Assembly - SeaDoo Rotax 1503 4-Tec 2005 Engine Shop Manual

DRIVEN PLATE JOURNAL DEPTH
NEW MINIMUM
NEW MAXIMUM
SERVICE LIMIT
DRIVE GEAR THICKNESS
NEW MINIMUM
NEW MAXIMUM
SERVICE LIMIT
LOCK WASHER THICKNESS
NEW MINIMUM
NEW MAXIMUM
SERVICE LIMIT
Spring Washer
Put spring washer package together as it is as-
sembled on the supercharger shaft. Measure the
height of the unloaded spring washer package.
A. Spring washer package height
SPRING WASHER PACKAGE HEIGHT
NEW
SERVICE LIMIT

ASSEMBLY

Assembly is essentially the reverse of removal
procedures. However pay particular attention to
the following.
SMR2005-033
Subsection 02 (INTAKE MANIFOLD AND SUPERCHARGER)
9.960 mm (.3921 in)
10.000 mm (.3937 in)
10.3000 mm (.4055 in)
11.000 mm (.4331 in)
11.050 mm (.4350 in)
10.500 mm (.4134 in)
6.900 mm (.2717 in)
7.100 mm (.2795 in)
6.600 mm (.2598 in)
10.500 mm (.4134 in)
9.700 mm (.3819 in)
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Section 01 ENGINES (1503 4-TEC)
Intake Manifold and Intercooler
Supercharged Intercooled Engine
Ensure O-rings are properly installed on intercool-
er and apply 4-stroke oil on them to ease installa-
tion.
While properly aligning the inner end of intercooler
in intake manifold, gently push intercooler until it
bottoms.
Rotate intercooler to position nipples as shown.
1. Intake manifold flange
2. Nipple parallel with manifold flange
NOTE: If intercooler is hard to push in, a clamp can
be used to press intercooler in.
1. Clamp
2. Plastic block between nipples
3. Plastic block
Reinstall collar.
The distance between engine block and intercool-
er outlet hose must be 3 - 7 mm (0.12 - 0.27 in) oth-
erwise the hose would scuff on the engine block.
21