2005 Seadoo ROTAX® 717 and 787 RFI™ Engine Shop Manual – PDF DOWNLOAD
DESCRIPTION:
2005 Seadoo ROTAX® 717 and 787 RFI™ Engine Shop Manual – PDF DOWNLOAD
This ENGINE SHOP MANUAL has been prepared as a guide to correctly service and repair the 717 and 787 RFI Rotax® engines. This edition was primarily published to be used by technicians who are already familiar with all service procedures relating to BRP products. Mechanical technicians should attend training courses given by BRP Training Dept. Please note that the instructions will apply only if proper hand tools and special service tools are used. It is understood that this manual may be translated into another language.
- In the event of any discrepancy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Service and Warranty Bulletins may be published to update the content of this manual.
- Make sure to read and understand these. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts.
- The use of BRP parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt. The engines identified in this document should not be utilized on product(s) other than those for which it was designed.
TABLE OF CONTENTS:
2005 Seadoo ROTAX® 717 and 787 RFI™ Engine Shop Manual – PDF DOWNLOAD
SAFETY NOTICE III
INTRODUCTION IV
GENERAL INFORMATION IV
ENGINE IDENTIFICATION NUMBER (E I N ) IV
ENGINE EMISSIONS INFORMATION IV
TIGHTENING TORQUES IV
ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES V
01 ENGINE MEASUREMENT
01 – MEASUREMENT PROCEDURES 1
CYLINDER HEADWARPAGE 1
CYLINDER TAPER 1
CYLINDER OUT OF ROUND 1
COMBUSTION CHAMBER VOLUME MEASUREMENT 1
PISTON/CYLINDER WALL CLEARANCE 2
RING/PISTON GROOVE CLEARANCE 4
RING END GAP 5
CRANKSHAFT (ASSEMBLED ENGINE) 5
CRANKSHAFT (DISASSEMBLED ENGINE) 6
ROTARY VALVE 8
02 717 ENGINE
01 – LEAK TEST 11
GENERAL 11
PREPARATION 11
TESTING PROCEDURE 11
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 15
02 – MAGNETO SYSTEM 17
DISASSEMBLY 19
CLEANING 21
ASSEMBLY 22
03 – TOP END 25
GENERAL 27
DISASSEMBLY 27
CLEANING 29
INSPECTION 30
ASSEMBLY 30
04 – BOTTOM END 37
GENERAL 39
DISASSEMBLY 39
CLEANING 41
INSPECTION 42
ASSEMBLY 43
05 – ROTARY VALVE 47
GENERAL 49
INSPECTION (ASSEMBLED ENGINE) 49
DISASSEMBLY 49
CLEANING 51
INSPECTION (DISASSEMBLED ENGINE) 51
ASSEMBLY 51
ROTARY VALVE TIMING 55
TABLE OF CONTENTS
06 – TECHNICAL SPECIFICATIONS 57
03 787 RFI ENGINE
01 – LEAK TEST 59
GENERAL 59
TESTING PROCEDURE 59
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 63
02 – MAGNETO SYSTEM 65
DISASSEMBLY 67
CLEANING 68
ASSEMBLY 69
03 – TOP END 71
GENERAL 73
DISASSEMBLY 74
CLEANING 79
INSPECTION 80
ASSEMBLY 80
ADJUSTMENT 86
04 – BOTTOM END 87
GENERAL 89
DISASSEMBLY 89
CLEANING 93
INSPECTION 94
ASSEMBLY 94
05 – ROTARY VALVE 101
GENERAL 103
INSPECTION (ASSEMBLED ENGINE) 103
DISASSEMBLY 103
CLEANING 105
INSPECTION (DISASSEMBLED ENGINE) 105
ASSEMBLY 105
ROTARY VALVE TIMING 109
06 – TECHNICAL SPECIFICATIONS 111
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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