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

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Section 01 ENGINES (1503 4-TEC)Subsection 06 (CYLINDER HEAD)Grease the bore in cylinder head and the leadingend of valve guide with Molykote G-N paste(P/N 413 703 700).13212R1503motr258ATYPICAL1. Special reamer2. NotchChase valve guide out of the cylinder head towardscombustion chamber by using a suitablepunch.R1503motr256ATYPICAL1. Valve guide leading end2. Cylinder head bore3. JigWith a suitable jig press the valve guide into thecold cylinder head as shown.1R1503motr255ATYPICAL1. PunchCheck valve guide bore for abreased material.The inlet and exhaust valve guides have the samelength and are interchangeable.NOTE: If valve guide has caused scoring duringextraction, replace the cylinder head.AR1503motr257ATYPICALA. Protrusion84 smr2005-036
Section 01 ENGINES (1503 4-TEC)Subsection 06 (CYLINDER HEAD)VALVE GUIDE PROTRUSIONVALVE SEAT CONTACT WIDTHMINIMUM12.4 mm (.4882 in)NEWMAXIMUM12.8 mm (.5039 in)NOTE: For lubrication of the reamer use only cuttingoil. Turn the reamer only forward, in cuttingdirection, never backward. Clean the reamer atshort intervals from swarf, moving the reamer onlywhile turning in cutting direction.Ream the new valve guide with a reamer 6 mmdiameter.Clean cylinder head carefully. Check that the valveseat is concentric with the new guide axis (checkcontact surface with engineer's blue).ExhaustIntakeExhaustIntakeSERVICE LIMIT1.25 to 1.55 mm(.049 to.061 in)1.10 to 1.30 mm(.043 to.051 in)2mm(.078in)1.8 mm (.07 in)If valve seat contact width is too wide or has darkspots, replace the cylinder head.ValveFaceandSeat23ABV01C1HAR1503motr107A11. Valve seat2. Exhaust valve contaminated area3. Valve face (contact surface to valve seat)Check valve face and seat for burning or pittingsand replace valve or cylinder head if there are signsof damage.Ensure to seat valves properly. Apply some lappingcompound on valve face and work valve onits seat with a lapping tool.Measure valve face contact width.NOTE: The location of contact area should be incenter of valve seat.Measure valve seat width, using a caliper.A. Valve face contact widthB. Valve seat contact widthValve Seat GrindingNOTE: The valve seats may be reground witha valve seat grinder which centers on the valveguide.– Grind the valve seat at 45°. Remove no morematerial than absolutely necessary to clean theseat up.– Using a 35° stone, narrow the valve seat untilthe appropriate outer diameter is obtained.smr2005-036 85
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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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