Description PartNumber Page DRIVESHAFT.ADAPTER , 481 DRIVESHAFT WRENCH , 481

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1 Section 06 STEERING AND PROPULSION Subsection04 (DRIVESHAFT) DRIVE SHAFT SERVICE TOOLS Description PartNumber Page DRIVESHAFT.ADAPTER , 481 DRIVESHAFT WRENCH , 481 SERVICE PRODUCTS Description Part Number Page LOCTITE577 (THREADSEALANT) PULLEYFLANGECLEANER smr201 ()'()44 475

2 Section 06 STEERINGAND PROPULSION Subsection 04 (DRIVESHAFT) Engineoil & Loctite 577 (thread sealant) Triple-guard grease & 2 Nom (18Ibfoin) 125 Nom (92 Ibfoft) LH threads 476 smr201d-044

Section 06 STEERING AND PROPULSION Subsection 04 (DRIVESHAFT) GENERAL The jet pump must be removed to replace any component of the drive system. Refer to JET II "" PUMP for removal procedure.

3 Section 06 STEERING AND PROPULSION Subsection 04 (DRIVESHAFT) GENERAL The jet pump must be removed to replace any component of the drive system. Refer to JET II "" PUMP for removal procedure. During assembly/installation, use torque values and service products as specified in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. A WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pins, etc.) must be replaced. WRONG 1. Rubber sealing lip NOT fully engaged Hoses, cables or locking ties removed during a procedure must be reinstalled as per factory standards. TROUBLESHOOTING DIAGNOSTIC TIPS Leaksat PTOSeal If water enters engine, or oil leaks from engine at PTO seal, check if drive shaft is fully engaged in sealing ring. Compress the drive shaft boot to visually check for proper contact. r -1 ~ L "~, /,~... I I i~ I I, 1 smr o13_a CORRECT 1. Rubber sealing lip fully engaged NOTE: If drive shaft boot cannot be compressed enough for the inspection, remove jet pump and torque drive shaft. If this does not work, remove drive shaft and inspect drive shaft threads. Refer to DRIVE SHAFT in this subsection. I Drive shaft boot Rubber sealing lip of drive shaft must be fully engaged into flange of sealing ring. smr201o-d44 477

Section 06 STEERINGAND PROPULSION PROCEDURES DRIVESHAFT Drive Shaft Removal Toprevent oil spillagewhen pulling out drive shaft, carry out the following: - Start engine.

4 Section 06 STEERINGAND PROPULSION PROCEDURES DRIVESHAFT Drive Shaft Removal Toprevent oil spillagewhen pulling out drive shaft, carry out the following: - Start engine. - Bring engine to 4000 RPM for 10 seconds. - Stop engine at this RPM. NOTE: If engine cannot be started, remove oil from the PTO area by following the procedure detailed in PTO HOUSINGREMOVALof the PTO HOUSINGAND MAGNETOsubsection. 1. Positionwatercraft at aworkstation that has access to a chain block, a hoist or other suitable lifting equipment. 2. Open seat. is Models 3. Remove the deck extension. Refer to BODY subsection.... '!,~ /..;\ /"",J't;/j""Ar/l~,- - 'WI' Models without is 9. Remove the supercharger (if applicable). All Models 10. Reach in behind the engine and lift the rubber protector to expose the PTO seal at the engine side of the drive shaft. 1. Rubber protector 2. Sealing ring 11. Remove all spark plugs from engine. Refer to IGNITION SYSTEM NOTE: Spark plug removal will ease engine rotation for drive shaft removal. 12. In engine compartment, install the DRIVE SHAFT WRENCH (PIN ) on the hexagon of sealing ring. 1.Deck extension 4. Lower the moving deck onto the fixed deck and install a few hexagonal screws on the rear suspension arm to hold the deck steady for the duration of the procedures. All Models 5. Remove the air intake silencer and its support. Refer to AIR INTAKE SYSTEM subsection. 6. Remove the ibr gate and VTS ring as an assembly. Refer to ibr AND VTS subsection. 7. Remove the jet pump assembly. Refer to JET PUMP subsection. is Models 8. Remove the supercharger air intake hose Driveshaft wrench 13. From rear of watercraft, install the DRIVE SHAFTADAPTER(PIN ) on drive shaft end. smr

., Section 06 STEERING AND PROPULSION 2. Carefully inspect the rubber sealing lip condition. Damage would allow water to enter engine or oil to leave engine. If damaged, replace drive shaft. I1!

5 ., Section 06 STEERING AND PROPULSION 2. Carefully inspect the rubber sealing lip condition. Damage would allow water to enter engine or oil to leave engine. If damaged, replace drive shaft. I1!mliI The rubber sealing lip is critical for proper sealing of engine at drive shaft connection into engine. 3. Inspect the rubber coating of drive shaft. If cracked or otherwise damaged, shaft corrosion will occur. 1. Drive shaft adapter 14. While a coworker holds the drive shaft wrench in the engine compartment, unscrew the drive shaft clockwise (LH threads) CLOCKWISE TO UNSCREW I1!mliI Ensure to unscrew clockwise on LH threads (opposite of usual threads). 15. Place rags under PTO housing to prevent oil spillage. If spillage occurs, clean immediately with the PULLEY FLANGE CLEANER (PIN ) to prevent oil stains. 16. Pullout drive shaft. NOTE: A slight jerk to the rear may be required to remove the drive shaft from the PTO seal. 17. Remove sealing ring. Refer to SEALING RING in this subsection. Drive Shaft Inspection 1. Inspect condition of drive shaft splines, taper surface and threads. If damage is found, replace drive shaft. smr Splines 2. Threads 3. Taper 4. Rubber sealing lip 5. Rubber coating 4. Measure drive shaft deflection. Excessive deflection could cause vibration and damage to drive shaft splines, impeller or PTO seal. 4.1 Place drive shaft on V-blocks and set-up a dial gauge in center of shaft. 4.2 Slowly rotate shaft; difference between highest and lowest dial gauge reading is deflection. Refer to the following illustration. IMPORTANT:When rotating drive shaft and reading the deflection, the gauge needle will bump on the molding flash mark. This is a normal situation, ignore this deflection peak. 479

Section 06 STEERINGAND PROPULSION '". :;T ':' 1 2 - MEASURING DRIVE SHAFT DEFLECTION 1. Dial gauge 2. V-blocks DRIVE SHAFT DEFLECTION Maximum 0.75mm (.03in) 1. Sealing ring aligned with carbon seal 5.

6 Section 06 STEERINGAND PROPULSION '". :;T ':' MEASURING DRIVE SHAFT DEFLECTION 1. Dial gauge 2. V-blocks DRIVE SHAFT DEFLECTION Maximum 0.75mm (.03in) 1. Sealing ring aligned with carbon seal 5. Wipe clean the threads and the tapered surface on drive shaft. 6. Apply engine oil to the tapered surface on drive shaft. Drive Shaft Installation 1. Install the SEALINGRING, see the procedure in this subsection. 2. Remove the damper at the end of drive shaft and replace it with a NEW one. smr ij16_o 1. Clean taper then coat with engine oil 7. Apply 2 beads of LOCTITE577 {THREAD SEALANn (PIN ) on threads as shown. B smr &004_o 1. Damper 3. Wipe clean the sealing ring and the carbon seal contact surfaces. 4. Properly align sealing ring with carbon seal. smr20q9.007.q10_8 LOCTITE 577 APPLICATION A. First 5 threads B. 3 mm (1/8 in) 8. From rear of watercraft, engage drive shaft through the drive shaft boot. 9. Continue pushing drive shaft towards engine carefully guiding it through the sealing ring, the pro seal and finally into the crankshaft splines. 480 smr201().()44

Section 06 STEERING AND PROPULSION NOTE: It may be necessary to move sealing ring and PTO seal up and down to position them in the same axis as the drive shaft.

7 Section 06 STEERING AND PROPULSION NOTE: It may be necessary to move sealing ring and PTO seal up and down to position them in the same axis as the drive shaft. If drive shaft does not enter into the PTO seal, check engine alignment. Refer to ENGINE REMOVAL AND INSTAL- LATION subsection. 10. Trace an index mark on the drive shaft which will be used for counting the turns the drive shaft will be rotated to fully engage drive shaft. 1. Mark 11. Install the DRIVE SHAFTADAPTER(PIN ) on drive shaft end. 13. Rotate drive shaft 2 turns then try pulling drive shaft out to ensure it is engaged. 14. In engine compartment, install the DRIVE SHAFT WRENCH (PIN ) on the hexagon of sealing ring. 1. Drive shaft adapter NOTE: Make sure all spark plugs are removed from engine. Removing spark plugs helps to engage threads more easily thus preventing cross-threading the sealing ring. 12. Carefully rotate drive shaft counterclockwise (LH threads) to engage threads in sealing ring. Be careful not to engage cross-threaded. smr oo2_a 1. Drive shaft wrench While a coworker holds the drive shaft wrench in engine compartment, continue turning drive shaft counterclockwise (approximately 8 turns). IMPORTANT: The number of turns is only a reference to give you an idea of the drive shaft engagement in the sealing ring. It is useful if you suspect cross-threading. When the number of turns has been reached, the torque is mandatory to properly secure the drive shaft. smr

ection 06 STEERINGAND PROPULSION ISubsection04 (DRIVESHAFT) 16. Torque drive shaft to 125 N-m (92Ibf-ft). 17. Reposition rubber protector above sealing ring. 18. Installjet pump.

8 ection 06 STEERINGAND PROPULSION ISubsection04 (DRIVESHAFT) 16. Torque drive shaft to 125 N-m (92Ibf-ft). 17. Reposition rubber protector above sealing ring. 18. Installjet pump. Refer to JET PUMP subsection. 19. InstalliBRgate and VTS ring, refer to tbr AND VTSsubsection. 20. Check engine oil level. Refill as necessary. 21. Installspark plugs on engine, refer to IGNI- TIONSYSTEM subsection. 22. Runwatercraft then ensure there is no oil leak in PTO seal area. 23. Properlyreinstall the deck extension, moving deckand rear ventilation box. Refer to BODY subsection. SEALINGRING Sealing Ring Removal 1. Remove drive shaft. Refer to DRIVE SHAFTin this subsection. 2. Carefully pry out sealing ring from PTO seal working alternately from side to side while retainingpto seal. Sealing Ring Inspection Inspect condition of threads, tapered surfaces, carbon seal contact surface and seal lip contact surface. If damage is found, replace sealing ring. Sealing Ring Cleaning Clean the following sealing ring surfaces and threads Seal lip contact surface 2. Threads {inside} 3. Carbonseal contact surface,i ~ smr

Section 06 STEERING AND PROPULSION II 1 1. Tapered surfaces Sealing Ring Installation 1. Carefully insert sealing ring in the PTO seal. 2. Ensure sealing ring is completely inserted in the PTO seal.

9 Section 06 STEERING AND PROPULSION II 1 1. Tapered surfaces Sealing Ring Installation 1. Carefully insert sealing ring in the PTO seal. 2. Ensure sealing ring is completely inserted in the PTO seal. NOTE: The sealing ring flange must be flush with the PTO seal flange. WRONG 1. Sealing ring incompletely inserted into PTOseal 3. Install all other removed parts. Refer to the proper subsections... CORRECT 1. Sealing ring fully inserted into PTO seal smr201().()44 483

5-3. ENGINE BOTTOM END

5-3. ENGINE BOTTOM END BOTTOM END ENGINE DRIVE SHAFT 5-3-1 CRANKCASE Remover: 560012 Installer: 560011 Remover: 560014 Installer: 560013 CRANKSHAFT 5-3-2 WATER PUMP, OIL PUMP Installer: 560025 Remover: 560024 Installer: 560003