Tble of Contents JET PUMP Section 5 - Jet Pump JET PUMP Generl Informtion..................... 5-2 Principles of Opertion................ 5-2 Mster Specifictions Jet Pump........... 5-3 Specil Tools........................ 5-3 Notes:................................. 5-5 Drive Housing Components............... 5-6 Pinion & Impeller Shft................... 5-10 Pinion nd Impeller Shft................. 5-11 Nozzle/Rudder Components.............. 5-12 Servicing Sttor, Impeller nd Wer Ring... 5-14 Disssembly......................... 5-14 Inspecting Components............... 5-16 Instlling Impeller..................... 5-18 Removing Jet Drive From Bot............ 5-19 Drive Housing Disssembly nd Ressembly............................ 5-20 Pinion Shft Removl................. 5-20 Impeller Shft Removl............... 5-23 Shimming Procedures................ 5-27 5 Pge 5-1
Generl Informtion Principles of Opertion NOTE: Due to running chnges, some illustrtions my not be exctly the sme s your drive unit. Service procedures remin the sme unless otherwise noted. The jet pump opertes by drwing wter into housing forwrd of the impeller. The wter is pressurized within the specilly designed housing nd then directed to the rer to provide thrust nd motion. c b 58192 -Forwrd Motion b-wter Thrust c -Reverse Gte (Shown In the Forwrd Position) The jet pump is equipped with steerble nozzle (rudder) t the ft end of the pump housing tht directs the thrust of wter. The jet of wter cn be directed right or left when the opertor turns the steering wheel in the respective direction. When the opertor turns the steering wheel to the right, for exmple, the nozzle turns to the right nd the jet force from the nozzle pushes the stern of the bot to the left cusing the bow of the bot to turn right. Forwrd, reverse drive nd the neutrl position re chieved by the position of reverse gte locted just ft of the nozzle. Forwrd drive hs the reverse gte clering the nozzle to llow ll the thrust to be directed stright bck. Reverse drive hs the reverse gte covering the entire opening enough to divert the thrust forwrd. Neutrl position hs the reverse gte covering 75 percent of the nozzle to direct the wter strem forwrd nd downwrd, s well s bckwrd. The shift position is controlled t the control box in the bot. 58193 -Reverse Gte (Shown In the Reverse Position) Pge 5-2
Mster Specifictions Jet Pump JET PUMP Pump Type Impeller Trim System Mounting System Exhust System Specil Tools Model 250 (3.0l) Optimx Jet Mixed flow/high volume Dimeter Ger Rtio 4-blde, Stinless steel Adjustble trim plte Rubber isolted grommet mount Tuned through-trnsom exhust with dul mufflers 7.25 in. (184 mm) 1.15:1 Jet Pump Tools Description Prt Number Pre-Lod Kit Impeller Shft 91-824871A2 b Thred Extender Kit used with Bcklsh Kit 91-824869A1 c Sel Protector Impeller Shft 91-850233 d Impeller Shft Wrench 91-832093A1 e Impeller Nut Socket 91-850297 f Pinion Ger Loction Tool 91-882758 g Bering Instller (press bll bering nd sels into pinion shft 91-832016 housing) h Bushing Instller, sttor bushings & sel 91-850831 i Sel Instller (impeller shft sels in drive housing) 91-832019 j Bering Instller (impeller shft bll bering in drive housing) 91-832017 k Bering Cup Instller, pinion shft housing nd drive housing 91-832018 front cover l Hndle Driver 91-824892 Pge 5-3
b c d e f g h i j l k Bcklsh Indictor Flg use MCII line 91-53459 Dil Indictor Kit 91-58222A1 Dil Indictor Adpter Kit 91-83155 Slide Hmmer 91-34569A1 Bering Puller Kit 91-83165M Retining Ring Pliers 91-25081 Pge 5-4
Notes: JET PUMP Pge 5-5
Drive Housing Components Pge 5-6
Drive Housing Components TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N m 1 HOUSING ASSEMBLY Jet Drive (COMPLETE) (NO IMPELLER) 1 1 HOUSING ASSEMBLY Jet Drive (BASIC) 2 1 FITTING-Syphon Drin Hose (.125-27) 3 10 STUD (M10 x 55) 35 47.5 4 2 SEAL-Oil 5 1 BEARING-Bll 6 1 RING-Snp 7 2 SCREW KIT 8 2 WASHER-Seling 9 1 GASKET-Drive Housing To Top Cover 10 1 O-RING 11 1 O-RING (.139 x.796) 12 1 O-RING (.210 x.412) 13 1 GROMMET-Pump Mount 14 10 NUT (M10) 15 1 TUBE-Wter 16 2 NUT (M8) 17 2 WASHER (1.50 OD x.390 ID x.12) 18 2 WASHER (1.50 OD x.900 ID x.125) 19 1 PLATE-Trim 20 2 SCREW (M8 x 35) 21 1 RIDE PLATE KIT (Pinted) 22 16 SCREW With Nylon Ptch (M6 x 20) 75 8.5 23 1 SEAL KIT-Ride Plte 24 1 INLET GRATE KIT (Pinted) 25 1 SPRING-Inlet Grte 26 1 TINES-Inlet Grte 27 1 FRAME-Inlet Grte 28 2 SCREW-With Nylon Ptch (M6 x 20) 75 8.5 29 2 SCREW-Pivot (Specil) 75 8.5 30 2 SCREW (M8 x 25) 16.7 22.6 31 OPT INLET GRATE 32 2 SCREW-With Nylon Ptch (M6 x 20) 33 2 SCREW (M8 x 25) 34 OPT ROCK GRATE 35 2 SCREW-With Nylon Ptch (M6 x 20) 36 2 SCREW (M8 x 25) 37 12 NUT (M10) 35 47.5 38 1 O-RING Top Cover 39 1 COVER ASSEMBLY Top of Jet Drive Housing 40 1 O-RING Top Cover Pge 5-7
Drive Housing Components Pge 5-8
Drive Housing Components TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N m 41 1 GASKET-Engine Adptor 42 12 STUD (M10 x 63) 43 1 CONNECTOR (.250-18) Pge 5-9
Pinion & Impeller Shft 7 Loctite 271 108 Specil Lubricnt 101 Pge 5-10
Pinion nd Impeller Shft TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N m 1 1 RING-Rubber 2 4 SCREW (M8 x 25) 180 20.5 3 1 HOUSING ASSEMBLY-Pinion Shft (Pinted) 4 2 SEAL-Pinion Shft Housing 5 1 BEARING-Bll 6 1 BEARING SET (Cone And Cup) 7 1 O-RING AR SHIM (.002) AR SHIM (.004) 8 AR SHIM (.005) AR SHIM (.0075) AR SHIM (.010) 9 1 GEAR/SHAFT ASSEMBLY-Pinion 10 1 SHAFT-Impeller 11 1 GEAR-Impeller Shft 12 1 WASHER 13 1 NUT (M14) 90 122 AR SHIM (.002) AR SHIM (.004) 14 AR SHIM (.005) AR SHIM (.0075) AR SHIM (.010) 15 1 COVER ASSEMBLY-Impeller Shft (Pinted) 16 1 BEARING SET (Cone And Cup) 17 1 O RING 18 4 SCREW (M8 x 25) 180 20.5 Pge 5-11
Nozzle/Rudder Components 6 Dielectric Grese 7 Loctite 271 Pge 5-12
Nozzle/Rudder Components TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. Nm 1 1 REVERSE GATE KIT (Pinted) 2 1 LOCKWASHER (.250 Internl) 3 1 ANODE 4 1 SCREW (M6 x 20) 70 7.9 5 2 BUSHING-Pivot 6 2 PIN-Trilobe 7 1 PIN-Clevis (.250 x 1.13) 8 1 WASHER 9 1 PIN-Cotter 10 1 DECAL-Reverse Gte (Powered By Mercury) 11 4 BOLT (Specil)-Pivot 50 68 12 2 RUDDER KIT (Pinted) 13 1 BUSHING-Pivot 14 1 LOCKWASHER (.250 Internl) 15 1 ANODE 16 1 SCREW (M6 x 20) 70 7.9 17 1 ANODE (With Bushings In Csting) 18 2 SCREW (M10 x 45) 35 47.5 19 2 SCREW (M10 x 35) 35 47.5 20 2 WASHER (Specil) 21 1 HOSE-Syphon (12.250 Inches) 22 1 SCREW (M8 x 30) 120 10 13.6 23 1 WASHER 24 1 STOP-Reverse Gte 25 1 NOZZLE ASSEMBLY-With Pivot Bushings (Pinted) 26 1 FITTING-Nozzle 27 1 STOP-Non Adjustble 28 1 SCREW (M8 x 25) 120 13.6 29 4 SCREW (M10 x 150) 35 47.5 30 4 WASHER 31 1 STATOR ASSEMBLY (Pinted) 32 2 PLUG-Pipe (.250-18) 33 2 BUSHING-Sttor Rer 34 1 SEAL 35 1 PROTECTOR-Sel 36 1 TAB WASHER 37 1 RING KIT-Wer (Pinted) 38 1 PLUG-Pipe (.750-14) 39 2 STUD (M6 x 36) 40 2 NUT (M6) 41 1 O-RING 42 1 O-RING 43 1 LATCH-Retiner Shift Cble 44 1 RETAINER-Shift Cble 45 1 CUP-Brrel-Shift Cble Retiner 46 1 NUT-Impeller Shft (1.250-12) 150 203 47 1 IMPELLER-SS-4 Blde 48 1 END KIT-Swivel 49 1 BOLT AND NUT KIT 50 1 NUT (.250-20) Pge 5-13
Servicing Sttor, Impeller nd Wer Ring Disssembly 1. Disconnect sprk plug leds from sprk plugs. 2. Disconnect shift nd steering cbles t reverse gte nd rudder. b 58193 -Shift Cble b-steering Cble IMPORTANT: This procedure lists the disssembly of externl pump components. If servicing specific component, follow the procedure in tht section. REMOVING REVERSE GATE, RUDDER AND NOZZLE AS AN ASSEMBLY 1. Remove four screws securing nozzle to sttor. Remove reverse gte/rudder/nozzle ssembly. 54579 -Screws (4) Pge 5-14
STATOR REMOVAL JET PUMP 1. Remove two screws securing trim plte to ride plte nd wer ring. 2. Remove four screws securing sttor ssembly to drive housing. Remove sttor ssembly. b -Screws (2) to Trim Plte & Wer Ring b-trim Plte c -Sttor 3. Drin sttor by tilting sttor forwrd nd llowing the oil to drin over the impeller shft sels. Complete oil drining by removing sttor fill plug nd pour the remining oil out the fill plug hole. IMPELLER REMOVAL 58195 c 28253 1. If removed, instll wer ring to support impeller nd shft during impeller removl. 2. Remove inlet screen on bottom of drive housing to llow ccess to mchined flts on impeller shft. Use Specil Tool 91-832093A1 to hold impeller shft for removing propeller nut. 3. While holding impeller shft, remove impeller nut using Specil Tool 91-850297. Impeller nut is stndrd right hnd thred. Remove impeller. b 28252 -Specil Tool 91-850297 b-specil Tool 91-832093A1 4. Remove wer ring. Pge 5-15
Inspecting Components WEAR RING 1. Inspect wer ring for excessive scoring nd/or grooves. Replce wer ring if deep grooves re present or if severe scoring hs tken plce. 2. Ensure O-ring is in counterbore before instlling wer ring to drive housing. b 28255 -O-rings b-inspect Surfce for Grooves/Scoring 3. Inspect sel in sttor for wer/dmge. 4. Inspect bellows on cbles for wer. 5. Inspect nodes. Replce s necessry. 6. Inspect pivot pins nd bushings. Replce s necessry. Torque on reverse gte pivot pins is 80 lb. ft. (108 Nm). Rudder pivot pins is 50 lb. ft. (68 Nm). Use Loctite 271 on threds. 7. Inspect impeller for crcks nd dmged bldes. 8. Inspect sttor vnes for crcks nd/or dmge. 9. If replcement is required, remove sttor sel using Puller 91-83165M. 28256 -Puller 91-83165M 10. Instll new sel using Specil Tool 91-850831. Smller dimeter sel lip fces out. Pge 5-16
IMPELLER JET PUMP 1. Plce impeller in wer ring bore nd push to one side. 2. Mesure clernce between impeller bldes nd wer ring with feeler guge. If clernce is over 0.100 in. (2.54 mm), replce impeller nd wer ring. NOTE: Impeller wer usully ccounts for 75% of the wer. Reducing the clernce cn improve both top speed nd ccelertion performnce. COMPONENT SPECIFICATIONS Wer Ring Bore Dimeter Impeller Outside Dimeter Clernce between Impeller nd Wer Ring 7.273-7.283 in. (184.73-184.98 mm) 7.225-7.235 in. (183.52-183.77 mm) 0.038-0.058 in. (0.96-1.47 mm) 3. Inspect leding edges of the impeller for nicks nd dmge. Leding edges should be shrpened to 0.020 in. (0.51 mm) on the outer 1/2 of the leding edge for optimum performnce. Dull leding edges cn increse cvittion during initil ccelertion. Pge 5-17
Instlling Impeller 1. Lubricte splines of impeller shft with Specil Lube 101. 2. Instll impeller nd nut on impeller shft. Torque impeller nut to 150 lb. ft. (203 Nm). 3. Instll inlet screen. Apply Loctite 242 to threds of screws nd bolts. Torque the two 6 mm screws to 75 lb. in. (8.5 Nm). Torque the two 8 mm bolts to 16.7 lb. ft. (22.5 Nm). 4. Instll wer ring nd sttor. Apply Perfect Sel to threds of four bolts. Torque to 35 lb. ft. (47 Nm). NOTE: The sttor oil should be checked periodiclly for contmintion nd fluid level. To check sttor oil, shift the reverse gte to the forwrd position. Using n llen socket nd extension, remove the sttor fill plug. Use smll screw driver to dip into the oil to check it for contmintion, discolortion nd level. If oil is low, dd oil. If oil is contminted or discolored, shft, sels nd bushings must be inspected nd/or replced before refilling sttor with new oil. After refilling sttor with oil, pply Loctite PST Pipe Selnt to fill plug threds nd reinstll plug. 5. Remove sttor fill plug nd fill sttor with Premium Ger Lube until oil flows out fill hole (cpcity is 19 fl. oz. (550 cc)). Instll fill plug. 58196 -Fill Plug 6. Apply Loctite 242 to screws (2) securing trim plte to the ride plte. Torque screws to 75 lb. in. (8.5 Nm). b 58195 -Screws (2) to Trim Plte & Wer Ring b-trim Plte 7. Instll nozzle ssembly nd node. Apply Loctite 271 to threds of screws. Torque ll four (4) screws to 35 lb. ft. (47N m). 8. Attch shift nd steering cbles. Refer to Section 1D: Sport Jet Instlltion for shift nd steering instlltion nd djustment. Pge 5-18
Removing Jet Drive From Bot JET PUMP Remove powerhed s outlined in Section 4. 1. Disconnect shift nd steering cbles from reverse gte nd rudder. Remove cble dptors nd bellows ssemblies. Loosen shift nd steering cbles t wer ring. b -Shift Cble b-steering Cble 2. Loosen shift nd steering cble through hull fittings. 3. Support pump. 58193 WARNING 28257 The pump unit must be supported to prevent it from dropping through the opening when the remining fsteners re removed. 4. Remove remining ten nuts from drive housing cover. Remove drive housing cover nd gsket. b 59292 -Nuts (10) b-gsket 5. Lower drive housing while sliding cbles out. Plce on bench or suitble work stnd for disssembly/repir. Pge 5-19
Drive Housing Disssembly nd Ressembly Pinion Shft Removl 1. Remove four screws securing pinion shft housing to drive housing. Remove pinion shft ssembly. 28257 NOTE: Tke cre not to dmge or misplce colored shims. 2. Remove rubber ring, O-ring nd shims. b c 53797 -Rubber Ring b-shims c -O-ring Pge 5-20
3. Press pinion shft out of pinion shft housing. JET PUMP 53796 4. Remove pinion shft bll bering nd two sels using Puller 91-83165M. 28264 5. Remove pinion shft outer rce from pinion shft housing using slide hmmer 91-34569A1. 28265 Pge 5-21
6. Press new outer rce into pinion shft housing using mndrel 91-832018. 91-832018 28264 7. Remove tpered roller bering from pinion shft using universl puller plte 91-37241. 8. Press new tpered roller bering onto pinion shft using Specil Tool 91-827983. 28265 9. Press new bll bering into pinion shft housing using Specil Tool 91-832016. Use Loctite 680 between pinion nd bll bering. 28266 Pge 5-22
10. Press pinion shft into pinion housing. JET PUMP 28267 11. Press new sels into pinion shft housing, one t time, using Specil Tool 91-820552. Inner sel fces in, outer sel fces out. -Specil Tool 91-820552 Impeller Shft Removl 28268 1. Remove sttor, wer ring nd impeller s described in Servicing Impeller. 2. Remove sttor fill screw. Drin oil into suitble continer. 3. Remove ride plte. 4. Remove four screws securing impeller shft cover to drive housing. Remove cover. 28257 Pge 5-23
NOTE: Tke cre not to dmge or misplce colored shims. b 28258 -O-ring b-shims 5. Remove nut nd wsher from end of impeller shft. Remove impeller shft ger. 6. Pull impeller shft from drive housing. 28259 28259 Pge 5-24
7. Remove bering retining ring from drive housing. JET PUMP 28262 8. Remove bering using Puller 91-83165M. 28263 9. Remove impeller shft sels using Slide Hmmer 91-34569A1. 10. Instll new sels using Specil Tool 91-832019. 11. Instll new bering using Specil Tool 91-832017. 28260 28261 12. Instll retining ring in drive housing fter bering is instlled. Pge 5-25
13. If replcing impeller shft ger bering, remove using universl plte. b -Suitble Mndrel b-universl Plte 14. Press new bering on ger using n pproprite size mndrel. 28269 28270 15. If replcing bering, remove outer rce from front cover using slide hmmer. Press new outer rce in cover using suitble mndrel. 54985 Pge 5-26
Shimming Procedures JET PUMP NOTE: Pinion ger shimming nd bcklsh procedures must be preformed when ny of the following components hve been replced:. Jet Drive Housing b. Pinion Ger c. Pinion Ger Bering Assembly d. Pinion Shft Housing e. Impeller Ger f. Impeller Ger Bering Assembly g. Impeller Shft Front Cover 1. Instll originl shims on pinion shft housing. Instll O-ring on pinion shft housing. NOTE: If originl shims re not vilble, strt with 0.030 in. (0.76 mm) shims (three brown colored shims). 2. Instll pinion shft ssembly into drive housing bore. Torque screws to 180 lb. in. (20.3 Nm). 28271 3. Rotte pinion shft ten revolutions to properly set roller berings. 4. Insert Pinion Loction Tool (Specil Tool 91-882758) in drive housing. NOTE: Crefully inspect loction tool to mke sure it is seted in drive housing bering. 5. Insert feeler guge through hole in pinion loction tool between guging surfce of tool nd flts on bottom of pinion ger teeth. IMPORTANT: The correct clernce is 0.025 inch (0.64 mm). 6. Use 0.025 inch (.064 mm) feeler guge s strting thickness. Adjust thickness of feeler guge until slight drg is felt s guge is drwn out between guging surfce of tool nd pinion ger. NOTE: Once the thickness is determined, the difference between feeler guge thickness nd.025 inch (0.64mm) required clernce must be either dded or subtrcted from the totl thickness of shims between pinion shft housing nd drive housing. Remove the screws securing the pinion shft housing ssembly to the drive housing. Lift ssembly out of the drive housing. Adjust shim thickness s required. Pge 5-27
7. Instll sel protector, Specil Tool 91-850233, on impeller shft. Instll impeller shft in drive housing, then remove sel protector. 54986 -Sel Protector, Specil Tool 91-850233 8. Instll ger/bering ssembly nd wsher on impeller shft. Apply Loctite 271 to threds of impeller shft. Hold impeller shft with Specil Tool 91-832093A1. Instll nut nd torque to 90 lb. ft. (122 Nm). 28257 9. Instll originl shims on impeller shft cover. Instll O-ring on impeller shft cover. NOTE: If originl shims re not vilble, strt with 0.030 in. (0.76 mm) shims (three brown colored shims). Lubricte O-ring nd bore with 2-4-C with Teflon. Lubricte cone bering with gercse lubricnt. Pge 5-28
10. Instll impeller shft cover. Torque screws to 180 lb. in. (20.5 Nm). JET PUMP 28257 11. Instll impeller shft pre-lod tool (91-824871A2). b c 54983 -Spring Set, Rer b-spring c -Spring Set, Forwrd 12. Instll wer ring nd sttor on impeller shft. Secure ssembly with two bolts (opposite corners). Torque bolts to 35 lb. ft. (47 Nm). Rotte impeller shft ten revolutions to properly set roller berings. Pge 5-29
13. Instll Bcklsh Indictor Rod (Specil Tool No. 91-53459) on pinion shft. 54987 14. Instll Dil Indictor Kit, Adpter Kit nd Thred Extender Kit. Position rod from dil indictor on the center mrk II of the bcklsh indictor rod. 15. Rotte pinion shft bck nd forth lightly to contct ger teeth in ech direction. NOTE: Averge totl mount of reding of indictor bcklsh specifiction is 0.007 inch (0.18 mm) to 0.009 inch (0.23 mm). If reding is less thn minimum, dd shims between impeller cover nd drive housing. If reding is more thn mximum remove shims between impeller cover nd drive housing. Rtio of bcklsh reding to shims is 1:1. 16. Instll impeller, wer ring nd sttor s outlined in Instlling Impeller in this section. 17. Apply RTV Selnt on rideplte. Instll rideplte. Apply Loctite 242 to threds of screws. Torque to 75 lb. in. (8.5 Nm). 18. Instll nozzle/reverse gte ssembly nd node. Apply Loctite #271 to threds of screws. Torque ll four (4) screws to 35 lb. ft. (47 Nm). Pge 5-30
19. Remove fill nd vent screws from bottom of drive housing. Fill drive housing with Premium Ger Lube. Cpcity is 27 oz. (825 cc). b c -Fill/Drin Screw b-vent Screw c -RTV Selnt 58199 NOTE: To obtin correct oil level pump housing must be level nd upright. Refer to Section 1D: Sport Jet Instlltion to complete instlltion of Drive Housing, Shift nd Steering Cble Instlltion nd Adjustment. Pge 5-31