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  1. #1
    xintersecty's Avatar
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    4-Tech Engine Rebuild Challenger 180

    I have worked on car engines up to a limited capacity. So I am not totally clueless and I have enough self-awareness that will need help. So this thread is to ask questions and learn the process to get my engine rebuilt. I have three seadoo products and to me this is time well worth it.

    Background:
    I have a 2006 Challenger 180 with an 215HP 4-Tech setup. I believe this is the same setup as the similar year RXT. I had just changed my oil and just launched from the ramp to test drive the boat. I had a drop in power and then the motor seized. I personally believe that the oil pump failed big time. When I got the boat out of the water the bilge is filled with oil. I have removed the super charger and that was not the source of failure.

    This weekend I am going to pull the motor. I have been through this thread: http://www.greenhulk.net/forums/showthread.php?t=46618

    I posted this in the jetski section as this is really more about the motor than the boat. Also all the motor guys hang here.

    I am looking for advice on what will need doing with this kind of failure. For example should I replace the pistons? Will the cylinders need re-honing? Of course what needs doing depends on the failure. Also I need help on stuff like cases and sub-sections. I would love to get the various cases on the motor cleaned up. There is corrosion and paint peeling at various places. I am willing to bet that I have the sodium valves. Should I rebuild the head myself or just get it swapped?

    Thanks in Advance!


  2. #2
    steven mace's Avatar
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    Man I would nearly say it's a bin job! Any damage to the block, replace it. The block is not like a car block. I'm a diesel mechanic and have built man of engines. I got my self a ski with a faulty engine and thinking I can rebuild it piss easy.. Well they are nothing like a car engine. More like. A motor bike engine. The main caps are part of the sump/lower case. So soon as the main tunnel is damaged you can't deck the cases.. There is bugger all you can do. Fingers crossed it has just damaged the crank and not the block.

  3. #3
    xintersecty's Avatar
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    OK I finally got the engine out of the boat. Here is a crane pictures
    Click image for larger version. 

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    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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  4. #4
    xintersecty's Avatar
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    Here is some detailed engine pictures. The previous owner (I got it from a guy who was flipping the boat) lived in Florida and it has a lot of salt water corrosion on it.
    Attachment 361676Attachment 361677Attachment 361678Attachment 361679Attachment 361680

  5. #5
    xintersecty's Avatar
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    Why is uploading pictures so difficult? Argghhh.


    Click image for larger version. 

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    Just about any message board I use, I always end up using the basic uploader.

    So I can't get the exhaust header off. There are two bolts that are turning but not going out. I suspect they are broken and the salt water corrosion has it stuck. I am going to need a new one any how as that break around the flange let's hot gas to escape.

  6. #6

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    in my opinion, with a seized motor and all that salt water wear, you would be better off just buying another motor from someone with a wrecked ski. They run around $2500 and you can't really rebuild it properly any cheaper.

  7. #7
    xintersecty's Avatar
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    Quote Originally Posted by toxicgun View Post
    in my opinion, with a seized motor and all that salt water wear, you would be better off just buying another motor from someone with a wrecked ski. They run around $2500 and you can't really rebuild it properly any cheaper.
    I have been looking. The other option is go the SBT route and I have read that their builds are iffy. Of course I had seen some people say their builds are fine. I will know more on wednesday when I get the heads off and pull the case bottom.

  8. #8

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    Quote Originally Posted by xintersecty View Post
    Quote Originally Posted by toxicgun View Post
    in my opinion, with a seized motor and all that salt water wear, you would be better off just buying another motor from someone with a wrecked ski. They run around $2500 and you can't really rebuild it properly any cheaper.
    I have been looking. The other option is go the SBT route and I have read that their builds are iffy. Of course I had seen some people say their builds are fine. I will know more on wednesday when I get the heads off and pull the case bottom.
    I'm personally looking at an sbt engine that bit it and it looks like very shoddy workmanship.

  9. #9
    xintersecty's Avatar
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    Quote Originally Posted by toxicgun View Post
    I'm personally looking at an sbt engine that bit it and it looks like very shoddy workmanship.
    Toxicgun, I appreciate the feedback.

  10. #10
    Kmorningstar_rxp's Avatar
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    Buy it with the 2 year no fault and let it rip.

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