You can always feel safe buying a PDF service manual from us, we guarantee excellent quality, followed with great customer service! ATV Manuals. Car Manuals. Engine Manuals. Excavator Manuals. Jet-Ski Manuals. Motorcycle, Scooter Manuals. Mower Manuals. Crank the engine a few turns to distribute the oil onto cylinder wall. Apply anti-seize lubricant on spark plug threads then reinstall them. Otherwise engine will have to be overhauled.
A water-flooded engine must be properly lubricated, operated then lubricated again, otherwise parts will be seriously damaged. If necessary, siphon and refill with fresh fluids. Turn fuel valve to OFF position then drain fuel filter bowl. Drain bilge if water is present. Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device. Remove spark plugs and dry them with a clean cloth.
A contact cleaner spray can be used. It may be preferable to replace spark plugs. Do NOT install spark plugs on engine.
Crank engine to drain crankcase. Insert a wire through oil level hole to check oil condition. A whitish oil indicates water contamination and must be replaced. Be careful when cranking engine, water will spray out from spark plug holes. Crank engine again. Reinstall spark plugs and spark plug cables. Drain completely the crankcase oil of the counterbalance shaft. Reinstall drain plug with Loctite Add 30 mL 1 oz of SAE 30 motor oil. Reinstall filler plug. All Models Turn fuel valve to ON position.
Start engine; It may be necessary to use the choke. If engine does not start, repeat previous steps as necessary. To avoid starting motor overheating, the cranking period should not exceed seconds and a rest period of 30 seconds should be observed between cranking cycles. NOTE: If engine does not start after several attempts, check ignition system for spark occurrence. Check crankshaft if needed, it may be misaligned or deflected. Make sure there is no sand or other particles in it and that it is not obstructed so that water can leave the engine.
Clean hose and fitting as necessary. Engine must be lubricated to prevent corrosion on internal parts. Water in engine drain hose must be free to flow out, otherwise water could be trapped in engine. Should water freeze in engine, severe damage will occur.
Check engine drain hose for obstructions. Follow manufacturers instructions for proper use. NOTE: Fuel stabilizer should be added prior engine lubrication to ensure carburetor protection against varnish deposit. Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. Always turn the fuel valve to OFF position when storing the watercraft.
Stop lubricating when grease is just coming out of seal. Clean the bilge with hot water and mild detergent or with bilge cleaner. Rinse thoroughly. Lift front end of watercraft to completely drain bilge. If any repairs are needed to body or to the hull, touch up paint and Gelcote repair kit are available. Wash the body with soap and water solution only use mild detergent. Rinse thoroughly with fresh water.
Remove marine organisms from the hull. Apply a nonabrasive wax. Never clean fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc. If the watercraft is to be stored outside, cover it with an opaque tarpaulin to prevent sun rays and grime from affecting the plastic components, watercraft finish as well as preventing dust accumulation.
XP Limited Lubricate seal carrier of drive shaft support with synthetic grease. The watercraft must never be Ieft in water for storage. Never leave the watercraft stored in direct sunlight. Anticorrosion Treatment Wipe off any residual water in the engine compartment. The seat should be partially left opened during storage the engine cover for the XP model. This will avoid engine compartment condensation and possible corrosion. Additional Recommended Protection In cool regions where freezing point may be encountered , cooling system should be filled with water and antifreeze solution.
Always use ethylene-glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines. Pour the antifreeze slowly mixed with water in coupler hose until the colored solution appears in the engine drain hose. Remove hose pincher s. Install coupler hose to fitting spigot. Install a hose pincher to engine water return hose beside fitting spigot.
Temporarily install a short piece of hose to engine water outlet at cylinder head. Insert a funnel into hose and pour antifreeze mixed with water in engine until the colored solution appears in the engine drain hose. Remove temporary hose and reconnect engine water return hose. Remove hose pinchers. All Models Most of the antifreeze will drain out when removing hose pincher s.
Use a container to recover it. Dispose of antifreeze as per your local laws and regulations. NOTE: Although antifreeze will mainly drain out, the antifreeze has mixed with the water that was possibly trapped in the cylinder water jackets and thus preventing freezing problems. At pre-season preparation, drain the remaining antifreeze from cooling system prior using the watercraft. The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to have all causes for all problems.
Low fuel level Stale or water fouled fuel Fuel filter dirty or restricted Carburetion dirty or out of adjustment Leaking crankshaft seal s , intake or rotary valve cover O-ring Restricted fuel valve Loose carburetor. Partially closed choke Flame arrester dirty or restricted Carburetor adjustment Loose main jet Rotary valve shaft seal leaking if applicable Oil pump adjustment Worn needle s and seal s Excessive rotary valve clearance if applicable.
Trailing edge damage contributes to poor top performance and stator vanes erosion. A Service Bulletin will be issued. Before disassembling any components of the engine, it is important to perform a leakage test to determine which part is defective.
It is also very important after servicing the engine, even for a complete engine rebuilt, to perform another leakage test; at this stage, it may avoid further engine problems and minimizing the risk of having to remove and reinstall the engine again. Static bench testing is the most effective way to conduct a leakage test.
Inboard testing does not allow complete access to, and observation of all engine surfaces and should be avoided whenever possible. On the engine, cylinders can not be verified individually due to leakage from one cylinder to another through a common intake manifold. When installing hoses of the Engine Leak Test Kit, use the collars provided in the kit to ensure a proper sealing.
When pressurizing the engine, first confirm that the components of the Engine Leak Test Kit are not leaking by spraying a solution of soapy water on all hoses, connections, fittings, plates, etc.
If there is a leak, bubbles will indicate leak location. Three areas of the engine will be tested in sequence as per the diagnostic flow chart see the end of this sub-section. Engine Cooling System 2. Bottom End and Top End 3. Rotary Valve Shaft NOTE: If a leak is found, it is important to continue testing as there is the possibility of having more than one leak. Continue pumping to compensate for the air lost to find another leak.
If any fuel leak is found, do not start the engine. Correct the leak and wipe off any fuel spillage. Do not use electric powered tools unless fuel system has passed pressure test.
Disconnect battery RED positive cable. Remove the exhaust manifold gasket and ensure the surface is cleaned. Disconnect engine cooling hoses. Install the appropriate exhaust manifold plate no. Tighten plate using fasteners provided in the kit. Use hoses provided in the kit and install them on the engine. Install pump using reducer and appropriate tube s as necessary. Loop hose and use clamps 2. Hose with clamps. Plug end with a screw 3. Block engine drain hose with a hose pincher 4.
Use 2 washers with exhaust manifold stud. NOTE: Water is not required for testing. Activate pump and pressurize engine cooling system to 34 kPa 5 PSI. Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking and pressure drops, verify all external jointed surfaces, temperature sensor and the O-ring between the spark plug area and the engine cylinder head cover. If none of these components are leaking, there is an internal leak and it can be detected with Bottom End and Top End testing.
Use 2 washers with exhaust manifold stud 3. Hose with adapter and nipple. Bottom End and Top End Remove the carburetor s and gasket s. Make sure the surface of the intake manifold engine or rotary valve cover engine are clean. Install the intake plate s no. Install plates no.
Simply remove the cover to expose the boot. Make sure the spark plugs are installed and tighten. Block pulse hose using a hose pincher. NOTE: Do not block the rotary valve shaft hoses. Install pump to the exhaust plate fitting. Intake plates 2. RAVE valve plates 3. Pulse hose blocked with a hose pincher 4. Exhaust plate. Do not exceed this pressure. If kit components are not leaking, verify engine jointed surfaces as per following areas: spark plugs cylinder head gasket cylinder base gasket crankcase halves rotary valve cover engine plugs exhaust manifold intake manifold engine oil injection pump engine.
Check also small oil injection pump lines and fittings; check for air bubbles or oil column going toward pump, which indicate a defective check valve.
If the above mentioned components are not leaking, block both oil hoses of the rotary valve shaft using hose pinchers. If there is still some leakage, remove the PTO flywheel to verify outer seal. If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft outer seals.
Proceed with the Rotary Valve Shaft testing if the crankshaft outer seals are not leaking. Block oil return hose of the rotary valve shaft with a hose pincher. Activate pump and pressurize to 5 PSI 34 kPa. Check plug of the rotary valve shaft in crankcase. Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal. Remove MAG side spark plug. If pressure drops, it indicates a defective MAG side crankshaft inner seal. If the above mentioned components are not leaking and there is a pressure drops, remove the rotary valve cover.
Check the seal of the rotary valve shaft. If the rotary valve shaft is not leaking, it could indicates a defective engine casting. Disassemble engine and carefully check for defects in castings. Pay attention to tapped holes which may go through sealed areas of engine and thus lead to leakage. All Models Disconnect temperature switch wire and spark plug cables. Disconnect magneto wiring harness. Always disconnect starter or battery cables exactly in the specified order, BLACK negative cable first.
It is recommended to disconnect electrical connections prior to disconnecting fuel lines. Cooling System Disconnect the engine water supply hose. Disconnect the engine water return hose. XP Limited Disconnect choke and throttle cables from carburetor linkage.
Disconnect fuel supply and fuel return hoses. Engine Support NOTE: Be careful when removing engine support s or rubber mount adapters, shims could have been installed underneath. Always note position of shims for reinstallation, to avoid altering engine alignment.
Remove engine support mount screws. Lifting Engine Engine Engine can be easily lifted using the following suggested tools: Cut porcelain from 2 old spark plugs.
Weld a lock washer approximately 20 mm diameter on each spark plug as shown. Using a chain block, a hoist or other suitable equipment, slightly lift engine to ease the remaining component removal. Remove spark plugs and replace by special tools.
Hook a sling into holes of special tools. All Engines Install a hose pincher to oil supply hoses of oil injection pump and rotary valve shaft except the engine ; then, disconnect hoses.
Clean with a bilge cleaner. Clean external parts of engine. Install a hose pincher to oil return hose of rotary valve shaft except the engine ; then, disconnect hose. Disconnect RED positive cable from starter post. However pay particular attention to the following.
Rubber Mount, Shim and Screw Check tightness and condition of rubber mounts. If they have been removed, apply Loctite blue on screw threads.
Torque screws to 25 Nm 18 lbfft. Strict adherence to this torque is important to avoid damaging threads of aluminum insert in bilge. Engine Support Engine Torque front and rear engine supports as shown in the following illustration.
Positive Starter Cable Torque nut of positive starter cable to 6 Nm 53 lbfin. Apply dielectric grease on nut. Check alignment of engine using the following alignment tools. Oil Injection Hoses and Engines Make sure to reinstall hoses before completely lowering engine in bilge. All Models To verify alignment proceed as follows: Install the appropriate plate with the support to hull with 4 nuts. If the alignment is incorrect loosen engine support screws to enable to align PTO flywheel with shaft end.
Carefully slide shaft through support. Insert shaft end into PTO flywheel. NOTE: Ensure the protective hose and carbon ring or seal carrier is removed to check engine alignment. If the alignment is correct, the shaft will slide easily without any deflection in PTO flywheel. Whenever shims are used to correct alignment, never install more than 1. Engine Support Screws Apply Loctite blue on screw threads.
Torque engine support screws to 25 Nm 18 lbfft when procedure is completed. Loctite 1 Loctite 1. Whenever doing any type of repair on watercraft or if any components of the fuel system are disconnected, a pressure test must be done before starting engine. Verify all electrical connections. Run engine and ensure there is no leakage. Using a suitable socket, unscrew retaining nut no. NOTE: If socket is found too large to be inserted in puller plate, machine or grind its outside diameter as necessary.
Install extension handle on end of puller plate. Tap lightly on ring gear using a hammer to release it from magneto flywheel. Fully thread on puller in puller plate.
Tighten puller bolt and at the same time, tap on bolt head using a hammer to release magneto flywheel from its taper. To replace generating coil: Heat the armature plate to 93C F around the screw holes to break the threadlocker bond. Unscrew retaining screws no. Remove screws. Engine Crankcase Replacement Engine Only Since replacement crankcases do not have timing mark for armature plate location, indexing marks should be made on armature plate and crankcase to ease reassembly and further ignition timing.
The following procedure is to find a common reference point on both crankcases old and new to position armature plate. Proceed as follows: Find a crankcase locating lug the top one in this example. Place a cold chisel at the end of chosen lug, then punch a mark on armature plate at this point.
Find manufacturers mark on armature plate. In line with this mark, punch another mark on adjacent crankcase lug. At assembly, align armature plate mark previously punched with the end of the same locating lug on the new crankcase. Manufacturers mark on armature plate 2. Punch a mark on crankcase lug aligned with plate mark. The new mark on crankcase will be used for further assembly positioning as a pre-timing position.
Remove engine magneto cover. Remove oil pump shaft from flywheel nut. Lock ring gear using special tool. Remove special tool locking ring gear. Insert crankshaft protector to outer end of crankshaft and fully thread puller in engine flywheel. If desired, magneto rotor can be removed without the engine flywheel.
Remove the 6 screws no. Tighten puller screw and at the same time, tap on screw head using a hammer to release engine flywheel from its taper. If necessary, the magneto rotor can be removed without the engine flywheel. Fully thread puller in engine flywheel. Strip end of old wire then crimp and solder on new coil. Apply Loctite blue to screws no. Prior to assembly, apply Loctite blue.
Whenever replacing either ring gear or magneto flywheel, Gun Kote must be applied to prevent possible corrosion. Always assemble magneto flywheel and ring gear prior to apply Gun Kote. If not done correctly, ring gear wont contact magneto flywheel flange. To apply Gun Kote proceed as follows: 1.
Clean thoroughly and degrease replacement part using a non oil base solvent. Apply coating in light thin coats using a spray gun. Bake parts in oven at F for 1 hour to cure Gun Kote. Lay ring gear on a steel plate, then heat with a propane torch in order to install it on magneto flywheel. Pay particular attention to position ring gear teeth chamfer side as per following illustration. Do not eliminate Gun Kote heat curing time because it will lose all its resistance and it will not give any protection.
Install magneto housing and torque screws no. Apply a drop of Loctite blue on threads of screws no. Position Woodruff key no. Apply Loctite blue on nut no. Install nut with lock washer and torque to Nm lbfft. Apply Loctite anti-seize on screws no. Torque screws no. Replace wiring harness bracket no. NOTE: The trigger coil is not adjustable. Install nut with lock washer and torque to Nm 77 lbfft.
Before installation, properly install O-ring no. Apply Loctite anti-seize compound on screws no. Torque screws in a criss-cross sequence to 9 Nm 80 lbfin. Install gasket no. Torque screws to 9 Nm 80 lbfin. Reinstall wiring harness bracket no. Torque trigger coil screws no. Torque stator screws no. One of the protusion end of magneto rotor must align with hole of engine flywheel. Apply Loctite green on screws no.
Apply Loctite blue on crankshaft taper. When reinstalling rotor to flywheel, one of the protrusion end of rotor must be aligned with hole in flywheel. Install flywheel and make sure to align keyway with the crankshaft Woodruff key. Install nut with lock washer and torque to Nm 85 lbfft. Never use any type of impact wrench. Unlock crankshaft. Reinstall pulse fitting with washer and torque to 19 Nm 14 lbfft.
Synthetic grease 24 Nm 17 lbfft 13 Loctite Loctite 9 34 rollers 6 10 7 5 8 3 Synthetic grease 7 8 4 3 4 5 6 34 rollers. The and engines have a rotary valve to control opening and closing of the intake. The engine uses reed valves in the crankcase. Located above the exhaust port is a guillotinetype slide valve. This rectangular valve is connected by a shaft to a diaphragm which is working against the return spring.
To the outside of the return spring is a red plastic adjustment knob. Turning the adjustment in or out changes the preload on the return spring which, in turn, will change the RPM at which the RAVE valve opens and closes. Cylinder exhaust ports are located on the same side of the intake, allowing a high volume tuned pipe design.
RAVE System THEORY For a 2-stroke-cycle engine to have high power capacity at high crankshaft speeds, a high volumetric or breathing efficiency is required and the fresh charge losses must be minimized. The result is achieved by opening the exhaust port early and utilizing the resonant effects of the tuned exhaust system to control fresh charge losses. When an engine of this design is run at a medium speed, efficiency falls off quickly.
The relatively high exhaust port effectively shortens the useful power stroke and because the exhaust system is tuned for maximum power, there is a large increase of fresh charge losses. As a result, the torque decreases along with a dramatic increase of the specific fuel consumption. Higher torque along with lower fuel consumption can be obtained at lower engine speeds if the time the exhaust port is open is shortened. As the throttle is opened and the engine begins producing more power, the pressure against the diaphragm will overcome the pressure of the return spring and the RAVE valve will open.
NOTE: A check valve on the pressure line eliminates the negative pressure from the crankcase. The RAVE valves are opened to the atmosphere. Pulse from crankcase 2. Check valve 3. Positive pressure to solenoid 4. Solenoid activated 5. Positive crankcase pressure to RAVE valves. Positive pressure blocked by the solenoid 4. Solenoid deactivated 5. RAVE valves are opened to atmosphere. Item 6 notes the peak power produced. That peak will not change if the exhaust port time of a similar engine without a RAVE valve was the same with all other features equal.
The shaded area item 3 is the improvement in power at lower engine speeds that is gained because of the lower exhaust port. If the port remains at this height, however, the power would peak as noted in item 5. Raising the exhaust port at the proper RPM item 7 will allow the engine peak power to continue to rise item 6. Item P1 in figure is the force of the return spring against the diaphragm. The exhaust pressure must be high enough to overcome this force before the valve begins opening.
Between P1 and P2, the usable power curve of the engine is moving from power curve 1 to power curve 2. This transition takes place very rapidly at full throttle and from a practical standpoint can be considered to be instantaneous at item 7.
Gradual application of the throttle, however, will result in the RAVE valve opening much later. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide.
Cleaning intervals would depend upon the users riding style and the quality of the oil used. If a customer uses a lower quality oil, more frequent cleaning may be required. No special solvents or cleaners are required when cleaning the valve. This is the minimum production clearance. There is only a first oversize piston available for the and engines. That piston is 0. When the oversize is installed, the guillotine will have a minimum clearance of 0.
This is the minimum operating clearance the guillotine should be used with. Clearance less than 0. Firmly hold cover to valve base. The spring inside the valve is applying a pressure against the cover. Remove bellow no. Unscrew valve piston no. NOTE: Hold the sliding valve to prevent it from turning. The compression spring inside the valve is applying pressure against the cover.
If shells, sand, salt or any other particles are present in cylinder head, clean with a vacuum cleaner. Remove cylinder head no. If shells, sand, salt water or any other particles are present in cylinder cooling jacket, clean with a vacuum cleaner. Loosen cylinder head bolts no.
Connect spark plug cables on grounding device. Remove cylinder head cover no. Remove screws no. Remove cylinders, being careful that connecting rods do not hit crankcase edge. If screws need to be heated for removal when engine is in watercraft, fuel system pressurization must be done first. Do not use open flame; use a heat gun. NOTE: Even if only 1 cylinder needs repair, both cylinders should be lifted to allow 1-piece cylinder base gasket replacement.
Secure with screws. Lower piston until it sits on pad. All Engines To remove circlip no. To extract piston pin no. Lower piston to be removed until it sits on pad. Fully thread on puller handle. Insert extractor spindle into the piston pin. Slide the sleeve and shoulder sleeve onto the spindle.
Screw in extracting nut with the movable extracting ring towards spindle. Carefully remove the piston no. The needles, thrust washers and the sleeve remain in the connecting rod bore and may be used again.
Firmly hold puller and rotate handle to pull piston pin no. Rotate spindle until the shoulder sleeve is flushed with the piston recess. The inspection of engine top end should include the following measurements. The Rotax engine powering the GTI is a two-stroke, twin-cylinder engine. It has a compression ratio of 6. The fuel delivery system is a Mikuni carburetor, and the engine runs on octane fuel. The overall length of the GTI is inches, the height is 41 inches and the width is 47 inches.
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