Ski-Doo Mini Z 2000 Shop Manual
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Ski-Doo Mini Z 2000 Shop Manual

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Summary of Contents for Ski-Doo Mini Z 2000

  • Page 2 Shop Manual MINI Z...
  • Page 3 Legal deposit: National Library of Quebec trimester 2000 National Library of Canada 2000 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2000 Technical Publications Bombardier Inc.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE ..........................INTRODUCTION ..........................SERVICE TOOLS AND 01 – Service Tools ................01-01-1 SERVICE PRODUCTS 02 – Service Products ..............01-02-1 LUBRICATION 01 – Lubrication and Maintenance Chart.......... 02-01-1 AND MAINTENANCE TROUBLESHOOTING 01 – Table of Contents ..............03-01-1 02 –...
  • Page 5 TABLE OF CONTENTS SECTION SUBSECTION PAGE STEERING/ 01 – Table of Contents..............08-01-1 FRONT SUSPENSION 02 – Steering System ..............08-02-1 03 – Suspension and Ski System............. 08-03-1 BODY AND FRAME 01 – Table of Contents..............09-01-1 02 – Body..................09-02-1 03 –...

  • Page 6: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair Ski-Doo Mini Z snowmobile. 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: Introduction

    INTRODUCTION INTRODUCTION This Shop Manual covers the Ski-Doo Mini Z* snow- ENGINE SERIAL NUMBER mobile. Engine Serial Number Location * Trademark of Bombardier Inc. VEHICLE IDENTIFICATION NUMBER Vehicle Identification Number Location A31H09A TYPICAL 1. Vehicle identification number Vehicle Identification Number Meaning 1.
  • Page 8 INTRODUCTION ARRANGEMENT OF THE MANUAL The manual is divided into 11 major sections: 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 LUBRICATION AND MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 TRANSMISSION 06 ELECTRICAL 07 REAR SUSPENSION 08 STEERING/FRONT SUSPENSION 09 BODY/FRAME 10 TECHNICAL DATA 11 WIRING DIAGRAM Each section is divided in various subsections, and again, each subsection has one or more division.
  • Page 9 INTRODUCTION LIST OF ABBREVIATIONS USED Max. maximum IN THIS MANUAL Min. minimum ampere milliliter ampere millimeter A•h ampere-hour mile per hour alternate current newton °C degree Celsius N.A. not applicable counterclockwise number centimeter 00.0 continuity cm² square centimeter overload (open circuit) cm³...
  • Page 10 INTRODUCTION This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Page heading indicates section and subsection detailed. Subsection title indicates Section 07 REAR SUSPENSION beginning of the subsection. SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN Italic subtitle above exploded view...
  • Page 11 INTRODUCTION Section 05 TRANSMISSION Title indicates main procedure Turn puller handle and sliding half at once to extract the bushing. to be carried-out. CAUTION: Italic bold face type setting indicates a particular procedure A-Series and B-Series Only concerning a model. Should installation procedure be required, refer to BRAKE 05-05 then look for Italic bold face setting...
  • Page 12 INTRODUCTION GENERAL INFORMATION A number of procedures throughout the book re- quire the use of special tools. Before commencing The information and component/system descrip- any procedure, be sure that you have on hand all tions contained in this manual are correct at time the tools required, or approved equivalents.
  • Page 13 INTRODUCTION THREADLOCKER 1. Clean threads (bolt and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on Uncovered Holes (bolts and nuts) threads (bolt and nut) and allow to dry for 30 seconds. 3. Choose proper strength Loctite threadlocker. 4.
  • Page 14 INTRODUCTION Preassembled Parts NOTE: If it is difficult to readjust, heat screw with a soldering iron (232°C (450°F)). STRIPPED THREAD REPAIR Stripped Threads A00A3OA 1. Apply here 2. Do not apply 1. Clean bolts and nuts with solvent. 1. Release agent 2.
  • Page 15 INTRODUCTION GASKET COMPOUND MOUNTING ON SHAFT All Parts Mounting with a Press A00A3UA 1. Bearing 2. Proper strength Loctite A00A3SA 3. Shaft 1. Proper strength Loctite 2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator 515 Standard (P/N 413 702 700) on both sides of gasket 3.
  • Page 16 INTRODUCTION CASE-IN COMPONENTS Metallic Gaskets A00A3VA 1. Proper strength Loctite 1. Clean inner housing diameter and outer gasket diameter. 2. Spray housing and gasket with Loctite Primer N (P/N 293 800 041). 3. Apply a strip of proper strength Loctite on lead- ing edge of outer metallic gasket diameter.
  • Page 17 INTRODUCTION TIGHTENING TORQUES FASTENER SIZE N•m Lbf•ft (8.8 GRADE) Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to following table. All torques apply to 8.8 grade fasteners. Bold face size (e.g. ) indicates nomi- nal value (mean value).
  • Page 18 Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error Suggestion ____________________________________________________________ We would be pleased if you could communicate to Bombardier any sug- ____________________________________________________________ gestions you may have concerning our publications. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov.
  • Page 19 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0...

  • Page 20: Service Tools And Service Products

    Subsection 01 (SERVICE TOOLS) SERVICE TOOLS This is a list of tools to properly service Ski-Doo snowmobile models specified on cover page. The list includes both the mandatory tools and the optional tools that are ordered separately. The list of Service Products, both mandatory and optional, are not part of any kit and must all be ordered separately.
  • Page 21 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE — MANDATORY SERVICE TOOLS Hose pincher (2) (P/N 295 000 076) A01B2I4 APPLICATION All vehicles. Fluke multimeter (P/N 529 022 000) F01B1O4 APPLICATION All models. 01-01-2 MMR2000_114_01_01A.FM...
  • Page 22 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Circuit tester Driver tool Pilot 22 mm (continuity light) (P/N 529 035 521) (P/N 529 035 523)
  • Page 23 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION — MANDATORY SERVICE TOOLS Clutch holder (P/N 529 006 400) A01B154 APPLICATION All TRA drive pulleys and Mini Z fly- wheel. Tension tester (P/N 414 348 200) A03D1T4 APPLICATION All models.
  • Page 24 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Drive axle sprocket adjuster (P/N 861 725 700) A01B2O4 APPLICATION All vehicles.
  • Page 25 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION — RECOMMENDED SERVICE TOOLS Track tension gauge (P/N 529 021 500) A00B3X4 APPLICATION All models. Drill bit (P/N 529 031 800) A01B564 APPLICATION All 3/16 in rivets. 01-01-6 MMR2000_114_01_01A.FM...
  • Page 26 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) VEHICLES — RECOMMENDED SERVICE TOOLS Protective mat (P/N 529 030 600) A01B45W APPLICATION All models. Snowmobile jack (P/N 529 020 000) A01A1JJ APPLICATION All models. 01-01-7 MMR2000_114_01_01A.FM...

  • Page 27: Service Products

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) SERVICE PRODUCTS MANDATORY SERVICE PRODUCTS Loctite ® is a trademarks of Loctite Corporation. Dow Corning ® is a trademarks of Dow Corning Corporation. Retaining compound Paste gasket Medium-strength threadlocker (P/N 413 703 100) (P/N 413 702 700) (P/N 293 800 015)
  • Page 28 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) MANDATORY SERVICE PRODUCTS (continued) Gasket/paint remover Silicone compound Petamo grease (P/N 413 708 500) (P/N 293 550 004) (P/N 420 899 271) Loctite ® Chisel Dow Corning ® 510 g (18 oz) A00B3R4 APPLICATION Lubricate pawl and pawl lock of re-...
  • Page 29 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS Silicone dielectric grease Synthetic chaincase oil Injection oil (3 oz) (12 x 355 mL) (P/N 413 802 900) (P/N 293 550 004) (P/N 413 803 300) (12 x 1 liter) (P/N 413 803 000) (3 x 4 liter)
  • Page 30 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Pipe sealant Anti-seize lubricant Storage oil (350 g spray can) (P/N 293 800 018) (P/N 293 800 023) (12 x 350 g) Loctite 592 (50 mL) Loctite anti-seize (P/N 413 711 600) lubricant 454 g (16 oz)
  • Page 31 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Plastic & vinyl cleaner Gel instant adhesive Paint for frame touch-up (P/N 413 711 200) (P/N 413 708 300) (P/N 413 401 000) 6 x 1 L Loctite 454-40 Black semi-gloss 20 g (.70 oz)
  • Page 32 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) High temperature RTV sealant Clear silicone Shock oil (32 oz) Ultra Copper (P/N 293 800 033) (P/N 413 711 806) (P/N 413 710 300) (80 mL) F01B1S4 APPLICATION All models to seal bottom pan.
  • Page 33 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Super Lube (grease) (P/N 293 550 014) A00B474 APPLICATION Exhaust tail pipe grommet. 01-02-7 MMR2000_114_01_02A.FM...

  • Page 34: Lubrication And Maintenance Chart

    Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART SYSTEM PART/TASK REFER TO Rewind Starter Lubrication and Rope Subsection 04-07 Condition Appropriate section: Engine Head Nuts See TOP END Appropriate section: Engine Mount Nuts See ENGINE REMOVAL Appropriate section: Exhaust System...
  • Page 35 Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) SYSTEM PART/TASK REFER TO Section 07: Suspension Condition See appropriate subsection Section 07: Suspension Stopper Straps Condition See appropriate subsection Track Condition Subsection 07-04 Track Tension and Alignment AS REQUIRED Subsection 07-04 Spark Plug * Subsection 06-03...
  • Page 36 Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 1 – ENGINE OIL LEVEL With snowmobile on a level surface, check the oil level by removing dipstick at engine base. Oil level must be to the top of the oil filler neck. If not, refill up to oil filler neck using SAE 5W/30 rec- ommended oil.
  • Page 37 Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) Reinstall the spark plug. NO. 6 – FUEL STRAINER WARNING Turn off fuel valve. This procedure must only be performed in a well ventilated area. Do not run engine during storage period.
  • Page 38 Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 7 – DRIVE CHAIN CONDITION For bottom pan cleaning, use Bombardier Cleaner (P/N 293 110 001 (spray can 400 g) and P/N 293 Visually inspect the chain for cracked, damaged or 110 002 (4 L)).

  • Page 39: Troubleshooting

    Section 03 TROUBLESHOOTING Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE ..........................03-02-1 FUEL AND OIL SYSTEMS ..................... 03-03-1 TRANSMISSION AND BRAKE SYSTEMS ................... 03-04-1 TRANSMISSION ........................ 03-04-1 BRAKE SYSTEM ........................ 03-04-3 MECHANICAL BRAKE ....................... 03-04-3 ELECTRICAL SYSTEM......................03-05-1 SUSPENSION AND TRACK ....................
  • Page 40 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) ENGINE The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. SYMPTOM ENGINE BACKFIRES. CONDITION NORMAL USE. Test/Inspection 1. Check spark plug. a. Carbon accumulation caused by defective spark plug. Clean carbon accumulation and replace spark plug.
  • Page 41 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) 8. Check exhaust system. a. Restriction. Replace. 9. Check ignition system. a. Decrease in power due to incorrect ignition. Check spark plug and ignition coil operation. 10. Check engine compression. a. Worn piston(s) and ring(s). Replace (refer to TECHNICAL DATA 10 for specification).
  • Page 42 Section 03 TROUBLESHOOTING Subsection 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 43 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM IRREGULAR ENGINE IDLE. CONDITION NORMAL USE AFTER ENGINE WARM UP. Test/Inspection 1. Check choke. a. Choke plate may be partially closed. Readjust. 2. Check pilot screw position. a. Inadequate fuel/air mixture. Adjust according to specifications (refer to TECHNICAL DATA 10). 3.
  • Page 44 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM REWIND STARTER ROPE DOES NOT REWIND. CONDITION NORMAL USE. Test/Inspection 1. Check rewind spring. a. Broken spring. Replace spring. SYMPTOM REWIND STARTER RATCHET DOES NOT ENGAGE. CONDITION NORMAL USE. Test/Inspection 1. Check ratchet and ratchet guide. a.
  • Page 45 Section 03 TROUBLESHOOTING Subsection 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. SYMPTOM HIGH FUEL CONSUMPTION OR RICH MIXTURE. CONDITION NORMAL USE.
  • Page 46 Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE). CONDITION NORMAL USE. Test/Inspection 1. Check fuel filter or strainer. a. Clogged filter or strainer. Clean. 2. Check if lines are perforated or kinked and make sure they do not leak at fittings. a.

  • Page 47: Transmission And Brake Systems

    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) TRANSMISSION AND BRAKE SYSTEMS0 The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. TRANSMISSION SYMPTOM LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING/DECELERATING. CONDITION NORMAL USE.
  • Page 48 Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM EXCESSIVE NOISE WITH DRIVE CHAIN. CONDITION NORMAL USE. Test/Inspection 1. Check drive chain lubrication. a. Drive chain is dry. Lubricate drive chain. 2. Check drive chain condition. a. Chain is cracked, damaged or some link rollers are missing. Replace drive chain.

  • Page 49: Brake System

    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) BRAKE SYSTEM MECHANICAL BRAKE SYMPTOM BRAKE HANDLE DOES NOT RETURN COMPLETELY. CONDITION NORMAL USE. Test/Inspection 1. Check brake return spring. a. Broken return spring. Replace. 2. Check if brake cable moves freely in its housing. a.

  • Page 50: Electrical System

    Section 03 TROUBLESHOOTING Subsection 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. SYMPTOM HEADLAMP NOT LIGHTING. CONDITION WHITE BULB. Test/Inspection 1. Check bulb. a.
  • Page 51 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINES DOES NOT START — NO SPARK AT SPARK PLUG. CONDITION AT ENGINE CRANKING. Test/Inspection 1. Verify spark plug condition. a. Defective, improperly set, worn-out, fouled. Identify source of problem and correct. Replace spark plug. 2.
  • Page 52 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINE IS MISFIRING — ERRATIC SPARK AT SPARK PLUG. CONDITION RIDING ON WET SNOW. Test/Inspection 1. Verify if spark plug wires and/or spark plug cap seals are sealing-out moisture. a. Defective wires and/or seals. Replace defective part.
  • Page 53 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM REAR LIGHT BULB FLASHES. CONDITION NORMAL USE. Test/Inspection 1. Check if rear light is properly connected. a. Connector housing is partially connected. Install connector housing properly. 2. Check continuity of wires. a. Corroded terminals and/or broken wires. Replace terminal(s) or crimp defective wires.

  • Page 54: Suspension And Track

    Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SUSPENSION AND TRACK The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. SYMPTOM REAR SUSPENSION BOTTOMS OUT. CONDITION NORMAL USE. Test/Inspection 1.
  • Page 55 Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM NOISE OR VIBRATIONS ORIGINATING FROM THE TRACK. CONDITION NORMAL USE. Test/Inspection 1. Check slide suspension retaining bolts. a. Missing bolt(s) allowing movement of certain components which in turn interfere with track rotation. Replace missing bolt(s).
  • Page 56 Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM REAR SUSPENSION IS LOW OR TOO STIFF. CONDITION NORMAL USE. Test/Inspection 1. Check track tension. a. Track is too tight. Adjust. 2. Check condition of cushion between shaft and front arm. a.
  • Page 57 Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM THE SNOWMOBILE IS UNSTABLE (IT MOVES FROM LEFT TO RIGHT AND VICE VERSA). CONDITION NORMAL USE. Test/Inspection 1. Check ski runner condition. a. Worn or bent ski runners. Replace ski runners. 2.

  • Page 58: Table Of Contents

    Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE REMOVAL AND INSTALLATION................04-02-1 REMOVAL FROM VEHICLE ....................04-02-2 ENGINE AND MUFFLER DISASSEMBLY AND ASSEMBLY..........04-02-2 INSTALLATION ON VEHICLE .................... 04-02-2 VALVE ADJUSTMENT ......................04-03-1 VALVE ADJUSTMENT ....................... 04-03-2 DISASSEMBLY/ASSEMBLY ....................
  • Page 59 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) CONNECTING ROD BIG END OIL CLEARANCE............... 04-05-7 CRANKPIN (outside diameter) ..................04-05-8 CAMSHAFT CAM HEIGHT ....................04-05-8 CAMSHAFT (outside diameter) ..................04-05-8 CAMSHAFT HOLDER (inside diameter) ................04-05-9 CHECKING SURFACE FLATNESS ..................04-05-9 RECTIFYING SURFACES....................

  • Page 60: Engine Removal And Installation

    Section 04 ENGINE Subsection 02 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION0 04-02-1 MMR2000_117_04_02A.FM...

  • Page 61: Removal From Vehicle

    Section 04 ENGINE Subsection 02 (ENGINE REMOVAL AND INSTALLATION) REMOVAL FROM VEHICLE Remove or disconnect the following then lift en- gine from vehicle: – chain guard – drive chain – drive sprocket (clutch) – muffler no. 3 – engine protector no. 5 –...

  • Page 62: Valve Adjustment

    Section 04 ENGINE Subsection 03 (VALVE ADJUSTMENT) VALVE ADJUSTMENT 04-03-1 MMR2000_118_04_03A.FM...
  • Page 63 Section 04 ENGINE Subsection 03 (VALVE ADJUSTMENT) VALVE ADJUSTMENT Valve Clearance Inspection Insert a feeler gauge between rocker arm no. 5 NOTE: Valve clearance inspection and adjustment and valve no. 6. Refer to the following table for must be performed with the engine cold. valve clearance.

  • Page 64: Disassembly/Assembly

    Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) DISASSEMBLY/ASSEMBLY TOP END 04-04-1 MMR2000_119_04_04A.FM...

  • Page 65: Top End Removal

    Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) TOP END REMOVAL DISASSEMBLY Remove the following then lift cylinder head no. 10: NOTE: Before disassembling, mark valve springs no. 7, valves no. 6 and rocker arms no. 5. This will – carburetor ensure that parts will not be inverse at reassem- –...

  • Page 66: Inspection

    Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) Put apart valve spring retainer and spring. Repeat procedure for exhaust valve but ensure that valve rotator no. 14 is removed first. Refer to the following photo. A31C29A EXHAUST AND INTAKE VALVES SECURED IN PLACE 1.

  • Page 67: Top End Installation

    Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) TOP END INSTALLATION Install cylinder head gasket no. 15 and check that both locating pins no. 16 are in place, as shown in the next photo. A31C2BA 1. Cylinder head gasket 2. Locating pin Check push rods no.

  • Page 68: Bottom End

    Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) BOTTOM END 12 N•m (106 lbf•in) Loctite 242 12 N•m (106 lbf•in) A31C2CS 04-04-5 MMR2000_119_04_04A.FM...

  • Page 69: Cleaning

    Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) NOTE: Engine must be removed from chassis to Push on connecting rod no. 4 and pull out piston perform the following procedures. no. 5. Remove both piston pin circlips no. 6 and push out CLEANING piston pin no.
  • Page 70 Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) To reinstall bearings, reverse housing and use From inside crankcase, rotate governor arm shaft same tools as for bearings removal, as shown in no. 14 then pull out governor slider no. 15 and the next photo. washer no.

  • Page 71: Inspection

    Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) From outside crankcase, remove lock pin no. 22 Governor System from governor arm shaft, as shown in the next Reinstall governor weights no. 21 with pins no. 20. photo. Remove governor arm shaft no. 14 with Install governor weight holder washer no.
  • Page 72 Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) Secure piston pin with both piston pin circlips no. 6. Space the piston ring end gaps 120° apart and do not align the gaps with the piston pin bore or the NOTE: Do not align the end gap of the piston pin thrust side axis.
  • Page 73 Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) Using a ring compressor, slide piston into cylinder with a hammer handle, as shown in the next photo. 1. Connecting rod cap 2. Torque wrench SLIDE PISTON INTO CYLINDER Camshaft 1. Ring compressor 2. Hammer handle Install exhaust and intake valve lifters inside crank- case.
  • Page 74 Section 04 ENGINE Subsection 04 (DISASSEMBLY/ASSEMBLY) Crankcase Verify that locating sleeves no. 25 are in place. Install gasket no. 26 on crankcase. Finalize crankcase assembling with crankcase cover no. 1. Torque screws in a crisscross se- quence to 12 N•m (106 lbf•in). NOTE: To protect seal and ease crankcase cover installation, apply grease on crankcase cover seal.

  • Page 75: Compression Test And Engine Dimension Measurement

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT COMPRESSION TEST Set ignition and emergency cut-out switches to the OFF position. Disconnect spark plug cap, then remove spark plug. Plug compression testing gauge into spark plug hole.

  • Page 76: Engine Dimension Measurement

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT VALVE SPRING FREE LENGTH If valve seat width is under the standard or over the service limit value, replace cylinder head with new one. STANDARD SERVICE LIMIT 30.5 mm (1.20 in) 29.5 mm (1.16 in) VALVE STEM (outside diameter)

  • Page 77: Guide-To-Stem Clearance

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) GUIDE-TO-STEM CLEARANCE CYLINDER INSIDE DIAMETER Subtract each valve stem outside diameter from STANDARD SERVICE LIMIT the corresponding valve guide inside diameter to obtain the stem-to-guide clearance. 60.0 mm (2.36 in) 60.165 mm (2.3687 in) STANDARD SERVICE LIMIT...

  • Page 78: Cylinder/Piston Clearance

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) F01D0NA F00B09A TYPICAL 1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge 1. Measuring perpendicularly (90º) to piston pin axis A. 10 mm (25/64 in) The measured dimension should be as described in the previous table.

  • Page 79: Ring/Piston Groove Clearance

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) RING/PISTON GROOVE CLEARANCE STANDARD SERVICE LIMIT 0.015 - 0.045 mm 0.15 mm (0.0006 - 0.0018 in) (0.006 in) NOTE: These clearances are applicable for 3 rings; top, second and oil ring. Using a feeler gauge check clearance between ring and groove.

  • Page 80: Piston Pin (Outside Diameter)

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) PISTON PIN (outside diameter) PISTON-TO-PISTON PIN BORE CLEARANCE STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT 13.0 mm (0.51 in) 12.954 mm (0.5100 in) 0.002 - 0.014 mm 0.08 mm Mesure piston pin with a micrometer, as shown in (0.0001 - 0.0006 in) (0.003 in) the next photo.

  • Page 81: Connecting Rod Big End Oil Clearance

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) NOTE: Do not rotate crankshaft while plastigauge is in place. MEASURE CONNECTING ROD BIG END A31C1YA CONNECTING ROD BIG END OIL 1. Connecting rod cap in place CLEARANCE 2. Torque both screws Remove connecting rod cap and measure the STANDARD SERVICE LIMIT...

  • Page 82: Crankpin (Outside Diameter)

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) CRANKPIN (outside diameter) STANDARD SERVICE LIMIT 25.98 mm 25.92 mm (1.023 in) (1.020 in) Measure crankpin outside diameter with a micro- meter, as shown in the next photo. A31C21A 1.

  • Page 83: Camshaft Holder (Inside Diameter)

    Section 04 ENGINE Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT) CAMSHAFT HOLDER RECTIFYING SURFACES (inside diameter) Stick a fine sand paper sheet on the surface plate then lightly oil the sand paper. STANDARD SERVICE LIMIT Rub manifold mating surface on sand paper using 14.0 mm (0.55 in) 14.048 mm (0.5531 in) 8-figure movements.

  • Page 84: Transistorized Magneto Ignition

    Section 04 ENGINE Subsection 06 (TRANSISTORIZED MAGNETO IGNITION) TRANSISTORIZED MAGNETO IGNITION 04-06-1 MMR2000_121_04_06A.FM...

  • Page 85: Cleaning

    Section 04 ENGINE Subsection 06 (TRANSISTORIZED MAGNETO IGNITION) NOTE: Engine must be removed to perform the Remove starter pulley no. 2 and fan no. 3. following procedures. Reinstall magneto flywheel nut then using puller, detach flywheel no. 5, as shown in the next photo. CLEANING CAUTION: Never hold flywheel using magnet section.

  • Page 86: Assembly

    Section 04 ENGINE Subsection 06 (TRANSISTORIZED MAGNETO IGNITION) ASSEMBLY Ignition Coil Air Gap Adjustment NOTE: To perform ignition coil air gap adjustment, Clean crankshaft extension (taper). flywheel must be tightened. Position Woodruff key no. 4 then reinstall fly- Loosen ignition coil screws. wheel with fan.

  • Page 87: Rewind Starter

    Section 04 ENGINE Subsection 07 (REWIND STARTER) REWIND STARTER 04-07-1 MMR2000_122_04_07A.FM...

  • Page 88: Removal

    Section 04 ENGINE Subsection 07 (REWIND STARTER) REMOVAL The following must be removed before rewind starter removal: – chain guard – drive chain – clutch – muffler – disconnect fuel hose – engine Using a small screwdriver, extract rope knot from starter grip no.

  • Page 89: Inspection

    Section 04 ENGINE Subsection 07 (REWIND STARTER) INSPECTION Check rope no. 2 for fraying. Replace if so. ASSEMBLY At assembly, position spring no. 11 outer end into spring guide notch then wind the spring counter- clockwise into guide. 1. Grease inside spring guide and sheave hub CAUTION: The use of standard multi-purpose grease could result in rewind starter malfunc- tion.
  • Page 90 Section 04 ENGINE Subsection 07 (REWIND STARTER) To adjust rope tension: Wind rope on sheave and place sheave into starter housing making sure that the sheave hub notch engages in the rewind spring hook. See the next photo. A31C1EA 1. Ratchet Finalize rewind starter assembly with friction spring no.

  • Page 91: Installation

    Section 04 ENGINE Subsection 07 (REWIND STARTER) Check ratchet operation: when turning ratchet INSTALLATION guide counterclockwise, ratchets must move in. Reinstall rewind starter ass‘y on engine. When turning ratchet guide clockwise, ratchets must move out as shown in the next photo. Reinstall engine in snowmobile.

  • Page 92: Carburetor

    Section 04 ENGINE Subsection 08 (CARBURETOR) CARBURETOR 04-08-1 MMR2000_123_04_08A.FM...

  • Page 93: Removal

    Section 04 ENGINE Subsection 08 (CARBURETOR) REMOVAL Loosen fuel strainer cup no. 2 and remove from carburetor. Keep O-ring no. 3, as shown in the next Remove engine protective plate. photo. Obstruct fuel line with a hose pincher (P/N 295 000 076), as shown in the next photo.
  • Page 94 Section 04 ENGINE Subsection 08 (CARBURETOR) Remove circlip no. 5 then remove choke cable at- Remove carburetor protector, as shown in the next tachment from carburetor choke lever, as shown photo. in the next photo. 1. Circlip 2. Choke cable attachment 3.

  • Page 95: Cleaning And Inspection

    Section 04 ENGINE Subsection 08 (CARBURETOR) Slide out carburetor and activate carburetor throt- Carburetor body and jets should be cleaned in a tle lever so that groove aligns with governor rod, carburetor cleaner following manufacturer’s in- as shown in the next photo. structions.
  • Page 96 Section 04 ENGINE Subsection 08 (CARBURETOR) To remove nozzle no. 12 use a flat screwdriver 13,14, Pilot Jet and push from inside carburetor, as shown in the Remove stop screw no. 15. following photo. Using a flat screwdriver remove pilot jet no. 13, as shown in the next photo.

  • Page 97: Carburetor Float Level

    Section 04 ENGINE Subsection 08 (CARBURETOR) 16,17, Float Valve STANDARD FLOAT 13.7 mm (0.54 in) HEIGHT Remove float pin no. 10 then remove float no. 9 from carburetor. If float height is not according to specifications on Check for worn valve seat on float. Replace if so. above table, replace float and/or float valve.

  • Page 98: Carburetor Adjustments

    Section 04 ENGINE Subsection 08 (CARBURETOR) A31C12A 1. Spacer 2. Air cleaner elbow ass‘y 1. Governor arm nut 2. Turn governor arm to fully open throttle CARBURETOR ADJUSTMENTS 3. Turn governor arm shaft Lift rear of snowmobile. Preliminary Idle Speed Adjustment Start engine and allow to warm up to normal tem- 21, Pilot Screw perature.

  • Page 99: Fuel Tank And Throttle Cable

    Section 04 ENGINE Subsection 09 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE 04-09-1 MMR2000_124_04_09A.FM...
  • Page 100 Section 04 ENGINE Subsection 09 (FUEL TANK AND THROTTLE CABLE) Fuel Tank Lines WARNING When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with a hose pincher (P/N 295 000 076) or equivalent device. Fuel is flammable and explosive under certain conditions.
  • Page 101 Section 04 ENGINE Subsection 09 (FUEL TANK AND THROTTLE CABLE) Throttle Cable Circlip at Handlebar Put silicone grease (P/N 413 701 700) around ca- ble barrel of throttle cable no. 7. Locate circlip no. 5 as per following photo. WARNING If this procedure is disregarded, throttle lever no.
  • Page 102 Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS CLUTCH..........................05-02-1 REMOVAL .......................... 05-02-2 DISASSEMBLY ........................05-02-3 CLEANING ......................... 05-02-3 INSPECTION ........................05-02-3 INSTALLATION........................05-02-4 BRAKE ............................ 05-03-1 REMOVAL .......................... 05-03-2 DISASSEMBLY ........................05-03-2 CLEANING ......................... 05-03-2 INSPECTION ........................05-03-3 INSTALLATION........................

  • Page 103: Clutch

    Section 05 TRANSMISSION Subsection 02 (CLUTCH) CLUTCH 05-02-1 MMR2000_125_05_02A.FM...

  • Page 104: Removal

    Section 05 TRANSMISSION Subsection 02 (CLUTCH) NOTE: Parts are not available separately. If clutch no. 1 is damaged, replace clutch assembly. REMOVAL NOTE: Clutch can be removed without removing brake. In that case drive chain no. 2 must be sep- arated and removed first.

  • Page 105: Disassembly

    Section 05 TRANSMISSION Subsection 02 (CLUTCH) 1, Clutch Removal Loosen driven sprocket locking nut no. 9, then re- move driven sprocket screw no. 10. Holding clutch with a wrench, loosen clutch retain- Pull out driven sprocket from drive axle. ing screw no. 3. A31D0AA A31D09A REMOVE DRIVEN SPROCKET...

  • Page 106: Installation

    Section 05 TRANSMISSION Subsection 02 (CLUTCH) INSTALLATION CAUTION: Ensure that keyway is properly po- sitioned when sliding clutch on shaft. To install clutch, reverse removal procedure pay- ing attention to the following. Pour a few drops of oil into clutch sleeves, as shown in the next illustration.

  • Page 107: Brake

    Section 05 TRANSMISSION Subsection 03 (BRAKE) BRAKE Loctite 242 Loctite 242 11 N•m (100 lbf•in) A31D0IS 05-03-1 MMR2000_126_05_03A.FM...

  • Page 108: Removal

    Section 05 TRANSMISSION Subsection 03 (BRAKE) REMOVAL Brake Cable Replacement Remove circlip no. 5 from brake cable at brake le- 2, Brake Pad Removal ver location, as shown in the next photo. Using Allen key, unlock brake cable no. 1 from ca- ble lock no.

  • Page 109: Inspection

    Section 05 TRANSMISSION Subsection 03 (BRAKE) INSPECTION Check that brake lever is set to normal position (no play), as shown in the next photo. 2, Brake Pad Brake pad must be replaced when lining is 1 mm (1/32 in) thick or less. A31D05B 1.

  • Page 110: Adjustment

    Section 05 TRANSMISSION Subsection 03 (BRAKE) ADJUSTMENT Fully apply brake with brake lever. If brake lever is not within 15 mm (19/32 in) to 20 mm (25/32 in) of the handlebar, readjust brake. Refer to the fol- lowing photo. A31D03A 1.

  • Page 111: Drive Chain

    Section 05 TRANSMISSION Subsection 04 (DRIVE CHAIN) DRIVE CHAIN REMOVAL INSPECTION NOTE: To ease drive chain removal, remove drive Check that chain is not stretched. chain automatic tensioner first. CAUTION: On a stretched chain, pitch has Rotate drive chain to locate connecting link circlip. changed (increased) and will not properly match the sprockets pitch, causing premature Using a flat screwdriver push on both ends of cir-...
  • Page 112 Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SPARK PLUGS........................06-02-1 NGK SPARK PLUG......................06-02-1 NGK SPARK PLUG NUMBERING SYSTEM ..............06-02-1 REFERENCE CHART ......................06-02-1 DESIGN SYMBOLS USED IN NGK SPARK PLUGS............06-02-2 DISASSEMBLY........................06-02-3 HEAT RANGE ........................06-02-3 FOULING ..........................

  • Page 113: Spark Plugs

    Section 06 ELECTRICAL Subsection 02 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG NGK SPARK PLUG NUMBERING SYSTEM Bombardier uses the NGK spark plug brand on all its snowmobile models. The heat range identification system is: Low number hot plug High number cold plug REFERENCE CHART NGK spark plug used on Bombardier Mini Z snow-...

  • Page 114: Design Symbols Used In Ngk Spark Plugs

    Section 06 ELECTRICAL Subsection 02 (SPARK PLUGS) DESIGN SYMBOLS USED IN NGK SPARK PLUGS CROSSCUTS AND GAP STYLES OF SPARK PLUGS Standard Projected Taper V-Type Surface Type Insulator Type Seat Type Discharge Type A01E1PS 06-02-2 MMR2000_128_06_02A.FM...

  • Page 115: Disassembly

    Section 06 ELECTRICAL Subsection 02 (SPARK PLUGS) DISASSEMBLY CAUTION: Severe engine damage might occur if a wrong heat range plug is used. First unscrew the spark plug 1 turn. A too “hot” plug will result in overheating and pre- Clean the spark plug and cylinder head with pres- ignition, etc.

  • Page 116: Spark Plug Installation

    Section 06 ELECTRICAL Subsection 02 (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 10.

  • Page 117: Testing Procedure

    Section 06 ELECTRICAL Subsection 03 (TESTING PROCEDURE) TESTING PROCEDURE IGNITION SYSTEM TESTING 1. SPARKING SEQUENCE During this operation, it is important to use the snowmobile spark plug and not a new one. Bring In the case of ignition problems, check the follow- the plug in contact with the engine.

  • Page 118: Spark Plug Cap Testing

    Section 06 ELECTRICAL Subsection 03 (TESTING PROCEDURE) Secondary Side 4. SPARK PLUG CAP TESTING Bring multimeter selector switch to Ω position. Remove spark plug cap by unscrewing cap from Remove spark plug cap by unscrewing cap from cable. cable. NOTE: A false resistance reading will result if NOTE: A false resistance reading will result if spark plug cap is not removed.

  • Page 119: Lamp Coil Testing

    Section 06 ELECTRICAL Subsection 03 (TESTING PROCEDURE) 5. LAMP COIL TESTING NOTE: Lamp coil is parallel 2 coils type. Bring multimeter selector switch to Ω position. Connect first multimeter probe to pink wire then second probe to lamp coil iron core, as shown in the next photo.
  • Page 120 Section 07 REAR SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS REAR SUSPENSION......................07-02-1 REMOVAL .......................... 07-02-2 DISASSEMBLY AND ASSEMBLY..................07-02-3 INSPECTION ........................07-02-5 DRIVE AXLE ........................... 07-03-1 REMOVAL........................... 07-03-2 DISASSEMBLY AND ASSEMBLY..................07-03-3 INSTALLATION ........................07-03-3 TRACK ............................ 07-04-1 GENERAL ...........................

  • Page 121: Rear Suspension

    Section 07 REAR SUSPENSION Subsection 02 (REAR SUSPENSION) REAR SUSPENSION 17-18 17-18 A31F04S 07-02-1 MMR2000_130_07_02A.FM...

  • Page 122: Removal

    Section 07 REAR SUSPENSION Subsection 02 (REAR SUSPENSION) NOTE: The following is the complete procedure Rear Suspension to remove rear suspension ass‘y. However some Position a small block below track. suspension components can be removed without Lower snowmobile so that track sits on block. removing suspension ass‘y.

  • Page 123: Disassembly And Assembly

    Section 07 REAR SUSPENSION Subsection 02 (REAR SUSPENSION) Unscrew front retainer axle no. 6 (retaining front strap) from tunnel. See the following photo. A31F08A 1. Upper idler wheel screw 2. Front arm screw 3. Front retainer axle screw A31F09A Lift rear of snowmobile. REMOVE SCREW Pull out suspension ass‘y.
  • Page 124 Section 07 REAR SUSPENSION Subsection 02 (REAR SUSPENSION) Pull out runner from track, as shown in the next photo. A31F0BA 1. Unscrew upper idler wheel axle PULL OUT RUNNER Remove both screws no. 5 retaining front arm to To reinstall runner, reverse removal procedure. tunnel.

  • Page 125: Inspection

    Section 07 REAR SUSPENSION Subsection 02 (REAR SUSPENSION) Remove bushing no. 13, as shown in the next photo. Clean all surfaces and check for excessive wear. A31F0DA REMOVE AND CLEAN BUSHING A31F0FA To reinstall, reverse removal procedure. REMOVE RUBBER STOPPER Reinstall rubber stopper no.
  • Page 126 Section 07 REAR SUSPENSION Subsection 02 (REAR SUSPENSION) 19,20, Upper Idler Wheels Remove bushing no. 20 and idler wheel no. 19 from shaft no. 4, as shown in the next photo. Clean parts and check for wear and bearing condi- tion.

  • Page 127: Drive Axle

    Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) DRIVE AXLE 07-03-1 MMR2000_131_07_03A.FM...

  • Page 128: Removal

    Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) REMOVAL Remove chain guard. Remove drive chain then remove driven sprocket. NOTE: To ease driven sprocket and drive axle re- moval, it may be useful to remove left side foot- rest. Remove rear suspension. Refer to REAR SUS- PENSION 07-02 of this manual.

  • Page 129: Disassembly And Assembly

    Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) Drive Axle Ass‘y Pull out drive axle ass‘y no. 8, as shown in the next photo. 1. Lock sleeve 2. Position punch in this hole Remove 3 bearing holder nuts no. 5 and screws no.
  • Page 130 Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) Drive Axle Alignment To ensure that drive axle sprockets are properly aligned with track guides, measure right side drive axle end. Drive axle must exceed bearing locking sleeve by 4 mm (5/32 in), as shown in the next photo. If not, realign drive axle.

  • Page 131: Track

    Section 07 REAR SUSPENSION Subsection 04 (TRACK) TRACK GENERAL This section gives guidelines for track removal. Some components require more detailed disas- sembly procedures. In these particular cases, re- fer to the pertaining section in this manual. INSPECTION Visually inspect track for: –...
  • Page 132 Section 07 REAR SUSPENSION Subsection 04 (TRACK) Alignment WARNING Before checking track tension, ensure that the track is free of all particles which could be thrown out while it is rotating. Keep hands, tools, feet and clothing clear of track. Ensure no one is standing in close proximity to the vehicle.
  • Page 133 Section 07 REAR SUSPENSION Subsection 04 (TRACK) Tighten lock nuts and the idler wheel retaining screws. A05F0EB TYPICAL 1. Retighten lock nuts 2. Retighten rear idler wheel retaining screws Restart engine, rotate track slowly and recheck alignment. 07-04-3 MMR2000_132_07_04A.FM...
  • Page 134 Section 08 STEERING/FRONT SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................08-02-1 INSPECTION ........................08-02-2 DISASSEMBLY AND ASSEMBLY ..................08-02-2 INSPECTION ........................08-02-3 STEERING ADJUSTMENT (skis) ..................08-02-3 LUBRICATION ........................08-02-5 SUSPENSION AND SKI SYSTEM ..................08-03-1 DISASSEMBLY........................

  • Page 135: Steering System

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) STEERING SYSTEM 13 6 08-02-1 MMR2000_133_08_02A.FM...

  • Page 136: Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) INSPECTION Remove U-clamp no. 7 with both half bushings, no. 6 as shown in the following photo. Check skis and runner shoes for wear, replace as necessary. Refer to SUSPENSION AND SKI SYS- TEM 08-03.

  • Page 137: Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) INSPECTION WARNING The cut off section of the ball joint must run 12, Ball Joint parallel with the steering arm. When tighten- Inspect ball joint ends for wear or looseness, if ex- ing lock nuts, restrain ball joint with appropri- cessive, replace.
  • Page 138 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) A. 47 mm (1-27/32 in) maximum Restrain tie rod while firmly retighten nuts so that ball joint sockets run parallel with steering arm and TO REMOVE CLIP — LIFT THEN PULL OUT pivot arm.

  • Page 139: Lubrication

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Re-attach tie rod end to steering arm then secure with clip. NOTE: A rubber cord must be hooked in front of skis to keep them closed. NOTE: To measure toe-out, place a straight edge against pre-adjusted track and measure distance between front and rear of skis and straight edge.

  • Page 140: Suspension And Ski System

    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM 08-03-1 MMR2000_133_08_03A.FM...

  • Page 141: Disassembly

    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 2, Rubber Mount Lift front of vehicle and support it off the ground. Note rubber mount position. Remove lower nut then upper nut of rubber mount. 1, Swing Arm Lift front of vehicle and support it off the ground.
  • Page 142 Section 09 BODY AND FRAME Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY ............................09-02-1 INSTALLATION AND ADJUSTMENT ................09-02-2 HEADLAMP BEAM AIMING....................09-02-2 BULB REPLACEMENT ....................... 09-02-2 DECAL ..........................09-02-3 WINDSHIELD INSTALLATION ..................09-02-3 CHAIN GUARD ........................09-02-3 WIRING HARNESS ......................

  • Page 143: Body

    Section 09 BODY AND FRAME Subsection 02 (BODY) BODY 09-02-1 MMR2000_134_09_02A.FM...

  • Page 144: Installation And Adjustment

    Section 09 BODY AND FRAME Subsection 02 (BODY) INSTALLATION AND ADJUSTMENT HEADLAMP BEAM AIMING BULB REPLACEMENT Beam aiming is correct when center of high beam Headlight is 25 mm (1 in) below the headlamp horizontal cen- If headlamp bulb is burnt, tilt hood. ter line, scribed on a test surface, 381 cm (12 ft 6 in) away.

  • Page 145: Decal

    Section 09 BODY AND FRAME Subsection 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 146: Piping

    Section 09 BODY AND FRAME Subsection 02 (BODY) PIPING WARNING Always ensure that the fuel and vent lines are properly fixed to their connectors, that they are not perforated or kinked and that they are properly routed away from any rotating, moving, heating or vibrating parts.

  • Page 147: Plastic Repair

    Section 09 BODY AND FRAME Subsection 02 (BODY) PLASTIC REPAIR REPAIR Two types of plastic material are used on Mini Z model, as described in the following table. MATERIAL WINDSHIELD Polycarbonate HOOD Polyethylene BOTTOM PAN Polyethylene Both plastic materials are irreparable. In the case that parts are broken or damaged, re- place with new one.

  • Page 148: Frame

    Section 09 BODY/FRAME Subsection 03 (FRAME) FRAME A31H0NS 09-03-1 MMR2000_135_09_03A.FM...

  • Page 149: Frame Cleaning

    Section 09 BODY/FRAME Subsection 03 (FRAME) FRAME CLEANING FRAME WELDING Clean frame no. 1, tunnel no. 2 and bumpers Steel Frame: no. 3 with appropriate cleaners and rinse with – electric welding high pressure hose. – amperage: 70-110 A Touch up all metal spots where paint has been –...
  • Page 150 Section 10 TECHNICAL DATA Subsection 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 151 Section 10 TECHNICAL DATA Subsection 02 (ENGINE) VEHICLE MODEL MINI Z 4 Stroke ENGINE TYPE Overhead Valves Number of Cylinders Bore mm (in) 60.00 (2.362) Stroke mm (in) 42.00 (1.654) Displacement 118.00 (7.20) Compression Ratio (corrected) 8.5: 1 Maximum Power Engine Speed ±...
  • Page 152 Section 10 TECHNICAL DATA Subsection 03 (VEHICLE) VEHICLE MODEL MINI Z 4 Stroke ENGINE TYPE Overhead Valve Drive Chain Ratio 10/48 Pitch mm (in) 12.7 (.500) Drive Chain Type/Links Single 40/78 Drive Sprocket Clutch Engagement N.A. Outside Diameter mm (in) 201.37 (7.93) Driven Sprocket Pitch Diameter...
  • Page 153 Section 10 TECHNICAL DATA Subsection 04 (TECHNICAL DATA LEGENDS) ENGINE TECHNICAL DATA VEHICLE TECHNICAL DATA LEGEND LEGEND BTDC: Before Top Dead Center N.A.: Not Applicable Kilo (x 1000) Force or downward pull applied to track to ob- tain specified tension deflection. MAG: Magneto Side N.A.: Not Applicable...
  • Page 154 Section 11 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) WIRING DIAGRAM WIRING DIAGRAM LEGEND CONNECTOR HOUSING AREA WARNING Ensure all terminals are properly crimped on the wires and all connector housings are properly fastened. 1. Wire colors 2. Housing area 3. Housing number per area 4.
  • Page 155 Section 11 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) CONNECTOR LOCATION IN HOUSING A00E4WB 11-01-2 MMR2000_137_11_01A.FM...
  • Page 156 Section 11 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) SYMBOLS DESCRIPTION 11-01-3 MMR2000_137_11_01A.FM...
  • Page 158 MINI Z A31Z02...
  • Page 159 7-03A 9-01 1-02 ANNEX 1...

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