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NOTE: Crankshaft deflection cannot be correctly measured between centers of a lathe. Connecting Rod Big End Axial Play CONNECTING ROD BIG END AXIAL PLAY MODEL 717 engines 787 RFI engines 947 DI engines NEW PARTS (min.) (max.) 0.311 mm (.012 in) 0.230 mm (.008 in) 0.390 mm (.015 in) 0.677 mm (.026 in) 0.617 mm (.024 in) 0.737 mm (.029 in) WEAR LIMIT 1.2 mm (.047 in) 1.2 mm (.047 in) 1.2 mm (.047 in) Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. F01D1WA 1 2 1. Measuring big end axial play 2. Feeler gauge Starter Drive Bearing 947 DI Engines Only Check bearing no. 23 of starter drive assembly no. 27 in crankcase. F06D1IA Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 1. Bearing of starter drive assembly 1 Removal Starter drive bearing can be easily removed from lower crankcase half using the following suggested tool or equivalent: – Snap-onhammerpullerincluding: – handle CJ93-1 – hammer CJ125-6 – claws CJ93-4. F01J0ZA Closepullerclawssothattheycanbeinsertedin end bearing. Holding claws, turn puller shaft clock wise so that claws open and become firmly tight against bearing. Slide puller hammer outwards and tap puller end. Retighten claws as necessary to always maintain them tight against bearing. Continue this way until bearing completely comes out. For installation, see below in this section. Reed Valve 947 DI Engines Only Check reed valve petals no. 29 for cracks or other defects. The reed petals must lie completely flat against the reed valve body no. 30. To check, hold against light. smr2004-Complete Line Up 143
Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) F06D1JA 1. No play 1 In case of a play, turn reed petals upside down and recheck. If there is still a play, replace petals. Check perfect condition of rubber coating on reed valve body. Check stopper distance from center of reed valve block. F06D1EA A A. 13 ± 0.25 mm (.512 ± .010 in) NOTE: Distance should be the same on both sides. Bent stopper as required to obtain the proper distance. Air Compressor Refer to ENGINE MANAGEMENT for components inspection. However, if you find aluminum dust or debris in this area, they may have flowed toward the injection oil reservoir. In this case, the oil reservoir and lines must be flushed and the filter replaced. CAUTION: Failure to properly clean the oil system will result in serious engine damage. ASSEMBLY Assembly is essentially the reverse of disassembly procedures. However pay particular attention to the following. NOTE: It is recommended to spray BOMBARDIER-ROTAX injection oil on all moving parts when reassembling the engine. Crankshaft and Bearing Apply Loctite 767 anti-seize on part of crankshaft where bearing fits. Prior to installation, place bearings no. 4 into a container filled with oil, previously heated to 75°C (167°F). This will expand bearing and ease installation. To properly position the outer bearing(s), a distance gauge must be temporarily installed against the inner bearing. Slide the outer bearing until stopped by the distance gauge, then remove it. ENGINE DISTANCE GAUGE 717 (P/N 529 034 800) (PTO) 787 RFI (P/N 529 034 900) (MAG) F01B0HA 947DI 1 1. Distance gauge (P/N 529 035 100) (MAG) (P/N 529 035 000) (PTO) 144 smr2004-Complete Line Up
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 and 26: F01D45A 717 ENGINES 1. Aligning cyl
Page 27 and 28: Apply Molykote 111 on threads of cy
Page 29 and 30: Compare the obtained value with the
Page 31 and 32: Section 04 ENGINE (2-STROKE) Subsec
Page 43: Section 04 ENGINE (2-STROKE) Subsec

717 Engines

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