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

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TABLE OF CONTENTSSAFETY NOTICE....................................................................................IIIINTRODUCTION ................................................................................... IVGENERAL INFORMATION.......................................................................................... IVENGINE EMISSIONS INFORMATION ............................................................................ IVENGINE IDENTIFICATION NUMBER (E.I.N.) .................................................................... IVTIGHTENING TORQUES ........................................................................................... IVARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES ............................. V01 ENGINES (<strong>1503</strong> 4-TEC)01 – LEAK TEST ...................................................................................................... 1PROCEDURES .................................................................................................. 1PREPARATION ........................................................................................................ 1PROCEDURE .......................................................................................................... 2DIAGNOSIS............................................................................................................ 3POSSIBLE ENGINE LEAKAGE AREA................................................................................ 3ASSEMBLY ............................................................................................................ 402 – INTAKE MANIFOLD AND SUPERCHARGER............................................................... 5INSPECTION (PARTS ASSEMBLED)................................................................................ 10REMOVAL ............................................................................................................ 12DISASSEMBLY ....................................................................................................... 17INSPECTION (PARTS DISASSEMBLED) ........................................................................... 20ASSEMBLY ........................................................................................................... 21INSTALLATION ....................................................................................................... 2603 – PTO HOUSING AND MAGNETO .......................................................................... 29GENERAL...................................................................................................... 31PROCEDURES ................................................................................................ 31PTO HOUSING ....................................................................................................... 31PTO SEAL............................................................................................................. 34COUPLING............................................................................................................ 35STATOR............................................................................................................... 35ROTOR AND TRIGGER WHEEL .................................................................................... 36RING GEAR........................................................................................................... 37STARTER DRIVE ASS'Y.............................................................................................. 38OIL SPRAY NOZZLE ................................................................................................. 3904 – LUBRICATION SYSTEM..................................................................................... 41GENERAL...................................................................................................... 45PROCEDURES ................................................................................................ 45ENGINE OIL PRESSURE............................................................................................. 45PTO OIL STRAINER.................................................................................................. 46SUCTION PUMP OIL STRAINER.................................................................................... 47ENGINE OIL PRESSURE REGULATOR............................................................................. 49OIL PRESSURE PUMP............................................................................................... 51OIL SUCTION PUMP................................................................................................. 54OIL SEPARATOR COVER............................................................................................ 57TOPS VALVE.......................................................................................................... 58OIL COOLER ......................................................................................................... 5805 – COOLING SYSTEM .......................................................................................... 61GENERAL...................................................................................................... 63PROCEDURES ................................................................................................ 63COOLANT PUMP .................................................................................................... 63COOLANT PUMP IMPELLER ....................................................................................... 64I
TABLE OF CONTENTSTHERMOSTAT........................................................................................................ 65ROTARY SEAL........................................................................................................ 6506 – CYLINDER HEAD............................................................................................. 69GENERAL...................................................................................................... 71PROCEDURES ................................................................................................ 71SPARK PLUG ......................................................................................................... 71EXHAUST MANIFOLD............................................................................................... 71VALVE COVER........................................................................................................ 72ROCKER ARM........................................................................................................ 73CAMSHAFT TIMING GEAR.......................................................................................... 76TIMING CHAIN....................................................................................................... 77CYLINDER HEAD..................................................................................................... 78CAMSHAFT........................................................................................................... 79VALVE SPRING ....................................................................................................... 80VALVE ................................................................................................................. 8207 – CYLINDER BLOCK............................................................................................ 89GENERAL...................................................................................................... 92PROCEDURES ................................................................................................ 92TIMING CHAIN....................................................................................................... 92CHAIN TENSIONER.................................................................................................. 92PISTON/CONNECTING ROD........................................................................................ 93PISTON RINGS ....................................................................................................... 98CRANKSHAFT ........................................................................................................ 99BALANCER SHAFT................................................................................................. 104CYLINDER BLOCK................................................................................................. 10708 – TECHNICAL SPECIFICATIONS ............................................................................ 113II
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Page 8 and 9: INTRODUCTIONARRANGEMENT OF THISMANU
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