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Repairing 240 EFI m2

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fred1965

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Hi everyone. I was having problems wit my sea doo challenger 2000, engine 240 EFI m2 and the
issue was that the plastic Drive Gear Blew out witch caused ENGINE REPAIR. So I'm trying to repair it by my self. I'm installing new oversize 0.20 piston
Until now everything is ok. Now this it the part where I start making question.

How can I disassemble the THROTTLE BODY?, I removed the Fuel Rail, Injector, and TPS, But the piece attached to the TPS seems to be stuck. It doesn't move freely like the other one at the top ( sorry I don't know the name of that part ).

I would like to replace the Bleed System. I saw Dr Honda in one on his projects He used yellow tygon. What is the size 1/4 3/32 7/32 really I don't know.

Where can I buy a best Drive Gear. I saw one in www.boats.net

Thanks Fred
 
You can use either 1/8" or 3mm tygon for the bleed system. Zip ties will work to clamp it all down.


Boats.net is fine for getting a new gear. They will ship you a new style gear.


As far as the part you are trying to remove... I'm not sure what you are asking. Please post a picture.
 
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Thank you Dr Honda for your fast response throttle body.jpg here is the piece between that 2 injector in one extreme is attached the TPS it seems
to stuck, if you can't see the picture please could you explain to me how to post picture here.

Thank you
 
If you are talking about the bolts holding the fuel rail on.....


I would clean the throttle body as good as you can, and then put some heat on the bolt heads to help break them lose. In this case, I would use a focused torch, to directly heat the bolt head, without heating the rest of the throttle body.

But, with that said... they shouldn't be that tight. They only get torqued to 35 Lb in. (about 2.9 Lb ft)
 
Oh....


Do you mean the butterflies? (The brass dicks that control the air)

They could be stiff because of the dirt on the springs and links. I would give it a good scrubbing with something like "Super Clean" and warm water. Then, oil all the links, springs, and shafts.

If they are truly stuck... then I would remove everything on the shafts, to check it. I don't recommend removing the butterflies, since the screws are set in place. You could damage the shaft. AND, aligning the butterflies again isn't easy.
 
Thanks Dr Honda, the butterflies attached to the TPS they're really stuck. I removed everything and I'm going to put the throttle budy in a bucket of oil I'll let you know, I don't know what to do.

Thank you.
 
Dr honda the throttle budy is really driving me crazy, could you please tell me how to disassembly the shafts with the butterflies attached to the TPS.
Thank you
 
Since they crush the screws... you will have to drill them out. Then you can pull the butterflies, and slide the shafts out. BUT be warned... you may destroy the parts trying.
 
One more time thank you. Dr Honda I'm ready now to assemble the engine
I just have some amateur questions
Do I have to buy a new?
Oil pump
Fuel pump
Screws for all engine.
I just got the tygon F-4040-A it is flexible, Is it supposed to be like that?. Maximum temperature working is 165 F

Fred
 
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No on all of the above.

BUT....


I would put in a new oil pump gear on the crank. AND... the rod bolts should be replaced. They are special, and stretch for torque
 
Hi. Dr Honda I want to know how to test the injectors. I'm doing it based off youtube videos but it doesn't work
I was using a 9 volt battery.
All my injector are bad, or there are another way.

Thank you
 
If you have them off the rail... and you are on a bench... then yes, a small amount of voltage will get them to "Click" open. 9v should work, but I would go up to 12v to try.

If you have a meter, then (honestly) I would check the coil in the injector to make sure it's not open, or burnt out.

If that checks... then hit it wit some power and listen for the click.
 
Hi Dr. Honda I almost finished fixing the engine, the injector are good ( if the click is ok )
I have another question my engine is 240 EFI M2 2001. It is use a GASKET-CRANK CASE?
I have to run the engine for the first 30 minute with premix 50:1 or it doesn't matter.

Thank you
 
are you asking if it needs a gasket for the crankcase? No... it doesn't have one. You seam the case together with either contact adhesive, and a silk thread... or I like threeBond 1211.

Yes... you want to mix your first tank so that you are burning extra oil. If you have the oil injection... then add 50:1 to the tank.
 
Hi Dr Honda. Thank for the help. I now notice that I have made a mistake, I cut the tubing kit SAE J1527 USCG TYPE A1
and now I see the price for this short piece is around 250.00-300.00. Is there any replacement part for this piece?:confused:

Thank you.
 
Is it just the fuel hose? If it is... go to a local auto parts store, and buy some fuel hose. (should be $1 per foot)

If it's something else... post a picture.
 
Hi Dr Honda. ECU.jpg . As you can see in the picture the ECU vacuum hose is broken.
How can I fix it?
What Do I have to do?

thank you.
 
Thanks Dr Honda ..I have removed all the screws that I saw, but I can't open the ECU I think it's something with the cable.

thank you
 
Hi Dr. Honda, I'm working on the ECU but I have not been able to open it yet
for replace the vacuum hose. ECU...jpg.

Thank you

fred
 
Well Dr Honda, as the ECU is a sealed unit and it can not be opened ...the hose broke of flush.so I used a little bit of plastic piping with some super glue and I hope it works as well..ECU and plastic pipe.jpg ECU and plastic pipe 2.jpg

Another problem my engine 0E 384567 240 EFI M2 2001 the manual and boats.net say the reed block assembly are five petal
So why my engine is using SEVEN..

thank you
 
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