PROPULSION
6.8
2004 Four Stroke PWC Service Manual
W ARNING
Before working on the drive system, be sure the lanyard cord and lock plate are removed from the engine stop
switch to kill the ignition or severe injury could result.
Pump Removal
1. Remove lanyard cord. Proceed with disconnecting the
battery by removing negative(--) cable.
2. Disconnect reverse and steering linkage from nozzles.
Discard cotter pin and nylock nuts.
3. Using a criss--cross pattern, remove the four (4) pump
mounting bolts.
4. With the mounting bolts removed, each component
can be removed from the assembly. These
components are:
S Steering nozzle w/reverse gate.
S Stator assembly w/impeller.
S Extension housing.
Pump Assembly
Pump assembly is the reversal of disassembly. Polaris recommends applying dielectric grease to all nozzle--to--
nozzle mating surfaces to prevent corrosion.
Follow torque specifications listed on page 6.2.
NOTE: Always install new Nylock nuts and cotter pins.
Pump Hou sin g Removal
1. Remove the pump components as described above.
2. Access the pump housing mounting bolts from inside the engine compartment. Remove the nuts, washers,
and steering cable locking plate.
3. Attempt to remove the housing from the hull using a small prybar. Do not damage the pump housing or hull
mating surfaces. If the housing will not come loose without excessive force, the ride plate and inlet grate must
be remove from the hull.
4. Follow ride plate and inlet grate removal procedures outlined in this chapter if components require removal.
5. With components removed, re--attempt removing the housing.
6. Always use light force when using a prybar against the hull and housing mating surfaces.
Pump Housing Installation
The mating surfaces between the hull and pump housing must be cleaned prior to installing the housing. Clean
surfaces with alcohol.
To install the housing, follow the procedures listed on page 5.15 and 5.16.
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