Rotax 2005 717 RFI User manual

C M Y CM MY CY CMY K
www.SeaDooManuals.net

2005
Engine Shop Manual
ROTAX®
717 and 787 RFI™
ENGINES
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Legal deposit:
National Library of Quebec
National Library of Canada 2005
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP).
©Bombardier Recreational Products Inc. (BRP) 2005
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Québec) Canada
PrintedinCanada
®™ Registered trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
* Trademark of Bombardier Inc. used under license.
BOMBARDIER LUBE®
RFI™
Rotax®
SEA-DOO®
Sea-Doo Synthetic Grease
TOPS™
This document contains the trademarks of the following companies:
Loctite®is a trademark of Loctite Corporation
Molykote©is a trademark of Dow Corning Corporation
Snap-on®is a trademark of Snap-on Tools Corporation
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TABLE OF CONTENTS
SAFETY NOTICE .................................................................................... III
INTRODUCTION ................................................................................... IV
GENERAL INFORMATION.......................................................................................... IV
ENGINE IDENTIFICATION NUMBER (E.I.N.) .................................................................... IV
ENGINE EMISSIONS INFORMATION ............................................................................ IV
TIGHTENING TORQUES ........................................................................................... IV
ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES ............................. V
01 ENGINE MEASUREMENT
01 –MEASUREMENT PROCEDURES............................................................................. 1
CYLINDER HEAD WARPAGE ........................................................................................ 1
CYLINDER TAPER..................................................................................................... 1
CYLINDER OUT OF ROUND ......................................................................................... 1
COMBUSTION CHAMBER VOLUME MEASUREMENT........................................................... 1
PISTON/CYLINDER WALL CLEARANCE . ............. .............................................................. 2
RING/PISTON GROOVE CLEARANCE............................................................................... 4
RING END GAP........................................................................................................ 5
CRANKSHAFT (ASSEMBLED ENGINE) ............................................................................. 5
CRANKSHAFT (DISASSEMBLED ENGINE) ......................................................................... 6
ROTARY VALVE........................................................................................................ 8
02 717 ENGINE
01 –LEAK TEST .................................................................................................... 11
GENERAL............................................................................................................. 11
PREPARATION ....................................................................................................... 11
TESTING PROCEDURE.............................................................................................. 11
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART.................................................................. 15
02 –MAGNETO SYSTEM......................................................................................... 17
DISASSEMBLY ....................................................................................................... 19
CLEANING............................................................................................................ 21
ASSEMBLY ........................................................................................................... 22
03 –TOP END....................................................................................................... 25
GENERAL............................................................................................................. 27
DISASSEMBLY ....................................................................................................... 27
CLEANING............................................................................................................ 29
INSPECTION.......................................................................................................... 30
ASSEMBLY ........................................................................................................... 30
04 –BOTTOM END ................................................................................................ 37
GENERAL............................................................................................................. 39
DISASSEMBLY ....................................................................................................... 39
CLEANING............................................................................................................ 41
INSPECTION.......................................................................................................... 42
ASSEMBLY ........................................................................................................... 43
05 –ROTARY VALVE .............................................................................................. 47
GENERAL............................................................................................................. 49
INSPECTION (ASSEMBLED ENGINE) .............................................................................. 49
DISASSEMBLY ....................................................................................................... 49
CLEANING............................................................................................................ 51
INSPECTION (DISASSEMBLED ENGINE).......................................................................... 51
ASSEMBLY ........................................................................................................... 51
ROTARY VALVE TIMING............................................................................................. 55
I
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TABLE OF CONTENTS
06 –TECHNICAL SPECIFICATIONS ............................................................................. 57
03 787 RFI ENGINE
01 –LEAK TEST .................................................................................................... 59
GENERAL............................................................................................................. 59
TESTING PROCEDURE.............................................................................................. 59
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART.................................................................. 63
02 –MAGNETO SYSTEM......................................................................................... 65
DISASSEMBLY ....................................................................................................... 67
CLEANING............................................................................................................ 68
ASSEMBLY ........................................................................................................... 69
03 –TOP END....................................................................................................... 71
GENERAL............................................................................................................. 73
DISASSEMBLY ....................................................................................................... 74
CLEANING............................................................................................................ 79
INSPECTION.......................................................................................................... 80
ASSEMBLY ........................................................................................................... 80
ADJUSTMENT........................................................................................................ 86
04 –BOTTOM END ................................................................................................ 87
GENERAL............................................................................................................. 89
DISASSEMBLY ....................................................................................................... 89
CLEANING............................................................................................................ 93
INSPECTION.......................................................................................................... 94
ASSEMBLY ........................................................................................................... 94
05 –ROTARY VALVE ............................................................................................. 101
GENERAL........................................................................................................... 103
INSPECTION (ASSEMBLED ENGINE) ............................................................................ 103
DISASSEMBLY ..................................................................................................... 103
CLEANING.......................................................................................................... 105
INSPECTION (DISASSEMBLED ENGINE)........................................................................ 105
ASSEMBLY ......................................................................................................... 105
ROTARY VALVE TIMING........................................................................................... 109
06 –TECHNICAL SPECIFICATIONS ............................................................................ 111
II
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SAFETY NOTICE
SAFETY NOTICE
This ENGINE SHOP MANUAL has been prepared as a guide to correctly service and repair the 717 and
787 RFI Rotax®engines.
This edition was primarily published to be used by technicians who are already familiar with all service
procedures relating to BRP products. Mechanical technicians should attend training courses given by
BRP Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any component.
Dealer and/or distributor assistance should be sought in case of doubt.
The engines identified in this document should not be utilized on product(s) other than those for which it
was designed.
WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage engine compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents.
We strongly recommend that any services be carried out and/or verified by a highly skilled professional
mechanic. It is understood that certain modifications may render use of the engine illegal under existing
federal, provincial and state regulations.
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INTRODUCTION
INTRODUCTION
GENERAL INFORMATION
This ENGINE SHOP MANUAL covers the 717 and
787 RFI Rotax made engines. It should be used in
conjunction with the appropriate VEHICLE SHOP
MANUAL.
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
This ENGINE SHOP MANUAL uses technical
terms which may be different from the ones of
the Parts Catalogs.
When ordering parts always refer to the specific
model Parts Catalogs.
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
717 Engines
The Engine Identification Number is located on the
upper side of the magneto housing.
1
F01D01A
TYPICAL
1. Engine Identification Number (E.I.N.)
787 RFI Engines
The Engine Identification Number is located on the
upper crankcase on PTO side.
F01D87A 1
1. Engine Identification Number (E.I.N.)
ENGINE EMISSIONS
INFORMATION
Refer to the appropriate VEHICLE SHOP MANU-
AL.
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in explod-
ed views and/or text.
WARNING
Torque wrench tightening specifications
must strictly be adhered to. Locking de-
vices (e.g.: locking tabs, elastic stop nuts,
self-locking fasteners, etc.) must be installed
or replaced with new ones, where specified.
If the efficiency of a locking device is im-
paired, it must be renewed.
IV
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INTRODUCTION
ARRANGEMENT OF THIS
MANUAL, ILLUSTRATIONS
AND PROCEDURES
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Several sections are divided in various subsec-
tions. There is a table of contents at the beginning
of many sections.
The illustrations show the typical construction of
the different assemblies and, in all cases, may not
reproduce the full detail or exact shape of the parts
shown, however, they represent parts which have
the same or a similar function.
CAUTION: These engines are designed with
parts dimensioned mostly in the metric sys-
tem. However some components may be
from the imperial system. When replacing
fasteners, make sure to use only those recom-
mended by BRP.
As many of the procedures in this manual are inter-
related, we suggest, that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection in which the procedure
is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before undertaking
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.
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INTRODUCTION
Subsection 04 (MAGNETO SYSTEM)
30
F01D4WS
Loctite
43
Loctite
43
Loctite
43
Loctite
43
Loctite
43
Loctite
648
145 Nm
(107 lbfft)
Anti-seize
lubricant
Page heading
indicates section
and subsection
detailed.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
F01A0CT
Illustration number
for publishing
process.
Subsection title
indicates
beginning of the
subsection.
Dotted box
contains parts of
a particular
model or an
exploded view.
Page number
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents
a liquid product
to be applied to a
surface. In this case
octite 243 to
screw threads.
Bold face number
indicates special
procedure
concerning this part.
VI
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INTRODUCTION
1
2
Section 06 FUEL SYSTEM
Subsection 03 (CARBURETORS)
31
Diaphragm
XP Model Only
CARBURETOR REMOVAL
Inspect parts for corrosion dammage (shaft, butterfly,
spring screw, check valve housing, etc.).
PUMP DIAPHRAGM LEAK TEST
TYPICAL
To remove carburetors from engine, proceed as fol-
lows:
Remove air vent tube support.
Unlock retaining slides holding air intake silencer base.
Remove air intake silencer base from watercraft.
Remove screws holding flame arrester base support
to cylinder head cover.
Unscrew base retaining screws then remove base from
carburetors and move to front of watercraft.
Turn the valve to OFF position.
NOTE: For fuel line removal, use pliers (P/N 295
000 054).
Disconnect pulse line from fuel pump.
Disconnect fuel fuel supply line from fuel pump.
Disconnect fuel return line.
Disconnect oil injection pump cable, throttle cable and
choke cable.
Remove screws no. 6 and lock washers no. 7 retaining
carburetors.
All Others Models
Remove 4 bolts no. 8 and lock washers no. 1 from
rotary valve cover then move carburetors and rotary
valve cover on top of engine.
NOTE: When removing rotary valve cover , pay
attention that the rotary valve stay in place, other-wise
it must be timed.
Remove carburetors from intake manifold.
Disconnect fuel bypass line between carburetors (twin
carburetors).
Remove carburetor(s) from rotary valve cover.
DISASSEMBLY AND INSPECTION
Using a suitable pump gauge tester, perform the fol-
lowing test proceeding as follows:
- Install pump gauge tester (P/N 295 000 083) on pulse
nipple.
- Pump tester until it reaches 28 kPa (4 PSI).
Diaphragm must stand pressure for 10 seconds. If
pressure drops, replace diaphragm.
F01F0XB
A
1
1
TYPICAL PAGE
Sub-title with part
name(s) from
exploded view.
TYPICA  mention
indicates a general
view which does not
represent full detail.
Sub-sub-title in this
case indicates that
particular procedure
for XP is finished, so
from this point, all
others models are
concerned.
Title in italic indicates a
particular procedure
concerning a model.
Service tool to be
used to perform a
certain procedure.
Title indicates main
procedure to be
carried-out.
Sub-sub-title in
capital indicates a
particular testing,
adjustment or
repair procedure.
Illustration
always follows
text it is
pertained to.
Numbered step are
used to give a
sequence to be
perfomed.
Numbers are used
for description of
components.
etters are used for
any measures.
Bold numbers in the
text refer to the parts
shown in the exploded
view at the beginning
of the subsection.
F01A0BT
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
MEASUREMENT PROCEDURES
NOTE: This section explains the procedures to
correctly measure engine components. For the
engine technical specifications, refer to INSPEC-
TION in the appropriate ENGINE subsection.
CYLINDER HEAD WARPAGE
Check gasketed surface of the cylinder head with
a straight edge and a feeler gauge. Make sure part
is within the given specification. If cylinder head is
out of specification, replace it. Verify combustion
chamber volume to use the correct cylinder base
gasket with the new part.
CYLINDER TAPER
Using a cylinder bore gauge, measure cylinder di-
ameter at 16 mm (5/8 in) from top of cylinder just
below auxiliary transfer port, facing exhaust port
and just below the auxiliary transfer port facing
the exhaust port. Compare readings. If the dif-
ference between readings exceed specification,
cylinder should be rebored and honed or replaced.
A
F01D8AA
1
2
TYPICAL
1. Measuring perpendicularly (90°) to piston pin axis
2. Auxiliary transfer port
A. 16 mm (5/8 in)
CYLINDER OUT OF ROUND
Using a cylinder bore gauge, measure cylinder
diameter at 16 mm (5/8 in) from top of cylinder.
Measure diameter in piston pin axis direction
then perpendicularly (90°) to it. If the difference
between readings exceed specification, cylinder
should be rebored and honed or replaced.
A
F01D8BA
A
1
2
TYPICAL
1. Measuringinpistonpinaxis
2. Measuring perpendicularly (90°) to piston pin axis
A. 16 mm (5/8 in)
COMBUSTION CHAMBER
VOLUME MEASUREMENT
NOTE: This procedure is required to determine
the thickness of the cylinder base gasket to be in-
stalled if a crank repair has involved replacement
of connecting rods or if you are experiencing
repetitive engine seizure.
The combustion chamber volume is the region in
the cylinder head above the piston at Top Dead
Center (TDC). It is measured with the cylinder
head installed on the engine.
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
F01D5VA
1
1. Combustion chamber
NOTE: When checking the combustion chamber
volume, engine must be cold, piston must be free
of carbon deposit and cylinder head must be lev-
eled.
–Remove both spark plugs and bring one piston
to Top Dead Center using a TDC gauge.
–Obtain a graduated burette (capacity 0 - 50 cc)
and fill with an equal part (50/50) of gasoline and
injection oil.
F00B0BA
1
1. Graduated burette (0 - 50 cc)
–Open burette valve to fill its tip. Add liquid in
burette until level reaches 0 cc.
–Inject the burette content through one spark
plug hole until liquid touches the top hole.
F00D0HA 1
TYPICAL
1. Top of spark plug hole
NOTE: The liquid level in cylinder must not drop
for a few seconds after filling. If so, there is a
leak between piston and cylinder. The recorded
volume would be false.
–Let burette stand upward for about 10 minutes,
until liquid level is stabilized.
–Read the burette scale to obtain the quantity of
liquid injected in the combustion chamber.
The volume should be within the allowable range.
Refer to TOP END section of the appropriate en-
gine for the specifications.
If the volume of the combustion chamber is not
within specifications, change cylinder base gasket
thickness as follow.
A higher volume dictates a thinner gasket.
A lower volume dictates a thicker gasket.
–Repeat the procedure for the other cylinder.
PISTON/CYLINDER WALL
CLEARANCE
Method with a Used Piston
Using a micrometer, measure piston skirt perpen-
dicularly (90°)topistonpinandatthespecifieddis-
tance as per following table.
ENGINE MAXIMUM “A” mm (in)
717 29 (1.142)
787 RFI 28 (1.102)
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
F01D0NA 1
A
1. Measuring perpendicularly (90°) to piston pin axis
A. See previous table
Notethepistondimensiononthepistondomeand
compare it with the obtained result.
F00D0EA 1
1. Piston dome
2. Piston measurement
NOTE: The measured dimension must not be less
than 0.12 mm (.005 in) of the one scribed on piston
dome. Otherwise, use a new piston and measure
piston/cylinder wall clearance following method
with a new piston.
If piston is within specifications, adjust and lock
the micrometer to the obtained piston dimension.
F00B08A
1
1. Micrometer set to the piston dimension
Proceed with FINAL MEASUREMENT PROCE-
DURE WITH EITHER A USED OR NEW PISTON
below.
Method with a New Piston
To determine the piston dimension, take the mea-
surement on the piston dome.
F00D0EA 1
1. Piston dome
2. Piston measurement
Adjust and lock a micrometer to the specified val-
ue on the piston dome.
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
F00B08A
1
1. Micrometer set to the piston dimension
Proceed with FINAL MEASUREMENT PROCE-
DURE WITH EITHER A USED OR NEW PISTON
below.
Final Measurement Procedure with
either a Used or New Piston
With the micrometer set to the piston dimension,
adjust a cylinder bore gauge to the micrometer
dimension and set the indicator to zero.
F00B09A
1
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
F00B0AA
1
1. Indicator set to zero
Position the dial bore gauge at 16 mm (5/8 in) be-
low cylinder top edge.
F01D0KA
1
A
1. Measuring perpendicularly (90°) to piston pin axis
A. 16 mm (5/8 in)
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
RING/PISTON GROOVE
CLEARANCE
Using a feeler gauge, check clearance between
rectangular ring and groove. If clearance exceeds
specified tolerance, replace piston.
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
NOTE: Ring/piston groove clearance can be cor-
rectly measured only on rectangular ring which is
bottom ring.
A35C31A
TYPICAL
RING END GAP
Position ring halfway between exhaust port and
top of cylinder.
NOTE: In order to correctly position ring in cylin-
der, use piston as a pusher.
Using a feeler gauge, check ring end gap. If gap
exceeds specified tolerance, rings should be re-
placed.
F01D0OA 1
1. Top of cylinder
2. Ring end gap
CRANKSHAFT (ASSEMBLED
ENGINE)
The following checks can be performed with en-
gine in watercraft without overhauling engine.
Crankshaft Alignment at Center
Main Journal
Since it is an assembled crankshaft it can become
misaligned or deflected. Crankshaft can be twist-
ed on center main journal, changing timing of one
cylinder in relation with the other.
F01D1NA 1
1. Main journal alignment here
To accurately check if crankshaft is twisted on cen-
ter main journal, proceed as follows:
–Remove magneto housing cover.
–Remove flywheel nut and magneto roto. Refer
to MAGNETO SYSTEM for procedures.
–Install the degree wheel (P/N 529 035 607) on
crankshaft end. Hand-tighten nut only.
–Remove both spark plugs.
–Install a TDC gauge in spark plug hole on MAG
side.
–Bring MAG piston at Top Dead Center.
–As a needle pointer, secure a wire with a cover
screw and a washer.
–Rotate degree wheel (NOT crankshaft) so that
needle pointer reads 360°.
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
1
F01D4IA
3
2
4
TYPICAL
1. TDC gauge
2. Degree wheel
3. Hand tighten nut
4. Needle pointer
–Remove TDC gauge and install on PTO side.
–Bring PTO piston at Top Dead Center.
Interval between cylinders must be exactly 180°
therefore, needle pointer must indicate 180°on
degree wheel (360°-180°=180°).
Any other reading indicates a misaligned crank-
shaft.
CrankshaftAlignmentatConnecting
Rod Journal
Counterweights can also be twisted on connect-
ing rod journal on any or both cylinder(s).
F01D1NB 1
1. Connecting rod journal alignment here
Such misalignment may make it difficult to manu-
ally turn the crankshaft. Verification can be done
by measuring deflection each end of crankshaft.
If deflection is found greater than specified toler-
ance, this indicates worn bearing(s), bent and/or
misaligned crankshaft. Proceed with the disas-
sembly of the engine.
CRANKSHAFT (DISASSEMBLED
ENGINE)
The following verifications can be performed with
theenginedisassembled.
Connecting Rod Straightness
Align a steel ruler on edge of small end connecting
rod bore. Check if ruler is perfectly aligned with
edge of big end.
F01D1QA
1
1. Ruler must be aligned with edge of connecting rod here
2. Align ruler here
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
Crankshaft Deflection
Crankshaft deflection is measured each end with
a dial indicator.
First, check deflection with crankshaft in
crankcase. If deflection exceeds the specified
tolerance, it can be either ball bearings wear, bent
or twisted crankshaft at connecting rod journal.
F01D1SA
1
1. Measuring PTO side deflection in crankcase
F01D1TA
1
1. Measuring MAG side deflection in crankcase
Remove crankshaft bearings and check deflection
again on V-shaped blocks as illustrated.
1
F01D97A
1. Measuring MAG side deflection on V-shaped blocks
F01D98A
1
1. Measuring PTO side deflection on V-shaped blocks
NOTE: Crankshaft deflection cannot be correctly
measured between centers of a lathe.
If the deflection exceeds the specified tolerance,
crankshaft should be repaired or replaced.
Connecting Rod Big End Axial Play
Using a feeler gauge, measure distance between
thrust washer and crankshaft counterweight.
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
F01D1WA
1
2
1. Measuring big end axial play
2. Feeler gauge
Connecting Rod Straightness
Align a steel ruler on edge of small end connecting
rod bore. Check if ruler is perfectly aligned with
edge of big end.
ROTARY VALVE
Rotary Valve/Cover Clearance
45°FEELER GAUGE METHOD
Remove intake manifold from rotary valve cover.
Remove rotary valve cover and valve.
Remove O-ring from rotary valve cover.
Reinstall cover WITHOUT its O-ring and torque
screwsto20N•m(15lbf•ft).
Insert a feeler gauge blade through cover inlet
ports to verify clearance. At least verify clearance
at two different places in each port.
Feeler gauge blade thickness according to specifi-
cations should fit between rotary valve and cover.
F01D53A
1
1. 45° feeler gauge
If rotary valve cover clearance is out of specifica-
tions, machine rotary valve cover seating surface
or replace the cover.
SOLDERING WIRE METHOD
Remove rotary valve cover.
Remove O-ring from rotary valve cover.
Use the following type of solder:
–resin core
–diameter : 0.8 mm (.032 in)
–electronic application (available at electronic
stores).
Install 2 soldering wire pieces of 13 mm (1/2 in)
long directly on rotary valve, one above and one
below rotary valve gear. Apply grease to hold sol-
der in position.
Refer to the following illustration for proper posi-
tion of rotary valve and pieces of soldering wire.
F01D3PA
1
TYPICAL
1. Soldering wires
Reinstall cover WITHOUT its O-ring and torque
screws to 20 N•m(15lbf•ft).
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Section 01 ENGINE MEASUREMENT
Subsection 01 (MEASUREMENT PROCEDURES)
Remove cover then clean and measure com-
pressed soldering wire thickness, it must be
within the specified tolerance.
If rotary valve cover clearance is over specified tol-
erances, machine rotary valve cover seating sur-
face or replace the cover.
Machining the Rotary Valve Cover
The amount of material over tolerance must be
removed from the rotary valve cover seating sur-
face.
Also cut the O-ring groove the same amount to
keep the 1.00 ± 0.03 mm (.039 ± .001 in) depth
between the bottom of the groove and the seating
surface.
Remove burrs on the edges of the seating surface
andO-ringgroove.
1
A
F01D3OA
SAME AMOUNT REMOVED FROM COVER SEATING
SURFACE AND O-RING GROOVE BASE
1. Cover seating surface
A. O-ring groove depth must be 1.00 ± 0.03 mm (.039 ± .001 in)
Reverify the clearance.
At assembly, the rotary valve timing must remain
as per original setting.
NOTE: If rotary valve crankcase surface is worn, it
is possible to have it reworked at the factory.
Rotary Valve Shaft Deflection
Deflection is measured with a dial gauge. Install
rotary valve shaft in crankcase half, without its
gear.
NOTE: End bearing must be in crankcase half.
Measure shaft deflection next to gear splines.
F01D CA
1
1. Rotary valve shaft
2. End bearing in place
If the deflection of rotary valve shaft exceeds the
specified tolerance, replace it.
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Section02717ENGINE
Subsection 01 (LEAK TEST)
LEAK TEST
SERVICE TOOLS
Description Part Number Page
engine leak test kit ............................................................... 295 500 352 ........................................... 11
large hose pincher................................................................ 529 032 500 ...........................................13
small hose pincher................................................................ 295 000 076 ..................................... 11–13
GENERAL
The engine leak test kit (P/N 295 500 352) is avail-
able to help diagnose engine problems such as en-
gine seizure, poor performance, oil leakage, etc.
95 500 35
ENGINE LEAK TEST KIT
Before disassembling any components of the en-
gine, it is important to perform a leakage test to
determine which part is defective.
It is also very important after servicing the engine,
even for a complete engine rebuilt, to perform an-
other leakage test; at this stage, it may avoid fur-
ther engine problems and minimizing the risk of
having to remove and reinstall the engine again.
Static bench testing is the most effective way to
conduct a leakage test. Inboard testing does not
allow complete access to, and observation of all
engine surfaces and should be avoided whenever
possible.
On this engine, cylinders can not be verified indi-
vidually due to leakage from one cylinder to anoth-
er through a common intake manifold.
When installing hoses of the leak test kit, use the
collars provided in the kit to ensure a proper seal-
ing.
When pressurizing the engine, first confirm that
the components of the leak test kit are not leaking
by spraying a solution of soapy water on all hoses,
connections, fittings, plates, etc. If there is a leak,
bubbles will indicate leak location.
Three areas of the engine will be tested in se-
quence as per the diagnostic flow chart (see the
end of this subsection).
1. Engine Cooling System.
2. Bottom End and Top End.
3. Rotary Valve Shaft.
NOTE: If a leak is found, it is important to continue
testing as there is the possibility of having more
than one leak. Continue pumping to compensate
fortheairlosttofindanotherleak.
PREPARATION
Using the appropriate VEHICLE SHOP MANUAL,
remove the engine from the vehicle and place it
on a bench or an appropriate engine support.
TESTING PROCEDURE
Engine Cooling System
Remove the exhaust manifold gasket and ensure
the surface is clean.
Install the appropriate exhaust manifold plate from
the engine leak test kit (P/N 295 500 352). Tighten
plate using fasteners provided in the kit.
NOTE: Do not torque plate excessively.
Install a small hose pincher (P/N 295 000 076) on
engine drain hose.
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