Sea-doo Challenger 5896, Shop Manual

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Section 09 PROPULSION AND DRIVE SYSTEMS
Sub-Section 01 (PROPULSION AND DRIVE SYSTEMS)
09-01-24
Reinstall drive shaft protector tube and protective
boot w
/ carbon ring.
Install the small O-rings (2) on drive shaft then
slide the floating ring over O-rings.
Temporarily install the remaining O-ring on drive
shaft end.
Push on pump until shaft comes close to PTO fly-
wheel.
While holding pump, guide and engage shaft
splines in PTO flywheel. Rotate shaft to properly
index splines. Make sure boot is well positioned
over shaft end.
If necessary, tap pump end with a rubber hammer
until retaining nuts and washers can be installed.
Apply Loctite 242 (blue) on threads and equally
tighten nuts in a criss-cross sequence and torque
to 35 N•m (26 lbf•ft).
If the stud is properly installed approximately 3
threads will extend beyond the nut. This will allow
for full thread engagement of the nut on the stud
while maximizing the installed length of the stud
in the transom anchor plate.
At PTO flywheel : compress the protective boot,
slide floating ring toward the boot and properly in-
stall the remaining O-ring in drive shaft groove.
Release boot and firmly push floating ring against
the O-ring.
Secure PTO flywheel boot clamp as follows :
– Use pliers (P / N 295 000 069) as for removal.
– Manually engage holding hook in large window.
This is a pre-clamping position only.
PRE-CLAMPING POSITION
1. Holding hook
2. Large window
– Insert pointed tips of pliers first in closing
hooks.
1. Closing hooks
– Squeeze pliers. When both large and small win-
dows are directly over the 2 locking hooks,
press those windows down to engage hooks in
windows.
Using a grease gun, carefully lubricate PTO fly-
wheel with synthetic grease (P / N 293 550 010),
until boot is just beginning to expand. From this
point, immediately stop.
1. Grease PTO flywheel
Secure flywheel guard to engine studs with wash-
ers and wing nuts.
Secure coolant inlet to impeller housing using tie
raps. F01J23A
1
2
1
F01J2BA
F01I0BA
1