WATERAX
MARK-3 Owner's Manual
03/2016
– Page 39 of 52
Disassembly of the Engine From the MARK-3
1. Remove pump end and coupling buffer.
2. Disconnect all wiring from engine.
3. Remove spark plug cable clamp.
4. Remove bracket R-799, which fastens to side of carburetor shroud to engine crankcase.
5. Remove muffler.
6. Remove spark plug cover and spark plug.
7. Using the piston locking tool 701159 to prevent the collar coupling from rotating, remove nut and
lockwasher from the collar coupling.
8. Remove collar coupling using puller R-932.
9. Remove pump mounting flange.
10. Remove engine from mounting frame.
11. Remove fan cowl with rewind starter.
12. Remove manual starter rope pulley.
13. Remove flywheel nut and lockwasher using piston locking tool 701159.
14. Remove flywheel/magneto/fan assembly using magneto puller R-927 and shaft protector tool R-928.
Disassembly of the Engine
1. Remove the key R-305.
2. Mark the position of the armature plate.
3. Remove armature plate with cables.
4. Remove the rubber grommet.
5. Remove the cylinder head, the cylinder and the crankcase studs.
6. Remove piston from connecting rod.
7. Remove the five machine screws, which fasten crankcase halves together.
8. To separate crankcase halves on engine with one-piece bearing, heat both crankcase halves (on the
outside face of the crankcase around the bearing housing portion) to a maximum of 120 °C (248 °F).
The use of an oven is recommended for a controlled and uniform temperature.
9. Hold the engine by the end of the shaft and separate crankcase halves using a plastic or rubber
mallet. Wear heat resistant gloves.
10. Remove crankshaft (with connecting rod).
11. Press out both oil seals using oil seal pressing tool R-933.
12. Remove bearings. To remove from crankshaft journals, use shaft protector tool R-928 and bearing
puller tool R-938.
Reassembly of the Engine
1. Place both crankcase halves on a table with inner faces up.
2. Using a depth micrometer, carefully check the distance from the sealing face of each crankcase half
to the lower face of each bearing housing.
3. For pump side crankcase half, call this dimension (A) (see image).
4. For magneto side crankcase half, call this dimension (B) (see image).
5. Add (A) + (B). Call this dimension (C).
6. Measure the thickness of ball bearing R-333. Call this dimension (D) (see image).
