SCREWDRIVER
SCREEN
PUMP
BEDPLATE
DRIVE GEAR
STARTER MOTOR GEAR
IDLER GEAR
ENGINE DISASSEMBLY / ASSEMBLY
4.54
2004 Four Stroke PWC Service Manual
Engine Assembly
5. Verify the blade of the screwdriver contacts the face of
the tensioner.
6. Push the blade of the screwdriver against the tensioner
face and twist. Do this until the tensioner goes in past
flush and activates.
7. Once activated, there should be no slack present in the
timing chain.
8. Install low pressure pump and screen into bedplate.
Clean bedplate and lower crankcase mating surfaces.
9. Apply a thin bead of Three Bond 1215t to the mating
surface and Install the bedplate. Tighten fasteners to
specification.
10. Install the high pressure oil pump assembly as outlined
on page 4.12.
11. Rotate the engine 180_. (Cylinder Head Up)
12. Coat the gears located at the front of the engine with
engine oil.
13. Install the starter motor gear, low pressure oil pump
idler gear.