Sec5 PDF
Sec5 PDF
Sec5 PDF
d
a
c
a - Forward Motion d - Reverse Gate
b - Water Thrust (Shown In the Forward
c - Nozzle (Rudder) Position)
c
a - Inlet Screen
a - Stator Assembly c - Screws (4)
b - Nozzle Assembly 7. Straighten tabs on impeller tab washer.
c a - Puller 91-83165M
53798 5. Install new stator seals using Special Tool
91-820554. Outer seal: lip faces out. Inner seal:
a - Impeller Shaft b - Impeller lip faces in.
Machined Flats c - Special Tool 91-824872
Inspecting Components a
a b
c
53800
b a - Handle Driver 91-824892
b - Seal Installer 91-820554
c - Seals (Top Seal Faces UP, Bottom Seal Faces Down)
a - O-ring
b - Inspect Surface for Grooves/Scoring
a b
b
c
d
a - Fill Hole
c
a - Steering Cable
b - Shift Cable Bracket
c - Shift Cable 5. Remove bracket from steering cable.
2. Loosen shift and steering cable thru hull fittings. 6. Remove remaining four nuts from drive housing
3. Support pump. cover. Remove drive housing cover and gasket.
a - Nuts
a 53796
a
b
53797
a - O-ring b - Shims
a - Seal Protector
a
11. Install new bearing using Special Tool
91-820557.
20. Press new outer race into front cover using Spe-
cial Tool 91-820556.
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 4. Rotate pinion shaft ten revolutions to properly
seat roller bearings.
d. Pinion Shaft Housing
5. Insert Pinion Location Tool (Special Tool
e. Impeller Gear 91-824890) in drive housing.
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) NOTE: Carefully inspect location tool to made sure it
1. Install original shims on pinion shaft housing.
is seated in drive housing bearing.
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).
a - Wear Ring
b - Stator
a b
15. Install Dial Indicator Kit, Adapter Kit and Thread a - Wear Ring
Extender Kit. b - Stator Assembly
19. Remove stator fill screw with washer and fill sta-
tor with High Performance Gear Lube. Capacity
is 3.4 oz. (100 cc). Install fill screw and washer.
c
d
Quicksilver Lubrication/Sealant
Application Points
A 2-4-C w/Teflon (92-825407A12)
B Loctite 271 (92-823089--1)
2
1 8
3
A A
4
9
10 A
B
17
16
B 11
15
18 12
13
14
Quicksilver Lubrication/Sealant
Application Points
A 2-4-C w/Teflon (92-825407A12)
B Loctite 271 (92-823089--1)