BOMBARDIER SEA-DOO GS 5626 1998, Shop Manual

Page: 91 / 426

Section 04 ENGINE
Subsection 05 (TOP END)
04-05-16
1. Needles and thrust washer
2. Sleeve
CLEANING
Discard all gaskets and O-rings.
Clean all metal components in a solvent.
Clean water passages and make sure they are not
clogged.
Remove carbon deposits from cylinder exhaust
port, RAVE valve (787 and 947 engines), cylinder
head and piston dome.
Clean piston ring grooves with a groove cleaner
tool, or a piece of broken ring.
INSPECTION
Visually inspect all parts for corrosion damage.
Inspect piston for damage. Light scratches can be
sanded with a fine sand paper.
NOTE: When repairing a seized engine, connect-
ing rods should be checked for straightness and
crankshaft for deflection/misalignment. Refer to
BOTTOM END 04-06 for procedures.
Inspect plane surfaces for warpage. Small defor-
mation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a surface
plate and rub part against oiled sand paper.
The inspection of engine top end should include
the following measurements.
N.A.: Not Applicable
NOTE: Replacement cylinder sleeves are avail-
able if necessary. Also, oversize pistons of 0.25
mm (.010 in) are available for all engines and over-
size pistons of 0.5 mm (.020 in) are available for
the 717 engine.
Cylinder Taper
Using a cylinder bore gauge, measure cylinder diam-
eter at 16 mm (5/8 in) from top of cylinder just below
auxiliary transfer port, facing exhaust port. If the dif-
ference between readings exceed specification, cyl-
inder should be rebored and honed or replaced.
F00B0NA
1
2
ENGINE
MEASUREMENT
TOLERANCES
NEW PARTS
(min.) (max.)
WEAR
LIMIT
Cylinder Taper N.A.
0.05 mm
(.002 in)
0.1 mm
(.004 in)
Cylinder Out
of Round
N.A.
0.008 mm
(.0003 in)
0.08 mm
(.003 in)
Piston/Cylinder Wall
Clearance for the
717 Engine
0.10 mm
(.0039 in)
N.A.
0.20 mm
(.008 in)
Piston/Cylinder Wall
Clearance for the
787 Engine
0.11 mm
(.0043 in)
N.A.
0.20 mm
(.008 in)
Piston/Cylinder Wall
Clearance for the
947 Engine
0.09 mm
(.0035 in)
N.A.
0.20 mm
(.008 in)
Ring/Piston Groove
Clearance 0.03 mm
(.001 in)
0.07 mm
(.003 in)
0.20 mm
(.008 in)
Ring End Gap
0.40 mm
(.016 in)
0.55 mm
(.022 in)
1.0 mm
(.039 in)