Specifications

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C M Y CM MY CY CMY K

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Summary of content (117 pages)

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C M Y CM MY CY CMY K www.SeaDooManuals.
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005 Engine Shop Manual ROTAX® 717 and 787 RFI™ ENGINES www.SeaDooManuals.
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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 Printed in Canada ®™ Registered trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
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TABLE OF CONTENTS SAFETY NOTICE .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... III INTRODUCTION .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. .. IV GENERAL INFORMATION. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . ENGINE IDENTIFICATION NUMBER (E.I.N.) . . .
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TABLE OF CONTENTS 06 – TECHNICAL SPECIFICATIONS . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 57 03 787 RFI ENGINE 01 – LEAK TEST .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 59 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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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 descriptions 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.
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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 subsections. There is a table of contents at the beginning of many sections.
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INTRODUCTION TYPICAL PAGE Page heading indicates section and subsection detailed. Subsection title indicates beginning of the subsection. Subsection 04 (MAGNETO SYSTEM) Italic sub-title above exploded view indicate pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 243 to screw threads. Loctite 243 Loctite 243 Exploded view assists you in identifying parts and related positions. Dotted box contains parts of a particular model or an exploded view.
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INTRODUCTION TYPICAL PAGE Sub-title with part name(s) from exploded view. Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS) Title indicates main procedure to be carried-out. Service tool to be used to perform a certain procedure. Title in italic indicates a particular procedure concerning a model. Sub-sub-title in this case indicates that particular procedure for XP is finished, so from this point, all others models are concerned.
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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 INSPECTION 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.
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Section 01 ENGINE MEASUREMENT Subsection 01 (MEASUREMENT PROCEDURES) 1 F01D5VA 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 leveled. – 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. 1 F00B0BA 1 F00D0HA TYPICAL 1.
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Section 01 ENGINE MEASUREMENT Subsection 01 (MEASUREMENT PROCEDURES) 1 A F00B08A 1 F01D0NA 1. Micrometer set to the piston dimension 1. Measuring perpendicularly (90°) to piston pin axis A. See previous table Proceed with FINAL MEASUREMENT PROCEDURE WITH EITHER A USED OR NEW PISTON below. Note the piston dimension on the piston dome and compare it with the obtained result. Method with a New Piston To determine the piston dimension, take the measurement on the piston dome. F00D0EA 2 1 1.
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Section 01 ENGINE MEASUREMENT Subsection 01 (MEASUREMENT PROCEDURES) 1 1 F00B08A 1. Micrometer set to the piston dimension Proceed with FINAL MEASUREMENT PROCEDURE WITH EITHER A USED OR NEW PISTON below. Final Measurement Procedure with either a Used or New Piston F00B0AA 1. Indicator set to zero Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge.
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Section 01 ENGINE MEASUREMENT Subsection 01 (MEASUREMENT PROCEDURES) NOTE: Ring/piston groove clearance can be correctly measured only on rectangular ring which is bottom ring. CRANKSHAFT (ASSEMBLED ENGINE) The following checks can be performed with engine in watercraft without overhauling engine. Crankshaft Alignment at Center Main Journal Since it is an assembled crankshaft it can become misaligned or deflected.
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Section 01 ENGINE MEASUREMENT Subsection 01 (MEASUREMENT PROCEDURES) 1 2 3 F01D1NB 4 1 1. Connecting rod journal alignment here Such misalignment may make it difficult to manually turn the crankshaft. Verification can be done by measuring deflection each end of crankshaft. If deflection is found greater than specified tolerance, this indicates worn bearing(s), bent and/or misaligned crankshaft. Proceed with the disassembly of the engine. F01D4IA TYPICAL 1. TDC gauge 2. Degree wheel 3.
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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. 1 1 F01D97A 1. Measuring MAG side deflection on V-shaped blocks F01D1SA 1 1. Measuring PTO side deflection in crankcase 1 F01D98A 1.
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Section 01 ENGINE MEASUREMENT Subsection 01 (MEASUREMENT PROCEDURES) 1 1 F01D53A 1. 45° feeler gauge 2 If rotary valve cover clearance is out of specifications, machine rotary valve cover seating surface or replace the cover. F01D1WA 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.
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Section 01 ENGINE MEASUREMENT Subsection 01 (MEASUREMENT PROCEDURES) Remove cover then clean and measure compressed soldering wire thickness, it must be within the specified tolerance. If rotary valve cover clearance is over specified tolerances, machine rotary valve cover seating surface or replace the cover. 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.
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Section 02 717 ENGINE 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 .........................
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Section 02 717 ENGINE Subsection 01 (LEAK TEST) 2 1 295 000 076 F01B2VA 3 1. Loop hose and use clamps 2. Use two washers with exhaust manifold stud 3. Hose with adapter and nipple F01B2UB 1 1. Engine drain hose blocked with a hose pincher Use hoses provided in the kit and install them on the engine. Install pump using reducer and appropriate tube(s) as necessary. Activate pump and pressurize engine cooling system to 34 kPa (5 PSI).
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Section 02 717 ENGINE Subsection 01 (LEAK TEST) If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft outer seals. Proceed with the ROTARY VALVE SHAFT testing if the crankshaft outer seals are not leaking. 3 Rotary Valve Shaft NOTE: It is mandatory to drain the injection oil from the rotary valve shaft. Block oil return hose of the rotary valve shaft with a large hose pincher (P/N 529 032 500). 1 2 529 032 500 F01B2ZA 1. Intake plates 2.
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Section 02 717 ENGINE Subsection 01 (LEAK TEST) 1 F01B32A 1. Pump with reducer and nipple Activate pump and pressurize to 34 kPa (5 PSI). Check plug of the rotary valve shaft in crankcase. Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal or crankcase is not sealed correctly. Remove MAG side spark plug. If pressure drops, it indicates a defective MAG side crankshaft inner seal or crankcase is not sealed correctly.
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Section 02 717 ENGINE Subsection 01 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING? YES CHECK TESTING KIT NO REPLACE O-RING OF CYLINDER HEAD AND/OR CYLINDER BASE GASKET PRESSURIZE ENGINE NO IS ENGINE LEAKING? RECHECK ENGINE SEALING YES CHECK TESTING KIT CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC.
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Section 02 717 ENGINE Subsection 02 (MAGNETO SYSTEM) MAGNETO SYSTEM SERVICE TOOLS Description Part Number extension handle .................................................................. M8 x 35 screws.................................................................... magneto coil centering tool .................................................. magneto puller...................................................................... puller plate ...........................................................
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Section 02 717 ENGINE Subsection 02 (MAGNETO SYSTEM) 16 4.5 Nm (40 lbfin) Loctite 243 9 Nm 11 (80 lbfin) 10 Loctite 243 12 8 13 5.5 Nm (49 lbfin) 14 Loctite 243 15 Loctite 243 4 9 Nm (80 lbfin) 5.5 Nm 9 (49 lbfin) 9 Nm (80 lbfin) 1 Loctite 7 243 5 2.6 Nm (23 lbfin) Anti-seize lubricant Loctite 648 9 Nm (80 lbfin) 1 6 145 Nm (107 lbfft) 17 3 2 Anti-seize lubricant 1 9 Nm (80 lbfin) smr2005-076-001_aen 18 smr2005-076 www.SeaDooManuals.
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Section 02 717 ENGINE Subsection 02 (MAGNETO SYSTEM) DISASSEMBLY NOTE: The magneto system can be disassembled without removing the engine from the watercraft. NOTE: If socket is found too large to be inserted in puller plate, machine or grind its outside diameter as necessary. Magneto Cover 1 Remove screws no. 1 and wire support no. 2, then withdraw magneto cover no. 3. Magneto Flywheel and Ring Gear To remove magneto flywheel no.
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Section 02 717 ENGINE Subsection 02 (MAGNETO SYSTEM) Proceed as follows: – Before removing the armature plate, find a crankcase locating lug (the top one in this example). – Place a cold chisel at the end of chosen lug, then punch a mark on armature plate at this point. 1 2 1 3 F01D4CA 2 1. Puller plate 2. Puller 3. Extension handle F01D4DA Lay magneto flywheel no. 4 on a steel plate. Tap lightly on ring gear no. 5 using a hammer to release it from magneto flywheel. 1 1. Crankcase locating lug 2.
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Section 02 717 ENGINE Subsection 02 (MAGNETO SYSTEM) Generating Coil To replace generating coil no. 12: – Heat the armature plate to 93°C (200°F) around the screw holes to break the threadlocker bond. 1 F00D09A 1. Heat the armature plate 1 F00D08A 1. Heat the armature plate CAUTION: Protect harness from flame. – Remove screws no. 13. – Uncrimp and unsolder BLACK/RED wire from coil. CAUTION: Protect harness from flame. – Remove screws no. 15.
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Section 02 717 ENGINE Subsection 02 (MAGNETO SYSTEM) ASSEMBLY 1 Generating Coil Strip end of old wire then crimp and solder on new coil. Apply Loctite 243 (blue) (P/N 293 800 060) to screws no. 13 and install the new coil no. 12 on armature plate. Use the magneto coil centering tool (P/N 420 876 922) and install so that it fits around armature plate before tightening screws. F00D0AA 1.
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Section 02 717 ENGINE Subsection 02 (MAGNETO SYSTEM) NOTE: Do not spray anticorrosion spray into magneto flywheel threaded holes. 1. Clean thoroughly and degrease replacement part using a non oil base solvent. 2. Apply coating in light thin coats. Refer to the manufacturer's instructions. Magneto Housing Install gasket no. 16 between magneto housing no. 10 and engine crankcase. Install magneto housing and torque screws no. 11 to 9 N•m (80 lbf•in).
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Section 02 717 ENGINE Subsection 03 (TOP END) TOP END SERVICE TOOLS Description Part Number aligning tool .......................................................................... circlip installer ....................................................................... piston pin puller .................................................................... piston ring compressor......................................................... rubber pad ............................................................
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Section 02 717 ENGINE Subsection 03 (TOP END) 9 10 8 8 12 24 Nm (17 lbfft) 1 Loctite 243 Molykote 111 10 11 9 12 2 11 15 14 14 3 24 Nm 7 (17 lbfft) Molykote 111 24 Nm (17 lbfft) 7 Loctite 243 Molykote 111 Loctite 243 5 24 Nm (17 lbfft) 4 6 13 16 Molykote 111 smr2005-077-001_aen 26 smr2005-077 www.SeaDooManuals.
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Section 02 717 ENGINE Subsection 03 (TOP END) GENERAL The 2-stroke Rotax® engine rotates counterclockwise seen from the rear (PTO flywheel). The 717 engine has a rotary valve to control opening and closing of the intake. Remove cylinder screws no. 7. Remove cylinders no. 6, while making sure connecting rods do not hit crankcase edge.  If screws need to be heated for removal when engine is in watercraft, fuel system pressurization must be done first. Do not use open flame; use a heat gun.
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Section 02 717 ENGINE Subsection 03 (TOP END) 1 2 3 1 F00B0IA F01D43A 1. Openings covered with rag and rubber pad To remove circlip no. 9, insert a pointed tool in piston notch then pry it out and discard.  WARNING Always wear safety glasses when removing piston circlips. TYPICAL 1. Puller 2. Shoulder sleeve 3. Sleeve – Fully thread on puller handle. – Insert extractor spindle into the piston pin. – Slide the sleeve and shoulder sleeve onto the spindle.
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Section 02 717 ENGINE Subsection 03 (TOP END) 1 F00B0KA 1 F00B0MA TYPICAL 1. Tool cut-out toward bottom of piston TYPICAL 1. Remove shoulder sleeve – Firmly hold puller and rotate handle to pull piston pin no. 10. – Rotate spindle until the shoulder sleeve is flushed with the piston recess. Carefully remove the piston no. 8. The needles no. 11, thrust washers no. 12 and the sleeve remain in the connecting rod bore and may be used again. 1 1 2 F00B0NA TYPICAL 1. Needles and thrust washer 2.
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Section 02 717 ENGINE Subsection 03 (TOP END) INSPECTION Piston Refer to table below to find top end engine dimension specifications. For dimension measurement procedures, refer to ENGINE MEASUREMENT. Visually inspect all parts for corrosion damage. Inspect pistons for damage. Light scratches can be sanded with a fine sand paper. NOTE: When repairing a seized engine, connecting rods should be checked for straightness and crankshaft for deflection/misalignment. Inspect plane surfaces for warpage.
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Section 02 717 ENGINE Subsection 03 (TOP END) 1 2 1 F01D0Q A F00B0OA 1. Outer ring removal after inner sleeve insertion into bore TYPICAL 1. Piston pin 2. Shoulder sleeve – Insert extractor spindle into the piston pin, screw on extracting nut. 2 – Make sure thrust washers no. 12 are present each side of rollers. 1 1 F01D0VA F00B0PA 1. Thrust washer each side TYPICAL 1. Puller installed on the opposite side of the piston pin 2. Tighten extracting nut – Insert piston pin no. 10 into piston no.
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Section 02 717 ENGINE Subsection 03 (TOP END) 1 1 2 F01D0RA F01D0TA 1. Piston pin flush here 2. Thrust washers 1. Pulling inner sleeve half – Place piston over connecting rod and align bores, then gently tap piston pin with a fiber hammer to push out inner plastic ring on opposite side. Support piston from opposite side. Circlip Always use new circlips no. 9.  WARNING Always wear safety glasses when installing piston circlips. CAUTION: Always use new circlips.
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Section 02 717 ENGINE Subsection 03 (TOP END) Cylinder Base Gasket F06B01A 1 TYPICAL 1. Circlip installer – Remove sleeve from pusher then insert circlip into its bore. – Reinstall sleeve onto pusher and push until circlip comes in end of tool. 1 NOTE: The general procedure is to install a new gasket of the same thickness.
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Section 02 717 ENGINE Subsection 03 (TOP END) The aligning tool (P/N 420 876 904) or the exhaust manifold can be used to align cylinders. 1 A01B1TA 1. Slide this edge NOTE: Ring compressor will not fit on oversize parts. Make sure to align ring end gap with piston locating pin. Slide tool over rings. 1 F01D44A 1 1. Exhaust flange aligning tool 1 F01D0ZA 1. Ring end gap aligned with piston locating pin Slide cylinder over piston. F01D45A 1.
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Section 02 717 ENGINE Subsection 03 (TOP END) 1 4 1 4 3 2 3 2 10 F01D35A F01D46A 9 8 2 7 3 Cylinder Head TORQUING SEQUENCE Install cylinder head gasket. Make sure to install O-rings no. 14 around spark plug holes and O-ring no. 15 of cylinder head as shown in the following illustration. Exhaust Manifold 1 F01D5AA 4 6 12 1 5 11 Make sure gaskets are properly positioned prior to finalizing manifold installation.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) BOTTOM END SERVICE TOOLS Description Part Number bearing heater....................................................................... distance gauge ..................................................................... Distance ring......................................................................... MAG side ring halves ........................................................... Protective cap..........................................................
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) Loctite 518 110 Nm (81 lbfft) 1 11 Molykote 111 Anti-seize lubricant 4 12 5 3 6 4 2 Loctite 642 6 Anti-seize lubricant 12 2 Loctite 5910 4 Anti-seize lubricant 5 Loctite 243 6 6 24 Nm 9 (17 lbfft) Molykote 111 11 Molykote 111 Loctite 518 7 24 Nm (17 lbfft) 4 10 10 Nm (89 lbfin) Loctite 518 Molykote 111 8 40 Nm (30 lbfft) F00D0YU 38 smr2005-078 www.SeaDooManuals.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) GENERAL Engine has to be removed from watercraft to take apart bottom end. Refer to appropriate VEHICLE SHOP MANUAL. Engine top end has to be disassembled to take apart bottom end. Refer to TOP END section in this manual. NOTE: Crankcase halves are factory matched and therefore, are not interchangeable or available as single halves.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) – starter, refer to appropriate VEHICLE SHOP MANUAL – rotary valve cover and valve, refer to ROTARY VALVE section – engine top end, refer to TOP END section. Put engine on a stand. Loosen crankcase screws. 3 1 1 2 F01D1LA TYPICAL 1. Separate halves by prying at provided lugs Remove crankshaft no. 3. 3 F01D20C Crankshaft End Bearings 1. M10 x 73.5 flanged screws 2. M8 x 68.5 flanged screws 3. M8 x 45 socket head screws Put engine back on a support.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) 2 1 3 4 5 6 1 F01B09A 1. 2. 3. 4. 5. 6. 7. 8. 7 8 Puller (P/N 420 877 635) Protective cap (P/N 420 876 557) Distance ring (P/N 420 876 569), MAG side only Ring (P/N 420 977 490), both sides MAG side ring halves (P/N 420 276 025) PTO side ring halves (P/N 420 977 475) Screw M8 x 40 (P/N 420 840 681) Screw M8 x 70 (P/N 420 841 201) NOTE: To facilitate ring or distance ring installation, lubricate their inside diameters. F01D1PA 2 1.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) F00D2CA FIRST PASS A32CB5A TYPICAL Crankcase Crankcase mating surfaces are best cleaned using a combination of the chisel gasket remover (P/N 413 708 500) and a brass brush. Brush a first pass in one direction then make the final brushing perpendicularly (90°) to the first pass cross (hatch). CAUTION: Never use a sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) TOLERANCE ENGINE MEASUREMENT New parts Min Max Wear limit 0.050 mm (.002 in) 0.030 mm N.A. N.A. PTO (.001 in) Connecting rod 0.311 mm 0.677 mm 1.2 mm (.026 in) (.047 in) big end axial play (.012 in) Crankshaft deflection MAG N.A. N.A. Crankcase Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with a fine sandpaper. Install sandpaper on a surface plate and rub part against oiled sand paper.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) Touch the inner race of the bearing with the temperature indicator stick (P/N 529 035 970). Stick will liquefy when the bearing reach the proper temperature. Slide in the inner bearing. Push bearing to end position. Install the retaining disk. To properly position the outer bearing(s), the distance gauge (P/N 529 034 800) must be temporarily installed against the inner bearing.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) NOTE: It is recommended to apply this specific sealant as described here to get an uniform application without lumps. If you do not use the roller method, you may use your finger to uniformly distribute the sealant. Use the Loctite 5910 (P/N 293 800 081) on mating surfaces. CAUTION: Do not use other products to seal crankcase. Do not use an activator with the Loctite 5910.
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Section 02 717 ENGINE Subsection 04 (BOTTOM END) Crankcase Screws Apply Loctite 518 (P/N 293 800 038) on screw threads and Molykote 111 (P/N 413 707 000) below head screws. Torque crankcase screws no. 7 and no. 9 to 24 N•m (17 lbf•ft) as per following illustrated sequence. 7 F01D20D 11 8 12 1 3 4 2 9 10 Using the same tools as for disassembly procedure, torque PTO flywheel to 110 N•m (81 lbf•ft). 5 13 6 14 Torque 2 M10 crankcase screws no. 8 to 40 N•m (30 lbf•ft). 1 F01D20B 1.
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) ROTARY VALVE SERVICE TOOLS Description Part Number degree wheel........................................................................ puller..................................................................................... pusher................................................................................... pusher................................................................................... TDC gauge.........................................
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) 9 6 5 10 14 8 15 7 11 3 13 1 Molykote 111 4 12 XP-S Injection oil Loctite 243 2 20 Nm (15 lbfft) smr2005-079-001_aen 48 smr2005-079 www.SeaDooManuals.
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) GENERAL Rotary Valve Shaft The clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without taking apart engine. However engine must be disassembled to work on rotary valve shaft/components. To remove the rotary valve shaft assembly, the engine must be removed from watercraft (refer to appropriate VEHICLE SHOP MANUAL). Open bottom end and remove crankshaft (refer to BOTTOM END section).
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) Shaft Bearing To remove bearing no. 8 use a bearing extractor such as Snap-on no. CJ-950 (or equivalent) as illustrated. Slide off distance sleeve no. 14, remove snap ring no. 7 and washer no. 15 then press shaft out. 1 1 F01D61A 1. Hold bolt F01D4NA 2 1. Bearing 2. Bearing extractor Snap-on CJ-950 CAUTION: Ensure that rotary valve shaft is perfectly perpendicular with press tip.
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) Rotary Valve Shaft Refer to table below to find dimension specifications. For measurement procedures, refer to ENGINE MEASUREMENT section. F01J0ZA Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing. Slide puller hammer outwards and tap puller end. Retighten claws as necessary to always maintain them tight against bearing.
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) 1 F01D2DA 2 1 3 1. Shield side (toward gear) Push bearing until it stops on its seat. A13C0FB 1. Seal 2. Ball bearing 3. Bearing extractor Snap-on CJ-950 Install washer no. 15, snap ring no. 7 and slide distance sleeve no. 14 on shaft no. 3. 1 2 3 4 F01D99A F01D2FA Seal Apply Molykote 111 (P/N 413 707 000) on seal lips. Position seal no. 11 with shielded portion against shaft splines. Shaft Bearing Install ball bearing as illustrated. 1. 2.
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) 1 A00C0YA 1. Pusher Push shaft until its stops on bearing seat. 1 2 F01D34A 1. Rotary valve shaft 2. Push shaft until it stops Snap Ring Position snap ring no. 4 so that its sharp edge faces outwards. Rotary Valve The rotary valve no. 13 controls the opening and closing of the inlet ports. Therefore its efficiency will depend on the precision of its installation.
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) 159° F01D73W 54 smr2005-079 www.SeaDooManuals.
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) ROTARY VALVE TIMING CAUTION: Never use the ridge molded in crank case as a timing mark. The degree wheel (P/N 529 035 607) and the TDC gauge (P/N 295 000 143) are required to measure rotary valve opening and closing angles in relation with MAG side piston.
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Section 02 717 ENGINE Subsection 05 (ROTARY VALVE) 1 65° F01D3EB 2 CLOSING MARK Step 1: Top of MAG inlet port. Align 360° line of degree wheel Step 2: Find 65° on outer scale of degree wheel and mark here – Remove degree wheel. – Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC. NOTE: Rotary valve is asymmetrical. Therefore, try flipping it over then reinstall on splines to obtain best installation position.
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Section 02 717 ENGINE Subsection 06 (TECHNICAL SPECIFICATIONS) TECHNICAL SPECIFICATIONS ENGINE Engine type Induction type Exhaust system Type Water injection fitting (head) Water injection fitting (cone) Starting system Lubrication Fuel/oil mixture Oil injection pump Oil injection type Number of cylinders Bore Standard First oversize Second oversize Stroke Displacement Corrected compression ratio Cylinder head volume Cylinder head warpage (maximum) Piston ring type and quantity New Ring end gap Wear
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Section 03 787 RFI ENGINE Subsection 01 (LEAK TEST) LEAK TEST SERVICE TOOLS Description Part Number Page engine leak test kit ............................................................... 295 500 352 ..................................... 59–60 small hose pincher................................................................ 295 000 076 ..................................... 60–61 supplementary engine leak test kit....................................... 295 500 780 .....................................
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Section 03 787 RFI ENGINE Subsection 01 (LEAK TEST) 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. F02D0WA 295 000 076 FRONT VIEW 1.
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Section 03 787 RFI ENGINE Subsection 01 (LEAK TEST) Install pump to the exhaust plate fitting. 2 If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft outer seals. Proceed with the ROTARY VALVE SHAFT testing if the crankshaft outer seals are not leaking. Rotary Valve Shaft NOTE: It is mandatory to drain the injection oil from the rotary valve shaft. Block oil return hose of the rotary valve shaft with a hose pincher. 4 1 3 F01B30A 1. 2. 3. 4.
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Section 03 787 RFI ENGINE Subsection 01 (LEAK TEST) Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal or crankcase is not sealed correctly. Remove MAG side spark plug. If pressure drops, it indicates a defective MAG side crankshaft inner seal or crankcase is not sealed correctly. If the above mentioned components are not leaking and there is a pressure drops, remove the rotary valve cover. Check the seal of the rotary valve shaft.
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Section 03 787 RFI ENGINE Subsection 01 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING? YES CHECK TESTING KIT NO REPLACE O-RING OF CYLINDER HEAD AND/OR CYLINDER BASE GASKET PRESSURIZE ENGINE NO IS ENGINE LEAKING? RECHECK ENGINE SEALING YES CHECK TESTING KIT CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC.
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Section 03 787 RFI ENGINE Subsection 02 (MAGNETO SYSTEM) MAGNETO SYSTEM SERVICE TOOLS Description Part Number crankshaft protector ............................................................. installer handle ..................................................................... magneto puller...................................................................... oil seal pusher....................................................................... ring gear locking tool ..................................
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Section 03 787 RFI ENGINE Subsection 02 (MAGNETO SYSTEM) 3 9 Nm (80 lbfin) Anti-seize lubricant Dielectric grease Molykote 111 7 13 Anti-seize lubricant Loctite 243 Molykote 111 8 6 14 9 Nm (80 lbfin) 10 Nm (89 lbfin) Loctite 243 15 5 120 Nm (89 lbfft) 4 Nm 12 (35 lbfin) Loctite 243 9 Nm (80 lbfin) 10 4 Loctite 243 11 Anti-seize lubricant 9 Anti-seize lubricant Dielectric grease 1 9 Nm (80 lbfin) 16 Dielectric grease 2 Ground cable Molykote 111 Dielectric grease 9 Nm 1 (8
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Section 03 787 RFI ENGINE Subsection 02 (MAGNETO SYSTEM) DISASSEMBLY Rotor and Ring Gear NOTE: The magneto system can be disassembled without removing the engine from the watercraft. NOTE: Crankshaft can also be locked by using the PTO flywheel extractor tool. For procedure, refer to BOTTOM END. Remove crankshaft position sensor no. 3. Lock ring gear no. 4 using the ring gear locking tool (P/N 529 035 846). Magneto Housing Cover Disconnect water hoses from heat exchanger cover.
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Section 03 787 RFI ENGINE Subsection 02 (MAGNETO SYSTEM) 420 876 557 1 1 F07D0LA REMOVE SCREWS 1. Magneto housing Stator Assembly Remove holding plate no. 9 and withdraw plug from cover. Unscrew bolts no. 10 and remove stator no. 11 from magneto cover. F01D7YA TYPICAL 1. Puller Tighten puller screw and at the same time, tap on screw head using a hammer to release magneto rotor from its taper. 3 1 Magneto Housing To remove magneto housing no. 7, starter has to be removed.
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Section 03 787 RFI ENGINE Subsection 02 (MAGNETO SYSTEM) Clean crankshaft taper and threads using pulley flange cleaner (P/N 413 711 809). Apply the pulley flange cleaner (P/N 413 711 809) on a rag first then clean the crankshaft. 1 2 ASSEMBLY Stator Install the stator no. 11 in magneto housing cover no. 2 and torque screws no. 20 to 9 N•m (80 lbf•in). Apply Loctite 243 (blue) (P/N 293 800 060) on screw threads. Install wiring harness bracket no. 9 of stator and torque screws no.
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Section 03 787 RFI ENGINE Subsection 02 (MAGNETO SYSTEM) Crankshaft Position Sensor Install crankshaft position sensor no. 3 on magneto housing. Apply Molykote 111 (P/N 413 707 000) on its O-ring. Apply Loctite 767 (antiseize lubricant) (P/N 293 800 070) on screw threads then torque it to 9 N•m (80 lbf•in). NOTE: The crankshaft position sensor is not adjustable. Cover Before installing cover, make sure oil pump shaft is properly positioned.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) TOP END SERVICE TOOLS Description Part Number circlip installer ....................................................................... piston pin puller .................................................................... piston ring compressor......................................................... rubber pad ............................................................................ set of sleeves .....................................................
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) 7 8 5 Loctite 243 Molykote 111 14 27 Nm (20 lbfft) 4 3 5 1 (34 rollers) 6 11 12 12 Molykote 111 2 15 18 16 17 Molykote 111 Molykote 111 30 19 Loctite 518 13 40 Nm (30 lbfft) 21 20 3 Nm (27 lbfin) Molykote 111 29 28 27 26 25 10 Nm (89 lbfin) 24 23 22 9 Molykote 111 10 smr2005-082-001_aen 72 smr2005-082 www.SeaDooManuals.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) GENERAL 4 The 2-stroke ROTAX engine rotates counterclockwise seen from the rear (PTO flywheel). The 787 RFI engine has a rotary valve to control opening and closing of the intake and it is also equipped with the Rotax Adjustable Variable Exhaust (RAVE) system. 3 2 5 RAVE System (Rotax Adjustable Variable Exhaust) BASIC OPERATION The RAVE valves change the height of the exhaust port.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) MAINTENANCE There are no wear parts anywhere in the system and there are no adjustments to be periodically checked. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide. Cleaning intervals would depend upon the user's riding style and the quality of the oil used. We suggest annual cleaning of the valve. If a customer uses a lower than recommended quality oil, more frequent cleaning may be required.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) F06D25A 1 Remove spring no. 30 retaining bellows no. 21 to valve piston no. 20. F06D0SA 1 F06D0TA 1. Remove spring 1. Bellows removed from piston Unscrew valve piston no. 20 from sliding valve no. 22. NOTE: Hold the sliding valve to prevent it from turning. 1 1. Spring Free bellows no. 21 from valve piston no. 20. F06D0TB 1 2 1. Unscrew piston 2. Hold sliding valve Remove compression spring no. 29. 75 smr2005-082 www.SeaDooManuals.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) 1 A06D26A F06D28A 1 1. Remove spring 1. Remove O-ring Remove supporting ring no. 28. Remove sliding valve no. 22. 1 F06D27A F06D0UA 1. Remove supporting ring 1. Remove sliding valve Remove O-ring no. 23. Remove bellows no. 21. 76 1 smr2005-082 www.SeaDooManuals.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) Remove tuned pipe, refer to the appropriate VEHICLE SHOP MANUAL. Proceed with ENGINE ON BENCH WORK. 1 Engine on Bench Work Remove cylinder screws no. 13. Remove cylinders no. 9, while making sure connecting rods do not hit crankcase edge.  WARNING If screws need to be heated for removal when engine is in watercraft, fuel system pressurization must be done first. Do not use open flame; use a heat gun. F06D0VA 1.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) 1 2 3 1 F00B0IA F01D43A 1. Openings covered with rag and rubber pad To remove circlip no. 5, insert a pointed tool in piston notch then pry it out and discard.  WARNING Always wear safety glasses when removing piston circlips. TYPICAL 1. Puller 2. Shoulder sleeve 3. Sleeve – Fully thread on puller handle. – Insert extractor spindle into the piston pin. – Slide the sleeve and shoulder sleeve onto the spindle.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) 1 F00B0KA 1 F00B0MA TYPICAL 1. Tool cut-out toward bottom of piston TYPICAL 1. Remove shoulder sleeve – Firmly hold puller and rotate handle to pull piston pin no. 4. – Rotate spindle until the shoulder sleeve is flushed with the piston recess. – Carefully remove the piston no. 3. – The needles, thrust washers and the sleeve remain in the connecting rod bore and may be used again. 1 1 2 F00B0NA 1. Needles and thrust washer 2.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) INSPECTION ASSEMBLY Refer to table below to find top end engine dimension specifications. For dimension measurement procedures, refer to ENGINE MEASUREMENT. Visually inspect all parts for corrosion damage. Inspect piston for damage. Light scratches can be sanded with a fine sand paper. NOTE: When repairing a seized engine, connecting rods should be checked for straightness and crankshaft for deflection/misalignment. Inspect plane surfaces for warpage.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) GASKET THICKNESS IDENTIFICATION HOLES 0.3 mm (.012 in) 3 0.4 mm (.016 in) 4 0.5 mm (.020 in) 5 0.6 mm (.024 in) 6 0.8 mm (.031 in) 8 Piston At assembly, place the pistons no. 3 with the letters ″AUS″ (over an arrow on the piston dome) facing in direction of the exhaust port. F01D8LA 1 Cylinder Base Gasket NOTE: The general procedure is to install a new gasket of the same thickness.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) NOTE: Make sure thrust washers are present each side of needles. – Install the shoulder sleeve tool on the opposite side of the piston pin. 1 2 Replacement roller bearings are delivered in a convenient plastic mounting device. For installation, proceed as follows: – Align replacement roller bearing with connecting rod bore. – Carefully push inner plastic sleeve into connecting rod bore; outer plastic ring will release rollers. 1 F00B0OA TYPICAL 1.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) 1 1 2 F01D0RA F01D0TA 1. Piston pin flush here 2. Thrust washers 1. Pulling inner sleeve half – Place piston over connecting rod and align bores, then gently tap piston pin with a fiber hammer to push out inner plastic ring on opposite side. Support piston from opposite side. Circlip Always use new circlips.  WARNING Always wear safety glasses when installing piston circlips. CAUTION: Always use new circlips.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) Cylinder To easily slide cylinder no. 9 over piston, use the piston ring compressor (P/N 420 876 979). F06B01A 1 TYPICAL 1. Circlip installer – Remove sleeve from pusher then insert circlip into its bore. – Reinstall sleeve onto pusher and push until circlip comes in end of tool. 1 A01B1TA 1. Slide this edge NOTE: Ring compressor will not fit on oversize parts. Make sure to align ring end gap with piston locating pin. Slide tool over rings.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) When reassembling cylinders to crankcase, it is important to have them properly aligned so that exhaust flanges properly match up with exhaust manifold. The exhaust manifold is used to align cylinders. Torque screws in a criss-cross sequence for each cylinder to 20 N•m (15 lbf•ft). Repeat the procedure, retightening all cylinder screws to 40 N•m (30 lbf•ft). 2 F01D7FA 1 F00D0FA 1.
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Section 03 787 RFI ENGINE Subsection 03 (TOP END) Apply also Molykote 111 (P/N 413 707 000) on threads of screws no. 14. Torque cylinder head screws no. 14 to 12 N•m (106 lbf•in) as per following illustrated sequence. Repeat the procedure, retightening all screws to 24 N•m (17 lbf•ft). 10 8 2 4 6 Torque exhaust manifold screws to 24 N•m (17 lbf•ft) as per following illustrated sequence. Repeat the procedure, retightening screws to 40 N•m (30 lbf•ft).
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) BOTTOM END SERVICE TOOLS Description Part Number bearing heater....................................................................... distance gauge ..................................................................... Distance ring......................................................................... extension handle .................................................................. gear/bearing puller .............................................
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) 30 mL (1 oz) SAE 30 motor oil 110 Nm (81 lbfft) 1 Loctite 518 11 Anti-seize lubricant Molykote 111 15 5 4 6 18 Anti-seize lubricant 2 14 4 Molykote 111 6 12 13 16 3 Anti-seize lubricant Loctite 642 Anti-seize lubricant Anti-seize lubricant 12 19 2 Molykote 111 Loctite 243 Loctite 518 40 Nm 8 (30 lbfft) 9 Nm (80 lbfin) F07D0VS Molykote 111 11 Loctite 518 Molykote 111 Loctite 518 7 24 Nm (17 lbfft) 4 6 4 Loctite 5910
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) GENERAL 1 Engine has to be removed from watercraft to take apart bottom end. Refer to appropriate VEHICLE SHOP MANUAL. Engine top end has to be disassembled to take apart bottom end. Refer to TOP END section in this manual. NOTE: Crankcase halves are factory matched and therefore, are not interchangeable or available as single halves. DISASSEMBLY PTO Flywheel To remove PTO flywheel no. 1, the crankshaft must be locked.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) Put engine on a stand. Loosen crankcase screws. 2 1 1 1 1 F01D1LA TYPICAL 1. Separate halves by prying at provided lugs F15D05A 2 Remove crankshaft and counterbalance shaft. 1. M10 x 73.5 flanged screws 2. M8 x 53.5 flanged screws Crankshaft End Bearings Put engine back on a support. Insert a pry bar between crankcase lugs to separate halves. CAUTION: Be careful to precision machined surfaces.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) 1 2 3 4 5 1 F01B2MA 1. 2. 3. 4. 5. 6. 7. 6 7 Puller (P/N 420 877 635) Protective cap (P/N 420 876 557) Distance ring (P/N 420 876 569) Ring (P/N 420 977 490) Ring halves (P/N 420 977 475) Screw M8 x 40 (P/N 420 840 681) Screw M8 x 70 (P/N 420 841 201) F01D1PA NOTE: To facilitate ring or distance ring installation, lubricate their inside diameters. 2 1. Press bearings out 2. Bearing extractor Crankshaft Gear The crankshaft gear no.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) 1 2 3 4 5 F00B0CA F00D0IA 2 1. 2. 3. 4. 5. 1 Puller (P/N 420 877 635) Protective cap (P/N 420 876 557) Ring (P/N 420 977 480) Ring halves (P/N 420 876 330) Screw M8 x 40 (P/N 420 840 681) 1. Puller 2. Protective cap Secure puller in a vise and remove gear and bearing. 1 F00D0KA 1. Tool installed Counterbalance Shaft Gear F00D0JA NOTE: If the inner PTO bearing needs to be replaced, remove the Woodruff key on the crankshaft.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) Use a press to remove the gear no. 14 from the counterbalance shaft. F00D0TA A32CB5A CLEANING TYPICAL General Discard all oil seals, gaskets, O-rings and sealing rings. Clean oil passages and make sure they are not clogged. Clean all metal components in a solvent. Crankshaft Clean crankshaft end with sand paper no.180 and remove all residue using pulley flange cleaner (P/N 413 711 809).
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) TOLERANCE MEASUREMENT NEW PART WEAR LIMIT mm (in) Crankshaft deflection MAG N.A. 0.05 (.020) Crankshaft deflection CENTER N.A. 0.08 (.003) Crankshaft deflection PTO N.A. 0.03 (.001) min. 0.230 (.008) max. 0.617 (.024) 1.2 (.047) Connecting rod big end axial play F00D2CA FIRST PASS Crankcase Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with a fine sandpaper.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) Touch the inner race of the bearing with the temperature indicator stick (P/N 529 035 970). Stick will liquefy when the bearing reach the proper temperature. A32CB7A TYPICAL A32CB9A CAUTION: Bearing should not be heated to more than 80°C (176°F). Do not heat bearing with direct flame or heat gun or heated oil. Inappropriate heating procedure(s) may cause inner seal failure.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) Install distance ring no. 12. Position its chamfer toward crankshaft counterweight. Slide inner bearing on crankshaft until it bottoms. To properly position outer bearing, distance gauge (P/N 529 034 900) must be temporarily installed against inner bearing. Slide outer bearing until stopped by distance gauge, then remove distance gauge. F00D0LA 1 1. Woodruff key on the crankshaft 1 529034900 1 2 2 F00D0MA 1. Keyway 2.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) 1 F00D0UA 1. Gear notch aligned with the crankcase – The notch of the couterweight on the opposite end of the counterbalance shaft must also be aligned with the cranckcase. 1 Crankcase Sealant Application IMPORTANT: When beginning the application of the crankcase sealant, the assembly and the first torquing should be done within 10 minutes. It is suggested to have all you need on hand to save time.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) F12R18A 1 F00D0PA Do not apply in excess as it will spread out inside crankcase. Crankshaft and Counterbalance Shaft Install crankshaft no. 3 in crankcase. NOTE: When installing crankshaft in crankcase, make sure drive pins no. 6 of bearings are properly installed in crankcase recesses. 1 1. Marks must be aligned Turn by hand the crankshaft and counterbalance shaft. Make sure they do not interfere with the crankcase.
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) 11 7 1 3 5 9 12 8 4 2 6 10 1 F00D0QA 1. Hollow side facing bearing F15D05C Crankcase Halves Assemble crankcase halves. Crankcase Screws Apply Loctite 518 (P/N 293 800 038) on screw threads and Molykote 111 (P/N 413 707 000) below head screws. Torque crankcase screws to 12 N•m (106 lbf•in) as per following sequence. Repeat procedure, retightening all screws to 24 N•m (17 lbf•ft).
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Section 03 787 RFI ENGINE Subsection 04 (BOTTOM END) 1 F01D84A 1. O-ring Apply Loctite 767 (anti-seize lubricant) (P/N 293 800 070) to crankshaft threads. Using the same tools as for disassembly procedure, torque PTO flywheel to 110 N•m (81 lbf•ft). 100 smr2005-083 www.SeaDooManuals.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) ROTARY VALVE SERVICE TOOLS Description Part Number Degree wheel ....................................................................... handle ................................................................................... puller..................................................................................... pusher................................................................................... pusher.......................................
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) 787 RFI Engines 9 6 5 10 14 8 15 7 11 3 4 13 Molykote 111 20 Nm 2 (15 lbfft) Injection oil Anti-seize 9 Nm (80 lbfin) 12 1 smr2005-084-001_aen 102 smr2005-084 www.SeaDooManuals.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) GENERAL Rotary Valve Shaft The clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without taking apart engine. However engine must be disassembled to work on rotary valve shaft/components. To remove the rotary valve shaft assembly, the engine must be removed from watercraft (refer to appropriate VEHICLE SHOP MANUAL). First remove snap ring no. 4 from crankcase.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) Shaft Bearing To remove bearing no. 8 use a bearing extractor such as Snap-on no. CJ-950 (or equivalent) as illustrated. Slide off distance sleeve no. 14, remove snap ring no. 7 and washer no. 15 then press shaft out. 1 1 F01D61A 1. Hold bolt F01D4NA 2 1. Bearing 2. Bearing extractor CAUTION: Ensure that rotary valve shaft is perfectly perpendicular with press tip.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) Rotary Valve Shaft Refer to table below to find dimension specifications. For measurement procedures, refer to ENGINE MEASUREMENT section. F01J0ZA Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing. Slide puller hammer outwards and tap puller end. Retighten claws as necessary to always maintain them tight against bearing.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) 1 F01D2DA 2 1 3 1. Shield side (toward gear) Push bearing until it stops on its seat. A13C0FB 1. Seal 2. Ball bearing 3. Bearing extractor Snap-on CJ-950 Install washer no. 15, snap ring no. 7 and slide distance sleeve no. 14 on shaft. 1 2 3 4 F01D99A F01D2FA Seal Apply Molykote 111 grease (P/N 413 707 000) on seal lips. Position seal no. 11 with shielded portion against shaft splines.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) 290876609 420 877 650 Push shaft until it stops on bearing seat. F01D8OA Snap Ring Position snap ring no. 4 so that its sharp edge faces outwards. Rotary Valve The rotary valve no. 13 controls the opening and closing of the inlet ports. Therefore its efficiency will depend on the precision of its installation. IDENTIFICATION OF THE ROTARY VALVE ENGINE ROTARY VALVE P/N DURATION 787 RFI 420 924 502 159° 107 smr2005-084 www.SeaDooManuals.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) There is no identification code on the valve. To find out the duration, place an angle finder on the valve and measure the valve cut-out angle or use the following template. 159° F01D73W 108 smr2005-084 www.SeaDooManuals.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) ROTARY VALVE TIMING CAUTION: Never use the ridge molded in crankcase as a timing mark. The following tools are required to measure rotary valve opening and closing angles in relation with MAG side piston.
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Section 03 787 RFI ENGINE Subsection 05 (ROTARY VALVE) 1 65° F01D3EB 2 CLOSING MARK Step 1: Top of MAG inlet port. Align 360° line of degree wheel Step 2: Find 65° on outer scale of degree wheel and mark here – Remove degree wheel. – Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC. NOTE: Rotary valve is asymmetrical. Therefore, try flipping it over then reinstall on splines to obtain best installation position.
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Section 03 787 RFI ENGINE Subsection 06 (TECHNICAL SPECIFICATIONS) TECHNICAL SPECIFICATIONS ENGINE Engine type Induction type Exhaust system Type Water injection fitting (head) Water injection fitting (cone) Water injection fitting (muffler) Exhaust valve Starting system Lubrication Fuel/oil mixture Oil injection pump Oil injection type Number of cylinders Bore Standard First oversize Second oversize Stroke Displacement Corrected compression ratio Cylinder head volume Cylinder head warpage (maximum)
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Section 03 787 RFI ENGINE Subsection 06 (TECHNICAL SPECIFICATIONS) ENGINE Engine type Induction type Exhaust system Type Water injection fitting (head) Water injection fitting (cone) Water injection fitting (muffler) Exhaust valve Starting system Lubrication Fuel/oil mixture Oil injection pump Oil injection type Number of cylinders Bore Standard First oversize Second oversize Stroke Displacement Corrected compression ratio Cylinder head volume Cylinder head warpage (maximum) Piston ring type and qua
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