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AUSA M50x4 Rotax Engine Workshop Manual

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AUSA M50x4 Rotax Engine Workshop Manual AUSA M-50 x 4 ROTAX ENGINE WORKSHOP MANUAL 1 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 0 TROUBLESHOOTING............................................................................................................ 03-02-1 COOLING SYSTEM ........................................................................................................... 03-02-1 MAGNETO SYSTEM ......................................................................................................... 03-02-2 LUBRICATION.................................................................................................................... 03-02-4 CYLINDER AND HEAD ...................................................................................................... 03-02-6 CRANKSHAFT AND BALANCER SHAFT.......................................................................... 03-02-7 GEARBOX .......................................................................................................................... 03-02-7 REWIND STARTER ............................................................................................................ 03-02-9 CVT..................................................................................................................................... 03-02-10 ENGINE GENERAL ............................................................................................................ 03-02-15 LEAK TEST............................................................................................................................. 03-03-1 GENERAL VERIFICATION ................................................................................................. 03-03-1 LEAK TEST PROCEDURE .................................................................................................. 03-03-1 PREPARATION AND TEST................................................................................................ 03-03-1 INSTALLATION.................................................................................................................. 03-03-3 REMOVAL AND INSTALLATION .......................................................................................... 03-04-1 GENERAL ........................................................................................................................... 03-04-3 ENGINE REMOVAL ........................................................................................................... 03-04-3 ENGINE INSTALLATION ................................................................................................... 03-04-8 ANTI-VIBRATION SYSTEM............................................................................................... 03-04-9 EXHAUST SYSTEM .......................................................................................................... 03-04-9 SHIFTING SYSTEM............................................................................................................ 03-04-10 COOLING SYSTEM ............................................................................................................... 03-05-1 WATER PUMP.................................................................................................................... 03-05-1 COOLING SYSTEM ........................................................................................................... 03-05-2 GENERAL ........................................................................................................................... 03-05-3 COOLING SYSTEM LEAK TEST ....................................................................................... 03-05-3 INSPECTION ......................................................................................................................03-05-3 DRAINING THE SYSTEM .................................................................................................. 03-05-4 COOLANT REPLACEMENT............................................................................................... 03-05-4 THERMOSTAT ................................................................................................................... 03-05-5 WATER TEMPERATURE SWITCH..................................................................................... 03-05-6 WATER PUMP HOUSING ................................................................................................. 03-05-6 WATER PUMP IMPELLER ................................................................................................. 03-05-7 WATER PUMP SHAFT....................................................................................................... 03-05-7 PRESSURE CAP................................................................................................................. 03-05-10 RADIATOR ......................................................................................................................... 03-05-10 COOLANT TANK ............................................................................................................... 03-05-11 VMR2004_154_03_01ATOC.FM 03-01-1 Section 03 ENGINE Subsection 01 (TABLE OF CONTENTS) COOLING FAN.................................................................................................................... 03-05-11 TEMPERATURE SENDER .................................................................................................. 03-05-12 REWIND STARTER................................................................................................................. 03-06-1 GENERAL............................................................................................................................ 03-06-2 REWIND STARTER............................................................................................................. 03-06-2 STARTING PULLEY............................................................................................................ 03-06-5 MAGNETO SYSTEM.............................................................................................................. 03-07-1 GENERAL............................................................................................................................ 03-07-2 MAGNETO HOUSING COVER........................................................................................... 03-07-2 OIL SEAL............................................................................................................................. 03-07-4 STATOR .............................................................................................................................. 03-07-5 CPS (Crankshaft Position Sensor) .................................................................................... 03-07-6 ROTOR ................................................................................................................................ 03-07-6 LUBRICATION SYSTEM......................................................................................................... 03-08-1 GENERAL............................................................................................................................ 03-08-2 ENGINE OIL PRESSURE TEST .......................................................................................... 03-08-2 OIL CHANGE....................................................................................................................... 03-08-3 OIL FILTER .......................................................................................................................... 03-08-3 OIL STRAINER....................................................................................................................03-08-4 ENGINE OIL PRESSURE REGULATOR............................................................................. 03-08-6 OIL PUMP ........................................................................................................................... 03-08-6 CYLINDER AND HEAD........................................................................................................... 03-09-1 GENERAL............................................................................................................................ 03-09-3 SPARK PLUG......................................................................................................................03-09-3 THERMOSTAT.................................................................................................................... 03-09-3 VALVE COVER .................................................................................................................... 03-09-4 VALVE ADJUSTMENT ....................................................................................................... 03-09-4 CHAIN TENSIONER............................................................................................................ 03-09-5 CHAIN TENSIONER HOUSING.......................................................................................... 03-09-5 DECOMPRESSOR............................................................................................................... 03-09-6 CAMSHAFT TIMING GEAR................................................................................................ 03-09-8 ROCKER ARM..................................................................................................................... 03-09-9 TIMING CHAIN ................................................................................................................... 03-09-11 CYLINDER
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