HSR S4 Standup 2007 Service Manual
  1. Manuals
  2. Brands
  3. HSR Manuals
  4. Boat
  5. S4 Standup 2007
  6. Service manual

HSR S4 Standup 2007 Service Manual

Watercraft
Hide thumbs
Table of Contents

Advertisement

Quick Links

Page 1/134

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the S4 Standup 2007 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for HSR S4 Standup 2007

  • Page 1 Page 1/134...

  • Page 2: Table Of Contents

    Table of Content General Information ..............7 1.1. 2007 HSR personal watercraft Identification Numbers ........7 1.2. HIN number ......................7 1.3. Engine number .......................8 1.4. Three stars – ultra low emission ................8 1.5. Safety instructions ....................8 1.6. CE Sticker........................8 1.7. Service Guidelines - Safety Warnings ..............9 1.8.
  • Page 3 2.6.1. Checking and setting the valve play ...............28 2.6.2. Removing the valve cover ................29 2.6.3. Checking the valve play..................30 2.6.4. Adjusting the valve play ..................31 2.6.5. Checking the valve of the 2 cylinder.............34 2.7. Malfunctions ......................34 2.7.1. Engine does not crank ..................34 2.7.2.
  • Page 4 High Pressure Oil Supply................105 Electrical System ..............107 5.1. Installing the Keyspan USB to RS-232 Adapter..........107 5.2. Configure the Keyspan Adapter................111 5.3. Configure the HSR Diagnostic Tool..............115 5.4. Diagnostics ......................117 5.4.1. Installation.....................117 5.4.2. Starting the diagnostic program for the first time ..........119 5.4.3.
  • Page 5 5.4.4. ECU Setup....................126 5.4.5. Control the throttle body attitude..............127 5.5. Electrical System ....................130 Appendix..................132 6.1. General Data .......................132 6.2. Directives ......................132 6.3. Proof of maintenance for work carried out ............133 Page 5/134...
  • Page 6 Page 6/134...

  • Page 7: General Information

    1. General Information Model information, Identification number, Engine number, safety warning 1.1. 2007 HSR personal watercraft Identification Numbers The engine I.D. number and hull I.D. number are used to register the watercraft. They are unique numbers that distinguish each watercraft from others of the same model.

  • Page 8: Engine Number

    1.3. Engine number Number is above the starter motor Engine Number : #10017203 1.4. Three stars – ultra low emission The three-star label identifies engines that meet the Air Resources Board’s Personal Waterwraft and Outboard marine engine 2008 exhaust emission standards.

  • Page 9: Service Guidelines - Safety Warnings

    1.7. Service Guidelines - Safety Warnings Clean inside and outside of watercraft prior to servicing. Clean all parts before installing. Always use a service apron to prevent damage to foot well and top- deck fiberglass. Watch for sharp edges which can cause personal injury. Protect hands and arms when working with sharp components.
  • Page 10 Never attempt engine or driveline inspections and/or repairs without first removing lanyard and battery cables. Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme care when handling gasoline. Do not smoke or allow open flames in or near the area where refueling is performed or where gasoline is stored.

  • Page 11: General Data

    1.8. General data 2007 Hydrospace S4 Turbocharged Length: ..…………….. 2,29 m (90,15 in.) Width:…………………….. 0,74 m (29,13 in.) Height:……………………. Dry Weight:………………. 168kg (370,16 in.) Category: …………………. Stand-up Riders:…………………….. Fuel Capacity: 18 liters 4,75 US Gal Emission Certification: Three Star - Ultra Low Emission ENGINE Emission control system SFI ( Sequential Fuel Injection )

  • Page 12: Standard Torque Specifications

    IMPELLER 12/17 Stainless steel – 3 blade – 140 mm COUPLING TYPE Six piece coupler + Damper MINIMUM DEPH FOR OPERATION 60cm (2 Ft) HULL / BODY Hull material Fiberglass texalium reinforced Carbon elements 1.8.1. Standard Torque Specifications The following torque specifications are to be used as a general guideline. Use standard torque values for the appropriate size fastener when torque values are not specified.
  • Page 13 x 0,6214 = mile (mi.) x 28,35 = Grams (g) Ounces (oz.) x 0,035 = Ounces (oz.) Grams (g) x 0,454 = kg x 2,2046 = lb. Cubic inches (cu in) x 16,387 = Cubic centimeters (cc) x 0,061 = Cubic inches ( cu in) Cubic centimeters (cc) x 0,568 = liters (l)

  • Page 14: Service Tools

    1.9. Service Tools HR00_99_20_002 Diagnostic cable and Software HSR00_9920_003 Impeller tool HSR00_99_01_076 Flywheel removal tool HSR00 Torx 50 for Head cylinder Chain Remover tool Not Available Balance Shaft Remover tool Not Available Page 14/134...

  • Page 15: Operating Materials

    Oil removing tool Not Available 1.10. Operating materials The use of other operating materials causes damage to the engine and the voiding of the warranty. 1.11. Fuel Unleaded gasoline according to DIN 51607 („superunleaded“), with an octane rating of at least 95 ROZ [RON] or 85 MOZ [MON].

  • Page 16: Lubricant

    Oil change with filter 2.4-2.6 liters [2.5-2.7qt(US)] 1.13. Running the Engine HSR recommends that during the first five hours of operation, you should not operate the engine over 6,000 U/min [RPM]. This protective running-in has a positive effect on the engine‘s lifespan.
  • Page 17 Page 17/134...

  • Page 18: Maintenance

    Weber Motor AG reserves the right to demand that proof of warranty be provided in writing for warranty service. See Proof of maintenance for work carried out. The vehicle owner or user is responsible adhering to the maintenance intervals. HSR assumes no liability for damage that arises due to maintenance not carried out.

  • Page 19: Maintenance Work By The User Of The Vehicle

    2.1. Maintenance work by the user of the vehicle 2.1.1. Regular checks before driving Always check the oil level before driving. See Chapter Oil level check. Under running and exceeding the motor oil fill level Specified in this manual can cause damage to the Engine.

  • Page 20: Maintenance Intervals

    2.2. Maintenance intervals Activities on the engine must be carried out by trained service personnel. Maintenance maintenance interval h¹ At end of Activity Procedure h¹ season after 10 - 12 Every Every 100 Motor oil and Change ■ 2) ■ 4) oil filter ■...

  • Page 21: Motor Oil And Oil Filter

    Fill approx. 10 ml [0.34 oz (US)] of clean motor oil directly through the spark plug holes. Before you replace the spark plugs, crank up the motor briefly with the starter. Replace the spark plugs. Never fill more motor oil than specified into the spark plug holes.
  • Page 22 1) Unscrew the oil dipstick (1) from the oil tank and wipe it clean with a cloth. 2) Replace the oil dipstick in the oil tank. Do not screw it in. Then remove it again and read the oil level. With a motor warm from operation, the oil level must be just below the The difference between MIN and...

  • Page 23: Changing The Motor Oil And Oil Filter

    2.4.2. Changing the motor oil and oil filter • Oil extraction pump • Catch basin for old oil, fill volume at least 4liters[4.3qt(US)] • Flathead screwdriver or wrench to open the screw clamps • Torque wrench to close the screw clamps •...
  • Page 24 The motor oil in the dry sump tank is pumped out with the help of the engine dry sump pump. 5. Remove the cable harness from the spark plugs and the injection valves. See Chapter Removing the spark plugs. 6. Remove the oil feed hose (2) on one side of the oil tank.

  • Page 25: Changing The Oil Filter

    2.4.4. Changing the oil filter 9. Unplug the plug from switch 70/65°C (3). 10. Unscrew the oilfiltercover(4). Tightening torque: 24 Nm ± 10 % [17.7 ft. lb.] 11. Replace the oilfilter(5) and O-ring (6). 12. Coat the O-ring (6) lightly with motor oil.

  • Page 26: Refilling The Motoroil

    2.4.5. Refilling the motoroil 13. Fill oil tank with 2.5 liters of motoroil. 14. Close the oil tank with the oil dipstick. 15. Warm up the motor in a body of water for approx. 10 minutes at 4000 - 4500 U/min. 16.
  • Page 27 Before disassembling, make sure that the plugs of the ignition coils and the injection valves are not switched during assembly. 4. Remove the screws and washers (4). 5. Remove the ignition coils (5) Install the spark plugs only in a cold engine.

  • Page 28: Checking The Spark Plugs

    2.5.3. Checking the spark plugs 7. Check the electrode distance of the spark plugs with the help of the feeler gauge. 0,69 - 0,84 mm [0.0272 - 0.0331 in.] 2.6. Valve play 2.6.1. Checking and setting the valve play IMPORTANT!!! •...

  • Page 29: Removing The Valve Cover

    2.6.2. Removing the valve cover 1. Removing the cable harness on the shaft sensor (1). 2. Remove the spark plugs. See Chapter Removing the spark plugs. 3. Unscrew the valve cover (2) along with bracket and valve (3). Tightening torque: 10 Nm ±...

  • Page 30: Checking The Valve Play

    2.6.3. Checking the valve play 4. Start the vehicle’s starter and let the engine crank until both cams of the second cylinder are pointing upwards. The rocker of the first cylinder demonstrates a little play. 5. Using a feeler gauge, measure the valve play (6) of all four valves of the first cylinder between the adjustment plates and the rockers.

  • Page 31: Adjusting The Valve Play

    2.6.4. Adjusting the valve play 6. To adjust the valve play on the intake side, it is necessary to remove the fuel distributor rail. Remove the cable harness on the coolant sensor (7). 7. Loosen the screws and washers (8) and remove the fuel distributor rail (9).
  • Page 32 Replace the O-rings (9) on the injector valves. Coat the O-rings lightly with motor oil. 8. Mount the valve adjustment tool (11) with two screws. Tightening torque: 10 Nm ± 10 % [7.4 ft. lb.] The engine may not be turned over until all valve Plays of the first cylinder are adjusted.
  • Page 33 9. Press the rocker downwards with a 24 combination wrench (12). 10. Clamp both valves by pressing in the sliding piece (13). 11. Remove the adjustment plate with the bar magnet. 12. Measure the strength of the adjustment plate and replace with an adjustment plate with which the permissible tolerance is adhered 13.

  • Page 34: Checking The Valve Of The

    2.7. Malfunctions If you cannot correct a malfunction yourself using the table below, contact your vehicle dealer‘s customer service. In case of improperly-made repairs, the warranty is voided and HSR is not liable for any resulting subsequent damage. 2.7.1. Engine does not crank...
  • Page 35 Battery voltage too low. Remove soiling and corrosion on the battery - Open-circuit voltage < 12 volts. poles and connect battery connections - During activation of the starter correctly. With non maintenance-free < 10.5 volts. batteries, check water level. Charge battery with external battery charger Engine mass point (1) not connected Check connection.

  • Page 36: Engine Cranks But Does Not Start

    2.7.2. Engine cranks but does not start Possible cause Remedy Lanyard not plugged in. Plug in lanyard. Defective fuse. Check the fuses in the cable harness. Too little or no fuel in the tank. Fill up fuel. Check the engine for signs of leaky fuel lines and, if necessary, have it checked by a professional shop.

  • Page 37: Engine Stalls But Can Be Started Again

    2.7.3. Engine stalls but can be started again Possible cause Remedy Too little or no fuel in the tank. Fill up fuel. Check the engine for signs of leaky fuel lines and, if necessary, have it checked by a professional shop. Too much motor oil.

  • Page 38: Engine Loses Power (Speed Limitations)

    plugged in or not plugged in correctly. Spark plugs defective. Check the spark plugs and, if necessary, replace them. See Chapter Spark plugs. 2.7.5. Engine loses power (speed limitations) Fault Possible cause Remedy Overheating of DO NOT LET THE ENGINE RUN Engine speed limited to exhaust manifold.
  • Page 39 Page 39/134...

  • Page 40: Engine Removal And Installation

    3. Engine Removal and Installation 3.1. Engine Removal Several subsystems must be removed before the engine can be extracted from the engine bay. These systems are: • Oil, see chapter 2.4.3 • Intercooler, support and hoses. • Engine electrical harness, and earth cable •...

  • Page 41: Engine Installation

    NOTE: Not all electrical connections can be discon- nected without removing hoses, pipes or sub- sys- tems. As components are removed, disconnect any electrical connections. 1. Locate the fuel hose quick disconnect on top of the fuel rail. Wrap a shop towel around the disconnect and press the two tabs in while pulling up on the connector.
  • Page 42 Page 42/134...

  • Page 43: Engine Disassembly/Assembly

    Cylinder Compression @ Sea Level Recommended Fuel Premium Unleaded 91, 92, 93 Octane Engine Oil Requirement HSR 100% Synthetic Four Stroke Engine Oil Oil Grade Requirement 10W- 60 Synthetic API A3/B3 Engine Oil Capacity 3.4 - 3.7 US Quarts (3.3 - 3.5 Liters)
  • Page 44 Cooling System Requirement OPEN cooling system with Thermostat Thermostat Opening Temperature 158 F (70°c) Valve Timing (1mm Valve Lift) EV OPENS 52_ BBDC EV CLOSES ATDC IV OPENS 14_ BTDC IV CLOSES 50_ ABDC Valve Diameter Exhaust Valves 29.5mm (1.161”) Intake Valves 32.5mm (1.279”) Valve Seat Contact Width...
  • Page 45 0.18 – 0.25mm (.007” - .010”) Valve Stem Diameter 5.465 – 5.479mm (.2151” – .2157”) 5.456 – 5.470mm (.2148” - .2153”) Valve Guide Inside Diameter 5.5mm – 5.507mm (.216”) 5.5mm – 5.509mm (.216”) Valve Stem Run out .03mm (.001”) Valve Stem-To-Guide Clearance .021mm - .044mm (.0008 - .0017”) .030mm - .053mm (.0011 - .0020”) Valve Spring Free Length...
  • Page 46 BEARING HOLE I.D. 19.991mm - 20mm (.787”) CAMSHAFT AXLE O.D. 19.90mm - 19.98mm (.783“) CAMSHAFT CLAMP I.D. Rocker Arm Specifications .013mm - .025mm (.0005“ - .0009“) BEARING AXIAL PLAY 13.980mm - 13.991mm (.55“) ROCKER ARM I.D. 9.994mm - 10mm (.393“) ROCKER ARM SHAFT O.D.

  • Page 47: Engine Fastener Torque Specifications

    OIL RING INSTALLED END GAP .50mm - .910mm (.019“ - .035“) OIL RING GROVE CLEARANCE Oil Pump Specifications Trochoid OIL PUMP TYPES SPRING FREE LENGTH = 2.7” (69mm) / PISTON O.D. OIL PRESSURE RELIEF VALVE = .43” (10.9mm) / PISTON LENGTH = 1.10” (27.7 - 28mm) OIL PRESSURE 21 @ IDLE - 80 @ MAX PSI (1.5 - 5.5 BAR) 4.1.1.

  • Page 48: Engine Specific Fastener Torque Specifications

    4.1.2. Engine Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Cylinder Head Nuts Apply Engine Oil M10 x 1.25 Step 1 to Threads. Step 2 180° M8 x 50 180° Step 3 M8 x 70 M8 x 90 Lower Crankcase Bolts Step 1 16 24 –...

  • Page 49: Engine Specific Fastener Torque Specifications

    Tensioner Rail Fastener Loctite 243 M8 x 25 Chain Guide Rail Fastener Loctite 243 M6 x 25 Chain Tensioner Plug Bolt 4.1.3. Engine Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Water Pump Cover Loctite 577 M6 x 20 M6 x 30 M6 x 35 4.1.4.

  • Page 50: Intake Manifold Specific Fastener Torque Specifications

    4.1.5. Intake Manifold Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Manifold – to – Cylinder Head M6 x 30 Lower Bracket – to – Lower M8 x 30 Crankcase 4.1.6. Alternator Assembly Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Magnet Rotor Fastener...

  • Page 51: Engine Management Components/ Sensor Specific Fastener Torque Specifications

    4.1.8. Engine Management Components/ Sensor Specific Fastener Torque Specifications Component FT. LBS. Notes Fastener(s) Temperature/ Pressure M6 x 10 Sensor ( MAP ) Temperature / Pressure M6 x 10 Sensor (Intake Manifold) Crank Position/ Speed Sensor M6 x 10 Coolant Manifold Temp. Sensor Ignition Coil Fasteners M6 x 20...

  • Page 52: Oil Filter Assembly

    4.2. Oil filter assembly Assembly Notes: Filter Cap Torque 18 ft.lbs. (25 Nm) Apply a light film of engine oil to sealing o- ring and filter cap threads during installation. OIL FILTER CHANGE INTERVAL: BREAK IN = 10 TO 12 HOURS / EVERY 25 HOURS THEREAFTER Page 52/134...

  • Page 53: Valve Cover Assembly

    4.3. Valve cover assembly Assembly Notes: Valve Cover Fastener Torque 7 ft.lbs. (10 Nm) Cam Phase Sensor Fastener Torque 6.6 ft.lbs. (9 Nm) Always use new gaskets and o- rings when removing or replacing parts. Torque valve cover fasteners in a criss- cross pattern beginning with the four inside fasteners.

  • Page 54: Valve Train Assembly

    4.4. Valve train assembly Assembly Notes: Camshaft Bearing Fastener Torque: 7 ft.lbs. (10 Nm) Rocker Arm Tower Fastener Torque: 9 ft.lbs. (13 Nm) VALVE CLEARANCE (COLD) IN: .08 - 0.15MM (.003 - .006IN.) / EX: .18 - .25MM (.007 - .010IN.) Verify camshaft orientation during installation.

  • Page 55: Dry Sump Oil Pump Assembly

    4.5. Dry sump oil pump assembly Assembly Notes: Screen Fastener Torque: 7 ft.lbs. (10 Nm) Apply Loctitet 243 to threads. Oil Pump Fastener Torque: 7 ft.lbs. (10 Nm) Apply Loctitet 243 to threads. Oil Pump Drive Gear Nut Torque: 28 ft.lbs. (38 Nm) Apply Loctitet 272 to threads. Plug Fastener Torque: 11 ft.lbs.

  • Page 56: Thermostat Housing Assembly

    4.6. Thermostat housing assembly Assembly Notes: Water Pipe Fastener Torque: 7 ft.lbs. (10 Nm) Thermostat Opening Temperature: 158_F / 70_C Snap ring chamfer faces outward, towards rear of engine. Always use new o- rings during installation and reassembly. Elbow pipe points down and toward the heat exchanger. Page 56/134...

  • Page 57: High Pressure Oil Pump Assembly

    4.7. High pressure oil pump assembly Assembly Notes: Use LIBERAL amounts of engine oil on timing rotor, inner and outer rotors, I.D. of retaining cap, and retaining cap o- rings during oil pump assembly. Snap ring chamfer must face outwards, towards rear of engine when installed. Verify retaining cap does not move when snap ring is installed.

  • Page 58: Exhaust-Side Chain Guide/Tensioner Assembly

    4.8. Exhaust-side chain guide/tensioner assembly Assembly Notes: Timing Chain Tensioner Plug Bolt Torque: 51 ft.lbs. (70Nm) INSTALLED FROM BOTTOM OF UPPER CRANKCASE Tensioner Guide Fastener Torque: 17 ft.lbs. (24 Nm) Apply Loctitet 243 to threads. Replace replace tensioner rail if damaged, or unevenly worn. Press tensioner into housing until flush with plug to set tensioner.

  • Page 59: Engine Case/Cylinder Head Assembly

    4.9. Engine case/cylinder head assembly Page 59/134...
  • Page 60 Assembly Notes: CYLINDER HEAD - TO - CRANKCASE TORQUE SEQUENCE SPECIFICATIONS Apply engine oil to bolt threads. 1st STEP: Torque cylinder head nuts in sequence. 15 ft.lbs. (20 Nm) Torque crankcase fasteners in sequence. 12 ft.lbs. (16 Nm) 2nd STEP: Torque cylinder head nuts in sequence 30 ft.lbs.

  • Page 61: Piston Assembly

    4.10. Piston assembly Assembly Notes: AVAILABLE BEARINGS: 1. RED .0783 - .0785IN. (1.990 - 1.995mm) 2. YELLOW .0785 - .0787IN. (1.995 - 2.000mm) 3. BLUE .0787 - .0789IN. (2.000 - 2.005mm) Rod Cap Fastener Torque: 1st Step: 7 ft.lbs. (10 Nm) 2nd Step: 14 ft.lbs.

  • Page 62: Valve Assemblies

    4.11. Valve assemblies Page 62/134...

  • Page 63: Balance Plate/Pto Assembly

    4.12. Balance plate/PTO assembly Assembly Notes: Balance Plate Fastener Torque: 51 ft.lbs. (70 Nm) Apply Loctite 577 to threads. Page 63/134...

  • Page 64: Crankshaft/Counter Balancer Assemblies

    4.13. Crankshaft/Counter balancer assemblies Page 64/134...

  • Page 65: Engine Disassembly Process

    4.14. Engine Disassembly Process 1. Remove valve cover from engine. 2. Remove the coolant outlet manifold, oil filter cover, and electric starter motor from engine case 3. Remove the two high pressure oil feed hose banjo bolts from the cylinder head exhaust- side rear mounting location.
  • Page 66 4. Remove the stator cover from the flywheel housing.(Photo D) NOTE: The stator is attached to the inside of the cover. Note the two alignment dowels as circled in photo. 5. Photo of stator inside of cover. (Photo E) 6. Remove the water pump cover and impeller. (Photo F) NOTE: The impeller can be removed by turning the nut counter-clockwise.
  • Page 67 7. Remove the front engine gear cover. (Photo G) NOTE: Place drain pan underneath cover to catch oil. 8. Install two of the PTO coupler bolts into the PTO- end of the crankshaft. Have an assistant place a pry bar across these two bolts to prevent the crankshaft from rotating.
  • Page 68 11. Photo of front of engine. Remove the starter motor drive gear assembly (A) and oil pump drive gear (B). (Photo J) 12. Remove lock pin and rotate engine 180_. Remove the sump cover. (Photo K) NOTE: The sump oil pump is attached to the inside of the sump cover.
  • Page 69 15. Rotate the engine assembly 180_ so that the valve train is up. Using the hand crank, crank the engine until the PTO piston is at TDC on the compression stroke. BOTH PTO ROCKER ARMS WILL BE LOOSE. 16. Using a flat- head screwdriver, push the rocker arm pins out enough to expose the detents on the pins.
  • Page 70 24. Rotate the engine assembly 180° so that the valve train is down, facing the floor. Using the hand crank, crank the timing chain out of the engine. 25. With the timing chain removed from the engine, the crankcase can be split in two. To begin, loosen and remove the four case bolts located in the oil sump gallery.
  • Page 71 28. Rotate the engine assembly 180_ so that the valve train is up. Evenly loosen and remove the cylinder head nuts. (Photo R) 29. Carefully pull the cylinder head assembly up and off of the crankcase. 30. Remove the chain guide fastener and chain guide. (Photo S) 31.
  • Page 72 33. Remove the balance shaft from the crankcase. Remove the PTO crankshaft case seal and discard. Remove the piston lower rod cap bolts. (Photo R) 34. Carefully push each piston through and out of the crankcase. Match each rod cap with its corresponding connecting rod.(Photo U) NOTE: The connecting rod caps are “cracked”...

  • Page 73: Engine Inspection Procedures

    4.15. Engine inspection procedures 4.15.1. Valve Inspection NOTE: Valves cannot be replaced. If valve face is burned or excessively worn, replace valve. Measure diameter of valve. • Out of specification: Replace Measure valve face width. • Out of specification: Replace valve Measure valve seat contact width.
  • Page 74 Measure valve margin thickness. • Out of specification: Replace valve Measure valve stem diameter. • Out of specification: Replace valve Measure valve guide inside diameter. • Out of specification: Replace valve guide Page 74/134...

  • Page 75: Cylinder Head Inspection

    Measure valve stem run out. • Out of specification: Replace valve Measure valve spring free and installed length. • Out of specification: Replace spring 4.15.2. Cylinder Head Inspection Measure cylinder head warpage. • Out of specification: Replace cylinder head Page 75/134...

  • Page 76: Cylinder Block Inspection

    4.15.3. Cylinder Block Inspection Measure cylinder bore size. • Out of specification: Replace cylinder block NOTE: Cylinders are plated with NiCaSil. Measure cylinder for taper and out- of- round limits. 1. BORE = Maximum diameter of Da - Df. 2. TAPER = Maximum of Da - De and Db - Df. 3.
  • Page 77 Measure cam lobe height. • Out of specification: Replace camshaft Measure camshaft run out. • Out of specification: Replace camshaft Measure camshaft bearing hole inside diameter. • Out of specification: Replace camshaft NOTE: Bearings must be removed to measure I.D. Page 77/134...

  • Page 78: Rocker Arm Inspection

    Measure camshaft axle outside diameter. • Out of specification: Replace axle Measure camshaft axle clamp inside diameter. • Out of specification: Replace cylinder head 4.15.5. Rocker Arm Inspection Measure rocker arm axial play. • Out of specification: Replace rocker arm Page 78/134...

  • Page 79: Crankshaft Inspection

    Measure rocker arm shaft outside diameter. • Out of specification: Replace rocker arm shaft Measure rocker arm post bore inside diameter. • Out of specification: Replace rocker arm post 4.15.6. Crankshaft Inspection Measure crankshaft deflection. • Out of specification: Replace crankshaft Page 79/134...
  • Page 80 NOTE: Do not move crankshaft until measurement process is completed. Do not place on oil holes. Measure crankshaft main bearing clearance. 1. Place upper journal bearings into upper casehalve. 2. Install crankshaft. Place a piece of Plastigauge across the journal surface. Install lower crankcase halve with journal bearings installed.

  • Page 81: Connection Rod Inspection

    4.15.7. Connection Rod Inspection Measure big end oil clearance. NOTE: Do not move crankshaft or connect- ing rods until measurement process is com- pleted. 1. Remove lower connecting rod caps. 2. Place a piece of Plastigauge across the journal surface. Install lower rod caps with journal bearings installed.

  • Page 82: Balance Shaft Inspection

    4.15.8. Balance Shaft Inspection Measure balance shaft run out at several locations. • Out of specification: Replace balance shaft Measure bearing diameter. • Out of specification: Replace balance shaft 4.15.9. Piston Inspection Measure piston diameter. • Out of specification: Replace piston Page 82/134...
  • Page 83 Measure piston pin boss inside diameter. • Out of specification: Replace piston Measure piston pin outside diameter. • Out of specification: Replace piston pin Confirm piston- to- cylinder clearance specification. • Out of specification: Replace piston pin Measure installed ring end gap. •...

  • Page 84: High Pressure Oil Pump Inspection

    Measure piston ring grove clearance. • Out of specification: Replace piston ring or piston 4.15.10. High Pressure Oil Pump Inspection Measure relief spring free length and piston dimensions. • Out of specification: Replace spring and piston Page 84/134...

  • Page 85: Chain Tensioner

    4.15.11. Chain Tensioner Verify chain tensioner function. 1. Push tensioner into housing until flush with threaded housing. Tensioner should lock into place. (6 audible clicks should be heard when tensioner is pushed in from fully extended position.) 2. Once locked, push tensioner inward. Tensioner should activate and spring outwards.

  • Page 86: Timing Chain

    4.15.13. Timing Chain Inspect timing chain. • Replace timing chain if any damage, obvious wear and tear, or broken / mis- shaped plates are found. 4.16. Engine Assembly 1. Remove any remaining gasket material from the upper and lower crankcase mating surfaces. 2.
  • Page 87 9. Carefully install each piston assembly into the cylinders. Take care in not scratching the cylinder bore. 10. Install the intake- side chain guide. Tighten fastener to specification. 11. Carefully rotate engine 180° Do not allow the pistons to fall out of cylinders. 12.
  • Page 88 18. Push pistons so the connecting rods engage the crankshaft. Obtain the two con- rod caps with bearings installed. Apply engine oil to connecting rod bearings. 19. Match each unique cap mating surface with the appropriate connecting rod. Loosely install each fastener, then tighten evenly.
  • Page 89 24. Verify the crankcase stud oil jackets are installed on the four studs as outlined in the photo. NOTE: Verify stud jackets are installed in the middle of each stud. 25. Carefully install the lower crankcase on to the upper crankcase.
  • Page 90 27. Apply a light film of grease to the crankshaft seal. Install the seal around the flange. Evenly press seal into crankcase. CAUTION!: Use extreme care when installing seal. Do not fold seal lips over when pressing around flange. 28. Rotate the engine 180° so the pistons face upwards. 29.

  • Page 91: Timing Chain Installation/Tdc Procedure

    32. Rotate the engine 180°. (Cylinder Head Down) 33. Install the oil pump relief valve piston and spring. Place cover over spring and insert fastener. Hand- tighten fastener. 34. Install the remaining lower crankcase fastener. 35. Rotate the engine 180°. (Cylinder Head Up) 36.
  • Page 92 PN- PW- 47079, into the two bedplate fastener bores. NOTE: The Timing Chain Installation Guide tool will guide the chain around the crankcase bends while preventing the chain from catching on the balance shaft sprocket. 5. Slowly insert the chain into chain gallery. Wiggle the chain slightly until it falls down through the engine and protrudes from the bottom of the cylinder head.
  • Page 93 8. Wrap the chain around the camshaft sprocket. 9. While firmly holding the chain against the camshaft sprocket, remove the stuffer, and wrap the chain around the balance shaft sprocket and under the crankcase support member. NOTE: The hooked- end of the Timing Chain Hook / Stuffer Tool will simplify pulling the chain around the sprocket.
  • Page 94 11. Rotate the camshaft until one of the holes in the PTO- end points to the floor. 12. Install the Camshaft Alignment Tool, PN- PW- 47077, into the hole, press against the rocker arm towers. NOTE: The Camshaft Alignment Tool will lock the camshaft into the correct timing position in relation to the crankshaft and balance shaft.

  • Page 95: Engine Assembly

    4.17.2. Engine Assembly 1. Reassemble the timing chain with a new plate. Crimp the new chain pins and plates together using the Chain Breaker Tool, PN- PW- 46985. 2. Verify the chain tensioner is set in the locked position. To set the chain tensioner, grasp end in palm of hand, and press assembly down on a hard surface.
  • Page 96 5. Verify the blade of the screwdriver contacts the face of the tensioner. 6. Push the blade of the screwdriver against the tensioner face and twist. Do this until the tensioner goes in past flush and activates. 7. Once activated, there should be no slack present in the timing chain.
  • Page 97 14. If the starter motor was removed, reinstall and tighten fasteners to specification. 15. Attach the starter motor battery cable to the motor at this time. 16. Press the water pump shaft into the mechanical seal. 17. Apply a thin bead of Three Bond 1215t to the front gear cover mating surface.
  • Page 98 21. Apply a generous amount of engine oilto thecrankshaft end and roller bearings. 22. Install the roller bearing, starting gear, and flywheel key into end of crankshaft. 23. Install the flywheel on to the crankshaft. Verify flywheel fits over key. 24.
  • Page 99 27. Apply a thin bead of Three Bond 1215t sealant to stator cover mating surface. 28. Install stator cover with stator mounted inside of cover. Route harness as not to pinch or cut wires. 29. Reinstall the high- pressure oil supply hoses and banjo bolt to the top of the cylinder head.

  • Page 100: Thermostat Removal/Installation

    4.18. Thermostat Removal/Installation NOTE: Coolant will flow out of the cylinder head into the bilge when the outlet rail elbow is removed. Tilt the bow down to prevent coolant from escaping outlet rail. 1. Remove the snap ring using a snap ring pliers. 2.

  • Page 101: Oil Lubrication System

    1. To replace the impeller shaft and mechanical seal, remove the front gear cover. 2. Carefully extract mechanical seal components out of the gear cover. 3. Press new gasket with washer recess facing out, washer with groves facing gasket, and new mechanical seal, with spring- end facing outward into cover using light and even force.

  • Page 102: Low Pressure Oil Circuit

    4.20.1. Low Pressure Oil Circuit 4.20.2. High Pressure Circuit Page 102/134...

  • Page 103: Crankcase Ventillation

    4.20.3. Crankcase Ventillation Engine blow- by is recovered via the oil separator or cyclone. The oil separator is located on the oil storage tank. Engine oil and fuel vapors are collected in the top housing of the oil storage tank. These vapors are routed to the separator. Heavy elements such as oil and unburned fuel are collected at the bottom of the separator and are routed back to the crankcase sump.

  • Page 104: High Pressure Pump Removal/Installation

    4.20.5. High Pressure Pump Removal/Installation NOTE: The engine must be removed to access the high pressure pump. 1. Remove snap ring. Carefully extract rotor cover from crankcase. 2. Extract outer and inner rotors from bore. Remove timing rotor from shaft. 3.

  • Page 105: High Pressure Oil Supply

    4.20.6. High Pressure Oil Supply Page 105/134...
  • Page 106 Page 106/134...

  • Page 107: Electrical System

    5. Electrical System 5.1. Installing the Keyspan USB to RS-232 Adapter The following steps are explained by using Windows XP Service Pack 2 !! If you are using an older version of Windows please contact our support. • Plug in the Keyspan Adapter in a free USB-Port. •...
  • Page 108 • Now you have to open the Keyspan Install File named “KeyspanUSA19hsWinV37.exe” !! You can download the file (driver) under http://www.keyspan.com/ • Sometimes Windows will ask you if you trust the publisher of the product. You confirm by clicking on the button “ok”. •...
  • Page 109 • Now the programm will start with installing the Keyspan Adapter. It takes several minutes to finish the installation, depending on the hardware configuration of your PC. Note: If Windows call you that the program hasn’t pass the Windows Logo Test select “continue installation”...
  • Page 110 • Please reboot the PC, restart the computer. Page 110/134...

  • Page 111: Configure The Keyspan Adapter

    5.2. Configure the Keyspan Adapter • Please connect the HSR Diagnostic cable with the Keyspan Adapter. That everything works the Keyspan Adapter has to configure on a Port between 1-4 as shown in the following steps! • Click on the Windows Start-Button and select “Programs”. Then select the entry “Keyspan Usb Serial Adapter”...
  • Page 112 Now in the main view you can see which port the Keyspan Adapter is using. • If the Port is between 1-4 you can close the Keyspan Assistant and you have to start the HSR Diagnostic Tool • Other case please click on the department (submenu) “Port Mapping”.
  • Page 113 • In the middle of the window there you can select which port should be used. Please select a free one between 1-4 ! After that wait about 30 seconds that the program can change your settings. Page 113/134...
  • Page 114 • When you have chosen a right port please close the Keyspan Assistant and open the HSR Diagnostic tool ! Page 114/134...

  • Page 115: Configure The Hsr Diagnostic Tool

    5.3. Configure the HSR Diagnostic Tool To open the diagnostic manual, refer to the diagnostic manual installation • In the menu of the HSR Diagnostic Tool you can see a submenu named “COM”, please click on it. • After that you see the entry “COM Port”, please select this one.
  • Page 116 Now a new little window has appeared. Please select the same port as you have chosen into the Keyspan Assistant and press the Button “Close”. • Now the HSR Diagnostic Tool should work correctly! If there are any problems please contact our Administrators. Page 116/134...

  • Page 117: Diagnostics

    5.4. Diagnostics 5.4.1. Installation Move the folder “software S0+” to your hard disk or desktop Page 117/134...
  • Page 118 Start the program :” SERVICE 1010 HSR.exe” Page 118/134...

  • Page 119: Starting The Diagnostic Program For The First Time

    5.4.2. Starting the diagnostic program for the first time If you start the diagnostic program (Service 1010 HSR.exe) for the first time, it could be that the following error is shown: Message File Not Found After a click on the button „OK“, the following dialogue window will open: Selecting the Message File Here you can select the language of your Message file (at the present English and Italian).

  • Page 120: Diagnostic

    1. Plug off the cover cap of the multipoint diagnostic connector which is on the wiring harness. Multipoint diagnostic connector 2. Connect the HSR diagnostic cable with the push-pull plug. Connecting the diagnostic cable (1) Connecting the diagnostic cable (2) 3.
  • Page 121 Serial interface 4. Switch on the ignition with the lanyard. Connecting the lanyard (1) Connecting the lanyard (2) Page 121/134...
  • Page 122 5. Start the diagnostic program (Service 1010 HSR.exe) with a double click on the icon. Service 1010 HSR.exe Should there be problems when you start the program for the first time, so you could find a solution in chapter Starting the diagnostic program for the first time.
  • Page 123 Data Console The values shown in the illustration above correspond approximately with the standard values of the non-running engine at the ambient temperature about 10°C (50°F). It’s advisable to set the following parameter in this console: RPM | SPARK1 BAP | SPARK2 MAP | TPS INJ1 | AIR_T INJ2 | ENGINE_T, BATT_V...
  • Page 124 In order to change the indicated parameter, click the button „Open“ and afterwards “Options…” in the menu bar. Then following window will open: Selecting the parameters Select the parameter which you want to have. With a click on the button „Close“ you take over the settings.
  • Page 125 AIR_T ......inlet manifold temperature sensor in [°C] ENGINE_T ......engine temperature in [°C] BATT_V ......battery voltage in [V] LAMBDA......not required LAMBDA_REF ....not required IDLE ........not required GEAR_VALUE ....not required OTS_SWITCH ....not required KILL_SWITCH ....not required DUTY_BOOST ....not required BLOCK ......not required FREE .......not required To abort the diagnosis, click the button Page 125/134...

  • Page 126: Ecu Setup

    5.4.4. ECU Setup To start the window for the ECU-Setup, click the button „Fine Linea“ (see Illustraton “Service 1010 HSR.exe”). ECU-Setup TPS Minimum Bit Value........ throttle body minimum position TPS Maximum Bit Value....... throttle body maximum position Frame Number ..........hull serial number Engine Number ..........

  • Page 127: Control The Throttle Body Attitude

    1. The computer must be connected by the diagnostic cable with the engine ad the ignition must be switched on with the lanyard. 2. Start the diagnostic program (Service 1010 HSR.exe) and start the ECU-Setup window. 3. Give full power and hold. Then double-click with the mouse on the value right of the input field of ”TPS Maximum Bit Value”.
  • Page 128 Adjusting throttle body minimum position 9. Double-click on the value right of the input field of “TPS Minimum Bit Value” to transfer the value into the input field. 10. Then turn the allen screw until the value increases by 1. In our example above, this would be the value of 81.
  • Page 129 Example for correct idle settings 11. Now snug down the lock nut. 12. Click on the button „Set End Line Values“ saves the values into the ECU. 13. With a click on the button „Close“ you quit the ECU-Setup. To start the diagnostic you have to click on the button „Diagnosi“ A click on the button „Read Diagnostic“...

  • Page 130: Electrical System

    5.5. Electrical System Page 130/134...
  • Page 131 Page 131/134...

  • Page 132: Appendix

    6.1. General Data Hydrospace Handels und Produktions GmbH & Co KG Company Wiener Straße 71 Address 3380 Pöchlarn Austria www.hsr-benelli.com Internet office@hydrospace.at E-Mail 6.2. Directives Hydrospace thus confirms that the construction of the engine corresponds to the following pertinent conditions: –...

  • Page 133: Proof Of Maintenance For Work Carried Out

    6.3. Proof of maintenance for work carried out Date: Work carried out: Motor oil change Oilfilter change Status: Spark plug change Valve play checked Hours of operation: Valve play adjusted …………………..........Company seal, signature: ………………………………………………….. ………………………………………………….. ………………………………………………….. ………………………………………………….. Date: Work carried out: Motor oil change Oilfilter change Status:...
  • Page 134 Date: Work carried out: Motor oil change Oilfilter change Status: Spark plug change Valve play checked Hours of operation: Valve play adjusted …………………..........Company seal, signature: ………………………………………………….. ………………………………………………….. ………………………………………………….. ………………………………………………….. Date: Work carried out: Motor oil change Oilfilter change Status: Spark plug change Valve play checked Hours of operation:...

Table of Contents

Save PDF