717 Engines

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Reinstall cover in place WITHOUT its O-ring and torque screws to 20 N m(15lbfft). Remove cover then clean and measure compressed soldering wire thickness, it must be within the specified tolerance 0.30 ± 0.05 mm (.012 ± .002 in). If rotary valve cover clearance is over specified tolerances, machine rotary valve cover seating surface or replace the cover. MACHINING INFORMATION The amount of material over tolerance must be removed from the rotary valve cover seating surface. Also cut the O-ring groove the same amount to keep the 1.00 ± 0.03 mm (.039 ± .001 in) depth between the bottom of the groove and the seating surface. Remove burrs on the edges of the seating surface andO-ringgroove. 1 F01D3OA SAME AMOUNT REMOVED FROM COVER SEATING SURFACE AND O-RING GROOVE BASE 1. Cover seating surface A. O-ring groove depth must be 1.00 ± 0.03 mm (.039 ± .001 in) Reverify the clearance. At assembly the rotary valve timing must remain as per original setting. NOTE: If rotary valve crankcase surface is worn, it is possible to have it reworked at the factory. A Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) Rotary Valve Shaft Gear Backlash Remove PTO flywheel guard. Remove spark plugs, rotary valve cover and valve. Manually feel backlash at one position, then turn crankshaft about 1/8 turn and recheck. Continue this way to complete one revolution. Backlash must be even at all positions. Otherwise overhaul engine to find which part is faulty (gear, rotary valve shaft or crankshaft with excessive deflection). DISASSEMBLY Rotary Valve Cover Unscrew 4 retaining screws and withdraw rotary valve cover no. 1 and rotary valve no. 13. Rotary Valve Shaft To remove the rotary valve shaft assembly, the engine must be removed from watercraft (refer to ENGINE). Open bottom end and remove crankshaft (refer to BOTTOM END). First remove snap ring no. 4 from crankcase. F01D22A 1. Removing snap ring To remove rotary valve shaft assembly, use the appropriate puller (P/N 290 876 488). smr2004-Complete Line Up 155 1
Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) F01D23B PULLER (P/N 290 876 488) Place puller over rotary valve shaft end and screw on puller bolt into shaft. While retaining bolt with a wrench, turn puller nut CLOCKWISE until shaft comes out. F01D61A 1. Hold bolt F01D27A Circlip and Spring Seat If it is necessary to disassemble components of rotary valve shaft assembly, use seat no. 6 to compress spring and remove circlips no. 5. 1 F01D25A 1. Compress seat 2. Remove circlips Shaft Bearing To remove bearing no. 8 useabearingextractor such as Snap-on no. CJ-950 (or equivalent) as illustrated. Slide off distance sleeve no. 14, remove snap ring no. 7 and washer no. 15 then press shaft out. F01D4NA 1. Bearing 2. Bearing extractor Snap-on CJ-950 2 CAUTION: Ensure that rotary valve shaft is perfectly perpendicular with press tip. End Bearing CAUTION: Do not remove plug against bearing in upper crankcase half. 156 smr2004-Complete Line Up 1 2 1
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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 55: Section 04 ENGINE (2-STROKE) Subsec
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717 Engines

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