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97 XP 800 impeller stuck to shaft!! HELP

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Brod

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So I was trying to take the jet pump off, got the nozzle off no problem, 4 nuts for the jet pump no problem, trying to pull that off the machine, BIG PROBLEM! Wont come off, seems the impeller is stuck to the shaft! Any ideas? I already tried unscrewing the impeller shaft, no luck.
thanks
 
Brod said:
So I was trying to take the jet pump off, got the nozzle off no problem, 4 nuts for the jet pump no problem, trying to pull that off the machine, BIG PROBLEM! Wont come off, seems the impeller is stuck to the shaft! Any ideas? I already tried unscrewing the impeller shaft, no luck.
thanks
Click to expand...

I just pulled the pump on my 98 XPS which I think is pretty much the same as your 98 XP. I pulled the tophat in front of the carbon seal back and popped the c-ring. I took the cooling main feed off the fitting on the pump inside, and disconnected the bailer tubes at the L fittings up top behind the seat. If you try to take them off the pump fittings, you will have to remove the VTS to get them back on if you have a VTS.

I backed the doo up to a tree on the trailer and got two ratcheting tiedown straps with vinyl coated hooks and hooked the vane on the nozzle top and bottom and hooked the other end of the straps together around a tree. I ratcheted the straps until I saw the pump move about an inch. I then pulled the trailer forward and the pump came right out with the driveshaft and the bailer tubes attached. Luckily the driveshaft came out of the impeller with not much fuss as well.

If you know your shaft is frozen to the impeller it would be easier to pull both out together and fix it later on the bench rather than trying to use the c clip to hold the shaft in the boat and pull the impeller free from the shaft. The gotcha here is if the shaft is frozen to the PTO flywheel you may have to remove the PTO flywheel with the shaft frozen in it which could require a chain wrench since you would not be able to use the impeller tool to torque the flywheel off. The other gotcha is if the driveshaft is not frozen in the flywheel, pulling on the C-clip could damage your carbon seal and the bellows and through hull fitting.
 
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Looks like a carrier bearing which I don't have. Pull the floating ring back and compress the bellows. Take the o-ring out of the groove, the shaft should pull right out.
 
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If you have all that don't the pump should slide off. You have the easier removal with the plastic pump support. You don't have to mess with bailer tubes. On the front of the impeller there it's a rubber boot. That had a plastic sleeve over it that sorta locks the seal right to the shaft. Typically you can pull them without popping that plastic sleeve off.

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Well I am at the hooking up to the tree part, don't know what else to do. Just want to make sure my shaft should be able to pull right out. Benn yanking on the pump assembly for a couple hours now.
 
if you look at my picture (post #3) it doesn't look like I have one. bearings with grease fittings front and back. I have two 97 XP's and they both look like my picture
 
Brod said:
Success !!!! definitely need a new shaft kit though. Thanks for the suggestions
Click to expand...

Glad you finally got it! If you are ordering a new shaft kit, this is what the parts catalog shows for a 97 XP drive assembly. If this doesn't look like yours it might be from another model or an upgrade of some kind.

97 xp driveshaft and pump.jpg
 
This machine looks like it had a drive shaft come apart at one time or another. Plenty of work to do, but have a good handle on it now
 
This is turning into a top end rebuild as well. I am attaching two pics to get suggestions on cause and fix for two problems I have encountered. First one is some white powder in the water jacket I assume, second is liquid that I sucked out of the bottom of the crank case. (water and oil I guess) As always, thanks in advance!!
IMG_20150710_194207.jpg
IMG_20150710_194227.jpg
 
Much larger issues than a to end if that milkshake was in the bottom end. I can see the corrosion has eaten the aluminum from the water jacket to the crankcase, not good.

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IMG_20150710_210931.jpgIMG_20150710_210952.jpgIMG_20150710_211008.jpgIMG_20150710_211023.jpgIMG_20150710_211053.jpgIMG_20150710_211123.jpgIMG_20150710_211109.jpg

The last pic of the wiring plug, that was pushed into the motor. Maybe that could be the cause of some of the water? Any help would be great, if this was a 1975 chevy 350 I would be doing a tutorial!! This is my first PWC and first engine tear down/rebuild.
 
Ok, it must have been the gasket that was throwing me off, I thought the case was corroded badly. I was thinking it would be tough to reseal like that. Thanks for the pics. What does the crank look/sound like? I just keep having a sinking feeling that the crank is not gonna look good or sound good with that milkshake in there. What's your budget look like, if those bearings sat with water in them a rebuilt top end isn't gonna be the only problem in short time unfortunately. I think you're in for a new engine. Sorry for the delay.
 
Good news is I don't think the Milkshake was touching the crank or bearings. everything spins freely. I am gonna put her back together and see how it goes. Whats the worse that can happen, LOL!
 
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