Page 2 Section 00 Sub-Section 0 () ® 1997 Shop Manual VOLUME 2 MX Z 440F/440/583/670 FORMULA 500/500 DELUXE/583/Z SUMMIT 500/583/670 GRAND TOURING 500/583 SKANDIC WT/SWT/WT LC 00-0-1...
Page 3 Section 00 Sub-Section 0 (1997 SHOP MANUAL) Legal deposit: National Library of Quebec trimester 1996 National Library of Canada1996 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. ©...
Page 4: Table Of Contents
TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE ..........................1997 BOMBARDIER SNOWMOBILES SHOP MANUAL VOLUME 2 (INTRODUCTION) ....LUBRICATION 01 – Lubrication and maintenance chart .......... 01-01-1 AND MAINTENANCE TROUBLESHOOTING 01 – Table of contents..............02-01-1 02 – Engine ..................02-02-1 03 –...
Page 5 TABLE OF CONTENTS SECTION SUB-SECTION PAGE STEERING/ 01 – Table of contents ..............07-01-1 FRONT SUSPENSION 02 – Steering system............... 07-02-1 03 – Suspension and ski system ............. 07-03-1 BODY/FRAME 01 – Table of contents ..............08-01-1 02 – Body..................08-02-1 03 –...
Page 6: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 1997 Ski-Doo snowmo- biles. See model list on next page. This edition was primarily published to be used by snowmobile mechanics who are already familiar with all service procedures relating to Bombardier made snowmobiles.
Page 7: 1997 Bombardier Snowmobiles Shop Manual Volume 2 (Introduction)
1997 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION This Shop Manual volume 2 covers the following Bombardier made 1997 snowmobiles: MODEL MODEL MODELS MODELS NUMBER NUMBER SUMMIT 500 (Canada) ....1157 MX Z 440F (Canada) ....... 1171 MX Z 440F (U.S.) ......1172 SUMMIT 500 (U.S.) ......
Page 8 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL LIST OF MODELS GROUPED BY COMMUN CHASSIS S-Series consists of: MX Z 440F/440/583/670 FORMULA 500/500 DELUXE/583/Z SUMMIT 500/583/670 GRAND TOURING 500/583 A06H01A TYPICAL 1. Vehicle serial number The engine also has a serial number. Fan-Cooled Engines A03H1UA TYPICAL —...
Page 9 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL ARRANGEMENT OF THE MANUAL The manual is divided into 09 major sections: 01 LUBRICATION AND MAINTENANCE 02 TROUBLESHOOTING 03 ENGINE 04 TRANSMISSION 05 ELECTRICAL 06 REAR SUSPENSION 07 STEERING/FRONT SUSPENSION 08 BODY/FRAME 09 TECHNICAL DATA ANNEXES Each section is divided in various sub-sections, and again, each sub-section has one or more divi-...
Page 10 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. TYPICAL PAGE Page heading indicates section and sub-section detailed. Sub-section title indicates Section 07 REAR SUSPENSION beginning of the sub-section.
Page 11 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL TYPICAL PAGE Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) Title indicates Turn puller handle and sliding half at once to extract INSTALLATION main procedure the bushing. to be carried-out. Countershaft CAUTION Always apply anti-seize lubricant (P/N 413 7010 Italic bold face type 00) on the countershaft before final pulley setting indicates a...
Page 12: General Information
1997 BOMBARDIER SNOWMOBILES SHOP MANUAL GENERAL INFORMATION Use Tools and Accessories Catalog to order the tools you need. The information and component/system descrip- 1994 TOOLS AND ACCESSORIES (P/N 480 1343 tions contained in this manual are correct at time 00). of publication.
Page 13: Tightening Torques
1997 BOMBARDIER SNOWMOBILES SHOP MANUAL The use of RIGHT and LEFT indications in the text, TIGHTENING TORQUES always refers to driving position (when sitting on Tighten fasteners to torque mentioned in explod- vehicle). ed views and text. When they are not specified refer to following table.
Page 14 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft...
Page 15 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS...
Page 16: Lubrication And Maintenance Chart
Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART REFER TO Starting Rope Condition — Engine Head Nuts Appropriate section: See Top End Appropriate section: See ENGINE Engine Mount Nuts REMOVAL Appropriate section: See ENGINE Exhaust System REMOVAL Engine Lubrication...
Page 17 Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) REFER TO Section 06: See appropriate Suspension Adjustments AS REQUIRED sub-section and Operator’s Guide Section 06: See appropriate Suspension Lubrication sub-section Section 06: See appropriate Suspension Condition sub-section Section 06: See appropriate Suspension Stopper Strap Condition sub-section Track Condition...
Page 18 Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 1 ENGINE LUBRICATION Models with a Choke Remove air silencers to spray storage oil into each Engine internal parts must be lubricated to protect carburetor bore. them from possible rust formation during the stor- age period.
Page 19 Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 3 FUEL FILTER REPLACEMENT Drain fuel tank. Remove fuel line grommet from fuel tank and pull out inlet fuel line from tank. A03H0LA TYPICAL 1. Filter A17C0DA To clean the filter, shake the snow out of it then, dry it out.
Page 20 Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 8 GENERAL INSPECTION Inspect the hood and repair any damage. Touch up all metal spots where paint has been scratched Remove any dirt or rust. off. Spray all metal parts including shock chromed rods with Bombardier Lube (P/N 293 6000 06).
Page 21: Troubleshooting
Section 02 TROUBLESHOOTING Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE ..........................02-02-1 FUEL AND OIL SYSTEMS..................... 02-03-1 TRANSMISSION AND BRAKE SYSTEMS ................02-04-1 TRANSMISSION ........................ 02-04-1 BRAKE SYSTEM ........................ 02-04-8 MECHANICAL BRAKE ....................... 02-04-8 HYDRAULIC BRAKE ......................02-04-9 MECHANICAL AND HYDRAULIC BRAKES ..............
Page 22: Engine
Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) ENGINE The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM ENGINE BACKFIRES CONDITION NORMAL USE...
Page 23 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF CONDITION NORMAL USE Test/Inspection 1. Perform engine leak test. Refer to engine leak verification flow chart. Check possible piston seizure. a.Damaged gasket and/or seal. Replace defective parts. 2. “Four-corner” seizure of piston(s). a.Accelerating too fast when engine is cold.
Page 24 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 4. Melted and/or perforated piston dome; melted section at ring end gap. a.When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This situation is due to an incomplete combustion of a poor quality oil.
Page 25 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM PISTON RING AND CYLINDER SURFACES ARE GROOVED CONDITION NORMAL USE Test/Inspection 1. Check oil quality. a.Poor oil quality. Use Bombardier Rotax oil. 2. Check injection pump and its hoses. a.Inadequate injection pump adjustment and/or defective hoses. Adjust pump according to specifications (refer to ENGINE 03) and/or replace hoses.
Page 26 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 8. Check driven pulley. a.Worn bushing and/or spring tension. Replace spring and/or adjust its tension according to specifications (refer to TECHNICAL DATA 09). 9. Check exhaust system. a.Restriction. Replace. 10. Check ignition timing. a.Decrease in power due to retarded ignition. Adjust according to specification (refer to TECHNICAL DATA 09).
Page 27 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE TURNS OVER BUT FAILS TO START CONDITION NORMAL USE Test/Inspection 1. Check switches. a.Ignition switch, emergency cut-out switch or tether switch is in the OFF position. Place all switches in the RUN or ON position. 2.
Page 28 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 5. Check ignition system trigger coil air gap. a.Air gap is too large. Adjust according to specifications (refer to TECHNICAL DATA 09). 6. Check dimension of pilot jet. a.Inadequate fuel/air mixture. Adjust according to specifications (refer to TECHNICAL DATA 09). 7.
Page 29 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 8. Check carburetion. a.Improperly adjusted or inadequate carburetor components. Adjust according to specifications (refer to TECHNICAL DATA 09) or replace inadequate component(s). 9. Check cylinder head gaskets. a.Worn gaskets. Replace. 10. Check ignition timing. a.Ignition timing is too advanced.
Page 30 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH “RAVE”. ENGINE HESITATES AT MID-SPEED AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE CONDITION NORMAL USE Test/Inspection 1. Check “RAVE” valve spring(s). a.Spring tension is too weak or spring(s) is (are) broken. Replace.
Page 31 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE PINGING CONDITION NORMAL USE Test/Inspection 1. Check fuel lines. a.Bent fuel lines (preventing fuel from flowing through). Relocate or replace fuel lines. 2. Check if carburetor(s) is (are) clean. a.Dirt prevents fuel from flowing through. Clean.
Page 32: Fuel And Oil Systems
Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM HIGH FUEL CONSUMPTION (OR RICH MIXTURE) CONDITION...
Page 33 Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM CONDITION NORMAL USE Test/Inspection 1. Check fuel tank vent hose. a.Kinked or clogged hose. Relocate or replace. 2. Check fuel filter. a.Clogged filter. Replace.
Page 34 Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE) CONDITION NORMAL USE Test/Inspection 1. Check fuel filter ball located in fuel tank. Ball must move freely. a.Corrosion due to oxidation at installation. Replace fuel filter.
Page 35: Transmission And Brake Systems
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) TRANSMISSION AND BRAKE SYSTEMS The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. TRANSMISSION SYMPTOM THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED...
Page 36 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED CONDITION NORMAL USE Test/Inspection 1. Check items 1, 2 and 3 of “The snowmobile accelerates slowly, especially when it is stopped”. 2.
Page 37 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY CONDITION NORMAL USE Test/Inspection 1. Check drive belt. a.Belt width is uneven at many places. Replace (refer to TECHNICAL DATA 09 for the part number). 2.
Page 38 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY CONDITION NORMAL USE Test/Inspection 1. Check driven pulley spring tension. a.Spring tension is too weak. Adjust according to specifications (refer to TECHNICAL DATA 09). 2.
Page 39 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE CONDITION NORMAL USE Test/Inspection 1. Check if drive pulley bushings are worn. a.Insufficient pressure on belt sides. Replace bushing. 2. Check condition of drive pulley fixed half shaft. a.Rusted drive or driven pulley shafts.
Page 40 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT WORN NARROW IN ONE SECTION CONDITION NORMAL USE Test/Inspection 1. Check if parking brake is released. a.Parking brake is engaged. Release parking brake. 2. Check track tension/alignment. a.Frozen or too tight track. Liberate track from ice or check track tension and alignment.
Page 41 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT DISINTEGRATION CONDITION NORMAL USE Test/Inspection 1. Check drive belt identification number. a.Excessive belt speed. Using unspecified type of belt. Replace belt with proper type of belt (refer to TECHNICAL DATA 09). 2.
Page 42: Brake System
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT “FLIP-OVER” AT HIGH SPEED CONDITION NORMAL USE Test/Inspection 1. Check pulley alignment. a.Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA 09). 2. Check drive belt identification number. a.Using unspecified type of belt.
Page 43: Hydraulic Brake
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) HYDRAULIC BRAKE SYMPTOM SPONGY BRAKE CONDITION CONDITION NORMAL USE Test/Inspection Replace brake fluid and bleed system. If problem still occurs, replace master cylinder. SYMPTOM BRAKE FLUID LEAKING CONDITION NORMAL USE Test/Inspection 1.
Page 44: Electrical System
Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM STARTER DOES NOT TURN CONDITION...
Page 45 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 7. Check brushes. a.Poor contact of brushes. Replace brushes. 8. Check commutator. a.Burnt commutator. Turn commutator on lathe. 9. Check height of commutator mica. a.Commutator mica too high. Undercut mica. 10. Check field coil resistance. a.Shorted field coil.
Page 46 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 4. Check clutch bushing. a.Worn clutch bushing. Replace clutch. 5. Check starter bushing. a.Worn starter bushing(s). Replace bushing(s). 6. Check ring gear. a.Worn ring gear. Replace ring gear . SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED CONDITION NORMAL USE Test/Inspection...
Page 47 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN TURNING IGNITION SWITCH CONDITION NORMAL USE Test/Inspection 1. Check battery cables and starter wires. a.Corroded and/or loose connection(s). Clean and/or retighten. 2. Check fuse. a.Oxidized fuse. Clean.
Page 48 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM HEADLAMP DIMING CONDITION NORMAL USE Test/Inspection 1. Check voltage at headlamp at different speeds. It must not be below 11 VAC. a.Insufficient voltage in lighting circuit. Replace voltage regulator and retest. 2. Visually inspect wiring harness for damaged and/or melted wires and/or bad wire terminal crimping and/or connections.
Page 49 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM FALSE FUEL AND/OR TEMPERATURE GAUGE READINGS CONDITION NORMAL USE Test/Inspection 1. Verify if gauge was connected on DC current by mistake (in case of optional installation). a.Faulty installation of optional equipment. Find optional wires connected directly to DC ground (BK wire to chassis) or to any DC hot wire (RD, RD/BL).
Page 50 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 6. Verify condition of ignition generator coils. a.Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting screws. Replace coils. 7. Verify CDI (Capacitor discharge ignition) module. a.Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting screws.
Page 51 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) CONDITION RIDING IN DEEP AND THICK SNOW Test/Inspection 1. Perform all verifications outlined under “Engine does not start–no spark at spark plug”. 2. Verify spark plug(s). Proceed with spark plug analysis in order to identify source of problem.
Page 52 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM BRAKE LIGHT REMAINS ON CONDITION NORMAL USE Test/Inspection 1. Check if bulb is properly installed. a.Bulb is not installed correctly (contact elements are reversed). Install bulb correctly. 2. Check brake switch. a.Switch contact remains closed. Adjust brake cable or brake switch.
Page 53: Suspension System And Track
Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SUSPENSION SYSTEM AND TRACK The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM REAR SUSPENSION BOTTOMS OUT CONDITION...
Page 54 Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) 5. Check track rods and/or internal traction teeth. a.One or various track rods and/or teeth are broken. Replace track. SYMPTOM DERAILING TRACK CONDITION NORMAL USE Test/Inspection 1. Check track tension. a.Track is too loose. Adjust.
Page 55 Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SYMPTOM HANDLE BAR IS DIFFICULT TO TURN CONDITION NORMAL USE Test/Inspection 1. Check position of front spring adjustment cams. a.More pressure on the ground when cam increases spring preload. Reduce front spring preload. 2.
Page 56: Engine
Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 443 AND 503 ENGINE TYPES................... 03-02-1 ENGINE REMOVAL AND INSTALLATION..............03-02-1 ENGINE REMOVAL AND INSTALLATION ..............03-02-2 TUNED PIPE IDENTIFICATION ..................03-02-2 ENGINE REMOVAL AND INSTALLATION ..............03-02-4 TOP END ........................03-02-5 CLEANING ........................
Page 57 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) ENGINE DIMENSION MEASUREMENT ............... 03-04-6 CYLINDER TAPER......................03-04-6 CYLINDER OUT OF ROUND ..................03-04-6 CYLINDER/PISTON CLEARANCE .................. 03-04-6 RING/PISTON GROOVE CLEARANCE ................03-04-7 RING END GAP....................... 03-04-7 CRANKSHAFT DEFLECTION ..................03-04-7 CONNECTING ROD BIG END AXIAL PLAY ..............03-04-8 CONNECTING ROD/PISTON PIN CLEARANCE............
Page 58 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) LIQUID COOLING SYSTEM ....................03-08-1 INSPECTION ........................03-08-3 DRAINING THE SYSTEM ....................03-08-3 DISASSEMBLY AND ASSEMBLY ................. 03-08-3 COOLING SYSTEM REFILLING PROCEDURE ............. 03-08-4 ROTARY VALVE, COOLANT PUMP AND RESERVOIR....................... 03-09-1 GENERAL ........................03-09-2 CLEANING ........................
Page 59: 443 And 503 Engine Types
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) 443 AND 503 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION 443 Engine Type 28 N•m (21 lbf•ft) 17 N•m (150 lbf•in) 37 N•m (27 lbf•ft) 35 N•m (26 lbf•ft) A03C13S FLAT RATE PARTS 03-02-1...
Page 60: Tuned Pipe Identification
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following: WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models). –...
Page 61 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) Skandic WT/SWT 503 Engine Type 21 N•m (15 lbf•ft) A22C0FS FLAT RATE PARTS 03-02-3...
Page 62 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following: WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models). –...
Page 63: Top End
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) TOP END 22 N•m 22 N•m (16 lbf•ft) (16 lbf•ft) 2 22 N•m (16 lbf•ft) only 22 N•m (16 lbf•ft) 22 N•m only (16 lbf•ft) 22 N•m (16 lbf•ft) Grease only A22C0KS FLAT RATE...
Page 64: Cleaning
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) NOTE: The following procedures can be done without removing the engine from chassis. CLEANING Discard all gaskets. Use Gasket Remover (P/N 413 7085 00) to clean mating surfaces. Clean all metal components in a non-ferrous met- al cleaner.
Page 65: Inspection
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) NOTE: The PTO cylinder or fan housing have to be removed to give access to MAG piston pin with the puller. NOTE: 0.25 and 0.5 mm oversized piston and rings are available if necessary. INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT 03-04.
Page 66 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) – When installing new needle bearing, insert needles with thrust washers. Instead of expan- sion sleeve, needles are held in place by 2 inner plastic cage halves. – Use piston pin puller (P/N 529 0210 00) to insert piston pin.
Page 67 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) NOTE: The ring compressor will not fit on over size pistons. Check flatness of intake sockets no. 10. Refer to ENGINE DIMENSION MEASUREMENT 03-04 529 0169 00 and look for checking surface flatness. At cylinder no.
Page 68 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) Position distance nuts no. 2 as illustrated. A17C06A 1. Distance nuts Cross torque cylinder head nuts nos. 1 and 2 to 22 N•m (16 lbf•ft); torque each cylinder head indi- vidually.
Page 69: Bottom End
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) BOTTOM END Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant Loctite 242 22 N•m (16 lbf•ft) 503: 22 N•m (16 lbf•ft) 443: 10 N•m (89 lbf•in) A03C1IT FLAT RATE FLAT RATE PARTS 03-02-11...
Page 70: Cleaning
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) NOTE: Engine must be removed from chas- To check proper clearance between bearing no. 3 sis to perform the following procedures. and counterweight, use feeler gauge (P/N 420 8766 20). Remove engine from chassis.
Page 71 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) For bearing lubrication purpose, a gap of 1.0 mm (.040 in) must be maintained between seals and bearings. When installing plain oil seals (seal without locat- ing ring or without spacing legs), ensure to main- tain 1.0 mm (.040 in) gap.
Page 72: Engine Support And Muffler
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) 454, 494, 583 AND 670 ENGINE TYPES3 ENGINE SUPPORT AND MUFFLER All Models 583 and 670 440 and 494 Loctite 454, 494 and 670 engines 23 N•m MX Z 440, (17 lbf•ft) 583 and 670 24 N•m...
Page 73: Removal From Vehicle
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) REMOVAL FROM VEHICLE 3,4,5, Tuned Pipe, Tail Pipe and Muffler These parts are identified on welded hook. Disconnect or remove the following from vehicle. Second number sequence of P/N is stamped on –...
Page 74 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) 3, Tuned Muffler This part is identified on welded support. Second number sequence of P/N is stamped on part. A03C1KA 1. Identification – Should a light exhaust leak be experienced at any ball joints, Dow Corning sealer no.
Page 75: 494, 583 And 670 Engine Types
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) TOP END 454, 583 and 670 engine types only 29 N•m Pipe sealant (21 lbf•ft) (P/N 413 7023 00) 494 engine only Loctite Grease Pipe sealant Grease (P/N 413 7023 00) 29 N•m (21 lbf•ft) 10 N•m...
Page 76: Cleaning
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) NOTE: The following procedures can be RAVE System done without removing the engine from NOTE: RAVE stands for Rotax Adjustable chassis. Variable Exhaust. Remove spring clip no. 3, cover no. 5 and spring CLEANING no.
Page 77: Assembly
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) A01C01A 1. Exhaust Use piston pin puller (P/N 529 0210 00) to ease piston pin installation. A24C05A To minimize the effect of acceleration forces on TYPICAL circlip, install each circlip so the circlip break is at 1.
Page 78 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) A00A1FA A. 0.43 mm (.017 in) feeler gauge A01C02B 2. Apply Loctite 242 to screw threads. Properly TYPICAL torque cylinders screws. 1. Circlip break 3. Lay down cylinder head and insert aligning pins in holes as shown.
Page 79 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) 420 8769 02 A24C0NA Apply Loctite 242 (P/N 413 7030 00) on cylinder screw threads. Install and torque screws in a criss-cross se- A25C0CA quence for each cylinder to 29 N•m (21 lbf•ft). For TYPICAL 454 and 670 engines longer screws go on exhaust 1.
Page 80 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) Torque screws no. 1 to 10 N•m (90 lbf•in). RAVE SYSTEM Install exhaust valve in cylinder with its mention TOP upward (see illustration at removal). Install gasket and valve rod housing with their pas- sages toward bottom.
Page 81: Bottom End
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) BOTTOM END Lithium grease 454, 494 engines only Loctite 454, 494 Anti-seize lubricant engines Anti-seize only lubricant Loctite 29 N•m (21 lbf•ft) Except 454, 494 and 670. See CDI Loctite SYSTEM 10 N•m...
Page 82: Cleaning
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) NOTE: Engine must be removed from chas- ASSEMBLY sis to perform the following procedures. 2,4,5,6,9, Crankshaft Bearing and CLEANING Labyrinth Sleeve Smear anti-seize lubricant (P/N 413 7010 00) on Discard all oil seals, gaskets, O-rings and sealing part of crankshaft where bearing fits.
Page 83 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) 1,8, Upper Crankcase and Lower Crankcase Crankcase halves are factory matched and there- fore, are not interchangeable or available as single halves. Prior to joining of crankcase halves, spray some new injection oil (or equivalent) on all moving parts of the crankshaft.
Page 84 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) NOTE: Torque the 2 smaller screws (15 and 16) on magneto side to 10 N•m (90 lbf•in). Apply pipe sealant (P/N 413 7023 00) on threads prior to assembly angular tube no. 11. At assembly on crankcase, apply medium strength threadlocker (P/N 413 7030 00) on stud threads no.
Page 85: Leak Test And Engine Dimension Measurement
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for liq- 10. Engine must stand this pressure during 3 min- uid cooled engines though it also applies to fan utes.
Page 86 Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Engine Check the following: 1. All jointed surfaces and screw/stud threads of engine: – spark plug base, insulator – cylinder head – cylinder base – crankcase halves (joint) – rotary valve cover –...
Page 87 Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Block both hoses of rotary valve gear lubrica- 1. Remove a spark plug or any plug of leak tester tion system with hose pinchers. kit on PTO side. If pressure drops, it indicates defective crank- shaft inner seal on PTO side.
Page 88: Finalizing Reassembly
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Remove rotary valve cover and check for leak COOLING SYSTEM LEAK TEST of rotary valve seal with soapy water. Install special plug (radiator cap) (P/N 529 0214 00) and hose pincher (P/N 529 0099 00) on overflow hose.
Page 89: Engine Leak Verification Flow Chart
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP...
Page 90: Engine Dimension Measurement
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT This section covers all engine types. CYLINDER TAPER ENGINE TYPE MAXIMUM 0.08 mm (.003 in) Compare cylinder diameter 16 mm (5/8 in) from top of cylinder to just below its intake port area. On rotary valve engines, measure just below aux- iliary transfer port, facing exhaust port.
Page 91: Ring/Piston Groove Clearance
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A01C0PA RING END GAP Position ring half way between transfer ports and intake port. On rotary valve engines, position ring just below transfer ports. NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher.
Page 92: Connecting Rod Big End Axial Play
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Measuring (on bench) NOTE: Crankshaft deflection can not be cor- rectly measured between centers of a lathe. Once engine is disassembled, check crankshaft If the deflection exceeds the specified tolerance, deflection on V-shaped blocks.
Page 93: Connecting Rod/Crankpin Clearance
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CRANKCASE/ROTARY VALVE GAP ENGINE TYPE MINIMUM MAXIMUM Liquid cooled 0.27 mm 0.40 mm engines (0.011 in) (0.016 in) First Method To measure this gap use a feeler gauge inserted between rotary valve and upper crankcase with the rotary valve cover in place without its O-ring.
Page 94: Checking Surface Flatness
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Install 2 short pieces (13 mm (1/2 in) long) of sol- der directly on rotary valve, one above and one be- low rotary valve gear. Apply grease to hold solder in position.
Page 95: Cdi System
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 454, 494, 583, and 670 Engines Dielectric grease (P/N 413 7017 00) 454,494 and 670 engines Loctite Loctite Loctite Loctite All engines except 454, 494 and 670 Loctite Dielectric grease (P/N 413 7017 00)
Page 96: Cleaning
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) NOTE: The following procedures can be done without removing the engine from chassis. To facilitate magneto removal, hold drive pulley with tool (P/N 529 0276 00). CDI means Capacitor Discharge System. CLEANING Clean all metal components in a non-ferrous met- al cleaner.
Page 97 Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) A25E1AA 1. Magneto harness through crankcase hole – Install new trigger coil and other parts re- moved. Adjustment A15E0NA Whenever the trigger coil or the magneto fly- ADJUSTING TRIGGER COIL AIR-GAP wheel is removed or replaced, the air-gap be- 1.
Page 98: Assembly
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) 2,5, Magneto Flywheel and Nut Clean crankshaft extension (taper) and apply Loc- tite 242 (blue) on taper, then position Woodruff key, flywheel and lock washer on crankshaft. Clean nut threads and apply Loctite 242 (blue) then tighten nut 125 N•m (92 lbf•ft) for 454, 494 and 670 engines.
Page 99: Ducati Ignition System
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) DUCATI IGNITION SYSTEM 443 and 503 Engines Dielectric grease Loctite 105 N•m (77 lbf•ft) Loctite 22 N•m (195 lbf•in) A07C03S FLAT RATE PARTS 03-05-5...
Page 100: Cleaning
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) NOTE: The following procedures can be NOTE: To correctly remove a threadlocked done without removing the engine from fastener it is first necessary to tap on the fas- chassis. tener to break threadlocker bond. This will elimi- nate the possibility of thread breakage.
Page 101: Assembly
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) ASSEMBLY Clean crankshaft extension (taper). Apply Loctite 242 (blue) on taper. Position Woodruff key, flywheel and lock washer on crankshaft. Clean nut threads and apply Loctite 242 (blue) be- fore tightening nut to 105 N•m (77 lbf•ft). At reassembly coat all electric connections with silicone dielectric grease (P/N 413 7017 00) to pre- vent corrosion or moisture penetration.
Page 102: Oil Injection System
Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 454, 494, 583 and 670 Engines O i l p u t s e t g a s k e Loctite Molykote Loctite Parts in illustration marked with X are not available as single parts.
Page 103 Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) 443 and 503 Engines Loctite 242 Loctite Molykote 111 A22C0DS PARTS FLAT RATE 03-06-2...
Page 104: Oil Pump Identification
Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) OIL PUMP IDENTIFICATION Different engines use different pumps. See iden- tification on lever no. 7. 420 2779 05 CAUTION Always mount proper pump on engine. OIL PUMP ENGINE TYPE IDENTIFICATION 443 MX Z A00C17A TYPICAL 494 Skandic WT LC...
Page 105 Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) A15C2DA A13C0PA 1. Adjuster nut 1. Small oil line 2. Bleeder screw 2. Marks aligned 3. Marks in line 3. Main oil line Reinstall all parts except air silencer. CAUTION Bleed the small oil line between pump and intake manifold by running engine at idle while holding Proper oil injection pump adjustment is very the pump lever in fully open position.
Page 106: Checking Operation
Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) CHECKING OPERATION If not, remove pump assembly and check the pump gear and drive shaft (if applicable) for de- fects, replace as necessary. Test pump as de- On Vehicle scribes below. NOTE: Main oil line must be full of oil. See NOTE: Through normal use, oil level must bleeding procedure above.
Page 107: Axial Fan Cooling System
Section 03 ENGINE Sous-section 07 (AXIAL FAN COOLING SYSTEM) AXIAL FAN COOLING SYSTEM 443 Engine 13 N•m (115 lbf•in) 443 and 503 engines only 47 N•m (35 lbf•ft) A03C0WS FLAT RATE PARTS 03-07-1...
Page 108 Section 03 ENGINE Sous-section 07 (AXIAL FAN COOLING SYSTEM) 503 Engine 13 N•m (115 lbf•in) 13 14 15 16 55 N•m (41 lbf•ft) A22C0IS PARTS FLAT RATE 03-07-2...
Page 109: Removal
Section 03 ENGINE Sous-section 07 (AXIAL FAN COOLING SYSTEM) NOTE: The following procedures can be done without removing engine from chassis. REMOVAL NOTE: To facilitate further disassembly, fan nut may be removed before removing fan housing. Remove rewind starter, starting pulley, trigger coil wire from 4-connector housing then fan housing ass’y.
Page 110 Section 03 ENGINE Sous-section 07 (AXIAL FAN COOLING SYSTEM) Using a press, drive the fan shaft no. 9 out. Remove circlip no. 11 then remaining bearing. To install, press one bearing in place then install circlip and shims. Press the other bearing from op- posite side until it is flush with housing.
Page 111: Liquid Cooling System
Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM All S-Series Engines Loctite A06C2VT FLAT RATE PARTS 03-08-1...
Page 112 Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) Skandic WT LC Loctite Loctite A29C0AS PARTS FLAT RATE 03-08-2...
Page 113: Inspection
Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) INSPECTION 6,7, Radiator and Radiator Protector Insert radiator protector into radiator C-rail and Check general condition of hoses and clamp tight- crimp C-rail at both ends. Refer to FRAME 09-02 ness. for radiator removal. DRAINING THE SYSTEM 5, Thermostat To check thermostat, put in water and heat water.
Page 114: Cooling System Refilling Procedure
Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) COOLING SYSTEM REFILLING PROCEDURE Recommended Coolant Use a blend of 60% antifreeze with 40% water. Do not reinstall pressure cap. CAUTION To prevent rust formation or freezing condi- tion, always replenish the system with 60% antifreeze and 40% water.
Page 115 Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) Turn engine off. Let it cool down for 15 to 20 min- utes. Open cap and refill filler neck completely. Start engine and let it idle. Do not race engine. If coolant level gets down, add more coolant in filler neck.
Page 116: Rotary Valve, Coolant Pump And Reservoir
Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) ROTARY VALVE, COOLANT PUMP AND RESERVOIR 454, 494, 583 and 670 Engines Injection oil reservoir Loctite To rotary valve gear Molykote Loctite 22 N•m (16 lbf•ft) A06C2UT TYPICAL FLAT RATE PARTS 03-09-1...
Page 117: General
Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) NOTE: Some verifications can be performed with engine in vehicle. Refer to ENGINE DI- MENSION MEASUREMENT 03-04. GENERAL Engine must be removed from vehicle to work on rotary valve shaft/components. Refer to Removal and installation of appropriate engine for proce- dures.
Page 118: Inspection
Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) To remove bearing, use a bearing puller (ex.: Snap-on no. CJ 950) and pusher (P/N 420 8766 12) as illus- trated. 420 8765 12 420 8766 12 A16C0OA INSPECTION Inspect rotary valve cover for warpage.
Page 119 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) 11, Bearing 6201 To install bearing 6201 use bearing pusher (P/N 420 8765 00). 420 8765 00 A13C0FA 1. Bearing 2. Shielded portion of seal here 3. Press 4. Bearing puller. Ex.: Snap-on no. CJ 950 A16C19A Install distance sleeve with its counterbore first.
Page 120 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) – Install rubber washer then support plate with its flange towards pump impeller. Use impeller support plate pusher (P/N 529 0207 00) for proper installation. – Install small thrust washer then friction washer positioning its grooves against pump impeller.
Page 121 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) 18,19, Pump Housing Bolt and Loctite 242 (Blue) Apply Loctite 242 (blue) on bolt threads. 420 8765 00 Rotary Valve The rotary valve controls the opening and closing of the inlet ports. Therefore its efficiency will de- pend on the precision of its installation.
Page 122 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) Installation To correctly install rotary valve, proceed as fol- lows: – Turning crankshaft, bring MAGneto side piston to Top Dead Center. Use a dial indicator (P/N 414 1047 00). 414 1047 00 A00B2EA A16C16A...
Page 123 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) To Time Rotary Valve Exactly to Specifications NOTE: If desynchronization (out of spec.) is unknown, install rotary valve to determine it before proceeding with the following. 132° First Method Turn crankshaft to bring MAG piston to TDC.
Page 124: Rewind Starter
Section 03 ENGINE Sub-Section 10 (REWIND STARTER) REWIND STARTER All Models Molykote G-n paste or equivalent Silicone compound grease Silicone compound grease 10 N•m (89 lbf•in) 583 MX Z, 583 Summit and 670 engines only A01C57T TYPICAL FLAT RATE PARTS 03-10-1...
Page 125: Removal
Section 03 ENGINE Sub-Section 10 (REWIND STARTER) REMOVAL Using a small screwdriver, extract rope knot from starter grip no. 16. Cut rope close to knot. Tie a knot near starter. Remove screws no. 3 and washers no. 2 secur- ing rewind starter no. 1 to engine then remove re- wind starter.
Page 126: Installation
Section 03 ENGINE Sub-Section 10 (REWIND STARTER) A01C0CA Position pawl no. 8, pawl lock no. 9 and circlip A01C14A no. 10. 1. Grease inside spring guide Install locking spring no. 11 and lubricate with MOLYKOTE G-n paste from Dow Corning ®...
Page 127 Section 03 ENGINE Sub-Section 10 (REWIND STARTER) Prior to installing starter grip no. 16 on new rope, it is first necessary to fuse the rope end with a lit match. pass rope through rubber buffer no. 15 and starter grip and tie a knot in the rope end. fuse the knot with a lit match then insert rope end down and pull the starter grip over the knot.
Page 128: Carburetor And Fuel Pump
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP All Models To other carburetor MX Z 440 F and Skandic WT series only A03C1MS FLAT RATE PARTS 03-11-1...
Page 129: Removal
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) REMOVAL 15, Filter Check for clogged filter. Clean or replace as re- Remove air silencer(s). Refer to BATTERY 05-05. quired. Disconnect fuel inlet line. Check inlet needle tip condition. If worn, the inlet Disconnect primer line from carburetor on some needle and seat must be replaced as a matched models.
Page 130: Disassembly And Assembly
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) DISASSEMBLY AND ASSEMBLY The size of the throttle slide cut-away affects the fuel mixture between 1/8 to 1/2 throttle opening. NOTE: To ease the carburetor disassembly and assembly procedures it is recommend- ed to use carburetor tool kit (P/N 404 1120 00).
Page 131 Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) FLOAT HEIGHT H CARBURETOR ± 1 mm MODEL (± .040 in) MX Z 440 F 23.9 (.941) MX Z 440 23.9 (.941) MX Z 583 18.1 (.713) MX Z 670 18.1 (.713) Formula 500/500 DL 18.1...
Page 132: Installation
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) NOTE: Do not obstruct hole in throttle slide Throttle slide openings when installing needle retaining plate. This is important to allow air escaping through and thus Wide allowing a quick response. open Close 13,6,...
Page 133: Carburetor Adjustments
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) CARBURETOR ADJUSTMENTS A02C09A A01C33A 1. Idle speed screw TYPICAL 2. Air screw 1. Screw in and out until no cable free play exists 2. Check that throttle side does not move 6, Air Screw Adjustment 3.
Page 134: Preliminary Idle Speed Adjustment
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) Twin Carburetor Models Only Repeat on the other one. This will ensure identical throttle slide preliminary idle setting. Recheck car- buretor synchronization. Adjust idle by turning both idle speed screws of the same amount. CAUTION On twin carburetor models, make sure both carburetors start to operate simultaneously.
Page 135: Idle Speed Final Adjustment
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) NOTE: On twin-carburetor models: Turn Throttle Slide Height Models adjustment screw the same amount to keep mm (in) carburetors synchronized. MX Z 440 F 1.5 (.059) Refer to TECHNICAL DATA 09 for the specifica- MX Z 440 1.8 (.071) tions.
Page 136: Hac System
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) HAC SYSTEM To magneto housing A03I0BS FLAT RATE PARTS 03-11-9...
Page 137: Fuel Pump
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) FUEL PUMP 443/503 engines 454 engine 583, 599, 670 and 779 engines A06C39T PARTS FLAT RATE 03-11-10...
Page 138: Removal
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) REMOVAL Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed Install a hose pincer (P/N 529 0099 00) on fuel air. supply line close to pump inlet. WARNING Solvent with a low flash point such as gaso- line, naphtha, benzol, etc., should not be...
Page 139: Fuel Tank And Throttle Cable
Section 03 ENGINE Sub-Section 12 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE Fuel Tank Lines Models with Easy Action Throttle Lever WARNING When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with a hose pincher (P/N 529 0099 00) or equivalent device.
Page 140 Section 03 ENGINE Sub-Section 12 (FUEL TANK AND THROTTLE CABLE) Throttle Cable O-ring and Retaining Ring at Carburetor (some models) Locate O-ring outside of carburetor cover and re- taining ring inside. 100.7° A01E18A 1. Full position (3 ± 2 Ω ) 2.
Page 141: Transmission
Section 04 TRANSMISSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DRIVE BELT........................04-02-1 1997 APPLICATION CHART ..................04-02-1 ROTATION DIRECTION....................04-02-1 DRIVE BELT DEFLECTION MEASUREMENT ............... 04-02-2 DEFLECTION ADJUSTMENT..................04-02-3 DRIVE PULLEY........................04-03-1 TRA ..........................04-03-1 GENERAL ........................04-03-2 REMOVAL........................
Page 142 Section 04 TRANSMISSION Sub-Section 01 (TABLE OF CONTENTS) CHAINCASE........................04-07-1 REMOVAL ........................04-07-2 INSPECTION ........................04-07-2 GEAR RATIO MODIFICATION..................04-07-2 INSTALLATION ....................... 04-07-2 DRIVE CHAIN ADJUSTMENT..................04-07-3 ADJUSTMENT........................ 04-07-4 GEARBOX........................... 04-08-1 3-SPEED GEARBOX (SHIFTER MECHANISM).............. 04-08-1 REMOVAL ........................04-08-2 ADJUSTMENT........................ 04-08-2 3-SPEED GEARBOX .......................
Page 143: Drive Belt
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) DRIVE BELT 1997 APPLICATION CHART PART WIDTH (NEW) MINIMUM WIDTH MODEL ± 0.25 mm (.010 in) NUMBER (WEAR LIMIT) SUMMIT 583/670 AND MX Z 670 415 0603 00 35 mm (1-3/8’’) 33 mm (1-19/64’’) SUMMIT 500, GRAND TOURING 500/583, FORMULA 500/500DL/583/Z 415 8607 00...
Page 144: Drive Belt Deflection Measurement
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) DRIVE BELT DEFLECTION MEASUREMENT NOTE: The drive belt deflection measure- ment must be performed each time a new drive belt is installed. NOTE: To obtain an accurate drive belt de- flection measurement, it is suggested to al- low a break-in period of 50 km (30 mi).
Page 145: Deflection Adjustment
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) Allen screws should be restrained while tighten- ing jam nut to prevent throwing adjustment out. Use drive belt tension adjuster (P/N 529 0087 00). 529 0087 00 A00D08A A15B05B 1. Upper O-ring 2. Force 3.
Page 146: Drive Pulley
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) DRIVE PULLEY All Models NOTE: This is a lubrication free drive pulley. 12 N•m Loctite Loctite Loctite (106 lbf•in) 27 N•m (20 lbf•ft) 13 N•m (115 lbf•in) Loctite 10 N•m (89 lbf•in) Loctite 95 N•m (70 lbf•ft) Repair kit...
Page 147: General
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) GENERAL Some drive pulley components (return spring, ramp) can be changed to improve vehicle perfor- mance in high altitude regions. The High Altitude Technical Data booklet (P/N 484 0648 00 and 484 0545 00 for binder) gives information about cali- bration according to altitude.
Page 148: Disassembly
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) To Remove Drive Pulley Ass’y: 32, Cushion Drive Retain drive pulley with clutch holder. CAUTION Install puller in pulley shaft then tighten. Do not disassemble cushion drive. Governor DISASSEMBLY cup and cushion drive are factory balanced as an assembly.
Page 149: Cleaning
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 19, Spring Cover Ass’y Using a paper towel with cleaning solvent (P/N 413 7082 00), clean crankshaft tapered end and It is pushed by clutch spring pressure. the taper inside the fixed half of the drive pulley, crankshaft threads and retaining screw threads.
Page 150: Inspection
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) INSPECTION Drive pulley should be inspected annually. 16,17, Thrust Washer and Roller 529 0313 00 Check roller for roundness of external diameter. Check thrust washer for thickness wear. Replace 529 0312 00 as required. CAUTION Ensure rollers are in good condition.
Page 151: Assembly
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Press bushing. 15, Pin Always use the same type of pin as originally in- stalled when servicing. Different types have dif- ferent weights for calibration purpose. Refer to TECHNICAL DATA 09-03. 21,22,23, Ramp, Dowel Tube and Screw 529 0313 00 Insert dowel tube from chamfered side.
Page 152 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 9,11,13,14, Screw, Lever Ass’y, Nut and Lift sliding half against spring cover and align spring cover arrow with sliding half mark. Cotter Pin Always install lever assemblies so that cotter pins are at the shown side. Besides install cotter pin head on top when lever is sat at bottom of sliding half.
Page 153: Installation
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) INSTALLATION WARNING 529 0055 00 Do not apply anti-seize or any lubricant on crankshaft and drive pulley tapers. WARNING Never use any type of impact wrench at drive pulley removal and installation. A16B02A Clean mounting surfaces as described in CLEAN- ING above.
Page 154: Drive Pulley Adjustment
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Recheck the torque of 90 to 100 N•m (66 to 74 Governor cup has 6 positions numbered 2 to 6. lbf•ft). Note that in position 1 there is no stamped num- ber (due to its location on casting). WARNING See TECHNICAL DATA 09-03 for original setting.
Page 155 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) A16D0HA 1. Loosen just enough to permit rotating of calibration screw 04-03-10...
Page 156: Driven Pulley
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) DRIVEN PULLEY S-Series Anti-seize lubricant (P/N 413 7010 00) Loctite 609 All MX Z except 440 F All MX Z except 440 F A03D2FS FLAT RATE PARTS 04-04-1...
Page 157 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Skandic WT/SWT/WT LC Anti-seize lubricant A22D11S PARTS FLAT RATE 04-04-2...
Page 158: Removal
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) REMOVAL CLEANING Remove belt guard and drive belt from vehicle. 6,7, Large Bushing and Small Bushing Remove the cap screw no. 13, lock washer During break-in period (about 10 hours of use), te- no.
Page 159: Bushing Replacement
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Replace bushing(s) if worn more than specified. Install support plate (P/N 529 0311 03) inside slid- ing half. DRIVEN PULLEY BUSHING WEAR LIMIT Place puller (P/N 529 0311 02) below bushing. mm (in) Small bushing 38.30 (1.508) Large bushing...
Page 160: Assembly
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Turn puller handle and sliding half at once to ex- 19, Cam tract the bushing. Coat cam interior with anti-seize lubricant. INSTALLATION 14,15, Countershaft and Anti-seize Lubricant 529 0313 00 CAUTION Always apply anti-seize lubricant (P/N 413 529 0312 00 7010 00) on the countershaft before final pul- ley installation.
Page 161: Adjustment
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) ADJUSTMENT Refer to PULLEY DISTANCE AND ALIGNMENT 04-05 to adjust pulley distance. Adjust drive belt 529 0065 00 height in driven pulley to obtain specified belt de- flection. 5, Spring General It is usual to experience spring setting during breaking period of a new spring.
Page 162 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Pulley Alignment and Drive Belt Deflection Refer to PULLEY DISTANCE AND ALIGNMENT 04-05 and DRIVE BELT 04-02 to perform adjust- ments. CAUTION Drive belt and pulley adjustments must always be checked whenever pulleys have been re- moved, replaced or disassembled.
Page 163: Pulley Distance And Alignment
Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) PULLEY DISTANCE AND ALIGNMENT GENERAL Measuring Procedure Using Straight Bar: The pulley distance we will refer to in this section, is the space separating the drive and driven pulley Always measure distances X and Y from the far- outside diameters (Z measurement).
Page 164: Pulley Alignment And Distance Specifications Chart
Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) Drive Belt Deflection NOTE: When pulley distance and alignment are adjusted to specifications, refer to DRIVE BELT 04-02 to adjust drive belt deflection. CAUTION This section deals mainly with adjustment procedures. For complete assembly require- ments, refer to the proper ENGINE or TRANSMISSION installation section.
Page 165 Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) S-Series Pulley Alignment Method Driven Pulley Movement When engine slotted mounting holes do not allow to set proper pulley offset X, adjust with shims (P/N 504 1082 00) between pulley and counter- shaft bearing support (pulley pushed toward brake disc).
Page 166: Brake
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) BRAKE HYDRAULIC DISC BRAKE S-Series Loctite Anti-seize lubricant Black Max MX Z 440 F Formula 500/500 Deluxe Summit 500/583 All Models GT 500/583 Except MX Z 440 F only Formula 500/500 Deluxe Summit 500/583 Anti-seize lubricant GT 500/583 A03D2DS...
Page 167: Removal
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) REMOVAL BRAKE DISC REMOVAL S-Series Brake disc can be withdraw without removing cal- iper. Proceed as follows: – Remove belt guard, belt and driven pulley. – Remove air silencer. – Unbolt bearing support no. 19 from chassis. –...
Page 168: Disassembly
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) 529 0302 00 A03D29A 1. Screw A03D1KA Pull bearing to driven pulley side out of counter- 1. Spacer shaft, using remover (P/N 529 0301 00). Begin with only the remover then add a spacer of differ- DISASSEMBLY ent width as the bearing comes out.
Page 169: Assembly
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) A06D15A INSTALLATION To install brake, reverse removal procedure paying attention to the following. A15D03A WARNING TYPICAL 1. Fixed pad 2. Inner caliper Avoid getting oil on brake pads. Do not lubri- A. 1 mm (1/32 in) minimum cate or apply antirust or antifreeze solution in brake cable.
Page 170: Adjustment
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) Refer to DRIVE AXLE 06-04 then look Chaincase Perpendicularity Adjustment. Torque castellated nut of upper sprocket to 53 N•m (39 lbf•ft). CAUTION Upper sprocket castellated nut must be tightened before adjusting bearing collar. Slide collar no. 18 towards bearing and turn, by hand, to engage the eccentric.
Page 171 Section 04 TRANSMISSION Sub-Section 06 (BRAKE) A06D0JA 1. Open bleeder 2. Clear hose to catch used brake fluid Brake Light There is no adjustment on these models. Check that switch is securely installed. 04-06-6...
Page 172: Chaincase
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) CHAINCASE S-Series Without Reverse Gear Loctite Chaincase 45 to 75 N•m (33 to 55 lbf•ft) 46 N•m Loctite Loctite 609 (34 lbf•ft) Loctite 242 SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER A06D17S FLAT RATE PARTS 04-07-1...
Page 173: Removal
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) REMOVAL Using 2 large screwdrivers inserted between chaincase no. 7 and frame, pry complete assem- To remove chaincase proceed as follows. bly from vehicle. Remove tuned exhaust pipe and muffler. INSPECTION WARNING Visually inspect the chain for cracked, damaged or missing links.
Page 174: Drive Chain Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) 5,16, Sprockets 18, Circlip Position the sprockets with the writing facing the CAUTION chaincase cover. It is of the utmost importance to install the 27, Conical Spring Washer circlip otherwise damage to the chaincase Install washer with its concave side towards drive components may occur.
Page 175: Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) A03A03A TYPICAL 1. Dipstick NOTE: Chaincase must be in its proper posi- tion when checking oil level. ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04-05. Track Tension and Alignment Refer to TRACK 06-05. 04-07-4...
Page 176: Gearbox
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) GEARBOX 3-SPEED GEARBOX (SHIFTER MECHANISM) Skandic WT/WT LC A22D0YS FLAT RATE PARTS 04-08-1...
Page 177: Removal
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) REMOVAL 1,2, Cable and Cable Housing Remove screw from underneath top portion of transmission. Remove cable barrel from shifter: see last photo. A22D0QA 1. Clip 2. Lock nut Adjust tie rod length in a way that gear shift lever does not contact console.
Page 178: 3-Speed Gearbox
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) 3-SPEED GEARBOX Skandic WT/SWT/WT LC A22D0CS FLAT RATE PARTS 04-08-3...
Page 179: Removal
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) REMOVAL Remove brake disc and driven pulley. Unfasten shifting rod and cable. See above CABLE RE- MOVAL. Remove rear suspension. Remove angle drive and square pin. Remove RH end bearing then push drive axle to- ward right side.
Page 180 Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) Drive out driven pulley shaft. Use alignment tool (P/N 420 4760 10) as a supporting plate to extract last gear and bearing. Spacer will fall into gearbox housing. 420 4760 10 A22D0FA 18,19,26,27,28, Reverse Shaft, LH Side A22D0HA Bearing, Brake Shaft, Sleeve and Gear 21,22,29,30, Screw, Washer,...
Page 181: Inspection
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) CAUTION Do not push against inner bearing race. A22D0KA 1. Gear shoulder towards RH side 18,19,26,27,28, Reverse Shaft, LH Side Bearing, Brake Shaft, Sleeve and Gear A22D0JA Install brake shaft taking care that gear shoulders 1.
Page 182: Installation
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) A22D0OA A22D0MA INSTALLATION Install shim and bearing on LH side. Reverse removal procedure. Check pulley align- Install driven pulley shaft, sliding sleeve then gear. ment. Turn brake shaft during installation and check that gears mesh. OIL LEVEL To check, pull dipstick.
Page 183: 2-Speed Gearbox
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) 2-SPEED GEARBOX Grand Touring 500/583 Grease Loctite 15 N•m (133 lbf•in) Grease 48 N•m (35 lbf•ft) Loctite 29 N•m (21 lbf•ft) 5 N•m Loctite (44 lbf•in) Loctite A03D17S PARTS FLAT RATE 04-08-8...
Page 184: Disassembly
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) DISASSEMBLY First remove 19-tooth reverse gear no. 18 and then remove reverse axle no. 20. NOTE: It is possible to see the sliding gear in motion through oil gauge hole. Unbolt gear shift linkage from shifter. Unscrew cover screws no.
Page 185 Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) Install drive axle with track then bearing and circlip Install chain no. 28, 44-tooth sprocket no. 34 and in chaincase bore. Install spacer no. 38 with its its spacer no. 38. Spacer’s large outer diameter large outer diameter against sprocket, 44-tooth must be against sprocket.
Page 186: Adjustment
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) 5,7,8, Screws and Locking Tab Tighten screws in a criss-cross sequence starting with the one above reverse axle. Install reverse axle screw and bend locking tab against screw head flat. Bolt shift linkage to shifter. ADJUSTMENT 28, Chain Fully tighten adjustment screw by hand, then...
Page 187: Oil Change
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) A06D1QA OIL CHANGE Place a container under bottom pan (gearbox A03A03A side). 1. Dipstick Unbolt gear shift linkage from fork axle. Unbolt and remove cover by separating it from housing Shifter can be put in reverse position to ease re- and by moving it toward the front in order to re- moval of dipstick.
Page 188: Drive Chain
Section 04 TRANSMISSION Sub-Section 09 (DRIVE CHAIN) DRIVE CHAIN SILENT CHAIN For 1997 there are 2 types of silent chain. One is 11-plate wide and the other (stronger) is 13-plate wide. Do not interchange sprockets. Fit chain on sprockets to make sure using right ones accord- ing to width.
Page 189: Electrical
Section 05 ELECTRICAL Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS WIRING DIAGRAMS......................05-02-1 CHART CODES........................05-02-1 UNPLUGING CONNECTORS .................... 05-02-3 TAB AND RECEPTACLE CONNECTORS REMOVAL ............05-02-3 TAB AND RECEPTACLE CONNECTORS INSTALLATION ..........05-02-3 ACCESSORIES INSTALLATION ..................05-02-4 IGNITION TIMING ......................... 05-03-1 DUCATI CDI SYSTEM......................
Page 190 Section 05 ELECTRICAL Sub-Section 01 (TABLE OF CONTENTS) CLEANING AND INSPECTION ..................05-06-6 CLEANING ..........................05-06-6 INSPECTION ........................05-06-6 SOLENOID SWITCH ....................... 05-06-8 STARTER REMOVAL ...................... 05-06-10 STARTER DISASSEMBLY ....................05-06-10 CLEANING ........................05-06-11 PARTS INSPECTION....................... 05-06-11 STARTER ASSEMBLY ....................05-06-12 STARTER INSTALLATION ....................05-06-13 TESTING PROCEDURE ......................
Page 191 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) WIRING DIAGRAMS ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) MX Z 440 F Annex 1 60/55 hal. 8/27 MX Z 440/583/670 Annex 2 60/55 hal. 8/27 Formula 500 DELUXE Annex 3 60/55 hal.
Page 192 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big)
Page 193: Unpluging Connectors
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) Connector Location Connectors on wiring diagrams carry the letter C followed by a number. Use this code with wiring diagram legend to find connector location on vehi- cle. UNPLUGING CONNECTORS Always unplug connectors by pulling on housing not on wire.
Page 194: Accessories Installation
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) ACCESSORIES INSTALLATION On all electric start models: The direct current (DC) utilizes the snowmobile frame as ground “wire” while all alternating current (AC) consum- ers (lights, heated grips, fuel gauge, etc.) utilize a separate ground wire.
Page 195: Ignition Timing
Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) IGNITION TIMING DUCATI CDI SYSTEM 443 and 503 Engine Types Proper ignition timing is determined by trigger coil position. If for any reason, ignition timing accuracy is sus- pected, it can be checked as follows. Verifying Magneto Flywheel Timing Mark Position Prior to checking the timing, it may be necessary...
Page 196 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) d. “0” now indicates exact TDC. a. Remove the fan cover from the engine. 5. Verify the position of the timing mark on the b. Maintain magneto flywheel so that previous magneto flywheel as follows: marks remain aligned.
Page 197 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) WARNING Place ski tips against a wall, raise rear of ve- hicle on a stand, so that track does not con- tact the ground. Do not allow anyone in front of or behind the vehicle while engine is run- ning.
Page 198: Nippondenso Trigger Coil System
Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) NIPPONDENSO TRIGGER COIL SYSTEM 454, 494, 583, and 670 Engine Types Ignition timing is adjusted by movement of trigger coil. On 583 engine raising position of trigger coil retards ignition. Lowering position of trigger ad- vances ignition.
Page 199 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) 5. Verify the position of the timing mark on the magneto flywheel as follows: NOTE: When checking timing, certain pro- cedures require that the magneto flywheel be turned in a clockwise direction, viewed facing the magneto.
Page 200 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) A06E27A TYPICAL 1. Timing light pick-up on MAG side 2. Timing inspection hole The magneto/damper mark must be aligned with center mark. If not, move trigger coil as explained above and recheck ignition timing. Tolerance is ± 1°.
Page 201: Spark Plugs
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG All Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier is using the NGK spark plug type on most of the 1997 snowmobile models. The heat range identification system is: High number hot plug Low number...
Page 202: Design Symbols Used In Ngk Spark Plugs
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DESIGN SYMBOLS USED IN NGK SPARK PLUGS PREFIX SUFFIX WIDE GAP 10: 1.0 mm (.040") 11: 1.1 mm (.044") B R 9 E S 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...
Page 203: Disassembly
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DISASSEMBLY CAUTION First unscrew the spark plug 1 turn. Severe engine damage might occur if a Clean the spark plug and cylinder head with pres- wrong heat range plug is used. surize air then completely unscrew. A too “hot”...
Page 204: Spark Plug Installation
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUG INSTALLATION Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to TECHNICAL DATA 09-02.
Page 205: Battery
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) BATTERY REMOVAL All Models WARNING Battery BLACK negative cable must always be disconnected first and connected last. WARNING Never charge or boost battery while in- stalled on vehicle. A22C09A S-Series 1. Loosen clamp Remove air silencer. Unfasten retaining strips.
Page 206: Cleaning
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) A29E0CA A22E0GA 1. Wing screw 1. Wing screw Skandic SWT All Models Remove battery bracket and remove battery from Withdraw battery from vehicle being careful not vehicle. lean it so that electrolyte flows out of vent tube. CAUTION Should any electrolyte spillage occur, imme- diately wash off with a solution of baking...
Page 207: Inspection
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) HYDROMETER TEST A17E0LA 1. Baking soda A17E0JA Remove corrosion from battery cable terminals 1. Specific gravity 1.260 and battery posts using a firm wire brush. A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte.
Page 208: Battery Storage
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) EXAMPLE NO. 1 Clean battery terminals and cable connections us- Temperature below 27°C (80°): ing a wire brush. Apply a light coat of dielectric Hydrometer Reading:1.250 grease (P/N 413 7017 00) or petroleum jelly on ter- Electrolyte temperature: −7°C (20°F) minals.
Page 209 Section 05 ELECTRICAL Sub-Section 05 (BATTERY) 5. Readjust the electrolyte level to the UPPER LEVEL line. A17E0FA 1. Battery electrolyte A17E0RA 2. Remove caps and fill battery to UPPER LEVEL 1. Battery electrolyte line with electrolyte (specific gravity: 1.260 at 20°C (68°F)).
Page 210 Section 05 ELECTRICAL Sub-Section 05 (BATTERY) 7. Disconnect battery charger. 10. Allow gas bubbles to escape by lightly shake battery. A17E0IB A17E0HA 8. Test battery state of charge. Use a hydrometer. 11. Readjust electrolyte level. A17E0JA 1. Specific gravity 1.260 9.
Page 211: Servicing
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) – State of charge: Because the electrolyte is CAUTION nearly pure water in a completely discharged battery, it cannot accept current as well as elec- Do not allow cleaning solution to enter bat- trolyte. This is the reason the battery will not tery interior since it will destroy the electro- accept current when the charging cycle first be- lyte.
Page 212: Battery Charging Equipment
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) – If the charging current is measurable before the For a service application and a permanent installa- end or at the end of about 10 hours, the battery tion, both ammeter and rheostat can be built into is good and charging should be completed in a small box adjacent to your charger.
Page 213 Section 05 ELECTRICAL Sub-Section 05 (BATTERY) All Models CAUTION Ensure that vent tube is not kinked or blocked then install protective boot over battery. Negative battery terminal should always be disconnected FIRST and reconnected LAST. Close and fasten retaining strips. Reinstall air silencer.
Page 214: Electric Starter
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) ELECTRIC STARTER S-Series with Electric Starting and Skandic WT/SWT A03E13S FLAT RATE PARTS 05-06-1...
Page 215: Removal
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) REMOVAL Check the wear on bushing no. 18 by measuring the amount of radial play between the armature – Disconnect BLACK ground cable from battery. shaft and the bushing. – Disconnect RED positive cable from battery. The radial play should not exceed 0.20 mm (0.008 in).
Page 216 Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Install bushing cover no. 19 then, using a punch, stake bushing cover in place. A19E05A 1. Cut close to connector Remove burrs with a file on the remaining welded portion. A19E02A 1. Stake bushing cover CAUTION 2.
Page 217: Cleaning And Inspection
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Install thrust washer against outer stop collar. CAUTION Place drive lever onto overrunning clutch then in- sert into drive housing. Do not overheat and quickly perform solder- ing to prevent solder from flowing to the brush through the wire.
Page 218: Installation
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A19E09A 1. Shorter stud 2. Bare wire INSTALLATION Make sure that starter and engine mating surfac- A09E0PA es are free of grime. Serious trouble may arise if 1. Screwdriver pulling starter pinion starter is not properly aligned. 2.
Page 219: Cleaning And Inspection
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) CLEANING AND INSPECTION CLEANING CAUTION Armature starter yoke ass’y and drive unit assembly must not be immersed in cleaning solvent. Clean brushes and holder with a clean cloth F01H0RA soaked in solvent. Brushes must be dried thor- 1.
Page 220 Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Field Windings and Brushes Test the Field Winding for Open Circuit: Use growler test probes. Place one test probe on the negative brush and the other test probe on the yoke. If growler lamp does not turn on, the field winding has an open-circuit.
Page 221: Solenoid Switch
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A03E05A TYPICAL 1. New 2. Wear limit Overrunning Clutch The pinion of the overrunning clutch should turn smoothly in the clockwise direction, and should not slip in a counterclockwise direction. If defec- tive, replace. Check the pinion teeth for wear and damage.
Page 222 Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Skandic WT LC 5 N•m (44 lbf•in) Dielectric grease Loctite 271 Ground cable 22 N•m Dielectric grease (16 lbf•ft) A29E09S FLAT RATE PARTS 05-06-9...
Page 223: Starter Removal
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) STARTER REMOVAL Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. Remove tuned pipe. Cut locking tie retaining cable to starter. F01H0PA TYPICAL 1. Trace indexing marks Remove starter support nuts then through bolts.
Page 224: Cleaning
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) CLEANING CAUTION Yoke ass’y and drive unit assembly must not be immersed in cleaning solvent. Discard all O-rings and gasket. F01H0RA Clean brushes and holders with a clean cloth soaked in solvent. Brushes must be dried thor- 1.
Page 225: Starter Assembly
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A03E05A A03E0EA 1. New 1. Armature shaft 2. Wear limit, 8.5 mm (.335 in) 2. Circlip 3. Pinion stop collar 4. Punch Overrunning Clutch 1,10, Housing and Yoke Ass’y Pinion of overrunning clutch should turn smoothly in clockwise direction, and should not slip in a Align previously traced indexing marks.
Page 226: Starter Installation
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) F01H0SA 1. Locating protrusion is the higher one F01H0UA Step : Retaining brush holder with a screwdriver Step : Align here Align end frame notch with brush holder notch/ yoke protrusion. CAUTION F01H0TA 1.
Page 227: Testing Procedure
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system. CHARGING ENGINE IGNITION SYSTEM TYPE SYSTEM OUTPUT NIPPONDENSO 454, 494, 583 (CDI) and 670 TRIGGER COIL 443 and 503 DUCATI (CDI) CDI System Identification Nippondenso...
Page 228: Use Of Bombardier Ignition Tester
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) All Systems The first 2 items can be checked with known au- tomotive equipment and other items as follows. Engine Stop/Tether Cut-Out Switches Verification Engine Stop Switch Unplug stop switch connector from main harness then using an ohmmeter, connect test probes to BLACK/YELLOW and BLACK wires.
Page 229 Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) Test Condition Multiple Problems There is always the possibility of more than one All Tests are Performed on the Vehicle at faulty part. If after a component has been re- Cranking Speed placed, the problem still persists, carefully repeat Vigorous manual cranking against compression the complete test procedure to find the other causes the flywheel to snap over, raising the out-...
Page 230: Nippondenso Cdi Trigger Coil System Testing
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) NIPPONDENSO CDI TRIGGER COIL SYSTEM TESTING Applicable to 454, 494, 583 and 670 Engine Results: Types a. Indicator lamp lights: Trigger coil output is NOTE: Ensure ignition cut-out switches are up to specifications. properly working and they are in the ON po- b.
Page 231: Ignition Module
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) A00E1JA 1. Black 2. White/Blue 4. Slip plastic protectors out of coil terminals. 5. Connect tester wires to coil terminals then set switch and dial as follows: NOTE: If necessary use jumper wires from coil terminals to tester wires.
Page 232: Magneto Output (Ignition Generator Coil)
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) 2. Connect tester wires then set switch and dial as follows: Tester Tester Tester Component switch dial wires wires position position wire of magneto harness BLACK/RED wire of magneto harness A15E0TA TYPICAL 6. Crank engine and observe indicator. 7.
Page 233 Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) 2. Connect tester wires then set switch and dial as follows: Tester Tester Tester Component switch dial wires wires position position YELLOW wire of magneto harness YELLOW wire of magneto harness Yellow Yellow A15E0VA 3.
Page 234: Summary Table
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) SUMMARY TABLE Tester Test to perform Components wires Switch Dial wires Trigger coil output BLUE/YELLOW wire of trigger coil WHITE/YELLOW wire of trigger coil Ignition coil output Engine ground Test adapter on MAG spark plug cable Ignition module output WHITE/BLUE...
Page 235: Resistance Measurements
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) RESISTANCE MEASUREMENTS Disconnect connector at ignition coil and magneto junction. Measure resistance between each ter- As an alternate method, magneto system compo- minal. Refer to the following table for values and nents can be checked with a digital ohmmeter. wire colors.
Page 236: Ducati Cdi System Testing
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) DUCATI CDI SYSTEM TESTING (Applicable to 443 and 503 Engine Types) Results: NOTE: Ensure ignition cut-out switches are properly working and they are in the ON po- a. Indicator lamp lights: Trigger coil output is sition prior to performing the following tests.
Page 237: Ignition Coil Output
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) IGNITION COIL OUTPUT IGNITION MODULE A paper clip of approximately 20 mm (3/4 in) will Ignition module can not be tested with the Bom- be used as a test adapter for the following test. bardier ignition tester.
Page 238: Summary Table
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) Results: a. Indicator lamp lights: Lighting generator coil output is up to specifications. b. Indicator lamp does not light: Lighting gen- erator coil is faulty. SUMMARY TABLE Test to Tester Component Switch Dial perform wires wires...
Page 239: Resistance Measurements
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) RESISTANCE MEASUREMENTS Disconnect connector at ignition coil and magneto junction. Measure resistance between each ter- As an alternate method, magneto system compo- minal. Refer to the following table for values and nents can be checked with a digital ohmmeter. wire colors.
Page 240: Voltage Regulator Inspection
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) VOLTAGE REGULATOR INSPECTION A faulty voltage regulator is often responsible for B) Voltmeter Test frequent burned bulbs. NOTE: Use a voltmeter able to read alternat- ing current (AC). For accurate reading, use a CAUTION RMS voltmeter.
Page 241: Inspection Of Ac Circuit Isolation
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) INSPECTION OF AC CIRCUIT ISOLATION All Electric Start Models If AC circuit is not isolated from frame, headlamp beam will weaken. INSPECTION Disconnect regulator/rectifier. Connect one digital ohmmeter probe (needle ohmmeter will not offer enough precision) to frame and other probe to one of 2 yellow magneto wires.
Page 242: Inspection Of Heating Elements
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) INSPECTION OF HEATING ELEMENTS All Models Except Skandic WT/SWT/WT LC All measurements must be performed at 21°C (70°F). Throttle Lever Heating Element Handlebar Grip Heating Element Resistance Measurement Resistance Measurement 8.73 to HIGH YELLOW BLACK wire 1.96 to...
Page 243: Rear Suspension
Section 06 REAR SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SC-10 SUSPENSIONS (ALL VERSIONS) ................. 06-02-1 COMPONENT REMOVAL AND INSTALLATION ............06-02-6 REMOVAL........................06-02-8 DISASSEMBLY AND ASSEMBLY ................. 06-02-9 SHOCK ABSORBER INSPECTION ................06-02-10 SHOCK ABSORBER SERVICING................... 06-02-11 INSTALLATION ......................
Page 244: Suspensions (All Versions)
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 SUSPENSIONS (ALL VERSIONS)2 SC-10 Sport on MX Z 440 F, Formula 500/500 DELUXE/583 temp. grease Loctite Loctite Loctite Loctite Loctite Loctite A03F26S FLAT RATE PARTS 06-02-1...
Page 245: Sc-10 Suspensions (All Versions)
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 Cross-country on MX Z 440/583/670 Front temp. Loctite grease Loctite MX Z 440 only Loctite Loctite Loctite Loctite A03F27S PARTS FLAT RATE 06-02-2...
Page 246 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 High-performance on Formula Z and Grand Touring 583 Front temp. grease Loctite Loctite Loctite Loctite Loctite A03F28S FLAT RATE PARTS 06-02-3...
Page 247 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 Mountain on Summit 500/583/670 Loctite Loctite temp. grease Loctite Loctite Loctite Loctite Loctite A03F29S FLAT RATE PARTS 06-02-4...
Page 248 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 Touring on Grand Touring 500 Loctite Loctite temp. grease Loctite Loctite Loctite Loctite Loctite A03F2AS FLAT RATE PARTS 06-02-5...
Page 249: Component Removal And Installation
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) COMPONENT REMOVAL AND INSTALLATION Lift rear of vehicle and support it off the ground. 21, Rear Axle Completely loosen track tension. Unscrew one rear idler wheel screw. Pull out rear axle from opposite side of offset in- ner wheel.
Page 250 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) 25, ACM Support Remove threaded rod ass’y. Loosen rear axle screw on one side and rear shackle screws. Unbolt MCA support and remove it. Remove cup. 15, Rear Shock Lift rear of vehicle. Slightly turn adjusting cam to expose spring end.
Page 251: Removal
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) A03F0TA RH SIDE SHOWN Lift rear of vehicle and support it off the ground. Loosen track tension. 7, Screw A03F1QA TYPICAL Unscrew rear arm top axle from chassis. At reassembly, wheel circlip must face outward. NOTE: To prevent axle from turning when unscrewing screws assembled with thread- REMOVAL...
Page 252: Disassembly And Assembly
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) 6, Screw 11, Axle Remove both screws retaining front arm to tun- Note position of axles at disassembly. Axles with nel. a paint stripe serve as idler wheel axles. These are more precise than those used as pivot axles.
Page 253: Shock Absorber Inspection
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) A03F0YA 1. Wear limit line CAUTION A03F12A Slider shoes must always be replaced in 1. Cap opening 2. Spring stopper opening pairs. 20, Stopper Strap 18, Spring Support Inspect strap for wear or cracks, bolt and nut for tightness.
Page 254: Shock Absorber Servicing
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Secure the shock body end in a vise with its rod Rod must comes out at a steady speed. If speed upward. suddenly increases particularly at end of exten- sion, replace shock. If suspecting a frozen gas shock proceed as fol- lows: Place shock in a freezer (temperature below 0°C...
Page 255 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Disassembly and Assembly Release N (nitrogen) pressure from the damper Schrader valve. WARNING Nitrogen gas is under extreme pressure. Use caution when releasing this gas vol- ume. Protective eye wear should be used. A27F04A TYPICAL With the seal assembly removed, slowly lift and...
Page 256 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) A27F06A TYPICAL WARNING Whenever using compressed air, use an O.S.H.A. approved air gun and wear protec- tive eye wear. A06F0VA Thoroughly clean, with a typical cleaning solution, NOTE: As a general rule we suggest replac- and blow dry using low pressure air.
Page 257 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Tuning for less damping it is important to remem- ber, never use less than 3 × 26 mm (1.02 in) shims against piston. This will guard against fatigue breakage. Piston no. 6 options include 4 pistons, 0, 2, 4, 6, slits for rebound damping bleeds.
Page 258 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) If the seal carrier assembly is replaced, use seal FRONT pilot (P/N 529 0265 00) to guide seal over damper shaft. Lubricate seal carrier guide pilot before use. Thick (in) (in) CAUTION 12 mm...
Page 259 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) A27F07A 1. Top of the piston A. Required distance A06F2DA 1. Damper nut torqued to 11-13 N•m (96-108 lbf•in) Install floating piston to depth of 151 mm (5.94 in) 2. Rebound shim pack for front damper, 190 mm (7.48 in) for rear damp- 3.
Page 260 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Slowly push piston into damper body. Slight up and down movement may be required to allow all air to pass through piston assembly. NOTE: Fast installation of the damper rod may displace the floating piston from its orig- inal position.
Page 261 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Preset your pressure regulator to 2070 kPa (300 PSI) nitrogen (N ), this gas pressure will restore the correct pressure for your damper. CAUTION Do not exceed the recommended pressure values.
Page 262: Installation
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) 25, Protector LUBRICATION At assembly, mount protector with its notch to- Lubricate front and rear arms at grease fittings us- ward front. ing low temperature grease (P/N 413 7061 00). A03F10A SC-10 SPORT, MOUNTAIN AND TOURING: 4 GREASE FITTING A03F1RA...
Page 263: Skandic Wt Suspension
Section 06 REAR SUSPENSION Sub-Section 03 (SKANDIC WT SUSPENSION) SKANDIC WT SUSPENSION Skandic WT/SWT/WT LC A22F18S FLAT RATE PARTS 06-03-1...
Page 264: Removal
Section 06 REAR SUSPENSION Sub-Section 03 (SKANDIC WT SUSPENSION) REMOVAL Release track tension. Lift rear of vehicle and support it off the ground. Unbolt front arm then rear arm. NOTE: To prevent cross shaft from turning when unscrewing screws assembled with threadlocker, proceed as follows: –...
Page 265: Shock Absorber Servicing
Section 06 REAR SUSPENSION Sub-Section 03 (SKANDIC WT SUSPENSION) Tighten nut 3/4 turn after contacting washers for better deep snow performance. Maximum pre- load is 3 turns after nut touching washers. This last adjustment is for trail riding with or without a load and for pulling a load.
Page 266 Section 06 REAR SUSPENSION Sub-Section 03 (SKANDIC WT SUSPENSION) CAUTION Do not clamp directly on shock body. Examine each shock for leaks. Extend and com- press the piston several times over its entire stroke then check that it moves smoothly and with uniform resistance.
Page 267: Drive Axle
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) DRIVE AXLE S-Series Summit and MX Z only A03D20S FLAT RATE PARTS 06-04-1...
Page 268 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) Skandic WT A22D14S PARTS FLAT RATE 06-04-2...
Page 269: Removal
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) REMOVAL Remove angle drive and square pin from bottom of gearbox. All Models Except Skandic WT/SWT/WT LC Remove belt guard and belt. Drain oil from chaincase or gearbox. Release drive Loosen gearbox retaining screws then move chain tension.
Page 270: Assembly
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) 9,13, Sprocket and Half-Sprocket S-Series To remove press fit sprockets, use a press and a suitable support as illustrated. A06D1XA A00F06A A. 65.8 mm (2-19/32 in) TYPICAL B. 159.3 mm (6-17/64 in) C.
Page 271 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) A24D05A A00F0CA TYPICAL 1. Grease seal type 2. Oil seal type 1. Indexing marks aligned 11, Bearing Protector The maximum desynchronization for the sprock- ets is 1.5 mm (1/16 in). At assembly, flat side of bearing protector must To check this tolerance, place axle assembly on a be against bearing.
Page 272: Axial Play
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) – Extract bearing from its support. Wrong chaincase perpendicularity will make it dif- ficult to correctly install the bearing in its support due to the countershaft and support misalign- ment. A00F05A 1. Bearing shield on this side 2.
Page 273 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) A01D08A 1. Distance between sprocket and tunnel 2. Drive axle pushed toward chaincase A01D07A TYPICAL 1. Upper shim location 2. 50 mm long screws when installing one shim or more 3. Lower shim location –...
Page 274: Installation
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) – Check track front alignment by measuring the CAUTION gap, on each side between guide cleat and the slider shoe, behind the suspension front axle as Install shim(s) following the pattern shown shown.
Page 275: Lubrication
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) ADJUSTMENT Sprocket/Track Alignment CAUTION Do not temper with sprocket/track alignment if frame or suspension is damaged. Sprockets might be repositioned to fit lugs with- out removing drive axle. Use drive axle sprocket adjuster kit (P/N 861 7257 00). A00F0GA SIDE VIEW 1.
Page 276: Track
Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) TRACK TRACK TYPE APPLICATION – RH drive axle end bearing – angle drive and square pin Refer to TECHNICAL DATA section 09-03. Move transmission sideway. Do not remove brake mechanism nor driven pulley. Refer to GENERAL SKANDIC WT SUSPENSION 06-03.
Page 277 Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) Insert pre-setted gauge between slider shoe and track. Allow gauge to settle by forcing track up and down. Track tension is as specified when edge of gauge reaches lign. A19F05A TYPICAL 1. Retaining screw 2.
Page 278 Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) Track Cleat WARNING Removal Before checking track alignment, ensure that – Raise rear of vehicle off the ground and lift the track is free of all particles which could snowguard then rotate track to expose a cleat be thrown out while track is rotating.
Page 279 Section 07 STEERING/FRONT SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................07-02-1 INSPECTION ........................07-02-3 DISASSEMBLY AND ASSEMBLY ..................07-02-3 INSPECTION ........................07-02-4 ADJUSTABLE HANDLEBAR ..................... 07-02-5 STEERING ADJUSTMENT (SKIS) ..................07-02-6 LUBRICATION ........................07-02-9 SUSPENSION AND SKI SYSTEM ..................07-03-1 DISASSEMBLY........................
Page 280: Steering System
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) STEERING SYSTEM S-Series 25 N•m (18 lbf•ft) 40 N•m (30 lbf•ft) 25 N•m (18 lbf•ft) 18 N•m (159 lbf•in) 18 N•m (159 lbf•in) 52 N•m (38 lbf•ft) 40 N•m (30 lbf•ft) 40 N•m (30 lbf•ft) 18 N•m (159 lbf•in)
Page 281 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Skandic WT 25 N•m (18 lbf•ft) A22G0KS PARTS FLAT RATE 07-02-2...
Page 282: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) INSPECTION Check skis and runner shoes for wear, replace as necessary. (See section 07-03). 17, Steering Arm and Ski Leg Make sure steering arm and ski leg splines inter- lock. WARNING Any parts having worn splines have to be re- places with new ones.
Page 283: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) To install, stick the heating element to the handle- For proper torque specifications refer to the spe- bar making sure the wires do not interfere with cific exploded view for the vehicle being serviced. operation of the accelerator or brake handle.
Page 284: Adjustable Handlebar
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Skandic WT Only Install special washers (locking disks) with teeth facing each others. A22G0LA 9,13,15, Ball Joint Nut and Jam Nut A22G0MA Tighten ball joint, nuts and jam nuts to specified torque (see exploded view). 1.
Page 285: Steering Adjustment (Skis)
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) See applicable exploded view for each model. 7,23,24,25, Steering Pad, Bolt, Nut and Rubber Attachment Adjust the steering handlebar to the desired posi- tion. CAUTION Lock the handlebar in place by tightening the 4 nuts as specified in the illustrations.
Page 286 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) WARNING Never lengthen tie rod so that threaded por- tion of ball joint exceeds 20 mm (25/32 in). A01G04A CAMBER: A specific inward or outward tilt angle of ski leg compared to a vertical line when viewing the ve- hicle from front.
Page 287 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Adjust the camber to 0° ± 0.5°. CAUTION Angle finder must sit square against swing arm. Positioning angle finder against weld bead or decal may result in false reading. 529 0216 00 A06G1KA TYPICAL —...
Page 288: Lubrication
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Skandic WT Only LUBRICATION – Skis should have a toe-out of 10 mm (3/8 in) when they are in a straight-ahead position and WARNING the vehicle is resting on the ground. Do not lubricate throttle and/or brake cable, NOTE: To make sure skis are in a straight- housing and spring coupler bolts.
Page 289 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) S-Series If so equipped A06G08S PARTS FLAT RATE 07-02-10...
Page 290: Suspension And Ski System
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM S-Series Some models Loctite 29 N•m (21 lbf•ft) 25 N•m (18 lbf•ft) 80 N•m Loctite (59 lbf•ft) 17.5 N•m MX Z 440 (159 lbf•in) 40 N•m (29 lbf•ft) Some models...
Page 291: Disassembly
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 5, Shock Lift front of vehicle and support it off the ground. Reduce spring preload by turning adjusting ring accordingly with the adjustment wrench in vehi- cle tool box. A03F12A 1.
Page 292: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) 7,8, Upper and Lower Half Arms Position half arms and tie rods horizontally before tightening nuts. 9,10,11, Bolt, Nut and Link Plate Attach link plate to frame with additional nuts and bolts, if applicable.
Page 293 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) A06G0XA WRONG POSITION 07-03-4...
Page 294 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) Skandic WT 13 N•m (115 lbf•in) Grease A22G0NS FLAT RATE PARTS 07-03-5...
Page 295: On-Vehicle Component Verification
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) ON-VEHICLE COMPONENT VERIFICATION 8, Shock Lift front of vehicle and support off the ground. Remove ski bolt and nut. Remove steel bushing from ski using a pusher. See pusher dimensions below. A22G0IA 1.
Page 296: Disassembly
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) A05G0CB 1. Allen screws A05G0DA NOTE: These washers and stopper can be 1. Washers and stopper wedged in cover wedged in cap. 2. Spring Pull out spring. 4,13,14,16,17, O-ring, Ski Leg, Bushing and Seal Suspension Free Operation Pull up ski leg.
Page 297: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) 8, Shock Absorber Secure the shock body end in a vise with its rod upward. A14F0BA 1. Clamp CAUTION Do not clamp directly on shock body. Examine each shock for leaks. Extend and com- press the piston several times over its entire A22G0QA stroke with its rod upward.
Page 298 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) A05G0CB TYPICAL 1. Bent angle toward the bottom 16,17, Seal Install seal before reinstalling ski leg. 07-03-9...
Page 299 Section 08 BODY/FRAME Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY............................08-02-1 INSTALLATION AND ADJUSTMENT ................08-02-1 HEADLAMP BEAM AIMING....................08-02-1 BULB REPLACEMENT ....................... 08-02-1 DECAL ..........................08-02-2 WINDSHIELD INSTALLATION................... 08-02-2 HOOD ..........................08-02-2 BELT GUARD ........................08-02-3 WIRING HARNESS ......................08-02-3 CABLES ..........................
Page 300: Body
Section 08 BODY/FRAME Sub-Section 02 (BODY) BODY INSTALLATION AND ADJUSTMENT HEADLAMP BEAM AIMING Required Conditions Place the vehicle on a flat surface perpendicular to Beam aiming is correct when center of high beam test surface (wall or screen) and 381 cm (12 ft 6 in) is 25 mm (1 in) below the headlamp horizontal away from it.
Page 301: Decal
Section 08 BODY/FRAME Sub-Section 02 (BODY) DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully posi- tion the decal.
Page 302: Belt Guard
Section 08 BODY/FRAME Sub-Section 02 (BODY) BELT GUARD CABLES Disassembly and Assembly WARNING NOTE: For additional information (ex.: ex- Before installation, ensure that all cables are ploded view) refer to the correspondent in perfect condition. Properly install the ca- parts catalog. ble ends and secure them in place.
Page 303: Plastic Maintenance And Repair
Section 08 BODY/FRAME Sub-Section 02 (BODY) PLASTIC MAINTENANCE AND REPAIR MAINTENANCE Apply wax on glossy finish only. Protect the vehi- cle with a cover to prevent dust accumulation dur- Clean the vehicle thoroughly, removing all dirt and ing storage. grease accumulation. CAUTION To clean use a soft clean cloth and either soapy water or isopropyl alcohol.
Page 304: Repair
Section 08 BODY/FRAME Sub-Section 02 (BODY) REPAIR The very first step before repairing plastic materials is to find out exactly which type of material is in- volved. Refer to following chart. CAUTION Consult chart and repair kit instructions carefully, some repair products are not compatible with certain plastics.
Page 305: Material Repair Procedure
Section 08 BODY/FRAME Sub-Section 02 (BODY) MATERIAL REPAIR PROCEDURE – Heat the surface with a heater lamp placed at 38 cm (15 in) for a period of 15 minutes. Fiberglass – Sand the repair using a smooth dry sand paper. This material is repairable and repaintable, using –...
Page 306 Section 08 BODY/FRAME Sub-Section 02 (BODY) CREST MAIN OFFICE AND MANUFACTURING PLANT CREST INDUSTRIES, INC. Phone: 313-283-4100 3841 13 Street Toll Free: 1-800-822-4100 Fax: 1-800-344-4461 Wyandotte, Michigan Fax: 313-283-4461 48192 Crest products used in R.I.M. repair procedure are available from following locations: DISTRIBUTOR WAREHOUSE LOCATIONS UNITED STATES CANADA...
Page 307: Frame
Section 08 BODY/FRAME Sub-Section 03 (FRAME) FRAME FRAME CLEANING NOTE: For aluminum frames use only alumi- num cleaner and follow instructions on con- tainer. (Dursol cleaner or equivalent). Clean frame and tunnel with appropriate cleaners and rinse with high pressure hose. Touch up all metal spots where paint has been scratched off.
Page 308 Section 08 BODY/FRAME Sub-Section 03 (FRAME) CAUTION High speed drilling will cause excessive heat which may destroy the cutting edge of the bit, therefore avoid using pneumatic drills. Grinding Procedure Rear Cap Grind rivet heads from top of rear cap and under- neath for side retaining rivets.
Page 309: Technical Data
Section 09 TECHNICAL DATA Sub-Section 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..............meter ............. mass ..............kilogram ..........force ..............newton ........... liquid ..............liter ............temperature ............Celsius ........... °C pressure ..............
Page 310 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) VEHICLE MODEL MX Z 440 F MX Z 440 MX Z 583 MX Z 670 ENGINE TYPE Number of Cylinders Bore mm (in) 67.5 (2.6575) 67.5 (2.6575) 76.0 (2.992) 78.0 (3.071) Stroke mm (in) 61.0 (2.402) 61.0 (2.402) 64.0 (2.520)
Page 311 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) FORMULA 500 VEHICLE MODEL FORMULA 500 FORMULA 583 FORMULA Z DELUXE ENGINE TYPE Number of Cylinders Bore mm (in) 69.5 (2.736) 69.5 (2.736) 76.0 (2.992) 76.0 (2.992) Stroke mm (in) 65.8 (2.59) 65.8 (2.59) 64.0 (2.52) 64.0 (2.52) Displacement...
Page 312 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) GRAND TOURING VEHICLE MODEL SUMMIT 500 SUMMIT 583 SUMMIT 670 ENGINE TYPE Number of Cylinders Bore mm (in) 69.5 (2.736) 76.0 (2.992) 78.0 (3.071) 69.5 (2.736) Stroke mm (in) 65.8 (2.59) 64.0 (2.520) 70.0 (2.760) 65.8 (2.59) Displacement...
Page 313 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) GRAND TOURING VEHICLE MODEL SKANDIC WT/SWT SKANDIC WT LC ENGINE TYPE Number of Cylinders Bore mm (in) 76.0 (2.992) 72.0 (2.835) 69.5 (2.736) Stroke mm (in) 64.0 (2.52) 61.0 (2.402) 65.8 (2.59) Displacement 580.7 (35.44) 496.7 (30.31) 499.3 (30.47)
Page 314 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL MX Z 440 F MX Z 440 MX Z 583 MX Z 670 ENGINE TYPE Chain Drive Ratio 22/44 23/44 25/44 26/44 Pitch Chain Type/Links Qty/Plates Qty Silent/72/11 Silent 72 – 13 Silent 74 –...
Page 315 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) FORMULA 500 VEHICLE MODEL FORMULA 500 FORMULA 583 FORMULA Z DELUXE ENGINE TYPE Chain Drive Ratio 23/44 23/44 25/44 25/44 Pitch Chain Type/Links Qty/Plates Qty Silent 72-11 Silent 72-11 Silent 74-11 Silent 74-13 Type of Drive Pulley TRAC TRAC...
Page 316 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) GRAND TOURING VEHICLE MODEL SUMMIT 500 SUMMIT 583 SUMMIT 670 ENGINE TYPE Chain Drive Ratio 22/44 22/44 23/44 23/44 Pitch Chain Type/Links Qty/Plates Qty Silent 72-11 Silent 72-13 Silent 72-13 Silent 72-11 Type of Drive Pulley TRAC TRAC TRAC...
Page 317 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) GRAND TOURING VEHICLE MODEL SKANDIC WT SKANDIC SWT SKANDIC WT LC ENGINE TYPE Chain Drive Ratio 23/44 N.A. N.A. N.A. Pitch N.A. N.A. N.A. Chain Type/Links Qty/Plates Qty Silent 72-13 N.A. N.A. N.A. Type of Drive Pulley TRAC TRAC...
Page 318 Section 09 TECHNICAL DATA Sub-Section 04 (TECHNICAL DATA LEGENDS) ENGINE LEGEND VEHICLE LEGEND BTDC: Before Top Dead Center DSA: Direct Shock Action CDI: Capacitor Discharge Ignition RRIM: Reinforced Reaction Injection Molding CTR: Center TRAC: Total Range Adjustable Clutch Kilo (× 1000) N.A.: Not Applicable MAG: Magneto Side...
Page 319 Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error Suggestion ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________ Date___________ Zip code/Postal code ________________________________________ Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error...
Page 320 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0...
Page 322 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 326 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 330 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 334 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 338 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 342 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 346 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 348 ANNEX 7...
Page 350 SKANDIC WT LC '97 STARTER SOLENOID 87 86 RD/GN 30 85 FUSE 20 A IGNITION RD/GN SWITCH STARTER 2 5 4 7 9 BK/YL BATTERY BL/YL WH/YL SPARK YL/BK IGNITION PLUGS MODULE GENERATOR COIL IGNITION COIL BK/YL BK/WH YL/GN YL/GN TEMPERATURE YL/GN SENSOR...
Page 351 SWITCH SWITCH HEATED GRIP IGNITION SWITCH 2 5 4 7 9 BK/YL BACK-UP ALARM YL/GN BACK-UP ALARM SWITCH HEATED THROTTLE SWITCH HEATED YL/GN GRIPS EMERGENCY CUT-OUT SWITCH WH/GY YL/GN RD/YL SWITCH LIGHTS BRAKE LIGHT SWITCH YL/GN D/YL ENGINE HIGH BEAM OVERHEATING L/BK SPEEDOMETER...

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Mx z 440 1997 Formula 500 deluxe 1997 Mx z 583 1997 Mx z 670 1997 Formula 583 1997 Formula z 1997 ... Show all

Ski-Doo MX Z 440F 1997 Shop Manual

Table of Contents

Troubleshooting

Engine

443 And 503 Engine Types

Top End

Bottom End

Engine Support and Muffler

Top End

Bottom End

Leak Test and Engine Dimension Measurement

Leak Test

Engine Dimension Measurement

Nippondenso Trigger Coil Ignition System

CDI System

Ducati Ignition System

Oil Injection Pump

Oil Injection System

Axial Fan Cooling System

Liquid Cooling System

Rotary Valve, Coolant Pump and Reservoir

Rewind Starter

Carburetor and Fuel Pump

Fuel Pump

Fuel Tank and Throttle Cable

Transmission

1997 Application Chart

Drive Belt

Tra

Drive Pulley

Driven Pulley

Pulley Distance and Alignment

Hydraulic Disc Brake

Brake

Chaincase

3-Speed Gearbox (Shifter Mechanism)

Gearbox

3-Speed Gearbox

2-Speed Gearbox

Drive Chain

Electrical

Ducati CDI System

Ignition Timing

Nippondenso Trigger Coil System

Spark Plugs

Ngk Spark Plug

Design Symbols Used in Ngk Spark Plugs

Battery

Electric Starter

Cleaning and Inspection

Testing Procedure

Nippondenso CDI Trigger Coil System Testing

Ducati CDI System Testing

Voltage Regulator Inspection

Inspection of Ac Circuit Isolation

Inspection of Heating Elements

Rear Suspension

Suspensions (All Versions)

Skandic WT Suspension

Drive Axle

Track

Table of Contents

Steering System

Suspension and Ski System

Quick Links

Chapters

Need help?

Questions and answers

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Summary of Contents for Ski-Doo MX Z 440F 1997