Ski-Doo FORMULA III 1997 Shop Manual
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Ski-Doo FORMULA III 1997 Shop Manual

Ski-Doo FORMULA III 1997 Shop Manual

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Peter Hubbard
May 14, 2025

what manufacturer of electric connectors are used on 196 Ski Doo FIII

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1 comments:
Mr. Anderson
May 21, 2025

The 1997 Ski-Doo Formula III uses Snap-on connectors, specifically the Snap-on TT 600-5 tool is mentioned for removing tab and receptacle connectors.

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Peter Hubbard
April 17, 2025

How to realign a crankshaft to correct twisted crank

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Summary of Contents for Ski-Doo FORMULA III 1997

  • Page 2 ® 1997 Shop Manual VOLUME 3 FORMULA III/III LT MACH 1/Z/Z LT...
  • Page 3 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 4 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 5 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 6 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 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 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 09 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 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 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 (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 15 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 16 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 17 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 18 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 19 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 20 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 21 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 22 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 23 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 24 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 25 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 26 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 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.Dirt prevents fuel from flowing through. Clean.
  • Page 29 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 30 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 31 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 32 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 33 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 34 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 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.Rusted drive or driven pulley shafts.
  • 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.Frozen or too tight track. Liberate track from ice or check track tension and alignment.
  • Page 38 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 39 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 40 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 41 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 42 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 43 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 44 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 45 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 46 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 47 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 48 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 49 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 50 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 51 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 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. 2.

  • Page 53: Table Of Contents

    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 54 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 55: 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 56: 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 57: 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 58: 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 59: Inspection

    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 60 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 61 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 62 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 63: Bottom End

    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 64: Cleaning

    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 65: Assembly

    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 66 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 67: 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 68 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 69 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 70: 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 71: 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 72: 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 73: 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 74: 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 75: 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 76 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 77: 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 78: Disassembly

    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 79 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 80: Assembly

    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 81 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 82: Adjustment

    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 83 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 84: Checking Operation

    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 85: Liquid Cooling System

    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 86: Inspection

    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 87: Cooling System Refilling Procedure

    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 88: 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 89: Removal

    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 90 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 91: Installation

    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 92: 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 93 Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) Carburetor TM 38 C159 A06C38T PARTS FLAT RATE 03-08-2...

  • Page 94: Removal

    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 95: Disassembly And Assembly

    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 96: Carburetor Float Level Adjustment

    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 97: Installation

    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 98: Carburetor Adjustments

    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 99 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 100 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 101: Preliminary Idle Speed Adjustment

    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 102 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 103 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 104 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 105: Fuel Pump

    Section 03 ENGINE Sub-Section 08 (CARBURETOR AND FUEL PUMP) FUEL PUMP All Models A06C3SS 03-08-14...

  • Page 106: Removal

    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 107: 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 108 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 109 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 110 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 111: 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) 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 112: 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 113: 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 114: 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 (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 115: 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 116: 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 117: 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 118: 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 119: 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 120 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 121: 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 122: 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 123 Section 04 TRANSMISSION Sub-Section 03 (DRIVE PULLEY) A16D0HA 1. Loosen just enough to permit rotating of calibration screw 04-03-10...

  • Page 124: Driven Pulley

    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 125: 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 126 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 127: 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 128: 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 129 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 130: 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 131: 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 132 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 133: 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 134: 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 135: Inspection

    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 136 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 137 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 138 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 139: Gear Ratio Modification

    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 140: 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 141: 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 142: 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 143 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 144: Wiring Diagrams

    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 145 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 146: 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 147: 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 148: 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 149 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 150 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 151: 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 152: 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 153: 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 154: 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 155: 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 156: 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 157: 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 158: 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 159: Magneto Output (Ignition Generator Coil)

    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 160: Summary Table

    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 161: 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 162: 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 163: 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 164: 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 165 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 166: 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 167: 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 168 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 169: 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 170 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 171: 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 172: 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 173: 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 174: 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 175 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 176: 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 177 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 178 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 179: 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 180: 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 181: 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 182 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 183 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 184 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 185: Steering System

    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 186: 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 187: 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 188: 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 189: Steering Adjustment (Skis)

    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 190 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 191: 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 192 Section 07 STEERING/FRONT SUSPENSION Sub-Section 02 (STEERING SYSTEM) F-Series If so equipped A06G08S PARTS FLAT RATE 07-02-8...

  • Page 193: Suspension And Ski System

    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 194: 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 195: 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 196 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 197 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 198: 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 199: 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 200: 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 201: 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 202: 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 203: 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 204 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 205: 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 206 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 207 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 208 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 209 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 210 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 211 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 212 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 213 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 214 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 215 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...

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Formula iii lt 1997Mach 1 1997Mach z 1997Mach z lt 1997

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