Sea-Doo ROTAX 787 RFI Engine Workshop Service Manual
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2005
Engine Shop Manual
ROTAX
®
717 and 787 RFI™
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 (Québec) Canada
Printed in Canada
®
™ Registered trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
* Trademark of Bombardier Inc. used under license.
BOMBARDIER LUBE
®
RFI™
Rotax
®
SEA-DOO
®
Sea-Doo Synthetic Grease
TOPS™
This document contains the trademarks of the following companies:
Loctite
®
is a trademark of Loctite Corporation
Molykote
©
is a trademark of Dow Corning Corporation
Snap-on
®
is a trademark of Snap-on Tools Corporation
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TABLE OF CONTENTS
SAFETY NOTICE .................................................................................... III
INTRODUCTION ................................................................................... IV
GENERAL INFORMATION.......................................................................................... IV
ENGINE IDENTIFICATION NUMBER (E.I.N.) .................................................................... IV
ENGINE EMISSIONS INFORMATION ............................................................................ IV
TIGHTENING TORQUES ........................................................................................... IV
ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES ............................. V
01 ENGINE MEASUREMENT
01 – MEASUREMENT PROCEDURES............................................................................. 1
CYLINDER HEAD WARPAGE ........................................................................................ 1
CYLINDER TAPER ..................................................................................................... 1
CYLINDER OUT OF ROUND ......................................................................................... 1
COMBUSTION CHAMBER VOLUME MEASUREMENT ........................................................... 1
PISTON/CYLINDER WALL CLEARANCE ............................................................................ 2
RING/PISTON GROOVE CLEARANCE............................................................................... 4
RING END GAP ........................................................................................................ 5
CRANKSHAFT (ASSEMBLED ENGINE) ............................................................................. 5
CRANKSHAFT (DISASSEMBLED ENGINE) ......................................................................... 6
ROTARY VALVE........................................................................................................ 8
02 717 ENGINE
01 – LEAK TEST .................................................................................................... 11
GENERAL ............................................................................................................. 11
PREPARATION ....................................................................................................... 11
TESTING PROCEDURE .............................................................................................. 11
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART .................................................................. 15
02 – MAGNETO SYSTEM......................................................................................... 17
DISASSEMBLY ....................................................................................................... 19
CLEANING ............................................................................................................ 21
ASSEMBLY ........................................................................................................... 22
03 – TOP END....................................................................................................... 25
GENERAL ............................................................................................................. 27
DISASSEMBLY ....................................................................................................... 27
CLEANING ............................................................................................................ 29
INSPECTION.......................................................................................................... 30
ASSEMBLY ........................................................................................................... 30
04 – BOTTOM END ................................................................................................ 37
GENERAL ............................................................................................................. 39
DISASSEMBLY ....................................................................................................... 39
CLEANING ............................................................................................................ 41
INSPECTION.......................................................................................................... 42
ASSEMBLY ........................................................................................................... 43
05 – ROTARY VALVE .............................................................................................. 47
GENERAL ............................................................................................................. 49
INSPECTION (ASSEMBLED ENGINE) .............................................................................. 49
DISASSEMBLY ....................................................................................................... 49
CLEANING ............................................................................................................ 51
INSPECTION (DISASSEMBLED ENGINE) .......................................................................... 51
ASSEMBLY ........................................................................................................... 51
ROTARY VALVE TIMING ............................................................................................. 55
I
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TABLE OF CONTENTS
06 – TECHNICAL SPECIFICATIONS ............................................................................. 57
03 787 RFI ENGINE
01 – LEAK TEST .................................................................................................... 59
GENERAL ............................................................................................................. 59
TESTING PROCEDURE .............................................................................................. 59
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART .................................................................. 63
02 – MAGNETO SYSTEM......................................................................................... 65
DISASSEMBLY ....................................................................................................... 67
CLEANING ............................................................................................................ 68
ASSEMBLY ........................................................................................................... 69
03 – TOP END....................................................................................................... 71
GENERAL ............................................................................................................. 73
DISASSEMBLY ....................................................................................................... 74
CLEANING ............................................................................................................ 79
INSPECTION.......................................................................................................... 80
ASSEMBLY ........................................................................................................... 80
ADJUSTMENT ........................................................................................................ 86
04 – BOTTOM END ................................................................................................ 87
GENERAL ............................................................................................................. 89
DISASSEMBLY ....................................................................................................... 89
CLEANING ............................................................................................................ 93
INSPECTION.......................................................................................................... 94
ASSEMBLY ........................................................................................................... 94
05 – ROTARY VALVE ............................................................................................. 101
GENERAL ........................................................................................................... 103
INSPECTION (ASSEMBLED ENGINE) ............................................................................ 103
DISASSEMBLY ..................................................................................................... 103
CLEANING .......................................................................................................... 105
INSPECTION (DISASSEMBLED ENGINE) ........................................................................ 105
ASSEMBLY ......................................................................................................... 105
ROTARY VALVE TIMING ........................................................................................... 109
06 – TECHNICAL SPECIFICATIONS ............................................................................ 111
II
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SAFETY NOTICE
SAFETY NOTICE
This ENGINE SHOP MANUAL has been prepared as a guide to correctly service and repair the 717 and
787 RFI Rotax
®
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.
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 engines 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.
smr2005-074 III
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INTRODUCTION
INTRODUCTION
GENERAL INFORMATION
This ENGINE SHOP MANUAL covers the 717 and
787 RFI Rotax made engines. It should be used in
conjunction with the appropriate VEHICLE SHOP
MANUAL.
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 ENGINE SHOP MANUAL uses technical
terms which may be different from the ones of
the Parts Catalogs.
When ordering parts always refer to the specific
model Parts Catalogs.
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
717 Engines
The Engine Identification Number is located on the
upper side of the magneto housing.
1
F01D01A
TYPICAL
1. Engine Identification Number (E.I.N.)
787 RFI Engines
The Engine Identification Number is located on the
upper crankcase on PTO side.
1. Engine Identification Number (E.I.N.)
ENGINE EMISSIONS
INFORMATION
Refer to the appropriate VEHICLE SHOP MANU-
AL.
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 de-
vices (e.g.: locking tabs, elastic stop nuts,
self-locking fasteners, etc.) must be installed
or replaced with new ones, where specified.
If the efficiency of a locking device is im-
paired, it must be renewed.
IV
smr2005-074
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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 engines are designed with
parts dimensioned mostly in the metric sys-
tem. However some components may be
from the imperial system. When replacing
fasteners, make sure to use only those recom-
mended 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.
smr2005-074 V
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INTRODUCTION
VI
smr2005-074
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INTRODUCTION
smr2005-074 VII
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This workshop service manual is designed to provide comprehensive data, characteristics, instructions, and methodology for performing repair interventions on the Sea-Doo ROTAX 787 RFI Engine. It includes special notes, important points, service data, precautions, and detailed illustrations, exploded diagrams, drawings, and photos to guide you through every service repair procedure. This manual is intended as a handy, easy-to-read reference book for both professional mechanics and DIY enthusiasts.
The manual provides detailed, comprehensive step-by-step procedures, explanations, and pictorial diagrams from bumper to bumper for the Sea-Doo ROTAX 787 RFI Engine. It covers adjustment and repair operations, including reference to service tool numbers and associated illustrations depicting the tools required. The manual can be viewed on any computer, zoomed, and printed, making it accessible and practical for all users.
It is important to note that this manual is not interactive and is available in .PDF format. Always use the correct special service tools or equipment specified, and ensure that all work is performed with great care and in a clean working area with adequate lighting. The manual also outlines procedures for servicing and repairing vehicles using safe, effective methods, and contains many notes, cautions, and warnings to be followed along with standard safety procedures to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.
To maximize the life of your Sea-Doo ROTAX 787 RFI Engine, it is essential to accurately follow the maintenance requirements outlined in the service manual, investigate and rectify all problems as soon as possible, use only genuine Sea-Doo ROTAX 787 RFI Engine parts, and keep complete records of all maintenance and repairs with dates and any new parts installed.
This manual is known by various names, including Sea-Doo ROTAX 787 RFI Engine Service service manual, Sea-Doo ROTAX 787 RFI Engine Service repair manual, Sea-Doo ROTAX 787 RFI Engine Service workshop manual, and Sea-Doo ROTAX 787 RFI Engine Service shop manual. It is designed primarily for use by trained technicians in a properly equipped workshop, but contains enough detail and basic information to make it useful to the owner who desires to perform basic maintenance and repair work.
For all maintenance and repair work on the Sea-Doo ROTAX 787 RFI Engine, all accident prevention guidelines must be strictly observed. A basic knowledge of mechanics, including the proper use of tools and workshop procedures, is necessary in order to carry out maintenance and repair work satisfactorily. The manual also contains information about adjusting work and valuable reference data for such adjustment values.
It is important to thoroughly familiarize yourself with the procedures before starting work and to perform all repairs listed in this manual with great care and in a clean working area with adequate lighting. Always use approved lubricants as specified in the manual of the Sea-Doo ROTAX 787 RFI Engine, and ensure that all threaded connections are tightened according to the required tightening torques listed on torque charts.
This Sea-Doo ROTAX 787 RFI Engine Service Repair Manual is a quality manual that is 100% complete and intact, with no missing or corrupt pages/sections. It provides technical information regarding the design, function, disassembly, adjusting work, and troubleshooting on the components and model of the Sea-Doo ROTAX 787 RFI Engine.
For a complete list of topics covered, please refer to the manual.
