Fellow Canadians, need help with 2001 Challenger 1800

[Rob_2000]

Hi everyone, new here and looking for some help.

I purchased a used Seadoo Challenger 1800 with a Mercury 240 last year. This forum helped me quite a bit as it was running a little rough but after completing all the recommended maintenance it is on its second summer running strong. It pulls hard and I am overly impressed with the performance.

Doesn't sound like I have a problem right? Well I don't....yet. I can't help but feel like I am on borrowed time. I don't think it has ever been rebuilt and I have no idea what the state of the infamous little gear is (oiler). I've been mixing a bit of oil into my gas even though the oil injection seems to be working fine and other than a bit of smoke at start up it gives me a bit of piece of mind.

So here's the thing. I would like to rebuild. I live in Ontario Canada and was wondering if
1. Any fellow Canucks able to track down a full rebuild kit;
2. Any shops between Ottawa and Toronto that are experienced with these engines that I could trust and what price would I be looking at; and,
3. Anyone rebuild one of these at home? I can get access to some pretty decent equipment and know some trained mechanics but don't know any marine technicians so I would be depending on these forums and a shop manual.

Anyway thanks everyone in advance, see you out on the water.

Rob

 

[Dr Honda]

Welcome.

To answer your questions.......

1) There are a few places on ebay that put out a full kit, but I do believe that our sponsor here is now carrying the rebuild parts now. You may want to hit the parts tab above, and send them a message.

2) DO NOT TAKE IT TO A SHOP !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! They charge too much. AND... most shops won't do a rebuild... they will just buy a rebuilt power head and charge you to do the install. (could be as much as $7k to $10K) But, of you can turn a wrench... you could do a full rebuild for around $1k to $1500 USD.

3) Absolutely !! We've had a bunch of guys do the basic rebuild at home. It's really not that hard... it just takes time. If you are good in the garage... you could do it over a weekend. But to be realistic... I would say it will take a week of easy work. Pull it and strip it down one weekend... do the cleaning one night... reassemble over a couple nights (taking your time) and put it back in the boat the following weekend. (This is assuming you are replacing all wear parts)


Since you are running now... the rebuild is easy. But I would personally hag out until the end of the boating season. That way you can pull the engine, and then look at all the parts before buying anything. You may get away will just replacing the piston rings, crank bearings, and the oil gear. (and a few gaskets) Doing it this way could save you $$$. Also, doing it this way will let you do it right, and not rush to put it back together if you need other things. (if the crank, or cyl's are out of spec, and need machine work)


Anyway... when you get ready to do the rebuild YOURSELF... we will be here to walk you though it.

 

[Rob_2000]

Ok thanks Doc. It's almost like speaking to a celebrity lol. I've read hundreds of your posts and all of them like this one are gold. I will def be signing up as a premium member and if I can get parts through a sponsor I will do that as well. My passion has always been motorcycles but the whole family has been bitten by the boating bug and so far we are really happy with the challenger. I appreciate your time and will keep you guys up to date. I'd love to turn it into a thread with pictures documenting the whole procedure.

 

[Dr Honda]

Great... I love all things with engines. My shop was really a motorcycle shop... but I rebuilt more Seadoo carbs than any other type.

If you find my thread on the islandia... you will see that I did a rebuild on a 240. Now, in my case... the engine was blown apart. (big holes) AND... I was able to resurrect an engine that most "Rebuild" shops wouldn't touch. BUT... if you aren't dealing with welding up holes, and replacing cyl sleeves... then everything else could be done in the home garage with normal tools. (maybe have to rent an engine hoist)


Off topic... my last project was a motorcycle. I salvaged a BKing that someone was using for Drag Racing. He went down, and beat up the bike, and got out of it. So, I picked it up cheap.

(Before/After)

 

[Dr Honda]

Here's my Islandia thread.

http://www.seadooforum.com/showthre...ndia-Project-(Engine-rebuild-and-other-stuff)

 

[Rob_2000]

Cool B King. I just tore down a TTR 50 for my little guy today, trying to get it running again. I'm thinking of picking up an older KTM for myself (2 stroke of course lol). I like learning and these little projects do the trick. The boat will be by far the biggest project I attempt. Going to come up with a solid plan and strategize how I'll track everything as I take it apart and make notes so assembly will hopefully be a bit easier. I always find it easier to tear down.

Thanks for the link to your post. Read it last year but I'm sure it will come in handy.

Keep the rubber side down.

Rob