PHOTO L
PUSH WITH
SCREWDRIVER
HERE
DETENTS
PHOTO M
PTO
MAG
EXHAUST SIDE
TAPERED PIN
FITTING W/HOLE
VERIFY TAPERED PIN MATES EVENLY WITH EACH CHAIN PIN.
THREADED BOLT FACE MUST FIT SQUARELY ON CHAIN
PLATE.
ENGINE DISASSEMBLY / ASSEMBLY
4.252004 Four Stroke PWC Service Manual
Engine Disassembly Process
15. Rotate the engine assembly 180_ so that the valve train
is up. Using the hand crank, crank the engine until the
PTO piston is at TDC on the compression stroke.
BOTH PTO ROCKER ARMS WILL BE LOOSE.
16. Using a flat--head screwdriver, push the rocker arm
pins out enough to expose the detents on the pins.
Remove the pins from the cylinder head. (Photo L)
17. Rotate the engine 360_ counter--clockwise. Perform
steps 15 and 16 on the MAG cylinder valve train.
NOTE: A piston is at TDC on the compression
stroke when the piston is up and there is axial free-
play in each of the rocker arms.
18. Place rocker arm assemblies and rocker arm pins on a
clean towel or piece of paper. Identify each part for use
during assembly. (Photo M)
NOTE: The MAG, exhaust--side rocker arm features
a cam phase sensor pickup nose as circled in photo
M.
19. Remove the valve shims. Place valve shims with
corresponding rocker arm and location.
20. Remove the chain tensioner bolt located next to the oil
filter location.
21. Attach the chain breaker tool, PN--PW--46985.
22. Using the chain breaker tool, carefully press the pin out
of the link plate. Once outer plate is loose, disconnect
the tool and remove the last pin.
23. Remove the two pins from the chain, but do not pull the
chain away from the cam sprocket.
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