersides. The boat should look brand new when completed. I will post pictures in a week or so when I am done. Just in time to winterize... DOH!

 

[Coastiejoe]

Glad the starter did what you needed.

OEM is the best way to go when it comes to starters.