2003 Sea-Doo GTX 4TEC LTD SC
2003 Sea-Doo GTX 4TEC SC
2004 Sea-Doo GTX 4TEC LTD SC
2004 Sea-Doo RXP SC
2005 Sea-Doo Challenger 180 - All
2005 Sea-Doo GTX 4TEC LTD SCIC
2005 Sea-Doo GTX 4TEC SC
2005 Sea-Doo RXP
2005 Sea-Doo RXT
2005 Sea-Doo Speedster 200 Twin SC Wake/Tower
2005 Sea-Doo Sportster 4TEC SC - All
2006 Sea-Doo Challenger CS/Tower
2006 Sea-Doo GTX 4TEC LTD 215
2006 Sea-Doo GTX 4TEC SC 215
2006 Sea-Doo RXP
2006 Sea-Doo RXT
2006 Sea-Doo Speedster 200 Twin SC Wake/Tower
2006 Sea-Doo Sportster 4TEC SC - All
2007 Sea-Doo GTX 4Tec LTD
2007 Sea-Doo GTX 215
2007 Sea-Doo Wake 215
2007 Sea-Doo RXT
2007 Sea-Doo Speedster 200 Twin SC/Tower/Wake
2007 Sea-Doo Speedster 200 215 IC
2007 Sea-Doo Challenger 215
2007 Sea-Doo RXP 215
2008 Sea-Doo 180 Challenger 215
2008 Sea-Doo 180 Challenger SE 215
2008 Sea-Doo 205 Utopia SE 430
2008 Sea-Doo 230 Challenger SE 430
2008 Sea-Doo 230 Wake 430
2008 Sea-Doo Challenger SE 430
2008 Sea-Doo GTX 215
2008 Sea-Doo Wake 215
2008 Sea-Doo Islandia SE 430
2008 Sea-Doo RXP 215
2008 Sea-Doo RXP X 255
2008 Sea-Doo RXT
2008 Sea-Doo RXT X 255
2008 Sea-Doo Speedster 200 Twin SC/Tower/Wake
2008 Sea-Doo GTX LTD 215
2009 Sea-Doo 150 Speedster HO
2009 Sea-Doo 150 Speedster SCIC
2009 Sea-Doo 180 Challenger SCIC
2009 Sea-Doo 180 Challenger SE HO
2009 Sea-Doo 180 Challenger SE SCIC
2009 Sea-Doo 200 Speedster
2009 Sea-Doo 230 Challenger SE HO
2009 Sea-Doo 230 Challenger SE SCIC
2009 Sea-Doo 230 Challenger SP SCIC
2009 Sea-Doo 230 Wake HO
2009 Sea-Doo 230 Wake SCIC
2009 Sea-Doo GTX 215
2009 Sea-Doo GTX LTD iS 255
2009 Sea-Doo Islandia SE
2009 Sea-Doo RXP 215
2009 Sea-Doo RXP X
2009 Sea-Doo RXT 215
2009 Sea-Doo RXT iS 255
2009 Sea-Doo RXT X
2009 Sea-Doo Speedster Wake
2009 Sea-Doo Wake Pro 215
2009 Sea-Doo RXP X 255
2009 Sea-Doo RXT X 255
2010 Sea-Doo 150 Speedster 255
2010 Sea-Doo 180 Challenger SE 255
2010 Sea-Doo 200 Speedster 510
2010 Sea-Doo 230 Challenger SE 510
2010 Sea-Doo 230 Wake SE 430
2010 Sea-Doo 230 Wake SE 510
2010 Sea-Doo GTX iS 215
2010 Sea-Doo GTX LTD iS 260
2010 Sea-Doo RXP X 255
2010 Sea-Doo RXT 215
2010 Sea-Doo RXT iS 260
2010 Sea-Doo RXT X 260
2010 Sea-Doo Wake Pro 215
2011 Sea-Doo 150 Speedster 255
2011 Sea-Doo 180 Challenger 215
2011 Sea-Doo 180 Challenger SE 215
2011 Sea-Doo 180 Challenger SE 255
2011 Sea-Doo 200 Speedster 510
2011 Sea-Doo 210 Challenger SE 430
2011 Sea-Doo 210 Wake 430
2011 Sea-Doo 230 Challenger SE 430
2011 Sea-Doo 230 Challenger SE 510
2011 Sea-Doo 230 SP 430
2011 Sea-Doo 230 Wake 430
2011 Sea-Doo 230 Wake 510
2011 Sea-Doo GTX iS 215
2011 Sea-Doo GTX LTD iS 260
2011 Sea-Doo RXP X 255
2011 Sea-Doo RXT 260
2011 Sea-Doo RXT iS 260
2011 Sea-Doo RXT X 260
2011 Sea-Doo Wake Pro 215
2011 Sea-Doo GTX 215
2011 Sea-Doo RXT X 260 aS
2012 Sea-Doo 150 Speedster 260
2012 Sea-Doo 180 Challenger 215
2012 Sea-Doo 180 Challenger SE 215
2012 Sea-Doo 180 Challenger SE 260
2012 Sea-Doo 180 SP Tower 260
2012 Sea-Doo 200 Speedster 510
2012 Sea-Doo 210 Challenger SE 430
2012 Sea-Doo 210 Tower SP 430
2012 Sea-Doo 210 Wake w/Tower 430
2012 Sea-Doo 230 Challenger SE 430
2012 Sea-Doo 230 Challenger SE 510
2012 Sea-Doo 230 SP Tower 430
2012 Sea-Doo 230 SP Tower 520
2012 Sea-Doo GTR 215
2012 Sea-Doo GTX 215
2012 Sea-Doo GTX Ltd iS 260
2012 Sea-Doo RXP X 260
2012 Sea-Doo RXT 260
2012 Sea-Doo RXT 260 RS
2012 Sea-Doo RXT iS 260
2012 Sea-Doo RXT X 260
2012 Sea-Doo RXT X 260 aS
2012 Sea-Doo Wake Pro 215
2013 Sea-Doo GTR 215
2013 Sea-Doo GTX 215
2013 Sea-Doo GTX LTD iS 260
2013 Sea-Doo RXP X 260
2013 Sea-Doo RXT 260
2013 Sea-Doo RXT X 260
2013 Sea-Doo RXT X 260 aS
2013 Sea-Doo Wake Pro 215
2014 Sea-Doo GTR 215
2014 Sea-Doo GTX LTD 215
2014 Sea-Doo GTX LTD iS 260
2014 Sea-Doo RXP X 260
2014 Sea-Doo RXT 260
2014 Sea-Doo RXT X 260
2014 Sea-Doo RXT X 260 aS
2014 Sea-Doo Wake Pro 215
2015 Sea-Doo GTR 215
2015 Sea-Doo GTX LTD 215
2015 Sea-Doo GTX LTD iS 260
2015 Sea-Doo RXP X 260
2015 Sea-Doo RXT 260
2015 Sea-Doo RXT X 260
2015 Sea-Doo RXT X 260 aS
2015 Sea-Doo RXT X 260 RS
2015 Sea-Doo Wake Pro 215
2016 Sea-Doo GTR 215
2016 Sea-Doo GTX LTD iS 260
2016 Sea-Doo RXT 260
2016 Sea-Doo RXT X 260 aS
2016 Sea-Doo Wake Pro 215
2017 Sea-Doo GTX LTD S 260
2017 Sea-Doo RXT 260
2017 Sea-Doo Wake Pro 230
2017 Sea-Doo GTR 230
2018 Sea-Doo GTX 230
2018 Sea-Doo GTX LTD 230
2019 Sea-Doo GTX LTD 230
Piston to Cylinder Clearance:
The piston size plus the clearance equals the final bore size. For the recommended clearances by make and model, see Table 1. The cylinder first should be bored to within 0.002” of the final bore size. The remaining 0.002” should be removed with a 400 grit cylinder hone. The honing process should be controlled such as to leave a 45 degree crosshatch pattern on the cylinder wall.
Port Chamfering:
Once the cylinder is honed to the final size, all of the ports in the cylinder wall should be chamfered with a file or chamfer tool. The chamfered edge should be cut at approximately a 30 degree angle around the entire port. The cylinder should then be honed with a 400 grit flex hone to apply a uniform finish and to re-establish the 45 degree cross-hatch pattern.
Cylinder Cleaning Process:
Clean cylinders in warm soapy water using a firm plastic brush (such as a tooth brush), then dry, and immediately lubricate with 2-stroke oil. Honing grit tends to reside in the crosshatch and must be scrubbed out. An extremely clean cylinder free of grit is critical in order to avoid “drag marks” and other damage to the cylinder wall after assembly.
Setting the Ring Cap:
Place the piston ring in the cylinder. Use the piston to push the ring approximately 5mm from the top of the cylinder in order to square the ring in the cylinder. Use a feeler gauge to measure the gap between the ends of the ring. If the gap is too small, one end of the ring must be filed. Re-install the ring and measure again to confirm the final dimension. Recommended ring gap clearances are shown in Table 2.
Piston Installation:
Install the base gasket (we recommend Threebond 1211 as a gasket treatment). Lubricate the wrist pin bearing with 2-stroke oil and install the piston on the connecting rod. The designation mark on the piston crown points in the direction as shown in Table 3. Install the c-clips with the open end in either the 6 or 12 o’clock position. Install the rings onto the piston. Using your hands or a ring compressor, collapse the rings into the ring grooves and install the cylinder. Torque cylinder to proper torque specifications.
Table 1: Piston to Cylinder Clearance |
|
Clearance |
Application |
2 Stroke |
|
.004”-.005” |
Kawasaki 440, 550, 650, 750, 900, 1100 |
.0045”-.0055” |
Yamaha 800, 1200pv, 1300 |
.005”-.006” |
Seadoo 580, 650, 720, 800 |
.007”-.008” |
Polaris 700, 1050 Seadoo 951, 800 RFI |
4 Strokes |
|
.001”-.0022” |
Seadoo 112 (N/A) |
.002”-.004” |
Seadoo 113 (S/C) |
.002”-.003” |
Yamaha 408, 410, 411 |
.0015”-.0025” |
Kawasaki 213, 214 |
.0005”-.0015” |
Honda 600, 601 |
Table 2: Ring End Gap |
|
Clearance/Tolerance |
Application |
2 Strokes |
|
.011” +/- .003” |
Kawasaki 1100 |
.012” +/- .002” |
Seadoo 800 |
.012”+/- .004” |
Kawasaki 440, 550, 650 |
.013” +/- .003” |
Seadoo 580, 650, 720 |
.013” +/- .005” |
Polaris 650, 700, 750, 780 |
.014” +/- .004” |
Polaris 900, 1050 |
.019” +/- .001” |
Tigershark 900 |
.022” +/- .003” |
Seadoo 951/DI |
4 Strokes |
|
.015”-.021” |
Yamaha FX Top Ring |
.019”-.027” |
Yamaha FX Middle Ring |
.011”-.023” |
Yamaha FX Oil Ring |
.013”-.017” |
Yamaha VX/FXHO Top Ring |
.017”-.023” |
Yamaha VX/FXHO Middle Ring |
.004”-.014” |
Yamaha VX/FXHO Oil Ring |
.006”-.014” |
Seadoo Top Ring/Middle Ring |
.006”-.012” |
Seadoo Oil Ring |
.010”-.016” |
Kawasaki Top Ring |
.016”-.022” |
Kawasaki Middle Ring |
.016”-.023” |
Kawasaki Oil Ring |
.007”-.013” |
Honda Top Ring |
.016”-.022” |
Honda Middle Ring |
.010”-.030” |
Honda Oil Ring |
Table 3: Piston Arrow Direction |
|
|
|
Make |
Engine |
Marking |
Position |
Seadoo |
All |
Arrow |
Towards exhaust |
Kawasaki |
All (except 4-stroke) |
Arrow |
Towards Exhaust |
Kawasaki |
4-strokes |
Dot |
Towards exhaust |
Polaris |
650, 750, 780 |
Arrow |
Towards front |
Polaris |
700, 900, 1050 |
Arrow |
Towards exhaust |
Yamaha |
500 |
“UP” |
Towards front |
Yamaha |
All others |
Arrow |
Towards exhaust |
Tigershark |
640, 1000 |
Arrow |
Towards exhaust |
Tigershark |
770, 900 |
Dot |
Towards exhaust |
Honda |
4-strokes |
In |
On the intake side |
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