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Ski-Doo Tundra II LT 1997 Shop Manual

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Page 2 Section 00 Sub-Section 0 () ® 1997 Shop Manual VOLUME 1 TUNDRA II LT TOURING E / LE / LE LT / SLE FORMULA S / SL SKANDIC 380 / 500 00-0-1...
Page 3 Section 00 Sub-Section 0 (1997 SHOP MANUAL) Legal deposit : National Library of Quebec trimester 1996 National Library of Canada1996 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. ©...
Page 4: Table Of Contents
TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE ..........................1997 BOMBARDIER SNOWMOBILES SHOP MANUAL VOLUME 1 (INTRODUCTION) ....LUBRICATION 01 – Lubrication and maintenance chart .......... 01-01-1 AND MAINTENANCE TROUBLESHOOTING 01 – Table of contents..............02-01-1 02 – Engine ..................02-02-1 03 –...
Page 5 TABLE OF CONTENTS SECTION SUB-SECTION PAGE BODY / FRAME 01 – Table of contents ..............08-01-1 02 – Body..................08-02-1 03 – Frame..................08-03-1 TECHNICAL DATA 01 – SI metric information guide............09-01-1 02 – Engines ..................09-02-1 03 – Vehicles..................09-03-1 04 –...
Page 6: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 1997 Ski-Doo snowmo- biles. See model list on next page. This edition was primarily published to be used by snowmobile mechanics who are already familiar with all service procedures relating to Bombardier made snowmobiles.
Page 7 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION LIST OF MODELS GROUPED BY COMMUN CHASSIS This Shop Manual VOLUME 1 covers the follow- ing Bombardier made 1997 snowmobiles : S-Series consists of : MODEL Touring E / LE / LE LT / SLE MODELS Skandic 380 / 500 NUMBER...
Page 8 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL Each vehicle has its particular vehicle ARRANGEMENT OF THE serial number MANUAL Serial Number Meaning : The manual is divided into 10 major sections : 01 LUBRICATION AND MAINTENANCE 02 TROUBLESHOOTING 03 ENGINE 0000 00000 04 TRANSMISSION Model no.
Page 9 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. TYPICAL PAGE Page heading indicates section and sub-section detailed. Sub-section title indicates Section 07 REAR SUSPENSION beginning of the sub-section.
Page 10 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL TYPICAL PAGE Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) Title indicates Turn puller handle and sliding half at once to extract INSTALLATION main procedure the bushing. to be carried-out. Countershaft CAUTION Always apply anti-seize lubricant (P/N 413 7010 Italic bold face type 00) on the countershaft before final pulley setting indicates a...
Page 11 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL GENERAL INFORMATION ILLUSTRATIONS AND PROCEDURES The information and component / system descrip- tions contained in this manual are correct at time Illustrations and photos show the typical con- of publication. Bombardier Inc. however, main- struction of the different assemblies and, in all tains a policy of continuous improvement of its cases, may not reproduce the full detail or exact products without imposing upon itself any obliga-...
Page 12 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL TIGHTENING TORQUES N•m FASTENER SIZE (8.8) Lbf•ft Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table. N•m FASTENER SIZE (8.8) Lbf•in N•m FASTENER SIZE (8.8) Lbf•ft...
Page 13 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS...
Page 14 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART REFER TO Starting Rope Condition — Engine Head Nuts Appropriate section : See Top End Appropriate section : See ENGINE Engine Mount Nuts REMOVAL Appropriate section : See ENGINE Exhaust System REMOVAL Engine Lubrication...
Page 15 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) REFER TO Section 06 : See appropriate Suspension Adjustments AS REQUIRED sub-section and Operator’s Guide Section 06 : See appropriate Suspension Lubrication sub-section Section 06 : See appropriate Suspension Condition sub-section Section 06 : See appropriate Suspension Stopper Strap Condition...
Page 16 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 1 ENGINE LUBRICATION With the engine stopped, remove the spark plug and spray storage oil (P / N 496 0141 00) into each Engine internal parts must be lubricated to protect cylinder.
Page 17 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) Replace fuel filter. To facilitate the fuel line instal- S-Series lation, slide grommet on fuel line about 50 mm (2 Lift hood and remove air filter from air intake si- in) away from elbow then install grommet on fuel lencer.
Page 18 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 8 GENERAL INSPECTION Remove any dirt or rust. To clean the entire vehicle, use only flannel ® clothes or Kimtowels wipers no. 58-380 from Kimberly-Clark. CAUTION : It is necessary to use flannel cloths or “Kimtowels”...
Page 19 Section 02 TROUBLESHOOTING Sub-Section 01 (TABLE OF CONTENTS) ENGINE ..........................02-02-1 FUEL AND OIL SYSTEMS..................... 02-03-1 TRANSMISSION AND BRAKE SYSTEMS ................02-04-1 TRANSMISSION ....................... 02-04-1 BRAKE SYSTEM ........................ 02-04-7 MECHANICAL BRAKE ...................... 02-04-7 HYDRAULIC BRAKE ......................02-04-7 MECHANICAL AND HYDRAULIC BRAKES ..............02-04-8 ELECTRICAL SYSTEM......................
Page 20: Engine
Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) ENGINE The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM ENGINE BACKFIRES.
Page 21 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test / Inspection 1. Perform engine leak test. Refer to engine leak verification flow chart. Check possible piston seizure. a. Damaged gasket and / or seal. Replace defective parts.
Page 22 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 4. Melted and / or perforated piston dome ; melted section at ring end gap. a. When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This situation is due to an incomplete combustion of a poor quality oil. Clean residue accumulation in combustion chamber and replace piston(s).
Page 23 Section 02 TROUBLESHOOTING Sub-Section 02 (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. a.Fouled spark plug(s). Replace. 2. Check if there is water in fuel. a.There is water in fuel.
Page 24 Section 02 TROUBLESHOOTING Sub-Section 02 (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.
Page 25 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM IRREGULAR ENGINE IDLE. CONDITION NORMAL USE AFTER ENGINE WARM UP. Test / Inspection 1. Check primer. a. Fuel leaks at primer nipple which is mounted to carburetor. Replace. 2. Check choke. a) Choke plunger may be partially opened. Readjust.
Page 26 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 6. Check antifreeze concentration. a.Antifreeze concentration is too high. Adjust concentration according to Bombardier’s recommendations. 7. Check tank cap. a.Cap does not hold pressure. Replace. 8. Check carburetion. a.Improperly adjusted or inadequate carburetor components. Adjust according to specifications (refer to TECHNICAL DATA 09) or replace inadequate component(s).
Page 27 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH “RAVE”. ENGINE HESITATES AT MID-SPEED AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE. CONDITION NORMAL USE. Test / Inspection 1. Check “RAVE” valve spring(s). a. Spring tension is too weak or spring(s) is (are) broken. Replace.
Page 28 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE PINGING. CONDITION NORMAL USE. Test / Inspection 1. Check fuel lines. a. Bent fuel lines (preventing fuel from flowing through). Relocate or replace fuel lines. 2. Check if carburetor(s) is (are) clean. a.
Page 29 Section 02 TROUBLESHOOTING Sub-Section 02 (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 30: Fuel And Oil Systems
Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM HIGH FUEL CONSUMPTION (OR RICH MIXTURE).
Page 31 Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM. CONDITION NORMAL USE. Test / Inspection 1. Check fuel tank vent hose. a. Kinked or clogged hose. Relocate or replace. 2. Check fuel filter. a.
Page 32 Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE). CONDITION NORMAL USE. Test / Inspection 1. Check fuel filter ball located in fuel tank. Ball must move freely. a. Corrosion due to oxidation at installation. Replace fuel filter.
Page 33: Transmission And Brake Systems
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) TRANSMISSION AND BRAKE SYSTEMS The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. TRANSMISSION SYMPTOM THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED.
Page 34 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING / DECELERATING. CONDITION NORMAL USE. Test / Inspection 1. Check drive chain tension. a. Drive chain is too loose. Adjust. 2. Check play of driven pulley Woodruff key (aluminum frame models) a.
Page 35 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY. CONDITION NORMAL USE. Test / Inspection 1. Check driven pulley spring tension. a. Spring tension is too weak. Adjust according to specifications (refer to TECHNICAL DATA 09). 2.
Page 36 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE. CONDITION NORMAL USE. Test / Inspection 1. Check if drive pulley bushings are worn. a. Insufficient pressure on belt sides. Replace bushing. 2. Check condition of drive pulley fixed half shaft. a.
Page 37 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT WORN NARROW IN ONE SECTION. CONDITION NORMAL USE. Test / Inspection 1. Check if parking brake is released. a. Parking brake is engaged. Release parking brake. 2. Check track tension / alignment. a.
Page 38 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT EDGE CORD BREAKAGE. CONDITION NORMAL USE. Test / Inspection 1. Check pulley alignment. a. Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA 09). A00DOFY SYMPTOM FLEX CRACKS BETWEEN COGS. CONDITION NORMAL USE.
Page 39: Brake System
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) BRAKE SYSTEM MECHANICAL BRAKE SYMPTOM BRAKE DOES NOT ADJUST AUTOMATICALLY. CONDITION NORMAL USE. Test / Inspection 1. Check ratchet wheel spring. a. Broken ratchet wheel tag. Replace. 2. Check mobile pad stud. a.
Page 40: Mechanical And Hydraulic Brakes
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) MECHANICAL AND HYDRAULIC BRAKES SYMPTOM BRAKE SYSTEM IS NOISY. CONDITION NORMAL USE. Test / Inspection 1. Check brake pad thickness. a. Pads are worn up to wear warner. Replace. 02-04-8...
Page 41: Electrical System
Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM STARTER DOES NOT TURN.
Page 42 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 9. Check height of commutator mica. a.Commutator mica too high. Undercut mica. 10. Check field coil resistance. a.Shorted field coil. Repair or replace yoke. 11. Check armature resistance. a.Shorted armature. Repair or replace armature. 12.
Page 43 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED. CONDITION NORMAL USE. Test / Inspection 1. Check clutch. a. Jammed clutch pinion gear. Replace or clean. 2. Check movement of clutch on splines. a.
Page 44 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 4. Check ignition switch. a. Defective contacts in ignition switch. Replace. 5. Check solenoid of electric starter. a. Shorted solenoid wiring harness or eroded contact washer. Replace. SYMPTOM HEADLAMP NOT LIGHTING. CONDITION WHITE BULB. Test / Inspection 1.
Page 45 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 5. Verify of optional electric accessories are overloading the magneto / generator. a. Excessive electrical load to magneto / generator. Reduce the electrical load by removing excess accessories. Reconnect as recommended by manufacturer. 6.
Page 46 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINES DOES NOT START – NO SPARK AT SPARK PLUG. CONDITION AT ENGINE CRANKING. Test / Inspection 1. Verify spark plug condition. a. Defective, improperly set, worn-out, fouled. Identify source of problem and correct. Replace spark plug. 2.
Page 47 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINE IS MISFIRING – ERRATIC SPARK AT SPARK PLUG. CONDITION RIDING ON WET SNOW. Test / Inspection 1. Verify if spark plug wires and / or spark plug cap seals are sealing-out moisture. a.
Page 48 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM FOULED (BLACK) SPARK PLUG TIP. CONDITION NORMAL USE. Test / Inspection 1. Check carburetor(s). a. Carburetion is too rich. Adjust according to specifications (refer to TECHNCAL DATA 09). 2. Check injection oil consumption. a.
Page 49 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM REAR LIGHT BULB FLASHES. CONDITION NORMAL USE. Test / Inspection 1. Check bulb tightness in housing. a. Looseness at bulb contact elements. Install bulb correctly. 2. Check if rear light is properly connected. a.
Page 50: Suspension System And Track
Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SUSPENSION SYSTEM AND TRACK The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM REAR SUSPENSION BOTTOMS OUT.
Page 51 Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SYMPTOM DERAILING TRACK. CONDITION NORMAL USE. Test / Inspection 1. Check track tension. a. Track is too loose. Adjust. 2. Check if track and slider shoes are properly aligned. a. Improper alignment. Adjust.
Page 52 Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SYMPTOM HANDLE BAR IS DIFFICULT TO TURN. CONDITION NORMAL USE. Test / Inspection 1. Check position of front spring adjustment cams. a. More pressure on the ground when cam increases spring preload. Reduce front spring preload.
Page 53 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) 277 ENGINE TYPE ......................... 03-02-1 ENGINE REMOVAL AND INSTALLATION................ 03-02-1 REMOVAL FROM VEHICLE ....................03-02-2 ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY......03-02-2 INSTALLATION ON VEHICLE .................... 03-02-2 TOP END ..........................03-02-3 TROUBLESHOOTING ......................
Page 54 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) LEAK TEST AND ENGINE DIMENSION MEASUREMENT ..........03-04-1 LEAK TEST.......................... 03-04-1 PREPARATION ........................03-04-1 PROCEDURE........................03-04-1 FINALIZING REASSEMBLY ....................03-04-4 COOLING SYSTEM LEAK TEST ..................03-04-4 ENGINE DIMENSION MEASUREMENT ................03-04-5 CYLINDER TAPER....................... 03-04-5 CYLINDER OUT OF ROUND ....................
Page 55 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) AXIAL FAN COOLING SYSTEM ................... 03-07-1 REMOVAL .......................... 03-07-2 CLEANING ......................... 03-07-2 DISASSEMBLY AND ASSEMBLY ..................03-07-2 REWIND STARTER ........................ 03-08-1 REMOVAL........................... 03-08-3 DISASSEMBLY........................03-08-3 ASSEMBLY......................... 03-08-3 INSTALLATION ........................03-08-4 CARBURETOR AND FUEL PUMP..................03-09-1 REMOVAL...........................
Page 56: 277 Engine Type
Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) 277 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION 48 N•m (35 lbf•ft) 48 N•m (35 lbf•ft) 21 N•m (15 lbf•ft) 25 N•m (18 lbf•ft) 48 N•m (35 lbf•ft) A05C0KS FLAT RATE PARTS 03-02-1...
Page 57: Removal From Vehicle
Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) REMOVAL FROM VEHICLE INSTALLATION ON VEHICLE Remove or disconnect the following then lift en- To install engine on vehicle, reverse removal pro- gine from vehicle : cedure. However, pay attention to the following : –...
Page 58: Top End
Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) TOP END 26 N•m (19 lbf•ft) 22 N•m (16 lbf•ft) Grease A05C0SS FLAT RATE PARTS 03-02-3...
Page 59: Troubleshooting
Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) TROUBLESHOOTING DISASSEMBLY Before completely disassemble engine, check air- 5, Piston tightness. Refer to LEAK TEST AND ENGINE DI- On this engine, piston pin needle bearing no. 6 is MENSION MEASUREMENT 03-04. mounted without a cage. NOTE : The following procedures can be Use piston pin puller (P / N 529 0210 00) along done without removing the engine from...
Page 60: Inspection
Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) Remove piston from connecting rod. – Grease thrust washers and install them on each end of needles. Install locating sleeve. Then push needle bearings along with thrust washers using a 21 mm (.826 in) –...
Page 61 Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) When installing new needle bearing, insert nee- dles with thrust washers. Instead of expansion sleeve, needles are held in place by 2 inner plastic cage halves. Use piston pin puller (P / N 529 0210 00) to insert piston pin.
Page 62: Bottom End
Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) BOTTOM END Lithium grease Anti-seize compound Lithium grease 22 N•m (16 lbf•ft) A05C0TS FLAT RATE PARTS 03-02-7...
Page 63: Cleaning
Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) NOTE : Engine must be removed from chas- sis to perform the following procedures. M8 x 110 mm CLEANING Discard all oil seals and gaskets. Clean all metal components in a non-ferrous met- al cleaner.
Page 64 Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) Prior to installation, place bearings into an oil con- Using a press, install crankshaft into MAG side tainer and heat the oil to 75°C (167°F) for 5 to 10 crankcase half. min. This will expand bearings and ease installa- tion.
Page 65 Section 03 ENGINE Sub-Section 02 (277 ENGINE TYPE) Torque the screws no. 7 to 22 N•m (16 lbf•ft) fol- lowing illustrated sequence. A02C04A 03-02-10...
Page 66: 377, 443 And 503 Engine Types
Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) 377, 443 AND 503 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION 377 and 443 Engine Types Skandic 380 Touring E/LE Formula S 28 N•m (21 lbf•ft) 17 N•m (150 lbf•in) 37 N•m (27 lbf•ft) 35 N•m...
Page 67 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) 503 Engine Type 28 N•m (21 lbf•ft) 17 N•m (150 lbf•in) 37 N•m (27 lbf•ft) 35 N•m (26 lbf•ft) A03C13S PARTS FLAT RATE 03-03-2...
Page 68: Engine Removal And Installation
Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following : WARNING : Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery ca- ble (on electric starting models). –...
Page 69 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) TOP END 22 N•m 22 N•m (16 lbf•ft) (16 lbf•ft) 22 N•m (16 lbf•ft) 22 N•m (16 lbf•ft) Grease 503 S-Series only A23C05S PARTS FLAT RATE 03-03-4...
Page 70 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) NOTE : The following procedures can be NOTE : The PTO cylinder or fan housing done without removing the engine from have to be removed to give access to MAG chassis.
Page 71 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) – Screw in puller in order to remove it from pis- ton. – Remove piston from connecting rod. – Install locating sleeve. Then push needle bear- ings along with thrust washers using a 21 mm (.826 in) diameter pusher.
Page 72 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) A01C01A 1. Exhaust All Engines Except 503 To center the piston pin with the connecting rod A21C01A bearing, use centering tool (P / N 529 0091 00). – Remove piston pin puller and expansion sleeve.
Page 73 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) At cylinder no. 4 and / or cylinder head no. 3 in- stallation, use aligning tool or exhaust manifold it- self to ensure sealing of intake manifold and exhaust before tightening cylinder head nuts. ALIGNING TOOL ENGINE TYPE P / N...
Page 74 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) Position distance nuts no. 2 as illustrated. A09C02A 377 ENGINE TYPE 1. Exhaust 2. Distance nuts A17C06A 503 ENGINE TYPE 1. Distance nuts Cross torque cylinder head nuts nos. 1 and 2 to 22 N•m (16 lbf•ft) ;...
Page 75 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) BOTTOM END Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant 22 N•m (16 lbf•ft) 503: 22 N•m (16 lbf•ft) 377: 10 N•m (89 lbf•in) 22 N•m (16 lbf•ft) A03C1IS PARTS FLAT RATE 03-03-10...
Page 76 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) NOTE : Engine must be removed from chas- To check proper clearance between bearing no. 3 sis to perform the following procedures. and counterweight, use feeler gauge (P / N 420 8766 20).
Page 77 Section 03 ENGINE Sub-Section 03 (377, 443 AND 503 ENGINE TYPES) For bearing lubrication purpose, a gap of 1.0 mm (.040 in) must be maintained between seals and bearings. When installing plain oil seals (seal without locat- ing ring or without spacing legs), ensure to main- tain 1.0 mm (.040 in) gap.
Page 78: Leak Test And Engine Dimension Measurement
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for liq- 10. Engine must stand this pressure during 3 min- uid cooled engines though it also applies to fan utes.
Page 79 Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Engine Check the following : 1. All jointed surfaces and screw / stud threads of engine : – spark plug base, insulator – cylinder head – cylinder base – crankcase halves (joint) –...
Page 80 Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Block both hoses of rotary valve gear lubrica- 1. Remove a spark plug or any plug of leak tester tion system with hose pinchers. kit on PTO side. If pressure drops, it indicates defective crank- shaft inner seal on PTO side.
Page 81: Finalizing Reassembly
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Remove rotary valve cover and check for leak COOLING SYSTEM LEAK TEST of rotary valve seal with soapy water. Install special plug (radiator cap) (P/N 529 0214 00) and hose pincher (P/N 529 0099 00) on over- flow hose.
Page 82: Engine Dimension Measurement
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT This section covers all engine types. CYLINDER TAPER ENGINE TYPE MAXIMUM 0.08 mm (.003 in) Compare cylinder diameter 16 mm (5/8 in) from top of cylinder to just below its intake port area. On rotary valve engines, measure just below aux- iliary transfer port, facing exhaust port.
Page 83: Ring / Piston Groove Clearance
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A01C0PA RING END GAP Position ring half way between transfer ports and intake port. On rotary valve engines, position ring just below transfer ports. NOTE : In order to correctly position the ring in the cylinder, use piston as a pusher.
Page 84: Connecting Rod Big End Axial Play
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Measuring (On bench) If the deflection exceeds the specified tolerance, crankshaft should be repaired or replaced. Once engine is disassembled, check crankshaft deflection on V-shaped blocks. If deflection ex- CONNECTING ROD BIG END ceeds the specified tolerance, it can be worn AXIAL PLAY...
Page 85: Connecting Rod / Crankpin Clearance
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A01C3HA A01C1NA 1. Distance ring 2. Shim location ENGINE NEW PARTS WEAR 3. Bearing TYPE MIN. - MAX. LIMIT 4. PTO 5. MAG 0.03-0.012 mm 0.015 mm CAUTION : Always install end-play ad- (.0001-.0005 in) (.0006 in) justment shims on the magneto side be-...
Page 86 Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) The result is the actual crankshaft end-play that must be within specification. If the result is over specification, add adjustment shim(s) to reach this specification. If the result is under specification, remove adjust- ment shim(s) to reach this specification.
Page 87: Checking Surface Flatness
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CHECKING SURFACE FLATNESS CHECKING CRANKSHAFT ALIGNMENT Intake manifold, intake manifold cover, rotary valve cover can be checked for perfectly mating Install a degree wheel (P / N 414 3529 00) on surfaces.
Page 88: Cdi System
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO IGNITION SYSTEM WITH SINGLE GENERATING COIL 277 Engine Dielectric grease Dielectric grease Loctite 242 Loctite 242 Loctite Dielectric grease 90 N•m (66 lbf•ft) 7 N•m (62 lbf•in) Loctite A25C0OS FLAT RATE PARTS 03-05-1...
Page 89: Cleaning
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) NOTE : The following procedures can be done without removing the engine from chassis. CLEANING Clean all metal components in a non-ferrous met- al cleaner. CAUTION : Clean armature and magneto using only a clean cloth. DISASSEMBLY To gain access to magneto assembly, remove the following parts as needed on different engines :...
Page 90 Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) A01C2JA 1. Protect harness from flame 2. Heat CAUTION : Protect harness from flame. – Remove screws. – Uncrimp and unsolder YELLOW and YELLOW/ BLACK wires from coil terminals. A25E0QA 1. Uncrimp and unsolder wire here –...
Page 91: Assembly
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) 420 8769 22 A25E0RD CAUTION : Before reinstalling magneto, remove the loose epoxy from harness. ASSEMBLY Position the armature plate on the crank- no. 1 case, aligning the marks on both parts. Put a drop of Loctite 242 (blue) on screw threads and tighten.
Page 92: Ducati Ignition System
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) DUCATI IGNITION SYSTEM 377, 443 and 503 Engines Dielectric grease Loctite 105 N•m (77 lbf•ft) Loctite 22 N•m (195 lbf•in) A07C03S FLAT RATE PARTS 03-05-5...
Page 93: Cleaning
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) NOTE : The following procedures can be – Tighten puller bolt and at the same time, tap on done without removing the engine from bolt head using a hammer to release magneto chassis. flywheel from its taper.
Page 94: Assembly
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) A25E0UB ADJUSTING TRIGGER COIL AIR-GAP 1. Flywheel protrusion 2. Trigger coil To replace armature : – Disconnect the 2-wire connector (GREEN and WHITE wires). – Disconnect YELLOW / BLACK and YELLOW wires. – Remove grommet from crankcase where mag- neto harness exits magneto housing.
Page 95: Oil Injection System
Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 277 Engine Loctite Grease Grease A05C07S FLAT RATE PARTS 03-06-1...
Page 96 Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) 377, 443 and 503 Engines Loctite Loctite 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) Grease A03C17S PARTS FLAT RATE 03-06-2...
Page 97: Oil Pump Identification
Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) OIL PUMP IDENTIFICATION ASSEMBLY Different engines need different pumps. See At gear no. 2 assembly, apply a light coat of low identification on pump lever no. 7. temperature grease (P / N 413 7061 00) on gear teeth.
Page 98: Checking Operation
Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) Retighten the adjuster nut. Check the small oil lines (between pump and in- take manifold). If required, fill the lines by running the engine at idle speed while holding the pump lever in fully open position. A15C1QA TYPICAL —...
Page 99 Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) Reconnect banjo fittings with a washers on each Oil Pump Test Bench side, start engine and run at idle while holding the Connect a hose filled with injection oil to main line pump lever in fully open position.
Page 100: Axial Fan Cooling System
Section 03 ENGINE Sub-Section 07 (AXIAL FAN COOLING SYSTEM) AXIAL FAN COOLING SYSTEM NOTE : For 277 engine radial fan cooling system, refer to 277 engine type 03-02. 377, 443 and 503 Engines 13 N•m (115 lbf•in) 443 and 503 engines only 47 N•m (35 lbf•ft)
Page 101: Removal
Section 03 MOTEUR Sub-Section 07 (AXIAL FAN COOLING SYSTEM) NOTE : The following procedures can be done without removing engine from chassis. REMOVAL NOTE : To facilitate further disassembly, fan nut may be removed before removing fan housing. Remove rewind starter, starting pulley, trigger coil wire from 4-connector housing then fan housing ass’y.
Page 102 Section 03 MOTEUR Sub-Section 07 (AXIAL FAN COOLING SYSTEM) Using a press, drive the fan shaft no. 9 out. Remove circlip no. 11 then remaining bearing. To install, press one bearing in place then install circlip and shims. Press the other bearing from op- posite side until it is flush with housing.
Page 103: Rewind Starter
Section 03 ENGINE Sub-Section 08 (REWIND STARTER) REWIND STARTER 277, 377, 443 and 503 Touring SLE Molykote G-n Paste or Equivalent Silicone Compound Grease Silicone Compound Grease 10 N•m (89 lbf•in) A03C1GS FLAT RATE PARTS 03-08-1...
Page 104 Section 03 ENGINE Sub-Section 08 (REWIND STARTER) 503 Skandic 500 and Formula SL 10 N•m (89 lbf•in) 8 N•m Molykote G-n (71 lbf•in) Paste or Equivalent Silicone Compound Grease Silicone Compound Grease A21C08S PARTS FLAT RATE 03-08-2...
Page 105: Removal
Section 03 ENGINE Sub-Section 08 (REWIND STARTER) REMOVAL Using a small screwdriver, extract rope knot from starter grip no. 15. Cut rope close to knot. Tie a knot near starter. Remove screws no. 3 and washers no. 2 secur- ing rewind starter no. 1 to engine then remove re- wind starter.
Page 106: Installation
Section 03 ENGINE Sub-Section 08 (REWIND STARTER) CAUTION : The use of standard multi-pur- Install locking spring no. 11 and lubricate with ® pose grease could result in rewind starter MOLYKOTE G-n paste from Dow Corning malfunction. equivalent. To install a new rope no. 6 : insert rope into sheave no.
Page 107 Section 03 ENGINE Sub-Section 08 (REWIND STARTER) Prior to installing starter grip no. 15 on new rope, it is first necessary to fuse the rope end with a lit match. pass rope through rubber buffer no. 14 and starter grip and tie a knot in the rope end. fuse the knot with a lit match then insert rope end down and pull the starter grip over the knot.
Page 108: Carburetor And Fuel Pump
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP Carburetors VM 30-190 VM 34-443 VM 34-467 VM 34-481 VM 34-482 To other carburetor All Carburetors Except VM-34-443 A15C2AS FLAT RATE PARTS 03-09-1...
Page 109: Removal
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) REMOVAL Remove air silencer(s). For S-Series, see BAT- TERY 05-05. Disconnect fuel inlet line. Disconnect primer line from carburetor on some models. Disconnect choke cable on some models. Unscrew carburetor cover no. 1 then pull out throttle slide no.
Page 110: Carburetor Float Level Adjustment
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) NOTE : The last digit of the needle identifi- CARBURETOR FLOAT LEVEL cation number gives the recommended posi- ADJUSTMENT tion of the E-clip from the top of the needle. 9,10, Float Arm and Float Arm Pin Example : 6DH4-3 Correct fuel level in float chamber is vital toward...
Page 111: Installation
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) Throttle slide openings Wide open Close 13,6, Pilot jet and air screw Throttle slide cutaway Needle taper and needle position Needle jet Main jet A00C04A VIEW FROM AIR INTAKE OPENING A01C5BA NOTE : For fine tuning refer to TECHNICAL 1.
Page 112: Carburetor Adjustments
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) CARBURETOR ADJUSTMENTS A02C09A A00C1TA 1. Idle speed screw CENTER POST TYPE 2. Air screw 1. Throttle cable 2. Needle retaining plate 6, Air Screw Adjustment 3. Throttle slide Make sure the nylon packing no. 4 is installed on Completely close the air screw (until a slight seat- all applicable throttle slides.
Page 113 Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) CAUTION : On twin carburetor models, make sure both carburetors start to oper- ate simultaneously. Beside do not interchange carburetors, the jetting may be different on each side. A red dot is printed on one carbure- tor and on the engine.
Page 114: Preliminary Idle Speed Adjustment
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) Throttle Slide height Models mm (in) Tundra II LT, Skandic 380, Touring E / LE / SLE, 1.3 (.051) Formula S, Alpine II Touring SLE, Skandic 500, 1.5 (.059) Formula SL Touring LE 1.6 (.063) A00C3FA...
Page 115: Choke
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) CHOKE Touring E / E LT / LE / SLE, Skandic 380 / 500 and Formula SL Choke Plunger Adjustment Adjust cable length to obtain the following plunger / adaptor distance. Retighten lock nut. PLUNGER / ADAPTOR CARBURETOR DISTANCE...
Page 116: Fuel Pump
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) FUEL PUMP S-Series Tundra LT A00C48S FLAT RATE PARTS 03-09-9...
Page 117: Removal
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) REMOVAL Install a hose pincher (P / N 529 0099 00) on fuel supply line close to pump inlet. A00C3CA HIGH-SUPPLY FUEL PUMP WITH TWIN OUTLETS 1. Inlet 2. Outlets A01B2JB 3.
Page 118: Assembly
Section 03 ENGINE Sub-Section 09 (CARBURETOR AND FUEL PUMP) Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed air. WARNING : Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as each is flammable and explosive.
Page 119: Fuel Tank And Throttle Cable
Section 03 ENGINE Sub-Section 10 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE Fuel Tank Lines Models with Easy Action Throttle Lever WARNING : When draining a fuel tank or when-ever a fuel line is disconnected, ob- struct line with a hose pincher (P/N 529 0099 00) or equivalent device.
Page 120 Section 03 ENGINE Sub-Section 10 (FUEL TANK AND THROTTLE CABLE) Throttle Cable Retainer Tundra II LT Models The retainer must be pushed on the throttle han- dle tab until it sits properly. A02C0EA 1. Throttle handle 2. Retainer 3. Cable barrel 4.
Page 121 Section 04 TRANSMISSION Sub-Section 01 (TABLE OF CONTENTS) DRIVE BELT..........................04-02-1 1997 APPLICATION CHART ....................04-02-1 ROTATION DIRECTION...................... 04-02-1 DRIVE BELT DEFLECTION MEASUREMENT ..............04-02-2 DEFLECTION ADJUSTMENT.................... 04-02-3 DRIVE PULLEY........................04-03-1 BOMBARDIER LITE ......................04-03-1 GENERAL ........................... 04-03-2 REMOVAL........................... 04-03-2 DISASSEMBLY........................
Page 122 Section 04 TRANSMISSION Sub-Section 01 (TABLE OF CONTENTS) BRAKE............................. 04-06-1 MECHANICAL DISC BRAKE ....................04-06-1 HYDRAULIC DISC BRAKE....................04-06-3 REMOVAL ........................... 04-06-4 DISASSEMBLY ........................04-06-5 CLEANING .......................... 04-06-5 INSPECTION ........................04-06-6 ASSEMBLY ......................... 04-06-6 INSTALLATION ........................04-06-6 ADJUSTMENT........................04-06-7 CHAINCASE..........................04-07-1 REMOVAL ...........................
Page 123: Drive Belt
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) DRIVE BELT 1997 APPLICATION CHART PART WIDTH (NEW) MINIMUM WIDTH MODEL ± 0.25 mm (.010 in) NUMBER (WEAR LIMIT) TUNDRA II LT 414 8276 00 33.3 mm (1-5/16’’) 30 mm (1-3/16’’) S-SERIES 415 0606 00 34.3 mm (1-27/64’’) 32 mm (1-1/4’’) ROTATION DIRECTION...
Page 124: Drive Belt Deflection Measurement
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) DRIVE BELT DEFLECTION MEASUREMENT NOTE : The drive belt deflection measure- ment must be performed each time a new drive belt is installed. NOTE : To obtain an accurate drive belt de- flection measurement, it is suggested to al- low a break-in period of 50 km (30 mi).
Page 125: Deflection Adjustment
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) To do so, loosen the 4 chaincase retaining nuts, unlock and raise driven pulley support. A00D08A 1. Upper O-ring 2. Force 3. Lower O-ring 4. Reference rule 5. Deflection DEFLECTION ADJUSTMENT Tundra II LT Drive belt deflection is adjusted by moving chain- case.
Page 126 Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) A15D0WA 1. Allen screw with jam nut Allen screws should be restrained while tighten- ing jam nut to prevent throwing adjustment out. Use drive belt tension adjuster (P / N 529 0087 00). A05D0PB 529 0087 00 TUNDRA II LT...
Page 127: Drive Pulley
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) DRIVE PULLEY BOMBARDIER LITE NOTE : This is a lubrication free drive pulley. Tundra II LT and 377 Engine S-Series 377 Engine S-Series Loctite 271 377 Engine S-Series 128 N•m (95 lbf•ft) 95 N•m (70 lbf•ft) A05D0IS FLAT RATE...
Page 128: General
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) GENERAL Some drive pulley components (return spring, cal- ibration disk) can be changed to improve vehicle performance in high altitude regions. The High Al- titude Technical Data booklet (P / N 484 0648 00 and 484 0545 00 for binder) gives information about calibration according to altitude.
Page 129: Cleaning
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 529 0273 00 A05D0NA A05D0MA 1. Curved end Remove washer no. 10 then circlip no. 11. 2. Spring cover slot A. 2 to 3 mm (1/16 to 1/8 in) CLEANING Tighten nut no. 8 to 128 N•m (95 lbf•ft). Clean pulley faces and shaft with fine steel wool INSTALLATION and clean dry clutch.
Page 130: Tra
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) All Models NOTE : This is a lubrication free drive pulley. 12 N•m (106 lbf•in) Loctite 12 N•m Loctite Loctite (106 lbf•in) Loctite 10 N•m (89 lbf•in) Loctite 95 N•m (70 lbf•ft) 10 N•m (89 lbf•in) Repair kit A19D07S...
Page 131: General
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) GENERAL WARNING : Never use any type of impact wrench at drive pulley removal and instal- Some drive pulley components (return spring, lation. ramp) can be changed to improve vehicle perfor- Remove retaining screw. mance in high altitude regions.
Page 132: Cleaning
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 25,29, Slider Shoe and Governor Cup Carefully lift governor cup until slider shoes come at their highest position into guides. Hold a slider shoe set then carefully lift its housing and remove them. Proceed the same way for other housings lifting one at a time.
Page 133: Inspection
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Reclean mounting surfaces with paper towel and CAUTION : Bushing must be bonded with cleaning solvent (P / N 413 7082 00). retaining compound (P / N 413 7031 00) then flared to prevent displacement in sliding Wipe off the mounting surfaces with a clean, dry half.
Page 134 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 420 8765 12 A01B41A TOOL REMOVAL CAUTION : Do not install sliding half on a vise to remove remaining tool. Spring Cover Bushing Replacement Under normal use there is no need to replace this bushing.
Page 135: Assembly
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 26,27,28, Calibration Screw, Washer and Locking Nut When installing calibration screw, make sure to in- stall washer as shown. 529 0313 00 529 0312 00 A01D2NA A16D07A 1. Note upper tool side 1. Washer Press bushing.
Page 136 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Position dowel tube split at the illustrated angle. 30 ± 5° A16D2PA A16D0BA 1. Head on top 2. All on the same side CAUTION : Lever assemblies must be in- stalled so that cotter pins are on the same side.
Page 137: Installation
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 6,25,29, Sliding Half, Slider Shoe and Governor Cup To install governor cup, use following tool : 529 0055 00 A16D0EA 1. Align A16B01A Carefully slide governor cup into sliding half. Align Insert spring and slider shoes into governor cup mark of governor cup with mark of fixed half.
Page 138: Drive Pulley Adjustment
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Raise and block the rear of the vehicle and sup- port it with a mechanical stand. WARNING : Ensure that the track is free of particles which could be thrown out while track is rotating. Keep hands, tools, feet and clothing clear of track.
Page 139 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) CAUTION : Always adjust all 3 calibration screws and make sure they are all set at the same number. A16D0HA 1. Loosen just enough to permit rotating of calibration screw 04-03-13...
Page 140: Driven Pulley
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) DRIVEN PULLEY Tundra II LT 13 N•m (115 lbf•in) Anti-seize lubricant (P/N 413 7010 00) A09D0QS FLAT RATE PARTS 04-04-1...
Page 141: Removal
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) NOTE : Driven pulley components (support, Disconnect oil injection supply line at injection cam, shoes, etc.) can be serviced without re- pump and plug line to prevent draining. moving the whole driven pulley from chaincase. Remove screws retaining rear engine support to Refer to the following procedures but neither re- chassis.
Page 142: Inspection
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) 6,9, Sliding Half Bushing and Bushing To disassemble a worn bushing (small), use a press and a suitable pusher. A25D0LA 1. Install bushing from this side of sliding half A25D0KA 2. Bushing TYPICAL After bushing installation, try fixed half shaft in- side bushing.
Page 143: Installation
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) 12, Fixed Half Shaft NOTE : If chaincase screws have been slackened, chaincase can be reinstalled to its Thoroughly clean the fixed half shaft. Remove initial position by securing driven pulley support rust with no. 320 grit sand paper. before tightening chaincase retaining screws.
Page 144 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Take a measurement when opening driven pulley and another one when driven pulley begins to close after a rotation of 10 mm (3/8 in). Spring pre-load is the average measurement between these 2. measurement measurement Spring...
Page 145 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) S-Series Anti-seize lubricant (P/N 413 7010 00) Loctite Loctite A15D1DS PARTS FLAT RATE 04-04-6...
Page 146: Removal
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) REMOVAL CLEANING Remove belt guard and drive belt from vehicle. 6,7, Large Bushing and Small Bushing Remove the cap screw no. 13, lock washer During break-in period (about 10 hours of use), te- no.
Page 147 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Replace bushing(s) if worn more than specified. Install support plate (P / N 529 0311 03) inside sliding half. DRIVEN PULLEY BUSHING WEAR LIMIT Place puller (P / N 529 0311 02) below bushing. mm (in) Small bushing 38.30 (1.508)
Page 148: Assembly
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Turn puller handle and sliding half at once to ex- 19, Cam tract the bushing. Coat cam interior with anti-seize lubricant. INSTALLATION 14,15, Countershaft and Anti-seize Lubricant 529 0313 00 CAUTION : Always apply anti-seize lubri- cant (P / N 413 7010 00) on the counter- shaft before final pulley installation.
Page 149: Adjustment
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) ADJUSTMENT To adjust spring pre-load, relocate spring end in cam, moving it clockwise to increase the pre-load Refer to PULLEY DISTANCE AND ALIGNMENT and counterclockwise to decrease it. Refer to 04-05 to adjust pulley distance. Adjust drive belt TECHNICAL DATA 09-03.
Page 150 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) 44° A24D06A NOTE : For high altitude regions, the High Altitude Technical Data Booklet (P / N 484 0648 00 and 484 0545 00 for binder) gives infor- mation about calibration according to altitude. 04-04-11...
Page 151: Pulley Distance And Alignment
Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) PULLEY DISTANCE AND ALIGNMENT GENERAL Measuring Procedure Using Straight Bar : The pulley distance we will refer to in this section, is the space separating the drive and driven pulley Always measure distances X and Y from the far- outside diameters (Z measurement).
Page 152: Pulley Alignment And Distance Specifications Chart
Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) Tundra II LT Only Bottom of alignment template must not seat on shaft nor fixed half shoulder and shim(s). A25D0QA TYPICAL 1. Shaft 2. Alignment template 3. Fixed half shoulder and shim(s) Drive Belt Deflection NOTE : When pulley distance and alignment A06D0LA...
Page 153 Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) Tundra II LT A05D0CA 1. Driven pulley movement 2. Engine movement CAUTION : The rear suspension must be A05D0PA mounted on the vehicle and track tension Step : Push and hold and alignment must be done to provide the Step : Raise support...
Page 154 Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) Move the engine to obtain specified pulley align- Pulley Distance Adjustment Method ment, torque engine support bolts to 55 N•m (41 Engine Movement lbf•ft) and remove engine support positioner. The engine support has slotted mounting holes. Driven Pulley Movement Move engine to obtain specified distance be- Shims can be mounted between chaincase and...
Page 155: Brake
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) BRAKE MECHANICAL DISC BRAKE Tundra II LT 4 N•m (35 lbf•in) 24 N•m (18 lbf•ft) A05D0QS FLAT RATE PARTS 04-06-1...
Page 156 Section 04 TRANSMISSION Sub-Section 06 (BRAKE) Formula S, Touring E / E LT and Skandic 380 / 500 Dielectric grease Anti-seize lubricant Anti-seize lubricant Loctite A03D27S PARTS FLAT RATE 04-06-2...
Page 157: Hydraulic Disc Brake
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) HYDRAULIC DISC BRAKE Touring LE / SLE, Formula SL Loctite Anti-seize lubricant Black Max A03D26S PARTS FLAT RATE 04-06-3...
Page 158: Removal
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) REMOVAL COUNTERSHAFT REMOVAL S-Series with Mechanical Brake Tundra II LT Proceed the same as for brake disc removal but The split caliper type brake should be removed unlock bearing collar on driven pulley side. from chaincase as an assembly.
Page 159: Disassembly
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) – Slacken set screw and unlock collar no. 18 if bearing is needed to be disassembled. See 529 0301 00 above S-Series illustration and procedure. – Remove 3 retaining screws no. 20 from coun- tershaft bearing housing.
Page 160: Inspection
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) INSPECTION 7, Fixed Brake Pad Tundra II LT 7, Brake Pad Thickness Torque screw no. 3 to 4 N•m (35 lbf•in). Bend Brake pads must be replaced when fixed pad locking tab no. 4 over a flat of screw head. projects only 1 mm (1/32 in) from caliper.
Page 161: Adjustment
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) Apply anti-seize lubricant (P / N 413 7010 00) on Apply Loctite 242 (P / N 413 7030 00) on set shaft and check that disc slides freely. screw threads, then tighten. The disc hub exceeds the disc more from one Close chaincase referring to CHAINCASE 04-07.
Page 162 Section 04 TRANSMISSION Sub-Section 06 (BRAKE) Install a hose on left side bleeder. Route this hose to a container. Pump a few times brake lever and while holding brake lever depressed, open bleeder and check for air to escape. Repeat with the same bleeder until no air appears in hose.
Page 163: Chaincase
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) CHAINCASE Tundra II LT Lithium grease A03D0QS FLAT RATE PARTS 04-07-1...
Page 164: Removal
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) REMOVAL Release track tension, use drive axle holder (P / N 529 0072 00). Chaincase and driven pulley can be removed from the vehicle as an assembly. Remove belt guard and drive belt. 529 0072 00 Unlock and raise driven pulley support.
Page 165: Assembly
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) The chain length may be affected depending the INSTALLATION combination of lower / upper sprockets as Reverse removal procedure. Pay particular atten- follows : tion to the following : GEAR RATIO / Torque castellated nut no. 7 to 14 N•m (124 CHAIN LENGTH CHART lbf•in), slacken then retorque to 0.5-2.5 N•m (5- 22 lbf•in).
Page 166: Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04-05. Track Tension and Alignment Refer to TRACK 06-05. 04-07-4...
Page 167 Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) S-Series Without Reverse Gear Loctite Chaincase 45 to 75 N•m (33 to 55 lbf•ft) 46 N•m Loctite Loctite 609 (34 lbf•ft) Loctite 242 SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER A06D17S FLAT RATE PARTS 04-07-5...
Page 168: Removal
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) REMOVAL INSPECTION To remove chaincase proceed as follows. Visually inspect the chain for cracked, damaged or missing links. Check for worn or defective bear- Remove tuned exhaust pipe and muffler. ings, sprockets and chain tensioner components. WARNING : Never remove exhaust com- WARNING : If chain deflection is greater ponents when engine is hot.
Page 169: Drive Chain Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) 27, Conical Spring Washer This initial adjustment should provide 3-5 mm (1/ 8-13/64 in) free-play when measured at the outer Install washer with its concave side towards drive circumference of the brake disc. pulley. CAUTION : Free-play must not exceed 5 mm (13/64 in), readjust if necessary.
Page 170: Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04-04. Track Tension and Alignment Refer to TRACK 06-05. 04-07-8...
Page 171: Gearbox
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) GEARBOX 2-SPEED GEARBOX Touring SLE and Skandic 380 / 500 Grease Loctite 15 N•m (133 lbf•in) Grease 48 N•m (35 lbf•ft) Loctite 29 N•m (21 lbf•ft) 5 N•m Loctite (44 lbf•in) Loctite A03D17S FLAT RATE PARTS 04-08-1...
Page 172: Disassembly
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) DISASSEMBLY First remove 19-tooth reverse gear no. 18 and then remove reverse axle no. 20. NOTE : It is possible to see the sliding gear in motion through oil gauge hole. Unbolt gear shift linkage from shifter. Unscrew cover screws no.
Page 173 Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) Install drive axle with track then bearing and circlip Install shim no. 13, 22-tooth sprocket (drive) no. in chaincase bore. Install spacer no. 38 with its 12 and washer no. 11 then tighten castellated nut large outer diameter against sprocket, 44-tooth no.
Page 174: Adjustment
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) 5,7,8, Screws and Locking Tab Tighten screws in a criss-cross sequence starting with the one above reverse axle. Install reverse axle screw and bend locking tab against screw head flat. Bolt shift linkage to shifter. ADJUSTMENT 28, Chain Fully tighten adjustment screw by hand, then...
Page 175: Oil Change
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) A06D1QA OIL CHANGE Place a container under bottom pan (gearbox A03A03A side). 1. Dipstick Unbolt gear shift linkage from fork axle. Unbolt and remove cover by separating it from housing Shifter can be put in reverse position to ease re- and by moving it toward the front in order to re- moval of dipstick.
Page 176: Drive Chain
Section 04 TRANSMISSION Sub-Section 09 (DRIVE CHAIN) DRIVE CHAIN GENERAL Bombardier drive chains exist in 2 types, for prop- er use refer to TECHNICAL DATA 09-03. A00D0RA TYPICAL 1. Rotation CHAIN SEPARATION When separating an endless chain, always use a chain bearing pin extractor.
Page 177 Section 04 TRANSMISSION Sub-Section 09 (DRIVE CHAIN) A00D0OA LENGTHENING 1 LINK A. Connecting link B. Inner link C. Outer link D. Circlip A00D0NA LENGTHENING 1/2 LINK A. Connecting link B. Link pin C. Cranked link D. Cotter pin E. Outer link F.
Page 178 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) WIRING DIAGRAMS......................05-02-1 CHART CODES........................05-02-1 UNPLUGING CONNECTORS .................... 05-02-3 TAB AND RECEPTACLE CONNECTORS REMOVAL ............05-02-3 TAB AND RECEPTACLE CONNECTORS INSTALLATION ..........05-02-3 ACCESSORIES INSTALLATION ..................05-02-4 IGNITION TIMING ......................... 05-03-1 NIPPONDENSO CDI SYSTEM (WITHOUT TRIGGER COIL) ..........05-03-1 DUCATI CDI SYSTEM......................
Page 179 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) ELECTRIC STARTER....................... 05-06-1 REMOVAL ........................... 05-06-2 DISASSEMBLY ........................05-06-2 CLEANING AND INSPECTION ..................05-06-4 ASSEMBLY ......................... 05-06-4 INSTALLATION ........................05-06-5 CLEANING AND INSPECTION ..................05-06-6 CLEANING .......................... 05-06-6 INSPECTION ........................05-06-6 SOLENOID SWITCH ......................05-06-8 TESTING PROCEDURE ......................
Page 180 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) WIRING DIAGRAMS ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) Tundra II LT Annex 1 60/55 hal. 8/27 Formula S / SL, Skandic 380 / 500 Annex 2 60/55 hal. 8/27 Touring E / E LT / LE / SLE Annex 3...
Page 181 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK / YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch –...
Page 182: Tab And Receptacle Connectors Installation
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) Connector Location Connectors on wiring diagrams carry the letter C followed by a number. Use this code with wiring diagram legend to find connector location on vehi- cle. UNPLUGING CONNECTORS Always unplug connectors by pulling on housing not on wire.
Page 183: Accessories Installation
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) ACCESSORIES INSTALLATION On all electric start models: The direct current (DC) utilizes the snowmobile frame as ground “wire” while all alternating current (AC) consum- ers (lights, heated grips, fuel gauge, etc.) utilize a separate ground wire.
Page 184: Ignition Timing
Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) IGNITION TIMING NIPPONDENSO CDI SYSTEM (WITHOUT TRIGGER COIL) 277 Engine Type The 277 engine type uses a single coil ignition system. Refer to CDI SYSTEM 03-05 for more in- formations. This section is mainly divided in 2 parts, the first one using a Top Dead Center gauge to verify the magneto flywheel timing mark position.
Page 185 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) The ignition components are affected by temper- ature variation, therefore, timing must be checked when engine is cold, after idling for a MAXIMUM of 20 seconds. NOTE : On applicable models, turn heating grips off prior to checking ignition timing.
Page 186 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) 3. Check if the yellow fin aligns with the fan cowl timing mark. Tolerance is 1°. NOTE : On the NIPPONDENSO ignition sys- tem, timing advance decreases as engine speed increases. When marks are aligned at 6000 RPM, spark occurrence is still Before Top Dead Center.
Page 187 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) A25E0RC 1. Turn counterclockwise to advance After adjustment, tighten armature plate retaining screws. CAUTION : Make sure armature plate screws are well secured. Armature plate screws must have medium strength thread- locker (P/N 413 7030 00) applied before tight- ening.
Page 188: Ducati Cdi System
Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) DUCATI CDI SYSTEM 377, 443 and 503 Engine Types Proper ignition timing is determined by trigger coil position. If for any reason, ignition timing accuracy is sus- pected, it can be verified as follows. Verifying Magneto Flywheel Timing Mark Position Prior to checking the timing, it may be necessary...
Page 189 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) NOTE : When checking timing, certain pro- c. Scribe or punch a mark on magneto flywheel cedures require that the magneto flywheel so that it perfectly aligns with the arrow on be turned in a clockwise direction, viewed facing crankcase, refer to illustration.
Page 190 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) 2. Start the engine and raise the engine speed at least to 2000 RPM while observing the timing marks, refer to illustration. The magneto fly- wheel mark scribed previously and the crank- case arrow should be perfectly aligned. If the marks do not align, a faulty trigger coil (check proper grounding of coil) or a faulty CDI module could be the cause : substitute one part at a...
Page 191: Spark Plugs
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG All Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier is using the NGK spark plug type on most of the 1997 snowmobile models. The heat range identification system is : High number hot plug Low number...
Page 192: Design Symbols Used In Ngk Spark Plugs
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DESIGN SYMBOLS USED IN NGK SPARK PLUGS PREFIX SUFFIX WIDE GAP 10: 1.0 mm (.040") 11: 1.1 mm (.044") B R 9 E S 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...
Page 193: Disassembly
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DISASSEMBLY A too “cold” plug will result in fouling (shorting the spark plug) or may create carbon build up First unscrew the spark plug 1 turn. which can heat up red-hot and cause pre-ignition or detonation.
Page 194: Spark Plug Installation
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUG INSTALLATION Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to TECHNICAL DATA 09-02.
Page 195: Battery
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) BATTERY REMOVAL All Models WARNING : Battery BLACK negative ca- ble must always be disconnected first and connected last. WARNING : Never charge or boost bat- tery while installed on vehicle. Remove belt guard. Unfasten spark plug cables from fan housing.
Page 196: Inspection
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) Remove corrosion from battery cable terminals This chart will be useful to find the correct read- and battery posts using a firm wire brush. ing. ELECTROLYTE INSPECTION TEMPERATURE OPERATION TO PERFORM Visually inspect battery casing for cracks or other °C °F possible damage.
Page 197: Battery Storage
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) BATTERY STORAGE 1. Remove the sealing tube from the vent elbow. Install vent tube, included in the battery kit, to Disconnect and remove battery from the vehicle. battery elbow. Check electrolyte level in each cell, add distilled WARNING : Failure to remove the sealing water up to upper level line.
Page 198 Section 05 ELECTRICAL Sub-Section 05 (BATTERY) CAUTION : If charging rate raises higher than 2.4 A reduce it immediately. If cell temperature rises higher than 50°C (122°F) (if the casing feels hot) discontinue charging tem- porarily or reduce the charging rate. WARNING : Gases given off by a battery being charged are highly explosive.
Page 199: Servicing
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) 9.Let battery settles for one hour. 12. Reinstall caps and clean any electrolyte spill- age using a solution of baking soda and water. A17E0KA A17E0LA 1. 60 minutes 1. Baking soda 10. Allow gas bubbles to escape by lightly shake battery.
Page 200: Battery Charging Equipment
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) The time required to charge a battery will vary de- – Since the battery chargers vary in the amount pending some factors such as: of voltage and current they provide, the time required for the battery to accept measurable –...
Page 201: Installation Of Battery
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) INSTALLATION OF BATTERY Ensure vent tube is properly installed on battery elbow. Connect vent tube to vehicle fitting on front frame. Route RED positive cable behind retaining strip and connect it to positive battery terminal. Con- nect RED wire (coming from ignition switch).
Page 202: Electric Starter
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) ELECTRIC STARTER S-Series with Electric Starting A03E13S FLAT RATE PARTS 05-06-1...
Page 203: Removal
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) REMOVAL The radial play should not exceed 0.20 mm (0.008 in). If greater, replace the bushing. To replace, – Disconnect BLACK ground cable from battery. press out the old one toward bushing cover and press in a new one with a bushing pusher.
Page 204 Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A19E05A 1. Cut close to connector A19E02A Remove burrs with a file on the remaining welded 1. Stake bushing cover portion. 2. Support CAUTION : Be careful not to damage plas- 3, Bushing (end frame) tic portion of yoke.
Page 205: Cleaning And Inspection
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) CLEANING AND INSPECTION Refer to the end of this sub-section. ASSEMBLY Prior to assembling, coat sliding surfaces and moving parts on armature shaft splines, overrun- ning clutch, solenoid switch plunger, drive lever and bushings with G.E. Versilube G 321 (P / N 413 7040 00) lubricant.
Page 206: Installation
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A19E09A 1. Shorter stud 2. Bare wire INSTALLATION Make sure that starter and engine mating surfac- A09E0PA es are free of grime. Serious trouble may arise if 1. Screwdriver pulling starter pinion starter is not properly aligned. 2.
Page 207: Cleaning And Inspection
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) CLEANING AND INSPECTION CLEANING Check the commutator out-of-round condition with V Blocks and an indicator. If the commutator CAUTION : Armature starter yoke ass’y out-of-round is more than 0.40 mm (.016 in), the and drive unit assembly must not be im- commutator should be turned on a lathe.
Page 208 Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Test Armature for Shorted Winding : When the armature is rotated in the growler with a steel strip (hack-saw blade) held above it, the strip will vibrate over that area of the armature which has short circuit.
Page 209: Solenoid Switch
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A03E05A TYPICAL 1. New 2. Wear limit Overrunning Clutch The pinion of the overrunning clutch should turn smoothly in the clockwise direction, and should not slip in a counterclockwise direction. If defec- tive, replace. Check the pinion teeth for wear and damage.
Page 210: Testing Procedure
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL Two types of ignition systems are found on ROTAX engines covered by this manual ; both are Capac- itor Discharge Ignition (CDI) systems. The follow- ing chart gives the engine types with their implemented system.
Page 211: Use Of Bombardier Ignition Tester
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) All Systems The first 2 items can be checked with known au- tomotive equipment and other items as follows. Engine Stop Tether Cut-Out Switches Verification Engine Stop Switch Unplug stop switch connector from main harness then using an ohmmeter, connect test probes to BLACK / YELLOW and BLACK wires.
Page 212 Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) Test Condition Indicator Lamp Does Not Light One component is defective. Proceed as instruct- All tests are performed on the vehicle at ed to find defective component. cranking speed Intermittent Ignition Problems Vigorous manual cranking against compression causes the flywheel to snap over, raising the out- In dealing with intermittent problems there is no put higher than by cranking without compression,...
Page 213: Nippondenso Cdi System Testing
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) NIPPONDENSO CDI SYSTEM TESTING (Applicable to 277 Engine Type) NOTE : Ensure ignition cut-out switches are properly working and they are in the ON po- sition prior to performing the following tests. WARNING : To prevent powerful electric shocks while cranking engine, do not touch neither electronic ignition components (ignition coil, high tension wire, wire harness,...
Page 214: Magneto Output
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) A00E1JA 1. Black 2. White / Blue 4. Slip plastic protectors out of coil terminals. 5. Connect tester wires to coil terminals then set switch and dial as follows : NOTE : If necessary use jumper wires from coil terminals to tester wires.
Page 215: Lighting Generator Coil Output
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) 2. Connect tester wires then set switch and dial 2. Connect tester wires then set switch and dial as follows : as follows : Tester Tester Tester Tester Tester Component Tester Component switch dial switch dial...
Page 216: Summary Table
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) SUMMARY TABLE RESISTANCE MEASUREMENTS As an alternate method, magneto system compo- Test to Tester Component Switch Dial nents can be checked with a digital ohmmeter. perform wires wires NOTE : All resistance measurements must Test adapter be performed with parts at room tempera- on MAG...
Page 217 Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) PART NAME WIRE COLOR* RESISTANCE OHM REMARKS Ignition generator BK with BK 40 - 76 coil Lighting generator YL with YL 0.05 - 0.6 coil No display change Primary winding 0.11 - 0.21 means open circuit.
Page 218: Ducati Cdi System Testing
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) DUCATI CDI SYSTEM TESTING (Applicable to 377, 443 and 503 Engine Types) MAGNETO OUTPUT NOTE : Ensure ignition cut-out switches are properly working and they are in the ON po- (Ignition Generator Coil) sition prior to performing the following tests.
Page 219: Ignition Coil Output
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) IGNITION COIL OUTPUT IGNITION MODULE A paper clip of approximately 20 mm (3/4 in) will Ignition module can not be tested with the Bom- be used as a test adapter for the following test. bardier ignition tester.
Page 220: Summary Table
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) Results : a. Indicator lamp lights : Lighting generator coil output is up to specifications. b. Indicator lamp does not light : Lighting gen- erator coil is faulty. SUMMARY TABLE Test to Tester Component Switch Dial...
Page 221: Resistance Measurements
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) RESISTANCE MEASUREMENTS Disconnect connector at ignition coil and magneto junction. Measure resistance between each ter- As an alternate method, magneto system compo- minal. Refer to the following table for values and nents can be checked with a digital ohmmeter. wire colors.
Page 222: Voltage Regulator Inspection
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) VOLTAGE REGULATOR INSPECTION A faulty voltage regulator is often responsible for B) Voltmeter Test frequent burned bulbs. NOTE : Use a voltmeter able to read alter- CAUTION : Never run an engine with a nating current (AC).
Page 223: Inspection Of Ac Circuit Isolation
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) INSPECTION OF AC CIRCUIT ISOLATION All Electric Start Models If AC circuit is not isolated from frame, headlamp beam will weaken. INSPECTION Disconnect regulator / rectifier. Connect one digital ohmmeter probe (needle ohmmeter will not offer enough precision) to frame and other probe to YELLOW or YELLOW / BLACK magneto wires.
Page 224: Inspection Of Heating Elements
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) INSPECTION OF HEATING ELEMENTS All measurements must be performed at 21°C (70°F). Throttle Lever Heating Element Handlebar Grip Heating Element Resistance Measurement HIGH YELLOW BLACK wire 8.73 to INTENSITY 10.67 ohms ORANGE wire HIGH YELLOW BLACK wire...
Page 225 Section 06 REAR SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) TORQUE REACTION SUSPENSION..................06-02-1 COMPONENT REMOVAL ....................06-02-2 REMOVAL........................... 06-02-2 DISASSEMBLY AND ASSEMBLY ..................06-02-2 INSPECTION ........................06-02-3 RIDE ADJUSTMENT......................06-02-3 LUBRICATION ........................06-02-6 SC-10 SPORT AND TOURING SUSPENSION..................06-03-1 COMPONENT REMOVAL AND INSTALLATION .............. 06-03-2 REMOVAL...........................
Page 226: Torque Reaction Suspension
Section 06 REAR SUSPENSION Sub-Section 02 (TORQUE REACTION SUSPENSION) TORQUE REACTION SUSPENSION Tundra II LT 19 N•m (168 lbf•in) 19 N•m (168 lbf•in) 48 N•m (35 lbf•ft) 24 N•m (18 lbf•ft) 48 N•m (35 lbf•ft) Loctite 11 N•m (97 lbf•in) Loctite 24 N•m Loctite...
Page 227: Component Removal
Section 06 REAR SUSPENSION Sub-Section 02 (TORQUE REACTION SUSPENSION) COMPONENT REMOVAL 9,10,12, Nut, Slotted Screw and Slider Shoe Lift rear of vehicle and support it off the ground. To replace a worn shoe, remove the front screw and stop nut, then slide the shoe rearward out of 5, Rear Arm the runner.
Page 228: Inspection
Section 06 REAR SUSPENSION Sub-Section 02 (TORQUE REACTION SUSPENSION) Adjust track tension / alignment. Refer to TRACK 06-05. RIDE ADJUSTMENT The front portion of rear suspension is adjustable for surface condition and steering effects. The stopper strap is adjustable for vehicle weight transfer control.
Page 229 Section 06 REAR SUSPENSION Sub-Section 02 (TORQUE REACTION SUSPENSION) A05F0MA A05F0OA SOFTEST ADJUSTMENT RH SIDE 1. Supporting edge closest to hexagonal 2. Spring The stiffest adjustment is reached when the sup- porting edge of cam is the farthest to hexagonal portion of cam.
Page 230 Section 06 REAR SUSPENSION Sub-Section 02 (TORQUE REACTION SUSPENSION) A05F0CA A05F0FA 1. 1st hole – Turn adjustment cam by hand to the desired po- 2. 3rd hole sition. A. 11 N•m (97 lbf•in) – Reinstall spring on its support making sure that NOTE : When towing a load, it is suggested it sits in the groove of support.
Page 231: Lubrication
Section 06 REAR SUSPENSION Sub-Section 02 (TORQUE REACTION SUSPENSION) LUBRICATION Lubricate front and rear arms at grease fittings using low temperature grease (P / N 413 7061 00). NOTE : There are 4 grease fittings. A05F0GA 06-02-6...
Page 232: Sport And Touring Suspension
Section 06 REAR SUSPENSION Sub-Section 03 (SC-10 SPORT AND TOURING SUSPENSION) SC-10 SPORT AND TOURING SUSPENSION S-Series temp. grease temp. Loctite grease Loctite temp. 18 N•m grease (160 lbf•in) Loctite only Loctite Long track models only Loctite Loctite Loctite Short track models only Loctite A03F24S FLAT RATE...
Page 233: Component Removal And Installation
Section 06 REAR SUSPENSION Sub-Section 03 (SC-10 SPORT AND TOURING SUSPENSION) COMPONENT REMOVAL AND REMOVAL INSTALLATION 19, Cam Lift rear of vehicle and support it off the ground. Decrease spring preload by turning LH cam clock- wise and RH cam counterclockwise. 1, Rear Arm Release spring tension by unfastening spring sup- port.
Page 234: Disassembly And Assembly
Section 06 REAR SUSPENSION Sub-Section 03 (SC-10 SPORT AND TOURING SUSPENSION) NOTE : To prevent cross shaft from turning when unscrewing screws assembled with threadlocker, proceed as follows : – Knock on screw head and / or heat to break threadlocker bond.
Page 235: Inspection
Section 06 REAR SUSPENSION Sub-Section 03 (SC-10 SPORT AND TOURING SUSPENSION) 12,13,14, Front Shock, Spring Stopper and Cap Use shock spring remover (P / N 529 0271 00) in a vise. Mount shock in it and turn shock so that spring coils matched spring compressor.
Page 236: Installation
Section 06 REAR SUSPENSION Sub-Section 03 (SC-10 SPORT AND TOURING SUSPENSION) INSTALLATION The rear portion of rear suspension is adjustable for driver’s weight. Do not install rear spring yet. Install assembled suspension into track with front portion first. Insert rear portion of suspension into track. 2,3,4,5,6 Spring, Washer, Idler Wheel, Spacer and Screw On each side, install rear spring, washer, idler...
Page 237 Section 06 REAR SUSPENSION Sub-Section 03 (SC-10 SPORT AND TOURING SUSPENSION) To adjust rear suspension adjustment cams, use multi wrench supplied in vehicle tool box. Turning adjustment cam moves edges of cam supporting spring rod. The softest adjustment is reached when the supporting edge of cam is the closest to hexagonal portion of cam.
Page 238: Lubrication
Section 06 REAR SUSPENSION Sub-Section 03 (SC-10 SPORT AND TOURING SUSPENSION) CAUTION : Whenever stopper strap LUBRICATION length is changed, track tension must be Lubricate front and rear arms at grease fittings us- readjusted to prevent any possibility of operat- ing low temperature grease (P / N 413 7061 00).
Page 239: Drive Axle
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) DRIVE AXLE Tundra II LT A05D03S S-Series 11 5 A03F1CS 06-04-1...
Page 240: Removal
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) REMOVAL All Models Drain oil from chaincase or gearbox. Remove chaincase cover and release drive chain tension (if applicable). Raise and block rear of vehicle off the ground. Remove suspension. (Refer to REAR SUSPEN- SION 06).
Page 241 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) S-Series A00F07A 1. Pipe Tundra II LT A03F1DA A. 155.4 mm (6-1/8 in) B. 278.4 mm (10-31/32 in) All Models Ensure to align indexing marks of each sprocket when assembling. A00F08A TYPICAL 1.
Page 242: Axial Play
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) A00F0AA A00F0DA 1. Plane surface The bearing on the splined side of axle must be A. 1.5 mm (1/16 in) MAXIMUM pushed until it is seated on shaft shoulder. The CAUTION : The same sprocket must not end bearing housing bearing must be flush with be pressed twice on the axle.
Page 243 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) CAUTION : When installing one shim or more between chaincase and frame, se- cure with 50 mm long screws. BEARING POSITION TOWARD TOWARD TOWARD TOWARD FRONT OF REAR OF BOTTOM TOP OF VEHICLE VEHICLE OF VEHICLE...
Page 244 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) AXIAL PLAY ADJUSTMENT A01D09A 1. No gap all around – Pull drive axle toward the end bearing housing and take note of the measurement between sprocket and tunnel. A01D04A The drive axle axial play is the difference between TOP VIEW these 2 measurements.
Page 245: Installation
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) If the difference between each side exceeds 3 mm (1/8 in), redistribute drive axle shims as follows : DIFFERENCE DRIVE AXLE SHIM BETWEEN REDISTRIBUTION EACH SIDE Remove 1 shim from larger 3 to 4.5 mm gap side.
Page 246: Lubrication
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) 3, Retainer Ring ADJUSTMENT Make sure that welded nuts are toward inside of Sprocket / Track Alignment tunnel. CAUTION : Do not temper with sprocket / Lock drive axle sprocket with a circlip. track alignment if frame or suspension is Reinstall the chaincase cover (if applicable).
Page 247: Track
Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) TRACK TRACK TYPE APPLICATION S-Series Remove the following items : Refer to TECHNICAL DATA 09-03. – speedometer cable GENERAL – muffler – chaincase cover This section gives guidelines for track removal. Some components require more detailed disas- –...
Page 248 Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) Tundra II LT 35 to 45 mm (1-3/8 to 1-25/32 in) when exerting a downward pull of 7.3 kg (16 lb). A01B4JA 1. Example 45 mm 2. Extrusion Insert pre-setted gauge between slider shoe and A05A01A track.
Page 249 Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) All Models CAUTION : Too much tension will result in power loss and excessive stress on sus- pension components. If too loose, the track will have a tendency to thump. To adjust, loosen the rear idler wheel retaining screws (one side only on Tundra II LT and S-Series) and the adjuster bolt lock nut ;...
Page 250: Track Cleat
Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) – Place new cleat in position and using small track cleat installer (P / N 529 0085 00) or large cleat installer (P / N 529 0288 00) bend cleat then push tabs into rubber. A05F0EB TYPICAL 1.
Page 251 Section 07 STEERING / FRONT SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) STEERING SYSTEM ......................07-02-1 INSPECTION ........................07-02-3 DISASSEMBLY AND ASSEMBLY ..................07-02-3 INSPECTION ........................07-02-3 ADJUSTABLE HANDLEBAR ..................... 07-02-5 STEERING ADJUSTMENT (SKIS) ..................07-02-5 LUBRICATION ........................07-02-9 SUSPENSION AND SKI SYSTEM ..................07-03-1 ON-VEHICLE COMPONENT REMOVAL................
Page 252: Steering System
Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) STEERING SYSTEM Tundra II LT 24 N•m 6 24 N•m (18 lbf•ft) (18 lbf•ft) 18 N•m 53 N•m (159 lbf•in) 7.5 N•m (39 lbf•ft) (66 lbf•in) 53 N•m (39 lbf•ft) 18 N•m (159 lbf•in) 18 N•m...
Page 253 Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) S-Series 25 N•m (18 lbf•ft) 40 N•m (30 lbf•ft) 25 N•m (18 lbf•ft) 18 N•m (159 lbf•in) 18 N•m (159 lbf•in) 52 N•m (38 lbf•ft) 40 N•m (30 lbf•ft) 40 N•m (30 lbf•ft) 18 N•m (159 lbf•in)
Page 254: Inspection
Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) INSPECTION 31, Heating Grip Element On vehicle equipped with heating grips, grips Check skis and runner shoes for wear, replace as might be unremovable as explained earlier, in this necessary (see section 08-03). case, carefully proceed as follows to prevent damaging heating elements.
Page 255 Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Screw threaded end of ball joint into tie rod. The 21, Hardened Washer maximum external threaded length not engaged Install a hardened washer on each side. in tie rod must not exceed the value L in the fol- lowing chart : A17G0SA A25G0MA...
Page 256: Adjustable Handlebar
Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) ADJUSTABLE HANDLEBAR 7,23,24,25, Steering Pad, Bolt, Nut and Rubber Attachment 1,3, Steering Column and Handlebar CAUTION : Prior to installation, perform han- dlebar adjustment. If applicable, remove the steering clamp and nuts holding the handlebar to the steering column.
Page 257 Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) CAMBER: A specific inward or outward tilt angle of ski leg compared to a vertical line when viewing vehicle from front. This angle is not adjustable on these models. Adjustments TOE-OUT Tundra II LT Adjustments should be performed following this...
Page 258 Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) A05G09A LONG TIE ROD SHOWN 1. Ball joint parallel with arm Ensure that pivot arm is still centered and check ski toe-out. TOE-OUT A05G05A 1. Turn to adjust Loosen lock nuts of long tie rods and turn each tie rod so that skis are in a straight ahead position.
Page 259 Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) WARNING : Do not attempt to adjust skis straight ahead position by turning ball joint on tie rod no. 14. Procedure : – Loosen jam nuts no. 13 and no. 15 of both tie rods no.
Page 260: Lubrication
Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) LUBRICATION Other grease fittings require low temperature grease (P/N 413 7061 00) injected with a grease WARNING : Do not lubricate throttle and/ gun. or brake cable, housing and spring cou- The following symbols will be used to show what pler bolts.
Page 261 Section 07 STEERING / FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) S-Series If so equipped A06G08S PARTS FLAT RATE 07-02-10...
Page 262: Suspension And Ski System
Section 07 STEERING / FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM Tundra II LT 13 N•m (115 lbf•in) Grease Grease Grease 29 N•m (21 lbf•ft) A05G0JS FLAT RATE PARTS 07-03-1...
Page 263: On-Vehicle Component Removal
Section 07 STEERING / FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) ON-VEHICLE COMPONENT Suspension Free Operation REMOVAL Remove cover and check for free movement of ski leg by lifting end of ski. 8, Shock DISASSEMBLY Lift front of vehicle and support off the ground. Unscrew shock piston pin nut then remove wash- Lift front of vehicle and support off the ground.
Page 264: Inspection
Section 07 STEERING / FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) 4,13,14,16,17, O-ring, Ski Leg, Bushing 8, Shock Absorber and Seal Secure the shock body end in a vise. Pull up ski leg. Steering arm will not interfere. A14F0BA 1.
Page 265 Section 07 STEERING / FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) Steering arm notch must face outside of vehicle. A05G0CB 1. Recess facing outside 16,17, Seal Install seal before reinstalling ski leg. 07-03-4...
Page 266 Section 07 STEERING / FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) S-Series Loctite 242 A03G0CS FLAT RATE PARTS 07-03-5...
Page 267: Disassembly
Section 07 STEERING / FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 5, Shock Lift front of vehicle and support it off the ground. On models so equipped reduce spring preload by turning adjusting ring accordingly with special key in vehicle tool box.
Page 268: Inspection
Section 07 STEERING / FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) INSPECTION INSTALLATION Check all rubber cushions for crack and wear. Re- For assembly, reverse the disassembly proce- place as required. dure. However, pay attention to the following. Check straightness of splines and proper inter- Apply low temperature grease (P / N 413 7061 locking with steering arm.
Page 269 Section 08 BODY / FRAME Sub-Section 01 (TABLE OF CONTENTS) BODY............................08-02-1 INSTALLATION AND ADJUSTMENT ................08-02-1 HEADLAMP BEAM AIMING....................08-02-1 BULB REPLACEMENT ....................... 08-02-1 DECAL ..........................08-02-2 WINDSHIELD INSTALLATION................... 08-02-2 BELT GUARD ........................08-02-2 WIRING HARNESS ......................08-02-2 CABLES ..........................08-02-2 PIPING ..........................
Page 270: Body
Section 08 BODY / FRAME Sub-Section 02 (BODY) BODY INSTALLATION AND ADJUSTMENT HEADLAMP BEAM AIMING Required Conditions Place the vehicle on a flat surface perpendicular to Beam aiming is correct when center of high beam test surface (wall or screen) and 381 cm (12 ft 6 in) is 25 mm (1 in) below the headlamp horizontal cen- away from it.
Page 271: Decal
Section 08 BODY / FRAME Sub-Section 02 (BODY) DECAL BELT GUARD To remove a decal ; heat old decal with a heat gun Disassembly and Assembly and peel off slowly. NOTE : For additional information (ex. : ex- Using isopropyl alcohol, clean the surface and dry ploded view) refer to the correspondent thoroughly.
Page 272: Plastic Maintenance And Repair
Section 08 BODY / FRAME Sub-Section 02 (BODY) PLASTIC MAINTENANCE AND REPAIR MAINTENANCE – waxes containing an abrasive or a cleaning agent in their formula Clean the vehicle thoroughly, removing all dirt and CAUTION : Clean R.I.M. Metton ® with iso- grease accumulation.
Page 273: Material Repair Procedure
Section 08 BODY / FRAME Sub-Section 02 (BODY) MATERIAL REPAIR PROCEDURE Large Crack – Sand and scuff outside and inside area by ex- R.I.M. polyurethane is light colored (tan) on the in- ceeding it 31.7 mm (1-1/4 in) on each side and side with a smooth surface.
Page 274 Section 08 BODY / FRAME Sub-Section 02 (BODY) CREST MAIN OFFICE AND MANUFACTURING PLANT CREST INDUSTRIES, INC. Phone : 313-283-4100 Toll Free : 1-800-822-4100 3841 13 Street Fax : 1-800-344-4461 Wyandotte, Michigan Fax : 313-283-4461 48192 Crest products used in R.I.M. repair procedure are available from following locations : DISTRIBUTOR WAREHOUSE LOCATIONS UNITED STATES CANADA...
Page 275: Frame
Section 08 BODY / FRAME Sub-Section 03 (FRAME) FRAME FRAME CLEANING NOTE : For aluminum frames use only alu- minum cleaner and follow instructions on container. (Dursol cleaner or equivalent). Clean frame and tunnel with appropriate cleaners and rinse with high pressure hose. Touch up all metal spots where paint has been scratched off.
Page 276 Section 08 BODY / FRAME Sub-Section 03 (FRAME) Grinding Procedure Rear Cap Grind rivet heads from top of rear cap and under- neath for side retaining rivets. A06H0XA 1. Rivets heads ground 2. Rivets to be ground from underneath To remove rivet, strike with a punch from rivet head side.
Page 277 Section 09 TECHNICAL DATA Sub-Section 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..............meter ............. mass ..............kilogram ..........force ..............newton ........... liquid ..............liter ............temperature ............Celsius ........... °C pressure ..............
Page 278 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) VEHICLE MODEL TUNDRA II LT TOURING E, TOURING LE TOURING SLE, TOURING E LT, SKANDIC 500, SKANDIC 380, FORMULA SL FORMULA S ENGINE TYPE Number of Cylinders Bore 72.00 62.00 67.5 72.00 (in) (2.835) (2.441) (2.66)
Page 279 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL TUNDRA II LT TOURING E, TOURING E LT FORMULA S ENGINE TYPE Chain Drive Ratio 14/25 21/44 21/44 Chain Pitch Type / Links Qty / Plates Qty Single / 62 Silent / 72 / 11 Silent / 72 / 11 Drive Pulley Type of Drive Pulley...
Page 280 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL TOURING LE SKANDIC 380 TOURING SLE, FORMULA SL SKANDIC 500 ENGINE TYPE Chain Drive Ratio 21/44 21/44 21/44 22/44 Chain Pitch Type / Links Qty / Plates Qty Silent / 72 / 11 Silent / 72 / 11 Silent / 72 / 11 Silent / 72 / 11...
Page 281 Section 09 TECHNICAL DATA Sub-Section 04 (TECHNICAL DATA LEGENDS) ENGINE TECHNICAL DATA VEHICLE TECHNICAL DATA LEGEND LEGEND BP : Breaker Points DSA : Direct Shock Action BTDC :Before Top Dead Center RRIM : Reinforced Reaction Injection Molding CDI : Capacitor Discharge Ignition TRA : Total Range Adjustable drive pulley CTR : Center N.A.
Page 282 Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error Suggestion ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________ Date___________ Zip code/Postal code ________________________________________ Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error...
Page 283 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0...
Page 294 Section 00 Sub-Section 0 () ® 1997 Shop Manual VOLUME 2 MX Z 440F/440/583/670 FORMULA 500/500 DELUXE/583/Z SUMMIT 500/583/670 GRAND TOURING 500/583 SKANDIC WT/SWT/WT LC 00-0-1...
Page 295 Section 00 Sub-Section 0 (1997 SHOP MANUAL) Legal deposit: National Library of Quebec trimester 1996 National Library of Canada1996 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. ©...
Page 296 TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE ..........................1997 BOMBARDIER SNOWMOBILES SHOP MANUAL VOLUME 2 (INTRODUCTION) ....LUBRICATION 01 – Lubrication and maintenance chart .......... 01-01-1 AND MAINTENANCE TROUBLESHOOTING 01 – Table of contents..............02-01-1 02 – Engine ..................02-02-1 03 –...
Page 297 TABLE OF CONTENTS SECTION SUB-SECTION PAGE STEERING/ 01 – Table of contents ..............07-01-1 FRONT SUSPENSION 02 – Steering system............... 07-02-1 03 – Suspension and ski system ............. 07-03-1 BODY/FRAME 01 – Table of contents ..............08-01-1 02 – Body..................08-02-1 03 –...
Page 298 SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 1997 Ski-Doo snowmo- biles. See model list on next page. This edition was primarily published to be used by snowmobile mechanics who are already familiar with all service procedures relating to Bombardier made snowmobiles.
Page 299 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION This Shop Manual volume 2 covers the following Bombardier made 1997 snowmobiles: MODEL MODEL MODELS MODELS NUMBER NUMBER SUMMIT 500 (Canada) ....1157 MX Z 440F (Canada) ....... 1171 MX Z 440F (U.S.) ......1172 SUMMIT 500 (U.S.) ......
Page 300 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL LIST OF MODELS GROUPED BY COMMUN CHASSIS S-Series consists of: MX Z 440F/440/583/670 FORMULA 500/500 DELUXE/583/Z SUMMIT 500/583/670 GRAND TOURING 500/583 A06H01A TYPICAL 1. Vehicle serial number The engine also has a serial number. Fan-Cooled Engines A03H1UA TYPICAL —...
Page 301 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL ARRANGEMENT OF THE MANUAL The manual is divided into 09 major sections: 01 LUBRICATION AND MAINTENANCE 02 TROUBLESHOOTING 03 ENGINE 04 TRANSMISSION 05 ELECTRICAL 06 REAR SUSPENSION 07 STEERING/FRONT SUSPENSION 08 BODY/FRAME 09 TECHNICAL DATA ANNEXES Each section is divided in various sub-sections, and again, each sub-section has one or more divi-...
Page 302 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. TYPICAL PAGE Page heading indicates section and sub-section detailed. Sub-section title indicates Section 07 REAR SUSPENSION beginning of the sub-section.
Page 303 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL TYPICAL PAGE Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) Title indicates Turn puller handle and sliding half at once to extract INSTALLATION main procedure the bushing. to be carried-out. Countershaft CAUTION Always apply anti-seize lubricant (P/N 413 7010 Italic bold face type 00) on the countershaft before final pulley setting indicates a...
Page 304 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL GENERAL INFORMATION Use Tools and Accessories Catalog to order the tools you need. The information and component/system descrip- 1994 TOOLS AND ACCESSORIES (P/N 480 1343 tions contained in this manual are correct at time 00). of publication.
Page 305 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL The use of RIGHT and LEFT indications in the text, TIGHTENING TORQUES always refers to driving position (when sitting on Tighten fasteners to torque mentioned in explod- vehicle). ed views and text. When they are not specified refer to following table.
Page 306 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft...
Page 307 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS...
Page 308: Lubrication And Maintenance Chart
Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART REFER TO Starting Rope Condition — Engine Head Nuts Appropriate section: See Top End Appropriate section: See ENGINE Engine Mount Nuts REMOVAL Appropriate section: See ENGINE Exhaust System REMOVAL Engine Lubrication...
Page 309 Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) REFER TO Section 06: See appropriate Suspension Adjustments AS REQUIRED sub-section and Operator’s Guide Section 06: See appropriate Suspension Lubrication sub-section Section 06: See appropriate Suspension Condition sub-section Section 06: See appropriate Suspension Stopper Strap Condition sub-section Track Condition...
Page 310 Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 1 ENGINE LUBRICATION Models with a Choke Remove air silencers to spray storage oil into each Engine internal parts must be lubricated to protect carburetor bore. them from possible rust formation during the stor- age period.
Page 311 Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 3 FUEL FILTER REPLACEMENT Drain fuel tank. Remove fuel line grommet from fuel tank and pull out inlet fuel line from tank. A03H0LA TYPICAL 1. Filter A17C0DA To clean the filter, shake the snow out of it then, dry it out.
Page 312 Section 01 LUBRICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 8 GENERAL INSPECTION Inspect the hood and repair any damage. Touch up all metal spots where paint has been scratched Remove any dirt or rust. off. Spray all metal parts including shock chromed rods with Bombardier Lube (P/N 293 6000 06).
Page 313: Troubleshooting
Section 02 TROUBLESHOOTING Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE ..........................02-02-1 FUEL AND OIL SYSTEMS..................... 02-03-1 TRANSMISSION AND BRAKE SYSTEMS ................02-04-1 TRANSMISSION ........................ 02-04-1 BRAKE SYSTEM ........................ 02-04-8 MECHANICAL BRAKE ....................... 02-04-8 HYDRAULIC BRAKE ......................02-04-9 MECHANICAL AND HYDRAULIC BRAKES ..............
Page 314: Engine
Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) ENGINE The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM ENGINE BACKFIRES CONDITION NORMAL USE...
Page 315 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF CONDITION NORMAL USE Test/Inspection 1. Perform engine leak test. Refer to engine leak verification flow chart. Check possible piston seizure. a.Damaged gasket and/or seal. Replace defective parts. 2. “Four-corner” seizure of piston(s). a.Accelerating too fast when engine is cold.
Page 316 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 4. Melted and/or perforated piston dome; melted section at ring end gap. a.When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This situation is due to an incomplete combustion of a poor quality oil.
Page 317 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM PISTON RING AND CYLINDER SURFACES ARE GROOVED CONDITION NORMAL USE Test/Inspection 1. Check oil quality. a.Poor oil quality. Use Bombardier Rotax oil. 2. Check injection pump and its hoses. a.Inadequate injection pump adjustment and/or defective hoses. Adjust pump according to specifications (refer to ENGINE 03) and/or replace hoses.
Page 318 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 8. Check driven pulley. a.Worn bushing and/or spring tension. Replace spring and/or adjust its tension according to specifications (refer to TECHNICAL DATA 09). 9. Check exhaust system. a.Restriction. Replace. 10. Check ignition timing. a.Decrease in power due to retarded ignition. Adjust according to specification (refer to TECHNICAL DATA 09).
Page 319 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE TURNS OVER BUT FAILS TO START CONDITION NORMAL USE Test/Inspection 1. Check switches. a.Ignition switch, emergency cut-out switch or tether switch is in the OFF position. Place all switches in the RUN or ON position. 2.
Page 320 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 5. Check ignition system trigger coil air gap. a.Air gap is too large. Adjust according to specifications (refer to TECHNICAL DATA 09). 6. Check dimension of pilot jet. a.Inadequate fuel/air mixture. Adjust according to specifications (refer to TECHNICAL DATA 09). 7.
Page 321 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 8. Check carburetion. a.Improperly adjusted or inadequate carburetor components. Adjust according to specifications (refer to TECHNICAL DATA 09) or replace inadequate component(s). 9. Check cylinder head gaskets. a.Worn gaskets. Replace. 10. Check ignition timing. a.Ignition timing is too advanced.
Page 322 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH “RAVE”. ENGINE HESITATES AT MID-SPEED AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE CONDITION NORMAL USE Test/Inspection 1. Check “RAVE” valve spring(s). a.Spring tension is too weak or spring(s) is (are) broken. Replace.
Page 323 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE PINGING CONDITION NORMAL USE Test/Inspection 1. Check fuel lines. a.Bent fuel lines (preventing fuel from flowing through). Relocate or replace fuel lines. 2. Check if carburetor(s) is (are) clean. a.Dirt prevents fuel from flowing through. Clean.
Page 324: Fuel And Oil Systems
Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM HIGH FUEL CONSUMPTION (OR RICH MIXTURE) CONDITION...
Page 325 Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM CONDITION NORMAL USE Test/Inspection 1. Check fuel tank vent hose. a.Kinked or clogged hose. Relocate or replace. 2. Check fuel filter. a.Clogged filter. Replace.
Page 326 Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE) CONDITION NORMAL USE Test/Inspection 1. Check fuel filter ball located in fuel tank. Ball must move freely. a.Corrosion due to oxidation at installation. Replace fuel filter.
Page 327: Transmission And Brake Systems
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) TRANSMISSION AND BRAKE SYSTEMS The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. TRANSMISSION SYMPTOM THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED...
Page 328 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED CONDITION NORMAL USE Test/Inspection 1. Check items 1, 2 and 3 of “The snowmobile accelerates slowly, especially when it is stopped”. 2.
Page 329 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY CONDITION NORMAL USE Test/Inspection 1. Check drive belt. a.Belt width is uneven at many places. Replace (refer to TECHNICAL DATA 09 for the part number). 2.
Page 330 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY CONDITION NORMAL USE Test/Inspection 1. Check driven pulley spring tension. a.Spring tension is too weak. Adjust according to specifications (refer to TECHNICAL DATA 09). 2.
Page 331 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE CONDITION NORMAL USE Test/Inspection 1. Check if drive pulley bushings are worn. a.Insufficient pressure on belt sides. Replace bushing. 2. Check condition of drive pulley fixed half shaft. a.Rusted drive or driven pulley shafts.
Page 332 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT WORN NARROW IN ONE SECTION CONDITION NORMAL USE Test/Inspection 1. Check if parking brake is released. a.Parking brake is engaged. Release parking brake. 2. Check track tension/alignment. a.Frozen or too tight track. Liberate track from ice or check track tension and alignment.
Page 333 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT DISINTEGRATION CONDITION NORMAL USE Test/Inspection 1. Check drive belt identification number. a.Excessive belt speed. Using unspecified type of belt. Replace belt with proper type of belt (refer to TECHNICAL DATA 09). 2.
Page 334: Brake System
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT “FLIP-OVER” AT HIGH SPEED CONDITION NORMAL USE Test/Inspection 1. Check pulley alignment. a.Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA 09). 2. Check drive belt identification number. a.Using unspecified type of belt.
Page 335: Hydraulic Brake
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) HYDRAULIC BRAKE SYMPTOM SPONGY BRAKE CONDITION CONDITION NORMAL USE Test/Inspection Replace brake fluid and bleed system. If problem still occurs, replace master cylinder. SYMPTOM BRAKE FLUID LEAKING CONDITION NORMAL USE Test/Inspection 1.
Page 336: Electrical System
Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM STARTER DOES NOT TURN CONDITION...
Page 337 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 7. Check brushes. a.Poor contact of brushes. Replace brushes. 8. Check commutator. a.Burnt commutator. Turn commutator on lathe. 9. Check height of commutator mica. a.Commutator mica too high. Undercut mica. 10. Check field coil resistance. a.Shorted field coil.
Page 338 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 4. Check clutch bushing. a.Worn clutch bushing. Replace clutch. 5. Check starter bushing. a.Worn starter bushing(s). Replace bushing(s). 6. Check ring gear. a.Worn ring gear. Replace ring gear . SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED CONDITION NORMAL USE Test/Inspection...
Page 339 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN TURNING IGNITION SWITCH CONDITION NORMAL USE Test/Inspection 1. Check battery cables and starter wires. a.Corroded and/or loose connection(s). Clean and/or retighten. 2. Check fuse. a.Oxidized fuse. Clean.
Page 340 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM HEADLAMP DIMING CONDITION NORMAL USE Test/Inspection 1. Check voltage at headlamp at different speeds. It must not be below 11 VAC. a.Insufficient voltage in lighting circuit. Replace voltage regulator and retest. 2. Visually inspect wiring harness for damaged and/or melted wires and/or bad wire terminal crimping and/or connections.
Page 341 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM FALSE FUEL AND/OR TEMPERATURE GAUGE READINGS CONDITION NORMAL USE Test/Inspection 1. Verify if gauge was connected on DC current by mistake (in case of optional installation). a.Faulty installation of optional equipment. Find optional wires connected directly to DC ground (BK wire to chassis) or to any DC hot wire (RD, RD/BL).
Page 342 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 6. Verify condition of ignition generator coils. a.Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting screws. Replace coils. 7. Verify CDI (Capacitor discharge ignition) module. a.Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting screws.
Page 343 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) CONDITION RIDING IN DEEP AND THICK SNOW Test/Inspection 1. Perform all verifications outlined under “Engine does not start–no spark at spark plug”. 2. Verify spark plug(s). Proceed with spark plug analysis in order to identify source of problem.
Page 344 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM BRAKE LIGHT REMAINS ON CONDITION NORMAL USE Test/Inspection 1. Check if bulb is properly installed. a.Bulb is not installed correctly (contact elements are reversed). Install bulb correctly. 2. Check brake switch. a.Switch contact remains closed. Adjust brake cable or brake switch.
Page 345: Suspension System And Track
Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SUSPENSION SYSTEM AND TRACK The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM REAR SUSPENSION BOTTOMS OUT CONDITION...
Page 346 Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) 5. Check track rods and/or internal traction teeth. a.One or various track rods and/or teeth are broken. Replace track. SYMPTOM DERAILING TRACK CONDITION NORMAL USE Test/Inspection 1. Check track tension. a.Track is too loose. Adjust.
Page 347 Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SYMPTOM HANDLE BAR IS DIFFICULT TO TURN CONDITION NORMAL USE Test/Inspection 1. Check position of front spring adjustment cams. a.More pressure on the ground when cam increases spring preload. Reduce front spring preload. 2.
Page 348 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 443 AND 503 ENGINE TYPES................... 03-02-1 ENGINE REMOVAL AND INSTALLATION..............03-02-1 ENGINE REMOVAL AND INSTALLATION ..............03-02-2 TUNED PIPE IDENTIFICATION ..................03-02-2 ENGINE REMOVAL AND INSTALLATION ..............03-02-4 TOP END ........................03-02-5 CLEANING ........................
Page 349 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) ENGINE DIMENSION MEASUREMENT ............... 03-04-6 CYLINDER TAPER......................03-04-6 CYLINDER OUT OF ROUND ..................03-04-6 CYLINDER/PISTON CLEARANCE .................. 03-04-6 RING/PISTON GROOVE CLEARANCE ................03-04-7 RING END GAP....................... 03-04-7 CRANKSHAFT DEFLECTION ..................03-04-7 CONNECTING ROD BIG END AXIAL PLAY ..............03-04-8 CONNECTING ROD/PISTON PIN CLEARANCE............
Page 350 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) LIQUID COOLING SYSTEM ....................03-08-1 INSPECTION ........................03-08-3 DRAINING THE SYSTEM ....................03-08-3 DISASSEMBLY AND ASSEMBLY ................. 03-08-3 COOLING SYSTEM REFILLING PROCEDURE ............. 03-08-4 ROTARY VALVE, COOLANT PUMP AND RESERVOIR....................... 03-09-1 GENERAL ........................03-09-2 CLEANING ........................
Page 351: 443 And 503 Engine Types
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) 443 AND 503 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION 443 Engine Type 28 N•m (21 lbf•ft) 17 N•m (150 lbf•in) 37 N•m (27 lbf•ft) 35 N•m (26 lbf•ft) A03C13S FLAT RATE PARTS 03-02-1...
Page 352: Engine Removal And Installation
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following: WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models). –...
Page 353 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) Skandic WT/SWT 503 Engine Type 21 N•m (15 lbf•ft) A22C0FS FLAT RATE PARTS 03-02-3...
Page 354: Engine Removal And Installation
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following: WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models). –...
Page 355: Top End
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) TOP END 22 N•m 22 N•m (16 lbf•ft) (16 lbf•ft) 2 22 N•m (16 lbf•ft) only 22 N•m (16 lbf•ft) 22 N•m only (16 lbf•ft) 22 N•m (16 lbf•ft) Grease only A22C0KS FLAT RATE...
Page 356: Cleaning
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) NOTE: The following procedures can be done without removing the engine from chassis. CLEANING Discard all gaskets. Use Gasket Remover (P/N 413 7085 00) to clean mating surfaces. Clean all metal components in a non-ferrous met- al cleaner.
Page 357: Inspection
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) NOTE: The PTO cylinder or fan housing have to be removed to give access to MAG piston pin with the puller. NOTE: 0.25 and 0.5 mm oversized piston and rings are available if necessary. INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT 03-04.
Page 358 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) – When installing new needle bearing, insert needles with thrust washers. Instead of expan- sion sleeve, needles are held in place by 2 inner plastic cage halves. – Use piston pin puller (P/N 529 0210 00) to insert piston pin.
Page 359 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) NOTE: The ring compressor will not fit on over size pistons. Check flatness of intake sockets no. 10. Refer to ENGINE DIMENSION MEASUREMENT 03-04 529 0169 00 and look for checking surface flatness. At cylinder no.
Page 360 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) Position distance nuts no. 2 as illustrated. A17C06A 1. Distance nuts Cross torque cylinder head nuts nos. 1 and 2 to 22 N•m (16 lbf•ft); torque each cylinder head indi- vidually.
Page 361: Bottom End
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) BOTTOM END Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant Loctite 242 22 N•m (16 lbf•ft) 503: 22 N•m (16 lbf•ft) 443: 10 N•m (89 lbf•in) A03C1IT FLAT RATE FLAT RATE PARTS 03-02-11...
Page 362: Cleaning
Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) NOTE: Engine must be removed from chas- To check proper clearance between bearing no. 3 sis to perform the following procedures. and counterweight, use feeler gauge (P/N 420 8766 20). Remove engine from chassis.
Page 363 Section 03 ENGINE Sub-Section 02 (443 AND 503 ENGINE TYPES) For bearing lubrication purpose, a gap of 1.0 mm (.040 in) must be maintained between seals and bearings. When installing plain oil seals (seal without locat- ing ring or without spacing legs), ensure to main- tain 1.0 mm (.040 in) gap.
Page 364: Engine Support And Muffler
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) 454, 494, 583 AND 670 ENGINE TYPES3 ENGINE SUPPORT AND MUFFLER All Models 583 and 670 440 and 494 Loctite 454, 494 and 670 engines 23 N•m MX Z 440, (17 lbf•ft) 583 and 670 24 N•m...
Page 365: Removal From Vehicle
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) REMOVAL FROM VEHICLE 3,4,5, Tuned Pipe, Tail Pipe and Muffler These parts are identified on welded hook. Disconnect or remove the following from vehicle. Second number sequence of P/N is stamped on –...
Page 366 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) 3, Tuned Muffler This part is identified on welded support. Second number sequence of P/N is stamped on part. A03C1KA 1. Identification – Should a light exhaust leak be experienced at any ball joints, Dow Corning sealer no.
Page 367: Top End
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) TOP END 454, 583 and 670 engine types only 29 N•m Pipe sealant (21 lbf•ft) (P/N 413 7023 00) 494 engine only Loctite Grease Pipe sealant Grease (P/N 413 7023 00) 29 N•m (21 lbf•ft) 10 N•m...
Page 368: Cleaning
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) NOTE: The following procedures can be RAVE System done without removing the engine from NOTE: RAVE stands for Rotax Adjustable chassis. Variable Exhaust. Remove spring clip no. 3, cover no. 5 and spring CLEANING no.
Page 369: Assembly
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) A01C01A 1. Exhaust Use piston pin puller (P/N 529 0210 00) to ease piston pin installation. A24C05A To minimize the effect of acceleration forces on TYPICAL circlip, install each circlip so the circlip break is at 1.
Page 370 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) A00A1FA A. 0.43 mm (.017 in) feeler gauge A01C02B 2. Apply Loctite 242 to screw threads. Properly TYPICAL torque cylinders screws. 1. Circlip break 3. Lay down cylinder head and insert aligning pins in holes as shown.
Page 371 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) 420 8769 02 A24C0NA Apply Loctite 242 (P/N 413 7030 00) on cylinder screw threads. Install and torque screws in a criss-cross se- A25C0CA quence for each cylinder to 29 N•m (21 lbf•ft). For TYPICAL 454 and 670 engines longer screws go on exhaust 1.
Page 372 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) Torque screws no. 1 to 10 N•m (90 lbf•in). RAVE SYSTEM Install exhaust valve in cylinder with its mention TOP upward (see illustration at removal). Install gasket and valve rod housing with their pas- sages toward bottom.
Page 373: Bottom End
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) BOTTOM END Lithium grease 454, 494 engines only Loctite 454, 494 Anti-seize lubricant engines Anti-seize only lubricant Loctite 29 N•m (21 lbf•ft) Except 454, 494 and 670. See CDI Loctite SYSTEM 10 N•m...
Page 374: Cleaning
Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) NOTE: Engine must be removed from chas- ASSEMBLY sis to perform the following procedures. 2,4,5,6,9, Crankshaft Bearing and CLEANING Labyrinth Sleeve Smear anti-seize lubricant (P/N 413 7010 00) on Discard all oil seals, gaskets, O-rings and sealing part of crankshaft where bearing fits.
Page 375 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) 1,8, Upper Crankcase and Lower Crankcase Crankcase halves are factory matched and there- fore, are not interchangeable or available as single halves. Prior to joining of crankcase halves, spray some new injection oil (or equivalent) on all moving parts of the crankshaft.
Page 376 Section 03 ENGINE Sub-Section 03 (454, 494, 583 AND 670 ENGINE TYPES) NOTE: Torque the 2 smaller screws (15 and 16) on magneto side to 10 N•m (90 lbf•in). Apply pipe sealant (P/N 413 7023 00) on threads prior to assembly angular tube no. 11. At assembly on crankcase, apply medium strength threadlocker (P/N 413 7030 00) on stud threads no.
Page 377: Leak Test And Engine Dimension Measurement
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for liq- 10. Engine must stand this pressure during 3 min- uid cooled engines though it also applies to fan utes.
Page 378 Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Engine Check the following: 1. All jointed surfaces and screw/stud threads of engine: – spark plug base, insulator – cylinder head – cylinder base – crankcase halves (joint) – rotary valve cover –...
Page 379 Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Block both hoses of rotary valve gear lubrica- 1. Remove a spark plug or any plug of leak tester tion system with hose pinchers. kit on PTO side. If pressure drops, it indicates defective crank- shaft inner seal on PTO side.
Page 380: Finalizing Reassembly
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Remove rotary valve cover and check for leak COOLING SYSTEM LEAK TEST of rotary valve seal with soapy water. Install special plug (radiator cap) (P/N 529 0214 00) and hose pincher (P/N 529 0099 00) on overflow hose.
Page 381: Engine Leak Verification Flow Chart
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP...
Page 382: Engine Dimension Measurement
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT This section covers all engine types. CYLINDER TAPER ENGINE TYPE MAXIMUM 0.08 mm (.003 in) Compare cylinder diameter 16 mm (5/8 in) from top of cylinder to just below its intake port area. On rotary valve engines, measure just below aux- iliary transfer port, facing exhaust port.
Page 383: Ring/Piston Groove Clearance
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A01C0PA RING END GAP Position ring half way between transfer ports and intake port. On rotary valve engines, position ring just below transfer ports. NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher.
Page 384: Connecting Rod Big End Axial Play
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Measuring (on bench) NOTE: Crankshaft deflection can not be cor- rectly measured between centers of a lathe. Once engine is disassembled, check crankshaft If the deflection exceeds the specified tolerance, deflection on V-shaped blocks.
Page 385: Connecting Rod/Crankpin Clearance
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CRANKCASE/ROTARY VALVE GAP ENGINE TYPE MINIMUM MAXIMUM Liquid cooled 0.27 mm 0.40 mm engines (0.011 in) (0.016 in) First Method To measure this gap use a feeler gauge inserted between rotary valve and upper crankcase with the rotary valve cover in place without its O-ring.
Page 386: Checking Surface Flatness
Section 03 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Install 2 short pieces (13 mm (1/2 in) long) of sol- der directly on rotary valve, one above and one be- low rotary valve gear. Apply grease to hold solder in position.
Page 387: Cdi System
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 454, 494, 583, and 670 Engines Dielectric grease (P/N 413 7017 00) 454,494 and 670 engines Loctite Loctite Loctite Loctite All engines except 454, 494 and 670 Loctite Dielectric grease (P/N 413 7017 00)
Page 388: Cleaning
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) NOTE: The following procedures can be done without removing the engine from chassis. To facilitate magneto removal, hold drive pulley with tool (P/N 529 0276 00). CDI means Capacitor Discharge System. CLEANING Clean all metal components in a non-ferrous met- al cleaner.
Page 389 Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) A25E1AA 1. Magneto harness through crankcase hole – Install new trigger coil and other parts re- moved. Adjustment A15E0NA Whenever the trigger coil or the magneto fly- ADJUSTING TRIGGER COIL AIR-GAP wheel is removed or replaced, the air-gap be- 1.
Page 390: Assembly
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) 2,5, Magneto Flywheel and Nut Clean crankshaft extension (taper) and apply Loc- tite 242 (blue) on taper, then position Woodruff key, flywheel and lock washer on crankshaft. Clean nut threads and apply Loctite 242 (blue) then tighten nut 125 N•m (92 lbf•ft) for 454, 494 and 670 engines.
Page 391: Ducati Ignition System
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) DUCATI IGNITION SYSTEM 443 and 503 Engines Dielectric grease Loctite 105 N•m (77 lbf•ft) Loctite 22 N•m (195 lbf•in) A07C03S FLAT RATE PARTS 03-05-5...
Page 392: Cleaning
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) NOTE: The following procedures can be NOTE: To correctly remove a threadlocked done without removing the engine from fastener it is first necessary to tap on the fas- chassis. tener to break threadlocker bond. This will elimi- nate the possibility of thread breakage.
Page 393: Assembly
Section 03 ENGINE Sub-Section 05 (CDI SYSTEM) ASSEMBLY Clean crankshaft extension (taper). Apply Loctite 242 (blue) on taper. Position Woodruff key, flywheel and lock washer on crankshaft. Clean nut threads and apply Loctite 242 (blue) be- fore tightening nut to 105 N•m (77 lbf•ft). At reassembly coat all electric connections with silicone dielectric grease (P/N 413 7017 00) to pre- vent corrosion or moisture penetration.
Page 394: Oil Injection System
Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 454, 494, 583 and 670 Engines O i l p u t s e t g a s k e Loctite Molykote Loctite Parts in illustration marked with X are not available as single parts.
Page 395 Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) 443 and 503 Engines Loctite 242 Loctite Molykote 111 A22C0DS PARTS FLAT RATE 03-06-2...
Page 396: Oil Pump Identification
Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) OIL PUMP IDENTIFICATION Different engines use different pumps. See iden- tification on lever no. 7. 420 2779 05 CAUTION Always mount proper pump on engine. OIL PUMP ENGINE TYPE IDENTIFICATION 443 MX Z A00C17A TYPICAL 494 Skandic WT LC...
Page 397 Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) A15C2DA A13C0PA 1. Adjuster nut 1. Small oil line 2. Bleeder screw 2. Marks aligned 3. Marks in line 3. Main oil line Reinstall all parts except air silencer. CAUTION Bleed the small oil line between pump and intake manifold by running engine at idle while holding Proper oil injection pump adjustment is very the pump lever in fully open position.
Page 398 Section 03 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) CHECKING OPERATION If not, remove pump assembly and check the pump gear and drive shaft (if applicable) for de- fects, replace as necessary. Test pump as de- On Vehicle scribes below. NOTE: Main oil line must be full of oil. See NOTE: Through normal use, oil level must bleeding procedure above.
Page 399: Axial Fan Cooling System
Section 03 ENGINE Sous-section 07 (AXIAL FAN COOLING SYSTEM) AXIAL FAN COOLING SYSTEM 443 Engine 13 N•m (115 lbf•in) 443 and 503 engines only 47 N•m (35 lbf•ft) A03C0WS FLAT RATE PARTS 03-07-1...
Page 400 Section 03 ENGINE Sous-section 07 (AXIAL FAN COOLING SYSTEM) 503 Engine 13 N•m (115 lbf•in) 13 14 15 16 55 N•m (41 lbf•ft) A22C0IS PARTS FLAT RATE 03-07-2...
Page 401: Removal
Section 03 ENGINE Sous-section 07 (AXIAL FAN COOLING SYSTEM) NOTE: The following procedures can be done without removing engine from chassis. REMOVAL NOTE: To facilitate further disassembly, fan nut may be removed before removing fan housing. Remove rewind starter, starting pulley, trigger coil wire from 4-connector housing then fan housing ass’y.
Page 402 Section 03 ENGINE Sous-section 07 (AXIAL FAN COOLING SYSTEM) Using a press, drive the fan shaft no. 9 out. Remove circlip no. 11 then remaining bearing. To install, press one bearing in place then install circlip and shims. Press the other bearing from op- posite side until it is flush with housing.
Page 403: Liquid Cooling System
Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM All S-Series Engines Loctite A06C2VT FLAT RATE PARTS 03-08-1...
Page 404 Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) Skandic WT LC Loctite Loctite A29C0AS PARTS FLAT RATE 03-08-2...
Page 405: Inspection
Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) INSPECTION 6,7, Radiator and Radiator Protector Insert radiator protector into radiator C-rail and Check general condition of hoses and clamp tight- crimp C-rail at both ends. Refer to FRAME 09-02 ness. for radiator removal. DRAINING THE SYSTEM 5, Thermostat To check thermostat, put in water and heat water.
Page 406: Cooling System Refilling Procedure
Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) COOLING SYSTEM REFILLING PROCEDURE Recommended Coolant Use a blend of 60% antifreeze with 40% water. Do not reinstall pressure cap. CAUTION To prevent rust formation or freezing condi- tion, always replenish the system with 60% antifreeze and 40% water.
Page 407 Section 03 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) Turn engine off. Let it cool down for 15 to 20 min- utes. Open cap and refill filler neck completely. Start engine and let it idle. Do not race engine. If coolant level gets down, add more coolant in filler neck.
Page 408: Rotary Valve, Coolant Pump And Reservoir
Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) ROTARY VALVE, COOLANT PUMP AND RESERVOIR 454, 494, 583 and 670 Engines Injection oil reservoir Loctite To rotary valve gear Molykote Loctite 22 N•m (16 lbf•ft) A06C2UT TYPICAL FLAT RATE PARTS 03-09-1...
Page 409: General
Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) NOTE: Some verifications can be performed with engine in vehicle. Refer to ENGINE DI- MENSION MEASUREMENT 03-04. GENERAL Engine must be removed from vehicle to work on rotary valve shaft/components. Refer to Removal and installation of appropriate engine for proce- dures.
Page 410: Inspection
Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) To remove bearing, use a bearing puller (ex.: Snap-on no. CJ 950) and pusher (P/N 420 8766 12) as illus- trated. 420 8765 12 420 8766 12 A16C0OA INSPECTION Inspect rotary valve cover for warpage.
Page 411 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) 11, Bearing 6201 To install bearing 6201 use bearing pusher (P/N 420 8765 00). 420 8765 00 A13C0FA 1. Bearing 2. Shielded portion of seal here 3. Press 4. Bearing puller. Ex.: Snap-on no. CJ 950 A16C19A Install distance sleeve with its counterbore first.
Page 412 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) – Install rubber washer then support plate with its flange towards pump impeller. Use impeller support plate pusher (P/N 529 0207 00) for proper installation. – Install small thrust washer then friction washer positioning its grooves against pump impeller.
Page 413 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) 18,19, Pump Housing Bolt and Loctite 242 (Blue) Apply Loctite 242 (blue) on bolt threads. 420 8765 00 Rotary Valve The rotary valve controls the opening and closing of the inlet ports. Therefore its efficiency will de- pend on the precision of its installation.
Page 414 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) Installation To correctly install rotary valve, proceed as fol- lows: – Turning crankshaft, bring MAGneto side piston to Top Dead Center. Use a dial indicator (P/N 414 1047 00). 414 1047 00 A00B2EA A16C16A...
Page 415 Section 03 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) To Time Rotary Valve Exactly to Specifications NOTE: If desynchronization (out of spec.) is unknown, install rotary valve to determine it before proceeding with the following. 132° First Method Turn crankshaft to bring MAG piston to TDC.
Page 416: Rewind Starter
Section 03 ENGINE Sub-Section 10 (REWIND STARTER) REWIND STARTER All Models Molykote G-n paste or equivalent Silicone compound grease Silicone compound grease 10 N•m (89 lbf•in) 583 MX Z, 583 Summit and 670 engines only A01C57T TYPICAL FLAT RATE PARTS 03-10-1...
Page 417: Removal
Section 03 ENGINE Sub-Section 10 (REWIND STARTER) REMOVAL Using a small screwdriver, extract rope knot from starter grip no. 16. Cut rope close to knot. Tie a knot near starter. Remove screws no. 3 and washers no. 2 secur- ing rewind starter no. 1 to engine then remove re- wind starter.
Page 418: Installation
Section 03 ENGINE Sub-Section 10 (REWIND STARTER) A01C0CA Position pawl no. 8, pawl lock no. 9 and circlip A01C14A no. 10. 1. Grease inside spring guide Install locking spring no. 11 and lubricate with MOLYKOTE G-n paste from Dow Corning ®...
Page 419 Section 03 ENGINE Sub-Section 10 (REWIND STARTER) Prior to installing starter grip no. 16 on new rope, it is first necessary to fuse the rope end with a lit match. pass rope through rubber buffer no. 15 and starter grip and tie a knot in the rope end. fuse the knot with a lit match then insert rope end down and pull the starter grip over the knot.
Page 420: Carburetor And Fuel Pump
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP All Models To other carburetor MX Z 440 F and Skandic WT series only A03C1MS FLAT RATE PARTS 03-11-1...
Page 421: Removal
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) REMOVAL 15, Filter Check for clogged filter. Clean or replace as re- Remove air silencer(s). Refer to BATTERY 05-05. quired. Disconnect fuel inlet line. Check inlet needle tip condition. If worn, the inlet Disconnect primer line from carburetor on some needle and seat must be replaced as a matched models.
Page 422: Disassembly And Assembly
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) DISASSEMBLY AND ASSEMBLY The size of the throttle slide cut-away affects the fuel mixture between 1/8 to 1/2 throttle opening. NOTE: To ease the carburetor disassembly and assembly procedures it is recommend- ed to use carburetor tool kit (P/N 404 1120 00).
Page 423 Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) FLOAT HEIGHT H CARBURETOR ± 1 mm MODEL (± .040 in) MX Z 440 F 23.9 (.941) MX Z 440 23.9 (.941) MX Z 583 18.1 (.713) MX Z 670 18.1 (.713) Formula 500/500 DL 18.1...
Page 424: Installation
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) NOTE: Do not obstruct hole in throttle slide Throttle slide openings when installing needle retaining plate. This is important to allow air escaping through and thus Wide allowing a quick response. open Close 13,6,...
Page 425: Carburetor Adjustments
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) CARBURETOR ADJUSTMENTS A02C09A A01C33A 1. Idle speed screw TYPICAL 2. Air screw 1. Screw in and out until no cable free play exists 2. Check that throttle side does not move 6, Air Screw Adjustment 3.
Page 426: Preliminary Idle Speed Adjustment
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) Twin Carburetor Models Only Repeat on the other one. This will ensure identical throttle slide preliminary idle setting. Recheck car- buretor synchronization. Adjust idle by turning both idle speed screws of the same amount. CAUTION On twin carburetor models, make sure both carburetors start to operate simultaneously.
Page 427 Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) NOTE: On twin-carburetor models: Turn Throttle Slide Height Models adjustment screw the same amount to keep mm (in) carburetors synchronized. MX Z 440 F 1.5 (.059) Refer to TECHNICAL DATA 09 for the specifica- MX Z 440 1.8 (.071) tions.
Page 428: Hac System
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) HAC SYSTEM To magneto housing A03I0BS FLAT RATE PARTS 03-11-9...
Page 429: Fuel Pump
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) FUEL PUMP 443/503 engines 454 engine 583, 599, 670 and 779 engines A06C39T PARTS FLAT RATE 03-11-10...
Page 430: Removal
Section 03 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) REMOVAL Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed Install a hose pincer (P/N 529 0099 00) on fuel air. supply line close to pump inlet. WARNING Solvent with a low flash point such as gaso- line, naphtha, benzol, etc., should not be...
Page 431: Fuel Tank And Throttle Cable
Section 03 ENGINE Sub-Section 12 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE Fuel Tank Lines Models with Easy Action Throttle Lever WARNING When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with a hose pincher (P/N 529 0099 00) or equivalent device.
Page 432 Section 03 ENGINE Sub-Section 12 (FUEL TANK AND THROTTLE CABLE) Throttle Cable O-ring and Retaining Ring at Carburetor (some models) Locate O-ring outside of carburetor cover and re- taining ring inside. 100.7° A01E18A 1. Full position (3 ± 2 Ω ) 2.
Page 433 Section 04 TRANSMISSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DRIVE BELT........................04-02-1 1997 APPLICATION CHART ..................04-02-1 ROTATION DIRECTION....................04-02-1 DRIVE BELT DEFLECTION MEASUREMENT ............... 04-02-2 DEFLECTION ADJUSTMENT..................04-02-3 DRIVE PULLEY........................04-03-1 TRA ..........................04-03-1 GENERAL ........................04-03-2 REMOVAL........................
Page 434 Section 04 TRANSMISSION Sub-Section 01 (TABLE OF CONTENTS) CHAINCASE........................04-07-1 REMOVAL ........................04-07-2 INSPECTION ........................04-07-2 GEAR RATIO MODIFICATION..................04-07-2 INSTALLATION ....................... 04-07-2 DRIVE CHAIN ADJUSTMENT..................04-07-3 ADJUSTMENT........................ 04-07-4 GEARBOX........................... 04-08-1 3-SPEED GEARBOX (SHIFTER MECHANISM).............. 04-08-1 REMOVAL ........................04-08-2 ADJUSTMENT........................ 04-08-2 3-SPEED GEARBOX .......................
Page 435: Drive Belt
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) DRIVE BELT 1997 APPLICATION CHART PART WIDTH (NEW) MINIMUM WIDTH MODEL ± 0.25 mm (.010 in) NUMBER (WEAR LIMIT) SUMMIT 583/670 AND MX Z 670 415 0603 00 35 mm (1-3/8’’) 33 mm (1-19/64’’) SUMMIT 500, GRAND TOURING 500/583, FORMULA 500/500DL/583/Z 415 8607 00...
Page 436: Drive Belt Deflection Measurement
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) DRIVE BELT DEFLECTION MEASUREMENT NOTE: The drive belt deflection measure- ment must be performed each time a new drive belt is installed. NOTE: To obtain an accurate drive belt de- flection measurement, it is suggested to al- low a break-in period of 50 km (30 mi).
Page 437: Deflection Adjustment
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) Allen screws should be restrained while tighten- ing jam nut to prevent throwing adjustment out. Use drive belt tension adjuster (P/N 529 0087 00). 529 0087 00 A00D08A A15B05B 1. Upper O-ring 2. Force 3.
Page 438: Drive Pulley
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) DRIVE PULLEY All Models NOTE: This is a lubrication free drive pulley. 12 N•m Loctite Loctite Loctite (106 lbf•in) 27 N•m (20 lbf•ft) 13 N•m (115 lbf•in) Loctite 10 N•m (89 lbf•in) Loctite 95 N•m (70 lbf•ft) Repair kit...
Page 439: General
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) GENERAL Some drive pulley components (return spring, ramp) can be changed to improve vehicle perfor- mance in high altitude regions. The High Altitude Technical Data booklet (P/N 484 0648 00 and 484 0545 00 for binder) gives information about cali- bration according to altitude.
Page 440: Disassembly
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) To Remove Drive Pulley Ass’y: 32, Cushion Drive Retain drive pulley with clutch holder. CAUTION Install puller in pulley shaft then tighten. Do not disassemble cushion drive. Governor DISASSEMBLY cup and cushion drive are factory balanced as an assembly.
Page 441: Cleaning
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 19, Spring Cover Ass’y Using a paper towel with cleaning solvent (P/N 413 7082 00), clean crankshaft tapered end and It is pushed by clutch spring pressure. the taper inside the fixed half of the drive pulley, crankshaft threads and retaining screw threads.
Page 442: Inspection
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) INSPECTION Drive pulley should be inspected annually. 16,17, Thrust Washer and Roller 529 0313 00 Check roller for roundness of external diameter. Check thrust washer for thickness wear. Replace 529 0312 00 as required. CAUTION Ensure rollers are in good condition.
Page 443: Assembly
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Press bushing. 15, Pin Always use the same type of pin as originally in- stalled when servicing. Different types have dif- ferent weights for calibration purpose. Refer to TECHNICAL DATA 09-03. 21,22,23, Ramp, Dowel Tube and Screw 529 0313 00 Insert dowel tube from chamfered side.
Page 444 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 9,11,13,14, Screw, Lever Ass’y, Nut and Lift sliding half against spring cover and align spring cover arrow with sliding half mark. Cotter Pin Always install lever assemblies so that cotter pins are at the shown side. Besides install cotter pin head on top when lever is sat at bottom of sliding half.
Page 445: Installation
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) INSTALLATION WARNING 529 0055 00 Do not apply anti-seize or any lubricant on crankshaft and drive pulley tapers. WARNING Never use any type of impact wrench at drive pulley removal and installation. A16B02A Clean mounting surfaces as described in CLEAN- ING above.
Page 446: Drive Pulley Adjustment
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Recheck the torque of 90 to 100 N•m (66 to 74 Governor cup has 6 positions numbered 2 to 6. lbf•ft). Note that in position 1 there is no stamped num- ber (due to its location on casting). WARNING See TECHNICAL DATA 09-03 for original setting.
Page 447 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) A16D0HA 1. Loosen just enough to permit rotating of calibration screw 04-03-10...
Page 448: Driven Pulley
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) DRIVEN PULLEY S-Series Anti-seize lubricant (P/N 413 7010 00) Loctite 609 All MX Z except 440 F All MX Z except 440 F A03D2FS FLAT RATE PARTS 04-04-1...
Page 449 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Skandic WT/SWT/WT LC Anti-seize lubricant A22D11S PARTS FLAT RATE 04-04-2...
Page 450: Removal
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) REMOVAL CLEANING Remove belt guard and drive belt from vehicle. 6,7, Large Bushing and Small Bushing Remove the cap screw no. 13, lock washer During break-in period (about 10 hours of use), te- no.
Page 451 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Replace bushing(s) if worn more than specified. Install support plate (P/N 529 0311 03) inside slid- ing half. DRIVEN PULLEY BUSHING WEAR LIMIT Place puller (P/N 529 0311 02) below bushing. mm (in) Small bushing 38.30 (1.508) Large bushing...
Page 452: Assembly
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Turn puller handle and sliding half at once to ex- 19, Cam tract the bushing. Coat cam interior with anti-seize lubricant. INSTALLATION 14,15, Countershaft and Anti-seize Lubricant 529 0313 00 CAUTION Always apply anti-seize lubricant (P/N 413 529 0312 00 7010 00) on the countershaft before final pul- ley installation.
Page 453: Adjustment
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) ADJUSTMENT Refer to PULLEY DISTANCE AND ALIGNMENT 04-05 to adjust pulley distance. Adjust drive belt 529 0065 00 height in driven pulley to obtain specified belt de- flection. 5, Spring General It is usual to experience spring setting during breaking period of a new spring.
Page 454 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Pulley Alignment and Drive Belt Deflection Refer to PULLEY DISTANCE AND ALIGNMENT 04-05 and DRIVE BELT 04-02 to perform adjust- ments. CAUTION Drive belt and pulley adjustments must always be checked whenever pulleys have been re- moved, replaced or disassembled.
Page 455: Pulley Distance And Alignment
Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) PULLEY DISTANCE AND ALIGNMENT GENERAL Measuring Procedure Using Straight Bar: The pulley distance we will refer to in this section, is the space separating the drive and driven pulley Always measure distances X and Y from the far- outside diameters (Z measurement).
Page 456: Pulley Alignment And Distance Specifications Chart
Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) Drive Belt Deflection NOTE: When pulley distance and alignment are adjusted to specifications, refer to DRIVE BELT 04-02 to adjust drive belt deflection. CAUTION This section deals mainly with adjustment procedures. For complete assembly require- ments, refer to the proper ENGINE or TRANSMISSION installation section.
Page 457 Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) S-Series Pulley Alignment Method Driven Pulley Movement When engine slotted mounting holes do not allow to set proper pulley offset X, adjust with shims (P/N 504 1082 00) between pulley and counter- shaft bearing support (pulley pushed toward brake disc).
Page 458: Brake
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) BRAKE HYDRAULIC DISC BRAKE S-Series Loctite Anti-seize lubricant Black Max MX Z 440 F Formula 500/500 Deluxe Summit 500/583 All Models GT 500/583 Except MX Z 440 F only Formula 500/500 Deluxe Summit 500/583 Anti-seize lubricant GT 500/583 A03D2DS...
Page 459: Removal
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) REMOVAL BRAKE DISC REMOVAL S-Series Brake disc can be withdraw without removing cal- iper. Proceed as follows: – Remove belt guard, belt and driven pulley. – Remove air silencer. – Unbolt bearing support no. 19 from chassis. –...
Page 460: Disassembly
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) 529 0302 00 A03D29A 1. Screw A03D1KA Pull bearing to driven pulley side out of counter- 1. Spacer shaft, using remover (P/N 529 0301 00). Begin with only the remover then add a spacer of differ- DISASSEMBLY ent width as the bearing comes out.
Page 461: Assembly
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) A06D15A INSTALLATION To install brake, reverse removal procedure paying attention to the following. A15D03A WARNING TYPICAL 1. Fixed pad 2. Inner caliper Avoid getting oil on brake pads. Do not lubri- A. 1 mm (1/32 in) minimum cate or apply antirust or antifreeze solution in brake cable.
Page 462: Adjustment
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) Refer to DRIVE AXLE 06-04 then look Chaincase Perpendicularity Adjustment. Torque castellated nut of upper sprocket to 53 N•m (39 lbf•ft). CAUTION Upper sprocket castellated nut must be tightened before adjusting bearing collar. Slide collar no. 18 towards bearing and turn, by hand, to engage the eccentric.
Page 463 Section 04 TRANSMISSION Sub-Section 06 (BRAKE) A06D0JA 1. Open bleeder 2. Clear hose to catch used brake fluid Brake Light There is no adjustment on these models. Check that switch is securely installed. 04-06-6...
Page 464: Chaincase
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) CHAINCASE S-Series Without Reverse Gear Loctite Chaincase 45 to 75 N•m (33 to 55 lbf•ft) 46 N•m Loctite Loctite 609 (34 lbf•ft) Loctite 242 SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER A06D17S FLAT RATE PARTS 04-07-1...
Page 465: Removal
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) REMOVAL Using 2 large screwdrivers inserted between chaincase no. 7 and frame, pry complete assem- To remove chaincase proceed as follows. bly from vehicle. Remove tuned exhaust pipe and muffler. INSPECTION WARNING Visually inspect the chain for cracked, damaged or missing links.
Page 466: Drive Chain Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) 5,16, Sprockets 18, Circlip Position the sprockets with the writing facing the CAUTION chaincase cover. It is of the utmost importance to install the 27, Conical Spring Washer circlip otherwise damage to the chaincase Install washer with its concave side towards drive components may occur.
Page 467: Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) A03A03A TYPICAL 1. Dipstick NOTE: Chaincase must be in its proper posi- tion when checking oil level. ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04-05. Track Tension and Alignment Refer to TRACK 06-05. 04-07-4...
Page 468: Gearbox
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) GEARBOX 3-SPEED GEARBOX (SHIFTER MECHANISM) Skandic WT/WT LC A22D0YS FLAT RATE PARTS 04-08-1...
Page 469: Removal
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) REMOVAL 1,2, Cable and Cable Housing Remove screw from underneath top portion of transmission. Remove cable barrel from shifter: see last photo. A22D0QA 1. Clip 2. Lock nut Adjust tie rod length in a way that gear shift lever does not contact console.
Page 470: 3-Speed Gearbox
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) 3-SPEED GEARBOX Skandic WT/SWT/WT LC A22D0CS FLAT RATE PARTS 04-08-3...
Page 471: Removal
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) REMOVAL Remove brake disc and driven pulley. Unfasten shifting rod and cable. See above CABLE RE- MOVAL. Remove rear suspension. Remove angle drive and square pin. Remove RH end bearing then push drive axle to- ward right side.
Page 472 Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) Drive out driven pulley shaft. Use alignment tool (P/N 420 4760 10) as a supporting plate to extract last gear and bearing. Spacer will fall into gearbox housing. 420 4760 10 A22D0FA 18,19,26,27,28, Reverse Shaft, LH Side A22D0HA Bearing, Brake Shaft, Sleeve and Gear 21,22,29,30, Screw, Washer,...
Page 473: Inspection
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) CAUTION Do not push against inner bearing race. A22D0KA 1. Gear shoulder towards RH side 18,19,26,27,28, Reverse Shaft, LH Side Bearing, Brake Shaft, Sleeve and Gear A22D0JA Install brake shaft taking care that gear shoulders 1.
Page 474: Installation
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) A22D0OA A22D0MA INSTALLATION Install shim and bearing on LH side. Reverse removal procedure. Check pulley align- Install driven pulley shaft, sliding sleeve then gear. ment. Turn brake shaft during installation and check that gears mesh. OIL LEVEL To check, pull dipstick.
Page 475 Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) 2-SPEED GEARBOX Grand Touring 500/583 Grease Loctite 15 N•m (133 lbf•in) Grease 48 N•m (35 lbf•ft) Loctite 29 N•m (21 lbf•ft) 5 N•m Loctite (44 lbf•in) Loctite A03D17S PARTS FLAT RATE 04-08-8...
Page 476: Disassembly
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) DISASSEMBLY First remove 19-tooth reverse gear no. 18 and then remove reverse axle no. 20. NOTE: It is possible to see the sliding gear in motion through oil gauge hole. Unbolt gear shift linkage from shifter. Unscrew cover screws no.
Page 477 Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) Install drive axle with track then bearing and circlip Install chain no. 28, 44-tooth sprocket no. 34 and in chaincase bore. Install spacer no. 38 with its its spacer no. 38. Spacer’s large outer diameter large outer diameter against sprocket, 44-tooth must be against sprocket.
Page 478: Adjustment
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) 5,7,8, Screws and Locking Tab Tighten screws in a criss-cross sequence starting with the one above reverse axle. Install reverse axle screw and bend locking tab against screw head flat. Bolt shift linkage to shifter. ADJUSTMENT 28, Chain Fully tighten adjustment screw by hand, then...
Page 479: Oil Change
Section 04 TRANSMISSION Sub-Section 08 (GEARBOX) A06D1QA OIL CHANGE Place a container under bottom pan (gearbox A03A03A side). 1. Dipstick Unbolt gear shift linkage from fork axle. Unbolt and remove cover by separating it from housing Shifter can be put in reverse position to ease re- and by moving it toward the front in order to re- moval of dipstick.
Page 480: Drive Chain
Section 04 TRANSMISSION Sub-Section 09 (DRIVE CHAIN) DRIVE CHAIN SILENT CHAIN For 1997 there are 2 types of silent chain. One is 11-plate wide and the other (stronger) is 13-plate wide. Do not interchange sprockets. Fit chain on sprockets to make sure using right ones accord- ing to width.
Page 481 Section 05 ELECTRICAL Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS WIRING DIAGRAMS......................05-02-1 CHART CODES........................05-02-1 UNPLUGING CONNECTORS .................... 05-02-3 TAB AND RECEPTACLE CONNECTORS REMOVAL ............05-02-3 TAB AND RECEPTACLE CONNECTORS INSTALLATION ..........05-02-3 ACCESSORIES INSTALLATION ..................05-02-4 IGNITION TIMING ......................... 05-03-1 DUCATI CDI SYSTEM......................
Page 482 Section 05 ELECTRICAL Sub-Section 01 (TABLE OF CONTENTS) CLEANING AND INSPECTION ..................05-06-6 CLEANING ..........................05-06-6 INSPECTION ........................05-06-6 SOLENOID SWITCH ....................... 05-06-8 STARTER REMOVAL ...................... 05-06-10 STARTER DISASSEMBLY ....................05-06-10 CLEANING ........................05-06-11 PARTS INSPECTION....................... 05-06-11 STARTER ASSEMBLY ....................05-06-12 STARTER INSTALLATION ....................05-06-13 TESTING PROCEDURE ......................
Page 483 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) WIRING DIAGRAMS ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) MX Z 440 F Annex 1 60/55 hal. 8/27 MX Z 440/583/670 Annex 2 60/55 hal. 8/27 Formula 500 DELUXE Annex 3 60/55 hal.
Page 484 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big)
Page 485: Unpluging Connectors
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) Connector Location Connectors on wiring diagrams carry the letter C followed by a number. Use this code with wiring diagram legend to find connector location on vehi- cle. UNPLUGING CONNECTORS Always unplug connectors by pulling on housing not on wire.
Page 486: Accessories Installation
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) ACCESSORIES INSTALLATION On all electric start models: The direct current (DC) utilizes the snowmobile frame as ground “wire” while all alternating current (AC) consum- ers (lights, heated grips, fuel gauge, etc.) utilize a separate ground wire.
Page 487: Ignition Timing
Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) IGNITION TIMING DUCATI CDI SYSTEM 443 and 503 Engine Types Proper ignition timing is determined by trigger coil position. If for any reason, ignition timing accuracy is sus- pected, it can be checked as follows. Verifying Magneto Flywheel Timing Mark Position Prior to checking the timing, it may be necessary...
Page 488 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) d. “0” now indicates exact TDC. a. Remove the fan cover from the engine. 5. Verify the position of the timing mark on the b. Maintain magneto flywheel so that previous magneto flywheel as follows: marks remain aligned.
Page 489 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) WARNING Place ski tips against a wall, raise rear of ve- hicle on a stand, so that track does not con- tact the ground. Do not allow anyone in front of or behind the vehicle while engine is run- ning.
Page 490: Nippondenso Trigger Coil System
Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) NIPPONDENSO TRIGGER COIL SYSTEM 454, 494, 583, and 670 Engine Types Ignition timing is adjusted by movement of trigger coil. On 583 engine raising position of trigger coil retards ignition. Lowering position of trigger ad- vances ignition.
Page 491 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) 5. Verify the position of the timing mark on the magneto flywheel as follows: NOTE: When checking timing, certain pro- cedures require that the magneto flywheel be turned in a clockwise direction, viewed facing the magneto.
Page 492 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) A06E27A TYPICAL 1. Timing light pick-up on MAG side 2. Timing inspection hole The magneto/damper mark must be aligned with center mark. If not, move trigger coil as explained above and recheck ignition timing. Tolerance is ± 1°.
Page 493: Spark Plugs
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG All Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier is using the NGK spark plug type on most of the 1997 snowmobile models. The heat range identification system is: High number hot plug Low number...
Page 494: Design Symbols Used In Ngk Spark Plugs
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DESIGN SYMBOLS USED IN NGK SPARK PLUGS PREFIX SUFFIX WIDE GAP 10: 1.0 mm (.040") 11: 1.1 mm (.044") B R 9 E S 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...
Page 495: Disassembly
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DISASSEMBLY CAUTION First unscrew the spark plug 1 turn. Severe engine damage might occur if a Clean the spark plug and cylinder head with pres- wrong heat range plug is used. surize air then completely unscrew. A too “hot”...
Page 496: Spark Plug Installation
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUG INSTALLATION Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to TECHNICAL DATA 09-02.
Page 497: Battery
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) BATTERY REMOVAL All Models WARNING Battery BLACK negative cable must always be disconnected first and connected last. WARNING Never charge or boost battery while in- stalled on vehicle. A22C09A S-Series 1. Loosen clamp Remove air silencer. Unfasten retaining strips.
Page 498: Cleaning
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) A29E0CA A22E0GA 1. Wing screw 1. Wing screw Skandic SWT All Models Remove battery bracket and remove battery from Withdraw battery from vehicle being careful not vehicle. lean it so that electrolyte flows out of vent tube. CAUTION Should any electrolyte spillage occur, imme- diately wash off with a solution of baking...
Page 499: Inspection
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) HYDROMETER TEST A17E0LA 1. Baking soda A17E0JA Remove corrosion from battery cable terminals 1. Specific gravity 1.260 and battery posts using a firm wire brush. A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte.
Page 500: Battery Storage
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) EXAMPLE NO. 1 Clean battery terminals and cable connections us- Temperature below 27°C (80°): ing a wire brush. Apply a light coat of dielectric Hydrometer Reading:1.250 grease (P/N 413 7017 00) or petroleum jelly on ter- Electrolyte temperature: −7°C (20°F) minals.
Page 501 Section 05 ELECTRICAL Sub-Section 05 (BATTERY) 5. Readjust the electrolyte level to the UPPER LEVEL line. A17E0FA 1. Battery electrolyte A17E0RA 2. Remove caps and fill battery to UPPER LEVEL 1. Battery electrolyte line with electrolyte (specific gravity: 1.260 at 20°C (68°F)).
Page 502 Section 05 ELECTRICAL Sub-Section 05 (BATTERY) 7. Disconnect battery charger. 10. Allow gas bubbles to escape by lightly shake battery. A17E0IB A17E0HA 8. Test battery state of charge. Use a hydrometer. 11. Readjust electrolyte level. A17E0JA 1. Specific gravity 1.260 9.
Page 503: Servicing
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) – State of charge: Because the electrolyte is CAUTION nearly pure water in a completely discharged battery, it cannot accept current as well as elec- Do not allow cleaning solution to enter bat- trolyte. This is the reason the battery will not tery interior since it will destroy the electro- accept current when the charging cycle first be- lyte.
Page 504: Battery Charging Equipment
Section 05 ELECTRICAL Sub-Section 05 (BATTERY) – If the charging current is measurable before the For a service application and a permanent installa- end or at the end of about 10 hours, the battery tion, both ammeter and rheostat can be built into is good and charging should be completed in a small box adjacent to your charger.
Page 505 Section 05 ELECTRICAL Sub-Section 05 (BATTERY) All Models CAUTION Ensure that vent tube is not kinked or blocked then install protective boot over battery. Negative battery terminal should always be disconnected FIRST and reconnected LAST. Close and fasten retaining strips. Reinstall air silencer.
Page 506: Electric Starter
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) ELECTRIC STARTER S-Series with Electric Starting and Skandic WT/SWT A03E13S FLAT RATE PARTS 05-06-1...
Page 507: Removal
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) REMOVAL Check the wear on bushing no. 18 by measuring the amount of radial play between the armature – Disconnect BLACK ground cable from battery. shaft and the bushing. – Disconnect RED positive cable from battery. The radial play should not exceed 0.20 mm (0.008 in).
Page 508 Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Install bushing cover no. 19 then, using a punch, stake bushing cover in place. A19E05A 1. Cut close to connector Remove burrs with a file on the remaining welded portion. A19E02A 1. Stake bushing cover CAUTION 2.
Page 509: Cleaning And Inspection
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Install thrust washer against outer stop collar. CAUTION Place drive lever onto overrunning clutch then in- sert into drive housing. Do not overheat and quickly perform solder- ing to prevent solder from flowing to the brush through the wire.
Page 510: Installation
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A19E09A 1. Shorter stud 2. Bare wire INSTALLATION Make sure that starter and engine mating surfac- A09E0PA es are free of grime. Serious trouble may arise if 1. Screwdriver pulling starter pinion starter is not properly aligned. 2.
Page 511: Cleaning And Inspection
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) CLEANING AND INSPECTION CLEANING CAUTION Armature starter yoke ass’y and drive unit assembly must not be immersed in cleaning solvent. Clean brushes and holder with a clean cloth F01H0RA soaked in solvent. Brushes must be dried thor- 1.
Page 512 Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Field Windings and Brushes Test the Field Winding for Open Circuit: Use growler test probes. Place one test probe on the negative brush and the other test probe on the yoke. If growler lamp does not turn on, the field winding has an open-circuit.
Page 513: Solenoid Switch
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A03E05A TYPICAL 1. New 2. Wear limit Overrunning Clutch The pinion of the overrunning clutch should turn smoothly in the clockwise direction, and should not slip in a counterclockwise direction. If defec- tive, replace. Check the pinion teeth for wear and damage.
Page 514 Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) Skandic WT LC 5 N•m (44 lbf•in) Dielectric grease Loctite 271 Ground cable 22 N•m Dielectric grease (16 lbf•ft) A29E09S FLAT RATE PARTS 05-06-9...
Page 515: Starter Removal
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) STARTER REMOVAL Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. Remove tuned pipe. Cut locking tie retaining cable to starter. F01H0PA TYPICAL 1. Trace indexing marks Remove starter support nuts then through bolts.
Page 516: Cleaning
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) CLEANING CAUTION Yoke ass’y and drive unit assembly must not be immersed in cleaning solvent. Discard all O-rings and gasket. F01H0RA Clean brushes and holders with a clean cloth soaked in solvent. Brushes must be dried thor- 1.
Page 517: Starter Assembly
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) A03E05A A03E0EA 1. New 1. Armature shaft 2. Wear limit, 8.5 mm (.335 in) 2. Circlip 3. Pinion stop collar 4. Punch Overrunning Clutch 1,10, Housing and Yoke Ass’y Pinion of overrunning clutch should turn smoothly in clockwise direction, and should not slip in a Align previously traced indexing marks.
Page 518: Starter Installation
Section 05 ELECTRICAL Sub-Section 06 (ELECTRIC STARTER) F01H0SA 1. Locating protrusion is the higher one F01H0UA Step : Retaining brush holder with a screwdriver Step : Align here Align end frame notch with brush holder notch/ yoke protrusion. CAUTION F01H0TA 1.
Page 519: General
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system. CHARGING ENGINE IGNITION SYSTEM TYPE SYSTEM OUTPUT NIPPONDENSO 454, 494, 583 (CDI) and 670 TRIGGER COIL 443 and 503 DUCATI (CDI) CDI System Identification Nippondenso...
Page 520: Use Of Bombardier Ignition Tester
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) All Systems The first 2 items can be checked with known au- tomotive equipment and other items as follows. Engine Stop/Tether Cut-Out Switches Verification Engine Stop Switch Unplug stop switch connector from main harness then using an ohmmeter, connect test probes to BLACK/YELLOW and BLACK wires.
Page 521 Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) Test Condition Multiple Problems There is always the possibility of more than one All Tests are Performed on the Vehicle at faulty part. If after a component has been re- Cranking Speed placed, the problem still persists, carefully repeat Vigorous manual cranking against compression the complete test procedure to find the other causes the flywheel to snap over, raising the out-...
Page 522: Nippondenso Cdi Trigger Coil System Testing
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) NIPPONDENSO CDI TRIGGER COIL SYSTEM TESTING Applicable to 454, 494, 583 and 670 Engine Results: Types a. Indicator lamp lights: Trigger coil output is NOTE: Ensure ignition cut-out switches are up to specifications. properly working and they are in the ON po- b.
Page 523: Ignition Module
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) A00E1JA 1. Black 2. White/Blue 4. Slip plastic protectors out of coil terminals. 5. Connect tester wires to coil terminals then set switch and dial as follows: NOTE: If necessary use jumper wires from coil terminals to tester wires.
Page 524: Magneto Output (Ignition Generator Coil)
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) 2. Connect tester wires then set switch and dial as follows: Tester Tester Tester Component switch dial wires wires position position wire of magneto harness BLACK/RED wire of magneto harness A15E0TA TYPICAL 6. Crank engine and observe indicator. 7.
Page 525 Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) 2. Connect tester wires then set switch and dial as follows: Tester Tester Tester Component switch dial wires wires position position YELLOW wire of magneto harness YELLOW wire of magneto harness Yellow Yellow A15E0VA 3.
Page 526: Summary Table
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) SUMMARY TABLE Tester Test to perform Components wires Switch Dial wires Trigger coil output BLUE/YELLOW wire of trigger coil WHITE/YELLOW wire of trigger coil Ignition coil output Engine ground Test adapter on MAG spark plug cable Ignition module output WHITE/BLUE...
Page 527: Resistance Measurements
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) RESISTANCE MEASUREMENTS Disconnect connector at ignition coil and magneto junction. Measure resistance between each ter- As an alternate method, magneto system compo- minal. Refer to the following table for values and nents can be checked with a digital ohmmeter. wire colors.
Page 528: Ducati Cdi System Testing
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) DUCATI CDI SYSTEM TESTING (Applicable to 443 and 503 Engine Types) Results: NOTE: Ensure ignition cut-out switches are properly working and they are in the ON po- a. Indicator lamp lights: Trigger coil output is sition prior to performing the following tests.
Page 529: Ignition Coil Output
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) IGNITION COIL OUTPUT IGNITION MODULE A paper clip of approximately 20 mm (3/4 in) will Ignition module can not be tested with the Bom- be used as a test adapter for the following test. bardier ignition tester.
Page 530: Summary Table
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) Results: a. Indicator lamp lights: Lighting generator coil output is up to specifications. b. Indicator lamp does not light: Lighting gen- erator coil is faulty. SUMMARY TABLE Test to Tester Component Switch Dial perform wires wires...
Page 531: Resistance Measurements
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) RESISTANCE MEASUREMENTS Disconnect connector at ignition coil and magneto junction. Measure resistance between each ter- As an alternate method, magneto system compo- minal. Refer to the following table for values and nents can be checked with a digital ohmmeter. wire colors.
Page 532: Voltage Regulator Inspection
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) VOLTAGE REGULATOR INSPECTION A faulty voltage regulator is often responsible for B) Voltmeter Test frequent burned bulbs. NOTE: Use a voltmeter able to read alternat- ing current (AC). For accurate reading, use a CAUTION RMS voltmeter.
Page 533: Inspection Of Ac Circuit Isolation
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) INSPECTION OF AC CIRCUIT ISOLATION All Electric Start Models If AC circuit is not isolated from frame, headlamp beam will weaken. INSPECTION Disconnect regulator/rectifier. Connect one digital ohmmeter probe (needle ohmmeter will not offer enough precision) to frame and other probe to one of 2 yellow magneto wires.
Page 534: Inspection Of Heating Elements
Section 05 ELECTRICAL Sub-Section 07 (TESTING PROCEDURE) INSPECTION OF HEATING ELEMENTS All Models Except Skandic WT/SWT/WT LC All measurements must be performed at 21°C (70°F). Throttle Lever Heating Element Handlebar Grip Heating Element Resistance Measurement Resistance Measurement 8.73 to HIGH YELLOW BLACK wire 1.96 to...
Page 535 Section 06 REAR SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SC-10 SUSPENSIONS (ALL VERSIONS) ................. 06-02-1 COMPONENT REMOVAL AND INSTALLATION ............06-02-6 REMOVAL........................06-02-8 DISASSEMBLY AND ASSEMBLY ................. 06-02-9 SHOCK ABSORBER INSPECTION ................06-02-10 SHOCK ABSORBER SERVICING................... 06-02-11 INSTALLATION ......................
Page 536: Suspensions (All Versions)
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 SUSPENSIONS (ALL VERSIONS)2 SC-10 Sport on MX Z 440 F, Formula 500/500 DELUXE/583 temp. grease Loctite Loctite Loctite Loctite Loctite Loctite A03F26S FLAT RATE PARTS 06-02-1...
Page 537 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 Cross-country on MX Z 440/583/670 Front temp. Loctite grease Loctite MX Z 440 only Loctite Loctite Loctite Loctite A03F27S PARTS FLAT RATE 06-02-2...
Page 538 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 High-performance on Formula Z and Grand Touring 583 Front temp. grease Loctite Loctite Loctite Loctite Loctite A03F28S FLAT RATE PARTS 06-02-3...
Page 539 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 Mountain on Summit 500/583/670 Loctite Loctite temp. grease Loctite Loctite Loctite Loctite Loctite A03F29S FLAT RATE PARTS 06-02-4...
Page 540 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 Touring on Grand Touring 500 Loctite Loctite temp. grease Loctite Loctite Loctite Loctite Loctite A03F2AS FLAT RATE PARTS 06-02-5...
Page 541: Component Removal And Installation
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) COMPONENT REMOVAL AND INSTALLATION Lift rear of vehicle and support it off the ground. 21, Rear Axle Completely loosen track tension. Unscrew one rear idler wheel screw. Pull out rear axle from opposite side of offset in- ner wheel.
Page 542 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) 25, ACM Support Remove threaded rod ass’y. Loosen rear axle screw on one side and rear shackle screws. Unbolt MCA support and remove it. Remove cup. 15, Rear Shock Lift rear of vehicle. Slightly turn adjusting cam to expose spring end.
Page 543: Removal
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) A03F0TA RH SIDE SHOWN Lift rear of vehicle and support it off the ground. Loosen track tension. 7, Screw A03F1QA TYPICAL Unscrew rear arm top axle from chassis. At reassembly, wheel circlip must face outward. NOTE: To prevent axle from turning when unscrewing screws assembled with thread- REMOVAL...
Page 544: Disassembly And Assembly
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) 6, Screw 11, Axle Remove both screws retaining front arm to tun- Note position of axles at disassembly. Axles with nel. a paint stripe serve as idler wheel axles. These are more precise than those used as pivot axles.
Page 545: Shock Absorber Inspection
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) A03F0YA 1. Wear limit line CAUTION A03F12A Slider shoes must always be replaced in 1. Cap opening 2. Spring stopper opening pairs. 20, Stopper Strap 18, Spring Support Inspect strap for wear or cracks, bolt and nut for tightness.
Page 546: Shock Absorber Servicing
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Secure the shock body end in a vise with its rod Rod must comes out at a steady speed. If speed upward. suddenly increases particularly at end of exten- sion, replace shock. If suspecting a frozen gas shock proceed as fol- lows: Place shock in a freezer (temperature below 0°C...
Page 547 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Disassembly and Assembly Release N (nitrogen) pressure from the damper Schrader valve. WARNING Nitrogen gas is under extreme pressure. Use caution when releasing this gas vol- ume. Protective eye wear should be used. A27F04A TYPICAL With the seal assembly removed, slowly lift and...
Page 548 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) A27F06A TYPICAL WARNING Whenever using compressed air, use an O.S.H.A. approved air gun and wear protec- tive eye wear. A06F0VA Thoroughly clean, with a typical cleaning solution, NOTE: As a general rule we suggest replac- and blow dry using low pressure air.
Page 549 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Tuning for less damping it is important to remem- ber, never use less than 3 × 26 mm (1.02 in) shims against piston. This will guard against fatigue breakage. Piston no. 6 options include 4 pistons, 0, 2, 4, 6, slits for rebound damping bleeds.
Page 550 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) If the seal carrier assembly is replaced, use seal FRONT pilot (P/N 529 0265 00) to guide seal over damper shaft. Lubricate seal carrier guide pilot before use. Thick (in) (in) CAUTION 12 mm...
Page 551 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) A27F07A 1. Top of the piston A. Required distance A06F2DA 1. Damper nut torqued to 11-13 N•m (96-108 lbf•in) Install floating piston to depth of 151 mm (5.94 in) 2. Rebound shim pack for front damper, 190 mm (7.48 in) for rear damp- 3.
Page 552 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Slowly push piston into damper body. Slight up and down movement may be required to allow all air to pass through piston assembly. NOTE: Fast installation of the damper rod may displace the floating piston from its orig- inal position.
Page 553 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) Preset your pressure regulator to 2070 kPa (300 PSI) nitrogen (N ), this gas pressure will restore the correct pressure for your damper. CAUTION Do not exceed the recommended pressure values.
Page 554: Installation
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) 25, Protector LUBRICATION At assembly, mount protector with its notch to- Lubricate front and rear arms at grease fittings us- ward front. ing low temperature grease (P/N 413 7061 00). A03F10A SC-10 SPORT, MOUNTAIN AND TOURING: 4 GREASE FITTING A03F1RA...
Page 555: Skandic Wt Suspension
Section 06 REAR SUSPENSION Sub-Section 03 (SKANDIC WT SUSPENSION) SKANDIC WT SUSPENSION Skandic WT/SWT/WT LC A22F18S FLAT RATE PARTS 06-03-1...
Page 556: Removal
Section 06 REAR SUSPENSION Sub-Section 03 (SKANDIC WT SUSPENSION) REMOVAL Release track tension. Lift rear of vehicle and support it off the ground. Unbolt front arm then rear arm. NOTE: To prevent cross shaft from turning when unscrewing screws assembled with threadlocker, proceed as follows: –...
Page 557: Shock Absorber Servicing
Section 06 REAR SUSPENSION Sub-Section 03 (SKANDIC WT SUSPENSION) Tighten nut 3/4 turn after contacting washers for better deep snow performance. Maximum pre- load is 3 turns after nut touching washers. This last adjustment is for trail riding with or without a load and for pulling a load.
Page 558 Section 06 REAR SUSPENSION Sub-Section 03 (SKANDIC WT SUSPENSION) CAUTION Do not clamp directly on shock body. Examine each shock for leaks. Extend and com- press the piston several times over its entire stroke then check that it moves smoothly and with uniform resistance.
Page 559: Drive Axle
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) DRIVE AXLE S-Series Summit and MX Z only A03D20S FLAT RATE PARTS 06-04-1...
Page 560 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) Skandic WT A22D14S PARTS FLAT RATE 06-04-2...
Page 561: Removal
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) REMOVAL Remove angle drive and square pin from bottom of gearbox. All Models Except Skandic WT/SWT/WT LC Remove belt guard and belt. Drain oil from chaincase or gearbox. Release drive Loosen gearbox retaining screws then move chain tension.
Page 562 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) 9,13, Sprocket and Half-Sprocket S-Series To remove press fit sprockets, use a press and a suitable support as illustrated. A06D1XA A00F06A A. 65.8 mm (2-19/32 in) TYPICAL B. 159.3 mm (6-17/64 in) C.
Page 563 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) A24D05A A00F0CA TYPICAL 1. Grease seal type 2. Oil seal type 1. Indexing marks aligned 11, Bearing Protector The maximum desynchronization for the sprock- ets is 1.5 mm (1/16 in). At assembly, flat side of bearing protector must To check this tolerance, place axle assembly on a be against bearing.
Page 564: Axial Play
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) – Extract bearing from its support. Wrong chaincase perpendicularity will make it dif- ficult to correctly install the bearing in its support due to the countershaft and support misalign- ment. A00F05A 1. Bearing shield on this side 2.
Page 565 Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) A01D08A 1. Distance between sprocket and tunnel 2. Drive axle pushed toward chaincase A01D07A TYPICAL 1. Upper shim location 2. 50 mm long screws when installing one shim or more 3. Lower shim location –...
Page 566: Installation
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) – Check track front alignment by measuring the CAUTION gap, on each side between guide cleat and the slider shoe, behind the suspension front axle as Install shim(s) following the pattern shown shown.
Page 567: Lubrication
Section 06 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) ADJUSTMENT Sprocket/Track Alignment CAUTION Do not temper with sprocket/track alignment if frame or suspension is damaged. Sprockets might be repositioned to fit lugs with- out removing drive axle. Use drive axle sprocket adjuster kit (P/N 861 7257 00). A00F0GA SIDE VIEW 1.
Page 568: Track
Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) TRACK TRACK TYPE APPLICATION – RH drive axle end bearing – angle drive and square pin Refer to TECHNICAL DATA section 09-03. Move transmission sideway. Do not remove brake mechanism nor driven pulley. Refer to GENERAL SKANDIC WT SUSPENSION 06-03.
Page 569 Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) Insert pre-setted gauge between slider shoe and track. Allow gauge to settle by forcing track up and down. Track tension is as specified when edge of gauge reaches lign. A19F05A TYPICAL 1. Retaining screw 2.
Page 570 Section 06 REAR SUSPENSION Sub-Section 05 (TRACK) Track Cleat WARNING Removal Before checking track alignment, ensure that – Raise rear of vehicle off the ground and lift the track is free of all particles which could snowguard then rotate track to expose a cleat be thrown out while track is rotating.
Page 571 Section 07 STEERING/FRONT SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................07-02-1 INSPECTION ........................07-02-3 DISASSEMBLY AND ASSEMBLY ..................07-02-3 INSPECTION ........................07-02-4 ADJUSTABLE HANDLEBAR ..................... 07-02-5 STEERING ADJUSTMENT (SKIS) ..................07-02-6 LUBRICATION ........................07-02-9 SUSPENSION AND SKI SYSTEM ..................07-03-1 DISASSEMBLY........................
Page 572: Steering System
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) STEERING SYSTEM S-Series 25 N•m (18 lbf•ft) 40 N•m (30 lbf•ft) 25 N•m (18 lbf•ft) 18 N•m (159 lbf•in) 18 N•m (159 lbf•in) 52 N•m (38 lbf•ft) 40 N•m (30 lbf•ft) 40 N•m (30 lbf•ft) 18 N•m (159 lbf•in)
Page 573 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Skandic WT 25 N•m (18 lbf•ft) A22G0KS PARTS FLAT RATE 07-02-2...
Page 574: Disassembly And Assembly
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) INSPECTION Check skis and runner shoes for wear, replace as necessary. (See section 07-03). 17, Steering Arm and Ski Leg Make sure steering arm and ski leg splines inter- lock. WARNING Any parts having worn splines have to be re- places with new ones.
Page 575 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) To install, stick the heating element to the handle- For proper torque specifications refer to the spe- bar making sure the wires do not interfere with cific exploded view for the vehicle being serviced. operation of the accelerator or brake handle.
Page 576: Adjustable Handlebar
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Skandic WT Only Install special washers (locking disks) with teeth facing each others. A22G0LA 9,13,15, Ball Joint Nut and Jam Nut A22G0MA Tighten ball joint, nuts and jam nuts to specified torque (see exploded view). 1.
Page 577: Steering Adjustment (Skis)
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) See applicable exploded view for each model. 7,23,24,25, Steering Pad, Bolt, Nut and Rubber Attachment Adjust the steering handlebar to the desired posi- tion. CAUTION Lock the handlebar in place by tightening the 4 nuts as specified in the illustrations.
Page 578 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) WARNING Never lengthen tie rod so that threaded por- tion of ball joint exceeds 20 mm (25/32 in). A01G04A CAMBER: A specific inward or outward tilt angle of ski leg compared to a vertical line when viewing the ve- hicle from front.
Page 579 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Adjust the camber to 0° ± 0.5°. CAUTION Angle finder must sit square against swing arm. Positioning angle finder against weld bead or decal may result in false reading. 529 0216 00 A06G1KA TYPICAL —...
Page 580: Lubrication
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Skandic WT Only LUBRICATION – Skis should have a toe-out of 10 mm (3/8 in) when they are in a straight-ahead position and WARNING the vehicle is resting on the ground. Do not lubricate throttle and/or brake cable, NOTE: To make sure skis are in a straight- housing and spring coupler bolts.
Page 581 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) S-Series If so equipped A06G08S PARTS FLAT RATE 07-02-10...
Page 582 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM S-Series Some models Loctite 29 N•m (21 lbf•ft) 25 N•m (18 lbf•ft) 80 N•m Loctite (59 lbf•ft) 17.5 N•m MX Z 440 (159 lbf•in) 40 N•m (29 lbf•ft) Some models...
Page 583: Disassembly
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 5, Shock Lift front of vehicle and support it off the ground. Reduce spring preload by turning adjusting ring accordingly with the adjustment wrench in vehi- cle tool box. A03F12A 1.
Page 584: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) 7,8, Upper and Lower Half Arms Position half arms and tie rods horizontally before tightening nuts. 9,10,11, Bolt, Nut and Link Plate Attach link plate to frame with additional nuts and bolts, if applicable.
Page 585 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) A06G0XA WRONG POSITION 07-03-4...
Page 586 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) Skandic WT 13 N•m (115 lbf•in) Grease A22G0NS FLAT RATE PARTS 07-03-5...
Page 587: On-Vehicle Component Verification
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) ON-VEHICLE COMPONENT VERIFICATION 8, Shock Lift front of vehicle and support off the ground. Remove ski bolt and nut. Remove steel bushing from ski using a pusher. See pusher dimensions below. A22G0IA 1.
Page 588: Disassembly
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) A05G0CB 1. Allen screws A05G0DA NOTE: These washers and stopper can be 1. Washers and stopper wedged in cover wedged in cap. 2. Spring Pull out spring. 4,13,14,16,17, O-ring, Ski Leg, Bushing and Seal Suspension Free Operation Pull up ski leg.
Page 589: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) 8, Shock Absorber Secure the shock body end in a vise with its rod upward. A14F0BA 1. Clamp CAUTION Do not clamp directly on shock body. Examine each shock for leaks. Extend and com- press the piston several times over its entire A22G0QA stroke with its rod upward.
Page 590 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) A05G0CB TYPICAL 1. Bent angle toward the bottom 16,17, Seal Install seal before reinstalling ski leg. 07-03-9...
Page 591 Section 08 BODY/FRAME Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY............................08-02-1 INSTALLATION AND ADJUSTMENT ................08-02-1 HEADLAMP BEAM AIMING....................08-02-1 BULB REPLACEMENT ....................... 08-02-1 DECAL ..........................08-02-2 WINDSHIELD INSTALLATION................... 08-02-2 HOOD ..........................08-02-2 BELT GUARD ........................08-02-3 WIRING HARNESS ......................08-02-3 CABLES ..........................
Page 592: Installation And Adjustment
Section 08 BODY/FRAME Sub-Section 02 (BODY) BODY INSTALLATION AND ADJUSTMENT HEADLAMP BEAM AIMING Required Conditions Place the vehicle on a flat surface perpendicular to Beam aiming is correct when center of high beam test surface (wall or screen) and 381 cm (12 ft 6 in) is 25 mm (1 in) below the headlamp horizontal away from it.
Page 593: Decal
Section 08 BODY/FRAME Sub-Section 02 (BODY) DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully posi- tion the decal.
Page 594: Belt Guard
Section 08 BODY/FRAME Sub-Section 02 (BODY) BELT GUARD CABLES Disassembly and Assembly WARNING NOTE: For additional information (ex.: ex- Before installation, ensure that all cables are ploded view) refer to the correspondent in perfect condition. Properly install the ca- parts catalog. ble ends and secure them in place.
Page 595: Plastic Maintenance And Repair
Section 08 BODY/FRAME Sub-Section 02 (BODY) PLASTIC MAINTENANCE AND REPAIR MAINTENANCE Apply wax on glossy finish only. Protect the vehi- cle with a cover to prevent dust accumulation dur- Clean the vehicle thoroughly, removing all dirt and ing storage. grease accumulation. CAUTION To clean use a soft clean cloth and either soapy water or isopropyl alcohol.
Page 596: Repair
Section 08 BODY/FRAME Sub-Section 02 (BODY) REPAIR The very first step before repairing plastic materials is to find out exactly which type of material is in- volved. Refer to following chart. CAUTION Consult chart and repair kit instructions carefully, some repair products are not compatible with certain plastics.
Page 597: Material Repair Procedure
Section 08 BODY/FRAME Sub-Section 02 (BODY) MATERIAL REPAIR PROCEDURE – Heat the surface with a heater lamp placed at 38 cm (15 in) for a period of 15 minutes. Fiberglass – Sand the repair using a smooth dry sand paper. This material is repairable and repaintable, using –...
Page 598 Section 08 BODY/FRAME Sub-Section 02 (BODY) CREST MAIN OFFICE AND MANUFACTURING PLANT CREST INDUSTRIES, INC. Phone: 313-283-4100 3841 13 Street Toll Free: 1-800-822-4100 Fax: 1-800-344-4461 Wyandotte, Michigan Fax: 313-283-4461 48192 Crest products used in R.I.M. repair procedure are available from following locations: DISTRIBUTOR WAREHOUSE LOCATIONS UNITED STATES CANADA...
Page 599: Frame
Section 08 BODY/FRAME Sub-Section 03 (FRAME) FRAME FRAME CLEANING NOTE: For aluminum frames use only alumi- num cleaner and follow instructions on con- tainer. (Dursol cleaner or equivalent). Clean frame and tunnel with appropriate cleaners and rinse with high pressure hose. Touch up all metal spots where paint has been scratched off.
Page 600 Section 08 BODY/FRAME Sub-Section 03 (FRAME) CAUTION High speed drilling will cause excessive heat which may destroy the cutting edge of the bit, therefore avoid using pneumatic drills. Grinding Procedure Rear Cap Grind rivet heads from top of rear cap and under- neath for side retaining rivets.
Page 601 Section 09 TECHNICAL DATA Sub-Section 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..............meter ............. mass ..............kilogram ..........force ..............newton ........... liquid ..............liter ............temperature ............Celsius ........... °C pressure ..............
Page 602 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) VEHICLE MODEL MX Z 440 F MX Z 440 MX Z 583 MX Z 670 ENGINE TYPE Number of Cylinders Bore mm (in) 67.5 (2.6575) 67.5 (2.6575) 76.0 (2.992) 78.0 (3.071) Stroke mm (in) 61.0 (2.402) 61.0 (2.402) 64.0 (2.520)
Page 603 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) FORMULA 500 VEHICLE MODEL FORMULA 500 FORMULA 583 FORMULA Z DELUXE ENGINE TYPE Number of Cylinders Bore mm (in) 69.5 (2.736) 69.5 (2.736) 76.0 (2.992) 76.0 (2.992) Stroke mm (in) 65.8 (2.59) 65.8 (2.59) 64.0 (2.52) 64.0 (2.52) Displacement...
Page 604 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) GRAND TOURING VEHICLE MODEL SUMMIT 500 SUMMIT 583 SUMMIT 670 ENGINE TYPE Number of Cylinders Bore mm (in) 69.5 (2.736) 76.0 (2.992) 78.0 (3.071) 69.5 (2.736) Stroke mm (in) 65.8 (2.59) 64.0 (2.520) 70.0 (2.760) 65.8 (2.59) Displacement...
Page 605 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) GRAND TOURING VEHICLE MODEL SKANDIC WT/SWT SKANDIC WT LC ENGINE TYPE Number of Cylinders Bore mm (in) 76.0 (2.992) 72.0 (2.835) 69.5 (2.736) Stroke mm (in) 64.0 (2.52) 61.0 (2.402) 65.8 (2.59) Displacement 580.7 (35.44) 496.7 (30.31) 499.3 (30.47)
Page 606 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL MX Z 440 F MX Z 440 MX Z 583 MX Z 670 ENGINE TYPE Chain Drive Ratio 22/44 23/44 25/44 26/44 Pitch Chain Type/Links Qty/Plates Qty Silent/72/11 Silent 72 – 13 Silent 74 –...
Page 607 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) FORMULA 500 VEHICLE MODEL FORMULA 500 FORMULA 583 FORMULA Z DELUXE ENGINE TYPE Chain Drive Ratio 23/44 23/44 25/44 25/44 Pitch Chain Type/Links Qty/Plates Qty Silent 72-11 Silent 72-11 Silent 74-11 Silent 74-13 Type of Drive Pulley TRAC TRAC...
Page 608 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) GRAND TOURING VEHICLE MODEL SUMMIT 500 SUMMIT 583 SUMMIT 670 ENGINE TYPE Chain Drive Ratio 22/44 22/44 23/44 23/44 Pitch Chain Type/Links Qty/Plates Qty Silent 72-11 Silent 72-13 Silent 72-13 Silent 72-11 Type of Drive Pulley TRAC TRAC TRAC...
Page 609 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) GRAND TOURING VEHICLE MODEL SKANDIC WT SKANDIC SWT SKANDIC WT LC ENGINE TYPE Chain Drive Ratio 23/44 N.A. N.A. N.A. Pitch N.A. N.A. N.A. Chain Type/Links Qty/Plates Qty Silent 72-13 N.A. N.A. N.A. Type of Drive Pulley TRAC TRAC...
Page 610 Section 09 TECHNICAL DATA Sub-Section 04 (TECHNICAL DATA LEGENDS) ENGINE LEGEND VEHICLE LEGEND BTDC: Before Top Dead Center DSA: Direct Shock Action CDI: Capacitor Discharge Ignition RRIM: Reinforced Reaction Injection Molding CTR: Center TRAC: Total Range Adjustable Clutch Kilo (× 1000) N.A.: Not Applicable MAG: Magneto Side...
Page 611 Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error Suggestion ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________ Date___________ Zip code/Postal code ________________________________________ Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error...
Page 612 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0...
Page 614 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 618 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 622 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 626 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 630 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 634 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 638 Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 640 ANNEX 7...
Page 642 SKANDIC WT LC '97 STARTER SOLENOID 87 86 RD/GN 30 85 FUSE 20 A IGNITION RD/GN SWITCH STARTER 2 5 4 7 9 BK/YL BATTERY BL/YL WH/YL SPARK YL/BK IGNITION PLUGS MODULE GENERATOR COIL IGNITION COIL BK/YL BK/WH YL/GN YL/GN TEMPERATURE YL/GN SENSOR...
Page 643 SWITCH SWITCH HEATED GRIP IGNITION SWITCH 2 5 4 7 9 BK/YL BACK-UP ALARM YL/GN BACK-UP ALARM SWITCH HEATED THROTTLE SWITCH HEATED YL/GN GRIPS EMERGENCY CUT-OUT SWITCH WH/GY YL/GN RD/YL SWITCH LIGHTS BRAKE LIGHT SWITCH YL/GN D/YL ENGINE HIGH BEAM OVERHEATING L/BK SPEEDOMETER...
Page 645 ® 1997 Shop Manual VOLUME 3 FORMULA III/III LT MACH 1/Z/Z LT...
Page 646 Legal deposit: National Library of Quebec trimester 1996 National Library of Canada1996 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1996 Technical Publications Bombardier Inc.
Page 647 TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE ..........................1997 BOMBARDIER SNOWMOBILES SHOP MANUAL VOLUME 3 (INTRODUCTION) ....LUBRICATION 01 – Lubrication and maintenance chart .......... 01-01-1 AND MAINTENANCE TROUBLESHOOTING 01 – Table of contents..............02-01-1 02 – Engine ..................02-02-1 03 –...
Page 648 TABLE OF CONTENTS SECTION SUB-SECTION PAGE TECHNICAL DATA 01 – SI metric information guide............09-01-1 02 – Engines ..................09-02-1 03 – Vehicles..................09-03-1 04 – Technical data legends............. 09-04-1 ANNEXES (wiring diagrams)
Page 649 SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 1997 Ski-Doo snowmo- biles. See model list on next page. This edition was primarily published to be used by snowmobile mechanics who are already familiar with all service procedures relating to Bombardier made snowmobiles.
Page 650 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION This Shop Manual VOLUME 3 covers the follow- LIST OF MODELS GROUPED BY ing Bombardier made 1997 snowmobiles: COMMUN CHASSIS MODEL F-Series consists of: MODELS NUMBER FORMULA III/III LT FORMULA* III (CANADA)....1148 MACH 1/Z/Z LT FORMULA* III (U.S.) .......
Page 651 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL Each vehicle has its particular vehicle ARRANGEMENT OF THE serial number MANUAL Serial Number Meaning: The manual is divided into 09 major sections: 01 LUBRICATION AND MAINTENANCE 02 TROUBLESHOOTING 03 ENGINE 0000 00000 04 TRANSMISSION Model no.
Page 652 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. TYPICAL PAGE Page heading indicates section and sub-section detailed. Sub-section title indicates Section 07 REAR SUSPENSION beginning of the sub-section.
Page 653 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL TYPICAL PAGE Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) Title indicates Turn puller handle and sliding half at once to extract INSTALLATION main procedure the bushing. to be carried-out. Countershaft CAUTION Always apply anti-seize lubricant (P/N 413 7010 Italic bold face type 00) on the countershaft before final pulley setting indicates a...
Page 654 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL GENERAL INFORMATION CAUTION The information and component/system descrip- Most components of those vehicles are built tions contained in this manual are correct at time with parts dimensioned in the metric sys- of publication. Bombardier Inc. however, main- tem.
Page 655 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL TIGHTENING TORQUES N•m FASTENER SIZE (8.8) Lbf•ft Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table. N•m FASTENER SIZE (8.8) Lbf•in N•m FASTENER SIZE (8.8) Lbf•ft...
Page 656 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS...
Page 657 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRIFICATION AND MAINTENANCE CHART) LUBRIFICATION AND MAINTENANCE CHART REFER TO Starting Rope Condition — Engine Head Nuts Appropriate section: See Top End Appropriate section: See ENGINE Engine Mount Nuts REMOVAL Appropriate section: See ENGINE Exhaust System REMOVAL Engine Lubrication...
Page 658 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRIFICATION AND MAINTENANCE CHART) REFER TO Section 06: See appropriate Suspension Adjustments AS REQUIRED sub-section and Operator’s Guide Section 06: See appropriate Suspension Lubrication sub-section Section 06: See appropriate Suspension Condition sub-section Section 06: See appropriate Suspension Stopper Strap Condition sub-section Track Condition...
Page 659 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRIFICATION AND MAINTENANCE CHART) NO. 1 ENGINE LUBRICATION If above fuel stabilizer is not used, drain fuel sys- tem including fuel tank and carburetor(s). Engine internal parts must be lubricated to protect them from possible rust formation during the stor- CAUTION age period.
Page 660 Section 01 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRIFICATION AND MAINTENANCE CHART) Lift hood and remove air filters from air intake si- To clean the entire vehicle, use only flannel lencer. clothes or Kimtowels ® wipers no. 58-380 from Kimberly-Clark. CAUTION It is necessary to use flannel cloths or “Kim- towels”...
Page 661 Section 02 TROUBLESHOOTING Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE ..........................02-02-1 FUEL AND OIL SYSTEMS..................... 02-03-1 TRANSMISSION AND BRAKE SYSTEMS ................02-04-1 TRANSMISSION ........................ 02-04-1 BRAKE SYSTEM ........................ 02-04-8 MECHANICAL BRAKE ....................... 02-04-8 HYDRAULIC BRAKE ......................02-04-9 MECHANICAL AND HYDRAULIC BRAKES ..............
Page 662: Engine
Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) ENGINE The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM ENGINE BACKFIRES CONDITION NORMAL USE...
Page 663 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF CONDITION NORMAL USE Test/Inspection 1. Perform engine leak test. Refer to engine leak verification flow chart. Check possible piston seizure. a.Damaged gasket and/or seal. Replace defective parts. 2. “Four-corner” seizure of piston(s). a.Accelerating too fast when engine is cold.
Page 664 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 4. Melted and/or perforated piston dome; melted section at ring end gap. a.When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This situation is due to an incomplete combustion of a poor quality oil.
Page 665 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM PISTON RING AND CYLINDER SURFACES ARE GROOVED CONDITION NORMAL USE Test/Inspection 1. Check oil quality. a.Poor oil quality. Use Bombardier Rotax oil. 2. Check injection pump and its hoses. a.Inadequate injection pump adjustment and/or defective hoses. Adjust pump according to specifications (refer to ENGINE 03) and/or replace hoses.
Page 666 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 8. Check driven pulley. a.Worn bushing and/or spring tension. Replace spring and/or adjust its tension according to specifications (refer to TECHNICAL DATA 09). 9. Check exhaust system. a.Restriction. Replace. 10. Check ignition timing. a.Decrease in power due to retarded ignition. Adjust according to specification (refer to TECHNICAL DATA 09).
Page 667 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE TURNS OVER BUT FAILS TO START CONDITION NORMAL USE Test/Inspection 1. Check switches. a.Ignition switch, emergency cut-out switch or tether switch is in the OFF position. Place all switches in the RUN or ON position. 2.
Page 668 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 5. Check ignition system trigger coil air gap. a.Air gap is too large. Adjust according to specifications (refer to TECHNICAL DATA 09). 6. Check dimension of pilot jet. a.Inadequate fuel/air mixture. Adjust according to specifications (refer to TECHNICAL DATA 09). 7.
Page 669 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) 8. Check carburetion. a.Improperly adjusted or inadequate carburetor components. Adjust according to specifications (refer to TECHNICAL DATA 09) or replace inadequate component(s). 9. Check cylinder head gaskets. a.Worn gaskets. Replace. 10. Check ignition timing. a.Ignition timing is too advanced.
Page 670 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH “RAVE”. ENGINE HESITATES AT MID-SPEED AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE CONDITION NORMAL USE Test/Inspection 1. Check “RAVE” valve spring(s). a.Spring tension is too weak or spring(s) is (are) broken. Replace.
Page 671 Section 02 TROUBLESHOOTING Sub-Section 02 (ENGINE) SYMPTOM ENGINE PINGING CONDITION NORMAL USE Test/Inspection 1. Check fuel lines. a.Bent fuel lines (preventing fuel from flowing through). Relocate or replace fuel lines. 2. Check if carburetor(s) is (are) clean. a.Dirt prevents fuel from flowing through. Clean.
Page 672: Fuel And Oil Systems
Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM HIGH FUEL CONSUMPTION (OR RICH MIXTURE) CONDITION...
Page 673 Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM CONDITION NORMAL USE Test/Inspection 1. Check fuel tank vent hose. a.Kinked or clogged hose. Relocate or replace. 2. Check fuel filter. a.Clogged filter. Replace.
Page 674 Section 02 TROUBLESHOOTING Sub-Section 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE) CONDITION NORMAL USE Test/Inspection 1. Check fuel filter ball located in fuel tank. Ball must move freely. a.Corrosion due to oxidation at installation. Replace fuel filter.
Page 675: Transmission And Brake Systems
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) TRANSMISSION AND BRAKE SYSTEMS4 The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. TRANSMISSION SYMPTOM THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED...
Page 676 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED CONDITION NORMAL USE Test/Inspection 1. Check items 1, 2 and 3 of “The snowmobile accelerates slowly, especially when it is stopped”. 2.
Page 677 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY CONDITION NORMAL USE Test/Inspection 1. Check drive belt. a.Belt width is uneven at many places. Replace (refer to TECHNICAL DATA 09 for the part number). 2.
Page 678 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY CONDITION NORMAL USE Test/Inspection 1. Check driven pulley spring tension. a.Spring tension is too weak. Adjust according to specifications (refer to TECHNICAL DATA 09). 2.
Page 679 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE CONDITION NORMAL USE Test/Inspection 1. Check if drive pulley bushings are worn. a.Insufficient pressure on belt sides. Replace bushing. 2. Check condition of drive pulley fixed half shaft. a.Rusted drive or driven pulley shafts.
Page 680 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT WORN NARROW IN ONE SECTION CONDITION NORMAL USE Test/Inspection 1. Check if parking brake is released. a.Parking brake is engaged. Release parking brake. 2. Check track tension/alignment. a.Frozen or too tight track. Liberate track from ice or check track tension and alignment.
Page 681 Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT DISINTEGRATION CONDITION NORMAL USE Test/Inspection 1. Check drive belt identification number. a.Excessive belt speed. Using unspecified type of belt. Replace belt with proper type of belt (refer to TECHNICAL DATA 09). 2.
Page 682: Brake System
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT “FLIP-OVER” AT HIGH SPEED CONDITION NORMAL USE Test/Inspection 1. Check pulley alignment. a.Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA 09). 2. Check drive belt identification number. a.Using unspecified type of belt.
Page 683: Hydraulic Brake
Section 02 TROUBLESHOOTING Sub-Section 04 (TRANSMISSION AND BRAKE SYSTEMS) HYDRAULIC BRAKE SYMPTOM SPONGY BRAKE CONDITION CONDITION NORMAL USE Test/Inspection Replace brake fluid and bleed system. If problem still occurs, replace master cylinder. SYMPTOM BRAKE FLUID LEAKING CONDITION NORMAL USE Test/Inspection 1.
Page 684: Electrical System
Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM STARTER DOES NOT TURN CONDITION...
Page 685 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 7. Check brushes. a.Poor contact of brushes. Replace brushes. 8. Check commutator. a.Burnt commutator. Turn commutator on lathe. 9. Check height of commutator mica. a.Commutator mica too high. Undercut mica. 10. Check field coil resistance. a.Shorted field coil.
Page 686 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 4. Check clutch bushing. a.Worn clutch bushing. Replace clutch. 5. Check starter bushing. a.Worn starter bushing(s). Replace bushing(s). 6. Check ring gear. a.Worn ring gear. Replace ring gear . SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED CONDITION NORMAL USE Test/Inspection...
Page 687 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN TURNING IGNITION SWITCH CONDITION NORMAL USE Test/Inspection 1. Check battery cables and starter wires. a.Corroded and/or loose connection(s). Clean and/or retighten. 2. Check fuse. a.Oxidized fuse. Clean.
Page 688 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM HEADLAMP DIMING CONDITION NORMAL USE Test/Inspection 1. Check voltage at headlamp at different speeds. It must not be below 11 VAC. a.Insufficient voltage in lighting circuit. Replace voltage regulator and retest. 2. Visually inspect wiring harness for damaged and/or melted wires and/or bad wire terminal crimping and/or connections.
Page 689 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM FALSE FUEL AND/OR TEMPERATURE GAUGE READINGS CONDITION NORMAL USE Test/Inspection 1. Verify if gauge was connected on DC current by mistake (in case of optional installation). a.Faulty installation of optional equipment. Find optional wires connected directly to DC ground (BK wire to chassis) or to any DC hot wire (RD, RD/BL).
Page 690 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) 6. Verify condition of ignition generator coils. a.Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting screws. Replace coils. 7. Verify CDI (Capacitor discharge ignition) module. a.Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting screws.
Page 691 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) CONDITION RIDING IN DEEP AND THICK SNOW Test/Inspection 1. Perform all verifications outlined under “Engine does not start — no spark at spark plug”. 2. Verify spark plug(s). Proceed with spark plug analysis in order to identify source of problem.
Page 692 Section 02 TROUBLESHOOTING Sub-Section 05 (ELECTRICAL SYSTEM) SYMPTOM BRAKE LIGHT REMAINS ON CONDITION NORMAL USE Test/Inspection 1. Check if bulb is properly installed. a.Bulb is not installed correctly (contact elements are reversed). Install bulb correctly. 2. Check brake switch. a.Switch contact remains closed. Adjust brake cable or brake switch.
Page 693: Suspension System And Track
Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SUSPENSION SYSTEM AND TRACK The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM REAR SUSPENSION BOTTOMS OUT CONDITION...
Page 694 Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) 5. Check track rods and/or internal traction teeth. a.One or various track rods and/or teeth are broken. Replace track. SYMPTOM DERAILING TRACK CONDITION NORMAL USE Test/Inspection 1. Check track tension. a.Track is too loose. Adjust.
Page 695 Section 02 TROUBLESHOOTING Sub-Section 06 (SUSPENSION SYSTEM AND TRACK) SYMPTOM HANDLE BAR IS DIFFICULT TO TURN CONDITION NORMAL USE Test/Inspection 1. Check position of front spring adjustment cams. a.More pressure on the ground when cam increases spring preload. Reduce front spring preload. 2.
Page 696: Engine
Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 599, 699 AND 809 ENGINE TYPES..................03-02-1 ENGINE REMOVAL AND INSTALLATION................ 03-02-1 REMOVAL FROM VEHICLE ....................03-02-2 INSTALLATION ON VEHICLE .................... 03-02-2 TOP END ..........................03-02-3 COMPONENT REMOVAL ....................03-02-4 CLEANING .........................
Page 697 Section 03 ENGINE Sub-Section 01 (TABLE OF CONTENTS) OIL INJECTION SYSTEM....................... 03-05-1 OIL INJECTION PUMP ....................... 03-05-1 OIL PUMP IDENTIFICATION ....................03-05-2 CLEANING .......................... 03-05-2 DISASSEMBLY ........................03-05-2 ASSEMBLY ......................... 03-05-2 ADJUSTMENT........................03-05-2 CHECKING OPERATION ....................03-05-4 LIQUID COOLING SYSTEM ....................03-06-1 INSPECTION ........................
Page 698: 599, 699 And 809 Engine Types
Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) 599, 699 AND 809 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION All Models 10 N•m (98 lbf•in) 15 N•m (133 lbf•in) 37 N•m (27 lbf•ft) 35 N•m (26 lbf•ft) 29 N•m (21 lbf•ft) A06C0TS FLAT RATE...
Page 699: Removal From Vehicle
Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) REMOVAL FROM VEHICLE INSTALLATION ON VEHICLE Remove or unplug the following then lift off en- To install engine on vehicle, reverse removal pro- gine from engine compartment. cedure. However, pay attention, to all appropriate component/system reinstallation procedures de- NOTE: 3-cylinder engine is more heavy then a 2 scribed throughout this Shop Manual and to the...
Page 700: Top End
Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) TOP END 10 N•m (89 lbf•in) 30 N•m (22 lbf•ft) Grease 10 N•m (89 lbf•in) Molykote 111 only (P/N 413 7070 00) Loctite 242 (P/N 413 7030 00) Grease 29 N•m (21 lbf•ft) 29 N•m...
Page 701: Component Removal
Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) COMPONENT REMOVAL Place a clean cloth or rubber pad (P/N 529 0234 00) over crankcase to prevent circlips no. 14 from Most engine components can be removed with falling into crankcase. Then with a pointed tool in- engine on vehicle such as: serted in piston notch, remove circlips from pis- ton no.
Page 702 Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) RAVE System Check valve rod housing and cylinder for clogged passages. A21C04A 1. Pusher 21mm (.826 in) RAVE System NOTE: RAVE stands for Rotax Adjustable Variable Exhaust. A06C3OA Remove spring clip no. 3, cover no. 4 and spring 1.
Page 703 Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) 1,2,11, Cylinder Head Cover, Cylinder Head and Cylinder Check flatness of part sealing surfaces. Refer to LEAK TEST AND ENGINE DIMENSION MEASUREMENT 03-03 and look for Checking Surface Flatness. –...
Page 704 Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) Install piston pin puller (P/N 529 0210 00) and turn handle until piston pin is correctly positioned in piston. 529 0169 00 A01B1QA TYPICAL 1. Place circlip in 2. Restrain A21C01A 3.
Page 705 Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) A06C1PA Also check for proper cylinder alignment. A06C0GA TYPICAL A06C1QA At assembly, torque cylinder head screws in the following illustrated sequence. Tightening torques are: M6 screws: 12 N•m (106 Ibf•in) M8 screws: 30 N•m (22 Ibf•ft) 03-02-8...
Page 706 Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) BOTTOM END 599 and 699 only 10 N•m (90 lbf•in) Loctite Loctite 10 N•m Silicone 732 (90 lbf•in) Anti-seize lubricant (P/N 413 7010 00) Molykote 111 (P/N 413 7070 00) Primer N Loctite 515 Loctite...
Page 707 Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) NOTE: Engine must be removed from chassis to 1, Reed Valve perform the following procedures. With blade stopper removed, check reed valve for proper tightness. There must be no play between CLEANING blade and valve body when exerting a finger pres- sure on blade at blade stopper location.
Page 708 Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) ASSEMBLY Crankcase halves no. 4 and water pump housing are factory matched and therefore, are not inter- changeable as single halves. 2,3, Crankshaft Bearing, Anti-seize Lubricant and Labyrinth Sleeve Prior to joining of crankcase halves, spray some new injection oil (or equivalent) on all moving Smear anti-seize lubricant (P/N 413 7010 00) on...
Page 709 Section 03 ENGINE Sub-Section 02 (599, 699 AND 809 ENGINE TYPES) 7, Seal 10 12 Install seal using pusher (P/N 420 8765 16). 420 8765 16 3 9 11 A06C3RA 809 ENGINE 1. Oil level plug A06C1RA 4 9 11 8,9, Plastic Gear and Steel Gear Apply grease to needle bearing of each gear.
Page 710: Leak Test And Engine Dimension Measurement
Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for liq- 8. Rotate crankshaft so that piston goes to uid cooled engines though it also applies to fan B.D.C.
Page 711 Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Engine Check the following: 1. All jointed surfaces and screw/stud threads of engine: – spark plug base, insulator – cylinder head – cylinder base – crankcase halves (joint) – rotary valve cover –...
Page 712 Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Block both hoses of rotary valve gear lubrica- 1. Remove a spark plug or any plug of leak tester tion system with hose pinchers. kit on PTO side. If pressure drops, it indicates defective crank- shaft inner seal on PTO side.
Page 713: Finalizing Reassembly
Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Remove rotary valve cover and check for leak COOLING SYSTEM LEAK TEST of rotary valve seal with soapy water. Install special plug (radiator cap) (P/N 529 0214 00) and hose pincher (P/N 529 0099 00) on overflow hose.
Page 714: Engine Leak Verification Flow Chart
Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP...
Page 715: Engine Dimension Measurement
Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT This section covers all engine types. CYLINDER TAPER ENGINE TYPE MAXIMUM 0.08 mm (.003 in) Compare cylinder diameter 16 mm (5/8 in) from top of cylinder to just below its intake port area. On rotary valve engines, measure just below aux- iliary transfer port, facing exhaust port.
Page 716: Ring/Piston Groove Clearance
Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A01C0PA RING END GAP Position ring half way between transfer ports and intake port. On rotary valve engines, position ring just below transfer ports. NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher.
Page 717: Connecting Rod Big End Axial Play
Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Measuring (on bench) CONNECTING ROD BIG END AXIAL PLAY Once engine is disassembled, check crankshaft deflection on V-shaped blocks. If deflection ex- ceeds the specified tolerance, it can be worn ENGINE NEW PARTS WEAR...
Page 718: Connecting Rod/Crankpin Clearance
Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) RECTIFYING SURFACES Stick a fine sand paper sheet on the surface plate then lightly oil the sand paper. Rub manifold mating surface on sand paper using 8-figure movements. Sand until mating surface is perfectly straight. A01C3HA ENGINE NEW PARTS...
Page 719 Section 03 ENGINE Sub-Section 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A06C1TA Interval between cylinders must be exactly 120°. Proceed the same for MAG side piston. Any other reading indicates a misaligned (twisted) crankshaft. 03-03-10...
Page 720: Cdi System
Section 03 ENGINE Sub-Section 04 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 599, 699 and 809 Engines Dielectric grease (P/N 413 7017 00) Dielectric grease (P/N 413 7017 00) Silastic 732 Loctite 242 699 Only 125 N•m (92 lbf•ft) Loctite Loctite 22 N•m...
Page 721: Cleaning
Section 03 ENGINE Sub-Section 04 (CDI SYSTEM) NOTE: The following procedures can be done without removing the engine from chassis. To fa- cilitate magneto removal, hold drive pulley with tool (P/N 529 0276 00). CDI means Capacitor Discharge System. CLEANING Clean all metal components in a non-ferrous met- al cleaner.
Page 722 Section 03 ENGINE Sub-Section 04 (CDI SYSTEM) A25E1AA 1. Magneto harness through crankcase hole – Install new trigger coil and other parts re- moved. Adjustment A15E0NA Whenever the trigger coil or the magneto fly- ADJUSTING TRIGGER COIL AIR-GAP wheel is removed or replaced, the air-gap be- 1.
Page 723 Section 03 ENGINE Sub-Section 04 (CDI SYSTEM) 2,5, Magneto Flywheel and Nut Clean crankshaft extension (taper) and apply Loc- tite 242 (blue) on taper, then position Woodruff key, flywheel and lock washer on crankshaft. Clean nut threads and apply Loctite 242 (blue) then tighten nut 125 N•m (92 lbf•ft).
Page 724: Oil Injection System
Section 03 ENGINE Sub-Section 05 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 599, 699 and 809 Engines Loctite 5 N•m (44 lbf•in) Loctite A06C3IS FLAT RATE PARTS 03-05-1...
Page 725 Section 03 ENGINE Sub-Section 05 (OIL INJECTION SYSTEM) OIL PUMP IDENTIFICATION 7, Pump Lever 420 2779 05 Different engines need different pumps. Oil pumps are identified by their levers. CAUTION Always mount proper pump on engine. OIL PUMP ENGINE TYPE IDENTIFICATION A00C17A TYPICAL...
Page 726 Section 03 ENGINE Sub-Section 05 (OIL INJECTION SYSTEM) A06C3JA A06C3JA A06C3JB 1. Adjuster nut 1. Small oil lines 2. Marks in line 2. Bleeder screw 3. Main oil line CAUTION Reinstall all parts. Bleed the small oil line between pump and intake Proper oil injection pump adjustment is very manifold by running engine at idle while holding important.
Page 727 Section 03 ENGINE Sub-Section 05 (OIL INJECTION SYSTEM) If not, remove pump assembly and check the WARNING pump gear and drive shaft (if applicable) for de- fects, replace as necessary. Test pump as de- Ensure not to operate carburetor throttle scribes below.
Page 728 Section 03 ENGINE Sub-Section 06 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM 599, 699 and 809 Engines Loctite A06C3HS FLAT RATE PARTS 03-06-1...
Page 729 Section 03 ENGINE Sub-Section 06 (LIQUID COOLING SYSTEM) INSPECTION 5, Thermostat To check thermostat, put in water and heat water. Check general condition of hoses and clamp tight- Thermostat should open when water tempera- ness. ture reaches the following degree. DRAINING THE SYSTEM ENGINE TEMPERATURE...
Page 730 Section 03 ENGINE Sub-Section 06 (LIQUID COOLING SYSTEM) COOLING SYSTEM REFILLING PROCEDURE Recommended Coolant Use a blend of 60% antifreeze with 40% water. Do not reinstall pressure cap. CAUTION To prevent rust formation or freezing condi- tion, always replenish the system with 60% antifreeze and 40% water.
Page 731: Rewind Starter
Section 03 ENGINE Sub-Section 07 (REWIND STARTER) REWIND STARTER All Models Molykote G-n paste or equivalent Silicone compound grease Silicone compound grease 10 N•m (89 lbf•in) A06C3GS FLAT RATE PARTS 03-07-1...
Page 732 Section 03 ENGINE Sub-Section 07 (REWIND STARTER) REMOVAL Using a small screwdriver, extract rope knot from starter grip no. 13. Cut rope close to knot. Tie a knot near starter. Remove screws no. 3 and washers no. 2 secur- ing rewind starter no. 1 to engine then remove re- wind starter.
Page 733 Section 03 ENGINE Sub-Section 07 (REWIND STARTER) A01C0CA Position pawl no. 8, pawl lock no. 9 and circlip A01C14A no. 10. 1. Grease inside spring guide Install locking spring no. 11 and lubricate with MOLYKOTE G-n paste from Dow Corning ®...
Page 734 Section 03 ENGINE Sub-Section 07 (REWIND STARTER) INSTALLATION On fan cooled models with oil injection pump, re- install oil pump on rewind starter assembly. Thread starter rope no. 6 through rope guide when applicable. A03C0VA Reinstall rewind starter assembly on engine. Prior to installing starter grip no.
Page 735: Carburetor And Fuel Pump
Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP Formula III/III LT and Mach 1 To other carburetors A03C1MT FLAT RATE PARTS 03-08-1...
Page 736 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) Carburetor TM 38 C159 A06C38T PARTS FLAT RATE 03-08-2...
Page 737 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) REMOVAL 15, Filter Check for clogged filter. Clean or replace as re- Remove air silencers. Disconnect fuel inlet lines. quired. Disconnect choke cable(s). Check inlet needle tip condition. If worn, the inlet All Models Except Mach Z/Z LT needle and seat must be replaced as a matched set.
Page 738 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) DISASSEMBLY AND ASSEMBLY All Models The position of the needle in the throttle slide is NOTE: To ease the carburetor disassembly and adjustable by means of an E-clip inserted into 1 of assembly procedures it is recommended to use 5 grooves located on the upper part of the needle.
Page 739 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) 8, Main Jet The main jet installed in the carburetor has been selected for a temperature of -20°C (0°F) at sea level. Different jetting can be installed to suit tem- perature and/or altitude changes. Always check spark plug tip and/or piston dome color to find out correct jetting.
Page 740 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) The following illustration shows the part of the On applicable models, make sure to align tab of carburetor which begins and stops to function at carburetor and air intake silencer (if applicable) different throttle slide openings.
Page 741 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) Make sure the nylon packing no. 4 is installed on Mach Z/Z LT all applicable throttle slides. CAUTION Serious engine damage can occur if this no- tice is disregarded. A06C0YA TYPICAL 1.
Page 742 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) Check throttle slide position at wide open throttle. Throttle slide must be flush or 1 mm (.040 in) low- er than carburetor outlet bore. At that same posi- tion, check that throttle slide does not contact carburetor cover.
Page 743 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) Throttle Slide Adjustment All Models Except Mach Z/Z LT WARNING Ensure the engine is turned OFF, prior to per- forming the throttle slide adjustment. For maximum performance, correct carburetor throttle slide adjustment is critical. The following method should be used with engine turned off: –...
Page 744 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) IDLE SPEED FINAL ADJUSTMENT WARNING 7, Idle Speed Screw This gap is very important. If the throttle Start engine and allow it to warm then adjust idle slide rests against the carburetor cover at speed to specifications by turning idle speed full throttle opening, this will create too screw clockwise to increase engine speed or...
Page 745 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) If tool tip does not seat under choke plunger, ad- CAUTION just as follows: Lift up protector cap and loosen choke cable lock Make sure that tool stopper is properly lean on nut, as shown in the next photo.
Page 746 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) Set choke lever to close and open positions and ensure that tool properly seats under plunger only when lever is set to fully open position. Set choke lever to close position and, by pulling and pushing choke lever, make sure there is no tension on cable (free play).
Page 747 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) A06C2MB 1. 0.3 mm (.012 in) gap maximum NOTE: If there is no gap between tab and plung- er, a rich condition will occur and throttle response will be affected; if the gap is too great, the plunger stroke will be reduced causing poor cold engine starting.
Page 748 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) FUEL PUMP All Models A06C3SS 03-08-14...
Page 749 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) REMOVAL CLEANING AND INSPECTION Install a hose pincer (P/N 529 0099 00) on fuel The entire pump should be cleaned with general supply line close to pump inlet. purpose solvent before disassembly. Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed air.
Page 750: Fuel Tank And Throttle Cable
Section 03 ENGINE Sub-Section 09 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE Fuel Tank Lines Models with Easy Action Throttle Lever WARNING When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with a hose pincher (P/N 529 0099 00) or equivalent device.
Page 751 Section 03 ENGINE Sub-Section 09 (FUEL TANK AND THROTTLE CABLE) Throttle Cable O-ring and Retaining Ring at Carburetor (some models) Locate O-ring outside of carburetor cover and re- taining ring inside. 100.7° A01E18A 1. Full position (3 ± 2 Ω ) 2.
Page 752: Transmission
Section 04 TRANSMISSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DRIVE BELT..........................04-02-1 1997 APPLICATION CHART ....................04-02-1 ROTATION DIRECTION...................... 04-02-1 DRIVE BELT DEFLECTION MEASUREMENT ..............04-02-2 DEFLECTION ADJUSTMENT.................... 04-02-3 DRIVE PULLEY........................04-03-1 TRA ............................. 04-03-1 GENERAL ........................... 04-03-2 REMOVAL...........................
Page 753 Section 04 TRANSMISSION Sub-Section 01 (TABLE OF CONTENTS) CHAINCASE..........................04-07-1 REMOVAL ........................... 04-07-2 INSPECTION ........................04-07-2 GEAR RATIO MODIFICATION.................... 04-07-2 INSTALLATION ........................04-07-2 DRIVE CHAIN ADJUSTMENT.................... 04-07-3 ADJUSTMENT........................04-07-4 DRIVE CHAIN ......................... 04-08-1 SILENT CHAIN........................04-08-1 04-01-2...
Page 754: Rotation Direction
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) DRIVE BELT 1997 APPLICATION CHART PART WIDTH (NEW) MINIMUM WIDTH MODEL ± 0.25 mm (.010 in) NUMBER (WEAR LIMIT) FORMULA III/III LT, MACH 1/Z/Z LT 415 0603 00 35 mm (1-3/8’’) 33 mm (1-19/64’’) ROTATION DIRECTION The maximum drive belt life span is obtained when the drive belt is installed as shown.
Page 755: Drive Belt Deflection Measurement
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) DRIVE BELT DEFLECTION MEASUREMENT 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 mi).
Page 756: Deflection Adjustment
Section 04 TRANSMISSION Sub-Section 02 (DRIVE BELT) Allen screws should be restrained while tighten- ing jam nut to prevent throwing adjustment out. Use drive belt tension adjuster (P/N 529 0087 00). A00D08A 1. Upper O-ring 2. Force 3. Lower O-ring 529 0087 00 A06D21A 4.
Page 757: Tra
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) DRIVE PULLEY All Models NOTE: This is a lubrication free drive pulley. 12 N•m (106 lbf•in) Loctite Loctite 13 N•m (115 lbf•in) 10 N•m (89 lbf•in) Loctite 95 N•m 95 N•m (70 lbf•pi) (70 lbf•ft) Repair kit A06D1ZS...
Page 758: General
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) GENERAL Some drive pulley components (return spring, ramp) can be changed to improve vehicle perfor- mance in high altitude regions. The High Altitude Technical Data booklet (P/N 484 0648 00 and 484 0545 00 for binder) gives information about cali- bration according to altitude.
Page 759: Disassembly
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) To Remove Drive Pulley Ass’y: 32, Cushion Drive Retain drive pulley with clutch holder. CAUTION Install puller in pulley shaft then tighten. Do not disassemble cushion drive. Governor DISASSEMBLY cup and cushion drive are factory balanced as an assembly.
Page 760: Cleaning
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 19, Spring Cover Ass’y Using a paper towel with cleaning solvent (P/N 413 7082 00), clean crankshaft tapered end and It is pushed by clutch spring pressure. the taper inside the fixed half of the drive pulley, crankshaft threads and retaining screw threads.
Page 761: Inspection
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) INSPECTION Drive pulley should be inspected annually. 16,17, Thrust Washer and Roller 529 0313 00 Check roller for roundness of external diameter. Check thrust washer for thickness wear. Replace 529 0312 00 as required. CAUTION Ensure rollers are in good condition.
Page 762 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Press bushing. 15, Pin Always use the same type of pin as originally in- stalled when servicing. Different types have dif- ferent weights for calibration purpose. Refer to TECHNICAL DATA 09-03. 21,22,23, Ramp, Dowel Tube and Screw 529 0313 00 Insert dowel tube from chamfered side.
Page 763 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) 9,11,13,14, Screw, Lever Ass’y, Nut and Lift sliding half against spring cover and align spring cover arrow with sliding half mark. Cotter Pin Always install lever assemblies so that cotter pins are at the shown side. Besides install cotter pin head on top when lever is sat at bottom of sliding half.
Page 764: Installation
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) INSTALLATION WARNING 529 0055 00 Do not apply anti-seize or any lubricant on crankshaft and drive pulley tapers. WARNING Never use any type of impact wrench at drive pulley removal and installation. A16B02A Clean mounting surfaces as described in CLEAN- ING above.
Page 765: Drive Pulley Adjustment
Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) Recheck the torque of 90 to 100 N•m (66 to 74 Governor cup has 6 positions numbered 2 to 6. lbf•ft). Note that in position 1 there is no stamped num- ber (due to its location on casting). WARNING See TECHNICAL DATA 09-03 for original setting.
Page 766 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) A16D0HA 1. Loosen just enough to permit rotating of calibration screw 04-03-10...
Page 767 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) DRIVEN PULLEY F-Series Anti-seize lubricant (P/N 413 7010 00) Anti-seize lubricant (P/N 413 7010 00) Loctite A06D22S FLAT RATE PARTS 04-04-1...
Page 768: Removal
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) REMOVAL CLEANING Remove belt guard and drive belt from vehicle. 6,7, Large Bushing and Small Bushing Remove the cap screw no. 13, lock washer During break-in period (about 10 hours of use), te- no.
Page 769 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Replace bushing(s) if worn more than specified. Install support plate (P/N 529 0311 03) inside slid- ing half. DRIVEN PULLEY BUSHING WEAR LIMIT Place puller (P/N 529 0311 02) below bushing. mm (in) Small bushing 38.30 (1.508) Large bushing...
Page 770: Assembly
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Small Bushing ASSEMBLY NOTE: Following procedure can be done with a 4, Cam Slider Shoe press using the same tools. Install puller in a vise. When replacing slider shoes, always install a new set (3 shoes) to maintain equal pressure on the Heat bushing area.
Page 771: Adjustment
Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) 13, Pulley Retaining Screw Torque to 25 N•m (18 lbf•ft). ADJUSTMENT 529 0065 00 Refer to PULLEY DISTANCE AND ALIGNMENT 04-05 to adjust pulley distance. Adjust drive belt height in driven pulley to obtain specified belt de- flection.
Page 772 Section 04 TRANSMISSION Sub-Section 04 (DRIVEN PULLEY) Pulley Alignment and Drive Belt Deflection Refer to PULLEY DISTANCE AND ALIGNMENT 04-05 and DRIVE BELT 04-02 to perform adjust- ments. CAUTION Drive belt and pulley adjustments must always be checked whenever pulleys have been re- moved, replaced or disassembled.
Page 773: General
Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) PULLEY DISTANCE AND ALIGNMENT GENERAL Measuring Procedure Using Straight Bar: The pulley distance we will refer to in this section, is the space separating the drive and driven pulley Always measure distances X and Y from the far- outside diameters (Z measurement).
Page 774: Pulley Alignment And Distance Specifications Chart
Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) Drive Belt Deflection NOTE: When pulley distance and alignment are adjusted to specifications, refer to DRIVE BELT 04-02 to adjust drive belt deflection. CAUTION This section deals mainly with adjustment procedures. For complete assembly require- ments, refer to the proper ENGINE or TRANSMISSION installation section.
Page 775 Section 04 TRANSMISSION Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT) Pulley Alignment Method Driven Pulley Movement When engine slotted mounting holes do not allow to set proper pulley offset X, adjust with shims (P/N 504 1082 00) between pulley and counter- shaft bearing support (pulley pushed toward brake disc).
Page 776: Brake
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) BRAKE HYDRAULIC DISC BRAKE F-Series Loctite Anti-seize lubricant Black Max Anti-seize lubricant A06D23S FLAT RATE PARTS 04-06-1...
Page 777: Removal
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) REMOVAL BRAKE DISC REMOVAL Brake disc can be withdraw without removing cal- iper. Proceed as follows: – Remove belt guard, belt and driven pulley. – Remove air silencers. – Unbolt bearing support no. 19 from chassis. –...
Page 778: Disassembly
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) 529 0302 00 A03D1KA 1. Spacer DISASSEMBLY A15D03A Only brake pads are available as spare parts. If cal- TYPICAL iper or master cylinder are damaged, replace each 1. Fixed pad of them as an assembly. 2.
Page 779: Installation
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) A06D15A INSTALLATION To install brake, reverse removal procedure paying A03D2KA attention to the following. 1. Brake disc not centered 2. Brake disc centered 3. Apply brake before checking WARNING Apply brake then recheck. Avoid getting oil on brake pads. 17, Brake Disc Apply anti-seize lubricant (P/N 413 7010 00) on 7, Brake Pad...
Page 780: Bleeding
Section 04 TRANSMISSION Sub-Section 06 (BRAKE) Slide collar no. 18 towards bearing and turn, by Brake Light hand, to engage the eccentric. This should require There is no adjustment on these models. Check about a quarter turn. that switch is securely installed. Turn collar in direction of countershaft rotation un- til collar and inner race lock together.
Page 781: Chaincase
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) CHAINCASE F-Series Loctite Chaincase 45 to 75 N•m (33 to 55 lbf•ft) 46 N•m Loctite Loctite 609 (34 lbf•ft) Loctite 242 SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER A06D17S FLAT RATE PARTS 04-07-1...
Page 782: Inspection
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) REMOVAL INSPECTION To remove chaincase proceed as follows. Visually inspect the chain for cracked, damaged or missing links. Check for worn or defective bear- Remove tuned pipes and muffler. ings, sprockets and chain tensioner components. WARNING WARNING Never remove exhaust components when...
Page 783: Drive Chain Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) 27, Conical Spring Washer 18, Circlip Install washer with its concave side towards drive CAUTION pulley. It is of the utmost importance to install the circlip otherwise damage to the chaincase components may occur. DRIVE CHAIN ADJUSTMENT NOTE: Brake disc key must be in good condition before checking chain free play.
Page 784: Adjustment
Section 04 TRANSMISSION Sub-Section 07 (CHAINCASE) A03A03A TYPICAL 1. Dipstick NOTE: Chaincase must be in its proper position when checking oil level. ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04-05. Track Tension and Alignment Refer to TRACK 06-04. 04-07-4...
Page 785: Drive Chain
Section 04 TRANSMISSION Sub-Section 08 (DRIVE CHAIN) DRIVE CHAIN SILENT CHAIN For 1997 there are 2 types of silent chain. One is 11-plate wide and the other (stronger) is 13-plate wide. Do not interchange sprockets. Fit chain on sprockets to make sure using right ones accord- ing to width.
Page 786 Section 05 ELECTRICAL Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS WIRING DIAGRAMS......................05-02-1 CHART CODES........................05-02-1 UNPLUGING CONNECTORS .................... 05-02-3 TAB AND RECEPTACLE CONNECTORS REMOVAL ............05-02-3 TAB AND RECEPTACLE CONNECTORS INSTALLATION ..........05-02-3 ACCESSORIES INSTALLATION ..................05-02-4 IGNITION TIMING ......................... 05-03-1 NIPPONDENSO TRIGGER COIL SYSTEM................
Page 787: Electrical
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) WIRING DIAGRAMS ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) Formula III/III LT Annex 1 60/55 hal. 8/27 Mach 1/Z/Z LT hal. = halogen CHART CODES Wiring Color Code The first color of a wire is the main color, second color is the stripe.
Page 788 Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big)
Page 789: Unpluging Connectors
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) Connector Location Connectors on wiring diagrams carry the letter C followed by a number. Use this code with wiring diagram legend to find connector location on vehi- cle. UNPLUGING CONNECTORS Always unplug connectors by pulling on housing not on wire.
Page 790: Accessories Installation
Section 05 ELECTRICAL Sub-Section 02 (WIRING DIAGRAMS) ACCESSORIES INSTALLATION On all electric start models: The direct current (DC) utilizes the snowmobile frame as ground “wire” while all alternating current (AC) consum- ers (lights, heated grips, fuel gauge, etc.) utilize a separate ground wire.
Page 791: Ignition Timing
Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) IGNITION TIMING NIPPONDENSO TRIGGER COIL SYSTEM Ignition timing is adjusted by movement of trigger coil. Raising position of trigger coil retards igni- tion. Lowering position of trigger advances igni- tion. CAUTION Each time ignition timing is adjusted by moving trigger coil, air-gap must be adjust- Refer to CDI MAGNETO 04-04 then look for Trig- ger Coil Adjustment after adjusting ignition tim-...
Page 792 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) b. Rotate the dial face so that “0” is in line with the needle when it stops moving. c. Again, slowly rotate the magneto flywheel back and forth across TDC and adjust the dial face to “0”, until the needle always stops ex- actly at “0”...
Page 793 Section 05 ELECTRICAL Sub-Section 03 (IGNITION TIMING) Checking Ignition Timing Use timing light (P/N 529 0319 00). To check the ignition timing, refer to illustration and proceed as follows: NOTE: Engine should be cold when checking tim- ing. Do not idle engine for more than 20 seconds and make checks quickly.
Page 794: Spark Plugs
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG All Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier is using the NGK spark plug type on most of the 1997 snowmobile models. The heat range identification system is: High number hot plug Low number...
Page 795: Design Symbols Used In Ngk Spark Plugs
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DESIGN SYMBOLS USED IN NGK SPARK PLUGS PREFIX SUFFIX WIDE GAP 10: 1.0 mm (.040") 11: 1.1 mm (.044") B R 9 E S 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...
Page 796: Disassembly
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) DISASSEMBLY CAUTION First unscrew the spark plug 1 turn. Severe engine damage might occur if a Clean the spark plug and cylinder head with pres- wrong heat range plug is used. surize air then completely unscrew. A too “hot”...
Page 797: Spark Plug Installation
Section 05 ELECTRICAL Sub-Section 04 (SPARK PLUGS) SPARK PLUG INSTALLATION Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to TECHNICAL DATA 09-02.
Page 798: Testing Procedure
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system. CHARGING ENGINE IGNITION SYSTEM TYPE SYSTEM OUTPUT NIPPONDENSO 599, 699 and (CDI) TRIGGER COIL CDI System Identification Nippondenso 1. Ignition module is connected to the ignition g e n e r a t o r c o i l v i a a 3 - w i r e c o n n e c t o r (BLACK/RED, WHITE and RED wires).
Page 799: Use Of Bombardier Ignition Tester
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) Engine Stop/Tether Cut-Out Switches Test Values Listed are Taken Against Compression Verification Always crank vigorously as in actual starting. Engine Stop Switch Always proceed in the following order: Unplug stop switch connector from main harness then using an ohmmeter, connect test probes to 1.
Page 800: Nippondenso Cdi Trigger Coil System Testing
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) NIPPONDENSO CDI TRIGGER COIL SYSTEM TESTING Applicable to 599, 699 and 809 Engine Types Results: NOTE: Ensure ignition cut-out switches are prop- a. Indicator lamp lights: Trigger coil output is erly working and they are in the ON position prior up to specifications.
Page 801: Ignition Module
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) 3. Crank engine and observe indicator. NOTE: If engine starts, allow it to idle while ob- serving indicator. Then, shut engine off. 4. Push reset button and repeat step 3 twice. Results: a. Indicator lamp lights: Ignition system is OK. b.
Page 802 Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) MAGNETO OUTPUT 1. Disconnect wiring harness junction block at en- gine (the one with YELLOW wires). (IGNITION GENERATOR COIL) 2. Connect tester wires then set switch and dial 1. Disconnect the 3-wire connector between igni- as follows: tion module and magneto harness.
Page 803: Magneto Output (Ignition Generator Coil)
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) SUMMARY TABLE Tester Test to perform Components wires Switch Dial wires Trigger coil output BLUE/YELLOW wire of trigger coil WHITE/YELLOW wire of trigger coil Ignition coil output Engine ground Test adapter on MAG spark plug cable Ignition module output WHITE/BLUE...
Page 804: Resistance Measurements
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) RESISTANCE MEASUREMENTS Disconnect connector at ignition coil and magneto junction. Measure resistance between each ter- As an alternate method, magneto system compo- minal. Refer to the following table for values and nents can be checked with a digital ohmmeter. wire colors.
Page 805: Voltage Regulator Inspection
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) VOLTAGE REGULATOR INSPECTION A faulty voltage regulator is often responsible for WARNING frequent burned bulbs. Ensure the track is free of particles which TESTING PROCEDURE might be thrown out while track is rotating. Keep hands, tools, feet and clothing clear of The regulator ground must be checked to ensure track.
Page 806: Inspection Of Ac Circuit Isolation
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) INSPECTION OF AC CIRCUIT ISOLATION All Electric Start Models If AC circuit is not isolated from frame, headlamp beam will weaken. INSPECTION Disconnect regulator/rectifier. Connect one digital ohmmeter probe (needle ohmmeter will not offer enough precision) to frame and other probe to one of 2 yellow magneto wires.
Page 807: Inspection Of Heating Elements
Section 05 ELECTRICAL Sub-Section 05 (TESTING PROCEDURE) INSPECTION OF HEATING ELEMENTS All measurements must be performed at 21°C (70°F). Throttle Lever Heating Element Handlebar Grip Heating Element Resistance Measurement Resistance Measurement 8.73 to HIGH YELLOW BLACK wire 1.96 to HIGH YELLOW BLACK wire INTENSITY...
Page 808: Rear Suspension
Section 06 REAR SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SC-10 SUSPENSION (HP VERSION)..................06-02-1 COMPONENT REMOVAL AND INSTALLATION .............. 06-02-2 REMOVAL........................... 06-02-4 DISASSEMBLY AND ASSEMBLY ..................06-02-4 SHOCK ABSORBER INSPECTION ..................06-02-6 INSTALLATION ........................06-02-7 RIDE ADJUSTMENT......................06-02-7 LUBRICATION ........................
Page 809: Suspension (Hp Version)
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSION (HP VERSION)) SC-10 SUSPENSION (HP VERSION) SC-10 High Performance on Formula III/III LT and Mach 1/Z/Z LT Front temp. grease Loctite Loctite Loctite Loctite Loctite A03F28S FLAT RATE PARTS 06-02-1...
Page 810: Component Removal And Installation
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSION (HP VERSION)) COMPONENT REMOVAL AND INSTALLATION Lift rear of vehicle and support it off the ground. 21, Rear Axle Completely loosen track tension. Unscrew one rear idler wheel screw. Pull out rear axle from opposite side of offset in- ner wheel.
Page 811 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSION (HP VERSION)) 25, ACM Support Remove threaded rod ass’y. Loosen rear axle screw on one side and rear shackle screws. Unbolt ACM support and remove it. Remove cup. 15, Rear Shock Lift rear of vehicle. Slightly turn adjusting cam to expose spring end.
Page 812: Removal
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSION (HP VERSION)) At reassembly, wheel circlip must face outward. – Loosen one screw then retighten. – Remove the opposite screw. REMOVAL – Remove the first one. Unscrew center idler wheel axle from tunnel then 19, Cam remove.
Page 813 Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSION (HP VERSION)) Close and lock bar. Adjust handle horizontal by changing position of clevis pin. Push down on handle until it locks. Remove spring stopper and cap then release handle. A03F13A 1. Stroke limiter on rear side 8,9, Pivot Arm and Flat Washer At installation pivot arm grease fitting must face rearward.
Page 814: Shock Absorber Inspection
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSION (HP VERSION)) 20, Stopper Strap 18, Spring Support Inspect strap for wear or cracks, bolt and nut for CAUTION tightness. If loose, inspect hole for deformation. Replace as required. Make sure it is attached To avoid track damage, spring supports through proper hole from the end.
Page 815: Installation
Section 06 REAR SUSPENSION Sub-Section 02 (SC-10 SUSPENSION (HP VERSION)) If suspecting an internal gas leak between oil INSTALLATION chamber and gas chamber, check shock as fol- Install assembled suspension into track with front lows: portion first. Install shock in a vise clamping on its bottom eye- Insert rear portion of suspension into track.
Page 816: Drive Axle
Section 06 REAR SUSPENSION Sub-Section 03 (DRIVE AXLE) DRIVE AXLE F-Series Lithium grease A06D24S FLAT RATE PARTS 06-03-1...
Page 817: Removal
Section 06 REAR SUSPENSION Sub-Section 03 (DRIVE AXLE) REMOVAL Drain oil from chaincase. Release drive chain ten- sion. Remove chaincase cover. Raise and block rear of vehicle off the ground. Remove suspension. Refer to SC-10 SUSPEN- SION 06-02. 2,8, End Bearing Housing and Seal Remove angle drive unit and coupling cable.
Page 818 Section 06 REAR SUSPENSION Sub-Section 03 (DRIVE AXLE) F-Series A00F0AA 1. Plane surface A. 1.5 mm (1/16 in) MAXIMUM CAUTION The same sprocket must not be pressed twice on the axle. If synchronization is found A06D1XA to be defective, use a new sprocket. A.
Page 819: Axial Play
Section 06 REAR SUSPENSION Sub-Section 03 (DRIVE AXLE) 5,12, Bearing Always push bearing by inner race. A00F0DA The bearing on the splined side of axle must be pushed until it is seated on shaft shoulder. The A01D05A end bearing housing bearing must be flush with TYPICAL end of drive axle.
Page 820 Section 06 REAR SUSPENSION Sub-Section 03 (DRIVE AXLE) AXIAL PLAY ADJUSTMENT BEARING POSITION TOWARD TOWARD TOWARD TOWARD FRONT REAR BOTTOM OF VEHICLE OF VEHICLE OF VEHICLE OF VEHICLE SHIM LOWER UPPER UPPER LOWER LOCATION This chart can be use as a “starting point” to cor- rect the chaincase perpendicularity.
Page 821 Section 06 REAR SUSPENSION Sub-Section 03 (DRIVE AXLE) When installing shims between the chaincase and the drive axle bearing, there must be same quantity of shims between the drive chain sprock- et and spacer. A01D09A 1. No gap all around 414 6053 00 –...
Page 822: Installation
Section 06 REAR SUSPENSION Sub-Section 03 (DRIVE AXLE) A01D0AA A00F0GA 1. Distance between guide cleat and slider shoe SIDE VIEW 2. Suspension front axle 1. Bearing 2. Seal If the difference between each side exceeds 3 3. Housing 4. Seal lip mm (1/8 in), redistribute drive axle shims as fol- A.
Page 823: Adjustment
Section 06 REAR SUSPENSION Sub-Section 03 (DRIVE AXLE) ADJUSTMENT Sprocket/Track Alignment CAUTION Do not temper with sprocket/track alignment if frame or suspension is damaged. Sprockets might be repositioned to fit lugs with- out removing drive axle. Use drive axle sprocket adjuster kit (P/N 861 7257 00). A01B2PA TYPICAL 06-03-8...
Page 824: Track
Section 06 REAR SUSPENSION Sub-Section 04 (TRACK) TRACK TRACK TYPE APPLICATION INSTALLATION Refer to TECHNICAL DATA section 09-03. Reverse the removal procedure. NOTE: When installing the track, respect rotation GENERAL direction indicated by an arrow on track thread. Check sprocket/track alignment as described in This section gives guidelines for track removal.
Page 825 Section 06 REAR SUSPENSION Sub-Section 04 (TRACK) A19F05A TYPICAL A01B4KA 1. Retaining screw 2. Adjuster bolt TYPICAL 1. Lign Alignment NOTE: Lightly oil track tension gauge center pin to avoid sticking. WARNING All Models Before checking track tension, ensure that Refer to TECHNICAL DATA 09-03 for proper ten- the track is free of all particles which could sion values.
Page 826 Section 06 REAR SUSPENSION Sub-Section 04 (TRACK) Track Cleat WARNING Removal Before checking track alignment, ensure that – Raise rear of vehicle off the ground and lift the track is free of all particles which could snowguard then rotate track to expose a cleat be thrown out while track is rotating.
Page 827: Steering
Section 07 STEERING/FRONT SUSPENSION Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................07-02-1 INSPECTION ........................07-02-2 DISASSEMBLY AND ASSEMBLY ..................07-02-2 INSPECTION ........................07-02-3 ADJUSTABLE HANDLEBAR ..................... 07-02-4 STEERING ADJUSTMENT (SKIS) ..................07-02-5 LUBRICATION ........................07-02-7 SUSPENSION AND SKI SYSTEM ..................07-03-1 DISASSEMBLY........................
Page 828 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) STEERING SYSTEM F-Series 25 N•m (18 lbf•ft) Lithium grease 40 N•m (30 lbf•ft) 25 N•m (18 lbf•ft) 18 N•m 18 N•m (159 lbf•in) (159 lbf•in) 52 N•m (38 lbf•ft) 40 N•m (30 lbf•ft) 40 N•m (30 lbf•ft) 18 N•m...
Page 829: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) INSPECTION Check skis and runner shoes for wear, replace as necessary. (Refer to FRONT SUSPENSION 07-03). 17, Steering Arm and Ski Leg Make sure steering arm and ski leg splines inter- lock. WARNING Any parts having worn splines have to be re- places with new ones.
Page 830: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) To install, stick the heating element to the handle- bar making sure the wires do not interfere with MODEL operation of the accelerator or brake handle. (in) (25/32) WARNING The ball joint should be restrained when tighten- Never use lubricants (e.g.
Page 831: Adjustable Handlebar
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) 21, Hardened Washer 11,12, Steering Arm Nut and Bolt Install a hardened washer on each side of the arm. Tighten steering arm nuts to specified torque (see exploded view). ADJUSTABLE HANDLEBAR 1,3, Steering Column and Handlebar If applicable, remove the steering clamp and nuts holding the handlebar to the steering column.
Page 832 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) Adjustments WARNING Adjustments should be performed following this Make sure that the steering pad and all con- sequence: trols are properly fixed to their normal loca- – Pivot arm centering. tion on the handlebar. –...
Page 833 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) CAMBER – Unbolt both upper control arms at ski leg hous- ing. Turn tie rod half turn at a time to obtain a NOTE: On vehicles without adjustable radius vertical ski leg (0° ± 0.5°). Bolt upper control arms (no.
Page 834: Lubrication
Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) – Lengthen the other one by turning it exactly the 26, Grease Fittings same amount, so that toe-out is not changed. Only use low temperature grease (P/N 413 7061 00). WARNING The following symbols will be used to show what type of lubricant should be used at the suitable Never lengthen tie rod so that threaded por- locations.
Page 835 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) F-Series If so equipped A06G08S PARTS FLAT RATE 07-02-8...
Page 836 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM F-Series 25 N•m (18 lbf•ft) Loctite 242 17.5 N•m (159 lbf•in) 80 N•m (59 lbf•ft) 40 N•m (29 lbf•ft) 14 N•m (124 lbf•in) 10 N•m (98 lbf•in) A06F2HS FLAT RATE PARTS...
Page 837: Disassembly
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 5, Shock Lift front of vehicle and support it off the ground. Reduce spring preload by turning adjusting ring accordingly with the adjustment wrench in vehi- cle tool box. A01B4LA 1.
Page 838: Inspection
Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) 1, Swing Arm Check skis and runners for wear, replace as nec- essary. Lift front of vehicle and support it off the ground. Check condition of ski stopper. Replace it when Remove cap, circlip then loosen steering arm bolt deteriorated.
Page 839 Section 07 STEERING/FRONT SUSPENSION Sub-Section 03 (SUSPENSION AND SKI SYSTEM) 13,14, Tie Rod and Lever Install levers on both sides at same angle (about horizontal). A06G0WA TYPICAL A06G0XA WRONG POSITION 07-03-4...
Page 840 Section 08 BODY/FRAME Sub-Section 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY............................08-02-1 INSTALLATION AND ADJUSTMENT ................08-02-1 HEADLAMP BEAM AIMING....................08-02-1 BULB REPLACEMENT ....................... 08-02-1 DECAL ..........................08-02-2 WINDSHIELD INSTALLATION................... 08-02-2 HOOD ..........................08-02-2 BELT GUARD ........................08-02-2 WIRING HARNESS ......................08-02-2 CABLES ..........................
Page 841: Installation And Adjustment
Section 08 BODY/FRAME Sub-Section 02 (BODY) BODY INSTALLATION AND ADJUSTMENT HEADLAMP BEAM AIMING Required Conditions Place the vehicle on a flat surface perpendicular to Beam aiming is correct when center of high beam test surface (wall or screen) and 381 cm (12 ft 6 in) is 25 mm (1 in) below the headlamp horizontal away from it.
Page 842: Decal
Section 08 BODY/FRAME Sub-Section 02 (BODY) DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully posi- tion the decal.
Page 843: Cables
Section 08 BODY/FRAME Sub-Section 02 (BODY) CABLES WARNING Before installation, ensure that all cables are in perfect condition. Properly install the ca- ble ends and secure them in place. Pay at- tention to route them properly, away from any rotating, moving, heating, or vibrating parts.
Page 844: Plastic Maintenance And Repair
Section 08 BODY/FRAME Sub-Section 02 (BODY) PLASTIC MAINTENANCE AND REPAIR MAINTENANCE Apply wax on glossy finish only. Protect the vehi- cle with a cover to prevent dust accumulation dur- Clean the vehicle thoroughly, removing all dirt and ing storage. grease accumulation. CAUTION To clean use a soft clean cloth and either soapy water or isopropyl alcohol.
Page 845: Repair
Section 08 BODY/FRAME Sub-Section 02 (BODY) REPAIR The very first step before repairing plastic materials is to find out exactly which type of material is in- volved. Refer to following chart. CAUTION Consult chart and repair kit instructions carefully, some repair products are not compatible with certain plastics.
Page 846: Material Repair Procedure
Section 08 BODY/FRAME Sub-Section 02 (BODY) MATERIAL REPAIR PROCEDURE – Use the same product if a final finish is re- quired. R.I.M. Urethane – Clean surface with Crest Hi-Solv product. R.I.M. Urethane is light colored (tan) on the inside – Apply a flexible primer such as Crest Prima Flex stock no.
Page 847 Section 08 BODY/FRAME Sub-Section 02 (BODY) CREST MAIN OFFICE AND MANUFACTURING PLANT CREST INDUSTRIES, INC. Phone: 313-283-4100 3841 13 Street Toll Free: 1-800-822-4100 Fax: 1-800-344-4461 Wyandotte, Michigan Fax: 313-283-4461 48192 Crest products used in R.I.M. repair procedure are available from following locations: DISTRIBUTOR WAREHOUSE LOCATIONS UNITED STATES CANADA...
Page 848: Frame
Section 08 BODY/FRAME Sub-Section 03 (FRAME) FRAME FRAME CLEANING NOTE: For aluminum frames use only aluminum cleaner and follow instructions on container. (Dur- sol cleaner or equivalent). Clean frame and tunnel with appropriate cleaners and rinse with high pressure hose. Touch up all metal spots where paint has been scratched off.
Page 849 Section 08 BODY/FRAME Sub-Section 03 (FRAME) CAUTION High speed drilling will cause excessive heat which may destroy the cutting edge of the bit, therefore avoid using pneumatic drills. Grinding Procedure Rear Cap Grind rivet heads from top of rear cap and under- neath for side retaining rivets.
Page 850 Section 09 TECHNICAL DATA Sub-Section 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ..............meter ............. mass ..............kilogram ..........force ..............newton ........... liquid ..............liter ............temperature ............Celsius ........... °C pressure ..............
Page 851 Section 09 TECHNICAL DATA Sub-Section 02 (ENGINES) VEHICLE MODEL FORMULA III/III LT MACH 1 MACH Z/Z LT ENGINE TYPE Number of Cylinders Bore mm (in) 67.5 (2.5394) 69.5 (2.7461) 70.5 (2.7756) Stroke mm (in) 61.0 (2.402) 61.0 (2.402) 68.0 (2.677) Displacement 597.94 (36.49) 699.2 (42.7)
Page 852 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL FORMULA III FORMULA III LT MACH 1 MACH Z ENGINE TYPE Chain Drive Ratio 25/44 23/44 26/44 26/44 Pitch Chain Type/Links Qty/Plates Qty Silent/74/13 Silent/72/13 Silent/74/13 Silent/74/13 Type of Drive Pulley TRAC TRAC Ramp Identification...
Page 853 Section 09 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL MACH Z LT ENGINE TYPE Chain Drive Ratio 25/44 Pitch Chain Type/Links Qty/Plates Qty Silent/74/13 Type of Drive Pulley TRAC Ramp Identification Calibration Screw Position or Calibration Disc Quantity Drive Pulley Spring Color Green/Blue ±...
Page 854 Section 09 TECHNICAL DATA Sub-Section 04 (TECHNICAL DATA LEGENDS) ENGINE LEGEND VEHICLE LEGEND BTDC: Before Top Dead Center DSA: Direct Shock Action CDI: Capacitor Discharge Ignition RRIM: Reinforced Reaction Injection Molding CTR: Center TRAC: Total Range Adjustable Clutch Kilo (× 1000) N.A.: Not Applicable MAG: Magneto Side...
Page 855 ANNEX WIRING DIAGRAM ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) Formula III/III LT Annex 1 60/55 hal. 8/27 Mach 1/Z/Z LT hal. = halogen CHART CODES Wiring Color Code The first color of a wire is the main color, second color is the stripe.
Page 856 ANNEX Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 857 ANNEX WIRING DIAGRAM ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) Formula III/III LT Annex 1 60/55 hal. 8/27 Mach 1/Z/Z LT hal. = halogen CHART CODES Wiring Color Code The first color of a wire is the main color, second color is the stripe.
Page 858 ANNEX Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (Big) Ground for starter (−) YELLOW...
Page 863 ® 1997 Shop Manual Supplement GRAND TOURING SE...
Page 864 Legal deposit: National Library of Quebec trimester 1996 National Library of Canada1996 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1996 Technical Publications Bombardier Inc.
Page 865 TABLE OF CONTENTS SECTION PAGE SAFETY NOTICE ..........................INTRODUCTION AND .......................... ABBREVIATION LIST LUBRICATION ....................AND MAINTENANCE TOOLS ....................01-1 TROUBLESHOOTING ....................02-1 ENGINE Table of contents................. 699 Engine ................. Leak test and engine dimension measurement ......CDI system (360-watt magneto system)........03-1 Oil injection system ..............
Page 866 TABLE OF CONTENTS SECTION PAGE DESS SYSTEM Component location ..............04-1 Theory and operation ..............04-1 Testing procedure ............... 04-2 DIGITAL PERFORMANCE Component location ..............05-1 MANAGEMENT (DPM) Theory and operation ..............05-1 SYSTEM Testing procedure ............... 05-10 AIR SUSPENSION SYSTEM Table of contents ................
Page 867 SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair the 1997 Ski-Doo Grand Touring SE. See model list on next page. This edition was primarily published to be used by snowmobile mechanics who are already familiar with all service procedures relating to Bombardier made snowmobiles.
Page 868 1997 GRAND TOURING SE SHOP MANUAL SUPPLEMENT INTRODUCTION The 1997 Grand Touring SE comprises 6 new systems. The 1997 Shop Manual Supplement describes how these systems operate as well as the procedures to test them. A06H32S 1. Magneto system 2. Heating elements switches system 3.
Page 869 1997 GRAND TOURING SE SHOP MANUAL SUPPLEMENT ABBREVIATION LIST Capacitor Discharge Ignition DESS Digitally Encoded Security System Digital Performance Management Hertz (1 cycle per second) Pound per Square Inch Magneto ( magneto side) mbar millibar MPEM Multi-Purpose Electronic Module A06H01A Power Take Off (drive pulley side) TYPICAL Read Only Memory...
Page 870: Tools
Section 01 TOOLS TOOLS A00B4HA TYPICAL — ADAPTOR (P/N 529 0338 00) A00I09A BYPASS WIRES (P/N 529 0333 00) These wires ensure continuity between the bat- tery and loads without the engine running. All ac- cessories are ON except for the buzzer. 0000 MkΩ...
Page 871: Troubleshooting
Section 02 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM DIGITAL PERFORMANCE MANAGEMENT (DPM) Always start by checking the fuse. SYSTEM Always start by checking the fuse. If the DPM seems to be defective, unplug fuse 1A while the engine is running. The carburation is now identical to that of carburetors without a DPM provided, of course, that all pipe fittings are tight and that solenoids are in good condition.
Page 872: 360-Watt Magneto System
Section 03 ELECTRICAL SYSTEM ELECTRICAL SYSTEM 360-WATT MAGNETO SYSTEM COMPONENT LOCATION Refer to photos included with the electrical dia- gram. THEORY AND OPERATION Charging System Lighting Coil This 360-watt coil produces alternating current. A00E51A + Positive - Negative 1. Magneto All accessories are fed with direct current.
Page 873 Section 03 ELECTRICAL SYSTEM Ignition System — MPEM Module This module also activates the warning buzzer (re- verse and DESS code). (Multi-Purpose Electronic Module) Finally, the MPEM controls load supply (head- This module operates on direct current (12 VDC). lamp, taillight, dashboard gauges, heated compo- nents, etc.).
Page 874: Heating Elements Switches System
Section 03 ELECTRICAL SYSTEM Connect an ohmmeter probe to ground and the other probe to each of the yellow wires. There must be no continuity. A06E2UA 1. Intensity control module 2. Screw location THEORY AND OPERATION Heating Elements Switches A06E2SA 1.
Page 875: Dimmer Switch System
Section 03 ELECTRICAL SYSTEM Heating Elements THEORY AND OPERATION Measure element resistance. Dimmer Switch RESISTANCE Ω ELEMENTS WIRES The dimmer switch allows selection of headlamp beam. Handle Wires of only one 9.7 ± 1 (only one) handle NOTE: When holding switch for more than 1 sec- YELLOW/BLACK ond to dim light (from high to low beam), light will 2 handles...
Page 876: Theory And Operation
Section 04 DESS SYSTEM DESS SYSTEM (Digitally Encoded Security System) COMPONENT LOCATION Multi-Purpose Electronic Module (MPEM) NOTE: The module must be programmed in order to accept a tether cord. This module cuts off the ignition at 2500 RPM in antitheft mode (wrong tether cord) or in case of a bad connection.
Page 877 Section 04 DESS SYSTEM TESTING PROCEDURE Buzzer Unplug buzzer wires. Plug a battery in good oper- ating condition to buzzer connectors. Observe po- larity (the + and - signs are printed on the buzzer). A06H34A 1. DESS indicator light Buzzer This buzzer comes on to indicate the DESS status.
Page 878 Section 04 DESS SYSTEM A06E2NA 1. 6-01 housing Switch Wire Continuity Check Check continuity (null resistance) between switch center terminal and WHITE/GRAY wire (6-01A). Check continuity (null resistance) between switch side ring and BLACK/GREEN wire connector (6- 01B). 04-3...
Page 879 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM COMPONENT LOCATION A06H31A 1. DPM module 2. Manifold 3. Pump 4. Engine temperature sensor 5. Air temperature sensor THEORY AND OPERATION PURPOSE Calibrate the air/fuel mixture in order to optimize the engine output while reducing fuel consump- tion.
Page 880 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM OVERALL SYSTEM OPERATION A06I0PS 1. DPM module 2. Carburetor bowls 3. Distribution gallery (upper tube) 05-2...
Page 881 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM Introduction DPM MODULE OPERATION The engine is being started using the electrical or General the manual starter. The DPM module increases pressure within all 3 carburetor bowls thus the air/fuel mixture is en- riched.
Page 882 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM Enrichment Mode (starting) A06I0QS When turning the ignition key to the ON position, The system pressurizes all 3 carburetor bowls in order to enrich the air/fuel mixture. This is accom- the module is energized and goes on standby. The module uses no electricity when on standby.
Page 883 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM CARBURETOR ACTIVE CALIBRATED JET CARBURETOR ENRICHMENT AIR JET SOLENOID COMPENSATION FROM AIR PUMP SOLENOID REAR VIEW A06I0NS This enrichment process of the air/fuel mixture If the throttle opening exceeds one quarter, the takes place at start-up and during engine warm- enrichment mode is interrupted during the start- up, and it depends on engine temperature.
Page 884 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM Compensation Mode A06I0US 1. Air jet 2. Needle jet air inlet Three conditions must be met for the compensa- 3. The atmospheric pressure must be lower than tion mode to operate: 1000 mbar. 1.
Page 885 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM FROM CARBURETOR (VENTURI) ACTIVE CALIBRATED JET FROM CARBURETOR (VENTURI) ENRICHMENT AIR JET SOLENOID COMPENSATION FROM FROM AIR SOLENOID CARBURETOR REAR VIEW PUMP (VENTURI) A06I0MS The compensation ratio will depend on the air The lower the atmospheric pressure, the leaner temperature and the atmospheric pressure.
Page 886 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM AIR PUMP OPERATION DPM MANIFOLD OPERATION A06I0OA 1. Manifold The DPM manifold consists of 2 tubes. Depend- ing on the mode, the upper tube (distribution gal- A06C3WA lery) distributes pump pressure or vacuum to 1.
Page 887 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM A06I0SA A06E2QA Enrichment Solenoid 1. Engine temperature sensor Solenoid Operating Principle Compensation Solenoid A solenoid is a winding coiled in order to produce a magnetic field. A metal rod crosses the coil and NOTE: Read Operating Principle of a Solenoid at cuts the magnetic field.
Page 888 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM A06E2PA 1. Air temperature sensor A06C3XA Manifold Air Jet 1. U-tube This jet allows the atmospheric pressure to reach carburetor bowls when the DPM is on standby. See manifold ass’y illustration. TESTING PROCEDURE Pump Pressure test The pump must create a minimum pressure of...
Page 889 Section 05 DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM Unplug upper solenoid wire (enrichment). Con- Dynamic test nect a good solenoid to module output connector. When checking the enrichment solenoid, discon- Use adaptor (P/N 529 0338 00) as required. nect engine temperature sensor connector. The DPM module now operates as though the engine CAUTION temperature was -20°C (-4°F) to allow maximum...
Page 890 Section 06 AIR SUSPENSION SYSTEM AIR SUSPENSION SYSTEM COMPONENT LOCATION The pressure in the air chamber increases when the compressor is activated, and it decreases when the release valve is activated. The compres- sor and the release valve are controlled by a three- way switch.
Page 891 Section 06 AIR SUSPENSION SYSTEM A06I0RA A06I0RA Spray soapy water on fittings in order to locate RESISTANCE leaks. PRESSURE ± 10 Ω Pressure Sensor Minimum (residual pressure) Release shock absorber pressure by activating Maximum (60 sec. of compressor the air suspension switch. operation) Remove the ignition key.
Page 892 Section 07 TECHNICAL DATA ENGINE VEHICLE MODEL GRAND TOURING SE ENGINE TYPE Number of Cylinders Bore mm (in) 69.75 (2.7461) Stroke mm (in) 61.0 (2.402) Displacement 699.2 (42.7) Compression Ratio (corrected) Maximum Power Engine Speed ± 100 RPM 8500 Piston Ring Type ST/R mm (in) 0.2 (.008)
Page 893 Section 07 TECHNICAL DATA VEHICLE VEHICLE MODEL GRAND TOURING SE ENGINE TYPE Chain Drive Ratio 25/44 Pitch Chain Type/Links Qty/Plates Qty Silent/74/13 Type of Drive Pulley TRAC Ramp Identification Calibration Screw Position or Calibration Disc Quantity Drive Pulley Spring Color Blue/Pink ±...
Page 894 Section 07 TECHNICAL DATA ENGINE LEGEND VEHICLE LEGEND CDI: Capacitor Discharge Ignition DSA: Direct Shock Action BTDC: Before Top Dead Center RRIM: Reinforced Reaction Injection Molding CTR: Center TRA: Total Range Adjustable Kilo (× 1000) N.A.: Not Applicable MAG: Magneto Side Minimum allowable width may not be less than 3.0 mm (1/8 in) of new drive belt.
Page 895 Section 08 WIRING DIAGRAM WIRING DIAGRAM COMPONENT LOCATION A06E2LA 1. DPM enrichment switch A06H2ZA 1. Starter wires 2. Magneto wires 3. MPEM: (ignition system and DESS) 4. DPM module A06E2KA HIGH-TENSION COIL A06E2HA 1. MPEM: 3-06 housing 2. MPEM: 3-02 housing 3.
Page 896 Section 08 WIRING DIAGRAM A06H2YA GAUGES 08-2...
Page 897 Section 08 WIRING DIAGRAM WIRING DIAGRAM LEGEND CODE CIRCUIT Rear brake light Ignition: between CDI and WH/BL coils XX/XX WH/GY Safety lanyard cap 1-02D WH/YL Trigger coil wire no. 1 WH/BK DESS pilot lamp (-) Magneto output/360-W WH/GN tachometer signal 2 3 4 TA/BK Back-up alarm...
Page 898 Section 08 WIRING DIAGRAM CONNECTOR HOUSING AREA CONNECTOR LOCATION IN HOUSING XX/XX 1-02D XX/XX 1-02D A00I04C A00I04D A06H33A AREA LOCATION Frame and hood junction Magneto Carburetors Rear of intake silencer Near driven pulley Under handlebar Under hood Near fuel tank Rear of seat A00E4WA 08-4...
Page 899 Section 08 WIRING DIAGRAM SYMBOLS DESCRIPTION Beam and tail light Female terminal Male terminal Electronic module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close Normally open Male terminal switch switch on instrument Engine Frame Spark plug Meter movement ground ground Frame...
Page 907 SHOP MANUAL SUPPLEMENT MX Zx 440 LC TABLE OF CONTENTS SAFETY NOTICE..........................01 — LUBRICATION ........................02 — TROUBLESHOOTING ......................03 — ENGINE..........................GENERAL ........................... LUBRICATION........................LIQUID COOLING SYSTEM ....................04 — TRANSMISSION ........................DRIVE PULLEY........................DRIVEN PULLEY ........................ BRAKE ..........................05 —...
Page 908: Safety Notice
SHOP MANUAL SUPPLEMENT MX Zx 440 LC SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair MX Zx 440 LC snowmobiles. This edition was primarily published to be used by snowmobile mechanics who are already familiar with all service procedures relating to Bombardier made snowmobiles.
Page 909: 01 - Lubrication
SHOP MANUAL SUPPLEMENT MX Zx 440 LC 01 — LUBRICATION Refer to 1997 ski-doo Shop Manual , volume 2. 02 — TROUBLESHOOTING Refer to 1997 ski-doo Shop Manual , volume 2. 03 — ENGINE Refer to 1997 ski-doo Shop Manual , volume 2.
Page 910: Liquid Cooling System
SHOP MANUAL SUPPLEMENT MX Zx 440 LC LIQUID COOLING SYSTEM A15C2IS PARTS PAGE 5 OF 18...
Page 911: 04 - Transmission
Always use ethyl-glycol antifreeze containing corrosion inhibitors specially recommended for aluminum en- gines. 04 — TRANSMISSION Refer to 1997 ski-doo Shop Manual , volume 2. DRIVE PULLEY DRIVEN PULLEY Newly designed lighter TRA drive pulley is used.
Page 912: 05 - Electrical
Ignition switch has been removed. A unique parallel circuit activates both heating throttle lever and handle grip. 06 — REAR SUSPENSION Refer to 1997 ski-doo Shop Manual , volume 2. 07 — STEERING/FRONT SUSPENSION Refer to 1997 ski-doo Shop Manual , volume 2.
Page 913: Steering Adjustment (Skis)
SHOP MANUAL SUPPLEMENT MX Zx 440 LC STEERING ADJUSTMENT (SKIS) 10 N•m (7 lbf•ft) 52 N•m (38 lbf•ft) Loctite 15 N•m (11 lbf•ft) 18 N•m 52 N•m (13 lbf•ft) (38 lbf•ft) 18 N•m (13 lbf•ft) 52 N•m (38 lbf•ft) Loctite 48 N•m (35 lbf•ft) 25 N•m...
Page 914 SHOP MANUAL SUPPLEMENT MX Zx 440 LC CAMBER: TOE-OUT: Specific inward or outward tilt angle of ski leg Difference measured between the front edge of compared to a vertical line when viewing the the skis “A” and rear edge “B” as viewed from snowmobile from front.
Page 915: Front Suspension And Skis
SHOP MANUAL SUPPLEMENT MX Zx 440 LC FRONT SUSPENSION AND SKIS 24 N•m (18 lbf•ft) 29 N•m (21 lbf•ft) 18 N•m (13 lbf•ft) 24 N•m (18 lbf•ft) A15F3ES TYPICAL — LEFT SIDE SHOWN PAGE 10 OF 18 PARTS...
Page 916: Shock Absorber Servicing
SHOP MANUAL SUPPLEMENT MX Zx 440 LC SHOCK ABSORBER SERVICING Damper Disassembly HPG Racing remote reservoir shocks with 4-posi- WARNING tions adjustment knob. Refer to Shop Manual and Never perform any maintenance onto Racing Handbook for damper disassembly and as- damper and reservoir assemblies until pres- sembly procedures.
Page 917 SHOP MANUAL SUPPLEMENT MX Zx 440 LC NOTE: Shock oil will leak from reservoir. Use shop cloth to catch excess oil. WARNING Use extreme caution when removing piston with compressed air. Protective eye wear should be used. A15F3JA 1. Reservoir cap assembly 2.
Page 918 SHOP MANUAL SUPPLEMENT MX Zx 440 LC Invert reservoir (hose connector upward). Using the two thumbs apply pressure on floating piston to position floating piston to depth of 43 ± 2 mm (1-11/16 ± 5/64 in). Measure from the top edge of reservoir body.
Page 919 SHOP MANUAL SUPPLEMENT MX Zx 440 LC NOTE: Fast installation of the damper rod may displace the floating piston from its original posi- tion. Do not allow this to occur. Reservoir Floating Piston Final Check (before damper seal carrier installation) Perform a final check of the floating piston posi- tion (43 ±...
Page 920 SHOP MANUAL SUPPLEMENT MX Zx 440 LC Preload Adjustment Lift snowmobile to remove tension from shock absorber. Perform preload adjustment on HPG shock ab- sorbers by setting adjusting nut upward (remove preload) or downward (add preload). CAUTION Ensure that shock absorber is extended when adjusting preload and make sure that tension remains on spring when removing preload.
Page 921: 08 - Body/Frame
SHOP MANUAL SUPPLEMENT MX Zx 440 LC 08 — BODY/FRAME Refer to 1997 ski-doo Shop Manual , volume 2. Newly designed waterproof seat. A15H47A WATERPROOF SEAT 09 — TECHNICAL DATA Refer to 1997 ski-doo Shop Manual , volume 2. SHOP...
Page 922 SHOP MANUAL SUPPLEMENT MX Zx 440 LC VEHICLE MODEL MX Zx 440 LC ENGINE TYPE Number of Cylinders Bore mm (in) 67.5 (2.6575) Stroke mm (in) 61.0 (2.402) Displacement 436.6 (26.6) Compression Ratio (corrected) Maximum Power Engine Speed ± 100 RPM 8450 Piston Ring Type ST/R...
Page 923 SHOP MANUAL SUPPLEMENT MX Zx 440 LC VEHICLE MODEL MX Zx 440 LC ENGINE TYPE Chain Drive Ratio 23/43 Pitch Chain Type/Links Qty/Plates Qty Silent 72 – 13 Type of Drive Pulley TRAC Ramp Identification Calibration Screw Position or Calibration Disc Quantity Drive Pulley Spring Color Pink/Pink...

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