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JET PUMP 91-809957A1 Manual

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JET PUMP
5
28237

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Summary of Contents for JET PUMP 91-809957A1

  • Page 1 JET PUMP 28237...

  • Page 2: Table Of Contents

    Table Of Contents Page General Information ..... . . Principles Of Operation ....Special Tools .

  • Page 3: General Information

    75 percent of the nozzle to direct the water stream forward and down- The jet pump operates by drawing water into a ward, as well as backward. The shift position is con- housing forward of the impeller. The water is pres- trolled at the control box in the boat.

  • Page 4: Special Tools

    Special Tools Jet Pump Tool Kit 91-809957A1 Description Part Number Pre-Load Kit 91-824871A2 Impeller Shaft Thread Extender Kit 91-824869A1 used w/ Backlash Kit Seal Protector 91-850233 Impeller Shaft Impeller Shaft Wrench 91-832093A1 Impeller Nut Socket 91-850297 Pinion Gear Location Tool...
  • Page 5 NOTES: 90-852396 MAY 1996 PUMP UNIT - 5-3...

  • Page 6: Drive Housing Components

    DRIVE HOUSING COMPONENTS Loctite “242” (Purchase Locally) RTV Silicone Sealer (92-809825) 5-4 - PUMP UNIT 90-852396 MAY 1996...
  • Page 7 DRIVE HOUSING COMPONENTS TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m HOUSING ASSY-Drive (Basic) (Painted) PIN-Dowel FITTING-Syphon Drain Hose FOAM-Exhaust Deflector w/ 3-M #874 Adhesive STUD (M10 x 76) w/ 271 Loctite NUT (M10) STUD (M10 x 55) w/ 271 Loctite SEAL-Oil BEARING-Ball RING-Snap...

  • Page 8: Pinion & Impeller Shaft

    PINION & IMPELLER SHAFT Loctite “271” (92-809820) 2-4-C w/Teflon (92-825407A12) Special Lubricant 101 (92-13872A1) 5-6 - PUMP UNIT 90-852396 MAY 1996...
  • Page 9 PINION & IMPELLER SHAFT TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m RING-Rubber SCREW (M8 x 25) 20.3 HOUSING ASSEMBLY-Pinion Shaft (Painted) SEAL-Pinion Shaft Housing BEARING-Ball BEARING SET O RING SHIM (Red) (.002) SHIM (Beige) (.004) SHIM (Blue) (.005) SHIM (Frost/Clear) (.0075) SHIM (Brown) (.010) SHIM (Yellow) (.020)

  • Page 10: Nozzle/Rudder Components

    NOZZLE/RUDDER COMPONENTS Loctite “271” (92-809820) 5-8 - PUMP UNIT 90-852396 MAY 1996...
  • Page 11 NOZZLE/RUDDER COMPONENTS TORQUE REF. REF. QTY. DESCRIPTION lb. in. lb. ft. N·m PIN-Clevis CONNECTOR-Cable End WASHER PIN-Cotter GATE ASSEMBLY (Painted) SCREW (M6 x 13) ANODE LOCKWASHER (.250 Internal) BUSHING-Pivot BOLT-Pivot w/ Loctite 271 RUDDER KIT (Painted) BUSHING-Pivot LOCKWASHER (.250 Internal) ANODE SCREW (M6 x 13) SCREW (M10 x 45)

  • Page 12: Servicing Stator, Impeller And Wear Ring

    Servicing Stator, Impeller STATOR REMOVAL 4. Remove two screws securing trim plate to ride and Wear Ring plate and wear ring. Disassembly 1. Disconnect spark plug leads from spark plugs. 2. Disconnect shift and steering cables at Reverse gate and Rudder. 28252 a - Screws (2) to Trim Plate &...

  • Page 13: Impeller Removal

    IMPELLER REMOVAL 3. Inspect seal in stator for wear/damage. 7. If removed, install wear ring to support impeller 4. Inspect bellows on cables for wear. and shaft during impeller removal. 5. Inspect anodes, replace as necessary. 8. Remove inlet screen on bottom of drive housing 6.

  • Page 14: Removing Jet Drive From Boat

    5. Remove stator fill screw with washer and fill sta- 1. Disconnect shift and steering cables from re- with High Performance Gear Lube verse gate and rudder. Remove cable adaptors (92-13783A24) until oil flows out fill hole (capac- and bellows assemblies. Loosen shift and steer- ity is 19 fl.

  • Page 15: Drive Housing Disassembly And Reassembly

    5. Lower drive housing while sliding cables out. 3. Press pinion shaft out of pinion shaft housing. 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.

  • Page 16: Impeller Shaft Removal

    6. Press new outer race into pinion shaft housing 10. Press pinion shaft into pinion housing. using mandrel 91-832018. 28264 7. Remove tapered roller bearing from pinion shaft using universal puller plate 91-37241. 28267 8. Press new tapered roller bearing onto pinion 11.
  • Page 17 4. Remove four screws securing impeller shaft cov- 6. Pull impeller shaft from drive housing. er to drive housing. Remove cover. 28259 7. Remove bearing retaining ring from drive hous- 28257 ing. NOTE: Take care not to damage or misplace colored shims.
  • Page 18 10. Install new seals using Special Tool 91-832019. 14. Press new bearing on gear using an appropriate size mandrel. 28260 11. Install bearing using Special Tool 28270 91-832017. 15. If replacing bearing, remove outer race from front cover using slide hammer. Press new outer race in cover using suitable mandrel.

  • Page 19: Shimming Procedures

    5. Insert feeler gauge through hole in pinion loca- Shimming Procedures tion tool between gauging surface of tool and NOTE: Pinion gear shimming and backlash proce- flats on bottom of pinion gear teeth. dures must be preformed when any of the following IMPORTANT: The correct clearance is .025 inch components have been replaced: (0.64 mm).
  • Page 20 8. Install gear/bearing assembly and washer on im- 11. Install impeller shaft pre-load tool peller shaft. Apply Loctite 271 to threads of im- (91-824871A2). peller shaft. Hold impeller shaft with Special Tool 91-832093A1. Install nut and torque to 90 lb. ft. (122 N·m).
  • Page 21 15. Rotate pinion shaft back and forth lightly to con- tact gear teeth in each direction. NOTE: Average total amount of reading of indicator backlash specification is .007 inch (.18 mm) to .009 inch (.23 mm). If reading is less than minimum, add shims be- tween impeller cover and drive housing.

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