JET PUMP R1 JUNE 1996 JET PUMP

Transcription

1 JET PUMP R1 JUNE 1996 JET PUMP 5-1

2 Tle Of Contents Pge Generl Informtion Priniples of Opertion Speil Tools Serviing Impeller Removing Impeller Inspeting Components Instlling Impeller Pge Removing Jet Drive From Bot Drive Housing Disssemly Pinion Shft Removl Impeller Shft Removl Shimming Proedures Nozzle/Rudder Components Pinion nd Impeller Shft Components JET PUMP R1 JUNE 1996

3 Generl Informtion NOTE: Due to running hnges, some illustrtions my not e extly the sme s your drive unit. Servie proedures remin the sme unless otherwise noted. Priniples of Opertion The jet pump opertes y drwing wter into housing forwrd of the impeller. The wter is pressurized within the speilly designed housing nd then direted to the rer to provide thrust nd motion. - Reverse Gte (Shown In the Forwrd Position) d - Forwrd Motion - Wter Thrust - Nozzle (Rudder) d - Reverse Gte (Shown In the Forwrd Position) The jet pump is equipped with steerle nozzle (rudder) t the ft end of the pump housing tht direts the thrust of wter. The jet of wter n e direted right or left when the opertor turns the steering wheel in the respetive diretion. When the opertor turns the steering wheel to the right, for exmple, the nozzle turns to the right nd the jet fore from the nozzle pushes the stern of the ot to the left using the ow of the ot to turn right. Forwrd nd reverse drive nd the neutrl position re hieved y the position of reverse gte loted just ft of the nozzle. Forwrd drive hs the reverse gte lering the nozzle to llow ll the thrust to e direted stright k. Reverse drive hs the reverse gte overing the entire opening enough to divert the thrust forwrd. Neutrl position hs the reverse gte overing 75 perent of the nozzle to diret the wter strem forwrd nd downwrd,s well s kwrd. The shift position is ontrolled t the ontrol ox in the ot. - Reverse Gte (Shown In the Reverse Position) R1 JUNE 1996 JET PUMP 5-1

4 Speil Tools Jet Pump Tool Kit A2 Desription Pre-Lod Kit Pinion Shft Prt Numer A1 Pre-Lod Kit Impeller Shft A1 d Thred Extender Kit A1 used w/ Bklsh Kit d Flushing Adptor f e e Sel Protetor Impeller Shft f Impeller Nut Wrenh g h i j g Pinion Ger Lotion Tool h Bering Instller press ll ering into pinion shft housing smll O.D. shft i j k Bering Instller press ll ering into pinion shft housing Bushing Instller sttor ushings Sel Instller sttor sels lrge O.D. shft n k l o p m l Sel Instller pinion shft sels in drive housing m Bering Instller impeller shft ll ering in drive housing q n Puller Br used for pulling drive housing sels o Ring Guide Instller instlls ring guide on drive housing over r p q Bering Cup Instller pinion shft housing nd drive housing front over Bering Instller tper roller ering on pinion shft t s r Hndle Driver s Bushing Instller instlls reverse gte pivot ushings t Bushing Press instlls rudder pivot ushings JET PUMP R1 JUNE 1996

5 Speil Tools (Continued) Bklsh Inditor Flg use MCII line Prt Numer Impeller Shft Holder Dil Inditor Kit A1 Dil Inditor Adpter Kit Slide Hmmer A1 Bering Puller Kit M Retining Ring Pliers Lurints/Adhesives Prt Numer Lotite, # Lotite, #242 Otin Lolly Perfet Sel C Lurint w/ Teflon A1 Serviing Impeller Removing Impeller 1. Disonnet sprk plug leds from sprk plugs. 2. Disonnet shift nd steering les. Remove shift le rket. 4. Remove two srews seuring sttor ssemly to ride plte. - Srews (2) to Sttor Assemly Remove four srews seuring sttor ssemly to drive housing. Remove sttor ssemly nd wer ring. - Steering Cle - Shift Cle Brket - Shift Cle 3. Remove four srews seuring nozzle ssemly to sttor. Remove nozzle ssemly. - Wer Ring - Sttor Assemly NOTE: Tilt sttor k to prevent oil from running out. 6. Remove inlet sreen on ottom of drive housing to llow ess to mhined flts on impeller shft. If using Speil Tool to hold impeller shft, inlet sreen does not need to e removed. - Sttor Assemly - Nozzle Assemly - Srews (4) - Inlet Sreen 7. Strighten ts on impeller t wsher R1 JUNE 1996 JET PUMP 5-3

6 8. Hold impeller shft with wrenh on mhined flts. 9. Remove impeller nut using Speil Tool or pproprite size wrenh. Remove impeller. Impeller nut is left hnd thred: turn lokwise to loosen. 3. Inspet sels in sttor for wer/dmge. 4. If replement is required, remove sttor sels using Puller M shown elow. - Impeller Shft Mhined Flts Inspeting Components Impeller - Speil Tool Inspet wer ring for exessive soring nd/or grooves. Reple wer ring if deep grooves re present or severe soring hs tken ple. 2. Insure O-ring is in ounterore efore instlling wer ring to drive housing. - Puller M 5. Instll new sttor sels using Speil Tool Outer sel: lip fes out. Inner sel: lip fes in Hndle Driver Sel Instller Sels (Top Sel Fes UP, Bottom Sel Fes Down) - O-ring - Inspet Surfe for Grooves/Soring 5-4 JET PUMP R1 JUNE 1996

7 Instlling Impeller 1. Lurite splines of impeller shft with 2-4-C w/ teflon grese. 2. Instll thrust wsher, impeller, t wsher nd nut on impeller shft. Torque impeller nut to 70 l. ft. (95 N m). Bend oth ts of t wsher ginst flts on nut. 3. Instll inlet sreen. Apply Lotite 242 to threds of srews. Torque srews to 75 l. in. (8.5 N m). 4. Instll wer ring nd sttor. Apply Perfet Sel to threds of four srews. Torque srews to 30 l. ft. (40.7 N m). 6. Apply Lotite 242 to srews (2) seuring sttor to the ride plte. Torque srews to 75 l. in. (8.5 N m). d - Wer Ring - Sttor Assemly 5. Remove sttor fill srew with wsher nd fill sttor with High Performne Ger Lue. Cpity is 3.4 oz. (100 ). Instll fill srew nd wsher. - Srews (2) to Sttor Assemly - Anode - Nozzle Assemly d - Srews (4) to Nozzle Assemly 7. Instll nozzle ssemly nd node. Apply Lotite #271 to threds of srews. Torque ll four (4) srews to 30 l. ft. (40.7 N m). 8. Atth shift nd steering les. REFER TO SECTION 6: SPORT JET INSTALLA- TION FOR SHIFT AND STEERING INSTALLATION AND ADJUSTMENT. - Fill Hole R1 JUNE 1996 JET PUMP 5-5

8 Removing Jet Drive From Bot REMOVE POWERHEAD AS OUTLINED IN SEC- TION Disonnet shift nd steering les. Remove shift le rket. 4. Remove three srews seuring steering le rket to drive housing. - Steering Cle - Shift Cle Brket - Shift Cle 2. Loosen shift nd steering le thru hull fittings. 3. Support pump. 5. Remove rket from steering le. 6. Remove remining four nuts from drive housing over. Remove drive housing over nd gsket. - Nuts WARNING The pump unit must e supported to prevent it from dropping through the opening when the remining fsteners re removed. 7. Lower drive housing nd ple on enh or suitle work stnd for disssemly/repir. 5-6 JET PUMP R1 JUNE 1996

9 Drive Housing Disssemly Pinion Shft Removl 1. Remove four srews seuring pinion shft housing to drive housing. Remove pinion shft ssemly. 3. Press pinion shft out of pinion shft housing Remove pinion shft ll ering nd two sels using Puller M. - Pinion Shft Assemly NOTE: Tke re not to dmge or misple olored shims. 2. Remove ruer ring, O-ring nd shims. 5. Remove pinion shft outer re from pinion shft housing using slide hmmer A Ruer Ring - Shims - O-ring R1 JUNE 1996 JET PUMP 5-7

10 6. Press new outer re into pinion shft housing using mndrel Press new ll ering into pinion shft housing using Speil Tool Remove tpered roller ering from pinion shft using universl puller plte Press pinion shft into pinion housing. 8. Press new tpered roller ering onto pinion shft using Speil Tool JET PUMP R1 JUNE 1996

11 11. Press new sels into pinion shft housing, one t time, using Speil Tool Inner sel fes in, outer sel fes out. NOTE: Tke re not to dmge or misple olored shims. - O-ring - Shims 5. Instll sel protetor on impeller shft. - Speil Tool Impeller Shft Removl 1. Remove Sttor, Wer Ring nd Impeller s desried in Serviing Impeller. 2. Remove fill nd vent srews, drin oil into suitle ontiner. 3. Remove ride plte Ride Plte 4. Remove four srews seuring impeller shft over to drive housing. Remove over. Remove O- ring - Sel Protetor 6. Push impeller shft ssemly out through front off drive housing. 7. Remove ering retining ring from drive housing R1 JUNE 1996 JET PUMP 5-9

12 8. Remove ering using Puller M. 14. Remove nut, wsher nd ger/ering ssemly. 15. If repling ering, remove using universl plte. 9. Remove impeller shft sels using Slide Hmmer A Instll new sels using Speil Tool Mndrel (15/16 in. soket) - Universl Puller Plte ( ) 16. Press new ering on ger using n pproprite size mndrel. 11. Instll new ering using Speil Tool Instll retining ring in drive housing fter ering is instlled. 13. Clmp n open end wrenh in vise. Ple flts of impeller shft in wrenh. - Mndrel (1-1/8 in. soket) 17. Instll ger/ering ssemly nd wsher on impeller shft. Apply Lotite 271 to threds of impeller shft. Instll nut nd torque to 90 l. ft. (122 N m) JET PUMP R1 JUNE 1996

13 18. Do not instll impeller shft if shimming is required (See next setion). Instll sel protetor ( ) on impeller shft. Instll impeller shft in drive housing using twisting motion. 19. Remove outer re from front over using Puller M. 2. Instll pinion shft ssemly into drive housing ore. 3. Torque srews to 180 l. in. (20.3 N m). 20. Press new outer re into front over using Speil Tool Shimming Proedures NOTE: Pinion ger shimming nd klsh proedures must e preformed when ny of the following omponents hve een repled:. Jet Drive Housing. Pinion Ger. Pinion Ger Bering Assemly d. Pinion Shft Housing e. Impeller Ger f. Impeller Ger Bering Assemly g. Impeller Shft Front Cover NOTE: Shims re olor oded to represent different thiknesses. These olor odes pply to oth pinion housing shims nd impeller over shims. Red.002 in. (.05 mm) Beige.004 in. (.10 mm) Blue.005 in. (.127 mm) Frost (Cler).0075 in. (.19 mm) Brown.010 in. (.25 mm) Yellow.020 in. (.51 mm) 1. Instll originl shims on pinion shft housing. Instll O-ring on pinion shft housing. NOTE: If originl shims re not ville, strt with.030 in. (.76 mm) shims (three rown olored shims). 4. Rotte pinion shft ten revolutions to properly set roller erings. 5. Insert Pinion Lotion Tool (Speil Tool ) in drive housing. NOTE: Crefully inspet lotion tool to mde sure it is seted in drive housing ering R1 JUNE 1996 JET PUMP 5-11

14 6. Insert feeler guge through hole in pinion lotion tool etween guging surfe of tool nd flts on ottom of pinion ger teeth. Lurite one ering with gerse lurint. 11. Instll impeller shft over. Torque srews to 180 l. in. (20.3 N m). Rotte impeller shft ten revolutions to properly set roller erings. 12. Instll impeller shft pre-lod tool ( A1). Remove sel protetor from impeller shft. Instll impeller thrust wsher, spring, nd spring set on impeller shft. IMPORTANT: The orret lerne is.025 inh (0.64 mm). 7. Use.025 inh (.064 mm) feeler guge s strting thikness. Adjust thikness of feeler guge until slight drg is felt s guge is drwn out etween guging surfe of tool nd pinion ger. NOTE: One the thikness is determined, the differene etween feeler guge thikness nd.025 inh (0.64mm) required lerne must e either dded or sutrted from the totl thikness of shims etween pinion shft housing nd drive housing. Remove the srews seuring the pinion shft housing ssemly to the drive housing. Lift ssemly out of the drive housing. Adjust shim thikness s required. 8. Instll Impeller Shft Sel Protetor (Speil Tool ) over impeller threds of impeller shft ssemly. 9. Using twisting motion instll impeller shft ssemly in drive housing. - Thrust Wsher - Spring - Spring Set 13. Instll wer ring nd sttor on impeller shft. Seure ssemly with two olts (opposite orners). Torque olts to 30 l. ft. (40.7 N m). - Wer Ring - Sttor 10. Instll originl shims on impeller shft over. Instll O-ring on impeller shft over. NOTE: If originl shims re not ville, strt with.030 in. (.76 mm) shims (three rown olored shims). Lurite O-ring nd ore with Quiksilver lurint 2-4-C JET PUMP R1 JUNE 1996

15 14. Instll Bklsh Inditor Rod (Speil Tool No ) on pinion shft. 18. Instll wer ring nd sttor. Apply Lotite 271 to four srews. Torque srews to 30 l. ft. (40.7 N m). - Bklsh Inditor Rod Instll Dil Inditor Kit, Adpter Kit nd Thred Extender Kit. - Wer Ring - Sttor Assemly 19. Remove sttor fill srew with wsher nd fill sttor with High Performne Ger Lue. Cpity is 3.4 oz. (100 ). Instll fill srew nd wsher. Position rod from dil inditor on the enter mrk II of the klsh inditor rod. 16. Rotte pinion shft k nd forth lightly to ontt ger teeth in eh diretion. NOTE: Averge totl mount of reding of inditor klsh speifition is.007 inh (.18 mm) to.009 inh (.23 mm). If reding is less thn minimum, dd shims etween impeller over nd drive housing. If reding is more thn mximum remove shims etween impeller over nd drive housing. Rtio of klsh reding to shims is 1: Instll impeller s outlined in Instlling Impeller in this setion. - Fill Hole 20. Instll rideplte. DO NOT reuse srews. Apply Lotite 242 to threds of new srews. Torque to 75 l. in. (8.5 N m) R1 JUNE 1996 JET PUMP 5-13

16 21. Apply Lotite 242 to srews (2) seuring sttor to the ride plte. Torque srews to 75 l. in. (8.5 N m). 22. Instll nozzle/reverse gte ssemly nd node. Apply Lotite #271 to threds of srews. Torque ll four (4) srews to 30 l. ft. (40.7 N m). 23. Remove fill nd vent srews from ottom of drive housing. Fill drive housing with High Performne Ger Lue. Cpity is 18.6 oz. (550 ). NOTE: To otin orret oil level pump housing must e level nd upright. 24. Atth shift nd steering les. REFER TO SECTION 6: SPORT JET INSTALLA- TION FOR SHIFT AND STEERING INSTALLATION AND ADJUSTMENT. d - Srews (2) to Sttor Assemly - Anode - Nozzle Assemly d - Srews (4) to Nozzle Assemly 5-14 JET PUMP R1 JUNE 1996

17 R1 JUNE 1996 JET PUMP 5-15

18 Nozzle/Rudder Components Quiksilver Lurition/Selnt Applition Points A B 2-4-C w/teflon ( A12) Lotite 271 ( ) Item Qty Desription Torque 1 2 Srew M6 x 1 x Lokwsher, Externl 3 1 Anode 4 1 Gte 5 1 Srew, Pivot 6 2 Srew (10-24 x 3/8 in.) 7 1 T Lok 8 1 Brket 9 1 Swivel L. In. L. Ft. N m 5-16 JET PUMP R1 JUNE 1996

19 Item Qty Desription Torque L. In. L. Ft. N m 10 2 Srew 1/4-20 x 5/8 in T, Loking 12 1 Brket 13 1 Nut 1/ Bolt, Pivot Srew M10 x 1.50 x O-ring 17 1 Srew Plug 18 2 Plug, Pipe 19 1 Sttor 20 1 Plug 21 2 Bushing 22 2 Sel 23 1 Wer Ring 24 1 Impeller Nut T Lok Wsher 26 1 Impeller 27 1 Wsher 28 1 O-ring 29 2 Srew M10 x 1.50 x Anode 31 4 Bushing 32 1 Nozzle 33 2 Fitting 34 1 Syphon Hose 35 2 St-strp 36 2 Srew M8 x 1.25 x Wsher 38 2 Reverse Gte Stop 39 2 Srew M10 x 1.50 x Rudder/Steering Lever (One Piee) 41 1 Cotter Pin 42 1 Wsher 43 1 Clevis Pin 44 3 Srew M8 x 1.25 x Steering Lever 46 1 Rudder 47 2 Lokwsher, Externl R1 JUNE 1996 JET PUMP 5-17

20 Pinion nd Impeller Shft Components B A A A A B B A Quiksilver Lurition/Selnt Applition Points A 2-4-C w/teflon ( A12) B Lotite 271 ( ) 5-18 JET PUMP R1 JUNE 1996

21 Item Qty Desription Torque L. In. L. Ft. N m 1 4 Bolt (M8 x 1.25 x 25) Ruer Ring 3 2 Sel 4 1 Bll Bering 5 1 Housing Assy. 6 AR Shim 7 1 O-ring 8 1 Bering Assy. 9 1 Ger Shft Assy 10 1 Impeller Shft 11 1 Ger 12 1 Bering Assy Wsher 14 1 Nut (M14 x 1.5) Cover Assy. 16 AR Shim 17 1 O-ring 18 4 Bolt (M8 x 25) R1 JUNE 1996 JET PUMP 5-19