Challenger 1800 finally runnig great,but...

[steve on the water]

So my trials this year continue. My engines are starting quickly and running better than ever. Having the carbs installed properly was not surprisingly a big difference. The throttles are matching RMPs when aligned for the first time ever. While pulling the boat after water testing for the carb fix, I noticed an audible leak. Water was rather quickly running from under the starboard engine. Since we were done for the day, we packed up and I assumed that the carbon ring was shot. I ordered one online and planned to head back to the lake this weekend to fix it. A quick look at the manual and the internet prior to leaving told me that this was not likely the issue since he water was coming from below the engine. It is coming in pretty quickly, the bilge pump need to kick on every minute or so.

Fast forward a week. I splashed the boat on the trailer and it started leaking before the engines were started. I had pulled the covers over the shafts and they were both dry. The dripping water sound appeared to be coming from the muffler/resonator on the port side. The water appears to be leaking from under the starboard engine. Is there a valve that could have gone bad to let water back through that path. I am wondering if a hose cracked under the engine that feeds into the exhaust. I tried to get a look with a mirror, but was unsuccessful. I wouldn't think this would start leaking very quickly though. Running great, just not sure of the path of water intrusion and what damage it may be causing.

Just one more issue to deal with.

 

[steve on the water]

Could a fitting have cracked if it wasn't winterized properly? I am just throwing out random ideas at this point.

 

[jhjesse]

Welch plug on the exhaust could've rotted out. Common problem. Look at the top welded plugs on the exhaust. There are two more underneath the pipe in the same position.

https://www.seadooforum.com/showthr...st-plug-cap-or-whatever-you-want-to-call-them

 

[steve on the water]

So if this is the issue, I do not think that I have done any damage by running with this failure.

I was having a hard time seeing in the manual if the water coming from under the starboard engine would have any connection with running water noise from the port resonator. It is hard to tell where the sound is coming from though. I thought I could feel the vibration on the outside though. The boat is 1.5 hours away so any and all theories are welcome. I will investigate them all until I find the culprit.

So if it is the welch plug, the best option is remove the exhaust and get a shop to weld a disk over the cleaned up hole?

 

[justinsrad98]

Yes!

 

[squad1]

Definitely get a good look/listen to the resonator. I just had mine spring a leak on the underside this summer.

https://www.seadooforum.com/showthread.php?t=90547

 

[steve on the water]

The failed plug diagnosis was 100% on the money. I need to get an extension to reach the allen screws on the foundation and then take it to the welder. He said not to drop it off, but wait for it. I like the way he is thinking. He wanted to see if he could do it in place, but I am not sure he can get his gun in there. He is going to take a drive by today to take a look and see.

I don't have my manual with me, is it red locktite for the allen screws?

 

[jhjesse]

If you use loctite only use blue.
I highly recommend you do not weld in place. MPEM's are expensive and hard to find.

 

[123indyrt]

Scuff it good, jb weld. Done

 

[dmiles]

If you use loctite only use blue.
I highly recommend you do not weld in place. MPEM's are expensive and hard to find.

I just installed USB jacks with and a digital voltmeter on my dash. I won't even do something like that without disconnecting the battery first.

 

[steve on the water]

Off to the welder in the morning. I am glad I took it off. It looks like a previous owner used a liquid gasket material to seal the upper mating surfaces. The upper water channel was 3/4 filled with red boogers. I think I need to get a new gasket to reinstall the tuned pipe.

 

[steve on the water]

During the removal process I realized the bushing, rubber bushings and bolt were missing from the support pipe foundation. I can find rubber bushings online but have had no luck locating the bushing (part 5 in the parts catalog). Does anyone have a suggestion where I can find bushing? I will fish in the bulge this weekend and hope to find the parts. Thanks.

 

[jhjesse]

Maybe eBay or Westsidepowersports. Nick Carins is a member here and really good guy.

I use copper coat gasket sealer with a new gasket.

Glad you didn't cheap out and use jb weld.

 

[steve on the water]

UGH... The shop was easy to work with and were cutting out for the day and left the fixed part on a pallet in the yard and just said to drop a check in the drop slot. Know I understand why they didn't want to be there when I picked it up. It looks like a third grader fixed it, all goobers and grinder marks and a few "caves". I could have probably done better. I reinstalled it with a new gasket and copper sealer. Went together nice and smoothly. Dipped it in the river on the trailer. Runs great, but the patch had a slow drip. I called them up and he said "what do you expect me to do for that price?" "We are not know for welding aluminum." Not what their website says or what they said when I asked if they could do the job. What a rip off. I am going to have to JB Weld it for our vacation now, because I have no more free time to fix it right. I am more than a little upset.

 

[steve on the water]

My wife has declared the boat is for sale as soon as our vacation is over.

 

[Lumps]

sorry to hear that. you were so close. these boats are always a bit of a heart break but still too much fun when they are working