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

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Section 01 ENGINES (1503 4-TEC)Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)1Remove ball bearing from supercharger housinghalf (engine side) by using a press and a suitablebearing pusher.21R1503motr236AF00B2DA 2 31. Supercharger shaft2. Ball bearing3. Retaining keyScrew out retaining disc with seal from housinghalf (engine side) by using the 4-pin socket(P/N 529 035 948).1. Supercharger housing half (engine side)2. Bearing pusherINSPECTION (PARTSDISASSEMBLED)Supercharged Clutch Componentsand GearReplace worn parts by new ones. A clutch repairkit is available. If all parts are within specifications,replace the 40 needle bearings and spring washerpackage on supercharger shaft.NOTE: Ceramic washers are not affected by wear.Check the wear limit on drive gear, lock washerand driven plate on supercharger shaft. Checkdrive gear for cracks.529035948NOTE: It may be necessary to heat the housingwith a heat gun to release the retaining disc.ABCR1503motr360AA. Driven plate thicknessB. Drive gear thicknessC. Lock washer thicknessF00B2AA 11. 4-pin socket20 SMR2005-033
Section 01 ENGINES (1503 4-TEC)Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)DRIVEN PLATE JOURNAL DEPTHNEW MINIMUM 9.960 mm (.3921 in)NEW MAXIMUM 10.000 mm (.3937 in)SERVICE LIMIT 10.3000 mm (.4055 in)DRIVE GEAR THICKNESSNEW MINIMUM 11.000 mm (.4331 in)NEW MAXIMUM 11.050 mm (.4350 in)Intake Manifold and IntercoolerSupercharged Intercooled EngineEnsure O-rings are properly installed on intercoolerand apply 4-stroke oil on them to ease installation.While properly aligning the inner end of intercoolerin intake manifold, gently push intercooler until itbottoms.Rotate intercooler to position nipples as shown.SERVICE LIMIT10.500 mm (.4134 in)1LOCK WASHER THICKNESS2NEW MINIMUMNEW MAXIMUMSERVICE LIMIT6.900 mm (.2717 in)7.100 mm (.2795 in)6.600 mm (.2598 in)Spring WasherPut spring washer package together as it is assembledon the supercharger shaft. Measure theheight of the unloaded spring washer package.F19D0EA1. Intake manifold flange2. Nipple parallel with manifold flangeNOTE: Ifintercoolerishardtopushin,aclampcanbe used to press intercooler in.13R1503motr248AAA. Spring washer package heightSPRING WASHER PACKAGE HEIGHTNEWSERVICE LIMIT10.500 mm (.4134 in)9.700 mm (.3819 in)F19D0FA2ASSEMBLYAssembly is essentially the reverse of removalprocedures. However pay particular attention tothe following.1. Clamp2. Plastic block between nipples3. Plastic blockReinstall collar.The distance between engine block and intercooleroutlet hose must be 3 - 7 mm (0.12 - 0.27 in) otherwisethe hose would scuff on the engine block.SMR2005-033 21
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 12 and 13: Section 01 ENGINES (1503 4-TEC)Subs
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