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Mercury 240EFI M2 Full Rebuild Pics
I have gained soo much knowledge from the website that I thought I would give someting back... After purchasing my boat, the plastic oil pump gear went and #4 seized with #6 on its way out. After getting costs of $4k to $6K for a rebuilt engine, it was upt to me to again fix my issues...
Attached are pictures of the rebuild. I currently have 5 full tanks of fuel thru the motor and the summer has been great...Knock on wood. Engine runs very strong at 6K RPM's. I made the decision to bore the engine to .030 over since two of the cylinders needed this anyway. Probably could have honed the remaining 4 cylinders but ended up with a full rebuild kit off ebay for $900. That plus $129 for new lower end berarings, new oil pump gear $40 and $300 for the bore & hone. So for $1,350 I am fresh and good to go. I will say that it was an interesting rebuild. Many vacume hoses, electrical plugs and fuel system components. I marked with blue tape and a sharpie everything when pulling the engine apart. You can also pull large components as a group ie. coil pack board... Putting back together seemed less confusing that taking it apart. It built well and you just need to take the time and double check the work especially critical parts like rod caps & bearings.
Hope this helps for anyone attempting to rebuild their engines. We really like the Challenger 2000 and now have fresh components which should keep us happy for a long time...
Last edited by ddeem; 07-15-10 at 11:58 PM.
Seadoo Challenger 2000 Mercury 240EFI M2 2001