WATERAX
MARK-3 Owner's Manual
03/2016
– Page 33 of 52
ENGINE OVERHAUL PROCEDURES
The following outlines how to conduct major overhaul service on the MARK-3 engine. It lists all
instructions to replace or service the following components:
•
Cylinder;
•
Crankshaft-connecting rod assembly;
•
Crankshaft ball bearings;
•
Crankcase;
•
Oil seals.
Cylinder
ID
ITEM NO
DESCRIPTION
QTY
1 800544
R-150 NUT M6X1.0 HEX FUJI LOCK ZINC
2
2 800545
R-149 LOCKWASHER M6 SPRING ZINC
2
3 600540* R-1113N GASKET CARBURATOR
1
4 800103
R-402 STUD M6 X 1.0 X 32.5 MM LG
2
5 800066* R-238 GASKET CYLINDER HEAD
1
6 800038
R-233 CYLINDER HEAD, 18 MM THREADS
1
7 800046* R-235 GASKET CYLINDER BASE
1
8 701233
R-257NR NIKASIL CYLINDER RED GRADE
185CC
1
8 701232
R-257NG NIKASIL CYLINDER GREEN GRADE
185CC
1
9 800062
R-117 STUD M8 X 1.25 X 32 MM LG
2
10 800067* R-237 GASKET MUFFLER
1
11 800548
R-119 LOCKWASHER M8 SPLIT ZINC
2
12 800539
R-206 WASHER M8 FLAT ZINC
4
13 800040
R-120 HEX NUT M8 X 1.25
6
* Included in 185cc Gasket Kit Top End (600590)
Cylinder Head With Decompression Switch
ID
ITEM NO
DESCRIPTION
QTY
- 600152
R-233DS CYL HEAD W/ DECOMP SWITCH
AND HEAD GASKET
-
1 600083
A-7627 DECOMPRESSION SWITCH
(MODIFIED) FOR MK-3-DS
1
2 800473
A-7628 COPPER GASKET DECOMPRESSION
SW
1
3 --
R-233DS-1 CYLINDER HEAD MACHINED FOR
DECOMP SWITCH (NOT SOLD SEPARATELY)
1
- 800066
R-238 GASKET CYLINDER HEAD (INCLUDED
IN R-233DS)
1
Installation notes
•
Torque value for decompression switch: 190-210 in-lbs [21-24 Nm]
•
Ensure that both decompression switch and cylinder head are cool prior to installation. The
threads on the decompression switch and on the cylinder head must be clean
