97 Challenger 1800 Noob

[bflowers1971]

Hey y'all! I am new to boating and 2 stroke stuff so please be gentle... I picked up a used Challenger 1800 (1997) the other day and, as you can imagine, it has some issues. I've downloaded the service manual and been studying it to iron everything out. I'd like to throw my concerns out there to get any input and advice. First off, thanks in advance!
Here goes: the port motor is claimed by the PO to be new (and it looks it) but it intermittently turns over like the starter is acting up. Once she starts, it'll only rev to 3500 rpm. I'm thinking it's a fuel issue and gonna look at the carbs. The starboard motor barely starts and has the same starter issue as the other one. The PO told me he thinks the timing needs to be set since he set it and it could be off 10 or 15 degrees (sounds like he "eyeballed it"). Since I'm getting into the timing, I'm planning on going through those carbs as well. Of course I'll be including new plugs and filters as well. I'm kinda scared of running it for more that a few seconds on the trailer without water and trying to figure out how to use the hose correctly. It sounds like I have to pinch off the hose to the transom drain so as not to let the hose water bypass the engine. I know that's a lot and trust me when I say there's more (mostly little cosmetic things). I hope I'm going in the right direction. thanks again if you read this whole post!

 

[bflowers1971]

Quick update: I set the timing on the starboard motor and now I just get a click from the electrical box. Haven't tested power at the starter yet but I'm thinking it bit the dust. It was having a hard time before. Also the port motor starts fine still, when I put it in the water, it would not buils rpms when in gear, maybe a bad neutral switch??

 

[snikwad003]

I was under the impression the timing was fixed except for what can be done in the mpem with a scan tool

 

[bflowers1971]

I was under the impression the timing was fixed except for what can be done in the mpem with a scan tool

I should clarify, rotary valve timing. The PO says he set it but it might be off so I took a peak and set it. It was off a bit, it's set at 147 degrees now.

 

[bflowers1971]

Ok, so another update. Tested the starboard starter and she's bad. Luckily, I went ahead and ordered one just in case. Got the old one out and I'll put the new one in tomorrow. I suppose I'll test compression after that.

 

[bflowers1971]

So on a side note, this boat has been modified a bit, it has no fuel filters on the lines and someone installed primer bulbs in line (pulse line). Also, the oil pump linkage (cable) that is supposed to go to the throttle has been disconnected. My guess is that it had accellerator pump issues and instead of rebuilding the carbs, the previous owner put those primers in. Glad I have the service manual...

 

[snikwad003]

Are the primer bulbs where the fuel filters should be?

 

[bflowers1971]

Not really, the primers are located in the middle of the pulse line. From the service manual, it looks like the filters should be close to the carbs.

 

[snikwad003]

I just did fuel lines last night so this is fresh in my mind: pulse line real short from crank case to pulse input of carb, starting at fuel pick up goes to fuel valve, then fuel filter then carb for each motor. Return lines are tee'd together for each carb then both motors return lines are tee'd just before returning to tank. Fuel filters should live here there is nothing wrong with inline filters I just wanted the canister type found on 2 stroke carbed jetskis. Hope this helps. I dont know how a squeeze ball primer in the pulse line would help unless it makes enough pulse to make the fuel pump pump.

Here is a better shot of the filter location

 

[bflowers1971]

Very helpful, thanks. Looks like I'll be replacing all the lines that are no to oe specs. Hopefully it'll run for the summer the way it is so I can put that on the list for the winter.

 

[snikwad003]

Are you gonna go the carbs?

 

[bflowers1971]

Most certainly they will need it. I need to get the starboard motor running first. I just finished putting the starter in and "clunk" it locked up. I turned it by hand but it would only go one direction so I pulled the plugs and turned it over. I've been cleaning up oil since... I think I've got an oil leak.

 

[bflowers1971]

Any recommendations on whete to get Mikuni kits?

 

[bflowers1971]

So it looks like tomorrow morning, I'll be setting the carbs to factory settings. Both motors turn over nicely, the port one starts and idles but when I took it to the lake, she'd fall on her face with any throttle. The starboard motor turns but will not fire. I've got spark so I'm suspecting that fuel is my issue. Wish me luck! The family and I start vacation Sunday AT THE LAKE! sure would be nice to take her out!

 

[bflowers1971]

Welp, I decided to finally check compression (I know, shoulda done that 1st) and I've got 170 PTO and 60 MAG). Both plugs out and WOT...

 

[snikwad003]

Well that sucks

 

[bflowers1971]

Indeed it does. I am assuming my next step is a top end rebuild right? Could it be loosing compression around the rotary valve? Probably would show low on both cylinders if that huh?

 

[snikwad003]

170 is realy high, maby you should double check rotary timing. Or your gauge reads high and you have 150 in the good jug and 40 in the bad. 155 psi is a perfect new 787

 

[bflowers1971]

 

[bflowers1971]

 

[bflowers1971]

170 is realy high, maby you should double check rotary timing. Or your gauge reads high and you have 150 in the good jug and 40 in the bad. 155 psi is a perfect new 787

I went ahead and pulled the head... pretty sure I found the problem.

 

[snikwad003]

Id say you found it. [emoji107]

 

[bflowers1971]

On a more positive note, the port engine has 130 psi on each cylinder! Yay!

 

[snikwad003]

If you had 170 on the other motor i think your guage is reading high i would try another gauge and see what it says keeping in mind it could be off too

 

[bflowers1971]

10-4, good advice.