Ski-Doo REV Series Shop Manual
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Ski-Doo REV Series Shop Manual

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Summary of Contents for Ski-Doo REV Series

  • Page 2 2004 Shop Manual REV SERIES...
  • Page 3 Legal deposit: National Library of Quebec National Library of Canada 2003 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2003 Technical Publications Bombardier Inc. Valcourt (Quebec) Canada Printed in Canada ®*...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ................. .. IX INTRODUCTION ..
  • Page 5 TABLE OF CONTENTS TROUBLESHOOTING 01 – ENGINE ......................37 ENGINE LEAK VERIFICATION FLOW CHART .
  • Page 6 TABLE OF CONTENTS CRANKSHAFT END-PLAY ..................120 CHECKING CRANKSHAFT ALIGNMENT .
  • Page 7 TABLE OF CONTENTS FUEL LEVEL SENSOR SCREWS................. . 161 FUEL SYSTEM PRESSURIZATION.
  • Page 8 TABLE OF CONTENTS KNOCK SENSOR (KS)....................196 E-RAVE SOLENOID .
  • Page 9 TABLE OF CONTENTS 04 – PULLEY DISTANCE AND ALIGNMENT ..............235 GENERAL .
  • Page 10 TABLE OF CONTENTS 05 – TESTING PROCEDURE ..................269 GENERAL .
  • Page 11 TABLE OF CONTENTS BODY/FRAME 01 – BODY......................343 INSTALLATION AND ADJUSTMENT .

  • Page 12: 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 made snowmobiles.

  • Page 13: Introduction

    INTRODUCTION INTRODUCTION This shop manual covers the following Bom- bardier made 2004 REV Series models: TYPICAL — REV SERIES MODEL MODEL ENGINE TYPE COUNTRY NUMBER GSX (E) LTD 1 + 1 600 HO SDI (R) BLACK 593 HO SDI CAN/U.S.
  • Page 14 INTRODUCTION MODEL MODEL ENGINE TYPE COUNTRY NUMBER 2821 GSX (E) SPORT 600 HO (R) SILVER 593 HO CAN/U.S. 2823 GSX (E) SPORT 600 HO SDI (R) SILVER 593 HO SDI CAN/U.S. 2824 GSX (E) LTD 1 + 1 600 HO SDI (R) SILVER 593 HO SDI CAN/U.S.
  • Page 15 INTRODUCTION MODEL MODEL ENGINE TYPE COUNTRY NUMBER 2867 MX Z (E) RENEGADE X 800 HO (R) BLACK 793 HO CAN/U.S. 2862 MX Z (E) RENEGADE X 800 HO (R) BLUE 793 HO CAN/U.S. 2863 MX Z (E) RENEGADE X 800 HO (R) BLUE 793 HO CAN/U.S.
  • Page 16 INTRODUCTION MODEL MODEL ENGINE TYPE COUNTRY NUMBER 2958 MX Z RENEGADE 600 HO (R) BLACK 593 HO CAN/U.S. 2959 MX Z RENEGADE 600 HO (R) BLACK 593 HO 2956 MX Z RENEGADE 600 HO (R) YELLOW 593 HO CAN/U.S. 2957 MX Z RENEGADE 600 HO (R) YELLOW 593 HO 2961...
  • Page 17 INTRODUCTION MODEL MODEL ENGINE TYPE COUNTRY NUMBER 4017 MX Z X 600 HO SDI (R) BLACK 593 HO SDI CAN/U.S. 4018 MX Z X 600 HO SDI (R) BLACK 593 HO SDI CAN/U.S. 4024 MX Z X 600 HO SDI (R) BLACK 593 HO SDI CAN/U.S.

  • Page 18: Vehicle Identification Number

    INTRODUCTION VEHICLE IDENTIFICATION LIST OF ABBREVIATIONS USED IN NUMBER THIS MANUAL Vehicle Identification Number Location ABBREVIATION MEANING ampere ampere A•h ampere-hour alternate current acceleration and control modulator ADSA advanced direct shock action absorbed glass mat TYPICAL 1. Vehicle identification number bottom dead center Identification Number Meaning before top dead center...
  • Page 19 INTRODUCTION ABBREVIATION MEANING ABBREVIATION MEANING inch pound per square inch in² square inch power take off in³ cubic inch rectangular kilo (thousand) right hand kilogram Rotax adjustable variable RAVE exhaust km/h kilometer per hour Rotax electronic reverse Kilopascal revolution per minute liter root mean square pound...

  • Page 20: Arrangement Of This Manual

    INTRODUCTION ARRANGEMENT OF THIS MANUAL This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Page heading indicates section and subsection detailed. Subsection title indicates Section 07 REAR SUSPENSION beginning of the subsection.
  • Page 21 INTRODUCTION Section 05 TRANSMISSION Title indicates main procedure Turn puller handle and sliding half at once to extract the bushing. to be carried-out. CAUTION: Italic bold face type setting indicates a particular procedure A-Series and B-Series Only concerning a model. Should installation procedure be required, refer to BRAKE then look for Italic bold face setting...
  • Page 22 INTRODUCTION GENERAL INFORMATION The information and component/system descrip- tions contained in this manual are correct at time of publication. Bombardier Inc. however, main- tains a policy of continuous improvement of its products without imposing upon itself any obliga- tion to install them on products previously manu- factured.

  • Page 23: Threadlocker

    INTRODUCTION THREADLOCKER – Apply Loctite Primer N (P/N 293 800 041) on threads (bolt and nut) and allow to dry for 30 Uncovered Holes (bolts and nuts) seconds. – Choose proper strength Loctite threadlocker. – Apply several drops along the threaded hole and at the bottom of the hole.

  • Page 24: Stripped Thread Repair

    INTRODUCTION Preassembled Parts – Avoid touching metal with tip of flask. NOTE: If it is difficult to readjust, heat screw with a soldering iron (232°C (450°F)). STRIPPED THREAD REPAIR Stripped Threads A00A3OA 1. Apply here 2. Do not apply – Clean bolts and nuts with solvent. –...

  • Page 25: Gasket Compound

    INTRODUCTION GASKET COMPOUND MOUNTING ON SHAFT All Parts Mounting with a Press A00A3UA 1. Bearing A00A3SA 2. Proper strength Loctite 3. Shaft 1. Proper strength Loctite 2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator Standard 515 (P/N 413 702 700) on both sides of gasket 3.

  • Page 26: Case-In Components

    INTRODUCTION CASE-IN COMPONENTS Tighten fasteners to torque mentioned in ex- ploded views and text. When they are not Metallic Gaskets specified refer to following table. Bold face size (e.g. M4) indicates nominal value (mean value). FASTENER N•m SIZE Lbf•in (8.8 GRADE) A00A3VA 1.
  • Page 27 INTRODUCTION FASTENER FASTENER N•m SIZE Lbf•ft N•m SIZE Lbf•ft (8.8 GRADE) (8.8 GRADE) XXIV...
  • Page 28 INTRODUCTION Bombardier Bombardier Bombardier...
  • Page 29 INTRODUCTION XXVI...

  • Page 30: 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 31: Engine - Mandatory Tools

    Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE — MANDATORY TOOLS Exhaust spring installer/remover Magneto puller ring Fuel and oil system leak tester (P/N 529 035 401) (P/N 420 876 080) (P/N 529 033 100) APPLICATION All axial fan cooled engines. APPLICATION APPLICATION All models.
  • Page 32 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Engine leak tester kit 14) Exhaust plate Supply harness (P/N 861 749 100) (P/N 529 035 869) (P/N 529 024 600) (2) NOTE: Should be used with 15) Exhaust plate hand pump (P/N 529 021 800).

  • Page 33: Engine - Recommended Tools

    (P/N 529 035 830) APPLICATION Liquid cooled engines except 4-TEC. APPLICATION REV series. APPLICATION All models equipped with a DESS. ENGINE — RECOMMENDED TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time.
  • Page 34 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Leak down tester Engine support bearing sup- Crankshaft bearing puller N–> N–> (P/N 529 035 661) port (P/N 420 877 635) (P/N 529 035 953) APPLICATION 1503 engines. N–> 4-Tooth socket (P/N 529 035 960) APPLICATION 1004 and 1503 engines.
  • Page 35 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Piston circlip installer Pusher (55/59 mm) Water pump ceramic seal N–> (P/N 529 035 765) (P/N 529 035 913) installer (P/N 529 035 766) APPLICATION 1004 and 1503 engines. Piston circlip installer APPLICATION 1004 engines.
  • Page 36 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Crankshaft feeler gauge Valve spring compressor cup Valve stem seal installer (P/N 420 876 620) a) (P/N 529 035 764) (P/N 529 035 687) b) (P/N 529 035 725) N–> APPLICATION 377 and 443 engines.
  • Page 37 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Torque angle gauge Attachment RAVE movement indicator Not sold by BOMBARDIER. (P/N 529 035 522) (P/N 861 725 800) Snap-On TA362 APPLICATION Mini Z. APPLICATION APPLICATION 1004 and 1503 engines. Pilot 22 mm All RAVE equipped engines.
  • Page 38 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Injection pump gear holder MAG seal pusher Oil pump seal installer (P/N 420 277 905) (P/N 420 277 875) (P/N 529 035 911) APPLICATION APPLICATION 277 engines. 1004 engines. APPLICATION PTO seal pusher Large hose pincher All liquid cooled engines except...

  • Page 39: Transmission - Mandatory Tools

    Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Engine stand Not sold by BOMBARDIER. APPLICATION 1503 engines. TRANSMISSION — MANDATORY TOOLS Drive pulley retainer TRA drive pulley puller (25 mm) Specific alignment bar (P/N 529 035 674) (P/N 529 007 900) (P/N 529 035 530) APPLICATION APPLICATION...

  • Page 40: Transmission - Recommended Tools

    Section 01 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 41 Section 01 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 42 Section 01 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 43 Section 01 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 44: Suspension - Mandatory Tools

    Section 01 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 45: Suspension - Recommended Tools

    Section 01 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) a. (P/N 529 028 800) narrow Pins NOTE: Angle finder with a mag- (P/N 529 008 204) netic base must be used.
  • Page 46 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) Shock wrench Gas shock valve tool (tire valve (P/N 529 035 727) type) (P/N 529 035 570) APPLICATION All T/A shocks. HPG shock holding tool (P/N 529 035 769) APPLICATION All HPG shocks.
  • Page 47 (P/N 520 000 126) (P/N 529 035 876) APPLICATION SC-10 II and III (coupling blocks). APPLICATION REV series. APPLICATION 2004 REV series. REV ball joint lock N–> (P/N 529 035 945) Ball joint installer support (P/N 529 035 875) APPLICATION APPLICATION REV series.

  • Page 48: Vehicle - Recommended Tools

    Section 01 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 49 (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. 2-TEC, 1004 and 1503 engine equipped models. Fuel pump nut wrench (P/N 529 035 899) Oil pressure gauge...

  • Page 50: Service Products

    Section 01 TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) SERVICE PRODUCTS Retaining compound (P/N 413 703 100) Loctite ® RC/609: Retaining compound (10 mL) (green) APPLICATION Used for retaining bushings, bearings in slightly worn hous- ing or on shaft. Medium-strength threadlocker (P/N 293 800 060) Loctite...
  • Page 51 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) High strength threadlocker Paste gasket Gasket/paint remover (P/N 293 800 005) (P/N 413 702 700) (P/N 413 708 500) Loctite ® 271: Loctite ® 515: Loctite ® Chisel 510 g (18 oz) Threadlocker (10 mL) (red, high Gasket eliminator (50 mL) strength)
  • Page 52 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Isoflex grease SYNTHETIC BOMBARDIER BOMBARDIER FORMULA XP-S (P/N 293 550 021) 4-STROKE engine oil II synthetic injection oil (50 g) 0W-40 (P/N 293 600 045) (P/N 293 600 054) (12 x 1 liter) (12 x 1 L) (P/N 293 600 046) (3 x 4 liter)
  • Page 53 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) BOMBARDIER injection oil Fuel stabilizer Storage oil (P/N 413 802 900) (P/N 413 408 600) CANADA: (P/N 413 711 600) (12 x 1 liter) (12 x 8 oz) U.S.A.: (P/N 413 711 900) (350 g spray can) (12 x 350 g) (P/N 413 803 000) (3 x 4 liters)
  • Page 54 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Grease LMZ no. 1 BOMBARDIER LUBE Brake fluid GTLMA (DOT 4) (P/N 413 707 500) (P/N 293 600 016) (P/N 293 600 062) (400 g) (12 x 14 oz) APPLICATION Mainly used between regulators or rectifiers and frame to trans- fer the heat build-up and to as-...
  • Page 55 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Anti-seize lubricant Pulley flange cleaner Plastic & vinyl cleaner (P/N 293 800 070) (P/N 413 711 809) (P/N 413 711 200) Loctite anti-seize lubricant (320 g) (6 x 1 L) 236 mL (8 oz) APPLICATION APPLICATION...
  • Page 56 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Pipe sealant RTV silicone sealant High temperature RTV sealant (P/N 293 800 018) (P/N 293 800 066) (P/N 293 800 090) Loctite 592 (50 mL) Loctite 5900 (300 mL) Ultra Copper (80 mL) APPLICATION APPLICATION Engine plugs and senders.
  • Page 57 Section 01 TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) Scratch remover N–> (P/N 861 774 800) APPLICATION All models. mmr2004-Rev...

  • Page 58: Maintenance

    Section 02 MAINTENANCE Subsection 01 (MAINTENANCE CHART) MAINTENANCE CHART Inspect, verify, clean, adjust, lubricate or replace if necessary 10 h Once Weekly Monthly C: Clean a year Preseason Refer to the 6000 km Storage 500 km preparation following Lubricate 240 km 800 km (3700 m.) (300 m.)
  • Page 59 Section 02 MAINTENANCE Subsection 01 (MAINTENANCE CHART) Inspect, verify, clean, adjust, lubricate or replace if necessary 10 h Once Weekly Monthly C: Clean a year Preseason Refer to the 6000 km Storage 500 km preparation following Lubricate 240 km 800 km (3700 m.) (300 m.) 3200 km...
  • Page 60 Vehicle Cleaning and Protection 02-02 (1) To be performed by an authorized Ski-Doo dealer. (2) Lubricate whenever the vehicle is used in wet conditions (wet snow, rain, puddles). (3) 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 61: Storage

    Section 02 MAINTENANCE Subsection 02 (STORAGE) STORAGE GENERAL WARNING Fuel is inflammable and explosive under Proper snowmobile storage is a necessity during certain conditions. Always work in a well the summer months or when a vehicle is not being ventilated area. Do not smoke or allow open used for more than one month.

  • Page 62: Engine Compartment

    Section 02 MAINTENANCE Subsection 02 (STORAGE) Reinstall the spark plugs and the outlet primer CAUTION: Do not use Heavy duty cleaner on decals or vinyl. hose or air silencers. For vinyl and plastic parts use Vinyl & Plastic WARNING Cleaner (P/N 413 711 200 (6 x 1 L)). This procedure must only be performed in a To remove scratches on windshield or hood use well-ventilated area.

  • Page 63: Preseason Preparation

    Section 02 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is necessary after the summer months or when a vehicle has not been used for more than one month. Refer to preseason preparation column from MAINTENANCE CHART jointly with the present preseason preparation procedure in order to cover each and every aspect of the snowmobile presea- son preparation procedure.

  • Page 64: Throttle Body Cleaning(On So Equipped Models)

    Section 02 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) THROTTLE BODY CLEANING SPARK PLUGS (ON SO EQUIPPED MODELS) Once preseason preparation is done, start engine with the old spark plug(s) to burn excess stor- Remove the throttle body from vehicle. age oil. Then, install new properly gapped spark Using the Pulley Flange Cleaner (P/N 413 711 plug(s).

  • Page 65: Troubleshooting

    Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) ENGINE 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. NOTE: For engine management system troubleshooting, refer to appropriate subsection. SYMPTOM ENGINE BACKFIRES.
  • Page 66 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. TEST/INSPECTION 1. Perform engine leak test. Refer to ENGINE LEAK VERIFICATION FLOW CHART. Check possible piston seizure. a. Damaged gasket and/or seal. Replace defective parts. 2. “Four-corner” seizure of piston(s). a.
  • Page 67 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. TEST/INSPECTION 4. Melted and/or perforated piston dome; melted section at ring end gap. a. When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This is due to an incomplete combustion of a poor quality oil.
  • Page 68 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 1. Check spark plug condition and gap. a. Fouled spark plugs or wrong spark plug gap. Replace or readjust gap.
  • Page 69 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE DETONATION AT MAXIMUM RPM. CONDITION NORMAL USE. TEST/INSPECTION 1. Check which type of fuel is used. a. Octane number is too low and/or alcohol level is too high. Use recommended fuel type. 2.
  • Page 70 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE TURNS OVER BUT FAILS TO START. CONDITION NORMAL USE. TEST/INSPECTION 1. Check switches. a. Ignition switch, emergency cut-out switch or tether switch is OFF. Place all switches in the RUN or ON position. If it still does not work, connect DESS switch BK/GN and BK/WH wires together (harness side).
  • Page 71 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM IRREGULAR ENGINE IDLE. CONDITION NORMAL USE AFTER ENGINE WARM UP. TEST/INSPECTION 1. Check choke. a. Choke plunger may be partially opened. Readjust. 2. Check carburetor adapter. a. Air enters through a crack. Replace. 3.
  • Page 72 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. TEST/INSPECTION 3. Check ignition timing. a. Ignition timing is too advanced. Adjust according to specifications (refer to TECHNICAL DATA). 4. Check if there are leaks at air intake silencer and/or engine crankcase. a.
  • Page 73 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. TEST/INSPECTION 16. Check if there are leaks at air intake silencer and/or engine crankcase. a. Leak(s). Repair or replace. 17. Check condition and heat range of spark plugs. a.
  • Page 74 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH RAVE. ENGINE HESITATES AT LOW OR MID-SPEED AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE. CONDITION NORMAL USE. TEST/INSPECTION 1. Check RAVE valve spring(s). a. Spring tension is too low or spring(s) is (are) broken. Replace.
  • Page 75 Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE PINGING. CONDITION NORMAL USE. TEST/INSPECTION 1. Check for proper fuel octane number according to engine type. a. Too low fuel octane number. Use appropriate fuel octane number (Refer to Operator’s Guide). 2. Check fuel lines. a.

  • Page 76: Engine Leak Verification Flow Chart

    Section 03 TROUBLESHOOTING Subsection 01 (ENGINE) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP AIR BUBBLES FOUND...

  • Page 77: Fuel And Oil Systems

    Section 03 TROUBLESHOOTING Subsection 02 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS 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. NOTE: For the SDI fuel system troubleshooting, also refer to appropriate ENGINE MANAGEMENT sub- section.
  • Page 78 Section 03 TROUBLESHOOTING Subsection 02 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM (MODELS WITH CARBURETOR ONLY). CONDITION NORMAL USE TEST/INSPECTION 1. Check fuel tank vent hose. a. Kinked or clogged hose. Relocate or replace. 2.
  • Page 79 Section 03 TROUBLESHOOTING Subsection 02 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS FUEL (SDI MODELS ONLY). CONDITION NORMAL USE TEST/INSPECTION 1. Check fuel filter inline. a. Corrosion due to oxidation. Replace fuel filter. 2. Check if lines are perforated, kinked, or if they leak at fittings. Replace lines.

  • Page 80: Transmission And Brake System

    Section 03 TROUBLESHOOTING Subsection 03 (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 81 Section 03 TROUBLESHOOTING Subsection 03 (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 82 Section 03 TROUBLESHOOTING Subsection 03 (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 83 Section 03 TROUBLESHOOTING Subsection 03 (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 84 Section 03 TROUBLESHOOTING Subsection 03 (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 85 Section 03 TROUBLESHOOTING Subsection 03 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM BELT TOO NARROW ON ONE SECTION. CONDITION NORMAL USE TEST/INSPECTION 1. Check for frozen track. a. Frozen track. Free track from ice. 2. Check parking brake. a. Parking brake is engaged. Release parking brake.
  • Page 86 Section 03 TROUBLESHOOTING Subsection 03 (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 87: Brake System

    Section 03 TROUBLESHOOTING Subsection 03 (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 88: Electrical System

    Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) ELECTRICAL 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. SYMPTOM STARTER DOES NOT TURN.
  • Page 89 Section 03 TROUBLESHOOTING Subsection 04 (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 90 Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM STARTER TURNS, BUT OVERRUNNING CLUTCH PINION DOES NOT MESH WITH RING GEAR. CONDITION NORMAL USE TEST/INSPECTION 7. Check ring gear. a. Worn ring gear. Replace ring gear. 8. Check for proper starter rotation direction. a.
  • Page 91 Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN ACTIVATED. CONDITION NORMAL USE TEST/INSPECTION 1. Check battery cables and starter wires. a. Corroded and/or loose connection(s). Clean and/or retighten. 2. Check fuse. a. Oxidized or burnt fuse. Clean or replace.
  • Page 92 Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) 360 W - 2 CYLINDER Check for SYMPTOM spark at spark plug mmr2004-Rev...
  • Page 93 Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) 360 W - 2 CYLINDER DC charging system all accessories are DC operated Symptom Symptom Symptom Bulbs are burnt and Battery will not stay charged unit even if battery has very little Battery goes dead electrolyte in it.
  • Page 94 Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM THE MPEM DOES NOT WORK. CONDITION NORMAL USE TEST/INSPECTION 1. Check that high tension coil wires do not touch any metal parts. a. Short circuit. Isolate and reroute wires. SYMPTOM ENGINE STALLS. CONDITION NORMAL USE TEST/INSPECTION...
  • Page 95 Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM FOULED (BLACK) SPARK PLUG TIP. CONDITION NORMAL USE TEST/INSPECTION 1. Check carburetor. a. Carburetion is too rich. Adjust according to specifications (refer to TECHNICAL DATA). 2. Check injection oil consumption. a. Injection pump flow is too high. Adjust according to specifications or replace.
  • Page 96 Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM RER (ROTAX ELECTRONIC REVERSE) DOES NOT WORK. CONDITION NORMAL USE TEST/INSPECTION 1. Check idle speed. a. Wrong idle speed. Adjust according to specification (refer to TECHNICAL DATA). 2. Check spark plug. a. Faulty spark plug. Replace.
  • Page 97 Section 03 TROUBLESHOOTING Subsection 04 (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 98 Section 03 TROUBLESHOOTING Subsection 04 (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 99 Section 03 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM TACHOMETER DOES NOT WORK. CONDITION NORMAL USE TEST/INSPECTION 1. Check continuity of wires. a. Corroded terminals and/or broken wires. Replace terminal(s) or crimp defective wires. 2. Check tachometer part number. a. Models with 360 W magneto have a different tachometer. Replace with appropriate one.

  • Page 100: Suspension And Track

    Section 03 TROUBLESHOOTING Subsection 05 (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 101 Section 03 TROUBLESHOOTING Subsection 05 (SUSPENSION AND TRACK) SYMPTOM REAR SUSPENSION IS TOO STIFF. CONDITION NORMAL USE TEST/INSPECTION 1. Check rear spring preload. a. Too much preload. Adjust to a softer position. 2. Check springs. a. Springs installed are too stiff. Install optional softer springs, refer to service bulletin SPRING REFERENCE ACCORDING TO LOAD.
  • Page 102 Section 03 TROUBLESHOOTING Subsection 05 (SUSPENSION AND TRACK) SYMPTOM HANDLEBAR IS DIFFICULT TO TURN. CONDITION NORMAL USE TEST/INSPECTION 1. Check if the handlebar turns freely when skis are off the ground. a. Ball joints corrosion restrains movement. Lubricate or replace the ball joint. b.
  • Page 103 Section 03 TROUBLESHOOTING Subsection 05 (SUSPENSION AND TRACK) SYMPTOM SLIDER SHOES WEAR OUT PREMATURELY/OR TRACK CLEATS BECOME BLUE. CONDITION NORMAL USE TEST/INSPECTION 1. Check track tension. a. Pressure is too great on slider shoes. Adjust according to specifications (refer to TECHNICAL DATA). Replace defective parts. 2.

  • Page 104: Engine

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) 593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES EXHAUST SYSTEM 593 engines 593 HO, 593 SDI and 793 HO engines mmr2004-Rev...

  • Page 105: Tuned Pipe

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) TUNED PIPE Installation Install doughnut shaped exhaust gasket no. 3 with Identification both of its notches aligned with Y-manifold protru- Each tuned pipe is identified by a number. To sions.
  • Page 106 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) TYPICAL Removal Remove tuned pipe no. 2. Disconnect the EGTS (Exhaust Gas Temperature Sensor) on SDI models. Remove springs no. 8 retaining the muffler no. 9. Remove the muffler.

  • Page 107: Engine System

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) ENGINE SYSTEM 593 engines mmr2004-Rev...

  • Page 108: Removal From Vehicle

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) REMOVAL FROM VEHICLE Vehicle and Engine Preparation Place vehicle at workstation that will have access to an engine-lifting hoist. Then start with initial preparation of vehicle by doing the following. Remove windshield.
  • Page 109 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Separate carburetors or throttle body from engine. Unplug coolant hose located between cylinder head and radiator. Remove rewind starter handle. 1. Coolant hose between cylinder head and radiator Remove reed valves with their gaskets.
  • Page 110 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Remove spark plugs and install spark plug lift ring (P/N 529 035 830) at the farthest spark plug hole. Unplug spark plug cables. Detach upper thermostat hose from thermostat housing.

  • Page 111: Inspection

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) A. Do not apply Loctite in this area, ± 10 mm (.39 in) B. Loctite area, ± 8 mm (.31 in) Torque engine support bolts to 48 N•m (35 lbf•ft). Hand torque engine stopper no.

  • Page 112: Top End

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) TOP END 593 Engine Types mmr2004-Rev...
  • Page 113 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) 593 HO Engine Types mmr2004-Rev...
  • Page 114 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) 593 SDI Engine Types mmr2004-Rev...
  • Page 115 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) 793 HO Engine Types mmr2004-Rev...

  • Page 116: Troubleshooting

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) TROUBLESHOOTING Before completely disassembling the engine, check airtightness. Refer to LEAK TEST AND ENGINE DIMENSION MEASUREMENT. COMPONENT REMOVAL WITH THE ENGINE INSTALLED Most engine components can be removed with engine on vehicle such as: –...

  • Page 117: Disassembly

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Maintenance All Models There are no wear parts anywhere in the system and there are no adjustments to be periodically checked. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide.
  • Page 118 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) TYPICAL 1. Allen socket screws TYPICAL 2. RAVE valve base 1. Spring 2. Valve piston Unscrew and remove the guillotine no. 9 from the 3.
  • Page 119 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Cylinder Head Cover All Engine Types Unplug spark plug cables. SDI Engine Types Disconnect the knock sensor no. 19. 793 HO Engine Types Disconnect the temperature sensor connector. All Engine Types Unplug coolant hose from upper thermostat hous- ing no.
  • Page 120 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) A02C29A TYPICAL TYPICAL 1. Properly seated all around All engines are equipped with cageless piston pin Install sleeve then shouldered sleeve over puller bearings. rod.

  • Page 121: Inspection

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Remove piston from connecting rod. Install locating sleeve. Then push needle bearings along with thrust washers and sleeve. A02C2CA TYPICAL — PISTON PIN EXTRACTION TYPICAL 1.

  • Page 122: Assembly

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Piston Check for cracked, dried or perforated bellows no. 13. When installing a new cageless bearing, replace Check if the compression springs no. 7 are in half plastic cages with sleeve.
  • Page 123 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) A02C2IA CAUTION: Piston temperature must not exceed TYPICAL — SHOULDERED SLEEVE INSTALLATION 46°C (115°F). Never use direct flame to heat the Install piston pin puller and turn handle until piston piston and never freeze the pin.
  • Page 124 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Insert circlip into support so that, when installed in piston groove, the tab faces upward. 1. Groove With round end of pusher, position circlip perpen- dicularly to the support axis.
  • Page 125 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) CAUTION: Always install new mono-hook cir- clips. If circlip installation fails at the first at- tempt, always retry with a new one because, on a second attempt, the circlip will lose its nor- mal retaining capabilities.
  • Page 126 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) In case of a play, turn blade upside down and recheck. If there is still a play, replace blade and/or valve body. Check distance from blade stopper outer edge and distance from center of reed valve block.

  • Page 127: Bottom End

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) BOTTOM END 593 Engine Types mmr2004-Rev...
  • Page 128 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) 593 HO Engine Types mmr2004-Rev...
  • Page 129 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) 593 SDI and 793 HO Engine Types mmr2004-Rev...

  • Page 130: Cleaning

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) NOTE: Engine must be removed from chassis to perform the following procedures. CLEANING Discard all oil seals, gaskets, O-rings and sealing rings. Clean all metal components in a non-ferrous metal cleaner.

  • Page 131: Inspection

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Follow the same procedure for the inner bearing NOTE: In the case of damaged bearing or less clearance between crankshaft counterbalance and the bearing or on the MAG side bearing, use a bearing separator such as Snap-On tool CJ 951 or SPX/OTC tool 1124 to facilitate the removal.
  • Page 132 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) Heat up the bearing(s) using bearing heater 1. Bearings (P/N 529 035 969). This will expand bearings and ease installation. If required, put a suitable Probe the inner race of the bearing with the tem- plate or shim to avoid the direct contact between perature indicator stick (P/N 529 035 970).
  • Page 133 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) NOTE: Heated bearings will slide onto the crank- shaft. If required, push with a steel tube on the inner ring of the bearing. Pay special attention to correct positioning of the drive pins and/or 1.
  • Page 134 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) NOTE: The 50 g tube corresponds to 50 cc of grease. Put 50 to 55 mL of grease in a syringe. CAUTION: Do not exceed the recommended amount of grease Fill inner side of PTO side bearing with Isoflex grease (about 10 mL).
  • Page 135 Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) 1. Oil bath Crankcase Assembly IMPORTANT: The total assembly sequence, in- TYPICAL — FILL WITH GREASE AND SET IN PLACE cluding sealing compound spreading, screwing Apply 6 mL of grease to MAG side outer bearing.

  • Page 136: Break-In

    Section 04 ENGINE Subsection 01 (593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES) SEAMING COMPLETED — CONTACT SURFACES COVERED AND SCREW HOLES SURROUNDED Screw all crankcase bolts in place in the following sequence and to the appropriate torque; this must be done in two steps torquing: first, screw bolts up to 60% of the final torque (18 N•m (13.5 lbf•ft) for most of the bolts), then, tighten to the required...

  • Page 137: Engine Leak Test And Dimension Measurement

    Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) ENGINE LEAK TEST AND DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for 593 and 793 types of engines. PREPARATION – Remove tuned pipe. – Install plug over exhaust manifold. –...
  • Page 138 Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) Engine Pump Shaft Oil Gear Reservoir Check the following: Install air pump on adapter and pressurize as above. – All jointed surfaces and screw/stud threads of engine: • spark plug base, insulator •...

  • Page 139: Finalizing Reassembly

    Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) – Check weep hole below coolant pump housing with soapy water. 1. Weep hole If there is a leak, it indicates that a pump shaft is defective (oil seal beside coolant ceramic seal). –...

  • Page 140: Engine Leak Verification Flow Chart

    Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP...

  • Page 141: Engine Dimension Measurement

    Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) ENGINE DIMENSION CYLINDER OUT OF ROUND MEASUREMENT ENGINE TYPE MAXIMUM This section covers all engine types. 0.08 mm (.003 in) CYLINDER HEAD WARPAGE Measuring 16 mm (5/8 in) from top of cylinder with a cylinder gauge, check if the cylinder out of round ENGINE TYPE MAXIMUM...
  • Page 142 Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) 1. Combustion chamber NOTE: When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposits and cylinder head must be lev- eled. – Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge.

  • Page 143: Used Piston Measurement

    Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) NOTE: When the combustion chamber is filled to top of spark plug hole, it includes an amount of 2.25 cc corresponding to the spark plug well. – Repeat the procedure for the other cylinder. COMBUSTION CHAMBER VOLUME ENGINE (cc)
  • Page 144 Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) Adjust and lock a micrometer to the specified value on the piston dome. 1. Micrometer set to the piston dimension 1. Indicator set to 0 (zero) With the micrometer set to the piston dimension, IMPORTANT: Always remove cylinders from adjust a cylinder bore gauge to the micrometer crankcase before measuring.

  • Page 145: Ring/Piston Groove Clearance

    Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) RING/PISTON GROOVE Measuring (in crankcase) CLEARANCE First, check deflection with crankshaft crankcase. If deflection exceeds the specified tol- Using a feeler gauge check clearance between erance, recheck deflection using V-shaped blocks rectangular ring and groove.

  • Page 146: Connecting Rod Big End Axial Play

    Section 04 ENGINE Subsection 02 (ENGINE LEAK TEST AND DIMENSION MEASUREMENT) CHECKING CRANKSHAFT Crankshaft Deflection in Center of Crankshaft ALIGNMENT ENGINE MAXIMUM IN CENTER OF Install a degree wheel (P/N 529 035 607) on crank- TYPE CRANKSHAFT mm (in) shaft end. 0.08 (.0031) Remove both spark plugs.

  • Page 147: Magneto System

    Section 04 ENGINE Subsection 03 (MAGNETO SYSTEM) MAGNETO SYSTEM models mmr2004-Rev...
  • Page 148 Section 04 ENGINE Subsection 03 (MAGNETO SYSTEM) 480 W on REV Series mmr2004-Rev...

  • Page 149: General

    Section 04 ENGINE Subsection 03 (MAGNETO SYSTEM) GENERAL NOTE: The following procedures can be done without removing the engine. To facilitate mag- neto removal, hold drive pulley with tool (P/N 529 027 600). During assembly/installation, use the torque val- ues and service products as in the exploded views.

  • Page 150: Assembly

    Section 04 ENGINE Subsection 03 (MAGNETO SYSTEM) – Disconnect trigger coil connector housing(s). – grommet from crankcase where trigger coil wire(s) exit(s) magneto housing. – retaining screws no. 4. – trigger coil(s) and carefully pull wires. ASSEMBLY Trigger Coil For installation, reverse the removal procedure. NOTE: It is important to remove the old silicon at trigger coil location then apply new silicon.
  • Page 151 Section 04 ENGINE Subsection 03 (MAGNETO SYSTEM) Magneto Flywheel Clean crankshaft extension (taper) and apply Loc- tite 243 (blue) on taper, then position Woodruff key, magneto flywheel no. 3 and lock washer on crankshaft. Clean magneto flywheel nut threads and apply Loctite 243 (blue) then tighten nut no.

  • Page 152: Oil Injection System

    Section 04 ENGINE Subsection 04 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM mmr2004-Rev...

  • Page 153: General

    Section 04 ENGINE Subsection 04 (OIL INJECTION SYSTEM) GENERAL (1) CAUTION: The BOMBARDIER Formula XP-S II synthetic injection oil is specially During assembly/installation, use the torque val- formulated and tested for the severe re- ues and service products as in the exploded quirement of these engines.

  • Page 154: Oil Pump Identification

    Section 04 ENGINE Subsection 04 (OIL INJECTION SYSTEM) DISASSEMBLY NOTE: Some oil pump components are not avail- able as single parts. Injection Oil Reservoir Empty injection oil reservoir no. 6 by siphoning injection oil. Remove: – air box – upper screw (near reservoir cap) –...

  • Page 155: Assembly

    Section 04 ENGINE Subsection 04 (OIL INJECTION SYSTEM) ASSEMBLY NOTE: During installation, always check for spring clips no. 1 tightness. Injection Oil Reservoir For installation, reverse the removal procedure. Injection Oil Level sensor For installation, reverse the removal procedure. Injection Oil Filter For installation, reverse the removal procedure.

  • Page 156: Adjustment

    Section 04 ENGINE Subsection 04 (OIL INJECTION SYSTEM) Stretch the adjusting cable through a maximum force of 32 N•m (7.2 lbf•ft). NOTE: It is better to have two persons to check the cable distance. One stretching the cable and other taking measurements. Check the visible distance of the stretched cable, while one person is stretching it and other check- ing the distance.

  • Page 157: Checking Operation

    Section 04 ENGINE Subsection 04 (OIL INJECTION SYSTEM) Check that oil in small oil lines has been sucked up (this will be indicated by a clear section of small oil lines). Repeat the procedure until this condition is attained. Reconnect small oil lines, start engine and run at idle while holding the pump lever in fully open po- sition.

  • Page 158: Liquid Cooling System

    Section 04 ENGINE Subsection 05 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM All Models except Summit mmr2004-Rev...
  • Page 159 Section 04 ENGINE Subsection 05 (LIQUID COOLING SYSTEM) All Summit Models mmr2004-Rev...

  • Page 160: Cooling System Leak Test

    Section 04 ENGINE Subsection 05 (LIQUID COOLING SYSTEM) COOLING SYSTEM LEAK TEST DISASSEMBLY AND ASSEMBLY WARNING Coolant Pump To prevent burning yourself, do not remove Refer to BOTTOM END section. the radiator cap if the engine is hot. Sender and Plug Install special radiator cap (P/N 529 021 400) in- Apply Loctite 592 (P/N 293 800 018) thread sealant cluded in engine leak tester kit (P/N 861 749 100)
  • Page 161 Section 04 ENGINE Subsection 05 (LIQUID COOLING SYSTEM) Rear Radiator and Rear Radiator Protector Refer to FRAME for rear radiator removal/installa- tion procedures. For cleaning and inspection refer to FRONT RADI- ATOR. Radiator and Radiator Protector Insert radiator protector no. 7 into radiator C-rail and crimp C-rail at rear end.

  • Page 162: Cooling System Refilling Procedure

    Section 04 ENGINE Subsection 05 (LIQUID COOLING SYSTEM) COOLING SYSTEM REFILLING PROCEDURE CAUTION: To prevent rust formation or freez- ing condition, always replenish the system with the Bombardier premixed coolant or with 50% antifreeze and 50% water. Pure antifreeze without water freezes (like slush ice). Always use ethylene glycol antifreeze containing cor- rosion inhibitors specifically recommended for aluminum engines.

  • Page 163: Rewind Starter

    Section 04 ENGINE Subsection 06 (REWIND STARTER) REWIND STARTER mmr2004-Rev...

  • Page 164: Inspection

    Section 04 ENGINE Subsection 06 (REWIND STARTER) INSPECTION NOTE: Due to dust accumulation, rewind starter must be periodically cleaned, inspected and relu- bricated. CAUTION: It is of the utmost importance that the rewind starter spring be lubricated period- ically using Molykote PG 54 (P/N 420 899 763). Otherwise, rewind starter component life will be shortened and/or rewind starter will not op- erate properly under very cold temperatures.

  • Page 165: Assembly

    Section 04 ENGINE Subsection 06 (REWIND STARTER) Take out knot and then pull out rope no. 1. ASSEMBLY At assembly, position spring no. 11 outer end into spring guide notch then wind the spring counter- clockwise into guide. WARNING Since the spring is tightly wound inside the guide it may fly out when rewind is handled.
  • Page 166 Section 04 ENGINE Subsection 06 (REWIND STARTER) TYPICAL Lubricate pawl no. 9 with Molykote PG 54 (P/N 420 899 763) then install over rope sheave. FREE PORTION Lubricate pawl lock no. 8 with Molykote PG 54 (P/N 420 899 763). Install over pawl. FREE PORTION INSERTED INTO SHEAVE Lubricate housing post with Molykote PG 54 .

  • Page 167: Installation

    Section 04 ENGINE Subsection 06 (REWIND STARTER) A03C0VA TYPICAL Reinstall rewind starter assembly on engine. Prior to installing starter grip on new rope, it is first necessary to fuse the rope end with a lit match. Pass rope through starter grip and tie a knot in Install step collar no.

  • Page 168: Carburetor And Throttle Cable

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) CARBURETOR AND THROTTLE CABLE CARBURETOR TM TYPE mmr2004-Rev...

  • Page 169: Identification

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) IDENTIFICATION TM type dual carburetor ass’y is identified on PTO side carburetor body. 1. Disconnect here Non-DPM Models Disconnect carburetor float bowl vent hose nipple from air silencer. DPM Models TYPICAL 1.

  • Page 170: Cleaning And Inspection

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) 1. Outlet line 1. Inlet line 2. Pinch here 2. Valve 3. OFF Disconnect outlet line from carburetor assembly Disconnect heated carburetor coolant inlet line taking care to recuperate coolant. taking care to recuperate coolant. CLEANING AND INSPECTION All Models Disconnect throttle and choke cables.

  • Page 171: Disassembly And Assembly

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) Pilot Jet WARNING Use narrow screwdriver from carburetor tool kit Solvent with a low flash point such as gaso- (P/N 404 112 000) to unfasten pilot jet no. 7. line, naphtha, benzol, etc., should not be used as they are flammable and explosive.

  • Page 172: Carburetor Adjustments

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) Turn dual carburetor ass’y upside down to free needle no. 10. Take care not to loose plastic washer no. 11 under needle circlip no. 12. 1. Circlip 1. Plastic washer At throttle slide assembly, needle retainer must Unscrew throttle slide cover screws no.
  • Page 173 Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) – oil pump and carburetor synchronization – final idle speed adjustment (engine running). 1. Adjust PTO carburetor first 2. Drill bit used as a gauge to measure throttle height 3. Idle speed screw 1.

  • Page 174: Installation

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) Choke Cable Adjustment THROTTLE SLIDE HEIGHT Adjust choke cable as per following procedure: MODELS (drill bit size) Loosen choke cable housing adjusting and locking ± 0.1 mm (± .004 in) nuts. GSX 500 ss Sport Connect choke cable on starter lever no.

  • Page 175: Dpm

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) Start engine and allow it to warm then adjust TEMPERATURE RESISTANCE idle speed to specifications by turning idle speed (OHMS) °C °F screw clockwise to increase engine speed or counterclockwise to decrease it. - 30 - 22 28 000...

  • Page 176: Dpm Manifold Testing

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) INSIDE DIAMETER mm (in) MODEL LEAN VENT JET GSX 800 R Limited MX Z 600 R Renegade MX Z 800 R Adrenaline/Renegade/ 1.2 (.047) 2.0 (.079) Renegade X/X Summit 600 R Adrenaline/X Summit 800 R Adrenaline/ 1.
  • Page 177 Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) Connecting the Pump, DPM Manifold and Water Column Connect hoses as shown. 1. 3.5 mm (9/64 in) ID hose 2. 6.0 mm (15/64 in) ID hose 3. 6.0 mm (15/64 in) T-fitting Water Column Preparation Mount water column vertically and secure it to a wall or workbench.

  • Page 178: Throttle Cable

    Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) If water level drops to an even level in less than 10 seconds, the DPM manifold is defective. Replace DPM manifold parts, (refer to Parts Catalog) and re-test. If test fails again, replace DPM manifold. If you are unable to attain any amount of vacuum (water level increases and decreases immediately in tube), check your set-up and re-do the test.
  • Page 179 Section 04 ENGINE Subsection 07 (CARBURETOR AND THROTTLE CABLE) 1. Throttle cable 2. Adjusting nut 3. Locking nut After throttle cable adjustment, synchronized car- buretors (refer to CARBURETOR SYNCHRONIZA- TION) and adjusted oil pump cable (refer to OIL INJECTION PUMP). SDI Models Refer to COMPONENT INSPECTION AND AD- JUSTMENT in ENGINE MANAGEMENT (2-TEC).

  • Page 180: Fuel Tank And Fuel Pump

    Section 04 ENGINE Subsection 08 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP All Models except SDI mmr2004-Rev...
  • Page 181 Section 04 ENGINE Subsection 08 (FUEL TANK AND FUEL PUMP) SDI Models mmr2004-Rev...

  • Page 182: Fuel Filter

    Section 04 ENGINE Subsection 08 (FUEL TANK AND FUEL PUMP) FUEL FILTER For fuel filter servicing, refer to PRESEASON PREPARATION. FUEL TANK Removal Remove seat, refer to BODY. Remove fuel tank cap. Remove filler neck plastic nut using special tool (P/N 529 035 891).

  • Page 183: Impulse/Fuel Lines Spring Clips (All Models)

    Section 04 ENGINE Subsection 08 (FUEL TANK AND FUEL PUMP) 1. Cut this locking tie FUEL TANK REMOVED 1. Hose pincher installed on fuel line Remove fuel tank no. 3 and set it aside. SDI Models Installation Release fuel pressure of the system. Refer to COMPONENT INSPECTION AND ADJUSTMENT.

  • Page 184: Float-Type Fuel Level Gauge

    Section 04 ENGINE Subsection 08 (FUEL TANK AND FUEL PUMP) FLOAT-TYPE FUEL LEVEL GAUGE SDI Models A 0.5 amp. fuse protects fuel level sensor circuity To remove gauge no. 4 from fuel tank, pull gauge in fuse box. out of its grommet then remove grommet. For reinstallation, proceed as follows: FUEL LEVEL SENSOR SCREWS –...

  • Page 185: Fuel Pump

    Section 04 ENGINE Subsection 08 (FUEL TANK AND FUEL PUMP) FUEL PUMP All Models except SDI mmr2004-Rev...

  • Page 186: Removal

    Section 04 ENGINE Subsection 08 (FUEL TANK AND FUEL PUMP) CLEANING AND INSPECTION NOTE: The following instructions are not applica- ble on SDI models. See COMPONENT INSPEC- The entire pump should be cleaned with general TION AND ADJUSTMENT concerning fuel pump purpose solvent before disassembly.

  • Page 187: 05 2-Tec Engine Management

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 01 (OVERVIEW) OVERVIEW SEMI-DIRECT INJECTION SYSTEM OVERVIEW FUEL TANK ELECTRIC MUFFLER FUEL PUMP EGTS IGNITION COIL WTS APS e-RAVE BATTERY LEGEND APS – Air pressure sensor ATS – Air temperature sensor CPS – Crankshaft position sensor ECM –...

  • Page 188: Operating Principle

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 01 (OVERVIEW) OPERATING PRINCIPLE The fuel pump module is located inside the fuel tank. The module includes the fuel pump, the fuel For this SDI 2-stroke engine, a highly advanced en- pressure regulator and the fuel level sensor (if so gine management system (EMS) has been used to equipped).

  • Page 189: Engine Management System (Ems)

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 01 (OVERVIEW) 1. Fuel tank 2. Fuel pickups In-Line Fuel Filter The in-line 10 micron fuel filter is fastened under the steering console. It comes as a complete as- sembly. TYPICAL — ECM The ECM is mounted in the front of the vehicle. ENGINE MANAGEMENT SYSTEM (EMS) The ECM is directly powered by the battery.

  • Page 190: Ems - General Functions

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 01 (OVERVIEW) – RER (Rotax Electronic Reverse) When starting the engine with a tether cord cap on the post, the DESS is activated and will emit – etc. audible signals: The ECM features a permanent memory that will –...

  • Page 191: Ecu - Engine Management Functions

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 01 (OVERVIEW) High Coolant Temperature IMPORTANT: The sensors and injectors are con- Warning Device tinuously powered with the supply from the bat- tery. The ECM switches the ground to com- When the coolant temperature is getting to high, plete the electrical circuits it controls.

  • Page 192: Electronic Fuel Injection

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 01 (OVERVIEW) This engine management system controls the fuel NOTE: An electric heating element has been injection, the ignition timing and the electronically added to the RAVE solenoid to ensure proper controlled RAVE. function in very cold weather. As shown in the SDI CONTROL SYSTEM illustra- KNOCK SENSOR tion, the ECM is the central point of the fuel injec-...

  • Page 193: Limp Home Modes

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 01 (OVERVIEW) CHARGING SYSTEM When a fault occurs, it sends visual messages through the referring LED and/or audible signals The ignition system consists of different sub-sys- through a buzzer to inform you of a particular con- tems where some are interrelated.

  • Page 194: Trigger Coil

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 01 (OVERVIEW) TYPICAL 1. PTO side high tension cable 2. MAG side high tension cable TRIGGER COIL Trigger coil is used for: 1) Forward engine rotation. 2) Reverse engine rotation. 3) As a crankshaft position sensor (CPS). This in- formation is sent to the ECM.

  • Page 195: Component Inspection And Adjustment

    Section 05 2–TEC 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 appro- electronic fuel injection system.

  • Page 196: Electrical System

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) To check fuel rail for leaks, first pressurize the sys- To perform verifications, a good quality multimeter tem then spray soapy water on all hose connec- such as Fluke 111 (P/N 529 035 868) should be tions, regulators and injectors.

  • Page 197: Resistance Measurement

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) RESISTANCE MEASUREMENT TEMPERATURE SENSOR TABLE When measuring the resistance with an ohmme- TEMPERATURE RESISTANCE (ohms) ter, all values are given for a temperature of 20°C WTS for (68°F). The resistance value of a resistance varies °C °F EGTS...

  • Page 198: Engine Connector Pin-Outs

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) The resistance value of a temperature sensor may CAUTION: Probe on top of terminal only. Do not try to probe inside terminal or to use a pa- test good at a certain temperature but it might be per clip to probe inside terminal, it will dam- defective at other temperatures.

  • Page 199: Air Induction System

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) AIR INDUCTION SYSTEM Electrical Inspection Refer to THROTTLE POSITION SENSOR (TPS) in THROTTLE BODY ELECTRONIC MANAGEMENT below. Replacement Removal To remove the throttle body from engine, proceed as follows: –...
  • Page 200 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) For TPS and e-RAVE solenoid replacement proce- dures, refer to the respective paragraph in ELEC- TRONIC MANAGEMENT below. Adjustment Throttle Body Synchronization CAUTION: It is not allowed to perform any change on the synchronization screw.
  • Page 201 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Tighten bottom nut to 4.5 N•m (40 lbf•in). 1. Cable sheath 2. Upper nut 3. Lock washer 4. Lower nut 5. Throttle lever 6. Adjusting screw 7. Pull in this direction Activate the throttle lever a few times.

  • Page 202: Fuel Delivery

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY Fuel delivery system diagnostic flow chart - SDI models Install fuel pressure gauge on fuel pressure line Fuel pump does not run Connect tether cord cap and push START/RER button momentarily Replace fuel pump module...

  • Page 203: Fuel Pump

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL PUMP Remove tether cord cap. Depress START/RER button and observe fuel pressure. Do not crank Fuel Pressure Test engine. Repeat twice. Release pressure using B.U.D.S. between tests so that the gauge is “re- Before proceeding to the pressure test, ensure set”...
  • Page 204 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Otherwise, probe terminals 4 and battery ground of fuel pump connector on vehicle harness side. When depressing the START/RER button, you should read battery voltage for approximately 2 seconds (then, the voltage will drop). If battery voltage does not appear, the problem can be in harness or in fuel pump connector.
  • Page 205 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Insert rear fuel pickup through fuel pump hole at an angle to reach the proper position. 1. Fuel pickup CAUTION: Do not twist hoses during installa- tion. Fuel pickups must be positioned in the Installation fuel tank as per following illustration.
  • Page 206 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Retaining rods axis 1. Arrows 2. Fuel hose ass’y 2. Torque wrench A. 17° ± 3° A. 90° Install a new blue hose clamp on fuel hose ass’y. Bleed the fuel system as following procedure.

  • Page 207: Fuel Rail

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) TYPICAL 1. Pump inlet nipple 2. Pump electric connector 3. Pump module flange nipple 4. E-clips Reverse removal procedure for installation. Install a new gasket, then reinstall fuel pump mod- ule as explained above.

  • Page 208: Fuel Injectors

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL INJECTORS 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 209 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CIRCUIT NUMBER INJECTOR NUMBER (ECM connector «DA») DA-15 1/1 (MAG external) DA-33 2/1 (PTO external) DA-14 1/2 (MAG internal) DA-30 2/2 (PTO internal) If it is good, check the resistance of the fuel injec- tor circuit.

  • Page 210: Electronic Management

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) ELECTRONIC MANAGEMENT ECM REPLACEMENT General Prior to replacing a suspected ECM, ensure that all the recommendations in the general introduction of this section have been followed. IMPORTANT: When the ECM is replaced, the tether cord cap(s) and the Closed Throttle must be reprogrammed/reset.

  • Page 211: Engine Wiring Harness

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Removal Unscrew all retaining screws and remove the en- gine ECM from its support. Remove air intake silencer. Install the new ECM to the support. Disconnect the wiring harness from all sensors/ Reconnect ECM connectors to ECM, and then bat- actuators.
  • Page 212 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) The ECM may generate several fault codes per- Check the continuity between pin 3 on wiring har- taining to the TPS. Refer to SYSTEM FAULT ness TPS connector and pin 24 on wiring harness CODES in DIAGNOSTIC PROCEDURES section ECM connector.
  • Page 213 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Closed Throttle Reset NOTE: When measuring between pins DA-24 and DA-39, resistance value increases while depress- NOTE: This operation performs a reset of the val- ing throttle lever. When measuring between pins ues in the ECM.

  • Page 214: Crankshaft Position Sensor (Cps)

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Otherwise, replace the CPS. VALUE If resistance tests good, reconnect the CPS and ENGINE TYPE ABOVE 1800 m AT SEA LEVEL disconnect the connector DA on the ECM. (6000 ft) 3.9°...

  • Page 215: Air Temperature Sensor (Ats)

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) When installing new CPS apply Loctite 5910 be- If resistance value is correct, try a new ECM. Refer tween CPS and crankcase. to ECM REPLACEMENT procedures elsewhere in this section. Torque to 8 N•m (71 lbf•in).

  • Page 216: Air Pressure Sensor (Aps)

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Refer to TEMPERATURE SENSOR TABLE at the Refer to TEMPERATURE SENSOR TABLE at the beginning of this section to find the corresponding beginning of this section to find the corresponding resistance value for this sensor temperature.

  • Page 217: Exhaust Gas Temperature Sensor (Egts)

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) EXHAUST GAS TEMPERATURE Install the tether cord cap, turn OFF engine cut-out switch and push START/RER button momentarily SENSOR (EGTS) to activate the ECM. Disconnect plug connector from APS and connect a voltmeter between pin 1 and 2 of wiring harness.

  • Page 218: Knock Sensor (Ks)

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) KNOCK SENSOR (KS) CIRCUIT NUMBER KS CONNECTOR (ECM CONNECTOR A) 1. Knock sensor (KS) DA-22 PIN 1 Dynamic Test DA-8 PIN 2 Lift rear of vehicle off the ground and support it If test is not good, repair the connector or replace with a wide-base mechanical stand.

  • Page 219: E-Rave Solenoid

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) E-RAVE SOLENOID DOUBLE IGNITION COIL 1. Ignition coil 1. E-RAVE solenoid NOTE: The ECM energizes the primary side of Resistance Test each ignition coil individually. It can detect if the double ignition coil is connected otherwise a trou- Disconnect the solenoid connector.
  • Page 220 Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Resistance Test Remove spark plug cables from ignition coil. Using a multimeter, check the resistance of pri- mary winding. NOTE: The secondary winding can not be mea- sured with an ohmmeter. Try a new double igni- tion coil if necessary.

  • Page 221: Tdc Setting (Top Dead Center)

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) TDC SETTING If in doubt, proceed with the following residual voltage test. (TOP DEAD CENTER) Residual Voltage Test Refer to IGNITION TIMING section. Connect a 12 V test lamp to capacitor terminals during a complete minute to discharge capacitor.

  • Page 222: Engine Start/Rer Button Verification

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) ENGINE START/RER BUTTON Tether Cord Cap Removed VERIFICATION Connect test probes to switch BLACK/GREEN and BLACK/WHITE wires. Measure resistance, there A quick operation test can be done using the ve- should be NO continuity (open circuit).

  • Page 223: Cranking System

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Proper socket 2. Improper socket SPARK ENGINE TORQUE PLUG mm (in) Hand tighten 593 SDI + 1/4 turn (.031) 2-TEC BR 9 ECS with a socket CRANKING SYSTEM See above for start/stop switch and the DESS post testing.

  • Page 224: Diagnostic Procedures

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES GENERAL Here is the basic order suggested to diagnose a suspected engine management or fuel injection related problem: – Check the chart in TROUBLESHOOTING section to have an overview of problems and suggested so- lutions.
  • Page 225 Section 05 2–TEC ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) P CODE EMS PILOT LAMP BUZZER DESCRIPTION P0106 Air pressure sensor voltage out of range. P0337 No crankshaft signal detected. P0336 High engine RPM detected. P0339 Crankshaft signal fault. P0654 Tachometer RPM signal shorted to battery. Tachometer RPM signal open circuit or P0654 shorted to ground.
  • Page 226 Section 05 2–TEC ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) P CODE EMS PILOT LAMP BUZZER DESCRIPTION P1654 Oil lamp shorted to battery. P1658 Oil lamp open circuit or shorted to ground. P0117 Engine temperature sensor voltage too low. Engine temperature sensor voltage too P0118 high.
  • Page 227 Section 05 2–TEC ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) P CODE EMS PILOT LAMP BUZZER DESCRIPTION Injector cyl. # 2 OR outer PTO injector P0264 (2 cyl.), open circuit or shorted to ground. Injector cyl. # 3 OR inner MAG injector P0268 (2 cyl.), shorted to battery.

  • Page 228: 2-Tec System Fault Codes

    Section 05 2–TEC ENGINE MANAGEMENT Subsection 03 (DIAGNOSTIC PROCEDURES) Writing in ECM WARNING When writing in ECM through B.U.D.S., there If the computer you are using is connected to will be an “EMS Tracking” message that will say the power outlet, there is a potential risk of “Remove key from vehicle“.
  • Page 229 Section 05 2–TEC 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.

  • Page 230: Transmission

    Section 06 TRANSMISSION Subsection 01 (DRIVE BELT) DRIVE BELT APPLICATION CHART MINIMUM WIDTH (wear limit) MODEL PART NUMBER mm (in) 417 300 197 34.2 (1–11/32) All 593/HO/SDI engine equipped models 417 300 166 35.3 (1–3/8) All 793 HO engine equipped models INSPECTION ROTATION DIRECTION Inspect belt for cracks, fraying or abnormal wear...

  • Page 231: Drive Belt Height Measurement And Adjustment

    Section 06 TRANSMISSION Subsection 01 (DRIVE BELT) 1. Flush Adjustment INCORRECT Before adjusting the belt height, ensure that a NOTE: For used drive belt, mark and reinstall in good-condition proper belt (refer to the APPLICA- the same position. TION CHART) is installed. DRIVE BELT HEIGHT Adjust pulley distance according to specification, refer to PULLEY DISTANCE AND ALIGNMENT.
  • Page 232 Section 06 TRANSMISSION Subsection 01 (DRIVE BELT) Models Equipped with HPV Type Driven Pulley A06D20A TYPICAL 1. Allen screws with jam nuts Allen screws must be restrained while tightening jam nut to prevent throwing adjustment out. Use 1. Screws drive belt tension adjuster (P/N 529 008 700). 2.

  • Page 233: 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 234 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 mmr2004-Rev...

  • Page 235: Drive Pulley

    Subsection 02 (DRIVE PULLEY) DRIVE PULLEY TRA III All REV Series Models NOTE: These are lubrication free drive pulleys. Always refer to appropriate parts catalog for replacement part. Most parts of TRA III are not interchangeable with those of the TRA.

  • Page 236: General

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) GENERAL Remove retaining screw. To remove drive pulley ass’y and/or fixed half from Some drive pulley components (return spring, engine, use puller (P/N 529 022 400). ramp) can be changed to improve vehicle perfor- mance in high altitude regions.
  • Page 237 Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) 32, Cushion Drive WARNING CAUTION: Do not disassemble cushion drive. Clutch spring is very strong. Never attempt Governor cup and cushion drive are factory to remove spring cover without the recom- balanced as an assembly. mended tools.

  • Page 238: Cleaning

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) 16,17, Thrust Washer and Roller Remove 3 Allen screws retaining spring cover then unscrew compressor. Check roller for roundness of external diameter. Check thrust washer for thickness wear. Replace CLEANING as required. CAUTION: Ensure rollers are in good condition. 5,6, Fixed and Sliding Halves Replace as required.
  • Page 239 Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) Secure the spring compressor (P/N 529 035 524) in a vise. Mount tool (P/N 529 031 200) and the sliding half ass’y on it. Clean sliding half bushing mounting surface with pulley flange cleaner (P/N 413 711 809). To install a new bushing, secure the spring com- pressor (P/N 529 035 524) in a vise and mount the sliding half ass’y.

  • Page 240: Assembly

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) 26,27,28, Calibration Screw, Washer and Locking Nut When installing calibration screw, make sure to install washer as shown. 1. Bushing Install the circlip. A16D07A TYPICAL 1. Washer Torque locking nut to 10 N•m (89 lbf•in). 15, Pin Always use the same type of pin as originally in- stalled when servicing.
  • Page 241 Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) MODEL ANGLE (A) Always install lever assemblies so that cotter pins are on the shown side. Besides install cotter pin With TRA III 45 ± 3° head on top when lever is sat at bottom of sliding half.
  • Page 242 Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) 593 /HO/SDI Engine Equipped Models Only 793 HO Engine Equipped Models TYPICAL 1. Align 593/HO/SDI Engine Equipped Models Only 1. Head on top 2. All on the same side All Models Torque nuts no. 9 as per the exploded view. CAUTION: Lever ass’y and rollers must move easily after installation.

  • Page 243: Installation

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) 6,25,29, Sliding Half, Slider Shoe and Governor Cup To install governor cup, use following tool: Insert spring and slider shoes into governor cup A16D0EA so that groove in each slider shoe is vertical to TYPICAL properly slide in guides.

  • Page 244: Drive Pulley Adjustment

    Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) 26,28,29, Calibration Screw, Locking Torque screw to 80 to 100 N•m (59 to 74 lbf•ft). Nut and Governor Cup Install drive belt and guard. Calibration screw has a notch on top of its head. Raise and block the rear of the vehicle and support it with a mechanical stand.
  • Page 245 Section 06 TRANSMISSION Subsection 02 (DRIVE PULLEY) To Adjust: Just loosen locking nut enough to pull calibration screw out and adjust to desired position. partially Do not completely remove the locking nut. Torque locking nuts to 10 N•m (89 lbf•in). CAUTION: Do not completely remove calibra- tion screw otherwise its inside washer will fall off.

  • Page 246: Driven Pulley

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) DRIVEN PULLEY FORMULA RER mmr2004-Rev...

  • Page 247: Removal

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) REMOVAL CLEANING Remove guard and drive belt from vehicle. Large Bushing and Small Bushing Remove pulley retaining screw no. 14 and shoul- During break-in period (about 10 hours of use), dered washer no. 12 then pull the driven pulley teflon from bushing no.

  • Page 248: Bushing Replacement

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) DRIVEN PULLEY BUSHING WEAR LIMIT mm (in) Small bushing 38.30 (1.508) Large bushing 108.2 (4.260) Slider Shoe Black slider shoe = forward. Red slider shoe = reverse. Check cam slider shoes no. 10 and no. 11 for wear.

  • Page 249: Installation

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) Compress outer cam using spring compressor (P/N 529 035 524). Install washer no. 4 then secure outer cam with circlip no. 3. CAUTION: Ensure that circlip is properly in- serted into shaft groove and that spacer recess is facing circlip.

  • Page 250: Adjustment

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) ADJUSTMENT Pulley Alignment and Drive Belt Deflection Refer to PULLEY DISTANCE AND ALIGNMENT and DRIVE BELT to perform adjustments. CAUTION: Drive belt and pulley adjustments must always be checked whenever pulleys have been removed, replaced or disassem- bled.

  • Page 251: Hpv Vsa

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) HPV VSA mmr2004-Rev...

  • Page 252: Removal

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) REMOVAL Remove half keys no. 6 and washer no. 7 to dis- assemble the cam and the 2 pulley halves. Remove guard and drive belt from vehicle. WARNING Remove cap screw no. 1 and shouldered washer no.

  • Page 253: Installation

    Section 06 TRANSMISSION Subsection 03 (DRIVEN PULLEY) ADJUSTMENT Install slider shoes as per following photo. Red slider shoes are being used for reverse and black Pulley Alignment and Drive Belt Height ones for forward. Refer to PULLEY DISTANCE AND ALIGNMENT and DRIVE BELT to perform adjustments.

  • Page 254: Pulley Distance And Alignment

    Y = Distance between straight bar and drive pulley fixed half edge, measured at the end of straight bar. Z = Distance between outside diameter of pulleys (not adjustable on the REV Series models). GENERAL PROCEDURE Remove guard, drive belt and air silencer. Loosen lock nut.

  • Page 255: Pulley Alignment And Distance Specifications Chart

    DISTANCE ALIGNMENT MODEL ± 0.50 mm (.020 in) ALL REV SERIES MODELS WITH FORMULA VSA OR FORMULA VSA 19.0 (0.748) 37.0 (1.456) 1.5 (0.060) 529 035 831 ALL REV SERIES MODELS WITH HPV 20.0 (0.787) 37.0 (1.456) 1.5 (0.060) mmr2004-Rev...
  • Page 256 GENERAL PROCEDURE. Pulley Distance Adjustment Method Pulley distance adjustment cannot be done on REV Series models. Pulley Alignment Method Remove driven pulley and add or remove spacer(s) as required to obtain the specified alignment.

  • Page 257: Brake

    Section 06 TRANSMISSION Subsection 05 (BRAKE) BRAKE HYDRAULIC BRAKE mmr2004-Rev...

  • Page 258: Brake Fluid

    Section 06 TRANSMISSION Subsection 05 (BRAKE) BRAKE FLUID CALIPER The brake fluid must be changed in accordance Removal with the maintenance chart. Unscrew screws no. 21 and remove locking tab Use recommended brake fluid SRF (DOT 4) no. 20 to pull out caliper no. 6 from chaincase. (P/N 293 600 063) or GTLMA (DOT 4) (P/N 293 600 062).

  • Page 259: Brake Pads

    Section 06 TRANSMISSION Subsection 05 (BRAKE) Installation Push pistons all the way in to allow caliper instal- lation over brake disc. Install the Banjo bolt no. 7 with two new sealing rings no. 8. Fasten caliper on chaincase. Do not forget to in- stall and fold locking tab over caliper bolt.

  • Page 260: Brake Disc

    Section 06 TRANSMISSION Subsection 05 (BRAKE) A. 1 mm (1/32 in) minimum Installation Install: – new brake pads – spring and push 2 pins to lock the brake pads – 2 retainers in the pin holes. 1. Bearing Support WARNING –...

  • Page 261: Countershaft

    Section 06 TRANSMISSION Subsection 05 (BRAKE) 1. Screws 1. Washers use as a 3 mm (1/8 in) spacer 2. Original retaining screw and shouldered washer Install remover (P/N 529 035 699) on countershaft 3. Bearing against circlip for complete bearing no. 17 removal. Ensure that countershaft is properly aligned, then tighten 3 retaining screws.

  • Page 262: Bleeding

    Section 06 TRANSMISSION Subsection 05 (BRAKE) BLEEDING Disconnect the switch. Take out the master cylinder from the handlebar. Bleed brake system as follows: Overturn the master cylinder so that the bottom is Keep sufficient recommended brake fluid in reser- on the top. voir at all times.

  • Page 263: Chaincase

    Section 06 TRANSMISSION Subsection 06 (CHAINCASE) CHAINCASE mmr2004-Rev...

  • Page 264: Removal And Disassembly

    Section 06 TRANSMISSION Subsection 06 (CHAINCASE) REMOVAL AND DISASSEMBLY Pull chaincase from drive axle and countershaft. Using 2 large prybars inserted between chaincase To remove chaincase proceed as follows. housing no. 7 and frame, pry complete assembly Remove battery and battery rack (if so equipped) from vehicle.

  • Page 265: Installation And Assembly

    Section 06 TRANSMISSION Subsection 06 (CHAINCASE) INSTALLATION AND ASSEMBLY This initial adjustment should provide 3 - 5 mm (1/8 - 13/64 in) free-play when measured at the Reverse removal and disassembly procedure and outer circumference of the brake disc. pay attention to the following. Replace oil seals, CAUTION: Free-play must not exceed 5 mm gaskets O-rings and drain plug.

  • Page 266: Adjustment

    Section 06 TRANSMISSION Subsection 06 (CHAINCASE) ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT. Track Tension and Alignment Refer to TRACK. mmr2004-Rev...

  • Page 267: Drive Chain

    DRIVE CHAIN SILENT CHAIN Only 13-plates wide type of silent chain is com- patible for REV series models. Do not use chain other that the 13-plates wide on REV series mod- els. Fit chain on top sprocket to make sure that you are using right one according to width.

  • Page 268: Electrical System

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION TIMING) IGNITION TIMING 593, 593 HO, 593 HO SDI and 793 HO Engines Normally ignition timing adjustment should not be required. It has been set at factory and it should remain correctly adjusted since every part is fixed and not adjustable.

  • Page 269: Checking Ignition Timing

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION TIMING) 1. Pointer 1. TIMING MARK IN LINE WITH POINTER END • With the TDC gauge indicating specified timing, CHECKING IGNITION TIMING scribe a mark on drive pulley inner half in line Use a timing light. with pointer end.

  • Page 270: Changing Timing

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION TIMING) Start the engine and point timing light on timing mark. Bring engine to 3500 RPM for a brief in- stant. TIMING ADVANCED BY ABOUT 2° CHANGING TIMING All Engine Types The timing mark must be aligned with pointer end. If such is not the case, note if timing is retarded or NOTE: To change the timing on the SDI engines, advanced.
  • Page 271 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION TIMING) MPEM Programmer NOTE: In fact the programmer takes a copy of all vehicle parameters scribed in MPEM. This All Engine Types except SDI copy will be modified within the programmer then Timing can also be changed using the MPEM pro- transferred to the MPEM.
  • Page 272 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION TIMING) Select YES using the key ↔. Press ENTER. Press ENTER. Select a timing correction factor corresponding to correction needed. Example: Timing mark as verified with a timing light at 3500 RPM was too early by 2°. The cor- rection factor programmed is no.
  • Page 273 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION TIMING) Scroll to no. 7 SAVE AND QUIT. O P E R A T I O N S U C C E S S F U L L P R E S S A N Y K E Y . . . A00A3EA Press any key.

  • Page 274: Spark Plugs

    Section 07 ELECTRICAL SYSTEM Subsection 02 (SPARK PLUGS) SPARK PLUGS DISASSEMBLY SPARK PLUG TIGHTENING TORQUE First unscrew the spark plug 1 turn. Clean the spark plug and cylinder head with pres- SPARK TORQUE MODEL surized air, then completely unscrew. PLUGS N•m (lbf•ft) WARNING All models...

  • Page 275: Battery

    Section 07 ELECTRICAL SYSTEM Subsection 03 (BATTERY) BATTERY NOTE: For manual start SDI models with a small battery/capacitor arrangement, refer to ENGINE MANAGEMENT SECTION. GENERAL Sealed valve regulated lead acid (VRLA) battery are used. They are non-spillable and maintenance reduced — no electrolyte level to be checked and readjusted.

  • Page 276: Battery Charge Testing

    Section 07 ELECTRICAL SYSTEM Subsection 03 (BATTERY) BATTERY CHARGE TESTING CAUTION: If battery becomes hot, stop charg- ing and allow it to cool before continuing. Voltmeter Test NOTE: Sealed VRLA batteries have an internal safety valve. If battery pressure increases due to NOTE: To determine the battery state of charge, overcharging, the valve opens to release excess these sealed batteries have to be tested with a...

  • Page 277: Cable Terminal Installation

    Section 07 ELECTRICAL SYSTEM Subsection 03 (BATTERY) Connect RED positive cable it to positive battery Follow the instructions provided with the crimp pli- terminal. Connect RED wire (coming from 30 A ers (P/N 529 035 730) to select the proper position fuse).
  • Page 278 Section 07 ELECTRICAL SYSTEM Subsection 03 (BATTERY) PROPERLY CRIMPED WIRE To verify, if the wire is properly crimped, apply some pulling force on wire and the terminal at the same time from both directions. CAUTION: Never solder the wire to the termi- nal.

  • Page 279: Electric Starter

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ELECTRIC STARTER) ELECTRIC STARTER REV Series Models with Electric Starting mmr2004-Rev...

  • Page 280: Removal

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ELECTRIC STARTER) REMOVAL – Disconnect BLACK (-) cable from battery. – Disconnect RED (+) cable from battery. WARNING Always disconnect BLACK (-) cable first and connect last. – Remove tuned pipe. – Disconnect RED cable from starter. –...

  • Page 281: Cleaning

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ELECTRIC STARTER) INSPECTION All Models except 4-Tec Engines Armature NOTE: An ohmmeter may be used for the follow- ing testing procedures, except for the one con- cerning the shorted windings in the armature. Check the commutator for roughness, burnt or scored surface.
  • Page 282 Section 07 ELECTRICAL SYSTEM Subsection 04 (ELECTRIC STARTER) Test for Ground Circuit in the Armature Test the Armature for Open Circuit Use growler test probes. Check between arma- Use growler test probes. Place one test probe ture core and the commutator bars. If growler on a commutator bar and the other test probe lamp turns on, bars are grounded.

  • Page 283: Assembly

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ELECTRIC STARTER) 1. Armature shaft 2. Snap ring 3. Collar 4. Punch 1. Roller bearing 2. Positive brush Starter Housing Assembly and Starter Housing Align previously traced indexing marks. Overrunning Clutch The pinion of the overrunning clutch should turn smoothly in a clockwise direction, and should not slip in a counterclockwise direction.

  • Page 284: Installation

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ELECTRIC STARTER) 1. Brush holder To ease end frame installation, retain brush holder with a small screwdriver while installing armature assembly. CAUTION: Make sure to place two end hous- ings on a flat surface before tightening the through bolts.

  • Page 285: Testing Procedure

    Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system. CHARGING IGNITION MODELS SYSTEM SYSTEM OUTPUT All REV liquid BOMBARDIER cooled except DC 360 W SDI models BOMBARDIER SDI models DC 480 W mmr2004-Rev...
  • Page 286 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) Bombardier DC 360 W 693 engines 1. MPEM 2. Ignition coil 3. Trigger coils mmr2004-Rev...
  • Page 287 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) Bombardier DC 480 W 1. ECM 2. Ignition coil 3. Trigger coil mmr2004-Rev...

  • Page 288: Checking Calibration Program

    Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) CHECKING CALIBRATION Multi-Purpose Electronic Module (MPEM) Connections PROGRAM Bombardier 360 W Using VCK (Vehicle Communication Kit) All Models The VCK (P/N 529 035 981 ) can be used with the B.U.D.S. software to check the calibration. De- tailed information about the B.U.D.S.
  • Page 289 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) NOTE: In fact the programmer takes a copy of all vehicle parameters scribed in MPEM. This copy will be modified within the programmer then transferred to the MPEM. Select no. 4. ENGINE PARAMETER. TYPICAL Select no.
  • Page 290 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) Check for proper calibration number. See table Stop engine when using WITH ENGINE RUNNING below. procedure. Select NO and press ENTER. Press MENU twice; ← Trs then turn off program- mer, unplug it from MPEM. Remove 9-volt adap- tor.

  • Page 291: Changing Mpem Calibration Program

    Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) CHANGING MPEM CALIBRATION PROGRAM T R A N S F E R Using VCK (Vehicle Communication Kit) All Models V E R I F Y The VCK (P/N 295 035 981) can be used with the B.U.D.S.

  • Page 292: System Testing

    Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) The reading must be 3 times within or above the range indicated in the corresponding table. If the reading is too low, the part is considered to be defective and must be replaced. •...
  • Page 293 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) Disconnect all switches from the main wiring har- ness and check the continuity of each wire by con- necting probes to the end of wires of the same color. Repeat with all other wires. It is impor- tant to mention that all wires of the same color within a given harness are connected together.
  • Page 294 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) – Activate the manual starter and check values indicated by the multimeter. – Repeat operation 3 times. – Compare readings with those appearing in the IGNITION table. 5. Trigger Coil Testing Resistance Testing –...
  • Page 295 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) – Connect other multimeter wire to engine Connect battery negative post to buzzer negative (ground), then place selector switch to V and tab. See next photo. scale to 0.00 Vac. CAUTION: To avoid buzzer damage, ensure that polarity is respected.
  • Page 296 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) TYPICAL – Compare readings with those appearing in the LIGHTING table. Conclusion If none of the above testing operations produced valid results, it is strongly recommended to keep on testing according to the list appearing in the RESISTANCE column of IGNITION or LIGHTING table.
  • Page 297 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) NOTE: For the 480 W models, use B.U.D.S. software. 360 W MODEL (ignition and electrical system testing) MULTIMETER RESISTANCE VOLTAGE V TEST TO BE WIRE PART PROBE NOTE MULTIMETER VALUE MULTIMETER VALUE PERFORMED COLOR CONNECTION...
  • Page 298 Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) 360 W MODEL (ignition and electrical system testing) MULTIMETER RESISTANCE VOLTAGE V TEST TO BE WIRE PART PROBE NOTE MULTIMETER VALUE MULTIMETER VALUE PERFORMED COLOR CONNECTION SCALE (ohms) SCALE (volt) Primary winding WH/BU 11–DC-2–F 00.0...

  • Page 299: Inspection Of Heating Elements

    Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) 360 W MODEL (ignition and electrical system testing) MULTIMETER RESISTANCE VOLTAGE V TEST TO BE WIRE PART PROBE NOTE MULTIMETER VALUE MULTIMETER VALUE PERFORMED COLOR CONNECTION SCALE (ohms) SCALE (volt) WH/GN 5–RC-85–F 10.5 to Coil —...

  • Page 300: Headlight And Accessories System Testing

    Section 07 ELECTRICAL SYSTEM Subsection 05 (TESTING PROCEDURE) HEADLIGHT AND ACCESSORIES SYSTEM TESTING 360 W Models Only Make an homemade adaptor as shown below. 1. Black wire in position no. 1 2. Red wire in position no. 2 3. P/N 278 001 671 4.

  • Page 301: Rear Suspension

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 SUSPENSION) SC-10 SUSPENSION 4 N•m (35 lbf•in) mmr2004-Rev...
  • Page 302 Section 08 REAR SUSPENSION Subsection 01 (SC-10 SUSPENSION) mmr2004-Rev...
  • Page 303 Section 08 REAR SUSPENSION Subsection 01 (SC-10 SUSPENSION) mmr2004-Rev...

  • Page 304: Component Removal And Installation

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 SUSPENSION) COMPONENT REMOVAL AND INSTALLATION Lift rear of vehicle and support it off the ground. Rear Axle Remove screw on rear axle no. 21 on side of off- set wheel. Completely loosen track tension. Pull out rear axle from opposite side of offset inner wheel.

  • Page 305: Suspension Assembly Removal

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 SUSPENSION) Remove the front idler wheels to gain access to the axle retaining self-locking screws no. 6. Fol- low the instructions provided in this section to un- fasten these screws. Slide out the axle and re- move the shock.
  • Page 306 Section 08 REAR SUSPENSION Subsection 01 (SC-10 SUSPENSION) 1. Stroke limiter on rear side Outer Bushing At installation, hole of outer bushing no. 10 must face adjustment screw. A01B4LA 1. Clevis pin 2. Bar 3. Handle placed horizontally Front Shock, Spring Stopper and Cap Use shock spring remover (P/N 529 035 504) and put it in a vise.

  • Page 307: Shock Absorber Inspection

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 SUSPENSION) RIGHT SIDE SHOWN 1. Right position: upward 2. Wrong position ALL MODELS EXCEPT SUMMIT LIQUID COOLED MODELS 1. 1 hole SHOCK ABSORBER INSPECTION 2. 2 hole A. 7 N•m (62 lbf• in ) All Models Equipped with Hydraulic Shock Slider Shoe NOTE: Hydraulic shocks are painted black.

  • Page 308: Installation

    Section 08 REAR SUSPENSION Subsection 01 (SC-10 SUSPENSION) Renew if any faults are present. All Models Equipped with Gas Pressurized Shock NOTE: Gas pressurized shocks are light gray or purple painted, or bare aluminum. Gas shock can be inspected as follows: Because of gas pressure, strong resistance is felt when compressing shock.
  • Page 309 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) SC-10 III SUSPENSION SC-10 III mmr2004-Rev...
  • Page 310 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) mmr2004-Rev...
  • Page 311 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) Models with up side down shocks mmr2004-Rev...

  • Page 312: Component Removal And Installation

    Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) COMPONENT REMOVAL AND INSTALLATION Lift rear of vehicle and support it off the ground. Rear Axle Remove screw on rear axle no. 21 on side of off- set wheel. Completely loosen track tension. Pull out rear axle from opposite side of offset inner wheel.

  • Page 313: Suspension Assembly Removal

    Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) SUSPENSION ASSEMBLY Rear Spring REMOVAL Decrease spring preload by turning cams no. 19 accordingly. Slightly turn adjusting cam to expose spring end. Lift rear of vehicle and support it off the ground. Using spring installer (P/N 529 005 000), remove both springs from adjusting cams.

  • Page 314: Disassembly And Assembly

    Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) Lift rear of vehicle at least 1 m (3 ft). Remove suspension. TYPICAL A. At least 1 m (3 ft) DISASSEMBLY AND ASSEMBLY Models with SC-10 III 121 in Suspension Inspect track thoroughly before reinstalling sus- In case of gas pressure shocks, to facilitate the pension.
  • Page 315 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) 1. Protrusion 2. Stoppers Center Rear Wheel and Top Idler Wheels Dowel Pin and Block Guide At installation on center rear wheel no. 13 and top idler wheels no. 14, circlip must face inner side. Dowel pin no.

  • Page 316: Shock Absorber Inspection

    Section 08 REAR SUSPENSION Subsection 02 (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 317: Hpg T/A Shock Servicing

    Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) Secure the shock body end in a vise with its rod Install shock in a vise clamping on its bottom eye- upward. let with its rod upward. Let it stand for 5 minutes. Completely push down the shock rod then re- lease.
  • Page 318 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) SERVICING SHOCK SIZE (P/N) TOOL Piston guide 529 026 600 Seal guide 529 026 500 C-36 Shock wrench 529 035 727 Piston guide 529 035 608 Seal guide 529 035 728 C-46 Shock wrench 529 035 727...
  • Page 319 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) Discard old oil into storage container. Never reuse damper oil during shock rebuild. All Types of Shocks except External Reservoir T/A Shocks Remove valve core. Using compressed air pressure, carefully remove floating piston from damper body.
  • Page 320 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) Place shock absorber in a position where external gas reservoir opened extremity is blocked. Refer to following photo. A06F0UA A. Remove damper nut Always arrange parts removed in the sequence of 1.
  • Page 321 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) NOTE: If revalving is to be done, it is imperative that you identify the original shim pack (size and number of shims). The seal carrier need not be removed if only revalving is to be done. Shims can be measured by using a vernier caliper or a micrometer.
  • Page 322 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) If floating piston has been removed, reinstall float- INSTALLATION ing piston into damper body (ensure that valve DISTANCE OF SHOCK P/N core has been removed). Use Molykote G-n paste FLOATING PISTON (P/N 711 297 433) to ease O-ring past damper body threads with floating piston guide.
  • Page 323 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) CAUTION: Moisture laden compressed air will NOTE: Some shock oil will overflow when in- contaminate the gas chamber and rust floating stalling damper. Wrap damper with shop cloth to piston. catch possible overflow oil. CAUTION: Use care when passing piston into WARNING damper body at damper body threads.
  • Page 324 Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) When removing and retightening the tire valve acorn nut use minimal torque. When the cap is 1. High pressure hose over tightened and subsequently removed it may 2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI) 3.

  • Page 325: Installation

    Section 08 REAR SUSPENSION Subsection 02 (SC-10 III SUSPENSION) Mount the shock on vise. Remove screw on top Damper gas pressure cannot be confirmed by of valve. Place the needle guide of gas refill tool using a pressure gauge. The volume of gas in the on the shock valve.

  • Page 326: Drive Axle

    Section 08 REAR SUSPENSION Subsection 03 (DRIVE AXLE) DRIVE AXLE mmr2004-Rev...

  • Page 327: Removal

    Section 08 REAR SUSPENSION Subsection 03 (DRIVE AXLE) REMOVAL Remove battery (if so equipped) to gain access, refer to BATTERY section. Drain oil from chaincase. Remove chaincase cover. Release drive chain tension. 1. Circlip Apply parking brake. Remove chain and sprockets then circlip from right side.

  • Page 328: Assembly

    Section 08 REAR SUSPENSION Subsection 03 (DRIVE AXLE) ASSEMBLY Drive Axle and Sprocket To assemble press fit sprockets no. 5, 6, use a press and a suitable pipe as illustrated. Sprockets must be assembled according to the following di- mensions measured from drive axle end. SUMMIT X AND HIGHMARK X 1.

  • Page 329: Lubrication

    Section 08 REAR SUSPENSION Subsection 03 (DRIVE AXLE) SUMMIT ADRENALINE/SPORT AND HIGHMARK 1. Measure from end of drive axle A. 48.3 mm (1.90 in) B. 150.8 mm (5.94 in) C. 273.8 mm (10.78 in) Ensure to align indexing marks of each sprocket when assembling.

  • Page 330: Adjustment

    Section 08 REAR SUSPENSION Subsection 03 (DRIVE AXLE) 1. Lubricate until grease flows out here ADJUSTMENT Sprocket/Track Alignment CAUTION: Do not tamper with sprocket/track alignment if frame or suspension is damaged. Sprockets may be repositioned to fit lugs without removing drive axle. Use drive axle sprocket adjuster kit (P/N 861 725 700).

  • Page 331: Track

    Section 08 REAR SUSPENSION Subsection 04 (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 332 Section 08 REAR SUSPENSION Subsection 04 (TRACK) Alignment WARNING Before checking track alignment, ensure that the track is free of all particles which could be thrown out while track is rotating. Keep hands, tools, feet and clothing clear of track. Ensure no one is standing in close proximity to the vehicle.
  • Page 333 Section 08 REAR SUSPENSION Subsection 04 (TRACK) Restart engine, rotate track 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). Reinstall the wheel caps. Track Cleat Removal –...

  • Page 334: Steering/Front Suspension

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) STEERING SYSTEM GSX Series, Summit Adrenaline/Sport/Highmark Some models Some models Some models mmr2004-Rev...
  • Page 335 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) MX Z 500 SS/600 HO/800 HO, Summit X/Highmark X/Highmark Xtreme mmr2004-Rev...

  • Page 336: Disassembly And Assembly

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) DISASSEMBLY AND ASSEMBLY CAUTION: Pay attention not to damage wires with the wrench. Grip Using a plastic hammer, tap on the side of the wrench end to make the grip slide out. NOTE: These models feature an integrated heat- ing element in the plastic sleeve of the grip no.
  • Page 337 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) MODEL TOOL PART NUMBER Models with straight 529 035 897 grips Models with J-hooks 529 035 936 1. Connectors unplugged Unplug LH harness on top of steering column. Cut locking ties retaining brake light switch/heat- ing grip harness to handlebar.
  • Page 338 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Reinstall terminals and replug connectors. Test Grease fitting no. 16 of swivel arms no. 14 must grips to ensure they heat properly. face toward center of vehicle. Steering Column Unfasten windshield. Remove cap no. 3 or steer- ing padding no.

  • Page 339: Inspection

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Heating Grip Element Refer to TESTING PROCEDURE for checking heating element no. 13 of grip. Ball Joint (left hand and right hand threads) Inspect ball joint ends no. 17 and no. 18 and small tie rod ends for wear or looseness, if excessive, replace them.
  • Page 340 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) TYPICAL 1. Large connector housings Remove console. 1. Cap Remove 2 bolts no. 5 retaining top of steering col- 2. Console cap umn. Unscrew 4 bolts retaining console. STEERING COLUMN IN REARWARD POSITION 1.
  • Page 341 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) ONE SIDE SHOWN — FORWARD POSITION 1. Bolts retaining windshield assembly STEERING COLUMN IN FORWARD POSITION 1. Longer bolt Readjust throttle lever housing no. 21 and switch housing accordingly to optimal angle so that you Reinstall the 2 bolts no.
  • Page 342 Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) 1. Torque to 25 N•m (18 lbf•ft) A. Equal gap all around CAUTION: Tighten the bolts equally in a criss- 1. Opening here cross sequence and ensure there is an equal 2. Extension against stopper gap on each side of the clamps no.

  • Page 343: Steering Adjustment (Skis)

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Retaining clip and hardware must be installed in the same position on both strap ends. J-Hook Adjustment Some Models Position J-hook so that its curved end is pointing downward and is roughly vertical. Ensure to ad- just J-hooks at the same position each side.
  • Page 344 TOTAL TOE-OUT MODEL ± 1 mm (± 3/64 in) 2 (5/64) All REV Series NOTE: To reduce tolerance when measuring, set one ski to proper toe-out (half the total toe-out) then measure from that ski to the opposite ski. mmr2004-Rev...

  • Page 345: Lubrication

    Section 09 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) RIGHT HAND SIDE SHOWN 1. Ski leg 2. Lower arm A. 2 mm (5/64 in) If the distance is more than the specified distance on one side then check for bent parts. LUBRICATION WARNING Do not lubricate throttle cable or housing.

  • Page 346: Front Suspension

    Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) FRONT SUSPENSION REV Series Summit models mmr2004-Rev...

  • Page 347: General Inspection

    Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) NOTE: The same procedure applies on both sides. Reduce spring preload by turning adjusting ring towards position 1 and continue until it stops. GENERAL INSPECTION Check for looseness, bent, worn out, rusted or other damage on components.
  • Page 348 Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) For shock absorber spring disassembly use shock absorber spring remover (P/N 529 035 504) in a vise. Mount shock absorber in it and turn shock absorber so that spring coils match spring com- pressor.
  • Page 349 Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) TYPICAL TYPICAL 1. Ball joint parallel with ski leg Remove lower arm no. 14 from frame. For front screw no. 17 removal, hold nut no. 18 from engine compartment. To remove ball joint, proceed as follows: –...
  • Page 350 Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Tie Rod Stabilizer Bar Refer to STEERING SYSTEM section and remove Remove shock absorbers, stabilizer bar slider tie rod from ski leg. blocks and unfasten lower ball joints from ski legs. Upper Arm Remove screws no.

  • Page 351: Inspection

    Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Lift front of vehicle enough so that stabilizer bar Check for straightness of lower and upper arms. no. 7 can be rotated downward to allow to slide it Replace as required. out. Check condition of ball joints.
  • Page 352 Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) 1. Install bushing as shown Lower Arm Position lower arm below stabilizer bar. Prior to installing ball joint in lower arm, ensure to clean the tapered surfaces with the Pulley flange cleaner product (P/N 413 711 809). Surface con- tacts must be clean and free of dirt, oil and grease.
  • Page 353 Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) To properly torque ball joint nut, use the A-arm nut wrench (P/N 529 035 876). Ensure to install the tool perpendicularly (90°) to torque wrench. TYPICAL Stabilizer Bar Notice that LH and RH sliding blocks are different. 1.
  • Page 354 Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) – Install screws and nuts. GSX and MX Z Trail – Ensure blocks slide easily when compressing and releasing suspension. MX Z Adrenaline and Renegade 1. Temporarily rotate block by 180° for its insertion 1.
  • Page 355 Section 09 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) MX Z X/Renegade X/Trail — Europe WARNING Install skis with proper side facing inward. Refer to warning on ski. Adjustment All Models Proceed with ski alignment. Refer to STEERING SYSTEM. Summit Readjust spring preload. Apply suspension synthetic grease (P/N 293 550 033) between bushing no.

  • Page 356: 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, proceed as follows. Remove windshield. See below. Beam aiming is correct when center of high beam Pull out steering support cap. 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 357: Decal

    Section 10 BODY/FRAME Subsection 01 (BODY) DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully po- sition the decal.

  • Page 358: Guard

    Section 10 BODY/FRAME Subsection 01 (BODY) CABLES WARNING Before installation, ensure that all cables are in perfect condition. Properly install the cable ends and secure them in place. Pay attention to route them properly, away from any rotat- ing, moving, heating or vibrating parts. TUBING WARNING Always ensure that the fuel, vent, primer, im-...

  • Page 359: Repair

    Section 10 BODY/FRAME Subsection 01 (BODY) – strong detergents – abrasive cleaners – waxes containing an abrasive or a cleaning agent in their formula. Apply wax on glossy finish only. Protect the ve- hicle with a cover to prevent dust accumulation during storage.

  • Page 360: Frame

    Section 10 BODY/FRAME Subsection 02 (FRAME) FRAME FRAME CLEANING CAUTION: If welding is to be done near plastic material, it is recommended to either remove NOTE: For bare aluminum frames use only the part from the area or to protect it with alu- aluminum cleaner and follow instructions on con- minum foil to prevent damage.

  • Page 361: Technical Data

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

  • Page 362: Engines

    Section 11 TECHNICAL DATA Subsection 02 (ENGINES) ENGINES GSX Sport GSX 500 SS Sport, GSX 600 HO Sport and GSX 600 HO SDI Sport 500 SS 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. CAN/U.S. Engine Type 593 HO 593 SDI ENGINE Number of cylinder Bore...
  • Page 363 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) GSX Sport GSX 500 SS Sport, GSX 600 HO Sport and GSX 600 HO SDI Sport 500 SS 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. CAN/U.S. Engine Type 593 HO 593 SDI FUEL SYSTEM Dell’Orto without Carburetor/throttle body type...
  • Page 364 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) GSX Limited GSX 600 HO SDI Limited and GSX 800 HO Limited 600 HO SDI 800 HO Country CAN/U.S. CAN/U.S. Engine Type 593 SDI 793 HO ENGINE Number of cylinder Bore Standard mm (in) 72 (2.835) 82 (3.228) Stroke...
  • Page 365 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) GSX Limited GSX 600 HO SDI Limited and GSX 800 HO Limited 600 HO SDI 800 HO Country CAN/U.S. CAN/U.S. Engine Type 593 SDI 793 HO FUEL SYSTEM Carburetor/throttle body type PTO/MAG Dell’Orto without IACV TM40–B292 Main jet PTO/MAG...
  • Page 366 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ 500 SS Adrenaline and MXZ 500 SS Trail 500 SS Adrenaline 500 SS Trail 500 SS Trail Country CAN/U.S. CAN/U.S. EUROPE Engine Type ENGINE Number of cylinder Bore Standard mm (in) 76 (2.992) Stroke mm (in) 65.80 (2.591)
  • Page 367 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ 500 SS Adrenaline and MXZ 500 SS Trail 500 SS Adrenaline 500 SS Trail 500 SS Trail Country CAN/U.S. CAN/U.S. EUROPE Engine Type FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40 – B289 Main jet PTO/MAG Needle jet...
  • Page 368 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ Adrenaline MXZ 600 HO Adrenaline and MXZ 600 HO SDI Adrenaline 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. Engine Type 593 HO 593 SDI ENGINE Number of cylinder Bore Standard mm (in) 72 (2.835) Stroke mm (in)
  • Page 369 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ Adrenaline MXZ 600 HO Adrenaline and MXZ 600 HO SDI Adrenaline 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. Engine Type 593 HO 593 SDI FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40–B292 Dell’Orto without IACV Main jet PTO/MAG...
  • Page 370 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ Renegade MXZ 600 HO Renegade 600 HO 600 HO Country CAN/U.S. EUROPE Engine Type 593 HO ENGINE Number of cylinder Bore Standard mm (in) 72 (2.835) Stroke mm (in) 73.00 (2.874) Displacement 594.40 (36.273) Compression ratio 12.25 ±...
  • Page 371 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ Renegade MXZ 600 HO Renegade 600 HO 600 HO Country CAN/U.S. EUROPE Engine Type 593 HO FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40–B238 Main jet PTO/MAG Needle jet PTO/MAG Pilot jet PTO/MAG 17.5 Needle identification PTO/MAG...
  • Page 372 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ Renegade X MXZ 600 HO Renegade X and MXZ 600 HO SDI Renegade X 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. Engine Type 593 HO 593 SDI ENGINE Number of cylinder Bore Standard mm (in)
  • Page 373 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ Renegade X MXZ 600 HO Renegade X and MXZ 600 HO SDI Renegade X 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. Engine Type 593 HO 593 SDI FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40–B238 Dell’Orto without IACV...
  • Page 374 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ 600 HO Trail, MXZ 600 HO X and MXZ 600 HO SDI X 600 HO Trail 600 HO X 600 HO SDI X Country CAN/U.S. CAN/U.S. CAN/U.S. Engine Type 593 HO 593 SDI ENGINE Number of cylinder Bore...
  • Page 375 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ 600 HO Trail, MXZ 600 HO X and MXZ 600 HO SDI X 600 HO Trail 600 HO X 600 HO SDI X Country CAN/U.S. CAN/U.S. CAN/U.S. Engine Type 593 HO 593 SDI FUEL SYSTEM Dell’Orto without Carburetor/throttle body type...
  • Page 376 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ X MXZ 600 HO X and MXZ 600 HO SDI X 600 HO 600 HO SDI Country EUROPE EUROPE Engine Type 593 HO 593 SDI ENGINE Number of cylinder Bore Standard mm (in) 72 (2.835) Stroke mm (in)
  • Page 377 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ X MXZ 600 HO X and MXZ 600 HO SDI X 600 HO 600 HO SDI Country EUROPE EUROPE Engine Type 593 HO 593 SDI FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40–B238 Dell’Orto without IACV Main jet PTO/MAG...
  • Page 378 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ Adrenaline MXZ 800 HO Adrenaline and MXZ 800 HO DPM Adrenaline 800 HO 800 HO DPM Country CAN/U.S. CAN/U.S. Engine Type 793 HO ENGINE Number of cylinder Bore Standard mm (in) 82 (3.228) Stroke mm (in) 75.70 (2.980)
  • Page 379 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ Adrenaline MXZ 800 HO Adrenaline and MXZ 800 HO DPM Adrenaline 800 HO 800 HO DPM Country CAN/U.S. CAN/U.S. Engine Type 793 HO FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40–B292 Main jet PTO/MAG Needle jet PTO/MAG...
  • Page 380 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ 800 HO Renegade and MXZ 800 HO Renegade X 800 HO Renegade 800 HO Renegade 800 HO Renegade X Country CAN/U.S. CAN/U.S. EUROPE Engine Type 793 HO ENGINE Number of cylinder Bore Standard mm (in) 82 (3.228)
  • Page 381 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ 800 HO Renegade and MXZ 800 HO Renegade X 800 HO Renegade 800 HO Renegade 800 HO Renegade X Country CAN/U.S. CAN/U.S. EUROPE Engine Type 793 HO FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40 –...
  • Page 382 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ X MXZ 800 HO X 800 HO 800 HO Country CAN/U.S. EUROPE Engine Type 793 HO ENGINE Number of cylinder Bore Standard mm (in) 82 (3.228) Stroke mm (in) 75.70 (2.980) Displacement 799.20 (48.770) Compression ratio 12.00 ±...
  • Page 383 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) MXZ X MXZ 800 HO X 800 HO 800 HO Country CAN/U.S. EUROPE Engine Type 793 HO FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40–B292 Main jet PTO/MAG Needle jet PTO/MAG Pilot jet PTO/MAG 17.5 Needle identification PTO/MAG...
  • Page 384 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) Summit Summit 600 HO Adrenaline and Summit 600 HO X 600 HO Adrenaline 600 HO Adrenaline 600 HO X Country CAN/U.S. EUROPE CAN/U.S. Engine Type 593 HO ENGINE Number of cylinder Bore Standard mm (in) 72 (2.835) Stroke...
  • Page 385 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) Summit Summit 600 HO Adrenaline and Summit 600 HO X 600 HO Adrenaline 600 HO Adrenaline 600 HO X Country CAN/U.S. EUROPE CAN/U.S. Engine Type 593 HO FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40 –...
  • Page 386 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) Summit Summit 800 HO Adrenaline and Summit 800 HO X 800 HO Adrenaline 800 HO X 800 HO X Country CAN/U.S. CAN/U.S. EUROPE Engine Type 793 HO ENGINE Number of cylinder Bore Standard mm (in) 82 (3.228) Stroke...
  • Page 387 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) Summit Summit 800 HO Adrenaline and Summit 800 HO X 800 HO Adrenaline 800 HO X 800 HO X Country CAN/U.S. CAN/U.S. EUROPE Engine Type 793 HO FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40 –...
  • Page 388 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) Summit 800 HO Highmark, Summit 800 HO Highmark Summit 800 HO X and Summit 800 HO Highmark Xtrem Highmark Highmark X Highmark Xtreme Country CAN/U.S. CAN/U.S. CAN/U.S. Engine Type 793 HO ENGINE Number of cylinder Bore Standard mm (in)
  • Page 389 Section 11 TECHNICAL DATA Subsection 02 (ENGINES) Summit 800 HO Highmark, Summit 800 HO Highmark Summit 800 HO X and Summit 800 HO Highmark Xtrem Highmark Highmark X Highmark Xtreme Country CAN/U.S. CAN/U.S. CAN/U.S. Engine Type 793 HO FUEL SYSTEM Carburetor/throttle body type PTO/MAG TM40 –...

  • Page 390: Vehicles

    Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) VEHICLES GSX Sport GSX 500 SS Sport, GSX 600 HO Sport and GSX 600 HO SDI Sport 500 SS 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. CAN/U.S. DRIVE Chain drive ratio 22/43 Pitch Chain Type/links qty/plate qty...
  • Page 391 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) GSX Sport GSX 500 SS Sport, GSX 600 HO Sport and GSX 600 HO SDI Sport 500 SS 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. CAN/U.S. Starter solenoid Fuse Fuel level sensor CAPACITIES Fuel tank L (U.S.
  • Page 392 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) GSX Limited GSX 600 HO SDI Limited and GSX 800 HO Limited 600 HO SDI 800 HO Country CAN/U.S. CAN/U.S. DRIVE Chain drive ratio 22/43 26/45 Pitch Chain Type/links qty/plate qty Silent 74/13 Silent 76/13 Type TRA III...
  • Page 393 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) GSX Limited GSX 600 HO SDI Limited and GSX 800 HO Limited 600 HO SDI 800 HO Country CAN/U.S. CAN/U.S. ELECTRICAL Battery 12 V, 18 A•h Headlamp 60/55 (H4) Taillight and stoplight 8/27 Tachometer and speedometer bulbs 2 x 3 Fuel and temperature gauge bulbs...
  • Page 394 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ 500 SS Adrenaline and MXZ 500 SS Trail 500 SS 500 SS Trail 500 SS Trail Adrenaline Country CAN/U.S. CAN/U.S. EUROPE DRIVE Chain drive ratio 22/43 Pitch Chain Type/links qty/plate qty Silent 74/13 Type TRA III Clutch engagement...
  • Page 395 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ 500 SS Adrenaline and MXZ 500 SS Trail 500 SS 500 SS Trail 500 SS Trail Adrenaline Country CAN/U.S. CAN/U.S. EUROPE Starter solenoid (with electric starter) — Fuse Fuel level sensor — CAPACITIES Fuel tank L (U.S.
  • Page 396 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ Adrenaline MZX 600 HO Adrenaline and MXZ 600 HO SDI Adrenaline 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. DRIVE Chain drive ratio 22/43 Pitch Chain Type/links qty/plate qty Silent 74/13 Type TRA III Clutch engagement 3800 ±...
  • Page 397 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ Adrenaline MZX 600 HO Adrenaline and MXZ 600 HO SDI Adrenaline 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. ELECTRICAL Battery (if so equipped) 12 V, 18 A•h Headlamp 60/55 (H4) Taillight and stoplight 8/27 Tachometer and speedometer bulbs 2 x 3...
  • Page 398 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ Renegade MZX 600 HO Renegade 600 HO 600 HO Country CAN/U.S. EUROPE DRIVE 22/43 21/43 Chain drive ratio 19/43 (10) — Pitch Chain Silent 74/13 Type/links qty/plate qty Silent 72/13 (10) — Type TRA III Clutch engagement...
  • Page 399 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ Renegade MZX 600 HO Renegade 600 HO 600 HO Country CAN/U.S. EUROPE ELECTRICAL Battery 12 V, 18 A•h — Headlamp 60/55 (H4) Taillight and stoplight 8/27 Tachometer and speedometer bulbs 2 x 3 Fuel and temperature gauge bulbs —...
  • Page 400 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ Renegade X MZX 600 HO Renegage X and MXZ 600 HO SDI Renegade X 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. DRIVE 22/43 21/43 Chain drive ratio 19/43 (10) Pitch Chain Silent 74/13 Type/links qty/plate qty Silent 72/13...
  • Page 401 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ Renegade X MZX 600 HO Renegage X and MXZ 600 HO SDI Renegade X 600 HO 600 HO SDI Country CAN/U.S. CAN/U.S. ELECTRICAL Battery (if so equipped) 12 V, 18 A•h Headlamp 60/55 (H4) Taillight and stoplight 8/27...
  • Page 402 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ 600 HO Trail, MXZ 600 HO X and MXZ 600 HO SDI X 600 HO Trail 600 HO X 600 HO SDI X Country CAN/U.S. CAN/U.S. CAN/U.S. DRIVE Chain drive ratio 22/43 Pitch Chain Type/links qty/plate qty...
  • Page 403 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ 600 HO Trail, MXZ 600 HO X and MXZ 600 HO SDI X 600 HO Trail 600 HO X 600 HO SDI X Country CAN/U.S. CAN/U.S. CAN/U.S. Tachometer and speedometer bulbs 2 x 3 Fuel and temperature gauge bulbs —...
  • Page 404 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ X MZX 600 HO X and MXZ 600 HO SDI X 600 HO 600 HO SDI Country EUROPE EUROPE DRIVE Chain drive ratio 22/43 Pitch Chain Type/links qty/plate qty Silent 74/13 Type TRA III Clutch engagement 3800 ±...
  • Page 405 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ X MZX 600 HO X and MXZ 600 HO SDI X 600 HO 600 HO SDI Country EUROPE EUROPE ELECTRICAL Battery — Headlamp 60/55 (H4) Taillight and stoplight 8/27 Tachometer and speedometer bulbs 2 x 3 Fuel and temperature gauge bulbs —...
  • Page 406 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ Adrenaline MZX 800 HO Adrenaline and MXZ 800 HO DPM Adrenaline 800 HO 800 HO DPM Country CAN/U.S. CAN/U.S. DRIVE Chain drive ratio 26/45 Pitch Chain Type/links qty/plate qty Silent 76/13 Type TRA III Clutch engagement 3800 ±...
  • Page 407 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ Adrenaline MZX 800 HO Adrenaline and MXZ 800 HO DPM Adrenaline 800 HO 800 HO DPM Country CAN/U.S. CAN/U.S. ELECTRICAL Battery (if so equipped) 12 V, 18 A•h Headlamp 60/55 (H4) Taillight and stoplight 8/27 Tachometer and speedometer bulbs 2 x 3...
  • Page 408 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ 800 HO Renegade and MXZ 800 HO Renegade X 800 HO Renegade 800 HO Renegade 800 HO Renegade Country CAN/U.S. CAN/U.S. EUROPE DRIVE 23/43 — Chain drive ratio 22/43 (10) Pitch Chain Type/links qty/plate qty Silent 74/13 Type...
  • Page 409 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ 800 HO Renegade and MXZ 800 HO Renegade X 800 HO Renegade 800 HO Renegade 800 HO Renegade Country CAN/U.S. CAN/U.S. EUROPE Starter solenoid (with electric starter) Fuse Fuel level sensor CAPACITIES Fuel tank L (U.S.
  • Page 410 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ X MZX 800 HO X 800 HO 800 HO Country CAN/U.S. EUROPE DRIVE Chain drive ratio 26/45 Pitch Chain Type/links qty/plate qty Silent 76/13 Type TRA III Clutch engagement 3800 ± 100 Spring color Violet/Green Spring length...
  • Page 411 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) MXZ X MZX 800 HO X 800 HO 800 HO Country CAN/U.S. EUROPE ELECTRICAL Battery (if so equipped) 12 V, 18 A•h Headlamp 60/55 (H4) Taillight and stoplight 8/27 Tachometer and speedometer bulbs 2 x 3 Fuel and temperature gauge bulbs —...
  • Page 412 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) Summit Summit 600 HO Adrenaline and Summit 600 HO X 600 HO 600 HO 600 HO X Adrenaline Adrenaline Country CAN/U.S. EUROPE CAN/U.S. DRIVE Chain drive ratio 19/45 19/43 19/45 Pitch Chain Type/links qty/plate qty Silent 74/13 Silent 72/13 Silent 74/13...
  • Page 413 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) Summit Summit 600 HO Adrenaline and Summit 600 HO X 600 HO 600 HO 600 HO X Adrenaline Adrenaline Country CAN/U.S. EUROPE CAN/U.S. CAPACITIES Fuel tank L (U.S. gal) 36 (9.5) Chaincase/gearbox mL (U.S. oz) 250 (8.5) Cooling system L (U.S.
  • Page 414 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) Summit Summit 800 HO Adrenaline and Summit 800 HO X 800 HO 800 HO X 800 HO X Adrenaline Country CAN/U.S. CAN/U.S. EUROPE DRIVE Chain drive ratio 19/45 21/45 Pitch Chain Type/links qty/plate qty Silent 74/13 Type TRA III...
  • Page 415 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) Summit Summit 800 HO Adrenaline and Summit 800 HO X 800 HO 800 HO X 800 HO X Adrenaline Country CAN/U.S. CAN/U.S. EUROPE CAPACITIES Fuel tank L (U.S. gal) 36 (9.5) Chaincase/gearbox mL (U.S. oz) 250 (8.5) Cooling system L (U.S.
  • Page 416 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) Summit 800 HO Highmark, Summit 800 HO Highmark X Summit 800 HO and Summit 800 HO Highmark Xtrem Highmark Highmark X Highmark Xtrem Country CAN/U.S. CAN/U.S. CAN/U.S. DRIVE Chain drive ratio 19/45 19/43 Pitch Chain Type/links qty/plate qty...
  • Page 417 Section 11 TECHNICAL DATA Subsection 03 (VEHICLES) Summit 800 HO Highmark, Summit 800 HO Highmark X Summit 800 HO and Summit 800 HO Highmark Xtrem Highmark Highmark X Highmark Xtrem Country CAN/U.S. CAN/U.S. CAN/U.S. Fuel tank L (U.S. gal) 36 (9.5) Chaincase/gearbox mL (U.S.

  • Page 418: Technical Data Legends

    Section 11 TECHNICAL DATA Subsection 04 (TECHNICAL DATA LEGENDS) TECHNICAL DATA LEGENDS ENGINE LEGEND Drive pulley retaining screw: torque to 80 to 100 N•m (59 to 74 lbf•ft), install drive belt, accelerate the vehicle at low speed ABDC: After Bottom Dead Center (maximum 30 km/h (20 MPH)) and apply the ATDC: After Top Dead Center...

  • Page 419: Vehicle Legend

    Section 11 TECHNICAL DATA Subsection 04 (TECHNICAL DATA LEGENDS) VEHICLE LEGEND N.A.: Not Applicable R.A.S. Response Angle Suspension RER: Rotax Electronic Reverse RRIM: Reinforced Reaction Injection Molding TRA: Total Range Adjustable VSA: Variable Sheave Angle Force applied midway between pulleys to obtain specified tension deflection.

  • Page 420: Wiring Diagram

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS Wiring diagrams can be found at the end of this subsection. WIRING DIAGRAM LEGEND WARNING Ensure all terminals are properly crimped on the wires and all connector housings are The following illustration shows the snowmobile properly fastened.

  • Page 421: Wire Location In Connector Housing

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) WIRE LOCATION IN CONNECTOR HOUSING The third portion of the connector identification number represents the location of the wire in the connector housing. This could be identified by ei- ther a number such as 1, 2, 3 or by a letter such as A, B, C depending on the type of connector used.
  • Page 422 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 10 9 mmr2004-Rev...

  • Page 423: Symbols Description

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) SYMBOLS DESCRIPTION mmr2004-Rev...

  • Page 424: Unpluging Connectors

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 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 425 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 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 426 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) MALE CONNECTOR HOUSING — CUT-AWAY 1. Lock 24-Circuit Connector Housing Push on both tabs to remove retainer. FEMALE CONNECTOR HOUSING — CUT-AWAY 1. Lock Receptacle connectors can be removed from fe- male housing with sharp head pin. Male Connector Housing 1.
  • Page 427 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 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. 8-CIRCUIT CONNECTOR HOUSING — CUT-AWAY 1.
  • Page 428 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 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 429 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 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 430: Tab And Receptacle Connectors Installation

    Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 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.
  • Page 431 Section 12 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) mmr2004-Rev...

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