Section 04 ENGINE
Subsection 03 (494, 583 AND 670 ENGINE TYPES)
04-03-5
NOTE:
The following procedures can be done
without removing the engine from chassis.
CLEANING
Discard all gaskets and O-rings.
Clean all metal components in a non-ferrous met-
al cleaner.
Scrape off carbon formation from cylinder ex-
haust port, cylinder head and piston dome using a
wooden spatula.
NOTE:
The letters
AUS
(over an arrow on the pis-
ton dome) must be visible after cleaning.
Clean the piston ring groove with a groove cleaner
tool, or with a piece of broken ring.
DISASSEMBLY
Place a clean cloth over crankcase then with a
pointed tool inserted in piston notch, remove cir-
clip
no. 20
from piston
no. 21
.
To remove piston pin
no. 19
, use piston pin puller
(P/N 529 0290 00) as follows:
– Fully screw puller handle.
– Insert puller end into piston pin.
– Install adaptor (P/N 529 0236 00) then screw
extracting nut (LH threads).
– Hold puller firmly and rotate puller handle coun-
terclockwise to pull piston pin.
NOTE:
0.25 mm oversize piston and rings are
available if necessary.
RAVE System
NOTE:
RAVE stands for Rotax Adjustable Variable
Exhaust.
Remove spring clip
no. 3
, cover
no. 5
and spring
no. 6
.
Cut clamp
no. 8
(remove spring on 454) and un-
screw valve piston
no. 7
.
Spread clamp
no. 10
and remove bellows
no. 9
.
Remove cylindrical screws
no. 11
then valve rod
housing
no. 13
.
Pull out exhaust valve
no. 16
.
1. Exhaust valve
INSPECTION
Refer to ENGINE DIMENSIONS MEASUREMENT
04-04.
RAVE System
Check valve rod housing and cylinder for clogged
passages.
TYPICAL
1. Draining hole
2. Passages
A01B1AA
A03C1PA
1
1
2
A24C05A
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