Engine Leakage Diagnostic Flow Chart - Rotax 2005 717 RFI Engine Shop Manual

ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

PRESSURIZE ROTARY VALVE GEAR
RESERVOIR IN CRANKCASE
YES
IS RESERVOIR LEAKING?
NO
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IS SYSTEM LEAKING?
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
CHECK ALL JOINTED SURFACES,
SCREW/STUD THREADS. MOUNTING
CHECK SMALL OIL LINES OF
AIR BUBBLES FOUND
BLOCK LARGE HOSES OF
LUBRICATION SYSTEM
NO
IS ENGINE STILL LEAKING?
CHECK CRANKSHAFT OUTER
PRESSURIZE ROTARY VALVE GEAR
RESERVOIR IN CRANKCASE
YES
IS RESERVOIR LEAKING?
UNSEAL PTO CYLINDER AND MAG CYLINDER
SEPARATELY BY REMOVING THE
APPROPRIATE SPARK PLUG
IS RESERVOIR LEAKING?
CHECK FOR LEAKAGE AT ROTARY
CHECK TESTING KIT
VALVE SHAFT CRANKCASE PLUG
REMOVE ROTARY VALVE COVER, CHECK
SEAL OF ROTARY VALVE SHAFT
CAREFULLY INSPECT ENGINE CASTINGS,
PARTICULARLY THE THREADED HOLE AREAS
ENGINE IS PERFECTLY SEALED
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PRESSURIZE ENGINE
COOLING SYSTEM
YES
NO
YES
CHECK TESTING KIT
FLANGES ETC.
YES
ANY LEAK FOUND?
NO
INJECTION PUMP
YES
OR OIL MOVING
TOWARD PUMP?
NO
ROTARY VALVE GEAR
YES
CHECK TESTING KIT
SEAL OF PTO AND
MAG SIDES
YES
ARE SEALS LEAKING?
NO
NO
YES
NO
YES
ANY LEAK FOUND?
NO
YES
IS SEAL LEAKING?
NO
YES
ANY LEAK FOUND?
NO
INTERNALLY
Section 02 717 ENGINE
Subsection 01 (LEAK TEST)
CHECK TESTING KIT
REPLACE O-RING OF CYLINDER HEAD
AND/OR CYLINDER BASE GASKET
RECHECK ENGINE SEALING
REPLACE GASKET OR O-RING,
RE-SEAL LEAKING AREA
REPLACE CHECK VALVE(S) / LINE(S)
REPLACE DEFECTIVE SEAL(S)
RECHECK ENGINE SEALING RECHECK ENGINE SEALING
REPLACE DEFECTIVE SEAL(S)
REPLACE OIL SEAL OF ROTARY
VALVE SHAFT END, OR
REPLACE CAP
REPLACE DEFECTIVE SEAL
REPLACE DEFECTIVE PARTS
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