240 Sundeck Thread - Questions and Answers

First question. The deck over the fuel tank feels soft. Only on the removable piece with the table mount.
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Is this usual or should I pop the seal and investigate?
 
I was under the impression that piece should be fiberglass, no wood filler. definitely pop it open and see what is going on. it's just a few screws.
the vertical panel under your bench removes to her, mine only had 6 screws. the caulk is to help with rattles, my mechanics never recalled it after he pulled it the first time.
 
I was under the impression that piece should be fiberglass, no wood filler. definitely pop it open and see what is going on. it's just a few screws.
the vertical panel under your bench removes to her, mine only had 6 screws. the caulk is to help with rattles, my mechanics never recalled it after he pulled it the first time.

So it is all fiberglass. Mine has some spider cracks on the underside but was missing one of the 4 screws along the sides and wasn't connected to the engine compartment wall at all. With those in there it should be more structural.

As for the boat in general, I keep fixing one thing and finding 3 more broken items. I got her running today and the sea water pump started immediately leaking (due for a rebuild anyway). Then there's an engine knock on the port side. I'm thinking cyl #5 or #7. Will pull those plugs and inspect inside the cylinder with a cam tomorrow. I really hope it's something dumb like a loose valve and I can just pop the valve cover off to fix it. It's a cyclical metal on metal knocking sound but only occurs 90% of the time and speeds up with rpm increase. Ignoring that, the engine purrs beautifully.

Let me give you this for a laugh and baseline of what I'm dealing with. New distributor cap, coil, etc and fresh fuel and I just get backfires if anything. I pull plug #1 and find top dead center after intake valve closes and look at the distributor. The rotor is pointed at cyl #4's electrode so I had to put the cap on rotated 90 degrees clockwise from normal. How does a distributor get put in wrong on a small block chevy?! Am I missing something?

Thanks to everyone on this forum along the way. I'd have lit the boat on fire already without friendly knowledge from people here.
 
Hello all.
Brand new to the forum and to Sea Ray. This is my first boat. I have rented a bunch but was finally ready to own.
I've got 4 teenage kids, my two boys are 6'4 and 6'6, and so we needed a big boat, but don't have a big budget. So I bought a 240 that needs to work. I did get it at what I think is a good price, but we shall see.
As you can see, it needs a lot of work. I am praying you guys are willing to offer me advice, and sources of supply that you have discovered while owning your boat.
The hull was actually damaged and they did bondo ‍(doh) and then covered that with rhino liner (double doh)
I have a fiberglass guy who is reasonable and is going to help with the body work.


Biggest issue of the moment is that I started winterizing and when I drained the water, I found what I think is fuel in the water. I did hear it run before buying, but this concerns me. Any thoughts?
 

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Hello all.
Brand new to the forum and to Sea Ray. This is my first boat. I have rented a bunch but was finally ready to own.
I've got 4 teenage kids, my two boys are 6'4 and 6'6, and so we needed a big boat, but don't have a big budget. So I bought a 240 that needs to work. I did get it at what I think is a good price, but we shall see.
As you can see, it needs a lot of work. I am praying you guys are willing to offer me advice, and sources of supply that you have discovered while owning your boat.
The hull was actually damaged and they did bondo ‍(doh) and then covered that with rhino liner (double doh)
I have a fiberglass guy who is reasonable and is going to help with the body work.


Biggest issue of the moment is that I started winterizing and when I drained the water, I found what I think is fuel in the water. I did hear it run before buying, but this concerns me. Any thoughts?

Hi! 2005 Sea Ray 240 SD, 350 Mag MPI Bravo III. I bought my boat planning to rediscover an old hobby. I forgot that a second hobby came with it - Boat Mechanic. o_O

We have a love/hate relationship with the boat. I hear this is pretty typical for an older boat. She is a joy to operate when she's running. Plenty of power and I'm sure you're kids will really enjoy water sports.

I have worked on just about everything that can be bolted onto the engine and am happy to share my experiences: Fuel system (pumps, injector, module replacement), starter, sea water pump, circulation pump x2, 50A fuse (and a homemade workaround), cooling troubles (solved with thru-hull), water in the fuel, roached smartcraft gauge (a guy near Jacksonville can replace and repair smartcraft gauges), outdrive oil leak, ignition service

I'll share some suggestions, all lessons learned "The hard way" by yours truly:
- Install a thru-hull flush kit. Makes flushing a breeze! No more getting under the outdrive to attach and remove the earmuffs. The single best improvement I've made. I paid for this - I think it was about $325 for parts & labor.
- Keep an eye on your temp and water pressure. The Bravo outdrive is known for corroding and squeezing down the water supply from the outdrive "bravoitis". I had a couple of months of overheat problems that was solved when we read the pressure and installed a thru-hull intake.
- Occasionally pull your props and inspect for fishing line. I had to have the outdrive seals and outer shaft replaced due to fishing line that worked its way into the seals
- If your motor is "Smartcraft" capable, get yourself a Vessel View device. So much easier than trying to read the LCD on the gauge.
- Check your hose clamps/watch out for rust - I had a SS clamp fail last fall that made quite a mess.

Feel free to ask - I've learned a lot over the past couple of years and enjoy figuring things out.

Good luck!
John
 
We have a 2005 240SD with the 350MAG (300 hp). We are looking at a newer 240. However, most that we are looking at have the Mercruiser 5.0 (260 hp). For those with the 5.0 in your 240SD - is this enough power?
 
We have a 2005 240SD with the 350MAG (300 hp). We are looking at a newer 240. However, most that we are looking at have the Mercruiser 5.0 (260 hp). For those with the 5.0 in your 240SD - is this enough power?
When you say "newer", what years are you talking about? After 2009 it became a smaller boat, even though it carried the same name.
 
When you say "newer", what years are you talking about? After 2009 it became a smaller boat, even though it carried the same name.

I LOVE our 2005, but I like some of the layout options of the 2011...
 
2005 SD240 - MAG 350 MPI Overheating
I wanted to share an experience I just had. I did all of my season starting maintenance, Oil change, Fuel filter change, gear lube change. I also decided to tackle the impeller (first time for me). Pulling the raw sea water pump out is not an easy task. I got it out, the old impeller looked good, but the wear in the pump and the bearings made it clear I need to replace the whole pump. I got the new pump and impeller, put them in got everything reassembled, put the muffs on started her up. OVERHEATING alarm within 5 minutes. Everything was installed perfectly, no leaks, all good.
Based on having no problems with overheating last year I was convinced I had an install problem. I decided to check the thermostat (super easy) it was visibly rusty and old. I replaced it and viola, all was good.
I am sharing just to let others know, installing new parts sometimes makes other go bad. It's not always your install that causes problems.

I ready for the 2023 season now!
 
Probably an automotive t-stat at a third of the price but contains ferrous metal. OEM won't rust.
 
I am looking for the snap-in carpeting (the backing is almost off on mine) for a 2005 240SD...
 
I am looking for the snap-in carpeting (the backing is almost off on mine) for a 2005 240SD...
If your carpet still looks good, you can apply a rubberized coating to the back side.

there have been threads posted here. Try a search.
 
Yeah, we were thinking about spraying the backside but since there are a few stains and such - we are just going to replace it instead...
 
Yeah, we were thinking about spraying the backside but since there are a few stains and such - we are just going to replace it instead...
We switched from carpet to Infinity. I sent fellow member @Quint4 my carpets and he used them as the template. The Infinity flooring is so much better than the OEM carpet. And you won't have to worry about stains. You will have to install the snaps though. I spent the money for a "professional" snap tool and it was worth every penny. Took me about 1.5 hours to install.
 
I am looking for the snap-in carpeting (the backing is almost off on mine) for a 2005 240SD...

I have been shopping carpet replacements. I am ready to move away from the berber. Mine is trashed.

This store seems to be the most on top of templates and install concerns. Their pricing is in line with others.
https://corinthianmarine.com/aquamat/
 
I have been shopping carpet replacements. I am ready to move away from the berber. Mine is trashed.

This store seems to be the most on top of templates and install concerns. Their pricing is in line with others.
https://corinthianmarine.com/aquamat/
I used corinthian…black pearl….very happy with their product. I made my own template and uses their velcro dots to get rid of the snaps

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Good afternoon,

I just bought a 1999 Sea Ray 240 Sundeck with a Mercruiser MCM 5.0L engine.

I am facing performance issues and am working on the fuel pump. It was a pain in the neck to get to it, but finally managed to take it out without taking the engine out. It was mounted under the motor. I am now wondering if anyone ever changed the location of this pump/cooler unit? If so, can you provide guidance?

Any help, photos or links are appreciated.

Tobo

 

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