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Engines swap -- 97 Challenger 1800 to 99 Challenger 1800
- Thread starter Satrebil
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Engines will be a straight swap, carbs I believe are different. The same...... but different plumbing and no divorced fuel pumps. Meaning the 97 had the fuel pumps on the carbs like the skis did, but 98-99 Seadoo removed (divorced) the pumps from the carbs and ran separate mikuni fuel pumps, if I remember correctly. They were not available for a while but you can now buy genuine Seadoo/Mikuni fuel pumps for the 98-99 boats. You used to have to modify a mikuni fuel pump to work, where the factory one just fits back into the same location. I just bought 2 last season.
Yes the carbs will swap over too. The difference would have been putting the 97 carbs in the 99 boat. They also changed the fuel line side from 1/4" to 5/16" in 98-99. but the routing would have been different and you would have had to redo the fuel lines.
If these engine failed on you you MUST rebuild all 4 of those carbs with Mikuni parts.
If these engine failed on you you MUST rebuild all 4 of those carbs with Mikuni parts.
Here is the 97 fuel system
Find part #57 the move to the left to the first carb. The dashed line coming from that is the pulse line to the engine that operates the fuel pump. Look at teh next diagram and find part# 18 you will see it written Engine, that is the pulse line for the divorced fuel pump. there are you major differences between the carbs. They would all work with some work if you know what I mean.
Here is the 99 fuel system.
Look to the right Part# 18 is the fuel pump
If you look at the PTO (rear) carb there should-----should be an accelerator pump. That will squirt a little fuel when you apply the throttle to help off idle bog. IF you replace those little gray lines there is a small brass recharge jet (#59 on the explosion drawing) inside the one side on the supply line to the pump. You'll need to cut it out of the gray line and install it into the new line IF you replace those. I have never replaced those on my boat from 99. The jet will slow the "recharge" of that line so it doesn't squirt too much into the engine. You do however need to make sure it is free from obstructions. You can also test the vacuum diaphragm on the accel pump with a hand held vacuum pump. Sounds over complicated but it's really simple.
Find part #57 the move to the left to the first carb. The dashed line coming from that is the pulse line to the engine that operates the fuel pump. Look at teh next diagram and find part# 18 you will see it written Engine, that is the pulse line for the divorced fuel pump. there are you major differences between the carbs. They would all work with some work if you know what I mean.
Here is the 99 fuel system.
Look to the right Part# 18 is the fuel pump
If you look at the PTO (rear) carb there should-----should be an accelerator pump. That will squirt a little fuel when you apply the throttle to help off idle bog. IF you replace those little gray lines there is a small brass recharge jet (#59 on the explosion drawing) inside the one side on the supply line to the pump. You'll need to cut it out of the gray line and install it into the new line IF you replace those. I have never replaced those on my boat from 99. The jet will slow the "recharge" of that line so it doesn't squirt too much into the engine. You do however need to make sure it is free from obstructions. You can also test the vacuum diaphragm on the accel pump with a hand held vacuum pump. Sounds over complicated but it's really simple.
If you look by the front right engine mount you can see how I remove the throttle cable brackets. I do it this way so I RARELY have to mess with the idle when I do a rebuild on carbs. I remove the screws that hold it to the carbs and take the whole bracket and cables with it and just remove it carefully from the carb bellcrank. Way, way, way easier
Be super careful with the plastic T on the returns. They can brake and are not replaceable.
Be super careful with the plastic T on the returns. They can brake and are not replaceable.
Part # 30 it's the fuel filter, only thing on the system. All my years riding skis/boating I've never once had water in my gas.
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