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JET PUMP 91-809957A1, Manual

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JET PUMP 91-809957A1 Manual Download Page 4

5-2 - PUMP UNIT

90-852396   MAY 1996

Special Tools

Jet Pump Tool Kit 91-809957A1

Description

Part Number

a

Pre-Load Kit

Impeller Shaft

91-824871A2

b

Thread Extender Kit

used w/ Backlash Kit

91-824869A1

c

Seal Protector

Impeller Shaft

91-850233

d

Impeller Shaft Wrench

91-832093A1

e

Impeller Nut Socket

91-850297

f

Pinion Gear Location Tool

91-831897

g

Bearing Installer

press ball bearing and
seals into pinion shaft
housing

91-832016

h

Bushing Installer

stator bushings & seal

91-850831

i

Seal Installer

impeller shaft seals in
drive housing

91-832019

j

Bearing Installer

impeller shaft ball
bearing in drive housing

91-832017

k

Bearing Cup Installer

pinion shaft housing and
drive housing front cover

91-832018

l

Handle Driver

91-824892

Backlash Indicator Flag

use MCII line

91-53459

Dial Indicator Kit

91-58222A1

Dial Indicator Adapter Kit

91-83155

Slide Hammer

91-34569A1

Bearing Puller Kit

91-83165M

Retaining Ring Pliers

91-25081

Lubricants/Adhesives

Part Number

Loctite, #271

92-809820

Loctite, #242

Obtain Locally

Perfect Seal

92-34227--1

2-4-C Lubricant w/ Teflon

92-825407A12

Special Lube 101

92-13872A1

Hi Performance Gear Lube

92-19007A24

a

b

d

e

f

g

h

i

j

l

k

c

Summary of Contents for 91-809957A1

Page 1: ...5 28237 JET PUMP ...

Page 2: ...der Components 5 8 Servicing Stator Impeller And Wear Ring 5 10 Disassembly 5 10 Removing Reverse Gate Rudder And Nozzle As An Assembly 5 10 Stator Removal 5 10 Impeller Removal 5 11 Inspecting Components 5 11 Installing Impeller 5 11 Removing Jet Drive From Boat 5 12 Drive Housing Disassembly And Reassembly 5 13 Pinion Shaft Removal 5 13 Impeller Shaft Removal 5 14 Shimming Procedures 5 17 ...

Page 3: ... left when the operator turns the steer ing wheel in the respective direction When the op erator turns the steering wheel to the right for exam ple the nozzle turns to the right and the jet force from the nozzle pushes the stern of the boat to the left causing the bow of the boat to turn right Forward and reverse drive and the neutral position are achieved by the position of a reverse gate lo cate...

Page 4: ... i Seal Installer impeller shaft seals in drive housing 91 832019 j Bearing Installer impeller shaft ball bearing in drive housing 91 832017 k Bearing Cup Installer pinion shaft housing and drive housing front cover 91 832018 l Handle Driver 91 824892 Backlash Indicator Flag use MCII line 91 53459 Dial Indicator Kit 91 58222A1 Dial Indicator Adapter Kit 91 83155 Slide Hammer 91 34569A1 Bearing Pul...

Page 5: ...90 852396 MAY 1996 PUMP UNIT 5 3 NOTES ...

Page 6: ...90 852396 MAY 1996 DRIVE HOUSING COMPONENTS 1 2 8 5 6 7 3 12 13 15 16 19 17 23 20 21 30 22 24 26 27 28 18 31 29 4 9 10 4 11 5 5 6 7 8 18 14 25 66 Loctite 242 Purchase Locally 85 RTV Silicone Sealer 92 809825 85 66 66 ...

Page 7: ... COVER ASSY W Gaskets Drive Housing Painted 13 2 STUD M10 x 66 14 1 O RING 15 1 GASKET Cover To Adapter Plate 16 AR GROMMET Pump Mount 250 AR GROMMET Pump Mount 375 AR GROMMET Pump Mount 500 17 1 NUT M8 18 2 BAFFLE ASSEMBLY Exhaust 19 1 SCREW M8 x 240 20 2 SCREW KIT 21 2 WASHER Sealing 22 1 SEAL Ride Plate Self Locking 23 1 SCREEN Inlet Painted 24 2 SCREW M8 x 16 w Loctite 242 200 23 25 2 SCREW Wi...

Page 8: ...6 PUMP UNIT 90 852396 MAY 1996 PINION IMPELLER SHAFT 1 2 4 3 5 7 6 8 9 10 11 12 13 14 15 16 17 18 4 Special Lubricant 101 92 13872A1 108 108 7 7 Loctite 271 92 809820 95 2 4 C w Teflon 92 825407A12 95 95 ...

Page 9: ...7 1 O RING AR SHIM Red 002 AR SHIM Beige 004 8 AR SHIM Blue 005 8 AR SHIM Frost Clear 0075 AR SHIM Brown 010 AR SHIM Yellow 020 9 1 GEAR SHAFT ASSEMBLY Pinion 10 1 SHAFT Impeller 11 1 GEAR Impeller Shaft 12 1 WASHER 13 1 NUT M14 90 122 AR SHIM Red 002 AR SHIM Beige 004 14 AR SHIM Blue 005 14 AR SHIM Frost Clear 0075 AR SHIM Brown 010 AR SHIM Yellow 020 15 1 COVER ASSEMBLY Impeller Shaft Painted 16...

Page 10: ...NIT 90 852396 MAY 1996 NOZZLE RUDDER COMPONENTS 1 39 40 34 37 36 35 27 31 32 28 29 30 26 23 24 25 22 21 20 19 11 12 8 14 10 5 9 16 18 17 7 13 38 4 2 33 15 3 6 9 10 12 20 21 22 31 7 Loctite 271 92 809820 7 7 7 7 7 ...

Page 11: ...E 15 1 SCREW M6 x 13 16 2 SCREW M10 x 45 35 47 17 1 ANODE 18 2 LOCKWASHER 437 External 19 2 SCREW M10 x 35 35 47 20 2 SCREW M8 x 30 120 13 5 21 2 WASHER 22 2 STOP Reverse Gate 23 1 NOZZLE ASSY W Pivot Bushings Painted 24 1 FITTING Nozzle 25 1 HOSE Syphon 12 00 In 26 4 SCREW M10 x 150 35 47 27 1 STATOR ASSEMBLY Painted 28 1 PLUG Pipe 29 1 SCREW KIT 50 5 6 30 1 WASHER Sealing 31 2 BUSHING Stator Rea...

Page 12: ...EVERSE GATE RUDDER AND NOZZLE AS AN ASSEMBLY 3 Remove four screws securing nozzle to stator Remove reverse gate rudder nozzle assembly 54579 c c Screws 4 STATOR REMOVAL 4 Remove two screws securing trim plate to ride plate and wear ring 28252 a b a Screws 2 to Trim Plate Wear Ring b Trim Plate 5 Remove four screws securing stator assembly to drive housing Remove stator assembly 28253 c c Stator 6 ...

Page 13: ...Surface for Grooves Scoring 3 Inspect seal in stator for wear damage 4 Inspect bellows on cables for wear 5 Inspect anodes replace as necessary 6 Inspect pivot pins and bushings replace as nec essary Torque on reverse gate and rudder pivot pins is 50 lb ft 68 N m Use Loctite 271 on threads 7 Inspect impeller for cracks and damaged blades 8 Inspect stator vanes for cracks and or damage 9 If replace...

Page 14: ...7 N m 8 Attach shift and steering cables REFER TO SECTION 1D SPORT JET INSTALLA TION FOR SHIFT AND STEERING INSTALLATION AND ADJUSTMENT Removing Jet Drive From Boat REMOVE POWERHEAD AS OUTLINED IN SEC TION 4 1 Disconnect shift and steering cables from re verse gate and rudder Remove cable adaptors and bellows assemblies Loosen shift and steer ing cables at wear ring 54896 a b a Shift Cable b Steer...

Page 15: ...inion shaft hous ing to drive housing Remove pinion shaft as sembly 28257 NOTE Take care not to damage or misplace colored shims 2 Remove rubber ring O ring and shims 53797 a b c a Rubber Ring b Shims c O ring 3 Press pinion shaft out of pinion shaft housing 53796 4 Remove pinion shaft ball bearing and two seals using Puller 91 83165M 28264 5 Remove pinion shaft outer race from pinion shaft housin...

Page 16: ... 28265 9 Press new ball bearing into pinion shaft housing using Special Tool 91 832016 28266 10 Press pinion shaft into pinion housing 28267 11 Press new seals into pinion shaft housing one at a time using Special Tool 91 820552 Inner seal faces in outer seal faces out 28268 a a Special Tool 91 820552 Impeller Shaft Removal 1 Remove Stator Wear Ring and Impeller as de scribed in Servicing Impeller...

Page 17: ...e or misplace colored shims 28258 a b a O ring b Shims 5 Remove nut and washer from end of impeller shaft Remove impeller shaft gear 28259 6 Pull impeller shaft from drive housing 28259 7 Remove bearing retaining ring from drive hous ing 28262 8 Remove bearing using Puller 91 83165M 28263 9 Remove impeller shaft seals using Slide Ham mer 91 34569A1 ...

Page 18: ...ng in drive housing after bear ing is installed 13 If replacing impeller shaft gear bearing remove using universal plate 28269 a b a Suitable Mandrel b Universal Plate 14 Press new bearing on gear using an appropriate size mandrel 28270 15 If replacing bearing remove outer race from front cover using slide hammer Press new outer race in cover using suitable mandrel 54985 ...

Page 19: ...ly seat roller bearings 4 Insert Pinion Location Tool Special Tool 91 824890 in drive housing NOTE Carefully inspect location tool to make sure it is seated in drive housing bearing 5 Insert feeler gauge through hole in pinion loca tion tool between gauging surface of tool and flats on bottom of pinion gear teeth IMPORTANT The correct clearance is 025 inch 0 64 mm 6 Use 025 inch 064 mm feeler gaug...

Page 20: ...cant 2 4 C Lubricate cone bearing with gearcase lubricant 10 Install impeller shaft cover Torque screws to 180 lb in 20 3 N m 28257 11 Install impeller shaft pre load tool 91 824871A2 54983 a b c a Spring Seat Rear b Spring c Spring Seat Forward 12 Install wear ring and stator on impeller shaft Se cure assembly with two bolts opposite corners Torque bolts to 35 lb ft 47 N m Rotate impeller shaft t...

Page 21: ... in this section 17 Apply RTV Sealant 92 809825 on rideplate Install rideplate DO NOT reuse screws Apply Loctite 242 to threads of new screws Torque to 75 lb in 8 5 N m 18 Install nozzle reverse gate assembly and anode Apply Loctite 271 to threads of screws Torque all four 4 screws to 35 lb ft 47 N m 19 Remove fill and vent screws from bottom of drive housing Fill drive housing with High Perfor ma...

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