2003 Seadoo Challenger 2000 dies intermittently

[Davin]

I have a 2003 Seadoo Challenger 2000 with the 240 jet drive Merc. I seem to be having an intermittent electric issue. The intermittency makes it REALLY difficult to pin down. Sometimes it will start backup within seconds, sometimes it will be out the majority of the day. I THINK that it might be the ECM, but was hoping somebody might be able to tell me that I'm wrong or a way to troubleshoot it without throwing a really expensive part at it.

It all started when the boat would randomly instantly die. Usually, I'd be able to start it right back up again, but it got worse with time. Now it dies and stays dead for long periods of time where I've had to be towed back in. It instantly stalls out without sputtering, hence why I do not suspect a fuel issue. Since it's intermittent it is hard to pin down, but when it's not wanting to start, I get no electric at the ignition. The boat does not even make the usual beep, or the fuel system prime. There is nothing. I've replaced the ignition switch and the main relay in hopes that it'd be a cheap fix but this did not do the trick.

I've read on multiple forums that the ECM's will sometimes go bad and won't complete the ground circuit needed to start and run.

Any suggestions on troubleshooting this or a way of isolating the scenario so that I know whether or not it actually is the ECM? Is a shop able to test these units before I buy new/rebuilt?

 

[Tim75]

Make sure your ground wires are in good condition. Just because it is tight and does not wiggle does not guarrentee a good connection. There are more ground wires than just the big one from block to battery. I won't say the ecm never fail, but it is seldom. Check the round connector to the ecm. Should be gold connector pins. No green ones allowed.

Check the 4-wire round connector for the injectors. These are not gold, but still no green ones allowed. Find the black with yellow stripe wire on top of engine, aft of flywheel. That is the kill wire. Look for chafed spots. Check the wires that go to the vst. Do you have a way to monitor fuel pressure while running?

Understand the difference between NO CRANK and NO START. Frequently, a no crank can be caused by shifter safeties. A no start can be caused by a bad kill switch.

The only place I have heard of that can test the ecm is brucatopower.com More info at screamandfly.com.

Another common and expensive problem is the dreaded tps. You have a gen 2 engine and I am not very familiar with them.