717 Engines

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Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) F01D35A 1 4 1 4 3 2 3 2 787 RFI Engines Prior installation, apply Molykote 111 below screw head and Loctite 243 (blue) on screw threads. Install M10 x 105 screws on exhaust side and the M10 x 73.5 on opposite side. Torque screws in a criss-cross sequence for each cylinderto20N m(15lbfft). Repeat the procedure, retightening all cylinder screws to 40 N m (30 lbf ft). F01D7FA 2 3 3 2 4 1 1 4 947 DI Engines Apply Molykote 111 below the screw head. The blue coating underneath the cylinder screw head can be only used once. Either replace with new bolts or remove blue coating and apply Molykote 111 below the screw heads. Install and torque screws to 40 N m(30lbf ft) in the indicated order. Refer to the following illustration. F12D07A 7 2 3 5 6 All Engines 4 Cylinder Head Install cylinder head gasket. 717 and 787 RFI Engines Make sure to install O-rings no. 12 around spark plug holes and O-ring no. 11 of cylinder head as shown in the following illustration. F01D5AA 1 1. O-rings 1 Apply Loctite 518 in O-ring groove of cylinder sleeves. 947 DI Engines Apply Loctite 243 (blue) below head of cylinder head bolts no. 14. 124 smr2004-Complete Line Up 1 8 26
Apply Molykote 111 on threads of cylinder head bolts no. 14. Torque bolts to 20 N m(15lbfft) as per following sequence in the next illustration. Repeat the torquing sequence by retightening to 40 N m (30 lbf ft). 11 F12D08A 7 12 2 4 1 Cylinder Head Cover 717 and 787 RFI Engines Install cylinder head cover no. 1. Apply Loctite 243 (blue) below head of screws no. 14. Apply also Molykote 111 on threads of screws no. 14. Torque cylinder head screws no. 14 to 12 N m (106 lbf in) as per following illustrated sequence. Repeat the procedure, retightening all screws to 24 N m(17lbfft). F01D46A 8 6 3 10 10 8 2 4 6 12 9 7 TORQUING SEQUENCE 3 1 5 11 5 9 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) ADJUSTMENT RAVE Valve 787 RFI Engines Turn the red plastic knob no. 17 until it is flush to the valve cover. F00D0GA 1. Knob flush with the cover Combustion Chamber Volume Measurement All Engines NOTE: This procedure is required to determine the thickness of the cylinder base gasket to be installed if a crank repair has involved replacement of connecting rods or if you are experiencing repetitive engine seizure. The combustion chamber volume is the region in the cylinder head above the piston at Top Dead Center. It is measured with the cylinder head installedontheengine. F01D5VA 1. Combustion chamber NOTE: When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposit and cylinder head must be leveled. smr2004-Complete Line Up 125 27 1 1
Page 1 and 2: TOP END 717 Engines Molykote 111 F1
Page 3 and 4: 947 DI Engines 26 10 N•m (89 lbf
Page 5 and 6: 2 3 1 F06D16B RAVE VALVE CLOSED 1.
Page 7 and 8: F06D0QA 1 1. Remove screws Remove R
Page 9 and 10: F06D28A 1. Remove O-ring 1 Remove s
Page 11 and 12: Remove cylinder head no. 2. If shel
Page 13 and 14: F00B0KA 1 1. Tool cut-out toward bo
Page 15 and 16: A F01D8AA 2 1. Measuring perpendicu
Page 17 and 18: F00B09A 2 1. Use the micrometer to
Page 19 and 20: F01D8KA 1 3 2 1. Sliding valve 2. O
Page 21 and 22: - Replace the inner halves by the a
Page 23 and 24: 947 DI Engines Securecirclipinpisto
Page 25: F01D45A 717 ENGINES 1. Aligning cyl
Page 29 and 30: Compare the obtained value with the
Page 31 and 32: Section 04 ENGINE (2-STROKE) Subsec

717 Engines

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