Fits: OEM #
420296565
711296565
2002 GTX 4TEC
2003 GTX 4TEC
2003 GTX 4TEC Wake
2003 Sportster 4TEC
2004 GTX 4TEC
2004 GTX 4TEC LTD
2004 GTX 4TEC Wake
2004 Speedster 200 - All
2004 Sportster 4TEC
2005 GTX 4TEC
2005 GTX 4TEC Wake
2005 Speedster 200 Twin/Tower/Wake
2005 Sportster 4TEC - All
2006 GTX 4TEC Wakeboard 155
2006 GTX 4TEC 155
2006 GTI 130
2006 GTI SE 155
2006 Islandia 220
2006 Speedster 200 Twin/Tower/Wake
2006 Sportster 4TEC - All
2006 Utopia
2007 GTI 130
2007 GTI SE 155
2007 GTX 4Tec
2007 Wake 155
2007 Islandia 220
2007 RXP
2007 Speedster 200 Twin/Tower/Wake
2007 Utopia
2007 RXP
2008 GTI 130
2008 GTI SE 155
2008 GTX 4Tec
2008 GTX 4Tec LTD
2008 Wake 155
2008 Speedster 200 Twin/Tower/Wake
2008 Utopia
2008 RXP 155
2009 150 Speedster 155
2009 205 Utopia SE
2009 205 Utopia SE SCIC
2009 230 Challenger
2009 230 Challenger SP
2009 GTI 130
2009 GTI SE 130
2009 GTI SE 155
2009 GTX 155
2009 Wake 155
2010 230 Challenger SP 310
2010 GTI 130
2010 GTI SE 130
2010 GTI SE 155
2010 GTX 155
2010 Wake 155
2011 150 Speedster 155
2011 210 Challenger 310
2011 210 Challenger SE 310
2011 210 SP 310
2011 210 Wake 310
2011 230 Challenger 310
2011 230 Challenger SE 310
2011 GTI 130
2011 GTI SE 130
2011 GTI SE 155
2011 GTS 130
2011 GTX 155
2011 GTI LTD 155
2011 Wake 155
2012 GTX S 155
2012 GTX 155
2012 GTS 130
2012 GTS 130
2012 GTI SE 130
2012 GTI SE 155
2012 GTI Ltd
2012 GTI 130
2012 Wake 155
2012 150 Speedster 155
2013 GTI LTD 155
2013 GTI SE 155
2013 GTX 155
2013 GTX S 155
2013 Wake 155
2013 GTS 130
2013 GTI SE 130
2014 GTI SE 155
2014 GTI LTD 155
2014 Wake 155
2014 GTX 155
2014 GTS 130
2014 GTI 130
2014 GTI SE 130
2015 GTS 130
2015 GTI 130
2015 GTI SE 130
2015 GTI SE 155
2015 GTX 155
2015 Wake 155
2015 GTI Ltd 155
2015 GTX S 155
2016 GTI 130
2016 GTI SE 155
2016 GTI SE 130
2016 GTX 155
2016 GTX S 155
2016 Wake 155
2016 GTI LTD 155
2017 GTI 130
2017 GTI SE 130
2017 GTI SE 155
2017 GTI LTD 155
2017 GTX 155
2017 GTX S 155
2017 Wake 155
2018 GTI SE 130
2018 GTX 155
2019 Fish Pro 155
2019 GTX 155
2019 GTI 130
2019 GTI 155
2019 Wake 155
2020 GTI 130
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 oclock 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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