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1. sss 59 4 10 PIStON AS SONA OU ege 61 411 Valve e 62 Page 3 134 S4 Standup Service Manual 4 12 Balance plate PTO aSSeEMbDIY cccsesecesesseeeesseeeenseeneeaseeeenseeseesseeeenseeeenneesonnees 63 4 13 Crankshaft Counter balancer assemblies 64 4 14 Engine Disassembly Process ccsccccseseeeseeeeseeeeeseeeseeeeseeeeaeeeeaseneeseeeeseesaeeneas 65 4 15 Engine inspection procedures cese ieeee reisen KEREN RR nennen nnns 73 415 1 Valve NSPECtON iden YUAN vid cadi KH BE YE Nae E RU Ra Yi GE i PT Ka 13 4 15 2 Cylinder Head Inspechon cece eee eee eee eee 75 4 15 3 Cylinder Block Inspection cc eee eee eee eee eee eee 76 4 15 4 Camshaft lnspechon eee ee eee aaa aaa 76 4 15 5 Rocker Arm Inspection sii sarata e taina im a cae ai la in E a a 78 4 15 6 Crankshaft Inspechon eee eee eee 79 4 15 7 Connection Rod Inspechon eee eee eee eee eee 81 4 15 8 Balance Shatt INSPEC CUON ioci ei a nt a i i ta n a 82 415 9 PISIONINSDECUGIN casele ian eu aaa a atleta ua n ie a i e a 82 4 15 10 High Pressure Oil Pump Inspechon eee eee eee eee 84 4 15 11 Chain RE e E 85 4 15 12 Starter Motor Clutch eee eee eee eee eee nnn nnns 85 4 15 13 TAFOIDO n EE 86 4 16 e le Ca E 86 4 17 Timing Chain Installation TDC Procedure
2. Gl boat Wel ile T uU 8 Page 78 134 S4 Standup Service Manual Measure rocker arm shaft outside diameter e Out of specification Replace rocker arm shaft Measure rocker arm post bore inside diameter e Out of specification Replace rocker arm post 4 15 6 Crankshaft Inspection Measure crankshaft deflection e Out of specification Replace crankshaft Page 79 134 S4 Standup Service Manual NOTE Do not move crankshaft until measurement process is completed Do not place on oil holes Measure crankshaft main bearing clearance 1 Place upper journal bearings into upper casehalve 2 Install crankshaft Place a piece of Plastigauge across the journal surface Install lower crankcase halve with journal bearings installed 3 Loosely install lower crankcase bolts turn engine up on stand 4 Install old cylinder head gasket cylinder and the cylinder head nuts Torque nuts and bolts to specified torque and tightening sequence 5 Carefully remove components and measure each compressed piece of Plastigauge 6 Reference bearing replacement guide if bearing oil clearance is out of specification e Out of specification Replace main bearings crankcase or crankshaft Crankshaft Main Bearing Replacement Guide Replacement of the crankshaft main bearings is required when the bearing oil clearance is out of specification Use this guide to select new bearings NOTE Bearing color code
3. sss 91 4 17 1 Timing Chain Installation 2 0 0 0 ccccccccccccceececeeeeeeceseeeeeeeseeeseeseseeeseneesaeesaees 91 4 17 2 Engine Assembly RE ac ma NEN 95 4 18 Thermostat Removal Installation 100 4 19 Water Pump Removal Installation 0 cccccccsesseeesseeeeseeeeseesesseeeseeeeseseeneeneneees 100 4 20 Oil Lubrication System EE 101 4 20 1 Low Pressure Oil Creunt eee eee nenea nea aeaae 102 4 20 2 High Pressure Circuit 102 420 9 CGrankcase ventilato nica c ii bt co ae Da aa i nn d a d gr 103 4 20 4 Low Pressure Pump Removal Installation cccccscceecceeeseeeseeeeeeeeseeaaes 103 4 20 5 High Pressure Pump Remowval Installation 104 4 20 6 High Pressure Oil SUDDIy EE 105 5 Te de Le EE CC E 107 5 1 Installing the Keyspan USB to RS 232 Adapter 107 5 2 Configure the Keyspan Adapter 111 cese ceeeee er eeee nennen nn nnns 111 5 3 Configure the HSR Diagnostic Tool eeecceeeeeeeeeeee 115 r MEN NANOS CS aos ss 117 5 4 1 Ju d VE eta osia a ta ta Dl d tt ada i Ma 117 5 4 2 Starting the diagnostic program for the first time 119 0 4 3 Reie re 120 Page 4 134 S4 Standup Service Manu
4. 15 Install the balance shaft with the gear facing the front of the engine NOTE Verify bearing surfaces are centered within journals 16 Install crankshaft so that the two single dot alignment marks located on the balance shaft gear and crankshaft gear face each other NOTE Verify bearing surfaces are centered within journals 17 Coat bearing surfaces with engine oil Page 87 134 HS S4 Standup Service Manual X 18 Push pistons so the connecting rods engage the crankshaft Obtain the two con rod caps with bearings installed Apply engine oil to connecting rod bearings 19 Match each unique cap mating surface with the appropriate connecting rod Loosely install each fastener then tighten evenly 20 Torque connecting rod cap bolts to specification 21 Verify the lower and upper crankcase mating surfaces are free from engine oil or foreign material 22 Apply a thin even bead of Three Bond 1213t case sealant to the upper crankcase mating surface 23 Apply sealant as outlined in photo Page 88 134 1 ZE S4 Standup Service Manual 24 Verify the crankcase stud oil jackets are installed on the four studs as outlined in the photo NOTE Verify stud jackets are installed in the middle of each stud 25 Carefully install the lower crankcase on to the upper crankcase 26 Loosely install two of the four lower crankcase fasteners Page 89 134 S4 Standup Service Manual
5. e Now in the main view you can see which port the Keyspan Adapter is using e Ifthe Port is between 1 4 you can close the Keyspan Assistant and you have to start the HSR Diagnostic Tool e Other case please click on the department submenu Port Mapping Page 112 134 S4 Standup Service Manual ATDCEICSDIGU i Keyspan USB Serial Adapter USA19H Assistant NWECZWePBUMGeDUnG Adapter Status Properties Port Mapping Diagnostics Help COMI Kommunikationsanschluss COM1 Iw Show All COM Assignments This COM port is in use and currently Idle COM port mapping for selected adapter port Adapter Port Mapping Mode Plug amp Play Instantiation Method Install the USB to U e Dynamic C Geographic Rs232 Adapter Delete All Keyspan USB Serial Adapter US419H COM Port Mappings e Papierkorb e Inthe middle of the window there you can select which port should be used Please select a free one between 1 4 After that wait about 30 seconds that the program can change your settings Page 113 134 S4 Standup Service Manual Adobe Reader Ld Eigene Dateien ATDCEICSDIGU a 1 Keyspan USB Serial i dap ter USA19H Assistant Adapter Status Properties Port Mapping Diagnostics Help Netzwerkumaebung COMI Kommunikationsanschluss COM1 Iw Show All COM Assignments This COM port is in use and currently Idle COM port mapping for selected adapter port
6. 2 4 3 Draining the motor oil IMPORTANT With a motor warm from operation the greatest oil volume is sucked out of the motor 1 Unscrew the oil dipstick from the oil tank See Chapter Oil level check 2 Insert the suction hose of the oil extraction pump into the oil tank through an opening in the cover 1 until it reaches the bottom of the oil tank X 260 mm 10 25 in 3 Pump all the motor oil out 4 Remove the suction hose and insert the oil dipstick again Page 23 134 S4 Standup Service Manual The motor oil in the dry sump tank is pumped out with the help of the engine dry sump pump 5 Remove the cable harness from the spark plugs and the injection valves See Chapter Removing the spark plugs 6 Remove the oil feed hose 2 on one side of the oil tank If necessary extend the oil feed hose gt Tightening torque V 3 Nm 10 2 2 ft Ib 7 Activate the engine s starter every 10 seconds in order to let the engine crank and wait 30 seconds 8 Repeat this procedure until the motor oil is pumped completely out Do not let engine crank longer than necessary To prevent damage due to insufficient lubrication and overloading of the starter Page 24 134 S4 Standup Service Manual 2 4 4 Changing the oil filter 9 Unplug the plug from switch 70 65 C 3 10 Unscrew the oilfiltercover 4 gt Tightening torque 24 Nm 10 17 7 ft Ib 11 Replace
7. 27 Apply a light film of grease to the crankshaft seal Install the seal around the flange Evenly press seal into crankcase CAUTION Use extreme care when installing seal Do not fold seal lips over when pressing around flange 28 Rotate the engine 180 so the pistons face upwards 29 Clean the cylinder head mating surface free from oil and foreign material Install a new cylinder head gasket with the part numbers and markings facing up and the larger coolant slots located on the exhaust side of the engine NOTE Always use a new cylinder head gasket re gardless of original condition 30 Install the cylinder head over the stud bolts with the exhaust manifold studs facing the oil filter side of the engine 31 Apply engine oil to stud threads and loosely install the cylinder head nuts Page 90 134 S4 Standup Service Manual 32 Rotate the engine 180 Cylinder Head Down 33 Install the oil pump relief valve piston and spring Place cover over spring and insert fastener Hand tighten fastener 34 Install the remaining lower crankcase fastener 35 Rotate the engine 180 Cylinder Head Up 36 Tighten cylinder head nuts and lower crankcase fasteners to specification as outlined on page 61 37 Rotate the engine 180 Cylinder Head Down 38 Proceed with the TIMING CHAIN INSTALLATION TDC PROCEDURE 4 17 Timing Chain Installation TDC Procedure A special procedure is required for installing
8. Adapter Port Mapping Mode Plug amp Play e Dynamic Delete All Keyspan USB Serial Adapter USA1 e Papierkorb e When you have chosen a right port please close the Keyspan Assistant and open the HSR Diagnostic tool Page 114 134 S4 Standup Service Manual 5 3 Configure the HSR Diagnostic Tool To open the diagnostic manual refer to the diagnostic manual installation Service 1 0 0 x OEM HSR CNS_C1WBR_O9SUS dcn Open Console COM Diagnostic End Of Line al Ge 3 f Console Data Console taj Install the USB to Rs2 Keyspan USB Serial 4 e Inthe menu of the HSR Diagnostic Tool you can see a submenu named COM please click on it e After that you see the entry COM Port please select this one Page 115 134 S4 Standup Service Manual Service 1 0 0 x OEM HSR CNS C1 WBR_O9SUS den ijj Install the USB to Rs2 e Now a new little window has appeared Please select the same port as you have chosen into the Keyspan Assistant and press the Button Close e Now the HSR Diagnostic Tool should work correctly If there are any problems please contact our Administrators Page 116 134 S4 Standup Service Manual 5 4 Diagnostics 5 4 1 Installation Move the folder software SO to your hard disk or desktop Hydrospace E File Edit View Favorites Tools Help E E gt Si E Search 7 Folders Hab Address
9. Options in the menu bar and then on Select All To select no one of the parameters you have to click on Options in the menu bar and then on Disable All The meanings of the abbreviations are ERCOUNTER ignition counter niai MIN RET engine speed BAP m n atmospherically pressure in mbar and or hPa Vip ada manifold pressure in mbar and or hPa TARGET MAP not required KLAMBDA not required In m injection time for cylinder 1 in ms Jr DE injection time for cylinder 1 in ms SPARK 1 eee ignition timing for spark plug 1 in degree SPARK2 ee ignition timing for spark plug 2 in degree wl not required li wet throttle body position in 96 DELTA TPO reni not required Page 124 134 S4 Standup Service Manual AIR EE inlet manifold temperature sensor in C ENGINE T engine temperature in C sj i carne stie eee tal battery voltage in V LAMBDA sea eat eat not required LAMBDA REF not required Ip E cm not required GEAR VALUE not required OTS SWITCH not required KILL SWITCH not required DUTY BOOST not required Serie not required FREE pa o em era a not required To abort the diagnosis click the button el Page 125 134 S4 Standup Service Manual 5 4 4 ECU Setup To start the window for
10. eee eee 48 4 1 3 Engine Specific Fastener Torque Specifications eee 49 4 1 4 Turbocharger Specific Fastener Torque Specifications 49 4 1 5 Intake Manifold Specific Fastener Torque Specifications o0 4 1 6 Alternator Assembly Specific Fastener Torque Specifications 50 4 1 7 Fuel Rail Specific Fastener Torque Specifications o0 4 1 8 Engine Management Components Sensor Specific Fastener Torque gt 81216 ez pi e 10 eee eee ree T ee ee PORN DR ee eee RO ee 51 4 1 9 Balance Plate PTO Specific Fastener Torque Specifications 51 4 1 10 Engine Mounts Specific Fastener Torque Gpecihcatons 51 4 2 OIliter ln IV cca east agata cuie dat due di a ij a ta d ia ata Ebrei aia illa 52 4 3 Valve cover assembly 234 aaa aaa aie angina a a aa dia aia i aa d m a 53 4 4 Valve EH 54 4 5 Dry sump oil pump ASSEMDIY ccccceeeseeeeeeeeeneeeenseeeeseseeneeeeaeeeeaseeoeseseeneeseaseneas 55 4 6 Thermostat housing assembly ssssssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnn 56 4 7 High pressure oil pump assembly m nn eee nnaa nenea mnnanmnnannnaannnsa 57 4 8 Exhaust side chain guide tensioner assembly 58 4 9 Engine case cylinder head assembly
11. ice STARTING GEAR ROLLER BEARINGS ONE WAY CLUTCH 25 Install two of the PTO coupler bolts into the PTO end of the crankshaft Have an assistant place a pry bar across these two bolts to prevent the crankshaft from rotating 26 Tighten flywheel bolt to specification Page 98 134 S4 Standup Service Manual 27 Apply a thin bead of Three Bond 1215t sealant to stator cover mating surface 28 Install stator cover with stator mounted inside of cover Route harness as not to pinch or cut wires 29 Reinstall the high pressure oil supply hoses and banjo bolt to the top of the cylinder head 30 Tighten banjo bolt to specification yo dp A PN NOTE Before installing the valve cover and gaskets the valve clearance must be checked Follow the procedure outlined in chapter Replace any valve clearance shims that are out of specification or worn After completing the valve clearance adjustment reinstall the valve cover using new gaskets and o rings Page 99 134 S4 Standup Service Manual 4 18 Thermostat Removal Installation NOTE Coolant will flow out of the cylinder head into the bilge when the outlet rail elbow is removed Tilt the bow down to prevent coolant from escaping outlet rail Nd 1 Remove the snap ring using a snap ring pliers 2 Carefully twist and pull the elbow out of the rail 3 Inspect the o rings Replace if found worn or damaged 4 Remove and replace thermostat
12. 010IN Verify camshaft orientation during installation Hole in camshaft is located on the PTO side of engine Always replace camshaft sprocket and timing chain together Page 54 134 S4 Standup Service Manual 4 5 Dry sump oil pump assembly COMPONENT LAYOUT f Freen ke j i Lh et aa 1 D A T een d GT T d Ob d LOWER SUMP BEDPLATE OIL SUPPLY ELBOW TO OIL COOLER Assembly Notes Screen Fastener Torque 7 ft lbs 10 Nm Apply Loctitet 243 to threads Oil Pump Fastener Torque 7 ft lbs 10 Nm Apply Loctitet 243 to threads Oil Pump Drive Gear Nut Torque 28 ft lbs 88 Nm Apply Loctitet 272 to threads Plug Fastener Torque 11 ft lbs 15 Nm Oil Supply Elbow Fastener Torque 7 ft lbs 10 Nm Clean bedplate and lower crankcase mating surfaces prior to apply silicone Verify surfaces are free from any oil residue Apply a thin bead of Three Bondt 1215 to mating surfaces of bedplate and lower crankcase Dry sump oil pump is not serviceable Replace component if operation is suspect Page 55 134 S4 Standup Service Manual 4 6 Thermostat housing assembly O RING INTAKE SIDE OF ENGINE BLEED HOSE FITTING ELBOW PIPE THERMOSTAT M WATER PIPE FASTENERS ve M6 X 20 A k COOLANT FLOW WHEN THERMOSTAT OPENS SNAP RING CHAMFER FACES OUT Assembly Notes Water Pipe Fastener Torque 7 ft lbs 10 Nm Thermostat Opening Temperature 158 F 70 C Snap ring chamfer face
13. 1 26 INTAKE 32mm 1 26 EXHAUST Cylinder Head Warpage Limit 04mm 001 Cylinder Specifications 85 00 85 01mm 3 34 BORE SIZE 008mm 0003 TAPER LIMIT 008mm 0003 OUT OF ROUND LIMIT N A WEAR LIMIT Camshaft Specifications 108 85mm 109 00mm 4 28 4 29 CAMSHAFT WIDTH 48 553mm 1 911 IN CAM LOBE HEIGHT 48 209mm 1 897 EX CAM LOBE HEIGHT 05mm Sprocket 02mm Base 001 MAXIMUM CAMSHAFT RUNOUT 020mm 050mm 001 RADIAL PLAY 25 972mm 25 988mm 1 02 Page 45 134 S4 Standup Service Manual BEARING HOLE I D CAMSHAFT AXLE O D CAMSHAFT CLAMP I D Rocker Arm Specifications BEARING AXIAL PLAY ROCKER ARM I D ROCKER ARM SHAFT O D ROCKER ARM HOLDER BORE I D ROCKER ARM AXIAL PLAY Crankshaft Specifications CRANKSHAFT DEFLECTION MAIN BEARING CLEARANCE BEARING CODES Balance Shaft Specifications AXIAL PLAY RADIAL PLAY BEARING DIAMETER RUN OUT Piston Specifications PISTON TO CYL CLEARANCE PISTON DIAMETER WEAR LIMIT PISTON PIN BOSS I D PIN O D PIN WEAR LIMIT TOP RING INSTALLED RING GAP Piston Ring Specifications TOP RING INSTALLED RING GAP TOP RING GROVE CLEARANCE MIDDLE RING INSTALLED RING GAP MIDDLE RING GROVE CLEARANCE 19 991mm 20mm 787 19 90mm 19 98mm 783 013mm 025mm 0005 13 980mm 13 991mm 55 9 994mm 10mm 393 10mm 10 009mm 393 16mm 26mm 006 010 0009 02mm 04mm 000
14. CA 5 Insert thermostat with bleed hole up J 6 Reinstall the elbow Reinstall the snap ring Verify the EH y snap ring chamfer faces out when installing 4 19 Water Pump Removal Installation GEAR COVER 1 The water pump cover can be removed by 4 fasteners EA AEAEE o that mount the cover to the front gear cover We Fa 2 Always replace the o ring with new during reassembly 3J SeN 3 The impeller can be removed by holding the crankshaft de Stationary while turning the impeller nut counter clockwise 4 Tighten fasteners to specified torque outlined at beginning of chapter Page 100 134 S4 Standup Service Manual 1 To replace the impeller shaft and mechanical seal remove the front gear cover 2 Carefully extract mechanical seal components out of the gear cover Le ag 3 Press new gasket with washer recess facing out washer with groves facing gasket and new mechanical Ty r seal with spring end facing outward into cover using JI KE light and even force 4 The impeller shaft sits inside crankcase bore Replace MECHANICAL SEAL GASKET shaft if worn or damaged 5 Tighten fasteners to specified torque outlined at beginning of chapter 4 20 Oil Lubrication System The lubrication system features two oil pumps The first pump is the low pressure pump that pumps oil to the oil cooler and then on to the oil storage tank The second pump high pressure is located on the PTO end of the e
15. Sea Level Engine Oil Requirement HSR 100 Synthetic Four Stroke Engine Oil Oil Grade Requirement 10W 60 Synthetic API A3 B3 Engine Oil Capacity 3 4 3 7 US Quarts 3 3 3 5 Liters With Oil Filter Replacement Dry Engine After Rebuild 3 9 4 2 US Quarts 3 7 4 0 Liters Page 43 134 S4 Standup Service Manual Cooling System Requirement OPEN cooling system with Thermostat Thermostat Opening Temperature 158 F 70 c Valve Timing 1mm Valve Lift EV OPENS 52 BBDC EV CLOSES 2_ ATDC IV OPENS 14 BTDC IV CLOSES 50_ ABDC Valve Diameter Exhaust Valves 29 5mm 1 161 Intake Valves 32 5mm 1 279 Valve Seat Contact Width IV 1 1mm 1 2mm 043 047 EV 1 3mm 1 4mm 051 055 Valve Face Width IV EV Valve Margin Thickness IV 5 472mm 2154 EV o 463mm 2150 Valve Seat Angle 45 Valve Clearance COLD IV 0 08 0 15mm 003 006 Page 44 134 S4 Standup Service Manual 0 18 0 25mm 007 010 Valve Stem Diameter IV 5 465 5 479mm 2151 2157 EV 5 456 5 470mm 2148 2153 Valve Guide Inside Diameter IV 5 5mm 5 507mm 216 EV 5 5mm 5 509mm 216 Valve Stem Run out 03mm 001 Valve Stem To Guide Clearance IV 021mm 044mm 0008 0017 EV 030mm 053mm 0011 0020 Valve Spring Free Length 38 2mm 1 5 INTAKE 38 2mm 1 5 EXHAUST Valve Spring Installed Length 32mm
16. areas of the valve cover and cylinder head Assembly occurs in reverse order Please note instructions after this symbol gt Page 29 134 S4 Standup Service Manual Exhaust side 2 6 3 Checking the valve play Pic ay pe Fa Pyne e 4 Start the vehicle s starter and let the engine crank until both cams of the second cylinder are pointing upwards The rocker of the first cylinder demonstrates a little play L P Intake side 5 Using a feeler gauge measure the valve play 6 of all four valves of the first cylinder between the adjustment plates and the rockers Permissible valve play Intake side 0 08 0 15 mm ZED 0 0031 0 0059 in Im rp p Exhaust side 0 18 0 25 mm 0 0071 0 0098 in Ds ud CM Page 30 134 I i S4 Standup Service Manual e 2 6 4 Adjusting the valve play 6 To adjust the valve play on the intake side it is necessary to remove the fuel distributor rail Remove the cable harness on the coolant sensor 7 T Loosen the screws and washers 8 and remove the fuel distributor rail 9 gt Tightening torque 10 Nm 10 7 4 ft Ib Page 31 134 S4 Standup Service Manual gt Replace the O rings 9 on the injector valves Coat the O rings lightly with motor oil 8 Mount the valve adjustment tool 11 with two screws Tightening torque 10 Nm 10 7 4 ft Ib The engine may not be turned
17. full power and hold Then double click with the mouse on the value right of the input field of TPS Maximum Bit Value So the value will be transferred into the input field Be sure it s full on throttle body 4 Release the throttle trigger and with a double click you have to take over the value for TPS Minimum Bit Value 5 If the bolt has been touch before by the rider the best would be to un screw it until the TPS mini does not move turn the screw clock wise and when the bit start to move then make turn more 6 The idle should be between 1400 1500 rpm if you have 100 rpm and you wish to adjust higher do not forget to reset the minimum value inside the ECU Example TPS Minimum between 72 to 82 bits never the same from 1 ski to the other one TPS Maximum between 235 to 245 bits never the same from 1 ski to the other one T To unlock the nut use a bended 10mm fork wrench 8 Adjust with a 5mm allen key Page 127 134 S4 Standup Service Manual 9 Double click on the value right of the input field of TPS Minimum Bit Value to transfer the value into the input field 10 Then turn the allen screw until the value increases by 1 In our example above this would be the value of 81 Now the correct idle setting is done Page 128 134 S4 Standup Service Manual End Of Production Line TPS Minimun Bit Value 0 gi Map 0 Map 1 TPS Maximum Bit Value 741 ep Lie DO Adiustment 1000 Inje
18. low Remove soiling and corrosion on the battery Open circuit voltage lt 12 volts poles and connect battery connections During activation of the starter correctly With non maintenance free lt 10 5 volts batteries check water level Charge battery with external battery charger Engine mass point 1 not connected Check connection or not connected properly Defective fuse Check the fuses in the cable harness Drive or jet pump blocked Remove blockage Cable harness plug connections not Check plug connections plugged in or not plugged in correctly Page 35 134 S4 Standup Service Manual 2 7 2 Engine cranks but does not start Possible cause Lanyard not plugged in Plug in lanyard Defective fuse Check the fuses in the cable harness Too little or no fuel in the tank Fill up fuel Check the engine for signs of leaky fuel lines and if necessary have it checked by a professional shop Cable harness plug connections not Check plug connections plugged in or not plugged in correctly Spark plugs defective Check the spark plugs and if necessary replace them See Chapter Spark plugs Page 36 134 S4 Standup Service Manual 2 7 3 Engine stalls but can be started again Possible cause Too little or no fuel in the tank Fill up fuel Check the engine for signs of leaky fuel lines and if necessary have it checked by a professional shop Too much motor oil Check the oil level See
19. read out from the ECU Page 122 134 S4 Standup Service Manual amp Service 1 0 0 x OEM CNS CIWBR_O9SUS den Open Console Datalogger COM Diagnostic End Of Line e 8 Console ERCOUNTER 1 DELTA TPS RPM AIR T ENGINE T BATT V TARGET MAP n LAMBDA KLAMBDA 4nnnn LAMBDA REF HI IDLE INJ2 2Enon GEAR_VALUE SPARKI Lan OTS_SWITCH SPARK2 3 KLL SWITCH PHASE Ren 7 o DUTY_BOOST TPS BLOCK FREE Data Console The values shown in the illustration above correspond approximately with the standard values of the non running engine at the ambient temperature about 10 C 50 F Its advisable to set the following parameter in this console RPM SPARK1 BAP SPARK2 MAP TPS INJ1 AIR T INJ2 ENGINE T BATT V Page 123 134 S4 Standup Service Manual In order to change the indicated parameter click the button Open and afterwards Options in the menu bar Then following window will open View Options Jol x Options EHCOUNTER Iv ENGINE T iv RFM r4 BATT V iw BAP iw LAMBDA iw MAP Iw LAMBDA REF Iw TARBET MAP Iw IDLE r4 KLAME DA iw GEAR ALUE iw INJ Iw DITS SWITCH E INJ2 iw KILL SWITCH iw SPARE iw DUTY BDDST Iw SPARE iw BLOCK iw PHASE iw FREE Iv TPS Iw DELTA TPS e h Selecting the parameters Select the parameter which you want to have With a click on the button Close x you take over the settings To select all parameters you have to click on
20. remove the four case bolts located in the oil sump gallery Photo O 26 The lower case bolt located on the PTO side also holds the oil pump relief piston cover in place Photo P 27 Once the plate is removed use a magnet to remove the spring and piston from inside the bore i p L T d au PHOTO Q nw Page 70 134 S4 Standup Service Manual 28 Rotate the engine assembly 180_ so that the valve train is up Evenly loosen and remove the cylinder head nuts Photo R 29 Carefully pull the cylinder head assembly up and off of the crankcase 30 Remove the chain guide fastener and chain guide Photo S 31 Rotate the engine assembly 180 Remove the tensioner chain guide from the crankcase 32 Using a soft faced hammer carefully tap the lower section of the crankcase loose from upper crankcase Once loose pull the lower crankcase up and away from the upper case Photo T H CAR Page 71 134 S4 Standup Service Manual 33 Remove the balance shaft from the crankcase Remove the PTO crankshaft case seal and discard Remove the piston lower rod cap bolts Photo R 34 Carefully push each piston through and out of the crankcase Match each rod cap with its corresponding connecting rod Photo U NOTE The connecting rod caps are cracked dur ing manufacture creating a unique mating surface between the connecting rod and cap Always verify that the lower cap matches the connect
21. the ECU Setup click the button Fine Linea see Illustraton Service 1010 HSR exe End Of Production Line TPS Minimun Bit Value TPS Maximum Bit Yalue 71 Frame Number AT HSRO00605K606 10010043 1 3 06 2007 Set End Line Yalues Set Default End Line Parameters Engine Number Date Calibration Map ID Map 0 Map 1 Idle CO Adjustment 1 000 1 000 0 00 Injection Offset Idle Valve Offset ECU Setup TPS Minimum Bit Value TPS Maximum Bit Value Calibration Map ID Set End Umevalues eee Set Default End Line Parameters Read Hour Meier Idle CO Adjustment Injection Offset sseeesseesssesss Idle Valve Offset throttle body minimum position throttle body maximum position hull serial number engine serial number date of the last ECU Setup A double click into the field will insert the actual date Mapping version number at present the actually version is 11005 saves the values in the ECU reset to default values and saves it in the ECU reads the engine total running time not required not required not required Page 126 134 S4 Standup Service Manual 5 4 5 Control the throttle body attitude 1 The computer must be connected by the diagnostic cable with the engine ad the ignition must be switched on with the lanyard 2 Start the diagnostic program Service 1010 HSR exe and start the ECU Setup window 3 Give
22. the timing chain into the engine Four service tools are required when installing the timing chain and setting the engine timing They are e Timing Chain Installation Guide PN PW 47079 e Timing Chain Hook Stuffer PN PW 47108 e Crankshaft Turning Hand Crank PN PW 46981 e Camshaft Alignment Tool PN PW 47077 4 17 1 Timing Chain Installation 1 Remove the rocker arm pins and rocker arms from the cylinder head 2 Install the Crankshaft Hand Crank Tool into the nose of the crankshaft Set the jam nut so the crankshaft can be turned left or right 3 Rotate the crankshaft until double dot alignment marks on each gear face each other The engine will be set to BDC when the two sets of double dots face each other 4 Install the the Timing Chain Installation Guide Page 91 134 S4 Standup Service Manual PN PW 47079 into the two bedplate fastener bores NOTE The Timing Chain Installation Guide tool will guide the chain around the crankcase bends while preventing the chain from catching on the balance shaft sprocket 5 Slowly insert the chain into chain gallery Wiggle the chain slightly until it falls down through the engine and protrudes from the bottom of the cylinder head CAUTION Do not drop the chain into the engine 6 Insert the stuffer end of the Timing Chain Hook Stuffer PN PW 47108 tool into the chain gallery NOTE The stuffer wedge will prevent the chain from catching on the sp
23. when the bearing oil clearance is out of specification Use this guide to select new bearings NOTE Bearing color code is imprinted on the side of each bearing REPLACEMENT BEARING THICKNESS RED 0783 0785 1 990 1 995mm YELLOW 0785 0787 1 995 2 000mm BLUE 0787 0789 2 000 2 005mm If the measured clearance is within specification replace with new bearings with the same color code If the used bearings reveal an oil clearance of 04 and 05mm install new bearings with the same color code Page 81 134 S4 Standup Service Manual 4 15 8 Balance Shaft Inspection Measure balance shaft run out at several locations e Out of specification Replace balance shaft Measure bearing diameter e Out of specification Replace balance shaft 4 15 9 Piston Inspection Measure piston diameter e Out of specification Replace piston Page 82 134 S4 Standup Service Manual Measure piston pin boss inside diameter e Out of specification Replace piston Measure piston pin outside diameter e Out of specification Replace piston pin Confirm piston to cylinder clearance specification e Out of specification Replace piston pin Measure installed ring end gap e Out of specification Replace rings or cylinder block Cylinder Page 83 134 S4 Standup Service Manual Measure piston ring grove clearance e Out of specification Replace piston ring or piston FP H
24. 17 Rotate the engine 360 counter clockwise Perform steps 15 and 16 on the MAG cylinder valve train NOTE A piston is at TDC on the compression p us Wi vm stroke when the piston is up and there is axial free a m play in each of the rocker arms WE PUSH WITH SCREWDRIVER 18 Place rocker arm assemblies and rocker arm pins on a clean towel or piece of paper Identify each part for use during assembly Photo M NOTE The MAG exhaust side rocker arm features a cam phase sensor pickup nose as circled in photo M 19 Remove the valve shims Place valve shims with PHOTO M corresponding rocker arm and location 20 Remove the chain tensioner bolt located next to the oil filter location 21 Attach the chain breaker tool ees HIR p p op LI LE 22 Using the chain breaker tool carefully press the pin out M of the link plate Once outer plate is loose disconnect the tool and remove the last pin VERIFY TAPERED PIN MATES EVENLY WITH EACH CHAIN PIN THREADED BOLT FACE MUST FIT SQUARELY ON CHAIN PLATE 23 Remove the two pins from the chain but do not pull the chain away from the cam sprocket Page 69 134 E S4 Standup Service Manual j 24 Rotate the engine assembly 180 so that the valve train is down facing the floor Using the hand crank crank the timing chain out of the engine 25 With the timing chain removed from the engine the crankcase can be split in two To begin loosen and
25. 7 0015 O3mm 04mm 0011 0015 YELLOW 1 995 2 000mm BLUE 2 000 2 005mm GREEN 2 005 2 010mm 15mm 25mm 005 009 014mm 066mm 0005 24 975mm 24 990mm 983 014mm 066mm 0005 002 002 041mm 059mm 0016 0023 84 961mm 84 979mm Measured 15mm from bottom 90 from pin 3 34 3 345 04mm 001 21 004mm 21 009mm 20 995mm 21 000mm 05mm 001 826 827 826 2mm 4mm 07 015 65mm 955mm 025 037 2mm 4mm 007 015 50mm 805mm 019 031 2mm mm 007 027 Page 46 134 S4 Standup Service Manual OIL RING INSTALLED END GAP o0mm 910mm 019 035 OIL RING GROVE CLEARANCE Oil Pump Specifications Trochoid OIL PUMP TYPES SPRING FREE LENGTH 2 7 69mm PISTON O D OIL PRESSURE RELIEF VALVE 43 10 9mm PISTON LENGTH 1 10 27 7 28mm OIL PRESSURE 21 IDLE 80 MAX PSI 1 5 5 5 BAR 4 1 1 Engine Fastener Torque Specifications 3 4 4 9 5 9 7 8 44 61 73 98 115 155 Page 47 134 S4 Standup Service Manual 4 1 2 Engine Specific Fastener Torque Specifications 15 20 Cylinder Head Nuts Apply Engine Oil M10 x 1 25 Step 1 30 0 to Threads Step 2 180 180 Step 3 M8 x 50 M8 x 70 M8 x 90 oe Lower Crankcase Bolts Step 1 Step 3 Gearcover to Engine Block 7 Plug Elbow
26. 77 to threads Page 63 134 S4 Standup Service Manual 4 13 Crankshaft Counter balancer assemblies AE 4 KA P CRANKSHAFT PLAIN BEARINGS IK zT Jj L x BALANCE SHAFT GEAR TIMING KEY CRANKSHAFT Page 64 134 S4 Standup Service Manual 4 14 Engine Disassembly Process 1 Remove valve cover from engine 2 Remove the coolant outlet manifold oil filter cover and electric starter motor from engine case 3 Remove the two high pressure oil feed hose banjo bolts from the cylinder head exhaust side rear mounting location Ladd a En amp Page 65 134 1 ZE S4 Standup Service Manual aa 4 Remove the stator cover from the flywheel housing Photo D NOTE The stator is attached to the inside of the cover Note the two alignment dowels as circled in photo 5 Photo of stator inside of cover Photo E 6 Remove the water pump cover and impeller Photo F NOTE The impeller can be removed by turning the nut counter clockwise Hold the flywheel stationary while removing the impeller Page 66 134 S4 Standup Service Manual 7 Remove the front engine gear cover Photo G NOTE Place drain pan underneath cover to catch oil 8 Install two of the PTO coupler bolts into the PTO end of the crankshaft Have an assistant place a pry bar across these two bolts to prevent the crankshaft from rotating Photo H 9 Remove the flywheel bolt and washer from
27. Battery and his support e Throttle cable Exhaust hose fuel rail cooling hose e Air intake and throttle body assembly will come out all in one do not disconnect the intake bracket e Starter motor will avoid you to disconnect the wires on the start relay e Cut the cable tie over the oil cooler e 4 Engine mounts bolts The use of an engine hoist or overhead crane system is required to both remove and install the engine assembly Always disconnect the positive RED and negative BLACK battery cables from the battery after removing the engine oil and prior to performing any engine work Failure to do so may cause severe injury or death NOTE The use of an engine hoist is strongly recommended for working on and removing the engine from the engine compartment Place masking tape around the engine compartment Doing so will prevent nicking and scratching of the hull when the engine is removed Page 40 134 S4 Standup Service Manual NOTE Not all electrical connections can be discon nected without removing hoses pipes or sub sys tems As components are removed disconnect any electrical connections 1 Locate the fuel hose quick disconnect on top of the fuel rail Wrap a shop towel around the disconnect and press the two tabs in while pulling up on the connector 2 Remove the fuel supply and fuel return hoses from the fuel rail Identify hoses for re assembly 3 Remove all of the hoses connected to the oil storage
28. Chapter Oil level check Excessive motor oil must be pumped out as quickly as possible 2 7 4 Engine stalls and cannot be started again Possible cause Lanyard not plugged in Plug in lanyard Defective fuse Check the fuses in the cable harness Too little or no fuel in the tank Fill up fuel Check the engine for signs of leaky fuel lines and if necessary have it checked by a professional shop Cable harness plug connections not Check plug connections Page 37 134 S4 Standup Service Manual Spark plugs defective Check the spark plugs and if necessary replace them See Chapter Spark plugs 2 7 5 Engine loses power speed limitations m eegene Remedy aa Engine speed limited to Overheating of DO NOT LET THE ENGINE RUN 1800 U Min RPM and exhaust manifold LONGER THAN 30 SECONDS the water temperature Rinse and check the sea water warning lamp lights up cooling circuit See Chapter Rinse sea water cooling circuit after driving Check the sea water pump Page 38 134 S4 Standup Service Manual REMOVAL INSTALLATION Ay lei t Page 39 134 S4 Standup Service Manual 3 Engine Removal and Installation 3 1 Engine Removal Several subsystems must be removed before the engine can be extracted from the engine bay These systems are e Oil see chapter 2 4 3 e Intercooler support and hoses e Engine electrical harness and earth cable e Oil storage tank assembly e
29. Connector Hose Connector in Lower Crankcase Oil Filter Cover Cap Dry Sump Oil Filter Screen Dry Sump Cover to Lower 16 24 N Oi M6 x 20 M12 x 1 5 O Loctite 577 M18 x 1 5 Loctite 243 M6 x 20 Ex NO N zi m O O O O LD O 11 30 17 7 7 Crankcase Dry Sump Pump Gear 28 Dry Sump Pump to Cover T T Dry Sump Hose Connector Balance Shaft Drive Gear Nut 51 Connecting Rod Bolts Step 1 Step 2 Step 3 Camshaft Clamps Rocker Arm Holders Exhaust Manifold Studs Short CA Co Loctite 272 M8 x 25 M6 x 20 0 Loctite 272 10 M10 x 1 32 20 90 M6 x 40 M6 x 20 18 Copper Crease M8 x 69 M8 x 118 24 Copper Grease M8 Flange M6 x 45 N N Qo N CO O P Long Exhaust Manifold Nuts 7 n ok N N O W zu LO wj O Page 48 134 S4 Standup Service Manual Tensioner Rail Fastener Loctite 243 Chain Guide Rail Fastener 7 0 Loctite 243 Chain Tensioner Plug Bolt St e 4 1 3 Engine Specific Fastener Torque Specifications Water Pump Cover Loctite 577 4 1 4 Turbocharger Specific Fastener Torque Specifications Segments 7 M6 x 16 Oil Return Oil Return Flange PMB XB x 16 Turbocharger Lower Los ME K E T x 40 Bracket Turbocharger Bracket to Manifold Bracket to Manifold wT 24 M xnn WasepieAGwioriskni 1T 8 1 Wastsgaie Bracket o Mani 7 10 ren aere In 0 Interco
30. File and Folder Tasks mij Rename this Folder E Move this Folder A Copy this Folder ES Publish this Falder Ea Ehe Web E share this Folder Gel E mail this Folder s Files Delete this folder Other Places d My Computer My Documents a My Network Places Details m Software SO 4 ms Wh Diagnosemanu IP Diagnostic Man Wh Installationsanl TE Manual54 erg Size Type Open Explore Search Sharing and Security 3S Add to archive 3S Add to Software SOL rar 3S Compress and email IE Compress to Software SO rar and email Send To Cut Copy Create Shortcut Delete Rename Properties Page 117 134 Gel eed ll Date Modified 16 11 2006 20 29 20 08 2006 13 22 20 02 2006 11 39 23 01 2006 10 38 22 11 2006 12 31 S4 Standup Service Manual Start the program SERVICE 1010 HSR exe OPEN and start the file SERVICE 1010 HSR exe K E ei u SA s 5 DL Lor EL S IC TO Excel io E LA E LR Office D a 5 Internet Explorer DI hayaan ang zs Adobe Photechon Bb neon E Page 118 134 S4 Standup Service Manual 5 4 2 Starting the diagnostic program for the first time If you start the diagnostic program Service 1010 HSR exe for the first time it could be that the following error is shown Loading Messages E 1 Messages File Not Found Message File Not Found After a click on the button OK the following dialogue
31. LTER CAP FILTER CARTRIDGE EXHAUST SIDE OF ENGINE Assembly Notes Filter Cap Torque 18 ft lbs 25 Nm Apply a light film of engine oil to sealing o ring and filter cap threads during installation OIL FILTER CHANGE INTERVAL BREAK IN 10 TO 12 HOURS EVERY 25 HOURS THEREAFTER Page 52 134 S4 Standup Service Manual 4 3 Valve cover assembly VALVE COVER FASTENERS ME X 45 CAM PHASE SENSOR PORT VALVE COVER GASKET Assembly Notes Valve Cover Fastener Torque 7 ft lbs 10 Nm Cam Phase Sensor Fastener Torque 6 6 ft lbs 9 Nm Always use new gaskets and o rings when removing or replacing parts Torque valve cover fasteners in a criss cross pattern beginning with the four inside fasteners Cam phase sensor port faces exhaust side of engine Verify valve cover sealing surface is dry and clean from containments Page 53 134 S4 Standup Service Manual 4 4 Valve train assembly AXLE CAPS BEARING AXLE CAMSHAFT SPROCKET a VALVE SHIMS c Kg js e SPRINGS Sg SPRING BASE AND RETAIN CG ING CAPS NOT SHOWN C E 2D D VALVE STEM SEAL LONG ROCKER ARM SHORT ROCKER ARM p puc s ct 089 ROCKER ARM PINS LONG ROCKER ARM Assembly Notes Camshaft Bearing Fastener Torque 7 ft lbs 10 Nm Rocker Arm Tower Fastener Torque 9 ft lbs 13 Nm VALVE CLEARANCE COLD IN 08 0 15MM 003 OOGIN EX 18 25MM 007
32. MOTOT e EE 23 2 4 4 Changing the oil d TEE 25 2 4 5 Refilling the motoroil ccc cccccecceeececeeeeseeeeeeeeeeeeceeeeeeeeseeeeseeesaeeeseeeseesaeeess 26 2 9 ODAK PUGS egaine ERE E E aia sune dana EO EEE EO 26 2 5 1 Checking TG spark e Ee E 26 2 9 2 Removing the spark plugs c eee eee 26 2 0 9 Checking the spark ee EE 28 20 WAL TE 28 Page 2 134 S4 Standu p Service Manual 2 6 1 Checking and setting the valve play 28 2 6 2 Removing the valve Cover 29 2 6 3 Checking ine valve play scccsco ossa cu t entes rcu sao aset ai ei ave nd dai e i 30 2 6 4 Adjusting the valve E 31 2 6 5 Checking the valve of the 2 cwllnder mean cea 34 ile O A EU E ei e E 34 2 1 1 Engine dos MOU e vcore core apoase ezite deodata tote ta tip it tut A 34 2 1 2 Engine cranks but does not estate 36 2 123 Engine stalls but can be started again 37 2 1 4 Engine stalls and cannot be started again 37 2 1 9 Engine loses power speed limitations eeeeeeeeeeeeeee eene 38 3 Engine Removal and Installation 40 9 1 Engine E ul CT 40 3 2 Engine NEE UE d OMi si caiete ba 41 4 Engine Disassembly Assembly 43 NR te UE ee EE 43 4 1 1 Engine Fastener Torque Specifications c eee eee nene eee 47 4 1 2 Engine Specific Fastener Torque Specifications
33. Nm 10 7 4 ft Ib 6 Unscrew the spark plugs 6 Tightening torque 27 Nm x 20 19 9 ft Ib Assembly occurs in reverse order Please note instructions after this symbol Page 27 134 S4 Standup Service Manual 2 5 3 Checking the spark plugs 7 Check the electrode distance of the spark plugs with the help of the feeler gauge 0 69 0 84 mm 0 0272 0 0331 in 2 6 Valve play 2 6 1 Checking and setting the valve play IMPORTANT e Hex wrench SW5 3 16 e Feeler gauge measurement range 0 08 mm 0 25 mm 0 0031 0 0098 in e Valve adjustment tool see spare parts catalogue e Combination wrench 24mm 15 16 e Barmagnet e Measurement tool for adjustment plate reading 0 01mm 0 0003 in e Adjustment plates from 2 5 3 7 mm 0 0984 0 1457 in see spare parts catalogue e Valve cover seals see spare parts catalogue e 2x O rings see spare parts catalogue To get correct measurement values check and adjust valve play with a cold engine Page 28 134 S4 Standup Service Manual 2 6 2 Removing the valve cover 1 Removing the cable harness on the cam shaft sensor 1 2 Remove the spark plugs See Chapter Removing the spark plugs 3 Unscrew the valve cover 2 along with bracket and valve 3 gt Tightening torque 10 Nm x 10 7 4 ft Ib gt The sequence of the connection Occurs according figure gt Replace the valve cover seals 4 gt Clean seal
34. Nylokt or Flex Lockt nuts when assembling components Never reuse Oetikert clamps when removed from fuel lines Replace with small gear clamps Always use Hydrospace authorized lubricants greases and locking agents when assembling components Failure to do so may cause severe engine or vehicle damage Always disconnect the black negative cable first from the battery when removing the battery When installing the battery attach the red positive cable first then the black negative cable Wear appropriate clothing eye protection and rubber gloves when working with batteries Battery acid contains sulphuric acid and is extremely poisonous Serious burns can result when in contact with skin clothing eyes or internal body components If battery acid is ingested drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Flush eyes for15minutes with water and seek prompt medical attention if acid comes in contact with eyes Thoroughly wash affected external body parts that come in contact with battery acid with water Keep hands arms legs feet and hair away from rotating parts hot engine and exhaust components drive pump and impeller and engine induction when engine is running Page 9 134 S4 Standup Service Manual Never attempt engine or driveline inspections and or repairs without first removing lanyard and battery cables Gasoline is highly flamma
35. Service Manual 2007 S4 Standup Service Manual Table of Content 12 Generalinforma ion EE 7 1 1 2007 HSR personal watercraft Identification Numbers 7 1 2 PHINTIUITIDOE EE 7 to ENGINE UMD TEE 8 1 4 Three stars ultra low emission cccccceeseeeeeeeeeeeeseeeeseeeneeenseseeseenseoeeesenseoeeens 8 1 5 Safety instructions eebe 8 1o e de arnon aia i Ci lt i Sl lia le ti nd tan 8 1 7 Service Guidelines Safety Warnings sscecessseseeeeceeneeeecenseeeseonseeeseeeeeesees 9 1 8 General Col loceoeueuocicu eines aia alma ninti lia iti E Bai iata dle alia at 11 1 8 1 Standard Torque Specifications eee nenea 12 1 8 2 COT ali Eeer 12 EE 14 1 10 Operating UAE LC 15 TE TR 15 1 12 RTL Iden neci seesaw E E 16 Tio RUNNING INE r Le Un 16 1 14 Operating the engine without sea Watel ccccscseeeseeseeeeeenseeeeeeeeeeeeeenseeeseennees 16 2 dE Ta ue 18 2 1 Maintenance work by the user of the vehicle 19 2 1 1 Regular checks before driving c eee eee eee aaa 19 2 1 2 Rinse sea water cooling circuit after driving cc eee 19 22 Maintenance REENEN 20 2 3 Decommissioning at the end of the season EE 20 2 4 Motor oil and oil filter E 21 2 4 1 EH ee EE SM 21 2 4 2 Changing the motor oil and oil filter 23 2 4 3 Draining the
36. TENSIONER CHAIN GUIDE UPPER CHAIN GUIDE INSTALLED FROM BOTTOM OF UPPER CRANKCASE INSTALLED FROM TOP OF CRANKCASE Assembly Notes Timing Chain Tensioner Plug Bolt Torque 51 ft lbs 7ONm INSTALLED FROM BOTTOM OF UPPER CRANKCASE Tensioner Guide Fastener Torque 17 ft lbs 24 Nm Apply Loctitet 243 to threads Replace replace tensioner rail if damaged or unevenly worn Press tensioner into housing until flush with plug to set tensioner Tensioner should remain in locked position Activate tensioner by pushing tensioner in and past flush Tensioner should activate and extend outwards Replace if function is incorrect Page 58 134 S4 Standup Service Manual 4 9 Engine case cylinder head assembly COMPONENT LAYOUT m he Im c CYLINDER HEAD NUTS Ve Im m LE HOCKER ARM TOWER FASTENERS ef MB X 20 e aii E RI CYLINDER HEAD UPPER CRANKCASE fell LOWER CRANKCASE PRESSURE RELIEF PISTON RELIEF SPRING WASHERS li Nn 7 m RELIEF VALVE COVER PLATE d MBX70 ER MB X 50 M8 X90 LONG BOLT OIL PUMP COVER Page 59 134 S4 Standup Service Manual Assembly Notes CYLINDER HEAD TO CRANKCASE TORQUE SEQUENCE SPECIFICATIONS Apply engine oil to bolt threads 1st STEP Torque cylinder head nuts in sequence 15 ft lbs 20 Nm Torque crankcase fasteners in sequence 12 ft lbs 16 Nm 2nd STEP Torque cylinder head nuts in sequence 30 ft lbs 40 Nm 3rd STEP Torque cylinder head nu
37. USES STARTING PROPULSION JET PUMP TYPE nleaded Gasoline 91 95 98 Octane R M 2 Nicasil f 2 85 x 66 mm 9 6 1 bar 140 14 5 psi Open loop with intercooler and thermostat KEE 30A Alternator 15A Fuel Pump 7 5A Stop switch 30A Main Electric motor 12V 800w Solas Axial Flow 12 Veins Steel stator in Exhaust Manifold Overheart switch RPM limit Page 11 134 S4 Standup Service Manual 60cm 2 Ft PHULL BODY 0 1 8 1 Standard Torque Specifications The following torque specifications are to be used as a general guideline Use standard torque values for the appropriate size fastener when torque values are not specified Always consult the specific manual section for torque values of fasteners and use of locking agent RECOMMENDED TORQUE SPECIFICATION STAINLESS STEEL FASTENERS METRIC 1 8 2 Convertion Chart m i in ule am Page 12 134 S4 Standup Service Manual x 0 6214 x 28 35 kg Cubic inches cu in x 16 387 Cubic centimeters cc Cubic centimeters CC A 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 liters I oz ES I Imperial quarts Imp qt x 1 137 liters l Imperial quarts Imp qt x 1 201 US quarts US qt Liters I x 1 057 US quarts US qt US gallons US gal X 3 785 Liters I Liters I x 0 264 US gallons US gal SE force per square inch
38. age 106 134 S4 Standup Service Manual 5 Electrical System 5 1 Installing the Keyspan USB to RS 232 Adapter The following steps are explained by using Windows XP Service Pack 2 If you are using an older version of Windows please contact our support e Plug in the Keyspan Adapter in a free USB Port e After a short time windows will start the manager for installing new software like in the following picture Please ignore this window it will disappear later automatically Please click cancel A HOODe Reader Eigene Dateien ichen never Hardware Willkommen SE 4 BE Es wird nach aktueller und aktualisierter Software auf dem EESTI DE Computer auf der Hardwareinstallations CD oder auf der Wim e mit Ihrer Erlaubnis gesucht Ci a aeter IO Soll eine Verbindung mit Windows Update hergestellt werden um nach Software zu suchen Ja nur diese eine Mal o4 Ja und jedes Mal wenn ein Ger t angeschlossen wird Merosot ontok Nein diesmal nicht Klicken Sie auf Weiter um den Vorgang fortzusetzen 2 sx Abbrechen q ER NM aVNC Serv Cis ec ra K E Page 107 134 S4 Standup Service Manual e Now you have to open the Keyspan Install File named KeyspanUSA 1 9hsWinV37 exe You can download the file driver under http www keyspan com e Sometimes Windows will ask you if you trust the publisher of the product You confirm by clicking on the button ok e After this there should
39. al 5 4 4 ECU SE e E 126 5 4 5 Control the throttle body atttude ccc eee eee 127 5 95 PlECUICA Eege 130 EE EE EE 132 6 1 e GC HR E 132 SPEED DIreCUVOS eee ee ee eee 132 6 3 Proof of maintenance for work carried out esee 133 Page 5 134 S4 Standup Service Manual Page 6 134 S4 Standup Service Manual 1 General Information Model information Identification number Engine number safety warning 1 1 2007 HSR personal watercraft Identification Numbers The engine I D number and hull I D number are used to register the watercraft They are unique numbers that distinguish each watercraft from others of the same model If the watercraft is ever stolen these numbers will help identify it The owner should keep a record of these numbers in a place other than the watercraft A second hull number is hidden inside the Hull only the manufacturer knows where is this number on each ski 1 2 HIN number e AT HSRO0608K606 e AT Manufacturing Country HSR HydroSpace Racing Manufacture 000608 Sequential Serial Numbers Production Month K Month code A January B February Production Year 6 Model Year 06 Model year 6 2006 Page 7 134 S4 Standup Service Manual 1 3 Engine number Number is above the starter motor Engine Number 10017203 1 4 Three stars ultra low emission The three star label identifies engines that meet t
40. appear the install assistant from the Keyspan Software as in the picture followed Keyspan USB Serial Adapter USAI9H 3 7 Setup Keyspan USB Serial Adapter USA19H Setup stan ezsa Ex az e Now you have to click next In the next window you confirm the licence with yes e Inthe next window please select the directory where to install the files for the Keyspan Adapter and click next Page 108 134 S4 Standup Service Manual Keyspan USB Serial Adapter USAI9H 3 7 Setup Choose Destination Location Select folder where setup will install files i Start Si E a lt eyspan USB Serial A E e eT e Now the programm will start with installing the Keyspan Adapter It takes several minutes to finish the installation depending on the hardware configuration of your PC Note If Windows call you that the program hasn t pass the Windows Logo Test select continue installation e If everything has completed you should see this window next site Please click finish to complete the installation Page 109 134 S4 Standup Service Manual Keyspan USB Serial Adapter USAI9H 3 7 Setup i3 Start z Si ES eyspan USB Serial A e Please reboot the PC restart the computer Page 110 134 S4 Standup Service Manual 5 2 Configure the Keyspan Adapter e Please connect the HSR Diagnostic cable with the Keyspan Adapter That everything works the Keyspan Adapter has to config
41. ble and explosive under certain conditions Always exercise extreme care when handling gasoline Do not smoke or allow open flames in or near the area where refueling is performed or where gasoline is stored Always refuel the watercraft outdoors and in a well ventilated area Do not fill the tank to the fuel cap If you get gasoline or oil on your skin or clothing wash it off immediately with soap and water and change clothing The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Only run engine outdoors or in a well ventilated area Never run the engine for more than 15 seconds without cooling water supply Page 10 134 S4 Standup Service Manual 1 8 General data 2007 Hydrospace S4 Turbocharged LONO M Height EE N A Fuel Capacity 18 liters 4 75 US Gal 2 29 m 90 15 in 0 74 m 29 13 in 168kg 370 16 in Stand up Emission Certification Three Star Ultra Low Emission Emission control system SFI Sequential Fuel Injection U FUEL SPARK PLUG SPARK PLUG GAP HORSEPOWER ENGINE DISPLACEMENT NUMBER OF CYLINDER CYLINDER Lining Material BORE x STROKE COMPRESSION RATIO CYLINDER COMPRESSION Cooling System THERMOSTAT OVER HEATING WARNING OVER HEATING Cooling NDUCTION TYPE LUBRIFICATION OIL REQUIREMENT RPM LIMITER Exhaust System ENGINE MANAGEMENT SYSTEM FUEL DELIVERY IDDLE SPEED MAGNETO GENERATOR OUTPUT BATTERY F
42. ched before that 4 See chapter Decommissioning at the end of the season 2 3 Decommissioning at the end of the season The decommissioning of the vehicle is necessary e atthe end of the season if the vehicle will be decommissioned during the winter months e if the vehicle will not be used for more than 30 days In addition to the maintenance work described in the maintenance interval table under end of the season various other service work is also required e Conserve the cylinders Check spark plugs See Chapter Checking the spark plugs Page 20 134 S4 Standup Service Manual Fill approx 10 ml 0 34 oz US of clean motor oil directly through the spark plug holes Before you replace the spark plugs crank up the motor briefly with the starter Replace the spark plugs Never fill more motor oil than specified into the spark plug holes Too much motor oil can cause engine damage e Fill the fuel tank all the way A full fuel tank prevents the formation of condensation inside the tank e Add fuel stabilizer After approx 30 days fuel begins to decompose You can use any common fuel Stabilizer in order to maintain the fuel quality 2 4 Motor oil and oil filter 2 4 1 Oil level check IMPORTANT Use a clean lint free cloth The oil level must be measured with oil warm from operation approx 80 C 176 F and with the motor at a standstill Measurements with cold oil are not meaningful The d
43. ction Offset 1 000 Frame Number MM Idle Valve Offset 0 00 Engine Number 1000918000 Date 27 09 2005 Calibration Map ID Set End Line Yalues Set Default End Line Parameters Read Hour Meter 0 2r HH MM Example for correct idle settings 11 Now snug down the lock nut 12 Click on the button Set End Line Values saves the values into the ECU 13 With a click on the button Close x you quit the ECU Setup To start the diagnostic you have to click on the button Diagnosi A click on the button Read Diagnostic reads out the error memory from the ECU With the register cards Sensors Actuactors Injection and Ignition you can browse between the individual engine building groups Any error will be indicated with the value ERROR Page 129 134 S4 Standup Service Manual 5 5 Electrical System p e 1 a PH z Se ji La r E i EE Paes Kl emm Page 130 134 S4 Standup Service Manual GS PAN ad md 20121 Page 131 134 S4 Standup Service Manual 6 Appendix 6 1 General Data Hydrospace Handels und Produktions GmbH amp Co KG Address Wiener Stra e 71 3380 Pochlarn Austria 6 2 Directives Hydrospace thus confirms that the construction of the engine corresponds to the following pertinent conditions EU directive about sport boats 94 25 EG with addendum 2003 44 EG USA EPA Fede
44. e crankcase sump The remaining vapors are collected at the top of the separator and routed to the air intake flame arrestor where they are drawn into the intake air stream and burned CHANKCASE SUMP 4 20 4 Low Pressure Pump Removal Installation NOTE The engine must be removed to access the low pressure pump 1 Remove the crankcase bedplate from the lower crankcase 2 Remove the fasteners securing the screen to the bedplate and pump 3 Remove the pump from the bedplate NOTE The low pressure pump is not serviceable and must be replaced as one component is when operation is suspect Page 103 134 S4 Standup Service Manual 4 20 5 High Pressure Pump Removal Installation NOTE The engine must be removed to access the high pressure pump ER RE SMS 1 Remove snap ring Carefully extract rotor cover from X crankcase INNER ROTOR HETAINING CAP 2 Extract outer and inner rotors from bore Remove timing rotor from shaft 3 Carefuly remove timing key OUTER ROTOR m e O RINGS NOTE Always use a new timing key and o rings P during pump assembly CHARER FACES OUT NOTE Verify snap ring bevel faces outward Page 104 134 S4 Standup Service Manual 4 20 6 High Pressure Oil Supply GREEN LOW PRESSURE PRE FILTRATION BLUE HIGH PRESSURE PRE FILTRATION RED HIGH PRESSURE POST FILTRATION Page 105 134 S4 Standup Service Manual gt ELECTRICAL SYSTEM P
45. esired motor temperature is achieved after a driving time of approx 10 minutes at 4000 4500 U min RPM Measurement with a motor warm from operation is necessary because the oil volume changes depending on the temperature To avoid mistaken measurements the vehicle must be level If the motor is operated for a longer time under extreme conditions the oil level may reach the MAX marking Page 21 134 S4 Standup Service Manual 1 Unscrew the oil dipstick 1 from the oil tank and wipe it clean with a cloth 2 Replace the oil dipstick in the oil tank Do not screw it in Then remove it again and read the oil level With a motor warm from operation the oil level must be just below the MAX marking The difference between MIN and MAX is approx 0 5 liter 0 53 at US Under running the MIN marking and exceeding the MAX marking can cause severe and under some circumstances irreparable damage to the engine Page 22 134 S4 Standup Service Manual 2 4 2 Changing the motor oil and oil filter e Oil extraction pump e Catch basin for old oil fill volume at least 4liters 4 3qt US e Flathead screwdriver or wrench to open the screw clamps e Torque wrench to close the screw clamps e TorquewrenchSW 27 11 16 for oil filter cover e Possible hose extension for oil feed hose with screw clamps e Funnel tube for motor oil e Motor oil see chapter Operating materials e Oilfilter see spareparts catalogue
46. he Air Resources Board s Personal Waterwraft and Outboard marine engine 2008 exhaust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission Engines 1 5 Safety instructions Under the handpole 1 6 CE Sticker Under the handpole bracket rosc Pace Hydrospace GmbH amp CoKG A 3380 Poechlarn Max b 1 Max 1 P 120 kg Ga Page 8 134 S4 Standup Service Manual 1 7 Service Guidelines Safety Warnings Clean inside and outside of watercraft prior to servicing Clean all parts before installing Always use a Service apron to prevent damage to foot well and top deck fiberglass Watch for sharp edges which can cause personal injury Protect hands and arms when working with sharp components Always use a soft faced hammer and extreme care when removing difficult or stuck components some fasteners are installed with locking agents or lubricants Use of impact drivers will aid in fastener removal Always follow torques specifications located throughout manual Fasteners secured with either too little or too much torque may fail and cause severe property damage injury or death Always follow torque sequence patterns when founding this manual Tighten each fastener evenly and to the specified torque value and with specified locking agent Always use new gaskets o rings and seals clips cir clips and snap rings when assembling components Never reuse
47. iming chain 8 Install low pressure pump and screen into bedplate Clean bedplate and lower crankcase mating surfaces 9 Apply a thin bead of Three Bond 1215t to the mating surface and Install the bedplate Tighten fasteners to specification 10 Install the high pressure oil pump assembly as outlined on page 4 12 11 Rotate the engine 180 Cylinder Head Up 12 Coat the gears located at the front of the engine with engine oil 13 Install the starter motor gear low pressure oil pump idler gear Page 96 134 S4 Standup Service Manual 14 If the starter motor was removed reinstall and tighten fasteners to specification 15 Attach the starter motor battery cable to the motor at this time 16 Press the water pump shaft into the mechanical seal 17 Apply a thin bead of Three Bond 1215t to the front gear cover mating surface 18 Install the front gear cover Tighten fasteners to specification 19 Install the water pump impeller Tighten impeller nut to specification 20 Install water pump housing and coolant hose Tighten fasteners to specification Page 97 134 S4 Standup Service Manual 21 Apply a generous amount of engine oilto thecrankshaft end and roller bearings 22 Install the roller bearing starting gear and flywheel key into end of crankshaft 23 Install the flywheel on to the crankshaft Verify flywheel fits over key 24 Apply Loctitet 262 to flywheel bolt and install
48. in P d 4 15 10 High Pressure Oil Pump Inspection Measure relief spring free length and piston dimensions e Out of specification Replace spring and piston Page 84 134 S4 Standup Service Manual 4 15 11 Chain Tensioner Verify chain tensioner function 1 Push tensioner into housing until flush with threaded housing Tensioner should lock into place 6 audible clicks should be heard when tensioner is pushed in from fully extended position 2 Once locked push tensioner inward Tensioner should activate and spring outwards e Replace tensioner assembly if tensioner will not lock then engage when pushed inward from locked position Chain Tensioner Guides Visually inspect both chain guides e Replace guides if any cracking or abnormal wear and tear is found NOTE Tensioner chain guide shown 4 15 12 Starter Motor Clutch Inspect clutch function e Clutch should move freely when rotated clockwise e Clutch should not rotate freely when rotated counter clockwise e Inspect rollers for wear and tear Replace assembly if found Page 85 134 FULLY EXTENDED INSPECT FOR WEAR S4 Standup Service Manual 4 15 13 Timing Chain Inspect timing chain e Replace timing chain if any damage obvious wear and tear or broken mis shaped plates are found 4 16 Engine Assembly 1 Remove any remaining gasket material from the upper and lower crankcase mating surfaces 2 Remove gasket mate
49. in writing for warranty service See Proof of maintenance for work carried out The vehicle owner or user is responsible adhering to the maintenance intervals HSR assumes no liability for damage that arises due to maintenance not carried Out Page 18 134 S4 Standup Service Manual 2 1 Maintenance work by the user of the vehicle 2 1 1 Regular checks before driving Always check the oil level before driving See Chapter Oil level check Under running and exceeding the motor oil fill level Specified in this manual can cause damage to the Engine 2 1 2 Rinse sea water cooling circuit after driving In order to protect the sea water cooling circuit against soiling calcium deposits and such the sea water cooling circuit must be rinsed after each use See the vehicle manufacturer s service manual Soiling in the sea water cooling circuit can cause severe engine damage Page 19 134 S4 Standup Service Manual 2 2 Maintenance intervals Activities on the engine must be carried out by trained service personnel Maintenance 1 maintenance interval hi At end of Activity Procedure h season S r Motor oil and ELEM oil filter E wt mags fp Lena cess 3 53 158 1 h hours of operation 2 or at least once a year if the hours of operation specified above are not reached before that 3 or at least every two years if the hours of operation specified above are not rea
50. ing rod 35 Always keep the connecting rod plain bearings rod caps and bolts with the piston assembly the engine was manufactured with 36 Remove the crankshaft assembly from the crankcase Remove each crankshaft plain bearing from both crankcase halves and place with its original crankshaft journal NOTE Always mark the bearings for identification during assembly and oil clearance measuring proce dures Page 72 134 S4 Standup Service Manual 4 15 Engine inspection procedures 4 15 1 Valve Inspection NOTE Valves cannot be replaced If valve face is burned or excessively worn replace valve Measure diameter of valve e Out of specification Replace Measure valve face width e Out of specification Replace valve Measure valve seat contact width 1 Apply light coating of Prussian Blue or similar dye compound to valve face 2 Install valve into valve guide 3 Tap valve several times to make a clear impression on the valve face Do not rotate valve 4 Remove valve and measure valve seat width e Out of specification Recondition or re e place cylinder head Page 73 134 S4 Standup Service Manual Measure valve margin thickness e Out of specification Replace valve Measure valve stem diameter e Out of specification Replace valve Measure valve guide inside diameter e Out of specification Replace valve guide Page 74 134 S4 Standup Service Manual Measure val
51. is imprinted on the side of each bearing REPLACEMENT BEARING THICKNESS YELLOW 0679 0681 1 726 1 731mm BLUE 0681 0683 1 731 1 736mm GREEN 0683 0685 1 736 1 741mm If the measured clearance is within specification replace with new bearings with the same color code If the oil clearance is outside of specification install the BLUE color coded bearings and re measure oil clearance If the measured clearance is too small install a YELLOW bearing If the measured clearance is too large install a GREEN bearing If the used bearings reveal an oil clearance of 04 and 05mm install new bearings with the same color code Page 80 134 S4 Standup Service Manual 4 15 7 Connection Rod Inspection Measure big end oil clearance NOTE Do not move crankshaft or connect ing rods until measurement process is com pleted 1 Remove lower connecting rod caps 2 Place a piece of Plastigauge across the journal surface Install lower rod caps with journal bearings installed 3 Torque rod bolts to specified torque 4 Remove caps and measure each compressed piece of Plastigauge 5 Reference bearing replacement guide if bearing oil clearance is out of specification e Out of specification Replace connecting rod bearings Measure small end inside diameter e Out of specification Replace connecting rod Connecting Rod Bearing Replacement Guide Replacement of the connecting rod bearings is required
52. ngine crankcase The high pressure pump draws oil in from the oil storage tank and supplies oil to all of the internal engine components The low pressure pump supplies approximately twice the amount of oil to the oil storage tank than what the high pressure pump requires This ensures a constant supply of oil A small amount of pressurized oil is supplied to the turbocharger bearing house and oil storage tank antisiphon valve The anti siphon valve is located on top of the oil storage tank The valve works by preventing oil from the tank to back feed into the engine in the even that oil pressure is lost Watercraft Rollover Page 101 134 S4 Standup Service Manual 4 20 1 Low Pressure Oil Circuit ENGINE PET OIL STORAGE SUMP OIL COOLER TANK 4 20 2 High Pressure Circuit OIL dopo CRANKCASE MAIN BEARINGS BALANCE SHAFT BEARINGS pHEBSURE L warten d FILTER PISTON OIL JETS PUMP o WD ae SE ANTI SIPHON VALVE CYLIN E VALVE THAIM TURO p RELIEF VALVE DRAIN TO SUMP Page 102 134 S4 Standup Service Manual 4 20 3 Crankcase Ventillation Engine blow by is recovered via the oil separator or cyclone The oil separator is located on the oil storage tank Engine oil and fuel vapors are collected in the top housing of the oil storage tank These vapors are routed to the separator Heavy elements such as oil and unburned fuel are collected at the bottom of the separator and are routed back to th
53. nning the Engine HSR recommends that during the first five hours of operation you should not operate the engine over 6 000 U min RPM This protective running in has a positive effect on the engine s lifespan 1 14 Operating the engine without sea water If it is necessary to operate the engine longer than 30 seconds without sea water the vehicle s rinsing equipment must be used See chapter Maintenance Rinse sea water cooling circuit after driving The engine may only be operated at idle speed for a maximum of 30 seconds without sea water Engine damage due to overheating Page 16 134 S4 Standup Service Manual 2 MAINTENANCE Page 17 134 S4 Standup Service Manual 2 Maintenance The table in chapter Maintenance intervals provides the manufacturer s recommended intervals for maintenance work If you follow the maintenance recommendations a long lifespan of the engine can be achieved and unnecessary environmental damage prevented The Maintenance intervals specified in the table should not be exceeded by more than 10 If not stated otherwise all activities on the engine described in this manual must be carried out by trained service personnel During the warranty period maintenance and repair work may only be carried out in Weber Motor service stations or in associated shops If necessary contact your vehicle dealer Weber Motor AG reserves the right to demand that proof of warranty be provided
54. oler Mounting Fasteners EE M6 x 35 Page 49 134 S4 Standup Service Manual 4 1 5 Intake Manifold Specific Fastener Torque Specifications Component FT LBS Fastener s Manifold to Cylinder Head M6 x 30 o 10 o Lower Bracket to Lower 22 30 M8 x 30 Crankcase 4 1 6 Alternator Assembly Specific Fastener Torque Specifications Component FT LBS Fastener s Cable Clamp Loctite 272 Sprague Clutch 10 Loctite 2752 M6 x 16 9 Ti 4 1 7 Fuel Rail Specific Fastener Torque Specifications Fuel Rail Fasteners Loctite 243 M6 x 20 Page 50 134 S4 Standup Service Manual 4 1 8 Engine Management Components Sensor Specific Fastener Torque Specifications Temperature Pressure m x 10 Sensor MAP Temperature Pressure M6 x 10 Sensor Intake Manifold Crank Position Crank Position Speed Sensor Sensor 7 SE x 10 EE Manifold Temp NEN Sensor Ignition Coil Fasteners Koch 10 Spark Plugs 2 ae Grease Starter Motor Fasteners Nyogel M6 x 50 4 1 9 Balance Plate PTO Specific Fastener Torque Specifications Balance Plate to Crankshaft Loctite 577 M10x1x 45 4 1 10 Engine Mounts Specific Fastener Torque Specifications Front Engine Mount to 40 55 Loctite 243 M10 x 80 Lower Crankcase Rear Engine Mount to 40 55 M10 x 40 Crankcase and Lower Crankcase Page 51 134 S4 Standup Service Manual 4 2 Oil filter assembly FI
55. over until all valve Plays of the first cylinder are adjusted Page 32 134 S4 Standup Service Manual 9 Press the rocker downwards with a 24 combination wrench 12 10 Clamp both valves by pressing in the sliding piece 13 11 Remove the adjustment plate with the bar magnet 12 Measure the strength of the adjustment plate and replace with an adjustment plate with which the permissible tolerance is adhered to 13 Replace the adjustment plate in the spring seat 14 Remove the sliding piece 13 and to check the valve play measure again 15 Repeat this procedure with all Valves of the first cylinder Page 33 134 S4 Standup Service Manual 2 6 5 Checking the valve of the 2 cylinder 16 Start the vehicle s starter and let the engine crank until both cams of the first cylinder are pointing upwards The rocker of the second cylinder demonstrates a little play 17 Check the valve play of the second cylinder in the same way you did the first cylinder 2 Malfunctions If you cannot correct a malfunction yourself using the table below contact your vehicle dealer s customer service In case of improperly made repairs the warranty is voided and HSR is not liable for any resulting subsequent damage 2 7 1 Engine does not crank Possible cause Main power switch not plugged in Plug in main power switch Page 34 134 S4 Standup Service Manual Battery voltage too
56. ral Register 40 CFR Part 91 USA CARB 13 California Code of Regulation Article 4 7 Spark Ignition Marine Engines Page 132 134 S4 Standup Service Manual 6 3 Proof of maintenance for work carried out Date Work carried out Motor oil change Status Oilfilter change Spark plug change Hours of operation Valve play checked Valve play adjusted Company seal signature Date Work carried out Motor oil change Status Oilfilter change Spark plug change Hours of operation Valve play checked Valve play adjusted Company seal signature Page 133 134 S4 Standup Service Manual Date Work carried out Motor oil change Status Oilfilter change Spark plug change Hours of operation Valve play checked Valve play adjusted Company seal signature Date Work carried out Motor oil change Status Oilfilter change Spark plug change Hours of operation Valve play checked Valve play adjusted Company seal signature Page 134 134
57. rial from bedplate mating surface 3 Clean the following parts with engine cleaning solvent e Upper Lower Crankcase e Cylinder Head e Bedplate e Lower Sump e Crankshaft Balance Shaft 4 After cleaning parts blow dry with compressed air sca Gee 5 With the engine facing up on stand lubricate cylinders with engine oil ae 6 Obtain both piston assemblies Lubricate piston assemblies with engine oil 7 Install the upper and oil control rings with the markings facing upwards SPRING OIL CONTROL RING PISTON MARK SCH 8 Place ring compressor tool on top of one cylinder 9 Align the ring end gaps as outlined in the photo The piston mark will face the INTAKE SIDE of the engine once installed into the cylinder Page 86 134 S4 Standup Service Manual 9 Carefully install each piston assembly into the cylinders Take care in not scratching the cylinder bore 10 Install the intake side chain guide Tighten fastener to specification 11 Carefully rotate engine 180 Do not allow the pistons to fall out of cylinders 12 Select and install the connecting rod crankshaft main bearings and balance shaft bearings Selection is made using bearing selection process described in this chapter 13 Coat all bearings and journals with engine oil Install water pump drive gear into crankcase 14 Install the chain tensioner guide into the exhaust side of the crankcase Tighten fastener to specification
58. rocket 7 Allow three to four chain links to fall past the cylinder head parting line NOTE Verify the chain is not caught on the bal ance shaft sprocket and that the marks on the gears are still in alignment Page 92 134 S4 Standup Service Manual 8 Wrap the chain around the camshaft sprocket 9 While firmly holding the chain against the camshaft sprocket remove the stuffer and wrap the chain around the balance shaft sprocket and under the crankcase support member NOTE The hooked end of the Timing Chain Hook Stuffer Tool will simplify pulling the chain around the sprocket 10 Carefully drop the chain UNDERNEATH the crankshaft and around the chain guide NOTE Do not drop the chain around the OUT SIDE of the crankshaft When performed prop erly the chain should drop easily through the engine and protrude from the cylinder head Page 93 134 S4 Standup Service Manual 11 Rotate the camshaft until one of the holes in the PTO end points to the floor 12 Install the Camshaft Alignment Tool PN PW 47077 into the hole press against the rocker arm towers NOTE The Camshaft Alignment Tool will lock the camshaft into the correct timing position in relation to the crankshaft and balance shaft 13 Wrap chain around camshaft sprocket and secure links with new pins and plate assembly NOTE Do not use the chain crimper to as semble chain links at this time 14 Rotate the engine 180 C
59. s outward towards rear of engine Always use new o rings during installation and reassembly Elbow pipe points down and toward the heat exchanger Page 56 134 S4 Standup Service Manual 4 7 High pressure oil pump assembly BALANCE SHAFT TIMING KEY BALANCE SHAFT TIMING ROTOR i iN d zi i zA A AAR OUTER ROTOR Ln F RETAINING CAP O RINGS SNAP RING CHAMFER FACES OUT Assembly Notes Use LIBERAL amounts of engine oil on timing rotor inner and outer rotors D of retaining cap and retaining cap o rings during oil pump assembly Snap ring chamfer must face outwards towards rear of engine when installed Verify retaining cap does not move when snap ring is installed An audible click must be heard and alignment pin must be inserted properly into engine case when installing the timing rotor into the oil pump bore Verify balance shaft timing key is oriented properly inside shaft keyway Page 57 134 S4 Standup Service Manual 4 8 Exhaust side chain guide tensioner assembly COMPONENT LAYOUT C TENSIONER MB X 25 LOCTITE 243 SCH E cs l i fi ub l 2m i Eeer 4 d E MF yp CAN kA i aud I os WA TENSIONER PLUG d M t 4l Hope WOH M d A cy J Wu i i M d S TIMING CHAIN MAN M H MUST USE CHAIN BREAKER TO WO TEE M DISASSEMBLE AND REASSEMBLE MO T 3 NA MB X 25 AA A NM L LOCTITE 243 W ON NAM A WA A eech
60. tank Identify each hose and its location during removal 4 Lift the oil storage tank up and out of the cradle 5 Remove the two lower tank hose connections Identify each hose and its location during removal 6 Carefully lift the oil storage tank out of the engine compartment 7 Locate and remove the four engine mounting nuts and washers NOTE The hoist chains must allow the engine to be moved in any direction and at any pitch CAUTION The lifting hoist must be able to lift at least 250 Ibs 113 kg 3 2 Engine Installation The installation of the engine and engine subsystems is the reverse of their removal During engine installation several important notes must be made e Always verify the correct number of engine mounting strap shims are installed on each engine mounting post Remove the pump to check driveshaft alignment add shims to upper or lower the engine e Always verify that the engine does not interfere with critical routings such as the steering cable cooling hoses and main wiring harness e Steering cable must be fix on the front left motor mounts to avoid damage from engine Page 41 134 S4 Standup Service Manual DISASSEMBLY INSPECTION AND RE ASSEMBLY ENGINE Page 42 134 S4 Standup Service Manual 4 Engine Disassembly Assembly 4 1 Engine Specifications 8 Valve SOHC Parallel Twin Cylinder w Balance Shaft Four Stroke 85 x 66mm 3 346 x 2 598 140 14 psi 9 6 1 bar
61. the front of the engine Install flywheel puller bolt into flywheel HSROO 99 01 076 Carefully tighten puller bolt until flywheel comes off of crankshaft nose Photo l 10 Remove the flywheel timing key and roller bearings from crankshaft Page 67 134 S4 Standup Service Manual 11 Photo of front of engine Remove the starter motor drive gear assembly A and oil pump drive gear B Photo J 12 Remove lock pin and rotate engine 180 Remove the sump cover Photo k NOTE The sump oil pump is attached to the inside of the sump cover 13 Install crankshaft hand crank PN PW 46981 into nose of crankshaft Tighten lock nut against crankshaft 14 The high pressure oil pump is located on the PTO side of the engine It is connected to the balance shaft Remove the snap ring from the high pressure oil pump pa ee cover Carefully extract the cap outer and inner rotors A RINGS timing key and timing rotor from engine Illustration 1 Gi i Ta f d ll U I Y INNER JL ROTORS SNAP RING ILLUSTRATION 1 Page 68 134 S4 Standup Service Manual 15 Rotate the engine assembly 180_ so that the valve train is up Using the hand crank crank the engine until the PTO piston is at TDC on the compression stroke BOTH PTO ROCKER ARMS WILL BE LOOSE 16 Using a flat head screwdriver push the rocker arm pins out enough to expose the detents on the pins Remove the pins from the cylinder head Photo L
62. the oilfilter 5 and O ring 6 12 Coat the O ring 6 lightly with motor oil gt During reassembly make sure that the oil filter snaps in IMPORTANT Assembly occurs in reverse order Please note instructions after this symbol gt Page 25 134 me ie S4 Standup Service Manual 2 4 5 Refilling the motoroil 13 Fill oil tank with 2 5 liters of motoroil 14 Close the oil tank with the oil dipstick 15 Warm up the motor in a body of water for approx 10 minutes at 4000 4500 U min 16 Fill up the oil level with a motor warm from operation until just below the MAX marking 2 5 Spark Plugs 2 5 1 Checking the spark plugs IMPORTANT e Socket wrench 16mm 5 8 e Feeler gauge measurement range 0 69 mm 0 84 mm 0 0272 0 0331 in e Torque wrench e 2x spark plugs 2 5 2 Removing the spark plugs 1 Remove cable harness on the ignition coils 1 2 Loosen the cable harness on the cable holders 2 3 Remove the cable harness on the injection valves 3 Page 26 134 S4 Standup Service Manual gt Before disassembling make sure that the plugs of the ignition coils and the injection valves are not switched during assembly 4 Remove the screws and washers 4 gt 5 Remove the ignition coils 5 gt Install the spark plugs only ina cold engine gt Grease the threads of the spark plugs with commercial graphite grease gt Tightening torque 10
63. ts in sequence 180 Torque crankcase fasteners in sequence 18 ft lbs 24 25 Nm Page 60 134 S4 Standup Service Manual 4 10 Piston assembly COMPONENT LAYOUT UPPER RINGS PE i PISTON PIN CONNECTING ROD BEARINGS Fa S Ea K f H C CONNECTING ROD ij Al 73 1 i i Fj d Li Wd a V Se A ROD CAP FASTENERS oat M10 X 1 32 cae ENGINE OIL Assembly Notes AVAILABLE BEARINGS 1 RED 0783 0785IN 1 990 1 995mm 2 YELLOW 0785 0787lN 1 995 2 000mm 3 BLUE 0787 0789IN 2 000 2 005mm Rod Cap Fastener Torque 1st Step 7 ft lbs 10 Nm 2nd Step 14 ft lbs 20 Nm 3rd Step Turn 90 __ APPLY ENGINE OIL TO FASTENER THREADS PRIOR TO INSTALLATION Connecting rod caps feature a cracked mating surface Cap must be marked during removal and installed correctly Page 61 134 S4 Standup Service Manual 4 11 Valve assemblies Di 1 VALVE SHIM __ VALVE KEEPER SPHIMG RETAINER 1 A d i Wa ik nl TE L L A h D d roe i i i i d i HI i A SPRING Fan T k A SPHING BUCKET i VALVE Page 62 134 S4 Standup Service Manual 4 12 Balance plate PTO assembly CAANK SHAFT FASTENERS d Op O M10 X 1 X 45 IM ff TE LOCTITE 577 Lo ae o nni i Ti l BALANCE PLATE Assembly Notes Balance Plate Fastener Torque 51 ft lbs 70 Nm Apply Loctite 5
64. ure on a Port between 1 4 as shown in the following steps e Click on the Windows Start Button and select Programs Then select the entry Keyspan Usb Serial Adapter and click Serial Keyspan Assistant Arbeitsplatz PROUT to Windows Update x v Windows Katalog BR Neues Office Dokument p Office Dokument ffnen 49 Dokumente Ce Einstellungen ES Suchen Hilfe und Support F Ausf hren ini o Herunterfahren 3 Start Programmzugriff und standards e Autostart E Microsoft Office Tools CH Spiele ig Symantec Client Security fi Ultravnic EH WinRAR e Zubeh r amp Internet Explorer KeUSDS Ons Microsoft Excel Microsoft Outlook Microsoft PowerPoint Microsoft Word Wi MSN Explorer Zi Outlook Express Sr Ww Ww we Ww we ge Remoteunterst tzung e Windows Media Player 3 Windows Messenger If FreePDF xP gt EH 54500 gt K Adobe Reader 8 Fi SAP Front End gt Ei Business Explorer L b ci ep Documentation html local w Documentation pdf local dm b Ort C Programme Keyspan USB Serial Adapter e Then the Keyspan USB Serial Assistant window should appear Page 111 134 S4 Standup Service Manual Keyspan USB Serial Adapter USA1 9H Assistant Adapter Status Properties Port Mapping Diagnostics Help age USAISH 1 COMS Idle Install the USB to Rs232 Adapt
65. ve stem run out e Out of specification Replace valve Measure valve spring free and installed length e Out of specification Replace spring 4 15 2 Cylinder Head Inspection Measure cylinder head warpage e Out of specification Replace cylinder head Page 75 134 S4 Standup Service Manual 4 15 3 Cylinder Block Inspection Measure cylinder bore size e Out of specification Replace cylinder block NOTE Cylinders are plated with NiCaSil Measure cylinder for taper and out of round limits 1 BORE Maximum diameter of Da Df 2 TAPER Maximum of Da De and Db Df 3 Out of Round Maximum of Da Db and De Df e Out of specification Replace cylinder block 4 15 4 Camshaft Inspection Measure camshaft width e Out of specification Replace camshaft Page 76 134 S4 Standup Service Manual Measure cam lobe height e Out of specification Replace camshaft Measure camshaft run out e Out of specification Replace camshaft Measure camshaft bearing hole inside diameter e Out of specification Replace camshaft NOTE Bearings must be removed to measure I D Page 77 134 S4 Standup Service Manual Measure camshaft axle outside diameter e Out of specification Replace axle Measure camshaft axle clamp inside diameter e Out of specification Replace cylinder head 4 15 5 Rocker Arm Inspection Measure rocker arm axial play e Out of specification Replace rocker arm G
66. window will open ffnen Dateiname Dateityp File wc Abbrechen Selecting the Message File Here you can select the language of your Message file at the present English and Italian The language files are in the same folder like the diagnostic program After that you are asked for the saving path fort he device file This is saved in the folder Datens tze SO Page 119 134 S4 Standup Service Manual 5 4 3 Diagnostic 1 Plug off the cover cap of the multipoint diagnostic connector which is on the wiring harness Multipoint diagnostic connector 2 Connect the HSR diagnostic cable with the push pull plug i CR Connecting the diagnostic cable 1 Connecting the diagnostic cable 2 3 Now attach the other side of the diagnostic cable to the serial interface RS232 COM 1 of your computer laptop Page 120 134 S4 Standup Service Manual Connecting the lanyard 1 Connecting the lanyard 2 Page 121 134 S4 Standup Service Manual we Service 1 0 0 x OEM HSR CNS C1WBR_O9SUS dcn Open Console COM Diagnostic End OF Line 1 Console start Diagnosi Fine Linea Status Service 1010 HSR exe Should there be problems when you start the program for the first time so you could find a solution in chapter Starting the diagnostic program for the first time 6 Click on the button Console Start 1 Afterwards the following window will appear with the current values
67. x 6 895 psi Kilopascals kPa x 0 145 Pounds force per square inch psi Kilopascals kPa Kilograms force per square cm Kilograms force per square cm Kilopascals kPa C to F 9 C 40 5 40 F F to C 5 F 40 9 40 C Kilopascals kPa Page 13 134 S4 Standup Service Manual 1 9 Service Tools HROO 99 20 002 Diagnostic cable and Software HSROO 9920 003 Impeller tool HSROO 99 01 076 Flywheel removal tool HSROO Torx 50 for Head cylinder Chain Remover tool Not Available Balance Shaft Remover tool Not Available Page 14 134 S4 Standup Service Manual Oil removing tool Not Available 1 10 Operating materials The use of other operating materials causes damage to the engine and the voiding of the warranty 1 11 Fuel Unleaded gasoline according to DIN 51607 superunleaded with an octane rating of at least 95 ROZ RON or 85 MOZ MON In case of emergency unleaded fuel with 91 ROZ RON or 82 5 MOZ MON may be used for a short time Lower quality fuels should only be used in case of emergency If used regularly they cause decreases in performance and possibly damage to the engine Page 15 134 S4 Standup Service Manual 1 12 Lubricant Oil specification Recommendation HSR oil 10w60 ACEA A3 B3 B4 API SL Filling quantity Initial filling 3 3liters 3 5qt US Oil change with filter 2 4 2 6 liters 2 5 2 7qt US 1 13 Ru
68. ylinder Head Up 15 Carefully rotate the crankshaft until the timing marks on the gears are pointing at each other The valve train should resemble the illustration below p rcs Timing mark for TDC e Front eyinder n MAG OVERLAP STROKE Page 94 134 S4 Standup Service Manual 4 17 2 Engine Assembly 1 Reassemble the timing chain with a new plate Crimp the new chain pins and plates together using the Chain Breaker Tool PN PW 46985 2 Verify the chain tensioner is set in the locked position To set the chain tensioner grasp end in palm of hand and press assembly down on a hard surface The tensioner is set in the locked position when it is flush with the tensioner housing 3 Install the chain tensioner into the crankcase Tighten housing cap to specification 4 Insert the blade of a flat head screwdriver between the tensioner and the tensioner rail guide Page 95 134 A A e Ets ROUNDED PIN FITTING WITHOUT HOLE THE ROUNDED PIN PRESSES AGAINST THE SIDE IN WHICH THE NEW PLATE I8 ATTACHED DO NOT OVER PRESBS THE PLATE FULLY EXTENDED S4 Standup Service Manual 5 Verify the blade of the screwdriver contacts the face of the tensioner e SCREWDRIVER 6 Push the blade of the screwdriver against the tensioner face and twist Do this until the tensioner goes in past flush and activates 7 Once activated there should be no slack present in the t

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