Sea-Doo ROTAX 1503 4-TEC Engine Workshop Service Manual
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
www.SeaDooManuals.net
2005
Engine Shop Manual
ROTAX
®
1503 4-TEC
ENGINES
www.SeaDooManuals.net
Legal deposit:
National Library of Quebec
National Library of Canada 2005
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP).
©
Bombardier Recreational Products Inc. (BRP) 2005
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada
Printed in Canada
®TM
Registered trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
* Trademark of Bombardier Inc. used under license.
SEA-DOO
®
BOMBARDIER LUBE
®
Sea-Doo Synthetic Grease
Sea-Doo
®
Learning Key
TM
DESS
TM
Rotax
®
TOPS
TM
This document contains the trademarks of the following companies:
Loctite
®
is a trademark of Loctite Corporation
Snap-on
®
is a trademark of Snap-on Tools Corporation
Molykote
©
is a trademark of Dow Corning Corporation
AMP
©
is a trademark of Tyco Electronics Corporation
www.SeaDooManuals.net
TABLE OF CONTENTS
SAFETY NOTICE .................................................................................... III
INTRODUCTION ................................................................................... IV
GENERAL INFORMATION.......................................................................................... IV
ENGINE EMISSIONS INFORMATION ............................................................................ IV
ENGINE IDENTIFICATION NUMBER (E.I.N.) .................................................................... IV
TIGHTENING TORQUES ........................................................................................... IV
ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES ............................. V
01 ENGINES (1503 4-TEC)
01 – LEAK TEST ...................................................................................................... 1
PROCEDURES .................................................................................................. 1
PREPARATION ........................................................................................................ 1
PROCEDURE .......................................................................................................... 2
DIAGNOSIS ............................................................................................................ 3
POSSIBLE ENGINE LEAKAGE AREA ................................................................................ 3
ASSEMBLY ............................................................................................................ 4
02 – INTAKE MANIFOLD AND SUPERCHARGER ............................................................... 5
INSPECTION (PARTS ASSEMBLED) ................................................................................ 10
REMOVAL ............................................................................................................ 12
DISASSEMBLY ....................................................................................................... 17
INSPECTION (PARTS DISASSEMBLED) ........................................................................... 20
ASSEMBLY ........................................................................................................... 21
INSTALLATION ....................................................................................................... 26
03 – PTO HOUSING AND MAGNETO .......................................................................... 29
GENERAL ...................................................................................................... 31
PROCEDURES ................................................................................................ 31
PTO HOUSING ....................................................................................................... 31
PTO SEAL ............................................................................................................. 34
COUPLING ............................................................................................................ 35
STATOR ............................................................................................................... 35
ROTOR AND TRIGGER WHEEL .................................................................................... 36
RING GEAR ........................................................................................................... 37
STARTER DRIVE ASS'Y .............................................................................................. 38
OIL SPRAY NOZZLE ................................................................................................. 39
04 – LUBRICATION SYSTEM ..................................................................................... 41
GENERAL ...................................................................................................... 45
PROCEDURES ................................................................................................ 45
ENGINE OIL PRESSURE............................................................................................. 45
PTO OIL STRAINER .................................................................................................. 46
SUCTION PUMP OIL STRAINER.................................................................................... 47
ENGINE OIL PRESSURE REGULATOR ............................................................................. 49
OIL PRESSURE PUMP............................................................................................... 51
OIL SUCTION PUMP................................................................................................. 54
OIL SEPARATOR COVER ............................................................................................ 57
TOPS VALVE .......................................................................................................... 58
OIL COOLER ......................................................................................................... 58
05 – COOLING SYSTEM .......................................................................................... 61
GENERAL ...................................................................................................... 63
PROCEDURES ................................................................................................ 63
COOLANT PUMP .................................................................................................... 63
COOLANT PUMP IMPELLER ....................................................................................... 64
I
www.SeaDooManuals.net
TABLE OF CONTENTS
THERMOSTAT ........................................................................................................ 65
ROTARY SEAL ........................................................................................................ 65
06 – CYLINDER HEAD ............................................................................................. 69
GENERAL ...................................................................................................... 71
PROCEDURES ................................................................................................ 71
SPARK PLUG ......................................................................................................... 71
EXHAUST MANIFOLD ............................................................................................... 71
VALVE COVER ........................................................................................................ 72
ROCKER ARM ........................................................................................................ 73
CAMSHAFT TIMING GEAR.......................................................................................... 76
TIMING CHAIN ....................................................................................................... 77
CYLINDER HEAD..................................................................................................... 78
CAMSHAFT ........................................................................................................... 79
VALVE SPRING ....................................................................................................... 80
VALVE ................................................................................................................. 82
07 – CYLINDER BLOCK............................................................................................ 89
GENERAL ...................................................................................................... 92
PROCEDURES ................................................................................................ 92
TIMING CHAIN ....................................................................................................... 92
CHAIN TENSIONER .................................................................................................. 92
PISTON/CONNECTING ROD ........................................................................................ 93
PISTON RINGS ....................................................................................................... 98
CRANKSHAFT ........................................................................................................ 99
BALANCER SHAFT................................................................................................. 104
CYLINDER BLOCK ................................................................................................. 107
08 – TECHNICAL SPECIFICATIONS ............................................................................ 113
II
www.SeaDooManuals.net
SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the Rotax
®
1503 4-TEC engines.
This edition was primarily published to be used by technicians who are already familiar with all service
procedures relating to BRP products. Mechanical technicians should attend training courses given by
BRP Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This ENGINE SHOP MANUAL uses technical terms which may be slightly different from the ones used
in the PARTS CATALOG.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any component.
Dealer and/or distributor assistance should be sought in case of doubt.
The engine identified in this document should not be utilized on product(s) other than those for which it
was designed.
WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage engine compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents.
We strongly recommend that any services be carried out and/or verified by a highly skilled professional
mechanic. It is understood that certain modifications may render use of the engine illegal under existing
federal, provincial and state regulations.
SMR2004-001 EN III
www.SeaDooManuals.net
INTRODUCTION
INTRODUCTION
GENERAL INFORMATION
This ENGINE SHOP MANUAL covers the Rotax
1503 4-TEC engine. It should be used in conjunc-
tion with the appropriate VEHICLE SHOP MANU-
AL.
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
This SHOP MANUAL uses technical terms which
may be different from the ones of the PARTS CAT-
ALOGS.
When ordering parts always refer to the specific
model PARTS CATALOGS.
ENGINE EMISSIONS
INFORMATION
Refer to the appropriate VEHICLE SHOP MANU-
AL.
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
The Engine Identification Number is located on
front end of the engine.
1. Engine Identification Number (E.I.N.)
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in explod-
ed views and/or text.
WARNING
Torque wrench tightening specifications
must strictly be adhered to. Locking devices
(ex.: locking tabs, elastic stop nuts, self-lock-
ing fasteners, etc.) must be installed or
replaced with new ones, where specified. If
the efficiency of a locking device is impaired,
it must be renewed.
IV
smr2005-002
www.SeaDooManuals.net
INTRODUCTION
ARRANGEMENT OF THIS
MANUAL, ILLUSTRATIONS
AND PROCEDURES
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Several sections are divided in various subsec-
tions. There is a table of contents at the beginning
of many sections.
The illustrations show the typical construction of
the different assemblies and, in all cases, may not
reproduce the full detail or exact shape of the parts
shown, however, they represent parts which have
the same or a similar function.
CAUTION: These watercraft are designed with
parts dimensioned mostly in the metric sys-
tem. However some components may be from
the imperial system. When replacing fasten-
ers, make sure to use only those recommended
by BRP.
As many of the procedures in this manual are inter-
related, we suggest, that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection in which the procedure
is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before undertaking
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.
smr2005-002 V
www.SeaDooManuals.net
INTRODUCTION
VI
smr2005-002
www.SeaDooManuals.net
INTRODUCTION
smr2005-002 VII
www.SeaDooManuals.net
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$31.99
Viewed 75 Times Today
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$31.99
This Sea-Doo ROTAX 1503 4-TEC Engine workshop service manual is an instant digital download, eliminating shipping costs and waiting time for a physical manual. It is available in .PDF format and is printable on Windows, Mac, and Linux OS with Adobe Reader.
Designed for professional mechanics and DIY enthusiasts, this manual provides comprehensive data, characteristics, instructions, and methodology for repair interventions on the Sea-Doo ROTAX 1503 4-TEC Engine and its components.
Special notes, important points, service data, precautions, and detailed, comprehensive step-by-step procedures, explanations, and pictorial diagrams are included for maintenance, adjustments, service, removal, and installation of vehicle components.
Illustrations, exploded diagrams, drawings, and photos guide you through every service repair procedure, including adjustment and repair operations with reference to service tool numbers and their usage.
Information on construction, function, troubleshooting, servicing specifications, tightening torque, checking and adjusting, disassembling, assembling, and servicing is provided in a simple, easy-to-read format.
The manual also includes guidelines for maximising the life of the Sea-Doo ROTAX 1503 4-TEC Engine, including maintenance requirements, genuine parts usage, approved lubricants, and complete record-keeping of all maintenance and repairs.
It contains technical information, photographs, notes, drawings, schematics, exploded and sectional drawings, and valuable reference data for adjustment values, ensuring efficient and safe maintenance and repair work.
For all maintenance and repair work, accident prevention guidelines must be strictly observed, and the necessary standard and special tools are required. The manual also emphasizes the importance of following safety measures and using the correct OEM fasteners.
This Sea-Doo ROTAX 1503 4-TEC Engine workshop service manual is a complete and intact resource, suitable for trained technicians and owners with basic knowledge of mechanics and the necessary tools to perform maintenance and repair work.
It covers a wide range of topics related to engine maintenance, boat maintenance, tune-up, fuel and combustion, troubleshooting, electrical systems, cooling system, propulsion system, exhaust system, lubrication system, and more.
With detailed descriptions, precise information, and comprehensive coverage, this manual is an essential resource for maintaining and repairing the Sea-Doo ROTAX 1503 4-TEC Engine.
