Sea-doo Challenger 5896, Shop Manual

Page: 62 / 274

Section 04 ENGINE
Sub-Section 02 (TOP END)
04-02-7
NOTE : Squish gap measurement is dis-
cussed further in this sub-section.
ASSEMBLY
Assembly is essentially the reverse of disassem-
bly procedures. However pay particular attention
to the following.
3, Piston
At assembly, place the pistons over the connect-
ing rods with the letters “AUS” (over an arrow on
the piston dome) facing in direction of the exhaust
port. On the
787 , it is the same side as the intake.
1. Exhaust side
787 ENGINE SHOWN
1. “AUS”
Carefully cover crankcase opening as for disas-
sembly.
4,6, Piston Pin and Roller Bearing
To install roller bearing and piston pin use piston
pin puller (P / N 290 877 092), proceed as fol-
lowsþ:
– Replacement bearings are held in place by a lo-
cating sleeve outside and 2 plastic cage halves
inside.
– Push needle bearing together with inner halves
out of the locating sleeve into the connecting
rod bore.
– Use any suitable 23 mm (.905 in) diameter
pusher as a tool. Make sure thrust washers are
present each side of needles.
1. Pusher
– Insert piston pin into piston until it comes flush
with inward edge of piston hub.
– Warm piston to approximately 50-60°C (122-
140°F) and install it over connecting rod.
– Insert extractor spindle into the piston pin,
screw on extracting nut.
– Rotate handle to pull piston pin carefully into
the piston.
GASKET
THICKNESS
IDENTIFICATION
HOLES
0.3 mm (0.012 in) 3
0.4 mm (0.016 in) 4
0.5 mm (0.020 in) 5
0.6 mm (0.024 in) 6
0.8 mm (0.031 in) 8
'
A01C01A
AUS
1
F01D7EA
1
F01D30A
1
F01D31A