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  1. #1
    BlueFishCrisis's Avatar
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    How to rebuild Polaris 148 mm jet pump

    This thread will cover the steps necessary to rebuild the Polaris 148 mm jet pump / stator. Your can review the removal and re-installation procedure for the jet pump here.

    After the pump is removed, and the nozzle is separated, you have this section (for an extended pump that is) left..

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    You will need the parts for a rebuild. Two new bearings, Two new Seals, and two new O rings for the stub shaft. Some kits also come with a replacement O ring for the tail cone, but this one did not.

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  2. #2
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    Start by removing the pump wedge, if so equipped. This is a twisted wedge, so it has been added to the scrap pile.

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    Next, you need to split and separate the pump extension from the stator. This only applies to the extended pump setups. This one was very tight. I had to use an old chisel to get it to separate, then a large flat head screwdriver to pry it apart.

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  3. #3
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    Remove the tail cone to expose the stub shaft. I use a bench vise to loosen the impeller for removal.

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    Next I used an impeller removal tool (I believe this is a Solas version if I remember correctly), a 3/4" drive socket wrench, and a breaker bar to break the impeller free.

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  4. #4
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    Unscrew the impeller, and push out the stub shaft.

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    With the stub shaft removed, you can see the two O rings that will be replaced.

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  5. #5
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    Remove the the spacer that the impeller is bolted to. The seals ride on this spacer so be sure it is smooth and in good condition before re-install.

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    Pry out the outer seal. I used a large flat head screwdriver and worked slowly around in a circle until it popped loose. Be careful not to contact the aluminum surface the seals make contact with. You do not want these surfaces scratched or gouged.

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    The inner seal is tight to the bearing, so you will need to use something thinner to start prying it free. I used an old chisel again. Once the inner lip of the seal was raised up away from the bearing, I returned to the large flat head to finish the job.

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  6. #6
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    Next I am going to punch out the bearing that was protected by the seals. To do this, flip the stator over. You will see an aluminum or SS spacer floating in between the two bearings. Slide this over to gain access to the inner race of the bearing on the other side. I then used a large flat head screwdriver and hammer to punch the bearing out. Move around the inner race in a circle to help push it out evenly.

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    Remove the spacer from the stator.

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  7. #7
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    Flip the stator over and punch the other bearing out in the same fashion. Again, protect the surfaces the bearing sits in from scratches and gouges.

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  8. #8
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    Lastly, remove the O ring which helps to seal the tail cone to the stator.

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    Since we are not replacing this O ring, I like to clean it with fogging fluid, then place it in a ziploc bag with 2 stroke oil.

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  9. #9
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    Got some cleaning to do.......

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  10. #10
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    All cleaned up and ready to go.

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