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AD Boivin SNOW-HAWK 800 HO 2007 Shop Manual

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SNOW-HAWK
800 HO
2007
MANUEL DE RÉPARATION
Incluant :
- Conseils de sécurité
- Fonctionnement du véhicule
- Entretien du véhicule
- Manuel de pièces
SHOP MANUAL
Include:
- Safety
- Vehicle information
- Maintenance information
- Parts catalog
PART #: SH-MAN-2007

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Summary of Contents for AD Boivin SNOW-HAWK 800 HO 2007

  • Page 1 SNOW-HAWK 800 HO 2007 SHOP MANUAL MANUEL DE RÉPARATION Include: Incluant : - Safety - Conseils de sécurité - Vehicle information - Fonctionnement du véhicule - Maintenance information - Entretien du véhicule - Parts catalog - Manuel de pièces PART #: SH-MAN-2007...
  • Page 2 AD Boivin Design 700 Jean-Marchand Street Lévis (Québec) G6V 9G6 Tel : (418) 838-3783 Fax : (418) 838-3957 www.adboivin.com Warranty Policies SNOW HAWK 800HO MY2007 June 6, 2007...

  • Page 3: Table Of Contents

    AD BOIVIN WARRANTY POLICIES __________________________________________________________ TABLE OF CONTENTS AD BOIVIN LIMITED WARRANTY ....................3 SNOW HAWK 2007..........................3 2.1. SCOPE OF THE LIMITED WARRANTY ..................3 2.2. WARRANTY COVERAGE PERIOD ....................3 2.3. CONDITIONS TO HAVE WARRANTY COVERAGE..............4 2.4.

  • Page 4: Ad Boivin Limited Warranty

    AD Boivin reserves the right to make warranty coverage contingent upon proof of proper maintenance. • AD Boivin reserves the right to improve or modify products from time to time without assuming any obligation to modify products previously manufactured.

  • Page 5: Conditions To Have Warranty Coverage

    Such limitations are necessary in order to allow AD Boivin to preserve both the safety of its products, and also that of its consumers and the general public.

  • Page 6: Exclusions

    • Damage resulting from removal of parts, improper repairs, service, maintenance, modifications or use of parts not manufactured or approved by AD Boivin or resulting from repairs done by a person that is not an authorized servicing dealer; • Damage caused by abuse, abnormal use, neglect, use of the product on surfaces other than snow, or operation described in the Snow Hawk Manual;...

  • Page 7: Transfer

    In the event of a controversy or a dispute in connection with this limited warranty, AD Boivin suggests that you try to resolve the issue at the dealership level. We recommend discussing issue with the authorized dealer’s service manager or owner.

  • Page 8: Warranty Information

    Because each authorized dealership has differences in local conditions, AD Boivin will allow you to claim up to 0.5 hour of extra labor for vehicle testing, if the situation should warrant it. Any request for vehicle testing must be appropriate and explained in detail.

  • Page 9: Damage In Transit

    AD Boivin by describing the shortages and/or damages on the Bill of Lading or delivery receipt and agrees to forward this notification to AD Boivin within 7 days after receipt of shipment. AD Boivin will not cover these claims under warranty but will make sure your request is properly processed by the carrier.

  • Page 10: Warranty Parts Management

    Quality Assurance department, dealer co-operation in parts handling procedures is valuable for everyone involved. 4.1. PARTS IDENTIFICATION Each part returned to AD Boivin / Warranty Department or kept at your dealership must be identified with a tag containing your dealer name and claim number.

  • Page 11: Address For Warranty Parts Return

    AD BOIVIN WARRANTY POLICIES __________________________________________________________ Identified parts will be returned at the expense of AD Boivin after an authorization. Here is a partial list of parts to be returned: 1. Short Block 2. Engine assembly 3. Piston 4. Crankshaft (new or rebuilt) 5.

  • Page 12: Appendix 1

    AD BOIVIN WARRANTY POLICIES __________________________________________________________ APPENDIX 1 Warranty Claim Sheet June 2007 AD Boivin Design Inc. Page 11 of 12...
  • Page 13 Snow Hawk Warranty Claim Sheet General Information Dealer Name: Client Name: Contact Person: Client Signature: VIN: Engine No.: Year: Date Damaged: Model: Description Dealer Unit Cost Total Parts Subtotal: LABOUR Description Time Flat rate Total Labour Subtotal: Notes: US or CAN Total Claim Cost...
  • Page 14 VERTISSEMENT / VIS LÉGAL AD Boivin Design Inc. ne sera tenu responsable d’aucune blessure – ou décès – pouvant survenir lors de l’utilisation du Snow Hawk. Comme tout autre véhicule récréatif, le Snow Hawk peut potentiellement être dangereux si les précautions suivantes ne sont pas prises : •...
  • Page 15 EGAL OTICE AD Boivin Design Inc. will not be held responsible for any physical injury – or death – occurred while riding a Snow Hawk. Like any other recreational vehicle, the Snow Hawk can be potentially dangerous if the following precautions are not taken: •...
  • Page 16 The stock airscrew setting with a 20 pilot jet is 1.6 turns out from full tight. *** AD Boivin is not responsible for any damage after utilisation of this chart. Many facteurs can influence the calibration of a vehicle like atmospheric pressure and humidity.
  • Page 17 WIRE, CABLE AND HOSE ROUTING 16-1 CHAPTER 16 WIRE, CABLE AND HOSE ROUTING...
  • Page 18 WIRE, CABLE AND HOSE ROUTING 16-2 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 19 WIRE, CABLE AND HOSE ROUTING 16-3 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 Raccourci vers Extranet.lnk 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 20 WIRE, CABLE AND HOSE ROUTING 16-4 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), Grey sheath The grey-sheathed wire then travels upward between the MAG side intake socket and the MAG side chassis as shown at right.
  • Page 21 WIRE, CABLE AND HOSE ROUTING 16-5 Temperature Sensors There are two temperature sensors on the Snow Hawk 800HO. The first temperature sensor is blue (Bosch), is located on the MAG side of the head and uses a special 2-circuit connector (GR and BK wires) it is shown as Sensor No.
  • Page 22 WIRE, CABLE AND HOSE ROUTING 16-6 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. Tie-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 23 WIRE, CABLE AND HOSE ROUTING 16-7 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 24 WIRE, CABLE AND HOSE ROUTING 16-8 RPM Output Signal and Accessory Connector 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. Tie-wrap Using a nylon tie-wrap, attach the two wires to the main wiring harness as shown at right.
  • Page 25 WIRE, CABLE AND HOSE ROUTING 16-9 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 26 WIRE, CABLE AND HOSE ROUTING 16-10 Rewind Starter Cord (503 shown, 800HO 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 27 WIRE, CABLE AND HOSE ROUTING 16-11 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 28 WIRE, CABLE AND HOSE ROUTING 16-12 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 29 WIRE, CABLE AND HOSE ROUTING 16-13 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 30 WIRE, CABLE AND HOSE ROUTING 16-14 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 31 DIMENSIONS AND TOLERANCES 15 - 1 CHAPTER 15 DIMENSIONS AND TOLERANCES...

  • Page 32: Dimensions And Tolerances

    DIMENSIONS AND TOLERANCES 15 - 2 DIMENSIONS AND TOLERANCES ENGINE Engine type Rotax 793 HO Bore 82.0 (in) (3.228) Stroke 75.7 (in) (2.980) Displacement 799.5 (48.789) Compression Ratio 12.00 ± 0,5 Max power engine speed 7850 ± 100 tr/mn Piston ring type Semi-trapez ring N.A.
  • Page 33 DIMENSIONS AND TOLERANCES 15 - 3 CARBURETION Carburator type Mikuni TM40 Main jet (MAG/PTO) 490 / 490 Needle Jet Pilot jet Needle Identification - Clip Position 9DGI7-58 Slide cutaway Float adjustment mm (in) N.A. Airscrew position 1.5 turns Idle RPM 1600 Fuel type Unleaded 87...
  • Page 34 DIMENSIONS AND TOLERANCES 15 - 4 SECONDARY TRANSMISSION Drive sprocket number of teeth Driven sprocket number of teeth Secondary transmission belt P/N 1360PTH8M-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 35 ELECTRICAL SYSTEM 14-1 CHAPTER 14 ELECTRICAL SYSTEM...
  • Page 36 ELECTRICAL SYSTEM 14-2 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 37 ELECTRICAL SYSTEM 14-3 Electrical System Ref. Part Descriptions 420 891 540 Magneto (12V, 360W) 420 888 314 Stator Assy 420 888 323 Flywheel 420 966 837 Pick-up Assy 205 063 044 Socket Head Screw M6x30 420 640 321 Screw M6x16 420 866 756 Counter Weight 420 852 532...
  • Page 38 ELECTRICAL SYSTEM 14-4 WIRING DIAGRAM...
  • Page 39 ELECTRICAL SYSTEM 14-5 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 40 ELECTRICAL SYSTEM 14-6 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 41 ELECTRICAL SYSTEM 14-7 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 42 ELECTRICAL SYSTEM 14-8 IGNITION TIMING 793 HO Engines Normally ignition-timing adjustment should not be required. It has been set at the factory and it should remain correctly adjusted since every part is fixed and not adjustable. The only time the ignition timing might have to be changed would be when removing and reinstalling the magneto housing, replacing the crankshaft, the magneto flywheel, the trigger coil or the...
  • Page 43 ELECTRICAL SYSTEM 14-9 Locate the piston TDC position as follows: a. Slowly rotate the drive pulley back and forth across TDC while observing the needle. Note that the needle stops moving only as the piston is changing direction. b. Rotate the dial face so that “0” is in line with the needle when it stops moving.
  • Page 44 ELECTRICAL SYSTEM 14-10 The timing mark must be aligned with the pointer end. If such is not the case, note if the timing is retarded or advanced. Tolerance is ± 0.5°. 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 Bombardier dealer change the settings using his programmer.
  • Page 45 ELECTRICAL SYSTEM 14-11 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 46 ELECTRICAL SYSTEM 14-12 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 47 ELECTRICAL SYSTEM 14-13 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 48 ELECTRICAL SYSTEM 14-14 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 49 ELECTRICAL SYSTEM 14-15 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 50 ELECTRICAL SYSTEM 14-16 360W SNOW HAWK 800HO 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. switches Engine stop switches Continuity in stop...
  • Page 51 CHASSIS, STEERING SYSTEM AND BODY 13-1 CHAPTER 13 CHASSIS, STEERING AND BODY...
  • Page 52 CHASSIS, STEERING SYSTEM AND BODY 13-2 CHASSIS AND STEERING SYSTEM...
  • Page 53 CHASSIS, STEERING SYSTEM AND BODY 13-3 CHASSIS AND STEERING SYSTEM...
  • Page 54 CHASSIS, STEERING SYSTEM AND BODY 13-4 CHASSIS AND STEERING SYSTEM...
  • Page 55 CHASSIS, STEERING SYSTEM AND BODY 13-5 CHASSIS AND STEERING SYSTEM...
  • Page 56 CHASSIS, STEERING SYSTEM AND BODY 13-6 CHASSIS AND STEERING SYSTEM 64 (4x) 90 (4x) 91 (4x) 92 (4x) 92 (4x) 93 (4x) 94 (4x) 95 (4x)
  • Page 57 CHASSIS, STEERING SYSTEM AND BODY 13-7 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 58 CHASSIS, STEERING SYSTEM AND BODY 13-8 Chassis Ref. Part Descriptions SH-084 Engine support SH-034 Choke support SH-129 Oil tank bracket SH-058 Hand starter wheel 6000LLEC Bearing 6000 184-110 Retaining ring SH-057 Hand starter wheel spacer MM9489T26 Eyebolt 5/16-18 x 1" SH-042 Belt tensioner block 20172CP...
  • Page 59 CHASSIS, STEERING SYSTEM AND BODY 13-9 Chassis Ref. Part Descriptions DDR6261 Rubber damper 92140A118 Washer M10 large 21111P Lock washer M10 20242P Hexagon head cap screw M10 x 1.5 x 80MM 061.6.25 Hexagon head flange bolt M6 x 1.0 x 25MM (Grade 10.9) 20159P Hexagon head bolt M6 x 1.0 x 20MM (Grade 10.9) 23162F...
  • Page 60 CHASSIS, STEERING SYSTEM AND BODY 13-10 BODY - HOOD...
  • Page 61 CHASSIS, STEERING SYSTEM AND BODY 13-11 BODY – HOOD...
  • Page 62 CHASSIS, STEERING SYSTEM AND BODY 13-12 Body - Hood Ref. Parts description SH-77A Hood assy 800HO 2007 ADB-083Y Yellow hood 1661-0619N A 3/16 Pop rivet (Alu,Black) 1641-0621N A 3/16 Pop rivet (Alu,large head,Black) 5937 Head light spring ADB-098Y Hood guide yellow 284118 Rubber hook bungee AN-125...
  • Page 63 CHASSIS, STEERING SYSTEM AND BODY 13-13 BODY – BELLY PAN...
  • Page 64 CHASSIS, STEERING SYSTEM AND BODY 13-14 BODY – BELLY PAN...
  • Page 65 CHASSIS, STEERING SYSTEM AND BODY 13-15 Body - Belly-pan Ref. Parts descriptions SH-76A Bellypan assy 800HO 2007 284118 Rubber hook bungee 1661-0619N A 3/16 pop rivet (alu,black) S6-100P A 3/16 Flat washer ADB-094 Black bellypan 1641-0621N A 3/16 pop rivet (alu, large head, black) SH-121 MAG side heat shield SH-065...
  • Page 66 CHASSIS, STEERING SYSTEM AND BODY 13-16 BODY – REAR MODULE 11 & 12 14 (M AG SID E) 15 (PTO SIDE)
  • Page 67 CHASSIS, STEERING SYSTEM AND BODY 13-17 Body - Rear module Ref. Parts descriptions SH-78A Rear module assy 800HO 2007 ADB-100Y Yellow rear module 200281 Seat base 22204P Button head cap screw M6 x 20 1641-0621N A 3/16 pop rivet (alu,large head, black) 336772 Rear lamp 284118...
  • Page 68 CHASSIS, STEERING SYSTEM AND BODY 13-18 Body - T unnel Cover Ref. Part Descriptions SH-263SA Radiator assembly SH-262 Side support S6-100 Falt washer BNO1-0618 Pop rivet 3/16 (medium head ) SH-086 Aluminium tunnel renforcement plate SN328-014 Hex flange nut 1/4-20 X 3/4" (fuel pump) SN328-016 Hex flange nut 1/4-20 X 1 1/4"...
  • Page 69 REAR SUSPENSION, SHOCKS AND TRACK 12 - 1 CHAPTER 12 REAR SUSPENSION, SHOCK AND TRACK...
  • Page 70 REAR SUSPENSION, SHOCKS AND TRACK 12 - 2 REAR SUSPENSION...
  • Page 71 REAR SUSPENSION, SHOCKS AND TRACK 12 - 3 REAR SHOCK...
  • Page 72 REAR SUSPENSION, SHOCKS AND TRACK 12 - 4 MIDDLE SHOCK...
  • Page 73 REAR SUSPENSION, SHOCKS AND TRACK 12 - 5 SH-18A Suspension arrière Ref. Part descriptions 30628P Hexagon head cap screw M10 x 1.5 x 45MM (Grade 10.9) 21111P Lock washer M10 181-188P Washer 3/8 I.D SH-416 Front outside bushing SF-2836-20 Oil lite bushing SH-43-SAG Bushing housing (Left side) 21682P...
  • Page 74 REAR SUSPENSION, SHOCKS AND TRACK 12 - 6 SH-18A Suspension arrière 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 Aluminium shaft spacer SH-428 Upper limiter strap shaft 503 163 700...
  • Page 75 REAR SUSPENSION, SHOCKS AND TRACK 12 - 7 SHOCK EXPLODED VIEW...
  • Page 76 REAR SUSPENSION, SHOCKS AND TRACK 12 - 8 Shock Ref. Part descriptions 1-13 11300-10362-5 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 77 REAR SUSPENSION, SHOCKS AND TRACK 12 - 9 REAR PAD...
  • Page 78 REAR SUSPENSION, SHOCKS AND TRACK 12 - 10 SH-24A Rear pad Ref. Part descriptions SH-820 UHMW Lower rear pad SH-821 UHMW Upper rear pad SH-829 Renforcement SH-830 Protector 284118 Rubber hook ''Bungee'' 22205P Button Head cap screw M6 X 25 23162F Hexagon elastic flange nut M6 160-167P...
  • Page 79 REAR SUSPENSION, SHOCKS AND TRACK 12 - 11 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 80: Shock Maintenance

    REAR SUSPENSION, SHOCKS AND TRACK 12 - 12 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 81 REAR SUSPENSION, SHOCKS AND TRACK 12 - 13 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 82 REAR SUSPENSION, SHOCKS AND TRACK 12 - 14 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 83 REAR SUSPENSION, SHOCKS AND TRACK 12 - 15 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 84 REAR SUSPENSION, SHOCKS AND TRACK 12 - 16 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) complete extension after the compression caused by a bump.
  • Page 85 REAR SUSPENSION, SHOCKS AND TRACK 12 - 17 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 86 REAR SUSPENSION, SHOCKS AND TRACK 12 - 18 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 = 131.0 mm (5.16 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 87 REAR SUSPENSION, SHOCKS AND TRACK 12 - 19 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 88 REAR SUSPENSION, SHOCKS AND TRACK 12 - 20 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 89 REAR SUSPENSION, SHOCKS AND TRACK 12 - 21 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 90 REAR SUSPENSION, SHOCKS AND TRACK 12 - 22 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 91 REAR SUSPENSION, SHOCKS AND TRACK 12 - 23 REAR PAD ADJUSTMENT Depending on snow conditions, the rear pad will need adjustments. If snow conditions are as follows: - Trail or hard surface; - Icy surface; Both rubber latches on the rear pad must be attached. If snow conditions are as follows: - Powdery trail or surface;...
  • Page 92 REAR SUSPENSION, SHOCKS AND TRACK 12 - 24 EXTENSION PLATE ADJUSTMENT There are two possible positions for the extension plate The tilted position allow the snowhawk to improve its speed and its handling The right position gives better performance on soft snow...
  • Page 93 FRONT FORK AND SKI 11 – 1 CHAPTER 11 FRONT FORK AND TWIN-AXIS SKI...
  • Page 94 FRONT FORK AND SKI 11 – 2 FORK LEG...
  • Page 95 FRONT FORK AND SKI 11 – 3 Fork leg Ref. Parts descriptions Fork leg assembly 791 464 018 849 350 102 Cartridge 849 310 511 Inner tube 849 340 059 Fork seal and bushing kit 849 311 568 Top cap assembly 849 350 103 Compression valve assembly 949 409 761...
  • Page 96 FRONT FORK AND SKI 11 – 4 FORK ASSEMBLY...
  • Page 97 FRONT FORK AND SKI 11 – 5 SH-41A Fork assembly Ref. Parts descriptions Front fork leg USD 46 mm PAIOLI 791 464 018 SH-028 Triple clamp SH-147 Aluminum fork adaptor (Sport Trail) SH-019 Lower clamp SH-059 Aluminum fork shaft SH-066 Fork lower steering bushing 29516P Hexagone head flange bolt M6 x 30 mm...
  • Page 98 FRONT FORK AND SKI 11 – 6 ENSEMBLE DE SKI...
  • Page 99 FRONT FORK AND SKI 11 – 7 SH-25A Ski assembly Ref. Parts descriptions RD0170 Ski (black) SH-31SA Base plate SH-309 Adaptor plate SH-310 Rubber ski cushion ST-201 Runner * Snow Tracker * SH-831 Carbide runner 60 SH-145 Rubber positionner P05000050090A Polyurethane bushing * RED * P05000050095A Polyurethane bushing * GOLD *...
  • Page 100 FRONT FORK AND SKI 11 – 8 FRONT FORK Removal Loosen the fork leg top cap before removing the leg from its supports. Disassembly Clean the fork. NOTICE: The Paioli tool kit (P/N 449 450 020) is needed to perform modifications such as seal replacements and complete fork disassembly.
  • Page 101 FRONT FORK AND 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 102 FRONT FORK AND 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 103 FRONT FORK AND 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. With a few sharp blows, pull the outer tube (P) out to separate it from the inner tube (A).
  • Page 104 FRONT FORK AND 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 sharp edge.
  • Page 105 FRONT FORK AND 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 106 FRONT FORK AND 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 107 FRONT FORK AND 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 108 FRONT FORK AND 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 109 FRONT FORK AND SKI 11 – 17 INSTALLATION Follow the same procedure as for the removal but in the reverse order. Adjustment of the front fork Compression Using a screwdriver, it is possible to choose a precise setting for the speed of compression from a range of 26 positions, depending on the conditions of the terrain and the purpose for which the vehicle is used.
  • Page 110 FRONT FORK AND SKI 11 – 18 TWIN AXIS SKI The basic idea is that the ski can now stay flat when the vehicle is at a lean angle of up to approximately 12 . Its’s the gold and red polyurethane bushings that permits such movement and the adjustment of the two locknuts permits (No.
  • Page 111 FRONT FORK AND SKI 11 – 19 SNOW TRACKER The * Snow Tracker * has bean designed to increase the responsiveness and steering accuracy of you vehicle when trail riding as well as act as an anti-darting mechanism. IF you use your vehicle off-trail or in powder snow conditions, you can use the Snow tracker device or you can remove it, we encourage to use whatever works best for you.
  • Page 112 HYDRAULIC BRAKE SYSTEM 10 - 1 CHAPTER 10 HYDRAULIC BRAKE SYSTEM...
  • Page 113 HYDRAULIC BRAKE SYSTEM 10 - 2 HYDRAULIC BRAKE SYSTEM 25 N-m (220 lbf-in) 15 (5x) 10 (5x) 14 N-m (125 lbf-in) 14 N-m (125 lbf-in) Follow the suggested sequence Chapter 9...
  • Page 114 HYDRAULIC BRAKE SYSTEM 10 - 3 Hydraulic brake system Ref. Parts description 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 115 HYDRAULIC BRAKE SYSTEM 10 - 4 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 116 HYDRAULIC BRAKE SYSTEM 10 - 5 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 117 HYDRAULIC BRAKE SYSTEM 10 - 6 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 118 SECONDARY TRANSMISSION SYSTEM 9 - 1 CHAPTER 9 SECONDARY TRANSMISSION SYSTEM...
  • Page 119 SECONDARY TRANSMISSION SYSTEM 9 - 2 SECONDARY TRANSMISSION SYSTEM 14 N-m (125 lbf-in) Follow the suggested sequence 14 N-m (125 lbf-in) Follow the suggested sequence...

  • Page 120: Secondary Transmission System

    SECONDARY TRANSMISSION SYSTEM 9 - 3 Secondary transmission system Ref. Parts description SH-26A Torque limiter assembly SH-203R Tensioner sprocket 28T SH-260 Drive sprocket 30T SH-204 Tensioner sprocket shaf t 184-153 Retaining ring 6004-2RS KML Roller bearing, tensioner 341-108P Washer 441.1 Split spring lock washer 30632P Hexagon head cap screw M10 x 1.5 x 65MM...
  • Page 121 SECONDARY TRANSMISSION SYSTEM 9 - 4 TORQUE LIMITER SYSTEM 7 (6x) 6 N-m (55 lbs-in) 10 N-m (89 lbs-in) 8 (2x) 8 (2x) 10 N-m (89 lbs-in)
  • Page 122 SECONDARY TRANSMISSION SYSTEM 9 - 5 SH-26A Torque limiter system Ref. Parts description 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 22320AI Socket set screw M8 x 1.25 x 20MM 22097P Flat head socket cap screw M6 x 1.0 x 8MM 293 800 060...
  • Page 123 SECONDARY TRANSMISSION SYSTEM 9 - 6 Removal of cog belt Tensionning screw 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 124 SECONDARY TRANSMISSION SYSTEM 9 - 7 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 125 SECONDARY TRANSMISSION SYSTEM 9 - 8 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 126 SECONDARY TRANSMISSION SYSTEM 9 - 9 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 127 SECONDARY TRANSMISSION SYSTEM 9 - 10 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 128 PRIMARY TRANSMISSION SYSTEM 8-1 CHAPTER 8 PRIMARY TRANSMISSION SYSTEM...
  • Page 129 PRIMARY TRANSMISSION SYSTEM 8-2 PRIMARY TRANSMISSION SYSTEM / PRIMARY CLUTCH Color 1 Color 2...
  • Page 130 PRIMARY TRANSMISSION SYSTEM 8-3 Primary clutch Ref. Part Descriptions Drive pulley ass'y 417222167 Fixed flange 417222171 Sliding flange ass'Y 417222758 Bushing 293370037 Circlip 417 222 312 Spring seat 414689500 Spring blue/yellow 417009205 Protector 417007500 Spring cover ass'y 417009204 Bushing 250200009 Lock washer 8mm 205084044 Socket head cap screw M8x40...
  • Page 131 PRIMARY TRANSMISSION SYSTEM 8-4 PRIMARY TRANSMISSION SYSTEM / SECONDARY CLUTCH...
  • Page 132 PRIMARY TRANSMISSION SYSTEM 8-5 Secondary clutch Ref. Part Descriptions Secondary clutch assembly 417 126 734 Half key 417 126 733 Spacer 417 126 722 Cam 50-40 417 126 322 Swivel abutment 417 126 381 Guard 417 126 688 Spring, green 417 126 878 Circlip 417 126 902...
  • Page 133 PRIMARY TRANSMISSION SYSTEM 8-6 GENERAL INFORMATION (PRIMARY CLUTCH) Some drive pulley components (return spring, ramp) can be changed to improve vehicle performance in high altitude regions. A service bulletin will give information about calibration according to altitude. CAUTION Such modifications should only be performed by experienced mechanics since they can greatly affect vehicle performance.
  • Page 134 PRIMARY TRANSMISSION SYSTEM 8-7 CAUTION These pulleys have metric threads. Do not use imperial threads puller. Always tighten puller by hand to ensure that the drive pulley has the same type of threads (metric vs imperial) prior to fully tightening. TO REMOVE DRIVE PULLEY ASS’Y Retain drive pulley with clutch holder.
  • Page 135 PRIMARY TRANSMISSION SYSTEM 8-8 Cushion Drive CAUTION Do not disassemble cushion drive. Governor cup and cushion drive are factory balanced as an assembly. 15, 18, Slider shoe and Governor Cup Carefully lift governor cup until slider shoes come at their highest position into guides. Hold a slider shoe set then carefully lift its housing and remove slider shoes.
  • Page 136 PRIMARY TRANSMISSION SYSTEM 8-9 8, Spring Cover Ass’y It is pushed by clutch spring pressure. WARNING Clutch spring is very strong. Never attempt to remove spring cover without the recommended tools. Use spring compressor (P/N 529 035 524). Install support guide. 1- Support guide Install sliding half then a seconds support guide.
  • Page 137 PRIMARY TRANSMISSION SYSTEM 8-10 WARNING This procedure must be performed in a well-ventilated area. CAUTION Avoid contact between cleaner and crankshaft seal because damage may occur. Remove all hardened oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and/or sand paper no.600.
  • Page 138 PRIMARY TRANSMISSION SYSTEM 8-11 INSPECTION Drive pulley should be inspected annually. 26, 27, Thrust Washer and Roller Check roller for roundness of external diameter. Check thrust washer for thickness wear. Replace as required. CAUTION Ensure rollers are in good condition. Replace as required. 31, 32, Fitting Bolt Ass’y and Flanged Bushing Check for wear, replace as required.
  • Page 139 PRIMARY TRANSMISSION SYSTEM 8-12 Spring Cover Bushing Replacement Under normal use there is no need to replace this bushing. Mount compressor (P/N 529 035 524) in a vise. Use tools (P/N 529 035 932 and 529 035 931) to remove old bushing. CAUTION Bushing must be bonded with retaining compound.
  • Page 140 PRIMARY TRANSMISSION SYSTEM 8-13 19, 20, 21 Calibration Screw, Washer and Lock Nut When installing calibration screw, make sure to install washer as shown. Torque locking nut to 10 N•m (89 lbf•in). 28, Pin Always use the same type of pin as originally installed when servicing.
  • Page 141 PRIMARY TRANSMISSION SYSTEM 8-14 Torque screws to 10 N•m (89 lbf•in) 1- Equal distance 32, 30, 29, 25, Screw, Lever Ass’y, Nut Cotter Pin NOTICE: While installing lever assemblies make sure that the curved sides of the levers are outwards as shown. Always install lever assemblies so that cotter pins are on the shown side.
  • Page 142 PRIMARY TRANSMISSION SYSTEM 8-15 CAUTION Lever ass’y rollers must move easily after installation. 1, 2, 6, 8, Fixed Half, Sliding Half, Spring, Spring Cover and Screw To install spring cover, use spring compressor (P/N 529 035 524). Assemble fixed and sliding halves. Note that fixed halves have different cone angle.
  • Page 143 PRIMARY TRANSMISSION SYSTEM 8-16 Install fork (P/N 529 005 500) into slider shoe grooves to maintain them for governor cup installation. Proceed on 3 sets of slider shoes. Make sure to align governor cup arrow with sliding half and fixed half mark. NOTICE: If fixed half has no mark, align governor cup mark with segment no.1 of inner half.
  • Page 144 PRIMARY TRANSMISSION SYSTEM 8-17 WARNING Never use any type of impact wrench at drive pulley removal and installation. Clean mounting surfaces as described in CLEANING above. Drive Pulley Ass’y The following installation procedure must be strictly adhered to. Install drive pulley on crankshaft extension. Install a new conical spring washer with its concave side towards drive pulley then install screw.
  • Page 145 PRIMARY TRANSMISSION SYSTEM 8-18 WARNING After 10 hours of operation, the transmission system of the vehicle must be inspected to ensure the retaining screw is properly torqued. DRIVE PULLEY ADJUSTEMENT The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM. Factors such as ambient temperature, altitude or surface condition may vary this critical engine RPM thus affecting Snow Hawk efficiency.
  • Page 146 PRIMARY TRANSMISSION SYSTEM 8-19 See TECHNICAL DATA for original setting. Each number modifies maximum engine RPM by about 200 RPM Lower numbers decrease engine RPM in steps of 200 RPM and higher numbers increase it in steps of 200 RPM. 1- Position 1 (not numbered) Example: Calibration screw is set at position 3 and is changed to position...
  • Page 147 PRIMARY TRANSMISSION SYSTEM 8-20 REMOVAL (SECONDARY CLUTCH) Remove guard and drive belt from vehicle. Remove cap screw no.24 shouldered washer no.20 then pull the driven pulley from the countershaft. Note shouldered washer position for reinstallation. Take care not to lose spacer no.26 1- Spacer 2- Shoulder on this side 3- Concave side facing driven pulley...
  • Page 148 PRIMARY TRANSMISSION SYSTEM 8-21 Pulley Half Cleaning Use pulley flange cleaner (P/N 421 711 809) INSPECTION 11, 12, Slider Shoe Check cam slider shoes for wear. Replace when inside edge thickness of cam slider shoe slope base is worn to 1 mm (0.039in) or less.
  • Page 149 PRIMARY TRANSMISSION SYSTEM 8-22 3, Cam Coat cam interior with anti-seize lubricant. INSTALLATION Countershaft CAUTION Always apply anti-seize lubricant (P/N 293 800 070) on the countershaft before final pulley installation. Should installation procedure be required, refer to BRAKE then look for BRAKE DISC and COUNTERSHAFT BEARING ADJUSTMENT.
  • Page 150 PRIMARY TRANSMISSION SYSTEM 8-23 CAUTION Drive belt and pulley adjustments must always be checked whenever pulleys have been removed, replaced or disassembled. 3, Cam Make sure to install proper cam. Refer to TECHNICAL DATA. Cam angle is identified on cam NOTE: For high altitude regions, a service bulletin will give information about calibration according to altitude.
  • Page 151 PRIMARY TRANSMISSION SYSTEM 8-24 DRIVE BELT MINIMUM WIDTH MODEL WIDTH NEW (WEAR LIMIT) SNOW HAWK 144-4740U3 1.375 ± 0.030 1.250 ± 0.030 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 152 PRIMARY TRANSMISSION SYSTEM 8-25 ADJUSTMENT Before adjusting the belt height, ensure that a good-condition proper belt (refer to the Application Chart) is installed. Loosen screws and turn adjustment ring as follows: To lower belt in driven pulley: turn adjustment ring counterclockwise and tighten the screws.
  • Page 153 PRIMARY TRANSMISSION SYSTEM 8-26 CHECKING DRIVE BELT TENSION Place a ruler on the drive belt. Use the tension gauge (P/N 414 348 200) to verify the tension of the drive belt. 1. Lower ring 2. Upper ring 3. Force 4. Deflection Slide the lower ring of the deflection scale to the required measurement.
  • Page 154 PRIMARY TRANSMISSION SYSTEM 8-27 Emergency starting It is possible to start the engine with an emergency starter cord and clip included in the toolkit stored in the bellypan of vehicle. WARNING Do not wrap the cord around your hand. Pull only by the very end of the cord.
  • Page 155 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 1 CHAPTER 7 ENGINE ( CYLINDERS / HEADS / BASE / EXHAUST )
  • Page 156 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 2 ENGINE / BOTTOM END...
  • Page 157 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 3 Engine bottom end Ref. Part descriptions 1-12 420 889 686 Crankcase assy. 420 640 836 Collar hexagone screw M8 x 75 420 640 431 Collar hexagone screw M8 x 45 420 640 311 Collar hexagone screw M6 x 45 205 063 044...
  • Page 158 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 4 ENGINE / CRANKSHAFT AND PISTONS...
  • Page 159 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 5 Engine crankshaft and pistons Ref. Part descriptions 1-10 420 889 675 Crankshaft assembly 420 832 638 Ball bearing 6207 with oil seal assembly 420 832 575 Ball bearing 6207 with drive pin 420 931 792 Oil seal 30x42x7 420 945 759...
  • Page 160 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 6 ENGINE / TOP END...

  • Page 161: Engine Top End

    ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 7 Engine top end Ref. Part descriptions 420 931 838 Gasket 0.5 420 931 837 Gasket 0.6 420 931 964 Gasket 0.7 420 931 839 Gasket 0.8 420 613 852 Cylinder ni si c plated 420 854 465 Exhaust valve...
  • Page 162 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 8 ENGINE / EXHAUST SYSTEM...

  • Page 163: Exhaust System

    ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 9 Exhaust system Ref. Parts descriptions SH-75A Exhault system 3060-30-013 Tuned pipe assy 3060-30-035 Superior muffler assy 3060-30-014 Lower muffler assy 3060-30-020 Tail pipe assy 3060-30-036 Upper rear half enveloppe 3060-30-037 Lower rear half envloppe 3060-30-029...

  • Page 164: Top End

    ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 10 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 165 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 11 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 166 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 12 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. TYPICAL – PISTON PIN EXTRACTION Remove puller.
  • Page 167 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 13 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.
  • Page 168 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 14 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 169 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 15 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 170 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 16 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...
  • Page 171 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 17 NOTICE: Carefully clean screws before reinstallation, specifically under screw head. Install exhaust manifold with gaskets. Do not tighten yet. Torque cylinder screws in a crisscross sequence as per the following table: At assembly, torque cylinder head screws to 29 N-m (21 Ibf-ft) in the illustrated sequence at right.

  • Page 172: Bottom End

    ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 18 Blade stoppers may slightly interfere with cylinder during installation. Adjusted distance will be reduced automatically upon installation. BOTTOM END NOTICE: The engine must be removed from the chassis to carry out the following operations.
  • Page 173 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 19 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). 7, Crankshaft Bearing Smear anti-seize lubricant (P/N 413 701 000) on part of crankshaft where bearing fits.
  • Page 174 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 20 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 175 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 21 Crankcase Assembly IMPORTANT: The total assembly sequence, including sealing compound spreading, screwing and torquing of bolts according to the proper sequence, must be performed within 10 minutes. Do not wait between each bolt torquing. All bolts must be torqued in a row.
  • Page 176 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 22 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 177 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 23 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.Unplug fuel inlet line from fuel rail 5.
  • Page 178 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 24 – 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.
  • Page 179 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 25 1. Check weep hole below coolant pump housing with soapy water. 1. Weep hole If there is a leak, it indicates that a pump shaft is defective (oil seal beside coolant ceramic seal). 2.
  • Page 180 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 26...
  • Page 181 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 27 ENGINE DIMENSION MEASUREMENT This section covers the 793HO 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 182 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 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 183 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 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 184 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 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 185 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 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.
  • Page 186 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 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 187 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 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 188 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 34 Crankshaft Deflection on PTO side Crankshaft Deflection on MAG side Crankshaft Deflection in Center of Crankshaft 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.
  • Page 189 ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 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 190 COOLING SYSTEM 6 - 1 CHAPTER 6 COOLING SYSTEM...
  • Page 191 COOLING SYSTEM 6 - 2 COOLING SYSTEM...

  • Page 192: Cooling System

    COOLING SYSTEM 6 - 3 Cooling System Ref. Part descriptions 509000323 Coolant reservoir 509000187 Closure cap SH-263SA Heat exchanger SH-264 Protector 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 415080200-S Overflow tube 414554800...
  • Page 193 COOLING SYSTEM 6 - 4 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 194 COOLING SYSTEM 6 - 5 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 195 COOLING SYSTEM 6 - 6 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 196 REWIND STARTER 5 - 1 CHAPTER 5 REWIND STARTER...
  • Page 197 REWIND STARTER 5 - 2 REWIND STARTER...

  • Page 198: Rewind Starter

    REWIND STARTER 5 - 3 REWIND STARTER Ref. Part descriptions 420810868 Connecting flange 420241236 Socket head screw M6 x 16 3-12 420889765 Rewind starter 420811404 Starter housing 420939115 Rewind spring 420852286 Rope sheave 412500200 Starter rope (2200mm) 420852297 Pawl 420852305 Pawl lock 420847925 Stage sleeve...
  • Page 199 REWIND STARTER 5 - 4 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 200: Rope Replacement

    REWIND STARTER 5 - 5 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 201 REWIND STARTER 5 - 6 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 202 REWIND STARTER 5 - 7 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 203 ENGINE REMOVAL 4-1 CHAPTER 4 ENGINE REMOVAL...

  • Page 204: Engine Removal

    ENGINE REMOVAL 4-2 ENGINE REMOVAL Remove the hood, bellypan and rear module from vehicle. Refer to Chapter 1, GENERAL INSTRUCTIONS. Remove the two forward brackets (P/N SH-032 L/R ) Remove tuned pipe, primary muffler and secondary muffler. Refer to chapter 7, ENGINE. Front fork Use a crate or box to support the vehicle just under the drive sprockets when removing the fork.
  • Page 205 ENGINE REMOVAL 4-3 Front fork Unfasten the tie rod end which connects the steering columb to the upper triple clamp. Unfasten the two fork bolts that retain the fork to the vehicle. Tie rod nut Upper fork bolt (other fork bolt is directly below it) Carburators Remove the rubber latch retaining the fuel tank and place it as shown on the right to have free access to air box and...
  • Page 206 ENGINE REMOVAL 4-4 Recoil Starter Using a flat-head screwdriver, push the knot out of the recess in the starter handle. Since it is often easier, cut the cord just before the knot while holding the cord securely such that it does not slip and go into the recoil housing.
  • Page 207 ENGINE REMOVAL 4-5 Engine Connector Cut the tie-wrap and disconnect the two-place housing that connects the Crank Position Sensor (CPS) to the wiring harness (blue and white/yellow wires). This connector is located just above the jackshaft, near the ignition coil and the water pump oil reservoir. The engine-side of the Crank Position Sensor (CPS) wire then passes down the height of the chassis –...
  • Page 208 ENGINE REMOVAL 4-6 Impulse Hose Disconnect the impulse hose from the crankcase of the engine. Cooling System Loosen the hose clamp that holds the forward cooling hose to the water pump housing inlet at the front of the engine. With a bucket below this point, let the coolant drain from the system completely.
  • Page 209 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 210 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 211 FUEL SYSTEM 3 - 1 CHAPTER 3 FUEL SYSTEM...
  • Page 212 FUEL SYSTEM 3 - 2 FUEL SYSTEM...
  • Page 213 FUEL SYSTEM 3 - 3 Fuel system Ref. Parts descripsions ADB-SH1 Fuel tank 31L 322111-BLK Gaz tank cap 907301-01 7/32" gaz tank (overflow) 95-S21TQ Rubber rope 21" SH-166 Air box 508 000 132 Intake adaptor 508 000 346 Gemi clamp 3060-20-003 Air filter 3060-20-005...
  • Page 214 FUEL SYSTEM 3 - 4 CARBURET0RS (TM 40)
  • Page 215 FUEL SYSTEM 3 - 5 Carburetors (TM 40) Ref. Part Descriptions 403 138 740 Carburator kit TM-40 404 162 017 Funnel (PTO) 404 161 955 Screw 404 161 945 O-ring 404 107 900 Main jet 490 404 161 887 Pilot jet 20 404 162 019 Needle 9DHI12-58-3 404 162 020...
  • Page 216 FUEL SYSTEM 3 - 6 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...
  • Page 217 FUEL SYSTEM 3 - 7 REMOVAL Loosen clamps # 7 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 218 FUEL SYSTEM 3 - 8 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 219 FUEL SYSTEM 3 - 9 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 220 FUEL SYSTEM 3 - 10 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 221: Carburetor Adjustments

    FUEL SYSTEM 3 - 11 CARBURETOR ADJUSTMENTS Adjustments should be performed following this sequence: Pilot screw adjustment Setting Mikuni TM 40 Carburetor synchronization and throttle slide height Pilot jet (preliminary idle speed adjustment) Air screw 1.5 turns 1.5 turns Slide cutaway Throttle cable adjustment Needle 9DHI12-58-3...
  • Page 222 FUEL SYSTEM 3 - 12 CARBURETOR SYNCHRONIZATION AND THROTTLE SLIDE HEIGHT (PRELIMINARY IDLE SPEED ADJUSTMENT) Throttle slide height First proceed on PTO carburetor. Model (drill bit size) ± 0.1 mm (±0.004'') Use a drill bit to measure the throttle slide height (see table at Snow hawk 800 HO 2007 1.6 mm ( 0,063'') right) on outlet side of carburetor (engine side).
  • Page 223 FUEL SYSTEM 3 - 13 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 224 FUEL SYSTEM 3 - 14 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 225: Fuel Pump

    FUEL SYSTEM 3 - 15 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 226 FUEL SYSTEM 3 - 16 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 227 PERIODIC MAINTENANCE 2 - 1 Chapter 2 PERIODIC MAINTENANCE...
  • Page 228 PERIODIC MAINTENANCE 2 - 2 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 229 PERIODIC MAINTENANCE 2 - 3 2.1. CARBURATION 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 230 PERIODIC MAINTENANCE 2 - 4 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 231 PERIODIC MAINTENANCE 2 - 5 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 232 PERIODIC MAINTENANCE 2 - 6 For more information, refer to Chapter 8 - Primary Transmission System. 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.
  • Page 233 PERIODIC MAINTENANCE 2 - 7 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 234 PERIODIC MAINTENANCE 2 - 8 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 235 PERIODIC MAINTENANCE 2 - 9 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. Steering mechanism Verify the condition of the tie rod ends and check for excessive play in the pivots of the steering system.
  • Page 236 PERIODIC MAINTENANCE 2 - 10 2.8. ELECTRICAL SYSTEM Spark plug Check the general condition of the plug, the colour of its electrodes, carbon deposits, plug gap and possible damage to the gasket A NGK BR9ECS spark plug is recommended. Check the spark plug gap. The suggested gap is 0.45 mm Lean Normal (0.018").
  • Page 237 PERIODIC MAINTENANCE 2 - 11 Symbols used on the NGK spark plugs...

  • Page 238: Torque Table

    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 239 GENERAL INSTRUCTIONS 1 - 1 CHAPTER 1 GENERAL INSTRUCTION...
  • Page 240 GENERAL INSTRUCTIONS 1 - 2 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 241 GENERAL INSTRUCTIONS 1 - 3 LOCATION OF MECHANISMS AND CONTROLS (503 SHOWN, 800HO 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 242 GENERAL INSTRUCTIONS 1 - 4 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 293 600 045) ( L )

  • Page 243: Operating Instructions

    GENERAL INSTRUCTIONS 1 - 5 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 244 GENERAL INSTRUCTIONS 1 - 6 Stopping the engine While the engine is idling, remove the engine cutoff cap (tether) or press the emergency-stop button. BREAK-IN PERIOD Engine CAUTION A cautious break-in period of 10 to 15 hours is essential before using the vehicle at full power.
  • Page 245 GENERAL INSTRUCTIONS 1 - 7 Drive Belt A new drive belt must be submitted to a 5-hour break-in period. Avoid high-speed driving and brisk accelerations during this period. Inspection – 10 hours A general inspection is recommended after the first 10 hours of use.
  • Page 246 GENERAL INSTRUCTIONS 1 - 8 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 247 TABLE OF CONTENTS GENERAL INSTRUCTIONS PERIODIC MAINTENANCE FUEL SYSTEM ENGINE REMOVAL REWIND STARTER COOLING SYSTEM ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) PRIMARY TRANSMISSION SYSTEM SECONDARY TRANSMISSION SYSTEM HYDRAULIC BRAKE SYSTEM FRONT FORK AND TWIN-AXIS SKI REAR SUSPENSION, SHOCKS, TRACK AND REAR PAD CHASSIS, STEERING AND BODY ELECTRICAL SYSTEM DIMENSIONS AND TOLERANCES...
  • Page 248 Due to improvements or other right side of vehicle. changes, it is possible that you will note a few differences. AD Boivin design Inc. reserves the right to make changes at any time. WARNING /CAUTION / NOTICE Please read this manual and follow the instructions carefully.

  • Page 249: Replacement Parts

    IMPORTANT MAINTENANCE WARNING WARNINGS: Working on this vehicle without wearing the appropriate clothing can be dangerous. Injuries WARNING could result if you are not adequately protected. Never have the motor running inside a building. Always wear the necessary equipment when The exhaust fumes contain carbon monoxide, a working on the vehicle: shoes, goggles, gloves colourless, odourless gas which can cause...
  • Page 250 Carte de garantie (An English copy is on the reverse ) NUMÉRO D'IDENTIFICATION DU VÉHICULE ______________________ MODÈLE _____________________________________________ COURRIER ÉLECTRONIQUE _____________________________________________ PROPRIÉTAIRE ENREGISTRÉ _____________________________________________ ADRESSE _____________________________________________ VILLE _____________________________________________ ÉTAT/PROVINCE _____________________________________________ ZIP/CODE POSTAL _____________________________________________ NUMÉRO DE TÉLÉPHONE _____________________________________________ LIEU D'ACHAT _____________________________________________ DATE D'ACHAT _____________________________________________ SIGNATURE DU PROPRIÉTAIRE...
  • Page 251 Warranty Card (Une version en français se situe au verso ) VEHICLE SERIAL NUMBER _____________________________________________ MODEL _____________________________________________ EMAIL ADDRESS _____________________________________________ REGISTERED OWNER _____________________________________________ ADDRESS _____________________________________________ CITY _____________________________________________ STATE/PROVINCE _____________________________________________ ZIP/POSTAL CODE _____________________________________________ TELEPHONE NUMBER _____________________________________________ PLACE OF PURCHASE _____________________________________________ DATE OF PURCHASE _____________________________________________ OWNER SIGNATURE _____________________________________________...

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Sh-man-2007

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