Step 1. Order the pump kit for your motor, it will come with a new impeller, gaskets, etc.
step 2. Put the throttle in reverse, it is easier lining up later.
step 3. Remove the 4 or 5 nuts holding your lower unit to the upper/middle unit.
step 4. Either ask a buddy for help catching the lower unit, or just leave a nut, or two, loosely threaded. Grab a rubber mallet, or a hammer and wood block, and lightly hit the lower unit. Don't hit it hard, like pounding in a nail, or chunks of aluminum will break off. Just tap it enough and the lower unit will fall loose.
step 5. Once loose, it will weigh the same as a bowling ball, and will be hard to balance. Follow the long shaft and you'll see a cover. Remove the 4 or 6 bolts holding the cover, and slide the cover off the shaft. Take a picture of what the impeller looks like inside the cover, or note the direction the fins are pointing.
step 6. Remove the gaskets you have replacements for, and replace them with the new one.
step 7. Apply a little grease with your finger, on the inside of the impeller cover. Then install the new impeller inside the cover, so the fins are pointed in the same direction as the old impeller.
step 8. Slide the impeller and cover back over the shaft, and tighten the bolts.
step 9. Find the plastic/rubber coupling and make sure it is either attached to the tube on the motor, or the little nozzle coming off the impeller cover.
step 10. Slide the lower unit back onto the motor, and get a couple of the nuts started, then evenly turn each nut until tight.
step 11. Take it out of reverse, put water muffs on the water intake, turn the hose on, and fire up the motor.
if done right, water should come out of the pee hole and exhaust. If that doesn't happen, immediately shut it down, remove the lower unit again, and make sure the coupling lines up. Then the next step is replacing the thermostat, which is usually as simple as removing two small bolts.
step 2. Put the throttle in reverse, it is easier lining up later.
step 3. Remove the 4 or 5 nuts holding your lower unit to the upper/middle unit.
step 4. Either ask a buddy for help catching the lower unit, or just leave a nut, or two, loosely threaded. Grab a rubber mallet, or a hammer and wood block, and lightly hit the lower unit. Don't hit it hard, like pounding in a nail, or chunks of aluminum will break off. Just tap it enough and the lower unit will fall loose.
step 5. Once loose, it will weigh the same as a bowling ball, and will be hard to balance. Follow the long shaft and you'll see a cover. Remove the 4 or 6 bolts holding the cover, and slide the cover off the shaft. Take a picture of what the impeller looks like inside the cover, or note the direction the fins are pointing.
step 6. Remove the gaskets you have replacements for, and replace them with the new one.
step 7. Apply a little grease with your finger, on the inside of the impeller cover. Then install the new impeller inside the cover, so the fins are pointed in the same direction as the old impeller.
step 8. Slide the impeller and cover back over the shaft, and tighten the bolts.
step 9. Find the plastic/rubber coupling and make sure it is either attached to the tube on the motor, or the little nozzle coming off the impeller cover.
step 10. Slide the lower unit back onto the motor, and get a couple of the nuts started, then evenly turn each nut until tight.
step 11. Take it out of reverse, put water muffs on the water intake, turn the hose on, and fire up the motor.
if done right, water should come out of the pee hole and exhaust. If that doesn't happen, immediately shut it down, remove the lower unit again, and make sure the coupling lines up. Then the next step is replacing the thermostat, which is usually as simple as removing two small bolts.
