2001 Sea Doo Challenger 240 EFI doesn't idle nor start well

[stuffbert@outlook.com]

Hi. Started the season, started ok, went out on water, max 2800 RPM and about 10 knots. Took it out, replaced fuel (as much as I could pump out--then added 10 gallons premium and sea foam), plugs, both fuel filters. Now hard to start (I have to turn the wheel). Checked spark with a inline light tester, light up on all 6 (idle). Once started (on land), seems to run fine at higher RPM--ran at 3000 for a minute or two (with water attached). Bring to idle, dies. I took off the lift pump output, fuel pumps out. Not sure if it is enough pressure, but it seemed to flow ok. I did not shoot out very far--couple of inches. Should I put a pressure gauge on the lift pump output to measure? Replacements hard to find. Any thoughts?

Thanks!

Phil

 

[ripcuda]

Hi. Welcome. Yes, you need to measure fuel pressure. There is a schrader valve on top the VST tank as part of the fuel pressure regulator assembly. You need to see 35psi fuel pressure at idle. Could have a weak EFI pump. When you say you had to crank steering to lock to start (that engages OTAS and "gooses" the throttle a little)... that would imply an overly-rich flooded condition that required opening the throttles a little (for more air) to get it to start. If that's the case... could be leaking injectors... causing a flooded/over-rich condition at idle or after turning engine off (and trying for a hot restart... before the flooded fuel had time to evaporate). FYI... 3 fuel pumps. #1) square lift pump (clackity-clack)... this is an electronic fuel line primer bulb to ensure fuel line is full from tank to pulse pump. #2) pulse pump... this is driven off engine pulses... it's mounted on port side of the block... it's the main fuel mover from tank, thru filter and into the VST tank. #3) VST/EFI high-pressure pump... feed high pressure (35psi) fuel to the injectors from the Vapor Separator Tank (VST). Also... not recommended to run engine above idle out-of-the-water (even on muffs)... think there's a sticker on the boat saying that too. Cheers!

 

[stuffbert@outlook.com]

Thanks! I'll check the fuel pressure via the schrader valve. If this is low, would that direct a cleaning of the VST screens and potentially replacing that pump? Would a problem with the pulse pump also lead to a low pressure at the schrader valve? Thanks again!

 

[ripcuda]

PM sent. Yes, the pulse pump if weak/failing could be not supplying enough fuel to the VST to cause it to have fuel pressure issues. The rebuild kits for the pulse pump are cheap (on fleabay)... so I'd just rebuild it for peace-of-mind and to rule it out. There are no filters inside the VST... the main fuel spin-on filter (and water separator) handle that task. Inside the VST is a large float valve to keep the fuel level proper for operation. Service manual gives details on how to test... by running, then draining VST to see how much fuel was in there. My issues with hard hot restarts were all fuel injector related. I sent my fuel injectors off to Brucato FIS (google them) for servicing (test/clean/adjust). This was a big improvement to idling and starting and running well for my 240efi. GL!

 

[stuffbert@outlook.com]

Well, tested the fuel pressure. About 34 psi. Undid the drain on the VST, drained about a cup and a half. Turned the key on, fuel flowed out of the drain. Can only get it to start with the wheel turned. I guess the next step is to remove the injectors and get them cleaned/checked, unless any other thoughts....Or maybe not. Another data point. Right after I turn off the key, the pressure at the schrader valve drops to zero. I'm guessing this means either the injectors are leaky or something is keeping them opened?

 

[ripcuda]

Yeah... sounds like a stuck or badly leaking injector. That would be causing your flooded condition and the reason you have to crank the wheel (engaging OTAS) to get it to start. At least your fuel pumps sounds like they are doing there part. Cheers!

 

[Tim75]

You have not mentioned any unusual amount of smoke starting or idling.
If you have a lot of smoke, you may have leaky injectors. Regardless,having them tested and cleaned is worthwhile. Order your new gaskets before you disassemble. They may take a while to get.

Or— visual check that your throttle plates are open enough to let the engine idle. Testing best done in the water. Leave the boat on the trailer to make it easier.

 

[stuffbert@outlook.com]

Thanks. Plan to put in water today and run for a while. Any good injector remove step through videos? Thanks also for the gasket order advice!

 

[stuffbert@outlook.com]

Well, got the injectors out. Pain. Sending off to get cleaned.