AUSA M-50 x 4 Manual de instrucciones

AUSA M-50 x 4

ROTAX ENGINE WORKSHOP

MANUAL

Section 03 ENGINE

Subsection 01 (TABLE OF CONTENTS)

VMR2004_154_03_01ATOC.FM 03-01-1

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

Section 03 ENGINE

Subsection 01 (TABLE OF CONTENTS)

03-01-2 VMR2004_154_03_01ATOC.FM

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 HEAD ................................................................................................................ 03-09-11

CAMSHAFT......................................................................................................................... 03-09-13

VALVE SPRING................................................................................................................... 03-09-14

VALVE ................................................................................................................................. 03-09-16

VALVE GUIDE PROCEDURE .............................................................................................. 03-09-18

CYLINDER ........................................................................................................................... 03-09-19

PISTON ............................................................................................................................... 03-09-21

PISTON RINGS ................................................................................................................... 03-09-24

Section 03 ENGINE

Subsection 01 (TABLE OF CONTENTS)

VMR2004_154_03_01ATOC.FM 03-01-3

CRANKSHAFT/BALANCER SHAFT ...................................................................................... 03-10-1

CRANKCASE...................................................................................................................... 03-10-1

CRANKSHAFT/BALANCER SHAFT.................................................................................. 03-10-2

GENERAL ........................................................................................................................... 03-10-3

CRANKSHAFT LOCKING PROCEDURE............................................................................ 03-10-3

TIMING CHAIN .................................................................................................................. 03-10-4

TIMING CHAIN GUIDE ...................................................................................................... 03-10-5

CRANKCASE...................................................................................................................... 03-10-5

BALANCER SHAFT............................................................................................................ 03-10-9

CRANKSHAFT.................................................................................................................... 03-10-10

GEARBOX .............................................................................................................................. 03-11-1

OUTPUT SHAFT AND TRANSMISSION .......................................................................... 03-11-1

CRANKCASE...................................................................................................................... 03-11-2

GENERAL ........................................................................................................................... 03-11-3

OIL SEALS.......................................................................................................................... 03-11-3

OUTPUT SHAFT ................................................................................................................ 03-11-3

CRANKCASE...................................................................................................................... 03-11-6

GEARBOX .......................................................................................................................... 03-11-12

SHIFTING INDICATOR SWITCH ....................................................................................... 03-11-21

STARTER DRIVE PINION .................................................................................................. 03-11-22

CVT......................................................................................................................................... 03-12-1

GENERAL ........................................................................................................................... 03-12-2

BELT REPLACEMENT............................................................................................................... 03-12-2

DRIVE PULLEY................................................................................................................... 03-12-3

DRIVEN PULLEY ....................................................................................................................... 03-12-10

Section 03 ENGINE

Subsection 02 (TROUBLESHOOTING)

VMR2004_125_03_02A.FM 03-02-1

TROUBLESHOOTING 0

The following charts are provided to help in diagnosing the probable source of troubles. It should be used

as a guideline. This section pertains to engine mechanical components only. Some related problems can

come from other systems such as ignition system, fuel system, etc. and have an impact on the engine.

Ensure to check the other systems prior to concluding that the engine is in fault.

COOLING SYSTEM

SYMPTOM HIGH ENGINE OPERATING TEMPERATURE.

CONDITION NORMAL USE.

Test/Inspection 1. Check coolant level.

a. Coolant less than recommended level.

Refill.

2. Check temperature sensor for electrical/mechanical failure.

a. Temperature sensor defective.

Replace.

3. Check thermostat.

a. Thermostat defective.

Replace.

4. Check gasket(s) underneath water pump cover.

a. Leakage in water pump cover area.

Retighten screws and/or replace gasket.

5. Check leak indicator hole (water pump housing area MAG side) if coolant leaks.

a. Coolant leaking from leak indicator hole means a damaged rotary seal inside mag-

neto cover.

Replace both rotary seal and oil seal (refer to COOLING SYSTEM and MAGNETO

SYSTEM).

6. Check coolant bleeding screw on thermostat housing.

a. Screw is loosed/missing and/or gasket ring is missing/broken.

Retighten/add screw and replace gasket ring.

7. Check condition of hoses and hose clamps fixation.

a. Hoses are brittle and/or hard.

Replace.

b. Hose clamps are loose.

Retighten clamps.

8. Check condition of impeller located on the water pump shaft.

a. Impeller wings broken and/or impeller thread is damaged.

Replace.

9. Check coolant drain screw on water pump housing MAG side (marked “Drain”).

a. Copper ring on drain screw leaks.

Retighten screw and/or replace copper gasket ring.

Section 03 ENGINE

Subsection 02 (TROUBLESHOOTING)

03-02-2 VMR2004_125_03_02A.FM

MAGNETO SYSTEM

SYMPTOM HIGH ENGINE OPERATING TEMPERATURE.

CONDITION NORMAL USE.

Test/Inspection 10. Check cooling fan and connection.

a. Fan motor faulty.

Replace.

b. Wire harness is brittle or hard (no connection).

Replace.

11. Check cylinder head and/or cylinder base gasket.

a. Worn out gasket(s) is (are) causing water leakage.

Replace gasket(s) and refill with coolant and oil (refer to COOLING/LUBRICATION

SYSTEM and TECHNICAL DATA).

12. Check intermediate gear(s) behind magneto cover.

a. Worn out and/or broken gear(s) is (are) causing less coolant supply.

Replace worn out and/or broken gear(s) (refer to LUBRICATION/MAGNETO SYSTEM).

13. Check radiator fan switch and fuse 20A.

a. Faulty fan switch and/or faulty fuse.

Replace defective part(s).

14. Check radiator condition for leakage.

a. Radiator cracked or deformed.

Replace radiator.

15. Check mud/dust in radiator fins.

a. Radiator fin obstructed, hard air cooling.

Clean radiator fins

16. Check if water pump shaft is seized.

a. Water pump shaft does not turn.

Replace defective part(s).

SYMPTOM NO SPARK.

CONDITION NORMAL USE.

Test/Inspection 1. Check engine stop switch position.

a. Engine stop switch is in OFF position.

Place engine stop switch to RUN position.

2. Check battery.

a. Battery shows less power.

Reload battery.

b. Battery has electrical failure.

Replace battery.

3. Check condition of fuse(s).

a. Faulty fuse(s).

Replace.

Section 03 ENGINE

Subsection 02 (TROUBLESHOOTING)

VMR2004_125_03_02A.FM 03-02-3

SYMPTOM NO SPARK.

CONDITION NORMAL USE.

Test/Inspection 4. Check spark plug electrode condition.

a. Gap is too big.

Readjust gap (refer to TECHNICAL DATA).

b. Spark plug condition is bad.

Diagnose spark plug condition and replace it (refer to IGNITION SYSTEM).

5. Check spark plug cable and ignition wire.

a. Cable and/or ignition wire is (are) damaged and/or shows electrical failure.

Replace damaged part(s).

6. Check ignition coil for damage and/or electrical failure.

a. Ignition coil damaged and/or resistance value out of specification

(refer to TECHNICAL DATA).

Replace ignition coil.

b. Connector is corroded or ignition coil shows electrical failure.

Clean connector area and/or replace ignition coil.

c. Wire harness is brittle or hard (no connection).

Replace.

7. Check CPS (crankshaft position sensor) for damage and/or electrical failure.

a. Sensor shows electrical failure and/or damages.

Replace CPS.

b. Connector is corroded.

Clean and reconnect.

c. Resistance value is out of specification (refer to TECHNICAL DATA).

Replace CPS.

8. Check wire harness for cracks or other damages.

a. Harness shows electrical failure and/or other damages.

Replace wire harness and/or damaged wire section.

9. Check magneto for damage and/or electrical failure.

a. Radial position of rotor wrong due to a broken woodruff key.

Replace woodruff key.

b. Connector on magneto is damaged and/or has electrical failure.

Repair and clean contacts of connector.

c. Coating on stator winding is damaged.

Replace magneto.

d. Resistance value is out of specification (refer to TECHNICAL DATA).

Replace magneto.

10. Check electronic module.

a. Module shows electrical failure or damages.

Replace electronic module.

b. Connectors are corroded.

Clean and reconnect.

c. Electronic module has bad ground to the vehicle frame.

Clean metal surface for good ground.

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