Page 1 MY2004 Set-up, Service and Shop Manual SNOW HAWK 600HO...
Page 2 FOREWORD Congratulations, and thank you for buying an A.D. NOTICE: Boivin design inc. Snow Hawk™ vehicle. The information in the NOTICES is designed to appreciate the confidence in our product that you explain maintenance procedures and to ensure the have demonstrated by making this purchase best possible use of the vehicle.
Page 3 IMPORTANT MAINTENANCE WARNINGS: WARNING Never have the motor running inside a building. WARNING The exhaust fumes contain carbon monoxide, a colourless, odourless gas which can cause Carrying out maintenance of this vehicle while death or severe injuries. the motor is running can be dangerous. Injuries could result from contact with moving parts.
Page 4 MANDATORY SERVICE PRODUCTS Loctite RC/609, 10 ml Loctite 271, 10 ml Loctite 243, 10 ml Retaining compound High strength Medium-strength P/N 413 703 100 threadlocker threadlocker P/N 293 800 005 P/N 293 800 015 Sealing compound, 30 ml Loctite Primer, 128g Loctite 515, 50 ml P/N 420 297 905 P/N 413 708 100...
Page 5 MANDATORY SERVICE PRODUCTS (continued) Loctite chisel, 510g Molykote PG 54, 10g Petamo Grease Gasket/paint remover P/N 420 899 763 P/N 420 899 271 P/N 420 899 763 Molykote G-n plus. 50g Isoflex Grease, 50g Loctite 518, 50 ml P/N 711 297 433 Gasket Paste P/N 293 550 021 P/N 293 800 038...
Page 6 RECOMMENDED SERVICE PRODUCTS Bombardier injection oil Premixed coolant 50/50 Pre-mix oil 3 x 4 litres P/N 413 803 000 16 x 1 litre P/N 293 600 038 12 x 500ml P/N 413 803 100 Synthetic injection oil Synthetic injection oil Fuel stabilizer Bombardier Formula XP-S II Bombardier Formula XP-S II...
Page 7 RECOMMENDED SERVICE PRODUCTS (continued) Storage oil 12 x 350 g Synthetic Grease 400 g LMZ Grease No 1, 400 g Canada P/N 413 711 600 P/N 413 711 500 P/N 413 707 500 P/N 413 711 900 Molykote 111, 50 g Bombardier lube Silicone dielectric grease, 3 oz P/N 413 707 000...
Page 8 RECOMMENDED SERVICE PRODUCTS (continued) Anti-seize compound, 236 ml Brake fluid SRF ( DOT 4 ) Brake fluid GTLMA (DOT 4) P/N 293 800 070 P/N 293 600 063 P/N 293 600 062 Shock oil 32 oz Pulley flange cleaner, 320 g Heavy Duty Cleaner P/N 293 600 035 P/N 413 711 809...
Page 9 RECOMMENDED SERVICE PRODUCTS (continued) Loctite 592, 50 ml Plastic and vinyl cleaner Loctite 648, 5 ml Pipe sealant P/N 413 711 200 High temperature and strength P/N 293 800 018 retaining compound P/N 413 711 400 Loctite Ultra Copper, 80 ml Loctite 5150, 300ml High temperature RTV sealant P/N 293 800 066...
Page 10: Table Of Contents
TABLE OF CONTENTS GENERAL INSTRUCTIONS PERIODIC MAINTENANCE FUEL SYSTEM ENGINE REMOVAL REWIND STARTER COOLING SYSTEM ENGINE (CYLINDERS / HEAD / BASE) PRIMARY TRANSMISSION SYSTEM SECONDARY TRANSMISSION SYSTEM HYDRAULIC BRAKE SYSTEM FRONT FORK AND TWIN-AXIS SKI REAR SUSPENSION, SHOCKS AND TRACK CHASSIS AND STEERING ELECTRICAL SYSTEM DIMENSIONS AND TOLERANCES...
Page 11: General Instructions
GENERAL INSTRUCTIONS 1 - 1 FIRST CONTACT The SNOW HAWK™ is a completely new type of vehicle. Technically speaking, it is a cross between a snowmobile and a motorcycle. However, its behaviour depends on the conditions in which it is used. Sometimes, it will react more like a bike while at other times, it will react more like a snowmobile or a jetski.
Page 12 GENERAL INSTRUCTIONS 1 - 2 LOCATION OF MECHANISMS AND CONTROLS (503 SHOWN, 600HO IDENTICAL) 1. Throttle control 2. Brake lever 3. Parking brake lever 4. Engine-cutoff (tether) 5. Gas tank cap 6. Dimmer switch 7. Choke control 8. Emergency-stop button 9.
Page 13 GENERAL INSTRUCTIONS 1 - 3 FUEL This vehicle is powered by a two-stroke engine that uses a pre- mixed gasoline and oil mixture. Gasoline: Regular unleaded gas with a minimum octane rating of 89 (R+M)/2 Motor oil: Bombardier / ROTAX Formula XPS Synthetic Gasoline Pre-mix oil (P/N 293600045) ( L )
Page 14: Operating Instructions
GENERAL INSTRUCTIONS 1 - 4 OPERATING INSTRUCTIONS Pre-driving inspection WARNING A pre-driving inspection is of the utmost importance before using the vehicle. Do not start the machine until you are sure all mechanisms and controls are functioning properly. Failing to proceed in the prescribed manner may result in severe injuries or even death.
Page 15 CAUTION The timing of all Snow Hawk 600HO’s is retarded by 3 a period of 1-hour during the first stages of the break-in period. You may notice a slight increase in performance and a reduction in fuel consumption after this time.
Page 16 Inspection – 10 hours A general inspection is recommended after the first 10 hours of use. This inspection must be carried out by an authorized SNOW HAWK ™ dealer. NOTICE: Most of the wear in this vehicle occurs during the break-in period.
Page 17 GENERAL INSTRUCTIONS 1 - 7 Roll the two O-rings down and pull the two white plastic collars down over the fork legs. To ensure that they will not interfere, let them hang loose at the base of the fork leg. Remove the circular fork disc De-latch the two rubber latches on the sides of the belly pan (towards the rear of the vehicle)
Page 18: Periodic Maintenance
PERIODIC MAINTENANCE 2 - 1 NOTICE: Regular inspection and maintenance of the Snow Hawk is of utmost importance. Follow the guidelines in the table below for optimum vehicle performance. Suggested intervals must be reduced if the vehicle is subjected to severe usage conditions.
Page 19 PERIODIC MAINTENANCE 2 - 2 2.1. CARBURETION Fuel lines and connections Check all hoses and connections in order to find and fix leaks and/or to help prevent them. Carburetor adjustment For carburetor adjustment, refer to Chapter 3 - Fuel system section.
Page 20 PERIODIC MAINTENANCE 2 - 3 Exhaust system Using a torque wrench, check the torque of the retaining bolts of the exhaust manifold. Apply a torque of 10 N-m (1 kg-m, 7.4 lbf- ft). Then, proceed to a visual inspection of the system to detect any leak or abnormality in the gasket material.
Page 21 PERIODIC MAINTENANCE 2 - 4 2.3. PRIMARY TRANSMISSION Primary and secondary clutches Remove the belt and verify that the sliding half-pulleys of the two clutches is in good working condition. To take the belt off, first use the special tool provided to open the secondary clutch (P/N 529 008 700).
Page 22 PERIODIC MAINTENANCE 2 - 5 2.4. SECONDARY TRANSMISSION Secondary transmission cog belt Examine the cog belt. Make sure it is not cracked, frayed or worn in an abnormal way. If in doubt as to the condition of the belt, replace it with a new one. Verify the tension of the secondary transmission belt according to the instructions found in Chapter 9 - Secondary Transmission System.
Page 23 PERIODIC MAINTENANCE 2 - 6 Brake pads Verify the thickness of the brake pad linings as illustrated. Brake pads must both be replaced if either one of them shows a clearance of less than 1 mm (1/32 in.). NOTICE: For the replacement of brake fluid, refer to Chapter 10 – Hydraulic Brake System.
Page 24 PERIODIC MAINTENANCE 2 - 7 2.7. REAR SUSPENSION AND TRACK Suspension Verify that all suspension bolts and nuts are well tightened, especially the four that retain the suspension to the chassis (use Loctite 243 here) Verify that none of the parts are damaged or missing.
Page 25 PERIODIC MAINTENANCE 2 - 8 2.8. CHASSIS AND STEERING Handlebar mounting bolts Verify and adjust the torque to 36.5 N-m (3.7 kg-m, 27 lbf-ft), following a criss-cross order.
Page 26 For alignment, refer to Chapter 13 – Chassis and Steering. Assembly The chassis of the SNOW HAWK is different in that most of the assembly is done by bolting components rather than welding them. Therefore, bolts must be checked and tightened as need be.
Page 27 PERIODIC MAINTENANCE 2 - 10 Porcelain Colour Probable Cause - Plug Temperature rating is too high - Plug gap too wide Light Grey (Overheated) - Air/Fuel mixture too lean - Stale gasoline - Plug temperature rating too low - Plug gap is too small Blackish (Fouled) - Air/Fuel mixture too rich - Oil/Fuel mixture too rich...
Page 28 PERIODIC MAINTENANCE 2 - 11 Symbols used on the NGK spark plugs...
Page 29 PERIODIC MAINTENANCE 2 - 12 Spark plug gap The suggested gap is 0.45 mm (0.018"). For more information, refer to Chapter 14 – Electrical System. Wiring Harness Electrical wires and connections should be inspected visually to quickly locate broken wires or faulty connections. For more information, refer to Chapter 14 –...
Page 30 FUEL SYSTEM 3 - 1 FUEL SYSTEM...
Page 31: Fuel System
FUEL SYSTEM 3 - 2 Fuel System Ref. Part Descriptions ADB-SH1 Fuel tank 31L 322111-BKL Gas tank cap 907301 7/32" gas tank (overflow) SH15 Rubber Strap 15" ADB-0140 Air box 508,000,240 Intake horn 508,000,199 Foam 508,000,132 Intake adaptor 508,000,346 Gear clamp 415,128,729 TM40 Carburetors (racked together, as a pair) 512,059,835...
Page 32 FUEL SYSTEM 3 - 3 CARBURET0RS (TM 40)
Page 33 FUEL SYSTEM 3 - 4 Carburetors (TM 40) Ref. Part Descriptions 403,138,740 TM40 Carburetors (racked together, as a pair) 404,162,017 Funnel (PTO) 404,161,955 Screw 404,161,945 O-ring 404,106,200 Main jet 380 404,161,944 Pilot jet 17.5 404,162,016 Needle 9DHI12-58-3 404,162,020 Piston Valve 2.0 404,137,600 Packing 404,152,200...
Page 34 FUEL SYSTEM 3 - 5 Carburetors (TM 40) Ref. Part Descriptions 404,161,912 Screw 404,136,100 Screw 404,161,911 Screw 404,161,910 Screw 404,161,909 Lever 404,140,000 404,136,900 Holder guide 404,161,908 Spring 404,161,907 Plunger ass'y 404,161,906 Screw 404,161,905 Nipple 404,162,001 Hose 404,161,903 Screw 404,162,000 Bracket 404,161,901 Starter lever 404,161,899...
Page 35 FUEL SYSTEM 3 - 6 REMOVAL Loosen clamps # 9 retaining air box # 5 to carburetor assembly and remove air box. Disconnect the carburetor support block that is located at the middle-bottom of the carburetor assembly. Pull rearwards on the upper portion of the block to disconnect it completely.
Page 36 FUEL SYSTEM 3 - 7 CAUTION Carburetor body and jets should be cleaned with carburetor cleaner following manufacturer’s instructions. When jets are very dirty or coated with varnish and gum, replace them. WARNING Solvents with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as they are flammable and explosive.
Page 37 FUEL SYSTEM 3 - 8 DISASSEMBLY AND RE-ASSEMBLY NOTICE: To ease the carburetor disassembly and assembly procedure, it is recommended to use carburetor tool kit (P/N 404 112 000) # 20 FLOAT BOWL Unscrew drain screw # 3 and screw # 52. Remove float bowl. # 19 FLOAT AND NEEDLE VALVE ASS’Y Unfasten both screws # 18 then, pull out float and needle valve assembly # 19.
Page 38 FUEL SYSTEM 3 - 9 CAUTION After throttle slide reassembly, proceed with a leak test. See below for procedure. # 7 NEEDLE Remove carburetor cover # 12. Loosen needle retainer screw # 33. Fully open throttle and hold in this position for the following step. Move aside needle retainer # 34.
Page 39: Carburetor Adjustments
FUEL SYSTEM 3 - 10 CARBURETOR ADJUSTMENTS Adjustments should be performed following this sequence: Pilot screw adjustment Setting Mikuni TM 40 Carburetor synchronization and throttle slide height Pilot jet 17.5 17.5 (preliminary idle speed adjustment) Air screw 1.5 turns 1.5 turns Slide cutaway Throttle cable adjustment Needle...
Page 40 (drill bit size) ± 0.1 mm (±0.004'') Use a drill bit to measure the throttle slide height (see table at Snow hawk 600 HO 2004 1.6 mm ( 0,063'') right) on outlet side of carburetor (engine side). Adjust PTO carburetor first...
Page 41 FUEL SYSTEM 3 - 12 INSTALLATION CAUTION Never allow throttle slide(s) to snap shut. To re-install the carburetor, carry out the removal operations in the reverse order. Be sure that the carburetor assembly is properly inserted into the engine intake sockets before tightening the two hose clamps.
Page 42 FUEL SYSTEM 3 - 13 CHOKE CABLE ADJUSTMENT Adjust choke cable as per following procedure: Loosen choke cable housing adjusting and locking nuts. Connect choke cable on starter lever # 57. While choke lever is fully open, pull choke cable until starter lever reaches the stopper.
Page 43: Fuel Pump
FUEL SYSTEM 3 - 14 FUEL PUMP REMOVAL Install a hose pincer (P/N 295 000 076) on fuel supply line close to pump inlet. Disconnect fuel outlet line(s). Disconnect impulse line. Remove screws securing fuel pump to chassis. PUMP VERIFICATION Check fuel pump valves operation as follows: Connect clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with pump of leak test kit.
Page 44 FUEL SYSTEM 3 - 15 CLEANING AND INSPECTION Check fuel pump valves operation as follows: The entire pump should be cleaned with general-purpose solvent before disassembly. Fuel pump components should be cleaned in general purpose solvent and dried with compressed air. WARNING Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as each is flammable and...
Page 45: Engine Removal
ENGINE REMOVAL 4-1 ENGINE REMOVAL Unfasten or remove the following parts of the vehicle: Remove the hood, bellypan and rear module from the vehicle. Removing the bellypan will require that you remove the ski as well. Exhaust Pipe Remove the hose clamp retaining the exhaust pipe as well as the two forward brackets (P/N’s SH032L and SH032R).
Page 46 ENGINE REMOVAL 4-2 Front Fork Unfasten the tie rod end which connects the steering column to the upper triple clamp. Unfasten the two fork pivot bolts that retain the fork to the vehicle. The upper bolt is shown at right, the other is directly below it.
Page 47 ENGINE REMOVAL 4-3 Make a knot as shown at right. Secondary Clutch Open the secondary clutch using the the spacer tool (P/N 529 008 700). For more details, see Chapter 8 – Primary Transmission System. Remove the bolt retaining the secondary clutch to the jackshaft and then slide the secondary off the jackshaft at the same time removing the drive belt.
Page 48 ENGINE REMOVAL 4-4 Airbox Loosen the too hose clamps that fasten the air box to the rear of the carburetors and remove the airbox completely. Carburetors Unfasten the black plastic clip that supports the bottom of the carburetors. Push the top of it forward to snap it out of place.
Page 49 ENGINE REMOVAL 4-5 Cut the tie-wraps that secure the wires from the engine to the voltage regulator. Then disconnect the four-place housing (yellow, yellow and yellow wires) and the two- place housing (green and black wires) that is next to the four-place housing.
Page 50 ENGINE REMOVAL 4-6 Water Pump Oil Resrevoir Using a drill and a 3/16 in. bit, drill out the two rivets that secure the water pump oil reservoir to the MAG side chassis. Cut the tie-wrap that secures the choke cable to the oil reservoir hose.
Page 51 ENGINE REMOVAL 4-7 Loosen the hose clamp farthest towards the PTO side on the PTO side heat exchanger and disconnect the hose there. This hose runs from the head of the engine to the inlet of the tunnel-mounted heat exchangers and should remain connected to the engine when removing.
Page 52 ENGINE REMOVAL 4-8 Re-Installating Engine To re-install the engine, follow the instructions above in the reverse order. However, pay close attention to the following details : Ensure that the 4 (per side) engine plate bolts are well torqued to 37 N-m (27lbf-ft, 325 lbf-in). Loctite 243 is recommended here.
Page 53 REWIND STARTER 5 - 1 REWIND STARTER...
Page 54: Rewind Starter
REWIND STARTER 5 - 2 REWIND STARTER Ref. Part descriptions 420810865 Connecting flange 420241236 Socket head screw M6 x 16 3-12 420889764 Rewind starter 420811404 Starter housing 420939115 Rewind spring 420852286 Rope sheave 412500200 Starter rope (2200mm) 420852297 Pawl 420852305 Pawl lock 420847925 Stage sleeve...
Page 55 REWIND STARTER 5 - 3 INSPECTION NOTICE: Due to dust accumulation, rewind starter must be periodically cleaned, inspected and re-lubricated. CAUTION It is of the utmost importance that the rewind starter spring be lubricated periodically using Molykote PG 54 (P/N 420 899 763).
Page 56: Rope Replacement
REWIND STARTER 5 - 4 ROPE REPLACEMENT Pull out rope. Hold rewind starter in a vise. Slide rope and untie the knot. Pull out the rope completely. 1) Knot to be untied. NOTICE: When rope is completely pulled out, spring preload is 4 ½ turns. DISASSEMBLY Undo knot previously tied at removal.
Page 57 REWIND STARTER 5 - 5 CAUTION It is of the utmost importance that the rewind starter spring be lubricated periodically using Molykote PG 54 (P/N 420 899 763). Otherwise, rewind starter component life will be shortened and/or rewind starter will not operate properly under very cold temperatures.
Page 58 REWIND STARTER 5 - 6 Lubricate pawl # 7 with Molykote PG 54 (P/N 420 899 763) then install over rope sheave. Lubricate pawl lock # 8 with Molykote PG 54. Install over pawl. Instal stepped sleeve # 9 with its sleeve first. Lubricate a new O-ring # 10 and lock ring # 11 whit Molykote PG 54.
Page 59: Cooling System
COOLING SYSTEM 6 - 1 COOLING SYSTEM...
Page 60 COOLING SYSTEM 6 - 2 Cooling System Ref. Part descriptions 509000281 Coolant reservoir 509000187 Closure cap SH-108SA MAG side heat exchanger SH-109SA PTO side heat exchanger SH-093 Coolant tube #4 SH-094 Coolant tube #3 SH-095 Coolant tube #1 SH-096 Coolant tube #5 SH-097 Coolant tube #2 Overflow tube...
Page 61 COOLING SYSTEM 6 - 3 WARNING This vehicle is equipped with a liquid cooling system. ALWAYS ride with the rear deflector pad installed and in conditions where there is enough snow to properly cool the engine. If the red temperature light on the steering column should ever illuminate, stop immediately and let the vehicle cool down, and then find some snow.
Page 62 COOLING SYSTEM 6 - 4 Pressure Cap (No. 2): Check if the cap pressurizes the system. If not, install a new 90 kPa (13 PSI) cap (do not exceed this pressure). Thermostat: To check the thermostat, put it in a basin of water and gradually heat it.
Page 63 COOLING SYSTEM 6 - 5 COOLING SYSTEM REFILLING PROCEDURE CAUTION To prevent the formation of corrosion or freezing, always re-fill the system with the recommended premixed coolant. REFILLING PROCEDURE NOTICE: Use the 50/50 premixed coolant rated for -37°C (- 35°F) (P/N 293 600 038).
Page 64 ENGINE (CYLINDERS / HEAD / BASE) 7 - 1 ENGINE / BOTTOM END 1-12 14-20 29 N-m ( 21.5 lbf-ft 3.0 kg-m, 258 lbf-in)
Page 65 ENGINE (CYLINDERS / HEAD / BASE) 7 - 2 Engine / Bottom End Ref. Part Descriptions 1-12 420889083 Crankcase ass‘y 420640836 Hex. collar screw M8 x 75 420640431 Hex. collar screw M8 x 45 420640311 Hex. collar screw M6 x 45 205063044 Socket head screw M6 x 30 420941925...
Page 66 ENGINE (CYLINDERS / HEAD / BASE) 7 - 3 Engine / Bottom End Ref. Part Descriptions 420974535 Oil Line 420874370 Reducer fitting 420956239 Oil Line 420951260 Clamp 420951240 Clamp 420960279 45-47 420956240 Oil Reservoir Assy 420850350 Rubber Gasket 420956250 Oil Cap 420812420 Oil Seal Cover 420941430...
Page 67 ENGINE (CYLINDERS / HEAD / BASE) 7 - 4 ENGINE / CRANKSHAFT AND PISTONS...
Page 68 ENGINE (CYLINDERS / HEAD / BASE) 7 - 5 Engine / Crankshaft and Pistons Ref. Part Descriptions 1 - 9 420889090 Crankshaft Assy 420832635 Brg. 6207 420832575 Brg. 6207 420931792 Oil Seal 420832606 Brg. 420926190 Washer 420832600 Brg. 420931285 Oil Seal 420246015 Woodruff key 420945759...
Page 69 ENGINE (CYLINDERS / HEAD / BASE) 7 - 6 ENGINE / TOP END...
Page 70 ENGINE (CYLINDERS / HEAD / BASE) 7 - 7 Engine / Top End Ref. Part Descriptions 420931895 Base Gasket 0.8 mm 420931894 Base Gasket 0.7 mm 420931892 Base Gasket 0.6 mm 420931893 Base Gasket 0.5 mm 420613710 Nicasil Cylinder 420854650 Exhaust Valve Guillotine 420430110 O-ring...
Page 71 ENGINE (CYLINDERS / HEAD / BASE) 7 - 8 Engine / Top End Ref. Part Descriptions 420941925 Screw M5 x 16 420850552 Gasket 420673070 Exhaust Manifold 420889920 Engine Gasket Set 420889925 Cyliinder Gasket Set 420297906 30mL Sealing Compound 293800038 50mL Loctite 518...
Page 72 ENGINE (CYLINDERS / HEAD / BASE) 7 - 9 TOP END NOTICE: The engine must be removed from the chassis to carry out the following operations. See Chapter 4 – Engine Removal for details. TROUBLESHOOTING Before completely disassembling the engine, check airtightness. Refer to the section named LEAK TEST AND ENGINE DIMENSION MEASUREMENT at the end of this chapter.
Page 73 ENGINE (CYLINDERS / HEAD / BASE) 7 - 10 All engines are equipped with cageless piston pin Bearings, as shown at right. Once the head and cylinder(s) has been removed, Use piston pin puller (P/N 529 035 503) along with 20 mm sleeve kit (P/N 529 035 542).
Page 74 ENGINE (CYLINDERS / HEAD / BASE) 7 - 11 Screw in (LH threads) extracting nut. Pull out piston pin no. 15 by unscrewing puller until shouldered sleeve end is flush with thrust washer of piston pin bearing. Remove puller. Pull out shouldered sleeve carefully. Remove piston from connecting rod.
Page 75 ENGINE (CYLINDERS / HEAD / BASE) 7 - 12 INSPECTION NOTICE: For details, Refer to LEAK TEST AND ENGINE DIMENSIONS MEASUREMENT AT THE END OF THIS CHAPTER. RAVE System Check valve rod housing and cylinder for clogged passages. NOTICE: Oil dripping from draining hole (No. 1) indicates a loose spring or damaged bellows.
Page 76 ENGINE (CYLINDERS / HEAD / BASE) 7 - 13 Oil needle bearing with injection oil. Grease thrust washers and install them on each end of needles. The grease will help to hold them in place. Insert cageless bearing into connecting rod. Heat piston with a 100 W lamp or a heat gun before piston installation to make the insertion of the pin much easier.
Page 77 ENGINE (CYLINDERS / HEAD / BASE) 7 - 14 All Models CAUTION Always install new circlips. To minimize the effect of acceleration forces on circlip, install each circlip so the circlip break is at 6 o’clock as illustrated. Use appropriate piston circlip installer.
Page 78 ENGINE (CYLINDERS / HEAD / BASE) 7 - 15 Using a plastic hammer, tap the pusher to put the circlip in place. Make sure to install new circlips with the tab toward the top as per the following photos. CAUTION Always install mono-hook...
Page 79 ENGINE (CYLINDERS / HEAD / BASE) 7 - 16 At assembly, torque cylinder head screws to 29 N-m (21 Ibf-ft) in the illustrated sequence at right. Tighten exhaust manifold bolts to 23 N-m (17 lbf-ft) in a criss- cross sequence. Apply Loctite 243 (P/N 293 800 060) on screws threads.
Page 80 ENGINE (CYLINDERS / HEAD / BASE) 7 - 17 BOTTOM END NOTICE: The engine must be removed from the chassis to carry out the following operations. See Chapter 4 – Engine Removal for details. CLEANING Discard all gaskets and O-rings. Clean all metal components in a non-ferrous metal cleaner.
Page 81 ENGINE (CYLINDERS / HEAD / BASE) 7 - 18 INSPECTION NOTE: Refer to LEAK TEST AND ENGINE DIMENSIONS MEASUREMENT (End of this chapter) ASSEMBLY Coat lip of all seals with Petamo grease (P/N 420 899 271). 5, Crankshaft Bearing Smear anti-seize lubricant (P/N 413 701 000) on part of crankshaft where bearing fits.
Page 82 ENGINE (CYLINDERS / HEAD / BASE) 7 - 19 With the syringe, fill the outer ball bearing and inner side of outer seal with 40 to 45 mL of Isoflex grease as shown at right. Apply 6 mL of grease to MAG side outer bearing. NOTICE: If replaced with new bearing, do not apply grease as new bearings come with grease already applied.
Page 83 ENGINE (CYLINDERS / HEAD / BASE) 7 - 20 Before screwing together both parts of crankcase, seal it with sealing compound (P/N 420 297 906). Make sure surfaces are perfectly clean and degreased before applying sealing compound. Spread a seam of 1.2 mm (1/16 in) maximum in diameter on the surface of lower crankcase half.
Page 84 ENGINE (CYLINDERS / HEAD / BASE) 7 - 21 Screw all crankcase bolts in place in the following sequence and to the appropriate torque; this must be done in two steps, torquing: first, screw bolts up to 60% of the final torque (18 N-m (13.5 lbf-ft) for most of the bolts), then, tighten to the required torque (i.e.
Page 85 ENGINE (CYLINDERS / HEAD / BASE) 7 - 22 LEAK TEST AND ENGINE MEASUREMENT LEAK TEST The following gives verification procedures for 593 HO engines. PREPARATION 1. Remove tuned pipe. 2. Install plug over exhaust manifold. 3. Remove carburetors. 4. Insert plugs in intake rubber boots. Tighten with existing clamps.
Page 86: Engine (Cylinders / Head / Base)
ENGINE (CYLINDERS / HEAD / BASE) 7 - 23 – If there is no leak at the tested location, continue pumping to maintain pressure and continue with the next item until the leak is found. Engine Check the following: 1. All jointed surfaces and screw/stud threads of engine: –...
Page 87 2. Leaks can be also on the oil pump side, which is blocked off on the Snow Hawk 600HO. Check this mounting area and the two mounting bolts for leaks. 3. If leak still persists, it indicates a defective casting somewhere in the engine.
Page 88 ENGINE (CYLINDERS / HEAD / BASE) 7 - 25 CHECK FOR OIL LEAKS AROUND OIL PUMP BLOCK-OFF PLATE OIL LEAKING FROM AROUND REPLACE GASKET EDGES OF BLOCK-OFF PLATE?
Page 89 ENGINE (CYLINDERS / HEAD / BASE) 7 - 26...
Page 90 ENGINE (CYLINDERS / HEAD / BASE) 7 - 27 ENGINE DIMENSION MEASUREMENT This section covers the 593HO engine type. CYLINDER HEAD WARPAGE Check gasketed surface of the cylinder head with a straightedge and a feeler gauge. CYLINDER TAPER Compare cylinder diameter 16 mm (5/8 in) from top of cylinder to just below its intake port area.
Page 91 ENGINE (CYLINDERS / HEAD / BASE) 7 - 28 Measuring 16 mm (5/8 in) from top of cylinder with a cylinder gauge, check if the cylinder out of round is more than the specified dimension. If larger, cylinder should be rebored and honed or should be replaced.
Page 92 ENGINE (CYLINDERS / HEAD / BASE) 7 - 29 2. Remove cylinder head. 3. Seal piston ring gap with a small amount of grease. 4. Reinstall cylinder head. 5. Obtain a graduated burette (capacity 0 - 50 cc) and fill with an equal part (50/50) of gasoline and injection oil.
Page 93 ENGINE (CYLINDERS / HEAD / BASE) 7 - 30 11. Install a thicker or thinner cylinder/crankcase gasket (refer to Parts Catalogs) in order to obtain the specified combustion chamber volume or the nearest. USED PISTON MEASUREMENT Note the measurement on the piston dome. 1.
Page 94 ENGINE (CYLINDERS / HEAD / BASE) 7 - 31 CYLINDER/PISTON CLEARANCE Used and New Pistons IMPORTANT: Make sure used piston is not worn more than specified. See USED PISTON MEASUREMENT above. Take the measurement on the piston dome. 1. Piston dome 2.
Page 95 ENGINE (CYLINDERS / HEAD / BASE) 7 - 32 1. Indicator set to 0 (zero) IMPORTANT: Always remove cylinders from crankcase before measuring. Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge. 1. Measuring perpendicularly (90°) to piston pin axis A.
Page 96 ENGINE (CYLINDERS / HEAD / BASE) 7 - 33 RING/PISTON GROOVE CLEARANCE Using a feeler gauge check clearance between rectangular ring and groove. Replace piston if clearance exceeds specified tolerance. Refer to Chapter 15 – Dimensions and Tolerances.. RING END GAP Position ring half-way between transfer ports and intake port.
Page 97 ENGINE (CYLINDERS / HEAD / BASE) 7 - 34 NOTICE: Crankshaft deflection cannot be correctly measured between centers of a lathe. If the deflection exceeds the specified tolerance, crankshaft should be repaired or replaced. Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight.
Page 98 ENGINE (CYLINDERS / HEAD / BASE) 7 - 35 CRANKSHAFT END-PLAY End-play is not adjustable but it should be between 0.10 - 0.30 mm (.004 - .012 in). CHECKING CRANKSHAFT ALIGNMENT Install a degree wheel (P/N 529 035 607) on crankshaft end.
Page 99: Primary Transmission System
PRIMARY TRANSMISSION SYSTEM 8-1 PRIMARY TRANSMISSION SYSTEM / PRIMARY CLUTCH 10 N-m (1 kg-m , 7.4 lbf-ft, 125 lbf-in) 90 N-m (9.2 kg-m , 66 lbf-ft, 797 lbf-in)
Page 100 PRIMARY TRANSMISSION SYSTEM 8-2 Primary Transmission System / Primary Clutch Ref. Part Descriptions 1-14 0400-0152 Primary Clutch Assembly 0405-0071 Fixed sheave 0410-0022 Sliding sheave 0150-1014 Spring seat 0440-2018 Spring Compression Limiter 0151-1007 Spring 0440-0005 Spring Cover 420-2453-700 Lock Washer 0080-0021 Socket Head Screw 0130-3006 Slider Block...
Page 101 PRIMARY TRANSMISSION SYSTEM 8-3 PRIMARY TRANSMISSION SYSTEM / SECONDARY CLUTCH 25 N-m ( 18.4 lbf-ft 2.5 kg-m, 221 lbf-in) 13 12...
Page 102 PRIMARY TRANSMISSION SYSTEM 8-4 Primary Transmission / Secondary Clutch Ref. Part Descriptions 1-15 8000-0001 Secondary Clutch Assembly 504 1416 00 Fixed Sheave 504 1432 00 Sliding Sheave Assembly 414 9180 00 Cam Slider blocks 415 0112 00 Small Garlock bushing 860 4230 00 Large Garlock bushing 417 1264 22...
Page 103 WARNING Any repair of the primary clutch must be carried out by an authorized Snow Hawk dealer or by a competent person. When installing parts, follow to the letter all the points given in the procedure and respect the assembly tolerances.
Page 104 PRIMARY TRANSMISSION SYSTEM 8-6 Remove the guide washer (No. 4). CLEANING Clean the faces of the pulley and the shaft with very fine steel wool and a dry cloth. With a clean, dry cloth, clean the interior socket of the sliding half-pulley. INSPECTION Make sure the sliding sheave doesn't exhibit an excessive amount of play and that the shaft of the fixed sheave is not...
Page 105 PRIMARY TRANSMISSION SYSTEM 8-7 After the first ten hours of vehicle use, the transmission must be inspected to make sure that the primary clutch retaining bolt is well tightened. REMOVAL (SECONDARY CLUTCH) Remove the drive-belt of the vehicle. Remove retaining bolt No. 19, lock washer No. 18, washer No.
Page 106 PRIMARY TRANSMISSION SYSTEM 8-8 Using a bore dial gauge, measure the diameter of the bushing. These measures must be taken at least 5mm (1/4 in) from the edge of the bushing. Replace the bushing if their diameter is greater than the prescribed limit of wear.
Page 107 PRIMARY TRANSMISSION SYSTEM 8-9 Small bushing NOTICE: The procedure described below can be carried out using a press and the same tools. Install the extractor in a vise. Heat the part where the bushing is located. Turn the extractor handle and the half-pulley at the same time to take the bushing out.
Page 108 Initial opposite direction to decrease it. Spring Preload The original spring preload of the Snow Hawk 600HO secondary clutch is 6.8 kg or 14.9 lbf NOTICE: If it is not possible to correct the initial torsion of the spring, try...
Page 109 PRIMARY TRANSMISSION SYSTEM 8-11 CLUTCH ALIGNMENT GENERAL INFORMATION Since the two clutches are rigidly mounted, the only alignment dimension that requires inspection is the distance between the inside of the fixed sheave of the primary clutch (inner sheave) and the inside of the fixed sheave of the secondary clutch (outer sheave).
Page 110 (WEAR LIMIT) 138-4628U3 1.375 ± 0.030 1.250 ± 0.030 SNOW HAWK 600HO DIRECTION OF ROTATION In order for the drive-belt to last as long as possible it must be installed as is shown in the illustration respecting the direction of rotation.
Page 111 PRIMARY TRANSMISSION SYSTEM 8-13 NOTICE: Contrary to a snowmobile, the belt of the Snow Hawk is pre- inserted into the secondary clutch from 1 to 3 mm. D = 1 to 3 mm CHECKING DRIVE BELT TENSION Place a ruler on the drive belt.
Page 112 PRIMARY TRANSMISSION SYSTEM 8-14 ADJUSTMENT OF THE DEFLECTION Adjust the deflection using the Allen screws (1) in the picture on the right. To increase the deflection: turn the Allen screws clockwise. To decrease the deflection: turn the Allen screws counter clockwise. 1.
Page 113 SECONDARY TRANSMISSION SYSTEM 9 - 1 SECONDARY TRANSMISSION SYSTEM 14 N-m ( 125 lbf-in) Follow the suggested sequence 14 N-m ( 125 lbf-in) Follow the suggested sequence...
Page 114: Secondary Transmission System
SECONDARY TRANSMISSION SYSTEM 9 - 2 Secondary transmission system Ref. Part descriptions TL-01 Torque limiter assembly SH-203R Tensioner sprocket 28T SH-201R Drive sprocket 28T SH-204 Tensioner shaft 184-153 Retaining ring 6004-2RS KML Roller bearing, tensioner 409.716 Washer 441.1 Split spring lock washer 20238P Hexagon head cap screw M10 x 1.5 x 60MM 90974 A116...
Page 115 SECONDARY TRANSMISSION SYSTEM 9 - 3 TORQUE LIMITER SYSTEM 7 (6x) 6 N-m ( 55 lbs-in ) 8 (2x) 10 N-m ( 89 lbs-in ) 8 (2x) 10 N-m ( 89 lbs-in )
Page 116 SECONDARY TRANSMISSION SYSTEM 9 - 4 Torque limiter system Ref. Part descriptions TL-003 Drive sprocket 56T TL-001 TL-002 Aluminum threaded disk TL-004 Outside pressure plate TL-005 Inside pressure plate 6525K1 O.D. 5" Wearing pad 21653P Socket head cap screw M8 x 1.25 x 30MM 22097P Flat head socket cap screw M6 x 1.0 x 8MM 293,800,060...
Page 117 SECONDARY TRANSMISSION SYSTEM 9 - 5 Removal of cog belt Boulon de tensionnement To gain access to the entire secondary transmission system, you must first completely remove the cab and belly pan. See Chapter 1 – General Instructions for details. Loosen the bolt that holds the tensioner sprocket in place.
Page 118 SECONDARY TRANSMISSION SYSTEM 9 - 6 Installation of Cog Belt Installation of a new cog belt is essentially the same as the steps outlined above, but in reverse order. One must pay special attention to the re-installation of the taper lock system: 1.
Page 119 SECONDARY TRANSMISSION SYSTEM 9 - 7 Inspection of Secondary Transmission System Check that the roller bearings in the tensioner sprocket bore are functioning properly. Check for excessive dry surface cracking of the rubber in the cog belt. If excessive surface cracks are present, replace belt.
Page 120 SECONDARY TRANSMISSION SYSTEM 9 - 8 TORQUE LIMITER SYSTEM DISASSEMBLY Lightly loosen the 6 Allen bolts (part # 7 on the exploded view of the torque limiter) in a criss-cross pattern. The threaded aluminum disc (part # 3 on the exploded view) can now be removed by hand.
Page 121 SECONDARY TRANSMISSION SYSTEM 9 - 9 REASSEMBLY Install pressure plate # 5 inside the cog sprocket # 1 using the small Allen screws # 8. Use loctite 243 on the Allen screw and torque to 10 N-m (89 lbf-in). Reassemble the torque limiter as shown in the exploded view on page 9-3.
Page 122 HYDRAULIC BRAKE SYSTEM 10 - 1 HYDRAULIC BRAKE SYSTEM 15 (5x) 25 N-m ( 220 lbf-in) 10 (5x) 14 N-m ( 125 lbf-in) 14 N-m ( 125 lbf-in)
Page 123: Hydraulic Brake System
HYDRAULIC BRAKE SYSTEM 10 - 2 Hydraulic brake system Ref. Part descriptions 10.6707.81 Master cylinder 20.6951.50 Caliper 107.6949.11 Replacement brake pad SH 048 Brake hub TDSH7-3116 Brake disc SH 039 Brake caliper spacer 053.8.45 Hexagon head cap screw M8 x 1.25 x 45MM 23164 Nylon nut M8 x 1.25 1215X30...
Page 124 HYDRAULIC BRAKE SYSTEM 10 - 3 Removal/Installation of Brake Disc and/or Hub To gain access to the brake system, the cab and belly pan must be completely removed. See Chapter 1 – General Instructions for details. To remove the brake disc and/or hub, the brake caliper must Retainer first be rotated up and out of the way.
Page 125 HYDRAULIC BRAKE SYSTEM 10 - 4 Verify that the thickness of the pad material (as shown between the arrows in the photo at the right) is greater than 1 mm (1/32 in). If the thickness is found to be less than this, replace the pads.
Page 126 HYDRAULIC BRAKE SYSTEM 10 - 5 Re-/Installation of Brake Disc and/or Hub Brake Disc Only: Install the five M6 x 16 button head bolts with Loctite 243 and torque to 14 N-m (125 lbf-in). (Reference No. 10 in the exploded view at the beginning of this chapter) Brake Disc and Hub: Follow the procedure outlined on page 9-4 of Chapter 9 –...
Page 127: Front Fork And Twin-Axis Ski
FRONT FORK AND TWIN-AXIS SKI 11 – 1 FRONT FORK...
Page 128 FRONT FORK AND TWIN-AXIS SKI 11 – 2 Front Fork Ref. Part Descriptions Fork Leg Assembly 791,464,018 849350102 Cartridge 849310511 Inner Tube 849340059 Fork Seal and Bushing Kit 849311568 Top Cap Assy. 849350103 Compression valve Assy. 949409760 Outer Tube 949603733 Lower Spring Seat 949313954 Spring...
Page 129 FRONT FORK AND TWIN-AXIS SKI 11 – 3 FRONT FORK ASSEMBLY...
Page 130 FRONT FORK AND TWIN-AXIS SKI 11 – 4 Front Fork Assembly Ref. Part Descriptions Front fork leg USD 46mm 791.464.018 SH-028 Triple clamp SH-024 Aluminum fork adaptor SH-019 Lower clamp SH-059 Fork shaft SH-066 Fork lower steering bushing 061.6.30 Hex head flange bolt M6x30 23162F Flanged locknut M6 SH-051...
Page 131 FRONT FORK AND TWIN-AXIS SKI 11 – 5 TWIN-AXIS SKI ASSEMBLY 12 12...
Page 132 FRONT FORK AND TWIN-AXIS SKI 11 – 6 Twin-Axis Ski Assembly Ref. Part Descriptions RD0170 Ski (black) SH-311 Base plate SH-309 Adaptor plate SH-813 Carbide Runner 60 8310120065ELZN Carriage Bolt M12x65 P05000050095A Gold polyurethane bushing 20279P Hex head bolt M12x80 P05000050090A Red polyurethane bushing 341-109P...
Page 133 FRONT FORK AND TWIN-AXIS SKI 11 – 7 TWIN AXIS SKI The twin-axis ski is a new development for 2004. The basic idea is that the ski can now stay flat when the vehicle is at a lean angle of up to approximately 20 It is the gold and red polyurethane bushings that permit such movement and the adjustment of the two locknuts (No.
Page 134 (SH415) holder damage the rebound adjustment needle resulting in a malfunction of the system. Snow Hawk Special Tool To prevent such a situation, set the rebound adjustment to its fastest position (by turning it counterclockwise) before taking the cap off.
Page 135 FRONT FORK AND TWIN-AXIS SKI 11 – 9 Unscrew the lock nut (C) from the piston rod and remove the fork leg top cap (B). Remove the upper spring retainer (R), the lock nut (C), the fork spring guide (G) and the O-ring (F). NOTICE: When the fork leg is turned upside down, the push rod, the needle and the return spring will fall from the piston rod.
Page 136 FRONT FORK AND TWIN-AXIS SKI 11 – 10 Install the lower part of the inner tube in a vise. CAUTION Exerting too much pressure on the lower part of the inner tube can damage it and affect the stability of the ride. Do not overtighten.
Page 137 FRONT FORK AND TWIN-AXIS SKI 11 – 11 CAUTION Scratches on the outer tube will cause oil leaks. Be careful not to scratch the outer tube while removing the dust seal. Use a flat screwdriver to remove the dust seal. Remove the stop ring.
Page 138 FRONT FORK AND TWIN-AXIS SKI 11 – 12 Reassembly Remove all the elements from the inner tube, one at a time, and clean the tube. Replace the seals and bushings with new ones, following the prescribed sequence. (See the illustration) NOTICE: While installing seals, wrap the end of the strut with a band of adhesive tape so that the seals will not be damaged by the...
Page 139 FRONT FORK AND TWIN-AXIS SKI 11 – 13 Once the bushings (S & R) are correctly installed, use the other end of the special tool (W) to insert the washer (Q), and then the oil seal (T). Re-install the stop ring (O). Re-install the dust seal (M).
Page 140 FRONT FORK AND TWIN-AXIS SKI 11 – 14 NOTICE: Before adjusting the torque, make sure the special tool (T) is well fitted into the socket at the end of the cartridge. Re-install the rubber cap (M). Install the spring stop washer (S). Make sure the O-ring (OR) is still in place.
Page 141 FRONT FORK AND TWIN-AXIS SKI 11 – 15 With the fork leg still in a vertical position and fully compressed, adjust the fluid level. Recommended level: X = 85 mm (3-5/16 in) NOTICE: It may be necessary to add or remove some fluid to reach the recommended level.
Page 142 FRONT FORK AND TWIN-AXIS SKI 11 – 16 The top cap (B) must be screwed on until the piston rod (G) touches the bottom of the cap (B) before the cap comes into contact with the lock nut (C). The space between the cap (B) and the nut (C) must be between 1 - 2 mm (0.040 –...
Page 143 FRONT FORK AND TWIN-AXIS SKI 11 – 17 Rebound Using a screwdriver, it is possible to choose a precise setting for the speed of rebound from a range of 28 positions, depending on the conditions of the terrain and the purpose for which the vehicle is used. Stiffer (Slower) Softer (Faster)
Page 144: Rear Suspension, Shocks And Track
REAR SUSPENSION, SHOCKS AND TRACK 12 - 1 REAR SUSPENSION...
Page 145 REAR SUSPENSION, SHOCKS AND TRACK 12 - 2 REAR SHOCK...
Page 146 REAR SUSPENSION, SHOCKS AND TRACK 12 - 3 MIDDLE SHOCK...
Page 147 REAR SUSPENSION, SHOCKS AND TRACK 12 - 4 Rear suspension Ref. Part descriptions 30628 Hexagon head cap screw M10 x 1.5 x 45MM (Grade 10.9) 21111P Lock washer M10 181-188 Washer 3/8 I.D SH-416 Outer bushing SF-2836-20 Oilite bushing SH-43-SAG Bushing housing (Left side) 21682P Socket head cap screw M10 x 1.5 x 35MM...
Page 148: Rear Suspension
REAR SUSPENSION, SHOCKS AND TRACK 12 - 5 Rear Suspension Ref. Part desciptions SH-63SA Lower shaft axle assy. 023-00 PVC spacer BR14L Shim R3250C-1 001B 83mm idler wheel assy. (plastic) 010-00 Wheel axle SH-424 Limiter strap SH-425 Lower shaft axle assy. SH-428 Upper shaft axle assy.
Page 149 REAR SUSPENSION, SHOCKS AND TRACK 12 - 6 SHOCK EXPLODED VIEW...
Page 150 REAR SUSPENSION, SHOCKS AND TRACK 12 - 7 Shock Ref. Part descriptions 1-13 11300-10362 Shock assembly 11303-21209 Rod assembly 11301-05056 Shock body 11301-03303 Floating piston 11301-03006 O-ring 11301-03805 Piston bushing 11302-09919 Compressed air valve 11201-90604 Screw 11301-03021 O-ring 11201-92151 Label 11301-91030 Collar 11301-03207...
Page 151 REAR SUSPENSION, SHOCKS AND TRACK 12 - 8 Rear suspension adjustment The rear suspension can be adjusted in two places 1- Rear spring preload adjustment. 2- Middle spring preload adjustment. Spring tension Loosen the jam nut # 1. Using the special tool # 3, turn the spring preload adjustment collar # 2, turning it CW to stiffen the rear suspension feeling and turning it CCW to soften the rear suspension feeling.
Page 152: Shock Maintenance
REAR SUSPENSION, SHOCKS AND TRACK 12 - 9 Shock Maintenance This type of shock absorber can be completely rebuilt. It can be calibred, the shims can be replaced, or the sealing rings can be replaced as need be. The driver can choose the precise adjustment that corresponds to his or her driving style.
Page 153 REAR SUSPENSION, SHOCKS AND TRACK 12 - 10 NOTICE: Pull the rod of the shock absorber out gently to avoid spilling oil or damaging the top cap and seal with the threads on the body of the shock absorber. Wrap it in a cloth when removing the shock absorber piston to soak up any oil that might run down the sides.
Page 154 REAR SUSPENSION, SHOCKS AND TRACK 12 - 11 After removing the parts, always lay them out in the order in which they were dismantled. NOTICE: In general, it is recommended that the lock nut from the shock absorber rod be replaced after the absorber has been reassembled 4 times to ensure adequate locking friction.
Page 155 REAR SUSPENSION, SHOCKS AND TRACK 12 - 12 REBOUND Leave a play of about 0.203 mm (0.008 in) between the stack of shims and the lock nut. When adjusting the shock absorber to increase the rebound damping, always use shims measuring 26 mm (1.02 in) against the piston to close the piston openings well.
Page 156 REAR SUSPENSION, SHOCKS AND TRACK 12 - 13 GENERAL INFORMATION Calibrating the shock absorber so that there is too much Original Configuration damping is a frequent error. When this is done, the suspension Rear Shocks has too much give. The suspension cannot carry out a Shim Stack (Compression) 414 8883 35 1 Damping shim Ø15 x 0.203...
Page 157 REAR SUSPENSION, SHOCKS AND TRACK 12 - 14 NOTICE: Carry out a meticulous inspection of the shims and replace any bent shims in order to get perfect calibration. Not having enough damping might lead to believe that bubbles have formed in the shock absorber because the gas pressure is not high enough.
Page 158 REAR SUSPENSION, SHOCKS AND TRACK 12 - 15 NOTICE: Using G-N Molykote Paste (P/N 413 7037 00) lubricate the inside of the piston guide. Install the piston to a depth of A = 141.0 mm (5.55 in). Measure this distance starting from the upper end of the shock absorber. NOTICE: If the floating piston is installed too far down in the body of the shock absorber, a light pressure exerted through the hole in the...
Page 159 REAR SUSPENSION, SHOCKS AND TRACK 12 - 16 Insert the shock absorber rod (complete) in the body of the shock absorber. Lightly lubricate the ring seal of the piston with shock absorber oil to make installation easier. Install the ring seal housing near the piston. Check the shock absorber oil capacity to make sure there is no air in the body of the shock absorber when it is being reassembled.
Page 160 REAR SUSPENSION, SHOCKS AND TRACK 12 - 17 ADJUSTING THE NITROGEN PRESSURE Nitrogen (N ) can now be added to the body of the shock absorber. Replace the needle valve. Adjust the pressure regulator to 2070 KPa (300 lb/in ) of nitrogen.
Page 161 REAR SUSPENSION, SHOCKS AND TRACK 12 - 18 Replace the spring retainer hat, then the spring. Next, screw the pre-load rings up to the spring. Adjust the pre-load according to the length of the spring. The shock absorber can now be installed on the vehicle.
Page 162 REAR SUSPENSION, SHOCKS AND TRACK 12 - 19 Track Alignment CAUTION The track of each SNOW HAWK was aligned and adjusted in the factory but it is recommended that the following be checked. The alignment of the track 1. Guides 2.
Page 163: Chassis And Steering
CHASSIS AND STEERING SYSTEM 13-1 CHASSIS AND STEERING SYSTEM...
Page 164 CHASSIS AND STEERING SYSTEM 13-2 CHASSIS AND STEERING SYSTEM...
Page 165 CHASSIS AND STEERING SYSTEM 13-3 CHASSIS AND STEERING SYSTEM...
Page 166 CHASSIS AND STEERING SYSTEM 13-4 CHASSIS AND STEERING SYSTEM...
Page 167 CHASSIS AND STEERING SYSTEM 13-5 CHASSIS AND STEERING SYSTEM 90 (4x) 91 (4x) 92 (4x) 92 (4x) 93 (4x) 94 (4x) 95 (4x)
Page 168 CHASSIS AND STEERING SYSTEM 13-6 Chassis Ref. Part Descriptions SH-001 Frame right side (MAG) SH-002 Frame left side (PTO) SH-116 Handle bar plate support SH-003L Rear frame left side (PTO) SH-003R Rear frame right side (MAG) SH-033L Left front chassis extension (PTO) SH-033R Right front chassis extention (MAG) SH-032L...
Page 169 CHASSIS AND STEERING SYSTEM 13-7 Chassis Ref. Part Descriptions SH-250 Jackshaft SH-253 Key 1.5" L SH-254 Key 3.375" L SH-084 Engine support SH-034 Choke bracket SH-129 Oil tank bracket SH-058 Hand starter wheel 6000LLEC Bearing 6000 184-110 Retaining ring SH-057 Handle starter wheel spacer MM9489T26 Eyebolt 5/16-18 x 1"...
Page 170 CHASSIS AND STEERING SYSTEM 13-8 Chassis Ref. Part Descriptions 368.10.125 Nylon nut M10 x 1.25 22204P Button head socket cap screw M6 x 1,0 x 20MM 8461k133-2 Adhesive rubber strip 1/8" thick x 2" wide x 16" L SH-132 Adhesive rubber strip (PTO) [modified #8461K133] 8461k133-1 Adhesive rubber strip 1/8"...
Page 171 PTO - HOOD - HAWK SH600D07 MAG - HOOD - TOP OF HOOD SH600D08 PTO - HOOD - TOP OF HOOD SH600D09 HOOD - ROTAX 600HO DECAL SH600D10 MAG - HOOD - HAWK HEAD SH600D11 PTO - HOOD - HAWK HEAD SH600D12...
Page 172 WEARING PLATE (stainless steel 16 gage) SH-082 BELLYPAN PROTECTOR SH-113 SMALL BRAKE GRILL SH-115 MAG SIDE GRILL NOIR SH-133 TOOL POCKET 600HO 1661-0619 3/16" ALUMINUM POP RIVET 341-102P 3/16" POP RIVET BACKING PLT. SH-121 BELLYPAN - MAG SIDE HEAT SHIELD @ PIPE STINGER SH-122...
Page 173 CHASSIS AND STEERING SYSTEM 13-11 Body - Rear Module Ref. Part Descriptions ADB-100 BLACK REAR MODULE 150789P SEAT ASSY 600HO 22205P BUTTON HEAD M6x25 @ SEAT BLAA68-100N ALU POP RIVET 3/16" DIA (LARGE HEAD) SH600D05 MAG - TAIL - NUMBER PLATE...
Page 174 3/16" POP RIVET BACKING PLT. ADB-101 BLACK TUNNEL COVER 513032979 SPRING CLAMP (light green) (Pump-2-adaptor) 513033022 RUBBER HOSE (Pump-2-adaptor) 403,901,811 FUEL PUMP 600HO 420,874,370 FUEL LINE ADAPTOR (b/t fuel pump and tank) BNO1-0618 POP RIVET 3/16" DIA MEDIUM BSO1-0622 LONG 3/16" POP RIVET SH-078...
Page 175 ELECTRICAL SYSTEM 14-1 CDI SYSTEM 20-23 27 N-m ( 20 lbf-ft 2.75 kg-m, 240 lbf-in) 21, 22, 23 Sikaflex Black, #221 (P/N 293530011) 22 N-m ( 16 lbf-ft 2.25 kg-m, 192 lbf-in)
Page 176: Electrical System
ELECTRICAL SYSTEM 14-2 Electrical System Ref. Part Descriptions Magneto (12V, 360W) (STD) 410922946 Stator Assy 410922953 Flywheel (STD) 410922951 Pick-up Assy (STD) 205063044 Socket Head Screw M6x30 420640321 Screw M5x16 420866756 Counter Weight 420852532 Starting Pulley 420945752 Lock Washer 8mm 207182044 Hex Head Screw M8x20 512059552...
Page 177 ELECTRICAL SYSTEM 14-3 WIRING DIAGRAM...
Page 178 ELECTRICAL SYSTEM 14-4 Electrical System - Wiring Harness Ref. Part Descriptions 515175684 Dimmer Switch 410105500 Emergency Stop Switch 515175571 Tether Switch 515145900 Tether Switch Nut 515151500 Tether Cap and Cord 410109700 Overheat Lamp 278001016 Bosch Temperature Sensor (Blue) 512047000 Indebras Temperature Sensor (Black) AN-125 Head Lamp Assy 336772...
Page 179 ELECTRICAL SYSTEM 14-5 CDI SYSTEM NOTICE: The following procedures can be carried out without removing the engine from the vehicle. Only the body panels must be removed. For more details, see Chapter 1 – General Instructions. CDI means Capacitor Discharge Ignition System CLEANING Clean all metal components in a non-ferrous metal cleaner.
Page 180 ELECTRICAL SYSTEM 14-6 NOTICE: To correctly remove a threadlocked fastener, first tap on the fastener to break the threadlocker bond. This will help avoid breakage. To remove magneto flywheel, install the crankshaft protector (P/N 420 876 557) onto the end of the crankshaft.
Page 181 Also, the ignition timing is to be checked at 3500 RPM with a timing light. Engine break-in retard timing for the Snow Hawk 600HO is as follows the first hour of operation. 600HO TYPICAL 1.
Page 182 Twist a wire as shown and use it as a pointer. Install the wire on what would be the upper starter bolt. Although there is no electric starter on any Snow Hawk, you can use the upper threaded hole in the crank case as a mounting position, indicated by the white arrow.
Page 183 Tolerance is ± 1°. Changing Timing As a Snow Hawk dealer, there is no immediate way to alter the MPEM’s internal timing settings other than to send the unit back to us and have us reset the unit for you or have your local...
Page 184 ELECTRICAL SYSTEM 14-10 SYSTEM TESTING IGNITION SYSTEM TESTING SEQUENCE In case of ignition problems, check the following in the prescribed order until the problem can be solved. 1. Sparking/spark plug condition. 2. Electrical connectors. 3. DESS switch and engine cut-out switch. 4.
Page 185 ELECTRICAL SYSTEM 14-11 Intermittent Ignition Problems It is difficult to make an attempt at diagnostics in the case of intermittent ignition problems. Thus, problems occurring only when the engine operating temperature is normal must be checked in similar conditions. In most cases when problems are caused by temperature or vibrations, these can only be solved by replacing parts.
Page 186 ELECTRICAL SYSTEM 14-12 NOTICE: For the next step, no switch must be connected to the main wiring harness. Disconnect all switches from the main wiring harness and check the continuity of each wire by connecting probes to the end of wires of the same color.
Page 187 ELECTRICAL SYSTEM 14-13 5. TRIGGER COIL TESTING Resistance Testing Connect the probes to the appropriate wires from the trigger coil housing. Refer to the corresponding IGNITION AND ELECTRICAL SYSTEM TESTING table in this subsection. Compare these readings with those appearing in the IGNITION table.
Page 188 ELECTRICAL SYSTEM 14-14 Voltage Testing Disconnect spark plug cap from spark plug. Fasten alligator clip to spark plug cable, near the spark plug (position No. 1 at right). Connect other multimeter wire to engine (ground), then place selector switch and scale to 0.00 Vac. Activate the manual starter and check the values indicated by the multimeter.
Page 189 ELECTRICAL SYSTEM 14-15 360W SNOW HAWK 600HO IGNITION AND ELECTRICAL SYSTEM TESTING TABLE TEST TO BE WIRE RESISTANCE VOLTAGE PART NOTE PERFORMED COLOR VALUE (OHMS) (VOLTS, V) BL and Engine stop switches Running insulation Engine stop BL/YL must be in run position.
Page 190: Dimensions And Tolerances
DIMENSIONS AND TOLERANCES 15 - 1 DIMENSIONS AND TOLERANCES ENGINE Engine type Rotax 593 HO Bore 72.00 (in) (2.835) Stroke 73.00 (in) (2.874) Displacement 594.40 (36.27) Compression Ratio 12.25 Max RPM Range 7900-8100 Piston ring type ST/N.A. Piston ring opening (new) (in) (0.016)
Page 191 DIMENSIONS AND TOLERANCES 15 - 2 CARBURETION Carburator type Mikuni TM40 Main jet (MAG/PTO) 380 / 380 Needle Jet Pilot jet 17.5 Needle Identification - Clip Position 9DHI12-58-3 Slide cutaway Float adjustment mm (in) N.A. Airscrew position 1.6 turns Idle RPM 1600 Fuel type Unleaded 87...
Page 192 DIMENSIONS AND TOLERANCES 15 - 3 SECONDARY TRANSMISSION Drive sprocket number of teeth Driven sprocket number of teeth Secondary transmission belt P/N 1280PTH8M-60 Cog belt adjustment Deflection (in) (0.288) Force 6.44 (lbf) (14.2) CHASSIS Overall length 2698 (in) (105) Overall width (in) (32.5) Overall height...
Page 193: Wire, Cable And Hose Routing
WIRE, CABLE AND HOSE ROUTING 16-1 WIRE, CABLE AND HOSE ROUTING WARNING Make sure that all the wires are well set in the terminals and that the connector holders are well installed. Keep the wires away from any rotating, moving, heating or vibrating part.
Page 194 WIRE, CABLE AND HOSE ROUTING 16-2 MPEM 1. 2-circuit housing (BL and WT/BL wires) 2. 6-circuit housing 3. 2-circuit housing (BK and WT/BL wires) 4. 12-circuit housing MAIN CHASSIS GROUND CONNECTION The main chassis ground of the entire electrical system is located on the MAG side chassis rail just above the ignition coil, Ground as indicated at right.
Page 195 WIRE, CABLE AND HOSE ROUTING 16-3 Near the base of the engine, close to the magneto, there are two cables. One is covered by a grey sheath and has a 2-circuit connector at its end (BL and WT/YL wires) This is the wire from the Crankshaft Position Sensor (CPS), The grey-sheathed wire then travels upward between the MAG side intake socket and the MAG side chassis as shown at right.
Page 196 There are many moving parts in the compact engine bay of the Snow Hawk 600HO and the wires must clear all of these. Voltage Regulator 1. The voltage regulator uses a special female, grey 4-...
Page 197 WIRE, CABLE AND HOSE ROUTING 16-5 Once the connectors are all well connected, group all of the cables from the voltage regulator, the magneto and parts of the main wiring harness and tie them together with one nylon tie wrap for compactness as shown at right. wrap From here, the tail lamp wire (WT, BK and RD wires) must pass under the engine impulse hose and along the MAG side chassis...
Page 198 WIRE, CABLE AND HOSE ROUTING 16-6 Handlebar-Mounted Devices/Switchgears 1. Brake switch The 2-circuit connector from the brake switch (YL and YL/WT wires) connects to the 2-circuit connector on the main wiring harness (YL and WT wires). 2. Dimmer switch The 3-circuit connector from the dimmer switch (GY, RD/YL and GY/BK wires) connects to the 3-circuit connector on the main wiring harness (GY, YL and VI/WT).
Page 199 WIRE, CABLE AND HOSE ROUTING 16-7 RPM Output Signal and Accessory Connector Tie wrap 1. Single-circuit connector (YL wire) for accessories (i.e. handwarmers, visor outlet, etc.). 2. 2-circuit connector (GR/WT and BK/RD wires) for an optional tachometer. Using a nylon tie-wrap, attach the two wires to the main wiring harness as shown at right.
Page 200 WIRE, CABLE AND HOSE ROUTING 16-8 3. Throttle Cable 4. Choke Cable Choke Cable The choke cable is attached to a racked system on the carburetors and is then routed vertically upwards, under the main wiring harness and is then attached to the small oil reservoir with a nylon tie wrap as shown at right.
Page 201 WIRE, CABLE AND HOSE ROUTING 16-9 Rewind Starter Cord (503 shown, 600HO identical) 1. Pass the rewind starter cord over the forward pulley. 2. Then under the rearward pulley. 3. Then, slide the rewind starter rode through the eyebolt. Install the D-ring starter handle immediately and tie a secure knot.
Page 202 WIRE, CABLE AND HOSE ROUTING 16-10 The brake hose then passes behind the steering plate and is attached with one nylon tie wrap at the corner. The second tie wrap is located in a hole just above the triangular cut-out in the PTO side of the chassis. The hose is then routed out through this cut-out, under the belt guard towards the brake caliper and is connected there.
Page 203 WIRE, CABLE AND HOSE ROUTING 16-11 Fuel hoses Fuel pump The fuel pump uses 3 hoses to function properly: 1. Impulse (Vacuum) Hose Once installed onto the pump, the impulse hose follows the MAG side chassis and is then connected to the rear of the engine, as shown at right.
Page 204 WIRE, CABLE AND HOSE ROUTING 16-12 Overflow/Vent hoses and Carburetor vent hoses Coolant Reservoir The coolant overflow/air bleeder line is attached to the reservoir with a black spring clamp. The overflow hose is then routed downwards along the length of the reservoir and through a guide to a position that is between the coolant hose and the engine.
Page 205 WIRE, CABLE AND HOSE ROUTING 16-13 Carburetor Vent Hoses The individual carburetor vent hoses are tee’d together at the top of the assembly, near the centre. The vent hose is then routed between the two carburetors, under the PTO-most coolant hose, through the triangular PTO chassis cut-out and is then secured to the chassis with a nylon tie wrap near the brake system.
Page 206 MODEL YEAR 2004 Snow Hawk 600HO High Altitude Set-up Recommendations CARBURETION GUIDE Altitude Item Main Jet Jet Needle 9DHI12-58-3 Needle Position Slide Cutaway Pilot Jet 17.5 Mixture Screw (Pilot Screw) Valve Seat Needle Jet Float Level Idle (rpm) 1400-1800 Idle Throttle Valve Position (mm)
Page 207 • Do not operate the vehicle on water, dirt or any other terrain conditions except snow; • The Snow Hawk is designed for a single operator only, no passenger are allowed; In order to validate your warranty coverage, please sign this form and send it back to us: FAX: (418) 838-3957 MAIL: AD Boivin Design Inc.

Snow Hawk 600HO Set-Up, Service And Shop Manual

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