Sea-Doo Top-End Kit 717/720 XP/SPX/HX/GTI/GSI/GS/SP/GTS 1995 1996 1997 1998: Watercraft Superstore
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    $287.95

    Sea-Doo Top-End Kit 717/720 XP/SPX/HX/GTI/GSI/GS/SP/GTS 1995 1996 1997 1998

    Sea-Doo Top-End Kit 717/720 XP/SPX/HX/GTI/GSI/GS/SP/GTS 1995 1996 1997 1998
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    $287.95

    Brand: SBT
    SKU #: 701SB105
    Shipping Weight: 6.00 pounds
    Quantity in Basket: None



    Top-end Kit includes:
    * 2 SBT Pistons
    * 2 Ring Sets
    * 2 Wrist-Pins
    * 2 Wrist-Pin Bearings
    * 2 C-Clips
    * 1 Base Gasket
    * 1 Water Jacket O-Ring Set
    * Exhaust Gasket(s)

    1995 HX
    1995 XP
    1996 GTI
    1996 GTS
    1996 HX
    1996 Speedster
    1996 Sportster
    1996 SPX
    1997 GS
    1997 GSI
    1997 GTI
    1997 GTS
    1997 HX
    1997 SP
    1997 Speedster
    1997 Sportster
    1998 Challenger
    1998 GS
    1998 GTI
    1998 GTS
    1998 Sportster
    1998 Sportster 1800
    1999 GS
    1999 GTI
    1999 GTS
    1999 Speedster SK
    1999 Sportster 1800
    2000 Challenger
    2000 GS
    2000 GTI
    2000 GTS
    2000 Sportster
    2001 Challenger
    2001 GS
    2001 GTI
    2001 GTS
    2002 Explorer
    2002 GTI
    2002 GTI LE
    2002 Sportster LT
    2003 GTI
    2003 GTI LE
    2004 GTI
    2004 GTI LE
    2005 GTI
    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
    Yamaha 500, 650, 701, 760, 1100, 1200

    .0045”-.0055”

    Yamaha 800, 1200pv, 1300

    .005”-.006”

    Seadoo 580, 650, 720, 800
    Polaris 650, 750, 780, 900
    Kawasaki 1200

    .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
    Yamaha 500, 650, 701, 760, 1100, 1200, 800,1200pv
    Tigershark 640, 770, 1000

    .013” +/- .003”

    Seadoo 580, 650, 720
    Kawasaki 750, 900, 1200

    .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