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2005
Engine Shop Manual
ROTAX
®
1503 4-TEC
ENGINES
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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
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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
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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
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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
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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
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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 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
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INTRODUCTION
VI
smr2005-002
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INTRODUCTION
smr2005-002 VII
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Description
This manual is a valuable resource for repairing and servicing the 2005 SeaDoo with ROTAX 1503 4-TEC Engine. It provides comprehensive instructions including routine maintenance, fault finding and diagnostics, technical data, component description, and trouble shooting. The digital format of the manual makes it easy to access and use. Whether you're a professional or a DIY enthusiast, this manual is perfect for keeping a comprehensive guide to all your SeaDoo's service and repair needs.
