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

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Section 01 ENGINES (1503 4-TEC)Subsection 06 (CYLINDER HEAD)2112R1503motr91A1. Rocker arm shaft2. Rocker arm shaft notchesInstall NEW rocker arm shaft screws no. 8.Torque as per following procedure:CAUTION: This assembly uses stretch screws.As the screws have been stretched from theprevious installation, it is very important to usenew screws at assembly. Failure to replacescrews and to strictly follow the torque proceduremay cause screws to loosen and lead toengine damage.– Torque screws at first to 10 N•m (89lbf•in)according to following sequence.6R1503motr93A521 3 4– Torquescrewsto20N•m (177 lbf•in).– Finish tightening screws turning an additional90° rotation with a torque angle gauge.R1503motr92A1. Rocker arm shaft screw2. Torque angle gaugeCAMSHAFT TIMING GEARNOTE: Although it is not necessary to positioncrankshaft to TDC for disassembly, it is a goodpractice to do it, as a troubleshooting step, toknow before disassembly if valve timing was appropriate.RemovalLock crankshaft with crankshaft locking tool(P/N 529 035 821), refer to CYLINDER BLOCKsection.Remove:– valve cover (refer to CYLINDER BLOCK section)– chain guide no. 12– Allen screws no. 13– camshaft timing gear no. 14.NOTE: Secure timing chain no. 15 with a retainingwire.InspectionCheck camshaft timing gear for wear or deterioration.If gear is worn or damaged, replace it as a set(camshaft timing gear and timing chain).For crankshaft timing gear, refer to CYLINDERBLOCK section.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.76 smr2005-036
Section 01 ENGINES (1503 4-TEC)Subsection 06 (CYLINDER HEAD)Using the camshaft locking tool (P/N 529 035 839),lock camshaft on TDC position.5290358392R1503motr94A11. Camshaft locking tool2. Camshaft on TDC positionInstall the camshaft timing gear with the writingvisible, i.e. to be able to see the position lineswhen looking from outside of engine.Ensure chain guides are in place.Loosely install screws.Install chain tensioner.NOTE: There can be 2 different positions to installthe timing gear on the camshaft. Basically bothpositions are working well, since the camshaft andcrankshaft are locked in their proper position. Dueto some tolerances, there could be one positionwhich fits better than the other one. To check this,perform the following test.Check if screws are still loose. If screws aresqueezed by the timing gear, remove the chaintensioner again and rotate timing gear by onetooth clockwise. Then install the chain tensioneragain.Tighten screws and torque to 10 N•m (89lbf•in).Remove locking tools.CAUTION: Crankshaft and camshaft must belockedonTDCpositiontoplacecamshafttiminggear and timing chain in the proper position.To double check, take a look at the timinggear lines. They must be parallel to the cylinderhead surface.1112R1503motr95A1. Position linesCAUTION: Ensure to remove locking toolswhen finished.R1503motr97A1. Good (with 1503 aligned)2. NeverTIMING CHAINRefer to CYLINDER BLOCK section.Install timing chain. Refer to CYLINDER BLOCKsection.smr2005-036 77
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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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