Inspection; Assembly - Rotax 2005 717 RFI Engine Shop Manual

Section 03 787 RFI ENGINE
Subsection 03 (TOP END)

INSPECTION

Refer to table below to find top end engine dimen-
sion specifications. For dimension measurement
procedures, refer to ENGINE MEASUREMENT.
Visually inspect all parts for corrosion damage.
Inspect piston for damage. Light scratches can be
sanded with a fine sand paper.
NOTE: When repairing a seized engine, connect-
ing rods should be checked for straightness and
crankshaft for deflection/misalignment.
Inspect plane surfaces for warpage. Small defor-
mation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a surface
plate and rub part against oiled sand paper.
ENGINE
NEW PARTS
MEASUREMENT
(min.)
Combustion
34.7 cc
chamber volume
Cylinder taper N.A.
Cylinder out of
N.A.
round
Piston skirt N.A.
Piston/cylinder 0.13 mm
wall clearance (.005 in)
Ring/piston 0.025 mm
groove clearance (.001 in)
0.40 mm
Ring end gap
(.016 in)
N.A.: NOT APPLICABLE
NOTE: Replacement cylinder sleeves are available
if necessary. Also, oversize pistons of 0.25 mm
(.010 in) are available.
RAVE Valve
Check RAVE valve bellows no. 21 for cracks.
Check sliding valve for wear, bent or other dam-
ages.
80
TOLERANCES
WEAR
(max.) LIMIT
37.9 cc N.A
0.05 mm 0.1 mm
(.002 in) (.004 in)
0.008 mm 0.08 mm
(.0003 in) (.003 in)
0.12 mm
N.A.
(.005 in)
0.24 mm
N.A
(.009 in)
0.070 mm 0.24 mm
(.0027 in) (.009 in)
0.55 mm 1.0 mm
(.022 in) (.039 in)
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ASSEMBLY

Assembly is essentially the reverse of disassem-
bly procedures. However pay particular attention
to the following.
RAVE Valve
Make sure to insert O-ring no. 23 onto rod of slid-
ing valve no. 22.
The TOP position of the sliding valve no. 22 is
indicated on one side.
1. Sliding valve
2. O-ring
3. TOP
Install a new gasket no. 24. It must be installed
at the same time as the sliding valve no. 22.
Position the valve housing no. 25 onto the cylinder
so that its opening is toward the bottom.
1. Bottom of valve housing
When the valve is mounted onto the cylinder,
move the valve piston no. 20 to ensure the sliding
valve no. 22 moves easily and does not stick.
smr2005-082