SeaDoo Rotax 1503 4-Tec 2005 Engine Shop Manual
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SeaDoo Rotax 1503 4-Tec 2005 Engine Shop Manual

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  • Page 1 www.SeaDooManuals.net...
  • Page 2 2005 Engine Shop Manual ® ROTAX 1503 4-TEC ENGINES www.SeaDooManuals.net...
  • Page 3 Legal deposit: National Library of Quebec National Library of Canada 2005 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP). Bombardier Recreational Products Inc. (BRP) 2005 ©...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ..................III INTRODUCTION ..
  • Page 5 TABLE OF CONTENTS THERMOSTAT ......................65 ROTARY SEAL.

  • Page 6: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair the Rotax ® 1503 4-TEC engines. This edition was primarily published to be used by technicians who are already familiar with all service procedures relating to BRP products.

  • Page 7: Introduction

    INTRODUCTION INTRODUCTION GENERAL INFORMATION This ENGINE SHOP MANUAL covers the Rotax 1503 4-TEC engine. It should be used in conjunc- tion with the appropriate VEHICLE SHOP MANU- The information and component/system descrip- tions contained in this manual are correct at time of writing.

  • Page 8: Arrangement Of This Manual, Illustrations And Procedures

    INTRODUCTION ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES The manual is divided into many major sections as you can see in the main table of contents at the beginning of the manual. Several sections are divided in various subsec- tions. There is a table of contents at the beginning of many sections.
  • Page 9 INTRODUCTION Page heading indicates section and subsection detailed. Subsection title indicates beginning of the subsection. Italic sub-title above exploded view indicate pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 243 to screw threads.
  • Page 10 INTRODUCTION Sub-title with part name(s) from exploded view. Section 06 FUEL SYSTEM Title indicates main procedure to be carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly, lows: spring screw, check valve housing, etc.). Sub-sub-title in Remove air vent tube support.

  • Page 11: Engines (1503 4-Tec)

    Section 01 ENGINES (1503 4-TEC) Subsection 01 (LEAK TEST) LEAK TEST SERVICE TOOLS Description Part Number Page Drive shaft adapter ............... 529 035 892 ..........2 Drive shaft adapter ............... 529 035 985 ..........2 SERVICE PRODUCTS Description Part Number Page Molykote 111................

  • Page 12: Procedure

    Section 01 ENGINES (1503 4-TEC) Subsection 01 (LEAK TEST) ENGINE TOOL 1503 4-TEC Naturally Aspirated Drive shaft adapter 1503 4-TEC (P/N 529 035 892) Supercharged 1503 4-TEC Drive shaft adapter Supercharged (P/N 529 035 985) Intercooled 1. Ignition coil 2. Spark plug –...

  • Page 13: Diagnosis

    Section 01 ENGINES (1503 4-TEC) Subsection 01 (LEAK TEST) Note the amount of leaking or percentage (de- pending on tester). LEAKAGE ENGINE PERCENTAGE CONDITION 0% to 15% Excellent condition. 16% to 25% Good condition Fair condition; engine will run 26% to 40% and performance might be down in some cases.

  • Page 14: Assembly

    Section 01 ENGINES (1503 4-TEC) Subsection 01 (LEAK TEST) – coolant escaping from weep hole means a dam- aged rotary seal on coolant pump shaft (refer to COOLING SYSTEM) 1. Weep hole – coolant escaping from coolant pump housing means damaged gasket(s) and/or loosened screws (refer to COOLING SYSTEM).

  • Page 15: Intake Manifold And Supercharger

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) INTAKE MANIFOLD AND SUPERCHARGER SERVICE TOOLS Description Part Number Page 4-pin socket ................529 035 948 ........20, 23 camshaft locking tool............529 035 839 ........... 11 leak test pump..............529 021 800 ........... 10 retaining key .................
  • Page 16 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Naturally Aspirated Engine — Intake Manifold and Throttle Body smr2005-033-200_aen TYPICAL SMR2005-033 www.SeaDooManuals.net...
  • Page 17 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Supercharged Engine — Intake Manifold and Throttle Body smr2005-033-201_aen SMR2005-033 www.SeaDooManuals.net...
  • Page 18 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Supercharged Intercooled Engine — Intake Manifold and Throttle Body smr2005-033-008_aen SMR2005-033 www.SeaDooManuals.net...
  • Page 19 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Supercharged Engines — Supercharger SMR2005-033 www.SeaDooManuals.net...

  • Page 20: Inspection (Parts Assembled)

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) INSPECTION (PARTS ASSEMBLED) Intercooler Leak Test Supercharged Intercooled Engine Perform intercooler leak test when engine looses performance, when there is white exhaust smoke or when temperature in exhaust system is to high. WARNING Let engine cool down prior to perform leak Pressurize the intercooler as follows:...

  • Page 21: Camshaft Locking Tool

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Supercharger Clutch Slipping Moment Supercharged Engines NOTE: Remove required parts to access super- charger. Refer to appropriate VEHICLE SHOP MANUAL. Remove air intake hose from supercharger. 1. Camshaft locking tool Check slipping moment counterclockwise by us- ing a torque wrench with actual torque viewer.

  • Page 22: Removal

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) If the torque is not within specifications, repair supercharger clutch. Verify supercharger clutch components as per INSPECTION (PARTS DISAS- SEMBLED) further in this section. REMOVAL Intake Manifold NOTE: Remove required parts to access intake manifold.
  • Page 23 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Unplug electrical connectors. Naturally Aspirated Engine NATURALLY ASPIRATED ENGINE 1. Ignition coils 2. TOPS 1. TOPS hose disconnected and moved away 3. TPS (hidden behind throttle body) 2. TPS connector 4.
  • Page 24 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) All Engines TYPICAL 1. EGTS connector TOPS VALVE 1. Push here and hold while pulling connector out 1. Oil filter housing 2. OPS TYPICAL 1. CTS connector Unplug the “B” connector from the ECM. TYPICAL 1.
  • Page 25 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) 1. Pull here to release Pull the connectors for the knock sensor (KS), crankshaft position sensor (CPS) and magneto 1. Detach hose out of the ECM support. For more details, refer 2.
  • Page 26 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Lift intake manifold up to pull it out of the mounting brackets just enough to reach throttle cable end. 1. Detach cable end from throttle body All Engines Pull intake manifold out. 1.

  • Page 27: Disassembly

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) 1. Upper retaining screws DISASSEMBLY 1. Inlet hose 2. Outlet hose Intake Manifold and Intercooler Remove retaining screws and pull out the super- Supercharged Intercooled Engines charger ass'y. Remove collar from intercooler. 1.
  • Page 28 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) smr2005-033-007_a 1. Intercooler 2. Profile Ring PLASTIC HAMMER 3. Collar NOTE: The cap nut on the supercharger shaft has Supercharger LH threads. Supercharged Engines Loosen cap nut (turn clockwise) on supercharger CAUTION: Be scrupulous when working on shaft turbine side while holding shaft with a retain- supercharger parts.

  • Page 29: Retaining Key

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) 1. Nut 2. L-ring 1. Washer 3. Spring washers 2. Turbine 4. Lock washer 3. O-ring 5. Ceramic washers 4. Step collar 6. Drive gear 7. Needle bearings Loosen nut on supercharger shaft engine side while holding shaft with a retaining key (P/N 529 Carefully push out supercharger shaft towards en- 035 949).

  • Page 30: Inspection (Parts Disassembled)

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Remove ball bearing from supercharger housing half (engine side) by using a press and a suitable bearing pusher. 1. Supercharger housing half (engine side) 2. Bearing pusher 1. Supercharger shaft 2.

  • Page 31: Assembly

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Intake Manifold and Intercooler DRIVEN PLATE JOURNAL DEPTH Supercharged Intercooled Engine NEW MINIMUM 9.960 mm (.3921 in) Ensure O-rings are properly installed on intercool- NEW MAXIMUM 10.000 mm (.3937 in) er and apply 4-stroke oil on them to ease installa- tion.
  • Page 32 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) 1. Outlet hose distance A. 3 - 7 mm (0.12 - 0.27 in) 1. Supercharger shaft Supercharger 2. Ball bearing 3. Bearing support plate Supercharged Engines 4. Protrusion of support plate on this side (underneath inner race) CAUTION: Every time when supercharger shaft Apply enough engine oil on ball bearing.

  • Page 33: Support Plate

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Mount supercharger housing half (engine side) on To press supercharger shaft in housing half (en- support plate (P/N 529 035 947). gine side), properly support bearing, using support plate (P/N 529 035 947) and bearing support/push- er (P/N 529 035 950) under supercharger housing half.
  • Page 34 Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) 1. Step collar 2. O-ring 3. Supercharger impeller 1. Supercharger shaft 4. Washer 2. Distance sleeve 5. Cap nut Apply engine oil on seal and push into retaining Complete installation of supercharger shaft, en- disc by hand.

  • Page 35: Loctite 243

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Install the lock washer. Apply engine oil to the spring washers. Position the spring washers as per illustration. CAUTION: When installing the spring washers, take care of the exact installation direction of the washers.

  • Page 36: Installation

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) INSTALLATION Intake Manifold Ensure that all gaskets are properly installed and in a good condition. Ensure to properly route and resecure wiring har- ness with locking ties. WARNING Always check O-ring for damage such as deformation at reinstallation.

  • Page 37: Super Lube Grease

    Section 01 ENGINES (1503 4-TEC) Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER) Ensure to install the tool perpendicularly (90°) to torque wrench to apply the proper torque to the screw. 4-TEC SUPERCHARGED ENGINES 1. Cable position in bracket 2. Cable barrel position in cam 1.

  • Page 38: Pto Housing And Magneto

    Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) PTO HOUSING AND MAGNETO SERVICE TOOLS Description Part Number Page fitting ..................293 710 037 ........... 31 impeller remover/installer ............. 529 035 820 ........... 35 locking tool ................529 035 821 ........35–37 syphon pump................
  • Page 39 Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) 4-TEC Supercharged only smr2005-032 www.SeaDooManuals.net...

  • Page 40: General

    Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) GENERAL Always perform the electric tests before removing or installing any components. Clean threads before using Loctite when installing the screws. PROCEDURES PTO HOUSING Removal TYPICAL Drain engine oil. Refer to LUBRICATION in the –...
  • Page 41 Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) PTO HOUSING REMOVAL Place rags under PTO housing to prevent spillage. Up to 250 mL (8 oz) of oil could flow out when re moving PTO housing. If spillage occurs, clean im- mediately with the pulley flange cleaner (P/N 413 711 809) to prevent oil stains.
  • Page 42 Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) smr2005-034-100_a TYPICAL 1. Washer 2. Disc spring 3. Starter drive ass'y NOTE: When installing a new starter drive ass’y, oil the shaft and threads of the gear with engine oil.

  • Page 43: Pto Seal

    Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) PTO SEAL Inspection Check the PTO seal no. 22 and O-rings no. 10 on the PTO housing. If brittle, hard or damaged, or if you see a sign of oil leakage, replace it. Removal Place rags under PTO housing to prevent spillage.

  • Page 44: Coupling

    Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) Installation Reinstall removed parts in the reverse order. CAUTION: When installing PTO seal on super- charged engines, make sure to position the Oetiker clamps as shown in the picture. TYPICAL Inspection Check if seal no.

  • Page 45: Rotor And Trigger Wheel

    Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) TYPICAL 1. Notch for stator TYPICAL 1. CPS screws 2. Holding plate Place the rubber grommets on both cables in the 3. CPS proper notches at the PTO housing. –...

  • Page 46: Ring Gear

    Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) Withdraw rotor no. 19 with trigger wheel no. 20. Properly reinstall cover. Installation For installation, reverse the removal procedure. However, pay attention to the following. Trigger wheel position has to be located with the location pin on the crankshaft gear.

  • Page 47: Starter Drive Ass'y

    Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) TYPICAL 1. Location pin 2. Location pin holes Apply Loctite 243 (P/N 293 800 060) on threads. smr2005-034-002_a Torque rotor screws to 24 N•m (17 lbf•ft). TYPICAL 1. Disc springs STARTER DRIVE ASS'Y 2.

  • Page 48: Oil Spray Nozzle

    Section 01 ENGINES (1503 4-TEC) Subsection 03 (PTO HOUSING AND MAGNETO) 1. Oil spray nozzle TYPICAL 2. Spray nozzle remover 1. Starter drive bearing – Remove oil spray nozzle carefully by using a slide hammer puller. Installation For installation, reverse the removal procedure. However, pay attention to the following.

  • Page 49: Lubrication System

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page hose adaptor................. 529 035 652 ........... 45 oil pressure gauge ..............529 035 709 ........... 45 oil seal guide................. 529 035 822 ........... 54 rotary seal pusher ..............
  • Page 50 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) All Engines 4-TEC Supercharged only 25 26 SMR2005-035 www.SeaDooManuals.net...
  • Page 51 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) Naturally Aspirated and Supercharged Engines smr2005-035-001_aen SMR2005-035 www.SeaDooManuals.net...
  • Page 52 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) Supercharged Intercooled Engine SMR2005-035 www.SeaDooManuals.net...

  • Page 53: General

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) GENERAL For oil change procedure, refer to LUBRICATION in the appropriate VEHICLE SHOP MANUAL. PROCEDURES ENGINE OIL PRESSURE NOTE: Depending the oil pressure switch, the threshold value to send a signal of low oil pressure may vary from a minimum of 180 kPa (26 PSI) to a maximum of 220 kPa (32 PSI).

  • Page 54: Pto Oil Strainer

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) Removal Remove: – engine oil (refer to OIL CHANGE in the appro- priate VEHICLE SHOP MANUAL) – PTO cover no. 5 (refer to PTO COVER/MAGNE- TO section) – oil strainer no. 6. INSTALLATION AT CYLINDER HEAD 1.

  • Page 55: Suction Pump Oil Strainer

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) 1. Oil inlet to the oil pump TYPICAL — NATURALLY ASPIRATED AND SUPERCHARGED ENGINES 1. Ventilation hose Installation For installation, reverse the removal procedure. Refill engine at the proper level with the recom- mended oil.

  • Page 56: Cleaning And Inspection

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) Cleaning and Inspection WARNING Clean oil strainer with a part cleaner then use an Wear safety glasses and work in a well air gun to dry it. ventilated area when working with strong chemical products.

  • Page 57: Engine Oil Pressure Regulator

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) Clean both contact surfaces of oil strainer cover. Check and clean the oil inlet and outlet area for dirt and other contaminations. ENGINE OIL PRESSURE REGULATOR The oil pressure regulator is located on the bottom TYPICAL of the PTO housing.
  • Page 58 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) smr2005-035-002_a TYPICAL — NATURALLY ASPIRATED ENGINE 1. Valve piston guide 2. Valve piston 3. Compression spring 4. Oil pressure regulator plug 5. O-Ring TYPICAL — SUPERCHARGED ENGINES 1. Oil pressure regulator NOTE: The oil pressure regulator system opens when the oil pressure exceeds 400 kPa (58 PSI).

  • Page 59: Oil Pressure Pump

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) COMPRESSION SPRING FREE LENGTH NEW NOMINAL 60 mm (2.362 in) SERVICE LIMIT 50.3 mm (1.980 in) Replace parts if important wear or damage are present. Clean bore and threads in the PTO housing from metal shavings and other contaminations.
  • Page 60 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) 1. Pittings on the teeth Using a feeler gauge, measure the clearance be- tween inner and outer rotors. TYPICAL CAUTION: Be careful not to damage the surface of the rotary seal bore in PTO housing cover. –...
  • Page 61 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) Using a vernier depth gauge, measure side wear NOTE: Never use oil in the press fit area of the as shown. rotary seal. Push coolant/oil pump shaft seal in place by using thumb.

  • Page 62: Oil Suction Pump

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) TYPICAL 1. Rotary seal 1. Coolant/oil pump shaft with oil seal guide 2. Rotary seal pusher 2. Rotary seal pusher Install the coolant/oil pump shaft using the rotary Tighten oil pump cover screws and torque to seal pusher (P/N 529 035 823) on the opposite side 10 N•m (89 lbf•in).
  • Page 63 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) WARNING Wear safety glasses and work in a well ventilated area when working with strong chemical products. Also wear suitable non- absorbent gloves to protect your hands. – Remove the oil suction pump cover with oil sep- arator housing and his cover.
  • Page 64 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) TYPICAL 1. Outer rotor 1. Oil pump shaft ass'y 2. Inner rotor 2. Outer rotor OUTER AND INNER ROTOR CLEARANCE Inspection SERVICE LIMIT Inspect oil pump shaft assembly, housing and cov- er for marks or other damages.

  • Page 65: Oil Separator Cover

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) Torque oil pump cover screws to 10 N•m (89 lbf•in) Tighten suction pump housing screws as per following sequence and torque to 10 N•m (89 lbf•in). Apply Loctite 243 (P/N 293 800 060) on threads.

  • Page 66: Tops Valve

    Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) WARNING The spring on the TOPS valve is tensioned and can shoot away the valve disc. Hold the valve disc with fingers while removing the washer. TYPICAL — SUPERCHARGED ENGINES 1. Ventilation hose –...
  • Page 67 Section 01 ENGINES (1503 4-TEC) Subsection 04 (LUBRICATION SYSTEM) 1. O-rings Inspection TYPICAL 1. Oil cooler If O-rings are brittle, cracked or hard, replace them. Removal Clean both contact surfaces of oil cooler. Remove: Check and clean the oil inlet and outlet area for dirt –...

  • Page 68: Cooling System

    Section 01 ENGINES (1503 4-TEC) Subsection 05 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page oil seal protector ..............529 035 822 ........... 67 rotary seal installer..............529 035 823 ........... 67 SERVICE PRODUCTS Description Part Number Page Loctite 243................
  • Page 69 Section 01 ENGINES (1503 4-TEC) Subsection 05 (COOLING SYSTEM) smr2005-088 www.SeaDooManuals.net...

  • Page 70: General

    Section 01 ENGINES (1503 4-TEC) Subsection 05 (COOLING SYSTEM) GENERAL Removal Supercharged Engines For additional information pertaining to the vehicle Remove supercharger inlet and outlet hoses to cooling system, refer to the appropriate VEHICLE make room. SHOP MANUAL. Check general condition of hoses and clamp tight- ness.

  • Page 71: Coolant Pump Impeller

    Section 01 ENGINES (1503 4-TEC) Subsection 05 (COOLING SYSTEM) 1. Weep hole pump housing gasket COOLANT PUMP IMPELLER Check if thermostat is in good condition. Refer to THERMOSTAT elsewhere in this section. Removal Installation Remove: – coolant pump no. 6 as described in this section The installation is the opposite of the removal pro- cedure.

  • Page 72: Thermostat

    Section 01 ENGINES (1503 4-TEC) Subsection 05 (COOLING SYSTEM) Dynamic Test CAUTION: Be careful not to damage impeller wings during installation. To check the operation of the thermostat, put it Torque impeller to 3 N•m (26 lbf•in). in water and heat water. Look inside the cylin- der head return hose connection to see the move- THERMOSTAT ment of the thermostat.
  • Page 73 Section 01 ENGINES (1503 4-TEC) Subsection 05 (COOLING SYSTEM) 1. Retaining screws 2. Oil pump cover 1. Pusher 2. Coolant/oil pump shaft – remove oil pump cover no. 12 – remove outer oil pump rotor no. 13 – remove rotary seal no. 14 with a screwdriver CAUTION: Be careful not to damage the surface of the rotary seal bore in magneto housing cov- 1.
  • Page 74 Section 01 ENGINES (1503 4-TEC) Subsection 05 (COOLING SYSTEM) Installation The installation is the opposite of the removal pro- cedure. Pay attention to the following details. NOTE: Never use oil in the press fit area of the oil seal and rotary seal. Push coolant pump shaft oil seal in place by using thumb.

  • Page 75: Cylinder Head

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) CYLINDER HEAD SERVICE TOOLS Description Part Number Page camshaft locking tool............529 035 839 ........75, 77 crankshaft locking tool............529 035 821 ....... 73, 76, 78 valve spring compressor clamp ..........529 035 724 ........... 80 valve spring compressor cup..........
  • Page 76 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) smr2005-036-003_aen smr2005-036 www.SeaDooManuals.net...

  • Page 77: General

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) GENERAL NOTE: When diagnosing an engine problem, al- ways perform a cylinder leak test. This will help pin-point a problem. Refer to the instructions in- cluded with your leak tester and LEAK TEST for procedures.

  • Page 78: Valve Cover

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Inspect plane surfaces for warpage. Small defor- mation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper. Installation NOTE: There is no gasket between cylinder block and exhaust manifold.

  • Page 79: Rocker Arm

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) 1. Rocker arm shaft screws – rocker arm shaft no. 9 with rocker arm assem- bly (exhaust side no. 10 and intake side no. 11). Torque screws to 10 N•m (89 lbf•in). ROCKER ARM Removal Lock crankshaft with crankshaft locking tool...
  • Page 80 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Inspection Spark Plug Tube Check seals on spark plug tube. If seals are brittle, cracked or hard, replace spark plug tube. 1. Rocker arm (exhaust side) 2. Roller A. Bore for rocker arm shaft smr2005-036-001_a 1.
  • Page 81 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Measure rocker arm shaft diameter. ROCKER ARM SHAFT DIAMETER NEW MINIMUM 19.980 mm (.7866 in) NEW MAXIMUM 19.993 mm (.7871 in) SERVICE LIMIT 19.965 mm (.7860 in) 1. Camshaft locking tool A.

  • Page 82: Camshaft Timing Gear

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) 1. Rocker arm shaft screw 2. Torque angle gauge 1. Rocker arm shaft 2. Rocker arm shaft notches CAMSHAFT TIMING GEAR Install NEW rocker arm shaft screws no. 8. Torque as per following procedure: NOTE: Although it is not necessary to position crankshaft to TDC for disassembly, it is a good CAUTION: This assembly uses stretch screws.

  • Page 83: Timing Chain

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Using the camshaft locking tool (P/N 529 035 839), Ensure chain guides are in place. lock camshaft on TDC position. Loosely install screws. Install chain tensioner. NOTE: There can be 2 different positions to install the timing gear on the camshaft.

  • Page 84: Cylinder Head

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) CYLINDER HEAD Removal Lock crankshaft with crankshaft locking tool (P/N 529 035 821), refer to CYLINDER BLOCK section. Drain coolant (refer to appropriate VEHICLE SHOP MANUAL). Disconnect coolant temperature and camshaft po- sition sensors (CTS and CAPS).

  • Page 85: Camshaft

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Installation For installation, reverse the removal procedure. Pay attention to the following details. Ensure dowel pins are in place. Install new cylinder head gasket. CAUTION: Each installation of the cylinder head requires a new cylinder head gasket. Us- ing a gasket twice will cause engine damage, even if the engine had not run.

  • Page 86: Valve Spring

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Inspection CAMSHAFT BORE — ENGINE FRONT MEASURED IN DIAMETER Check each lobe and bearing journal of camshaft for scoring, scuffing, cracks or other signs of wear. NEW MINIMUM 25.000 mm (.9842 in) Measure camshaft bearing journal diameter and NEW MAXIMUM 25.013 mm (.9848 in)
  • Page 87 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) WARNING Always wear safety glasses when disassem- LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE bling valve springs. Be careful when unlock- ing valves. Components could fly away be- Remove valve cotters no.

  • Page 88: Valve

    Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) VALVE Removal Remove valve spring. Push valve stem then pull valves no. 26 and no. 27 out of valve guides. A. Valve spring length OUTER VALVE SPRING FREE LENGTH NEW NOMINAL 45.45 mm (1.789 in) SERVICE LIMIT 43 mm (1.693 in)
  • Page 89 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Inspection VALVE STEM DIAMETER Valve Stem Seal NEW MINIMUM Inspection of valve stem seals is not needed be- Exhaust 5.946 mm (.2341 in) cause new seals should always be installed when- Intake 5.961 mm (.2347 in) ever cylinder head is removed.
  • Page 90 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Grease the bore in cylinder head and the lead- ing end of valve guide with Molykote G-N paste (P/N 413 703 700). TYPICAL 1. Special reamer 2. Notch TYPICAL Chase valve guide out of the cylinder head to- 1.
  • Page 91 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) VALVE GUIDE PROTRUSION VALVE SEAT CONTACT WIDTH MINIMUM 12.4 mm (.4882 in) MAXIMUM 12.8 mm (.5039 in) 1.25 to 1.55 mm Exhaust (.049 to.061 in) NOTE: For lubrication of the reamer use only cut- 1.10 to 1.30 mm Intake ting oil.
  • Page 92 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) Installation For installation, reverse the removal procedure. Pay attention to the following details. Install valve stem seal no. 28. A. Valve seat outer diameter EXHAUST 1. Valve stem seal Apply engine oil on valve stem and install it. CAUTION: Be careful when valve stem is passed through sealing lips of valve stem seal.
  • Page 93 Section 01 ENGINES (1503 4-TEC) Subsection 06 (CYLINDER HEAD) After spring is installed, ensure it is properly locked by tapping on valve stem end with a soft hammer so that valve opens and closes a few times. CAUTION: An improperly locked valve spring will cause engine damage.

  • Page 94: Cylinder Block

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) CYLINDER BLOCK SERVICE TOOLS Description Part Number Page crankshaft locking tool............529 035 821 ....100, 104, 107, 112 handle ................... 420 877 650 ......... 110 piston circlip installer ............529 035 765 ........... 97 pusher...................
  • Page 95 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) SMR2005-037 www.SeaDooManuals.net...
  • Page 96 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) SMR2005-037 www.SeaDooManuals.net...

  • Page 97: General

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) GENERAL Installation The installation is essentially the reverse of the re- When disassembling parts that are duplicated in moval procedure but, pay attention to the follow- the engine, (e.g.: pistons, connecting rods etc.), ing details.

  • Page 98: Piston/Connecting Rod

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) Installation The installation is essentially the reverse of the re- moval procedure but, pay attention to the follow- ing details. Torque chain tensioner plug screw to 18 N•m (160 lbf•in). PISTON/CONNECTING ROD Removal Disassemble cylinder block as per procedure in this section.
  • Page 99 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) A. Piston pin diameter in the area of the bushing CONNECTING ROD SMALL END DIAMETER mm (in) NEW MINIMUM 23.01 (.9059) NEW MAXIMUM 23.02 (.9063) 1. Crankshaft 2. Feeler gauge SERVICE LIMIT 23.07 (.908) CONNECTING ROD BIG END AXIAL PLAY mm (in) PISTON PIN DIAMETER mm (in)

  • Page 100: Piston Rings

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) 1. Measuring perpendicularly (90°) to piston pin axis A. 18 mm (.709 in) The measured dimension should be as described A. Connecting rod big end bearing in the subsequent table. If not, replace piston. CONNECTING ROD BIG END DIAMETER mm (in) PISTON MEASUREMENT mm (in) SERVICE LIMIT...

  • Page 101: Piston Pin

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) If clearance exceeds specified tolerance, rehone cylinder sleeve and replace piston ass'y by an oversize one. NOTE: It is not necessary to have all pistons re- placed with an oversize if they are not all out of specification.
  • Page 102 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) Installation Using piston ring compressor pliers, such as Snap- On RC-980, slide piston into cylinder. For installation, reverse the removal procedure. Pay attention to the following details. Apply engine oil on the piston pin. Insert piston pin into piston and connecting rod.

  • Page 103: Piston Rings

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) PISTON RINGS Removal Remove piston ass'y as described above. Remove rings. Inspection Ring/Piston Groove Clearance Using a feeler gauge measure each ring/piston groove clearance. If the clearance is too large, the piston and the piston rings should be replaced.

  • Page 104: Crankshaft

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) Ring End Gap NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand. RING END GAP mm (in) Check that rings rotate smoothly after installation. NEW MINIMUM Space the piston ring end gaps 120°...
  • Page 105 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) Removal Remove: – engine oil (refer to OIL CHANGE in the appro- priate VEHICLE SHOP MANUAL) – engine from vehicle (refer to the appropriate VE- HICLE SHOP MANUAL) – cylinder head (refer to CYLINDER HEAD sec- tion) –...
  • Page 106 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) – connecting rod screws 1. Thrust washer 1. Connecting rod screws – crankshaft no. 5. NOTE: Before removing the connecting rod caps, mark them to remember the right position when reassembling. It is recommended to measure connecting rod big end axial play prior to remove connecting rod.
  • Page 107 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) Crankshaft Pin Measure all crankshaft pin diameters. Compare to inside diameter of connecting rod bearings (else- where in this section). 1. Balancer gear 2. Crankshaft timing gear Crankshaft Radial Play Measure all crankshaft journals. Compare to in- side diameter of crankshaft bearings (elsewhere in this section).
  • Page 108 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) 1. Mark on balancer shaft 1. Dial gauge 2. Mark on crankshaft 2. Crankshaft For correct installation of the connecting rods, re- CRANKSHAFT AXIAL CLEARANCE mm (in) fer to PISTON/CONNECTING ROD in this section. NEW MINIMUM 0.08 (.003) CAUTION: It is absolutely necessary to follow...

  • Page 109: Balancer Shaft

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) 529035821 1. Thrust washer 2. Sealing surface Install cylinder block lower half. Refer to CYLIN- DER BLOCK in this section. Install the crankshaft cover before mounting the 1. Crankshaft locking tool engine bracket.
  • Page 110 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) ENGINE UPSIDE DOWN 1. Oil reservoir plug screw with O-ring – cylinder block screws no. 3 1. Thrust washer – balancer shaft. Inspection Check balancer shaft and replace if damaged. If the gear on the balancer shaft is damaged, re- place balancer shaft.
  • Page 111 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) BALANCER SHAFT SEAT DIAMETER mm (in) NEW MINIMUM 31.984 (1.2592) NEW MAXIMUM 32.000 (1.2598) SERVICE LIMIT 31.960 (1.2583) BALANCER SHAFT SEAT RADIAL CLEARANCE mm (in) SERVICE LIMIT 0.07 (.0028) Balancer Shaft Axial Clearance When assembling the cylinder-block, measure the balance shaft axial play: 1.

  • Page 112: Cylinder Block

    Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) 529035821 1. Thrust washer 2. Sealing surface Install cylinder block lower half. Refer to CYLIN- DER BLOCK in this section. Install the crankshaft cover before mounting the 1. Crankshaft locking tool engine bracket.
  • Page 113 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) Bearings Starter drive bearing can be easily removed from crankcase lower half using the following suggest- When bearings need to be removed from the ed tool or equivalent: cylinder block, mark them to identify the correct –...
  • Page 114 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) CYLINDER OUT OF ROUND mm (in) NEW MAXIMUM 0.008 (.0003) SERVICE LIMIT 0.015 (.0006) Bearings To measure the wear of the crankshaft bearings no. 13 and no. 14 and balancer shaft bearings no.
  • Page 115 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) Assembly For assembly, reverse the disassembly procedure. Pay attention to the following details. Torque oil spray nozzle to 18 N•m (160 lbf•in). To install starter drive bearing no. 21 of starter drive assembly, use pusher (P/N 420 876 502) and handle (P/N 420 877 650).
  • Page 116 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) Use the silicone-based Loctite 5910 (P/N 293 800 081) on mating surfaces. CAUTION: Do not use other products to seal crankcase. Do not use an activator with the Loctite 5910. Using other products or non sil- icone-based sealant over a previously sealed crankcase with Loctite 5910 will lead to poor adhesion and possibly a leaking crankcase.
  • Page 117 Section 01 ENGINES (1503 4-TEC) Subsection 07 (CYLINDER BLOCK) 529035821 NOTE: Before continuing the assembly process, the axial clearance of balancer shaft and crank- shaft has to be checked. Refer to CRANKSHAFT 1. Crankshaft locking tool and BALANCER SHAFT in this section for the pro- cedure.

  • Page 118: Technical Specifications

    Section 01 ENGINES (1503 4-TEC) Subsection 08 (TECHNICAL SPECIFICATIONS) TECHNICAL SPECIFICATIONS ENGINE NATURALLY ASPIRATED SUPERCHARGED ROTAX 1503 4-TEC, 4-stroke, Single Over Head Engine type Camshaft (SOHC), liquid cooled Number of cylinders Number of valves 12 valves with hydraulic lifters (no adjustment) Bore Standard 100 mm (3.9 in)
  • Page 119 Section 01 ENGINES (1503 4-TEC) Subsection 08 (TECHNICAL SPECIFICATIONS) ENGINE NATURALLY ASPIRATED SUPERCHARGED Minimum (new) 20.00 mm (.7874 in) Rocker arm bore diameter Maximum (new) 20.02 mm (.7882 in) Wear limit 20.03 mm (.7886 in) Minimum (new) 19.98 mm (.7866 in) Rocker arm shaft diameter Maximum (new) 19.99 mm (.7870 in)
  • Page 120 Section 01 ENGINES (1503 4-TEC) Subsection 08 (TECHNICAL SPECIFICATIONS) ENGINE NATURALLY ASPIRATED SUPERCHARGED Minimum (new) 31.48 mm (1.2394 in) 31.69 mm (1.2476 in) Intake Maximum (new) 31.59 mm (1.2437 in) 31.8 mm (1.2520 in) Wear limit 31.43 mm (1.2374 in) 31.65 mm (1.2461 in) Cam lobe Minimum (new)
  • Page 121 Section 01 ENGINES (1503 4-TEC) Subsection 08 (TECHNICAL SPECIFICATIONS) ENGINE NATURALLY ASPIRATED SUPERCHARGED Minimum (new) Not applicable 9.960 mm (.3921 in) Supercharger shaft driven plate journal Maximum (new) Not applicable 10.0 mm (.3937 in) depth Wear limit Not applicable 9.700 mm (.3819 in) Minimum (new) Not applicable 11.0 mm (.4331 in)
  • Page 122 NOTES www.SeaDooManuals.net...
  • Page 123 NOTES www.SeaDooManuals.net...
  • Page 124 www.SeaDooManuals.net...

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