Waterax MARK-3 - Engine Overhaul Procedures; Cylinder and Cylinder Head

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