Ski-Doo REV Series Shop Manual

Section04ENGINE
Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT)
ENGINE LEAK TEST AND DIMENSION
MEASUREMENT
LEAK TEST
The following gives verification procedures for 593
and 793 types of engines.
PREPARATION
– Remove tuned pipe.
– Install plug over exhaust manifold.
– Remove carburetors/throttle body assembly (as
applicable).
– Unplug fuel inlet line from fuel rail.
– Insert plugs in intake rubber boots. Tighten
with existing clamps.
A33C19A
– Using a hose pincher (P/N 295 000 076), block
impulse hose.
– Install air pump on exhaust plug.
NOTE: If necessary, lubricate air pump piston with
mild soap.
CAUTION: Using hydrocarbon lubricant (such
as engine oil) will damage rubber seal of pump
piston.
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.
mmr2004-Rev 111

Ski-Doo REV Series Specifications

General

Chassis	REV
Track Width	15 in
Fuel Capacity	10.6 gal
Seating Capacity	1
Reverse	Available on most models
Electric Start	Available on most models