Rotax 2005 717 RFI Engine Shop Manual Download

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Section 03 787 RFI ENGINE

Subsection 05 (ROTARY VALVE)

F01D3EB

65°

CLOSING MARK

Step 1:

Top of MAG inlet port. Align 360° line of degree wheel

Step 2:

Find 65° on outer scale of degree wheel and mark here

– Remove degree wheel.
– Position rotary valve on shaft splines to have

edges as close as possible to these marks with
the MAG piston at TDC.

NOTE:

Rotary valve is asymmetrical. Therefore,

try flipping it over then reinstall on splines to obtain
best installation position.

Apply injection oil on rotary valve before reassem-
bling rotary valve cover.
– Remove TDC gauge.

Rotary Valve Cover

Install O-ring

no. 12

and rotary valve cover

no. 1

then torque screws

no. 2

to 20 N•m (15 lbf•ft) in

a criss-cross sequence.

110

smr2005-084

www.SeaDooManuals.net

Summary of Contents for 2005 717 RFI

Page 1: ...C M Y CM MY CY CMY K www SeaDooManuals net...

Page 2: ...2005 Engine Shop Manual ROTAX 717 and 787 RFI ENGINES www SeaDooManuals net...

Page 3: ...er Recreational Products Inc BRP Valcourt Qu bec Canada Printed in Canada Registered trademarks of Bombardier Recreational Products Inc BRP or its affiliates Trademark of Bombardier Inc used under lic...

Page 4: ...OOVE CLEARANCE 4 RING END GAP 5 CRANKSHAFT ASSEMBLED ENGINE 5 CRANKSHAFT DISASSEMBLED ENGINE 6 ROTARY VALVE 8 02 717 ENGINE 01 LEAK TEST 11 GENERAL 11 PREPARATION 11 TESTING PROCEDURE 11 ENGINE LEAKAG...

Page 5: ...SEMBLY 69 03 TOP END 71 GENERAL 73 DISASSEMBLY 74 CLEANING 79 INSPECTION 80 ASSEMBLY 80 ADJUSTMENT 86 04 BOTTOM END 87 GENERAL 89 DISASSEMBLY 89 CLEANING 93 INSPECTION 94 ASSEMBLY 94 05 ROTARY VALVE 1...

Page 6: ...mended when considering replacement of any component Dealer and or distributor assistance should be sought in case of doubt The engines identified in this document should not be utilized on product s...

Page 7: ...arts Catalogs When ordering parts always refer to the specific model Parts Catalogs ENGINE IDENTIFICATION NUMBER E I N 717 Engines The Engine Identification Number is located on the upper side of the...

Page 8: ...arts which have the same or a similar function CAUTION These engines are designed with parts dimensioned mostly in the metric sys tem However some components may be from the imperial system When repla...

Page 9: ...positions TYPICAL PAGE F01A0CT Illustration number for publishing process Subsection title indicates beginning of the subsection Dotted box contains parts of a particular model or an exploded view Pa...

Page 10: ...her wise it must be timed Remove carburetors from intake manifold Disconnect fuel bypass line between carburetors twin carburetors Remove carburetor s from rotary valve cover DISASSEMBLY AND INSPECTIO...

Page 11: ...ed specification cylinder should be rebored and honed or replaced A F01D8AA 1 2 TYPICAL 1 Measuring perpendicularly 90 to piston pin axis 2 Auxiliary transfer port A 16 mm 5 8 in CYLINDER OUT OF ROUND...

Page 12: ...for a few seconds after filling If so there is a leak between piston and cylinder The recorded volume would be false Let burette stand upward for about 10 minutes until liquid level is stabilized Rea...

Page 13: ...wise use a new piston and measure piston cylinder wall clearance following method with a new piston If piston is within specifications adjust and lock the micrometer to the obtained piston dimension F...

Page 14: ...re gauge 2 Dial bore gauge F00B0AA 1 1 Indicator set to zero Position the dial bore gauge at 16 mm 5 8 in be low cylinder top edge F01D0KA 1 A 1 Measuring perpendicularly 90 to piston pin axis A 16 mm...

Page 15: ...haft Alignment at Center Main Journal Since it is an assembled crankshaft it can become misaligned or deflected Crankshaft can be twist ed on center main journal changing timing of one cylinder in rel...

Page 16: ...F01D1NB 1 1 Connecting rod journal alignment here Such misalignment may make it difficult to manu ally turn the crankshaft Verification can be done by measuring deflection each end of crankshaft If d...

Page 17: ...01D1TA 1 1 Measuring MAG side deflection in crankcase Remove crankshaft bearings and check deflection again on V shaped blocks as illustrated 1 F01D97A 1 Measuring MAG side deflection on V shaped bloc...

Page 18: ...Feeler gauge blade thickness according to specifi cations should fit between rotary valve and cover F01D53A 1 1 45 feeler gauge If rotary valve cover clearance is out of specifica tions machine rotar...

Page 19: ...the edges of the seating surface and O ring groove 1 A F01D3OA SAME AMOUNT REMOVED FROM COVER SEATING SURFACE AND O RING GROOVE BASE 1 Cover seating surface A O ring groove depth must be 1 00 0 03 mm...

Page 20: ...h a common intake manifold When installing hoses of the leak test kit use the collars provided in the kit to ensure a proper seal ing When pressurizing the engine first confirm that the components of...

Page 21: ...ts are not leaking and pressure drops verify all external jointed surfaces tem perature sensor and the O ring between the spark plug area and the cylinder head cover If none of these components are le...

Page 22: ...ck valve If the above mentioned components are not leak ing block both oil hoses of the rotary valve shaft using small hose pincher P N 295 000 076 on each side NOTE If leakage stops at this point pro...

Page 23: ...pressure drops it indicates a defective MAG side crankshaft inner seal or crankcase is not sealed correctly If the above mentioned components are not leak ing and there is a pressure drops remove the...

Page 24: ...SEAL OF ROTARY VALVE SHAFT IS SEAL LEAKING CAREFULLY INSPECT ENGINE CASTINGS PARTICULARLY THE THREADED HOLE AREAS YES YES NO PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING CHECK TESTING KIT REPLAC...

Page 25: ...ntering tool 420 876 922 22 magneto puller 529 035 547 19 puller plate 420 876 081 19 sleeves 420 847 220 19 SERVICE PRODUCTS Description Part Number Page anticorrosion spray 219 700 304 22 Loctite 24...

Page 26: ...12 14 Loctite 243 15 5 5 N m 49 lbf in 13 Loctite 243 5 9 Loctite 243 7 6 145 N m 107 lbf ft Loctite 648 17 3 2 1 9 N m 80 lbf in Anti seize lubricant 9 N m 80 lbf in 1 9 N m 80 lbf in 1 2 6 N m 23 l...

Page 27: ...against ring gear no 5 F01D47A 2 3 4 1 1 Screw 2 Extension handle 3 Puller plate 4 Sleeve Install extension handle on end of puller plate F01D48A 1 TYPICAL 1 Sleeves on opposite side Using a suitable...

Page 28: ...ure is to find a common ref erence point on both crankcases old and new to position armature plate Proceed as follows Before removing the armature plate find a crankcase locating lug the top one in th...

Page 29: ...C 200 F around the screw holes to break the threadlocker bond F00D09A 1 1 Heat the armature plate CAUTION Protect harness from flame Remove screws no 15 Uncrimp and unsolder YELLOW and YEL LOW BLACK w...

Page 30: ...hat it fits around armature plate before tightening screws no 15 F00D0AA 1 1 Magneto coil centering tool Magneto Flywheel and Ring Gear Apply Loctite 648 green P N 413 711 400 to magneto flywheel mati...

Page 31: ...unch a mark on crankcase lug aligned with plate mark The new mark on crankcase will be used for fur ther assembly positioning as a pre timing position F01D4GA 1 TYPICAL 1 For further assembly use thes...

Page 32: ...ip installer 529 035 562 32 piston pin puller 529 035 503 28 30 piston ring compressor 420 876 979 33 rubber pad 295 000 101 27 sleeves 529 035 542 28 30 SERVICE PRODUCTS Description Part Number Page...

Page 33: ...bf ft Loctite 243 Molykote 111 2 15 14 3 14 7 24 N m 17 lbf ft Loctite 243 Molykote 111 7 24 N m 17 lbf ft Loctite 243 Molykote 111 6 13 16 5 4 24 N m 17 lbf ft Molykote 111 9 10 8 12 11 12 11 9 10 8...

Page 34: ...ing cylinders no 6 make sure connecting rods do not hit crankcase edge Engine in Watercraft If engine is left in watercraft refer to the appro priate VEHICLE SHOP MANUAL to remove the tuned pipe Proce...

Page 35: ...the piston pin puller P N 529 035 503 with the sleeves P N 529 035 542 F00B0IA 2 3 1 TYPICAL 1 Puller 2 Shoulder sleeve 3 Sleeve Fully thread on puller handle Insert extractor spindle into the piston...

Page 36: ...ton F00B0MA 1 TYPICAL 1 Remove shoulder sleeve Carefully remove the piston no 8 The needles no 11 thrust washers no 12 and the sleeve remain in the connecting rod bore and may be used again 1 2 F00B0N...

Page 37: ...in N A NOT APPLICABLE NOTE Replacement cylinder sleeves are available if necessary Also oversize pistons of 0 25 mm 010 in and 0 5 mm 020 in are available ASSEMBLY Assembly is essentially the reverse...

Page 38: ...e tool is available Replacement roller bearings are delivered in a con venient plastic mounting device For installation proceed as follows Align replacement roller bearing with connect ing rod bore Ca...

Page 39: ...sleeve half Circlip Always use new circlips no 9 WARNING Always wear safety glasses when installing piston circlips CAUTION Always use new circlips At instal lation take care not to deform them Circl...

Page 40: ...t of the same thickness However if you do not know the gasket thickness that was installed or if a crank repair has involved replacement of connecting rods refer to COMBUSTION CHAM BER VOLUME MEASUREM...

Page 41: ...roperly aligned so that exhaust flanges properly match up with exhaust manifold no 5 The aligning tool P N 420 876 904 or the exhaust manifold can be used to align cylinders F01D44A 1 1 Exhaust flange...

Page 42: ...of screws no 1 Apply also Molykote 111 P N 413 707 000 on threads of screws no 1 Torque cylinder head screws no 1 to 12 N m 106 lbf in as per following illustrated sequence Repeat the procedure retig...

Page 43: ...00 001 39 PTO side ring halves 420 977 475 41 Puller 420 877 635 41 Ring 420 977 490 41 Screw M8 x 40 420 840 681 41 Screw M8 x 70 420 841 201 41 temperature indicator stick 529 035 970 44 SERVICE PRO...

Page 44: ...lubricant 12 3 110 N m 81 lbf ft 1 6 5 6 Anti seize lubricant Loctite 642 12 4 Anti seize lubricant Loctite 243 6 6 4 5 Loctite 5910 2 11 7 24 N m 17 lbf ft 10 10 N m 89 lbf in Loctite 518 Loctite 518...

Page 45: ...eel splines F01D1AA 1 TYPICAL 1 PTO flywheel remover Using a suitable wrench or socket with a break er bar unscrew PTO flywheel COUNTERCLOCK WISE when facing it and hold extension handle locking the m...

Page 46: ...ck on a support Insert a pry bar between crankcase lugs to separate halves CAUTION Be careful to precision machined surfaces F01D1KA 1 TYPICAL 1 Separate halves by prying at provided lugs F01D1LA 1 TY...

Page 47: ...g installa tion lubricate their inside diameters F01D1OA 1 TYPICAL 1 Removing crankshaft bearing As an alternate method use a bearing extractor such as Proto no 4332 and a press to remove two bearings...

Page 48: ...TION Never use a sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing F00D2BA F00D2CA FIRST PASS F00D2DA SECOND PASS Finish the cleaning with acetone CA...

Page 49: ...sem bly procedures However pay particular attention to the following NOTE It is recommended to spray injection oil on all moving parts when reassembling the engine Crankshaft End Bearings Heat up the...

Page 50: ...end position Install the retaining disk To properly position the outer bearing s the dis tance gauge P N 529 034 800 must be temporar ily installed against the inner bearing Slide the outer bearing u...

Page 51: ...leave incompatible microscopic particles Use a plexiglass plate and apply some sealant on it Use a soft rubber roller 50 75 mm 2 3 in available in arts products suppliers and roll the sealant to get a...

Page 52: ...40 N m 30 lbf ft Oil Fittings If inlet and outlet oil fittings no 11 of rotary valve shaft have been removed from crankcase rein stall them with their end pointing toward ignition housing Apply Loctit...

Page 53: ...degree wheel 529 035 607 55 puller 420 876 488 49 pusher 420 876 501 51 pusher 420 876 605 52 TDC gauge 295 000 143 55 SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 56 Mo...

Page 54: ...INE Subsection 05 ROTARY VALVE 8 2 20 N m 15 lbf ft 7 10 6 9 5 11 3 4 14 15 13 12 1 XP S Injection oil Loctite 243 8 Molykote 111 7 10 6 9 5 11 3 4 14 15 13 12 1 smr2005 079 001_aen 48 smr2005 079 www...

Page 55: ...ugs rotary valve cover and valve Manually feel backlash at one position then turn crankshaft about 1 8 turn and recheck Continue this way to complete one revolution Backlash must be even at all positi...

Page 56: ...il lustrated Slide off distance sleeve no 14 re move snap ring no 7 and washer no 15 then press shaft out F01D4NA 1 2 1 Bearing 2 Bearing extractor Snap on CJ 950 CAUTION Ensure that rotary valve sha...

Page 57: ...part against oiled sand paper Rotary Valve Shaft Refer to table below to find dimension specifica tions For measurement procedures refer to EN GINE MEASUREMENT section TOLERANCES ENGINE MEASUREMENT N...

Page 58: ...l 2 Ball bearing 3 Bearing extractor Snap on CJ 950 Install washer no 15 snap ring no 7 and slide distance sleeve no 14 on shaft no 3 1 2 3 4 6 5 F01D2FA 1 Seal 2 Ball bearing 3 Snap ring 4 Distance s...

Page 59: ...Valve The rotary valve no 13 controls the opening and closing of the inlet ports Therefore its efficiency will depend on the precision of its installation IDENTIFICATION OF THE ROTARY VALVE ENGINE ROT...

Page 60: ...Section 02 717 ENGINE Subsection 05 ROTARY VALVE F01D73W 159 54 smr2005 079 www SeaDooManuals net...

Page 61: ...must be set so that timing occurs as follows TIMING ENGINE OPENING BTDC CLOSING ATDC 717 147 5 65 5 5 Timing Procedure The following timing procedure example uses these specifications OPENING 147 BTDC...

Page 62: ...G piston at TDC NOTE Rotary valve is asymmetrical Therefore try flipping it over then reinstall on splines to obtain best installation position Apply XP S mineral injection oil P N 413 802 900 on rota...

Page 63: ...d warpage maximum 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular New 0 25 0 40 mm 010 016 in Ring end gap Wear limit 1 00 mm 039 in New 0 025 0 070 mm 001 003 in Ring piston...

Page 64: ...fective way to conduct a leakage test Inboard testing does not allow complete access to and observation of all engine surfaces and should be avoided whenever possible When installing hoses of the engi...

Page 65: ...ng components If kit components are not leaking and pressure drops verify all external jointed surfaces tem perature sensor and the O ring between the spark plug area and the engine cylinder head cove...

Page 66: ...ntioned components are not leak ing block both oil hoses of the rotary valve shaft using a small hose pincher P N 295 000 076 on each NOTE If leakage stops at this point proceed with ROTARY VALVE SHAF...

Page 67: ...seal or crankcase is not sealed correctly If the above mentioned components are not leak ing and there is a pressure drops remove the ro tary valve cover Check the seal of the rotary valve shaft If t...

Page 68: ...K SEAL OF ROTARY VALVE SHAFT IS SEAL LEAKING CAREFULLY INSPECT ENGINE CASTINGS PARTICULARLY THE THREADED HOLE AREAS YES YES NO PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING CHECK TESTING KIT REPL...

Page 69: ...650 69 magneto puller 420 976 235 67 oil seal pusher 420 877 740 69 ring gear locking tool 529 035 846 67 SERVICE PRODUCTS Description Part Number Page dielectric grease 293 550 004 70 Loctite 243 bl...

Page 70: ...N m 89 lbf ft Loctite 243 Loctite 243 15 4 4 N m 35 lbf in 12 9 N m 80 lbf in 11 Dielectric grease 16 2 Molykote 111 1 Ground cable Dielectric grease 6 N m 53 lbf in Anti seize lubricant 9 Anti seize...

Page 71: ...l pump shaft Rotor and Ring Gear NOTE Crankshaft can also be locked by using the PTO flywheel extractor tool For procedure refer to BOTTOM END Remove crankshaft position sensor no 3 Lock ring gear no...

Page 72: ...be removed Refer to STARTING SYSTEM Unscrew retaining screws no 8 then withdraw housing F07D0LA 1 REMOVE SCREWS 1 Magneto housing Stator Assembly Remove holding plate no 9 and withdraw plug from cover...

Page 73: ...t Magneto Housing To install oil seal no 13 of magneto housing no 7 use the oil seal pusher P N 420 877 740 and the installer handle P N 420 877 650 F01B2NA 1 2 1 Oil seal pusher 2 Installer handle F0...

Page 74: ...ankshaft position sensor is not ad justable Cover Before installing cover make sure oil pump shaft is properly positioned Apply Loctite 767 anti seize lubricant P N 293 800 070 to the end of shaft Bef...

Page 75: ...035 562 83 piston pin puller 529 035 503 78 81 piston ring compressor 420 876 979 84 rubber pad 295 000 101 77 set of sleeves 529 035 542 78 81 SERVICE PRODUCTS Description Part Number Page Loctite 2...

Page 76: ...lers Loctite 243 Molykote 111 14 1 11 12 12 2 13 Loctite 518 Molykote 111 40 N m 30 lbf ft 9 10 30 Molykote 111 10 N m 89 lbf in 15 16 17 19 18 20 Molykote 111 3 N m 27 lbf in 21 29 27 28 26 25 24 23...

Page 77: ...to the valves 2 F06D3BA 1 3 TYPICAL 1 Solenoid 2 Pressure hose from crankcase 3 To atmospheric pressure NOTE A check valve on the pressure line elimi nates the negative pressure from the crankcase To...

Page 78: ...r line of the cylinder This is the minimum production clearance There is only a first oversize piston available for the 787 RFI engine That piston is 0 25 mm 010 in larger in diameter than the stock p...

Page 79: ...no 20 F06D0SA 1 1 Spring Free bellows no 21 from valve piston no 20 F06D0TA 1 1 Bellows removed from piston Unscrew valve piston no 20 from sliding valve no 22 NOTE Hold the sliding valve to prevent i...

Page 80: ...D26A 1 1 Remove spring Remove supporting ring no 28 F06D27A 1 1 Remove supporting ring Remove O ring no 23 F06D28A 1 1 Remove O ring Remove sliding valve no 22 F06D0UA 1 1 Remove sliding valve Remove...

Page 81: ...edge Engine in Watercraft Remove air intake silencer and support refer to the appropriate VEHICLE SHOP MANUAL Remove tuned pipe refer to the appropriate VE HICLE SHOP MANUAL Proceed with ENGINE ON BEN...

Page 82: ...e piston pin puller P N 529 035 503 with the set of sleeves P N 529 035 542 F00B0IA 2 3 1 TYPICAL 1 Puller 2 Shoulder sleeve 3 Sleeve Fully thread on puller handle Insert extractor spindle into the pi...

Page 83: ...m piston F00B0MA 1 TYPICAL 1 Remove shoulder sleeve Carefully remove the piston no 3 The needles thrust washers and the sleeve re main in the connecting rod bore and may be used again 1 2 F00B0NA 1 Ne...

Page 84: ...ce 0 13 mm 005 in N A 0 24 mm 009 in Ring piston groove clearance 0 025 mm 001 in 0 070 mm 0027 in 0 24 mm 009 in Ring end gap 0 40 mm 016 in 0 55 mm 022 in 1 0 mm 039 in N A NOT APPLICABLE NOTE Repla...

Page 85: ...8 mm 031 in 8 Piston At assembly place the pistons no 3 with the let ters AUS over an arrow on the piston dome fac ing in direction of the exhaust port A01C01A AUS 1 1 Exhaust side NOTE The exhaust p...

Page 86: ...ston Plastic Mounting Device Method This is an alternate method when no service tool is available Replacement roller bearings are delivered in a con venient plastic mounting device For installation pr...

Page 87: ...nner sleeve half Circlip Always use new circlips WARNING Always wear safety glasses when installing piston circlips CAUTION Always use new circlips At instal lation take care not to deform them Circli...

Page 88: ...tap tool with a hammer to insert circlip into its groove F00B0RA CAUTION The hand retaining the piston should absorb the energy to protect the con necting rod Cylinder To easily slide cylinder no 9 o...

Page 89: ...4 3 2 4 smr2005 082 002_a 1 M10 x 73 5 2 M10 x 105 3 Loctite 518 4 Molykote 111 Torque screws in a criss cross sequence for each cylinder to 20 N m 15 lbf ft Repeat the proce dure retightening all cy...

Page 90: ...installation Apply Loctite 518 P N 293 800 038 on 2 screws On the other screws apply Molykote 111 P N 413 707 000 on threads Install screws Refer to the following illustration for proper position of s...

Page 91: ...0 156 89 Puller 420 877 635 91 92 Ring 420 977 480 92 Ring 420 977 490 91 Ring halves 420 876 330 92 Ring halves 420 977 475 91 Screw M8 x 40 420 840 681 91 92 Screw M8 x 70 420 841 201 91 temperature...

Page 92: ...42 Anti seize lubricant Loctite 5910 Loctite 518 40 N m 30 lbf ft Loctite 518 Loctite 518 24 N m 17 lbf ft 30 mL 1 oz SAE 30 motor oil 5 6 12 6 15 16 6 4 6 2 7 11 12 18 11 4 3 4 19 15 14 F07D0VS 9 N m...

Page 93: ...00 156 295000156 Install special tool F06I02A 1 1 PTO flywheel extractor Install the extension handle P N 295 000 125 on the PTO flywheel extractor 295000125 Loosen PTO flywheel COUNTERCLOCKWISE when...

Page 94: ...precision machined surfaces F01D1KA 1 TYPICAL 1 Separate halves by prying at provided lugs F01D1LA 1 TYPICAL 1 Separate halves by prying at provided lugs Remove crankshaft and counterbalance shaft Cr...

Page 95: ...ft bearing PTO End Crankshaft Bearing As an alternate method the outer PTO bearing and crankshaft gear can be removed in one step using another puller See CRANKSHAFT GEAR no 18 below MAG End Crankshaf...

Page 96: ...emoved by using the following tools F00B0CA 1 2 3 4 5 1 Puller P N 420 877 635 2 Protective cap P N 420 876 557 3 Ring P N 420 977 480 4 Ring halves P N 420 876 330 5 Screw M8 x 40 P N 420 840 681 F00...

Page 97: ...with sand paper no 180 and remove all residue using pulley flange cleaner P N 413 711 809 A32CB5A TYPICAL Crankcase Crankcase mating surfaces are best cleaned us ing a combination of the chisel gaske...

Page 98: ...8 max 0 617 024 1 2 047 Crankcase Inspect plane surfaces for warpage Small defor mation can be corrected by grinding surface with a fine sandpaper Install sandpaper on a surface plate and rub part aga...

Page 99: ...ac ing bearing it s recommended to start the bearing heating process prior to removal operation Two bearings can be heated at the same time on one bearing heater A32CB8A 1 TYPICAL 1 Bearings Touch the...

Page 100: ...the crankshaft Also make sure to align the gear keyway with the Woodruff key on the crankshaft F00D0LA 1 1 Woodruff key on the crankshaft F00D0MA 1 2 1 Keyway 2 Long flange toward the crankshaft coun...

Page 101: ...and to save time NOTE It is recommended to apply this specific sealant as described here to get an uniform appli cation without lumps If you do not use the roller method you may use your finger to uni...

Page 102: ...s CAUTION Marks on the crankshaft and coun terbalance shaft must be aligned otherwise en gine will vibrate and premature wear will occur F00D0PA 1 1 Marks must be aligned Turn by hand the crankshaft a...

Page 103: ...al step torque only M10 screws no 8 of crankcase to 40 N m 30 lbf ft as per following sequence F15D05C 11 7 1 3 5 9 8 12 4 6 10 2 Counterbalance Shaft Gear Oil When crankcase assembly is completed add...

Page 104: ...4 BOTTOM END F01D84A 1 1 O ring Apply Loctite 767 anti seize lubricant P N 293 800 070 to crankshaft threads Using the same tools as for disassembly proce dure torque PTO flywheel to 110 N m 81 lbf ft...

Page 105: ...Part Number Page Degree wheel 529 035 607 109 handle 420 877 650 106 puller 290 876 488 103 pusher 290 876 609 106 pusher 420 876 501 105 TDC gauge short 295 000 143 109 SERVICE PRODUCTS Description...

Page 106: ...I ENGINE Subsection 05 ROTARY VALVE 787 RFI Engines 20 N m 15 lbf ft 9 N m 80 lbf in 2 1 12 Anti seize 13 Injection oil Molykote 111 11 4 3 15 8 7 14 10 6 5 9 smr2005 084 001_aen 102 smr2005 084 www S...

Page 107: ...ve spark plugs rotary valve cover and valve Manually feel backlash at one position then turn crankshaft about 1 8 turn and recheck Continue this way to complete one revolution Backlash must be even at...

Page 108: ...valent as il lustrated Slide off distance sleeve no 14 re move snap ring no 7 and washer no 15 then press shaft out F01D4NA 1 2 1 Bearing 2 Bearing extractor CAUTION Ensure that rotary valve shaft is...

Page 109: ...Surface part against oiled sand paper Rotary Valve Shaft Refer to table below to find dimension specifica tions For measurement procedures refer to EN GINE MEASUREMENT section TOLERANCES ENGINE MEASU...

Page 110: ...FB 1 Seal 2 Ball bearing 3 Bearing extractor Snap on CJ 950 Install washer no 15 snap ring no 7 and slide distance sleeve no 14 on shaft 1 2 3 4 6 5 F01D2FA 1 Seal 2 Ball bearing 3 Snap ring 4 Distanc...

Page 111: ...snap ring no 4 so that its sharp edge faces outwards Rotary Valve The rotary valve no 13 controls the opening and closing of the inlet ports Therefore its efficiency will depend on the precision of it...

Page 112: ...05 ROTARY VALVE There is no identification code on the valve To find out the duration place an angle finder on the valve and measure the valve cut out angle or use the following template F01D73W 159 1...

Page 113: ...e must be set so that timing occurs as follows TIMING ENGINE OPENING BTDC CLOSING ATDC 787 RFI 147 5 63 5 5 Timing Procedure The following timing procedure example uses these specifications OPENING 14...

Page 114: ...edges as close as possible to these marks with the MAG piston at TDC NOTE Rotary valve is asymmetrical Therefore try flipping it over then reinstall on splines to obtain best installation position Ap...

Page 115: ...der head warpage maximum 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular New 0 40 0 55 mm 016 022 in Ring end gap Wear limit 1 00 mm 039 in New 0 025 0 070 mm 001 003 in Ring...

Page 116: ...rpage maximum 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular New 0 40 0 55 mm 016 022 in Ring end gap Wear limit 1 00 mm 039 in New 0 025 0 070 mm 001 003 in Ring piston groo...

Page 117: ...C M Y CM MY CY CMY K www SeaDooManuals net...

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