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2005Engine Shop Manual

ROTAX®

717 and 787 RFI™ENGINES


Legal deposit:National Library of QuebecNational Library of Canada 2005All rights reserved. No parts of this manual may be reproduced in any form without the prior writtenpermission of Bombardier Recreational Products Inc. (BRP).©Bombardier Recreational Products Inc. (BRP) 2005

Technical PublicationsBombardier Recreational Products Inc. (BRP)Valcourt (Québec) Canada

Printed in Canada®™ 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 GreaseTOPS™

This document contains the trademarks of the following companies:Loctite® is a trademark of Loctite CorporationMolykote© is a trademark of Dow Corning CorporationSnap-on® is a trademark of Snap-on Tools Corporation


TABLE OF CONTENTS

SAFETY NOTICE .... ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... III

INTRODUCTION .... ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. .. IVGENERAL INFORMATION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IVENGINE IDENTIFICATION NUMBER (E.I.N.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IVENGINE EMISSIONS INFORMATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IVTIGHTENING TORQUES .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IVARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . V

01 ENGINE MEASUREMENT01 – MEASUREMENT PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CYLINDER HEAD WARPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1CYLINDER TAPER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1CYLINDER OUT OF ROUND .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1COMBUSTION CHAMBER VOLUME MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1PISTON/CYLINDER WALL CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2RING/PISTON GROOVE CLEARANCE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4RING END GAP.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5CRANKSHAFT (ASSEMBLED ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5CRANKSHAFT (DISASSEMBLED ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6ROTARY VALVE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

02 717 ENGINE01 – LEAK TEST .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11PREPARATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11ENGINE LEAKAGE DIAGNOSTIC FLOW CHART.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

02 – MAGNETO SYSTEM... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DISASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

03 – TOP END.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27DISASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

04 – BOTTOM END .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37


05 – ROTARY VALVE . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49INSPECTION (ASSEMBLED ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49DISASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51INSPECTION (DISASSEMBLED ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51ROTARY VALVE TIMING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

I


TABLE OF CONTENTS

06 – TECHNICAL SPECIFICATIONS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

03 787 RFI ENGINE01 – LEAK TEST .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59ENGINE LEAKAGE DIAGNOSTIC FLOW CHART.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

02 – MAGNETO SYSTEM... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

DISASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

03 – TOP END.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73DISASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

04 – BOTTOM END .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87


05 – ROTARY VALVE . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103INSPECTION (ASSEMBLED ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103DISASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105INSPECTION (DISASSEMBLED ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105ROTARY VALVE TIMING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

06 – TECHNICAL SPECIFICATIONS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

II


SAFETY NOTICE

SAFETY NOTICEThis ENGINE SHOP MANUAL has been prepared as a guide to correctly service and repair the 717 and787 RFI Rotax® engines.This edition was primarily published to be used by technicians who are already familiar with all serviceprocedures relating to BRP products. Mechanical technicians should attend training courses given byBRP 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 readand understand these.In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of thegeneral configuration of the parts. They are not to be interpreted as technical drawings or exact replicasof 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 itwas designed.

� WARNING

Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repairprocedures.

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 theinformation 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 professionalmechanic. It is understood that certain modifications may render use of the engine illegal under existingfederal, provincial and state regulations.

smr2005-074 III


INTRODUCTION

INTRODUCTIONGENERAL INFORMATIONThis ENGINE SHOP MANUAL covers the 717 and787 RFI Rotax made engines. It should be used inconjunction with the appropriate VEHICLE SHOPMANUAL.The information and component/system descrip-tions contained in this manual are correct at timeof writing. BRP however, maintains a policy ofcontinuous improvement of its products withoutimposing upon itself any obligation to install themon products previously manufactured.BRP reserves the right at any time to discontinueor change specifications, designs, features, mod-els or equipment without incurring obligation.This ENGINE SHOP MANUAL uses technicalterms which may be different from the ones ofthe Parts Catalogs.When ordering parts always refer to the specificmodel Parts Catalogs.

ENGINE IDENTIFICATIONNUMBER (E.I.N.)717 Engines

The Engine Identification Number is located on theupper side of the magneto housing.

1

F01D01A

TYPICAL1. Engine Identification Number (E.I.N.)

787 RFI Engines

The Engine Identification Number is located on theupper crankcase on PTO side.

��

1. Engine Identification Number (E.I.N.)

ENGINE EMISSIONSINFORMATIONRefer to the appropriate VEHICLE SHOP MANU-AL.

TIGHTENING TORQUESTighten fasteners to torque mentioned in explod-ed views and/or text.

� WARNING

Torque wrench tightening specificationsmust strictly be adhered to. Locking de-vices (e.g.: locking tabs, elastic stop nuts,self-locking fasteners, etc.) must be installedor replaced with new ones, where specified.If the efficiency of a locking device is im-paired, it must be renewed.

IV

smr2005-074


INTRODUCTION

ARRANGEMENT OF THISMANUAL, ILLUSTRATIONSAND PROCEDURESThe manual is divided into many major sections asyou can see in the main table of contents at thebeginning of the manual.Several sections are divided in various subsec-tions. There is a table of contents at the beginningof many sections.The illustrations show the typical construction ofthe different assemblies and, in all cases, may notreproduce the full detail or exact shape of the partsshown, however, they represent parts which havethe same or a similar function.

CAUTION: These engines are designed withparts dimensioned mostly in the metric sys-tem. However some components may befrom the imperial system. When replacingfasteners, 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 anytask, you read and thoroughly understand the en-tire section or subsection in which the procedureis contained.A number of procedures throughout the book re-quire the use of special tools. Before undertakingany procedure, be sure that you have on hand allthe tools required, or approved equivalents.

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INTRODUCTION

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INTRODUCTION

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Section 01 ENGINE MEASUREMENTSubsection 01 (MEASUREMENT PROCEDURES)

MEASUREMENT PROCEDURESNOTE: This section explains the procedures tocorrectly measure engine components. For theengine technical specifications, refer to INSPEC-TION in the appropriate ENGINE subsection.

CYLINDER HEAD WARPAGECheck gasketed surface of the cylinder head witha straight edge and a feeler gauge. Make sure partis within the given specification. If cylinder head isout of specification, replace it. Verify combustionchamber volume to use the correct cylinder basegasket with the new part.

CYLINDER TAPERUsing a cylinder bore gauge, measure cylinder di-ameter at 16 mm (5/8 in) from top of cylinder justbelow auxiliary transfer port, facing exhaust portand just below the auxiliary transfer port facingthe exhaust port. Compare readings. If the dif-ference between readings exceed specification,cylinder should be rebored and honed or replaced.

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TYPICAL1. Measuring perpendicularly (90°) to piston pin axis2. Auxiliary transfer portA. 16 mm (5/8 in)

CYLINDER OUT OF ROUNDUsing a cylinder bore gauge, measure cylinderdiameter at 16 mm (5/8 in) from top of cylinder.Measure diameter in piston pin axis directionthen perpendicularly (90°) to it. If the differencebetween readings exceed specification, cylindershould be rebored and honed or replaced.

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TYPICAL1. Measuring in piston pin axis2. Measuring perpendicularly (90°) to piston pin axisA. 16 mm (5/8 in)

COMBUSTION CHAMBERVOLUME MEASUREMENTNOTE: This procedure is required to determinethe thickness of the cylinder base gasket to be in-stalled if a crank repair has involved replacementof connecting rods or if you are experiencingrepetitive engine seizure.The combustion chamber volume is the region inthe cylinder head above the piston at Top DeadCenter (TDC). It is measured with the cylinderhead installed on the engine.

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1. Combustion chamber

NOTE: When checking the combustion chambervolume, engine must be cold, piston must be freeof 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 andinjection oil.

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1. Graduated burette (0 - 50 cc)

– Open burette valve to fill its tip. Add liquid inburette until level reaches 0 cc.

– Inject the burette content through one sparkplug hole until liquid touches the top hole.

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TYPICAL1. Top of spark plug hole

NOTE: The liquid level in cylinder must not dropfor a few seconds after filling. If so, there is aleak between piston and cylinder. The recordedvolume 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 notwithin specifications, change cylinder base gasketthickness 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 WALLCLEARANCE

Method with a Used PistonUsing a micrometer, measure piston skirt perpen-dicularly (90°) to piston pin and at the specified dis-tance as per following table.

ENGINE MAXIMUM “A” mm (in)

717 29 (1.142)

787 RFI 28 (1.102)

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F01D0NA1

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1. Measuring perpendicularly (90°) to piston pin axisA. See previous table

Note the piston dimension on the piston dome andcompare it with the obtained result.

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1. Piston dome2. Piston measurement

NOTE: The measured dimension must not be lessthan 0.12 mm (.005 in) of the one scribed on pistondome. Otherwise, use a new piston and measurepiston/cylinder wall clearance following methodwith a new piston.If piston is within specifications, adjust and lockthe micrometer to the obtained piston dimension.

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1. Micrometer set to the piston dimension

Proceed with FINAL MEASUREMENT PROCE-DURE WITH EITHER A USED OR NEW PISTONbelow.

Method with a New PistonTo determine the piston dimension, take the mea-surement on the piston dome.

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1. Piston dome2. Piston measurement

Adjust and lock a micrometer to the specified val-ue on the piston dome.

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1. Micrometer set to the piston dimension

Proceed with FINAL MEASUREMENT PROCE-DURE WITH EITHER A USED OR NEW PISTONbelow.

Final Measurement Procedure witheither a Used or New PistonWith the micrometer set to the piston dimension,adjust a cylinder bore gauge to the micrometerdimension and set the indicator to zero.

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1. Use the micrometer to set the cylinder bore gauge2. Dial bore gauge

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1. Indicator set to zero

Position the dial bore gauge at 16 mm (5/8 in) be-low cylinder top edge.

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1. Measuring perpendicularly (90°) to piston pin axisA. 16 mm (5/8 in)

Read the measurement on the cylinder boregauge. The result is the exact piston/cylinder wallclearance.NOTE: Make sure the cylinder bore gauge indica-tor is set exactly at the same position as with themicrometer, otherwise the reading will be false.

RING/PISTON GROOVECLEARANCEUsing a feeler gauge, check clearance betweenrectangular ring and groove. If clearance exceedsspecified tolerance, replace piston.

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NOTE: Ring/piston groove clearance can be cor-rectly measured only on rectangular ring which isbottom ring.

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TYPICAL

RING END GAPPosition ring halfway between exhaust port andtop 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 gapexceeds specified tolerance, rings should be re-placed.

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1. Top of cylinder2. Ring end gap

CRANKSHAFT (ASSEMBLEDENGINE)The following checks can be performed with en-gine in watercraft without overhauling engine.

Crankshaft Alignment at CenterMain JournalSince it is an assembled crankshaft it can becomemisaligned or deflected. Crankshaft can be twist-ed on center main journal, changing timing of onecylinder in relation with the other.

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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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TYPICAL1. TDC gauge2. Degree wheel3. Hand tighten nut4. 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° ondegree wheel (360° - 180°= 180°).Any other reading indicates a misaligned crank-shaft.

Crankshaft Alignment at ConnectingRod JournalCounterweights can also be twisted on connect-ing rod journal on any or both cylinder(s).

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1. Connecting rod journal alignment here

Such misalignment may make it difficult to manu-ally turn the crankshaft. Verification can be doneby measuring deflection each end of crankshaft.If deflection is found greater than specified toler-ance, this indicates worn bearing(s), bent and/ormisaligned crankshaft. Proceed with the disas-sembly of the engine.

CRANKSHAFT (DISASSEMBLEDENGINE)The following verifications can be performed withthe engine disassembled.

Connecting Rod StraightnessAlign a steel ruler on edge of small end connectingrod bore. Check if ruler is perfectly aligned withedge of big end.

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1. Ruler must be aligned with edge of connecting rod here2. Align ruler here

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Crankshaft DeflectionCrankshaft deflection is measured each end witha dial indicator.First, check deflection with crankshaft incrankcase. If deflection exceeds the specifiedtolerance, it can be either ball bearings wear, bentor twisted crankshaft at connecting rod journal.

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1. Measuring PTO side deflection in crankcase

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1. Measuring MAG side deflection in crankcase

Remove crankshaft bearings and check deflectionagain on V-shaped blocks as illustrated.

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1. Measuring MAG side deflection on V-shaped blocks

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1. Measuring PTO side deflection on V-shaped blocks

NOTE: Crankshaft deflection cannot be correctlymeasured between centers of a lathe.If the deflection exceeds the specified tolerance,crankshaft should be repaired or replaced.

Connecting Rod Big End Axial PlayUsing a feeler gauge, measure distance betweenthrust washer and crankshaft counterweight.

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1. Measuring big end axial play2. Feeler gauge

Connecting Rod StraightnessAlign a steel ruler on edge of small end connectingrod bore. Check if ruler is perfectly aligned withedge of big end.

ROTARY VALVE

Rotary Valve/Cover Clearance45° FEELER GAUGE METHODRemove 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 torquescrews to 20 N•m (15 lbf•ft).Insert a feeler gauge blade through cover inletports to verify clearance. At least verify clearanceat two different places in each port.Feeler gauge blade thickness according to specifi-cations should fit between rotary valve and cover.

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1. 45° feeler gauge

If rotary valve cover clearance is out of specifica-tions, machine rotary valve cover seating surfaceor replace the cover.

SOLDERING WIRE METHODRemove 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 onebelow 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.

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TYPICAL1. Soldering wires

Reinstall cover WITHOUT its O-ring and torquescrews to 20 N•m (15 lbf•ft).

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Remove cover then clean and measure com-pressed soldering wire thickness, it must bewithin 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 CoverThe amount of material over tolerance must beremoved from the rotary valve cover seating sur-face.Also cut the O-ring groove the same amount tokeep the 1.00 ± 0.03 mm (.039 ± .001 in) depthbetween the bottom of the groove and the seatingsurface.Remove burrs on the edges of the seating surfaceand O-ring groove.

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SAME AMOUNT REMOVED FROM COVER SEATINGSURFACE AND O-RING GROOVE BASE1. Cover seating surfaceA. O-ring groove depth must be 1.00 ± 0.03 mm (.039 ± .001 in)

Reverify the clearance.At assembly, the rotary valve timing must remainas per original setting.NOTE: If rotary valve crankcase surface is worn, itis possible to have it reworked at the factory.

Rotary Valve Shaft DeflectionDeflection is measured with a dial gauge. Installrotary valve shaft in crankcase half, without itsgear.NOTE: End bearing must be in crankcase half.Measure shaft deflection next to gear splines.

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1. Rotary valve shaft2. End bearing in place

If the deflection of rotary valve shaft exceeds thespecified tolerance, replace it.

smr2005-085 9


Section 02 717 ENGINESubsection 01 (LEAK TEST)

LEAK TESTSERVICE TOOLSDescription Part Number Page

engine leak test kit ............................................................... 295 500 352 ........................................... 11large hose pincher ................................................................ 529 032 500 ........................................... 13small hose pincher................................................................ 295 000 076 ..................................... 11–13

GENERALThe 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.

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ENGINE LEAK TEST KIT

Before disassembling any components of the en-gine, it is important to perform a leakage test todetermine 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 ofhaving to remove and reinstall the engine again.Static bench testing is the most effective way toconduct a leakage test. Inboard testing does notallow complete access to, and observation of allengine surfaces and should be avoided wheneverpossible.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 thecollars provided in the kit to ensure a proper seal-ing.

When pressurizing the engine, first confirm thatthe components of the leak test kit are not leakingby 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 theend 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 continuetesting as there is the possibility of having morethan one leak. Continue pumping to compensatefor the air lost to find another leak.

PREPARATIONUsing the appropriate VEHICLE SHOP MANUAL,remove the engine from the vehicle and place iton a bench or an appropriate engine support.

TESTING PROCEDURE

Engine Cooling SystemRemove the exhaust manifold gasket and ensurethe surface is clean.Install the appropriate exhaust manifold plate fromthe engine leak test kit (P/N 295 500 352). Tightenplate using fasteners provided in the kit.NOTE: Do not torque plate excessively.Install a small hose pincher (P/N 295 000 076) onengine drain hose.

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1. Engine drain hose blocked with a hose pincher

Use hoses provided in the kit and install them onthe engine.Install pump using reducer and appropriate tube(s)as necessary.

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1. Loop hose and use clamps2. Use two washers with exhaust manifold stud3. Hose with adapter and nipple

Activate pump and pressurize engine cooling sys-tem to 34 kPa (5 PSI).Wait 3 minutes and check if pressure drops; if so,verify all testing components.– If kit components are not leaking and pressure

drops, verify all external jointed surfaces, tem-perature sensor and the O-ring between thespark plug area and the cylinder head cover. Ifnone of these components are leaking, there isan internal leak and it can be detected with BOT-TOM END AND TOP END testing.

Bottom End and Top EndRemove the carburetor and gasket. Make surethe surface of the intake manifold is clean.Install the intake plate with fasteners from the kitand tighten adequately.Make sure the spark plugs are installed and tight-ened.Block pulse hose using a small hose pincher(P/N 295 000 076).NOTE: Do not block the rotary valve shaft hoses.Install pump to the exhaust plate fitting.

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1. Intake plates2. Pulse hose blocked with a hose pincher3. Exhaust plate

Activate pump and pressurize engine to 34 kPa(5 PSI).

CAUTION: Do not exceed this pressure.Wait 3 minutes and check if pressure drops; if so,verify all testing components.If kit components are not leaking, verify enginejointed surfaces as per following areas:– spark plugs– cylinder head gasket– cylinder base gasket– crankcase halves– rotary valve cover– engine plugs– exhaust manifold– intake manifold– oil injection pump.Check also small oil injection pump lines and fit-tings; check for air bubbles or oil column goingtoward pump, which indicate a defective checkvalve.If the above mentioned components are not leak-ing, block both oil hoses of the rotary valve shaftusing small hose pincher (P/N 295 000 076) oneach side.NOTE: If leakage stops at this point, proceed withROTARY VALVE SHAFT testing.If there is still some leakage, remove the PTO fly-wheel to verify outer seal.

If no leak is found on the PTO side outer seal,remove magneto flywheel and verify crankshaftouter seals.Proceed with the ROTARY VALVE SHAFT testingif the crankshaft outer seals are not leaking.

Rotary Valve ShaftNOTE: It is mandatory to drain the injection oilfrom the rotary valve shaft.Block oil return hose of the rotary valve shaft witha large hose pincher (P/N 529 032 500).

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1. Oil return hose blocked with hose pincher

Install pump with reducer and nipple to the oil sup-ply hose of the rotary valve shaft.

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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 innerseal or crankcase is not sealed correctly.Remove MAG side spark plug. If pressure drops,it indicates a defective MAG side crankshaft innerseal or crankcase is not sealed correctly.If the above mentioned components are not leak-ing and there is a pressure drops, remove the ro-tary valve cover. Check the seal of the rotary valveshaft.If the rotary valve shaft is not leaking, it couldindicates a defective engine casting. Disassem-ble engine and carefully check for defects in cast-ings. Pay attention to tapped holes which may gothrough sealed areas of engine and thus lead toleakage.

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ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

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Section 02 717 ENGINESubsection 02 (MAGNETO SYSTEM)

MAGNETO SYSTEMSERVICE TOOLSDescription Part Number Page

extension handle .................................................................. 295 000 125 ........................................... 19M8 x 35 screws.................................................................... 420 841 591 ........................................... 19magneto coil centering tool .................................................. 420 876 922 ........................................... 22magneto puller...................................................................... 529 035 547 ........................................... 19puller plate............................................................................ 420 876 081 ........................................... 19sleeves ................................................................................. 420 847 220 ........................................... 19

SERVICE PRODUCTSDescription Part Number Page

anticorrosion spray ............................................................... 219 700 304 ........................................... 22Loctite 243 (blue).................................................................. 293 800 060 ..................................... 22–23Loctite 648 (green) ............................................................... 413 711 400 ........................................... 22Loctite 767 (antiseize lubricant) ............................................ 293 800 070 ........................................... 23Loctite chisel (gasket remover) ............................................ 413 708 500 ........................................... 21

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DISASSEMBLYNOTE: The magneto system can be disassembledwithout removing the engine from the watercraft.

Magneto CoverRemove screws no. 1 and wire support no. 2,then withdraw magneto cover no. 3.

Magneto Flywheel and Ring GearTo remove magneto flywheel no. 4, lock it withpuller plate (P/N 420 876 081), sleeves (P/N 420847 220) and extension handle (P/N 295 000 125).Using three M8 x 35 screws (P/N 420 841 591), in-stall screws through puller plate and slide sleeveson screws then secure puller plate on magneto fly-wheel so that sleeves are against ring gear no. 5.

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1. Screw2. Extension handle3. Puller plate4. Sleeve

Install extension handle on end of puller plate.

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TYPICAL1. Sleeves on opposite side

Using a suitable socket, unscrew retaining nutno. 6 COUNTERCLOCKWISE when facing it.

NOTE: If socket is found too large to be inserted inpuller plate, machine or grind its outside diameteras necessary.

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TYPICAL1. Extension handle locking crankshaft

Remove nut no. 6 and lock washer no. 7 frommagneto flywheel.Magneto flywheel is easily freed from crankshaftwith magneto puller (P/N 529 035 547).

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Fully thread on puller in puller plate.Tighten puller bolt and at the same time, tap onbolt head using a hammer to release magneto fly-wheel from its taper.

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1. Puller plate2. Puller3. Extension handle

Lay magneto flywheel no. 4 on a steel plate. Taplightly on ring gear no. 5 using a hammer to re-lease it from magneto flywheel.

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1. Magneto flywheel

Armature PlateBefore removing, locate the manufacturer's refer-ence mark on the armature plate no. 8 and en-sure there is a corresponding indexing mark on thecrankcase housing.NOTE: Since replacement crankcases do not havetiming mark for armature plate location, indexingmarks should be made on armature plate andcrankcase to ease reassembly and further ignitiontiming.The following procedure is to find a common ref-erence point on both crankcases (old and new) toposition armature plate.

Proceed as follows:– Before removing the armature plate, find a

crankcase locating lug (the top one in this ex-ample).

– Place a cold chisel at the end of chosen lug, thenpunch a mark on armature plate at this point.

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1. Crankcase locating lug2. Mark armature plate at the end of lug

– At assembly, align armature plate mark (previ-ously punched) with the end of the correspond-ing locating lug on the new crankcase.

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TYPICAL1. Lug end of crankcase2. Align mark and lug end here

Remove three retaining screws no. 9 and with-draw armature plate.

Magneto HousingTo remove magneto housing no. 10, starter has tobe removed. Refer to appropriate VEHICLE SHOPMANUAL.Unscrew retaining screws no. 11, then withdrawhousing.

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Generating CoilTo replace generating coil no. 12:– Heat the armature plate to 93°C (200°F) around

the screw holes to break the threadlocker bond.

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1. Heat the armature plate

CAUTION: Protect harness from flame.– Remove screws no. 13.– Uncrimp and unsolder BLACK/RED wire from

coil.

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1. Uncrimp and unsolder wire here

Battery Charging CoilTo replace battery charging coil no. 14:– Heat the armature plate to 93°C (200°F) around

the screw holes to break the threadlocker bond.

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1. Heat the armature plate

CAUTION: Protect harness from flame.– Remove screws no. 15.– Uncrimp and unsolder YELLOW and YEL-

LOW/BLACK wires from coil.– Uncrimp and unsolder ground wire (BLACK)

from coil core.

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1. Uncrimp and unsolder ground wire (BLACK)2. Uncrimp and unsolder YELLOW and YELLOW/BLACK wires

CLEANINGClean all metal components in a solvent.

CAUTION: Clean coils and magnets using onlya clean cloth.Clean crankshaft taper and threads using Loctitechisel (gasket remover) (P/N 413 708 500). Applythe product on a rag first then clean the crankshaft.

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ASSEMBLY

Generating CoilStrip end of old wire then crimp and solder on newcoil.Apply Loctite 243 (blue) (P/N 293 800 060) toscrews no. 13 and install the new coil no. 12 onarmature plate.Use the magneto coil centering tool (P/N 420 876922) and install so that it fits around armature platebefore tightening screws.

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1. Magneto coil centering tool

CAUTION: Before reinstalling the magneto, re-move the loose epoxy from harness.

Battery Charging CoilPosition new coil no. 14, crimp and solder allwires.Prior to assembly, apply Loctite 243 (blue)(P/N 293 800 060).Use the magneto coil centering tool (P/N 420 876922) and install it so that it fits around armatureplate before tightening screws no. 15.

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1. Magneto coil centering tool

Magneto Flywheel and Ring GearApply Loctite 648 (green) (P/N 413 711 400) tomagneto flywheel mating surface. Lay ring gearon a steel plate, then heat with a propane torch inorder to install it on magneto flywheel.Pay particular attention to position ring gear teethchamfer side as per following illustration.

F01D3BA 1

1. Teeth chamfer

NOTE: Ensure that ring gear contacts magnetoflywheel flange.Whenever replacing either ring gear or magnetoflywheel, anticorrosion spray (P/N 219 700 304)must be applied to prevent possible corrosion.

CAUTION: Always assemble magneto flywheeland ring gear prior to apply anticorrosionspray. If not done correctly, ring gear won'tcontact magneto flywheel flange.To apply anticorrosion spray proceed as follows:

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NOTE: Do not spray anticorrosion spray into mag-neto 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 HousingInstall gasket no. 16 between magneto housingno. 10 and engine crankcase.Install magneto housing and torque screws no. 11to 9 N•m (80 lbf•in).

Armature PlatePosition the armature plate on the crankcase,aligning the marks on both parts.When reinstalling armature plate on a newcrankcase housing, proceed as follows.Find manufacturer's mark on armature plate. Inline with this mark, punch another mark on adja-cent crankcase lug.

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TYPICAL1. Manufacturer's mark on armature plate2. Punch a mark on crankcase lug aligned with plate mark

The new mark on crankcase will be used for fur-ther assembly positioning as a pre-timing position.

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TYPICAL1. For further assembly, use these marks

Apply a drop of Loctite 243 (blue) (P/N 293 800060) on threads of screws no. 9 and torque to5.5 N•m (49 lbf•in).

Magneto FlywheelApply Loctite 243 (blue) (P/N 293 800 060) oncrankshaft taper.Position Woodruff key and magneto flywheel.Apply Loctite 243 (blue) (P/N 293 800 060) onnut no. 6. Install nut with lock washer no. 7 andtorque to 145 N•m (107 lbf•ft).

CAUTION: Never use any type of impactwrench at magneto installation.

Ignition TimingFor ignition timing procedures, refer to appropriateVEHICLE SHOP MANUAL.

Magneto Housing CoverProperly install O-ring no. 17 in magneto housing.Apply Loctite 767 (antiseize lubricant) (P/N 293800 070) on screws no. 1, install cover and wiresupport no. 2. Torque screws no. 1 in a criss-cross sequence to 9 N•m (80 lbf•in).

smr2005-076 23


Section 02 717 ENGINESubsection 03 (TOP END)

TOP ENDSERVICE TOOLSDescription Part Number Page

aligning tool .......................................................................... 420 876 904 ........................................... 34circlip installer ....................................................................... 529 035 562 ........................................... 32piston pin puller .................................................................... 529 035 503 ..................................... 28, 30piston ring compressor......................................................... 420 876 979 ........................................... 33rubber pad ............................................................................ 295 000 101 ........................................... 27sleeves ................................................................................. 529 035 542 ..................................... 28, 30


Loctite 243 (blue).................................................................. 293 800 060 ..................................... 34–35Loctite 518............................................................................ 293 800 038 ........................................... 35Molykote 111........................................................................ 413 707 000 ..................................... 34–35

smr2005-077 25



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26 smr2005-077



GENERALThe 2-stroke Rotax® engine rotates counterclock-wise seen from the rear (PTO flywheel).The 717 engine has a rotary valve to control open-ing and closing of the intake.

DISASSEMBLY

Cylinder Head Cover and Cylinder HeadEngine in WatercraftIf engine is left in watercraft, refer to the appropri-ate VEHICLE SHOP MANUAL to remove the fol-lowing components:– temperature sensor wire– spark plug cables– air intake silencer and support.Proceed with ENGINE ON BENCH WORK below.

Engine on Bench WorkRemove cylinder head cover screws no. 1.Remove cylinder head cover no. 2.If shells, sand, salt or any other particles arepresent in cylinder head, clean with a vacuumcleaner.Remove cylinder head no. 3.If shells, sand, salt water or any other particlesare present in cylinder cooling jacket, clean witha vacuum cleaner.

Exhaust ManifoldRemove 8 Allen screws no. 4 then withdraw ex-haust manifold no. 5.

CylinderNOTE: When removing cylinders no. 6, make sureconnecting rods do not hit crankcase edge.

Engine in WatercraftIf engine is left in watercraft, refer to the appro-priate VEHICLE SHOP MANUAL to remove thetuned pipe.Proceed with ENGINE ON BENCH WORK.

Engine on Bench WorkRemove cylinder head cover no. 2 and cylinderhead no. 3 as explained above.Remove exhaust manifold no. 5.

Remove cylinder screws no. 7.Remove cylinders no. 6, while making sure con-necting rods do not hit crankcase edge.

� WARNING

If screws need to be heated for removal whenengine is in watercraft, fuel system pressur-ization must be done first. Do not use openflame; use a heat gun.

NOTE: Even if only 1 cylinder needs repair, bothcylinders should be lifted to allow 1-piece cylinderbase gasket replacement.

PistonNOTE: Engine features cageless piston pin bear-ings.Remove cylinders no. 6 as explained above.Bring piston no. 8 to Top Dead Center (TDC) andinstall the rubber pad (P/N 295 000 101) overcrankcase opening. Secure with screws. Lowerpiston until it sits on pad.

F01B0JA

1

1. Rubber pad

If the other cylinder has been removed, complete-ly cover its opening with a clean rag.

smr2005-077 27



F01D43A

1

1. Openings covered with rag and rubber pad

To remove circlip no. 9, insert a pointed tool inpiston notch then pry it out and discard.

� WARNING

Always wear safety glasses when removingpiston circlips.

F01D0PA

1

TYPICAL1. Piston notch

To extract piston pin no. 10, use the piston pinpuller (P/N 529 035 503) with the sleeves (P/N 529035 542).

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TYPICAL1. Puller2. Shoulder sleeve3. Sleeve

– Fully thread on puller handle.– Insert extractor spindle into the piston pin.– Slide the sleeve and shoulder sleeve onto the

spindle.– Screw in extracting nut with the movable ex-

tracting ring toward spindle.

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TYPICAL1. Puller2. Sleeve3. Shoulder sleeve4. Extracting nut

NOTE: The tool cutout must be positioned towardthe bottom of the piston.

28 smr2005-077



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TYPICAL1. Tool cut-out toward bottom of piston

– Firmly hold puller and rotate handle to pull pis-ton pin no. 10.

– Rotate spindle until the shoulder sleeve isflushed with the piston recess.

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TYPICAL1. Shoulder sleeve flush with piston recess

– Loosen the extracting nut and remove puller.– Remove the shoulder sleeve from piston.

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TYPICAL1. Remove shoulder sleeve

Carefully remove the piston no. 8.The needles no. 11, thrust washers no. 12 and thesleeve remain in the connecting rod bore and maybe used again.

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TYPICAL1. Needles and thrust washer2. Sleeve

CLEANINGDiscard all gaskets and O-rings.Clean all metal components in a solvent.Clean water passages and make sure they are notclogged.Remove carbon deposits from cylinder exhaustport, cylinder head and piston dome.Clean piston ring grooves with a groove cleanertool, or a piece of broken ring.

smr2005-077 29



INSPECTIONRefer to table below to find top end engine dimen-sion specifications. For dimension measurementprocedures, refer to ENGINE MEASUREMENT.Visually inspect all parts for corrosion damage.Inspect pistons for damage. Light scratches canbe sanded with a fine sand paper.NOTE: When repairing a seized engine, connect-ing rods should be checked for straightness andcrankshaft for deflection/misalignment.Inspect plane surfaces for warpage. Small defor-mation can be corrected by grinding surface witha fine sand paper. Install sand paper on a surfaceplate and rub part against oiled sand paper.

TOLERANCESENGINE

MEASUREMENT NEW PARTS(min.) (max.)

WEARLIMIT

Combustion chambervolume 31.2 cc 34.0 cc N.A.

Cylinder taper N.A. 0.05 mm(.002 in)

0.1 mm(.004 in)

Cylinder out of round N.A. 0.008 mm(.0003 in)

0.08 mm(.003 in)

Piston skirt N.A. N.A. 0.12 mm(.005 in)

Piston/cylinder wallclearance

0.10 mm(.0039 in) N.A. 0.20 mm

(.008 in)

Ring/piston grooveclearance

0.025 mm(.001 in)

0.070 mm(.0027 in)

0.20 mm(.008 in)

Ring end gap 0.25 mm(.010 in)

0.40 mm(.016 in)

1.0 mm(.039 in)

N.A.: NOT APPLICABLE

NOTE: Replacement cylinder sleeves are availableif necessary. Also, oversize pistons of 0.25 mm(.010 in) and 0.5 mm (.020 in) are available.

ASSEMBLYAssembly is essentially the reverse of disassem-bly procedures. However pay particular attentionto the following.

PistonAt assembly, place the pistons no. 8 with the let-ters ″AUS″ (over an arrow on the piston dome) fac-ing in direction of the exhaust port.

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1. Exhaust side

Carefully cover crankcase opening as for disas-sembly.

Piston Pin and Roller BearingTo install roller bearing no. 11 and piston pin no. 10use, piston pin puller (P/N 529 035 503) with thesleeves (P/N 529 035 542).– Replacement bearings are held in place by a lo-

cating sleeve outside and 2 plastic cage halvesinside.

– Push needle bearing together with inner halvesout of the locating sleeve into the connectingrod bore.

– Replace the inner halves by the appropriatesleeve tool in the connecting rod bore.

– Insert piston pin into piston until it comes flushwith inward edge of piston hub.

– Warm piston to approximately 50 - 60°C (122 -140°F) and install it over connecting rod.

NOTE: Make sure thrust washers no. 12 arepresent each side of needles.– Install the shoulder sleeve tool on the opposite

side of the piston pin.

30 smr2005-077



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TYPICAL1. Piston pin2. Shoulder sleeve

– Insert extractor spindle into the piston pin,screw on extracting nut.

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TYPICAL1. Puller installed on the opposite side of the piston pin2. Tighten extracting nut

– Rotate handle to pull piston pin carefully into thepiston.

Plastic Mounting Device MethodThis is an alternate method when no service toolis available.Replacement roller bearings are delivered in a con-venient plastic mounting device. For installation,proceed as follows:– Align replacement roller bearing with connect-

ing rod bore.– Carefully push inner plastic sleeve into con-

necting rod bore; outer plastic ring will releaserollers.

F01D0QA

1

1. Outer ring removal after inner sleeve insertion into bore

– Make sure thrust washers no. 12 are presenteach side of rollers.

F01D0VA

1

1. Thrust washer each side

– Insert piston pin no. 10 into piston no. 8 until itcomes flush with inward edge of piston hub.

smr2005-077 31



F01D0RA

1

2

1. Piston pin flush here2. Thrust washers

– Place piston over connecting rod and alignbores, then gently tap piston pin with a fiberhammer to push out inner plastic ring on oppo-site side. Support piston from opposite side.

F01D0SA

– As necessary, pull halves of inner sleeve withlong nose pliers.

F01D0TA

1

1. Pulling inner sleeve half

CirclipAlways use new circlips no. 9.

� WARNING

Always wear safety glasses when installingpiston circlips.

CAUTION: Always use new circlips. At instal-lation, take care not to deform them. Circlipsmust not move freely after installation.Secure circlip with its opening located at the bot-tom of the piston.

CAUTION: To minimize the stress on thecirclips, it is important to install them as de-scribed.

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1. Circlip opening at 6 o'clock (at bottom)

To easily insert circlip into piston, use the circlipinstaller (P/N 529 035 562).

32 smr2005-077



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TYPICAL1. Circlip installer

– Remove sleeve from pusher then insert circlipinto its bore.

– Reinstall sleeve onto pusher and push until cir-clip comes in end of tool.

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TYPICAL1. Circlip near end of tool

– Position end of tool against piston pin opening.– Firmly hold piston against tool and tap tool with

a hammer to insert circlip into its groove.

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TYPICAL

CAUTION: The hand retaining the pistonshould absorb the energy to protect the con-necting rod.

Cylinder Base GasketNOTE: The general procedure is to install a newgasket of the same thickness. However, if you donot know the gasket thickness that was installedor if a crank repair has involved replacement ofconnecting rods, refer to COMBUSTION CHAM-BER VOLUME MEASUREMENT in ENGINE MEA-SUREMENT section to properly determine the re-quired gasket thickness.Different thicknesses of cylinder base gasketsno. 13 are used for a precise adjustment of thecombustion chamber volume.To identify gasket thickness, refer to the identifi-cation holes on the gasket.

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TYPICAL1. Identification holes

GASKET THICKNESS IDENTIFICATIONHOLES

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

CylinderTo easily slide cylinder no. 6 over piston no. 8, usethe piston ring compressor (P/N 420 876 979).

smr2005-077 33



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1. Slide this edge

NOTE: Ring compressor will not fit on oversizeparts.Make sure to align ring end gap with piston locat-ing pin. Slide tool over rings.

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Slide cylinder over piston.

F01D10A

When reassembling cylinders to crankcase, it isimportant to have them properly aligned so thatexhaust flanges properly match up with exhaustmanifold no. 5.

The aligning tool (P/N 420 876 904) or the exhaustmanifold can be used to align cylinders.

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1. Exhaust flange aligning tool

F01D45A

1

1. Aligning cylinders using exhaust manifold

Cylinder ScrewApply Molykote 111 (P/N 413 707 000) below thescrew head.Apply also Loctite 243 (blue) (P/N 293 800 060) onscrew threads.Install and torque screws no. 7 in a criss-crosssequence for each cylinder to 24 N•m (17 lbf•ft).Refer to the following illustration.

34 smr2005-077



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Cylinder HeadInstall cylinder head gasket.Make sure to install O-rings no. 14 around sparkplug holes and O-ring no. 15 of cylinder head asshown in the following illustration.

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Apply Loctite 518 (P/N 293 800 038) in O-ringgroove of cylinder sleeves.

Cylinder Head CoverInstall cylinder head cover no. 2.Apply Loctite 243 (blue) (P/N 293 800 060) belowhead of screws no. 1.Apply also Molykote 111 (P/N 413 707 000) onthreads of screws no. 1.Torque cylinder head screws no. 1 to 12 N•m(106 lbf•in) as per following illustrated sequence.Repeat the procedure, retightening all screws to24 N•m (17 lbf•ft).

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TORQUING SEQUENCE

Exhaust ManifoldMake sure gaskets are properly positioned prior tofinalizing manifold installation.Apply Molykote 111 (P/N 413 707 000) on threadsof exhaust manifold screws no. 4.Install exhaust manifold no. 5 and torque screwsto 24 N•m (17 lbf•ft) as per following illustratedsequence.

F01D59A

1 35

824

7

6

smr2005-077 35


Section 02 717 ENGINESubsection 04 (BOTTOM END)

BOTTOM ENDSERVICE TOOLSDescription Part Number Page

bearing heater....................................................................... 529 035 969 ........................................... 43distance gauge ..................................................................... 529 034 800 ........................................... 44Distance ring......................................................................... 420 876 569 ........................................... 41MAG side ring halves ........................................................... 420 276 025 ........................................... 41Protective cap....................................................................... 420 876 557 ........................................... 41PTO flywheel remover.......................................................... 295 000 001 ........................................... 39PTO side ring halves............................................................. 420 977 475 ........................................... 41Puller..................................................................................... 420 877 635 ........................................... 41Ring ...................................................................................... 420 977 490 ........................................... 41Screw M8 x 40 ..................................................................... 420 840 681 ........................................... 41Screw M8 x 70 ..................................................................... 420 841 201 ........................................... 41temperature indicator stick................................................... 529 035 970 ........................................... 44


chisel gasket remover .......................................................... 413 708 500 ........................................... 42Loctite 518............................................................................ 293 800 038 ........................................... 46Loctite 5910.......................................................................... 293 800 081 ........................................... 45Loctite 767 (antiseize lubricant) ............................................ 293 800 070 ..................................... 44, 46Molykote 111........................................................................ 413 707 000 ..................................... 45–46pulley flange cleaner............................................................. 413 711 809 ........................................... 41

smr2005-078 37



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38 smr2005-078



GENERALEngine has to be removed from watercraft to takeapart bottom end. Refer to appropriate VEHICLESHOP MANUAL.Engine top end has to be disassembled to takeapart bottom end. Refer to TOP END section inthis manual.NOTE: Crankcase halves are factory matched andtherefore, are not interchangeable or available assingle halves.

DISASSEMBLY

PTO FlywheelTo remove PTO flywheel no. 1, the crankshaftmust be locked. Refer to MAGNETO SYSTEMand follow the procedure to lock the magneto fly-wheel.PTO flywheel is loosen using the PTO flywheelremover (P/N 295 000 001).

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Insert special tool in PTO flywheel splines.

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TYPICAL1. PTO flywheel remover

Using a suitable wrench or socket with a break-er bar, unscrew PTO flywheel COUNTERCLOCK-WISE when facing it and hold extension handlelocking the magneto flywheel.

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NOTE: When splines of PTO flywheel are wornout and special tool cannot be used, proceed withthe following alternate method.Use a pipe wrench and install it on PTO flywheelas illustrated.

F00D10A

1


Crankshaft End SealsIf crankshaft end seals no. 5 have to be re-placed, bottom end must be opened. Refer toCRANKCASE and CRANKSHAFT END BEARINGSbelow.

CrankcaseBefore opening crankcase no. 2, remove the fol-lowing parts:– engine supports– magneto flywheel and housing, refer to MAG-

NETO SYSTEM section

smr2005-078 39



– starter, refer to appropriate VEHICLE SHOPMANUAL

– rotary valve cover and valve, refer to ROTARYVALVE section

– engine top end, refer to TOP END section.Put engine on a stand. Loosen crankcase screws.

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1. M10 x 73.5 flanged screws2. M8 x 68.5 flanged screws3. M8 x 45 socket head screws

Put engine back on a support. Insert a pry barbetween crankcase lugs to separate halves.

CAUTION: Be careful to precision machinedsurfaces.

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TYPICAL1. Separate halves by prying at provided lugs

F01D1LA

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Remove crankshaft no. 3.

Crankshaft End BearingsNOTE: Do not needlessly remove crankshaft bear-ings no. 4.Take apart crankcase as per procedure above.Remove end seals.

F06D1GA 1

TYPICAL1. End seal

To remove end bearings no. 4 from crankshaftno. 3, use the following tools.

40 smr2005-078



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1. Puller (P/N 420 877 635)2. Protective cap (P/N 420 876 557)3. Distance ring (P/N 420 876 569), MAG side only4. Ring (P/N 420 977 490), both sides5. MAG side ring halves (P/N 420 276 025)6. PTO side ring halves (P/N 420 977 475)7. Screw M8 x 40 (P/N 420 840 681)8. Screw M8 x 70 (P/N 420 841 201)

NOTE: To facilitate ring or distance ring installa-tion, lubricate their inside diameters.

F01D1OA

1

TYPICAL1. Removing crankshaft bearing

As an alternate method, use a bearing extractorsuch as Proto no. 4332 and a press to removetwo bearings at a time.

F01D1PA

1

2

1. Press bearings out2. Bearing extractor

CLEANING

GeneralDiscard all oil seals, gaskets, O-rings and sealingrings.Clean oil passages and make sure they are notclogged.Clean all metal components in a solvent.

CrankshaftClean crankshaft end with sand paper no.180 andremove all residue using pulley flange cleaner(P/N 413 711 809).

smr2005-078 41



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TYPICAL

CrankcaseCrankcase mating surfaces are best cleaned us-ing a combination of the chisel gasket remover(P/N 413 708 500) and a brass brush. Brush a firstpass in one direction then make the final brushingperpendicularly (90°) to the first pass cross (hatch).

CAUTION: Never use a sharp object to scrapeaway old sealant as score marks incurred aredetrimental to crankcase sealing.

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FIRST PASS

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SECOND PASS

Finish the cleaning with acetone.

CAUTION: Be careful not to spray cleaner onthe painted surface of the engine. Do not wipewith rags. Use a new clean hand towel only.

INSPECTIONRefer to table below to find bottom end engine di-mension specifications. For dimension measure-ment procedures, refer to ENGINE MEASURE-MENT.

42 smr2005-078



TOLERANCE

New partsENGINEMEASUREMENT

Min MaxWear limit

MAG N.A. N.A. 0.050 mm(.002 in)Crankshaft

deflection PTO N.A. N.A. 0.030 mm(.001 in)

Connecting rodbig end axial play

0.311 mm(.012 in)

0.677 mm(.026 in)

1.2 mm(.047 in)

CrankcaseInspect plane surfaces for warpage. Small defor-mation can be corrected by grinding surface witha fine sandpaper. Install sandpaper on a surfaceplate and rub part against oiled sand paper.

BearingsInspect crankshaft bearings no. 4. Check for cor-rosion, scoring, pitting, chipping or other evidenceof wear. Make sure plastic cage is not melted.Rotate and make sure they turn smoothly.

ASSEMBLYAssembly is essentially the reverse of disassem-bly procedures. However pay particular attentionto the following.NOTE: It is recommended to spray injection oil onall moving parts when reassembling the engine.

Crankshaft End BearingsHeat up the bearing(s) using the bearing heater(P/N 529 035 969). This will expand bearings andease installation.

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TYPICAL

CAUTION: Bearing should not be heated tomore than 80°C (176°F). Do not heat bearingwith direct flame or heat gun or heated oil.Inappropriate heating procedure(s) may causeinner seal failure.Turn bearing(s) several times during heatingprocess for heating it (them) properly.NOTE: Normally it takes approximately 10 min-utes to heat up a bearing so in the event of replac-ing bearing, it's recommended to start the bearingheating process prior to removal operation. Twobearings can be heated at the same time on onebearing heater.

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TYPICAL1. Bearings

smr2005-078 43



Touch the inner race of the bearing with the tem-perature indicator stick (P/N 529 035 970). Stickwill liquefy when the bearing reach the propertemperature.

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TYPICAL

� WARNING

Do not touch heated bearing with bare han-dle. Wear heat resisting gloves before han-dling the heated bearing(s).

Smear Loctite 767 (antiseize lubricant) (P/N 293800 070) on part of crankshaft where bearing fits.

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TYPICAL

Install the distance ring no. 12. Make sure to posi-tion it with its chamfer toward the counterweightof the crankshaft.

Slide in the inner bearing. Push bearing to endposition.Install the retaining disk.To properly position the outer bearing(s), the dis-tance gauge (P/N 529 034 800) must be temporar-ily installed against the inner bearing. Slide theouter bearing until stopped by the distance gauge,then remove the distance gauge.

F01B0HA

1

1. Distance gauge

F01D1YA

1

2

TYPICAL1. Distance gauge2. Outer bearing

CrankcaseNOTE: Rotary valve shaft must be installed incrankcase before closing halves.

CAUTION: Before joining crankcase halves,make sure that crankshaft gear is well engagedwith rotary valve shaft gear.

Crankcase Sealant ApplicationIMPORTANT: When beginning the application ofthe crankcase sealant, the assembly and the firsttorquing should be done within 10 minutes. It issuggested to have all you need on hand to savetime.

44 smr2005-078



NOTE: It is recommended to apply this specificsealant as described here to get an uniform appli-cation without lumps. If you do not use the rollermethod, you may use your finger to uniformly dis-tribute the sealant.Use the Loctite 5910 (P/N 293 800 081) on matingsurfaces.

CAUTION: Do not use other products to sealcrankcase. Do not use an activator with theLoctite 5910. Using other products or non sil-icone-based sealant over a previously sealedcrankcase with Loctite 5910 will lead to pooradhesion and possibly a leaking crankcase.Even after cleaning, the Loctite 5910 wouldleave incompatible microscopic particles.Use a plexiglass plate and apply some sealant onit. Use a soft rubber roller (50 - 75 mm (2 - 3 in))(available in arts products suppliers) and roll thesealant to get a thin uniform coat on the plate(spread as necessary). When ready, apply thesealant on crankcase mating surfaces.

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TYPICAL

Do not apply in excess as it will spread out insidecrankcase.

Crankshaft SealsWhen installing seals no. 5, apply a light coat ofMolykote 111 (P/N 413 707 000) on seal lips.

CrankshaftWhen installing crankshaft in crankcase, makesure drive pins no. 6 of bearings are properlyinstalled in crankcase recesses.

F00D0OA

1

1. Drive pins

Crankcase HalvesAssemble crankcase halves.NOTE: Temporarily install armature plate to aligncrankcase halves with each other.

smr2005-078 45



Crankcase ScrewsApply Loctite 518 (P/N 293 800 038) on screwthreads and Molykote 111 (P/N 413 707 000) be-low head screws.Torque crankcase screws no. 7 and no. 9 to24 N•m (17 lbf•ft) as per following illustratedsequence.

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Torque 2 M10 crankcase screws no. 8 to 40 N•m(30 lbf•ft).

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1. Torque to 40 N•m (30 lbf•ft)

Oil FittingsIf inlet and outlet oil fittings no. 11 of rotary valveshaft have been removed from crankcase, rein-stall them with their end pointing toward ignitionhousing. Apply Loctite 518 (P/N 293 800 038) onthreads of fittings.

StudsAt assembly in crankcase, apply Loctite 518(P/N 293 800 038) on threads of studs no. 10.Torque to 10 N•m (89 lbf•in).

PTO FlywheelApply Loctite 767 (antiseize lubricant) (P/N 293800 070) to crankshaft threads.

Using the same tools as for disassembly proce-dure, torque PTO flywheel to 110 N•m (81 lbf•ft).

46 smr2005-078


Section 02 717 ENGINESubsection 05 (ROTARY VALVE)

ROTARY VALVESERVICE TOOLSDescription Part Number Page

degree wheel........................................................................ 529 035 607 ........................................... 55puller..................................................................................... 420 876 488 ........................................... 49pusher................................................................................... 420 876 501 ........................................... 51pusher................................................................................... 420 876 605 ........................................... 52TDC gauge............................................................................ 295 000 143 ........................................... 55


Loctite 243 (blue).................................................................. 293 800 060 ........................................... 56Molykote 111........................................................................ 413 707 000 ........................................... 52XP-S mineral injection oil ...................................................... 413 802 900 ........................................... 56

smr2005-079 47



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48 smr2005-079



GENERALThe clearance of rotary valve cover or rotary valveshaft gear backlash can be performed without tak-ing apart engine.However engine must be disassembled to workon rotary valve shaft/components.

INSPECTION (ASSEMBLEDENGINE)

Rotary Valve/Cover ClearanceRemove air intake silencer and carburetor. Referto appropriate VEHICLE SHOP MANUAL.Refer to table below to find dimension specifica-tions. For measurement procedures, refer to EN-GINE MEASUREMENT section.

TOLERANCESENGINE


Rotary valve/coverclearance

0.25 mm(.010 in)

0.3 mm(.014 in)

NOTE: If the rotary valve/cover clearance is toosmall, this could create an overheating situationand if the clearance is too high, this could create ahard starting situation.

Rotary Valve Shaft Gear BacklashVerify rotary valve shaft gear backlash as follows:Remove PTO flywheel guard.Remove spark plugs, rotary valve cover and valve.Manually feel backlash at one position, then turncrankshaft about 1/8 turn and recheck. Continuethis way to complete one revolution.Backlash must be even at all positions. Otherwiseoverhaul engine to find which part is faulty (gear,rotary valve shaft or crankshaft with excessive de-flection).

DISASSEMBLY

Rotary Valve CoverRemove air intake silencer. Refer to appropriateVEHICLE SHOP MANUAL.Unscrew 4 retaining screws no. 2 and withdrawrotary valve cover no. 1 and rotary valve no. 13.

Rotary Valve ShaftTo remove the rotary valve shaft assembly, theengine must be removed from watercraft (refer toappropriate VEHICLE SHOP MANUAL).Open bottom end and remove crankshaft (refer toBOTTOM END section).First remove rotary valve cover and valve then re-move snap ring no. 4 from crankcase.

F01D22A

1

1. Removing snap ring

To remove rotary valve shaft assembly, use thepuller (P/N 420 876 488).

F01D23B

Place puller over rotary valve shaft end and screwon puller bolt into shaft. While retaining bolt witha wrench, turn puller nut CLOCKWISE until shaftcomes out.

smr2005-079 49



F01D61A 1

1. Hold bolt

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Circlip and Spring SeatIf it is necessary to disassemble components ofrotary valve shaft assembly, use seat no. 6 to com-press spring and remove circlips no. 5.

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1. Compress seat2. Remove circlips

Shaft BearingTo remove bearing no. 8 use a bearing extractorsuch as Snap-on no. CJ-950 (or equivalent) as il-lustrated. Slide off distance sleeve no. 14, re-move snap ring no. 7 and washer no. 15 thenpress shaft out.

F01D4NA

1

2

1. Bearing2. Bearing extractor Snap-on CJ-950

CAUTION: Ensure that rotary valve shaft is per-fectly perpendicular with press tip.

End BearingCAUTION: Do not remove plug against bearingin upper crankcase half.

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1. Do not remove this plug

End bearing no. 9 can be easily removed from up-per crankcase half using the following suggestedtool (or equivalent):– Snap-on hammer puller including:

• handle CJ93-1• hammer CJ125-6• claws CJ93-4.

50 smr2005-079



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Close puller claws so that they can be insertedin end bearing. Holding claws, turn puller shaftclockwise so that claws open and become firmlytight against bearing.Slide puller hammer outwards and tap puller end.Retighten claws as necessary to always maintainthem tight against bearing. Continue this way un-til bearing completely comes out.

F01D28A

1

1. End bearing

CLEANINGDiscard all seals and O-rings.Clean all metal components in a solvent.Clean oil passages and make sure they are notclogged.Clean rotary valve shaft and inside of distancesleeve no. 14.

INSPECTION (DISASSEMBLEDENGINE)

Rotary Valve CoverInspect rotary valve cover no. 1 for warpage.Small deformation can be corrected by surfacingwith fine sand paper on a surface plate. Surfacepart against oiled sand paper.

Rotary Valve ShaftRefer to table below to find dimension specifica-tions. For measurement procedures, refer to EN-GINE MEASUREMENT section.

TOLERANCESENGINE


Rotary valve shaftdeflection N.A. 0.08 mm

(.003 in)

GearVisually check gear wear pattern. It should beeven on tooth length all around. Otherwise itcould indicate a bent shaft, check deflection.Replace gear if damaged.Check for presence of brass filings in gear hous-ing.

BearingsInspect bearings no. 8 and no. 9. Check for scor-ing, pitting, chipping or other evidence of wear.Make sure plastic cage (on bigger bearing) is notmelted. Rotate them and make sure they turnsmoothly.


End BearingTo install end bearing no. 9 in crankcase, use thepusher (P/N 420 876 501).

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1. Pusher

Position ball bearing shielded side towards rotaryvalve.

smr2005-079 51



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1. Shield side (toward gear)

Push bearing until it stops on its seat.

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SealApply Molykote 111 (P/N 413 707 000) on seal lips.Position seal no. 11 with shielded portion againstshaft splines.

Shaft BearingInstall ball bearing as illustrated.

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1. Seal2. Ball bearing3. Bearing extractor Snap-on CJ-950

Install washer no. 15, snap ring no. 7 and slidedistance sleeve no. 14 on shaft no. 3.

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1. Seal2. Ball bearing3. Snap ring4. Distance sleeve5. Washer 0.5 mm (.020 in)6. Rotary valve shaft

Rotary Valve Shaft AssemblyCAUTION: Crankcase halves must be separat-ed and crankshaft must not be present to installrotary valve shaft assembly in crankcase.To install rotary valve shaft in crankcase, use thepusher (P/N 420 876 605).

52 smr2005-079



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1. Pusher

Push shaft until its stops on bearing seat.

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1. Rotary valve shaft2. Push shaft until it stops

Snap RingPosition snap ring no. 4 so that its sharp edgefaces outwards.

Rotary ValveThe rotary valve no. 13 controls the opening andclosing of the inlet ports. Therefore its efficiencywill depend on the precision of its installation.

IDENTIFICATION OF THE ROTARY VALVE

ENGINE ROTARYVALVE P/N DURATION

717 420 924 502 159°

There is no identification code on the valve. Tofind out the duration, place an angle finder on thevalve and measure the valve cut-out angle or usethe following template.

smr2005-079 53



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54 smr2005-079



ROTARY VALVE TIMINGCAUTION: Never use the ridge molded in crankcase as a timing mark.The degree wheel (P/N 529 035 607) and the TDCgauge (P/N 295 000 143) are required to measurerotary valve opening and closing angles in relationwith MAG side piston.

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Rotary valve must be set so that timing occurs asfollows:

TIMING

ENGINEOPENING

BTDCCLOSING

ATDC

717 147° ± 5 65.5° ± 5

Timing ProcedureThe following timing procedure example usesthese specifications:OPENING: 147° BTDCCLOSING: 65° ATDCProceed as follows:– Turning crankshaft, bring MAG side piston to

Top Dead Center using the TDC gauge.

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1. Bring piston to TDC

– For opening mark, first align 360° line of degreewheel with BOTTOM of MAG side inlet port.Then, find 147° line on inner scale of degreewheel and mark crankcase at this point.

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OPENING MARKStep 1: Bottom of MAG inlet port. Align 360° line of degree wheelStep 2: Find 147° on inner scale of degree wheel and mark here

NOTE: Do not rotate the crankshaft.– For closing mark, first align 360° line of degree

wheel with TOP of MAG side inlet port. Then,find 65° line on outer scale of degree wheel andmark crankcase at this point.

smr2005-079 55



F01D3EB

65°

1

2

CLOSING MARKStep 1: Top of MAG inlet port. Align 360° line of degree wheelStep 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 withthe MAG piston at TDC.

NOTE: Rotary valve is asymmetrical. Therefore,try flipping it over then reinstall on splines to obtainbest installation position.Apply XP-S mineral injection oil (P/N 413 802 900)on rotary valve before reassembling rotary valvecover.– Remove TDC gauge.

Rotary Valve CoverInstall O-ring no. 12 and rotary valve cover no. 1.Apply Loctite 243 (blue) (P/N 293 800 060) onthreads of rotary valve cover screws no. 2 thentorque them to 20 N•m (15 lbf•ft) in a criss-crosssequence.

56 smr2005-079


Section 02 717 ENGINESubsection 06 (TECHNICAL SPECIFICATIONS)

TECHNICAL SPECIFICATIONSENGINE GTI

Engine type ROTAX 717, 2-strokeInduction type Rotary valve

Type Water cooled, water injectedWater injection fitting (head) 3.5 mm (.139 in)Exhaust systemWater injection fitting (cone) 3.5 mm (.139 in)

Starting system Electric startFuel/oil mixture VROI (Variable Rate Oil Injection)Oil injection pump Gear drivenLubricationOil injection type

XP-STM synthetic 2-stroke or XP-STM synthetic blendor XP-STM mineral injection oil

Number of cylinders 2Standard 82 mm (3.228 in)First oversize 82.25 mm (3.238 in)BoreSecond oversize 82.50 mm (3.248 in)

Stroke 68 mm (2.677 in)Displacement 718.2 cm³ (43.81 in³)Corrected compression ratio 6.2:1Cylinder head volume 42.4 ± 0.4 ccCylinder head warpage (maximum) 0.05 mm (.002 in)Piston ring type and quantity 1 semi-trapez — 1 rectangular

New 0.25 - 0.40 mm (.010 - .016 in)Ring end gap

Wear limit 1.00 mm (.039 in)New 0.025 - 0.070 mm (.001 - .003 in)

Ring/piston groove clearanceWear limit 0.2 mm (.008 in)New (minimum) 0.10 mm (.0039 in)

Piston/cylinder wall clearanceWear limit 0.20 mm (.008 in)

Cylinder taper (maximum) 0.10 mm (.004 in)Cylinder out of round (maximum) 0.080 mm (.003 in)

New 0.311 - 0.677 mm (.012 - .027 in)Connecting rod big end axialplay Wear limit 1.2 mm (.047 in)Crankshaft deflection MAG: 0.050 mm (.002 in) PTO: 0.030 mm (.001 in)

Opening 147° ± 5 BTDCRotary valve timing

Closing 65.5° ± 5 ATDCRotary valve duration 159°Rotary valve/cover clearance 0.25 - 0.35 mm (.010 - .014 in)

New 0.020 - 0.033 mm (.0008 - .0013 in)Connecting rod/crankshaftpin radial clearance Wear limit 0.050 mm (.002 in)

New 0.020 - 0.033 mm (.0008 - .00013 in)Connecting rod/piston pinradial clearance Wear limit 0.05 mm (.002 in)ADDITIONAL INFORMATION:

smr2005-086 57


Section 03 787 RFI ENGINESubsection 01 (LEAK TEST)

LEAK TESTSERVICE TOOLSDescription Part Number Page

engine leak test kit ............................................................... 295 500 352 ..................................... 59–60small hose pincher................................................................ 295 000 076 ..................................... 60–61supplementary engine leak test kit....................................... 295 500 780 ..................................... 59–60

GENERALAn engine leak test kit (P/N 295 500 352) and asupplementary engine leak test kit (P/N 295 500780) are available to help diagnose engine prob-lems such as engine seizure, poor performance,oil leakage, etc.

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ENGINE LEAK TEST KIT

295500780

SUPPLEMENTARY ENGINE LEAK TEST KIT

Before disassembling any components of the en-gine, it is important to perform a leakage test todetermine 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 ofhaving to remove and reinstall the engine again.Static bench testing is the most effective way toconduct a leakage test. Inboard testing does notallow complete access to, and observation of allengine surfaces and should be avoided wheneverpossible.When installing hoses of the engine leak test kit orsupplementary engine leak test kit, use the collarsprovided in the kit to ensure a proper sealing.When pressurizing the engine, first confirm thatthe components of the engine leak test kit or sup-plementary engine leak test kit are not leaking byspraying 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 theend 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 continuetesting as there is the possibility of having morethan one leak. Continue pumping to compensatefor the air lost to find another leak.

TESTING PROCEDUREUsing the appropriate VEHICLE SHOP MANUAL,remove the engine from the vehicle and place iton a bench.

smr2005-080 59



Engine Cooling SystemRemove the exhaust manifold gasket and ensurethe surface is clean.Install the appropriate exhaust manifold plate fromthe engine leak test kit (P/N 295 500 352). Tightenplate using fasteners provided in the kit.NOTE: Do not torque plate excessively.Install a small hose pincher (P/N 295 000 076) onengine drain hose.

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Use hoses provided in the kit and install them onthe engine.Install pump using reducer and appropriate tube(s)as necessary.

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REAR VIEW1. Loop hose and use clamps2. Hose with clamps. Install pump to the end3. Block engine drain hose with a hose pincher

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FRONT VIEW1. Exhaust manifold plate

Activate pump and pressurize engine cooling sys-tem to 34 kPa (5 PSI).Wait 3 minutes and check if pressure drops; if so,verify all testing components.– If kit components are not leaking and pressure

drops, verify all external jointed surfaces, tem-perature sensor and the O-ring between thespark plug area and the engine cylinder headcover. If none of these components are leaking,there is an internal leak and it can be detectedwith BOTTOM END AND TOP END testing.

Bottom End and Top EndMake sure the surface of the rotary valve cover isclean.Install the intake plates with fasteners from the kitand tighten adequately.NOTE: Use the intake and exhaust plates includedin the supplementary engine leak test kit (P/N 295500 780).Remove the RAVE valves and gaskets.Install the RAVE valve plates with fasteners fromthe kit and tighten adequately.NOTE: On RAVE system, the boot and O-ring canbe checked for leakage with the valve in place.Simply remove the cover to expose the parts.Make sure the spark plugs are installed and tight-ened.Block pulse hose using a small hose pincher(P/N 295 000 076).NOTE: Do not block the rotary valve shaft hoses.

60 smr2005-080



Install pump to the exhaust plate fitting.

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1. Intake plates2. RAVE valve plates3. Pulse hose blocked with a hose pincher4. Exhaust plate

Activate pump and pressurize engine to 34 kPa(5 PSI).

CAUTION: Do not exceed this pressure.Wait 3 minutes and check if pressure drops; if so,verify all testing components.If kit components are not leaking, verify enginejointed surfaces as per following areas:– spark plugs– cylinder head gasket– cylinder base gasket– crankcase halves– rotary valve cover– engine plugs– exhaust manifold– oil injection pump.Check also small oil injection pump lines and fit-tings; check for air bubbles or oil column goingtoward pump, which indicate a defective checkvalve.If the above mentioned components are not leak-ing, block both oil hoses of the rotary valve shaftusing a small hose pincher (P/N 295 000 076) oneach.NOTE: If leakage stops at this point, proceed withROTARY VALVE SHAFT testing.If there is still some leakage, remove the PTO fly-wheel to verify outer seal.

If no leak is found on the PTO side outer seal,remove magneto flywheel and verify crankshaftouter seals.Proceed with the ROTARY VALVE SHAFT testingif the crankshaft outer seals are not leaking.

Rotary Valve ShaftNOTE: It is mandatory to drain the injection oilfrom the rotary valve shaft.Block oil return hose of the rotary valve shaft witha hose pincher.

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1. Oil return hose blocked with hose pincher

Install pump with reducer and nipple to the oil sup-ply hose of the rotary valve shaft.

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1. Pump with reducer and nipple

Activate pump and pressurize to 34 kPa (5 PSI).Check plug of the rotary valve shaft in crankcase.

smr2005-080 61



Remove PTO side spark plug. If pressure drops,it indicates a defective PTO side crankshaft innerseal or crankcase is not sealed correctly.Remove MAG side spark plug. If pressure drops,it indicates a defective MAG side crankshaft innerseal or crankcase is not sealed correctly.If the above mentioned components are not leak-ing and there is a pressure drops, remove the ro-tary valve cover. Check the seal of the rotary valveshaft.If the rotary valve shaft is not leaking, it couldindicates a defective engine casting. Disassem-ble engine and carefully check for defects in cast-ings. Pay attention to tapped holes which may gothrough sealed areas of engine and thus lead toleakage.

62 smr2005-080



ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

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Section 03 787 RFI ENGINESubsection 02 (MAGNETO SYSTEM)

MAGNETO SYSTEMSERVICE TOOLSDescription Part Number Page

crankshaft protector ............................................................. 420 876 557 ........................................... 67installer handle ..................................................................... 420 877 650 ........................................... 69magneto puller...................................................................... 420 976 235 ........................................... 67oil seal pusher....................................................................... 420 877 740 ........................................... 69ring gear locking tool ............................................................ 529 035 846 ........................................... 67


dielectric grease ................................................................... 293 550 004 ........................................... 70Loctite 243 (blue).................................................................. 293 800 060 ........................................... 69Loctite 767 (antiseize lubricant) ............................................ 293 800 070 ..................................... 69–70Molykote 111........................................................................ 413 707 000 ..................................... 69–70pulley flange cleaner............................................................. 413 711 809 ........................................... 69

smr2005-081 65



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DISASSEMBLYNOTE: The magneto system can be disassembledwithout removing the engine from the watercraft.

Magneto Housing CoverDisconnect water hoses from heat exchanger cov-er.Loosen magneto cover screws no. 1. Removemagneto cover no. 2.

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1. Disconnect water inlet hose2. Heat exchanger cover

Remove oil pump shaft from magneto rotor nut.

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1. Oil pump shaft

Rotor and Ring GearNOTE: Crankshaft can also be locked by using thePTO flywheel extractor tool. For procedure, referto BOTTOM END.Remove crankshaft position sensor no. 3.Lock ring gear no. 4 using the ring gear lockingtool (P/N 529 035 846).

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1. Ring gear locking tool

Using a suitable socket, unscrew retaining nutno. 5 of magneto rotor COUNTERCLOCKWISEwhen facing it.Remove the ring gear locking tool.Insert the crankshaft protector (P/N 420 876 557)to outer end of crankshaft and fully thread themagneto puller (P/N 420 976 235) in magneto ro-tor no. 6.

smr2005-081 67



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TYPICAL1. Puller

Tighten puller screw and at the same time, tap onscrew head using a hammer to release magnetorotor from its taper.

Magneto HousingTo remove magneto housing no. 7, starter has tobe removed. Refer to STARTING SYSTEM.Unscrew retaining screws no. 8, then withdrawhousing.

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REMOVE SCREWS1. Magneto housing

Stator AssemblyRemove holding plate no. 9 and withdraw plugfrom cover.Unscrew bolts no. 10 and remove stator no. 11from magneto cover.

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1. Holding plate2. Stator assembly3. Remove screws

CLEANINGClean all metal components in a solvent.

CAUTION: Clean coils and magnets using onlya clean cloth.

68 smr2005-081



Clean crankshaft taper and threads using pulleyflange cleaner (P/N 413 711 809). Apply the pulleyflange cleaner (P/N 413 711 809) on a rag first thenclean the crankshaft.

ASSEMBLY

StatorInstall the stator no. 11 in magneto housing cov-er no. 2 and torque screws no. 20 to 9 N•m(80 lbf•in). Apply Loctite 243 (blue) (P/N 293 800060) on screw threads.Install wiring harness bracket no. 9 of stator andtorque screws no. 12 to 4 N•m (35 lbf•in). ApplyLoctite 767 (antiseize lubricant) (P/N 293 800 070)on screw threads.

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1. Stator screws2. Bracket

Magneto HousingTo install oil seal no. 13 of magneto housing no. 7,use the oil seal pusher (P/N 420 877 740) and theinstaller handle (P/N 420 877 650).

F01B2NA

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1. Oil seal pusher2. Installer handle

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Apply Molykote 111 (P/N 413 707 000) on oil seallips.Install gasket no. 14 between magneto housingand engine crankcase.Install magneto housing. Apply Loctite 243 (blue)(P/N 293 800 060) on threads of housing screwsno. 8 and torque them to 9 N•m (80 lbf•in).

Rotor and Ring GearApply Loctite 243 (blue) (P/N 293 800 060) oncrankshaft taper.Install ring gear on crankshaft.Apply Loctite 243 (blue) (P/N 293 800 060) on nutno. 5. Install nut with lock washer no. 15 andtorque to 120 N•m (89 lbf•ft).

CAUTION: Never use any type of impactwrench at magneto installation.

smr2005-081 69



Crankshaft Position SensorInstall crankshaft position sensor no. 3 on mag-neto housing. Apply Molykote 111 (P/N 413 707000) on its O-ring.Apply Loctite 767 (antiseize lubricant) (P/N 293800 070) on screw threads then torque it to 9 N•m(80 lbf•in).NOTE: The crankshaft position sensor is not ad-justable.

CoverBefore installing cover, make sure oil pump shaftis properly positioned. Apply Loctite 767 (anti-seize lubricant) (P/N 293 800 070) to the end ofshaft.Before installation, properly install O-ring no. 16 inengine magneto cover no. 2.Apply Loctite 767 (antiseize lubricant) (P/N 293800 070) on screws no. 1. Torque screws in acriss-cross sequence to 9 N•m (80 lbf•in).Apply dielectric grease (P/N 293 550 004) on elec-trical connections.

70 smr2005-081


Section 03 787 RFI ENGINESubsection 03 (TOP END)

TOP ENDSERVICE TOOLSDescription Part Number Page

circlip installer ....................................................................... 529 035 562 ........................................... 83piston pin puller .................................................................... 529 035 503 ..................................... 78, 81piston ring compressor......................................................... 420 876 979 ........................................... 84rubber pad ............................................................................ 295 000 101 ........................................... 77set of sleeves ....................................................................... 529 035 542 ..................................... 78, 81


Loctite 243 (blue).................................................................. 293 800 060 ........................................... 85Loctite 518............................................................................ 293 800 038 ..................................... 85–86Molykote 111........................................................................ 413 707 000 ..................................... 85–86

smr2005-082 71



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GENERALThe 2-stroke ROTAX engine rotates counterclock-wise seen from the rear (PTO flywheel).The 787 RFI engine has a rotary valve to controlopening and closing of the intake and it is alsoequipped with the Rotax Adjustable Variable Ex-haust (RAVE) system.

RAVE System(Rotax Adjustable Variable Exhaust)BASIC OPERATIONThe RAVE valves change the height of the exhaustport. The RAVE valve solenoid, which is controlledby the Engine Control Module (ECM), allows posi-tive crankcase pressure to inflate the bellows andopen the RAVE valves.On 787 RFI engine, the RAVE valves are controlledby the ECM.To open the RAVE valves, the ECM activates asolenoid which directs the positive pressure fromengine crankcase to the valves.

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TYPICAL1. Solenoid2. Pressure hose from crankcase3. To atmospheric pressure

NOTE: A check valve on the pressure line elimi-nates the negative pressure from the crankcase.To close the RAVE valves, the ECM deactivatesthe solenoid which blocks the crankcase positivepressure. The RAVE valves are opened to the at-mosphere.

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RAVE VALVE OPENED1. Pulse from crankcase2. Check valve3. Positive pressure to solenoid4. Solenoid activated5. Positive crankcase pressure to RAVE valves

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RAVE VALVE CLOSED1. Pulse from crankcase2. Check valve3. Positive pressure blocked by the solenoid4. Solenoid deactivated5. RAVE valves are opened to atmosphere

ADJUSTMENTOn top of the RAVE, there is a red plastic ad-justment knob. Turning the adjustment in or outchanges the preload on the return spring which,in turn, will change the RPM at which the RAVEvalve opens and closes.

smr2005-082 73



MAINTENANCEThere are no wear parts anywhere in the systemand there are no adjustments to be periodical-ly checked. The only possible maintenance re-quired would be cleaning of carbon deposits fromthe guillotine slide. Cleaning intervals would de-pend upon the user's riding style and the qualityof the oil used. We suggest annual cleaning ofthe valve. If a customer uses a lower than recom-mended quality oil, more frequent cleaning maybe required.No special solvents or cleaners are required whencleaning the valve.

BORING PRECAUTIONIn its stock configuration the RAVE valve guillo-tine has a minimum of 0.5 mm (.020 in) clearanceto the cylinder bore measured at the center lineof the cylinder. This is the minimum productionclearance.There is only a first oversize piston available for the787 RFI engine. That piston is 0.25 mm (.010 in)larger in diameter than the stock piston. Whenthe oversize is installed, the guillotine will havea minimum clearance of 0.375 mm (.015 in) withthe cylinder bore. This is the minimum operat-ing clearance the guillotine should be used with.Clearance less than 0.375 mm (.015 in) will requirereworking of the guillotine to achieve the properclearance and radius.

DISASSEMBLY

RAVE ValveLoosen Allen screws no. 26 each side of RAVEvalve.

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1. Remove screws

Remove RAVE valve no. 15.Remove the cover no. 18 of the valve by releasingthe spring no. 16.

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Firmly hold cover to valve base. The com-pression spring inside the valve is applyingpressure against the cover.

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1. Spring

Remove the compression spring no. 19.

74 smr2005-082



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1. Remove spring

Remove spring no. 30 retaining bellows no. 21 tovalve piston no. 20.

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1. Spring

Free bellows no. 21 from valve piston no. 20.

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1. Bellows removed from piston

Unscrew valve piston no. 20 from sliding valveno. 22.NOTE: Hold the sliding valve to prevent it fromturning.

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1. Unscrew piston2. Hold sliding valve

Remove compression spring no. 29.

smr2005-082 75



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1. Remove spring

Remove supporting ring no. 28.

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1. Remove supporting ring

Remove O-ring no. 23.

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1. Remove O-ring

Remove sliding valve no. 22.

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1. Remove sliding valve

Remove bellows no. 21.

76 smr2005-082



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1. Remove bellows

Cylinder Head Cover and Cylinder Head

Engine in WatercraftDisconnect temperature sensor wire and sparkplug cables.Connect spark plug cables on grounding device.Proceed with ENGINE ON BENCH WORK below.

Engine on Bench WorkRemove cylinder head cover screws no. 14.Remove cylinder head cover no. 1.If shells, sand, salt or any other particles arepresent in cylinder head, clean with a vacuumcleaner.Remove cylinder head no. 2.If shells, sand, salt water or any other particlesare present in cylinder cooling jacket, clean witha vacuum cleaner.

Exhaust ManifoldRemove 8 Allen screws and lock washers thenwithdraw exhaust manifold.

CylinderNOTE: When removing cylinder, make sure con-necting rods do not hit crankcase edge.

Engine in WatercraftRemove air intake silencer and support, refer tothe appropriate VEHICLE SHOP MANUAL.

Remove tuned pipe, refer to the appropriate VE-HICLE SHOP MANUAL.Proceed with ENGINE ON BENCH WORK.

Engine on Bench WorkRemove cylinder screws no. 13.Remove cylinders no. 9, while making sure con-necting rods do not hit crankcase edge.

� WARNING

If screws need to be heated for removal whenengine is in watercraft, fuel system pressur-ization must be done first. Do not use openflame; use a heat gun.

NOTE: Even if only 1 cylinder needs repair, bothcylinders should be lifted to allow 1-piece cylinderbase gasket replacement.

PistonNOTE: Engine features cageless piston pin bear-ings.Bring piston to Top Dead Center (TDC) and installthe rubber pad (P/N 295 000 101) over crankcaseopening. Secure with screws. Lower piston untilit sits on pad.

F01B0JA

1

1. Rubber pad

If the other cylinder has been removed, complete-ly cover its opening with a clean rag.

smr2005-082 77



F01D43A

1

1. Openings covered with rag and rubber pad

To remove circlip no. 5, insert a pointed tool inpiston notch then pry it out and discard.

� WARNING

Always wear safety glasses when removingpiston circlips.

F01D0PA

1

TYPICAL1. Piston notch

To extract piston pin no. 4, use the piston pin puller(P/N 529 035 503) with the set of sleeves (P/N 529035 542).

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TYPICAL1. Puller2. Shoulder sleeve3. Sleeve

– Fully thread on puller handle.– Insert extractor spindle into the piston pin.– Slide the sleeve and shoulder sleeve onto the

spindle.– Screw in extracting nut with the movable ex-

tracting ring toward spindle.

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TYPICAL1. Puller2. Sleeve3. Shoulder sleeve4. Extracting nut

NOTE: The tool cutout must be positioned towardthe bottom of the piston.

78 smr2005-082



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TYPICAL1. Tool cut-out toward bottom of piston

– Firmly hold puller and rotate handle to pull pis-ton pin no. 4.

– Rotate spindle until the shoulder sleeve isflushed with the piston recess.

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TYPICAL1. Shoulder sleeve flush with piston recess

– Loosen the extracting nut and remove puller.– Remove the shoulder sleeve from piston.

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TYPICAL1. Remove shoulder sleeve

– Carefully remove the piston no. 3.– The needles, thrust washers and the sleeve re-

main in the connecting rod bore and may beused again.

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1. Needles and thrust washer2. Sleeve

CLEANINGDiscard all gaskets and O-rings.Clean all metal components in a solvent.Clean water passages and make sure they are notclogged.Remove carbon deposits from cylinder exhaustport, RAVE valve, cylinder head and piston dome.Clean piston ring grooves with a groove cleanertool, or a piece of broken ring.

smr2005-082 79



INSPECTIONRefer to table below to find top end engine dimen-sion specifications. For dimension measurementprocedures, refer to ENGINE MEASUREMENT.Visually inspect all parts for corrosion damage.Inspect piston for damage. Light scratches can besanded with a fine sand paper.NOTE: When repairing a seized engine, connect-ing rods should be checked for straightness andcrankshaft for deflection/misalignment.Inspect plane surfaces for warpage. Small defor-mation can be corrected by grinding surface witha fine sand paper. Install sand paper on a surfaceplate and rub part against oiled sand paper.

TOLERANCESENGINE


WEARLIMIT

Combustionchamber volume 34.7 cc 37.9 cc N.A

Cylinder taper N.A. 0.05 mm(.002 in)

0.1 mm(.004 in)

Cylinder out ofround N.A. 0.008 mm

(.0003 in)0.08 mm(.003 in)

Piston skirt N.A. N.A. 0.12 mm(.005 in)

Piston/cylinderwall clearance

0.13 mm(.005 in) N.A 0.24 mm

(.009 in)

Ring/pistongroove clearance

0.025 mm(.001 in)

0.070 mm(.0027 in)

0.24 mm(.009 in)

Ring end gap 0.40 mm(.016 in)

0.55 mm(.022 in)

1.0 mm(.039 in)

N.A.: NOT APPLICABLE

NOTE: Replacement cylinder sleeves are availableif necessary. Also, oversize pistons of 0.25 mm(.010 in) are available.

RAVE ValveCheck RAVE valve bellows no. 21 for cracks.Check sliding valve for wear, bent or other dam-ages.


RAVE ValveMake sure to insert O-ring no. 23 onto rod of slid-ing valve no. 22.The TOP position of the sliding valve no. 22 isindicated on one side.

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1. Sliding valve2. O-ring3. TOP

Install a new gasket no. 24. It must be installedat the same time as the sliding valve no. 22.Position the valve housing no. 25 onto the cylinderso that its opening is toward the bottom.

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1. Bottom of valve housing

When the valve is mounted onto the cylinder,move the valve piston no. 20 to ensure the slidingvalve no. 22 moves easily and does not stick.

80 smr2005-082



��

Cylinder Base GasketNOTE: The general procedure is to install a newgasket of the same thickness. However, if you donot know the gasket thickness that was installedor if a crank repair has involved replacement ofconnecting rods, refer to COMBUSTION CHAM-BER VOLUME MEASUREMENT in ENGINE MEA-SUREMENT section to properly determine the re-quired gasket thickness.Different thicknesses of cylinder base gaskets areused for a precise adjustment of the combustionchamber volume.To identify gasket thickness, refer to the identifi-cation holes on the gasket.

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TYPICAL1. Identification holes

GASKET THICKNESS IDENTIFICATIONHOLES

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

PistonAt assembly, place the pistons no. 3 with the let-ters ″AUS″ (over an arrow on the piston dome) fac-ing in direction of the exhaust port.

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1. Exhaust side

NOTE: The exhaust ports are located on the sameside as the intake.Carefully cover crankcase opening as for disas-sembly.

Piston Pin and Roller BearingTo install roller bearing no. 4 and piston pin no. 6use the piston pin puller (P/N 529 035 503) withthe set of sleeves (P/N 529 035 542).– Replacement bearings are held in place by a lo-

cating sleeve outside and 2 plastic cage halvesinside.

– Push needle bearing together with inner halvesout of the locating sleeve into the connectingrod bore.

– Replace the inner halves by the appropriatesleeve tool in the connecting rod bore.


– Warm piston to approximately 50 - 60°C (122 -140°F) and install it over connecting rod.

smr2005-082 81



NOTE: Make sure thrust washers are presenteach side of needles.– Install the shoulder sleeve tool on the opposite

side of the piston pin.

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TYPICAL1. Piston pin2. Shoulder sleeve

– Insert extractor spindle into the piston pin,screw on extracting nut.

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TYPICAL1. Puller installed on the opposite side of the piston pin2. Tighten extracting nut

– Rotate handle to pull piston pin carefully into thepiston.

Plastic Mounting Device MethodThis is an alternate method when no service toolis available.

Replacement roller bearings are delivered in a con-venient plastic mounting device. For installation,proceed as follows:– Align replacement roller bearing with connect-

ing rod bore.– Carefully push inner plastic sleeve into con-

necting rod bore; outer plastic ring will releaserollers.

F01D0QA

1

1. Outer ring removal after inner sleeve insertion into bore

– Make sure thrust washers are present eachside of rollers.

F01D0VA

1

1. Thrust washer each side


82 smr2005-082



F01D0RA

1

2

1. Piston pin flush here2. Thrust washers

– Place piston over connecting rod and alignbores, then gently tap piston pin with a fiberhammer to push out inner plastic ring on oppo-site side. Support piston from opposite side.

F01D0SA

– As necessary, pull halves of inner sleeve withlong nose pliers.

F01D0TA

1

1. Pulling inner sleeve half

CirclipAlways use new circlips.

� WARNING

Always wear safety glasses when installingpiston circlips.

CAUTION: Always use new circlips. At instal-lation, take care not to deform them. Circlipsmust not move freely after installation.Secure circlip with its opening located at the bot-tom of the piston.

CAUTION: To minimize the stress on thecirclips, it is important to install them as de-scribed.

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1. Circlip opening at 6 o'clock (at bottom)

To easily insert circlip into piston, use the circlipinstaller (P/N 529 035 562).

smr2005-082 83



��!/��

TYPICAL1. Circlip installer

– Remove sleeve from pusher then insert circlipinto its bore.

– Reinstall sleeve onto pusher and push until cir-clip comes in end of tool.

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TYPICAL1. Circlip near end of tool

– Position end of tool against piston pin opening.– Firmly hold piston against tool and tap tool with

a hammer to insert circlip into its groove.

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CAUTION: The hand retaining the pistonshould absorb the energy to protect the con-necting rod.

CylinderTo easily slide cylinder no. 9 over piston, use thepiston ring compressor (P/N 420 876 979).

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1. Slide this edge

NOTE: Ring compressor will not fit on oversizeparts.Make sure to align ring end gap with piston locat-ing pin. Slide tool over rings.

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1. Ring end gap aligned with piston locating pin

Slide cylinder over piston.

F01D10A

84 smr2005-082



When reassembling cylinders to crankcase, it isimportant to have them properly aligned so thatexhaust flanges properly match up with exhaustmanifold.The exhaust manifold is used to align cylinders.

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1. Aligning cylinders using exhaust manifold

Apply Molykote 111 (P/N 413 707 000) belowscrew head and Loctite 518 (P/N 293 800 038) onscrew threads.Install M10 x 73.5 screws on exhaust side and theM10 x 105 on opposite side.

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smr2005-082-002_a

1. M10 x 73.52. M10 x 1053. Loctite 5184. Molykote 111

Torque screws in a criss-cross sequence for eachcylinder to 20 N•m (15 lbf•ft). Repeat the proce-dure, retightening all cylinder screws to 40 N•m(30 lbf•ft).

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Cylinder HeadInstall cylinder head gasket.Make sure to install O-rings no. 12 around sparkplug holes and O-ring no. 11 of cylinder head asshown in the following illustration.

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1. O-rings

Apply Loctite 518 (P/N 293 800 038) in O-ringgroove of cylinder sleeves.

Cylinder Head CoverInstall cylinder head cover no. 1.Apply Loctite 243 (blue) (P/N 293 800 060) belowhead of screws no. 14.

smr2005-082 85



Apply also Molykote 111 (P/N 413 707 000) onthreads 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 to24 N•m (17 lbf•ft).

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TORQUING SEQUENCE

Exhaust ManifoldMake sure gaskets are properly positioned prior tofinalizing manifold installation.Apply Loctite 518 (P/N 293 800 038) on 2 screws.On the other screws, apply Molykote 111 (P/N 413707 000) on threads. Install screws. Refer to thefollowing illustration for proper position of screws.

smr2005-048-001_a

1. Screw with Loctite 5182. Screw with Molykote 111

Torque exhaust manifold screws to 24 N•m(17 lbf•ft) as per following illustrated sequence.Repeat the procedure, retightening screws to40 N•m (30 lbf•ft).

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ADJUSTMENT

RAVE ValveTurn the red plastic knob no. 17 until it is flush tothe valve cover.

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1. Knob flush with the cover

86 smr2005-082


Section 03 787 RFI ENGINESubsection 04 (BOTTOM END)

BOTTOM ENDSERVICE TOOLSDescription Part Number Page

bearing heater....................................................................... 529 035 969 ........................................... 94distance gauge ..................................................................... 529 034 900 ........................................... 96Distance ring......................................................................... 420 876 569 ........................................... 91extension handle .................................................................. 295 000 125 ........................................... 89gear/bearing puller ................................................................ 290 877 665 ........................................... 91Protective cap....................................................................... 420 876 557 ..................................... 91–92PTO flywheel extractor......................................................... 295 000 156 ........................................... 89Puller .................................................................................... 420 877 635 ..................................... 91–92Ring ...................................................................................... 420 977 480 ........................................... 92Ring ...................................................................................... 420 977 490 ........................................... 91Ring halves ........................................................................... 420 876 330 ........................................... 92Ring halves ........................................................................... 420 977 475 ........................................... 91Screw M8 x 40 ..................................................................... 420 840 681 ..................................... 91–92Screw M8 x 70 ..................................................................... 420 841 201 ........................................... 91temperature indicator stick................................................... 529 035 970 ........................................... 95


chisel gasket remover .......................................................... 413 708 500 ........................................... 93Loctite 518............................................................................ 293 800 038 ........................................... 99Loctite 5910 ......................................................................... 293 800 081 ........................................... 97Loctite 767 (anti-seize lubricant) ........................................... 293 800 070 ................................... 95, 100Molykote 111........................................................................ 413 707 000 ........................................... 99pulley flange cleaner............................................................. 413 711 809 ........................................... 93

smr2005-083 87



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88 smr2005-083



GENERALEngine has to be removed from watercraft to takeapart bottom end. Refer to appropriate VEHICLESHOP MANUAL.Engine top end has to be disassembled to takeapart bottom end. Refer to TOP END section inthis manual.NOTE: Crankcase halves are factory matched andtherefore, are not interchangeable or available assingle halves.

DISASSEMBLY

PTO FlywheelTo remove PTO flywheel no. 1, the crankshaftmust be locked. Refer to MAGNETO SYSTEMand follow the procedure to lock the magneto fly-wheel.PTO flywheel is loosened using PTO flywheel ex-tractor (P/N 295 000 156).

295000156

Install special tool.

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1. PTO flywheel extractor

Install the extension handle (P/N 295 000 125) onthe PTO flywheel extractor.

295000125

Loosen PTO flywheel COUNTERCLOCKWISEwhen facing it.

MAG Crankshaft SealMAG crankshaft seal is retained by the magne-to housing. For replacement procedure, refer toMAGNETO SYSTEM section.

PTO Crankshaft SealIf PTO crankshaft seal no. 5 has to be re-placed, bottom end must be opened. Referto CRANKCASE and CRANKSHAFT END BEAR-INGS below.

CrankcaseBefore opening the crankcase, remove the follow-ing parts:– magneto flywheel and housing, refer to MAG-

NETO SYSTEM section– 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.

smr2005-083 89



Put engine on a stand. Loosen crankcase screws.

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1. M10 x 73.5 flanged screws2. M8 x 53.5 flanged screws

Put engine back on a support. Insert a pry barbetween crankcase lugs to separate halves.

CAUTION: Be careful to precision machinedsurfaces.

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F01D1LA

1


Remove crankshaft and counterbalance shaft.

Crankshaft End BearingsNOTE: Do not needlessly remove crankshaft bear-ings.Take apart crankcase as per procedure above.Remove PTO seal.

F06D1GA 1

TYPICAL1. PTO seal

To remove MAG and PTO end bearings no. 4 fromcrankshaft, use the following tools.

90 smr2005-083



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1. Puller (P/N 420 877 635)2. Protective cap (P/N 420 876 557)3. Distance ring (P/N 420 876 569)4. Ring (P/N 420 977 490)5. Ring halves (P/N 420 977 475)6. Screw M8 x 40 (P/N 420 840 681)7. Screw M8 x 70 (P/N 420 841 201)

NOTE: To facilitate ring or distance ring installa-tion, lubricate their inside diameters.

F01D1OA

1

TYPICAL1. Removing crankshaft bearing

PTO End Crankshaft BearingAs an alternate method, the outer PTO bearingand crankshaft gear can be removed in one stepusing another puller. See CRANKSHAFT GEARno. 18 below

MAG End Crankshaft BearingAs an alternate method, use a bearing extractorsuch as Proto no. 4332 and a press to removetwo bearings at a time.

F01D1PA

1

2

1. Press bearings out2. Bearing extractor

Crankshaft GearThe crankshaft gear no. 18 and bearing no. 5 canbe removed in one step using the gear/bearingpuller (P/N 290 877 665).

290877665

Install the puller as per following illustration.

smr2005-083 91



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1. Puller2. Protective cap

Secure puller in a vise and remove gear and bear-ing.

F00D0JA

NOTE: If the inner PTO bearing needs to be re-placed, remove the Woodruff key on the crank-shaft.

Counterbalance Shaft BearingsBearings no. 15 on counterbalance shaft no. 13can be removed by using the following tools:

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1. Puller (P/N 420 877 635)2. Protective cap (P/N 420 876 557)3. Ring (P/N 420 977 480)4. Ring halves (P/N 420 876 330)5. Screw M8 x 40 (P/N 420 840 681)

F00D0KA 1

1. Tool installed

Counterbalance Shaft GearTo remove gear no. 14, first trace an index markon the gear and counterbalance shaft.NOTE: There is no Woodruff key to position thegear on the counterbalance shaft. An index markmust be traced to ease assembly procedure.

F00D0SA 1

1. Index mark

92 smr2005-083



Use a press to remove the gear no. 14 from thecounterbalance shaft.

F00D0TA

CLEANING

GeneralDiscard all oil seals, gaskets, O-rings and sealingrings.Clean oil passages and make sure they are notclogged.Clean all metal components in a solvent.

CrankshaftClean crankshaft end with sand paper no.180 andremove all residue using pulley flange cleaner(P/N 413 711 809).

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TYPICAL

CrankcaseCrankcase mating surfaces are best cleaned us-ing a combination of the chisel gasket remover(P/N 413 708 500) and a brass brush. Brush a firstpass in one direction then make the final brushingperpendicularly (90°) to the first pass cross (hatch).

CAUTION: Never use a sharp object to scrapeaway old sealant as score marks incurred aredetrimental to crankcase sealing.

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smr2005-083 93



�� -�

FIRST PASS

��

SECOND PASS

Finish the cleaning with acetone.

CAUTION: Be careful not to spray cleaner onthe painted surface of the engine. Do not wipewith rags. Use a new clean hand towel only.

INSPECTIONRefer to table below to find bottom end dimensionspecifications. For measurement procedures, re-fer to ENGINE MEASUREMENT.

TOLERANCE

NEW PART WEARLIMITMEASUREMENT

mm (in)

Crankshaftdeflection MAG N.A. 0.05 (.020)

Crankshaftdeflection CENTER N.A. 0.08 (.003)

Crankshaftdeflection PTO N.A. 0.03 (.001)

Connecting rod bigend axial play

min. 0.230 (.008)max. 0.617 (.024) 1.2 (.047)

CrankcaseInspect plane surfaces for warpage. Small defor-mation can be corrected by grinding surface witha fine sandpaper. Install sandpaper on a surfaceplate and rub part against oiled sand paper.

BearingInspect crankshaft bearings no. 4. Check for cor-rosion, scoring, pitting, chipping or other evidenceof wear. Make sure plastic cage is not melted.Rotate and make sure they turn smoothly.

ASSEMBLYAssembly is essentially the reverse of disassem-bly procedures. However pay particular attentionto the following.NOTE: It is recommended to spray injection oil onall moving parts when reassembling the engine.

Crankshaft End BearingsHeat up the bearing(s) using the bearing heater(P/N 529 035 969). This will expand bearings andease installation.

94 smr2005-083



�� -/��

TYPICAL

CAUTION: Bearing should not be heated tomore than 80°C (176°F). Do not heat bearingwith direct flame or heat gun or heated oil.Inappropriate heating procedure(s) may causeinner seal failure.Turn bearing(s) several times during heatingprocess for heating it (them) properly.NOTE: Normally it takes approximately 10 min-utes to heat up a bearing so in the event of replac-ing bearing, it's recommended to start the bearingheating process prior to removal operation. Twobearings can be heated at the same time on onebearing heater.

�� -/��

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TYPICAL1. Bearings

Touch the inner race of the bearing with the tem-perature indicator stick (P/N 529 035 970). Stickwill liquefy when the bearing reach the propertemperature.

�� -/:�

TYPICAL

� WARNING

Do not touch heated bearing with bare han-dle. Wear heat resisting gloves before han-dling the heated bearing(s).

Smear Loctite 767 (anti-seize lubricant) (P/N 293800 070) on part of crankshaft where bearing fits.

�� -/!�

TYPICAL

smr2005-083 95



Install distance ring no. 12. Position its chamfertoward 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 installedagainst inner bearing. Slide outer bearing untilstopped by distance gauge, then remove distancegauge.

529034900

F01D1YA

1

2

TYPICAL1. Distance gauge2. Outer bearing

Crankshaft GearPosition the long flange of the gear no. 18 towardthe counterweight of the crankshaft. Also, makesure to align the gear keyway with the Woodruffkey on the crankshaft.

F00D0LA 1

1. Woodruff key on the crankshaft

F00D0MA

1

2

1. Keyway2. Long flange toward the crankshaft counterweight

Counterbalance Shaft GearPress gear no. 14 onto counterbalance shaftno. 13 taking care to align both marks previouslytraced.

CAUTION: Counterbalance shaft must be prop-erly assembled, otherwise engine will vibrateand premature wear will occur.Proceed as follows to check if the gear no. 14 isproperly positioned on the counterbalance shaft:– Temporarily install the counterbalance shaft in

the crankcase.– Rotate the counterbalance shaft to align the

notch of the gear with the crankcase.

96 smr2005-083



F00D0UA

1

1. Gear notch aligned with the crankcase

– The notch of the couterweight on the oppositeend of the counterbalance shaft must also bealigned with the cranckcase.

F00D0VA

1

1. Counterweight notch aligned with the crankcase

If notches are not aligned with the crankcase, re-move the gear and repeat the procedure until thenotches are properly aligned.

CrankcaseNOTE: Rotary valve shaft must be installed incrankcase before closing halves.

CAUTION: Before joining crankcase halves,make sure that crankshaft gear is well engagedwith rotary valve shaft gear.

Crankcase Sealant ApplicationIMPORTANT: When beginning the application ofthe crankcase sealant, the assembly and the firsttorquing should be done within 10 minutes. It issuggested to have all you need on hand to savetime.NOTE: It is recommended to apply this specificsealant as described here to get an uniform appli-cation without lumps. If you do not use the rollermethod, you may use your finger to uniformly dis-tribute the sealant.Use the silicone-based Loctite 5910 (P/N 293 800081) on mating surfaces.NOTE: Refer to the product label for the curingtime.

CAUTION: Do not use other products to sealcrankcase. Do not use an activator with theLoctite 5910. Using a non silicone-basedsealant over a previously sealed crankcasewith Loctite 5910 will lead to poor adhesionand possibly a leaking crankcase. Even aftercleaning, the Loctite 5910 would leave incom-patible microscopic particles.Use a plexiglass plate and apply some sealant onit. Use a soft rubber roller (50 - 75 mm (2 - 3 in))(available in arts products suppliers for printmak-ing) and roll the sealant to get a thin uniform coaton the plate (spread as necessary). When ready,apply the sealant on crankcase mating surfaces.

�� .��

smr2005-083 97



�� .��

Do not apply in excess as it will spread out insidecrankcase.

Crankshaft and Counterbalance ShaftInstall crankshaft no. 3 in crankcase.NOTE: When installing crankshaft in crankcase,make sure drive pins no. 6 of bearings are properlyinstalled in crankcase recesses.

F00D0OA

1

1. Drive pins

After crankshaft installation, install counterbal-ance shaft no. 13. Make sure to properly indexcrankshaft and counterbalance shaft by gear align-ing marks.

CAUTION: Marks on the crankshaft and coun-terbalance shaft must be aligned, otherwise en-gine will vibrate and premature wear will occur.

F00D0PA 1

1. Marks must be aligned

Turn by hand the crankshaft and counterbalanceshaft. Make sure they do not interfere with thecrankcase.

PTO Crankshaft SealWhen installing seal no. 5, apply a light coat oflithium grease on seal lips.Position PTO seal against the retaining shim; thegap between the seal no. 5 and bearing no. 4 willensure proper lubrication of the bearing.

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1. Seal against the retaining shim

Counterbalance Shaft Bearing CoverInstall the bearing cover no. 19 with its hollow sidetoward the bearing.

98 smr2005-083



F00D0QA

1

1. Hollow side facing bearing

Crankcase HalvesAssemble crankcase halves.

Crankcase ScrewsApply Loctite 518 (P/N 293 800 038) on screwthreads and Molykote 111 (P/N 413 707 000) be-low 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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As a final step, torque only M10 screws no. 8 ofcrankcase to 40 N•m (30 lbf•ft) as per followingsequence.

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Counterbalance Shaft Gear OilWhen crankcase assembly is completed, add30 mL (1 oz) of motor oil SAE 30 to the counter-balance shaft gear through the crankcase fillerplug.

F07D06A1

1. Remove plug and add SAE 30 motor oil

Oil FittingsIf inlet and outlet oil fittings no. 11 of rotary valveshaft have been removed from crankcase, rein-stall them with their end pointing toward ignitionhousing. Apply Loctite 518 (P/N 293 800 038) onthreads of fittings.

PTO FlywheelInstall O-ring onto crankshaft.

smr2005-083 99



F01D84A

1

1. O-ring

Apply Loctite 767 (anti-seize lubricant) (P/N 293800 070) to crankshaft threads.Using the same tools as for disassembly proce-dure, torque PTO flywheel to 110 N•m (81 lbf•ft).

100 smr2005-083


Section 03 787 RFI ENGINESubsection 05 (ROTARY VALVE)

ROTARY VALVESERVICE TOOLSDescription Part Number Page

Degree wheel ....................................................................... 529 035 607 ......................................... 109handle ................................................................................... 420 877 650 ......................................... 106puller..................................................................................... 290 876 488 ......................................... 103pusher................................................................................... 290 876 609 ......................................... 106pusher................................................................................... 420 876 501 ......................................... 105TDC gauge (short)................................................................. 295 000 143 ......................................... 109


Molykote 111 grease............................................................ 413 707 000 ......................................... 106

smr2005-084 101



787 RFI Engines

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102 smr2005-084



GENERALThe clearance of rotary valve cover or rotary valveshaft gear backlash can be performed without tak-ing apart engine.However engine must be disassembled to workon rotary valve shaft/components.

INSPECTION (ASSEMBLEDENGINE)

Rotary Valve/Cover ClearanceRemove air intake silencer and throttle body. Re-fer to appropriate VEHICLE SHOP MANUAL.Refer to table below to find dimension specifica-tions. For measurement procedures, refer to EN-GINE MEASUREMENT section.

TOLERANCESENGINE


Rotary valve/coverclearance

0.25 mm(.010 in)

0.3 mm(.014 in)

NOTE: If the rotary valve/cover clearance is toosmall, this could create an overheating situationand if the clearance is too high, this could create ahard starting situation.

Rotary Valve Shaft Gear BacklashVerify rotary valve shaft gear backlash as follows:Remove PTO flywheel guard.Remove spark plugs, rotary valve cover and valve.Manually feel backlash at one position, then turncrankshaft about 1/8 turn and recheck. Continuethis way to complete one revolution.Backlash must be even at all positions. Otherwiseoverhaul engine to find which part is faulty (gear,rotary valve shaft or crankshaft with excessive de-flection).

DISASSEMBLY

Rotary Valve CoverRemove air intake silencer and throttle body. Re-fer to appropriate VEHICLE SHOP MANUAL.Unscrew 4 retaining screws and withdraw rotaryvalve cover no. 1 and rotary valve no. 13.

Rotary Valve ShaftTo remove the rotary valve shaft assembly, theengine must be removed from watercraft (refer toappropriate VEHICLE SHOP MANUAL).First remove snap ring no. 4 from crankcase.

F01D22A

1

1. Removing snap ring

Open bottom end and remove crankshaft (refer toBOTTOM END section).To remove rotary valve shaft assembly, use theappropriate puller (P/N 290 876 488).

290876488

Place puller over rotary valve shaft end and screwon puller bolt into shaft. While retaining bolt witha wrench, turn puller nut CLOCKWISE until shaftcomes out.

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F01D61A 1

1. Hold bolt

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Circlip and Spring SeatIf it is necessary to disassemble components ofrotary valve shaft assembly, use seat no. 6 to com-press spring and remove circlips no. 5.

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1. Compress seat2. Remove circlips

Shaft BearingTo remove bearing no. 8 use a bearing extractorsuch as Snap-on no. CJ-950 (or equivalent) as il-lustrated. Slide off distance sleeve no. 14, re-move snap ring no. 7 and washer no. 15 thenpress shaft out.

F01D4NA

1

2

1. Bearing2. Bearing extractor

CAUTION: Ensure that rotary valve shaft is per-fectly perpendicular with press tip.

End BearingCAUTION: Do not remove plug against bearingin upper crankcase half.

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1. Do not remove this plug

End bearing no. 9 can be easily removed from up-per crankcase half using the following suggestedtool (or equivalent):– Snap-on hammer puller including:– handle CJ93-1– hammer CJ125-6– claws CJ93-4.

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Close puller claws so that they can be insertedin end bearing. Holding claws, turn puller shaftclockwise so that claws open and become firmlytight against bearing.Slide puller hammer outwards and tap puller end.Retighten claws as necessary to always maintainthem tight against bearing. Continue this way un-til bearing completely comes out.

F01D28A

1

1. End bearing

CLEANINGDiscard all seals and O-rings.Clean all metal components in a solvent.Clean oil passages and make sure they are notclogged.Clean rotary valve shaft and inside of distancesleeve no. 14.

INSPECTION (DISASSEMBLEDENGINE)

Rotary Valve CoverInspect rotary valve cover no. 1 for warpage.Small deformation can be corrected by surfacingwith fine sand paper on a surface plate. Surfacepart against oiled sand paper.

Rotary Valve ShaftRefer to table below to find dimension specifica-tions. For measurement procedures, refer to EN-GINE MEASUREMENT section.

TOLERANCESENGINE


Rotary valve shaftdeflection N.A. 0.08 mm

(.003 in)

GearVisually check gear wear pattern. It should beeven on tooth length all around. Otherwise itcould indicate a bent shaft, check deflection.Replace gear if damaged.Check for presence of brass filings in gear hous-ing.

BearingsInspect bearings no. 8 and no. 9. Check for scor-ing, pitting, chipping or other evidence of wear.Make sure plastic cage (on bigger bearing) is notmelted. Rotate them and make sure they turnsmoothly.


End BearingTo install end bearing no. 9 in crankcase, use push-er (P/N 420 876 501).

420876501

Position ball bearing shielded side towards rotaryvalve.

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1. Shield side (toward gear)

Push bearing until it stops on its seat.

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SealApply Molykote 111 grease (P/N 413 707 000) onseal lips. Position seal no. 11 with shielded por-tion against shaft splines.

Shaft BearingInstall ball bearing using bearing extractor as illus-trated.

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1. Seal2. Ball bearing3. Bearing extractor Snap-on CJ-950

Install washer no. 15, snap ring no. 7 and slidedistance sleeve no. 14 on shaft.

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1. Seal2. Ball bearing3. Snap ring4. Distance sleeve5. Washer 0.5 mm (.020 in)6. Rotary valve shaft

Rotary Valve Shaft AssemblyCAUTION: Crankcase halves must be separat-ed and crankshaft must not be present to installrotary valve shaft assembly in crankcase.To install rotary valve shaft in crankcase, use apusher (P/N 290 876 609) and handle (P/N 420 877650).

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290876609

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Push shaft until it stops on bearing seat.

F01D8OA

Snap RingPosition snap ring no. 4 so that its sharp edgefaces outwards.

Rotary ValveThe rotary valve no. 13 controls the opening andclosing of the inlet ports. Therefore its efficiencywill depend on the precision of its installation.

IDENTIFICATION OF THE ROTARY VALVE

ENGINE ROTARYVALVE P/N DURATION

787 RFI 420 924 502 159°

smr2005-084 107



There is no identification code on the valve. To find out the duration, place an angle finder on the valveand measure the valve cut-out angle or use the following template.

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108 smr2005-084



ROTARY VALVE TIMINGCAUTION: Never use the ridge molded incrankcase as a timing mark.The following tools are required to measure rotaryvalve opening and closing angles in relation withMAG side piston.Degree wheel (P/N 529 035 607)

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TDC gauge (short) (P/N 295 000 143)

295000143

Rotary valve must be set so that timing occurs asfollows:

TIMING

ENGINEOPENING

BTDCCLOSING

ATDC

787 RFI 147° ± 5 63.5° ± 5

Timing ProcedureThe following timing procedure example usesthese specifications:OPENING: 147° BTDCCLOSING: 65° ATDCProceed as follows:– Turning crankshaft, bring MAG side piston to

Top Dead Center using a TDC gauge.

1

F01D2IA

1. Bring piston to TDC

– For opening mark, first align 360° line of degreewheel with BOTTOM of MAG side inlet port.Then, find 147° line on inner scale of degreewheel and mark crankcase at this point.

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OPENING MARKStep 1: Bottom of MAG inlet port. Align 360° line of degree wheelStep 2: Find 147° on inner scale of degree wheel and mark here

NOTE: Do not rotate the crankshaft.– For closing mark, first align 360° line of degree

wheel with TOP of MAG side inlet port. Then,find 65° line on outer scale of degree wheel andmark crankcase at this point.

smr2005-084 109



F01D3EB

65°

1

2

CLOSING MARKStep 1: Top of MAG inlet port. Align 360° line of degree wheelStep 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 withthe MAG piston at TDC.

NOTE: Rotary valve is asymmetrical. Therefore,try flipping it over then reinstall on splines to obtainbest installation position.Apply injection oil on rotary valve before reassem-bling rotary valve cover.– Remove TDC gauge.

Rotary Valve CoverInstall O-ring no. 12 and rotary valve cover no. 1then torque screws no. 2 to 20 N•m (15 lbf•ft) ina criss-cross sequence.

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Section 03 787 RFI ENGINESubsection 06 (TECHNICAL SPECIFICATIONS)

TECHNICAL SPECIFICATIONSENGINE GTI RFI GTI RFI LE

Engine type ROTAX 787 RFI, 2-strokeInduction type Rotary valve

Type Water cooled, water injected with regulatorWater injection fitting (head) 4.0 mm (.157 in)Water injection fitting (cone) Not applicable

Exhaust system

Water injection fitting (muffler) 4.5 mm (.177 in)Exhaust valve Rotax Adjustable Variable Exhaust (RAVE)Starting system Electric start

Fuel/oil mixture VROI (Variable Rate Oil Injection)Oil injection pump Direct drivenLubricationOil injection type XP-S™ synthetic 2-stroke

Number of cylinders 2Standard 82 mm (3.228 in)First oversize 82.25 mm (3.238 in)BoreSecond oversize Not applicable

Stroke 74 mm (2.91 in)Displacement 781.6 cm³ (47.7 in³)Corrected compression ratio 6.0:1Cylinder head volume 47.7 ± 0.4 ccCylinder head warpage (maximum) 0.05 mm (.002 in)Piston ring type and quantity 1 semi-trapez -- 1 rectangular


Wear limit 1.00 mm (.039 in)New 0.025 - 0.070 mm (.001 - .003 in)

Ring/piston grooveWear limit 0.24 mm (.009 in)New (minimum) 0.13 mm (.005 in)Piston/cylinder wall

clearance Wear limit 0.22 mm (.009 in)Cylinder taper (maximum) 0.10 mm (.004 in)Cylinder out of round (maximum) 0.08 mm (.003 in)

New 0.230 - 0.617 mm (.009 - .024 in)Connecting rod big endaxial play Wear limit 1.2 mm (.047 in)

Crankshaft deflectionMAG: 0.050 mm (.002 in);

PTO: 0.030 mm (.001 in)Opening 147° ± 5° BTDC

Rotary valve timingClosing 63.5° ± 5° ATDC

Rotary valve duration 159°Rotary valve/cover clearance 0.25 - 0.35 mm (.010 - .014 in)


New 0.02 - 0.033 mm (.0008 - .00013 in)Connecting rod/piston pinradial clearance Wear limit 0.05 mm (.002 in)

Type SAE 30 motor oilCounterbalance shaft oil

Capacity 30 mL (1 U.S. oz)ADDITIONAL INFORMATION:

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Section 03 787 RFI ENGINESubsection 06 (TECHNICAL SPECIFICATIONS)

ENGINE 3D RFI 3D RFI PREMIUMEngine type ROTAX 787 RFI, 2-strokeInduction type Rotary valve

Type Water cooled (water jacket), water injection in muffler onlyWater injection fitting (head) Not applicableWater injection fitting (cone) Not applicable

Exhaust system

Water injection fitting (muffler) 3 x 3.5 mm (.138 in)Exhaust valve Rotax Adjustable Variable Exhaust (RAVE)Starting system Electric start

Fuel/oil mixture VROI (Variable Rate Oil Injection)Oil injection pump Direct drivenLubricationOil injection type XP-S™ synthetic 2-stroke

Number of cylinders 2Standard 82 mm (3.228 in)First oversize 82.25 mm (3.238 in)BoreSecond oversize Not applicable

Stroke 74 mm (2.91 in)Displacement 781.6 cm3 (47.7 in3)Corrected compression ratio 6.0:1Cylinder head volume 47.7 ± 0.4 ccCylinder head warpage (maximum) 0.05 mm (.002 in)Piston ring type and quantity 1 semi-trapez -- 1 rectangular


Wear limit 1.00 mm (.039 in)New 0.025 - 0.070 mm (.001 - .003 in)Ring/piston groove

clearance Wear limit 0.24 mm (.009 in)New (minimum) 0.13 mm (.005 in)Piston/cylinder wall

clearance Wear limit 0.22 mm (.0087 in)Cylinder taper (maximum) 0.10 mm (.004 in)Cylinder out of round (maximum) 0.08 mm (.003 in)

New 0.230 - 0.617 mm (.009 - .024 in)Connecting rod big end axialplay Wear limit 1.2 mm (.047 in)

Crankshaft deflectionMAG side: 0.050 mm (.002 in);

PTO side: 0.030 mm (.001 in)Opening 147° ± 5° BTDC

Rotary valve timingClosing 63.5° ± 5° ATDC

Rotary valve duration 159°Rotary valve/cover clearance 0.25 - 0.35 mm (.010 - .014 in)


New 0.020 - 0.033 mm (.0008 - .0013 in))Connecting rod/piston pinradial clearance Wear limit 0.050 mm (.002 in)

Type SAE 30 motor oilCounterbalance shaft oil

Capacity 30 mL (1 U.S. oz)ADDITIONAL INFORMATION:

112 smr2005-087


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