BRP RORAX V-810 Shop Manual Download Page 20 | Manualshive

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Section 01 V-810 ENGINE

Subsection 05

(CYLINDER AND HEAD)

CYLINDER AND HEAD

SERVICE TOOLS

Description

camshaft locking tool ...........................................................

.

circlip installer

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crankshaft locking bolt .........................................................

.

crankshaft locking bolt .........................................................

.

piston ring compressor tool .................................................

.

valve guide installer .............................................................

.

valve guide remover ............................................................

.

valve spring compressor clamp ...........................................

.

valve spring compressor cup ...............................................

.

SERVICE TOOLS - OTHER SUPPLIER

Part Number

Page

529 035 926 ......................... 34-35, 37-38

529 035 921 ........................................... 53

529 035 617

. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . · · · · · ·

37

529 035 926 ..................................... 37, 48

529 035 919 ........................................... 49

529 035 853 ........................................... 47

529 035 924 ........................................... 47

529 035 724 ........................................... 44

529 035 725 ........................................... 44

Description

Part Number

Page

Snap-ON pliers

. . . . . . . .

..

. . . .

.

. . . . . . . . . . . . . . . . . . . . .

.

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YA

8230

........................................... 45

SERVICE PRODUCTS

Description

Part Number

Page

anti-seize lubricant

.

. . . . .. .. ... ... ... . . .. . ... .. ... . .. .. .. . .... .. . ... . . ... ... .. . .. . 293 800 070 ........................................... 48

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Summary of Contents for RORAX V-810

Page 1: ...219 100 230...

Page 2: ...2006 Engine Shop Manual ROTAX V 810 ENGINES BOMBARDIER ATV...

Page 3: ...IV ENGINE EMISSIONS INFORMATION IV ENGINE IDENTIFICATION NUMBER E l N IV CYLINDERS IDENTIFICATION IV TIGHTENING TORQUES IV ARRANGEMENT OF THIS MANUAL ILLUSTRATIONS AND PROCEDURES V 01 V 810 ENGINE 01...

Page 4: ...the illustrations throughout the manual is to assist identification of the general configuration of the parts They are not to be interpreted as technical drawings or exact replicas of the parts The us...

Page 5: ...e adhered to Locking de vices e g locking tabs elastic stop nuts self locking fasteners etc must be installed or replaced with new ones where specified If the efficiency of a locking device is im pair...

Page 6: ...ate freely Othewise replace n Removal Heat up 11 e magneto housing cover to about 1OO C 2 1 2 Flforan easy ballbe aringremoval 1 Call outs for ii above illustration Installation V01A71 vmr2006 038 For...

Page 7: ...ut of leak indicator hole means a dam aged rotary seal on water pump shaft refer to COOLING SYSTEM coolant escaping from water pump housing means damaged gasket s and or loosened screws refer to COOLI...

Page 8: ...tion and required pressure Install gauge adapter into previously cleaned spark plug hole Supply combustion chamber with air pressure 1 TYPICAL 1 Leak Tester 2 Air supply hose Note the amount or percen...

Page 9: ...RVICE TOOLS Description installer handle oil seal pusher water pump ceramic seal installer vmr2006 040 Section 01 V 810 ENGINE Subsection 02 COOLING SYSTEM Part Number Page 420 877 650 9 529 035 757 9...

Page 10: ...re specified If the efficiency of a locking device is impaired it must be renewed PROCEDURES WATER PUMP HOUSING It is located on the engine MAG side Removal Drain cooling system Remove radiator outlet...

Page 11: ...2 Needle pin 3 Thrust washer Using a soft hammer to push out water pump shaft with rotary seal no 3 from inside of crankcase MAG side CAUTION When removing water pump shaft always replace rotary seal...

Page 12: ...id damaging the ceramic component 10 2006 04 01 8_ 1 Water pump shaft with rotary seal 2 Water pump rotary seal installer Water pump shaft with rotary seal must rotate freely NOTE For installation use...

Page 13: ...NGINE Subsection 03 LUBRICATION SYSTEM The engine oil pressure should be within the fol lowing values NOTE Oil pressure switch works between 20 kPa 2 9 PSI and 40 kPa 5 8 PSI OIL 1250 RPM 6000 RPM PRE...

Page 14: ...Retaining ring 2 Oil pump gear 3 Needle pin 4 Thrust washer oil pump cover screws and pull oil pump cover vmr2006 042 oil pump shaft with inner rotor and outer rotor 1 Retaining screws 2 01 pump cover...

Page 15: ...fer to OIL PRESSURE TEST above ENGINE OIL STRAINER The engine oil strainer no 7 is located between both crankcase halves 3 vmr2006 04 2 017_8 7 Engine oil strainer 2 Retaining plate 3 Screws Removal R...

Page 16: ...tector magneto puller SERVICE PRODUCTS Section 01 V 810 ENGINE Subsection 04 MAGNETO SYSTEM Part Number Page 529 035 617 23 529 036 034 23 529 035 748 23 Description Part Number Page Bombardier gasket...

Page 17: ...MAGNETO COVER Removal Lock crankshaft at TDC refer to CYLINDER ANO HEAD Drain engine oil refer to appropriate VEHICLE SHOP MANUAL Disconnect CPS Crankshaft Position Sensor con nector and cut tie rap R...

Page 18: ...g cover 1 Threads for cable holding strip 2 Notch for stator v T r2 6 041 ROTOR Removal Lock crankshaft with crankshaft locking bolt P N 529 035 617 refer to CYLINDER AND HEAD Remove magneto cover ret...

Page 19: ...if damaged Installation For installation reverse the removal procedure Pay attention to the following details NOTE Apply engine oil on sprag clutch SPRAG CLUTCH GEAR Removal Remove rotor refer to ROTO...

Page 20: ...ide installer valve guide remover valve spring compressor clamp valve spring compressor cup SERVICE TOOLS OTHER SUPPLIER Part Number Page 529 035 926 34 35 37 38 529 035 921 53 529 035 617 37 529 035...

Page 21: ...ONT CYLINDER HEAD NO 1 4 28 Engine oil I 16 20N m 15 lbf in REAR CYLINDER HEAD NO 2 vmr2006 043 20 N m 15 lbf ft 10 N m ulbf inJ Loctite 648 Section 01 V 810 ENGINE Subsection 05 CYLINDER AND HEAD 7N...

Page 22: ...s before applying a threadlocker Re fer to SELF LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure WARNING Torque wrench tightening specifications must st...

Page 23: ...Never per form this operation immediately after the en gine has been run because the exhaust sys tem can be very hot Wait until exhaust sys tem is warm or cold Remove chain tensioner plug 0 ring no 2...

Page 24: ...camshaft timing gear have to be parallel to the cylinder head base See the following illustration for a proper positioning vmr2006 043 vmr200G 043 007_a 1 Printed marks on camshaft timing gear 2 Cyli...

Page 25: ...the groove in the crankshaft is aligned with the hole 1 Screwdriver Lock crankshaft with crankshaft locking bolt P N 529 035 926 1 Crankshaft Jocking bolt Camshaft Timing Cylinder 2 Rear Turn cranksha...

Page 26: ...5 Locking nut thrust washers no 8 CAUTION Pay attention not to lose thrust washers or drop them into the timing chain compartment 1 2 thrust washers 2 Rocker arm exhaust side 3 Cylinder head spark plu...

Page 27: ...inner fenders refer to BODY exhaust pipe spring exhaust pipe nuts radiator inlet hose air filter box and throttle body air intake manifold chain tensioner see CHAIN TENSIONER above valve cover and pro...

Page 28: ...mshaft bearing Ournal timing chain side D Camshaft bearingjournal spark plug side CAMSHAFT LOBE EXHAUST VALVES Minimum New 31 940 mm 1 2575 in Maximum New 32 140 mm 1 2654 in Service limit 31 920 mm 1...

Page 29: ...spring Check valve spring for free length and straight ness A Valve spring length VALVE SPRING FREE LENGTH Nominal New 40 81 mm 1 607 in Service limit 39 00 mm 1 535 in Replace valves springs if not w...

Page 30: ...tact area should be in center of valve seat Measure valve seat width using a caliper VALVE SEAT CONTACT WIDTH EXHAUST VALVE Minimum New 1 25 mm 049 in Maximum New 1 55 mm 061 in Service limit 2 00 mm...

Page 31: ...nder base gasket 4 Camshaft timing chain Inspection Cylinder Check cylinder for cracks scoring and wear ridges on the top and bottom of the cylinder If so re place cylinder Cylinder Taper Measure cyli...

Page 32: ...90 to piston pm A 8 mm 315 m The measured dimension should be as described in the following table If not replace piston PISTON MEASUREMENT Minimum New 90 950 mm 3 5807 in Maximum New 90 966 mm 3 5813...

Page 33: ...l on the piston pin Insert piston pin into piston and connecting rod CAUTION Take care that pistons will be in stalled with the punched arrow on piston top direction to the rear side of the engine Fro...

Page 34: ...e limit 1 50 mm 059 in Measure position for ring end gap in the area of 8 to 16 mm 315 to 630 in from top of cylinder NOTE In order to correctly position the ring in the cylinder use piston as a pushe...

Page 35: ...rankcase support sleeve oil seal installer plain bearing remover installer plain bearing remover installer Section 01 V 810 ENGINE Subsection 06 BOTTOM END Part Number Page 529 036 031 67 529 036 033...

Page 36: ...58 Engine oil 10 N m 89 lbfein 25 N m 18 lbfeft I 10 N m 2 0 I Multi purpose grease 89 lbf in Engine oil Engine oil 12 Section 01 V 810 ENGINE Subsection 06 BOTTOM END Engine oil J Engine oil _ 20N m...

Page 37: ...ournal diameter PTO sup port bearing Refer to CRANKSHAFT later in this section Replace if the measurement is out of specification 1 Plain bearing 2 Oil bore A Measure plain bearing inside diameter PLA...

Page 38: ...s are located on the engine PTO side behind the PTO cover vm t200 044 0 1 t_a 7 Intermediate gear 2 Oil pump gear 3 Water pump gear 4 Breather gear vmr2006 M4 Section 01 V 810 ENGINE Subsection 06 BOT...

Page 39: ...ase Inspection Inspection is the same for both timing chains NOTE Check timing chain on camshaft timing gear for excessive radial play Check chain condition for wear and teeth condi tion 1 7iming chai...

Page 40: ...scorings or other damages vmr2006 044 NOTE Measure plain bearing inside diameter and compare to PTO MAG side journal diameters of crankshaft refer to CRANKSHAFT below Replace if the measurements are o...

Page 41: ...earings in crankcase half MAG side must be positioned near to oil bore in clockwise direction refer to no 3 in next illustration 1 Crankcase half MAG inside 2 Oil bore 3 Partition CAUTION The partitio...

Page 42: ...STON PIN DIAMETER NEW MINIMUM 19 996 mm 7872 in NEW MAXIMUM 20 000 mm 7874 in SERVICE LIMIT 19 980 mm 7866 in PISTON PIN BORE CLEARANCE SERVICE LIMIT I 0 080 mm 0035 in NOTE If the connecting rod smal...

Page 43: ...ea carefully 1 Half plam bearing of connect i ng rod big end 2 Split surface of the connecting rod 3 Nose of plain bearing m line with connecting rod groove NOTE Oil the plain bearings of the connecti...

Page 44: ...BRP Rotax paper type replaceable Intake valve opening 10 BTOC Intake valve closing 45 ABOC Exhaust vaIve opening 50 BBOC Exhaust valve closing O ATOC Intake Valve clearance 0 06 mm 0024 1n to 0 14 mm...

Page 45: ...31 94 mm 1 2575 in Exhaustvalve Maximum New 32 14 mm 1 2654 in Service limit 31 92 mm 1 2567 in 76 ENGINE Crankshaft j01Jrnal diameter MAG PTO side Crankshaft radial clearance MAG PTO side Crankshaft...

Page 46: ...sed loop for engine Ethylene glycol 50 50 antifreeze water Coolant Coolant containing corrosion inhibitors for internal combustion aluminum enoines Thermostat Opening temperature 65 C 149 F CAPACITIES...

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