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

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Section 01 ENGINES (1503 4-TEC)Subsection 06 (CYLINDER HEAD)InspectionSpark Plug TubeCheck seals on spark plug tube. If seals are brittle,cracked or hard, replace spark plug tube.R1503motr88A 2A1smr2005-036-001_a1. Spark plug tube2. Seal to the valve cover3. Seal to the cylinder headRocker ArmInspect each rocker arm for cracks and scored frictionsurfaces. If so, replace rocker arm assembly.Check the rocker arm rollers for free movement,wear and excessive radial play. Replace rockerarm assembly as necessary.1. Rocker arm (exhaust side)2. RollerA. Bore for rocker arm shaftMeasure rocker arm bore diameter. If diameter isout of specification, change the rocker arm assembly.ROCKER ARM BORE DIAMETERNEW MINIMUMNEW MAXIMUMSERVICE LIMIT20.007 mm (.7877 in)20.020 mm (.7881 in)20.035 mm (.7887 in)Press the hydraulic lifter with your thumb. If thehydraulic lifter groove disappears inside rockerarm casting, replace rocker arm assembly. Liftermust turn freely in rocker arm bore. Otherwise,replace.AR1503motr87A121. Rocker arm (intake side)2. RollerA. Bore for rocker arm shaft1R1503motr89A1. Hydraulic lifter grooveRocker Arm ShaftCheck for scored friction surfaces, if so, replaceparts.74 smr2005-036
Section 01 ENGINES (1503 4-TEC)Subsection 06 (CYLINDER HEAD)Measure rocker arm shaft diameter.ROCKER ARM SHAFT DIAMETER1NEW MINIMUMNEW MAXIMUMSERVICE LIMIT19.980 mm (.7866 in)19.993 mm (.7871 in)19.965 mm (.7860 in)R1503motr90AAR1503motr111A1. Camshaft locking toolA. Measure rocker arm shaft diameter hereAny area worn excessively will require parts replacement.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Apply engine oil on rocker arm shaft.IMPORTANT: The rocker arm shaft can only be installedin one specific position. Therefore crankshaftas well as camshaft has to be positionedwith their locking pins when the piston of cylinderno. 3 is on ignition TDC. Refer to CYLINDERBLOCK section for crankshaft and the followingfor the camshaft locking.Use camshaft locking tool (P/N 529 035 839).Rotate camshaft so that tool can be pushed incamshaft hole and lock camshaft in place.Then, the camshaft sprocket lines should be linedup as shown in the following illustration.R1503motr95A1. Position lines1Position the rocker arm shaft with the notches ontop.1529035839smr2005-036 75
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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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