Drive shaft...
Its all apart now, so you think i should toss it backtogether and try again?
When i had the drive shaft in and pump out, I tried to turn the impeller by hand to see if maybe it would spin and it wouldn't, grant it im sure my hands dont put out that much Tq.
No... do not put it back together. You'll need to determine if it is def the drive shaft, but from your first post, it is.
What happens when you strip your drive shaft, happens mostly from torque. There are situations where this might happen but if you stop, then start slowly, you might get the impeller to hook up and allow at least a small amount of forward movement before it losses its hook up. But, when you load it up, it will break lose and finish chewing the gears up, especially with the weight you were describing.
There is a lot of torque on these shafts and annual greasing at the PTO and impeller is important to help keep the splines of your shaft in top shape, especially for loading it up for tubing, regardless of weight.
What you need to do is determine if it's at the PTO hub or the impeller. You can put the shaft back in, not attached to the pump. Then, take a pipe wrench, grab the shaft and turn it counterclockwise. The compression of the motor will probably be enough to see if the threads are striped at the hub. If it turns the motor over, through the compression stroke, then it's probably in the part of the shaft at the impeller.
The stripping normally happens at the PTO hub due to a lack of greasing. Make sure the rubber boot is on, and there is grease in it when you repair it.
You def have a drive shaft problem and should not re-assemble it till you are certain of which part is damaged and repair it.
I just went through your thread and profile and see it's the 96 Sportster. That boat uses the 717 engine. While this motor is a nice motor, the boat does have a weight limit. It may be that you are regularly overloading the boat with way to much torque. I think it should still perform but with the additional weight and torque on the motor, regular maintenance would be a requirement.
The total load limit is about 650 lbs. That includes the driver, 4 passengers and all your equipment. The twin engine Speedster has a 2 person capacity on tow, the Sportster is designed for one. The 717 engine only puts out about 32 horsepower at the pump. While thats enough to ride around in and do some light towing, I don't think its designed to tow the heavier skiers..:cheers: