General; Procedures; Timing Chain; Chain Tensioner - SeaDoo Rotax 1503 4-Tec 2005 Engine Shop Manual

Section 01 ENGINES (1503 4-TEC)
Subsection 07 (CYLINDER BLOCK)

GENERAL

When disassembling parts that are duplicated in
the engine, (e.g.: pistons, connecting rods etc.),
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 with-
in the group of parts. Besides, since used parts
have matched together during the engine opera-
tion, they will keep their matched fit when you re-
assemble them together within their "group".

PROCEDURES

TIMING CHAIN

Inspection
Check timing chain on camshaft gear for exces-
sive radial play.
Check chain condition for wear and rollers condi-
tion.
1. Timing chain
If chain is excessively worn or damaged, replace
it as a set (camshaft timing gear and timing chain).
Removal
Remove:
– engine oil (refer to OIL CHANGE in in the appro-
priate VEHICLE SHOP MANUAL)
– engine from vehicle (refer to the appropriate VE-
HICLE SHOP MANUAL)
– cylinder head (refer to CYLINDER HEAD sec-
tion)
– PTO housing (refer to PTO HOUSING/MAGNE-
TO section)
– crankshaft (refer to CRANKSHAFT elsewhere in
this section)
– timing chain.
92
Installation
The installation is essentially the reverse of the re-
moval procedure but, pay attention to the follow-
ing details.
Ensure to perform proper valve timing. Lock
crankshaft and camshaft at TDC (refer to CYLIN-
DER HEAD section for the camshaft locking
procedure).
Install chain then, install chain tensioner.
CAUTION: Improper valve timing will damage
engine components.

CHAIN TENSIONER

Removal
NOTE: Removal of the intake manifold allows eas-
ier access to the chain tensioner, but is not neces-
sary. Refer to INTAKE MANIFOLD AND SUPER-
CHARGER section.
Remove:
– chain tensioner plug screw no. 18 with gasket
ring no. 19
– chain tensioner no. 20.
1. Plug screw
2. Gasket ring
3. Chain tensioner
Inspection
Check chain tensioner for excessive wear or
cracks. Also check free movement of the chain
tensioner piston.
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SMR2005-037