03' Sportster Driveshaft

[ben6119]

New member here with a quick question.

I picked up a VERY nice 2003 Sportster with the 951 engine, the boat is in like new condtion all over, I bought it knowing the jet pump needs work. Where the driveshaft seats in the impeller the splines rusted and stripped out. I have the pump off and it spins freely / seems in very good shape, I know at this point I need to change the driveshaft, impeller and at least wear ring while it is apart. Any tips to doing this? I am fairly handy but have not worked on these pumps before. Is there a specific impeller that would improve fuel economy while I have it apart or just stock the best?

Thanks!
~B~

 

[ben6119]

Does anyone have any tips for this job? I have a brand new complete pump as the old impeller would not come out of the pump as well as a good condition used driveshaft, any tips on how to properly replace the driveshaft and re-install the pump to minimize leaks/issues? I bought the boat taken apart so I am at a loss, the service manual gives an idea of how it should go back together but no real world information

Thanks!
~B~

 

[Dr Honda]

Sorry no one helped with your original post.


Really, it's a straight forward install. You will want to make sure you have grease on the ends of the drive shaft, and that the impeller seal is good, so that grease doesn't wash out. Also... there are little rubber bumpers in the ends of the shaft. Make sure they are in, before putting the shaft back in, otherwise, the shaft won't center up properly. Sometimes, the PTO side bumper will get stuck in the engine, because of the grease.

 

[ben6119]

Sorry no one helped with your original post.


Really, it's a straight forward install. You will want to make sure you have grease on the ends of the drive shaft, and that the impeller seal is good, so that grease doesn't wash out. Also... there are little rubber bumpers in the ends of the shaft. Make sure they are in, before putting the shaft back in, otherwise, the shaft won't center up properly. Sometimes, the PTO side bumper will get stuck in the engine, because of the grease.

Thanks for the tips!
I went ahead when gathering parts and got everything so all the seals on the pump except the big ring seal are brand new, all the o-rings, driveshaft bumpers, etc. I got a SBT kit for the driveline, new carbon seal, o-rings, etc. and the boot and ring on the impeller are also brand new so hoping I can get it back together without any issues, still not sure where to put sealant on the pump when reinstalling but other than that I "think" I am prepared LOL

Thanks!
~B~

 

[ben6119]

Well, I tried fixing the boat today but it is WAAAYYYYY past my mechanical ability and tool supply. The collar on the driveshaft is completely fused onto the driveshaft with corrosion, the only way I can see to get the shaft out is to grind the collar off which I really don't want to attempt inside the engine compartment with a full tank of gas, of try and cut thru the driveshaft itself and take it out in two pieces. I don't feel comfortable attempting either of these so it looks like my boat will be a lawn ornament until I can afford to have a mechanic or the dealer make the repairs. :banghead:

~B~

 

[Guest_User]

Well, I tried fixing the boat today but it is WAAAYYYYY past my mechanical ability and tool supply. The collar on the driveshaft is completely fused onto the driveshaft with corrosion, the only way I can see to get the shaft out is to grind the collar off which I really don't want to attempt inside the engine compartment with a full tank of gas, of try and cut thru the driveshaft itself and take it out in two pieces. I don't feel comfortable attempting either of these so it looks like my boat will be a lawn ornament until I can afford to have a mechanic or the dealer make the repairs. :banghead:

~B~

try reinstalling the old pump and impeller to hold the old driveshaft. then soak the living crap out of the sealing ring on the driveshaft with PB blaster or another known good penetrating oil... after a while tap on the sealing ring, or even try and grab it with channel locks or large pliers to maybe twist it free...

post a few pics so we can see how bad it is...

you should be able to do the job with some mechanical ability...

good luck...

 

[ben6119]

Unfortunately I don't have the old pump, it was destroyed trying to remove the old impeller which was also seized into the pump, all I have is my brand spanking new one and I really don't want to put the mangled old driveshaft anywhere near the new impeller and pump, I have soaked it in PB blaster and have tried putting a decent size pipe wrench on the collar and holding the PTO from turning with a prybar to no avail.

Thanks!
~B~

 

[ben6119]

I had a mechanic come out and look at the boat who allegedly knows what he is doing, he said the only way to get it out was move the engine and take it out from the inside, but he said it didn't have to be re-aligned if you moved the engine and didn't have the tools so I was done at that point. Later this afternoon I am going to try and cut the driveshaft in half behind the collar with a sawzall, if that works it should be simple to get back together.

~B~

 

[Coastiejoe]

Good call on NOT letting him do it.

Good luck on cutting the shaft.

 

[Dr Honda]

I had a mechanic come out and look at the boat who allegedly knows what he is doing, he said the only way to get it out was move the engine and take it out from the inside, but he said it didn't have to be re-aligned if you moved the engine and didn't have the tools so I was done at that point. Later this afternoon I am going to try and cut the driveshaft in half behind the collar with a sawzall, if that works it should be simple to get back together.

~B~

OMG !!!!!

He's an idiot !!! (or at least has zero knowledge of seadoo) It's dam near impossible to get the engine(s) out with the driveshaft still in the boat. They come out the pump end.


The stainless ring probably isnt' stuck the shaft with rust. They dont' even touch. So... it would have to be big, grown, crusty rust. BUT... the 2 O-rings inside do get hard, and very stiff.

So....

1) Shoot a little penitrating oil beween the ring, and driveshaft.
2) Put a block of wood behind the PTO
3) use a prybar or tire spoon on the block of wood, to push on the stainless ring. (you need the leverage if it's never been moved before)
4) pop off the C-clip, and now, it will all go out the pump end.


FIY: the pump has to be mounted to the boat, so you have something to push on. Otherwise... the shaft will just move.

 

[Guest_User]

your in FL, maybe reach out to someone to help out...

good luck...


yes to what Doc H says!!!

 

[ben6119]

FIY: the pump has to be mounted to the boat, so you have something to push on. Otherwise... the shaft will just move.

I don't have the old pump anymore but I braced the shaft with a 2x4 and backed the boat against it where it was being held, even with a pipe wrench the collar would not budge, it was far too corroded. 10 years in salt water had done it in, I did get the old shaft out today though, I used a 4" grinder and ground the collar in half and then had to use a large screwdriver and a 4lb hammer to get it off and get the shaft out, it was VERY corroded and there was no way the collar could move on it. I wanted to get it back together but the driveshaft bumpers kept me from being able to, I had 4-all used; one tore in half taking it out of the old shaft, one was lost in the PTO and the two I took out of the new (used) shaft would not go back in, it was like they swelled up and once installed they would pop back out in a few seconds so I am going to Riva in the morning to see if I can get some new ones.

Thanks for the tips!
~B~

 

[ben6119]

I finally got a chance to put the boat back together today, tried last week but the driveshaft bumpers were swelled up and I coudn't re-use them so had to make a trip to Riva for new ones, the re-install today was fairly straight forward, I also started the boat today for the first time since I bought it, it hasn't been run in about 3mos and it fired right up. I wanted to take it out and see how it did on the water but this is the busiest weekend of the year here in the Keys for road and boat traffic and I am just not going to fight all the crowds, will take it out later this week

~B~