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Snowmobile Ski Doo REV SERIES (2004 year). Instruction - part 33

Section 04 ENGINE
Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT)

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?

CHECK LEAKAGE AT DRAIN HOLE

BELOW COOLANT PUMP HOUSING

ANY LEAK FOUND?

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

YES

ENGINE LEAK VERIFICATION

FLOW CHART

A32C1KS

YES

A32C1KS

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Section 04 ENGINE

Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT)

ENGINE DIMENSION
MEASUREMENT

This section covers all engine types.

CYLINDER HEAD WARPAGE

ENGINE TYPE

MAXIMUM

0.05 mm (.002 in) per

50 mm (2 in) of surface

All

0.5 mm (.020 in) for total

length of cylinder head

Check gasketed surface of the cylinder head with
a straightedge and a feeler gauge.

CYLINDER TAPER

ENGINE TYPE

MAXIMUM

All

0.10 mm (.004 in)

Compare cylinder diameter 16 mm (5/8 in) from
top of cylinder to just below its intake port area.

If the difference exceeds the specified dimension
the cylinder should be rebored and honed or
should be replaced. Nikasil cylinder can be honed
using diamond hone but can not be rebored.

NOTE: Be sure to restore the chamfer around all
cylinder sleeve port openings.

A33C1BA

1. Below the intake port

A. 16 mm (5/8 in) from top

CYLINDER OUT OF ROUND

ENGINE TYPE

MAXIMUM

All

0.08 mm (.003 in)

Measuring 16 mm (5/8 in) from top of cylinder with
a cylinder gauge, check if the cylinder out of round
is more than the specified dimension. If larger,
cylinder should be rebored and honed or should
be replaced. Nikasil cylinder can be honed using
diamond hone but cannot be rebored.

NOTE: Be sure to restore the chamfer around all
cylinder sleeve port openings.

A33C1CA

1. Piston pin position
2. Measures to be compared

A. 16 mm (5/8 in)

COMBUSTION CHAMBER
VOLUME MEASUREMENT

The combustion chamber volume is the region in
the cylinder head above the piston at Top Dead
Center. It is measured with the cylinder head in-
stalled on the engine.

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Section 04 ENGINE
Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT)

F01D5VA

1. Combustion chamber

NOTE: When checking the combustion chamber
volume, engine must be cold, piston must be free
of carbon deposits and cylinder head must be lev-
eled.

– Remove both spark plugs and bring one piston

to Top Dead Center a using a TDC gauge.

A33C1DA

1. Bring piston to TDC

– Obtain a graduated burette (capacity 0 - 50 cc)

and fill with an equal part (50/50) of gasoline and
injection oil.

F00B0BA

1. Graduated burette (0 - 50 cc)

– Open burette valve to fill its tip. Add liquid in

burette until level reaches 0 cc.

– Inject the burette content through the spark

plug hole until liquid touches the top spark plug
hole.

F00D0HA

1. Top of spark plug hole

NOTE: The liquid level in cylinder must not drop
for a few seconds after filling. If so, there is a
leak between piston and cylinder. The recorded
volume would be false.

– Let burette stand upward for about 10 minutes,

until liquid level is stabilized.

– Read the burette scale to obtain the quantity of

liquid injected in the combustion chamber.

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Section 04 ENGINE

Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT)

NOTE: When the combustion chamber is filled to
top of spark plug hole, it includes an amount of
2.25 cc corresponding to the spark plug well.

– Repeat the procedure for the other cylinder.

ENGINE

TYPE

COMBUSTION CHAMBER VOLUME

(cc)

(up to top thread of spark

plug hole)

593

26.67 ± 1.29 - 1.18

593

HO/SDI

26.4 ±1.2

693

31.71 + 1.51 - 1.38

793 HO

36.34 + 1.73 - 1.58

– Install a thicker or thinner cylinder/crankcase

gasket (refer to Parts Catalogs) in order to ob-
tain the specified combustion chamber volume
or the nearest.

ENGINE

TYPE

CHANGE IN COMBUSTION CHAMBER

VOLUME (cc) for every 0.1 mm

(.004 in) of gasket thickness

593 HO

0.41

793 HO

0.53

USED PISTON MEASUREMENT

Note the measurement on the piston dome.

F00D0EA

1. Piston dome
2. Piston measurement

Using a micrometer, measure piston skirt at
15 mm (.590 in) perpendicularly (90°) to piston
pin.

F01D0NA

1. Measuring perpendicularly (90°) to piston pin axis

A. 15 mm (.590 in)

ENGINE

TYPE

MAXIMUM PISTON SKIRT WEAR

mm (in)

All

0.15 (.006)

The measured dimension must not be less than
0.15 mm (.006 in) of the one scribed on piston
dome. Otherwise, install a new piston.

CYLINDER/PISTON CLEARANCE

Used and New Pistons

IMPORTANT: Make sure used piston is not worn
more than specified. See USED PISTON MEA-
SUREMENT above.

Take the measurement on the piston dome.

F00D0EA

1. Piston dome
2. Piston measurement

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