Section 01
ENGINE
Subsection 02
(TOP END)
01-02-9
TYPICAL — PISTON DOME SHOWN
1. Exhaust side
9,10, Piston Pin and Roller Bearing
To install roller bearing and piston pin, use piston
pin puller (P/N 290 877 094) used at removal. For
installation procedure, refer to the
1997 Sea-Doo
Shop Manual.
8, Circlip
Secure circlips
no. 8
taking into consideration the
following.
1. Circlip opening at 6 o’clock (at bottom)
To easily insert circlip
no. 8
, use circlip installer
(P/N 290 877 517).
1. Circlip installer
1,2, Cylinder Head and Cylinder Block
Both the cylinder head and cylinder block are po-
sitioned with locating dowels.
There is only one way to install cylinder base gas-
ket
no. 6
and cylinder head gasket
no. 5
. They are
also properly positioned by locating dowels.
To easily slide cylinder block
no. 2
over pistons
no. 7
, install on piston ring compressor (P/N 290
876 965).
1. Ring compressor
NOTE:
For each ring, make sure to align ring end
gap with piston locating pin.
Install studs
no. 25
.
Install cylinder block
no. 2
.
Install O-rings
no. 26
.
NOTE:
The O-rings must be installed and properly
positioned in the cylinder block. The O-rings are
meant to dampen stud vibration.
Apply Loctite 242 (blue) on the threads of the cyl-
inder block studs
no. 25
.
Apply Loctite 242 (blue) below head of cylinder
head bolts
no. 3
.
Apply synthetic grease on threads of cylinder
head bolts
no. 3
.
-
CAUTION
To minimize the stress on the circlips, install
them so that their openings are located at 6
o’clock (at bottom). Always use new circlips.
At installation, take care not to deform them.
◆
WARNING
Always wear safety glasses when installing
piston circlips.
A01C01A
AUS
1
F06D18A
1
F06B01A
1
A01B1TA
1
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