engine, rotax 1503 4-tec - Sea-Doo.net

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Section 01 ENGINES (<strong>1503</strong> 4-TEC)Subsection 07 (CYLINDER BLOCK)AAR610motr136A1R610motr76AA. Connecting rod big end bearingCONNECTING ROD BIG END DIAMETER mm (in)SERVICE LIMIT 45.080 (1.774)CONNECTING ROD BIG ENDCLEARANCE mm (in)SERVICE LIMIT 0.09 (.0035)Use NEW bearings no. 12, when connecting rodbig end diameter is out of specification.PistonInspect piston for scoring, cracking or other damages.Replace piston and piston rings if necessary.Using a micrometer, measure piston at 18 mm(.709 in) perpendicularly (90°) to piston pin axis.1. Measuring perpendicularly (90°) to piston pin axisA. 18 mm (.709 in)The measured dimension should be as describedin the subsequent table. If not, replace piston.PISTON MEASUREMENT mm (in)NEW NOMINAL99.951 to 99.969(3.935 to 3.936)SERVICE LIMIT 99.80 (3.929)Piston/Cylinder Wall ClearanceAdjust and lock a micrometer to the piston dimension.1F00B08A1. Micrometer set to the piston dimensionWith the micrometer set to the dimension, adjusta cylinder bore gauge to the micrometer dimensionand set the indicator to 0 (zero).SMR2005-037 95
Section 01 ENGINES (<strong>1503</strong> 4-TEC)Subsection 07 (CYLINDER BLOCK)F00B09A21. Use the micrometer to set the cylinder bore gauge2. Dial bore gauge1If clearance exceeds specified tolerance, rehonecylinder sleeve and replace piston ass'y by anoversize one.NOTE: It is not necessary to have all pistons replacedwith an oversize if they are not all out ofspecification. Mixed standard size and oversizepiston are allowed.NOTE: Make sure the cylinder bore gauge indicatoris set exactly at the same position as with themicrometer, otherwise the reading will be false.Piston PinUsing synthetic abrasive woven, clean piston pinfrom deposits.Inspect piston pin for scoring, cracking or otherdamages.Measure piston pin. See the following illustrationfor the proper measurement positions.Piston Pin/Connecting Rod Bearing ClearanceMeasure inside diameter of connecting rod.1CONNECTING ROD SMALL ENDDIAMETER mm (in)NEW MINIMUM 23.01 (.9059)NEW MAXIMUM 23.02 (.9063)SERVICE LIMIT 23.07 (.908)F00B0AATYPICAL1. Indicator set to 0 (zero)Position the dial bore gauge 62 mm (2.44 in) abovecylinder base, measuring perpendicularly (90°) topiston pin axis.Read the measurement on the cylinder boregauge. The result is the exact piston/cylinder wallclearance.PISTON/CYLINDER CLEARANCE mm (in)NEW NOMINAL0.024 to 0.056(.0009 to.0022)SERVICE LIMIT 0.090 (.004)NOTE: Make sure used piston is not worn.21R610motr73A1. Bore gauge2. Connecting rod96 SMR2005-037
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2005Engine Shop ManualROTAX ® 1503
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TABLE OF CONTENTSSAFETY NOTICE.....
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SAFETY NOTICESAFETY NOTICEThis manu
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INTRODUCTIONARRANGEMENT OF THISMANU
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