General; Procedures; Spark Plug; Exhaust Manifold - SeaDoo Rotax 1503 4-Tec 2005 Engine Shop Manual

GENERAL

NOTE: When diagnosing an engine problem, al-
ways perform a cylinder leak test. This will help
pin-point a problem. Refer to the instructions in-
cluded with your leak tester and LEAK TEST for

procedures.

Always place the vehicle on level surface.
Always disconnect the negative wire from the bat-
tery before working on the engine.
Even if the removal of many parts is not neces-
sary to reach another part, it is recommended to
remove these parts in order to check them.
For installation, use the torque values and Loc-
tite products as mentioned. Clean threads before
using Loctite product when installing screws.
When disassembling parts that are duplicated in
the engine, (e.g.: valves, bushings), it is strongly
recommended to note their position (cylinder 1, 2
or 3) and to keep them as a "group". If you find
a defective component, it would be much easier
to find the cause of the failure within the group of
parts (e.g.: you found a worn valve guide. A bent
spring could be the cause and it would be easy to
know which one among the springs is the cause
to replace it if you grouped them at disassembly).
Besides, since used parts have matched together
during the engine operation, they will keep their
matched fit when you reassemble them together
within their "group".
PROCEDURES

SPARK PLUG

Removal
Remove fuel rail cover from engine.
Unplug the ignition coil connector on the spark
plug you need to remove.
Remove the ignition coil no. 1.
Clean spark plug and ignition coil area before dis-
assembly.
Unscrew spark plug no. 2 then use the ignition coil
to take spark plug out of spark plug hole.
smr2005-036
Section 01 ENGINES (1503 4-TEC)
1. Ignition coil
2. Spark plug
Inspection
Check spark plug and each ignition coil condition
(refer to appropriate VEHICLE SHOP MANUAL).
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Check spark plug gap.
Place spark plug into ignition coil, screw spark plug
then remove the ignition coil. Torque spark plug.
Reinstall the ignition coil.
NOTE: Prior to inserting the ignition coil in its
location, apply some BOMBARDIER LUBE lubri-
cant around the seal area that touches the spark
plug hole. After installation, ensure the seal seats
properly with the engine top surface.

EXHAUST MANIFOLD

Removal
Refer to the appropriate VEHICLE SHOP MANU-
AL to disconnect hoses and other required com-
ponents.
Unscrew the exhaust manifold no. 28 beginning
with the bottom screws. This will help holding the
manifold while you remove the screws.
Remove exhaust manifold.
Inspection
Inspect exhaust manifold condition paying atten-
tion for cracks or other damage. Check contact
surfaces and hose. Replace any defective part.
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Subsection 06 (CYLINDER HEAD)
71