Section02717ENGINE
Subsection 03 (TOP END)
GENERAL
The 2-stroke Rotax
®
engine rotates counterclock-
wise seen from the rear (PTO flywheel).
The 717 engine has a rotary valve to control open-
ing and closing of the intake.
DISASSEMBLY
Cylinder Head Cover and Cylinder Head
Engine in Watercraft
If engine is left in watercraft, refer to the appropri-
ate VEHICLE SHOP MANUAL to remove the fol-
lowing components:
– temperature sensor wire
– spark plug cables
– air intake silencer and support.
Proceed with ENGINE ON BENCH WORK below.
Engine on Bench Work
Remove cylinder head cover screws no. 1.
Remove cylinder head cover no. 2.
If shells, sand, salt or any other particles are
present in cylinder head, clean with a vacuum
cleaner.
Remove cylinder head no. 3.
If shells, sand, salt water or any other particles
are present in cylinder cooling jacket, clean with
a vacuum cleaner.
Exhaust Manifold
Remove 8 Allen screws no. 4 then withdraw ex-
haust manifold no. 5.
Cylinder
NOTE: When removing cylinders no. 6, make sure
connecting rods do not hit crankcase edge.
Engine in Watercraft
If engine is left in watercraft, refer to the appro-
priate VEHICLE SHOP MANUAL to remove the
tuned pipe.
ProceedwithENGINEONBENCHWORK.
Engine on Bench Work
Remove cylinder head cover no. 2 and cylinder
head no. 3 as explained above.
Remove exhaust manifold no. 5.
Remove cylinder screws no. 7.
Remove cylinders no. 6, while making sure con-
necting rods do not hit crankcase edge.
WARNING
If screws need to be heated for removal when
engine is in watercraft, fuel system pressur-
ization must be done first. Do not use open
flame; use a heat gun.
NOTE: Even if only 1 cylinder needs repair, both
cylinders should be lifted to allow 1-piece cylinder
base gasket replacement.
Piston
NOTE: Engine features cageless piston pin bear-
ings.
Remove cylinders no. 6 as explained above.
Bring piston no. 8 toTopDeadCenter(TDC)and
install the rubber pad (P/N 295 000 101) over
crankcase opening. Secure with screws. Lower
piston until it sits on pad.
F01B0JA
1
1. Rubber pad
If the other cylinder has been removed, complete-
ly cover its opening with a clean rag.
smr2005-077 27
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