2004 GTI LE RFI drive rattling sound at idle, squeals with RPM increase... a bearing?

[den458]

My 2004 GTI LE RFI purchased new 10 seasons ago, has 140 hrs use. 60-ish couple, we have used it gently, for cruising, since day one. Has been a dream to own except for the occasional routine component failures like starter & rectifier. Last outing, I heard a noise that coincided with loss of power. Immediately dropped to idle, there was a rattling sound. Initial thought was debris in the impeller. With slight increase in RPM, the rattle turns into more of a squeal. Failed bearings squeal, right? In the water, with seat off, engine sounds normal, the rattle / squeal is rearward of engine, in the propulsion system, I think. No impeller debris issue. Home on the trailer, engine will not turn over now, like something is binding. Have exploded view parts list & drawings, internal & external, of propulsion system (thank you Rivamotorsports.com). Am handy with tools & have done simpler maintenance on it (plugs, winterizing, replace cone oil). Would like to try the repair myself if not too complex. Of the 43 parts comprising the internal propulsion system, not one is listed as BEARING. Is the problem more likely in the pump? Appreciate any advice on how to isolate the problem or failing component. Thanks in advance, Den.

 

[Dr Honda]

It's not hard to rebuild the pump.


But first... remove the pump, from the ski, and make sure the engine will turn over. (Do not start it with the drive shaft hanging loose)


Assuming it will turn over... then remove the impeller, and the rear cone. At that point you will see the shaft an the bearings. Knock them out, and replace. Replace the pump shaft if it's damaged.


If the engine won't turn over.... there will be bigger issues.

 

[Coastiejoe]

It does sound like the bearings in the pump area to me as well...

Once you tear this area down, I would replace the seal unit and all items in that area. Like you said,, you have had it 10 yrs and I assume you have never replaced anything that is on the shaft. Just a good opportunity to do so.

At least it i winter time and you have plenty of time to fix it...

 

[den458]

Thanks for replies, gentlemen. Can either of you point me to a nicely documented, step by step, jetpump removal procedure (or video) for my 2004 GTI LE RFI? Thanks again, Den

 

[Dr Honda]

Nope... becasue it's WAY to easy to bother making a vid.

1) Remove the nut/bolt on any control cable.
2) Remove the 4 bolts that hold the nozzle.
3) Remove the 4 nuts that hold the pump to the hull.
4) pull

THAT'S IT.


Now... if some hill-billy mechanic worked on it... they may have sealed the pump to the hull with RTV. If that's the case.... you have to wiggle it until the RTV rips. If it has the neoprene gasket... the pump should come off.

 

[Coastiejoe]

Once you have it out take a good look at the shaft splines. It is not uncommon for them to fail. So once it is in your hand look at yours just to make sure they are good for the future.

 

[den458]

Am getting ready to pull the pump today, time permitting.
As I look inside the hull, it looks like some water hoses feed the pump.
Two small, clear hoses, on with pull-ties, connect to top of pump, pulled off easily.
Two larger diameter, black hoses, on with hose clamps.
These two larger hoses must both be disconnected also, right?