the challenger is a heavy azz boat for 140mm pumps, so it all has to be good. wear ring clearance, impellers, carbon seals and floating ring, and most important the proper amount of tension on the bellows...
a good "looking" carbon ring can still leak if it doesnt have the correct tension on it... they are meant to dribble, but will suck air like a pig.
look at the wear pattern on the carbon ring to determine whats going on, if any pattern is offset and not even all the way around there is probably an alignment issue to...
I`ve never known anyone to resurface a carbon seal....