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2001 Sea Doo Challenger 1800 with Merc 240EFI

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JohnCiccarelli

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I just bought this boat and it won't start. Well it ran for about 2 seconds and then would not restart. I am thinking that it is a fuel problem. I was told by an outboard mechanic that the high pressure pump should run to pressurize the fuel rail and it should sound like a motor running. The sound that I hear is a fast ticking problem. Does this mean that the pump is bad or is this the type of sound that is makes. I have jet skis with EFI and you can clearly hear the pump and it sounds like a motor running.

Any Ideas? John
 
The ticking sound is probably from the lift pump on the side of the engine.

There is a pressure valve on the vapor separator to check the fuel pressure on the rail.
 
Hey John. I have the same exact boat with the same problem. I've talked to a few owners and I think I narrowed it down to the vapor separator. I also have the ticking sound from the primer pump on the side of the engine. Ticking also coming from the square plug next to it. Relay switch I think it's called. I have changed both new. I changed the water fuel separator. It was pretty rusted on the inside. I pulled the drain plug at the bottom of the vapor separator and got no fuel to come out. I figured this was it. I pulled the vapor separator out today and found the inside filter clogged very bad with what appeared to be thick grease. Just years of build up I guess. (poor maintenance ). There is a fuel pump inside thus unit as well. I hooked power to it from the battery and it kicked on so thankfully it's good. So after cleaning this unit up I'm going to put it back together and hope it cranks. The inner filter was so clogged that there was no way fuel was getting through it. I could actually leave the key on for a while and let that ticking pump push enough fuel through the system that the boat would actually fire for a second then cut off. It's not an easy removal and I'm sure putting it back together is going be more time consuming. Wish me luck
 
Hey John. I have the same exact boat with the same problem. I've talked to a few owners and I think I narrowed it down to the vapor separator. I also have the ticking sound from the primer pump on the side of the engine. Ticking also coming from the square plug next to it. Relay switch I think it's called. I have changed both new. I changed the water fuel separator. It was pretty rusted on the inside. I pulled the drain plug at the bottom of the vapor separator and got no fuel to come out. I figured this was it. I pulled the vapor separator out today and found the inside filter clogged very bad with what appeared to be thick grease. Just years of build up I guess. (poor maintenance ). There is a fuel pump inside thus unit as well. I hooked power to it from the battery and it kicked on so thankfully it's good. So after cleaning this unit up I'm going to put it back together and hope it cranks. The inner filter was so clogged that there was no way fuel was getting through it. I could actually leave the key on for a while and let that ticking pump push enough fuel through the system that the boat would actually fire for a second then cut off. It's not an easy removal and I'm sure putting it back together is going be more time consuming. Wish me luck
I am going to look at mine today. I will let you know what I find.

I want to replace the fuel water separator and the ones I find have a different part number. 9-37805R vs 9-37805. Mine has the r at the end and the ones I see online do not. Do you know if there is a difference.
 
I'd have to look it up... but since it's EFI... I'm guessing that it should be around 42~48 psi.

Yes... it's the port that looks like a tire valve.

I found it in the service manual and it looks like 34 - 36 psi.

I removed the vapor separator assembly and took it apart and I was surprised that it was clean inside. I also tested the pump and it works fine.

I was surprised that there was very little fuel (about 4 ounces ) in the vapor separator. Shouldn't this fill when I squeeze the primer valve? I do get fuel out of the hose when it is not attached to the vapor separator.
 
It will only fill to the level of the float.

Basically, there is a needle and seat hooked to a float, and that regulates the amount of fuel in the separator. If you think the level is excessively low... check the float/needle/seat.
 
Problem Solved. The problem turned out to be bad connection from the vapor separator to the Fuel Rail. The previous owner must have had it apart left the 2 screws that hold the 2 pipes in place loose. This caused a fuel leak inside the induction manifold assembly. There was very little fuel pressure and a lot of gas pouring into bottom of the motor. When it started it poured a lot of gas out of the exhaust. It now seems to run fine. The water test is tomorrow.

The good news is I learned a lot about how this fuel injection works. I have a lot of experience with 2 stroke jet skis, but this is the first merc jet boat.

Thanks for all of the help. John
 
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Glad you found it. The Merc EFI system is very convoluted compared to a regular EFI system. Once you learn it... it will be easier to find the problems.
 
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