94 waverunner III GP impeller jammed

[jrr4948]

I have a 1994 Waverunner III GP. I tried to start it for the first time since last season and after taking just about everything apart I now see the impeller is jammed in the housing. Why would this happen? Can I grind it down a fraction after I get it out with a puller? I have the shaft removed and everyting including the engine out which does spin freely. Also many of the bolts snapped since it was in salt water. Can I drill them out and through bolt the plates back with sealant? New to the forum. Thanks much. JRR

[xzpolskix]

Welcome to the forum man. I'm sure one of the water guys will be able to help you out.

[QuickMick]

Originally Posted by jrr4948

I have a 1994 Waverunner III GP. I tried to start it for the first time since last season and after taking just about everything apart I now see the impeller is jammed in the housing. Why would this happen?There is corrosion between you impeller wear ring (Stainless) and the impeller housing (Aluminum). both pieces are machined and press fit together at the factory. When corrosion gets in between them it bulges the stainless wear ring out and thus makes high spots which the impeller will rub on. Pull it off and grind down the high spots with a grinder or dremel tool. You can use black marksalot on the areas that your grinding to see if you have ground enough. Mark the areas with marksalot and re install the parts, spin the prop and it will scratch off the interferance areas and will also scrape off the marks alot, this is the area that need to be ground. Keep grinding untill you have about .030 clearance. Can I grind it down a fraction after I get it out with a puller? I have the shaft removed and everyting including the engine out whicThe prop is a press fit on the shaft, no need to remove it from the driveshaft. h does spin freely. Also many of the bolts snapped since it was in salt water. Can I drill them out and through bolt the plates back with sealant? which bolts broke? The (4) 14mm ones that hold your pump to your hull? Or the (4) 10mm bolts that hold your pump nozzle/stator to your pump? I guess you could through bolt any of the (4) 14mm bolts but not the long 10mm bolts. Drain your fuel and oil and flip that ski over and drill out the broke bolts. Be sure to soak the bolts with some WD40, use a good high speed drill bit and drill the bolts slow with lil pressure.New to the forum. Thanks much. JRR

I hope this helps, good luck removing the bolts.

[jrr4948]

Thanks for the help. Just so I am clear...use a puller to remove the impeller (blades) from the housing. Then start grinding until I can get it back in and able to turn. Then mark with a marker and grind the high spots. It should turn freely. Also I only snapped the 10mm bolts that hold both plates under the bottom that bolt to the hull. Can these be drilled and retapped. They look like bolts moulded into the hull with a cap on the inside so I cannot get to them except from the outside. Can I through bolt the 10mm bolts for both plates or do you think they can be retapped?
Thanks again for your assistance.....JRR

[jrr4948]

I bought a puller and still cannot get the impeller to slide out of the housing! The funny thing is I do not see any real corrosion on the housing sleeve or the impeller itself! This does not look like rocket science. Am I missing something or is this just a stainless prop blade inside of a circular tube?
It won’t turn, spin or slide even with a puller on it. Last year it worked great. Any suggestions? Thanks again all….. JRR

[jrr4948]

Finally removed the housing and was able to sand it down. It spins freely now!
JRR

[QuickMick]

Remember, now that there is corrosion between the SS liner and the Aluminum housing, it will keep corroding. So you will most likely have to grind it down every3-4 months.