Section 03 787 RFI ENGINE
Subsection 03 (TOP END)
F06D0VA
1
1. Remove bellows
Cylinder Head Cover and Cylinder Head
Engine in Watercraft
Disconnect temperature sensor wire and spark
plug cables.
Connect spark plug cables on grounding device.
Proceed with ENGINE ON BENCH WORK below.
Engine on Bench Work
Remove cylinder head cover screws no. 14.
Remove cylinder head cover no. 1.
If shells, sand, salt or any other particles are
present in cylinder head, clean with a vacuum
cleaner.
Remove cylinder head no. 2.
If shells, sand, salt water or any other particles
are present in cylinder cooling jacket, clean with
a vacuum cleaner.
Exhaust Manifold
Remove 8 Allen screws and lock washers then
withdraw exhaust manifold.
Cylinder
NOTE: When removing cylinder, make sure con-
necting rods do not hit crankcase edge.
Engine in Watercraft
Remove air intake silencer and support, refer to
the appropriate VEHICLE SHOP MANUAL.
Remove tuned pipe, refer to the appropriate VE-
HICLE SHOP MANUAL.
Proceed with ENGINE ON BENCH WORK.
Engine on Bench Work
Remove cylinder screws no. 13.
Remove cylinders no. 9, while making sure con-
necting rods do not hit crankcase edge.
WARNING
If screws need to be heated for removal when
engine is in watercraft, fuel system pressur-
ization must be done first. Do not use open
flame; use a heat gun.
NOTE: Even if only 1 cylinder needs repair, both
cylinders should be lifted to allow 1-piece cylinder
base gasket replacement.
Piston
NOTE: Engine features cageless piston pin bear-
ings.
BringpistontoTopDeadCenter(TDC)andinstall
the rubber pad (P/N 295 000 101) over crankcase
opening. Secure with screws. Lower piston until
it sits on pad.
F01B0JA
1
1. Rubber pad
If the other cylinder has been removed, complete-
ly cover its opening with a clean rag.
smr2005-082 77
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