Boat project 07’ 180 Challenger 215 *Update video

[4tec hoarder]

You should fully charge the battery, if that’s not possible, jump it with a good battery, but not with that vehicle running.

 

[Macker29]

I am not a Sea-doo mechanic, but perhaps the wiring harness is bad from being submerged in water for that long. Might need to replace the entire harness.

Also looks like there is corrosion on the solenoid connection and the fuse you pictured. I would imagine there is corrosion in the harnesses that you cannot see.

 

[StayinSalty]

Thanks 4Tec. I’ll give it a shot.

Macker, I have a feeling it’s some sort of wiring issue too.

When it overheated on me several years ago I immediately shut the engine down for fear of starting a fire. That’s how hot it got.

From what I remember, I tried to restart the motor several minutes later but got nothing. Now I do know it was a seized motor at that point but figure the motor or components would of at least made some sort of sound. Maybe something got fried? Food for thought

thanks guys

 

[MacSeaDoo]

There are to many variables right now to figure out what is really preventing your engine from turning over. You need to start eliminating variables.

If you don't have a way to hand crank the engine, you need to rely on the starter. Can you be sure that the starter works properly? If it has never given you issues in the past we can assume it works. If so...

1.. I would pull the pump off. This way we are only focusing on the engine. (There are lots of youtube videos, it is basically a linkage and 4 bolts. You should rebuild the pump regardless due to the length of time sitting)
2.. I would eliminate all wiring and everything. Pull the plugs. Open the throttle fully (Drown mode) and jump the starter side of the solenoid with a know good battery. It should turn over very quickly. If it doesn't turn, your engine is seized and you need to haver it rebuilt.
3.. If it does turn over quickly. Feed the battery side of the solenoid with the known battery and then supply the solenoid 12 v to the switch side. If that works, the solenoid is fine. The put it back and try the switch.
4.. If you get it turning over, change the oil.
5.. Then do a compression test.
6.. If it has compression, you now know you have continuity in the reciprocating side of the engine.

Then on to Fuel and Spark.

 

[StayinSalty]

Thanks Macseadoo!

The mechanic told me the engine runs once the new battery is jumped, which he used a jump box that plugs into the wall. And it runs good once it gets going. He did say the wires get hot when he jumped it. He replaced the starter, relay, starter bendix and installed a brand new battery.

That being said, I believe the engine is good and it is a wiring issue. Thoughts?

Didn’t think of rebuilding the jet pump before but Ill definitely do it now. You’re right, it makes sense to do it.

 

[MacSeaDoo]

I am confused. "He replaced the starter, relay, starter bendix and installed a brand new battery"

So the Solenoid, The Starter, and the Battery are new. As well as the wiring to the starter from the solenoid.

If this were the case, you should be able to jump the solenoid and it should start like he says it does. If it does not start, your mechanic is lying about what he replaced or the outcome.

 

[StayinSalty]

I am confused. "He replaced the starter, relay, starter bendix and installed a brand new battery"

So the Solenoid, The Starter, and the Battery are new. As well as the wiring to the starter from the solenoid.

If this were the case, you should be able to jump the solenoid and it should start like he says it does. If it does not start, your mechanic is lying about what he replaced or the outcome.

Yeah that’s what I’m told. Except there is no new wiring. I’ll include a pic of the starter relay and the ground wires on the engine.

If I can tonight, I’m going to test the battery with a multimeter and try to jump the solenoid.

I also noticed there is a plug with purple wires going to the relay. If you look behind the plug, where the green plastic is, it looks like it melted. I would imagine it’s not normal. I’ll include a pic

 

[MacSeaDoo]

I wish I was your neighbor because we would get to the bottom of your issues pretty quickly. You would have to buy the beer though.

 

[Macker29]

Thanks 4Tec. I’ll give it a shot.

Macker, I have a feeling it’s some sort of wiring issue too.

When it overheated on me several years ago I immediately shut the engine down for fear of starting a fire. That’s how hot it got.

From what I remember, I tried to restart the motor several minutes later but got nothing. Now I do know it was a seized motor at that point but figure the motor or components would of at least made some sort of sound. Maybe something got fried? Food for thought

thanks guys

I recently had an unseen corrosion issue on the fuel pump wiring going to the ecu. I could not see it, but it was there. Took me over a month to figure it out. We replaced the wiring and connectors from the fuel pump to the ecu and it fixed the problem. Again, I am by no means an expert, but I do believe your issue is electrical and wiring-based.

Could simply be one of the connectors going into the solenoid or somewhere else (like the one you pictured with some melting). No clue, but start at the battery and work your way towards the ecu. Will take some time, but you'll eventually find it.

 

[StayinSalty]

I wish I was your neighbor because we would get to the bottom of your issues pretty quickly. You would have to buy the beer though.

Haha me too! Probably buy you airfare and pay for beer and still save money

 

[StayinSalty]

I recently had an unseen corrosion issue on the fuel pump wiring going to the ecu. I could not see it, but it was there. Took me over a month to figure it out. We replaced the wiring and connectors from the fuel pump to the ecu and it fixed the problem. Again, I am by no means an expert, but I do believe your issue is electrical and wiring-based.

Could simply be one of the connectors going into the solenoid or somewhere else (like the one you pictured with some melting). No clue, but start at the battery and work your way towards the ecu. Will take some time, but you'll eventually find it.

Thanks brother. I’m thinking the same. Wasn’t able to get to it tonight. Probably won’t be till the weekend. I know once I fix it I’m gonna laugh.

 

[MacSeaDoo]

That wiring is not new and neither is the solenoid judging by the bolts.

 

[racerxxx]

Those cable end are disgusting. The one doesn't even look like it's tight. It's start with making that right. You could remove all the cables, tape them up, and check continuity of the solenoid with a meter by pressing the start button.

 

[4TECGTX]

You've been given a lot of good advice here, good luck

 

[StayinSalty]

That wiring is not new and neither is the solenoid judging by the bolts.

Yeah the wires are definitely old. Don’t know why the solenoid doesn’t have new bolts. Makes no sense

 

[StayinSalty]

Those cable end are disgusting. The one doesn't even look like it's tight. It's start with making that right. You could remove all the cables, tape them up, and check continuity of the solenoid with a meter by pressing the start button.

That’s exactly what I’m going to do. I’m going to also clean the terminal ends and a wire brush. Thanks!

 

[StayinSalty]

You've been given a lot of good advice here, good luck

Yeah absolutely. You guys rock. I’d like to say “I’m” going to fix it but more like “we” lol

 

[StayinSalty]

Ok so I took the terminals off of the starter and relay. I polished off all the grime. Still no luck when starting the engine. I tried jumping from another battery still no luck. I took out the spark plus and tried to start it. The engine started turning and didn’t sound bad at all.

side note: I located a harness replacement that goes from the harness to the starter. When comparing the pictures of the new one and mine it’s pretty clear mine was damaged. I attached photos.

 

[StayinSalty]

I also tested the battery when not trying to start it which was 12.4

While trying to start it, the multimeter read around 10.

 

[StayinSalty]

I cleaned the terminals behind the battery switch. Tried to start and same result.

However, I did notice that the positive cable from the starter is hot at the starter relay.

 

[StayinSalty]

For the hell of it I replaced all of the fuses under the steering wheel.

I also took the plug on the starter relay off and began pulling it apart. Ordered a replacement. Should be here tomorrow

 

[StayinSalty]

That wiring is not new and neither is the solenoid judging by the bolts.

Found some corrosion in the wire harness that looks like it goes to the bilge pump.

Also, I’ve noticed I don’t hear the fuel pump engage when I put the key in. Should i?

any idea on how to clean inside plugs?

 

[Macker29]

Outside of a getting a new harness, the only way to truly get rid of that corrosion is to snip the wires and change the connectors. We had to change the connectors going to the fuel pump and into the ECU.

 

[4TECGTX]

Get a tool to depin the connectors, they're very cheap, and clean each pin individually. Do not cut the ends of unless they are nearly rotted right off

 

[StayinSalty]

Thanks guys.

I went and cleaned all of the ground cables for now. Still no luck.

maybe it’s best to just replace the entire wire harness. Any idea where to get one?