Guest_User
New Member
where`s RJ?
-
This site contains eBay affiliate links for which Sea-Doo Forum may be compensated.
RESTO Project Dog House: 1996 Challenger
- Thread starter rjcress
- Start date
- Status
Guest_User
New Member
Beuller???
rjcress
Active Member
Sorry. Summer is WAY too busy. Between work, more work, Boy Scout trips, TaeKwonDo stuff, stuff around the house, etc... I barely have time to pee.
VERY eager to get back to the lake this weekend and spend some quality time with the family and the Challenger.
Went white water rafting with the Scouts this past weekend on the Nantahala. Was awesome, even though it never got above 65 degrees and rained the whole weekend...and I left my wetsuit on the mother ship in Virginia. Cheap rental Wetsuits to the rescue!
VERY eager to get back to the lake this weekend and spend some quality time with the family and the Challenger.
Went white water rafting with the Scouts this past weekend on the Nantahala. Was awesome, even though it never got above 65 degrees and rained the whole weekend...and I left my wetsuit on the mother ship in Virginia. Cheap rental Wetsuits to the rescue!
Guest_User
New Member
good to hear from ya! busy is good!:cheers:
rjcress
Active Member
Just passed 20 hours on the new engine this weekend.
Running strong.
Still getting a bit of hesitation on the build of RPM when going from idle to full throttle. I suspect this is a fuel delivery issue, maybe related to the 2nd inline fuel filter.
1st is the little stock screen filter, 2nd is the fram clear plastic inline filter I installed last year. I found a month ago that the screen filter had some goo on it and that when I cleaned that off, the hesitation went away. I clean the screen filter every weekend that I use the boat, but still get some hesitation, mainly when the engine is not fully warmed up. I think I'll take a fuel line splice like the one pictured below and remove the fram inline filter next time to see if that corrects the problem.
Otherwise, really enjoying the Challenger this year. The kids have become tubing junkies and my wife actually told someone that we LOVE the boat (not love, but LOVE). That is a MAJOR win.
When I told her that I am still hoping to get Andy to sell me his Challenger 1600... or tell me exactly what he wants so I can find a pontoon to trade him... she didn't complain.
Running strong.
Still getting a bit of hesitation on the build of RPM when going from idle to full throttle. I suspect this is a fuel delivery issue, maybe related to the 2nd inline fuel filter.
1st is the little stock screen filter, 2nd is the fram clear plastic inline filter I installed last year. I found a month ago that the screen filter had some goo on it and that when I cleaned that off, the hesitation went away. I clean the screen filter every weekend that I use the boat, but still get some hesitation, mainly when the engine is not fully warmed up. I think I'll take a fuel line splice like the one pictured below and remove the fram inline filter next time to see if that corrects the problem.
Otherwise, really enjoying the Challenger this year. The kids have become tubing junkies and my wife actually told someone that we LOVE the boat (not love, but LOVE). That is a MAJOR win.
When I told her that I am still hoping to get Andy to sell me his Challenger 1600... or tell me exactly what he wants so I can find a pontoon to trade him... she didn't complain.
rjcress
Active Member
Just read nate_4_01's post on similar issue and have added RAVES to the list of things for me to check.
I've noticed that I have trouble getting steady RPM between about 5800k and 6500k. It will run all day at 5700. If I nudge the throttle up a touch it wants to go straight to 6500k. Similar going the other way... at 6500k if I reduce throttle slightly, it wants to drop to 5700k.
I had been running the gas/oil mix pretty fat during break-in and while I confirmed that the oil injection system was using sufficient oil, and haven't cleaned the RAVES yet. So, wondering if they are gummed up from too much oil in the gas and sticking a bit.
Will make a note to check this soon... hoping to have time next week.
I've noticed that I have trouble getting steady RPM between about 5800k and 6500k. It will run all day at 5700. If I nudge the throttle up a touch it wants to go straight to 6500k. Similar going the other way... at 6500k if I reduce throttle slightly, it wants to drop to 5700k.
I had been running the gas/oil mix pretty fat during break-in and while I confirmed that the oil injection system was using sufficient oil, and haven't cleaned the RAVES yet. So, wondering if they are gummed up from too much oil in the gas and sticking a bit.
Will make a note to check this soon... hoping to have time next week.
Waterluvr
New Member
Anyone that can get a boat up and running to the degree of having the wife extoll love for it is winning at life. Well done, many a husband has endured scorn and angst from a wife less than impressed with the dollars that get dumped into a boat with less than stellar results. :cheers:
Guest_User
New Member
in a perfect world you`ll have no hesitation and smooth transition through the carbs circuits.
But when all known is well, you have to look at what`s different. I agree on the to much oil theory, start running straight fuel and see what happens and check your carb adjustments.
I`ve learned the different procedures to help with any hesitation, or hard starts due to heat soak, extended idling, etc...
I would also check the RAVES for build up, also a melted black piston, or poor bellows will do crazy things with rpms, like a switch, when the pressure builds up and it slams open,
with these 787`s there is a rpm window where the rpm`s jump as the Raves start to open, just the nature of the beast!
well I guess I must be the luckiest guy to have a great wife too! her words when we found out about the fabulous deal we got> do what you do best and fix it...:lols: there was carte blanche right there with common sense...
hahahahaha, oh the jetboat!? read your last PM...
But when all known is well, you have to look at what`s different. I agree on the to much oil theory, start running straight fuel and see what happens and check your carb adjustments.
I`ve learned the different procedures to help with any hesitation, or hard starts due to heat soak, extended idling, etc...
I would also check the RAVES for build up, also a melted black piston, or poor bellows will do crazy things with rpms, like a switch, when the pressure builds up and it slams open,
with these 787`s there is a rpm window where the rpm`s jump as the Raves start to open, just the nature of the beast!
well I guess I must be the luckiest guy to have a great wife too! her words when we found out about the fabulous deal we got> do what you do best and fix it...:lols: there was carte blanche right there with common sense...
hahahahaha, oh the jetboat!? read your last PM...
rjcress
Active Member
Cleaned the RAVES today at about 23 hours on this engine. The Mag side was a bit more caked on, but both were pretty nasty.
I noticed that on the 15 minute ride from the ramp to my parent's house, the RAVES were both leaking thin, but very black liquid. When I took the covers off, it looked like the red bellows (is that the right name for the flexible rubber part inside?) had come off of the inner cap for 1/4-1/3 of the circumference on both.
After cleaning and reassembly, the PTO RAVE still leaked some thin black liquid.
Thoughts on this?
I noticed that on the 15 minute ride from the ramp to my parent's house, the RAVES were both leaking thin, but very black liquid. When I took the covers off, it looked like the red bellows (is that the right name for the flexible rubber part inside?) had come off of the inner cap for 1/4-1/3 of the circumference on both.
After cleaning and reassembly, the PTO RAVE still leaked some thin black liquid.
Thoughts on this?
IDoSeaDoo
Well-Known Member
Yea, it's one of the reasons I'm going 4tec. The Raves are an inherently flawed system. The short of it is that your rave housings and valve are worn out. You could try to shorten your bellows retaining spring by cutting off a small section of it and screwing it back together, but you will probably need to replace the rave housing and valve.
rjcress
Active Member
Talked to Tom at SES.
He says that there is no danger to the motor.
I will try replacing the RAVE housing gaskets (I have some spares) and see if that fixes it.
If not, then when I send in the motor in the off season to have the freeze cracks welded, he will inspect and replace any RAVE parts that need it.
I'll pay for the RAVE parts, as SES didn't touch anything but the rave blades themselves, to radius them.
He says that there is no danger to the motor.
I will try replacing the RAVE housing gaskets (I have some spares) and see if that fixes it.
If not, then when I send in the motor in the off season to have the freeze cracks welded, he will inspect and replace any RAVE parts that need it.
I'll pay for the RAVE parts, as SES didn't touch anything but the rave blades themselves, to radius them.
DAGRE147
New Member
Been stalking your thread for a while now, using your methods for my own resto of my 96 Challenger. Though mine was mechanically sound, I've had my hands full with the cosmetics. Was wondering if you ever decided what to do about your bow seat? I saw you considered laying a traction mat down, how did that pan out?
rjcress
Active Member
Glad to hear that the thread has been useful to you.
I have decided what to do about the front seat cushion, but haven't actually done it yet.
The upholstery kit has a seat cover for the front pad. I will cut marine plywood or plastic, like starboard, for the base, to match the shape of the seat cover. Then I'll put a couple of layers of foam over it. Likely to use a blue, closed cell foam sleeping pad from the camping section at Wally-world. I'll fasten it down with the same type of plastic xmas trees that were used in the stock seat. I don't think it will be difficult, just been too busy with myriad other things.
I have decided what to do about the front seat cushion, but haven't actually done it yet.
The upholstery kit has a seat cover for the front pad. I will cut marine plywood or plastic, like starboard, for the base, to match the shape of the seat cover. Then I'll put a couple of layers of foam over it. Likely to use a blue, closed cell foam sleeping pad from the camping section at Wally-world. I'll fasten it down with the same type of plastic xmas trees that were used in the stock seat. I don't think it will be difficult, just been too busy with myriad other things.
rjcress
Active Member
BTW, folks. Over 30 hours on the Challenger this summer and it is still running great.
We now have a single and double tube for the kids... which they LOVE, and I picked up a kid's sized wake board for them, which they will try soon.
When I envisioned how we would use the jet boat, I had hoped it would work out this well for us. Now that it has been running reliably, we are loving it.
Of course, I probably just jinxed it by saying all of that.
We now have a single and double tube for the kids... which they LOVE, and I picked up a kid's sized wake board for them, which they will try soon.
When I envisioned how we would use the jet boat, I had hoped it would work out this well for us. Now that it has been running reliably, we are loving it.
Of course, I probably just jinxed it by saying all of that.
rjcress
Active Member
Oh! And in case anyone was wondering what happened to PaleRider... I talk to him via phone and email every now and then. He is fine, did not sell his Challenger and is currently thinking that he will not sell it. I don't expect that we will ever see him back on this forum, thought. He requested that I not share his reasons for leaving.
rjcress
Active Member
I will try to measure and post when I get around to finishing the front seat. I'm not a draftsman, so I'm not sure my measurements of the curved surfaces will be overly useful. However, it looks like the dimensions match the little recessed area where it sits... so I'm thinking that the recessed area will be your best template.
IDoSeaDoo
Well-Known Member
Hey RJ, if you still haven't seen my thread on plugged drain lines, check it on your boat. I believe I've had several 787's (including challneger) blow up on me because of this: the drain line that comes off the rear of the motor (the one that T's in from both jugs) gets clogged. My ski was clogged with sand, my challenger had a little rock in the exhaust pipe fitting. Anyway, this makes your motor run hotter and may be causing your rave problem. It's damn near impossible to pull this off the rear or the engine with the exhaust in place, but also really hard to remove it off the exhaust pipe... Anyway, however you do it, verify that that line is flowing freely and that your exhaust fitting isn't home to rocks or seashells like mine was. Good luck! PS my 4tec project is coming along nicely, ideally I'll be out this summer on it. Maybe I'll even make that trip up to SML like I wanted to
rjcress
Active Member
Hey RJ, if you still haven't seen my thread on plugged drain lines, check it on your boat. I believe I've had several 787's (including challneger) blow up on me because of this: the drain line that comes off the rear of the motor (the one that T's in from both jugs) gets clogged. My ski was clogged with sand, my challenger had a little rock in the exhaust pipe fitting. Anyway, this makes your motor run hotter and may be causing your rave problem. It's damn near impossible to pull this off the rear or the engine with the exhaust in place, but also really hard to remove it off the exhaust pipe... Anyway, however you do it, verify that that line is flowing freely and that your exhaust fitting isn't home to rocks or seashells like mine was. Good luck! PS my 4tec project is coming along nicely, ideally I'll be out this summer on it. Maybe I'll even make that trip up to SML like I wanted to
Thanks for the note... over 2 months ago.
Been away from the forum working on my website with any spare time I have had. I will check the exhaust line. Well, given the age of the lines, might just replace it to be safe.
rjcress
Active Member
My update:
I didn't do jack on the Challenger over the winter. It sat beside my house under a tarp from the time I winterized it until about 3 weeks ago when I had to move it since it was blocking in the camper and I was taking the kids to Pilot Mountain to camp (awesome trip, btw).
I still have to remove the back seat and install the new upholstery, make the base for the front rear-facing seat and assemble it, and go review this thread in detail to see what other open issues there were when I forced myself to stop thinking about the Challenger for the winter. I was incredibly successful in wiping it from my brain. Too successful.
Hoping to get the Challenger back in the water soon. I have to head to SML for a work weekend to install replace the shower valve in the port head & install a new shower drain box and install the electronic ignition on the starboard engine. I installed on the Port engine last year and it was the best upgrade I've done. Made that 1986 454 run like a brand new engine. Anyhow, I would like to get the rear seat reupholstered before dragging the Challenger up there so I don't have to pull it home. I like to leave it at the lake all summer.
Oh, and I didn't pull the engine in the Challenger to send to SES to have the water jackets welded where I let them freeze and crack the prior winter. Just got too busy. I'll keep running on the grey permatex one more season. Ordered the rebuild kit (bellows, o-ring, base gasket) for the RAVES this morning. Hopefully, that ends the black liquid seeping from them.
I didn't do jack on the Challenger over the winter. It sat beside my house under a tarp from the time I winterized it until about 3 weeks ago when I had to move it since it was blocking in the camper and I was taking the kids to Pilot Mountain to camp (awesome trip, btw).
I still have to remove the back seat and install the new upholstery, make the base for the front rear-facing seat and assemble it, and go review this thread in detail to see what other open issues there were when I forced myself to stop thinking about the Challenger for the winter. I was incredibly successful in wiping it from my brain. Too successful.
Hoping to get the Challenger back in the water soon. I have to head to SML for a work weekend to install replace the shower valve in the port head & install a new shower drain box and install the electronic ignition on the starboard engine. I installed on the Port engine last year and it was the best upgrade I've done. Made that 1986 454 run like a brand new engine. Anyhow, I would like to get the rear seat reupholstered before dragging the Challenger up there so I don't have to pull it home. I like to leave it at the lake all summer.
Oh, and I didn't pull the engine in the Challenger to send to SES to have the water jackets welded where I let them freeze and crack the prior winter. Just got too busy. I'll keep running on the grey permatex one more season. Ordered the rebuild kit (bellows, o-ring, base gasket) for the RAVES this morning. Hopefully, that ends the black liquid seeping from them.
Last edited by a moderator:
- Status
Similar threads
