Service Manual Engine Rotax 655 Aprilia Pegaso 650 1995-2000
DESCRIPTION:
This Repair Manual contains essential advice and data for professional maintenance and repair of ROTAX engine type 655. The Repair Manual is based on the state of knowlege at the time of publication. BOMBARDIER-ROTAX reserves the right to make technical modifications to the engine in view of further development without updating this manual. A professional repair requires the use of genuine spare parts as well as the employment of the specified securing. sealing and lubricating agents. All data and procedures in this Repair Manual are described to the best of our knowlege, however excluding any liability.
SCREENSHOT OF THE MANUAL:
TABLE OF CONTENTS:
Preface
Important Information
Repeating symbols 6
General precaution and safety information 6
Engine components 9
Engine number— location9
Lubrication system 10
Cooling circuit 11
Technical data
Technical Data 13
Maintenance schedule 16
Requirements for maintenance and engine reparr 16
General notes to procedure of maintenance and repair work 17
Special tools, securing-, sealing- and lubrication agents 21
Tightening torques, securing and lubricating agents 26
Removal of the engine
Engine removal 30
Setting up engine on trestle 31
Engine disassembly
Electric starter — removal32
Valve cover — removal 32
Crankshaft top dead centre — positioning 33
Cylinder head, cylinder, valve train — disassembly 34
Piston — removal35
Ignition unit — disassembly 36
Electric starter drive — removal 37
Chain Sprocket — removal 37
Oil seal Of the main Shaft — removal and refitting 38
Clutch cover — removal 38
Clutch and primary drive – disassembly 39
Camshaft drive — disassembly 4O
Rev-counter drive (only engine version Pegasc 650) 41
Oil pump drive — disassembly 41
Crankcase — Splitting 42
Crankshaft an balance shaft— removal 44
Gearshift and gearbox — disassembly 44
Individual component maintenance
Crankcase46
Bali bearing — removal and fitting 47
Crankshaft bearing —- radial clearance 49
Crankshaft bearing — removal and fIttIngSO
Crankcase half — magneto Side 51
Oil pressure regulating valve 51
Oil pressure retaining valve 52
Oil pressure switch 53
Neutral gear indication 53
Crankcase half — Clutch side 53
Crankshaft57
Balance shaft 59
Balance drive 60
Gearbox 62
Gearshift mechanism 65
Camshaft drive 66
Camshaft chain 66
Chain tensioner guide, chain guide und chain damper 67
Oil pump drive 67
Primary drive and clutch 68
Clutch cover71
Rev counter shaft 72
Water pump 73
Thermostat74
Cylinder75
Piston, piston pIn76
Cylinder head 78
Valve guIdeSTQ
Valve seats82
Valves 83
Valve springs 83
Valves — fitting in cylinder head 84
Camshaft85
Centrifugal decompressor 86
Rocker arms87
Valve cover 87
Electric Starter drive 88
Ignition unIt90
Ignition unit — components 90
ignition unit— wiring dIagram91
Ignition unit—trouble shooting 92
Ignition cover94
Spark plug 94
Final drive sprocket 95
Electric starter 95
Engine reassemblyCrankcase — completing 97
Crankshaft and balance Shaft— installation 99
Crankshaft and balance Shaft — readjusting 100
Gear shafts — installation 101
Gearshift mechanism — installation 101
Gearshift mechanism — check103
Crankcase — reassembly 104
Camshaft drive — installation 106
Oil pump drive — installation 108
Rev counter drive — installation (only Pegaso 650) 109
Clutch — installation 109
Piston — installation 111
Cylinder— installation 112
Cylinder head — installation 113
Camshaft installation and valve play adjustment 114
Camshaft drive — adjustment 118
Camshaft chain tensioner — installation 119
Valve cover — installation 120
Camshaft Chain tensioner— adjustment 121
Clutch cover — installation 121
Final drive Sprocket — fastening 124
Electric starter drive — installation 124
ignition unit — installation 125
Electric starter— installation 127
Engine Installation 128
Oil circuit — venting 128
Oil pressure — check 129
Trouble shooting 138
Index148
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