Mercury 240 pump housing removal

[entwistlem]

Looking for some advice prior to our shop manual arriving. What is the process for removing the jet pump on our 2002 Challenger 1800 with the single Merc. 240 engine? Does the engine need to removed first to gain access to the lower end fasteners?

The boat was given to my son and we're hoping to bring it back to good working order this spring. All the control cables need replacing and it looks like dropping the pump is the best way to go about it.

Many thanks - great site and appreciate all we've learned from your posts.

Mark

 

[Double07]

I just went through a complete overhaul of both engine and jet pump on a 2001 Utopia, and I am asuming they share similar motor and pump setup.
The engine mounts directly on the jetpump with an adapter plate in the middle
You need to remove the engine before removing the pump.

If all you are doing is changing the control cable, I am not sure if you have to drop the pump for that. Maybe someone else can comment.
However, I have to say that having the pump and motor out on a table made work a little easier for me.

 

[entwistlem]

2002 Sea Doo Challenger 1800 jet pump removal

I just went through a complete overhaul of both engine and jet pump on a 2001 Utopia, and I am asuming they share similar motor and pump setup.
The engine mounts directly on the jetpump with an adapter plate in the middle
You need to remove the engine before removing the pump.

If all you are doing is changing the control cable, I am not sure if you have to drop the pump for that. Maybe someone else can comment.
However, I have to say that having the pump and motor out on a table made work a little easier for me.

Thanks for the quick reply and good advice - appreciate it. Yes, the primary reason for removing the pump would be to replace the control cables, but I'd like to pull the pump and motor even if it's not required. As you say, having everything out of the boat and in front of you o the bench is the best approach in my opinion.

Thanks again for the information - my guess is the two hulls are similar with respect to engine and pump mounting.

Mark

 

[Double07]

You are welcome.
Removing the engine isnt too complicated. You will see that once your manual arrives.
If you have a hoist, it is fairly easy to do, but you will need a lifting eye. The lifting eye sells between 30 to 45 bucks on ebay. It threads right into the flywheel and provides an opening to hook the hoist on to. You just have to make sure you get the right thread & size for your flywheel.

 

[entwistlem]

You are welcome.
Removing the engine isnt too complicated. You will see that once your manual arrives.
If you have a hoist, it is fairly easy to do, but you will need a lifting eye. The lifting eye sells between 30 to 45 bucks on ebay. It threads right into the flywheel and provides an opening to hook the hoist on to. You just have to make sure you get the right thread & size for your flywheel.

View attachment 8221

Double07 -
Also good to know... I live in New England and with the temps now in the 40's and low 50's we plan to uncover the boat this weekend and start where we left off last fall before the snow began to fall. I can measure the threads on the flywheel and hopefully find an eye with the right dimensions. Otherwise we may have to wait a week or so and I'd rather get started tomorrow. With lots of Mercuries around here and mechanics I know, maybe I can borrow one. My guess is this unit is very close to an outboard of the same size - we'll see how it goes.

Thanks again,
Mark

 

[entwistlem]

Sea Doo Challenger 1800 jet pump removal

Double07 -
Also good to know... I live in New England and with the temps now in the 40's and low 50's we plan to uncover the boat this weekend and start where we left off last fall before the snow began to fall. I can measure the threads on the flywheel and hopefully find an eye with the right dimensions. Otherwise we may have to wait a week or so and I'd rather get started tomorrow. With lots of Mercuries around here and mechanics I know, maybe I can borrow one. My guess is this unit is very close to an outboard of the same size - we'll see how it goes.

Thanks again,
Mark

Well, thanks to your advice and a good friend at the local Mercury dealer,We borrowed the lifting eye and pulled the motor Sunday afternoon. Here's what we learned. Eleven nuts hold the engine to the base plate. Four nuts hold the jet pump to the base plate. All nuts can be accessed from the inside of the boat and the engine does not need to be removed to drop the jet pump, although it sure is much easier with the engine removed. Now that we know how it all goes together, I think removing the jet pump with the engine installed will be fairly easy, but this first time, with all the unknowns, we did the right thing. Having the engine out makes for easy access to everything we want to inspect/replace, so time was not lost. Control cables (steering and reverse bucket) can be removed without dropping the jet pump, but once again - sure is easier with the pump remved from the hull.
Electrical harness, fuel line, cooling and exhaust all disconnect with not too much effort. Engine will not come up straight (balanced) so be careful that last bolt in the center-back of the engine (under the exhaust expansion tank) does not bind - like it did for us. Breaking the gasket seal from the aft end first while slowly lifting is the trick.

I forgot to grab the model numbers off the power head and pump, but can anyone tell me if this pump unit is the "M2" model?

Thanks,
Mark

 

[Double07]

You are right Mark...
The lifting eye doesnt appear to be at the center of gravity when lifting the motor. I think the weight of the expansion tank causes it to lean towards the back of the boat. It looks like the equivalent engine in the outboards dont have that tank.
What I did in my case was to use a rope or a ratcehting tie down to wrap around the expansion tank and hook it up to the hoist while the motor is till level inside the boat. When I started lifting, the motor came straight up without binding against the studs, but yes you have to be carefull not to bend the studs.

Regarding the pump, I think all the Mercury powered seadoo boats share the same pump (someone more experienced can confirm this)
in my case, I have a 2001 utopia with the optimax engine, and my pump is the M2 model.

-Chika

 

[entwistlem]

You are right Mark...
The lifting eye doesnt appear to be at the center of gravity when lifting the motor. I think the weight of the expansion tank causes it to lean towards the back of the boat. It looks like the equivalent engine in the outboards dont have that tank.
What I did in my case was to use a rope or a ratcehting tie down to wrap around the expansion tank and hook it up to the hoist while the motor is till level inside the boat. When I started lifting, the motor came straight up without binding against the studs, but yes you have to be carefull not to bend the studs.

Regarding the pump, I think all the Mercury powered seadoo boats share the same pump (someone more experienced can confirm this)
in my case, I have a 2001 utopia with the optimax engine, and my pump is the M2 model.

-Chika

Chika,
Thanks again. I'll add the extra suppoort when I put the engine back in. I think you're right - the lower portion of the outboard is th expansion tank for outboards, so this power head qould be much closer to balanced without it.

Last night I looked on Sea Doo Warehouse for the engine-to-baseplate gasket and couldn't find it listed (although it's shown on the propulsion diagram). Any advise on where best to go for parts for this boat or is Sea Doo Warehouse the place to be and I'm just not finding what I need?

Now it's really just a matter of cleaning up parts, sand-blasting if necessary, repainting and re-installing.

Thanks again,
Mark

 

[Double07]

I found that boats.net are reasonable in pricing and they carry OEM parts. I know they are OEM because they ordered a lot of my parts from the dealer because they didnt stock them, but turnaround time was ok. There might be other cheaper places that I am not aware of.

To get my parts, I would go to this mercury parts site: http://www.mercurypartsexpress.com/us/index.html
it is very easy to locate parts here. Just put in your engine number, and you can get a list of all the parts for your engine and pump with the part numbers and prices.

I would then take the part number to boats.net (http://www.boats.net) and purchase from them. Some times the savings were significant. If there is no big difference, I would order from the closest dealer to me.

It looks like what you are looking for is #19 in the inserted picture.

here it is in boat.net: http://www.boats.net/parts/detail/mercury/M-859398.html

Dont you need the gasket between the plate and the pump also?

again, this is for my motor. Confirm the right part number with you engine number.

-Chika

 

[entwistlem]

I found that boats.net are reasonable in pricing and they carry OEM parts. I know they are OEM because they ordered a lot of my parts from the dealer because they didnt stock them, but turnaround time was ok. There might be other cheaper places that I am not aware of.

To get my parts, I would go to this mercury parts site: http://www.mercurypartsexpress.com/us/index.html
it is very easy to locate parts here. Just put in your engine number, and you can get a list of all the parts for your engine and pump with the part numbers and prices.

I would then take the part number to boats.net (http://www.boats.net) and purchase from them. Some times the savings were significant. If there is no big difference, I would order from the closest dealer to me.

It looks like what you are looking for is #19 in the inserted picture.

here it is in boat.net: http://www.boats.net/parts/detail/mercury/M-859398.html

Dont you need the gasket between the plate and the pump also?

again, this is for my motor. Confirm the right part number with you engine number.

-Chika

View attachment 8275

Chika,
Great info and last night I located the model number on my engine so today I will spend some time on these sites and order some parts. Many thanks.

Yes, I probably do need the plate-to-pump gasket as well... I'm sure there will be more as I go forward - you know how that goes!

Thanks again,
Mark

 

[performancefz1]

how do we fill this pump ? I can't seem to find the right information in the manual . not sure how to fill it and the grade/ quantity of oil . Any help would be greatly appreciated .

 

[El Toro 33809]

I got the quart bottle of the Quicksilver gear lube and a pump from Walmart to do mine. When I say pump, it is like a pump on a bottle of lotion. It will screw onto the quart bottle of gear lube and you pump until it flows out the excess hole.

 

[performancefz1]

nice to have found this information on this web site , although i have the shop manual i could not understand ho to get oil into the jet pump . I found everything i needed at west marine , pump and oil , easy job once it is explained . Freaking shop manual couldn't show i simple picture !

 

[audiobill5]

Hi,
Newbee Bill here for the 1st time, thanks!
I'm a Mercury parts guy that swears by the yellow stripe Merc (or Quicksilver) high performance gear lube!
Have used it for years in many customers' boats and for decades on my own stuff.

Got rid of my 1972 big block powered GM Gen IV 454 jet boat, and am now looking at a Challanger 2000 Merc EFI to possibly buy here at the Marina.

Safe/fast boating, Bill