Ski-Doo ELITE SERIES Shop Manual
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Ski-Doo ELITE SERIES Shop Manual

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  • Page 2 2004 Shop Manual ELITE SERIES Bombardier Recreational Products Inc.
  • Page 3 Legal deposit: National Library of Quebec National Library of Canada 2004 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. © Bombardier Recreational Products Inc. 2004 Technical Publications Bombardier Recreational Products Inc.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ................. . VIII INTRODUCTION ..
  • Page 5 TABLE OF CONTENTS FUEL SYSTEM......................37 SPARK PLUGS.
  • Page 6 TABLE OF CONTENTS COOLANT PUMP IMPELLER ..................102 ROTARY SEAL.
  • Page 7 TABLE OF CONTENTS EMS — ENGINE MANAGEMENT FUNCTIONS ..............173 VCM —...
  • Page 8 TABLE OF CONTENTS CLEANING ......................222 INSPECTION.
  • Page 9 TABLE OF CONTENTS REMOVAL ......................251 CLEANING .
  • Page 10 TABLE OF CONTENTS STEERING ARM ....................288 LUBRICATION .

  • Page 11: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 2004 Ski-Doo ® snowmo- biles. See model list below. This edition was primarily published to be used by snowmobile mechanic technicians who are already familiar with all service procedures relating to Bombardier †...

  • Page 12: Introduction

    INTRODUCTION INTRODUCTION VEHICLE IDENTIFICATION This shop manual covers the following BRP made 2004 Elite series models: NUMBER VEHICLE IDENTIFICATION NUMBER LOCATION TYPICAL — ELITE SERIES MODEL MODEL ENGINE COLOR NUMBER TYPICAL Elite SE 1. Vehicle identification number 1500 Silver 2227 CAN/U.S.

  • Page 13: Engine Serial Number

    INTRODUCTION ENGINE SERIAL NUMBER ABBREVIATION MEANING capacitor discharge ignition ENGINE SERIAL NUMBER LOCATION Crankshaft Position Sensor center centimeter cm² square centimeter cm³ cubic centimeter direct current digitally encoded security DESS system digital performance management °F degree Fahrenheit fan cooled TYPICAL fl.

  • Page 14: Arrangement Of This Manual

    INTRODUCTION ABBREVIATION MEANING ABBREVIATION MEANING total range adjustable meter U.S. oz ounce (United States) magneto volt Max. maximum volt (alternative current) Min. minimum Volt (direct current) milliliter variable sheave angle millimeter water temperature sensor multi-purpose electronic MPEM module ARRANGEMENT THIS MANUAL mile per hour newton...

  • Page 15: Illustrations And Procedures

    INTRODUCTION GENERAL INFORMATION Use a metal brush or a tap to clean the hole prop- erly then use a solvent (Methyl-Chloride), let act The information and component/system descrip- during 30 minutes and wipe off. The solvent uti- tions contained in this manual are correct at time lization is to ensure the adhesive works properly.
  • Page 16 INTRODUCTION Blind Holes – Apply several drops of proper strength Loctite on stud threads. – Install stud. – Install cover, etc. – Apply drops of proper strength Loctite on un- covered threads. – Tighten nuts as required. Preassembled Parts 1. On threads 2.

  • Page 17: Stripped Thread Repair

    INTRODUCTION Adjusting Screw – If a plate is used to align bolt: – Apply release agent on mating surfaces. – Put waxed paper or similar film on the sur- faces. – Twist bolt when inserting it to improve thread conformation. NOTE: NOT intended for engine stud repairs.

  • Page 18: Mounting On Shaft

    INTRODUCTION NOTE: Avoid grinding. Mounting in Tandem – Clean both mating surfaces with solvent. – Apply retaining compound on internal element bore. – Spray Loctite Primer N on both mating surfaces and on both sides of gasket. Allow to dry 1 or –...

  • Page 19: Tightening Torque

    INTRODUCTION TIGHTENING TORQUE Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer to following table. The table also gives the metric conversion. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: lock- ing tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones, where specified.
  • Page 20 INTRODUCTION XVII...
  • Page 21 INTRODUCTION XVIII...

  • Page 22: Service Tools And Service Products

    Subsection 01 (SERVICE TOOLS) SERVICE TOOLS This is a list of tools to properly service Ski-Doo snowmobiles. The list includes both the mandatory tools and the recommended tools. If you need to replace or add your tool inventory these items can be ordered through the regular parts channel.
  • Page 23 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) 1) Piston pin puller Engine leak tester kit 14) Exhaust plate (P/N 529 035 503) (P/N 861 749 100) (P/N 529 024 600) (2) NOTE: Should be used with 15) Exhaust plate hand pump (P/N 529 021 800).
  • Page 24 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Supply harness DESS KEY for B.U.D.S. (P/N 529 035 869) (P/N 529 035 896) APPLICATION All DESS equipped models. APPLICATION (Vehicle Communication Kit) All models equipped with a (P/N 529 035 981) DESS.

  • Page 25: Engine - Recommended Tools

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE — RECOMMENDED TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Support plate Hand pump Crankshaft locking tool N–> N–> (P/N 529 035 976) (P/N 529 021 800) (P/N 529 035 821)
  • Page 26 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Crankshaft bearing puller Torque flange remover Piston pin/connecting rod bear- N–> (P/N 420 877 635) (P/N 529 035 958) ing centering tool (P/N 529 009 100) NOTE: diameter 9.65 mm (.380 in). APPLICATION All engines except cageless en- gines.
  • Page 27 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Support sleeve PTO cover oil seal installer Valve spring compressor cup (P/N 529 035 944) (P/N 529 035 910) a) (P/N 529 035 764) b) (P/N 529 035 725) N–>...
  • Page 28 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Valve stem seal installer Torque angle gauge Attachment (P/N 529 035 687) Not sold by BOMBARDIER. (P/N 529 035 522) Snap-On TA362 APPLICATION APPLICATION Mini Z. 1004 and 1503 engines. APPLICATION 1004 and 1503 engines.
  • Page 29 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) RAVE movement indicator Injection pump gear holder MAG seal pusher (P/N 861 725 800) (P/N 420 277 905) (P/N 420 277 875) APPLICATION 277 engines. APPLICATION PTO seal pusher All liquid cooled engines except (P/N 420 876 660) 1004 and 1503.

  • Page 30: Transmission - Mandatory Tools

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Oil pump seal installer 2-stroke engine lifting tool Engine stand N–> (P/N 529 035 911) (P/N 529 035 940) Not sold by BOMBARDIER. APPLICATION 1004 engines. Large hose pincher APPLICATION (P/N 529 032 500) 2-stroke engines.

  • Page 31: Transmission - Recommended Tools

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Pulley spring compressor Driven pulley opening tool Driven pulley spring compressor (P/N 529 035 524) (P/N 529 017 200) (P/N 529 035 300) APPLICATION Most models. Clutch holder (P/N 529 027 600) APPLICATION APPLICATION All models.
  • Page 32 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Drive pulley puller Short dial indicator Alignment tool N–> (P/N 529 025 000) (P/N 295 000 143) (P/N 420 476 010) APPLICATION Skandic LT. Governor cup APPLICATION (P/N 529 035 894) Skandic WT.
  • Page 33 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Countershaft bearing remover Transmission adjuster Alignment bar (P/N 529 035 812) (P/N 529 030 300) a. (P/N 529 035 808) b. (P/N 529 035 586) c. (P/N 529 035 594) d.
  • Page 34 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Bushing extractor/installer Large bushing extractor Sliding half bushing N–> (P/N 529 031 300) (P/N 529 035 576) remover/installer (P/N 529 035 931) APPLICATION Formula type driven pulley. APPLICATION APPLICATION NOTE: Use this tool only with TRA III and TRA IV.

  • Page 35: Suspension - Mandatory Tools

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Drive axle sprocket adjuster Belt tension tool (P/N 861 725 700) (P/N 529 035 957) APPLICATION Elite. Parts included in the kit: 1) Block with threads (P/N 529 010 700) 2) Block without threads...

  • Page 36: Suspension - Recommended Tools

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION — RECOMMENDED TOOLS a) Track cleat remover Camber angle tool Track cleat installer (P/N 529 008 200) (P/N 529 021 600) (P/N 529 028 800 ) narrow Pins NOTE: Angle finder with a mag- (P/N 529 008 204) netic base must be used.
  • Page 37 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Shock wrench Gas shock valve tool (tire valve Spring installer (bar) (P/N 529 035 727) type) (P/N 529 005 000) (P/N 529 035 570) APPLICATION All T/A shocks. APPLICATION Tundra and all SC-10 suspen- sions.
  • Page 38 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Extension to torque ball joint Ball joint installer Adjustment wrench N–> N–> (P/N 529 035 975) (P/N 520 000 126) (P/N 529 035 876) APPLICATION SC-10 II and III (coupling blocks). APPLICATION REV series.

  • Page 39: Vehicle - Recommended Tools

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) VEHICLE — RECOMMENDED TOOLS Protective mat Adjustment wrench Crimping tool N–> (P/N 529 030 600) (P/N 529 035 603) (dies sold separately) (P/N 529 035 909) APPLICATION APPLICATION To remove and install fuel tank To crimp specific terminals.
  • Page 40 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Adjustment wrench Fuel line remover Heated grips insertion tool (P/N 529 035 891) (P/N 529 035 714) a. (P/N 529 035 897) b. (P/N 529 035 936) APPLICATION APPLICATION REV series.

  • Page 41: Service Products

    Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) SERVICE PRODUCTS Retaining compound High strength threadlocker Paste gasket (P/N 413 703 100) (P/N 293 800 005) (P/N 413 702 700) Loctite ® RC/609: Loctite ® 271: Loctite ® 515: Retaining compound Threadlocker (10 mL) (red, high...
  • Page 42 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Gasket/paint remover Isoflex grease SYNTHETIC BOMBARDIER (P/N 413 708 500) (P/N 293 550 021) 4-STROKE engine oil Loctite ® Chisel 510 g (18 oz) (50 g) 0W-40 (P/N 293 600 054) (12 x 1 L) APPLICATION APPLICATION...
  • Page 43 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) BOMBARDIER FORMULA XP-S BOMBARDIER injection oil Fuel stabilizer II synthetic injection oil (P/N 413 802 900) (P/N 413 408 600) (P/N 293 600 045) (12 x 1 liter) (12 x 8 oz) (12 x 1 liter) (P/N 413 803 000) (3 x 4 liters)
  • Page 44 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Storage oil Grease LMZ no. 1 BOMBARDIER LUBE CANADA: (P/N 413 711 600) (P/N 413 707 500) (P/N 293 600 016) U.S.A.: (P/N 413 711 900) (400 g) (12 x 14 oz) (350 g spray can) (12 x 350 g) APPLICATION Mainly used between regulators...
  • Page 45 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Brake fluid GTLMA (DOT 4) Anti-seize lubricant Pulley flange cleaner (P/N 293 600 062) (P/N 293 800 070) (P/N 413 711 809) Loctite anti-seize lubricant (320 g) 236 mL (8 oz) APPLICATION All models with hydraulic brake.
  • Page 46 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Plastic & vinyl cleaner Pipe sealant RTV silicone sealant (P/N 413 711 200) (P/N 293 800 018) (P/N 293 800 066) (6 x 1 L) Loctite 592 (50 mL) Loctite 5900 (300 mL) APPLICATION APPLICATION...
  • Page 47 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) High temperature RTV sealant Scratch remover N–> (P/N 293 800 090) (P/N 861 774 800) Ultra Copper (80 mL) APPLICATION All models. APPLICATION All models. NOTE: Only the P/N has been changed.

  • Page 48: Maintenance

    Section 02 MAINTENANCE Subsection 01 (MAINTENANCE CHART) MAINTENANCE CHART I: Inspect, verify, clean, adjust, lubricate or replace if Once Weekly Monthly necessary 10 h a year Every Preseason Refer to the C: Clean every every 10000 km Storage 500 km every preparation following...
  • Page 49 Section 02 MAINTENANCE Subsection 01 (MAINTENANCE CHART) I: Inspect, verify, clean, adjust, lubricate or replace if Once Weekly Monthly necessary 10 h a year Every Preseason Refer to the C: Clean every every 10000 km Storage 500 km every preparation following L: Lubricate 240 km...
  • Page 50 Vehicle Cleaning and Protection 02-03 To be performed by an authorized Ski-Doo dealer. Lubricate whenever the vehicle is used in wet conditions (wet snow, rain, puddles). Before installing new spark plugs at preseason preparation, it is suggested to burn excess storage oil by starting the engine with the old spark plugs.

  • Page 51: Storage

    Section 02 MAINTENANCE Subsection 02 (STORAGE) STORAGE GENERAL COOLING SYSTEM Proper snowmobile storage is a necessity during Antifreeze should be replaced for the storage pe- the summer months or when a vehicle is not being riod to prevent antifreeze deterioration. used for more than one month.

  • Page 52: Engine Compartment

    Section 02 MAINTENANCE Subsection 02 (STORAGE) WARNING If a leak is present, immediately stop the en- gine. Do not start engine until the leak is re- paired. WARNING At preseason preparation, ensure to perform a fuel pressure test and ensure there is no leak.

  • Page 53: Rags In Air Intake And Exhaust System

    Section 02 MAINTENANCE Subsection 02 (STORAGE) For vinyl and plastic parts, use Vinyl & Plastic Cleaner (P/N 413 711 200 (6 x 1 L)). To remove scratches on windshield or hood use BOMBARDIER Scratch Remover Kit (P/N 861 774 800). CAUTION: Never clean plastic parts or hood with strong detergent, degreasing agent, paint thinner, acetone, products containing chlorine,...

  • Page 54: Preseason Preparation

    Section 02 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) PRESEASON PREPARATION DRIVE BELT AND FINAL DRIVE Proper vehicle preparation is necessary after the summer months or when a vehicle has not been BELT CONDITION used for more than one month. Inspect belt for cracks, fraying or abnormal wear. Refer to preseason preparation column from Replace if necessary.

  • Page 55: Troubleshooting

    Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) ENGINE The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. This section pertains to engine mechanical components only. Some related problems can come from other systems such as ignition system, fuel system, etc.

  • Page 56: Alternator

    Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. TEST/INSPECTION 10. Check condition of hoses and hose clamps fixation. a. Hoses are brittle and/or hard. Replace. b. Hose clamps are loose. Retighten clamps. 11. Check condition of impeller located on the water pump shaft. a.

  • Page 57: Lubrication

    Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) LUBRICATION SYMPTOM LOW OR NO OIL PRESSURE. CONDITION NORMAL USE. TEST/INSPECTION 1. Check oil level and search for leakage on crankcase and/or sealing parts. a. Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts. Use Bombardier’s recommended oil (refer to TECHNICAL DATA).

  • Page 58: Cylinder And Cylinder Head

    Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM OIL CONTAMINATION (white appearance). CONDITION NORMAL USE. TEST/INSPECTION 1. Check control bore (beside water pump housing) if water and oil leaks. a. Leakage of oil/water mixture from bore means damaged water pump seal ring and rotary seal. Replace sealing ring, rotary seal and refill with recommended oil and/or coolant (refer to COOLING SYSTEM).

  • Page 59: Crankshaft

    Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) CRANKSHAFT SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATIONS. CONDITION NORMAL USE. TEST/INSPECTION 1. Check noise coming from crankshaft area. a. Crankshaft bushings are damaged. Replace the crankshaft bushings (refer to ENGINE BLOCK). b. Connecting rod bushings are damaged. Replace the connecting rod bushings (refer to ENGINE BLOCK).
  • Page 60 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM STARTER TURNS, BUT ENGINE DOES NOT CRANK. CONDITION NORMAL USE. TEST/INSPECTION 1. Check the starter gear. a. Starter gear and/or intermediate gear is worn or damaged. Replace starter gear and/or intermediate gear (refer to ENGINE BLOCK). 2.

  • Page 61: Engine General

    Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) ENGINE GENERAL 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. 2. Check leakage on intake manifold. a.
  • Page 62 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. TEST/INSPECTION 4. Piston color is dark due to seizure on intake and exhaust sides. a. Cooling system leaks and lowers coolant level. Tighten clamps or replace defective parts. Add antifreeze in cooling system until appropriate level is reached. Replace damaged parts.
  • Page 63 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH MAXIMUM OPERATING RPM. CONDITION NORMAL USE. TEST/INSPECTION 4. Check for water in fuel (wrong fuel). a. There is water in fuel or wrong fuel. Drain fuel system, search for leakage and refill it with appropriate fuel.
  • Page 64 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. TEST/INSPECTION 1. Check if cooling system shows any failure (see COOLING SYSTEM). a. System is leaking. Repair and/or replace damaged part(s). 2. Check function of lubrication system (see LUBRICATION SYSTEM). a.

  • Page 65: Transmission And Brake System

    Section 03 TROUBLESHOOTING Subsection 02 (TRANSMISSION AND BRAKE SYSTEM) TRANSMISSION AND BRAKE SYSTEM The following chart is provided to help diagnose 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 FROM A STANDING START.
  • Page 66 Section 03 TROUBLESHOOTING Subsection 02 (TRANSMISSION AND BRAKE SYSTEM) 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 FROM A STANDING START.
  • Page 67 Section 03 TROUBLESHOOTING Subsection 02 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM VIBRATIONS ORIGINATING FROM DRIVE PULLEY. CONDITION NORMAL USE. TEST/INSPECTION 1. Check drive belt. a. Belt width is uneven on several places. Replace. 2. Check tightening torque of drive pulley screw. a.
  • Page 68 Section 03 TROUBLESHOOTING Subsection 02 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY. CONDITION NORMAL USE. TEST/INSPECTION 1. Check driven pulley spring tension. a. Spring tension is too low. Adjust according to specifications (refer to TECHNICAL DATA) or replace spring. 2.
  • Page 69 Section 03 TROUBLESHOOTING Subsection 02 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE. CONDITION NORMAL USE. TEST/INSPECTION 1. Check if drive pulley bushings are worn. a. Slipping due to insufficient pressure on belt sides. Replace bushing. 2.
  • Page 70 Section 03 TROUBLESHOOTING Subsection 02 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM BELT TOO NARROW ON ONE SECTION. CONDITION NORMAL USE. TEST/INSPECTION 1. Check for frozen tracks. a. Frozen tracks. Free tracks from ice. 2. Check parking brake. a. Parking brake is engaged. Release parking brake.
  • Page 71 Section 03 TROUBLESHOOTING Subsection 02 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM BELT DISINTEGRATION. CONDITION NORMAL USE. TEST/INSPECTION 1. Check drive belt identification number. a. Excessive belt speed. Wrong type of belt. Replace with proper type of belt (refer to TECHNICAL DATA). 2.

  • Page 72: Brake System

    Section 03 TROUBLESHOOTING Subsection 02 (TRANSMISSION AND BRAKE SYSTEM) 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). 2. Check drive belt identification number. a.

  • Page 73: Electrical System

    Section 03 TROUBLESHOOTING Subsection 03 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM The following chart is provided to help diagnose the probable source of troubles. It should be used as a guideline. SYMPTOM STARTER DOES NOT TURN. CONDITION NORMAL USE. TEST/INSPECTION 1. Check fuse. a.
  • Page 74 Section 03 TROUBLESHOOTING Subsection 03 (ELECTRICAL SYSTEM) SYMPTOM STARTER TURNS BUT DOES NOT CRANK THE ENGINE. CONDITION NORMAL USE. TEST/INSPECTION 7. Check engine. a. Engine seized. Overhaul the engine. 8. Check height of commutator mica. a. Commutator mica too high. Undercut mica.
  • Page 75 Section 03 TROUBLESHOOTING Subsection 03 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED. CONDITION NORMAL USE. TEST/INSPECTION 1. Check clutch. a. Jammed clutch pinion gear. Replace or clean. 2. Check starter relay. a. Shorted starter relay winding(s). Replace starter relay.
  • Page 76 Section 03 TROUBLESHOOTING Subsection 03 (ELECTRICAL SYSTEM) SYMPTOM HEADLAMP NOT LIGHTING. CONDITION WHITE BULB. TEST/INSPECTION 1. Check bulb. a. Gas leak. Replace bulb. CONDITION BROKEN ELEMENT. TEST/INSPECTION 1. Check for loose headlamp housing and bulb socket. a. Vibration problem. Tighten headlamp mounting screws. Lock bulb in socket. Replace bulb. CONDITION MELTED FILAMENT (ends of element holder) AND BLACK BULB.
  • Page 77 Section 03 TROUBLESHOOTING Subsection 03 (ELECTRICAL SYSTEM) SYMPTOM FALSE FUEL AND/OR TEMPERATURE GAUGE READINGS. CONDITION NORMAL USE. TEST/INSPECTION 1. Verify sender unit for free movement and/or correct arm position. a. Defective or damaged part. Correct or replace sender unit. 2. Verify sender unit/gauge wiring harness condition. a.

  • Page 78: Suspension And Track

    Section 03 TROUBLESHOOTING Subsection 04 (SUSPENSION AND TRACK) SUSPENSION AND TRACK The following chart is provided to help diagnose the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM SUSPENSION IS TOO LOW.
  • Page 79 Section 03 TROUBLESHOOTING Subsection 04 (SUSPENSION AND TRACK) SYMPTOM WHEN STEERING WHEEL IS TURNED, SNOWMOBILE UNDERSTEERS. CONDITION NORMAL USE. TEST/INSPECTION 1. Check ski runner condition. a. Worn ski runners. Replace. 2. Check ski spring preload. a. Insufficient ski pressure on the ground. Increase spring preload.
  • Page 80 Section 03 TROUBLESHOOTING Subsection 04 (SUSPENSION AND TRACK) SYMPTOM THE SNOWMOBILE ZIGZAGS. CONDITION NORMAL USE. TEST/INSPECTION 1. Check ski runner condition. a. Worn or bent ski runners. Replace ski runners. 2. Check ski alignment. a. Improper ski alignment. Align skis in order to obtain proper toe-out (opening) (to adjust, refer to STEERING SYSTEM). 3.
  • Page 81 Section 03 TROUBLESHOOTING Subsection 04 (SUSPENSION AND TRACK) SYMPTOM DERAILING TRACKS. CONDITION NORMAL USE. TEST/INSPECTION 1. Check track tension. a. Tracks are too loose. Adjust. 2. Check if tracks and slider shoes are properly aligned. a. Improper alignment. Adjust. SYMPTOM NOISE OR VIBRATION COMING FROM THE TRACKS.

  • Page 82: Engine

    Section 04 ENGINE Subsection 01 (LEAK TEST) LEAK TEST LEAK TEST PROCEDURE The procedure has to be done when engine op- erating temperature of approx. 70°C (158°F) is reached. WARNING Prevent burning yourself due to handling on the hot engine. PREPARATION Remove: WARNING...

  • Page 83: Procedure

    Section 04 ENGINE Subsection 01 (LEAK TEST) As the engine is turned over, observe the move- ment of intake rocker arm of the cylinder no. 3. After it completes the cycle and the intake valve closes, observe the piston. When it reaches its uppermost position that is TDC compression stroke.

  • Page 84: Installation

    Section 04 ENGINE Subsection 01 (LEAK TEST) – air escaping into crankcase area means exces- sively worn and/or broken piston rings. INSTALLATION NOTE: For installation use the torque values and Loctite products from the exploded views (refer to proper engine subsection). For installation, reverse the preparation proce- dure.
  • Page 85 Section 04 ENGINE Subsection 01 (LEAK TEST) 1. Weep hole – coolant escaping from coolant pump housing means damaged gasket(s) and/or loosened screws (refer to COOLING SYSTEM). NOTE: For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine.

  • Page 86: Intake System

    Section 04 ENGINE Subsection 02 (INTAKE SYSTEM) INTAKE SYSTEM TYPICAL Template...

  • Page 87: Removal

    Section 04 ENGINE Subsection 02 (INTAKE SYSTEM) REMOVAL Disconnect battery cables from battery. WARNING Air Intake Manifold Always connect battery cables exactly in the Open hood. specified order, RED positive cable first then Remove long hose between throttle body and the BLACK negative battery cable last.
  • Page 88 Section 04 ENGINE Subsection 02 (INTAKE SYSTEM) Unplug the "B" connector from the Engine ECU. CONNECTORS OVERVIEW 1. Ignition coils 2. OSPS 1. Push this end to unlock 3. OPS 4. Idle bypass valve 5. Engine connector 6. TPS 7. KS 8.
  • Page 89 Section 04 ENGINE Subsection 02 (INTAKE SYSTEM) 1. CTS connector Disconnect idle bypass valve connector. 1. Idle bypass valve 2. Coolant hose collar Disconnect TPS connector. 1. Idle bypass valve connector Slacken coolant hose collar at the front of RH lower screw of throttle body.
  • Page 90 Section 04 ENGINE Subsection 02 (INTAKE SYSTEM) 1. OPS connector Disconnect CAPS connector. 1. RCTS connector Pull the connectors for KS and CPS out of the ECU support. Refer to WIRING DIAGRAMS section. Disconnect KS, CPS and diagnostic connectors. TYPICAL 1.

  • Page 91: Installation

    Section 04 ENGINE Subsection 02 (INTAKE SYSTEM) Remove intake manifold retaining screws and First, position intake manifold on front mounting push the oil dipstick tube out of the manifold slot. bracket then push manifold toward engine to then proceed with rear mounting bracket. Lift intake manifold up to pull it out of the mounting brackets.
  • Page 92 Section 04 ENGINE Subsection 02 (INTAKE SYSTEM) Reinstall remaining parts in the opposite order of their removal and pay attention to the following. Ensure to properly route and resecure wiring har- ness with locking ties. Reconnect all connectors. Properly reconnect battery. WARNING Always connect battery cables exactly in the specified order, RED positive cable first then...

  • Page 93: Exhaust System

    Section 04 ENGINE Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM 1. Connecting pipe Unbolt the muffler from its rubber mounts. A 13 mm socket can be modified as per following TYPICAL photos to undo the front right retaining nut. WARNING Certain components in the engine compart- ment may be very hot.

  • Page 94: Exhaust Manifold

    Section 04 ENGINE Subsection 03 (EXHAUST SYSTEM) Tighten the muffler rubber mount nuts. After installation, ensure there is no exhaust gas leak when engine is running. EXHAUST MANIFOLD Removal Remove muffler, then unbolt exhaust manifold. Inspection Inspect exhaust manifold paying attention for cracks or other damage.

  • Page 95: Removal And Installation

    Section 04 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION ENGINE REMOVAL Use B.U.D.S. to release fuel pressure. Refer to B.U.D.S. instructions. Disconnect the BLACK (-) cable from battery. WARNING Battery BLACK (-) cable must always be dis- connected first and connected last. WARNING Never charge or boost battery while installed.
  • Page 96 Section 04 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) 1. Bleed hose disconnected from Y-fitting 2. Heated throttle body hose 1. Retaining straps Siphon coolant from the top hose on radiator. Remove air silencer access panel. TYPICAL 1. Top hose 1. Access panel Unfasten air silencer retaining straps.
  • Page 97 Section 04 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) TYPICAL 1. Collar TYPICAL 1. Air silencer Disconnect air temperature sensor at rear of air 2. Formed foam silencer. Remove the belt guard and the drive pulley. Disconnect the 2 coolant hoses from RH side of engine and siphon coolant from these hoses.
  • Page 98 Section 04 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) FRONT RH SIDE SHOWN TYPICAL 1. Engine mount center screw removed 1. BLACK cable 2. RED cable Disconnect the radiator wiring harness and move it toward front of vehicle. TYPICAL — LH SIDE SHOWN 1.
  • Page 99 Section 04 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) 1. Hose to be disconnected Remove the engine from the vehicle using an ap- propriate lifting device. CAUTION: Always install a new ball bearing Drive Shaft and Engine Support into the engine support. Position a new ball bearing in the engine support Removal with its drive pin placed outward.

  • Page 100: Engine Installation

    Section 04 ENGINE Subsection 04 (REMOVAL AND INSTALLATION) Loosely install a new collar on the seal carrier. Once engine support is installed on the engine, fasten the new collar to secure seal carrier boot to PTO housing. ENGINE INSTALLATION Before engine installation make sure the engine rubber mounts are in good condition.

  • Page 101: Pto Housing

    Section 04 ENGINE Subsection 05 (PTO HOUSING) PTO HOUSING Template...

  • Page 102: General

    Section 04 ENGINE Subsection 05 (PTO HOUSING) GENERAL Clean threads before using Loctite when installing the CPS. PTO HOUSING Removal NOTE: When drive shaft will be removed, some oil will flow out. To prevent it, start engine, run at 4000 RPM for 10 seconds and stop engine at this RPM.
  • Page 103 Section 04 ENGINE Subsection 05 (PTO HOUSING) NOTE: To release PTO seal from drive shaft, it CAUTION: Ensure to use prying lugs to sepa- rate PTO housing to prevent damaging contact may be necessary to gently tap flange of PTO seal surface.
  • Page 104 Section 04 ENGINE Subsection 05 (PTO HOUSING) 1. Washer 2. Disc spring 3. Starter drive ass'y CAUTION: Ensure the starter drive gear shaft is well engaged in its bore. Gently install PTO housing. CAUTION: While installing housing, pay partic- 1. Screws M6 x 35 ular attention that gasket does not get pinched 2.

  • Page 105: Pto Seal

    Section 04 ENGINE Subsection 05 (PTO HOUSING) Place a small pan under PTO housing to prevent spillage. If spillage occurs, clean immediately with the pulley flange cleaner (P/N 413 711 809) to prevent oil stains. Remove: – engine support (with drive shaft). See above in PTO HOUSING –...

  • Page 106: Adapter Sleeve And Flange Coupling

    Section 04 ENGINE Subsection 05 (PTO HOUSING) 1. Nut 2. Retaining ring with lug 3. Hexagonal screws 1. CPS screws 4. Flange coupling 2. CPS NOTE: Carefully remove the flange coupling Inspection no. 18 using torque flange remover (P/N 529 035 Check CPS condition.

  • Page 107: Coupling

    Section 04 ENGINE Subsection 05 (PTO HOUSING) Torque nut to 250 N•m (184 lbf•ft) and secure nut Installation with the retaining ring with lug. For installation, reverse the removel procedure. Torque PTO coupling to 250 N•m (184 lbf•ft). Ap- COUPLING ply Loctite 648 on threads.

  • Page 108: Ring Gear

    Section 04 ENGINE Subsection 05 (PTO HOUSING) Encoder wheel position has to be located with the Ring gear and encoder wheel position has to be lo- location pin on the crankshaft gear. cated with the location pin on the crankshaft gear. Apply Loctite 243 on threads.
  • Page 109 Section 04 ENGINE Subsection 05 (PTO HOUSING) 1. Disc springs 1. Starter drive support 2. Washer 3. Starter drive gear CAUTION: Be sure not to forget the distance washer, disc springs and washer on the starter Inspection drive shaft when assembling. Check condition of the teeth, shaft, etc.

  • Page 110: Cooling System

    Section 04 ENGINE Subsection 06 (COOLING SYSTEM) COOLING SYSTEM Template...

  • Page 111: General

    Section 04 ENGINE Subsection 06 (COOLING SYSTEM) GENERAL NOTE: It is not required to use a hose pincher on overflow hose with this test cap. CAUTION: All hoses and fittings of the cooling system have calibrated inside diameters to as- sure proper cooling of the engine.

  • Page 112: Draining The System

    Section 04 ENGINE Subsection 06 (COOLING SYSTEM) DRAINING THE SYSTEM The heat exchangers need to be drained. Proceed as follows. WARNING Remove muffler and the rear shield plate. Refer To prevent risk of burn injuries, Never open to EXHAUST SYSTEM. coolant reservoir cap, drain or refill cooling Disconnect LH hose no.

  • Page 113: Coolant Replacement

    Section 04 ENGINE Subsection 06 (COOLING SYSTEM) Lower front of vehicle. Reconnect hose on engine head. The remaining disconnected hose and muffler are to be rein- stalled while performing the refilling process. Dispose coolant as per local regulations. COOLANT REPLACEMENT Recommended Coolant Use a blend of 50% antifreeze with 50% water.

  • Page 114: Coolant Pump Housing

    Section 04 ENGINE Subsection 06 (COOLING SYSTEM) NOTE: Follow hydrometer manufacturer instruc- tions for proper use. The reading should be - 37°C (- 37°F) or lower. Add demineralized water or antifreeze accord- ingly. Refill to the proper level. CAUTION: Pure antifreeze will freeze at a higher temperature than the optimal water/an- tifreeze mix.

  • Page 115: Thermostat

    Section 04 ENGINE Subsection 06 (COOLING SYSTEM) THERMOSTAT Remove thermostat retaining screws. The thermostat is a single action type. Removal NOTE: The thermostat is located inside a hous- ing no. 23 underneath engine support in alternator area. 1. Thermostat retaining screws 2.

  • Page 116: Rotary Seal

    Section 04 ENGINE Subsection 06 (COOLING SYSTEM) 1. Impeller 1. Weep hole CAUTION: Coolant/Oil pump shaft no. 17 and Coolant leaking out of the hole indicates a defec- impeller no. 16 have left-hand threads. Re- tive rotary seal. Leaking oil indicates a faulty oil move by turning clockwise and install by turn- seal.
  • Page 117 Section 04 ENGINE Subsection 06 (COOLING SYSTEM) – remove outer oil pump rotor no. 21 CAUTION: Be careful not to damage the sur- face of the rotary seal bore in magneto housing cover. – always replace also the oil seal no. 11 behind the rotary seal.

  • Page 118: Care

    Section 04 ENGINE Subsection 06 (COOLING SYSTEM) Install the coolant/oil pump shaft using the rotary TECHNICAL DATA seal installer (P/N 529 035 823) on the opposite Type Closed loop cooling system side to the rotary seal and the oil seal protector (P/N 529 035 822) with a press.

  • Page 119: Lubrication System

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) LUBRICATION SYSTEM 28 29 Template...
  • Page 120 Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) Template...

  • Page 121: General

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) GENERAL – Wait at least 30 seconds then pull dipstick out and wipe clean. Prior to changing the oil, ensure vehicle is on a level surface. WARNING Oil and oil filter must be replaced at the same Engine oil may be hot.

  • Page 122: Engine Oil Pressure Test

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) 1. Oil cap NOTE: Before checking the oil level on this en- 1. Oil filter housing gine, it is necessary to let it idle for 30 seconds 2. Pressure test plug before shutting it off. Thereafter it is necessary to wait 30 seconds.

  • Page 123: Oil Type And System Capacity

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) OIL TYPE AND SYSTEM Run engine for 10 seconds at 4000 RPM and shut it off at this RPM. This will move oil from PTO CAPACITY housing to oil tank to allow maximum oil draining. Refer to TECHNICAL DATA.

  • Page 124: Oil Strainers

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) Inspection Torque oil filter screw to 9 N•m (80 lbf•in). Check oil filter cover O-ring no. 4 and oil filter OIL STRAINERS screw O-ring, change if necessary. Check and clean the oil filter inlet and outlet area The oil strainers do not need to be cleaned at every for dirt and other contaminations.
  • Page 125 Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) – Detach air silencer from throttle body. – Disconnect battery cables and vent tube then remove battery. Refer to BATTERY in CHARG- ING SYSTEM section for proper procedures. – Remove retaining screws no. 25 and no. 26 . –...

  • Page 126: Engine Oil Pressure Regulator

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) 1. O-ring 2. Rubber ring gasket If rubber rings are brittle, cracked or hard, replace them. 1. Screws M6 x 25 Clean both contact surfaces of oil strainer cover. 2. Screws M6 x 85 Check and clean the oil inlet and outlet area for dirt Torque suction pump cover screws to 10 N•m and other contaminations.

  • Page 127: Oil Pressure Pump

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) 1. Oil pressure regulator 1. Valve piston guide 2. Valve piston 3. Compression spring NOTE: The oil pressure regulator system opens 4. Oil pressure regulator plug when the oil pressure exceeds 400 kPa (58 PSI). Inspection Removal Inspect valve piston and valve piston guide for...
  • Page 128 Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) Removal – remove rotary seal no. 11 with a screwdriver Remove: – engine oil (refer to OIL CHANGE) – PTO housing (refer to PTO HOUSING/MAG- NETO section) – coolant pump housing no. 19 and impeller no.
  • Page 129 Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) Using a vernier depth gauge, measure side wear as shown. 1. Pittings on the teeth Using a feeler gauge, measure the clearance be- tween inner and outer rotors. 1. PTO housing surface 2. Vernier depth gauge 1.

  • Page 130: Oil Suction Pump

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) NOTE: Never use oil in the press fit area of the rotary seal. Push coolant/oil pump shaft seal in place by using thumb. 1. Oil seal guide 2. Coolant/oil pump shaft 1. Oil seal Install the new rotary seal by using the rotary seal pusher (P/N 529 035 823).
  • Page 131 Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) 1. Oil pump cover – Remove oil pump shaft ass’y no. 29. TYPICAL 1. Crankcase ventilation hose – Remove outer rotor no. 30. – Disconnect wiring harness from OSPS no. 24. – Detach air silencer from throttle body. –...
  • Page 132 Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) Using a vernier depth gauge, measure side wear as shown. 1. Pittings on the teeth Using a feeler gauge, measure the clearance be- tween inner and outer rotors. 1. Oil pump housing surface 2.

  • Page 133: Oil Cooler

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) TYPICAL 1. Oil cooler Removal 1. Screws M6 x 85 Remove: 2. Screws M6 x 25 – cooling hoses no. 34 and no. 35 Torque oil pump cover screws to 10 N•m – retaining screws no. 36 (88 lbf•in).

  • Page 134: Oil Separator

    Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) 1. O-rings Inspection If O-rings are brittle, cracked or hard, replace them. TYPICAL Clean both contact surfaces of oil cooler. 1. Crankcase ventilation hose Check and clean the oil inlet and outlet area for dirt and other contaminations.
  • Page 135 Section 04 ENGINE Subsection 07 (LUBRICATION SYSTEM) Installation For installation, reverse the removal procedure. Pay attention to the following details. 1. Screws M6 x 25 2. Screws M6 x 85 Apply grease on O-rings and rubber rings. Torque screws to 10 N•m (88 lbf•in). Apply Loc- tite 243 (blue) on threads.

  • Page 136: Cylinder Head And Valves

    Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) CYLINDER HEAD AND VALVES Template...

  • Page 137: General

    Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) NOTE: For cylinder head removal, it is not neces- Unscrew spark plug no. 2 then use the single- sary to remove engine from vehicle. spark ignition coil to take spark plug out of spark plug hole.

  • Page 138: Rocker Arm

    Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) CUT THIS TAB NOTE: Install the valve cover screws according to following sequence. 1. Valve cover screws – valve cover no. 5 and profile sealing ring no. 6. 1. Valve cover 2.
  • Page 139 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) 1. Spark plug tube 1. Oil supply from the camshaft to the rocker arm shaft, then to the rocker arms and finally to the valve adjustment – rocker arm shaft screws no. 8. Discard screws Inspection Spark Plug Tube Check seals on spark plug tube.
  • Page 140 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) 1. Rocker arm (intake side) 2. Roller A. Bore for rocker arm shaft 1. Hydraulic lifter groove Rocker Arm Shaft Check for scored friction surfaces, if so, replace parts. Measure rocker arm shaft diameter. ROCKER ARM BORE DIAMETER NEW MINIMUM 19.980 mm (.7866 in)
  • Page 141 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) Use camshaft locking tool (P/N 529 035 839). Rotate camshaft so that tool can be pushed in camshaft hole and lock camshaft in place. 1. Rocker arm shaft 2. Rocker arm shaft notches 1.

  • Page 142: Camshaft Timing Gear

    Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) Installation For installation, reverse the removal procedure. Pay attention to the following details. Using the camshaft locking tool (P/N 529 035 839), lock camshaft on TDC position. 1. Rocker arm shaft screw 2.

  • Page 143: Timing Chain

    Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) CYLINDER HEAD Loosely install screws. Install chain tensioner. Removal NOTE: There can be 2 different positions to install Lock crankshaft with crankshaft locking tool the timing gear on the camshaft. Basically both (P/N 529 035 821), refer to CRANKSHAFT LOCK- positions are working well, since the camshaft and ING in ENGINE BLOCK section.
  • Page 144 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) Installation For installation, reverse the removal procedure. Pay attention to the following details. Ensure dowel pins are in place. Install new cylinder head gasket. CAUTION: Each installation of the cylinder head requires a new cylinder head gasket. Us- ing a gasket twice will cause engine damage, even if the engine had not run.

  • Page 145: Camshaft

    Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) CAMSHAFT CAMSHAFT LOBE - EXHAUST VALVE NEW MINIMUM 31.699 mm (1.248 in) Removal NEW MAXIMUM 31.809 mm (1.252 in) Remove: – valve cover SERVICE LIMIT 31.670 mm (1.247 in) – rocker arms CAMSHAFT LOBE - INTAKE VALVE –...

  • Page 146: Valve Spring

    Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) 1. Camshaft lock position For other parts, refer to proper installation proce- dure. VALVE SPRING 1. Valve spring compressor clamp 2. Valve spring compressor cup Removal Remove: – rocker arms – cylinder head. Compress valve springs no.

  • Page 147: Valve

    Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) Installation For installation, reverse the removal procedure. Pay attention to the following details. Colored area of the valve spring must be placed on top. NOTE: Valve cotters must be properly engaged in valve stem grooves.
  • Page 148 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) Remove valve stem seal no. 28 with special pliers such as Snap-on YA 8230. A. Valve stem diameter VALVE STEM DIAMETER mm (in) NEW MINIMUM Exhaust 5.946 mm (.2341 in) Inspection Intake 5.961 mm (.2347 in) Valve Stem Seal...
  • Page 149 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) Chase valve guide out of the cylinder head to- VALVE GUIDE diameter mm (in) wards combustion chamber by using a suitable NEW MINIMUM punch. Exhaust 5.994 mm (.2359 in) Intake NEW MAXIMUM Exhaust 6.018 mm (.2369 in) Intake...
  • Page 150 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) VALVE GUIDE PROTRUSION mm (in) MINIMUM 12.4 mm (.4882 in) MAXIMUM 12.8 mm (.5039 in) NOTE: For lubrication of the reamer use only cut- ting oil. Turn the reamer only forward, in cutting direction, never backward.
  • Page 151 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) VALVE SEAT CONTACT WIDTH mm (in) 1.25 to 1.55 mm Exhaust (.049 to .061 in) 1.10 to 1.30 mm Intake (.043 to .051 in) SERVICE LIMIT Exhaust 2 mm (.078 in) Intake 1.8 mm (.07 in) If valve seat contact width is too wide or has dark...
  • Page 152 Section 04 ENGINE Subsection 08 (CYLINDER HEAD AND VALVES) Installation After spring is installed, ensure it is properly locked by tapping on valve stem end with a soft For installation, reverse the removal procedure. hammer so that valve opens and closes a few Pay attention to the following details.

  • Page 153: Engine Block

    Section 04 ENGINE Subsection 09 (ENGINE BLOCK) ENGINE BLOCK Template...
  • Page 154 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) Template...

  • Page 155: General

    Section 04 ENGINE Subsection 09 (ENGINE BLOCK) GENERAL When disassembling parts that are duplicated in the engine, (e.g.: pistons, connecting rods etc.), it is strongly recommended to note their position (cylinder 1, 2 or 3) and to keep them as a “group”. If you find a defective component, it would be much easier to find the cause of the failure within the group of parts (e.g.: you found a worn valve...
  • Page 156 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) ENGINE UPSIDE DOWN 1. Oil tank plug screw with O-ring – engine block screws no. 3 and no. 4 1. Connecting rod screws NOTE: Before removing the connecting rod bear- ing caps, mark them to remember the right posi- tion when reassembling.
  • Page 157 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) 1. Balancer gear 2. Crankshaft timing gear 1. Thrust washer Connecting Rod Big End Axial Play – crankshaft no. 24. Using a feeler gauge, measure distance between butting face of connecting rod and crankshaft counterweight.
  • Page 158 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) CRANKSHAFT PIN DIAMETER mm (in) NEW MINIMUM 45.032 mm (1.7729 in) NEW MAXIMUM 45.048 mm (1.7735 in) SERVICE LIMIT 45.029 mm (1.7728 in) CRANKSHAFT PIN RADIAL CLEARANCE mm (in) SERVICE LIMIT 0.09 mm (.0035 in) Installation For installation, reverse the removal procedure.

  • Page 159: Timing Chain

    Section 04 ENGINE Subsection 09 (ENGINE BLOCK) CAUTION: Never forget thrust washers no. 18 on center of crankshaft to control axial adjust- ment. Insert thrust washers as soon as crankshaft is in place as per following illustration. 1. O-ring 2. Crankshaft cover CAUTION: Install crankshaft locking tool (P/N 529 035 821) right away to position crank-...

  • Page 160: Chain Tensioner

    Section 04 ENGINE Subsection 09 (ENGINE BLOCK) 1. Timing chain If chain is excessively worn or damaged, replace it as a set (camshaft timing gear and timing chain). Removal Remove: – (refer to OIL CHANGE in LUBRICATION sec- tion) 1. Plug screw –...
  • Page 161 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) – oil suction pump with oil separator ass'y (re- fer to SUCTION PUMP REMOVAL in LUBRICA- TION section) – engine mounting brackets – oil reservoir plug screws no. 1 with O-ring no. 2 1.
  • Page 162 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) BALANCER SHAFT SEAT DIAMETER mm (in) NEW MINIMUM 31.984 mm (1.2592 in) NEW MAXIMUM 32.000 mm (1.2598 in) SERVICE LIMIT 31.960 mm (1.2583 in) BALANCER SHAFT SEAT RADIAL CLEARANCE mm (in) SERVICE LIMIT 0.07 mm (.0028 in) Installation For installation, reverse the removal procedure.

  • Page 163: Engine Block

    Section 04 ENGINE Subsection 09 (ENGINE BLOCK) – cylinder head (refer to CYLINDER HEAD RE- MOVAL in CYLINDER HEAD AND VALVES sec- tion) – PTO housing (refer to PTO HOUSING RE- MOVAL in PTO HOUSING/MAGNETO section) – starter gear (refer to STARTER GEAR RE- MOVAL in PTO HOUSING/MAGNETO section) –...
  • Page 164 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) NOTE: It is not necessary to have all cylinders rehoned if they are not all out of specification. Mixed standard size and oversize cylinders are al- lowed. Measure cylinder bore at 3 recommended posi- tions.
  • Page 165 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) CRANKSHAFT BUSHING INSIDE DIAMETER mm (in) 50.1 mm (1.9724 in) SERVICE LIMIT A. Perpendicular to crankshaft axis B. Parallel to crankshaft axis CYLINDER OUT OF ROUND mm (in) NEW MAXIMUM 0.008 mm (.0003 in) 0.015 mm (.0006 in) SERVICE LIMIT ENGINE UPSIDE DOWN...
  • Page 166 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) Check if ball inside moves freely in the banjo Bushings have to be flush with the engine block screw. Clean nozzle and banjo screw from dirt split surface and their protrusions have to fit in the and debris.
  • Page 167 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) NOTE: It is recommended to apply this specific sealant as described here to get an uniform appli- cation without lumps. If you do not use the roller method, you may use your finger to uniformly dis- tribute the sealant (unlike the Drei Bond sealing compound, using a finger will not affect the adhe- sion).

  • Page 168: Piston/Connecting Rod

    Section 04 ENGINE Subsection 09 (ENGINE BLOCK) CRANKSHAFT AXIAL CLEARANCE mm (in) NEW MINIMUM 0.08 mm (.003 in) NEW MAXIMUM 0.22 mm (.009 in) SERVICE LIMIT 0.35 mm (.014 in) 1. O-ring 2. Crankshaft cover CAUTION: Install crankshaft locking tool (P/N 529 035 821) right away to position crank- shaft at TDC before installing the camshaft and rockers (refer to CYLINDER HEAD AND VALVE).
  • Page 169 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) Remove connecting rod screws. 1. Piston 2. Piston pin 3. Circlip 1. Connecting rod screws Detach piston no. 21 from connecting rod. NOTE: Before removing the connecting rod bear- ing caps, mark them to remember the right posi- Inspection tion when reassembling.
  • Page 170 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) A. Piston pin diameter in the area of the bushing CONNECTING ROD SMALL END DIAMETER mm (in) NEW MINIMUM 23.01 mm (.9059 in) NEW MAXIMUM 23.02 mm (.9063 in) SERVICE LIMIT 23.07 mm (.908 in) A.
  • Page 171 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) 1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge 1. Measuring perpendicularly (90°) to piston pin axis A. 18 mm (.709 in) The measured dimension should be as described in the subsequent table.
  • Page 172 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) If clearance exceeds specified tolerance, rehone Replace connecting rod if diameter of connect- cylinder sleeve and replace piston ass'y by an ing rod small end is out of specifications. Refer oversize one. to CRANKSHAFT AND BALANCER SHAFT for re- moval procedure of connecting rod.
  • Page 173 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) CAUTION: Install piston with punched arrow toward exhaust side. 1. Half bushing of connecting rod big end 2. Split surface of the connecting rod 3. Protrusion of bushing in line with connecting rod groove Torque NEW connecting rod screws no.

  • Page 174: Piston Rings

    Section 04 ENGINE Subsection 09 (ENGINE BLOCK) PISTON RINGS Ring End Gap Removal RING END GAP mm (in) Remove piston ass'y as described above. NEW MINIMUM Remove rings. RECTANGULAR 0.15 mm (.006 in) Inspection 0.15 mm (.006 in) TAPER-FACE OIL SCRAPER RING 0.15 mm (.006 in) Ring/Piston Groove Clearance Using a feeler gauge measure each ring/piston...
  • Page 175 Section 04 ENGINE Subsection 09 (ENGINE BLOCK) NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand. Check that rings rotate smoothly after installation. Space the piston ring end gaps 120° apart and do not align the gaps with the piston pin bore or the thrust side axis.

  • Page 176: Engine Management

    Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) OVERVIEW ENGINE CONTROL MODULE — OVERVIEW ROTAX 4-TEC 1503 Template...

  • Page 177: Complete Electrical System Overview

    Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) COMPLETE ELECTRICAL SYSTEM OVERVIEW ECM ECU ENGINE FUSE BLOCK The complete electrical system is managed by The communication link is also used to communi- micro-controllers working together. Overall, the cate informative messages, monitoring and diag- VCM (vehicle control module) manages the ve- nostic codes to the VCK (vehicle communication hicle electrical system, the ECM (engine control...

  • Page 178: Alternator

    Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) ALTERNATOR AIR INDUCTION The alternator is the primary source of electrical Air for combustion is drawn directly at the front energy. It transforms magnetic field into electric of the engine through one 52 mm throttle body. current (AC).

  • Page 179: Intake Manifold

    Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) INTAKE MANIFOLD Throttle Body It is a 52 mm throttle body mounted on intake manifold. Fitted on the throttle body, there is the TPS and the idle bypass valve which allows the ECM ECU to control the RPM while the throttle plate is closed.

  • Page 180: Electronic Management

    Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) ELECTRONIC MANAGEMENT ECM FUNCTIONS ECM (ENGINE CONTROL MODULE) The engine control module is controlled by the ECM ECU. The ECM ECU gets its power by the engine fuse block which is directly powered by the battery. It is responsible for the following engine manage- ment/electrical functions: –...
  • Page 181 Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) High Coolant Temperature The tether cord cap contains a magnet and a ROM Warning Device chip. The magnet actually closes the reed switch inside the post which is the equivalent of a me- When the coolant temperature is getting too chanical ON/OFF switch.

  • Page 182: Ems - Engine Management Functions

    Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) EMS — ENGINE MANAGEMENT FUNCTIONS 1503 4-TEC CONTROL SYSTEM INPUTS OUTPUTS This engine management system controls both Signals from sensors are used by the ECM ECU the fuel injection and the ignition timing. to determine the injection parameters (fuel maps) required for optimum air-fuel ratio.
  • Page 183 Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) Ignition Coils Engine Modes of Operation Three separate ignition coils induce voltage to a The ECM ECU controls different operation modes high level in the secondary windings to produce a of the engine to allow proper operation for all pos- spark at the spark plug.

  • Page 184: Vcm - Vehicle Control Module

    Section 05 ENGINE MANAGEMENT Subsection 01 (OVERVIEW) VCM — VEHICLE CONTROL MODULE Power Distribution The VCM distributes power from battery to all ac- cessories. Accessories are protected by fuses in- tegrated in the VCM. Fuse ratings are identified beside their holder. IMPORTANT: Some components are continu- ously powered with the supply from the battery through VCM.

  • Page 185: Component Inspection And Adjustment

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) COMPONENT INSPECTION AND ADJUSTMENT GENERAL WARNING Fuel lines remain under pressure at all times. Engine problems are not necessarily related to the Always proceed with care and use appropri- electronic fuel injection system. ate safety equipment when working on pres- It is important to ensure that the mechanical in- surized fuel system.

  • Page 186: Electrical System

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) To check fuel rail for leaks, first pressurize the sys- WARNING tem then spray soapy water on all hose connec- All electrical actuators (idle bypass valve, tions, regulators and injectors. Air bubbles will TOPS resistance, injectors, fuel pump, ig- show the leaking area.

  • Page 187: Engine Connector Pin Out

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) After a problem has been solved, ensure to clear Also remember this validates the operation of the fault(s) in the ECM ECU using the VCK. Refer the sensor at ambient temperature. It does not to DIAGNOSTIC PROCEDURES subsection.

  • Page 188: Connectors On Engine

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: Probe on top of terminal only. Do not try to probe inside terminal or to use a pa- per clip to probe inside terminal, it can damage the square-shaped terminal. CAUTION: Do not disconnect the ECM ECU connector needlessly.

  • Page 189: Air Induction System

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) AIR INDUCTION SYSTEM – Throttle body has been replaced and the Closed Throttle and Idle Actuator reset has not been performed. THROTTLE BODY – ECM ECU has been replaced and the Closed Throttle and Idle Actuator reset has not been performed.
  • Page 190 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) For TPS and idle bypass valve replacement proce- Lubricate cable with BOMBARDIER LUBE lubri- dures, refer to the respective paragraph in ELEC- cant. TRONIC MANAGEMENT below. When throttle is released, cable must have a free play of 0.5 - 4 mm (1/64 - 5/32 in).
  • Page 191 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Adjustment nut 2. Jam nut 3. Throttle lever stopper Tighten jam nut and recheck adjustment. WARNING Make sure idle speed stopper contacts throt- tle cam when throttle lever is fully released at handlebar.

  • Page 192: Fuel Delivery

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY 1503 4-TEC Fuel pump does not run Fuel pump runs Connect tether cord cap for 2 sec. then stops Install fuel pressure gauge Check fuses. on fuel pressure line Check DESS post connection.

  • Page 193: Fuel Pump

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL PUMP Install tether cord cap Activate the cut-out switch so the engine will not crank. Insert key in Ignition Before proceeding to the pressure test ensure the switch. Turn key to ON and observe fuel pres- battery is fully charged.
  • Page 194 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Otherwise, probe terminals of fuel pump connec- tor on vehicle harness side. When installing tether cord cap, you should read battery voltage for ap- proximately 2 seconds (then voltage will drop to approximately 11 V).
  • Page 195 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Slide old resistor card ass’y out of aluminum ex- trusion. Reverse removal procedure for installation. Align the arrow on fuel pump module with the TYPICAL one on fuel tank. Keep arrows aligned during fuel 1.

  • Page 196: Fuel Rail

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Regulator Kit (P/N 861 302 100) Remove fuel pump module as explained above. Remove 2 screws retaining regulator to pump module flange. Remove regulator from pump module flange. Replace O-rings with new ones. Install them in pump module flange bore.

  • Page 197: Fuel Injector

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL INJECTOR Leakage Test To perform a leakage test, the injectors and fuel rail have to be removed from the engine. Refer to REMOVAL in FUEL RAIL REPLACEMENT for the procedure.
  • Page 198 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CIRCUIT NUMBER (ECM ECU connector INJECTOR NUMBER “A”) A-15 A-33 A-14 – If it does not read 12 V, check continuity of cir- cuit as per following table. If it is good, try a new VCM.

  • Page 199: Electronic Management

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) IMPORTANT: When the ECM ECU is replaced, the Closed Throttle and Idle Actuator must be re- programmed/reset. Refer to its specific section for adjustment. To allow transferring the previous recorded infor- mation from the old ECM ECU or VCM to the new one, use the vehicle communication kit (VCK) with the B.U.D.S.
  • Page 200 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Reconnect ECM ECU connectors to ECM ECU IF THE PREVIOUS VCM WAS NOT READ WITH B.U.D.S. then battery cables. – Enter the vehicle and engine serial numbers in IF THE PREVIOUS ECM ECU WAS the Vehicle tab.

  • Page 201: Engine Wiring Harness

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) ENGINE WIRING HARNESS 1. Wiring harness 4-TEC ENGINES Remove complete wiring harness. 1. Ignition coils 2. BBV 3. OPS (hidden behind throttle body) Installation 4. Idle bypass valve 5. Engine connector First connect the ECM ECU connector A to the 6.

  • Page 202: Throttle Position Sensor (Tps)

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Connect the CPS, KS, OPS, and the MAPS to the wiring harness. Also connect now the TPS, OSPS, idle bypass and TOPS resistance to the wiring harness. Install all remaining parts, which has been re- moved.
  • Page 203 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Using the vehicle communication kit (VCK) with CONNECTION VOLTAGE the B.U.D.S. software, use the Throttle Opening Terminal 1 with engine display under Monitoring . ground Slowly and regularly depress the throttle. Ob- serve the needle movement.
  • Page 204 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: When measuring between terminals This reset is very important. The setting of the A-24 and A-39, resistance value decreases while TPS will determine the basic parameters for all depressing throttle lever. when measuring be- fuel mapping and several ECM ECU calculations tween terminals A-24 and A-25, resistance value and the setting of the idle bypass valve will deter-...

  • Page 205: Idle Bypass Valve

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) IDLE BYPASS VALVE CRANKSHAFT POSITION SENSOR (CPS) An idle bypass valve with good resistance mea- surement can still be faulty. It is also possible that a mechanical failure occurs which is not de- tectable without measuring the air flow.
  • Page 206 Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Encoder Wheel Inspection To check the encoder wheel for bent teeth, pro- ceed as follows. Remove PTO cover. Refer to PTO HOUSING in ENGINE section. Install a dial indicator on crankcase casting. Po- sition the gauge on a tooth and set it to zero (0).

  • Page 207: Camshaft Position Sensor (Caps)

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CAMSHAFT POSITION SENSOR (CAPS) ECM ECU CONNECTOR – If 12 V is not read, check continuity of circuit 2-19 from VCM to the CAPS. If it tests good, try a new VCM. Otherwise, repair wiring harness. Remove the CAPS from the cylinder head.

  • Page 208: Coolant Temperature Sensor (Cts)

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) COOLANT TEMPERATURE SENSOR (CTS) Touch the CAPS with a conductor (ex.: screw- driver) and look if the voltage at the multimeter switches from 12 V to less than 1 V. 1.

  • Page 209: Manifold Air Pressure Sensor (Maps)

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Voltage Test If resistance value is incorrect, repair the connec- tors or replace the wiring harness between ECM Check the voltage output from ECM ECU to the ECU connector and the CTS. manifold air pressure sensor ( MAPS).

  • Page 210: Knock Sensor (Ks)

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) KNOCK SENSOR (KS) Using a multimeter, recheck resistance value be- tween terminals 9 and 23. If wiring harness is good, try a new ECM ECU. Refer to ECM ECU REPLACEMENT procedures 1.

  • Page 211: Oil Pressure Sensor (Ops)

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) OIL PRESSURE SENSOR (OPS) If the values are correct, check the continuity of the wiring harness. Disconnect the ECM ECU connector A from the ECM ECU and check continuity of circuit 6. If wiring harness is good, try a new ECM ECU.

  • Page 212: Tops

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) To check the function of the OSPS (oil separator Disconnect the ECM ECU connector A from the pressure sensor), disconnect the TOPS resistance ECM ECU and check continuity of circuit 31. and perform pressure test as follows.

  • Page 213: Ignition Coils

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) IGNITION COILS Voltage Test WARNING When disconnecting coil from spark plug, al- ways disconnect coil from main harness first. Never check for engine ignition spark from an open coil and/or spark plug in the engine compartment as spark may cause fuel vapor to ignite.

  • Page 214: Tdc Setting (Top Dead Center)

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) If wiring harness is defective, repair the connector WARNING or replace the wiring harness between ECM ECU Always reconnect ignition coil cables at the connector and the ignition coil. same spark plugs where they come from. If wiring harness is good, test resistance of pri- Otherwise, severe backfire may occur with mary and secondary winding of ignition coil.

  • Page 215: Spark Plugs

    Section 05 ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Tether Cord Cap on DESS Post SPARK ENGINE TORQUE Connect test probes to switch BLACK and PLUG (in) BLACK/YELLOW wires. Measure resistance, it must be close to 0 ohm. Hand tighten 1503 + 1/4 turn 4-TEC...

  • Page 216: Diagnostic Procedures

    Section 05 ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES GENERAL TERMS USED TERMS USED IN OTHER Here is the basic order suggested to diagnose a IN THIS MANUAL DOCUMENTS/ suspected engine management or fuel injection SOFTWARES related problem: ECM ECU (Engine ECM (Engine control –...

  • Page 217: Self-Diagnostic Mode

    Section 05 ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) SELF-DIAGNOSTIC MODE Refer to the following chart. For other problems, refer to COMPONENT INSPECTION AND ADJUST- MENT section. CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps (while installing DESS tether Confirms that proper DESS (Normal condition).

  • Page 218: Vck (Vehicle Communication Kit)

    Section 05 ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) VCK (VEHICLE After all connections are done, connect the DESS tether cord to its post, turn on the ignition switch COMMUNICATION KIT) and the engine cut-out switch to activate the com- The VCK (Vehicle Communication Kit) (P/N 529 munication.

  • Page 219: 4-Tec System Fault Codes

    Section 05 ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) 4-TEC SYSTEM FAULT CODES When using the service action suggested in the Fault section of B.U.D.S., Refer to WIRING DIA- General GRAM to have the explanation of the system cir- cuits coding that are referred to in B.U.D.S. The faults registered in the VCM/ECM ECU are kept when the battery is disconnected.
  • Page 220 Section 05 ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) TPS “OUT OF RANGE” Fault It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole range of movement of the throttle. To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom- mended to release the throttle quickly as this may also show up a fault that is intermittent.

  • Page 221: Transmission

    Section 06 TRANSMISSION Subsection 01 (DRIVE BELT) DRIVE BELT APPLICATION CHART MINIMUM WIDTH (wear limit) MODEL PART NUMBER mm (in) Elite 417 300 207 34.2 (1.346) INSPECTION Inspect belt for cracks, fraying or abnormal wear (uneven wear, wear on one side, missing cogs, cracked fabric).

  • Page 222: Drive Belt Height Measurement And Adjustment

    Section 06 TRANSMISSION Subsection 01 (DRIVE BELT) DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT Measurement NOTE: The drive belt height measurement must be performed each time a new drive belt is in- stalled. NOTE: To obtain an accurate drive belt height measurement, it is suggested to allow a break-in period of 50 km (30 miles).

  • Page 223: Drive Belt Deflection Measurement (Reference Only)

    Section 06 TRANSMISSION Subsection 01 (DRIVE BELT) DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY) NOTE: The drive belt deflection measurement must be performed each time a new drive belt is installed. NOTE: To obtain an accurate drive belt deflection measurement, it is suggested to allow a break-in period of 50 km (30 miles).
  • Page 224 Section 06 TRANSMISSION Subsection 01 (DRIVE BELT) A00D08A 1. Upper O-ring — force 2. Force 3. Lower O-ring — deflection 4. Reference rule 5. Deflection Template...

  • Page 225: Drive Pulley

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) DRIVE PULLEY TRA IV HD NOTE: This is a lubrication free drive pulley. Always refer to appropriate parts catalog for replacement part. Most parts of TRA IV HD are not interchangeable with those of the TRA. Template...

  • Page 226: General

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) GENERAL WARNING Never use any type of impact wrench at drive Some drive pulley components (return spring, pulley removal and installation. ramp) can be changed to improve vehicle perfor- mance in high altitude regions. A service bulletin will give information about calibration according Remove retaining screw.
  • Page 227 Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) A16D02A TYPICAL 1. Hold slider shoes 2. Lift one housing at a time NOTE: To ease disassembly, forks (P/N 529 005 500) should be used to hold slider shoes prior to removing governor cup. TYPICAL 1.

  • Page 228: Cleaning

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) CLEANING Install support guide. 5,6, Fixed and Sliding Half Clean pulley faces and shaft with fine steel wool and clean dry cloth. 5,29, Fixed Half/Crankshaft End and Governor Cup/Fixed Half Post Parts must be at room temperature before clean- ing.

  • Page 229: Inspection

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) INSPECTION ASSEMBLY Drive pulley should be inspected annually. NOTE: This drive pulley is lubrication free. Do not lubricate any component. 16,17, Thrust Washer and Roller 26,27,28, Calibration Screw, Washer Check roller for roundness of external diameter. and Locking Nut Check thrust washer for thickness wear.
  • Page 230 Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) Position dowel tube split at the angle A. WARNING Whenever replacing centrifugal levers, al- ways replace all 3 at the same time. Other- wise, drive pulley misbalancing will occur because of levers difference. MODEL ANGLE (A) TRA IV HD...

  • Page 231: Installation

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) TYPICAL Make sure to align governor cup arrow with sliding half and fixed half mark. INSTALLATION WARNING Do not apply anti-seize or any lubricant on TYPICAL crankshaft and drive pulley tapers. 1. Align Tighten cover screws no.

  • Page 232: Drive Pulley Adjustment

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) Governor cup has 6 positions numbered 1 to 6. WARNING To Adjust: Ensure that the track is free of particles which could be thrown out while track is rotating. Just loosen locking nut enough to pull calibration Keep hands, tools, feet and clothing clear of screw out and adjust to desired position.

  • Page 233: Driven Pulley

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) DRIVEN PULLEY HPV VSA Template...

  • Page 234: Removal

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) REMOVAL Pulley Half Cleaning Use Pulley Flange Cleaner (P/N 413 711 809). Remove guard and drive belt from vehicle. Remove cap screw no. 1 and shouldered washer INSPECTION no. 13 then pull the driven pulley from the coun- tershaft.

  • Page 235: Installation

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) 12, Screws These screws are machined at there end. With the adjustment ring set to position 0 (zero), screw ends are flush with inner side of fixed pulley half once tightened. CAUTION: If any of these screws is not flush with inner side of sliding pulley, bushings will worn unequally.

  • Page 236: Adjustment

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) Driven pulley end-play is 0 (zero). 1, Pulley Retaining Screw Torque to 22 N•m (16 lbf•ft). ADJUSTMENT Pulley Alignment and Drive Belt Height Refer to PULLEY DISTANCE AND ALIGNMENT and DRIVE BELT to perform adjustments. Loosen screws no.

  • Page 237: Pulley Distance And Alignment

    Section 06 TRANSMISSION Subsection 04 (PULLEY DISTANCE AND ALIGNMENT) PULLEY DISTANCE AND ALIGNMENT GENERAL Both pulley distance and pulley alignment must be checked out to ensure the highest efficiency of the transmission system. Furthermore, optimum drive belt operation and minimal wear will be ob- tained only with proper pulley alignment.

  • Page 238: Pulley Alignment And Distance Specifications Chart

    Section 06 TRANSMISSION Subsection 04 (PULLEY DISTANCE AND ALIGNMENT) Retighten the engine supports. Adjust all torque rods so they slightly touch the engine block or engine support depending on their location. Drive Belt Deflection NOTE: When pulley distance and alignment are adjusted to specifications, refer to DRIVE BELT to adjust drive belt deflection.

  • Page 239: Brake

    Section 06 TRANSMISSION Subsection 05 (BRAKE) BRAKE HYDRAULIC BRAKE Template...

  • Page 240: General

    Section 06 TRANSMISSION Subsection 05 (BRAKE) GENERAL There are two identical hydraulic brakes installed on the vehicle. In this section procedure for mainly one side is provided. Procedure for an- other side is the same with few differences of component locations. BRAKE FLUID Recommended Fluid The brake fluid must be changed in accordance...
  • Page 241 Section 06 TRANSMISSION Subsection 05 (BRAKE) 1. Screws Remove the steering cover by unscrewing the re- taining screws. Place a container under Banjo bolt no. 3 then un- screw it. Discard the sealing rings no. 4. Installation The installation is the reverse of removal proce- dure.

  • Page 242: Caliper

    Section 06 TRANSMISSION Subsection 05 (BRAKE) CALIPER To completely drain the brake fluid, continuously press the brake lever until all liquid escaped out. There is one caliper installed on each side of the CAUTION: Spilling brake fluid on plastic, rub- vehicle.

  • Page 243: Brake Disc

    Section 06 TRANSMISSION Subsection 05 (BRAKE) 1. Piston 2. Pad spring Install new brake pads. 1. Caliper 2. Pad pins WARNING 3. Brake pads Avoid getting fluid, oil or grease on brake – Remove the brake pads no. 9. pads. Contaminated brake pads can affect stopping capacities.
  • Page 244 Section 06 TRANSMISSION Subsection 05 (BRAKE) 1. Tie rap 2. Brake support 1. Speed sensor – Remove the remaining sprocket plate nuts and – Remove the nuts retaining the sprocket plate remove it from the brake disc. no. 21. – Remove the flange no. 22, magnetic adaptor no.

  • Page 245: Brake Light Switch

    Section 06 TRANSMISSION Subsection 05 (BRAKE) – Unscrew the brake disc set screw no. 26. 1. Puller – Loosen the track tension and move the disc in- wards. – Remove bearing housing no. 24 and slide out the brake disc no. 13. –...

  • Page 246: Bleeding

    Section 06 TRANSMISSION Subsection 05 (BRAKE) Fix the master cylinder in a rigid way preferably in CAUTION: Use only DOT 4 brake fluid, SRF (P/N 293 600 063) or GTLMA (P/N 293 600 062). a vise. Do not use fluids other than the recommended Pull out the switch wire and rubber cover.

  • Page 247: Gearbox And Final Drive Belt

    Section 06 TRANSMISSION Subsection 06 (GEARBOX AND FINAL DRIVE BELT) GEARBOX AND FINAL DRIVE BELT Template...
  • Page 248 Section 06 TRANSMISSION Subsection 06 (GEARBOX AND FINAL DRIVE BELT) Template...

  • Page 249: Gearbox

    Section 06 TRANSMISSION Subsection 06 (GEARBOX AND FINAL DRIVE BELT) GEARBOX OIL CHANGE Remove the dipstick. Remove metal particles from the magnet at the end of dipstick. NOTE: It is normal to find metallic particles stuck to dipstick magnet. If bigger pieces of metal are found, overhaul the gearbox.

  • Page 250: Reverse Switch Adjustment

    Section 06 TRANSMISSION Subsection 06 (GEARBOX AND FINAL DRIVE BELT) REVERSE SWITCH ADJUSTMENT To adjust, loosen lock nut no. 8 and turn fork axle accordingly. Short to ground the ORANGE/WHITE wire of VCM. Refer to TESTING PROCEDURE. Shift in reverse. Reverse alarm must sound.

  • Page 251: Inspection

    Section 06 TRANSMISSION Subsection 06 (GEARBOX AND FINAL DRIVE BELT) Remove the input no. 2 and output no. 3 shafts together. Remove the fork axle no. 4. Discard all oil seals. Use a workshop press to remove ball bearings from shafts. INSPECTION Bearings Check bearing condition.

  • Page 252: Deflection Adjustment

    Section 06 TRANSMISSION Subsection 06 (GEARBOX AND FINAL DRIVE BELT) Check final drive belt all over its length for cracks. IMPORTANT: Loosen the two M6 x 25 bolts Replace if any cracks are found. no. 16 retaining the shifter pivot plate to RH rein- forcement.

  • Page 253: Installation

    Section 06 TRANSMISSION Subsection 06 (GEARBOX AND FINAL DRIVE BELT) Loosen final drive belt tension. Refer to DEFLEC- TION ADJUSTMENT. Remove final drive belt from drive sprocket. Remove LH side rear suspension. Refer to SC–10 III SUSPENSION. Remove LH side drive axle. Refer to DRIVE AXLE. Unbolt LH side hub and end bearing of drive axle.

  • Page 254: Electrical System

    Section 07 ELECTRICAL SYSTEM Subsection 01 (ALTERNATOR) ALTERNATOR Template...

  • Page 255: Removal

    Section 07 ELECTRICAL SYSTEM Subsection 01 (ALTERNATOR) REMOVAL Disconnect BLACK negative cable from battery. WARNING Battery BLACK negative cable must always be disconnected first and connected last. Remove air silencer, foam and belt guard. Disconnect RED cable from alternator. Discon- nect electric connector from alternator.

  • Page 256: Battery

    Section 07 ELECTRICAL SYSTEM Subsection 02 (BATTERY) BATTERY GENERAL CAUTION: Should any electrolyte spillage oc- cur, immediately wash off with a solution of Absorbed Glass Mat (AGM) battery (YIX30L, P/N baking soda and water to prevent damage to 515 175 949) is used for the Elite model. AGM vehicle components.

  • Page 257: Battery Charging

    Section 07 ELECTRICAL SYSTEM Subsection 02 (BATTERY) STATE OF CHARGE VOLTAGE READING ACTION CHARGE TIME* 100% 12.8 - 13.0 V None None required 75% – 100% 12.5 - 12.8 V Needs charge 3 - 6 hours 50% – 75% 12.0 - 12.5 V Needs charge 5 - 11 hours At least 13 hours then verify...
  • Page 258 Section 07 ELECTRICAL SYSTEM Subsection 02 (BATTERY) NOTE: Make sure not to cut wire strands while stripping the wire. Install the appropriate terminal on the wire accord- ing to the requirement. Refer to appropriate parts catalog. INSTALLATION OF TERMINAL Follow the instructions provided with the crimp pli- CRIMPING OF WIRE ers (P/N 529 035 730) to select the proper position of the tool.

  • Page 259: Electric Starter

    Section 07 ELECTRICAL SYSTEM Subsection 03 (ELECTRIC STARTER) ELECTRIC STARTER ROTAX ® STARTER Repair Set Template...

  • Page 260: Removal

    Section 07 ELECTRICAL SYSTEM Subsection 03 (ELECTRIC STARTER) REMOVAL WARNING Short circuiting electric starter is always a danger, therefore disconnect the battery ground cable before carrying out any kind of maintenance on starting system. Do not place tools on battery. NOTE: For starter drive ass'y servicing, refer to PTO HOUSING.

  • Page 261: Cleaning

    Section 07 ELECTRICAL SYSTEM Subsection 03 (ELECTRIC STARTER) TYPICAL 1. Thrust washer Remove the other end cover with brushes and brush holder assembly. 1. Brushes Remove armature. 2. Retaining screw 3. Brush holder Remove springs. CLEANING CAUTION: Yoke ass'y and drive unit assembly must not be immersed in cleaning solvent.

  • Page 262: Parts Inspection

    Section 07 ELECTRICAL SYSTEM Subsection 03 (ELECTRIC STARTER) PARTS INSPECTION Armature NOTE: An ohmmeter may be used for the follow- ing testing procedures, except for the one con- cerning shorted windings in armature. Check commutator for roughness, burnt or scored surface.

  • Page 263: Installation

    Section 07 ELECTRICAL SYSTEM Subsection 03 (ELECTRIC STARTER) Yoke Assembly and Clutch Housing To ease end frame installation, retain brush holder with a small screwdriver while installing end Align previously traced indexing marks. frame. F01H0QA TYPICAL 1. Align marks Open brushes and slide over commutator. Align end frame locating notch with yoke locating protrusion and properly sit brush holder into yoke.

  • Page 264: Starter Specification

    Section 07 ELECTRICAL SYSTEM Subsection 03 (ELECTRIC STARTER) STARTER SPECIFICATION NOTE: If starter does not mesh properly, try to pull it out and slightly rotate the starter gear; then re- install starter. One could also temporarily remove VOLTAGE 12 V both O-rings, properly mesh gears then remove Counterclockwise starter to reinstall O-rings, being careful not to ro-...

  • Page 265: Testing Procedure

    Section 07 ELECTRICAL SYSTEM Subsection 04 (TESTING PROCEDURE) TESTING PROCEDURE INSPECTION OF HEATING ELEMENTS Throttle Lever Heating Element Resistance Measurement at 20°C to 30°C (68°F to 86°F) INTENSITY WIRES OHMS BROWN and HIGH 1.73 to 4.22 BLACK/YELLOW BROWN/YELLOW 5.73 to 18.54 BLACK/YELLOW UNDERNEATH DASH ON LEFT HAND SIDE OF Steering Grip Heating Element...

  • Page 266: Rear Suspension

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) SC-10 III SUSPENSION Template...

  • Page 267: Sc-10 Iii Suspension

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) Template...
  • Page 268 Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) Template...
  • Page 269 Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) Template...

  • Page 270: General

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) GENERAL There are two identical SC-10 III suspensions in- stalled on the vehicle. In this section procedure for mainly one side is given. Procedure for other side is the same with few differences of compo- nent locations.

  • Page 271: Suspension Assembly Removal

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) SUSPENSION ASSEMBLY REMOVAL Lift rear of vehicle and support it off the ground. Remove flanged nuts no. 29 and pull out stabiliz- ing bar no. 30. Remove nut no. 27 on bottom end of shock. Installation is reverse of removal procedure.

  • Page 272: Disassembly And Assembly

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) Self-Locking Screws 1. Panel CAUTION: These self-locking screws must al- ways be replaced by new ones everytime they Remove rear arm top axle self-locking screws are removed. no. 2 from chassis. NOTE: To prevent axle from turning when un- Lift rear of vehicle at least 1 m (3 ft).
  • Page 273 Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) Dowel Pin and Block Guide Dowel pin no. 15 must exceed block guide no. 16 by 2 to 2.3 mm (.079 to .091 in). At installation, insert dowel pin into pivot arm hole. Block Both blocks no.
  • Page 274 Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) TYPICAL 1. Slider shoe 2. Molding line (wear limit indicator) Replace slider shoes no. 11 when wear limit is reached. A01B4LA CAUTION: Slider shoes must always be re- 1. Clevis pin placed in pairs.

  • Page 275: Shock Absorber Inspection

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 III SUSPENSION) SHOCK ABSORBER INSPECTION LUBRICATION NOTE: Shocks installed on this vehicle are painted Lubricate front and rear arms at grease fittings black or dark gray. using suspension synthetic grease (P/N 293 550 033).

  • Page 276: Drive Axle

    Section 08 REAR SUSPENSION Subsection 02 (DRIVE AXLE) DRIVE AXLE Template...

  • Page 277: Removal

    Section 08 REAR SUSPENSION Subsection 02 (DRIVE AXLE) REMOVAL Raise and block rear of vehicle off the ground. Remove suspension on appropriate side. Refer to proper subsection. Remove speedometer sensor no. 11 or end bear- ing housing plastic cap no. 1 depending on the side of drive axle removal., Remove brake caliper on appropriate side.

  • Page 278: Installation

    Section 08 REAR SUSPENSION Subsection 02 (DRIVE AXLE) Bearing Use drive axle sprocket adjuster kit (P/N 861 725 700). Always push bearing no. 8 by inner race. A00F0DA TYPICAL INSTALLATION Reverse removal procedure. Check condition of O-rings no. 2 before drive axle installation.

  • Page 279: Track

    Section 08 REAR SUSPENSION Subsection 03 (TRACK) TRACK TRACK TYPE APPLICATION ADJUSTMENT Refer to TECHNICAL DATA. Track Tension and Alignment Track tension and alignment are inter-related. Do GENERAL not adjust one without checking the other. Track tension procedure must be carried out prior to This section gives guidelines for track removal.
  • Page 280 Section 08 REAR SUSPENSION Subsection 03 (TRACK) Alignment WARNING Before checking track alignment, ensure that the tracks are free of all particles which could be thrown out while tracks are rotating. Keep hands, tools, feet and clothing clear of tracks. Ensure no one is standing in close proximity to the vehicle.
  • Page 281 Section 08 REAR SUSPENSION Subsection 03 (TRACK) Restart engine, rotate tracks slowly and recheck alignment. If the satisfactory alignment is achieved, then tighten the idler wheel retain- ing screws to 48 N•m (35 lbf•ft). Track Cleat Removal – Raise rear of vehicle off the ground and lift snowguard then hand rotate track to expose a cleat to be replaced.

  • Page 282: Steering/Front Suspension

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) STEERING SYSTEM Template...

  • Page 283: General

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) GENERAL CAMBER: A specific inward or outward tilt angle of ski leg During assembly/installation, use the torque val- compared to a vertical line when viewing the ve- ues and service products as in the exploded hicle from front.
  • Page 284 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) With the steering wheel in straight ahead position, measure the distance A between bolt center of left side swivel arm no. 3 and the stopper plate of lower steering column attachment. Distance A must be equal to 71.2 mm (2.803 in).
  • Page 285 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Loosen jam nuts of short tie rod no. 12. Turn short tie accordingly. Tighten jam nuts to 18 N•m (159 lbf•in). TYPICAL 1. Angle finder Using special tool (P/N 529 021 600) mounted to the ski leg, position the angle finder on the tool as shown in the following illustration.

  • Page 286: Grip

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Make sure skis are in a straight-ahead position by placing a straight edge against pre-adjusted track and measure the distance between front and rear of skis and straight edge. Measuring points are 220 mm (8-21/32 in) at front and rear of ski pivot axis.
  • Page 287 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Removal Remove the screws no. 19 as shown in the fol- lowing photo. TYPICAL — STEERING PAD SHOULD BE COMPLETELY REMOVED 1. Retaining screws Remove master cylinder from steering wheel and 1. Screws to be removed put it aside.

  • Page 288: Lower Steering Column

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) LOWER STEERING COLUMN Removal Remove chain as explained in UPPER AND LOWER STEERING COLUMN POSITIONING. Detach the short tie rod no. 12 from the lower steering column no. 11. Note that a hardened flat washer no.

  • Page 289: Steering Arm

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) All long tie-rod end using a nut, need a hardened washer no. 24 on each side of the part where the tie-rod is installed. Note position of the hardened washer no. 24 on short tie rod end.

  • Page 290: Lubrication

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Inspection Push down on steering arm to eliminate axial play on ski leg before pinch bolt and nut tightening. Make sure steering arm and ski leg splines inter- lock. Tighten the steering arm pinch bolt and nut to the torque specified in the exploded view.

  • Page 291: Front Suspension

    Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) FRONT SUSPENSION Template...

  • Page 292: Disassembly

    Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) DISASSEMBLY Shock Lift front of vehicle and support it off the ground. Reduce spring preload by turning adjusting ring accordingly. Remove lower bolt then upper bolt of shock no. 5. For shock spring disassembly use shock spring re- mover (P/N 529 035 504) in a vise.
  • Page 293 Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Upper and Lower Arms Position lower arm no. 7 and upper arm no. 8 hor- izontally before tightening nuts. Apply the tight- ening torque to the bolt head on the swing arm attachments.

  • Page 294: Body/Frame

    Section 10 BODY/FRAME Subsection 01 (BODY) BODY INSTALLATION AND BULB REPLACEMENT ADJUSTMENT Headlamp HEADLAMP BEAM AIMING If any headlight bulb is burnt, open access door in dashboard. Beam aiming is correct when center of high beam is 25 mm (1 in) below the headlamp horizontal cen- ter line, scribed on a test surface, 381 cm (12 ft 6 in) away.

  • Page 295: Rearview Mirror

    Section 10 BODY/FRAME Subsection 01 (BODY) CAUTION: Never touch glass portion of an halogen bulb with bare fingers, as it short- ens its operating life. If by mistake glass is touched, clean it with isopropyl alcohol which will not leave a film on the bulb. Taillight If the taillight bulb is burnt, expose the bulb by re- moving red plastic lens.

  • Page 296: Guard

    Section 10 BODY/FRAME Subsection 01 (BODY) LEFT HAND SIDE SHOWN TYPICAL 1. Hinge removed 1. Headlamp trim Unbolt then remove the storage compartment GUARD cover. Remove the headlamp trim. Remove both top screws retaining the side panels to the Disassembly and Assembly dashboard.
  • Page 297 Section 10 BODY/FRAME Subsection 01 (BODY) TYPICAL — STORAGE COMPARTMENT REMOVED REMOVAL OF LEFT HAND SIDE PLASTIC MOLDING 1. Nose 2. Left hand side fog light connectors Drill the 2 rivets retaining the rear of side panel to the rear part. Remove the fuel tank cap then, loosen the collar retaining the filler neck.

  • Page 298: Wiring Harness

    Section 10 BODY/FRAME Subsection 01 (BODY) TUBING 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 rotat- ing, moving, heating or vibrating parts. Also check for leaks.

  • Page 299: Windshield Repair

    Section 10 BODY/FRAME Subsection 01 (BODY) Air Bubbles CAUTION: If for some reason the snowmobile has to be stored outside, it is preferable to Possible cause: cover it with an opaque tarpaulin. This will – Air pocket trapped between layers of laminate prevent the sun rays from affecting the plastic and gelcoat.
  • Page 300 Section 10 BODY/FRAME Subsection 01 (BODY) A blister is a visible bump on the body surface that Test spray the gelcoat mixture on paper to verify may not necessarily come right through the gel- its consistency and pattern. You may have to ap- coat layer.

  • Page 301: Tools And Materials List

    Section 10 BODY/FRAME Subsection 01 (BODY) Outside Inside Remove the damaged gelcoat and fiberglass with Wipe down the area with acetone on a cloth. Ap- a 24-grit disk using a power sander. Grind out- ply the same procedure as for outside repair when ward at least 2 inches from the fracture to allow laminating the alternating pieces of fiberglass ma- the patch to bond to strong material.
  • Page 302 Section 10 BODY/FRAME Subsection 01 (BODY) Materials – fiberglass mat – fiberglass cloth – polyester resin – cardboard – masking tape – sandpaper (100-grit, 220-grit, 320-grit, 400-grit, 600-grit, 1000-grit) – 24-grit sanding disks – gelcoat putty – liquid gelcoat – acetone –...

  • Page 303: Frame

    Section 10 BODY/FRAME Subsection 02 (FRAME) FRAME FRAME CLEANING For proper drilling instructions and to prevent pre- mature wear, follow the procedure below. NOTE: On bare aluminum frame use only alu- Always use a variable speed electric drill. minum cleaner and follow instructions on con- tainer.

  • Page 304: Technical Data

    Section 11 TECHNICAL DATA Subsection 01 (SI METRIC INFORMATION GUIDE) SI METRIC INFORMATION GUIDE SI* METRIC INFORMATION GUIDE BASE UNITS length ............ meter ............ mass ............. kilogram ..........force............newton..........liquid ............. liter ............temperature .......... Celsius ..........°C pressure ..........kilopascal..........

  • Page 305: Engine

    Section 11 TECHNICAL DATA Subsection 02 (ENGINE) ENGINE ELITE ENGINE BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke, Engine type Over Head Camshaft (OHC), liquid cooled Number of cylinders Number of valves 12 valves with hydraulic lifters (no adjustment) Bore Standard 100 mm (3.9 in) Stroke 63.4 mm (2.49 in) Displacement...
  • Page 306 Section 11 TECHNICAL DATA Subsection 02 (ENGINE) ELITE ENGINE (cont'd) New nominal 1.1 to 1.3 mm (.043 to .051 in) Intake Wear limit 1.6 mm (.063 in) Valve seat contact width New nominal 1.25 to 1.55 mm (.049 to .061 in) Exhaust Wear limit 1.8 mm (.071 in)
  • Page 307 Section 11 TECHNICAL DATA Subsection 02 (ENGINE) ELITE ENGINE (cont'd) New minimum 24.939 mm (.9818 in) Front New maximum 24.960 mm (.9827 in) Wear limit 24.930 mm (.9815 in) Camshaft bearing journal New minimum 39.892 mm (1.5705 in) PTO and center New maximum 39.905 mm (1.5711 in) Wear limit...
  • Page 308 Section 11 TECHNICAL DATA Subsection 02 (ENGINE) ELITE ENGINE (cont'd) New minimum 22.996 mm (.9053 in) Piston pin diameter New maximum 23.000 mm (.9055 in) Wear limit 22.990 mm (.9051 in) Piston pin bore clearance Wear limit 0.080 mm (.0035 in) New minimum 31.984 mm (1.2592 in) Balance shaft journal diameter...
  • Page 309 Section 11 TECHNICAL DATA Subsection 02 (ENGINE) ELITE FUEL SYSTEM Rotax EMS (engine management system) Multipoint Fuel Fuel injection type Injection. Single throttle body (52 mm (2.05 in)) Fuel pressure 58 PSI Idle speed 1500 ± 50 RPM Throttle Position Sensor (TPS) 1.6 k - 2.4 k Crankshaft Position Sensor (CPS)

  • Page 310: Vehicle

    Section 11 TECHNICAL DATA Subsection 03 (VEHICLE) VEHICLE ELITE DRIVE Final drive ratio 38/63 Final drive belt deflection mm (in) 11 (.433) Forward gear ratio 23/31 Reverse gear ratio 17/38 Pitch Chain Type/links qty/plate qty Silent 46/13 Type TRA IV HD Clutch engagement 2200 ±...
  • Page 311 Section 11 TECHNICAL DATA Subsection 03 (VEHICLE) ELITE ELECTRICAL Battery 12 V, 30 A•h Headlamp 2 x 60/55 (H4) Fog Lights 2 x 55 (H3) Taillight and stoplight 8/27 Tachometer and speedometer bulbs 2 x 1.5 Fuel and temperature gauge bulbs CAPACITIES Fuel tank L (U.S.

  • Page 312: Technical Data Legends

    Section 11 TECHNICAL DATA Subsection 04 (TECHNICAL DATA LEGENDS) TECHNICAL DATA LEGENDS ENGINE LEGEND VEHICLE LEGEND ABDC: After Bottom Dead Center ADSA: Advance Direct Shock Action N.A.: Not Applicable ATDC: After Top Dead Center TRA: Total Range Adjustable BBDC: Before Bottom Dead Center VSA: Variable Sheave Angle BTDC: Before Top Dead Center...

  • Page 313: Wiring Diagram

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) WIRING DIAGRAM CONNECTOR HOUSING AREA Wiring diagram can be found at the end of this subsection. The first digit of the connector identification num- ber presents the location of the connector on the WIRING DIAGRAM LEGEND vehicle.

  • Page 314: Housing Reference Code Per Area

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) HOUSING REFERENCE CODE PER AREA The next two letters of the connector identification number represents a connector reference code. If there are many connectors in the same area this helps identify which wire is in which connector. WIRE LOCATION IN CONNECTOR HOUSING The third portion of the connector identification...
  • Page 315 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) 10 9 Template...

  • Page 316: Symbols Description

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) SYMBOLS DESCRIPTION Template...

  • Page 317: Unpluging Connectors

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) UNPLUGING CONNECTORS Always unplug connectors by pulling on housing not on wire. 1. Insert screwdriver here 2. Pull this side Locking Receptacle Connector To remove: TYPICAL – Insert tool Snap-on TT 600-5 in access opening then pull housing toward wire side.
  • Page 318 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) 1. Lock – Pry tab to free connector then pull wire out of housing. – Pry tab to free connector then pull wire out of housing. MALE CONNECTOR HOUSING — CUT-AWAY FEMALE CONNECTOR HOUSING — CUT-AWAY Multilock Connector Housing Male Connector Housing Female Connector Housing...
  • Page 319 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) To remove: To remove: – Insert tool AMP- 755430-2 under lock and twist – Insert tool AMP-755430-2 under lock and twist to lift it. to lift it. MALE CONNECTOR HOUSING — CUT-AWAY 1.
  • Page 320 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) Lift the top plastic lock of the female terminal to be removed and hold in position. Lift the female terminal to unlock from the housing and push out of housing. 1. Push tab and hold while pulling connector out Push on both tabs to remove retainer.
  • Page 321 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) 7-Pin Connector Refer to the illustration for the connector pinout. 8-Circuit Connector Housing Pry housing to release lock. 1. VCM (vehicle control module) 2. Pull out the green locking tab 3. Push down this tab and hold while pulling out connector 1.
  • Page 322 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) Insert tool AMP-755430-2 under tab and pry it to free connector. Pull on the female terminal wire to remove female terminal from housing. 8-CIRCUIT CONNECTOR HOUSING — CUT-AWAY 1. Tab Removal of Deutsch connectors from Engine Connector Bracket TYPICAL 1.
  • Page 323 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) TYPICAL 1. Release button 2. Deutsch connectors 1. Push in tab Lift the cover by pushing it forward. TYPICAL 1. Cover 1. Deutsch connectors 2. Press release button Connector housing A and B on ECM Terminal Removal Unlock the connector housing cover by pushing in the tabs on top of the housing with a flat screw-...
  • Page 324 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) Cut both locking ties that secure the harness to Insert the probe into the housing as shown, and the housing. locate the appropriate wire in the back of the housing. You may have to slightly cam the probe against the locking tab to release it, then remove the terminal from the housing.
  • Page 325 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) When re-inserting the connector, the locking tab must be installed facing the smaller cutout of the connector cavity. TYPICAL A. 3 mm (1/8 in) max. Position wire in terminal. Squeeze the terminal tabs with your fingers to temporarily retain terminal in place.

  • Page 326: Tab And Receptacle Connectors Installation

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAM) A00E1FA TYPICAL 1. Top of terminal tabs 1. Receptacle 2. Align tabs with pliers edge 2. Housing Crimp terminal. Ensure no tiny wire goes out of WARNING terminal. This might cause strange problems of Keep wires away from any rotating, moving, the electrical system.

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