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

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Section 01 ENGINES (1503 4-TEC)Subsection 07 (CYLINDER BLOCK)1R1503motr41A 21. Dial gauge2. CrankshaftCRANKSHAFT AXIAL CLEARANCE mm (in)NEW MINIMUM 0.08 (.003)NEW MAXIMUM 0.22 (.009)SERVICE LIMIT 0.35 (.014)InstallationFor installation, reverse the removal procedure.Pay attention to following details.NOTE: Before installing the crankshaft, makesure that the timing chain is on the crankshaft andthe chain guide has been installed first. Thoseparts cannot be installed when the crankshaft isin place.CAUTION: Crankshaft and balancer shaftmarks have to be aligned.R1503motr17A 1 21. Mark on balancer shaft2. Mark on crankshaftFor correct installation of the connecting rods, referto PISTON/CONNECTING ROD in this section.CAUTION: It is absolutely necessary to followthis procedure. Otherwise severe engine damagecan occur.CAUTION: Never forget thrust washers no. 4on center of crankshaft to control axial adjustment.Insert thrust washers as soon as crankshaft is inplace as per following illustration.1R1503motr09ATHRUST WASHER INSERT DIRECTION1. Thrust washerCAUTION: Thrust washers have to be flushwith the cylinder block sealing surface.SMR2005-037 103
Section 01 ENGINES (1503 4-TEC)Subsection 07 (CYLINDER BLOCK)152903582121R1503motr16A1. Thrust washer2. Sealing surfaceInstall cylinder block lower half. Refer to CYLIN-DER BLOCK in this section.Install the crankshaft cover before mounting theengine bracket. Apply oil on O-ring and press coverin. Crankshaft cover has to be flush with cylinderblock surface.1R1503motr19A 21. O-ring2. Crankshaft coverCAUTION: Install crankshaft locking tool(P/N 529 035 821) right away to position crankshaftat TDC before installing the camshaft androckers (refer to CYLINDER HEAD).R1503motr18A1. Crankshaft locking toolBALANCER SHAFTRemovalRemove:– engine oil (refer to OIL CHANGE in the appropriateVEHICLE SHOP MANUAL)– engine from vehicle (refer to the appropriate VE-HICLE SHOP MANUAL)– cylinder head (refer to CYLINDER HEAD section)– PTO housing (refer to PTO HOUSING/MAGNE-TO section)– starter gear (refer to PTO HOUSING/MAGNETOsection)– starter drive ass'y– oil suction pump with oil separator ass'y (referto LUBRICATION section)– engine mounting brackets– oil reservoir plug screws no. 1 with O-ring no. 2104 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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INTRODUCTIONTYPICAL PAGESub-title w
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