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

Section 01 ENGINES (1503 4-TEC)Subsection 06 (CYLINDER HEAD)InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Ensure dowel pins are in place.Install new cylinder head gasket.CAUTION: Each installation of the cylinderhead requires a new cylinder head gasket. Usinga gasket twice will cause engine damage,even if the engine had not run.Install cylinder screws M11 no. 17. Torquescrews as per following procedure.CAUTION: This assembly uses stretch screws.As the screws have been stretched from theprevious installation, it is very important tomeasure each screw at assembly. If screw isout of specification, replace by a new. Failureto replace screws and to strictly follow thetorque procedure may cause screws to loosenand lead to engine damage.SERVICE LIMITCYLINDER SCREW M11148.5 mm (5.846 in)R1503motr100A21. Cylinder screws M112. Angle torque wrenchRemove crankshaft locking tool then install plugwith sealing ring.CAMSHAFTRemovalRemove:– valve cover– rocker arms– chain tensioner (refer to CYLINDER BLOCKsection)– camshaft timing gear– camshaft lock no. 20– camshaft no. 21.112smr2005-036-002_aNOTE: Torque screws no. 16 after the tighteningof the cylinder head screws is finished.Torque screws according to following sequence.First torque to 40 N•m (30lbf•in).Then tighten screws turning an additional 120° rotationwith a torque angle gauge and finish tighteningwith a 90° rotation. Torque screws no. 16to 10 N•m (89lbf•in).R1503motr101A1. Camshaft lock2. Camshaftsmr2005-036 79