2001 Speedster 240 EFI spins but doesn't start

[Gary13]

Hi, I am trying to help a friend. She has a 2001 Speedster with the Merc 240 EFI.
She has owned the boat for four years and enjoyed it until last year when a ski rope was injested. She took it to a local shop, which tried to sell her a new pump. They kept the boat for 7 months. She finally insisted they return the boat if they weren't going to fix it. She picked it up paid $250 for a new battery and plugs then took it to another shop. The second shop replaced the wear ring but had problems getting it to start. They cleaned/replaced fuel filter and lines(another $600) The boat started on the trailer but when she put it in the water it started, stumbled and died. This sequence was repeated several times until it wouldn't start.
At this point the motor spins over quickly but doesn't start even on the trailer.

Honestly this is the first Merc powered seadoo I have looked at while I am comfortable troublshooting the Rotax two strokes this is a little outside my confidence arena.

I checked compression, 120 - 125 all holes.

Connected a plug to the wire and held it against a ground. The spark looked bright.

Turning the key to the first stop produces a single beep along with a whirring noise which I assume is an electric fuel pump.
I was tempted to squirt 2stroke mix into the intake to verify whether it was gettnig fuel despite the second shops efforts to rehab the fuel system but I wasn't ASsure if this was ok with fuil injection system?

She originally contacted the local Seadoo shop, they were unwilling to work on the merc engined speedster.
The two shops mentioned above were not Seadoo shops. Looking around the engine bay I was shocked to note the new marine battery was just sitting in the battery tray with the bracket loose next to it. Further investigation revealed at least one of the fuel line hose clamps was loose. Not impressed by the quality of work the two local marine shops.

She has the service manual on CD and is looking for it so that i can review the test procedures.
While I am waiting for her to locate the disk I thought I would post here in case there were any suggestions or common problems with this model.

Thanks,
Gary

 

[Dr Honda]

I really hate to hear about shops that are dishonest, or don't do the work. But... first things first....

1) What manual is it? And what is the serial number is on the engine? The reason I'm asking is... there was a major change with the 240 EFI engine. That change happened in 2001-1/2. Normally we don't see the new engine until late 2002, but it's good to know before we get into it.

2) Seadoo shops haven't OFFICALLY worked on Merc powered Seadoo boats since 2007 (?) When Merc and BRP broke relations... they stopped.

3) Yes... the "Whering" noise is probably the high pressure pump for the EFI.


Now for things to check...

a) I know you said you checked for spark... but check ALL the plugs for spark. The merc engine is a strange beast, and the system is self ballasting, and each plug is (more or less) it's own "System" So... you may have found the ONE plug that has spark.


FUEL: To me... it sounds like you aren't getting fuel.

b) Remove the rubber hose from the small square/box shaped pump on the port side of the engine, and make sure you can suck fuel up the hose. I've seen a bunch of times, where there is a small leak in that hose, and you just can't get anything into the engine.

c) Verify that the square pump is working. It is basically a "Lift pump" to prime the system. It only pumps when you crank the engine. There is also a fuse directly next to it. (make sure the fuse is good, and you have power while cranking) Also there is a filter just before that pump (should be a small metal fitting) Since it is small... it could be plugged up. Check it too.

d) if that checks... make sure you have fuel in the vapor tank. (it's the aluminum tank on the front of the engine that has the high pressure system) There is a small drain screw on the bottom edge. If you remove it... there should be fuel. (I'm guessing it's going to basically empty)

e) IF you have fuel in that tank... you should see a Schrader valve on top of the tank. (like a tire valve stem) Put a gauge on that, and you are looking for ~46 psi when you turn the key on. (when you hear the whering sound)


Check that over... an let me know what you find.

 

[Gary13]

Tony:
Thanks for the quick reply, I didn't get the serial number from the motor. The ECU P# is 824003A31 if that is indicative of the version power head?


I believe this is the pump/filter you mention verifying


Starboard side of power head


This looks like a reservoir of some type located Port Side toward the bow?


I am suppose to stop over later this afternoon to run through your suggested checks and will post the results.
Thanks again!
Gary

 

[Dr Honda]

The ECU number didn't help... but from the pics, I can see it's the "Early" engine. (Pre 2001-1/2)

Yes... that's the pump and filter.

The bottom pic is the vapor tank. You can see the Schrader valve on the top of the tank. It's rusty... but you will see it. The drain plug is just out of the picture, on the bottom.

 

[Gary13]

Tony:
Good spark on all 6.
Easy to siphon fuel to lift pump.
Filter clean.
Fuel out of the lift pump.
A little fuel drained out of the drain screw on the vapor tank.
checked pressure with key in on position and cranking, both barely moved the pressure gauge, certainly not 46psi.
Actually can hear two pumps, lift pump is noisey, the other pump(high pressure pump?) is quieter.
Gary

 

[Dr Honda]

OK...


You said "A little fuel out of the drain." Did you completely drain the tank? How much is a little? (enough to fill the tank 3/4 full?)

If it was just a couple oz... then there could be an issue there.

I would pull the feed hose from the tank, and see if you get fuel up to the vapor tank. if you do... good. if you don't... the big spin-on filter could be plugged up.


IF YOU DO GET FUEL TO THE VAPOR TANK......

1) Pull the drain plug, and let the lift pump run. You should see a good flow out the drain. If you do not get fuel flow... then the valve in the tank could be plugged/stuck. (The tank is like a toilet tank. There's a valve, and it gets close with a float when the level is high enough)

2) If you do get flow... then the tank needs to be taken apart. There is a strainer screen on the bottom of the high pressure pump, and that could be plugged up.

3) After you clean it... if you still don't have pressure... the pump could be bad, or the pressure regulator could have gone bad.



NOTE: Be very careful taking the tank apart. The O-ring kit is CRAZY expensive. Don't rip any of the rubber gaskets.

 

[Gary13]

Only a few ozs of fuel drained from the reservoir...

Tony, I appreciate your help. Unfortunately I am going in today for yet another procedure on my back (via 951X4) and will be out of commission for a bit...

Fortunately, my friend talked to the last shop. She explained that I had found several fuel lines with the hose clamps loose, battery bracket loose etc. They are asking her to bring it back and let them go back thru the fuel system no charge....

Thanks again,
Gary

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