SeaDoo Rotax 1503 4-Tec 2005 Page 91 Engine Shop Manual Download

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Section 01 ENGINES (1503 4-TEC)

Subsection 06 (CYLINDER HEAD)

VALVE GUIDE PROTRUSION

MINIMUM

12.4 mm (.4882 in)

MAXIMUM

12.8 mm (.5039 in)

NOTE:

For lubrication of the reamer use only cut-

ting oil. Turn the reamer only forward, in cutting
direction, never backward. Clean the reamer at
short intervals from swarf, moving the reamer on-
ly while turning in cutting direction.

Ream the new valve guide with a reamer 6 mm
diameter.

Clean cylinder head carefully. Check that the valve
seat is concentric with the new guide axis (check
contact surface with engineer's blue).

Valve Face and Seat

R1503motr107A

1. Valve seat
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)

Check valve face and seat for burning or pittings
and replace valve or cylinder head if there are signs
of damage.

Ensure to seat valves properly. Apply some lap-
ping compound on valve face and work valve on
its seat with a lapping tool.

Measure valve face contact width.

NOTE:

The location of contact area should be in

center of valve seat.

Measure valve seat width, using a caliper.

VALVE SEAT CONTACT WIDTH

NEW

Exhaust

1.25 to 1.55 mm

(.049 to.061 in)

Intake

1.10 to 1.30 mm

(.043 to.051 in)

SERVICE LIMIT

Exhaust

2 mm (.078 in)

Intake

1.8 mm (.07 in)

If valve seat contact width is too wide or has dark
spots, replace the cylinder head.

V01C1HA

A. Valve face contact width
B. Valve seat contact width

Valve Seat Grinding

NOTE:

The valve seats may be reground with

a valve seat grinder which centers on the valve
guide.
– Grind the valve seat at 45°. Remove no more

material than absolutely necessary to clean the
seat up.

– Using a 35° stone, narrow the valve seat until

the appropriate outer diameter is obtained.

smr2005-036

www.SeaDooManuals.net

Summary of Contents for Rotax 1503 4-Tec 2005

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

Page 2: ...2005 Engine Shop Manual ROTAX 1503 4 TEC ENGINES www SeaDooManuals net ...

Page 3: ...rt Quebec Canada Printed in Canada TMRegistered trademarks of Bombardier Recreational Products Inc BRP or its affiliates Trademark of Bombardier Inc used under license SEA DOO BOMBARDIER LUBE Sea Doo Synthetic Grease Sea Doo Learning KeyTM DESSTM Rotax TOPSTM This document contains the trademarks of the following companies Loctite is a trademark of Loctite Corporation Snap on is a trademark of Sna...

Page 4: ...OVAL 12 DISASSEMBLY 17 INSPECTION PARTS DISASSEMBLED 20 ASSEMBLY 21 INSTALLATION 26 03 PTO HOUSING AND MAGNETO 29 GENERAL 31 PROCEDURES 31 PTO HOUSING 31 PTO SEAL 34 COUPLING 35 STATOR 35 ROTOR AND TRIGGER WHEEL 36 RING GEAR 37 STARTER DRIVE ASS Y 38 OIL SPRAY NOZZLE 39 04 LUBRICATION SYSTEM 41 GENERAL 45 PROCEDURES 45 ENGINE OIL PRESSURE 45 PTO OIL STRAINER 46 SUCTION PUMP OIL STRAINER 47 ENGINE ...

Page 5: ...2 ROCKER ARM 73 CAMSHAFT TIMING GEAR 76 TIMING CHAIN 77 CYLINDER HEAD 78 CAMSHAFT 79 VALVE SPRING 80 VALVE 82 07 CYLINDER BLOCK 89 GENERAL 92 PROCEDURES 92 TIMING CHAIN 92 CHAIN TENSIONER 92 PISTON CONNECTING ROD 93 PISTON RINGS 98 CRANKSHAFT 99 BALANCER SHAFT 104 CYLINDER BLOCK 107 08 TECHNICAL SPECIFICATIONS 113 II www SeaDooManuals net ...

Page 6: ... parts The use of BRP parts is most strongly recommended when considering replacement of any component Dealer and or distributor assistance should be sought in case of doubt The engine identified in this document should not be utilized on product s other than those for which it was designed WARNING Unless otherwise specified engine should be turned OFF and cold for all maintenance and repair proce...

Page 7: ...his SHOP MANUAL uses technical terms which may be different from the ones of the PARTS CAT ALOGS When ordering parts always refer to the specific model PARTS CATALOGS ENGINE EMISSIONS INFORMATION Refer to the appropriate VEHICLE SHOP MANU AL ENGINE IDENTIFICATION NUMBER E I N The Engine Identification Number is located on front end of the engine F18D03A 1 1 Engine Identification Number E I N TIGHT...

Page 8: ...rts which have the same or a similar function CAUTION These watercraft are designed with parts dimensioned mostly in the metric sys tem However some components may be from the imperial system When replacing fasten ers make sure to use only those recommended by BRP As many of the procedures in this manual are inter related we suggest that before undertaking any task you read and thoroughly understa...

Page 9: ...d 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 Page number Italic sub title above exploded view indicate pertaining models Drop represents a liquid product to be applied to a surface In this case Loctite 243 to screw threads Bold face number indica...

Page 10: ...ther 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 INSPECTION Using a suitable pump gauge tester perform the fol lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on pulse nipple Pump tester until it reaches 28 kPa 4 PSI Diaphragm mu...

Page 11: ...o handling on the hot engine Remove any parts to have access to engine safety lanyard WARNING Safety lanyard must be removed to prevent engine to be cranked while fuel rail is re moved to prevent fuel to be sprayed out Fuel is flammable jet pump refer to JET PUMP in the appropriate VEHICLE SHOP MANUAL coolant tank cap WARNING To prevent burning yourself only remove the coolant tank cap by wearing ...

Page 12: ...4 TEC Naturally Aspirated 1503 4 TEC Supercharged Drive shaft adapter P N 529 035 892 1503 4 TEC Supercharged Intercooled Drive shaft adapter P N 529 035 985 529035892 DRIVE SHAFT ADAPTER Rotate engine counterclockwise until the cylinder no 1 is at Top Dead Center TDC compression stroke NOTE Cylinder numbers are molded on valve cov er As the engine is turned over observe the move ment of intake ro...

Page 13: ...ition diagnose and repair engine Proceed the same way with remaining cylinders DIAGNOSIS Pressurize area to be tested spray soap water so lution at the indicated location and look and or lis ten for air bubbles air escaping on intake port means leaking intake valve s air escaping on exhaust port means leaking ex haust valve s air bubbles out of coolant tank means leaking cylinder head gasket air e...

Page 14: ...ints mentioned above see the appropriate engine section to diagnose and repair the engine ASSEMBLY NOTE For assembly use the torque values and Loctite products from the exploded views refer to proper engine section For assembly reverse the preparation procedure NOTE Prior to inserting the ignition coil in its lo cation apply some Molykote 111 P N 413 707 000 around the seal area that touches the s...

Page 15: ...9 035 839 11 leak test pump 529 021 800 10 retaining key 529 035 949 18 19 25 support plate 529 035 947 22 23 support pusher 529 035 950 23 support pusher 529 035 950 22 Torx adapter 529 035 938 17 27 SERVICE PRODUCTS Description Part Number Page Kluber Isoflex grease 293 550 021 24 Loctite 243 293 800 060 23 27 Loctite 5910 293 800 081 25 Super Lube grease 293 550 030 27 SMR2005 033 5 www SeaDooM...

Page 16: ...Aspirated Engine Intake Manifold and Throttle Body 10 N m 89 lbf in Loctite 243 10 N m 89 lbf in 6 N m 53 lbf in 10 N m 89 lbf in 6 N m 53 lbf in 18 N m 159 lbf in 10 N m 89 lbf in Loctite 243 Loctite 243 Oil Loctite 243 Oil smr2005 033 200_aen TYPICAL 6 SMR2005 033 www SeaDooManuals net ...

Page 17: ...Supercharged Engine Intake Manifold and Throttle Body 10 N m 89 lbf in Loctite 243 Oil Loctite 243 6 N m 53 lbf in 18 N m 159 lbf in Loctite 243 6 N m 53 lbf in 10 N m 89 lbf in 10 N m 89 lbf in Oil Loctite 243 Loctite 243 smr2005 033 201_aen SMR2005 033 7 www SeaDooManuals net ...

Page 18: ... Supercharged Intercooled Engine Intake Manifold and Throttle Body Loctite 243 10 N m 89 lbf in Loctite 243 6 N m 53 lbf in Oil Oil 18 N m 159 lbf in Loctite 243 10 N m 89 lbf in Loctite 243 6 N m 53 lbf in Oil Loctite 243 smr2005 033 008_aen 8 SMR2005 033 www SeaDooManuals net ...

Page 19: ...R Supercharged Engines Supercharger R1503motr357S 30 N m 22 lbf ft Loctite 5910 30 N m 22 lbf ft 30 N m 22 lbf ft 10 N m 89 lbf in Loctite 243 Anti seize lubricant Oil Klueber isoflex 30 N m 22 lbf ft Oil Loctite 243 Loctite 243 Loctite 243 SMR2005 033 9 www SeaDooManuals net ...

Page 20: ...ooler 2 Outlet hose 3 Inlet nipple Plug intercooler inlet nipple Install an adapter on the outlet hose to connect the leak test pump P N 529 021 800 529 021 800 Pressurize the intercooler as follows PRESSURE TEST 69 kPa 10 PSI for 10 minutes min If there is a pressure drop first spray hoses and adapters with a soapy solution to ensure they are not leaking Otherwise remove intercooler from manifold...

Page 21: ...to allow insertion of the locking tool R1503motr111A 1 1 Camshaft locking tool Check slipping moment counterclockwise by us ing a torque wrench with actual torque viewer A mirror is useful to see the viewer 1 R1503motr244A 1 Torque wrench NOTE Before checking the supercharger slipping moment it is recommended to turn the clutch a full revolution This way the parts can mate together and you will ge...

Page 22: ...em refer to ENGINE MANAGEMENT section of the appropri ate VEHICLE SHOP MANUAL Disconnect battery cables from battery WARNING Always disconnect battery cables exactly in the specified order BLACK negative cable first then the RED positive battery cable last Disconnect fuel hose connector at fuel rail R1503motr78A 1 2 1 1 1 2 Step 1 Squeeze Step 2 Pull out 1 Supporting tabs 2 Squeeze in middle of su...

Page 23: ... 6 KS 7 CPS 8 Magneto 9 B Kostal connector 10 OSPS NOTE The TPS connector is hidden behind the TOPS hose Disconnect hose from TOPS valve then move away to access the TPS connector Slightly pry locking tab of connector to unlock R1503motr75A 1 3 2 1 TOPS hose disconnected and moved away 2 TPS connector 3 Slightly pry tab to unlock Supercharged Engines 2 1 R1503motr223A 5 4 3 SUPERCHARGED ENGINES 1 ...

Page 24: ...Push here and hold while pulling connector out 1 R1503motr64A TYPICAL 1 CTS connector 1 R1503motr65A TYPICAL 1 CAPS connector 1 R1503motr66A TYPICAL 1 EGTS connector 1 F18D0BA 2 1 Oil filter housing 2 OPS Unplug the B connector from the ECM 1 R1503motr70A 1 Push this end to unlock 14 SMR2005 033 www SeaDooManuals net ...

Page 25: ...ally Aspirated Engine Loosen air intake silencer collar Unlock throttle cable housing from throttle body Cable is to be detached later on R1503motr72A 1 2 1 Air intake silencer collar 2 Unlock throttle cable housing Supercharged Engines Remove inlet hose from throttle body Disconnect throttle cable from throttle body R1503motr252A 2 1 1 Detach hose 2 Disconnect cable Supercharged Intercooled Engin...

Page 26: ...e Detach throttle cable end from throttle body F18D2XA 1 1 Detach cable end from throttle body All Engines Pull intake manifold out R1503motr77A TYPICAL NOTE The flame arrester and the intercooler if so equipped in the intake manifold are maintenance free Supercharger Supercharged Engines NOTE Remove required parts to access super charger Refer to appropriate VEHICLE SHOP MANUAL Remove hoses from ...

Page 27: ...A 1 1 Retaining screws To remove the upper screw not shown on the picture above use the Torx adapter P N 529 035 938 529035938 1 R1503motr250A 1 Upper retaining screws DISASSEMBLY Intake Manifold and Intercooler Supercharged Intercooled Engines Remove collar from intercooler 1 F19D0DB 2 1 Intercooler 2 Collar Carefully pull intercooler out of intake manifold SMR2005 033 17 www SeaDooManuals net ...

Page 28: ... in damage of the supercharg er Strictly follow the described procedures Take apart supercharger housing 1 F00B28A 3 2 1 1 1 1 Retaining screws 2 Housing half intake side 3 Housing half engine side F00B29A PLASTIC HAMMER NOTE The cap nut on the supercharger shaft has LH threads Loosen cap nut turn clockwise on supercharger shaft turbine side while holding shaft with a retain ing key P N 529 035 94...

Page 29: ...g spring washers lock washer drive gear and needle pins by turning the supercharger ass y upside down 1 R1503motr359A 2 3 4 5 6 7 1 Nut 2 L ring 3 Spring washers 4 Lock washer 5 Ceramic washers 6 Drive gear 7 Needle bearings Carefully push out supercharger shaft towards en gine side by using a press 1 F00B2CA 1 Supercharger shaft CAUTION Every time when removing the su percharger shaft both ball b...

Page 30: ...press and a suitable bearing pusher 1 R1503motr236A 2 1 Supercharger housing half engine side 2 Bearing pusher INSPECTION PARTS DISASSEMBLED Supercharged Clutch Components and Gear Replace worn parts by new ones A clutch repair kit is available If all parts are within specifications replace the 40 needle bearings and spring washer package on supercharger shaft NOTE Ceramic washers are not affected...

Page 31: ...00 mm 3819 in ASSEMBLY Assembly is essentially the reverse of removal procedures However pay particular attention to the following Intake Manifold and Intercooler Supercharged Intercooled Engine Ensure O rings are properly installed on intercool er and apply 4 stroke oil on them to ease installa tion While properly aligning the inner end of intercooler in intake manifold gently push intercooler un...

Page 32: ...on ball bearing against protrusion of support plate for the in stallation This way the installation pressure will be applied to the inner race and will not be transmitted to the bearing balls which would otherwise shorten the bearing life CAUTION To install ball bearings and super charger shaft always use a press never use any beating force like a hammer 4 3 1 F00B2FA 2 1 Supercharger shaft 2 Ball...

Page 33: ...aring support push er P N 529 035 950 under supercharger housing half 529035950 3 F00B2GA 1 2 1 Support plate 2 Bearing support pusher 3 Protrusion here CAUTION Before pressing in the supercharg er shaft be sure to properly support the inner race of ball bearing in supercharger housing half with the recommended tool This way the installation pressure will be applied to the inner race and will not ...

Page 34: ...absolutely clean The compressor shaft spins at up to 45 000 RPM and any debris could cause a failure Install the first ceramic washer NOTE The ceramic washers differ in their inner diameter Install first the ceramic washer with the bigger inner diameter The ceramic washer with the smaller inner diameter will be installed on the lock washer side CAUTION Manipulate ceramic washers with care those pa...

Page 35: ...4 5 6 7 1 Nut 2 L ring 3 Spring washers 4 Lock washer 5 Ceramic washers 6 Drive gear 7 Needle bearings Hold the lock washer of the supercharger shaft engine side using the retaining key P N 529 035 949 529035949 Tigthen the impeller cap nut to 30 N m 22 lbf ft Apply Loctite 5910 P N 293 800 081 on super charger housing sealing surface For correct pro cedure refer to ENGINE BLOCK Installation in EN...

Page 36: ... ifold R1503motr59B 1 1 Oil dipstick tube Apply Loctite 243 P N 293 800 060 on the in take manifold screws Torque them to 10 N m 89 lbf in following the tightening sequence shown 5 R1503motr210A 3 1 2 6 7 4 Ensure to properly route and resecure wiring har ness with locking ties WARNING Always check O ring for damage such as deformation at reinstallation Replace the O ring if it is damaged When ins...

Page 37: ...e the upper screw use the Torx adapter P N 529 035 938 F00B20A Ensure to install the tool perpendicularly 90 to torque wrench to apply the proper torque to the screw A F00B1UA 1 1 Tool perpendicular 90 to torque wrench A 90 CAUTION Not installing the tool as shown will change the torque applied to the screw Proper torque and tightening sequence are important After complete installation of the supe...

Page 38: ...peller remover installer 529 035 820 35 locking tool 529 035 821 35 37 syphon pump 529 035 880 31 SERVICE PRODUCTS Description Part Number Page Isoflex Topas NB52 grease 293 550 021 38 Loctite 243 293 800 060 31 34 36 38 Loctite 648 413 711 400 39 Loctite anti seize 293 800 070 35 pulley flange cleaner 413 711 809 31 32 34 smr2005 032 29 www SeaDooManuals net ...

Page 39: ...rged only 23 9 17 15 18 14 Loctite 243 10 N m 89 lbf in Loctite 243 6 7 Oil 8 20 21 12 13 19 Oil Loctite anti seize Oil Loctite 5910 16 Loctite 243 10 N m 89 lbf in Loctite 243 12 N m 106 lbf in Oil Loctite 243 10 N m 89 lbf in 3 N m 26 lbf in Left handed thread Oil 11 22 Oil 1 2 Loctite 243 10 N m 89 lbf in 10 30 smr2005 032 www SeaDooManuals net ...

Page 40: ...hon pump P N 529 035 880 to the fitting 529 035 880 The front of the engine must be tilted down ap proximately 15 degrees to facilitate the removal of the oil Raise the rear of the watercraft ac cordingly Siphon the oil from the fitting When done remove the syphon pump and the fitting Apply Loctite 243 P N 293 800 060 and reinstall the drain plug NOTE If spillage occurs clean immediately with the ...

Page 41: ...tions prior to disconnecting fuel lines Slightly lift rear part of engine and safely block in this position Remove rear LH side engine sup port no 1 1 R1503motr50A TYPICAL 1 Engine support Remove thru hull fitting boot 1 F18J0BA 2 1 Thru hull fitting boot 2 Remove this collar coolant pump housing no 2 refer to COOLING SYSTEM screws no 3 and no 4 NOTE Carefully separate the PTO housing from the eng...

Page 42: ...n the disc springs no 6 and washer no 7 as per the following illustration smr2005 034 100_a TYPICAL 1 Washer 2 Disc spring 3 Starter drive ass y NOTE When installing a new starter drive ass y oil the shaft and threads of the gear with engine oil CAUTION Ensure the starter drive gear shaft is well engaged in its bore Gently install PTO housing CAUTION While installing housing pay partic ular attent...

Page 43: ...fill engine with oil and cooling system with coolant Refer to LUBRICATION and COOLING SYSTEM sections of the appropriate VEHICLE SHOP MANUAL PTO SEAL Inspection Check the PTO seal no 22 and O rings no 10 on the PTO housing If brittle hard or damaged or if you see a sign of oil leakage replace it Removal Place rags under PTO housing to prevent spillage If spillage occurs clean immediately with the ...

Page 44: ...ller remover installer P N 529 035 820 529035820 CAUTION Apply some oil on the tool to protect the seal located in the PTO coupling R1503motr48A TYPICAL Inspection Check if seal no 13 is brittle cracked or hard Check coupling for worn splines If damaged replace faulty part R1503motr49A Installation For installation reverse the removal procedure However pay attention to the following Torque PTO cou...

Page 45: ...e stator notch in the magneto housing cover 1 R1503motr51A TYPICAL 1 Notch for stator Place the rubber grommets on both cables in the proper notches at the PTO housing 1 R1503motr52A 2 TYPICAL 1 Grommet on CPS cable 2 Grommet on stator cable Apply Loctite 243 P N 293 800 060 on threads Torque stator and CPS screws to 10 N m 88 lbf in ROTOR AND TRIGGER WHEEL Removal Lock crankshaft with locking too...

Page 46: ...tion For installation reverse the removal procedure However pay attention to the following Trigger wheel position has to be located with the location pin on the crankshaft gear Apply Loctite 243 P N 293 800 060 on threads Torque rotor screws to 24 N m 17 lbf ft RING GEAR Removal Lock crankshaft with locking tool P N 529 035 821 Refer to CYLINDER BLOCK section Remove PTO housing cover hexagonal scr...

Page 47: ...sher no 7 located on the starter drive shaft smr2005 034 002_a TYPICAL 1 Disc springs 2 Washer 3 Starter drive gear Inspection Check condition of the teeth shaft etc and if the sprag clutch operates well If damaged replace faulty part Installation For installation reverse the removal procedure However pay attention to the following NOTE When installing a new starter drive ass y oil the shaft and t...

Page 48: ...ing Fix supercharger spray nozzle remover tight on oil spray nozzle 1 R1503motr264A 2 1 Oil spray nozzle 2 Spray nozzle remover Remove oil spray nozzle carefully by using a slide hammer puller Installation For installation reverse the removal procedure However pay attention to the following Apply Loctite 648 P N 413 711 400 on oil spray nozzle fitting surface CAUTION The oil spray nozzle must be i...

Page 49: ... Part Number Page hose adaptor 529 035 652 45 oil pressure gauge 529 035 709 45 oil seal guide 529 035 822 54 rotary seal pusher 529 035 823 53 54 SERVICE PRODUCTS Description Part Number Page Loctite 243 293 800 060 49 51 54 57 59 pulley flange cleaner 413 711 809 47 55 SMR2005 035 41 www SeaDooManuals net ...

Page 50: ...bf in Loctite 243 10 N m 89 lbf in 24 N m 18 lbf ft Loctite 5910 Loctite 243 10 N m 89 lbf in Oil 3 N m 27 lbf in Left handed threads 20 25 26 Loctite 243 10 N m 89 lbf in 18 17 16 Loctite 243 12 N m 106 lbf in 15 Oil 23 24 6 Oil 22 21 Multi purpose grease Loctite 243 10 N m 89 lbf in 1 2 4 3 19 Oil 42 SMR2005 035 www SeaDooManuals net ...

Page 51: ...ged Engines 7 Oil 18 N m 159 lbf in 18 N m 159 lbf in Oil 8 10 N m 89 lbf in Loctite 243 9 5 25 N m 44 221 lbf in Loctite 243 10 10 N m 89 lbf in 13 12 30 29 28 27 38 Oil 36 37 35 34 10 N m 89 lbf in Loctite 243 11 Loctite 243 Loctite 243 14 smr2005 035 001_aen SMR2005 035 43 www SeaDooManuals net ...

Page 52: ...R1503motr369S 34 18 N m 159 lbf in Oil 35 37 36 38 28 29 30 13 11 9 27 10 7 8 Loctite 243 10 N m 89 lbf in 18 N m 159 lbf in 10 N m 89 lbf in Loctite 243 12 Loctite 243 10 N m 89 lbf in Oil 5 25 N m 44 221 lbf in Loctite 243 10 N m 89 lbf in Oil Loctite 243 14 44 SMR2005 035 www SeaDooManuals net ...

Page 53: ...ure switch and install gauge F18D2YA 1 INSTALLATION AT PRESSURE SWITCH LOCATION 1 Remove oil pressure switch and install gauge here To prevent the EMS to go in limp home mode at 2500 RPM or to generate a fault code start en gine THEN ground OPS connector to engine Read oil pressure at different RPM as per follow ing table OIL PRESSURE MEASURED AT PRESSURE SWITCH LOCATION 1503 4 TEC NATURALLY ASPIR...

Page 54: ...e at 80 C 176 F Min 138 20 4000 7500 172 241 25 35 Reinstall plug PTO OIL STRAINER NOTE The oil strainer does not need to be cleaned at every oil change Clean it during other inspections especially when the engine is disas sembled Removal Remove engine oil refer to OIL CHANGE in the appro priate VEHICLE SHOP MANUAL PTO cover no 5 refer to PTO COVER MAGNE TO section oil strainer no 6 1 R1503motr117...

Page 55: ... the engine is disas sembled Removal Remove ventilation hose no 7 1 R1503motr133A TYPICAL NATURALLY ASPIRATED AND SUPERCHARGED ENGINES 1 Ventilation hose R1503motr374A 1 TYPICAL SUPERCHARGED INTERCOOLED ENGINE 1 Ventilation hose Disconnect wiring harness from TOPS valve no 8 and oil separator pressure switch OSPS no 9 Detach intake hose from throttle body naturally aspirated engine only Remove oth...

Page 56: ...0A TYPICAL NATURALLY ASPIRATED AND SUPERCHARGED ENGINES 1 Oil strainer R1503motr370A 1 TYPICAL SUPERCHARGED INTERCOOLED ENGINE 1 Oil strainer Cleaning and Inspection Clean oil strainer with a part cleaner then use an air gun to dry it WARNING Always wear eye protector Chemicals can cause a rash break out in and an injury to your eyes Inspect rubber rings no 13 and no 14 1 R1503motr121A 2 TYPICAL N...

Page 57: ...l procedure Position screws according to their length as shown 1 R1503motr119A 2 TYPICAL 1 Screws M6 x 25 2 Screws M6 x 85 Torque suction pump cover screws to 10 N m 89 lbf in as per sequence illustrated below Ap ply Loctite 243 P N 293 800 060 on threads 1 R1503motr144A 3 4 6 2 5 ENGINE OIL PRESSURE REGULATOR The oil pressure regulator is located on the bottom of the PTO housing 1 R1503motr123A T...

Page 58: ...no 17 and valve piston guide no 18 WARNING Oil pressure regulator plug on oil pump hous ing is spring loaded smr2005 035 002_a TYPICAL NATURALLY ASPIRATED ENGINE 1 Valve piston guide 2 Valve piston 3 Compression spring 4 Oil pressure regulator plug 5 O Ring smr2005 035 003_a TYPICAL SUPERCHARGED ENGINES 1 Valve piston guide 2 Valve piston 3 Compression spring 4 Compression spring 5 Oil pressure re...

Page 59: ...n max imum Apply Loctite 243 P N 293 800 060 on threads OIL PRESSURE PUMP The oil pressure pump is located in the PTO hous ing and is driven by the balance shaft Removal Remove engine oil refer to OIL CHANGE in the appro priate VEHICLE SHOP MANUAL PTO housing refer to PTO HOUSING AND MAGNETO section coolant pump housing no 19 and impeller no 20 refer to COOLING SYSTEM section screws no 21 oil pump...

Page 60: ...l pump housing and cover and replace if damaged 1 R1503motr129A 1 Pittings on the teeth Using a feeler gauge measure the clearance be tween inner and outer rotors 2 R1503motr130A 1 C A B 1 Outer rotor 2 Inner rotor OUTER AND INNER ROTOR CLEARANCE SERVICE LIMIT A B C 0 25 mm 009 in If clearance between inner and outer rotors ex ceeds the tolerance replace coolant oil pump shaft assembly Ensure to a...

Page 61: ...es the oil pressure de creases Check the inside of oil pump housing and its cover for scoring or other damages and replace if dam aged Installation For installation reverse the removal procedure Pay attention to the following details NOTE Never use oil in the press fit area of the rotary seal Push coolant oil pump shaft seal in place by using thumb 1 R1503motr128A 1 Oil seal Install the new rotary...

Page 62: ...eal guide 2 Coolant oil pump shaft 2 R1503motr143A 1 1 Coolant oil pump shaft with oil seal guide 2 Rotary seal pusher Tighten oil pump cover screws and torque to 10 N m 89 lbf in Apply Loctite 243 P N 293 800 060 on threads Final Test After engine is completely reassembled start en gine and make sure oil pressure is within specifi cations OIL SUCTION PUMP The oil suction pump is located on the fr...

Page 63: ...and no 11 Place rags under cover to prevent spillage If spillage occurs clean with the pulley flange cleaner P N 413 711 809 WARNING Wear safety glasses and work in a well ventilated area when working with strong chemical products Also wear suitable non absorbent gloves to protect your hands Remove the oil suction pump cover with oil sep arator housing and his cover NOTE On the supercharged interc...

Page 64: ... gauge measure the clearance be tween inner and outer rotors R1503motr138A 2 1 C B A 1 Outer rotor 2 Inner rotor OUTER AND INNER ROTOR CLEARANCE SERVICE LIMIT A B C 0 25 mm 009 in If clearance between inner and outer rotors ex ceeds the tolerance replace oil pump shaft as sembly Ensure to also check oil pump housing and cover and replace if damaged If clearance between outer rotor and its bore in ...

Page 65: ... for scoring or other damages and replace if dam aged Installation For installation reverse the removal procedure Pay attention to the following details 2 1 R1503motr134A 2 1 Screws M6 x 85 2 Screws M6 x 25 Torque oil pump cover screws to 10 N m 89 lbf in Tighten suction pump housing screws as per following sequence and torque to 10 N m 89 lbf in Apply Loctite 243 P N 293 800 060 on threads R1503m...

Page 66: ...m 89 lbf in Apply Loc tite 243 P N 293 800 060 on threads TOPS VALVE Removal Remove the oil separator cover as described above Unscrew and remove the TOPS valve Remove the valve disc and the spring on the bot tom of the TOPS valve after removing the retain ing washer WARNING The spring on the TOPS valve is tensioned and can shoot away the valve disc Hold the valve disc with fingers while removing ...

Page 67: ...148A 1 O rings Inspection If O rings are brittle cracked or hard replace them Clean both contact surfaces of oil cooler Check and clean the oil inlet and outlet area for dirt and other contaminations Installation For installation reverse the removal procedure Pay attention to the following details Apply grease on O rings Torque oil pump cover screws to 10 N m 89 lbf in Apply Loctite 243 P N 293 80...

Page 68: ...ING SYSTEM COOLING SYSTEM SERVICE TOOLS Description Part Number Page oil seal protector 529 035 822 67 rotary seal installer 529 035 823 67 SERVICE PRODUCTS Description Part Number Page Loctite 243 290 897 651 64 smr2005 088 61 www SeaDooManuals net ...

Page 69: ...Section 01 ENGINES 1503 4 TEC Subsection 05 COOLING SYSTEM F18E0ZS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 62 smr2005 088 www SeaDooManuals net ...

Page 70: ...l seal PROCEDURES COOLANT PUMP 1 F18E0YA 1 Coolant pump Removal Supercharged Engines Remove supercharger inlet and outlet hoses to make room 1 F18F0CA 2 3 1 Supercharger 2 Inlet hose 3 Outlet hose All Engines Drain cooling system and engine oil refer to ap propriate VEHICLE SHOP MANUAL Remove from housing ride plate inlet and outlet hoses cylinder head outlet hose no 1 oil cooler inlet hose no 2 o...

Page 71: ...te 243 P N 290 897 651 on screw threads and torque to 10 N m 89 lbf in Tightening sequence for screws on coolant pump housing is as per following illustration F18E10B 3 2 4 5 1 8 8 7 6 COOLANT PUMP IMPELLER Removal Remove coolant pump no 6 as described in this section unscrew the impeller no 8 clockwise 1 F18E13A 1 Impeller CAUTION Coolant oil pump shaft no 9 and im peller no 8 have left hand thre...

Page 72: ... there is no leak check the operation of the ther mostat Dynamic Test To check the operation of the thermostat put it in water and heat water Look inside the cylin der head return hose connection to see the move ment of the thermostat Thermostat should open when water temperature reaches 87 C 188 F If there is no operation replace the coolant pump Installation For installation reverse the removal ...

Page 73: ...or extract the coolant oil pump shaft no 9 from outside PTO housing cover with a pusher 1 F18E16A 2 1 Pusher 2 Coolant oil pump shaft remove rotary seal no 14 with a screwdriver F18E17A CAUTION Be careful not to damage the surface of the rotary seal bore in magneto housing cov er always replace also the oil seal no 15 behind the rotary seal 1 F18E18A 1 Oil seal 66 smr2005 088 www SeaDooManuals net...

Page 74: ... 035 823 529035823 CAUTION Never use a hammer for the rotary seal or water oil pump shaft installation On ly use a press to avoid damaging the ceramic component 1 F18E19A 2 1 Rotary seal 2 Rotary seal installer Install the coolant oil pump shaft using the rotary seal installer P N 529 035 823 on the opposite side to the rotary seal and the oil seal protector P N 529 035 822 with a press 1 F18E1AA ...

Page 75: ... 529 035 839 75 77 crankshaft locking tool 529 035 821 73 76 78 valve spring compressor clamp 529 035 724 80 valve spring compressor cup 529 035 725 80 SERVICE PRODUCTS Description Part Number Page Klueber Isoflex grease 293 550 021 80 Loctite 243 blue 293 800 060 72 Molykote G N paste 413 703 700 84 smr2005 036 69 www SeaDooManuals net ...

Page 76: ...bf in Engine oil 17 18 19 Loctite 243 10 N m 89 lbf in 26 27 Engine oil 20 Loctite 243 10 N m 89 lbf in 9 18 N m 159 lbf in 24 23 16 2 10 N m 89 lbf in 18 N m 159 lbf in 6 N m 53 lbf in 21 Engine oil 15 13 10 N m 89 lbf in 6 N m 53 lbf in Grease Klueber Isoflex Topas NB52 7 Loctite 243 14 12 25 22 20 N m 14 5 lbf ft 90 28 smr2005 036 003_aen 70 smr2005 036 www SeaDooManuals net ...

Page 77: ...you reassemble them together within their group PROCEDURES SPARK PLUG Removal Remove fuel rail cover from engine Unplug the ignition coil connector on the spark plug you need to remove Remove the ignition coil no 1 Clean spark plug and ignition coil area before dis assembly Unscrew spark plug no 2 then use the ignition coil to take spark plug out of spark plug hole 1 R1503motr44A 2 1 Ignition coil...

Page 78: ...ated sequence R1503motr152A 7 5 1 3 9 11 8 6 4 2 10 12 VALVE COVER Removal Remove valve cover shield no 3 valve cover screws no 4 1 R1503motr81A 1 Valve cover screws valve cover no 5 and profile sealing ring no 6 1 R1503motr82A 2 1 Valve cover 2 Profile sealing ring Inspection Check if the profile sealing ring on the valve cover and the rubber bushing on the valve cover screws are brittle cracked ...

Page 79: ...g tube no 7 1 R1503motr83A 1 Spark plug tube rocker arm shaft screws no 8 Discard screws R1503motr93B 1 1 Rocker arm shaft screws rocker arm shaft no 9 with rocker arm assem bly exhaust side no 10 and intake side no 11 1 R1503motr84A 2 3 1 Rocker arm shaft 2 Rocker arms exhaust side 3 Rocker arm intake side 1 R1503motr85A 1 Oil supply from the camshaft to the rocker arm shaft then to the rocker ar...

Page 80: ... 2 1 Rocker arm intake side 2 Roller A Bore for rocker arm shaft A 1 R1503motr88A 2 1 Rocker arm exhaust side 2 Roller A Bore for rocker arm shaft Measure rocker arm bore diameter If diameter is out of specification change the rocker arm assem bly ROCKER ARM BORE DIAMETER NEW MINIMUM 20 007 mm 7877 in NEW MAXIMUM 20 020 mm 7881 in SERVICE LIMIT 20 035 mm 7887 in Press the hydraulic lifter with you...

Page 81: ...arm shaft can only be in stalled in one specific position Therefore crank shaft as well as camshaft has to be positioned with their locking pins when the piston of cylin der no 3 is on ignition TDC Refer to CYLINDER BLOCK section for crankshaft and the following for the camshaft locking Use camshaft locking tool P N 529 035 839 Rotate camshaft so that tool can be pushed in camshaft hole and lock c...

Page 82: ...ge 1 R1503motr92A 2 1 Rocker arm shaft screw 2 Torque angle gauge CAMSHAFT TIMING GEAR NOTE Although it is not necessary to position crankshaft to TDC for disassembly it is a good practice to do it as a troubleshooting step to know before disassembly if valve timing was ap propriate Removal Lock crankshaft with crankshaft locking tool P N 529 035 821 refer to CYLINDER BLOCK section Remove valve co...

Page 83: ...e the camshaft and crankshaft are locked in their proper position Due to some tolerances there could be one position which fits better than the other one To check this perform the following test Check if screws are still loose If screws are squeezed by the timing gear remove the chain tensioner again and rotate timing gear by one tooth clockwise Then install the chain tensioner again Tighten screw...

Page 84: ...se chain tensioner refer to CYLINDER BLOCK section valve cover shield see VALVE COVER RE MOVAL above camshaft timing gear cylinder head screws M6 no 16 1 R1503motr98A 1 Cylinder head screws M6 cylinder head screws M11 no 17 retaining cylinder head to cylinder block 1 R1503motr99A 1 Cylinder head screws M11 Pull up cylinder head no 18 Remove gasket no 19 Cleaning Remove carbon deposits from combust...

Page 85: ...e to replace screws and to strictly follow the torque procedure may cause screws to loosen and lead to engine damage CYLINDER SCREW M11 SERVICE LIMIT 148 5 mm 5 846 in smr2005 036 002_a NOTE Torque screws no 16 after the tightening of the cylinder head screws is finished Torque screws according to following sequence First torque to 40 N m 30 lbf in Then tighten screws turning an additional 120 ro ...

Page 86: ...AMSHAFT BEARING JOURNAL ENGINE FRONT NEW MINIMUM 24 939 mm 9818 in NEW MAXIMUM 24 960 mm 9826 in SERVICE LIMIT 24 910 mm 9807 in CAMSHAFT BORE MEASURED IN DIAMETER NEW MINIMUM 40 000 mm 1 5748 in NEW MAXIMUM 40 016 mm 1 5754 in SERVICE LIMIT 40 050 mm 1 5767 in CAMSHAFT BORE ENGINE FRONT MEASURED IN DIAMETER NEW MINIMUM 25 000 mm 9842 in NEW MAXIMUM 25 013 mm 9848 in SERVICE LIMIT 25 050 mm 9862 i...

Page 87: ...r cup R1503motr104A LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE Remove valve cotters no 24 Withdraw valve spring compressor valve spring retainer no 25 and valve springs 1 R1503motr105A 2 3 1 Valve spring retainer 2 Inner valve spring 3 Outer valve spring Inspection Check valve springs for rust corrosion or other vis ible damages If so replace faulty valve springs Check valve sprin...

Page 88: ... the removal procedure Pay attention to the following details Colored area of the valve spring must be placed on top NOTE Valve cotters must be properly engaged in valve stem grooves 1 R1503motr105B 1 Position of the valve spring VALVE Removal Remove valve spring Push valve stem then pull valves no 26 and no 27 out of valve guides R1503motr106A 1 2 1 Intake valve 38 mm 2 Exhaust valve 31 mm Remove...

Page 89: ...VE STEM DIAMETER NEW MINIMUM Exhaust 5 946 mm 2341 in Intake 5 961 mm 2347 in NEW MAXIMUM Exhaust 5 960 mm 2346 in Intake 5 975 mm 2352 in SERVICE LIMIT Exhaust Intake 5 93 mm 233 in Replace valve guide if it is out of specification or has other damages such as wear or friction sur face Refer to valve guide replacement below VALVE GUIDE DIAMETER NEW MINIMUM Exhaust Intake 5 994 mm 2359 in NEW MAXI...

Page 90: ...and exhaust valve guides have the same length and are interchangeable NOTE If valve guide has caused scoring during extraction replace the cylinder head Grease the bore in cylinder head and the lead ing end of valve guide with Molykote G N paste P N 413 703 700 3 R1503motr256A 1 2 TYPICAL 1 Valve guide leading end 2 Cylinder head bore 3 Jig With a suitable jig press the valve guide into the cold c...

Page 91: ...ylinder head if there are signs of damage Ensure to seat valves properly Apply some lap ping compound on valve face and work valve on its seat with a lapping tool Measure valve face contact width NOTE The location of contact area should be in center of valve seat Measure valve seat width using a caliper VALVE SEAT CONTACT WIDTH NEW Exhaust 1 25 to 1 55 mm 049 to 061 in Intake 1 10 to 1 30 mm 043 t...

Page 92: ...a smooth even uniform sealing surface of the appropriate in side and outside diameter is obtained on both the valve and the seat Use only a hand held valve grinding mandrel with a suction cup rotat ing the valve back and forth through about 45 and then advancing the valve 45 before repeat ing this operation Installation For installation reverse the removal procedure Pay attention to the following ...

Page 93: ...HEAD After spring is installed ensure it is properly locked by tapping on valve stem end with a soft hammer so that valve opens and closes a few times CAUTION An improperly locked valve spring will cause engine damage smr2005 036 87 www SeaDooManuals net ...

Page 94: ...rankshaft locking tool 529 035 821 100 104 107 112 handle 420 877 650 110 piston circlip installer 529 035 765 97 pusher 420 876 502 110 SERVICE PRODUCTS Description Part Number Page chisel gasket remover 413 708 500 111 Loctite 243 blue 293 800 060 111 Loctite 5910 293 800 081 111 SMR2005 037 89 www SeaDooManuals net ...

Page 95: ... 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Engine oil Engine oil 24 N m 18 lbf ft 24 N m 18 lbf ft 24 N m 18 lbf ft 10 N m 89 lbf in 24 N m 18 lbf ft 10 N m 89 lbf in 18 N m 159 lbf in 18 N m 159 lbf in 24 N m 18 lbf ft 24 N m 18 lbf ft 21 22 20 18 3 2 1 7 17 16 19 40 N m 30 lbf ft 55 N m 41 lbf ft Grease 90 SMR2005 037 www SeaDooManuals net ...

Page 96: ...1 13 5 14 15 15 6 4 4 Engine oil 45 N m 33 lbf ft 90 260 N m 191 lbf ft Loctite anti seize Engine oil Engine oil Engine oil Engine oil 6 Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil 23 SMR2005 037 91 www SeaDooManuals net ...

Page 97: ...HOP MANUAL engine from vehicle refer to the appropriate VE HICLE SHOP MANUAL cylinder head refer to CYLINDER HEAD sec tion PTO housing refer to PTO HOUSING MAGNE TO section crankshaft refer to CRANKSHAFT elsewhere in this section timing chain Installation The installation is essentially the reverse of the re moval procedure but pay attention to the follow ing details Ensure to perform proper valve...

Page 98: ...tr08A 1 Connecting rod screws NOTE Before removing the connecting rod caps mark them to remember the right position when reassembling Pull piston with connecting rod out of the cylin ders Remove one piston circlip no 8 and discard it 1 R610motr134A 1 Piston circlip NOTE The removal of both piston circlips is not necessary to remove piston pin Push piston pin no 9 out of piston 1 R1503motr27A 3 2 1...

Page 99: ...AMETER mm in NEW MINIMUM 23 01 9059 NEW MAXIMUM 23 02 9063 SERVICE LIMIT 23 07 908 PISTON PIN DIAMETER mm in NEW MINIMUM 22 996 9053 NEW MAXIMUM 23 000 9055 SERVICE LIMIT 22 990 904 PISTON PIN BORE CLEARANCE mm in SERVICE LIMIT 0 080 0035 If the connecting rod small end diameter is out of specification replace connecting rod Connecting Rod Big End Radial Play Measure inside diameter of connecting ...

Page 100: ...r measure piston at 18 mm 709 in perpendicularly 90 to piston pin axis 1 R610motr136A A 1 Measuring perpendicularly 90 to piston pin axis A 18 mm 709 in The measured dimension should be as described in the subsequent table If not replace piston PISTON MEASUREMENT mm in NEW NOMINAL 99 951 to 99 969 3 935 to 3 936 SERVICE LIMIT 99 80 3 929 Piston Cylinder Wall Clearance Adjust and lock a micrometer ...

Page 101: ...by an oversize one NOTE It is not necessary to have all pistons re placed with an oversize if they are not all out of specification Mixed standard size and oversize piston are allowed NOTE Make sure the cylinder bore gauge indica tor is set exactly at the same position as with the micrometer otherwise the reading will be false Piston Pin Using synthetic abrasive woven clean piston pin from deposit...

Page 102: ...ew piston circlips NOTE Take care that the hook of the piston circlip is positioned properly 1 R1503motr28A 2 1 Sleeve with piston circlip inside 2 Assembly jig from piston clip installer R610motr134B CORRECT POSITION OF THE PISTON CIRCLIP Using piston ring compressor pliers such as Snap On RC 980 slide piston into cylinder R1503motr29A CAUTION Install piston with punched arrow toward exhaust side...

Page 103: ...n gine damage Knowing that the screws have been stretched from the previous installation it is very important to use new screws at as sembly R1503motr31A 1 1 Angle torque wrench PISTON RINGS Removal Remove piston ass y as described above Remove rings Inspection Ring Piston Groove Clearance Using a feeler gauge measure each ring piston groove clearance If the clearance is too large the piston and t...

Page 104: ...l scraper ring first then the taper face ring with the word TO facing up then the rect angular ring with the word T facing up A31C2NA 1 2 3 1 Rectangular ring 2 Taper face ring 3 Oil scraper ring CAUTION Ensure that top and second rings are not interchanged NOTE Use a ring expander to prevent breakage during installation The oil ring must be installed by hand Check that rings rotate smoothly after...

Page 105: ... to OIL CHANGE in the appro priate VEHICLE SHOP MANUAL engine from vehicle refer to the appropriate VE HICLE SHOP MANUAL cylinder head refer to CYLINDER HEAD sec tion PTO housing refer to PTO HOUSING MAGNE TO section starter gear refer to PTO HOUSING MAGNETO section starter drive ass y oil suction pump with oil separator ass y refer to LUBRICATION section engine mounting brackets oil tank plug scr...

Page 106: ...ssembling It is recommended to measure connecting rod big end axial play prior to remove connecting rod Refer to PISTON CONNECTING ROD in this section for the procedure R1503motr07A 1 1 Mark on connecting rod thrust washers no 4 R1503motr09A 1 1 Thrust washer crankshaft no 5 1 R1503motr10A 1 Crankshaft Inspection Replace crankshaft if the gears are worn or other wise damaged SMR2005 037 101 www Se...

Page 107: ...RVICE LIMIT 49 95 1 9665 CRANKSHAFT JOURNAL RADIAL CLEARANCE mm in SERVICE LIMIT 0 07 0028 Crankshaft Pin Measure all crankshaft pin diameters Compare to inside diameter of connecting rod bearings else where in this section R1503motr14A 1 2 1 Micrometer 2 Crankshaft pin area for bearing CRANKSHAFT PIN DIAMETER mm in NEW MINIMUM 45 032 1 7729 NEW MAXIMUM 45 048 1 7735 SERVICE LIMIT 45 029 1 7728 CR...

Page 108: ... place CAUTION Crankshaft and balancer shaft marks have to be aligned R1503motr17A 1 2 1 Mark on balancer shaft 2 Mark on crankshaft For correct installation of the connecting rods re fer to PISTON CONNECTING ROD in this section CAUTION It is absolutely necessary to follow this procedure Otherwise severe engine dam age can occur CAUTION Never forget thrust washers no 4 on center of crankshaft to c...

Page 109: ... to position crank shaft at TDC before installing the camshaft and rockers refer to CYLINDER HEAD 529035821 1 R1503motr18A 1 Crankshaft locking tool BALANCER SHAFT Removal Remove engine oil refer to OIL CHANGE in the appro priate VEHICLE SHOP MANUAL engine from vehicle refer to the appropriate VE HICLE SHOP MANUAL cylinder head refer to CYLINDER HEAD sec tion PTO housing refer to PTO HOUSING MAGNE...

Page 110: ...tion Check balancer shaft and replace if damaged If the gear on the balancer shaft is damaged re place balancer shaft Check gear on the crankshaft at the same time and replace crankshaft if necessary refer to CRANK SHAFT above Balancer Shaft Bearing Seat Play Measure all balancer shaft bearing seats Com pare to inside diameter of balancer shaft bearings elsewhere in this section 1 R1503motr23A 2 1...

Page 111: ...UM 0 02 001 NEW MAXIMUM 0 25 010 SERVICE LIMIT 0 35 014 Installation For installation reverse the removal procedure Pay attention to following detail CAUTION Balancer shaft and crankshaft marks have to be aligned R1503motr17A 1 2 1 Mark on balancer shaft 2 Mark on crankshaft CAUTION Never forget thrust washers no 6 on PTO side to control axial adjustment on bal ancer Insert thrust washers as soon ...

Page 112: ...ckers refer to CYLINDER HEAD 529035821 1 R1503motr18A 1 Crankshaft locking tool CYLINDER BLOCK Disassembly Remove engine oil refer to OIL CHANGE in the appro priate VEHICLE SHOP MANUAL engine from vehicle refer to the appropriate VE HICLE SHOP MANUAL cylinder head refer to CYLINDER HEAD sec tion PTO housing refer to PTO HOUSING MAGNE TO section starter gear refer to PTO HOUSING MAGNETO section sta...

Page 113: ...0ZA Close puller claws so that they can be inserted in end bearing Holding claws turn puller shaft clockwise so that claws open and become firmly tight against bearing Slide puller hammer outwards and tap puller end Retighten claws as necessary to always maintain them tight against bearing Continue this way un til bearing completely comes out Inspection Cylinder Check cylinder for cracks scoring a...

Page 114: ...irst one and compare NOTE Take the same measuring points as de scribed in CYLINDER TAPER above A R1503motr25A B A Perpendicular to crankshaft axis B Parallel to crankshaft axis CYLINDER OUT OF ROUND mm in NEW MAXIMUM 0 008 0003 SERVICE LIMIT 0 015 0006 Bearings To measure the wear of the crankshaft bearings no 13 and no 14 and balancer shaft bearings no 15 both cylinder block halves with OLD bear ...

Page 115: ... following details Torque oil spray nozzle to 18 N m 160 lbf in To install starter drive bearing no 21 of starter drive assembly use pusher P N 420 876 502 and handle P N 420 877 650 420876502 420877650 Use NEW bearings when diameters are out of specification If OLD bearings can be used again make sure they are at the same position as they were before Correctly install bearings Top crankshaft bear...

Page 116: ...ly 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 uniformly dis tribute this sealant Use the silicone based Loctite 5910 P N 293 800 081 on mating surfaces CAUTION Do not use other products to seal crankcase Do not use an activator with the Loctite 5910 Using other products or non sil icone based s...

Page 117: ... cover before mounting the engine bracket Apply oil on O ring and press cov er in Crankshaft cover has to be flush with cylin der block surface 1 R1503motr19A 2 1 O ring 2 Crankshaft cover CAUTION Install crankshaft locking tool P N 529 035 821 right away to position crank shaft at TDC before installing the camshaft and rockers refer to CYLINDER HEAD 529035821 1 R1503motr18A 1 Crankshaft locking t...

Page 118: ...led oil cooler Lubrication Oil type 10W40 4 stroke oil API service classification SL SJ or SH XP S 10W40 or an approved equivalent Intake valve opening 10 BTDC Intake valve closing 45 ABDC Exhaust valve opening 50 BBDC Exhaust valve closing 5 ATDC 0 ATDC Minimum new 5 961 mm 2347 in Maximum new 5 975 mm 2352 in Intake Wear limit 5 930 mm 2330 in Minimum new 5 946 mm 2341 in Maximum new 5 960 mm 23...

Page 119: ... 04 in Rectangular 0 02 mm 0008 in Taper face 0 015 mm 0006 in Oil scraper ring Minimum new 0 02 mm 0008 in Rectangular 0 07 mm 0028 in Taper face 0 06 mm 0024 in Oil scraper ring Maximum new 0 055 mm 0021 in Ring piston groove clearance All Wear limit 0 15 mm 006 in Minimum new 0 024 0 056 mm 001 0022 in 0 04 mm 001 in Piston cylinder wall clearance Wear limit 0 1 mm 0039 in Cylinder taper maximu...

Page 120: ... 007 mm 0028 in Connecting rod big end diameter Service limit 45 080 mm 1 7740 in Connecting rod big end clearance Service limit 0 065 mm 0026 in Minimum new 0 135 mm 0053 in Maximum new 0 287 mm 0113 in Connecting rod big end axial play Wear limit 0 500 mm 0197 in Crankshaft deflection Maximum 0 050 mm 002 in Minimum new 23 010 mm 9059 in Maximum new 23 020 mm 9063 in Connecting rod small end dia...

Page 121: ...hickness Wear limit Not applicable 6 600 mm 2598 in ELECTRICAL NATURALLY ASPIRATED SUPERCHARGED Magneto generator output 360 W 6000 RPM Ignition system type DI Digital Induction Ignition timing Not adjustable Make and type NGK DCPR8E Spark plug Gap 0 7 0 8 mm 030 in Engine RPM limiter setting 7650 RPM SC engine 7650 RPM SC IC engine 8000 RPM COOLING NATURALLY ASPIRATED SUPERCHARGED Type Liquid coo...

Page 122: ...NOTES www SeaDooManuals net ...

Page 123: ...NOTES www SeaDooManuals net ...

Page 124: ...C M Y CM MY CY CMY K www SeaDooManuals net ...

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SeaDoo Rotax 1503 4-Tec 2005, Engine Shop Manual

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