You are so fortunate that you didn't have far to travel. We like to take long cruises of 30-50 miles and there are areas where nothing is around. I am so glad we didn't keep that HydroSurge (HS) on our 240EFI! When I originally started talking against the HS, people thought I was nuts, just trying to bash SeaDoo or Merc! I felt strongely the design was flawed and should be recalled. I even spent the money to change my grate because I didn't want to destroy my jetpump and/or get stuck in the middle of nowhere.
I don't know whom should be held responsible Merc or SeaDoo. With the SeaDoo 4-Tec's induction in the SpeedSter 2004 line, I think this problem will be forgotten if it was even considered in the first place.
I wonder what type of weed control device the 4-Tec's will have? Nevertheless, I believe SeaDoo will sell fewer jetboats without the Merc inside. They are making a costly mistake. I could list the reasons, but that's for another post at another time.
My advice to you is to see if any broken tines are still inside your jetpump. Is so, examine the breakpoints on the tine and on the toothless grate. If the color is consistent across the entire break... they will insist you picked up a large rock or clam shell etc... But, if there is a noticeable change in color in and around the breakpoints, perhaps you could nail them on a bad casting of the tines i.e. Merc would be responsible for the damage.
I think you should push on both SeaDoo and Merc. Losing the use of your JetWild machine is unacceptable!!!
Merc should at least send out a public notice concerning the risk of using the HS and perhaps offer a discount replacement. The replacement fixed six tine grate is less than $130. They could win alot of points with their customers this way, but I wouldn't hold your breath, we are only a small portion of their concerns.
Check out this site for parts:
http://www.mercruiserparts.com/select_models2.asp?type_id=SJET
FYI On parts... Order them early and often because their distribution/delivery system is junk! Rumor has it... Three times as many people shipping 1/3 the amount of parts... now, doesn't that sound like progress LOL!!!
I wish your jetboat a speedy recovery that allows you to JetWild soon!!!
SpeedSter240EFI
Rj