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

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Section 01 ENGINES (1503 4-TEC)Subsection 01 (LEAK TEST)21ENGINETOOL1503 4-TECNaturally Aspirated1503 4-TECSuperchargedDrive shaft adapter(P/N 529 035 892)1503 4-TECSuperchargedIntercooledDrive shaft adapter(P/N 529 035 985)R1503motr154A1. Ignition coil2. Spark plug– Remove valve cover cowl.– Unscrew and remove valve cover.21529035892DRIVE SHAFT ADAPTERR1503motr155ARotate engine counterclockwise until the cylinderno. 1 is at Top Dead Center (TDC) compressionstroke.NOTE: Cylinder numbers are molded on valve cover.As the engine is turned over, observe the movementof intake rocker arm of the cylinder to bechecked. After it completes the cycle and the intakevalve closes, observe the piston. When itreaches its uppermost position that is TDC compressionstroke.1. Valve cover2. Valve cover screwPROCEDUREThe following procedure has to be performed foreach cylinder separately.With an appropriate wrench lever, engine is rotatedusing the drive shaft adapter. Refer to the followingtable.2 SMR2005-032
Section 01 ENGINES (1503 4-TEC)Subsection 01 (LEAK TEST)1Note the amount of leaking or percentage (dependingon tester).LEAKAGEPERCENTAGEENGINECONDITION0% to 15% Excellent condition.16% to 25% Good condition26% to 40%41% and higherFair condition; engine will runand performance might bedown in some cases.Poor condition, diagnose andrepair engine.R1503motr156A1. Intake rocker armsProtect the hull area then position the wrenchlever so that it rest against hull to prevent furthercrankshaft rotation.Install gauge adapter into previously cleaned sparkplug hole.Connect to adequate air supply.NOTE: Each tester will have specific instructionon the gauge operation and required pressure.Set needle of measuring gauge to zero.Supply combustion chamber with air.Proceed the same way with remaining cylinders.DIAGNOSISPressurize area to be tested, spray soap/water solutionat the indicated location and look and/or listenfor air bubbles.– air escaping on intake port means leaking intakevalve(s)– air escaping on exhaust port means leaking exhaustvalve(s)– air bubbles out of coolant tank means leakingcylinder head gasket– air escaping into crankcase area means excessivelyworn and/or broken piston rings.3R1503motr157A1. Measuring gauge2. Adequate adapter for spark plug hole3. Air supply12POSSIBLE ENGINE LEAKAGEAREASpray soap/water solution at the indicated locationand look and/or listen for air bubbles.Paying attention to the following checkpoints:– clamp(s) tightened– coolant hoses– air/oil escaping from crankcase means damagedgasket(s) and/or loosened screws (referto ENGINE BLOCK)– air/water escaping from cylinder/head meansdamaged gasket(s) and/or loosened screws (referto CYLINDER HEAD)– oilycontaminationonweephole(speedsensorarea) means a damaged oil seal on coolantpump shaftSMR2005-032 3
Page 2 and 3: 2005Engine Shop ManualROTAX ® 1503
Page 4 and 5: TABLE OF CONTENTSSAFETY NOTICE.....
Page 6 and 7: SAFETY NOTICESAFETY NOTICEThis manu
Page 8 and 9: INTRODUCTIONARRANGEMENT OF THISMANU
Page 10 and 11: INTRODUCTIONTYPICAL PAGESub-title w
Page 14 and 15: Section 01 ENGINES (1503 4-TEC)Subs
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