Section 03 ENGINE
Sub-Section 05 (TOP END)
03-05-6
All Engines
Remove tuned pipe and exhaust manifold, refer
to ENGINE 03-08.
Remove screws
no. 17
.
Remove cylinders, being careful that connecting
rods do not hit crankcase edge.
NOTE:
Even if only one cylinder needs repair,
both cylinders should be lifted to allow 1-piece cyl-
inder base gasket replacement.
3, Piston
NOTE:
The 717 and 787 engines feature cageless
piston pin bearings.
Bring piston to Top Dead Center and install rubber
pad (P/N 295 000 101) over crankcase opening. Se-
cure with screws. Lower piston until it sits on pad.
1. Rubber pad
If the other cylinder has been removed, complete-
ly cover its opening with a clean rag.
1. Openings covered with rag and rubber pad
To remove circlip
no. 5
, insert a pointed tool in pis-
ton notch then pry it out and discard.
TYPICAL
1. Piston notch
To extract piston pin
no. 4
, use piston pin puller
(P/N 290 877 092) as follows:
– Fully thread on puller handle.
– Insert extractor spindle into the piston pin.
– Slide the expansion sleeve (P/N 290 877 041)
onto the spindle.
– Screw in extracting nut (P/N 290 877 155) with
the movable extracting ring towards spindle.
â—†
WARNING
If screws need to be heated for removal
when engine is in watercraft, fuel system
pressurization must be done first. Do not use
open flame;
use a heat gun.
F01B0JA
1
â—†
WARNING
Always wear safety glasses when removing
piston circlips.
F01D43A
1
F01D0PA
1
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