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RESTO 1998 SeaDoo Challenger 1800 Restoration Project
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The original SeaDoo Mikuni fuel pumps were 14 years old and couldn`t be trusted given I went this far already. So the fuel pump mounts were modified to accept High Volume dual outlet Mikuni pumps.
Relocated one hole on each bracket, drilled and tapped for m6, and a little grinding down the brackets edge to clearance the pulse line fitting...
Use Allen socket heads/hardware to secure the pump to bracket.
Rebuilt the carbs using all new Mikuni kits. including new needle and seat, and also including new accelerator pump diaphragms.
Ran all new supply and return lines using Tygon with fire retardent convoluted covering.
Rearward facing fuel supply on the mag carbs were filled with epoxy and capped. Each carb now has it`s own direct fuel supply from pump.
also fixed the shoe shine return line repair from the previous owner, using Brass fittings and tygon tying independently to the return line to the tank...
Note* I did not take pics of all 4 carb`s rebuilt, just have a few. I also did not repaint them, as I will keep a vigilant eye on their condition. They are well cleaned and reassembled.
WSM intake gaskets were used and coated with Permatex High Tack spray. HP Thread sealer applied to stainless bolts, and torqued.
Relocated one hole on each bracket, drilled and tapped for m6, and a little grinding down the brackets edge to clearance the pulse line fitting...
Use Allen socket heads/hardware to secure the pump to bracket.
Rebuilt the carbs using all new Mikuni kits. including new needle and seat, and also including new accelerator pump diaphragms.
Ran all new supply and return lines using Tygon with fire retardent convoluted covering.
Rearward facing fuel supply on the mag carbs were filled with epoxy and capped. Each carb now has it`s own direct fuel supply from pump.
also fixed the shoe shine return line repair from the previous owner, using Brass fittings and tygon tying independently to the return line to the tank...
Note* I did not take pics of all 4 carb`s rebuilt, just have a few. I also did not repaint them, as I will keep a vigilant eye on their condition. They are well cleaned and reassembled.
WSM intake gaskets were used and coated with Permatex High Tack spray. HP Thread sealer applied to stainless bolts, and torqued.
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Took the boat out to break in the engines, running a little heavy 40:1 premix. Put about 2 hours on it. Still had a water leak and discovered it was a melted exhaust outlet...
This boat was just never cared for, it`s almost as if the engine hatch were never opened underway to see anything going on for YEARS!!!, But Armor all on the seats did make it shine!
ordered a new exhaust outlet, some stainless .080 pipes and silicone couplers with T bolt clamps. and came up with this...
Since anything after the waterbox`s with water control valves are for sound suppression/noise I thought how loud could it really be? Louder than the FF in the GPR
anyways, they work, sound good, and no drone under the swim platform!
modified the muffler support for the Starboard pipe.
these were mocked up with the bad outlet, when the outlet showed up, it was completed...
This last time out the boat doesnt sound loud at all, but was a short ride. Came up on plane and lost the splines in the port engine impeller. ooops!
I`m currently replacing the impellers and one drive shaft due to stripped splines. Guess the 14 year old impellers were not up to the task of a repower... and the port engine might need to come back some.
I have only aligned, side to side and axis for driveshaft alignment. Did not touch for and aft, I now see that this contributed to the low out of spec tension on that carbon seal... but we`re learning...
next!...
This boat was just never cared for, it`s almost as if the engine hatch were never opened underway to see anything going on for YEARS!!!, But Armor all on the seats did make it shine!
ordered a new exhaust outlet, some stainless .080 pipes and silicone couplers with T bolt clamps. and came up with this...
Since anything after the waterbox`s with water control valves are for sound suppression/noise I thought how loud could it really be? Louder than the FF in the GPR
anyways, they work, sound good, and no drone under the swim platform!
modified the muffler support for the Starboard pipe.
these were mocked up with the bad outlet, when the outlet showed up, it was completed...
This last time out the boat doesnt sound loud at all, but was a short ride. Came up on plane and lost the splines in the port engine impeller. ooops!
I`m currently replacing the impellers and one drive shaft due to stripped splines. Guess the 14 year old impellers were not up to the task of a repower... and the port engine might need to come back some.
I have only aligned, side to side and axis for driveshaft alignment. Did not touch for and aft, I now see that this contributed to the low out of spec tension on that carbon seal... but we`re learning...
next!...
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recently my friend had informed me that silicone hose and vibration plus heat don`t go well together... he recommended that I replace the tuned pipe to water box with marine exhaust hose...
but said the silicone hoses only last one season... I guess I`ll add this to my list to change over the off season...
a few more pics...
but said the silicone hoses only last one season... I guess I`ll add this to my list to change over the off season...
a few more pics...
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Guest_User
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Here is what I found:
The end of the shaft whittled down a bit until it lost engagement. The Impeller splines took the brunt of it, and the drive shaft bumper in the PTO was mashed flat.
The only thing I could think of was maybe the drive shaft moved forward at some point where it was not engaged and mashed the bumper. Now that there is even more forward movement in the drive shaft it did not stay engaged...
corrective measures: Port Engine
Checked motor mounts, and moved engine back 1/4-5/16th`s.
Checked and aligned.
Cleaned up the old drive shafts.
replace impellers
installed my back up set of wear rings in the pumps.
Starboard engine:
checked and confirmed alignment!
Both wear patterns of the carbon seals were on target!
The end of the shaft whittled down a bit until it lost engagement. The Impeller splines took the brunt of it, and the drive shaft bumper in the PTO was mashed flat.
The only thing I could think of was maybe the drive shaft moved forward at some point where it was not engaged and mashed the bumper. Now that there is even more forward movement in the drive shaft it did not stay engaged...
corrective measures: Port Engine
Checked motor mounts, and moved engine back 1/4-5/16th`s.
Checked and aligned.
Cleaned up the old drive shafts.
replace impellers
installed my back up set of wear rings in the pumps.
Starboard engine:
checked and confirmed alignment!
Both wear patterns of the carbon seals were on target!
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Guest_User
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few more:::
Note: these were those nasty rusted drive shafts that I spent time cleaning up, priming and painting. surprisingly the paint is still on the drive shafts after a few hours of run time...
Note: these were those nasty rusted drive shafts that I spent time cleaning up, priming and painting. surprisingly the paint is still on the drive shafts after a few hours of run time...
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re-alignment/replaced a few hour old wear rings for the new solas impellers:
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Installed the Solas 15\23`s. Closed up the pumps and added Amsoil synthetic oil.
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Next:
straightened out that slightly turned front mount and checked alignment again. Good and locked down!
Installed new neoprene pump seals, the drive shafts, pumps, exit nozzle and reverse buckets. linkages etc etc again...
The black drive shafts are the one`s I removed all de-rusted, primed and painted to protect them for now...
I kept the one new one as a spare, the other is trashed...
will hook up the battery and change the plugs and ride soon...
straightened out that slightly turned front mount and checked alignment again. Good and locked down!
Installed new neoprene pump seals, the drive shafts, pumps, exit nozzle and reverse buckets. linkages etc etc again...
The black drive shafts are the one`s I removed all de-rusted, primed and painted to protect them for now...
I kept the one new one as a spare, the other is trashed...
will hook up the battery and change the plugs and ride soon...
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Welcome to the forum.
WOW, lots of great work here. So much for a turnkey boat. I think your "trusted" friend should refund about 50% back to you.
I bet he wants it back now....LOL
Keep us posted of your "maiden" launch.
WOW, lots of great work here. So much for a turnkey boat. I think your "trusted" friend should refund about 50% back to you.
I bet he wants it back now....LOL
Keep us posted of your "maiden" launch.
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Guest_User
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changed out the plugs since I had a long long low rpm hike back to the ramp on one engine last Monday.
Surprisingly the carb adjustments look good. I set the mixture screw so it runs fatter bc of the premix.
Port engine looks good for just a few hours run time. The Starboard engine plugs also look good considering the 2000-2500 rpm slow hike back to the ramp.
All in all they look good for running Yamalube 2W...
Surprisingly the carb adjustments look good. I set the mixture screw so it runs fatter bc of the premix.
Port engine looks good for just a few hours run time. The Starboard engine plugs also look good considering the 2000-2500 rpm slow hike back to the ramp.
All in all they look good for running Yamalube 2W...
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7/26/12
Took the boat out around noon. Ran pretty darn good! Had the misses and Nikko, and it was hilarious seeing the dog swim with his new K9 life jacket!
we put on 2.5 hours of various running, and a few beach/swim rest stops.
I still have a small water leak , engine/driveline/exhaust all sealed up and fine, have no idea where the water is coming from, since the boat is 14 years old, it could be the ride plate seal/shoe, some area that`s missing sealant, or the bond line...
The auto bilge does a good job of pumping it out, but nonetheless, it`s still wet back there...
I`ll just have to keep and eye on it... and hope I spot where it`s coming from...
otherwise, I like these new 15\23 solas props, they are a bit easier on the boat/engines and same top speed. I ran my usual route, out to the bay, around blood island, back in the river, to the wading 542 bridge and back, various rpm and burned 1/2 tank!, not to shabby!
Took the boat out around noon. Ran pretty darn good! Had the misses and Nikko, and it was hilarious seeing the dog swim with his new K9 life jacket!
we put on 2.5 hours of various running, and a few beach/swim rest stops.
I still have a small water leak , engine/driveline/exhaust all sealed up and fine, have no idea where the water is coming from, since the boat is 14 years old, it could be the ride plate seal/shoe, some area that`s missing sealant, or the bond line...
The auto bilge does a good job of pumping it out, but nonetheless, it`s still wet back there...
I`ll just have to keep and eye on it... and hope I spot where it`s coming from...
otherwise, I like these new 15\23 solas props, they are a bit easier on the boat/engines and same top speed. I ran my usual route, out to the bay, around blood island, back in the river, to the wading 542 bridge and back, various rpm and burned 1/2 tank!, not to shabby!
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Guest_User
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Welcome to the forum.
WOW, lots of great work here. So much for a turnkey boat. I think your "trusted" friend should refund about 50% back to you.
I bet he wants it back now....LOL
Keep us posted of your "maiden" launch.
Thank you! I actually wrote this thread with a new attitude. Luckily I have a great wife (together 26 years) that was very supportive and she said, just fix it! you can doo it!...lol...
It`s a done deal, the harm is done, and we never did receive any compensation as told. I was timely and upfront with the found issues and basically ignored... My fault for not taking my own advice and being more aggressive with the situation, but life is short I`ll get passed this...
I`d like to keep this thread drama free and just share the good, and learn about up coming issues.
I plan on changing the steering head, steering cable, steering nozzles, steering wheel and engine mounts over the off season.
I may just remove the engines and driveline/pumps and place them in the garage for the cold winter.
Thanks for reading!...Andy...
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update: 8/1/12
went out at high tide yesterday morning with the misses for a 34-35 mile trip, just around the rivers, after the GSP bridge was looking nasty so we stayed inland. Mullica and wading...
My lovely assistant found the leak, on the way back I asked her to watch for anything obvious and she say`s that black thing is leaking!!!, I asked her to point it out and she said she`ll take a vid of it bc she had the camera!, saweet!...
The water control valve is leaking under load... ding ding ding...
and here`s a few pics of what I found wrong with the new valve.
(good thing I saved an old one)...
otherwise, the boat is running pretty well...
surprisingly we did he same route I did with the GPR and used just about the same amount of fuel/oil... not to shabby
went out at high tide yesterday morning with the misses for a 34-35 mile trip, just around the rivers, after the GSP bridge was looking nasty so we stayed inland. Mullica and wading...
My lovely assistant found the leak, on the way back I asked her to watch for anything obvious and she say`s that black thing is leaking!!!, I asked her to point it out and she said she`ll take a vid of it bc she had the camera!, saweet!...
The water control valve is leaking under load... ding ding ding...
and here`s a few pics of what I found wrong with the new valve.
(good thing I saved an old one)...
otherwise, the boat is running pretty well...
surprisingly we did he same route I did with the GPR and used just about the same amount of fuel/oil... not to shabby
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Guest_User
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while I`m waiting for the replacement WCV to arrive, I had saved the one`s I took out, and looked it over. I reinstalled the good older one and will swap out later.
Hopefully next ride there be no more water leaks... geez!!!
OK, folks, Thanks for reading! That`s it for now, we are waiting to go out sometime next week... cross your fingers!
I hope this helps someone here with their Challenger 1800, and I hope to learn anything from comments about previous repair or future repairs. I can handle constructive criticisims. Thanks...
Hopefully next ride there be no more water leaks... geez!!!
OK, folks, Thanks for reading! That`s it for now, we are waiting to go out sometime next week... cross your fingers!
I hope this helps someone here with their Challenger 1800, and I hope to learn anything from comments about previous repair or future repairs. I can handle constructive criticisims. Thanks...
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Guest_User
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Wow !!!!! you got a lot done in one day !It's going to take me an hour to read it all.
I know you posted this all in one day... but what was the time... start to finish?
Hi Tony, I can safely say between the trailer work and boat repair I have easily over 300+ hours. not to count research/ordering/phone time/traveling around sourcing supplies.
we bought the boat, transferred ownership on Apr 7. and just these last couple of weeks to a month we have been on the water, and repairing what we see. so we are down to the nitty gritty...lol...
put into the time line all the rain we had here on the east coast delaying the work, but I tried to make good use of my time with "in the garage" prep/build/repair...
I don`t think it was to bad and terribly long, just took an enormous amount of time away from the family stuff...
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Today`s ride was fun. Even N enjoyed himself.a little swim a little lunch, Life is good!
as previously mention, installed an old WCV so we can get out on the water today.
When we returned the new replacement WCV was at the front door! Now that`s good service from PPG right there! awesome... warranty part!
yesterday I had the throttle controls out to inspect something and painted the knobs red bc they were faded...
as previously mention, installed an old WCV so we can get out on the water today.
When we returned the new replacement WCV was at the front door! Now that`s good service from PPG right there! awesome... warranty part!
yesterday I had the throttle controls out to inspect something and painted the knobs red bc they were faded...
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Nice job! It's all about the maintanence---or lack there of in your previous owners case. It looks great and you should be proud of yourself. Where abouts in Jersey are you? Looks like your in tea water.
If no one has told you what BOAT stands for yet I'll be glad to!
Break
Out
Another
Thousand
Looks like you have that covered!:thumbsup:
If no one has told you what BOAT stands for yet I'll be glad to!
Break
Out
Another
Thousand
Looks like you have that covered!:thumbsup:
100guard
New Member
HOLY SMOKES!!!!!!!!!!!!
Bravo Sir.
If only I had an iota of mechanical inclination as you do. I'm NOT a DIY'er and just taking the Jpump off my 98 speedster (to replace wear ring and obviously now jpump cone oil) is daunting me.
I'm amazed you have done all that.
I'm unclear if you were able to salvage your old drive shafts or not? Do you think they would be useable as an impeller removal tool? and rather compatible with my 98 Speedster? I'm about to buy one from ebay, but if you have one that I can use, I am happy to send you the cash.
Absolutely amazed by all the work you did.
Great vid!
Bravo Sir.
If only I had an iota of mechanical inclination as you do. I'm NOT a DIY'er and just taking the Jpump off my 98 speedster (to replace wear ring and obviously now jpump cone oil) is daunting me.
I'm amazed you have done all that.
I'm unclear if you were able to salvage your old drive shafts or not? Do you think they would be useable as an impeller removal tool? and rather compatible with my 98 Speedster? I'm about to buy one from ebay, but if you have one that I can use, I am happy to send you the cash.
Absolutely amazed by all the work you did.
Great vid!
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100guard
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I agree. I read that some people just bent an old drive shaft into an elbow and used that. I thought it was a great idea.
lol...like I know what that is.
Awesome! 7.99..Sigh....they don't do USPS., UPS $20. UPS is known for astronomical brokerage fees...we're talkin' 40-50% of the value of the item shipped LOL.
I'll just grab one from ebay I guess then.
I love their interface. You can set your vehicle/craft and they'll filter for things that fit/might fit. That makes things nice. Too bad they don't have much for mine.
Yeah I got that., bought a digital torque thingy as well., so I'm set. Tomorrow my wear ring should be in, so hopefully in the afternoon or Friday I'll get it back together.a service manual has the information and torque specs for the bolts/nuts. I recommend to get a copy if you can.
Thanks
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