Ski-Doo TOURING E LT 1997 - Engine Leak Verification Flow Chart

Section 03 ENGINE
Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)
03-04-5
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 BANJO FITTING(S)/LINE(S)
REMOVE BLEED SCREW ON CYLINDER HEAD
ARE ANY AIR BUBBLES IN COOLANT?
BLOCK LARGE HOSES OF
ROTARY VALVE GEAR
LUBRICATION SYSTEM
IS ENGINE STILL LEAKING?
REPLACE O-RING OF CYLINDER HEAD
AND/OR CYLINDER BASE GASKET
PRESSURIZE ROTARY VALVE GEAR
RESERVOIR IN CRANKCASE
ARE SEALS LEAKING?
CHECK CRANKSHAFT OUTER
SEAL OF PTO AND
MAG SIDES
PRESSURIZE ROTARY VALVE GEAR
RESERVOIR IN CRANKCASE
IS RESERVOIR LEAKING?
UNSEAL PTO CYLINDER AND MAG
CYLINDER SEPARATELY
IS RESERVOIR LEAKING?
IS RESERVOIR LEAKING?
CHECK LEAKAGE AT DRAIN HOLE
BELOW COOLANT PUMP HOUSING
ANY LEAK FOUND?
REPLACE DEFECTIVE SEAL(S)
REPLACE DEFECTIVE SEAL(S)
REPLACE OIL SEAL OF ROTARY
VALVE SHAFT END, BESIDE
COOLANT SEAL
REPLACE DEFECTIVE SEAL
REPLACE DEFECTIVE PARTS
REMOVE ROTARY VALVE COVER, CHECK
SEAL OF ROTARY VALVE SHAFT
IS SEAL LEAKING?
CAREFULLY INSPECT ENGINE CASTINGS,
PARTICULARLY THE THREAD HOLE AREAS
ANY LEAK FOUND?
ENGINE IS PERFECTLY SEALED
INTERNALLY
NO
YES
YES
YES
YES
NO
NO
NO
YES
YES
YES
NO
NO
YES
NO
NO
NO
NO
YES
YES
YES
NO
ENGINE LEAK VERIFICATION
FLOW CHART
A00A23S
YES
NO