Snowmobile Ski Doo REV SERIES (2006 year). Instruction - part 15

Section 03 ENGINES
Subsection 01 (LEAK TEST)

A33C1AA

– Activate pump and pressurize engine to 34 kPa

(5 PSI). Do not exceed this pressure.

– Engine must stand this pressure during 3 min-

utes. If pressure drops before 3 minutes, check
tester kit by spraying a soapy solution on pump
cylinder, all plugs and fittings.
• If tester kit is leaking, bubbles will indicate

where leak comes from.

• If tester kit is not leaking, check engine as per

following procedure.

PROCEDURE

NOTE: A flow chart has been prepared as a visual
reference. See last page of this chapter.

Using flow chart and following text, pressurize
area to be tested and spray soapy solution at the
indicated location.

TEST PRESSURE: 34 KPA (5 PSI)

FOR 3 MINUTES

• If there is a leak at the tested location, it is

recommended to continue testing next items
before overhauling engine. There is a possi-
bility of more than one leak.

• If there is no leak at the tested location, con-

tinue pumping to maintain pressure and con-
tinue with next items until leak is found.

Engine

Check the following:

– All jointed surfaces and screw/stud threads of

engine:
• spark plug base, insulator
• cylinder head
• RAVE valve bellows, piston and housing

• cylinder crankcase halves (joint)
• oil injection pump mounting flange (O-ring)
• coolant pump housing
• bleed screws/plugs
• crankcase grease reservoir fitting.

– Small injection oil lines coming from pump.

A32C1GA

1

2

1

TYPICAL
1. Injection nipples
2. Small injection oil lines

Check for air bubbles or oil column going toward
pump. It indicates defective check valve in injec-
tion nipples.

– Remove cooling system cap.

Check for air bubbles in antifreeze. It indicates de-
fective cylinder head O-ring or cylinder base gas-
ket.

– Remove drive pulley then check crankshaft out-

er seal.

– Remove rewind starter and magneto system

then check crankshaft outer seal.

– Check pump shaft gear oil reservoir.

Pump Shaft Oil Gear Reservoir

Install air pump on adapter and pressurize as
above.

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Section 03 ENGINES

Subsection 01 (LEAK TEST)

A32C1HA

If pressure drops, it indicates a defective crank-
shaft inner seal.

2

A32C1IA

1

TYPICAL — CRANKSHAFT INSTALLED IN UPPER
HALF CRANKCASE
1. Crankshaft inner seal on PTO side
2. Crankshaft inner seal on MAG side

– Check weep hole below coolant pump housing

with soapy water.

A32C1JA

1

1. Weep hole

If there is a leak, it indicates that a pump shaft is
defective (oil seal beside coolant ceramic seal).

– Leaks can be also on oil pump side. Check

mounting area for leaks.

A32C1GB

1

TYPICAL
1. Check mounting area

– If leak still persists, it indicates a defective cast-

ing somewhere in engine.

Disassemble engine and carefully check for de-
fects in castings. Pay attention to tapped holes
which may go through engine sealed area and
thus lead to leakage.

FINALIZING REASSEMBLY

After reassembling engine, always recheck for
leakage.

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49

Section 03 ENGINES
Subsection 01 (LEAK TEST)

ENGINE LEAK VERIFICATION FLOW CHART

PRESSURIZE ENGINE

IS ENGINE LEAKING?

CHECK ALL JOINTED SURFACES,

SCREW/STUD  THREADS. MOUNTING

FLANGES ETC.

ANY LEAK FOUND?

CHECK SMALL OIL LINES OF

INJECTION PUMP

AIR BUBBLES FOUND

OR OIL MOVING

TOWARD PUMP?

REPLACE GASKET OR O-RING,

RE-SEAL LEAKING AREA

REPLACE INJECTION NIPPLE(S)

REMOVE BLEED SCREW ON CYLINDER HEAD

ARE ANY AIR BUBBLES IN COOLANT?

BLOCK HOSE OF PUMP SHAFT

GEAR

LUBRICATION SYSTEM

IS ENGINE STILL LEAKING?

REPLACE O-RING OF CYLINDER HEAD

AND/OR CYLINDER BASE GASKET

PRESSURIZE PUMP SHAFT GEAR

RESERVOIR IN CRANKCASE

ARE SEALS LEAKING?

CHECK CRANKSHAFT OUTER

SEAL OF PTO AND

MAG SIDES

PRESSURIZE PUMP SHAFT GEAR

RESERVOIR IN CRANKCASE

IS RESERVOIR LEAKING?

UNSEAL PTO CYLINDER AND MAG

CYLINDER SEPARATELY

IS RESERVOIR LEAKING?

IS RESERVOIR LEAKING?

CHECK LEAKAGE AT DRAIN HOLE

BELOW COOLANT PUMP HOUSING

ANY LEAK FOUND?

REPLACE DEFECTIVE SEAL(S)

REPLACE DEFECTIVE SEAL(S)

REPLACE OIL SEAL OF PUMP

SHAFT CERAMIC, BESIDE

COOLANT SEAL

REPLACE DEFECTIVE O-RING

REPLACE DEFECTIVE PARTS

CHECK OIL PUMP

 MOUNTING AREA FOR LEAKS

IS O-RING LEAKING?

CAREFULLY INSPECT ENGINE CASTINGS,

PARTICULARLY THE THREAD HOLE AREAS

ANY LEAK FOUND?

ENGINE IS PERFECTLY SEALED

INTERNALLY

NO

YES

YES

YES

YES

NO

NO

NO

YES

YES

YES

NO

NO

YES

NO

NO

NO

NO

YES

YES

YES

NO

ENGINE LEAK VERIFICATION

FLOW CHART

A32C1KS

YES

NO

A32C1KS

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Section 03 ENGINES

Subsection 02 (EXHAUST SYSTEM)

EXHAUST SYSTEM

SERVICE TOOLS

Description

Part Number

Page

exhaust spring installer/remover .......................................... 529 035 401 ..................................... 54–55

SERVICE PRODUCTS

Description

Part Number

Page

RTV sealant .......................................................................... 293 800 090 ........................................... 55

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