JET PUMP 91-809957A1 User manual

5
28237
JET PUMP

5-0 - PUMP UNIT 90-852396 MAY 1996
Table Of Contents Page
General Information 5-1. . . . . . . . . . . . . . . . . . . . . . .
Principles Of Operation 5-1. . . . . . . . . . . . . . . . . .
Special Tools 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing Components 5-4. . . . . . . . . . . . . . . . .
Pinion & Impeller Shaft 5-6. . . . . . . . . . . . . . . . . . . . .
Nozzle/Rudder 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. . . . . . . . . . . . . . . . . .

90-852396 MAY 1996 PUMP UNIT - 5-1
General Information
NOTE: Due to running changes, some illustrations
may not be exactly the same as your drive unit. Ser-
vice procedures remain the same unless otherwise
noted.
Principles of Operation
The jet pump operates by drawing water into a
housing forward of the impeller. The water is pres-
surized within the specially designed housing and
then directed to the rear to provide thrust and mo-
tion.
a
b
c
54898
a - Forward Motion
b - Water Thrust c - Reverse Gate
(Shown In the Forward
Position)
The jet pump is equipped with a steerable nozzle
(rudder) at the aft end of the pump housing that di-
rects the thrust of water. The jet of water can be di-
rectedrightorleftwhentheoperatorturnsthesteer-
ing wheel in the respective direction. When the op-
eratorturnsthesteeringwheeltotheright,forexam-
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-
cated just aft of the nozzle. Forward drive has the
reverse gate clearing the nozzle to allow all the
thrust to be directed straight back. Reverse drive
has the reverse gate covering the entire opening
enough to divert the thrust forward. Neutral position
has the reverse gate covering 75 percent of the
nozzle to direct the water stream forward and down-
ward,as well asbackward. Theshift positioniscon-
trolled at the control box in the boat.
a54896
a - Reverse Gate (Shown In the Reverse Position)

5-2 - PUMP UNIT 90-852396 MAY 1996
Special Tools
Jet Pump Tool Kit 91-809957A1
Description Part Number
aPre-Load Kit
Impeller Shaft 91-824871A2
bThread Extender Kit
used w/ Backlash Kit 91-824869A1
cSeal Protector
Impeller Shaft 91-850233
dImpeller Shaft Wrench 91-832093A1
eImpeller Nut Socket 91-850297
fPinion Gear Location Tool 91-831897
gBearing Installer
press ball bearing and
seals into pinion shaft
housing
91-832016
hBushing Installer
stator bushings & seal 91-850831
iSeal Installer
impeller shaft seals in
drive housing
91-832019
jBearing Installer
impeller shaft ball
bearing in drive housing
91-832017
kBearing Cup Installer
pinion shaft housing and
drive housing front cover
91-832018
lHandle 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
ab
d
e
fgh
ij
l
k
c

90-852396 MAY 1996 PUMP UNIT - 5-3
NOTES:

5-4 - PUMP UNIT 90-852396 MAY 1996
DRIVE HOUSING COMPONENTS
1
2
8
5
6
7
3
1213
15
16
19
17
23
20
21
30
22
24 26
27
28
18
31
29
4
9
10
4
11
5
5
67
8
18
14
25
66 Loctite “242” (Purchase Locally)
85 RTV Silicone Sealer (92-809825)
85
66
66

90-852396 MAY 1996 PUMP UNIT - 5-5
DRIVE HOUSING COMPONENTS
REF.
TORQUE
REF
.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 HOUSING ASSY-Drive (Basic) (Painted)
2 1 PIN-Dowel
3 1 FITTING-Syphon Drain Hose
4 2 FOAM-Exhaust Deflector w/ 3-M #874 Adhesive
5 6 STUD (M10 x 76) w/ 271 Loctite
6 12 NUT (M10) 35 47
7 4 STUD (M10 x 55) w/ 271 Loctite
8 2 SEAL-Oil
9 1 BEARING-Ball
10 1 RING-Snap
11 1GASKET-Drive Housing
12 1COVER ASSY W/Gaskets-Drive Housing (Painted)
13 2STUD (M10 x 66)
14 1O RING
15 1GASKET-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 1SCREW (M8 x 240))
20 2SCREW KIT
21 2 WASHER-Sealing
22 1 SEAL-Ride Plate, Self Locking
23 1SCREEN-Inlet (Painted)
24 2SCREW (M8 x 16) w/ Loctite 242 200 23
25 2SCREW With Nylon Patch (M6 x 20) w/ Loctite 242 75 8.5
26 1 PLATE-Trim
27 2 NUT (M8)
28 2 WASHER
29 2 SCREW (M8 x 35) 35 47
30 1RIDE PLATE KIT (Painted)
31 16 SCREW With Nylon Patch (M6 x 13) w/ Loctite 242 75 8.5

5-6 - 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
7Loctite “271” (92-809820)
95 2-4-C w/Teflon (92-825407A12)
95
95

90-852396 MAY 1996 PUMP UNIT - 5-7
PINION & IMPELLER SHAFT
REF.
TORQUE
REF
.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 RING-Rubber
2 4 SCREW (M8 x 25) 180 20.3
3 1 HOUSING ASSEMBLY-Pinion Shaft (Painted)
4 2 SEAL-Pinion Shaft Housing
5 1 BEARING-Ball
6 1 BEARING SET
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 1GEAR-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 1BEARING SET
17 1O RING
18 4SCREW (M8 x 25) 180 20.3

5-8 - PUMP UNIT 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
7Loctite “271” (92-809820)
7
7
7
7
7

90-852396 MAY 1996 PUMP UNIT - 5-9
NOZZLE/RUDDER COMPONENTS
REF.
TORQUE
REF
.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 PIN-Clevis
2 1 CONNECTOR-Cable End
3 1 WASHER
4 1 PIN-Cotter
5 1 GATE ASSEMBLY (Painted)
6 1 SCREW (M6 x 13)
7 1 ANODE
8 1 LOCKWASHER (.250 Internal)
9 2 BUSHING-Pivot
10 4 BOLT-Pivot w/ Loctite 271 50 68
11 1RUDDER KIT (Painted)
12 2 BUSHING-Pivot
13 1 LOCKWASHER (.250 Internal)
14 1 ANODE
15 1 SCREW (M6 x 13)
16 2SCREW (M10 x 45) 35 47
17 1 ANODE
18 2 LOCKWASHER (.437 External)
19 2SCREW (M10 x 35) 35 47
20 2SCREW (M8 x 30) 120 13.5
21 2 WASHER
22 2 STOP-Reverse Gate
23 1NOZZLE ASSY-W/Pivot Bushings (Painted)
24 1 FITTING-Nozzle
25 1 HOSE-Syphon (12.00 In.)
26 4SCREW (M10 x 150) 35 47
27 1STATOR ASSEMBLY (Painted)
28 1 PLUG-Pipe
29 1 SCREW KIT 50 5.6
30 1 WASHER-Sealing
31 2 BUSHING-Stator Rear
32 1 SEAL
33 2 WASHER-Tab
34 1 RING KIT-Wear (Painted)
35 1PLUG-Pipe (.750-14)
36 1O RING
37 1O RING
38 1IMPELLER KIT-SS-5 Blade
39 1TAB WASHER-Impeller Shaft
40 1NUT-Impeller Shaft 150 203

5-10 - PUMP UNIT 90-852396 MAY 1996
Servicing Stator, Impeller
and Wear Ring
Disassembly
1. Disconnect spark plug leads from spark plugs.
2. Disconnect shift and steering cables at Reverse
gate and Rudder.
54896
ab
a - Shift Cable
b - Steering Cable
IMPORTANT: This procedure lists the dissas-
sembly of external pump components. If servic-
ing a specific component, follow the procedure in
that section.
REMOVING REVERSE 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. Removefourscrews securing statorassemblyto
drive housing. Remove stator assembly.
28253
c
c - Stator
6. Drain stator by tilting stator forward and allowing
the oil to drain over the impeller shaft seals.
Complete oil draining by removing stator fill
screwandpour theremainingoiloutthefillscrew
hole.

90-852396 MAY 1996 PUMP UNIT - 5-11
IMPELLER REMOVAL
7. If removed, install wear ring to support impeller
and shaft during impeller removal.
8. Remove inlet screen on bottom of drive housing
to allow access to machined flats on impeller
shaft. If using Special Tool 91-832093A1 to hold
impeller shaft, inlet screen does not need to be
removed.
9. Straighten tabs on impeller tab washer.
10. Whileholdingimpeller shaft, removeimpellernut
using Special Tool 91-850297. Impeller nut is a
standard right hand thread. Remove impeller.
28252
a
b
a - Special Tool 91-850297
b - Special Tool 91-832093A1
11. Remove wear ring.
Inspecting Components
1. Inspect wear ring for excessive scoring and/or
grooves. Replace wear ring if deep grooves are
present or if severe scoring has taken place.
2. Ensure O-ring is in counterbore before installing
wear ring to drive housing.
28255
c
d
c - O-rings
d - Inspect 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. Ifreplacementisrequired,removestatorsealus-
ing Puller 91-83165M.
28256
10. Install new seal using Special Tool 91-850831.
Smaller diameter seal lip faces out.
Installing Impeller
1. Lubricate splines of impeller shaft with Special
Lube 101 (92-13872A1).
2. Install impeller, tab washer and nut on impeller
shaft. Locate bent tab in impeller slot. Torque im-
peller nut to 150 lb. ft. (203 N·m). Bend one tab
against flat on nut.
3. Install inlet screen. Apply Loctite 242 to threads
ofscrews andbolts.Torquethetwo6 mmscrews
to 75 lb. in. (8.5 N·m). Torque the two 8 mm bolts
to 200 lb. in. (22.5 N·m).
4. Install wear ring and stator. Apply Perfect Seal to
threadsoffour bolts. Torque to 35 lb. ft.(47N·m).

5-12 - PUMP UNIT 90-852396 MAY 1996
5. Remove stator fill screw with washer and fill sta-
tor with High Performance Gear Lube
(92-13783A24) until oil flows out fill hole (capac-
ity is 19 fl. oz. / 550 cc). Install fill screw and
washer.
54894
a
a - Fill Screw
6. Apply Loctite 242 to screws (2) securing trim
plate to the ride plate. Torque screws to 75 lb. in.
(8.5 N·m).
a28252
b
a - Screws (2) to Trim Plate & Wear Ring
b - Trim Plate
7. Install nozzle assembly and anode. Apply Loc-
tite 271 to threads of screws. Torque all four (4)
screws to 35 lb. ft. (47 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
ab
a - Shift Cable
b - Steering Cable
2. Loosen shift and steering cable thru hull fittings.
3. Support pump.
28257
WARNING
The pump unit must be supported to prevent it
from dropping through the opening when the re-
maining fasteners are removed.
4. Remove remaining four nuts from drive housing
cover. Remove drive housing cover and gasket.
5498
0
a
a - Nuts (4)

90-852396 MAY 1996 PUMP UNIT - 5-13
5. Lower drive housing while sliding cables out.
Place on bench or suitable work stand for disas-
sembly/repair.
Drive Housing Disassembly
and Reassembly
Pinion Shaft Removal
1. Remove four screws securing pinion 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
ab
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
housing using slide hammer 91-34569A1.
28265

5-14 - PUMP UNIT 90-852396 MAY 1996
6. Press new outer race into pinion shaft housing
using mandrel 91-832018.
28264
7. Remove tapered roller bearing from pinion shaft
using universal puller plate 91-37241.
8. Press new tapered roller bearing onto pinion
shaft using Special Tool 91-827983.
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”.
2. Remove stator fill screw, drain oil into a suitable
container.
3. Remove ride plate.

90-852396 MAY 1996 PUMP UNIT - 5-15
4. Removefourscrews securing impellershaftcov-
er to drive housing. Remove cover.
28257
NOTE: Take care not to damage 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.

5-16 - PUMP UNIT 90-852396 MAY 1996
10. Install new seals using Special Tool 91-832019.
28260
11. Install new bearing using Special Tool
91-832017.
28261
12. Install retaining ring 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

90-852396 MAY 1996 PUMP UNIT - 5-17
Shimming Procedures
NOTE: Pinion gear shimming and backlash proce-
dures must be preformed when any of the following
components have been replaced:
a. Jet Drive Housing
b. Pinion Gear
c. Pinion Gear Bearing Assembly
d. Pinion Shaft Housing
e. Impeller Gear
f. Impeller Gear Bearing Assembly
g. Impeller Shaft Front Cover
NOTE: Shims are color coded to represent different
thicknesses. These color codes apply to both pinion
housing shims and impeller cover shims.
Red .002 in. (.05 mm)
Beige .004 in. (.10 mm)
Blue .005 in. (.127 mm)
Frost (Clear) .0075 in. (.19 mm)
Brown .010 in. (.25 mm)
Yellow .020 in. (.51 mm)
1. Install original shims on pinion shaft housing.
Install O-ring on pinion shaft housing.
NOTE: If original shims are not available, start with
.030 in. (.76 mm) shims (three brown colored shims).
2. Install pinion shaft assembly into drive housing
bore. Torque screws to 180 lb. in. (20.3 N·m).
28271
3. Rotate pinion shaft ten revolutions to properly
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 gauge as a start-
ing thickness. Adjust thickness of feeler gauge
untila slight dragisfelt as gaugeisdrawn outbe-
tween gauging surface of tool and pinion gear.
NOTE: Once the thickness is determined, the differ-
ence between feeler gauge thickness and .025 inch
(0.64mm) required clearance must be either added
or subtracted from the total thickness of shims be-
tween pinion shaft housing and drive housing.
•Remove the screws securing the pinion shaft
housing assembly to the drive housing. Lift as-
sembly out of the drive housing.
•Adjust shim thickness as required.
7. Install seal protector, Special Tool 91-850233,
on impeller shaft. Install impeller shaft in drive
housing, then remove seal protector.
5498
6
a
a - Seal Protector, Special Tool 91-850233

5-18 - PUMP UNIT 90-852396 MAY 1996
8. Install gear/bearing assembly and washer on im-
peller shaft. Apply Loctite 271 to threads of im-
peller shaft. Hold impeller shaft with Special Tool
91-832093A1. Install nut and torque to 90 lb. ft.
(122 N·m).
28257
9. Install original shims on impeller shaft cover.
Install O-ring on impeller shaft cover.
NOTE: If original shims are not available, start with
.030 in. (.76 mm) shims (three brown colored shims).
•Lubricate O-ring and bore with Quicksilver lubri-
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).
5498
3
abc
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 ten revolutions to properly
seat roller bearings.
13. Install Backlash Indicator Rod (Special Tool No.
91-53459) on pinion shaft.
54987
14. Install Dial Indicator Kit, Adapter Kit and Thread
Extender Kit.
•Position rod from dial indicator on the center
mark “II” of the backlash indicator rod.